JP2005035847A - Method of recycling waste ceramic ware - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of recycling waste ceramic ware by crushing the waste ceramic ware with a simple apparatus to efficiently recycle as a concrete product. <P>SOLUTION: The concrete product is produced by crushing the waste ceramic ware and mixing with an inorganic binder having large early strength development property. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for recycling waste ceramics that efficiently recycles ceramics such as roof tiles and flower pots.

  The waste products (waste products) such as roof tiles and flower pots are treated as stable items and can be finally disposed of at stable disposal sites. Accordingly, conventionally, the waste baked goods have been finally disposed of exclusively at the stable disposal site. However, in recent years, construction of final disposal sites has not progressed, and as a result, disposal costs have gradually increased.

Some of the waste baked goods are crushed and recycled as raw materials for the same baked goods, but this was only carried out slightly in the waste baked goods manufacturing plant. Almost never done.
As described above, the main reason why waste baked goods are hardly recycled is that the cost of disposal was low, but no other suitable recycling method was found. Recycling as a raw material for pottery, which has been carried out in detail, requires that the scraps of pottery such as roof tiles and flowerpots be pulverized to the same level as clay, which is the main raw material, and requires excessive facilities. The running cost is high.

Under such circumstances, in recent years, due to soaring disposal costs due to tightness of final disposal sites, an efficient method for recycling waste ware has been eagerly desired.

  Then, an object of this invention is to provide the recycling method of the waste baked goods which made it possible to crush the waste baked goods with a simple apparatus, and to recycle efficiently as a concrete product.

In order to achieve the above object, the inventor has intensively studied and has come up with a method for effectively recycling waste ware at low cost.
That is, in order to achieve the above object, the present invention is a method for recycling waste ware, characterized by crushing the waste ware, mixing an inorganic binder having high early strength, and producing a concrete product. And

  ADVANTAGE OF THE INVENTION According to this invention, the recycling method of the waste baked goods which crushed the waste baked goods with a simple apparatus and was made to be able to recycle efficiently as a concrete product is provided.

Below, the best form for implementing the waste baking thing which concerns on this invention is demonstrated.
In the present invention, the waste pottery product is at least one waste pottery selected from the group consisting of clay pots, ordinary bricks, pottery tiles and pottery pots made of clay, kneaded, molded and fired ceramic pots. Preferably it is.
That is, in this specification, “waste baked goods” are generally wastes of “ceramic baked products kneaded, molded and baked using clay as a main raw material”.

Examples of such a waste product include at least one of the following items (1) to (4).
(1) Clay roof tile shown in JIS A5208: 1996.
(2) Ordinary brick shown in JIS A1250: 2000.
(3) Among the ceramic tiles shown in JIS A5209: 1994, the ceramic tile.
(4) A ceramic flower pot that is kneaded, molded and baked using clay as the main material.
What are generally considered as so-called “baked goods” include clay tiles, bricks, ceramic tiles, ceramic pots, ceramic tableware, and ceramic figurines.
In the present invention, not all such “baked goods” waste products are handled as “waste pottery”, but bricks and porcelain and water-absorbing items are targeted as “waste pottery”. That is, the porcelain waste is not the target. The water absorption of the “waste baked goods” is 5% or more and 25% or less, preferably 8% or more and 15% or less in terms of water absorption.
“Concrete product” refers to roof tiles, artificial paving stones, building exterior materials, building interior materials, and the like.

In the present specification, “pulverizing waste ceramics” generally refers to pulverizing, classifying and sizing the waste ceramics. For such pulverization, it is preferable to use, for example, an apparatus / method described in Japanese Patent Application No. 2002-194026.
That is, according to this prior application specification, in order to crush waste baked goods, the crushing processing apparatus provided with the crushing equipment containing a rough crushing equipment, a crushing equipment, and a classification equipment is used. Such crushing equipment can further include fine grinding equipment.

In such a crushing processing apparatus, for example, the waste burned material is crushed with a coarse crushing facility such as a jaw crusher, a hammer crusher, or a biaxial crusher. Next, the coarsely pulverized product is put into a pulverization facility. As the pulverization equipment, a jaw crusher, a roll mill or the like having a pulverization degree different from that of the coarse pulverization equipment can be used.
Then, the pulverized product from the pulverization facility is put into a classification facility such as a two-stage sieve. In such a two-stage sieve, three sections can be obtained under the sieve, the middle part of the sieve, and the sieve. Here, for example, the sieve top is returned to the crushing equipment and crushed. The pulverized product is again introduced into the sieve and sieved. Furthermore, if necessary, the particles are sized using a sizing facility.
As described above, it is suitable to use a two-stage sieve as the sieve. Of course, a one-stage sieve or a three-stage or more multistage sieve may be used.
A ball mill, a pin mill, a cone crusher, a vibration conveyor, a vibration sieve, or the like can be used as the sizing equipment.

  It is preferable that the crushing apparatus further includes a quantitative supply device for supplying raw materials to the coarse pulverization facility, the pulverization facility, and the fine pulverization facility. This contributes to stable operation of the machine and product quality. Examples of the quantitative supply device include a belt feeder, a screw conveyor, an apron conveyor, a table feeder, and a paddle feeder.

  Further, in the present specification, the “inorganic binder having a large early strength development property” refers to a binder that reaches the 28-day strength of ordinary Portland cement (measured according to JIS R5201) in 12 to 24 hours. .

In the method for recycling waste ceramics according to the present invention, in a preferred embodiment, alumina cement is used as the inorganic binder having a high early strength.
Alumina cement is composed mainly of aluminum oxide Al ₂ O ₃ (abbreviated as A in the cement industry) and lime CaO (abbreviated as C in the cement industry). Aluminum oxide and lime partially form crystals, some in the form of C ₁₂ A ₇ and others in the form of CA.

Alumina cement is usually used as a refractory or as a refractory binder, and its fire resistance is 1100-1300 ° C., exceeding the melting temperature of the glaze. In the present invention, when alumina cement is used as the above-described inorganic binder having a high early-stage strength development property, it is also included as an embodiment that the produced concrete product is glazed and fired at 600 to 1300 ° C. The firing temperature is 600 to 1300 ° C., preferably 700 to 1000 ° C., depending on the type of glaze, and the firing time is 20 to 120 minutes, preferably 40 to 90 minutes.
Thus, when alumina cement is used instead of Portland cement, glaze can be applied and main baking can be performed. The water supply rate is 15% or less, the surface is vitrified, and the lifetime is semi-permanent. In addition, it is not necessary to rely on waterproofing processing that had to be repainted in 5 to 10 years.

  When alumina cement is used, the curing time can be greatly shortened since the strength comparable to that of ordinary Portland cement can be obtained in about one day. Therefore, there is no need for steam curing (autoclave), such as running costs. Furthermore, in addition to this advantage, the present inventors have found that the water permeability is reduced even before applying glaze and baking. This means that the balance between the low drying shrinkage of alumina cement and the mixing rate of sand and gravel (waste ceramic sand and gravel) obtained by crushing, classifying and sizing the waste ceramics that are put in aggregate is precise. This is probably due to the fact that the hardened cement body was constructed.

Here, the form which manufactures a cement roof tile with the recycling method of the waste ware based on this invention is demonstrated.
In this embodiment, ordinary cement roof tiles are manufactured using gravel, sand, Portland cement, water and, if necessary, a water reducing agent and a setting retarder. Cement roof tiles are produced using the sand (waste baked material sand) obtained by pulverization, gravel (waste baked material gravel) obtained by pulverizing, classifying and sizing, and alumina cement and water.
Here, as described above, it is preferable to use, for example, the apparatus and method described in Japanese Patent Application No. 2002-194026 for the pulverization treatment of the waste burned material. The “sand” is preferably sieved to a particle size range of 1 mm, and the “gravel” is sieved to about 1 mm to 5 mm and 5 mm to 20 mm.

  When producing cement roof tiles, the mixing ratio of each component is 20-50% of waste baked material sand, 20-50% of waste baked material gravel, 10-30% alumina cement, water / cement ratio: 0.2. The range is 0.6. Then, these materials are mixed and kneaded. If necessary, other admixtures may be added. Other admixtures include setting modifiers, thickeners, sustained release dispersants, AE water reducing agents, fluidizing agents, other high performance water reducing agents, early strengthening agents, accelerators, water retention agents, waterproofing agents, coloring. Agents, antifungal agents, crack reducing agents, polymer emulsions, surfactants, other water-soluble polymers, and glass fibers. Later, the product can be obtained by pouring into a formwork, curing, and demolding.

In addition, other concrete products can be manufactured similarly. In other words, it is possible to perform early demolding and commercialization without using equipment such as autoclaves. Demand for special tiles (such as demon tiles), custom tiles, custom artificial paving stones, custom building exterior materials, and custom house interior materials Can respond immediately. Various conditions according to each product will be described in detail in later examples.
In addition, when a concrete product is manufactured using another “inorganic binder with high early strength development”, a concrete product including a roof tile such as a cement tile can be manufactured in the same manner.

Furthermore, the method for recycling waste ceramics according to the present invention includes the use of jet cement as an “inorganic binder having a high early strength”.
“Jet cement” has much higher amounts of aluminum oxide (Al ₂ O ₃ ) and sulfur trioxide (SO ₃ ) than ordinary cement, and its mineral composition is about 2.5 times the amount of calcium aluminate. There are many cements. The conventional portland cement calcium aluminate has the form of 3CaO.Al ₂ O ₃ (abbreviated as C ₃ A). On the other hand, the jet cement is in the form of 11CaO · 7Al ₂ 0 ₃ · CaF ₂ (also abbreviated as C ₁₁ A ₇ · CaF ₂ ). An appropriate amount of SO ₃ is added to this to help control condensation and develop early strength. Jet cement develops strength since early-strength cement and super-early-strength cement do not yet exhibit strength at all. The early-strength cement increases the amount of 3CaO.SiO ₂ (also abbreviated as C ₃ S), and exhibits early elasticity by making the powder finer. But it has its limits. The jet cement skillfully utilizes the super-hardness of a new compound called activated calcium aluminate (C ₁₁ A ₇ · CaF ₂ ) and C ₃ S as the main component of Portland cement. Therefore, to obtain a compressive strength of 20 N / mm ² , it takes at least 3 days for ordinary cement and 1.5 days or more for early-strength cement, whereas it takes only 3 hours for jet cement.

That is, jet cement having early high strength can be used in the method for recycling waste ceramics according to the present invention, as with alumina cement.
However, in the case of jet cement, since the fire resistance is the same as that of Portland cement, it cannot be burned with glaze. Jet cement exhibits rapid strength development of the hardened concrete, and develops strength comparable to that of ordinary Portland cement (measured according to JIS A1108) in about 1 day (12 to 24 hours). Therefore, early demolding and early commercialization are possible without using equipment such as autoclaves. Demand for special tiles (such as demon tiles), custom tiles, custom artificial paving stones, custom building exterior materials, custom housing interior materials, etc. It is possible to meet.

  Furthermore, the method for recycling waste ceramics according to the present invention includes, as an embodiment, a case where a mixture of alumina cement and Portland cement is used as the “inorganic binder having a high early strength”. The mixing ratio can be up to alumina cement: Portland cement = 1: 9 to 9: 1 (weight ratio).

  Furthermore, the method for recycling waste baked goods according to the present invention includes a case where a mixture of jet cement and Portland cement is used as an “inorganic binder having a high early strength”. The mixing ratio can be up to jet cement: Portland cement = 1: 9 to 9: 1 (weight ratio).

  In addition, as said Portland cement, the Portland cement prescribed | regulated to JISR5210 is suitable, for example.

Furthermore, in the recycling method of waste baked goods according to the present invention, it is also possible to use two or more kinds of pulverized products and / or sized products obtained by crushing the waste baked products and having different particle size ranges. Including as a form.
Aggregates obtained by pulverizing the waste ceramics can be divided into fine aggregates and coarse aggregates. Of course, it is possible to produce a concrete product with one type of aggregate, but since the quality of the product depends on the particle size of the aggregate, it is possible to mix two or more types of aggregates having different particle size ranges. Is preferred. The particle size of the aggregate can be classified into, for example, aggregates derived from four types of waste products of 1 mm or less (A), 1 mm to 5 mm (B), 5 mm to 20 mm (C), and 20 mm or more (D). .
Here, the reason why the upper and lower limits overlap in these particle size ranges is to determine the particle size range by sieving with a sieve. For example, 1 mm or less (A) is a particle size range of a section that has passed a 1 mm mesh, and 1 mm to 5 mm (B) is a particle size range of a section that has not passed a 1 mm mesh and has passed a 5 mm mesh. Define the scope. The same applies to the description relating to other particle size ranges in the present specification.
These mixing ratios vary depending on the type of concrete product to be manufactured. In the case of roof tiles, it is suitable that A: B = 1: 1. Moreover, when manufacturing an artificial paving stone, it is suitable to set it as A: B: C = 2: 2: 1 grade. Moreover, when manufacturing a building exterior material, it is suitable that A: B = 1: 1. Moreover, when manufacturing a housing interior material, it is suitable to make it about A: B = 1: 1. The above are all weight ratios.

  Of course, gravel and sand used in the production of ordinary concrete products and structures as aggregates may be mixed with aggregates obtained by crushing waste ceramics in proportions that do not contradict the purpose of the present invention. good.

  Hereinafter, the method for recycling waste ware according to the present invention will be described in more detail with reference to examples.

この中で最も重要な性能は吸水率であり、アルミナセメントと屋根瓦破片及び植木鉢破片等焼き物の破片を破砕機で破砕し、さらに分級、整粒した骨材を使用して製造したセメント瓦は普通ポルトランドセメントと砂と砂利を使用して製造したセメント瓦に比較して吸水率が大幅に少なく、そのままで瓦としての規格（JIS規格、吸水率１５％以下）を満足する値となっている。 The present Example 1 is a method for recycling waste ceramics in which cement tiles are produced using aggregates that have been crushed with a crusher and further classified and sized, such as broken pieces of roof tiles and flower pot fragments.
The aggregate of cement tile is mainly used in ˜1 mm (A) and 1 mm to 5 mm (B).
The mixing ratio is, for example, A: B: alumina cement = 2: 2: 1. The water-cement ratio is set to be the same as or slightly lower than that of ordinary cement roof tiles. Specifically, the water cement ratio is set to 20% to 70%, preferably 30 to 60%. The water cement ratio is a weight ratio, and the same applies to the following examples.
The kneaded ready-mixed concrete is poured into a formwork, cured for half a day to 1 day, then deshaped and shipped. In the case of cement roof tiles using ordinary Portland cement, curing in the air requires one week or more after demolding. The shortest curing time and short time to commercialization are the biggest merit of using alumina cement.
By taking advantage of this merit, it is possible to make custom orders for roof tiles, etc., especially for custom tiles such as demon tiles and ridge tiles, which are called “functions”, but it can take time and cost to meet these demands easily. It becomes.
Cement tiles manufactured using aggregates that have been crushed with alumina cement, roof tile fragments, flower pot fragments, etc., and further classified and sized, have the performance shown in Table 1 below.
In addition, the concrete components of this cement tile were as follows.

The most important performance among these is the water absorption rate. Cement tiles manufactured using aggregates that have been classified and sized by pulverizing pieces of ceramics such as alumina cement, roof tile fragments and flower pot fragments with a crusher. Compared to cement roof tiles made from ordinary Portland cement, sand and gravel, the water absorption rate is significantly less, and the value as it is satisfies the standard (JIS standard, water absorption rate 15% or less) as a tile. .

  The present Example 2 relates to a method for recycling waste ceramics in which the cement tile produced in Example 1 is glazed and baked to lower the water absorption rate and enhance the function as the tile. The glaze uses crushed materials such as waste liquor bottles and wine bottles, and the baking temperature is 600 ° C. to 1300 ° C., preferably 800 ° C. to 1100 ° C. for 30 minutes to 90 minutes, preferably 45 minutes to 75 minutes. Good quality cement roof tiles with low water absorption can be produced.

Example 3 relates to a method for recycling waste ceramics in which pieces of ceramics such as roof tile fragments and flowerpot fragments are crushed with a crusher and further classified and sized aggregates and jet cement are used to produce cement tiles. Is.
The aggregate of cement tile is mainly used in ˜1 mm (A) and 1 mm to 5 mm (B).
The mixing ratio is, for example, A: B: jet cement = 2: 2: 1. The water-cement ratio is set to be the same as or slightly lower than that of ordinary cement roof tiles. Specifically, the water cement ratio is set to 20% to 70%, preferably 30 to 60%.
The kneaded ready-mixed concrete is poured into a formwork, cured for half a day to 1 day, then deshaped and shipped. In the case of cement roof tiles using ordinary Portland cement, curing in the air requires one week or more after demolding. The shortest curing time and short time to commercialization are the biggest advantages of using jet cement.
By taking advantage of this merit, it is possible to make custom orders for roof tiles, etc., especially for custom tiles such as demon tiles and ridge tiles, which are called “functions”, but it can take time and cost to meet these demands easily. It becomes.
Cement tiles made from aggregates that have been crushed by pulverizing jet cement, roof tile fragments, flower pot fragments, etc. using a crusher, and classified and sized, are equivalent to cement tiles using ordinary Portland cement. Therefore, it cannot be used as a roof tile as it is, and the surface needs to be waterproofed.

Example 4 relates to a waste pottery recycling method for producing artificial paving stones by crushing pieces of ceramics such as roof tile pieces and flowerpot pieces with a crusher, and further classifying and sizing the aggregate. .
The aggregate of the artificial paving stone action is mainly used in ˜1 mm (A), 1 mm to 5 mm (B), 5 mm to 20 mm (C) and the like. Depending on the case, 20 mm or more (D) may be mixed.
The mixing ratio is, for example, A: B: C: inorganic binder = 2: 2: 1: 1. The water-cement ratio is set to be the same as or slightly lower than that of ordinary cement roof tiles. Specifically, the water cement ratio is set to 20% to 70%, preferably 30 to 60%.

  The kneaded ready-mixed concrete is poured into a formwork, cured for half a day to one day, and then demolded. The time to shipment depends on the mixing ratio of Portland cement to alumina cement or jet cement. If the proportion of alumina cement or jet cement is approximately 50% or more, it can be shipped immediately after demolding. Moreover, if the ratio of Portland cement is 100, it is necessary to cure for 5 to 7 days until shipment. When the mixing ratio of alumina cement or jet cement and Portland cement is between 100% and 50% Portland cement, the time required for shipping is 1 day or more and less than 5 days. The mixing ratio of alumina cement or jet cement and Portland cement is set appropriately depending on the time required until shipment.

This Example 5 relates to a method for recycling waste ceramics in which exterior ceramic materials are produced by crushing broken pieces of roof tiles and broken pieces of flowerpots with a crusher, and using classified and sized aggregates. It is.
Aggregates for building exterior materials for construction mainly use ˜1 mm (A), 1 mm to 5 mm (B), 5 mm to 20 mm (C) and the like. Depending on the case, 20 mm or more (D) may be mixed.
The mixing ratio is, for example, A: B: C: alumina cement = 2: 2: 1: 1. The water-cement ratio is set to be the same as or slightly lower than that of ordinary cement roof tiles. Specifically, the water cement ratio is set to 20% to 70%, preferably 30 to 60%.
The kneaded ready-mixed concrete is poured into a formwork, cured for half a day to 1 day, then deshaped and shipped. As described in the first embodiment, the building exterior material manufactured using the aggregate and alumina cement obtained by crushing pieces of ceramics such as roof tile fragments and flower pot fragments with a crusher, and classifying and sizing the aggregate, as described in Example 1. It has low characteristics and is suitable for building exterior materials. In addition, the shortest curing time and short time to commercialization are the greatest merit of using alumina cement.
By taking advantage of this merit, it becomes possible to produce a custom-made building exterior material (design, etc.).

This Example 6 relates to a method for recycling waste ceramics that produces building exterior materials using aggregates that are crushed by broken pieces of roof tile fragments and flower pot pieces, etc., and further classified and sized. It is.
The aggregate for building exterior materials for construction mainly uses ˜1 mm (A), 1 mm to 5 mm (B), 5 mm to 20 mm (C) and the like. Depending on the case, 20 mm or more (D) may be mixed.
The mixing ratio is, for example, A: B: C: alumina cement = 2: 2: 1: 1. The water-cement ratio is set to be the same as or slightly lower than that of ordinary cement roof tiles. Specifically, the water cement ratio is set to 20% to 70%, preferably 30 to 60%.
The kneaded ready-mixed concrete is poured into a formwork, cured for half a day to 1 day, then deshaped and shipped. As described in the first embodiment, the building exterior material manufactured using the aggregate and alumina cement obtained by crushing pieces of ceramics such as roof tile fragments and flower pot fragments with a crusher, and classifying and sizing the aggregate, as described in Example 1. It has low characteristics and is suitable for building exterior materials. In addition, the shortest curing time and short time to commercialization are the greatest merit of using alumina cement.
By taking advantage of this merit, it becomes possible to produce a custom-made building exterior material (design, etc.).

  As described above, according to the present invention, the most recently reclaimed roof tile fragments and flower pot fragments such as pottery pieces are competitive products in roof tiles, artificial paving stones, building exterior materials, house interior materials, etc. Can be provided, and the amount of pieces of ceramics such as roof tile fragments and plant pot fragments buried in the final disposal site can be reduced, which can contribute to the extension of the life of the disposal site.

Claims (8)

A method for recycling waste ceramics, characterized by crushing waste ceramics and mixing an inorganic binder with high early strength development to produce a concrete product. The waste pottery is at least one waste pottery selected from the group consisting of clay pots, ordinary bricks, pottery tiles and pottery pots made of clay, kneaded, molded and fired using clay as the main material The method for recycling waste ceramics according to claim 1. 2. The method for recycling waste ceramics according to claim 1, wherein alumina cement is used as the inorganic binder having a high early-stage strength development property. 4. The method for recycling waste ceramics according to claim 3, wherein the manufactured concrete product is glazed and fired at 600 to 1300 ° C. 3. The method for recycling waste ceramics according to claim 1 or 2, wherein jet cement is used as the inorganic binder having a high early-stage strength development property. The method for recycling waste ceramics according to claim 1 or 2, wherein alumina cement and Portland cement are mixed and used as the inorganic binder having high early strength development. 3. The method for recycling waste ceramics according to claim 1 or 2, wherein jet cement and portland cement are mixed and used as the inorganic binder having high early strength development. A method for recycling waste ceramics, comprising using two or more kinds of pulverized products and / or granulated products obtained by crushing waste ceramics, each having a different particle size range.