JP2005154177A - Non-fired type solidified body and method of producing the same, and formed body using non-fired type solidified body and method of producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a non-fired type solidified body using coal ash and having high water retentivity, high strength and high density, and a formed body using the non-fired type solidified body and having high strength, high porosity, high water retentivity and high stability. <P>SOLUTION: Coal ash solidified aggregate P30 and a concrete block P50 are produced by using cement, coal ash (fly ash), metal slag and water as raw materials and successively carrying out a primary kneading treatment 10, a primary compacting treatment 20, a crushing treatment 30, a secondary kneading treatment 40 and a secondary compacting treatment 50. A vibrating forming press machine 100 is used for the primary compacting treatment 20 and the secondary compacting treatment 50. The machine 100 has a function to vibrate the whole forming mold in which the kneaded material P10 or the P40 is filled in a pressed state so as to give vibration to rapidly liquefy the whole kneaded material. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a non-fired solidified body using coal ash and a technique for constructing a molded body using the non-fired solidified body.

In Japan, coal ash generated in coal-fired power plants and the like is said to reach about 6 million tons per year. Conventionally, it is treated as waste, and its reuse is strongly desired. Currently, various researches on the reuse of coal ash have been undertaken, and as one of them, solidified bodies such as artificial aggregates using coal ash (fly ash) have been proposed. On the other hand, efforts to protect the global environment are emphasized, and blocks that have water retention and voids suitable for vegetation in the promotion of greening, or blocks that have water retention as countermeasures to suppress the heat island phenomenon have been developed. The use of coal ash aggregate is being studied.
Solidified bodies such as artificial aggregates using coal ash can be broadly classified into fired molds and non-fired molds. The calcining mold is sintered at a high temperature of about 1,000 to 1,400 ° C. and requires equipment such as a large calcining plant in the calcining process, so that the coal ash is solidified with cement or the like. The development of molds has been promoted in recent years (for example, see Patent Document 1).
JP-A-10-291848

In the case of a molded body such as a block that takes into account measures to suppress vegetation and heat island phenomenon, etc., it is suitable to use a high water-retaining (high water absorption) and high-strength aggregate as the molded body. In order to improve the stability of the steel, a high-density aggregate is desired. However, at present, it has not been possible to obtain a non-fired solidified body (aggregate) having high water retention, high strength and high density.
Moreover, it was not possible to obtain a molded body having strength, porosity, water retention and stability suitable for vegetation, etc., using a non-fired solidified body using coal ash as an aggregate.
The present invention has been made in view of such points, and has high water retention, high strength, high density non-fired solidified body using coal ash, and high strength, high porosity, high water retention using the non-fired solidified body. -It aims at providing the molded object which has high stability.

  In order to solve the above problems, the invention described in each claim is configured.

(First invention of the present invention)
A first invention of the present invention that solves the above-mentioned problems is a non-fired solidified body as described in claim 1.
The non-fired solidified body according to claim 1 is a non-fired solidified body using coal ash and contains at least coal ash, cement, and metal slag. Moreover, this non-baked solidified body has the performance that the compressive strength is 25 N / mm ² or more, the density is 2.1 g / cm ³ or more, and the water absorption is 8% or more.
Note that the non-fired solidified body having such performance is, for example, a vibration that rapidly liquefies the entire kneaded material containing at least coal ash, cement, metal slag and water. It can be obtained by giving and compacting the whole object.

(Second invention of the present invention)
A second invention of the present invention that solves the above-mentioned problems is a molded body as described in claim 2.
The molded body according to claim ² is a non-fired solidified body having the performance according to claim 1, wherein the compressive strength is 25 N / mm ² or more, the density is 2.1 g / cm ³ or more, and the water absorption is 8% or more. Is a block-shaped molded body using at least the non-fired solidified body and cement. Further, this molded body has a performance of a porosity of 16% or more and a compressive strength of 16 N / mm ² or more.
In addition, the molded body having such performance includes, as an example, vibrations that rapidly liquefy in a state where the non-fired solidified body having the above performance and the entire kneaded material containing at least cement and water are pressurized. It can be obtained by giving to the whole kneaded material and compacting.

(Third invention of the present invention)
A third invention of the present invention that solves the above-mentioned problems is a molded article as set forth in claim 3.
The molded body according to claim ³ is a non-fired solidified body having performances of a compressive strength of 25 N / mm ² or more, a density of 2.1 g / cm ³ or more, and a water absorption of 8% or more. Is a block-shaped molded body using at least the non-fired solidified body, cement, and metal slag. Moreover, this molded object has the performance whose compressive strength is 25 N / mm < ² > or more.
In addition, as an example, the molded body having such performance is rapidly liquefied in a state in which the non-fired solidified body having the above performance and the entire kneaded material containing at least cement, metal slag and water are pressurized. It can be obtained by applying vibration to the entire kneaded material and compacting.

(Fourth invention of the present invention)
A fourth invention of the present invention for solving the above-mentioned problems is a method for producing a non-fired solidified body as described in claim 4.
The manufacturing method of Claim 4 is a manufacturing method which manufactures a non-baking type solidified body using coal ash. This manufacturing method includes a step of obtaining a kneaded material in which coal ash, cement, metal slag, and water are kneaded, and an amplitude operation (vibration) of the entire molding mold while the kneaded material is filled in the molding mold and pressed. And a step of obtaining a compacted non-fired solidified body. In the claims and in the specification, “amplifying the entire molding frame” means that a vibration that can rapidly liquefy the entire kneaded material filled in the molding frame is molded. The mode given to a formwork is said.

(Fifth invention of the present invention)
A fifth invention of the present invention for solving the above-mentioned problems is a method for producing a non-fired solidified body as described in claim 5.
The manufacturing method according to claim 5, further comprising a step of obtaining a crushed non-fired solidified body by crushing the compacted non-fired solidified body in the manufacturing method according to claim 4. It is.

(Sixth invention of the present invention)
A sixth invention of the present invention for solving the above-mentioned problems is a method for producing a non-fired solidified body as described in claim 6.
In the manufacturing method according to claim 6, in the manufacturing method according to claim 4 or 5, in the step of obtaining a consolidated non-fired solidified body, the entire mold is vibrated at 10 to 50 J / l per second. This is a manufacturing method in which amplitude operation (vibration) is performed with energy.

(Seventh invention of the present invention)
A seventh invention of the present invention for solving the above-mentioned problems is a method for producing a molded body as described in claim 7.
The manufacturing method according to claim 7 is a manufacturing method for manufacturing a block-shaped molded body using the crushed non-fired solidified body obtained by the manufacturing method according to claim 5 or 6. This production method includes a step of obtaining a kneaded product obtained by kneading a crushed non-fired solidified material, cement and water, and an amplitude operation of the entire molding form in a state where the kneaded product is filled in a molding mold and pressed. And a step of obtaining a compacted block-shaped molded body.

(Eighth invention of the present invention)
An eighth invention of the present invention for solving the above-mentioned problems is a method for producing a molded body as described in claim 8.
The method for producing a molded body according to claim 8 is the manufacturing method according to claim 7, wherein in the step of obtaining a compacted block-shaped molded body, the entire molding frame is 10-50 J / l per second. This is a manufacturing method in which amplitude operation (vibration) is performed using vibration energy.

(Ninth invention of the present invention)
A ninth invention of the present invention for solving the above-mentioned problems is a method for producing a molded body as described in claim 9.
The method for producing a molded body according to claim 9 is a method for producing a block-shaped molded body using the crushed non-fired solidified body obtained by the production method according to claim 5 or 6. . This manufacturing method includes a step of obtaining a kneaded product obtained by kneading a crushed non-fired solidified body, cement, metal slag and water, and filling the molded product into a mold and pressurizing the entire mold. And a step of obtaining a compacted block-shaped molded body by performing an amplitude operation.

(Tenth invention of the present invention)
A tenth aspect of the present invention that solves the above-described problems is a molded article as set forth in the tenth aspect.
In the manufacturing method according to claim 10, in the manufacturing method according to claim 9, in the step of obtaining a compacted block-shaped molding, the entire molding frame is 10-50 J / l per second. This is a manufacturing method in which amplitude operation (vibration) is performed using vibration energy.

According to the first aspect of the present invention, it is possible to provide a non-fired solidified body using coal ash and having high strength, high density, and high water retention (high water absorption).
Further, according to the invention described in claim 2, the block having high porosity (high water permeability), high strength, high water retention (high water absorption), and high stability particularly suitable for measures for suppressing vegetation and heat island phenomenon. It is possible to provide a so-called porous concrete block.
Further, according to the invention described in claim 3, it is possible to provide a high-strength concrete block (block-shaped molded body) with good water retention (water absorption) particularly suitable for measures for suppressing the heat island phenomenon. .
In addition, according to the invention described in claim 4, high strength, high density, high water retention (high water absorption) compaction using coal ash by an inexpensive and simple process without requiring any special additive. A non-fired solidified product can be obtained. In the production method of the present invention, the entire kneaded product can be liquefied rapidly by performing an amplitude operation (vibration) on the entire molding mold in a state where the kneaded product is filled into the mold and pressed. Become.
In addition, according to the invention described in claim 5, a high strength, high density, high water retention (high water absorption) pulverized non-fired solidified body, so-called aggregate, using coal ash can be obtained. .
Further, according to the invention described in claim 6, when producing a compacted non-fired solidified body having high strength, high density and high water retention (high water absorption), the entire kneaded material is rapidly liquefied. It is possible to set a vibration condition suitable for the amplitude operation of the entire molding form so as to apply vibration.
In addition, according to the invention described in claim 7, a porous material having high porosity (high water permeability), high strength, high water retention (high water absorption), and high stability particularly suitable for measures for suppressing vegetation and heat island phenomenon. A concrete block (block-shaped molded body) can be obtained by an inexpensive and simple process without requiring a special additive. In the production method of the present invention, the entire kneaded product can be liquefied rapidly by performing an amplitude operation (vibration) on the entire molding mold in a state where the kneaded product is filled into the mold and pressed. Become.
Further, according to the invention described in claim 8, when the molded body according to claim 7 is manufactured, the entire mold is subjected to an amplitude operation so as to give vibration that rapidly liquefies the entire kneaded product. It is possible to set a suitable vibration condition.
In addition, according to the invention described in claim 9, a high strength concrete block (block-shaped molded body) having good water retention (water absorption) particularly suitable for measures for suppressing the heat island phenomenon requires a special additive. And can be obtained by an inexpensive and simple process. In the production method of the present invention, the entire kneaded product can be liquefied rapidly by performing an amplitude operation (vibration) on the entire molding mold in a state where the kneaded product is filled into the mold and pressed. Become.
Further, according to the invention described in claim 10, when the molded body according to claim 9 is manufactured, the entire molding mold is subjected to an amplitude operation so as to give vibration that rapidly liquefies the entire kneaded product. It is possible to set a suitable vibration condition.

  Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. The present embodiment is for explaining a preferred embodiment of the present invention, and the present invention is not limited thereby.

In the present embodiment, coal ash solidified aggregate using coal ash (hereinafter referred to as “coal ash solidified aggregate P30”) and a block concrete block (porous concrete block) using the coal ash solidified aggregate P30. ) A process flowchart relating to the manufacture of P50 is shown in FIG. FIG. 2 shows a schematic configuration of the vibration molding press 100 used in the primary compaction process and the secondary compaction process.
In this embodiment, cement, coal ash (fly ash), metal slag, and water are used as raw materials, and the coal ash solidified aggregate P30 and the concrete block P50 are obtained by sequentially performing the processing steps according to the processing flowchart shown in FIG. Can be manufactured. Here, coal ash increases the water absorption of the non-fired solidified body, and metal slag plays a role of increasing strength and density. Further, this processing step is mainly composed of a primary kneading process 10, a primary compaction process 20, a crushing process 30, a secondary kneading process 40, and a secondary compaction process 50. Hereinafter, detailed processing in each of these processing steps will be described with reference to FIGS. 1 and 2.

[Primary kneading process]
In the primary kneading process 10, cement, coal ash (fly ash), metal slag, and water are blended at a predetermined blending ratio described later, and a process of kneading (mixing) with a mixer is performed. Thereby, the homogeneous kneaded material (mixture) P10 in which each component was uniformly dispersed is obtained. In addition, the mixer in this primary kneading | mixing process 10 and the secondary kneading | mixing process 40 mentioned later can use a thing of a known structure, The detailed description about the said structure is abbreviate | omitted. “Fly ash” as used in the present embodiment refers to coal ash (mainly composed of silica and alumina) generated when coal is burned in a coal-fired power plant or the like, and is collected by an electric dust collector. It is a fine powder ash. Regarding the “metal slag” used in the present embodiment, steel slag or non-ferrous metal slag can be used as appropriate. This primary kneading treatment 10 corresponds to “a step of obtaining a kneaded product obtained by kneading coal ash, cement, metal slag and water” in the present invention.

[Primary compaction process]
In the primary compacting process 20, the kneaded product P10 obtained in the primary kneading process 10 is vibrated under a pressurized condition to reduce the voids in the kneaded product P10 and perform a compacting process to increase the density of the mixture. Here, the inventors of the present invention have high water retention (high water absorption) particularly suitable for vegetation and temperature rise suppression (heat island phenomenon suppression), and to obtain a high-pressure, high-density homogeneous pressurized solidified product P20. This kind of compaction process was studied earnestly. As a result of the study, the present inventors performed a compaction process using the vibration molding press 100 having a schematic configuration shown in FIG. Succeeded in finding that you can get. In addition, by performing this compaction treatment, it is possible to obtain a porous concrete block P50 satisfying the required strength as a block in a state of high porosity (high water permeability) suitable for vegetation and heat island phenomenon suppression. I succeeded in finding it.

As shown in FIG. 2, the vibration molding press 100 includes a molding mold 110 having a filling area 110 a, a pressure press device 120 that applies pressing force to the filling material filled in the filling area 110 a, and a molding mold 110. It is mainly composed of a vibration device 130 capable of giving uniform vibration (indicated by a chain line arrow in FIG. 2) as a whole. In the primary compaction process 20, the kneaded product P10 obtained in the primary kneading process 10 is first filled in the filling region 110a of the vibration molding press 100, and then the pressure press device 120 is driven to vibrate the kneaded product P10. Pressurization is performed up to a predetermined pressure (for example, a pressure of about 0.5 kgf / cm ² or more) that provides a compacted state suitable for molding. Then, the entire kneaded product P10 under pressure is rapidly liquefied by driving the vibration device 130 and performing an amplitude operation (vibration) of the entire mold 110 in the vertical direction in FIG. The effective vibration is given to.

  Here, the kneaded material in the mold 110 is liquefied when subjected to vibrations of a certain vibration energy or higher. Due to the liquefaction, the coarse voids that exist in the mold filling state are reduced by consolidation due to sedimentation of metal slag and filling with cement, coal ash, and water kneaded material (paste). Will lead to an increase in strength. In a conventional vibration molding press as described later with reference to FIG. 12, the vibration energy given from the vibration mold is propagated while being attenuated from the periphery of the mold to the inside of the kneaded product. The smaller the inside. For this reason, it is necessary to make the inside of a kneaded material liquefy by continuing a vibration for a long time, and to solidify the whole kneaded material. However, if vibration is continuously applied to the kneaded material for a long time, material separation occurs in the liquefied part due to the difference in density of cement, coal ash, metal slag, and water, and the kneaded material becomes non-uniform. Even after that, a solidified product having predetermined characteristics cannot be obtained. Therefore, the present inventors have found that in order to obtain a uniform solidified product, the entire kneaded product is required to be liquefied in a short time. For this purpose, the method of the present embodiment (primary compaction process 20) in which the vibration energy per unit time is increased and the duration time is shortened by rapidly liquefying the entire kneaded material is effective. is there. Moreover, in the kneaded material, the density of coal ash and metal slag is 70% of cement and 1.3 times that of crushed stone, respectively. The above-described method (primary compaction process 20) is particularly effective. In addition, there is a method using an admixture such as a water reducing agent to suppress material separation. However, when coal ash is contained in the kneaded product, the admixture is adsorbed on the coal ash and the amount of admixture used increases. The above-described method (primary compaction treatment 20) using no admixture is excellent in terms of production cost.

As an example, the entire mold 110 (vibration device 130) is generally operated in amplitude with vibration energy of 10 to 50 J / l (joule / liter) per second. As a result, vibration that rapidly liquefies the entire kneaded product P10 is applied, and the solidified product that has been compacted (consolidated) in a state in which each component in the kneaded product P10 is homogeneously dispersed. Obtained and subjecting this solidified product to the required curing, a pressurized solidified product P20 is obtained. The operating time (vibration energy application time) of the vibration device 130 at this time is a time during which the entire kneaded material P10 can be rapidly liquefied, that is, vibration energy with respect to the liquefied kneaded material 10. Is set to a time such that material separation does not occur due to excessive addition. The operation time can be set as appropriate in consideration of conditions relating to materials such as the type and mixing ratio of raw materials actually used, operation conditions such as vibration energy, and the like.
The pressure-solidified product P20 obtained in this way is a consolidated non-fired solidified body that is not fired, and corresponds to the “consolidated non-fired solidified body” in the present invention. Further, this primary compaction process 20 is the “step of obtaining a compacted pressed solidified product by performing an amplitude operation on the entire mold in a state where the kneaded product is filled in the mold and pressed. It corresponds to.

In contrast, a vibration molding press 200 as shown in FIG. 12 has been proposed.
The vibration molding press machine 200 shown in FIG. 12 applies a pressing force to the mold 110 having the filling region 110a and the filling material filled in the filling region 110a, similar to the vibration molding press machine 100 of the present embodiment. While the pressure press device 120 is provided, the configuration of the vibration device 210 is different from that of the vibration device 130 of the present embodiment. That is, the vibration device 130 can swing the molding mold 110 itself as a whole to give vibrations that rapidly liquefy the entire kneaded material P10 filled in the filling region 110a. On the other hand, the vibration device 210 has a configuration in which a vibration force is only locally applied to the molding form 110 in a fixedly arranged state. Therefore, the vibration device 210 having such a configuration gives non-uniform vibration (small internal vibration) to the filling as indicated by the chain line arrow in FIG. 12, and the filling filled in the filling region 110a. There is a limit to applying vibrations that rapidly liquefy the entire object.

[Curing treatment]
The required curing method described above is atmospheric steam curing, with a maximum temperature of 65 ° C. and a curing time of 20 hours in the steam curing chamber. If necessary, it is also possible to use an autoclave curing which is a high-temperature and high-pressure hydrothermal curing.

[Crushing treatment]
In the crushing process 30, a process of crushing the pressure-solidified product P <b> 20 obtained in the primary compaction process 20 into a size suitable for use as an aggregate in the secondary kneading process 40 is performed. Thereby, the crushed coal ash solidified aggregate P30 obtained by crushing the pressure-solidified product P20 to a desired size is obtained. As an example, the coal ash solidified aggregate P30 having a diameter of 5 to 20 mm can be obtained by crushing the pressure-solidified product P20. This crushed coal ash solidified aggregate P30 corresponds to the “crushed non-fired solidified body” in the present invention. In addition, the crusher in this crushing process can use a thing of a known structure, and detailed description about the said structure is abbreviate | omitted. This crushing process 30 corresponds to the “step of obtaining a crushed non-fired solidified body by crushing a compacted non-fired solidified body” in the present invention.

[Secondary kneading process]
In the secondary kneading process 40, the coal ash solidified aggregate P30, cement, coal ash (fly ash), and water obtained in the crushing process 30 are blended at a predetermined blending ratio described later and kneaded (mixed) again by a mixer. Process. Thereby, the homogeneous kneaded material (mixture) P40 in which each component was uniformly dispersed is obtained. Note that coal ash (fly ash) may be omitted as necessary as a raw material to be kneaded in the secondary kneading process 40. This secondary kneading process 40 corresponds to the “step of obtaining a kneaded product obtained by kneading a crushed non-fired solidified body, cement and water” in the present invention.

[Secondary compaction process]
In the secondary compaction process 50, the kneaded product P40 obtained in the secondary kneading process 40 is subjected to a process of vibrating under pressure using the vibration molding press 100 shown in FIG. That is, in the secondary compaction process 50, the kneaded product P40 obtained in the secondary kneading process 40 is first filled in the filling region 110a of the vibration molding press 100, and then the pressure press device 120 is driven to obtain the kneaded product. P40 is pressurized to a predetermined pressure (for example, a pressure of about 0.5 kgf / cm ² or more) that achieves a consolidated state suitable for vibration molding. Then, the vibration device 130 is driven to swing the entire molding frame 110 in an up-and-down direction in FIG. 2, for example, thereby applying vibrations that rapidly liquefy the entire kneaded material P40 under pressure. .

  Here, the kneaded material P40 in the mold 110 is liquefied when subjected to vibrations of a certain vibration energy or higher. Due to this liquefaction, coarse voids existing in a state filled in the mold 110 are reduced by compaction due to sedimentation of the coal ash solidified aggregate P30, so that the kneaded material P40 is solidified and increased in strength. Leads to. In the conventional vibration molding press 200 as shown in FIG. 12, the vibration energy given from the vibration device 210 propagates while being attenuated from the periphery of the molding frame 110 to the inside of the kneaded material, and therefore the periphery of the molding material 110 of the kneaded material. It becomes large and becomes smaller as the inside. For this reason, it is necessary to make the inside of a kneaded material liquefy by continuing a vibration for a long time, and to solidify the whole kneaded material. However, if vibration is continuously applied to the kneaded material for a long time, material separation occurs in the liquefied part due to the difference in density of coal ash solidified material, cement, water, and coal ash, and the kneaded material becomes non-uniform. Even after curing, a concrete block having predetermined characteristics cannot be obtained. In particular, in the case of a kneaded product for a porous block, it is required to make the kneaded product dense while leaving a necessary gap. For this purpose, it is necessary to prevent vibration paste from being excessively applied to the kneaded product so as to fill the voids that require sagging of the paste. Therefore, the present inventors have found that in order to obtain a uniform molded body, the entire kneaded product is required to be liquefied in a short time. For this purpose, the method of the present embodiment (secondary compaction process 50) in which the vibration energy per unit time is increased and the entire kneaded material is rapidly liquefied to shorten the duration is effective. is there. In addition, there is a method of using an admixture such as a water reducing agent to suppress the separation of coal ash solidified aggregate and paste, but if the admixture contains coal ash solidified aggregate or coal ash, coal ash Since it is adsorbed and the amount of admixture used is increased, the above-described method (secondary compaction treatment 50) using no admixture is excellent in terms of production cost.

As an example, the entire mold 110 (vibration device 130) is generally operated in amplitude with vibration energy of 10 to 50 J / l (joule / liter) per second. As a result, uniform vibration is imparted to the entire kneaded product P40, and a concrete block P50 as a solidified body compacted in a state where each component in the kneaded product P40 is homogeneously dispersed is obtained. Become. The operating time (vibration energy application time) of the vibration device 130 at this time is a time during which the entire kneaded product P40 can be rapidly liquefied, that is, vibration energy relative to the liquefied kneaded product P40. Is set to a time such that material separation does not occur due to excessive addition. The operation time can be set as appropriate in consideration of conditions relating to materials such as the type and mixing ratio of raw materials actually used, operation conditions such as vibration energy, and the like.
The concrete block P50 thus obtained is a block-shaped molded body compacted using the pulverized coal ash solidified aggregate P30, and corresponds to the “block-shaped molded body” in the present invention. In the secondary compaction process 50, cement acts as a binder. This secondary compaction process 50 is the “step of obtaining a compacted block-shaped molded body by performing an amplitude operation on the entire molding frame in a state where the kneaded product is filled in the molding frame and pressed in the present invention”. It corresponds.

An example of the shape of the concrete block P50 manufactured by the above manufacturing method and a concrete block P60 described later is shown in FIG.
As shown in FIG. 11, the concrete blocks P50 and P60 are generally T-shaped in plan view, the length in the vertical direction is 350 mm, the length in the horizontal direction is 420 mm, and the length in the height direction is 280 mm. It has become.

Here, the blending ratio relating to the production of the coal ash solidified aggregate P30 and the performance evaluation result of the coal ash solidified aggregate P30 will be described with reference to FIG. 3 and FIG.
The inventors of the present invention manufactured coal ash solidified aggregates P30-1, P30-2, and P30-3 by performing the above-described processing steps. FIG. 3 shows the blending ratio of each component in the primary kneading process 10 for these coal ash solidified aggregates P30-1 to P30-3.
As shown in FIG. 3, the coal ash solidified aggregate P30-1 is composed of cement 350 [kg] (13 [wt%]), coal ash (fly ash) 700 [kg] (26 [wt%]), metal slag. It is an aggregate obtained as a result of blending with 1400 [kg] (53 [wt%]) and water 220 [kg] (8 [wt%]). Further, the coal ash solidified aggregate P30-2 includes cement 400 [kg] (15 [wt%]), coal ash (fly ash) 650 [kg] (25 [wt%]), metal slag 1300 [kg] ( 50 [wt%]) and water 250 [kg] (10 [wt%]). Further, the coal ash solidified aggregate P30-3 includes cement 450 [kg] (18 [wt%]), coal ash (fly ash) 600 [kg] (24 [wt%]), metal slag 1200 [kg] ( 47 [wt%]) and water 280 [kg] (11 [wt%]).
Thus, in this Embodiment, in manufacture of the coal ash solidification aggregate P30, cement, coal ash (fly ash), metal slag, and water are 13-18 [wt%] and 24-26 [wt%], respectively. ], 47 to 53 [wt%], and 8 to 11 [wt%].

The present inventors performed the measurement about the compressive strength, density, and water absorption which are evaluation items about the said coal ash solidification aggregates P30-1 to P30-3. In addition, the measurement regarding each of these evaluation items is based on the following measurement method.
(Compressive strength)
The maximum compressive load that the specimen (coal ash solidified aggregates P30-1 to P30-3) can withstand is the cross-sectional area of the specimen (coal ash solidified aggregates P30-1 to P30-3) perpendicular to the compressive force. The divided value was defined as “compressive strength” (for details, see, for example, JIS A1108).
(density)
A value obtained by dividing the mass of the test specimen (coal ash solidified aggregate P30-1 to P30-3) by the volume of the test specimen (coal ash solidified aggregate P30-1 to P30-3) is defined as “density”. (For details, see, for example, JIS A1110).
(Water absorption rate)
Absolutely dry specimens (coal ash solidified aggregates P30-1 to P30-3) of the total amount of water contained in the surface dry saturated specimens (coal ash solidified aggregates P30-1 to P30-3) The percentage with respect to the mass of was defined as “water absorption” (for details, see, for example, JIS A1109).

The measurement results regarding the compressive strength, density, and water absorption rate of the coal ash solidified aggregates P30-1 to P30-3 are shown in FIG.
As shown in FIG. 4, a high compressive strength of 25 N / mm ² or more, a density of 2.1 g / cm ³ or more, and a water absorption of 8% or more (8 to 14%) by the treatment process of the present embodiment. It became possible to obtain a coal ash solidified aggregate P30 having strength, high density and high water retention. Moreover, the state of the metal slag in the coal ash solidified aggregate P30 at this time is schematically shown in FIG.
As shown in FIG. 7, as in the comparative example (prior art), when only the vibration device 210 (see FIG. 12) is used and the entire molding mold 110 is operated in amplitude and is not rapidly liquefied, coal is used. In the ash-solidified aggregate P30, the metal slag is biased. In other words, in the prior art, there is a limit to applying uniform vibration that rapidly liquefies the entire kneaded material P10 by the vibration device 210 in the primary compaction process 20, and once in the primary kneading process 10 is uniformly kneaded. The metal slag in the kneaded product P10 is solidified by uneven distribution from the density difference in the kneaded product P10 due to the vibration that continues for a long time. On the other hand, according to the present embodiment, since the vibration device 130 applies a uniform vibration that rapidly liquefies the entire kneaded material P10, the kneaded material once kneaded uniformly in the primary kneading process 10. The metal slag in P10 is solidified without being unevenly distributed.

Next, the blending ratio of each blending element and the performance evaluation result of the concrete block P50 related to the production of the concrete block P50 will be described with reference to FIGS.
The inventors of the present invention manufactured concrete blocks P50-1, P50-2, P50-3, P50-4, P50-5, P50-6, and P50-7 by carrying out the above processing steps. FIG. 5 shows the blending ratio of each component in the secondary kneading process 40 for these concrete blocks P50-1 to P50-7. In FIGS. 5 and 6, an example in which the coal ash solidified aggregate P30-1 in FIG. 3 is used as the coal ash solidified aggregate to be kneaded in the secondary kneading process 40 is described.

As shown in FIG. 5, the concrete block P50-1 includes cement 250 [kg] (15 [wt%]), coal ash (fly ash) 20 [kg] (1 [wt%]), and coal ash solidified aggregate. It is a concrete block molding obtained as a result of blending with 1400 [kg] (81 [wt%]) and water 50 [kg] (3 [wt%]). The concrete block P50-2 includes cement 280 [kg] (16 [wt%]), coal ash (fly ash) 15 [kg] (1 [wt%]), coal ash solidified aggregate 1380 [kg] ( 80 [wt%]) and 56 [kg] (3 [wt%]) of water. The concrete block P50-3 includes cement 310 [kg] (18 [wt%]), coal ash (fly ash) 10 [kg] (1 [wt%]), coal ash solidified aggregate 1360 [kg] ( 78 [wt%]) and 62 [kg] (4 [wt%]) of water. In addition, the concrete block P50-4 includes cement 230 [kg] (13 [wt%]), coal ash (fly ash) 20 [kg] (1 [wt%]), and coal ash solidified aggregate 1500 [kg] ( 84 [wt%]) and 42 [kg] (2 [wt%]) of water. The concrete block P50-5 includes cement 240 [kg] (14 [wt%]), coal ash (fly ash) 15 [kg] (1 [wt%]), and coal ash solidified aggregate 1450 [kg] ( 82 [wt%]) and 44 [kg] (3 [wt%]) of water. The concrete block P50-6 includes cement 250 [kg] (14 [wt%]), coal ash (fly ash) 10 [kg] (1 [wt%]), and coal ash solidified aggregate 1400 [kg] ( 82 [wt%]) and 46 [kg] (3 [wt%]) of water. The concrete block P50-7 includes cement 256 [kg] (15 [wt%]), coal ash (fly ash) 14 [kg] (1 [wt%]), coal ash solidified aggregate 1405 [kg] ( 80 [wt%]) and 63 [kg] (4 [wt%]) of water.
As described above, in the present embodiment, in the production of the concrete block P50, cement, coal ash (fly ash), coal ash solidified aggregate, and water are respectively 13 to 18 [wt%], 1 [wt%], It mix | blends by the mixing | blending ratio of 78-84 [wt%] and 2-4 [wt%].

The inventors of the present invention performed measurements on the above-described concrete blocks P50-1 to P50-7 for evaluation items such as compressive strength, porosity, and density. In addition, the measurement regarding each of these evaluation items is based on the following measurement method.
(Compressive strength)
A value obtained by dividing the maximum compressive load that the test specimens (concrete blocks P50-1 to P50-7) can withstand by the cross-sectional area of the test specimen (concrete blocks P50-1 to P50-7) perpendicular to the compressive force, Compressive strength ”(refer to JIS A1108 for details).
(Porosity)
A value obtained by dividing the total volume of the voids in the test body (concrete blocks P50-1 to P50-7) by the total volume of the test body (concrete blocks P50-1 to P50-7) is referred to as “porosity”. Stipulated.
(density)
A value obtained by dividing the mass of the test body (concrete blocks P50-1 to P50-7) by the volume of the test body (concrete blocks P50-1 to P50-7) was defined as “density”.

The measurement result regarding the compressive strength thru | or porosity and density of concrete block P50-1-P50-7 is shown by FIG.
As shown in FIG. 6, the high strength and high density concrete block P50 having a compressive strength of 18 N / mm ² or more and a density of 1.97 g / cm ³ or more, and a porosity of 18 by the treatment process of the present embodiment. %, A high porosity (high water permeability) having a density of 1.87 g / cm ³ or more, a high density concrete block P50, a compressive strength of 16 N / mm ² or more, a porosity of 16% or more, and a density of It became possible to obtain a concrete block P50 having a high strength, a high porosity (high water permeability), and a high density of 1.95 g / cm ³ or more. Moreover, the state of the coal ash solidified aggregate in the concrete block P50 at this time is schematically shown in FIG.
As shown in FIG. 8, a concrete block is used in the case where the entire molding mold 110 is not liquefied rapidly by using the vibration device 210 (see FIG. 12) as in the comparative example (prior art). In P50, the coal ash solidified aggregate P30 is biased. That is, in the prior art, there is a limit to applying uniform vibration that rapidly liquefies the entire kneaded material P40 by the vibration device 210 in the secondary compaction process 50, and once in the secondary kneading process 40, the mixture is once homogeneously kneaded. The coal ash solidified aggregate P30 in the kneaded material P40 thus formed is unevenly distributed and solidified due to liquefaction caused by uneven vibration. On the other hand, according to the present embodiment, since the vibration device 130 provides uniform vibration that rapidly liquefies the entire kneaded material P40, the kneaded material once kneaded uniformly in the secondary kneading process 40. The coal ash solidified aggregate P30 in P40 is solidified without being unevenly distributed.
The concrete block P50 of the present embodiment uses a coal ash solidified aggregate P30 having high strength, high density, high porosity (high water permeability), high stability, and high water retention (high water absorption). Therefore, it is particularly effective as a concrete block suitable for vegetation and heat island phenomenon control measures.

  In the above embodiment, the case where the coal ash solidified aggregate P30, cement, coal ash (fly ash), and water are kneaded (mixed) in the secondary kneading process 40 has been described. It can also be kneaded (mixed). In this case, the concrete block P60 is obtained by sequentially performing the secondary kneading process 40 and the secondary compaction process 50 in the same manner. Note that coal ash (fly ash) may be omitted as necessary as a raw material to be kneaded in the secondary kneading process 40. The secondary kneading treatment 40 at this time corresponds to the “step of obtaining a kneaded product obtained by kneading the crushed non-fired solidified body, cement, metal slag and water” in the present invention. The consolidation process 50 corresponds to the “step of obtaining a compacted block-shaped molded body by performing an amplitude operation on the entire molded mold in a state where the kneaded material is filled in the molded mold and being pressurized” in the present invention. .

Here, the blending ratio of each blending element and the performance evaluation result of the concrete block P60 relating to the production of the concrete block P60 will be described with reference to FIGS. 9 and 10.
The inventors of the present invention manufactured concrete blocks P60-1, P60-2, and P60-3 by performing the above-described processing steps. The blending ratio of each component in the secondary kneading process 40 for these concrete blocks P60-1 to P60-3 is shown in FIG. 9 and 10, an example in which the coal ash solidified aggregate P30-1 in FIG. 3 is used as the coal ash solidified aggregate to be kneaded in the secondary kneading process 40 is described.

As shown in FIG. 9, the concrete block P60-1 includes cement 270 [kg] (11 [wt%]), coal ash (fly ash) 80 [kg] (3 [wt%]), metal slag 1300 [kg]. ] (51 [wt%]), concrete block molding obtained as a result of blending with coal ash solidified aggregate 800 [kg] (31 [wt%]) and water 113 [kg] (4 [wt%]) is there. The concrete block P60-2 includes cement 280 [kg] (11 [wt%]), coal ash (fly ash) 70 [kg] (3 [wt%]), metal slag 1400 [kg] (55 [wt] %]), A concrete block molding obtained as a result of blending with coal ash solidified aggregate 700 [kg] (27 [wt%]) and water 115 [kg] (4 [wt%]). The concrete block P60-3 includes cement 290 [kg] (11 [wt%]), coal ash (fly ash) 60 [kg] (2 [wt%]), metal slag 1500 [kg] (59 [wt] %]), A concrete block molding obtained as a result of blending with coal ash solidified aggregate 600 [kg] (23 [wt%]) and water 117 [kg] (5 [wt%]).
As described above, in the present embodiment, when the concrete block P60 is manufactured, cement, coal ash (fly ash), metal slag, coal ash solidified aggregate, and water are respectively 11 [wt%] and 2-3 [wt]. %], 51 to 59 [wt%], 23 to 31 [wt%], and 4 to 5 [wt%].

The present inventors performed the measurement about the compressive strength and density which are evaluation items about the concrete blocks P60-1 to P60-3 by the same measurement method as the measurement method used in the evaluation of the concrete block P50. The measurement result is shown in FIG.
As shown in FIG. 10, it is possible to obtain a high-strength, high-density concrete block P60 having a compressive strength of 25 N / mm ² or more and a density of 2.4 g / cm ³ or more by the treatment process of the present embodiment. It became.
The concrete block P60 of the present embodiment uses the coal ash solidified aggregate P30 having high strength, high density and high stability, and high water retention (high water absorption), and therefore, measures for suppressing the heat island phenomenon in particular. It is effective as a concrete block suitable for.

As described above, according to the present embodiment, since coal ash (fly ash) is used for manufacturing the coal ash solidified aggregate P30 and the concrete blocks P50 and P60, coal ash generated in a coal-fired power plant or the like ( Effective use of fly ash is possible.
Further, according to the present embodiment, in particular, the configuration of the vibration molding press 100 used in the primary compaction process 20 and the secondary compaction process 50 is devised so that the entire kneaded product P10 and the kneaded product P40 have uniform vibrations. To produce a porous concrete block P50 having high strength, high density, high porosity (high water permeability), high stability and water retention (water absorption), especially suitable for suppressing vegetation and heat island phenomenon. Is possible. In addition, it is possible to produce a concrete block P60 having high strength, high density, high stability and high water retention (water absorption) particularly suitable for suppressing the heat island phenomenon. Further, it is possible to produce a high strength, high density, high water retention and homogeneous coal ash solidified aggregate P30 suitable for producing these concrete blocks P50 and P60.

  The present invention is not limited to the configuration described in the above embodiment, and various changes, additions, and deletions are possible.

  In the present invention, in the primary compaction process 20 and the secondary compaction process 50 of the above-described embodiment, the vibration energy that causes the entire molding mold 110 (vibration device 130) to perform an amplitude operation is the pressure-solidified product P20 or the concrete block. It can be set as appropriate according to the properties of P50 and P60, and preferably a value between 10 and 50 J / l (joule / liter) per second can be used as appropriate.

Moreover, in this invention, the compounding ratio of each compounding element which concerns on manufacture of coal ash solidification aggregate P30 is cement 13-18 [wt%], coal ash (fly ash) 24-26 [wt%], metal slag 47 It can select suitably in the range of -53 [wt%] and water 8-11 [wt%].
Moreover, in this invention, the compounding ratio of each compounding element which manufactures the concrete block P50 is cement 13-18 [wt%], coal ash (fly ash) 1 [wt%], coal ash solidified aggregate 78-84 [ wt%] and water 2 to 4 [wt%].
Moreover, in this invention, the compounding ratio of each compounding element which manufactures the concrete block P60 is cement 11 [wt%], coal ash (fly ash) 2-3 [wt%], metal slag 51-59 [wt%]. The coal ash solidified aggregate can be appropriately selected within the range of 23 to 31 [wt%] and water of 4 to 5 [wt%].

It is a process flowchart which concerns on manufacture of the concrete block P50 using the coal ash solidification aggregate P30 and the said coal ash solidification aggregate P30 in this Embodiment. It is a figure which shows schematic structure of the vibration molding press 100 used for the primary compaction process 20 and the secondary compaction process 50. FIG. It is a figure which shows the mixture ratio of each combination element which concerns on manufacture of coal ash solidification aggregate P30. It is a figure which shows the performance evaluation result of coal ash solidification aggregate P30. It is a figure which shows the mixture ratio of each compounding element which concerns on manufacture of the concrete block P50. It is a figure which shows the performance evaluation result of concrete block P50. It is a figure which shows typically the mode of the metal slag in coal ash solidification aggregate P30. It is a figure which shows typically the mode of the coal ash solidification aggregate in the concrete block P50. It is a figure which shows the mixture ratio of each compounding element which concerns on manufacture of the concrete block P60. It is a figure which shows the performance evaluation result of concrete block P60. It is a perspective view which shows the shape of concrete blocks P50 and P60. It is a figure which shows schematic structure of the conventional vibration shaping press 200.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Primary kneading process 20 Primary compaction process 30 Crushing process 40 Secondary kneading process 50 Secondary compaction process 100 Vibration molding press 110 Molding mold 110a Filling area 120 Pressure press apparatus 130 Vibration apparatus P10, P40 Kneaded material P20 Pressurized solidified material P30 Coal ash solidified aggregate P50, P60 Concrete block

Claims (10)

A non-fired solidified body using coal ash,
Contains coal ash, cement and metal slag,
A non-fired solidified body having a compressive strength of 25 N / mm ² or more, a density of 2.1 g / cm ³ or more, and a water absorption of 8% or more. A block-shaped molded body using the non-fired solidified body according to claim 1,
Containing the non-fired solidified body and cement,
A molded article having a porosity of 16% or more and a compressive strength of 16 N / mm ² or more. A block-shaped molded body using the non-fired solidified body according to claim 1,
Containing the non-fired solidified body, cement and metal slag;
A molded article having a compressive strength of 25 N / mm ² or more. A method for producing a non-fired solidified body that produces a non-fired solidified body using coal ash,
Obtaining a kneaded product obtained by kneading coal ash, cement, metal slag and water;
Filling the kneaded product into the mold and pressurizing the entire mold in a pressed state to obtain a compacted non-fired solidified body;
The manufacturing method of the non-baking type solidified body characterized by having. It is a manufacturing method of the non-baking type solidified body according to claim 4,
Furthermore, it has the step which obtains a crushed non-baking type solidified body by crushing the compacted non-baking type solidified body, The manufacturing method of the non-baking type solidified body characterized by the above-mentioned. It is a manufacturing method of the non-baking type solidified body according to claim 4 or 5,
In the step of obtaining the compacted non-fired solidified body, the entire mold is subjected to an amplitude operation at a vibration energy of 10 to 50 J / l per second. A method for producing a molded body, wherein a block-shaped molded body is produced using the crushed non-fired solidified body obtained by the production method according to claim 5 or 6,
Obtaining a kneaded product obtained by kneading the crushed non-fired solidified material, cement and water;
Filling the kneaded product into a mold and pressurizing the entire mold in a pressurized state to obtain a consolidated block-shaped molded body;
The manufacturing method of the molded object characterized by having. It is a manufacturing method of the molding according to claim 7,
In the step of obtaining the compacted block-shaped molded body, the entire molding frame is subjected to an amplitude operation at a vibration energy of 10 to 50 J / l per second. A method for producing a molded body, wherein a block-shaped molded body is produced using the crushed non-fired solidified body obtained by the production method according to claim 5 or 6,
Obtaining a kneaded product obtained by kneading the crushed non-fired solidified body, cement, metal slag and water;
Filling the kneaded product into a mold and pressurizing the entire mold in a pressurized state to obtain a consolidated block-shaped molded body;
The manufacturing method of the molded object characterized by having. It is a manufacturing method of a fabrication object according to claim 9,
In the step of obtaining the compacted block-shaped molded body, the entire molding frame is subjected to an amplitude operation at a vibration energy of 10 to 50 J / l per second.

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