Composite comprising a mineral wool comprising a sugar

Abstract

The invention relates to a process for the preparation of a shaped composite, comprising the preparation of a mixture into which fragments of mineral wool comprising a size comprising a sugar, a non-cement silica carrier distinct from the wool, a non-cement alkali metal carrier distinct from the wool, and water, are introduced, the non-cement silica carrier and the non-cement alkali metal carrier forming, with the water, a mineral binder which gradually solidifies around the solid particles present in the mixture, and then the shaping of the mixture into a shaped composite, in particular into briquettes. The invention also relates to a process for the manufacture of mineral wool, in which a molten mass is produced which is converted into mineral wool by means of a fiberizing device, the shaped composite being introduced as vitrifiable charge into a melting chamber, such as a cupola furnace.

Claims

1. A process for preparing a shaped composite, the process comprising: mixing fragments of mineral wool sized with a sizing composition comprising a sugar with a non-cement silica carrier distinct from the wool, a non-cement alkali metal carrier distinct from the wool, and water, to obtain a mixture, wherein the non-cement silica carrier and the non-cement alkali metal carrier form, with the water, a mineral binder that gradually solidifies around solid particles present in the mixture; and then shaping the mixture into a shaped composite.

2. The process of claim 1, wherein a pH of the mixture is at least equal to 10.

3. The process of claim 1, wherein the fragments of mineral wool comprise a rock wool or a glass wool.

4. The process of claim 1, wherein the fragments of mineral wool are introduced into the mixture in a proportion of 10 to 60% by weight of the mixture.

5. The process of claim 1, wherein a sum of weights of the non-cement silica carrier and the non-cement alkali metal carrier is from 5 to 30% by weight of the mixture.

6. The process of claim 1, wherein the mixture comprises from 5 to 50% by weight of aggregates.

7. The process of claim 1, wherein a sum of the moles of silica introduced into the mixture by the non-cement silica carrier and of the moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier is greater than 0.5 mol per kg of mixture.

8. The process of claim 1, wherein the sizing composition is present in the fragments of mineral wool in a proportion of 0.1 to 10% by weight of size dry matter with respect to a total weight of fragments of dry wool.

9. The process of claim 1, wherein either no cement is introduced into the mixture or cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture.

10. The process of claim 1, wherein either no cement is introduced into the mixture or cement is introduced into the mixture such that a ratio of weight of the cement to weight of non-cement silica carrier is less than 1.

11. The process of claim 1, wherein a ratio of number of moles of silica introduced into the mixture by the non-cement silica carrier to moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier ranges from 0.2 to 3.

12. The process of claim 1, wherein the non-cement silica carrier introduces into the mixture at least 0.1 mol of silica per kg of the mixture.

13. The process of claim 1, wherein the non-cement alkali metal carrier introduces into the mixture at least 0.1 mol of alkali metal per kg of mixture.

14. The process of claim 1, wherein the mixture further comprises a non-cement alkaline earth metal carrier distinct from the wool.

15. The process of claim 14, wherein the non-cement alkaline earth metal carrier comprises Ca(OH).sub.2 or CaCO.sub.3.

16. The process of claim 14, wherein: the non-cement silica carrier and the non-cement alkaline earth metal carrier comprise one and the same slag, and the non-cement alkali metal carrier comprises sodium carbonate; and cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture.

17. The process of claim 16, wherein the cement is introduced into the mixture in a proportion of at least 0.1% by weight of the mixture.

18. The process of claim 16, wherein more than 50% of moles of silica introduced into the mixture by the non-cement silica carrier and more than 50% of moles of alkaline earth metal introduced into the mixture by the non-cement alkaline earth metal carrier are introduced into the mixture by the same slag.

19. The process of claim 16, wherein more than 50% of moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier are introduced into the mixture by sodium carbonate.

20. The process of claim 1, wherein the non-cement silica carrier comprises a sodium silicate or a slag, said slag comprising at least 10% by weight of silica, being amorphous to more than 80% of its weight and its D50 being less than or equal to 100 ?m.

21. The process of claim 1, wherein the non-cement alkali metal carrier comprises sodium hydroxide, sodium silicate or sodium carbonate.

22. The process of claim 1, wherein the water is present in the mixture in a proportion of 5 to 30%6 of the weight of the mixture.

23. The process of claim 1, wherein the sugar is present in the sizing composition in a proportion of 30 to 90% by weight of the dry matter of the size.

24. The process of claim 1, wherein a D50 of the non-cement silica carrier is less than or equal to 100 ?m.

25. The process of claim 1, wherein the shaped composite in the form of briquettes, in which conversion of the mixture into the briquettes occurs by molding and optionally compaction.

26. A process for manufacturing mineral wool, the process comprising producing a molten mass that is converted into mineral wool with a fiberizing device, wherein the shaped composite of claim 1 is introduced as a vitrifiable charge into a melting chamber.

27. A process for preparing a shaped composite, the process comprising: mixing fragments of mineral wool sized with a sizing composition comprising a sugar with a non-cement silica carrier distinct from the wool, a non-cement alkali metal carrier distinct from the wool, and water to obtain a mixture, wherein the non-cement silica carrier and the non-cement alkali metal carrier form, with the water, a mineral binder that gradually solidifies around solid particles present in the mixture; and then shaping the mixture into a shaped composite wherein a ratio of number of moles of silica introduced into the mixture by the non-cement silica carrier to moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier ranges from 0.2 to 3, and wherein the water is present in the mixture in a proportion of 5 to 30% of the weight of the mixture.

28. The process of claim 27, wherein: the non-cement silica carrier and the non-cement alkaline earth metal carrier comprise one and the same slag, and the non-cement alkali metal carrier comprises sodium carbonate; and cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture.

29. The process of claim 27, wherein: the non-cement silica carrier and the non-cement alkaline earth metal carrier comprise one and the same slag, and the non-cement alkali metal carrier comprises sodium carbonate; cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture; and more than 50% of moles of silica introduced into the mixture by the non-cement silica carrier and more than 50% of moles of alkaline earth metal introduced into the mixture by the non-cement alkaline earth metal carrier are introduced into the mixture by the same slag.

30. A process for preparing a shaped composite, the process comprising: mixing fragments of mineral wool sized with a sizing composition comprising a sugar with a non-cement silica carrier distinct from the wool, a non-cement alkali metal carrier distinct from the wool, a non-cement alkaline earth metal carrier distinct from the wool, and water to obtain a mixture, wherein the non-cement silica carrier and the non-cement alkali metal carrier form, with the water, a mineral binder that gradually solidifies around solid particles present in the mixture; and then shaping the mixture into a shaped composite, wherein the water is present in the mixture in a proportion of 5 to 30% of the weight of the mixture.

31. The process of claim 30, wherein: the non-cement silica carrier and the non-cement alkaline earth metal carrier comprise one and the same slag, and the non-cement alkali metal carrier comprises sodium carbonate; and cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture.

32. The process of claim 30, wherein: the non-cement silica carrier and the non-cement alkaline earth metal carrier comprise one and the same slag, and the non-cement alkali metal carrier comprises sodium carbonate; cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture; and a ratio of number of moles of silica introduced into the mixture by the non-cement silica carrier to moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier ranges from 0.2 to 3.

33. The process of claim 30, wherein: the non-cement silica carrier and the non-cement alkaline earth metal carrier comprise one and the same slag, and the non-cement alkali metal carrier comprises sodium carbonate; cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture; a ratio of number of moles of silica introduced into the mixture by the non-cement silica carrier to moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier ranges from 0.2 to 3; and more than 50% of moles of silica introduced into the mixture by the non-cement silica carrier and more than 50% of moles of alkaline earth metal introduced into the mixture by the non-cement alkaline earth metal carrier are introduced into the mixture by the same slag.

Description

EXAMPLES A1 to A11

(1) The ingredients shown in table 1 are mixed in a mixer. The amounts indicated are parts by weight in grams of dry matter, apart, of course, from the Total water column, which adds up all the water introduced into the mixture, in whatever way that this is.

(2) In table 1, the mineral waste products originated from the recovery of dust at different stages of the process for the manufacture of mineral wool and may be regarded as vitrifiable materials of particle or pseudofiber type. They are regarded as being an inert mineral charge which does not participate in the formation of the binder.

(3) TABLE-US-00001 TABLE 1 (parts by weight) Sugar- Sodium Mineral Ex. comprising Phenolic Total Active silicate waste No. Fiber size resin water Cement slag Na.sub.2SiO.sub.35H.sub.2O NaOH Na.sub.2CO.sub.3 Ca(OH).sub.2 CaCO.sub.3 products A1 33.6 0.7 16 12 0 0 0 0 0 0 10 A2 33.6 0.7 16 12 0 0 0 0 0 0 10 A3 33.6 0.7 16 0.6 11.4 1.44 1.44 10 A4 33.6 0.7 16 0 12 1.44 1.44 10 A5 33.6 0.7 16 0 12 4.32 1.44 10 A6 33.6 0.7 16 6 6 10 A7 33.6 0.7 16 0 12 4.32 10 A8 33.6 0.7 16 0.6 11.4 4.32 10 A9 33.6 0.7 16 0 12 4.32 1.44 10 A10 33.6 0.7 16 0 12 1.44 1.44 1.44 10 A11 33.6 0.7 16 2.4 9.6 4.32 10 A12 33.6 0.7 16 3.6 8.4 4.32 10 A13 33.6 0.7 16 6 6 4.32 10 A14 33.6 0.7 16 12 0 4.32 10 A15 33.6 0.7 16 2.4 9.6 4.32 1.44 10 A16 33.6 0.7 16 6 6 4.32 1.44 10 A17 33.6 0.7 16 12 0 4.32 1.44 10

(4) The fragments of mineral wool comprised a rock wool fiber and a sugar-comprising sizing composition. The content of these fragments of mineral wool has been broken down in table 1 between what is mineral (fiber column) and the sizing composition. The size comprised, under dry conditions, 68% by weight of sucrose, 12% by weight of ammonium sulfate, 0.5% by weight of silane and 19.5% by weight of additives of the maleic anhydride and tetraethylpentamine type, these last two compounds being mixed together before mixing with the other ingredients of the sizing composition.

(5) The fragments of mineral wool were introduced into the mixture in the wet state. In table 1, the Fiber column gives the amounts of fragments without water or sizing composition. The Sugar-comprising size and Phenolic resin columns give the amounts of sizing material which has been deposited on the rock wool. The Total water column gives the sum of the water initially introduced by the fragments and the water added. The cement used was a Portland cement. The active slag was a blast furnace slag and comprised (% by weight):

(6) TABLE-US-00002 SiO.sub.2 32.3% CaO 38.2% (i.e., 27.3% of Ca) MgO 9.2% (i.e., 5.54% of Mg) Al.sub.2O.sub.3 14.9%
and also other oxides in a minor proportion making up its composition to 100%. The slag was amorphous to more than 90% by weight. This slag is both a non-cement silica carrier and an alkaline earth metal carrier. Its particle size was fine since its D90 was less than 90 ?m and its D50 was 30 ?m.

(7) The sizing composition comprised, in the dry state, 68% by weight of sucrose, 12% by weight of ammonium sulfate, 0.5% by weight of silane and 19.5% by weight of additives of the maleic anhydride and tetraethylpentamine type, these last two compounds being mixed together before mixing with the other ingredients of the sizing composition. The sodium silicate is both a silica carrier and an alkali metal carrier. It comprises 28.3% by weight of SiO.sub.2 and 21.7% by weight of Na. It was amorphous to more than 80% by weight.

(8) Test specimens with dimensions of 4 cm?4 cm?16 cm were produced by molding under vibration and then releasing from the mold. Two types of tests were carried out. Some involved the preparation of 4?4?16 cm.sup.3 test specimens on which compressive strength tests were carried out, measured in MPa. For these tests, the compositions of table 1 were used without addition, to the mixture, of inert vitrifiable material of the inert slag or gravel type as this is not necessary in order to test the mineral binder according to the invention. The results of these tests are reported in the left-hand part of table 2 in the Compressive strength (MPa) in 4?4?16 cm column, as a function of the number of days (from 3 to 28 days). For other tests, the same compositions as in table 1 were prepared except that the fiber was absent. The sizing material was added to the composition without being deposited beforehand on fiber. In this test, the setting time of the mass of mixture is assessed during the curing thereof by giving a grade of (no solidity) to 3 (very good solidity), from the resistance to the penetration of a spatula, as a function of the number of days (from 1 to 28 days).

(9) These results are reported in the right-hand part of table 2 in the Setting time (0 to 3) with regard to paste (without fibers) column.

(10) TABLE-US-00003 TABLE 2 Setting time (0 to 3) with Compressive strength regard to paste (MPa) in 4 ? 4 ? 16 cm (without fibers) Ex. No. 3 d 4 d 7 d 10 d 14 d 28 d 1 d 2 d 3 d 7 d 14 d 28 d A1 0 0 0 0 0 0 0 0 0 0 A2 8.4 25 30 0 0 0 1 2 3 A3 6.1 21 27 3 3 3 3 3 3 A4 7.6 23 28 3 3 3 3 3 3 A5 15.1 26 35 3 3 3 3 3 3 A6 <3 <3 <3 0 0 0 0 0 0 A7 7 10.1 13.1 25 3 3 3 3 3 3 A8 2 3 3 3 3 3 A9 11 15.6 20 3 3 3 3 3 3 A10 10.4 17 35.1 3 3 3 3 3 3 A11 7.4 13 22.6 25 3 3 3 3 3 3 A12 5.8 13 26.3 30 3 3 3 3 3 3 A13 3.9 6.75 9.9 0 0 1 2 3 3 A14 2.8 5 6.1 0 0 0 0 1 2 A15 7.95 23.8 30.1 3 3 3 3 3 3 A16 0.8 3 27.9 0 0 1 2 3 3 A17 <3 <3 <3 0 0 0 0 1 2

(11) It is found that the examples having high cement contents in the case of the presence of a sugar-comprising size lead to poor results. Examples A5 and A10, comprising the highest amount of alkaline earth metal carrier, give the best results in terms of compressive strength. In particular, the comparison of examples A4 and A10 shows that the increase in the amount of alkaline earth metal carrier greatly improves the results. This is because it is seen, in table 1, that the compositions of these two examples are identical except that a small amount of CaCO.sub.3 has been added for example A10.

(12) Table 3 gives the numbers of moles of non-cement silica, non-cement alkaline earth metal and non-cement alkali metal for the mixtures of the examples of table 1.

(13) TABLE-US-00004 TABLE 3 Ex. Non-cement alkaline Non-cement No. Non-cement SiO.sub.2 earth metal alkali metal A1 0 0 0 A2 0 0 0 A3 0.068 0.104 0.05 A4 0.071 0.109 0.05 A5 0.064 0.129 0.08 A6 0.032 0.055 0 A7 0.085 0.109 0.04 A8 0.082 0.104 0.04 A9 0.085 0.109 0.076 A10 0.072 0.123 0.05 A11 0.052 0.087 0.08 A12 0.045 0.076 0.08 A13 0.032 0.055 0.08 A14 0.000 0.000 0.08 A15 0.052 0.107 0.08 A16 0.032 0.074 0.08 A17 0.000 0.019 0.08

(14) The compositions shown in table 1 are devoid of high contents of inert mineral charge so as to facilitate the preparation of the test specimens for the curing tests. However, in real use, aggregates of inert mineral charge, such as gravel or inert coarse slag, are normally introduced into the mixture. These two charges are crystalline and made of large particles and are not silica or alkali metal or alkaline earth metal carriers within the meaning of the invention. Examples B1 to B17 illustrate compositions having higher contents of inert mineral charge.

EXAMPLES B1 to B17

(15) Table 4 gives the percentages by weight of all the ingredients of mixtures corresponding to those of table 1 to which, however, 24 parts by weight of aggregates of inert mineral charge, consisting of 14 parts by weight of gravel and 20 parts by weight of inert coarse slag, have been added. The Inert mineral charge column represents the sum of the percentages of all the inert charges introduced, including the mineral waste products shown in table 1.

(16) TABLE-US-00005 TABLE 4 (% by weight) Sodium Inert Ex. Size with Phen. Total Active silicate mineral No. Fiber sugar resin water Cement slag Na.sub.2SiO.sub.35H.sub.2O NaOH Na.sub.2CO.sub.3 Ca(OH).sub.2 CaCO.sub.3 charge B1 31.61 0.66 15.05 11.29 41.38 B2 31.61 0.00 0.66 15.05 11.29 41.38 B3 30.77 0.64 14.65 0.55 10.44 1.32 1.32 40.3 B4 30.77 0.64 14.65 10.99 1.32 1.32 40.3 B5 29.98 0.62 14.28 10.71 3.86 1.29 39.26 B6 31.61 0.66 15.05 5.64 5.64 41.38 B7 30.37 0.63 14.46 10.85 3.91 39.78 B8 30.37 0.63 14.46 0.54 10.31 3.91 39.78 B9 29.98 0.62 14.28 10.71 3.86 1.29 39.26 B10 30.37 0.63 14.46 10.85 1.30 1.30 1.30 39.78 B11 30.37 0.63 14.46 2.17 8.68 3.91 39.78 B12 30.37 0.63 14.46 3.25 7.59 3.91 39.78 B13 30.37 0.63 14.46 5.42 5.42 3.91 39.78 B14 30.37 0.63 14.46 10.85 3.91 39.78 B15 29.98 0.62 14.28 2.14 8.57 3.86 1.29 39.26 B16 29.98 0.62 14.28 5.35 5.35 3.86 1.29 39.26 B17 29.98 0.62 14.28 10.71 3.86 1.29 39.26

(17) Table 5 gives the numbers of moles per kg of briquette of different carriers and some ratios for the compositions of the examples of table 4.

(18) TABLE-US-00006 TABLE 5 Sum of the number Ratio of the Number of moles of Number of moles of of moles of silica number of moles of Number of moles of non-cement alkaline non-cement alkali and of alkali silica to the Ratio of weight of Ex. non-cement SiO.sub.2/kg earth metal/kg of metal/kg of metal/kg of number of moles of cement to weight No. of briquette briquette briquette briquette alkali metal of silica carriers B1 0.000 0.000 0.000 0.000 B2 0.000 0.000 0.000 0.000 B3 0.623 0.953 0.458 1.081 1.360 0.05 B4 0.650 0.998 0.458 1.108 1.420 0.00 B5 0.571 1.151 0.714 1.285 0.800 0.00 B6 0.301 0.517 0.000 0.301 1.00 B7 0.768 0.985 0.362 1.130 2.125 0.00 B8 0.741 0.940 0.362 1.103 2.050 0.04 B9 0.759 0.973 0.678 1.437 1.118 0.00 B10 0.651 1.112 0.452 1.103 1.440 0.00 B11 0.470 0.786 0.723 1.193 0.650 0.25 B12 0.407 0.687 0.723 1.130 0.563 0.43 B13 0.289 0.497 0.723 1.012 0.400 1.00 B14 0.000 0.000 0.723 0.723 0.000 B15 0.464 0.955 0.714 1.178 0.650 0.25 B16 0.286 0.660 0.714 0.999 0.400 1.00 B17 0.000 0.170 0.714 0.714 0.000