JPH07172900A - Ceramic paving material and its production - Google Patents

Abstract

PURPOSE:To obtain a ceramic pavig material high in product yield and having effective surface property though the whole raw material consists of wate materials. CONSTITUTION:The ceramic paving material uses following material of 1-4 formed from the waste as strutural materials. 1. 20-40wt.% powder of pots head and/or tile scrap having 3-1mm particle diamter. 2. 10-30wt.% sewage sludge molten slag and/or blast furnace slag having 3-1mm particle diameter 3. 5-40wt.% lacustrine sludge dried powder and/or municipal waste incineration ash having <=1mm particle diameter 4. 10-30wt.% SiO2-Al2O3 based waste powder of fine powder and having >=1500 deg.C m.p. The paving material is produced by kneading and molding the raw materials of 1-4 and firing at 1050-1300 deg.C.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a ceramic pavement material and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventional ceramic tiles, bricks, porcelain plates,
As a method for producing a flat plate, for example, a so-called porcelain such as a spray-dried powder or a filter-pressed powder obtained by directly molding a base soil mainly made of clay, feldspar, or silica, or pulverizing the base soil is used. The method of forming and baking soil is performed.

Silica stone in the above-mentioned base soil or porcelain soil
The three components of feldspar-clay are mixed, for example, in the range shown by the hatched portion in the diagram of FIG. 1, and the chemical component of such composition is SiO ₂ —Al ₂ O ₃ —CaO—R ₂ O (where R: Na Or K), SiO ₂ : 55 to 75%, Al ₂ O ₃ : 25 to 18% as a base for Ca
_{O: 0.1 ~4%, Na 2} O: 0.5 ~2%, K 2 O: 1.5~5%, Fe 2 O 3: 0.1~4%
Is the ratio.

Further, a method for forming black or black-brown spots or an attractive uneven pattern on the surface of the fired product by adding an auxiliary material such as a pigment or a substance that easily vitrifies to the above-mentioned base soil is carried out. It also offers products with various designs.

It has also been confirmed that, for example, waste sludge-melted slag, lakes and marshes, sludge dry powder recovered from rivers, or waste such as waste tile scraps and glass scraps can be used as the above-mentioned auxiliary materials, thus reducing raw material costs. Recently, various application examples have been reported in order to enable recycling and utilization of resources and solve the environmental problems associated with the above waste treatment. In particular, pavement materials are a useful application for products manufactured with the above-mentioned waste-added base soil, and by replacing them with conventional concrete paving stones and asphalt, it is possible to improve the aesthetics of the city. You can do it.

In recent years, in order to further promote the effective use of waste, there is also provided a ceramic pavement material in which the whole amount of the base soil is composed of, for example, only the sewer sludge molten slag or the sludge dry powder. ing.

[0007]

However, in the case where the raw material is composed only of the above-mentioned sewer sludge-melting slag, lake sludge, sludge dry powder recovered from rivers, or waste such as waste tile scraps and glass scraps. Inconvenience caused by the following factors occurs.

That is, in the above-mentioned base soil, the average melting temperature is about 1350 to 1380 ° C., but the melt is locally generated in the temperature range of 1050 to 1150 ° C. before reaching the melting temperature. It is known that the melt in such a low temperature region gradually increases as the temperature rises. At this time the silica - feldspar - from where relatively high SiO ₂ -Al ₂ O ₃ -based component has a melting point in a conventional matrix soil composed of three components of the clay is present in the periphery of the melt, the SiO ₂ since -al ₂ O ₃ system the melting point of the melt yelling melt the components is increased, a rapid increase of the melt is suppressed.

On the other hand, when the base soil composed only of the above waste is formed and fired, when a melt in the above low temperature region is produced, the surrounding SiO ₂ -Al ₂ O ₃ component is insufficient. There is a tendency that the melt rapidly increases in volume and foams, or the molded body melts and flows, and it is difficult to obtain a yield commensurate with a profitable base.

Further, since the waste contains a large amount of fine particle components, the degassing property during molding is poor, and shrinkage occurs during drying after molding. For pavement materials that require a certain dimensional accuracy. It was inadequate and it was unavoidable that the yield would decrease.

Further, the mechanical strength of the product containing only the waste as the base soil is relatively low, and it is difficult to satisfy the strength required for the pavement material. In order to eliminate the above-mentioned inconvenience, for example, after the waste is granulated into a predetermined particle size, an aggregate that is fired in a rotary kiln or the like is manufactured in advance,
A method of mixing the aggregate and the above raw materials to produce an appropriate particle size composition, a method of adding cement or an inorganic / organic binder at the time of kneading, or adding a high melting point material such as a high alumina refractory raw material. There are various means for solving the above problems, such as a method of suppressing the melt flow during firing, but this leads to an increase in cost.

The present invention has been made in view of the above-mentioned conventional circumstances. Although the waste material constitutes all the raw materials,
It is an object of the present invention to provide a ceramic pavement material which has a high product yield and has an attractive surface property.

[0013]

In order to achieve the above object, the present invention employs the following means. That is, a porcelain pavement material composed of the following substances generated from wastes as constituent materials, and sewage and / or tile waste having a particle size of 3 to 1 mm: 20 to 40% by weight and a particle size of 3 to 1 mm. Sludge melting slag and / or blast furnace slag: 10-30
% By weight, lake sludge dry powder with a particle size of 1 mm or less and / or municipal waste incineration ash: 5-40% by weight, fine powder, melting point 15
SiO ₂ -Al ₂ O ₃ based waste powder of 00 ° C or higher: 10 to 30% by weight,
After kneading and molding the above raw materials,
A ceramic pavement material manufactured by firing at 00 ° C.

[0014]

According to the above construction, cerven and / or tile waste having a particle size of 3 to 1 mm and sewer sludge molten slag and / or blast furnace slag are mixed as coarse aggregate, and While improving deaeration,
It is possible to suppress shrinkage of the base material during drying. Moreover, the above-mentioned sewage sludge molten slag and / or blast furnace slag is melted at the time of firing and permeates and diffuses through the surrounding pores, whereby black or blackish brown spots are scattered on the surface of the pavement material.

On the other hand, lake sludge dry powder having a particle size of 1 mm or less and / or municipal waste incineration ash, or finely powdered SiO ₂ -Al ₂ O ₃
The systematic waste powder will fill the void matrix portion of the above-mentioned raw material, so that it is possible to obtain a base soil that is easily tightened by the pressure at the time of molding, and shrinks in the void matrix portion due to firing, resulting in sponge. Structures can be formed.

Further, the SiO ₂ -Al ₂ O ₃ -based waste powder has the following unique action. That is, by this, the SiO ₂ -Al ₂ O ₃ component present in an appropriate amount in a general porcelain made of a quartz-feldspar-clay system as a raw material is also compounded in the base soil of the present invention, and the rapid change in the firing process is caused. It is possible to suppress an increase in the amount of melt. Moreover, since the SiO ₂ -Al ₂ O ₃ -based waste powder is blended in a fine powder, the above-mentioned SiO ₂ -Al ₂ O ₃ component can be widely distributed in the matrix, which allows a rapid increase in the melt. It is possible to effectively suppress the foaming and the melt flow caused by seaweed.

Therefore, as such a SiO ₂ -Al ₂ O ₃ -based waste powder, one having a melting point of less than 1500 ° C. cannot start the above-mentioned action since it starts melting at a low temperature and should be eliminated. However, if the particles are composed of particles having a particle size larger than that of the fine powder, the SiO ₂ —Al ₂ O ₃ component will be unevenly distributed in the matrix, which may cause local significant shrinkage or softening and foaming, which is not preferable.

These substances having the suitability as SiO ₂ -Al ₂ O ₃ -based waste powder are not only selected from fly ash produced at a coal-fired power plant, but also collected by a dust collector at a brick factory. Examples thereof include dust collecting powder and crushed powder of bricks.

Therefore, in order to achieve the effects of each of the above constituent materials in a well-balanced manner, it is necessary to make the compounding amount as disclosed above. Such problems arise.

That is, if the blending amount of cerven and / or tile waste is less than 20% by weight, the coarse aggregate will be insufficient and the degassing property at the time of molding will be reduced, or the shrinkage at the time of drying will be excessive. On the other hand, the yield is lowered, while when it exceeds 40% by weight, the matrix is coarse and the product having the required strength cannot be obtained.

Further, the sewage sludge molten slag and / or the blast furnace slag are blended in order to melt during firing to form black or blackish brown spots on the product surface, so the blending amount is less than 10% by weight. The amount produced is insufficient and the desired effect cannot be expected, and if it exceeds 30% by weight, the components that melt during firing may become excessive and deform, which is not preferable.

Lake sludge dry powder with a particle size of 1 mm or less and /
If the content of municipal waste incineration ash is less than 5% by weight, it is difficult to obtain a dense product. On the other hand, if it exceeds 40% by weight, the SiO ₂ -Al ₂ O ₃ component is relatively insufficient, and therefore, during firing. There is a risk of foaming and melting flow of the resin and causing deformation.

Further, when the amount of SiO ₂ -Al ₂ O ₃ based waste powder is less than 10% by weight, the above deformation is caused and 30% by weight is caused.
If it exceeds, the sintering in the matrix is difficult to occur and the mechanical strength of the product becomes insufficient.

In the present invention, addition of a colorant in addition to the above-mentioned constituent raw materials is not hindered, and red mud containing iron oxide, iron oxide dust, Mn cake or the like as a black color former may be added. it can.

[0025]

EXAMPLES The present invention will be described below based on examples. Table 1 shows the chemical composition and physical properties of each constituent material used in the following examples, and Table 2 shows the composition of the following examples 1 to 5 and conventional products and the physical property values of the products obtained thereby. Indicates.

The physical properties of each product were measured as follows. Calcination shrinkage rate: Calculated by the following formula using a length meter that can measure up to 0.05 mm, according to JIS R2208 (test method for residual expansion shrinkage rate of refractory bricks).

L ₀ = (l ₁ −l ₀ ) / l ₀ × 100 where l ₀ : initial average length (mm) between both end faces of the test piece l ₁ : average after heating between both end faces of the test piece Length (mm) ○ Dimensions: According to JIS R2202, use a length meter that can measure in units of 1 mm.

Bending strength: In accordance with JIS R2213,
The test piece dried at 105 to 120 ° C. was pressed by a three-point bending test at a pressing speed of 50 to 60 kg / sec, the maximum load was measured, and the value was calculated by the following formula.

Bending strength (kgf / cm ² ) = (3 × maximum load ×
Distance between supporting rolls) / {2 x width of test body x (thickness of test body) ² } ○ Compressive strength: in accordance with JIS R1250, 105 to 12
The test piece dried at 0 ° C. was pressed at a pressing rate of 10 to 15 kg / sec, and the maximum load was measured and calculated by the following formula.

Compressive strength (kgf / cm ² ) = maximum load / (longitudinal dimension of pressing surface × horizontal dimension) ○ Water absorption rate: test dried at 105 to 120 ° C. according to JIS A5209 (ceramic tile) After measuring the mass of one piece, it was immersed in water for 24 hours, the saturated mass was immediately measured, and calculated by the following formula.

Water absorption rate (%) = (saturated water mass-dry mass) /
Dry mass x 100 ○ Water permeability test: According to JIS A6910, set the water permeability test device of the measuring pipette on the surface of the test piece after soaking in the above water for 24 hours, put water to a height of 250 mm, and measure the time to decrease 1 ml Then, the water permeability is calculated by the following formula.

Permeability (ml / hr) = 3600 / (Time to decrease by 1 ml) (sec) ○ Slip resistance test: According to JIS A1407, the test piece is fixed to a slip tester, and the floor slip coefficient U is calculated by the following formula. Calculate and convert the obtained value into the BPN value of ASTEM E303.

U = E / (P × D) where U: floor slip resistance coefficient, E: scale of hammer up position (kgcm), P: spring force (converted to 3 kg), D: contact of test piece Distance (cm)… 90 ± 5mm. <Example 1> The materials shown in Table 1 were blended in the composition shown in the corresponding Example column of Table 2, and 5% by weight of the kneading water was added to the mixture to sufficiently knead them. Bulk specific gravity of 6 compacts with a thickness of 48 mm is simultaneously molded using a mold.
2.00 I got a brick base.

When a hammering test was conducted with a test hammer, no occurrence of lamination was recognized, and this base was
After being dried at room temperature for 24 hours in the room, it was placed on a mullite-cordierite box and loaded on the upper stage of a truck of a tunnel kiln operating at a firing zone maximum temperature of 1220 ± 10 ° C to perform firing.

The obtained pavement material has a dark brown color and a speckled pattern with black spots, and a slip resistance value: BPN.
It exhibits a non-slip property of 70 or more and has a water absorption rate of 3 to 10%.

Example 2 The materials shown in Table 1 were blended in the composition shown in the column of the corresponding Example in Table 2, and a 0.5% solution of an organic dispersant "Sun extract (trade name)" was used as kneading water. Was added to the outside by 5% and kneaded for 20 minutes with an upper roll mixer to obtain a base soil. This base soil was molded under the same conditions as in Example 1 above and fired in a tonnen kiln at a temperature of 1170 ° C. to obtain a pavement material.

The surface color was dark brown, shrinkage of 5% occurred during firing, and partial foaming was observed, but defects such as cracks and swelling were not observed, and a good pavement material was obtained. In particular, a high bending strength of 15 MN / m ² was obtained, and when it was laid on the roadway, no cracking occurred.

<Example 3> The materials shown in Table 1 were blended in the composition shown in the corresponding Example column of Table 2, and 5% by weight of kneading water was added to the mixture, and kneading was carried out in the same manner as in Example 1 above. After molding, it was fired at 1140 ° C to obtain a sintered body having high strength with a gray black spot and a high sliding resistance value.

<Example 4> The materials shown in Table 1 were blended in the composition shown in the corresponding Example column of Table 2, and a 0.5% solution of the organic dispersant "Sun extract (trademark)" was used as kneading water. After adding 5% and kneading and molding under the same conditions as in Example 2, baking at 1100 ° C. shows 7% baking shrinkage,
The color changed from red to pink.

<Example 5> The materials shown in Table 1 were blended in the composition shown in the corresponding Example column of Table 2, and a 0.5% solution of an organic dispersant "Sun extract (trademark)" was used as kneading water. After adding 5% and kneading and molding under the same conditions as in Example 2, firing at 1170 ° C. resulted in a white slip resistance value BPN =
45 suitable products for pavement materials were obtained.

Comparative Example As shown in Table 1, quartz, feldspar,
A green soil consisting of three components of clay was formed in the same manner as described in Example 1 and fired at 1300 ° C. Although the obtained product is dense and has high strength, its surface is extremely slippery and has no water permeability, and thus is not suitable as a pavement material.

[0042]

[Table 1]

[0043]

[Table 2]

As described above, in Examples 1 to 4, the industrial waste that could only be disposed of or landfilled can be reused as a raw material of a product having a high added value, and further, it can be obtained. The surface of the resulting product can be formed with irregular textures and spots.

[0045]

As described above, according to the present invention, cerven, tile waste, sewage sludge molten slag, blast furnace slag, lake sludge dry powder, municipal waste incineration ash, SiO ₂ -Al ₂ O ₃ -based waste powder. As described above, by mainly molding and firing the substances that have been disposed of with the above-mentioned composition, while providing the water permeability and strength required for pavement materials, the surface has attractive irregularities and spots. As a result, it is possible to provide an extremely high-value-added ceramic pavement material that can improve the aesthetics of the city.

[Brief description of drawings]

FIG. 1 is a diagram showing a mixture of constituent components of a ceramic base soil.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B09B 3/00 E01C 5/04 7322-2D

Claims (3)

[Claims] 1. A ceramic pavement material comprising the following substances produced from waste as constituent materials. Selben and / or tile waste with a particle size of 3 to 1 mm: 20
-40% by weight Sewer sludge molten slag with a particle size of 3 to 1 mm and / or blast furnace slag: 10 to 30% by weight Lake sludge dry powder and / or municipal waste incineration ash with a particle size of 1 mm or less: 5 to 40% by weight SiO ₂ -Al ₂ O ₃ -based waste powder with a melting point of 1500 ° C or higher: 10 to 30% by weight 2. The ceramic pavement material according to claim 1, which has a sponge structure having a water absorption rate of 2 to 10%. 3. A method for producing a ceramic pavement material, which comprises kneading and molding the raw materials according to claim 1 and then firing at 1050-1300 ° C.