A mineral fiber decorative panel directly prepared using liquid hot molten slag

Abstract

This invention discloses a mineral fiber decorative board directly prepared from molten metallurgical slag. Using molten metallurgical slag as raw material, the board undergoes multiple processes including blowing, modification, mixing, laying, and pressing to produce an inorganic fiber board with excellent mechanical properties, as well as superior fire resistance, water resistance, moisture resistance, and mildew resistance, making it highly valuable. This method maximizes the utilization of mineral components and thermal energy in the molten metallurgical slag while conserving significant water, thermal, and land resources, opening a new avenue for the treatment of molten metallurgical slag. The preparation process is relatively simple, easy to implement, and has low production costs, thus possessing high economic value. Furthermore, since inorganic fiber materials are widely available and environmentally friendly, the preparation method described in this invention does not cause environmental pollution and has good environmental performance.

Description

Technical Field

[0001] This invention relates to the field of comprehensive utilization technology of metallurgical waste slag resources, and in particular to mineral fiber decorative panels directly prepared from manganese-based ferroalloy metallurgical liquid hot melt slag. Background Technology

[0002] Metallurgical hot melt slag is a waste slag produced in the process of pyrometallurgy. It has a high temperature, usually above 1400℃, and its chemical composition is mainly SiO2, Al2O3, CaO and MgO. The mineral composition and thermal energy contained in the slag are of great utilization value.

[0003] Traditional methods for treating metallurgical molten slag include water quenching and air rinsing, which waste significant amounts of water, heat, and land resources. In recent years, direct treatment technologies for molten slag have developed rapidly, primarily focusing on using molten slag to produce insulation boards and microcrystalline stone, and recovering heat from the slag. However, these methods have limitations. Developing new products and exploring new applications for molten slag is urgently needed, and directly preparing mineral fiberboard from molten slag represents one such new approach. Summary of the Invention

[0004] To address the aforementioned problems, the technical objective of this invention is to provide a mineral fiber decorative panel that is directly prepared using liquid hot melt slag.

[0005] This invention is achieved through the following technical solution:

[0006] A mineral fiber decorative panel prepared directly from liquid hot molten slag is manufactured by the following steps:

[0007] S1: Pour manganese-based metallurgical hot melt slag with a temperature above 1450℃ into the modulation electric furnace, and adjust the composition of the hot melt slag to the required composition.

[0008]

[0009]

[0010] S2: The conditioned high-temperature hot melt slag is blown into mineral fibers using a four-roller centrifuge. The fibers are processed to a length of 20-40 mm and a diameter of 4-6 μm, and the surface of the mineral fibers is modified.

[0011] S3: The surface-modified mineral fibers are transported to the metering silo for storage; and the weight metering mechanism ensures that the mineral fibers are evenly fed into the rubber powder mixer through the needle roller feeder;

[0012] S4: Through the combined action of air force and mechanical force, the powdered adhesive is uniformly mixed into the fiber prepared in step S3 in a mixer; under the combined action of air force and mechanical force, the fiber and adhesive are in a suspended state, increasing the uniformity of mixing;

[0013] S5: After the mineral fibers and adhesive are evenly mixed, the mineral fibers are spread into a 12-20cm thick cotton felt using a laying machine; this ensures that the fibers and adhesive powder are fully mixed and their uniformity is guaranteed.

[0014] S6: Cotton felt is pressed and shaped using a continuous press at a temperature of 180-200℃;

[0015] S7: After shaping, the board is cut and packaged to obtain the final product;

[0016] In step S4, the amount of powdered binder added is 7% to 30% of the mineral fiber mass.

[0017] Furthermore, the desired composition is adjusted in step S1 by adding one or more of the following minerals: coal gangue, silica, and bauxite.

[0018] Furthermore, the coal gangue contains 40-45% SiO2, 30-40% Al2O3, and 0.1-0.5% Fe2O3; the silica contains 92-98% SiO2; and the bauxite contains 20-30% SiO2, 40-60% Al2O3, and 1-3% Fe2O3.

[0019] Furthermore, the powdered adhesive mentioned in steps S4 and S5 is at least one of phenolic resin, urea-formaldehyde resin, melamine resin, epoxy resin, unsaturated polyester, polypropylene resin, and polyvinyl chloride resin, and the particle size of the powdered adhesive is required to have a passing rate of more than 98% through a 200-mesh sieve.

[0020] Furthermore, in step S2, surface modification is achieved by uniformly coating a coupling agent, wherein the amount of coupling agent added is 1‰-2‰ of the mineral fiber mass.

[0021] Furthermore, during the transfer of manganese-based metallurgical hot molten slag in step S1, the slag liquid needs to be kept warm, and the slag temperature needs to be maintained above 1400℃ to ensure the fluidity of the slag.

[0022] The beneficial effects achievable by employing the technical means of this invention are as follows: The mineral fiber decorative board prepared directly from molten metallurgical slag, using molten metallurgical slag as raw material, undergoes multiple processes including blowing, modification, mixing, laying, and pressing to produce an inorganic fiber board with excellent mechanical properties, as well as superior fire resistance, water resistance, moisture resistance, and mildew resistance, making it highly valuable for practical use. This method maximizes the utilization of mineral components and thermal energy in the molten metallurgical slag while conserving significant amounts of water, thermal energy, and land resources, thus opening a new path for the treatment of molten metallurgical slag.

[0023] Inorganic fiberboard, produced by mixing and molding inorganic fibers and thermosetting resins through multiple processes including blending, laying, and pressing, exhibits excellent mechanical properties, as well as superior fire resistance, water resistance, moisture resistance, and mildew resistance, thus demonstrating great practicality. The aforementioned preparation process is relatively simple, easy to implement, and has low production costs, thus possessing high economic value. Furthermore, since inorganic fiber materials are widely available and environmentally friendly, the preparation method described in this invention does not cause environmental pollution and has good environmental performance. Detailed Implementation

[0024] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] Example 1:

[0026] This embodiment provides a process for preparing fire-resistant and water-resistant fiberboard, including the following steps:

[0027] S1: Pour 20 tons of ferromanganese alloy hot melt slag (above 1450℃) from the electric furnace in the smelting workshop into a transfer bag; pour it from the transfer bag into the melting electric furnace, add 3 tons of bauxite to the furnace, and melt it evenly. The chemical composition is shown in the table below:

[0028]

[0029] S2: The conditioned hot melt slag is blown into mineral fibers. During the blowing process, a coupling agent is coated on the fiber surface to modify the fiber surface. The blowing is centrifugal, and the shape of the fiber is adjusted by the blowing airflow speed, centrifugal speed, and airflow angle. The fiber length is controlled at 20-40 mm, and the fiber diameter is controlled at 4-6 μm. The surface modification is achieved by uniformly spraying a modified coupling agent, and the amount of coupling agent added is 1%-2‰.

[0030] S3: The surface-modified mineral fibers are transported to the metering silo for storage; and the weight metering mechanism ensures that the mineral fibers are evenly fed into the rubber powder mixer through the needle roller feeder;

[0031] S4: Through the combined action of air force and mechanical force, the powdered adhesive is uniformly mixed into the fiber prepared in step S3 in a mixer; under the combined action of air force and mechanical force, the fiber and adhesive are in a suspended state, increasing the uniformity of mixing;

[0032] S5: After the mineral fibers and adhesive are evenly mixed, the mineral fibers are spread into a 12-20cm thick cotton felt using a laying machine; this ensures that the fibers and adhesive powder are fully mixed and their uniformity is guaranteed.

[0033] S6: Press the cotton felt for 90 seconds at 180℃ and 3.5MPa using a continuous press;

[0034] S7: After shaping, the board is cut and packaged to obtain the final product;

[0035] In this embodiment, the inorganic fiber used is slag wool, and the resin used is solid phenolic resin, wherein the amount of phenolic resin added is 10% of the mass of slag wool.

[0036] In this embodiment, an inorganic fiberboard was prepared using the above process, and the test results are shown in the table below:

[0037] Inspection items unit Test results density <![CDATA[g / cm 3 ]]> 1.1 Water absorption rate ％ 0.8 static bending strength MPa 28 elastic modulus MPa 4200 flammability rating A 24-hour water absorption thickness expansion rate ％ 0.3 Surface bonding strength Mpa 2.5 nail holding power N 2130 Internal bonding strength after 2 hours of boiling Mpa 0.32

[0038] (The test method refers to GB / T 17657-2013 "Test Methods for Physical and Chemical Properties of Wood-based Panels and Decorative Wood-based Panels")

[0039] The test data shows that the inorganic fiberboard prepared by the process described in this embodiment has good mechanical properties such as elastic modulus and static bending strength.

[0040] Example 2:

[0041] This embodiment provides a process for preparing fire-resistant and water-resistant fiberboard, including the following steps:

[0042] S1: Pour 20 tons of ferromanganese alloy hot melt slag (above 1450℃) from the electric furnace in the smelting workshop into a transfer bag; then pour it from the transfer bag into the melting electric furnace. Add 5 tons of bauxite and 2 tons of silica to the electric furnace, and melt it evenly. The chemical composition is shown in the table below:

[0043]

[0044] S2: The conditioned hot melt slag is blown into mineral fibers. During the blowing process, a coupling agent is coated on the fiber surface to modify the fiber surface. The blowing is centrifugal, and the shape of the fiber is adjusted by the blowing airflow speed, centrifugal speed, and airflow angle. The fiber length is controlled at 20-40mm, and the fiber diameter is controlled at 4-6μm. The surface modification is achieved by uniformly spraying a modified coupling agent, and the amount of coupling agent added is 1‰-2‰.

[0045] S3: The surface-modified mineral fibers are transported to the metering silo for storage; and the weight metering mechanism ensures that the mineral fibers are evenly fed into the rubber powder mixer through the needle roller feeder;

[0046] S4: Through the combined action of air force and mechanical force, the powdered adhesive is uniformly mixed into the fiber prepared in step S3 in a mixer; under the combined action of air force and mechanical force, the fiber and adhesive are in a suspended state, increasing the uniformity of mixing;

[0047] S5: After the mineral fibers and adhesive are evenly mixed, the mineral fibers are spread into a 12-20cm thick cotton felt using a laying machine; this ensures that the fibers and adhesive powder are fully mixed and their uniformity is guaranteed.

[0048] S6: Press for 70 seconds at 200℃ and 3.5MPa. The cotton felt is pressed and shaped using a continuous press.

[0049] S7: After shaping, the board is cut and packaged to obtain the final product;

[0050] In this embodiment, the inorganic fiber used is slag wool, and the resin used is epoxy-modified phenolic resin, wherein the amount of phenolic resin added is 20% of the mass of slag wool.

[0051] In this embodiment, an inorganic fiberboard was prepared using the above process, and the test results are shown in the table below:

[0052] Inspection items unit Test results density <![CDATA[g / cm 3 ]]> 1.0 Water absorption rate ％ 0.2 static bending strength MPa 43 elastic modulus MPa 5300 flammability rating A 24-hour water absorption thickness expansion rate ％ 0.27 Surface bonding strength Mpa 2.8 nail holding power N 2213 Internal bonding strength after 2 hours of boiling Mpa 0.35

[0053] (The test method refers to GB / T 17657-2013 "Test Methods for Physical and Chemical Properties of Wood-based Panels and Decorative Wood-based Panels")

[0054] The test data above show that the inorganic fiberboard prepared by the above process has good mechanical properties such as elastic modulus and static bending strength.

[0055] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Modifications or equivalent substitutions made by those skilled in the art to the technical solutions of the present invention, as long as they do not depart from the spirit and scope of the technical solutions of the present invention, are all covered within the scope of the claims of the present invention.

Claims

1. A mineral fiber decorative panel directly prepared using liquid hot molten slag, characterized in that: It is prepared by the following steps: S1: Pour manganese-based metallurgical hot melt slag with a temperature above 1450℃ into the modulation electric furnace, and adjust the composition of the hot melt slag to the required composition. S2: The conditioned high-temperature hot melt slag is blown into mineral fibers using a four-roller centrifuge. The fibers are processed to a length of 20-40 mm and a diameter of 4-6 μm, and the surface of the mineral fibers is modified. S3: The surface-modified mineral fibers are transported to the metering silo for storage; and the weight metering mechanism ensures that the mineral fibers are evenly fed into the rubber powder mixer through the needle roller feeder; S4: Through the combined action of pneumatic and mechanical forces, the powdered adhesive is uniformly mixed into the fiber prepared in step S3 in a mixer; S5: After the mineral fibers and powdered adhesive are evenly mixed, the mineral fibers are spread into a cotton felt with a thickness of 12-20cm by a laying machine. S6: Cotton felt is pressed and shaped using a continuous press at a temperature of 180-200℃; S7: After shaping, the board is cut and packaged to obtain the final product; In step S4, the amount of powdered binder added is 7% to 30% of the mineral fiber mass. In step S2, surface modification is achieved by uniformly coating a coupling agent, wherein the amount of coupling agent added is 1‰-2‰ of the mineral fiber mass; In steps S4 and S5, the powdered adhesive is at least one of phenolic resin, urea-formaldehyde resin, melamine resin, epoxy resin, unsaturated polyester, polypropylene resin, and polyvinyl chloride resin, and the particle size of the powdered adhesive is required to have a 200-mesh sieve passing rate greater than 98%.

2. The mineral fiber decorative panel directly prepared using liquid hot melt slag according to claim 1, characterized in that: The desired composition is adjusted in step S1 by adding one or more of the following minerals: coal gangue, silica, and bauxite.

3. The mineral fiber decorative panel directly prepared using liquid hot melt slag according to claim 2, characterized in that: The coal gangue contains 40-45% SiO2, 30-40% Al2O3, and 0.1-0.5% Fe2O3; the silica contains 92-98% SiO2; and the bauxite contains 20-30% SiO2, 40-60% Al2O3, and 1-3% Fe2O3.

4. The mineral fiber decorative panel directly prepared using liquid hot melt slag according to claim 1, characterized in that: In step S1, the molten slag needs to be kept warm during the transfer of manganese metallurgical hot molten slag. The temperature of the molten slag needs to be kept above 1400℃ to ensure the fluidity of the molten slag.

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