KR20210152193A - Ceramic filter of the manufacturing method. - Google Patents

Abstract

The present invention relates to a ceramic filter and a manufacturing method thereof, wherein the ceramic filter can be manufactured into various shapes and sizes and desired lengths by a manufacturing method in which several rolls of narrow and uniform base sheets are selected and applied or coated with ceramic mixed slurry, only a certain part of one or more coated base sheets are overlapped and are wound on a rod or a pipe, which is a molding frame of various shapes such as square or round, in an oblique line to determine a thickness, and a tube or a pipe of a certain thickness is continuously molded, is cut into a desired length, and is dried and sintered to produce the ceramic filter.

Description

Ceramic filter and its manufacturing method. {CERAMIC FILTER OF THE MANUFACTURING METHOD.}

The present invention is intended to be used as a core part of a device for reducing environmental pollutants generated from exhaust gas of each industrial process such as incinerators, cement, steel, power plants and internal combustion engines, and is used in small and medium-sized dust collectors and in large plant processes. It is to provide a ceramic filter that can collect fine dust and waste gas with constant dust collection and reduction efficiency during the use cycle by differentiation of the filtration area, abrasion resistance and durability of the ceramic filter.

In the case of conventionally developed ceramic filters, vacuum molding or compression molding using ceramic fibers was the most common method. When used for a long time, the durability of the filter decreases due to deterioration of the ceramic fiber, which reduces the filtration efficiency, and the ceramic fiber is damaged when the dust from the outer wall is blown off by spraying compressed air in the reverse direction during the filter regeneration operation. Damaged ceramic fibers are included in exhaust gas and discharged even under normal operation conditions, thereby generating secondary pollutants.

In addition to the vacuum molding method, molding methods such as extrusion molding, press molding, hydrostatic pressure molding, and winding molding are being developed. Therefore, the manufacturing cost increases, manufacturing is not easy, and the production is difficult due to severe wear of the mold.

In addition, in the case of most of the above molding methods, since they are made by demolding, separating, and sintering only the product after molding by the pressurization method, there is a difficulty in the continuous production process, the defect rate is high, the productivity is low, the manufacturing cost is high, and the functionality There are problems such as low porosity, poor air permeability, and a rapid increase in pressure loss due to clogging during the process due to the limitations of the relative filter manufacturing size and filtration area.

In order to solve the problems of the prior art as described above, the present invention is to produce a product by shortening the size, productivity, diversity, and process of a typical ceramic filter product production manufacturing process. A ceramic mixed slurry is prepared and each material including nonwoven fabric, felt, fabric and synthetic resin, paper, etc. is dimensioned and supplied in a roll state of base paper of the desired width and thickness, or a regular roll in which a nonwoven fabric is dimensioned in the width direction The state is applied or coated on several sheets of base paper with ceramic mixed slurry, overlapping only a certain part of the several sheets of base paper, and winding diagonally around a rod or pipe of various shapes such as square or round to determine the thickness, and then A ceramic filter and its manufacturing method are characterized by being made into a ceramic pipe shape, which is made, cut to a certain length, dried, and sintered at 400 to 1,800° C. for at least 3 hours.

The present invention can increase the size of the ceramic filter, so that the filtration area can be increased, the manufacturing cost is low, the manufacturing method is easy, and at the same time, various shape changes and mass production of large ceramic filters of desired length in the longitudinal direction An object of the present invention is to provide an easy method for manufacturing a ceramic filter.

The present invention applies or coats ceramic mixed slurry to several sheets of base paper in a narrow and constant roll state, overlapping only a certain portion of several sheets of coated base paper, and determining the thickness of rods or pipes of various shapes such as square or round shape to determine the thickness of the slanted line It relates to various types of ceramic filters produced by winding a continuous tube, cutting them to a desired length, drying them, and sintering them at 500° C. or higher, and a method for manufacturing the same. As a manufacturing method that can make a desired length of a ceramic filter in the longitudinal direction, the manufacturing cost is low and the manufacturing method is easy. It relates to a ceramic filter which is relatively excellent in controlling range and enlargement, and a method for manufacturing the same.

The method of manufacturing a ceramic filter by coating or applying the ceramic mixed slurry of the present invention on a base paper in a roll state and winding it in an oblique line is a manufacturing method capable of manufacturing a ceramic filter of a desired length with a minimum molding process in manufacturing a ceramic filter.

Since the existing manufacturing method and the existing process can be shortened, most of the essential equipment in the ceramic filter manufacturing process, such as molding equipment, pressurization device, or vacuum device, had to limit the manufacturing size of the ceramic filter. It is a manufacturing method that has the advantages of low manufacturing cost and easy manufacturing method since it is possible to produce large filters within the limits allowed by the sintering furnace as it can be molded.

In addition, according to the present invention, it is possible to manufacture a ceramic filter capable of maximizing the filtration area of the filter in a predetermined space because it is easy to change the shape and manufacture a complex shape. In addition, the ceramic filter of the present invention has excellent abrasion resistance and durability, and can be used at high pressure, so that it can be easily applied to the post-treatment process of various industrial processes.

1 is a process diagram showing the basic flow of a ceramic filter and its manufacturing method
2 is a perspective view of a ceramic filter and a method for manufacturing the same.

In order to achieve the above object, the present invention

a) i) the ceramic powder is prepared by mixing 30 to 95 parts by weight of a ceramic powder selected from the group consisting of silicon carbide, alumina, silymanite, kaolin, silica, titania and slag, diatomaceous earth, and clay;

ii) preparing the pore-forming agent by mixing 3 to 35 parts by weight of one or more powders selected from each group consisting of wood powder, activated carbon, synthetic resin powder, talc, naphthalene, and the like;

iii) The organic binder is powdered methylcellulose (methylcellulose. MC), ethylcellulose (EC), polyvinyl alcohol (PVA), carboxymethylcellulose (carboxymehylcellulose. CMC), grain (rice, wheat, corn, etc.) preparing a binder made in powder form or by selecting one or more from the group consisting of a slurry having a viscosity and mixing 3 to 60 parts by weight;

iv) The inorganic binder is prepared by mixing 20 to 85 parts by weight of one or more powders selected from the group consisting of various glazes, barium carbonate (BaCO3), frit, and glass powder;

v) preparing by mixing 20 to 70 parts by weight of one or more selected from the group of water and alcohol as a solvent used to make a slurry by mixing the ceramic powder, pore-forming agent, organic binder, and inorganic binder;

In step b) , for smooth separation of the mold 53 and the molded article 60, the base paper 10 in a roll state cut to a desired size between 0.1 to 10 mm in thickness and 1 to 990 mm in width is a felt, non-woven fabric, One or more selected from the group consisting of textile fibers, paper, rubber, urethane, synthetic resin, etc., the base paper is first wound in a diagonal line 14, and the ceramic mixed slurry of step a) or another mixture is applied or coated (12). winding the base paper 14 diagonally;

c) the ceramic mixture prepared in step a) above step b) has a thickness of 0.1 to 10 mm and a width of 1 to 990 mm in the form of several rolls of base paper 20 cut to desired dimensions Select one or more from the group consisting of fibers, paper, rubber, urethane, synthetic resin, plastic, etc., and apply or coat (22) the ceramic mixed slurry on the surface to the selected base paper according to the desired thickness on the rotating mold 53 manufacturing a molded article 60 in the form of a pipe having a thickness by winding several layers with an oblique line 24 at an interval;

d) In step c), the molded product 24 of the molding step on the mold 53 in the form of a circular pipe is pressed or compressed with a belt 40 for pressure and compression using a belt driving device 45 to obtain a thickness, shape, A molding step of forming a uniform and constant shape with a surface, strength, etc.;

e) The base paper 34 used in the state of the base paper 30 on the surface of the molded article made in step d) or applied or coated with ceramic mixed slurry by the same or another mixture has a thickness of 0.1 to It is 10 mm and has a length between 1 and 990 mm in width, or in a roll state, one or more selected from the group consisting of felt, non-woven fabric, textile fiber, paper, rubber, urethane, synthetic resin, plastic, etc. and used as a surface finishing agent. step;

f) In the process of manufacturing the molding 60 in step e), the surface roughness and pressing with a roller 63 to increase self-bonding strength;

g) dimension-cutting the molded product 60 to a desired length using a dimension cutting device 65 in step f);

h) drying the molded product cut to a desired length in step g) by natural drying, hot air drying, low temperature drying, etc.;

i) manufacturing a porous ceramic body in the form of a ceramic pipe by sintering the molded product dried in step h) at 400 to 1800° C. for 3 to 100 hours;

j) a manufacturing step of secondarily passing the drying process of step h) and the sintering process of step i) after processing the ceramic filter manufactured by sintering in step i), such as dimensional cutting and surface secondary coating;

k) One type of commercial catalyst or functional material selected for the ceramic filter prepared by sintering in steps i) and j ) , such as zeolite, platinum, palladium, rhodium, silver, vanadium, tungsten, TiO ₂ , or ZnO, Mn 10 to 50 parts by weight of the selected powder, 10 to 90 parts by weight of distilled water, pulverized, and the mixed liquid is supported by immersion or coating in the pores of the ceramic filter wall, adding new functionality, and processes h) and i) manufacturing step through;

l) packaging the ceramic filter manufactured in step i) or j) by assembling the upper and lower parts into a product;

In addition, although the present invention provides a ceramic filter manufactured by the above method, the order of the manufacturing process may be changed or omitted depending on the application process purpose.

The ceramic filter of the present invention provides a ceramic filter manufactured as described above. The ceramic filter of the present invention can be used as a dust collecting filter for various dust collection facilities, and in particular, thermal power generation, iron and steel making, melting furnace, incinerator, crematorium, etc. It is used as a dust collector of a dust collector or a core component used to simultaneously reduce dust, nitrogen oxides (NOx), and volatile organic compounds (VOC's) in one device in a process that generates dust, exhaust gas of diesel engines, and automobiles. It can be used as a core part used to simultaneously reduce particulate matter such as exhaust gas and nitrogen oxides, and it can be used for air purifiers, catalyst carriers, or heavy water that filters impurities from industrial water.

Hereinafter, preferred examples are presented to aid understanding of the present invention, but the following examples only illustrate the present invention of a method for manufacturing a ceramic filter, and do not limit the scope of the present invention.

[Example]

Example 1

Add 50 to 80 parts by weight of alumina (Al ₂ O ₃ ), 20 to 30 parts by weight of a pore-forming agent, 15 to 40 parts by weight of an organic binder, and 20 to 45 parts by weight of an inorganic binder, and mix in a mixer for 1 hour or more to obtain a ceramic mixed slurry was prepared.

On the other hand, one roll of base paper (paper) is wound diagonally on a stainless-type circular metal forming frame (diameter 150 mm, length 2000 mm), and then the ceramic mixed slurry prepared above is coated on five roll base paper (nonwoven fabric). The surface was finished by winding the base paper (non-woven fabric) in a roll state in an oblique line immediately after applying it, overlapping each other to a certain extent. It was possible to make moldings that maintain strength.

The molded product prepared above was cut into lengths of 500mm, 1,000mm, 2,000mm, and 2,500mm, dried with hot air at 60°C for 12 hours, put in an electric furnace, heated up in sequence for 40 hours, and finally maintained at 1,100°C for 4 hours and cooled naturally. Ceramic filter hairs were manufactured.

Through Example 1, the density of the ceramic filter was adjusted according to the purpose, and a basic circular ceramic filter having performances such as strength, porosity, pore size and chemical resistance, abrasion resistance, and durability was obtained by cutting the dimensions to a desired length.

Example 2

A ceramic filter was manufactured in the same manner as in Example 1, except that silicon carbide (SiC) was used instead of alumina in Example 1.

Example 3

A ceramic filter was manufactured in the same manner as in Example 1, except that 52 parts by weight of alumina and 52 parts by weight of silicon carbide (SiC) were mixed and used instead of parts by weight of alumina (Al ₂ O _{3 ) in Example 1} did

Example 4

In Examples 1 and 2, each ceramic mixed slurry was made, and three were coated with the alumina mixed slurry of Example 1 on five base papers (non-woven fabric) in a roll state, and two were the silicon carbide mixed slurry of Example 2 A ceramic filter was prepared in the same manner as in Example 1, except for coating.

10 Dimension-cut base base paper roll 12 Mixed slurry coating or coating device
14 Base paper coated or coated with mixed slurry
20 Size-cut base paper roll 22 Mixed slurry coating or coating device
24 Base paper coated or coated with mixed slurry
30 Dimension-cut finish base paper roll 32 Mixed slurry coating or applicator
34 Finished base paper coated or coated with mixed slurry
40 Belt for pressing and pressing 45 Belt drive
50 Inner frame drive motor 53 Inner frame
60 Molding 63 Molding Surface Roller
65 Molding size cutting device

Claims (15)

a) i) the ceramic powder is prepared by mixing 30 to 95 parts by weight of a ceramic powder selected from the group consisting of silicon carbide, alumina, silymanite, kaolin, silica, titania and slag, diatomaceous earth, and clay;
ii) preparing the pore-forming agent by mixing 3 to 35 parts by weight of one or more powders selected from each group consisting of wood powder, activated carbon, synthetic resin powder, talc, naphthalene, and the like;
iii) The organic binder is powdered methylcellulose (methylcellulose. MC), ethylcellulose (EC), polyvinyl alcohol (PVA), carboxymethylcellulose (carboxymehylcellulose. CMC), grain (Rice, wheat, corn, etc.) preparing a binder made in powder form or by selecting one or more from the group consisting of a slurry having a viscosity and mixing 3 to 60 parts by weight;
iv) The inorganic binder is prepared by mixing 20 to 85 parts by weight of one or more powders selected from the group consisting of various glazes, barium carbonate (BaCO3), frit, and glass powder;
v) preparing by mixing 20 to 70 parts by weight of one or more selected from the group of water and alcohol as a solvent used to make a slurry by mixing the ceramic powder, pore-forming agent, organic binder, and inorganic binder;
In step b) , for smooth separation of the mold 53 and the molded article 60, the base paper 10 in a roll state cut to a desired size between 0.1 to 10 mm in thickness and 1 to 990 mm in width is a felt, non-woven fabric, One or more selected from the group consisting of textile fibers, paper, rubber, urethane, synthetic resin, etc., the base paper is first wound in a diagonal line 14, and the ceramic mixed slurry of step a) or another mixture is applied or coated (12). winding the base paper 14 diagonally;
c) the ceramic mixture prepared in step a) above step b) has a thickness of 0.1 to 10 mm and a width of 1 to 990 mm in the form of several rolls of base paper 20 cut to desired dimensions Select one or more from the group consisting of fibers, paper, rubber, urethane, synthetic resin, plastic, etc., and apply or coat (22) the ceramic mixed slurry on the surface to the selected base paper according to the desired thickness on the rotating mold 53 manufacturing a molded article 60 in the form of a pipe having a thickness by winding several layers with an oblique line 24 at an interval;
d) In step c), the molded product 24 of the molding step on the mold 53 in the form of a circular pipe is pressed or compressed with a belt 40 for pressure and compression using a belt driving device 45 to obtain a thickness, shape, A molding step of forming a uniform and constant shape with a surface, strength, etc.;
e) The base paper 34 used in the state of the base paper 30 on the surface of the molded article made in step d) or applied or coated with ceramic mixed slurry by the same or another mixture has a thickness of 0.1 to It is 10 mm and has a length between 1 and 990 mm in width, or in a roll state, one or more selected from the group consisting of felt, non-woven fabric, textile fiber, paper, rubber, urethane, synthetic resin, plastic, etc. and used as a surface finishing agent. step;
f) In the process of manufacturing the molding 60 in step e), the surface roughness and pressing with a roller 63 to increase self-bonding strength;
g) dimension-cutting the molded product 60 to a desired length using a dimension cutting device 65 in step f);
h) drying the molded product cut to a desired length in step g) by natural drying, hot air drying, low temperature drying, etc.;
i) manufacturing a porous ceramic body in the form of a ceramic pipe by sintering the molded product dried in step h) at 400 to 1800° C. for 3 to 100 hours;
j) a manufacturing step of secondarily undergoing the drying process of step h) and the sintering process of step i) after processing the ceramic filter manufactured by sintering in step i), such as dimensional cutting and surface secondary coating;
k) One type of commercial catalyst or functional material selected for the ceramic filter prepared by sintering in steps i) and j ) , such as zeolite, platinum, palladium, rhodium, silver, vanadium, tungsten, TiO ₂ , or ZnO, Mn 10 to 50 parts by weight of the selected powder, 10 to 90 parts by weight of distilled water, pulverized, and the mixed liquid is supported by immersion or coating in the pores of the ceramic filter wall, adding new functionality, and processes h) and i) manufacturing step through;
l) A method of manufacturing a ceramic filter, characterized in that the ceramic filter manufactured in step i) or j) is assembled into a product by assembling the upper part and the lower part and packaging the ceramic filter. [Claim 2] The ceramic filter according to claim 1, wherein the method for manufacturing a ceramic filter is provided by the above method, but the order of the manufacturing process may be changed, a certain process range may be repeated, or some processes may be omitted depending on the applied process and use. A method for manufacturing a filter. The method according to claim 1, wherein, in separating the ceramic mixed slurry made in step a) from the molding die after molding in step c), just wind one or more rolls of base paper on the molding die in step b) or coat a release agent A method of manufacturing a ceramic filter, characterized in that it is applied to separate the molded product and the mold. The method according to claim 1, wherein the ceramic mixed slurry prepared in step a) is coated or applied to one or more roll base papers in step c) and then wound in an oblique line, and the coated or coated base paper in one or more roll state is constant. A method of manufacturing a ceramic filter, characterized in that it is partially overlapped and wound in an oblique line on a mold to obtain a desired thickness. The method according to claim 1, wherein, as in the preparation of the mixed slurry in step a) and each embodiment, ceramic mixed slurries A, B, and C are made respectively, and in step c), the mixed slurry A is coated or applied to the base paper in one or more rolls. and coating or coating C in the same way as coating or applying ceramic mixed slurry B on base paper in one or more rolls to form ceramic mixed slurry A and B to C by overlapping a portion of the coated or coated base paper A method of manufacturing a ceramic filter, characterized in that it is wound on a frame with an oblique line and molded into a tube or pipe having two or more characteristics. The method of claim 1, wherein in step d), the molding strength is increased, surface roughness and density are increased by pressing or compressing the molded product using the movement of the drive belt. The method according to claim 1, wherein in step e), one or more roll base papers are coated or applied, and the base paper is wound in an oblique line on a forming mold to a desired thickness, or the same ceramic mixed slurry or other ceramic mixed slurry. A method of manufacturing a ceramic filter, characterized in that the surface of the molded product is uniform and uniform by coating or applying the . The method according to claim 1, wherein step f) increases the molding strength by pressing or compressing the molded product in a direction to push the molded product using the movement of the roller applied with force, improving the surface roughness, and increasing the density and self-coupling force. A method of manufacturing a ceramic filter. The method of claim 1, wherein in step g), the molded product is cut to a desired length using a size cutting device such as a rotary blade, a file saw, a dotted line cutting device, or a laser. The method according to claim 1, wherein in step h), the molded product cut to a desired length is dried by natural drying, hot air drying, low temperature drying, or the like. The method of claim 1, wherein in step i), the dried molded product is sintered at 400 to 1800° C. for 3 to 100 hours to manufacture a porous ceramic body in the form of a ceramic pipe. The method of claim 1, wherein in step j), the ceramic filter manufactured by sintering is subjected to a second drying process in step h) and a sintering process in step i) after processing such as dimensional cutting and surface secondary coating. A method of manufacturing a ceramic filter, characterized in that. The method of claim 1, wherein in step k), a commercial catalyst or functional material selected for the ceramic filter prepared by sintering in steps i) and j) is zeolite, platinum, palladium, rhodium, silver, vanadium, tungsten, TiO ₂ , or ZnO, Mn, etc. are mixed with 10 to 50 parts by weight of one or more selected powders and 10 to 90 parts by weight of distilled water, and the mixed liquid is immersed or coated in the pores of the ceramic filter wall. A method of manufacturing a ceramic filter, characterized in that it is manufactured through the processes h) and i) by adding a. The method according to claim 1, wherein Figure 1 is a basic process diagram of a ceramic filter and a method for manufacturing the same. Or, a method of manufacturing a ceramic filter, characterized in that some processes can be omitted. 15. A method of manufacturing a ceramic filter, characterized in that manufactured by the manufacturing method of any one of claims 1 to 14.

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