KR100581191B1 - Artificial abrasive stone made from wastes and method for manufacturing thereof - Google Patents

Abstract

The present invention relates to an artificial abrasive for stone washing using waste, and a method for manufacturing the same, using waste materials such as waste glass, waste ceramics, etc., which are difficult to recycle or have low added value, to reduce manufacturing costs, and reduce environmental pollution. It is for the purpose of prevention.

The artificial abrasive for stone washing using waste according to the present invention, which comprises about 60 to 95 parts by weight of waste glass powder and waste ceramics, waste tiles, waste clay, waste natural abrasive sludge or a mixture thereof, in a weight ratio to the weight of the raw material mixture In one of the mixtures, powder having a particle size of about 150 mesh or less is added to the raw material mixture, carbonate and sulfate as a blowing agent, boron oxide as a thermal stabilizer, and sodium silicate as a mixing stabilizer. In the method for producing an artificial abrasive for stone washing using waste according to the present invention, raw materials such as waste glass and waste pottery are mixed according to each mixing ratio, and after kneading with addition of a binder, it is molded into a predetermined shape, and the molded body is fired. Foaming, stabilizing and cooling, and finally polishing the surface to complete the abrasive.

Stone wash, Jeans, Abrasive, Waste glass, Natural friction material

Description

Artificial abrasive for stone washing using waste and its manufacturing method {ARTIFICIAL ABRASIVE STONE MADE FROM WASTES AND METHOD FOR MANUFACTURING THEREOF}

1 is a manufacturing process of the stone washing artificial abrasive using waste according to the present invention.

The present invention relates to an artificial abrasive for stone washing using waste and a method of manufacturing the same, and more particularly, to solid waste such as waste glass, waste ceramics, waste tiles, waste clay or sludge generated after use of existing natural abrasives. The present invention relates to a stone washing artificial abrasive and a method for manufacturing the same, using waste, which is used as a raw material to preserve the environment and reduce manufacturing costs.

In the manufacture of garments, such as jeans is a process for producing the color of the jeans naturally is subjected to, for example, stone washing process.

The stone washing process is carried out by washing the jeans in a large washing machine in a jeans manufacturer and a bleaching company with water or caustic soda, chemicals or enzymes for the discoloration of the dye, and a cloth decolorizing abrasive which contacts the clothing surface. This is a special washing process that softens the texture of the fabric as well as discoloring the color of the jeans to natural and various colors by friction between the surface of the jeans and the abrasive.

The fabric discoloration abrasive used in this stone washing process should be lighter than water and have good polishing power. In addition, the sludge abrasive must contain a discolored dye so that the discolored portion of the jeans is not contaminated by the discolored dye from the jeans. In other words, for effective stone washing, an abrasive having such special performance should be used.

Most of the abrasives currently used around the world are natural abrasives produced in regions such as Indonesia, Turkey, Mexico, Greece, and Ecuador.

These natural abrasives have a great advantage of high friction and instantaneous abrasive force due to their high coefficient of surface friction, but they are easily worn within 40 minutes to 1 hour after they are put into the washing machine due to their wide specific gravity and too low surface hardness and strength. Brown spots may occur on the surface of the cotton fabric discolored by the iron contained therein, and a large amount of manpower is required for the worn abrasive material to get inside the pouch of the stonewashed clothing and to remove the worn powder from the washed clothing. There are big disadvantages in the process.

Moreover, since most of these natural abrasives are produced by volcanic eruptions and contain a large amount of sulfur, the water quality of the river is contaminated by laundry wastewater containing sulfur, and a large amount of worn abrasive generated during the stone washing process is sludged. As a result, sedimentation in rivers or rivers can cause serious environmental pollution, requiring additional costs for treating them.

In addition, on the user side of abrasives, these natural abrasive resources are ubiquitous in some countries, so most of the cotton producing countries depend on imports of natural abrasives in their entirety, but their supply and prices are not stable. In other words, the existing natural abrasive has a great disadvantage of low hardness, which is a property of itself, and locally localized resources.

Against this backdrop, many countries, including Korea, which produces jeans, are making great efforts to research and develop artificial abrasives for washing fabrics that can solve the above problems.

As an artificial abrasive for washing fabrics, for example, Korean Patent Publication No. 1996-0014067. Artificial abrasive according to the patent is excellent in durability about 2.5 times the natural abrasive, and has the advantage of reducing the amount of dust and waste water generated. However, since relatively expensive raw materials such as perlite, feldspar, and sodium silicate are used, the manufacturing cost is too high. In particular, due to the excessive use of sodium silicate, the heat treatment conditions of the product are well controlled. Here, the reason for the heat treatment is that if the heat treatment does not cause fine cracks inside the product and break well when used, the broken product will not only damage the fabric discolored but also the durability is poor. In addition, this product has a problem in that the silicic acid component is easily entangled with each other on the walls of the furnace or when the products are fired.

In addition, Korean Patent Laid-Open Publication No. 2001-0096640 discloses a glass powder which combines the base with softening upon firing of a base and a base made of diatomaceous earth, perlite, fly ash, clay, or a mixture thereof, thereby forming pores upon firing. A fabric decolorizing abrasive comprising calcium carbonate and sodium hydroxide is shown. The fabric discoloration abrasive has the advantages of strong durability and excellent polishing power, and because of the sodium hydroxide to prevent cracking and lower the firing temperature, but the aging of the production equipment is rapid due to mechanical corrosion due to alkalinity during the plastic production of sodium hydroxide Among them, diatomaceous earth and clay, which are used as a base, are relatively expensive in view of the price of existing natural abrasives, and thus there is a big problem in economic efficiency.

In addition, Korean Patent Laid-Open Publication No. 1999-0084252 has proposed a method for producing lightweight artificial corners, wherein the manufacturing method is based on 100 parts by weight of sodium hydroxide 5 to 10 parts by weight of a mixture consisting of 90 to 100 parts by weight of soil and 0 to 10 parts by weight of perlite. An aqueous solution containing 15 parts by weight and 0.2 to 5 parts by weight of potassium carbonate is added and mixed, followed by molding, drying and firing. Lightweight artificial corners for discoloration of fabrics produced by this manufacturing method can be prevented from cracking by lowering the firing temperature with sodium hydroxide as described above, but they are broken in a short time due to incomplete sintering. There are disadvantages of being easily corroded.

As described above, many research results have been proposed in foreign countries along with domestic research results on artificial abrasives. For example, US Pat. Nos. 3,874,861 (April 1975), 4,207,114 (June 1980), 4,933,306 (June 1990), 5,359,745 (November 1994) 5,928,773 (July 1999) are related to the manufacture of porous shaped bodies. In particular, the patents which are directly related to the stone washing artificial abrasive material as in the present invention are 4,933,306 (June 1990), 5,359,745 (Nov. 1994), 5,928,773 (July 1999).

U.S. Patent No. 4,933,306 (June 1990) mixes sodium silicate and calcium carbonate in an unadjusted waste glass powder containing up to 1 mm in particle size of raw glass for the manufacture of artificial abrasives Is put in a special container or placed on the belt of the belt as it is without forming and calcined at a temperature of 700 ℃. During this firing process, a solid mass of 1 to 30 cm is produced, which is then placed in a large cylinder and polished to form an artificial abrasive. This patent may be simple in the process itself, but there may be various problems in the process. The biggest problem is that it is impossible to produce high quality artificial abrasives. This is because the stone washing process differs depending on the clothing for each season because it cannot satisfy this demand.

U.S. Patent No. 5,359,745 (Nov. 1994) is a raw material for the manufacture of artificial abrasives for stone washing, in which 10 to 20% of calcium carbonate, a traditional blowing agent, is used as a blowing agent, and up to 6% of bentonite clay as a binder of abrasives, in waste glass powder. This added mixture is used to produce artificial abrasives by foamed glass production. This patent uses waste glass as the raw material, but specifically suggests the exact composition of the soda-lime glass used in the examples, specifically limiting the types of waste glass such as soda glass, borosilicate glass, aluminum silicate glass, etc. It is difficult to control pore formation because only calcium carbonate is used as the blowing agent, and because the density of the prepared abrasive is between 0.4 g / cm 3 and 0.70 g / cm 3, the density is low and buoyancy is high. Since it is present on the surface layer has a low fluidity with the laundry, there is a disadvantage that the contact with the laundry is reduced, the friction effect of the desired bar is reduced.

In addition, U.S. Patent 5,928,773 (July 1999) proceeds by adding an enzyme to the wash water in order to enhance the decolorizing effect, in which case an artificial abrasive can be used to maintain the pH, which is an area for enhancing the function of the enzyme. It is an attempt to manufacture from a viewpoint. The patent is characterized by the addition of lignosulfonates as pH adjusting agents. In addition, this process maintains a raw material composition similar to that of ordinary foam glass, and is prepared by adjusting the content of raw glass to 93% or more of the total. In this case, the manufactured artificial abrasives have disadvantages in that the molded bodies themselves have high glassy properties and thus are weak to physical shocks and thermal shocks, so that cooling conditions are difficult in the manufacturing process, and the manufactured molded articles have a low impact strength.

On the other hand, since Japan also has a large-scale jeans production facility, much effort is being made to develop artificial abrasives. Japanese Patent Application Laid-open No. Hei 2-111668 (1990), Japanese Patent Application Laid-open No. Hei 3-208873 (1991), and Japanese Patent Application Laid-open No. Hei 5-98585 (1993) are representative examples. However, these three patents are all related to the manufacture of artificial abrasives for stone washing, but the basic raw materials and production methods for producing the artificial abrasives proposed in these patents are very specific. That is, Japanese Patent Laid-Open No. 2-111668 (1990) uses a polymer material obtained by adding absorbent fibers to a synthetic fiber such as polypropylene and polyester, as a basic raw material. Japanese Patent Application Laid-Open No. 3-208873 (1991) manufactures artificial abrasives by adding 100% by weight of cement to a hydrous agent, artificial lightweight aggregate, an expanding agent, a surfactant, and the like to solidify it. Japanese Patent Application Laid-Open No. 5-98585 (1993) manufactured an artificial abrasive for decolorizing jeans by forming, firing, and foaming a mixture of anti-fossil powder, clay, and silicon carbide as a blowing agent, and using silicon carbide as a blowing agent. Therefore, since the firing temperature must be maintained at 1200 ℃ energy loss is large.

In addition, there are a number of domestic and foreign patents related to the manufacture of artificial abrasives, but the approach is not similar to the present invention with the above patent. However, the important fact is that none of the above patents has yet introduced any information that a commercial or commercial production process has taken place. The reason is that although the mechanical and physical properties of the product itself can be controlled, the production cost is not competitive in the market economy compared to the price of natural abrasives. Therefore, the successful manufacture of artificial abrasives requires that the manufactured artificial abrasives have mechanical or physicochemical properties, and that the manufacturing cost must be competitive in price. Of course, technology is required to minimize the manufacturing cost thereof.

The present invention is to solve the problems as described above, using a non-recyclable or very low value-added waste, such as waste glass, waste ceramics, waste tiles, waste clay and waste natural abrasive sludge as raw materials It is intended to provide a stone washing artificial abrasive and its manufacturing method using waste to minimize the production cost and to minimize the generation of sludge as a waste by strengthening the mechanical strength of the abrasive to give a high friction function and high wear resistance. Its purpose is.

Stone-washing artificial abrasive using the waste according to the present invention for achieving the above object, 60 to 95 parts by weight of waste glass powder and waste ceramics, waste tiles, waste clay or waste natural abrasives in a weight ratio to the total weight of the raw material mixture Any one of the sludges or a mixture thereof is characterized in that the additive is mixed with 0.3 to 33 parts by weight based on 100 parts by weight of the raw material mixture containing 5 to 40 parts by weight of the powder.

The additive may comprise 0.2 to 12.0 parts by weight of carbonate, 0.1 to 6.0 parts by weight of sulfate, 0.0 to 5.0 parts by weight of boron oxide and 0.0 to 10.0 parts by weight of sodium silicate.

In addition, the method for producing an artificial abrasive for stone washing using waste according to the present invention includes (a) raw materials such as waste glass, waste ceramics, waste tiles, waste clay and waste natural abrasive sludge and carbonate, sulfate, boron oxide and silicic acid. Preparing additives such as soda; (b) pulverizing the raw material and the additive of step (a); (c) about 60 to 95 parts by weight of the waste glass powder, based on the total weight of the mixture and one or more of waste ceramics, waste tiles, waste clay or waste natural abrasive sludge, or a mixture thereof, based on the total weight of the mixture; Mixing 0.3 to 33 parts by weight of an additive in which carbonate, sulfate, boron oxide and sodium silicate are mixed with respect to 100 parts by weight of the mixture of about 5 to 40 parts by weight of the mixture; (d) kneading by properly adding a predetermined amount of CMC (Carboxyl Methyl Cellulose), PVA (Poly vinyl alcohol), or water glass to the raw material mixture mixed in step (c) as a binder for molding; (e) molding the raw material mixture kneaded in step (d); (f) firing the molded article according to the step (e) to 400 to 750 ° C, foaming at a temperature of approximately 800 to 1050 ° C for 5 to 15 minutes, and stabilizing the foamed molded body at 500 to 700 ° C, and then 20 to Cooling to 40 ° C .; And (g) grinding the surface of the molded article cooled in the step (f) into a ball mill to polish the surface so that porous pores are formed on the smooth surface of the foamed molded article, thereby completing an artificial abrasive.

In the step (c), an additive consisting of 0.2 to 12.0 parts by weight of carbonate, 0.1 to 6.0 parts by weight of sulfate, 0.0 to 5.0 parts by weight of boron oxide, and 0.0 to 10.0 parts by weight of sodium silicate may be mixed.

(h) may further comprise the step of fine-tuning the particle size of the entire raw material mixture obtained in the step (c) according to the laundry of the stone washing target to adjust the particle size.

The features and advantages of the present invention will become more apparent from the following detailed description. Prior to this, the terms or words used in the present specification and claims are defined in the technical spirit of the present invention on the basis of the principle that the inventor can appropriately define the concept of the term in order to explain his invention in the best way. It must be interpreted to mean meanings and concepts.

Waste materials that can be used as the main raw materials of artificial abrasives in the present invention are waste glass, waste tiles, waste ceramics, waste clay, waste natural abrasive sludge generated after the use of existing natural abrasives and the like.

Among the many wastes, the above-listed wastes were selected as a raw material of the artificial abrasive according to the present invention.

Glassy wastes can be categorized into flat glass, hollow glass, fiber glass, and optical glass, depending on their shape and use, and their recycling conditions are relatively low compared to metal or plastic waste. Although these glass materials have a high possibility of recycling due to the physical and chemical properties of the glass itself, practically no recycling such as conversion of other uses is made except for being recovered and reused. However, among these waste glass, waste glass is recycled into glass fiber, waste glass is divided into three colors and crushed to a certain size and can be used in the glass bottle factory, but waste produced in other special glass or glass product manufacturing plants. In order to recycle glass, it is necessary to classify it by properties or to remove impurities by a special treatment process. However, since the work is cumbersome and difficult, it is rarely recycled. Such waste glass that is not recycled is required to be treated separately by landfilling, and thus additional resources are required as well as loss of resources. Therefore, if you can find an efficient and high value-added recycling method for the non-recyclable waste glass without being restricted by color, size, type, composition, etc. It would also be very desirable in terms of environmental preservation. The waste glass to be used in the present invention is aimed at the glass that can be any conventional waste glass but in particular is not possible to recycle or recycle at all.

On the other hand, in the case of waste ceramics and waste tiles are generated as a defect in the primary firing (about 700 ℃ to 1000 ℃) process for the manufacture of ceramics and tiles. These waste ceramics and waste tiles are not only reusable after crushing, but also used to make some sidewalk blocks because they have no special use, and most of them are disposed of without permission to contaminate the environment.

Waste clays that can be considered together with these waste ceramics and waste tiles. Refined clay, or possession, is needed to make pottery and tiles. In the process of making ceramics using this material, a considerable amount of contaminated material, that is, waste clay, is generated, and a separate regeneration work is required to reuse the waste clay. In addition, in order to make the possession of ordinary kaolin collected and refined, this process of refining the large amount of low-grade clay with a high iron content, but does not have a special use requires a way to increase the added value. These waste clays and low grade clays can be excellent raw materials for the production of artificial abrasives. At present, Korea is almost entirely dependent on imports for the manufacture of ceramics and tiles, so recycling and recycling waste clay has a greater meaning.

Finally, worn sludge in the sludge state after the use of natural abrasives for bleaching jeans is an industrial waste requiring separate treatment. This sludge waste natural abrasive material is not recycled or used at all, and the treatment requires extra cost because it must be treated by a special method such as landfill or ocean dumping. On the other hand, the amount of waste generated in the sludge state is increased due to the addition of worn waste fabric to the injected abrasive, so that the impact on the production cost of the natural abrasive is minimal. Therefore, if the sludge waste natural abrasives generated from natural abrasives are reused as artificial abrasives, it is possible to maintain various functions of existing natural abrasives and to treat wastes effectively. You will be able to get The study of reusing such natural abrasive as a raw material of artificial abrasive is important in many aspects. Because, even if effective artificial abrasives are proposed and produced in the near future, waste natural abrasive sludge will still occur before complete replacement is made, and the sludge state produced by the artificial abrasives even if they are all converted to effective artificial abrasives in the future. Waste will only be relatively reduced, and similar types of waste will be unavoidable.

That is, as described above, the artificial abrasive for stone washing using waste according to the present invention uses the waste as its raw material in terms of recycling and environmental pollution prevention of the waste, and specific components thereof are as follows.

Stone-washing artificial abrasive using the waste according to the present invention, 60 to 95 parts by weight of waste glass powder and waste ceramics, waste tiles, waste clay, waste natural abrasive sludge based on the total weight of the raw material mixture except for the additives described below 0.3 to 33 parts by weight of an additive in which carbonate, sulfate, boron oxide and sodium silicate are mixed with respect to 100 parts by weight of a mixture in which one or a mixture of at least two or more thereof are powdered and mixed 5 to 40 parts by weight It can be mixed.

The waste glass powder may have a specific surface area of 5,000 to 55,000 cm ² / g.

The waste glass, waste ceramics, waste tiles, waste clay and waste natural abrasive sludge may have a particle size of about 150 mesh or less.

The additive may be mixed with 0.2 to 12.0 parts by weight of carbonate as a blowing agent, 0.1 to 6.0 parts by weight of sulfate, 0.0 to 5.0 parts by weight of boron oxide as a thermal stabilizer, and 0.0 to 10.0 parts by weight of sodium silicate as a misc stabilizer.

The density of the artificial abrasive according to the present invention is preferably about 0.6 to 1.0 g / cm ³ , the reason is as follows.

The abrasives, including their surfaces, should have a porosity throughout so that the abrasives can continue to be abrasive even as the abrasive wears off. In addition, the provision of porosity is also a requirement for controlling the density of the abrasive. The porosity is largely divided into fully open porosity and completely free bubble porosity, and in order to have appropriate density condition, the porosity of the abrasive should not be either of fully open porosity or completely free bubble porosity. Branch porosity should be properly controlled. This is because the artificial abrasive has a high buoyancy of less than 0.6 g / cm ^{3 in the} case of high porosity of the independent bubble type, and is present in the upper layer of the washing machine during washing. This is because the efficiency of contact with the laundry decreases because the fluidity is lowered in both cases because the / cm ³ or more does not reach the bottom of the washing machine. For this reason the density of the abrasive according to the invention is determined.

On the other hand, in the present invention, for example, foaming is used as one of methods for imparting porosity in order to match the density of the abrasive.

Raw materials of the stone washing artificial abrasive using the waste according to the present invention has the following characteristics as the abrasive for stone washing.

The first reason for using waste glass as a basic raw material of artificial abrasive is to achieve foaming for the formation of pores inside the bulk artificial abrasive as described above, and the second reason is to provide high mechanical strength and high wear resistance. This is to increase the cohesion between the particles of the solid raw material constituting the. Raw materials composed of abrasives should be strongly sintered or combined in the manufacture of abrasives. Waste ceramics, waste tiles, waste clay and waste natural abrasives, which are intended to be used in the present invention, are composed mainly of oxides of aluminum and silicon. All of these components have high melting point, so that at least 1250 ℃ of heat is required for bonding by the sintering process, and it is difficult to obtain strong bonding between particles even at this temperature condition, and it is difficult to obtain natural high mechanical strength or wear resistance. Particularly, since waste ceramics and waste tiles have lost much of the layer structure, which is a structure that can have a bonding force through the firing process for the manufacture of artificial abrasives, during the firing process for the manufacture of ceramics and tiles, the particles are bonded or aggregated by themselves. This will be difficult. That is, in the present invention, a separate binder is required in order to make a molded body using waste ceramics, waste tiles and other waste natural abrasive sludge as a raw material. In this case, the binder is required to combine different material species during the firing process, it is preferable to have a chemically similar component, and also to have a low melting point. In this aspect, the glass can be used as a good binder. In the present invention, waste glass is used as the base material and the binder of the artificial abrasive, and a small amount of additive is added to increase the binding efficiency.

The reason for selecting waste ceramics, waste tiles, waste clay and waste natural abrasive sludge as raw materials for the production of artificial abrasives is that these wastes can impart another functionality of artificial abrasives. In other words, there may be a number of ways to prevent re-contamination of the wear-decolored cotton fabric by the dye is decolorized, but considering the case of natural abrasive, the dye is desorbed or absorbed in the worn abrasive during the washing process Should be Such functionality can be exhibited by the porous structure of the abrasive or the layered structural properties of the abrasive itself, and these materials have a layered structure that can exert such a function.

For these reasons, the above-mentioned waste glass, waste ceramics, waste tiles, waste clay, and waste natural friction material sludge are used as raw materials for the stone washing abrasive using waste according to the present invention.

Hereinafter, with reference to Figure 1 will be described a method for producing an artificial abrasive for stone washing using waste according to the present invention.

(a) Prepare raw materials such as waste glass, waste ceramics, waste tiles, waste clay, and waste natural abrasive sludge and additives such as carbonate, sulfate, boron oxide and sodium silicate, respectively.

(b) The raw materials and the additives are ground to a certain particle size, for example, 150 mesh or less. Grinding can be carried out through a conventional mill.

(c) 60 to 95 parts by weight of the waste glass powder, waste ceramics, waste tiles, waste clay and waste natural abrasive sludge, or a mixture of at least two of them, in a weight ratio to the total weight of the raw material mixture, among them Any one of 5 to 40 parts by weight is mixed to form a raw material mixture, and 0.3 to 33 parts by weight of an additive is mixed with 100 parts by weight of the raw material mixture. The waste glass powder may have a specific surface area of 5,000 to 55,000 cm ² / g.

Here, 0.2-12.0 weight part of carbonates, 0.1-6.0 weight part of sulfates, 0.0-5.0 weight part of boron oxides as a thermal stabilizer, and 0.0-10.0 weight part of sodium silicate as a mixing stabilizer are added as a foaming agent which is an additive.

(d) To the raw material mixed powder mixed in step (c) is kneaded by appropriately adding a certain amount of CMC, PVA, or water glass as a binder for molding.

(e) The kneaded raw material mixture is molded into a certain shape. For example, the raw material mixture may be placed in an extruder and extruded to a diameter of about 1.5 to 5.0 cm, and then cut into a length of about 1.5 to 5.0 cm to be press-molded into a cylindrical shape. Here, the shape and size of the molded article is not limited to this, and can be freely changed according to the type of clothes.

(f) The molded body is fired to 400 to 750 ° C, foamed at a temperature of 800 to 1050 ° C for about 5 to 15 minutes, the foamed molded body is stabilized at a temperature of 500 to 700 ° C, and then cooled to 20 to 40 ° C. The molded article molded in the step (e) may be preheated / baked, foamed, stabilized, and cooled while passing through a tunnel-type furnace in which temperatures of the preheated / baked portion, the foamed portion, and the stabilized portion can be individually controlled.

(g) Put the cooled molded product into a ball mill and polish the surface to the extent that porous pores appear on the smooth surface of the molded molded product to complete the artificial abrasive material for stone washing.

The present invention may further comprise the step (h) of finely pulverizing the mixture obtained through the step (c) according to the manufacturing conditions of the artificial abrasive suitable for the type of cotton mesh to 150 mesh or stonewashed to the corresponding particles (h) Can be. That is, the fine grinding step (h) is a selective process for producing an artificial abrasive according to the present invention, and is freely selected according to the type of cotton fabric to control the particles of the raw material.

Hereinafter, a method for preparing artificial abrasive for stone washing using waste according to the present invention will be described in detail.

Waste glass powder used in the present invention, such as waste glass that is not tricolor separation at all is very low value or non-renewable waste glass that requires a separate waste treatment process, such as landfill is thermal crushing or mechanical It is pulverized by a pulverizing apparatus, and means only the waste glass powder having a specific surface area of 5,000 to 55,000 cm ² / g. When the specific surface area of the pulverized waste glass powder is less than 5,000 cm ² / g, more than 12.0 parts by weight is required for the total amount of carbon salts and sulfates of the blowing agent in the additive, and the preheating temperature of the foaming process is not only increased to 750 ° C. or more. , It is difficult to control the density of the artificial abrasive prepared. When the specific surface area is 55,000 cm ² / g, the addition amount of the carbonate and sulfate salts of the foaming aid may be 0.3 parts by weight based on the total amount of raw materials, and the temperature conditions of the foaming process may be controlled in the range of 800 to 1050 ° C. In addition, the density of the abrasive is also adjustable and the porosity is increased. However, when the specific surface area exceeds 55,000 cm ² / g no further effect is obtained, but rather the energy cost of the micronization of the powder becomes high.

The content of the waste glass powder in the raw material mixture is preferably 60 to 95 parts by weight. When the content of the waste glass is less than 60 parts by weight or more than 95 parts by weight, it is impossible to make the porosity of the artificial abrasive and the proper density control by the addition of the additive.

The additive used in step (c) of the present invention is 0.2 to 12.0 parts by weight of carbonate, 0.1 to 6.0 parts by weight of sulfate, 0.0 to 5.0 parts by weight of boron oxide, and 0.0 to 10.0 parts by weight of sodium silicate in a weight ratio based on the total weight of the raw material mixture. It is. Hereinafter, the functions and features of the additives will be described.

Carbonate and sulfate as the blowing agent used in the present invention is a material used to enhance the foaming effect.

The porosity inside the artificial abrasive can be achieved by foaming in the glassy inside the abrasive. When the foaming proceeds, first, the surface of the finely ground glass particles is melted or softened, and bubbles are generated by the reaction of the blowing agent existing between the glass particles, and foaming of the glassy part is produced by these gases. Angry is done. Therefore, the foaming temperature should be raised to the melting point or softening point of the glass in order to lower the viscosity of the glassy part in the foaming process for effective foaming of the glassy part. In this case, if the blowing agent added before the foaming temperature is increased, the foaming effect is deteriorated if it is first decomposed or extinguished due to the reaction. Added to supplement this point is the carbonate and sulfate type compounds. Examples of such carbonates may include Na ₂ CO _3, NaHCO ₃ , CaCO ₃ , K ₂ CO ₃ , BaCO ₃ , and examples of sulfates include Na ₂ SO _4, NaHSO ₄ , CaSO _4, BaSO _4, K ₂ SO ₄ Can be used.

As mentioned above, carbonates and sulfates are used as blowing agents. The foaming agent in the form of a carbonate form is a foaming agent which simply decomposes at the foaming temperature conditions to generate gas to favorably open pores, and is preferably included in an amount of 0.2 to 12.0 parts by weight based on the entire raw material mixture. If the content of the carbonate is less than 0.2 parts by weight, the low content of gas generated from these blowing agents is low foaming is difficult to form the open pores, the entire pore formation will be formed as independent pores. On the other hand, when the content of the carbonate is 12.0 parts by weight or more, due to the generation of excess gas, the pore formation is not uniform, and most of the generated pores are generated as open pores, making it difficult to control the density of the artificial abrasive.

The foaming agent in the form of sulphate produces a gas like the foaming agent in the form of carbonate, but it causes oxidation-reduction reaction in the glass part and induces gradual foaming in the glass part. It is preferable to add 0.1-6.0 weight part with respect to the. Under these conditions, the foamed glass portion inside the artificial abrasive will mainly form small independent waste holes between 30 and 300 μm. If the content is less than 0.1 part by weight, the efficiency of the oxidation-reduction reaction, which is a reaction of bubbles forming the porous structure in the glassy portion inside the abrasive, is reduced, resulting in foamed glass having a high density. On the other hand, if the total content exceeds 6.0 parts by weight, excessive foaming proceeds in the glassy portion inside the abrasive, thereby lowering the uniformity of porosity, which is the source of the frictional force of the abrasive, and lowering the mechanical strength of the abrasive to produce a good abrasive. it's difficult.

Sodium silicate included in the additive of the present invention is a composition adjusting material for vitrification of the glassy portion inside the abrasive. As mentioned above, in order to foam the glassy portion of the artificial abrasive, the temperature in the foaming process must be maintained up to the melting or softening point of the glass. In other words, the molten structure must be formed in the glass particles. In the present invention, by using sodium silicate, the molten state structure of the glass can be formed without reaching the melting point or softening point of the glass. Sodium silicate which can be used in the present invention is usually used as water glass. The content of sodium silicate used in the present invention is preferably 0.0 to 10.0 parts by weight based on 100 parts by weight of the raw material mixture. The content of sodium silicate varies greatly depending on the type of waste glass used. For example, when the waste glass is formed mostly of soda glass, the addition of sodium silicate is not required, but most of the waste glass has various kinds of glass. In the foaming of the artificial abrasive glassy part, a considerable amount of sodium silicate has to be added because it is difficult to stabilize the glassy part due to the relatively large difference in viscosity of the heated part. However, in the case of adding an excess of sodium silicate in excess of 10.0 parts by weight to 100 parts by weight of the raw material mixture, the volume of the powder glass itself increases due to agglomeration of glass particles, which also lowers the foaming efficiency. It is preferable not to.

The boron oxide included in the additive of the present invention reduces the thermo-mechanical strain of the molded article foamed in the foaming process, and simplifies the thermal stress during stabilization and cooling, thereby making the machine of artificial abrasive, the final product. It greatly increases human toughness. The content of boron oxide used in the present invention is preferably 0.0 to 5.0 parts by weight based on 100 parts by weight of the raw material mixture. The amount of boron oxide added differs depending on the type of waste glass used, as in the case of sodium silicate. When the waste glass is borosilicate glass having a high content of boron oxide, no addition of boron oxide is required. However, in the case of ordinary soda lime glass, boron oxide should be added. If the content of boron oxide is insufficient, it is difficult to obtain thermal stabilization of the molded body during the cooling of the foamed molded body after the foaming process. Stabilization can be maintained. However, further additions are undesirable in terms of economics.

In the step (h) of the present invention, the waste glass powder and the additive obtained in the step (c) are added to the fine mixture or finely pulverized to a particle size of 150 mesh or less or finer. The sorting of the particles may be a sorter commonly used in the art, for example, a conventional stand. If the particle size is larger than approximately 150 mesh, the pore dispersion of the foamed portion inside the final product artificial abrasive may be uneven and rough. The particle size of the entire raw material mixture before foaming depends on the type of laundry being stonewashed. In other words, in the case of winter clothing, the surface of the artificial abrasive is rough because the thickness of the clothing is thick, but in the case of the summer clothing, the surface of the artificial abrasive should be small and dense because the thickness of the artificial abrasive is thin. Therefore, the particle size of the mixture is approximately 150 mesh. It should be selected and adjusted to a particle size of less or less.

In step (d) of the present invention, a predetermined amount of CMC, PVA, or water glass as a binder is used to form the mixture mixed by the process (c) or the raw material mixture of which the particle size is adjusted in the process (h) into an artificial abrasive shaped body. As a step of kneading by appropriately adding, using a conventional stirrer or kneader can be kneaded by adding the appropriate moisture so that molding is well formed in the molding machine.

In step (e) of the present invention, the raw material mixture kneaded in step (d) is molded into a predetermined shape and size. For example, the dough is extruded to a diameter of 1.5 to 5 cm through a compressor, and the extrudate is approximately 1.5 to 5 cm. It can be cut into lengths of to form a cylindrical shape. The shape and size of the abrasive is not limited to the shape and size described above, and may be variously modified according to the type of clothing.

In the step (f) of the present invention, the molded body is preheated to a temperature of 400 to 750 ° C, calcined, and foamed at a temperature of 800 to 1050 ° C for 5 to 15 minutes, and the foamed molded body is stabilized at 500 to 700 ° C, and then 20 As a step of cooling to ~ 40 ℃, this process can be made using a conventional tunnel-type furnace capable of temperature control section. For example, the molded body is placed in a plate-shaped container coated with steel, non-steel, or ceramic so as to be spaced apart so that the molded bodies do not stick to each other after foaming, and then, this is put into a furnace. By preheating and firing at 400 to 750 ° C. before foaming, it is possible to suppress the formation of thick glassy shells on the surface of the molded body and the formation of large cavities that inhibit uniform pore formation inside the molded body. When the preheating temperature is less than 400 ° C., swelling to the outside of the molded body is suppressed, and as a result, the foaming state is badly bad or foaming does not occur. When the preheating temperature exceeds 750 ° C., the thermal shock not only destroys the densely formed structure inside the molded body, but also causes large cracks or fragments in the molded body. Thus, after preheating, it is foamed at 800 ~ 1050 ℃. At this time, if the foaming temperature is less than 800 ℃ foaming reaction is insufficient to increase the density of the final molded body after foaming is difficult to adjust to the appropriate density of 0.6 ~ 1.0g / cm ³ of the artificial abrasive, foaming temperature exceeds 1,050 ℃ In this case, the loss of dense pore walls creates pores and enlarges the pores, limiting the porous structure of the artificial abrasive due to the loss of uniformity. As a result, it is difficult to produce high quality artificial abrasives that are economical and practical.

The foamed molded article is stabilized at 500 to 700 ° C and then cooled to 20 to 40 ° C. Since the molded article formed with the foam structure is in a softened or partially molten state as a whole under the conditions of the foaming temperature, the foamed structure should be stabilized, which is achieved by quenching the foamed molded article to 500 to 700 ° C. In case of quenching below 500 ℃, the thermal shock creates thermal strain which causes cracking or breaking of foam glass, and in case of quenching at temperature above 700 ℃, Inhibition of the reduction reaction is limited and may be over-foamed.

In the step (g) of the present invention, the cooled compact is placed in a ball mill to gently polish the surface such that porous pores appear on the smooth surface of the foamed molded article to obtain a finished stone washing artificial abrasive, which is a powder of the surface. Simply removal can produce the final artificial abrasive.

Hereinafter, a method for manufacturing an artificial abrasive for stone washing using waste according to the present invention will be described in more detail with reference to Examples. However, these examples are for illustrative purposes only and the scope of the present invention is not limited to these examples.

<Example 1>

To the mixture of 80 kg of waste glass powder having a particle size of about 150 mesh or less and 20 kg of waste clay powder having a particle size of about 150 mesh or less, 2 kg of carbonate, 1 kg of sulphate, and 1 kg of boron oxide were added and mixed well. A suitable amount of CMC mixed solution is added with sodium silicate, water and a molding binder, mixed for 10 minutes in a mixer, and kneaded. Then, the dough is placed in an extruder, extruded to a size of 3 cm in diameter, cut into 3 cm in length and shaped into a cylindrical shape. The molded body was dried and then passed through a tunnel furnace adjusted to a preheating part at 650 ° C, a foaming part at 950 ° C, and a stabilization part at 500 ° C. The time passing through the foam part was kept at 15 minutes. The foamed molded product passed through the stabilizing part was cooled to room temperature, and then a fired body was obtained. These sintered bodies are placed in a ball mill, and finally, an artificial abrasive is obtained by polishing and removing the smooth surface of the glass until porosity appears in the surface portion. Density and compressive strength of the artificial abrasives produced in this way were measured according to the conventional materials analysis method, and the wear rate was measured by putting a 1kg abrasive into a ball mill and turning the ball mill for 2 hours. It was determined as follows. The results are shown in Table 1.

<Example 2>

To the mixture of 80 kg of waste glass powder having a particle size of about 150 mesh or less and 20 kg of waste ceramic powder having a particle size of about 150 mesh or less, 2 kg of carbonate, 1 kg of sulfate, and 1 kg of boron oxide were added and mixed well. Here, the appropriate amount of CMC mixture is added with sodium silicate, water, and a molding binder, mixed and kneaded in a mixer for 10 minutes, and then put into an extruder and extruded to a size of about 3 cm in diameter, and cut into a length of about 3 cm to form a cylindrical shape. do. The molded body was dried and then passed through a tunnel furnace adjusted to a preheating part at 650 ° C., a foaming part at 1000 ° C., and a stabilization part at 500 ° C. FIG. The time passing through the foam part was kept at 15 minutes. The foamed molded product passed through the stabilizer was cooled to room temperature, and then a fired body was obtained. These sintered bodies are placed in a ball mill, and finally, an artificial abrasive is obtained by polishing and removing the smooth surface of the glass until porosity appears in the surface portion. Density and compressive strength among the characteristics of the artificial abrasives produced in this way were measured according to the conventional materials engineering method, and the wear rate was 1 kg of the abrasives alone into the ball mill and the ball mill was rotated for 2 hours. It was determined as follows. The results are shown in Table 1.

<Example 3>

80 kg of waste glass powder having a particle size of about 150 mesh or less and 20 kg of waste tile powder having a particle size of about 150 mesh or less are added to each mixture by adding 2 kg of carbonate, 1 kg of sodium sulfate, and 1 kg of boron oxide, respectively. Then, add an appropriate amount of CMC mixed solution with sodium silicate, water, and a molding binder, mix and knead in a mixer for 10 minutes, put it in an extruder, and extrude it to a size of approximately 3 cm in diameter, cut it into 3 cm lengths, and cut it into a cylindrical shape. Mold. The molded body was dried and then passed through a tunnel furnace adjusted to a preheating part at 650 ° C., a foaming part at 1000 ° C., and a stabilization part at 500 ° C. FIG. The time passing through the foam part was kept at 15 minutes. The foamed molded product passed through the stabilizing part was cooled to room temperature, and then a fired body was obtained. These firing bodies are placed in a ball mill and finally removed by polishing the glassy smooth surface until porosity appears on the surface. Density and compressive strength among the characteristics of the artificial abrasive prepared in this way were measured according to the conventional material engineering method, and the wear rate was measured by putting 1 kg of abrasive into the ball mill, turning the ball mill for 2 hours, and then quantifying the amount of wear. Decided. The results are shown in Table 1.

<Example 4>

To the mixture of 80 kg of waste glass powder having a particle size of about 150 mesh or less and 20 kg of waste natural abrasive sludge having a particle size of about 150 mesh or less, add 3 kg of carbonate, 1 kg of sulfate, and 1 kg of boron oxide, and mix well. An appropriate amount of CMC mixed solution is added thereto with sodium silicate, water, and a molding binder, mixed and kneaded in a mixer for 10 minutes, and then put into an extruder, extruded to a size of 3 cm in diameter, and cut into 3 cm in length to form a cylindrical shape. The molded body was dried and then passed through a tunnel furnace adjusted to a preheating part at 650 ° C, a foaming part at 950 ° C, and a stabilization part at 500 ° C. The time passing through the foam part was kept at 15 minutes. The foamed molded product passed through the stabilizing part was cooled to room temperature, and then a fired body was obtained. These firing bodies are placed in a ball mill and finally removed by polishing the glassy smooth surface until porosity appears on the surface. Density and compressive strength of the artificial abrasives produced in this way were measured according to the conventional materials analysis method, and the wear rate was measured by putting 1kg of abrasive into the ball mill, turning the ball mill for 2 hours, and then quantifying the amount of wear. It was. The results are shown in Table 1.

<Example 5>

In a mixture of 76 kg of waste glass powder having a particle size of about 150 mesh or less, 12 kg of waste clay powder having a particle size of about 150 mesh or less and 12 kg of waste ceramic powder, 3 kg of carbonate, 1 kg of sulfate, and 1 kg of boron oxide were mixed. Add each of them and mix well, add appropriate amount of CMC mixed solution with sodium silicate, water and molding binder, mix for 10 minutes in a mixer, knead it, put it into an extruder and extrude to a size of 3cm in diameter, and make it 3cm in length. Cut out and shape into a cylindrical shape. The molded body was dried and then passed through a tunnel furnace adjusted to a preheating part at 650 ° C, a foaming part at 1050 ° C, and a stabilization part at 500 ° C. The time passing through the foam part was kept at 15 minutes. The foamed molded product passed through the stabilizing part was cooled to room temperature, and then a fired body was obtained. These sintered bodies are placed in a ball mill, and finally, an artificial abrasive is obtained by polishing and removing the smooth surface of the glass until porosity appears in the surface portion. Density and compressive strength of the artificial abrasives produced in this way were measured according to the usual material engineering method, and the wear rate was put into the ball mill with 1 kg of abrasive, the ball mill was rotated for 2 hours, and then the amount of wear was measured. It was decided as follows. The results are shown in Table 1.

<Example 6>

3 kg of carbonate, 2 kg of sodium sulfate, boron oxide 1 in a mixture of 72 kg of waste glass powder having a particle size of about 150 mesh or less, 14 kg of waste clay powder having a particle size of about 150 mesh or less and 14 kg of waste natural abrasive sludge together. Add each kg and mix well, add the appropriate amount of CMC mixture with sodium silicate, water and molding binder, mix it for 10 minutes in a mixer, knead it, put it into an extruder, and extrude it into a size of 3 cm in diameter, Cut to 3cm in length to form a cylindrical shape. The molded body was dried and then passed through a tunnel furnace adjusted to a preheating part at 650 ° C, a foaming part at 950 ° C, and a stabilization part at 500 ° C. The time passing through the foam part was kept at 15 minutes. The foamed molded product passed through the stabilizing part was cooled to room temperature, and then a fired body was obtained. These sintered bodies are placed in a ball mill, and finally, an artificial abrasive is obtained by polishing and removing the smooth surface of the glass until porosity appears in the surface portion. Density and compressive strength of the characteristics of artificial abrasives prepared in this way were measured according to the conventional materials engineering method, and wear rate was measured by putting 1kg abrasive into the ball mill, turning the ball mill for 2 hours, and then quantifying the amount of wear. Decided. The results are shown in Table 1.

<Example 7>

2 kg of carbonate, 2 kg of sulphate, and 1 kg of boron oxide were added to a mixture of 72 kg of waste glass powder having a particle size of 150 mesh or less, 14 kg of waste clay powder having a particle size of approximately 150 mesh or less, and 14 kg of waste tile powder. Add and mix well, add the appropriate amount of CMC mixture with sodium silicate, water and molding binder, mix it for 10 minutes in a mixer, knead it, put it into an extruder, and extrude to a size of 3 cm in diameter, and length Cut to 3cm to form a cylindrical shape. The molded body was dried and then passed through a tunnel furnace adjusted to a preheating part at 650 ° C, a foaming part at 950 ° C, and a stabilization part at 500 ° C. The time passing through the foam part was kept at 15 minutes. The foamed molded product passed through the stabilizing part was cooled to room temperature, and then a fired body was obtained. These sintered bodies are placed in a ball mill, and finally, an artificial abrasive is obtained by polishing and removing the smooth surface of the glass until porosity appears in the surface portion. Density and compressive strength among the characteristics of the artificial abrasive prepared in this way were measured according to a conventional material engineering method, and the wear rate was measured by putting 1 kg of abrasive into the ball mill, turning the ball mill for 2 hours, and then quantifying the amount of wear. It was decided together. The results are shown in Table 1.

<Example 8>

72 kg of waste glass powder with a particle size of less than about 150 mesh, 7 kg of waste clay, 7 kg of waste ceramics, 7 kg of waste tile, and 7 kg of waste natural abrasive sludge were mixed to adjust the particle size to about 150 mesh or less. 2 kg of carbonate, 1 kg of sulphate, and 1 kg of boron oxide were added to the mixture, and the mixture was mixed together. Then, an appropriate amount of CMC mixture was added to the mixture with sodium silicate, water, and a molding binder. After mixing for a minute, kneading, it is put into an extruder and extruded to a size of 3cm in diameter, cut into 3cm in length to form a cylindrical shape. After drying the molded body, it was passed through a tunnel furnace adjusted to a preheating part at 650 ° C, a foaming part at 1000 ° C, and a stabilization part at 500 ° C. The time passing through the foam part was kept at 15 minutes. The foamed molded product passed through the stabilizing part was cooled to room temperature, and then a fired body was obtained. These firing bodies are placed in a ball mill and finally removed by polishing the glassy smooth surface until porosity appears on the surface. Density and compressive strength of the characteristics of artificial abrasives prepared in this way were measured according to the conventional materials engineering method, and wear rate was measured by putting 1kg abrasive into the ball mill, turning the ball mill for 2 hours, and then quantifying the amount of wear. Decided. The results are shown in Table 1.

Table 1

                                      Wear rate (%) = (abrasion amount / raw material input amount) x 100

Example Density (g / cm3) Compressive strength (kg / cm ² ) Wear rate (dry)% One 0.73-0.95 40 to 45 5.3 2 0.67-0.97 38-43 5.5 3 0.71-0.97 37-44 5.6 4 0.72-0.96 35 to 42  6.1 5 0.66-1.12 39-45  5.6 6 0.71-0.96 38-42  5.7 7 0.67-0.98 39-48  5.9 8 0.68 to 1.02 38-45  6.1 Natural Abrasives 0.57-1.10 25-30  18.2

Table 1 compares the compressive strength and wear rate of the artificial abrasive prepared by the embodiments according to the present invention and the conventional natural abrasive, as shown in Table 1, the abrasive prepared by the embodiments according to the present invention Its compressive strength is higher than that of the existing natural abrasives, and it can be seen that the wear rate is significantly lower than that of the natural abrasives.

As described above, according to the stone-washing artificial abrasive using the waste according to the present invention and a method for manufacturing the same, it is difficult to recycle as a main raw material for the manufacture of artificial abrasives or it is difficult to recycle due to its low added value such as waste glass, The cost of manufacturing can be reduced by using waste ceramics, waste tiles, waste clay, and waste natural abrasive sludge. In particular, manufacturing costs can be significantly reduced because no separate processing process is required to use these wastes as raw materials. .

In addition, by recycling these wastes, a cost reduction effect for disposal of the wastes is derived, and environmental pollution by wastes can be prevented.

In addition, since the sludge is less generated during the stone washing process due to the compressive strength and the wear rate of the abrasive, the life of the abrasive can be extended and the cost can be reduced, and the environmental pollution caused by the sludge can be prevented.

While the invention has been described and illustrated in connection with a preferred embodiment for illustrating the principles of the invention, the invention is not limited to the configuration and operation as such is shown and described. Rather, it will be apparent to those skilled in the art that many changes and modifications to the present invention are possible without departing from the spirit and scope of the appended claims. Accordingly, all such suitable changes and modifications and equivalents should be considered to be within the scope of the present invention.

Claims (5)

delete 60 to 95 parts by weight of waste glass powder; 5 to 40 parts by weight of any one or a mixture of waste ceramics, waste tiles, waste clay, or waste natural abrasive sludge; For 100 parts by weight of the raw material mixture consisting of, 0.3 to 33 parts by weight of an additive containing a foaming agent and a misc stabilizer is mixed, Said additive is 0.2-12.0 parts by weight of carbonate, 0.1-6.0 parts by weight of sulfate, 0.0-5.0 parts by weight of boron oxide and 0.0-10.0 parts by weight of sodium silicate. (a) preparing raw materials such as waste glass, waste ceramics, waste tiles, waste clay, and waste natural abrasive sludge and additives such as carbonate, sulfate, boron oxide and sodium silicate, respectively; (b) pulverizing the raw material and the additive of step (a); (c) about 60 to 95 parts by weight of the waste glass powder, based on the total weight of the mixture and one or more of waste ceramics, waste tiles, waste clay or waste natural abrasive sludge, or a mixture thereof, based on the total weight of the mixture; Mixing 0.3 to 33 parts by weight of an additive in which carbonate, sulfate, boron oxide and sodium silicate are mixed with respect to 100 parts by weight of the mixture of about 5 to 40 parts by weight of the mixture; (d) kneading by appropriately adding a predetermined amount of CMC, PVA, or water glass as a binder for molding to the raw material mixture mixed in step (c); (e) molding the raw material mixture kneaded in step (d); (f) firing the molded article according to the step (e) to 400 to 750 ° C, foaming at a temperature of approximately 800 to 1050 ° C for 5 to 15 minutes, and stabilizing the foamed molded body at 500 to 700 ° C, and then 20 to Cooling to 40 ° C .; And (g) grinding the surface of the molded article cooled in step (f) into a ball mill and polishing the surface to form porous pores on the smooth surface of the foamed molded article, thereby completing an artificial abrasive. Artificial abrasives manufacturing method using. 4. The additive according to claim 3, wherein in step (c), an additive consisting of 0.2 to 12.0 parts by weight of carbonate, 0.1 to 6.0 parts by weight of sulfate, 0.0 to 5.0 parts by weight of boron oxide, and 0.0 to 10.0 parts by weight of sodium silicate is mixed. Method for manufacturing artificial abrasive using waste. According to claim 3, (h) further comprising the step of adjusting and selecting the particle size by finely pulverizing the particles of the entire raw material mixture obtained in the step (c) according to the laundry to be stonewashed Artificial abrasive production method using waste.

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