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WO2021224358A1 - A filter and a method for manufacturing thereof - Google Patents

A filter and a method for manufacturing thereof Download PDF

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Publication number
WO2021224358A1
WO2021224358A1 PCT/EP2021/061926 EP2021061926W WO2021224358A1 WO 2021224358 A1 WO2021224358 A1 WO 2021224358A1 EP 2021061926 W EP2021061926 W EP 2021061926W WO 2021224358 A1 WO2021224358 A1 WO 2021224358A1
Authority
WO
WIPO (PCT)
Prior art keywords
liquid cement
filter
cement coating
previous
porous ceramic
Prior art date
Application number
PCT/EP2021/061926
Other languages
French (fr)
Inventor
Hubert WITKOWSKI
Witold DYTRYCH
Janusz JAROSLAWSKI
Original Assignee
Witkowski Hubert
Dytrych Witold
Jaroslawski Janusz
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Witkowski Hubert, Dytrych Witold, Jaroslawski Janusz filed Critical Witkowski Hubert
Publication of WO2021224358A1 publication Critical patent/WO2021224358A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0215—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86—Catalytic processes
    • B01D53/8668—Removing organic compounds not provided for in B01D53/8603 - B01D53/8665
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86—Catalytic processes
    • B01D53/88—Handling or mounting catalysts
    • B01D53/885—Devices in general for catalytic purification of waste gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B01J21/063—Titanium; Oxides or hydroxides thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B01J21/08—Silica
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/06—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of zinc, cadmium or mercury
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/48—Silver or gold
    • B01J23/50—Silver
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/72—Copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
    • B01J27/02—Sulfur, selenium or tellurium; Compounds thereof
    • B01J27/057—Selenium or tellurium; Compounds thereof
    • B01J27/0573—Selenium; Compounds thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
    • B01J35/39—Photocatalytic properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/40—Catalysts, in general, characterised by their form or physical properties characterised by dimensions, e.g. grain size
    • B01J35/45—Nanoparticles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/58—Fabrics or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/104—Silver
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/207—Transition metals
    • B01D2255/20707—Titanium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/207—Transition metals
    • B01D2255/20715—Zirconium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/207—Transition metals
    • B01D2255/20761—Copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/207—Transition metals
    • B01D2255/20792—Zinc
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/80—Type of catalytic reaction
    • B01D2255/802—Photocatalytic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/92—Dimensions
    • B01D2255/9202—Linear dimensions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/92—Dimensions
    • B01D2255/9205—Porosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
    • B01D2257/708—Volatile organic compounds V.O.C.'s
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/91—Bacteria; Microorganisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/06—Polluted air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/45—Gas separation or purification devices adapted for specific applications
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/80—Employing electric, magnetic, electromagnetic or wave energy, or particle radiation
    • B01D2259/804—UV light

Definitions

  • the invention relates to a filter and a method for manufacturing thereof.
  • PL428273 discloses a method for producing polymeric filtering membranes having anti-microbial properties by depositing on a plasma-activated surface functional nanostructures from a suspension, a solution or a dispersion.
  • US20160101390 discloses a method for modifying polymeric membranes to mitigate biofouling by exposing a membrane surface to dopamine powder dissolved in a buffer solution, that results in the formation of a polydopamine thin film on the membrane.
  • PL421707 discloses a method for thermal deposition of functional nanostructures using a suspension or a solution with anti-microbial activity on polymeric filtering materials such as membranes and fibre depth filters.
  • US9598598 discloses methods of preparing antifouling coatings on reverse osmosis membranes with initiated chemical vapor deposition.
  • KR100535940 discloses a semi-permanent photocatalytic filter with a TiCh layer and a UV lamp activating said layer.
  • CN201399313 discloses an indoor air purifying device that comprises a layer of filter cloth, two layers of activated carbon fiber felt, a layer of granular activated carbon flat layer and an ultraviolet lamp, wherein the surface of the activated carbon fiber felt is provided with Ti02 with photo catalytic activity in deposition.
  • cement coatings for applying on building surfaces that exhibit photocatalytic properties without any sources of UV radiation other than the solar light. Such surfaces do not have satisfactory purification efficiency.
  • JP2000220117A discloses an atmosphere sound insulation panel manufactured by forming cement-based paint film containing a photocatalyst activated by an ultraviolet ray on the outer face of the sound insulation panel, oxidizing or decomposing a toxic substance in exhaust gas and reducing NOx.
  • EP1369532A2 discloses an air purifying and sound insulating wall and a highway air purifying and sound insulating wall having a formed surface made of RB ceramics or CRB ceramics that supports a photocatalyst.
  • the object of the invention is a method for manufacturing a filter, the method comprising: providing a porous ceramic filter; applying a liquid cement coating on the porous ceramic filter, the liquid cement coating comprising titanium dioxide (TiCh) particles; performing first drying of the filter; soaking the filter in water; performing second drying of the filter; and exposing the filter to UV-A radiation. Consequently, the obtained filter is a porous material having its surface coated by cement coating with embedded titanium dioxide particles. Due to the porous nature of the filter structure, it has a high effective surface. The liquid cement coating is applied in an amount such as not to obstruct the pores of the porous ceramic filter.
  • the process of drying- soaking-drying is performed according to the composition of the liquid cement, such as to provide appropriate conditioning of the cement and achieve its strength and durability over the lifetime of the filter.
  • Use of cement coating as a carrier for titanium dioxide particles is beneficial, as it exhibits good adhesion to the ceramic filter surface and has an intrinsic porosity that allows to expose the titanium dioxide particles over the pores of the cement coating.
  • the filter is exposed to UV-A radiation to activate the titanium dioxide particles, i.e. to enhance their photocatalytic activity.
  • the filter manufactured in such manner can be effectively used to purify gases, in particular air, from microbial pollutants, such as bacteria, fungi, molds, viruses and volatile organic compounds or in view of the photocatalytic properties of activated titanium dioxide particles.
  • the porous ceramic filter may have a porosity of 10 to 40 ppi (pores per linear inch). Such porosity provides optimal balance between the effective surface of the filter and possibility of gas to be cleaned to flow through the filter.
  • the porous ceramic filter can be made of at least one of: silicon carbide (SiC), zirconium dioxide (ZrCh), carbon compounds (such as amorphous carbon) or aluminium compounds (such as aluminium oxide (AI2O3)).
  • SiC silicon carbide
  • ZrCh zirconium dioxide
  • carbon compounds such as amorphous carbon
  • aluminium compounds such as aluminium oxide (AI2O3)
  • the liquid cement coating may have a density selected depending on the porosity of the porous ceramic filter.
  • the density should be selected such as to allow optimal application of the liquid cement coating on the porous ceramic filter. The higher the density, the thicker layer of the liquid cement coating applied. The density should not be excessively high, such as not to obstruct the pores of the porous ceramic filter.
  • the method may comprise applying the liquid cement coating by immersion of the porous ceramic filter in the liquid cement or by hydrodynamic spraying of the liquid cement on the porous ceramic filter.
  • the method may comprise applying the liquid cement coating in an amount of at least 30g per each 100x100x20mm volume of the porous ceramic filter.
  • the method may further comprise removing excess of the liquid cement coating by means of a shaker.
  • This operation simplifies application of the liquid cement coating.
  • a relatively dense coating can be applied first, even such as to obstruct some or even all of the pores, and next the excess can be shaken off by means of the shaker, for example centrifuge or a shaker net.
  • the method may comprise applying the liquid cement coating in an amount such as to cover a whole surface of the porous ceramic filter.
  • the method may comprise removing the excess of the liquid cement coating such as to have the whole surface of the porous ceramic filter covered by the liquid cement coating. Namely, it is preferable to have a whole raw surface of the ceramic porous filter covered by the liquid cement coating to provide the largest filtering surface.
  • the method may comprise performing the first drying of the filter at a temperature between 18 and 22°C over 24 hours at humidity of 75%; soaking the filter in demineralized water for 48 hours; and/or performing the second drying of the filter at a temperature between 18 and 22°C over 12 hours to lower humidity to less than 15%. These are optimal drying and soaking process parameters. In general, it is preferable to dry at temperatures not exceeding 28°C.
  • the method may comprise exposing the dried filter to UV-A radiation between 17 and 23 mW/cm 2 , preferably for 18 hours. This provides optimal activation of the titanium dioxide particles within the coating.
  • the liquid cement coating may comprise the titanium dioxide particles in an amount of at least 0.01%, preferably from 0,01% to 15%, preferably from 0,01% to 10% by weight of the liquid cement coating.
  • the titanium dioxide particles may be nanoparticles, preferably having a size of 20 nm.
  • the liquid cement coating may further comprise zinc oxide (ZnO) nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 4% by weight of the liquid cement coating; and/or reduced graphene oxide (RGO) nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 4% by weight of the liquid cement coating; and/or silica nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 5% by weight of the liquid cement coating; and/or silver nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 5% by weight of the liquid cement coating; and/or copper nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 5% by weight of the liquid cement coating.
  • the zinc oxide, reduced graphene oxide, silica, silver or copper nanoparticles are used as additional anti-microbial agents for filter
  • the liquid cement coating may further comprise a photosensitizer.
  • a photosensitizer allows to improve the efficiency of the titanium dioxide.
  • zinc selenide (ZnSe) particles are used as the photosensitizer in an amount of up to 1% by weight of the liquid cement coating. In that case, the photosensitizer can be activated by 400 nm light.
  • the porous ceramic filter may have a shape of a plate, preferably of a size 100 x 100 x 20 mm.
  • a plate-shaped filter can be used for example in air filters with airflow forced along a path on which one or more of such filters are installed.
  • Various other shapes are possible, such as larger (i.e. wider, longer or thicker) plates that are flat or curved, cubes, balls, and any other 3D geometrical shapes.
  • relatively large porous structures can be installed in acoustic screens or a self-supporting walls in the proximity of emitters of air pollutants, in particular alongside of roads.
  • the plate can be formed of two sub-plates facing each other, at least one of which comprises in the internal surface at least one recess for receiving a lightguide. This allows making a relatively thick plates, wherein the internal pores are not illuminated by outside light, but by light generated by light guides (for example, diodes or optical fibres) installed in the recess.
  • the recess may be machined after the porous ceramic filter plate is formed or can be formed in a mould for forming the porous ceramic filter plate.
  • the invention also relates to a filter comprising a porous ceramic filter coated by a cement coating comprising activated titanium dioxide (T1O2) particles.
  • the filter may be manufactured according to the method as described herein.
  • the invention relates to a method for producing a filter, especially with a photocatalytic layer, wherein in the first step a cement coating with titanium dioxide is applied on a ceramic filter made of materials selected from: silicon carbide, AI2O3, zirconium oxide, carbon compounds or aluminium compounds in an amount of not less than 30 to 35 g per volume of a carrier having a size of 100 x 100 x 20.
  • the excess coating is then removed using a shaker and the ceramic material is dried at a temperature of 20°C +/- 10% over 24 hours, followed by soaking the ceramic material in preferably demineralised water for 48 h, after which it is dried again at 20°C +/- 10% over 12 h. After reaching humidity below 15% the product is exposed to UV-A light for 18 h, while maintaining the intensity of UV-A radiation at the level of 20 mW/cm 2 +/- 15%
  • Fig. 1 shows a first embodiment of the filter
  • Fig. 2 shows a second embodiment of the filter.
  • Fig. 1 shows a first embodiment of the filter, having a shape of a flat plate 10, e.g. of dimensions 100 x 100 x 20 mm.
  • the filter comprises a porous ceramic filter core coated with cement coating.
  • the filter has a porosity of about 10 ppi (pores per linear inch).
  • Fig. 2 shows in an exploded view a second embodiment of the filter, having a shape of a flat plate 20, formed of two sub-plates 21, 22 facing each other, one of which comprises in the internal surface a plurality of recesses 23 for receiving lightguides in form of long light- emitting diodes 24.
  • a cement coating was applied on a porous ceramic filter made of silicon carbide in an amount of 30 g per volume of a the ceramic filter having the size of 100 x 100 x 20 mm.
  • the excess coating was then removed using a shaker and the ceramic material was dried at a temperature of 20°C +/- 10% over 24 hours, followed by soaking the ceramic material in demineralised water for 48 h, after which it was dried again at 20°C +/- 10% over 12 h, as it reached humidity below 15%.
  • it was illuminated by UV-A light for 18 h, while maintaining the intensity of UV-A radiation at the level of 20 mW/cm 2 +/- 15%.
  • the photocatalytic coating was applied by hydrodynamic spraying of liquid cement coating on both sides of the porous ceramic filter.
  • the density of the coating sprayed was adapted to the porosity of the porous ceramic filter.
  • the cement coating contained 10% by weight of nanometric titanium dioxide.
  • the obtained filter insert has a highly porous structure, through which air can flow freely, and whose surface has a photocatalytic effect when exposed to UV radiation, originating both from sunlight and artificial light.
  • a cement coating was applied on a porous ceramic filter made of zirconium oxide in an amount of 35 g per volume of a the ceramic filter having the size of 100 x 100 x 20 mm.
  • the excess coating was then removed using a shaker and the ceramic material was dried at a temperature of 20°C +/- 10% over 24 hours, followed by soaking the ceramic material in demineralised water for 48 h, after which it was dried again at 20°C +/- 10% over 12 h, as it reached humidity below 15%. Next, it was illuminated by UV-A light for 18 h, while maintaining the intensity of UV-A radiation at the level of 20 mW/cm 2 +/- 15%.
  • the photocatalytic coating was applied by immersing the porous ceramic filter in liquid cement coating.
  • the cement coating contained 0,01% by weight of nanometric titanium dioxide and copper or silver nanoparticles in an amount of 5% by weight.
  • the obtained filter insert has a highly porous structure, through which air can flow freely, and whose surface has a photocatalytic effect when exposed to UV radiation, originating both from sunlight and artificial light.
  • a cement coating was applied on a porous ceramic filter made of silicon carbide in an amount of 30 g per volume of a the ceramic filter having the size of 100 x 100 x 20 mm.
  • the excess coating was then removed using a shaker and the ceramic material was dried at a temperature of 20°C +/- 10% over 24 hours, followed by soaking the ceramic material in demineralised water for 48 h, after which it was dried again at 20°C +/- 10% over 12 h, as it reached humidity below 15%.
  • it was illuminated by UV-A light for 18 h, while maintaining the intensity of UV-A radiation at the level of 20 mW/cm 2 +/- 15%.
  • the photocatalytic coating was applied by hydrodynamic spraying of liquid cement coating on both sides of the porous ceramic filter.
  • the density of the coating sprayed was adapted to the porosity of the porous ceramic filter.
  • the cement coating contained 10% by weight of 20nm titanium dioxide particles and 1% by weight of 20nm zirconium oxide particles.
  • the filter was next installed in an air purification device, wherein air was forced through the filter by a ventilator.
  • the air purification device was positioned in a chamber having a volume of 12m 3 .

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Biomedical Technology (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Catalysts (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)

Abstract

A method for manufacturing a filter, the method comprising: providing a porous ceramic filter; applying a liquid cement coating on the porous ceramic filter, the liquid cement coating comprising titanium dioxide (TiO2) particles; performing first drying of the filter; soaking the filter in water; performing second drying of the filter; and exposing the filter to UV-A radiation.

Description

A FILTER AND A METHOD FOR MANUFACTURING THEREOF
TECHNICAL FIELD
The invention relates to a filter and a method for manufacturing thereof.
BACKGROUND
There are known various types of filters that can be used to clean gases, in particular air, from microorganisms.
For example, PL428273 discloses a method for producing polymeric filtering membranes having anti-microbial properties by depositing on a plasma-activated surface functional nanostructures from a suspension, a solution or a dispersion.
US20160101390 discloses a method for modifying polymeric membranes to mitigate biofouling by exposing a membrane surface to dopamine powder dissolved in a buffer solution, that results in the formation of a polydopamine thin film on the membrane.
PL421707 discloses a method for thermal deposition of functional nanostructures using a suspension or a solution with anti-microbial activity on polymeric filtering materials such as membranes and fibre depth filters. US9598598 discloses methods of preparing antifouling coatings on reverse osmosis membranes with initiated chemical vapor deposition.
There are known coatings that are used in filtration systems which have biocidal properties when exposed to light such as UV light.
For example, KR100535940 discloses a semi-permanent photocatalytic filter with a TiCh layer and a UV lamp activating said layer.
CN201399313 discloses an indoor air purifying device that comprises a layer of filter cloth, two layers of activated carbon fiber felt, a layer of granular activated carbon flat layer and an ultraviolet lamp, wherein the surface of the activated carbon fiber felt is provided with Ti02 with photo catalytic activity in deposition. There are also known cement coatings for applying on building surfaces, that exhibit photocatalytic properties without any sources of UV radiation other than the solar light. Such surfaces do not have satisfactory purification efficiency.
JP2000220117A discloses an atmosphere sound insulation panel manufactured by forming cement-based paint film containing a photocatalyst activated by an ultraviolet ray on the outer face of the sound insulation panel, oxidizing or decomposing a toxic substance in exhaust gas and reducing NOx.
EP1369532A2 discloses an air purifying and sound insulating wall and a highway air purifying and sound insulating wall having a formed surface made of RB ceramics or CRB ceramics that supports a photocatalyst.
SUMMARY OF THE INVENTIOIN
There is a need to provide an alternative method for manufacturing a filter which would allow efficient purification. The object of the invention is a method for manufacturing a filter, the method comprising: providing a porous ceramic filter; applying a liquid cement coating on the porous ceramic filter, the liquid cement coating comprising titanium dioxide (TiCh) particles; performing first drying of the filter; soaking the filter in water; performing second drying of the filter; and exposing the filter to UV-A radiation. Consequently, the obtained filter is a porous material having its surface coated by cement coating with embedded titanium dioxide particles. Due to the porous nature of the filter structure, it has a high effective surface. The liquid cement coating is applied in an amount such as not to obstruct the pores of the porous ceramic filter. The process of drying- soaking-drying is performed according to the composition of the liquid cement, such as to provide appropriate conditioning of the cement and achieve its strength and durability over the lifetime of the filter. Use of cement coating as a carrier for titanium dioxide particles is beneficial, as it exhibits good adhesion to the ceramic filter surface and has an intrinsic porosity that allows to expose the titanium dioxide particles over the pores of the cement coating. Once the cement coating is finally dried, the filter is exposed to UV-A radiation to activate the titanium dioxide particles, i.e. to enhance their photocatalytic activity. The filter manufactured in such manner can be effectively used to purify gases, in particular air, from microbial pollutants, such as bacteria, fungi, molds, viruses and volatile organic compounds or in view of the photocatalytic properties of activated titanium dioxide particles.
The porous ceramic filter may have a porosity of 10 to 40 ppi (pores per linear inch). Such porosity provides optimal balance between the effective surface of the filter and possibility of gas to be cleaned to flow through the filter.
The porous ceramic filter can be made of at least one of: silicon carbide (SiC), zirconium dioxide (ZrCh), carbon compounds (such as amorphous carbon) or aluminium compounds (such as aluminium oxide (AI2O3)). Such materials offer optimal strength and durability as the carrier for the ceramic coating and have a surface that offers good adhesion for the ceramic coating.
The liquid cement coating may have a density selected depending on the porosity of the porous ceramic filter. The density should be selected such as to allow optimal application of the liquid cement coating on the porous ceramic filter. The higher the density, the thicker layer of the liquid cement coating applied. The density should not be excessively high, such as not to obstruct the pores of the porous ceramic filter.
The method may comprise applying the liquid cement coating by immersion of the porous ceramic filter in the liquid cement or by hydrodynamic spraying of the liquid cement on the porous ceramic filter.
The method may comprise applying the liquid cement coating in an amount of at least 30g per each 100x100x20mm volume of the porous ceramic filter.
The method may further comprise removing excess of the liquid cement coating by means of a shaker. This operation simplifies application of the liquid cement coating. A relatively dense coating can be applied first, even such as to obstruct some or even all of the pores, and next the excess can be shaken off by means of the shaker, for example centrifuge or a shaker net.
The method may comprise applying the liquid cement coating in an amount such as to cover a whole surface of the porous ceramic filter. The method may comprise removing the excess of the liquid cement coating such as to have the whole surface of the porous ceramic filter covered by the liquid cement coating. Namely, it is preferable to have a whole raw surface of the ceramic porous filter covered by the liquid cement coating to provide the largest filtering surface. The method may comprise performing the first drying of the filter at a temperature between 18 and 22°C over 24 hours at humidity of 75%; soaking the filter in demineralized water for 48 hours; and/or performing the second drying of the filter at a temperature between 18 and 22°C over 12 hours to lower humidity to less than 15%. These are optimal drying and soaking process parameters. In general, it is preferable to dry at temperatures not exceeding 28°C.
The method may comprise exposing the dried filter to UV-A radiation between 17 and 23 mW/cm2, preferably for 18 hours. This provides optimal activation of the titanium dioxide particles within the coating. The liquid cement coating may comprise the titanium dioxide particles in an amount of at least 0.01%, preferably from 0,01% to 15%, preferably from 0,01% to 10% by weight of the liquid cement coating.
The titanium dioxide particles may be nanoparticles, preferably having a size of 20 nm.
The liquid cement coating may further comprise zinc oxide (ZnO) nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 4% by weight of the liquid cement coating; and/or reduced graphene oxide (RGO) nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 4% by weight of the liquid cement coating; and/or silica nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 5% by weight of the liquid cement coating; and/or silver nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 5% by weight of the liquid cement coating; and/or copper nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 5% by weight of the liquid cement coating. The zinc oxide, reduced graphene oxide, silica, silver or copper nanoparticles are used as additional anti-microbial agents for filtering.
The liquid cement coating may further comprise a photosensitizer. Use of a photosensitizer allows to improve the efficiency of the titanium dioxide. For example, zinc selenide (ZnSe) particles are used as the photosensitizer in an amount of up to 1% by weight of the liquid cement coating. In that case, the photosensitizer can be activated by 400 nm light.
The porous ceramic filter may have a shape of a plate, preferably of a size 100 x 100 x 20 mm. Such plate-shaped filter can be used for example in air filters with airflow forced along a path on which one or more of such filters are installed. Various other shapes are possible, such as larger (i.e. wider, longer or thicker) plates that are flat or curved, cubes, balls, and any other 3D geometrical shapes. In particular, relatively large porous structures can be installed in acoustic screens or a self-supporting walls in the proximity of emitters of air pollutants, in particular alongside of roads.
The plate can be formed of two sub-plates facing each other, at least one of which comprises in the internal surface at least one recess for receiving a lightguide. This allows making a relatively thick plates, wherein the internal pores are not illuminated by outside light, but by light generated by light guides (for example, diodes or optical fibres) installed in the recess. The recess may be machined after the porous ceramic filter plate is formed or can be formed in a mould for forming the porous ceramic filter plate.
The invention also relates to a filter comprising a porous ceramic filter coated by a cement coating comprising activated titanium dioxide (T1O2) particles. The filter may be manufactured according to the method as described herein.
In a particular aspect, the invention relates to a method for producing a filter, especially with a photocatalytic layer, wherein in the first step a cement coating with titanium dioxide is applied on a ceramic filter made of materials selected from: silicon carbide, AI2O3, zirconium oxide, carbon compounds or aluminium compounds in an amount of not less than 30 to 35 g per volume of a carrier having a size of 100 x 100 x 20. The excess coating is then removed using a shaker and the ceramic material is dried at a temperature of 20°C +/- 10% over 24 hours, followed by soaking the ceramic material in preferably demineralised water for 48 h, after which it is dried again at 20°C +/- 10% over 12 h. After reaching humidity below 15% the product is exposed to UV-A light for 18 h, while maintaining the intensity of UV-A radiation at the level of 20 mW/cm2 +/- 15%
BRIEF DESCRIPTION OF DRAWINGS
The invention is presented by means of example embodiments on a drawing, wherein: Fig. 1 shows a first embodiment of the filter; Fig. 2 shows a second embodiment of the filter.
DETAILED DESCRIPTION OF EMBODIMENTS
The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention.
Fig. 1 shows a first embodiment of the filter, having a shape of a flat plate 10, e.g. of dimensions 100 x 100 x 20 mm. The filter comprises a porous ceramic filter core coated with cement coating. The filter has a porosity of about 10 ppi (pores per linear inch).
Fig. 2 shows in an exploded view a second embodiment of the filter, having a shape of a flat plate 20, formed of two sub-plates 21, 22 facing each other, one of which comprises in the internal surface a plurality of recesses 23 for receiving lightguides in form of long light- emitting diodes 24. First example of the manufacturing method
A cement coating was applied on a porous ceramic filter made of silicon carbide in an amount of 30 g per volume of a the ceramic filter having the size of 100 x 100 x 20 mm. The excess coating was then removed using a shaker and the ceramic material was dried at a temperature of 20°C +/- 10% over 24 hours, followed by soaking the ceramic material in demineralised water for 48 h, after which it was dried again at 20°C +/- 10% over 12 h, as it reached humidity below 15%. Next, it was illuminated by UV-A light for 18 h, while maintaining the intensity of UV-A radiation at the level of 20 mW/cm2 +/- 15%.
The photocatalytic coating was applied by hydrodynamic spraying of liquid cement coating on both sides of the porous ceramic filter. The density of the coating sprayed was adapted to the porosity of the porous ceramic filter. The cement coating contained 10% by weight of nanometric titanium dioxide.
The obtained filter insert has a highly porous structure, through which air can flow freely, and whose surface has a photocatalytic effect when exposed to UV radiation, originating both from sunlight and artificial light.
Second example of the manufacturing method
A cement coating was applied on a porous ceramic filter made of zirconium oxide in an amount of 35 g per volume of a the ceramic filter having the size of 100 x 100 x 20 mm. The excess coating was then removed using a shaker and the ceramic material was dried at a temperature of 20°C +/- 10% over 24 hours, followed by soaking the ceramic material in demineralised water for 48 h, after which it was dried again at 20°C +/- 10% over 12 h, as it reached humidity below 15%. Next, it was illuminated by UV-A light for 18 h, while maintaining the intensity of UV-A radiation at the level of 20 mW/cm2 +/- 15%. The photocatalytic coating was applied by immersing the porous ceramic filter in liquid cement coating. The cement coating contained 0,01% by weight of nanometric titanium dioxide and copper or silver nanoparticles in an amount of 5% by weight.
The obtained filter insert has a highly porous structure, through which air can flow freely, and whose surface has a photocatalytic effect when exposed to UV radiation, originating both from sunlight and artificial light.
Third example of the manufacturing method and results obtained A cement coating was applied on a porous ceramic filter made of silicon carbide in an amount of 30 g per volume of a the ceramic filter having the size of 100 x 100 x 20 mm. The excess coating was then removed using a shaker and the ceramic material was dried at a temperature of 20°C +/- 10% over 24 hours, followed by soaking the ceramic material in demineralised water for 48 h, after which it was dried again at 20°C +/- 10% over 12 h, as it reached humidity below 15%. Next, it was illuminated by UV-A light for 18 h, while maintaining the intensity of UV-A radiation at the level of 20 mW/cm2 +/- 15%.
The photocatalytic coating was applied by hydrodynamic spraying of liquid cement coating on both sides of the porous ceramic filter. The density of the coating sprayed was adapted to the porosity of the porous ceramic filter. The cement coating contained 10% by weight of 20nm titanium dioxide particles and 1% by weight of 20nm zirconium oxide particles.
The filter was next installed in an air purification device, wherein air was forced through the filter by a ventilator. The air purification device was positioned in a chamber having a volume of 12m3.
In a first experiment, air in the chamber having humidity of 50% contained 7,8 * 102 CFU/m3 (Colony Forming Units) of fungi and 5,8 * 102 CFU/m3 of bacteria. After 1 hour of operation under UV-A illumination, concentration of fungi was reduced by 13% and concentration of bacteria was reduced by 14%. After 3 hours of operation, concentration of fungi was reduced by 49% and concentration of bacteria was reduced by 45%.
In a second experiment, air in the chamber having humidity of 70% contained 7,8 * 102 CFU/m3 (Colony Forming Units) of fungi and 5,8 * 102 CFU/m3 of bacteria. After 1 hour of operation under UV-A illumination, concentration of fungi was reduced by 68% and concentration of bacteria was reduced by 66%. After 3 hours of operation, concentration of fungi was reduced by 87% and concentration of bacteria was reduced by 72%.
While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. Therefore, the claimed invention as recited in the claims that follow is not limited to the embodiments described herein.

Claims

1. A method for manufacturing a filter, the method comprising: providing a porous ceramic filter; applying a liquid cement coating on the porous ceramic filter, the liquid cement coating comprising titanium dioxide (TiCh) particles; performing first drying of the filter; soaking the filter in water; performing second drying of the filter; and exposing the filter to UV-A radiation.
2. The method according to claim 1, wherein the porous ceramic filter has a porosity of 10 to 40 ppi (pores per linear inch).
3. The method according to any of previous claims, wherein the porous ceramic filter is made of at least one of: silicon carbide (SiC), zirconium dioxide (ZrCh), carbon compounds (such as amorphous carbon) or aluminium compounds (such as aluminium oxide (AI2O3)).
4. The method according to any of previous claims, wherein the liquid cement coating has a density selected depending on the porosity of the porous ceramic filter.
5. The method according to any of previous claims, comprising applying the liquid cement coating by immersion of the porous ceramic filter in the liquid cement.
6. The method according to any of previous claims, comprising applying the liquid cement coating by hydrodynamic spraying of the liquid cement on the porous ceramic filter.
7. The method according to any of previous claims, comprising applying the liquid cement coating in an amount of at least 30g per each 100x100x20mm volume of the porous ceramic filter.
8. The method according to any of previous claims further comprising removing excess of the liquid cement coating by means of a shaker.
9. The method according to any of previous claims, comprising applying the liquid cement coating in an amount such as to cover a whole surface of the porous ceramic filter.
10. The method according to claim 9, comprising removing the excess of the liquid cement coating such as to have the whole surface of the porous ceramic filter covered by the liquid cement coating.
11. The method according to any of previous claims, comprising performing the first drying of the filter at a temperature between 18 and 22°C over 24 hours at humidity of 75%.
12. The method according to any of previous claims, comprising soaking the filter in demineralized water for 48 hours.
13. The method according to any of previous claims, comprising performing the second drying of the filter at a temperature between 18 and 22°C over 12 hours to lower humidity to less than 15%.
14. The method according to any of previous claims, comprising exposing the dried filter to UV-A radiation between 17 and 23 mW/cm2, preferably for 18 hours.
15. The method according to any of previous claims, wherein the liquid cement coating comprises the titanium dioxide particles in an amount of at least 0.01%, preferably from 0,01% to 15%, preferably from 0,01% to 10% by weight of the liquid cement coating.
16. The method according to any of previous claims, wherein the titanium dioxide particles are nanoparticles, preferably having a size of 20 nm.
17. The method according to any of previous claims, wherein the liquid cement coating further comprises zinc oxide (ZnO) nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 4% by weight of the liquid cement coating.
18. The method according to any of previous claims, wherein the liquid cement coating further comprises reduced graphene oxide (RGO) nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 4% by weight of the liquid cement coating.
19. The method according to any of previous claims, wherein the liquid cement coating further comprises silica nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 5% by weight of the liquid cement coating.
20. The method according to any of previous claims, wherein the liquid cement coating further comprises silver nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 5% by weight of the liquid cement coating.
21. The method according to any of previous claims, wherein the liquid cement coating further comprises copper nanoparticles, preferably having a size of 20 nm, preferably in an amount from 1% to 5% by weight of the liquid cement coating.
22. The method according to any of previous claims, wherein the liquid cement coating further comprises a photosensitizer.
23. The method according to any of previous claims, wherein zinc selenide (ZnSe) particles are used as the photosensitizer in an amount of up to 1% by weight of the liquid cement coating.
24. The method according to any of previous claims, wherein the porous ceramic filter has a shape of a plate (10, 20), preferably of a size 100 x 100 x 20 mm.
25. The method according to claim 24, wherein the plate (10, 20) is formed of two sub plates (21, 22) facing each other, at least one of which comprises in the internal surface at least one recess (23) for receiving a lightguide (24).
26. A filter comprising a porous ceramic filter coated by a cement coating comprising activated titanium dioxide (TiCh) particles.
27. The filter according to claim 26, manufactured according to the method of any of claims 1-25.
PCT/EP2021/061926 2020-05-05 2021-05-05 A filter and a method for manufacturing thereof WO2021224358A1 (en)

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