Gas adsorbing element and method for forming same

Abstract

A gas adsorbing element is formed into a honeycomb-shaped laminate having many small channels penetrating from one end surface to the other and in which hydrophobic high silica zeolite powder is exposed on the walls of the small channels. The hydrophobic high silica zeolite is, for example, a zeolite which is produced by removing most of the aluminum component from an ordinary zeolite. In forming the honeycomb-shaped laminate, it is favorable that non-flammable sheets are laminated and the laminate is impregnated with a dispersion of high silica zeolite powder and with an inorganic binder, and that the high silica zeolite powder is fixed in fiber gaps and on the surface of the non-flammable paper. It is desirable that the non-flammable sheet is a low density inorganic fiber paper and is baked either before or after forming the honeycomb-shaped laminate. This element adsorbs little water vapor even when the process air is highly humid, and is able to adsorb and remove organic solvent vapor and bad odor material in the air with high efficiency.

1. A gas adsorbing element  device comprising:
 a honeycomb-shaped laminate having many small channels penetrating from a first end surface to a second end surface, including a hydrophobic high silica zeolite powder placed  fixed on walls of said small channels, said high silica zeolite having the composition of xM 2 / n O—Al 2 O 3 .ySiO 2 .zH 2 O, where M is an alkaki metal or alkaline-earth metal, n is its valence, and y is a mol ratio of silica and aluminum which  to alumina and is greater than approximately  8  200, wherein    
   the honeycomb - shaped laminate has an adsorbing zone and a desorbing zone, such that the adsorbing and desorbing zones are repeatedly interchanged with one another.    
 
     
     
       2. A gas adsorbing element according to  claim 1 , wherein high silica zeolite is zeolite from which most of an aluminum component is removed. 
     
     
       3. A method of manufacturing a gas adsorbing element, comprising the steps of:
 (a) laminating sheets having a main component of inorganic fiber to form single-faced corrugated sheets;    (b) laminating the single-faced corrugated sheets to form a honeycomb-shaped laminate having a shape of a gas adsorbing element having many small channels; and    (c) fixing hydrophobic high silica zeolite powder in fiber gaps and on the wall of the small channels in which a mol ratio of silica and alumina is more than approximately 8:1 using an inorganic binder.    
     
     
       4. A method of manufacturing a gas adsorbing element according to  claim 3 , wherein high silica zeolite in said step (c) is zeolite from which most of an aluminum component is removed. 
     
     
       5. A method of manufacturing a gas adsorbing element according to  claim 3 , wherein the sheets in said step (a) are low density papers. 
     
     
       6. A method of manufacturing a gas adsorbing element according to  claim 3 , wherein the inorganic fiber paper in said step (a) is baked either before or after forming the honeycomb-shaped laminate. 
     
     
       7. A method of manufacturing a gas adsorbing element according to  claim 3 , wherein the thickness of the inorganic fiber sheet is approximately 0.10˜0.30 mm, the wavelength of the corrugate is approximately 2.5 to 4.5 mm, the wave height of the corrugate is approximately 1.0 to 3.0 mm, and the length of the small channels is approximately 100 to 500 mm. 
     
     
       8. A method of manufacturing a gas adsorbing element according to  claim 4 , wherein the sheets in said step (a) are low density papers. 
     
     
       9. A method of manufacturing a gas adsorbing element according to  claim 4 , wherein the inorganic fiber sheets in said step (a) are baked either before or after forming the block. 
     
     
       10. A method of manufacturing a gas adsorbing element according to  claim 4 , wherein the thickness of the inorganic fiber sheets is approximately 0.10˜0.30 mm, the wavelength of the corrugate is approximately 2.5 to 4.5 mm, the wave height of the corrugate is approximately 1.0 to 3.0 mm, and the length of the small channels is approximately 100 to 500 mm. 
     
     
       11. A method of manufacturing a gas adsorbing element according to  claim 5 , wherein the inorganic fiber sheets in said step (a) are baked either before or after forming the block. 
     
     
       12. A method of manufacturing a gas adsorbing element according to  claim 5 , wherein the thickness of the inorganic fiber sheets is approximately 0.10˜0.30 mm, the wavelength of the corrugate is approximately 2.5 to 4.5 mm, the wave height of the corrugate is approximately 1.0 to 3.0 mm, and the length of the small channels is approximately 100 to 500 mm. 
     
     
       13. A method of manufacturing a gas adsorbing element according to  claim 6 , wherein the thickness of the inorganic fiber sheets is approximately 0.10˜0.30 mm, the wavelength of the corrugate is approximately 2.5 to 4.5 mm, the wave height of the corrugate is approximately 1.0 to 3.0 mm, and the length of the small channels is approximately 100 to 500 mm. 
     
     
       14. A method of manufacturing a gas adsorbing element, comprising the steps of:
 (a) laminating sheets having a main component of inorganic fiber to obtain laminated sheets;    (b) forming the laminated sheets into a honeycomb structure having many small channels;    (c) impregnating the honeycomb structure with a dispersion of high silica zeolite powder in which a mol ratio of silica and alumina is more than approximately 8:1 and with an inorganic binder;    (d) fixing the high silica zeolite powder in fiber gaps in the honeycomb structure; and    (e) baking the laminated sheets before or after forming the honeycomb shaped structure.    
     
     
       15. A gas adsorbing device according to  claim 1 , wherein the honeycomb- shaped laminate is a rotor.   
     
     
       16. A gas adsorbing device according to  claim 15 , wherein
   the adsorbing and desorbing zones are provided in different sectors of the rotor, and        the device further comprises a motor to rotate the rotor so as to interchange the adsorbing and desorbing zones.     
     
     
       17. A gas adsorbing device according to  claim 1 , further comprising a heater to heat a reactivating gas which is passed through the desorbing zone. 
     
     
       18. A gas adsorbing device according to  claim 1 , wherein the honeycomb- shaped laminate simultaneously adsorbs and desorbs volatile organic compounds.   
     
     
       19. A gas adsorbing device according to  claim 1 , wherein
   the honeycomb - shaped laminate is a rotor, and        the device further comprises:      a casing to rotatably support the rotor,        a separator to separate the adsorbing zone from the desorbing zone, and        a motor to rotate the rotor within the casing.       
     
     
       20. A gas adsorbing device according to  claim 19 , further comprising a heater to heat reactivation air supplied to the desorbing zone. 
     
     
       21. A method of adsorbing organic solvent vapor, comprising:
   passing the organic solvent vapor over a gas adsorbing element comprising:      a honeycomb - shaped laminate having many small channels penetrating from a first end surface to a second end surface, including a hydrophobic high silica zeolite powder fixed on walls of said small channels, said high silica zeolite having the composition of xM   2   /   n   O—Al   2   O   3   .ySiO   2   .zH   2   O, where M is an alkaki metal or alkaline - earth metal, n is its valence, and y is a mol ratio of silica to alumina and is greater than approximately  200 ; and          desorbing the organic solvent vapor from the gas adsorbing element to thereby reactivate the gas adsorbing element.     
     
     
       22. A method of adsorbing organic solvent vapor according to  claim 21 , wherein
   the honeycomb - shaped laminate has an adsorbing zone and a desorbing zone, and        organic solvent vapor is passed over the adsorbing zone of the gas adsorbing element at the same time as organic solvent vapor is desorbed from the desorbing zone of the gas adsorbing element.     
     
     
       23. A method of adsorbing organic solvent vapor according to  claim 22 , wherein the adsorbing and desorbing zones are repeatedly interchanged with one or another. 
     
     
       24. A method of adsorbing organic solvent vapor according to  claim 22 , wherein
   the honeycomb - shaped laminate is rotatably supported in a casing having a separator to separate the adsorbing zone from the desorbing zone, and        the honeycomb - shaped laminate is rotated in the casing.     
     
     
       25. A method of adsorbing organic solvent vapor according to  claim 21 , wherein the organic solvent vapor is desorbed by passing a heated reactivation air through the honeycomb- shaped laminate.