JP3707270B2 - Water-permeable ceramic block and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a permeable ceramic block suitable for paving exterior structures such as road structures such as roadways and sidewalks, parks and other plazas, parking lots, and various structures (buildings, etc.) and a method for manufacturing the same.
[0002]
[Prior art]
In recent years, it has become an important issue to reduce rainwater flowing into sewers and urban rivers by reducing rainwater into the ground, reducing the burden on sewage treatment plants, and preventing river flooding. . In addition, by reducing rainwater into the ground, it is possible to prevent the depletion of groundwater, prevent land subsidence, and plant in urban areas.PlantingIt is also important to promote. In addition, there is a demand for a sidewalk that is less likely to bounce when it rains, is less prone to puddles, and has a good walking feeling. A water permeable block has attracted attention as a material suitable for satisfying such a requirement.
[0003]
As such a water-permeable block, for example, there is a so-called water-permeable interlocking block in which an aggregate is bonded with cement and has a certain amount of voids, which are commercialized by various companies. However, there is a limit to the bonding strength of cement, and instead of increasing water permeability, the strength is lowered, or conversely, in order to prevent a decrease in strength, the amount of cement binder is increased or the aggregate particle size is reduced. There are problems such as insufficient water permeability or severe deterioration of water permeability over time. In addition, various problems have been pointed out, such as white flower phenomenon (causing dripping phenomenon) due to carbonation of Ca on the block surface, easy adhesion of dirt, and difficulty in recovering from washing.
[0004]
In addition, there are water permeable ceramic blocks using ceramic aggregates as raw materials, but these have been pointed out the problem of raw material depletion, and the amount of generation depends on economic trends and the cost is high.
[0005]
Another problem is that sewage sludge and municipal waste are being melted into slag and are being used for other purposes than landfill disposal, but so far they are mostly used for roadbed materials and concrete aggregates. Local governments that have sewage treatment plants and waste disposal plants cannot find effective ways to use sewage sludge melting slag and garbage melting slag.
[0006]
[Problems to be solved by the invention]
The object of the present invention is to solve the above-mentioned problems of conventional water-permeable interlocking blocks, and not only has excellent water permeability and strength, but also has excellent water retention, especially for paving sidewalks, parks and other plazas. It is in providing the suitable water-permeable ceramic block and its manufacturing method.
[0007]
Another object is to stably supply the raw material for the water-permeable ceramic block at a low cost.
[0008]
Furthermore, it is one of the purposes to make effective use of sewage sludge melting slag and waste melting slag, which are in need of disposal, as the main aggregate.
[0009]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a water-permeable ceramic block in which an aggregate mainly composed of at least one of sewage sludge molten slag or refuse molten slag is integrated with a sintered binder, A clear diffraction peak is obtained by diffraction, and CaO and SiO₂Or CaO and Al2O_ThreeAnd SiO₂A water permeable ceramic block characterized by having a crystal structure of a double oxide containing
[0010]
Here, the sewage sludge melting slag is generally obtained by separating the sewage into sewage and sludge, further melting the sludge concentrated and dewatering cake, collecting it, and cooling it. There are crushed slag, air-cooled slag, and slow-cooled slag.
[0011]
As the refuse melting slag, municipal waste is generally obtained by incineration, melting, recovery, and cooling, and includes granulated slag, air-cooled slag, slow-cooled slag, etc. depending on the cooling method.
[0012]
In order to use as an aggregate, it is cheaper than natural raw materials, and is optimal as a use for civil engineering and building materials that consume a large amount.
[0013]
The granulated slag rapidly cools the melt with water and the particles become fine sand. The particle size distribution is a preferable particle size distribution for the aggregate of the water permeable block. Therefore, it is preferable to use granulated slag as sewage sludge melting slag or garbage melting slag. If these aggregates are mainly used, other types of aggregates and sintered binders may be added.
[0014]
Since granulated slag is usually obtained by rapid cooling from the melt, it is a vitreous having a very low crystallinity. As it is, it is difficult to ensure the structural strength as a block because of its low strength and brittle material. However, in this patent, since the granulated slag is crystallized by the process of integrating with the sintered binder, a predetermined strength can be ensured. That is, in the block, CaO and SiO of diffraction peaks obtained by X-ray diffraction.₂Or CaO and Al₂O_ThreeAnd SiO₂The content of the crystalline component calculated from the diffraction peak due to the crystal structure of the double oxide containing is in the range of 50 to 100% by weight.
[0015]
Here, the content of the crystalline component is CaO and SiO2 or CaO among diffraction peaks in which the diffraction angle (2θ) obtained by X-ray diffraction using Cu-Kα rays is in the range of 20 to 55 °. From the diffraction peak due to the crystal structure of the double oxide containing Al 2 O 3 and SiO 2, it is obtained as follows.
[0016]
The so-called internal standard method is used to quantify the crystal components of CaO and SiO2, or a double oxide containing CaO, Al2O3 and SiO2.
[0017]
First, a pure powder sample of crystals to be quantified and a pure alumina powder [synthetic corundum (α-Al 2 O 3)] as a standard sample are prepared. The pure crystal powder and the pure alumina powder are mixed at a weight ratio of 1: 1, X-ray diffraction is performed, the intensity ratio of the main diffraction peaks of both is examined, and standard data is obtained.
[0018]
  Next, sewage sludge melting slag or waste melting slag after firingBlock made mainly ofThe pulverized product and pure alumina powder are mixed at a weight ratio of 1: 1, X-ray diffraction is performed, the same peak intensity as described above is examined, and compared with standard data. In this way, sewage sludge melting slag or refuse melting slag after firingBlock made mainly ofThe weight percentage of the crystalline component desired to be obtained is determined.
[0019]
CaO and SiO2, or a double oxide containing CaO, Al2O3 and SiO2, anorthite (CaO.2SiO2, Al2O3), β-wollastonite (CaO.SiO2), or gehlenite (2CaO.SiO2, Al2O3), etc. The above measurement is performed for each crystal, and the total weight ratio of the crystal components is defined as the content of the crystal components.
[0020]
If the content of the crystal component of CaO and SiO2 or a double oxide containing CaO, Al2O3 and SiO2 is in the range of 50 to 100%, the strength of the crystals of the particles constituting the aggregate is high, and the predetermined block Strength can be secured. If the content of the crystal component is smaller than this range, it is difficult to maintain the strength because there are substantially many vitreous particles. Further, a double oxide containing CaO and SiO2 or CaO, Al2O3 and SiO2 is specified as three kinds of anorcite, β-wollastonite and gehlenite, and the total content of the crystalline components is 50 to 100% by weight. It is further desirable to be within the range.
[0021]
In the water-permeable ceramic block of the present invention, the aggregate observed in the cross section or the aggregate integrated with the sintered binder is substantially present in the vicinity of 4.75 to 0.5 mm particles and the periphery thereof. It is comprised by the particle | grains of 5 mm or less. The aggregate portion has a structure in which the coarse particles having a size of 0.5 mm or more fill the gap between the coarse aggregates having a size of 0.5 mm or more, thereby increasing the bonding force between the particles and improving the strength of the block. .
[0022]
In addition, the fine particles located between the coarse aggregates absorb the expansion of the coarse aggregates during firing,Volume expansionTherefore, there is an effect of suppressing shape deformation due to firing and a phenomenon in which cracks are generated on the surface layer.
[0023]
Furthermore, it is preferable that the fine particles of 0.5 mm or less present around the coarse particles are particles mainly composed of ceramics because the above-described effects are further enhanced.
[0024]
Here, the porcelain particles used for the aggregate may be either porcelain particles or porcelain particles, or both may be mixed. Specifically, as the porcelain particles, it is possible to use tile debris, ceramic tube debris or the like. The porcelain particles may include porcelain tile scraps, power insulator scraps, and the like, and one or more of these may be used in combination.
[0025]
The block porosity in the range of 10 to 40% is a condition for simultaneously satisfying the strength, water permeability function and water retention function. The amount of water retention is influenced not only by the amount of voids but also by the size of the voids. If the voids are too large, water easily permeates and the water retention amount decreases. If the gap is too small, the amount of water absorbed into the gap under atmospheric pressure is small, and the water retention amount is also small. In this case, the water retention amount with respect to the void amount may be high, but the water permeability is impaired.
[0026]
When the water retention function is satisfied, unlike asphalt pavement and concrete pavement, it has the effect of preventing a significant increase in road surface temperature. This is because the water stored in the block gradually evaporates after raining or watering. In addition, by satisfying both the water permeability function and the water retention function, it is possible to promote the evaporation of moisture from the ground as well as after rain or water spraying, and it can be expected to be effective in preventing the road surface temperature from rising.
[0027]
The porosity is determined by cutting and removing the surface layer from the block, cutting out a test piece of about 5 × 5 × 5 cm square, drying at 105 ° C. for 24 hours, cooling to room temperature, weight w (g) and volume V (cm^ThreeThe bulk density ρ1 = w / V is obtained, and the apparent density ρ2 obtained by the Archimedes method for the test piece processed in the same manner is obtained by the following equation.
[0028]
Porosity (%) = (1−ρ1 / ρ2) × 100
A cross section obtained by cutting and polishing a block at an arbitrary position, and measuring the line by measuring an arbitrary 20 mm long straight line in an inner cross section excluding an approximately 10 mm thick peripheral portion around the block. Confirmed above, the aggregate particle size does not substantially exceed a maximum of 9.5 mm, and the average number of aggregates integrated with the aggregate or sintered binder is 4 to 20 on average. Furthermore, when the space where the aggregate or the aggregate integrated with the sintered binder does not exist is defined as a space, it is preferable that the number of the space is 4 to 18 on average.
[0029]
Furthermore, it is more preferable that the average number of aggregates and voids integrated with aggregates or sintered binders on a straight line of 20 mm is 4 to 10 on average.
[0030]
In the present invention, the aggregate and the size and number of voids integrated with the aggregate in the block or the sintered binder are specified as follows. That is, among the cross sections obtained by cutting and polishing the block at an arbitrary position, an arbitrary straight line is drawn on the inner cross section excluding the approximately 10 mm thick surface around the block, and the bone integrated with the aggregate or the sintered binder. The length of each line segment cut by the outline of the material is measured, and the particle size of the aggregate is measured. The reason why the surface portion of the block around 10 mm thick is removed is that the surface of the block may be made of another material in order to enhance designability or to provide other functions. Some sewage sludge molten slag and garbage molten slag aggregates have pores in the grain, but the periphery of the pores in the grain is not considered as the outline of the aggregate. The part where the aggregate is not present on the straight line and the same plane as the cross section is regarded as a void. When counting the number of aggregates and voids, the aggregate or void that intersects at least part of the straight line is counted as one. Aggregates and voids that intersect at straight ends and do not have intersections at both ends are counted as one. The block must be cut and polished carefully so that aggregate particles do not fall off.
[0031]
In order to obtain a more accurate measurement value, it is preferable to draw two or more 20 mm straight lines at three or more cross-sections having an area of about 4 × 4 cm or more, and take the average of the measurement values in each. Furthermore, it is preferable to use a magnifying glass having a magnification of 2 to 20 times, a microscope, a magnifying projector, or the like. Also, in order to distinguish between aggregates on the cross section and aggregates that are not on the cross section but in the back of the gap, only the aggregate on the cross section is colored, or the bone on the cross section is obtained with a microscope with a shallow depth of focus. Only the material may be lifted.
[0032]
The size of either the aggregate or the aggregated particles of the aggregate and the sintered binder is specified because the boundary between the aggregate and the sintered binder is unclear depending on the type of sintering binder and firing conditions. This is because there is a case where it becomes. However, there is no problem here because the balance between the aggregate and the gap is more important than the aggregate size.
[0033]
If the size of the aggregate integrated with the aggregate or the sintered binder exceeds 9.5 mm at the maximum, the strength is impaired, and such large particles confirmed inside the block are also present on the block surface. If it does, it will become a defect of a product and surface smoothness and design property will be impaired.
[0034]
The average number of aggregates integrated with aggregates or sintered binders on a straight line of 20 mm is preferably 4-20 on average, and if less than 4, aggregates with aggregates or sintered binders are integrated. The size of the aggregate is too large or there are many continuous voids, leading to a decrease in strength. When the number is more than 20, the size of the aggregate integrated with the aggregate or the sintered binder is too small, and because there are many fine particles, the filling property at the time of molding is hindered, resulting in insufficient strength after firing. Moreover, the part with a small space | gap size increases, and water permeability falls.
[0035]
The average number of voids present on a 20 mm straight line is more preferably 4 to 18 on average, and there is the same reason as the number of aggregates, but if added, in order to fully develop the water permeability function For example, it is preferable that the aggregates are adjacent to each other and the gaps are mostly adjacent to the gaps rather than the aggregates are adjacent to each other. That is, on an arbitrary straight line, it is preferable that the aggregate and the gap are close to a shape in which they are almost alternately present. This is equivalent to the fact that the number of aggregates and voids is almost the same.
[0036]
Furthermore, it is more preferable that the average number of aggregates and voids integrated with aggregates or sintered binders on a straight line of 20 mm is 4 to 10 on average.
[0037]
In order to express the strength and water permeability function in a more balanced manner, it is necessary to be within this range, and when the number is more than 10, either the strength or the water permeability function is slightly impaired.
[0038]
Further, the ceramic block preferably has a loss on ignition of 3% or less.
[0039]
When the loss on ignition is more than 3%, it is evidence that unreacted materials exist due to insufficient firing, and the strength is insufficient. Moreover, water permeability may be inhibited or clogging may be caused. The loss on ignition is also referred to as loss on ignition, and is the percentage of the weight loss after cooling at 1000 ° C. for 30 minutes against the weight of the product dried at 105 ° C. for 24 hours and then cooled to room temperature.
[0040]
Further, the water-permeable ceramic block as described above is used as a base material having a thickness of 20 to 80 mm, is composed of an aggregate mainly composed of ceramic particles, and has a void ratio of 25 to 45% and higher than the base material. It is preferable to form a two-layer structure with a plate having a thickness of 3 to 10 mm as a surface layer, and in the water-permeable ceramic block, the surface layer has a Mohs hardness of 6 or more, and is obtained in accordance with ASTM E303. The slip resistance value when wet is preferably 40 BPN or more.
[0041]
The reason why the aggregate is mainly composed of ceramic particles is that the surface is not easily soiled and can be easily washed with water. In addition, it is difficult to wear, maintaining aesthetics, and aggregate powder generated by wear is present on the surface of the surface layer, making it easy to slip regardless of whether it is wet or not. This tendency becomes particularly remarkable when the Mohs hardness on the surface of the surface layer is less than 6. The surface layer having a porosity of 25 to 45% and a higher porosity than that of the base material can prevent rainwater and the like from flowing down, but can suppress the entry of clogging components such as earth and sand. Of course, the surface layer may be composed of aggregates mainly composed of sewage sludge molten slag.
[0042]
Here, the porcelain particles used for the surface layer may be either porcelain particles or porcelain particles, or both of them may be mixed. Specifically, as the porcelain particles, it is possible to use tile debris, ceramic tube debris or the like. The porcelain particles may include porcelain tile scraps, power insulator scraps, and the like, and one or more of these may be used in combination.
[0043]
Furthermore, it is preferable that the side surface shape of these water-permeable ceramic blocks is a trapezoid. By using the trapezoidal shape, chipping of the surface layer during construction can be prevented, and joints with an appropriate width can be formed between the blocks. However, the difference in length between the upper and lower bases is set to be as small as 3 mm or less in consideration of walking feeling, high heel walking, ease of running with a wheelchair, and the like.
[0044]
Alternatively, it is preferable that joints for restricting joint width are provided on the side surfaces of the water-permeable ceramic blocks. The protrusion has a thickness of about 1 to 3 mm and a height of about 10 to 80 mm. The protrusions are provided at positions where the protrusions of adjacent blocks do not hit each other when the blocks are laid down.
[0045]
When the above-mentioned water permeable block is shown in the figure as one embodiment, it has a shape as shown in FIGS. That is, it has a layered structure of a surface layer 1 having a thickness of about 3 to 10 mm and a base layer 2. The total thickness is set to about 40 to 100 mm in consideration of the acting load. The planar shape is a square, and the size is a square or a rectangle having a side length of about 90 to 400 mm in consideration of ease of construction.
[0046]
In the present invention, the bending strength of the block was determined according to JIS A1106, and the compressive strength was determined according to JIS R2206.
[0047]
  Further, the present invention includes an aggregate containing 75% by weight or more of at least one selected from sewage sludge molten slag and refuse molten slag and containing 7 to 25% by weight of particles of 0.5 mm or less, and a sintered binder. After molding the mixture, the molded body is fired at a temperature in the range of 800 to 1200 ° C., and the sewage sludge molten slag or dust molten slag contains 80% by weight or more of particles having a particle size of 4.75 mm or less, and , Mainly glassy,The molded bodyCrystallization proceeds in the firing step, and CaO and SiO are obtained by X-ray diffraction.₂Or CaO and Al₂O₃And SiO₂A clear diffraction peak showing the crystal structure of a double oxide containing CaO and SiO₂Or CaO and Al₂O₃And SiO₂The content of the crystalline component calculated from the diffraction peak due to the crystal structure of the double oxide containing is in the range of 50 to 100% by weightAdopting things as permeable ceramic blocksA method for producing a water-permeable ceramic block is provided.
[0048]
Here, when 7 to 25% by weight of particles of 0.5 mm or less are included in the aggregate, when the coarse particles of 0.5 mm or more are bonded to each other with a sintered binder, the fine particles of 0.5 mm or less are in the gaps. As a result, the bonding force between the particles is increased, and the strength as a block is improved.
[0049]
In addition, the fine particles are positioned between the coarse aggregates to absorb the expansion of the coarse aggregates during firing,Volume expansionTherefore, there is an effect of suppressing the phenomenon of shape deformation due to firing and the occurrence of cracks in the surface layer.
[0050]
When the amount of fine particles of 0.5 mm or less is 7% by weight or less, the above-described effects are insufficient, and a high-strength product cannot be obtained, or the shape of the block and cracks often occur. On the other hand, when the amount is 25% by weight or more, the amount of filling the gaps between the aggregate particles increases, and the water permeability is impaired.
[0051]
Although it does not specifically limit as particle | grains of 0.5 mm or less used for this aggregate, It is preferable to use ceramic particle | grains. Here, the porcelain particles used for the aggregate may be either porcelain particles or porcelain particles, or both may be mixed. Specifically, as the porcelain particles, it is possible to use tile debris, ceramic tube debris or the like. The porcelain particles may include porcelain tile scraps, power insulator scraps, and the like, and one or more of these may be used in combination.
[0052]
  Sewage sludge melting slag and refuse melting slag, which are the main aggregates, contain particles of 4.75 mm or less in an amount of 80% by weight or more.It is important toThe sintering binder is at least one selected from feldspar, clay, natural stone, ceramics, glass, sewage sludge molten slag, sewage sludge incinerated ash, dust molten slag, dust incinerated ash powder, and molding paste As the agent, it is preferable to use at least one selected from carboxymethylcellulose (CMC), methylcellulose, starch, water glass and cement.
[0053]
In the forming step, it is preferable to use a vibration press.
[0054]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of a method for producing a water-permeable block of the present invention will be described in detail.
[0055]
First, a paste and a sintered binder are added to and mixed with the aggregate.
[0056]
The aggregate contains 75% by weight or more of at least one selected from sewage sludge molten slag and waste molten slag, and particles of 4.75 mm or less are 80% by weight or more.
[0057]
If the aggregate contains more than 25% of raw materials other than sewage sludge melting slag and garbage melting slag, the feature that sewage sludge melting slag and garbage melting slag is inexpensive is lost, and the disposal of sewage sludge and municipal waste The effect of effective use is also reduced. When the particle size of 4.75 mm or less is less than 80% by weight, strength and product surface smoothness are impaired.
[0058]
As for the particle size distribution of the aggregate, the range of 1.18 to 0.5 mm is more preferably less than 30% by weight, and the range of 0.5 mm or less is less than 10% by weight. Properties and water permeability are further improved.
[0059]
In the present invention, the aggregate particle size distribution is expressed as a weight ratio by screening 2 kg of aggregate with a sieve defined in JIS Z8801.
[0060]
The sewage sludge melting slag and waste melting slag used in the present invention mainly contains glass. Crystallized slag often has particles of 4.75 mm or less in 80% by weight or less, and it is necessary to pulverize it. This is because extra energy is required for the pulverization and classification steps for adjustment to the above. In addition, glassy slag is often obtained by quenching from the molten state, and the particles are in the form of fine sand. A blending amount of 25% by weight or less of aggregate with distribution is sufficient.
[0061]
Further, the vitreous aggregate advances crystallization by firing. Glassy aggregates are extremely easy to react with sintered binders, other aggregates, additives, etc. during firing, and have a strong bond.YuiBy crystallization, the volume expands, acting to offset the shrinkage during sintering of the sintered binder and other aggregates, reducing internal strain, and having excellent water permeability and dimensional accuracy This is because there is an effect that can be obtained.
[0062]
Whether or not the aggregate of the sewage sludge melting slag or the refuse melting slag is glassy can be confirmed by, for example, X-ray diffraction. When the X-ray diffraction pattern of the powder sample obtained by finely pulverizing the slag particles is examined and no clear diffraction peak is observed, it can be judged as glassy.
[0063]
Also, whether the crystallization has progressed in the firing step is determined by the X-ray diffraction pattern of the powder sample obtained by crushing the X-ray diffraction pattern of the block cross section after firing or the slag particles giving the same temperature history as firing. If a diffraction peak is obtained by investigation, it can be determined that crystallization has progressed. The present invention is characterized in that a clear diffraction peak showing a crystal structure of a double oxide containing CaO and SiO2 or CaO, Al2O3 and SiO2 is recognized. These double oxides are chemically stable crystalline and are suitable for use in blocks used as paving materials.
[0064]
On the other hand, as a sintered binder, feldspar, clay, natural stone, ceramics, glass, sewage sludge molten slag, sewage sludge incinerated ash, waste molten slag, waste incinerated ash powder with a melting point lower than the aggregate or a particle size distribution is smaller. Can be used. BaInda melts at the time of firing to bond the aggregates, but the maximum particle size of the binder is such that the aggregates are uniformly bonded, and the melting at firing takes time and energy costs It is preferable to set it to 0.5 mm or less so as not to rise. The amount of the binder is determined in consideration of the strength and water permeability of the block, but is usually added in an amount of 3 to 20 parts by weight with respect to 100 parts by weight of the aggregate.
[0065]
Moreover, as a molding paste, organic pastes, such as carboxymethylcellulose (CMC), methylcellulose, and starch, and inorganic pastes, such as water glass and cement, can be used. Usually, the powder form is hydrated and used in the form of an aqueous solution or paste. However, a method of mixing with dry powder and adding water to the mixture later may be employed.
[0066]
The amount of the paste is determined in consideration of the shape retention at the time of subsequent molding and the handleability of the molded body at the time of firing, and is usually added in an amount of 5 to 20 parts by weight with respect to 100 parts by weight of the aggregate.
[0067]
When mixing the aggregate, the paste, and the sintered binder, first, it is preferable to mix the aggregate in a liquid state, for example, in a shower while adding it little by little. Next, it is good to mix, adding a sintering binder little by little to the mixture of aggregate and paste. Here, the aggregate and the paste are mixed in advance, and the sintered binder is further added and mixed to the mixture in order to uniformly distribute the liquid paste on the aggregate surface. When the two are mixed at the same time, the paste and fine sintered binder tend to aggregate, and the aggregated adhesive adheres to the mold during molding, or the adhesive and sintered binder aggregate to reduce the original bonding effect. End up. For the same purpose, fine particles contained in the aggregate, for example, particles of 0.5 mm or less, are preliminarily screened, and after mixing the aggregate and paste of 0.5 mm or more, like the sintered binder, It is also preferable to add.
[0068]
It is also possible to first mix the powder-form paste with dry powder, and then add water to the mixture later. However, when this paste is made into a liquid, it is highly viscous and poorly dispersible, and tends to cause aggregation. It is very effective in some cases.
[0069]
Although it is possible to form a block only with the above-described base material, it is also preferable to form a surface layer of another specification on the base material. In that case, in the forming step, it is preferable to form a surface layer having a thickness of 3 to 10 mm on a base material having a thickness of 20 to 80 mm.
[0070]
The surface layer material is also prepared in the same manner as the substrate.
[0071]
The surface layer material has a maximum dimension of 5.0 mm or less and an aggregate containing 50% or more of porcelain having a particle size distribution of less than 10% by weight within a range of 0.5 mm or less, or a maximum dimension of 5.0 mm An aggregate containing 50% by weight or more of sewage sludge molten slag or dust molten slag having a particle size distribution of less than 10% by weight within a range of 0.5 mm or less is used. You may mix and use both.
[0072]
As porcelain, waste materials such as porcelain tiles and power insulators can be used.
[0073]
When the maximum size of the aggregate is 5 mm or more, the slip resistance value of the surface layer when wet becomes small, and it becomes slippery when wet such as rain. The slip resistance value is determined in accordance with ASTM E303. When the particle size in the range of 0.5 mm or less is 10% by weight or more, the filling property at the time of molding is poor, the shrinkage behavior is different between the base layer and the surface layer at the time of firing, which causes generation of strain between layers and cracks in the surface layer. Moreover, the dimension of a space | gap also increases a small part and water permeability will fall.
[0074]
In order to color the surface layer, pigments can be added to it when preparing the surface layer material. As the pigment, powders such as iron oxide, titanium oxide, and cobalt oxide can be used, and they are usually added to and mixed with the aggregate. The amount of the pigment is 0.2 to 10 parts by weight with respect to 100 parts by weight of the aggregate, although it depends on the degree of color development.
[0075]
In addition, when preparing the surface layer material, a speckle material having a dimension equal to or smaller than that of the aggregate can be added to make the surface design a natural stone or to form various patterns, thereby improving the design. As the spotted material, artificial inorganic particles that have already been colored, particles such as ummo, manganese, iron, steel slag, sewage sludge molten slag, dust molten slag, garnet, and the like are preferred, and the amount thereof is preferably Depending on the design of the formation pattern, about 2 to 10 parts by weight are added to 100 parts by weight of the aggregate. Next, the above materials are filled and molded using a mold so that the desired thickness after firing is taken into consideration..
[0076]
Although it becomes a product only with a base material, when it makes a two-layer structure with the surface layer, first put the base layer material into a mold, perform primary molding using a vibration press, then put the surface layer material on it, and again Press to mold.
[0077]
Next, the molded body obtained in the molding process described above is fired to obtain a water-permeable block. Prior to firing, the molded body is dried, or when water glass is used as a paste, the water glass is primarily cured by the action of carbon dioxide, or when cement is used. It accelerates and cures the hydration reaction to facilitate handling.
[0078]
A tunnel kiln, a roller hearth kiln, etc. can be used for baking. The firing conditions are determined in consideration of the fire resistance of the aggregate, the melting behavior of the sintered binder, etc., but are usually in the range of 800 to 1200 ° C. The firing time depends on the types of the base layer material and surface layer material, the size of the molded body, and the like, but cannot be generally stated, but is about 2 to 72 hours.
[0079]
【Example】
Examples of the present invention will be described below.
[0080]
Example 1
Sewage sludge granulated slag was used as a main aggregate, and 10 parts by weight of a pulverized porcelain tile scrap of 0.5 mm or less was added to this as a mixed aggregate. The particle size is 4.75 mm in the maximum dimension, 63% by weight of particles in the range of 4.75 to 1.18 mm, 25% by weight of particles in the range of 1.18 to 0.5 mm, and in the range of 0.5 mm or less. Particles had a particle size distribution of 12% by weight. Further, as a result of examining this aggregate by X-ray diffraction, a clear diffraction pattern was not obtained. (Figure 3)
To this, water glass No. 3 as a paste was added and mixed so as to be 10 parts by weight with respect to 100 parts by weight of the aggregate, and the obtained mixture was mixed with powder of waste glass sheet (maximum size 0.3 mm) as a binder. A base layer material was obtained by adding and mixing so as to be 10 parts by weight with respect to 100 parts by weight of the material.
[0081]
On the other hand, a piece of porcelain tile waste (maximum dimension: 1.7 mm, 6 wt% in a range of 0.5 mm or less) is used as an aggregate, and iron oxide pigment is added to 2 parts by weight with respect to 100 parts by weight of the aggregate. Further, water glass No. 3 as a paste is added and mixed so as to be 8 parts by weight with respect to 100 parts by weight of the aggregate, and powder of the sheet glass waste (as a binder) is added to the resulting mixture. The surface layer material was obtained by adding and mixing 8 parts by weight with respect to 100 parts by weight of the aggregate.
[0082]
Next, the base material is put into a mold so that the thickness is 55 mm, and 1 kgf / cm is used using a vibration press.²After the primary molding at a pressure of 1, the above-mentioned surface layer material is put thereon so that the thickness becomes 15 mm, and again 1 kgf / cm²Was molded by pressurizing at a pressure of
[0083]
Next, carbon dioxide gas was allowed to act on the molded body to primarily cure water glass No. 3 as a paste, and then fired at 1100 ° C. for 4 hours using a tunnel kiln, the size being 100 × 200 mm, the thickness of the surface layer Was 12 mm, the thickness of the base layer was 48 mm, and the total thickness was 60 mm.
[0084]
The blocks thus obtained were evaluated for characteristics as follows.
[0085]
Of the cross-section of the block cut and polished at an arbitrary position, an arbitrary straight line is drawn on the inner cross-section excluding the approximately 10 mm thick surrounding area around the block, and the outline of the aggregate wrapped with the sintered binder is used. The lengths of the cut line segments were measured, this was performed for three straight lines, and further repeated for three cross sections. The maximum dimension at that time was 5.3 mm. The maximum particle size of the first raw material aggregate that is classified is larger than the maximum particle size of elongated particles. In the case of classification (sieving), the particle width (minor axis) works, whereas on the cross section, the straight line is near the major axis of the particle The reason is that the aggregate is wrapped with a sintered binder. The number of aggregates and voids wrapped with a sintered binder and present on a straight line having a length of 20 mm was determined. This was also performed on three straight lines for one cross section, and this was repeated for three cross sections, and the average of the nine values was taken. The average of the aggregates wrapped with the sintered binder was 7.3, and the average number of voids was 6.7.
[0086]
As a result of examining this section by X-ray diffraction, strong diffraction patterns of gelenite (2CaO · Al2O3 · SiO2), anorcite (CaO · Al2O3 · 2SiO2) and β-wollastonite (CaO · SiO2) were confirmed. . (See FIG. 4) This shows that crystallization has progressed in the firing step. Using the pulverized block, the content of crystalline components of gehlenite (2CaO · Al2O3 · SiO2), anorcite (CaO · Al2O3 · 2SiO2) and β-wollastonite (CaO · SiO2) was examined. %Met.
[0087]
The loss on ignition is 0.2%, the porosity is 21%, and the water permeability is 2.2 to 3.4 × 10.^-2cm / sec, Mohs hardness of the surface layer is 6.5, slip resistance when wet is 52 BPN, bending strength is 52 to 72 kgf / cm²Met.
[0088]
Example 2
A granular material obtained by melting and water-cooling garbage incineration ash was used as an aggregate. The particle size is less than the maximum dimension of 4.75 mm, particles in the range of 4.75 to 1.18 mm are 68 wt%, particles in the range of 1.18 to 0.5 mm are 22 wt%, 0.5 mm or less. The range of particles had a particle size distribution of 10% by weight.
[0089]
This was manufactured using substantially the same manufacturing conditions as in Example 1.
[0090]
First, water glass No. 3 as a paste is added and mixed so as to be 10 parts by weight with respect to 100 parts by weight of the aggregate, and the obtained mixture is mixed with powder of sheet glass waste (maximum dimension: 0.3 mm) as a binder. A base layer material was obtained by adding and mixing so as to be 10 parts by weight with respect to 100 parts by weight of the material.
[0091]
On the other hand, a piece of porcelain tile waste (maximum dimension: 1.7 mm, 6 wt% in a range of 0.5 mm or less) is used as an aggregate, and iron oxide pigment is added to 2 parts by weight with respect to 100 parts by weight of the aggregate. Further, water glass No. 3 was added and mixed as a paste so as to be 8 parts by weight with respect to 100 parts by weight of the aggregate, and the obtained mixture was mixed with powder of glass sheet waste as a binder (maximum (Size 0.3 mm) was added to and mixed with 100 parts by weight of the aggregate to obtain a surface layer material.
[0092]
Next, the base material is put into a mold so that the thickness is 55 mm, and 1 kgf / cm is used using a vibration press.²After the primary molding at a pressure of 1, the above-mentioned surface layer material is put thereon so that the thickness becomes 15 mm, and again 1 kgf / cm²Was molded by pressurizing at a pressure of
[0093]
Next, carbon dioxide gas was allowed to act on the molded body to primarily cure water glass No. 3 as a paste, and then fired at 1100 ° C. for 4 hours using a tunnel kiln, the size being 100 × 200 mm, the thickness of the surface layer Was 12 mm, the thickness of the base layer was 48 mm, and the total thickness was 60 mm.
[0094]
The blocks thus obtained were evaluated for characteristics as follows.
[0095]
Of the cross-section of the block cut and polished at an arbitrary position, an arbitrary straight line is drawn on the inner cross-section excluding the approximately 10 mm thick surrounding area around the block, and the outline of the aggregate wrapped with the sintered binder is used. The lengths of the cut line segments were measured, this was performed for three straight lines, and further repeated for three cross sections. The maximum dimension at that time was 5.3 mm. The maximum particle size of the first raw material aggregate that is classified is larger than the maximum particle size of elongated particles. In the case of classification (sieving), the particle width (minor axis) works, whereas on the cross section, the straight line is near the major axis of the particle The reason is that the aggregate is wrapped with a sintered binder. The number of aggregates and voids wrapped with a sintered binder and present on a straight line having a length of 20 mm was determined. This was also performed on three straight lines for one cross section, and this was repeated for three cross sections, and the average of the nine values was taken. The average of the aggregates wrapped with the sintered binder was 7.0 and the average number of voids was 7.5.
[0096]
The loss on ignition is 0.2%, the porosity is 25%, and the water permeability is 2.7 to 4.2 × 10.^-2cm / sec, Mohs hardness of the surface layer is 6.5, slip resistance value when wet is 55 BPN, bending strength is 47 to 65 kgf / cm²Met.
[0097]
【The invention's effect】
The water-permeable block of the present invention and the method for producing the same are excellent in water permeability and strength, and at the same time have high water retention, low surface abrasion, good slip resistance when wet, and are not easily soiled. Easy to recover.
[0098]
In addition, the sewage sludge melting slag and waste melting slag, which are in trouble with disposal, can be effectively used, and the product can be supplied at a lower cost because the raw material cost is lower than when using other expensive raw materials.
[Brief description of the drawings]
FIG. 1 is a schematic plan view of a water permeable block according to an embodiment of the present invention.
FIG. 2 is a schematic side view of a water permeable block according to an embodiment of the present invention.
FIG. 3 is an X-ray diffraction pattern diagram of sewage sludge granulated slag aggregate.
FIG. 4 is an X-ray diffraction pattern diagram of a cross section of the product of the present invention using sewage sludge granulated slag aggregate.
[Explanation of symbols]
1: Surface layer
2: Base layer
3: Projection for joint width regulation

Claims (6)

After forming a mixture containing 75% by weight or more selected from sewage sludge molten slag and waste molten slag and containing 7 to 25% by weight of particles of 0.5 mm or less, and a sintered binder, A method of firing the molded body at a temperature in the range of 800 to 1200 ° C., wherein the sewage sludge molten slag or dust molten slag contains 80% by weight or more of particles having a particle size of 4.75 mm or less, and is mainly composed of glass. A clear diffraction peak showing the crystal structure of a double oxide containing CaO and SiO ₂ or CaO, Al ₂ O ₃ and SiO ₂ by crystallization in the step of firing the molded body is obtained, the content of CaO and SiO ₂ or CaO and Al ₂ O ₃ and crystalline component calculated from the diffraction peak due to the crystal structure of the mixed oxide comprising SiO ₂ is 50 to 100-fold Method for producing a% of permeable ceramic block, characterized in that the employed as water-permeable ceramic block being within the range. 2. The method for producing a water-permeable ceramic block according to claim 1 , wherein the diffraction peak is a diffraction peak identified as at least one of anorthite, β-wollastonite, and gehlenite. The method for producing a water-permeable ceramic block according to claim 1 or 2, wherein particles of 0.5 mm or less of the aggregate are ceramic particles. Said sintering binder, feldspar, clay, natural stone, ceramics, glass, sewage sludge slag, sewage sludge incineration ash, waste slag, of claims 1 to 3, which is at least one member selected from powder of waste incineration ash The manufacturing method of the water-permeable ceramic block in any one. The permeable ceramic block according to any one of claims 1 to 4 , wherein the mixture contains at least one selected from carboxymethylcellulose (CMC), methylcellulose, starch, water glass, and cement as a forming paste. Production method. The method for producing a water-permeable ceramic block according to any one of claims 1 to 5 , wherein a vibration press is used in the forming step.

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