KR101143019B1 - Board for building interior materials having a vermiculite mixed with a sludge produced from water treatment plant and preparation method thereof - Google Patents

Abstract

PURPOSE: An interior board having vermiculite and sludge produced from a water treatment plant and a manufacturing method thereof are provided to remarkably improve rigidity and bending strength compared with an existing vermiculite board. CONSTITUTION: A manufacturing method of an interior board having vermiculite and sludge produced from a water treatment plant is as follows. A mixture is produced by simultaneously plasticizing and mixing water treatment sludge and vermiculite. An interior board is manufactured by molding the produced mixture. The molded board is dried at high temperatures.

Description

Board for building interior materials having a vermiculite mixed with a sludge produced from water treatment plant and preparation method

The present invention relates to a board for building interior materials containing purified sludge and vermiculite, a method for manufacturing the same, and a device for manufacturing the same.

In order to produce purified water in a purified water treatment plant, it is possible to agglomerate various inorganic and organic substances contained in the purified water by using a sedimentation basin which precipitates coarse particles having a specific gravity greater than that in the purified water, and inorganic polymer coagulants such as poly aluminum chloride (PAC). The separation process must be performed.

In this process, the production of purified sludge is essential, and its production amount is several hundred thousand tons per year, and many efforts have been made for the final treatment or recycling thereof.

Water purification sludge has a water content of about 80%, and most of the solid part is an inorganic material composed of clay, and is composed of some PACs (Poly Aluminum Chloride) used in the water purification process and some inorganic chemicals used in the dehydration process.

As the weathering of the clay, clay is mainly composed of silicon, aluminum and water to become clay mineral. The structure is similar to mica and has a two- or three-layer structure. Water, calcium, iron, and magnesium are contained between the layers to form various clay minerals. Clay contains water between the layers and has the characteristic of volume expansion by thermal expansion and evaporation under high temperature heating conditions. In other words, dry sludge having a structure similar to clay also causes volume expansion under high temperature heating conditions, resulting in low specific gravity.

As a method of recycling purified water sludge, 70% or more of the purified sludge is made of clay, and after dehydration and drying, a suitable binder is added and recycled to building materials such as blocks. And recycling to deodorant materials.

Patent document 1 [Korea Patent Application 10-2004-0064859] is a technology that turns waste into civil engineering and construction materials, and mixes organic and inorganic sludge, coal ash, waste gypsum, etc. And mixing, stirring, molding, compression, or extruding to recycle them to civil engineering and construction materials.

In Patent Document 2 [Korean Patent Application 10-2003-0014184], sewage and wastewater discharged from various industries are treated in a water treatment plant, etc. Recycling is applied as a major element in the production of sidewalk blocks to help human life. It is possible to reduce costs due to the disposal of malignant waste, reduce environmental damage, reduce block manufacturing cost, and improve quality. Disclosed is a process for its production in which the advantages are provided.

Patent Document 3 [Korean Patent Application No. 10-2001-0024130] discloses a method to replace sand and gravel of a depleted natural resource and reduce environmental pollution by molding building materials such as brick panels using sewage sludge. have.

Patent Document 4 (Korean Patent Application No. 10-2000-0063324) discloses a method for manufacturing building materials such as tiles and blocks using sludge generated when sewage is purified in a sewage treatment facility.

Vermiculite, on the other hand, is a mineral belonging to a monoclinic system having a crystal structure such as mica and is also called vermiculite. Vermiculite is composed of CMg, Fe ⁺³ , Al ₃ (Al, Si) ₄ O ₁₀ (OH) ₂ -4H ₂ O, which is a clay mineral composed of hydroxides of aluminum, magnesium and iron, with a specific gravity of 2.7. to be. In addition, the cation exchange capacity is large and has the property of expanding due to 4H ₂ O when heated.

In addition, vermiculite is porous and has good absorption ability, and thus has been widely used as a heat-resistant material and a soundproofing material. However, since the amount of vermiculite is limited and cannot be used indefinitely, there is a demand for a method that can be used as a building material such as excellent heat resistance and soundproof material while reducing the amount of vermiculite.

Patent document 5 [Korean Patent Application 10-2004-0036545] relates to a ladle or tundish, which is a conveying vessel for transporting molten steel from a steelmaking furnace to a casting facility, and more specifically, a ladle or tundish. The present invention discloses a vermiculite board and a method of manufacturing the same, which are attached to the iron bar of the shell to prevent damage to the iron bar and the permanent field refractory material and to prevent temperature drop of the melt.

Patent document 6 [Korean Patent Application 10-2006-0125751] relates to a high strength vermiculite board, which includes 100 parts by weight of expanded vermiculite, 1-10 parts by weight of clay, 70-90% by weight of epoxy resin and 10-30% by weight of phenol resin. The present invention relates to a method of sintering vermiculite powder containing 50 to 90 parts by weight, sintering the pulverized vermiculite powder, expanding the volume, mixing and stirring the expanded vermiculite, clay, and organic binder, and then putting the mold into a molding machine and press molding. .

Accordingly, the present inventors continue to generate and increase, and while studying the recycling of high value-added products using purified sludge which is urgently pursued in the treatment method, the board for building interior materials including purified sludge and vermiculite By using recycled purified water sludge, which is a waste generated in the water purification process, manufacturing cost can be reduced, not only satisfies all the physical properties required for building interior materials, but also has excellent heat resistance and hardness compared to conventional vermiculite boards. And it was found out that the bending strength significantly improved, and completed the present invention.

It is an object of the present invention to provide a board for building interior materials comprising purified sludge and vermiculite.

Another object of the present invention is to provide a method of manufacturing the board for interior materials.

Still another object of the present invention is to provide an apparatus for manufacturing the board for interior materials.

In order to achieve the above object, the present invention provides a board for building interior materials with improved hardness and flexural strength, including purified sludge and vermiculite.

In addition, the present invention comprises the steps of preparing a mixture by firing and mixing the purified sludge and vermiculite at the same time or separately (step 1);

Manufacturing a board by molding the mixture prepared in step 1 (step 2) and

It provides a method for manufacturing the board for building interior materials comprising the step (step 3) of drying the board formed in the step 2 at a high temperature.

Further, the present invention is purified sludge dewatering reservoir;

A purified sludge drying furnace in communication with the reservoir;

A purified sludge calcining furnace in communication with the drying furnace;

Vermiculite grinder;

Vermiculite kiln in communication with the vermiculite mill;

An agitator communicating with the purified water sludge kiln and vermiculite kiln; And

Provided is an apparatus for manufacturing a board for building interior materials comprising a dryer and a dryer in communication with the stirrer.

The board for building interior materials including purified sludge and vermiculite according to the present invention can be used by recycling the purified water sludge, which is a waste generated in the water purification process, to reduce the manufacturing cost and not only satisfy all the physical properties required for the building interior materials. Since the resistance to heat is very excellent and the hardness and flexural strength are remarkably improved as compared to the existing vermiculite board, it may be useful for manufacturing a board for building interior materials.

1 is a schematic diagram showing a system for manufacturing a board including purified sludge and vermiculite according to the present invention.
2 is a test report of the water content and bending strength of the board according to an embodiment of the present invention measured by the Korea Institute of Construction Living Environment Test.
3 is a test report of the non-combustibility test and gas hazard test of the board according to an embodiment of the present invention measured by the Korea Institute of Construction Living Environment Test.

Hereinafter, the present invention will be described in detail.

The present invention provides a board for building interior materials with improved hardness and flexural strength, including purified sludge and vermiculite.

In the board according to the present invention, the purified water sludge may be a mixture of various inorganic materials and organic matter contained in the constant water by using inorganic polymer coagulant including PAC (Poly Aluminum Chloride) during the purification process.

In the board according to the present invention, it is preferable to mix 10-90% by weight of the purified water sludge and 90-10% by weight of vermiculite, more preferably 30-80% by weight of purified water sludge and 70-20% by weight of vermiculite. It is even more preferred to mix 50-70% by weight purified sludge and 50-30% by weight vermiculite, most preferably 60% by weight purified sludge and 40% by weight vermiculite.

If the purified sludge is mixed in less than 10% by weight and more than 90% by weight of vermiculite, there is a problem in that the economic effect of adding the purified sludge is insignificant and the effect of improving hardness and bending strength is hardly exhibited. When mixed with excess and less than 10% by weight vermiculite, there is a problem that the weight of the board is too heavy.

In the board according to the present invention, 0.1-30 parts by weight of an inorganic adhesive may be further added to 100 parts by weight of the purified sludge and vermiculite mixture when mixing purified sludge and vermiculite.

The inorganic adhesive serves to bond the purified sludge and vermiculite well with each other, but may be used alone or mixed with an inorganic adhesive such as silicate, alumina, magnesium, potassium, sodium, etc., but is not limited thereto. .

In addition, the present invention provides a method for manufacturing a board for building interior materials comprising the purified sludge and vermiculite comprising the following steps.

Calcining the purified sludge and vermiculite simultaneously or separately and mixing to prepare a mixture (step 1);

Manufacturing a board by molding the mixture prepared in step 1 (step 2) and

High temperature drying the board formed in the step 2 (step 3).

Hereinafter, the present invention will be described in detail step by step.

In the production method according to the present invention, step 1 is a step of preparing a mixture by firing or mixing the purified water sludge and vermiculite at the same time or separately.

At this time, the purified water sludge used in this step 1 is an agglomeration of various inorganic and organic substances contained in the water by using inorganic polymer coagulant including PAC (Poly Aluminum Chloride) during the purification process, before performing the calcining process Further drying may be carried out to lower the water content to 20-50%.

In addition, vermiculite used in the present step 1 may further perform a grinding process for smooth firing before performing the firing process.

Furthermore, the operating temperature of the firing process is preferably 500-1000 ° C.

If the operating temperature of the firing process is less than 500 ° C., there is a problem that firing does not occur sufficiently, and if it exceeds 1000 ° C., energy is wasted.

In addition, it is preferable to mix 10-90% by weight of the purified sludge and 90-10% by weight of vermiculite, more preferably, 30-80% by weight of purified water sludge and 70-20% by weight of vermiculite, and 50- It is even more preferred to mix 70% by weight and 50-30% by weight of vermiculite, most preferably by mixing 60% by weight of purified sludge and 40% by weight of vermiculite. The reason for limiting the mixing weight ratio of the purified sludge and vermiculite is as described above.

Further, when mixing the purified sludge and vermiculite, 0.1-30 parts by weight of an inorganic adhesive may be further added to 100 parts by weight of the purified sludge and vermiculite mixture.

The inorganic adhesive serves to bond the purified sludge and vermiculite well with each other, but may be used alone or mixed with an inorganic adhesive such as silicate, alumina, magnesium, potassium, sodium, etc., but is not limited thereto. .

In the manufacturing method according to the present invention, step 2 is a step of molding the mixture prepared in step 1. At this time, the molding machine may be used in the form of a board, but is not particularly limited.

In the manufacturing method according to the invention, the step 3 is a step of drying the board formed in the step 2 at a high temperature. In this case, the dryer may use a general high temperature dryer without particular limitation.

Furthermore, this invention provides the manufacturing apparatus of the board for building interior materials containing the said clean water sludge and vermiculite containing the following structure (refer FIG. 1).

Purified sludge dewatering reservoir;

A purified sludge drying furnace in communication with the reservoir;

A purified sludge calcining furnace in communication with the drying furnace;

Vermiculite grinder;

Vermiculite kiln in communication with the vermiculite mill;

An agitator communicating with the purified water sludge kiln and vermiculite kiln; And

Molding and dryer in communication with the stirrer.

Hereinafter, the present invention will be described in detail with reference to the manufacturing apparatus shown in FIG. 1.

In the manufacturing apparatus according to the present invention, the purified water sludge dewatering storage tank serves to store the water content so that the water content is 70-85% by dewatering the sludge generated in the water treatment plant.

In the production apparatus according to the present invention, the purified water sludge drying furnace serves to make the water content to 50% or less by drying the purified water sludge to lower the water content to 70-85% through the dehydration process in a dehydration storage tank.

In the manufacturing apparatus according to the present invention, the purified water sludge firing furnace communicated with the drying furnace at 500-1000 ℃ using a heat source such as electricity or LNG, LPG, diesel oil, the water content of the drying rate of the water in the drying furnace 50% or less It serves to fire by heating.

In the manufacturing apparatus according to the present invention, the vermiculite crusher serves to pulverize vermiculite for the process of smooth firing of vermiculite.

In the manufacturing apparatus according to the present invention, the vermiculite calcination furnace communicating with the vermiculite pulverizer serves to calcinate vermiculite by heating to 500-1000 ° C. using a heat source such as electricity, LNG, LPG, or diesel oil.

In the manufacturing apparatus according to the present invention, the stirrer communicating with the purified water sludge kiln and vermiculite kiln serves to uniformly stir the calcined purified sludge and vermiculite.

At this time, during the stirring process, an inorganic adhesive may be added to assist in combining the purified sludge and vermiculite.

In the manufacturing apparatus according to the invention, the molding and the dryer in communication with the stirrer to form a board of the desired size in a uniformly stirred mixture in a molding machine, and then dried in a high temperature dryer to manufacture a board for building interior purposes Play a role.

The board for building interior materials including purified sludge and vermiculite according to the present invention can be used by recycling the purified water sludge, which is a waste generated in the water purification process, to reduce the manufacturing cost and not only satisfy all the physical properties required for the building interior materials. The heat resistance is very excellent, and since the hardness and bending strength are significantly improved compared to the existing vermiculite board, it may be useful for the manufacture of boards for building interior materials.

Hereinafter, the present invention will be described in more detail with reference to the following examples. However, the following examples are merely to illustrate the present invention, but the content of the present invention is not limited by the following examples.

< Example  1> essence Sludge  And manufacture of boards containing vermiculite 1

First, the purified water sludge generated in the water treatment process was dried in a drying furnace until the water content became 50%, and then calcined in a purified water sludge firing furnace at 950 ° C. Next, vermiculite was pulverized in a mill and then calcined in a vermiculite kiln at 750 ° C.

10 wt% of the calcined sludge and 90 wt% of vermiculite respectively calcined above were added to an agitator and stirred, followed by an inorganic adhesive [liquid binder: 70 wt% of liquid sodium silicate, 10 wt% of liquid silicon dioxide; Powdered silica: 10% by weight sodium silicate powder, 3% by weight silicon dioxide powder; Curing agent: 7% by weight of calcium oxide] was added an additional 20 parts by weight based on 100 parts by weight of the mixture of the purified sludge and vermiculite and then stirred again.

The stirred mixture was transferred to a board molding machine to form a thickness of 10-75 mm, width 600 mm, length 600 mm, and then dried in a drying furnace at 850 ° C. to prepare a board for building interior materials.

< Example  2> essence Sludge  And manufacture of boards containing vermiculite 2

A board for building interior materials was manufactured in the same manner as in Example 1, except that 20 wt% of calcined purified sludge and 80 wt% of vermiculite were mixed.

< Example  3> essence Sludge  And manufacture of boards containing vermiculite 3

A board for building interior materials was manufactured in the same manner as in Example 1, except that 30 wt% of calcined purified sludge and 70 wt% of vermiculite were mixed.

< Example  4> essence Sludge  And manufacture of boards containing vermiculite 4

A board for building interior materials was manufactured in the same manner as in Example 1, except that 40 wt% of calcined purified sludge and 60 wt% of vermiculite were mixed.

< Example  5> essence Sludge  And manufacture of boards containing vermiculite 5

A board for a building interior material was manufactured in the same manner as in Example 1, except that 50 wt% of calcined purified sludge and 50 wt% of vermiculite were mixed.

< Example  6> essence Sludge  And manufacture of boards containing vermiculite 6

A board for building interior materials was manufactured in the same manner as in Example 1, except that 60 wt% of calcined purified sludge and 40 wt% of vermiculite were mixed.

< Example  7> essence Sludge  And manufacture of boards containing vermiculite 7

A board for building interior materials was manufactured in the same manner as in Example 1, except that 70 wt% of calcined purified sludge and 30 wt% of vermiculite were mixed.

< Example  8> essence Sludge  And manufacture of boards containing vermiculite 8

A board for building interior materials was manufactured in the same manner as in Example 1, except that 80 wt% of calcined purified sludge and 20 wt% of vermiculite were mixed.

< Example  9> essence Sludge  And manufacture of boards containing vermiculite 9

A board for building interior materials was manufactured in the same manner as in Example 1, except that 90 wt% of calcined purified sludge and 10 wt% of vermiculite were mixed.

< Comparative example  1> Manufacture of Vermiculite Board

A board for building interior materials was manufactured in the same manner as in Example 1, except that 100 wt% of calcined vermiculite was used.

< Experimental Example  1> Heat resistance and nonflammability rating

In order to evaluate the heat resistance and incombustibility of prime board, styrofoam board, fiberglass board, rock wool board, and polyurethane board, which are commonly used as a board containing purified sludge and vermiculite prepared in Example 4 In general, the test items to be applied were evaluated. The results are shown in Table 1, FIG. 2 and FIG. 3.

Prime Styrofoam Fiberglass Rock wool Polyurethane Example 4 Thickness (mm)
6 50 75 75 75 10-75 Specific gravity (g / cm ³ )
- 0.01-0.032 0.01-0.16 0.024-0.4 0.032 0.045-0.060 Thermal conductivity
(w / mk) 0.024 0.034 0.034-0.04 0.035-0.04 0.022-0.025 - Heat permeation resistance
(m ² / kw) 2.1 2.205 2.142 2.142 3.409 - Heat transmission rate
(w / m ² k) 0.48 0.454 0.466 0.466 0.293 - Gas Hazard Standard conformity CO gas generation during combustion Standard conformity Standard conformity CO gas generation during combustion Standard conformity Specific gravity (g / cm ³ )
- 0.012-0.032 0.01-0.16 0.024-0.04 0.032 0.045-0.060 Absorbency (%)
- 0.7 2 2 - 2-3 Capillary phenomenon
- none none none none - Flame resistant
- Flammability Non-combustible Non-combustible Flammability Non-combustible Flame propagation
- Self-extinguishing 15-20 15 30-50 none Smoke
- 10-400 0-20 none 55-550 none Hazardous combustion
- Toxic Gas Slightly harmful none Toxic Gas none Toxic Gas
Kinds - HCN, CO Adhesive ingredient Adhesive components HCN, CO none combustibility
- Combustion Flame Retardant Nonflammable Combustion Nonflammable Safe operating temperature (℃) - 70 300 600 180 900

2 is a test report of the water content and bending strength of the board according to an embodiment of the present invention measured by the Korea Institute of Construction Living Environment Test.

3 is a test report of the non-combustibility test and gas hazard test of the board according to an embodiment of the present invention measured by the Korea Institute of Construction Living Environment Test.

As shown in Table 1, Figure 2 and Figure 3, the board prepared in Example 4 has a relatively excellent characteristics compared to the comparison target boards for gas hazard, flame resistance, flame propagation, smoke generation, combustion hazard, combustibility In particular, it showed the highest value of 900 ℃ at the safe operating temperature, the highest resistance to heat.

In addition, as shown in the test report attached to FIG. 3, it was found that the suitability as both a building interior material and an incombustibility and gas harmfulness to the board manufactured in Example 4 was satisfactorily satisfied.

Therefore, the board for building interior materials including the purified sludge and vermiculite according to the present invention not only satisfies all the heat resistance and nonflammability required for the building interior materials, and is very excellent in heat resistance, and thus can be usefully used as a board for building interior materials.

< Experimental Example  2> physical property evaluation

In order to determine the physical properties of the boards prepared in Examples 2, 4, 6 and 8 and the board prepared in Comparative Example 1, the flexural strength, hardness and weight were evaluated.

Specifically, the flexural strength was evaluated according to the test method according to KSP2263-2005, and the hardness was the Rockwell hardness method indicating the required weight when pressing a steel ball of 1.588 mm diameter on the specimen to reach a certain depth of the specimen. Evaluated. The flexural strength, hardness and weight are shown in Table 2 below.

Flexural strength (N / mm ² ) Hardness (kg / cm ² ) Weight (kg) Example 8

Example 6

Example 4

Example 2

Comparative Example 1 6.1

5.4

4.5

3.6

2.8 25.4

17.28

10.84

5.42

3.72 2.9

2.7

2.5

2.4

2.3

As shown in Table 2, it was found that the higher the content of the purified sludge, the higher the flexural strength, hardness, and weight. In particular, the bending strength of the board manufactured in Example 8 was 2.17 times improved, the hardness was improved 6.8 times, and the weight was increased 1.26 times compared to the board prepared in Comparative Example 1.

Therefore, the board for building interior materials including the purified sludge and vermiculite according to the present invention not only significantly improves the bending strength and hardness, but also adjusts the mixing ratio of the purified sludge and vermiculite, so that a board having a desired weight can be obtained. It can be usefully used.

Claims (13)

10-90% by weight of purified sludge and 90-10% by weight of vermiculite are simultaneously calcined or separately calcined and mixed at 500-1,000 ° C., and then 0.1-30% by weight of inorganic adhesive based on 100 parts by weight of the mixture of the calcined purified water sludge and vermiculite Adding parts to prepare a mixture (step 1);
Forming a board by molding the mixture prepared in step 1 (step 2); And
A board for building interior materials having improved hardness and bending strength, including purified sludge and vermiculite, which is manufactured according to a manufacturing method including a step of drying the board formed at step 2 at a high temperature.
The method of claim 1,
The purified water sludge is a building interior board, characterized in that generated from the water treatment process.
The method of claim 1,
In step 1, the purified sludge is 30-80% by weight and vermiculite is 70-20% by weight of the building interior board.
The method of claim 1,
In step 1, the purified sludge is 50-70% by weight and vermiculite is 50-30% by weight of the building interior board.
The method of claim 1,
In step 1, the purified sludge is 60% by weight and vermiculite is characterized in that 40% by weight board.
The method of claim 1,
The firing temperature of the purified water sludge in the step 1 is 950 ℃ building board.
The method of claim 1,
The firing temperature of the vermiculite in the step 1, characterized in that the board for building interior materials.
delete delete The method of claim 1,
The clean water sludge used in step 1 further comprises a drying step of lowering the water content to 20-50% before passing through the firing step.
The method of claim 1,
Vermiculite used in the step 1 further comprises the step of pulverizing before going through the firing step. delete delete

Images