JP2005111331A - Catalyst carrier and catalyst filter - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a catalyst carrier capable of ensuring strengths after baking even if much pulp is contained and having a void ratio of 40% or above. <P>SOLUTION: Paper composed of inorganic fibers, organic fibers, an inorganic binder and an organic binder is impregnated with a dispersion of the inorganic binder and an inorganic filler and the impregnated paper is baked to obtain the catalyst carrier having both of strengths and the void ratio. Further, even from paper containing an organic component in a large quantity, a catalyst supported filter having strengths can be obtained by infiltrating slurry into a honeycomb filter, which is formed by laminating single-faced corrugated molded objects, each of which is formed by laminating a corrugated sheet comprising the above paper and flat paper, and baking the infiltrated honeycomb filter. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a support for a catalyst or a hygroscopic agent and a filter carrying the catalyst and the hygroscopic agent.

  Conventionally, this type of honeycomb-shaped carrier is obtained by processing a paper made of ceramic fibers or glass fibers and organic fibers as components and minerals such as mountain bark (sepiolite) as a base paper into a honeycomb shape. A material in which an inorganic honeycomb carrier is formed by firing is known (see, for example, Patent Document 1).

  Hereinafter, the honeycomb-shaped catalyst carrier will be described with reference to FIG. 1 and FIG.

  As shown in FIG. 1, ceramic paper 101 is made of ceramic fibers, pulp, mountain bark, organic and inorganic binders, and is a piece of ceramic paper 102 that has been processed into a wave shape and bonded with an organic and inorganic mixed adhesive. A wave forming body is formed. As shown in FIG. 2, the single-wave molded body of FIG. 1 is laminated to obtain a honeycomb-shaped laminated body. By firing it, a honeycomb-shaped catalyst carrier can be obtained.

  Further, in this type of honeycomb-shaped support, a sheet made of ceramic fiber, pulp, organic or inorganic binder is formed as a component into a honeycomb shape, impregnated with colloidal silica or ethyl silicate, and then the silicon compound is mixed with silica gel. It is known that a catalyst carrier can be obtained as a result of burning and removing organic matter in the sheet by converting to sinter and then firing (see, for example, Patent Document 2).

The ceramic paper 101 shown in FIG. 1 is composed of ceramic fibers, organic fibers, and organic binders. FIG. 2 shows a single-wave molded body in which this paper is bonded to a ceramic paper 102 processed into a wave. Process into a honeycomb laminate. This is impregnated into a colloidal silica or ethyl silicate solution and heat-treated to cure the honeycomb-shaped laminate.
Japanese Patent Laid-Open No. 5-64745 (FIGS. 1 and 2) Japanese Patent Laid-Open No. 4-18896

  Originally, organic pulp is required in the paper in order to form a one-wave structure, and in order to use it as a catalyst carrier, it is necessary to eventually burn off the organic matter by firing. However, in such a conventional honeycomb-shaped catalyst carrier, the burned-out portion becomes a cavity and the strength is weakened, so that the amount of the organic pulp is reduced as much as possible. However, if the organic pulp content is small, single-wave processing becomes difficult, and there is a problem that it is difficult to produce a large amount quickly. Further, when colloidal silica or the like is impregnated in order to obtain sufficient strength, the particle size is small, so that there is a problem that the particles enter into the back of the fiber and it is difficult to obtain a space for supporting the catalyst. For this reason, such a single-wave honeycomb catalyst carrier is required to have a structure having a high porosity with sufficient strength after firing even if there is a large amount of organic matter in a state where paper is rolled up.

  The present invention solves such a conventional problem, and provides a catalyst carrier that can ensure strength after firing even if it contains a large amount of pulp, and has a porosity of 40% or more. The purpose is that.

  Another object of the present invention is to obtain a catalyst filter, an adsorption filter, and an adsorption catalyst filter by impregnating a catalyst carrier processed into a honeycomb shape into a dispersion medium of catalyst particles, adsorbent particles, or a mixed material of an adsorbent and a catalyst. It is said.

  In order to achieve the above object, the catalyst carrier of the present invention is impregnated with a dispersion of colloidal silica and a filler such as talc and fired, even if it is a ceramic fiber mixed paper containing a large amount of organic pulp. Thus, it is possible to obtain a catalyst carrier having a high porosity even after firing.

  By this means, the strength after firing of the single-wave honeycomb structure can be improved with a relatively small amount of colloidal silica, and a structure having a high porosity can be obtained.

  Further, by supporting a catalyst or adsorbent on the catalyst carrier obtained by this method, a catalytic reaction filter that can be used in a gas phase or a liquid phase and an adsorption filter that can adsorb and desorb gas and moisture can be obtained.

  According to the present invention, it is possible to provide a catalyst carrier having an effect of being light and strong.

  Moreover, an air purification filter, an air reforming filter, etc. can be provided by producing the catalyst carrier and supporting the catalyst or adsorbent on the catalyst carrier.

  Moreover, since the ceramic paper contains a large amount of organic pulp, the porosity after firing is high, and the amount of catalyst and adsorbent attached is large.

  In the present invention, 40 to 80% by weight of inorganic fibers, preferably 0 to 80% by weight of ceramic fibers, 0 to 80% by weight of glass fibers, and 0 to 20% by weight of other inorganic mineral-based fibrous substances, the total amount of inorganic fibers 60 to 60%. When the composition is 80% by weight and the organic pulp is 5 to 30% by weight, it is difficult to process the paper with a low composition, and when the composition is too high, the voids of the structure after firing are too large to maintain the strength of the structure. Therefore, preferably 10 to 25% by weight, inorganic fiber paper squeezed using one or both of an organic binder and an inorganic binder as a main raw material, an inorganic binder, preferably colloidal silica, and an inorganic filler, preferably talc, sepiolite. After impregnating a dispersion of magnesium silicate, etc., and drying it, it is preferably fired at 400 ° C or higher, preferably at 800 ° C or higher only when the shape of the paper does not change In the case of paper containing the organic fiber and the organic binder, a catalyst carrier obtained by burning off the organic binder and a method for producing the catalyst carrier are shown. Even improved paper has the characteristic that the strength after firing is maintained by the inorganic filler and the inorganic binder that binds it.

  In the present invention, the inorganic fiber paper is formed into a single wave molded body, the single wave molded bodies are laminated to form a honeycomb block body, and the honeycomb block body is formed of the inorganic filler and the inorganic binder. By firing the honeycomb structure dried on the dispersion at the above temperature, a catalyst carrier filter having a wide opening area, a low pressure loss, and a wide contact area can be obtained. As a laminating method, there are a method of superimposing single waves one by one, and a method of obtaining a circular laminate that winds up a long single-wave molded body.

  The catalyst carrier filter described above is impregnated with a dispersion liquid in which a catalyst material and an inorganic binder are dispersed, and the catalyst is supported on the voids and the surface inside the paper of the honeycomb structure so as to be used for a gas phase or liquid phase reaction. A catalytic filter is obtained.

  Further, the inorganic fiber paper is formed into a single-wave molded body, the single-wave molded bodies are laminated to form a honeycomb-shaped block body, and the honeycomb-shaped block is attached to a dispersion of the inorganic filler and the inorganic binder. After drying, before firing the honeycomb structure at the above temperature, impregnated with a dispersion liquid in which the catalyst material and the inorganic binder are dispersed, and the catalyst is supported in the voids and the surface inside the paper of the honeycomb structure, and thereafter Thus, a honeycomb-structured gas phase or liquid phase reaction catalyst filter can also be obtained by firing at the above temperature.

  The gas phase reaction catalyst filter obtained by using the production method described above can be used in an air purifier or the like, and can be used for air purification and reforming.

  In addition, the catalyst filter for liquid phase reaction obtained using the manufacturing method of the said method can be utilized as a purifier of a river or waste water.

  By using an adsorbent instead of the catalyst, an adsorption / desorption filter that adsorbs / desorbs organic gas and moisture in the air can be obtained. In addition, since the substance adsorbed on the adsorbent is released from the adsorbent by thermal energy such as a heater, it can be used for humidity control or gas concentration by separating the adsorption and release systems.

  The moisture absorption / desorption filter can be used in a dehumidifier, a humidity controller, and the like.

  Furthermore, by supporting the catalyst and adsorbent on the honeycomb structure at the same time or adsorbing catalyst particles carrying catalyst particles on the adsorbent surface, the organic gas or the like is concentrated by adsorption, and a heat source such as a heater in another part. Alternatively, it is possible to obtain an adsorptive decomposition filter that causes decomposition by reacting a substance adsorbed with a catalyst by energy of light.

  The adsorptive decomposition filter can be applied to a deodorizer, a decomposition apparatus for low-concentration chemical substances including environmental hormones in the liquid phase, and the like.

  Embodiments of the present invention will be described below with reference to the drawings.

  In addition, the same number is attached | subjected about the same component as the past, and the description is abbreviate | omitted.

(Example 1)
It consists of 70% ceramic fiber and 8% glass fiber as inorganic fiber, 10% pulp as organic fiber, 10% organic binder and 2% inorganic binder, 0.2mm thickness and 52g / m basis weight. Using the paper-made ceramic paper of No. ² as 101, talc (for example, Nippon Talc Co., Ltd. L-1) as an inorganic filler, colloidal silica (for example, Nissan Chemical Co., Ltd. Snowtex C) as an inorganic binder, and a foam inhibitor ( For example, Sannoco Co., Ltd. SN deformer 380) and water were sufficiently stirred using a magnetic stirrer in a blending slurry as shown in A, B, and C of Table 1, and impregnated with the ceramic paper 101. Thereafter, the organic material was removed by baking at 550 ° C. for 2 hours.

(Example 2)
Ceramic paper made of 60% by weight ceramic fiber, 9% by weight inorganic fiber, 17% by weight pulp, 12% by weight organic binder, and 2% by weight inorganic binder, with a thickness of 0.17 mm and a basis weight of 53 g / m ² 101 was impregnated with a liquid having the same composition as in Example 1 as shown in D, E, and F of Table 1 above, and then baked at 550 ° C. for 2 hours to remove organic substances.

(Comparative example)
The ceramic paper 101 used in Example 1 and Example 2 was applied once or twice to colloidal silica (for example, Nissan Chemical Co., Ltd. Snowtex C, Snowtex 40) as shown in Comparative Examples-GL of Table 1 above. After impregnating and drying, the organic matter was removed by baking at 550 ° C. for 2 hours in the same manner as in Example 1 and Example 2.

  The solid content in the impregnation liquid of the ceramic paper 101 shown in Example 1 and Example 2 is 20 to 18 parts by weight of colloidal silica with respect to 1 to 10 parts by weight of talc, and the amount of talc of about 1 part by weight. With the addition of no significant change is seen. On the other hand, if too much is added, the strength is not improved and the weight of the paper is increased, resulting in waste. Preferably it is 19.5-17 weight part with respect to 3-10 weight part of talc.

  The solid content concentration of the impregnating liquid is preferably 30% by weight or less because sedimentation proceeds at a high concentration or a significant increase in viscosity occurs. On the other hand, in a dilute liquid of 10% by weight or less, there is little loading of solid content by one impregnation, and in order to obtain the desired strength after firing, impregnation more than once is necessary. A solids concentration of less than 30% by weight is desirable.

  In Example 1 and Example 2 above, talc was used as the inorganic filler in the impregnating liquid, but this is a plate-like particle, preferably having a particle size of 1 μm or less, from 5 μm. Larger particles are not preferred because the filler settles in the dispersion and is difficult to handle. Also, if the particle size is large, it is difficult for the particles to enter the gaps between the fibers of the ceramic paper 101, the inorganic binder and the inorganic fibers are difficult to bond, and the strength after firing is difficult to obtain. Can be said to be desirable.

  In addition, instead of the talc of Example 1 and Example 2, fibrous fillers such as sepiolite, zonotolite, wollastonite, gypsum fiber, and dawsonite as inorganic fillers, silicon carbide whiskers, silicon nitride whiskers, potassium titanate whiskers, and the like Whisker crystals, other zonotlites, zeolites and the like may be used.

  In Example 1 and Example 2, colloidal silica was used as the inorganic binder, but alumina sol, sodium silicate, silica sol dispersed in an organic solvent, lithium silicate, or the like may be used.

  Conventionally, paper having a pulp fiber content of several weight% has been desirable. However, in view of processability including a honeycomb shape, it is desirable that the organic content is large. Is 20% by weight or more in total, sufficient strength can be obtained by adding talc and an inorganic binder.

(Example 3)
The ceramic paper 101 used in Example 1 was used to form a corrugated paper 101 having a wavelength of 2.6 mm and a wave height of 1.5 mm. The solid content was 24% acrylic ester, 36% ethylene vinyl acetate, and 40% colloidal silica. 1 is bonded to the flat paper 102 to form a single-wave molded body shown in FIG. 1, and the single-wave molded body is laminated using the same adhesive as described above, and the honeycomb-shaped laminated body shown in FIG. Get the body. This honeycomb-shaped laminate was impregnated with the impregnation liquid of Example 1-B shown in Table 1 above, dried, and fired using a pattern as shown in Table 2.

  As shown in Table 2, the maximum temperature during firing is preferably 800 ° C. or higher because the compressive strength of the honeycomb structure is improved.

  In Example 3, the maximum firing temperature was 800 ° C., but may be a higher temperature as long as the porosity does not decrease due to deformation of the honeycomb-shaped laminate or melting of the material.

Example 4
As in Example 3-C, a honeycomb-shaped laminated catalyst carrier obtained by impregnating the impregnating solution of Example 1-B in Table 1 and calcining at a temperature of 800 ° C. or higher is obtained by using, for example, a platinum catalyst, manganese A catalyst-carrying filter is obtained by impregnating a catalyst particle such as a palladium catalyst, a palladium catalyst, a tin catalyst, or a titanium catalyst with a dispersion of, for example, colloidal silica, lithium silicate, or sodium silicate, followed by heat drying. .

(Example 5)
As in Example 3-C, a honeycomb-shaped laminated catalyst carrier obtained by impregnating the impregnating liquid of Example 1-B in Table 1 and calcining at a temperature of 800 ° C. or higher is obtained by using, for example, zeolite or silica gel. An adsorption / desorption filter is obtained by impregnating an adsorbent and a dispersion such as colloidal silica, lithium silicate, sodium silicate and the like, followed by heat drying.

(Example 6)
The honeycomb-shaped laminated catalyst carrier obtained by impregnating the impregnating liquid of Example 1-B in Table 1 as described in Example 3-C and calcining at a temperature of 800 ° C. or higher is obtained by, for example, hydrophilic zeolite or hydrophobic Adsorbents such as water-soluble zeolite and silica gel, and catalyst particles such as platinum-based catalysts, manganese-based catalysts, palladium-based catalysts, tin-based catalysts, and titanium-based catalysts, and dispersions such as colloidal silica, lithium silicate, and sodium silicate. An adsorptive decomposition filter for the purpose of decomposing the adsorbate by the catalyst is obtained by impregnation and heat drying.

(Example 7)
In particular, in the filter obtained by any one of Examples 4 to 6, the honeycomb laminated body is formed into a circular shape as shown in FIG. 5, and the circular filter is rotated by the filter rotation power unit 105, thereby rotating the honeycomb type. The continuous regeneration type catalyst filter, adsorption / desorption filter, and adsorption / decomposition filter can be obtained. In particular, in the case of an adsorption / desorption filter, by providing the ventilation part 103 and the heat treatment part 104 to the ventilation hole of the obtained filter, the ventilation part 103 adsorbs organic gas and moisture in the gas, and heat treatment is performed. The organic gas and moisture are desorbed in the unit 104, and the filter can be regenerated so that the gas and moisture can be adsorbed in the ventilation unit 103, and continuous use is possible. In the case of an adsorption decomposition filter, by providing a light source in place of the heat treatment unit 104 or the heat treatment unit 104, an organic gas in the gas is adsorbed by the ventilation unit, and a heat treatment unit or a light irradiation unit (not shown). In this case, the reaction between the catalyst and the organic gas is caused by the thermal energy or light energy, the organic gas is decomposed, and the filter can be regenerated so that the organic gas can be adsorbed by the vent 103 again. Can be used. In addition, in the catalyst filter, an apparatus capable of continuously decomposing organic gas can be obtained by placing a heat treatment unit or a light source in the rear part of the ventilation unit 103.

(Example 8)
In any of Examples 4 to 6, after impregnating the impregnation liquid of Example 1-B in Table 1 above, the catalyst dispersion or adsorbent dispersion described in any of Examples 4 to 6 The catalyst filter, adsorption / desorption filter, or adsorptive decomposition filter can also be obtained by impregnating the liquid or a mixed dispersion of adsorbent and catalyst, drying, and then burning off the organic components in a temperature range where the material does not deteriorate. Thus, a rotary filter as in the seventh embodiment can be obtained.

  The catalyst carrier and the catalyst filter of the present invention provide a catalyst carrier having a thin wall surface compared to the extrusion molding or the like in the conventional catalyst carrier because the ceramic paper is subjected to one-wave processing and further laminating processing, and the conventional ceramic fiber The amount of pulp in the ceramic paper is larger than that of the mixed paper of the organic pulp and the characteristics of improving the processability of the ceramic paper are obtained, which is expected to improve the productivity compared to the conventional catalyst carrier . Further, even if there is no special equipment or technique for processing special paper, since the paper processability is improved, a catalyst carrier having hardness can be obtained relatively easily.

  Further, a filter carrying a catalyst or an adsorbent can be used by being incorporated in a device for purifying and reforming the gas phase and liquid phase.

Illustration of a single wave molded body Illustration of honeycomb-shaped single-wave laminate Fig. 1 Relationship between basic weight and strength Diagram of relationship between basis weight and strength 2 Diagram showing a circular honeycomb laminate and a rotating regeneration structure

Explanation of symbols

101 Ceramic paper (flat paper)
102 Ceramic paper (wave paper)
103 Ventilation part (adsorption part)
104 Heat treatment unit (reproduction unit)
105 Filter rotation power section

Claims (14)

Organic paper and inorganic fiber, and paper squeezed using one or both of organic binder and inorganic binder as a binder component are dipped in a dispersion of inorganic binder and inorganic filler and then dried. A catalyst carrier obtained by burning off the organic binder when the organic fiber and the organic binder are used as raw materials. The catalyst carrier according to claim 1, wherein a magnesium silicate compound is used as the inorganic filler. The catalyst carrier according to claim 2, wherein talc is used as the magnesium silicate compound. Paper made of 5 to 30% by weight of organic fibers, 40 to 80% by weight of inorganic fibers, and 5 to 20% by weight of one or both of an organic binder and an inorganic binder as a binder component. 4. 30% by weight, 1-10% by weight of an inorganic filler and 65-90% by weight of water dispersion and dried, and the baking temperature is 400 ° C. or higher. Catalyst carrier. A sheet of paper made of 5 to 30% by weight of organic fiber, 40 to 80% by weight of inorganic fiber, and 5 to 20% by weight of one or both of an organic binder and an inorganic binder is formed into a single-wave molded body. The single-wave molded body is laminated to form a honeycomb block body, and the honeycomb block is applied to a dispersion of 10 to 30% by weight of an inorganic binder, 1 to 10% by weight of an inorganic filler, and 65 to 90% by weight of water. A honeycomb-shaped catalyst carrier obtained by burning off the organic binder when the organic fiber and an organic binder are used as the binder at a drying and burning temperature of 400 ° C. or higher. A catalyst filter for gas phase or liquid phase reaction, wherein a catalyst material is supported on the honeycomb-shaped catalyst carrier according to claim 5. A gas phase or liquid phase reaction comprising a structure in which the honeycomb catalyst carrier according to claim 5 is impregnated in a dispersion liquid in which a catalyst material and an inorganic binder are dispersed, thereby supporting the catalyst material on the inside and on the surface of the honeycomb catalyst carrier. Catalyst filter. A sheet of paper made from 5 to 30% by weight of organic fiber, 40 to 80% by weight of inorganic fiber, and 5 to 20% by weight of one or both of an organic binder and an inorganic binder is formed into a single wave molded body. The single-wave molded body is laminated to form a honeycomb-shaped block body, and the honeycomb-shaped block is applied to a dispersion of 10 to 30% by weight of an inorganic binder, 1 to 10% by weight of an inorganic filler, and 65 to 90% by weight of a solvent. The dried honeycomb structure is impregnated with a dispersion in which the catalyst material and the inorganic binder are dispersed, whereby the catalyst is supported in the voids and the surface inside the paper of the honeycomb structure, and this is fired at least at 400 ° C. or more. Catalytic filter for gas phase or liquid phase reaction. The catalyst filter according to any one of claims 6 to 8, wherein the catalyst and the organic component chemically react with each other by passing heat through the gas containing the organic component or through the gas, and other energy action. Used air purifier. The water quality using the catalyst filter according to any one of claims 6 to 8, wherein the catalyst and the organic component react with each other by the action of heat, light, or other energy through the liquid containing or containing the organic component. Improvement device. 9. The adsorption / desorption filter according to any one of claims 6 to 8, wherein an adsorbent is used instead of the catalyst, and the adsorbent is supported in a void portion and a surface inside the paper of the honeycomb catalyst carrier. The air conditioner using the adsorption / desorption filter according to claim 11, wherein the air passing through is conditioned by passing air containing moisture. 9. The adsorptive decomposition filter according to any one of claims 6 to 8, wherein a composite material using a mixture of an adsorbing material and a catalyst material is supported in a void and a surface inside the paper of the honeycomb catalyst carrier instead of the catalyst. Air containing organic gas, organic gas, and liquid containing organic components are passed through, adsorbing these organic compounds to the adsorbent, and the catalyst and organic compounds react by heat, light, and other energy action in another place. An apparatus for improving water and air quality using the filter according to claim 13.

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