JP4448565B2 - Porous lightweight ceramic product and manufacturing method thereof - Google Patents
Porous lightweight ceramic product and manufacturing method thereof Download PDFInfo
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- JP4448565B2 JP4448565B2 JP20745197A JP20745197A JP4448565B2 JP 4448565 B2 JP4448565 B2 JP 4448565B2 JP 20745197 A JP20745197 A JP 20745197A JP 20745197 A JP20745197 A JP 20745197A JP 4448565 B2 JP4448565 B2 JP 4448565B2
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62204—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/22—Glass ; Devitrified glass
- C04B14/24—Glass ; Devitrified glass porous, e.g. foamed glass
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/132—Waste materials; Refuse; Residues
- C04B33/135—Combustion residues, e.g. fly ash, incineration waste
- C04B33/1352—Fuel ashes, e.g. fly ash
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/08—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding porous substances
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/36—Glass starting materials for making ceramics, e.g. silica glass
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
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- Environmental & Geological Engineering (AREA)
- Dispersion Chemistry (AREA)
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- Combustion & Propulsion (AREA)
- Civil Engineering (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
Description
【０００１】
【発明の属する技術分野】
本発明は多孔質軽量セラミック製品に関するものであり、特に非常に空隙率の高くかつ強度の大きな多孔質軽量セラミック製品及びその製造方法に関するものである。
【０００２】
【従来の技術及び発明が解決しようとする課題】
従来の多孔質セラミック製品の製造法には、発泡性未焼成セラミック粉体に結合材を混合し、成形後、焼成する方法や、主原料として黒曜石やシラス等の火山噴出物を用い、これらに粘土や結合材を混合して、成形後、焼成する方法等がある。
しかしながら、それら方法により得られた多孔質セラミック製品は、嵩比重が十分に低くなく、かつ空隙率が十分に多くないものであった。
【０００３】
【課題を解決するための手段】
本発明者は上記課題を解決すべく鋭意研究の結果、火山噴出物として多量に産出する黒曜石、シラス等の加熱発泡球状体粗粒子、すなわち火山噴出物発泡球状粗粒子、例えばパーライトを主原料とし、あるいは人工発泡ガラス質球状粗粒子、例えばスラグの加熱発泡球状粗粒子を主原料とし、これに火力発電所から大量に排出されるフライアッシュの相当量及び合成樹脂、動・植物等の有機物細片を混有した結合材を加えて混合した後、成形し、焼成することによって、非常に軽量化された多孔質セラミックを提供することに成功した。すなわち本発明は、下記構成の多孔質軽量セラミック製品及びその製造方法である。
（１）多数のガラス質中空球状粗粒子の間をフライアッシュを含む多孔質セラミックマトリックス焼結体が結合充填してなり、かつ前記多孔質セラミツクマトリックス焼結体中の多孔質空隙部が有機物細片の焼失孔（ただし、吸水膨潤した高吸水性ポリマーの消失孔を除く）である多孔質軽量セラミック製品であって、粒径０．５〜５．０ｍｍのガラス質中空球状粗粒子１００重量部に対して、フライアッシュ１５〜３５０重量部と、多孔質セラミックマトリックス焼結体５〜８０重量部が均質混在した焼結体であり、その物理特性が、嵩比重０．２〜１．２、圧縮強度：５．０〜５０ｋｇｆ／ｃｍ 2 、曲げ強度：０．５〜５．０ｋｇｆ／ｃｍ 2 であることを特徴とする多孔質軽量セラミック製品。
（２）ガラス質中空球状粗粒子が、天然ガラス質発泡体粗粒子であることを特徴とする（１）項に記載の多孔質軽量セラミック製品。
（３）ガラス質中空球状粗粒子が、人工発泡ガラス質粗粒子であることを特徴とする（１）項に記載の多孔質軽量セラミック製品。
【０００４】
（４）粒径０．５〜５．０ｍｍのガラス質中空球状粗粒子１００重量部に対して、フライアッシュ１５〜３５０重量部と、粒径が１０〜２０００μｍの有機物細片３０〜７０重量％を均質に含有する未焼成セラミック粉体を含む結合材６０〜４５０重量部とが混合された混合物を成形し、乾燥した後、７５０〜１２００℃で焼成して、多数のガラス質中空球状粗粒子の間をフライアッシュを含む多孔質セラミックマトリックス焼結体が結合充填してなり、かつ前記多孔質セラミツクマトリックス焼結体中の多孔質空隙部が有機物細片の焼失孔（ただし、吸水膨潤した高吸水性ポリマーの消失孔を除く）である多孔質軽量セラミック製品であって、粒径０．５〜５．０ｍｍのガラス質中空球状粗粒子１００重量部に対して、フライアッシュ１５〜３５０重量部と、多孔質セラミックマトリックス焼結体５〜８０重量部が均質混在した焼結体であり、その物理特性が、嵩比重０．２〜１．２、圧縮強度：５．０〜５０ｋｇｆ／ｃｍ 2 、曲げ強度：０．５〜５．０ｋｇｆ／ｃｍ 2 であるすることを特徴とする多孔質軽量セラミック製品の製造方法。
（５）結合材中に占める未焼成セラミック粉体が４０〜７０重量％であることを特徴とする（４）項に記載の多孔質軽量セラミック製品の製造方法。
（６）結合材が、無機結合材を含むことを特徴とする（４）項又は（５）項のいずれか１項に記載の多孔質軽量セラミック製品の製造方法。
（７）結合材が、ガラス質粉体を含むことを特徴とする（４）項〜（６）項のいずれか１項に記載の多孔質軽量セラミック製品の製造方法。
（８）結合材が、粘土鉱物を含むことを特徴とする（４）項〜（７）項のいずれか１項に記載の多孔質軽量セラミック製品の製造方法。
（９）結合材が、有機質結合材を含むことを特徴とする（４）項〜（８）のいずれか１項に記載の多孔質軽量セラミック製品の製造方法。
（１０）結合材が、水溶性のアルカリ金属ケイ酸塩を含むことを特徴とする（４）項〜（９）のいずれか１項に記載の多孔質軽量セラミック製品の製造方法。
【０００５】
【発明の実施の形態】
本願発明の実施の形態を以下に説明する。
まず、本願発明で主原料として用いらるガラス質中空球状粗粒子としては、例えば天然ガラス質発泡粗粒子である黒曜石細片や真珠岩細片等の高温加熱による発泡粗粒子であるパーライト、人工ガラス質粗粒子である水砕スラグ細片やシリカ細片の高温加熱発泡粗粒子であるスラグバルーンやシリカバルーン等が挙げられ、発泡球状粗粒子の粒径は０．５０〜５．０ｍｍであるものが好ましい。
その嵩密度は０．１／ｃｍ３〜１．０／ｃｍ３のものが好ましい。
【０００６】
次に、本願発明で主原料として使用されるフライアッシュは、石炭や石油ピッチ等を燃焼させたあとに出る残渣灰であり、火力発電所等から大量に排出されるものであって、現在、その利用技術、利用量が少ないために、各分野にてその利用が鋭意検討されているものである。
フライアッシュの成分組成は、例えばＳｉＯ２：５０〜６８％，Ａｌ２Ｏ3：２０〜３５％、Ｆｅ２Ｏ3：２〜７％，ＣａＯ：０．６〜７％、ＭｇＯ：０．２〜２％，Ｎａ２Ｏ：０．１〜２％、Ｋ２Ｏ：０．３〜１．５％，Ｉｇ．ｌｏｓｓ：２〜４％からなり、非晶質であり、かつ各フライアッシュ粒子は粒径５〜２０μｍの球状体で内部が中空となっているものである。
よって、フライアッシュ粒子は、転動性、充填性が良好で、前記多数のガラス質中空球状粗粒子間に容易に隈無く充填される。
【０００７】
本願発明は、多くのガラス質中空球状粗粒子間にフライアッシュと多孔質セラミックマトリックス焼結体が焼結充填された状態の多孔質軽量セラミック製品を提供するものであるが、その製造においては、まず成形性を付与させるため、ガラス質中空球状粗粒子とフライアッシュと未焼成セラミックマトリックス生成材料（結合材）、好ましくは少量の有機物細片を混有させた未焼成セラミックマトリックス生成材料（結合材）との均質混合物を加水あるいは可塑化材を添加混合して、生地となし、それを一定形状に成形し、乾燥した後、焼成する。
前記未焼成セラミックマトリックス生成材料中の有機物細片としては、高温加熱により揮発焼失するもので、例えば木材・竹材・穀類等の植物細片、脂肪細片、プランクトン等の動物細片、ポリスチロール、ポリエチレン、ポリプロピレン等の合成樹脂細片が挙げられる。さらに、有機質短繊維、例えばナイロン短繊維、ポリプロピレン短繊維等も使用できる。
なお上記植物細片としては、加工食品も採用でき、例えば茹であげたうどんやそうめん等の細断片を使用することもできる。
【０００８】
また、焼成によりセラミックスマトリックスを生成する未焼成セラミックとしては、例えば長石、陶土、粘土鉱物等のケイ酸アルミニウム系無機材料が挙げられ、それらには焼結剤としてのアルカリ金属・アルカリ土類金属ケイ酸塩、ガラス粉、釉薬粉等を添加することが好ましく、さらに無機系粘結材の水溶性アルカリケイ酸塩（水ガラス）や有機質粘結材のコーンスターチ、ＣＭＣ等を添加したものが好ましい。
なお、成形のための可塑性付与材としては、通常有機系のもの、例えば前記粘結材と同じコーンスターチ、ＣＭＣやアルギン酸ソーダー、ＰＶＡ、ポリアクリル系エマルジン、多価アルコール系ワックス等を添加使用することができる。
前記水溶性アルカリケイ酸塩（水ガラス）は成形用及び焼結用に共用される可塑性付与材兼焼結剤として好ましいものであるが、これは液状のもの（水溶液）をそのまま使用しても、あるいは粉末状のものに水を加え混合して使用してもよい。
【０００９】
本願発明においては、さらに耐熱性補強材を加配することもできる。このような耐熱性補強材としては、例えば鉱滓、シャモット等が採用でき、これら耐熱性補強材を加配し、焼結して得られた多孔質軽量セラミック製品は、高い機械的強度及び耐熱性を備えたものとなる。
【００１０】
上記のようなガラス質中空球状粗粒子に、フライアッシュ及び有機物細片を含む結合材を均質に混合した混合物を所要形状に成形した後、乾燥し、７５０〜１２００℃程度の焼成温度域において焼結させることにより、多孔質軽量セラミック製品を得ることができる。
【００１１】
上記発明のセラミックス製品の配合組成において、ガラス質中空球状粗粒子を用いるのは、該粗粒子は黒曜石、真珠岩等の天然ガラス等を原料にして多量に生産され価格も安価で、内部が中空で軽量であり、かつ一定の強度も備えているため、これを主要構成材料とすることにより製品の軽量化及びある程度の強度向上に寄与するためであり、さらにそれがガラス質であるから、その周りに接触充填されるフライアッシュ、セラミックマトリックスとの焼結接合が容易であり、その結果焼成製品はガラス質球状粗粒子表層とセラミックマトリックスが強固に結合して、全体強度が向上するのである。
そして、主原料としてガラス質中空球状粗粒子とフライアッシュを用いたことにより、製品の空隙率を多大に確保し、かつ有機物細片及び未焼成セラミックセラミックを含む結合材を使用したことによりに、製品の空隙率を最大に確保することができるのである。
なお、該セラミック製品中には、素材中の各ガラス質中空球状粗粒子同士の接触部分（以下、第１点接触部分という）間に形成される大きな空隙部（以下、第１空隙部という）、及び第１空隙部内に充填されたフライアッシュの各粒子同士の接触部分（以下、第２点接触部分という）間に形成される小さな空隙部（以下、第２空隙部という）、さらにセラミックマトリックス内の有機物細片の消失孔である空隙部（以下、第３空隙部という）の３種の多量の空隙部が存在するため、全体の空隙率が高く、かつ第１，第２、第３空隙部が接続状態となって連通する結果、軽量化及び良好な通気性・通液性が確保される。
さらに、ガラス質中空球状粗粒子は、７５０〜１２００℃に加熱された際に、高温部（約１０００〜１２００℃）の加熱領域で加熱されると、各粗粒子は、熔融、発泡して所々に部分的に発泡穴が形成されたものとなり、各粗粒子自体がその球状壁の所々に貫通穴を備えるものとなる結果、より良好な通気性・通液性が実現される。
よって、本発明の多孔質軽量セラミック製品は、下記のような材料として利用できる。
軽量タイル、軽量壁板パネル、断熱材料、吸音材料、濾過材料、触媒を担持させた触媒、微生物を利用する排水処理に使用される各種バクテリア、細菌類を担持した排水処理材料、遠赤外線放射材料、各種フェライトなどを組成物素材とした電波吸収性パネル等。
【００１２】
【実施例】
本願発明の実施例を以下に説明する。
［実施例１］
ガラス質球状粗粒子（粒径１〜２ｍｍ）
（パーライト） １００重量部
フライアッシュ粉末 ５０重量部
上記の混合物に、下記組成の結合材を２０重量部を添加混合した。
珪酸ソーダ（３号） ４０重量％
蛍石粉末 １５重量％
陶石粉末 ２０重量％
発泡スチロール微小球 ５重量％
メトローズ ５重量％
水 １５重量％
得られた上記混合配合物を型枠に投入し低圧成形してタイル状成形体を得た後、乾燥し、その後９５０℃の焼成帯で、９０分間焼結させた。
この結果、得られた多孔質軽量セラミックス製品はカサ比重が１以下であり、圧縮強度２０〜３０ｋｇ／ｃｍ２、高温耐熱性（１０００℃以上）・耐熱衝撃性に優れ、かつ通気性・通水性に優れ吸音率も高いものであった。
【００１３】
［実施例２］
ガラス質球状粗粒子（粒径１〜２ｍｍ）
（パーライト） １００重量部
フライアッシュ粉末 １００重量部
上記の混合物に、下記組成の結合材を３０重量部を添加混合した。
蛍石粉末 １５重量％
ガラス粉末 ２０重量％
カオリン粉末 ２０重量％
ポリメタアクリル樹脂細片 １０重量％
メトローズ ５重量％
水 ３０重量％
上記混合物を型枠に入れてタイル状成形体にした後、１０００℃の焼成帯で、６０分間焼結させた。
この結果、得られた多孔質軽量セラミックス製品はカサ比重が１以下であり、圧縮強度１０〜４０ｋｇ／ｃｍ２、高温耐熱性（１０００℃以上）・耐熱衝撃性に優れ、かつ通気性・通水性に優れ吸音率も高いものであった。
【００１４】
【発明の効果】
以上の本願発明によれば下記のような優れた作用効果が得られる。
本発明の製造方法においては、主原料としてガラス質中空球状粗粒子とフライアッシュを用いたことにより、製品の空隙率を多大に確保し、かつ有機物細片及び未焼成セラミックセラミックを含む結合材を使用したことによりに、製品の空隙率を最大に確保することができる。
なお、該セラミック製品は、素材中の各フライアッシュ粒子が中空であるため軽量であり、かつ粒子同士の接触部分は点接触で連結され、また有機物細片の焼失孔が残存するため、マトリックス部分が連通多孔質となっていて、気液通過性が良好となる。
本発明の多孔質軽量セラミック製品は、安価なガラス質中空球状粗粒子及びフライアッシュを主原料とするため、製品製造コストが低く、かつ火力発電所等より大量に発生され、その処分が問題となっているフライアッシュの有効活用に寄与するものでもある。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a porous lightweight ceramic product, and more particularly to a porous lightweight ceramic product having a very high porosity and a high strength, and a method for producing the same.
[0002]
[Prior art and problems to be solved by the invention]
Conventional methods for producing porous ceramic products include a method in which a binder is mixed with foamable unfired ceramic powder and then fired after molding, and volcanic ejecta such as obsidian and shirasu are used as the main raw materials. There is a method in which clay and a binder are mixed and fired after molding.
However, the porous ceramic products obtained by these methods have a bulk specific gravity that is not sufficiently low and a porosity is not sufficiently high.
[0003]
[Means for Solving the Problems]
As a result of diligent research to solve the above-mentioned problems, the present inventor mainly uses heated foamed spherical coarse particles such as obsidian and shirasu that are produced in large quantities as volcanic ejecta, that is, volcanic ejected foamed coarse spherical particles such as perlite. Alternatively, artificial foamed glassy spherical coarse particles, such as heated foamed spherical coarse particles of slag, are used as the main raw material, and a considerable amount of fly ash discharged in large quantities from thermal power plants and organic resin fines such as synthetic resins, animals and plants, etc. The present inventors succeeded in providing a very lightweight porous ceramic by adding and mixing a binder having a mixture of pieces, followed by molding and firing. That is, this invention is the porous lightweight ceramic product of the following structure, and its manufacturing method.
(1) number of between glassy hollow spheres coarse particles with a porous ceramic matrix sintered body bonded filling containing fly ash Ri Na, and porous void portion is organic material of the porous ceramic arrive matrix sintered body It is a porous lightweight ceramic product which is a burnt pore of a fine piece (excluding disappearance pores of a superabsorbent polymer which has swollen and absorbs water), and has a glassy hollow spherical coarse particle size of 0.5 to 5.0 mm. Is a sintered body in which 15 to 350 parts by weight of fly ash and 5 to 80 parts by weight of a porous ceramic matrix sintered body are homogeneously mixed, and the physical properties thereof are 0.2 to 1.2 in bulk specific gravity. , compressive strength: 5.0~50kgf / cm 2, bending strength: porous lightweight ceramic product which is a 0.5~5.0kgf / cm 2.
(2) The porous lightweight ceramic product according to item (1) , wherein the vitreous hollow spherical coarse particles are natural vitreous foam coarse particles.
(3) The porous lightweight ceramic product according to item (1 ), wherein the glassy hollow spherical coarse particles are artificial foamed vitreous coarse particles.
[0004]
(4) 15 to 350 parts by weight of fly ash and 30 to 70% by weight of organic fine particles having a particle diameter of 10 to 2000 μm with respect to 100 parts by weight of glassy hollow spherical coarse particles having a particle diameter of 0.5 to 5.0 mm A mixture of 60 to 450 parts by weight of a binder containing unfired ceramic powder containing homogeneously is molded, dried, and then fired at 750 to 1200 ° C. to obtain a large number of vitreous hollow spherical coarse particles The porous ceramic matrix sintered body containing fly ash is bonded and filled between the porous ceramic matrix sintered bodies, and the porous voids in the porous ceramic matrix sintered body are burned out pores of organic fine particles (however, the water-absorbed and swollen A porous lightweight ceramic product (excluding vanishing pores of water-absorbing polymer), and fly ash 15 per 100 parts by weight of vitreous hollow spherical coarse particles having a particle size of 0.5 to 5.0 mm It is a sintered body in which 350 parts by weight and 5 to 80 parts by weight of a porous ceramic matrix sintered body are homogeneously mixed. Its physical characteristics are a bulk specific gravity of 0.2 to 1.2, and a compressive strength: 5.0 to 50 kgf. / cm 2, bending strength: 0.5~5.0kgf / porous lightweight ceramic product manufacturing method which is characterized in that is cm 2.
(5) The method for producing a porous lightweight ceramic product according to (4), wherein the unfired ceramic powder in the binder is 40 to 70% by weight.
(6) The method for producing a porous lightweight ceramic product according to any one of (4) or (5) , wherein the binder comprises an inorganic binder.
(7) The method for producing a porous lightweight ceramic product according to any one of (4) to (6) , wherein the binder contains a vitreous powder.
(8) The method for producing a porous lightweight ceramic product according to any one of (4) to (7) , wherein the binder contains a clay mineral.
(9) The method for producing a porous lightweight ceramic product according to any one of (4) to (8) , wherein the binder includes an organic binder.
(10) The method for producing a porous lightweight ceramic product according to any one of (4) to (9) , wherein the binder contains a water-soluble alkali metal silicate.
[0005]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below.
First, as the vitreous hollow spherical coarse particles used as the main raw material in the present invention, for example, perlite, which is a coarse foamed particle by heating at a high temperature, such as obsidian fine pieces and nacreous fine pieces which are natural vitreous foam coarse particles, artificial Examples include slag balloons and silica balloons that are high-temperature heated foamed coarse particles of granulated slag and silica fine particles that are glassy coarse particles, and the diameter of the foamed spherical coarse particles is 0.50 to 5.0 mm. Those are preferred.
The bulk density is preferably 0.1 / cm 3 to 1.0 / cm 3 .
[0006]
Next, fly ash used as the main raw material in the present invention is residual ash that is produced after burning coal, petroleum pitch, etc., and is discharged in large quantities from thermal power plants, etc. Due to its small utilization technology and amount, its use has been intensively studied in various fields.
The component composition of fly ash is, for example, SiO 2 : 50 to 68%, Al 2 O 3 : 20 to 35%, Fe 2 O 3 : 2 to 7%, CaO: 0.6 to 7%, MgO: 0.2 ~2%, Na 2 O: 0.1~2 %, K 2 O: 0.3~1.5%, Ig. loss: 2 to 4%, which is amorphous, and each fly ash particle is a spherical body having a particle size of 5 to 20 μm and hollow inside.
Therefore, the fly ash particles have good rolling properties and filling properties, and are easily filled without any problem between the numerous glassy hollow spherical coarse particles.
[0007]
The present invention provides a porous lightweight ceramic product in which fly ash and a porous ceramic matrix sintered body are sintered and filled between many glassy hollow spherical coarse particles. In the production thereof, First, in order to impart formability, an unfired ceramic matrix generating material (binding material) in which glassy hollow spherical coarse particles, fly ash, and an unfired ceramic matrix forming material (binding material), preferably a small amount of organic fine particles are mixed. And a plasticizer is added and mixed to form a dough, which is formed into a certain shape, dried, and fired.
As organic matter fragments in the unfired ceramic matrix-forming material, it is volatilized and burned off by high-temperature heating, for example, plant fragments such as wood, bamboo, and grains, fat fragments, animal fragments such as plankton, polystyrene, Examples include synthetic resin strips such as polyethylene and polypropylene. Further, organic short fibers such as nylon short fibers and polypropylene short fibers can also be used.
In addition, processed food can also be used as the above-mentioned plant fine pieces, and for example, fine pieces such as udon and somen noodles that have been boiled can be used.
[0008]
Examples of the unfired ceramic that forms a ceramic matrix by firing include aluminum silicate-based inorganic materials such as feldspar, porcelain clay, and clay minerals. These include alkali metal and alkaline earth metal silica as a sintering agent. It is preferable to add acid salt, glass powder, glaze powder, etc., and further, water-soluble alkali silicate (water glass) of an inorganic binder, corn starch of organic binder, CMC, etc. are preferably added.
In addition, as a plasticizer for molding, usually an organic material, for example, the same corn starch, CMC, sodium alginate, PVA, polyacrylic emeraldine, polyhydric alcohol wax, etc., as used in the above-mentioned binder are used. Can do.
The water-soluble alkali silicate (water glass) is preferable as a plasticizer / sintering agent shared for molding and sintering, but this may be used as a liquid (aqueous solution) as it is. Alternatively, it may be used by adding water to a powdery product and mixing it.
[0009]
In the present invention, a heat-resistant reinforcing material can be further distributed. As such a heat-resistant reinforcing material, for example, iron ore, chamotte, etc. can be adopted, and porous lightweight ceramic products obtained by adding and sintering these heat-resistant reinforcing materials have high mechanical strength and heat resistance. It will be prepared.
[0010]
A mixture in which the binder containing fly ash and organic fine particles is homogeneously mixed with the glassy hollow spherical coarse particles as described above is formed into a required shape, dried, and baked in a baking temperature range of about 750 to 1200 ° C. By bonding, a porous lightweight ceramic product can be obtained.
[0011]
In the compounding composition of the ceramic product of the present invention, glassy hollow spherical coarse particles are used because the coarse particles are produced in large quantities from natural glass such as obsidian and pearlite, and the price is low and the interior is hollow. Because it is lightweight and also has a certain strength, it is intended to contribute to weight reduction of the product and a certain degree of strength improvement by making it a main constituent material, and since it is glassy, It is easy to sinter and join the fly ash and the ceramic matrix which are contact-filled around. As a result, in the sintered product, the vitreous spherical coarse particle surface layer and the ceramic matrix are firmly bonded, and the overall strength is improved.
And by using glassy hollow spherical coarse particles and fly ash as the main raw material, by ensuring a large porosity of the product, and by using a binder containing organic fine pieces and unfired ceramic ceramic, The maximum porosity of the product can be secured.
In the ceramic product, a large void portion (hereinafter referred to as a first void portion) formed between contact portions (hereinafter referred to as first point contact portions) between the vitreous hollow spherical coarse particles in the raw material. , And a small void portion (hereinafter referred to as the second void portion) formed between the contact portions (hereinafter referred to as second point contact portions) of the particles of fly ash filled in the first void portion, and further a ceramic matrix Since there are a large amount of three kinds of voids (hereinafter referred to as third voids) which are the disappearance holes of the organic fine particles, the overall void ratio is high, and the first, second, third As a result of communicating the gap portion in a connected state, weight reduction and good air permeability and liquid permeability are ensured.
Furthermore, when the vitreous hollow spherical coarse particles are heated to 750 to 1200 ° C. and heated in a heating region of a high temperature part (about 1000 to 1200 ° C.), the coarse particles are melted and foamed in some places. As a result, each of the coarse particles itself has through holes in the spherical walls, so that better air permeability and liquid permeability are realized.
Therefore, the porous lightweight ceramic product of the present invention can be used as the following materials.
Lightweight tiles, lightweight wall panels, heat insulation materials, sound absorbing materials, filtration materials, catalysts carrying catalysts, various bacteria used in wastewater treatment using microorganisms, wastewater treatment materials carrying bacteria, far-infrared radiation materials , Radio wave absorptive panels made of various ferrites as composition materials.
[0012]
【Example】
Examples of the present invention will be described below.
[Example 1]
Glassy spherical coarse particles (particle size 1-2mm)
(Perlite) 100 parts by weight fly ash powder 50 parts by weight 20 parts by weight of a binder having the following composition was added to and mixed with the above mixture.
Sodium silicate (No.3) 40% by weight
Fluorite powder 15% by weight
20% by weight of porcelain stone powder
Styrofoam microspheres 5% by weight
Metroz 5% by weight
15% water
The obtained mixed composition was put into a mold and subjected to low-pressure molding to obtain a tile-shaped molded body, which was then dried and then sintered in a firing zone at 950 ° C. for 90 minutes.
As a result, the obtained porous lightweight ceramic product has a specific gravity of 1 or less, a compressive strength of 20 to 30 kg / cm 2 , excellent high temperature heat resistance (1000 ° C. or higher) and thermal shock resistance, and breathability and water permeability. Excellent sound absorption coefficient.
[0013]
[Example 2]
Glassy spherical coarse particles (particle size 1-2mm)
(Perlite) 100 parts by weight Fly ash powder 100 parts by weight 30 parts by weight of a binder having the following composition was added to and mixed with the above mixture.
Fluorite powder 15% by weight
Glass powder 20% by weight
Kaolin powder 20% by weight
10% by weight of polymethacrylic resin strip
Metroz 5% by weight
30% water
The mixture was put into a mold to form a tile-shaped molded body, and then sintered in a firing zone at 1000 ° C. for 60 minutes.
As a result, the obtained porous lightweight ceramic product has a specific gravity of 1 or less, a compressive strength of 10 to 40 kg / cm 2 , excellent high temperature heat resistance (1000 ° C. or higher) and thermal shock resistance, and breathability and water permeability. Excellent sound absorption coefficient.
[0014]
【The invention's effect】
According to the present invention described above, the following excellent effects can be obtained.
In the production method of the present invention, the use of vitreous hollow spherical coarse particles and fly ash as the main raw materials ensures a large porosity of the product, and a binder containing organic fine pieces and unfired ceramic ceramics. By using it, the porosity of the product can be ensured to the maximum.
The ceramic product is lightweight because each fly ash particle in the material is hollow, and the contact portion between the particles is connected by point contact, and the burnout pores of the organic fine pieces remain, so that the matrix portion Is communicated porous, and gas-liquid permeability is improved.
Since the porous lightweight ceramic product of the present invention is mainly made of inexpensive glassy hollow spherical coarse particles and fly ash, the product manufacturing cost is low, and it is generated in large quantities from thermal power plants, etc., and its disposal is a problem. It also contributes to the effective use of fly ash.
Claims (10)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP20745197A JP4448565B2 (en) | 1997-08-01 | 1997-08-01 | Porous lightweight ceramic product and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP20745197A JP4448565B2 (en) | 1997-08-01 | 1997-08-01 | Porous lightweight ceramic product and manufacturing method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH1149585A JPH1149585A (en) | 1999-02-23 |
| JP4448565B2 true JP4448565B2 (en) | 2010-04-14 |
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| JP20745197A Expired - Fee Related JP4448565B2 (en) | 1997-08-01 | 1997-08-01 | Porous lightweight ceramic product and manufacturing method thereof |
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| JP (1) | JP4448565B2 (en) |
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| AU2002210906A1 (en) * | 2000-10-17 | 2002-04-29 | Oda Construction Co., Ltd. | Porous, sound absorbing ceramic moldings and method for production thereof |
| DE102009005446A1 (en) * | 2009-01-21 | 2010-07-22 | Schott Ag | Granules, process for its preparation and its use |
| JP5586041B2 (en) * | 2009-08-24 | 2014-09-10 | 東興パーライト工業株式会社 | Manufacturing method of ceramics |
| CN106927851B (en) * | 2017-03-31 | 2020-01-10 | 北京师范大学 | Light foamed ceramic hollow ball particle |
| CN111233334B (en) * | 2020-02-25 | 2022-05-17 | 内蒙古工业大学 | Preparation method of anorthite-quartz-glass phase multiphase ceramic |
| CN111410550A (en) * | 2020-04-20 | 2020-07-14 | 浙江工贸职业技术学院 | Preparation method of porous ceramic |
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| JPH1149585A (en) | 1999-02-23 |
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