KR101391649B1 - Multilayered Carbon Filter Block, Filter for Water Purification Using the Same and Manufacturing Method thereof - Google Patents

Abstract

In the present invention, in the activated carbon filter block for a cylindrical cartridge filter, the activated carbon filter block is formed by laminating a plurality of unit activated carbon blocks having different densities from the outer circumferential surface to the inner circumferential surface direction, A water purification filter and a manufacturing method thereof are provided.
The multilayered activated carbon filter block of the present invention comprises a fibrous activated carbon layer having a relatively low pressure loss and a very high adsorption rate on the raw water contact surface and a powder activated carbon layer having a high contact area with water and excellent chlorine removal efficiency, Can be constituted by a granular activated carbon layer having a small packing density, the pore distribution is formed asymmetrically and is excellent in terms of flow rate, pressure loss and filter life, and since the particle layers have different density grades, This is an excellent feature.

Description

TECHNICAL FIELD The present invention relates to a multi-layer type activated carbon filter block, a water filter using the same,

The present invention relates to a multi-layer type activated carbon filter block, a water filter using the same, and a method of manufacturing the same. More particularly, the present invention relates to an activated carbon filter having a multi- The present invention relates to a multi-layer type activated carbon filter block having excellent water and chlorine removal efficiency and extending service life, a water purification filter using the same, and a manufacturing method thereof.

Activated carbon has long been used as a typical adsorbent since it has various pore structure. Activated carbon can remove chlorine, organic substances, all organic halogens including trihalomethanes, organic carbon that can be biologically produced by ozone treatment, and substances causing taste and odor. At present, activated carbon is used for industrial purposes as waste gas treatment, recovery of volatile solvent, deodorization, removal of toxic organic matter in water treatment field, and recently also used as a pretreatment adsorption filter for treatment of highly purified water of a water purification plant or domestic water purifier. It is gradually expanding.

For example, Patent Document 1 discloses a technique in which a slurry composed of granular activated carbon and an acrylic fiber binder is adsorbed on a nonwoven fabric and dried to produce an activated carbon filter molding agent. Patent Document 2 discloses a technique relating to an activated carbon filter formed article in which a binder and a polyamide resin are mixed with a mixture of granular activated carbon and powdered activated carbon. On the other hand, Patent Document 3 discloses a technique in which activated carbon fibers are crushed and made into a filter filler. Patent Document 4 discloses a technique relating to the production of a porous formed article in which zeolite carrying activated carbon and metal ions is solidified with a binder with a low melting point polymer. Patent Document 5 discloses a technique for manufacturing a water treatment filter in which a porous polymer binder is mixed with at least two kinds of activated carbon and has a predetermined diameter

The known techniques include a method in which activated carbon alone or activated carbon having a different particle range of two or more kinds is mixed with a binder and formed into a tube shape or a cylindrical shape through heat treatment, and then the outer surface of the tube is wrapped with a nonwoven fabric. However, such a block-shaped carbon filter has a problem in that the pore distribution is symmetrically configured, and therefore, the pressure loss is increased to shorten the lifetime, or the channel removal phenomenon lowers the chlorine removal rate, thereby deteriorating the purification performance of the water.

As a result of efforts to develop an activated carbon block filter having a simple manufacturing process and a low cost, a low pressure loss, a long lifetime and a high flow rate and a chlorine removal rate, Pore distribution, and particle packing density gradient, it has been found that the water content and the chlorine removal rate are excellent and the service life is remarkably prolonged. Thus, the present invention has been accomplished.

Korean Patent No. 341240 Korean Patent No. 843576 Korean Patent No. 473755 Japanese Patent Application Laid-Open No. 2006-95517 Japanese Laid-Open Patent Publication No. 2010-104974

It is an object of the present invention to provide a multi-layered activated carbon filter block having an excellent flow rate and a high chlorine removal rate and extending service life.

Another object of the present invention is to provide a water purification filter using the above-mentioned multilayered activated carbon filter block.

It is still another object of the present invention to provide a method for manufacturing the above-mentioned multilayered activated carbon filter block.

In order to attain the above object, the present invention provides an activated carbon filter block for a cylindrical cartridge filter, wherein the activated carbon filter block is formed by laminating a plurality of unit activated carbon blocks having different densities from an outer circumferential surface to an inner circumferential surface, .

Preferably, the unit activated carbon block is any one selected from the group consisting of a fibrous activated carbon block, a granular activated carbon block, and a powdered activated carbon block.

It is preferable that each of the unit activated carbon blocks is bound to a binder selected from the group consisting of fibrous activated carbon, granular activated carbon, and powdered activated carbon in order.

It is preferable that at least a part of the binder is a hydrophilized binder.

The binder is preferably a fibrous binder or a powder binder.

The fibrous activated carbon is prepared by a powdery binder; The granular or powdery activated carbon is preferably bound by a fibrous binder.

The packing density of the unit activated carbon block is 0.3 to 0.7 g / cm < ³ > 0.3 to 0.8 g / cm < ³ > of granular activated carbon block; And the powdered activated carbon block is 0.3 to 0.5 g / cm < ³ >.

The filter block is formed in three layers in the order of the first activated carbon block, the second activated carbon block and the third activated carbon block in the direction from the outer circumferential surface to the inner circumferential surface, the first activated carbon block is a fibrous activated carbon block; The second activated carbon block is a granular activated carbon block; And the third activated carbon block are powdery activated carbon blocks; .

The water purification filter of the present invention is manufactured by laminating nonwoven fabrics on the outer and inner surfaces of the multilayered activated carbon filter block.

A method for manufacturing a multilayered activated carbon filter block according to the present invention comprises the steps of: separating a space in a concentric manner from an outer circumferential surface to an inner circumferential surface of an inner space of a cylindrical metal mold and filling a mixture of activated carbon and a binder in each of the separated spaces; And heat treating the filled mixture.

Wherein the fibrous activated carbon is a powdery binder; The granular or powdery activated carbon is preferably mixed with a fibrous binder.

The multilayered activated carbon filter block of the present invention comprises a fibrous activated carbon layer having a relatively low pressure loss and a very high adsorption rate on the raw water contact surface and a powder activated carbon layer having a high contact area with water and excellent chlorine removal efficiency, Can be constituted by a granular activated carbon layer having a small packing density, the pore distribution is formed asymmetrically and is excellent in terms of flow rate, pressure loss and filter life, and since the particle layers have different density grades, This is an excellent feature.

FIG. 1 is a schematic perspective view of a part of a multi-layered activated carbon filter block according to an embodiment of the present invention.

Hereinafter, the multilayered activated carbon filter block of the present invention will be described in detail.

[Multi-layer type activated carbon block]

The multi-layered activated carbon filter block of the present invention is formed by laminating a plurality of unit activated carbon blocks having different densities from the outer circumferential surface to the inner circumferential surface.

The unit activated carbon block is any one selected from the group consisting of a fibrous activated carbon block, a granular activated carbon block, and a powdered activated carbon block.

The activated carbon forming the activated carbon blocks has an average specific surface area of 500 to 2000 m ² / g and can be used as an effective adsorbent because of its high surface area. It can be divided into powder, granular and fibrous depending on particle size and shape.

The fibrous activated carbon forming the fibrous activated carbon block refers to an activity of a shape having a diameter of 5 to 20 탆 and a length of 100 탆 to 10 mm. Theoretically, the length of the fibrous activated carbon may exceed 10 mm, but it is preferably 10 mm or less for the fibrous activated carbon block of the present invention. The fibrous activated carbon of the above-mentioned size is commercially available. In some cases, the activated carbon fiber on the fabric may be pulverized to a size within the above-mentioned range. Since the fibrous activated carbon generally has a relatively high specific surface area than that of the powder or granular material and most of the pores involved in the adsorption are exposed on the fiber surface, the adsorption and desorption rates of residual chlorine and other odorous substances in the raw water, There is a very fast feature. However, there is a disadvantage in that the filling density is low and the adsorption amount per unit volume is small.

On the other hand, the granular activated carbon forming the granular activated carbon block refers to activated carbon having a particle size of 0.5 to 4 mm, and the powdery activated carbon forming the powder activated carbon block usually has a particle size of 1 to 150 μm. The powdered activated carbon has a high adsorption amount and a high chlorine removal rate due to a high packing rate per unit volume, but has a problem of a small amount of water or an increased pressure loss. On the other hand, granular activated carbon has the advantage of low adsorption amount but low pressure loss because it can not expect high filling rate per unit volume.

Each unit activated carbon block is formed by binding the above-mentioned fibrous activated carbon, granular activated carbon, and powdered activated carbon with a binder. The binder is used for binding the activated carbon particles to improve the filling rate and to prevent the particles from falling off. As the binder used for the above-mentioned purpose, thermosetting resins typified by urethane or epoxy, thermoplastic resins typified by low melting point polyethylene, polyester and the like and those conventionally used in the art can be used. Preferably, low melting point polyethylene or polyester and ultra high molecular weight polyethylene are advantageous. This is because adhesion of activated carbon is improved due to melting of the binder surface even at a low heat treatment temperature.

The shape of the binder may be either fibrous or powdery. As the fiber used for the binder, a fibrous binder in the form of a short fiber is generally used.

On the other hand, in the use of the binder, a powdery binder is preferable for the fibrous activated carbon, and fibrous form is advantageous for the granular and powdery activated carbon. Since the adhesion surface area between the activated carbon and the binder can be increased and the amount of the binder used can be minimized.

On the other hand, the amount of the binder used is preferably such that the ratio of [activated carbon: binder] in the fibrous activated carbon block, granular activated carbon block and powdered activated carbon block is in the range of [40 to 90: 10 to 60] by weight. If the content of each activated carbon is less than 40% by weight, there is a problem in adsorption power, and if it is more than 90% by weight, the pressure loss increases.

The binder may be at least partially hydrophilized to minimize the resistance of the water to be filtered. The hydrophilization treatment may be performed according to a known method depending on the material of each binder. For example, in the case of a binder made of polypropylene or polyester, there is known a method of hydrophilizing by the above-described hydrophilization treatment method through an atmospheric pressure plasma treatment.

When the binder subjected to the hydrophilization treatment is used, the content thereof is preferably 10 to 40% by weight based on the total binder content. If the content of the hydrophilic binder is less than 10 wt%, the increase in the flow rate is insufficient, and if the hydrophilic binder is more than 40 wt%, the mixing with the activated carbon becomes uneven.

The packing densities of the unit activated carbon blocks constituting the multilayered activated carbon filter block of the present invention can be freely adjusted in consideration of the required performance and the manufacturing cost, but the fibrous activated carbon block is 0.3 to 0.7 g / cm ³ ; 0.3 to 0.8 g / cm < ³ > of granular activated carbon block; And the powdery activated carbon block is 0.3 to 0.5 g / cm < ³ >. When the filling density of each layer is out of the lower limit value, the strength is low and it tends to brittle. When the filling density exceeds the upper limit value, hardness is not obtained.

FIG. 1 is a schematic perspective view of a part of a multi-layered activated carbon filter block 10 manufactured according to an embodiment of the present invention. 1, the multi-layered activated carbon filter block 10 has a three-layered structure of the first activated carbon block 11, the second activated carbon block 12 and the third activated carbon block 13 in the order from the outer circumferential surface to the inner circumferential surface. Unit activated carbon blocks.

In the above, the outer peripheral surface is the raw water contact surface.

Wherein the first activated carbon block is a fibrous activated carbon block; The second activated carbon block is a granular activated carbon block; And the third activated carbon block are preferably composed of a powdery activated carbon block. The arrangement of the above-mentioned activated carbon block is intended to facilitate the escape of the air present in the activated carbon mixture at the time of manufacture and to secure the extension of service life by suppressing the pressure loss and channeling phenomenon while maintaining proper residual chlorine removal rate and flow rate. That is, when the powdered activated carbon block is located on the raw water contact surface, the service life is shortened due to the increase of the pressure loss. When the granular activated carbon block is located on the raw water contact surface, the pressure loss is decreased but the effective surface area is likely to be lost due to the channeling phenomenon. Therefore, if such a block arrangement is provided, it will have an extended service life due to low pressure loss and excellent flow rate and removal rate without channeling phenomenon.

Meanwhile, the thickness of the unit activated carbon blocks constituting each layer in the multilayered activated carbon filter block of the present invention can be arbitrarily adjusted. When the unit activated carbon blocks are laminated in three layers as in the above embodiment, the ratio of the thickness of each layer to the thickness of each layer is preferably 1: 2: 3, but is not particularly limited as long as it can maintain a sufficient strength of 10 MPa or more .

It is possible to change the stacking order of the blocks according to the required performance. For example, the first activated carbon block is a powdered activated carbon block; The second activated carbon block is a granular activated carbon block; And the third activated carbon block may be a fibrous activated carbon block. Other order stacking is also possible.

In the embodiment according to FIG. 1, the multi-layered activated carbon filter block is formed by laminating three unit activated carbon blocks, but in another embodiment, the multi-layered activated carbon filter block may be composed of only two unit blocks. In this case, one unit activated carbon block may be a fibrous block, and the other unit activated carbon block may be a granular activated carbon block or a powder activated carbon block.

In another embodiment, the multi-layered activated carbon filter block may be constructed by stacking four or more unit activated carbon blocks. In this case, it is needless to say that one unit filter block can be used more than once and stacked.

 [Water filter]

The multilayered activated carbon filter block according to the present invention is manufactured by laminating nonwoven fabrics on the outer and inner circumferential surfaces thereof. The nonwoven fabric is used for preventing the dropping of activated carbon during filtration of raw water, and any of those conventionally used in the art can be used for this purpose.

[Manufacturing method of multilayer activated carbon block]

A method for manufacturing a multilayered activated carbon filter block according to the present invention comprises the steps of: separating a space in a concentric manner from an outer circumferential surface to an inner circumferential surface of an inner space of a cylindrical metal mold and filling a mixture of activated carbon and a binder in each of the separated spaces; And heat treating the filled mixture. Hereinafter, a method of manufacturing the multilayered activated carbon filter block of the present invention will be described in detail.

In the manufacturing method of the present invention, the first step is a step of separating the inner space of the cylindrical metal mold into concentric circles in the direction of the inner circumferential surface from the outer circumferential surface, and filling the mixture of the activated carbon and the binder into the separated spaces. Here, the means for separating the inner space of the metal mold is not particularly limited. For example, the space in the metal mold can be separated by disposing a separating sheet or a film in a concentric shape and placing the metal sheet in the metal mold. The separating means is removed when the filling is completed.

Each of the concentrically separated spaces is filled with a mixture of activated carbon and a binder. At this time, the shapes, sizes and compositions of the mixtures of the activated carbon and the binder are as described above.

There is no particular limitation on the preparation of the mixture of the activated carbon and the binder. For example, the preparation of the mixture is carried out for a predetermined time or longer by using a Jar-type mixer or the like to increase the contact area between the activated carbon and the binder, And can be performed so as to have a uniform distribution.

In the mixture of activated carbon and binder, in order to smoothly perform mixing and increase the contact area between the activated carbon and the binder and uniform distribution of the binder, the fibrous activated carbon is mixed with the powdery binder, and the powdery or granular activated carbon is mixed with the fibrous binder .

In the production method of the present invention, the second step is a step of heat-treating the filled mixture. When the metal mold is removed after the heat treatment step, the mixture obtained in the first step, that is, the mixture of the activated carbon powder and the binder constituting each layer is a laminate of unit activated carbon blocks having a constant packing density and air permeability, that is, An activated carbon filter block is obtained.

The heat treatment is carried out by pressing and heating by appropriate means. Preferably, the pressing and heating are performed by a method of compressing at a pressure of 50 to 1,000 kgf / cm < ² > and a temperature of 150 to 300 DEG C while heating for 1 to 3 hours.

If the pressure for compressing the mixture is less than 50 kgf / cm ² in the above-mentioned pressure range, the compression may not be sufficient and dropping of the particles may occur. If the pressure exceeds 1000 kgf / cm ² , the molded body may be partially broken. If the heat treatment temperature is less than 150 ° C, it is difficult to sufficiently immobilize the activated carbon. If the heat treatment temperature is 300 ° C or higher, a flow of the binder may occur within the above-mentioned period of time and uneven unit blocks may be formed. The effect on the heat treatment time is also similar to that of temperature and pressure.

On the other hand, the produced multi-layered activated carbon filter block is subjected to a cooling process after being separated from the mold, and cooling is usually carried out at normal temperature (25 ° C).

Hereinafter, the present invention will be described in more detail with reference to Examples. The present invention is described in more detail with reference to the following Examples. However, the scope of the present invention is not limited to these Examples.

< Example  1>

(Melting point: 170 占 폚) of 80% by weight of powdery activated carbon (D Company, iodine adsorption power: 950 mg / g) and 14% by weight of low melting point polyethylene short fibers 6 wt% polyethylene short fibers were mixed for 3 hours via a Jar-type blender; Granulated activated carbon (D yarn, iodine adsorption force: 950 mg / g) and the above-mentioned binder were mixed in the same manner; Fibrous activated carbon (D Co., iodine; 1000mg / g) in the same manner as in ultra-high-molecular-weight polyethylene powder binder, a mixture of (M Company, Mw 2x10 ⁶⁾ were prepared by the activated carbon / binder mixture.

The prepared activated carbon / binder mixture was then mixed with a fibrous activated carbon mixture from the inside to the outside of the mold using a polyester separating sheet in a cylindrical stainless steel mold having a 10-inch outer diameter, an inner diameter of 3 inches, and a height of 20 cm, The powdery activated carbon mixture and the granular activated carbon mixture were filled at a ratio of 1: 2: 3 in a thickness ratio and the separation film was removed.

Thereafter, heat treatment was performed at 170 ° C for 1 hour under a pressure of 500 kgf / cm ² using a thermal compressor, and sufficient cooling was performed at room temperature. After separating the multilayered activated carbon filter block from the mold, the filter block was wrapped with a nonwoven fabric (W company, density 15g / m ² ), inserted into the cartridge, and evaluated.

< Example  2>

Layered activated carbon filter block was prepared in the same manner as in Example 1, except that the content of powdery activated carbon was 85 wt%.

< Example  3>

Layered activated carbon filter block was prepared in the same manner as in Example 1, except that the content of the granular activated carbon was changed to 85 wt%.

< Example  4>

Layered activated carbon filter block was prepared in the same manner as in Example 1, except that a hydrophilic-treated binder was not included.

< Comparative Example  1 to 3>

Layered activated carbon filter block composed of only a fibrous activated carbon mixture, a powdered activated carbon mixture, and a granular activated carbon mixture each having the same composition as that prepared in Example 1 were prepared in the same manner as in Example 1.

<Evaluation>

1. Measurement of filling density

In the multilayer filter block of the present invention, the packing densities of the activated carbon layers were obtained by dividing the activated carbon filter block by the weight of the unit volume after molding the activated carbon filter block alone, and then converting the volume into the volume when formed into a multilayer structure .

2. Measurement of flow rate

As in the conventional filtration experiment, the multi-layered activated carbon filter block manufactured from the present invention was inserted into the cartridge, and pure water at room temperature was supplied at a flow rate of 20 L / min by an outside-in method and the residual chlorine concentration Was defined as the accumulated amount of filtered water until it reached 95%.

3. Measurement of pressure loss

As in the conventional filtration experiment, the filter block manufactured from the present invention is inserted into the cartridge, and then the flow rate test is performed in an outside-in manner. The difference in the numerical value on the inlet side of the raw water and the outlet side of the raw water Was defined as pressure loss.

4. Measurement of chlorine removal rate

The residual chlorine concentration of the filtered water was measured with a residual chlorine analyzer (EUTECH) after the chlorine of the raw water was supplied at 2,000 ppm, and the removal rate was calculated by the following equation.

Removal rate = (chlorine concentration in raw water - raw water concentration of filtered water) / chlorine concentration in raw water

The above evaluation results are summarized in Table 1 below.

division Volume (L) Pressure loss (MPa) Filling density (g / cm ³ ) Example 1 410,000 0.05 to 0.09 0.50 Example 2 390,000 0.06 to 0.11 0.54 Example 3 380,000 0.04 to 0.10 0.51 Example 4 360,000 0.05 to 0.09 0.52 Comparative Example 1 250,000 0.06 to 0.12 0.49 Comparative Example 2 170,000 0.08-0.15 0.55 Comparative Example 3 210,000 0.07 to 0.13 0.52

In Table 1, Comparative Examples 1, 2, and 3 show that the filter block composed of the fibrous activated carbon, powder, or granular activated carbon alone has a relatively high pressure loss and low permeability compared to the filter block composed of the powder activated carbon block combined with the fibrous or granular activated carbon block Respectively. On the contrary, the asymmetric multilayer filter block of the present invention has relatively higher flow rate and lower pressure loss than the activated carbon filter block manufactured by itself. Particularly, the filter block manufactured by including the hydrophilic binder has a It can be confirmed that there is an improvement effect.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be construed as limiting the scope of the invention as defined by the appended claims. .

The filter block of the present invention can be used not only as a RO pretreatment filter for a portable water purifier, a direct water purification water purifier for domestic use, and a water purifier for domestic use, but is also suitable for general industrial water treatment and advanced water treatment.

10 .. Multi-layer type activated carbon filter block
11. The first activated carbon block
12. The second activated carbon block
13. The third activated carbon block

Claims (11)

In an activated carbon filter block for a cylindrical cartridge filter,
The activated carbon filter block is formed by laminating a plurality of unit activated carbon blocks having different densities from the outer circumferential surface to the inner circumferential surface direction,
Wherein the unit activated carbon block is any one selected from the group consisting of a fibrous activated carbon block, a granular activated carbon block, and a powdered activated carbon block, and each unit activated carbon block is sequentially selected from the group consisting of fibrous activated carbon, granular activated carbon and powdered activated carbon Wherein the fibrous activated carbon is combined with a powdery binder and the granular or powdery activated carbon is combined with a fibrous binder.
Multi - layered activated carbon filter block. delete delete 2. The multilayered activated carbon filter block according to claim 1, wherein at least a part of the dispersoid or fibrous binder is a hydrophilized binder. delete delete The method according to claim 1, wherein the filling density of each unit activated carbon block
Fibrous activated carbon block 0.3 to 0.7 g / cm &lt; ³ &gt;;
The granular activated carbon block from 0.3 to 0.8 g / cm ^3; And
And the powdery activated carbon block is 0.3 to 0.5 g / cm &lt; ³ &gt;. [2] The filter according to claim 1, wherein the filter block has three layers in the order of the first activated carbon block, the second activated carbon block and the third activated carbon block in the direction from the outer circumferential surface to the inner circumferential surface,
The first activated carbon block is a fibrous activated carbon block;
The second activated carbon block is a granular activated carbon block; And
The third activated carbon block is a powdered activated carbon block; Layer activated carbon filter block. A water purification filter manufactured by laminating nonwoven fabrics on the outer and inner surfaces of the multilayered activated carbon filter block of claim 1. The method of claim 1, wherein the inner space of the cylindrical mold is divided into concentric circles in the direction of the inner circumferential surface from the outer circumferential surface, and a mixture of the activated carbon and the binder is filled in each of the separated spaces, wherein the fibrous activated carbon is composed of a powdery binder and the granular or powdery activated carbon Mixing and filling; And
And heat treating the packed mixture. &Lt; RTI ID = 0.0 &gt; 11. &lt; / RTI &gt; delete

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