RU2448065C2 - Method to produce heat insulation and insulant material for building products - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: method to produce heat insulation and insulant material for building products includes mixing of a binder based on amorphous silica with dispersion of 1-10 mm with loose heat insulation filler with dispersion of 0.5-15.0 mm for 3-10 minutes until a homogeneous dry mixture is produced, subsequent tempering of the dry mixture with an aqueous solution of an alkaline component during subsequent mixing for 1-5 minutes and subsequent moulding of products by method of their pressing with force of 5.0-10.2 kg/cm² with subsequent thermal treatment at 150-850°C. The other version of the method includes mixing of the binder with a loose heat insulation filler, introduction of an alkali-containing component into the mixture, subsequent mixing to produce a homogeneous mass and moulding of products by the method of semidry pressing.

EFFECT: production of ecologically pure material with good strength properties, lower heat conductivity, simplified process of production and reduced prime cost of a finished product.

10 cl, 4 tbl, 1 ex

Description

The invention relates to the building materials industry, specifically relates to the production of heat-insulating and insulation materials for various (and in various) building products (products), and can be used in civil and industrial construction, in particular for insulation and heat, sound insulation of various designs and elements of buildings and structures of walls, partitions, attics, loggias, floors, ceilings, including directly at the facility under construction.

Known methods for producing thermal insulation materials based on siliceous rocks, which include siliceous rocks of sedimentary origin, such as diatomites, tripoli and flasks. These are natural hydrated silicas in an amorphous state (amorphous silicas) belonging to the opal group.

These known methods for producing silica-based heat-insulating materials can be divided, in particular, into two groups depending on the type of porosity:

- foam slurry foam with subsequent drying and firing products;

- thermochemical expansion due to the use of burnable additives (coke), dissociative additives (limestone) or the removal of hydrated water.

The first group is represented by the technology for producing foam diatomite products (Meisel I.L., Sandler V.G. Technology of heat-insulating materials. M .: Higher school, 1988) consists in fine grinding of diatomite, preparation of foam diatomite mass and molding of products, stabilization of the porous structure of products by drying and the formation of a porous ceramic crock by roasting the dried raw. Very high humidity of the foam mass, reaching 200-250%, is the reason for large shrinkage deformation during drying (20-25%), which affects the quality of the finished product. Drying of foam diatomaceous products is carried out in forms, which determines unfavorable conditions for the removal of moisture, since its evaporation can occur only from the surface. This fact, as well as significant drying shrinkage of the foam mass, determine the long (48-96 h) duration of the drying process.

Burn products in tunnel ovens at a maximum temperature of 800-900 ° C for 18-22 hours.

According to another well-known monograph (Gorlov Yu.P. Technology of heat-insulating acoustic materials and products. M: Higher school, 1989, pp. 197-207), the products have a density of 450-600 kg / m ³ , strength 0.6-0.9 MPa Thus, the disadvantage of this method is the increased density, high energy costs associated with long thermal processes and high water content, significant shrinkage of the obtained material.

In particular, a known method of manufacturing a heat-insulating material, comprising mixing siliceous rock from the group: tripoli, diatomite, flask and alkaline component, laying the mixture into molds and its heat treatment (RU 2053984 C1, class C04B 38/02, 02/10/1996).

The resulting products are not distinguished by good water resistance. In addition, this method does not obtain granular insulating material.

From RU 2293073, 02/10/2007, a method for manufacturing a non-combustible insulation is known, which includes preparing a raw material mixture by co-grinding quartz sand and sodium silicofluoride, mixing with liquid glass, a pre-prepared aqueous solution of PO-6K foaming agent, and pouring the resulting raw material mixture between the outer and inner layers building structure, carry out joint grinding of quartz sand and sodium silicofluoride at a ratio of 9-10: 1 weight.h. Accordingly, for 5-6 hours to obtain a grinding product with a specific surface of 1700-2500 cm / g, liquid glass is mixed for 5-7 minutes with a pre-prepared aqueous solution of PO-6K foaming agent in a ratio of PO-6K foaming agent and water of 1:50 weight .h. when the ratio of the specified aqueous solution and liquid glass 1: 1.5 parts by weight with obtaining the raw material mixture immediately before pouring it.

However, this method is also not intended to produce granular insulating material.

From SU 1548178, 03/07/1990, a method is known for producing a heat-insulating lightweight porous aggregate by mixing silicate binder (60-80 wt%), which is a product with a density of 1.5-1.72 g / cm ³ obtained by treatment with an alkali solution of finely ground tuff with finely divided tuff 11-25 microns and a gasifier in the form of soot or carbon black 0.5-1.5, calcium silicate 2.5-4.5, sodium metasilicate 6-9. Thermal insulation material has the following properties: average density 300-600 kg / m ³ , compressive strength 2-6 MPa, heat resistance 680-820 ° C, temperature resistance 750-900 ° C, hydrolytic class 2-3, acid resistance of mineral acids 80 -99%, water absorption by volume 1.5-12%, heat conductivity 0.080-0.115 W / m * deg, temperature of preliminary heat treatment 120-135 ° С.

However, the method is quite complicated, as it is based on the use of a multicomponent composition and is uneconomical.

A known method of manufacturing insulation material, mainly expanded clay with a shape factor of 1.05-1.2, by grinding clay, molding crumbs in the form of rods, drying and aging for 2-6 hours in a sealed storage hopper. After aging, the crumb is fed to the molding of raw granules by volume compression / SU 8676603, 1979 /.

A known method of manufacturing expanded clay with a shape factor of 1.05-1.2 is complex and lengthy. In the known method, it is necessary to observe the size of the crumbs 5-30 mm, maintain a certain humidity and observe the drying for 2-6 hours.

A known method of forming blanks from clay raw materials in the form of a cube in the manufacture of fired artificial aggregate - ceramdora (SU 765236, 1980).

In the known method, it is necessary to obtain ceramdor, which is a substitute for natural gravel and gravel, with high density and strength, for which calcination is carried out according to the new regime, which allows almost completely to carry out the processes associated with the release of gaseous products before firing, which eliminates the production of porous granules for light brands of expanded clay.

Each of these known methods is not without certain drawbacks, namely, it is distinguished by a certain complexity, duration and does not allow to obtain environmentally friendly and at the same time durable and waterproof material with good thermal insulation properties.

An object of the invention is to obtain an environmentally friendly product with good strength properties, reduced thermal conductivity, as well as simplifying the process and reducing the cost of the finished product.

The stated technical problem is achieved by the claimed group of the invention regarding a method for producing a heat-insulating and insulating material.

One of the inventions of the claimed group is a method for producing thermal insulation and insulation material for building products based on amorphous silica, comprising mixing a binder based on amorphous silica with a dispersion of 1-10 mm with a loose heat-insulating filler with a dispersion of 0.5-15.0 mm for 3 -10 min until a homogeneous dry mixture is obtained, subsequent mixing of the dry mixture with an aqueous solution of an alkaline component with further stirring for 1-5 minutes and subsequent molding of the products dry pressing house with a force of 5-10.2 kg / cm ² and heat treatment at 150-850 ° C.

Moreover, in the composition of the binder (binder) based on amorphous silica, it is additionally possible to use a silica-containing binder (binder) with a density of 1.2-2.2 g / cm ³ or 1.3-2.4 g / cm ³ and a module of 15-30 at various ratios of them, obtained on the basis of silica-containing raw materials (component) and inorganic binder.

And in particular, a silica binder is used, obtained using quarry clay, calcined clay, loam, sandy loam, loess deposits.

Upon receipt of the specified silica binder, which can be additionally used in the binder together with amorphous silica, for example, a silicate binder (liquid glass with a module of 2.3-4.0, silicate block, sodium hydrosilicates, aluminosilicates) is used as an inorganic binder , waste from the production of window and industrial glass, silica gel (waste from metallurgical production or production of aluminum fluoride with a content of silicon dioxide, for example, 88.0-88.2 wt.%.

Such a binder, in particular, is a known binder described in patent RU 2236374, 09/20/2004 or binder according to patent RU 2283818, 09/20/2006.

The method is carried out using, as a bulk heat-insulating filler, a mineral filler based on silica-containing species, wood waste, and vegetable waste from agricultural production.

The method is carried out using expanded clay, expanded vermiculite, perlite sand as a mineral filler; as well as using waste products such as sunflower husks and straw from the processing of flax as plant waste.

The method is carried out using as amorphous silica, for example, tripoli or silica fume industrial production.

To implement the method according to the invention, various grinding devices and various mixing devices are used, which ensure grinding of the components to the required predetermined size and effective mixing of the initial mixture. These devices include roller and disk mills, various dissolvers, ball mills, bead, disk mixers, mixers with an anchor mixer, a planetary mixer, screw, planetary mixers with three-dimensional movement of spiral-tape working bodies.

Another invention of the claimed group (embodiment of the invention) is a method for producing thermal insulation and insulation material for building products based on clay siliceous binder (binder) obtained from clay raw materials and inorganic binders, including mixing the binder with a loose heat insulating filler selected from the group comprising expanded vermiculite , perlite sand expanded clay, wood waste in the form of sawdust and shavings, vegetable waste from agricultural production , subsequent introduction into the mixture obtained with stirring of an alkali-containing component in the form of its aqueous solution and further mixing them to obtain a homogeneous mass and further molding of heat-insulating products from it by semi-dry pressing with a pressing force of 2.5-35.0 kg / cm and heat treatment with 150-850 C, depending on the type of heat-insulating filler for a period of time ensuring its full cure.

At the same time, a binder obtained on the basis of clay raw materials, such as quarry clays, calcined clays, loams, sandy loams, loess deposits with a moisture content of not more than 6% and more than 10%, and an inorganic binder are used as a binder (binder).

In particular, as such a binder (binder) in the method, a binder obtained by a known method obtained according to patent RU 2236374, 09/20/2004, or by a method obtained according to application RU No. 2009121120 filed with the Patent Office of the Russian Federation on 03.06.2009, or according to patent RU 2283818, 09/20/2006.

When implementing the inventive method (variants thereof) as alkali-containing component, for example, sodium hydroxide is used. In this case, upon receipt of the insulating and heat-insulating material by the method claimed as the invention using amorphous silica as a binder, the ratios of the starting components are selected, for example, the following, wt.%:

amorphous silica 39.0-39.5 above heat-insulating filler 26.0-26.5 alkaline component (as an aqueous solution) 3.0-3.5 water rest

Moreover, as indicated above, the clay binder used in the implementation of the claimed method variants, as well as a silica-containing additional binder used along with (or in conjunction with) amorphous silica, is obtained either according to the known patent RU 2236374, 09/20/2004, or according to application No. 2009121120 from 06/03/2009.

According to the method described in patent application No. 2009121120 from 06/03/2009, a silica-containing binder is obtained on the basis of an inorganic binder, a silica-containing component and water with intensive mixing, which consists in the presence of hydrofluoric acid salts, taken in an amount of from 0, 5 to 10.0 wt.% Based on the mixture, alkali metal or ammonium hydroxide or a silicate bond are used as the inorganic binder, silica-containing component is used as the silica-containing component a component with a particle size of 0.2 to 20.0 mm or pre-crushed to a particle size of 40 Å to 60 μm, selected from the group consisting of silica sand or quartz flour with a moisture content of not more than 4%, quarry clays with a moisture content of more than 10 %, calcined clays, loams, loamy sand, loess deposits, silica fume obtained from ferroalloy production waste, stone processing waste obtained from sawing or grinding, for example, granite or granite crushed stone production, hydromica, such as used in the production of vermiculi one or expanded perlite, while intensive mixing is carried out in a high-speed mixer with a stirring speed of 1500-6000 rpm, a vibration frequency of mixed particles of 2000-45000 rpm, at 80-90 ° C or when exposed to an electric field with a strength of 15-40 W and current up to 60A, and mixing is carried out for a period of time from 10 minutes to 12 hours, depending on the dispersion of the silica-containing component, after which the mixture is cooled with constant stirring at a speed of 40 to 100 rpm at 15-25 ° for 10-12 hours or with air aeration at 10-20 ° C for 6-11 hours to provide a binder with a density of 1.3-2.4 g / cm ³ and silicate module 15-30 in the following ratio, the initial mixture, wt.%:

the above inorganic ligament 5.0-30.0 the above silica-containing component 15.0-65.0 hydrofluoric acid salt 0.5-10.0 water rest

As an inorganic binder, a silicate binder is used, selected from the group consisting of sodium hydrosilicates, liquid glass, silicate block, cullet formed during the production or use of glass, silica sol, silica gel, aluminosilicates, and fresh water, sea water, and mineralized water are used .

As silica-containing raw materials (components), for example, silica sand, silica flour with a SiO ₂ content _of up to 99 wt.% And a moisture content of not more than 4% are used, silica fume obtained from ferroalloy production waste, stone processing waste obtained by sawing or grinding, for example , granite or in the production of crushed granite, hydromica, such as used in the production of vermiculite or expanded perlite, as well as various clays (quarry with a moisture content of not more than 10%), calcined, loams, sandy loam, loess deposits.

As the hydrofluoric acid salt, in particular, calcium fluoride (CaF ₂ ), sodium fluoride (NaF), sodium silicofluoride, aluminum fluoride and others are used.

Thus, in accordance with the claimed group of the invention, thermal insulation and insulation materials are obtained using a well-known silica-containing binder, including clay raw materials and / or using amorphous silica of both natural and industrial origin as a binder, mixing them with bulk heaters , for example, expanded vermiculite, perlite sand, expanded clay, or industrial waste, such as wood shavings and sawdust, or agricultural processing and, for example, husks of sunflower, straw and straw from processing flax and mixing them with an aqueous solution of an alkali-containing component.

Molding is carried out by semi-dry pressing with a pressing force of 2.5 kg / cm ² to 35.0 kg / cm ² . Molded products are subjected to heat treatment at temperatures of 150-850 ° C for the time necessary for complete curing of the product.

The introduction into the composition of the molding mixture prepared using a silica binder, amorphous silica, such as tripoli, can reduce the heat treatment of products from 850 ° C to 150 ° C.

With a slight change in the volume of bulk insulation used and pressing efforts, the use of amorphous silicas and changes in the heat treatment regimes make it possible to widely control the strength characteristics of the products and their thermal conductivity. The increase in strength characteristics is associated with crystallization of silica up to its vitrification, and low thermal conductivity is associated with an increase in porosity due to the emitted gas by amorphous silica during its heat treatment in the presence of an alkaline medium and complete dehydration of the product.

Such properties of heaters manufactured by this technology allow their use in any areas of construction production, for example, in the production of reinforced concrete panels, insulation of various structures and surfaces.

An increase in strength characteristics with a simultaneous decrease in the thermal conductivity of products whose heat treatment took place at temperatures up to 250 ° C, under the influence of high temperatures, for example, during a fire, allows them to be used as fireproof coatings for building structures in industrial and civil buildings.

The following are examples of the implementation of the claimed group of the invention, illustrating it, but not limiting the scope of its claims.

In the above examples, a binder is used in the form of amorphous silica (tripoli, microsilica of industrial production), in the form of a clay binder, and also based on mixtures thereof.

Example (using amorphous silica as a binder)

As bulk insulation - any of the above. The manufacturing process is as follows. Loose insulation, for example vermiculite of a fraction of 2 mm, is mixed with amorphous silica, for example tripoli of a fraction of 1-10 mm, until a homogeneous dry mixture is obtained in forced-action mixers, for example planetary, for 3-10 minutes. Then this mixture is closed with an aqueous solution of an alkaline component, for example sodium hydroxide, and mixed for 1-5 minutes.

The finished mixture is pressed, for example, with a force of 10.2 kg / cm ² . The raw product is subjected to heat treatment at 780 ° C. The product obtained in its characteristics fully complies with that given in the table for products made using a binder.

The composition of the molding mixture is as follows, wt.%:

Vermiculite 26.2 Silica (tripoli) 39.3 Water 31,4 Sodium hydroxide 3,1

The property of dissolving amorphous silicas in an aqueous alkaline medium with the formation of an adhesive, which after heat treatment becomes practically insoluble in water, allows its use in the production of heat-insulating materials. In this case, the properties of the products will not differ in any way from those made on the basis of a silica binder.

The use of this method of production of heat-insulating products allows the most efficient use of all the components that make up the molding mixture in order to obtain products with predetermined parameters of both strength characteristics and thermal conductivity.

Tables 1-3 and 4 provide examples of the implementation of the claimed method (and its variants) using the other astringents and amorphous silicas mentioned above, as well as their properties.

Table 1 Clay binder No pp Indicators Units rev. Expanded clay Expanded clay Expanded clay Expanded clay one Dry material volume cm ³ 400 400 500 500 2 Volumetric weight of dry material kg / m ³ 450 450 450 450 3 Binder Consumption (from clay) ml 90 90 90 90 four Water consumption ml 0 0 0 0 5 The consumption of amorphous silica (silica fume prom.) g fifteen fifteen 25 25 6 Pressing load kg / cm 2.5 2.5 12.0 12.0 7 Heat treatment temperature ° C 250 850 250 850 8 Compressive strength kg / cm ² 18,4 22.8 27.1 31.3 9 Bending strength kg / cm ² 8.2 5.1 11.7 6.4 10 Thermal conductivity kcal / mh 0,062 0.059 0,075 0,069

table 2 Microsilica binder industrial No pp Indicators Units rev. Perlite Perlite Perlite Perlite one Dry material volume cm 400 400 600 600 2 Volumetric weight of dry material kg / cm ³ fifty fifty fifty fifty 3 Binder Consumption ml 35 35 35 35 four Water consumption ml 0 0 0 0 5 The consumption of amorphous silica (silica fume prom.) g 10 10 fifteen fifteen 6 Pressing load kg / cm ² 3,1 3,1 8.0 8.0 7 Heat treatment temperature ° C 250 780 250 780 8 Compressive strength kg / cm ² 6.5 7.8 11,4 16.8 9 Bending strength kg / cm ² 7.1 5,4 13.1 12.1 10 Thermal conductivity kcal / mh 0,054 0,049 0,063 0.059

Table 3 Astringent tripoli No pp Indicators Units rev. Vermiculite Vermiculite Vermiculite Vermiculite l Dry material volume cm ³ 300 300 500 500 2 Volumetric weight of dry material kg / m ³ one hundred one hundred one hundred one hundred 3 Sodium hydroxide g 6 6 9 9 four Water consumption ml 200 200 250 250 5 Consumption of amorphous silica (trepe) g 150 150 200 200 6 Pressing load kg / cm ² 5,0 5,0 10,2 10,2 7 Heat treatment temperature ° C 250 780 250 780 8 Compressive strength kg / cm ² 14.0 18.1 21.5 29.1 9 Bending strength kg / cm ² 15,5 13,2 19,4 16,2 10 Thermal conductivity kcal / mh 0.056 0.051 0,061 0.058

Table 4 Properties of thermal insulation products (half cylinders). (based on amorphous silicas) product name Strength MPa Thermal conductivity, W / (m · K) Test temperature, ° С 25 one hundred 200 300 600 750 Chelyabinsk 0.37 Experimental data 0,030 0,034 0,065 0,078 0,110 0.167 0,029 0,038 0,069 0,075 0.113 0.160 0,031 0,036 0,063 0,073 0.106 0.163 Average value 0,030 0,036 0,066 0,075 0,110 0.163 Kola 0.38 Experimental data 0,040 0,043 - 0,078 0.130 0.125 0,036 0,037 0,079 0.133 0.130 0,039 0,044 0,080 0.128 0.129 Average value 0,038 0,041 0,079 0.130 0.128

Thus, thermal insulation and insulation materials obtained by the method (and its variants) according to the claimed group of inventions, due to their variety of shapes and fairly good properties, including such as fire resistance, can be widely used in the building materials industry.

Claims (10)

1. A method of producing a heat-insulating and insulating material for building products, comprising mixing a binder based on amorphous silica with a dispersion of 1-10 mm with a loose heat-insulating filler with a dispersion of 0.5-15.0 mm for 3-10 minutes to obtain a homogeneous dry mixture subsequent mixing of the dry mixture with an aqueous solution of an alkaline component with further stirring for 1-5 minutes and subsequent molding of the products by pressing with a force of 5.0-10.2 kg / cm ² followed by heat treatment at 150-850 ° C. 2. The method of producing heat-insulating and insulating material according to claim 1, characterized in that the binder based on amorphous silica further comprises a silica binder with a density of 1.2-2.2 g / cm ³ or 1.3-2.4 g / cm ³ module 15-30, obtained on the basis of a silica-containing component and an inorganic binder. 3. The method according to claim 2, characterized in that the binder obtained using silica-containing component (raw material) quarry clays, calcined clays, loams, sandy loams, loess deposits is used as a binder based on silica-containing raw materials and inorganic binder. 4. The method of producing heat-insulating and heat-insulating material according to claim 1, characterized in that as a bulk heat-insulating filler, a mineral filler based on silica-containing species, wood waste, vegetable waste from agricultural production is used. 5. The method according to claim 4, characterized in that as a mineral filler use expanded vermiculite, perlite sand, expanded clay. 6. The method according to claim 4, characterized in that the sunflower husk, straw duster from flax processing are used as plant waste. 7. The method according to one of claims 1 to 6, characterized in that tripoli or silica fume are used as amorphous silica in industrial production. 8. A method of obtaining a heat-insulating and insulating material for building products based on a silica-containing binder (binder) obtained on the basis of a silica-containing clay raw material and inorganic binder, including mixing a binder with a loose heat-insulating filler selected from the group comprising expanded vermiculite, perlite sand, to wood waste in the form of sawdust and shavings, vegetable waste from agricultural production, subsequent introduction into the resulting mixture and the mixture was schelochesoderzhaschego component in the form of its aqueous solution and further mixing them until a homogeneous mass, and further forming insulation products therefrom by dry pressing under a force pressing 2,5-35 kg / cm ² and heat treating them at 150-850 ° C depending on the type of heat-insulating filler for a period of time ensuring its full cure. 9. The method according to claim 8, characterized in that a silica-containing binder is used obtained using quarry clays, calcined clays, loams, loamy sand, loess deposits as clay raw materials. 10. The method according to claim 8, characterized in that caustic soda is used as an alkali-containing component.