JP3254395B2 - Manufacturing method of cement-based building material and wall material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a novel cementitious building materials containing molten slag as admixture, and a method for manufacturing a wall material.

[0002]

2. Description of the Related Art Conventionally, waste incineration ash and molten slag of sewage sludge have been effectively used for applications such as fired products such as tiles, concrete, and roadbed materials.
-339672, JP-A-6-279084, JP-A-6-57715).

[0003] In the case of a fired product, a molten slag is produced by mixing a molten slag with a clay and a flux, followed by molding and firing. In this case, the molten slag is used as a substitute for the clay. In concrete, molten slag is used as a substitute for sand required for cement mortar.

[0004] In roadbed materials, it is used as a substitute for asphalt. In these prior arts, the particle size of the molten slag is relatively large.

[0005]

As described above, the use of molten slag has been gradually expanding, but a technique for using molten slag as an admixture for cement-based building materials (for example, wall materials) has been developed. Not. The problems when using the molten slag as a wall material are which admixture material is to be replaced and how to treat and mix the molten slag.

As the conventional admixture material for the wall material, various materials such as fly ash, silica sand, pearlite, pulp and the like are used, and are most suitable for improving various physical properties such as strength, weather resistance and specific gravity. Various formulations have been researched and developed. If the above physical properties are extremely deteriorated by mixing the molten slag, it is not practical. Use example, wallboard, along with sufficient deflection strength and small specific gravity (about 1.0) is required, but should be small brittle for nailing or the like is performed, a conventional molten slag as described above All of the molded articles were brittle.

The present invention is based on a new discovery that fly ash or quartz sand can be replaced by powdering of molten slag, and the molten slag flow of refuse incineration ash or sewage sludge burning
Single atomize or dub the molten slag stream of incinerated ash
It is an object of the present invention to provide a novel cement-based building material using a slag powder that has been lutomized as a building material admixture. Furthermore, the present invention aims to provide a method of manufacturing a wall material using the molten slag powder.

[0008]

Means for Solving the Problems The inventors of the present invention pulverize molten slag into various particle diameters and replace the molten slag powder with various admixtures of cement-based building materials to obtain physical properties of molded building materials. As a result, it was found that the molten slag powder could be replaced with fly ash or quartz sand.

[0009] Based on such a finding, in a building material formed by mixing cement, fly ash, and other required materials , all or part of the fly ash is formed.
Instead, the molten slag powder is mixed,
The end is the molten slag flow of refuse incineration ash or sewage sludge incineration ash.
The molten slag flow is injected into the swirling coolant layer to cool
Single atomizing treatment to solidify or the molten slag flow
It is broken into droplets by spraying with a gas jet,
Double atomizer that injects into the cooling liquid layer and cools and solidifies
Beaded glass fiber or flocculent glass fiber and glass
A cement-based building material characterized by being composed of a mixture with granules was developed. Also, cement, silica sand,
In building materials that are formed by mixing with other required materials, molten slag powder is used instead of all or part of the silica sand.
The molten slag powder is mixed with
Turning the slag flow or the molten slag flow of sewage sludge incineration ash
Single atomizer that injects into the cooling liquid layer and cools and solidifies
Gas treatment or spraying the molten slag stream with a gas jet
To separate the droplets and inject them into the rotating cooling liquid layer.
Bead-like glass fiber
It consists of a mixture of fiber or glass fiber and fiber
A cement-based building material with the following characteristics was developed.

As described above, according to the cement-based building material in which molten slag powder is mixed instead of fly ash or silica sand, fly ash or silica sand can be saved,
The added value of the molten slag can be increased, and the above-mentioned industrial application value of the present invention becomes enormous, and the presence of the molten slag (glass) on the surface causes a glossy pattern to be formed as a wall material. Mixing the molten slag is beneficial, and the occurrence of cracks during nailing can be reduced depending on the mixing ratio.

The molten slag powder has a median diameter of 40 μm.
It is preferable to pulverize below. The molten pulverized slag powder does not significantly affect the physical properties of the molded building material when it is replaced with fly ash or quartz sand, which is also powdery. As described above, since molten slag can be used as an admixture for cement-based building materials, it has become possible to produce wall materials having appropriate physical properties using molten slag.

Namely, the production method of the wall material of the present invention, the molten slag (preferably a median diameter 40μm or less) In that powdering, molten slag flow or molten slag flow sewage sludge incineration ash of waste incineration ash to Inject into the swirling coolant layer
Single atomization or the molten Sula cooling solidification
Gas stream is broken into droplets by spraying a gas jet,
Double door that injects into the swirling cooling liquid layer and cools and solidifies
It is made of a mixture of beard-like glass fibers or flocculent glass fibers and glass particles by tomizing , and this molten slag powder is
It is characterized by being mixed with cement and other materials for wall materials and molded. According to such a production method, the molten slag powder can be used in place of fly ash, quartz sand, or a conventionally known equivalent material equivalent thereto, so that the material can be effectively used.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION As cement-cement-based building materials to which the present invention is applied, there are various building materials such as outer wall materials and roofing materials, and the method of using the molten slag of the present invention can be applied to these various building materials. For example, the outer wall material can be formed by mixing required amounts of cement, molten slag powder, fly ash, silica sand, pearlite, silica fume, pulp, and water.

Here, the molten slag powder can replace fly ash and / or silica sand. Therefore, the molten slag powder can be mixed instead of fly ash without mixing fly ash at all. Similarly, a molten slag powder can be mixed instead of silica sand without mixing silica sand at all. As the cement, various cements such as alumina cement, ultra-fast cement, acid-resistant cement, sulfate-resistant cement, oil well cement, white cement, color cement, and colloid cement can be used.

[0015] Fly ash is, for example, collected dust obtained by burning pulverized coal in a thermal power plant. The chemical composition of this fly ash is approximately 53-63% silica,
24 to 29% alumina, 3 to 8% iron oxide,
The mineral composition of fly ash is approximately 70
85%, mullite 8-16%, quartz 5-12%.

As silica sand, for example, glass chips are used. That is, in this embodiment, silica sand is finely divided silica. In the present embodiment, the pearlite is mixed for the purpose of reducing the weight. Silica fume is an industrial by-product of ultrafine particles obtained by collecting waste gas generated during the production of ferrosilicon (silicon iron) and silicon metal, and has a true specific gravity of 2.1 to
It is about 2.2, and the unit weight is 250-300kg
/ M ^{3, the} bulk density is extremely small, the specific surface area is about 200,000 cm ² / g, and the average particle size is 20 to 30 μm.

As the pulp, those molded from either softwood or hardwood can be used, and any of mechanical pulp, chemical pulp and semi-chemical pulp can be used. As the pulp to be mixed with the outer wall material, waste paper can be reused. Here, since molten slag can be substituted for fly ash or silica sand, by reducing the amount of fly ash or silica sand to increase the molten slag powder, it is formed by a basic blending without mixing the molten slag powder. It is possible to provide an outer wall material having the same physical properties as the outer wall material.

After mixing the required amount of each material,
The outer wall material can be manufactured by vibration molding or press molding. For such a molding step, conventionally known various methods can be adopted. The feature of the production method of the present invention resides in that the powdered molten slag is mixed with the admixture for wall material, and does not specify the molding step at all. As a method for producing the molten slag powder, there are a dry pulverization method in which the molten slag is pulverized by a vibrating mill, and a pulverization method using an atomizing apparatus. The molten slag powder used in the present embodiment preferably has a median diameter of 40 μm or less.

Various types of molten slag, such as sewage sludge incinerated ash molten slag and refuse incinerated ash molten slag, can be used.

[0020]

[Examples] Examples in which sewage sludge incinerated and crushed slag or refuse incinerated ash and crushed slag are replaced with fly ash, and sewage sludge incinerated and crushed slag or garbage incinerated ash and crushed slag are converted to silica sand An alternative embodiment will be described. The molten slag sample is a granulated granulated slag produced by quenching sewage sludge incinerated ash molten slag or refuse incinerated ash molten slag with water, each having a median diameter of 40 μm.
What was dry-pulverized with a vibration mill until the following was used was used.

The mineral composition of the sewage sludge incinerated ash molten slag and the refuse incinerated ash molten slag used as the samples are as follows.
The results of the line analysis were as shown in Table 1.

[0022]

[Table 1]

Table 2 shows the basic composition of the outer wall material (composition when molten slag is not mixed) and each composition in which fly ash contained in this basic composition was replaced with molten slag powder. The outer wall material according to each composition shown in Table 2 was obtained by press-molding a mixture (mortar) obtained by sufficiently kneading the materials from each composition under the conditions of 80 kg / cm ² and 70 ° C., 100% RH. And then autoclaved at 175 ° C. for 11 hours and then dried sufficiently.

[0024]

[Table 2]

As shown in Table 2, in the basic composition, 347 g of fly ash was contained, and the total weight of admixtures (fly ash, silica sand, pearlite, silica fume, pulp) excluding cement and water was included. Is 1
The weight ratio of fly ash to the total amount of the admixtures is about 35% because the weight is about 55.5 g. In the examples shown in Table 2, in the 35% fly ash included in the basic formulation, 5% was replaced with molten slag powder, 10% was replaced, 20% was replaced, 3
A wall material was manufactured with each of the blends in which 5% was substituted (all fly ash was replaced with molten slag), and physical properties were tested.

Table 3 shows the physical property test results of the wall material using the garbage incinerated ash granulated slag powder, and Table 4 shows the physical property test result of the wall material using the sewage sludge incinerated ash molten slag powder.

[0027]

[Table 3]

[0028]

[Table 4]

The physical properties in the case of the basic composition shown in Table 3 are different from those in the case of the basic composition shown in Table 4 because the lots are different. However, the wall material of the composition to be compared with the basic composition was manufactured in the same lot. As shown in Tables 3 and 4, in the composition in which 10% of fly ash was replaced by molten slag powder, almost no change in physical properties was observed.

Further, in the case of using crushed slag powder of garbage incinerated ash, sufficiently practical physical properties can be obtained even when all (35%) of fly ash is replaced. On the other hand, when sewage sludge incineration ash granulated molten slag powder is used, practical properties can be obtained up to 20% of fly ash, but if all of them are replaced, the breaking load However, the proportional limit load is greatly reduced, and it is expected that the use of the wall material will be limited.

Next, each composition in which the silica sand contained in the basic composition of the outer wall material was replaced with molten slag powder is shown in Table 5.

[0032]

[Table 5]

As shown in Table 5, in the basic composition, 99.1 g of silica sand was contained, and the weight of the admixture (fly ash, silica sand, pearlite, silica fume, pulp) excluding cement and water was calculated. The sum is 100
Since the weight is 5.5 g, the weight ratio of fly ash to the total of the admixtures is about 10%. In the example shown in Table 5, the composition in which 5% of the 10% silica sand contained in the basic composition was replaced by molten slag powder, and the composition in which 10% was replaced (a composition in which all of the silica sand was replaced by molten slag) )
Then, a wall material was manufactured, and a physical property test was performed.

Table 6 shows the physical property test results of the wall material using the garbage incinerated ash granulated molten slag powder, and Table 7 shows the physical property test result of the wall material using the sewage sludge incinerated ash molten slag powder.

[0035]

[Table 6]

[0036]

[Table 7]

As shown in Tables 6 and 7, almost no change in physical properties was observed when any of the molten slag powders was used. From this example, it has been clarified that even if all of the silica sand is replaced with the molten slag powder, the physical properties of the produced wall material can be made equivalent.
The inventors of the present application have also developed an atomizing treatment apparatus capable of mass-producing molten slag powder at low cost. Hereinafter, this apparatus will be described with reference to FIG.

The apparatus includes a raw material container 1 into which molten slag is injected, and a cooling cylinder 2 disposed below the raw material container 1, and an upper cover for covering an upper end opening of the cooling cylindrical body 2. A gas separator 4 detachably attached to the upper lid 3 is attached to the upper lid 3 so as to be fitted into a center opening 3 a of the upper lid 3. The raw material container 1 includes a lid 5 for closing an upper opening thereof, and the lid 5 has a gas supply port 5a formed at a central position thereof. On the other hand, at the center of the bottom wall of the raw material container 1, a molten metal nozzle hole 6 having a pore shape penetrating vertically is formed. Further, a heating coil 7 is wound around the outer periphery of the raw material container 1.
The molten slag 8 injected into the raw material container 1 can be heated and maintained at a predetermined temperature.

The cooling cylinder 2 is formed in a substantially cylindrical shape.
The cylinder axis is inclined at an angle of 10 to 30 ° with respect to the vertical direction. This cooling cylinder 2 has an upper lid 3
A cooling liquid supply passage 9 is provided in an annular shape on the slightly lower outer periphery. A plurality of cooling liquid ejection holes 10 communicating with the cooling liquid supply flow path 9 are formed at regular intervals in the circumferential direction. These ejection holes 10 are opened on the inner peripheral surface of the cylindrical body 2 so that the coolant can be ejected and supplied from a tangential direction.

When a pressurized coolant is supplied to the coolant supply passage 9 and ejected from the coolant ejection hole 10,
On the inner peripheral surface of the cooling cylinder 2, a cooling liquid layer 11 that flows down while rotating at a high speed along the inner peripheral surface is formed. In addition,
A layer thickness adjusting ring 12 for adjusting the layer thickness of the cooling liquid layer 11 is attached to a lower portion of the inner peripheral surface of the cooling cylinder 2. The flow rate of the cooling liquid is suppressed by the ring 12, and the cooling liquid layer 11 having a substantially constant inner diameter is formed at a lower flow rate in the vertical direction.

A discharge pipe 13 is connected to a lower end opening, which is a coolant discharge end of the cooling cylinder 2, and a downstream end of the discharge pipe 13 is provided with a molten slag powder (not shown). A collecting net basket for separating the water from the cooling liquid is provided. The cooling liquid is configured to return to the cooling liquid supply passage 9 of the cooling cylinder 2 and circulate. The gas splitter 4 has an upper cover 3 having a center located coaxially with the melt nozzle hole 6 of the raw material container 1.
Mounted on The gas divider 4 has a nozzle hole 14 in the form of a fine hole penetrating vertically at a center position thereof. An auxiliary heater 15 made of, for example, a carbon heating element is mounted in the gas divider 4 so as to surround the nozzle hole 14. By supplying power to the heater 15, the temperature of the molten slag flowing down through the nozzle hole 14 is suppressed from decreasing, and is maintained at a predetermined temperature.

Further, a gas chamber 16 to which a compressed gas is externally supplied is formed outside the auxiliary heater 15 in the gas divider 4 in an annular shape. The gas chamber 16 is configured so that a gas jet Gj directed downward of the gas divider 4 is jetted from the gas chamber 16 as indicated by an arrow in the drawing. The gas jet is blown downwardly from the gas divider 4 in an inverted conical shape, intersects at a position slightly below the lower end opening of the nozzle hole 14, and then spreads out in a conical shape.

Next, the production procedure of the molten slag powder when the gas separator 4 is attached to the upper lid 3 of the cooling cylinder 2 (hereinafter, the production in this state is referred to as "double atomizing treatment") will be described. In this case, a plug is attached to the molten metal nozzle hole 6 of the raw material container 1, the molten slag 8 is injected into the raw material container 1, and a cooling liquid (water) is supplied to the cooling liquid supply flow path 9 of the cooling cylinder 2. Then, an operation of forming the cooling liquid layer 11 in the cooling cylinder 2 is performed.

At this time, the energization of the auxiliary heater 15 of the gas divider 4 is further performed by turning on the nozzle holes 1 of the gas divider 4.
In addition to adjusting the molten slag flow 8a flowing down through the chamber 4 so as to maintain the molten slag stream 8a at a predetermined melting temperature, a compressed gas such as compressed air is supplied to the gas chamber 16 and an inverted cone arranged under the gas divider 4 is provided. To form a gas jet Gj. In this state, a compressed gas adjusted to a predetermined pressure is supplied through the gas supply port 5a of the lid 5 of the raw material container 1, and
The molten slag 8 in the raw material container 1 is caused to flow downward through the molten metal nozzle hole 6 by removing the plug that closes the molten metal nozzle hole 6.

At this time, the molten slag flow 8a once flows into the nozzle hole 14 of the gas separator 4, and further forms a fine stream corresponding to the diameter of the lower end of the nozzle hole 14.
It flows down to the intersection of the gas jets Gj. Here, the molten slag flow 8a is divided into fine streak-like droplets by spraying the gas jet Gj. These droplets are carried to the cooling liquid layer 11 together with the gas jet Gj, and
Is injected within, La Is a cooling liquid layer within 11 to cool solidify while receiving the same fragmentation effect.

The molten slag is relatively viscous and
Since the surface tension is small, in the above-described double atomizing treatment, the fiber is divided into fibers by spraying the gas jet Gj. This is injected into the cooling liquid layer 11, and is cooled and solidified while undergoing a dividing action,
A molten slag powder whose diameter is reduced to several μm to several tens μm is generated. This product is discharged from the cooling cylinder 2 to the discharge pipe 13 together with the cooling liquid, and is separated from the cooling liquid and recovered in the recovery net basket.

According to the double atomizing treatment, a molten slag powder having a median diameter of 40 μm or less can be easily produced in a short time. In addition, the said apparatus can produce | generate a molten slag powder also in the state in which the gas splitter 4 is not attached (manufacture in this state is called "single atomizing process"), and in this case, the median diameter is 200 micrometers or less. It was possible to produce something.

Next, a table shows an example of the results of a single atomizing treatment and a double atomizing treatment conducted experimentally using the above-described apparatus and using garbage incineration ash and sewage sludge incineration ash. . That is, the properties of the product obtained by each of the above processes largely depend on the viscosity and surface tension in a molten state. On the other hand, even if molten slag of garbage or sewage sludge, or even a common mineral raw material, is melted, the composition of the slag greatly varies, and thus the viscosity and surface tension in the molten state are variously different.

Therefore, for example, the relationship between the melting temperature and the viscosity of various compositions of molten slag using garbage incineration ash and molten slag using sewage sludge is checked in advance, and the relationship between the melting temperature and the viscosity when flowing down to the cooling cylinder 2 is examined. By examining in advance the relationship between the manufacturing conditions such as the melting temperature and the hole diameter of the molten metal nozzle hole 6 and the flow rate of the cooling liquid layer 11 in the cooling cylinder 2 and the properties of the product, the composition is thereafter changed to By setting the conditions in accordance with the conditions, it is possible to stably obtain a product having a required diameter in the form of powder or granules or rock wool.

From such a viewpoint, an example of a result obtained by treating the incineration ash of garbage and the incineration ash of sewage sludge under various production conditions and experimentally determining the relationship between the conditions and the properties of the product. Are shown in Tables 8 and 9. Table 8 shows the processing conditions in the single atomizing process and the properties of the obtained product, and Table 9 shows the processing conditions in the double atomizing process and the properties of the obtained product. It is shown. The cooling cylinder 2 in the apparatus used for these processes has an inner diameter of 100 mm and an inclination angle of the cylinder axis of 20 °.

[0051]

[Table 8]

[0052]

[Table 9]

Test No. in Table 8 1, No. 2
Is obtained by performing the above-described single atomization treatment using garbage incineration ash under the conditions shown in the same table. In this case, the product is a beard-like glass fiber having a diameter of 50 to 90 μm,
A mixture with glass particles having a diameter of 80 to 320 μm is obtained. FIG. 2 shows a stereomicrograph thereof. Test No. 3
Uses incinerated ash from sewage sludge. In this case,
A mixture of beard-like glass fibers and glass grains having a diameter of 4 to 140 μm is obtained. FIG. 3 shows a stereomicrograph thereof.

On the other hand, Test No. 4, N
o. No. 5 is obtained by performing double atomizing treatment using incineration ash under the conditions shown in the same table.
A mixture of about m m cotton-like glass fibers and about 80 μm diameter glass particles is obtained. Fig. 4 shows the stereomicrograph.
Shown in Test No. In No. 6, incinerated ash of sewage sludge is used, and in this case, flocculent glass fibers having a diameter of 2 to 120 μm are obtained. FIG. 5 shows a stereomicrograph thereof.

The molten slag powder thus obtained may be used as it is as a building material admixture, or it may be sieved to remove relatively large particles, to reduce the median diameter, and then to reduce the building material admixture. It can also be used as Further, by optimizing various conditions, a product having a particle size of about several μm can be obtained by the above apparatus, and such a product can be used as a building material admixture.

[0056]

As described above, according to the present invention,
While able to provide novel use of molten slag powder as admixture for cement-based building materials of the outer wall material such as the molten slag powder
Molten slag flow or sewage sludge incineration ash of waste incineration ash as youngest
By injecting the molten slag flow into the rotating coolant layer
Single atomizing treatment to solidify or the molten slag flow
Is divided into droplets by spraying with a gas jet, and this is swirled
Double atomizer that injects into the cooling liquid layer and cools and solidifies
By a mixture of a whisker-like glass fibers or cotton-like glass fibers and glass particles by size treated, the physical properties change may provide a cementitious building material not seen little, other materials (fly to be replaced in the molten slag powder Ash, quartz sand) can be saved, and the added value of the molten slag itself can be increased.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing a pulverizing apparatus by atomizing a molten slag.

FIG. 2 is a micrograph (magnification: 10 times) showing an example of a particle structure of a product obtained by single atomizing garbage incineration ash molten slag.

FIG. 3 is a micrograph (magnification: 10 times) showing an example of a particle structure of a product obtained by single atomizing sewage sludge incineration ash molten slag.

FIG. 4 is a micrograph (magnification: 10 times) showing an example of a particle structure of a product obtained by performing a double atomization treatment on refuse incineration ash molten slag.

FIG. 5 is a micrograph (magnification: 10 times) showing an example of a particle structure of a product obtained by double atomizing sewage sludge incineration ash molten slag.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification code FI (C04B 28/02 C04B 18:04 18:04 18:08) Z 18:08) B09B 3/00 303D (58) Fields surveyed (Int.Cl. ⁷ , DB name) C04B 18/04 C04B 18/08 C04B 14/06 C04B 28/00-28/08

Claims (5)

(57) [Claims] Cement [1 claim], and fly ash in building materials to be molded by mixing the other of the required materials, molten slag instead of all or part of the fly ash
The molten slag powder is mixed with garbage incineration ash.
Handed the molten slag flow or molten slag flow of sewage sludge incinerator ash
A single atomizing process in which the molten slag flow is injected into the rotating cooling liquid layer and solidified by cooling, or the molten slag flow is blown with a gas jet.
The droplets are broken into small droplets, which are then
A cement-based building material comprising a mixture of beard-like glass fibers or flocculent glass fibers and glass particles by a double atomizing treatment of pouring, cooling and solidifying . Cement [2 claim ## and sand, in a building material to be molded by mixing the other of the required materials, and mixing the molten slag powder instead of all or part of the silica sand, the molten slag The powder is the molten slurry of the incineration ash
It is turning the grayed flow or slag flow sewage sludge incineration ash
Single atomizing treatment for injecting into the cooling liquid layer and cooling and solidifying, or melting the molten slag flow by blowing gas jet
Drop into droplets, inject them into the swirling coolant layer and cool
A cement-based building material comprising a mixture of beard-like glass fibers or flocculent glass fibers and glass particles which have been subjected to a double atomizing treatment for solidification . 3. The molten slag powder has a median diameter of 40 μm.
The cement-based building material according to claim 1, wherein the cement-based building material is not more than m. 4. A molten slag powder, the waste incineration ash melting scan
Whirling the slag flow or the molten slag flow of sewage sludge incineration ash
Single atomizing treatment for cooling and solidifying by injecting into the cooling liquid layer or spraying the molten slag flow with a gas jet
Break it into droplets and inject it into the rotating coolant layer
It is made of a mixture of beard-like glass fibers or flocculent glass fibers and glass particles by cooling and solidifying double atomizing , and this molten slag powder is mixed with cement and other materials for wall materials and molded. Method of manufacturing wall material. 5. The molten slag powder has a median diameter of 40 μm.
The method for producing a wall material according to claim 4, wherein the thickness is not more than m.