JP2001048534A - Production of gypsum fiber - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing gypsum fibers, which is suitable for producing in an industrial scale the gypsum fibers which are useful as a material for reinforcing rubbers, plastics, coatings, and so on, a paper material, and an heat-insulating material. SOLUTION: This method for producing gypsum fibers comprises reacting a calcium salt with a salt having a sulfate radical in an aqueous solution. Therein, the reaction system is maintained at atmospheric pressure and at a temperature of >=80 deg.C. The calcium salt is reacted with the salt having the sulfate radical in the reaction system containing one or more kinds of materials selected from a water-repelling liquid and a treating agent which can treat an inorganic substance to give water repellency to the surface.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing gypsum fiber, and the gypsum fiber obtained by the method of the present invention is useful as a reinforcing material such as rubber, plastic, paint, a paper material, a heat insulating material and the like. Things.

[0002]

BACKGROUND OF THE INVENTION Gypsum, gypsum (CaSO ₄ · 2H
₂ O), and it is known that three types of hemihydrate gypsum _{(CaSO 4 · 1 / 2H 2} O) and anhydrite (CaSO ₄₎ is present, an attempt to control the shape of the gypsum is primarily gypsum And has been done in hemihydrate gypsum.

In gypsum, it has been reported that a plate-like gypsum useful as a ceramic material can be obtained by the presence of an organic acid in an aqueous solution when growing crystals [Asahi Glass Research Report, 3 [ 1], 44-57 (195
3)].

With respect to hemihydrate gypsum, attempts have been made to make it into a fibrous form. According to JP-A-49-30626, an aqueous mixture of gypsum dihydrate, gypsum hemihydrate or anhydrous gypsum is placed in a pressure vessel. Gypsum fibers are synthesized by heating at a temperature of 105 to 150 ° C. This fiber has been marketed under the name "Franklin Fiber" [Menou.
gh. J. , Rubber World, 192, 1,
14-15 (1985)]. However, the aforementioned gypsum fiber is synthesized under pressurized conditions, involves a great deal of cost in its production equipment, and is inferior in productivity because the production process has to be carried out in a batch process. It was not suitable for production.

[0005] On the other hand, attempts have been made to convert hemihydrate gypsum into fibers under normal pressure.
9, 1556 to 1564 (1988)], a method for producing fibrous hemihydrate gypsum by adding methanol to a saturated aqueous solution of gypsum to form an organogel and removing the methanol from the organogel. ing. [Gypsum and lime, No. 239, 230-238 (199
2)], an attempt was made to synthesize a large hemihydrate gypsum whisker by adjusting the degree of supersaturation of gypsum produced by the reaction of a calcium chloride-sulfuric acid aqueous solution by further adding hydrochloric acid or nitric acid to this system. Have been.

Further, [Asahi Glass Research Report [4] 50-66
(1954)], in an experiment in which an aqueous solution of calcium chloride (including sodium chloride) and an aqueous solution of sodium sulfate were allowed to react in approximately equivalent amounts with a siphon, a length of 80 to 10 was used.
A hemihydrate gypsum of 0 μm and a width of 5 μm was obtained. [Journal of the Ceramic Society of Japan, 98 [5] 483-489.
(1990)] reports that a needle crystal having a length of 140 μm and a diameter of 4 μm is synthesized by reacting calcium chloride with an aqueous solution of sodium sulfate.

[0007]

However, according to the method of adding an organic solvent such as methanol to a saturated solution of gypsum, the waste liquid containing the organic solvent is generated, which is not suitable for mass production. However, the method of adding an acid such as hydrochloric acid or nitric acid to the method is difficult to control because the acid concentration of the slurry changes every moment during the reaction, and the yield is poor.

Further, hemihydrate gypsum fibers obtained by reacting only an aqueous solution of calcium chloride and sodium sulfate have a large width or diameter of 4 to 5 μm, and as a result, have a small aspect ratio and are effectively used as needle crystals. It is difficult. That is, as the fibrous substance becomes thicker, the crystals become more non-uniform and the theoretical strength lowers. Therefore, when used as a reinforcing material, the diameter of the fibrous substance is desirably 3 μm or less, preferably 2 μm or less, more preferably 1 μm or less. If the diameter is the same, it is better that the aspect ratio (length / thickness) is large, and the reinforcing material should secure at least 20 or more, preferably 40 or more, and more preferably 80 or more. .

In view of such circumstances, an object of the present invention is to provide a novel method for producing gypsum fiber which can be easily carried out on an industrial scale.

[0010]

Means for Solving the Problems In view of such circumstances, the present inventors have conducted intensive studies and studies and found that a calcium salt and a salt having a sulfate group were reacted in an aqueous solution to produce gypsum fibers. At the same time, the reaction system is maintained at a normal pressure and at a temperature of 80 ° C. or higher, and a water-repellent liquid or one or more treatment agents capable of rendering the surface water-repellent by treating the surface with an inorganic substance are contained in the reaction system. A novel method for synthesizing gypsum fibers characterized by causing a calcium salt to react with a salt having a sulfate group in the presence thereof has led to the completion of the present invention.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION As a calcium salt used in the practice of the present invention, calcium chloride having high solubility in water is suitable. As a salt having a sulfate group, any salt having a certain degree of solubility can be used without any problem, and sulfate salts of sodium, potassium, aluminum, cobalt, cesium, magnesium, manganese, ammonia, zinc, and the like can be mentioned. From the viewpoint of raw material costs, sodium, potassium, magnesium and ammonium sulfate salts are suitable. The water-repellent liquid is not particularly limited as long as it is a liquid at a temperature of 80 ° C. or higher in the reaction system. Examples thereof include silicone oil, kerosene, fatty acids, and paraffin, and the inorganic substance may be treated. Treatment agents capable of rendering the surface water-repellent include metal salts of fatty acids, various surface treatment agents (for example, silane-based, titanate-based, aluminate-based, etc.) having a hydrophobic group, and various surfactants And the like. The reaction system should be at normal pressure and the reaction temperature should be kept above 80 ° C. If the reaction temperature is lower than 80 ° C., the main component is gypsum dihydrate. In order to minimize the mixing of dihydrate gypsum, it is preferably at least 95 ° C., particularly preferably under boiling conditions (the boiling temperature varies depending on the amount of dissolved ions, but usually 100 ° C.).
C or higher) is suitable.

In reacting a calcium salt with a salt having a sulfate group, either a calcium salt or a salt having a sulfate group is previously introduced into the reaction system, and the salt having a sulfate group or the calcium salt is added thereto. In addition to the method of contacting the other salt containing gypsum, a calcium salt and a salt having a sulfate group are continuously introduced into a reaction system containing a reaction mother liquor, and a part of the reaction solution is continuously taken out to form a gypsum crystal. Is also possible.

In practicing the present invention, a method of dropping an aqueous solution containing a sulfate group into an aqueous solution containing a calcium salt or dropping an aqueous solution of a calcium salt into an aqueous solution containing a salt having a sulfate group is suitable. The concentration of calcium or sulfate on the dropped side is not particularly limited, but should preferably be 0.1 mol / l or more, more preferably 0.5 mol / l or more. This is because, when the concentration of calcium or sulfate is high, fine crystal nuclei of gypsum are precipitated, whereby fine needle-like crystals can be grown. The concentration of the aqueous solution containing the other salt that reacts with the aqueous processing solution containing one salt is not particularly limited, and may be added to the aqueous processing solution as a powder.

The slurry concentration of the gypsum produced by the reaction is 6.0% of the total so as to secure a space for growing gypsum needle-like crystals and grow fine crystals under normal atmospheric pressure without applying pressure. It should be less than 5.0% of the total to produce high aspect ratio fibers.

Under these conditions, a calcium salt or a sulfuric acid is required to allow the reaction system to contain at least one of a water-repellent liquid and a treating agent capable of rendering the surface water-repellent by treating the substance with an inorganic substance. To any of the salts with roots,
One or more water repellents selected from the above water repellents may be added. The concentration of the water-repellent agent should be in the range of 50 ppm to 30%, preferably 300 ppm to 10% of the gypsum finally formed. If it is less than 50 ppm, the effect of growing crystals cannot be exhibited, and if it exceeds 30%, the viscosity of the reaction system increases, and particles other than fibrous particles are partially generated.

Further, the above-mentioned water-repellent agent and a) a compound which produces at least one ion of copper, magnesium, iron, ammonia, nickel and manganese; or b) polyvinyl alcohol, glucose, glycerin, tannic acid, Any one or more of diethylene glycols can be used in combination. For the concentration of the ion-generating compound, the weight of the nuclide of the ion ranges from 50 ppm to 30%, preferably 300 ppm, of the final gypsum.
It needs to be in the range of 10 ppm to 10%. 50p
If it is less than pm, the crystal growth effect cannot be exhibited,
If it exceeds 30%, the diameter of the gypsum fiber tends to be rather large. The concentration of the organic substance is in the range of 50 ppm to 30% by weight of the gypsum produced, preferably 300 ppm.
It needs to be in the range of 10 ppm to 10%. 50p
If it is less than pm, the crystal growth effect cannot be exhibited,
If it exceeds 30%, the viscosity of the reaction system increases, and particles other than fibrous particles are partially generated.

In carrying out the method of the present invention, the reaction time of the aqueous solution containing a calcium salt and the aqueous solution containing a sulfate group is not particularly limited, but it is more preferable that the reaction time be 3 minutes or more. If the dripping time is too long, the shape does not deteriorate, so it is meaningless to spend more than 200 minutes for industrial production.

The gypsum fiber obtained according to the present invention has a diameter of 0.05 to 3 μm and a length of 10 to 100 depending on the processing conditions.
The shape can be controlled to be uniform between 0 μm. The main component of the fiber thus obtained is hemihydrate gypsum, and dihydrate gypsum may be mixed depending on the processing conditions, but it is acceptable as long as the form of the gypsum fiber is not impaired.

These fibers can be recovered by solid-liquid separation of the slurry. If the reaction product is dried as it is, the gypsum hemihydrate may be changed to gypsum depending on the conditions, so that it can be treated with a substance exhibiting cation-anion aggregation to impart water resistance. Such a treatment is not particularly limited, such as a method of charging the slurry after the reaction, a method of treating the cake after the solid-liquid separation, and a method of treating the once dried fiber. Examples of the substance exhibiting cation-anion aggregation include ionic starch, ionic aggregating agent, protein hydrolyzate (eg, casein, gelatin), and anionic polycarboxylic acid polymer (eg, sodium polyacrylate, ammonium styrene maleate monoester copolymer ammonium salt). Aqueous solution).

Further, the obtained hemihydrate gypsum fiber is 400 to 8
It can be heated at a temperature of 00 ° C. to be used as an anhydrous gypsum fiber.

[0021]

The calcium compound fibrillation is described in [Gypsum and Lime, 1990, No. 229,446-457
(1990)]. According to this content,
When the saturation solubility C _S of the gypsum at a certain _temperature, new nuclei is not generated nuclei is the upper limit of the supersaturation region to grow the C _0, new nuclei are generated in the solubility is higher than the C ₀ state,
Nuclei grow between C ₀ and C _S. When the reaction is carried out in equivalent amounts or at once, the solubility greatly exceeds C ₀ ,
It is clear that the reaction proceeds rapidly and the crystal becomes large, that is, the diameter becomes large. From such a viewpoint, in the synthesis of [Asahi Glass Research Report, [4] 50 to 66 (1954)], an aqueous solution of calcium chloride (including sodium chloride) is used.
And an aqueous sodium sulfate solution, the length is 8
The reason why only a thick hemihydrate gypsum of 0 to 100 μm and a width of 5 μm was made was due to the fact that the reaction was carried out in siphons in approximately equivalent amounts.
98 [5] 483-489 (1990)], when calcium chloride was reacted with an aqueous solution of sodium sulfate, a thick needle-like crystal having a length of 140 μm and a diameter of 4 μm was formed in a short time. It is thought that it was caused by

[0022] In contrast, in the method of one of gradually contact the other from excessive conditions, up solubility of gypsum is gradually nuclei are generated in beyond the C _0, it drops to C _0. Subsequently, the solubility is maintained between C ₀ and C _{S in} a balance between the amount of continuously supplied ions and the amount of growing nuclei. Since the nucleus grows gradually over time as described above, an environment in which the crystal habit is more likely to grow and the crystal habit is more likely to be realized, resulting in a thin fibrous shape. As for the mechanism when there is a water-repellent treatment agent, these substances are adsorbed on a specific crystal plane at the stage where crystal nuclei are formed, compared to the case without them, because it is in the radial direction of the fiber. It is considered that the fibers are elongated in the length direction.

As for the mechanism in the case where specific ions are present, it is conceivable that the formation of calcium sulfate at a time is controlled as compared with the case where those ions are not present. That is, when a specific ion is present in the reaction system, it plays a role of retaining the sulfate group to some extent, and it is presumed that even if the reaction is performed rapidly, the nucleus grows slowly as a result. In addition, when specific organic substances are present in the reaction system, the action is similar to that of the mechanism for water-repellent substances. It is considered that the fibers extend in the length direction because of the radial direction. Further, when two or more of these methods are used in combination, it is determined that the combined effect is exhibited.

[0024]

[Example 1] Seven kinds of calcium chloride aqueous solutions having different molar concentrations of calcium (A.4 mol / l,
B. 2 mol / l, C.I. 1 mol / l, D.I. 0.6mo
l / l, E.I. 0.4 mol / l, F.I. 0.2mol /
1, G. 0.1 mol / l), while four kinds of aqueous sodium sulfate solutions (a.2) having different molar concentrations of sulfate groups.
mol / l, b. 1 mol / l, c. 0.5mol /
l, d. 0.25 mol / l), put the aqueous calcium chloride solution in each flask, boil it under normal pressure and maintain it in a boiling state, and add a chemical equivalent of sulfuric acid to the calcium chloride aqueous solution to form gypsum, respectively. An aqueous sodium solution was added dropwise within 5 seconds. As for the amount of the additive, an amount corresponding to 1% of the weight of the gypsum produced by the weight of the water-repellent agent was added to the aqueous solution of calcium chloride or the aqueous solution of sodium sulfate before the reaction. After completion of the dropping, the mixture was left for 5 minutes, the solid-liquid was separated, the reaction product was dried at 80 ° C., and the obtained sample was analyzed by an X-ray diffraction method. The relation between the additive and the shape of the gypsum fiber was as shown in Table 1.

[0025]

[Table 1]

[Comparative Example 1] In the same manner as in Example 1, except that the additives shown in Table 2 (including no additives) were added, the same treatment as in Example 1 was performed, and an evaluation test of the reaction product was performed. The results of these tests were as shown in Table 2.

[0027]

[Table 2]

From the test results in Tables 1 and 2, it was found that when a sulfate group was brought into contact with an aqueous solution containing calcium, a water-repellent liquid,
Alternatively, when a treating agent capable of rendering the surface water-repellent by treating with an inorganic substance is present, it is recognized that the fiber shape of the gypsum is clearly improved as compared with the case where these water-repellent treating agents are not present.

[Example 2] The molar concentration of the sulfate group differs 4
Sodium sulfate aqueous solution (a. 2 mol / l, b.
1 mol / l, c. 0.5 mol / l, d. 0.25m
ol / l) and four kinds of calcium chloride aqueous solutions having different molar concentrations of calcium (A.4 mol / l, B.2 mol)
/ L, C.I. 1 mol / l, D.I. 0.6 mol / l), and the sodium sulfate aqueous solution was put into respective flasks and boiled to maintain a boiling state. Then, a chemically equivalent aqueous solution of calcium chloride which produces gypsum with respect to the sodium sulfate aqueous solution was added. It was dropped within 5 seconds. The amount of the additive is 1% of the weight of the gypsum generated by the weight of the water-repellent agent.
Was added to an aqueous solution of sodium sulfate or an aqueous solution of calcium chloride before the reaction. After dropping, 5
The reaction product was dried at 80 ° C. for 20 minutes to separate the solid and liquid, and the obtained sample was analyzed by X-ray diffraction. As a result, all of the samples were recognized as gypsum fibers composed of hemihydrate gypsum. The relationship between the gypsum fiber and the shape of the gypsum fiber was as shown in Table 3.

[0030]

[Table 3]

[Comparative Example 2] The same treatment as in Example 2 was carried out except that the additives (including no additives) shown in Table 4 were added, and an evaluation test of the reaction product was performed. The results of these tests were as shown in Table 4.

[0032]

[Table 4]

From the test results in Tables 3 and 4, it can be seen that when calcium is brought into contact with an aqueous solution containing a sulfate group, a treatment agent capable of rendering the surface water-repellent by treating it with a water-repellent liquid or an inorganic substance exists. The fiber shape of the gypsum is clearly improved as compared with the case where these water repellents are not present.

[Example 3] The molar concentration of calcium was 1 m
ol / l of a calcium chloride aqueous solution and, on the other hand, a sodium sulfate aqueous solution having a sulfate salt molarity of 0.5 mol / l, and the calcium chloride aqueous solution was kept in a boiling state. After the addition of the above silicone oil, a chemically equivalent aqueous sodium sulfate solution for forming gypsum was dropped into the calcium chloride aqueous solution within 5 seconds. After the completion of the dropwise addition, the mixture was allowed to stand for 5 minutes, then the solid-liquid was separated, and the reaction product was dried at 80 ° C. The obtained sample is
As a result of analysis by the X-ray diffraction method, all were found to be gypsum fibers made of hemihydrate gypsum, and the relationship between the amount added and the shape of the gypsum fibers was as shown in Table 5.

[0035]

[Table 5]

From these test results, it was recognized that good gypsum fibers could be obtained when the concentration of silicone oil was in the range of 50 ppm to 30%.

[Example 4] The molar concentration of the sulfate group was 0.5 m
ol / l of an aqueous solution of sodium sulfate and an aqueous solution of calcium chloride having a molar concentration of calcium of 1 mol / l were prepared. The aqueous solution of sodium sulfate was kept in a boiling state, and a predetermined amount of kerosene was added thereto. An aqueous solution of calcium chloride having a chemical equivalent of gypsum to the aqueous sodium sulfate solution was added dropwise within 5 seconds. After dropping,
After standing for 5 minutes, the solid and liquid were separated, and the reaction product was heated to 80 ° C.
And dried. The obtained samples were analyzed by the X-ray diffraction method. As a result, all of the samples were found to be gypsum fibers made of hemihydrate gypsum, and the relationship between the amount added and the shape of the gypsum fibers was as shown in Table 6.

[0038]

[Table 6]

From these test results, it was recognized that good gypsum fibers could be obtained when the concentration of kerosene was in the range of 50 ppm to 30%.

[Reference Example 1] In Example 3, the dropping time was as shown in Table 7 without adding silicone oil. After the dropping was completed, the mixture was allowed to stand for 5 minutes, then separated into solid and liquid, and dried at 80 ° C. The test results were as shown in Table 7.

[0041]

[Table 7]

From these test results, it was recognized that good gypsum fibers were obtained when the dripping time was 1 minute or more.

Reference Example 2 A test was performed in the same manner as in Example 3 except that the silicon oil was changed to ammonium chloride. The relationship between the amount of addition and the shape of the gypsum fiber was as shown in Table 8.

[0044]

[Table 8]

Reference Example 3 A test was conducted in the same manner as in Example 4 except that kerosene was changed to diethylene glycol. The relationship between the amount of addition and the shape of the gypsum fiber is
As shown in Table 9.

[0046]

[Table 9]

According to Tables 8 and 9, these substances are 50p
The effect is shown in the range of pm to 30%.

Example 5 The same test was performed as in Example 3 except that the additives and the dropping time were as shown in Table 10, and the test results were as shown in Table 10.

[0049]

[Table 10]

From the test results shown in Table 10, when these methods are carried out in a system containing a compound or an organic substance that generates a specific ion in addition to the water-repellent agent, an effect of further improving the fiber shape of the gypsum is recognized.

Example 6 Calcium molar concentration was 1 m
ol / l aqueous calcium chloride solution was placed in each flask and maintained at 70, 80, and 95 ° C. at a boiling state, and 1% paraffin was added based on the weight of the formed gypsum. Was heated to the same temperature as the aqueous calcium chloride solution in each flask, and a chemical equivalent of gypsum was dropped within 5 seconds, with 0.5 mol / l of potassium sulfate, magnesium sulfate, and ammonium sulfate being added.
Thereafter, the mixture was allowed to stand for 5 minutes to be subjected to solid-liquid separation, and the reaction product was dried at a temperature of 80 ° C. to obtain an intended product. The gypsum thus obtained was analyzed by X-ray diffraction, and its composition (the value obtained by dividing the maximum peak of hemihydrate gypsum by the maximum peak of dihydrate gypsum in the X-ray diffraction method) was determined. The result of examining the relationship of the obtained gypsum was as shown in Table 11.

[0052]

[Table 11]

From the test results in Table 11, it is confirmed that fibrous hemihydrate can be synthesized when the reaction temperature is 80 ° C. or higher in the presence of paraffin.

[Comparative Example 3] The molar concentration of calcium was 1 m
ol / l calcium chloride aqueous solution and a sodium sulfate aqueous solution having a sulfate group molar concentration of 0.5 mol / l are prepared, boiled separately, and synchronized at a chemical equivalent ratio of gypsum for 5 minutes. The two are brought into contact with each other
The reaction product was separated into solid and liquid and dried at a temperature of 80 ° C. to obtain a target product. The gypsum thus obtained was confirmed to be hemihydrate gypsum by X-ray diffraction, and the shape was coarse particles having a thickness of 5 μm and a length of 60 μm.

Example 7 The gypsum fibers shown in Examples, Comparative Examples and Reference Examples were coated with an epoxy resin, and their adhesion was evaluated. The test results obtained in accordance with the following composition, curing conditions and evaluation criteria were as shown in Table 12. Composition: resin (Epicoat 828) 100 parts Curing agent (dicyandiamide) 7 parts Erosil (# 300) 1 part Gypsum fiber 10 parts Curing conditions: 190 ° C / 30 minutes Evaluation criteria: 90 ° C warm water for 2 hours, paint The evaluation was performed according to the method of JIS K5400. (The average value of three samples is rounded and the higher the value, the higher the adhesion and the better the performance as a fiber.) Sample 1: Gypsum fiber obtained in Comparative Example 3 Sample 2: Cc of Comparative Example 1 Gypsum fiber obtained with (aminosilane) Sample 3: Gypsum fiber obtained with Aa (decanoic acid) of Example 1 Sample 4: Gypsum fiber obtained with 0.005% of silicone oil of Example 3 5: Gypsum fiber obtained at a titration time of 1 minute of Reference Example 1 Sample 6: Gypsum fiber obtained at 0.1% of silicone oil of Example 3 Sample 7: Db (methacryloxysilane) of Example 1 Gypsum fiber obtained in Example 8: Gypsum fiber obtained in 0.3% of silicone oil of Example 3 Sample 9: Gypsum fiber obtained in Experiment No. 1 of Example 5 Sample 10: Experiment of Example 5 No.4 Gypsum fiber obtained had

[0056]

[Table 12]

From the test results in Table 12, it is recognized that the smaller the diameter of the gypsum fiber and the higher the aspect ratio, the better the performance as a fiber.

[0058]

According to the method of the present invention, a gypsum fiber having a preferable fiber diameter and an aspect ratio can be prepared by reacting a calcium salt and a salt containing a sulfate group at a normal atmospheric pressure. Since the productivity can be dramatically improved and the manufacturing equipment thereof can be dramatically simplified, the effect in the implementation on an industrial scale is enormous.

Claims (1)

[Claims] When a gypsum is formed by reacting a calcium salt and a salt having a sulfate group in an aqueous solution, the reaction system is maintained at normal pressure and at a temperature of 80 ° C. or higher, and a water-repellent solution is formed in the reaction system. A method for producing a gypsum fiber, characterized in that a calcium salt and a salt having a sulfate group are reacted in the presence of at least one kind of a treatment agent capable of rendering a surface water-repellent by treating it with a liquid or an inorganic substance. .