KR102134427B1 - Clay bricks comprising bottom ash with sound proofness and preparing method thereof - Google Patents

Abstract

The present invention relates to an environmentally friendly porous clay plastering brick containing recycled raw materials and a method for manufacturing the same, and more specifically, it is eco-friendly, including a bottom ash (bottom ash) containing unburned carbon classified as waste resources. By characterizing the structure and arrangement of the grooves in the clay plastering brick, the present invention relates to a clay plastering brick having excellent sound insulation, heat insulation and adhesion, and a lightweight method.

Description

CLAY BRICKS COMPRISING BOTTOM ASH WITH SOUND PROOFNESS AND PREPARING METHOD THEREOF}

The present invention relates to an economical and environmentally friendly, excellent soundproofing, heat insulation and adhesion, and a lightweight plastered brick and a method for manufacturing the same.

Thermal power plants produce electricity by burning anthracite coal at about 1600℃ as the main raw material. At this time, the coal ash that has been burned for power generation is divided into two types according to the size of the particles. A particle size of 100 µm or more is called a bottom ash and a bottom ash of less than 100 µm is fly ash, Fly ash).

In Korea, there are 10 thermal power plants, and the amount of coal ash generated there is about 6 million tons per year. Of these, 3.5 million tons are used as cement substitutes, but the remaining approximately 2.5 million tons are landfilled. In particular, fly ash is mostly recycled, but floor materials are difficult to utilize, so all of them are landfilled.

However, the flooring contains many heavy metals, so if it is landfilled as it is, it can cause serious environmental pollution to the surrounding soil. Therefore, research on how to recycle the flooring is urgent.

In this regard, Korean Patent Publication No. 2011-0055309 discloses a method of manufacturing an eco-clay brick using a geopolymer reaction of a flooring material. However, the flooring is a flooring material from which unburned carbon is removed, and there is a problem in that a separate process for removing unburned carbon is additionally required.

Republic of Korea Patent No. 2011-0055309 (Korea Institute of Geoscience and Mineral Resources)

The present invention is to solve the above problems, and provides an eco-friendly and economical, lightweight, plastering brick with excellent sound insulation, heat insulation and adhesion using a bottom ash (bottom ash), which is a coal waste, and a method for manufacturing the same It has its purpose.

The clay plastering brick according to the present invention for achieving the above object is in the clay plastering brick containing unburned carbon (bottom ash, bottom ash), clay, kaolin and clay, the composition for preparing clay plastering brick 100 With respect to weight percent, the flooring is included in 40 to 50% by weight, the clay is included in 30 to 35% by weight, the kaolin is included in 5 to 10% by weight, and the clay is in the range of 15 to 25% by weight. Included, the clay plastering brick includes a plurality of rectangles as grooves in the clay plastering brick, and a space between each groove in an array of rows of the grooves and each groove in an array of adjacent rows is opened. It is characterized by not overlapping each other on the basis of.

In addition, the method of manufacturing a clay plastering brick of the present invention is a) 40 to 50% by weight of the flooring material containing unburned carbon, 30 to 35% by weight of clay, 5 to 10% by weight of kaolin, 15 to 25% by weight of clay Preparing a mixture; b) putting the mixture into a molding machine, followed by drying in a drying cart; And c) separating the dried mixture from the drying cart and firing in a kiln at a temperature of 1040°C.

The clay plastering brick according to the present invention and its manufacturing method are not only economical and eco-friendly, but also have excellent advantages of sound insulation, heat insulation and adhesion.

1 is a simplified illustration of a clay plastering brick of the present invention.
Figure 2 is a simplified illustration of the top surface of the clay plaster brick of the present invention.
Figure 3 is a simplified illustration of a cross section of a laminate in which the clay plaster brick of the present invention is laminated.

In the present invention, when a part “includes” a certain component, this means that other components may be further included, rather than excluding other components, unless otherwise specified. In addition, for convenience of description, in the present specification, a long axis means a part having a relatively long length, and a short axis means a part having a relatively short length.

Hereinafter, the present invention will be described in more detail.

According to an aspect of the present invention, the clay plastering brick includes bottom ash (bottom ash), clay, kaolin, and clay containing unburned carbon, and based on 100% by weight of the composition for preparing clay plastering brick, the flooring is 40 to 50% by weight, the clay is included in 30 to 35% by weight, the kaolin is included in 5 to 10% by weight, the clay is characterized in that it is included in 15 to 25% by weight, brick Even when the firing temperature is lowered from the conventional 1150°C to 1040°C during manufacturing, sufficient compressive strength can be obtained, thereby saving energy.

In addition, the clay plastering brick of the present invention includes a plurality of rectangles as grooves in the clay plastering brick, and the space between each groove in the arrangement of rows of the grooves and each groove in the arrangement of other adjacent rows is By taking a structure that does not overlap each other on the basis of heat, there is an advantage of excellent sound insulation, heat insulation and adhesion.

When burning the bituminous coal or anthracite coal supplied to the boiler of the thermal power plant, the flooring material is characterized in that it is a flooring material that has not yet been burned and filtered to the floor. The flooring material may contain 10% by weight or more of unburned carbon, and when the unburned carbon is contained, heat is generated due to combustion of unburned carbon contained in the clay plastering brick during the firing process. It has the effect of rapidly increasing the temperature of the brick. Therefore, it is possible to lower the temperature of the kiln that provides the necessary heat during firing from the conventional temperature (1150°C or higher) to 1040°C. Since sufficient compressive strength can be produced even at such a low temperature, it is possible to save energy required to maintain the temperature of the kiln during firing, and the amount of fuel required to operate the kiln can be fired at a conventional kiln temperature (1150℃ or higher). The reduction in fuel cost can be seen by more than 40% reduction.

According to an aspect of the present invention, the content of the flooring material may be included in 40 to 50% by weight, more preferably 42 to 55% by weight, based on 100% by weight of the total composition for preparing clay plaster bricks including the same. When the content of the flooring material is less than the above range, the content of unburned carbon in the composition for preparing plastered clay bricks is insufficient, so a sufficient exothermic effect cannot be expected, and when it exceeds the content, the content of unburned carbon in the composition for preparing clay plastered bricks Excessively, the content of other compositions is relatively insufficient, so the compressive strength of the finished clay plaster can be lowered.

The clay is a collection of hydrous alumina silicate minerals, which must be able to float when the particles are fine and loose in water, and exhibit plasticity when water is added. In addition, it is characterized by being hardened when dried, and sintered firmly when fired at a high temperature. In particular, when used together with kaolin, there is an advantage of increasing the strength by increasing the bonding strength of the clay plastering brick.

According to an aspect of the present invention, the content of the clay is included in 30 to 35% by weight based on 100% by weight of the total composition for preparing clay plaster. When the clay is less than the above range, the properties of the clay showing stiffness and strong sintering power may not be properly exhibited, which may cause difficulties in firing, and when it exceeds the above range, the drying shrinkage and the firing shrinkage force increase to increase drying and firing. When cracking and deformation of clay plastering bricks may occur.

The kaolin is produced by decomposition of quartz rough rock, andesite, granite, etc. by hydrothermal or weathering, silica component 40 to 45% by weight, alumina component 35 to 40% by weight, iron oxide 1 to 3% by weight , Other calcium, magnesium, sodium oxide is contained in a small amount. The kaolin can be used in combination with clay to increase the strength by increasing the bonding strength of the clay plastering bricks, and by utilizing low-grade kaolin that is less utilized, it can increase the utilization of waste resources, but it is advanced and intermediate so that it does not fall in light weight and durability. , It can be used by properly optimizing low-grade kaolin.

According to one aspect of the present invention, the content of the kaolin is included in 5 to 10% by weight relative to 100% by weight of the composition for preparing clay plaster brick. When the content of the kaolin is less than the above range, the compressive strength of the plastered clay brick may be reduced, and when it exceeds the above range, the light weight of the clay plastered brick may be reduced.

The clay is a white clay composed mainly of kaolinite and halosite, the silica component of the clay serves as a skeleton of the clay plaster brick, and the alumina component gives fire resistance to widen the plastic range, as well as chemical action , Excellent resistance to abrasion and thermal shock.

According to one aspect of the present invention, the content of the clay may be included in 15 to 25% by weight, more preferably 17 to 23% by weight, based on 100% by weight of the composition for preparing clay plaster brick. When the content of the clay is less than the above range, resistance to the external environment may be deteriorated, and when it exceeds the above range, plasticity falls and drying strength decreases during drying, and plasticity strength decreases during sintering to decrease compressive strength. Can be.

As described above, the clay plastering brick of the present invention includes a flooring material, clay, kaolin and white clay, and by controlling the content of clay and kaolin as described above, it is fired at 1040°C lower than the conventional firing temperature (1150°C or higher). Despite this, it is possible to achieve sufficient compressive strength. By lowering the firing temperature in this way, it is possible to save more than 40% of the fuel required to operate the firing kiln, which has a much advantageous economical advantage. In addition, there is an eco-friendly advantage by actively utilizing the flooring material classified as waste materials.

A clay plastering brick according to an aspect of the present invention includes a plurality of rectangles as grooves in a clay plastering brick, as described above, within a space between each groove in an arrangement of rows of the grooves, and within an arrangement of other adjacent rows. By not overlapping the space between the grooves of each other on the basis of heat, there is an advantage of excellent sound insulation, heat insulation and tackiness due to the formation of an air layer in the groove, and there is an advantage of manufacturing a lightweight clay plastering brick.

More specifically, referring to FIGS. 1 to 3, the clay plastering brick may have a rectangular groove shape in the clay plastering brick, based on the upper surface 110. In addition, with respect to the arrangement of the grooves, if the arrangement in the direction of the long axis of the upper surface 110 of the clay plastered brick is called an'row' arrangement, and the arrangement in the direction of a short axis is called an'column', It is characterized in that the spaces 200 between the grooves in the arrangement of the rows of the grooves and the spaces 210 between the grooves in the arrangement of other adjacent rows do not overlap each other based on the columns. When the groove in the clay plastering brick exhibits the characteristic arrangement as described above, when the clay plastering brick is stacked as shown in FIG. 3, a plurality of air layers are formed due to the grooves in the clay plastering brick, and the plurality of air layers and Since a plurality of brick layers are alternately present, sound and heat transfer are suppressed, and thus sound insulation and heat insulation are effective. At this time, the stacking of the clay plastering brick means bonding the upper surface 110 of the clay plastering brick to the lower surface 140 of another clay plastering brick, and the side portion 120 of the clay plastering brick stacked as shown in FIG. ) May be stacked by coincidence, or the side surfaces 120 of the clay plastered brick may be shifted.

Based on the top surface 110 of the clay plastering brick, the spacing 300 between each recess and the outermost shell of the clay plastering brick may be 15 to 20 mm. If the gap 300 is less than the above range, the clay plastering brick may not be able to withstand the impact from the outside, and if it exceeds the range, there is insufficient space in which the grooves in the clay plastering brick are arranged, from the presence of the groove. The expected sound insulation and insulation effects can be reduced.

According to an embodiment of the present invention, the total cross-sectional area of the groove in the clay plastering brick, based on the top surface 110 of the clay plastering brick, is 20 to 20% with respect to 100% of the entire top surface 110 of the clay plastering brick. It can be 40%. If the total cross-sectional area of the groove is less than the above range, the weight of the clay plastering brick is increased, so it is difficult to expect the effect of weight reduction, and if it exceeds the above range, the durability of the clay plastering brick is insufficient, so it cannot withstand impact from the outside and can be destroyed. have.

In addition, according to one embodiment of the present invention, the groove in the clay plastering brick includes both end portions in the direction of the top surface 110 and the bottom surface 140 of the clay plastering brick, the groove in the clay plastering brick of the present invention Silver may be that both ends are open. When both ends are open, a part of the mortar 150 penetrates into the groove when the mortar 150 is applied to the upper surface 110 of the clay plaster brick for adhesion between the clay plaster bricks. There is an effect that can be made more solid. At this time, based on the top surface 110 of the clay plastering brick, the cross-sectional area of each groove may be less than 500 mm ^2, when the cross-sectional area of each groove exceeds 500 mm ² , the mortar 150 penetrates into the groove. The effect of sound insulation and heat insulation that can be expected from the air layer formed due to the grooves may decrease due to an increase in the amount.

Method for producing a clay plastering brick according to another aspect of the present invention a) 40 to 50% by weight of the flooring material containing unburned carbon, 30 to 35% by weight of clay, 5 to 10% by weight of kaolin and 15 to 25% by weight of clay Crushing to prepare a mixture; b) putting the mixture into a molding machine, followed by drying in a drying cart; And c) separating the dried mixture from the drying cart and firing in a kiln at a temperature of 1040°C.

According to one embodiment of the present invention, in the step a), flooring, clay, kaolin and white clay containing unburned carbon may be pulverized to a particle size of 5 µm to 1 mm, respectively. If the particle size is less than the above range, the problem of increasing the required cost by increasing the content of each material may occur, and when it exceeds the above range, compressive strength may be lowered.

In addition, according to an embodiment of the present invention, the mixture produced in step a) may further include 15 to 25 parts by weight of water based on 100 parts by weight of the entire mixture. If the content of water to be added is less than the above range, the mixture may not be properly formed due to insufficient cohesiveness of the mixture, and if it exceeds the above range, the efficiency may decrease due to an increase in drying time in the step of drying in a drying cart after entering the molding machine Can.

The step b) is a step in which the mixture in which the water formed in step a) is added is introduced into a molding machine for preparing clay plaster brick of the present invention and dried in a drying cart.

Step c) is a step of separating the mixture for preparing the dried clay plaster brick from the drying cart and firing it with the heat of the kiln. It is more efficient for mass production that the kiln is a tunnel type kiln. The temperature of the kiln is characterized in that it is 1040 ℃, which is the flooring contained in the composition for clay plastering brick contains unburned carbon, the unburned carbon receives heat from the tunnel kiln to generate heat, and due to the heat, clay This is possible because the temperature of the plastered brick can rise rapidly and accelerate the firing process of the plastered brick. That is, it is possible to lower the temperature of the kiln (1150°C or higher) required during the firing process of the conventional clay plastering brick to 1040°C, which is the temperature of the kiln of the present invention, due to the heating of the unburned carbon, thereby controlling the kiln operation. Energy can be saved, and the cost required for the operation of the kiln is reduced by 40% or more than the conventional one.

As described above, the clay plaster brick of the present invention includes a bottom ash (bottom ash), clay, kaolin and white clay containing unburned carbon, and based on 100% by weight of the total composition for preparing clay plaster brick, the floor ash is 40 to 50% by weight, the clay is included in 30 to 35% by weight, the kaolin is included in 5 to 10% by weight, the clay is characterized in that it is included in 15 to 25% by weight, brick Despite lowering the firing temperature from the conventional 1150°C to 1040°C during manufacturing, sufficient compressive strength can be obtained, thereby reducing the energy required to operate the firing kiln, thereby reducing manufacturing costs.

In addition, the clay plastering brick of the present invention includes a plurality of rectangles as grooves in the clay plastering brick, and the space between each groove in the arrangement of rows of the grooves and each groove in the arrangement of other adjacent rows is By taking a structure that does not overlap each other on the basis of heat, there is an advantage of excellent sound insulation, heat insulation and adhesion.

Hereinafter, preferred examples are provided to help understanding of the present invention, but the following examples are merely illustrative of the present invention, and it is apparent to those skilled in the art that various changes and modifications are possible within the scope and technical thought scope of the present invention. It is also natural that such modifications and modifications fall within the scope of the appended claims. In the following examples and comparative examples, "%" and "part" indicating the content are on a weight basis unless otherwise specified.

Example And Comparative example : Manufacturing of bricks

Example 1 to 4

The flooring, clay, kaolin and white clay are crushed into particles of 1 mm each to make a crushed product, and the mixture ratio is made as shown in Table 1 below. After kneading by adding 20 parts by weight of water with respect to 100 parts by weight of the mixture, and then forming a shape by an injection method, it is dried for 72 hours on a drying cart. A brick having a characteristic structure of the present invention (refer to FIGS. 1 and 2) was prepared by arranging grooves in a clay brick through a firing process of baking the dried mixture with a tunnel kiln at 1040°C.

Comparative example 1 to 6

Bricks were manufactured in the same configuration and method as those of Examples 1 to 4, except that the composition and combination ratio of each of the ground, clay, kaolin to white clay were as shown in Table 1 below.

Comparative example 7 to 8

The composition and combination ratio of each crushed material of flooring, clay, kaolin to white clay are as shown in Table 1 below, and the above Examples 1 to 1, except that the shape of the clay plastering brick follows the conventional one including three circular grooves. Bricks were manufactured in the same configuration and method as in the manufacturing method of 4.

(weight%) Example 1 Example 2 Example 3 Example 4 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 Comparative Example 5 Comparative Example 6 Comparative Example 7 Comparative Example 8 Flooring 42 50 45 40 50 45 50 40 40 40 42 50 clay 32 30 30 35 - 30 20 37 32 33 32 30 china clay 6 5 10 10 15 - 10 5 3 12 6 5 White clay 20 15 15 15 35 25 20 18 25 15 20 15 Firing temperature (℃) 1040 1040 1040 1040 1040 1040 1040 1040 1040 1040 1040 1040

Experimental Example 1. Compressive strength experiment

To confirm the compressive strength properties of the clay plastered bricks prepared in Examples 1 to 4 and Comparative Examples 1 to 6, uniaxial compressive strength was measured based on KS F 4004 standards, and the results are shown in Table 2 below. .

Experimental Example 2. Crack generation experiment

The clay plastered bricks prepared in Examples 1 to 4 and Comparative Examples 1 to 6 were left at room temperature for 12 hours to check whether cracks occurred or not, and the results are shown in Table 2 below.

<Have cracks occurred?>

○: cracks are clearly visible to the naked eye.

×: no cracking was observed with the naked eye

Example 1 Example 2 Example 3 Example 4 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 Comparative Example 5 Comparative Example 6 Compressive strength (N/mm ² ) 32.6 34.3 35.5 31 20.2 22.5 25.3 23 26.4 28.6 Cracking × × × × × × × ○ × ×

Referring to Table 2, in the case of clay plastered bricks of Examples 1 to 4, which satisfies both the composition and content of the present invention, 1040° C. than the cases of Comparative Examples 1 to 6, which do not fully satisfy the composition and content of the present invention. It was confirmed that the compressive strength at firing is better. In addition, in the case of the clay plastering brick of Comparative Example 4 exceeding the content range of the clay suggested in the present invention, it was confirmed that cracks occurred in the finished brick.

Experimental Example 3. Thermal conductivity experiment

In order to confirm the thermal insulation effect by the characteristic structure of the grooves in the clay plastered brick of the present invention, each component and content were made to be the same, but the structures of the grooves included in the bricks were different from Examples 1 to 2 and comparison Thermal conductivity experiments for Examples 7 to 8 were performed. In the thermal conductivity experiment, the thermal conductivity was measured according to the test method of KS L 3121, and the results are shown in Table 3 below.

Example 1 Example 2 Comparative Example 7 Comparative Example 8 Thermal conductivity (W/mK) 0.1270 0.1642 0.3524 0.2754

Referring to Table 3, in the case of clay plastering bricks comprising the structure of the characteristic grooves according to the present invention (Examples 1 to 2), of the clay plastering bricks including the conventional structure including three circular grooves It was confirmed that the thermal insulation effect was superior to the case (Comparative Examples 7 to 8).

Experimental Example 4. Soundproofing experiment

In order to confirm the soundproofing effect due to the characteristic structure of the grooves in the clay plastered brick of the present invention, each component and content were made to be the same, but the structures of the grooves included in the bricks were different from Examples 1 to 2 and comparison Sound insulation experiments were performed for Examples 7 to 8.

Using the clay plastering bricks prepared in Examples 1 to 2 and Comparative Examples 7 to 8, a temporary wall having a length of 3 m and a length of 4 m was produced, and a noise generating device (ST-NG1) was placed at a point about 2 m away from one side of the wall. , Radio Design Labs). A noise meter (product name 407730, EXTECH) was installed at a distance of 1 m from the noise generating device to the other side of the wall and 2 m to the other side of the wall, and the noise level was measured and compared by frequency of the sound source. Table 4.

In Table 4, the mean of the noise difference means an average value of the difference between the measured value of the noise meter at a distance of 1 m from the wall and the measured value of the noise meter at a distance of 2 m in the opposite direction from the wall.

Hz Example 1 Example 2 Comparative Example 7 Comparative Example 8 1m (dB) 2m (dB) 1m (dB) 2m (dB) 1m (dB) 2m (dB) 1m (dB) 2m (dB) 20 54.2 42.1 53.8 41.5 53.6 45.3 52.8 47.2 100 71.3 60.2 70.2 61.5 69.8 64.9 70.5 64.6 200 73.3 59.4 71.8 60.2 70.1 64.9 72.5 68.9 400 70.3 55.3 68.2 53.8 69.9 58.2 70.2 59 500 72.7 57.8 70.0 55.2 71.7 62.2 71.8 63.8 800 71.9 53.2 68.8 50.1 70.2 60.6 69.5 62.6 1k 74.3 50.1 73.8 52.2 72.8 56.7 72.5 55.4 4k 82.7 57.2 80.5 55.6 81.5 68.1 80.5 70.2 10k 37 29.7 42 30.2 40 30.7 38.5 31.7 16k 31.4 26.4 30.2 27.5 30.2 28.1 30 29.1 Noise difference average 14.77 14.15
9.01 7.63

Referring to Table 4 above, in the case of clay plastering bricks comprising the structure of the characteristic grooves according to the present invention (Examples 1 to 2), of the clay plastering bricks including the conventional structure including three circular grooves It was confirmed that the soundproofing effect was superior to the case (Comparative Examples 7 to 8).

Claims (5)

In a clay plastering brick comprising a bottom ash (bottom ash), clay, kaolin and white clay containing unburned carbon,
With respect to 100% by weight of the composition for preparing clay plastering brick, the flooring material is included in 40 to 50% by weight, the clay is included in 30 to 35% by weight, and the kaolin is included in 5 to 10% by weight, and the clay Is contained in 15 to 25% by weight,
The firing temperature of the clay plastering brick is 1040 ℃,
The clay plastering brick includes a plurality of rectangles as grooves in the clay plastering brick, and the space between each groove in the arrangement of rows of the grooves and each groove in the arrangement of other adjacent rows is based on a column. Clay plastering brick characterized by not overlapping each other. According to claim 1,
Based on the upper surface of the plastered brick, the total cross-sectional area of the groove is 20 to 40% with respect to 100% of the total area of the upper surface of the plastered brick, and both ends of the groove are opened. Clay plastering brick. a) 40 to 50% by weight of the flooring material containing unburned carbon, 30 to 35% by weight of clay, 5 to 10% by weight of kaolin, and 15 to 25% by weight of white clay to prepare a mixture;
b) putting the mixture in a molding machine and drying it in a drying cart; And
c) separating the dried mixture from the drying cart and firing in a kiln at a temperature of 1040° C., the method of manufacturing the clay plastered brick of claim 1. According to claim 3,
Method of manufacturing a clay plastering brick, characterized in that the particle size of the pulverized product produced in step a) is 5 μm to 1 mm. According to claim 3,
The mixture of step a) is 15 to 25 parts by weight of water with respect to 100 parts by weight of the total mixture, characterized in that the clay plastering method.

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