JP2001328859A - Indoor ceramic construction material having respirability - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a respirable indoor ceramic construction material obtained from a coal fly ash and a coal clinker ash which are industrial wastes of a coal-fired power plant and are reused resources. SOLUTION: This indoor ceramic construction material is produced by mixing 30-40% of the coal fly ash and 30-40% of the coal clinker ash exhausted from the coal-fired power plants, 10-20% of a waste glass of 10-20% of a water glass as a sintering binder, 10-30% of a clay powder as an additive and a starch or a flour for imparting moldability, sintering and coagulating, is capable of possessing interiority by adding a moderate inorganic pigment or spotting material and providing a design as necessary and has respirability having performances reducing sick house syndrome by being excellent in hygroscopicity and air permeability for adjusting an indoor humidity, adsorptivity of chemical substances, frost damage resistance and lightness and possessing hyperthermic effects by far-infrared radiation, etc., and the method for producing the material is also provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a ceramic product manufactured using coal ash fly ash or coal ash clinker ash, which is a large amount of industrial waste discharged from a coal-fired power plant, as a main raw material of a ceramic building material. , Housing,
Since it has breathing performance and breathability that absorbs and exhales moisture in the indoor space of the building, absorption performance of absorbing chemical substances, warming effect by far infrared rays, effect of shielding and reducing electromagnetic waves, etc. Conserve the environment healthy,
An object of the present invention is to provide an indoor ceramic building material having breathability, which has an effect of reducing sick house syndrome, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Coal ash generated from a coal-fired power plant is regulated by the "Law Concerning the Promotion of Utilization of Recycled Resources" as a business operator's duty to reduce, reduce, and recycle resources. I have. The domestic power company's coal-fired power generation capacity doubled from about 22 million kilowatts at the end of 1997 to about 44 million kilowatts at the end of 2007, and the coal ash emitted from each thermal power plant was about From 5.5 million tons to more than 10 million tons around 2000, and it has tended to increase further thereafter. Most of coal ash is used as cement raw material and as backfill material for outcrop mining sites. It is used as road and road material, but its use rate is only about 60% or more.
As one of the effective utilization methods of coal ash, a technology of using materials such as permeable road surface materials has been realized. However, its use as a permeable road surface material has attracted attention because it has a strong environmental investment meaning to suppress the heat island phenomenon, but its cost is higher than that of conventional asphalt pavement, and its use has not been widespread. At present, coal ash fly ash and coal ash clinker ash are used in large quantities mainly as road embankments by mixing cement materials, but their use has been delayed. High-fluidity concrete can be made using coal ash fly ash, and it can be cast into high-density bars that are difficult to cast with ordinary concrete, but its use is limited. From now on, coal ash fly ash is rarely used continuously and in large quantities as a recycled resource. Therefore, creation of technology for continuously and in large quantities using coal ash fly ash and coal ash clinker ash as renewable resources is desired under the Recycling Law.

In the living environment of modern people, there is a mismatch between the performance of a building structure for the purpose of energy saving and building materials used for a house or a building, causing sick house syndrome. In modern housing and building styles, chemical substances volatilized from building materials of houses and buildings, especially those that are polluted by contaminated air due to the transformation of the building structure to energy saving, high airtightness, and high insulation, especially Because of the continued use of chemicals in wall materials, insulation, and the like, people indoors have been exposed to air mixed with chemicals such as formaldehyde, VOCs, and environmental hormones from such building materials for a long time. The interior space of modern life includes chemical substances volatilized from building materials and furniture, as well as the accumulation of moisture in the room, causing frequent occurrence of mites and molds, house dust such as dead mites and mold spores, and exhaust from gas products. The air is polluted, which has caused sick house syndrome. In addition, electromagnetic waves from appliances also cause health damage. In addition, PVC products, which are often used for building materials,
There is a danger of dioxin being generated due to disposal and incineration at each reform, which threatens our future.

As a method of reducing the above-mentioned sick house syndrome, there is a demand for providing a new building material having an effect of complementing a drawback of a building structure, such as a building material compatible with modern houses and buildings, and a high airtightness. Furthermore, in order to widely use and spread the building materials, it is necessary to reduce the manufacturing price, and it is possible to adjust the color tone and design from the space design side, and it is a building material that is easy for people who do not use chemical substances, such as reforming. Therefore, there has been a demand for the development of ceramic building materials for indoor use made of natural materials that do not generate dioxin even if they are discarded or incinerated, and technology for manufacturing the same.

[0005]

The present invention employs the following means in order to solve such a problem. As a technique for recycling coal ash fly ash and coal ash clinker ash, many techniques for using ceramic paving materials as a main raw material are provided and known. Known ceramic paving materials have the property of water permeability. The present invention has been completed by developing known techniques for manufacturing a water-permeable ceramic pavement material. That is, it is expected that the main factor of sick house syndrome is to suppress the growth of mold and mites. Dioxin that can reduce sick house syndrome with absorption performance of absorbing chemical substances such as toluene, thermal effect by far infrared rays, and effect of shielding or reducing the effects of electromagnetic waves. It is intended to provide a ceramic material for indoor use in a house or a building having a breathability, which does not emit ash, and a manufacturing technique therefor.

The present invention relates to a technology for manufacturing a ceramic building material for indoor use having a function mainly using coal ash fly ash or coal ash clinker ash, and it is possible to improve the working environment in the production process and reduce the production unit price. The products obtained according to the invention are breathable due to the continuous pores. That is, the ceramic building material obtained by the present invention is lightweight, has resistance to cold damage, and has properties such as high moisture absorption performance and ventilation performance, chemical substance adsorption performance, far infrared heating effect, electromagnetic wave shielding / mitigating effect, and the like. An object of the present invention is to provide an indoor ceramic building material having breathability, which can reduce sick house syndrome, and a manufacturing technique therefor.

[0007]

Means for Solving the Problems The present inventors have conducted intensive studies to achieve the above object. As a result, first, when manufacturing ceramic building materials, it was made to improve the solubility of the aggregate and the sintered binder during firing. It was noted that coal ash fly ash and coal ash clinker ash contain Sio2 because strength can be developed by adjusting the amount of Sio2 component. Secondly, in order to use coal ash fly ash and coal ash clinker ash as main raw materials and utilize them as a recycled resource, waste glass and / or water glass are used as a binder. It has been found that the production cost can be reduced and a favorable working environment can be maintained as compared with the use of sodium. Third, by sintering the ceramic building material of the present invention so as to have continuous pores, moisture absorption performance and ventilation performance to adjust humidity, thermal effect by far infrared rays, frost damage resistance, light weight, electromagnetic wave Since it was discovered that it could be provided with properties such as shielding and reduction, and because it could be expected to reduce sick house syndrome, a room-building ceramic building material having breathability and a manufacturing technique thereof were discovered.

[0008] That is, the ceramic building material for a respirable room of the present invention comprises two layers, a base layer and a surface layer having a design, and 30% to 40% by weight of coal ash fly ash discharged from a coal-fired power plant. , Coal ash clinker ash 3
0 to 40% by weight, waste glass 1 as sintering binder
0% to 20% by weight and / or 10% by weight of water glass
20% by weight, 10% to 30% by weight of clay powder as an additive, 5% to 10% by weight of starch and / or wheat flour for imparting moldability, and sintered and coagulated. The surface design can be applied by adding an appropriate inorganic pigment or spotting material according to the requirements.It has excellent moisture absorption and air permeability, freezing damage resistance, light weight that adjusts the indoor humidity as its performance, thermal effect by far infrared rays, electromagnetic wave It is an indoor ceramic building material characterized in that it has an effect of shielding or reducing air pollution.

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

[0010] Coal ash fly ash and coal ash clinker ash, which are the main raw materials of the present invention, are industrial wastes generated after the combustion of coal in thermal power generation and are usually in a fine dust state. Since the ground of the landfill is weakened and the landfilled coal ash is pushed out by the pressure of the ground, dust is generated and there is a risk that the land will be degraded for a long time, so coal ash fly ash,
The technology for continuous and large-scale reuse of coal ash clinker ash as a resource is a global concern.

The coal ash fly ash, which is the main raw material of the present invention, is obtained by collecting incinerated ash of coal with a high-performance electric dust collector, and its main components are silica and alumina. The coal ash clinker ash, which is the main raw material of the present invention, is obtained by crushing coal ash that has fallen to the bottom of the boiler in a red hot state with a crusher and adjusting the particle size, and the particles have compaction performance mainly of fine gravel and coarse sand. It has the same particle size distribution as high sand. In addition, since the shape of the particles is a pore structure, the water permeability is as high as that of sand and gravel.

In the present invention, 60% to 80% by weight of a mixture of coal ash fly ash and clinker ash, 10% to 40% by weight of a mixture of waste glass and water glass,
10 wt% to 20 wt% of clay powder, 5 wt% to 10 wt% of starch / wheat flour and water for molding are mixed and granulated by a granulator, and the composition is cured for 20 to 60 minutes. Then, the molded body which is filled in a mold of a vibration molding machine, press-molded is cured and dried, and then fired at a temperature of 1100 ° C to 1200 ° C.

[0013] The base layer in the present invention is formed using such a mixed coagulated material of coal ash fly ash and coal ash clinker ash, waste glass, water glass, and starch / wheat flour. Coal ash mixed coagulated material, waste glass, water glass, starch /
Or, the appropriate use ratio of flour is 60 to 90: 5 by weight.
After mixing at a ratio of 20: 5 to 20: 5 to 10, granulation, curing, and press molding, a base layer portion of the ceramic building material is obtained.

The surface layer of the present invention is obtained by adding an inorganic pigment having a desired hue and a small amount of water as required when firing the above-mentioned molded article. In order to express a bright hue, it is preferable to use clay that does not contain iron powder.

[0015] The hue particles are mixed with waste glass and / or water glass in a weight ratio of 70 to 90: 5 to 20: 5 to 10 to give starch and wheat flour in order to impart moldability; After granulation, curing, and press molding, the surface layer portion of the present invention is suitably obtained.

The base layer and the surface layer thus manufactured are put into a mold, compression-molded by a press molding machine, and the obtained molded body is cured and dried.
By firing at a temperature of 0 ° C. for about 2 to 3 hours, waste glass and water glass are partially melted to strongly bind the coal ash coagulated particles in the base layer, and to bond the surface layer and the base layer. become. In addition, since continuous pores are formed between particles combined by partial dissolution and recrystallization of waste glass and water glass, the molded article has high moisture absorption because continuous pores are formed between the particles. , Will have air permeability.

[0017] The molded body manufactured in this way has a far-infrared effect because it is made of a carbon material called coal ash, and further has a structure of continuous pores formed between the aggregate particles, thereby blocking electromagnetic waves. Has an effect.

In the case of a panel-type thin ceramic building material, the thickness of the surface layer is preferably about 2 mm to 10 mm, and the thickness of the base layer is preferably about 2 mm to 10 mm. In the case of ceramic building materials used as wall materials, the thickness of the surface layer is 5 m
m to 30 mm, and the thickness of the base layer is preferably 20 mm to 50 mm.

There are various filling methods for providing a two-layer structure of the base layer and the surface layer. For example, after filling the base material and applying vibration once, the surface material can be filled and shaking again by applying vibration, or after filling the base material, the surface material can be filled and subjected to vibration molding. it can.

In the ceramic building material of the present invention, the surface of the aggregate is substantially solubilized by the sintered binder, whereby the aggregate and the sintered binder are integrated, thereby forming an interface between the aggregate and the sintered binder. Preferably, the chemical composition continuously changes from the composition of the aggregate alone to the composition of the sintered binder alone.

[0021]

EXAMPLES Hereinafter, the present invention will be specifically described with reference to Examples.

Example 1 800 g of coal ash fly ash, 800 g of coal ash clinker ash, and 400 g of waste glass were dry-mixed, and then 500 cc of water was added to the mixture, mixed, granulated by a granulator, cured, and cured. 150 g of granules were taken, mixed with 15 g of waste glass and 10 g of starch, and then cured to prepare a raw material for a base layer. The waste glass used has a particle size of 1 mm or less.

On the other hand, 97 g of coal ash clinker ash and clay powder 97 having a low iron content in order to clarify the hue
g and pigment 6g are mixed with 50 cc of water, mixed, granulated by a granulator, cured, 150 g of granulated material is mixed, 15 g of waste glass and 10 g of starch are mixed, cured, and cured. Parts of raw materials were prepared.

First, the base layer raw material is put into a panel-shaped formwork, and then the surface layer raw material is put thereon, pressed and pressed by a press, dried at 70 ° C. for 24 hours, and then placed in a firing furnace. It was charged and fired at a temperature of 1,100 ° C. for 2 hours to produce a ceramic building material for a respirable room. In the case of panel type, 316mm × 316mm × 6
2 mm of respirable indoor ceramic building material was produced. Similarly, one ceramic building material for a respirable room having a wall material of 200 mm × 150 mm × 40 mm was manufactured.

Example 2 800 g of coal ash fly ash, 800 g of coal ash clinker ash, and 400 g of waste glass were dry-mixed, charged into a granulator and rotated, and 500 cc of water was added to the mixture to give a diameter of 1 to 4 mm. After the granules are made and cured, 1500 g of the granules are taken, 150 g of waste glass and 150 g of water glass.
Was mixed and then cured to prepare a base layer material.

On the other hand, 97 g of coal ash fly ash having a mesh size of 30 mesh or less, 120 g of coal ash clinker ash, and 97 g of clay powder are dry-mixed, and 6 g of an inorganic pigment are mixed. After adding 50 cc to form a spherical body having a diameter of 1 to 3 mm and curing, 150 g of the granulated material was taken, 25 g of water glass and 15 g of starch were mixed and cured to prepare a raw material for the surface layer portion.

Thereafter, a ceramic building material was manufactured in the same manner as in Example 1.

The present invention has the following effects because it is configured as described above.

Using coal ash fly ash and coal ash clinker ash discharged from a coal-fired power plant as main resources of ceramic building materials as renewable resources, high moisture absorption, air permeability, chemical substance adsorption performance, far-infrared heating effect In addition, the present invention provides an indoor ceramic building material having respirability to reduce sick house syndrome by producing a product having an electromagnetic wave shielding effect and the like, and a manufacturing technique therefor.

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (reference) C04B 33/13 E04B 1/70 B 1/92 E04B 1/64 C04B 35/00 V 1/70 B09B 3/00 ZAB 1 / 92 303L

Claims (7)

[Claims] 1. Coal ash fly ash discharged from a coal-fired power plant 25% to 60% by weight, coal ash clinker ash 20% to 55% by weight, waste glass 5% to 2%
0% by weight, 5% to 20% by weight of water glass, 5% to 30% by weight of clay powder, 5% to 10% by weight of starch and / or flour are used for sintering and indoor use. Ceramic building materials 2. 5% to 20% by weight of waste glass, 5% by weight of water glass
10% by weight of waste glass only instead of 20% by weight
Use 40% by weight / or 10% by weight of water glass only
The respirable indoor ceramic building material according to claim 1, which is used in an amount of 40% by weight. 3. The method according to claim 1, wherein bentonite is used in an amount of 10 to 30% by weight instead of 5 to 30% by weight of the clay powder.
The ceramic building material for indoor use having breathability according to any one of claims 1 to 3. 4. A mixture 1 in which clay powder and bentonite are mixed in an appropriate ratio in place of clay powder 10 to 30% by weight.
The ceramic building material for indoor use with breathability according to claim 1, wherein the material is 0% by weight to 30% by weight. 5. Coal ash fly ash 45% to 80% by weight instead of 25% to 60% by weight of coal ash fly ash and 20% to 55% by weight of coal ash clinker ash discharged from a coal-fired power plant Claim 1 wherein the material is
The ceramic building material for indoor use having breathability according to claim 4. 6. A diatomaceous earth in an amount of 20% by weight to 75% by weight.
The respirable indoor ceramic building material according to any one of claims 1 to 4, wherein the material is made of: 7. The respirable indoor ceramic building material according to claim 1, wherein the surface is designed by adding a suitable inorganic pigment or spotting material.