TWI873655B - Method for manufacturing floor bricks using solid recovered fuel fly ash and bottom ash - Google Patents

Abstract

The present invention is manufacturing method of using solid recovered fuel fly ash and bottom ash to form floor brick. A solid renewable fuel is burned to produce a mixed ash and a mixed residue. The mixed ash is then mixed with a furnace stone powder. A natural sand or/and the slag is added according to a mixing ratio and mixed for a first time to form a mixture. The mixed substrate is mixed with an alkaline solution for a second time according to a liquid to solid ratio to form a slurry.

Description

Method for preparing floor tiles using mixed burning ash

The present invention relates to a method, in particular a method for preparing floor tiles using mixed-burning ash.

In addition to the over-exploitation of natural resources, the rapid economic development has also led to an increase in waste generation, especially waste generated by the production processes of the textile, photovoltaic panel, semiconductor and paper industries, as well as hazardous industrial waste.

Regarding the above waste, the government is currently actively promoting reduction at the source of the industry and is also committed to recycling and reusing the above waste.

To this end, in recent years, the Environmental Protection Agency has been vigorously promoting the use of "Solid Recovered Fuel" (SRF) to recycle waste. Solid recovered fuel can also be called solid recovered fuel or solid reused fuel.

Solid renewable fuel (SRF) is converted from non-hazardous and flammable materials such as plastics and biomass (such as waste paper, wood and other wood fiber waste) and meets fuel quality standards (net calorific value, chlorine content, mercury content, lead content and cadmium content). Solid renewable fuel (SRF) has three major advantages: low environmental impact, low fuel cost, and can be used in high-energy-efficiency boilers and combustion facilities.

Solid renewable fuel (SRF) is more effective in reducing carbon emissions than coal. In addition, separating combustible waste into solid renewable fuel (SRF) for use as industrial boiler fuel can also reduce the load on existing incinerators.

At present, the main users of existing solid renewable fuel (SRF) are industrial boilers, cement kilns, steelmaking furnaces and coke furnaces, special combustion power generation equipment, etc., and do not cover waste incineration equipment.

According to the "Technical Guidelines and Quality Specifications for the Production of Solid Renewable Fuels" formulated by the Environmental Protection Administration, the types of waste that meet the requirements for solid renewable fuels (SRF) include waste plastics (waste PET, waste PP, waste PE and waste PLA, etc.), waste rubber, waste paper, waste wood, waste fiber (waste cloth, waste man-made fiber and textile residues, etc.), sludge, animal and plant waste (bagasse) and garbage, etc.

However, burning solid renewable fuel (SRF) in a circulating fluidized bed boiler will still produce mixed combustion ash and mixed combustion bottom ash, and because the components of mixed combustion ash and mixed combustion bottom ash are diverse and complex, they will still cause a considerable burden on the environment.

With today's environmental awareness, it is very necessary to reuse the mixed combustion ash and mixed combustion bottom ash produced after burning solid renewable fuel (SRF) and it must be vigorously promoted.

Therefore, how to recycle the mixed combustion ash and mixed combustion bottom ash produced after burning solid renewable fuel (SRF) for reuse is a problem that technicians in this field want to solve.

One of the purposes of the present invention is to provide a method for preparing floor tiles using calcined ash, using furnace stone powder as the raw material of inorganic polymerization technology, mixing with natural sand and alkaline solution, and replacing natural sand with calcined ash and calcined bottom ash, and making brick bodies through high pressure, effectively utilizing calcined ash and calcined bottom ash as resources, and reducing the carbon dioxide generated by the use of cement powder in the product manufacturing process.

To achieve the above-mentioned purpose, the present invention provides a method for preparing floor tiles using mixed ash, which comprises: taking a solid renewable fuel and performing a combustion process to generate a mixed ash and a mixed bottom ash; taking the mixed ash and a furnace stone powder for mixing, and adding a natural sand and/or the mixed bottom ash according to a mixing ratio for a first time to form a mixed bottom material; taking the mixed bottom material and an alkaline solution and mixing them according to a liquid-solid ratio for a second time to form a slurry; and pouring the slurry into a brick-making mold, and performing a high-pressure process according to a pressure to form a floor tile.

The present invention provides an embodiment, wherein in the step of taking the calcined ash and a furnace stone powder for mixing, and adding a natural sand or/and the calcined bottom ash according to a mixing ratio and mixing for a first time to form a mixed bottom material, a weight percentage of the calcined ash is 20wt% to 60wt%, and a weight percentage of the furnace stone powder is 20wt%.

The present invention provides an embodiment, wherein in the step of mixing the calcined ash and furnace stone powder, adding natural sand or/and the calcined bottom ash according to a mixing ratio and mixing for a first time to form a mixed bottom material, a weight percentage of the calcined bottom ash in the mixing ratio is 0wt%, a weight percentage of the natural sand is 20wt% to 60wt%, and further, the sum of the weight percentages of the calcined ash and the natural sand is 80wt%.

The present invention provides an embodiment, wherein in the step of forming a mixed base material by mixing the calcined ash and a furnace stone powder, and adding a natural sand or/and the calcined bottom ash according to a mixing ratio and mixing for a first time, a weight percentage of the calcined bottom ash in the mixing ratio is 40wt% to 60wt%, a weight percentage of the natural sand is 0wt%, and further, the sum of the weight percentages of the calcined ash and the calcined bottom ash is 80wt%.

The present invention provides an embodiment, wherein in the step of taking the mixed ash and a furnace stone powder for mixing, and adding a natural sand or/and the mixed bottom ash for mixing for a first time according to a mixing ratio to form a mixed bottom material, the mixing ratio has a weight percentage of the mixed bottom ash of 10wt% and a weight percentage of the natural sand of 10wt%.

The present invention provides an embodiment, wherein in the step of taking the mixed base material and an alkaline solution and mixing them for a second time according to a liquid-to-solid ratio to form a slurry, the alkaline solution is a sodium salt solution.

The present invention provides an embodiment, wherein the sodium salt solution is a NaOH solution or a Na ₂ SO ₃ solution.

The present invention provides an embodiment, wherein in the step of taking the mixed base material and an alkaline solution and mixing them for a second time according to a liquid-to-solid ratio to form a slurry, the liquid-to-solid ratio is between 0.2 and 0.3.

The present invention provides an embodiment, wherein in the step of forming a floor tile after pouring the slurry into a tile-making mold and performing a high-pressure process according to a pressure, the pressure is between 70Kgf/ ^cm2 and 90Kgf/ ^cm2 .

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Figure 1: It is a schematic diagram of the process of preparing floor tiles using mixed burning ash in one embodiment of the present invention.

In order to enable the review committee to have a deeper understanding and recognition of the characteristics and effects of the present invention, the preferred embodiments and detailed descriptions are provided as follows: It is known that the mixed combustion ash and mixed combustion bottom ash produced from solid renewable fuel are products produced after the new solid renewable fuel (SRF) is put into a circulating fluidized bed boiler for combustion. Since the mixed combustion ash and mixed combustion bottom ash will cause excessive expansion, resulting in a decrease in strength, and because the composition of the mixed combustion ash and mixed combustion bottom ash is complex, it will cause a burden on the environment.

The present invention improves a method for preparing floor tiles using mixed ash and slag, using furnace stone powder as the raw material of inorganic polymerization technology, mixing with natural sand and alkaline solution, and replacing natural sand with mixed ash and mixed bottom slag, and making brick bodies through high pressure, effectively utilizing mixed ash and mixed bottom slag as resources, and reducing the carbon dioxide generated by the use of cement powder in the product manufacturing process.

In the following, the present invention will be described in detail by illustrating various embodiments of the present invention with reference to drawings. However, the concept of the present invention may be embodied in many different forms and should not be construed as being limited to the exemplary embodiments described herein.

First, please refer to Figure 1, which is a schematic diagram of the process of using mixed ash to prepare floor tiles according to an embodiment of the present invention. As shown in the figure, the steps include: Step S10: After taking solid renewable fuel for combustion process, mixed ash and mixed bottom ash are generated; Step S20: Mixing the mixed ash and furnace stone powder, and adding natural sand and/or mixed bottom ash according to the mixing ratio for a first time to form a mixed base material; Step S30: Mixing the mixed base material and alkaline solution according to the liquid-solid ratio for a second time to form a slurry; and Step S40: Pour the slurry into a brick-making mold, and perform a high-pressure process according to the pressure to form a floor tile.

In this embodiment, as described in step S10, a solid renewable fuel is used to perform a combustion process, and a mixed combustion ash and a mixed combustion bottom ash are obtained through the combustion process.

The solid recycled fuel mentioned above is a flammable waste that must meet the fuel quality standards. It is called SRF (Solid recovered fuel, abbreviated as SRF), and can also be called solid recovered fuel, solid reused fuel or solid recycled fuel.

The solid renewable fuel waste in this embodiment includes non-hazardous and flammable industrial waste and general garbage or industrial employee waste. Industrial waste includes waste plastic, waste rubber, waste paper, waste wood, waste fiber, organic sludge, pulp and paper sludge, textile sludge, etc. General garbage or industrial employee waste usually needs to be separated by mechanical sorting (MT) or mechanical biological treatment (MBT) to be used as the raw material of the solid renewable fuel.

In this embodiment, the combustion process uses a circulating boiler, an industrial boiler, a cement kiln, a steelmaking furnace, a coke furnace, or a dedicated combustion power generation equipment. This embodiment uses a circulating boiler for illustration, but is not limited to this.

Continuing from the above, in this embodiment, as described in step S20, after obtaining the mixed ash and the mixed ash bottom ash, the mixed ash and a furnace stone powder are mixed, and a natural sand or/and the mixed ash bottom ash are added according to a mixing ratio and mixed for a first time to form a mixed base material.

Among them, in this embodiment, the weight percentage of the mixed ash is 20Wt% to 60Wt%, and the weight percentage of the furnace stone powder is 20Wt%.

In addition, in this embodiment, the mixing ratio of the mixed ash can be 0Wt%, that is, when the mixing ratio of the mixed ash has a weight percentage of 0Wt%, the weight percentage of the natural sand is 20Wt% to 60Wt%, and further, the sum of the weight percentages of the mixed ash and the natural sand is 80Wt%.

Furthermore, in this embodiment, the natural sand in the mixing ratio can be 0 wt%, that is, when the weight percentage of the mixed combustion bottom ash in the mixing ratio is 40 wt% to 60 wt%, the weight percentage of the natural sand is 0 wt%, and further, the sum of the weight percentages of the mixed combustion ash and the mixed combustion bottom ash is 80 wt%.

Among them, in this embodiment, there is another preferred implementation mode, and the mixed ash, the furnace stone powder, the natural sand and the mixed ash can also be mixed, and the formula composition is that the mixed ash has a weight percentage of 60Wt%, the mixed ash has a weight percentage of 10Wt%, the natural sand has a weight percentage of 10Wt%, and the furnace stone powder has a weight percentage of 20Wt%

Continuing with the above, please refer to Figure 1 again. As described in steps S30 to S40 of this embodiment, the mixed base material and an alkaline solution are mixed for a second time according to a liquid-solid ratio to form a slurry, and the slurry is poured into a brick-making mold, and a high-pressure process is performed according to a pressure to form a floor tile.

The alkaline solution is a sodium salt solution, and the sodium salt solution is a NaOH solution or a Na ₂ SO ₃ solution.

In this embodiment, the sodium salt solution is used because the sodium alkali solution is a commonly known inorganic polymerization technology. This technology uses an inorganic polymer as an amorphous or semi-crystalline material. This material is mainly aluminosilicate (Alumino-Silicate) minerals or wastes, which are placed in an alkaline solution to precipitate Si and Al colloids from the mineral surface to form an inorganic polymer precursor (Geopolymer Precursor).

Subsequently, an alkaline metal silicate solution is added to provide sufficient Si ions and trigger a polymerization reaction to form the backbone of the inorganic polymer. Generally speaking, the formation of the inorganic polymer includes the following four processes: (1) the dissolution of aluminum silicate mineral powder in the alkaline solution; (2) the diffusion of dissolved silicon and aluminum ions from the surface of the solid particles to the gaps between the particles; (3) a polymerization reaction occurs between the alkaline metal silicate solution and the silicon and aluminum ions; (4) the gel phase gradually eliminates the remaining water and solidifies and hardens into a silicon-aluminum inorganic polymer material.

Inorganic polymers are formed by SiO ₄ and AlO ₄ tetrahedrons sharing oxygen atoms to form a closed framework structure of Si-O-Al, similar to zeolite. Its hardening mechanism is similar to that of cement, where inorganic polymerization occurs between particles of the system colloid. The hardening time at room temperature is about 1.5-2 hours, and after four hours, the compressive strength is more than 80%. The biggest difference between it and cement is that the bonding form of cement after hardening is hydration bonding, while that of inorganic polymers is chemical bonding.

Through the above-mentioned inorganic polymerization technology, the mixed base material and an alkaline solution are mixed for the second time according to the liquid-solid ratio to form the slurry, wherein the liquid-solid ratio is between 0.2 and 0.3.

Finally, the slurry is poured into the brick-making mold and pressure is applied to form the floor tile made in this embodiment, wherein the pressure is between 70Kgf/ ^cm2 and 90Kgf/ ^cm2 .

The advantage of this embodiment is that natural sand and alkaline solution are used to replace natural sand with calcined ash and calcined bottom ash before mixing, and bricks are made through high pressure, which effectively utilizes calcined ash and calcined bottom ash as resources. It can also reduce the carbon dioxide generated by the use of cement powder in the product manufacturing process, so that calcined ash and calcined bottom ash can be fully utilized to achieve the purpose of sustainable development of resources.

Next, the following practical example is given to illustrate the implementation of the method of preparing floor tiles using mixed-burning ash in this embodiment.

Embodiment A:

The mixing ratio is: 20 wt% of the mixed ash, 20 wt% of the furnace stone powder, 60 wt% of the natural sand, and 0 wt% of the mixed bottom ash; the first time is 2 minutes (mixing time of the mixed ash, the furnace stone powder, the natural sand, and the mixed bottom ash); the liquid-solid ratio is 0.21; the second time is 3 minutes (mixing time of the mixed bottom material and the alkaline solution); and the pressure is 80 Kgf/ ^cm2 .

Embodiment B:

The mixing ratio is: 40 wt% of the mixed ash, 20 wt% of the furnace stone powder, 40 wt% of the natural sand, and 0 wt% of the mixed bottom ash; the first time is 2 minutes (mixing time of the mixed ash, the furnace stone powder, the natural sand and the mixed bottom ash); the liquid-solid ratio is 0.29; the second time is 3 minutes (mixing time of the mixed bottom material and the alkaline solution); and the pressure is 80 Kgf/ ^cm2 .

Embodiment C:

The mixing ratio is: 20 wt% of the mixed ash, 20 wt% of the furnace stone powder, 0 wt% of the natural sand, and 60 wt% of the mixed bottom ash; the first time is 2 minutes (mixing time of the mixed ash, the furnace stone powder, the natural sand and the mixed bottom ash); the liquid-solid ratio is 0.23; the second time is 3 minutes (mixing time of the mixed bottom material and the alkaline solution); and the pressure is 80 Kgf/ ^cm2 .

Embodiment D:

The mixing ratio is: 10 wt% of the mixed ash, 20 wt% of the furnace stone powder, 60 wt% of the natural sand, and 10 wt% of the mixed bottom ash; the first time is 2 minutes (mixing time of the mixed ash, the furnace stone powder, the natural sand, and the mixed bottom ash); the liquid-solid ratio is 0.22; the second time is 3 minutes (mixing time of the mixed bottom material and the alkaline solution); and the pressure is 80 Kgf/ ^cm2 .

The floor tiles prepared by the above-mentioned embodiments A, B, C and D were subjected to hot pressure expansion analysis in accordance with the provisions of the national standard CNS1258, with the purpose of obtaining the expansion coefficient of cement mortar. The test instruments used were a high-pressure steam boiler and a comparative side length meter for measuring the length change of cement mortar; the high-pressure steam boiler is a high-pressure steam furnace equipped with an automatic pressure The pressure controller is also equipped with a safety valve. From the beginning of pressurization, the pressure in the boiler will reach the specified pressure of 20.8kgf/cm2 within 45 to 75 minutes and maintain it for at least three hours. After the steaming is completed, the sample is taken out and the water temperature is reduced to 23 degrees within 15 minutes. The sample and water are kept at this temperature for 15 minutes, and then the length change is measured. The analysis results are shown in Table 1 below.

The thermal expansion analysis of the floor tiles of Example A, Example B, Example C and Example D is as described in Table 1 above. Although the brick bodies of the individual examples all expand, no cracking occurs, and the expansion rate is also lower than the standard limit of 0.8%. Therefore, the floor tiles made by the present invention meet the requirements of the national standard CNS1258.

The above-mentioned embodiments are a method for preparing floor tiles using calcined ash and slag, using furnace stone powder as the raw material of inorganic polymerization technology, mixing with natural sand and alkaline solution, and replacing natural sand with calcined ash and calcined bottom slag, and then making bricks through high pressure, effectively making use of calcined ash and calcined bottom slag as resources, and reducing the carbon dioxide generated by cement powder in the product manufacturing process.

Therefore, this invention is novel, progressive and can be used in the industry. It should undoubtedly meet the patent application requirements of the Patent Law of our country. Therefore, I have filed an invention patent application in accordance with the law. I hope that the Bureau will approve the patent as soon as possible. I am very grateful.

However, the above is only a preferred embodiment of the present invention and is not intended to limit the scope of implementation of the present invention. All equivalent changes and modifications made according to the shape, structure, features and spirit described in the patent application scope of the present invention should be included in the patent application scope of the present invention.

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Claims (5)

A method for preparing floor tiles using mixed ash, comprising: Taking a solid renewable fuel and performing a combustion process to produce a mixed ash and a mixed bottom ash; Taking the mixed ash and a furnace stone powder for mixing, and adding a natural sand or/and the mixed bottom ash according to a mixing ratio for a first time to form a mixed base material; Taking the mixed base material and an alkaline solution for mixing according to a liquid-solid ratio for a second time to form a slurry; and Pouring the slurry into a brick-making mold, and performing a high-pressure process according to a pressure to form a floor tile; Wherein, a weight percentage of the mixed ash is 20 wt% to 60 wt%, and a weight percentage of the furnace stone powder is 20 wt%. Wt%, and when the weight percentage of the mixed ash in the mixing ratio is 0 Wt%, the weight percentage of the natural sand is 20 Wt% to 60 Wt%, and the sum of the weight percentages of the mixed ash and the natural sand is 80 Wt%, and when the weight percentage of the mixed ash in the mixing ratio is 10 Wt%, the weight percentage of the natural sand is 10 Wt%. A method for preparing floor tiles using mixed ash as described in claim 1, wherein in the step of taking the mixed base material and an alkaline solution and mixing them for a second time according to a liquid-to-solid ratio to form a slurry, the alkaline solution is a sodium salt solution. A method for preparing floor tiles using mixed-burned ash as described in claim 2, wherein the sodium salt solution is a NaOH solution or a Na ₂ SO ₃ solution. A method for preparing floor tiles using mixed ash as described in claim 1, wherein in the step of taking the mixed base material and an alkaline solution and mixing them for a second time according to a liquid-to-solid ratio to form a slurry, the liquid-to-solid ratio is between 0.2 and 0.3. A method for preparing floor tiles using mixed-burned ash as described in claim 1, wherein the slurry is poured into a tile-making mold and subjected to a high-pressure process under a pressure to form a floor tile, and the pressure is between 70 Kgf/ ^cm2 and 90 Kgf/ ^cm2 .