JP4477848B2 - Manufacturing method of inorganic building materials - Google Patents
Manufacturing method of inorganic building materials Download PDFInfo
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- JP4477848B2 JP4477848B2 JP2003332797A JP2003332797A JP4477848B2 JP 4477848 B2 JP4477848 B2 JP 4477848B2 JP 2003332797 A JP2003332797 A JP 2003332797A JP 2003332797 A JP2003332797 A JP 2003332797A JP 4477848 B2 JP4477848 B2 JP 4477848B2
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- Y—GENERAL 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
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Description
本発明は、無機質建材の廃材を使用する無機質建材の製造方法に関するものである。さらに詳しくは、無機質建材を製造する際、発生する不良品や端材、現場施工時に発生する端材等を利用する無機質建材の製造方法に関するものである。 The present invention relates to a manufacturing method for the inorganic building materials that use waste of mineral building materials. More specifically, when manufacturing the inorganic building materials, defective products and scraps generated, a manufacturing method for the inorganic building materials utilizing scraps or the like generated during construction site.
建築物の外装材などに広く用いられている無機質窯業系建材（セメント板）は、製造する際、発生する不良品や端材、現場施工時に発生する端材の処理が問題になっている。原材料費の合理化の面からのみでなく、資源の有効利用、環境保護の面からリサイクル利用が種々図られている。 Inorganic ceramic building materials (cement boards) widely used for building exterior materials and the like are problematic in terms of the processing of defective products and scraps generated during production, and scraps generated during construction on site. In addition to rationalization of raw material costs, various recycling uses are being made from the viewpoint of effective use of resources and environmental protection.
そのうちでも、不良品や端材の原料配合への再利用について様々の利用技術が提案されている。例えば、セメント板廃材を粒径３００μｍ以下に粉砕し、該粉砕物をマットにフォーミングして１５０ｋｇ／ｃｍ2 以上の高圧でプレスした上でオートクレーブ養生を行なうことを特徴とするセメント板の製造方法がある（特開平０９−１９３１１７号公報参照）。 Among them, various utilization techniques have been proposed for the reuse of defective products and scrap materials to blend raw materials. For example, there is provided a method for producing a cement board, characterized in that cement board waste is pulverized to a particle size of 300 μm or less, the crushed material is formed on a mat and pressed at a high pressure of 150 kg / cm 2 or more and then autoclaved. Yes (see JP 09-193117 A).
この特開平９−１９３１１７号公報記載のセメント板の製造方法によれば、セメント板廃材を粒径３００μｍ以下に粉砕して硬化反応に関与する活性面積を増大させ、しかもマットを高圧プレスして原料相互を密接させ、そしてオートクレーブ養生する。すると、該セメント板廃材に若干残存している未反応のＣａＯ、ＳｉＯ2、およびＡｌ2Ｏ3等の活性物質に因る硬化反応が円滑に進み、その結果セメント板廃材を大量に使用しても高強度なセメント板製品が得られ、セメント板廃材の再利用効率が実に１０倍程度向上する。 According to the method for producing a cement board described in JP-A-9-193117, the cement board waste material is pulverized to a particle size of 300 μm or less to increase the active area involved in the curing reaction, and the mat is pressed at high pressure. Close each other and cure autoclave. Then, the curing reaction due to the active substances such as unreacted CaO, SiO 2 , and Al 2 O 3 slightly remaining in the cement board waste material proceeds smoothly. As a result, a large amount of cement board waste material is used. In addition, a high-strength cement board product can be obtained, and the reuse efficiency of cement board waste can be improved by about 10 times.
この特開平０９−１９３１１７号公報に開示された方法は、発生源の明らかなセメント板廃材で、その廃材の発生源のセメント板を製造するというもので、大量に廃材を使用する上では非常に好ましいが、セメント板の品質の変化はさけられない。 The method disclosed in Japanese Patent Application Laid-Open No. 09-193117 is a method of manufacturing a cement board as a source of generation of the waste material with a cement board waste material having a clear generation source. Although preferred, changes in the quality of the cement board are not avoided.
その他、無機質建材の廃材を物性などへの影響の少ないレベルまで粉砕して、その粉体を充填材として原料に添加して使用をする方法がある。しかしながら、この影響の少ないレベルまで粉砕して再利用するという方法では、繊維を含んだ廃材を粉砕するため、均一な粒子径にすることが難しい。また、混入後の建材物性に影響のないレベルまで小さく粉砕すると、かなりの微粉が存在する。小さく粉砕して使用する場合、抄造方式では、濾過抵抗が大きくなり、生産性が悪化し、生産性の面から添加量に制限を受ける。また、脱水プレス方式では、脱水時の抵抗が大きくなり、これも生産性が悪化する。そこで、また、濾過抵抗（脱水抵抗）に影響の無いレベルの粉砕（粒子径大）では、建材物性への影響があるため、建材物性面から制限されることになる。
本発明は、このような事情に鑑みてなされたものであり、建材物性への影響を許容することができる程度に廃材を使用する無機質建材の製造方法を提供することを目的としている。 The present invention has been made in view of such circumstances, and its object is to provide a manufacturing method for the inorganic building materials that use waste to the extent that can tolerate the effects of the construction material properties.
上記問題を解決するために、本発明の請求項１に係る無機質建材の製造方法は、セメントと、珪酸質材料と、パルプと、充填材とを主成分とし、吸水率が３０〜４０％、平均粒径が１００〜５００μｍである粉砕した無機質建材の廃材を撥水処理し、１４０℃以上で前養生処理した無機質建材の撥水処理廃材を、セメントと、珪酸質材料と、パルプと、充填材とを主成分とする無機質建材の原料に、前記主成分７０〜９５ｗｔ％に対して５〜３０ｗｔ％の割合で添加して混合し、成形することを特徴とする。 In order to solve the above problem, the manufacturing method of an inorganic building material according to claim 1 of the present invention is mainly composed of cement, siliceous material, pulp, and filler, and has a water absorption rate of 30 to 40%. Water-repellent treatment of crushed inorganic building materials with an average particle size of 100-500 μm , and filling with water, water-repellent treatment of inorganic building materials pre-cured at 140 ° C. or higher , cement, siliceous material, pulp It is characterized in that it is added to a raw material of an inorganic building material mainly composed of a material at a ratio of 5 to 30 wt% with respect to 70 to 95 wt% of the main component, and is mixed and molded .
本発明の請求項２に係る無機質建材の製造方法は、請求項１に記載の発明において、前記廃材は嵩比重が０．１〜１．０ｇ／ｃｍ３のものである。 The process of claim inorganic building material according to the second invention is the invention according to claim 1, wherein the waste material is intended bulk density of 0.1 to 1.0 g / cm 3.
本発明の請求項３に係る無機質建材の製造方法は、請求項１または２に記載の発明において、粉砕した前記廃材をアルキルアルコキシシラン及びその重合物で撥水処理したものである。 The method for producing an inorganic building material according to claim 3 of the present invention is the method according to claim 1 or 2 , wherein the crushed waste material is subjected to a water repellent treatment with an alkylalkoxysilane and a polymer thereof.
本発明の請求項４に係る無機質建材の製造方法は、請求項３に記載の発明において、前記アルキルアルコキシシランのアルキル基の炭素数を４〜８としたものである。 The manufacturing method of the inorganic building material which concerns on Claim 4 of this invention makes the carbon number of the alkyl group of the said alkyl alkoxysilane 4-8 in the invention of Claim 3 .
本発明の請求項５に係る無機質建材の製造方法は、請求項３または４に記載の発明において、前記アルキルアルコキシシラン及びその重合物の分子量を３００〜６０００としたものである。 The manufacturing method of the inorganic building material which concerns on Claim 5 of this invention sets the molecular weight of the said alkyl alkoxysilane and its polymer to 300-6000 in the invention of Claim 3 or 4 .
本発明の請求項６に係る無機質建材の製造方法は、請求項３ないし５のいずれかに記載の発明において、前記アルキルアルコキシシラン及びその重合物の粘度を０．２０Ｐａ・ｓ以下としたものである。 The method for producing an inorganic building material according to claim 6 of the present invention is the invention according to any one of claims 3 to 5 , wherein the viscosity of the alkylalkoxysilane and the polymer thereof is 0.20 Pa · s or less. is there.
本発明に係る無機質建材の製造方法によれば、無機質建材の廃材の混合割合を５〜３０ｗｔ％として無機質建材物性への影響を少なくして、生産性を損なわずに無機質建材の廃材を大量に利用することができる。 According to the method for producing an inorganic building material according to the present invention, the mixing ratio of the inorganic building material waste is set to 5 to 30 wt% to reduce the influence on the physical properties of the inorganic building material, and a large amount of the inorganic building material waste material is obtained without impairing the productivity. Can be used.
廃材は平均粒径が１００〜５００μｍに粉砕したものを用いることで、生産性を損なわず、品質も保持した無機質建材を得ることができる。 By using a waste material whose average particle size is pulverized to 100 to 500 μm, it is possible to obtain an inorganic building material that maintains the quality without impairing the productivity.
また、廃材を撥水処理して用いることで、建材の濾過抵抗及び脱水抵抗を低下させることができ、成形の生産性を向上することができる。 Further, by using the waste material after being subjected to water repellent treatment, the filtration resistance and dehydration resistance of the building material can be reduced, and the productivity of molding can be improved.
本発明の無機質建材の製造方法は、セメントと、珪酸質材料と、パルプと、充填材とを主成分とする無機質建材の製造方法であって、１００〜５００μｍに粉砕した該無機質建材の廃材をアルキルアルコキシシラン及びその重合物で撥水処理したものを前記主成分７０〜９５ｗｔ％に対して５〜３０ｗｔ％の割合で添加したものである。 The method of manufacturing an inorganic building material of the present invention, a cement, a siliceous material, and pulp, a manufacturing method for the inorganic building materials as a main component and filler, waste material of the mineral building material ground to 100 ～500Myuemu What was water-repellent-treated with alkylalkoxysilane and a polymer thereof was added at a ratio of 5 to 30 wt% with respect to 70 to 95 wt% of the main component.
本発明において無機質建材（窯業系建材又はセメント板ともいう）とは、通常セメント類、ケイ酸含有物質、補強繊維材料等を原料として乾式法あるいは湿式法（抄造法）によって製造された建材である。本発明において使用される無機質建材廃材とは、建築物の修理、撤去等によって生ずるセメント板廃材、あるいはセメント板を製造する際、発生する不良品や端材、現場施工時に発生する端材等である。 In the present invention , an inorganic building material (also referred to as a ceramic building material or a cement board) is a building material usually produced by a dry method or a wet method (paper making method) using cements, silicic acid-containing substances, reinforcing fiber materials, etc. as raw materials. . Inorganic building material waste materials used in the present invention are cement board waste materials generated by repairs, removal, etc. of buildings, or defective products and scrap materials generated when manufacturing cement boards, scrap materials generated at the site construction, etc. is there.
無機質建材の主成分の一つとされるセメントは、特に限定されず、ポルトランドセメント、ジェットセメント、高炉スラグセメント、フライアッシュセメント、アルミナセメント等が使用される。配合割合は、３０〜５０ｗｔ％で使用される。 The cement considered as one of the main components of the inorganic building material is not particularly limited, and Portland cement, jet cement, blast furnace slag cement, fly ash cement, alumina cement and the like are used. The blending ratio is 30 to 50 wt%.
他の主成分の珪酸質原料としては、ケイ石粉、シリカ粉、シリカヒューム、シラスバルーン、パーライト、マイカ、ケイ藻土、ドロマイト、ウォラストナイト、ガラス粉、ケイ質粘土、ベントナイト等の１種または２種以上が使用される。配合割合は、３０〜５０ｗｔ％で使用される。 Other main components silicotungstic acid feedstock of silica stone powder, silica powder, silica fume, shirasu balloons, perlite, mica, diatomaceous earth, dolomite, wollastonite, glass powder, siliceous clay, one or bentonite Or 2 or more types are used. The blending ratio is 30 to 50 wt%.
さらに無機質建材の他の主成分のパルプは、パルプに限られず、パルプ廃液、パルプ繊維、故紙解繊物でもよく、主成分中で０．１〜５ｗｔ％の割合で配合する。 Furthermore, the pulp of the other main component of the inorganic building material is not limited to pulp, and may be pulp waste liquid, pulp fiber, waste paper defibrated material, and blended at a ratio of 0.1 to 5 wt% in the main component.
さらに他の主成分の充填材としては、高炉スラグ、フライアッシュ、石炭灰等の珪酸質原料や、ＣａＯ、ＳｉＯ2、およびＡｌ2Ｏ3等の活性物質、酸化アルミニウム、水酸化アルミニウム、ボーキサイトなどアルミナ系鉱物、マグネシア、ジルコンなどの耐火物が使用されうる。配合割合は、残部に使用される。 Still other main component fillers include siliceous raw materials such as blast furnace slag, fly ash and coal ash, active substances such as CaO, SiO 2 and Al 2 O 3 , aluminum oxide, aluminum hydroxide, bauxite, etc. Refractories such as alumina-based minerals, magnesia and zircon can be used. The blending ratio is used for the balance.
無機質建材の主成分にはその他に、補強用にポリエステル繊維、ポリアミド繊維、アクリル繊維、アセテート繊維、ポリエチレン繊維、ポリプロピレン繊維等の有機繊維やガラス繊維、炭素繊維、セラミック繊維、金属繊維等の無機繊維等や鉄筋マット、ラス網等の補強材料の１種または２種以上が使用されてもよい。 Other inorganic building materials include organic fibers such as polyester fibers, polyamide fibers, acrylic fibers, acetate fibers, polyethylene fibers, polypropylene fibers, glass fibers, carbon fibers, ceramic fibers, and metal fibers for reinforcement. 1 type, or 2 or more types of reinforcement materials, such as etc., a reinforcing bar mat, a lath net, etc. may be used.
本発明において撥水処理に使用する撥水処理剤としては、アルキルアルコキシシラン及びその重合物、ワックス、パラフィン、シリコン等が使用される。 As the water repellent treatment agent used for the water repellent treatment in the present invention, alkylalkoxysilane and its polymer, wax, paraffin, silicon and the like are used.
その他、塩化カルシウム、塩化マグネシウム、水酸化マグネシウム、硫酸アルミニウム、アルミン酸ソーダ、水ガラス等のセメント硬化促進剤等が使用されてもよい。 In addition, cement hardening accelerators such as calcium chloride, magnesium chloride, magnesium hydroxide, aluminum sulfate, sodium aluminate, and water glass may be used.
無機質建材の撥水処理した廃材を主成分７０〜９５ｗｔ％に対して５〜３０ｗｔ％の割合に添加して用いるとしたのは、５ｗｔ％未満では、廃材の利用の効果が少なく、５ｗｔ％以上が好ましく、３０ｗｔ％を超えると、廃材の利用のことからは好ましいが、製品の品質が悪くなり、不良品が発生するおそれがある。 The use of waste materials treated with water-repellent inorganic building materials in a proportion of 5 to 30 wt% with respect to 70 to 95 wt% of the main component is less than 5 wt%, and the effect of using the waste material is small and 5 wt% or more. However, if it exceeds 30 wt%, it is preferable from the viewpoint of the use of waste materials, but the quality of the product is deteriorated, and a defective product may be generated.
本発明において、添加する廃材の粒径を１００〜５００μｍとしたのは、１００μｍ未満では、抄造方式では濾過抵抗が大きくなり、生産性が悪化し、生産性の面から廃材の使用量を少なくしなければならなくなるからである。また、脱水プレス方式でも、脱水時の抵抗が大きくなり、これも生産性が悪化し、廃材の使用量を少なくしなければならなくなるからである。また、粒径が５００μｍを超えると、無機質建材の品質、特に外観に悪影響を及ぼすおそれがあるので、添加量を減らさねばならなくなるからである。 In the present invention, the particle size of the waste material to be added is set to 100 to 500 μm. If the particle size is less than 100 μm, the filtration resistance increases in the paper making method, the productivity deteriorates, and the amount of waste material used is reduced from the viewpoint of productivity. Because you have to do it. In addition, even in the dewatering press method, resistance during dehydration increases, which also deteriorates productivity and requires a reduction in the amount of waste material used. In addition, if the particle size exceeds 500 μm, the quality of the inorganic building material, particularly the appearance, may be adversely affected, so the amount added must be reduced.
本発明において、添加する廃材の嵩比重が０．１〜１．０ｇ／ｃｍ3としたのは、この範囲のものが、生産性が許容される範囲であり、品質的に不良品を生産する率が小さいからである。 In the present invention, the bulk specific gravity of the waste material to be added is set to 0.1 to 1.0 g / cm 3, and this range is a range in which productivity is allowed, and a defective product is produced in quality. This is because the rate is small.
本発明において、添加する粉砕した廃材の吸水率が３０〜４０％としたのは、この範囲を外れると、濾過抵抗が大きくなり、抄造方式の成形で生産性が悪くなるおそれがある。 In the present invention, the water absorption rate of the pulverized waste material to be added is set to 30 to 40%. If the water absorption rate is out of this range, the filtration resistance increases, and the productivity may be deteriorated by forming the papermaking method.
廃材の粉砕方法は、ボールミル、ローラミル等の磨砕式の粉砕方法でも、ハンマーミル、インパクトミル等の衝撃式方法のいずれでもよい。 The waste material may be pulverized by either a grinding method such as a ball mill or a roller mill, or an impact method such as a hammer mill or an impact mill.
以下、本発明による無機質建材の製造で使用する無機質建材の廃材の条件を変えて成形した実施例を表１に示す。なお、比較のために同表に比較例及び参考例も示している。 Hereinafter, Table 1 shows examples of molding by changing the conditions of waste materials of inorganic building materials used in the production of inorganic building materials according to the present invention. For comparison, comparative examples and reference examples are also shown in the same table.
無機質建材廃材を使用する無機質建材は、図１に示すような方法で製造される。 The inorganic building material using the inorganic building material waste is manufactured by a method as shown in FIG.
まず、無機質建材の原料は、普通セメント４０ｗｔ％、珪酸質材料４０ｗｔ％、パルプ５ｗｔ％、充填材等１５ｗｔ％の割合に混合して調製する。 First, the raw material of the inorganic building material is prepared by mixing at a ratio of 40 wt% of ordinary cement, 40 wt% of siliceous material, 5 wt% of pulp, 15 wt% of filler and the like.
それと別に、無機質建材廃材を粉砕し、平均粒径が３０〜６００μｍに篩い分けし、その粉砕物をアルキル基の炭素数を４〜８とし、分子量を３００〜６０００としたアルキルアルコキシシラン及びその重合物で撥水処理し、さらに１４０℃で前養生処理し、この廃材が上記無機質建材の原料を７０〜９５に対して５〜３０ｗｔ％になるように秤量する。 Separately, the inorganic building material waste is pulverized, sieved to an average particle size of 30 to 600 μm, and the pulverized product is alkylalkoxysilane having an alkyl group with 4 to 8 carbon atoms and a molecular weight of 300 to 6000, and polymerization thereof. Water-repellent treatment is carried out with an object, and further pre-curing treatment is performed at 140 ° C., and this waste material is weighed so that the raw material of the inorganic building material is 5 to 30 wt% based on 70 to 95.
そして、上記無機質建材の原料と混合し、固形分３〜３０％のスラリー化し、抄造方式によりグリーンシートを得、脱水プレス方式により加圧成形後、養生を１７０℃程度のオートクレーブ養生を施して成形製品を得る。 And it mixes with the raw material of the above-mentioned inorganic building materials, makes a slurry of 3 to 30% solid content, obtains a green sheet by a papermaking method, press-molds by a dehydrating press method, and then forms a curing by applying an autoclave curing at about 170 ° C. Get the product.
濾過抵抗は、この固形分３〜３０％のスラリーを用いて測定し、脱水抵抗は脱水プレス時に評価した。廃材の吸水率、平均粒径及び嵩比重は、篩い分けして撥水処理した廃材について測定した。 Filtration resistance was measured using a slurry having a solid content of 3 to 30%, and dehydration resistance was evaluated at the time of dehydration press. The water absorption rate, average particle diameter, and bulk specific gravity of the waste material were measured for the waste material that had been sieved and subjected to water repellent treatment.
表１に示す結果から、撥水処理無しでは、吸水率が大きくて、濾過抵抗も大きい。すなわち、抄造時の濾過抵抗の評価では、撥水処理なしの廃材を同率添加したものより、良好な結果が得られた。また、同様の濾過抵抗では、再生材の添加量を従来より増やせることが確認できた。さらに、脱水プレス時の脱水抵抗を評価したところ、濾過時同様の結果が得られた。 From the results shown in Table 1, the water absorption rate is large and the filtration resistance is large without water repellent treatment. That is, in the evaluation of the filtration resistance at the time of papermaking, a better result was obtained than that obtained by adding the same rate of waste material without water repellent treatment. In addition, it was confirmed that with the same filtration resistance, the amount of the recycled material added can be increased as compared with the conventional one. Furthermore, when the dehydration resistance at the time of dehydration press was evaluated, the same result at the time of filtration was obtained.
廃材の平均粒径が３０μｍでは、濾過抵抗、脱水抵抗が大きくなる。廃材の平均粒径が６００μｍでは、濾過抵抗が大きいと共に品質面、特に外観で問題があった。実施例では、濾過抵抗、脱水抵抗が大きいということがなく生産性がよかった。 When the average particle size of the waste material is 30 μm, the filtration resistance and the dehydration resistance are increased. When the average particle size of the waste material was 600 μm, there was a problem in terms of quality, particularly appearance, as well as high filtration resistance. In the examples, the filtration resistance and dehydration resistance were not large and the productivity was good.
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