JPS62100470A - Manufacture of tile from sewage-treated sludge - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] The present invention aims to solve the following problems.

(Industrial Application Field) This invention relates to a method for producing tiles using sewage treatment sludge as a raw material.

(Conventional technology) Some sewage treatment sludge is used as compost, but most of it is used in landfills. That is, since the above-mentioned sludge has problems such as the presence of heavy metals, bad odor, and decomposition, it is incinerated and the incinerated ash is used for landfill. However, there was a problem in that a large amount of fuel was required for the above-mentioned incineration.

(Problems to be Solved by the Invention) In order to eliminate the above-mentioned conventional problems, the present invention provides that sewage treatment sludge can be used for manufacturing tiles, and furthermore, fuel for sludge incineration can be made unnecessary. The present invention aims to provide a method for manufacturing tiles using sewage treatment sludge.

The configuration of the present invention is as follows.

(Means for Solving the Problems) The present invention takes the measures as described in the claims above, and its effects are as follows.

(Function) Sewage treatment sludge and plastic ceramic raw materials are mixed to form clay powder. Next, the clay powder is shaped and fired. The molded product is solidified by the firing.

Moreover, the organic matter in the sludge contained in the molded product is removed by the firing.

(Example) Examples of the present application will be described below.

First, dewatered sewage treatment sludge is prepared. Such sewage treatment sludge may be supplied as a raw sludge cake or dried.

The raw sludge cake is supplied in the form of a black plate that has been compressed and dehydrated to a consistency that can be held in the hand, and contains about 70% water. Dried sludge includes polymer-based sludge and lime-based sludge, and the former contains about 75% combustible components and has a calorific value of about 4,700 kcal/kg in a dry state. Among the improved sewage treatment sludge, polymer-based sludge softens and melts at around 1050'C in the firing process described below, and lime-based sludge softens and melts at around 1200'C. lη mud as above (if it is lumpy, it is better to crush it)
is mixed with well-known plastic ceramic raw materials and optionally granular aggregate to form clay powder for tile forming. For the above-mentioned mixing, well-known wet mixing or dry mixing can be used.

Wet mixing is performed as follows. Immediately, as is well known, the above-mentioned raw materials are weighed and blended and wet-pulverized with water using a ball mill to form a slurry at a temperature of 50 to 60%. Next, the slurry is dehydrated using a filter press to form a clay cake. The mixture is further dried to a moisture content suitable for molding, and then crushed to obtain clay powder. Alternatively, the slurry is spray-dried using a spray dryer to form a clay powder. On the other hand, in dry mixing, mixing is carried out with an appropriate amount of moisture added so that the moisture content is suitable for the clay powder, so there is no need for a drying process as in the case of wet mixing. Next, the kneaded clay powder is pressure-molded into a predetermined shape. By firing the molded product in an arbitrary firing furnace, porcelain, stoneware, or ceramic products (products such as floor tiles, pavement tiles, interior and exterior tiles, etc.) can be obtained. Regarding the firing temperature mentioned above, porcelain and stoneware products are usually fired at 1150 to 1300°C, but in this example, since the aforementioned lη mud is used as the raw material, the firing temperature is 1050 to 1200°C.
It is possible to perform firing at a relatively low temperature, and it is possible to significantly reduce fuel costs.

- In the production process as described in section h, even if raw sludge as mentioned above is used as a raw material, organic matter in the sludge is removed and the sludge is dehydrated by firing it after shaping. It is possible to prevent odor generation and decomposition.

Next, when adding clay as one of the above-mentioned plastic ceramic raw materials, it may be done as follows. That is, after dry mixing the sludge and powdered plastic raw material or granular aggregate, etc., the clay is turned into slurry using a ball mill or a stirrer, and the dry weight is 5.
Add ~20%. If such a method is used, it is possible to allow the slag to play the role of a binder for easy-to-add granulation, and it is possible to reduce costs and save energy in the raw material preparation process.

Next, as a different method, sludge incineration ash obtained by incinerating the F sewage treatment sludge may be used instead of the sludge, and this may be mixed with the plastic ceramic raw material. The above-mentioned incineration process can be carried out using the incineration process in public sewage treatment facilities, and in that case, the sludge incineration ash sent out from the sewage treatment facility can be used as the sludge incineration ash described in -1-. can do. Sludge incineration ash (polymer-based incineration ash) is a fine yellow-brown powder with a temperature of 1050℃ (= J
Begins to soften and melt in the vicinity. Approximately 90% of the powder particles have a particle size of 40 microns or less, with 50 to 60% concentrated in the range of 5 to 20 microns. (Incineration ash such as tC can be used as a raw material without the need for processing such as pulverization.

In addition, when using sludge incineration ash as described above, there are operations such as mixing each with plastic ceramic raw materials to form a sludge, and 1. Or, in the case of molding the clay material into a predetermined shape, the work environment for mixing and molding should be good, as there will be no generation of air or rot. It can be made into something.

Next, if granular aggregate that maintains its original shape at the temperature at which the sludge softens and melts as described above is used as part of the raw material, the granular aggregate is uniformly mixed with other raw materials, By making the granular aggregate uniformly mixed in the molded product after molding, the following effects can be obtained. That is, even if the volume decreases when sludge or other powder raw materials soften and melt during the firing process, the aggregate reduces the volume loss of the entire molded product and resists shrinkage due to volume reduction, thereby increasing the volume of the fired product. The dimensions and shape can be stabilized. Further, concave portions are formed on the surface of the product due to the volume reduction of the molten powder raw material, and a non-slip effect (particularly preferable when the product is a pavement stone) can be imparted to the surface.

Next, various experimental examples based on the above embodiment will be shown.

Experimental example = 1 1st. Table 1 Add 5 to 6% water to the above raw materials, stir and mix, and granulate to make clay. Next, using a hydraulic molding machine, 250kg/cIJ
The product was molded into a size of 100 x 100 x 15 mm under a pressure of 100 x 100 x 15 mm and fired in a 1100'c tunnel kiln for 22 hours to obtain the products shown in Table 1-2.

Table 1-2 The characteristic values shown in Table 1-2 are considered to be suitable for lightweight heat-insulating interior materials. Of course, it is also possible to apply a top glaze to the surface to make a glazed product.

Experimental Example-2 Table 2-1 Add 5 to 6% water to the above raw materials, stir and mix, and granulate to make clay. Next, using a hydraulic molding machine, 250kg/ca
Formed into 100 x 100 x 15 m at a pressure of t,
As a result of firing in a roller hearth kiln at 1200°C for 60 minutes, the characteristic values shown in Table 2-2 were obtained.

Table 2-2 The characteristic values shown in Table 2-2 are considered to be suitable for lightweight heat-insulating interior and exterior materials. Of course, it is also possible to make a glazed product by applying a biaxial pattern to the surface.

Experimental Example-3 Table 3-1 The above raw materials were stirred and mixed to make clay. Next, using a hydraulic forming machine, 100 x 1 was formed at a pressure of 200 kg/cm.
00 x 50Im and heated in a tunnel kiln at 1080℃ for 2
As a result of baking for 2 hours, a product with the characteristics shown in Table 3-2 was obtained.

Table 3-2 The characteristic values in Table 3-2 are suitable for water-permeable pavement tiles.

Experimental Example-4 Table 4-1 The above raw materials were stirred and mixed to make clay. Next, use a hydraulic molding machine to form 100 x 100 sheets at a pressure of 250 kg/cd.
As a result of molding into X100 and firing in a tunnel kiln at 1080°C for 22 hours, a product having the characteristics shown in Table 4-2 was obtained.

Table 4-2 The characteristic values in Table 4-2 are suitable for unglazed floor coverings, and in particular, the slip resistance of 0.9 to 1.0 is an excellent property not found in existing porcelain and stoneware materials. It is a characteristic that

Experimental Example-5 Table 5-1 Water is added to the above raw materials in an amount of 4 to 6% of the total weight, and the mixture is stirred and granulated to produce clay. Next, using a hydraulic molding machine, 250 kg
The material was molded into a 100 x 100 x 5 piece of clay under a pressure of /c+d and fired for 45 minutes in a roller hearth kiln at 1200°C to obtain a base having the properties shown in Table 5-2.

Table 5-2 The results in Table 5-2 indicate that it is suitable as a base for glazed exterior tiles or glazed interior tiles for cold regions, and if two strands suitable for each are glazed and fired, glazed exterior tiles can be made. Products such as tiles and glazed interior tiles for cold regions can be obtained.

Experimental Example-6 The raw materials listed above in Table 6-1 were ground in a ball mill for 2 hours with approximately the same amount of water, and dried until the moisture content was approximately 6% (afterwards, the raw materials were ground to 20 methane +.Next, using a hydraulic forming machine, 100 x 10QXI at a pressure of 250kg/cn+
Formed into Qmm and 2.1080'l::I.
As a result of baking for 2 hours, a special product shown in Table 6-2 was obtained.

The characteristic values shown in Tables 6 to 2 are most suitable for unglazed exterior tiles and unglazed floor tiles.

Experimental Example-7 The raw materials listed above in Table 7-1 were milled together with approximately the same amount of water in a ball mill for 2 hours, dried until the moisture content was approximately 6%, and then ground to a mass of 20 mesh to form a clay. make. Next, using a hydraulic molding machine, it was molded into a 100x100x5 shape at a pressure of 250kg/ci, dried until the moisture content was 2% or less, and then glazed.
7th result of baking in 00℃ roller hearth kiln for 40 minutes
A product with the values shown in Table 2 was obtained.

Table 7-2 The above characteristic values are suitable for glazed interior tiles.

Experimental Example-8 The raw materials listed above in Table 8-1 were ground in a ball mill for 2 hours with approximately the same amount of water, dried until the moisture content was approximately 6%, and then ground to pass 20 min. make. Next, using a hydraulic molding machine, the fins were molded into 100 x 100 x 5 fins at a pressure of 250 kg/cd, and baked in a roller hearth kiln at 1180°C for 45 minutes, resulting in products having the characteristic values shown in Table 8-2.

Table 8-2 The above characteristic values are most suitable for unglazed exterior tiles and unglazed floor tiles. Of course, top glaze is applied, glazed exterior tiles,
We can also make glazed floor tile products.

(Effects of the Invention) As described above, in the present invention, when manufacturing tiles, sewage treatment sludge that is discarded as waste is used as a raw material, and it is mixed with a plastic ceramic raw material to form a clay material. Since the tiles are manufactured by molding, the cost of raw materials is extremely low, which has the effect of lowering the product price.

Moreover, even if sludge, which emits an odor, is used as a raw material, the sludge is molded and then the tiles are fired. It has the feature that it can be constructed.

This has the effect of making tiles free of odor and rotting problems even when using sludge as a raw material.In addition, it eliminates the need for incineration, which was traditionally done to prevent odor and rot. , and burn the labor costs for that! This has the effect of eliminating the need for one expense.

Furthermore, in the invention of the present application cylinder 2, even if sludge is used as a raw material as described above, the sludge is incinerated in advance to form ash, and the ash is used for mixing with plastic ceramic raw materials and molding. Because these steps are carried out, there is no odor generated during those steps, and these steps can be carried out in a good working environment.

Furthermore, in the invention of the present invention, when mixing raw materials to make clay powder for molding, incineration ash and plastic ceramic raw materials are dry mixed and a slurry of clay is added to the slurry. It has the advantage of being able to play the role of a clay powder for humidifying and granulating powder, and forming clay powder that is easy to mold.

Moreover, in this case, since the clay slurry is added after dry mixing, there is an advantage that there is very little water-containing layer after addition. This has the effect of eliminating the need for a large-scale drying process such as wet mixing, and reducing labor and fuel costs.

Claims (3)

[Claims] (1) Mix sewage treatment sludge and plastic ceramic raw materials to form clay powder, then mold the clay powder, remove organic matter from the sludge, and mold the molded product. A method for manufacturing tiles using sewage treatment sludge, which is characterized by firing to solidify the sludge. (2) Sewage treatment sludge is incinerated to produce incineration ash, the incineration ash is mixed with plastic ceramic raw materials to form clay powder, the clay powder is molded, and the molded product is fired. A method for manufacturing tiles using sewage treatment sludge. (3) Dry and pulverized sewage treatment sludge, or incineration of sewage treatment sludge to produce incineration ash, and powdered ceramic raw materials, or granular aggregate as necessary, are dry mixed, and A sewage treatment sludge is then used, which is characterized in that clay slurry is added thereto to form clay powder through humidified granulation, the clay powder is molded, and the molded product is fired. Tile manufacturing method.