JPH11209130A - Manufacture of super-lightweight aggregate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce lightweight aggregate for concrete or mortar, or lightweight massive/sandy foamed glass for a heat insulating/cold insulating material, a sound absorbing material and a soil-improving material from glass cullet whose principal raw material is waste glass. SOLUTION: The glass cullet, whose principal raw material is the waste glass, is pulverized and at least two kinds among calcium carbonate, silicon carbide, pulverized carbon, pulverized plastic and borax are added thereto as a foaming agent, this fine powder mixture is laid all over a belt in a tunnel kiln incorporating a belt conveyor or a roller-hearth kiln and is melted, foamed and burned in the kiln at 700 to 1000 deg.C. The produced plate-like foamed glass is cooled rapidly at a room temp., the monolithic and massive formed glass obtd. by natural disintegration due to strains is further grain-refined by an impact with a crusher or the like. Next, the produced massive or sandy foamed glass is classified with a sieve, is mixed with the cement or a resin or the like as the fine aggregate having an average particle diameter of 0.15 to 5 mm and the coarse aggregate having an average particle diameter of 5 to 15 mm and is used. Other wise, the super-lightweight aggregate for use as the heat insulating/cold insulating material, the sound absorbing material, the soil- improving material, etc., is produced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention uses a glass cullet, which is obtained from waste glass bottles and the like discharged from each household and is usually discarded to a final disposal site, as a main raw material, which is finely pulverized and melted.
The irregularly shaped foam glass obtained by foaming and further crushing by quenching is further refined by a crusher or the like, and the bulk specific gravity and the particle size distribution are controlled to optimize the mixing with the raw materials such as cement or resin. Manufacturing
It is used as an ultra-light aggregate. However, its application is not limited to concrete aggregates, but it is lightweight, heat-retaining, sound-absorbing, water-absorbing, etc. ,
Utilizing properties such as water repellency and nonflammability, it covers various fields.

[0002]

2. Description of the Related Art Conventionally, spherical foam glass used as an aggregate for lightweight mortar, for example, is prepared by adding a binder to fine glass powder and forming a spherical material by a pelletizer or the like as a pre-process of firing and foaming, and then using a rotary kiln or the like. In order to maintain the shape of the formed spherical foam glass, a sufficient annealing time of 1 hour or more is required for the production.

[0003] As lightweight aggregate for ready-mixed concrete, vermiculite is used as a raw material and foamed, and a bulk specific gravity of about 1.0 g / cm3 "Mesalite" or a perforated or obsidian raw material having a bulk density of about 0 is produced. A commercial name of "Perlite" of 0.3 g / cm3 is commercially produced and used.

[0004]

Generally, when producing a useful product from waste, a complicated process is required because the raw material is compared with a similar product produced from a natural material in terms of performance versus cost. You must avoid costs. In other words, in the production of foamed glass, the pretreatment process of foaming and firing is simplified as much as possible, the annealing time after firing is reduced as much as possible to reduce the manufacturing cost, raw materials are mined from the mountain, and some It is necessary to overcome the competition with products such as "Mesalite" or "Perlite" which are foamed through.

[0005]

In the present invention, the pretreatment process of foaming and firing is only a process of finely pulverizing glass and a process of mixing with a foaming agent, and the powder is directly placed on a belt conveyor for production. The molding process such as the conventional pelletizing is omitted, and the cost can be reduced. Furthermore, after the foaming / firing process, the steel is rapidly exposed to air, rapidly cooled, and further subjected to impact by a crusher or the like. Generally, what is required to be several tens of meters can be greatly shortened, and what is generally required for an annealing time of several hours and a long one of 10 hours or more is extremely reduced to one tenth or less in the present invention. As a result, the manufacturing cost can be reduced significantly.

[0006]

According to the present invention, the forming step as a pretreatment step required for producing foamed glass is omitted, and the kiln for firing is shortened by omitting the annealing step after foaming and firing. The construction cost has been reduced, and the production time has been significantly reduced due to the elimination of the annealing time. As a result, the production cost has been significantly reduced. Furthermore, the dimensions of the obtained bulk foamed glass are generally determined in proportion to the thickness of the glass mixed fine powder on the belt conveyor before firing, and further refined by a crusher or the like, and the bulk specific gravity is determined by the required foaming agent weight and firing. Because it can be controlled by temperature and firing time, the quality and performance problems of the resulting products are improved compared to conventional products, applications are reduced due to reduced costs, and a great deal of processing and recycling of waste glass It has made it possible to make a significant contribution to the preservation of the global environment.

[0007]

Example 1 A glass bottle discarded to a final disposal site of black, blue, green, etc. was roughly separated by removing a cap and the like, and then finely pulverized to 10 to 20 microns by a ball mill. 0.5%, calcium carbonate 1.0% and borax 0.5% were mixed together, and the mixed fine powder was placed on a belt in a roller hearth kiln having a belt conveyor having a length of 15 m and a width of 70 cm and a length of 1 m. And continuously spread to a thickness of 10 mm, and 90
After foaming and firing in a furnace maintained at 0 ° C. for 20 minutes, the obtained plate-like foamed glass was quenched in the air to obtain an amorphous bulk foam having a bulk specific gravity of 0.3 g / cm 3 and an average particle size of 30 mm. I got glass. The bulk foamed glass is further refined by a crusher so as to have an average particle diameter of 3 mm and 7.5 mm and sieved, and each has a diameter of 0.15 to 5 mm.
And those having a diameter of 5 to 15 mm were mixed with cement and used as fine aggregate and coarse aggregate for concrete, respectively.

[0008]

According to the present invention, the irregular shaped lump or sandy foam glass produced according to the present invention is produced by producing a fine distribution by a crusher as a normal distribution having a diameter of 3.0 mm, which is said to be most suitable for mixing with cement. It can be used commercially as a lightweight fine aggregate, and can be used as a lightweight coarse aggregate if the crushing is suppressed to an average diameter of 7.5 mm by the crusher. Lightweight aggregate can be produced at once. The product according to the invention is
Of course, it can be mixed with resin, clay or gypsum, etc., and it is used for resin mortar, outer wall panel, floor panel, non-combustible door, fired lightweight tile, fired lightweight tile, sound absorbing plate, etc. It is also used as a soil conditioner. Further, the material of the product of the present invention is waste glass, which does not cause environmental destruction such as mining raw materials from mountains, and can greatly contribute to recycling of waste glass and global environmental conservation.

[Brief description of the drawings]

FIG. 1 shows a manufacturing process diagram in the present invention. The sheet-like foamed glass foamed and sintered on the belt conveyor in the roller hearth is discharged immediately after sintering, and self-destructs due to the strain caused by rapid cooling to form an appropriately sized foamed glass lump. It is further processed through crushing, sieving and bagging processes to the final product.

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[Procedure amendment]

[Submission date] March 13, 1998

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claims

[Correction method] Change

[Correction contents]

[Claims]

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0003

[Correction method] Change

[Correction contents]

[0003] As a lightweight aggregate for ready-mixed concrete, shale is used as a raw material, and foaming is performed using “Mesalite” (trade name) having a bulk specific gravity of about 1.0 g / cm 3, or a bulk specific gravity of about 0.1 g / cm 3 obtained by foaming using perlite or obsidian. 3g / cm3 trade name "Perlite" and the like are commercially manufactured and used.

Claims (1)

[Claims] 1. A glass cullet composed mainly of waste glass is finely pulverized to 5 to 50 microns, and at least two of calcium carbonate, silicon carbide, fine carbon, fine plastic and borax are used as a foaming agent. 0.1 to 5.0% by weight, and the mixed fine powder is placed on a belt in a tunnel kiln or roller hearth kiln with a built-in belt conveyor.
Spread to 25mm thickness, 700 ~ 1,0 in the kiln
Melting, foaming, and sintering at 00 ° C., quenching the plate-like foamed glass produced with a residence time in the kiln of 5 to 50 minutes at room temperature, and transforming the irregularly shaped foamed glass produced by spontaneous collapse due to strain into: Further, the particles are refined by the impact of a crusher or the like, and then the formed lump or sandy foamed glass is separated by a sieve, and fine aggregate having a diameter of 0.15 to 5 mm and 5 to 5 mm are obtained.
15mm diameter coarse aggregate and 15mm diameter aggregate or more, mixed with raw materials such as cement or resin, or used as soil improvement material, heat insulation / cooling material, addition amount of foaming agent and residence time in furnace Further, a method for producing an ultra-light aggregate in which the bulk specific gravity of the lump foam glass is controlled to 0.02 to 1.0 g / cm3 by controlling the furnace temperature within the above range.