JP2007142204A - Carbon material for electric double layer capacitor and manufacturing method - Google Patents
Carbon material for electric double layer capacitor and manufacturing method Download PDFInfo
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Abstract
Description
本発明は、静電容量の大きい新しい電気二重層キャパシタ用炭素材と製造方法に関するものである。 The present invention relates to a new carbon material for electric double layer capacitors having a large capacitance and a method for producing the same.
従来より、電気二重層キャパシタの分極性電極材として、種々の炭素質原料からアルカリ賦活して得られる活性炭を用いる方法が提案されている。たとえば、国際公開ＷＯ９１／１２２０３号には、活性炭原料をアルカリ金属の水酸化物浴中７００℃未満で熱処理して得られる高静電容量炭素質素材が開示されている（特許文献１）。ここで活性炭原料としては、一般に活性炭を製造するための炭素質原料であればいかなるものでもよく、その例としてはたとえばヤシ殻、木粉、石炭、樹脂などがあげられるとしてあり、実施例では、ヤシ殻、木粉、石炭、フェノール樹脂を炭化したものを用いている。また、アルカリ金属の水酸化物としては、ナトリウム、カリウム、セシウム、リチウムなどの水酸化物が用いられるとされており、実施例では専ら水酸化ナトリウムを用いている。 Conventionally, a method using activated carbon obtained by alkali activation from various carbonaceous raw materials has been proposed as a polarizable electrode material for an electric double layer capacitor. For example, International Publication No. WO91 / 12203 discloses a high-capacity carbonaceous material obtained by heat-treating an activated carbon material in an alkali metal hydroxide bath at less than 700 ° C. (Patent Document 1). Here, the activated carbon raw material may be any carbonaceous raw material for producing activated carbon, and examples thereof include coconut shell, wood powder, coal, resin, and the like. Carbonized from coconut shell, wood powder, coal, phenol resin. As alkali metal hydroxides, hydroxides such as sodium, potassium, cesium and lithium are used, and sodium hydroxide is exclusively used in the examples.
このような炭素材料については、フェノール樹脂、フラン樹脂およびポリアクリロニトリル樹脂から選ばれる樹脂を炭化して炭素材とした後、溶融状態の水酸化カリウムを用いる賦活法で賦活した活性炭を主体とすること（特許文献２）や、紙基材フェノール樹脂積層板を粉砕して温度５００〜９００℃で炭化処理した後、アルカリ金属水酸化物にて温度４００〜９００℃で賦活処理して得た炭素材（特許文献３）をはじめ、イオン交換樹脂の炭化物をアルカリ賦活したもの（特許文献４）、塩化ビニル系樹脂を焼成しアルカリ賦活したもの（特許文献５）、炭素繊維の粉砕物をアルカリ賦活したもの（特許文献６−７）等も提案されている。 For such carbon materials, the carbon selected from phenolic resins, furan resins and polyacrylonitrile resins is carbonized and then mainly activated carbon activated by an activation method using molten potassium hydroxide. (Patent Document 2) or carbon material obtained by pulverizing and carbonizing a paper base phenolic resin laminate at a temperature of 500 to 900 ° C., and then activating the alkali metal hydroxide at a temperature of 400 to 900 ° C. (Patent Document 3), ion-exchange resin carbide activated alkali (Patent Document 4), vinyl chloride resin fired and alkali activated (Patent Document 5), carbon fiber pulverized product alkali activated A thing (patent documents 6-7) etc. is also proposed.
しかしながら、これら従来の技術では、活性炭や種々の樹脂、繊維等からの炭素材を用いることに特徴があるものの、その原料並びに原料処理にともなう炭素材の製造コストは高価なものとなり、このことが製品となるキャパシタの価格を高いものにしてしまうという問題がある。また、電気二重層キャパシタ用炭素材としてはより大きな静電容量を有するものとすることは低抵抗化が求められてもいた。 However, these conventional techniques are characterized by the use of carbon materials from activated carbon, various resins, fibers, etc., but the raw material and the carbon material production costs associated with the raw material processing become expensive. There is a problem that the price of the capacitor as a product is increased. In addition, as a carbon material for an electric double layer capacitor, a lower resistance has been required to have a larger capacitance.
従来の小電力分野から、電気自動車用バッテリーの補助電源等の大容量分野への応用が期待されている電気二重層キャパシタにおいては電極材としての炭素材の実用化のためには以上のような課題を解決することが必須とされていた。 In the electric double layer capacitor, which is expected to be applied to a large capacity field such as an auxiliary power source for an electric vehicle battery from the conventional low power field, the above is required for practical use of a carbon material as an electrode material. It was essential to solve the problem.
一方、炭素材の原料の一種としての石炭は、上記の樹脂や繊維原料に比べてより安価に利用できることから、石炭を用いることについての検討も行われている。たとえば、石炭ピッチコークスからなる素材を炭化処理し、その後アルカリ賦活処理したものとすること（特許文献８）や、石炭を炭化処理し、水蒸気賦活したものとすること（特許文献９）もすでに提案されている。 On the other hand, since coal as a kind of raw material for carbon materials can be used at a lower cost than the above-mentioned resin and fiber raw materials, studies have been conducted on using coal. For example, it is already proposed that a material made of coal pitch coke is carbonized and then alkali activated (Patent Document 8), or that coal is carbonized and steam activated (Patent Document 9). Has been.
だが、このように石炭を原料とする場合にも、上記と同様に、より安価で簡便に製造することができ、しかもより大きな静電容量等の特性を有する炭素材とすることが課題とされていた。
本発明は、以上のとおりの背景から、従来の問題点を解消し、大きな静電容量と低抵抗特性とを有する電気二重層キャパシタを実現可能とする炭素材を安価に簡便に製造することのできる、新しい電気二重層キャパシタ用炭素材の製造方法を提供する。 In view of the above background, the present invention eliminates the problems of the prior art, and can easily and inexpensively manufacture a carbon material that can realize an electric double layer capacitor having a large capacitance and low resistance characteristics. A new carbon material manufacturing method for electric double layer capacitors is provided.
本発明の製造方法は、上記の課題を解決するものとして以下のことを特徴としている。 The manufacturing method of the present invention is characterized by the following as a solution to the above problems.
第１：石炭の溶剤抽出物を不活性雰囲気下で８００℃から９５０℃の温度範囲において加熱し、得られた固体残渣をアルカリ賦活する電気二重層キャパシタ用炭素材の製造方法。 1st: The manufacturing method of the carbon material for electric double layer capacitors which heats the solvent extract of coal in the temperature range of 800 to 950 degreeC under inert atmosphere, and alkali-activates the obtained solid residue.
第２：石炭の溶媒抽出物は、石炭を、沸点２００℃〜３５０℃の範囲の石炭乾留油を溶剤として３００〜４５０℃の温度範囲で抽出処理したものである上記の電気二重層キャパシタ用炭素材の製造方法。 Second: The coal solvent extract is the above-described coal for electric double layer capacitors, which is obtained by extracting coal from a boiling point of 200 ° C to 350 ° C in a temperature range of 300 to 450 ° C using coal dry distillation oil as a solvent. Material manufacturing method.
第３：アルカリ金属水酸化物によりアルカリ賦活する上記の電気二重層キャパシタ用炭素材の製造方法。 Third: The method for producing a carbon material for an electric double layer capacitor described above, wherein the alkali is activated by an alkali metal hydroxide.
第４：比表面積２０００ｍ2／ｇ以上で、抵抗が９．５Ω以下、静電容量が４５Ｆ／ｇ以上、１８Ｆ／ｃｃ以上である炭素材を製造する上記いずれかの製造方法。 Fourth: Any one of the above production methods for producing a carbon material having a specific surface area of 2000 m 2 / g or more, a resistance of 9.5Ω or less, a capacitance of 45 F / g or more, and 18 F / cc or more.
上記のとおりの本発明の製造方法によれば、比較的安価な石炭を原料とし、しかも溶剤抽出という簡便で低コストの処理により得られる抽出物を用いることができ、得られた炭素材は、電気二重層キャパシタ用の電極材として従来品と同等以上の大きな静電容量と低抵抗性を実現可能とする。これにより、本発明による炭素材は、ハイブリッド車、電気自動車、パーソナルコンピュータ、その他ソーラー発電や風力発電等の蓄電池等に有用な高性能キャパシタを安価に提供することができる。 According to the production method of the present invention as described above, a relatively inexpensive coal is used as a raw material, and an extract obtained by a simple and low-cost treatment of solvent extraction can be used. As an electrode material for electric double layer capacitors, it is possible to realize a large capacitance and low resistance equivalent to or higher than those of conventional products. Thereby, the carbon material according to the present invention can provide a high-performance capacitor useful for a hybrid vehicle, an electric vehicle, a personal computer, and other storage batteries such as solar power generation and wind power generation at low cost.
上記のとおりの特徴を有する本発明について以下にその実施の形態について説明する。 Embodiments of the present invention having the features as described above will be described below.
本発明の電気二重層キャパシタ用炭素材の製造方法においては、その原料として石炭の溶剤抽出物を用いるが、この場合の石炭の溶剤抽出は、近年、石炭の灰分低減の方法として注目され、たとえば、得られる脱灰炭を「ハイパーコール」と呼ぶことが提案されてもいる（ＮＥＤＯ：石炭利用次世代技術開発調査、平成１４年１１月）（ＡＩＳＴ Ｔｏｄａｙ ２００１．６）。 In the method for producing a carbon material for an electric double layer capacitor of the present invention, a solvent extract of coal is used as a raw material thereof. In this case, solvent extraction of coal has recently attracted attention as a method for reducing the ash content of coal. It has also been proposed to call the resulting demineralized coal “Hypercoal” (NEDO: Coal Next-Generation Technology Development Survey, November 2002) (AIST Today 2001.6).
本発明の製造方法では、このように従来より知られている方法をはじめとして各種の石炭の溶剤抽出物が原料物質としての対象となる。なかでも、本発明では、石炭を、沸点２００℃〜３５０℃の範囲の石炭乾留油あるいはこれに類似する多環芳香族炭化水素を溶剤として３００〜４５０℃の温度範囲で抽出処理したものが好適に考慮される。この場合の石炭については、炭素含有量が７０重量％以下の亜炭、７０〜７８重量％程度の褐炭、７８〜９０重量％程度の瀝青炭および９０重量％以上の無煙炭のいずれのものでもよいが、瀝青炭、無煙炭がより好ましいものとして考慮される。なお、溶剤による抽出率を高めるためには軟化開始温度がより低いものとすることができる。 In the production method of the present invention, various solvent extracts of coal including the conventionally known methods are used as raw materials. Especially, in this invention, what extracted the coal in the temperature range of 300-450 degreeC by using coal distillate oil of the boiling point range of 200 to 350 degreeC or the polycyclic aromatic hydrocarbon similar to this as a solvent is suitable. To be considered. The coal in this case may be any of lignite with a carbon content of 70% by weight or less, lignite with about 70 to 78% by weight, bituminous coal with about 78 to 90% by weight, and anthracite with 90% by weight or more, Bituminous coal and anthracite are considered as more preferred. In addition, in order to raise the extraction rate by a solvent, a softening start temperature can be made lower.
抽出のための溶剤としては、たとえば、メチルナフタリン油、ナフタリン油、タール軽油、あるいはこれらの混合物である石炭乾留油（石炭を乾留してコークスを製造する際の副生油の蒸留油）や、これに類似のジメチルナフタレン、テトラリン、その他の多環芳香族炭化水素が好適に考慮される。もちろん、石炭の種類や性能によっては、他の炭化水素（油）であってもよい。 As a solvent for extraction, for example, methyl naphthalene oil, naphthalene oil, tar light oil, or a coal dry distillation oil that is a mixture thereof (distilled oil of by-product oil when producing coke by dry distillation of coal), Similar dimethylnaphthalene, tetralin, and other polycyclic aromatic hydrocarbons are preferably considered. Of course, other hydrocarbons (oil) may be used depending on the type and performance of coal.
これらの溶剤による石炭の抽出処理は、石炭の種類にもよるが、乾燥炭基準で、溶剤に対する石炭沸度が１０〜６０重量％の範囲とし、３００〜４５０℃の温度で、減圧、常圧、そして加圧のいずれかの条件で、５〜１００分間程度行うことが好ましい。 The extraction process of coal with these solvents depends on the type of coal, but on the basis of dry coal, the boiling point of coal with respect to the solvent is in the range of 10 to 60% by weight, at a temperature of 300 to 450 ° C., reduced pressure, normal pressure And it is preferable to carry out for about 5 to 100 minutes under any condition of pressurization.
なお、石炭はあらかじめ乾燥して用いることが一般的であるが、３０重量％程度の水分を含む状態であってもよい。そして、石炭は、８ｍｍ程度以下の大きさに粉砕したものを用いることが好ましい。 In addition, although it is common to use coal after drying beforehand, the state containing about 30 weight% of water | moisture content may be sufficient. And it is preferable to use what pulverized coal to the magnitude | size of about 8 mm or less.
また、加熱は不活性雰囲気下で行うが、この雰囲気は、たとえば窒素ガスやアルゴンガス等の雰囲気下としてもよいし、真空減圧下であってもよい。 Moreover, although heating is performed in an inert atmosphere, this atmosphere may be, for example, an atmosphere such as nitrogen gas or argon gas, or may be under vacuum and reduced pressure.
得られた抽出物については、含有されている不純物としての金属（塩）を除去するためにイオン交換処理してもよい。本発明の製造方法では、石炭の溶剤抽出物は、次いで、８００℃〜９５０℃の温度において加熱処理する。この加熱は、通常、９００℃までの加熱温度を目安とすることができる。この加熱によって固体残渣分を得る。 The obtained extract may be subjected to an ion exchange treatment in order to remove a metal (salt) as an impurity contained therein. In the production method of the present invention, the solvent extract of coal is then heat-treated at a temperature of 800 ° C to 950 ° C. This heating can be generally performed at a heating temperature of up to 900 ° C. A solid residue is obtained by this heating.
さらに本発明の製造方法では、この生成された固体残渣に対してアルカリ賦活処理を行う。 Further, in the production method of the present invention, an alkali activation treatment is performed on the generated solid residue.
アルカリ賦活は、アルカリ金属の水酸化物や重炭酸塩等を用いて行うことができる、より好ましく用いられるアルカリ金属酸化物としては、水酸化カリウムが特に好適であり、そのほか、水酸化ナトリウム、水酸化リチウム、水酸化セシウムなどを用いることもできる。 The alkali activation can be performed using an alkali metal hydroxide, bicarbonate, or the like. As the alkali metal oxide more preferably used, potassium hydroxide is particularly suitable. Lithium oxide, cesium hydroxide, or the like can also be used.
上記の固形残渣とアルカリ金属酸化物との混合割合は、重量比で、１：０５〜１：１０（好ましくは１：１〜１：５）とすることが好適に考慮される。アルカリ金属酸化物の過少は賦活不足を招き、その過多は得られる炭素材の脆化を招く。 The mixing ratio of the solid residue and the alkali metal oxide is suitably considered to be 1:05 to 1:10 (preferably 1: 1 to 1: 5) by weight. Too little alkali metal oxide leads to insufficient activation, and too much causes embrittlement of the resulting carbon material.
賦活処理に際しては、アルカリ金属酸化物の固体またはその水溶液を用いる。固体を用いるときは、アルカリ金属酸化物が吸湿性であることから、保管に際して空気中の湿分を遮断する必要があり、また賦活前の原料と均等に混ぜる操作が必要である。アルカリ金属酸化物の水溶液を用いるときは、市販されている水溶液を用いて、その水溶液に賦活前の固体残渣を混入するだけでもよい。 In the activation treatment, an alkali metal oxide solid or an aqueous solution thereof is used. When using a solid, since the alkali metal oxide is hygroscopic, it is necessary to block moisture in the air at the time of storage, and an operation of mixing with the raw material before activation is necessary. When using an aqueous solution of an alkali metal oxide, a commercially available aqueous solution may be used, and the solid residue before activation may be simply mixed in the aqueous solution.
賦活処理時の温度は４００〜９００℃、好ましくは６００〜９００℃、さらに好ましくは７００〜９００℃が適当であり、温度が余りに低いときは静電容量の大きな炭素材が得られがたく、一方温度が余りに高いときには装置の材質に大きな制約が加わるので実際的でなくなる。 The temperature during the activation treatment is 400 to 900 ° C, preferably 600 to 900 ° C, more preferably 700 to 900 ° C. When the temperature is too low, it is difficult to obtain a carbon material having a large capacitance. When the temperature is too high, the material of the device is greatly restricted, which is not practical.
賦活処理後は、アルカリ洗浄、酸洗浄、脱水、粉砕、造粒などの精製工程や二次加工工程に供することができる。 After the activation treatment, it can be subjected to a purification step such as alkali washing, acid washing, dehydration, pulverization, granulation, or a secondary processing step.
このようにして得た炭素材は、たとえば、ＢＥＴ比表面積が２０００ｍ2／ｇ程度以上、細孔容積が１ｍｌ／ｇ以上であるが、比表面積や細孔容積の値の如何にかかわらず、静電容量の大きな電気二重層コンデンサ用炭素材として好適に用いることができる。 The carbon material thus obtained has, for example, a BET specific surface area of about 2000 m 2 / g or more and a pore volume of 1 ml / g or more. It can be suitably used as a carbon material for electric double layer capacitors having a large capacitance.
電気二重層キャパシタは、たとえば、（ａ）上記で得た炭素材の粉末品、導電材料、バインダーおよび溶媒を混合してペースト状の混合物を調製してからシート状に成形して電極材料となし、該シート２枚をセパレータを介して重ねて外装容器に収容し、この中に電解液を注入する方法や、（ｂ）上記で得た炭素材の粉末品と電解液との混合物を調製してペースト状となし、これをセパレータを介在させた状態で外装容器に収容する方法、（ｃ）上記で得た炭素材の粉末品に樹脂系粉末品（たとえばフェノール樹脂）を混合した後、高温（６００〜１０００℃）で熱処理して炭素成形体を作り、電解液を含浸させて、これをセパレータを介在させた状態で外装容器に収容する方法をはじめ、従来採用されている各種の方法により作製される。電解液としては、水溶液系電解液や非水溶媒系電解液が用いられる。 An electric double layer capacitor is, for example, (a) prepared by mixing a powdered carbon material obtained above, a conductive material, a binder and a solvent to prepare a paste-like mixture, and then forming it into a sheet shape to form an electrode material. The two sheets are stacked with a separator and housed in an outer container, and an electrolytic solution is injected into the outer container. (B) A mixture of the carbon material powder obtained above and an electrolytic solution is prepared. A paste, and a method of containing this in an outer container with a separator interposed therebetween; (c) a resin-based powder product (for example, a phenol resin) is mixed with the carbon material powder product obtained above; By heat treatment at (600 to 1000 ° C.), a carbon molded body is made, impregnated with an electrolytic solution, and accommodated in an outer container with a separator interposed therebetween. Produced. As the electrolytic solution, an aqueous electrolytic solution or a non-aqueous solvent electrolytic solution is used.
本発明の製造方法においては、たとえば静電容量が４５Ｆ／ｇ以上、１８Ｆ／ｃｃ以上で、抵抗値が９．５Ω以下の良好な特性が実現されることになる。 In the manufacturing method of the present invention, for example, good characteristics with a capacitance of 45 F / g or more and 18 F / cc or more and a resistance value of 9.5Ω or less are realized.
そこで以下に実施例を示し、さらに詳しく本発明について説明する。もちろん以下の例によって発明が限定されることはない。 Therefore, the present invention will be described in more detail with reference to the following examples. Of course, the invention is not limited by the following examples.
水分含有率４．５重量％の瀝青炭（平均粒径３ｍｍ粉砕品）を、乾燥高基準で２５重量％の割合になるようにしてタール軽油により、３５０℃の温度、Ｎ2ガス雰囲気下に抽出処理した。 Bituminous coal with a water content of 4.5% by weight (pulverized product with an average particle size of 3 mm) is extracted with tar light oil at a temperature of 350 ° C. in an N 2 gas atmosphere so that the dry weight is 25% by weight. Processed.
次いで得られた抽出物を９００℃に加熱して固体残渣を生成させた。この固体残渣に対しては、重量比で１：３となるようにＫＯＨの水溶液を用いて７００℃の温度で賦活処理した。 The resulting extract was then heated to 900 ° C. to produce a solid residue. The solid residue was activated at a temperature of 700 ° C. using an aqueous solution of KOH so that the weight ratio was 1: 3.
得られたアルカリ賦活処理炭素材を用いて前記の方法（ａ）に従って電気二重層キャパシタを構成した。 Using the obtained alkali activated carbon material, an electric double layer capacitor was constructed according to the method (a).
このものについての特性を従来品等と比較評価し、その結果を表１に示した。 The characteristics of this product were compared and evaluated with conventional products and the results are shown in Table 1.
表１に示した、本発明の方法により製造された炭素材「石炭の溶剤抽出物」の場合には、比表面積が非常に大きく、低抵抗であって、大きな静電容量を実現していることがわかる。 In the case of the carbon material “coal solvent extract” produced by the method of the present invention shown in Table 1, the specific surface area is very large, the resistance is low, and a large capacitance is realized. I understand that.
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