KR100237349B1 - The process of manufacturing ceramics using wastes - Google Patents

Abstract

The present invention relates to a method of manufacturing ceramics having improved water permeability using waste, and to a method of manufacturing ceramics which not only has the same quality as a ceramic product made using general raw materials but also solves problems of ceramics manufactured by a conventional method. It is about.

The method for producing a ceramic according to the present invention comprises the steps of: (i) completely incinerating the waste into ash of fine powder; (ii) adding 3 to 10 parts by weight of a mixture such as sodium silicate to 100 parts by weight of ash and mixing; (iii) press molding at a pressure of 400-2000 kg / cm ² using a hydraulic press; And (iv) firing at 1100 to 1400 ° C. for 3 to 4 hours (first manufacturing method), and in the case of ceramics requiring water permeability, (v) pulverizing the manufactured ceramics to granulate Thereafter, adding 3 to 10 parts by weight of a mixture containing sodium silicate and the like to 100 parts by weight of ceramic particles and mixing the mixture; (vi) press forming at a pressure of 1000 to 2000 kg / cm ² using a hydraulic press; And (vii) firing at 1100 to 1400 ° C. for 3 to 4 hours (second production method).

In addition, the manufacturing method using only 100% waste (a) a step of pulverizing the completely burned coal ash to fine powder; (b) mixing 8 to 11 parts by weight of water with 100 parts by weight of coal ash; (c) press forming at a pressure of at least 1200 kg / cm ² using a hydraulic press; And (d) firing at 1200 to 1240 ° C. (third production method).

The ceramics according to the present invention are completely sterilized and the harmful components are removed through the high temperature firing process, and are not harmful to the human body at all. This simplification makes it possible to inexpensively provide ceramics having the same quality as ceramics made of ordinary raw materials. Therefore, the ceramics according to the present invention, which are much superior in strength, weight, and appearance in comparison with conventional cement and concrete building materials, may be used as a building material. In particular, the present invention is particularly suitable for use in sidewalk blocks and the like, which can be selectively produced ceramics excellent in water permeability.

Description

Manufacturing method of permeable ceramics using waste

The present invention relates to a method of manufacturing ceramics using waste, and to a method of manufacturing ceramics having not only the same quality as a ceramic product made using general raw materials but also solving problems of ceramics manufactured by a conventional method. Conventional wastes (garbage) except for recyclables have been treated in a way that most of them are landfilled or incinerated without a separate recycling method, and the conventional waste treatment has serious problems such as environmental pollution and landfill shortage.

In addition, the coal ash is being researched to be recycled to cement, brick, light aggregate, etc., but the consumed coal ash is less than 10% of the total generation, and most of the coal ash that cannot be recycled is buried at the beach. In addition, the coal and cement blended products made by recycling the coal ash had many problems such as corrosion of the product due to friction between acidic and alkaline components and generation of sulfur components harmful to the human body after about 5 to 10 years.

Ceramics is a general term for products composed of non-metallic inorganic compounds that have increased their use value by high temperature heat treatment. Ceramics are currently used in many fields such as tiles, ceramics, bricks, sidewalk blocks, building abrasive blocks, cervical stones, boundary stones, and lightweight aggregates. It is used. Conventional methods for producing ceramics are mainly 12 to 17 or more kinds of stone powder, such as feldspar, pottery stone, loess, clay, dolomite, mixed by press molding by pressing and firing at high temperature, such a conventional manufacturing method is to manufacture ceramics Due to the large number of materials required for the manufacturing process, including the supply and demand of raw materials, the manufacturing process is complicated, and there is a problem that it is much more expensive than concrete or cement, which is often used as a building material such as bricks and sidewalk blocks. Therefore, cement is mainly used for bricks and sidewalk blocks.Simet has a large weight, which is inconvenient to install, and its strength is so weak that the sidewalk blocks need to be replaced every three to five years and the damaged sidewalk blocks must be treated. There was a problem.

In addition, the ceramics manufactured according to the conventional method have almost no water permeability, and thus have problems when used in places where water permeability is required such as sidewalk blocks or tiles.

An object of the present invention is to provide a recycling method of waste by manufacturing ceramics using ash from incinerated waste, contributing to environmental conservation, and to replace the depleted natural resources.

In addition, an object of the present invention is to provide a recycled product of waste that is not harmful to the human body by ceramic waste is produced by producing a product so that the waste is completely sterilized and the harmful components such as sulfur are removed through a high temperature firing process.

In addition, an object of the present invention is to provide a ceramics using waste having the same quality as the ceramics made of a general raw material, and moreover, to solve problems such as water permeability and production cost, which are disadvantages of ceramics manufactured according to the conventional manufacturing method. It aims to manufacture ceramics which are excellent in strength, good water permeability, and lightweight.

In addition, the present invention is to provide a low-cost ceramics by reducing the production cost, so that the ceramics building material that is much superior in strength, weight, and appearance can be used to replace the cement, concrete building materials such as brick, sidewalk block, etc. The purpose.

1 is a block diagram showing a manufacturing process of ceramics according to the first manufacturing method of the present invention,

2 is a block diagram showing a manufacturing process of ceramics according to the second manufacturing method of the present invention,

3 is a block diagram showing a manufacturing process of ceramics according to the third manufacturing method of the present invention.

The present invention relates to a method for producing ceramics using waste, and to a method for producing ceramics having not only the same quality as a ceramic product made using general raw materials but also solving problems of ceramics manufactured by a conventional method.

The method for producing ceramics according to the present invention includes a method of producing ceramics through a series of manufacturing processes in which a predetermined mixture is added to ashes in which wastes are incinerated to be pressed and fired (hereinafter referred to as "first manufacturing method"); A method of producing a “permeable ceramics” having excellent water permeability by additionally performing a series of processes on ceramics manufactured according to the first manufacturing method (hereinafter referred to as “second manufacturing method”); And a method of manufacturing ceramics using only ash incinerated with 100% waste (hereinafter referred to as “third manufacturing method”).

Hereinafter, each method is explained in full detail.

(1) Method of Production

The first manufacturing method comprises the steps of: (i) completely incinerating the waste into ash of fine powder; (ii) adding and mixing a predetermined mixture containing sodium silicate as a main raw material to ashes incinerated with waste; (iii) press forming with a hydraulic press; And (iv) baking to make ceramics. Hereinafter, each step will be described in more detail.

(i) incineration of waste

The waste is incinerated completely into ash of fine powder. As wastes, all kinds of wastes that can be solidified, such as general wastes, wastes from sewage treatment plants, industrial wastes, and wastes from coal-fired power plants, can be used.In this case, the wastes are completely incinerated and ashes of fine powder Should be

(ii) mixing sodium silicate

To the ash of (i), a mixture containing sodium silicate as a main component (50% or more) and a small amount of pottery and glass is added and mixed well. The mixture of sodium silicate, pottery and glass is added to the ash to serve as a kind of binder. The mixture sodium bisulfate is melted and solidified again through a series of manufacturing processes through a high temperature (over 1100 ° C.) firing process. It acts as a binder that binds the ashes together. In the mixture, the fine powder is finely divided into 300 mesh or more, and the finely powdered stone has the shape of a wave shape unlike the general stone powder, which is spherical, thereby acting as a binder that aggregates ashes. In addition, the glass in the mixture, like sodium silicate, is melted through a series of manufacturing processes through a high temperature firing process and then solidified again to act as a binder.

The mixture containing sodium silicate as a main component may additionally include a paint of a desired color, and when the mixture containing the paint is used, ceramics of various colors may be manufactured. The ratio of ash and the mixture is preferably added in an amount of 3 to 10 parts by weight based on 100 parts by weight of ash.

In addition to the mixture, it is possible to add clay and / or feldspar to the ash of (i), thereby producing various products. The proportion to be added may be adjusted according to the characteristics of the product to be produced, usually 10 to 30 parts by weight of clay, 5 to 20 parts by weight of feldspar, based on 100 parts by weight of ash. In addition, components such as kaolin and talc may be additionally added to diversify the product. It is preferable to mix mixing sufficiently using a mixer.

(iii) press forming

According to the above (ii), a mixture of sodium silicate and the like in the ash is put into a mold for molding and press-molded at a high pressure of 400 to 2000 kg / cm ² using a hydraulic molding press. Forming molds are used according to the desired product, such as tiles, bricks, sidewalk blocks, building abrasive blocks, cervical stones, etc.

The pressure during press molding depends on the type of finished ceramics. In general, relatively thin ceramics, such as tiles, are molded at a pressure of about 400 kg / cm ² , and in the case of sidewalk blocks, about 1000 kg / cm ² , and thick like cervical stones. Mold at a high pressure of about 2000kg / cm ² . Since it is molded at high pressure, concrete is usually 80kg / cm ² , red brick has a strength of about 10kg / cm ² , while the ceramic sidewalk block according to the present invention has a strength of about 220kg / cm ² .

(iv) firing

The press-molded according to (iii) is calcined at 1100 to 1400 ° C. for 3 to 4 hours in a kiln to finally produce the desired ceramics. Baking is more preferably performed at 1160 to 1280 ° C for 3 to 4 hours.

(2) Article 2 Manufacturing Method

Generally, in order to manufacture ceramics which are more permeable than ceramics, after performing a series of steps (i) to (iv) according to the first manufacturing method, (v) grinding the ceramics prepared according to the above steps and then Adding and mixing a mixture of; (vi) press molding with a hydraulic press; And (vii) further firing to form ceramics. However, unlike the case where the finished product is made only by the series of steps (i) to (iv), when forming the permeable ceramics that perform the additional process, a constant mold may be used regardless of the finished product in (ii). .

Depending on the ceramics to be produced, i.e., to produce ceramics that do not require water permeability, the ceramics may be manufactured according to the processes of (i) to (iv). Permeable ceramics can be selectively produced by performing the processes of v) to (vii). The ceramics thus prepared are pulverized and granulated, and then, a predetermined mixture serving as a binder is added, and when pressed and calcined again, the ceramics exhibit excellent water permeability. This is because a myriad of fine pores are formed in the inside. Hereinafter, each process will be described in detail.

(v) mixing the ceramics with sodium silicate after grinding

After crushing and granulating the ceramics produced according to the processes (i) to (iv), a predetermined mixture is added and mixed. The size of the pores in the ceramics is changed according to the size of the particles to be pulverized, the larger the size of the particles, the greater the permeability, but it is difficult to bond between particles and the appearance is not good, the particle size is preferably 10mm or less, within this range the desired permeability You can adjust the size of the particles depending on the degree of sex.

The predetermined mixture is the same as the mixture used in the above (ii), that is, sodium silicate as the main component (50% or more) and contains a small amount of pottery and glass, and serves to bind the ground ceramic particles to each other, The specific action is as described above. The mixing ratio is preferably mixed by adding 3 to 10 parts by weight of the mixture to 100 parts by weight of the ground ceramic particles.

(vi) press molding

Put the mixture of sodium silicate and the like in the ceramic particles according to the above (v) in the mold for molding and press-molded at a high pressure of 1000 ~ 2000kg / cm ² using a hydraulic molding press. Molds for molding use the corresponding molds according to the desired products, such as tiles, bricks, sidewalk blocks, building abrasive blocks, and cervical stones.

(vii) firing

The press-molded according to the above (vi) is calcined at 1100 to 1400 ° C. for 3 to 4 hours in a kiln to finally produce the desired ceramics. Baking is more preferably performed at 1160 to 1280 ° C for 3 to 4 hours.

(3) Method 3

The present method for producing ceramics using only 100% waste incinerated ash includes: (a) pulverizing coal ash to fine powder; (b) adding 8 to 11 parts by weight of water to 100 parts by weight of finely divided coal ash; (c) press molding using a hydraulic press; And (d) firing at 1200 to 1240 ° C.

Hereinafter, each step will be described in detail.

(a) coal ash grinding

Completely combusted coal ash is pulverized into fine powder.

In this third manufacturing method, coal ash is used as waste.

(b) mixing water

According to the above (a), 8 to 11 parts by weight of water is added to 100 parts by weight of finely divided coal ash, followed by complete mixing.

It is preferable to mix mixing sufficiently using a high speed light-plate mixer.

(c) press forming

The coal ash containing moisture according to (b) is press-molded at a pressure of 1200 kg / cm ² or more using a hydraulic press.

(d) firing

The press-molded according to (c) is fired at 1200 ~ 1240 ℃ in the kiln.

Ceramics manufactured according to the present invention, that is, ceramics manufactured by the first to third manufacturing methods, like ceramics made of general raw materials, tiles, ceramics, brick, sidewalk blocks, building abrasive blocks, cervical stones, boundary stones, lightweight It can be used in many fields such as aggregate, and the quality is the same as that of general ceramics. In addition, the production cost is much lower than that of ceramics manufactured from general raw materials, so it can be widely used for building materials such as bricks and sidewalk blocks, and the strength is 1.7 times higher than that of general cement building materials and 1.5 times higher than ordinary stones. It is very excellent as a building material, and its construction is easy because it has a specific gravity of more than 30% compared to general cement building material. In addition, when manufacturing ceramics using the first manufacturing method or the second manufacturing method, as described above, it is possible to produce a variety of products using a variety of additives, such as paint, clay, feldspar, kaolin, talc.

In addition, when manufacturing ceramics using only 100% waste, that is, coal ash, using the third manufacturing method, the ceramics using ordinary raw materials and the same quality as the ceramics made using the first manufacturing method or the second manufacturing method are the most inexpensive. It is possible to produce ceramic products at a cost.

The present invention will be described in more detail with reference to the following Examples. The following examples are not to be construed as limiting the scope of the invention, and it is to be understood that conventional changes are possible by those skilled in the art within the scope of the invention.

Example 1

[Manufacture of Ceramics Bricks Using Waste]

Completely incinerate the general waste to make ash of fine powder, and then to 1000 g of ash, 60 g of a mixture containing sodium silicate as its main ingredient (50 g of sodium silicate + 5 g of fine powder finely ground over 300 mesh) It was added and mixed sufficiently in the mixer. The mixture was placed in a mold for forming a brick, press-molded at a pressure of 100 kg / cm ² using a hydraulic molding press, and then put into a firing furnace and fired at 1200 ° C. for 3 hours to obtain a ceramic brick.

Example 2

[Manufacture of Ceramics Bricks Using Waste]

Incineration of general waste completely to make ash of fine powder, 60g of clay (1000g of sodium silicate + 5g of glass finely ground finely divided into 50g of sodium silicate) to clay of 1000g of ash 200g and feldspar 100g were added, and it fully mixed in the mixer. The mixture was placed in a mold for forming a brick, press-molded at a pressure of 1000 kg / cm ² using a hydraulic molding press, and then put into a firing furnace and fired at 1240 ° C. for 3 hours to obtain a ceramic brick.

Example 3

[Manufacture of Cervical Cervical Stones Using Waste]

After grinding the completely burned laundry material into fine powder, 70 g of 200 g of crystallized powder (5 g of fine silicate + 5 g of glass finely divided into 60 g of sodium silicate) and 200 g of crystallite were added to 1000 g of ash. Mix well in the mixer. The mixture was placed in a frame for cervical stone molding, press-molded at a pressure of 2000 kg / cm ² using a hydraulic molding press, and then put into a firing furnace and calcined at 1280 ° C. for 4 hours to obtain a ceramic cervical stone.

Example 4

[Manufacture of Ceramic Tiles Using Waste]

Incineration of general waste completely to make ash of fine powder, 60g of clay (1000g of sodium silicate + 5g of glass finely ground finely divided into 50g of sodium silicate) to clay of 1000g of ash , 200 g and feldspar were added, and it fully mixed in the mixer. The mixture was placed in a mold for molding, press-molded at a pressure of 400 kg / cm ² using a hydraulic molding press, and then put into a firing furnace and fired at 1280 ° C. for 3 hours. The calcined body thus obtained was put into a grinder and pulverized to a size of 3 mm, and again mixed with 60 parts by weight of a mixture mainly containing sodium silicate, based on 100 parts by weight of the crushed ceramic particles, which was then mixed into a mold for forming a tile. After press molding at a pressure of 500 kg / cm ² using a hydraulic molding press, the resultant was put in a firing furnace and calcined at 1280 ° C. for 3 hours to obtain a ceramic tile having good water permeability.

Example 5

[Production of Ceramic Sidewalk Block Using Waste]

Incineration of general waste completely to make ash of fine powder, 70g of clay (5g + 5g of glass finely ground with sodium silicate 60g + 300 mesh) to clay 1000g of ash 300 g was added and it fully mixed in the mixer. The mixture was placed in a mold for molding, press-molded at a pressure of 1000 kg / cm ² using a hydraulic molding press, and then put into a firing furnace and fired at 1280 ° C. for 3 hours. The calcined body was put into a grinder and pulverized to a size of 4 mm, and again mixed with 100 parts by weight of the ground silicate mixture, which is mainly composed of sodium silicate, in 70 parts by weight, and then mixed into a mold for tending block tendency. After press molding at a pressure of 1200 kg / cm ² using a hydraulic press, it was put in a kiln and fired at 1280 ° C. for 3 hours to obtain a ceramic permeable block having good water permeability.

Example 6

[Manufacture of Ceramic Bricks Using 100% Waste]

The completely burned coal ash was pulverized into ash of fine powder, and then 100g of water was added to 1000g of ash and mixed well using a high speed plate mixer. The mixture was placed in a mold for forming a brick, press-molded at a pressure of 1200 kg / cm ² using a hydraulic molding press, and then put into a firing furnace, and then fired at 1240 ° C. for 3 hours to obtain a ceramic brick.

Example 7

[Comparison of Compressive Strength]

The compressive strength of the ceramics prepared according to the above example was measured by the method of KSF4004-95, and the results are shown in Table 1.

From the above results, it can be seen that the ceramics prepared according to the present invention have a much higher compressive strength than general cement blocks (about 80 kgf / cm ² ).

Example 8

[Comparison of Permeability]

The absorption rate (%) of the ceramics prepared according to Examples 4 and 5 was measured by the method of KSF4004-95, and the results are shown in Table 2.

From the above results, it can be seen that the ceramics prepared according to the present invention have a much better absorption rate than general cement sidewalk blocks (about 10%).

As described above, the manufacture of ceramics according to the present invention contributes to environmental preservation by recycling wastes, and the waste is completely sterilized through high-temperature firing processes and harmful components are removed, thereby making it possible to recycle wastes that are not harmful to the human body.

In addition, according to the present invention, by using waste and a simple manufacturing raw material, the production cost of ceramics is drastically reduced, so that ceramics having the same quality as ceramics made of general raw materials can be provided at a low cost. The third manufacturing method can provide ceramics of the same quality in the least expensive way. Therefore, as can be seen from the above embodiment, the ceramics according to the present invention, which is much superior in strength and appearance in comparison with conventional cement and concrete building materials, and has a small weight, can be easily used as a building material. .

In addition, as can be seen from the above embodiment, the present invention solves the water permeability problem of the ceramics to selectively produce ceramics having excellent water permeability, and thus is particularly suitable for use in sidewalk blocks and the like requiring water permeability.

Claims (3)

(i) a process of incineration of waste completely to ash of fine powder; (ii) adding 3 to 10 parts by weight of a mixture containing 50% by weight or more of sodium silicate and containing a small amount of pottery and glass to 100 parts by weight of the ash of the fine powder; (iii) press molding at a pressure of 400 to 2000 kg / cm ² using a hydraulic molding press after putting ash mixed with sodium silicate and the like into a mold for molding according to the above (II); (iv) baking the press-molded product according to (iii) at 1100 to 1400 ° C. for 3 to 4 hours in a kiln; (v) pulverizing the prepared ceramics of (iv) to 10 mm or less, and then adding the mixture of (ii) to 3 to 10 parts by weight of 100 parts by weight of the ground ceramic particles, followed by mixing; (vi) a step of putting the ceramic particles mixed with sodium silicate and the like into the mold for molding according to the above (v) and then pressing the mold at a pressure of 1000 to 2000 kg / cm ² using a hydraulic molding press; And (vii) calcining the press-molded product according to the above (vi) at 1100 to 1400 ° C. for 3 to 4 hours in a firing furnace. The method according to claim 1, wherein the firing is performed at 1160 to 1280 ° C for 3 to 4 hours. The method according to claim 1, wherein (ii) further comprises adding and mixing clay and / or feldspar to 10 to 30 parts by weight and 5 to 20 parts by weight, respectively, based on 100 parts by weight of ash. Method for producing water-permeable ceramics using waste.

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