JPS62288138A - Rock wool - Google Patents

Abstract

PURPOSE:To obtain rock wool having improved colorability (design property), heat resistance, mechanical characteristic and corrosion resistance to water from inexpensive raw materials at a fiberizing temperature similar to that of conventional slag wool based rock wool, by blending ferrochromium slag with quartzite and iron ore slag. CONSTITUTION:Rock wool obtained by blending 5-90wt% ferrochromium slag with 5-30wt% quartzite and 0-90wt% iron ore slag. The composition thereof is 35-50wt% SiO2, 10-25wt% Al2O3, 2-20wt% CaO, 5-30wt% MgO and 0.2-10wt% Cr2O3 as principal components. The total content of TiO2, K2O, Na2O, MnO, FeO and S is up to 5wt% at the maximum.

Description

[Detailed Description of the Invention] 3. Detailed Description of the Invention and Field of Application> The present invention has a colored property (1: i-craftability), and has heat resistance,
Regarding rock wool, which has excellent mechanical properties (fiber tensile strength and flexibility) and water erosion resistance, it is made from ferro-Omus slag, silica stone, and iron ore slag, and is almost the same as ordinary rock wool. This invention relates to rock wool that has a lI fibrillation temperature and is excellent in color (design), heat resistance, mechanical properties, and water erosion resistance. This rock wool can be used as a mineral fiber board (ceiling board) with design properties, as a substitute for asbestos, and as a substitute for ceramic wool.
It has made it possible to expand conventional applications such as ts textiles and industrial fields (mats for industrial use), or to develop new applications.

<Conventional technology> Conventionally, slag-based rock wool using iron ore slag was
Add natural stone such as silica stone as a component adjustment material to iron ore slag, melt it in a cupola or electric furnace, and blow the molten product with a high-speed rotating body using centrifugal force or compressed air. Fibers are manufactured using a method that uses both compressed air and compressed air. Such slag wool-based natural wool has a grayish-white appearance and lacks design, and has higher heat resistance than glass wool but lower than ceramic wool, and
It is inferior to glass wool in mII tensile strength, is less flexible than glass wool or ceramic wool, and has performance problems such as being easily eroded by water, which is common to inorganic fibers.

Reflecting the performance of slag wool-based rock wool and the advantage that it can be manufactured at low cost, the non-flammable sound absorbing mineral material TA is currently being developed.
Fiberboard (ceiling board), mainly medium to high temperature 500 to 600℃
) are used in large quantities as industrial heat insulating materials and fireproof coating materials, but at present it is not possible to expand the use of conventional products or develop new uses.

Problems to be Solved by the Present Invention> The present invention uses the same fiberizing temperature as conventional slag wool-based rock wool, and the same fiberizing method, that is, centrifugal force or compressed air, or even both. It is possible to use a fiberization method that can be used in combination, and as a result of cheap raw materials and cheap melting energy, it can be manufactured at low cost, and has good coloring (design), heat resistance, mechanical properties, and resistance to water erosion. The purpose of this process was to obtain superior rock wool. many kinds,
As a result of consideration, ferrochrome slag 5~g□wt% silica
5~3Qwt% iron ore slag
0 to 9Qwt%, Sin, 35
~50wt%, 8120310~25wt%, CaO2
~20wt%, MOo 5~30wt%, Cr203
Rock wool, whose main component is 0.2 to 10 wt%, has excellent properties such as coloring (design), heat resistance, mechanical properties, and water erosion resistance. Rock wool related products (mineral ceiling panels, insulation materials,
This is because it has made it possible to expand the use of fireproof coating materials) and to develop new uses such as asbestos fibers, non-separable fibers to replace ceramic wool, and the agricultural field (agricultural mats).

<Method for Solving Problems> As a method of imparting color (design), which is the first objective of the present invention, a method of coloring fibers by adding a colored ionic substance can be used. However, there is a limit to the coloring of fibers with colored ionic substances, and it is easily influenced by the composition (on the degree of coloring), such as whether the atmosphere at the time of melting the raw material composition is oxidizing or reducing. If the valence of the colored ionic substance changes, not only will it be impossible to obtain the desired coloring of the fiber, but even if the colored raw material composition is made into a final fiber, it will not reflect the fiber shape.
Care must be taken as there will be differences in the degree of coloring.

In general, 5iO2-Aj! In a 2o3-CaO-MgO-based rock wool composition, as a method for coloring fibers by adding colored ions, Fe++...dark green, M
n++...Red-purple color, Cu++...Green-yellow color, Or
++1...Dark blue color can be used, but Cr+++ ionic material is excellent as an effective coloring agent with a colored design for fibers having a fiber diameter of 1 to 10μ, and other ionic materials have a bright orange color. Since it is not possible, I actually used it 5
No benefit from coloring can be expected. In the present invention, J, Cr +
Coloring with ionic substances is the final product of 1 to 10μ
Diameter mm is colored as a light blue color, and minerals using this fiber! The S1M board (ceiling board) has an excellent design even when unpainted.

As a specific coloring method, the addition of Cr+++ ion substances is carried out in the form of Cr2o3 addition, but considering the degree of coloring of 4JA Lit, Q, 2wt% or more, and the upper limit is determined from the viewpoint of the blending ratio of other components and the heat resistance of the fiber. Therefore, a range of 1Qwt% or less is appropriate.

Regarding the improvement of heat resistance and mechanical properties, which are the second and third objectives of the present invention, SiO□37 to 42 wt%, Aj!
20310-15wt%, CaO35-40wt%, M
Oo 5-10wt%, FeO+MnO+Ti
In slag-based rock wool with a composition of 5 wt% or less of trace components such as O'2 +S, we mainly reduce CaO among alkaline earth metals, and reduce SiO2, A1□03, F
Increasing the amount of eO, Cr2O3, etc. is a method that can be achieved at low cost, but from the viewpoint of coloring, avoid increasing the amount of FeO,
From the viewpoint of fiberization temperature, it is necessary to increase the amount of MQO.

SiO2 is 35-50wt% to obtain high quality fibers.
If the Sin is less than 235wt%, it is difficult to obtain high quality fibers with a diameter of 2 to 10μ;
%, the viscosity of the melt increases, making it difficult to form fibers at the same fiberizing temperature as in the past.

Al2O3 is combined with SiO2 and improves the heat resistance of the fibers, but as the amount added increases, the appropriate fiberization temperature increases due to increases in viscosity and devitrification temperature, so it must be kept at 25 wt% or less. In addition, if it is less than iowt%, it will be difficult to obtain heat resistance and high quality fibers, so A1203
The content is preferably 10 to 25 wt%, particularly 15 to 20 wt%. It is preferable to reduce the amount of alkaline earth metal CaO as much as possible for the purpose of improving the heat resistance of the fibers, but from the viewpoint of preventing an increase in the viscosity of the melt, it is mainly used as MQO (similar to CaO, which has a viscosity reducing function). However, MQO increases the heat resistance of the fiber, especially the dimensional stability at high temperatures of 41
It is important that the total content m of +CaO is 30 wt% or more. Further, since the CaO component does not have a positive effect on the water erosion resistance and the flexibility of the obtained fiber, the amount of CaO added must be 20 wt% or less. On the other hand, contrary to CaO, it is necessary to mix MqO at 10wt% or more in order to improve the corrosion resistance against water and the flexibility of the obtained 1lIli, and actively increasing the blending amount is one solution. However, 5102, A120
In order to secure the required amount of 3, the upper limit is 30wt%.
Limited to:

In addition to coloring the fibers, Cr2O3 has the function of improving the heat resistance of the fibers. It is sufficient to mix Cr2O3 as coloring at 2wt% to 5wt%, but SiO
, in a composite form with Al2O3, is preferably blended in an amount of 1 wt% or more in order to improve the heat resistance of the fiber. The upper limit of 1t)wt% is due to limitations caused by the raw materials used, and by maintaining the blended amounts of the necessary components. As mentioned above, the objectives of the present invention are colorability (designability), heat resistance, mechanical properties,
The main components of rock wool, which has excellent corrosion resistance against water, have been described, but Fe01S, as an unavoidable component,
It is preferable that the total amount of Na2O1, 20, etc. be kept at 5 wt% or less in order not to impair the properties aimed at by the present invention. Furthermore, TiO□ and MnO as unavoidable trace components
has a slightly positive effect on the above-mentioned desired properties, so there is no problem in adding an appropriate amount. Said,
It is advisable to use ferrochrome slag, silica stone, and iron ore slag as raw materials whose composition can be adjusted at low cost and within the composition range for obtaining the fibers targeted by the present invention. Next, the raw materials and blending amounts will be explained in detail. The main component of ferrochrome slag, which is produced as a by-product when producing ferroalloy, is 5iO23.
0~35wt%, Al20320~25wt%, MOo
30~35wt%, CaOO~5wt%, Or
2034~9wt%, trace components (Fed, MnO, etc.)
Iei at 3wt% or less! It is available as a J-colored crushed stone block. Silica stone is available as a natural crushed stone containing 510298% or more. In addition, iron ore slag, which is the main raw material for conventional slag-based rock wool, is a by-product when producing pig iron, and its main component is SiO230-35.
W℃%, A12o310-15wt%, MOo 5
~10wt%, Ca035~40wt%, trace components (T
i 02 , Mn0-FeQ, S, etc.) 5 wt% or less, and can be obtained as a gray-black crushed stone block. The above raw material ore is mixed with 5 to 90 wt% of chromium slag and 5 to 90 wt% of silica stone.
The fiber composition of the present invention can be obtained by mixing 30 wt% of iron ore slag and O to 90 wt% of iron ore slag.

It should be noted that a small amount of silicon manganese slag, basalt, diabase, peridotite, axite, vermiculite, silica brick, manganese silicate, and manganese oxide may be blended within a range that does not impair the properties aimed at by the present invention. It is possible.

When the above raw material composition is melted in a cupola furnace, when it is melted in an electric furnace with a size of 10 to 10100 IlI1,
A suitable size is 1 to 5 m, and it can be melted at 1400 to 1600°C using coke fuel, carbon or molybdenum electrodes.

Examples of the present invention will be described below.

Example 1 The raw material composition (wt%) of the present invention having a particle size of 1 to 3 m shown as an example in Table 1 was heated and melted in an electric furnace using a carbon Ti electrode, and the mixture was heated and melted at the fiberization temperature shown in Table 2. , the melt was transferred to a plurality of internally cooled high-speed rotating bodies (φ=10 inches, φ=14 inches, rotational speed 4000 rDIIl) and a compressed air stream (approximately 1
The fibers were made into fibers and collected at a speed of 00 m/5 ec).

The comparative examples (Comparative Example 1: Conventional slag-based O-Tsuku wool, Comparative Example 2: Natural stone-based rock wool) were the same as the Examples except that the raw material mixture shown in Table 1 was melted at the fiberization temperature shown in Table 2. It was made into fibers and collected.

Table 2 shows the composition and properties of the rock wool of the present invention prepared as described above.

Example 2゜1000 solid components consisting of each composition listed in Table 3!
An aqueous slurry was prepared using a 4% aqueous dispersion of 1.
The aqueous slurry is made into paper using a last paper making machine in the laboratory.
The dewatered paper board obtained is then dehydrated and press-molded using a press molding machine. The obtained press-molded product was dried using a hot air dryer at 230° C. for 1 hour and then at 150° C. for 2 hours to obtain a mineral fiberboard with a ratio of about 0.4 and a thickness of 12 rM1. Table 4 shows specific gravity, bending strength, flammability, and appearance.
Shown below.

Example 3 In an oxygen-blown cupola furnace, the raw material compositions of Comparative Example 1 and Example 1-1 with a size of 10 to 100 m+ were melted, and a plurality of internally cooled high-speed rotating bodies (φ=10 inches, φ=14 inch, approximately 4000 rpm+a) and in compressed air flow (approximately 100 m
/5ec). At this time, the uncured phenol resin binder (about 1.5 wt% in solid content) obtained by spraying the water-soluble phenol m-fat binder with 2Qwt% water content onto $I11 from around the high speed rotating body.
After collecting the adhering fibers and pre-compressing them, they were placed in a caterpillar double conveyor thermosetting furnace (temperature 250°C).
, 10 minutes) to harden the binder to a bulk density of 40
A lightweight rock wool product having Ky/m3 and thickness of 100jIl was obtained.

Cut the above lightweight product into a size of length x width = 10 x 10 (cm), and use Tensilon to cut it to a crosshead speed of 50.
11aZ, compressed to 50am, left compressed to 50mm for 10 minutes, then removed weight, thickness recovery rate = h/ho
x100 (%) was calculated (h; thickness after test, h;
(Thickness before test), the obtained results are shown in Table 5.

From the above results, the lightweight product according to the present invention is compared with the conventional product,
Excellent recovery rate.

<Effects> As described above in Examples 1 to 4, it is understood that the rock wool of the present invention has excellent performance in coloration (design), heat resistance, mechanical properties, and water erosion resistance. be done.

In addition, since inexpensive ferrochrome slag can be used, it can be produced industrially at low cost, which will expand the use of conventional rock wool-related products (ceiling panels, insulation materials, fireproof coatings), and create new applications (asbestos substitutes, (ceramic wool replacement, agricultural field, etc.) has become possible.

Claims (1)

[Claims] Ferrochrome slag 5-90wt%, silica stone 5-30wt
%, iron ore slag 0 to 90 wt%, SiO_235 to 50 wt%, Al_2O_310 to
25wt%, CaO2~20wt%, MgO5~30w
t%, Cr_2O_30.2-10wt% as main components, and trace components of TiO_2, K_2O, Na_2O
, MnO, FeO and S in a total amount of up to 5 wt%.