Foam Coated Filter Media for High Temperature Exhaust Gas
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Solution Overview
Problem
Conventional filter media fail to maintain high thermal stability and dust removal efficiency at medium to high temperatures, with existing foam coating methods consuming excessive energy and having limitations in thermal stability and dust removal efficiency.
Innovation Solution
A method involving the formation of a microporous surface layer on an inorganic fiber support using a foam coating process, with a specific ratio of heat-resistant resin, foam stabilizer, foaming agent, and thickener, followed by drying, pressing, and heat-treating to create a filter medium with uniformly distributed pores of 30 µm or less, enhancing heat resistance and dust collection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional filter media are directly applied to filter dust collectors at high temperature of 250°C or more, then dust collection performance can be maintained, but thermal stability deteriorates and the filter media becomes badly worn
Solution Approach 1:
The invention uses a composite structure consisting of an inorganic fiber support (glass fiber, quartz fiber, or alumina fiber) combined with a heat-resistant resin coating layer. This composite material approach allows the filter to maintain both mechanical integrity at high temperatures and effective dust collection performance, resolving the contradiction between reliability and thermal stability.
Solution Approach 2:
The invention changes the material parameters by selecting specific heat-resistant resins (polyimide, PTFE, aramid) that can withstand temperatures of 250°C or more. By modifying the chemical composition and thermal properties of the coating layer, the filter media maintains its structural stability and dust collection efficiency under high-temperature conditions.
2Reliability
If a porous surface layer is formed on the filter medium to prevent fine dust infiltration, then dust collection efficiency and life span are improved, but energy consumption increases due to vaporization of water in drying process
Solution Approach 1:
The invention optimizes the foam coating parameters by controlling the foam stability, bubble size, and drying temperature. By adjusting these parameters, the coating process achieves effective pore formation with reduced energy consumption, balancing dust collection efficiency with energy efficiency in the drying stage.
3Reliability
If foam coating method is used to form surface layer on filter medium, then porosity and dust removal efficiency are maximized, but thermal stability may be compromised without proper material selection
Solution Approach 1:
The invention creates a composite coating layer using heat-resistant resins (polyimide, PTFE, or aramid) combined with foam stabilizers and foaming agents. This composite formulation ensures that the porous surface layer maintains both high dust removal efficiency and thermal stability at temperatures of 250°C or more, resolving the contradiction between porosity and thermal stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting filter medium exhibits 99% or higher partial dust collection efficiency, 99.999% or higher total dust collection efficiency, and high heat resistance, effectively treating medium to high temperature exhaust gases while reducing energy consumption and improving surface filtration effects.
Implementation Method 1
a method involving the formation of a microporous surface layer on an inorganic fiber support using a foam coating process
Implementation Method 2
followed by drying, pressing, and heat-treating to create a filter medium with uniformly distributed pores
Implementation Method 3
followed by drying, pressing, and heat-treating to create a filter medium with uniformly distributed pores of 30 µm or less, enhancing heat resistance
Implementation Method 4
The resulting filter medium exhibits 99% or higher partial dust collection efficiency, 99.999% or higher total dust collection efficiency, and high heat resistance, effectively treating medium to high temperature exhaust gases
Data Source
AI summary
Disclosed herein is a method of producing a filter medium for treating medium and high temperature exhaust gas using foam coating and a filter medium produced using the method. The filter medium has excellent heat resistance and heat contraction resistance, and exhibits partial dust collection efficiency of 99% or more by weight, total dust collection efficiency of 99.999% or more by weight, and high dust removal efficiency, for all dust particle sizes. Further, the filter media can be efficiently used to treat medium and high temperature exhaust gas because pores having an average pore size of 30 D or less are uniformly distributed on the surface of the filter media.