JPH062298A - Sheet and solid form using slag wool from sewage sludge - Google Patents

Abstract

PURPOSE:To simultaneously resolve both the problems involving sewage sludge disposal and those concerning resources saving by reusing sewage sludge. CONSTITUTION:The objective sheet or solid form containing, as inorganic fiber component, (A) sewage sludge slag wool produced from sewage sludge incorporated with a calcium component regulator or (B) a mixture of the slag wool and inorganic short fibers except the slag wool, and manufactured using a molding material comprising (1) 100 pts.wt. of the inorganic fiber component and (2) 10-30 pts.wt. of a binder component.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet and a three-dimensional molded article using slag wool obtained by fiberizing sewage sludge slag.

[0002]

2. Description of the Related Art A sheet obtained by making an aqueous suspension using inorganic fibers or organic fibers, or an aqueous paste-like material using inorganic fibers or organic fibers is sucked, pressed or sucked / pressurized. A three-dimensional molded body made of a molded product obtained by the above is used.

[0003]

[Problems to be Solved by the Invention] Although the generation of sewage sludge is enormous with the spread of sewerage in recent years, the sewage sludge can be reused as a resource because the landfill disposal area of sewage sludge is limited by itself. It is beginning to be considered.

An object of the present invention is to measure the effective use of sewage sludge that has been conventionally subjected to waste treatment.

[0005]

A sheet using slag wool made from sewage sludge according to the invention of claim 1 is a sewage sludge slag wool 10 to 90 obtained by fiberizing sewage sludge slag to which a calcium component modifier is added. A mixed fiber of 90% by weight and 90% by weight of an inorganic short fiber other than slag wool is contained as an inorganic fiber component, and 10 to 30 parts by weight of a binder component is added to 100 parts by weight of the inorganic fiber component. It is composed of a wet papermaking sheet made of a raw material for papermaking.

[0006] Specifically, this wet papermaking sheet is prepared by continuously pouring a raw material for papermaking using a suspension containing a binder component onto a wire net and dehydrating it under reduced pressure to obtain a wet sheet, which is then heated. A method of drying, or a suspension containing no binder component or containing a part of the binder component is continuously poured on a wire net and dehydrated under reduced pressure to obtain a wet sheet. Then, the rest of the binder component is applied, and then the mixture is heated and dried.

According to the second aspect of the present invention, a three-dimensional molded body using slag wool made from sewage sludge is a slag containing 10 to 100% by weight of sewage sludge slag wool obtained by fiberizing sewage sludge slag to which a calcium component modifier is added. A raw material for molding containing a mixed fiber of 90 to 0% by weight of an inorganic short fiber other than wool as an inorganic fiber component, and further adding 10 to 30 parts by weight of a binder component to 100 parts by weight of the inorganic fiber component. It consists of a molded product.

This molded molding is molded, for example, by the following method.

(1) After depositing a paste-form forming raw material to an appropriate thickness on an air-permeable forming die such as a wire mesh having an uneven surface having substantially the same shape as the forming surface of the forming die material, Is inserted between a pair of upper and lower female and male mold members, and the mold members are heated while being pressed and molded.

(2) A male or female mold for adsorption having a group of fine through holes is immersed in a molding raw material made of a suspension and sucked from the inside of the mold so that the surface of the mold contains The solid component is adhered to form an adhesion layer, and when the adhesion layer has a predetermined thickness, the mold is taken out of the suspension, and thereafter, a pressing die by a female mold or a male mold corresponding to the above-mentioned mold. A method of abutting a mold and a heating mold to form a mold.

(3) A male mold for adsorption having a group of fine through holes is immersed in a molding raw material by suspension and sucked from the inside of the mold so that the solid component in the molding raw material is attracted to the surface of the mold. The adhesive layer is formed by adhering, the suspension is discharged when the adhered layer has a predetermined thickness, and the female die corresponding to the male die is pressed against the male die to be fitted to the female die. A method for forming an adhesive layer by passing dry steam or hot compressed air through the adhesive layer to the male mold.

(4) An inorganic fiber component and a binder component are sprayed by separate spray guns onto the lower mold of the mold formed of the upper mold and the lower mold to form a deposited layer having a predetermined thickness. After that, the upper mold and the lower mold are combined and heated and pressure-molded.

In the sheet and the three-dimensional molded body using the slag wool produced by the sewage sludge of the present invention having the above structure, the sewage sludge slag wool obtained by fiberizing the sewage sludge slag to which the calcium component modifier is added is the sewage sludge. Alternatively, it can be obtained by blending a sewage sludge incineration ash with a calcium component modifier, melting the ash, and fiberizing the melt. This fiberizing method includes a method of blowing compressed air or a steam jet to a fine stream of the melt, a method of utilizing the centrifugal force of a rotor rotating at high speed, and a method of using both of them together.

When sewage sludge slag is made into fiber,
Since spherical particles called shots are produced, an aggregate of short fibers having a fiber diameter of 2 to 20 μm and a fiber length of about 10 to 100 mm obtained by extracting raw cotton-like slag wool excluding this is used.

The calcium component modifier added to the sewage sludge or the sewage sludge incineration ash when obtaining the sewage sludge slag wool is composed of, for example, calcium carbonate, dolomite, etc., and has an action of lowering the melt viscosity of the sewage sludge slag. 20 to 100 parts by weight of ash in sewage sludge
It is preferably added in a proportion of 60 parts by weight.

The sewage sludge slag wool obtained by fiberizing the sewage sludge slag to which the calcium component modifier is added is
The main component is P ₂ O ₅ ... 30% by weight or less, SiO ₂
···· 10 to 50% by weight, Al ₂ O ₃ ··· 3 to 20% by weight, CaO ··· 10 to 70% by weight, MgO ··· 20% by weight or less, Fe ₂ O ₃ ·. ... 5-25%, Na ₂ O + K
Those containing ₂ O + S = 5% by weight or less are preferable.

That is, since P ₂ O ₅ adversely affects the toughness of the obtained slag wool, it is preferable to set it to 30% by weight or less. By adding the calcium component modifier, P ₂ O ₅ is fixed and the toughness and strength are improved.

SiO ₂ is preferably contained in a large amount from the viewpoint of improving the fiber strength, but since the viscosity at the time of melting increases and the melting temperature rises, it is preferably 50% by weight or less. From the viewpoint of fiber strength, 10% by weight or more is preferable.

Al ₂ O ₃ is preferably contained in a large amount from the viewpoint of improving heat resistance, but since the melt viscosity is extremely increased,
It is preferably 20% by weight or less, and more preferably 3% by weight or more from the viewpoint of heat resistance.

The presence of CaO makes the fiber brittle and easily deteriorates, so that the content of CaO is preferably 70% by weight or less. However, it is preferably 10% by weight or more from the viewpoint of having the effect of lowering the viscosity during melting.

Although MgO is involved in lowering melt viscosity, improving fiber strength, improving fiber flexibility, etc., it deteriorates the operability during the production of slag wool, so that it is preferably 20% by weight or less.

Fe ₂ O ₃ contributes to improvement of heat resistance, fiber strength, etc., so that the content of Fe ₂ O ₃ is preferably 5% by weight or more. However, since problems in operation such as iron removal occur during the production of slag wool, it is preferably set to 25% by weight or less.

Inorganic short fibers other than slag wool function as a reinforcing material and also function as an aggregate as a carrier for slag wool. Examples thereof include carbon fiber, alumina fiber, alumina silica fiber, quartz fiber and glass. Fibers, rock wool fibers, kaolin fibers, zirconia fibers, potassium titanate fibers, etc., of 1 mm or more in length are used. In addition, in the case of a molded product of a molded molding, inorganic short fibers other than slag wool may be omitted, but in the case of a wet papermaking sheet, inorganic short fibers other than slag wool are 10% by weight of the inorganic fiber component. If it is less than the above range, a sheet having satisfactory strength cannot be obtained.

Further, the fact that the content of the inorganic short fibers other than slag wool exceeds 90% by weight departs from the object of the present invention to measure the utilization of sewage sludge slag wool.

The binder component serves to retain the shape of the molded product, and a curable resin or a thermoplastic resin as well as a resin composed of a mixture thereof, starch, heat-fusible fiber, alumina sol, colloidal silica or the like is used. To be done. In particular, the binder component made of a resin is in powder form, for example, a particle size of 0.1 to 1000 μm, preferably 0.1.
Those having a size of about 1 to 100 μ are used. The curable resin may be either a thermosetting resin or an electron beam curable resin. When the curable resin and the thermoplastic resin are used in combination, the amount of the thermoplastic resin is reduced, It is preferable to use a thermoplastic resin that is compatible with the curable resin in combination.

The resins that can be used as the binder component will be described below.

(1) "Curable resin" Silicone resin such as silicone resin modified with organopolysiloxane resin, alkyd resin, acrylic resin, epoxy resin, polyester resin, phenol resin, polyimide, polyetherimide, etc. Imide resin, epoxy resin, urea resin, ethylene
Urea resin, urea resin such as dimethylol ethylene urea resin, melamine resin, silicon resin, furan resin, furan resin such as diallyl phthalate resin, aniline resin,
Formaldehyde resins such as acetone / formaldehyde resins, urethane resins, allyl resins, unsaturated polyester resins, polyether resins such as polyether sulfone, melamine resins, urethane resins, etc.

Particularly, a useful binder component made of a curable resin exerts an excellent action in terms of binder performance and heat resistance, and therefore, the above-mentioned silicone resin, methyltrimethoxysilane, methyltriethoxysilane, ethyltriethylsilane and the like. It is composed of a hydrolyzed condensate of a silane compound such as methoxysilane and ethyltriethoxysilane and an acid. As a resin composed of a hydrolyzed condensate of a silane compound such as methyltrimethoxysilane, methyltriethoxysilane, ethyltrimethoxysilane and ethyltriethoxysilane, and an acid, an acid of 0.00001 per mol of the silane compound is used. A hydrolyzed condensate or the like using about 0.001 mol is used.

The most preferable example of using the above-mentioned silicone resin as the binder component is 100 parts by weight of the thermosetting organopolysiloxane resin powder and the general composition formula "R ¹ Si (OR ² )". _a (R ³ ) _b O
_{(2-ab) / 2} "(in the composition formula, R ¹ is a monovalent organic group having at least one epoxy group, R ² and R ³ are substituted or unsubstituted monovalent hydrocarbon groups, 0 .5 ≦ a ≦ 3.
0, 0 ≦ b ≦ 3.0, 2.0 ≦ a + b ≦ 3.0))
Mixture of 0% by weight and phosphoric acid 80-20% by weight 0.5-3
0 parts by weight is added.

The general composition formula "R ¹ Si (OR ² ) _a (R
³ ) _b O _{(2-ab) / 2} ”is an epoxy group-containing organosilicon compound, which is an organosilane or an organodisiloxane, and the epoxy group contained in R ¹ reacts with phosphoric acid to form water and water. This produces a caking compound that is soluble in alcohol. In addition, since the alkoxy group represented by (OR ² ) can be hydrolyzed, excess and unreacted phosphoric acid act as a catalyst to hydrolyze and condense to form a polymer, which results in moisture resistance and water resistance. , It becomes a binder component that has an excellent effect on mechanical strength.

(2) "Thermoplastic resin" Ethylene resin such as polyethylene, ethylene / vinyl acetate copolymer, ethylene / propylene copolymer, ethylene / ethyl acrylate copolymer, ethylene / acrylic acid copolymer, Fluoroethylene resin such as polytrifluoroethylene, polytetrafluoroethylene, tetrafluoroethylene / hexafluoropropylene copolymer, tetrafluoroethylene / ethylene copolymer, tetrafluoroethylene / fluoroalkyl vinyl ether copolymer, polyethylene terephthalate, Saturated ester resin such as polybutylene terephthalate, polyvinyl chloride, vinyl chloride-ethylene copolymer, vinyl chloride
Vinyl acetate copolymers, vinyl chloride resins such as polytrifluoroethylene chloride, vinylidene chlorides such as polyvinylidene chloride, polyvinylidene fluoride, propylene resins, polystyrene, polyparamethylstyrene, butadiene-styrene copolymers Styrene-based resin such as polybutylene-based resin, acrylonitrile-butadiene-styrene copolymer, acrylonitrile-based resin such as acrylonitrile-styrene copolymer, methyl polyacrylate, ethyl polyacrylate, propyl polyacrylate, methyl methacrylate・ Acrylic acid resin such as styrene copolymer, cellulose propionate, cellulose acetate, acetic acid
Cellulose resins such as cellulose butyrate, ethyl cellulose, cellulose triacetate, and acetylbutyl cellulose, carbonate resins such as polycarbonate and modified polycarbonate, nylon 6, nylon 6.6, nylon 6,10, nylon 6-nylon 6.6 Combined, Nylon 7, Nylon 9, Nylon 11, Nylon 12, Nylon-based resins such as polyamide-imide, Polyacetal-based resins such as polyoxymethylene, Polyphenylene-based resins such as polyphenylene oxide, polyphenylene sulfide, Polymethacryl, Polymethylmethacrylate, Methacrylic resins such as styrene / methylmethacrylate copolymers, polyether resins such as polyetherimide and polyetherketone, polytetrafluoroethylene copolymers, poly Fluorinated ethylene copolymers, polyhexafluoroethylene copolymers, etc. Fluorinated ethylene resins, polytetrafluoropropylene copolymers, polypentafluoropropylene copolymers, polyhexafluoropropylene copolymers, etc. Fluorinated propylene resin, polysulfone, polyether sulfone, polyallyl sulfone, polythioether sulfone and other sulfone resins, polyepichlorohydrin, polyamide / epichlorohydrin copolymer, polyamine / epichlorohydrin copolymer, polyamide / polyamine / epichlorohydrin copolymer Epichlorohydrin-based resin by combination, aromatic polyamide, cationic polyamide / polyamine copolymer, amide-based resin by acrylamide / β-methacryloxyethyltrimethylammonium methylsulfate copolymer, diamine / pro Amine-based resins such as pill-methylamine copolymer, natural resins such as rosin, etc.

[0032]

The sheet and the three-dimensional molded article using the slag wool produced by the sewage sludge of the present invention use only the slag wool as the inorganic fiber component, or the slag wool and the inorganic short fiber other than the slag wool are mixed. Since it uses fibers, it has good properties such as nonflammability, heat insulation, and sound absorption. Wet papermaking sheets are used for building walls,
It has an excellent function as a lining material for surface materials such as floors and ceilings, and a rubber sheet reinforcing material. Moreover, molded moldings are laid on, for example, heat insulation / insulation materials for pipes, walls, floors, and ceilings of buildings. It has an excellent function as a heat retaining / heat insulating / sound absorbing material.

[0033]

[Examples] Specific configurations of a sheet and a three-dimensional molded body using slag wool produced by the sewage sludge of the present invention will be described below based on manufacturing examples.

[Example 1] Calcium carbonate was added to sewage sludge having an ash composition shown in Table 1 so that the weight of sewage sludge ash: calcium carbonate was 71.4: 28.6. The added raw material is heated and melted in a swirling melting furnace, and the melt is made into fibers by a plurality of internally cooled high-speed rotating bodies and a compressed air flow,
By collecting this with a cotton collecting belt, slag wool by sewage sludge was obtained.

The composition components of the obtained slag wool are shown in [Table 2]. The viscosity of the slag wool measured by a high temperature rotary viscometer at 1550 ° C. is 6 poises, and the viscosity at 1450 ° C. is 10 poises. Further, the average fiber diameter measured by taking out 60 arbitrary pieces of the slag wool from the slag wool collected by the cotton collecting belt after taking the shot and photographing them with an electron microscope photograph is 3.5 μm.

[0036]

[Table 1]

[0037]

[Table 2]

70% by weight of slag wool by the sewage sludge after removing the shots described above and E having an average fiber length of 6 mm
100 parts by weight of mixed fibers with 30% by weight of glass fibers are dispersed in water together with 50 parts by weight of a vinyl acetate resin emulsion having a solid content of 40% by weight as a binder component to prepare an aqueous suspension having an inorganic fiber concentration of 0.2% by weight. Got

This aqueous suspension was continuously poured onto a 32 mesh stainless steel wire net and dehydrated under reduced pressure to obtain a wet sheet, which was then dried by heating. A sheet having a basis weight of 69.5 g / m ² was obtained.

The physical properties of the obtained sheet are shown in [Table 3].

[0041]

[Table 3]

[Example 2] 100 parts by weight of mixed fiber of 80% by weight of slag wool with the same sewage sludge as that used in Example 1 and 20% by weight of E glass fiber having an average fiber diameter of 9μ and an average fiber length of 6 mm Was dispersed in water together with 20 parts by weight of fibrous polyvinyl alcohol as a binder component, thoroughly stirred and then dehydrated to obtain a paste-like molding raw material having a water content of 100%.

The molding raw material was sprayed onto the upper surface of a three-dimensional molding die having a W-shaped cross section with a maximum depth of 50 mm by a wire mesh of 30 mesh, and the pressure was reduced from below the three-dimensional molding die by a vacuum pump to obtain the molding raw material. It was adsorbed on the upper surface of the mold to form a deposited layer having a thickness of about 20 mm.

Then, after placing the three-dimensional molding die on which the deposited layer is formed on the lower die of the hot press,
After press-molding between the upper and lower molds at 100 ° C., 3 kg / cm ² for 90 seconds, the three-dimensional mold made of wire mesh was removed to obtain another embodiment of the present invention. 15mm cross section W
A letter-shaped molding was obtained.

[0045]

[Effect] The sheet and the three-dimensional molded article using the slag wool produced by the sewage sludge of the present invention expands the application of the slag wool produced by the sewage sludge, and the sewage sludge is reused as a resource. It has a great effect on the post-treatment of sludge and on the protection of resources.

Front page continuation (72) Inventor Atsushi Mori 2-13-25, Rokuura, Kanazawa-ku, Yokohama-shi, Kanagawa Prefecture (72) Takashi Shindo 1-2-503 Nagata Minamidai, Minami-ku, Yokohama-shi, Kanagawa Prefecture Inagawa Inagawa Shuro 1-2-1, Marunouchi, Chiyoda-ku, Tokyo Nihon Steel Tube Co., Ltd. (72) Inventor Setsuo Toyoshima 2-3-2, Higashishinozaki, Edogawa-ku, Tokyo Honshu Paper Manufacturing Co., Ltd. (72) Inventor Shunichi Amaku 2-3-2 Higashishinozaki, Edogawa-ku, Tokyo Honshu Paper Manufacturing Co., Ltd.

Claims (2)

[Claims] 1. Sewage sludge slag wool 10 to 90% by weight obtained by fiberizing sewage sludge slag containing a calcium component modifier, and inorganic short fibers 9 other than slag wool.
A wet papermaking sheet comprising a raw material for papermaking, which contains a mixed fiber of 0 to 10% by weight as an inorganic fiber component, and further, 10 to 30 parts by weight of a binder component is added to 100 parts by weight of the inorganic fiber component. A sheet that uses slag wool produced by sewage sludge. 2. A mixed fiber of 10 to 100% by weight of sewage sludge slag wool obtained by fiberizing sewage sludge slag to which a calcium component modifier is added, and 90 to 0% by weight of inorganic short fiber other than slag wool are inorganic. A slag wool made from sewage sludge, which is characterized by comprising a molding product containing a raw material for molding, which is contained as a fiber component and 10 to 30 parts by weight of a binder component is added to 100 parts by weight of the inorganic fiber component. The three-dimensional molded body used.