MXPA00006802A - Process for the preparation, preferably from waste materials, of silicate foam with closed pores, and the product produced by the process - Google Patents

Abstract

The process of the invention characterised in that to 100 parts by weight of a silicate powder having 2000-8000 m2/g specific surface, 1-10 parts by weight of gas-forming material with particle size of 10-100&mgr;m and 0.5-15 parts by weight of montmorillonite, 0.5-2 parts by weight of alkali hydrogen phosphate or alkali dihydrogen phosphate or a mixture of alkali metal phosphate and sodium silicate in form of aqueous solution, 0.01-5 parts by weight of rare earth metal oxide or a mixture of such oxides were added, then the mixture obtained is homogenised, pre-dried, coated with 1-5 parts by weight of titanium oxide and/or titanium oxide hydroxide and/or aluminium oxide hydroxide, then subjected to heat treatment at 720-1000°C, and the mixture obtained is moulded. The subject of the invention:also the product of the above process.

Description

PROCESS FOR THE PREPARATION OF SILICATE FOAM WITH CLOSED PORES AND THE PRODUCT PRODUCED BY MEANS OF THE PROCESS, PREFERABLY FROM WASTE MATERIALS Field of the Invention The present invention relates to a process for the preparation of silicate foam hg closed pores and the product produced by the process, preferably from waste materials.

BACKGROUND OF THE INVENTION Silica foam granules are produced by means of the process according to the present invention, which can be used alone or together with inorganic or organic bonding material for the manufacture of sheets or articles of the desired shape. The product according to the present invention is of low specific weight, flameproof and has excellent properties of thermal insulation, sound dampening and is anti-vibration. Various processes are known for the preparation of glass foams. Hungarian Patent No. 171 046 describes a process for the manufacture of frothing waste glass products. According to said process, the waste glass is mixed with powdered alkali metal hydroxides, phosphoric acid and / or silicone fluoride as additives to lower the melting point, and foam generation is carried out in the presence of a Gas-forming material at a temperature of 600 to 805 ° C. According to the process described in US Pat. No. 4,413,907, the glass powder, the additives and the water are mixed, then the foamed product is manufactured in a high temperature oven. US Pat. No. 4,734,322 refers to a process characterized by the addition of a mixture of calcium carbonate and magnesium carbonate to the glass powder, then the product is made from the mixture obtained at a temperature of between 700 and 800 °. C. Japanese Patent Publication No. 03 13 7038 relates to a process for the production of glass foam; according to said process, the starting glass powder is mixed with 1 to 5% by weight of strontium carbonate and thermal insulation glass foam is produced from this mixture. The disadvantage of the processes mentioned above is that only a small part of the glass foam granules produced by them have closed pores, and therefore, their resistance properties are not satisfactory, these materials can not be used as materials against vibration.

Adding it from the Invention Our goal was to develop a process by which the disadvantages of the processes mentioned above could be eliminated and that the silicate foam product can be manufactured with a closed pore structure and high strength. Suitable waste materials were glass waste, sintered enamel earth, cast waste sand, waste ceramics, silicate wastes from the manufacture of electric bulbs or fluorescent lamps or other waste organic or inorganic silicate , but the original ground glass or silicate powder can also be applied.

Detailed Description of the Invention According to the above, the present invention relates to a process for the preparation, preferably from waste materials, of a silicate foam hg closed pores by mixing silicate powder, a material of gas formation, alkaline solution, optionally wetting the mixture in water, and then homogenizing, granulating and subjecting the obtained mixture to heat treatment. The process is characterized in that at 100 parts by weight of silicate powder, preferably glass waste powder, sintered enamel waste, molding waste sand, waste ceramic, waste organic or inorganic silicate or a mixture thereof. which have a specific surface area of 2000 to 8000 cm2 / g, 1 to 10 'parts by weight of gas forming material with a particle size of 10 to 100 μm are added, preferably ground limestone and / or dolomite and / or magnesite and / or witerite are added, mixture is homogenized and then 0.5 to 15 parts by weight of montmorillonite optionally activated with a solution of 1 to 10% by weight of alkali metal hydroxide or metal carbonate, and / or serpentine and / or alumina and / or aluminum oxide hydroxide, optionally 0.2 to 3 parts by weight of alkali metal hydroxide or metal carbonate in the form of a solution of 1 to 10% by weight, additionally 0.5 to 2 parts by weight of phosphate are added of alkaline hydrogen or alkali metal dihydrogen phosphate or a mixture of alkali metal phosphate and sodium silicate in the form of an aqueous solution, as well as 0.01 to 5 parts by weight of rare earth metal oxide or a mixture of said oxides , they are also optionally added from 0.1 to 5 parts by weight of colored metal oxide or a mixture of said oxides or a heavy metal oxide or a mixture of said oxides, the mixture obtained in this way is then homogenized, if desired it is wetted with water and granulated, then is previously dried, the granules are covered with from 1 to 5 parts by weight of titanium dioxide and / or titanium oxide hydroxide and / or aluminum oxide hydroxide, then it is subjected to a heat treatment at a temperature of 720 a 1000 ° C, the granules obtained are optionally coated with 0.1 to 1% by weight of polymer film or optionally 90 to 50 parts by weight of granules are mixed with 10 to 50 parts by weight of inorganic or inorganic binding material and they are given the desired shape. A further object of the present invention is a silicate foam granulated by the above process and having from 0.4 to 0.45 g / cm 3 of weight per volume and closed pores, which contains from 0.1 to 2% by weight of polymer film on the surface or a formed product which contains 90 to 50 parts by weight of silicate foam granules having closed pores and are manufactured by means of the above process and 10-50 parts by weight of organic or inorganic binding material. The product formed can be a sheet or a building block of the desired shape. The role of the rare earth oxide or the mixture of said oxides used in the process according to the present invention, is to adjust the optimum tension of the surface of the mixture or to induce a rapid crystallization process in the metal. In this way, the strength of the formed granules is surprisingly increased. The addition of titanium dioxide or titanium oxide hydroxide before heat treatment prevents adhesion of the grains. By using colored metal oxide or a mixture of said oxides, as well as heavy metal oxide or a mixture of said oxides in the process according to the present invention, granules of the desired color can be produced.

The witerite optionally used in the process is a mineral based on barium carbonate. In the process, the aqueous extract of the ash of the sunflower seed husk can be used as the alkaline solution. Activation of minerals similar to montmorillonite and / or serpentine can be carried out either before mixing or in situ, when mixed with the silicate powder. If desired, the surface of the granules can be coated with a thermoplastic film or thermal setting polymer. When the granules are mixed with the binding material, products formed from said mixture can be manufactured. Cement, gypsum, bitumen, thermoplastic polymers or synthetic thermal-setting resins can be applied as bonding materials. The process and the product according to the present invention have the following advantages: The process provides the production of silicate foam granules having closed pores, a particle size more homogeneous than those produced by means of known processes, and improved strength properties. By means of the process a product with term and sound proofing properties can be formed using, not only waste glass, but other waste silicates.

The product obtained by means of this process is an excellent material against vibration. - By means of the process according to the present invention, not only waste materials, but original glass powders and silicate powders can be used to produce the silicate foam with closed pores. The process according to the present invention is illustrated by means of the following examples: Example 1 100 parts by weight of lead glass waste powder of a specific surface area of 4000 cm2 / g were mixed with montmorillonite previously treated with sodium hydroxide solution and 5 parts by weight of ground dolomite were added to the mixture. which has a particle size of 50 to 70 μm. The mixture was then homogenized, by grinding the components together in a ball mill. The pretreatment of the montmorillonite was carried out by grinding together two parts by weight of partner hydroxide, 18 parts by weight of water and 8 parts by weight of montmorillonite in a ball mill. In a blender, it was added to the homogenized mixture containing two parts lead glass waste by weight of alkaline hydrogen phosphate, 18 parts by weight of water and 0.2 parts by weight of a mixture of rare earth metal oxides (consisting of lanthanum, cerium and europium oxides). The wet mixture was granulated and previously dried at 120 ° C. The granules were mixed in a disintegrator, with four parts by weight of titanium dioxide. The coated granules were heated for two minutes in an oven at a temperature of 720 ° C, and then allowed to cool to room temperature. The granulated product had closed pores, a volume density of 0.35 g / cm3, a water absorption capacity of 0.9% by weight.

Example 2 The process described in Example 1 was followed with the exception that dry sludge formed in the polished cut glass was used as the starting material and this mixture was homogenized with ground limestone instead of ground dolomite. To the above mixture were added four parts by weight of montmorillonite and earth together with 2.5 parts by weight of the ash obtained from the incineration of the sunflower seed shell. The mixture obtained in this way was homogenized by grinding it, then it was treated as described in Example 1, but titanium oxide hydroxide was used, instead of titanium dioxide.

The granulated product with closed pores had a water absorption capacity of 1.5% by weight, a volume density of 0.32 g / cm3.

Example 3 Mixed waste glass was milled (communal green waste glass, white and brown) and then homogenized according to Example 1, together with 2.5 parts by weight of ground limestone, 2.5 parts by weight of dry barium sulfate (waste mud), 20 parts by weight of water, 10.0 parts by weight of alumina and eight parts by weight of molding waste, then one part by weight of sodium hydroxide, 20 parts by weight of water, two parts by weight of a mixture of metal oxides was added to the previous mixture. of rare earth, according to Example 1 and the mixture of 0.5 parts by weight of trisodium phosphate and 1.5 parts by weight of sodium silicate in the form of an aqueous solution of 5% by weight. The mixture was homogenized, then granulated and dried at a temperature of 130 ° C. Subsequently two parts by weight of titanium dioxide were added, and the mixture was heated for two minutes in an oven at a temperature of 820 ° C, then the temperature was increased to 950 ° C, the granules were maintained for one minute in This temperature was taken out of the oven and cooled to ambient air temperature.

The product had a water absorption capacity of 1.0% by weight, and a volume density of 0.30 g / cm3.

Example 4 To 100 parts by weight of mixed communal waste glass powder, eight parts by weight of dolomite, three parts by weight of serpentine ore enriched with magnesium and five parts by weight of zinc carbonate were added. Zinc carbonate was used in the form of an aqueous solution of 5% by weight. The mixture was milled in a ball mill, homogenized, and then the process described in Example 3 was followed with the exception that the heat treatment was carried out at a temperature of 780 ° C for 2.5 minutes. Then this product was cooled to room temperature. The product had closed pores, a volume density of 0.35 g / cm 3, and a water absorption capacity of 1.2% by weight.

Example 5 To 100 parts by weight of the powder obtained from the blended communal waste glass mixture, five parts by weight of earth limestone, 0.7 parts by weight of montmorillonite, three parts by weight of zinc carbonate and one part were added. by weight of a mixture of rare earth metal oxides according to Example 1. The zinc carbonate was used as an aqueous solution of 10% by weight. The mixture was ground and homogenized. Two parts by weight of a 1: 1 mixture of sodium phosphate and disodium hydrogen phosphate in the form of an aqueous solution of 5% by weight were added before the granulation. After measuring that the granules had a suitable particle size they were previously dried from 3 to 6 mm at a temperature of 120 ° C and the coating was formed on the surface of the granules by means of the mixture of these, with four parts by weight of a 1: 1 mixture of aluminum oxide hydroxide and titanium dioxide to a thickness of 10μ. Then the granules were kept for three minutes at a temperature of 850 ° C, and cooled. The product had a volume density of 0.30 g / cm3 and a water absorption capacity of 0.8% by weight.

Example 6 To 100 parts of production waste of fluorescent lamp (magnesium, lead and mixed borosilicate glass), six parts by weight of earth limestone, eight parts by weight of montmorillonite and one part by weight of a mixture of rare earth metal oxides according to Example 1.

The obtained mixture was ground in a ball mill to produce a specific surface powder of 3500 cm2 / g, and was then homogenized. Then two parts by weight of a 2: 1 mixture of sodium silicate and trisodium phosphate were added in the form of an aqueous solution of 5% by weight. The wet mix was granulated, the granules were previously dried at a temperature of 120 ° C, then coated with four parts by weight of a 1: 1: 1 mixture of titanium dioxide, titanium oxide hydroxide and oxide hydroxide. of aluminum. Subsequently, the granules were maintained for three minutes at a temperature of 850 ° C, and were cooled to room temperature. The product obtained in this way had a volume density of 0.38 g / cm 3 and a water absorption capacity of 0.5% by weight.

Example 7 To 100 parts by weight of pulverized waste borosilicate glass was added eight parts by weight of dolomite, five parts by weight of montmorillonite, 0.5 parts by weight of a mixture of rare earth metal oxide according to Example 1 and five parts by weight of zinc waste carbonate. Zinc carbonate was used in the form of an aqueous solution of 10% by weight. The mixture was milled and homogenized in a ball mill.

The granulation was carried out with the wet solution described in Example 6, After forming the granules of the appropriate size (3-6 mm) they were coated with a layer of a thickness of 10 μ using different materials described in the Example 5. The granules were subsequently dried at a temperature of 120 ° C, subjected to heat treatment at a temperature of 790 ° C. The product obtained had closed pores, a volume density of 0.32 g / cm3 and a water absorption capacity of .2% by weight.

Example 8 To 100 parts by weight of a mixture of magnesium glass and borosilicate glass, eight parts by weight of dolomite, three parts by weight of montmorillonite, three parts by weight of alumina, one part by weight of a mixture were added. of rare earth metal oxides according to Example 1 and two parts by weight of a mixture of ethyl waste silicate and colloidal silica were added. The mixture was milled in a ball mill, homogenized and granulated using the wet material described in Example 6.

The granules were dried at a temperature of 120 ° C, coated following the procedure of Example 6, then subjected to thermal treatment for 4 minutes at a temperature of 750 ° C. After the heat treatment, the granules were cooled to room temperature. The product obtained in this way had a volume density of 0.28 g / cm3 and a water absorption capacity of 1.6% by weight.

Example 9 The procedure described in Example 8 was followed, with the exception that before homogenization, three parts by weight of manganese, copper and chromium oxide were added in the form of coloring material. The product had a volume density of 0.28 g / cm 3 and a water absorption capacity of 1.6% by weight.

Example 10 The process described in Example 8 was followed, but to avoid water absorption, the granules were electrostatically coated by waste of epoxy resin, then subjected to thermal treatment for 10 minutes at a temperature of 140 ° C. The product obtained had a volume density of 0.32 g / cm 3 and a water absorption capacity of 1.0% by weight.

EXAMPLE 1 70 parts by weight of the granules obtained in Example 1 were mixed with 30 parts by weight of gypsum and water. The dough was placed in a mold and dried. The sheet produced in this way had excellent thermal insulation and soundproofing properties.

Example 12 80 parts by weight of the granules obtained in Example 1 were mixed with 20 parts by weight of polyester resin, then the mass was placed in a mold and hardened at a temperature of 120 ° C. The obtained building block had thermal insulation and sound proof properties.

Claims (4)

R E I V I N D I C A I N N E S Having described the present invention, it is considered as a novelty and, therefore, the content of the following CLAIMS is claimed as property.

1 . A process for the production, preferably using waste materials, of silicate foam with closed pores, by means of the mixture of earth silicate, gas forming material and alkaline solution, optionally moistening the mixture with water and then subjecting it to homogenization , granulation and heat treatment, which is characterized because at 100 parts by weight of silicate powder having a specific surface of 2000 to 8000 cm2 / g, preferably glass waste, waste of sintering enamel, waste of molding sand, ceramic waste, waste organic or inorganic silicate or a mixture thereof, are added from 1 to 10 parts by weight of gas forming material with a particle size of 10 to 100 μm, preferably limestone is added earth and / or dolomite and / or magnesite and / or witerite, the mixture obtained is homogenized and then added from 0.5 to 15 parts by weight of montmorillonite optionally activated with a solution of 1 to 10% by weight of alkali metal hydroxide or metal carbonate, and / or serpentine hydroxide and / or alumina and / or aluminum oxide hydroxide, optionally 0.2 to 3 parts by weight of hydroxide of alkali metal or metal carbonate in the form of a solution of 1 to 10% by weight, of 0.5 to 2 parts by weight of alkaline hydrogen phosphate or alkaline dihydrogen phosphate or a mixture of alkali metal phosphate and sodium silicate sodium in the form of an aqueous solution, from 0.01 to 5 parts by weight of rare earth metal oxide or a mixture of said oxides, optionally from 0.1 to 5 parts by weight of colored metal oxide or a mixture of said oxides or a heavy metal oxide or a mixture of said oxides, the mixture obtained in this way is then homogenized, optionally wetted with water and granulated, previously dried, the granules are coated with from 1 to 5 parts by weight of di titanium oxide and / or titanium oxide hydroxide and / or aluminum oxide hydroxide, then subjected to a heat treatment at a temperature of 720 to 1000 ° C, the surface of the obtained granules is optionally coated with a film, using from 0.1 to 1% by weight of polymer or synthetic resin, or optionally from 90 to 50 parts by weight of granules are mixed with from 10 to 50 parts by weight of inorganic or inorganic bonding material and the obtained mixture is molded.

2. A process as described in Claim 1, further characterized in that the surfaces of the granules are coated with epoxy resin.

3. A process as described in Claim 1, further characterized in that cement, gypsum, bitumen, thermoplastic polymers or thermal setting resins are used as the bonding material.

4. The silicate foam product with closed pores characterized by the granules produced by the process as described in Claim 1, which has a volume weight of 0.3 to 0.45 g / cm 3 and whose surface is optionally coated with 0.1 to 2 parts by weight of a polymer or a synthetic resin, a product in the form of a sheet or other form consisting of 90 to 50 parts by weight of the closed pore silicate foam granules produced by the process as described in Claim 1, and from 10 to 50 parts by weight. weight of organic or inorganic binding material. SUMMARIZES The process of the present invention is characterized in that at 100 parts by weight of a silicate powder having a specific surface area of 2000 to 8000 cm2 / g, from 1 to 10 parts by weight of a gas forming material is added with a particle size of 10 to 100 μm and 0.5 to 15 parts by weight of montmorillonite, from 0.5 to 2 parts by weight of alkaline hydrogen phosphate or alkaline dihydrogen phosphate or a mixture of alkali metal phosphate and sodium silicate in the form of an aqueous solution, from 0.01 to 5 parts by weight of metal oxide rare earth or a mixture of said oxides, then the obtained mixture is homogenized, previously dried, covered with 1 to 5 parts by weight of titanium oxide and / or titanium oxide hydroxide and / or aluminum oxide hydroxide, then it is subjected to heat treatment at a temperature of 720 to 1000 ° C, and the obtained mixture is molded. The subject matter of the present invention is also the product made by means of the above process.