WO2014081218A1 - Method for manufacturing ceramic filter - Google Patents

Method for manufacturing ceramic filter Download PDF

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Publication number
WO2014081218A1
WO2014081218A1 PCT/KR2013/010620 KR2013010620W WO2014081218A1 WO 2014081218 A1 WO2014081218 A1 WO 2014081218A1 KR 2013010620 W KR2013010620 W KR 2013010620W WO 2014081218 A1 WO2014081218 A1 WO 2014081218A1
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Prior art keywords
filter
ceramic
composition powder
ceramic composition
present
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PCT/KR2013/010620
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French (fr)
Korean (ko)
Inventor
이명화
최현진
김정욱
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한국생산기술연구원
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Priority to JP2015543983A priority Critical patent/JP6039820B2/en
Publication of WO2014081218A1 publication Critical patent/WO2014081218A1/en
Priority to US14/729,757 priority patent/US9796632B2/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B01D69/108—Inorganic support material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
    • C04B35/185—Mullite 3Al2O3-2SiO2
    • 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
    • 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
    • B01D39/2082—Other inorganic materials, e.g. ceramics the material being filamentary or fibrous
    • B01D39/2089—Other inorganic materials, e.g. ceramics the material being filamentary or fibrous otherwise bonded, e.g. by resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0039—Inorganic membrane manufacture
    • B01D67/0041—Inorganic membrane manufacture by agglomeration of particles in the dry state
    • B01D67/00411—Inorganic membrane manufacture by agglomeration of particles in the dry state by sintering
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
    • C04B35/486—Fine ceramics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0039—Inorganic membrane manufacture
    • B01D67/0041—Inorganic membrane manufacture by agglomeration of particles in the dry state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/02—Inorganic material
    • B01D71/024—Oxides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/38—Non-oxide ceramic constituents or additives
    • C04B2235/3817—Carbides
    • C04B2235/3826—Silicon carbides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron

Definitions

  • the present invention relates to a method for manufacturing a high temperature ceramic filter, the method comprising: filtering air containing a ceramic composition powder with a polymer filter to form a ceramic composition powder layer on the polymer filter surface; And it relates to a method for producing a high-temperature ceramic filter through a dry process comprising the step of sintering the polymer filter medium in which the ceramic composition powder layer is formed.
  • the filter is mostly used to prevent the discharge of particulate contaminants contained in the exhaust gas, but the polymer filter used has a weak problem in heat resistance, chemical resistance, abrasion resistance, and flame resistance.
  • polyester shrinks at 150 ° C. and PTFE (Teflon), which is excellent in heat resistance, may not withstand temperatures up to 300 ° C. or more.
  • the discharged particulate matter is the surface of the filter material such as polyester, polypropylene, acrylic, polyamide, polyimide, glass fiber, etc. This will reduce the life of the filter because it damages the filter.
  • a spark occurs during the combustion process of each industry, leading to a fire, or to puncture the filter to reduce the filtration effect of the exhaust gas.
  • the ceramic filter has much better heat resistance, chemical resistance, and abrasion resistance than the polymer filter.
  • the ceramic filter has excellent heat resistance, and thus, there is no need to separately install a cooling device in the exhaust device, thereby reducing installation and maintenance costs.
  • the vacuum forming process is expensive to manufacture a vacuum chamber and a vacuum pump, and is limited by the size of the ceramic filter that can be manufactured according to the size limitation of the vacuum chamber.
  • the production cost is high due to the high fixed cost to change the mold for each constant production due to severe wear of the ceramic material.
  • the inventors of the present invention while studying the method of manufacturing a high-temperature ceramic filter that can easily control the pore size of the filter and can be manufactured at low cost and low energy, aerosolized the ceramic powder composition and manufactured by a dry process rather than a wet process.
  • the present invention has been completed by confirming that the filter exhibits excellent filter characteristics and at the same time can solve the above problems.
  • An object of the present invention is to provide a method for producing a high-temperature ceramic filter through a dry process that is easy to adjust the pore size and requires low cost and low energy.
  • the present invention provides a method of manufacturing a ceramic filter, comprising the following steps.
  • step 2 Sintering the polymer filter medium in which the ceramic composition powder layer is formed (step 2).
  • step 1 in order to uniformly form the ceramic composition powder on the surface of the polymer filter medium, air containing the ceramic composition powder is filtered through the polymer filter medium.
  • ceramic composition powder means a composition in powder form capable of forming a ceramic.
  • the ceramic composition powder refers to a composition in the form of a powder that is accumulated on a polymer filter to a predetermined thickness and then sintered to form a ceramic.
  • the ceramic composition powder is silicon carbide (SiC), mullite (3Al 2 O 3 ⁇ SiO 2 ), Zirconia (ZrO 2 ), Calcium carbonate (CaCO 3 ), Carboxymethyl cellulose or a combination thereof.
  • the ceramic composition powder may further include water. The inclusion of water further has the advantage that the ceramic composition powder is more adhered to the surface of the polymer filter body and is easier to form the ceramic composition powder layer.
  • the step of filtering the powder may be divided into the initial stage and the later stage may use a ceramic composition powder of different particle size.
  • the particle size of the powder is about 100 ⁇ m
  • the particle size of the powder is about 5 ⁇ m.
  • the larger the particle size of the powder is used in the initial stage, so that the ceramic composition powder may be formed quickly in the initial stage, and the thickness may be facilitated by using the smaller particle size in the later stage.
  • the fine particles are filtered at the surface with high efficiency, there is an advantage that the dust removal efficiency is increased due to the large pores on the inside and the small pores on the outside.
  • the ceramic composition powder may include silicon carbide as a ceramic component.
  • the content of the silicon carbide may be preferably 70 to 75 parts by weight, more preferably 73 to 74 parts by weight, most preferably 73.8 parts by weight based on 100 parts by weight of the total ceramic composition powder.
  • the content of the silicon carbide is greater than the upper limit may cause cracks in the ceramic layer due to the lack of a binder, and when less than the lower limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide.
  • the pore size of the filter can be adjusted according to the particle size of the silicon carbide and thus the filtration efficiency of particulate contaminants in the exhaust gas can be controlled.
  • the particle size of the silicon carbide may be preferably 5 ⁇ m to 100 ⁇ m, more preferably 10 ⁇ m to 50 ⁇ m, most preferably 25 ⁇ m.
  • the pores may be so dense that the pores may be blocked due to contaminants, and when the particle size of the silicon carbide is larger than 100 ⁇ m, the pore size may be too large to reduce the filtration efficiency of the fine contaminants.
  • the ceramic carbide is manufactured using the particle size of the silicon carbide particles having a particle size of 10 ⁇ m, 25 ⁇ m and 50 ⁇ m, and as a result of measuring the filtration efficiency, silicon carbide of 10 ⁇ m to 50 ⁇ m It was confirmed that fine contaminants of 1 ⁇ m or less can be filtered by 90% or more in the particle size range of.
  • the ceramic composition powder may include mullite as an inorganic binder.
  • the content of the mullite may be preferably 3 to 4 parts by weight, more preferably 3.5 to 3.8 parts by weight, most preferably 3.7 parts by weight based on 100 parts by weight of the total ceramic composition powder.
  • the content of the mullite is greater than the upper limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide, and when less than the lower limit, cracks may occur due to the lack of the binder.
  • the ceramic composition powder may include zirconia as an inorganic binder.
  • the content of the zirconia may be preferably 3 to 4 parts by weight, more preferably 3.5 to 3.8 parts by weight, and most preferably 3.7 parts by weight based on 100 parts by weight of the total ceramic composition powder.
  • the content of the zirconia is greater than the upper limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide, and when less than the lower limit, cracking may occur due to the lack of the binder.
  • the ceramic composition powder may include calcium carbonate as an inorganic binder.
  • the content of the calcium carbonate may be preferably 0.5 to 1.0 parts by weight, more preferably 0.7 to 0.9 parts by weight, most preferably 0.8 parts by weight based on 100 parts by weight of the total ceramic composition powder.
  • the content of the calcium carbonate is greater than the upper limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide, and when less than the lower limit, cracks may occur due to the lack of the binder.
  • the ceramic composition powder may include carboxymethyl cellulose (CMC) as an organic binder.
  • CMC carboxymethyl cellulose
  • the content of the carboxymethyl cellulose may be preferably 1 to 2 parts by weight, more preferably 1.5 to 1.7 parts by weight, and most preferably 1.6 parts by weight based on 100 parts by weight of the total ceramic composition powder.
  • the content of the carboxymethyl cellulose is greater than the upper limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide, and when less than the lower limit, cracks may occur due to the lack of the binder.
  • the ceramic composition powder may further include water to increase the adhesion of the powder as described above.
  • the content of water may be preferably 10 to 20 parts by weight, more preferably 15 to 17 parts by weight, and most preferably 16.4 parts by weight based on 100 parts by weight of the total ceramic composition powder.
  • the content of the water is greater than the upper limit, it is difficult to perform a dry process, and when less than the lower limit, the adhesion of the powder may be lowered.
  • the ceramic composition powder is 70 to 75: 3 to 4: 3 to 4: 0.5 to 1.0: 1 by weight of silicon carbide, mullite, zirconia, calcium carbonate, carboxymethylcellulose and water It may be included in the ratio of ⁇ 2: 10-20. Most preferably, the ceramic composition powder may include silicon carbide, mullite, zirconia, calcium carbonate, carboxymethylcellulose and water in a ratio of 73.8: 3.7: 3.7: 0.8: 1.6: 16.4 by weight. By using the ceramic composition powder in the above ratio, it is possible to produce a ceramic filter having excellent mechanical strength and excellent heat resistance without cracking.
  • polymer filter medium used in the present invention means a filter material of a polymer material.
  • the polymer filter body may be used by purchasing a commercially available polymer filter medium or directly manufactured by a conventional manufacturing method.
  • the polymer filter body may preferably have a pore size of 5 ⁇ m or less, more preferably 1 ⁇ m to 5 ⁇ m.
  • the ceramic composition powder layer can be easily formed on the surface of the polymer filter in step 1) of filtering the air containing the ceramic composition powder into the polymer filter.
  • the polymer filter may be made of polyester, polypropylene, acrylic, polyamide, polyimide or glass fiber, but is not limited thereto.
  • the filtration rate may be preferably 0.5 ⁇ 10 m / min.
  • the formation efficiency of the ceramic composition powder layer in the filtration rate range is excellent.
  • the ceramic composition powder layer may preferably be a thickness of 1 mm to 10 mm.
  • the thickness of the ceramic composition powder layer is 1 mm or more, mechanical strength and heat resistance of the ceramic layer obtained after sintering are excellent, and when the thickness is 10 mm or less, the filter has an appropriate pore size and excellent filtration efficiency.
  • the manufacturing method of the present invention can easily adjust the thickness of the ceramic composition powder layer to facilitate the pore size adjustment of the filter, which has the advantage of solving the pressure loss problem generated when passing through the filter.
  • Step 2 is a step of preparing a ceramic filter by sintering the polymer filter body in which the ceramic composition powder layer is formed.
  • the sintering temperature is preferably 1400 °C to 1500 °C, most preferably 1450 °C.
  • the temperature increase rate is preferably in the range of 3 to 4 °C / min, most preferably 3.3 °C / min in terms of crack prevention.
  • the sintering time may be preferably 1 hour to 5 hours, more preferably 1 hour to 3 hours, most preferably 2 hours.
  • the method of manufacturing the ceramic filter of the present invention is not only easy to adjust the pore size of the filter through the thickness control of the ceramic composition powder layer as described above, but also requires a separate mold and pressurization device, so that it can be manufactured at low cost and low energy.
  • the shape and size of the polymer filter medium to be used has a variety of forms and has the advantage of producing a ceramic filter having a variety of sizes from small to large.
  • the present invention also provides a ceramic filter manufactured by the above method.
  • the ceramic filter of the present invention has a form in which a ceramic layer is formed on the surface of the polymer filter body by being manufactured by the above method, and has the advantage that the ceramic filter such as high heat resistance, chemical resistance and abrasion resistance is provided by the surface ceramic layer.
  • the ceramic filter according to the present invention does not use the conventional pressurization method, it is possible to easily adjust the pore size of the filter, thereby solving the problem of pressure loss generated when passing through the filter.
  • the method of manufacturing a ceramic filter according to the present invention does not require a separate mold manufacturing process, so that a filter can be manufactured at low cost, and a filter can be manufactured without a separate mold, and thus the filter shape can be easily changed and filtered according to a use. By maximizing the area, high-performance filters can be manufactured.
  • the ceramic filter and the method of manufacturing the same according to the present invention can produce a high performance ceramic filter using low cost and low energy, which can be usefully used in the filter-related industry.
  • FIG. 1 is a schematic view showing a ceramic filter manufacturing process of the present invention.
  • Figure 2 is a state (A) of the polymer filter medium used in the manufacture of the ceramic filter of the present invention, the appearance of the ceramic filter (B), and the appearance of the surface of the ceramic filter observed with a scanning electron microscope (C) It is shown.
  • 3 is a graph showing the filtration efficiency of the ceramic filter of the present invention.
  • FIG. 1 schematically shows a ceramic filter manufacturing process of the present invention.
  • a ceramic composition comprising silicon carbide, mullite, zirconia, calcium carbonate, carboxymethylcellulose and water in a ratio of 73.8: 3.7: 3.7: 0.8: 1.6: 16.4 by weight.
  • Powder was injected through the powder inlet through the polymer filter medium (average pore size 3 ⁇ m, Polyester, Daesung Filterta Tech) with air.
  • silicon carbide particles having particle sizes of 10 ⁇ m (Example 1), 25 ⁇ m (Example 2) and 50 ⁇ m (Example 3) were used, respectively.
  • the filtration rate was also adjusted to 5 m / min and the thickness of the ceramic composition powder layer was 5 mm.
  • the polymer filter having the ceramic powder layer formed thereon was sintered at 1450 ° C. for 2 hours to prepare a ceramic filter.
  • the temperature increase rate of 3.3 ° C./min was maintained from room temperature to the sintering temperature.
  • the collection efficiency of the ceramic filters prepared in Examples 1 to 3 was measured.
  • a manufactured ceramic filter was mounted in the filter bag test apparatus, and fly ash was generated as test particles. After fixing the velocity of the fluid passing through the filter bag to 1m / min, the number of dust at the front and rear of the filter was measured by the Aerodynamic Particle Sizer (Model: 3321, TSI Instruments) to measure the filtration efficiency.
  • the ceramic filter manufactured using silicon carbide having a particle size of 10 ⁇ m to 50 ⁇ m may filter 90% or more of fine contaminants of 1 ⁇ m or less.

Abstract

The present invention relates to a method for manufacturing a high temperature ceramic filter, the method utilizing dry processing comprising: filtering air comprising ceramic composition powder by means of a polymer filter, and forming a ceramic composition powder layer on the surface thereof; and sintering the polymer filter having the ceramic composition powder layer thereon. The ceramic filter according to the present invention facilitates controlling the size of the pores thereon and can maximize the filtering surface area thereof, thereby imparting a high performance effect thereto. Accordingly, the method for manufacturing a ceramic filter according to the present invention can be effectively utilized in filter-related industries as a high-performance ceramic filter can be manufactured at low cost and low energy.

Description

세라믹 필터의 제조방법Manufacturing method of ceramic filter
본 발명은 고온용 세라믹 필터의 제조방법에 관한 것으로, 세라믹 조성물 파우더를 포함하는 공기를 고분자 여과체로 여과하여, 상기 고분자 여과체 표면에 세라믹 조성물 파우더 층을 형성하는 단계; 및 상기 세라믹 조성물 파우더 층이 형성된 고분자 여과체를 소결하는 단계를 포함하는 건식공정을 통한 고온용 세라믹 필터의 제조방법에 관한 것이다.The present invention relates to a method for manufacturing a high temperature ceramic filter, the method comprising: filtering air containing a ceramic composition powder with a polymer filter to form a ceramic composition powder layer on the polymer filter surface; And it relates to a method for producing a high-temperature ceramic filter through a dry process comprising the step of sintering the polymer filter medium in which the ceramic composition powder layer is formed.
산업의 발전에 따라 각 산업공정에서 배출되는 입자상 및 가스상 오염물질에 의한 피해가 점점 심화되고 있는 실정이다. 따라서, 배기가스 내에 포함된 입자상 오염물질의 배출을 막기 위하여 대부분 필터를 사용하고 있으나, 사용하고 있는 고분자 필터는 내열성, 내화학성, 내마모성 및 난연성에 있어서 취약한 문제점이 있다. 예컨대, 폴리에스터의 경우 150℃에서 수축이 일어나며, 내열성이 우수한 PTFE(테프론)의 경우도 최고 300℃ 이상의 온도를 견디지 못하는 문제점이 있다. 또한, 산업용 필터를 사용하는 공정은 마모성이 강한 입자상 오염물질이 다량으로 배출되기 때문에, 이렇게 배출된 입자상 물질이 폴리에스터, 폴리프로필렌, 아크릴, 폴리아미드, 폴리이미드, 유리섬유 등의 필터 소재의 표면을 손상시키게 되므로 필터의 수명을 줄이는 역할을 하게 된다. 뿐만 아니라, 각 산업의 연소공정 중에 불꽃이 발생하여 화재로 이어지거나, 필터에 구멍을 내어 배기가스의 여과 효과를 떨어뜨리는 문제점이 있다. As the industry develops, the damage caused by particulate and gaseous pollutants emitted from each industrial process is getting worse. Therefore, the filter is mostly used to prevent the discharge of particulate contaminants contained in the exhaust gas, but the polymer filter used has a weak problem in heat resistance, chemical resistance, abrasion resistance, and flame resistance. For example, polyester shrinks at 150 ° C., and PTFE (Teflon), which is excellent in heat resistance, may not withstand temperatures up to 300 ° C. or more. In addition, since the process using an industrial filter emits a large amount of abrasive abrasives having high abrasion, the discharged particulate matter is the surface of the filter material such as polyester, polypropylene, acrylic, polyamide, polyimide, glass fiber, etc. This will reduce the life of the filter because it damages the filter. In addition, there is a problem that a spark occurs during the combustion process of each industry, leading to a fire, or to puncture the filter to reduce the filtration effect of the exhaust gas.
따라서, 이러한 문제점을 해결하기 위하여 세라믹 필터의 개발이 이루어져 왔다. 세라믹 필터는 고분자 필터에 비하여 내열성, 내화학성, 내마모성 등이 훨씬 우수한 특징이 있고, 특히 내열성이 우수하여 배기 장치 내에 냉각 장치 등을 별도로 설치할 필요가 없어 설치비 및 유지비를 절감할 수 있는 장점이 있다. Therefore, the development of a ceramic filter has been made to solve this problem. The ceramic filter has much better heat resistance, chemical resistance, and abrasion resistance than the polymer filter. In particular, the ceramic filter has excellent heat resistance, and thus, there is no need to separately install a cooling device in the exhaust device, thereby reducing installation and maintenance costs.
기존에 개발된 세라믹 필터의 경우, 조성물을 슬러리 형태로 만들어서 진공성형이나 압출ㆍ성형해서 튜브형태로 만드는 것이 가장 보편적인 방법이었다. 그러나, 이러한 방법은 여과 효율과 압력손실을 자유롭게 조절하는 것이 어려울 뿐만 아니라 제조되는 비용이 고가이고, 장시간 사용할 때 세라믹 필터의 내부에 먼지가 퇴적됨에 따라 여과 성능이 떨어진다는 단점이 있다. 또한, 필터의 재생시 압축 공기를 역분사하여 외벽의 먼지를 털어낼 때 세라믹 필터가 파손되고, 이렇게 파손된 세라믹 필터를 이용하여 정상운전시 먼지가 배기가스 중에 포함되어 배출됨으로써 2차 공해를 발생시키는 문제가 있다. 뿐만 아니라, 세라믹 필터의 깊이방향(내ㆍ외벽)으로 전체가 동일한 기공도를 가지는 구조로 이루어져 내부에 먼지가 포집될 경우에는 필터의 눈막힘 현상의 발생으로 압력손실이 증가하는 문제가 있다. In the case of the conventionally developed ceramic filter, it was the most common method to make the composition into a slurry form and vacuum forming, extrusion or molding into a tube form. However, this method has disadvantages that it is difficult to freely control the filtration efficiency and the pressure loss, and the manufacturing cost is high, and the filtration performance is deteriorated as the dust is deposited inside the ceramic filter during long time use. In addition, when the filter is regenerated, the ceramic filter is broken when the compressed air is sprayed back to shake off the dust on the outer wall, and the secondary filter generates dust by exhausting dust in the exhaust gas during normal operation using the broken ceramic filter. There is a problem. In addition, since the structure has the same porosity as the whole in the depth direction (inner and outer wall) of the ceramic filter, when dust is collected therein, there is a problem that the pressure loss increases due to clogging of the filter.
또한, 제조공정 측면에서 진공성형 공정의 경우는 진공 챔버 및 진공펌프의 제조에 많은 비용이 소요되며 진공 챔버의 크기 제한에 따라 제작할 수 있는 세라믹 필터의 크기에 제약을 받게 되므로 대형 필터는 제조하지 못하는 문제가 있으며, 세라믹 소재의 심한 마모로 일정 생산량마다 금형을 바꿔야 하는 높은 고정비로 생산단가가 높게 된다는 문제점도 있다. In addition, in terms of the manufacturing process, the vacuum forming process is expensive to manufacture a vacuum chamber and a vacuum pump, and is limited by the size of the ceramic filter that can be manufactured according to the size limitation of the vacuum chamber. There is a problem, and there is a problem that the production cost is high due to the high fixed cost to change the mold for each constant production due to severe wear of the ceramic material.
또한, 상기 진공성형 방법 이외에도 압출성형, 프레스 성형, 정수압(hydrostatic pressure) 성형 등의 방법들이 개발되고 있으나, 이 경우에도 제작시 금형제작이 필수적이며 가압장치를 구비해야 하므로 제작비용이 증가하고 제조가 용이하지 못할 뿐만 아니라 금형이 결정되면 제작형상의 변경이 용이하지 않고, 대형필터의 생산이 어려운 문제점을 가진다. 또한, 상기 성형방식의 경우는 가압방식에 의한 성형이므로 기공도가 낮아 통기성이 떨어지며, 필터 통과시 압력손실을 증가시키는 문제점이 있다. In addition to the vacuum forming method, methods such as extrusion molding, press molding, and hydrostatic pressure molding have been developed, but in this case, a mold manufacturing is essential when manufacturing and a pressurizing device is required, thus increasing the manufacturing cost and manufacturing cost. Not only is it not easy, but once the mold is determined, it is not easy to change the manufacturing shape, it is difficult to produce large filters. In addition, in the case of the molding method, since the molding by the pressure method, the porosity is low, the air permeability is lowered, there is a problem of increasing the pressure loss when passing through the filter.
이에, 본 발명자들은 필터의 기공 크기 조절이 용이하며 저비용 및 저에너지로 제조가능한 고온용 세라믹 필터의 제조방법을 연구하던 중 세라믹 파우더 조성물을 에어로졸화하여 습식공정이 아닌 건식공정을 통해 제조한 고온용 세라믹 필터가 우수한 필터 특성을 보임과 동시에 상기와 같은 문제를 보완할 수 있음을 확인함으로써 본 발명을 완성하였다.Therefore, the inventors of the present invention, while studying the method of manufacturing a high-temperature ceramic filter that can easily control the pore size of the filter and can be manufactured at low cost and low energy, aerosolized the ceramic powder composition and manufactured by a dry process rather than a wet process. The present invention has been completed by confirming that the filter exhibits excellent filter characteristics and at the same time can solve the above problems.
본 발명의 목적은 기공 크기 조절이 용이하며 저비용 및 저에너지를 필요로 하는 건식공정을 통한 고온용 세라믹 필터의 제조방법을 제공하는 것이다.An object of the present invention is to provide a method for producing a high-temperature ceramic filter through a dry process that is easy to adjust the pore size and requires low cost and low energy.
상기 과제를 해결하기 위해, 본 발명은 하기 단계를 포함하는, 세라믹 필터의 제조방법을 제공한다.In order to solve the above problems, the present invention provides a method of manufacturing a ceramic filter, comprising the following steps.
세라믹 조성물 파우더를 포함하는 공기를 고분자 여과체로 여과하여, 상기 고분자 여과체 표면에 세라믹 조성물 파우더 층을 형성하는 단계(단계 1); 및 Filtering the air including the ceramic composition powder with a polymer filter to form a ceramic composition powder layer on the surface of the polymer filter (step 1); And
상기 세라믹 조성물 파우더 층이 형성된 고분자 여과체를 소결하는 단계(단계 2).Sintering the polymer filter medium in which the ceramic composition powder layer is formed (step 2).
상기 단계 1은, 세라믹 조성물 파우더를 고분자 여과체 표면에 균일하게 형성시키기 위하여, 상기 세라믹 조성물 파우더를 포함하는 공기를 상기 고분자 여과체로 여과하는 단계이다.In the step 1, in order to uniformly form the ceramic composition powder on the surface of the polymer filter medium, air containing the ceramic composition powder is filtered through the polymer filter medium.
본 발명에서 사용되는 용어 "세라믹 조성물 파우더"는 세라믹을 형성할 수 있는 파우더 형태의 조성물을 의미한다. 구체적으로, 상기 세라믹 조성물 파우더는 고분자 여과체 상에 일정 두께로 축적된 후 소결되어 세라믹을 형성할 수 있는 파우더 형태의 조성물을 의미한다.The term "ceramic composition powder" as used herein means a composition in powder form capable of forming a ceramic. Specifically, the ceramic composition powder refers to a composition in the form of a powder that is accumulated on a polymer filter to a predetermined thickness and then sintered to form a ceramic.
본 발명에서, 상기 세라믹 조성물 파우더는 탄화규소(SiC), 뮬라이트(3Al2O3ㆍSiO2), 지르코니아(ZrO2), 탄산칼슘(CaCO3), 카르복시메틸셀룰로오스 또는 이의 조합일 수 있다. 또한, 상기 세라믹 조성물 파우더는 물(water)을 추가로 포함할 수 있다. 물을 추가로 포함함으로써 세라믹 조성물 파우더가 고분자 여과체 표면에 더욱 잘 부착되어 세라믹 조성물 파우더 층을 형성하기 더욱 용이한 장점이 있다. 본 발명에서, 상기 파우더를 여과하는 단계는 초기단계와 후기단계로 나누어 다른 입자 크기의 세라믹 조성물 파우더를 사용할 수 있다. 바람직하기로, 초기단계에는 파우더의 입자 크기가 100 ㎛ 내외인 것을 사용하며, 후기단계에는 파우더의 입자 크기가 5 ㎛ 내외인 것을 사용한다. 상기와 같이 초기단계에 파우더의 입자 크기가 더 큰 것을 사용하여 세라믹 조성물 파우더가 초기단계에는 빠르게 형성될 수 있게 하고 후기단계에 입자 크기가 더 작은 것을 사용함으로써 두께 조절을 용이하게 할 수 있다. 또한, 상기와 같이 초기단계에 파우더의 입자 크기가 더 큰 것을 사용함으로써 미세한 입자가 고효율로 표면에서 여과되며, 탈진시 안쪽의 큰 기공과 바깥쪽의 작은 기공으로 인해 탈진효율이 높아지는 장점이 있다.In the present invention, the ceramic composition powder is silicon carbide (SiC), mullite (3Al2O3ㆍ SiO2), Zirconia (ZrO2), Calcium carbonate (CaCO3), Carboxymethyl cellulose or a combination thereof. In addition, the ceramic composition powder may further include water. The inclusion of water further has the advantage that the ceramic composition powder is more adhered to the surface of the polymer filter body and is easier to form the ceramic composition powder layer. In the present invention, the step of filtering the powder may be divided into the initial stage and the later stage may use a ceramic composition powder of different particle size. Preferably, in the initial stage, the particle size of the powder is about 100 μm, and in the later stage, the particle size of the powder is about 5 μm. As described above, the larger the particle size of the powder is used in the initial stage, so that the ceramic composition powder may be formed quickly in the initial stage, and the thickness may be facilitated by using the smaller particle size in the later stage. In addition, by using a larger particle size of the powder in the initial stage as described above, the fine particles are filtered at the surface with high efficiency, there is an advantage that the dust removal efficiency is increased due to the large pores on the inside and the small pores on the outside.
본 발명에서, 상기 세라믹 조성물 파우더는 세라믹 성분으로서 탄화규소를 포함할 수 있다.In the present invention, the ceramic composition powder may include silicon carbide as a ceramic component.
본 발명에서, 상기 탄화규소의 함량은 전체 세라믹 조성물 파우더 100 중량부를 기준으로 바람직하기로 70 내지 75 중량부, 더욱 바람직하기로 73 내지 74 중량부, 가장 바람직하기로 73.8 중량부일 수 있다. 상기 탄화규소의 함량이 상기 상한보다 많을 경우 바인더의 부족으로 세라믹 층에 균열이 생길 수 있고 상기 하한보다 적을 경우 탄화규소의 부족으로 기계적 강도가 저하되고 내열성이 떨어질 수 있다.In the present invention, the content of the silicon carbide may be preferably 70 to 75 parts by weight, more preferably 73 to 74 parts by weight, most preferably 73.8 parts by weight based on 100 parts by weight of the total ceramic composition powder. When the content of the silicon carbide is greater than the upper limit may cause cracks in the ceramic layer due to the lack of a binder, and when less than the lower limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide.
본 발명에서, 탄화규소의 입자 크기에 따라 필터의 기공 크기를 조절할 수 있고 이에 따라 배기가스 내 입자상 오염물질의 여과 효율을 조절할 수 있다.In the present invention, the pore size of the filter can be adjusted according to the particle size of the silicon carbide and thus the filtration efficiency of particulate contaminants in the exhaust gas can be controlled.
본 발명에서, 상기 탄화규소의 입자 크기는 바람직하기로 5 ㎛ 내지 100 ㎛, 더욱 바람직하기로 10 ㎛ 내지 50 ㎛, 가장 바람직하기로 25 ㎛일 수 있다. 상기 탄화규소의 입자 크기가 5 ㎛ 미만인 경우 기공이 너무 치밀해져 오염물질로 인해 기공이 막힐 수 있고 100 ㎛ 초과인 경우 기공 크기가 너무 커서 미세 오염물질의 여과 효율이 떨어질 수 있다.In the present invention, the particle size of the silicon carbide may be preferably 5 ㎛ to 100 ㎛, more preferably 10 ㎛ to 50 ㎛, most preferably 25 ㎛. When the particle size of the silicon carbide is less than 5 μm, the pores may be so dense that the pores may be blocked due to contaminants, and when the particle size of the silicon carbide is larger than 100 μm, the pore size may be too large to reduce the filtration efficiency of the fine contaminants.
구체적으로, 본 발명의 일 실시예에서는 상기 탄화규소의 입자 크기가 10 ㎛, 25 ㎛ 및 50 ㎛인 것을 사용하여 세라믹 필터를 제조하고 이의 여과 효율을 측정한 결과, 10 ㎛ 내지 50 ㎛의 탄화규소의 입자 크기 범위에서 1 ㎛ 이하의 미세 오염물질을 90% 이상 여과할 수 있음을 확인하였다.Specifically, in one embodiment of the present invention, the ceramic carbide is manufactured using the particle size of the silicon carbide particles having a particle size of 10 ㎛, 25 ㎛ and 50 ㎛, and as a result of measuring the filtration efficiency, silicon carbide of 10 ㎛ to 50 ㎛ It was confirmed that fine contaminants of 1 μm or less can be filtered by 90% or more in the particle size range of.
본 발명에서, 상기 세라믹 조성물 파우더는 무기 바인더로서 뮬라이트를 포함할 수 있다.In the present invention, the ceramic composition powder may include mullite as an inorganic binder.
본 발명에서, 상기 뮬라이트의 함량은 전체 세라믹 조성물 파우더 100 중량부를 기준으로 바람직하기로 3 내지 4 중량부, 더욱 바람직하기로 3.5 내지 3.8 중량부, 가장 바람직하기로 3.7 중량부일 수 있다. 상기 뮬라이트의 함량이 상기 상한보다 많을 경우 탄화규소의 부족으로 기계적 강도가 저하되고 내열성이 떨어질 수 있으며 상기 하한보다 적을 경우 바인더의 부족으로 균열이 생길 수 있다.In the present invention, the content of the mullite may be preferably 3 to 4 parts by weight, more preferably 3.5 to 3.8 parts by weight, most preferably 3.7 parts by weight based on 100 parts by weight of the total ceramic composition powder. When the content of the mullite is greater than the upper limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide, and when less than the lower limit, cracks may occur due to the lack of the binder.
본 발명에서, 상기 세라믹 조성물 파우더는 무기 바인더로서 지르코니아를 포함할 수 있다.In the present invention, the ceramic composition powder may include zirconia as an inorganic binder.
본 발명에서, 상기 지르코니아의 함량은 전체 세라믹 조성물 파우더 100 중량부를 기준으로 바람직하기로 3 내지 4 중량부, 더욱 바람직하기로 3.5 내지 3.8 중량부, 가장 바람직하기로 3.7 중량부일 수 있다. 상기 지르코니아의 함량이 상기 상한보다 많을 경우 탄화규소의 부족으로 기계적 강도가 저하되고 내열성이 떨어질 수 있으며 상기 하한보다 적을 경우 바인더의 부족으로 균열이 생길 수 있다.In the present invention, the content of the zirconia may be preferably 3 to 4 parts by weight, more preferably 3.5 to 3.8 parts by weight, and most preferably 3.7 parts by weight based on 100 parts by weight of the total ceramic composition powder. When the content of the zirconia is greater than the upper limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide, and when less than the lower limit, cracking may occur due to the lack of the binder.
본 발명에서, 상기 세라믹 조성물 파우더는 무기 바인더로서 탄산칼슘를 포함할 수 있다.In the present invention, the ceramic composition powder may include calcium carbonate as an inorganic binder.
본 발명에서, 상기 탄산칼슘의 함량은 전체 세라믹 조성물 파우더 100 중량부를 기준으로 바람직하기로 0.5 내지 1.0 중량부, 더욱 바람직하기로 0.7 내지 0.9 중량부, 가장 바람직하기로 0.8 중량부일 수 있다. 상기 탄산칼슘의 함량이 상기 상한보다 많을 경우 탄화규소의 부족으로 기계적 강도가 저하되고 내열성이 떨어질 수 있으며 상기 하한보다 적을 경우 바인더의 부족으로 균열이 생길 수 있다.In the present invention, the content of the calcium carbonate may be preferably 0.5 to 1.0 parts by weight, more preferably 0.7 to 0.9 parts by weight, most preferably 0.8 parts by weight based on 100 parts by weight of the total ceramic composition powder. When the content of the calcium carbonate is greater than the upper limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide, and when less than the lower limit, cracks may occur due to the lack of the binder.
본 발명에서, 상기 세라믹 조성물 파우더는 유기 바인더로서 카르복시메틸셀룰로오스(CMC)를 포함할 수 있다.In the present invention, the ceramic composition powder may include carboxymethyl cellulose (CMC) as an organic binder.
본 발명에서, 상기 카르복시메틸셀룰로오스의 함량은 전체 세라믹 조성물 파우더 100 중량부를 기준으로 바람직하기로 1 내지 2 중량부, 더욱 바람직하기로 1.5 내지 1.7 중량부, 가장 바람직하기로 1.6 중량부일 수 있다. 상기 카르복시메틸셀룰로오스의 함량이 상기 상한보다 많을 경우 탄화규소의 부족으로 기계적 강도가 저하되고 내열성이 떨어질 수 있으며 상기 하한보다 적을 경우 바인더의 부족으로 균열이 생길 수 있다.In the present invention, the content of the carboxymethyl cellulose may be preferably 1 to 2 parts by weight, more preferably 1.5 to 1.7 parts by weight, and most preferably 1.6 parts by weight based on 100 parts by weight of the total ceramic composition powder. When the content of the carboxymethyl cellulose is greater than the upper limit, the mechanical strength may be lowered and the heat resistance may be lowered due to the lack of silicon carbide, and when less than the lower limit, cracks may occur due to the lack of the binder.
본 발명에서, 상기 세라믹 조성물 파우더는 상기한 바와 같이 파우더의 부착력을 증가시키기 위하여 물(water)을 추가로 포함할 수 있다.In the present invention, the ceramic composition powder may further include water to increase the adhesion of the powder as described above.
본 발명에서, 상기 물의 함량은 전체 세라믹 조성물 파우더 100 중량부를 기준으로 바람직하기로 10 내지 20 중량부, 더욱 바람직하기로 15 내지 17 중량부, 가장 바람직하기로 16.4 중량부일 수 있다. 상기 물의 함량이 상기 상한보다 많을 경우 건식 공정을 수행하기 어렵고 상기 하한보다 적을 경우 파우더의 부착력이 저하될 수 있다.In the present invention, the content of water may be preferably 10 to 20 parts by weight, more preferably 15 to 17 parts by weight, and most preferably 16.4 parts by weight based on 100 parts by weight of the total ceramic composition powder. When the content of the water is greater than the upper limit, it is difficult to perform a dry process, and when less than the lower limit, the adhesion of the powder may be lowered.
본 발명의 바람직한 일 구현예로서, 상기 세라믹 조성물 파우더는 탄화규소, 뮬라이트, 지르코니아, 탄산칼슘, 카르복시메틸셀룰로오스 및 물을 중량 기준으로 70~75:3~4:3~4:0.5~1.0:1~2:10~20의 비율로 포함하는 것일 수 있다. 가장 바람직하기로, 상기 세라믹 조성물 파우더는 탄화규소, 뮬라이트, 지르코니아, 탄산칼슘, 카르복시메틸셀룰로오스 및 물을 중량 기준으로 73.8:3.7:3.7:0.8:1.6:16.4의 비율로 포함하는 것일 수 있다. 상기와 같은 비율의 세라믹 조성물 파우더를 사용함으로써 균열 없이 기계적 강도가 우수하고 내열성이 우수한 세라믹 필터를 제조할 수 있다.As a preferred embodiment of the present invention, the ceramic composition powder is 70 to 75: 3 to 4: 3 to 4: 0.5 to 1.0: 1 by weight of silicon carbide, mullite, zirconia, calcium carbonate, carboxymethylcellulose and water It may be included in the ratio of ~ 2: 10-20. Most preferably, the ceramic composition powder may include silicon carbide, mullite, zirconia, calcium carbonate, carboxymethylcellulose and water in a ratio of 73.8: 3.7: 3.7: 0.8: 1.6: 16.4 by weight. By using the ceramic composition powder in the above ratio, it is possible to produce a ceramic filter having excellent mechanical strength and excellent heat resistance without cracking.
본 발명에서 사용되는 용어 "고분자 여과체"는 고분자 소재의 여과체를 의미한다. 상기 고분자 여과체는 통상적으로 입수 가능한 고분자 여과체를 구입하여 사용하거나 통상적인 제조방법으로 직접 제조한 것을 사용할 수 있다.The term "polymer filter medium" used in the present invention means a filter material of a polymer material. The polymer filter body may be used by purchasing a commercially available polymer filter medium or directly manufactured by a conventional manufacturing method.
본 발명에서, 상기 고분자 여과체는 바람직하기로 5 ㎛ 이하, 더욱 바람직하기로 1 ㎛ 내지 5 ㎛의 기공 크기를 갖는 것일 수 있다. 상기와 같은 기공 크기를 가진 고분자 여과체를 사용함으로써, 세라믹 조성물 파우더를 포함하는 공기를 고분자 여과체로 여과하는 단계 1)에서 상기 고분자 여과체의 표면에 세라믹 조성물 파우더 층이 용이하게 형성될 수 있다.In the present invention, the polymer filter body may preferably have a pore size of 5 μm or less, more preferably 1 μm to 5 μm. By using the polymer filter medium having the pore size as described above, the ceramic composition powder layer can be easily formed on the surface of the polymer filter in step 1) of filtering the air containing the ceramic composition powder into the polymer filter.
본 발명에서, 상기 고분자 여과체는 폴리에스터, 폴리프로필렌, 아크릴, 폴리아미드, 폴리이미드 또는 유리섬유로 이루어진 것일 수 있으며, 이에 제한되는 것은 아니다.In the present invention, the polymer filter may be made of polyester, polypropylene, acrylic, polyamide, polyimide or glass fiber, but is not limited thereto.
본 발명에서, 상기 여과 속도는 바람직하기로 0.5~10 m/min일 수 있다. 상기 여과 속도 범위에서 세라믹 조성물 파우더 층의 형성 효율이 우수하다.In the present invention, the filtration rate may be preferably 0.5 ~ 10 m / min. The formation efficiency of the ceramic composition powder layer in the filtration rate range is excellent.
본 발명에서, 상기 세라믹 조성물 파우더 층은 바람직하기로 1 mm 내지 10 mm의 두께일 수 있다. 상기 세라믹 조성물 파우더 층의 두께가 1 mm 이상일 경우 소결 이후 얻어지는 세라믹 층의 기계적 강도 및 내열성이 우수한 장점이 있고 상기 두께가 10 mm 이하일 경우 필터가 적절한 기공 크기를 가져 여과 효율이 우수하다.In the present invention, the ceramic composition powder layer may preferably be a thickness of 1 mm to 10 mm. When the thickness of the ceramic composition powder layer is 1 mm or more, mechanical strength and heat resistance of the ceramic layer obtained after sintering are excellent, and when the thickness is 10 mm or less, the filter has an appropriate pore size and excellent filtration efficiency.
본 발명의 제조방법은 상기와 같이 세라믹 조성물 파우더 층의 두께 조절이 용이하여 필터의 기공 크기 조절을 용이하게 할 수 있어 필터 통과시 발생되는 압력손실 문제를 해결할 수 있는 장점을 갖는다.As described above, the manufacturing method of the present invention can easily adjust the thickness of the ceramic composition powder layer to facilitate the pore size adjustment of the filter, which has the advantage of solving the pressure loss problem generated when passing through the filter.
상기 단계 2는, 상기 세라믹 조성물 파우더 층이 형성된 고분자 여과체를 소결하여 세라믹 필터를 제조하는 단계이다. Step 2 is a step of preparing a ceramic filter by sintering the polymer filter body in which the ceramic composition powder layer is formed.
본 발명에서, 상기 소결 온도는 바람직하기로 1400℃ 내지 1500℃, 가장 바람직하기로 1450℃이다.In the present invention, the sintering temperature is preferably 1400 ℃ to 1500 ℃, most preferably 1450 ℃.
본 발명에서, 상기 소결시 실온에서 소결온도까지 서서히 승온시키는 것이 세라믹의 균열 방지 측면에서 바람직하다. 이때 상기 승온속도는 3 내지 4 ℃/min의 범위, 가장 바람직하기로 3.3 ℃/min로 유지하는 것이 균열 방지 측면에서 바람직하다.In the present invention, it is preferable to gradually increase the temperature from the room temperature to the sintering temperature during the sintering in view of crack prevention of the ceramic. At this time, the temperature increase rate is preferably in the range of 3 to 4 ℃ / min, most preferably 3.3 ℃ / min in terms of crack prevention.
본 발명에서, 상기 소결 시간은 바람직하기로 1 시간 내지 5 시간, 더욱 바람직하기로 1 시간 내지 3 시간, 가장 바람직하기로 2 시간일 수 있다.In the present invention, the sintering time may be preferably 1 hour to 5 hours, more preferably 1 hour to 3 hours, most preferably 2 hours.
본 발명의 세라믹 필터의 제조방법은 상기한 바와 같이 세라믹 조성물 파우더 층의 두께 조절을 통해 필터의 기공 크기 조절이 용이할 뿐만 아니라 별도의 금형 및 가압장치 등이 필요치 않아 저비용 및 저에너지로 제조가 가능하고, 사용되는 고분자 여과체의 형태 및 크기를 따라 다양한 형태를 가지며 소형으로부터 대형까지 다양한 크기를 갖는 세라믹 필터를 제조할 수 있는 장점을 갖는다.The method of manufacturing the ceramic filter of the present invention is not only easy to adjust the pore size of the filter through the thickness control of the ceramic composition powder layer as described above, but also requires a separate mold and pressurization device, so that it can be manufactured at low cost and low energy. In addition, according to the shape and size of the polymer filter medium to be used has a variety of forms and has the advantage of producing a ceramic filter having a variety of sizes from small to large.
또한, 본 발명은 상기 방법으로 제조된 세라믹 필터를 제공한다.The present invention also provides a ceramic filter manufactured by the above method.
본 발명의 세라믹 필터는 상기 방법으로 제조됨으로써 고분자 여과체 표면 상에 세라믹 층이 형성되어 있는 형태를 가지며, 표면의 세라믹 층에 의해 높은 내열성, 내화학성 및 내마모성 등의 세라믹 필터가 가지는 장점을 갖는다.The ceramic filter of the present invention has a form in which a ceramic layer is formed on the surface of the polymer filter body by being manufactured by the above method, and has the advantage that the ceramic filter such as high heat resistance, chemical resistance and abrasion resistance is provided by the surface ceramic layer.
본 발명에 따른 세라믹 필터는 종래의 가압방식을 이용하고 있지 않아 필터의 기공 크기 조절을 용이하게 할 수 있어 필터 통과시 발생되는 압력손실 문제를 해결할 수 있다.Since the ceramic filter according to the present invention does not use the conventional pressurization method, it is possible to easily adjust the pore size of the filter, thereby solving the problem of pressure loss generated when passing through the filter.
또한, 본 발명에 따른 세라믹 필터의 제조방법은 별도의 금형제작 과정을 필요로 하지 않으므로 저비용으로 필터를 제작할 수 있으며, 별도의 금형 없이 필터를 제조할 수 있어 필터형상 변경이 용이하여 용도에 따라 여과면적을 극대화하여 고성능의 필터를 제조할 수 있다. In addition, the method of manufacturing a ceramic filter according to the present invention does not require a separate mold manufacturing process, so that a filter can be manufactured at low cost, and a filter can be manufactured without a separate mold, and thus the filter shape can be easily changed and filtered according to a use. By maximizing the area, high-performance filters can be manufactured.
따라서, 본 발명에 따른 세라믹 필터 및 이의 제조방법은 저비용 및 저에너지를 사용하여 고성능의 세라믹 필터를 제조할 수 있어 필터 관련 산업에 유용하게 사용할 수 있다.Therefore, the ceramic filter and the method of manufacturing the same according to the present invention can produce a high performance ceramic filter using low cost and low energy, which can be usefully used in the filter-related industry.
도 1은 본 발명의 세라믹 필터 제조 공정을 나타낸 모식도이다.1 is a schematic view showing a ceramic filter manufacturing process of the present invention.
도 2는 본 발명의 세라믹 필터 제조시 사용된 고분자 여과체의 모습(A), 제조된 세라믹 필터의 모습(B), 및 상기 세라믹 필터의 표면 모습을 주사전자현미경으로 관찰한 모습(C)을 나타낸 것이다.Figure 2 is a state (A) of the polymer filter medium used in the manufacture of the ceramic filter of the present invention, the appearance of the ceramic filter (B), and the appearance of the surface of the ceramic filter observed with a scanning electron microscope (C) It is shown.
도 3은 본 발명의 세라믹 필터의 여과 효율을 나타낸 그래프이다.3 is a graph showing the filtration efficiency of the ceramic filter of the present invention.
이하, 실시예를 통해 본 발명의 구성 및 효과를 보다 더 구체적으로 설명하고자 하나, 이들 실시예는 본 발명의 예시적인 기재일뿐 본 발명의 범위가 이들 실시예에만 한정되는 것은 아니다.Hereinafter, the configuration and effects of the present invention will be described in more detail with reference to examples, but these examples are merely illustrative of the present invention, and the scope of the present invention is not limited only to these examples.
실시예 1-3: 본 발명의 세라믹 필터 제조Example 1-3 Preparation of Ceramic Filter of the Present Invention
도 1에 본 발명의 세라믹 필터 제조과정을 모식적으로 나타내었다.1 schematically shows a ceramic filter manufacturing process of the present invention.
구체적으로, 고온용 세라믹 필터를 제조하기 위하여, 먼저 탄화규소, 뮬라이트, 지르코니아, 탄산칼슘, 카르복시메틸셀룰로오스 및 물을 중량 기준으로 73.8:3.7:3.7:0.8:1.6:16.4의 비율로 포함하는 세라믹 조성물 파우더를 파우더 주입구를 통하여 공기와 함께 고분자 여과체(평균 기공 크기 3 ㎛, Polyester, 대성휠타테크)를 통과하도록 주입하였다. 이때 탄화규소는 입자 크기가 각각 10 ㎛(실시예 1), 25 ㎛(실시예 2) 및 50 ㎛(실시예 3)인 것을 사용하였다. 또한 여과 속도는 5 m/min으로 조절하였으며 세라믹 조성물 파우더 층의 두께는 5 mm가 되도록 하였다.Specifically, in order to manufacture a high-temperature ceramic filter, first, a ceramic composition comprising silicon carbide, mullite, zirconia, calcium carbonate, carboxymethylcellulose and water in a ratio of 73.8: 3.7: 3.7: 0.8: 1.6: 16.4 by weight. Powder was injected through the powder inlet through the polymer filter medium (average pore size 3 ㎛, Polyester, Daesung Filterta Tech) with air. In this case, silicon carbide particles having particle sizes of 10 μm (Example 1), 25 μm (Example 2) and 50 μm (Example 3) were used, respectively. The filtration rate was also adjusted to 5 m / min and the thickness of the ceramic composition powder layer was 5 mm.
그 후, 세라믹 파우더 층이 형성된 고분자 여과체를 1450℃에서 2 시간 동안 소결하여 세라믹 필터를 제조하였다. 상기 소결시 실온에서 소결온도까지 3.3 ℃/min의 승온속도를 유지하였다.Thereafter, the polymer filter having the ceramic powder layer formed thereon was sintered at 1450 ° C. for 2 hours to prepare a ceramic filter. During the sintering, the temperature increase rate of 3.3 ° C./min was maintained from room temperature to the sintering temperature.
실험예 1: 본 발명의 세라믹 필터의 구조적인 특성 조사Experimental Example 1 Investigation of Structural Characteristics of the Ceramic Filter of the Present Invention
상기 실시예 2에서 제조한 본 발명의 세라믹 필터의 구조적인 특성을 조사하기 위하여 본 발명의 세라믹 필터의 표면을 주사전자현미경(SEM)으로 관찰하였다.In order to investigate the structural characteristics of the ceramic filter of the present invention prepared in Example 2, the surface of the ceramic filter of the present invention was observed with a scanning electron microscope (SEM).
그 결과를 하기 도 2에 나타내었다.The results are shown in FIG. 2.
도 2에서, (A)는 본 발명의 세라믹 필터를 제조하기 위해 사용한 고분자 여과체의 모습을 나타낸 것이고, (B)는 제조된 세라믹 필터의 모습을 나타낸 것이며, (C)는 상기 세라믹 필터의 표면 모습을 주사전자현미경으로 관찰한 결과를 나타낸 것이다.In Figure 2, (A) shows the appearance of the polymer filter body used to manufacture the ceramic filter of the present invention, (B) shows the appearance of the ceramic filter produced, (C) is the surface of the ceramic filter The results were observed by scanning electron microscopy.
도 2를 통해, 본 발명의 제조방법에 의해 고분자 여과체의 표면 상에 균일하고 치밀한 세라믹 층이 형성되었음을 확인할 수 있었다.2, it was confirmed that the uniform and dense ceramic layer was formed on the surface of the polymer filter medium by the production method of the present invention.
실험예 2: 본 발명의 세라믹 필터의 성능 평가Experimental Example 2: Performance Evaluation of the Ceramic Filter of the Present Invention
본 발명의 세라믹 필터의 성능 평가를 위하여, 상기 실시예 1 내지 3에서 제조한 세라믹 필터의 여과 효율(collection efficiency)을 측정하였다.In order to evaluate the performance of the ceramic filter of the present invention, the collection efficiency of the ceramic filters prepared in Examples 1 to 3 was measured.
제조된 필터의 여과효율을 측정하기 위해서 여과백 테스트 장치에 제조된 세라믹필터를 장착하고 Fly ash를 테스트 입자로 발생시켰다. 여과백을 통과하는 유체의 속도를 1m/min로 고정시킨 후, 필터의 전, 후단에서 먼지의 개수농도를 Aerodynamic Particle Sizer (Model: 3321, TSI Instruments)로 측정하여 여과효율을 측정하였다.In order to measure the filtration efficiency of the manufactured filter, a manufactured ceramic filter was mounted in the filter bag test apparatus, and fly ash was generated as test particles. After fixing the velocity of the fluid passing through the filter bag to 1m / min, the number of dust at the front and rear of the filter was measured by the Aerodynamic Particle Sizer (Model: 3321, TSI Instruments) to measure the filtration efficiency.
그 결과를 도 3에 나타내었다.The results are shown in FIG.
도 3을 통해, 10 ㎛ 내지 50 ㎛의 입자 크기를 갖는 탄화규소를 사용하여 제조한 세라믹 필터가 1 ㎛ 이하의 미세 오염물질을 90% 이상 여과할 수 있음을 확인하였다.3, it was confirmed that the ceramic filter manufactured using silicon carbide having a particle size of 10 μm to 50 μm may filter 90% or more of fine contaminants of 1 μm or less.

Claims (11)

  1. 세라믹 조성물 파우더를 포함하는 공기를 고분자 여과체로 여과하여, 상기 고분자 여과체 표면에 세라믹 조성물 파우더 층을 형성하는 단계(단계 1); 및 Filtering the air including the ceramic composition powder with a polymer filter to form a ceramic composition powder layer on the surface of the polymer filter (step 1); And
    상기 세라믹 조성물 파우더 층이 형성된 고분자 여과체를 소결하는 단계(단계 2)를 포함하는, 세라믹 필터의 제조방법.And sintering the polymer filter medium in which the ceramic composition powder layer is formed (step 2).
  2. 제1항에 있어서, 상기 세라믹 조성물 파우더는 탄화규소(SiC), 뮬라이트(3Al2O3ㆍSiO2), 지르코니아(ZrO2), 탄산칼슘(CaCO3), 카르복시메틸셀룰로오스 또는 이의 조합인 것을 특징으로 하는 제조방법.According to claim 1, wherein the ceramic composition powder is silicon carbide (SiC), mullite (3Al 2 O 3 ㆍ SiO 2 ), zirconia (ZrO 2 ), calcium carbonate (CaCO 3 ), carboxymethyl cellulose or a combination thereof Manufacturing method.
  3. 제1항에 있어서, 상기 세라믹 조성물 파우더는 물(water)을 추가로 포함하는 것을 특징으로 하는 제조방법.The method of claim 1, wherein the ceramic composition powder further comprises water.
  4. 제2항에 있어서, 상기 탄화규소의 입자 크기는 5 ㎛ 내지 100 ㎛인 것을 특징으로 하는 제조방법.The method of claim 2, wherein the silicon carbide has a particle size of 5 μm to 100 μm.
  5. 제1항에 있어서, 상기 세라믹 조성물 파우더는 탄화규소, 뮬라이트, 지르코니아, 탄산칼슘, 카르복시메틸셀룰로오스 및 물을 중량 기준으로 70~75:3~4:3~4:0.5~1.0:1~2:10~20의 비율로 포함하는 것을 특징으로 하는 제조방법.The method of claim 1, wherein the ceramic composition powder is silicon carbide, mullite, zirconia, calcium carbonate, carboxymethyl cellulose and water by weight 70 ~ 75: 3 ~ 4: 3 ~ 4: 0.5 ~ 1.0: 1 ~ 2: Manufacturing method characterized in that it comprises at a ratio of 10 to 20.
  6. 제1항에 있어서, 상기 고분자 여과체는 폴리에스터, 폴리프로필렌, 아크릴, 폴리아미드, 폴리이미드 또는 유리섬유로 이루어진 것을 특징으로 하는 제조방법.The method of claim 1, wherein the polymer filter member is made of polyester, polypropylene, acrylic, polyamide, polyimide or glass fiber.
  7. 제1항에 있어서, 상기 여과 속도는 0.5~10 m/min인 것을 특징으로 하는 제조방법.The method of claim 1, wherein the filtration rate is 0.5 to 10 m / min.
  8. 제1항에 있어서, 상기 세라믹 조성물 파우더 층은 1 mm 내지 10 mm의 두께인 것을 특징으로 하는 제조방법.The method of claim 1 wherein the ceramic composition powder layer is 1 mm to 10 mm thick.
  9. 제1항에 있어서, 상기 소결 온도는 1400℃ 내지 1500℃인 것을 특징으로 하는 제조방법.The method of claim 1, wherein the sintering temperature is 1400 ° C to 1500 ° C.
  10. 제1항에 있어서, 상기 소결시 3 내지 4 ℃/min의 승온속도를 유지하는 것을 특징으로 하는 제조방법.According to claim 1, wherein the sintering manufacturing method characterized in that to maintain a temperature increase rate of 3 to 4 ℃ / min.
  11. 제1항에 있어서, 상기 소결 시간은 1 시간 내지 5 시간인 것을 특징으로 하는 제조방법.The method according to claim 1, wherein the sintering time is 1 hour to 5 hours.
PCT/KR2013/010620 2012-11-21 2013-11-21 Method for manufacturing ceramic filter WO2014081218A1 (en)

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