JP2018162177A - Porous carbon material and method for producing the same - Google Patents
Porous carbon material and method for producing the same Download PDFInfo
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本発明は、脱臭や脱色、有機化合物の分解や微生物燃料電池など、各種分野において有用な多孔質炭素材料に関する。 The present invention relates to a porous carbon material useful in various fields such as deodorization and decolorization, decomposition of organic compounds and microbial fuel cells.
多孔質炭素材料は、軽量な上に耐熱性、耐蝕性、導電性などに優れ、工業用のフィルター、電池用電極、吸着材および断熱材等の様々な用途分野で古くから使用されている。 Porous carbon materials are lightweight and excellent in heat resistance, corrosion resistance, conductivity, and the like, and have been used for a long time in various application fields such as industrial filters, battery electrodes, adsorbents, and heat insulating materials.
前記多孔質炭素材料の製造技術としては、コークス粒を石炭系や石油系ピッチのような炭化収率の高いバインダーとともに混練したのち、成形及び焼成炭化する方法が古くから知られている。この多孔質炭素材料はコークス粒子をピッチの炭化物で結合したものであり、粒子結合型の組織構造を有している。 As a technique for producing the porous carbon material, a method in which coke grains are kneaded with a binder having a high carbonization yield such as coal-based or petroleum-based pitch, and then molded and calcined by carbonization has been known for a long time. This porous carbon material is formed by bonding coke particles with pitch carbides and has a particle-bonded structure.
例えば、特許文献1には、多孔質炭素材の製造方法としてコークス、バインダーを配合して混錬成型し、900〜1600℃で焼成し、孔径を1〜100μmの範囲内でシャープな分布を有する多孔質炭素材の製造方法が開示されている。 For example, in Patent Document 1, as a method for producing a porous carbon material, coke and a binder are blended and kneaded and fired at 900 to 1600 ° C., and the pore diameter has a sharp distribution within a range of 1 to 100 μm. A method for producing a porous carbon material is disclosed.
しかし、上記の方法によって得られる多孔質炭素材料は、例えば、排水中の難分解性の有機化合物を酸化分解するための電極や、バクテリアや菌類などの微生物を発電に利用する微生物燃料電池の電極といったより高度な用途に対しては、別途触媒金属の担持や表面の親水化処理を行わなければならない。 However, the porous carbon material obtained by the above method is, for example, an electrode for oxidatively degrading a hardly decomposable organic compound in waste water, or an electrode for a microbial fuel cell that uses microorganisms such as bacteria and fungi for power generation. For more advanced applications such as these, it is necessary to separately carry a catalyst metal and make the surface hydrophilic.
そのため、活性炭等の多孔質炭素材料を水や有機溶剤による金属塩溶液へ浸漬したり(例えば特許文献2)、電解法または気相法による金属被覆などの手法によって多孔質炭素材料へ金属を担持することが行われている。 Therefore, a porous carbon material such as activated carbon is immersed in a metal salt solution using water or an organic solvent (for example, Patent Document 2), or metal is supported on the porous carbon material by a method such as metal coating by an electrolytic method or a gas phase method. To be done.
しかし、特許文献2の手法では、金属成分を多量に担持することが難しく、かつ多孔質炭素材料の閉気孔には液が入らないので内部への金属成分の均一な分布が難しい。また、金属被覆による手法では金属成分が表層に偏在するほか、炭素材料の表面を被覆してしまうので多孔質炭素材料の特性を発現しにくいことが問題となる。 However, according to the method of Patent Document 2, it is difficult to carry a large amount of a metal component, and liquid does not enter the closed pores of the porous carbon material, so that uniform distribution of the metal component inside is difficult. In addition, the metal coating technique has a problem that the metal component is unevenly distributed on the surface layer and the surface of the carbon material is covered, so that it is difficult to express the characteristics of the porous carbon material.
このように、従来の手法では、金属成分をサブミクロンからミクロンオーダーの粒子サイズで多孔質炭素材料の内部にまで多量かつ均一に担持させることが困難であったり、安価に量産し難いという課題があった。 As described above, in the conventional method, there is a problem that it is difficult to carry a metal component in a large amount and uniformly in a porous carbon material with a particle size of submicron to micron order, and it is difficult to mass-produce at low cost. there were.
なお、特許文献3には、平均粒径3μm以下の鉄化合物を添加する人造黒鉛電極の製造方法が開示されている。しかし、本文献における鉄化合物は黒鉛電極製造時の脱ガスによるパフィングを抑制し炭化を促進させるための触媒としての機能を果たすために添加されるものであるので、量的に少量であって、最終的には黒鉛化の際に脱離させてしまうため、炭素材料へ金属を担持させるためのものではない。 Patent Document 3 discloses a method for producing an artificial graphite electrode in which an iron compound having an average particle size of 3 μm or less is added. However, since the iron compound in this document is added to serve as a catalyst for suppressing puffing due to degassing during the production of a graphite electrode and promoting carbonization, the amount is small, Ultimately, it is desorbed during graphitization, and is not intended to support a metal on a carbon material.
本発明は、各種用途で使用可能であり、特に水処理用途において有用な金属成分が微粒子の状態で多孔質内部に高濃度かつ均一に担持された多孔質炭素材料の製造方法を提供することにある。 The present invention provides a method for producing a porous carbon material that can be used in various applications, and in particular, a metal component useful in water treatment applications is supported in a high concentration and uniformly in a porous state in the form of fine particles. is there.
すなわち、本発明は、平均粒子径が10〜1000μmの炭素質粒子100重量部に、鉄化合物粒子1〜15重量部及び炭素前駆体となる結着材10〜80重量部を含む混練成形物の焼成物であって、平均粒子径が1μm以下の四酸化三鉄が内部に均一に分散した構造を有し、曲げ強度が20MPa以上で比抵抗が100μΩ・m以下であることを特徴とする多孔質炭素材料である。
上記多孔質炭素材料は、開気孔率が10〜20%であることが好ましい。
That is, the present invention provides a kneaded molded article comprising 1 to 15 parts by weight of iron compound particles and 10 to 80 parts by weight of a binder serving as a carbon precursor in 100 parts by weight of carbonaceous particles having an average particle diameter of 10 to 1000 μm. A porous product having a structure in which triiron tetroxide having an average particle size of 1 μm or less is uniformly dispersed therein, a bending strength of 20 MPa or more, and a specific resistance of 100 μΩ · m or less. Carbonaceous material.
The porous carbon material preferably has an open porosity of 10 to 20%.
また、本発明は、平均粒子径が10〜1000μmの炭素質粒子100重量部に、鉄化合物粒子1〜15重量部及び炭素前駆体となる結着材10〜80重量部を配合して混練成形して成形物とすること、次いでこの成形物を焼成炉内で非酸化性雰囲気下800〜1600℃で焼成することを特徴とする平均粒子径が1μm以下の四酸化三鉄粒子が内部に均一に分散した構造を有し、曲げ強度が20MPa以上で比抵抗が100μΩ・m以下である多孔質炭素材料の製造方法である。 In the present invention, 100 parts by weight of carbonaceous particles having an average particle diameter of 10 to 1000 μm are blended with 1 to 15 parts by weight of iron compound particles and 10 to 80 parts by weight of a binder serving as a carbon precursor. The molded product is then fired at 800 to 1600 ° C. in a non-oxidizing atmosphere in a firing furnace, and triiron tetraoxide particles having an average particle size of 1 μm or less are uniformly formed inside. In which the bending strength is 20 MPa or more and the specific resistance is 100 μΩ · m or less.
上記製造方法は、炭素質粒子が、石油系又は石炭系重質油より得られる生コークス及びか焼コークスから選択される少なくとも一種の炭素質材料であり、結着材が石炭系又は石油系のバインダーピッチであり、鉄化合物粒子が酸化第二鉄(Fe2O3)であることが好ましい。 In the production method, the carbonaceous particles are at least one carbonaceous material selected from raw coke and calcined coke obtained from petroleum-based or coal-based heavy oil, and the binder is coal-based or petroleum-based. a binder pitch, it is preferable iron compound particle is ferric oxide (Fe 2 O 3).
本発明によれば、大量に安定供給できる原料を使用して、多孔質炭素材料の特性を維持しつつ、鉄粒子を微細なFe3O4(マグネタイト、導電性)として微粒子の状態で高濃度かつ均一に担持された多孔質炭素材料を容易に得ることができる。 According to the present invention, using a raw material that can be stably supplied in a large amount, while maintaining the characteristics of the porous carbon material, the iron particles are made into fine Fe 3 O 4 (magnetite, conductive) in a high concentration state in the form of fine particles. And the porous carbon material carry | supported uniformly can be obtained easily.
以下、本発明を詳細に説明する。
本発明の多孔質炭素材料は、炭素質粉末100重量部に、鉄化合物粒子1〜15重量部及び結着材10〜80重量部を含む混練成形物の焼成物であり、平均粒子径が1μm以下の四酸化三鉄(Fe3O4)が内部に均一に分散した構造を有し、曲げ強度が20MPa以上で比抵抗が100μΩ・m以下である。また、本発明の多孔質炭素材料の製造方法は、規定の粒度に粉砕した炭素質粒子を骨材として使用し、これに鉄化合物粒子及びバインダーピッチ等の結着材を配合し、混錬成形し、次いでこれを非酸化性雰囲気下で焼成して、上記焼成物を製造するものである。
Hereinafter, the present invention will be described in detail.
The porous carbon material of the present invention is a fired product of a kneaded molded product containing 1 to 15 parts by weight of iron compound particles and 10 to 80 parts by weight of a binder in 100 parts by weight of carbonaceous powder, and has an average particle diameter of 1 μm. The following triiron tetroxide (Fe 3 O 4 ) has a structure uniformly dispersed therein, a bending strength of 20 MPa or more and a specific resistance of 100 μΩ · m or less. Further, the method for producing a porous carbon material of the present invention uses carbonaceous particles pulverized to a specified particle size as an aggregate, and blends binders such as iron compound particles and a binder pitch, and knead molding. Then, this is fired in a non-oxidizing atmosphere to produce the fired product.
本発明で骨材として使用される炭素質材料としては、天然黒鉛または人造黒鉛や、石油系あるいは石炭系の重質油からディレードコーキングプロセスにより製造されるディレードコークス(生コークス)または、ディレードコークスを非酸化性雰囲気で900〜1600℃でか焼したか焼コークス、樹脂材料などを原料として得られるハードカーボン、木炭や竹炭などの植物由来の炭素材料を使用することができる。
上記の炭素質材料の中でも、人工黒鉛、生コークス又はか焼コークスが電気伝導性の面から骨材として好ましく、鉄化合物や結着材との混錬や成形のし易さの面から生コークス又はか焼コークスがより好ましい。
As the carbonaceous material used as an aggregate in the present invention, natural graphite or artificial graphite, delayed coke produced from a petroleum-based or coal-based heavy oil by a delayed coking process (raw coke) or delayed coke are used. Carbon materials derived from plants such as hard carbon obtained from calcined coke calcined at 900 to 1600 ° C. in a non-oxidizing atmosphere, resin materials and the like, and charcoal and bamboo charcoal can be used.
Among the above carbonaceous materials, artificial graphite, raw coke or calcined coke is preferable as an aggregate from the viewpoint of electrical conductivity, and raw coke from the viewpoint of ease of kneading and forming with an iron compound or a binder. Or calcined coke is more preferable.
まず、原料の配合に先駆けて、上記炭素質材料を粉砕、分級して所望の粒度の炭素質粒子(骨材粒子ともいう。)となるように調整を行う。
多孔質炭素材料の気孔径(メジアン径)と気孔率は、炭素質粒子の粒径や結着材の使用量、焼成温度等によって制御することができる。例えば、骨材粒子の粒径を大きくすることにより、これらの数字は大きくなる。具体的に、骨材となる炭素質粒子の粒径について言えば、その全ての粉末の粒径が、好ましくは5mm以下、より好ましくは3mm以下であり、そのうち0.1mm以下の細粒が、好ましくは10%(重量基準)以上、より好ましくは20%以上存在するとよい。また、中間的な粒径をもつ粒子、例えば0.5〜1.0mm程度のものを除外することによって、気孔径や気孔率と機械強度(曲げ強さ)のバランスが良好にすることも好ましい。
炭素質粒子の平均粒子径としては、10〜1000μmであり、好ましくは20〜1000μm、より好ましくは50〜800μmである。炭素粒子の平均粒子径が1000μmを超えてしまうと、得られる多孔質炭素材料の空隙性状が粗となり過ぎ、平均粒子径が10μm未満であると得られる多孔質炭素材料が緻密になり過ぎるため適さない。なお、本明細書でいう平均粒子径とはレーザー散乱・回折式粒子径測定法で測定される体積標準粒子径における累積50%径(d50)である。
First, prior to blending the raw materials, the carbonaceous material is pulverized and classified so as to obtain carbonaceous particles having a desired particle size (also referred to as aggregate particles).
The pore diameter (median diameter) and porosity of the porous carbon material can be controlled by the particle diameter of the carbonaceous particles, the amount of binder used, the firing temperature, and the like. For example, these numbers increase by increasing the particle size of the aggregate particles. Specifically, regarding the particle size of the carbonaceous particles to be the aggregate, the particle size of all the powders is preferably 5 mm or less, more preferably 3 mm or less, of which 0.1 mm or less fine particles, Preferably it is 10% (by weight) or more, more preferably 20% or more. It is also preferable that the balance between the pore diameter and the porosity and the mechanical strength (bending strength) is improved by excluding particles having an intermediate particle diameter, for example, about 0.5 to 1.0 mm. .
The average particle diameter of the carbonaceous particles is 10 to 1000 μm, preferably 20 to 1000 μm, more preferably 50 to 800 μm. If the average particle diameter of the carbon particles exceeds 1000 μm, the void properties of the resulting porous carbon material will be too coarse, and if the average particle diameter is less than 10 μm, the resulting porous carbon material will be too dense and suitable. Absent. In addition, the average particle diameter as used in this specification is the 50% cumulative diameter (d50) in the volume standard particle diameter measured by the laser scattering / diffraction particle diameter measuring method.
結着材は、800℃以上の非酸化性雰囲気下の焼成処理で自ら炭素化すると共に、骨材を結着することができるものであれば特に限定されるものではないが、フェノール樹脂やフラン樹脂、ポリイミド樹脂などの残炭率が40%以上の樹脂材料、又はバインダーピッチの使用が好ましい。 The binder is not particularly limited as long as it can carbonize itself by a baking treatment in a non-oxidizing atmosphere at 800 ° C. or higher and can bind an aggregate. It is preferable to use a resin material having a residual carbon ratio of 40% or more such as a resin or a polyimide resin, or a binder pitch.
バインダーピッチとは、製鋼用の黒鉛電極などを製造する際の結着材として使用される石油系又は石炭系のピッチであり、例えば、バインダーピッチ BP−97(株式会社シーケム製)があげられる。バインダーピッチは樹脂系材料よりも安価であり、炭素化した時の電気伝導性が良好であるために結着材としてより好ましい。 The binder pitch is a petroleum-based or coal-based pitch used as a binder when producing a graphite electrode for steel making, and examples thereof include binder pitch BP-97 (manufactured by Seachem Co., Ltd.). Binder pitch is more preferable as a binder because it is cheaper than resin-based materials and has good electrical conductivity when carbonized.
本発明の多孔質炭素材料の製造に使用される鉄化合物は、多孔質炭素材料の製造プロセス中で分解・還元されるようなものであれば特に限定はされないが、取り扱いや安全性などの面から硫酸鉄、酢酸鉄、クエン酸鉄、水酸化鉄、又は酸化鉄が好ましく、より好ましくは酸化第二鉄が適する。 The iron compound used in the production of the porous carbon material of the present invention is not particularly limited as long as it can be decomposed and reduced in the production process of the porous carbon material, but it has aspects such as handling and safety. To iron sulfate, iron acetate, iron citrate, iron hydroxide, or iron oxide is preferable, and ferric oxide is more preferable.
酸化鉄には、四酸化三鉄(Fe3O4)、酸化第二鉄(Fe2O3)などが存在し、これらはいずれも本発明の多孔質炭素材料の製造に使用することができるが、結晶が微細であって粒子自体の強度が強くなく、微粉となりやすく、混錬のし易さの面から顔料用のベンガラ(Fe2O3を主成分とする赤色顔料)、鱗片状酸化鉄(Fe2O3を主成分とする薄板状粒子)が好ましく、純度や粉体性状、コストの面などからベンガラがより好ましい。多孔質炭素材料に添加された鉄化合物は、焼成後において、例えばベンガラではFeO、Fe3O4、Fe、又はそれらが2種以上混在した状態まで還元されるが、好ましくは、電導性の向上のためFe3O4が単独となるように還元されていることが好ましい。 Iron oxide includes triiron tetroxide (Fe 3 O 4 ), ferric oxide (Fe 2 O 3 ), and the like, all of which can be used for producing the porous carbon material of the present invention. However, from the viewpoint of ease of kneading because the crystal is fine and the particle itself is not strong, it is easy to knead, and it is a bengara for pigment (a red pigment mainly composed of Fe 2 O 3 ), scaly oxidation Iron (thin plate particles containing Fe 2 O 3 as a main component) is preferable, and bengara is more preferable in terms of purity, powder properties, cost, and the like. The iron compound added to the porous carbon material is reduced to a state where FeO, Fe 3 O 4 , Fe, or a mixture of two or more thereof, for example, in Bengala after firing, but preferably improved conductivity Therefore, it is preferable that Fe 3 O 4 is reduced so as to be single.
鉄化合物は、その平均粒子径が100μm以下であり、好ましくは0.05〜100μm、より好ましくは0.1〜50μmである。平均粒子径が100μmを超えると原料の混練後に粗大な粒子が残留することによって多孔質炭素材料中の鉄成分粒子が大きくなりすぎるほか、所望の空隙性状を得ることが難しくなるために適さない。 The iron compound has an average particle size of 100 μm or less, preferably 0.05 to 100 μm, more preferably 0.1 to 50 μm. If the average particle diameter exceeds 100 μm, coarse particles remain after kneading the raw materials, resulting in excessively large iron component particles in the porous carbon material, and it is difficult to obtain desired void properties.
原料の配合割合は、混練条件や成形方法によって調整されるが、炭素質粒子(骨材)と結着材については、骨材100重量部に対し、結着材10〜80重量部の範囲とする。例えば、押出し成形によって多孔質炭素電極を製造する場合は、易黒鉛化性炭素粒子が100重量部に対し、バインダーピッチが10〜80重量部、好ましくは20〜50部にする。バインダーピッチが10重量部未満以下であると、機械強度が低下するため電極が脆くなる。またバインダーピッチが80重量部を超えると電気特性や気孔性状が悪化する。配合割合は上記の範囲で適宜調整される。 The mixing ratio of the raw materials is adjusted depending on the kneading conditions and the molding method, but the carbonaceous particles (aggregate) and the binder are in the range of 10 to 80 parts by weight of the binder with respect to 100 parts by weight of the aggregate. To do. For example, when a porous carbon electrode is produced by extrusion molding, the binder pitch is 10 to 80 parts by weight, preferably 20 to 50 parts per 100 parts by weight of the graphitizable carbon particles. If the binder pitch is less than 10 parts by weight, the electrode becomes brittle because the mechanical strength decreases. On the other hand, if the binder pitch exceeds 80 parts by weight, the electrical properties and the porosity are deteriorated. The blending ratio is appropriately adjusted within the above range.
また、鉄化合物は、骨材100重量部に対して1〜15重量部の範囲で配合される。配合量は好ましくは1〜15重量部であり、より好ましくは2〜12重量部である。骨材及び結着材とともに鉄化合物を配合することによって、材料全体に鉄成分を高濃度かつ均一に担持させることができるほか、焼成後の多孔質炭素材料の機械強度を向上させることができる。
なお、鉄化合物の配合量が1重量%未満では曲げ強度はあまり上がらず、添加の効果が得られない。一方、添加量が15重量部を超えると炭素材料表面への鉄成分の析出も多く、表面の鉄成分が空気中で徐々に酸化され赤錆が発生してしまうために適さない。
Moreover, an iron compound is mix | blended in 1-15 weight part with respect to 100 weight part of aggregates. The amount is preferably 1 to 15 parts by weight, more preferably 2 to 12 parts by weight. By blending the iron compound together with the aggregate and the binder, the iron component can be uniformly supported at a high concentration throughout the material, and the mechanical strength of the porous carbon material after firing can be improved.
In addition, when the compounding amount of the iron compound is less than 1% by weight, the bending strength does not increase so much and the effect of addition cannot be obtained. On the other hand, when the addition amount exceeds 15 parts by weight, the precipitation of iron components on the surface of the carbon material is also large, and the iron components on the surface are gradually oxidized in the air and red rust is generated.
次に、前処理で所望の粒度となるように調整を行った炭素質粒子(骨材)に、結着材と鉄化合物を所定の割合で配合して混練する。混練方法については、鉄化合物が均一に分散可能な方法であれば良く、例えば、所望の粒度となるように粉砕・分級されたピッチコークスや石油コークス等のコークス粒子に、タールやピッチ等のバインダーピッチと鉄化合物を所定量配合して、これをニーダー等の混練機に投入し、バインダーピッチの溶融温度以上で混練するなど、炭素成形体の製造においてごく一般的に行われている方法が挙げられる。
なお、鉄化合物は水や有機溶剤の溶液での状態で配合するのではなく、粉末の状態のままで骨材及び結着材と配合・混練が行われることが好ましい。
Next, the carbonaceous particles (aggregate) adjusted so as to have a desired particle size in the pretreatment are mixed with a binder and an iron compound at a predetermined ratio and kneaded. Any kneading method may be used as long as the iron compound can be uniformly dispersed. For example, a binder such as tar or pitch is added to coke particles such as pitch coke and petroleum coke that have been pulverized and classified to have a desired particle size. Examples of methods commonly used in the production of carbon molded products include blending a predetermined amount of pitch and an iron compound, putting this into a kneader such as a kneader, and kneading at a melting temperature of the binder pitch or higher. It is done.
The iron compound is preferably blended and kneaded with the aggregate and the binder in a powder state, rather than being blended in a state of water or an organic solvent solution.
また、原料の混練時に多孔質炭素材料の気孔性状や機械特性などに悪影響を及ぼさない範囲内で、骨材、結着材、鉄化合物に加えて、さらに炭素繊維のチョップドファイバー、或いはマグネシウム、マンガン、銅、亜鉛、又はモリブデンなど鉄以外の金属成分を酸化物粉末として添加してもよい。
なお、鉄化合物以外の金属成分の添加量については、鉄化合物100重量部に対して1〜10重量部となるように配合されることが好ましい。
In addition to aggregates, binders, and iron compounds, carbon fiber chopped fiber, magnesium, manganese, and so on, as long as the porosity and mechanical properties of the porous carbon material are not adversely affected during raw material kneading Metal components other than iron such as copper, zinc, or molybdenum may be added as oxide powder.
In addition, about the addition amount of metal components other than an iron compound, it is preferable to mix | blend so that it may become 1-10 weight part with respect to 100 weight part of iron compounds.
混練して得られた混練物の成形は、所定の可塑性を示す温度で、所定の形状の押出口を有するダイからの押出し成形のほか、混練物を冷却して二次粉砕した粒子を所望の形状の成形型に入れて上部から加圧成形する形込め成形であっても良く、更には、二次粉砕した粒子を水中でのラバープレスで圧縮成型する冷間静水圧プレス(CIP)成形で製造することもできる。 Molding of the kneaded material obtained by kneading is performed at a temperature exhibiting a predetermined plasticity, in addition to extrusion molding from a die having an extrusion port of a predetermined shape, and by cooling the kneaded material to a desired secondary pulverized particle. It may be a mold-in-molding method in which it is put into a mold having a shape and pressed from above, and further, by cold isostatic pressing (CIP) molding in which the secondary pulverized particles are compression-molded with a rubber press in water. It can also be manufactured.
上記のような成形で得られた成形物は焼成炉内で非酸化性雰囲気下にて焼成を行う。この焼成で、鉄化合物は還元され、Fe2O3はFeO、Fe3O4、Fe、又はそれらが二種以上混在する状態まで還元される。配合する鉄化合物の量や大きさ、焼成の雰囲気によって多少は異なるが、焼成温度は800〜1600℃の温度範囲内で行われることが好ましく、800〜1300℃で焼成されることがより好ましく、800〜1000℃が更に好ましい。黒鉛化まで行うと鉄成分が揮散してしまうので鉄化合物粒子の添加効果が消失するほか、疎水性が強くなるので不適である。また、焼成温度が1600℃以上であると鉄化合物の融解により、鉄化合物粒子同士が融着して大きな粒子となり易くなってしまう。また、800℃以下であると結着材の炭素化が不十分となるので得られた多孔質炭素材料の導電性が低下してしまうため好ましくない。
なお、焼成時の非酸化性雰囲気は、還元雰囲気や不活性ガス雰囲気等であり、一酸化炭素(CO)やアルゴン/水素混合ガスなどの還元性を有するガスの吹込みを行なってもよいが、石炭やコークスブリーズ(コークス粉)など炭素を含む還元剤と一緒に焼成炉内で焼成を行うことがFe3O4を得易く好ましい。
The molded product obtained by the above molding is fired in a non-oxidizing atmosphere in a firing furnace. By this firing, the iron compound is reduced, and Fe 2 O 3 is reduced to FeO, Fe 3 O 4 , Fe, or a state in which two or more thereof are mixed. Although it varies somewhat depending on the amount and size of the iron compound to be blended and the firing atmosphere, the firing temperature is preferably performed within a temperature range of 800 to 1600 ° C, more preferably fired at 800 to 1300 ° C. 800-1000 degreeC is still more preferable. If graphitization is performed, the iron component is volatilized, so the effect of adding the iron compound particles disappears and the hydrophobicity becomes strong, which is not suitable. On the other hand, if the firing temperature is 1600 ° C. or higher, the iron compound particles are easily fused to become large particles due to melting of the iron compound. Moreover, since carbonization of a binder becomes inadequate when it is 800 degrees C or less, since the electroconductivity of the obtained porous carbon material will fall, it is unpreferable.
Note that the non-oxidizing atmosphere at the time of firing is a reducing atmosphere, an inert gas atmosphere, or the like, and a gas having reducing properties such as carbon monoxide (CO) or an argon / hydrogen mixed gas may be injected. It is preferable to perform firing in a firing furnace together with a reducing agent containing carbon such as coal or coke breeze (coke powder) because Fe 3 O 4 is easily obtained.
本発明の製造方法により得られる多孔質炭素材料は、鉄成分が四酸化酸鉄(Fe3O4)となって、好ましくは0.5wt%以上の量で、表層部に偏在することなく、内部まで高濃度かつ均一に分散担持されている。その成形物内部にまでFe3O4が、平均粒子径1μm以下、好ましくは0.1〜0.5μmのサイズの粒子として均一に分散している。原料の酸化第二鉄粒子として、ベンガラのような非常に脆い微細な多結晶体を使用すれば、混練時に容易に粉砕されながら微細化して均一に分散担持される。 In the porous carbon material obtained by the production method of the present invention, the iron component is iron tetroxide (Fe 3 O 4 ), preferably in an amount of 0.5 wt% or more, and unevenly distributed in the surface layer portion, Highly concentrated and uniformly dispersed and supported up to the inside. Fe 3 O 4 is uniformly dispersed as particles having an average particle diameter of 1 μm or less, preferably 0.1 to 0.5 μm, up to the inside of the molded product. If a very brittle fine polycrystal like Bengala is used as the raw material ferric oxide particles, it is finely pulverized and uniformly dispersed and supported during kneading.
本発明の多孔質炭素材料は、比抵抗が100μΩm以下、曲げ強度が20MPa以上の成形体、特に開気孔率が10〜20%の成形体が得られる。比抵抗が75〜85μΩm、曲げ強度が25〜35MPa、開気孔率が15〜18%であことがより好ましい。比抵抗および曲げ強度が上記範囲内であることによって、多孔質炭素材料としての導電性を維持しつつ、切削などにより成形体に2次加工を行っても十分な機械強度が確保できる。 The porous carbon material of the present invention provides a molded product having a specific resistance of 100 μΩm or less and a bending strength of 20 MPa or more, particularly a molded product having an open porosity of 10 to 20%. More preferably, the specific resistance is 75 to 85 μΩm, the bending strength is 25 to 35 MPa, and the open porosity is 15 to 18%. When the specific resistance and bending strength are within the above ranges, sufficient mechanical strength can be ensured even if secondary processing is performed on the molded body by cutting or the like while maintaining the conductivity as the porous carbon material.
また、一般に黒鉛表面の水の接触角は110°前後で疎水性が高いが、本発明の製法により得られる成形体は表面性状が水の接触角が30〜90°と比較的親水性であり、多孔質炭素材料100重量部に対して、5wt%以上、好ましくは7wt%以上の吸水率(水浸漬24時間後)を示す。
本発明の多孔質炭素材料は、導電性のFe3O4粒子を含むため、導電性や触媒活性等が優れ、電解用の電極や触媒等に使用できる。特に、電解水処理を行うための電極用に適する。
In general, the contact angle of water on the graphite surface is around 110 ° and the hydrophobicity is high, but the molded product obtained by the method of the present invention has a relatively hydrophilic surface property with a contact angle of 30 to 90 ° with water. The water absorption is 5 wt% or more, preferably 7 wt% or more (after 24 hours of water immersion) with respect to 100 parts by weight of the porous carbon material.
Since the porous carbon material of the present invention contains conductive Fe 3 O 4 particles, it is excellent in conductivity, catalytic activity, etc., and can be used for an electrode or catalyst for electrolysis. In particular, it is suitable for an electrode for performing electrolytic water treatment.
本発明の多孔質炭素材料は、焼成後に賦活処理を行ってもよい。賦活処理は高温での酸化ガス(H2O,CO2,O2など)との原料の接触反応によるガス賦活を行うことが好ましく、多孔質炭素材表面の鉄化合物粒子がやや酸化されるものの、例えば焼成直後の炉内に大気を導入することによってガス賦活を行うといった方法を採ることができる。 The porous carbon material of the present invention may be activated after firing. The activation treatment is preferably performed by gas activation by contact reaction of raw materials with oxidizing gas (H 2 O, CO 2 , O 2, etc.) at high temperature, although the iron compound particles on the surface of the porous carbon material are slightly oxidized For example, a method of performing gas activation by introducing the atmosphere into the furnace immediately after firing can be employed.
また、更に必要に応じて白金やパラジウム、酸化チタン等といった触媒機能を有する金属の分散液等に本発明の多孔質炭素材料を浸漬したのち再焼成するなどして別途担持させることもできる。 Further, if necessary, the porous carbon material of the present invention may be immersed in a dispersion of a metal having a catalytic function such as platinum, palladium, titanium oxide, etc., and then re-fired to carry it separately.
以下、実施例に基づいて本発明の内容を具体的に説明するが、本発明はこれらの実施例に限定されるものではない。 EXAMPLES Hereinafter, although the content of this invention is demonstrated concretely based on an Example, this invention is not limited to these Examples.
実施例1
真密度1.82g/cm3のピッチコークス(PC)を粉砕し、2.4〜1mm:40%、0.3〜0.075mm:35%、0.074mm以下:25%の粒度配合(平均粒径755μm)になるように調整したピッチコークス粒子100重量部に、ベンガラ(戸田ピグメント製 Toda Color R580 平均粒径0.19μm)10重量部と石炭系重質油から得られたバインダーピッチ(BP:軟化点97℃)40重量部を添加し、200℃で20分間加熱混練した。この混練物を20mmφ×100mmの大きさで円柱状に押出し成型した。成型後900℃の非酸化性雰囲気中で焼成炭化し、目的物の多孔質炭素材料(円柱体)を得た。
Example 1
Pitch coke (PC) having a true density of 1.82 g / cm 3 was pulverized, and 2.4 to 1 mm: 40%, 0.3 to 0.075 mm: 35%, 0.074 mm or less: 25% particle size blend (average) 100 parts by weight of pitch coke particles adjusted to have a particle size of 755 μm), 10 parts by weight of Bengala (Toda Color R580, average particle size of 0.19 μm manufactured by Toda Pigment) and a binder pitch (BP) obtained from heavy coal oil : Softening point 97 ° C) 40 parts by weight was added, and the mixture was heated and kneaded at 200 ° C for 20 minutes. This kneaded product was extruded into a cylindrical shape with a size of 20 mmφ × 100 mm. After molding, it was calcined and carbonized in a non-oxidizing atmosphere at 900 ° C. to obtain a target porous carbon material (cylindrical body).
実施例2〜3
ベンガラの配合量を10重量部に代えて、2又は5重量部とした以外、実施例1と同様の方法で、多孔質炭素材料を得た。
Examples 2-3
A porous carbon material was obtained in the same manner as in Example 1 except that the amount of Bengala was changed to 2 or 5 parts by weight instead of 10 parts by weight.
比較例1
ベンガラを配合しない以外、実施例1と同様の方法で、多孔質炭素材料を得た。
Comparative Example 1
A porous carbon material was obtained in the same manner as in Example 1 except that Bengala was not blended.
比較例2
硫酸第一鉄(硫酸鉄(II)七水和物99.5%、1級 和光純薬製)と純水で20%硫酸鉄水溶液を調整し、比較例1と同じ方法で作成した多孔質炭素材料を浸漬し、減圧脱気して、多孔質炭素材料の空隙に硫酸鉄水溶液を含浸させた。水溶液から多孔質炭素を取り出したのち、紙ウエスで表面を拭取り、多孔質炭素の重量増分から硫酸第一鉄の含浸量を算出した。
一日間室温で乾燥したのち、60℃の乾燥機で乾燥後、900℃の非酸化性雰囲気中で再度焼成し、鉄入り多孔質炭素材料を得た。硫黄が完全には除去できず、硫黄臭がした。得られた多孔質炭素はその後、水洗、乾燥を行ったが硫黄臭は消えなかった。
Comparative Example 2
A porous material prepared by the same method as Comparative Example 1 by preparing a 20% aqueous solution of iron sulfate with ferrous sulfate (iron (II) sulfate heptahydrate 99.5%, first grade Wako Pure Chemical Industries, Ltd.) and pure water. The carbon material was immersed and degassed under reduced pressure, and the porous carbon material was impregnated with an aqueous iron sulfate solution. After removing the porous carbon from the aqueous solution, the surface was wiped with a paper waste, and the amount of ferrous sulfate impregnated was calculated from the weight increment of the porous carbon.
After drying at room temperature for one day, it was dried with a dryer at 60 ° C. and then fired again in a non-oxidizing atmosphere at 900 ° C. to obtain an iron-containing porous carbon material. Sulfur was not completely removed, and there was a smell of sulfur. The obtained porous carbon was then washed with water and dried, but the sulfur odor did not disappear.
比較例3
ベンガラの配合量を10重量部に代えて、20重量部とした以外、実施例1と同様の方法で、多孔質炭素材料を得た。
Comparative Example 3
A porous carbon material was obtained in the same manner as in Example 1 except that the blending amount of Bengala was changed to 10 parts by weight and 20 parts by weight.
比較例4
ベンガラに代えて鋳鉄粉(鉄粉#300、協和純薬工業製)を10重量部配合した以外、実施例1と同様の方法で多孔質炭素材料を得ようとしたが、押出成形ができず、試料を得ることができなかった。
Comparative Example 4
A porous carbon material was obtained in the same manner as in Example 1 except that 10 parts by weight of cast iron powder (iron powder # 300, manufactured by Kyowa Junyaku Kogyo Co., Ltd.) was used instead of Bengala. A sample could not be obtained.
実施例及び比較例で作成した多孔質炭素材料(円柱体)は、下記の方法で各種評価を行った。これらの配合処方及び結果を表1に示す。表中、骨材、結着材、鉄化合物の数値(下段)は、重量部である。 The porous carbon material (cylindrical body) created in Examples and Comparative Examples was subjected to various evaluations by the following methods. Table 1 shows these formulation and results. In the table, the numerical values (lower part) of the aggregate, the binder, and the iron compound are parts by weight.
[嵩比重]
多孔質炭素材料をノギスで直径と長さを測定し、さらに丸棒の重量から見かけ比重(嵩比重)とした。
[Bulk specific gravity]
The diameter and length of the porous carbon material were measured with calipers, and the apparent specific gravity (bulk specific gravity) was determined from the weight of the round bar.
[比抵抗]
定電流電源装置(マルチメーター)を用いた四端子測定法で測定した。通電用の二端子を多孔質炭素材料の両端に接続し、さらに検出用二端子を円柱側面に65mm間隔になるように接続し、室温にて両端の通電用二端子に2Aの電流をかけたときの側面の検出用二端子間の電圧を測定することで実抵抗とし、さらに円柱の断面積と端子間距離から比抵抗(実抵抗×長さ/断面積)を求めた。
[Resistivity]
The measurement was performed by a four-terminal measurement method using a constant current power supply (multimeter). Two terminals for energization were connected to both ends of the porous carbon material, and further, two terminals for detection were connected to the side surface of the cylinder at intervals of 65 mm, and a current of 2 A was applied to the two terminals for energization at both ends at room temperature. The actual resistance was obtained by measuring the voltage between the two detection terminals on the side surface, and the specific resistance (actual resistance × length / cross-sectional area) was determined from the cross-sectional area of the cylinder and the distance between the terminals.
[曲げ強さ]
JIS R 7222の曲げ強さ測定方法に準拠し、曲げ試験機(卓上万能試験機 AGS‐500A SHIMADZU社製)を用いて、多孔質炭素材料に毎秒50Nの一定荷重速度で加重を加え、得られた最大荷重から以下の式から曲げ強さを求めた
曲げ強さ= 8×最大荷重×支点間距離/(円周率×円柱直径)。
[Bending strength]
In accordance with the bending strength measurement method of JIS R 7222, using a bending tester (desktop universal testing machine AGS-500A manufactured by SHIMADZU), a porous carbon material is loaded at a constant load rate of 50 N / sec. The bending strength was calculated from the following formula using the following formula: bending strength = 8 × maximum load × distance between fulcrums / (circumference ratio × cylinder diameter).
[吸水率]
予め重量測定した多孔質炭素材料を室温の純水に浸漬し、24時間後取り出し後、3分間室温で静置し、水の滴りがなく、水が十分切れたところで重量を測定し、増えた重量増割合を吸水率とした。
[Water absorption rate]
The porous carbon material weighed in advance was immersed in pure water at room temperature, taken out after 24 hours, and then allowed to stand at room temperature for 3 minutes. When there was no water dripping and the water was sufficiently cut, the weight was measured and increased. The weight increase rate was defined as the water absorption rate.
[SEM観察、元素分析] 多孔質炭素の空隙や微細形状や鉄成分粒子の分布観察は、多孔質炭素材料を電動カッターでカットし、破断面を走査型電子顕微鏡(SEM S‐4700 日立ハイテクノロジーズ社製)による形状観察、エネルギー分散型X線分析(EDX EMAX400 HORIBA社製)による破断面の元素分析を実施した。 [SEM observation, elemental analysis] Porous carbon material was observed with an electric cutter, and the fracture surface was scanned with a scanning electron microscope (SEM S-4700 Hitachi High Technologies). Shape observation by the company) and elemental analysis of the fracture surface by energy dispersive X-ray analysis (EDX EMAX400 by HORIBA).
[開気孔率]
JIS R 1634 開気孔率の真空法の測定方法に準拠し、多孔質炭素材料の乾燥重量、純水に浸けたときの円柱の水中重量、並びにそれを真空にして飽水させたときの飽水重量を測定し、得られた重量を使って以下の式から開気孔率を求めた。
開気孔率(%)= (飽水重量−乾燥重量)/(飽水重量−水中重量)×100
[Open porosity]
In accordance with the measurement method of the vacuum method of JIS R 1634, the dry weight of the porous carbon material, the weight of the cylinder when immersed in pure water, and the saturated water when it is saturated with vacuum. The weight was measured, and the open porosity was determined from the following formula using the obtained weight.
Open porosity (%) = (saturated water weight−dry weight) / (saturated water weight−in water weight) × 100
[平均気孔率]
多孔質炭素材料を長手方向に半裁した後、高さ5mm程度の半円柱に切断したものを使用し、 X線CT装置(X線透過検査装置TUX−3200N マーストーケンソリューション社製)にて全方位の透過像を撮像し、再構成処理により三次元立体画像データを取得した。得られた三次元画像データを画像処理ソフトにて3mm×3mm×10mmのサイズ(300×300×1000ボクセル)に切り出し、 三次元画像解析ソフトにて空隙の各箇所における径を算出して統計処理で平均気孔率を求めた。
[Average porosity]
A porous carbon material is cut in half in the longitudinal direction, and then cut into a semi-cylinder with a height of about 5 mm, and omnidirectional with an X-ray CT device (X-ray transmission inspection device TUX-3200N manufactured by Marstoken Solutions) The three-dimensional stereoscopic image data was acquired by reconstruction processing. The obtained three-dimensional image data is cut into a size of 3 mm x 3 mm x 10 mm (300 x 300 x 1000 voxels) with image processing software, and statistical processing is performed by calculating the diameter at each location of the void with three-dimensional image analysis software. The average porosity was determined.
[Fe含有量]
多孔質炭素材料をディスクミルで微粉砕(平均粒径75μm程度)し、電気炉で炭素分を燃焼させ、残った灰分をアルカリ溶融し、酸で溶かす。それを使って予めFeピークとFe量の検量線を求めたICP(高周波誘導結合プラズマ)発光分光分析法でFe分を測定し、使った多孔質炭素材料と残った灰分量からFe含有量を求めた。
[Fe content]
The porous carbon material is finely pulverized with a disk mill (average particle size of about 75 μm), the carbon content is burned in an electric furnace, and the remaining ash content is alkali-melted and dissolved with an acid. Using it, the Fe content was measured by ICP (high frequency inductively coupled plasma) emission spectroscopic analysis in which a calibration curve for the Fe peak and Fe content was previously obtained, and the Fe content was determined from the porous carbon material used and the remaining ash content. Asked.
[XRD]
多孔質炭素材料をディスクミルで微粉砕(平均粒径75μm程度)し、X線回折装置(リガク社製、RINT−TTRIII、X線管球:CuKα、管電流:300mA、管電圧:50kV)にて鉄成分の同定を行った。
[XRD]
A porous carbon material is finely pulverized with a disk mill (average particle size of about 75 μm) and is applied to an X-ray diffractometer (Rigaku Corporation, RINT-TTRIII, X-ray tube: CuKα, tube current: 300 mA, tube voltage: 50 kV). The iron component was identified.
[Fe溶出量]
JIS K 0102 工場排水試験方法に準拠し、多孔質炭素材料をディスクミルで粒径5mm以下に粉砕し、重量体積比10%になるように水を加え、常温で振とう機で六時間連続して水平に振とうする。溶出操作後、遠心加速度3000Gにて20分間遠心分離を実施し、得られた試料液(上澄み)を、孔径1μmのメンブランフィルターを用いて濾過する。濾液をつかって高周波誘導結合プラズマ発光分光分析装置(VARIAN社製、720−ES)にて水に溶出した鉄成分の定性を行なった。
[Fe elution amount]
In accordance with the JIS K 0102 factory drainage test method, the porous carbon material is pulverized to a particle size of 5 mm or less with a disk mill, water is added so that the weight to volume ratio is 10%, and the mixture is continuously shaken at room temperature for 6 hours. Shake horizontally. After the elution operation, centrifugation is performed at a centrifugal acceleration of 3000 G for 20 minutes, and the obtained sample solution (supernatant) is filtered using a membrane filter having a pore diameter of 1 μm. The filtrate was used to qualify the iron component eluted in water with a high-frequency inductively coupled plasma emission spectrometer (720-ES, manufactured by VARIAN).
本発明の多孔質炭素材料は、表1の実施例1〜3に見られるように比較例1の鉄化合物無添加の多孔質炭素材料とほぼ同等の比抵抗を有しながら、機械強度は比較例1、2よりも優れるために形状加工性の自由度の高い、かつ鉄を大量に含有する多孔質炭素材料を容易に得ることを可能とする。
また、本発明の多孔質炭素材料は、比較例2の溶液浸漬型とは異なり、含有する金属成分が吸水率の違いに見られるようにその内部の空孔を閉塞したり表層部に偏在することなく、図1で観察されるように100nmから500nmほどの粒径となって、その内部まで高濃度かつ均一に分散されている。また、X線回折装置(XRD)による結晶状態を調べたところ、図2に示すとおり、実施例1〜3の多孔質炭素材料に含まれる鉄成分はFe3O4であることが確認され、溶出試験でもFeイオンは比較例3とは異なり検出されなかった。なお、図2(XRD)において、20-30°の大きなピークはPC炭素由来であり、それ以外はマグネタイト・Fe3O4のピークとほぼ一致した。
While the porous carbon material of the present invention has almost the same specific resistance as that of the porous carbon material to which no iron compound is added in Comparative Example 1 as seen in Examples 1 to 3 in Table 1, the mechanical strength is compared. Since it is superior to Examples 1 and 2, it is possible to easily obtain a porous carbon material having a high degree of freedom in shape workability and containing a large amount of iron.
Further, unlike the solution immersion type of Comparative Example 2, the porous carbon material of the present invention closes the internal pores or is unevenly distributed in the surface layer so that the contained metal component can be seen in the difference in water absorption. Instead, as observed in FIG. 1, the particle diameter is about 100 nm to 500 nm, and the inside is uniformly dispersed at a high concentration. We also examined the crystalline state by the X-ray diffractometer (XRD), as shown in FIG. 2, the iron component contained in the porous carbon material of Example 1-3, it is confirmed as Fe 3 O 4, Unlike the comparative example 3, Fe ions were not detected in the dissolution test. In FIG. 2 (XRD), a large peak at 20-30 ° is derived from PC carbon, and other than that, it almost coincided with the peak of magnetite / Fe 3 O 4 .
本発明の多孔質炭素材料は、例えば、排水等の脱臭や脱色処理のための材料や、これらの電気化学的処理のための電極材料、酵素や藻類,バクテリアなどの担持材料、微生物燃料電池の電極材料として好適に使用されるものである。
The porous carbon material of the present invention includes, for example, materials for deodorizing and decoloring treatment such as waste water, electrode materials for these electrochemical treatments, supporting materials such as enzymes, algae, and bacteria, and microbial fuel cells. It is suitably used as an electrode material.
Claims (4)
The carbonaceous particles are at least one carbonaceous material selected from raw coke and calcined coke obtained from petroleum-based or coal-based heavy oil, and the binder is a coal-based or petroleum-based binder pitch; The method for producing a porous carbon material according to claim 3, wherein the iron compound particles are ferric oxide.
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