KR20100084917A - Method for manufacturing of fly ash filament fiber using refused glass - Google Patents

Abstract

The present invention relates to a method for producing coal ash fiber using cullet, and more particularly, to a method for producing coal ash fiber by mixing a scallop of a predetermined ratio to fly ash and melting and spinning it into fibers. will be.

According to the present invention, by adding the cullet to the coal ash to produce the coal ash fiber provides an effect that can produce the coal ash fiber having excellent tensile strength and uniform composition without causing the trimming phenomenon at low melting temperature.

Description

Method for manufacturing coal ash fiber using cullet {Method for manufacturing of fly ash filament fiber using refused glass}

The present invention relates to a method for producing fly ash fibers using cullet, and more particularly, to a method for producing coal ash fibers by mixing a scallop of a predetermined ratio with coal ash and melting and spinning them into fibers. will be.

Coal ash from power plants is used as a raw material for cement, asphalt filler, roadbed, or topsoil, and may be mixed with sand during shore reclamation. In addition, research on the development of construction materials has been conducted to find various uses such as using small amounts as additives or increasing soil damaging agents to increase the durability of dam concrete.

However, these coal ash stocks are increasing rapidly, and their reuse is recommended, but the use of the coal ash is not diversified, and the value is lost due to low availability.

On the other hand, E-glass fiber (Glass fiber) mainly used in the electric field means a glass fiber containing absolutely low alkali components (Na, K, Li), has an extremely low electrical conductivity. However, E-glass fiber has an adverse production condition in resource-poor countries such as Korea, and production is gradually declining. Meanwhile, E-glass fiber is losing its competitiveness due to the price hike of B ₂ O ₃ , an essential raw material used here. In addition, the world is running out of resources.

Therefore, there is an urgent need to develop a method for producing industrial fibers such as E-glass fibers using coal ash to create a high value for the reuse of coal ash.

However, in order to produce industrial fibers using coal ash, high spinning temperatures are required, and since the physical properties of coal ash are low, it is difficult to manufacture the fibers by melt spinning coal ash. That is, the fiber manufactured using coal ash should provide higher melting temperature than E-glass fiber in manufacturing, so it is not only easy to cause breakage during melt spinning but also a large amount of melt spinning at high temperature. There is a problem that energy use is inevitable.

The present invention aims to solve the problems of the prior art as described above and the technical problems that have been requested from the past.

It is an object of the present invention to provide a method for producing coal ash fiber using cullet, which can produce coal ash fiber without trimming at low melting temperature.

It is also an object of the present invention to provide a method for producing fly ash fibers using cullet capable of producing fly ash fibers having excellent tensile strength and uniform composition.

In order to achieve the above object, the present invention, the crushing step of crushing the cullet and coal ash, respectively, the mixing step of mixing 2 to 50% by weight of the cullet to the coal ash to produce a mixture, the mixture Melting step of melting, and spinning step of spinning the molten mixture to the fiber, characterized in that it comprises.

In a preferred embodiment, the melting step includes a first melting step of melting the mixture, a cooling step of quenching the first molten mixture and a second melting step of melting the cooled mixture. do.

In a preferred embodiment, the pulverizing step is characterized in that the coal ash and cullet is pulverized to less than 350 mesh each.

In a preferred embodiment, the spinning temperature in the spinning step is characterized in that 1000 to 1400 ℃.

In a preferred embodiment, the coal ash is silica (SiO ₂ ), alumina (Al ₂ O ₃ ), iron oxide (Fe ₂ O ₃ ), titanium dioxide (TiO ₂ ), potassium oxide (K ₂ 0), sulfur trioxide (SO ₃ ), Calcium oxide (CaO), magnesium oxide (MgO), and sodium oxide (Na ₂ O).

In a preferred embodiment, the coal ash is 45 to 70% by weight of silica (SiO ₂ ), 15 to 40% by weight of alumina (Al ₂ O ₃ ), 3 to 10% by weight of iron oxide (Fe ₂ O ₃ ), titanium dioxide (TiO ₂ ) 0.01 to 2% by weight, potassium oxide (K ₂ 0) 0.01 to 6% by weight, sulfur trioxide (SO _{3 )} 0.01 to 5% by weight, calcium oxide (CaO) 0.01 to 20% by weight, magnesium oxide (MgO) 0.01 to 10 wt%, and 0.01 to 1 wt% of sodium oxide (Na ₂ O).

In addition, the present invention provides a fly ash fiber produced by the above production method.

In addition, the present invention provides a woven fabric, characterized in that produced using the coal ash fiber.

In addition, the present invention provides a woven fabric, characterized in that produced by mixing the natural fiber or synthetic fibers in the coal ash fiber.

In addition, the present invention provides a nonwoven fabric, characterized in that produced using the coal ash fiber.

In addition, the present invention provides a non-woven fabric, characterized in that produced by mixing the natural fiber or synthetic fibers in the coal ash fiber.

The present invention has the following excellent effects.

First, the coal ash fiber manufacturing method using the cullet of the present invention has an effect that can be produced without trimming at low melting temperature by manufacturing the fiber from the crushed coal ash.

In addition, the fly ash fiber produced by the fly ash fiber manufacturing method using the cullet of the present invention has an excellent tensile strength and has the effect of having a uniform composition.

The terms used in the present invention were selected as general terms as widely used as possible, but in some cases, the terms arbitrarily selected by the applicant are included. In this case, the meanings described or used in the detailed description of the present invention are considered, rather than simply the names of the terms. The meaning should be grasped.

Hereinafter, the technical structure of the present invention will be described in detail with reference to preferred embodiments shown in the accompanying drawings.

However, the present invention is not limited to the embodiments described herein but may be embodied in other forms. Like reference numerals designate like elements throughout the specification.

1 and 2 are views showing the apparatus used in the method for producing coal ash fiber using cullet according to an embodiment of the present invention.

Looking at the process of manufacturing coal ash fiber using cullet with reference to FIGS. 1 and 2 as follows.

First, coal ash and cullet are crushed, respectively. At this time, it is preferable to grind the coal ash and the cullet to 350 mesh or less. The coal ash is silica (SiO ₂ ), alumina (Al ₂ O ₃ ), iron oxide (Fe ₂ O ₃ ), titanium dioxide (TiO ₂ ), potassium oxide (K ₂ 0), sulfur trioxide (SO _{3 )} , calcium oxide (CaO ), Coal ash containing magnesium oxide (MgO), and sodium oxide (Na ₂ O). In general, the composition of coal ash is slightly different from the domestic anthracite coal and imported bituminous coal, and the analysis value of the rough chemical composition is shown in Table 1 below. The numerical values in parentheses of Table 1 represent the average of the analysis values.

Table 1: Chemical Composition of Fly Ash

Ingredient Name Domestic anthracite coal Imported bituminous coal Silicon dioxide 50.0 ~ 56.5% (52.4%) 46.7 ~ 69.3% (59.6%) Aluminum oxide 30.7 to 34.8% (33.4%) 18.7-24.8% (23.3%) Iron oxide 4.3 ~ 5.9% (4.6%) 3.6-9.5% (7.3%) Calcium oxide 0.5 to 1.2% (0.7%) 1.0 to 16.9% (3.6%) Magnesium oxide 0.6 to 1.0% (0.7%) 3.6-9.5% (7.3%) Sodium oxide 0.4 to 0.8% (0.3%) 0.1 to 0.7% (0.5%) Potassium oxide 3.5 to 5.1% (4.5%) 0.4 to 1.3% (0.8%) Trioxide 0.1 to 0.8% (0.3%) 0.8 to 3.2% (1.7%) Titanium dioxide 1.2 to 1.4% (1.5%) 0.6 to 1.3% (1.0%) Etc 1.3 to 1.7% (1.5%) 0.5 to 1.5% (1.1%)

The addition of Na ₂ O, K ₂ O-rich cullet to the coal ash, the Na ₂ O, K ₂ O components play a role of low melting point can melt the coal ash which is impossible in the ordinary E-glass molten state is enough as the current technology Facility equipment similar to glass fibers can produce inorganic fibers suitable for industrial fibers without trimming.

At this time, the chemical composition of the general cullet is approximately as Table 2 below.

Table 2: Chemical Composition of cullet

SiO ₂ 71.72% SO ₃ 0.436% Al ₂ O ₃ 1.23% CaO 6.73% Fe ₂ O ₃ 0.191% MgO 4.18% TiO ₂ 0.137% Na ₂ O 14.95% K ₂ O 0.338%

The cullet also has a temperature that maintains viscosity at about 150 to 200 ° C. when it is spun from E-glass, and when the cullet is mixed with 5 to 50% of coal, it can be spun into existing facilities depending on the composition of coal ash. At 10.degree. C., the viscosity may be at or below Log 10 ^3, allowing spinning. That is, the viscosity becomes Log 10 ³ or less at 1250 ° C., which is a preferable spinning condition, so that fiber spinning can be continued without trimming.

The coal ash fibers thus spun may be manufactured in woven or non-woven fabrics, such as conventional A-glass, C-glass, and E-glass, to be used in various products.

Then, the pulverized coal ash and the cullet are mixed, and the mixture of the coal ash and the cullet is melted in the melting furnace 100. The outside of the crucible 120 is surrounded by adiabatic refractory 130. Inside the crucible 120, two electrodes 140 made of platinum are provided, and a siliconite hole 150 into which a heating element for heating the crucible is inserted is provided. A bushing cooling coil 172 for cooling the edge of the bushing 170 is provided at the edge of the bushing 170 through which the fiber is radiated, and a bushing clamp for supplying power to the bushing 170 and adjusting temperature. And a bushing tip cooling tube 190 for cooling the spun rock fibers.

The pulverized mixture enters the crucible 120 through a raw material inlet tube 112 connected to the raw material inlet 110. The mixture introduced into the crucible 120 is first heated and melted by the silicon condenser heating element installed in the crucible 120 through the silicon conical hole 150. At this time, the melting temperature can be maintained at a temperature of 1000 to 1400 ℃ lower than the initial melting temperature due to the addition of the cullet.

Subsequently, the mixture is melted and then heated by the two electrodes 140, and its height is kept constant by a height adjusting device (not shown) connected through the platinum probe tube 160.

The molten mixture is then spun into filament fibers through a bushing 170 with a 0.5 mm nozzle. The number of nozzles can be up to 200, 400 or 800 holes.

At this time, the spinning temperature in the bushing 170 must be electrically precisely adjusted to maintain a constant viscosity of the melt. Therefore, the spinning temperature is preferably maintained at 1000 to 1400 ℃, in particular, spinning at 1250 ℃ is most suitable.

The filament fibers spun through the nozzle of the bushing 170 are surface treated through a sizing applicator and wound around the winder through a gathering shoe. The filament fibers are wound while being cooled in a winder that rotates at a high speed, and can adjust the speed of the winder to produce a coal ash fiber having a diameter of 5 to 30 μm.

Example 1

Coal ash powder, which is a coal ash fiber material, was directly purchased from a power plant and mixed with 100 kg at 10 rpm for 30 minutes to be 10% by weight of cullet, which was fed to an electric furnace to perform fiber spinning. At this time, the fiber can be obtained without trimming at 1250 ° C., and the tensile strength of the fiber thus prepared was confirmed to be 2800 Mpa based on 10 μm.

Example 2

The cullet was crushed about 320 mesh and mixed with the power plant coal ash, and the powder was directly put into the electric furnace. At this time, the cullet was added at 20% by weight to lower the melting point of the coal ash so that the spinning was uniform. Repeated experiments showed that the highest productivity was achieved at the spinning temperature of approximately 1220 ° C, with a viscosity of 102.8 dpas. The fiber thus prepared was confirmed to exhibit a tensile strength of 3000Mpa and an elastic modulus of 68Gpa based on 10㎛.

Example 3

When 20 to 50% by weight of cullet was added to the coal ash, the viscosity was numerically uniform, so that the spinning temperature could reach up to 1200 ° C., but the quality of the fibers was not desirable. Therefore, when the non-woven short fibers can be used, but the quality is not desirable as long fibers when more than 30%. At this time, the strength was about 2000Mpa, and it can be called A-glass fiber level, while the modulus of elasticity was 70Gpa, indicating an increase.

1 and 2 are views showing the apparatus used in the method for producing coal ash fiber using cullet according to an embodiment of the present invention.

<Explanation of symbols for the main parts of the drawings>

100: melting furnace 110: raw material inlet

112: raw material input pipe 120: crucible

130: heat insulation refractory 140: electrode

150: silicon hole 160: platinum probe tube

170: bushing 172: bushing cooling coil

180: bushing clamp 190: bushing tip cooling tube

Claims (11)

Grinding step of grinding each of the cullet and coal ash; A mixing step of mixing 2 to 50% by weight of the cullet with respect to the coal ash to the coal ash to prepare a mixture; A melting step of melting the mixture; And Spinning the molten mixture into fibers; Method for producing coal ash fiber using cullet, characterized in that it comprises a. The method of claim 1, The melting step may be a first melting step of melting the mixture; Cooling the first molten mixture; And A secondary melting step of melting the cooled mixture; Method for producing coal ash fiber using cullet, characterized in that it comprises a. The method of claim 1, The pulverizing step is a method for producing coal ash fiber using cullet, characterized in that the crushed coal ash and cullet to 350 mesh or less, respectively. The method of claim 1, The spinning temperature in the spinning step is a method for producing coal ash fiber using cullet, characterized in that 1000 to 1400 ℃. The method of claim 1, The coal ash is silica (SiO ₂ ), alumina (Al ₂ O ₃ ), iron oxide (Fe ₂ O ₃ ), titanium dioxide (TiO ₂ ), potassium oxide (K ₂ O), sulfur trioxide (SO _{3 )} , calcium oxide (CaO ), Magnesium oxide (MgO), and sodium oxide (Na ₂ O) method for producing a mineral fiber using a cullet, characterized in that it comprises. The method of claim 5, The coal ash is 45 to 70% by weight of silica (SiO ₂ ), 15 to 40% by weight of alumina (Al ₂ O ₃ ), 3 to 10% by weight of iron oxide (Fe ₂ O ₃ ), 0.01 to 2% by weight of titanium dioxide (TiO ₂ ) %, Potassium oxide (K ₂ 0) 0.01 to 6% by weight, sulfur trioxide (SO _{3 )} 0.01 to 5% by weight, calcium oxide (CaO) 0.01 to 20% by weight, magnesium oxide (MgO) 0.01 to 10% by weight, and oxidation Method for producing a mineral fiber using cullet, characterized in that it contains 0.01 to 1% by weight of sodium (Na ₂ O). Fly ash fiber manufactured by the manufacturing method of any one of Claims 1-6. A woven fabric produced using the coal ash fiber of claim 7. A woven fabric characterized by mixing natural fiber or synthetic fiber in the coal ash fiber of claim 7. A nonwoven fabric prepared using the coal ash fiber of claim 7. A nonwoven fabric prepared by mixing natural fiber or synthetic fiber in the coal ash fiber of claim 7.

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