Activated carbon bodies having epoxy resin and bentonite binders

Abstract

A carbon body and method for making the body. The body is characterized by carbon particles bonded together with bentonite clay and a cured epoxy resin. The bentonite content is about 5% to about 30% by weight based on carbon. The epoxy resin and curing agent content as measured before curing is about 5% to about 40% by weight based on carbon. The curing agent as measured before curing makes up about 5 parts to about 40 parts per 100 weight parts based on the epoxy resin. The resin has an average functionality of at least 3. The body has higher strength after exposure to temperatures of up to about 250.degree. C. in air than bodies absent the bentonite and resin. Additionally, the body has the properties of surface area retention after exposure to high temperatures, and water resistance. The method for making the body involves forming an aqueous mixture comprising of in percent by weight based on carbon, about 4% to about 10% thermally gellable organic binder which can be cellulose ether(s), derivatives of cellulose ethers, and combinations of these, 0 to about 7% of co-binder, the bentonite, resin, and curing agent. The mixture is formed into a green body which is then dried, subjected to a first heat-treatment or curing, and then to a second heat treatment to restore surface area.