Washing catalyst material and preparation method thereof

Abstract

The invention provides a washing catalyst material. The washing catalyst material comprises a base material and a composite material layer, the substrate includes inorganic fibers selected from glass fibers, ceramic fibers, alumina fibers, or combinations thereof. The composite material layer is formed on the base material and comprises an inorganic filler, an inorganic adhesive material, a curing agent and a catalyst, and the inorganic filler is selected from aluminum oxide, aluminum hydroxide, silicon dioxide, titanium dioxide or a combination thereof; the inorganic adhesive material is selected from silicon dioxide, titanium dioxide, aluminum oxide, phosphate, borate, water glass, silicate or a combination thereof; the curing agent is selected from epoxy resin, acrylic acid, polyurethane or a combination thereof; the catalyst is selected from cerium dioxide, activated carbon or a combination thereof. The invention further discloses a preparation method of the washing catalyst material.

Description

Technical Field

[0001] This application relates to a catalyst material, and particularly to a water-washing catalyst material for removing gaseous molecular pollutants and a preparation method thereof. Background Art

[0002] For industrial processes that require high cleanliness (such as semiconductors, liquid crystal panels, pharmaceuticals, and biochemistry), airborne molecular contaminants (AMC) in the environment can affect production efficiency and product yield. The main existing technologies for removing AMC include: non-destructive condensation, adsorption, absorption, and destructive direct combustion, catalytic incineration, and biological methods. Among them, the absorption method uses a wet scrubbing device, and a washing liquid (such as pure water) sprays the gas through a shower plate to make the gas and the washing liquid fully contact. The gas molecular contaminants enter the liquid film through the gas-phase film and are absorbed by the washing liquid.

[0003] The washing effect of the wet scrubbing device is affected by factors such as the liquid-gas ratio, the pH / conductivity / temperature / circulation volume of the washing liquid, the liquid-gas specific surface area, the washing residence time, the exhaust gas volume, the wetting factor, and the gas solubility. The shower plate of the wet scrubbing device can increase the contact area and contact time between the gas and the liquid to improve the removal rate of AMC. The configuration and material of the shower plate affect the removal effect of AMC and the durability of the shower plate. Previously, the shower plate was made of organic materials or paper, and such a shower plate has poor water resistance and is prone to outgassing pollution or bacterial growth problems after being used for a period of time; there is also a technology that uses inorganic ceramic materials to make the shower plate. However, the inorganic ceramic materials need to be forged at high temperature, which is not only time-consuming but also increases the cost.

[0004] How to improve the AMC removal rate of the wet scrubbing device, extend the service life of the shower plate, and reduce its manufacturing cost is the main purpose of developing this application. Summary of the Invention

[0005] The technical problem to be solved by this application is to provide a water-washing catalyst material, including: a substrate and a composite material layer. The substrate includes inorganic fibers selected from glass fiber, ceramic fiber, alumina fiber, or a combination thereof. The composite material layer is formed on the substrate and includes: an inorganic filler, an inorganic binder, a curing agent, and a catalyst. The inorganic filler is selected from alumina, aluminum hydroxide, silica, titanium dioxide, or a combination thereof; the inorganic binder is selected from silica, titanium dioxide, alumina, phosphate, borate, water glass, silicate, or a combination thereof; the curing agent is selected from epoxy resin, acrylic acid, polyurethane, or a combination thereof; the catalyst is selected from cerium dioxide, activated carbon, or a combination thereof.

[0006] In one embodiment, the above-mentioned substrate has an oblique waveform structure, the peak height of the oblique waveform structure is between 3 mm and 8 mm, the distance between two adjacent peaks of the oblique waveform structure is between 5 mm and 15 mm, and the angle between the oblique waveform structure and the center line of the geometric shape of the above-mentioned substrate is between 15° and 60°.

[0007] In one embodiment, the thickness of the above-mentioned composite material layer is between 0.2 mm and 1 mm.

[0008] In one embodiment, the particle size of the above-mentioned inorganic filler is between 0.01 μm and 10 μm.

[0009] In one embodiment, the particle size of the above-mentioned catalyst is between 0.1 μm and 50 μm.

[0010] To achieve the above object, the present application further provides a preparation method of a water-washing catalyst material, including: mixing an inorganic filler, an inorganic sol, a curing agent, and a catalyst to form a slurry, wherein the weight ratio of the catalyst in the slurry is between 1% and 10%; cutting an inorganic fiber sheet to form a substrate; soaking the substrate in the slurry to form a slurry-containing substrate; hot-pressing the slurry-containing substrate at 100°C to 200°C to produce a formed substrate; soaking the formed substrate in the slurry at least once; and drying the slurry of the formed substrate at 100°C to 200°C to make the slurry form a composite material layer, thereby completing a water-washing catalyst material.

[0011] In one embodiment, the above-mentioned inorganic filler is selected from alumina, aluminum hydroxide, silica, titanium dioxide or a combination thereof; the above-mentioned inorganic sol is selected from silica sol, titanium dioxide sol, alumina sol, phosphate sol, borate sol, water glass, silicate sol or a combination thereof; the above-mentioned curing agent is selected from epoxy resin, acrylic acid, polyurethane or a combination thereof; the above-mentioned catalyst is selected from cerium dioxide, activated carbon or a combination thereof.

[0012] In one embodiment, the pH value of the above-mentioned slurry is between 3 and 5, and the viscosity of the above-mentioned slurry is between 450 cps and 2000 cps.

[0013] In one embodiment, the above-mentioned inorganic fiber sheet is selected from inorganic fibers such as glass fiber, ceramic fiber, alumina fiber or a combination thereof, and the weight of the above-mentioned inorganic fiber sheet per square meter is between 20 g and 65 g.

[0014] In one embodiment, the hot-pressing time of the above-mentioned slurry-containing substrate at 100°C to 200°C is between 10 minutes and 30 minutes; the drying time of the slurry of the above-mentioned formed substrate at 100°C to 200°C is between 10 minutes and 30 minutes.

[0015] The water-washing catalyst material of the present application includes a curing agent and a catalyst. The curing agent can increase the chemical resistance and durability of the overall water-washing catalyst material, and greatly extend the service life of the water shower plate. The catalyst is a porous material, which can increase the contact area between gas and liquid and improve the filtering effect of AMC. The preparation method of the water-washing catalyst material of the present application can be formed by hot pressing the slurry-containing substrate at 100°C to 200°C through the composition of the slurry. The formed substrate soaked in the slurry again can be cured by drying at 100°C to 200°C to complete the water-washing catalyst material, greatly reducing the processing temperature and manufacturing cost.

[0016] Details of other effects and embodiments of the present application are described below with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments recorded in the present application. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0018] Figure 1 It is a flowchart of the steps of the preparation method of the water-washing catalyst material of the present application;

[0019] Figure 2 It is a top view and side view schematic diagram of the water-washing catalyst material according to an embodiment of the present application;

[0020] Figure 3 It is a tolerance test chart of the embodiment and the comparative example of the present application; and

[0021] Figure 4 It is a three-dimensional schematic diagram of the water shower plate using the water-washing catalyst material of the present application.

[0022] SYMBOL DESCRIPTION

[0023] 2: Water-washing catalyst material

[0024] 4: Water shower plate

[0025] 21: Substrate

[0026] 22: Composite material layer

[0027] 211: Oblique corrugated structure

[0028] d: Distance

[0029] h: Height

[0030] L: Center line

[0031] α: Angle

[0032] t: Thickness

[0033] S11, S12, S13, S14, S15, S16: Steps Detailed implementation manners

[0034] The following further describes the implementation manners of the present application in conjunction with the drawings and component symbols, so that those with ordinary knowledge in the technical field to which the present application pertains can implement the present application after studying this specification.

[0035] Figure 1 It is a step flow chart of the preparation method of the water-washing catalyst material of the present application. As Figure 1 shown, the preparation method of the water-washing catalyst material of the present application includes the following steps: Step S11: Mix inorganic filler, inorganic sol, curing agent and catalyst to form a slurry, wherein the weight ratio of the catalyst in the slurry ranges from 1% to 10%; Step S12: Cut an inorganic fiber sheet to form a substrate; Step S13: Immerse the substrate in the slurry to form a slurry-containing substrate; Step S14: Hot press the slurry-containing substrate at 100°C to 200°C to produce a formed substrate; Step S15: Immerse the formed substrate in the slurry at least one more time; and Step S16: Dry the slurry of the formed substrate at 100°C to 200°C to form a composite material layer, thereby completing the water-washing catalyst material.

[0036] In step S11, the inorganic filler is selected from alumina, aluminum hydroxide, silica, titanium dioxide or a combination thereof; the inorganic sol is selected from silica sol, titanium dioxide sol, alumina sol, phosphate sol, borate sol, water glass, silicate sol or a combination thereof; the curing agent is selected from epoxy resin, acrylic acid, polyurethane or a combination thereof; the catalyst is selected from cerium dioxide (CeO 2 2), activated carbon or a combination thereof. Calculated based on the total weight of the slurry, the weight ratio of the inorganic filler ranges from 50% to 70%, the weight ratio of the inorganic sol ranges from 10% to 30%, and the weight ratio of the curing agent ranges from 3% to 5%. The pH value of the prepared slurry ranges from 3 to 5, and the viscosity of the slurry increases with the increase of the catalyst addition ratio. Excessive viscosity affects the hydrophilicity. Therefore, the catalyst addition ratio is set to range from 1% to 10% to make the viscosity of the slurry range from 450 cps to 2000 cps.

[0037] In step S12, the inorganic fiber sheet is selected from inorganic fibers such as glass fiber, ceramic fiber, alumina fiber or a combination thereof. The weight of the inorganic fiber sheet per square meter ranges from 20 grams to 65 grams. There are pores between the fibers of the inorganic fiber sheet for gases and liquids to pass through and come into contact. It is worth noting that there is no sequence between step S11 and step S12, and the slurry can be prepared first or the substrate can be cut first.

[0038] In step S13, the amount of slurry adhered to the slurry-containing substrate increases as the viscosity of the slurry increases; in step S14, the slurry-containing substrate is placed in a heating mold, and the hot pressing time of the slurry-containing substrate at 100°C to 200°C is between 10 minutes and 30 minutes to shape the slurry-containing substrate into a formed substrate. The configuration of the formed substrate is, for example, a geometric shape with an oblique corrugated structure; in step S15, the formed substrate is immersed in the slurry once or several times to increase the slurry coverage of the formed substrate; in step S16, the formed substrate is dried at 100°C to 200°C for a time between 10 minutes and 30 minutes, and the preparation of the water-washing catalyst material can be completed.

[0039] In the preparation method of the water-washing catalyst material of the present application, through the composition of the slurry, the slurry-containing substrate can be formed by hot pressing at 100°C to 200°C. The formed substrate immersed in the slurry again can be cured by drying at 100°C to 200°C to complete the water-washing catalyst material, greatly reducing the processing temperature and manufacturing cost.

[0040] Figure 2 It is a top view and side view schematic diagram of the water-washing catalyst material of an embodiment of the present application. As Figure 2 shown, the water-washing catalyst material 2 includes: a substrate 21 and a composite material layer 22 formed on the substrate. The substrate 21 includes inorganic fibers selected from glass fiber, ceramic fiber, alumina fiber or a combination thereof; the composite material layer 22 includes: inorganic filler, inorganic binder, curing agent and catalyst. The inorganic filler is selected from alumina, aluminum hydroxide, silica, titanium dioxide or a combination thereof; the inorganic binder is selected from silica, titanium dioxide, alumina, phosphate, borate, water glass, silicate or a combination thereof; the curing agent is selected from epoxy resin, acrylic acid, polyurethane or a combination thereof; the catalyst is selected from cerium dioxide, activated carbon or a combination thereof.

[0041] The outer shape of the substrate 21 can be determined according to the usage requirements, such as but not limited to: rectangle, square, circle, ellipse. In this embodiment, the outer shape of the substrate 21 is a rectangle and has an oblique corrugated structure 211. The peak height h of the oblique corrugated structure 211 is between 3 mm and 8 mm, the distance d between two adjacent peaks of the oblique corrugated structure 211 is between 5 mm and 15 mm, and the angle α between the oblique corrugated structure 211 and the center line L (symmetry line or perpendicular line of the opposite two sides) of the geometric shape of the substrate 21 is between 15° and 60°. The oblique corrugated structure 211 can form flow channels for gas and liquid, and improve the contact ratio of gas and liquid, thereby enhancing the filtering effect of AMC.

[0042] The thickness of the composite material layer 22 ranges from 0.2 mm to 1 mm, the particle size of the inorganic filler ranges from 0.01 μm to 10 μm, the inorganic binder is formed by drying the water content of an inorganic sol selected from silica sol, titanium dioxide sol, alumina sol, phosphate sol, borate sol, water glass, silicate sol or a combination thereof, and the particle size of the catalyst ranges from 0.1 μm to 50 μm.

[0043] In the water-washing catalyst material of the present application, the curing agent can increase the overall chemical resistance and durability of the water-washing catalyst material, and greatly extend the service life of the water spray plate; cerium dioxide or activated carbon as the catalyst or cerium dioxide supported on activated carbon is a porous material, which can increase the contact area between gas and liquid and improve the filtering effect of AMC. Among them, cerium dioxide has the characteristics of Ce 3+ / Ce 4+ double oxidation state, which can directly promote the redox reaction, contribute to the transport of oxygen, improve the oxygen storage capacity (OSC), and supply more oxygen in the oxidation reaction. Moreover, CeO 2 has more crystalline defects and a less stable structure, so it has more exchangeable structure oxygen and higher oxidation ability. Its higher catalytic activity can further improve the filtering effect of volatile organic compounds (VOCs).

[0044] Examples and comparative examples

[0045] Cut the alumina fiber sheet as the substrate, prepare slurries with different ratios, and make examples and comparative examples of the water-washing catalyst material. The slurry ratios (weight ratios) and slurry physical properties of the examples and comparative examples are shown in Table 1.

[0046] Table 1

[0047]

[0048] It can be seen from the data in Table 1 that the proportion of the catalyst has little effect on the pH value of the slurry, and the viscosity of the slurry increases with the increase of the proportion of the catalyst.

[0049] The water-washing catalyst material of the example and the water spray plate material without catalyst of the comparative example are cut into test pieces of 10 cm × 10 cm. The coating weight of the slurry of the test pieces and the time for the water to vertically climb 10 cm are shown in Table 2.

[0050] Table 2

[0051]

[0052]

[0053] As can be seen from the data in Table 2, the coating weight of the slurry increases with the increase of the catalyst ratio. When the catalyst ratio is below 5%, it does not affect or even shortens the vertical water climbing time. When the catalyst ratio is above 5%, the vertical water climbing time increases, that is, the hydrophilicity of the water-washed catalyst material is reduced.

[0054] The filtration results of isopropanol (IPA) in the gas by the water-washed catalyst materials using different catalysts and the water spraying plate material without catalyst (Comparative Example 2) are shown in Table 3.

[0055] Table 3

[0056]

[0057] As can be seen from the data in Table 3, the catalyst of the water-washed catalyst material can effectively improve the filtration rate of organic compounds in AMC.

[0058] The water-washed catalyst material of the embodiment and the existing water spraying plate material without curing agent and catalyst (Comparative Example 3) were respectively immersed in acidic (pH = 2), neutral (pH = 7) and alkaline (pH = 11) solutions, and shaken for 4 weeks with a shaker at a rotation speed of 1000 rpm. Based on the weight before the test, the weight losses of the embodiment and Comparative Example 3 after 1 week, 2 weeks, 3 weeks and 4 weeks were measured as the tolerance test. Figure 3 This is the tolerance test chart of the water-washed catalyst material of the embodiment of the present application and the existing water spraying plate material without curing agent and catalyst of the comparative example. As Figure 3 shown, the water spraying plate material of Comparative Example 3 is not resistant to acid and alkali, disintegrates after 2 weeks in the acidic solution, disintegrates after 3 weeks in the neutral solution (water), and the weight loss in the alkaline solution reaches more than 20%; for the water-washed catalyst material of the embodiment, the weight loss does not exceed 3% after 4 weeks in the acidic solution and the neutral solution, and the weight loss does not exceed 1% after 4 weeks in the alkaline solution. From the results of the tolerance test, it can be seen that the water-washed catalyst material of the present application has excellent chemical resistance and durability, and can greatly extend the service life of the water spraying plate.

[0059] Figure 4 This is a three-dimensional schematic diagram of the water spraying plate using the water-washed catalyst material of the present application. As Figure 4 shown, the water spraying plate 4 includes a plurality of water-washed catalyst materials 2 stacked up and down. The structure and material of the water-washed catalyst material 2 are as described in the above embodiment. In this embodiment, the outer shape of the water-washed catalyst material 2 is rectangular and has an oblique wave structure 211. The plurality of water-washed catalyst materials 2 are stacked in reverse order, so that the inclination angles of the oblique wave structures 211 of two adjacent water-washed catalyst materials 2 are opposite (as Figure 4As shown by the arrow notation, the stacking thickness t of multiple water-washing catalyst materials 2 (i.e., the thickness of the water-spraying plate 4) is, for example but not limited to, 200 mm to 800 mm. The oblique corrugated structure 211 forms the flow channels of gas and liquid, which can increase the contact area and contact time between gas and liquid, and effectively improve the effect of filtering out AMC.

[0060] In summary, the water-washing catalyst material of the present application includes a curing agent and a catalyst. The curing agent can increase the chemical resistance and durability of the overall water-washing catalyst material, and greatly extend the service life of the water-spraying plate. The catalyst is a porous material, which can increase the contact area between gas and liquid and improve the filtering effect of AMC. The preparation method of the water-washing catalyst material of the present application can be formed by hot pressing the slurry-containing substrate at 100°C to 200°C through the composition of the slurry. The formed substrate soaked in the slurry again can be cured by drying at 100°C to 200°C to complete the water-washing catalyst material, which greatly reduces the processing temperature and manufacturing cost, thereby solving the problems of the prior art and achieving the purpose of the present application.

[0061] The above-described embodiments and / or implementation manners are only used to illustrate the preferred embodiments and / or implementation manners for implementing the technology of the present application, and do not impose any formal restrictions on the implementation manners of the technology of the present application. Any person skilled in the art can make some changes or modifications to other equivalent embodiments without departing from the scope of the technical means disclosed in the content of the present application, but should still be regarded as the same technology or embodiment as the present application in essence.

Claims

1. A water-washing catalyst material, characterized in that, the water-washing catalyst material comprises: a substrate including inorganic fibers selected from glass fibers, ceramic fibers, alumina fibers or combinations thereof; and a composite material layer formed on the substrate, including: an inorganic filler selected from alumina, aluminum hydroxide, silica, titanium dioxide or combinations thereof; an inorganic binder selected from silica, titanium dioxide, alumina, phosphates, borates, water glass, silicates or combinations thereof; a curing agent selected from epoxy resins, acrylics, polyurethanes or combinations thereof; and a catalyst selected from cerium dioxide, activated carbon or combinations thereof.

2. The water-washing catalyst material according to claim 1, characterized in that, the substrate has an inclined corrugated structure, the peak height of the inclined corrugated structure is between 3 mm and 8 mm, the distance between two adjacent peaks of the inclined corrugated structure is between 5 mm and 15 mm, and the included angle between the inclined corrugated structure and the center line of the geometric shape of the substrate is between 15° and 60°.

3. The water-washing catalyst material according to claim 1, characterized in that, the thickness of the composite material layer is between 0.2 mm and 1 mm.

4. The water-washing catalyst material according to claim 1, characterized in that, the particle size of the inorganic filler is between 0.01 μm and 10 μm.

5. The water-washing catalyst material according to claim 1, characterized in that, the particle size of the catalyst is between 0.1 μm and 50 μm.

6. A preparation method of a water-washing catalyst material, characterized in that, the preparation method of the water-washing catalyst material comprises: mixing an inorganic filler, an inorganic sol, a curing agent and a catalyst to form a slurry, wherein the weight ratio of the catalyst in the slurry is between 1% and 10%; cutting an inorganic fiber sheet to form a substrate; immersing the substrate in the slurry to form a slurry-containing substrate; hot-pressing the slurry-containing substrate at 100°C to 200°C to produce a formed substrate; immersing the formed substrate in the slurry at least once again; and drying the slurry of the formed substrate at 100°C to 200°C so that the slurry forms a composite material layer, thereby completing a water-washing catalyst material.

7. The preparation method of the water-washing catalyst material according to claim 6, characterized in that, the inorganic filler is selected from alumina, aluminum hydroxide, silica, titanium dioxide or combinations thereof; the inorganic sol is selected from silica sol, titanium dioxide sol, alumina sol, phosphate sol, borate sol, water glass, silicate sol or combinations thereof; the curing agent is selected from epoxy resins, acrylics, polyurethanes or combinations thereof; the catalyst is selected from cerium dioxide, activated carbon or combinations thereof.

8. The preparation method of the water-washing catalyst material according to claim 6, characterized in that, the pH value of the slurry is between 3 and 5, and the viscosity of the slurry is between 450 cps and 2000 cps.

9. The preparation method of the water-washing catalyst material according to claim 6, characterized in that, the inorganic fiber sheet is selected from inorganic fibers of glass fibers, ceramic fibers, alumina fibers or combinations thereof, and the weight of the inorganic fiber sheet per square meter is between 20 g and 65 g.

10. The preparation method of the water-washing catalyst material according to claim 6, characterized in that, The hot pressing time of the pulp-containing substrate at 100°C to 200°C is between 10 minutes and 30 minutes; the drying time of the slurry of the formed substrate at 100°C to 200°C is between 10 minutes and 30 minutes.

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