KR100940869B1 - Clay Bricks for Interior Using Stone Sludge and Methods for Preparing Thereof - Google Patents

Abstract

The present invention relates to a clay brick for interior use using stone powder sludge and a method of manufacturing the same. More particularly, the present invention proposes an active recycling method of stone powder sludge by preparing interior clay brick using stone powder sludge as a main raw material of clay brick. In addition, the present invention relates to a clay brick for interior decoration and a method of manufacturing the same by adding water glass and silicon carbide to improve sinterability and weight reduction characteristics.

According to the interior clay brick of the present invention, it is possible to recycle the sedimentary stone sludge is buried can reduce the raw material cost, it is possible to be fired at a low temperature it is economical by reducing the fuel cost in the manufacturing process. In addition, since the interior clay brick contains pores and is light in weight, the thermal conductivity is lowered, so when the building brick is applied to the building, the heat insulation effect can be expected to reduce energy.

Stone powder sludge, interior materials, clay brick, water glass, silicon carbide

Description

Clay Bricks for Interior Using Stone Sludge and Methods for Preparing Thereof}

The present invention relates to a clay brick for interior use using stone powder sludge and a method of manufacturing the same. More particularly, the present invention proposes an active recycling method of stone powder sludge by preparing interior clay brick using stone powder sludge as a main raw material of clay brick. In addition, the present invention relates to a clay brick for interior decoration and a method of manufacturing the same by adding water glass and silicon carbide to improve sinterability and weight reduction characteristics.

Stone powder is produced in the process of manufacturing crushed aggregates in quarries. The particle size is separated and the stone powder having a particle size of 0.1 mm or more is used as crushed sand and the stone powder having a particle size of 0.1 mm or less is used as a stone powder sludge.

Stone powder sludge is generated more than 3 million tons per year in Seoksan alone, and also in large quantities in stone processing plants, but due to the lack of proper treatment methods, the recycling rate is extremely insignificant.

Stone powder sludge has poor sinterability and cannot be used alone as a brick material, and has been used in the manufacture of clay bricks as a part of clay bricks made of various conventional raw materials.

Representatively, in the manufacture of plastering bricks, techniques for improving the strength of bricks by adding lime sludge together with coal ash have been disclosed (Korean Patent No. 795129). However, the patent uses only the clay powder sludge as an auxiliary raw material for reinforcing specific characteristics of bricks, which are mainly composed of kaolin and clay.

In addition, one of waste lime and waste stone sludge is added with clay as a main component, and for the purpose of strengthening strength and functionalization, pottery stone, feldspar, zeolite powder, illite powder, tourmaline powder, pyrite powder, ocher, kaoring, and white clay The technology for recycling clay bricks and sidewalk bricks prepared by adding 1 to 3 of volcanic ash powder, monazite powder, and blast furnace slag was disclosed (Korean Patent Publication No. 2004-0096832). The sludge is not an essential ingredient and even if the waste-rock sludge is added, it takes up only a part of the raw materials, so the utilization rate of the sludge sludge is low.

Therefore, there is a growing demand for a method for recycling large amounts of stone sludge, which is left in a natural state and causes environmental pollution.

Accordingly, the present inventors have made diligent efforts to solve the problems of the prior arts. As a result, clay brick sludge is used only to improve the recycling rate of stone sludge, and furthermore, by adding water glass and silicon carbide to the sludge sludge. The present invention was completed by confirming that the production of clay bricks can improve physical properties such as plasticity and light weight characteristics of clay bricks.

It is an object of the present invention to provide an interior clay brick and a method of manufacturing the same.

In order to achieve the above object, the present invention provides a clay brick for interior use containing stone dust sludge, water glass and silicon carbide.

The present invention also comprises: (a) adding 5 to 15 parts by weight of water glass and 0.5 to 1.5 parts by weight of silicon carbide to 100 parts by weight of stone flour sludge to prepare a mixture; (b) forming the mixture to form a molded article; (c) drying the molded body at 60 to 100 ° C. for 55 to 66 hours in a dryer; And (d) firing the dried molded body at 900 to 1200 ° C. for 20 to 35 hours.

According to the interior clay brick of the present invention, it is possible to recycle the sedimentary stone sludge is buried can reduce the raw material cost, it is possible to be fired at a low temperature it is economical by reducing the fuel cost in the manufacturing process. In addition, since the interior clay brick contains pores and is light in weight, the thermal conductivity is lowered, so when the building brick is applied to the building, the heat insulation effect can be expected to reduce energy.

The present invention, in one aspect, relates to an interior clay brick containing stone dust sludge, water glass and silicon carbide.

By using only the clay powder sludge as a substantial raw material of the clay brick, the interior clay brick according to the present invention is different from the existing clay brick using the stone powder sludge simply as an additive component, and thus, it is mostly left at the site of generation. This is meaningful because it actively recycles sedimentary sludge that has contaminated the surrounding environment.

In addition, by adding water glass to the interior clay brick made of stone powder sludge according to the present invention to improve the sinterability, and by adding silicon carbide to improve the lightening characteristics, the interior clay brick made of stone powder sludge as a main raw material There is another significance in that the physical properties were improved.

In the present invention, the raw material content of the interior clay brick may be characterized in that 5 to 15 parts by weight of water glass and 0.5 to 1.5 parts by weight of silicon carbide with respect to 100 parts by weight of stone powder sludge.

In the present invention, the built-in clay brick may be characterized in that the pores are formed, by forming a plurality of pores by silicon carbide, it is possible to achieve a lighter weight of the clay brick, when the pore distribution increases the thermal conductivity is low Therefore, it can be expected to save energy by showing insulation effect when applied to buildings.

In another aspect, the present invention provides a method for preparing a mixture comprising: (a) adding 5 to 15 parts by weight of water glass and 0.5 to 1.5 parts by weight of silicon carbide to 100 parts by weight of stone flour sludge; (b) forming the mixture to form a molded article; (c) drying the molded body at 60 to 100 ° C. for 55 to 66 hours in a dryer; And (d) firing the dried molded body at 900 to 1200 ° C. for 20 to 35 hours.

In the present invention, the stone powder sludge may be characterized in that it occurs in the process of grinding or processing the granite.

As a representative example, the stone dust sludge may be generated in the process of grinding or processing feldspar granite, and the chemical crystal phase of the stone powder sludge generated in the process of grinding or processing the feldspar granite is the same as feldspar. , Has a chemical composition as shown in Table 1 below.

Chemical Composition of Stone Powder Sludge ingredient SiO ₂ TiO ₂ Al ₂ O ₃ FeO MnO CaO MgO K ₂ O Na ₂ O P ₂ O ₅ LOI Sum content 70.94 0.34 15.05 2.06 0.03 2.82 0.63 3.20 4.17 0.10 0.49 99.82

Water glass is a material in which sodium (Na) ions are bonded to a silicon oxide polymer and are widely used as a waterproofing agent, a binder, a peptizing agent, and the like. Specifically, the alkali silicate salt obtained by melting silicon dioxide and alkali is prepared in a concentrated aqueous solution, which can be obtained by melting a mixture of silica sand and soda ash at 1300-1500 ° C. in a low pressure steam cooker. Since carbon dioxide absorbs carbon dioxide and precipitates a gel-like silicic acid, it shows strong adhesive force.

Water glass in the present invention serves to facilitate the molding at the same time to improve the sinterability in the manufacturing process of the clay brick. Therefore, when water glass is added less than 5 parts by weight with respect to 100 parts by weight of stone powder sludge, the effect of improving the sinterability of clay bricks is not exhibited, and molding is not easy. It is preferable that the addition amount of water glass is 5-15 weight part with respect to 100 weight part of stone dust sludges.

In the present invention, silicon carbide serves to reduce the weight of clay bricks produced by generating pores by forming gas bubbles while oxidizing at a high temperature of 1000 ° C. or higher. Therefore, if the silicon carbide is added to less than 0.5 parts by weight with respect to 100 parts by weight of stone powder sludge, the weight of the clay brick produced in the present invention is not achieved, and if it is added in excess of 1.5 parts by weight, pores are formed excessively, and the In addition to the deterioration in durability and the high cost of silicon carbide, a problem arises in that a high cost arises. Therefore, the amount of silicon carbide added is preferably 0.5 to 1.5 parts by weight based on 100 parts by weight of stone dust.

In the present invention, the molding of step (b) may be characterized in that the extrusion molding or pressing.

Here, extrusion molding is a molding method in which a raw material is supplied to an extruder, pushed out of a mold, and converted into a continuous body having a constant cross section. Press molding is a molding method in which a desired molded body is obtained by compressing the raw material by applying pressure to the raw material.

Stone flour sludge according to the present invention lacks plasticity, so water glass is added for extrusion. In this case, the water glass forms sodium silicate (Na ₂ O-SiO ₂ ) glass in the sintering process at 900 to 1200 ° C. to melt the sediment powder, thereby improving the plasticity of the sediment powder sludge.

When drying the molded body of the stone powder sludge, water glass and silicon carbide mixture as described above, when dried to less than 60 ℃ water glass forms a film on the surface of the brick body, there is a problem that the drying time is too long or does not dry enough, 100 If the drying is higher than the ℃, there is a risk of cracking in the molded body, and the water glass is excessively precipitated on the surface of the brick body to melt adhesion during sintering, it is preferable to dry the molded body at a temperature of 60 ~ 100 ℃.

In addition, when the molded body of the stone powder sludge, water glass and silicon carbide mixture is dried at a temperature of 60 ~ 100 ℃, drying less than 55 hours does not sufficiently dry, if drying for more than 65 hours is excessively dried to crack Since there is a problem that a phenomenon may appear, the drying time of the molded body is preferably 55 to 65 hours.

In addition, the dryer used when drying the molded body of the stone powder sludge, water glass and silicon carbide mixture can be used without limitation as long as it is a dryer commonly used in the art.

Next, when the dried molded body is fired at a temperature below 900 ° C. or more than 1200 ° C., there is a problem in that the physical properties of the clay brick which is not sufficiently baked or manufactured by oversintering are lowered. It is preferable to bake at the temperature of 900-1200 degreeC.

In addition, the dried molded body is fired at a temperature of 900 ~ 1200 ℃, if the firing is less than 20 hours, the baking is not made sufficiently, if the time exceeds 35 hours, there is no profit due to the increase in the firing time 900 It is preferable to bake for 20 to 35 hours at a temperature of ~ 1200 ℃.

The clay brick for interior use according to the present invention manufactured in this way has the effect of recycling the resources due to the use of stone sludge, the possibility of low-temperature firing due to the improvement of plasticity that can be expected by the use of water glass, and the effect of reducing the firing cost and It shows the effects such as the weight reduction of clay bricks due to the use of silicon carbide and the possibility of use as a heat insulating material.

Hereinafter, the present invention will be described in more detail with reference to Examples. These examples are only for illustrating the present invention, and 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: Preparation of interior clay brick

Stone powder sludge brick, clay brick 1 and clay brick 2 were prepared in the composition ratios of Table 2.

Stone powder sludge water glass Silicon Carbide Stone powder sludge brick 100 kg - - Clay brick 1 90 kg 10 kg - Clay Bricks 2 90 kg 10 kg 0.5kg

The dried stone powder sludge, water glass and silicon carbide were mixed at a composition ratio as shown in Table 2 to prepare a mixture. Thereafter, the mixture was extruded to produce a 110 × 230 × 90 mm cuboid shaped body, and then the molded body was placed in a tunnel dryer and dried at 80 ° C. to 90 ° C. for 60 hours, and the dried molded part 25 at 1000 ° C. to 1100 ° C. By firing for ˜30 hours, stone powder sludge brick, clay brick 1 and clay separate 2 was prepared.

Experimental Example  1: Physical property test of clay brick

The physical properties of the stone powder sludge brick, clay brick 1 and clay brick 2 prepared in Example 1 were respectively measured, and the physical properties of the bricks according to the raw material content were compared. Here, specific gravity and water absorption were measured by the KSL 3114 method, the apparent porosity, water absorption and specific gravity of the firebrick, and the light weight ratio was calculated using the following formula (I).

Light weight ratio = specific gravity of clay brick / stone sludge brick specific gravity ----- (I)

Properties of the brick importance Absorption rate (%) Lightweight 1000 ℃ 1100 ℃ 1000 ℃ 1100 ℃ 1000 ℃ 1100 ℃ Stone powder sludge brick 1.4 1.6 28 24 One One Clay brick 1 1.71 2.02 16 4 1.22 1.26 Clay Bricks 2 1.35 1.45 20 7.5 0.96 0.91

As a result, as shown in Table 3, clay brick 1 has a lower absorption rate compared to the stone powder sludge brick, the sintering is better, but the light weight ratio is rather higher, it can be seen that due to the addition of water glass. On the other hand, clay brick 2 has a lower absorption rate and lighter weight ratio than stone powder sludge brick, and not only has good sintering but also improved weight, and thus, it can be seen that it generally contains many pores that interior materials should have. It can be seen that the more pores, the better the thermal insulation performance, which makes it suitable for interior clay bricks.

These results can be interpreted inferred from the fact that the sintering degree of clay brick is proportional to specific gravity and inversely proportional to absorption.

Having described the specific part of the present invention in detail, it is obvious to those skilled in the art that such a specific description is only a preferred embodiment, thereby not limiting the scope of the present invention. something to do. Thus, the substantial scope of the present invention will be defined by the appended claims and their equivalents.

1 is a flow chart showing the manufacturing process of the interior clay brick according to the present invention.

Claims (5)

The built-in brick containing 5-15 weight part of water glass and 0.5-1.5 weight part of silicon carbides with respect to 100 weight part of stone flour sludges whose particle size is 0.1 mm or less. delete A method of making an embedded brick, comprising the following steps: (a) adding 5 to 15 parts by weight of water glass and 0.5 to 1.5 parts by weight of silicon carbide to 100 parts of stone flour sludge having a particle size of 0.1 mm or less to prepare a mixture; (b) forming the mixture to form a molded article; (c) drying the molded body at 60 to 100 ° C. for 55 to 66 hours in a dryer; And (d) calcining the dried molded body at 900-1200 ° C. for 20-35 hours to produce a brick for interior use. The method of claim 3, wherein the powdered sludge occurs during the grinding or processing of the granite. The method of claim 3, wherein the molding of step (b) is extrusion or press molding.

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