JP7369062B2 - Filter manufacturing method - Google Patents
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- JP7369062B2 JP7369062B2 JP2020031974A JP2020031974A JP7369062B2 JP 7369062 B2 JP7369062 B2 JP 7369062B2 JP 2020031974 A JP2020031974 A JP 2020031974A JP 2020031974 A JP2020031974 A JP 2020031974A JP 7369062 B2 JP7369062 B2 JP 7369062B2
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- 238000004519 manufacturing process Methods 0.000 title claims description 66
- 239000003054 catalyst Substances 0.000 claims description 190
- 239000002002 slurry Substances 0.000 claims description 144
- 239000003960 organic solvent Substances 0.000 claims description 91
- 238000000034 method Methods 0.000 claims description 34
- 239000007787 solid Substances 0.000 claims description 23
- 239000007788 liquid Substances 0.000 claims description 10
- 239000007921 spray Substances 0.000 claims description 8
- 238000009795 derivation Methods 0.000 claims description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 26
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 21
- 239000000463 material Substances 0.000 description 19
- 239000007789 gas Substances 0.000 description 15
- 238000006243 chemical reaction Methods 0.000 description 12
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 12
- 239000004810 polytetrafluoroethylene Substances 0.000 description 12
- 238000010586 diagram Methods 0.000 description 11
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 9
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 9
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 9
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 9
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 9
- 239000002245 particle Substances 0.000 description 8
- 239000004744 fabric Substances 0.000 description 7
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 6
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 6
- 239000012196 polytetrafluoroethylene based material Substances 0.000 description 6
- 239000004809 Teflon Substances 0.000 description 5
- 229920006362 Teflon® Polymers 0.000 description 5
- 239000000428 dust Substances 0.000 description 5
- 238000000354 decomposition reaction Methods 0.000 description 4
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 3
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 239000006185 dispersion Substances 0.000 description 3
- 235000019253 formic acid Nutrition 0.000 description 3
- 239000012528 membrane Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 238000005507 spraying Methods 0.000 description 3
- IKHGUXGNUITLKF-UHFFFAOYSA-N Acetaldehyde Chemical compound CC=O IKHGUXGNUITLKF-UHFFFAOYSA-N 0.000 description 2
- IKHGUXGNUITLKF-XPULMUKRSA-N acetaldehyde Chemical compound [14CH]([14CH3])=O IKHGUXGNUITLKF-XPULMUKRSA-N 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 150000002013 dioxins Chemical class 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 238000011068 loading method Methods 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000005871 repellent Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000001133 acceleration Effects 0.000 description 1
- 238000011001 backwashing Methods 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 239000007809 chemical reaction catalyst Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000006477 desulfuration reaction Methods 0.000 description 1
- 230000023556 desulfurization Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000002440 industrial waste Substances 0.000 description 1
- 239000012046 mixed solvent Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- -1 polytetrafluoroethylene Polymers 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 239000004071 soot Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000002341 toxic gas Substances 0.000 description 1
- 238000004056 waste incineration Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000002351 wastewater Substances 0.000 description 1
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- 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
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/36—After-treatment
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Filtering Materials (AREA)
- Catalysts (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Description
本開示は、フィルタの製造方法に関する。 The present disclosure relates to a method of manufacturing a filter.
特許文献１には、触媒粒子を担持した延伸ポリテトラフルオロエチレン（以下「ＰＴＦＥ」と記す）多孔質膜またはテープの製造方法が開示されている。かかる延伸ＰＴＦＥ多孔質膜またはテープの製造方法では、分散液中の触媒粒子の平均粒径は、含浸されるテープ状多孔質ＰＴＦＥの平均孔径よりも有意に小さく、かつ、０．００１～０．１μｍの範囲内とすることが好ましいとされている。また、テープ状多孔質ＰＴＦＥに所期の触媒担持量の１０倍量の触媒が含浸されるように触媒分散液等における触媒濃度を０．１～１０質量％の範囲内で任意に調整できることが好ましいとされている。
Patent Document 1 discloses a method for manufacturing a stretched polytetrafluoroethylene (hereinafter referred to as "PTFE") porous membrane or tape supporting catalyst particles. In such a method for producing an expanded porous PTFE membrane or tape, the average particle size of the catalyst particles in the dispersion is significantly smaller than the average pore size of the tape-shaped porous PTFE to be impregnated, and is in the range of 0.001 to 0.000. It is said that it is preferable to set it within the range of 1 μm. In addition, the catalyst concentration in the catalyst dispersion liquid etc. can be arbitrarily adjusted within the range of 0.1 to 10% by mass so that the tape-shaped porous PTFE is impregnated with catalyst in an
特許文献２には、ＰＴＦＥ分散系と触媒粒子を混合してスラリーを作成する工程と、そのスラリーを乾燥して作成した粉末からペーストを作成する工程と、そのペーストから作成したエレメントを加熱・延伸膨張し、ポリマー結節を有する多孔質延伸膨張ＰＴＦＥマトリックスにする工程と、含む化学的反応性基材の製造方法が開示されている。 Patent Document 2 describes a process of mixing a PTFE dispersion system and catalyst particles to create a slurry, a process of drying the slurry to create a paste from the powder, and heating and stretching an element created from the paste. A method of manufacturing a chemically reactive substrate is disclosed that includes expanding into a porous expanded PTFE matrix having polymer nodules.
しかしながら、特許文献１に開示された延伸ＰＴＦＥ多孔質膜またはテープの製造方法では、触媒粒子を微粒にするためには大きな粉砕動力が必要となるばかりか、ＰＴＦＥの平均孔径にあわせて触媒粒子径を調整する必要があり、先ず触媒粉体を準備するのに非常に多くのエネルギーを必要とし高コストになり、延伸時には触媒担持分布が生じ、排ガスと触媒の接触効率が低下するという課題がある。また、触媒濃度は０．１～１０質量パーセントの範囲内でしか適用できないため、触媒担持量を増加させるには複数の含浸工程が必要となり、製造コスト、製造時間が増大するという課題がある。更に、含浸により触媒を担持しているため、触媒スラリーにテープ状多孔質ＰＴＦＥ全体を含浸させる必要があり、廃棄する触媒粉末や溶媒が増えるという課題がある。 However, in the method for manufacturing an expanded porous PTFE membrane or tape disclosed in Patent Document 1, not only is a large crushing power required to make the catalyst particles into fine particles, but the catalyst particle size is adjusted to match the average pore size of PTFE. First, it requires a large amount of energy to prepare the catalyst powder, resulting in high costs, and there is a problem that the catalyst loading distribution occurs during stretching, reducing the contact efficiency between the exhaust gas and the catalyst. . Further, since the catalyst concentration can only be applied within the range of 0.1 to 10% by mass, multiple impregnation steps are required to increase the amount of catalyst supported, resulting in an increase in manufacturing cost and manufacturing time. Furthermore, since the catalyst is supported by impregnation, it is necessary to impregnate the entire tape-shaped porous PTFE with the catalyst slurry, which poses the problem of increasing amounts of catalyst powder and solvent to be discarded.
また、特許文献２に開示された化学的反応性基材の製造方法では、加熱・延伸膨張するエレメント（ペースト）に含まれる触媒粒子が原因でエレメントに欠点が生じ、また延伸膨張性が悪くなるという課題がある。また、触媒粒子が含まれるエレメント（ペースト）を延伸膨張すると、高延伸倍率を実現できないという課題がある。特にエレメント（ペースト）に欠点がある場合に延伸倍率が低くなり多孔質マトリックスの強度が不十分となるちという課題がある。 In addition, in the method for manufacturing a chemically reactive base material disclosed in Patent Document 2, catalyst particles contained in the element (paste) that is heated and stretched and expanded cause defects in the element, and the stretching and expanding properties deteriorate. There is a problem. Furthermore, when an element (paste) containing catalyst particles is stretched and expanded, there is a problem that a high stretching ratio cannot be achieved. In particular, when the element (paste) has a defect, the stretching ratio becomes low and the strength of the porous matrix becomes insufficient.
本開示は、上述する事情に鑑みてなされたもので、テフロン（登録商標）等のＰＴＦＥ系の材料をろ材に採用したフィルタを低コストで製造し、かつガスとの高い接触効率を実現するフィルタの製造方法を提供することを目的とする。 The present disclosure has been made in view of the above-mentioned circumstances, and provides a filter that uses a PTFE-based material such as Teflon (registered trademark) as a filter material, is manufactured at low cost, and achieves high contact efficiency with gas. The purpose is to provide a manufacturing method for.
上記目的を達成するため、少なくとも一実施形態に係るフィルタの製造方法は、
ろ材ごとに、触媒スラリーに含まれる有機溶媒／水系中の前記有機溶媒の濃度と前記触媒スラリーを前記ろ材に塗布したときに前記ろ材に担持される触媒の担持量との関係を導き出す関係導出ステップと、
前記関係導出ステップにおいて導き出された前記関係に基づいて前記ろ材に担持させる目標担持量から前記有機溶媒の濃度を決定する濃度決定ステップと、
前記濃度決定ステップにおいて決定された前記有機溶媒の濃度以上の前記触媒スラリーを製造するスラリー製造ステップと、
前記スラリー製造ステップにおいて製造された前記触媒スラリーを前記ろ材に塗布するスラリー塗布ステップと、
を有する。
In order to achieve the above object, a method for manufacturing a filter according to at least one embodiment includes:
A relationship derivation step of deriving, for each filter medium, a relationship between the concentration of the organic solvent in the organic solvent/aqueous system contained in the catalyst slurry and the amount of catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium. and,
a concentration determining step of determining the concentration of the organic solvent from the target amount supported on the filter medium based on the relationship derived in the relationship deriving step;
a slurry production step of producing the catalyst slurry having a concentration of the organic solvent determined in the concentration determination step or higher;
a slurry application step of applying the catalyst slurry produced in the slurry production step to the filter medium;
has.
少なくとも一実施形態に係るフィルタの製造方法によれば、ろ材ごとに、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度と触媒スラリーをろ材に塗布したときにろ材に担持される触媒の担持量との関係を導き出すので、はっ水性を有する材料、例えばテフロン等のＰＴＦＥ系の材料を含むろ材を採用したフィルタを低コストで製造できる。また、ろ材上に触媒を均一に塗布できるので、ガスとの高い接触効率が実現できる。 According to the filter manufacturing method according to at least one embodiment, the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system and the concentration of the catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium are determined for each filter medium. Since the relationship with the supported amount is derived, it is possible to manufacture a filter using a filter medium containing a water-repellent material, for example, a PTFE-based material such as Teflon, at a low cost. Furthermore, since the catalyst can be applied uniformly onto the filter medium, high contact efficiency with gas can be achieved.
以下、添付図面を参照して幾つかの実施形態に係るフィルタの製造方法について説明する。ただし、実施形態として記載されている又は図面に示されている構成部品の寸法、材質、形状、その相対的配置等は、本発明の範囲をこれに限定する趣旨ではなく、単なる説明例にすぎない。 Hereinafter, methods for manufacturing filters according to some embodiments will be described with reference to the accompanying drawings. However, the dimensions, materials, shapes, relative arrangements, etc. of the components described as the embodiments or shown in the drawings are not intended to limit the scope of the present invention thereto, and are merely illustrative examples. do not have.
ここで説明するフィルタは、一例として、バグフィルタとも称されるフィルタであって、例えば、石炭焚ボイラの排ガス処理装置、油焚ボイラの排ガス処理装置、一般廃棄物処理プラントの排ガス処理装置、又は、産業廃棄物焼却プラント排ガス処理装置（脱硫装置、脱硝装置又は除塵装置を含む）、セメントプラントや製鉄プラント排ガスなど煤塵を含む排ガスの除塵装置に用いられる。また、このフィルタはガスタービンの排ガス浄化システム、その他有毒ガス処理システムの除塵機能として、ＨＥＰＡフィルタなどにも使用できる。 The filter described here is, for example, a filter also called a bag filter, and is used, for example, in an exhaust gas treatment device of a coal-fired boiler, an exhaust gas treatment device of an oil-fired boiler, an exhaust gas treatment device of a general waste treatment plant, or It is used in industrial waste incineration plant exhaust gas treatment equipment (including desulfurization equipment, denitrification equipment, or dust removal equipment), and dust removal equipment for exhaust gas containing soot and dust, such as cement plant and steel plant exhaust gas. Furthermore, this filter can also be used as a HEPA filter, etc. as a dust removal function in gas turbine exhaust gas purification systems and other toxic gas treatment systems.
また、ここで説明するフィルタは、ろ材（例えばろ布）に触媒（例えば、脱硝触媒、酸化触媒、ダイオキシン類分解触媒（ＤＸＮｓ分解触媒）等）を担持した触媒付きフィルタである。触媒付きフィルタは触媒を水に添加した触媒スラリーをろ材（ろ布）表面に均一に塗布することによって製造される。これまでろ材には主にガラス素材が用いられてきたが、ここで説明するろ材には、テフロン等のＰＴＦＥ系の材料を含む素材が用いられる。また、ＰＴＦＥ系材質を含む素材ははっ水性を有することから、ここで説明する触媒スラリーには、触媒を有機溶媒／水系に添加したものが用いられる。 Moreover, the filter described here is a filter with a catalyst, in which a catalyst (for example, a denitrification catalyst, an oxidation catalyst, a dioxins decomposition catalyst (DXNs decomposition catalyst), etc.) is supported on a filter medium (for example, a filter cloth). A filter with a catalyst is manufactured by uniformly applying a catalyst slurry, which is a mixture of a catalyst and water, onto the surface of a filter medium (filter cloth). Until now, glass materials have been mainly used for filter media, but the filter media described here uses a material containing a PTFE-based material such as Teflon. Furthermore, since materials containing PTFE-based materials have water repellency, the catalyst slurry described here uses a catalyst added to an organic solvent/water system.
図１は、一実施形態に係るフィルタの製造方法を概略的に示すフローチャートである。
図１に示すように、一実施形態に係るフィルタの製造方法は、関係導出ステップ（Ｓ１１）、濃度決定ステップ（Ｓ１２）、スラリー製造ステップ（Ｓ１３）及びスラリー塗布ステップ（Ｓ１４）を有する。
FIG. 1 is a flowchart schematically showing a method for manufacturing a filter according to an embodiment.
As shown in FIG. 1, the filter manufacturing method according to one embodiment includes a relationship derivation step (S11), a concentration determination step (S12), a slurry manufacturing step (S13), and a slurry application step (S14).
関係導出ステップ（Ｓ１１）では、ろ材ごとに、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度と触媒スラリーをろ材に塗布したときにろ材に担持される触媒の担持量との関係を導き出す。 In the relationship derivation step (S11), for each filter medium, the relationship between the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system and the amount of catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium is determined. derive.
触媒スラリーは、上述したように触媒を有機溶媒／水系に添加したものが用いられる。触媒は、上述したように、例えば、脱硝触媒、酸化触媒、ダイオキシン類分解触媒（ＤＸＮｓ分解触媒）等である。有機溶媒／水系中の有機溶媒は、例えば、メタノール、エタノール、プロパノール、ブタノール、エチレングリコール、ホルムアルデヒド、アセトアルデヒド、アセトン、メチルエチルケトン、ギ酸、又は酢酸である。有機溶媒／水系中の有機溶媒は、一種類に限られず、二種類以上を混合したものであってもよい。ろ材は、上述したように、例えば、テフロン等のＰＴＦＥ系の材料を含む素材が用いられる。 The catalyst slurry used is one in which a catalyst is added to an organic solvent/water system as described above. As mentioned above, the catalyst is, for example, a denitrification catalyst, an oxidation catalyst, a dioxins decomposition catalyst (DXNs decomposition catalyst), or the like. Organic solvents in organic solvent/aqueous systems are, for example, methanol, ethanol, propanol, butanol, ethylene glycol, formaldehyde, acetaldehyde, acetone, methyl ethyl ketone, formic acid or acetic acid. The organic solvent in the organic solvent/aqueous system is not limited to one type, and may be a mixture of two or more types. As described above, the filter medium is made of, for example, a material containing a PTFE-based material such as Teflon.
図２は、図１に示した関係導出ステップ（Ｓ１１）において導き出された関係の一例を示す図である。図２に示す例では、有機溶媒／水系中の有機溶媒はエタノールであり、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度は、０ｗｔ％，５ｗｔ％，１０ｗｔ％，２０ｗｔ％，３０ｗｔ％又は４０ｗｔ％である。また、触媒スラリーの触媒濃度は例えば２５ｗｔ％であるが、触媒濃度をこれに限る必要もなければ触媒濃度を一定にする必要もない。触媒スラリーをろ材に塗布したときに担持される触媒の担持量の単位はｇ／ｍ２である。また、ろ材の違いは、例えば、ろ材の素材に含まれるＰＴＦＥ系材料の含有率の違いやろ材繊維の形状の違いとしてとらえることできるが、この関係においては、水平においた固体試料に液体、本実施形態では水（イオン交換水）を着滴させ、固体試料を徐々に傾けて固体試料に着滴した液体が滑り始める固体試料の傾斜角度（「転落角」又は「滑落角」と称される）によって特定される。 FIG. 2 is a diagram showing an example of the relationships derived in the relationship deriving step (S11) shown in FIG. 1. In the example shown in FIG. 2, the organic solvent in the organic solvent/water system is ethanol, and the concentrations of the organic solvent in the organic solvent/water system contained in the catalyst slurry are 0 wt%, 5 wt%, 10 wt%, 20 wt%, 30 wt%. % or 40wt%. Furthermore, although the catalyst concentration of the catalyst slurry is, for example, 25 wt%, there is no need to limit the catalyst concentration to this, nor is it necessary to keep the catalyst concentration constant. The unit of the amount of catalyst supported when the catalyst slurry is applied to the filter medium is g/m 2 . In addition, differences in filter media can be understood as, for example, differences in the content of PTFE-based materials contained in the filter media material and differences in the shape of the filter media fibers, but in this relationship, it is important to understand that liquids and books are placed in a horizontally held solid sample. In the embodiment, water (ion-exchanged water) is deposited, and the solid sample is gradually tilted to determine the tilt angle of the solid sample (referred to as the "falling angle" or "sliding angle") at which the liquid that has landed on the solid sample begins to slide. ).
図２に示す例では、例えば、転落角が１４度で特定されるろ材に有機溶媒／水系中の有機溶媒の濃度が２０ｗｔ％の触媒スラリーを１回だけ塗布することによって１１０ｇ／ｍ２の触媒がろ材に担持される。 In the example shown in FIG. 2, for example, a catalyst slurry having a concentration of 20 wt% of organic solvent in an organic solvent/water system is applied only once to a filter medium whose falling angle is specified as 14 degrees, thereby producing 110 g/ m2 of catalyst. It is supported on the filter material.
濃度決定ステップ（Ｓ１２）では、関係導出ステップ（Ｓ１１）において導き出された関係に基づいてろ材に担持させる目標担持量から有機溶媒の濃度を決定する。目標担持量は、一回の触媒スラリーの塗布によってろ材に担持させる触媒の担持量である。したがって、例えば、一回の触媒スラリーの塗布によってろ材に担持させる触媒担持量が１１０ｇ／ｍ２のときに目標担持量は１１０ｇ／ｍ２となる。 In the concentration determination step (S12), the concentration of the organic solvent is determined from the target amount supported on the filter medium based on the relationship derived in the relationship derivation step (S11). The target supported amount is the amount of catalyst supported on the filter medium by one application of the catalyst slurry. Therefore, for example, when the amount of catalyst supported on the filter medium by one application of catalyst slurry is 110 g/m 2 , the target amount of supported catalyst is 110 g/m 2 .
図２に示す例では、例えば、転落角が１４度で特定されるろ材は、目標担持量が１１０ｇ／ｍ２とすると有機溶媒の濃度を２０ｗｔ％に決定する。 In the example shown in FIG. 2, for example, if the target loading amount of a filter medium specified by a falling angle of 14 degrees is 110 g/m 2 , the concentration of the organic solvent is determined to be 20 wt%.
尚、触媒担持量Ｙ［ｇ／ｍ２］と転落角（滑落角）Ｘ［°］との間には「Ｙ＝Ａ×ｓｉｎＸ」の関係式が成立する。ここで、転落角Ｘ１［°］のときに目標担持量Ｙ１［ｇ／ｍ２］となるＡ（Ａ＝Ｆ（Ｚ），Ｚは有機溶媒の濃度（ｗｔ％））を求めることで、有機溶媒の濃度を算出できる。 Note that the relational expression “Y=A×sinX” is established between the supported amount of catalyst Y [g/m 2 ] and the falling angle (sliding angle) X [°]. Here, by determining A (A = F (Z), Z is the concentration of organic solvent (wt%)) that gives the target supported amount Y1 [g/m 2 ] when the falling angle is X1 [°], The concentration of solvent can be calculated.
スラリー製造ステップ（Ｓ１３）では、濃度決定ステップ（Ｓ１２）において決定された有機溶媒の濃度以上の触媒スラリーを製造する。例えば、濃度決定ステップ（Ｓ１２）において決定された有機溶媒の濃度以上の触媒スラリーは、有機溶媒、触媒及び水を混合することで製造される。 In the slurry manufacturing step (S13), a catalyst slurry having a concentration of the organic solvent determined in the concentration determining step (S12) or higher is manufactured. For example, a catalyst slurry having a concentration equal to or higher than that of the organic solvent determined in the concentration determining step (S12) is produced by mixing the organic solvent, the catalyst, and water.
図２に示す例において、転落角が１４度で特定されるろ材に担持量が１１０ｇ／ｍ２（目標担持量）の触媒を担持させるために、有機溶媒の濃度が２０ｗｔ％以上の触媒スラリーを製造する。よって、スラリー製造ステップ（Ｓ１３）で製造される触媒スラリーに含まれる有機溶媒の濃度は２０ｗｔ％以上であれば、３０ｗｔ％，４０ｗｔ％であってもよい。有機溶媒の濃度を２０ｗｔ％以上とするのは２０ｗ％以上であれば目標担持量以上の触媒の担持が可能であるからである。 In the example shown in Figure 2, in order to support a catalyst with a supported amount of 110 g/m 2 (target supported amount) on a filter medium whose falling angle is specified as 14 degrees, a catalyst slurry with an organic solvent concentration of 20 wt% or more is added. Manufacture. Therefore, the concentration of the organic solvent contained in the catalyst slurry manufactured in the slurry manufacturing step (S13) may be 30 wt% or 40 wt% as long as it is 20 wt% or more. The reason why the concentration of the organic solvent is set to 20 wt % or more is that if the concentration is 20 wt % or more, it is possible to support the catalyst in an amount greater than the target supported amount.
スラリー塗布ステップ（Ｓ１４）では、スラリー製造ステップ（Ｓ１３）において製造された触媒スラリーをろ材に塗布する。触媒スラリーの塗布は、例えば、スプレーノズルによって触媒スラリーをろ材に噴霧してもよいし、触媒スラリーにろ材を浸漬させてもよい。 In the slurry application step (S14), the catalyst slurry produced in the slurry production step (S13) is applied to the filter medium. The catalyst slurry may be applied by, for example, spraying the catalyst slurry onto the filter medium using a spray nozzle, or by immersing the filter medium in the catalyst slurry.
尚、触媒スラリーをろ材（ろ布）に塗布することでろ材に付着した触媒スラリーの付着エネルギーＥは、下記の数式１で表すことができる。 Incidentally, the adhesion energy E of the catalyst slurry that adheres to the filter medium (filter cloth) by applying the catalyst slurry to the filter medium (filter cloth) can be expressed by the following equation 1.
ｒ：接触半径
ｍ：液滴の質量
ｇ：重力加速度
Ｘ：転落角（滑落角）
上述した一実施形態に係るフィルタの製造方法によれば、ろ材ごとに、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度と触媒スラリーをろ材に塗布したときにろ材に担持される触媒の担持量との関係を導き出すので、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度を適切に設定することができ、はっ水性を有する材料、例えばテフロン等のＰＴＦＥ系の材料を含むろ材を採用したフィルタを低コストで製造できる。また、ろ材上に触媒を均一に塗布できるので、ガスとの高い接触効率が実現できる。 According to the filter manufacturing method according to the embodiment described above, for each filter medium, the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system and the catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium are determined. By deriving the relationship between the supported amount of It is possible to manufacture filters using filter media containing the above-mentioned filters at low cost. Furthermore, since the catalyst can be applied uniformly onto the filter medium, high contact efficiency with gas can be achieved.
一実施形態に係るフィルタの製造方法では、有機溶媒／水系中の有機溶媒は、少なくとも表面張力が５０ｍＮ／ｍ以下である。表面張力が５０ｍＮ／ｍ以下の有機溶媒は、例えば、メタノール、エタノール、プロパノール、ブタノール、エチレングリコール、ホルムアルデヒド、アセトアルデヒド、アセトン、メチルエチルケトン、ギ酸、又は酢酸である。メタノールの表面張力は２２．６ｍＮ／ｍであり、エタノールの表面張力は２２．６ｍＮ／ｍである。また、プロパノールの表面張力は２３．７ｍＮ／ｍであり、ブタノールの表面張力は２５．４ｍＮ／ｍである。また、エチレングリコールの表面張力は４８．４ｍＮ／ｍであり、ホルムアルデヒドの表面張力は２７．４ｍＮ／ｍであり、アセトアルデヒドの表面張力は２１．２ｍＮ／ｍである。アセトンの表面張力は２３．３ｍＮ／ｍであり、メチルエチルケトンの表面張力は２４．６ｍＮ／ｍである。ギ酸の表面張力は３７．７ｍＮ／ｍであり、酢酸の表面張力は２７．７ｍＮ／ｍである。これらの有機溶媒は水の表面張力よりも十分に小さく有意であり、水との親和性も期待できる。 In the method for manufacturing a filter according to one embodiment, the organic solvent in the organic solvent/water system has a surface tension of at least 50 mN/m or less. Organic solvents with a surface tension of 50 mN/m or less are, for example, methanol, ethanol, propanol, butanol, ethylene glycol, formaldehyde, acetaldehyde, acetone, methyl ethyl ketone, formic acid, or acetic acid. The surface tension of methanol is 22.6 mN/m, and the surface tension of ethanol is 22.6 mN/m. Further, the surface tension of propanol is 23.7 mN/m, and the surface tension of butanol is 25.4 mN/m. Further, the surface tension of ethylene glycol is 48.4 mN/m, the surface tension of formaldehyde is 27.4 mN/m, and the surface tension of acetaldehyde is 21.2 mN/m. The surface tension of acetone is 23.3 mN/m and the surface tension of methyl ethyl ketone is 24.6 mN/m. The surface tension of formic acid is 37.7 mN/m and the surface tension of acetic acid is 27.7 mN/m. The surface tension of these organic solvents is significantly lower than that of water, and affinity with water can be expected.
一実施形態に係るフィルタの製造方法のスラリー塗布ステップ（Ｓ１４）では、スプレーノズルによって触媒スラリーをろ材に噴霧する（以下、スプレーノズルによって触媒スラリーをろ材に噴霧することを「スプレー噴霧」という）。 In the slurry application step (S14) of the filter manufacturing method according to one embodiment, the catalyst slurry is sprayed onto the filter medium using a spray nozzle (hereinafter, spraying the catalyst slurry onto the filter medium using the spray nozzle is referred to as "spraying").
このようにすれば、ろ材を触媒スラリーに浸漬させることで触媒スラリーをろ材に塗布するときよりも触媒スラリーの量が少なくて済むので、ろ材を触媒スラリーに浸漬させることで触媒スラリーをろ材に塗布するときよりも触媒スラリーの廃棄等に係るコストを低く抑えることができる。 In this way, by immersing the filter medium in the catalyst slurry, the amount of catalyst slurry will be smaller than when applying the catalyst slurry to the filter medium, so by immersing the filter medium in the catalyst slurry, the catalyst slurry can be applied to the filter medium. The cost of disposing of the catalyst slurry can be kept lower than when the catalyst slurry is disposed of.
図３Ａは、有機溶媒濃度と脱硝反応速度定数比との関係を示す図であり、図３Ｂは、サンプル１、サンプル２及びサンプル３のフィルタの脱硝反応速度比を示す図である。サンプル１、サンプル２及びサンプル３のフィルタはいずれも同一のろ材に有機溶媒濃度が異なる触媒スラリーを塗布したものである。ろ材は転落角が１４度で特定される材質（ＰＴＦＥ）である。触媒スラリーに含まれる触媒は脱硝反応触媒（Ｖ－Ｔｉ系脱硝触媒）であり、触媒スラリーの溶媒はエタノールと水の混合溶媒である。ろ材にはスプレーノズルによって触媒が塗布され、スプレーノズルのスプレー圧力は０．０１～０．２ＭＰａである。ろ材に担持する触媒の担持量（目標担持量）はいずれも１１０ｇ／ｍ２である。 FIG. 3A is a diagram showing the relationship between the organic solvent concentration and the denitrification reaction rate constant ratio, and FIG. 3B is a diagram showing the denitrification reaction rate ratio of the filters of Sample 1, Sample 2, and Sample 3. The filters of Sample 1, Sample 2, and Sample 3 are all the same filter medium coated with catalyst slurries having different concentrations of organic solvents. The filter medium is a material (PTFE) whose falling angle is specified as 14 degrees. The catalyst contained in the catalyst slurry is a denitrification reaction catalyst (V-Ti type denitrification catalyst), and the solvent of the catalyst slurry is a mixed solvent of ethanol and water. A catalyst is applied to the filter medium by a spray nozzle, and the spray pressure of the spray nozzle is 0.01 to 0.2 MPa. The amount of catalyst supported on the filter medium (target supported amount) was 110 g/m 2 in each case.
サンプル１のフィルタを製造する過程でろ材に塗布する触媒スラリーに含まれる有機溶媒濃度は２０ｗｔ％であり一回の塗布によって完成できるので（図２参照）、サンプル１のフィルタはろ材に触媒スラリーを一回塗布することによって製作され、サンプル１には目標担持量（１１０ｇ／ｍ２）の触媒が担持される。サンプル２及びサンプル３のフィルタを製造する過程でろ材に塗布する触媒スラリーに含まれる有機溶媒濃度はそれぞれ１０ｗｔ％及び５ｗｔ％であり一回の塗布によって完成できないので（図２参照）、サンプル２及びサンプル３のフィルタはろ材に触媒スラリーを二回塗布することによって製作され、サンプル２には目標担持量を大きく超える担持量の触媒が担持される。 The concentration of organic solvent contained in the catalyst slurry applied to the filter medium in the process of manufacturing the sample 1 filter is 20 wt%, and it can be completed with one application (see Figure 2). It is manufactured by applying one coat, and sample 1 supports a target amount of catalyst (110 g/m 2 ). In the process of manufacturing the filters of Samples 2 and 3, the organic solvent concentrations contained in the catalyst slurry applied to the filter media are 10wt% and 5wt%, respectively, and cannot be completed with one application (see Figure 2). The filter of Sample 3 was manufactured by applying the catalyst slurry twice to the filter medium, and Sample 2 had a supported amount of catalyst that greatly exceeded the target supported amount.
図３に示すように、サンプル１のフィルタの脱硝反応速度定数比を１．００とすると、サンプル２のフィルタの脱硝反応速度比は０．８６、サンプル３のフィルタの脱硝反応速度比は０．７３である。よって、サンプル１のフィルタの脱硝反応性能はサンプル３のフィルタの１．３７倍（１．００／０．７３）である。これによるとサンプル１のフィルタはサンプル３のフィルタよりも触媒担持量が少ないにもかかわらずサンプル２のフィルタよりも脱硝反応性能に優れている。 As shown in FIG. 3, when the denitrification reaction rate constant ratio of the sample 1 filter is 1.00, the denitrification reaction rate constant ratio of the sample 2 filter is 0.86, and the denitrification reaction rate ratio of the sample 3 filter is 0. It is 73. Therefore, the denitrification reaction performance of the sample 1 filter is 1.37 times (1.00/0.73) that of the sample 3 filter. According to this, although the sample 1 filter has a smaller amount of catalyst supported than the sample 3 filter, it has better denitrification reaction performance than the sample 2 filter.
図４Ａはサンプル１のフィルタを製造する過程で、ろ材に触媒スラリーを塗布した状態の表面画像を示す図であり、図４Ｂはサンプル２のフィルタを製造する過程（１回塗布後）で、ろ材に触媒スラリーを塗布した状態の表面画像である。また、図４Ｃはサンプル３のフィルタを製造する過程（１回塗布後）で、ろ材に触媒スラリーを塗布した状態の表面画像を示す図である。図４Ａに示すように、サンプル１のフィルタは触媒スラリーが均等に分散している。そのため、触媒がろ材に均等に担持されていると考えられる。一方、図４Ｂ及び図４Ｃに示すように、サンプル２及び３のフィルタは触媒スラリーが凝集している。そのため触媒がろ材に均等に担持されていないと考えられる。よって、フィルタを製造する過程でろ材に触媒スラリーを一回で塗布可能な有機溶媒濃度の方がろ材に触媒スラリーを複数回塗布が必要な有機溶媒濃度よりも触媒スラリーが均等に担持され、接ガス面積も大きいため脱硝反応性能に優れている。 FIG. 4A is a diagram showing a surface image of the filter material coated with catalyst slurry during the process of manufacturing the filter of sample 1, and FIG. This is a surface image of the surface with catalyst slurry applied to it. Moreover, FIG. 4C is a diagram showing a surface image of a state in which the catalyst slurry is applied to the filter medium in the process of manufacturing the filter of Sample 3 (after one application). As shown in FIG. 4A, the filter of sample 1 has catalyst slurry evenly distributed. Therefore, it is considered that the catalyst is evenly supported on the filter medium. On the other hand, as shown in FIGS. 4B and 4C, the catalyst slurry in the filters of samples 2 and 3 was aggregated. Therefore, it is thought that the catalyst was not evenly supported on the filter medium. Therefore, in the process of manufacturing a filter, the organic solvent concentration that allows the catalyst slurry to be applied to the filter medium in one go is better than the organic solvent concentration that requires multiple applications of the catalyst slurry on the filter medium, as the catalyst slurry is more evenly supported and the contact is more stable. Since the gas area is large, the denitrification reaction performance is excellent.
上記を鑑みて、一実施形態に係るフィルタの製造方法では、目標担持量は、フィルタの完成時の完成担持量であり、スラリーの塗布ステップにおける触媒スラリーの塗布回数は一回である。 In view of the above, in the filter manufacturing method according to one embodiment, the target supported amount is the completed supported amount when the filter is completed, and the number of times the catalyst slurry is applied in the slurry application step is one.
このようにすれば、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度が触媒担持量に対して適切となり、一回の触媒スラリーの塗布によって触媒をムラなくろ材（ろ布）に担持できる。また、触媒スラリーの塗布が一回で済むので、優れた性能のフィルタを低コストで製造できる。 In this way, the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system will be appropriate for the amount of catalyst supported, and the catalyst will be evenly supported on the filter material (filter cloth) by one application of the catalyst slurry. can. Furthermore, since the catalyst slurry only needs to be applied once, a filter with excellent performance can be manufactured at low cost.
また、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度が適切となるので、有機溶媒を取り扱うときに必要となる排水、排気処理設備のコストも低減できる。 Furthermore, since the concentration of the organic solvent in the organic solvent/aqueous system contained in the catalyst slurry becomes appropriate, the cost of waste water and exhaust treatment equipment required when handling organic solvents can also be reduced.
また、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度が適切となり、一回の触媒スラリーの塗布によって触媒をムラなくろ材（ろ布）に担持できるので、フィルタの差圧が低減され、触媒を反応に有効に利用できる。 In addition, the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system becomes appropriate, and the catalyst can be evenly supported on the filter material (filter cloth) by one application of the catalyst slurry, reducing the differential pressure of the filter. , the catalyst can be used effectively for the reaction.
加えて、フィルタの差圧低減により、フィルタが用いられる集塵ブロアの動力の低減、逆洗回数の低減が可能となり、フィルタの寿命も延ばすことができる。 In addition, by reducing the differential pressure of the filter, it is possible to reduce the power of the dust collection blower in which the filter is used, reduce the number of times of backwashing, and extend the life of the filter.
他の一実施形態に係るフィルタの製造方法では、目標担持量は、フィルタの完成時の完成担持量未満であり、スラリーの塗布ステップにおける触媒のスラリーの塗布回数は少なくとも二回以上である。例えば、目標担持量をフィルタの完成時の完成担持量の半分以下とし、スラリーの塗布ステップにおける触媒スラリーの塗布回数を二回以上にできる。この場合において一回目に塗布する触媒スラリーに含まれる有機溶媒と二回目以降に塗布する触媒スラリーに含まれる有機溶媒とが同一種類のものでなくてもよい。また、一回目に塗布する触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度と二回目に塗布する触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度は同一の濃度でなくてもよい。 In the filter manufacturing method according to another embodiment, the target supported amount is less than the completed supported amount when the filter is completed, and the number of times the catalyst slurry is applied in the slurry application step is at least two times. For example, the target supported amount can be set to less than half of the completed supported amount when the filter is completed, and the number of times the catalyst slurry is applied in the slurry application step can be increased to two or more times. In this case, the organic solvent contained in the catalyst slurry applied for the first time and the organic solvent contained in the catalyst slurry applied for the second time and thereafter may not be of the same type. Additionally, the concentration of the organic solvent contained in the catalyst slurry applied in the first application/in the aqueous system and the concentration of the organic solvent contained in the catalyst slurry applied in the second application/in the aqueous system are not the same. Good too.
このようにすれば、触媒スラリーの塗布回数が一回のときよりも触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度を低く抑えることができるので、触媒スラリーの塗布回数が一回のときよりも触媒スラリーの廃棄等にかかるコストを低く抑えることができる。 In this way, the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system can be kept lower than when the catalyst slurry is applied once. The cost of disposing of the catalyst slurry can be kept lower than in the past.
本発明は上述した実施形態に限定されることはなく、上述した実施形態に変形を加えた形態や、これらの形態を適宜組み合わせた形態も含む。 The present invention is not limited to the embodiments described above, and also includes forms in which modifications are added to the embodiments described above, and forms in which these forms are appropriately combined.
例えば、水平に置いた固体試料に水滴を１２０μｌ着滴させ、固体試料を徐々に傾けて固体試料に着滴した液体が滑り始める固体試料の傾斜角度が５度以上２５度以下によって特定されたろ材が用いられる。そして、触媒スラリーが含まれる有機溶媒／水系中の有機溶媒の濃度と触媒スラリーをろ材に塗布したときにろ材に担持される触媒の担持量との関係に基づいてろ材に触媒を１００ｇ／ｍ２担持させている。 For example, when 120 μl of water is deposited on a solid sample placed horizontally, the solid sample is gradually tilted, and the liquid that has landed on the solid sample begins to slide.A filter material that is identified by the inclination angle of the solid sample being 5 degrees or more and 25 degrees or less. is used. Then, based on the relationship between the concentration of the organic solvent in the organic solvent/aqueous system containing the catalyst slurry and the amount of catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium, 100 g/m 2 of catalyst was applied to the filter medium. I am carrying it.
上記各実施形態に記載の内容は、例えば、以下のように把握される。 The contents described in each of the above embodiments can be understood as follows, for example.
（１）一の態様に係るフィルタの製造方法は、
ろ材ごとに、触媒スラリーに含まれる有機溶媒／水系中の前記有機溶媒の濃度と前記触媒スラリーを前記ろ材に塗布したときに前記ろ材に担持される触媒の担持量との関係を導き出す関係導出ステップ（Ｓ１１）と、
前記関係導出ステップ（Ｓ１１）において導きだされた前記関係に基づいて前記ろ材に担持させる目標担持量から前記有機溶媒の濃度を決定する濃度決定ステップ（Ｓ１２）と、
前記濃度決定ステップ（Ｓ１２）において決定された前記有機溶媒の濃度以上の前記触媒スラリーを製造するスラリー製造ステップ（Ｓ１３）と、
前記スラリー製造ステップ（Ｓ１３）において製造された前記触媒スラリーを前記ろ材に塗布するスラリー塗布ステップ（Ｓ１４）と、
を有する。
(1) A method for manufacturing a filter according to one aspect,
A relationship derivation step of deriving, for each filter medium, a relationship between the concentration of the organic solvent in the organic solvent/aqueous system contained in the catalyst slurry and the amount of catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium. (S11) and
a concentration determining step (S12) of determining the concentration of the organic solvent from a target amount of the organic solvent to be supported on the filter medium based on the relationship derived in the relationship deriving step (S11);
a slurry production step (S13) of producing the catalyst slurry having a concentration of the organic solvent determined in the concentration determination step (S12) or higher;
a slurry application step (S14) of applying the catalyst slurry produced in the slurry production step (S13) to the filter medium;
has.
このような製造方法によれば、ろ材ごとに、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度と触媒スラリーをろ材に塗布したときにろ材に担持される触媒の担持量との関係を導き出すので、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度を適切に設定することができ、はっ水性を有する材料、例えばＰＴＦＥ等のテフロン系の材料を含むろ材を採用したフィルタを低コストで製造できる。 According to this manufacturing method, for each filter medium, the relationship between the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system and the amount of catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium is determined. Therefore, the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system can be appropriately set. can be manufactured at low cost.
（２）別の態様に係るフィルタの製造方法は、（１）に記載のフィルタの製造方法であって、
前記有機溶媒は、少なくとも表面張力が５０ｍＮ／ｍ以下である。
(2) A method for manufacturing a filter according to another aspect is the method for manufacturing a filter according to (1), comprising:
The organic solvent has a surface tension of at least 50 mN/m or less.
このような製造方法によれば、表面張力が５０ｍＮ／ｍ以下であり、水の表面張力より十分に小さく有意であり、水との親和性も期待できる。 According to such a manufacturing method, the surface tension is 50 mN/m or less, which is significantly smaller than the surface tension of water, and affinity with water can also be expected.
（３）更に別の態様に係るフィルタの製造方法は、（１）又は（２）に記載のフィルタの製造方法であって、
前記目標担持量は、前記フィルタの完成時の完成担持量であり、前記スラリー塗布ステップ（Ｓ１４）における前記触媒スラリーの塗布回数は一回である。
(3) A method for manufacturing a filter according to yet another aspect is the method for manufacturing a filter according to (1) or (2), comprising:
The target supported amount is the completed supported amount when the filter is completed, and the number of times the catalyst slurry is applied in the slurry application step (S14) is one.
このような製造方法によれば、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度が触媒担持量に対して適切となり、一回の触媒スラリーの塗布によって触媒をムラなくろ材（ろ布）に担持できる。また、触媒スラリーの塗布が一回で済むので、優れた性能のフィルタを低コストで製造できる。 According to such a production method, the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system is appropriate for the amount of catalyst supported, and the catalyst is evenly applied to the filter material (filter cloth) by one application of the catalyst slurry. ) can be carried. Furthermore, since the catalyst slurry only needs to be applied once, a filter with excellent performance can be manufactured at low cost.
（４）更に別の態様に係るフィルタの製造方法は、（１）又は（２）に記載のフィルタの製造方法であって、
前記目標担持量は、前記フィルタの完成時の完成担持量未満であり、前記スラリー塗布ステップ（Ｓ１４）における前記触媒スラリーの塗布回数は少なくとも二回以上である。
(4) A method for manufacturing a filter according to yet another aspect is the method for manufacturing a filter according to (1) or (2), comprising:
The target supported amount is less than the completed supported amount when the filter is completed, and the number of times the catalyst slurry is applied in the slurry application step (S14) is at least two times.
このような製造方法によれば、触媒スラリーの塗布回数が一回のときよりも触媒スラリーに含まれる有機溶媒の濃度を低く抑えることができるので、触媒スラリーの塗布回数が一回のときよりも触媒スラリーの廃棄等にかかるコストも低く抑えることができる。 According to this manufacturing method, the concentration of the organic solvent contained in the catalyst slurry can be kept lower than when the catalyst slurry is applied once, so the concentration of the organic solvent contained in the catalyst slurry can be kept lower than when the catalyst slurry is applied once. The cost of disposing of the catalyst slurry, etc. can also be kept low.
（５）更に別の態様に係るフィルタの製造方法は、（１）から（４）のいずれか一つに記載のフィルタの製造方法であって、
前記スラリー塗布ステップ（Ｓ１４）では、スプレーノズルによって前記触媒スラリーを前記ろ材に噴霧する。
(5) A method for manufacturing a filter according to yet another aspect is the method for manufacturing a filter according to any one of (1) to (4), comprising:
In the slurry application step (S14), the catalyst slurry is sprayed onto the filter medium using a spray nozzle.
このような製造方法によれば、ろ材を触媒スラリーに浸漬させることで触媒スラリーをろ材に塗布するときよりも触媒スラリーの量が少なくて済むので、ろ材を触媒スラリーに浸漬させることで触媒スラリーをろ材に塗布するときよりも触媒スラリーの廃棄等に係るコストも低く抑えることができる。 According to this manufacturing method, by immersing the filter medium in the catalyst slurry, the amount of catalyst slurry is smaller than when applying the catalyst slurry to the filter medium. Costs associated with disposal of the catalyst slurry can also be kept lower than when coating the catalyst slurry on a filter medium.
（６）更に別の態様に係るフィルタの製造方法は、（１）から（５）のいずれか一つに記載のフィルタの製造方法であって、
前記関係において前記ろ材は、水平に置いた固体試料に液体を着滴させ、前記固体試料を徐々に傾けて前記固体試料に着滴した前記液体が滑り始める前記固体試料の傾斜角度によって特定される。
(6) A method for manufacturing a filter according to yet another aspect is the method for manufacturing a filter according to any one of (1) to (5), comprising:
In the above relationship, the filter medium is specified by the inclination angle of the solid sample where a liquid is deposited on a horizontally placed solid sample, the solid sample is gradually tilted, and the liquid that has landed on the solid sample begins to slide. .
このような製造方法によれば、ろ材はろ材のはっ水性よって特定され、触媒スラリーに含まれる有機溶媒の濃度と触媒スラリーを塗布したときにろ材に担持される触媒の担持量をろ材のはっ水性に適応させることができる。 According to this manufacturing method, the filter medium is specified by its water repellency, and the concentration of the organic solvent contained in the catalyst slurry and the amount of catalyst supported on the filter medium when the catalyst slurry is applied are determined by the filter medium's water repellency. Can be adapted to water repellency.
（７）一の態様に係るフィルタは、水平に置いた固体試料に液体を着滴させ、前記固体試料を徐々に傾けて前記固体試料に着滴した前記液体が滑り始める前記固体試料の傾斜角度によって特定されたろ材に、触媒スラリーに含まれる有機溶媒／水系中の前記有機溶媒の濃度と前記触媒スラリーを前記ろ材に塗布したときに前記ろ材に担持される触媒の担持量との関係に基づいて前記ろ材に担持させる目標担持量から前記有機溶媒の濃度を決定する。 (7) In the filter according to the first aspect, a liquid is deposited on a solid sample placed horizontally, and the solid sample is gradually tilted to an angle of inclination of the solid sample at which the liquid deposited on the solid sample starts to slide. Based on the relationship between the concentration of the organic solvent in the organic solvent/aqueous system contained in the catalyst slurry and the amount of catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium specified by The concentration of the organic solvent is determined based on the target amount of the organic solvent to be supported on the filter medium.
このような構成によれば、ろ材はろ材のはっ水性よって特定され、触媒スラリーに含まれる有機溶媒の濃度と触媒スラリーを塗布したときにろ材に担持される触媒の担持量をろ材のはっ水性に適応させることができる。また、触媒スラリーに含まれる有機溶媒／水系中の有機溶媒の濃度を適切に設定することができるので、はっ水性を有する材料、例えばＰＴＦＥ等のテフロン系の材料を含むろ材を採用し、触媒スラリーが均等に担持され、接ガス面積が大きくなった、脱硝反応性能に優れたフィルタを低コストで製造できる。 According to such a configuration, the filter medium is specified by its water repellency, and the concentration of the organic solvent contained in the catalyst slurry and the amount of catalyst supported on the filter medium when the catalyst slurry is applied are determined by the repellency of the filter medium. Can be adapted to water-based. In addition, since the concentration of the organic solvent contained in the catalyst slurry/organic solvent in the aqueous system can be appropriately set, a filter material containing a water-repellent material, for example, a Teflon-based material such as PTFE, is used to catalyze the catalyst slurry. A filter with excellent denitrification reaction performance, in which slurry is evenly supported and the area in contact with gas is increased, can be manufactured at low cost.
（８）別の態様に係るフィルタは、
水平に置いた固体試料に水滴を１２０μｌ着滴させ、
前記固体試料を徐々に傾けて前記固体試料に着滴した前記水滴が滑り始める前記固体試料の傾斜角度が５°以上２５°以下によって特定されたろ材に、
触媒スラリーに含まれる有機溶媒／水系中の前記有機溶媒の濃度と前記触媒スラリーを前記ろ材に塗布したときに前記ろ材に担持される触媒の担持量との関係に基づいて、
前記ろ材に触媒を１００ｇ／ｍ２担持させている。
(8) A filter according to another aspect is:
Drop 120 μl of water onto a solid sample placed horizontally,
The solid sample is gradually tilted so that the water droplets that have landed on the solid sample begin to slide on a filter medium specified by an inclination angle of 5° or more and 25° or less,
Based on the relationship between the concentration of the organic solvent in the organic solvent/aqueous system contained in the catalyst slurry and the amount of catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium,
The filter medium supports 100 g/m 2 of catalyst.
このような構成によれば、ガスとの高い接触効率を実現できる。 According to such a configuration, high contact efficiency with gas can be realized.
（９）更に別の態様に係るフィルタは、上記（８）に記載のフィルタであって、
前記有機溶媒の表面張力が５０ｍＮ／ｍ以下である。
(9) A filter according to yet another aspect is the filter described in (8) above,
The surface tension of the organic solvent is 50 mN/m or less.
このような構成によれば、有機溶媒の濃度が５０ｍＮ／ｍ以下で有り、水の表面張力より十分に小さく有意であり、水との親和性も期待できる。 According to such a configuration, the concentration of the organic solvent is 50 mN/m or less, which is significantly smaller than the surface tension of water, and affinity with water can be expected.
（１０）更に別の態様に係るフィルタは、上記（８）に記載のフィルタであって、
前記有機溶媒がエタノールである。
(10) A filter according to yet another aspect is the filter described in (8) above,
The organic solvent is ethanol.
このような構成によれば、有機溶媒がエタノールであり、他の有機溶媒を用いる場合に比べて安価なフィルタとすることができる。 According to such a configuration, the organic solvent is ethanol, and the filter can be made cheaper than when other organic solvents are used.
Ｓ１１ 関係導出ステップ
Ｓ１２ 濃度決定ステップ
Ｓ１３ スラリー製造ステップ
Ｓ１４ スラリー塗布ステップ
S11 Relationship derivation step S12 Concentration determination step S13 Slurry manufacturing step S14 Slurry application step
Claims (6)
前記関係導出ステップにおいて導き出された前記関係に基づいて前記ろ材に担持させる目標担持量から前記有機溶媒の濃度を決定する濃度決定ステップと、
前記濃度決定ステップにおいて決定された前記有機溶媒の濃度以上の前記触媒スラリーを製造するスラリー製造ステップと、
前記スラリー製造ステップにおいて製造された前記触媒スラリーを前記ろ材に塗布するスラリー塗布ステップと、
を有する、フィルタの製造方法。 A relationship derivation step of deriving, for each filter medium, a relationship between the concentration of the organic solvent in the organic solvent/aqueous system contained in the catalyst slurry and the amount of catalyst supported on the filter medium when the catalyst slurry is applied to the filter medium. and,
a concentration determining step of determining the concentration of the organic solvent from the target amount supported on the filter medium based on the relationship derived in the relationship deriving step;
a slurry production step of producing the catalyst slurry having a concentration of the organic solvent determined in the concentration determination step or higher;
a slurry application step of applying the catalyst slurry produced in the slurry production step to the filter medium;
A method for manufacturing a filter, comprising:
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2020
- 2020-02-27 JP JP2020031974A patent/JP7369062B2/en active Active
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2021
- 2021-01-21 CN CN202180016084.6A patent/CN115151328B/en active Active
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|---|---|---|---|---|
| JP2008043580A (en) | 2006-08-18 | 2008-02-28 | Mitsubishi Electric Corp | Deodorizing filter and air cleaning device |
| JP2012130853A (en) | 2010-12-21 | 2012-07-12 | Mitsubishi Heavy Ind Ltd | Bag filter, and exhaust gas treatment apparatus |
| JP2019171307A (en) | 2018-03-29 | 2019-10-10 | 東レフィルム加工株式会社 | Photocatalyst sheet |
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| CN115151328A (en) | 2022-10-04 |
| WO2021171840A1 (en) | 2021-09-02 |
| JP2021133317A (en) | 2021-09-13 |
| CN115151328B (en) | 2024-08-09 |
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