KR100432775B1 - Compositions and manufacturing of low temperature calcined brick - Google Patents
Compositions and manufacturing of low temperature calcined brick Download PDFInfo
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- KR100432775B1 KR100432775B1 KR10-2001-0047124A KR20010047124A KR100432775B1 KR 100432775 B1 KR100432775 B1 KR 100432775B1 KR 20010047124 A KR20010047124 A KR 20010047124A KR 100432775 B1 KR100432775 B1 KR 100432775B1
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
- C04B28/26—Silicates of the alkali metals
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
- C04B18/10—Burned or pyrolised refuse
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/54—Pigments; Dyes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Abstract
본 발명은 미분탄을 사용하는 석탄화력발전소와 도시쓰레기 소각로 및 하,폐수처리장에서 발생되는 플라이 애쉬를 이용한 건축용 저온소성 성형벽돌 제품의 조성물 및 그 제조방법에 관한 것으로 더욱 상세하게는 다량의 미연탄소분이 함유된 플라이애쉬를 주로 사용하고 규산소다와 산화철을 첨가하여 상온에서 혼합,성형하여 소성한 벽돌을 제조하는 것으로 플라이애쉬를 대량으로 활용하여 환경 친화적이며 저온 소성으로 인한 에너지를 절감시키고 압축강도가 양호하고 밀도가 작아 경량제품으로 제조가 가능하고 수축률이 작아서 제품의 칫수 안정성과 불량률이 적은 소성벽돌을 제조할 수 있는 조성물과 제조방법에 관한 것으로 소성벽돌을 제조함에 있어서, 플라이애쉬 100중량부에 대하여 산화철 5-15중량부를 첨가시켜 혼합한 후 액상규산소다 20-40중량부를 첨가하여 균질,혼합시켜서 상기 혼합물을 금형에 장입하고 100-200kg/cm2의 성형압력으로 압축,탈형하고 건조된 성형물을 50℃,105℃ 및 550℃에서 각각 2시간 유지한 후 최종적으로 약 850℃에서 4시간 소성한 후 냉각시켜서 제조하는 것을 특징으로 하는 저온소성 성형벽돌 제품의 제조방법.The present invention relates to a composition of a low-temperature fired molded brick product for building using fly ash generated from a coal fired power plant using pulverized coal, an urban waste incinerator, and a sewage and wastewater treatment plant, and more particularly, a large amount of unburned carbon powder It is mainly used fly ash, and it is made of mixed and molded at room temperature by adding sodium silicate and iron oxide to make brick fired. It is eco-friendly by using fly ash in large quantities, saving energy due to low temperature firing and good compressive strength. The present invention relates to a composition and a method for manufacturing a fired brick having a low density, low density, and a low shrinkage rate and low dimensional stability and a low defect rate of the product. 5-15 parts by weight of iron oxide, mixed with liquid silica 20 to 40 parts by weight was added a homogeneous, by mixing and the mixture was charged in a mold, each for 2 hours to extract, the demoulding and drying of the formed product in forming pressure 100-200kg / cm 2 eseo 50 ℃, 105 ℃ and 550 ℃ After finally firing at about 850 ℃ for 4 hours, the method for producing a low-temperature fired molded brick product, characterized in that the manufacturing.
Description
본 발명은 미분탄을 사용하는 석탄화력발전소와 도시쓰레기 소각로 및 하,폐수처리장에서 발생되는 플라이 애쉬를 이용한 건축용 저온소성 성형벽돌 제품의 조성물 및 그 제조방법에 관한 것으로 더욱 상세하게는 다량의 미연탄소분이 함유된 플라이애쉬를 주로 사용하고 규산소다와 산화철을 첨가하여 상온에서 혼합,성형하여 소성한 벽돌을 제조하는 것으로 플라이애쉬를 대량으로 활용하여 환경 친화적이며 저온 소성으로 인한 에너지를 절감시키고 압축강도가 양호하고 밀도가 작아 경량제품으로 제조가 가능하고 수축률이 작아서 제품의 칫수 안정성과 불량률이 적은 소성벽돌을 제조할 수 있는 조성물과 제조방법에 관한 것이다.The present invention relates to a composition of a low-temperature fired molded brick product for building using fly ash generated from a coal fired power plant using pulverized coal, an urban waste incinerator, and a sewage and wastewater treatment plant, and more particularly, a large amount of unburned carbon powder It is mainly used fly ash, and it is made of mixed and molded at room temperature by adding sodium silicate and iron oxide to make brick fired. It is eco-friendly by using fly ash in large quantities, saving energy due to low temperature firing and good compressive strength. The present invention relates to a composition and a method for manufacturing a fired brick having a low density and a low shrinkage rate and a small shrinkage rate and a low dimensional stability of a product.
일반적으로 미분탄을 사용하는 석탄화력발전소에서 배출되는 플라이애쉬의 사용은 그 일부를 콘크리트 혼화제로 활용하고 나머지 대부분은 매립처리하므로 매년 수백만톤에 달하는 플라이애쉬의 처리방법에 대한 대안이 강구되지 않아 환경적인 문제로 대두되고 있는 실정이다.In general, the use of fly ash from coal-fired power plants using pulverized coal utilizes a part of it as concrete admixture and most of it is landfill, so there are no alternatives for treating millions of tons of fly ash every year. The situation is emerging as a problem.
종래에 플라이애쉬를 원료로 사용하여 소성벽돌을 제조하는 방법은 대부분이 약 30%의 점토질을 대체한 조성물이며 점토와 같은 타 원료와의 균질 혼합이 곤란하고 또한 최고 소성온도가 점토벽돌의 제조공정과 유사하므로 별다른 장점이 없었다.Conventionally, a method of manufacturing a fired brick using fly ash as a raw material is a composition in which most of the clay material is replaced by about 30%, and homogeneous mixing with other raw materials such as clay is difficult, and the maximum firing temperature is a process of producing a brick brick. Similar to, there was no advantage.
또한 플라이애쉬 입자간 소결온도는 사용하는 석탄과 연소조건에서 생성된 플라이애쉬의 조성에 따라 약간씩 변화하며 통상 약 1,400℃ 이상이 되고 일부 표면조성의 연화점 역시 약 1,200℃ 이상인 것으로 알려져 있으므로 장석질과 같은 융제를 첨가하여 종래의 점토벽돌 또는 석탄 플라이애쉬로 일부 대체한 점토벽돌은 1,100-1,200℃ 온도에서 소성,제조하였다.In addition, the sintering temperature between the fly ash particles varies slightly depending on the coal used and the composition of the fly ash produced under the combustion conditions, and is generally about 1,400 ° C or higher, and the softening point of some surface compositions is also about 1,200 ° C or higher. Clay bricks partially replaced by conventional clay bricks or coal fly ashes by adding the same flux were calcined and manufactured at a temperature of 1,100-1,200 ° C.
그러므로 상기한 소성온도보다 낮은 저온에서 소성시키기 위해서는 저온에서 용융하며 보다 강한 결합력을 가지는 융제를 사용하거나 액상의 점결제를 사용해야 하는 문제점이 있었다.Therefore, in order to bake at a low temperature lower than the above-mentioned firing temperature, there is a problem of using a flux having a stronger bonding force or using a liquid binder as it melts at a low temperature.
따라서 본 발명은 상기한 종래의 문제점을 해결하기 위한 목적으로 창출된 것으로 플라이애쉬를 다량으로 활용하면서 상온에서 혼합 및 성형이 가능케하고, 원료의 균질,혼합을 용이하게하며, 소성시 수축률이 작아서 불량률을 최소화하고 소성온도를 저하시켜 에너지 소비효율을 향상시킬 수 있는 저온소성 성형벽돌 제품의 조성물 및 그 제조방법을 제공하기 위한 것이다.Therefore, the present invention has been created for the purpose of solving the above-mentioned problems, allowing the mixing and molding at room temperature while using a large amount of fly ash, facilitates homogeneous mixing of the raw materials, and the shrinkage rate during firing is small so that the defective rate It is to provide a composition and a manufacturing method of a low-temperature fired molded brick product that can minimize and minimize the firing temperature to improve the energy consumption efficiency.
상기한 조성물과 제조방법을 제공하기 위하여 플라이애쉬에 액상 무기질 점결제로서 액상규산소다와 융제 및 색상조절을 겸할 수 있는 첨가제로 산화철(Fe2O3)로 이루어진 조성물과 플라이애쉬 100중량부에 대하여 산화철 5-15중량부를 첨가시켜 혼합한 후 액상규산소다 20-40중량부를 첨가하여 균질,혼합시켜서 상기 혼합물을 금형에 장입하고 100-200kg/cm2의 성형압력으로 압축,탈형하고 건조된 성형물을 50℃,105℃ 및 550℃에서 각각 2시간 유지한 후 최종적으로 약 850℃에서 4시간 소성한 후 냉각시켜서 소성벽돌을 제조하는 것이며 상기한 방법에 의해 제조된 벽돌은 소성시 수축률이 약 2%이하이고 비중이 1.2-1.4인 소성벽돌을 제공할 수 있는 것이다.In order to provide the composition and the manufacturing method to the fly ash as a liquid inorganic caking additive liquid silicate and additives that can combine the flux and color control with respect to the composition consisting of iron oxide (Fe 2 O 3 ) and 100 parts by weight of fly ash 5-15 parts by weight of iron oxide was added and mixed, 20-40 parts by weight of liquid sodium silicate was added, homogeneous and mixed to charge the mixture into a mold and pressed, demolded and dried at a molding pressure of 100-200 kg / cm 2 . After maintaining for 2 hours at 50 ℃, 105 ℃ and 550 ℃ respectively, and finally calcined at about 850 ℃ 4 hours and then cooled to prepare a fired brick, the brick produced by the above method is about 2% shrinkage upon firing It is possible to provide a fired brick having a specific gravity of 1.2 to 1.4 or less.
이하 발명의 요지를 첨부된 도면에 연계시켜 그 구성과 작용을 상세히 설명하면 다음과 같다.Hereinafter, the configuration and operation of the present invention will be described in detail with reference to the accompanying drawings.
본 발명은 플라이애쉬 100중량부에 액상규산소다 20-40중량부와 산화철(Fe2O3) 5-15중량부로 이루어진 저온소성 성형벽돌 제품의 조성물을 특징으로 하는데, 이와 같은 소성벽돌을 제조하는 방법은, 플라이애쉬 100중량부에 대하여 산화철 5-15중량부를 첨가시켜 혼합한 후 액상규산소다 20-40중량부를 첨가하여 균질,혼합시켜서 상기 혼합물을 금형에 장입하고 100-200kg/cm2의 성형압력으로 압축,탈형하고 건조된 성형물을 50℃,105℃ 및 550℃에서 각각 2시간 유지한 후 최종적으로 약 850℃에서 4시간 소성한 후 냉각시켜서 제조하는 것이다.The present invention features a composition of a low-temperature fired molded brick product comprising 20-40 parts by weight of liquid sodium silicate and 5-15 parts by weight of iron oxide (Fe 2 O 3 ) in 100 parts by weight of the fly ash. In the method, 5-15 parts by weight of iron oxide is added to 100 parts by weight of fly ash, mixed, 20-40 parts by weight of liquid sodium silicate is added, homogeneous and mixed, and the mixture is charged into a mold to form 100-200 kg / cm 2 . After pressing, demolding and drying the molded product under pressure at 50 ° C., 105 ° C. and 550 ° C. for 2 hours, the resulting molded product is finally baked at about 850 ° C. for 4 hours and then cooled.
상기한 액상규산소다는 몰비가 3.0-3.4,비중이 1.38이상이며, 액상규산소다 100중량부에 대하여 물을 60중량부 이하로 첨가한 수용액을 사용한다.The aqueous solution of sodium silicate has a molar ratio of 3.0-3.4, specific gravity of 1.38 or more, and an aqueous solution in which water is added in an amount of 60 parts by weight or less based on 100 parts by weight of liquid sodium silicate.
또한 상기 플라이애쉬,액상규산소다 및 산화철 원료를 상온에서 혼합하여 최고 소성온도는 800-950℃로 제조한다.In addition, the fly ash, liquid sodium silicate and iron oxide raw materials are mixed at room temperature to produce a maximum firing temperature of 800-950 ° C.
이와같이 된 본 발명은 압축강도가 양호하고 소성시 수축률이 작고 균열결함이 발생하지 않으며 미연탄소분이 다량 함유된 플라이애쉬를 대량으로 사용할 수 있고 제품표면이 미려하고 종래 점토벽돌보다 저온에서 소성할 수 있는 소성벽돌을 제공하기 위하여 미연탄소분이 함유된 플라이애쉬 100중량부에 대하여 액상 무기질 점결제인 액상규산소다 20-40중량부와 융제 및 색상조절을 겸할 수 있는 첨가제인 산화철 5-15중량부를 상온에서 혼합,성형하며 최고 소성온도가 800-950℃로 제조할 수 있게한 것이다.In the present invention, the compressive strength is good, the shrinkage rate during firing is low, cracking does not occur, and the fly ash containing a large amount of unburned carbon content can be used in a large quantity, and the surface of the product is beautiful and can be fired at a lower temperature than the conventional clay brick. To provide a fired brick, 20-40 parts by weight of liquid sodium silicate, a liquid inorganic binder, and 5-15 parts by weight of iron oxide, an additive capable of controlling flux and color, based on 100 parts by weight of fly ash containing unburned carbon powder. It is mixed and molded, and its maximum firing temperature is 800-950 ℃.
상기 플라이애쉬는 미분탄을 연료로 사용하는 석탄화력발전소에서 배출되는 플라이애쉬를 사용하며 그 분말도는 3,000-4,000cm2/g의 범위에 있고 비중이 2이상의 것을 사용하고 함유된 미연탄소분에 구애받지 않고 CaO, MgO, K2O 및 Na2O의 성분이 많을수록 좋고, 입자가 미분화된 것일수록 좋지만 양자 모두 필수조건은 아니므로 배출되는 플라이애쉬를 처리하지 않고 직접 활용할 수 있다.The fly ash uses a fly ash discharged from a coal-fired power plant that uses pulverized coal as fuel, and its powder degree is in the range of 3,000-4,000 cm 2 / g and has a specific gravity of 2 or more and is not limited to unburned carbon powder. And the more components of CaO, MgO, K 2 O and Na 2 O is better, the finer the particles are finer, but both are not essential, so it can be used directly without treating the discharged fly ash.
또한 도시쓰레기 소각로에서 발생하는 플라이애쉬와 하,폐수 처리장의 슬러지 소각로에서 배출되는 잔재도 활용할 수 있으며 역시 전처리 없이 사용할 수 있는 것이다.In addition, fly ash from urban waste incinerators and residues from sludge incinerators in sewage and wastewater treatment plants can be utilized and can also be used without pretreatment.
액상 무기질 점결제인 규산소다는 몰비(SiO2/Na2O)가 3.0-3.4이고 비중이 1.38이상인 것이 좋고, 액상규산소다를 그대로 사용하거나 규산소다의 점도를 조절하기 위해서 통상 시판되는 액상규산소다 100중량부에 물을 60중량부 이하로 첨가한 혼합물을 사용하며 첨가량은 플라이애쉬 100중량부를 기준으로 상기에서 준비된 규산소다액을 15-30중량부를 첨가하며 융제 및 제품의 색상을 조절하는 역할을 겸하는 첨가제로 산화철의 첨가량은 플라이애쉬 내에 함유된 산화철 양에 따라 조절하되 전체 산화철의 양이 플라이애쉬 100중량부에 대하여 5-15중량부가 되도록 첨가시킨다.Sodium silicate, a liquid inorganic binder, preferably has a molar ratio (SiO 2 / Na 2 O) of 3.0-3.4 and a specific gravity of 1.38 or more, and is commercially available liquid silicate for use of liquid silicate as it is or to control the viscosity of sodium silicate. 100 parts by weight of water is used in a mixture of 60 parts by weight or less, and the addition amount is based on 100 parts by weight of fly ash, and 15-30 parts by weight of the sodium silicate solution prepared above serves to control flux and color of the product. As an additive, the amount of iron oxide is controlled according to the amount of iron oxide contained in the fly ash, but the amount of iron oxide is added in an amount of 5-15 parts by weight based on 100 parts by weight of the fly ash.
상기 산화철은 소성온도를 낮추어 주는 융제 역할과 제품의 색상을 조절하는 역할을 겸하게 되며 또한 플라이애쉬 입자 사이의 공극을 메워 줌으로써 흡수율을 낮추는 기능을 수행하게 되는 것이다.The iron oxide is to act as a flux to lower the firing temperature and to control the color of the product, and also to reduce the absorption rate by filling the voids between the fly ash particles.
상기 제조방법에 있어 성형압력은 100-200kg/cm2이 적당하며 상온에서 혼합,성형한 후 건조시키고 50℃,105℃ 및 550℃에서 각각 2시간 유지한 후 최종적으로 약 850℃에서 가열함으로서 건조와 소성공정을 완료하게 되는 것이다.In the above production method, the molding pressure is suitable for 100-200kg / cm 2 , and after mixing and molding at room temperature, drying and maintaining at 50 ° C., 105 ° C. and 550 ° C. for 2 hours, and finally heating at about 850 ° C. And the firing process will be completed.
상기와 같은 방법으로 제조된 벽돌은 소성시 수축률이 약 2%이하로 작아서 결함 발생률이 적고 비중이 1.2-1.4로서 종래의 점토벽돌의 비중 1.8보다 경량이며압축강도가 양호하고 소성온도를 약 300℃ 정도 저하시킬 수 있어서 에너지 절약이 가능하다.The brick produced by the above method has a small shrinkage rate of less than about 2% at the time of firing, so the defect rate is small and the specific gravity is 1.2-1.4, which is lighter than the specific gravity 1.8 of the conventional clay brick, the compressive strength is good, and the firing temperature is about 300 ° C It can reduce the degree, and energy saving is possible.
또한 본 발명을 적용한 실시예를 보면 다음과 같다.In addition, the embodiment to which the present invention is applied is as follows.
실시예 1.Example 1.
플라이애쉬 2,000g에 산화철 200g을 첨가하여 충분히 혼합한 후 몰비가 3.2인 규산소다용액 800g을 첨가하여 균질,혼합시킨다.200 g of fly ash is added to 200 g of iron oxide, followed by mixing.
상기한 혼합물을 금형(190×90×90mm)에 1,500g을 장입한 후 150kg/cm2의 압력으로 일축 압축시킨 다음 탈형하고 건조된 성형물을 약 100℃/h의 속도로 가열하면서 50℃,105℃ 및 550℃에서 각각 2시간 유지하고 최종적으로 850℃에서 4시간 소성한 후 냉각시킨다.The mixture was charged into a mold (190 × 90 × 90mm), 1,500 g, uniaxially compressed at a pressure of 150 kg / cm 2 , and then demolded and dried at 50 ° C., while the dried molding was heated at a rate of about 100 ° C./h. It is maintained at 2 ° C. and 550 ° C. for 2 hours and finally calcined at 850 ° C. for 4 hours and then cooled.
이때 제조된 성형제품의 수축률은 1.6%,압축강도는 230kg/cm2,비중이 1.3이며 색상은 적갈색을 띈 소성벽돌 제품이 제조되었다.At this time, the shrinkage of the molded product was 1.6%, the compressive strength is 230kg / cm 2 , the specific gravity is 1.3 and the color was reddish brown brick product was produced.
실시예 2.Example 2.
상기한 실시예 1.과 동일한 조건하에서 액상규산소다를 몰비가 3.2,비중이 1.39인 액상규산소다와 물의 비율이 5:1인 수용액 700g을 첨가하고 산화철은 100g첨가하여 동일하게 제조하였을 때 수축률이 1.9%,압축강도는 240kg/cm2,비중이 1.4이며 표면 색상이 적갈색인 소성벽돌 제품이 제조되었다.Under the same conditions as in Example 1, 700 g of an aqueous solution of liquid sodium silicate having a molar ratio of 3.2 and a specific gravity of 1.39 was added to 700 g of an aqueous solution having a ratio of 5: 1 to water and 100 g of iron oxide. A plastic brick product of 1.9%, compressive strength of 240kg / cm 2, specific gravity of 1.4, and reddish brown color was produced.
본 발명은 상술한 특정의 바람직한 실시예에 한정되지 아니하며, 청구범위에서 청구하는 본 발명의 요지를 벗어남이 없이 당해 발명이 속하는 기술분야에서 통상의 지식을 가진 자라면 누구든지 다양한 변형실시가 가능한 것은 물론이고, 그와 같은 변경은 청구범위 기재의 범위 내에 있게 된다.The present invention is not limited to the above-described specific preferred embodiments, and various modifications can be made by any person having ordinary skill in the art without departing from the gist of the present invention claimed in the claims. Of course, such changes will fall within the scope of the claims.
그러므로 본 발명은 대부분 폐기되는 플라이애쉬를 대량으로 활용할 수 있어 환경친화적이며 상온에서 원료를 혼합할 수 있으며 종래 점토벽돌에 비하여 저온에서 소성할 수 있고 비중이 1.2-1.4로 저비중이면서 압축강도가 양호하고 소성시 수축률이 2%이하로 낮아서 제품의 불량률이 적고 칫수의 안정성이 향상된 소성벽돌을 제공할 수 있는 효과가 있는 것이다.Therefore, the present invention can use the large amount of fly ash, which is mostly discarded, environmentally friendly, can mix the raw materials at room temperature, and can be fired at a low temperature compared to the conventional clay brick, and the specific gravity is 1.2-1.4, low specific gravity and good compressive strength And the shrinkage rate at the time of firing is less than 2% to reduce the defect rate of the product and there is an effect that can provide a plastic brick with improved stability of the dimensions.
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