KR101847708B1 - Method for manufacturing light weight artificial stone having high intensity using stone sludge and bentonite - Google Patents

Abstract

The present invention relates to a high-strength lightweight artificial stone using stone sludge and bentonite and a method of manufacturing the same, and a high strength and lightweight artificial stone according to the present invention can remarkably reduce manufacturing cost by utilizing waste stone sludge, It has an advantage of being environmentally friendly, and especially, it can reduce the weight of artificial stone by mixing waste stone sludge with bentonite and maintain high strength at the same time. In addition, the artificial stone according to the present invention is advantageous in that it is rapidly solidified in a molding mold, and therefore, the molded article for manufacturing artificial stone can be separated from the molding mold and dried very quickly, There is a very shortening effect. The artificial stone according to the present invention also has the advantage that the surface of the glaze and the paint of various colors are very uniformly applied and colored.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method of manufacturing a high strength lightweight artificial stone using stone sludge and bentonite,

The present invention relates to a method for manufacturing a high strength lightweight artificial stone using stone sludge and bentonite.

Artificial stone (artificial stone) is used variously as interior materials and exterior materials such as buildings or sculptures. In the past, sand, rock crushed materials and pigments were mixed at proper ratios, In particular, yellow and iron oxide (II) were used as mixed pigments in order to give various colors to artificial stones. Portland cement, white portland cement, magnesia cement, water glass, calcium chloride mixed materials and the like were used as binder for manufacturing artificial stone .

However, the artificial stone produced by using the sand and rock crushed material has the problem that the particles are uneven and easily cracked. In particular, there is a problem that it is very difficult to uniformly impart color to the artificial stone. Also, in order to make artificial stones using sand, a large amount of expensive sand is required, and there is also a problem that manufacturing costs of artificial stones increase.

Therefore, various artificial stone materials and manufacturing methods which have uniform particles and can lower the manufacturing cost have been studied variously. In the following Patent Document 1, a method of manufacturing artificial stone using a floor material is disclosed. That is, the following patent document 1 discloses a method for manufacturing an artificial stone for interior use, which is used in a building that exhibits a function of absorbing moisture and absorbing moisture and absorbing a harmful odor by using flooring and activated carbon generated during thermal power generation, Lt; / RTI > However, the artificial stone produced by the manufacturing method disclosed in Patent Document 1 has a limitation in that strength, durability and chemical resistance are lowered by using flooring material generated during thermal power generation, and thus it is difficult to use it as an exterior material other than the interior material of a building.

On the other hand, a large amount of natural stone waste powder and waste sludge are generated in processes such as extraction and processing of natural stone, and it is very high in specific gravity due to the nature of natural stone and is very low in self- For this reason, stone waste powder and waste sludge are disposed of as industrial wastes every year in the landfill or treated as industrial wastes at high cost.

Therefore, there is an urgent need to develop a method for manufacturing artificial stones that can be used as interior materials and exterior materials of buildings, various structures, etc., by utilizing the waste powder of stone and sludge of waste.

Patent Document 1: JP-A-10-0912234

In order to solve the above problems, the present invention has found that the artificial stone for building interior and exterior materials can be manufactured by remarkably reducing the weight by mixing bentonite with stone sludge, and having excellent chemical resistance and strength. .

Therefore, one aspect of the present invention is to provide an artificial stone for an interior and exterior lightweight construction material excellent in chemical resistance and strength and a method of manufacturing the same.

In order to achieve the above-mentioned object, the present invention provides a sludge treatment plant comprising 55 to 65 parts by weight of stone sludge, 20 to 25 parts by weight of bentonite, 10 to 15 parts by weight of potassium sulfate, 5 to 7 parts by weight of potassium borate, 2 to 3 parts by weight of zeolite, 2 to 3 parts by weight of potassium and 20 to 40 parts by weight of water to prepare a suspension;
A molded body forming step of putting the suspension into a mold and applying a vibration at atmospheric pressure to form a molded body;
Drying the molded body by separating the molded body from the molding die and drying it in a drying furnace;
Applying a glaze to the dried molded body;
A printing step of printing various patterns on the molded article to which the glaze is applied; And
And a sintering step of sintering the printed molded article in a roller kiln for 1 to 6 hours in an oxidizing atmosphere of 1,100-1,200 ° C to prepare a high strength lightweight artificial stone using the stone sludge and bentonite do.

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The high strength and lightweight artificial stone according to the present invention has a remarkable advantage of being eco-friendly by using the waste stone sludge which has been treated as industrial waste in the prior art, And it is possible to maintain high strength at the same time. In addition, the artificial stone according to the present invention is advantageous in that it is rapidly solidified in a molding mold, and therefore, the molded article for manufacturing artificial stone can be separated from the molding mold and dried very quickly, There is a very shortening effect. The artificial stone according to the present invention also has the advantage that the surface of the glaze and the paint of various colors are very uniformly applied and colored.

1 is a process diagram schematically showing an entire process of manufacturing a high strength lightweight artificial stone according to an embodiment of the present invention.

Before describing the invention in more detail, it is to be understood that the words or words used in the specification and claims are not to be construed in a conventional or dictionary sense, It should be interpreted as meaning and concept consistent with the technical idea of the present invention. Therefore, the constitution of the embodiments described in the present specification is merely a preferred example of the present invention, and does not represent all the technical ideas of the present invention, so that various equivalents and variations And the like.

Hereinafter, preferred embodiments of the present invention will be described in detail so that those skilled in the art can easily carry out the present invention.

The present invention relates to an artificial stone for building interior and exterior materials having remarkably reduced chemical resistance and strength by mixing bentonite with stone sludge, and a method for producing the same. In particular, bentonite is added to stone sludge in order to reduce weight and maintain high strength. .

At the stage of processing the natural stone used as the material of various building interior and exterior materials and various structures into the standardized plate form, a great amount of the stone is produced as a by-product. In other words, a natural stone plate having a commercial property is obtained by cutting the natural stone native rock with a certain thickness and width using a processing saw blade or the like. In order to cool the natural stone plate to cut using metal and industrial diamond saw blades As the water is continuously supplied, the stone is cut, so that at least the volume of stone corresponding to the thickness of the saw blade is discharged in the form of powder, and such stone powder is discharged in the form of stone sludge by mixing with water.

Such waste stone sludge has not been used specifically and has been treated as simple industrial waste, and therefore, environmental pollution and high cost of industrial waste treatment have been constantly raised as a problem.

In particular, when the waste stone sludge is re-hardened and dried to measure its weight, the weight of the waste stone sludge is greater than that of the native rock. Therefore, it is costly to manufacture various artificial stones by recycling them, There was a limit in terms of.

Accordingly, the present inventor has developed a groundbreaking technique for manufacturing artificial stones that can be used as interior and exterior materials of various buildings and plates of various structures by recycling such waste stone sludge. The present invention reduces the weight of the waste stone sludge And the bentonite is mixed to maintain high strength.

The stone sludge used in the present invention may use marble stone sludge, granite stone sludge, or limestone stone sludge.

Bentonite is a highly expansive clay mineral whose name comes from the Fort Benton mine in Wyoming, USA. Geologically, bentonite is one of the volcanic materials that has been produced since the inhabitants of the Cretaceous and Mesozoic ammonites and dinosaurs. Most commercial minerals are produced by hydrolyzing volcanic rocks or ash.

The bentonite used in the present invention is preferably in powder form.

The high strength lightweight artificial stone of the present invention comprises 55 to 65 parts by weight of stone sludge, 20 to 25 parts by weight of bentonite, 10 to 15 parts by weight of potassium sulfate, 5 to 7 parts by weight of potassium borate, 2 to 3 parts by weight of zeolite, 3 parts by weight.

In particular, when the content of the stone sludge is less than 55 parts by weight, the strength of the artificial stone is lowered and the manufacturing cost is increased. When the amount of the stone sludge is more than 65 parts by weight, There is a problem that is growing too much.

If the content of bentonite is less than 20 parts by weight, the weight of the artificial stone is increased, and the degree to which the stone sludge, bentonite and other components are gelled to each other is lowered. When the content of bentonite is more than 25 parts by weight, the strength of the artificial stone is lowered and the manufacturing cost is increased.

Bentonite has the property of absorbing 5 to 10 times its own weight of water, and the water-absorbing bentonite is characterized by expanding and gluing other components. That is, the bentonite has a function of complementing the low viscosity of the components used for producing the artificial stone and helping the components easily mix and coagulate while mixing them. Thus, the artificial stone according to the present invention is very short So that it can be formed into a molded article to such an extent that the shape can be maintained in time.

In addition, when bentonite used in the present invention is mixed with stone sludge or the like to make a suspension, the suspension produced in this way exhibits a function of maintaining a state in which the suspension component is not precipitated even after prolonged time has elapsed. Accordingly, the use of bentonite has the advantage that the suspension for manufacturing artificial stones can be preserved for a long time without being continuously stirred.

The potassium sulfate used in the present invention exerts the function of further improving the cohesion of various components for producing artificial stone of the present invention. When the content of potassium sulfate is less than 10 parts by weight, the cohesion of components for producing artificial stone is lowered. When the content of potassium sulfate exceeds 15 parts by weight The strength of the artificial stone is deteriorated.

The potassium borate used in the present invention exhibits a function of further enhancing cohesion of various components for producing artificial stone of the present invention together with potassium sulfate. When the content of potassium borate is less than 5 parts by weight, the cohesion of components for producing artificial stone is lowered. When the content of potassium borate exceeds 7 parts by weight The strength of the artificial stone is deteriorated.

The zeolite used in the present invention exerts a natural deodorant and air filtering function and is included in the artificial stone of the present invention to exhibit a function of adsorbing various odor components contained in the room air and a function of adsorbing and removing various soot substances do. The zeolite used in the production of artificial stone of the present invention is included in 2 to 3 parts by weight, and when it is less than 2 parts by weight, the deodorizing function and the contaminant removing function are lowered, and when it exceeds 3 parts by weight, it is uneconomical.

The potassium silicate used in the present invention exerts a quick-setting function, and the artificial stone of the present invention plays a role of shortening the manufacturing time. The potassium silicate used in the artificial stone of the present invention is contained in an amount of 2 to 3 parts by weight. When the amount of the potassium silicate exceeds 2 parts by weight, the coagulation time of the artificial stone becomes longer. When the amount is more than 3 parts by weight, There is a problem that the fluidity may be deteriorated when put into a mold.

The artificial stone according to the present invention may further include various pigments according to various purposes, and the kind of pigment is not particularly limited and may include various pigment components conventionally used in the production of artificial stone. The pigment may preferably be contained in an amount of 1 to 5 parts by weight.

A concrete manufacturing method of a high strength lightweight artificial stone according to the present invention is as follows.

The method of manufacturing artificial stone according to the present invention comprises the steps of: 55 to 65 parts by weight of stone sludge, 20 to 25 parts by weight of bentonite, 10 to 15 parts by weight of potassium sulfate, 5 to 7 parts by weight of potassium borate, 2 to 3 parts by weight of zeolite, To 3 parts by weight and 20 to 40 parts by weight of water to prepare a suspension; A molded body forming step of putting the suspension into a mold and applying a vibration at atmospheric pressure to form a molded body; Drying the molded body by separating the molded body from the molding die and drying it in a drying furnace; Applying a glaze to the molded body dried after the drying step; A printing step of printing various patterns on the molded article to which the glaze is applied; And a plastic forming step of firing the printed molded article in an oxidizing atmosphere.

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At this time, the glaze application can be performed at 120 to 180 gr / cm 2, and after the glaze is applied, the printing paste is selected according to the design and printed with a silk screen or in a Roto color, It is possible to print with a printing machine.

In addition, the artificial stone manufacturing method according to the present invention may further include a step of plastic-working it at a high temperature after the drying step, the glaze applying step or the printing step.

The calcining step may be performed by calcining the artificial stone compact in a calcining kiln in an oxidizing atmosphere at a calcining temperature of about 1,100 to 1,200 ° C and for about 1 to 6 hours.

The artificial stone according to the present invention can be completed through such a plastic working step.

Hereinafter, concrete examples of producing a high strength and lightweight artificial stone according to the present invention and comparative examples in which the effects of the present invention can be comparatively confirmed will be described. However, the scope of the present invention is not limited to the following examples.

Examples 1 to 5

After 24 hours of sedimentation of the waste stone sludge from the process of granite cutting, 60 kg of precipitated stone sludge as a lower layer was prepared by removing all the water present in the upper layer. 20 kg of bentonite powder purchased from AMCOL Co., 13 kg of potassium sulfate, 6 kg of potassium borate, 3 kg of zeolite and 3 kg of potassium silicate were mixed with the above stone sludge precipitate, 30 L of water was added thereto and stirred evenly using a stirrer To make a suspension.

The thus prepared suspension was placed in a mold having dimensions of 50 cm x 3 cm x 50 cm each of the width, length and depth of the inner space, and was stored at 25 DEG C for 1 hour to 5 hours (Example 1: : 2 hours, Example 3: 3 hours, Example 4: 4 hours, Example 5: 5 hours).

Thereafter, the mold was removed, and an artificial stone compact having dimensions of 50 cm x 3 cm x 50 cm in width x length x depth was collected, dried in an oven at about 100 ° C, and dried for about 5 hours.

Examples 6 to 10

The artificial stone compacts prepared through Examples 1 to 5 were each fired in a firing kiln at 1,100 ° C for about 5 hours, and artificial stones were produced through the same procedure (in the same manner as in Example 6 To 10 artificial stones).

Comparative Examples 1 to 5

After 24 hours of sedimentation of the waste stone sludge from the process of granite cutting, 60 kg of precipitated stone sludge as a lower layer was prepared by removing all the water present in the upper layer. On the other hand, 13 kg of potassium sulfate, 6 kg of potassium borate, 3 kg of zeolite and 3 kg of potassium silicate were mixed with the stone sludge precipitate, 30 L of water was added thereto, and the mixture was stirred evenly using a stirrer.

The thus-prepared mixture was placed in a mold having dimensions of 50 cm x 3 cm x 50 cm in width × depth × depth of the internal space, and the mixture was stirred at 25 ° C. for 1 hour to 5 hours (Comparative Example 1: : 2 hours, Comparative Example 3: 3 hours, Comparative Example 4: 4 hours, Comparative Example 5: 5 hours).

Thereafter, the mold was removed, and an artificial stone compact having dimensions of 50 cm x 3 cm x 50 cm in width x length x depth was collected, dried in an oven at about 100 ° C, and dried for about 5 hours.

Comparative Examples 6 to 10

The artificial stone compacts prepared in Comparative Examples 1 to 5 were each fired in a firing kiln at 1,100 ° C for about 5 hours to produce artificial stones (Comparative Example 1 to 5) To 10 artificial stones).

[Compressive strength test]

According to KS F2519-2000, the compressive strengths of the artificial stones prepared in Examples 1 to 10 and Comparative Examples 1 to 10 were measured, and the results are shown in Table 1 below.

[Specific Gravity Test]

According to KS F 2518, the specific gravity of the artificial stones prepared in Examples 1 to 10 and Comparative Examples 1 to 10 was measured, and the results are shown in Table 1 below.

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Compressive strength (kgf / ㎠) importance Example 1 280 2.3 Example 2 285 2.3 Example 3 284 2.3 Example 4 282 2.3 Example 5 281 2.3 Example 6 315 2.3 Example 7 321 2.3 Example 8 325 2.3 Example 9 322 2.3 Example 10 323 2.3 Comparative Example 1 230 2.7 Comparative Example 2 214 2.7 Comparative Example 3 221 2.7 Comparative Example 4 218 2.7 Comparative Example 5 212 2.7 Comparative Example 6 254 2.7 Comparative Example 7 255 2.7 Comparative Example 8 249 2.7 Comparative Example 9 245 2.7 Comparative Example 10 248 2.7

As can be seen from the results of Table 1, the artificial stones of Examples 1 to 5 are significantly superior in compressive strength to the artificial stones of Comparative Examples 1 to 5, and the artificial stones of Examples 6 to 10 and the artificial stones of Comparative Examples 6 to 10 It can be confirmed that the compression strength is remarkably higher than that of Comparative Example.

In particular, it can be confirmed that the artificial stones of Examples 1 to 5 are more excellent in compression strength than the artificial stones of Comparative Examples 6 to 10 which have undergone the sintering step.

The results of Table 1 show that the artificial stones of Examples 1 to 10 are significantly lighter in weight than the artificial stones of Comparative Examples 1 to 10.

[Glaze application test]

The glaze was applied to the surfaces of the artificial stones of Examples 1 to 10 and Comparative Examples 1 to 10 at a rate of 150 gr / cm 2, and about 5 hours later, the application state of the glaze was visually observed, The results are shown in Table 2 below. ≪ tb > < TABLE > Id = Table 2 Columns = 2 < tb >

[Paint tinting test]

The stone paint of Examples 1 to 10 and Comparative Examples 1 to 10 was applied at a rate of 150 gr / cm 2, and after about 5 hours, the coloring state of the paint was visually observed to obtain grades 1 to 5 The results are shown in Table 2 below. ≪ tb > < TABLE > Id = Table 2 Columns = 2 < tb >

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Glaze application test Paint tinting test Example 1 One One Example 2 One One Example 3 One One Example 4 One One Example 5 One One Example 6 One One Example 7 One One Example 8 One One Example 9 One One Example 10 One One Comparative Example 1 4 3 Comparative Example 2 3 4 Comparative Example 3 4 3 Comparative Example 4 3 4 Comparative Example 5 3 3 Comparative Example 6 3 3 Comparative Example 7 4 4 Comparative Example 8 3 3 Comparative Example 9 3 4 Comparative Example 10 4 3

As can be seen from the results of Table 2, the artificial stones of Examples 1 to 10 are significantly superior to the artificial stones of Comparative Examples 1 to 10 in glaze application power.

In addition, the results of Table 2 show that the artificial stones of Examples 1 to 10 are significantly superior in paint coloring power to the artificial stones of Comparative Examples 1 to 10.

[Deformation test of external dimension by moisture]

The artificial stones of Examples 1 to 10 and Comparative Examples 1 to 10 were immersed in water for 7 days and taken out to measure the external strain (%). The results are shown in Table 3 below.

[Chemical resistance test]

The artificial stones of Examples 1 to 10 and Comparative Examples 1 to 10 were immersed in a 25% sulfuric acid aqueous solution for 5 hours and then taken out to measure the surface denaturation. The degree of surface modification was measured according to the degree of chemical resistance. : Excellent, 3: Normal, 4: Bad, 5: Very poor). The results are shown in Table 3 below.

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External strain due to moisture Deformation rate (%) Chemical resistance Example 1 0.1 One Example 2 0.1 2 Example 3 0.1 One Example 4 0.1 2 Example 5 0.05 One Example 6 0.05 One Example 7 0.05 One Example 8 0.05 One Example 9 0.05 One Example 10 0.05 One Comparative Example 1 0.25 4 Comparative Example 2 0.25 4 Comparative Example 3 0.25 4 Comparative Example 4 0.25 4 Comparative Example 5 0.25 4 Comparative Example 6 0.20 3 Comparative Example 7 0.20 3 Comparative Example 8 0.20 3 Comparative Example 9 0.20 3 Comparative Example 10 0.20 3

As can be seen from the results of Table 3, the artificial stones of Examples 1 to 10 were significantly lower in external dimensional strain due to moisture than the artificial stones of Comparative Examples 1 to 10.

The results of Table 3 show that the artificial stones of Examples 1 to 10 are remarkably superior in chemical resistance than the artificial stones of Comparative Examples 1 to 10.

Claims (4)

delete delete 55 to 65 parts by weight of stone sludge, 20 to 25 parts by weight of bentonite, 10 to 15 parts by weight of potassium sulfate, 5 to 7 parts by weight of potassium borate, 2 to 3 parts by weight of zeolite, 2 to 3 parts by weight of potassium silicate, And 40 parts by weight of a water-soluble organic solvent to prepare a suspension;
A molded body forming step of putting the suspension into a mold and applying a vibration at atmospheric pressure to form a molded body;
Drying the molded body by separating the molded body from the molding die and drying it in a drying furnace;
Applying a glaze to the dried molded body;
A printing step of printing various patterns on the molded article to which the glaze is applied; And
And a calcining step of calcining the printed molded body in an oxidizing atmosphere at 1,100-1,200 ° C for 1 to 6 hours by putting the printed molded body in a roller kiln and baking it. delete

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