Fibers, fiber manufacturing method

Abstract

An object of the present invention is to provide a fiber and a method for manufacturing the fiber that can more effectively utilize waste discharged from integrated gasification combined cycle power generation. The fiber contains, as a raw material, waste discharged from integrated gasification combined cycle power generation (IGCC).

Description

Technical Field

[0001] The present invention relates to a fiber and a method for manufacturing the fiber. Background Art

[0002] As a method of thermal power generation using coal as fuel, integrated gasification combined cycle power generation (hereinafter, also referred to as IGCC (Integrated coal Gasification Combined Cycle)) is known. In IGCC, a gas turbine is driven by gasification gas as fuel to obtain electric power, and waste heat of 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 performed with a higher thermal efficiency than conventional coal-fired thermal power generation. Specifically, in the case of a 1400-degree to 1500-degree class industrial frequency IGCC, a thermal efficiency of about 48 to 50% of the low calorific value standard can be achieved at the power transmission end. This thermal efficiency is higher than the thermal efficiency of about 40% of conventional supercritical pressure coal-fired thermal power generation (SC coal-fired thermal power generation) or ultra-supercritical pressure coal-fired thermal power generation (USC coal-fired thermal power generation), and is equivalent to the thermal efficiency of advanced ultra-supercritical pressure coal-fired thermal power generation (A-USC coal-fired thermal power generation) under development. In addition, IGCC can use low-quality coal that cannot be used in conventional coal-fired thermal power generation, so a reduction in fuel cost or diversification of fuel suppliers can be expected.

[0004] As described above, IGCC is expected to be a new generation of power generation method with high efficiency. However, regarding the waste generated during the operation of IGCC, only a utilization method such as pulverization and the like for use as an aggregate for cement has been established (refer to Patent Document 1), and further improvement is required.

[0005] Prior Art Documents

[0006] Patent Documents

[0007] Patent Document 1: Japanese Patent Laid-Open No. 2017-014052 Summary of the Invention

[0008] Technical Problem to be Solved by the Invention

[0009] The present invention has been made in view of the above problems, and an object thereof is to provide a fiber and a method for manufacturing the fiber that can more effectively utilize the waste discharged from integrated gasification combined cycle power generation.

[0010] Means for Solving the Technical Problem

[0011] In order to solve the above problems, the fiber according to the present invention is characterized in that it contains, as a raw material, waste discharged from integrated gasification combined cycle power generation (IGCC).

[0012] Advantages of the Invention

[0013] According to the present invention, it is possible to provide a fiber and a fiber manufacturing method that can more effectively utilize waste discharged from integrated gasification combined cycle power generation. Description of the Drawings

[0014] Figure 1 It is a diagram showing the component composition of the raw material (IGCC waste) in Example 1.

[0015] Figure 2 It is a schematic diagram of the electric furnace used in Example 1.

[0016] Figure 3 It is a table showing the results of the melt spinnability of Example 1.

[0017] Figure 4 It is a table showing the temperature conditions of Example 1.

[0018] Figure 5 It is a graph showing the temperature conditions of Example 1.

[0019] Figure 6 It is an XRD pattern of the fiber formed from the raw material S1.

[0020] Figure 7 It is an enlarged view (microscopic photograph) of the fiber formed from the raw material S1.

[0021] Figure 8 It is a diagram showing the mixing ratio (%) of the raw materials related to Example 2.

[0022] Figure 9 It is a diagram showing the component composition of waste and the like related to Example 2.

[0023] Figure 10 It is a diagram showing the component composition of the raw materials related to Example 2.

[0024] Figure 11 It is a table showing the results of the melt spinnability and the like of the raw materials related to Example 2.

[0025] Figure 12 It is a table showing the temperature conditions of Example 2.

[0026] Figure 13 It is a graph showing the temperature conditions of Example 2. Detailed Description of the Invention

[0027] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In addition, in the following description,

[0028] SiO2 is sometimes referred to as the S component, and the content of SiO2 is denoted as [S].

[0029] Al2O3 is sometimes referred to as the A component, and the content of Al2O3 is denoted as [A].

[0030] CaO is sometimes referred to as the C component, and the content of CaO is denoted as [C].

[0031] [Embodiment 1]

[0032] The fiber according to Embodiment 1 uses the waste discharged from an integrated gasification combined cycle power generation (IGCC) (hereinafter, also referred to as IGCC waste. The IGCC waste includes slag, coal ash, etc. discharged from the IGCC) as a raw material. The IGCC waste as the raw material mainly contains SiO2 and Al2O3, the proportion of Al2O3 in the total of SiO2 and Al2O3 in the fiber is within a specific range, and it also contains a specific amount of CaO.

[0033] The raw material of the fiber according to Embodiment 1 is IGCC waste, and the total content of SiO2 and Al2O3 in the raw material is preferably 40% by mass or more and 70% by mass or less. Whether the total of [S] and [A] is less than 40% by mass or exceeds 70% by mass, it will cause the melting temperature of the raw material to become higher or the viscosity of the melt to become higher, so the melt spinning property is poor. In addition, melt spinning refers to a method in which a melt obtained by melting the raw material with heat is discharged from holes (through holes) formed in a spinneret to form a fiber shape and then cooled and solidified. And the melt spinning property refers to the ease of manufacturing the fiber in melt spinning.

[0034] In the raw material of the fiber according to Embodiment 1, the proportion ([A] / ([A]+[S])) (mass ratio) of Al2O3 in the total of SiO2 and Al2O3 is preferably in the range of 0.15 to 0.40. Whether [A] / ([A]+[S]) (mass ratio) is less than 0.15 or exceeds 0.40, it will cause the melting temperature of the fiber to become higher or the viscosity of the melt to become higher, so the melt spinning property is poor.

[0035] In the raw material of the fiber according to 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 higher, so it is not preferred from the viewpoint of energy saving. And the content of CaO is more preferably 30% by mass or less.

[0036] As long as the raw material formulation of the fiber according to Embodiment 1 satisfies the above composition conditions for the components SiO2, Al2O3, and CaO, the fiber according to Embodiment 1 can be obtained without restrictions on the raw materials. As the raw material of the fiber according to Embodiment 1, it is preferable to use waste discharged from integrated gasification combined cycle power generation (IGCC) (IGCC waste), etc. The reason is that since IGCC waste contains SiO2 and Al2O3 as main components, it is suitable for obtaining the fiber according to Embodiment 1 or can suppress the raw material cost.

[0037] In addition, the fiber according to Embodiment 1 does not exclude the inclusion of inevitable impurities. As the main inevitable impurities, there are MgO, Na2O, K2O, TiO2, CrO2, etc.

[0038] In Embodiment 1, no substantial difference was found between the component ratio (mass ratio) of the raw material and the component ratio (mass ratio) of the fiber manufactured by melting the raw material. Therefore, the component ratio of the raw material can be regarded as the component ratio of the fiber manufactured by melting the raw material.

[0039] The fiber according to Embodiment 1 has a high degree of amorphousness. Therefore, the fiber hardly exhibits a reduction in strength caused by the peeling at the crystal phase / amorphous phase interface, and thus a high-strength fiber can be obtained.

[0040] Here, the degree of amorphization, which is the scale of becoming amorphous, is calculated by the following mathematical formula (1) from the X-ray diffraction (XRD) pattern.

[0041] Degree of amorphization (%) = [la / (la + lc)] × 100 ··· (1)

[0042] In the above formula (1), la and lc are as follows, respectively.

[0043] la: The integrated value of the scattering intensity of the amorphous halo.

[0044] lc: The integrated value of the scattering intensity of the crystalline peak when performing X-ray diffraction analysis on the fiber.

[0045] Although the degree of amorphization of the fiber according to Embodiment 1 depends on its composition, it usually shows a value of 90% or more. When the degree of amorphization of the fiber is high, it reaches 95% or more, and in the highest case, it consists essentially only of the amorphous phase. Here, consisting essentially only of the amorphous phase means that only the amorphous halo is confirmed in the X-ray diffraction pattern, and no crystalline peak is confirmed.

[0046] Example 1

[0047] Hereinafter, Example 1 according to Embodiment 1 will be described.

[0048] In the following test examples, as the raw material of the fiber (raw material S1), IGCC waste discharged from integrated gasification combined cycle power generation (IGCC) was prepared. The IGCC waste used was that discharged from integrated coal gasification combined cycle power generation in the country. In addition, the raw material S1 was 100% of the IGCC waste.

[0049] Moreover, in Example 1, the components of the raw material S1 (IGCC waste) were analyzed by X-ray fluorescence spectrometry. Figure 1 The component composition of the raw material S1 (IGCC waste) is shown.

[0050] Moreover, an electric furnace was used when manufacturing the raw material S1 into fibers. The schematic of the electric furnace is shown in Figure 2 . The electric furnace 1 is a cylindrical body with a height H of 60 cm and an outer diameter D of 50 cm, having a through hole 4 with an inner diameter d of 10 cm formed in the center. Inside the through hole 4, a carbon particle heating tube 2 with an inner diameter of 2.1 cm and a length of 10 cm is suspended by a suspension rod 3. 30 g of the raw material (raw material S1) is loaded into the carbon particle heating tube 2. A hole with a diameter of 2 mm is provided at the center of the bottom of the carbon particle heating tube 2. When melting the formulation by heating, it flows out from the hole provided at the bottom of the carbon particle heating tube by gravity. The flowing molten material contacts the external air and cools and solidifies to become fibers. Here, since the flowing molten material cools rapidly, the fibers are basically composed only of amorphous substances.

[0051] The electric furnace was heated up by a prescribed temperature rising program, but it was previously confirmed that the temperature of the molten material in the carbon particle heating tube 2 followed at a temperature about 50 degrees lower than the furnace temperature.

[0052] The conditions and results of the melt spinning of the raw material S1 in Example 1 are shown in Figure 3 .

[0053] In addition, in Example 1, the melt spinnability was evaluated as follows.

[0054] ○: It becomes continuous filaments.

[0055] △: The molten and softened raw material flows out from the hole provided at the bottom of the carbon particle heating tube, generating extremely short fibers but not continuous filaments.

[0056] ×: Nothing flows out from the hole provided at the bottom of the carbon particle heating tube, and no filaments are formed.

[0057] Figure 3 It is a table summarizing the results of the presence or absence of temperature holding (annealing), the presence or absence of temperature change, and the melt spinnability of the raw material S1 used in Examples A1, A2 and Comparative Examples E1 to E3.Figure 4 It is a table showing the time variation of the furnace temperature for Examples A1, A2 and Comparative Examples E1 to E3.

[0058] Figure 4 (a) is a table showing the time variation of the furnace temperature for Example A1.

[0059] Figure 4 (b) is a table showing the time variation of the furnace temperature for Example A2.

[0060] Figure 4 (c) is a table showing the time variation of the furnace temperature for Comparative Example E1.

[0061] Figure 4 (d) is a table showing the time variation of the furnace temperature for Comparative Example E2.

[0062] Figure 4 (e) is a table showing the time variation of the furnace temperature for Comparative Example E3.

[0063] Figure 5 It is Figure 4 a graph that charts the time variation of the furnace temperature for Examples A1, A2 and Comparative Examples E1 to E3 shown.

[0064] (Example A1)

[0065] The raw material S1 was placed into the carbon particle heating tube. Then, after raising the furnace temperature to 1350 degrees (the temperature of the raw material S1 was 1300 degrees), it was maintained at approximately 1350 degrees for a specified time (55 minutes) (temperature maintenance: ○). After that, while changing the furnace temperature (temperature change: ○), the result of the spinnability was confirmed, and the raw material S1 became a fiber (melt spinnability: ○).

[0066] (Example A2)

[0067] The raw material S1 was placed into the carbon particle heating tube. Then, after raising the furnace temperature to 1375 degrees (the temperature of the raw material S1 was 1325 degrees), it was maintained at approximately 1375 for a specified time (120 minutes) (temperature maintenance: ○). After that, while changing the furnace temperature (temperature change: ○), the result of the spinnability was confirmed, and the raw material S1 became a fiber (melt spinnability: ○).

[0068] (Comparative Example E1)

[0069] After placing the raw material S1 into the carbon particle heating tube, the furnace temperature was raised to 1350 degrees (the temperature of the raw material S1 was 1300 degrees), and then it was maintained at approximately 1350 degrees for a specified time (94 minutes) (temperature maintenance: ○). After that, the spinnability was confirmed without changing the furnace temperature (temperature change: ×), but the raw material S1 did not become a fiber (melt spinnability: ×).

[0070] (Comparative Example E2)

[0071] After placing raw material S1 into the carbon particle heating tube, the temperature inside the furnace was raised to 1400 °C (the temperature of raw material S1 was 1350 °C). While changing the temperature inside the furnace (temperature change: ○), the spinnability was confirmed. However, the molten and softened raw material flowed out from the holes provided at the bottom of the carbon particle heating tube, producing extremely short fibers but raw material S1 did not become fibers (melt spinnability: △). Also, after raising the temperature to 1400 °C, the temperature was not maintained for a specified time (temperature maintenance: ×).

[0072] (Comparative Example E3)

[0073] After placing raw material S1 into the carbon particle heating tube, the temperature inside the furnace was raised to 1320 °C (the temperature of raw material S1 was 1270 °C). Then, it was maintained at about 1320 °C for a specified time (20 minutes) (temperature maintenance: ○). After that, without changing the temperature inside the furnace (temperature change: ×), it was confirmed whether spinning occurred, but raw material S1 did not become fibers (melt spinnability: ×).

[0074] (Investigation)

[0075] Examples A1 and A2 and Comparative Examples E1 to E3 show that it is possible to manufacture fibers using IGCC waste discharged from integrated gasification combined cycle power generation (IGCC) as a raw material.

[0076] As conditions for manufacturing fibers using IGCC waste as a raw material, the following conditions can be confirmed as being preferable.

[0077] (1) Heating to 1300 °C or higher.

[0078] (2) Before forming into fibers, maintaining at a temperature of 1300 °C or higher for a specified time (preferably 50 minutes or more, more preferably 55 minutes or more).

[0079] (3) While changing the temperature of the IGCC waste (in this example, the temperature rises), making it flow out from the formed holes.

[0080] Figure 6 is the XRD pattern of the fiber formed from raw material S1. As Figure 6 shown, in the X-ray diffraction (XRD) pattern of the fiber obtained in Example A1 above, only an amorphous halo was confirmed and no crystalline peaks were confirmed. From this, it can be seen that the fiber generated from IGCC waste is basically composed only of amorphous material.

[0081] And,[[]] Figure 7 is an enlarged view (microscopic photograph) of the fiber formed from Figure 6 the raw material S1 shown asFigure 7 As shown, fibers with an outer diameter exceeding 500 μm can be obtained. Such fibers, as described in the reference Figure 6 are basically composed only of amorphous substances. The reason is considered to be that after the molten IGCC waste flows out from the hole at the center of the bottom of the carbon particle heating tube 2, it becomes amorphous because a regular atomic arrangement cannot be obtained through quenching. Moreover, in Example 1 of this time, it was confirmed that fibers with an outer diameter exceeding 500 μm are basically composed only of amorphous substances. Here, it is generally considered that the finer the outer diameter of the fiber, the faster the cooling rate. Therefore, it can be inferred that if the outer diameter is finer than the outer diameter (505.97 μm) of the fiber Figure 7 shown, it is basically composed only of amorphous substances. More specifically, it can be inferred that if the outer diameter of the fiber is 500 μm or less, it is basically composed only of amorphous substances.

[0082] [Embodiment 2]

[0083] Among the fibers according to this Embodiment 2, the waste discharged from integrated gasification combined cycle power generation (IGCC) is included as a raw material. Specifically, the fibers according to this Embodiment 2 include, as a raw material, at least one of the waste discharged from a thermal power plant of IGCC that does not use coal as fuel and basalt among the waste discharged from integrated gasification combined cycle power generation (IGCC).

[0084] In addition, similarly to Embodiment 1, the total content of SiO2 and Al2O3 in the raw material of the fibers according to this Embodiment 2 is preferably 40% by mass or more and 70% by mass or less. And, in the raw material of the fibers according to this Embodiment 2, the proportion ([A] / ([A]+[S])) (mass ratio) of Al2O3 in the total of SiO2 and Al2O3 is preferably in the range of 0.15 to 0.40. And, in the raw material of the fibers according to this Embodiment 2, the content of CaO is preferably 5% by mass or more and 30% by mass or less. And, similarly to the fibers according to Embodiment 1, the fibers according to this Embodiment 2 are preferably composed basically only of an amorphous phase.

[0085] Example 2

[0086] Hereinafter, Example 2 according to the embodiment will be described.

[0087] In this Example 2, as the raw material of the fiber, a substance in which IGCC waste, the waste discharged from a thermal power plant of IGCC that does not use coal as fuel, and basalt are mixed at a specified mixing ratio (mass%) was prepared. Hereinafter, with reference to Figure 8 the mixing ratios of the respective raw materials S2 to S11 are described (since rounding is performed for the decimal part, the total does not necessarily become 100%). In addition, inFigure 8 Among them, IGCC slag represents IGCC waste, and FA1 to FA8 represent waste from coal-fired power plants that are not IGCC (FA1 to FA8 are waste discharged from different power plants). Also, BA1 represents basalt. In addition, in this Example 2, the components of raw materials S2 to S11 were analyzed by X-ray fluorescence spectrometry. And when manufacturing fibers from raw materials S2 to S11, the electric furnace described in the reference Figure 2 was used.

[0088] Raw material S2 is mixed in a ratio of 50% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant and 50% by mass of waste discharged from coal-fired power plant FA2.

[0089] Raw material S3 is mixed in a ratio of 75% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant and 25% by mass of waste discharged from coal-fired power plant FA2.

[0090] Raw material S4 is mixed in a ratio of 90% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant and 10% by mass of waste discharged from coal-fired power plant FA2.

[0091] Raw material S5 is mixed in a ratio of 30% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant, 5% by mass of basalt (BASALT), 15% by mass of waste discharged from coal-fired power plant FA2, and 50% by mass of waste discharged from coal-fired power plant FA7.

[0092] Raw material S6 is mixed in a ratio of 50% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant and 50% by mass of waste discharged from coal-fired power plant FA3.

[0093] Raw material S7 is mixed in a ratio of 20% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant, 10% by mass of waste discharged from coal-fired power plant FA2, 30% by mass of waste discharged from coal-fired power plant FA3, and 40% by mass of waste discharged from coal-fired power plant FA4.

[0094] Raw material S8 is mixed in a ratio of 25% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant, 10% by mass of waste discharged from coal-fired power plant FA4, and 65% by mass of waste discharged from coal-fired power plant FA6.

[0095] The raw material S9 is mixed at a ratio of 10% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant, 16% by mass of waste discharged from a coal-fired power plant FA2, 36% by mass of waste discharged from a coal-fired power plant FA3, and 37% by mass of waste discharged from a coal-fired power plant FA6.

[0096] The raw material S10 is mixed at a ratio of 25% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant, 10% by mass of waste discharged from a coal-fired power plant FA4, and 65% by mass of waste discharged from a coal-fired power plant FA6.

[0097] The raw material S11 is mixed at a ratio of 60% by mass of IGCC waste discharged from an integrated gasification combined cycle power plant and 40% by mass of waste discharged from a coal-fired power plant FA2.

[0098] Moreover, in Example 2, the components of the waste materials and basalt (waste materials, etc.) that became the raw materials S2 to S11 were analyzed by X-ray fluorescence analysis. When analyzing, an X-ray fluorescence analysis device (Philips PW2404) of Philips Japan, Ltd. was used, and the sample chamber of the X-ray fluorescence analysis device was set to a vacuum state to analyze the components of the waste materials, etc. Figure 9 The component compositions of the waste materials, etc. related to Example 2 are shown. In addition, hereinafter, 0% by mass means a trace amount that cannot be measured, and strictly speaking, it is not "0".

[0099] In the IGCC waste discharged from a domestic integrated 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 other content is 9% by mass.

[0100] In basalt (BASALT BA1), [F] is 19% by mass, [S] is 46% by mass, [A] is 11% by mass, [C] is 17% by mass, and the other content is 6% by mass.

[0101] In the waste discharged from a domestic coal-fired power plant FA1, [F] is 13% by mass, [S] is 57% by mass, [A] is 17% by mass, [C] is 6% by mass, and the other content is 7% by mass.

[0102] In the waste discharged from a domestic coal-fired power plant FA2, [F] is 55% by mass, [S] is 35% by mass, [A] is 5% by mass, [C] is 2% by mass, and the other content is 3% by mass.

[0103] Among the waste discharged from the domestic coal-fired power plant FA3, [F] is 2% by mass, [S] is 62% by mass, [A] is 27% by mass, [C] is 3% by mass, and the other content is 5% by mass.

[0104] Among the waste discharged from the domestic coal-fired power plant FA4, [F] is 97% by mass, [S] is 0% by mass, [A] is 0% by mass, [C] is 0% by mass, and the other content is 3% by mass.

[0105] Among the waste discharged from the domestic coal-fired power plant FA5, [F] is 21% by mass, [S] is 35% by mass, [A] is 12% by mass, [C] is 22% by mass, and the other content is 10% by mass.

[0106] Among the waste discharged from the domestic coal-fired power plant FA6, [F] is 1% by mass, [S] is 73% by mass, [A] is 22% by mass, [C] is 0% by mass, and the other content is 4% by mass.

[0107] Among the waste discharged from the domestic coal-fired power plant FA7, [F] is 1% by mass, [S] is 19% by mass, [A] is 17% by mass, [C] is 55% by mass, and the other content is 8% by mass.

[0108] Among the waste discharged from the domestic coal-fired power plant FA8, [F] is 0% by mass, [S] is 34% by mass, [A] is 13% by mass, [C] is 42% by mass, and the other content is 11% by mass.

[0109] Figure 10 It is a diagram showing the component compositions of the raw materials S2 to S11 related to Example 2. Figure 10 The shown component compositions are Figure 8 calculated from the mixing ratios of the respective raw materials S2 to S11 and Figure 9 the component compositions of waste and the like. In addition, since rounding is performed for the digits after the decimal point, the total does not necessarily become 100%.

[0110] In raw material S2, [F] is 32% by mass, [S] is 45% by mass, [A] is 8% by mass, [C] is 10% by mass, and the other content is 6% by mass. And, [S] + [A] is 53% by mass, and A / ([S] + [A]) is 0.15.

[0111] In raw material S3, [F] is 21% by mass, [S] is 49% by mass, [A] is 10% by mass, [C] is 13% by mass, and the other content is 8% by mass. And, [S] + [A] is 59% by mass, and A / ([S] + [A]) is 0.16.

[0112] In raw material S4, [F] is 14% by mass, [S] is 52% by mass, [A] is 10% by mass, [C] is 16% by mass, and the content of others is 8% by mass. Moreover, [S]+[A] is 63% by mass, and [A] / ([S]+[A]) is 0.17.

[0113] In raw material S5, [F] is 12% by mass, [S] is 33% by mass, [A] is 13% by mass, [C] is 34% by mass, and the content of others is 8% by mass. Moreover, [S]+[A] is 46% by mass, and [A] / ([S]+[A]) is 0.28.

[0114] In 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. Moreover, [S]+[A] is 77% by mass, and [A] / ([S]+[A]) is 0.25.

[0115] In 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 4% by mass. Moreover, [S]+[A] is 44% by mass, and [A] / ([S]+[A]) is 0.25.

[0116] In raw material S8, [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. Moreover, [S]+[A] is 78% by mass, and [A] / ([S]+[A]) is 0.22.

[0117] In raw material S9, [F] is 11% by mass, [S] is 60% by mass, [A] is 20% by mass, [C] is 3% by mass, and the content of others is 6% by mass. Moreover, [S]+[A] is 80% by mass, and [A] / ([S]+[A]) is 0.25.

[0118] In 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. Moreover, [S]+[A] is 78% by mass, and [A] / ([S]+[A]) is 0.22.

[0119] In raw material S11, [F] is 27% 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. Moreover, [S]+[A] is 55% by mass, and [A] / ([S]+[A]) is 0.16.

[0120] Figure 11 It is a table summarizing the presence or absence of temperature holding (annealing), the presence or absence of temperature change, and the results of melt spinning properties of raw materials S2 to S11.Figure 12 It is a table showing the temperature conditions (time change of the furnace temperature) of the raw materials S2 to S11 in Example 2. Here,

[0121] Figure 12 (a) is a table showing the time change of the furnace temperature in Examples A3 and A4.

[0122] Figure 12 (b) is a table showing the time change of the furnace temperature in Comparative Example A5.

[0123] Figure 12 (c) is a table showing the time change of the furnace temperature in Comparative Examples E4 to 9.

[0124] Figure 12 (d) is a table showing the time change of the furnace temperature in Comparative Example E10.

[0125] And, Figure 13 is a graph showing the temperature conditions (time change of the furnace temperature) of the raw materials S2 to S11 in Example 2.

[0126] (Example A3)

[0127] The raw material S2 was placed in a carbon particle heating tube. Then, after raising the furnace temperature from room temperature (25 °C) to about 1375 °C (raw material temperature 1325 °C), it was maintained at about 1375 °C for 1 hour (temperature holding: ○). After that, while raising the furnace temperature from about 1375 °C (raw material temperature 1325 °C) to about 1450 °C (raw material temperature 1400 °C) over 15 hours (temperature change: ○), the melt was made to flow out from the hole provided at the bottom of the carbon particle heating tube by gravity. The solidified melt became a spherical substance and fell from the hole provided at the center of the bottom of the carbon particle heating tube, and then the melt fell in a fibrous form, thereby generating fibers (melt spinning property: ○). And, as a result of observing the XRD pattern of the fibers obtained from the raw material S2, a crystalline peak was confirmed (amorphousness: ×).

[0128] (Example A4)

[0129] The raw material S3 was placed into the carbon particle heating tube. Then, after raising the temperature inside the furnace from room temperature (25 °C) to approximately 1375 °C (raw material temperature 1325 °C), it was maintained at approximately 1375 °C for 1 hour (temperature holding: ○). After that, while raising the temperature inside the furnace from approximately 1375 °C (raw material temperature 1325 °C) to approximately 1450 °C (raw material temperature 1400 °C) over 15 hours (temperature change: ○), the melt was made to flow out from the hole provided at the bottom of the carbon particle heating tube by gravity. The melt solidified into a spherical substance and fell from the hole at the center of the bottom of the carbon particle heating tube. Then, the melt fell in a fibrous form, thereby generating fibers (melt spinning property: ○). Moreover, as a result of observing the XRD pattern of the fibers obtained from the raw material S3, only an amorphous halo was confirmed in the X-ray diffraction (XRD) pattern of the fibers, and no crystalline peak was confirmed (amorphous property: ○).

[0130] (Example A5)

[0131] The raw material S4 was placed into the carbon particle heating tube. Then, after raising the temperature inside the furnace from room temperature (25 °C) to approximately 1375 °C (raw material temperature 1325 °C), it was maintained at approximately 1375 °C for 1 hour (temperature holding: ○). After that, while raising the temperature inside the furnace from approximately 1375 °C (raw material temperature 1325 °C) to approximately 1400 °C (raw material temperature 1350 °C) over 8 hours (temperature change: ○), the melt was made to flow out from the hole provided at the bottom of the carbon particle heating tube by gravity. The melt solidified into a spherical substance and fell from the hole at the center of the bottom of the carbon particle heating tube. Then, the melt fell in a fibrous form, thereby generating fibers (melt spinning property: ○). Moreover, as a result of observing the XRD pattern of the fibers obtained from the raw material S4, only an amorphous halo was confirmed in the X-ray diffraction (XRD) pattern of the fibers, and no crystalline peak was confirmed (amorphous property: ○).

[0132] (Comparative Example E4)

[0133] The raw material S5 was placed into the carbon particle heating tube. Then, after raising the temperature inside the furnace from room temperature (25 °C) to approximately 1375 °C (raw material temperature 1325 °C), it was maintained at approximately 1375 °C for 1 hour (temperature holding: ○). After that, while raising the temperature inside the furnace from approximately 1375 °C (raw material temperature 1325 °C) to approximately 1400 °C (raw material temperature 1350 °C) over 5 hours (temperature change: ○), the melt was made to flow out from the hole provided at the bottom of the carbon particle heating tube by gravity. The melt solidified into a spherical substance and fell from the hole at the center of the bottom of the carbon particle heating tube. However, the melt did not fall in a fibrous form and no fibers were generated (melt spinning property: ×). Additionally, since no fibers were obtained, the XRD pattern was not confirmed (amorphous property: -).

[0134] (Comparative Example E5)

[0135] The raw material S6 was placed into the carbon particle heating tube. Subsequently, after raising the temperature inside the furnace from room temperature (25 °C) to approximately 1375 °C (raw material temperature 1325 °C), it was maintained at approximately 1375 °C for 1 hour (temperature holding: ○). After that, while raising the temperature inside the furnace from approximately 1375 °C (raw material temperature 1325 °C) to approximately 1400 °C (raw material temperature 1350 °C) over 5 hours (temperature change: ○), the melt was made to flow out from the hole provided at the bottom of the carbon particle heating tube by gravity. The melt did not fall in the form of fibers from the hole provided at the center of the bottom of the carbon particle heating tube (melt spinning property: ×). Additionally, no fibers were obtained, so the XRD pattern was not confirmed (amorphous property: -).

[0136] (Comparative Example E6)

[0137] The raw material S7 was placed into the carbon particle heating tube. Subsequently, after raising the temperature inside the furnace from room temperature (25 °C) to approximately 1375 °C (raw material temperature 1325 °C), it was maintained at approximately 1375 °C for 1 hour (temperature holding: ○). After that, while raising the temperature inside the furnace from approximately 1375 °C (raw material temperature 1325 °C) to approximately 1400 °C (raw material temperature 1350 °C) over 5 hours (temperature change: ○), the melt was made to flow out from the hole provided at the bottom of the carbon particle heating tube by gravity. The melt did not fall in the form of fibers from the hole provided at the center of the bottom of the carbon particle heating tube (melt spinning property: ×). Additionally, no fibers were obtained, so the XRD pattern was not confirmed (amorphous property: -).

[0138] (Comparative Example E7)

[0139] The raw material S8 was placed into the carbon particle heating tube. Subsequently, after raising the temperature inside the furnace from room temperature (25 °C) to approximately 1375 °C (raw material temperature 1325 °C), it was maintained at approximately 1375 °C for 1 hour (temperature holding: ○). After that, while raising the temperature inside the furnace from approximately 1375 °C (raw material temperature 1325 °C) to approximately 1400 °C (raw material temperature 1350 °C) over 5 hours (temperature change: ○), the melt was made to flow out from the hole provided at the bottom of the carbon particle heating tube by gravity. The melt did not fall in the form of fibers from the hole provided at the center of the bottom of the carbon particle heating tube (melt spinning property: ×). Additionally, no fibers were obtained, so the XRD pattern was not confirmed (amorphous property: -).

[0140] (Comparative Example E8)

[0141] The raw material S9 was placed into the carbon particle heating tube. Then, after raising the temperature inside the furnace from room temperature (25 °C) to approximately 1375 °C (raw material temperature 1325 °C), it was maintained at approximately 1375 °C for 1 hour (temperature holding: ○). After that, while raising the temperature inside the furnace from approximately 1375 °C (raw material temperature 1325 °C) to approximately 1400 °C (raw material temperature 1350 °C) over 5 hours (temperature change: ○), the melt was made to flow out through the hole provided at the bottom of the carbon particle heating tube by gravity. The melt did not fall in the form of fibers from the hole provided at the center of the bottom of the carbon particle heating tube (melt spinning property: ×). In addition, no fibers were obtained, so the XRD pattern was not confirmed (amorphous property: -).

[0142] (Comparative Example E9)

[0143] The raw material S10 was placed into the carbon particle heating tube. Then, after raising the temperature inside the furnace from room temperature (25 °C) to approximately 1375 °C (raw material temperature 1325 °C), it was maintained at approximately 1375 °C for 1 hour (temperature holding: ○). After that, while raising the temperature inside the furnace from approximately 1375 °C (raw material temperature 1325 °C) to approximately 1400 °C (raw material temperature 1350 °C) over 5 hours (temperature change: ○), the melt was made to flow out through the hole provided at the bottom of the carbon particle heating tube by gravity. The melt did not fall in the form of fibers from the hole provided at the center of the bottom of the carbon particle heating tube (melt spinning property: ×). In addition, no fibers were obtained, so the XRD pattern was not confirmed (amorphous property: -).

[0144] (Comparative Example E10)

[0145] The raw material S11 was placed into the carbon particle heating tube. Then, after raising the temperature inside the furnace from room temperature (25 °C) to approximately 800 °C (raw material temperature 750 °C) over about 20 minutes, the heating rate was changed, and the temperature inside the furnace was raised from approximately 800 °C (raw material temperature 750 °C) to approximately 1350 °C (raw material temperature 1300 °C) over about 60 minutes. After that, the heating rate was further changed, and while raising the temperature inside the furnace from approximately 1350 °C (raw material temperature 1300 °C) to approximately 1375 °C (raw material temperature 1325 °C) over about 340 minutes (temperature change: ○), the melt was made to flow out through the hole provided at the bottom of the carbon particle heating tube by gravity (melt spinning property: ○, temperature holding: ×). And, as a result of observing the XRD pattern of the fibers obtained from the raw material S11, crystalline peaks were confirmed (amorphous property: ×).

[0146] (Investigation)

[0147] The results of Example 2 above show that fibers can be manufactured from raw materials containing IGCC waste discharged from integrated gasification combined cycle power generation (IGCC). More specifically, it is shown that in addition to IGCC waste, fibers can also be manufactured from raw materials containing at least one of waste discharged from a thermal power plant that is not an IGCC using coal as fuel and basalt.

[0148] Moreover, from the results of Example 2, it is known 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. Also, it is known that in the raw material of the fiber, the proportion ([A] / ([A]+[S])) (mass ratio) of Al2O3 in the total of SiO2 and Al2O3 is preferably in the range of 0.15 to 0.40. Further, it is known that the content of CaO in the raw material of the fiber is preferably 5% by mass or more and 30% by mass or less.

[0149] Moreover, although not a necessary structure of the present invention, the fibers hardly reduce in strength due to peeling at the crystalline phase / amorphous phase interface, and in order to obtain high-strength fibers, it is preferably composed essentially only of the amorphous phase.

[0150] Industrial Applicability

[0151] The fibers obtained from the raw materials containing IGCC waste are processed into rovings, chopped strands, woven fabrics, non-woven fabrics, etc., and can be used as coating materials or reinforcement materials.

[0152] Symbol Explanation

[0153] 1 - Electric furnace, 2 - Carbon particle heating tube, 3 - Suspension rod, 4 - Through hole, 5 - Fiber, D - Outer diameter of the electric furnace, H - Height of the electric furnace, d - Inner diameter of the opening of the electric furnace.

Claims

1. A fiber, characterized in that, Contains, as a raw material, waste discharged from an integrated gasification combined cycle power generation (IGCC). Among them, the fiber contains SiO2, Al2O3, and CaO as components. In the fiber, The total content of SiO2 and Al2O3 is 40% by mass or more and 70% by mass or less. Al2O3 / (SiO2 + Al2O3) (mass ratio) is in the range of 0.15 to 0.

40. The content of CaO is 10% by mass or more and 30% by mass or less. The method for manufacturing the fiber includes: A step of heating the raw material to 1300 degrees or more. A step of maintaining the raw material at a temperature of 1300 degrees or more for a specified time of 50 minutes or more. And A step of forming the raw material into a fibrous shape by flowing it out from a formed hole while raising the temperature of the raw material.

2. The fiber according to claim 1, characterized in that, Contains, as the raw material, at least one of waste discharged from a coal-fired thermal power plant and basalt.

3. The fiber according to claim 1, characterized in that, Contains, as the raw material, only waste discharged from an integrated gasification combined cycle power generation (IGCC).

4. The fiber according to claim 1, characterized in that, Consists essentially only of amorphous substances.

5. The fiber according to claim 1, characterized in that, The outer diameter is 500 μm or less.

6. A method for manufacturing fibers, characterized in that, It includes: A step of heating a raw material containing waste discharged from an integrated gasification combined cycle power generation (IGCC) to 1300 degrees or more. A step of maintaining the raw material at a temperature of 1300 degrees or more for 50 minutes or more. And A step of forming the raw material into a fibrous shape by flowing it out from a formed hole while raising the temperature of the raw material, Among them, the raw material contains SiO2, Al2O3, and CaO as components. In the raw material, The total content of SiO2 and Al2O3 is 40% by mass or more and 70% by mass or less. Al2O3 / (SiO2 + Al2O3) (mass ratio) is in the range of 0.15 to 0.

40. The content of CaO is 10% by mass or more and 30% by mass or less.

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