WO2010094084A1 - Processus et procédé de fabrication d'un produit à base de silice - Google Patents

Processus et procédé de fabrication d'un produit à base de silice Download PDF

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Publication number
WO2010094084A1
WO2010094084A1 PCT/AU2010/000201 AU2010000201W WO2010094084A1 WO 2010094084 A1 WO2010094084 A1 WO 2010094084A1 AU 2010000201 W AU2010000201 W AU 2010000201W WO 2010094084 A1 WO2010094084 A1 WO 2010094084A1
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WO
WIPO (PCT)
Prior art keywords
granular material
partially
paste
glass
fusing
Prior art date
Application number
PCT/AU2010/000201
Other languages
English (en)
Inventor
Peter Geddes
Original Assignee
Refire Glass Research Pty Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2009900777A external-priority patent/AU2009900777A0/en
Application filed by Refire Glass Research Pty Limited filed Critical Refire Glass Research Pty Limited
Priority to AU2010215085A priority Critical patent/AU2010215085A1/en
Publication of WO2010094084A1 publication Critical patent/WO2010094084A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B19/00—Other methods of shaping glass
    • C03B19/06—Other methods of shaping glass by sintering, e.g. by cold isostatic pressing of powders and subsequent sintering, by hot pressing of powders, by sintering slurries or dispersions not undergoing a liquid phase reaction
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
    • C03C1/004—Refining agents
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B32/00—Artificial stone not provided for in other groups of this subclass
    • C04B32/005—Artificial stone obtained by melting at least part of the composition, e.g. metal
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00129—Extrudable mixtures

Definitions

  • the present invention relates to a process and method for producing a silica based product.
  • the present invention relates to a recycled silica based building product and method and process for manufacture thereof.
  • Glass cullet is derived generally from broken and crushed glass containers such as recycled bottles and jars, and from breakages and inferior products made during glass manufacturing. Cullet may also include material originating from plate glass sources. The current rate of recycling of glass cullet is typically much lower than the rate of generation of the cullet resulting in growing stockpiles of glass cullet.
  • Large glass cullet pieces having a size of typically over 10mm are readily sorted into batches of similar colours prior to recycling.
  • Examples of building products that may be made from such large cullet pieces are block pavers, cladding elements to walls such as wall tiles, roof tiles, panels such as fa ⁇ ade curtain walls for high rise buildings, internal bench tops, wall panels and partitioning.
  • Prior art processes for making such building products from recycled glass typically also require the mixing or pressing of shards or granules of recycled glass into cement or resin based materials and forming a shape in a mould. Such moulds containing the recycled glass are then air dried or put into autoclaves or ovens to cure and lock the glass shards or granules into the desired form.
  • the cullet fines which typically have sizes of 10mm and substantially smaller are not readily colour sorted. Accordingly, mixed colour cullet fines are generally used in low value products such as filler in bitumen, as a flux agent in bricks and as an abrasive, discarded in landfill, or accumulated in large holding depots.
  • Object of the invention is generally used in low value products such as filler in bitumen, as a flux agent in bricks and as an abrasive, discarded in landfill, or accumulated in large holding depots.
  • the present invention provides a process for producing a silica based form comprising the steps of: making a paste of granular material, the granular material including silica; extruding the paste to an extruded form; partially or fully fusing the granular material within the extruded form; wherein the step of partially or fully fusing the granular material includes the use of microwaves.
  • the process preferably further includes the step of cooling the form, after the step of partially or fully fusing of the granular material.
  • the process preferably further includes the step of pre-heating the form prior to the step of partially or fully fusing of the granular material.
  • the process preferably further includes the step of moulding a lower surface of the extruded form prior to the step of partially or fully fusing the granular material.
  • the process preferably further including the step of moulding an upper surface of the extruded form prior to the step of partially or fully fusing the granular material
  • the process preferably further includes the step of supporting the extruded form in a first mould prior to the step of partially or fully fusing the granular material.
  • the step of moulding the upper surface preferably includes the use of an overhead roller.
  • the overhead roller is preferably adapted to rotate around a longitudinal axis, and an outer contact surface of the roller contains one or more beads and/or grooves which impart longitudinally extending corrugations in the form.
  • the paste of granular material preferably includes a binder, the process including the step of setting the binder within the extruded form prior to the step of partially or fully fusing the granular material.
  • the silica is preferably in part at least derived from recycled glass.
  • the paste of granular material preferably further includes one or more of a mineral material, a flux, or an additive.
  • the process preferably further includes the step of annealing the form during the step of cooling the form.
  • the process preferably further including the step of controlling the porosity of the form by varying one or more of: granule particle size ranges in the granular material; and a pressure of extrusion of the paste.
  • the present invention provides a method of manufacturing a glass floor covering element, the method including the steps of: grading glass cullet into granular particles of a desired size; mixing the cullet with a binding agent to form a paste or mixture, the binding agent being adapted to substantially volatilize at elevated temperatures; extruding the granular paste/mixture to an extruded form onto a preformed mould; partially or fully fusing the granular material within the extruded form in a kiln until the binding agent has substantially volatilized and the cullet has fused together forming a homogeneous floor covering element.
  • the step of partially or fully fusing the granular material preferably includes the use of microwaves.
  • the method preferably includes the step of placing glass powder in the hopper prior to extruding the mixture.
  • the method preferably includes the step of placing a release agent in the mould prior to extruding the mixture.
  • the method preferably includes the step of mixing the cullet particles with cullet particles of a different size and/or colour.
  • the mould is preferably fired to a temperature between about 870 0 C - 970 0 C for a period of approximately 20 minutes.
  • the present invention provides a system for producing silica based forms comprising: an extruder for extruding a paste of granular material to an extruded form; and a microwave furnace for partially or fully fusing the granular material within the form.
  • the system preferably further includes a cooling apparatus to cool the form from the furnace.
  • the system preferably further includes an overhead roller adapted to further shape the extruded form.
  • Rg. 1 is a schematic perspective view of an extrusion and forming process
  • Rg. 2 is a schematic perspective view of a further extrusion and forming process using an overhead roller
  • Rg. 3 is a schematic representation of a microwave sintering furnace
  • Rg. 4 is a schematic representation of a production line utilising the extrusion and forming process.
  • Rg. 5 is a schematic view of a mould for manufacturing a paving tile.
  • a process for producing a silica based form 116 is described herein, and depicted in the figures.
  • the form 116 may be shaped by extrusion, casting in a mould, or a combination of extrusion and casting.
  • a paste of primarily silica granular material is prepared for extrusion into a form 116 of a building product such as a tile or paver.
  • the "green" or unfired / unfused form 116 is then fired in a furnace to fuse the granular material into the form of the building product.
  • Recycled glass or "cullet” provides a ready source of silica material.
  • Raw material sources of silica may also be included.
  • Recycled glass commonly has up to 6% or more of contaminants such as plastics, ceramics, soil, water, paper and/or metals. These contaminants may be removed, for example the recycled glass may be dried of water in a rotary kiln until a water content of 2% or less is attained.
  • the recycled glass and/or other source of silica are then ground or otherwise reduced to a particle or granule size typically ranging from 0.5 to 3 mm, to form a granular material.
  • Mineral material also in granular form, may be added as a component to the granulated silica prepared as described above.
  • the addition of the mineral material to a mixture of granular material may alter the properties of the resultant building product.
  • the mineral additions may vary the colour, strength, finish, porosity or otherwise of the product.
  • the mineral material may be present in a proportion of 0 to 20% w/w or more of the granular material mix.
  • the mixture of granular material may include a binder.
  • the binder may be inorganic and/or organic in composition and may be added to the granular material mix, by way of example, in a proportion of 1 to 8% w/w of the granular material mix.
  • the binder is in a proportion of 1 to 5% w/w of the granular material mix.
  • binders that may be used are as follows: • Hydrolysed ethyl silicate and boron oxide, each in proportion of 0.75 to 1% w/w of the granular material;
  • the binder may be thermosetting and/or catalytic in action such that the speed of setting or gelling can be adjusted as appropriate by temperature or the proportion of a catalytic agent.
  • the binder may also bind when the form 116 is dried.
  • the binder may also include a shear sensitive component so that setting or gelling may occur on the application of high shear as may occur in the passage of the paste of granular material through an extruder die.
  • the choice of binder used may also be influenced by whether a microwave furnace or a more conventional furnace is used, for example gas fired furnaces.
  • the binder may be removed during fusing of the granular material as a consequence of the heat and/or microwaves applied.
  • the binder may be appreciably volatile at sintering temperatures or may be burnt off.
  • the binder may remain during the fusing process.
  • Flux A flux agent(s) may also be added to the granular material in order to assist in the sintering or partial fusion of the granules together.
  • the flux agent(s) may be suitable for aiding the complete fusion or melting of the granular material mixture.
  • Examples of fluxes for sintering or partial fusion that may be suitable are various metal tetrachlorides, metal oxychlorides and metal alkoxides of tin, vanadium, zirconium or titanium. The action of such fluxes may be improved by the use of alcohol solvents and in particular ethanol.
  • fluxes such as the following may be used:
  • a eutectic mixture of 56% w/w lithium carbonate with 44% w/w sodium sulphate may be used at 0.5% w/w of the granular material.
  • the flux agent chosen may vary in composition and action in order to facilitate the fusing action via the use of microwaves.
  • the flux may provide a material susceptible to microwave heating which in turn promotes localised heating.
  • the flux agent may also improve the conductivity of the granular material in order to facilitate the action of the microwaves upon the granular material.
  • a possible flux is sodium silicate.
  • the use of microwaves for heating or fusing of silica or glass granular material provides faster and more controllable heating and fusing compared with conventional techniques.
  • fluxes and other additive components may be used that vary in their microwave absorption properties, in order to assist heating and then fusing as desired.
  • Flux may also be applied to the granular material to provide a more glossy surface finish of the product by promoting more fusion at the surface.
  • additives examples include: pigments for colour, agent/s to improve the homogeneity and/or viscosity of the mixing and agent/s to improve the extrusion properties of the resultant paste of the granular material.
  • a pre-extrusion slurrying, mixing and drying stage may be required in order to obtain a suitably homogenous blend of all the components in a granular material mixture.
  • the above possible components to the granular material may be suitably mixed using an appropriate mixer, for example a dual cone mixer, a high intensity mixer for viscous and highly granular mixtures or a similar performing mixer.
  • an appropriate mixer for example a dual cone mixer, a high intensity mixer for viscous and highly granular mixtures or a similar performing mixer.
  • Fig. 1 illustrates an extrusion and forming process 110 according to a first embodiment of the invention.
  • a paste 112 of granular material is fed into an extruder 114 where it is continuously extruded through a die (not shown) into an extruded form 116.
  • the form 116 is extruded directly onto a support or mould 118.
  • the cross-sectional shape of the extruded form 116 is determined by the extruder die and/or the mould 118.
  • the extruder 114 produces a flat sheet extruded form 116 which is continuously laid upon a corrugated mould 118 to produce corrugated roof tiles.
  • the under surface of the extruded form 116 assumes the corrugated shape of the mould 118.
  • the extruded form 116 is cut to length to produce an intermediate form 120 which is moved away from the extruder in the direction of the arrow 122.
  • the cross-sectional shape of the extruded form 116 can be determined solely by the shape of the extruder die. Fig.
  • FIG. 2 shows a further forming arrangement 210 using an overhead roller 212 with a corrugated profile which is applied to the upper surface 218 of the intermediate form 120 so as to produce the corrugations in the form 116 defined by beads and grooves on the upper surface 218 of the final form 216.
  • a series of overhead rollers may be used to progressively apply the desired shape to the upper surface 218 of the intermediate form 120.
  • an overhead mould (not shown) with the desired shape may be applied to the upper surface 218 of the intermediate form 120 to produce the final form 216.
  • an extruder may have a die capable of directly extruding the final form 216 and thus obviating the use of a mould support 118, overhead rollers 212 and/or an overhead mould.
  • the process may have the following example operating conditions: extrusion with a pressure of 40 MPa to produce roof tile forms of nominal thickness 20 mm, length 400 mm, width 250 mm and weight 4.6 kg. It will be readily appreciated that process described above may be applied to produce a variety of building products, for example: block pavers, cladding elements to walls such as ribbed wall tiles, roof tiles, translucent and transparent modular bricks (for wall lighting), and garden edging.
  • silica and/or glass based block pavers of nominally 30 mm thick, 300 mm square and 6.2 kg may be produced.
  • co-extrusion techniques may be used to produce a form derived from multiple pastes, where the different pastes may vary by way of example in colour, porosity properties, strength and/or components of the granular material in general. Co-extrusion may be achieved by the use of a die with multiple orifices, each orifice being fed by a different paste source.
  • Example building products which may be produced by such co-extrusion techniques are those with multiple layers where each layer may be of a different composition, roof tiles with longitudinal or transverse bands of colour or varying transparency and any number of other variations in properties possible with co- extrusion techniques.
  • the words “fused” or “fusing” are to be taken to include sintering / partial fusing / tack fusing where the granules are joined at one or more points to each other but are still distinct as individual granules, at least in part.
  • the words “fused” or “fusing” are also to be taken as full and partial melting of the entire granular material, unless specified otherwise.
  • the green form product may be fused via the following steps.
  • sintered (partially fused) glass / silica block paver form for a building product is used.
  • Waste heat as hot forced air from the cooling and/or annealing sections may be used to dry the form of volatiles before fusing. This section may also additionally set the binder within the form. The green forms may be heated in this dryer section to approximately 34O 0 C for one hour.
  • This optional section may be used to pre-heat the form prior to the fusing furnace section. Such pre-heating may improve the heating and fusing time efficiencies. Pre-heating may also be useful if a microwave furnace is used for fusing in order to bring the form into a temperature range within which microwaves may be used for fusing. By way of example, an intermediate gas fired section may be used to raise the temperature of the form from 245 0 C to 475 0 C.
  • the use of particular fluxing components in the mix of granular material may make the gas fired intermediate heat section redundant.
  • a microwave furnace may be used to bring the form to a temperature suitable for fusing.
  • a microwave furnace of HOkW capacity may heat 250 pavers or tiles for one hour to bring the temperature of the forms from 475 0 C to the fusing (sintering) temperature, between 760° to 87O 0 C depending on additives.
  • An alternative furnace arrangement for heating may also be used where a combination of heating techniques may be used, for example microwaves augmented with infra-red or gas firing.
  • (D) Fuse Section In this section the form is further heated in a furnace to partially fuse / sinter / tack fuse the granules of the granular material in the form together.
  • Microwaves may be used in a cycled or semi-continuous manner with a lower power input of 35kW for 250 pavers under strict temperature control for the required fusing time.
  • a temperature of between 760° to 87O 0 C may be used.
  • a temperature of 900° to 1000 0 C may be used.
  • an alternative furnace arrangement may be used where a combination of heating techniques may be used.
  • (E) Initial Cooling Section This section may have two stages. The first stage may only occupy a few minutes from when the form emerges from the fuse section. During the first stage the molten glass portions gain strength by becoming more viscous as they cool to approximately 695 0 C. The second stage of initial cooling is more prolonged at approximately one hour. The temperature is reduced to that suitable for annealing; in the present example of 45 mm thick block pavers this may be 475 0 C.
  • (F) Annealing Sections A series of temperature annealing sections may be used to anneal the form in order to relieve stresses.
  • the particular series of annealing sections and the temperatures to be used may depend on the particular shape and size of the form of the building product and the original components in the granular material that made up the green form.
  • the heating, cooling and annealing cycle may be: continuous, a series of steps or a series of discontinuous ramps; for example a sawtooth fashion.
  • the temperature cycle used may depend upon the desired heat transfer rate between the core of the form 116 and the surface of the form 116.
  • a control system for heating or cooling may employ a series of discontinuous ramps which emulate a saw tooth pattern superimposed over the normal "required” ramp up, and cool down profiled rates. This reduces the differential between the glass core temperature and the glass surface temperature of the form 116.
  • An example heating, cooling and/or annealing cycle for a block paver form is provided.
  • Such block paver forms are typically angular, a rectangular solid shape typically of 20 to 45 mm or more in thickness. Highly angular forms are susceptible to stresses on cooling. The accepted standards for cooling and annealing times may be typically quite lengthy if an attempt is made to adapt them to such highly angular forms 116.
  • the special algorithm for the control system may be developed with the aid of trials conducted by monitoring the air temperature/s surrounding the form, the surface temperature/s across the form and the core temperature/s within the form.
  • the air temperature/s surrounding the form may be determined with thermocouples, the surface temperature/s of the form may be determined via the use of radiation pyrometers and the core temperature/s for the form may be determined by the use of imbedded thermocouples. Trials may then be conducted for the heating, annealing and/or cooling of the form whilst monitoring air, surface and core temperatures of the form.
  • the air temperature will be deliberately overdriven (remain at full power longer) for short bursts and then short cooling periods applied to bring the surface temperature and the core temperature back to closer limits for annealing.
  • Each short cooling period may cease when the surface temperature again matches the air temperature.
  • the actual average heating rate for the glass product may be taken as the mean temperature of the surface and the core at the end of each of the successive short cooling periods.
  • the air heating rate as distinct from the glass, core and/or surface, heating rate/s and cycle time/s is a determining factor in reducing the differential between surface and core temperature/s.
  • the percentage or relative change measured between successive differential temperature values (which may be positive or negative) can be applied to the air heating rate; which in turn will be a function of the required average glass heating rate.
  • a particular algorithm for the product may then be generated with the assistance of the trial data. The algorithm will depend on air temperature, product/form shape, thickness and other dimensions, colour, heating rate and/or cooling rate, surface temperature, core temperature, allowable temperature differential/s and sampling time for the various measurements during the trial/s and when implementing the control system.
  • Fig. 3 illustrates a microwave sintering furnace or kiln 310 for fusing roof tile or block paver forms 116.
  • the example furnace in Rg. 3 is a continuous tunnel furnace featuring connected zones, or sections, for binder removal 312, microwave main heating 314, microwave tack fusing 316, first stage initial cooling 318 and second stage initial cooling 320.
  • the continuous tunnel furnace 312, 314, 316, 318, 320 is mounted in a structure 322 to allow appropriate services access to the tunnel furnace as well as the incorporation of a suitable movement system (not shown) for the forms 116, as described previously above.
  • Each of the zones or sections of the tunnel furnace may be isolated from the other by the use of suitable, refractory lined doors 324.
  • the binder removal 312 zone or section heats the forms 116 from 120° to 47O 0 C in order to set the binder prior to fusing and remove all volatiles. Air inlets 326 and exhaust outlets 328 to the binder removal zone 312 aid in the removal of volatiles and other evolved gases within this zone. From the binder removal 312 the forms 116 proceed to the microwave main heating 314 zone where they are heated from 470° to 87O 0 C in preparation for fusing. The forms 116 then proceed to the microwave tack fusing 316 zone where the granules in the granular material are be tack fused or sintered together at a temperature of 87O 0 C.
  • Fig. 4 illustrates an example of the overall production line 410 for the production of building product forms 116.
  • the green forms 116 may be produced by extrusion 110 and further forming 210 as shown in Figs. 1 and 2.
  • the green forms 116 are then transported, as indicated by the movement arrows 412, to a dryer section 414 to set the binder and remove some or all of the volatiles.
  • the green forms 116 proceed to the microwave sintering furnace 310. After fusing the forms 116 proceed to a series of cooling 416 and annealing 418 sections. At the two unload points 420, 422 the forms 116 may be unloaded from the production line 410, or proceed for another circuit in the cooling 416 and annealing 418 sections.
  • the overall production line 410 may be controlled at a control station 420.
  • Varying porosity characteristics may be desirable in some applications. For example highly porous block pavers drain water and provide a non-slip surface for walking upon. However for wall tiles and fa ⁇ ade panels, it is desirable that the building product be impervious to water with a low porosity and high gloss.
  • the size and density of the pores or voids may also vary the light transmission or reflectance properties as well as the appearance or surface finish of the product. The light transmission properties may be varied from transparent, translucent to opaque.
  • Porosity may be varied by a number of techniques that may be introduced into the process described above. For example:
  • fine particle size components such as bentonite
  • Such fine components may be beneficial in filling voids to reduce porosity, improving the strength and finish of the product.
  • microwave furnaces for heating and fusing provides a level of process control not readily attainable with conventional heating and fusing techniques. This improved level of control may allow for a superior quality product to be manufactured.
  • the surface texture of the paver 510 is of importance.
  • the paver 510 can be made slip resistant, making the paver 510 ideal for use outdoors or in wet areas.
  • Glass cullet 512 is initially washed and then transferred to rotating trommel for sorting by size. During the wash process itself some very fine granulated glass powders are collected which are typically less than 1.0mm in size.
  • the trommel includes a series of wire mesh cylinder sections which are axially located side by side along its length. Each mesh cylinder has holes or perforations formed in its radial surface of a given size. The perforations may be round, square or any other suitable shape.
  • the sizes of the holes vary from about 1.5mm up to about 50mm.
  • the trommel is arranged such that the cullet 512 originally enters within the centre of the cylinder having the smallest apertures. As the trommel rotates, the cullet 512 moves axially through the trommel.
  • the trommel may be axially angled slightly downwards to facilitate movement of the cullet 512.
  • the cullet 512 enters the end of the trommel having the smallest apertures. As the trommel rotates, any cullet 512 smaller than the smallest apertures falls through the apertures into a storage container. As the cullet reaches the next mesh cylinder, larger cullet 512 particles pass through the larger apertures into a further storage container, until all of the cullet 512 has been graded by size.
  • the cullet 512 may also be mixed in a ribbon blender. In order to manufacture the floor covering element 510, the cullet 512 from the sorting process is selected which has a size of 10mm or less.
  • Additives such as fast setting binders, deflocculant and water may be employed to aid binding during manufacture.
  • the additives will not be discussed in detail, as they are the same as those binder, flux and other additives described above.
  • the cullet 512 is dipped in these additives.
  • the combined glass cullet 512 and binder and additives produce a mixture 516.
  • the mixture 516 is loaded into a hopper and extruded as described above, into a mould 520, as shown in Fig. 5.
  • the glass mixture 516 may have a tendency to stick to the lower mould 520 substrate during the first firing/drying stage. Accordingly, in one embodiment, the mould 520 is coated with a release agent.
  • the binding additives are volatilized and burn away, leaving a resulting product which consists of at least 95% w/w glass particles, with minimal remaining binder residual.
  • the pavers 510 are kiln fired as described above to a temperature range of 870C - 970C, and held for a predetermined period of time.
  • the pavers 510 are manufactured upside down. Accordingly, the lower base surface 522 of the mould 520 ultimately becomes the upper exposed surface of the paver 510.
  • the base surface 522 of the mould in some embodiments may receive a dusting of glass powder having a desired colour before the final transfer of the extruded glass mixture 516.
  • This serves the purpose of imparting the desired colour characteristics in the finished paver 510, and enhancing the non-slip properties of the pavers 510.
  • This also advantageously enables the production of glass pavers having a body made from the mixed coloured fines which may have an unappealing colour, however, the upper visible surface can be presented in a more appealing colour if desired.
  • Different embodiments of the pavers 510 having different surface effects and characteristics are described below:
  • the paver 510 of a first embodiment is made from recycled glass that has not been colour sorted, but has been ground to a "fine" size (range 0.5mm to 1.5mm). This produces a texture finish resembling a multicoloured or speckled fine stone.
  • the paver 510 of a second embodiment is made from recycled glass that has been sorted into individual colours and only contains one colour.
  • the glass cullet 512 is close to powder size (around 0.25mm-1.5mm) being the "fines" that are recovered after colour sorting, washing and sorting the cullet 512 to size.
  • the paver 510 of the second embodiment is a premium paver 510, as the colour is completely uniform and the texture is matt but fine and provides a good slip resistance.
  • the paver 510 of a third embodiment is made predominately from larger cullet and in one colour, generally having a fairly uniform thickness. Generally, this is achieved using small to medium glass cullet 512 having a size range up to 10mm.
  • the surface 522 upon which the glass cullet 512 is placed when firing is coated with a release agent.
  • the mould 520 may be first covered with a very fine dusting of a single colour of powdered glass "fines".
  • the powdered glass is formed by ground glass having a size range of 0.25mm - 1.00mm. This initial finely dusted powder layer can be the same or a different colour to the balance of the glass placed on top.
  • the paver 510 of this embodiment is more decorative than those of the above described embodiments and provides good slip resistance.
  • the paver 510 of a fifth embodiment is made using the larger cullet 512 as in the third embodiment, but is a mix of two different colours to produce a mottled effect. This again is a more decorative paver and many different colour accents can be achieved.
  • the mould surface 522 upon which the glass cullet 512 is placed when firing is first covered with a very fine dusting of a single colour of powdered glass "fines" (preferable size range 0.25mm - 1.00mm. This initial finely dusted powder layer can be the same or a different colour to the balance of the glass mixture 516 placed on top.
  • the fifth embodiment exhibits excellent slip resistance.
  • the mould surface 522 may also be coated with a release agent.
  • the paver 510 of a sixth embodiment is made using the larger cullet 512 as in the third embodiment but without the initial surface application of the glass powder "fines".
  • the resulting paver 510 surface is similar to the third embodiment above, however it is more marbled in appearance, but slightly less textured.
  • the slip resistance of the sixth embodiment is not as high as the first to fifth embodiments. However, this paver 510 has excellent applications for indoor floor surfaces.
  • the strength of the recycled glass paver 510 is significantly greater than concrete. Accordingly, the glass paver 510 can be manufactured in sizes substantially thinner than a concrete paver while still providing the same or superior strength. This results in weight and cost savings for transportation and installation.
  • a further advantage of the glass paver 510 is that it is impervious to moisture attack and staining. Accordingly, the performance characteristics and appearance of the paver 510 are more enduring than conventional concrete and clay pavers.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • General Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Finishing Walls (AREA)
  • Glass Compositions (AREA)

Abstract

La présente invention concerne un processus de fabrication d'une forme (116) à base de silice comprenant les étapes consistant à élaborer une pâte constituée d'un matériau granuleux, ledit matériau granuleux comprenant de la silice ; à extruder la pâte pour obtenir une forme extrudée (116) ; à porter à fusion partielle ou totale le matériau granuleux constituant la forme extrudée (116) ; ladite étape consistant à porter à fusion partielle ou totale le matériau granuleux impliquant le recours aux micro-ondes.
PCT/AU2010/000201 2009-02-23 2010-02-22 Processus et procédé de fabrication d'un produit à base de silice WO2010094084A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2010215085A AU2010215085A1 (en) 2009-02-23 2010-02-22 A process and method for producing a silica based product

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2009900777A AU2009900777A0 (en) 2009-02-23 Extrusion and Forming of Glass
AU2009900777 2009-02-23

Publications (1)

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WO2010094084A1 true WO2010094084A1 (fr) 2010-08-26

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AU (1) AU2010215085A1 (fr)
WO (1) WO2010094084A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111489850A (zh) * 2020-03-12 2020-08-04 久盛电气股份有限公司 一种堆芯仪表系统用矿物绝缘电缆及其制作方法

Citations (15)

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US472199A (en) * 1892-04-05 sea-bury
GB1037878A (en) * 1962-12-26 1966-08-03 Engelhard Ind Inc Production of refractory silica articles
US3770867A (en) * 1971-11-19 1973-11-06 Dresser Ind Method of extruding silica compositions
US3811851A (en) * 1972-07-05 1974-05-21 Univ California Method of making foamed glass products with excreta and glass batch
GB1428788A (en) * 1973-09-18 1976-03-17 Rolls Royce Method of producing a refractory article
US4221596A (en) * 1976-10-04 1980-09-09 General Motors Corporation Method for low pressure forming of fused silica compositions and resultant bodies
US4349386A (en) * 1979-09-04 1982-09-14 Joseph Davidovits Mineral polymers and methods of making them
US4509985A (en) * 1984-02-22 1985-04-09 Pyrament Inc. Early high-strength mineral polymer
US5254818A (en) * 1991-04-03 1993-10-19 Sgn-Societe Generale Pour Les Techniques Nouvelles Microwave melting furnace for the vitrification and/or densification of materials
US5610116A (en) * 1992-12-15 1997-03-11 Heraeus Quarzglas Gmbh Catalyst carrier and method for producing same
WO2000001640A1 (fr) * 1998-07-01 2000-01-13 Ecc International Ltd. Materiaux inorganiques expanses
US6296697B1 (en) * 1996-03-11 2001-10-02 Wir Corporation Thermally insulating building material
US6468374B1 (en) * 1999-02-18 2002-10-22 Corning Incorporated Method of making silica glass honeycomb structure from silica soot extrusion
US20060027951A1 (en) * 2004-08-03 2006-02-09 Peterson Irene M Method for fabricating ceramic articles
WO2006125287A1 (fr) * 2005-05-25 2006-11-30 Oliveira Rodolfo Dafico Bernar Composites d'aluminosilicate naturels et agregats synthetises dans un milieu alcalin et procede de fabrication de ceux-ci

Patent Citations (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US472199A (en) * 1892-04-05 sea-bury
GB1037878A (en) * 1962-12-26 1966-08-03 Engelhard Ind Inc Production of refractory silica articles
US3770867A (en) * 1971-11-19 1973-11-06 Dresser Ind Method of extruding silica compositions
US3811851A (en) * 1972-07-05 1974-05-21 Univ California Method of making foamed glass products with excreta and glass batch
GB1428788A (en) * 1973-09-18 1976-03-17 Rolls Royce Method of producing a refractory article
US4221596A (en) * 1976-10-04 1980-09-09 General Motors Corporation Method for low pressure forming of fused silica compositions and resultant bodies
US4349386A (en) * 1979-09-04 1982-09-14 Joseph Davidovits Mineral polymers and methods of making them
US4509985A (en) * 1984-02-22 1985-04-09 Pyrament Inc. Early high-strength mineral polymer
US5254818A (en) * 1991-04-03 1993-10-19 Sgn-Societe Generale Pour Les Techniques Nouvelles Microwave melting furnace for the vitrification and/or densification of materials
US5610116A (en) * 1992-12-15 1997-03-11 Heraeus Quarzglas Gmbh Catalyst carrier and method for producing same
US6296697B1 (en) * 1996-03-11 2001-10-02 Wir Corporation Thermally insulating building material
WO2000001640A1 (fr) * 1998-07-01 2000-01-13 Ecc International Ltd. Materiaux inorganiques expanses
US6468374B1 (en) * 1999-02-18 2002-10-22 Corning Incorporated Method of making silica glass honeycomb structure from silica soot extrusion
US20060027951A1 (en) * 2004-08-03 2006-02-09 Peterson Irene M Method for fabricating ceramic articles
WO2006125287A1 (fr) * 2005-05-25 2006-11-30 Oliveira Rodolfo Dafico Bernar Composites d'aluminosilicate naturels et agregats synthetises dans un milieu alcalin et procede de fabrication de ceux-ci

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111489850A (zh) * 2020-03-12 2020-08-04 久盛电气股份有限公司 一种堆芯仪表系统用矿物绝缘电缆及其制作方法

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