WO2020116491A1 - 吸着用焼結体及びその製造方法並びに吸着装置 - Google Patents

吸着用焼結体及びその製造方法並びに吸着装置 Download PDF

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Publication number
WO2020116491A1
WO2020116491A1 PCT/JP2019/047346 JP2019047346W WO2020116491A1 WO 2020116491 A1 WO2020116491 A1 WO 2020116491A1 JP 2019047346 W JP2019047346 W JP 2019047346W WO 2020116491 A1 WO2020116491 A1 WO 2020116491A1
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Prior art keywords
adsorbent
adsorption
sintered body
powder
activated carbon
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PCT/JP2019/047346
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English (en)
French (fr)
Inventor
誠 清野
英之 矢野
敏文 加藤
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味の素株式会社
日本フイルコン株式会社
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Application filed by 味の素株式会社, 日本フイルコン株式会社 filed Critical 味の素株式会社
Priority to JP2020559952A priority Critical patent/JP7262485B2/ja
Priority to KR1020217020901A priority patent/KR20210096665A/ko
Priority to EP19892655.2A priority patent/EP3892368A4/en
Priority to CN201980079920.8A priority patent/CN113423500A/zh
Publication of WO2020116491A1 publication Critical patent/WO2020116491A1/ja
Priority to US17/337,708 priority patent/US20210291142A1/en

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    • B01D2259/4541—Gas separation or purification devices adapted for specific applications for portable use, e.g. gas masks
    • 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
    • B01D53/46—Removing components of defined structure
    • B01D53/48—Sulfur compounds
    • B01D53/50—Sulfur oxides
    • B01D53/508—Sulfur oxides by treating the gases with solids
    • 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
    • B01D53/46—Removing components of defined structure
    • B01D53/54—Nitrogen compounds
    • B01D53/56—Nitrogen oxides
    • B01D53/565—Nitrogen oxides by treating the gases with solids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2220/00—Aspects relating to sorbent materials
    • B01J2220/40—Aspects relating to the composition of sorbent or filter aid materials
    • B01J2220/46—Materials comprising a mixture of inorganic and organic materials
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/28—Treatment of water, waste water, or sewage by sorption
    • C02F1/283—Treatment of water, waste water, or sewage by sorption using coal, charred products, or inorganic mixtures containing them
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/28—Treatment of water, waste water, or sewage by sorption
    • C02F1/285—Treatment of water, waste water, or sewage by sorption using synthetic organic sorbents
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/28—Treatment of water, waste water, or sewage by sorption
    • C02F1/288—Treatment of water, waste water, or sewage by sorption using composite sorbents, e.g. coated, impregnated, multi-layered
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00—Nature of the contaminant
    • C02F2101/30—Organic compounds
    • C02F2101/308—Dyes; Colorants; Fluorescent agents

Definitions

  • the present invention relates to an adsorbed sintered body, particularly an adsorbed sintered body containing a powder adsorbent for adsorbing a substance to be treated in a fluid, a method for producing the same, and an adsorbing apparatus.
  • Adsorbents such as activated carbon, activated clay and zeolite are used for air purification, dioxin removal, flue gas desulfurization and denitration, odor removal, factory waste gas and liquid treatment, advanced water treatment, chemical purification, food and beverage decolorization. , Water purifiers for home use, air purifiers, refrigerator deodorants, gas masks, etc. Used for various adsorption purposes for industrial, household and medical purposes.
  • Patent Document 1 discloses an activated carbon cartridge for gas purification in which granular activated carbon having a particle size of 2.4 to 4.7 mm (2400 to 4700 ⁇ m) is filled between an inner cylinder and an outer cylinder.
  • granular activated carbon refers to activated carbon having a large particle size
  • finely powdered activated carbon having a small particle size is referred to as “powder” activated carbon.
  • particle size indication of 150 ⁇ m or more is defined as “granular” activated carbon
  • particle size indication of less than 150 ⁇ m is defined as “powder” activated carbon.
  • the large particle size adsorbent has a smaller specific surface area (outer surface area per unit mass) than the fine powder adsorbent, in order to obtain the same adsorption performance as when using the powder adsorbent, it is necessary to use the granular adsorbent. It is necessary to increase the amount of material, and in an adsorption device or the like, when a granular adsorbent is filled in a cartridge or the like and used as a filter or the like, the cartridge or the adsorption device becomes large.
  • the filling volume tends to vary from container to container as compared with the powder adsorbent, and a constant amount is produced in the manufacture of products such as filter cartridges.
  • external force such as vibration or pressure during transportation or use may crush or break the granular adsorbent in the container, which may cause a problem such as an increase in pressure loss.
  • a powder adsorbent such as powdered activated carbon has a larger specific surface area and higher adsorption performance than a granular adsorbent, but even if it is filled in a container such as a cartridge and used as a filter, etc.
  • the voids are significantly reduced, making it difficult for the fluid to pass through, resulting in high pressure loss (high differential pressure), which is not suitable for practical use. Therefore, the powder adsorbent is not suitable for a filter filled in a container such as a cartridge, and has been conventionally used exclusively for a batch type (batch type) adsorption process.
  • Patent Document 2 discloses an aggregate formed by adsorbing an adsorbent with a thermoplastic resin as a binder and bonding and/or adhering the adsorbent to each other through the binder. Disclosed are adsorptive molded articles based on the above and filters to which the same are applied. However, such an aggregate deteriorates the adsorption performance because most of the surface of the adsorbent is covered with the thermoplastic resin.
  • a powder adsorbent having a small particle size tends to be covered with a thermoplastic resin on most of its surface, and it is difficult to form the aggregate into a desired size due to a decrease in pressure loss.
  • granular activated carbon having a large particle size is actually used.
  • Patent Document 3 discloses that high-performance particles such as activated carbon particles are impregnated or adsorbed with a foaming agent. Disclosed is a molded article which is mixed with a matrix resin, and the mixture is foamed and solidified in a liquid or molten state of the matrix resin, and the high-functional particles are present inside the pores generated by the foaming.
  • the molded product 10 when such a so-called foamed plastic is used as the matrix of the adsorbent, the molded product is generally flexible and poor in mechanical strength, and particularly easily deformed under a high pressure and a high flow rate. Not suitable for continuous adsorption devices that adsorb substances. Specifically, for example, as shown in FIG. 14( a) and FIG. 15( a ), the molded product 10 at the time of using high pressure or high flow rate is made of foamed plastic 12 as compared with the molded product 10 before use. Therefore, the entire volume is easily collapsed by the compressive force 16 of FIG. 14( b ), and the pores 13 tend to be smaller than before use as shown in FIG. 15( b ), so that the density of the activated carbon particles 11 is high. The pressure loss increases and the flow velocity decreases significantly.
  • the adsorbent is impregnated with a foaming agent to form pores in the matrix resin, it is not easy to form appropriate pores unless the adsorbent is sufficiently impregnated with the foaming agent. Further, when the content of the adsorbent is increased for the purpose of improving the adsorption performance, the number of pores also tends to increase and the mechanical strength tends to decrease, so that it is difficult to improve the absorption efficiency.
  • the open-cell structure which is considered to be preferable in the obtained molded product is a so-called sponge-like structure and further lowers in mechanical strength, so that it is used by filling it in a container such as a cartridge as described above, a fluid (7 There is a problem that it is not suitable for the use of continuous treatment for adsorbing the substance to be treated in ().
  • an object of the present invention is to provide an adsorptive material which has excellent adsorption capacity and can achieve low pressure loss, a method for producing the same, and an adsorption device.
  • the present inventors have found that in a resin structure in which voids are formed in a three-dimensional network, the powder adsorbent is accommodated in the voids so that the powder adsorbent can move freely. It has been found that a specific adsorption sintered body, which is fixed to the surface of the body and/or at least a part of which is embedded inside the resin structure, has an excellent adsorption capacity and at the same time can achieve a low pressure loss. Has been completed.
  • the present invention includes the following contents.
  • the void (3) is provided with a resin structure (2) formed in a three-dimensional mesh shape,
  • the powder adsorbent (1a, 1b) adheres to the free adsorbent (1a) movably contained in the void (3) between the resin structures (2) and the surface (2a) of the resin structure (2).
  • a fixed adsorbent (1b) at least a part of which is embedded inside the resin structure (2)
  • the powder adsorbent (1a, 1b) is at least one selected from powdered activated carbon, powdered activated clay and zeolite, and is a sintered body for adsorption.
  • the resin raw material of the resin structure (2) is at least one thermoplastic resin selected from polypropylene (PP), polyethylene (PE), polyvinylidene fluoride (PVDF) and ethylene vinyl acetate (EVA) copolymer.
  • PP polypropylene
  • PE polyethylene
  • PVDF polyvinylidene fluoride
  • EVA ethylene vinyl acetate copolymer
  • the plurality of free adsorbents (1a) are movably accommodated in at least a part of the voids (3), and the plurality of adjacent free adsorbents (1a) are not fixed to each other and at least a part of The adsorbing sintered body according to any one of [1] to [5], wherein a channel (3a) for the fluid (7) is formed between the free adsorbent (1a) in the void (3).
  • [7] The adsorbing sintered body according to any one of [1] to [6], wherein the powder adsorbent (1a, 1b) is powder activated carbon having a pointed portion.
  • a step of forming a adsorbent mixture by mixing a powder adsorbent, which is at least one selected from powdered activated carbon, powdered activated clay and zeolite, with a thermoplastic resin, A step of heating the adsorbent mixture at a temperature higher than the softening point of the thermoplastic resin and lower than the melting point of the powder adsorbent raw material; A resin structure in which a plurality of thermoplastic resins are fused and cooled and solidified to form voids (3) in a three-dimensional mesh shape, and free adsorbent (1a) is movably accommodated in the voids (3).
  • a powder adsorbent which is at least one selected from powdered activated carbon, powdered activated clay and zeolite
  • thermoplastic resin is at least one selected from polypropylene (PP), polyethylene (PE), polyvinylidene fluoride (PVDF) and ethylene vinyl acetate (EVA) copolymers, [10] to [12]. ] The manufacturing method in any one of these. [14] The production method according to any one of [10] to [13], wherein the thermoplastic resin has a particle size of 10 to 200 ⁇ m.
  • an adsorptive material that is excellent in adsorption capacity and can achieve low pressure loss, a manufacturing method thereof, and an adsorption device.
  • Sectional drawing which shows the sintered compact for adsorption of this invention.
  • Enlarged image of the surface showing the raw material powdered activated carbon Enlarged image of the surface showing the raw material powdered activated carbon
  • Enlarged image of the surface showing the raw material powdered activated carbon Enlarged image of surface showing powdered activated clay as raw material
  • Enlarged image of the surface showing the raw material zeolite Enlarged cross-section image showing only the resin structure of the sintered body for adsorption
  • Surface image showing a sintered body for adsorption of the present invention manufactured from powdered activated carbon Enlarged surface image showing a sintered body for adsorption of the present invention manufactured from powdered activated carbon
  • Enlarged surface image showing a sintered body for adsorption of the present invention manufactured from powdered activated carbon Enlarged surface image showing a sintered body for adsorption of the present invention manufactured from powdered activated carbon
  • Schematic diagram showing the permeation adsorption test device A graph showing the results of a liquid permeation adsorption test using coconut shell activated carbon.
  • the adsorbed sintered body of the present invention comprises a powder adsorbent (1a, 1b) and a resin structure (2) having voids (3) formed in a three-dimensional mesh.
  • Resin structure (2) in the present invention powder, granules, by heating the particles of the thermoplastic resin pellets or the like, the contact portion of the plurality of thermoplastic resin is melted to form a joint, It can be formed by fusing together thermoplastic resins.
  • the resin structure obtained in this manner has a structure in which concave voids sandwiched by convex portions derived from the shape of the thermoplastic resin are formed in a three-dimensional mesh shape.
  • the powder adsorbent (1a, 1b) adheres to the free adsorbent (1a) movably contained in the void (3) between the resin structures (2) and the surface (2a) of the resin structure (2). And/or a fixed adsorbent (1b) at least a part of which is embedded inside the resin structure (2).
  • the powder adsorbent (1a, 1b) is composed of at least one selected from powder activated carbon, powder activated clay and zeolite.
  • the adsorbed sintered body of the present invention is particularly useful for adsorbing a substance to be treated in the fluid (7).
  • the fluid (7) is passed through the adsorbing sintered body (20)
  • the entire surface of the free adsorbent (1a) that is not fixed and bonded to the resin structure (2) comes into direct contact with the fluid (7).
  • an action of capturing and adsorbing the substance to be treated in the fluid (7) can be generated.
  • the adsorption sintered body (20) of the present invention is compared with the adsorbent material of the type in which the entire surface or a part of the surface is covered with a matrix resin, or the adsorbent material of the type in which the adsorbent exists only in the voids.
  • a larger adsorption area can be secured, the adsorption efficiency can be remarkably increased, and the adsorption performance can be improved.
  • the free adsorbent (1a) can move freely. By restricting the movement of the free adsorbent to some extent, the agglomeration of the free adsorbent is suppressed.
  • the adsorbed substance captured by the free adsorbent (1a) can be removed from the flowing free adsorbent (1a) if the conditions are selected, and the adsorbing sintered body (20) can be reused. That is, in order to remove the adsorbed substance, for example, a method can be selected in which the structure of the adsorbing sintered body (20) is heated within a range that can be maintained, and a good solvent for the adsorbed substance is added for extraction. Further, it is also possible to select a method of changing the liquid properties such as pH and salt concentration in the liquid phase by depressurization and in the liquid phase by accelerating the removal. Furthermore, it is also possible to use a combination of a plurality of these parallelizable methods.
  • a metal such as silver, copper, or nickel, a metal oxide thereof, or a non-volatile acid or base agent is preliminarily powder-adsorbed. It can be supported on the material. Further, these can be directly supported on the adsorbing sintered body.
  • the adsorption device of the present invention loads a single or a plurality of layers (20a, 20b) of the adsorption sintered body (20) into a container.
  • the adsorption device (30) has excellent strength characteristics due to the rigid resin structure (2) and can maintain a certain shape and void (3) during transportation and use. ..
  • the respective layers (20a, 20b) are not mixed.
  • the method for producing an adsorbent sintered body of the present invention is a step of forming an adsorbent mixture by mixing at least one powder adsorbent raw material selected from powdered activated carbon, powdered activated clay and zeolite with a thermoplastic resin.
  • Embodiments of the adsorption sintered body and the manufacturing method thereof according to the present invention will be described below in more detail with reference to FIGS. 1 to 13.
  • the adsorbing sintered body (20) has a powder adsorbent (powder adsorbent) (1a, 1b) for adsorbing the substance to be treated in the fluid (7) and voids (cavities) (3) formed into a three-dimensional mesh.
  • the formed resin structure (2) The substance to be treated is any component or substance contained in gas or liquid and capable of being adsorbed by the powder adsorbent (1a, 1b), for example, pigment component, odor component, harmful substance, pollutant substance, heavy metal, valuable metal, toxicity. Including components, radioactive components, water, oil, etc.
  • the powder adsorbent (1a, 1b) in the present invention is at least one selected from powdered activated carbon, powdered activated clay and zeolite.
  • the adsorbent sintered body (20), other adsorbent substances, such as acid clay, alumina, silica, silica gel, silica-alumina, permiculite, barlite, kaolin, diatomaceous earth. , Sepiolite, etc. may be included.
  • a granular adsorbent such as granular activated carbon (adsorbent having an average diameter of 150 ⁇ m or more) within the range where the adsorbing capacity does not significantly decrease. May be included.
  • Activated carbon used in the powder adsorbent (1a, 1b) for example, coconut shell, walnut shell, apricot shell, fruit shell, rice husk, soybean, coffee, nuts, pistachio, charcoal, large sawdust, sawdust, bark, ash, wood Formed by activating raw materials selected from materials, peat, grass peat, lignite, brown coal, bituminous coal, anthracite, tar, pitch, coke, coal, petroleum, waste tires, waste plastics, synthetic resins, fibers, construction waste materials, and sewage sludge. Adsorption performance is imparted by the numerous internal micropores.
  • activation method for example, gas activation with water vapor, carbon dioxide, air and the like, and chemical activation with zinc chloride, phosphoric acid, sulfuric acid, calcium chloride, potassium dichromate, potassium permanganate, sodium hydroxide and the like are applied. it can.
  • the average diameter of the powder adsorbent in the present invention is not particularly limited as long as the effects of the present invention can be achieved, but it is preferably less than 150 ⁇ m. That is, in the present specification, an adsorbent having an average diameter of less than 150 ⁇ m is preferably defined as a powder adsorbent. In addition, a “powder” adsorbent according to JIS K1474 and having a particle size display of less than 150 ⁇ m is also included in the powder adsorbent in the present invention. The "average diameter" in this specification is measured by the laser diffraction scattering method based on the Mie scattering theory.
  • the average diameter of the adsorbent being less than 150 ⁇ m is a concept including adsorbents having any median diameter of less than 150 ⁇ m. That is, the value of the average diameter merely represents the intermediate value of the distribution range, and for example, the average diameter of the adsorbent being less than 150 ⁇ m does not mean that the adsorbent having a diameter of 150 ⁇ m or more is not included at all.
  • the average diameter of the powder adsorbent is more preferably 1 ⁇ m or more and less than 150 ⁇ m, further preferably 5 ⁇ m or more and less than 150 ⁇ m, and particularly preferably 15 ⁇ m or more and 100 ⁇ m or less.
  • the average diameter of the powder adsorbent (1a, 1b) contained in the adsorbent sintered body (20) set the average diameter of the powder adsorbent used during the production of the adsorbent sintered body (20) within the above numerical range. It can be adjusted. That is, the average diameter of the powder adsorbent used in the production can be the average diameter of the powder adsorbent (1a, 1b) contained in the adsorption sintered body (20).
  • the average diameter of the powder adsorbent (1a, 1b) is too small, a large amount of fine powder adsorbent (1a, 1b) is mixed with the resin raw material of the resin structure (2) during production, and the resin structure (2) Strength may decrease. Further, the fine free adsorbent (1a) may be easily separated from the adsorption sintered body (20) together with the fluid (7) through the gap (4) between the resin structures (2). Further, the pressure loss may easily increase. If the average diameter is too large (for example, 150 ⁇ m or more), the adsorption area of the adsorbent tends to be small and the adsorption performance tends to decrease. Further, a sufficient amount of the free adsorbent (1a) cannot be accommodated in the void (3), which tends to make the construction of the adsorbing sintered body (20) difficult.
  • FIG. 2a to 2e are electron micrograph images showing the raw materials of the powder adsorbents (1a, 1b) constituting the adsorption sintered body (20).
  • FIG. 2a is a surface enlarged image of powdered activated carbon in which charcoal of coconut shell is activated by steam
  • FIG. 2b is activated sawdust by a chemical (phosphoric acid)
  • FIG. 2c is activated sawdust by a chemical (zinc chloride). (400 times) is shown.
  • the powdered activated carbon is generally a lump, rod-shaped, or elongated plate-shaped raw material having a portion having a pointed portion
  • the powder adsorbent (1a, 1b) has a tip with the tip of the resin structure (2) during floating ( It is locked in 2a) and the gap (4) to prevent the adsorption sintered body (20) from flowing out. Therefore, the powder adsorbent (1a, 1b) hardly moves between the plurality of voids (3).
  • FIG. 2d is an enlarged image of each surface showing powdered activated clay as the raw material for the powder adsorbent (400 times) and FIG. 2e showing zeolite (2000 times).
  • the adsorbing sintered body (20) preferably contains the powder adsorbent (1a, 1b) in an amount of 25 to 65 mass %, more preferably 30 to 60 mass %. If the content of the powder adsorbent (1a, 1b) is too low, the adsorption performance of the adsorption sintered body (20) tends to decrease. On the other hand, if the content of the powder adsorbent (1a, 1b) is too high, the adsorbability is high, but the resin ratio is small and the strength of the whole adsorbing sintered body (20) tends to decrease.
  • the content of the powder adsorbent (1a, 1b) contained in the adsorbent sintered body (20) is used in the production of the adsorbent sintered body (20), in the adsorbent mixture before sintering.
  • thermoplastic resin is used as the resin raw material of the resin structure (2).
  • Preferred is at least one thermoplastic resin selected from polypropylene (PP), polyethylene (PE), polyvinylidene fluoride (PVDF), ethylene vinyl acetate (EVA) copolymer.
  • the thermoplastic resin as the resin raw material of the resin structure (2) is used in the form of particulate solid, and may be in any form such as powder, granules and pellets.
  • the particle size of the thermoplastic resin particles is preferably 10 to 200 ⁇ m. By setting the particle size of the thermoplastic resin within the above range, it becomes easy to form the voids (3) in a substantially uniform size without variation.
  • a plasticizer such as adipic acid ester, a stabilizer such as an epoxy compound, an antioxidant such as a phenol compound, etc. may be added and used.
  • the particle size of the thermoplastic resin in this specification is measured by an image analysis method taken by a CCD camera. Specifically, an image analysis type particle size distribution measurement device (VD-3000 manufactured by Jusco International, PITA-04 manufactured by Seishin Enterprise, etc.) was used to take an image of 1400-15,000 particles of thermoplastic resin randomly dispersed. The individual particle diameter D of each particle is calculated from the image obtained in this way, and the distribution of D is created, and then the median diameter is taken as the particle diameter of the thermoplastic resin. The individual particle size D can be calculated by the arithmetic mean (D1+D2)/2 of both, where the maximum width of the particles in the image is the maximum diameter D1 and the minimum width is the minimum diameter D2.
  • FIG. 3 is an electron microscope showing an adsorption sintered body that does not include the powder adsorbent (1a, 1b), showing a state of a cross section cut by a cutter to form a resin structure by sintering only a resin raw material. It is an enlarged cross-sectional image (500 times).
  • the white part in Fig. 3 shows the resin structure (2) having a continuous tuft-like and three-dimensional mesh structure without corners, and the black part inside thereof is the space where the free adsorbent (1a) is movably arranged. It shows (3).
  • the powder adsorbents (1a, 1b) of the adsorbing sintered body (20) shown in FIG. 1 are free adsorbents (free adsorbents) housed in the voids (3) between the resin structures (2) in a floating manner.
  • the floating means that the powder adsorbent is not fixed to the resin structure (2) or the plurality of powder adsorbents are not fixed to each other, but is moved, shaken, vibrated, rotated, expanded, contracted, or floated. It means that every movement is possible.
  • the powder adsorbent (1a, 1b) of the adsorbing sintered body (20) shown in FIG. 1 further includes a fixed adsorbent (1b) carried by the resin structure (2).
  • the fixed adsorbent (1b) is fixed to the surface (2a) of the resin structure (2), or at least a part thereof is embedded inside the resin structure (2). That is, the fixed adsorbent (1b) is the first fixed adsorbent (1b1) fixed to the surface (2a) of the resin structure (2), and a part (partial surface) inside the resin structure (2).
  • a third fixed adsorbent (1b3) may be present.
  • the first and second fixed adsorbents (1b1, 1b2) whose surfaces are exposed in the voids (3) contribute to the improvement of adsorption capacity and are fixed to the resin structure (2). Even if it has a small diameter, it will not flow out.
  • the third fixed adsorbent (1b3) Since the third fixed adsorbent (1b3) is contained in the resin structure (2), it has a low adsorption capacity, but the powder adsorbent (1a, 1b) having a smaller diameter is added to the resin structure (2). Since it tends to be taken in, the fixed adsorbent (1b3) is also composed of a relatively small-diameter powder adsorbent, and blockages caused by a large amount of the small-diameter powder adsorbent (1a, 1b) remaining in the voids (3). It is possible to prevent and suppress an increase in pressure loss.
  • the average diameter of the free adsorbent is usually larger than that of the powder adsorbent.
  • the average diameter of the free adsorbent (1a) is preferably 5 ⁇ m or more and less than 150 ⁇ m, more preferably 15 ⁇ m or more and 100 ⁇ m or less.
  • the average diameter of the fixed adsorbent (1b) is estimated to be about 1 to 50 ⁇ m.
  • FIG. 2a powdered activated carbon obtained by activating coconut shell carbide with water vapor as a powder adsorbent raw material
  • activated carbon obtained by activating sawdust with a chemical (phosphoric acid)
  • Fig. 2c powder of activated carbon obtained by activating sawdust with a chemical (zinc chloride), respectively
  • FIG. 2c powder of activated carbon obtained by activating sawdust with a chemical (zinc chloride), respectively
  • An adsorption sintered body (20) comprising a free adsorbent (1a) of powdered activated carbon and a fixed adsorbent (1b) of powdered activated carbon fixed to the resin structure (2) can be confirmed.
  • the black void (3) inside the resin skeleton constitutes a three-dimensional space in which the free adsorbent (1a) can freely move.
  • Part of the fixed adsorbent (1b) is fixed to the surface (2a) of the resin structure (2), and part of the fixed adsorbent (1b) is fitted into the concave portion (2b) of the surface (2a). Can be retained in (2).
  • the fixed adsorbent (1b) is provided in the resin structure (2), so that the adsorption area and the saturated adsorption capacity are increased to achieve high adsorption performance. Can be maintained.
  • the resin structure (2) does not have an adsorbing ability unless a special functional substance is added, the fixed adsorbent (1b) should be carried on the surface (2a) or the inside of the resin structure (2). Thereby, the adsorption performance of the entire adsorption sintered body (20) can be significantly improved. Further, in the present invention, the fixed adsorbent (1b) does not flow out from the gap (4) between the resin structures (2).
  • one or more free adsorbents (1a) are movably accommodated in the void (3).
  • a plurality of adjacent free adsorbents (1a) do not stick to each other and at least some of the voids (3) are released.
  • a channel (3a) (FIGS. 1 and 6) for the fluid (7) is formed between the adsorbents (1a) to enable adsorption of the entire surface of the free adsorbent (1a). Even if the free adsorbent (1a) once comes into contact with another free adsorbent (1a) or the resin structure (2), the flow path (3a) can be separated again by the flow of the fluid (7). ..
  • FIGS. 4d and 4e show the surface of an adsorption sintered body (20) of the present invention produced by using activated clay (FIG. 2d) and zeolite (FIG. 2e) as powder adsorbent raw materials, taken by an electron microscope. An enlarged image (1500 times) is shown.
  • a gray resin structure (2) having a smooth rounded surface (2a) with a black void (3) formed in a three-dimensional mesh shape, and a resin structure (2)
  • a large diameter powdered activated clay and zeolite as a free adsorbent (1a) placed inside, and a smaller diameter powdered activated clay and zeolite as a fixed adsorbent (1b) fixed to the resin structure (2) With a large diameter powdered activated clay and zeolite as a free adsorbent (1a) placed inside, and a smaller diameter powdered activated clay and zeolite as a fixed adsorbent (1b) fixed to the resin structure (2), The sintered body for adsorption (20) provided with can be confirmed.
  • a single-layer or plural-layer adsorbing sintered body (20) is loaded into a container as shown by reference numeral (81) in FIG. 10, for example. It is formed.
  • the adsorption device of the present invention the resin structure with high mechanical strength (2), the adsorbent in the container is crushed during transportation and use. It is possible to maintain a certain shape and void (3) without causing problems such as breakage and increase in pressure loss.
  • FIG. 5 shows a two-layer (20a, 20b) adsorption device (30).
  • each layer (20a, 20b) of the adsorbing sintered body (20) having a cylindrical shape, a prismatic shape or a shape having an internal cavity is sequentially loaded, for example, even if they are loaded or laminated in series, each layer (20a , 20b) do not mix.
  • FIG. 5 shows a two-layer (20a, 20b) adsorption device (30), an adsorption device in which three or more layers are stacked can be formed.
  • powdered activated carbon as a raw material forming the powder adsorbent (1a, 1b) and a thermoplastic resin as a resin raw material forming the resin structure (2) are mixed to form an adsorbent mixture.
  • the adsorbent mixture may contain other optional components.
  • the content of the powdered activated carbon in the adsorbent mixture is preferably 25 to 65% by mass, more preferably 30 to 60% by mass.
  • the content of the thermoplastic resin in the adsorbent mixture is preferably 35 to 75% by mass, more preferably 40 to 70% by mass.
  • the average diameter of the powdered activated carbon is preferably less than 150 ⁇ m, more preferably 1 ⁇ m or more and less than 150 ⁇ m, still more preferably 5 ⁇ m or more and less than 150 ⁇ m, and particularly preferably 15 ⁇ m or more and 100 ⁇ m or less.
  • the particle size of the thermoplastic resin is preferably 10 to 200 ⁇ m, more preferably 30 to 80 ⁇ m.
  • the powdered activated carbon hardly crushes, expands or shrinks, and can form the powder adsorbent (1a, 1b) while maintaining the initial size.
  • the thermoplastic resin is preferably at least one selected from polypropylene, polyethylene, polyvinylidene fluoride and ethylene vinyl acetate copolymer. In the present invention, it is not necessary to use a foaming agent.
  • the powdered activated carbon preferably has a water content of 30% by mass or less, more preferably 15% by mass or less, more preferably 8% by mass or less, and particularly preferably substantially free of water.
  • thermoplastic resin At least one kind of thermoplastic resin selected from polypropylene (PP), polyethylene (PE), polyvinylidene fluoride (PVDF) and ethylene vinyl acetate (EVA) copolymer, which are preferable for use in the present invention, is used. As long as a plastic resin is used, these generally have poor water absorbency, and it is not necessary to consider the influence of the water content in the method for producing the adsorbing sintered body (20) of the present invention.
  • PP polypropylene
  • PE polyethylene
  • PVDF polyvinylidene fluoride
  • EVA ethylene vinyl acetate
  • the water content of the powder adsorbent is measured as follows. When measuring 1 to 3g of the powder adsorbent (w1) and drying at 110°C for a sufficient time until the mass change rate becomes 0.05%/min or less, and measuring the mass (w2) after drying, the water content ( %) becomes 100 x (w1-w2)/w2.
  • the adsorbent mixture is introduced into a heating furnace to heat the adsorbent mixture at a temperature higher than the softening point of the thermoplastic resin and lower than the melting point of the powdered activated carbon, for example, 90 to 180°C.
  • a temperature higher than the softening point of the thermoplastic resin and lower than the melting point of the powdered activated carbon for example, 90 to 180°C.
  • the contact portions of the plurality of thermoplastic resins are melted to form a joint, and the thermoplastic resins are fused to each other to form a skeleton surrounding the void (3).
  • most of the powdered activated carbon does not adhere to the thermoplastic resin.
  • it is cooled and solidified to form a three-dimensional mesh-like resin structure (2) in which the free adsorbent (1a) is movably accommodated in the void (3).
  • the resin structure (2) may have a three-dimensional mesh-like three-dimensional mesh structure.
  • a high-strength adsorbent sintered body (20) containing the free adsorbent (1a) made of powdered activated carbon is produced.
  • FIG. 4a to FIG. 4c are examples of respective embodiments of the adsorbing sintered body (20) manufactured by using the activated carbon powder as a raw material by the manufacturing method of the present invention.
  • the adsorption sintered body (20) of the present invention preferably by using a powdered activated carbon and a thermoplastic resin having a low water content as the resin raw material, it is possible to suppress the expansion of voids due to the severe evaporation and foaming of water, Voids (3) of appropriate size can be formed uniformly.
  • a raw material with a low water content in the heating process, heat is uniformly transferred from the outside of the heating source to the inside of the heating source without being affected by moisture, and there is no temperature difference, and the entire thermoplastic resin is melted uniformly. it can.
  • the particle size of the thermoplastic resin is preferably 10 to 200 ⁇ m, more preferably 30 to 80 ⁇ m.
  • the powder activated carbon is used as the raw material in the embodiment of the production method
  • the adsorption sintered body (20) can be produced by the same production method as described above even if powder activated clay or zeolite is used as the raw material (FIG. 4d). And FIG. 4e).
  • the fluid (7) containing the substance to be treated When the fluid (7) containing the substance to be treated is passed through an adsorption device (not shown) loaded with a single layer of the sintered body for adsorption (20), the fluid (7) will be discharged between the resin structures (2). Is introduced into the space (3) through the space (4). At this time, since the free adsorbent (1a) is not bonded to the resin structure (2) and the plurality of free adsorbents (1a) are not fixed or bonded to each other, as shown in FIG. The flowing fluid (7) floats or oscillates in the void (3), and the entire surface of the free adsorbent (1a) comes into direct contact with the fluid (7), ensuring the substance to be treated in the fluid (7). It is captured and adsorbed on. Further, the flow path (3a) formed between the free adsorbents (1a) can increase the adsorption area and secure the flow of the fluid (7) to prevent the pressure loss of the adsorbing sintered body (20
  • the fluid (7) also contacts the fixed adsorbent (1b) fixed to the surface (2a) or the inside of the resin structure (2), and the substance to be treated in the fluid (7) is adsorbed and adsorbed. It
  • the fluid (7) treated in the void (3) passes through the void (4) and is continuously introduced into the other voids (3). The same adsorption process is repeated in a plurality of other voids (3), and finally the resin structure (2) is discharged to the outside of the adsorption device. Since the gap (4) is small, the floating free adsorbent (1a) is held in the gap (3) between the resin structures (2) and does not flow out of the adsorption sintered body (20).
  • the adsorbing sintered body (20) of the present invention can contain a powder adsorbent having an excellent adsorbing performance at a high content rate, and can adsorb a substance to be treated with high efficiency. Since the adsorption sintered body (20) of the present invention has excellent strength, the container can be downsized when used in a container such as a cartridge in applications such as a filter. The miniaturization can be achieved, and the transportability and storability can be made extremely excellent.
  • the adsorption sintered body (20) of the present invention suppresses a decrease in adsorption performance due to an increase in pressure loss, and the adsorption performance can be maintained for a long period of time while maintaining a predetermined processing amount, so that the running cost can be reduced.
  • the adsorbed sintered body (20) of the present invention can be integrally molded into a desired shape and size by using powdered activated carbon having excellent adsorption performance as a sintered body, and various types of continuous adsorption treatments are possible. Further, since a plurality of layers having different adsorption characteristics can be loaded in the container depending on the application, an adsorption device having multiple functions can be provided.
  • the adsorption sintered body (20) of the present invention can also be used for batch type (batch type) adsorption treatment.
  • the adsorbing sintered body (20) of the present invention has good handleability.
  • the activated carbon of coconut shell was activated with steam to obtain 0.109 parts by mass of activated carbon powder (FIG. 2a) having an average particle diameter of about 30 ⁇ m as a powder body (69) (Comparative Example 1).
  • 2.109 parts by mass of powdered activated carbon obtained by classifying 32 ⁇ m or less of powdered activated carbon (Fig. 2a) obtained by activating the charcoal of coconut shells with water vapor and having an average particle size of about 30 ⁇ m by a vibration classifier (manufactured by Fritsch Co.) (69) was obtained (Comparative Example 1′).
  • 0.109 parts by mass of activated carbon powder FIG.
  • Example 1 to 4 A frit (filter for preventing powder outflow) (62a) is placed in each syringe (61) having a volume of about 3 ml, and the adsorbing sintered bodies (20) of Examples 1 to 4 are loaded thereon, and further.
  • the frit (62b) was arranged to form the pressure loss test apparatus (60) of FIG.
  • the differential pressure between the adsorbing sintered bodies (20) when air adjusted to 0.2 L/min by the flow meter (64) is passed through the adsorbing sintered bodies (20) is a pressure gauge (Keyence AP- 53A) (63) for each of Examples 1 to 4.
  • Comparative Examples 1 and 2 filled with powdered activated carbon are 50 kPa or more. Comparative Examples 1'and 2'in which powdered activated carbon of 32 ⁇ m or less was classified and removed also showed a high differential pressure value of 30 kPa or more. Comparative Examples 1 and 2 were densely packed with powdered activated carbon containing fine powder of 32 ⁇ m or less, and Comparative Examples 1′ and 2′ were also densely packed with powdered activated carbon, and the voids between the powders were small, so There was a pressure loss.
  • the adsorbing sintered bodies (20) of Examples 1 and 2 according to the present invention each contained 10 kPa of the resin structure (2) in addition to the same amount of powdered activated carbon as that of the comparative example.
  • the following low differential pressure values were shown.
  • Comparative Examples 3 and 4 filled with the powdered activated clay and the powdered body (69) of zeolite showed high differential pressure values of 29 kPa and 97 kPa, respectively.
  • fine powder was packed at a high density, and voids between the powders were small, so that the pressure loss was high.
  • the adsorbing sintered bodies (20) according to the present invention of Examples 3 and 4 include the resin structure (2) in addition to the same amount of powdered activated clay and zeolite as in Comparative Examples 3 and 4. None of them showed a low differential pressure value of 10 kPa or less. Therefore, in Examples 1 to 4 of the present invention, it was confirmed that the low pressure loss treatment was realized. Further, the adsorbed sintered bodies (20) of Examples 1 to 4 were also excellent in strength.
  • Granules (89) (Comparative Example 5) were obtained by mixing 0.076 parts by mass of granular activated carbon having an average diameter of about 800 ⁇ m in which charcoal of coconut shell was activated with steam and 0.177 parts by mass of polyethylene beads having a diameter of 100 ⁇ m.
  • a large-diameter granular activated carbon having a particle size of about 800 ⁇ m it is not possible to form the adsorbing sintered body of the present invention in which the activated carbon is movably arranged in the voids between the resin structures, and the number of particles is extremely smaller than that of the powder.
  • FIG. 11a shows the test results of Example 5 and Comparative Example 5
  • FIG. 11b shows the test results of Example 6 and Comparative Example 6, with the horizontal axis indicating time [minutes]. ]
  • the vertical axis represents the residual concentration of methylene blue [mg/l].
  • the amount was about 500 mg/l, whereas in Example 6, the amount was decreased to 300 mg/l or less.
  • FIG. 13 shows the test results of Example 5 and Comparative Examples 7 and 8, with the horizontal axis representing time [minutes] and the vertical axis representing cyclohexane concentration [ppm].
  • Comparative Examples 7 and 8 cyclohexane passed through from the first 10 minutes, whereas in Example 5, cyclohexane did not pass through even after 60 minutes and adsorption was completely maintained.
  • the odor of cyclohexane as the outlet gas was felt from the first 10 minutes, whereas in Example 5, no odor was felt. Therefore, it was confirmed that Example 5 of the present invention containing 30% by mass of the powder adsorbent (1a, 1b) was excellent in gas adsorption performance, particularly in deodorizing property and harmful gas removing property.
  • the reason for using the powdered activated carbon of sawdust is that, in Examples 1 to 6, the strength of the sawdust is relatively weaker than that of the other raw materials, and if high sinterability and high strength can be confirmed with the powdered sawdust powder, other coconut shells This is because it can be predicted that the powdered activated carbon, the powdered activated clay, and the zeolite will naturally provide sufficient sinterability and strength.
  • Example 6 30% by mass (Example 6), 40% by mass (Example 2), 50% by mass (Example 7) and 60% by mass (implementation) of the powder adsorbent (1a, 1b) were used.
  • Example 8) The adsorbing sintered compacts (20) contained could be taken out from the heating furnace in a state where the shape was maintained, and the shape was not deformed even when strongly pressed, and sufficient strength could be confirmed.
  • Example 9 Into a 100 ml Erlenmeyer flask, put the adsorption sintered body (20) of Example 9, add 50 ml of caffeine aqueous solution with a concentration of 100 mg/l, set it on a shaker with a rubber stopper until the adsorption reaches almost equilibrium. It was shaken at room temperature (20° C.) and 200 rpm. The liquid after shaking was collected and caffeine was separated using a high performance liquid chromatograph (Chromaster (registered trademark) manufactured by Hitachi High-Tech Science Co., Ltd.), and the caffeine residual concentration for Example 9 was determined from the absorbance at a wavelength of 280 nm. It was measured and the adsorption removal rate of caffeine was obtained.
  • Chromaster registered trademark manufactured by Hitachi High-Tech Science Co., Ltd.
  • Example 9 [4-3] Test Results and Discussion
  • the adsorption removal rate of caffeine was equal to 97%. Therefore, it was confirmed that the adsorption performance of the powder adsorbent (1a, 1b) was maintained at a high level even in the adsorption sintered body (20). Further, the adsorbed sintered body (20) of Example 9 was also excellent in strength.
  • Example 10 A 3 L odor bag made of polyester (manufactured by Omi Odo Air Service Co., Ltd.) was charged with the adsorbing sintered body (20) of Example 10 and a piece of filter paper of about 3 cm square, and 3 L of clean air was added and sealed with a rubber stopper. A 3% solution of dimethyl sulfide (hereinafter referred to as DMS) was injected into an odor bag with a microsyringe so that the internal DMS concentration was 200 mg/m 3 , soaked into a piece of filter paper, and the injection port was sealed with cellophane tape.
  • DMS dimethyl sulfide
  • the DMS was vaporized inside the odor bag, and allowed to stand at room temperature (20°C) until the adsorption reached almost equilibrium.
  • the rubber stopper was opened and the DMS concentration in the odor bag was measured using Gas Detector Tube No. 77 manufactured by Gastec Co., Ltd. to determine the adsorption removal rate of DMS.
  • Example 10 The same test as in Example 10 was conducted except that 0.055 parts by mass of the drug-supported zeolite pulverized to an average particle size of about 35 ⁇ m was used instead of the adsorption sintered body (20), and the adsorption removal rate of DMS was performed. I asked.
  • the adsorbing sintered body (20) of the present invention has high strength and exhibits excellent adsorption performance such as decolorization and deodorization even in low pressure loss in liquid and gas. I was able to confirm that.
  • the adsorption sintered body of the present invention a method for producing the same, and an adsorption apparatus are used for air purification, dioxin removal, flue gas desulfurization and denitration, factory waste gas and waste liquid treatment, advanced treatment of purified water, purification of chemicals, food and beverages. It can be used for various purposes such as decolorization, household water purifier, air purifier, refrigerator deodorant, gas mask, etc.

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Abstract

【課題】高吸着能及び低圧力損失で流体(7)中の被処理物質を吸着する。 【解決手段】本発明の吸着用焼結体(20)は、粉末吸着材(1a,1b)と、空隙(3)が三次元網目状に形成された樹脂構造体(2)とを備える。粉末吸着材(1a,1b)は、樹脂構造体(2)間の空隙(3)に遊動可能に収容された遊離吸着材(1a)と、樹脂構造体(2)の表面(2a)に固着され及び／又は樹脂構造体(2)の内部に少なくともその一部が埋設された固定吸着材(1b)とを含み、粉末吸着材(1a,1b)は、粉末活性炭、粉末活性白土及びゼオライトから選ばれる少なくとも１種である。

Description

吸着用焼結体及びその製造方法並びに吸着装置
　本発明は、吸着用焼結体、特に、流体中の被処理物質を吸着する粉末吸着材を含む吸着用焼結体及びその製造方法並びに吸着装置に関する。
　活性炭、活性白土及びゼオライト等の吸着材は、大気浄化、ダイオキシン除去、排煙脱硫及び脱硝、悪臭除去、工場の廃ガス及び廃液処理、浄水の高度処理、化学薬品の精製、食品及び飲料の脱色、家庭用浄水器、空気清浄機、冷蔵庫脱臭剤、ガスマスク等、工業用、家庭用、医療用の様々な吸着用途に使用される。
　例えば、特許文献１は、粒径２.４～４.７mm（２４００～４７００μm）の粒状活性炭が内筒と外筒との間に充填されたガス浄化用の活性炭カートリッジを開示する。一般に「粒状」活性炭とは、粒度が大きい活性炭を指し、粒度が小さい微細粉状の活性炭は「粉末」活性炭と呼ばれる。JIS K 1474では、粒度表示１５０μm以上を「粒状」活性炭、１５０μm未満を「粉末」活性炭と定義されている。大粒径の粒状吸着材は、微細な粉末吸着材に比べ比表面積（単位質量当たりの外表面積）が小さいため、粉末吸着材を使用した場合と同程度の吸着性能を得るには、粒状吸着材の増量が必要であり、吸着装置等において、粒状吸着材をカートリッジ等に充填してフィルタ等として使用する場合、カートリッジや吸着装置が大型化する。また吸着性能を高めるために、粒状吸着材を容器に緊密充填しようとした場合、粉末吸着材と比べて、容器ごとに充填体積にばらつきが生じ易く、フィルタ用カートリッジ等の製品の製造において、一定品質を維持することが容易ではないという問題がある。また搬送又は使用時の振動や圧力等の外力により、容器内の粒状吸着材が粉砕、破壊等され、圧力損失が上昇するなどの不具合を生じることがある。
　一方、粉末活性炭等の粉末吸着材は、粒状吸着材に比べて比表面積が大きく吸着性能が高いが、仮にカートリッジ等の容器内に充填してフィルタ等として使用したとしても、粉末吸着材間の空隙が著しく減少し、流体が通り難く、通過しても高圧力損失（高差圧）となり実用に適さない。このため、粉末吸着材は、カートリッジ等の容器内に充填してのフィルタ用などには不向きであり、従来、専らバッチ式（回分式）の吸着処理に用いられてきた。
　吸着材を充填した容器における圧力損失を改善する試みとして、例えば、特許文献２は、吸着材を、熱可塑性樹脂をバインダとし、バインダを介して相互に結合及び／又は接着させて形成した凝集体に基づく吸着性成形品、およびそれを適用したフィルタを開示する。しかしこのような凝集体は、吸着材の表面の多くが熱可塑性樹脂に被覆されてしまうため、吸着性能が低下する。特に粒度の小さい粉末吸着材はその表面のほとんどが熱可塑性樹脂に被覆されてしまう傾向にあり、また圧力損失低下のために凝集体を所望の大きさにすることも困難となるため、特許文献２の実施例でも実際には粒度の大きい粒状活性炭が使用されている。
　また吸着性成形品に含まれる吸着材の表面が熱可塑性樹脂に被覆される問題を改善する試みとして、例えば、特許文献３は、活性炭粒子等の高機能性粒子に発泡剤を含浸あるいは吸着させ、マトリックス樹脂と混合し、該マトリックス樹脂の液体あるいは溶融状態において、該混合物を発泡させて固化し、高機能性粒子を発泡で生じた空孔内部に存在させた成形品を開示する。
　しかしながら、このようないわゆる発泡プラスチックを吸着材のマトリックスとして使用した場合、一般に成形品は柔軟で機械的強度に乏しく、特に高圧、高流速下で変形し易いため、流体(7)中の被処理物質を吸着する連続式の吸着装置に適さない。具体的には、例えば、図１４（ａ）及び図１５（ａ）に示すように、使用前の成形品10に対し、高圧又は高流速使用時の成形品10は、発泡プラスチック12で構成されるため、図１４（ｂ）の圧縮力16により体積全体が潰れ易く、また、図１５（ｂ）の通り空孔13が使用前に比べ縮小する傾向となるため、活性炭粒子11の密度が高くなり圧力損失が上昇し流速が著しく低下する。
　また、吸着材に発泡剤を含浸等させてマトリックス樹脂中に空孔を形成するため、吸着材に発泡剤が十分に含浸等していないと適切な空孔を形成することは容易ではない。また吸着性能を高める目的で吸着材の含有量を増量した場合、空孔も増大し機械的強度が低下する傾向となるため、吸収効率の向上が図り難い。
　また得られる成形品において好ましいとされている連続気泡構造は、いわゆるスポンジ状の構造となり、さらに機械強度が低下するため、上述のようにカートリッジ等の容器内に充填して用いる等、流体(7)中の被処理物質を吸着する連続式処理の用途には不向きであるという問題があった。
特開２０１４－１０４４４８号公報 特表２０１２－５０８６４５号公報 特開平１－３０１７３２号公報
　そこで本発明は、吸着能力に優れると同時に低圧力損失を達成できる吸着性材料及びその製造方法並びに吸着装置を提供することを目的とする。
　本発明者らは、上記目的を達成すべく、鋭意検討した結果、空隙を三次元網目状に形成した樹脂構造体において、粉末吸着材が、空隙に遊動可能に収容されると同時に、樹脂構造体の表面に固着され及び／又は樹脂構造体の内部に少なくともその一部が埋設された、特定の吸着用焼結体が、吸着能力に優れると同時に低圧力損失を達成できることを見出し、本発明を完成するに至った。
　すなわち、本発明は以下の内容を含む。
［１］粉末吸着材(1a,1b)と、
　空隙(3)が三次元網目状に形成された樹脂構造体(2)とを備え、
　粉末吸着材(1a,1b)は、樹脂構造体(2)間の空隙(3)に遊動可能に収容された遊離吸着材(1a)と、樹脂構造体(2)の表面(2a)に固着され及び／又は樹脂構造体(2)の内部に少なくともその一部が埋設された固定吸着材(1b)とを含み、
　粉末吸着材(1a,1b)は、粉末活性炭、粉末活性白土及びゼオライトから選ばれる少なくとも１種であることを特徴とする吸着用焼結体。
［２］粉末吸着材(1a,1b)の平均径は、１５０μm未満である、［１］に記載の吸着用焼結体。
［３］粉末吸着材(1a,1b)を２５～６５質量％含有する、［１］又は［２］に記載の吸着用焼結体。
［４］樹脂構造体(2)の樹脂原料は、ポリプロピレン（ＰＰ）、ポリエチレン（ＰＥ）、ポリフッ化ビニリデン（ＰＶＤＦ）及びエチレン酢酸ビニル（ＥＶＡ）共重合体から選ばれる少なくとも１種の熱可塑性樹脂である、［１］～［３］の何れかに記載の吸着用焼結体。
［５］熱可塑性樹脂の粒径は、１０～２００μmである、［１］～［４］の何れかに記載の吸着用焼結体。
［６］複数の遊離吸着材(1a)は、少なくとも一部の空隙(3)に遊動可能に収容され、隣接する複数の遊離吸着材(1a)は、互いに固着せずに、少なくとも一部の空隙(3)の遊離吸着材(1a)間に流体(7)の流路(3a)を形成する、［１］～［５］の何れかに記載の吸着用焼結体。
［７］粉末吸着材(1a,1b)は、尖形部分を有する粉末活性炭である、［１］～［６］の何れかに記載の吸着用焼結体。
［８］流体(7)中の被処理物質の吸着用である、［１］～［７］の何れかに記載の吸着用焼結体。
［９］［１］～［８］の何れかに記載の吸着用焼結体(20)の単一又は複数の層(20a,20b)を容器に装填したことを特徴とする吸着装置。
［１０］粉末活性炭、粉末活性白土及びゼオライトから選ばれる少なくとも１種である粉末吸着材と、熱可塑性樹脂とを混合して、吸着材混合物を形成する工程と、
　熱可塑性樹脂の軟化点より高くかつ粉末吸着材原料の融点より低い温度で吸着材混合物を加熱する工程と、
　複数の熱可塑性樹脂を融着しかつ冷却固化して、空隙(3)が三次元網目状に形成され、かつ空隙(3)に遊離吸着材(1a)が遊動可能に収容された樹脂構造体(2)を形成する工程とを含むことを特徴とする吸着用焼結体の製造方法。
［１１］粉末吸着材の平均径は、１５０μm未満である、［１０］に記載の製造方法。
［１２］吸着材混合物中の粉末吸着材の含有率が２５～６５質量%である、［１０］または［１１］に記載の製造方法。
［１３］熱可塑性樹脂は、ポリプロピレン（ＰＰ）、ポリエチレン（ＰＥ）、ポリフッ化ビニリデン（ＰＶＤＦ）及びエチレン酢酸ビニル（ＥＶＡ）共重合体のから選ばれる少なくとも１種である、［１０］～［１２］の何れかに記載の製造方法。
［１４］熱可塑性樹脂の粒径は、１０～２００μmである、［１０］～［１３］の何れかに記載の製造方法。
　本発明によれば、吸着能力に優れると同時に低圧力損失を達成できる吸着性材料及びその製造方法並びに吸着装置を提供することができる。
本発明の吸着用焼結体を示す部分断面図 原料の粉末活性炭を示す表面拡大画像 原料の粉末活性炭を示す表面拡大画像 原料の粉末活性炭を示す表面拡大画像 原料の粉末活性白土を示す表面拡大画像 原料のゼオライトを示す表面拡大画像 吸着用焼結体の樹脂構造体のみを示す断面拡大画像 粉末活性炭から製造された本発明の吸着用焼結体を示す表面画像 粉末活性炭から製造された本発明の吸着用焼結体を示す表面拡大画像 粉末活性炭から製造された本発明の吸着用焼結体を示す表面拡大画像 粉末活性白土から製造された本発明の吸着用焼結体を示す表面拡大画像 ゼオライトから製造された本発明の吸着用焼結体を示す表面拡大画像 本発明の吸着用焼結体を装填した吸着装置を示す断面図 本発明の吸着用焼結体に通液又は通気した実施の形態を示す部分断面図 圧力損失試験装置を示す概略図 圧力損失試験の結果を示すグラフ 圧力損失試験の結果を示すグラフ 通液吸着試験装置を示す概略図 ヤシ殻活性炭を用いた通液吸着試験の結果を示すグラフ 大鋸屑活性炭を用いた通液吸着試験の結果を示すグラフ 通気吸着試験装置を示す概略図 通気吸着試験の結果を示すグラフ 従来の成形品を容器に装填した状態を示す断面図 従来の成形品を示す部分断面図
　本発明の吸着用焼結体は、粉末吸着材(1a,1b)と、空隙(3)が三次元網目状に形成された樹脂構造体(2)とを備える。本発明における樹脂構造体(2)は、粉体、粒体、ペレット状等の熱可塑性樹脂の粒子を加熱することにより、複数の熱可塑性樹脂の接触部分が溶融して接合部を形成し、熱可塑性樹脂が互いに融着することにより形成させることができる。このようにして得られた樹脂構造体は、熱可塑性樹脂の形状に由来する凸部に挟まれた凹状の空隙が三次元網目状に形成された構造となる。粉末吸着材(1a,1b)は、樹脂構造体(2)間の空隙(3)に遊動可能に収容された遊離吸着材(1a)と、樹脂構造体(2)の表面(2a)に固着され及び／又は樹脂構造体(2)の内部に少なくともその一部が埋設された固定吸着材(1b)とを含む。粉末吸着材(1a,1b)は、粉末活性炭、粉末活性白土及びゼオライトから選ばれる少なくとも１種で構成される。
　本発明の吸着用焼結体は、特に流体(7)中の被処理物質の吸着用として有用である。吸着用焼結体(20)に流体(7)を通過させると、樹脂構造体(2)に固定されずかつ接合されない遊離吸着材(1a)の全表面が、流体(7)に直接接触して、流体(7)中の被処理物質を捕捉吸着する作用を発生し得る。また、本発明では、空隙(3)の遊離吸着材(1a)だけでなく、樹脂構造体(2)に固定吸着材(1b)を設けるため、本発明の吸着用焼結体(20)は、従来存在した、ほとんどの吸着材が、その全表面または一部表面をマトリックス樹脂に被覆されるタイプの吸着性材料や、空隙内だけに吸着材が存在するタイプの吸着性材料に比べて、より大きな吸着面積を確保でき、吸着効率が顕著に増大して吸着性能の向上が達成できる。
　また、吸着用焼結体(20)に流体(7)が通過するとき、また空隙(3)が三次元網目状に形成されていることにより、遊離吸着材(1a)は遊動可能である一方、遊離吸着材の移動がある程度制限されることにより、遊離吸着材の凝集が抑制される。従って、空隙(3)の目詰りと樹脂構造体(2)間の間隙(4)の目詰りの発生を抑制でき、その結果、粉末吸着材(1a,1b)を使用した場合でも、吸着用焼結体(20)での圧力損失の増加が抑制され、長期間継続的に流体(7)中の被吸着物質を吸着する作用が生じ得る。
　更に、遊離吸着材(1a)が捕捉した被吸着物質は、条件を選べば、流動する遊離吸着材(1a)から除去でき、吸着用焼結体(20)の再利用も可能である。即ち、吸着物質を除去するには、例えば吸着用焼結体(20)の構造を維持可能な範囲で加熱し、吸着物質の良溶媒を加え抽出する手法を選択できる。また、気相であれば減圧により、液相であればpHや塩濃度等の液性を変化させ、除去を促進させる手法も選択可能である。更に、これらの並立可能な手法を複数組み合わせて使用することもできる。本発明の吸着用焼結体において、被吸着物質の除去能力を高めるため、銀、銅、ニッケル等の金属やこれらの金属酸化物、不揮発性の酸・塩基等の薬剤をあらかじめ原料の粉末吸着材に担持させておくことができる。また吸着用焼結体に直接これらを担持させることもできる。
　本発明の吸着装置は、吸着用焼結体(20)の単一又は複数の層(20a,20b)を容器に装填する。容器内に粉末活性炭を直接充填した場合と比べ、吸着装置(30)は、剛性の樹脂構造体(2)により強度特性に優れ、搬送時及び使用時に一定の形態及び空隙(3)を維持できる。また、吸着用焼結体(20)の複数の層(20a,20b)を装填しても、各層(20a,20b)が混ざり合わない。
　本発明の吸着用焼結体の製造方法は、粉末活性炭、粉末活性白土及びゼオライトから選ばれる少なくとも１種の粉末吸着材原料と、熱可塑性樹脂とを混合して、吸着材混合物を形成する工程と、熱可塑性樹脂の軟化点より高くかつ粉末吸着材原料の融点より低い温度で吸着材混合物を加熱する工程と、複数の熱可塑性樹脂を融着しかつ冷却固化して、樹脂構造体(2)を形成する工程とを含む。
　本発明による吸着用焼結体及びその製造方法の実施の形態をさらに詳細に、図１～図１３を参照して以下に説明する。
　本発明の吸着用焼結体(20)の一態様を図１に示す。吸着用焼結体(20)は、流体(7)中の被処理物質を吸着する粉末吸着材（粉末吸着剤）(1a,1b)と、空隙（空洞）(3)が三次元網目状に形成された樹脂構造体(2)とを備える。被処理物質は、気体又は液体中に含まれかつ粉末吸着材(1a,1b)に吸着可能なあらゆる成分及び物質、例えば、色素成分、臭気成分、有害物質、公害物質、重金属、有価金属、毒性成分、放射能成分、水分、油分等を含む。
　本発明における粉末吸着材(1a,1b)は、粉末活性炭、粉末活性白土及びゼオライトから選ばれる少なくとも１種である。本発明の効果を達成し得る範囲で、吸着用焼結体(20)は、その他の吸着性物質、例えば、酸性白土、アルミナ、シリカ、シリカゲル、シリカ・アルミナ、パーミキュライト、バーライト、カオリン、珪藻土、セピオライト等を含んでいてもよい。また吸着用焼結体を吸着装置等に使用する場合の圧力損失をさらに低下させるため、吸着能力が著しく低下しない範囲で、粒状活性炭等の粒状吸着材（平均径が１５０μm以上の吸着材）を含んでいてもよい。粉末吸着材(1a,1b)に使用する活性炭は、例えば、ヤシ殻、クルミ殻、杏殻、果実殻、籾殻、大豆、コーヒー、ナッツ、ピスタチオ、木炭、大鋸屑、鋸屑、樹皮、素灰、木質材料、泥炭、草炭、亜炭、褐炭、瀝青炭、無煙炭、タール、ピッチ、コークス、石炭、石油、廃タイヤ、廃プラスチック、合成樹脂、繊維、建設廃材、下水汚泥から選択される原料を賦活化して形成され、無数の内部微細孔により吸着性能が付与される。賦活法としては、例えば、水蒸気、二酸化炭素、空気等によるガス賦活と、塩化亜鉛、リン酸、硫酸、塩化カルシウム、二クロム酸カリウム、過マンガン酸カリウム、水酸化ナトリウム等による薬品賦活とを適用できる。
　本発明における粉末吸着材の平均径は、本発明の効果が達成し得る限り特に限定されるものではないが１５０μm未満が好ましい。すなわち本明細書においては、好ましくは平均径１５０μｍ未満の吸着材が粉末吸着材として定義される。またJIS K 1474に準じた、粒度表示１５０μm未満の「粉末」吸着材も本発明における粉末吸着材に含まれる。本明細書の「平均径」は、ミー（Mie）散乱理論に基づくレーザー回折散乱法により測定される。具体的には、レーザー回折散乱式粒径分布測定装置（堀場製作所社製LA-500、セイシン企業社製LMS-2000e等）により、粉末吸着材原料の粒径分布を体積基準で作成して、そのメディアン径を平均径とする。なお、例えば、吸着材の平均径が１５０μm未満とは、１５０μm未満のあらゆるメディアン径の吸着材を含む概念である。即ち、平均径の値は、分布範囲の中間値を表すに過ぎず、例えば、吸着材の平均径が１５０μm未満とは、１５０μm 以上の吸着材を全く含まない意味ではない。粉末吸着材の平均径は、より好ましくは１μｍ以上、１５０μｍ未満であり、さらに好ましくは５μｍ以上、１５０μｍ未満であり、特に好ましくは１５μｍ以上、１００μｍ以下である。吸着用焼結体(20)に含まれる粉末吸着材(1a,1b)の平均径は、吸着用焼結体(20)の製造時に使用する粉末吸着材の平均径を上記数値範囲に設定することで調整することができる。すなわち、製造時に使用する粉末吸着材の平均径を吸着用焼結体(20)に含まれる粉末吸着材(1a,1b)の平均径とすることができる。
　粉末吸着材(1a,1b)の平均径が小さすぎると、製造時に樹脂構造体(2)の樹脂原料に微細な粉末吸着材(1a,1b)が大量に混合され、樹脂構造体(2)の強度が低下する可能性がある。また微細な遊離吸着材(1a)は、樹脂構造体(2)間の間隙(4)を通じて、流体(7)と共に吸着用焼結体(20)から離脱し易くなる可能性がある。更に、圧力損失も上昇し易くなる可能性がある。平均径が大きすぎると（例えば、１５０μm以上であると）、吸着材の吸着面積が小さく吸着性能が低下する傾向となる。また、十分な量の遊離吸着材(1a)を空隙(3)に収容できず、吸着用焼結体(20)の構成が困難となる傾向となる。
　図２ａ～図２ｅは、吸着用焼結体(20)を構成する粉末吸着材(1a,1b)の原料を示す電子顕微鏡写真画像である。特に、図２ａは、ヤシ殻の炭化物を水蒸気により、図２ｂは、大鋸屑を薬品（リン酸）により、図２ｃは、大鋸屑を薬品（塩化亜鉛）により、それぞれ賦活化した粉末活性炭の表面拡大画像（４００倍）を示す。粉末活性炭は、一般に、尖形部分を有する部分を有する塊状、棒状又は細長板状の原料であるため、粉末吸着材(1a,1b)は、遊動時に尖端が樹脂構造体(2)の表面(2a)及び間隙(4)に係止して、吸着用焼結体(20)の外部への流出を阻止する。このため、粉末吸着材(1a,1b)が、複数の空隙(3)間を移動することも殆ど無い。図２ｄは、粉末吸着材原料として、粉末活性白土を示し（４００倍）、図２ｅは、ゼオライトを示す（２０００倍）各表面拡大画像である。吸着用焼結体(20)は、粉末吸着材(1a,1b)を好ましくは２５～６５質量％含有し、さらに好ましくは３０～６０質量％で含有する。粉末吸着材(1a,1b)の含有率が低すぎると、吸着用焼結体(20)の吸着性能が低下する傾向となる。一方、粉末吸着材(1a,1b)の含有率が高すぎると、高吸着能であるが、樹脂割合が小さく吸着用焼結体(20)全体の強度が低下する傾向となる。本発明において、吸着用焼結体(20)に含まれる粉末吸着材(1a,1b)の含有率は、吸着用焼結体(20)の製造時に使用する、焼結前の吸着材混合物中に含まれる粉末吸着材の含有率として定義でき、吸着材混合物中の粉末吸着材の含有量を適宜設定することで調整することができる。
　樹脂構造体(2)の樹脂原料としては、熱可塑性樹脂が用いられる。好ましくは、ポリプロピレン（ＰＰ）、ポリエチレン（ＰＥ）、ポリフッ化ビニリデン（ＰＶＤＦ）、エチレン酢酸ビニル（ＥＶＡ）共重合体から選択される少なくとも１種の熱可塑性樹脂である。樹脂構造体(2)の樹脂原料としての熱可塑性樹脂は粒子状の固体で使用され、粉体、粒体、ペレット等のいずれの形態であってもよい。熱可塑性樹脂粒子の粒径は１０～２００μｍであるのが好ましい。熱可塑性樹脂の粒径を前記範囲とすることにより、空隙(3)の大きさをばらつき無く略均一寸法に形成し易くなる。熱可塑性樹脂には、その種類および特性に応じて、アジピン酸エステル等の可塑剤やエポキシ系化合物等の安定剤、フェノール系化合物等の酸化防止剤等を添加して使用することもできる。
　本明細書における熱可塑性樹脂の粒径は、CCDカメラで撮影した画像解析法により測定される。具体的には、画像解析式粒度分布測定装置（ジャスコインタナショナル社製VD-3000、セイシン企業社製PITA-04等）により、無作為に分散させた熱可塑性樹脂の粒子1400～15,000個を撮影して得られた画像から各粒子の個別粒径Dを算出し、Dの分布を作成したのちそのメディアン径を熱可塑性樹脂の粒径とする。なお、個別粒径Dは、画像中の粒子の最大幅を最大径D1、最小幅を最小径D2とし、両者の算術平均(D1 + D2)/2　によって求めることができる。
　図３は、粉末吸着材（1a,1b）を含まない吸着用焼結体であり、樹脂原料のみを焼結して樹脂構造体を形成し、カッターで切断した断面の状態を示す、電子顕微鏡による断面拡大画像（５００倍）である。図３の白色部は、角部が無い連続房状かつ三次元網目構造の樹脂構造体(2)を示し、その内側の黒色部は、遊動可能に遊離吸着材(1a)が配置される空隙(3)を示す。
　図１に示す吸着用焼結体(20)の粉末吸着材(1a,1b)は、樹脂構造体(2)間の空隙(3)に遊動可能に収容された遊離吸着材（遊離吸着剤）(1a)を含む。ここで、遊動可能とは、粉末吸着材が樹脂構造体(2)に固着されず又は複数の粉末吸着材が互いに固着せずに、移動、揺動、振動、回転、伸縮、拡大縮小又は浮沈等、あらゆる運動が可能であることを意味する。
　図１に示す吸着用焼結体(20)の粉末吸着材(1a,1b)は、樹脂構造体(2)に担持された固定吸着材(1b)を更に備える。固定吸着材(1b)は、樹脂構造体(2)の表面(2a)に固着され又は樹脂構造体(2)の内部に少なくともその一部が埋設される。すなわち、固定吸着材(1b)は、樹脂構造体(2)の表面(2a)に固着された第１の固定吸着材(1b1)、樹脂構造体(2)内部にその一部（一部表面）が埋設されかつ残部（残部表面）が樹脂構造体(2)から突出した第２の固定吸着材(1b2)、及び／または樹脂構造体(2)内部に全体（全表面）が埋設された第３の固定吸着材(1b3)と、が存在し得る。固定吸着材(1b)において、空隙(3)に表面が露出する第１及び第２の固定吸着材(1b1,1b2)は、吸着能向上に寄与すると共に、樹脂構造体(2)に固定されて小径でも外部に流出しない。第３の固定吸着材(1b3)は、樹脂構造体(2)内に包含されるため、低吸着能ではあるが、より小径の粉末吸着材(1a,1b)が樹脂構造体(2)に取り込まれ易い傾向にあるため、固定吸着材(1b3)も比較的小径の粉末吸着材から構成され、小径の粉末吸着材(1a,1b)が空隙(3)に大量残存することにより生じる閉塞を防止し、圧力損失上昇を抑止できる。
　吸着用焼結体(20)の製造工程において、粉末吸着材(1a,1b)のうち、粒子径の小さいものほど、樹脂構造体(2)の表面(2a)に固着され、あるいは樹脂構造体(2)の内部に少なくともその一部が埋設され易い傾向にあるため、固定吸着材(1b)は、遊離吸着材(1a)に比べ、相対的にその粒径が小さくなる傾向となる。また逆に、遊離吸着材(1a)は相対的にその粒径が大きくなる傾向となる。従って、吸着用焼結体(20)の原料として使用した、粉末吸着材に比べて、吸着用焼結体を切断するなどして、内部の遊離吸着材の一部又は全部を回収し、その平均径を測定した場合、通常、遊離吸着材の平均径は粉末吸着材の平均径よりも大きくなる。遊離吸着材(1a)の平均径は、好ましくは５μ以上、１５０μm未満、さらに好ましくは１５μ以上、１００μm以下である。固定吸着材(1b)の平均径は１～５０μm程度と推測される。
　図４ａ～図４ｃは、粉末吸着材原料として、ヤシ殻の炭化物を水蒸気で賦活して得られた粉末活性炭（図２ａ）、大鋸屑を薬品（リン酸）で賦活して得られた粉末活性炭（図２ｂ）及び大鋸屑を薬品（塩化亜鉛）で賦活して得られた粉末活性炭（図２ｃ）をそれぞれ用い製造された本発明による吸着用焼結体(20)の断面を各倍率で電子顕微鏡撮影した表面拡大画像を示す。何れも、黒色の空隙(3)を三次元網目状に形成して滑らかな丸みを帯びた表面(2a)を有する樹脂構造体(2)と、樹脂構造体(2)の内部に配置された粉末活性炭の遊離吸着材(1a)と、樹脂構造体(2)に固着した粉末活性炭の固定吸着材(1b)とを備える吸着用焼結体(20)を確認できる。樹脂骨格の内部の黒色の空隙(3)は、遊離吸着材(1a)が自由に運動できる三次元空間を構成する。固定吸着材(1b)は、その一部が樹脂構造体(2)の表面(2a)に固着され、また、その一部が表面(2a)の凹部(2b)に嵌合されて樹脂構造体(2)に保持され得る。
　本発明では、空隙(3)の遊離吸着材(1a)だけでなく、樹脂構造体(2)に固定吸着材(1b)が設けられるため、吸着面積及び飽和吸着容量を増大して高吸着性能を維持し得る。換言すると、樹脂構造体(2)には、特別な機能物質を付加しない限り吸着能が無いため、樹脂構造体(2)の表面(2a)又は内部に固定吸着材(1b)を担持させることにより、吸着用焼結体(20)全体の吸着性能を大幅に向上できる。また、本発明では、固定吸着材(1b)が樹脂構造体(2)間の間隙(4)から流出しない。
　図４ａ～図４ｃから確認できるように、１又は２以上の遊離吸着材(1a)が空隙(3)に遊動可能に収容される。２以上の遊離吸着材(1a)が１の空隙(3)に収容される場合、隣接する複数の遊離吸着材(1a)は、互いに固着せずに、少なくとも一部の空隙(3)の遊離吸着材(1a)間に流体(7)の流路(3a)（図１及び図６）を形成して、遊離吸着材(1a)の全表面吸着を可能にする。遊離吸着材(1a)が他の遊離吸着材(1a)に又は樹脂構造体(2)に一度接触しても、流体(7)の流動により、再び離間して流路(3a)を形成できる。
　図４ｄ及び図４ｅは、粉末吸着材原料として、活性白土（図２ｄ）及びゼオライト（図２ｅ）をそれぞれ用い製造された本発明の吸着用焼結体(20)の断面を電子顕微鏡撮影した表面拡大画像（１５００倍）を示す。図４ｄ及び図４ｅから、黒色の空隙(3)を三次元網目状に形成して滑らかな丸みを帯びた表面(2a)を有する灰色の樹脂構造体(2)と、樹脂構造体(2)の内部に配置された遊離吸着材(1a)としての大径の粉末活性白土及びゼオライトと、樹脂構造体(2)に固着した固定吸着材(1b)としてのより小径の粉末活性白土及びゼオライトとを備える吸着用焼結体(20)を確認できる。
　吸着用焼結体(20)を充填した本発明の吸着装置は、単一層又は複数層の吸着用焼結体(20)を例えば図１０の符号(81)に示すように容器に装填して形成される。容器内に粒状吸着材を直接充填した従来技術と比べ、本発明の吸着装置は、機械的強度の高い樹脂構造体(2)により、搬送時及び使用時等において、容器内の吸着材が粉砕、破壊等され、圧力損失が上昇するなどの不具合を生じることなく、一定の形態及び空隙(3)を維持できる。図５は、二層(20a,20b)の吸着装置(30)を示す。例えば、円柱状若しくは角柱状又は内部空洞を有する形状の吸着用焼結体(20)の各層(20a,20b)を順次、例えば直列に装填又は積層しても、剛性を保持して各層(20a,20b)が混ざり合わない。図５は、二層(20a,20b)の吸着装置(30)を示すが、三層以上に積層した吸着装置も形成可能である。
　原料として粉末活性炭を用いた本発明による吸着用焼結体(20)の製造方法の一態様を以下に説明する。
　最初に、粉末吸着材(1a,1b)を構成する原料として粉末活性炭（粉末吸着材原料）と、樹脂構造体(2)を構成する樹脂原料としての熱可塑性樹脂とを混合し、吸着材混合物を形成する。吸着材混合物には、必要により、その他の任意成分が含まれていてもよい。吸着材混合物中の粉末活性炭の含有率は２５～６５質量％が好ましく、３０～６０質量％がより好ましい。吸着材混合物中の熱可塑性樹脂の含有率は３５～７５質量％が好ましく、４０～７０質量％がより好ましい。粉末活性炭の平均径は１５０μm未満が好ましく、より好ましくは１μｍ以上、１５０μｍ未満であり、さらに好ましくは５μｍ以上、１５０μｍ未満であり、特に好ましくは１５μｍ以上、１００μｍ以下である。熱可塑性樹脂の粒径は１０～２００μmが好ましく、３０～８０μｍがより好ましい。粉末活性炭は、破砕、膨張、収縮することが殆ど無く、当初の大きさを維持しながら粉末吸着材(1a,1b)を形成できる。粉末吸着材原料と製造後の粉末吸着材(1a,1b)との粉末径がほぼ等しいことは、例えば、等倍率（４００倍）の画像を示す図２ａと図４ａ、図２ｂと図４ｂからも見て取れる。熱可塑性樹脂は、ポリプロピレン、ポリエチレン、ポリフッ化ビニリデン及びエチレン酢酸ビニル共重合体から選ばれる少なくとも１種が好ましい。本発明において、発泡剤を使用する必要はない。粉末活性炭の含水率は、好ましくは３０質量％以下、より好ましくは１５質量%以下、より好ましくは８質量%以下、特に好ましくは実質的に水分を含まないものが好ましい。粉末活性炭の含水率が低いと、後述の加熱工程において、粉末活性炭付近の温度が低下せずエネルギ消費を抑え、より短時間でかつ安定的に吸着用焼結体を形成できる。なお熱可塑性樹脂については、本発明に使用するのに好ましいポリプロピレン（ＰＰ）、ポリエチレン（ＰＥ）、ポリフッ化ビニリデン（ＰＶＤＦ）、エチレン酢酸ビニル（ＥＶＡ）共重合体から選択される少なくとも１種の熱可塑性樹脂を使用する限り、これらは一般に水の吸収性に乏しく、本発明の吸着用焼結体(20)の製造方法において含水率の影響を考慮する必要はない。
　粉末吸着材の含水率は、以下のように測定される。粉末吸着材を1～3g測りとり(w1)、110℃にて質量変化率が0.05%/min以下となるまで十分な時間乾燥させ、乾燥後の質量(w2) を測定したとき、含水率(%)は100×(w1-w2)/w2となる。
　次に、吸着材混合物を加熱炉に導入して、熱可塑性樹脂の軟化点より高くかつ粉末活性炭の融点より低い温度、例えば９０～１８０℃で吸着材混合物を加熱する。加熱により、複数の熱可塑性樹脂の接触部分が溶融し接合部を形成し、熱可塑性樹脂が互いに融着して空隙(3)を包囲する骨格を形成する。このとき、大部分の粉末活性炭は、熱可塑性樹脂に固着等しない。その後、冷却固化して、空隙(3)に遊動可能に遊離吸着材(1a)を収容した三次元網目状の樹脂構造体(2)が形成される。樹脂構造体(2)は立体格子状の三次元網目構造を有していてもよい。これにより、粉末活性炭からなる遊離吸着材(1a)を含む、高強度の吸着用焼結体(20)が製造される。図４ａ～図４ｃは、本発明の製造方法により粉末活性炭を原料として製造された吸着用焼結体(20)の各実施の形態の例である。本発明の吸着用焼結体(20)の製造において、好ましくは含水率の低い粉末活性炭および熱可塑性樹脂を樹脂原料として使用することにより、水分の激しい蒸発及び発泡による空隙の拡大を抑制でき、適度な寸法の空隙(3)を均一に形成し得る。含水率の低い原料を使用することで、加熱工程において、水分の影響を受けずに加熱源近位の外部から遠位の内部まで均一伝熱し温度差が無く、熱可塑性樹脂全体を均一に溶融できる。また、粉末活性炭から水分が殆ど蒸発放出せず、樹脂構造体(2)形成段階の熱可塑性樹脂に外力が加わらず変形が無いため、空隙(3)が膨張しないで所定範囲内の略均一な大きさに形成維持され得る。また、このような適度な寸法と空隙(3)を均一に形成する観点から、熱可塑性樹脂の粒径は１０～２００μｍが好ましく、３０～８０μｍがより好ましい。
　前記製造方法の実施の形態では、粉末活性炭を原料としたが、粉末活性白土又はゼオライトを原料に用いても、前記同様の製造方法により、吸着用焼結体(20)を製造できる（図４ｄ及び図４ｅ）。
　本発明による吸着用焼結体(20)に流体(7)を通液又は通気した実施の形態を図６より以下説明する。
　単一層の吸着用焼結体(20)を装填した吸着装置（図示せず）に、被処理物質を含む流体(7)を通過させると、流体(7)は、樹脂構造体(2)間の間隙(4)を通過して空隙(3)に導入される。このとき、遊離吸着材(1a)は、樹脂構造体(2)に無接合状態のため、また、複数の遊離吸着材(1a)は互いに固着又は結合していないため、図６のように、流動する流体(7)により空隙(3)内を遊動又は揺動し、遊離吸着材(1a)の全表面が流体(7)に直接接触して、流体(7)中の被処理物質を確実に捕捉吸着する。また、遊離吸着材(1a)間に形成された流路(3a)によって、吸着面積増大と共に、流体(7)の流れを確保して吸着用焼結体(20)の圧力損失上昇を防止できる。
　また、流体(7)は、樹脂構造体(2)の表面(2a)又は内部に固定された固定吸着材(1b)にも接触して、流体(7)中の被処理物質が捕捉吸着される。空隙(3)で処理された流体(7)は、間隙(4)を通過して他の空隙(3)に連続的に導入される。複数の他の空隙(3)でも同様の吸着処理を繰り返し、最終的に樹脂構造体(2)の外部、即ち吸着装置の外部に流出される。間隙(4)は小さいため、遊動する遊離吸着材(1a)は、樹脂構造体(2)間の空隙(3)に保持され、吸着用焼結体(20)の外部に流出しない。
　本発明の吸着用焼結体(20)は、吸着性能に優れる粉末吸着材を高い含有率で含有させることができ、被処理物質を高い効率で吸着処理が可能である。本発明の吸着用焼結体(20)は、強度にも優れるため、フィルタ等の用途において、カートリッジ等の容器に充填して使用する場合も、容器を小型化でき、フィルタ等の吸着装置の小型化を達成し得、運搬性、保管性も極めて良好なものとすることができる。
　本発明の吸着用焼結体(20)は、圧力損失の上昇による吸着性能の低下が抑制され、所定処理量を保持しつつ吸着性能を長期間持続可能であるため、ランニングコストの低減を図ることができる。
　本発明の吸着用焼結体(20)は、吸着性能に優れる粉末活性炭を焼結体として所望の形態及び大きさに一体成形でき、様々な形態の連続式の吸着処理が可能となる。更に、容器中に異なる吸着特性の複数の層を用途に応じて装填することもできるため、多機能を具備する吸着装置を提供できる。
　また本発明の吸着用焼結体(20)は、バッチ式（回分式）の吸着処理にも使用し得る。粉末吸着材を使用したバッチ式の吸着処理では、粉末吸着材が空気中に飛散し易いため取扱い性が低く、局所排気設備の設置等により、粉塵による作業環境悪化を防ぐ対策が必要となる場合があるが、本発明の吸着用焼結体(20)は取扱い性も良好である。
［実施例］
　以下、本発明による吸着用焼結体(20)の実施例を説明する。
［１］圧力損失試験
　本発明の吸着用焼結体(20)（実施例１～４）の圧力損失について、粉末体(69)（比較例１～４並びに比較例１’及び２’）と共に下記試験を行った。
［１－１］吸着用焼結体(20)及び粉末体(69)の製造
　粉末吸着材(1a,1b)の原料としてヤシ殻の炭化物を水蒸気で賦活した平均粒子径約30μmの粉末活性炭（図２ａ）０.１０９質量部と樹脂構造体(2)の樹脂原料としてポリエチレン粉末０.１６４質量部とを混合し、約１２５℃で加熱焼結して、粉末吸着材(1a,1b)を４０質量%含有する本発明の吸着用焼結体(20)（図４ａ）（実施例１）を得た。同様に、粉末吸着材(1a,1b)の原料として大鋸屑を薬品（リン酸）で賦活した平均粒子径約42μmの粉末活性炭（図２ｂ）０.１０９質量部と樹脂構造体(2)の樹脂原料としてポリエチレン粉末０.１０９質量部とを混合し、約１２５℃で加熱焼結して、粉末吸着材(1a,1b)を４０質量%含有する本発明の吸着用焼結体(20)（図４ｂ）（実施例２）を得た。実施例１及び２に使用した原料の粉末活性炭の含水率は何れも約７質量%であった。粉末吸着材(1a,1b)の原料として平均粒子径約11μmの粉末活性白土（図２ｄ）０.１３９質量部と樹脂構造体(2)の樹脂原料としてポリエチレン粉末０.１３９質量部とを混合し、約１２５℃で加熱焼結して、粉末吸着材(1a,1b)を５０質量%含有する本発明の吸着用焼結体(20)（図４ｄ）（実施例３）を得た。粉末吸着材(1a,1b)の原料として平均粒子径約35μmのゼオライト（図２ｅ）０.１３９質量部と樹脂構造体(2)の樹脂原料としてポリエチレン粉末０.１３９質量部とを混合し、約１２５℃で加熱焼結して、粉末吸着材(1a,1b)を５０質量%含有する本発明の吸着用焼結体(20)（図４ｄ）（実施例４）を得た。実施例３及び４に使用した原料の粉末活性白土及びゼオライトの含水率は何れも約７質量%であった。
　ヤシ殻の炭化物を水蒸気で賦活した平均粒子径約30μmの粉末活性炭（図２ａ）０.１０９質量部を粉末体(69)として得た（比較例１）。ヤシ殻の炭化物を水蒸気で賦活した平均粒子径約30μmの粉末活性炭（図２ａ）から振動分級機（フリッチュ社製）により３２μm以下を分級除去した粉末活性炭０.１０９質量部を粉末体(69)として得た（比較例１’）。大鋸屑を薬品（リン酸）で賦活した平均粒子径約42μmの粉末活性炭（図２ｂ）０.１０９質量部を粉末体(69)として得た（比較例２）。大鋸屑を薬品（リン酸）で賦活した平均粒子径約42μmの粉末活性炭（図２ｂ）から振動分級機により３２μm以下を分級除去した粉末活性炭０.１０９質量部を粉末体(69)として得た（比較例２’）。平均粒子径約11μmの粉末活性白土（図２ｄ）０.１０９質量部を粉末体(69)として得た（比較例３）。平均粒子径約35μmのゼオライト（図２ｅ）０.１０９質量部を粉末体(69)として得た（比較例４）。
［１－２］試験方法
＜実施例１～４＞
　容積約３mlの各シリンジ(61)内にフリット（粉体流出防止用フィルタ）(62a)を配置し、その上に実施例１～４の吸着用焼結体(20)を各々装填し、更にフリット(62b)を配置して、図７の圧力損失用試験装置(60)とした。流量計(64)で０.２L/分に調整した空気を吸着用焼結体(20)に流したときの吸着用焼結体(20)間の差圧を圧力計（キーエンス社製　AP-53A）(63)により各実施例１～４について測定した。
＜比較例１～４並びに比較例１’及び２’＞
　吸着用焼結体(20)の代わりに、比較例１～４並びに比較例１’及び２’の各粉末体(69)をシリンジ(61)に充填した以外は、前記実施例同様な試験方法で各比較例の差圧を測定した。
［１－３］試験結果及び考察
　横軸に試験対象物名、縦軸に差圧［kPa］を示す図８の圧力損失試験結果の通り、粉末活性炭を充填した比較例１及び２は５０kPa以上の高差圧値を示し、更に３２μm以下の粉末活性炭を分級除去した比較例１’及び２’も３０kPa以上の高差圧値を示した。比較例１及び２は、３２μm以下の微細粉末を含む粉末活性炭が高密度で充填され、比較例１’及び２’も粉末活性炭が高密度で充填されて、粉末間の空隙が小さいため、高圧力損失であった。これに対し、実施例１及び２の本発明による吸着用焼結体(20)は、比較例と同量の粉末活性炭に加えて樹脂構造体(2)を含むにも関わらず、何れも１０kPa以下の低差圧値を示した。粉末活性白土及びゼオライトの粉末体(69)を充填した比較例３及び４は、それぞれ２９kPa及び９７kPaの高差圧値を示した。比較例３及び４は、微細な粉末が高密度で充填されて、粉末間の空隙が小さいため高圧力損失であった。これに対し、実施例３及び４の本発明による吸着用焼結体(20)は、比較例３及び４と同量の粉末活性白土及びゼオライトに加え樹脂構造体(2)を含むにも関わらず、何れも１０kPa以下の低差圧値を示した。よって、本発明の実施例１～４では、低圧力損失処理の実現を確認できた。また、実施例１～４の吸着用焼結体(20)は強度にも優れていた。
［２］通液吸着試験
　本発明の吸着用焼結体(20)（実施例５及び６）の通液吸着性能について、粒状活性炭を使用した粒状体(89)（比較例５及び６）と共に下記試験を行った。
［２－１］吸着用焼結体(20)及び粒状体(89)の製造
　粉末吸着材(1a,1b)の原料としてヤシ殻の炭化物を水蒸気で賦活した平均粒子径約30μmの粉末活性炭（図２ａ）０.０７６質量部と樹脂構造体(2)の樹脂原料としてのポリエチレン粉末０.１７７質量部とを混合し、約１２５℃で加熱焼結して、粉末吸着材(1a,1b)を３０質量%含有する本発明による高強度の吸着用焼結体(20)（図４ａ）（実施例５）を得た。同様に、粉末吸着材(1a,1b)の構成原料として大鋸屑を薬品（リン酸）で賦活した平均粒子径約42μmの粉末活性炭（図２ｂ）０.０７６質量部と樹脂構造体(2)の樹脂原料としてのポリエチレン粉末０.１７７質量部とを混合し、約１２５℃で加熱焼結して、粉末吸着材(1a,1b)を３０質量%含有する本発明による高強度の吸着用焼結体(20)（図４ｂ）（実施例６）を得た。実施例５及び６に使用する粉末活性炭の含水率は約８質量%であった。
　ヤシ殻の炭化物を水蒸気で賦活した平均径８００μm程度の粒状活性炭０.０７６質量部と直径１００μmポリエチレンビーズ０.１７７質量部とを混合して粒状体(89)（比較例５）を得た。粒径８００μm程度の大径の粒状活性炭では、樹脂構造体間の空隙に遊動可能に活性炭を配置した本発明の吸着用焼結体を形成できず、また、粉末に比べ粒数が極めて少ないため、活性炭が存在しない空隙も多数形成されるため、可能な限り実施例５同様の条件にすべくポリエチレン粉末と同量のポリエチレンビーズを使用した。同様に、大鋸屑原料を薬品（リン酸）で賦活した平均径８００μm程度の粒状活性炭０.０７６質量部と直径１００μmポリエチレンビーズ０.１７７質量部とを混合して粒状体(89)（比較例６）を得た。尚、平均径８００μmは、液相処理で多用される粒状活性炭の粒径に相当する。
［２－２］試験方法
＜実施例５及び６＞
　通液吸着試験装置(80)により、実施例５及び６の吸着用焼結体(20)を各々装填した内径８.６mmの容器(81)に対し、容器(82)に貯めた濃度１２００mg/lのメチレンブルー溶液２０mlをチューブポンプ(83)により３.２ml/分で送液し循環させた（図１０）。一定時間毎に０.１mlずつ循環液を採取し１００倍に希釈した後、分光光度計（島津製作所製　UV-1700)で波長６６５nmの吸光度を測定し、実施例５及び６について循環液のメチレンブルー残留濃度を求めた。
＜比較例５及び６＞
　吸着用焼結体(20)の代わりに、各容器(81)に充填した比較例５及び６の粒状体(89)を使用した以外は、前記実施例５及び６と同様な試験方法で比較例５及び６についてメチレンブルー残留濃度を求めた。
［２－３］試験結果及び考察
　図１１ａは、実施例５及び比較例５の試験結果を示し、図１１ｂは、実施例６及び比較例６の試験結果を示し、それぞれ横軸に時間［分］、縦軸にメチレンブルー残留濃度［mg/l］を表す。例えば１０分後のメチレンブルー残留濃度を比較すると、図１１ａより、比較例５では約７８０mg/lであるのに対し、実施例５では約３００mg/lまで減少した。また、図１１ｂより、比較例６では約５００mg/lであるのに対し、実施例６では３００mg/l以下まで減少した。従って、粒径８００μmの粒状活性炭のみを含む比較例５及び６に比べ、粉末吸着材(1a,1b)を３０質量%含む本発明の実施例５及び６では、液体の吸着性能、特に脱色特性に優れていることを確認できた。また、実施例５及び６の吸着用焼結体(20)は強度にも優れていた。
［３］通気吸着試験
　本発明の吸着用焼結体(20)（実施例５）の通気吸着性能について、粒状活性炭を使用した粒状体(99)（比較例７及び８）と共に下記試験を行った。
［３－１］吸着用焼結体(20)及び粒状体(99)の製造
　実施例５の吸着用焼結体(20)は前記同様の方法により得られた。ヤシ殻の炭化物を水蒸気で賦活した平均径２０００μm程度の粒状活性炭０.０７６質量部と直径１００μmポリエチレンビーズ０.１７７質量部とを混合して粒状体(99)（比較例７）を得た。粒径２０００μm程度の大径の粒状活性炭では、樹脂構造体間の空隙に遊動可能に活性炭を配置した本発明の吸着用焼結体を形成できず、また、粉末に比べ粒数が極めて少ないため、活性炭が存在しない空隙も多数形成されるため、可能な限り実施例５同様の条件にすべくポリエチレン粉末と同量のポリエチレンビーズを使用した。ヤシ殻の炭化物を水蒸気で賦活した平均径２０００μm程度の粒状活性炭０.０７６質量部のみの粒状体(99)（比較例８）を得た。尚、平均径２０００μmは、気相処理で多用される粒状活性炭の粒径に相当する。
［３－２］試験方法
　＜実施例５＞
　図１２に示す通気吸着試験装置(90)により、シクロヘキサンを含浸させた供給源を内部に配置してシクロヘキサンガス濃度を約１００ppmに調製したガス捕集袋(92)から、ダイヤフラムポンプ(93)によって、吸着用焼結体(20)（実施例５）を装填した内径８.６mmの容器(91)に対し、シクロヘキサンガスを０.２ml/分で供給した。吸着用焼結体(20)通過後の出口ガスを１０分間で２L採取し、ガス検知管（ガステック社　102L）により１０分毎のシクロヘキサン濃度を測定した。また、官能試験により出口ガスの臭気を評価した。
＜比較例７及び８＞
　吸着用焼結体(20)の代わりに、容器(81)に充填した比較例７及び８の粒状体(99)をそれぞれ使用した以外は、実施例５同様な試験方法でシクロヘキサン濃度を測定し、官能試験をした。
［３－３］試験結果及び考察
　図１３は、実施例５並びに比較例７及び８の試験結果を示し、横軸に時間［分］、縦軸にシクロヘキサン濃度［ppm］を表す。比較例７及び８では最初の１０分からシクロヘキサンが破過するのに対し、実施例５では６０分でもシクロヘキサンが破過せず完全に吸着を持続した。また、官能試験の結果、比較例７及び８では、最初の１０分から出口ガスのシクロヘキサン臭気を感じたのに対し、実施例５では臭気を全く感じなかった。従って、粉末吸着材(1a,1b)を３０質量%含む本発明の実施例５では、気体の吸着性能、特に脱臭性及び有害ガス除去特性に優れていることを確認できた。
［４］焼結性及び強度確認試験
　粉末吸着材(1a,1b)を含む吸着用焼結体(20)の焼結性及び強度を確認した。
［４－１］吸着用焼結体(20)製造及び試験方法
　吸着用焼結体(20)が０.２７３gとなるように、粉末吸着材(1a,1b)の構成原料として大鋸屑を薬品（リン酸）で賦活した平均粒子径約42μmの粉末活性炭（図２ｂ）と、樹脂構造体(2)を形成するポリエチレン粉末とを混合し約１２５℃で加熱焼結して、粉末吸着材(1a,1b)をそれぞれ５０及び６０質量%含有する吸着用焼結体(20)（実施例７及び８）を得た。大鋸屑の粉末活性炭を使用する理由は、前記実施例１～６では、他の原料に比べ大鋸屑が比較的強度が弱く、大鋸屑粉末活性炭で高焼結性及び高強度を確認できれば、他のヤシ殻粉末活性炭、粉末活性白土及びゼオライトでも当然に十分な焼結性及び強度が得られると予測できるからである。
［４－２］試験方法
　実施例７～８について、外観目視により焼結性、及び触手により強度をそれぞれ確認した。
［４－３］試験結果及び考察
　粉末吸着材(1a,1b)を３０質量％（実施例６）、４０質量％（実施例２）、５０質量％（実施例７）及び６０質量％（実施例８）含有する吸着用焼結体(20)は、いずれも加熱炉から形状を維持した状態で取り出すことができ、強く押圧しても形状が変形せず十分な強度を確認できた。
［５］回分式液相吸着試験
　本発明の吸着用焼結体(20)の回分式液相吸着性能について、粉末活性白土(図2d)と共に下記試験を行った。
［５－１］吸着用焼結体(20)製造
　粉末吸着材(1a,1b)の原料として平均粒子径約11μmの粉末活性白土（図２ｄ）０.１９７質量部と樹脂構造体(2)の樹脂原料としてポリエチレン粉末０.１３１質量部とを混合し、約１２５℃で加熱焼結して、粉末吸着材(1a,1b)を６０質量%含有する本発明の吸着用焼結体(20)（実施例９）を得た。使用した粉末活性白土の含水率は約７質量%であった。
［５－２］試験方法
＜実施例９＞
　１００ml三角フラスコに実施例９の吸着用焼結体(20)を入れ、濃度１００mg/lのカフェイン水溶液５０mlを加え、ゴム栓をして振とう機にセットし、吸着がほぼ平衡に達するまで常温(20℃)、２００rpmで振とうした。振とう後の液を採取し、高速液体クロマトグラフ装置（日立ハイテクサイエンス社製　Chromaster（登録商標）)を用いてカフェインを分離し、波長２８０nmの吸光度より実施例９についてのカフェイン残留濃度を測定し、カフェインの吸着除去率を求めた。
＜比較例９＞
　吸着用焼結体(20)の代わりに、粉末活性白土（図２ｄ）０.１９７質量部を使用した以外は、前記実施例９と同様な試験方法でカフェインの吸着除去率を求めた。
［４－３］試験結果及び考察
　実施例９、比較例９ともにカフェインの吸着除去率は97%と等しい値を示した。したがって、粉末吸着材(1a,1b)の吸着性能は吸着用焼結体(20)中にあっても高度に維持されていることを確認できた。また、実施例９の吸着用焼結体(20)は強度にも優れていた。
［６］回分式気相吸着試験
　本発明の吸着用焼結体(20)の回分式気相吸着性能について、薬品担持ゼオライトと共に下記試験を行った。
［６－１］吸着用焼結体(20)製造
　粉末吸着材(1a,1b)の原料として、平均粒子径約35μmに粉砕した薬品担持ゼオライト０.０５５質量部と樹脂構造体(2)の樹脂原料としてポリエチレン粉末０.０５５質量部とを混合し約１２５℃で加熱焼結して、粉末吸着材(1a,1b)を５０質量%含有する本発明による高強度の吸着用焼結体(20)（実施例１０）を得た。使用した薬品担持ゼオライトの含水率は約７質量%であった。
［６－２］試験方法
＜実施例１０＞
　ポリエステル製3Lにおい袋（近江オドエアーサービス社製）に実施例１０の吸着用焼結体(20)と約３cm四方のろ紙片を入れ、清浄空気を3L加えてゴム栓で封止した。ジメチルスルフィド（以下DMSと称する）3%溶液を、内部のDMS濃度が２００mg/m3となるようにマイクロシリンジでにおい袋に注入してろ紙片にしみこませ、注入口をセロハンテープで封止した。DMSをにおい袋内部で気化させ、吸着がほぼ平衡に達するまで常温(20℃)で静置した。ゴム栓を開けてにおい袋中のDMS濃度をガステック社製ガス検知管No.７７を用いて測定し、DMSの吸着除去率を求めた。
＜比較例１０＞
　吸着用焼結体(20)の代わりに、平均粒子径約35μmに粉砕した薬品担持ゼオライト０.０５５質量部を使用した以外は、前記実施例１０と同様な試験を行い、DMSの吸着除去率を求めた。
［６－３］試験結果及び考察
　実施例１０のDMSの吸着除去率は96%、比較例１０のDMSの吸着除去率は97%とほぼ等しい値を示した。したがって、粉末吸着材(1a,1b)の吸着性能は吸着用焼結体(20)中にあっても高度に維持されていることを確認できた。また、実施例１０の吸着用焼結体(20)は強度にも優れていた。
［７］実施例の結論
　前記実施例より、本発明の吸着用焼結体(20)は、高強度であると共に、液体及び気体において低圧力損失でも脱色及び脱臭等の優れた吸着性能を示すことを確認できた。
　本発明の吸着用焼結体、その製造方法および吸着装置は、大気浄化、ダイオキシン除去、排煙脱硫及び脱硝、工場の廃ガス及び廃液処理、浄水の高度処理、化学薬品の精製、食品及び飲料の脱色、家庭用浄水器、空気清浄機、冷蔵庫脱臭剤、ガスマスク等の様々な用途に使用できる。
　(1a,1b)・・粉末吸着材、　(1a)・・遊離吸着材、　(1b)・・固定吸着材、　(2)・・樹脂構造体、　(2a)・・表面、　(2b)・・凹部、　(3)・・空隙、　(20)・・吸着用焼結体、　(30)・・吸着装置、

Claims (14)

  1. 　粉末吸着材と、
    　空隙が三次元網目状に形成された樹脂構造体とを備え、
    　粉末吸着材は、樹脂構造体間の空隙に遊動可能に収容された遊離吸着材と、樹脂構造体の表面に固着され及び／又は樹脂構造体の内部に少なくともその一部が埋設された固定吸着材とを含み、
    　粉末吸着材は、粉末活性炭、粉末活性白土及びゼオライトから選ばれる少なくとも１種であることを特徴とする吸着用焼結体。
  2. 　粉末吸着材の平均径は、１５０μm未満である、請求項１に記載の吸着用焼結体。
  3. 　粉末吸着材を２５～６５質量％含有する、請求項１又は２に記載の吸着用焼結体。
  4. 　樹脂構造体の樹脂原料は、ポリプロピレン（ＰＰ）、ポリエチレン（ＰＥ）、ポリフッ化ビニリデン（ＰＶＤＦ）及びエチレン酢酸ビニル（ＥＶＡ）共重合体から選ばれる少なくとも１種の熱可塑性樹脂である、請求項１～３の何れか１項に記載の吸着用焼結体。
  5. 　熱可塑性樹脂の粒径は、１０～２００μmである、請求項１～４の何れか１項に記載の吸着用焼結体。
  6. 　複数の遊離吸着材は、少なくとも一部の空隙に遊動可能に収容され、隣接する複数の遊離吸着材は、互いに固着せずに、少なくとも一部の空隙の遊離吸着材間に流体の流路を形成する、請求項１～５の何れか１項に記載の吸着用焼結体。
  7. 　粉末吸着材は、尖形部分を有する粉末活性炭である、請求項１～６の何れか１項に記載の吸着用焼結体。
  8. 　流体中の被処理物質の吸着用である、請求項１～７の何れか１項に記載の吸着用焼結体。
  9. 　請求項１～８の何れか１項に記載の吸着用焼結体の単一又は複数の層を容器に装填したことを特徴とする吸着装置。
  10. 　粉末活性炭、粉末活性白土及びゼオライトから選ばれる少なくとも１種である粉末吸着材と、熱可塑性樹脂とを混合して、吸着材混合物を形成する工程と、
    　熱可塑性樹脂の軟化点より高くかつ粉末吸着材原料の融点より低い温度で吸着材混合物を加熱する工程と、
    　複数の熱可塑性樹脂を融着しかつ冷却固化して、空隙が三次元網目状に形成され、かつ空隙に遊離吸着材が遊動可能に収容された樹脂構造体を形成する工程とを含むことを特徴とする吸着用焼結体の製造方法。
  11. 　粉末吸着材の平均径は、１５０μm未満である、請求項１０に記載の製造方法。
  12. 　吸着材混合物中の粉末吸着材の含有率が２５～６５質量%である、請求項１０または１１に記載の製造方法。
  13. 　熱可塑性樹脂は、ポリプロピレン（ＰＰ）、ポリエチレン（ＰＥ）、ポリフッ化ビニリデン（ＰＶＤＦ）及びエチレン酢酸ビニル（ＥＶＡ）共重合体のから選ばれる少なくとも１種である、請求項１０～１２の何れか１項に記載の製造方法。
  14. 　熱可塑性樹脂の粒径は、１０～２００μmである、請求項１０～１３の何れか１項に記載の製造方法。
     
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