JPH06212516A - Production of ceramic fiber - Google Patents

Production of ceramic fiber

Info

Publication number
JPH06212516A
JPH06212516A JP4339040A JP33904092A JPH06212516A JP H06212516 A JPH06212516 A JP H06212516A JP 4339040 A JP4339040 A JP 4339040A JP 33904092 A JP33904092 A JP 33904092A JP H06212516 A JPH06212516 A JP H06212516A
Authority
JP
Japan
Prior art keywords
aluminum
weight
fiber
melt
ash
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
JP4339040A
Other languages
Japanese (ja)
Inventor
Yutaka Murakami
豊 村上
Yutaka Sasaki
豊 佐々木
Soichiro Motoi
操一郎 元井
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Taiheiyo Cement Corp
Original Assignee
Onoda Cement Co Ltd
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
Application filed by Onoda Cement Co Ltd filed Critical Onoda Cement Co Ltd
Priority to JP4339040A priority Critical patent/JPH06212516A/en
Publication of JPH06212516A publication Critical patent/JPH06212516A/en
Pending legal-status Critical Current

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  • Inorganic Fibers (AREA)

Abstract

PURPOSE:To obtain heat-resistant ceramic fiber having a large fiber length with hardly any amount of shots by melt spinning a specific mixture containing coal ash and aluminum sludge, etc. CONSTITUTION:A mixture comprising (A) 50-80wt.% coal ash and (B) 20-50wt.% aluminum sludge and/or aluminum residual ash at 0.7-1.5 weight ratio of (SiO2/ Al2O3) is melted at >=1700 deg.C and the resultant melt is then spun. Thereby, fine fiber having low thermal shrinkage is obtained in high yield.

Description

【発明の詳細な説明】Detailed Description of the Invention

【0001】[0001]

【産業上の利用分野】本発明は、産業廃棄物である石炭
灰とアルミニウム残灰及び/又はアルミニウムスラッジ
を原料とし、ショットが少なく、熱収縮の小さい、優れ
た耐熱性セラミック繊維の製造法に関する。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an excellent heat-resistant ceramic fiber, which is produced from coal ash and aluminum residual ash and / or aluminum sludge, which are industrial wastes, as a raw material, has a small amount of shots and a small heat shrinkage .

【0002】[0002]

【従来の技術】石炭灰は、微粉炭燃焼の際の灰分が半融
状態となったもので、産業廃棄物の1つであり、有効利
用が模索されている。
2. Description of the Related Art Coal ash is one in which the ash content in pulverized coal combustion is in a semi-molten state and is one of industrial wastes, and its effective utilization is being sought.

【0003】従来、石炭灰を主原料とした繊維として
は、これに成分補正原料としてSiO2、アルカリ土類金属
酸化物等を添加し、溶融、紡糸したロックウールクラス
の無機繊維がある。しかしながら、このような無機繊維
は、耐熱性に劣り、弾性がなく脆いという欠点を有して
いた。
Conventionally, as a fiber mainly made of coal ash, there is an inorganic fiber of rock wool class which is obtained by adding SiO 2 , alkaline earth metal oxide and the like as a raw material for component correction, and melting and spinning. However, such an inorganic fiber has a drawback that it is inferior in heat resistance, has no elasticity, and is brittle.

【0004】一方、通常のセラミック繊維は、Al2O3
SiO2を主体とした原料を高温で溶融し、生成した融液を
ブローイング法やスピニング法で繊維化することにより
得られる。
On the other hand, normal ceramic fibers are Al 2 O 3 and
It is obtained by melting a raw material mainly composed of SiO 2 at a high temperature, and forming a melt into a fiber by a blowing method or a spinning method.

【0005】しかしながら、これらの原料として、比較
的高純度の窯業原料、例えばバイヤーアルミナ、シリマ
ナイト、カイヤナイト、デイカイト、カオリン、珪石等
が使用されるため、費用がかかり、不経済である。ま
た、このようなAl2O3-SiO2系のセラミック繊維ではAl2O
3 の含有量が多い程耐熱性に優れ、Al2O3 がSiO2より少
ないと十分な耐熱性が得られない。従って、十分な耐熱
性を得るためには、Al2O 3 の含有量を多くする必要があ
るが、このようにすると、融液の粘度が低下すると共に
表面張力が増大し、紡糸の際にショットが多量に生成し
(40μm 以上のものが45〜55重量%)、繊維の歩
留が低下する。また、ショットを多く含む繊維は、断熱
性が悪く、更にそれが脱落し、他の部品等を傷付けると
いう欠点を有する。
However, comparing these raw materials,
High-purity ceramic raw materials, such as Bayer alumina and Silyma
Knight, Kyanite, Deikite, Kaolin, silica stone, etc.
Is used, it is expensive and uneconomical. Well
Al like this2O3-SiO2Al in the ceramic fibers2O
3The higher the content of Al, the better the heat resistance,2O3Is SiO2Less than
Without it, sufficient heat resistance cannot be obtained. Therefore, sufficient heat resistance
In order to obtain the2O 3It is necessary to increase the content of
However, if this is done, the viscosity of the melt will decrease and
The surface tension increases and a lot of shots are generated during spinning.
(45-55% by weight of 40 μm or more), fiber length
The stay is reduced. Also, the fibers that contain a lot of shots are insulated
If it is bad and it falls off and damages other parts etc.
It has a drawback.

【0006】また、通常のセラミック繊維は、繊維径が
1〜3.5μm のものが大部分を占め、繊維長は平均1
〜3cmであるが、5mm以下の短繊維が10〜30重量%
も含まれている。このように5mm以下の短繊維を多く含
むものは、強度が弱く、繊維に撚りがかけ難いという欠
点を有する。
Most of the ordinary ceramic fibers have a fiber diameter of 1 to 3.5 μm, and the fiber length is 1 on average.
~ 3 cm, but 10 to 30% by weight of short fibers of 5 mm or less
Is also included. As described above, those containing a large amount of short fibers of 5 mm or less have the drawbacks that the strength is weak and the fibers are difficult to twist.

【0007】[0007]

【発明が解決しようとする課題】従って本発明の目的
は、産業廃棄物を有効に利用し、ショット量が少なく、
かつ繊維長の長い優れた耐熱性セラミック繊維を安価に
製造する方法を提供することにある。
SUMMARY OF THE INVENTION Therefore, an object of the present invention is to effectively utilize industrial waste, to reduce the shot amount,
Another object of the present invention is to provide a method for inexpensively producing an excellent heat-resistant ceramic fiber having a long fiber length.

【0008】[0008]

【課題を解決するための手段】斯かる実状に鑑み、本発
明者は鋭意研究を行った結果、産業廃棄物たる石炭灰、
アルミニウム残灰、アルミニウムスラッジを不純物を除
去することなく特定の比率で用いれば、高価な窯業原料
を使用せず経済的であり、しかも意外にもショット含有
量が少なく、繊維が長く、耐熱性も優れているセラミッ
ク繊維が得られることを見出し本発明を完成した。
In view of the above situation, the present inventor has conducted diligent research, and as a result, coal ash, which is industrial waste,
If you use aluminum residual ash and aluminum sludge in a specific ratio without removing impurities, it is economical without using expensive ceramic raw materials, and surprisingly the shot content is small, the fiber is long, and the heat resistance is also high. The inventors have completed the present invention by finding that excellent ceramic fibers can be obtained.

【0009】すなわち、本発明は(1)石炭灰50〜8
0重量%並びに(2)アルミニウム残灰及び/又はアル
ミニウムスラッジ20〜50重量%を含有し、SiO2/Al
2O3の重量比が0.7〜1.5である混合物を1700
℃以上の融液となし、この融液から紡糸することを特徴
とするセラミック繊維の製造法を提供するものである。
That is, the present invention provides (1) coal ash 50 to 8
SiO 2 / Al containing 0% by weight and (2) 20 to 50% by weight of aluminum residual ash and / or aluminum sludge.
1700 for a mixture in which the weight ratio of 2 O 3 is 0.7-1.5.
The present invention provides a method for producing a ceramic fiber, which comprises forming a melt at a temperature of not less than 0 ° C and spinning from the melt.

【0010】本発明に用いる石炭灰は、微粉炭燃焼の火
力発電所等で、ボイラーの燃焼ガス中の微粉炭灰分を捕
集したものである。本発明で用いる石炭灰は、例えば次
の表1に示す化学組成のものである。
The coal ash used in the present invention is obtained by collecting the pulverized coal ash content in the combustion gas of a boiler at a pulverized coal combustion thermal power plant or the like. The coal ash used in the present invention has, for example, a chemical composition shown in Table 1 below.

【0011】[0011]

【表1】 [Table 1]

【0012】石炭灰は50〜80重量%含有せしめる
が、この量が50重量%未満であると表面張力が増大
し、ショットの発生量が多くなり、80重量%を超える
と融液の粘性が高くなり細い繊維が製造できないので好
ましくない。
Coal ash is contained in an amount of 50 to 80% by weight. If this amount is less than 50% by weight, the surface tension increases and the amount of shots increases, and if it exceeds 80% by weight, the viscosity of the melt is increased. It is not preferable because it becomes too high to produce fine fibers.

【0013】本発明に用いるアルミニウム残灰は、アル
ミニウム再生工場から発生する残灰であり、一般に、次
の表2の組成をもっている。
The aluminum residual ash used in the present invention is a residual ash generated from an aluminum recycling plant, and generally has the composition shown in Table 2 below.

【0014】[0014]

【表2】 [Table 2]

【0015】また、本発明に用いるアルミニウムスラッ
ジは、アルマイト業界からの廃棄物で表面加工のエッチ
ング工程において発生した沈澱物を脱水したものであ
り、一般に次の表3の組成をもっている。
The aluminum sludge used in the present invention is a waste product from the alumite industry and is obtained by dehydrating a precipitate generated in the etching step of surface processing, and generally has the composition shown in Table 3 below.

【0016】[0016]

【表3】 [Table 3]

【0017】上記のアルミニウム残灰及び/又はアルミ
ニウムスラッジの含有量は、20〜50重量%である
が、この量が20重量%未満であると融液の粘性が高く
なり細い繊維が紡糸しにくく、しかも繊維の耐熱性が低
下し、50重量%を超えると融液の表面張力が増大し、
ショットの発生が多い繊維となってしまい好ましくな
い。
The content of the above-mentioned aluminum residual ash and / or aluminum sludge is 20 to 50% by weight. If this amount is less than 20% by weight, the viscosity of the melt becomes high and fine fibers are difficult to spin. Moreover, the heat resistance of the fiber decreases, and when it exceeds 50% by weight, the surface tension of the melt increases,
This is not preferable because the fibers often generate shots.

【0018】本発明においては、更に上記原料のSiO2
Al2O3 の重量比が0.7〜1.5であることが必要であ
る。この重量比が0.7未満であると、融液の表面張力
が増大し、ショットの発生が多くなり、1.5を超える
と、融液の粘性が高くなりすぎ、紡糸繊維が太くなって
しまい、いずれも好ましくない。
In the present invention, the above-mentioned raw material SiO 2 /
It is necessary that the weight ratio of Al 2 O 3 is 0.7 to 1.5. If this weight ratio is less than 0.7, the surface tension of the melt will increase and shots will often occur. If it exceeds 1.5, the viscosity of the melt will be too high and the spun fiber will become thick. Both are not preferable.

【0019】本発明では、上記の原料を、その不純物を
除去することなく、炉により1700℃以上の融液とす
る。このように不純物を除去しないで溶融することによ
り次の如き利点が得られる。
In the present invention, the above raw material is made into a melt at 1700 ° C. or higher in a furnace without removing its impurities. By melting without removing impurities in this way, the following advantages are obtained.

【0020】すなわち、不純物中のFe2O3 、MgO 、ZnO
は高温粘性を幾分上昇し、Al2O3分を高めたことによる
表面張力増大を緩和してさらに高温における圧縮復元性
を付与する。また、MgO は、熱収縮を低減する効果を発
揮し、PbO 、SO3 と共に表面張力の低下に寄与してい
る。更に、微量のCaO 、Sr2O 、Na2O 、K2O 、MnO は溶
融温度を下げるのに有効に作用し、ZrO2 は低熱収縮性
に、TiO2 は柔軟性を付与する。
That is, Fe 2 O 3 , MgO and ZnO in impurities
Increases the high temperature viscosity to some extent and alleviates the increase in surface tension caused by increasing the Al 2 O 3 content, and imparts compressive recoverability at higher temperatures. Further, MgO exerts an effect of reducing heat shrinkage, and contributes to a decrease in surface tension together with PbO 2 and SO 3 . Furthermore, a trace amount of CaO, Sr 2 O, Na 2 O, K 2 O, and MnO act effectively to lower the melting temperature, ZrO 2 imparts low heat shrinkability, and TiO 2 imparts flexibility.

【0021】本発明でのみみられる産業廃棄物を高度に
利用するという顕著な作用効果の一つは、アルミニウム
残灰又はアルミニウムスラッジ中の金属Alを始めとする
Ni、Cu等の微量金属によるものである。ことにアルミニ
ウム残灰中に多量に含有されている金属Alは10-5Ω−
cmと極めて小さい比抵抗のため、通電抵抗を低下させ大
きな安定電流を流せるので溶融時間を短縮せしめ、均質
な融液の調製を可能とする。このことから電力原単位は
下げられ、融液が均質のため繊維収率が向上し結果とし
てコストを下げることができる。しかも、この金属Alは
次式の高温反応により、SiO2 を除去し、Al2O3 を増量
するため耐熱性を向上する効果的な作用を有する。
One of the remarkable effects of highly utilizing the industrial waste found only in the present invention is the metal Al in the aluminum residual ash or aluminum sludge.
This is due to trace metals such as Ni and Cu. In particular, a large amount of metallic Al contained in the residual aluminum ash was 10 −5 Ω−.
Since the specific resistance is very small, such as cm, the current resistance is reduced and a large stable current can be passed, so the melting time is shortened and a homogeneous melt can be prepared. As a result, the power consumption rate can be reduced, and since the melt is homogeneous, the fiber yield can be improved, resulting in cost reduction. Moreover, this metallic Al has an effective action of improving the heat resistance by removing SiO 2 and increasing the amount of Al 2 O 3 by the high temperature reaction of the following formula.

【0022】3SiO2 + 2Al = Al2O3 + 3SiO↑3SiO 2 + 2Al = Al 2 O 3 + 3SiO ↑

【0023】また、AlN はAlとの高温酸化反応によりN
2 を発生し、このガスの攪拌効果で融液を均質化してい
る。
AlN is converted to N by high temperature oxidation reaction with Al.
2 is generated, and the melt is homogenized by the stirring effect of this gas.

【0024】本発明における融液からの紡糸手段は、特
に制限されず常法に従って行われる。
The spinning method from the melt in the present invention is not particularly limited and may be carried out according to a conventional method.

【0025】[0025]

【発明の効果】本発明では、上述のように微量成分の複
合相乗効果により溶融温度が1700℃以上と低く、し
かも繊維化に必要な適性粘度である20〜30poise が
容易に得られ、表面張力の上昇が抑えられるため、ショ
ット量の少ない、繊維長の長い、優れた耐熱性のセラミ
ック繊維を高収率で得ることができる。
According to the present invention, as described above, due to the combined synergistic effect of the trace components, the melting temperature is as low as 1700 ° C. or more, and the suitable viscosity required for fiber formation is 20 to 30 poise, and the surface tension As a result, the amount of shots can be suppressed, and a ceramic fiber with a small shot amount, a long fiber length, and excellent heat resistance can be obtained in a high yield.

【0026】[0026]

【実施例】以下、実施例を挙げて本発明を更に詳細に説
明するが本発明はこれらに限定されるものではない。
The present invention will be described in more detail with reference to examples, but the present invention is not limited thereto.

【0027】実施例1 下記、表4及び5に示す化学組成の石炭灰(プレアゾー
ル炭)73.7重量%、アルミニウム残灰26.3重量
%を混合し、顆粒状とした調合原料(SiO2/Al 2O3
1.03)を500KVA のエルー炉で溶融した。約30
分で1700℃以上の融液が生成したところで炉を傾倒
し、流出する細流に圧縮空気(7kg/cm2)を吹付け得
られたセラミック繊維の物性を表7に示す。
Example 1 Coal ash (pre-azo) having the chemical composition shown in Tables 4 and 5 below.
73.7% by weight, aluminum residual ash 26.3% by weight
% To make a granulated compound raw material (SiO2/ Al 2O3=
1.03) was melted in a 500 KVA Eru furnace. About 30
The furnace is tilted when a melt of 1700 ° C or higher is generated in a minute
Compressed air (7 kg / cm2) Can be sprayed
Table 7 shows the physical properties of the obtained ceramic fibers.

【0028】実施例2 実施例1と同様にして、表4及び6に示す化学組成の石
炭灰(プレアゾール炭)57.1重量%、アルミニウム
スラッジ42.9重量%を混合し、顆粒状とした調合原
料(SiO2/Al2O3 =1.00)を溶融して、Al2O3 含有
量の大きいセラミック繊維が得られた。表7にその物性
を示す。
Example 2 In the same manner as in Example 1, 57.1% by weight of coal ash (preazole coal) having the chemical composition shown in Tables 4 and 6 and 42.9% by weight of aluminum sludge were mixed to give a granular form. melting the blended raw material (SiO 2 / Al 2 O 3 = 1.00), large ceramic fibers of Al 2 O 3 content was obtained. Table 7 shows the physical properties.

【0029】実施例3 実施例1と同様にして、表4、5及び6に示す化学組成
の石炭灰(プレアゾール炭)65.2重量%、アルミニ
ウム残灰22.5重量%、アルミニウムスラッジ12.
3重量%を混合し、顆粒状とした調合原料(SiO2/Al2O
3 =0.90)を溶融して、Al2O3 含有量の大きいセラ
ミック繊維が得られた。表7にその物性を示す。
Example 3 In the same manner as in Example 1, 65.2% by weight of coal ash (preazole coal) having the chemical composition shown in Tables 4, 5 and 6, 22.5% by weight of residual aluminum ash, and aluminum sludge 12.
3% by weight was mixed to make a granulated compound raw material (SiO 2 / Al 2 O
3 = 0.90) was melted to obtain a ceramic fiber having a high Al 2 O 3 content. Table 7 shows the physical properties.

【0030】比較例 実施例1と同様にして、ジョージアカオリンにアルミナ
を混合し、SiO2/Al2O 3 =1.00なる化学組成のセラ
ミック繊維を得た。表7にその物性を示す。
Comparative Example Georgia kaolin and alumina were processed in the same manner as in Example 1.
Mix, SiO2/ Al2O 3Cera with a chemical composition of 1.00
Mick fiber was obtained. Table 7 shows the physical properties.

【0031】[0031]

【表4】 [Table 4]

【0032】[0032]

【表5】 [Table 5]

【0033】[0033]

【表6】 [Table 6]

【0034】[0034]

【表7】 [Table 7]

Claims (1)

【特許請求の範囲】[Claims] 【請求項1】 (1)石炭灰50〜80重量%並びに
(2)アルミニウム残灰及び/又はアルミニウムスラッ
ジ20〜50重量%を含有し、SiO2/Al2O3 の重量比が
0.7〜1.5である混合物を1700℃以上の融液と
なし、この融液から紡糸することを特徴とするセラミッ
ク繊維の製造法。
1. A method comprising (1) 50 to 80% by weight of coal ash and (2) 20 to 50% by weight of aluminum residual ash and / or aluminum sludge, and having a weight ratio of SiO 2 / Al 2 O 3 of 0.7. A method for producing a ceramic fiber, which comprises forming a mixture having a melting point of about 1.5 to 1700 ° C. or higher and spinning the melt.
JP4339040A 1992-12-18 1992-12-18 Production of ceramic fiber Pending JPH06212516A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP4339040A JPH06212516A (en) 1992-12-18 1992-12-18 Production of ceramic fiber

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP4339040A JPH06212516A (en) 1992-12-18 1992-12-18 Production of ceramic fiber

Publications (1)

Publication Number Publication Date
JPH06212516A true JPH06212516A (en) 1994-08-02

Family

ID=18323706

Family Applications (1)

Application Number Title Priority Date Filing Date
JP4339040A Pending JPH06212516A (en) 1992-12-18 1992-12-18 Production of ceramic fiber

Country Status (1)

Country Link
JP (1) JPH06212516A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103820881A (en) * 2014-02-08 2014-05-28 北京大学 Method for preparing ceramic fibers from high-aluminum fly ash

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103820881A (en) * 2014-02-08 2014-05-28 北京大学 Method for preparing ceramic fibers from high-aluminum fly ash

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