CN115160013A - Preparation method and application of ceramic carrier with thin-wall honeycomb structure - Google Patents
Preparation method and application of ceramic carrier with thin-wall honeycomb structure Download PDFInfo
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- CN115160013A CN115160013A CN202210679818.5A CN202210679818A CN115160013A CN 115160013 A CN115160013 A CN 115160013A CN 202210679818 A CN202210679818 A CN 202210679818A CN 115160013 A CN115160013 A CN 115160013A
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Abstract
The application relates to a preparation method and application of a ceramic carrier with a thin-wall honeycomb structure, wherein the preparation method of the ceramic carrier with the thin-wall honeycomb structure comprises the following steps: taking and mixing the layered double hydroxide, magnesium oxide, silicon carbide and kaolin, then adding an additive, a fatty acid salt and water, mixing and stirring for 16-25min, kneading, pugging, performing extrusion forming, shunting to obtain a honeycomb structure, drying at 100-110 ℃ for 1-1.5h, cooling, and roasting to obtain the ceramic carrier with the thin-wall honeycomb structure. The preparation method of the ceramic carrier is simple to operate, high in production efficiency, and high in yield of 100%, and has excellent porosity and specific surface area, good mechanical strength and good coating performance on the catalyst.
Description
Technical Field
The application relates to the technical field of ceramic carriers, in particular to a preparation method and application of a ceramic carrier with a thin-wall honeycomb structure.
Background
At present, the emission of automobile exhaust becomes a problem to be solved urgently, and the environment on which people live is protected by oxidizing and reducing harmful gas in the exhaust into harmless gas. CN01800963 is dried and sintered after the raw material is molded, and then surface treatment is carried out in air flow, so that a catalyst carrier is obtained, the catalyst carrier has good coating performance, however, one-step independent surface roughening operation needs to be carried out on the carrier, the operation is complex, and the production efficiency is reduced. CN201210024358 provides a catalyst carrier for a purifier, which is kneaded in a kneader for a certain period of time to obtain a slurry, but the obtained catalyst carrier has a low yield, and surface defects such as cracks are likely to occur on the surface of the catalyst carrier particularly in extrusion molding.
Disclosure of Invention
In view of the problems in the prior art, the first aspect of the present invention provides a method for preparing a ceramic carrier with a thin-walled honeycomb structure, comprising: taking and mixing the layered double hydroxide, magnesium oxide, silicon carbide and kaolin, then adding an additive, a fatty acid salt and water, mixing and stirring for 16-25min, kneading, pugging, performing extrusion forming, shunting to obtain a honeycomb structure, drying at 100-110 ℃ for 1-1.5h, cooling, and roasting to obtain the ceramic carrier with the thin-wall honeycomb structure.
The layered double hydroxide is a generic term for Hydrotalcite (HT) and Hydrotalcite-Like Compounds (HTLCs) and is commercially available, such as NiFe-LDHs, or ZnAl-LDHs, niAl-LDHs, etc., and in one embodiment, is available from jonan golden spring chemical ltd.
In one embodiment, the magnesium oxide has a bulk density of 0.2 to 0.35g/mL, preferably 0.25 to 0.3g/mL.
More preferably, the particle diameter D50 of the magnesium oxide is 4-6 μm.
In this application, magnesia having a bulk density of 0.25 to 0.3g/mL and a particle size D50 of 4 to 6 μm was purchased from the company, schchen Shiqin Innovative materials science and technology, inc.
In one embodiment, the silicon carbide has a particle size of 700 to 900 mesh, preferably 800 mesh.
In the application, the silicon carbide with the grain size of 800 meshes is purchased from Henan power-assisted grinding tool Limited company and has the model of W20.
Preferably, the kaolin is water-washed kaolin.
In one embodiment, the kaolin has a particle size of 700 to 900 mesh, preferably 800 mesh.
Kaolin with a particle size of 800 meshes is purchased from processing plants of Shifeng mineral products in Lingshou county.
In one embodiment, the weight ratio of the layered double hydroxide, magnesium oxide, silicon carbide and kaolin is (30-35): 1: (5-10): (30-35), preferably 32.
In one embodiment, the additive is methylcellulose and/or starch hydrolysate.
Preferably, the weight ratio of the methyl cellulose to the starch hydrolysate is 1: (5-10), more preferably 1.
Preferably, the DE value of the starch hydrolysate is less than or equal to 20.
Starch hydrolysates with DE values of 20 or less are available from kagaku corporation, shandong.
Preferably, the methyl cellulose has a methoxyl group of 26 to 35wt%, preferably 28 to 32wt%.
More preferably, the viscosity of the 1wt% aqueous solution of the methyl cellulose at 20 ℃ is 17000-22000mPa.s.
In the application, the methyl cellulose with the viscosity of 1wt% aqueous solution at 20 ℃ of 17000-22000mPa.s and the methoxyl of 28-32wt% is purchased from Hongbo fine chemical engineering Co., ltd, yixing, and the brand is HB-20000.
Preferably, the weight ratio of the additive to the magnesium oxide is (10-15): 1, preferably 13.
The surface and the partition wall of the existing ceramic carrier are smooth, the fixing effect is poor when a catalyst is coated on the rear surface, an alumina coating is coated on the ceramic carrier in the prior art, or roughening treatment is carried out in the preparation process of the ceramic carrier, however, the two methods not only increase the complexity of operation, but also possibly cause the situation of reducing the mechanical property of the ceramic carrier in the roughening treatment process, and influence the yield. The applicant found in experiments unexpectedly that when the weight ratio of methylcellulose to starch hydrolysate in the additive is 1: (5-10), when the viscosity of a 1wt% aqueous solution of the methyl cellulose is 17000-22000mPa.s at 20 ℃, magnesium oxide with the specific particle size D50 of 4-6 mu m, silicon carbide and kaolin with the specific particle size are obtained, and the finally prepared ceramic carrier has certain roughness and increased adsorption capacity with a catalyst, and the applicant thinks that the possible reason is that the content of macromolecules above tetrasaccharide in the starch hydrolysate with the DE value is in a certain level, and simultaneously, certain entanglement binding force is formed among larger molecular chains, and the effect between inorganic molecules with specific and different particle sizes is irregular, so that the influence of water molecules is avoided.
In one embodiment, the weight ratio of the fatty acid salt to the additive is 1: (3-5), preferably 1.
Preferably, the fatty acid salt is sodium stearate.
In one embodiment, the weight ratio of water to stearate is (25-35): 1, preferably 30.
In one embodiment, the firing comprises: heating to 180-200 ℃ at a heating rate of 60-65 ℃/min, heating to 400-450 ℃ at a heating rate of 10-15 ℃/min, heating to 600-650 ℃ at a heating rate of 50-55 ℃/min, heating to 1000-1100 ℃ at 45-50 ℃/min, heating to 1250-1300 ℃ at a heating rate of 70-80 ℃/min, heating to 1400-1500 ℃ at a heating rate of 15-25 ℃/min, and carrying out heat preservation roasting for 8-10h.
In a preferred embodiment, the parameters of the roasting include raising the temperature to 190 ℃ at a heating rate of 62 ℃/min, then raising the temperature to 420 ℃ at a heating rate of 13 ℃/min, then raising the temperature to 630 ℃ at a heating rate of 53 ℃/min, then raising the temperature to 1050 ℃ at 48 ℃/min, then raising the temperature to 1280 ℃ at a heating rate of 75 ℃/min, and finally raising the temperature to 1460 ℃ at a heating rate of 20 ℃/min, and carrying out heat preservation roasting for 9.5h.
The applicant has found unexpectedly in experiments that when the firing parameters are such that firing is performed at the firing parameters specified in the application at 1400-1500 ℃ in the presence of layered double hydroxides in the present application, and particularly at the initial stage of firing at 180-200 ℃ at a heating rate of 60-65 ℃/min, then at a heating rate of 10-15 ℃/min to 400-450 ℃, and then at a heating rate of 50-55 ℃/min to 600-650 ℃, the reduction in pore volume, specific surface area, and reduction in carrier capacity caused by layered double hydroxides can be avoided, and the applicant believes that the possible reason is that at the initial stage of firing at 200 ℃, heating is performed at a heating rate of 60-65 ℃/min, at which time residual water molecules in the double hydroxides undergo relatively rapid interlayer dehydration, at which time the pores collapse and increase, and at the later stage, at which temperature reaches 400-450 ℃ at a heating rate of 10-15 ℃/min, at which water molecules in the hydroxide decomposition process, the residual water molecules undergo relatively rapid interlayer dehydration, at which time, the pores collapse and increase in the later stage, the course of the layered double hydroxides, the formation of water molecules, and the stable pore structure can be constructed under the conditions that the pore volume, the entire flow channel structure, and the temperature of the support can be stably reduced, and the later stage, the temperature, and the conditions that the pore volume of the support can be reduced, and the temperature can be avoided.
In addition, the applicant has surprisingly found that the ceramic supports obtained in the present application, with the specific additives and sintering parameters, have excellent compressive strength and thermal shock resistance, and the applicant believes that the possible reasons are that methylcellulose and starch hydrolysates reduce the free space of the molecules of the mix, increase the disorder of the molecular arrangement, increase the bonding force between the molecules, and the specific distribution of the molecules avoids the generation of local stresses during the firing process.
In one embodiment, the drying time of 1-1.5h at 100-110 ℃ is specifically as follows: heating to 100-110 deg.C at a rate of 8-10 deg.C/min, and drying for 1-1.5h.
Preferably, the temperature is raised to 105 ℃ at a rate of 9 ℃/min and then dried for 1.2h.
The applicant has found in experiments that, surprisingly, the drying process carried out at a rate of 8-10 ℃ up to 100-110 ℃ avoids the occurrence of cracks on the surface of the ceramic support of the resulting honeycomb structure.
In one embodiment, the rate of extrusion is from 12 to 14cm/min, preferably 13cm/min.
Preferably, the pressure for the extrusion molding is 8 to 10MPa, preferably 9MPa.
The applicant finds that the yield is increased and the defects of distortion deformation, surface wrinkling and the like of the ceramic carrier are avoided when the extrusion forming speed is 12-14cm/min and the extrusion pressure is 8-10MPa, and the applicant considers that the possible reason is that under the extrusion speed, a certain friction force bearing time exists between the mixture and the mold wall, the unevenness of the discharging speed caused by the defect of local viscosity of the mixture after pugging is avoided, the mixture is uniformly stressed in all directions, and the solvent with low boiling point is uniformly volatilized under the extrusion pressure of 8-10MPa, so that the wrinkling phenomenon is avoided.
The invention also provides an application of the preparation method of the ceramic carrier with the thin-wall honeycomb structure in the preparation of a ceramic catalyst.
The technical scheme who provides this application brings beneficial effect includes:
(1) According to the preparation method, specific methyl cellulose and starch hydrolysate are adopted, and meanwhile, inorganic raw material molecules are combined under a specific proportion, so that the roughness of a partition wall is larger than 1 mu m under the condition that the surface of a ceramic carrier is not treated, and the subsequent coating is facilitated.
(2) The present application uses specific calcination parameters to avoid the reduction in porosity and pore volume that occurs after the layered double hydroxide is calcined.
(3) The method increases the yield under the extrusion rate of 12-14cm/min and the extrusion pressure of 8-10MPa, and avoids the phenomena of surface distortion, wrinkling and the like of the ceramic carrier.
(4) In the application, the drying process is carried out at the temperature of 100-110 ℃ at a specific heating rate, so that the condition that the surface of the obtained ceramic carrier with the honeycomb structure has cracks is avoided.
(5) The preparation method of the ceramic carrier is simple to operate, high in production efficiency, and high in yield of 100%, and has excellent porosity, specific surface area, good mechanical strength and good coating performance on the catalyst.
Detailed Description
Example 1
Embodiment 1 provides a method for preparing a ceramic carrier with a thin-walled honeycomb structure, which specifically comprises the following steps:
taking layered double metal hydroxide purchased from Jinquan chemical Limited, jinan, magnesium oxide with the bulk density of 0.25-0.3g/mL and the D50 of 4-6 mu m purchased from Prochen Temminck Innovation materials science and technology Limited, magnesium oxide purchased from Henan Power assisted grinding tools Limited, the model is W20, silicon carbide with the particle size of 800 meshes, silicon carbide purchased from Shichen Ming mineral processing factories, washing kaolin with the particle size of 800 meshes, mixing, adding methyl cellulose, starch hydrolysate, sodium stearate and water, mixing and stirring for 16min, kneading, refining, extruding and distributing at the pressure of 8MPa and the speed of 12cm/min to obtain a honeycomb structure, heating to 100 ℃ at the speed of 8 ℃/min, drying for 1.5h, cooling and roasting, wherein the roasted specific operation is heating to 180 ℃ at the heating rate of 60 ℃/min, heating to 400 ℃ at the temperature of 50 ℃/min, heating to 600 ℃ at the temperature of 45-1000 ℃/min, and finally heating to the temperature of 10 ℃/min.
The weight ratio of the layered double hydroxide to the magnesium oxide to the silicon carbide to the water-washed kaolin is 30:1:5:30; the weight ratio of the methyl cellulose to the starch hydrolysate is 1:5, the DE value of the starch hydrolysate is less than or equal to 20, and the starch hydrolysate is purchased from Kayu chemical Co., ltd; the methoxyl of the methyl cellulose is 28-32wt%, the viscosity of 1wt% water solution of the methyl cellulose at 20 ℃ is 17000-22000mPa.s, and the methyl cellulose is purchased from Hongbo fine chemical engineering Co., ltd, yixing city, and the mark is HB-20000.
The weight ratio of the total amount of the methylcellulose and the starch hydrolysate to the magnesium oxide is 10:1.
the weight ratio of sodium stearate to the total amount of methylcellulose and starch hydrolysate was 1.
The weight ratio of water to sodium stearate is 25.
The preparation method of the ceramic carrier with the thin-wall honeycomb structure is applied to preparing a ceramic catalyst.
Example 2
Embodiment 2 provides a method for preparing a ceramic carrier with a thin-walled honeycomb structure, which specifically comprises the following steps:
taking layered double metal hydroxide purchased from Jinquan chemical Limited, jinan, magnesium oxide with the bulk density of 0.25-0.3g/mL and the D50 of 4-6 mu m purchased from Prochen counter innovative materials technology Limited, magnesium oxide purchased from Henan Power assisted grinding tool Limited, the model is W20, silicon carbide with the particle size of 800 meshes, silicon carbide purchased from Shichen Fei mineral processing factory, the particle size is 800 meshes, washing kaolin with water, mixing, adding methyl cellulose, starch hydrolysate, sodium stearate and water, mixing and stirring for 25min, kneading, refining, extruding and distributing at the pressure of 10MPa and the speed of 14cm/min to obtain a honeycomb structure, then heating to 110 ℃ at the speed of 10 ℃/min, drying for 1h, cooling and roasting, wherein the roasted specific temperature is heated to 200 ℃ at the heating rate of 65 ℃/min, then heated to 450 ℃ at the heating rate of 55 ℃/min, then heated to 650 ℃ at the speed of 50 ℃/min to 80 ℃/min, and finally heated to 1300 ℃ at the heating rate of 80 ℃/min to 1500 ℃ at the temperature of 8 ℃/min.
The weight ratio of the layered double hydroxide to the magnesium oxide to the silicon carbide to the water-washed kaolin is 35:1:10:35; the weight ratio of the methyl cellulose to the starch hydrolysate is 1:10, the DE value of the starch hydrolysate is less than or equal to 20, and the starch hydrolysate is purchased from Kayu chemical Co., ltd; the methoxyl group of the methyl cellulose is 28-32wt%, the viscosity of 1wt% water solution of the methyl cellulose at 20 ℃ is 17000-22000mPa.s, and the methyl cellulose is purchased from Hongbo fine chemical engineering Co., ltd, yixing, and the mark is HB-20000.
The weight ratio of the total amount of the methylcellulose and the starch hydrolysate to the magnesium oxide is 15:1.
the weight ratio of sodium stearate to the total amount of methylcellulose and starch hydrolysate was 1.
The weight ratio of water to sodium stearate is 35.
The preparation method of the ceramic carrier with the thin-wall honeycomb structure is applied to preparing a ceramic catalyst.
Example 3
Embodiment 3 provides a method for preparing a ceramic carrier with a thin-wall honeycomb structure, which comprises the following steps:
taking layered double hydroxides purchased from Jinnan chemical industries, inc., magnesium oxide with the bulk density of 0.25-0.3g/mL and the D50 of 4-6 mu m purchased from the Schchen Temmin Innovation materials technology, inc., silicon carbide with the model number of W20 and the particle size of 800 meshes purchased from Ministry Power-assisted grinding tools, inc., washing kaolin with water with the particle size of 800 meshes, mixing, adding methyl cellulose, starch hydrolysate, sodium stearate and water, mixing and stirring for 20min, kneading, refining, extruding at the pressure of 9MPa, shunting to obtain a honeycomb structure, heating to 105 ℃ at the rate of 9 ℃/min, drying for 1.2h, cooling, and roasting, wherein the roasted specific operation is heating to 190 ℃ at the heating rate of 62 ℃/min, heating to 420 ℃ at the heating rate of 53 ℃/min, heating to 630 ℃ at the heating rate of 48 ℃/min, heating to 75 ℃/min, and heating to 1280.5 ℃ at the heating rate of 20 ℃/min, and finally heating to 1460.5 ℃ at the temperature of 1050 ℃.
The weight ratio of the layered double hydroxide, the magnesium oxide, the silicon carbide and the water-washed kaolin is 32; the weight ratio of the methyl cellulose to the starch hydrolysate is 1:7, the DE value of the starch hydrolysate is less than or equal to 20, and the starch hydrolysate is purchased from Jiayu chemical industry Co., ltd; the methoxyl group of the methyl cellulose is 28-32wt%, the viscosity of 1wt% water solution of the methyl cellulose at 20 ℃ is 17000-22000mPa.s, and the methyl cellulose is purchased from Hongbo fine chemical engineering Co., ltd, yixing, and the mark is HB-20000.
The weight ratio of the total amount of the methylcellulose and the starch hydrolysate to the magnesium oxide is 13:1.
the weight ratio of sodium stearate to the total of methylcellulose and starch hydrolysate is 1.
The weight ratio of water to sodium stearate is 30.
The preparation method of the ceramic carrier with the thin-wall honeycomb structure is applied to preparing a ceramic catalyst.
The ceramic carrier obtained in the application has a water absorption of about 15wt% measured by using a water absorption detection device, a thermal expansion coefficient of less than 0.8 x 10-6/K measured by using an expansion coefficient tester, 3 times of cyclic sintering without cracking at 650 ℃, an isostatic strength of more than 1.03MPa measured in an isostatic tester, a compressive strength of transverse direction measured by using a universal material testing machine: above 1.4MPa, longitudinal: higher than 5MPa.
Example 4
Embodiment 4 provides a method for preparing a ceramic carrier with a thin-wall honeycomb structure, which is similar to embodiment 3, except that a starch hydrolysate is not added, methyl cellulose is replaced by methoxyl with the content of 28-32wt%, and the viscosity of a 1wt% aqueous solution of the methyl cellulose at 20 ℃ is 22000-32800mPa.s, which is purchased from Hongbo fine chemical engineering Co., ltd., yixing, and the brand number is HB-205000.
The preparation method of the ceramic carrier with the thin-wall honeycomb structure is applied to preparing a ceramic catalyst.
Example 5
Example 5 provides a method for preparing a ceramic carrier with a thin-walled honeycomb structure, which is the same as example 3 in the specific implementation manner, except that the firing operation is as follows: heating to 420 ℃ at a heating rate of 50 ℃/min, heating to 630 ℃ at a heating rate of 53 ℃/min, heating to 1050 ℃ at 48 ℃/min, heating to 1280 ℃ at a heating rate of 75 ℃/min, heating to 1460 ℃ at a heating rate of 20 ℃/min, and carrying out heat preservation roasting for 9.5h.
The preparation method of the ceramic carrier with the thin-wall honeycomb structure is applied to preparing a ceramic catalyst.
Example 6
Example 6 provides a method for preparing a ceramic carrier having a thin-walled honeycomb structure, which is similar to example 3, except that the extrusion molding rate is 18cm/min and the extrusion pressure is 12MPa.
The preparation method of the ceramic carrier with the thin-wall honeycomb structure is applied to preparing a ceramic catalyst.
Performance evaluation
1. Roughness: the ceramic carriers obtained in the embodiments 1 to 6 are respectively tested for the roughness of the partition wall by using a surface roughness tester, each sample of the embodiment is tested for 10 times, and finally, the tested average value is respectively taken, and when the roughness is more than or equal to 1 mu m, the ceramic carrier is marked as qualified, otherwise, the ceramic carrier is marked as unqualified.
2. Porosity: the ceramic supports obtained in examples 1 to 6 were tested for porosity using a pore distribution tester, wherein the porosity was 60 to 70%, first-class, the porosity was 50 to 60% (excluding 60 wt%), second-class, less than 50wt%, third-class, and the like.
3. Appearance quality: the surfaces of the ceramic supports obtained in examples 1 to 6 were observed, and the presence or absence of appearance defects such as warpage and wrinkling was recorded.
The performance evaluation results are shown in table 1:
TABLE 1
The above description is merely exemplary of the present application and is presented to enable those skilled in the art to understand and practice the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the application. Thus, the present application is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (10)
1. A preparation method of a ceramic carrier with a thin-wall honeycomb structure is characterized by comprising the following steps: taking and mixing the layered double hydroxide, magnesium oxide, silicon carbide and kaolin, then adding an additive, a fatty acid salt and water, mixing and stirring for 16-25min, kneading, pugging, performing extrusion forming, shunting to obtain a honeycomb structure, drying at 100-110 ℃ for 1-1.5h, cooling, and roasting to obtain the ceramic carrier with the thin-wall honeycomb structure.
2. The method for preparing a ceramic carrier of a thin-walled honeycomb structure according to claim 1, wherein: the bulk density of the magnesium oxide is 0.2-0.35g/mL.
3. The method for preparing a ceramic carrier of a thin-walled honeycomb structure according to claim 1, wherein: the weight ratio of the layered double hydroxide to the magnesium oxide to the silicon carbide to the kaolin is (30-35): 1: (5-10): (30-35).
4. The method for preparing a ceramic carrier of a thin-walled honeycomb structure according to claim 1, wherein: the additive is methylcellulose and/or starch hydrolysate.
5. The method for preparing a ceramic carrier of a thin-walled honeycomb structure according to claim 4, wherein: the DE value of the starch hydrolysate is less than or equal to 20.
6. The method of making a thin-walled honeycomb structured ceramic support of any of claims 1 to 5, wherein the firing comprises: heating to 180-200 ℃ at a heating rate of 60-65 ℃/min, heating to 400-450 ℃ at a heating rate of 10-15 ℃/min, heating to 600-650 ℃ at a heating rate of 50-55 ℃/min, heating to 1000-1100 ℃ at 45-50 ℃/min, heating to 1250-1300 ℃ at a heating rate of 70-80 ℃/min, heating to 1400-1500 ℃ at a heating rate of 15-25 ℃/min, and carrying out heat preservation roasting for 8-10h.
7. The method for preparing the ceramic carrier with the thin-walled honeycomb structure according to claim 1, wherein the drying at 100-110 ℃ for 1-1.5h is specifically as follows: heating to 100-110 deg.C at a rate of 8-10 deg.C/min, and drying for 1-1.5h.
8. The method for preparing a ceramic carrier of a thin-walled honeycomb structure according to claim 1, wherein: the pressure of the extrusion forming is 8-10MPa.
9. The method for preparing a ceramic carrier of a thin-walled honeycomb structure according to claim 1, wherein: the extrusion forming speed is 12-14cm/min.
10. Use of a method of preparing a ceramic support of a thin-walled honeycomb structure according to any one of claims 1 to 9 for the preparation of a ceramic catalyst.
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