KR100791051B1 - Method for manufacturing interior materials or exterior materials using clay, ash and dust - Google Patents

Abstract

A manufacturing method for interior material and exterior material from clay, ash and dust is provided to obtain interior material that is calcined at low temperature and effectively deodorizes formaldehyde and exterior material having improved compressive strength. The manufacturing method for interior material from clay and ash comprises steps of: (a) mixing 50-90 parts by weight of clay and 10-50 parts by weight of ash; (b) forming the mixture into a shape; (c) drying the shape at 60-100 deg.C; and (d) calcining the dried shape at 1100-1200deg.C for 20-25 hours. For manufacturing exterior material, the dried shape is calcined at 1100-1200deg.C for 30-35 hours. The manufacturing method for interior material from clay and dust comprises steps of: (a) mixing 50-90 parts by weight of clay and 10-50 parts by weight of dust comprising at least 98% of alumina; (b) forming the mixture into a shape; (c) drying the shape at 60-100 deg.C; and (d) calcining the dried shape at 1100-1200deg.C for 20-25 hours.

Description

Method for manufacturing interior or exterior materials using clay, coal and dust {Method for Manufacturing Interior Materials or Exterior Materials Using Clay, Ash and Dust}

Field of invention

The present invention relates to a method for producing an interior or exterior material using clay, coal ash and dust, and more specifically, clay, coal ash and dust are mixed and pulverized. Next, extrusion molding or press molding the mixed raw material to produce a molded body, and then drying the molded body at 60 ~ 100 ℃, and firing the dried molded body at 1100 ~ 1200 ℃ for 20 to 35 hours It relates to a method for producing interior or exterior materials using clay, coal ash and dust.

Background of the Invention

Coal ash is finely pulverized (200-mesh sieve through 70-80%) in a coal-fired power plant and injected into the furnace at high speed with hot air, and is burned instantly in a suspended state at a temperature range of 1500 ± 200 ℃, which is above the melting point of most minerals The remaining material after burning is called ash and can be classified into fly ash and bottom ash according to the location of dust collection. The average particle diameter of fly ash is 0.3 ~ 1.0mm and bottom Ash has an average particle diameter of 1.0 to 2.5mm which is slightly larger than fly ash. The coal ash contains a lot of unburned coal and ash component, is present in a state of little moisture to absorb the moisture, and reduce the fuel cost when firing. In addition, by hydrating with water causes a pozzolanic reaction to increase the dry strength, and to increase the sintering strength during firing has a great influence on the compressive strength of the brick, absorption and weight reduction of the brick.

Coal recovery from domestic thermal power plants was estimated at 4.5 million tons in 2000, and is expected to reach about 6 million tons by 2010, of which the low level is estimated to be about 10-15%. In addition, most of the low ash generated is buried in the sea, and artificial marble dust is generated more than about 50,000 tons per year, but recycling is rarely done and landfilling is a problem. It is urgent to develop technology and research on this. In addition, building materials that emit formaldehyde and volatile organic compounds, which are the main culprit of sick house syndrome, will not be used not only in multi-use facilities but also in apartments, schools, and offices.

Clay is a collection of hydrous aluminosilicate minerals that, when added with moisture, exhibits plasticity and hardens upon drying, indicating stiffness. The unit volume mass of low ash and dust is 968kg / ㎥ and 465kg / ㎥, respectively, and it is much lighter than 1,900kg / ㎥, the unit volume mass of the raw material of clay products used as exterior materials and floor materials of buildings. By burning a number of cavities inside and outside of the brick to reduce the weight of the brick itself, it is possible to manufacture a brick having excellent heat insulation and deodorizing performance by the cavity generated inside and outside.

In addition, the indoor air is contaminated by formaldehyde or human toxic chemicals (VOC) from new homes or remodeled homes, causing temporary or chronic headaches, eye, nose, throat problems, vomiting, and dizziness. The use of interior deodorant with excellent deodorizing function, which can prevent the "Sick House Syndrome", which causes abnormalities in the health of residents such as itching and itching, can improve indoor air quality and create a comfortable space without harmful substances.

Generally we use adsorbents (deodorants) to get rid of the smell in the refrigerator. The purpose of using the adsorbent is to purify the material by removing impurities, decolorize to remove color from the product by adsorbing the pigment, remove moisture, remove odor, separate the material, etc., and use it as a catalyst to accelerate the reaction by adsorbing chemical reactants. Is also important. Adsorption refers to the phenomenon that when two phases come into contact with each other, the component material constituting the phase is concentrated at the interface, and molecules of gas or solution adhere to the solid surface. This is different from absorption, where solutes migrate from one phase to another across the interface of two phases, ie molecules melt into the interior of a solid or liquid. In addition, when the adsorption occurs on the surface or the interface is positive adsorption, on the contrary, when the component concentration is thinner than the inside is called negative adsorption, the material causing a large amount of positive adsorption is called an adsorbent. If the surface is rough or porous, the effective surface area (specific surface area) for the unit volume (or unit weight) of the adsorbent is large, so that the amount of adsorption increases, resulting in an excellent adsorbent. As an industrially used adsorbent, charcoal is an adsorbent used for a long time, and particularly, activated carbon having strong adsorption power is used. In addition, there are oxides of various metals, especially activated alumina, silica, titanium oxide, and the like, and natural ones include elvan, bentonite, acidic clay, diatomaceous earth, zeolite, starch, and the like. However, since the products are natural products, there is a problem that additional cost is added to the interior of the building, and the work must be doubled, but the product of the present invention is excellent in deodorizing performance and can be applied to the inner wall of the building as it is, and recycled. As a product, it has the advantage of reducing the cost without being harmful to the human body.

Existing insulation materials generally use products in the form of SPRAY foam, and more advanced foam-type products have recently been released. Although the construction is convenient, the foam-type product has a weak characteristic of heat is a major cause of generating toxic gases in the event of fire. In general, the effect of thermal insulation may be various, but the heat transfer is difficult due to the low thermal conductivity and high porosity of the material itself.

In the related art related to the 'concrete product using the bottom ash and a method of manufacturing the concrete product' (Korean Patent Application No. 10-2001-0023281), the patent aims to use part of the aggregate as a substitute for concrete products, Particle size distribution and irregularity of particles have been a problem, and the impact of unburned carbon powder contained in low ash is a cause of deterioration of the quality of concrete products. In addition, in order to be used in existing ceramic products there is a problem that needs to be supplied as a raw material by grinding or sifting low ash separately before blending, there is a problem that the economy is inferior compared to the production of existing ceramic products. In addition, there are 'lightweight clay bricks and clay floor bricks using purified water sludge and its manufacturing method' (Korean Patent Application No. 10-2003-0074264), and the recycling of industrial wastes such as purified water sludge, coal ash, etc. As a main raw material, to produce a light clay brick and a clay floor brick by mixing the waste and calcined, the method has only a role as an additive in the production of existing clay brick or clay floor block, building other than the function as an exterior material or floor packaging material There is a problem in that it is not possible to achieve high value-added of the use that can be used in the interior.

In addition, 'Extruded lightweight concrete panel using low ash and its manufacturing method' (Korea Patent Registration No. 10-0556259) and 'Manufacturing method and light weight aggregate of light weight aggregate using fly ash and clay' (Korea Patent Application No. 1993-0021082), but there are a number of conventional patents, but the patents are effective to recycle waste resources such as low ash or fly ash, such as lightweight, deodorant, compressive strength, etc. There is a problem that does not improve the physical properties.

Accordingly, the present inventors have made diligent efforts to solve the disadvantages of the prior art,

Recycling the waste resources buried in low ash, artificial marble dust and clay, and burning the unburned dust contained in the low ash and dust during firing to form a number of pores to achieve light weight, and increase the content of waste The present invention was completed by further confirming that the pore distribution was further increased to have a low thermal conductivity and a high deodorizing effect.

After all, the main object of the present invention is to provide a method for producing interior or exterior materials using clay, coal ash and dust.

In order to achieve the above object, the present invention comprises the steps of (a) mixing 50 to 90 parts by weight of clay and 10 to 50 parts by weight of coal ash; (b) forming a molded article by molding the mixed raw materials; (c) drying the molded body at 60 to 100 ° C; And (d) firing the dried molded body at 1100 to 1200 ° C. for 20 to 25 hours.

The present invention comprises the steps of mixing 50 to 90 parts by weight of clay and 10 to 50 parts by weight of dust; (b) forming a molded article by molding the mixed raw materials; (c) drying the molded body at 60 to 100 ° C; And (d) firing the dried molded body at 1100 to 1200 ° C. for 20 to 25 hours, thereby providing a method of manufacturing interior materials using clay and dust.

The present invention (a) mixing 40 to 60 parts by weight of clay, 20 to 50 parts by weight of coal ash and 10 to 20 parts by weight of dust; (b) pulverizing the mixed raw materials; (c) molding the pulverized raw material to produce a molded body; (d) drying the molded body at 60 to 100 ° C; And (e) firing the dried molded body at 1100 to 1200 ° C. for 20 to 25 hours, thereby providing a method of preparing interior materials using clay, coal ash and dust.

The present invention also comprises: (a) mixing 50 to 90 parts by weight of clay and 10 to 50 parts by weight of coal ash; (b) forming a molded article by molding the mixed raw materials; (c) drying the molded body at 60 to 100 ° C; And (d) firing the dried molded body at 1100 to 1200 ° C. for 30 to 35 hours.

The present invention comprises the steps of mixing 50 to 90 parts by weight of clay and 10 to 50 parts by weight of dust; (b) forming a molded article by molding the mixed raw materials; (c) drying the molded body at 60 to 100 ° C; And (d) firing the dried molded body at 1100 to 1200 ° C. for 30 to 35 hours to provide a method of manufacturing an exterior material using clay and dust.

The present invention (a) mixing 40 to 60 parts by weight of clay, 10 to 50 parts by weight of coal ash and 10 to 20 parts by weight of dust; (b) pulverizing the mixed raw materials; (c) molding the pulverized raw material to produce a molded body; (d) drying the molded body at 60 to 100 ° C; And (e) calcining the dried molded body at 1100 to 1200 ° C. for 30 to 35 hours, thereby providing a method of manufacturing an exterior material using clay, coal ash and dust.

In the present invention, the step (b) may be characterized in that the grinding to less than 3mm.

Hereinafter, the present invention will be described in detail.

Interior materials according to the present invention is 50 to 90 parts by weight of clay and 10 to 50 parts by weight of coal ash, or 50 to 90 parts by weight of clay and 10 to 50 parts by weight of dust, or 40 to 60 parts by weight of clay, 20 to 50 parts by weight of coal ash. 10-20 parts by weight of parts and dust are mixed and ground. The coal ash may use a fly ash or raw ash ash, the mixed raw material may be characterized in that pulverized to less than 3mm. After preparing the molded body by extruding or pressing the mixed raw material, the molded body is dried for 24 hours in a drying chamber of 60 ~ 100 ℃, the dried molded body in a tunnel kiln at a temperature of 1100 ~ 1200 ℃ 24 hours It is prepared by firing for a while, and then cooled to prepare an interior material.

The exterior material according to the present invention may be mixed with 50 to 90 parts by weight of clay and 10 to 50 parts by weight of coal ash, or 50 to 90 parts by weight of clay and 10 to 50 parts by weight of dust, or 40 to 60 parts by weight of clay and 10 to 50 parts by weight of coal ash. 10-20 parts by weight of parts and dust are mixed and ground. The coal ash may use a fly ash or raw ash ash, the mixed raw material may be characterized in that pulverized to less than 3mm. The mixed raw material is extruded or press-molded to prepare a molded body, and the molded body is dried in a drying chamber at 60 to 100 ° C. for 24 hours, and then the dried molded body is fired at 1100 to 1200 ° C. for 34 hours in a tunnel kiln. After manufacturing, it is cooled to prepare an exterior material.

Clay used in the present invention, when added to the aggregate of the water-containing alumina silicate mineral, the plasticity is expressed, it hardens when dried, shows the rigidity and is sintered red color by iron when fired at high temperature, the content of the clay 50 to 90% by weight of the raw material or the interior material is preferred, when the clay content is less than 50% by weight, the plastic strength is weak, there is a weak resistance to the external environment.

The coal ash used in the present invention is composed of raw ash ash and fly ash, the content of the coal ash is preferably 10 to 50% by weight of the total of the interior or exterior material raw materials. When the content of the coal ash is less than 10% by weight of the total interior or exterior materials, it is difficult to mold according to the appropriate amount of moisture, if more than 50% by weight, there is a problem that the plasticity of the blended raw material is lowered, the molding strength and hardness is lowered.

In addition, the content of the dust is preferably 10 to 50% by weight of the total interior or exterior material ingredients, when the content of the dust is less than 10% by weight of the interior or exterior materials, it is difficult to mold to suit the appropriate moisture content, 50% by weight or more In this case, there is a problem that the plasticity of the blended raw material is lowered and the molding strength and hardness are lowered.

The chemical composition of the dust is 98% or more composed of alumina (Al ₂ O ₃ ) component, the alumina component is sintered at a temperature of 1400 ℃ or more, so as the amount of dust added at the firing temperature of the present invention 1170 ℃ of the fired body There is a problem that causes a decrease in strength or maintain the shape of the plastic body. In addition, as the amount of dust increases, the porosity increases, so that a fired body having excellent heat insulation and deodorization performance can be manufactured. However, the strength is lowered, so that it is difficult to manufacture interior materials or exterior materials by adding 20% or more of dust. Accordingly, in the present invention, by adding low ash, the calcining property of the base may be improved by increasing the sintering property of the base due to the exothermic phenomenon of unburned carbon when firing at 1100 to 1200 ° C. Can be.

The unit volume masses of low ash and dust used in the present invention are 968 kg / m 3 and 465 kg / m 3, respectively, and are much lighter than 1,900 kg / m 3, which is the unit volume mass of the raw material for clay products used as exterior materials and floor materials of buildings. Heating the unburned powder generates a large number of cavities inside and outside of the brick to reduce the weight of the brick itself, and the interior and exterior of the cavities generated inside and outside can be manufactured with excellent interior or exterior materials.

According to the present invention, the exterior material of the clay brick KS L 4201 (clay brick) and the standard of excellent recycled product quality of GR F 4014 (recycled clay brick) are commonly presented in terms of compressive strength of 210kgf / cm ² or more, absorption 10 It is manufactured to satisfy% or less.

Hereinafter, the present invention will be described in more detail with reference to Examples. These examples are only for illustrating the present invention, it will be apparent to those skilled in the art that the scope of the present invention is not to be construed as being limited by these examples.

Example  1: according to the invention Lightweight  Improved Fabrication of Interior Materials

(1) Preparation of interior materials according to the present invention and conventional methods

In this embodiment, the coal ash, artificial marble dust and clay generated in the thermal power plant was used, the results of analyzing the chemical composition of the materials are shown in Table 1 below.

In order to produce a light weight improved interior according to the present invention, 50 to 90% by weight of clay and 10 to 50% by weight of coal ash, or 50 to 90% by weight of clay and 10 to 50% by weight of dust, or clay 40 ~ 60% by weight, 20 to 50% by weight of ash and 10 to 20% by weight of dust are mixed and ground. 150 g of the mixed raw material was put into a mold having a diameter of 75 mm to form a molded body, and the molded body was dried in a drying chamber at 90 ° C. for 24 hours. Thereafter, the dried semi-finished product was prepared by firing at 1170 ° C. for 24 hours at the maximum temperature of the tunnel kiln (Experimental Examples 1 to 16).

Chemical Composition of Materials Used in Interior Materials Chemical Composition (%) Type SiO ₂ Al ₂ O ₃ Fe ₂ O ₃ TiO ₂ CaO MgO K ₂ O Na ₂ O C Ignition loss Dust 0.24 36.77 0.02 0.03 0.01 0.01 0.03 0.02 - 62.54 Low society 45.54 18.59 8.57 1.33 2.17 0.78 0.51 0.18 18.05 4.07 Fly ash 44.69 28.29 4.49 1.47 0.78 0.70 3.42 0.22 14.47 1.14 clay 51.43 30.52 1.79 0.15 4.76 0.85 1.03 2.39 - 6.93

In addition, in order to manufacture the interior material according to the conventional method, a molded body was manufactured by molding 150 g of clay with a clay component of 100% by weight into a mold having a diameter of 75 mm, and the molded body was dried in a drying chamber at 90 ° C. for 24 hours. The dried semi-finished product was then calcined at 1170 ° C., the highest temperature of the tunnel kiln, for 24 hours (Comparative Example 1).

(2) Lightweight  Experiment

Comparative results of the calcined body measured by measuring the apparent porosity, water absorption, and specific gravity of KSL 3114 firebrick are shown in Table 2 below.

Performance comparison table of the fired bodies prepared in Experimental Examples 1 to 16 and Comparative Example 1 division Raw material blending ratio (%) Porosity (%) Volume specific gravity Density (g / cm ³ ) Light weight rate (%) clay Dust Raw food Experimental Example 1 90 - 10 21.0 1.78 1.624 7.2 Experimental Example 2 80 - 20 22.1 1.66 1.479 9.3 Experimental Example 3 70 - 30 22.4 1.61 1.357 11.4 Experimental Example 4 60 - 40 32.7 1.48 1.277 13.4 Experimental Example 5 50 - 50 37.7 1.31 1.250 15.5 Experimental Example 6 90 10 - 21.0 1.78 1.734 10.5 Experimental Example 7 80 20 - 28.1 1.70 1.469 15.9 Experimental Example 8 70 30 - 29.5 1.63 1.478 21.3 Experimental Example 9 60 40 - 42.1 1.40 1.231 26.7 Experimental Example 10 50 50 - 50.4 1.18 1.014 32.2 Experimental Example 11 60 10 30 39.9 1.37 1.170 16.8 Experimental Example 12 50 10 40 39.3 1.25 1.014 18.9 Experimental Example 13 40 10 50 38.9 1.24 1.008 21.0 Experimental Example 14 60 20 20 44.9 1.26 1.110 20.1 Experimental Example 15 50 20 30 50.4 1.09 0.963 22.2 Experimental Example 16 40 20 40 49.6 1.08 0.891 24.3 Comparative Example 1 100 - - 16.9 2.08 1.758 5.1

As shown in Table 2, Experimental Example 1 prepared a molded body by mixing 10% by weight raw raw ash and 90% by weight of clay, and the measurement results showed a porosity of 21.0%, a volume ratio of 1.78, a density of 1.624, and a light weight of 7.2%. Experimental Example 2 prepared a molded body by mixing 20% by weight raw raw ash and 80% by weight of clay, and the measurement results showed a porosity of 22.1%, a specific gravity of 1.66, a density of 1.479 and a light weight of 9.3%. Experimental Example 3 prepared a molded body by mixing 30% by weight raw raw ash and 70% by weight of clay, and the measurement results showed a porosity of 22.4%, a specific gravity of 1.6, a density of 1.357, and a weight of 11.4%. Experimental Example 4 prepared a molded body by mixing 40% by weight of raw ash and 60% by weight of clay, and the measurement results showed a porosity of 32.7%, a specific gravity of 1.48, a density of 1.277, and a weight of 13.4%.

Experimental Example 5 prepared a molded body by mixing 50% by weight raw ash and 50% by weight of clay, and the measurement results showed a porosity of 37.7%, a volume specific weight of 1.31, a density of 1.250, and a light weight of 15.5%. Experimental Example 6 produced a molded body by mixing 10% by weight of dust and 90% by weight of clay, and the measurement results showed a porosity of 21.0%, a volume specific gravity of 1.78, a density of 1.734, and a light weight of 10.5%. Experimental Example 7 prepared a molded body by mixing 20% by weight of dust and 80% by weight of clay, and the measurement results showed a porosity of 28.1%, a specific gravity of 1.70, a density of 1.469, and a weight of 15.9%. In Experimental Example 8, a molded body was prepared by mixing 30% by weight of dust and 70% by weight of clay. The measured results showed a porosity of 29.5%, a specific gravity of 1.63, a density of 1.478, and a weight of 21.3%.

Experimental Example 9 prepared a molded body by mixing 40% by weight of dust and 60% by weight of clay, and the measurement results showed a porosity of 42.1%, a specific gravity of 1.40, a density of 1.231, and a light weight of 26.7%. Experimental Example 10 prepared a molded body by mixing 50% by weight of dust and 50% by weight of clay, and the measurement results showed porosity of 50.4%, specific gravity of 1.18, density of 1.014, and light weight of 32.2%. Experimental Example 11 prepared a molded body by mixing 10% by weight of dust, 30% by weight raw ash and 60% by weight of clay, the measurement results showed a porosity of 39.9%, volume ratio of 1.37, density 1.170 and light weight of 16.8%. Experimental Example 12 prepared a molded body by mixing 10% by weight of dust, 40% raw ash ash and 50% clay, the measurement results showed a porosity of 39.3%, volume specific weight 1.25, density 1.014 and light weight 18.9%.

Experimental Example 13 was prepared by mixing 10% by weight of dust, 50% by weight raw ash and 40% by weight of clay, the measurement results showed a porosity of 38.9%, volume specific weight 1.24, density 1.008 and light weight 21.0%. The raw material blending ratio of Experimental Example 14 was prepared by mixing 20% by weight of dust, 20% by weight of raw ash and 60% by weight of clay, and the measurement results showed porosity of 44.9%, volume specific gravity of 1.26, density of 1.110 and light weight of 20.1%. It was. Experimental Example 15 prepared a molded body by mixing 20% by weight of dust, 30% by weight raw ash and 50% by weight of clay, and the measurement results showed a porosity of 50.4%, a volume specific weight of 1.09, a density of 0.963 and a light weight of 22.2%. Experimental Example 16 prepared a molded body by mixing 20% by weight of dust, 40% by weight of raw ash and 40% by weight of clay, and the measurement results showed a porosity of 49.6%, a specific gravity of 1.08, a density of 0.891, and a weight of 24.3%.

The fired body prepared by Comparative Example 1 was measured by the method of measuring the apparent porosity, water absorption and specific gravity of KSL 3114 refractory brick. As a result, the fired body had a porosity of 16.9%, a volume specific gravity of 2.08, a density of 1.758, and a light weight. The rate was 5.1%.

As described above, when the mixing ratio of clay and raw ash is 1: 1, the volume specific gravity is the lowest and the light weight ratio is the highest. When the mixing ratio of clay and dust is 1: 1, the porosity is in the experimental example. It is high and shows the highest light weight rate. Next, when the mixing ratio of clay, dust and raw ash was 2: 1: 2, the density was found to be the smallest.

Example  2: according to the invention Deodorizing performance  Improved Fabrication of Interior Materials

(1) Preparation of interior materials according to the present invention and conventional methods

In order to manufacture the interior material improved deodorant according to the invention, 150g of the raw material mixed with 30% by weight of dust, 10% by weight raw ash and 60% by weight of clay was put into a mold having a diameter of 75mm to prepare a molded body. Was dried in a drying chamber at 90 ° C. for 24 hours. The dried semi-finished product was fired for 24 hours at 1170 ° C. in a tunnel kiln to prepare a fired body (Experimental Example 17).

In addition, in order to manufacture the interior material according to the conventional method, 150g of the raw material mixed with 70% by weight of clay and 30% by weight of secondary clay used in the field was put into a mold having a diameter of 75mm to form a molded body, and the molded body was 90 It was dried for 24 hours in a drying room at ℃. The dried semi-finished product was fired at 1170 ° C. for 24 hours at the maximum temperature of the tunnel kiln to prepare a fired body (Comparative Example 2).

(2) Deodorization performance test

Formaldehyde gas was injected into the fired body to measure the deodorizing performance at 30 minute intervals for 0 to 120 minutes, as shown in Table 3 below.

Comparative table of deodorizing performance of the fired bodies prepared in Experimental Example 17 and Comparative Example 2 division Raw material blending ratio Deodorization test (HCHO; formaldehyde) clay Dust Raw food Elapsed time (minutes) Blank concentration (ppm) Sample concentration (ppm) Deodorization rate (%) Experimental Example 17 60 30 10 0 81.0 81.0 - 30 78.0 31.0 60.3 60 75.0 27.0 64.0 90 72.0 24.0 66.7 120 70.0 22.0 68.6 Comparative Example 2 100 - - 0 81.0 81.0 - 30 78.0 72.0 7.7 60 75.0 68.0 9.3 90 72.0 64.0 11.1 120 70.0 62.0 11.4

The raw material blending ratio of Experimental Example 17 was prepared by mixing 60% by weight of clay, 30% by weight of dust and 10% by weight of raw low ash, and a fired body was formed. The result obtained by injecting formaldehyde gas into the fired body was measured in 120 minutes. Deodorization rate was 68.6%.

The raw material blending ratio of Comparative Example 2 was prepared by firing the body to 100% by weight of clay, and the result obtained by injecting formaldehyde gas into the calcined body showed a final deodorization rate of 11.4% at 120 minutes.

As described above, it can be seen that the deodorization rate of formaldehyde gas of the fired body prepared by mixing clay, dust and raw low ash is 6 times higher than that of the fired body produced using clay. Since the deodorization rate of formaldehyde gas, which is one of the causative agents of sick house syndrome, is high, when the plastic body is used as a building material, it is possible to create a pleasant and clean indoor environment by improving indoor air quality.

Example  3: manufacture of interior materials with improved thermal insulation performance according to the present invention

(1) Preparation of interior materials according to the present invention and conventional methods

In order to manufacture the interior material with improved thermal insulation performance according to the present invention, by using a roller crusher that can be crushed to 3mm or less by mixing 10 ~ 40% by weight raw ash, 50 ~ 70% by weight clay and 10 ~ 30% by weight dust The pulverized raw material was put into a pressure presser equipped with a mold of 230 × 114 × 65 mm, and molded at a pressure of 250 kg / cm 2 to prepare a molded product, and the molded product was dried in a drying chamber at 90 ° C. for 24 hours. Thereafter, the dried semi-finished product was fired at a tunnel kiln maximum temperature of 1170 ° C. for 24 hours to prepare a fired body (Experimental Examples 18 to 21).

In addition, in order to manufacture the interior material according to the conventional method, the raw material pulverized using a roller crusher that can be crushed to 3mm or less by mixing 70% by weight of clay and 30% by weight of secondary clay used in the field. A molded article was manufactured by molding into a pressure presser equipped with a mold of 65 mm at a pressure of 250 kg / cm 2, and the molded article was dried in a drying chamber at 90 ° C. for 24 hours. Thereafter, the dried semi-finished product was calcined for 24 hours at the tunnel kiln maximum temperature 1170 ℃ (Comparative Example 3).

(2) thermal conductivity experiment

The results of measuring the thermal conductivity of the fired body are as shown in Table 4 below.

Comparative table of thermal conductivity of fired bodies prepared in Experimental Examples 18 to 21 and Comparative Example 3 division Raw material blending ratio (%) Density (g / cm ³ ) Light weight rate (%) Thermal Conductivity (W / mK) clay Dust Raw food Experimental Example 18 70 20 10 1.18 17.2 0.334 Experimental Example 19 60 30 10 1.05 25.6 0.354 Experimental Example 20 60 10 30 1.27 14.6 0.502 Experimental Example 21 50 10 40 1.07 17.4 0.368 Comparative Example 3 100 - - 1.70 5.1 1.044

In Experimental Example 18, a fired body was prepared by mixing 70 wt% of clay, 20 wt% of dust, and 10 wt% of raw ash ash, and the thermal conductivity of the fired body showed a value of 0.334 (W / mK). Experimental Example 19 prepared a fired body by mixing 60% by weight of clay, 30% by weight of dust and 10% by weight of raw ash ash, and the thermal conductivity of the fired body showed a value of 0.354 (W / mK).

In Experimental Example 20, a fired body was prepared by mixing 60 wt% of clay, 10 wt% of dust, and 30 wt% of raw ash ash, and the thermal conductivity of the fired body showed a value of 0.502 (W / mK). Experimental Example 21 prepared a fired body by mixing 50% by weight of clay, 10% by weight of dust and 40% by weight of raw ash ash, and the thermal conductivity of the fired body showed a value of 0.368 (W / mK).

In Comparative Example 3, a fired body was manufactured from 100 wt% clay, and the thermal conductivity of the fired body showed a value of 1.044 (W / mK).

As described above, the thermal conductivity of the fired body prepared by mixing clay, dust, and raw ash was 0.335 to 0.502, and the thermal conductivity of the fired concrete, soil, and clay fired was 1.628 (W / mK), 0.580 ( Compared to W / mK) and 1.044 (W / mK), it can be seen that the present invention shows a very excellent thermal insulation performance, and when used as an indoor building material, thermal insulation is improved, thereby saving energy.

Example  4: manufacture of an exterior material having improved compressive strength according to the present invention

(1) Production of exterior materials according to the present invention and conventional methods

In order to manufacture an exterior material having improved compressive strength according to the present invention, a diameter of 150 g of a raw material mixed with 60 to 90 wt% of clay, 10 to 20 wt% of dust, 10 to 20 wt% of raw ash ash, and 10 to 30 wt% of fly ash is used. The molded article was manufactured by molding into a 75 mm mold, and the molded article was dried in a drying chamber at 90 ° C. for 24 hours. The dried semi-finished product was calcined for 34 hours at the maximum temperature of 1180 ℃ tunnel kiln to prepare a fired body (Experimental Examples 22-30).

In addition, in order to manufacture the exterior material according to the conventional method, 150g of 100% by weight of the raw material of clay used in the field was molded into a mold having a diameter of 75mm to form a molded body, and the molded body was dried in a drying chamber at 90 ° C. for 24 hours. . The dried semi-finished product was fired at 1180 ° C. for 34 hours at the maximum temperature of the tunnel kiln to prepare a fired body (Comparative Example 4).

(2) strength test

The pressurized area (A) was obtained for each sample in advance in the fired body, and the pressurization speed of the compressive strength machine was set at 5 to 10 kgf / cm 2 (49 to 98 N / cm 2) every second to measure the maximum load (W) when the sample was broken. Next, the compressive strength (C) was calculated by putting each value into the following Equation 1, and the results of comparing and analyzing the compressive strength are as shown in Table 5 below.

Where C is the compressive strength, W is the maximum load {kgf (N)}, and A is the pressure area (cm 2).

Next, the water absorption of the fired body was measured. The sample was dried in an air bath at 105 to 120 ° C. for 24 hours, allowed to cool to room temperature, and then weighed to dry weight (m1). The dried sample was immediately allowed to stand in water at 20 ± 5 ° C. for 24 hours, and then To remove the moisture from the surface with a wet cloth as soon as possible, and measured by the weight (m2) including the moisture, and put in the following formula (2) to measure the absorption rate (a), the results of the comparative analysis of the absorption rate is shown in Table 5 As shown in.

Where a is water absorption (%), m1 is dry weight (g), and m2 is water (g) including water.

Comparative table of compressive strength of the fired bodies prepared in Experimental Examples 22 to 30 and Comparative Example 4 division Raw material blending ratio (%) Compressive strength (kgf / cm ² ) Absorption rate (%) clay Dust Raw food Fly ash Experimental Example 22 90 - 10 - 405.2 6.8 Experimental Example 23 80 - 20 - 392.6 7.1 Experimental Example 24 90 10 - - 295.3 7.9 Experimental Example 25 80 20 - - 225.1 9.3 Experimental Example 26 90 - - 10 418.1 6.5 Experimental Example 27 80 - - 20 410.3 7.0 Experimental Example 28 80 10 - 10 309.4 8.1 Experimental Example 29 60 10 10 20 293.8 9.2 Experimental Example 30 60 10 - 30 281.2 8.9 Comparative Example 4 100 - - - 306.2 8.5

Raw material mixture ratio of Experimental Example 22 was prepared by mixing 90% by weight of clay and 10% by weight of raw low ash, and a fired body was measured. The compressive strength of the fired body was 405.2kgf / cm ² and the water absorption was found to be 6.8%. In addition, the raw material blending ratio of Experimental Example 23 was prepared by mixing 80% by weight of clay and 20% by weight of raw ash ash to prepare a fired body, and as a result of measuring the compressive strength of the fired body is 392.6kgf / cm ² , the absorption rate is 7.1% appear.

The mixing ratio of raw materials of Experimental Example 24 was prepared by mixing 90% by weight of clay and 10% by weight of dust, and the compressive strength of the fired body was 295.3kgf / cm ² and the water absorption was found to be 7.9%. , The mixing ratio of the raw material of Experiment 25 was mixed with 80% by weight of clay and 20% by weight of dust to prepare a fired body, the compressive strength of the fired body was measured 225.1kgf / cm ² , the absorption was found to be 9.3%.

Raw material mixture ratio of Experimental Example 26 was prepared by mixing 90% by weight of clay and 10% by weight of fly ash to prepare a fired body, the result of measuring the compressive strength of the fired body was 418.1kgf / cm ² , the absorption was 6.5% In addition, the raw material blending ratio of Experimental Example 27 was prepared by mixing 80% by weight of clay and 20% by weight of fly ash to prepare a fired body, as a result of measuring the compressive strength of the fired body is 410.3kgf / cm ² , the absorption rate to 7.0% appear.

The raw material blending ratio of Experimental Example 28 was prepared by mixing 80% by weight of clay, 10% by weight of dust and 10% by weight of fly ash to prepare a fired body, and the compressive strength of the fired body was measured as 309.4kgf / cm ² , the absorption rate is 8.1%, the raw material blending ratio of Experimental Example 29 was prepared by mixing 60% by weight of clay, 10% by weight of dust, 10% by weight of raw ash and 20% by weight of fly ash to prepare a fired body, the compressive strength of the fired body The measurement result was 293.8kgf / cm ² , the absorption rate was 9.2%, and the raw material blending ratio of Experimental Example 30 was prepared by mixing 60% by weight of clay, 10% by weight of dust and 30% by weight of fly ash. The compressive strength of the fired body was measured to be 281.2 kgf / cm ² and the absorption was found to be 8.9%.

The raw material blending ratio of Comparative Example 4 was prepared by firing the body by 100% by weight of clay, the compressive strength of the fired body is a result of measuring the compressive strength is 306.2kgf / cm ² , the absorption rate was 8.5%.

As described above, it can be seen that the compressive strength of the fired body produced by mixing clay, dust, raw ash and fly ash is increased, and the absorption rate is lowered. This is when using the plastic body as a building material, the strength is improved compared to the conventional exterior material has the effect of improving the safety. However, when the same product is measured, the compressive strength decreases when the absorption rate is high.However, when comparing different products, the relationship between the compressive strength and the absorption rate does not coincide with general phenomena according to the particle size or plasticity of the raw materials of each product. In some cases.

Having described the specific parts of the present invention in detail, it will be apparent to those skilled in the art that such specific descriptions are merely preferred embodiments, and thus the scope of the present invention is not limited thereto. will be. Thus, the substantial scope of the present invention will be defined by the appended claims and their equivalents.

As described in detail above, the interior or exterior materials according to the present invention can recycle waste resources buried in coal-fired power plant coal ash, artificial marble dust and clay, thereby reducing raw material costs, and firing at low temperatures, thereby reducing fuel costs. Economical effect, the interior material can obtain a high deodorization rate to formaldehyde, the causative agent of sick house syndrome, to prevent indoor air pollution, and because it is made of inorganic raw materials, there is no generation of toxic gas in the event of fire, permanently There is an effect applicable to buildings. In addition, it is possible to manufacture products that do not dissolve heavy metals by mixing industrial wastes and existing clay raw materials, and the thermal conductivity is lowered, which can be expected to save energy because of its excellent thermal insulation effect when applied to buildings. Exterior material according to the present invention has the effect of improving the compressive strength is improved safety.

Claims (7)

Manufacturing method of interior materials using clay and coal ash comprising the following steps: (a) mixing 50 to 90 parts by weight of clay and 10 to 50 parts by weight of coal ash; (b) forming a molded article by molding the mixed raw materials; (c) drying the molded body at 60 to 100 ° C; And (d) firing the dried molded body at 1100 to 1200 ° C. for 20 to 25 hours. Manufacturing method of interior materials using clay and dust comprising the following steps: (a) mixing 50 to 90 parts by weight of clay and 10 to 50 parts by weight of dust containing at least 98% alumina; (b) forming a molded article by molding the mixed raw materials; (c) drying the molded body at 60 to 100 ° C; And (d) firing the dried molded body at 1100 to 1200 ° C. for 20 to 25 hours. Method for preparing interior materials using clay, coal ash and dust comprising the following steps: (a) mixing 10 to 20 parts by weight of dust containing 40 to 60 parts by weight of clay, 20 to 50 parts by weight of coal ash and 98% or more of alumina; (b) pulverizing the mixed raw materials; (c) molding the pulverized raw material to produce a molded body; (d) drying the molded body at 60 to 100 ° C; And (e) firing the dried molded body at 1100 to 1200 ° C. for 20 to 25 hours. Method for producing an exterior material using clay and coal ash comprising the following steps: (a) mixing 50 to 90 parts by weight of clay and 10 to 50 parts by weight of coal ash; (b) forming a molded article by molding the mixed raw materials; (c) drying the molded body at 60 to 100 ° C; And (d) firing the dried molded body at 1100 to 1200 ° C. for 30 to 35 hours. Method for manufacturing an exterior material using clay and dust comprising the following steps: (a) mixing 50 to 90 parts by weight of clay and 10 to 50 parts by weight of dust containing at least 98% alumina; (b) forming a molded article by molding the mixed raw materials; (c) drying the molded body at 60 to 100 ° C; And (d) firing the dried molded body at 1100 to 1200 ° C. for 30 to 35 hours. Method for producing an exterior material using clay, coal ash and dust comprising the following steps: (a) mixing 10 to 20 parts by weight of dust containing 40 to 60 parts by weight of clay, 10 to 50 parts by weight of coal ash and 98% or more of alumina; (b) pulverizing the mixed raw materials; (c) molding the pulverized raw material to produce a molded body; (d) drying the molded body at 60 to 100 ° C; And (e) firing the dried molded body at 1100 to 1200 ° C. for 30 to 35 hours. The method of claim 3 or 6, wherein the step (b) is pulverized to 3 mm or less.