KR100690574B1 - Method for producing multi-layered ceramic filter and ceramic filter using the same - Google Patents

Abstract

The present invention relates to a method for producing a multilayer ceramic filter and a ceramic filter using the same, in particular, ceramic powder, clay, selected from the group consisting of silicon carbide, alumina, silimite, kaolin, silica, titania, and diatomaceous earth A slurry prepared by mixing a pore-forming agent, a binder, and a dispersion liquid is formed by being supported on a nonwoven fabric, a woven fabric, or a sponge supporting member, and then the molded article is dried and sintered, and the molded article is dried before or after sintering or after sintering. The present invention relates to a method for producing a multilayer ceramic filter, which is further coated with a slurry mixed with ceramic powder, a pore-forming agent, a binder, and a dispersion, dried and sintered, and a ceramic filter using the same.

According to the present invention, the manufacturing cost is reduced, the manufacturing method is easy, the shape change and the production of large filters are easy, the wear resistance and the heat resistance of the ceramic filter can be significantly improved, and the porosity control range can be improved. It has the same heat resistance and abrasion resistance through the release cross-sectional structure, but can be configured at low weight and minimizes clogging.

Multi-layer, Filter, Ceramic, Clay, Carrier, Ceramic Filter

Description

Manufacturing method of multilayer ceramic filter and ceramic filter using same {METHOD FOR PRODUCING MULTI-LAYERED CERAMIC FILTER AND CERAMIC FILTER USING THE SAME}

1 is a cross-sectional view of an embodiment of a molding die used in the method of manufacturing a multilayer ceramic filter of the present invention.

2 is a photograph of a round tube ceramic filter manufactured by one embodiment of a method of manufacturing a multilayer ceramic filter of the present invention.

3 is a photograph of a radial bending tube ceramic filter manufactured by one embodiment of a method of manufacturing a multilayer ceramic filter of the present invention.

4 is a photograph of various types of ceramic filters manufactured by one embodiment of a method of manufacturing a multilayer ceramic filter of the present invention.

5 is a photograph of a ceramic filter assembled with the upper and lower caps manufactured by one embodiment of a method of manufacturing a multilayer ceramic filter of the present invention.

6 is a scanning electron micrograph of the additional coating area of the ceramic filter manufactured by one embodiment of the method of manufacturing a multilayer ceramic filter of the present invention.

7 is a scanning electron micrograph of a carrier-containing region of a ceramic filter manufactured by one embodiment of a method of manufacturing a multilayer ceramic filter of the present invention.

FIG. 8 is a scanning electron microscope photograph of a carrier-containing region and an additional coating region of the ceramic filter manufactured according to an embodiment of the method of manufacturing a multilayer ceramic filter of the present invention.

9 is a photograph showing a ceramic filter of an extended length manufactured according to an embodiment of the present invention.

10 is a photograph showing an embodiment in which a multilayer ceramic filter manufactured according to an embodiment of the present invention is mounted in a dust collector.

The present invention relates to a method for manufacturing a multilayer ceramic filter and a ceramic filter using the same. More particularly, the manufacturing cost can be reduced, the manufacturing method is easy, and at the same time, it is easy to change the shape and produce a large filter, Regarding the method of manufacturing a multilayer ceramic filter which can significantly improve wear resistance and heat resistance, relatively improve the porosity control range, and can be configured at low weight through a release cross-sectional structure and minimize clogging, and a ceramic filter using the same will be.

As the industry develops, the harmful substances such as dust, soot, waste gas, smoke, and volatile organic chemicals (VOC's) generated in each industrial process are increasing. Therefore, in order to prevent the emission of such pollutants, some polymer filters are used, but polymer filters have weak problems in heat resistance, chemical resistance, abrasion resistance, and flame resistance. In other words, polyester shrinks at 150 ° C, and PTFE (Teflon), which has excellent heat resistance, has only heat resistance up to 250 ° C. The atmosphere of the process using an industrial filter is dust, various waste gases, and moisture. At the same time, it is a harsh environment, and most polymer nonwoven filters such as polyester, polypropylene, acrylic, polyamide, polyimide, and glass fiber can be used to jet dust or dust off the filter surface. As the dust falls, the surface wear of the filter by the dust is more serious than expected, which not only destroys the filter and shortens the cycle of use of the filter. Lead to, or filter out, waste incinerators, boilers, coal-fired power plants, coal If the screen has a problem in that the combined power generation against the environmental regulations is enhanced due to danger of exposure during the exhaust gas atmosphere.

Therefore, in order to solve these problems, ceramic filters have been developed. Ceramic filters have much better heat resistance, chemical resistance, and abrasion resistance than polymer filters. There is no need to reduce installation and maintenance costs.

In the case of the conventionally developed ceramic filter, it is generally the most common method to use the tube form using ceramic fiber by vacuum molding or extrusion molding, which is relatively excellent in filtration efficiency and back pressure characteristics but expensive to be manufactured. The deterioration of the ceramic fiber due to deterioration of the ceramic fiber when used for a long time, not only decreases the filtration efficiency, but also causes the ceramic fiber to break when the dust of the outer wall is shaken off by back spraying compressed air during regeneration of the filter. When the ceramic fiber is contained in the exhaust gas during normal operation and is discharged, there is a problem of generating secondary pollution. Also, if the whole ceramic filter has the same porosity structure and dust is caught inside, the filter may be clogged. There is a problem that the pressure loss increases and the back pressure increases due to the generation.

In addition, in the manufacturing process, the vacuum molding process is expensive to manufacture the vacuum chamber and the vacuum pump, and is limited by the size of the ceramic filter that can be manufactured according to the size limitation of the vacuum chamber, so that large filters cannot be manufactured. There is a problem, and the vacuum molding has a size limitation of the manufactured ceramic filter, there is a problem that the production cost is high due to the high fixed cost to change the mold for each constant production due to severe wear of the ceramic material.

In addition to the vacuum molding method, methods such as extrusion molding, press molding, and hydrostatic pressure molding have been developed, but even in this case, a mold manufacturing is essential when manufacturing and a pressurizing device is required, which increases manufacturing cost and is not easy to manufacture. In addition, if the mold is determined, it is not easy to change the manufacturing shape, it is difficult to produce a large filter. In addition, in the case of the molding method, since the molding by the pressure method, the porosity is low, the breathability is lowered, there is a problem that increases the pressure loss when passing through the filter.

In order to solve the problems of the prior art as described above, an object of the present invention is to provide a low-weight ceramic filter excellent in wear resistance and heat resistance excellent in wear resistance and heat resistance, and can have a relatively wide porosity control range.

Another object of the present invention is to provide a method for producing a ceramic filter which is low in manufacturing cost, easy to manufacture, and at the same time easy to change shape and produce large filters.

Another object of the present invention is to provide a method of manufacturing a ceramic filter that can collect dust on the surface, to prevent clogging, at the same time to reduce the pressure loss, and significantly improve the air permeability and collection efficiency.

Another object of the present invention is to provide a ceramic filter that can maximize the filtration area of the filter by changing the shape in a predetermined space to maximize the dust collection efficiency.

In order to achieve the above object, the present invention
In the manufacturing method of a multilayer ceramic filter,

a) iii) silicon carbide, alumina, silymanite, kaolin, silica, titania

      Oh, and at least one selected from the group consisting of diatomaceous earth

      25 to 60 parts by weight of ceramic powder;

  Ii) 10 to 40 parts by weight of clay;

  Iii) 5 to 40 parts by weight of pore-forming agent;

  Iii) 1 to 20 parts by weight of the binder; And

  Iii) 20 to 60 parts by weight of the dispersion

  Mixing to prepare a slurry;

b) the slurry prepared in step a) on a carrier which is a nonwoven fabric, woven fabric or sponge.

   Preparing to form a molding by supporting;

c) drying the molded product carrying the slurry in step b);

d) inside or outside the molding dried in step c)

  Iii) silicon carbide, alumina, silymanite, kaolin, silica, titania

      And one or more selected from the group consisting of diatomaceous earth

      Mick powder 40 to 80 parts by weight;

  Ii) 10 to 40 parts by weight of the pore-forming agent;

  Iii) 7 to 30 parts by weight of the binder; And

  Iii) 10 to 50 parts by weight of the dispersion

  Further applying a slurry of mixing;

e) drying the molding further applied in step d); And

f) sintering the molded article dried in step e)

Including;
It provides a method for producing a multilayer ceramic filter comprising the step of forming the carrier in a predetermined form before or after the support of step b).

In addition, the present invention
In the manufacturing method of the ceramic filter,

a) iii) silicon carbide, alumina, silymanite, kaolin, silica, titania

      Oh, and at least one selected from the group consisting of diatomaceous earth

      25 to 60 parts by weight of ceramic powder;

  Ii) 10 to 40 parts by weight of clay;

  Iii) 5 to 40 parts by weight of pore-forming agent;

  Iii) 1 to 20 parts by weight of the binder; And

  Iii) 20 to 60 parts by weight of the dispersion

  Mixing to prepare a slurry;

b) the slurry prepared in step a) on a carrier which is a nonwoven fabric, woven fabric or sponge.

   Preparing to form a molding by supporting;

c) drying the molded product carrying the slurry in step b);

d) sintering the molded article dried in step c);

e) inside or outside the molding sintered in step d)

  Iii) silicon carbide, alumina, silymanite, kaolin, silica, titania

      And one or more selected from the group consisting of diatomaceous earth

      Mick powder 40 to 80 parts by weight;

  Ii) 10 to 40 parts by weight of the pore-forming agent;

  Iii) 7 to 30 parts by weight of the binder; And

  Iii) 10 to 50 parts by weight of the dispersion

  Further applying a slurry of mixing;

f) drying the molding further applied in step e); And

g) secondary sintering the molded product dried in step f)

Including;
It provides a method for producing a multilayer ceramic filter comprising the step of forming the carrier in a predetermined form before or after the support of step b).

The present invention also provides a ceramic filter manufactured by the above methods.

Hereinafter, the present invention will be described in detail.

The ceramic filter of the present invention is a slurry prepared by mixing at least one ceramic powder, clay, pore-forming agent, binder, and dispersion liquid selected from the group consisting of silicon carbide, alumina, silimite, kaolin, silica, titania, and diatomaceous earth. After molding to form a carrier, the molded molded product is dried, and further coated with a slurry of a ceramic powder, a pore-forming agent, a binder, and a dispersion liquid inside or outside the dried molded product, and dried and sintered. It is produced by the first method. In addition, the ceramic filter of the present invention is prepared by mixing at least one ceramic powder, clay, pore-forming agent, binder, and dispersion liquid selected from the group consisting of silicon carbide, alumina, silimite, kaolin, silica, titania, and diatomaceous earth. After the slurry is supported on a carrier to be molded, the molded article is dried and sintered, and a slurry obtained by mixing ceramic powder, a pore-forming agent, a binder, and a dispersion liquid inside or outside the sintered molding is further coated and dried. And a second method of sintering.

The first manufacturing method of the ceramic filter of the present invention will be described as follows.

a) slurry production

This step comprises: i) 25 to 60 parts by weight of ceramic powder selected from the group consisting of silicon carbide, alumina, silimite, kaolin, silica, titania, and diatomaceous earth, ii) 10 to 40 parts by weight of clay, i) 5 to 40 parts by weight of the pore-forming agent, i) 1 to 20 parts by weight of the binder, and i) 20 to 60 parts by weight of the dispersion, to prepare a slurry.

The ceramic powder of i) used in the present invention is a component constituting the basic structure of the ceramic filter after sintering, and serves as a support for the ceramic filter.

The ceramic powder may be a ceramic powder of various conventional forms used in the art. The ceramic powder is silicon carbide, alumina, silymanite (sillimanite group, Al ₂ O ₃ · SiO ₂ ), kaolin (kaolin group, Al ₂ O ₃ · 2SiO ₂ · 2H ₂ O), silica (SiO ₂ ), titania It is preferable to use diatomaceous earth or the like, and more preferably to use alumina, silicon carbide or a mixture thereof.

The ceramic powder may use components having various particle sizes, and certain components may have the same particle size, and may be used by mixing the same components having different particle sizes, in particular, the particle size of 0.001 ㎛ to 1 mm It is preferable. When the particle size of the ceramic powder is within the above range, there is an effect that can improve pore formation and mechanical strength of the ceramic filter.

The ceramic powder is preferably included in the slurry composition 25 to 60 parts by weight, more preferably 30 to 50 parts by weight. If the content is in the above range, there is an effect that can maintain the physical strength and shape of the ceramic filter, and at the same time has an effect that can significantly improve the filtration efficiency. In addition, it is possible to prevent distortion and cracking during sintering and to increase wear resistance of the ceramic filter.

The clay of ii) used in the present invention is a component constituting the basic structure of the ceramic filter after sintering and serves to facilitate bonding between ceramic particles during sintering.

The clay may be a component having a variety of particle size, a certain component may have the same particle size, and may be used by mixing the same component having a different particle size, in particular, it is a particle size of 0.001 ㎛ to 1 mm desirable. When the particle size of the clay is in the above range, there is an effect that can improve the pore formation and mechanical strength of the ceramic filter.

The clay is preferably included in 10 to 40 parts by weight, more preferably 15 to 25 parts by weight of the slurry composition. When the content is in the above range, there is an effect that can maintain the physical strength and shape of the ceramic filter, and at the same time has an effect that can significantly improve the filtration efficiency. In addition, it is possible to prevent distortion and cracking during sintering and to increase wear resistance of the ceramic filter.

The pore-forming agent of i) used in the present invention functions to form pores of the ceramic filter.

The pore-forming agent may be carbon, activated carbon, wood powder, sawdust, salt, naphthalene, talc or the like.

Of course, the pore-forming agent can be used a component having a variety of particle size, it is particularly preferred that the particle size of 0.001 ㎛ to 1 mm. If the particle size of the pore-forming agent is within the above range, there is an effect that can improve the pore formation and mechanical strength of the appropriate size of the ceramic filter.

The pore-forming agent is burned off during the sintering process to form pores of the ceramic filter, the content of which is preferably included in the slurry composition 5 to 40 parts by weight, more preferably 10 to 25 parts by weight. If the content is within the above range, there is an effect that can be completely burned during sintering to effectively form pores of the ceramic filter.

The binder of i) used in the present invention functions to form a slurry and a carrier.

The binder may be a conventional organic binder, an inorganic binder, or a mixture thereof, and in particular, it is preferable to use a mixture of an inorganic binder and an organic binder.

Specifically, the binder may be an inorganic binder of frit, barium carbonate (BaCO ₃ ), or mono aluminum phosphate (MAP), a water binder, polyvinyl butyral, polyvinyl alcohol, or polyvinylacetate. An organic binder can be used, and it is particularly preferable to mix frit and water grass.

The binder is preferably contained in 1 to 20 parts by weight, more preferably 5 to 10 parts by weight of the slurry composition. If the content is within the above range, there is an effect that can effectively combine the slurry and the carrier.

The dispersion of iii) used in the present invention may vary depending on the type of the binder, and it is particularly preferable to use water or alcohol.

The dispersion is preferably contained in 20 to 60 parts by weight, more preferably 20 to 30 parts by weight of the slurry composition. When the content is in the above range, it is possible to effectively mix each component included in the slurry, there is an effect that the slurry can be effectively bound to the carrier by maintaining the proper viscosity.

The ceramic powder, clay, pore-forming agent, and the binder as described above may be mixed and added to the dispersion at the same time, or may be mixed by sequentially separating and input at a predetermined interval. In particular, the mixing of the components is better for the convenience of mixing after mixing the ceramic powder, clay, pore-forming agent, and inorganic binder (mix only when using inorganic binder) in the dispersion, and then mixing the organic binder in the mixture. .

Mixing time of the mixture is preferably carried out for 1 to 10 hours.

The slurry mixed as described above may be further aged for 1 hour or more for stabilization.

b) support

This step is to prepare a molding by supporting the slurry prepared in step a) on a carrier.

Of course, the carrier used in the present invention may vary in size depending on the size of the ceramic filter to be manufactured.

The carrier may be any porous structure capable of supporting a slurry, and in particular, it is more preferable to use a nonwoven fabric, a woven fabric, or a sponge for ease of application.

The nonwoven fabric combines short fibers with an adhesive based on a web or sheet-like fiber aggregate, or makes fibers intertwine with thermoplastic fibers, or entangles the fibers by needle punching or sewing. In the form of polyester, aramid, polyphenylenesulfide, home-acrylic, polyimide, polytetrafluoroethylene (PTFE), viscose It is preferable to use (biscose), natural fiber, glass fiber, ceramic fiber, metal fiber or the like.

The woven fabric is manufactured by spinning, weaving, cotton, or the like, and is preferably woven loosely for supporting the slurry, and includes sufficient pores for supporting the slurry in the woven fabric.

The supporting step of this step may be applied to the slurry on the carrier, immersed the carrier in the slurry, or spraying (spray) the slurry on the carrier, it is possible to adhere, fusion, After the manufacture of a ceramic filter to be produced through sewing, self-bonding or molding using a mold, etc., it may be to carry a slurry.

In particular, a sufficient ceramic mixture is included in the support, and the process of immersing and squeezing the support in the slurry solution is repeated two or three times so that the support can be seated, or the process of applying or spraying and squeezing the slurry to the support is carried out. It is more preferable that the slurry solution is sufficiently supported on the carrier by repeating ˜3 times.

When the carrier is chopped or molded to a predetermined size and then supported on a slurry, the drying step may be performed immediately. If the carrier is not chopped or molded to a predetermined size, the step of forming the carrier to a shape suitable for the purpose is performed. It can be carried out further to produce a molding of a certain form.

The support on which the slurry is supported may be variously molded into a desired shape according to the purpose. In particular, the support may be closely adhered to a molding frame having a round tube, a radial bending tube, or a square tube, and clamped. It can be fixed to a round tube shape, a radial tube shape, a square tube shape or the like. When manufacturing the ceramic filter of the radial bending tube shape using the radial bending tube-shaped molding frame as shown in Figure 1 can be applied to the same where the circular tube is applied while maximizing the filtration area to increase the filtering efficiency There are advantages to it.

In addition, in the case of tightly coupling the carrier to the molding die, a demolding film may be added between the carrier and the mold to facilitate separation of the mold and the carrier after drying. The release film may preferably be a resin film made of rubber, urethane resin, epoxy resin, or the like, or a paper film such as kraft paper.

c) drying

This step is a step of drying the molded product carrying the slurry prepared in step b). At this time, the drying serves to prevent the shape deformation of the molding during the safe sintering and sintering preparation and sintering process.

The drying may be carried out by natural drying, hot air drying, sunlight drying or shade drying, and in particular, it is preferable to perform infrared drying so as to shorten the drying time and to prevent deformation and molding of the molded product.

d) additional application

This step comprises the following: c) 40 to 80 parts by weight of the ceramic powder, ii) 10 to 40 parts by weight of the pore-forming agent, i) 7 to 30 parts by weight of the binder, and v) dispersion 10 It is a step of further coating a slurry prepared by mixing to 50 parts by weight.

The ceramic powder of i) used in the present invention may use the same components as the ceramic powder of i) in step a).

Preferably, the ceramic powder is included in the slurry composition in an amount of 40 to 80 parts by weight, and when the content is within the above range, by forming fine pores outside or inside the forming layer, it is possible to reduce clogging inside the filter. In addition, the filter can be easily recycled.

The pore-forming agent of ii) used in the present invention may use the same components as the pore-forming agent of step i).

The pore-forming agent is preferably included in 10 to 40 parts by weight in the slurry composition, if the content is in the above range has the effect that can be completely burned during sintering to effectively form pores of the ceramic filter.

As the binder of vi) used in the present invention, the same components as the binder of vi) of step a) may be used.

The binder is preferably included in 7 to 30 parts by weight in the slurry composition, when the content is in the above range has the effect that the slurry can be effectively bonded to the molding.

The dispersion of iii) used in the present invention may use the same components as the dispersion of iii) of step a).

The dispersion is preferably contained in 10 to 50 parts by weight in the slurry composition, when the content is in the above range can be effectively mixed with each component contained in the slurry, the slurry is effectively bonded to the molding to maintain the proper viscosity It can work.

Slurry for further coating consisting of the above components may further comprise iii) clay as necessary.

The clay may use the same components as the clay of step ii), the content of which is included in the slurry composition 10 to 40 parts by weight.

The slurry including the above components is further coated inside or outside the molded product dried in step c), and the additional coating is repeated two or more times depending on the requirements of the ceramic filter and the purpose required for each layer. Of course it can be carried out by.

In addition, the slurry may further vary in content and thickness in order to vary the porosity of the surface layer, the strength of the surface layer, the viscosity of the slurry solution required for further application, or the functionality of the surface layer, depending on the use of the ceramic filter. Of course.

The additional coating may be carried out by a method such as coating with a brush, a method of immersing the molding in a slurry, or a method of spraying using a spray or the like.

The additional coating of this step is to form a sintered layer that does not contain a support, so that a dense sintered layer is formed on the surface to improve the strength of the ceramic filter, and at the same time the pores are controlled only by the pore-forming agent or the binder on the surface layer A surface layer having finer pores is formed, and dust collection is mainly performed on the surface, thereby reducing the clogging of the inside of the filter, thereby facilitating the recycling of the filter, and particularly applicable to high temperature and high pressure type. And the surface roughness is improved compared to the sintered layer of the region containing the carrier there is an effect that subsequent additional coating is easy.

e) drying

This step is to dry the molding further coated in step d), the drying may be carried out in the same manner as step c).

f) sintering

This step is a step of sintering the molded product dried in step e).

The sintering can be sintered at a constant temperature by removing the mold of the dried molding and put in the sintering furnace, the temperature of the sintering furnace to the sintering temperature.

In addition, the sintering is a processing step of making the body of the filter by cutting to the size of the ceramic filter to be manufactured; And a top cap having a lower cap and a jaw supporting wing that fits to the outer diameter of the body by drying the slurry on a carrier, and the upper and lower caps are assembled with a ceramic bond to block the lower portion and the upper portion into a wing shape. After the assembly step of assembling in an open form is further performed, it may be sintered.

The sintering may proceed with sintering by setting an appropriate sintering temperature according to the composition and ratio of the slurry, and in particular, the sintering may be 0.5 to room temperature to 500 ° C. so as to prevent deformation, crushing, and breakage of moldings that may occur during elevated temperature. It is preferable to raise the temperature at a rate of ˜3 ° C./min. In particular, at a temperature of 150 to 450 ° C., it is preferable to slowly increase the temperature at a rate of 0.5 to 1 ° C./min, and finally 900 to 1,300 ° C. depending on the composition of the ceramic powder. The temperature is raised to the sintering temperature of and maintained for 2 to 48 hours to complete the sintering.

In addition, the second manufacturing method of the ceramic filter of the present invention will be described.

a) slurry production

It can be carried out in the same manner as step a) of the first manufacturing method of the ceramic filter.

b) support

It may be carried out in the same manner as step b) of the first manufacturing method of the ceramic filter.

c) drying

It may be carried out in the same manner as step c) of the first manufacturing method of the ceramic filter.

d) sintering

It can be carried out in the same manner as step d) of the first manufacturing method of the ceramic filter.

e) additional application

This step comprises the following: d) 50 to 80 parts by weight of ceramic powder, ii) 10 to 40 parts by weight of pore-forming agent, i) 7 to 30 parts by weight of binder, and iii) dispersion 10 It is a step of further coating a slurry prepared by mixing to 30 parts by weight.

The additional coating step may be carried out in the same manner as step d) of the first manufacturing method of the ceramic filter.

f) drying

This step is to dry the molded article further coated in step e), the drying may be carried out in the same manner as step c) of the step a).

g) sintering

This step is a step of sintering the molded article dried in step f), the sintering may be carried out in the same manner as step f) of the first manufacturing method.

Further, the second manufacturing method which is further coated after the sintering may be applied not only when the additional coating is performed before the sintering but also when the additional coating is made before the sintering by the first manufacturing method as described above.

The final ceramic filter manufactured according to the above method can be manufactured in various forms as shown in Figures 2 to 5, the region including the carrier as shown in Figures 6 to 8 has a high porosity, further coating In the case of the layer, it can be manufactured in a structure having a dense porosity. In addition, as shown in FIG. 9, two or more ceramic filters may be bonded to each other with an adhesive to be used as a ceramic filter having an extended length. In this case, a pipe having a size smaller than the inner circumferential surface of the ceramic filter may be inserted between the ceramic filters.

The adhesive may of course use a conventional adhesive used in the art, and preferably a ceramic adhesive.

In addition, the ceramic filter of the present invention is the (c) dried ceramic filter, further applied and dried ceramic filter, (d) sintered ceramic filter, (d) further sintered and dried to improve the functionality of the ceramic filter And (d) further applying a functional material to the inside or outside of the ceramic filter, or (d) additionally applied and dried and sintered ceramic filter, followed by drying, wherein the application of the functional material is functional. Of course, it is possible to apply a variety of known coating methods that can be appropriately bonded between the material and the ceramic filter, in particular, (d) after sintering may further include a sintering step after the application of the functional material, drying.

The functional material may be used alone or in combination of zeolite, platinum, palladium, rhodium, silver, TiO ₂ , or ZnO.

The functional material applied to the inside or the outside of the ceramic filter may coat the inside and the outside of the ceramic filter with the same components, or may be coated with different components inside and outside.

As described above, the first and second manufacturing methods of the ceramic filter according to the present invention are low in manufacturing cost, easy in manufacturing method, and at the same time, easy to change shape and produce large filters, wear resistance, heat resistance, and pores. There is also an advantage that the adjustment range is relatively excellent. In addition, the first and second manufacturing methods according to the present invention can form a dense sintered layer on the inside or outside of the ceramic filter to improve the strength of the ceramic filter and at the same time provide a surface layer having finer pores. It can be formed to reduce the clogging inside the filter, the filter can be easily recycled, in particular, the effect is applicable to high temperature and high pressure type, and the roughness is improved compared to the sintered layer of the region containing the support The advantage is that the coating is easy.

In addition, the present invention provides a ceramic filter manufactured by the above method, the ceramic filter of the present invention can be generally used as a post-treatment device of each industry, as shown in Figure 10 as a dust collecting filter of various dust collecting equipment In particular, the present invention can be used in an incinerator, a dust collector of a cremator, a dust collector of engine exhaust gas, a catalyst carrier which is an air purifier of automobile exhaust gas, or a volatile organic compound (VOC's) removal apparatus by a photocatalytic action in an air cleaner.

Hereinafter, preferred examples are provided to help understanding of the present invention, but the following examples are merely to illustrate the present invention, and the scope of the present invention is not limited to the following examples.

EXAMPLE

Example 1

50 parts by weight of water was added to the mixer, and 40 parts by weight of alumina (Al ₂ O ₃ ), 25 parts by weight of clay, 25 parts by weight of activated carbon, and 5 parts by weight of frit (VA950, Duklim) were mixed with an inorganic binder. . To the mixture was added 5 parts by weight of the water pool with an organic binder, and then mixed in a mixer for 2 hours to prepare a primary slurry solution.

The prepared primary slurry solution was applied to be sufficiently supported on a nonwoven fabric having a width of 1000 mm × length of 1500 mm × thickness of 2 mm.

Then, after forming a mold of the round tube form of PVC, bonding the demolding film on the surface of the mold, and wound the non-woven fabric immersed in the slurry solution in the form of a mold to prepare a molding, the temperature of 30 ~ 90 ℃ Hot air dried at 1 hour.

Then add 25 parts by weight of water to the mixer, add 70 parts by weight of alumina (Al ₂ O ₃ ), 25 parts by weight of activated carbon, and 5 parts by weight of frit (VA950, Duklim) and 10 parts by weight of water pool as a binder The slurry solution for further coating, which was prepared by mixing, was further coated by brushing the inside and the outside of the dried molding. This was carried out in the same manner as the drying method described above and dried.

After removing the mold and demolding film from the dried molding, the molding is placed in an electric furnace to increase the temperature at a rate of 3 ℃ / min up to room temperature ~ 150 ℃, slowly at a rate of 0.5 ~ 1 ℃ / min to 150 ~ 450 ℃ The temperature was increased and maintained at a temperature of 900 to 1,300 ° C. for 2 hours to complete sintering to prepare ceramic filters having double layers having different sizes.

FIG. 6 is a scanning electron micrograph of only the additional coating pore layer, FIG. 7 is a scanning microscope picture of the carrier-containing region, and FIG. 8 is a ceramic filter having a double layer having different size porosity with the additional coating layer. Runners electron micrograph.

Example 2

Except that the slurry solution for further coating in Example 1 was applied only to the inside of the molding, it was carried out in the same manner as in Example 1 to prepare a ceramic filter having a double layer of different sizes.

Example 3

Except that the slurry solution for further coating in Example 1 was applied only to the outside of the molding, it was carried out in the same manner as in Example 1 to prepare a ceramic filter having a double layer of different sizes.

Example 4

Except for using silicon carbide (SiC) in place of alumina in the first slurry solution in Example 1 was carried out in the same manner as in Example 1 to prepare a ceramic filter having a double layer of different sizes.

Example 5

In Example 1, except that 25 parts by weight of alumina and 25 parts by weight of silicon carbide (SiC) were used in place of the alumina (Al ₂ O ₃ ) parts by weight of the first slurry solution in the same manner as in Example 1 Ceramic filters having double layers of different sizes were prepared.

Example 6

The same method as in Example 1 was performed except that the nonwoven fabric immersed in the slurry solution was formed by using the molding die in the form of a radial bending tube (FIG. 1) instead of the molding die in the circular tube form. To prepare a ceramic filter having a double layer of different sizes as shown in FIG.

Example 7

In Example 1, except that the non-woven fabric immersed in the slurry solution using a square tube-shaped mold instead of the round tube-shaped mold was carried out in the same manner as in Example 1 of different sizes A ceramic filter having a double layer was prepared.

Example 8

In Example 1, a nonwoven fabric immersed in a slurry solution was formed by using a molding die in the form of a radial bending tube, followed by hot air drying.

Then, the dried molding is cut to form the body of the filter, and the lower cap and the upper cap having the shape of the chin support wing that fit the outer diameter of the body are precipitated or applied to the nonwoven fabric with the same slurry solution as above, followed by drying. Prepared. At this time, the body and the upper and lower caps were assembled with ceramic adhesive, the lower part was blocked, and the upper part was assembled and dried in the form of open wings.

Thereafter, a ceramic filter having a double layer having different sizes with upper and lower caps attached thereto was prepared in the same manner as in Example 1 above.

Example 9

In Example 1, the slurry solution for further coating was first applied and then dried, and the same procedure as in Example 1 was performed except for the second additional coating and drying on the surface thereof to have a double layer having different sizes. Ceramic filters were prepared.

Example 10

50 parts by weight of water was added to the mixer, and 40 parts by weight of alumina (Al ₂ O ₃ ), 25 parts by weight of clay, 25 parts by weight of activated carbon, and 5 parts by weight of frit (VA950, Duklim) were mixed with an inorganic binder. . To the mixture was added 5 parts by weight of the water pool with an organic binder, and then mixed in a mixer for 2 hours to prepare a primary slurry solution.

The primary slurry solution prepared above was applied so as to be sufficiently supported on a nonwoven fabric having a width of 1000 mm x 1500 mm x thickness 8 mm.

Then, after forming a mold of the round tube form of PVC, bonding the demolding film on the surface of the mold, and wound the non-woven fabric immersed in the slurry solution in the form of a mold to prepare a molding, the temperature of 30 ~ 90 ℃ Hot air dried at 1 hour.

After removing the mold and demolding film from the dried molding, the molding is placed in an electric furnace to increase the temperature at a rate of 3 ℃ / min up to room temperature ~ 150 ℃, slowly at a rate of 0.5 ~ 1 ℃ / min to 150 ~ 450 ℃ The temperature was raised and maintained at a temperature of 900 to 1,300 ° C. for 2 hours to complete sintering.

Then, 20 parts by weight of water was added to the mixer, and 70 parts by weight of alumina (Al ₂ O ₃ ), 25 parts by weight of activated carbon, and 5 parts by weight of frit (VA950, Duklim) and 10 parts by weight of water pool were added as a binder and uniform. The slurry coating solution for further coating prepared by mixing was added to the inside and the outside of the sintered molded product by applying a brush.

This was carried out in the same manner as the above drying and sintering to dry and sinter to prepare a ceramic filter having a double layer of different sizes.

Example 11

In Example 10, except that the slurry solution for further coating was applied only to the inside of the molding, the same procedure as in Example 10 was performed to prepare ceramic filters having double layers having different sizes.

Example 12

Except that the slurry solution for further coating in Example 10 was applied only to the outside of the molding, it was carried out in the same manner as in Example 10 to prepare a ceramic filter having a double layer of different sizes.

Example 13

In Example 10, except that silicon carbide (SiC) was used in place of the alumina in the first slurry solution, the same procedure as in Example 10 was carried out to prepare a ceramic filter having double layers having different sizes.

Example 14

In Example 10, except that 25 parts by weight of alumina and 25 parts by weight of silicon carbide (SiC) were used in place of the alumina (Al ₂ O ₃ ) parts by weight of the first slurry solution in the same manner as in Example 10 Ceramic filters having double layers of different sizes were prepared.

Example 15

The same method as in Example 10, except that the nonwoven fabric immersed in the slurry solution using a molding die in the form of a radial bending tube (Fig. 1) in place of the molding die in the form of a round tube in Example 10 To prepare a ceramic filter having a double layer of different sizes.

Example 16

In Example 10, except that the non-woven fabric immersed in the slurry solution by using a square tube-shaped mold instead of a round tube-shaped mold was carried out in the same manner as in Example 10 to have a different size A ceramic filter having a double layer was prepared.

Example 17

In Example 10, a nonwoven fabric immersed in a slurry solution was molded using a mold of a radial bending tube, followed by hot air drying.

Then, the dried molding is cut to form the body of the filter, and the lower cap and the upper cap having the shape of the chin support wing that fit the outer diameter of the body are precipitated or applied to the nonwoven fabric with the same slurry solution as above, followed by drying. Prepared. At this time, the body and the upper and lower caps were assembled with ceramic adhesive, the lower part was blocked, and the upper part was assembled and dried in the form of open wings.

Thereafter, a ceramic filter having double layers having different sizes was prepared by the same method as in Example 10.

Example 18

After applying the slurry solution for the additional coating in Example 10 first, and then applying a second additional coating on the surface thereof was carried out in the same manner as in Example 10 to obtain a ceramic filter having a double layer of different sizes Prepared.

Through Examples 1 to 18 above, a large ceramic filter having a diameter of 100 mm or more and a size of 1 m or more could be manufactured, having a high porosity of 40% or more, and having excellent heat resistance up to at least 1000 ° C. .

The manufacturing method of the multilayer ceramic filter according to the present invention does not require a separate expensive mold manufacturing and does not require a pressure device or a vacuum device to manufacture the ceramic filter, and thus, the manufacturing cost of the ceramic filter is low, and the manufacturing method is easy. It is easy to change the shape, and it is possible to produce a large filter to the extent that the size of the sintering furnace allows. In addition, since there is no pressurization or vacuum process, the porosity can be controlled in a relatively wide range, and the pore size can be adjusted with a small deviation by selecting it in the range of 0.001-5 mm according to the density of the carrier, the size and the amount of the pore-forming agent. The high porosity of 40% or more can be molded, and the ceramic filter manufactured according to the present invention can be manufactured with a low weight porous filter.

In addition, the present invention is easy to change the shape, it is easy to manufacture a complex shape can be produced a ceramic filter that can maximize the filtration area of the filter in a certain space.

In the present invention, the pores of the ceramic filter have a dense structure on the surface and a coarse structure on the inside, so that the surface has excellent abrasion resistance and heat resistance, so that it can be used under high temperature and high pressure, and the filter layer has a dense structure and a back structure on the back. Reduce the total weight, collect dust from the surface to prevent clogging inside the ceramic filter, and can easily produce a ceramic filter with low pressure loss, high air permeability and collection efficiency as a whole, After use, the ceramic filter may be heated at a high temperature to incinerate and remove dust, thereby easily recycling the ceramic filter.

In addition, the ceramic filter of the present invention does not require a heat exchanger device through fluid cooling at a high temperature, it is very light with a porous structure of 40% or more, and the collection efficiency is more than 99.8%, it is possible to collect at a faster filtration rate than conventional dust filters. There is no deterioration or damage of the filter even at high temperature and high pressure, and there is no concern about the fire caused by the spark, so it can be easily applied to waste incinerators, cremators, boilers, cement manufacturing processes, coal-fired power plants, and coal gasification combined cycle facilities.

Claims (16)

In the manufacturing method of a multilayer ceramic filter, a) iii) silicon carbide, alumina, silymanite, kaolin, silica, titania       Oh, and at least one selected from the group consisting of diatomaceous earth       25 to 60 parts by weight of ceramic powder;   Ii) 10 to 40 parts by weight of clay;   Iii) consisting of carbon, activated carbon, wood powder, salt, naphthalene, and talc       5 to 40 parts by weight of a pore-forming agent selected from the group consisting of paper;   Iii) inorganic binder or MAP (mono aluminum phosphate), water binder, polyvinyl butyral, polyvinyl alcohol, and polyvinyl selected from the group consisting of frit and barium carbonate (BaCO3); 1 to 20 parts by weight of an organic binder selected from the group consisting of acetate; And   Iii) 20 to 60 parts by weight of the dispersion   Mixing to prepare a slurry; b) preparing a molding by supporting the slurry prepared in step a) on a carrier which is a nonwoven fabric, woven fabric or sponge; c) drying the molded product carrying the slurry in step b); d) inside or outside the molding dried in step c)   Iii) silicon carbide, alumina, silymanite, kaolin, silica, titania       And one or more selected from the group consisting of diatomaceous earth       Mick powder 40 to 80 parts by weight;   Ii) consisting of carbon, activated carbon, wood powder, salt, naphthalene, and talc 10 to 40 parts by weight of a pore-forming agent selected from the group consisting of:   Iii) inorganic binder or MAP (mono aluminum phosphate), water binder, polyvinyl butyral, polyvinyl alcohol, and polyvinyl selected from the group consisting of frit and barium carbonate (BaCO3); 7 to 30 parts by weight of an organic binder selected from the group consisting of acetate; And   Iii) 10 to 50 parts by weight of the dispersion   Further applying a slurry of mixing; e) drying the molding further applied in step d); And f) sintering the molded article dried in step e) Including; Forming a carrier in a predetermined form before or after the support of step b), characterized in that it comprises a step of forming a ceramic filter. In the manufacturing method of a multilayer ceramic filter, a) iii) silicon carbide, alumina, silymanite, kaolin, silica, titania       Oh, and at least one selected from the group consisting of diatomaceous earth       25 to 60 parts by weight of ceramic powder;   Ii) 10 to 40 parts by weight of clay;   Iii) consisting of carbon, activated carbon, wood powder, salt, naphthalene, and talc       5 to 40 parts by weight of a pore-forming agent selected from the group consisting of paper;   Iii) inorganic binder or MAP (mono aluminum phosphate), water binder, polyvinyl butyral, polyvinyl alcohol, and polyvinyl selected from the group consisting of frit and barium carbonate (BaCO3) 1 to 20 parts by weight of an organic binder selected from the group consisting of acetate; And   Iii) 20 to 60 parts by weight of the dispersion   Mixing to prepare a slurry; b) preparing a molding by supporting the slurry prepared in step a) on a carrier which is a nonwoven fabric, woven fabric or sponge; c) drying the molded product carrying the slurry in step b); d) sintering the molded article dried in step c); e) inside or outside the molding sintered in step d)   Iii) silicon carbide, alumina, silymanite, kaolin, silica, titania       And one or more selected from the group consisting of diatomaceous earth       Mick powder 40 to 80 parts by weight;   Ii) consisting of carbon, activated carbon, wood powder, salt, naphthalene, and talc 10 to 40 parts by weight of a pore-forming agent selected from the group consisting of at least one;   Iii) inorganic binder or MAP (mono aluminum phosphate), water binder, polyvinyl butyral, polyvinyl alcohol, and polyvinyl selected from the group consisting of frit and barium carbonate (BaCO3); 7 to 30 parts by weight of an organic binder selected from the group consisting of acetate; And   Iii) 10 to 50 parts by weight of the dispersion   Further applying a slurry of mixing; f) drying the molding further applied in step e); And g) secondary sintering the molded product dried in step f) Including; Forming a carrier in a predetermined form before or after the support of step b), characterized in that it comprises a step of forming a ceramic filter. delete The method according to claim 1 or 2, I) the ceramic powder of step a) is alumina, silicon carbide, or a mixture thereof. delete delete delete The method according to claim 1 or 2, The nonwoven fabric is selected from the group consisting of polyester, aramid, polyphenylene sulfide, home-acrylic, polyimide, PTFE, viscose, natural fiber, glass fiber, ceramic fiber, and metal fiber of porous structure A method for producing a multilayer ceramic filter. The method according to claim 1 or 2, The molded article of step b) is a round tube shape, radial bending tube shape, or a method of producing a multilayer ceramic filter, characterized in that the rectangular tube shape. The method according to claim 1 or 2, The method of claim 1, wherein the molded article of step b) combines the demolding film on the molding die and then combines the carrier of step b). The method according to claim 1 or 2, The method of claim 1, wherein the slurry of step d) or step e) of claim 2 further comprises 10 to 40 parts by weight of clay. The method according to claim 1 or 2, The method of manufacturing the multilayer ceramic filter of claim 1, wherein the sintering of step f) or step d) and g) of claim 2 is carried out at a rate of 0.5 to 1 ° C / min at a temperature of 150 to 450 ° C. The ceramic filter of claim 1, wherein the ceramic filter is manufactured by the manufacturing method of claim 1. The method of claim 13, And wherein the ceramic filter has a double layer of a sintered layer of the carrier and a layer of additional coating. The method of claim 13, And wherein the ceramic filter is in the shape of a round, square, or radially bent tube. The method of claim 13, The ceramic filter is a ceramic filter, characterized in that for the dust collector of the incinerator or crematorium, the dust collector of the engine exhaust gas, the automobile exhaust gas catalyst carrier, or the volatile organic compound removal device.

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