CN106268027A - 一种高温滤材及其制备方法和应用 - Google Patents
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Abstract
一种高温滤材及其制备方法和应用,涉及一种过滤材料。所述高温滤材为单层结构的复合滤布或多层结构的复合滤布,所述复合滤布的组分按质量百分比为:宝德纶纤维为10%~90%,聚四氟乙烯纤维为10%~90%。高温滤材中的单层结构的复合滤布的制备方法;原料混合—开松—梳理—铺网—多层纤网层—针刺—定型—压光—成品;所述高温滤材中的多层结构的复合滤布的制备方法:原料混合—开松—梳理—铺网—多层纤网层—合刺—复刺—定型—压光—成品。高温滤材的应用是将单层结构的复合滤布或多层结构的复合滤布用于高温烟气除尘设备。具有高强度、一定密度和弹性的特点,呈无定向三维立体结构,无定向三维立体结构可为单层结构或多层结构。
Description
技术领域
本发明涉及一种过滤材料,尤其是涉及一种高温滤材及其制备方法和应用。
背景技术
纯宝德纶纤维化学名聚芳噁二唑纤维(简称POD纤维,商品名宝德纶),宝德纶是无机纤维,可以在250℃高温下长期使用,可在300℃下短时间使用,瞬间使用温度可达400℃。高温尺寸稳定性好:300℃下干热收缩率为1%,在燃烧时几乎不产生收缩。耐化学性能:除浓硫酸、发烟硫酸和三氟乙酸外,宝德纶不溶于任何已知的溶剂,耐有机溶剂性能异常突出;宝德纶化学结构较为稳定,耐碱性优于耐酸性;纤维具有柔韧性,高断裂伸长,不脆断,便于无纺布加工。
但由于宝德纶纤维对一些化学物质的耐蚀性也较差,尤其是用于带有酸性的高温环境滤料容易被腐蚀,因此,使用单纯的宝德纶纤维制成的过滤材料存在上述缺陷。
而聚四氟乙烯纤维不仅耐高温,其纤维熔点为327℃,实际使用温度240~260℃;聚四氟乙烯纤维化学稳定性极好,具有耐高湿、耐腐蚀、耐水解等优点,同时可承受各种强氧化物的氧化腐蚀,又具有良好的低磨擦性,较好的抗挠曲性,耐腐蚀性优于其他合成纤维品种,但导热性差,耐磨性也不好,热膨胀系数大,易产生静电。所以纯聚四氟乙烯纤维不便于无纺布加工成高温过滤材料,而且纯聚四氟乙烯纤维滤料拉伸强力差,耐磨性不好等,影响滤料的使用寿命。
由于聚四氟乙烯(PTFE)纤维具有良好的耐折性、耐腐蚀性等性能,宝德纶具有耐温性,强力高,耐磨性好,可纺性佳等性能,如将聚四氟乙烯纤维与宝德纶纤维两种原料混合制作成高温滤材(滤布)将具有更好的物理化学性能,能将宝德纶纤维和聚四氟乙烯纤维优点融合。
发明内容
本发明目的之一是提供一种可明显提高原料的可纺性、可加工性、耐腐蚀性、耐磨性及耐疲劳性的高温滤材;
本发明的目的之二是提供所述高温滤材的制备方法;
本发明的目的之三是提供所述高温滤材的应用。
为实现上述目的,本发明采用如下技术方案:
一种高温滤材,所述高温滤材为单层结构的复合滤布或多层结构的复合滤布,所述复合滤布的组分按质量百分比为:宝德纶纤维为10%~90%,聚四氟乙烯纤维为10%~90%。
所述高温滤材中的单层结构的复合滤布的制备方法;包括以下工序:
原料混合—开松—梳理—铺网—多层纤网层—针刺—定型—压光—成品;其中,原料混合工序为:按上述比例将宝德纶纤维与PTFE纤维混合后,经过和毛机和毛,边和毛边加水,形成混合原料,然后静置,让混合纤维充分吸收水份,消除纤维静电,制备出宝德纶与聚四氟乙烯的混合纤维;各工序的共同要求条件为:制备环境的相对湿度最好为60%~80%;生产设备均采用金属材料制作而成,保证充分导电和散热,而且要充分接地;在梳理机的喂入端和铺网机输入端均安装负离子风棒,上毛网传送带采用具有导电性的传输帘,保证充分消除纤维静电和热量。
进一步:所述加水最好采用喷雾状喷水;所述混合纤维的含水率为混合纤维总量的1%~5%;所述静置时间为24h。
所述高温滤材中的多层结构的复合滤布的制备方法;包括以下工序:
原料混合—开松—梳理—铺网—多层纤网层—合刺—复刺—定型—压光—成品;其中,原料混合工序为:按上述比例将宝德纶纤维与PTFE纤维混合,经过和毛机和毛,边和毛边加水,形成混合原料,然后静置,让混合纤维充分吸收水份,消除纤维静电,制备出宝德纶和聚四氟乙烯的混合纤维;各工序的共同要求条件为:制备环境的相对湿度最好为60%~80%;生产设备均采用金属材料制作而成,保证充分导电和散热,而且要充分接地;在梳理机的喂入端和铺网机输入端均安装负离子风棒;上毛网传送带采用具有导电性的传输帘,保证充分消除纤维静电和热量。
进一步:所述加水最好采用喷雾状喷水;所述混合纤维的含水率为混合纤维总量的1%~5%;所述静置时间为24h。
所述高温滤材的应用,是将单层结构的复合滤布或多层结构的复合滤布用于高温烟气除尘设备。
与现有技术比较,本发明具有如下有益效果:
通过上述制作方法所制成的针刺毡布,具有高强度、一定密度和弹性的特点,呈无定向三维立体结构,无定向三维立体结构可为单层结构或多层结构。其纤维层内部呈曲折路径,孔隙尺寸小,而空隙率可达75%以上,阻力小,透气性能好,除尘效率超过99.9%。由于所制成的针刺毡布经过定型、压光等后处理和表面处理后,其表面平整光滑,不易被粉尘所堵塞,可实现更优的物理化学性能。
宝德纶纤维和PTFE纤维复合高温滤料,不论是它的耐腐蚀性、耐磨性及耐疲劳性,还是它的抗拉强度都优于单纯的宝德纶纤维或纯PTFE纤维滤料,与其它高温滤料也具有明显的优势,因此宝德纶纤维与聚四氟乙烯纤维两种材料复合具有良好的增强效应,该种高温针刺毡过滤材料在高温烟气除尘设备中运用具有很好的效果,使用寿命长。本发明能有效地提高过滤材料的使用寿命,耐酸碱程度高,过滤速度快,污染治理效果好,满足了烟气高温过滤行业的需要,可适用于水泥行业、垃圾焚烧炉、钢铁冶炼厂、焦化炉火电厂、炭黑化工、冶金、燃煤锅炉、耐火材料等工业的高温烟气过滤等领域,是一种十分理想的高温复合过滤材料。
由于水的介电常数小,纤维的介电常数大,增加纤维原料的吸水性(给出原料纤维含水率数值范围),来降低原料纤维的电阻值,增加原料纤维导电性,消除静电;另一方面纤维原料里的水分子从液态变成汽态可吸收纤维与设备间的磨擦热量,减少纤维发热,便于疏理成网,无纺加工制作成高温过滤材料。所以通过以下方法来增加原料的吸水性。宝德纶纤维含有亲水基团,无定形结构为主,低结晶度,其吸水能力远高于PTFE纤维,它与PTFE混合来增加纤维原料的吸水性。
宝德纶纤维疏松,纤维表面粗糙,微孔隙多,密度小,表面有很多毛细孔,比表面积大,而PTFE纤维密度大,表面光滑,又很致密,PTFE吸水能力远低于其它纤维,宝德纶与PTFE混合来增加原料的吸水性。
调节好生产车间环境相对湿度在60%~80%,水分子浓度增加,纤维吸附水能力大大加强,水分子容易进纤维内部缝隙孔洞;但相对湿度又不适宜太高,如相对湿度太高,环境中多余的水分纤维原料无法吸收,多余的水分会附在辊子表面,发生原料纤维粘辊现象。
具体实施方式
实施例1
1)采用50%宝德纶纤维+50%PTFE纤维混合后,经过和毛机和毛,边和毛边加水,采用喷雾状加水,按纤维总量的5%喷水,形成混合原料,静置24h,让混合纤维充分吸收水份。
实施例2
1)例如采用30%宝德纶纤维+70%PTFE纤维混合后,经过和毛机和毛,边和毛边加水,采用喷雾状加水,按纤维总量的5%喷水,形成混合原料,静置24h,让混合纤维充分吸收水份。
1)例如采用60%宝德纶纤维+40%PTFE纤维混合后,经过和毛机和毛,边和毛边加水,采用喷雾状加水,按纤维总量的5%喷水,形成混合原料,静置24h,让混合纤维充分吸收水份。
本发明制备的高温滤材的应用,是将单层结构的复合滤布或多层结构的复合滤布用于高温烟气除尘设备。
Claims (6)
1.一种高温滤材,为单层结构的复合滤布或多层结构的复合滤布,其特征在于,所述复合滤布的组分按质量百分比为:宝德纶纤维为10%~90%,聚四氟乙烯纤维为10%~90%。
2.如权利要求1所述一种高温滤材中的单层结构的复合滤布的制备方法,其特征在于,所述复合滤布的组分按质量百分比为:宝德纶纤维为10%~90%,聚四氟乙烯纤维为10%~90%;所述制备方法包括以下工序:
原料混合—开松—梳理—铺网—多层纤网层—针刺—定型—压光—成品;其中,原料混合工序为:按比例将宝德纶纤维与PTFE纤维混合后,经过和毛机和毛,边和毛边加水,形成混合原料,然后静置,让混合纤维充分吸收水份,消除纤维静电,制备出宝德纶与聚四氟乙烯的混合纤维;各工序的共同要求条件为:制备环境的相对湿度最好为60%~80%;生产设备均采用金属材料制作而成,保证充分导电和散热,而且要充分接地;在梳理机的喂入端和铺网机输入端均安装负离子风棒,上毛网传送带采用具有导电性的传输帘,保证充分消除纤维静电和热量。
3.如权利要求2所述一种高温滤材中的单层结构的复合滤布的制备方法,其特征在于,所述加水采用喷雾状喷水;所述混合纤维的含水率为混合纤维总量的1%~5%;所述静置时间为24h。
4.如权利要求1所述一种高温滤材中的多层结构的复合滤布的制备方法,其特征在于,所述复合滤布的组分按质量百分比为:宝德纶纤维为10%~90%,聚四氟乙烯纤维为10%~90%;所述制备方法包括以下工序:
原料混合—开松—梳理—铺网—多层纤网层—合刺—复刺—定型—压光—成品;其中,原料混合工序为:按比例将宝德纶纤维与PTFE纤维混合,经过和毛机和毛,边和毛边加水,形成混合原料,然后静置,让混合纤维充分吸收水份,消除纤维静电,制备出宝德纶和聚四氟乙烯的混合纤维;各工序的共同要求条件为:制备环境的相对湿度最好为60%~80%;生产设备均采用金属材料制作而成,保证充分导电和散热,而且要充分接地;在梳理机的喂入端和铺网机输入端均安装负离子风棒;上毛网传送带采用具有导电性的传输帘,保证充分消除纤维静电和热量。
5.如权利要求4所述一种高温滤材中的多层结构的复合滤布的制备方法,其特征在于,所述加水采用喷雾状喷水;所述混合纤维的含水率为混合纤维总量的1%~5%;所述静置时间为24h。
6.如权利要求1所述一种高温滤材的应用,是将单层结构的复合滤布或多层结构的复合滤布用于高温烟气除尘设备。
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