US20040067175A1 - Ceramic filter element and method for production thereof - Google Patents
Ceramic filter element and method for production thereof Download PDFInfo
- Publication number
- US20040067175A1 US20040067175A1 US10/332,582 US33258203A US2004067175A1 US 20040067175 A1 US20040067175 A1 US 20040067175A1 US 33258203 A US33258203 A US 33258203A US 2004067175 A1 US2004067175 A1 US 2004067175A1
- Authority
- US
- United States
- Prior art keywords
- catalyst
- support
- filter element
- catalyst material
- bonding
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- 239000000919 ceramic Substances 0.000 title claims abstract description 33
- 238000004519 manufacturing process Methods 0.000 title claims description 21
- 239000000463 material Substances 0.000 claims abstract description 187
- 239000003054 catalyst Substances 0.000 claims abstract description 92
- 239000002245 particle Substances 0.000 claims abstract description 39
- 230000003197 catalytic effect Effects 0.000 claims abstract description 23
- 238000001914 filtration Methods 0.000 claims abstract description 9
- 238000000034 method Methods 0.000 claims description 33
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 21
- 238000000926 separation method Methods 0.000 claims description 18
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 13
- 150000004645 aluminates Chemical class 0.000 claims description 12
- 238000000576 coating method Methods 0.000 claims description 12
- 238000005245 sintering Methods 0.000 claims description 12
- 239000011248 coating agent Substances 0.000 claims description 10
- 239000004408 titanium dioxide Substances 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 9
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 8
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 8
- 230000000694 effects Effects 0.000 claims description 8
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 8
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 8
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims description 7
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 7
- 229910000510 noble metal Inorganic materials 0.000 claims description 6
- 239000011369 resultant mixture Substances 0.000 claims description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 4
- JLDSOYXADOWAKB-UHFFFAOYSA-N aluminium nitrate Chemical compound [Al+3].[O-][N+]([O-])=O.[O-][N+]([O-])=O.[O-][N+]([O-])=O JLDSOYXADOWAKB-UHFFFAOYSA-N 0.000 claims description 4
- ZCCIPPOKBCJFDN-UHFFFAOYSA-N calcium nitrate Chemical compound [Ca+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O ZCCIPPOKBCJFDN-UHFFFAOYSA-N 0.000 claims description 4
- 229910017052 cobalt Inorganic materials 0.000 claims description 4
- 239000010941 cobalt Substances 0.000 claims description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 4
- 150000001875 compounds Chemical class 0.000 claims description 4
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 239000010949 copper Substances 0.000 claims description 4
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 4
- 229910052737 gold Inorganic materials 0.000 claims description 4
- 239000010931 gold Substances 0.000 claims description 4
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 4
- 229910052759 nickel Inorganic materials 0.000 claims description 4
- 229910052763 palladium Inorganic materials 0.000 claims description 4
- 229910052697 platinum Inorganic materials 0.000 claims description 4
- 229910052703 rhodium Inorganic materials 0.000 claims description 4
- 239000010948 rhodium Substances 0.000 claims description 4
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims description 4
- 150000004760 silicates Chemical class 0.000 claims description 4
- 229910052709 silver Inorganic materials 0.000 claims description 4
- 239000004332 silver Substances 0.000 claims description 4
- 238000003980 solgel method Methods 0.000 claims description 4
- 239000007767 bonding agent Substances 0.000 claims description 3
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 3
- 229910003465 moissanite Inorganic materials 0.000 claims description 3
- 229910052863 mullite Inorganic materials 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 2
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims description 2
- 239000000292 calcium oxide Substances 0.000 claims description 2
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 2
- 239000003623 enhancer Substances 0.000 claims 1
- 239000007789 gas Substances 0.000 abstract description 21
- 238000006243 chemical reaction Methods 0.000 abstract description 6
- 230000009467 reduction Effects 0.000 abstract description 5
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 abstract 6
- 239000011230 binding agent Substances 0.000 abstract 4
- 239000003638 chemical reducing agent Substances 0.000 abstract 1
- 239000011949 solid catalyst Substances 0.000 abstract 1
- 239000000126 substance Substances 0.000 description 24
- 239000010410 layer Substances 0.000 description 18
- 239000000428 dust Substances 0.000 description 9
- GQPLMRYTRLFLPF-UHFFFAOYSA-N Nitrous Oxide Chemical class [O-][N+]#N GQPLMRYTRLFLPF-UHFFFAOYSA-N 0.000 description 8
- 230000008901 benefit Effects 0.000 description 8
- 239000012876 carrier material Substances 0.000 description 7
- 239000012528 membrane Substances 0.000 description 7
- 238000000746 purification Methods 0.000 description 5
- 239000002912 waste gas Substances 0.000 description 5
- 239000011246 composite particle Substances 0.000 description 4
- 238000006722 reduction reaction Methods 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000004907 flux Effects 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
- 150000002894 organic compounds Chemical class 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000004071 soot Substances 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 229910002651 NO3 Inorganic materials 0.000 description 1
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 150000001722 carbon compounds Chemical class 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 238000004523 catalytic cracking Methods 0.000 description 1
- 238000003421 catalytic decomposition reaction Methods 0.000 description 1
- 238000010531 catalytic reduction reaction Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 230000009849 deactivation Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 150000002013 dioxins Chemical class 0.000 description 1
- 238000001962 electrophoresis Methods 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- -1 for example Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- JCXJVPUVTGWSNB-UHFFFAOYSA-N nitrogen dioxide Inorganic materials O=[N]=O JCXJVPUVTGWSNB-UHFFFAOYSA-N 0.000 description 1
- 239000001272 nitrous oxide Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000002957 persistent organic pollutant Substances 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000012429 reaction media Substances 0.000 description 1
- 239000012266 salt solution Substances 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000010421 standard material Substances 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- GFNGCDBZVSLSFT-UHFFFAOYSA-N titanium vanadium Chemical compound [Ti].[V] GFNGCDBZVSLSFT-UHFFFAOYSA-N 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/0001—Making filtering elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
- B01D39/2068—Other inorganic materials, e.g. ceramics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2407—Filter candles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9431—Processes characterised by a specific device
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/0212—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters with one or more perforated tubes surrounded by filtering material, e.g. filter candles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
- F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/206—Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2265/00—Casings, housings or mounting for filters specially adapted for separating dispersed particles from gases or vapours
- B01D2265/06—Details of supporting structures for filtering material, e.g. cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2273/00—Operation of filters specially adapted for separating dispersed particles from gases or vapours
- B01D2273/20—High temperature filtration
Definitions
- the invention relates to a ceramic filter element, in particular a filter candle or filter tube, in accordance with the preamble to Patent claims 1 and 15 , as well as a filter candle or filter tube in accordance with the preamble to Patent claim 28 .
- the invention also relates to a method for the manufacture of such filter elements.
- the reduction of nitrous oxides from gases is carried out by selective reaction of the nitrous oxides with the reduction media in solid catalytic converters.
- solid catalytic converters In order for an adequate catalytic activity to be attained, and in order to exclude the depositing of salt on the surface of the catalyst, so leading to its deactivation, correspondingly high gas temperatures are required.
- reduction catalytic converters are used for waste gas purification in power stations in the waste gas flow between the boiler and the air pre-heater at temperatures of some 300° C. to 350° C.
- the ceramic catalyst material is in this situation arranged in most cases in the form of rigid plates or honeycomb bodies, but in part also in the form of bulk deposit layers.
- the gases containing nitrous oxides are mixed with the reaction medium and that the mixture is conducted through at least one filter element having catalytic effect, which consists of a ceramic carrier material and the catalytic effect substances.
- the catalytic effect filter element is also used for extracting dust from the gases containing nitrous oxides.
- the filter element consists either of felts or non-woven fleece materials, which are manufactured from fibres of the ceramic carrier material by compaction and have been doped with the catalytic effect substances, or of porous sinter bodies, which are manufactured from granules of the ceramic carrier material by sintering and have been doped with the catalytic effect substances.
- the filter element may exhibit the form of a filter candle or filter element.
- the doping of the ceramic carrier material in the catalytic effect substances is effected by these substances being applied onto the ceramic carrier material before, during, or after the manufacture of the felts, non-woven fleeces, or sinter bodies. This can be done, for example, by impregnating the filter elements with salt solution and subsequent heating of the filter elements doped with the salts.
- a filter device for gas purification which exhibits a single tubular body made of heat-resistant foam ceramics, which simultaneously has the effect of a dust filter and, with the appropriate coating, as a catalytic converter.
- EP 0 470 659 a method is described for the separation of dust and organic compounds from oxygen-containing gases, in particular from combustion waste gases.
- the waste gas which is to be purified is conducted through at least one filter element functioning as a catalytic converter, which is composed of a ceramic carrier material and the substances functioning as catalysts.
- the filter element may consist of a porous sinter body, which is manufactured from granules of ceramic carrier material by sintering and has been doped with the catalytically effective substances.
- WO 9012950 describes a Diesel soot filter, which consists of honeycomb bodies, of which the first honeycomb body is provided with a first surface layer which, in an inherently known manner, has the effect of catalytically converting the nitrous oxides and carbon monoxide into nitrogen or carbon dioxide respectively, while the second honeycomb bodies are provided with a second surface layer and in an inherently known manner catalytically cause a reduction of the ignition temperature of the soot adhering here.
- a gas purification device in the form of a filter candle is known.
- the filter candle exhibits on the outside a membrane layer of ultra-fine silicon carbide particles, in order to filter out dust particles.
- a catalytically effective layer of sintered silicon carbide powder follows in the direction of flow inwards.
- As the catalytic converter a vanadium-titanium compound is provided for, with which the silicon carbide filter is impregnated.
- the filter candle is created by a subsequent coating of a porous element, which has the disadvantage that the porous layer cannot be applied entirely uniformly in the pore area, and therefore the distribution of the catalyst material is not homogenous.
- there is the problem of the adherence of the applied layer to the silicon carbide particles whereby an added difficulty is that, in the area of the hot-gas filtration, temperature fluctuation stresses occur, which can encourage the separation of the coating.
- the distance between the support material particles is greater than with filter elements with which the support material particles are first sintered and the bonding/catalyst materials are then introduced.
- the bonding/catalyst materials form for preference web-type connections between the support material particles, whereby free spaces remain between the webs to allow the passage of the gas which is to be filtered.
- per volume unit there is more catalyst material available in the filter element, as a result of which the degree of efficiency of the filter element is additionally increased in comparison with conventional filter elements.
- the degree of efficiency of the filter element is further increased by the fact that the bonding material exhibits either catalyst material or is partly replaced by catalyst material.
- the catalyst material simultaneously takes on a bonding function for the support material particles, so that it is possible to do without a pure bonding material in whole or in part.
- the catalyst material can be increased to the degree to which the bonding material is reduced.
- the catalyst and bonding materials are present as composite particles. These composite particles can consist of 90 to 99% by weight of catalyst material and the remainder of bonding material.
- the catalyst material is already incorporated at the time of manufacture of the ceramic filter element, as a result of which a homogenous distribution of the catalyst material in the filter element is attained. As a result, the degree of efficiency of the filter element is likewise increased in comparison with conventional ceramic filter elements.
- the catalyst material consists of oxides of the rare earths, of aluminates, of silicates, of titanates, or of titanium dioxide, or, for special preference, of calcium aluminate.
- one substance of the substances cited may be concerned, or mixtures of several substances, each from one of the substance classes named, or mixtures of substances from several of the substance classes named.
- aluminates, titanates, or titanium dioxide is used, if the bonding material is entirely replaced by the catalyst material.
- Other catalyst materials are likewise suitable.
- bonding material conventional materials are used, such as, for example, kaolin, flux agents, or clay.
- an adherence agent to be added to the catalyst material in turn, which consists for preference of a flux.
- the catalyst material is modified with promoters, or, if the catalyst material consists of a mixture of substances of the substance classes referred to heretofore, at least one of these substances is modified with promoters.
- support material for the support bodies the known materials SiC, mullite, or aluminium oxide are used.
- the proportion of the support material amounts to 60 to 90% by weight and that of the catalyst/bonding material 10 to 40 % by weight.
- the proportion of the support material is about 65 to 75% by weight, and that of the catalyst bonding material 25 to 35 % by weight.
- the support material may consist of SiC or Al 2 O 3 , and the catalyst bonding material of clay-earth element (calcium aluminate) and clay.
- the catalyst material is located only in the second layer of the filter element.
- the method for the manufacture of such a filter element in which the support body is manufactured first and then the layer for the particle separation is applied onto the support body, is characterised in that the bonding material is mixed fine-grained and homogenously with the catalyst material in each case, that this mixture is then mixed with the support material, and that this resultant mixture is then introduced into a mould for the manufacture of the support body and sintered.
- a further variant of the manufacturing method makes provision for composite particles to be manufactured from bonding material and catalyst material, and that these composite particles are then mixed with the support material. To manufacture the support body, the resultant mixture is introduced into the mould and sintered.
- a further embodiment makes provision for at least one source material in powder form or at least one source material present in a solution, which under the effects of heat form catalyst and/or bonding properties, being mixed with the support material, and that the resultant mixture is placed in a mould and sintered for the manufacture of the support body.
- powder-form source materials for example, calcium oxide and aluminium oxide are well-suited, from which calcium aluminate is formed.
- the catalyst material is formed during the sintering of the filter element by chemical reactions.
- These source materials may contain both substances from which the catalyst material forms, as well as the bonding material.
- the support material particles do not sinter with one another. Only by the sintering of the bonding and/or catalyst material, in particular of the bonding particles, will the holding effect of the support material particles be achieved.
- the problem is resolved by a ceramic filter element which is characterised in that the support material is replaced at least in part by the catalyst material.
- the catalyst material consists of one or several aluminates, of one or several titanates, or of titanium dioxide.
- the catalyst material consists of one or more oxides or mixed oxides of the rare earths, with which the support material grains are coated.
- the catalyst material consists of a mixture of at least one oxide or mixed oxide of the rare earths and at least one aluminate, a titanate, or titanium oxide.
- Support material and catalyst material are used jointly for the manufacture of the support body, whereby both materials are present in fine-grain form and are mixed.
- the coating according to method step b) is carried out for preference by means of the sol-gel method.
- the support material grains can be sprayed with the sol in a mixer.
- the advantage of this method lies in the fact that the excellent thermal shock resistance of silicon carbide, which is used for preference for the support material, is exploited, and an economical and uniform coating of the original grain is achieved before the burning of the filter element with catalyst. It is likewise of advantage, if selecting method step b), for the coating to be carried out by spraying on the ceramic mud. This is done for preference by the support material grains being sprayed with the ceramic mud in a mixer.
- step c for preference two grain fractions are used, which are mixed with each other, whereby a fine-grain sintering is carried out with reduced burn temperature.
- the bonding of the carrier body constructed directly from catalyst material is therefore carried out by means of an inherent bonding process, in order to avoid the wetting of the catalytically active surface by an additional bonding agent.
- fine grain sintering is therefore chosen as the bonding, which is achieved by mixing in a fine fraction of the same material.
- the support material grains it is also possible for the support material grains to be additionally doped with catalytically-active noble or non-noble metals. For preference this takes place after the sintering. After the sintering it is also possible for the catalyst material grains to be doped with catalytically-active noble or non-noble metals (method steps a), b), c)).
- materials for the doping particular consideration can be given to platinum, palladium, rhodium, gold, silver, nickel, copper, manganese, or cobalt. The doping serves to provide the additional achieved increase in catalytic activity and selectivity for special chemical reactions.
- the modification of the catalyst material can be effected by wet-chemical doping methods or gas-phase coating methods.
- the problem is resolved by a filter candle or tube according to claim 22 .
- a filter candle or tube according to the invention can be manufactured by the cylindrical mould body, closed on one side, of a conventional filter candle or tube being filled with a deposit of catalyst material, and the open side of the mould is closed, so that the catalyst deposit is not carried out. It has proved advantageous in this context if the closure is formed as a porous ceramic layer.
- the catalyst material there come into consideration oxides or mixed oxides of the rare earths, aluminates, silicates, titanates, and titanium dioxide.
- the catalyst material may consist of a single substance, of several substances from one of the substance classes referred to heretofore, or of a mixture of substances from different substances classes as referred to heretofore.
- Of particular preference in this situation is the use of calcium aluminate.
- the catalyst material is modified with promoters.
- a high effect of the filter candle according to the invention is achieved if the catalyst material is doped with catalytically-active noble or non-noble metals.
- doping materials particular preference is given to platinum, palladium, rhodium, gold, silver, nickel, copper, manganese, or cobalt.
- the advantage of the invention lies in the fact that catalytically-active ceramic filter elements are obtained which are resistant to high temperature, resistant to steam, and resistant to hetero-element compounds. They can therefore be arranged directly in the hot smoke or waste gases flow, and at the same time guarantee the removal of dust from the hot gas as well as the total conversion of organic pollutants and residual components. In addition to the gas purification effect, the substance foundation for the formation of dioxins is therefore also removed (DeNovo synthesis).
- the catalytic design of the filter elements may contain the bi-functional effect of the catalyst system, i.e. the total oxidation or the thermal-catalytic splitting, and therefore the subsequent reactions, which depend on the catalyst material used in each case, or the doping material used, as appropriate.
- Typical wall thicknesses of the inner support body of the filter candle are between 10 and 15 mm.
- the application temperatures of the filter candles according to the invention range up to 1000° C.
- mullite grain is used as a standard material, although other materials can also be used. In general, all ceramic oxides, nitrides, and carbides are suitable.
- the membrane layer can be an asymmetrical membrane layer formed from several layers.
- the membrane layer thickness can measure up to 200 ⁇ m, whereby the pore size is between 0.05 to 40 ⁇ m.
- the membrane layer is manufactured from bonded inert grain or from fine particles manufactured by means of polymer sol-gel methods. As coating methods, consideration may be given to spraying, electrophoresis, film casting, mud casting, or the sol-gel method.
- FIG. 1 represents a filter candle or tube 10 in a vertical section.
- the filter candle or tube 10 has a first external coating 11 for particle separation, and a second internal layer 12 , which forms the support body.
- the direction of flow is indicated with arrows.
- FIG. 2 shows an enlarged section from the second layer 12 .
- the support material particles 1 exhibit an irregular shape and are arranged at distances from one another. These particles 1 are connected to one another by means of the particles 2 , consisting of catalyst and bonding material, which form web-like bridges 3 . Between the web-like bridges 3 free spaces 4 remain for the passage of the gas which is being filtered, whereby the free spaces are represented enlarged for the purpose of clarity.
- the particles 2 represented here in diagrammatic form are compound particles of catalyst and bonding agent material.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- Ceramic Engineering (AREA)
- Environmental & Geological Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Inorganic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Geometry (AREA)
- Biomedical Technology (AREA)
- Geology (AREA)
- Analytical Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Toxicology (AREA)
- Catalysts (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
- Filtering Materials (AREA)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/544,586 US20070031304A1 (en) | 2000-07-13 | 2006-10-10 | Filter candle |
US12/946,889 US8388898B2 (en) | 2000-07-13 | 2010-11-16 | Ceramic filter element |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE10034045A DE10034045A1 (de) | 2000-07-13 | 2000-07-13 | Keramisches Filterelement und Verfahren zu seiner Herstellung |
DE10034045.8 | 2000-07-13 | ||
PCT/EP2001/008171 WO2002005928A1 (de) | 2000-07-13 | 2001-07-13 | Keramisches filterelement und verfahren zu seiner herstellung |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/544,586 Division US20070031304A1 (en) | 2000-07-13 | 2006-10-10 | Filter candle |
US12/946,889 Continuation US8388898B2 (en) | 2000-07-13 | 2010-11-16 | Ceramic filter element |
Publications (1)
Publication Number | Publication Date |
---|---|
US20040067175A1 true US20040067175A1 (en) | 2004-04-08 |
Family
ID=7648783
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/332,582 Abandoned US20040067175A1 (en) | 2000-07-13 | 2001-07-13 | Ceramic filter element and method for production thereof |
US11/544,586 Abandoned US20070031304A1 (en) | 2000-07-13 | 2006-10-10 | Filter candle |
US12/946,889 Expired - Fee Related US8388898B2 (en) | 2000-07-13 | 2010-11-16 | Ceramic filter element |
Family Applications After (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/544,586 Abandoned US20070031304A1 (en) | 2000-07-13 | 2006-10-10 | Filter candle |
US12/946,889 Expired - Fee Related US8388898B2 (en) | 2000-07-13 | 2010-11-16 | Ceramic filter element |
Country Status (6)
Country | Link |
---|---|
US (3) | US20040067175A1 (de) |
EP (2) | EP1772178A1 (de) |
JP (1) | JP5322364B2 (de) |
AU (1) | AU2001281982A1 (de) |
DE (2) | DE10034045A1 (de) |
WO (1) | WO2002005928A1 (de) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070245702A1 (en) * | 2006-04-25 | 2007-10-25 | Sharp Kabushiki Kaisha | Honeycomb structure and manufacturing method thereof, and air cleaner and water purifier containing the honeycomb structure |
US20100223848A1 (en) * | 2007-05-02 | 2010-09-09 | Pall Corporation | Gasification apparatus and method for generating syngas from gasifiable feedstock material |
CN113476958A (zh) * | 2021-06-22 | 2021-10-08 | 南京玻璃纤维研究设计院有限公司 | 一种滤料及其制备方法和应用 |
CN114573321A (zh) * | 2022-03-21 | 2022-06-03 | 安徽紫朔环境工程技术有限公司 | 一种基于3d打印技术催化陶瓷滤管的制备方法 |
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EA022656B1 (ru) * | 2008-10-22 | 2016-02-29 | Саутерн Рисерч Инститьют | Способ очистки сингаза |
CN107427772B (zh) * | 2015-03-20 | 2021-02-05 | 托普索公司 | 催化的陶瓷烛式过滤器和清洁工艺尾气或废气的方法 |
CN107648936A (zh) * | 2017-08-24 | 2018-02-02 | 江苏亚峰科技集团有限公司 | 一种滤芯 |
CN113453781B (zh) | 2019-03-27 | 2024-03-19 | 庄信万丰股份有限公司 | 用于处理来自固定排放源的含颗粒废气的催化过滤系统 |
DE102020115015A1 (de) * | 2020-06-05 | 2021-12-09 | Rath Gmbh | Filterkerze aufweisend einen Konzentrationsgradienten an Katalysatormetallen, Verfahren zu deren Herstellung sowie deren Verwendung in einem Abgasreinigungsverfahren |
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US20070245702A1 (en) * | 2006-04-25 | 2007-10-25 | Sharp Kabushiki Kaisha | Honeycomb structure and manufacturing method thereof, and air cleaner and water purifier containing the honeycomb structure |
US7883563B2 (en) * | 2006-04-25 | 2011-02-08 | Sharp Kabushiki Kaisha | Honeycomb structure and manufacturing method thereof, and air cleaner and water purifier containing the honeycomb structure |
US20100223848A1 (en) * | 2007-05-02 | 2010-09-09 | Pall Corporation | Gasification apparatus and method for generating syngas from gasifiable feedstock material |
US8562701B2 (en) | 2007-05-02 | 2013-10-22 | Pall Corporation | Gasification apparatus and method for generating syngas from gasifiable feedstock material |
CN113476958A (zh) * | 2021-06-22 | 2021-10-08 | 南京玻璃纤维研究设计院有限公司 | 一种滤料及其制备方法和应用 |
CN114573321A (zh) * | 2022-03-21 | 2022-06-03 | 安徽紫朔环境工程技术有限公司 | 一种基于3d打印技术催化陶瓷滤管的制备方法 |
Also Published As
Publication number | Publication date |
---|---|
AU2001281982A1 (en) | 2002-01-30 |
DE10034045A1 (de) | 2002-01-31 |
EP1772178A1 (de) | 2007-04-11 |
US8388898B2 (en) | 2013-03-05 |
US20070031304A1 (en) | 2007-02-08 |
JP5322364B2 (ja) | 2013-10-23 |
DE50111106D1 (de) | 2006-11-09 |
EP1303341B1 (de) | 2006-09-27 |
WO2002005928A1 (de) | 2002-01-24 |
JP2004503375A (ja) | 2004-02-05 |
EP1303341A1 (de) | 2003-04-23 |
US20110058990A1 (en) | 2011-03-10 |
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Owner name: PALL CORPORATION, NEW YORK Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HEIDENREICH, STEFFEN;WALCH, ASTRID;REEL/FRAME:029442/0337 Effective date: 20121029 |