JP2009291695A - Intermediate of film-shaped catalytic structure - Google Patents

Intermediate of film-shaped catalytic structure Download PDF

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JP2009291695A
JP2009291695A JP2008146420A JP2008146420A JP2009291695A JP 2009291695 A JP2009291695 A JP 2009291695A JP 2008146420 A JP2008146420 A JP 2008146420A JP 2008146420 A JP2008146420 A JP 2008146420A JP 2009291695 A JP2009291695 A JP 2009291695A
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film
catalyst
catalyst structure
cylindrical case
shaped
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JP5311883B2 (en
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Minoru Goto
実 後藤
Kunio Matsui
邦夫 松井
Kenji Ichinodo
健二 一ノ戸
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Kao Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide an intermediate of a film-shaped catalytic structure, the production operation of which is facilitated. <P>SOLUTION: The intermediate of the film-shaped catalytic structure is obtained by housing a film-shaped catalyst assemble in a cylindrical casing. The film-shaped catalyst assemble 10 is constituted so that a film-shaped catalyst 11 and a corrugated film-shaped catalyst 12 are layered alternately on each other in desired layers and all or a part of the contact portions 13 of the film-shaped catalyst 11 with the convex parts of the corrugated film-shaped catalyst 12 are stuck to one another temporarily. Since the film-shaped catalyst assemble 10 can be handled as one molding, the operation is facilitated when the film-shaped catalyst assemble 10 is housed in the cylindrical casing to obtain the intermediate. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は、気液反応用等の触媒として適しているフィルム状触媒構造体の製造に使用できるフィルム状触媒構造体の中間体、前記中間体の製造方法、前記中間体を用いたフィルム状触媒構造体の製造方法に関する。   The present invention relates to an intermediate of a film-like catalyst structure that can be used for the production of a film-like catalyst structure suitable as a catalyst for gas-liquid reaction, etc., a method for producing the intermediate, and a film-like catalyst using the intermediate The present invention relates to a method for manufacturing a structure.

フィルム状基材に触媒を担持させたフィルム状触媒が知られており(特許文献1〜3)、これらのフィルム状触媒は、表面積を増加させる目的や原料の流路を形成する目的で、波形やハニカム状に加工成形して使用されることがある。   A film-like catalyst in which a catalyst is supported on a film-like substrate is known (Patent Documents 1 to 3), and these film-like catalysts are corrugated for the purpose of increasing the surface area or forming a raw material flow path. Or may be used after being formed into a honeycomb shape.

特許文献4には、平板状帯材と波板状帯材からなる巻回タイプのハニカム・ブロック体がメタルケーシング内に収容された、自動車の排ガス浄化用となるメタルハニカム体が記載されている。   Patent Document 4 describes a metal honeycomb body for purifying automobile exhaust gas, in which a wound type honeycomb block body made of a flat strip and a corrugated strip is housed in a metal casing. .

特許文献5には、平板素材と波板素材に所定の張力を掛けながら芯材に巻き付けて大口径金属触媒担体を製造する方法が記載されている。
WO2005/035122号 特開8−141393号公報 特開2000−189814号公報 特開平6−205989号公報 特開平8−80440号公報
Patent Document 5 describes a method of manufacturing a large-diameter metal catalyst carrier by winding a flat plate material and a corrugated plate material around a core material while applying a predetermined tension.
WO2005 / 035122 JP-A-8-141393 JP 2000-189814 A Japanese Patent Laid-Open No. 6-205989 Japanese Patent Laid-Open No. 8-80440

特許文献4、5に記載の発明では、製造時に平板と波板がずれを生じることから、作業性が悪かったり、目的とするものが得られないという課題がある。   In the inventions described in Patent Documents 4 and 5, since the flat plate and the corrugated plate are displaced at the time of manufacture, there is a problem that workability is poor or the intended product cannot be obtained.

本発明は、上記した課題を解決でき、筒状ケース内にフィルム状触媒集合体が収容されており、フィルム状触媒構造体の製造用として使用できる、フィルム状触媒構造体の中間体及びフィルム状触媒構造体を提供することを課題とする。   The present invention can solve the above-mentioned problems, the film-like catalyst assembly is accommodated in a cylindrical case, and can be used for the production of a film-like catalyst structure. It is an object to provide a catalyst structure.

本発明は、更に上記したフィルム状触媒構造体の中間体の製造方法、前記中間体を用いて得られるフィルム状触媒構造体の製造方法を提供することを他の課題とする。   Another object of the present invention is to provide a method for producing an intermediate of the above-described film-like catalyst structure and a method for producing a film-like catalyst structure obtained using the above-mentioned intermediate.

本発明は、課題の解決手段として、下記の各発明を提供する。
(1)筒状ケース内にフィルム状触媒集合体が収容されたフィルム状触媒構造体の中間体であって、
前記フィルム状触媒集合体が、シート状のフィルム状触媒と波形状のフィルム状触媒が交互に所望数積層され、前記シート状のフィルム状触媒と前記波形状のフィルム状触媒の凸部との接触部の全部又は一部が仮止めされたものである、フィルム状触媒構造体の中間体。
(2)前記フィルム状触媒集合体の1つを1ユニットとして、筒状ケース内に1又は複数ユニットが収容されている、請求項1記載のフィルム状触媒構造体の中間体。
(3)前記集合体が、その筒状ケースの軸に垂直な断面形状が、前記筒状ケースの断面形状と同じか又は前記断面形状を複数に分割したそれぞれの形状と同じになるように仮止めされたものである、請求項1又は2記載のフィルム状触媒構造体の中間体。
(4)前記集合体が、その筒状ケースの軸に垂直な断面形状が扇形になるように仮止めされたものである、請求項1又は2記載のフィルム状触媒構造体の中間体。
(5)前記集合体が、その筒状ケースの軸に垂直な断面形状が円形になるように仮止めされたものである、請求項1又は2記載のフィルム状触媒構造体の中間体。
(6)前記集合体が、毎葉の波形状フィルム状触媒とシート状フィルム状触媒とを、平板状にして交互に積層し仮止めされたものである、請求項1又は2記載のフィルム状触媒構造体の中間体。
(7)請求項1〜6のいずれか1項記載のフィルム状触媒構造体の中間体の製造方法であって、
前記シート状のフィルム状触媒と前記波形状のフィルム状触媒の凸部との接触部を仮止めした後又は仮止めしながら、所望数だけ積層して集合体を成形する工程、
前記集合体の1つを1ユニットとして、1又は複数ユニットを筒状ケースに収容する工程、
を有するフィルム状触媒構造体の中間体の製造方法。
(8)請求項1〜6のいずれか1項記載のフィルム状触媒構造体の中間体を用いたフィルム状触媒構造体の製造方法であって、フィルム状触媒構造体の中間体の仮止めを除去する工程を有するフィルム状触媒構造体の製造方法。
(9)請求項1〜6のいずれか1項記載のフィルム状触媒構造体の中間体の仮止めが除去されたフィルム状触媒構造体であって、前記フィルム状触媒集合体が、前記筒状ケースの内壁面を外側方向に押圧するように収容されているフィルム状触媒構造体。
The present invention provides the following inventions as means for solving the problems.
(1) An intermediate of a film-like catalyst structure in which a film-like catalyst assembly is accommodated in a cylindrical case,
In the film-shaped catalyst assembly, a desired number of sheet-shaped film catalysts and corrugated film-shaped catalysts are alternately stacked, and the sheet-shaped film catalyst and the convex portions of the corrugated film-shaped catalyst are in contact with each other. An intermediate of the film-like catalyst structure, wherein all or part of the part is temporarily fixed.
(2) The intermediate body of the film-like catalyst structure according to claim 1, wherein one of the film-like catalyst aggregates is regarded as one unit, and one or a plurality of units are accommodated in a cylindrical case.
(3) The aggregate is temporarily set so that a cross-sectional shape perpendicular to the axis of the cylindrical case is the same as the cross-sectional shape of the cylindrical case or a shape obtained by dividing the cross-sectional shape into a plurality of parts. The intermediate body of the film-form catalyst structure of Claim 1 or 2 which was stopped.
(4) The intermediate body of the film-like catalyst structure according to claim 1 or 2, wherein the aggregate is temporarily fixed so that a cross-sectional shape perpendicular to the axis of the cylindrical case becomes a fan shape.
(5) The intermediate body of the film-like catalyst structure according to claim 1 or 2, wherein the aggregate is temporarily fixed so that a cross-sectional shape perpendicular to the axis of the cylindrical case is circular.
(6) The film according to claim 1 or 2, wherein the aggregate is obtained by alternately laminating and corrugating the corrugated film-shaped catalyst and the sheet-shaped film-shaped catalyst in a flat plate shape. Intermediate of catalyst structure.
(7) A method for producing an intermediate of the film-like catalyst structure according to any one of claims 1 to 6,
A step of forming an aggregate by stacking a desired number after temporarily fixing the contact portion between the sheet-like film-like catalyst and the convex portion of the wave-shaped film-like catalyst,
One of the aggregates as a unit, and the step of accommodating one or more units in a cylindrical case,
The manufacturing method of the intermediate body of the film-form catalyst structure which has this.
(8) A method for producing a film-like catalyst structure using the film-like catalyst structure intermediate according to any one of claims 1 to 6, wherein the intermediate of the film-like catalyst structure is temporarily fixed. The manufacturing method of the film-form catalyst structure which has the process to remove.
(9) A film-like catalyst structure from which the temporary fixing of the intermediate body of the film-like catalyst structure according to any one of claims 1 to 6 is removed, wherein the film-like catalyst assembly is the cylindrical shape. A film-like catalyst structure housed so as to press the inner wall surface of the case in the outward direction.

本発明のフィルム状触媒構造体の中間体は、筒状ケース内に、シート状のフィルム状触媒と波形状のフィルム状触媒が交互に積層され、それらが接触部において仮止めされた集合体が収容されたものである。   The intermediate body of the film-like catalyst structure of the present invention is an assembly in which a sheet-like film catalyst and a wave-like film-like catalyst are alternately laminated in a cylindrical case, and these are temporarily fixed at a contact portion. Contained.

前記シート状のフィルム状触媒と前記波形状のフィルム状触媒の凸部との接触部は、全部又は一部が仮止めされたものである。このため、波形状のフィルム状触媒と、それと接する両側のシート状フィルム状触媒が共に仮止めされている場合、集合体を1つの成形体として取り扱うことができるので、筒状ケース内への収容作業性が非常に良い。   The contact portion between the sheet-like film-like catalyst and the convex portion of the wave-like film-like catalyst is temporarily or partially fixed. For this reason, when the corrugated film-shaped catalyst and the sheet-shaped film catalysts on both sides in contact with the corrugated film catalyst are both temporarily fixed, the assembly can be handled as a single molded body, so that it can be accommodated in the cylindrical case. Workability is very good.

また、中間体を筒状ケース内に入るような略円柱形にするときの巻き取り作業を行う際、巻き取る前に一組の波形状フィルム状触媒とシート状フィルム状触媒が仮止めされている場合には、張力調整が容易となる。特に、波形状のフィルム状触媒では、低張力による作業となるため、巻き乱れが生じやすく、本発明のような仮止めを行うことで、巻き乱れが防止することができる。   Also, when performing the winding operation when making the intermediate body into a substantially cylindrical shape that enters the cylindrical case, a set of corrugated film catalyst and sheet film catalyst are temporarily fixed before winding. If it is, the tension can be easily adjusted. In particular, since a wavy film-like catalyst is an operation with low tension, turbulence is likely to occur, and the turbulence can be prevented by performing temporary fixing as in the present invention.

<フィルム状触媒構造体の中間体で用いるフィルム状触媒とその製造方法>
本発明で用いるフィルム状触媒は、特許文献1等に記載された公知のものを用いることができる。
<Film catalyst used in intermediate of film catalyst structure and production method thereof>
As the film-like catalyst used in the present invention, a known catalyst described in Patent Document 1 or the like can be used.

シート状のフィルム状触媒は、支持体(例えば、銅箔、ステンレス箔、アルミニウム箔等からなる長尺状の支持体)上に触媒粉末を含む塗料組成物を塗布・製膜して触媒中間体を得た後、乾燥及び硬化させて得ることができる。塗料組成物は、触媒活物質(Ag,Au,Cu,Ni,Fe,Al等)を多孔性材料(活性炭、アルミナ、シリカ、ゼオライト、チタニア、シリカ−アルミナ、珪藻土等)に担持させた粉末状触媒、バインダー、溶媒のほか、必要に応じて分散助剤(界面活性剤、カップリング剤等)、滑剤(無機粒子、繊維状物質等)、多孔化助剤(高沸点溶剤)等をミル等で塗料化したものである。   A sheet-like film catalyst is obtained by applying a coating composition containing a catalyst powder on a support (for example, a long support made of copper foil, stainless steel foil, aluminum foil, etc.) and forming a catalyst intermediate. Can be obtained by drying and curing. The coating composition is a powder form in which a catalyst active material (Ag, Au, Cu, Ni, Fe, Al, etc.) is supported on a porous material (activated carbon, alumina, silica, zeolite, titania, silica-alumina, diatomaceous earth, etc.) In addition to catalysts, binders and solvents, milling etc. as necessary dispersion aids (surfactants, coupling agents, etc.), lubricants (inorganic particles, fibrous substances, etc.), porosity aids (high-boiling solvents), etc. It is made into a paint.

波形状のフィルム状触媒は、前記のシート状触媒を波形状に加工して得ることができる。波形状に加工する方法は特に制限されず、特許文献2、3に記載の方法のほか、図5に示された下記の方法にて加工することもできる。   The corrugated film catalyst can be obtained by processing the sheet catalyst into a corrugated shape. The method of processing into a wave shape is not particularly limited, and in addition to the methods described in Patent Documents 2 and 3, it can also be processed by the following method shown in FIG.

図5では、保護材111及びフィルム状触媒100がそれぞれ送り出しロール103、102、101から送り出され、支えロール104で方向が変えられ、保護材とフィルム状触媒が重ねられた状態で、加工用歯車115及び116の間を通ることで、波形状に加工された長尺状のフィルム状触媒100’となる。波形状に加工された長尺状のフィルム状触媒100’は、2つの歯車115、116による押出作用で矢印方向に押し出されていき、2枚の保護材111は、それぞれ巻き取りロール102’、103’で巻き取られる。   In FIG. 5, the protective material 111 and the film-like catalyst 100 are sent out from the feed rolls 103, 102, 101, respectively, the direction is changed by the support roll 104, and the protective gear and the film-like catalyst are overlapped with each other in the processing gear. By passing between 115 and 116, a long film catalyst 100 ′ processed into a wave shape is obtained. The long film catalyst 100 ′ processed into a wave shape is extruded in the direction of the arrow by the extrusion action of the two gears 115, 116, and the two protective materials 111 are respectively wound into the winding rolls 102 ′, Rolled up at 103 '.

前工程で波形状に加工された長尺状のフィルム状触媒100’は、必要に応じて、所望形状及び大きさに切断することができる。   The long film catalyst 100 ′ processed into a wave shape in the previous step can be cut into a desired shape and size as necessary.

<フィルム状触媒構造体の中間体>
まず、図1により、フィルム状触媒構造体の中間体に用いる集合体について説明する。図1は前記集合体の部分断面図である。
<Intermediate of film-like catalyst structure>
First, the assembly used for the intermediate body of the film-like catalyst structure will be described with reference to FIG. FIG. 1 is a partial cross-sectional view of the assembly.

集合体10は、シート状のフィルム状触媒11と波形状のフィルム状触媒12が交互に所望数積層されている。積層数は、目的とする中間体に応じて適宜調整する。フィルム状触媒の構成としては、例えば厚み40μmの銅箔の両面にそれぞれ厚み5〜100μmの触媒層塗膜を塗工したものを用いることができる。波形状フィルム状触媒の波形状としては、例えばピッチ1〜30mm、山高さ0.2〜30mm、山部頂点には半径0.3mm以上の丸みを有したものを用いることができる。   In the assembly 10, a desired number of sheet-like film-like catalysts 11 and wave-like film-like catalysts 12 are alternately laminated. The number of stacked layers is appropriately adjusted according to the target intermediate. As a structure of a film-form catalyst, what coated the catalyst layer coating film of 5-100 micrometers in thickness, respectively on both surfaces of 40-micrometer-thick copper foil can be used, for example. As the wave shape of the wave-shaped film catalyst, for example, one having a pitch of 1 to 30 mm, a peak height of 0.2 to 30 mm, and a peak of the peak part having a radius of 0.3 mm or more can be used.

集合体10は、シート状のフィルム状触媒11と波形状のフィルム状触媒面12の凸部(又は凹凸部)との接触部13の全部又は一部が仮止めされている。波形状のフィルム状触媒と、それと接する両側のシート状フィルム状触媒が共に仮止めされている場合、全体が一体となった状態(1ユニット)のものとなる。このように接触部13を仮止めされた集合体10は、全体が一体となった状態であるから、筒状ケース内に集合体10ごと、即ち、1ユニットごとに収容するときの作業性が向上される。   In the aggregate 10, all or a part of the contact portion 13 between the sheet-like film-like catalyst 11 and the convex portion (or the concave-convex portion) of the corrugated film-like catalyst surface 12 is temporarily fixed. When the wave-shaped film-like catalyst and the sheet-like film-like catalysts on both sides in contact with the wave-shaped film catalyst are temporarily fixed together, the whole is integrated (1 unit). Since the assembly 10 with the contact portion 13 temporarily fixed as described above is in an integrated state, the workability when accommodating the assembly 10 in the cylindrical case, that is, for each unit, is improved. Be improved.

仮止め手段としては、接触部13を一時的に固定でき、かつ後に仮止めを除去できる手段であればよく、低沸点乃至は低融点のワックス、熱可塑性接着剤等を用いることができる。   Any temporary fixing means may be used as long as the contact portion 13 can be temporarily fixed and the temporary fixing can be removed later. A wax having a low boiling point or a low melting point, a thermoplastic adhesive, or the like can be used.

全ての接触部13を仮止めする必要はなく、例えば、仮止め部は波形状凸部において断続的でもよく、1つおきに接触部13を仮止めするようにしてもよい。   It is not necessary to temporarily fix all the contact portions 13. For example, the temporary fix portions may be intermittent at the corrugated convex portion, or every other contact portion 13 may be temporarily fixed.

集合体10の形態は特に制限されず、図2に示す筒状ケース(15a〜15d)の軸に垂直な断面形状が円形、楕円形、扇形、多角形等のものがある。また、積層形態としては、波形状フィルム状触媒とシート状フィルム状触媒とを、交互に巻回したものでもよいし、毎葉の平板状にして交互に積層したものでもよい。ここで、積層したシート間の圧力は、例えば感圧シート等を集合体10と集合体10を収容する容器内表面との間に挿入して圧力を測定することにより、外側方向の圧力分布を確認できる
次に、図2(A)〜(D)により、形態の異なる集合体10a〜10dを用いたフィルム状触媒構造体の中間体について説明する。図2(A)〜(D)は、フィルム状触媒構造体の中間体20(20a〜20d)の筒状ケースの軸に垂直な断面図である。なお、仮止め部分は図示されていない。
The form of the aggregate 10 is not particularly limited, and there are cross-sectional shapes perpendicular to the axis of the cylindrical cases (15a to 15d) shown in FIG. 2 such as a circle, an ellipse, a fan, and a polygon. Moreover, as a lamination | stacking form, what wound the wave-like film-form catalyst and the sheet-form film-form catalyst alternately may be sufficient, and what laminated | stacked alternately in the shape of a flat plate of every leaf may be used. Here, the pressure between the stacked sheets is measured by inserting a pressure-sensitive sheet or the like between the assembly 10 and the inner surface of the container containing the assembly 10 to measure the pressure distribution in the outer direction. Next, the intermediate body of the film-like catalyst structure using the aggregates 10a to 10d having different forms will be described with reference to FIGS. 2A to 2D are cross-sectional views perpendicular to the axis of the cylindrical case of the intermediate 20 (20a to 20d) of the film-like catalyst structure. The temporary fixing portion is not shown.

中間体20(20a〜20d)は、筒状ケース15(15a〜15d)内に所望数の集合体10(10a〜10d)が収容されたものである。筒状ケース15(15a〜15d)の軸に垂直な断面形状は特に制限されず、円形、楕円形、多角形等にすることができ、円形や楕円形の一部が曲面ではなく平面であるものでもよいし、多角形の一部が平面ではなく曲面であるものでもよい。   The intermediate body 20 (20a to 20d) is obtained by accommodating a desired number of aggregates 10 (10a to 10d) in a cylindrical case 15 (15a to 15d). The cross-sectional shape perpendicular to the axis of the cylindrical case 15 (15a to 15d) is not particularly limited, and can be a circle, an ellipse, a polygon, or the like, and a portion of the circle or ellipse is not a curved surface but a plane. It may be a thing, and a part of polygon may be not a plane but a curved surface.

図2(A)に示す中間体20aは、筒状ケース15a内に前記断面形状が扇形である4つの集合体10aが、全体が円形になるようにして、即ち、筒状ケース15aの前記断面形状と一致するようにして収容されている。図2(A)では、筒状ケース15aは、内部が十字状に仕切られた構造になっているが、このように各集合体10aの間は仕切り部材で仕切られていてもよいし、仕切られず、各集合体10aが接触した状態で収容されていてもよい。中間体20aでは、1つの集合体10aが1ユニットとなり、図2(A)では、計4ユニットが収容されている。   The intermediate body 20a shown in FIG. 2 (A) has a cylindrical case 15a in which the four aggregates 10a having a fan-shaped cross-section are circular, that is, the cross-section of the cylindrical case 15a. It is accommodated so as to match the shape. In FIG. 2A, the cylindrical case 15a has a structure in which the inside is partitioned in a cross shape. However, the aggregates 10a may be partitioned by a partition member in this way, Instead, each assembly 10a may be accommodated in contact. In the intermediate body 20a, one aggregate 10a becomes one unit, and a total of 4 units are accommodated in FIG.

図2(B)に示す中間体20bは、筒状ケース15b内に前記断面形状が円形である多数の集合体10bが、全体が円形になるようにして、即ち、筒状ケース15bの前記断面形状と一致するようにして収容されている。中間体20bでは、1つの集合体10bが1ユニットとなり、図2(B)では、多数のユニットが収容されている。   The intermediate body 20b shown in FIG. 2B has a cylindrical case 15b in which a large number of aggregates 10b having a circular cross-sectional shape are circular, that is, the cross-section of the cylindrical case 15b. It is accommodated so as to match the shape. In the intermediate body 20b, one aggregate 10b is one unit, and in FIG. 2B, a large number of units are accommodated.

図2(C)に示す中間体20cは、筒状ケース15c内に平板状の多数の集合体10cが、全体が円形になるようにして、即ち、筒状ケース15cの前記断面形状と一致するようにして収容されている。このとき、集合体10cは全体として1ユニットでもよいし、長さ(図2(C)の平面に現れた長さ)の異なる複数のユニットの組み合わせでもよい。   In the intermediate body 20c shown in FIG. 2C, a large number of flat plate-like assemblies 10c are formed in a circular shape in the cylindrical case 15c, that is, match the cross-sectional shape of the cylindrical case 15c. Is housed in this way. At this time, the aggregate 10c may be one unit as a whole or a combination of a plurality of units having different lengths (lengths appearing on the plane of FIG. 2C).

図2(D)に示す中間体20dは、筒状ケース15d内に複数の仕切り板16が配置されており、筒状ケース15dと複数の仕切り板16で囲まれた空間内に、平板状の多数の集合体10dが収容されている。このとき、集合体10dは、前記の各空間内に収容されているもの全体を1ユニットとしてもよいし、前記の各空間内に複数ユニットが収容されるようにしてもよい。   In the intermediate body 20d shown in FIG. 2D, a plurality of partition plates 16 are arranged in a cylindrical case 15d, and a flat plate-like shape is formed in a space surrounded by the cylindrical case 15d and the plurality of partition plates 16. A large number of aggregates 10d are accommodated. At this time, the aggregate 10d may be configured such that the entire unit accommodated in each of the spaces is a single unit, or a plurality of units may be accommodated in the spaces.

<フィルム状触媒構造体の中間体の製造方法>
(1)中間体の製造方法の一実施形態
本発明の中間体の製造方法の一実施形態を図3(A)〜(D)により説明する。
<Method for producing intermediate of film-like catalyst structure>
(1) One Embodiment of Intermediate Production Method One embodiment of the intermediate production method of the present invention will be described with reference to FIGS.

図3(A)に示す工程は、シート状のフィルム状触媒11と波形状のフィルム状触媒12の凸部との接触部13が接着剤で仮止めされた状態のものを、棒状の芯材30の周囲に巻き付けて、最終的に円柱状の集合体10を得る工程である。   In the step shown in FIG. 3A, the contact portion 13 between the sheet-like film-shaped catalyst 11 and the convex portion of the wave-shaped film-like catalyst 12 is temporarily fixed with an adhesive. This is a step of winding around 30 and finally obtaining a cylindrical aggregate 10.

図3(A)で用いた芯材30は断面が円形であるが、断面が三角形、四角形又はそれ以上多角形、楕円形、扇形のものでもよい。これらの芯材を用いる場合には、角を丸くしたものを用いることが好ましい。   The core material 30 used in FIG. 3A has a circular cross section, but the cross section may be triangular, quadrangular or more polygonal, elliptical, or fan-shaped. When using these core materials, it is preferable to use those having rounded corners.

棒状の芯材30の周囲に巻きつけるときの張力は、目的とする中間体20となるように適宜調整する。例えば、予め設定された触媒としての有効面積(実質的に集合体10の全表面積)が得られ、かつ次工程で使用する筒状ケース15内に収容できる大きさの集合体10(好ましくは筒状ケース15の内径よりもやや小さめの外径の集合体10)が得られるように張力を加える。   The tension at the time of winding around the rod-shaped core material 30 is appropriately adjusted so as to be the target intermediate 20. For example, the aggregate 10 (preferably a cylinder preferably having a size that can obtain a preset effective area (substantially the entire surface area of the aggregate 10) and can be accommodated in the cylindrical case 15 used in the next step. Tension is applied so that an aggregate 10) having an outer diameter slightly smaller than the inner diameter of the case 15 is obtained.

ここで、波形状のフィルム状触媒をシート状フィルム触媒と固定せずに巻き取る場合、波形状を維持して巻き取ろうとすると、低張力による作業となるため、巻き乱れが生じやすい。そのため、本発明のような仮止めを行うことで、所望の張力を掛けることが可能となり、巻き乱れを防止することができ、さらに波形状フィルム触媒を変形させながら巻き取ることができる。このようにして張力を掛けて巻き取られた集合体10は、ケース内において張力が解放された状態になることにより、波形状のフィルム状触媒がその形状を復元しようとして集合体10の外径が膨張し、筒状ケース外側方向へ押圧状態となることができる。この結果、ケース収納後の応力緩和やケース内の応力分布均一化が図られる。   Here, when winding a wave-shaped film catalyst without fixing it to a sheet-shaped film catalyst, if it is attempted to wind it while maintaining the wave shape, it becomes a work with a low tension, and therefore turbulence tends to occur. Therefore, by performing temporary fixing as in the present invention, it becomes possible to apply a desired tension, to prevent winding disturbance, and to wind up while deforming the corrugated film catalyst. The aggregate 10 wound with tension applied in this way is in a state in which the tension is released in the case, so that the wavy film-like catalyst tries to restore its shape and the outer diameter of the aggregate 10 Swells and can be pressed toward the outside of the cylindrical case. As a result, stress relaxation after the case is stored and stress distribution in the case is made uniform.

仮止めは、例えば、図3(A)に示すようにして、芯材30に巻き付ける前の所望段階において、接着剤塗布装置40により、波形状のフィルム状触媒12の凸部12aに接着剤を塗布する方法を適用できる。   For example, as shown in FIG. 3A, the temporary fixing is performed by applying an adhesive to the convex portions 12a of the corrugated film-like catalyst 12 by the adhesive application device 40 at a desired stage before being wound around the core material 30. A method of applying can be applied.

図3(B)に示す工程は、作業台50上に置かれた筒状ケース15内に、芯材30と共に集合体10を収容する工程である。   The step shown in FIG. 3B is a step of housing the assembly 10 together with the core member 30 in the cylindrical case 15 placed on the work table 50.

この工程では、集合体10を構成するシート状のフィルム状触媒11と波形状のフィルム状触媒12が仮止めされているため、集合体10全体が1つの成形体の形態となっている。このため、集合体10が取り扱いやすく、筒状ケース15内の収容作業が容易である。また、集合体10を、張力を解放せずに中心方向に押し縮めた状態で収容すると、その後、張力が解放された状態になると自ら外側方向に拡がるため、集合体10の外表面は筒状ケース15の内表面に密着された状態になる。このため、中間体20の保管や運搬時において、集合体10が筒状ケース15内でがたつくことがない。なお、集合体10を拡がらないようにする手段として、プラスチックや不織布等の締め付けバンドを使用することもできる。   In this step, since the sheet-like film catalyst 11 and the wave-shaped film catalyst 12 constituting the aggregate 10 are temporarily fixed, the entire aggregate 10 is in the form of one molded body. For this reason, the assembly 10 is easy to handle and the accommodating operation in the cylindrical case 15 is easy. Further, when the aggregate 10 is accommodated in a state where the aggregate 10 is compressed in the center direction without releasing the tension, the outer surface of the aggregate 10 expands in the outward direction when the tension is released thereafter. The case 15 is in close contact with the inner surface. For this reason, the aggregate 10 does not rattle in the cylindrical case 15 when the intermediate body 20 is stored or transported. In addition, as a means for preventing the assembly 10 from spreading, a fastening band such as plastic or nonwoven fabric can be used.

(2)中間体の製造方法の別実施形態
本発明の中間体の製造方法の別実施形態を図4(A)、(B)により説明する。図4(B)に示す中間体20eは、筒状ケース15e内に最大径の筒状集合体10e、筒状集合体10eの内側に収容された中間径の筒状集合体10e’、更に筒状集合体10e’の内側に収容された最小径の筒状集合体10e”の組み合わせからなるものである。
(2) Another Embodiment of Intermediate Production Method Another embodiment of the intermediate production method of the present invention will be described with reference to FIGS. An intermediate body 20e shown in FIG. 4B includes a cylindrical aggregate 10e having a maximum diameter in a cylindrical case 15e, a cylindrical aggregate 10e ′ having an intermediate diameter accommodated inside the cylindrical aggregate 10e, and a cylinder. The cylindrical aggregate 10e ″ having the minimum diameter accommodated inside the cylindrical aggregate 10e ′.

筒状集合体10e、10e’、10e”は、図3(A)に示す工程において、それぞれ異なる外径の芯材30を用い、10e、10e’に関しては、各々の内側の筒状集合体の外径に適合する内径を持った芯材を用いて得ることができる。そして、図4(A)に示すように、筒状ケース15e内に、まず最大径の筒状集合体10eを入れ、次に中間径の筒状集合体10e’を入れ、最後に最小径の筒状集合体10e”を入れることで、図4(B)に示す中間体20eを得ることができる。また、筒状集合体10e、10e’、10e”を組み合わせた状態のものを一纏めにして筒状ケース15e内に収容するようにしてもよい。   In the step shown in FIG. 3A, the cylindrical aggregates 10e, 10e ′, and 10e ″ use core materials 30 having different outer diameters, and 10e and 10e ′ are each of the cylindrical aggregates on the inner side. 4 (A), a cylindrical aggregate 10e having a maximum diameter is first placed in a cylindrical case 15e, as shown in FIG. Next, an intermediate body 20e shown in FIG. 4B can be obtained by inserting a cylindrical aggregate 10e ′ having an intermediate diameter and finally inserting a cylindrical aggregate 10e ″ having a minimum diameter. Further, a combination of the cylindrical aggregates 10e, 10e ', and 10e "may be collectively accommodated in the cylindrical case 15e.

ここで、一対の波形状及びシート形状のフィルム触媒を巻き取る際、シート状フィルム触媒を外側にして巻き取る場合、最大径の筒状集合体10eの外周面には、シート状のフィルム状触媒11(図1参照)が位置し、内周面には波形状のフィルム状触媒12(図1参照)が位置する。そして、中間径の筒状集合体10e’の外周面には、シート状のフィルム状触媒11が位置し、内周面には波形状のフィルム状触媒12が位置する。更に最小径の筒状集合体10e”の外周面には、シート状のフィルム状触媒11が位置し、内周面には波形状のフィルム状触媒12が位置する。一方、シート状フィルム触媒を内側にして巻き取る場合、それぞれの筒状集合体の外周面には、波形状フィルム状触媒が位置し、内周面にはシート状フィルム触媒が位置する。   Here, when winding a pair of wave-shaped and sheet-shaped film catalysts, when the sheet-shaped film catalyst is wound outside, the sheet-shaped film-shaped catalyst is formed on the outer peripheral surface of the cylindrical aggregate 10e having the maximum diameter. 11 (see FIG. 1) is located, and a corrugated film catalyst 12 (see FIG. 1) is located on the inner peripheral surface. A sheet-like film catalyst 11 is positioned on the outer peripheral surface of the cylindrical aggregate 10e 'having an intermediate diameter, and a wave-shaped film catalyst 12 is positioned on the inner peripheral surface. Further, a sheet-like film catalyst 11 is positioned on the outer peripheral surface of the cylindrical aggregate 10e ″ having the smallest diameter, and a wave-shaped film catalyst 12 is positioned on the inner peripheral surface. When winding up inside, a corrugated film catalyst is located in the outer peripheral surface of each cylindrical aggregate, and a sheet-like film catalyst is located in an inner peripheral surface.

図4(B)に示す形態では、筒状集合体10e、10e’、10e”は、張力が解放された状態では、いずれも自ら外側に拡がるため、筒状ケース15eの内表面と最大径の筒状集合体10eの外表面は密着されており、最大径の筒状集合体10eの芯材内表面と中間径の筒状集合体10e’の外表面は密着されており、中間径の筒状集合体10e’の芯材内表面と最小径の筒状集合体e”の外表面は密着されている。このため、中間体20eの保管、運搬、使用時において、集合体10e、10e’、10e”が筒状ケース15e内でがたつくことがない。   In the form shown in FIG. 4B, the cylindrical aggregates 10e, 10e ′, 10e ″ all expand outward themselves in a state where the tension is released, so that the inner diameter of the cylindrical case 15e and the maximum diameter are increased. The outer surface of the cylindrical aggregate 10e is in close contact, the inner surface of the core of the cylindrical aggregate 10e with the maximum diameter and the outer surface of the cylindrical aggregate 10e 'with the intermediate diameter are in close contact with each other. The inner surface of the core material of the aggregate 10e ′ and the outer surface of the cylindrical assembly e ″ having the smallest diameter are in close contact with each other. For this reason, the aggregates 10e, 10e ', 10e "do not rattle in the cylindrical case 15e when the intermediate 20e is stored, transported, or used.

<フィルム状触媒構造体の製造方法>
本発明のフィルム状触媒構造体は、上記した中間体の仮止めを除去する工程を経て製造することができる。
<Method for producing film-like catalyst structure>
The film-like catalyst structure of the present invention can be produced through a step of removing the temporary fixing of the intermediate.

仮止めの除去方法としては、仮止め手段として低沸点乃至は低融点の接着剤を用いた場合には、前記接着剤の沸点乃至は融点以上に加熱して除去する方法、前記接着剤を溶解できる溶剤中に中間体を浸漬する方法、前記した2つの方法を組み合わせる方法等を適用することができる。   As a temporary fixing removal method, when an adhesive having a low boiling point or a low melting point is used as a temporary fixing means, the adhesive is removed by heating to the boiling point or the melting point of the adhesive or higher, and the adhesive is dissolved. A method of immersing the intermediate in a solvent that can be used, a method of combining the two methods described above, and the like can be applied.

この仮止めの除去工程により、層間に接着部が無く、触媒露出面積がより広いフィルム状触媒構造体を得ることができる。   By this temporary fixing removal step, a film-like catalyst structure having no adhesion portion between layers and a wider catalyst exposed area can be obtained.

<フィルム状触媒構造体>
フィルム状触媒構造体は、前記中間体の仮止めが除去されたものであり、筒状ケース内のフィルム状触媒集合体が、筒状ケースの内壁面を外側方向に押圧する状態であるものである。なお、本発明のフィルム状触媒構造体は、両端が開口部を有した筒状ケース内にフィルム状触媒集合体が収容された構造で、フィルム状触媒集合体は、一方の開口部から他方の開口部へ通じた空間を有している。
<Film catalyst structure>
The film-like catalyst structure is obtained by removing the temporary fixing of the intermediate body, and the film-like catalyst assembly in the cylindrical case is in a state of pressing the inner wall surface of the cylindrical case in the outward direction. is there. The film-like catalyst structure of the present invention has a structure in which a film-like catalyst assembly is accommodated in a cylindrical case having openings at both ends. It has a space leading to the opening.

<フィルム状触媒の製造例>
(粉末状触媒の製造)
合成ゼオライトに担持させた銅・ニッケル・ルテニウム3元系の触媒活物質よりなる粉末状触媒を、以下のように調製した。
<Production example of film catalyst>
(Production of powdered catalyst)
A powdered catalyst made of a copper / nickel / ruthenium ternary catalyst active material supported on a synthetic zeolite was prepared as follows.

容量1Lのフラスコに合成ゼオライト(平均粒径6μm)を仕込み、次いで硝酸銅、硝酸ニッケル及び塩化ルテニウムを、各金属原子のモル比でCu:Ni:Ru=4:1:0.01となるように水に溶かしたものを入れ、攪拌しながら昇温した。90℃で10質量%炭酸ナトリウム水溶液をpH9〜10にコントロールしながら徐々に滴下した。1時間の熟成後、沈殿物を濾過・水洗後80℃で10時間乾燥し、600℃で3時間焼成して、粉末状触媒を得た。得られた粉末状触媒における、金属酸化物の割合は50質量%、合成ゼオライトの割合は50質量%であった。   Synthetic zeolite (average particle size: 6 μm) is charged into a 1 L flask, and then copper nitrate, nickel nitrate and ruthenium chloride are added so that the molar ratio of each metal atom is Cu: Ni: Ru = 4: 1: 0.01. A solution dissolved in water was added to the flask and heated with stirring. A 10% by mass aqueous sodium carbonate solution was gradually added dropwise at 90 ° C. while controlling the pH at 9-10. After aging for 1 hour, the precipitate was filtered, washed with water, dried at 80 ° C. for 10 hours, and calcined at 600 ° C. for 3 hours to obtain a powdered catalyst. In the obtained powdery catalyst, the proportion of metal oxide was 50% by mass, and the proportion of synthetic zeolite was 50% by mass.

(シート状のフィルム状触媒の製造)
溶媒としてMIBK、バインダーとしてフェノール樹脂(住友ベークライト製PR−9480)、製造例1で調製した粉末状触媒の順に、250mlの広口ポリエチレン製ビンに入れた。粉末状触媒80質量部(65g)に対し、フェノール樹脂の不揮発分が20質量部となる配合比率とし、MIBKの配合量は、配合物の固形分が60質量%となる量とした。さらに分散メディアとして、直径1mmのガラスビーズ(見かけ容積65ml)を広口ポリエチレン製ビンに入れた。
(Manufacture of sheet-like film catalyst)
MIBK as a solvent, phenol resin as a binder (PR-9480 manufactured by Sumitomo Bakelite), and powdered catalyst prepared in Production Example 1 were placed in this order in a 250 ml wide-mouth polyethylene bottle. The blending ratio was such that the nonvolatile content of the phenol resin was 20 parts by weight with respect to 80 parts by weight (65 g) of the powdered catalyst, and the amount of MIBK was such that the solid content of the blend was 60% by weight. Further, glass beads having a diameter of 1 mm (apparent volume of 65 ml) were placed in a wide-mouth polyethylene bottle as a dispersion medium.

広口ポリエチレン製ビンをペイントシェーカーにセットし、30分間混合分散処理を行い、塗料組成物を得た。   A wide-mouth polyethylene bottle was set on a paint shaker and mixed and dispersed for 30 minutes to obtain a coating composition.

長尺状の銅箔(厚さ40μm、秤量310g/m)を支持体とし、前記塗料組成物を銅箔の両面にコンマコーターにより塗布した。塗工機付帯の乾燥炉では100℃で120秒間処理を行い、シート状のフィルム状触媒を得た。 A long copper foil (thickness 40 μm, weighing 310 g / m 2 ) was used as a support, and the coating composition was applied to both sides of the copper foil with a comma coater. In the drying furnace attached to the coating machine, treatment was performed at 100 ° C. for 120 seconds to obtain a sheet-like film catalyst.

(波形状のフィルム状触媒の製造)
上記の製造方法で得られたシート状のフィルム状触媒を用い、図5に示す装置を用い、波板状のフィルム状触媒を製造した。送り速度は2m/minとした。
(Manufacture of corrugated film catalyst)
Using the sheet-like film-like catalyst obtained by the above production method, a corrugated film-like catalyst was produced using the apparatus shown in FIG. The feed rate was 2 m / min.

実施例1
(フィルム状触媒構造体の中間体の製造)
上記の製造例で得たシート状のフィルム状触媒(幅500mm)と波形状のフィルム状触媒(幅500mm)を用い、図3(A)に示す製造方法にて、直径が約900mmの円柱状の集合体10を得た。仮止め用の接着剤としてマイクロクリスタリンワックス(融点60℃)を用いた。得られた集合体10は、バンドを用いて周囲を固定した。
Example 1
(Production of intermediate of film-like catalyst structure)
Using the sheet-like film catalyst (width 500 mm) obtained in the above production example and a corrugated film catalyst (width 500 mm), the production method shown in FIG. The assembly 10 was obtained. Microcrystalline wax (melting point 60 ° C.) was used as an adhesive for temporary fixing. The obtained assembly 10 was fixed at the periphery using a band.

次に、図3(B)に示すようにして、内径910mm、高さ550mmの筒状ケース内に集合体10の先端部を入れながら、途中でバンドを外した後、全体を収容して中間体20を得た。   Next, as shown in FIG. 3B, the band is removed halfway while the tip of the assembly 10 is put into a cylindrical case having an inner diameter of 910 mm and a height of 550 mm, and then the whole is accommodated and intermediated. Body 20 was obtained.

(フィルム状触媒構造体の製造)
中間体20に対して130℃の空気中で、90分間硬化処理を行った。その後、130℃に加熱した高級アルコール(C1021OHが主成分)浴中に中間体20を浸漬し、窒素を吹き込むことにより浴を撹拌しながら5時間維持した。その後、浴から引き上げて乾燥することにより、仮止め用の接着剤が除去されたフィルム状触媒構造体を得た。
(Production of film-like catalyst structure)
The intermediate 20 was subjected to curing treatment in air at 130 ° C. for 90 minutes. Thereafter, the intermediate 20 was immersed in a higher alcohol (mainly C 10 H 21 OH) bath heated to 130 ° C., and maintained for 5 hours while stirring the bath by blowing nitrogen. Then, the film-like catalyst structure from which the adhesive for temporary fixing was removed was obtained by pulling up from the bath and drying.

フィルム状触媒構造体の中間体に使用されるフィルム状触媒集合体の部分断面図。The fragmentary sectional view of the film-form catalyst assembly used for the intermediate body of a film-form catalyst structure. フィルム状触媒構造体の中間体(又はフィルム状触媒構造体)の平面図。The top view of the intermediate body (or film-form catalyst structure) of a film-form catalyst structure. フィルム状触媒構造体の中間体の製造方法の説明図。Explanatory drawing of the manufacturing method of the intermediate body of a film-form catalyst structure. フィルム状触媒構造体の中間体の別実施形態である製造方法の説明図。Explanatory drawing of the manufacturing method which is another embodiment of the intermediate body of a film-form catalyst structure. 波形状のフィルム状触媒の製造方法を説明するための概念図。The conceptual diagram for demonstrating the manufacturing method of a waveform film-like catalyst.

符号の説明Explanation of symbols

10、10a〜10e フィルム状触媒構造体の集合体
15、15a〜15e 筒状ケース
20、20a〜20e フィルム状触媒構造体の中間体
30 芯材
10, 10a-10e Aggregates of film-like catalyst structures
15, 15a-15e cylindrical case
20, 20a-20e Intermediate of film-like catalyst structure
30 core material

Claims (9)

筒状ケース内にフィルム状触媒集合体が収容されたフィルム状触媒構造体の中間体であって、
前記フィルム状触媒集合体が、シート状のフィルム状触媒と波形状のフィルム状触媒が交互に所望数積層され、前記シート状のフィルム状触媒と前記波形状のフィルム状触媒の凸部との接触部の全部又は一部が仮止めされたものである、フィルム状触媒構造体の中間体。
An intermediate of a film-like catalyst structure in which a film-like catalyst assembly is accommodated in a cylindrical case,
In the film-shaped catalyst assembly, a desired number of sheet-shaped film catalysts and corrugated film-shaped catalysts are alternately stacked, and the sheet-shaped film catalyst and the convex portions of the corrugated film-shaped catalyst are in contact with each other. An intermediate of the film-like catalyst structure, wherein all or part of the part is temporarily fixed.
前記フィルム状触媒集合体の1つを1ユニットとして、筒状ケース内に1又は複数ユニットが収容されている、請求項1記載のフィルム状触媒構造体の中間体。   The intermediate body of the film-form catalyst structure of Claim 1 by which one or more units are accommodated in the cylindrical case by making one of the said film-form catalyst aggregates into 1 unit. 前記集合体が、その筒状ケースの軸に垂直な断面形状が、前記筒状ケースの断面形状と同じか又は前記断面形状を複数に分割したそれぞれの形状と同じになるように仮止めされたものである、請求項1又は2記載のフィルム状触媒構造体の中間体。   The aggregate is temporarily fixed so that the cross-sectional shape perpendicular to the axis of the cylindrical case is the same as the cross-sectional shape of the cylindrical case or the same shape as each of the cross-sectional shapes divided into a plurality of parts. The intermediate body of the film-form catalyst structure of Claim 1 or 2 which is what is. 前記集合体が、その筒状ケースの軸に垂直な断面形状が扇形になるように仮止めされたものである、請求項1又は2記載のフィルム状触媒構造体の中間体。   The intermediate body of the film-like catalyst structure according to claim 1 or 2, wherein the aggregate is temporarily fixed so that a cross-sectional shape perpendicular to the axis of the cylindrical case is a fan shape. 前記集合体が、その筒状ケースの軸に垂直な断面形状が円形になるように仮止めされたものである、請求項1又は2記載のフィルム状触媒構造体の中間体。   The intermediate body of the film-like catalyst structure according to claim 1 or 2, wherein the aggregate is temporarily fixed so that a cross-sectional shape perpendicular to the axis of the cylindrical case is circular. 前記集合体が、毎葉の波形状フィルム状触媒とシート状フィルム状触媒とを、平板状にして交互に積層し仮止めされたものである、請求項1又は2記載のフィルム状触媒構造体の中間体。   The film-like catalyst structure according to claim 1 or 2, wherein the aggregate is obtained by alternately laminating and alternately laminating a corrugated film catalyst and a sheet-like film catalyst in a flat plate shape. Intermediates. 請求項1〜6のいずれか1項記載のフィルム状触媒構造体の中間体の製造方法であって、
前記シート状のフィルム状触媒と前記波形状のフィルム状触媒の凸部との接触部を仮止めした後又は仮止めしながら、所望数だけ積層して集合体を成形する工程、
前記集合体の1つを1ユニットとして、1又は複数ユニットを筒状ケースに収容する工程、
を有するフィルム状触媒構造体の中間体の製造方法。
It is a manufacturing method of the intermediate body of the film-form catalyst structure of any one of Claims 1-6,
A step of forming an aggregate by stacking a desired number after temporarily fixing the contact portion between the sheet-like film-like catalyst and the convex portion of the wave-shaped film-like catalyst,
One of the aggregates as a unit, and the step of accommodating one or more units in a cylindrical case,
The manufacturing method of the intermediate body of the film-form catalyst structure which has this.
請求項1〜6のいずれか1項記載のフィルム状触媒構造体の中間体を用いたフィルム状触媒構造体の製造方法であって、フィルム状触媒構造体の中間体の仮止めを除去する工程を有するフィルム状触媒構造体の製造方法。   It is a manufacturing method of the film-form catalyst structure using the intermediate body of the film-form catalyst structure of any one of Claims 1-6, Comprising: The process of removing the temporary fix | stop of the intermediate body of a film-form catalyst structure The manufacturing method of the film-form catalyst structure which has this. 請求項1〜6のいずれか1項記載のフィルム状触媒構造体の中間体の仮止めが除去されたフィルム状触媒構造体であって、前記フィルム状触媒集合体が、前記筒状ケースの内壁面を外側方向に押圧するように収容されているフィルム状触媒構造体。   It is the film-like catalyst structure from which the temporary fix | stop of the intermediate body of the film-like catalyst structure of any one of Claims 1-6 was removed, Comprising: The said film-like catalyst assembly is the inside of the said cylindrical case. A film-like catalyst structure accommodated so as to press the wall surface outward.
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