CN107266049A - 一种过滤效率高的壁流式蜂窝陶瓷过滤体及其制备方法 - Google Patents

一种过滤效率高的壁流式蜂窝陶瓷过滤体及其制备方法 Download PDF

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CN107266049A
CN107266049A CN201710559243.2A CN201710559243A CN107266049A CN 107266049 A CN107266049 A CN 107266049A CN 201710559243 A CN201710559243 A CN 201710559243A CN 107266049 A CN107266049 A CN 107266049A
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honeycomb ceramic
filter
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张庆
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Wuhu Baoyi Amusement Equipment Co Ltd
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Abstract

一种过滤效率高的壁流式蜂窝陶瓷过滤体，其特征在于，首先将氧化铝微粉和助熔剂混合，以硫酸钛为前驱体，对氧化铝颗粒表面进行修饰；其次制备泥料，泥料经真空炼制、陈腐、挤出成型和微波干燥，得到干胚体；然后将制备改性浆料，将干胚体表面改性；最后高温烧结，得到过滤效率高的壁流式蜂窝陶瓷过滤体。本发明的陶瓷过滤体，具有抗热震、强度高、气孔率高等特点，性能优异，能够很好地满足高温含尘废气净化处理的技术要求。

Description

一种过滤效率高的壁流式蜂窝陶瓷过滤体及其制备方法
技术领域
本发明属于陶瓷领域，尤其涉及一种过滤效率高的壁流式蜂窝陶瓷过滤体及其制备方法。
背景技术
目前，壁流式蜂窝陶瓷作为含尘废气净化、尤其是高温含尘气体除尘处理用过滤元件，已广泛应用于柴油机尾气处理等废气净化技术领域。然而，壁流式蜂窝陶瓷在长期的除尘运行过程中，微细粉尘容易随气流进入孔道壁内的微孔中，并在联通微孔的颈部塞积，从而降低蜂窝陶瓷的孔隙率、增大气体过滤阻力、降低对含尘废气过滤的处理效率。尽管采用高压脉冲反吹等方式可以清除部分孔道壁内微孔中的颗粒物，但由于孔道壁中微孔是不规则的联通结构，在高压脉冲气体反吹过程中，仍然有大量颗粒物在微孔的颈部塞积，导致大量粉尘颗粒残留在蜂窝陶瓷过滤体的孔道壁中。随着运行时间的延长和反吹次数的增多，该部分残留粉尘颗粒在孔道壁内微孔中形成紧密堆积，大幅度降低了过滤效率，最终致使过滤元件报废。
为改善和提高壁流式蜂窝陶瓷的性能，目前现有技术对该领域的研究一般仅局限于陶瓷过滤体的材料选择、组成配方、成型工艺、烧成工艺等方面。例如，与一般陶瓷过滤体相比，堇青石质陶瓷具有低热膨胀性、耐高温、耐热冲击等特性，因此是目前高温含尘废气处理主要选用的过滤元件。但现有技术仍然无法很好地解决上述粉尘颗粒塞积的问题，急需研究开发有效的技术措施以提高壁流式蜂窝陶瓷的使用性能，提高过滤效率、延长使用寿命。
发明内容
本发明的目的在于提供一种使用寿命长的过滤效率高的壁流式蜂窝陶瓷过滤体及其制备方法。
为了实现上述的目的，本发明采用如下的技术方案：
一种过滤效率高的壁流式蜂窝陶瓷过滤体，其特征在于，首先将氧化铝微粉和助熔剂混合，以硫酸钛为前驱体，对氧化铝颗粒表面进行修饰；其次制备泥料，泥料经真空炼制、陈腐、挤出成型和微波干燥，得到干胚体；然后将制备改性浆料，将干胚体表面改性；最后高温烧结，得到过滤效率高的壁流式蜂窝陶瓷过滤体。
所述的过滤效率高的壁流式蜂窝陶瓷过滤体，其特征在于，其由如下步骤制备而成：
（1）将高岭土、滑石粉以1：0.9-1.1的质量比混合，置于80-90℃的真空干燥箱中干燥5-6h，再经湿法球磨，烘干，粉碎过筛得到200-250目的混合粉末，待用；
（2）将氧化铝微粉和混合粉末以1：0.02-0.03的质量比置于反应容器中，加入相当于氧化铝微粉重量份15-20倍的去离子水，超声震荡50-60min，使其充分分散，边搅拌边滴加硫酸钛溶液，室温下磁力搅拌30-40min，然后滴加氨水将体系的pH值调节至9.5-10.5，继续磁力搅拌2-3h，过滤，洗涤、干燥，得到表面修饰氧化铝微粉；
（3）将表面修饰氧化铝微粉、粘土、木粉加入到混料机中，再加入羟丙基甲基纤维素，混合60-80min，加入聚乙烯醇、丙三醇和水，继续混合50-60min，得到泥料；
（4）将泥料在真空度为0.15-0.2MPa的条件下真空脱气炼制2-3次，陈腐20-24h，在成型机上通过挤压成形，得到湿胚体，将湿胚体置于微波炉中干燥3-5min，得到干胚体；
（5）将堇青石、羟丙基甲基纤维素、聚丙烯酸钠和水以1：0.15-0.2：0.2-0.22：15-18的质量比混合，置于球磨机内，球磨机转速为600-800r/min的条件下球磨混合6-8h，得到改性浆料；
（6）将干胚体缓慢浸入改性浆料中，停留2-3min后缓慢取出，置于微波炉中微波加热50-60s；将胚体放入马弗炉中，空气氛围下，以4-5℃/min速率升温至600℃，保温2h，然后在0.4-0.5MPa气压下氮气环境中以8-10℃/min速率升温至1100℃，保温30-40min，最后以2-3℃/min速率升温到1500℃，保温60-80min，自然冷却至室温，得到一种过滤效率高的壁流式蜂窝陶瓷过滤体。
所述的过滤效率高的壁流式蜂窝陶瓷过滤体的制备方法，其特征在于，步骤（2）中硫酸钛溶液中钛与氧化铝的质量比为1：200-250。
所述的过滤效率高的壁流式蜂窝陶瓷过滤体的制备方法，其特征在于，步骤（3）中表面修饰氧化铝微粉、粘土、木粉、羟丙基甲基纤维素、聚乙烯醇、丙三醇和水的质量比为1：0.3-0.4：0.12-0.15：0.003-0.004：0.006-0.008：0.06-0.08：0.4-0.45。
所述的过滤效率高的壁流式蜂窝陶瓷过滤体的制备方法，其特征在于，步骤（4）和步骤（6）中微波炉的功率为700-800W。
通过上述的技术方案，本发明的有益效果是：
本发明首先将高岭土和滑石粉混合干燥、湿法球磨、干燥，得到混合粉末；然后将氧化铝微粉和混合粉末混合后，以硫酸钛为前驱体，以硫酸钛作前驱体，通过包覆工艺对氧化铝粉体表面进行修饰；一方面，高岭土和二氧化钛的引入，高岭土可作为助熔剂，氧化铝大颗粒之间依靠二氧化钛与氧化铝的固溶反应及固相烧结反应实现颈部烧结，进而实现了陶瓷过滤体的低温制备，降低了降低陶瓷过滤体的烧结温度；另一方面，二氧化钛是一种环境安全的清洁剂，在紫外线作用下，可以降解消除汽车尾气中的氮氧化合物，起到净化空气的作用。堇青石质陶瓷具有低热膨胀性、耐高温、耐热冲击等特性，以堇青石制备的改性浆料，将陶瓷过滤体表面改性，经高温烧结，陶瓷过滤体表面覆盖一层堇青石质陶瓷，可以改善粉尘颗粒塞积的问题，提高壁流式蜂窝陶瓷的使用性能，提高过滤效率、延长使用寿命。本发明的陶瓷过滤体，具有抗热震、强度高、气孔率高等特点，性能优异，能够很好地满足高温含尘废气净化处理的技术要求。
具体实施方式
本实施例的过滤效率高的壁流式蜂窝陶瓷过滤体，其由如下步骤制备而成：
（1）将高岭土、滑石粉以1：0.9的质量比混合，置于90℃的真空干燥箱中干燥6h，再经湿法球磨，烘干，粉碎过筛得到250目的混合粉末，待用；
（2）将氧化铝微粉和混合粉末以1：0.03的质量比置于反应容器中，加入相当于氧化铝微粉重量份20倍的去离子水，超声震荡60min，使其充分分散，边搅拌边滴加硫酸钛溶液，室温下磁力搅拌40min，然后滴加氨水将体系的pH值调节至10，继续磁力搅拌3h，过滤，洗涤、干燥，得到表面修饰氧化铝微粉；
（3）将表面修饰氧化铝微粉、粘土、木粉加入到混料机中，再加入羟丙基甲基纤维素，混合80min，加入聚乙烯醇、丙三醇和水，继续混合60min，得到泥料；
（4）将泥料在真空度为0.2MPa的条件下真空脱气炼制3次，陈腐24h，在成型机上通过挤压成形，得到湿胚体，将湿胚体置于微波炉中干燥5min，得到干胚体；
（5）将堇青石、羟丙基甲基纤维素、聚丙烯酸钠和水以1：0.2：0.22：18的质量比混合，置于球磨机内，球磨机转速为800r/min的条件下球磨混合8h，得到改性浆料；
（6）将干胚体缓慢浸入改性浆料中，停留3min后缓慢取出，置于微波炉中微波加热60s；将胚体放入马弗炉中，空气氛围下，以5℃/min速率升温至600℃，保温2h，然后在0.5MPa气压下氮气环境中以10℃/min速率升温至1100℃，保温40min，最后以3℃/min速率升温到1500℃，保温80min，自然冷却至室温，得到一种过滤效率高的壁流式蜂窝陶瓷过滤体。
本实施例的步骤（2）中硫酸钛溶液中钛与氧化铝的质量比为1：200。
本实施例的步骤（3）中表面修饰氧化铝微粉、粘土、木粉、羟丙基甲基纤维素、聚乙烯醇、丙三醇和水的质量比为1：0.4：0.15：0.004：0.006：0.08：0.45。
本实施例的步骤（4）和步骤（6）中微波炉的功率为700W。

Claims (5)

1.一种过滤效率高的壁流式蜂窝陶瓷过滤体，其特征在于，首先将氧化铝微粉和助熔剂混合，以硫酸钛为前驱体，对氧化铝颗粒表面进行修饰；其次制备泥料，泥料经真空炼制、陈腐、挤出成型和微波干燥，得到干胚体；然后将制备改性浆料，将干胚体表面改性；最后高温烧结，得到过滤效率高的壁流式蜂窝陶瓷过滤体。
2.根据权利要求书1所述的过滤效率高的壁流式蜂窝陶瓷过滤体，其特征在于，其由如下步骤制备而成：
（1）将高岭土、滑石粉以1：0.9-1.1的质量比混合，置于80-90℃的真空干燥箱中干燥5-6h，再经湿法球磨，烘干，粉碎过筛得到200-250目的混合粉末，待用；
（2）将氧化铝微粉和混合粉末以1：0.02-0.03的质量比置于反应容器中，加入相当于氧化铝微粉重量份15-20倍的去离子水，超声震荡50-60min，使其充分分散，边搅拌边滴加硫酸钛溶液，室温下磁力搅拌30-40min，然后滴加氨水将体系的pH值调节至9.5-10.5，继续磁力搅拌2-3h，过滤，洗涤、干燥，得到表面修饰氧化铝微粉；
（3）将表面修饰氧化铝微粉、粘土、木粉加入到混料机中，再加入羟丙基甲基纤维素，混合60-80min，加入聚乙烯醇、丙三醇和水，继续混合50-60min，得到泥料；
（4）将泥料在真空度为0.15-0.2MPa的条件下真空脱气炼制2-3次，陈腐20-24h，在成型机上通过挤压成形，得到湿胚体，将湿胚体置于微波炉中干燥3-5min，得到干胚体；
（5）将堇青石、羟丙基甲基纤维素、聚丙烯酸钠和水以1：0.15-0.2：0.2-0.22：15-18的质量比混合，置于球磨机内，球磨机转速为600-800r/min的条件下球磨混合6-8h，得到改性浆料；
（6）将干胚体缓慢浸入改性浆料中，停留2-3min后缓慢取出，置于微波炉中微波加热50-60s；将胚体放入马弗炉中，空气氛围下，以4-5℃/min速率升温至600℃，保温2h，然后在0.4-0.5MPa气压下氮气环境中以8-10℃/min速率升温至1100℃，保温30-40min，最后以2-3℃/min速率升温到1500℃，保温60-80min，自然冷却至室温，得到一种过滤效率高的壁流式蜂窝陶瓷过滤体。
3.根据权利要求书2所述的过滤效率高的壁流式蜂窝陶瓷过滤体的制备方法，其特征在于，步骤（2）中硫酸钛溶液中钛与氧化铝的质量比为1：200-250。
4.根据权利要求书2所述的过滤效率高的壁流式蜂窝陶瓷过滤体的制备方法，其特征在于，步骤（3）中表面修饰氧化铝微粉、粘土、木粉、羟丙基甲基纤维素、聚乙烯醇、丙三醇和水的质量比为1：0.3-0.4：0.12-0.15：0.003-0.004：0.006-0.008：0.06-0.08：0.4-0.45。
5.根据权利要求书2所述的过滤效率高的壁流式蜂窝陶瓷过滤体的制备方法，其特征在于，步骤（4）和步骤（6）中微波炉的功率为700-800W。
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