CN116104612B - Thin-wall narrow-micropore distribution cordierite diesel particulate filter and preparation method thereof - Google Patents

Thin-wall narrow-micropore distribution cordierite diesel particulate filter and preparation method thereof Download PDF

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Publication number
CN116104612B
CN116104612B CN202310200952.7A CN202310200952A CN116104612B CN 116104612 B CN116104612 B CN 116104612B CN 202310200952 A CN202310200952 A CN 202310200952A CN 116104612 B CN116104612 B CN 116104612B
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equal
cordierite
thin
temperature
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CN116104612A (en
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程国园
潘吉庆
黄妃慧
刘洪月
张兆合
江涛
郝立苗
邢延岭
关洋
陈一韬
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Shandong Aofu Environmental Protection Science & Technology Co ltd
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F01N3/0222Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D46/00Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0001Making filtering elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D46/00Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418Honeycomb filters
    • B01D46/2451Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2482Thickness, height, width, length or diameter
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D46/00Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418Honeycomb filters
    • B01D46/2451Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2484Cell density, area or aspect ratio
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/02Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
    • F01N2330/04Methods of manufacturing

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  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Filtering Materials (AREA)

Abstract

The invention belongs to the technical field of cordierite honeycomb ceramic filters, and particularly relates to a thin-wall narrow-micropore distribution cordierite diesel particle filter and a preparation method thereof. The method comprises the following steps: 1) Adopting a dry method to uniformly mix the raw materials respectively for standby; 2) Mixing kaolin, alumina, talcum, silicon dioxide, pore-forming agent and binder uniformly, mixing with lubricant and water, kneading, and refining to obtain a plastic mud section; 3) Extruding into honeycomb structure, drying and shaping; 4) Firing the green body: the initial temperature is raised at the rate of less than 30 ℃/h, the temperature is raised at the rate of less than 40 ℃/h at the temperature of 500-1000 ℃, the temperature is raised at the rate of less than 70 ℃/h at the temperature of 1000-heat preservation, and the heat preservation time is 8-16 hours; 5) And (3) punching, plugging and surrounding the cordierite honeycomb ceramic body to obtain the ceramic body. The invention can obtain the narrow micropore distribution cordierite DPF with 6 mil-8 mil thin wall, 6-10 mu m median pore diameter, D10 more than or equal to 4 mu m and D90 less than or equal to 17 mu m.

Description

Thin-wall narrow-micropore distribution cordierite diesel particulate filter and preparation method thereof
Technical Field
The invention belongs to the technical field of cordierite honeycomb ceramic filters, and particularly relates to a thin-wall narrow-micropore distribution cordierite diesel particle filter and a preparation method thereof.
Background
Exhaust particles of automobile exhaust, especially fine particles and polycyclic aromatic hydrocarbons with carcinogenic mutation effect, can cause great harm to the environment and human health. With the increasing severity of environmental pollution, people are increasingly aware that controlling automobile exhaust emissions is one of the most economical and effective means of controlling environmental pollution. The honeycomb ceramic filter has wide application in removing automobile exhaust particulate matters due to the unique wall flow structure, and can well filter carbon smoke particles in exhaust gas to purify the exhaust gas. However, with the continuous tightening of emission regulations, the traditional post-treatment technology cannot meet the use requirement, and needs to be optimized and upgraded, so that a new honeycomb ceramic technology meeting the severe regulation limits of China seven and the like is developed, and therefore, a thin-wall high-filtration-efficiency honeycomb ceramic filter becomes a research hot spot.
At present, the wall thickness of a Diesel Particulate Filter (DPF) which meets the national six-law regulation limit standard and is used in a large amount is generally 9-12 mil, and the median pore diameter is 9-13 mu m. The porosity of the conventional cordierite diesel particulate filter is generally 45-55%, the wall thickness is 8-10 mil, the median pore diameter is 9-13 mu m, the filter belongs to a porous structure of cordierite, the porous structure is mainly obtained by pore forming of an organic pore forming material, the particle size of the organic pore forming material has a large influence on the median pore diameter of the filter, the median pore diameter of the filter using coarse-particle pore forming material is large, and the median pore diameter of the filter using fine-particle pore forming material is small. However, for a thin-wall 6-8 mil product, the honeycomb ceramic filter is formed by extrusion through a die, so that not only is the granularity of a pore-forming material used reduced or the granularity distribution narrowed, but also the granularity and the distribution of other raw materials are required to be controlled, and the raw materials with thicker granularity or wider granularity distribution cannot be extruded through the die because the width of the groove of the die is narrower; meanwhile, in order to ensure high filtering efficiency of the product, the preparation of the honeycomb ceramic filter with narrow micropore distribution is needed, and the invention solves the problem of extrusion molding by controlling the particle size distribution of raw materials, and also achieves narrow micropore distribution and high filtering efficiency. On the other hand, the thinner the wall thickness of the filter is, the greater the extrusion molding difficulty is, because the thinner the wall thickness is, the easier the extruded green body collapses, the thinner the wall thickness increases the requirement on the pug, the pug hardness must be improved, and the pug lubricity must be increased, which is also another difficulty in developing the thin-wall product to be solved by the invention.
Disclosure of Invention
In order to solve the defects in the prior art, the invention provides a cordierite DPF with 6 mil-8 mil thin wall, 6-10 mu m median pore diameter and narrow micropore distribution, and a preparation method of the cordierite DPF. In terms of technology, DPF thinning can cause the reduction of median pore diameter, because honeycomb ceramics are extruded and molded by using a die, the width of the die groove limits the granularity of raw materials, and the development difficulty of products with thin walls and large median pore diameters is increased; meanwhile, the thin wall increases the cracking risk of the product in use; meanwhile, the difficulty of the extrusion molding process is increased by the thin-wall product, and the product is easier to collapse when the wall thickness is thinner, so that the requirements on hardness and lubricity of the pug before extrusion are higher. The advantage of the present invention is that a narrower pore distribution and thinner wall thickness is successfully achieved, resulting in a significant reduction in DPF pressure drop. In one aspect, thinning can reduce pressure drop. On the other hand, the narrow pore distribution also contributes significantly to the pressure drop reduction. The material has a median pore diameter of 6-10 mu m, and also has narrow micropore distribution with D10 more than or equal to 4 mu m and D90 less than or equal to 17 mu m. On the other hand, the narrow micropore distribution DPF prepared by the method increases the uniformity of micropores, has better heat shock resistance and ensures the use safety.
The technical scheme provided by the invention is as follows:
a preparation method of a thin-wall narrow-micropore-distribution cordierite diesel particulate filter comprises the following steps:
1) The method comprises the steps of adopting a dry method to respectively and uniformly mix raw materials for preparing cordierite for later use, wherein the raw materials comprise raw kaolin, calcined kaolin, alumina, talcum, silicon dioxide, pore-forming agent and binder;
2) Firstly, uniformly mixing raw kaolin, calcined kaolin, alumina, talcum, silicon dioxide, pore-forming agent and binder, and then, carrying out wet mixing kneading on uniformly mixed powder, lubricant and water to prepare a mud section with plasticity;
3) Extruding the plastic mud section into a honeycomb structure, and drying and shaping;
4) Firing the green body: heating the initial temperature to 500 ℃ at a speed of less than 30 ℃/h, heating the initial temperature to 500-1000 ℃ at a speed of less than 40 ℃/h, heating the temperature to 1000 ℃ to a temperature to be kept at the temperature of less than 70 ℃/h, and keeping the temperature for 8-16 hours to obtain a cordierite honeycomb ceramic body, wherein the initial temperature is 0-30 ℃, and the temperature to be kept at 1410-1440 ℃;
5) And (3) punching, plugging and surrounding the obtained cordierite honeycomb ceramic body to obtain the finished product of the thin-wall narrow-micropore distributed cordierite diesel particle filter.
Based on the technical scheme, the narrow micropore distribution cordierite DPF with 6 mil-8 mil ultrathin wall, 6-10 mu m median pore diameter, D10 more than or equal to 4 mu m and D90 less than or equal to 17 mu m can be obtained.
Specifically, the particle size D50 of talcum is 23-26 mu m, and D100 is less than or equal to 80 mu m; the addition amount is less than or equal to 45 weight percent.
In the technical scheme, too large particle size distribution of talcum can lead to difficult extrusion molding and wide micropore distribution of products.
Specifically, the granularity D50 of the raw kaolin is 8-10 mu m, and D100 is less than or equal to 21 mu m; the addition amount is less than or equal to 15wt%.
In the technical scheme, the raw kaolin has overlarge particle size distribution, which can lead to wide micropore distribution of the product.
Specifically, the granularity D50 of the calcined kaolin is 8-10 mu m, and D100 is less than or equal to 21 mu m; the addition amount is less than or equal to 15wt%.
In the technical scheme, the too large particle size distribution of the calcined kaolin can lead to wide micropore distribution of the product.
Specifically, the granularity D50 of the alumina is 5-6 mu m, and D100 is less than or equal to 18 mu m; the addition amount is less than or equal to 21wt%.
In the technical scheme, the excessive granularity distribution of the alumina can lead to wide micropore distribution of the product.
Specifically, the granularity D50 of the silicon dioxide is 28-30 mu m, and D100 is less than or equal to 63 mu m; the addition amount is less than or equal to 23 weight percent.
In the technical scheme, the excessive size distribution of the silicon dioxide can cause difficult extrusion molding and wide micropore distribution of the product.
Specifically, the granularity D50 of the first pore-forming agent is 25-27 mu m, and D100 is less than or equal to 59 mu m; the addition amount is less than or equal to 30 weight percent;
specifically, the granularity D50 of the second pore-forming agent is 16-18 mu m, and D100 is less than or equal to 40 mu m; the addition amount is less than or equal to 30 weight percent.
In the technical scheme, too large particle size distribution of the pore-forming agent can lead to difficult extrusion molding and wide micropore distribution of the product.
Specifically, the addition amount of the binder is less than or equal to 10wt%.
Specifically, the addition amount of the lubricant is less than or equal to 4wt%.
The invention also provides the thin-wall and narrow-micropore-distribution cordierite diesel particle filter prepared by the method.
The DPF has the advantages of narrow micropore distribution, uniform micropores and good connectivity, and can improve the filtering efficiency of finer particle soot. At the same time, the microporous distribution is narrowed, the wall thickness is thinned, and the purpose of reducing the back pressure can be achieved. It may be used as a diesel particulate filter for seventh stage emission regulations.
The honeycomb ceramic grid can be in a single geometric shape such as triangle, square, hexagon, circle and the like, can be in various geometric shapes, can be in an asymmetric structure, and can be in a symmetrical structure.
The cell density of the honeycomb ceramics of the invention can be any cell density capable of being extruded into a honeycomb shape, such as 200cpsi, 300cpsi, 400cpsi, etc.
Drawings
FIG. 1 is a honeycomb ceramic filter pore distribution of example 5 of the present invention.
FIG. 2 is a microscopic image of a honeycomb ceramic filter of example 5 of the present invention.
Detailed Description
The principles and features of the present invention are described below with examples only to illustrate the present invention and not to limit the scope of the present invention.
The raw materials for preparing the thin-wall, narrow-micropore distributed honeycomb ceramics are shown in table 1.
TABLE 1 list of raw materials
The preparation method of the thin-wall narrow-micropore-distribution cordierite diesel particle filter comprises the following steps:
1) The method comprises the steps of adopting a dry method to respectively and uniformly mix raw materials for preparing cordierite for later use, wherein the raw materials comprise raw kaolin, calcined kaolin, alumina, talcum, silicon dioxide, pore-forming agent and binder;
2) Firstly, uniformly mixing raw kaolin, calcined kaolin, alumina, talcum, silicon dioxide, pore-forming agent and binder, then, wet-mixing and kneading uniformly mixed powder, lubricant and water to prepare a plastic mud section, wherein pore-forming agents 1 and 2 are polymethyl methacrylate respectively;
3) Extruding the plastic mud section into a honeycomb structure, and drying and shaping;
4) Firing the green body, wherein the specific parameters are unified as follows: heating at 25-500 deg.c at about 10 deg.c/hr, heating at 500-1000 deg.c at about 20 deg.c/hr, heating at 1000-1425 deg.c at about 25 deg.c/hr, and maintaining for 10 hr to obtain honeycomb cordierite ceramic body;
5) And (3) punching, plugging and surrounding the obtained cordierite honeycomb ceramic body to obtain the finished product of the thin-wall narrow-micropore distributed cordierite diesel particle filter.
Specific embodiments are shown in table 2:
table 2 list of embodiments
Comparative examples 1 and 2 are honeycomb ceramic filters prepared from a common raw material which satisfies the national six-stage emission regulation standard, has the same D50 as the raw materials listed in table 1, has a D100 outside the control range, and has a broad particle size distribution, and has a slightly broad micropore distribution.
Examples 1 to 6 are thin-walled, narrow-pore-distribution honeycomb ceramic filters prepared using the raw materials with narrow particle size distribution in table 1, which can satisfy the extrusion molding properties of 6 to 8mil for thin walls due to the narrow particle size distribution of the raw materials. Meanwhile, the raw materials with narrow particle size distribution can reduce the micropore distribution, the raw materials with the same particle size D50 have narrower particle size distribution, the product has narrower micropore distribution, the micropores are more uniform, the connectivity is better, the filtering efficiency of the product is higher, and the thermal shock performance is better. In comparative examples 1 and 2, the raw material particle size D100 was not limited, and the extrusion of 6 to 8mil thin-walled honeycomb ceramic filters was likely to be difficult, and the distribution of micropores in the honeycomb ceramics was broad.
Comparative example 5 and example 6, the median pore diameter of the micropores can be adjusted by adjusting the particle size of the pore-forming agent; as can be seen from comparative examples 1 to 6 and comparative examples 1 to 2, the porosity can be adjusted by adjusting the types and proportions of the raw materials, and the porosity can be adjusted not only by adjusting the types and proportions of the raw materials, but also by adjusting the addition amount of the pore-forming agent, which is not shown in the limited examples.
The thin-wall product has very high requirement on the material property of mud, and the addition of the raw kaolin is very beneficial to the extrusion molding of the thin-wall product, and meanwhile, the raw kaolin can enhance the green body strength.
The foregoing description of the preferred embodiments of the invention is not intended to limit the invention to the precise form disclosed, and any such modifications, equivalents, and alternatives falling within the spirit and scope of the invention are intended to be included within the scope of the invention.

Claims (4)

1. A preparation method of a thin-wall narrow-micropore-distribution cordierite diesel particulate filter is characterized by comprising the following specific steps:
1) The method comprises the steps of adopting a dry method to uniformly mix raw materials for preparing cordierite respectively for later use, wherein the raw materials consist of raw kaolin, calcined kaolin, alumina, talcum, silicon dioxide, pore-forming agent and binder;
2) Firstly, uniformly mixing raw kaolin, calcined kaolin, alumina, talcum, silicon dioxide, pore-forming agent and binder, and then, carrying out wet mixing kneading on uniformly mixed powder, lubricant and water to prepare a mud section with plasticity;
3) Extruding the plastic mud section into a honeycomb structure, and drying and shaping;
4) Firing the green body: heating the initial temperature to 500 ℃ at a speed of less than 30 ℃/h, heating the initial temperature to 500-1000 ℃ at a speed of less than 40 ℃/h, heating the temperature to 1000 ℃ to a temperature to be kept at the temperature of less than 70 ℃/h, and keeping the temperature for 8-16 hours to obtain a cordierite honeycomb ceramic body, wherein the initial temperature is 0-30 ℃, and the temperature to be kept at 1410-1440 ℃;
5) Punching, plugging and surrounding the obtained cordierite honeycomb ceramic body to obtain a finished product of a thin-wall narrow-micropore-distribution cordierite diesel particle filter, wherein the finished product of the cordierite diesel particle filter has a thin wall of 6 mil-8 mil, a median pore diameter of 6-10 mu m, a narrow micropore distribution of D10 is more than or equal to 4 mu m and D90 is less than or equal to 17 mu m;
the granularity D50 of the talcum is 23-26 mu m, and D100 is less than or equal to 80 mu m; the addition amount is less than or equal to 45wt%;
the granularity D50 of the raw kaolin is 8-10 mu m, and D100 is less than or equal to 21 mu m; the addition amount is less than or equal to 15wt%;
the granularity D50 of the calcined kaolin is 8-10 mu m, and D100 is less than or equal to 21 mu m; the addition amount is less than or equal to 15wt%;
the granularity D50 of the alumina is 5-6 mu m, and D100 is less than or equal to 18 mu m; the addition amount is less than or equal to 21wt%;
the granularity D50 of the silicon dioxide is 28-30 mu m, and D100 is less than or equal to 63 mu m; the addition amount is less than or equal to 23 weight percent;
the granularity D50 of the pore-forming agent is 25-27 mu m, and D100 is less than or equal to 59 mu m; the addition amount is less than or equal to 30 weight percent; or the granularity D50 of the pore-forming agent is 16-18 mu m, and D100 is less than or equal to 40 mu m; the addition amount is less than or equal to 30 weight percent.
2. A thin-walled, narrow-pore distribution cordierite diesel particulate filter prepared according to the method of claim 1.
3. The thin-walled, narrow-pore distribution cordierite diesel particulate filter of claim 2, wherein: the selection of the shape of the honeycomb cell in the honeycomb structure includes, but is not limited to: triangular, tetragonal, hexagonal single hole shape, and tetragonal, hexagonal asymmetric shape.
4. The thin-walled, narrow-pore distribution cordierite diesel particulate filter of claim 2, wherein: the selection of cell density for honeycomb structures includes, but is not limited to: 200cpsi, 300cpsi, and 400cpsi.
CN202310200952.7A 2023-03-06 2023-03-06 Thin-wall narrow-micropore distribution cordierite diesel particulate filter and preparation method thereof Active CN116104612B (en)

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CN117720334B (en) * 2024-01-30 2024-05-14 山东奥福环保科技股份有限公司 High-porosity, thin-wall and high-strength honeycomb ceramic and preparation method and application thereof

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CN115108819A (en) * 2022-02-22 2022-09-27 山东奥福环保科技股份有限公司 Large-size thin-wall narrow-pore-size-distribution wall-flow honeycomb ceramic catalyst carrier and preparation method thereof

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