JP2007210872A - Method of manufacturing super lightweight ceramic roof tile clay - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a simple method of manufacturing super lightweight ceramic roof tile clay as a novel resource for ceramic raw material by easily and artificially converting/forming flyash balloon (FAB) as a novel raw material into the super lightweight ceramic roof tile clay in the manufacture of a lightweight ceramic roof tile which necessitates stable supply capacity to allow large consumption through a long period and the development of lightweight roof tile clay having excellent plasticity/firing crystallinity/fire resistance or the like. <P>SOLUTION: The super lightweight ceramic roof tile clay is manufactured by adding a large quantity of the FAB to plastic roof tile raw soil, mixing high fire resistant/high heat capacity natural kaoline as an aluminum source, silica sand as a silica source and weathered granite/wasted roof tile chamotte as other extenders with natural feldspar to increase the mutual fusion/melting crystallization ability which is a novel technology, humidifying in a pulverizer or a kneader without liquefying the compound slurry-like and after that, homogeneously and finely mixing under a normal temperature and pressure to practically humidify and knead. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

The present invention belongs to the field of production of ultralight earthenware clay for producing ultralight earthenware tiles, and is included in coal ash fly ash for the production of ultralight earthenware tiles.・ A small amount of fly ash balloon (FAB) as shown in 14 is used as a main ingredient of the light weight agent, and a large amount (less than 10% by weight, 10% by weight or more means a large or large amount) is added, and one tile Reduces the weight of natural tile raw clay (clay) that hits and consumes and reduces the weight by applying the low specific gravity of the lightening agent without changing the total volume per piece of current ceramic tile. Technology. Further, it is a great feature that an inorganic hollow fly ash balloon having an apparent specific gravity in the range of 0.6 to 0.8 is added and blended as a main raw material of the lightening agent. The combined fired tile is a two-layered inorganic coating layer that is uniformly coated, and can be reduced in weight to an apparent specific gravity of 1.0 or less by an infinite number of microspheres having an independent hollow structure. . That is, the specific gravity of the general earthenware tile is 2.0 to 2.3, but in the present invention, the specific gravity of the fired product can be significantly reduced by the ratio condition of blending the light weight agent fly ash balloon, for example, It is possible to reduce the weight of the present ceramic tile of 2.4 kg to 3.0 kg to 50% or less. The present invention relates to a method for practically manufacturing an ultralight tile clay necessary for manufacturing the ultralight earthenware tile.

It can be said that the earthenware tile industry has neglected the research and development of lighter tiles while consuming large amounts of natural tile clay (plastic clay) through mass production of tiles. In particular, after the Great Hanshin Earthquake, as rooftop materials for wooden houses are being reduced in weight as a countermeasure against earthquakes, the groundwork of the ceramic tile manufacturing industry has been shaken because ceramic tiles are too heavy. In addition, the problem of reducing the load weight of roof tiles in wooden houses is strongly demanded to establish and put to practical use a method for producing ultralight ceramic tile clay for producing ultralight ceramic tiles.

Along with the problem of reducing roof tiles, the pottery tile industry has not been researching and developing alternative resources, as mass consumption of natural tile clay (plastic tile clay) has progressed for many years due to mass production of tiles. As for alternative resources, it is a serious situation that causes unstable raw material shortages. Against this background, countermeasures against the depletion of natural roof tiles are an issue for the industry.

Furthermore, the environmental pollution of large automobile waste gas caused by heavy truck transportation leads to global warming due to carbon dioxide emissions, and the weight reduction of the load within the specified load weight range per lightweight ceramic tile. This leads to the effect of suppressing the emission of carbon dioxide for transportation. In summary, it is possible to transport with the number of roof tiles increased by the weight of the weight reduced by one transport within the specified weight range. For example, 2.4kg per roof tile is as light as 50% of 1.2kg. In this case, it is possible to carry twice as many sheets as in the past by carrying a single roof tile, and the number of times of carrying two times is sufficient. That is, it leads to a practical effect of reducing the emission of carbon dioxide contained in the exhaust gas to 50%. Against this background, establishment and practical application of a method for producing an ultralight ceramic tile clay for producing an ultralight ceramic tile is strongly desired.

The fly ash balloon (FAB) separates and refines an inorganic hollow material lighter than water contained in coal ash fly ash. Fly ash, fly ash balloons, etc. are discharged from the coal-fired power plant near the inventor's address as industrial waste from a large amount of coal ash every year. It has been disposed of in landfills. The amount of coal ash generated nationwide reached about 9.2 million tons at the end of 2002, and depending on this disposal method is concerned that it will eventually cause environmental destruction.

Regarding past technologies such as lightweight ceramics, for example, Patent Document 1 describes the light weight effect of ceramics obtained by selecting and adding fly ash balloons (FAB) with high fire resistance, but the fire resistance of the fly ash balloons Is in the range of SK27 or SK28 shown in FIG. 14, and is excellent in fire resistance as a raw material of aggregate for the production of earthenware tiles. However, in the present invention, natural kaolin shown in FIGS. 3 and 5 is selected as an aluminum source for the homogeneous fire resistance improvement of the entire product, and natural feldspar as shown in FIG. As practical use. Furthermore, utilizing the fire resistance and crystallinity of silica as a silica source, it is an abundant resource nationwide as an alternative, and the natural silica sand shown in FIG. 2 is specified and selected, and the silica sand is used as an aggregate. However, the technical content of this technology is very different from that of Patent Document 1 as a practical technology that can be used for mass production.

It does not clearly indicate the specific proper nouns and characteristic principles of the lightening agent as in Patent Document 2, but simply uses a lightening agent marketed as an imported foreign lightening agent. Techniques related to lightweight pottery that have been used with several examples have also been proposed. Such a point is a part in which the technical contents are greatly different from those of the present invention. Furthermore, the technical content of the present invention is significantly different from Patent Document 2 as a practical technology capable of mass production.
JP-A-11-43381 Patent No. 3411242

Traditionally, ceramic tiles have excellent heat insulation, freezing and durability, but are heavy, and the biggest drawback is that they put too much burden on producers, distributors, distributors, contractors, consumers and the environment. It was. Especially in our country, which is an earthquake-prone country, it is required to reduce the total weight of roofing materials by reducing the weight per tile as a seismic measure related to life. Specifically, we have reduced the average weight of 15 tons to 10 tons. The tile industry has been a practical issue. However, for the production of earthenware tiles that can be reduced in weight on the producer side, it is excellent in plasticity, moldability, fired crystallinity, fire resistance, etc., and also has lightweight characteristics and can withstand large-scale consumption over a long period of time. It has been essential to develop tile clays that have the above-mentioned requirements and can be stably supplied over the long term. Furthermore, in terms of logistics, the transportation of heavy objects is a major cause of global warming due to a large amount of carbon dioxide emission due to the large consumption of fossil fuels, and the techniques described in Patent Documents 1 and 2 described above are various utilization tests. However, it has not yet been put into practical use that can be mass-produced.

Regarding the research and development of alternative raw materials for tiled clay, it can be said that the pottery tile industry has continued to consume large amounts of natural tiled clay (clay) through mass production of tiles, and has not researched and developed alternative tiled clay. This is a serious situation that causes an unstable shortage of raw materials, and measures to deplete natural roof tiles are an issue for the industry. Therefore, the present invention specifically achieves ultra-lightening of the earthenware tile, and at the same time, the increase in the composition by adding a large amount of the lightening agent fly ash balloon shown in FIG. If the conditions for adding and combining crystal accelerators, aggregates, etc. are satisfied, it will lead to a significant reduction in the consumption of natural tile raw soil. It can be said that the invention of this technology has made it possible to establish a practical application of a system that greatly saves the consumption of pottery tile natural earth.

For the research and development of such light weight agents, the inventor can use a fly ash balloon (FAB), which is an inorganic hollow body capable of producing ultralight earthenware tiles, as a raw material for light weight materials. The present invention was completed with an ingenuity in solving the problem that not only focused on, but also could be put into practical use and easily converted into ultra-light ceramic tile clay. In addition, the new technology for producing and converting the fly ash balloon into an ultra-lightweight ceramic tile clay that can be used practically as an effective resource for stable ceramic materials in the manufacture of lightweight ceramic tiles has a simple generation method, and has established its effectiveness and practical application. The invention should be able to be made, but as shown in FIG. 10, the uniqueness and effectiveness of the present invention also exist in this respect.

The solution of defects such as the cristobalite phenomenon and the cold cracking caused by the phenomenon that cause a large volume expansion at around 250 ° C. during the firing of the product must be an invention that can be put into practical use with inevitable requirements that cannot be avoided.

In the present invention, as shown in FIG. 1, in order to solve the above-mentioned problems, a large amount of inorganic hollow fly ash balloon is blended as a raw material of a lightening agent into a plastic clay, which is a main raw material of earthenware tile. It is characterized by. In addition, an aluminum source for improving fire resistance, a fusion accelerator, and a crystallization accelerator are added to the pre-formation compound of the above composition and homogenized, so the mixture is stirred and homogenized with a large pulverizer or earth smelter. It is possible to produce an ultralight earthenware tile clay for the production of ultralight earthenware tiles, which is characterized by employing a technique of finely mixing and kneading finely, and performing a hydro-humidification kneading process.

As a second means for solving the problem, a compound product produced by adding and combining a large amount of inorganic hollow fly ash balloon (FAR) shown in FIGS. 7, 8, 9, 13, and 14, the entire homogeneous fire resistance Alumina (Al ₂ O ₃ ) and kaolinite (Al ₂ O ₃ .2SiO ₂ .2H ₂ O) having the characteristics of melting point 2050 ° C. and boiling point 3000 ° C. as an aluminum source in order to improve caloric properties and shown in FIG. ), And the natural kaolin mineral shown in FIGS. 3 and 5 mainly composed of halosite (Al ₂ O ₃ .2SiO ₂ .4H ₂ O), and the fire resistance of silica dioxide SiO ₂ as the silica source. Moreover, the ultralight ceramic tile clay shown in FIG. 10 can be manufactured for the production of an ultralight ceramic tile characterized by suitably combining the kaolin and artificially improving the high fire resistance and high calorific value. .

The other aluminum source is an aluminum compound with improved fire resistance selected from a group of substances such as aluminum hydroxide, soluble aluminum salts, and various hydrated aluminas. Further, since the cause of defects such as cristobalite phenomenon and cold cracking is a phenomenon caused by a shortage of aluminum source with respect to the silica source, the present invention adds the natural kaolin shown in FIGS. It was solved by increasing (Al ₂ O ₃ ) and compounding.

As a third means to solve the problem, natural silica sand or weathering, which is silica silica as a silica source and the undissolved residue is used as an aggregate to improve the melt crystal strength of inorganic hollow fly ash balloons that have weak melt crystal strength. By selecting granite, combining silica dioxide SiO ₂ from the mineral group, a super lightweight earthen tile clay can be produced by a method characterized by increasing the firing strength of the fired tile.

Silica as a silicic acid raw material ranges from a single crystal of quartz to an aggregate of quartz. Practically, the natural silica sand shown in FIG. 2 having a high purity of the silica component that can be used together with the aggregate that remains undissolved is suitable.

As a fourth problem solving means, the mineral feldspar mineral shown in FIG. 6 is selected in order to improve the melt crystal force of the inorganic hollow fly ash balloon having the weak melt crystal force property, and the plastic raw material is selected. Firing of fired roof tiles by increasing the fusion power of the fly ash balloon shown in FIGS. 7, 8, 13 and 14 with fusion, bonding, and crystal fusion, and improving the mutual fusion power with other additive materials and aggregates. The ultralight earthenware tile clay shown in FIG. 10, which is characterized by increasing the strength, can be manufactured.

Therefore, in order to efficiently dissolve, fuse and bond inorganic hollow fly ash balloons (FAB) in a short and simple process into kneaded clay, a fusion accelerator called feldspar K ₂ OAL ₂ O ₃ 6SiO ₂ is regularly added. Therefore, it was necessary to develop and commercialize a production system that stirs and kneads homogeneously. Further, the feldspar orthoclase (KAlSi ₃ O _8), albite (NaAlSi ₃ O _8), there is a anorthite _(CaAl 2 _Si 2 _{O 8)} and the main minerals of barium feldspar _(BaAl 2 _Si 2 _{O 8)} By using it effectively according to the application, including feldspar-like gravel, the manufacturing method of the ultralight earthenware clay was completed.

As a fifth problem solving means, inorganic hollow fly ash balloon (FAB) added in large quantities to the plastic tile base soil shown in Fig. 1 and natural kaolin, feldspar, quartz sand, weathered granite, etc. The technology to produce ultralight earthenware tile clay for the production of ultralight earthenware tiles does not liquefy these compounds in a slurry state. The ultra-lightweight earthenware tile clay can be manufactured with the characteristic of humidifying and kneading using a practical method that employs the technique of stirring and mixing homogeneously and finely and kneading.

In nature, clay minerals are mainly kaolinitic clay, and the contained aluminum silicate mineral weathering action is repeated, and the effects of dissolution, leaching and seabed weathering are affected by hydrothermal alteration by acidic hot water for a long time. It is generally considered to generate. However, as a practical artificial production method, it is necessary to use a stirring / kneading technique in which the compounds are uniformly and uniformly mixed well by the above-described method in a short and simple process.

In order to satisfy the moldability when producing the current earthenware tiles and the ultra-lightweight earthenware tiles of the present invention, plastic tiles that are necessary raw materials have recently been depleted, but their depletion countermeasures and research and development have been overlooked. It was. The ultralight earthenware tile clay shown in FIG. 10 is produced for the production of ultralight earthenware tiles using inorganic hollow fly ash balloons as a lightening agent, as shown in FIGS. 7, 8, 9, 13, 14 and the like. Regarding technology development, there has never been a case where practical application that leads to commercialization that enables mass production in a factory has been established. Also, according to the law on the promotion of the use of recyclable resources enacted in 1991, fly ash and fly ash balloons that are discharged in large quantities from thermal power plants are designated as designated by-products, and the use of reclaimed resources can be expanded. Due to the established circumstances, fly ash balloons discharged from coal-fired thermal power plants can be manufactured artificially to make ultra-light earthenware tile clay by utilizing the present invention. It can be used as a raw material for an effective and stable supply resource, and solves the difficult problem of lightening ceramic tiles behind the ceramic tile industry.

Furthermore, the present invention provides an industrial waste inorganic hollow body fly ash balloon (FAB) as a stable raw material that can be trusted over a long period of time as a lightening agent for the production of effective lightweight earthenware tiles, and artificially ultralightweight earthenware tiles. It should be characterized by being able to efficiently and easily be converted to clay. In addition, in the conversion of the fly ash balloon into an artificial and ultra-lightweight earthenware clay, a small amount of a fusion / melting accelerator and a crystallization accelerator of a silica source are added in addition to the aluminum source to liquefy the slurry. First, it is possible to produce ultralight earthenware tile clay at room temperature by humidifying and kneading using the technique of stirring and mixing homogeneously and finely under normal temperature and normal pressure conditions.

The large-scale consumption of natural tile clay (clay) due to the mass production of ceramic tiles over the years has led to the depletion of natural tile clay and has become an issue for the industry. The present invention specifically achieves ultra-lightening of earthenware tiles, and at the same time, it is possible to increase the weight by adding a large amount of lightening agent fly ash balloon, fire resistance improver, fusion accelerator, crystal accelerator, aggregate If the conditions for each addition / combination are satisfied, it will lead to a significant reduction in the consumption and consumption of natural roof tile. The invention of this technology makes it possible to establish a practical system that greatly saves the consumption of pottery tile natural raw material, and alleviates the difficult problem of depletion of tile tiles behind the pottery tile industry. The

The particle size distribution of the inorganic hollow fly ash balloon (FAB) shown in FIGS. 8 and 9 is silica dioxide SiO having a non-uniform particle size / particle with a particle size distribution range of 44 μm to 296 μm, mainly from 124.45 μm to 148 μm. ₂ and an ultrafine particle body of high fire resistance mainly composed of alumina oxide Al ₂ O ₃ . Most of the coking coal used in thermal power plants is imported from foreign countries, and its components differ depending on the origin and combustion conditions. The weight ratio (Al ₂ O ₃ : SiO ₂ ) of silica and alumina contained in the inorganic hollow fly ash balloon is about 63 parts by weight: 30 parts by weight, in addition to 1.7 parts by weight of iron, such as magnesium and calcium. It contains several kinds of heavy metals such as ultra-trace amount of titanium oxide (TiO ₂ ) and zinc oxide, and is colored gray because unburned carbon remains. Further, the inorganic hollow body fly ash balloon has no viscosity or plasticity and is extremely poor in moldability. In addition, the calcination crystal power is weak, and there is a concern about the crystallinity / meltability necessary for the baked product and insufficient heat amount.

As an example of the new technology 1, as shown in FIG. 10, in order to obtain the plasticity and formability of the produced ultralight earthenware tile clay, 10 to 90 parts by weight of the tile raw earth and the inorganic hollow body fly ash balloon are used. The compound blended in the range of the part uses the properties of viscosity, plasticity and fired strength inherent in the tile roof. Further, the tile raw earth used is a hexagonal layer of kaolinite / montmorite clay as shown in FIG. 10, and the particle size distribution is 20 μm or less with a particle size distribution of 20 μm or less. %, And a plastic raw soil having a particle size distribution amount of around 40% was suitable.

Regarding the blending ratio of the inorganic hollow body fly ash balloon (FAB) as an example of the new technology 2, in order to determine the plasticity and moldability of the artificial tile clay, the blending ratio with the tile raw clay (clay) is 10 wt. It is preferable that the mixing ratio in the range of 30 parts by weight to 90 parts by weight and the mixing ratio of the clay raw clay (clay): inorganic hollow body fly ash balloon is in the range of 30:70 to 40:60 parts by weight.

As shown in FIG. 14 for the blending ratio of natural kaolin as an example of the new technology 3, a high fire-resistant inorganic hollow body fly ash balloon (FAR) is suitable as an aggregate, but the product is earthen tile clay. The effect of improving the overall fire resistance and the amount of important heat is poor. Therefore, it is essential to add alumina having a melting point of 2050 ° C. and a boiling point of 3000 ° C. as shown in FIG. 11. As an alternative, the addition of natural kaolin shown in FIGS. 3 and 5 is in the range of 1 to 15 parts by weight. And preferably in the range of 5 to 8 parts by weight to compensate for the lack of fire resistance. The fire resistance of natural kaolin is preferably in the range of SK No. 33 to SK No. 36 according to the second-type Zeger cone measurement method. The kaolin used is mainly composed of kaolinite and halosite in the kaolin deposit. As another alumina source, it was confirmed that weathered granite also had an additive effect.

In order to improve the calcining crystal strength and calcining strength of coal ash as an example of the new technology 4, natural feldspar shown in FIG. 6 is added to the tile clay and coal ash compound in the range of 1 to 15 parts by weight. Addition of 8 parts by weight preferably promotes dissolution and adhesion of tile clay, silica sand, weathered granite, waste tile chamotte and inorganic hollow fly ash balloon (FAB), and mutual dissolution due to the characteristics of feldspar The improvement in hardness and strength of the fired product was confirmed.

Natural silica sand shown in FIG. 2 is added in the range of 1 to 25 parts by weight, preferably 15 parts by weight, as an alternative to silica as an example of the new technology 5. The silica content purity of the silica sand is preferably 90% or more. In addition, the effect was confirmed that the undissolved residue can be used as an aggregate, and a partial effect by adding weathered granite as another silica source was also confirmed.

As another compounding material as an example of the new technique 6, chamotte obtained by finely pulverizing waste tiles was used in an amount of 1 to 20 parts by weight, preferably 10 parts by weight as an increase / combination material. The effect also confirmed the use effect of the aggregate. As other applications, it was confirmed that the recycling of waste in the environment and resources field can be established for the disposal of waste tiles.

The newly produced artificial lightweight tile clay as an example of the new technology 7 includes a raw plastic raw material, an inorganic hollow fly ash balloon, kaolin, feldspar, quartz sand, weathered granite, as shown by the flow in FIG. After adding appropriate amount of waste tile chamotte and adding water / humidification, careful mixing and kneading technology is carried out with a pulverizer or earth smelter. In order to make the kneading of these compounds uniform and homogeneous, the kneading time is carried out on the basis of a range of 30 minutes to 60 minutes per cubic meter. The hydrothermal reaction of the synthesis of kaolinite (Al ₂ O ₃ .2SiO ₂ .2H ₂ O) constituting kaolin is classified and classified by reaction. In general, these reactions are observed at 170 ° C. to 350 ° C., and the reaction time required for crystallization varies significantly depending on predetermined setting conditions such as reaction temperature. The fly ash balloon shown in FIG. 7 of the inorganic hollow body to be used is a silica alumina of a hollow spherical balloon centered on particle size particles, mostly glassy, and the presence of quartz and a small amount of mullite is confirmed. Further, as a kaolinite synthesis raw material for the inorganic hollow fly ash balloon, these mixtures are burned at a high temperature in the firing kiln, and the reactivity itself is low, and a high hydrothermal treatment temperature is required. The halosite (Al ₂ O ₃ 2SiO ₂ 4H ₂ O) constituting kaolin exhibits an endothermic peak at 100 ° C to 200 ° C, an endothermic reaction at 500 ° C to 600 ° C, and an exothermic reaction at 900 ° C to 1150 ° C. Is essentially the same as Kaolinite.

The present invention will be described with reference to FIG. 1 by way of example with reference to the accompanying drawings. FIG. 1 shows a flow chart of the manufacturing process. Here, reference numeral 1 is a plastic base, reference numeral 2 is the fly ash balloon (FAB), which is a lightening agent, reference numeral 3 is the kaolin, which is an added aluminum source, reference numeral 4 is the feldspar, a melt crystallization accelerator, and reference numeral 5 is silica. Silica sand, which can be used together with aggregates of the source silica and dissolved residue, symbol 6 is weathered granite, symbol 7 is waste tile chamotte, symbol 8 is an agitation / humidification (hydration) step, symbol 9 is an agitation / humidification kneading step The product indicated by reference numeral 10 in FIG. 10 is an ultralight ceramic tile clay. As shown in the figure, as a raw material for the lightening agent in the plastic clay, the aluminum source and the crystallization accelerator are added uniformly and homogeneously to the compound before production containing a large amount of the fly ash balloon. It includes each step of artificially producing ultra-lightweight earthen tile clay by humidifying and kneading using a kneading technique.

In the production of the artificial lightweight tile clay of the present invention, the fire ash balloon of the sample 8 shown in FIGS. 7, 8, 9, 13 and 14 affects the formation and conversion of the artificial lightweight tile clay. FIG. 4 shows the effects of the promoters of Sample 3 and Sample 3 for enhancing the properties. The implementation here was to confirm the production of artificial tile clay by changing the production conditions of the blending amount / addition amount of each accelerator, and carried out with Comparative Examples 1, 2, and 3 shown in the table for each sample. Examples 1, 2, 3, 4, 5, 6, and 7. That is, in each humidifying kneading treatment, Comparative Example 1 is a simple compound (hereinafter referred to as “compound”) of plastic raw earth and fly ash balloon, in which each accelerator is not added, and Comparative Example 2 is natural to this compound. Ferrite and quartz sand were used as crystal accelerators. In Comparative Example 3, the natural feldspar and the quartz sand were used as the crystal accelerator added to this compound, and the natural kaolin was used as a fire resistance accelerator as an aluminum source. Examples 1-7 carry out by changing the compounding quantity of the fire resistance and crystallinity promoter to add, and represent the effect. In addition, the humidification kneading treatment time was set to be within 30 minutes for the compound amount of 0.1 cubic meter or less.

FIG. 7 shows the amount of components contained in Sample 8 fly ash balloon (FAB) in Comparative Examples 1, 2, and 3. For qualitative analysis of sample 8 by fluorescent X-ray, 10 g of sample was divided and placed in a tungsten carbide container and pulverized with a vibration mill. The pulverized product was placed in a weighing bottle and dried at 105 ° C. ± 5 ° C. for 12 hours or more, and then allowed to cool in a desiccator. The dried product was fired in a porcelain crucible at 1050 ° C. for 2 hours. This fired product and 10 times its amount of lithium tetraborate were placed in a platinum (Pt) 95% + gold (Au) 5% alloy pan and melted at 1200 ° C. to produce a glass bead. This glass speed was analyzed with a fluorescent X-ray qualitative analyzer SYSTEM 3270E manufactured by Rigaku Corporation. Therefore, Au in the detection element contains contaminants from the alloy dish. From the above analysis results, it is confirmed that the fly ash balloon satisfies the conditions as a suitable lightening agent raw material for producing an ultralight ceramic tile clay that can be artificially manufactured.

The content of the feldspar contained in Sample 3 in Comparative Examples 1, 2, and 3 is shown in FIG. Sample 3 was placed in a weighing bottle, dried at 105 ° C. ± 5 ° C. for 12 hours or more, and then allowed to cool in a desiccator. The dried product was fired in a porcelain crucible at 1050 ° C. for 2 hours. This fired product and 10 times its amount of lithium tetraborate are placed in a platinum (Pt) 95% + gold (Au) 5% alloy pan and melted at 1200 ° C. to produce a glass bead, manufactured by Rigaku Denki Co., Ltd. Were analyzed using a fluorescent X-ray qualitative analyzer SYSTEM 3270E. From the above analysis results, it is confirmed that the feldspar of Sample 2 satisfies the conditions as a suitable raw material as a crystal accelerator.

FIG. 5 shows the content of the kaolin (sample 3) in Comparative Example 3. About 10 g of sample 3 was collected and placed in a tungsten carbide container, and first ground by a vibration mill. The pulverized product was put in a weighing bottle, dried at 105 ° C. ± 5 ° C. for 12 hours or more, then allowed to cool in a desiccator, and this dried was precisely weighed in a magnetic crucible and baked at 1050 ° C. for 2 hours. The fired product was pulverized and dried in an agate mortar, and 10 times the amount of lithium tetraborate was used as a solvent to prepare a glass bead. The glass beads were analyzed with a fluorescent X-ray analyzer. FIG. 3 shows a thermal expansion test of Sample 3, and the average linear thermal expansion coefficient (room temperature to 500 ° C.) is a raw material having a power of 3.92 × 10 −6. From the above analysis results, it is confirmed that the kaolin mineral as the aluminum source satisfies all conditions suitable as an accelerator for improving the refractory heat quantity.

In order to confirm the effect of the comparative example 3, it shows in FIG. For the qualitative analysis of sample 6 organism by fluorescent X-ray, the product sample was placed in a tungsten carbide (WC) container and pulverized by a vibration mill. The finely pulverized product was dried and allowed to cool at 105 ° C. to 110 ° C., then precisely weighed in a magnetic crucible and heated at 1050 ° C. in an electric furnace to confirm the loss on ignition. Using a sample after ignition, a glass bead prepared by melting 10 times the amount of lithium tetraborate in a platinum (Pt) 95% + gold (Au) 5% alloy dish at 1200 ° C. was analyzed. . From the above analysis results, it is confirmed that the product satisfies suitable conditions for the accelerator for improving the refractory calorific value.

As for the explanation of Examples 1 to 7, 5% of the natural kaolin of Sample 3 (Examples 1 to 4), 7% of the fly ash balloon as a fire resistance improvement accelerator of the fly ash balloon (FAB) of Sample 8, % Of the natural kaolin (Examples 5 to 7), 8% of the natural feldspar of Sample 3 (Examples 1 to 7) and 10% of the natural silica sand were added, respectively, in the table as in the above comparative example. As shown, the production of ultralight ceramic tile clay is observed. Therefore, it is noted here that it is possible to artificially produce ultralight ceramic tile clay.

In the fluorescent X-ray qualitative analysis of the ultralight earthenware clay product obtained in Example 3 above, the content of refractory alumina oxide Al ₂ O ₃ is 20 wt%, as shown by sample 6 in FIG. The content value of silica dioxide SiO ₂ exhibiting fire resistance and crystallinity was 66 wt%.

In the fire resistance test, SK No. 20 was measured, and the content of iron oxide Fe ₂ O _{3 that} caused burnt organisms to turn red showed a measured value of 2.5 wt%. Shown color. The other inclusions are as shown in FIG.

In the particle size distribution measurement, 2% to 5 μt silt measures 15%, and the particle size of the ultrafine particles of 2 μm or less in the form of hexagonal layers of kaolinite clay or montmorillonite clay shown in FIG. The distribution measurement showed 40%. This numerical value is high fire resistance, high plasticity and high formability.

In the firing test of the product, firing was performed for 2 hours from room temperature to 200 ° C, 3 hours from 200 ° C to 500 ° C, 5 hours from 500 ° C to 1000 ° C, and 2 hours 30 minutes from 1000 ° C to 1200 ° C. The measurement method was fired in a 16 KW siliconite electric furnace, and it was confirmed that the crystallinity of the fired product sufficiently satisfied the elements of ceramic tiles fired at 1200 ° C.

The artificial ultralight earthenware clay clay thus produced by mass blending of the fly ash balloon (FAB) is an accelerator for plasticity, moldability, fire resistance, crystallinity, meltability, and other blending materials. The chemical compounding, uniform agitation, and kneading processes, etc., can be controlled by adjusting the conditions of the crusher, earth smelter, etc., and suitable and practical quality control is possible. can do. Furthermore, since the present invention does not liquefy into a slurry, a complicated process of heating while applying pressure such as an autoclave process is omitted, so that a rapid practical application of a large-scale production process can be applied.

And, the fly ash balloon (FAB) included in the fly ash that is mass-discharged / discarded from the thermal power plant, solving the super light weight of earthen tiles and the resource depletion problem of natural clay (soil) Reusing and commercializing industrial waste as a recycling resource helps to prevent environmental destruction, and reduces the consumption of natural plastic roof tile (clay) required for production per piece of earthenware tile. It leads to the super light weight of the earthenware tile that has been considered heavy. In addition, a new production method for ultralight earthenware clay will be established by stabilizing the supply of raw materials and recycling system.

It is a production | generation flowchart which shows the manufacturing process which is one Example of this invention. It is a fluorescence X-ray-diffraction figure of the silica source (sample 2 silica sand) added by the comparative example 3 and the Example. It is explanatory drawing which shows the differential thermogravimetric analysis curve of the aluminum source (sample 3 kaolin) added by the comparative example 3 and the Example. It is a graph which shows the comparative examples 1-3 and the examples 1-7 which are illustrated. Fluorescent X-ray qualitative analysis test report of natural kaolin used as sample 3 in Comparative Example 3 and each example as an aluminum source to be exemplified, and main components such as content of silica SiO ₂ and alumina Al ₂ O ₃ Represents. A qualitative analysis test report and Comparative Examples 2 and 3 as illustrated fused-melt-crystallization accelerator X-ray fluorescence of natural feldspar used in each example as a sample 3, containing silica SiO2 and alumina Al ₂ O ₃ Represents the main component such as the amount of ingredients. Fluorescent X-ray qualitative analysis test report of sample 8 fly ash balloon used in the comparative examples and examples as the main raw material of the illustrated lightening agent, including content of silica SiO ₂ and alumina Al ₂ O ₃ Represents the main component. Fluorescent X-ray qualitative analysis test report of sample 8 fly ash balloon (FAB) used in the comparative example and each example as the main raw material of the illustrated lightening agent. The amount etc. are expressed in a graph. Fluorescent X-ray qualitative analysis test report of sample 8 fly ash balloon (FAB) used in the comparative example and each example as the main raw material of the illustrated lightening agent. Express quantity etc. with numerical values. It is a qualitative analysis test result by fluorescent X-rays of the sample 6 product (generated ultralight earthenware clay clay) in the comparative example 3 and each example illustrated, and the content of silica SiO ₂ and alumina Al ₂ O ₃ Represents the main component content. Electron micrograph of alumina Al ₂ O ₃ (aluminum oxide) powder used as an aluminum source magnified 20,000 times, used for improving fire resistance as exemplified. Kaolinite / Montmorinite hexagonal layered crushed sediment with a grain size of 2 μm or less, which is a 20,000 times enlargement of the plastic ground of the other party mixed with the fly ash balloon illustrated Electron micrograph of A photomicrograph obtained by magnifying the exemplified lightening agent fly ash balloon 500 times shows a particle size distribution with uneven particle size. It is a fire resistance measurement table | surface of the fly ash balloon (FAB) of the sample 8 as a lightening agent to illustrate, It represents that the fire resistance of this fly ash balloon is SK28.

Explanation of symbols

1 roof tile soil (plastic clay)
2 Aluminum source (fire resistance improver → natural kaolin mineral)
3 Melting accelerator (natural feldspar mineral)
4 Silica source (Combination with natural silica sand and aggregate as a crystal accelerator)
5 Weathered granite 6 Waste tile chamotte 7 Water treatment 8 Humidification and kneading treatment with pulverizer and earth smelter 9 Production (production of ultralight earthenware tile clay)

Claims (7)

In order to reduce the weight without changing the total volume per piece of earthenware roof tile, the fly ash balloon (FAB) of inorganic hollow body with apparent specific gravity in the range of 0.6 to 0.9 is used as the main raw material of the lightening agent. As a main feature, it is added to and combined with silica, alumina, and a plastic clay for the production of earthenware tiles composed mainly of detrimental deposits of ultrafine particles of 2 μm or less. Moreover, the fire resistance of natural roof tiles is preferably SK18 or higher. In order to improve the fire resistance of the roof tiles and their mixed soil compounds, an aluminum source, a fusion accelerator / crystallization accelerator, silica. Since each accelerator such as a source is added and homogenized, it is characterized by a humidified kneading process using a technique of finely stirring and kneading finely. Therefore, the manufacturing method of the ultralight earthenware tile clay for manufacturing the ultralight earthenware roof tile characterized by baking the obtained kneaded product to hollow body porous at around 1200 degreeC after shaping | molding, and reducing weight. The fly ash balloon (FBA) has a high fire resistance and is in the range of SK27 to 28 of the second type Zegel cone measurement, which is suitable as an aggregate. The ratio of the contrast ratio of the plastic raw earth: fly ash balloon is in the range of 10:90 to 90:10 parts by weight for each application. The fly ash balloon has a hollow structure that is lighter than water and has a hollow structure, and the particle size of fine and small spheres is in the range of about 40 μm to about 300 μm. In addition, the present invention has a two-layer structure in which the entire spherical surface is uniformly coated with an inorganic coating layer mainly composed of a silicate compound, and manufactures an independent hollow body porous ultralight ceramic tile. A method for producing an ultralight earthenware clay according to 1. The fly ash balloon, a light weight agent that is added in large quantities (less than 10%, 10% or more means large quantity or large quantity), is highly fire-resistant. In order to improve the fire resistance and calorific properties of the entire unproduced product uniformly, natural kaolin minerals mainly composed of alumina (aluminum oxide Al ₂ O ₃ ), kaolinite and halosite are selected as the aluminum source. In addition, silica dioxide SiO ₂ contained in silica as a silica source is also selected to improve fire resistance, and these main component minerals contained in high fire-resistant clay are combined to artificially increase the fire resistance and heat capacity. The method for producing an ultralight earthenware clay according to claim 1, wherein the method is preferably improved. Silica dioxide SiO ₂ is selected by selecting natural silica sand or weathered granite as silica source silica, as a crystal accelerator for improving the melt crystal strength of fly ash balloons, which has the disadvantage of weak melt crystal strength. The method for producing an ultralight earthenware tile clay according to any one of claims 1 to 3, wherein a combination of minerals and minerals is combined to increase the firing and crystal strength of the fired tile. In order to improve the melt crystal strength of the fly ash balloon, a natural feldspar mineral is selected as a fusion accelerator, and the fusion power of the tile raw earth and the ungenerated fly ash balloon is increased. The ultra-lightweight earthenware tile clay according to any one of claims 1 to 4, wherein the fusion strength between the other additive raw materials and aggregates of claim 1 is improved to increase the firing strength of the fired tile. Production method. The technology to produce artificial lightweight tile clay by combining fly ash balloon to be added to the tile clay and natural kaolin, feldspar, quartz sand, weathered granite, etc. and waste tile chamotte, liquefies these compounds into a slurry. In addition, the above-mentioned humidifying kneading treatment is carried out using a technique of stirring in a pulverizer or earth smelting machine, and mixing and kneading the whole compound uniformly at room temperature and normal pressure. A method for producing an ultralight ceramic tile clay according to claim 1. The hollow porous ultra-light earthenware roof tiles fired from the ultra-light tile clay according to the previous claim have an apparent specific gravity of 0.8-2. 2. The production of ultralight earthenware tile clay according to claim 1, characterized in that the water supply rate is less than 6.0 and has a low water supply rate of less than 6.0%, and the bending fracture load has a high strength of 1960 N or more. Method.