KR20010074309A - Production method of light weight and multi-pore ceramic using waste glass and mineral resources and the product therefrom - Google Patents
Production method of light weight and multi-pore ceramic using waste glass and mineral resources and the product therefrom Download PDFInfo
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- KR20010074309A KR20010074309A KR1020010024722A KR20010024722A KR20010074309A KR 20010074309 A KR20010074309 A KR 20010074309A KR 1020010024722 A KR1020010024722 A KR 1020010024722A KR 20010024722 A KR20010024722 A KR 20010024722A KR 20010074309 A KR20010074309 A KR 20010074309A
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- 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
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62204—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
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- 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
- C04B2111/40—Porous or lightweight materials
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- 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
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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- 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
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/6261—Milling
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- 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
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Ceramic Engineering (AREA)
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- Organic Chemistry (AREA)
- Processing Of Solid Wastes (AREA)
Abstract
Description
본 발명은 산업폐기물의 일종인 폐유리와 광물소재를 이용한 경량 다공성 세라믹 제품의 제조방법에 관한 것으로, 더욱 상세하게는 폐유리 및 폐점토, 폐규조토, 폐주물사, 폐분진, 석재가공 스러지와 같은 폐광물소재를 파쇄기를 이용하여 파쇄 및 분말가공하여 주원료로 이용하고 여기에 국내외 광산에서 생산되는 광물소재등을 선택하여 적정비율로 혼합후 성형기를 이용하여 성형후 소성로에서의 저온소성 공정 및 냉각공정을 통하여 다양한 다공성 경량세라믹 제품을 제조하는 방법에 관한 것이다.The present invention relates to a method for manufacturing a lightweight porous ceramic product using waste glass and mineral material, which is a kind of industrial waste, and more specifically, waste glass and waste clay, waste diatomaceous earth, waste casting sand, waste dust, stone processing sludge, and the like. The waste mineral material is crushed and powder processed using a crusher to be used as the main raw material, and mineral materials produced at domestic and overseas mines are selected and mixed at an appropriate ratio. It relates to a method for producing a variety of porous lightweight ceramic products through.
통상적으로 우리 일상생활이나 산업화 과정에서 발생되고 있는 폐유리 및 폐광물소재들은 산업활동의 증가와 함께 매년 증가되고 있는 실정이며 이들을 이용하는 기술도 다양하면서 점증되고 있는 실정이다.In general, the waste glass and waste mineral materials generated in our daily life or industrialization are increasing year by year with the increase of industrial activities, and the technology using them is increasing in various ways.
이들을 살펴보면, 일상생활에서 사용하고 폐기되는 판유리, 음료수병, 닝겔병, 농약병, 술병, 유리섬유 등과 같은 각종 병이나 유리 등과 같은 폐유리를 이용하거나 다른 재료를 혼합시켜 새로운 제품을 활용하고 있는 바, 분말로 분쇄한 폐유리에 삼산화 안티몬이나 질산나트륨 등을 혼합한 분말유리 혼합물을 성형틀에 약간의 두께로 깔고 그 상면에 적정한 크기로 분쇄한 폐입자를 일정두께로 깔은 다음 염화나트륨 수용액을 분사하여 이를 소성로에서 920℃의 열로 가열한 후 서냉시킴으로서 얻게되는 폐유리를 이용한 유리타일의 제조, 대한민국 특허등록번호제239216호의 산업폐기물인 제철소 폐분진과 폐유리를 원료로 타일을 제조하는 방법, 대한민국 특허출원번호제1999-32098호의 파쇄시킨 폐유리를 시멘트 및 보조첨가제와 함께 일정비율로 섞은 후 성형기에서 압축성형하여 블럭을 성형한 후 양생과정을 거쳐 완제품의 블럭을 제조하는 폐유리를 이용한 보도블럭 및 그 제조방법, 대한민국 특허등록번호제281793호의 미세한 유리분말에 탄소를 균일하게 혼합한 것을 금속형틀에 이형제로 알루미나 슬러리를 도포한 형틀에 넣고 전기머플로에서 승온 및 유지과정을 통해 폐유리를 원료로 한 경량골재의 제조방법과 같은 많은 것들이 소개되어져 있다.If you look at them, they are using new products by using waste glass such as various glass or glass such as flat glass, beverage bottle, Ningel bottle, pesticide bottle, liquor bottle, glass fiber, etc. that are used and discarded in daily life. The powdered glass mixture containing antimony trioxide or sodium nitrate was mixed with a small amount of powder into a waste glass crushed into powder, and the waste particles crushed to an appropriate size on the upper surface were spread to a certain thickness and then sprayed with an aqueous sodium chloride solution. To produce a glass tile using waste glass obtained by heating it to 920 ° C. in a kiln and then slowly cooling it, a method of producing tiles from waste dust and waste glass, which are industrial wastes of Korean Patent Registration No. 239216, as raw materials, Korea The crushed waste glass of patent application No. 1999-32098 is mixed with cement and auxiliary additives at a certain ratio. Press block made of waste glass, which is manufactured by compression molding in a molding machine, and then cured to produce blocks of finished products, and a method of manufacturing the same, and finely mixed carbon in fine glass powder of Korean Patent No. 281793 Many things have been introduced, such as the production of lightweight aggregates from waste glass through heating and holding in an electric muffle, in a mold coated with alumina slurry as a mold release agent.
상기와 같이 폐유리를 이용한 보도블럭, 경량골재, 장식용구, 대리석 등 다양한 제품이 응용개발되고 있는 실정이나 본 발명의 폐유리 및 광물소재를 이용한 경량다공성 세라믹 제품의 제조방법과 같은 것은 아직까지 미진한 실정이다.As described above, various products such as sidewalk blocks, lightweight aggregates, decorative tools, marbles, etc. using waste glass are being developed and applied, but methods such as manufacturing methods of lightweight porous ceramic products using waste glass and mineral materials of the present invention are still incomplete. It is true.
본 발명은 상기한 바와 같이 폐유리 및 폐광물소재를 이용하여 다공성 경량 세라믹 제품을 제조함으로서 가정 및 산업용 폐기물인 폐유리와 폐광물를 유용하게 자원 재활용할 수 있는 폐유리 및 폐광물을 이용한 다공성 경량세라믹 제품 및 그 제조방법을 제공하는 데 그 목적이 있다.The present invention is a porous lightweight ceramic using waste glass and waste minerals that can be recycled resources and useful resources of waste glass and waste minerals for home and industrial waste by manufacturing porous lightweight ceramic products using waste glass and waste mineral material as described above The object is to provide a product and a method of manufacturing the same.
상기한 목적을 달성하기 위하여 본 발명은 폐유리 및 폐점토, 폐규조토, 폐주물사, 폐분진, 석재가공 스러지와 같은 폐광물소재를 분쇄기를 이용하여 분쇄 및 분말가공하여 주원료로 이용하고 여기에 국내외 광산에서 생산되는 광물소재등을 선택하여 적정비율로 혼합후 성형기를 이용하여 성형후 소성로에서의 저온소성 및냉각토록 한다.In order to achieve the above object, the present invention utilizes waste mineral materials such as waste glass and waste clay, waste diatomaceous earth, waste foundry sand, waste dust, stone processing sludge as a main raw material by pulverizing and powder processing using a pulverizer. Select mineral materials produced in mines, mix them in proper ratio, and use the molding machine to make low-temperature firing and cooling in the kiln after molding.
본 발명의 다른 목적은 상기와 같은 제조방법을 통하여 건축 내외장재, 경량골재, 수질 및 대기환경정화재, 여과 및 휠터재, 다공성 인공토양 개량재, 조경자재, 건강보조재료, 기타 세라믹제품과 같은 다양하고 특수한 세라믹 경량 및 다공성 제품을 공급할 수 있다.Another object of the present invention is a variety of materials, such as building interior and exterior materials, lightweight aggregate, water and atmospheric environment purification materials, filtration and filter materials, porous artificial soil improvement materials, landscaping materials, health supplement materials, other ceramic products through the manufacturing method as described above Specialty ceramic lightweight and porous products can be supplied.
본 발명의 또 다른 목적은 산업폐기물을 재활용하여 환경오염을 방지하고 폐자원을 자원화함으로서 원료수입대체 및 국내자원보존의 효과를 기대할 수 있으며 이를통해 외화를 절약하려는데 있다.Another object of the present invention is to prevent the environmental pollution by recycling industrial waste and to recycle the waste resources can expect the effect of raw material import substitution and domestic resources conservation and thereby to save foreign currency.
도 1 은 본 발명의 폐유리와 광물소재를 이용한 경량 다공성 세라믹 제조공정을 보여주는 제조공정도이다.1 is a manufacturing process showing a lightweight porous ceramic manufacturing process using the waste glass and the mineral material of the present invention.
도 2 는 본 발명의 제조공정에 있어서 습식인 경우 폐유리와 광물소재를 이용한 경량 다공성 세라믹 제조공정을 보여주는 제조공정도이다.Figure 2 is a manufacturing process showing the lightweight porous ceramic manufacturing process using the waste glass and the mineral material when wet in the manufacturing process of the present invention.
<도면의 주요 부분에 대한 부호의 설명><Explanation of symbols for the main parts of the drawings>
101 폐유리 102 폐광물소재101 Waste Glass 102 Waste Mineral Materials
103 기타광물소재 104,105 분쇄103 Other mineral materials 104,105 Grinding
201 계량 202 혼합201 Weighing 202 Mix
203 수분사 204 비닐포장203 Moist yarn 204 Vinyl packaging
301 압축성형 401 건조301 Compression Molding 401 Drying
501 소성 601 냉각501 firing 601 cooling
S100 원료가공단계 S200 원료혼합단계S100 Raw material processing step S200 Raw material mixing step
S300 제품성형단계 S400 건조단계S300 Molding Step S400 Drying Step
S500 소성단계 S600 냉각단계S500 firing step S600 cooling step
상기한 목적을 달성하기 위해 본 발명을 첨부한 도면에 의거하여 좀 더 상세히 설명하면 더욱 명백해질 것이다.DETAILED DESCRIPTION OF THE INVENTION In order to achieve the above object, the present invention will be more clearly described with reference to the accompanying drawings.
하기에서 본 발명을 설명함에 있어, 관련된 공지 기능 또는 구성에 대한 구체적인 설명이 본 발명의 요지를 불필요하게 흐릴 수 있다고 판단되는 경우에는 그 상세한 설명은 생략할 것이다. 그리고 후술되는 용어들은 본 발명에서의 기능을 고려하여 정의된 용어들로서 이는 사용자, 운용자의 의도 또는 관례 등에 따라 달라질 수 있다. 그러므로 그 정의는 본 명세서 전반에 걸친 내용을 토대로 내려져야 할 것이다.In the following description of the present invention, if it is determined that a detailed description of a related known function or configuration may unnecessarily obscure the subject matter of the present invention, the detailed description thereof will be omitted. Terms to be described later are terms defined in consideration of functions in the present invention, and may be changed according to intentions or customs of users or operators. Therefore, the definition should be made based on the contents throughout the specification.
도 1은 본 발명에 따른 폐유리 및 광물소재를 이용한 경량 다공성 세라믹 제품의 제조방법을 나타내는 공정도이다.1 is a process chart showing a method for manufacturing a lightweight porous ceramic product using waste glass and mineral material according to the present invention.
본 발명에 따른 폐유리 및 광물소재를 이용한 경량다공성 세라믹 제품을 제조하는 과정은 첨부된 도 1에 도시된 바와 같이, 폐유리 및 폐광물소재를 분쇄하는 원료가공단계(S100)와 상기 유리분말, 점토분말 및 광물소재분말을 일정 중량비로 계량하고 혼합시킨 후 물을 혼합시키는 원료혼합단계(S200)와, 상기 혼합된 원료를 일정한 형태로 성형하는 제품성형단계(S300)와 상기 성형제품을 건조시키는 건조단계(S400)와 상기 건조된 제품을 소성로에 투입하여 소성시키는 소성단계(S500) 및 상기 소성된 것을 작업자가 작업가능한 온도로 냉각을 시키는 냉각단계(S600)로 이루어진다.The process for producing a lightweight porous ceramic product using waste glass and mineral material according to the present invention is shown in Figure 1, the raw material processing step (S100) and the glass powder, pulverizing the waste glass and waste mineral material, The raw material mixing step (S200) for mixing water and mixing the clay powder and mineral material powder in a predetermined weight ratio and mixing the water, and the product forming step (S300) for molding the mixed raw material in a predetermined form and drying the molded product It consists of a drying step (S400) and a firing step (S500) for putting the dried product into a firing furnace (S500) and a cooling step (S600) for cooling the fired to a temperature at which the worker can work.
상기 원료가공단계(S100)에서는 폐유리 및 광물소재를 분말화하기 위하여 원료인 폐유리(101)를 햄머크라샤(hammer crusher), 진동 밀(vibration mill)이나 볼 밀(ball mill)과 같은 분쇄기를 이용하여 분말입도 50∼200메쉬(mesh) 이상의 분말로 분쇄(104)한다. 또한 폐점토, 폐규조토, 폐주물사, 폐분진, 석재가공슬러지 등과 같은 폐광물소재(102)를 상기 폐유리 분쇄시와 같이 햄머크라샤, 진동 밀이나 볼 밀과 같은 분쇄기를 이용하여 분말입도가 50∼200메쉬(mesh) 이상의 분말로 분쇄(105)한다. 기타광물소재(103)는 국내외 광산에서 생산되는 광물소재를 원료구입시 분말입도가 50∼200메쉬(mesh) 이상의 분말규격을 갖는 제품으로 용도에 맞춰 구입하도록 하여 제품에 맞춰 선택(106)한다.In the raw material processing step (S100), in order to powder the waste glass and the mineral material, the waste glass 101, which is a raw material, is used as a crusher such as a hammer crusher, a vibration mill or a ball mill. The powder is pulverized 104 into a powder having a particle size of 50 to 200 mesh or more. In addition, the waste mineral material 102, such as waste clay, waste diatomaceous earth, waste foundry sand, waste dust, stone processing sludge, etc., may be pulverized using a grinder such as a hammer crusher, a vibration mill or a ball mill, as in the case of crushing the waste glass. It is pulverized 105 into a powder of 200 mesh or more. The other mineral material 103 is selected to suit the product by purchasing the mineral material produced in domestic and foreign mines as a product having a powder particle size of 50 ~ 200 mesh (mesh) or more at the time of purchase of raw materials according to the purpose.
상기에 있어서, 미세분말은 분말가공비용이 입도에 따라 고가화되며 원료혼합시 원료의 비중차로 인해 혼합정도가 떨어지는 문제가 있으나 보다 높은 입도로 분말화시 저온소성의 가능으로 에너지비용을 절감할 수 있으며 소성시간을 단축시킬 수 있고 건식 및 습식 방식으로 제품성형시 생산성이 높고 제품의 강도 및 표면품질상태가 매우 양호한 장점을 가지는 특성이 있다. 상기에서 분말크기를 50∼200메쉬(mesh) 이상으로 분말규격을 제한한 것은 50메쉬(mesh) 이하의 분말원료로 실험한 결과 제품성형시 제품표면 및 형태가 불량하고 파손이 발생하며, 제품의 소성시간이 길어지고 20℃∼100℃의 온도상승을 요하며 제품의 강도저하 등 상당한 문제점을 가지는 것으로 나타났으나 50메쉬(mesh) 이상시에는 이러한 문제점들이 나타나지 않았기 때문이다.In the above, the fine powder has a problem that the powder processing cost is high according to the particle size and the mixing degree is lowered due to the specific gravity difference of the raw materials when mixing the raw materials, but the energy cost can be reduced by the low-temperature firing when powdered to a higher particle size It is possible to shorten the firing time and to have the advantages of high productivity when forming a product in a dry and wet manner, and very good strength and surface quality of the product. In the above, the powder size is limited to 50 ~ 200 mesh or more, and the powder size of 50 mesh or less is tested. As a result of product molding, the product surface and shape are poor and breakage occurs. The firing time is long, the temperature rise of 20 ℃ ~ 100 ℃ and appeared to have a significant problem, such as a reduction in the strength of the product, but it is because these problems did not appear when more than 50 mesh (mesh).
상기 원료혼합단계(S200)에서는 상기 원료가공단계(S100)에서의 가공된 원료들을 적정비율로 혼합하는 바 그 혼합방식에 있어서 건식방법과 습식방법으로 나눌수 있다. 여기에서는 바람직한 실시예로 건식방법을 중심으로 설명한다. 상기 원료가공단계(S100)에서 분쇄된 폐유리 분말 20중량%∼80중량%와 분쇄된 폐점토분말 10중량%∼60중량% 그리고 생산하고자 하는 제품의 용도에 따라 선택된 광물소재분말 10중량%∼50중량%의 배합비를 갖도록 계량(201)하고 상기 계량된 각 원료들을 혼합기(mixer)에 넣어 300rpm∼900rpm의 회전 속도로 10분∼30분간 혼합(202)시켜 원료혼합이 완료되면 상기 원료의 총중량 대비 5중량% ∼15중량%의 물을 상기 혼합기의 속도를 50rpm∼150rpm의 상태로 가동시키면서 분사(spray)(203)시킨다. 상기 수분사시 원료 뭉침이 적으며 원료에 고르게 흡수되도록 분사되는 물은 안개와 같이 입자가 미세하도록 함이 바람직하다. 상기 수분사(203)까지 포함하여 혼합(202)이 완료된 원료는 보유수분의 증발 방지를 위하여 비닐포장(204)에 담아 보관한다. 상기에서 사용되는 포장지는 상기 비닐 외에 수분의 증발을 제한할 수 있는 재료를 사용할 수 있음은 물론이다.In the raw material mixing step (S200), the raw materials processed in the raw material processing step (S100) are mixed at an appropriate ratio, and the mixing method may be divided into a dry method and a wet method. Here, a description will be given focusing on the dry method as a preferred embodiment. 20 wt% to 80 wt% of the waste glass powder crushed in the raw material processing step (S100), 10 wt% to 60 wt% of the crushed waste clay powder, and 10 wt% to the mineral material powder selected according to the intended use of the product to be produced. Weighing (201) to have a blending ratio of 50% by weight and put each of the weighed raw materials into a mixer (mixer) 10 minutes to 30 minutes at a rotational speed of 300rpm to 900rpm to mix (202) when the raw material mixing is completed, the total weight of the raw material 5-15% by weight of water is sprayed 203 while operating the speed of the mixer at a state of 50 rpm to 150 rpm. It is preferable that the water is sprayed so that the raw material is less aggregated and the water is sprayed to be absorbed evenly in the raw material so that the particles are fine like fog. The raw material of which mixing 202 is completed, including the water yarn 203, is stored in a vinyl package 204 to prevent evaporation of retained moisture. The wrapping paper used in the above can be used a material that can limit the evaporation of water in addition to the vinyl.
상기 원료혼합단계(S200)의 습식혼합단계는 상기 건식혼합단계(S200)와 유사하다. 다만 분사되는 물의 분사정도가 상이한 바 즉, 상기 건식방법의 원료가공단계(S100)에서의 선택된 소재를 계량(211)하고 상기 계량된 각 원료들을 혼합기 (mixer)에 넣어 혼합(212)시키며 상기 원료혼합시 원료의 총중량 대비 15중량%∼65중량%의 물을 상기 혼합기 속도를 50rpm∼150rpm의 상태로 가동시키면서 분사(213)시키며 이와같이 혼합이 완료된 원료는 수분의 증발을 방지할 수 있도록 비닐포장 (214)에 담아 보관한다.The wet mixing step of the raw material mixing step (S200) is similar to the dry mixing step (S200). However, the injection degree of the water sprayed is different, that is, the selected material in the raw material processing step (S100) of the dry method is weighed (211) and put each of the weighed raw materials in a mixer (mixer) (212) and the raw material 15% to 65% by weight of water is mixed with the sprayer while operating the mixer speed at a speed of 50rpm to 150rpm (213) when mixing, and the raw material is mixed with a plastic bag to prevent evaporation of water. 214).
상기 제품성형단계(S300)에서는 상기 비닐포장된 것에서 비닐을 제거한 것을성형기에 투입시켜 성형하는 단계로 이에도 건식방법과 습식방법이 있는 바 전술한 것처럼 바람직한 실시예로 건식방법을 중심으로 설명하면, 상기 비닐포장(204)된 혼합원료를 비닐을 제거시켜 통상의 기계 또는 유압방식의 프레스기에 장입시킨 후 타일 및 벽돌공정과 동일하게 제품특성과 용도, 제품규격에 따라 상기 프레스의 압력 및 실린더 스트로크(stroke)를 조정하여 적정 압축력을 주어 프레스기를 가동시킴으로서 일정 형태를 가진 제품으로 압축성형(301)시킨다.In the product molding step (S300) is a step of molding by removing the vinyl from the vinyl package to the molding machine to the molding method, which also has a dry method and a wet method as described above with reference to the dry method as a preferred embodiment, The vinyl-packed 204 mixed raw material is removed from the vinyl and loaded into a conventional mechanical or hydraulic press. The pressure and cylinder stroke of the press according to the product characteristics, uses, and product specifications are the same as those of the tile and brick process. By adjusting the stroke) to give the appropriate compression force to operate the press machine to compression molding (301) into a product having a certain shape.
상기에서 압축을 위한 프레스기는 전용기(transfer machine)를 사용할 수 있으며 또한 통상적으로 타일이나 벽돌제조공장에서 사용되어지는 타일 및 벽돌 생산용 유압프레스(30ton∼600ton)또는 철판 절곡용 프레스를 개조시킨 것을 사용할 수도 있다. 상기 압축성형(301)에 필요한 금형(mold)은 전용금형을 제작하여 사용하거나 상기 타일 및 벽돌공장에서 사용 중인 금형을 사용할 수 있다.The press for the compression machine can use a transfer machine and can also be used to modify the hydraulic press (30ton ~ 600ton) or the sheet bending press used for tile and brick production, which is commonly used in tile or brick manufacturing plants. It may be. The mold (mold) required for the compression molding 301 may be used to produce a dedicated mold or a mold used in the tile and brick factory.
상기 제품성형단계(S300)의 습식방법은 상기 비닐포장(214)된 혼합원료의 비닐을 제거시킨 후 성형기에 투입시켜 압출성형(310)시킨다. 이때 성형기는 제품의 특성과 용도, 규격에 따라 전용기 또는 일반적인 습식 타일, 벽돌공장 또는 도자기공장에서 사용하는 압출성형토련기(20kg/㎠∼300kg/㎠)를 사용할 수 있으며, 상기 성형에 필요한 금형은 타일 및 벽돌공장에서 사용중인 금형들을 공용으로 사용할 수 있다. 상기와 같이 습식방법의 성형공정은 습식타일 및 점토벽돌공정과 동일하며, 제품특성과 용도, 규격에 따라 압출된 반제품이 2차 가공을 필요로 할 시 예를들어 세라믹 볼을 만들고자 하면 원통형 표면 연마기에 넣고 회전시키면 다양한 모양의 볼 형태 등의 제조가 가능하다.The wet method of the product molding step (S300) is to remove the vinyl of the mixed raw material in the vinyl packaging 214 and then put into a molding machine to extrude the molding 310. At this time, the molding machine may use an extruder (20kg / ㎠ ~ 300kg / ㎠) used in a dedicated machine or a general wet tile, brick factory or pottery factory according to the characteristics, uses, and specifications of the product, the mold required for the molding The molds used in the tile and brickwork can be shared. As described above, the forming process of the wet method is the same as the wet tile and clay brick process, and when the semi-extruded semi-finished product needs secondary processing according to product characteristics, uses, and specifications, for example, to make a ceramic ball, a cylindrical surface grinder If you put it in the rotation, it is possible to manufacture a ball shape of various shapes.
상기 건조단계(S400)에서는 상기 성형(301)과정을 통해 성형된 반제품을 두께 8mm 이상의 고른 표면을 가지는 합판에 담아 그늘진 곳에서 자연건조시키거나 터널식 연속건조로에 넣어 50℃∼150℃의 열풍을 강제순환시키면서 상기 압축성형된 반제품의 수분함량을 3% 이내로 건조(401)시킨다.In the drying step (S400) to put the semi-finished product formed by the molding (301) in a plywood having an even surface of more than 8mm thickness to dry naturally in the shade or to put in a tunnel type continuous drying furnace to force hot air of 50 ℃ ~ 150 ℃ The water content of the compression molded semifinished product is dried (401) within 3% while circulating.
상기 소성단계(500)에서는 상기 건조(401)된 반제품에 대하여 타일 및 벽돌과 같이 부피가 크고 중량이 많이 나가는 제품에 대해서는 SIC 봉판을 사용하고, 볼, 입자와 같이 작은규격의 제품들은 SUS 상자를 이용하여 연속식 또는 단속식 소성로(furnace)에 투입시키며 투입된 반제품의 소성온도 조건으로는 상온에서 분당 2.5℃∼12℃ 증가시키는 것을 기준으로 제품에 따라 720℃∼850℃까지 온도를 상승시킨 후 30분간 온도를 유지시켜 소성(501)시키도록 한다. 상기 소성로에서는 유리분말이 용융되면서 혼합된 광물소재 분말들을 벌집(honeycomb)모양의 형태로 조직 결합할 수 있도록 온도를 중점관리하도록 한다. 이는 저온소성으로 혼합원료 중의유리분말만 용융시킴으로서 혼합되어있는 광물소재 분말들은 분말상태 그대로 유지하도록 하므로서 다공성 및 경량화로 탈습, 탈취, 방음, 단열, 방화, 원적외선방출 등 또한 겨울철 동파 및 물속에서 붕괴되거나 깨지지 않도록 하고자 하는 것이며 일반 세라믹 제품이 고온소성으로 돌처럼 고형화되는 것과는 특성상 차이점이 있다.In the firing step 500, SIC rods are used for products that are bulky and heavy, such as tiles and bricks, for the dried semi-finished products, and products of small specifications such as balls and particles are made of SUS boxes. It is put into continuous or intermittent firing furnace, and the temperature of firing of semi-finished product is increased by increasing the temperature from 720 ℃ to 850 ℃ according to the product based on the increase of 2.5 ℃ to 12 ℃ per minute at room temperature. The temperature is maintained for a minute to cause firing (501). In the kiln, the glass powder is melted, so that the temperature of the mineral powder mixed with the honeycomb (honeycomb) in the form of a structure so as to focus the temperature control. It melts the glass powder in the mixed raw materials by low temperature firing, so that the mixed mineral material powders are kept in the powder state while dehumidifying, deodorizing, soundproofing, thermal insulation, fire protection, far-infrared radiation, etc. by the porosity and light weight, and also collapsed in winter and water. It is intended to prevent cracking, and there is a difference in characteristics from that of general ceramic products solidifying like stones by high temperature firing.
상기 냉각단계(S600)에서는 상기 소성된 제품을 냉각시 급냉으로 인한 온도하락으로 제품이 열충격에 의한 파손발생이 가능하므로 이를 방지하기 위하여 분당 5℃∼14℃씩 낮추는 것을 기준으로 350℃까지 서서히 온도를 하락시킨후 20℃∼30℃ 정도의 작업자가 작업하기 좋은 적정 온도까지 냉각(601)시켜 원하는 품질의 제품(700)을 생산한다.In the cooling step (S600), since the product may be damaged due to thermal shock due to a drop in temperature due to quenching of the fired product, the temperature is gradually decreased to 350 ° C on the basis of lowering 5 ° C. to 14 ° C. per minute to prevent this. After lowering the cooling temperature (601) to a suitable temperature for the operator of about 20 ℃ to 30 ℃ to produce a product 700 of the desired quality.
본 발명은 다양하게 변형될 수 있고 여러 가지 형태를 취할 수 있으며 상기 발명의 상세한 설명에서는 그에 따른 특별한 실시예에 대해서만 기술하였다. 하지만 본 발명은 상세한 설명에서 언급되는 특별한 형태로 한정되는 것이 아닌 것으로 이해되어야 하며, 오히려 첨부된 청구범위에 의해 정의되는 본 발명의 정신과 범위 내에 있는 모든 변형물과 균등물 및 대체물을 포함하는 것으로 이해되어야 한다.The present invention can be variously modified and can take various forms and only the specific embodiments thereof are described in the detailed description of the invention. It is to be understood, however, that the present invention is not limited to the specific forms referred to in the description, but rather includes all modifications, equivalents, and substitutions within the spirit and scope of the invention as defined by the appended claims. Should be.
본 발명의 폐유리를 이용한 경량다공성 세라믹 제품제조방법을 통해서 폐유리 및 폐광물소재와 같은 산업폐기물을 재활용하며 수질 및 토양오염등을 방지하여 환경보존 및 산업폐기물을 자원화하여 원료수입 대체로 외화절약을 할 수 있는 효과를 가지는 매우 유익한 발명임이 틀림없다.Recycling industrial wastes such as waste glass and waste mineral materials through the method of manufacturing lightweight porous ceramic products using waste glass of the present invention, preventing water quality and soil pollution, and recycling environmental preservation and industrial wastes to import raw materials and save foreign currency. It must be a very advantageous invention with an effect that can be achieved.
또한 일반 세라믹 제조방법과 본 발명의 제조방법을 통해 동일한 제품을 생산시 소비되는 에너지 소비량을 단순비교시 본 발명의 경우 저온(720℃∼850℃)소성으로 일반 세라믹제조시의 소성온도(1,200℃∼1,500℃)에 비하여 월등하게 낮아 약1/3이상 에너지 절감효과를 얻을 수 있다.In addition, in the case of the present invention, the firing temperature (1,200 ° C.) at the time of manufacturing a general ceramic at low temperature (720 ° C. to 850 ° C.) is fired in the present invention. -1,500 ℃) is significantly lower than about 1/3 energy saving effect can be obtained.
또한 저온소성방식으로 소성시킴으로서 혼합원료 중 유리분말만 용융시켜 혼합되어있는 광물소재 분말들은 분말상태 그대로 유지하도록 함으로서 고온소성방식에 의하여 돌처럼 고형화 상태로 되며 중량이 무거운 일반 세라믹 제품과는 다르며 또한 다공성 및 경량으로 탈습, 탈취, 방음, 단열, 방화, 원적외선 방출등 또한 겨울철 동파 및 물속에서 붕괴되거나 깨지지 않는 효과를 가진다.In addition, by firing by low-temperature firing method, only the glass powder in the mixed raw material is melted, so that the mixed mineral material powders are kept in the powder state, and solidified like stones by high-temperature firing method. And lightweight, dehumidifying, deodorizing, sound insulation, heat insulation, fire prevention, far-infrared emission, etc. also has the effect of not being collapsed or broken in winter freezing and water.
또한 본 제품의 원료는 폐기물들을 재활용하므로 가격경쟁력이 우수하며 국내외에서 생산되는 광물소재분말을 원료로 대체사용함으로 원료수급이 원활하다.In addition, the raw material of this product recycles wastes, so it has excellent price competitiveness and supply and demand of raw materials is smoothly replaced by using mineral material powder produced at home and abroad.
또한 본 발명의 제조방법을 통하여 건축내외자재, 경량골재, 수질 및 대기 환경정화재, 여과 및 휠터재, 인공토양개량재, 조경자재, 건강보조재료, 기타 세라믹제품 등 다양하고 특성있는 신제품개발을 할 수 있다.In addition, through the manufacturing method of the present invention, it is possible to develop new and diverse new products such as building materials, lightweight aggregate, water quality and atmospheric environment purification material, filtration and filter material, artificial soil improvement material, landscaping material, health supplement material, and other ceramic products. Can be.
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| KR101309713B1 (en) * | 2011-11-23 | 2013-09-25 | 주식회사 카멜 | the ceramic to manufacture using waste of Masato and method for the same |
| CN114770702A (en) * | 2022-05-05 | 2022-07-22 | 张家港市永茂住宅工业有限公司 | Processing equipment and processing method for prefabricated part of water channel cover plate for constructional engineering |
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