CN111804063A - Preparation method of high-temperature-resistant filter material - Google Patents
Preparation method of high-temperature-resistant filter material Download PDFInfo
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- CN111804063A CN111804063A CN202010778617.1A CN202010778617A CN111804063A CN 111804063 A CN111804063 A CN 111804063A CN 202010778617 A CN202010778617 A CN 202010778617A CN 111804063 A CN111804063 A CN 111804063A
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/02—Particle separators, e.g. dust precipitators, having hollow filters made of flexible material
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
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- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
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- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
- D06M13/50—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with organometallic compounds; with organic compounds containing boron, silicon, selenium or tellurium atoms
- D06M13/51—Compounds with at least one carbon-metal or carbon-boron, carbon-silicon, carbon-selenium, or carbon-tellurium bond
- D06M13/513—Compounds with at least one carbon-metal or carbon-boron, carbon-silicon, carbon-selenium, or carbon-tellurium bond with at least one carbon-silicon bond
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- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/244—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons
- D06M15/256—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons containing fluorine
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- D—TEXTILES; PAPER
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- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/53—Polyethers
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- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/643—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/10—Filtering material manufacturing
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- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/16—Synthetic fibres, other than mineral fibres
- D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
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Abstract
A preparation method of a high-temperature resistant filter material belongs to the technical field of filter dust removal materials. Comprises the steps of 1) mixing, 2) opening, 3) lapping, 4) needling, 5) dipping and 6) laminating; 1) mixing: uniformly mixing basalt fibers and polybenzimidazole fibers in a weight ratio of 3-4: 1-2; 5) dipping: padding the needled felt with a treatment solution, wherein the rolling allowance is 29-33%; then, drying at 190-220 ℃, baking at 250-320 ℃, rolling at the drying and baking speed of 4-5 m/min; the treatment fluid consists of the following components in percentage by mass: 15-26% of polytetrafluoroethylene dispersion liquid, 2-6% of dimethyl diphenyl polysiloxane, 0.7-3% of 3-aminopropyl triethoxysilane, 0.5-1% of tween and the balance of water. The filter material obtained by the invention has good high temperature resistance, can resist 280-295 ℃ for a long time, has an instant heat-resistant temperature of 320 ℃, and has a service life of more than 2 years.
Description
Technical Field
A preparation method of a high-temperature resistant filter material belongs to the technical field of filter dust removal materials.
Background
The filter material is a non-woven filter felt made of basalt fibers, and can be used for manufacturing a filter bag, and the filter bag is installed in dust removal equipment and used for removing dust of industrial waste gas. The existing filtering material is mostly formed by combing basalt fibers into a net and compounding the net with base cloth by needling to form a filtering felt; the filter felt is then impregnated with an impregnating solution to increase strength. With the enhancement of environmental awareness, the application of the filtering material is gradually wide, and the filtering material is commonly used in a dust removal, desulfurization and denitrification continuous waste gas treatment process.
The applicant found in research that the existing filter materials have the following problems:
firstly, the existing filter material has poor high temperature resistance, can be used for a long time only within the temperature of 280-295 ℃, but cannot resist the instantaneous high temperature of more than 310 ℃. The existing dust removal, desulfurization and denitrification continuous waste gas treatment process is a continuous process, dust is removed by using dust removal equipment containing a filter material, then the dust-removed waste gas is introduced into a desulfurization tower and denitrification tower to carry out desulfurization and denitrification, the desulfurization and denitrification process requires that the temperature of the filtered waste gas is over 280 ℃, otherwise, the desulfurization and denitrification effect is influenced, and therefore, the waste gas cannot be subjected to cooling treatment before passing through the filter material. In actual industrial waste gas, the temperature of the waste gas is fluctuated, the conventional temperature is 280-295 ℃, but the instantaneous ultrahigh temperature condition of 310-320 ℃ can occur, so that the conventional filtering material is damaged and hardened, and the filtering performance is lost.
Secondly, the existing filter materials have a short life. When the filter material is used at the exhaust gas temperature of 280-295 ℃, the existing filter material can be used for only half a year-1 year, the problems of damage, hardening and layering can occur, the filter bag is repeatedly replaced, and the dust removal cost is increased. If the instantaneous temperature of the waste gas exceeds 310 ℃, the conventional filter material can be continuously used for only 1-3 days. If the filter material is damaged and layered, dust cannot be effectively removed, so that the waste gas cannot meet the emission requirement; the stiffness of the filter material can result in the filter material being impermeable to air and likewise ineffective in removing dust.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the preparation method of the high-temperature-resistant filter material overcomes the defects of the prior art, and the high-temperature-resistant filter material prepared by the method has good high-temperature resistance, can resist temperature of 280-295 ℃ for a long time, has an instant heat-resistant temperature of 320 ℃, and has a service life of more than 2 years.
The technical scheme adopted by the invention for solving the technical problems is as follows: the preparation method of the high-temperature resistant filter material comprises the steps of 1) mixing, 2) opening, 3) lapping, 4) needling, 5) dipping and 6) laminating; the specific operation is as follows:
1) mixing: uniformly mixing basalt fibers and polybenzimidazole fibers in a weight ratio of 3-4: 1-2 to obtain mixed fibers;
3) lapping: the mixed fiber net is cross-lapped on the upper surface and the lower surface of the basalt base cloth to form an upper fiber layer and a lower fiber layer, and the gram weight of the upper fiber layer is 200-220 g/m2The gram weight of the lower fiber layer is 180-220 g/m2Obtaining a plain felt;
5) dipping: padding the needled felt with the treatment fluid to obtain a padding allowance of 29-33% (by mass); then drying at 190-220 ℃ and baking at 250-320 ℃ in sequence, wherein the drying and baking speed is 4-5 m/min, and rolling to obtain an impregnated felt;
the treatment fluid consists of the following components in percentage by mass: 15-26% of polytetrafluoroethylene dispersion liquid, 2-6% of dimethyl diphenyl polysiloxane, 0.7-3% of 3-aminopropyl triethoxysilane, 0.5-1% of tween and the balance of water.
The opening operation in the step 2) is as follows: and (3) coarsely opening and finely opening the mixed fibers, and then sending the mixed fibers into a carding machine for carding to form a mixed fiber net.
The needling operation in the step 4) comprises the following specific steps: and (3) sequentially pre-needling, upward needling, downward needling, upward needling and surface modification on the plain felt, wherein the drafting ratio in the needling process is 2-3%, so that the needled felt is obtained.
The step 6) of coating specifically comprises the following steps: coating a PTFE film on the upper surface of the impregnated felt; the film coating temperature is 360-390 ℃, the film coating speed is 6-10 m/min, and the film coating pressure is 4.5-7 kg/cm, so that the high-temperature-resistant filter material is obtained.
The polybenzimidazole fiber of the step 1) has the fiber number of 1.7-2.2 Dtex and the fiber length of 51-60 mm; the basalt fiber single fiber has the diameter of 6-8 mu m and the fiber length of 46-56 mm.
The treatment liquid in the step 5) consists of the following components in percentage by mass: 18-25% of polytetrafluoroethylene dispersion, 3-5% of dimethyl diphenyl polysiloxane, 0.8-1.5% of 3-aminopropyl triethoxysilane, 0.6-0.9% of tween and the balance of water;
the Tween in the step 5) is Tween T-80.
The specific operation of uniformly mixing in the step 1) is as follows: and (3) layering, stacking and mixing, namely paving a layer of basalt fiber, paving a layer of polybenzimidazole fiber, and repeating the operations for 2-4 times.
And 3) the number of the cross lapping layers is 8 layers of mixed fiber nets on the upper fiber layer, and 7-8 layers of mixed fiber nets on the lower fiber layer.
The gram weight of the PTFE membrane in the step 6) is 2.2-5 g/m2The thickness is more than or equal to 10 mu m, and the aperture is 0.5-3 mu m.
The invention is described below:
the invention has high durabilityThe temperature filtering material sequentially comprises from top to bottom: PTFE membrane, upper fiber layer, basalt base cloth and lower fiber layer. The upper fiber layer, the base cloth layer and the lower fiber layer are subjected to the dipping treatment in the step 5). When the filter bag is sewn, the PTFE membrane faces the outside of the filter bag, and the lower fiber layer faces the inside of the filter bag. The mixed fibers used by the upper fiber layer and the lower fiber layer are basalt fibers and PBI fibers which are mixed according to the weight ratio of 3-4: 1-2. The thickness of the high-temperature resistant filter material obtained in the step 6) is 2.6-3.0 mm, and the gram weight is 870-930 g/m2。
The continuous use temperature of the martial rock fiber can reach 350 ℃, and the instant use temperature can reach 600 ℃. The fiber melting temperature is 1450-1500 ℃. The basalt fiber has good acid resistance and alkali resistance, and the strength retention rate can reach more than 90 percent after the basalt fiber is soaked in a strong alkali solution for treatment for a long time. After long-time soaking in sulfuric acid solution, the strength retention rate can reach more than 85%. The basalt fiber with the diameter of 6-8 mu m mainly solves the problems of too thick single fiber and poor filtering precision of the basalt fiber in the basalt market, and the anti-folding property of the fiber can be well solved by using the basalt fiber with the diameter of 6-8 mu m.
The PBI fiber has excellent temperature resistance, acid and alkali resistance and steam hydrolysis resistance. The long-term use temperature of the PBI fiber can reach 310 ℃, and the instantaneous use temperature is 450 ℃. At different temperatures, the PBI fiber can still maintain about 50% of the initial strength even after being treated by high-temperature sulfuric acid steam with the temperature of more than 400 ℃. After the PBI fiber is soaked in 10-50% sulfuric acid for 24 hours to 144 hours, the strength retention rate is over 90%; the strength of PBI fiber is not obviously reduced after being placed in 75% concentrated sulfuric acid steam for 3 h. The strength retention rate of the PBI fiber is more than 95% after the PBI fiber is treated for 144 hours in 35% hydrochloric acid concentration immersion. The strength retention of the PBI fiber after being treated in 70% nitric acid solution for 144h is 100%. The strength retention rate of the PBI fiber is 65-95% after the PBI fiber is treated in a 10% sodium hydroxide solution for 2-144 h. The PBI fiber has strong steam hydrolysis resistance, and the strength of the PBI fiber is basically unchanged after the PBI fiber is subjected to high-pressure steam treatment at 182 ℃ for 16 h.
Step 1) mixing basalt fibers and PBI fibers according to a weight ratio of 3-4: 1-2 to obtain a mixed fiber with excellent comprehensive performance, wherein the mixed fiber is high in filtering precision, acid-resistant, alkali-resistant, steam hydrolysis-resistant, high in cohesion among fibers and long in service life of a filtering material.
In the research of the applicant, the problem of uneven fiber distribution often occurs in the filter material made of the existing mixed fibers, different fibers are distributed in a patch shape, and the different fibers distributed in the patch shape cause uneven filter performance distribution, reduce the folding resistance of the filter material and are easy to break. The specific operation of uniformly mixing in the step 1) adopts layered superposition mixing, so that two fibers can be mixed in a layered manner, the filtering precision and the uniformity are obviously improved, the cohesive force between the fibers is also improved, and the service life of the filtering material is prolonged.
The basalt base cloth can improve the strength of the filter material, increase the temperature resistance of the filter material and slow down the strong attenuation of the filter material in the ultra-high temperature dust removal at 280-320 ℃.
Preferably, the polybenzimidazole fiber titer of the step 1) is 1.7-2.2 Dtex, and the fiber length is 51 mm; the basalt fiber fineness is 6-8 mu m, and the fiber length is 51 mm.
And 3) cross lapping, wherein the environmental temperature is 20-35 ℃, and the relative humidity is 40-75%.
The solid content of the polytetrafluoroethylene dispersion liquid obtained in the step 5) is 58-62 wt%, wherein the surfactant content is 4-7 wt%, and the pH value is 8.5-10.5. The density is 1.48 to 1.52g/m3，Viscosity of 10 to 30X 103Pa·S。
And 5) baking for 4-6 min. Drying can remove moisture in the upper fiber layer and the lower fiber layer, and then baking at 250-320 DEG C
Further preferably, the PTFE membrane in the step 6) has air permeability of 50-75L/m2S (127 pa), tensile breaking strength is greater than or equal to 3 MPa in the longitudinal direction and greater than or equal to 3 MPa in the transverse direction, elongation at break is greater than or equal to 80% in the longitudinal direction and greater than or equal to 80% in the transverse direction.
Preferably, the diameter of the single fiber of the basalt base cloth in the step 3) is 5-9 μm. The yarn is 400Dtex, and the warp and weft density of the base fabric is as follows: 5 warps/cm and 6 +/-0.55 wefts/cm.
Compared with the prior art, the invention has the beneficial effects that:
1. the high-temperature-resistant filter material prepared by the preparation method has good high-temperature resistance, can resist temperature of 280-295 ℃ for a long time, can resist temperature of 320 ℃ instantly, and has a service life of more than 2 years.
Firstly, basalt fibers and polybenzimidazole fibers are used for preparing mixed fibers according to the weight ratio of 3-4: 1-2, so that the filtering precision, acid and alkali resistance and steam hydrolysis resistance of an upper fiber layer and a lower fiber layer are improved. In addition, the inorganic fibers and the organic fibers are combined, and after the basalt fibers and the polybenzimidazole fibers are mixed according to the weight ratio of 3-4: 1-2, the abrasion resistance of the filter material and the cohesive force among the fibers are improved, so that the upper fiber layer and the lower fiber layer are firmly attached to the basalt base cloth, and the filter material is not easy to delaminate and break.
Secondly, the formula of the treating fluid is improved; the dimethyl diphenyl polysiloxane and the 3-aminopropyl triethoxysilane both have good heat resistance, wherein the dimethyl diphenyl polysiloxane has a high flash point and excellent heat and water resistance, and can solve the problem that a filter material is hard at high temperature, and the 3-aminopropyl triethoxysilane can improve the binding force between polytetrafluoroethylene and fibers, improve the heat resistance strength of the filter material, and avoid the filter material from being damaged in a high-temperature environment. The Tween-80 has the effects of stability, static resistance and emulsifier, can prevent the generation of bubbles, and improve the cohesiveness of the upper fibrous layer and the PTFE membrane so as to prevent the PTFE membrane layer from being peeled off from the upper fibrous layer.
The filter material solves the problem of filter property loss caused by instantaneous temperature rise of waste gas, and meets the requirements of a dust removal, desulfurization and denitrification continuous process.
2. The high-temperature resistant filter material has high filter precision.
Firstly, the too coarse filtering performance of basalt fibers is poor, in the step 1), the basalt fibers and polybenzimidazole fibers are mixed according to the weight ratio of 3-4: 1-2, the polybenzimidazole fibers are organic fibers, the titer of the polybenzimidazole fibers can reach 1.7-2.2 Dtex, and the filtering precision can be obviously improved by compounding the two fibers.
Secondly, the superposition mixing is adopted in the step 1), so that the two fibers are fully mixed, the filtration precision and the cohesive force between the fibers are improved, and the problem of uneven filtration caused by the mixed fibers is solved.
And thirdly, padding the treatment liquid by adopting a formula of 18-25% of polytetrafluoroethylene dispersion liquid, 3-5% of dimethyl diphenyl polysiloxane, 0.8-1.5% of 3-aminopropyl triethoxysilane, 0.6-0.9% of tween and the balance of water, and drying at 190-220 ℃ and baking at 250-320 ℃ to improve the bonding strength and the filtering precision among the upper fiber layer, the base cloth layer and the lower fiber layer. Further, the PTFE membrane can further improve the filtration accuracy and the dust separation rate by coating in step 6).
Detailed Description
The preparation method of a high temperature resistant filter material of the present invention is further described with reference to the following specific examples, wherein example 1 is the best example.
PBI fiber, which is produced by PBI performance products Inc in America and has the specification of 1.7-2.2 Dtex multiplied by 51 mm;
basalt fiber, produced by Shandong Xinghu Dacheng Special fiber science and technology Limited, is in the specification of single fiber phi 6-8 mu m multiplied by 51mm of the basalt fiber;
basalt base cloth produced by Shandong Xinghuo Dacheng Special fiber science and technology Limited company and having a gram weight of 420 g/m2The diameter of the single fiber is 5-9 μm. The yarn is 400Dtex, and the warp and weft density of the base fabric is 5 warps/cm; weft density is 6 +/-0.55 roots/cm;
3-aminopropyltriethoxysilane, produced by Shanghai Allantin Biotechnology, Inc., CAS No. 919-30-2, product No. A107147;
dimethyldiphenylpolysiloxane, product of McCard reagent, CAS number 68083-14-7;
tween-80, chemical name: polyoxyethylene (20) sorbitan fatty acid ester, produced by Shuangli chemical industry Co., Ltd, Yixing city, with hydroxyl value of 68-85 mgKOH/g and HLB value of 15;
polytetrafluoroethylene dispersion, Zhonghao Cheng optical chemical research institute Co., Ltd., CAS number 9002-84-0. The solid content is 60wt%, wherein the surfactant content is 4-7 wt%, the pH value is 8.5-10.5, and the density is 1.48-1.52 g/m3，Viscosity of 10 to 30X 103Pa·S；
PTFE film manufacturer, Shanghai Lingfulum film technology Co., Ltd., LFL-K type; grammage of PTFE film2.2~5g/m2The thickness is more than or equal to 10 mu m, the aperture is 0.5-2 mu m, and the air permeability of the PTFE membrane is 50-75L/m2S (127 pa), tensile breaking strength is more than or equal to 3 MPa in the longitudinal direction and more than or equal to 3 MPa in the transverse direction, elongation at break is more than or equal to 80% in the longitudinal direction and more than or equal to 80% in the transverse direction;
examples 1-5 the equipment used in step 1) is a bale opener; the equipment used in the step 2) is an opener and a carding machine; the equipment used in the step 3) is a lapping machine; 4) the equipment used for needling is a needling machine; 4) the needle punching process parameters are shown in table 1.
TABLE 1 needling Process parameters
Example 1
The method of the embodiment comprises the following steps:
1) mixing: mixing basalt fibers and polybenzimidazole fibers according to a weight ratio of 4:1, adopting layered superposition mixing, firstly laying a layer of basalt fibers, then laying a layer of polybenzimidazole fibers, and repeating the operation for 4 times to obtain mixed fibers;
2) opening: coarsely opening and finely opening the mixed fibers, and then sending the mixed fibers into a carding machine for carding to form a mixed fiber net;
3) lapping: the mixed fiber net is crossly lapped on the upper surface and the lower surface of the basalt base cloth, the number of crossly lapped layers is 8 layers of mixed fiber net on the upper fiber layer, the number of mixed fiber net on the lower fiber layer is 8 layers of mixed fiber net, an upper fiber layer and a lower fiber layer are formed, the gram weight of the upper fiber layer is 200g/m2The gram weight of the lower fiber layer is 200g/m2The lapping environment temperature is 20-35 ℃, and the relative humidity is 40-75%, so that a plain felt is obtained;
4) and (3) needling: sequentially carrying out pre-needling, upward needling, downward needling, upward needling and face trimming on the plain felt, wherein the drafting ratio in the needling process is 2 percent, so as to obtain the needled felt;
5) dipping: padding the needled felt with the treatment fluid, wherein the rolling residue rate is 30%; then drying at 200-210 ℃ and baking at 290-310 ℃ for 5min in sequence, wherein the drying and baking speed is 4m/min, and rolling to obtain an impregnated felt;
the treatment fluid consists of the following components in percentage by mass: 23% of polytetrafluoroethylene dispersion liquid, 4% of dimethyl diphenyl polysiloxane, 1.2% of 3-aminopropyl triethoxysilane, 0.7% of tween and the balance of water. (ii) a
6) Film covering: coating a PTFE film on the upper surface of the impregnated felt; the laminating temperature is 380 ℃, the laminating speed is 8m/min, and the laminating pressure is 6kg/cm, so that the high-temperature-resistant filter material is obtained.
Example 2
The method of the embodiment comprises the following steps:
1) mixing: mixing basalt fibers and polybenzimidazole fibers according to a weight ratio of 3:1, adopting layered superposition mixing, firstly laying a layer of basalt fibers, then laying a layer of polybenzimidazole fibers, and repeating the operation for 4 times to obtain mixed fibers;
2) opening: coarsely opening and finely opening the mixed fibers, and then sending the mixed fibers into a carding machine for carding to form a mixed fiber net;
3) lapping: the mixed fiber net is crossly lapped on the upper surface and the lower surface of the basalt base cloth, the number of crossly lapped layers is 8 layers of mixed fiber net on the upper fiber layer, the number of mixed fiber net on the lower fiber layer is 7 layers of mixed fiber net, an upper fiber layer and a lower fiber layer are formed, the gram weight of the upper fiber layer is 220g/m2The gram weight of the lower fiber layer is 190 g/m2The lapping environment temperature is 20-35 ℃, and the relative humidity is 40-75%, so that a plain felt is obtained;
4) and (3) needling: sequentially carrying out pre-needling, upward needling, downward needling, upward needling and face trimming on the plain felt, wherein the drafting ratio in the needling process is 3 percent, so as to obtain the needled felt;
5) dipping: padding the needled felt with the treatment fluid, wherein the rolling residue rate is 30%; then drying at 190-200 ℃ and baking at 290-310 ℃ for 4.5min in sequence, wherein the drying and baking speed is 5m/min, and rolling to obtain an impregnated felt;
the treatment fluid consists of the following components in percentage by mass: 25% of polytetrafluoroethylene emulsion, 3% of dimethyl diphenyl polysiloxane, 1.5% of 3-aminopropyl triethoxysilane, 80.6% of Tween T and the balance of water;
6) film covering: coating a PTFE film on the upper surface of the impregnated felt; the laminating temperature is 370 ℃, the laminating speed is 7m/min, and the laminating pressure is 5.5kg/cm, so that the high-temperature-resistant filter material is obtained.
Example 3
The method of the embodiment comprises the following steps:
1) mixing: mixing basalt fibers and polybenzimidazole fibers according to a weight ratio of 3.5:1.5, adopting layered superposition mixing, firstly laying a layer of basalt fibers, then laying a layer of polybenzimidazole fibers, and repeating the above operations for 3 times to obtain mixed fibers;
2) opening: coarsely opening and finely opening the mixed fibers, and then sending the mixed fibers into a carding machine for carding to form a mixed fiber net;
3) lapping: the mixed fiber net is crossly lapped on the upper surface and the lower surface of the basalt base cloth, the number of crossly lapped layers is 8 layers of mixed fiber net on the upper fiber layer, the number of mixed fiber net on the lower fiber layer is 7 layers of mixed fiber net, an upper fiber layer and a lower fiber layer are formed, the gram weight of the upper fiber layer is 210g/m2The gram weight of the lower fiber layer is 180 g/m2The lapping environment temperature is 20-35 ℃, and the relative humidity is 40-75%, so that a plain felt is obtained;
4) and (3) needling: sequentially carrying out pre-needling, upward needling, downward needling, upward needling and face trimming on the plain felt, wherein the drafting ratio in the needling process is 2 percent, so as to obtain the needled felt;
5) dipping: padding the needled felt with the treatment fluid to obtain a rolling residual rate of 31 percent; then drying at 210-220 ℃ and baking at 270-290 ℃ for 5.5min in sequence, wherein the drying and baking speed is 4m/min, and rolling to obtain an impregnated felt;
the treatment fluid consists of the following components in percentage by mass: 18% of polytetrafluoroethylene emulsion, 5% of dimethyl diphenyl polysiloxane, 0.8% of 3-aminopropyl triethoxysilane, 0.8% of tween T-800.9 and the balance of water;
6) film covering: coating a PTFE film on the upper surface of the impregnated felt; the film coating temperature is 360 ℃, the film coating speed is 6m/min, and the film coating pressure is 7kg/cm, so that the high-temperature-resistant filter material is obtained.
Example 4
The method of the embodiment comprises the following steps:
1) mixing: mixing basalt fibers and polybenzimidazole fibers according to a weight ratio of 3.7: 2, adopting layered superposition mixing, firstly laying a layer of basalt fibers, then laying a layer of polybenzimidazole fibers, and repeating the operation for 2 times to obtain mixed fibers;
2) opening: and (3) coarsely opening and finely opening the mixed fibers, and then sending the mixed fibers into a carding machine for carding to form a mixed fiber net.
3) Lapping: the mixed fiber net is crossly lapped on the upper surface and the lower surface of the basalt base cloth, the number of crossly lapped layers is 8 layers of mixed fiber net on the upper fiber layer, the number of mixed fiber net on the lower fiber layer is 8 layers of mixed fiber net, an upper fiber layer and a lower fiber layer are formed, the gram weight of the upper fiber layer is 200g/m2The gram weight of the lower fiber layer is 200g/m2The lapping environment temperature is 20-35 ℃, and the relative humidity is 40-75%, so that a plain felt is obtained;
4) and (3) needling: sequentially carrying out pre-needling, upward needling, downward needling, upward needling and face trimming on the plain felt, wherein the drafting ratio in the needling process is 2 percent, so as to obtain the needled felt;
5) dipping: padding the needled felt with the treatment fluid to obtain 29% of rolling allowance; then drying at 190-200 ℃ and baking at 250-270 ℃ for 6min in sequence, wherein the drying and baking speed is 5m/min, and rolling to obtain an impregnated felt;
the treatment fluid consists of the following components in percentage by mass: 26% of polytetrafluoroethylene emulsion, 2% of dimethyl diphenyl polysiloxane, 3-aminopropyl triethoxysilane, 3% of Tween T-800.5% and the balance of water.
6) Film covering: coating a PTFE film on the upper surface of the impregnated felt; the film coating temperature is 370 ℃, the film coating speed is 8m/min, and the film coating pressure is 6kg/cm, so that the high-temperature-resistant filter material is obtained.
Example 5
The method of the embodiment comprises the following steps:
1) mixing: mixing basalt fibers and polybenzimidazole fibers according to a weight ratio of 3: 2, adopting layered superposition mixing, firstly laying a layer of basalt fibers, then laying a layer of polybenzimidazole fibers, and repeating the operation for 4 times to obtain mixed fibers;
2) opening: and (3) coarsely opening and finely opening the mixed fibers, and then sending the mixed fibers into a carding machine for carding to form a mixed fiber net.
3) Lapping: the mixed fiber net is crossly lapped on the upper surface and the lower surface of the basalt base cloth, and the number of layers of the crossly lapped net is upperThe fiber layer is 8 layers of mixed fiber net, the lower fiber layer is 7 layers of mixed fiber net to form an upper fiber layer and a lower fiber layer, and the gram weight of the upper fiber layer is 210g/m2The gram weight of the lower fiber layer is 180 g/m2The lapping environment temperature is 20-35 ℃, and the relative humidity is 40-75%, so that a plain felt is obtained;
4) and (3) needling: sequentially carrying out pre-needling, upward needling, downward needling, upward needling and face trimming on the plain felt, wherein the drafting ratio in the needling process is 2 percent, so as to obtain the needled felt;
5) dipping: padding the needled felt with the treatment fluid to obtain a rolling residue rate of 33%; then drying at 210-220 ℃ and baking at 300-320 ℃ for 4min in sequence, wherein the drying and baking speed is 4m/min, and rolling to obtain an impregnated felt;
the treatment fluid consists of the following components in percentage by mass: 15% of polytetrafluoroethylene emulsion, 6% of dimethyl diphenyl polysiloxane, 0.7% of 3-aminopropyl triethoxysilane, 0.1% of Tween T-800.5 and the balance of water.
6) Film covering: coating a PTFE film on the upper surface of the impregnated felt; the film coating temperature is 390 ℃, the film coating speed is 10m/min, and the film coating pressure is 4.5kg/cm, so that the high-temperature-resistant filter material is obtained.
Performance testing
The filter materials obtained in the examples were subjected to performance tests for dust removal performance and heat resistance. The test standards and test items are detailed in the table below.
The service life detection method comprises the following steps: the filter materials of the examples are made into filter bags, each filter bag of the examples is respectively arranged in a dust removing device, and the continuous waste gas treatment of dust removal, desulfurization and denitration is operated for more than 300 days all the year round. The normal temperature of the waste gas is 280-295 ℃, and the instantaneous high temperature is 312-318 ℃. And monitoring the treated waste gas, and judging that the service life of the filter material in the embodiment is terminated when the dust content in the waste gas after dust removal treatment is more than 10 mg/Nm.
Folding endurance times: and testing at 320 ℃ for 24h, and testing the standard T/CAEPI 21-2019, wherein the folding times are used for verifying whether the filtering material is hardened under the ultrahigh temperature condition. The folding times are about more, and the better the high temperature hardening resistance effect is proved.
TABLE 2 Heat resistance test results
TABLE 3 dust removal Performance test results
As can be seen from table 2: the filter material obtained by the invention has good breaking strength, elongation at break and fiber layer stripping rate under the long-time high-temperature condition of 24 hours at 320 ℃, has good heat resistance, can resist the normal work at 320 ℃, and is suitable for being applied to a dust removal-desulfurization-denitration continuous waste gas treatment process. The examples all have better folding endurance and are not easy to harden when tested after 24h in an environment of 320 ℃. In practical application tests, the filter materials of the embodiments 1 to 5 have been used for 2 years, and can still be used normally at present.
As can be seen from table 3: the filter performance of the embodiment 1-5 is better, and the dust removal requirement can be met.
The foregoing is directed to preferred embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. However, any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present invention are within the protection scope of the technical solution of the present invention.
Claims (10)
1. The preparation method of the high-temperature-resistant filter material is characterized by comprising the steps of 1) mixing, 2) opening, 3) lapping, 4) needling, 5) dipping and 6) laminating; the specific operation is as follows:
1) mixing: uniformly mixing basalt fibers and polybenzimidazole fibers in a weight ratio of 3-4: 1-2 to obtain mixed fibers;
3) lapping: the mixed fiber net is cross-lapped on the upper surface and the lower surface of the basalt base cloth to form an upper fiber layer and a lower fiber layer, and the upper fiber layer is arranged on the basalt base clothThe weight of the powder is 200 to 220g/m2The gram weight of the lower fiber layer is 180-220 g/m2Obtaining a plain felt;
5) dipping: padding the needled felt with a treatment solution, wherein the rolling allowance is 29-33%; then drying at 190-220 ℃ and baking at 250-320 ℃ in sequence, wherein the drying and baking speed is 4-5 m/min, and rolling to obtain an impregnated felt;
the treatment fluid consists of the following raw materials in percentage by mass: 15-26% of polytetrafluoroethylene dispersion liquid, 2-6% of dimethyl diphenyl polysiloxane, 0.7-3% of 3-aminopropyl triethoxysilane, 0.5-1% of tween and the balance of water.
2. The method for preparing a high-temperature-resistant filter material as claimed in claim 1, wherein: the opening operation in the step 2) is as follows: and (3) coarsely opening and finely opening the mixed fibers, and then sending the mixed fibers into a carding machine for carding to form a mixed fiber net.
3. The method for preparing a high-temperature-resistant filter material as claimed in claim 1, wherein: step 4), the needling operation comprises the following steps: and (3) sequentially pre-needling, upward needling, downward needling, upward needling and surface modification on the plain felt, wherein the drafting ratio in the needling process is 2-3%, so that the needled felt is obtained.
4. The method for preparing a high-temperature-resistant filter material as claimed in claim 1, wherein: step 6) the specific operation of film covering is as follows: coating a PTFE film on the upper surface of the impregnated felt; the film coating temperature is 360-390 ℃, the film coating speed is 6-10 m/min, and the film coating pressure is 4.5-7 kg/cm, so that the high-temperature-resistant filter material is obtained.
5. The method for preparing a high-temperature-resistant filter material as claimed in claim 1, wherein: the polybenzimidazole fiber of the step 1) has the fiber number of 1.7-2.2 Dtex and the fiber length of 51-60 mm; the basalt fiber single fiber has the diameter of 6-8 mu m and the fiber length of 46-56 mm.
6. The method for preparing a high-temperature-resistant filter material as claimed in claim 1, wherein: the treatment liquid in the step 5) is prepared from the following raw materials in percentage by mass: 18-25% of polytetrafluoroethylene dispersion, 3-5% of dimethyl diphenyl polysiloxane, 0.8-1.5% of 3-aminopropyl triethoxysilane, 0.6-0.9% of tween and the balance of water.
7. The method for preparing a high temperature resistant filter material according to claim 1 or 6, wherein: the Tween in the step 5) is Tween T-80.
8. The method for preparing a high-temperature-resistant filter material as claimed in claim 1, wherein: the specific operation of uniformly mixing in the step 1) is as follows: and (3) layering, stacking and mixing, namely paving a layer of basalt fiber, paving a layer of polybenzimidazole fiber, and repeating the operations for 2-4 times.
9. The method for preparing a high-temperature-resistant filter material as claimed in claim 1, wherein: and 3) the number of the cross lapping layers is 8 layers of mixed fiber nets on the upper fiber layer, and 7-8 layers of mixed fiber nets on the lower fiber layer.
10. The method for preparing a high temperature resistant filter material according to claim 4, wherein: the gram weight of the PTFE membrane in the step 6) is 2.2-5 g/m2The thickness is more than or equal to 10 μm, and the aperture is 0.5-2 μm.
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