JP7038708B2 - 軽量高強度セラミック粒子及びその製造方法 - Google Patents
軽量高強度セラミック粒子及びその製造方法 Download PDFInfo
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- JP7038708B2 JP7038708B2 JP2019522261A JP2019522261A JP7038708B2 JP 7038708 B2 JP7038708 B2 JP 7038708B2 JP 2019522261 A JP2019522261 A JP 2019522261A JP 2019522261 A JP2019522261 A JP 2019522261A JP 7038708 B2 JP7038708 B2 JP 7038708B2
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Description
1、低円筒圧縮強度;
2、少量のフライアッシュ;
3、危険な液体活性剤。
a 固体原料を秤量して混合し、固体活性剤を調製するステップ:アルカリ金属ケイ酸塩溶液にアルカリ金属水酸化物を溶解し、室温に冷却した後、少量の白色沈殿物が観察されるまで撹拌を続け、得られた溶液をきれいな容器に注ぎ入れ、白色結晶が室温で1~20分間で凝集体に形成され、凝集体を粉砕して固体活性剤を形成するステップ;
b 混合ステップ:前記固体原料と前記固体活性化剤を十分に混合して混合原料を形成するステップ;
c ペレット化ステップ:混合原料をペレット化して粒子にするステップ;
d 硬化ステップ:前記粒子を温度70~100℃および湿度70~90%の条件下に1~2時間維持して硬化させるステップ;
e 乾燥ステップ:硬化した粒子を100~300℃の温度で乾燥するステップ;
f 焼結ステップ:乾燥した粒子を所定の焼結処理により60~90分間焼結するステップ;
g 最終製品を形成するステップ:前記焼結した粒子を室温に冷却して軽量高強度セラミック粒子を得るステップ;
を含む。
1、ボールミルにかけることなく原料を直接混合しペレット化することができるため、エネルギー消費を最小限に抑え、処理工程を省くことができる。
2、粒子が最初に硬化され、次に焼結されるため、焼結処理は粉塵を生じず、最小の汚染をもたらす。
3、製品は軽量で高強度で、密度レベルは700~1100kg/m3、円筒圧縮強度は10~20MPaで、損傷を受けにくい。当該製品は、高性能コンクリートを製造するための軽量骨材として、または建築用壁板、橋、パイプおよび他の用途における使用に適した耐力構造として用いることができる。
4、原料の強度を増大させるために、多量のアルミナおよびボーキサイトを含む高アルミナフライアッシュが本発明の固体原料に添加されている。
5、本発明の固体原料には、固体原料と固体活性剤との混合効果を向上させるために界面活性剤がさらに添加されている。したがって、得られたセラミック粒子はより均質な特性およびより安定した品質を有する。
6、本発明で使用される固体活性剤は液体活性剤より取扱いが容易である。液体活性剤は強アルカリ性であるので、それは装置を容易に腐食しそして人間の健康に有害である。
固体原料の秤量:850gのフライアッシュ、20gの広東省白色粘土、100gの高アルミナフライアッシュ、30gのシリカフューム、8gのリグノスルホン酸ナトリウムを秤量し、これらの固体原料を混合した。
固体原料の秤量:880gのフライアッシュ、40gのボーキサイト、10gのリグノスルホン酸ナトリウム、および70gのベントナイトを秤量し、これらの固体原料を混合した。
固体原料の秤量:860gのフライアッシュ、40gのシリカフューム、50gのボーキサイト、20gのセルロース、および10gのライトポリマー社から入手可能なCT017を秤量し、これらの固体原料を混合した。
温度:室温~80℃。
湿度:70~90%。
固体原料の秤量:800gのフライアッシュ、30gの広東白色粘土、80gのベントナイト、10gのリグノスルホン酸ナトリウム、および50gの高アルミナフライアッシュを秤量した。これらの固体原料を混合した。
温度:室温~90℃。
湿度:70~90%。
固体原料の秤量:750gのフライアッシュ、100gの赤泥、10gのシリカフューム、および50gの方解石を秤量し、これらの固体原料を混合した。
温度:室温~70℃。
湿度:70~90%。
固体原料の秤量:850gのフライアッシュ、20gの広東省白色粘土、および30gのシリカフュームを秤量した。これらの固体原料を混合した。
温度:室温~100℃。
湿度:70~90%。
固体原料の秤量:880gのフライアッシュおよび70gのベントナイトを秤量し、これらの固体原料を混合した。
温度:室温~80℃。
湿度:70~90%。
固体原料の秤量:800gのフライアッシュ、30gの広東省白色粘土、80gのベントナイト、10gのリグノスルホン酸ナトリウム、および50gの高アルミナフライアッシュを秤量し、これらの固体原料を混合した。得られた混合物に8gの水を加え、均一になるまで攪拌した。
温度:室温~90℃。
湿度:70~90%。
固体物の秤量:750gのフライアッシュ、100gの赤泥、10gのシリカフューム、50gの方解石を秤量し、これらの固体原料を混合した。得られた混合物に水を加えて均一になるまで攪拌した。
温度:室温~70℃。
湿度:70~90%。
Claims (10)
- 固体原料および固体活性剤を原料として含み、前記固体原料および前記固体活性剤はそれぞれ質量部で表すことができ、前記固体原料が100部で、前記固体活性剤が1~15部である、軽量高強度セラミック粒子であって、
前記固体原料が、フライアッシュを100部、高アルミナフライアッシュ、ボーキサイトおよび赤泥を6~18部、シリカフュームを1~5部、界面活性剤を0.1~3部、可塑剤を6~24部含み、
前記固体活性剤が、アルカリ金属水酸化物5~20部を60~95質量%のアルカリ金属ケイ酸塩溶液80~95部に溶解し、室温に冷却した後、結晶が凝集体に形成され、凝集体を粉砕して形成される、
軽量高強度セラミック粒子。 - 前記フライアッシュは、以下の成分:
強熱減量2~10%と、SiO230%~70%と、Al2O310%~50%と、CaO1%~15%と、Fe2O31%~18%と、MgO0.01%~8%と、TiO20.01%~3%と、を含む、請求項1に記載の軽量高強度セラミック粒子。 - 前記可塑剤が、広東白色粘土、広東黒色粘土、カオリン、ベントナイト、PVA、およびセルロースからなる群から選択される1種以上である、請求項1に記載の軽量高強度セラミック粒子。
- 前記高アルミナフライアッシュおよび前記ボーキサイトが37%以上のアルミナ含有量を有し、前記赤泥と前記高アルミナフライアッシュおよび前記ボーキサイトとの質量部の比が1:2~1:5である、請求項1に記載の軽量高強度セラミック粒子。
- 前記固体原料が、鉄鉱石尾鉱を0.01~5部、方解石を0.01~5部さらに含む、請求項1に記載の軽量高強度セラミック粒子。
- 前記アルカリ金属水酸化物が水酸化ナトリウム、水酸化カリウムおよび水酸化リチウムからなる群から選ばれる1種以上であり、
前記アルカリ金属ケイ酸塩溶液中の前記アルカリ金属ケイ酸塩がケイ酸ナトリウム、ケイ酸カリウムおよびケイ酸リチウムからなる群から選択される1種以上である、請求項1に記載の軽量高強度セラミック粒子。 - 前記界面活性剤がリグノスルホン酸ナトリウム、Light Polymers Inc.から入手可能なCT017、またはそれらの混合物である、請求項1に記載の軽量高強度セラミック粒子。
- 前記界面活性剤がリグノスルホン酸ナトリウムとLight Polymers Inc.から入手可能なCT017の混合物であり、リグノスルホン酸ナトリウムとLight Polymers Inc.から入手可能なCT017との質量部の比が2:1~5:1である、請求項7に記載の軽量高強度セラミック粒子。
- a 前記固体原料を秤量して混合し、固体活性剤を調製するステップ:アルカリ金属ケイ酸塩溶液にアルカリ金属水酸化物を溶解し、室温に冷却した後、少量の白色沈殿物が観察されるまで撹拌を続け、得られた溶液をきれいな容器に注ぎ入れ、白色結晶が室温で1~20分間で凝集体に形成され、前記凝集体を粉砕して固体活性剤を形成するステップ;
b 混合ステップ:前記固体原料と前記固体活性剤を十分に混合して混合原料を形成するステップ;
c ペレット化ステップ:前記混合原料をペレット化して粒子にするステップ;
d 硬化ステップ:前記粒子を温度70~100℃および湿度70~90%の条件下に1~2時間維持して硬化させるステップ;
e 乾燥ステップ:前記硬化した粒子を100~300℃の温度で乾燥するステップ;
f 焼結ステップ:前記乾燥した粒子を所定の焼結処理により60~90分間焼結するステップ;
g 最終製品を形成するステップ:前記焼結した粒子を室温に冷却して請求項1~8のいずれか一項に記載の軽量高強度セラミック粒子を得るステップ;
を含む、軽量高強度セラミック粒子の製造方法。 - 前記焼結ステップが、20~40℃/分の速度で100~300℃から500~700℃に昇温する具体的工程と、その後、5~25℃/分の速度で1050~1350℃にさらに昇温する具体的工程と、を含む、請求項9に記載の軽量高強度セラミック粒子の製造方法。
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