JP2006199043A - Laminate with excellent dust collection efficiency - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a laminate suitable for bag filter cloth, which is able to retain its function while keeping up sufficient strength even under severe conditions of requiring heat and chemical resistances, low in pressure loss to allow fine dust collection, and excellent in dust collection efficiency. <P>SOLUTION: The laminate with excellent dust collection efficiency comprises a sheet laminate having web layers on both sides of a base cloth, and the base cloth and the web layers are intertwined; wherein the base cloth consists of polyphenylene sulfide and/or polytetrafluoroethylene, and 20% or more of at least one of the web layers consists of a polyphenylene sulfide yarn having a surface area of 230-800 m<SP>2</SP>/Kg. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

The present invention relates to a laminate mainly composed of polyphenylene sulfide (hereinafter referred to as “PPS”) fibers, and particularly to a laminate excellent in dust collection efficiency, which is suitably used as a filter requiring heat resistance and chemical resistance. .

Exhaust gas generated from coal-fired boilers, municipal waste incinerators, industrial waste incinerators, metal melting / calcining furnaces, etc. contains a large amount of harmful substances and soot. Is important to. Various methods are known for exhaust gas dust collection. Recently, a filtration type dust collection method using a bag filter has attracted attention from the viewpoint of good dust collection efficiency and dioxin reduction measures.

  Bag filter filtration type dust collection method generally uses a filter cloth sewn in a cylindrical shape or envelope shape. Usually, the filter cloth has an appropriate fiber according to the required degree of heat resistance and chemical resistance. The material is selected.

  The exhaust gas temperature at the dust collector inlet in the exhaust gas dust collection of the above-described boiler and incinerator is generally about 130 to 250 ° C. If the temperature is 130 ° C. or lower, a general-purpose fiber such as polyester is used as a filter cloth material. If the temperature is 130 ° C. or higher, a so-called heat resistant fiber is used. Among them, the PPS fiber of the present invention has a heat-resistant temperature of 190 ° C. and is excellent in acid resistance and alkali resistance, so that it has been widely used in recent years for exhaust gas dust collection.

  PPS fiber has both heat resistance and chemical resistance, so there is no need to add functions by post-processing methods, etc., and since it has fiber characteristics equivalent to general-purpose fibers such as polyester, it is relatively easy. Laminates and the like are manufactured and widely used as the exhaust gas dust collecting filter cloth described above.

  However, recently, due to trends such as global environmental maintenance problems, the performance required for exhaust gas dust collection has become more advanced, dust collection efficiency is higher than conventional ones, pressure loss is low, There is a demand for filter cloth that can collect finer dust.

  As a means of obtaining a filter cloth that can collect fine dust with low pressure loss and high dust collection efficiency, a method of increasing the surface area without reducing the total fiber weight and making the fiber diameter of the filter cloth thinner, For example, a conventional method of attaching an ultrathin microporous film to the surface of a filter cloth is known. However, since the PPS fiber is excellent in heat resistance and chemical resistance as described above, the use temperature and the content of the target gas are naturally used under severe conditions as compared with general materials. Therefore, it is difficult to obtain sufficient filter cloth strength with a method in which the fiber diameter is reduced and the surface area is increased, so that the life of the filter cloth is shortened, and in the method of attaching a microporous film, the microporous film is short-term. There was a problem of peeling off.

  The present invention has been made to solve the above-mentioned conventional problems, and its purpose is to maintain a sufficient strength and function even under severe conditions where heat resistance and chemical resistance are required. It is an object of the present invention to provide a laminate that can be suitably used for the manufacture of a filter cloth for a bag filter that can collect fine dust with low pressure loss and high dust collection efficiency.

As a result of intensive studies to solve the above problems, the present inventors have finally completed the present invention. That is, the present invention provides: (1) a sheet-like laminate having web layers on both sides of a base fabric, and the base fabric and the web layer being entangled, wherein the base fabric is made of polyphenylene sulfide and / or polytetrasulfide; A laminate having excellent dust collection efficiency, characterized in that it is composed of fluoroethylene and 20% or more of at least one of the web layers is composed of polyphenylene sulfide fibers having a surface area of 230 to 800 m ² / Kg; 2) A basis weight of 350 to 750 g / m ² and a thickness of 1.5 to 3.0 mm, wherein the laminate having excellent dust collection efficiency according to (1), (3) a polyphenylene sulfide fiber The laminated body having excellent dust collection efficiency according to (1), which has an irregular cross-sectional shape.

According to the present invention, even under severe conditions where heat resistance and chemical resistance are required, fine dust can be collected with low pressure loss, which can maintain its function while maintaining sufficient strength, Moreover, it is possible to provide a laminate suitable for a filter cloth for bag filters having high dust collection efficiency.

The laminate of the present invention has a sheet-like laminate having webs on both sides of a base fabric, and the base fabric and the web are entangled, and the base fabric is made of PPS and / or polytetrafluoroethylene. And 20% or more of at least one of the webs is composed of PPS fibers having a surface area of 230 to 800 m ² / Kg, whereby the above object is achieved.

In a preferred embodiment, the laminate of the present invention has a basis weight of 350 to 750 g / m ² and a thickness of 1.5 to 3.0 mm.

  The base fabric used in the present invention is preferably produced from PPS and / or polytetrafluoroethylene. From the viewpoint that the heat resistance and chemical resistance of the base fabric and the web are aligned at the same level, it is preferable to mainly use the same type of PPS as the web described later. Polytetrafluoroethylene is also preferably used because of its excellent chemical resistance.

  The PPS used in the present invention is formed of a polymer having a unit of (-C6 H4 -S-) and / or a derivative thereof.

  The PPS is usually prepared by dissolving sodium sulfide in a polar solvent such as N-methylpyrrolidone, adding a polymerization accelerator, spinning a polymer obtained by polycondensation reaction with paradichlorobenzene by a melt spinning method, Obtained by stretching.

  The polytetrafluoroethylene used in the present invention is formed of a polymer having units of (—CF 2 —CF 2 —) and / or derivatives thereof.

  The polytetrafluoroethylene can be obtained, for example, by polymerizing tetrafluoroethylene under a pressure of 2200 to 1600 psi using a small amount of oxygen as a catalyst.

  The base fabric used in the present invention is a base fabric formed from fibers as long as the air permeability of the resulting laminate is not significantly impaired and the purpose of improving the strength and dimensional stability of the resulting laminate is achieved, It may be a film-shaped molded body, a molded body from slit yarn, a net-shaped molded body, or the like. From the viewpoint of breakage at the time of needle punching used for entanglement, a base fabric formed from fibers is preferred.

  For the base fabric formed from the above fibers, the above-described PPS fibers and / or polytetrafluoroethylene fiber monofilament yarns, multifilament yarns, or spun yarns may be used alone or in combination to obtain plain weave, twill weave, mocleno weave, or leno weave. For example, it is suitably formed by weaving. There is no particular limitation on the fineness and woven density of the fibers used.

The laminate of the present invention is a sheet-like material in which webs are entangled on both sides of the base fabric, and 20% or more of at least one of the webs is composed of PPS fibers having a surface area of 230 to 800 m ² / Kg. It is characterized by.

Conventionally, a round cross section of 2 to 3 denier has been used for the PPS fiber forming the laminated web used for the filter cloth for bag filters. Its surface area is 210-160 m ² / Kg.

In addition to PPS fibers, there are a wide range of variations. In particular, in consideration of dust collection efficiency, for example, there are polyester fibers having a surface area of 300 to 500 m ² / Kg. Under dust collection conditions, the polyester fiber is inferior in durability because its heat-resistant temperature is too low.

  On the other hand, it is possible to increase the surface area by increasing the surface area while maintaining the round cross-sectional shape of the PPS fiber, but there is a limit because the strength decreases with increasing the size.

  In the present invention, the cross-sectional shape of the PPS fiber is made irregular as a specific means for increasing the surface area without causing a significant decrease in strength. The irregular shape is not particularly limited, but representative examples include a trilobal shape having three peaks and valleys and a cross shape having four peaks and valleys. Other than that, it may be irregular.

  Since the PPS fiber has a melt spinning method, the PPS fiber having an irregular cross section can be easily obtained by changing the shape of the spinning nozzle. If a Y-shaped nozzle is used, a trilobal cross-section is obtained, and a cross-shaped PPS fiber is obtained using a cross-shaped nozzle.

The laminated body of this invention is obtaining the outstanding dust collection efficiency by using the PPS fiber of surface area 230-800m < ² > / Kg for a web. If the surface area of the single fiber is less than 230 m ² / Kg, there is no great difference from the conventional product, and improvement in dust collection efficiency cannot be expected.

If the surface area of the single fiber exceeds 800 m ² / Kg, the fiber strength becomes extremely small, and it is not preferable because the laminate itself is difficult to manufacture due to cutting during web formation.

  The dust collection mechanism of the filtration type dust collection method using the bag filter in the present invention is generally considered as follows. When dust with a certain particle size distribution is passed through a filter cloth, coarse particles adhere to the fibers constituting the filter cloth mainly due to inertial collisions, and fine particles mainly due to diffusion and blocking effects. To form particle bridges. The primary adhesion layer thus formed has a large number of bent fine pores, and the space ratio is larger than the space ratio of the original filter cloth itself. These small pores collect fine particles.

The laminate of the present invention has webs on both sides of a base fabric, and 20% or more of at least one of the webs is composed of PPS fibers having a surface area of 230 to 800 m ² / Kg. With this laminate, it is possible to further increase the space ratio of the primary adhesion layer described in the dust collection mechanism, so that excellent dust collection efficiency can be obtained. If the PPS fiber having a surface area of 230 to 800 m ² / Kg is less than 20%, the space ratio of the laminate is not significantly different from the conventional one, and the desired dust collection efficiency cannot be obtained.

The composition ratio of the PPS fiber having a surface area of 230 to 800 m ² / Kg is sufficient if it is 20% or more of one side, and it constitutes 100% of one web or occupies any part of the other web and has excellent dust collection. Since efficiency is obtained, there is no problem.

In the laminate of the present invention, a specific method for constituting 20% or more of at least one of the webs with PPS fibers having a surface area of 230 to 800 m ² / Kg is not particularly limited. There are a method of laminating a web and a method of laminating PPS fibers having different surface areas by layering in the thickness direction.

Further, in the laminate of the present invention, 20% or more of at least one of the webs is composed of PPS fibers having a surface area of 230 to 800 m ² / Kg, a basis weight of 350 to 750 g / m ² , and a thickness of 1. It is characterized by being 5-3.0 mm.

When the basis weight is less than 350 g / m ² , the air permeability is increased and the desired dust collection efficiency cannot be obtained, which is not preferable.

On the contrary, if the basis weight is larger than 750 g / m ² , there is no problem in the dust collection efficiency, but the cost of raw materials used increases, which is not preferable for economic reasons.

  Moreover, the variation in thickness at a constant basis weight means the variation in density. The density affects the air permeability, and when the thickness of the laminate of the present invention exceeds 3.0 mm, the air permeability becomes large for the basis weight, and the desired dust collection efficiency cannot be obtained, which is not preferable.

  When the thickness is 1.5 mm or less, there is a problem in durability such as wear resistance, even though there is no problem in air permeability.

According to the present invention, even under severe conditions where heat resistance and chemical resistance are required, fine dust can be collected with low pressure loss, which can maintain its function while maintaining sufficient strength, Moreover, it is possible to provide a laminate suitable for a filter cloth for bag filters having high dust collection efficiency.

Claims (3)

In a sheet-like laminate having a web layer on both sides of a base fabric, and the base fabric and the web layer being entangled, the base fabric is composed of polyphenylene sulfide and / or polytetrafluoroethylene, and A laminate having excellent dust collection efficiency, wherein 20% or more of at least one of the web layers is composed of polyphenylene sulfide fibers having a surface area of 230 to 800 m ² / Kg. The laminate having an excellent dust collection efficiency according to claim 1, wherein the basis weight is 350 to 750 g / m ² and the thickness is 1.5 to 3.0 mm. The laminate having excellent dust collection efficiency according to claim 1, wherein the polyphenylene sulfide fiber has an irregular cross-sectional shape.