WO2012085211A2 - Utilisation d'une matière en fibre vitreuse artificielle - Google Patents

Utilisation d'une matière en fibre vitreuse artificielle Download PDF

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Publication number
WO2012085211A2
WO2012085211A2 PCT/EP2011/073805 EP2011073805W WO2012085211A2 WO 2012085211 A2 WO2012085211 A2 WO 2012085211A2 EP 2011073805 W EP2011073805 W EP 2011073805W WO 2012085211 A2 WO2012085211 A2 WO 2012085211A2
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WO
WIPO (PCT)
Prior art keywords
mmvf
heat
treated
size
base material
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PCT/EP2011/073805
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English (en)
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WO2012085211A3 (fr
Inventor
Luc Johannes Petrus SMEETS
Stuart Lambie
Andreas Leismann
Pieter-Willem Provo KLUIT
Jean-Marie Wilhelmus Cuypers
Arnoldus Maria Kerssemakers
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Rockwool International A/S
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Publication of WO2012085211A2 publication Critical patent/WO2012085211A2/fr
Publication of WO2012085211A3 publication Critical patent/WO2012085211A3/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02—Compositions of linings; Methods of manufacturing
    • F16D69/025—Compositions based on an organic binder
    • F16D69/026—Compositions based on an organic binder containing fibres
    • 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
    • C03C13/00—Fibre or filament compositions
    • C03C13/06—Mineral fibres, e.g. slag wool, mineral wool, rock wool
    • 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
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/002—Thermal treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B23/00—Heating arrangements
    • F26B23/02—Heating arrangements using combustion heating
    • F26B23/026—Heating arrangements using combustion heating with pulse combustion, e.g. pulse jet combustion drying of particulate materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/006—Materials; Production methods therefor containing fibres or particles
    • F16D2200/0065—Inorganic, e.g. non-asbestos mineral fibres
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/006—Materials; Production methods therefor containing fibres or particles
    • F16D2200/0069—Materials; Production methods therefor containing fibres or particles being characterised by their size

Definitions

  • This invention relates to uses of man-made vitreous fibre (MMVF) materials in friction applications, for instance as components of friction materials for forming friction elements such as brake pads, brake linings and brake blocks.
  • MMVF man-made vitreous fibre
  • the MMVF supplied for these uses are produced by first forming a vitreous melt, from mineral materials, and forming this melt into fibres, then collecting the fibres.
  • Man-made vitreous fibres are non-crystalline, fibrous inorganic substances made primarily from rock, slag, glass or other processed minerals. They include glass fibres, rock wool, stone wool, slag wool and refractory ceramic fibres.
  • US2006/0241207 discloses a wet friction material for use in a fluid environment.
  • the material comprises a fibrous base material, preferably a combination of small diameter carbon fibres and small diameter ceramic, silica or mineral fibres, with a fibre diameter of 1 to 20pm and a tensile modulus of 150 to 350 Gpa.
  • MMVF man- made vitreous fibre
  • heat-treated MMVF can be used in the same ways as MMVF material already used in these applications, and can be more cost-effective but without significant performance reductions.
  • the heat-treatment has been carried out by means of pulse combustion, which we find is particularly efficient and effective and can result in the generation of heat-treated material having desirable particle size distribution characteristics (i.e., low shot levels).
  • Heat treatment is carried out after the MMVF are formed.
  • the heat- treated material can preferably be recycled - i.e. waste MMVF material that would otherwise have to be disposed of, making the process more ecological as well.
  • DE1020070021 13A1 discloses a method for producing agglomerate-free fine-particle carbon solids, boron nitride solid or molybdenum disulphide solid from a dispersion or suspension.
  • the solids are produced by drying the dispersion or suspension in a pulse combustion dryer. There is no disclosure about MMVF.
  • SU 1318556 relates to methods of obtaining inorganic fibres from mineral melts.
  • the mineral melt is introduced onto the rollers of a multi-roll centrifuge.
  • the fibres that form are blown away by internal and external circular flows.
  • the external blast of air is created by a pulse stream of combustion products at a temperature adapted for forming fibre for the melt to be processed.
  • the pulse combustion disclosed is part of the process of making the fibres.
  • the heat-treated material is preferably recycled waste MMVF and is preferably heat-treated by pulse combustion.
  • a method of making a composite friction material comprising providing recycled man-made vitreous fibre material, providing at least one other component and blending the recycled MMVF and at least one other component and shaping the blend.
  • MMVF man-made vitreous fibre
  • MMVF man-made vitreous fibre
  • a further advantage of use of a pulse combustion system is that it can be produced so as to be a mobile unit.
  • Friction materials are widely used in a variety of applications. For instance, friction materials are required for brake or clutch devices and they are used e.g. in the form of brake pads, brake shoes, brake linings, friction plates and clutch facings. Examples of suitable application fields in the invention are industrial machines and transport systems or vehicles such as lifts, passenger cars, motorcycles, bicycles, trucks, railway vehicles, aircrafts, baggage cars and cable cars. Composite friction materials are commonly used in automotive braking. In particular the invention is valuable in commercial vehicle friction applications, such as in linings and disc pads, and in railway blocks.
  • composition of friction materials may vary with respect to constituents used and the relative amounts thereof, depending on the desired properties of the friction material and the friction material system employed. Usually however the following components are contained in a friction material formulation:
  • frictional additives such as abrasives and lubricants.
  • Friction materials can be roughly divided into metallic, semi-metallic, low-steel, and non-asbestos organic, NAO/non-steel (also called ceramic) friction materials depending on the metal content.
  • a metallic friction material is predominantly metallic.
  • Semi-metallic friction materials typically include about 30 to 65 vol% of metallic components.
  • Low-steel friction materials typically include about 5 to 25 vol% of metallic components.
  • Non-asbestos organic materials are free of asbestos.
  • NOA/non-steel or ceramic friction materials are free of steel components. The invention is useful in all of these.
  • reinforcing fibres with complementing properties can be used, in addition to the heat-treated MMVF material.
  • reinforcing fibres are glass fibres, non-heat-treated mineral fibres, metallic fibres, carbon fibres, aramid fibres, potassium titanate fibres, sepiolite fibres and ceramic fibres.
  • Metallic components for reinforcement may also have a shape other than a fibre shape.
  • the friction material formulation typically comprises one or more fillers.
  • the fillers may be organic or inorganic. Examples of fillers are barium sulphate, calcium carbonate, mica, vermiculite, alkali metal titanates molybdenum trioxide, cashew dust, and rubber dust. Further examples are sillimanite, mullite, magnesium oxide, silica, and iron oxide.
  • the fillers sometimes play also a role in modifying certain characteristics for the friction material, e.g. enhancement of heat stability or noise reduction. Therefore, the specific filler to be used depends on the other constituents of the friction material. Mica, vermiculite, cashew dust, and rubber dust are known and can be used as noise suppressors.
  • the friction material formulation typically also comprises one or more frictional additives in order to modify the friction coefficient as well as the wear rate.
  • lubricants which decrease friction coefficients and wear rates
  • abrasives which increase friction coefficients and wear rates.
  • typical lubricants are graphite and metal sulfides such as antimony sulphide, tin sulphide, copper sulphide and lead sulphide.
  • abrasives having differing hardness ranging from mild abrasives such as quartz to alumina having a high hardness.
  • Abrasives typically have Mohs hardness values of around 7 to 8.
  • abrasives are metal oxide abrasives and silicates abrasives, e.g. quartz, zirconium silicate, zirconium silicate, zirconium oxide, aluminium oxide and chromium oxide.
  • the composite friction material comprises the heat-treated MMVF material, preferably in an amount in the range 5 to 35 vol%, preferably in the range 10 to 20 vol%, in particular in the range 12 to 18 vol%.
  • the heat-treated MMVF material is generally used in the same ranges of amounts as standard non-heat-treated MMVF fibre materials.
  • components of the composite friction material in particular in the context of commercial vehicle linings and disc pads, can include:
  • Resin in an amount in the range 15 to 35, preferably 20 to 30 vol%
  • Rubber base in an amount in the range 5 to 25, preferably 10 to 20 vol %
  • Filler such as calcium carbonate, in an amount in the range 25 to 55, preferably 30 to 50 vol%
  • vitreous fibres such as E-glass, in an amount in the range of 1 to 10, preferably 2 to 5 vol%
  • Graphites and petroleum coke in a total amount in the range 2 to 20, preferably 5 to 15 vol%
  • the heat-treated MMVF fibres can also be used in other friction composites, such as for passenger cars, for instance disc pads. They may also be used in motorcycle applications such as pads and linings. Further uses can be in railway applications such as pads and blocks.
  • MMVF fibres Other uses for the heat-treated MMVF fibres include clutch facings and friction materials for use in elevators, escalators, ski lifts, industrial equipment and machinery.
  • the friction composites can be made in known manner, by blending the required materials, if necessary with heat, shaping/moulding, if necessary with heat, and curing.
  • the composite friction material preferably has values of the following properties in the defined ranges:
  • MMVF base material which is heat- treated, preferably by pulse combustion.
  • the heat-treatment preferably by pulse combustion, is carried out after the MMVF have been formed.
  • the MMVF for heat-treatment can be glass or slag wool but is preferably stone wool.
  • the stone wool fibres are formed of a composition that contains, by weight of oxides, at least 15% total CaO plus MgO plus FeO (total iron oxide being calculated and reported as FeO).
  • the content of alkali metal oxides Na 2 O plus K 2 O is not more than 10%, especially not more than 7%, in particular not more than 4%, especially not more than 3%.
  • the stone wool may be formed of a composition having oxide contents in the following ranges:
  • SiO 2 30 to 60%, preferably 36 to 45% AI203 4 to 30%, preferably 14 to 24%
  • MgO 2 to 25% preferably 5 or 7 to 12%
  • Na 2 O up to 6%, preferably 1 to 4%
  • TiO 2 up to 6%, preferably 0.4 to 4%
  • the stone wool may be formed of a composition including P 2 O 5 in an amount of not more than 3%, preferably not more than 2%.
  • the MMVF base material is formed of waste MMVF and the use according to the invention involves recycled MMVF material.
  • waste MMVF from a factory such as spinning waste, edge trimmings etc, or products which have been produced but rejected for their intended use.
  • it can be a post-consumer product, namely waste MMVF which has previously been used in one of the known applications for MMVF and has reached the end of its useful life (namely end-of-life material).
  • waste is post-consumer waste material it is generally in the form of a coherent bonded product.
  • the preferred pulse combustion heat-treatment method has the advantage that it is possible to use waste MMVF materials of all kinds, including those which are generated as end-of-life products formerly used as horticultural growth substrates.
  • waste MMVF materials of all kinds, including those which are generated as end-of-life products formerly used as horticultural growth substrates.
  • the uses and methods above allow the reuse of such substrates despite the fact that they contain high levels of water and normally organic material, such as plant material embedded within the substrate and/or plastic film surrounding the substrate.
  • this invention provides a convenient means of reusing this particular end-of-life material other than, say, sending it to landfill or using it for the fabrication of bricks.
  • the MMVF that is recycled is waste horticultural growth substrate.
  • This includes plugs, slabs, blocks and mats and can be a mixture of one or more of these types of product.
  • it is green house substrate including organic material, such as plastic film and plant material, and often nutrients added by the grower during use or horticulture.
  • the waste MMVF material has a content of water, for instance at least 10% water (by weight based on weight of the waste MMVF).
  • the level of water in the waste MMVF initially provided can preferably be at least 40% and in some cases can be at least 50%, but generally it is preferred that the water content is not more than 55%. Horticultural growth substrates in most cases have water content within these ranges at the end of their useful life.
  • the product should preferably be treated to form the base MMVF material so as to reduce the water content to not more than 70%.
  • the water content is not more than 50%, especially when the method includes a fine grinding step (discussed below). In some cases it is preferred that the water content is not more than 40% although normally this is not necessary.
  • the waste MMVF used to form the MMVF base material used in the method is preferably end-of-life used horticultural growth substrate.
  • Such material preferably has a content of plastic/polymeric material in the range 0.05 to 0.5%, by weight based on the wet material. It preferably has a content of binder in the range 0.5 to 5%, by weight based on the wet material. It preferably has a content of plant residues in the range 1 to 5%, by weight based on the wet material. It preferably has a wet density in the range 520 to 780 kg/m 3 It preferably has a dry density in the range 260 to 450 kg/m 3 . It preferably has an ignition loss in the range 2 to 7%, by weight based on the wet material.
  • MMVF material provided for heat-treatment is in the form of a coherent product it is normally size-reduced before heat-treatment.
  • the MVF material is heat-treated.
  • the heat-treatment has the effect of removing organic material and can affect the nature of the MMVF itself.
  • This heat-treatment is preferably by means of pulse combustion.
  • the heat-treated MMVF material is produced by a method comprising providing man-made vitreous fibre (MMVF) base material in a form having size at least 80% not more than 40 mm and preferably having water content not more than 70%, subjecting the MMVF base material to heat- treatment by use of a pulse combustor and thereby forming a particulate material in the form of particles having size at least 80% not more than 20 mm.
  • the MMVF base material used in the method should have size at least 80% below 40mm.
  • the "size" is the maximum dimension and this can be determined by known methods including sieving.
  • waste MMVF is not received in a form in which at least 80% by weight is in the form of particles having size not more than 40 mm, then it is necessary to carry out a step of reducing this material to the required particle size.
  • waste horticultural growth substrate and other waste MMVF products are often received in the form of a coherent substrate product such as a slab, block or mat (including mixtures of one or more of these types of product) often having minimum dimension at least 50 mm, often at least 100 mm.
  • Waste horticultural growth substrate may also include plug products, often having minimum dimension below 40 mm but above 20 mm, and such products may not require size reduction before heat-treatment for use in the invention.
  • the minimum dimension is the shortest distance from one surface of the coherent product to another parallel surface.
  • a slab of dimensions 1200 mm x 750 mm x 75 mm will have minimum dimension of 75 mm.
  • Reduction to the particle size at least 80% below 40 mm can be carried out by any suitable method, including shredding, milling and grinding, preferably shredding.
  • This size reduction step can in itself result in loss of water from the substrate, if water is initially present.
  • This step should result in a product which has a content of water not more than 70 wt%, preferably not more than 55%, especially not more than 50 wt% and in some cases preferably not more than 40%, especially not more than 35%, in particular not more than 25 wt%.
  • the water content of the base MMVF material is reduced during the pulse combustion step but it can also be reduced to some extent in advance, as mentioned above.
  • An advantage of the method of pulse combustion preferably used in the invention is that it is not always necessary to have a separate water reduction step prior to the pulse combustion step.
  • MMVF base material is produced from horticultural growth substrate packaged in polymeric film.
  • waste horticultural growth substrate is received in a form with organic materials, which can be plant residues, and usually include polymeric packaging material.
  • a large part (often at least 50 %, preferably at least 80%) of this polymeric film packaging material is normally removed during, before or after the size reduction step (most often during the size reduction step) and subjected to a separate size reduction process to at least 80 wt % below 40 mm, preferably below 30 mm and more preferably below 20 mm.
  • shredding This is done separately from the mineral material size reduction process because this fine shredding process of the polymeric film is made easier in the absence of moist MMVF.
  • the size reduced polymeric film material is combined with the size reduced MMVF base material and both are included in the pulse combustion step.
  • inclusion of the polymeric film material in this stage has the advantage of providing energy to the process. This increases the energy efficiency of the process as a whole.
  • the additional energy provided by the polymeric film can be used in a step of pre-drying the MMVF base material prior to the pulse combustion step.
  • Organic material can include plant residues, polymeric packaging film, and binder.
  • the base material is formed of MMVF product (including water and organics such as remaining polymeric film and/or plant residues in some cases) but may also comprise other material, which can be in wet or dry form. Other materials include coco growth substrate, sawdust, perlite, pumice and peat. Preferably at least 70% of the base material is MMVF, based on solid material, and in particular at least 80% of the base material is MMVF, based on solid material. In particular, substantially 100% of the inorganic material in the base material is MMVF.
  • the base material can be subjected to a fine grinding stage to generate particulate base material in which at least 80 wt% of the material has size not more than 20 mm, preferably not more than 15 mm and more preferably not more than 10 mm, but this is usually not necessary. If this step is used it is normally done after a step of removal of substantial amounts (e.g. at least 80 wt % of the originally present amount) of polymeric packaging film, if present in the MMVF product starting material.
  • the water content of the base material entering the fine grinding step is preferably not more than 60 wt%, more preferably not more than 50 wt%, in particular not more than 45 wt %.
  • the base material may also comprise particulate products of the process of pulse combustion recycled into the method itself.
  • binder in the base material, especially if a granulation step is to be included. If binder is used it is preferably organic and is burned off during the pulse combustion step. However, it is often unnecessary to include binder and therefore from an economical and environmental point of view, it is preferred not to include binder. Thus preferably no binder is added during course of the heat-treatment method (from the step of providing the MMVF base material to the generation of the end product). Preferably also no binder is added during the generation of the MMVF base material from waste MMVF, if it is produced in this way.
  • the water (or moisture) content is assessed at the various stages by subjecting a weighed sample to heating at 105°C for a time long enough for a constant weight to be achieved (i.e. for any moisture to have evaporated) and re-weighed to determine the loss of weight.
  • Water content of the base material entering the pulse combustion step is normally not more than 50 wt % but can be up to 70 wt % and in some cases is preferably not more than 35 %.
  • the material subjected to the heat-treatment step is preferably a blend of MMVF base material and size-reduced polymeric film.
  • the amount of MMVF base material in the blend is preferably at least 50 wt %, more preferably at least 70 or 80 wt %.
  • this step it is passed to a reaction chamber connected to a pulse combustion apparatus, which results in a temperature in the reaction chamber in the range 600 to 1050°C, preferably 600 to 1000°C or 600 to 850°C.
  • the pulse combustion step has the effect of very rapidly removing the organic materials by combustion but without melting the MMVF component of the base material. Instead the MMVF component is at least partly sintered.
  • the size distribution in the end product can be influenced by the temperature conditions in the pulse combustion apparatus.
  • the temperature in the pulse combustion reactor chamber can be in the range 600 to 700 deg. C (rather than higher temperatures, which tend to lead to larger overall sizes of the end product).
  • a significant mass reduction in the product occurs, whereby often at least 30%, preferably at least 40% of the mass of the base starting material is lost, often around 50% of the mass, although it can be up to 70%, depending on the moisture content and organics content of the base material.
  • the dwell time is usually not more than 5 s, and often at least 0.5 s, for instance in the range 1 to 3 s.
  • the frequency of the pulse combustor should be at least 100 Hz, preferably at least 150 Hz, for instance about 200 Hz.
  • the pulse combustor is generally fuelled by methane and/or propane and can be provided with a methane and/or propane-air input.
  • the conditions are chosen to maximise turbulence in the reaction chamber, which is believed to improve the efficiency of the process.
  • the turbulence can be increased by, for example, providing dividing plates in the combustion chamber.
  • Pulse combustors are well known for use in other applications. For instance, forms of pulse combustor apparatus are described in US 4529377, WO 2008/004407, US 5136793, US 4838784, US 5255634 and WO 2005/019749, all for treatment of different types of base material than MMVF base material.
  • the final product generally has very low water content such that it is substantially dry - the water content is generally below 5 wt%, preferably below 2 wt % and in some cases substantially zero.
  • the final product is also substantially free of organics, which are thus usually below 5 wt %, in particular below 2 wt% and especially substantially zero.
  • the used heat-treated MMVF material preferably has a particle size distribution such that the shot content (i.e., content of non-fiberised material) is low. Particle size is determined by sieving.
  • the heat-treated material used is such that at least 90 wt%, more preferably at least 95 wt%, has size below 600 microns.
  • the used material has a low shot content - namely, a size distribution such that not more than 40 wt% has sieve size more than 125 microns. More preferably not more than 20 wt %, in particular not more than 17 wt%, especially not more than 14 wt%, has sieve size more than 125 microns.
  • the used material has a size distribution such that not more than 50 wt% has sieve size more than 63 microns. More preferably not more than 40 wt%, especially not more than 30 wt%, especially not more than 25 wt %, especially not more than 22 wt% has sieve size more than 63 microns.
  • the heat-treated MMVF material is preferably in the form of fibres.
  • the average length of the fibres used is preferably in the range 100 to 200 microns, more preferably in the range 120 to 150 microns.
  • Average particle size is determined by the following method:
  • the length of the fibres is measured automatically using a microscope, with camera and image analysing software. For an accurate automatic determination it is important to prepare a well dispersed sample on a Petri dish.
  • a sample is heat cleaned at 590°C for 10 minutes.
  • Heat-treated MMVF material having the defined particle size distribution can be obtained directly from a pulse combustion process.
  • material obtained from the cyclone of the pulse combustion system can have the desired particle size distribution without further treatment.
  • a fine final particle size distribution can also be obtained, either from the dust cyclone or from the reactor chamber, by the choice of a relatively fine particle size distribution for the starting MMVF material. For instance, at least 80 wt% of the material may have particle size below 5 mm.
  • the reaction temperature can also influence the size distribution of the heat-treated MMVF, as discussed above.
  • the product of the pulse combustion process may be subjected to sieving in order to obtain the desired low shot content.
  • the heat-treated MMVF material product has a composition that contains, by weight of oxides, at least 15% total CaO plus MgO plus FeO (total iron oxide being calculated and reported as FeO).
  • the content of alkali metal oxides Na 2 O plus K 2 O is not more than 10%, especially not more than 7%, in particular not more than 4%, especially not more than 3%.
  • the product can have a composition having oxide contents in the following ranges:
  • SiO 2 30 to 60%, preferably 36 to 45%
  • MgO 2 to 25% preferably 5 or 7 to 12%
  • Na 2 O up to 6%, preferably 1 to 4%
  • TiO 2 up to 6%, preferably 0.4 to 4%
  • the product may have a composition including P 2 O 5 in an amount of not more than 3%, preferably not more than 2%.
  • the product preferably has ignition loss below 1 %.
  • Figure 1 is an overview of an example of an entire pulse combustor plant for generating heat-treated MMVF base material.
  • MMVF base material in a form having a size at least 80% not more than 40 mm and a water content not more than 70% also called waste MMVF material or end of life (EOL) material
  • EOL end of life
  • a pulse combustor apparatus (1 ) which apparatus consists of a reactor chamber (4) and a pulse combustor burner (5), via the first feeding screw (2) (or other appropriate feeding device).
  • the EOL material has previously been reduced in size in, e.g., a shredding process.
  • the EOL material is pre-heated by use of exhaust gases from the particulate material exiting the pulse combustor apparatus (1 ) which preheating step will be explained further below.
  • the preheated EOL material then exits the first feeding screw (2) and is fed to a second feeding screw (3) (or other appropriate feeding device) which transports the EOL material and feeds it to the top of the reactor chamber (4) of the pulse combustor apparatus (1 ).
  • the reactor chamber (4) of the pulse combustor apparatus (1 ) is situated on top of the pulse combustor burner (5), which pulse combustor apparatus is known per se.
  • the pulse combustor burner (5) is coupled to a fan (12) for supplying air to the pulse combustor burner (5). Pressurised air could be used instead of a fan.
  • fuel such as methane and/or propane gas is supplied to the pulse combustor burner (5).
  • the pulse combustor burner is driven at a frequency of at least 100 Hz, preferably at least 150 Hz, for instance 200 Hz.
  • organic waste residues such as plastic, roots, binder etc. present in the EOL material are essentially instantaneously burned away and the MMVF waste material is dried, incinerated and partly sintered at a temperature in the reaction chamber (4) in the range 600 to 1050°C, preferably 600 to 850°C.
  • the pulsing of the pulse combustor and the internal configuration of the reaction chamber create a turbulent flow in the reactor chamber (4) which ensures that the EOL material in the reactor chamber does not stick or sinter together into lumps but sinters and forms a particulate material having a size at least 80% not more than 20 mm.
  • the dwell time can for instance be 1 to 2 seconds.
  • the hot particulate material (temperature approximately 900 to 1050°C) leaves the reactor chamber (4) and enters a first transport screw (6) (or other appropriate transporting device).
  • the hot gases and dust from the particulate material enter a heat exchanger (8), which heat exchanger is coupled to the first feeding screw (2).
  • the heat generated from the heat exchanger (8) is then used for pre-heating the EOL material in the first feeding screw (2).
  • the dust-filled gas stream containing fine and coarse dust arising from the particulate material in the first transport screw (6) leads to a dust filter or dust cyclone (9) which precipitates or separates the fine dust from the gas.
  • the dust filter or dust cyclone (9) can also be any other appropriate device able to separate dust from gas in order to maintain and secure permitted dust emissions.
  • the dust is fed to a second transport screw (7) (or other appropriate transporting device) and the cleaned gas from the dust filter is led to the stack (1 1 ) via a blower (10).
  • the particulate material (coarse fraction) in the first transport screw (6) exits into the second transport screw (7) and is transported to a storage facility.
  • Figure 1 and the description thereof is only an example of a pulse combustor plant for producing the MMVF material used in the invention.
  • the equipment or apparatus might in other embodiments differ from what is shown.
  • Heat-treated MMVF coarse the crude product which was sieved to remove all material above 250 pm in size in order to separate the largest part of non- mineral fibre waste products from the fibres and shot.
  • the evaluation took place in a lining formulation for commercial vehicles containing 15 vol% of the heat-treated MMVF products.
  • the components of the friction formulation were compounded and hardened with each other in a usual manner to obtain the friction material.
  • the production process included a dry mixing process, a hot moulding step of the mixture and post-curing of the materials in an oven.
  • the friction evaluation was performed on a Krauss machine using the ECE R90 annex 6 test procedure, described in paragraph 3.2.2, for commercial vehicle linings.
  • the test method for the impact strength was ISO 148-1.
  • the hardness was measured with a Rockwell hardness tester using the HRS scale.
  • the used friction formulation for testing had the following composition (in volume%):

Abstract

L'invention porte sur l'utilisation d'une matière en fibre vitreuse (MMVF) artificielle traitée par la chaleur, en tant que composant d'une matière de friction composite. Elle porte aussi sur un procédé de fabrication d'une matière de friction composite, le procédé consistant à utiliser une matière de fibre vitreuse artificielle traitée par la chaleur, utiliser au moins un autre composant et mélanger la MMVF traitée par la chaleur et au moins un autre composant et à façonner le mélange.
PCT/EP2011/073805 2010-12-22 2011-12-22 Utilisation d'une matière en fibre vitreuse artificielle WO2012085211A2 (fr)

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WO2014026998A1 (fr) * 2012-08-13 2014-02-20 Rockwool International A/S Fibres revêtues de graphite
WO2017212029A1 (fr) * 2016-06-10 2017-12-14 Rockwool International A/S Matériau de friction
CN112608129A (zh) * 2020-12-09 2021-04-06 钢城集团凉山瑞海实业有限公司 耐火材料及制备方法，轨枕耐高温防烧损装置及制备方法

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