Fiber and fiber manufacturing method

Abstract

It is an object of the invention to provide a fiber and a fiber manufacturing method, in which a waste material discharged from integrated coal gasification combined cycle can be utilized more effectively. The fiber includes a waste material discharged from integrated coal gasification combined cycle (IGCC) as a raw material.

Description

DESCRIPTION FIBER AND FIBER MANUFACTURING METHOD TECHNICAL FIELD

[0001] The present invention relates to a fiber and a fiber manufacturing method. BACKGROUND ART

[0002] As one mode of thermal power generation using coal as fuel, Integrated coal Gasification Combined Cycle (hereinafter, also described as IGCC) is known. In IGCC, coal gasification gas is used as fuel to drive a gas turbine to obtain electric power, while at the same time, exhaust heat from the gas turbine is recovered to generate steam, and the generated steam is used to drive a steam turbine to obtain electric power.

[0003] By using IGCC, power generation can be achieved with higher thermal efficiency than in conventional coal- fired power generation. Specifically, in the case of a commercial IGCC of 1400-degree to 1500-degree class, a thermal efficiency of about 48% to 50% based on the lower heating value can be realized at the sending end. This thermal efficiency is higher than the thermal efficiency of about 40% of conventional supercritical pressure coal-fired power generation (SC coal-fired power generation) and ultra-supercritical pressure coal-fired power generation (USC coal-fired power generation), and is a thermal efficiency equivalent to that of advanced ultra- supercritical pressure coal-fired power generation (A-USC coal-fired power generation) that is currently under development. Furthermore, since IGCC can utilize low-grade coal that could not be used in conventional coal-fired power generation, fuel cost reduction and diversification of fuel procurement sources can be expected.

[0004] As described above, IGCC is expected as a highly efficient next-generation power generation method. However, for the waste generated when IGCC is operated, utilization methods thereof have been established only to the extent that the waste is subjected to processing such as pulverization and is utilized as aggregate for cement (see Patent Document 1), and there is still room for further improvement. CITATION LIST PATENT DOCUMENT

[0005] Patent Document 1: JP 2017-014052 A DISCLOSURE OF THE INVENTION PROBLEM TO BE SOLVED BY THE INVENTION

[0006] The invention was achieved in view of the above- described problems, and it is an object of the invention to provide a fiber and a fiber manufacturing method, in which a waste material discharged from integrated coal gasification combined cycle can be utilized more effectively. MEANS FOR SOLVING PROBLEM

[0007] In order to solve the above-described problems, a fiber according to the invention includes a waste material discharged from integrated coal gasification combined cycle (IGCC) as a raw material. EFFECT OF THE INVENTION

[0008] According to the invention, a fiber and a fiber manufacturing method, in which a waste material discharged from integrated coal gasification combined cycle can be utilized more effectively, can be provided. BRIEF DESCRIPTION OF DRAWINGS

[0009] Fig. 1 is a diagram illustrating an outline of an electric furnace utilized in Example 1; Fig. 2 is a graph showing the temperature conditions of Example 1; Fig. 3 is an XRD spectrum of a fiber formed from raw material S1; Fig. 4 is an enlarged view (micrograph) of the fiber formed from raw material S1; and Fig. 5 is a graph showing the temperature conditions for Example 2. BEST MODE (S) FOR CARRYING OUT THE INVENTION

[0010] Hereinafter, embodiments of the invention will be described with reference to the drawings. Incidentally, in the following description, SiO2 may be referred to as component S, and the content of <semantics>SiO2<annotation encoding="application / x-tex">SiO_2< / annotation>< / semantics> may be described as <semantics>[S]<annotation encoding="application / x-tex">[S]< / annotation>< / semantics>. <semantics>Al2O3<annotation encoding="application / x-tex">Al_2O_3< / annotation>< / semantics> may be referred to as component A, and the content of <semantics>Al2O3<annotation encoding="application / x-tex">Al_2O_3< / annotation>< / semantics> may be described as [A]. CaO may be referred to as component C, and the content of CaO may be described as [C].

[0011] [Embodiment 1] A fiber according to the present Embodiment 1 uses a waste material discharged from integrated coal gasification combined cycle (IGCC) (hereinafter, also referred to as IGCC waste material. The IGCC waste material includes slag, coal ash, and the like discharged from IGCC) as a raw material. The IGCC waste material as the raw material contains <semantics>SiO2<annotation encoding="application / x-tex">SiO_2< / annotation>< / semantics> and <semantics>Al2O3<annotation encoding="application / x-tex">Al_2O_3< / annotation>< / semantics> as main components, the proportion occupied by Al2O3 in the sum of SiO2 and Al2O3 is in a specific range, and the IGCC waste material further contains a specific amount of CaO.

[0012] The raw material of the fiber according to the present Embodiment 1 is an IGCC waste material, and the total content of <semantics>SiO2<annotation encoding="application / x-tex">SiO_2< / annotation>< / semantics> and <semantics>Al2O3<annotation encoding="application / x-tex">Al_2O_3< / annotation>< / semantics> in the raw material is preferably 40% by mass or more and 70% by mass or less. When the sum of [S] and [A] is either less than 40% by mass or more than 70% by mass, the melting temperature of the raw material becomes high or the viscosity of the molten material becomes high, which results in inferior melt spinnability. Incidentally, melt spinning refers to a technique of discharging a molten material obtained by melting a raw material by heat through a hole (through- hole) formed in a spinneret to produce a fibrous form and then cooling and hardening the fibrous form. Furthermore, melt spinnability refers to the ease of manufacturing of a fiber by melt spinning.

[0013] With regard to the raw material of the fiber according to the present Embodiment 1, it is preferable that the proportion occupied by Al2O3 in the sum of SiO2 and <semantics>Al2O3<annotation encoding="application / x-tex">Al_2O_3< / annotation>< / semantics> ([A] / ([A] + [S])) (mass ratio) is in the range of <semantics>0.15 to 0.40. When [A] / ([A]+[S]) (mass ratio) is either<annotation encoding="application / x-tex">0.15 \text{ to } 0.40. \text{ When } [A] / ([A] + [S]) \text{ (mass ratio) is either}< / annotation>< / semantics> less than 0.15 or more than 0.40, the melt temperature becomes high or the viscosity of the molten material becomes high, which results in inferior melt spinnability.

[0014] With regard to the raw material of the fiber according to the present Embodiment 1, the content of CaO is preferably 5% by mass or more and 30% by mass or less. When the content of Cao is less than 5% by mass, the melting temperature of the fiber becomes high, and therefore, it is not preferable from the viewpoint of energy saving. Furthermore, the content of CaO is more preferably 30% by mass or less. With regard to the raw material of the fiber according to the present Embodiment 1, when SiO2, Al2O3, and CaO of the components are blended so as to satisfy the above-mentioned composition conditions, the fiber according to the present Embodiment 1 can be obtained without any restriction on the raw materials. As the raw materials of the fiber according to the present Embodiment 1, it is preferable to use a waste material (IGCC waste material) discharged by integrated coal gasification combined cycle (IGCC), or the like. The reason for this is that since an IGCC waste material includes SiO2 and Al2O3 as main components, the IGCC waste is suitable for obtaining the fiber according to the present Embodiment 1, and the raw material cost can be suppressed.

[0016] Incidentally, it should be noted that the fiber according to the present Embodiment is not precluded from including unavoidable impurities. Examples of main unavoidable impurities include MgO, Na2O, K2O, TiO2, and <semantics>CrO2<annotation encoding="application / x-tex">CrO_2< / annotation>< / semantics>.

[0017] In the present Embodiment 1, there is no substantial difference between the component ratio (mass ratio) of the raw materials and the component ratio (mass ratio) of the fiber manufactured by melting the raw materials. For this reason, the component ratio of the raw materials can be regarded as the component ratio of the fiber manufactured by melting the raw materials.

[0018] The fiber according to the present Embodiment 1 is highly amorphous. For this reason, the fiber has almost no decrease in strength caused by separation at the crystalline phase / non-crystalline phase interface, and a fiber having high strength can be obtained. Here, the degree of amorphization, which is a measure of amorphousness, is calculated by the following Mathematical Formula (1) based on an X-ray diffraction (XRD) spectrum. Degree of amorphization (%) = <semantics>[la / (la+lc)]×100<annotation encoding="application / x-tex">[la / (la + lc)] \times 100< / annotation>< / semantics> <semantics>⋯<annotation encoding="application / x-tex">\cdots< / annotation>< / semantics> (1) In the above Formula (1), la and lc are respectively as follows. la: integrated value of the scattering intensity of the amorphous halo. lc: integrated value of the scattering intensity of a crystalline peak when the fiber is subjected to X-ray diffraction analysis. The degree of amorphization of the fiber according to the present Embodiment 1 may vary depending on the composition of the fiber; however, the degree of amorphization usually presents a value of 90% or higher. The degree of amorphization of the fiber even reaches as high as 95% or higher in some cases, and in case where the degree of amorphization is the highest, the fiber is substantially composed only of an amorphous phase. Here, being substantially composed only of an amorphous phase implies that only the amorphous halo is recognized in the X=ray diffraction spectrum, and a peak for a crystalline material was not recognized. Example Series 1

[0019] Example Series 1 according to the present Embodiment 1 will be described below. In the following test examples, an IGCC waste material discharged by integrated coal gasification combined cycle (IGCC) was prepared as a raw material (raw material S1) of the fiber. Regarding the IGCC waste material, a material discharged from a domestic Integrated coal Gasification Combined Cycle was used. The raw material S1 was a 100% IGCC waste material.

[0020] Furthermore, in the present Example Series 1, the components of the raw material S1 (IGCC waste material) were analyzed by a fluorescent X-ray analysis method. Table 1 shows the component composition of the raw material S1 (IGCC waste material). Table 1 [Image disponible dans le document PDF, Image available in the PDF document]

[0021] Furthermore, an electric furnace was used for manufacturing the raw material S1 into a fiber. An outline of the electric furnace is shown in Fig. 1. The electric furnace 1 is a cylindrical body having a height H of 60 cm and an outer diameter D of 50 cm, in which a through-hole 4 having an inner diameter d of 10 cm is formed at the center. A Tammann tube 2 having an inner diameter of 2.1 cm and a length of 10 cm is suspended by a suspension rod 3 in the through-hole 4. The Tammann tube 2 is charged with 30 g of the raw material (raw material S1). A hole having a diameter of 2 mm is provided at the center of the bottom part of the Tammann tube 2, and when the blend is melted by heating, the molten material flows out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material that has flowed out is exposed to external air to be cooled and is solidified into a fiber. Here, since the molten material that has flowed out is rapidly cooled, the fiber is substantially only amorphous.

[0022] In the electric furnace, temperature is raised according to a predetermined temperature raising program, and it has been confirmed in advance that the temperature of the molten material in the Tammann tube 2 follows the temperature profile inside the furnace at a temperature approximately lower by 50 degrees.

[0023] The conditions for melt spinning and the results of melt spinning of the raw material S1 in Example Series 1 are shown in Table 2. Table 2 [Image disponible dans le document PDF, Image available in the PDF document] Incidentally, in the present Example Series 1, melt spinnability was rated as follows. A: A continuous long thread is formed. B: The raw material that has been melted and softened comes out through the hole provided in the bottom part of the Tammann tube, and very short fibers are generated; however, a continuous long thread is not formed. C: Nothing comes out through the hole provided in the bottom part of the Tammann tube, and no thread is formed.

[0024] Table 2 is a table summarizing the results of the presence or absence of temperature retention (annealing), the presence or absence of temperature change, and melt spinnability for the raw material S1 used in Examples A1 and A2 and Comparative Examples E1 to E3. Tables 3 A-e are tables showing changes over time in the temperature inside the furnace in Examples A1 and A2 and Comparative Examples E1 to E3. Table 3(a) is a table showing changes over time in the temperature inside the furnace in Example A1. Table 3(b) is a table showing changes over time in the temperature inside the furnace in Example A2. Table 3(c) is a table showing changes over time in the temperature inside the furnace in Comparative Example E1. Table 3(d) is a table showing changes over time in the temperature inside the furnace in Comparative Example E2. Table 3(e) is a table showing changes over time in the temperature inside the furnace in Comparative Example E3. Table 3(a) [Image disponible dans le document PDF, Image available in the PDF document] Table 3(b) [Image disponible dans le document PDF, Image available in the PDF document] Table 3(c) [Image disponible dans le document PDF, Image available in the PDF document] Table 3(d) [Image disponible dans le document PDF, Image available in the PDF document] Table 3(e) [Image disponible dans le document PDF, Image available in the PDF document] Fig. 2 is a graph obtained by plotting the changes over time in the temperature inside the furnace in Examples A1 and A2 and Comparative Examples E1 to E3 shown in Fig. 4.

[0025] (Example A1) The raw material S1 was placed in the Tammann tube. Next, the temperature inside the furnace was raised to 1350 degrees (the temperature of the raw material S1 was 1300 degrees), and then the raw material S1 was maintained at approximately 1350 degrees for a predetermined time (55 minutes) (temperature retention: Yes). Subsequently, spinnability was checked while changing the temperature inside the furnace (temperature change: Yes), and the raw material S1 formed a fiber (melt spinnability: A).

[0026] (Example A2) The raw material S1 was placed in the Tammann tube. Next, the temperature inside the furnace was raised to 1375 degrees (the temperature of the raw material S1 was 1325 degrees), and then the raw material S1 was maintained at approximately 1375 degrees for a predetermined time (120) minutes) (temperature retention: Yes). Subsequently, spinnability was checked while changing the temperature inside the furnace (temperature change: Yes), and the raw material S1 formed a fiber (melt spinnability: A).

[0027] (Comparative Example E1) The raw material S1 was placed in the Tammann tube, subsequently the temperature inside the furnace was raised to 1350 degrees (the temperature of the raw material S1 was 1300 degrees), and then the raw material S1 was maintained at approximately 1350 degrees for a predetermined time (94) minutes) (temperature retention: Yes). Subsequently, spinnability was checked without changing the temperature inside the furnace (temperature change: No); however, the raw material S1 did not form a fiber (melt spinnability: C).

[0028] (Comparative Example E2) The raw material S1 was placed in the Tammann tube, subsequently the temperature inside the furnace was raised to 1400 degrees (the temperature of the raw material S1 was 1350 degrees), and then spinnability was checked while changing the temperature inside the furnace (temperature change: Yes). However, the raw material that had been melted and softened came out through the hole provided in the bottom part of the Tammann tube, and very short fibers were generated; however, the raw material S1 did not form a fiber (melt spinnability: B). Furthermore, after the temperature was raised to 1400 degrees, temperature retention of maintaining the temperature for a predetermined time was not carried out (temperature retention: No).

[0029] (Comparative Example E3) The raw material S1 was placed in the Tammann tube, subsequently the temperature inside the furnace was raised to 1320 degrees (the temperature of the raw material S1 was 1270 degrees), and then the raw material S1 was maintained at approximately 1320 degrees for a predetermined time (20) minutes) (temperature retention: Yes). Subsequently, it was checked whether the raw material S1 was spun without changing the temperature inside the furnace (temperature change: No); however, the raw material S1 did not form a fiber (melt spinnability: C).

[0030] (Discussion) From Examples A1 and A2 and Comparative Examples E1 to E3, it was found that a fiber can be manufactured by using an IGCC waste material discharged by integrated coal gasification combined cycle (IGCC) as a raw material. Regarding the conditions in the case of manufacturing a fiber by using an IGCC waste material as a raw material, it was verified that the following conditions are preferable. (1) Heating to 1300 degrees or higher. (2) Maintaining the IGCC waste material at a temperature of 1300 degrees or higher for a predetermined time (preferably 50 minutes or longer, and more preferably 55 minutes or longer) before molding the IGCC waste material into a fiber. (3) Causing the IGCC waste material to flow out through the formed hole while changing the temperature of the IGCC waste material (in the present Example, temperature is increased).

[0031] Fig. 3 is an XRD spectrum of a fiber formed from the raw material S1. As shown in Fig. 3, only the amorphous halo was recognized in the X-ray diffraction (XRD) spectrum of the fiber obtained in the Example A1, and a peak for a crystalline material was not recognized. From this, it was understood that the fiber produced from the IGCC waste material was substantially composed only of an amorphous material.

[0032] Furthermore, Fig. 4 is an enlarge view (micrograph) of the fiber formed from the raw material S1 shown in Fig. 3. As shown in Fig. 4, a fiber having an outer diameter of more than 500 <semantics>μ<annotation encoding="application / x-tex">\mu< / annotation>< / semantics>m could be obtained. This fiber is substantially composed only of an amorphous material as described with reference to Fig. 3. This is speculated to be because, after the IGCC waste material in a molten state has flowed out through the hole provided at the center of the bottom part of the Tammann tube 2, the IGCC waste material is quenched and then becomes amorphous without adopting a regular atomic arrangement. Then, in this Example 1, it was recognized that a fiber having an outer diameter of more than 500 <semantics>μ<annotation encoding="application / x-tex">\mu< / annotation>< / semantics>m is substantially composed only of an amorphous material. Here, generally, it is conceived that as the outer diameter of the fiber is finer, the rate of cooling is faster. Therefore, it is presumed that as the outer diameter is finer than the outer diameter (505.97 <semantics>μ<annotation encoding="application / x-tex">\mu< / annotation>< / semantics>m) of the fiber shown in Fig. 4, the fiber is substantially composed only of an amorphous material. More specifically, it is presumed that a fiber having an outer diameter of 500 <semantics>μ<annotation encoding="application / x-tex">\mu< / annotation>< / semantics>m or less is substantially composed only of an amorphous material.

[0033] [Embodiment 2] A fiber according to the present Embodiment 2 includes a waste material discharged from integrated coal gasification combined cycle (IGCC) as a raw material. Specifically, the fiber according to the present Embodiment 2 includes at least one of basalt and a waste material discharged from a non-IGCC thermal power plant that uses coal as fuel, as a raw material in the waste material discharged from integrated coal gasification combined cycle (IGCC). In the same way as in Embodiment 1, it is preferable that the total content of <semantics>SiO2<annotation encoding="application / x-tex">SiO_2< / annotation>< / semantics> and <semantics>Al2O3<annotation encoding="application / x-tex">Al_2O_3< / annotation>< / semantics> in the raw material of the fiber according to the present Embodiment 2 is 40% by mass or more and 70% by mass or less. Furthermore, with regard to the raw material of the fiber according to the present Embodiment 2, it is preferable that the proportion occupied by <semantics>Al2O3<annotation encoding="application / x-tex">Al_2O_3< / annotation>< / semantics> in the sum of <semantics>SiO2<annotation encoding="application / x-tex">SiO_2< / annotation>< / semantics> and <semantics>Al2O3<annotation encoding="application / x-tex">Al_2O_3< / annotation>< / semantics> ([A] / ([A] + [S])) (mass ratio) is in the range of 0.15 to 0.40. Furthermore, with regard to the raw material of the fiber according to the present Embodiment 2, it is preferable that the content of CaO is 5% by mass or more and 30% by mass or less. Furthermore, similarly to the fiber according to Embodiment 1, it is preferable that the fiber according to the present Embodiment 2 is substantially composed only of an amorphous phase. Example Series 2

[0034] Example Series 2 according to the present Embodiment 2 will be described below. In the present Example Series 2, a mixture obtained by an IGCC waste material, a waste material discharged from a non-IGCC thermal power plant that uses coal as fuel, and basalt at a predetermined mixing ratio (% by mass) was prepared as a raw material of the fiber. The respective mixing ratios of raw materials S2 to S11 will be described below with reference to Table 4 (since the numbers after the decimal point are rounded off, the sum may not necessarily add up to 100%). Incidentally, in Table 4, the IGCC slag indicates an IGCC waste material, and FA1 to FA8 indicate waste materials from coal-fired power plants that are not IGCC (FA1 to FA8 are waste materials discharged from different power plants). Furthermore, BA1 indicates basalt (basalt). Table 4 [Image disponible dans le document PDF, Image available in the PDF document] Incidentally, in the present Example Series 2, the components of raw materials S2 to S11 were analyzed by a fluorescent X-ray analysis method. Furthermore, the electric furnace described with reference to Fig. 1 was used for manufacturing fibers from the raw materials S2 to S11.

[0035] Raw material S2 was a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 50% by mass and a waste material FA2 discharged from a coal-fired power plant at a proportion of 50% by mass.

[0036] Raw material S3 was a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 75% by mass and a waste material FA2 discharged from the coal-fired power plant at a proportion of 25% by mass.

[0037] Raw material S4 was a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 90% by mass and a waste material FA2 discharged from the coal-fired power plant at a proportion of 10% by mass.

[0038] Raw material S5 was a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 30% by mass, basalt at a proportion of 5% by mass, a waste material FA2 discharged from the coal-fired power plant at a proportion of 15% by mass, and a waste material FA7 discharged from a coal-fired power plant at a proportion of 50 by mass.

[0039] Raw material S6 was a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 50% by mass and a waste material FA3 discharged from a coal-fired power plant at a proportion of 50% by mass.

[0040] Raw material S7 is a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 20% by mass, a waste material FA2 discharged from the coal-fired power plant at a proportion of 10% by mass, a waste material FA3 discharged from the coal-fired power plant at a proportion of 30% by mass, and a waste material FA4 discharged from a coal-fired power plant at a proportion of 40% by mass.

[0041] Raw material S8 is a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 25% by mass, a waste material FA4 discharged from the coal-fired power plant at a proportion of 10% by mass, and a waste material FA6 discharged from a coal-fired power plant at a proportion of 65% by mass.

[0042] Raw material S9 is a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 10% by mass, a waste material FA2 discharged from the coal-fired power plant at a proportion of 16% by mass, a waste material FA3 discharged from the coal-fired power plant at a proportion of 36% by mass, and a waste material FA6 discharged from the coal-fired power plant at a proportion of 37% by mass.

[0043] Raw material S10 is a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 25% by mass, a waste material FA4 discharged from the coal-fired power plant at a proportion of 10% by mass, and a waste material FA6 discharged from the coal-fired power plant at a proportion of 65% by mass.

[0044] Raw material S11 is a mixture of an IGCC waste material discharged from an integrated coal gasification combined cycle power plant at a proportion of 60% by mass and a waste material FA2 discharged from the coal-fired power plant at a proportion of 40% by mass.

[0045] Furthermore, in the present Example 2, the components of the waste materials constituting the raw materials S2 to S11 and basalt (waste material or the like) were analyzed by a fluorescent X-ray analysis method. For the analysis, the components of the waste materials and the like were analyzed by using a fluorescent X-ray analyzer (Philips PW2404) of Philips Japan, Ltd., while keeping the sample chamber of the fluorescent X-ray analyzer in a vacuum state. Table 5 shows the component compositions of the waste materials and the like according to Example 2. Incidentally, in the following description, 0% by mass means that the amount is so small that the amount cannot be measured, and this does not strictly mean "zero (0)". Table 5 [Image disponible dans le document PDF, Image available in the PDF document]

[0046] In the IGCC waste material discharged from a domestic integrated coal gasification combined cycle power plant, [F] is 9% by mass, [S] is 54% by mass, [A] is 11% by mass, [C] is 17% by mass, and the content of others is 9% by mass.

[0047] In the basalt (basalt BA1), <semantics>[F]<annotation encoding="application / x-tex">[F]< / annotation>< / semantics> is 19% by mass, [S] is 46% by mass, [A] is 11% by mass, [C] is 17% by mass, and the content of others is 6% by mass.

[0048] In the waste material FA1 discharged from the domestic coal-fired power plant, [F] is 13% by mass, [S] is 57% by mass, [A] is 17% by mass, [C] is 6% by mass, and the content of others is 7% by mass.

[0049] In the waste material FA2 discharged from the domestic coal-fired power plant, [F] is 55% by mass, [S] is 35% by mass, [A] is 5% by mass, [C] is 2% by mass, and the content of others is 3% by mass.

[0050] In the waste material FA3 discharged from the domestic coal-fired power plant, [F] is 2% by mass, [S] is 62% by mass, [A] is 27% by mass, [C] is 3% by mass, and the content of others is 5% by mass.

[0051] In the waste material FA4 discharged from the domestic coal-fired power plant, [F] is 97% by mass, [S] is 0% by mass, [A] is 0% by mass, [C] is 0% by mass, and the content of others is 3% by mass.

[0052] In the waste material FA5 discharged from the domestic coal-fired power plant, [F] is 21% by mass, [S] is 35% by mass, [A] is 12% by mass, [C] is 22% by mass, and the content of others is 10% by mass.

[0053] In the waste material FA6 discharged from the domestic coal-fired power plant, [F] is 1% by mass, [S] is 73% by mass, [A] is 22% by mass, [C] is 0% by mass, and the content of others is 4% by mass.

[0054] In the waste material FA7 discharged from the domestic coal-fired power plant, [F] is 1% by mass, [S] is 19% by mass, [A] is 17% by mass, [C] is 55% by mass, and the content of others is 8% by mass.

[0055] In the waste material FA8 discharged from the domestic coal-fired power plant, [F] is 0% by mass, [S] is 34% by mass, [A] is 13% by mass, [C] is 42% by mass, and the content of others is 11% by mass.

[0056] Table 6 is a diagram showing the component compositions of the raw materials S2 to S11 according to Example 2. [Image disponible dans le document PDF, Image available in the PDF document] CA 3171810 Date reçue / Received date 2026-01-14 9 Table The component compositions shown in Table 6 were calculated from the mixing ratio of each of the raw materials S2 to S11 shown in Table 4 and the component compositions of the waste materials and the like shown in Table 5. Incidentally, since the numbers after the decimal point are rounded off, the sum may not necessarily add up to 100%.

[0057] In the raw material S2, <semantics>[F]<annotation encoding="application / x-tex">[F]< / annotation>< / semantics> is 32% by mass, <semantics>[S]<annotation encoding="application / x-tex">[S]< / annotation>< / semantics> is 45% by mass, [A] is 8% by mass, [C] is 10% by mass, and the content of others is 6% by mass. Furthermore, [S] + [A] is 53% by mass, and [A] / ([S] + [A]) is 0.15.

[0058] In the raw material S3, <semantics>[F]<annotation encoding="application / x-tex">[F]< / annotation>< / semantics> is <semantics>21%<annotation encoding="application / x-tex">21\%< / annotation>< / semantics> by mass, <semantics>[S]<annotation encoding="application / x-tex">[S]< / annotation>< / semantics> is 49% by mass, [A] is 10% by mass, [C] is 13% by mass, and the content of others is 8% by mass. Furthermore, [S] + [A] is <semantics>59%<annotation encoding="application / x-tex">59\%< / annotation>< / semantics> by mass, and [A] / ([S] + [A]) is 0.16.

[0059] In the raw material S4, <semantics>[F]<annotation encoding="application / x-tex">[F]< / annotation>< / semantics> is 14% by mass, <semantics>[S]<annotation encoding="application / x-tex">[S]< / annotation>< / semantics> is 52% by mass, [A] is 10% by mass, [C] is 16% by mass, and the content of others is 8% by mass. Furthermore, [S] + [A] is 63% by mass, and [A] / ([S] + [A]) is 0.17.

[0060] In the raw material S5, <semantics>[F]<annotation encoding="application / x-tex">[F]< / annotation>< / semantics> is 12% by mass, <semantics>[S]<annotation encoding="application / x-tex">[S]< / annotation>< / semantics> is 33% by mass, [A] is 13% by mass, [C] is 34% by mass, and the content of others is 8% by mass. Furthermore, [S] + [A] is <semantics>46%<annotation encoding="application / x-tex">46\%< / annotation>< / semantics> by mass, and [A] / ([S] + [A]) is 0.28.

[0061] In the raw material S6, [F] is 6% by mass, [S] is 58% by mass, [A] is 19% by mass, [C] is 10% by mass, and the content of others is 7% by mass. Furthermore, [S] + [A] is <semantics>77%<annotation encoding="application / x-tex">77\%< / annotation>< / semantics> by mass, and [A] / ([S] + [A]) is 0.25.

[0062] In the raw material S7, [F] is 47% by mass, [S] is 33% by mass, [A] is 11% by mass, [C] is 5% by mass, and the content of others is <semantics>4%<annotation encoding="application / x-tex">4\%< / annotation>< / semantics> by mass. Furthermore, [S] + [A] is <semantics>44%<annotation encoding="application / x-tex">44\%< / annotation>< / semantics> by mass, and [A] / ([S] + [A]) is 0.25.

[0063] In the raw material S8, [F] is <semantics>13%<annotation encoding="application / x-tex">13\%< / annotation>< / semantics> by mass, [S] is 61% by mass, [A] is 17% by mass, [C] is 5% by mass, and the content of others is 4% by mass. Furthermore, [S] + [A] is <semantics>78%<annotation encoding="application / x-tex">78\%< / annotation>< / semantics> by mass, and [A] / ([S] + [A]) is 0.22.

[0064] In the raw material S9, <semantics>[F]<annotation encoding="application / x-tex">[F]< / annotation>< / semantics> is <semantics>11%<annotation encoding="application / x-tex">11\%< / annotation>< / semantics> by mass, <semantics>[S]<annotation encoding="application / x-tex">[S]< / annotation>< / semantics> is 60% by mass, [A] is 20% by mass, [C] is 3% by mass, and the content of others is 6% by mass. Furthermore, [S] + [A] is 80% by mass, and [A] / ([S] + [A]) is 0.25.

[0065] In the raw material S10, [F] is 13% by mass, [S] is 61% by mass, [A] is 17% by mass, [C] is 5% by mass, and the content of others is 4% by mass. Furthermore, [S] + [A] is <semantics>78%<annotation encoding="application / x-tex">78\%< / annotation>< / semantics> by mass, and [A] / ([S] + [A]) is 0.22.

[0066] In the raw material S11, [F] is <semantics>27%<annotation encoding="application / x-tex">27\%< / annotation>< / semantics> by mass, [S] is 46% by mass, [A] is 9% by mass, [C] is 11% by mass, and the content of others is 7% by mass. Furthermore, [S] + [A] is <semantics>55%<annotation encoding="application / x-tex">55\%< / annotation>< / semantics> by mass, and [A] / ([S] + [A]) is 0.16.

[0067] Table 7 is a table summarizing the results of the presence or absence of temperature retention (annealing), the presence or absence of temperature change, and melt spinnability for the raw materials S2 to S11. [Image disponible dans le document PDF, Image available in the PDF document] Date reçue / Received date 2026-01-14 [ Table Table 8(a)-(d) are tables showing the temperature conditions (changes over time in the temperature inside the furnace) for the raw materials S2 to S11 of Example 2. Here, Table 8(a) is a table showing changes over time in the temperature inside the furnace of Examples A3 and A4. Table 8b(b) is a table showing changes over time in the temperature inside the furnace of Comparative Example A5. Table 8(c) is a table showing changes over time in the temperature inside the furnace of Comparative Examples E4 to E9. Table 8(d) is a table showing changes over time in the temperature inside the furnace of Comparative Example E10. Table 8(a) [Image disponible dans le document PDF, Image available in the PDF document] Table 8(b) [Image disponible dans le document PDF, Image available in the PDF document] Table 8(c) [Image disponible dans le document PDF, Image available in the PDF document] Table 8(d) [Image disponible dans le document PDF, Image available in the PDF document] Furthermore, Fig. 5 is a graph obtained by plotting the temperature conditions (changes over time in the temperature inside the furnace) for the raw materials S2 to S11 of Example 2.

[0068] (Example A3) The raw material S2 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature (25°C) to about 1375°C (raw material temperature 1325°C), and then the raw material S2 was maintained at about 1375°C for one hour (temperature retention: Yes). Subsequently, while the temperature inside the furnace was raised from about 1375°C (raw material temperature 1325°C) to about 1450°C (raw material temperature 1400°C) for 15 hours (temperature change: Yes), the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material solidified into a spherical form and dropped through the hole provided at the center of the bottom part of the Tammann tube, and as the molten material continuously dropped in the form of fiber, a fiber was produced (melt spinnability: A). Furthermore, the XRD spectrum of the fiber obtained from the raw material S2 was examined, and peaks for a crystalline material were recognized (peaks for crystalline material present).

[0069] (Example A4) The raw material S3 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature (25°C) to about 1375°C (raw material temperature 1325°C), and then the raw material S3 was maintained at about 1375°C for one hour (temperature retention: . Subsequently, while the temperature [Image disponible dans le document PDF, Image available in the PDF document] inside the furnace was raised from about 1375°C (raw material temperature 1325°C) to about 1450°C (raw material temperature 1400°C) for 15 hours (temperature change: Yes), the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material solidified into a spherical form and dropped through the hole provided at the center of the bottom part of the Tammann tube, and as the molten material continuously dropped in the form of fiber, a fiber was produced (melt spinnability: A). Furthermore, the XRD spectrum of the fiber obtained from the raw material S3 was examined, and only the amorphous halo was recognized in the X-ray diffraction (XRD) spectrum of the fiber, so that no peak for a crystalline material was recognized (amorphous).

[0070] (Example A5) The raw material S4 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature (25°C) to about 1375°C (raw material temperature 1325°C), and then the raw material S4 was maintained at about 1375°C for one hour (temperature retention: Yes). Subsequently, while the temperature inside the furnace was raised from about 1375°C (raw material temperature 1325°C) to about 1400°C (raw material temperature for 8 hours (temperature change: Yes), [Image disponible dans le document PDF, Image available in the PDF document] the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material solidified into a spherical form and dropped through the hole provided at the center of the bottom part of the Tammann tube, and as the molten material continuously dropped in the form of fiber, a fiber was produced (melt spinnability: A). Furthermore, the XRD spectrum of the fiber obtained from the raw material S4 was examined, and only the amorphous halo was recognized in the X-ray diffraction (XRD) spectrum of the fiber, so that no peak for a crystalline material was recognized (amorphous).

[0071] (Comparative Example E4) The raw material S5 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature (25°C) to about 1375°C (raw material temperature 1325°C), and then the raw material S5 was maintained at about 1375°C for one hour (temperature retention: Yes). Subsequently, while the temperature inside the furnace was raised from about 1375°C (raw material temperature 1325°C) to about 1400°C (raw material temperature 1350°C) for 5 hours (temperature change: Yes), the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material solidified into a spherical form and dropped through the hole provided at the center of the bottom part of the Tammann tube; however, the molten material did not drop in the form of fiber, and a fiber was not produced (melt spinnability: C). Incidentally, since a fiber was not obtained, the XRD spectrum was not checked.

[0072] (Comparative Example E5) The raw material S6 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature (25°C) to about 1375°C (raw material temperature 1325°C), and then the raw material S6 was maintained at about 1375°C for one hour (temperature retention: Yes). Subsequently, while the temperature inside the furnace was raised from about 1375°C (raw material temperature 1325°C) to about 1400°C (raw material temperature 1350°C) for 5 hours (temperature change: Yes), the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material did not drop in the form of fiber through the hole provided at the center of the bottom part of the Tammann tube (melt spinnability: C). Incidentally, since a fiber was not obtained, the XRD spectrum was not checked.

[0073] (Comparative Example E6) The raw material S7 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature (25°C) to about 1375°C (raw material temperature 1325°C), and then the raw material S7 was maintained at about 1375°C for one hour (temperature retention: Yes). Subsequently, while the temperature inside the furnace was raised from about 1375°C (raw material temperature 1325°C) to about 1400°C (raw material temperature 1350°C) for 5 hours (temperature change: Yes), the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material did not drop in the form of fiber through the hole provided at the center of the bottom part of the Tammann tube (melt spinnability: C). Incidentally, since a fiber was not obtained, the XRD spectrum was not checked.

[0074] (Comparative Example E7) The raw material S8 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature (25°C) to about 1375°C (raw material temperature 1325°C), and then the raw material S8 was maintained at about 1375°C for one hour (temperature retention: Yes). Subsequently, while the temperature inside the furnace was raised from about 1375°C (raw material temperature 1325°C) to about 1400°C (raw material temperature 1350°C) for 5 hours (temperature change: Yes), the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material did not drop in the form of fiber through the hole provided at the center of the bottom part of the Tammann tube (melt spinnability: C). Incidentally, since a fiber was not obtained, the XRD spectrum was not checked.

[0075] (Comparative Example E8) The raw material S9 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature (25°C) to about 1375°C (raw material temperature 1325°C), and then the raw material S9 was maintained at about 1375°C for one hour (temperature retention: Yes). Subsequently, while the temperature inside the furnace was raised from about 1375°C (raw material temperature 1325°C) to about 1400°C (raw material temperature 1350°C) for 5 hours (temperature change: Yes), the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material did not drop in the form of fiber through the hole provided at the center of the bottom part of the Tammann tube (melt spinnability: C). Incidentally, since a fiber was not obtained, the XRD spectrum was not checked.

[0076] (Comparative Example E9) The raw material S10 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature (25°C) to about 1375°C (raw material temperature 1325°C), and then the raw material S10 was maintained at about 1375°C for one hour (temperature retention: Yes). Subsequently, while the temperature inside the furnace was raised from about 1375°C (raw material temperature 1325°C) to about 1400°C (raw material temperature 1350°C) for 5 hours (temperature change: Yes), the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity. The molten material did not drop in the form of fiber through the hole provided at the center of the bottom part of the Tammann tube (melt spinnability: C). Incidentally, since a fiber was not obtained, the XRD spectrum was not checked.

[0077] (Comparative Example E10) The raw material S11 was placed in the Tammann tube. Next, the temperature inside the furnace was raised from room temperature to about 800°C (raw material [Image disponible dans le document PDF, Image available in the PDF document] temperature 750°C) for about 20 minutes, and then by changing the temperature increase rate, the temperature inside the furnace was raised from about 800°C (raw material temperature 750°C) to about 1350°C (raw material temperature 1300°C) for about 60 minutes. Subsequently, while the temperature inside the furnace was further raised, by changing the temperature increase rate, from about 1350°C (raw material temperature 1300°C) to about 1375°C (raw material temperature 1325°C) for about 340 minutes (temperature change: Yes), the molten material was caused to flow out through the hole provided in the bottom part of the Tammann tube by gravity (melt spinnability: A, temperature retention: No). Furthermore, the XRD spectrum of the fiber obtained from the raw material S11 was examined, and peaks for a crystalline material were recognized (peaks for crystalline material present). From the results of Example Series 2, it was found that a fiber can be manufactured from a raw material including an IGCC waste material discharged by integrated coal gasification combined cycle (IGCC). More specifically, it was found that a fiber can be manufactured from a raw material including at least one of basalt and a waste material discharged from a non-IGCC thermal power plant that uses coal as fuel, in addition to an IGCC waste material.

[0079] Furthermore, from the results of Example 2, it was understood that the total content of SiO2 and Al2O3 in the raw material of the fiber is preferably 40% by mass or more and 70% by mass or less. Furthermore, it was understood that in the raw material of the fiber, the proportion occupied by Al2O3 in the sum of SiO2 and Al2O3 ([A] / ([A] + [S])) (mass ratio) is preferably in the range of 0.15 to 0.40. Furthermore, it was understood that in the raw material of the fiber, the content of CaO is preferably 5% by mass or more and 30% by mass or less. Although it is not an essential configuration of the invention, the fiber has almost no decrease in strength caused by separation at the crystalline phase / non- crystalline phase interface, and in order to obtain a fiber having high strength, it is preferable that the fiber is substantially composed only of an amorphous phase. INDUSTRIAL APPLICABILITY

[0080] A fiber obtained from a raw material including an IGCC waste material can be processed into roving, chopped strands, woven fabrics, nonwoven fabrics, and the like and used as coating materials or reinforcing materials. EXPLANATIONS OF LETTERS OR NUMERALS

[0081] 1 ELECTRIC FURNACE 2 TAMMANN TUBE 3 SUSPENSION ROD 4 OPENING 5 FIBER D OUTER DIAMETER OF ELECTRIC FURNACE Н HEIGHT OF ELECTRIC FURNACE d INNER DIAMETER OF OPENING OF ELECTRIC FURNACE

Claims

<pat:Claims com:id="claims"> <pat:Claim com:id="CLM-00001"> <pat:ClaimNumber>1< / pat:ClaimNumber> <pat:ClaimText>1. A fiber manufacturing method, comprising the steps of: I) heating a raw material at a temperature between 1300°C and 1325C°; II) maintaining the temperature of the raw material at the step (I) for a period between 50 and 120 minutes; and III) causing the raw material after the step (II) to flow out through a forming hole to form a fiber while increasing the temperature of the raw material up to 1400 C°, wherein the raw material comprises: a) 50 to 100 % by mass of waste from an integrated coal gasification combined cycle (IGCC); and b) 0 to 50 % by mass of copper slag, wherein as to the raw material, i) the total content of SiO2 and Al2O3 is 40 % by mass or more and 70% by mass or less, ii) a mass ratio of Al2O3 / (SiO2+Al2O3) is within a range of 0.15 to 0.40, and iii) content of CaO is between 10 and 30% by mass. < / pat:ClaimText> < / pat:Claim> <pat:Claim com:id="CLM-00002"> <pat:ClaimNumber>2< / pat:ClaimNumber> <pat:ClaimText>2. The fiber manufacturing method according to claim 1, wherein the raw material further includes fly ash or basalt. < / pat:ClaimText> < / pat:Claim> <pat:Claim com:id="CLM-00003"> <pat:ClaimNumber>3< / pat:ClaimNumber> <pat:ClaimText>3. The fiber manufacturing method according to claim 1, the mass ratio of the waste from an integrated coal gasification combined cycle (IGCC) in the raw material is 75% by mass or more. < / pat:ClaimText> < / pat:Claim> <pat:Claim com:id="CLM-00004"> <pat:ClaimNumber>4< / pat:ClaimNumber> <pat:ClaimText>4. The fiber manufacturing method according to claim 1, wherein the fiber is substantially composed only of an amorphous phase. < / pat:ClaimText> < / pat:Claim> <pat:Claim com:id="CLM-00005"> <pat:ClaimNumber>5< / pat:ClaimNumber> <pat:ClaimText>5. The fiber manufacturing method according to claim 1, wherein an outer diameter of the fiber is 500 µm or less. < / pat:ClaimText> < / pat:Claim> <pat:Claim com:id="CLM-00006"> <pat:ClaimNumber>6< / pat:ClaimNumber> <pat:ClaimText>6. A fiber manufacturing method, by using raw material consisting of a) 50 to 100 % by mass of waste from an integrated coal gasification combined cycle (IGCC), and b) 0 to 50 % by mass of waste from a coal-fired power plant other than an integrated coal gasification combined cycle (IGCC), wherein as to said raw material i) the total content of SiO2 and Al2O3 is 40 % by mass or more and 70% by mass or less, ii) the Al2O3 / (SiO2+Al2O3) (mass ratio) is in the range of 0.15 to 0.40, iii) the content of CaO is between 10 and 30% by mass, and said method comprising of step (I) of heating said raw material to a temperature between 1300 and 1325C°, step (II) of maintaining the temperature of said raw material reached in said step (I) for a period of between 50 and 120 minutes, and step (III) of causing the raw materials after step (II) to flow out through a formed hole to form a fiber while increasing the temperature of said raw material up to 1400 C°. < / pat:ClaimText> < / pat:Claim> < / pat:Claims>