Porous zeolite, carbon and aluminophosphate powders have been colloidally assembled and post-processed in the form of monoliths, flexible free standing films and coatings for gas separation and odor removal. Zeolite 13X monoliths with macroporosites up to 50 vol% and a high CO2 uptake were prepared by colloidal processing and sacrificial templating. The durability of silicalite-I supports produced in a binder-free form by pulsed current processing (PCP) were compared with silicalite-I supports produced using clay-binders and conventional thermal treatment. Long-term acid and alkali treatment of the silicalite-I substrates resulted in removal of the clay binder and broadened the size-distribution of the interparticle macropores. Furthermore, strong discs of hydrothermally treated beer waste (HTC-BW) were produced by PCP and the discs were activated by physical activation in CO2 at high temperatures. The activated carbon discs showed high strength up to 7.2 MPa while containing large volume of porosities at all length scales. PCP was further used to structure aluminomphosphate powders (AlPO4-17 and AlPO4-53) into strong functional monoliths. The aluminophosphate monoliths had strengths of 1 MPa, high CO2 uptake and were easy to regenerate. Zeolite Y, silicalite and ZSM5 were selected as potential zeolite adsorbents for removal of sulfur containing compound, e.g. ethyl mercaptan (EM) and propyl mercaptan (PM). A novel processing procedure was used to fabricate free-standing films and coatings of cellulose nanofibrils (CNF) with a high content of nanoporous zeolite; 89 w/w% and 96 w/w%, respectively. Thin flexible free-standing films and coatings of zeolite-CNF on paperboards with thickness around 100 µm and 40 µm, respectively, were produced. Headspace solid phase microextraction (SPME) coupled to gas chromatography- mass spectroscopy (GC/MS) analysis showed that the zeolite-CNF films can efficiently remove considerable amount of odors below concentration levels that can be sensed by the human olfactory system. / <p>At the time of the doctoral defense, the following paper was unpublished and had a status as follows: Paper 5: Manuscript.</p>

Inorganic porous materials are widely used in a number of applications, where is a need to functionalize and produce materials with a multiscale porosity. The first part of the thesis describes how a novel and facile powder processing approach, using pulsed current processing (PCP) or, as it is commonly called, spark plasma sintering (SPS), has been employed to produce mechanically stable, hierarchically porous bodies from different porous powders. Surfactant-templated mesoporous spheres were PCP-treated to yield meso/macro porous monoliths. The bimodal pore size can be tailored by choice of templating molecules in the aerosol-assisted synthesis process and by the particle size of the spheres. Diatomite powders were used to produce macro/macroporous monoliths. The densification behaviour of this inexpensive and renewable macroporous raw material was evaluated in detail, and an optimum temperature range was identified where the PCP process yields mechanically strong monoliths. Binder-less, hierarchically porous zeolite monoliths were produced from various zeolite powders, e.g. silicalite-1, ZSM-5 and zeolite Y. Line-broadening analysis of X-ray powder diffraction data by the Rietveld method and electron microscopy showed that the formation of strong interparticle bonds during the PCP process is associated with a local amorphization reaction that is induced by the high contact stress and temperature. Xylene isomerisation studies showed that binder-less ZSM-5 monoliths display a high catalytic selectivity. Direct (in-situ) nanoparticle functionalization of surfactant templated mesoporous silica particles has also been demonstrated. Pre-synthesized TiO2 nanoparticles were dispersed in a precursor solution, containing surfactant and silica source, and processed in an aerosol-generator to produce spherical nanoparticle-functionalized mesoporous particles.