JP2006315914A - Porous light weight material and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an artificial soil material or artificial pumice stone by manufacturing a porous lightweight sintered foamed body using waste glass, clay and waste material-utilized woody charcoal as raw materials. <P>SOLUTION: A method of manufacturing the porous lightweight material is carried out by kneading the waste glass powder, clay powder, the woody charcoal powder and a foaming agent with water, granulating the kneaded product and then firing the granule. A layered nearly spherical body is formed because the energy transfer of each material occurs by heat of firing in foaming step occurs and then the clay useful for the growth of plant gathers to the outside, the glass gathers in the middle and the woody charcoal gathers in the center to form layer distribution. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

The present invention relates to an artificial soil material excellent in water absorption and water retention and an artificial pumice stone having high safety and moderate strength, and sintered foam using a mixture of waste glass, waste material-use charcoal and clay generated in large quantities. It is realized by the body.

The applicants of the present invention disclosed in Japanese Patent Application Laid-Open No. 2002-104889, in a state where Shimajiri mudstone powder composed of clay and fine sand particles, glass powder, and a foaming agent are mixed and fired by passing through a heating furnace. Proposed a technique for obtaining materials in which Shimajiri mudstone powder and glass powder were uniformly and harmoniously integrated.
The mixed foam of the Shimajiri mudstone powder and the glass powder thus produced contains a large amount of minerals due to the Shimajiri mudstone, and the mixed material with the foamed glass powder can contain a large amount of air and water. As a result, the roots of the crops are improved, and the light pot soil for horticulture by foaming is easy to handle and the transportation cost is reduced, which is expected to have a great effect on the promotion of horticulture agriculture. The

The present invention further improves a mixed foam formed by firing such clay powder and glass powder in a heating furnace to realize a mixed porous lightweight material, thereby improving soil conditioner, water purification material, planting. It was found that it can be applied to various uses such as an artificial medium for planting and a dehumidifying material.

On the other hand, as Patent No. 2586759 (Japanese Patent Application No. 3-160261), it relates to a foamed building material and a method for producing the same. In particular, it has excellent heat insulation, no water absorption, and the surface is not slippery. A foamed building material excellent in mechanical strength and suitable as a flooring material and a method for producing the same have been proposed.
The details are as follows: a foamable raw material obtained by mixing 60 to 10 parts by weight of clay, 40 to 90 parts by weight of feldspar and 2 parts by weight or less of a gas generating component, and a non-foamable raw material are laminated and fired. A method for producing a foamed building material is characterized in that a sintered body having a foamed layer and a non-foamed layer is formed, and then a cross section of the pores is exposed by grinding or polishing the surface of the foamed layer of the sintered body.

Also, as disclosed in JP-A-8-59365, fine sand that is produced in large quantities as waste when the used casting sand mold is opened, the pores are uniformly distributed, and the strength, air permeability and water retention are improved. It has been proposed to provide an excellent, sterile and highly safe sintered body, and a soil conditioner, water purification material and artificial soil for plant growth comprising the same.
The details are: a porous sintered body obtained by adding water to fine sand derived from a foundry sand mold, kneading and molding, drying if necessary, and then firing, as well as a soil improver comprising the same, water purification Artificial soil for wood and plant growth.
Patent No. 2586759 JP-A-8-59365

However, in the case of Patent Document 1, a foamable raw material obtained by mixing clay, feldspar, and a gas generating component and a non-foamable raw material are formed into layers and then fired to obtain a fired layer having a foam layer and a non-foam layer. A cross-section of the pores is exposed by grinding or polishing the surface of the foamed layer of the sintered body, and the use is limited to a building material such as a flooring material that does not absorb water. Therefore, it cannot be used for applications requiring water absorption or water retention, such as soil improvement materials, water purification materials, artificial culture media for planting, and dehumidifying materials as in the present invention.

On the other hand, in the case of Patent Document 2, it is used as a soil improver, a water purification material, an artificial soil for plant growth, etc., but a molded product obtained by adding water to a fine sand derived from a used foundry sand mold and kneading and molding. It is a porous sintered body obtained by drying and firing and does not contain clay, so it does not seem suitable as an artificial soil material. And it is not a foaming material containing waste glass powder as in the present invention, the raw materials and the manufacturing method are completely different, the product composition and cross-sectional shape are also different, so it seems that the intended purpose can not be fully achieved, The object of the present invention of recycling waste glass cannot be achieved.
The technical problem of the present invention pays attention to such a problem, and manufactures a porous lightweight sintered foam from waste glass, clay, and waste wood charcoal as raw materials to realize artificial soil material or artificial pumice stone. There is.

The technical problem of the present invention is solved by the following means. Claim 1 is a porous product obtained by firing a granulated product obtained by mixing at least waste glass powder and / or a sintered foam powder of waste glass powder, clay powder and a foaming agent. Lightweight material. As described above, the porous lightweight material formed by firing the granulated product obtained by mixing the waste glass powder and / or the sintered foam powder of the waste glass powder, the clay powder, and the foaming agent, It becomes porous by foaming, it is reduced in weight, and energy transfer of each substance occurs at the time of foaming due to baking heat. It becomes a layered substantially spherical body in which has occurred.

Since such a layered spherical sintered material is a foam, in addition to being lightweight, it has a high water absorption effect and a high water retention effect. Therefore, it is suitable for use as an artificial soil culture medium, a dehumidifying material, a water purification material or the like when cultivating plants. Moreover, since the outside is a clay-like foam layer, it is optimal for growing plants.

A second aspect of the present invention is the porous lightweight material according to the first aspect of the present invention, which is obtained by firing a granulated product in which wood charcoal powder is also mixed. Thus, the waste glass powder according to claim 1 and / or the granulated product in which the sintered foam powder of the waste glass powder, the clay powder, the foaming agent, and the charcoal powder are mixed are fired. Therefore, due to the energy transfer of each substance at the time of firing as described above, the clayy substance is concentrated on the outside, the glassy substance is concentrated on the inner side, and the carbonaceous substance is concentrated on the core of the center to form a multilayered almost spherical body. .

Thus, not only the water absorption effect and the water retention effect are further increased by increasing the number of layers, but also a carbonaceous layer is formed, so that the dehumidifying action and water purification action peculiar to charcoal are further improved.

Claim 3 is characterized in that at least waste glass powder and / or powder of sintered foam of waste glass powder, clay powder and foaming agent are kneaded with water, granulated, and then fired. This is a method for producing a lightweight material. In this way, according to the manufacturing method in which the waste glass powder and / or the sintered foam powder of the waste glass powder, the clay powder, and the foaming agent are kneaded with water and granulated, and then fired. By such an action of energy transfer of each substance by the heat of firing at the time of foaming, a porous lightweight material having a layer distribution for each component can be easily manufactured. It should be noted that the clay is mainly concentrated on the outer side, and the vitreous is mainly concentrated on the inner side, and the layer structure is not completely separated for each component. Moreover, although the external shape after granulation depends on the granulation technique, it does not have to be a perfect sphere, and is often an irregular sphere. The size varies, and is about 4 to 15 mm.

Claim 4 is the method for producing a porous lightweight material according to claim 3, wherein the powder of wood charcoal is kneaded with water together and granulated, and then fired. Thus, the waste glass powder according to claim 3 and / or the sintered powder of the waste glass powder, the clay powder, and the granulated product in which the charcoal powder is mixed with the foaming agent are fired. Therefore, due to the energy transfer of each substance during foaming by firing heat, mainly the clay is concentrated on the outside, the glass is mainly concentrated on the intermediate layer, and the carbon is mainly concentrated on the core of the center. Such multilayer, substantially spherical, porous, lightweight materials can be easily manufactured.

According to claim 5, the waste glass powder and / or the sintered glass powder of the waste glass powder is 50 to 70 W%, clay is 15 to 30 W%, wood charcoal is 15 to 30 W%, and the foaming agent is 0. The method for producing a porous lightweight material according to claim 4, wherein the firing temperature is 600 to 950 ° C. Thus, waste glass powder and / or powder of sintered foam of waste glass powder is 50 to 70 W%, clay is 15 to 30 W%, wood charcoal is 15 to 30 W%, and foaming agent is 0.5 to When the porosity is 3.0% and the firing temperature is 600 to 950 ° C., the intended porous lightweight material can be produced with good yield. When the raw material ratio is exceeded, the balance of the relative ratio with other raw materials is lost, and a high-quality product cannot be manufactured. Further, if the firing temperature exceeds the range of 600 to 950 ° C., the firing is excessive and the fuel cost increases and the production efficiency also decreases. If the firing temperature is lower than this temperature range, the firing is insufficient and foaming and strength are insufficient. It becomes a good product.

As described in claim 1, a porous lightweight material obtained by firing a granulated product obtained by mixing waste glass powder and / or sintered glass powder of waste glass powder, clay powder, and a foaming agent, It becomes porous by foaming as a whole, and it is reduced in weight, and energy transfer of each substance occurs at the time of foaming due to baking heat, so clay that is useful for plant cultivation is concentrated on the outside, and glassy is concentrated on the inside. Thus, a layered substantially spherical body with a layer distribution is formed. Since such a layered spherical sintered material is a foam, in addition to being lightweight, it has a high water absorption effect and a high water retention effect. Therefore, it is suitable for use as an artificial soil culture medium, a dehumidifying material, a water purification material or the like when cultivating plants. Moreover, since the outside is a clay-like foam layer, it is optimal for growing plants.

A granulated product in which the waste glass powder and / or the sintered foam powder of the waste glass powder, the clay powder, the foaming agent and the charcoal powder are mixed as in claim 2 is fired. Therefore, due to the energy transfer of each substance at the time of firing as described above, a clay-like substance is concentrated on the outside, a glassy substance is concentrated on the inside, and a carbonaceous substance is concentrated on the core of the center. Become. Thus, not only the water absorption effect and the water retention effect are further increased by increasing the number of layers, but also a carbonaceous layer is formed, so that the dehumidifying action and water purification action peculiar to charcoal are further improved.

According to the manufacturing method in which the waste glass powder and / or the sintered foam powder of the waste glass powder, the clay powder and the foaming agent are kneaded with water and granulated, and then fired. Due to the action of energy transfer of each substance by the firing heat during foaming as in Item 1, a porous lightweight material having a layer distribution for each component can be easily produced.

As in claim 4, the waste glass powder of claim 3 and / or the sintered powder of the waste glass powder, the clay powder, and the granulated product in which the charcoal powder is mixed with the foaming agent is fired. Therefore, due to the energy transfer of each substance during foaming by firing heat, mainly the clay is concentrated on the outside, the glass is mainly concentrated on the intermediate layer, and the carbon is mainly concentrated on the core of the center. Thus, a multi-layered substantially spherical porous lightweight material can be easily manufactured.

As in claim 5, waste glass powder and / or powder of sintered foam of waste glass powder is 50 to 70 W%, clay is 15 to 30 W%, wood charcoal is 15 to 30 W%, and foaming agent is 0. When the firing temperature is from 5 to 3.0% and the firing temperature is from 600 to 950 ° C., the intended porous lightweight material can be produced with good yield. Within such a raw material ratio range, the relative ratio between the raw materials is well balanced, and a high-quality product can be manufactured. Further, if the firing temperature is in the range of 600 to 950 ° C., firing is sufficient and sufficient foaming and strength can be ensured.

Next, an embodiment of how the porous lightweight material and the manufacturing method thereof according to the present invention are actualized will be described. FIG. 1 is a flowchart showing a method for producing a porous lightweight material according to the present invention. Step S1 is a raw material used for manufacturing a porous lightweight material, and at least waste glass, clay, wood charcoal, and a foaming agent are used. These raw materials are pulverized and pulverized to form glass powder, clay powder and wood charcoal powder as in step S2.

Waste glass powder is a powder of about 300 μm or less obtained by crushing and pulverizing a waste glass bottle or the like, and can be produced by recycling waste glass. At this time, instead of the waste glass powder or together with the waste glass powder, a powder of a sintered foam of the waste glass powder can be used. Sintered foam of waste glass powder is a pumice-like material that is made by mixing waste glass powder and a foaming agent and firing it in a heating furnace. Although the powder of the generated debris can be collected and used, a powder obtained by crushing the fired foam may be used.

As the clay powder, it is desirable to use clay such as Shimajiri mudstone as described above. That is, when natural clay is dried and pulverized, most of it becomes a fine powder of about 10 μm or less. Moreover, the wood charcoal which can be manufactured using a waste material is desirable from a viewpoint of recycling. Wood charcoal is also pulverized to a fine powder of about 300 μm or less.

The amount (total weight ratio) of each raw material is 50 to 70 W% for waste glass powder and / or sintered foam powder of waste glass powder, 15 to 30 W% for clay powder, and 15 for wood charcoal powder. About 30 W% is preferable. As a foaming agent, carbonate type 0.5-3.0% or silicon carbide type 0.5-3.0W% may be used alone or in combination. If it deviates from the range of the raw material ratio as described above, the balance of the relative ratio with other raw materials is lost, and a high-quality product cannot be manufactured smoothly.

Then, as in Step S3, these raw material powders are mixed, and then granulated by adding an appropriate amount of water as necessary and kneading. After drying in the state of the granulated material in this way, in Step S4, when sintered and sintered at about 600 to 950 ° C. in a heating furnace for 10 to 30 minutes, the porous structure as in Step S5 is obtained. Quality and lightweight materials can be obtained. When the firing temperature is in the range of about 600 to 950 ° C., the intended porous lightweight material can be produced with good yield. Exceeding the range of 600 to 950 ° C. results in excessive firing, resulting in high fuel cost and reduced production efficiency. When the temperature range is below or the firing time is 10 minutes or less, firing is insufficient and insufficient foaming or insufficient strength. It becomes a defective product.

FIG. 1 shows an example in which each raw material is pulverized and then blended. In this way, instead of separately pulverizing each raw material in steps S1 and S2, waste glass, clay and wood charcoal that have been crushed to some extent are combined. When the mixture is pulverized by a pulverizer and a foaming agent is further added, it is also possible to simultaneously pulverize / mix each raw material and mix the foaming agent.

FIG. 2 is a longitudinal cross-sectional view of the spherical porous lightweight material produced in this way, and as described above, the heat of firing in the firing step causes energy transfer of each substance in the granulated product during foaming. The clay 1 is concentrated on the outside, the glassy 2 is concentrated in the middle, and the carbon 3 is concentrated on the core of the center to form a multilayered substantially spherical body. Such a layered spherical sintered material becomes a ceramic ball, and forms a porous and lightweight artificial pumice with countless fine bubbles. As a result, the water absorption effect and water retention efficiency are also high. Therefore, it is optimal as artificial soil when cultivating plants, and is suitable as a medium used for fields, horticultural facilities, flower pots, etc. when cultivating vegetables, flower buds and other plants. It is also effective as a dehumidifying material and water purification material in various facilities.

The size of the fine bubbles by the foaming is about 0.1 to 1.0 mm, and open-type bubbles (also referred to as open cells) in which the bubbles are partially continuous and communicated are desirable. However, depending on the type and amount of the foaming agent, the firing temperature, the length of the firing holding time, etc., the degree of open-type bubbles and independent bubbles can be freely selected and set.

In the case where wood charcoal is omitted as a raw material in step S1, and waste glass powder and / or a sintered foam powder of waste glass powder, a clay powder, and a granulated product of only a foaming agent are fired, FIG. Since there is no wood charcoal in FIG. 3, a glassy layer 2 is mainly formed in the central core as shown in FIG. In this way, if there is no charcoal layer, the effect derived from wood charcoal cannot be expected, but the action of foamed glass and foamed clay can be expected to achieve the water absorption effect and water retention efficiency as described above. It can be used as artificial soil for cultivation and is also effective as a dehumidifying material and water purification material. In particular, since the outer side is a clay-like foam layer, it is optimal for plant cultivation.

As described above, when waste glass powder, clay powder, and charcoal powder are baked in a granulated state together with a foaming agent, the energy transfer of each substance occurs during foaming due to the calcination heat, and the outer layer is used for plant cultivation. Useful clay, glassy in the middle layer, wood charcoal layer in the center of the core, and the whole is a foam, so the water absorption effect and water retention effect are high, artificial when growing plants It is a lightweight material that is extremely effective as soil, dehumidifying material, and water purification material.

It is a flowchart which shows the manufacturing method of the porous lightweight material by this invention. It is a longitudinal cross-sectional view of the spherical porous lightweight material which consists of waste glass powder, clay powder, and wood charcoal powder. It is a longitudinal cross-sectional view of the spherical porous lightweight material which consists of waste glass powder and clay powder.

Explanation of symbols

1 Clayy layer 2 Glassy layer 3 Charcoal layer

Claims (5)

A porous lightweight material obtained by firing a granulated material obtained by mixing at least waste glass powder and / or a sintered foam powder of waste glass powder, clay powder, and a foaming agent. 2. The porous lightweight material according to claim 1, wherein a granulated material mixed with a powder of wood charcoal is fired. Production of porous lightweight material characterized in that at least waste glass powder and / or powder of sintered foam of waste glass powder, clay powder and foaming agent are kneaded with water, granulated, and then fired. Method. The method for producing a porous lightweight material according to claim 3, wherein the powder of the charcoal is kneaded with water together and granulated, followed by firing. The waste glass powder and / or the sintered glass powder of the waste glass powder is 50 to 70 W%, the clay powder is 15 to 30 W%, the charcoal powder is 15 to 30 W%, and the foaming agent is 0. The method for producing a porous lightweight material according to claim 4, wherein the firing temperature is 600 to 950 ° C.

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