KR20090068092A - Ultra light weight inorganic fine-grained aggregate and its manufacturing method - Google Patents

Ultra light weight inorganic fine-grained aggregate and its manufacturing method Download PDF

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KR20090068092A
KR20090068092A KR20080016393A KR20080016393A KR20090068092A KR 20090068092 A KR20090068092 A KR 20090068092A KR 20080016393 A KR20080016393 A KR 20080016393A KR 20080016393 A KR20080016393 A KR 20080016393A KR 20090068092 A KR20090068092 A KR 20090068092A
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aggregate
ultra
inorganic fine
manufacturing
molding
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KR100935573B1 (en
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임태영
황종희
김창열
오해곤
지영만
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한국산업기술평가원(관리부서:요업기술원)
한국미부주식회사
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/02Agglomerated materials, e.g. artificial aggregates
    • C04B18/027Lightweight materials
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02Granular materials, e.g. microballoons
    • C04B14/04Silica-rich materials; Silicates
    • C04B14/08Diatomaceous earth
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04Waste materials; Refuse
    • C04B18/06Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
    • C04B18/08Flue dust, i.e. fly ash
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04Waste materials; Refuse
    • C04B18/16Waste materials; Refuse from building or ceramic industry
    • C04B18/165Ceramic waste
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B22/00Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
    • C04B22/06Oxides, Hydroxides
    • C04B22/062Oxides, Hydroxides of the alkali or alkaline-earth metals
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/02Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/40Porous or lightweight materials
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Abstract

A super lightweight fine inorganic aggregate and a manufacture method thereof are provided to improve foamability and intensity while preventing the fine aggregate from getting tangle. A method for manufacturing a super lightweight fine inorganic aggregate comprises the following steps of: aging a raw material containing waste glass powder, foaming agent, organic/inorganic binder and one or more additives selected from the group consisting of an auxiliary agent, diatomite, fly ash and perlite powder; primarily molding the aged material into an aggregate and secondarily molding the aggregate; foaming the aggregate; and fast-cooling the foamed aggregate. The raw material contains sodium hydroxide or not.

Description

초경량 무기질 미립경량골재 및 그의 제조방법{Ultra light weight inorganic fine-grained aggregate and its manufacturing method}Ultra light weight inorganic fine-grained aggregate and its manufacturing method

본 발명은 초경량 무기질 미립경량골재 및 그의 제조방법에 관한 것으로, 종래의 인조골재의 제조방법보다 발포성 및 발포균일화를 향상시키고 엉김을 방지할 수 있게 하며, 제조된 골재의 무게를 감소시키고 강도를 증진시킬 수 있도록 한 초경량 무기질 미립경량골재 및 그의 제조방법에 관한 것이다.The present invention relates to an ultra-light inorganic fine aggregate and its manufacturing method, and to improve the foaming and foam uniformity and prevent entanglement, and to reduce the weight of the aggregate produced and to enhance the strength compared to the conventional manufacturing method of artificial aggregate It relates to an ultra-light inorganic fine particulate aggregate and a method for producing the same.

일반적으로 콘크리트는 건축 및 토목용 재료로서 예전부터 가장 보편적으로 널리 사용되는 것으로, 최근 콘크리트 건축물들이 고층화 및 대형화되어 감에 따라 그 중량을 감소시키기 위한 노력을 하고 있으며, 이에 대한 해결책 중의 하나로서 콘크리트의 재료 중 비중에 가장 큰 영향을 미치고 있는 골재를 경량화하기 위해 많은 노력을 하고 있다. In general, concrete is the most widely used in the past as a building and civil engineering material, and as a result of the recent increase of concrete buildings, the construction of concrete buildings is trying to reduce its weight. Much effort is being made to reduce the weight of aggregates, which have the greatest impact on specific gravity among materials.

아울러, 한정된 골재원 속에서 양질의 콘크리트용 골재를 수급하기가 점차 어려워지고 있으며, 하천으로부터 채취되는 강모래, 강자갈 등의 골재들도 수급 부족현상이 나타나고 있는 실정이다. 따라서 이러한 문제의 해결을 위해 인조경량골재에 대한 관심도가 높아지고 있으며, 특히 구조용 인조경량골재에 대해서는 특히 많은 연구개발이 이루어지고 있는 상황이다. 즉, 이러한 경량골재를 사용하여 경량콘크리트(Lightweight Concrete)를 생산할 수 있으며, 이에 따라 건물의 고층화와 함께 건물의 단열성능향상을 통한 에너지 절감효과와 부족한 천연골재의 의존도를 낮출 수 있다. In addition, it is increasingly difficult to supply high-quality concrete aggregates in a limited aggregate source, and supply and demand aggregates, such as river sand and strong gravel, are collected from rivers. Therefore, in order to solve these problems, interest in artificial lightweight aggregates is increasing, and in particular, many research and developments are being made on artificial lightweight aggregates. In other words, the light weight aggregate can be used to produce light weight concrete. Accordingly, the energy saving effect and the dependence of insufficient natural aggregate can be lowered through the increase of the building's insulation performance along with the increase of the building's height.

또한 선박의 데크(Deck)에는 용접부와 같은 미려하지 못한 부분의 일정 두께(약 7mm)를 마무리하여야 하는데, 예전에는 불연재인 폴리머시멘트나 폴리머와 같은 재료를 사용하여 얇게 도포하여 마감하였으나 시멘트는 비중이 높아 선박의 전체 중량을 감소시키는데 문제점이 있었으며, 폴리머와 같은 경우는 화재시 유독가스의 발생으로 사용치 못하고 있다. In addition, the deck of the ship should be finished with a certain thickness (about 7mm) of unsatisfactory parts such as welded parts. In the past, it was finished by thin coating using non-combustible polymer cement or polymer, but cement has a specific gravity. There was a problem in reducing the overall weight of the vessel, high, such as polymers are not used due to the generation of toxic gases in the fire.

따라서 화재시 문제점이 없으며, 선박의 전체무게를 줄일 수 있고, 시공재료의 강도 향상을 고려하여 시멘트에 무기 질 재료인 경량골재를 채움재로 사용하는 것이 바람직하다고 할 수 있다.Therefore, there is no problem in fire, it is possible to reduce the overall weight of the ship, in consideration of improving the strength of the construction material it can be said that it is preferable to use a lightweight aggregate, which is an inorganic material in cement as a filler.

그러나 기존의 경량골재는 너무 크기 때문에 이를 선박에 적용할 수 없었으며 종래 인조경량골재는 그 원료에 있어서 석탄재(국내특허 공고 제95-8609호)라든가, 석면(국내특허공고 제81-123호), 폐플라스틱(국내특허공고 제80-1056호), 탄광폐석(국내특허공고 제80-1054호), 혈암(국내특허공고제79-1985호), 침전지의 침전물(국내특허공고 제73-166호), 적와용 점토(국내특허공고 제71-242호)등과 같은 폐원료를 위주로 개발하여왔다. 이러한 재료들을 이용하는 것은 폐기물을 재활용하는 방법에 있어서 바람직하다고 할 수 있으나, 경량골재의 입도가 크고 잡다한 폐기물을 원료로 사용하였으므로 비중과 셀의 형태도 매우 불균질한 상태이다. 따라서 상 기와 같은 원료와 방법으로는 제조되는 경량골재의 발포성 및 발포균일화 향상, 엉김 방지 등의 효과를 기대할 수 없으며, 제조되었다 하더라도 대부분 비중이 0.5이상, 크기가 1mm이상일 뿐만 아니라 강도에 있어서도 많은 문제점이 있었다.However, existing lightweight aggregate could not be applied to ships because it is too large. Conventional artificial lightweight aggregates are used as raw materials such as coal ash (Domestic Patent Publication No. 95-8609) or asbestos (Domestic Patent Publication No. 81-123). , Waste plastic (Domestic Patent Publication No. 80-1056), coal mine waste stone (Domestic Patent Publication No. 80-1054), shale (Domestic Patent Publication No. 79-1985), sediment of sedimentation pond (Domestic Patent Publication No. 73-166) ) And waste materials such as red clay (Korean Patent Publication No. 71-242). The use of such materials may be desirable in the method of recycling waste, but since the granularity of light aggregates and miscellaneous wastes are used as raw materials, the specific gravity and the shape of the cells are also very heterogeneous. Therefore, the raw materials and methods as described above can not expect the effect of improving the foaming and foam uniformity of the lightweight aggregate produced, preventing tangling, and even if manufactured, the specific gravity is more than 0.5, the size is not less than 1mm, and many problems in strength as well. There was this.

본 발명은 상술한 문제점을 해결하기 위한 것으로서, 경량골재를 제조하기 위한 원료조성물로 폐 유리 분말을 사용함으로서 환경보호 자원재활용 면에서 우수한 효과를 가질 수 있게 할 뿐만 아니라 숙성공정과 급랭공정이 포함된 개선된 제조방법에 의해 경량골재의 발포성 및 발포균일화 향상, 엉김 방지, 강도증진 등의 효과를 가질 뿐만 아니라 비중 0.2이하, 크기 0.2~0.3mm 이하의 초경량 미립경량골재를 제조할 수 있게 하는데 그 목적이 있다.The present invention is to solve the above problems, by using the waste glass powder as a raw material composition for producing light weight aggregates can not only have an excellent effect in terms of recycling environmental protection resources, but also includes a aging process and quenching process The improved manufacturing method not only has the effect of improving the foamability and foam uniformity of the lightweight aggregate, preventing entanglement, and increasing the strength, but also enables the production of ultra-light fine aggregates having a specific gravity of 0.2 or less and a size of 0.2 to 0.3 mm or less. There is this.

본 발명은 상기의 목적을 달성하기 위하여,폐 유리 분말, 발포제 및 성형조제로서 유기 또는 무기 바인더로 되는 필수성분과, 반응조제, 규조토, 플라이애쉬 및 퍼라이트분말로 이루어진 군에서 선택되는 1종 또는 2종 이상의 혼합물인 보조첨가제 및 수산화나트륨을 선택성분으로 함유하는 원료 조성물을 숙성시키고, 상기 숙성된 원료조성물을 1차 성형하여 응집체를 제조하고 2차 성형하여 발포시킨 후, 상기 발포된 응집체를 급랭시키는 초경량 무기질 미립경량골재의 제조방법을 제공한다.In order to achieve the above object, the present invention, one or two selected from the group consisting of an essential ingredient consisting of an organic or inorganic binder as a waste glass powder, a blowing agent and a molding aid, and a reaction aid, diatomaceous earth, fly ash and perlite powder. Aging raw material composition containing a supplementary additive and sodium hydroxide, which are mixtures of species or more, as an optional ingredient, firstly molding the matured raw material composition to prepare agglomerates, secondly molding and foaming, and then quenching the expanded agglomerates Provided is a method for producing an ultra-light inorganic fine particulate aggregate.

또한, 본 발명은 상기의 목적을 달성하기 위하여, 상기 제조방법에 의해 제조된 초경량 무기질 미립경량골재를 제공한다.In addition, the present invention provides an ultra-light inorganic fine particulate aggregate produced by the above production method in order to achieve the above object.

상기 초경량 무기질 미립경량골재의 제조방법에 있어서, 상기 필수성분은, 고형분 기준으로 폐 유리 분말 70~95중량%, 발포제 4~20 중량% 및 성형조제로서 유 기 또는 무기 바인더 1~10중량%로 이루어지는 실시예를 구성할 수 있다.In the method for producing the ultra-light inorganic fine aggregate, the essential component is 70 to 95% by weight of waste glass powder, 4 to 20% by weight of blowing agent and 1 to 10% by weight of organic or inorganic binder as a molding aid. The embodiment made up can be comprised.

또한, 상기 초경량 무기질 미립경량골재의 제조방법에 있어서, 상기 선택성분은, 상기 필수성분 100중량부를 기준으로, 반응조제 1~20중량부, 규조토, 플라이애쉬 및 퍼라이트분말로 이루어진 군에서 선택되는 1종 또는 2종 이상의 혼합물로 되는 보조첨가제 1~40중량부 및 수산화나트륨 1~20중량부로 이루어지는 실시예를 구성할 수 있다.In addition, in the manufacturing method of the ultra-light inorganic fine aggregate, the optional component, based on 100 parts by weight of the essential components, 1 to 20 parts by weight of the reaction aid, diatomaceous earth, fly ash and perlite powder is selected from the group consisting of 1 The embodiment which consists of 1-40 weight part of supplementary additives which consists of a species or 2 or more types of mixtures, and 1-20 weight part of sodium hydroxide can be comprised.

또한, 상기 초경량 무기질 미립경량골재의 제조방법에 있어서, 상기 원료 조성물의 숙성은, 65~120℃에서 1~3시간 숙성시키는 실시예를 구성할 수 있다.In addition, in the production method of the ultra-light inorganic fine particulate aggregate, the maturation of the raw material composition, may be configured to the embodiment aged for 1 to 3 hours at 65 ~ 120 ℃.

또한, 상기 초경량 무기질 미립경량골재의 제조방법에 있어서, 상기 1차 성형은, 상기 숙성된 원료 조성물을 로타리킬른에 공급하여 300~450℃의 온도에서 성형하는 실시예를 구성할 수 있다.In addition, in the manufacturing method of the ultra-light inorganic fine particulate aggregate, the primary molding, it is possible to form an embodiment of molding at a temperature of 300 ~ 450 ℃ by supplying the aged raw material composition to the rotary kiln.

또한, 상기 초경량 무기질 미립경량골재의 제조방법에 있어서, 상기 2차 성형은, 상기 1차 성형 후, 제조된 응집체를 로타리킬른에서 800℃~1100℃의 온도로 성형하는 실시예를 구성할 수 있다.In addition, in the manufacturing method of the ultra-light inorganic fine aggregate, the secondary molding, after the primary molding, may be configured to form an embodiment of the aggregate formed in the rotary kiln at a temperature of 800 ℃ ~ 1100 ℃. .

또한, 상기 초경량 무기질 미립경량골재의 제조방법에 있어서, 상기 2차 성형은, 유리보다 고온에서 소결되는 세라믹계 이형제를 투입하여 수행하는 실시예를 구성할 수 있다.In addition, in the manufacturing method of the ultra-light inorganic fine particulate aggregate, the secondary molding may be configured to perform an embodiment by adding a ceramic-based release agent sintered at a higher temperature than glass.

또한, 상기 초경량 무기질 미립경량골재의 제조방법에 있어서, 상기 발포된 응집체의 급랭은, 급랭기를 이용하여, 급랭기의 입구온도 750℃~800℃ 출구온도 40℃~60℃하에서 급랭시키는 실시예를 구성할 수 있다.Further, in the method for producing the ultra-light inorganic fine aggregate, the rapid cooling of the foamed aggregate is an embodiment of rapid cooling at the inlet temperature 750 ℃ ~ 800 ℃ outlet temperature 40 ℃ ~ 60 ℃ of the quench machine. Can be configured.

또한, 상기 급랭공정에 사용되는 급랭기는 회전하는 튜브형의 수랭식 급랭기를 사용하는 실시예를 구성할 수 있다.In addition, the quenching machine used in the quenching step may constitute an embodiment using a rotating tubular water-cooled quencher.

본 발명에 의하면, 발포성 및 발포균일화 향상, 엉김 방지, 강도증진 등의 효과를 가지면서도 비중 0.2이하, 크기 0.2~0.3mm 이하의 초경량 미립경량골재를 제조할 수 있게 할 뿐만 아니라 원료 조성물로서 폐유리 및 무기질 폐부산물 등을 이용함으로서, 환경보호 및 자원재활용면에서도 우수한 효과를 가질 수 있게 하는 등의 이점을 얻을 수 있게 된다.According to the present invention, it is possible to prepare ultra-light fine aggregates having a specific gravity of 0.2 or less and a size of 0.2 to 0.3 mm or less while having the effects of improving foaming and foam uniformity, preventing entanglement, and increasing strength, as well as waste glass as a raw material composition. And by using the inorganic waste by-products, etc., it is possible to obtain advantages such as to have an excellent effect in terms of environmental protection and resource recycling.

상기 본 발명의 목적과 특징 및 장점은 첨부도면 및 다음의 상세한 설명을 참조함으로서 더욱 쉽게 이해될 수 있을 것이다.The objects, features and advantages of the present invention will be more readily understood by reference to the accompanying drawings and the following detailed description.

이하, 첨부된 도면을 참조하여 본 발명의 바람직한 실시예의 구성 및 그 작용 효과에 대해 상세히 설명하면 다음과 같다.Hereinafter, with reference to the accompanying drawings will be described in detail the configuration and effect of the preferred embodiment of the present invention.

도 1은 본 발명의 일 실시예에 따른 초경량 무기질 미립경량골재의 제조방법의 공정도로서, 본 발명은 도시된 바와 같이, 필수성분과 선택성분을 함유한 원료조성물을 숙성시키고, 상기 숙성된 원료조성물을 1차 성형하여 응집체를 제조하고 2차 성형하여 발포시킨 후, 상기 발포된 응집체를 급랭시켜 초경량 무기질 미립경량골재를 제조하는 것을 특징으로 하되, 상기 필수성분은 폐 유리 분말, 발포제 및 성형조제로서 유기 또는 무기 바인더로 이루어지며, 상기 선택성분은 반응조제, 규조토, 플라이애쉬 및 퍼라이트분말로 이루어진 군에서 선택되는 1종 또는 2종 이상 의 혼합물인 보조첨가제 및 수산화나트륨으로 이루어지는 것을 특징으로 한다.1 is a process chart of the manufacturing method of the ultra-light inorganic fine aggregate aggregate according to an embodiment of the present invention, the present invention is, as shown, to mature the raw material composition containing the essential and optional ingredients, the raw material composition After primary molding to prepare agglomerates and secondary molding to foam, the foamed aggregates are quenched to produce ultra-light inorganic fine particulate aggregate, the essential components are waste glass powder, foaming agent and molding aid It is composed of an organic or inorganic binder, characterized in that the optional component consists of a co-additive and sodium hydroxide, one or two or more selected from the group consisting of reaction aids, diatomaceous earth, fly ash and perlite powder.

상기 필수성분은, 상기 나열한 폐 유리 분말, 발포제 및 성형조제로서 유기 또는 무기 바인더의 혼합비율을 다양하게 적용할 수 있으나, 일 실시예로서, 고형분 기준으로 폐 유리 분말 70~95중량%, 발포제 4~20 중량% 및 성형조제로서 유기 또는 무기 바인더 1~10중량%로 이루어지는 것이 바람직하며, 그 이유는 상기 성형조제의 함량이 너무 낮으면 부서지기 쉬우므로 성형이 곤란하고, 성형조제의 함량이 너무 많으면 자체 응집 및 설비에 점착 등이 발생하여 성형이 곤란하게 되기 때문이다. 성형조제로 사용되는 유기 또는 무기 바인더는 그예로, 규산 소다(물유리)와 같은 무기 바인더, PVA수용액, 메틸셀룰로오스 수용액 등과 같은 유기 바인더를 사용할 수 있다.The essential component may be variously applied to the mixing ratio of the organic or inorganic binder as the above-mentioned waste glass powder, foaming agent and molding aid, in one embodiment, 70 to 95% by weight of the waste glass powder, foaming agent 4 It is preferably made of 1 to 10% by weight of the organic or inorganic binder as ~ 20% by weight and the molding aid, because the content of the molding aid is too low to be brittle, difficult to mold, the content of the molding aid is too This is because when it is large, self-aggregation and adhesion occur in the equipment, and molding becomes difficult. As the organic or inorganic binder to be used as a molding aid, for example, an inorganic binder such as sodium silicate (water glass), an organic binder such as aqueous PVA solution, aqueous methyl cellulose solution or the like can be used.

상기 선택성분은, 상기 나열한 반응조제, 보조첨가제 및 수산화나트륨의 혼합비율을 다양하게 적용할 수 있으나, 일 실시예로서, 상기 필수성분 100중량부를 기준으로, 반응조제 0~20중량부, 규조토, 플라이애쉬 및 퍼라이트분말로 이루어진 군에서 선택되는 1종 또는 2종 이상의 혼합물로 되는 보조첨가제 0~40중량부 및 수산화나트륨 0~20중량부로 이루어지는 것이 바람직하며, 그 이유는 발포불량 및 성형온도 상승을 방지하는 수산화나트륨의 함량이 너무 많으면 발포 과다 및 강도 저하를 유발할 수 있으며, 보조첨가제의 함량이 지나치게 많으면 기포벽이 과도하게 두꺼워져 발포불량이 발생할 수 있기 때문이다.The optional component may be variously applied to the mixing ratio of the above-described reaction aids, co-additives and sodium hydroxide, as an example, based on 100 parts by weight of the essential components, 0 to 20 parts by weight, diatomaceous earth, It is preferable to consist of 0 to 40 parts by weight of an auxiliary additive and 0 to 20 parts by weight of sodium hydroxide, which are one or two or more mixtures selected from the group consisting of fly ash and perlite powder. If the content of sodium hydroxide to prevent too much can cause excessive foaming and strength reduction, if the content of the auxiliary additives is too large because the bubble wall is excessively thick can cause poor foaming.

상기와 같은 필수 성분과 선택성분을 함유한 원료조성물의 숙성공정은, 발포향상 및 발포균일화를 위한 것으로서, 다양한 조건에서 숙성할 수 있으나, 일 실시 예로 65~120℃에서 1~3시간 숙성시키는 것이 바람직하며, 그 이유는 온도가 120℃ 이상일 경우, 혼합배치의 급격하고 과도한 표면건조로 인해 내/외의 특성 불균일이 발생하며, 입상화과정에서 생성된 과립이 부서지면서 분말상이 많이 발생하여 제품수율이 하락되며, 온도가 65℃ 이하일 경우, 반응온도가 낮아 숙성이 제대로 되지 않으며 숙성을 위한 시간이 많이 필요하게 되어 생산성이 하락되고, 시간이 3시간 이상으로 너무 길 경우, 과도한 건조상태로 인해 과립의 부서짐으로 인한 분말상이 많이 발생하여 제품수율 및 생산성이 하락되며 시간이 1시간 이하로 너무 짧을 경우, 반응시간 부족으로 인해 충분한 숙성효과가 발생하지 않게 되기 때문이다.The aging process of the raw material composition containing the essential and optional ingredients as described above, for foaming improvement and foam homogenization, can be aged under various conditions, but in one embodiment it is aged for 1 to 3 hours at 65 ~ 120 ℃ The reason for this is that when the temperature is 120 ° C. or higher, irregularity of internal and external properties occurs due to the rapid and excessive surface drying of the mixed batch, and the granules produced during the granulation process are broken down so that a lot of powdery phase results in product yield. If the temperature is lower than 65 ℃, the reaction temperature is low, the aging is not properly done, it takes a lot of time for aging, productivity is reduced, if the time is too long more than 3 hours, due to excessive drying conditions of the granules Product yield and productivity decrease due to many powdery phases due to crushing, and reaction time is insufficient when time is too short. It is because due to not enough aging effects occur.

통상 발포유리의 발포원리는 파유리분말에 발포제가 침투된 상태에서 열이 가해짐에 따라 발포제가 분해되면서 가스를 발생시켜 기공이 형성되는 것으로, 기존의 제조공정에서는 발포제인 인산칼슘(또는 액체인산칼슘)이 충분히 분말유리에 침투되어 반응할 수 있는 시간을 갖지 못함에 따라 발포의 정도나 균일성에서 미흡한 부분이 있었으나 본 발명의 상기 일 실시예에 따른 상기 제조방법에서는 발포제와 분말유리가 혼합된 후, 온도 65~120℃ 범위에서 1~3시간 정도 숙성이 이루어짐에 따른 발포향상에 따라 비중 0.2이하(0.10~0.20)의 초 경량제품도 제조가 가능해질 뿐만 아니라 발표균일화 향상에 따라, 도 2에 도시된 미립경량골재의 상태와 도 3에 도시된 본 발명의 초경량 무기질 미립경량골재의 상태의 비교를 통해 알 수 있듯이, 발포제와 유리분말과의 반응 균일화로 인해 내부의 기공크기 및 분포가 균일하게 나타날 수 있게 된다.In general, the foaming principle of the foamed glass is to form gas as the foaming agent decomposes as heat is applied while the foaming agent penetrates the cullet powder, thereby generating pores. In the conventional manufacturing process, calcium phosphate (or liquid phosphate), which is a foaming agent, is formed. As calcium did not sufficiently penetrate into the powder glass and did not have time to react, there was a lack of foaming degree or uniformity, but in the manufacturing method according to the embodiment of the present invention, the blowing agent and the powder glass were mixed. Afterwards, according to the expansion of foaming as it is aged for 1 to 3 hours in a temperature range of 65 to 120 ° C., ultra-light weight products having a specific gravity of 0.2 or less (0.10 to 0.20) can be manufactured, as well as improved uniformity of presentation, FIG. 2. As can be seen from the comparison of the state of the particulate light aggregate shown in the state of the ultra-light inorganic fine aggregate of the present invention shown in Figure 3, the blowing agent and the glass powder The reaction with uniform pore size and because of the distribution of the interior of and is able to receive a uniform.

상기 1차 성형은, 성형을 통해 구형의 응집체를 얻기 위한 것으로서, 다양한 설비와 조건을 적용하여 성형할 수 있으나, 일 실시예로서, 로타리킬른에 공급하여 300~450℃의 온도에서 성형하는 것이 바람직하며, 그 이유는 1차 성형온도가 너무 낮으면 응집력이 약해 성형강도가 낮아져 쉽게 부서질 수 잇으며, 너무 높으면 성분간 2차 반응(발포)하여 골재제조가 불가능하게 된다.The primary molding is to obtain spherical aggregates through molding, and can be molded by applying various equipment and conditions. As an example, the primary molding is preferably supplied at a rotary kiln and formed at a temperature of 300 to 450 ° C. The reason is that if the primary molding temperature is too low, the cohesive strength is weak and the molding strength can be easily broken, and if too high, the secondary reaction between the components (foaming) makes it impossible to produce aggregate.

상기 2차 성형은, 상기 1차 성형에 의해 얻어진 구형의 응집체를 발포시키기 위한 것으로서, 다양한 설비와 조건을 적용하여 성형할 수 있으나, 실시예로서, 상기 1차 성형 후, 제조된 응집체를 로타리킬른에서 800℃ 이상 1100℃ 이하의 온도로 성형하는 것이 바람직하며, 그 이유는 2차 성형 시, 유리가 연화되고 소결됨과 동시에 발포제가 분해하면서 가스성분을 방출하게 되고 방출된 가스는 소결된 미립자의 내부에 미세한 셀을 형성하게 되는데 상기 2차 성형 시, 온도가 너무 낮으면 발포가 제대로 이루어지지 않아 비중이 과다하게 되고 경량골재의 제조가 불가능하게 되며, 너무 높으면 과도한 액상생성으로 형태유지가 곤란하고 점착 등이 발생할 수 있기 때문이다.The secondary molding is for foaming spherical aggregates obtained by the primary molding, and may be molded by applying various facilities and conditions. As an example, after the primary molding, the produced aggregates are rotary kiln. It is preferable to mold at a temperature of 800 ° C. or higher and 1100 ° C. or lower, because in the second molding, the glass softens and sinters, and at the same time, the blowing agent decomposes, releasing gas components, and the released gas is released into the sintered fine particles. In the second molding, when the temperature is too low, the foaming is not properly performed, the specific gravity becomes excessive, and the production of lightweight aggregate becomes impossible. If the temperature is too high, it is difficult to maintain the shape due to excessive liquid production and adhesion. Etc. may occur.

또한, 상기 2차 성형에서 상기 유리가 소결되면서 응집체들이 들러붙을 수 있게 되는데, 이를 방지하기 위하여 유리보다 고온에서 소결되는 세라믹계 이형제를 투입하여 수행하는 것이 바람직하며, 세라믹계 이형제로서 지르콘샌드, 카올린 뿐만 아니라 유리보다 높은 온도에서 소결되는 저가의 일반 세라믹 분말을 사용하여도 된다. 한편, 상기 사용된 이형제는 재사용 가능하며, 이로 인해 제조비용을 감소시킬 수 있다.In addition, in the secondary molding, the glass is sintered so that aggregates may be stuck to each other. In order to prevent this, it is preferable to carry out by introducing a ceramic mold release agent which is sintered at a higher temperature than glass, and zircon sand and kaolin as a ceramic mold release agent. In addition, a low cost general ceramic powder may be used which is sintered at a higher temperature than glass. On the other hand, the release agent used is reusable, thereby reducing the manufacturing cost.

상기 1차 성형 및 2차 성형은 각기 다른 로탈리킬른에서 수행해도 되지만 제 조비용 절감을 위해 단일 로타리킬른에서 1차 성형에 이어 2차 성형을 수행하는 것도 가능하다. The first molding and the second molding may be performed in different rotary kilns, but in order to reduce manufacturing costs, it is also possible to perform secondary molding followed by primary molding in a single rotary kiln.

상기 발포된 응집체의 급랭공정은, 경량골재의 발포향상, 강도증진 및 엉김방지를 위한 공정으로서, 통상 발포향상은 발포된 골재의 서랭으로 인한 골재내부의 기공 수축방지를 통해서 가능하며, 강도향상은 유리의 표면 급랭에 따른 표면압축응력형성으로 인한 강화원리에 의해 가능하고, 엉김방지 역시 표면부 급랭으로 인한 표면수축 및 미세크랙발생으로 인한 분리효과에 의해 가능한데, 본 발명에서는 일 실시예로서, 소성/발포 공정에서 연결된 튜브형 회전설비를 이용해서 입구온도 750~800℃에서 약 20~30분 만에 40~50℃로 냉각함으로서, 팽창된 골재가 순간적 급랭으로 인해 부피축소가 방지되면서 발포상태가 유지되어 비중이 낮은 초 경량골재(비중 0.2이하)의 제조가 가능해지며, 연화점 이상의 고온에 있다가 급격한 표면냉각이 이루어지면 내/외부와의 온도차로 인해 표면에 압축응력이 형성되게 되어 강도가 향상되고, 급랭이 이루어지면서 표면부 수축 및 미세 크랙으로 인한 표면분리가 발생하여 엉김을 방지할 수 있게 된다.The quenching process of the foamed aggregate is a process for improving the foam, strength and preventing entanglement of light weight aggregates, usually foaming is possible through the prevention of pore shrinkage in the aggregate due to the slow cooling of the foamed aggregate, the strength is improved It is possible by the reinforcing principle due to the formation of surface compression stress due to the surface quenching of the glass, and also to prevent entanglement is possible by the separation effect due to surface shrinkage and microcracks generated by the surface quenching, in one embodiment of the present invention, Cooling to 40 ~ 50 ℃ in 20 ~ 30 minutes at inlet temperature of 750 ~ 800 ℃ by using the tubular rotary equipment connected in the foaming process, the expanded aggregate prevents volume reduction due to instant quenching and maintains the foaming state. It is possible to manufacture ultra-light weight aggregate (low specific gravity 0.2 or less) with low specific gravity. Is due to the temperature difference between the portion to be a compressive stress formed in the surface strength is improved, so that the quench be done As prevent surface portion by shrinkage and flocculation is separated from the surface caused by micro-cracks.

한편, 상기 급랭공정을 수행하기 위해 다양한 설비 및 조건의 적용이 가능하나 일 실시예로서, 회전하는 튜브형의 수랭식 급랭기를 사용하는 것이 가능하고, 냉각 및 체류시간은 20~30분 범위에서 유지될 수 있게 하는 것이 바람직하며, 그 이유는 상기 냉각 및 체류시간을 30분 이상으로 관리할 경우, 냉각속도가 낮아 냉각효과가 미흡하며, 20분 이하로 급랭할 경우 급격한 냉각으로 인해 오히려 경량골재 표면에 과도한 크랙이 발생하여 강도를 저하시킬 수 있기 때문이다.On the other hand, it is possible to apply a variety of equipment and conditions to perform the quenching process, but in one embodiment, it is possible to use a rotating tube-type water-cooled quenching machine, the cooling and residence time can be maintained in the range 20 to 30 minutes The reason is that if the cooling and dwelling time is maintained at 30 minutes or more, the cooling rate is low, so the cooling effect is insufficient. This is because cracks may occur to lower the strength.

또한, 이상에서 설명한 본 발명은 전술한 실시예 및 첨부된 도면에 의해 한정되는 것은 아니고, 본 발명의 기술적 사상을 벗어나지 않는 범위내에서 여러가지 치환, 변형 및 변경이 가능함은 본 발명이 속하는 기술분야에서의 통상의 지식을 가진 자에게 있어 명백할 것이다.In addition, the present invention described above is not limited to the above-described embodiments and the accompanying drawings, and various substitutions, modifications, and changes are possible within the scope of the technical idea of the present invention. It will be apparent to those of ordinary skill in the art.

도 1은 본 발명의 일 실시예에 따른 초경량 무기질 미립경량골재의 제조방법의 공정도1 is a process chart of the manufacturing method of ultra-light inorganic fine particulate aggregate according to an embodiment of the present invention

도 2는 종래의 미립경량골재의 상태를 전자현미경으로 촬영한 사진Figure 2 is a photograph taken with an electron microscope of the state of the conventional fine aggregate aggregate

도 3은 본 발명의 일 실시예에 따른 초경량 무기질 미립경량골재의 상태를 전자현미경으로 촬영한 사진Figure 3 is a photograph taken with an electron microscope of the state of the ultra-light inorganic fine particulate aggregate according to an embodiment of the present invention

Claims (10)

폐 유리 분말, 발포제 및 성형조제로서 유기 또는 무기 바인더로 되는 필수성분과, 반응조제, 규조토, 플라이애쉬 및 퍼라이트분말로 이루어진 군에서 선택되는 1종 또는 2종 이상의 혼합물인 보조첨가제 및 수산화나트륨을 선택성분으로 함유하는 원료 조성물을 숙성시키고,As waste glass powders, foaming agents and molding aids, an essential ingredient consisting of an organic or inorganic binder, a co-additive and sodium hydroxide which are one or two or more mixtures selected from the group consisting of reaction aids, diatomaceous earth, fly ash and perlite powder are selected. Aging raw material composition to be contained as a component, 상기 숙성된 원료조성물을 1차 성형하여 응집체를 제조하고 2차 성형하여 발포시킨 후,After the aged raw material composition is primary molded to produce an aggregate and secondary molded and foamed, 상기 발포된 응집체를 급랭시키는To quench the foamed aggregates 초경량 무기질 미립경량골재의 제조방법.Ultra-light inorganic fine aggregate aggregate manufacturing method. 제 1항에 있어서, The method of claim 1, 상기 필수성분은,The essential ingredient, 고형분 기준으로 폐 유리 분말 70~95중량%;70-95% by weight of waste glass powder on a solids basis; 발포제 4~20 중량% 및 4-20 wt% of blowing agent and 성형조제로서 유기 또는 무기 바인더 1~10중량%로 이루어지는1 to 10% by weight of an organic or inorganic binder as a molding aid 초경량 무기질 미립경량골재의 제조방법.Ultra-light inorganic fine aggregate aggregate manufacturing method. 제 1항에 있어서,The method of claim 1, 상기 선택성분은,The optional ingredient, 상기 필수성분 100중량부를 기준으로, 반응조제 1-20중량부;1-20 parts by weight of the reaction aid based on 100 parts by weight of the essential components; 규조토, 플라이애쉬 및 퍼라이트분말로 이루어진 군에서 선택되는 1종 또는 2종 이상의 혼합물로 되는 보조첨가제 1~40중량부; 및 1 to 40 parts by weight of an auxiliary additive comprising one or a mixture of two or more selected from the group consisting of diatomaceous earth, fly ash and perlite powder; And 수산화나트륨 1~20중량부로 이루어지는Consisting of 1-20 parts by weight of sodium hydroxide 초경량 무기질 미립경량골재의 제조방법.Ultra-light inorganic fine aggregate aggregate manufacturing method. 제 1항에 있어서,The method of claim 1, 상기 원료 조성물의 숙성은,Aging of the raw material composition, 65~120℃에서 1~3시간 숙성시키는Aged 1 ~ 3 hours at 65 ~ 120 ℃ 초경량 무기질 미립경량골재의 제조방법Manufacturing method of ultra light inorganic fine aggregate 제 1항에 있어서, The method of claim 1, 상기 1차 성형은, The primary molding, 상기 숙성된 원료 조성물을 로타리킬른에 공급하여 300~450℃의 온도에서 성형하는The aged raw material composition is supplied to a rotary kiln to be molded at a temperature of 300 to 450 ° C. 초경량 무기질 미립경량골재의 제조방법.Ultra-light inorganic fine aggregate aggregate manufacturing method. 제 1항에 있어서,The method of claim 1, 상기 2차 성형은,The secondary molding, 상기 1차 성형 후, 제조된 응집체를 로타리킬른에서 800℃~1100℃의 온도로 성형하는After the primary molding, the produced aggregate is molded in a rotary kiln at a temperature of 800 ℃ ~ 1100 ℃ 초경량 무기질 미립경량골재의 제조방법.Ultra-light inorganic fine aggregate aggregate manufacturing method. 제 1항에 있어서,The method of claim 1, 상기 2차 성형은,The secondary molding, 유리보다 고온에서 소결되는 세라믹계 이형제를 투입하여 수행하는 Performed by adding a ceramic-based release agent sintered at a higher temperature than glass 초경량 무기질 미립경량골재의 제조방법.Ultra-light inorganic fine aggregate aggregate manufacturing method. 제 1항에 있어서,The method of claim 1, 상기 발포된 응집체의 급랭은,The quenching of the foamed aggregate, 급랭기를 이용하여, 급랭기의 입구온도 750℃~800℃ 출구온도 40℃~60℃하에서 급랭시키는Using a quencher, the quencher is quenched at an inlet temperature of 750 ° C to 800 ° C and an outlet temperature of 40 ° C to 60 ° C. 초경량 무기질 미립경량골재의 제조방법.Ultra-light inorganic fine aggregate aggregate manufacturing method. 제 8항에 있어서,The method of claim 8, 상기 급랭기는.The quencher. 회전하는 튜브형의 수랭식 급랭기인Rotating tubular water-cooled quencher 초경량 무기질 미립경량골재의 제조방법.Ultra-light inorganic fine aggregate aggregate manufacturing method. 제 1항의 제조방법에 의해 제조된 초경량 무기질 미립경량골재.Ultra-light inorganic fine aggregate aggregate produced by the manufacturing method of claim 1.
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KR100978289B1 (en) * 2009-12-29 2010-08-27 선일공업 (주) Preparation method for adiabatic mortar using low absorption lightweight aggregates made from bottom ash and waste glass
CN105036682A (en) * 2015-07-29 2015-11-11 苏州科淼新材料有限公司 Sound-proof fire-resistant building material with humidity adjustment function and preparation method thereof
CN107337420A (en) * 2017-07-24 2017-11-10 浙江阿斯克建材科技股份有限公司 Integral hydrophobic heat-insulating calcium silicate spray paint and its manufacture method
CN113880552A (en) * 2021-09-10 2022-01-04 武汉科技大学 Foamed ceramic based on waste incineration fly ash and preparation method thereof

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Publication number Priority date Publication date Assignee Title
KR960029276A (en) * 1995-01-17 1996-08-17 이강년 Artificial lightweight aggregate including fly ash and its manufacturing method
JPH10279334A (en) 1997-04-03 1998-10-20 Nippon Cement Co Ltd Production of artificial lightweight aggregate
JPH11209130A (en) * 1998-01-22 1999-08-03 Kamaike Yutaka Manufacture of super-lightweight aggregate
KR100481043B1 (en) * 2001-12-05 2005-04-07 요업기술원 A fine-grained lightweight aggregate by use of the waste glass and the method for producing it

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR100978289B1 (en) * 2009-12-29 2010-08-27 선일공업 (주) Preparation method for adiabatic mortar using low absorption lightweight aggregates made from bottom ash and waste glass
CN105036682A (en) * 2015-07-29 2015-11-11 苏州科淼新材料有限公司 Sound-proof fire-resistant building material with humidity adjustment function and preparation method thereof
CN107337420A (en) * 2017-07-24 2017-11-10 浙江阿斯克建材科技股份有限公司 Integral hydrophobic heat-insulating calcium silicate spray paint and its manufacture method
CN107337420B (en) * 2017-07-24 2020-07-24 浙江阿斯克建材科技股份有限公司 Integral hydrophobic heat-insulating spray paint of calcium silicate and its preparing process
CN113880552A (en) * 2021-09-10 2022-01-04 武汉科技大学 Foamed ceramic based on waste incineration fly ash and preparation method thereof

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