Solidified body, roadbed material, and method for manufacturing solidified body

Abstract

[Problem] To provide a solidified body and a method for producing the solidified body, whereby it is possible to produce a solidified body in which CO2 is fixed without performing a deaeration step or a carbonation step in an airtight container. [Solution] This solidified body comprises: a binder; at least one of a carbonated steelmaking slag, a woody material, a synthetic resin, and natural fibers; and water. The content of at least one of the carbonated steelmaking slag, woody material, synthetic resin, and natural fibers is 1%-90% by mass.

Description

[Technical Field]

[0001] The present invention relates to a solidified body, a roadbed material, and a method for manufacturing a solidified body. [Background technology]

[0002] Various decarbonization technologies are being considered in order to achieve carbon neutrality. Among them, carbonate concrete-related technologies using CO2 are easier to put into practical use than other CO2 utilization technologies, and have high potential for CO2 fixation. Patent Document 1 discloses a method for manufacturing carbonated steel slag solidified bodies produced using steelmaking slag and CO2 as raw materials. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5263190 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, an airtight container is degassed, and then a carbonation process is carried out over a long period of time by supplying carbon dioxide gas to cause a carbonation reaction in the uncarbonated Ca-containing raw material of the preform, which poses a problem of a very large load. Furthermore, there is also the problem that it is difficult to carbonate the entire interior of the solidified body. The present invention has been made in consideration of these problems, and its purpose is to provide a solidified body that can fix CO2 without carrying out a degassing process or a carbonation process in an airtight container, a roadbed material including the solidified body, and a method for manufacturing the solidified body. [Means for solving the problem]

[0005] The means for solving the above problems are as follows. [1] A solidified body comprising a binder, at least one of carbonated steelmaking slag, wood material, synthetic resin and natural fiber, and water, wherein the content of the at least one of carbonated steelmaking slag, wood material, synthetic resin and natural fiber is 1% by mass or more and 90% by mass or less. [2] The solidified body described in [1], wherein the carbonated steelmaking slag is finely divided powder of carbonated steelmaking slag having a particle size of 1 mm or less, and the carbonate content of the finely divided powder of carbonated steelmaking slag is 1 mass% or more. [3] The solidified body according to [1] or [2], wherein the wood material is at least one of wood flour, wood chips, wood wool, wood fiber, pulp, semi-carbonized material, carbonized material, cellulose nanofiber, carbon nanofiber, and carbon fiber. [4] The wood material includes at least one of semi-carbonized material and carbonized material, The solidified body according to [1] or [2], wherein the content of at least one of the semi-carbonized material and the carbonized material contained in the wood material is 1 mass % or more. [5] A solidified body according to any one of [1] to [4], wherein the binder is at least one of ground granulated blast furnace slag, ground granulated steelmaking slag, vitreous aluminosilicate, hydrated lime, cement, and waste concrete. [6] The solidified body according to [5], wherein the ground steelmaking slag is at least one of converter slag, secondary refining slag, hot metal pretreatment slag, and electric furnace slag. [7] The solidified body according to [5], wherein the vitreous aluminosilicate is at least one of fly ash, volcanic ash, and silica fume. [8] A solidified body according to any one of [1] to [7], wherein the water is at least one of fresh water, salt water, seawater, hot spring water, and aqueous sodium hydroxide solution. [9] A roadbed material having a content of the solidified body described in [1] of 1% by mass or more.

[10] A method for producing a solidified body, comprising: a kneading step of kneading a binder, at least one of carbonated steelmaking slag, wood material, synthetic resin and natural fiber, and water to form a mixture; and a solidification step of shaping and solidifying the mixture, wherein in the kneading step, the content of at least one of the carbonated steelmaking slag, wood material, synthetic resin and natural fiber is mixed and kneaded to be between 1% and 90% by mass.

[11] The method for producing a solidified body according to

[10] , wherein in the kneading step, the water and the binder are mixed and kneaded so that the mass ratio of the water and the binder is 0.1 or more and 0.7 or less.

[0006] According to the present invention, a solidified body is produced by solidifying a binder and a raw material capable of fixing carbon with a hydrate, so that the solidified body according to the present invention can fix CO2 in an airtight container without the need for a degassing process or a carbonation process. By using such a solidified body, it becomes possible to easily produce a solidified body in which a large amount of CO2 is fixed, which can contribute to the realization of carbon neutrality. DETAILED DESCRIPTION OF THE INVENTION

[0007] [Embodiment 1] The present invention will be described below through embodiments of the present invention. In the solidified body according to this embodiment, a part of the binder is replaced with a CO2-containing substance, and this is mixed with water to obtain a solidified body. This results in a solidified body in which CO2 is fixed. In embodiment 1, a solidified body containing a binder, carbonated steelmaking slag, and water will be described.

[0008] A method for producing a solidified body according to the first embodiment will be described. First, a binder, which is the raw material for the solidified body, carbonated steelmaking slag, and water are kneaded to form a mixture. This process is the kneading step. Next, the mixture of binder, carbonated steelmaking slag, and water is formed into a predetermined shape and cured in air, a humid atmosphere, or water for at least one day to solidify through a hydration reaction. This process is the solidification step. By solidifying the raw materials through a hydration reaction in this way, a solidified body in which CO2 is fixed can be produced. The produced solidified body can be used, for example, as a seawall material, foot protection material, fishing reef, wall material, sand compaction pile material, calcia modifier, roadbed material, or aggregate.

[0009] The binder is a material that has the function of binding particles together and solidifying them through a hydration reaction. Examples of binders include at least one of ground granulated blast furnace slag, ground granulated steelmaking slag, vitreous aluminosilicate, hydrated lime, cement, and waste concrete. The particle size of the ground granulated blast furnace slag and ground granulated steelmaking slag may be 1 mm or less. A particle size of 1 mm or less means a particle size that can be sieved through a sieve with 1 mm openings.

[0010] The binder is mixed so that the binder content in the solidified body is 10% by mass or more and 99% by mass or less. The ground steelmaking slag used as the binder is, for example, at least one of converter slag, secondary refining slag, hot metal pretreatment slag, and electric furnace slag. The vitreous aluminosilicate used as the binder is, for example, at least one of fly ash, volcanic ash, and silica fume. Table 1 below shows an example of the component composition.

[0011] [Table 1]

[0012] The water may be, for example, at least one of fresh water, salt water, seawater, hot spring water, and aqueous sodium hydroxide solution. It is sufficient for the water to contain moisture. However, using salt water or seawater containing chloride ions, or hot spring water containing sulfate ions, thiosulfate ions, and chloride ions, or aqueous sodium hydroxide solution containing high-pH sodium ions, promotes the improvement of the strength of the mixture obtained by kneading, and improves the strength of the solidified body. Using hot spring water containing carbonate ions increases the amount of CO2 fixed in the solidified body. Table 2 below shows examples of the components contained in these waters.

[0013] [Table 2]

[0014] The water-binder ratio, which indicates the mass ratio of water to binder (mass of water / mass of binder) during kneading, is preferably 0.1 or more and 0.7 or less. If the water-binder ratio during kneading is less than 0.1, the fluidity of the mixture obtained in the kneading step decreases, which is undesirable. On the other hand, if the water-binder ratio during kneading is greater than 0.7, the time required to improve the strength of the solidified body in the solidification step increases, and the strength of the solidified body decreases, which is undesirable.

[0015] Carbonated steelmaking slag is mixed so that the content of carbonated steelmaking slag in the solidified body is 1% by mass or more and 90% by mass or less. A content of carbonated steelmaking slag less than 1% by mass is undesirable because the amount of CO2 fixed in the solidified body is low. On the other hand, a content of carbonated steelmaking slag greater than 90% by mass is undesirable because the amount of binder is reduced and the strength of the solidified body is reduced. Carbonated steelmaking slag can be produced by adding steam to steelmaking slag, then introducing a CO2-containing gas and performing a carbonation treatment for one day. Instead of adding steam to steelmaking slag, carbonated steelmaking slag can also be produced by placing the steelmaking slag in water, introducing a CO2-containing gas into the water, and performing a carbonation treatment for one day. The CO2 concentration of the introduced CO2-containing gas needs to be 10% by volume or more. The CO2-containing gas may be flue gas with a CO2 concentration of 10% by volume or more emitted from manufacturing process equipment in a steelworks.

[0016] It is preferable to use finely ground steelmaking slag with a particle size of 1 mm or less as the steelmaking slag used for carbonated steelmaking slag. A particle size of 1 mm or less means a particle size that can be sieved through a sieve with 1 mm openings. Using finely ground steelmaking slag with a particle size of 1 mm or less promotes the reaction by increasing the reaction interface area during the carbonation treatment, thereby increasing the amount of CO2 fixed in the carbonated steelmaking slag. Using finely ground carbonated steelmaking slag with a particle size of 1 mm or less increases the specific surface area during the solidification step, promoting the supply of alkali and improving the strength of the solidified body.

[0017] Carbonated steelmaking slag contains carbonates. The carbonates may be, for example, calcium carbonate, calcium carbonate hydrate, magnesium carbonate, or magnesium carbonate hydrate. It is preferable to carbonate steelmaking slag so that the carbonate content in the carbonated steelmaking slag is 1% by mass or more. Carbonates contain CO2, so a large amount of carbonate content means that an equivalent amount of CO2 is fixed in the solidified body. Therefore, using carbonated steelmaking slag with a carbonate content of 1% by mass or more as a raw material for the solidified body increases the amount of CO2 fixed in the solidified body. Since the higher the carbonate content in carbonated steelmaking slag, the more CO2 is fixed in the solidified body, so there is no need to set an upper limit for the carbonate content.

[0018] In this way, by replacing part of the binder of the solidified body with carbonated steelmaking slag, a solidified body in which CO2 is fixed can be produced. The solidified body according to embodiment 1 can be produced by solidifying the binder and carbonated steelmaking slag with a hydrate, so that the solidified body can be produced without performing a degassing process or a carbonation process in an airtight container. Furthermore, while calcium carbonate and biochar, which are CO2 fixation materials, produce residues of components other than Ca and ash components, the production of solidified bodies using carbonated steelmaking slag can also suppress the generation of such residues.

[0019] [Embodiment 2] Next, a solidified body containing a binder, a wood material, and water will be described as embodiment 2. The binder and water are the same as those in embodiment 1, so a description thereof will be omitted.

[0020] A method for producing a solidified body according to the second embodiment will now be described. First, a binder, which is the raw material for the solidified body, wood material crushed to 4.75 mm or less, and water are kneaded together to form a mixture. This process is the kneading step. Wood material of 4.75 mm or less refers to wood material that can be sieved through a 4.75 mm mesh sieve among the crushed wood materials. Next, the mixture of binder, wood material, and water is formed into a predetermined shape and cured in air, a humid atmosphere, or water for at least one day to solidify through a hydration reaction. This process is the solidification step. By solidifying the raw materials through a hydration reaction in this way, a solidified body with CO2 fixed can be produced.

[0021] The wood material is mixed so that the wood material content in the solidified body is between 1% and 90% by mass. Examples of wood materials include wood flour, wood chips, wood wool, wood fiber, pulp, semi-carbonized material, carbonized material, cellulose nanofiber, carbon nanofiber, and carbon fiber. By using wood material as the raw material for the solidified body, CO2 can be fixed in the solidified body. The specific gravity of the solidified body can be adjusted by changing the ratio of the raw wood material. High-specific-gravity solidified body is used as artificial stone to be installed underwater. Using high-specific-gravity solidified body as artificial stone makes it excellent in wave stability. Low-specific-gravity solidified body is used as revetment material, exterior wall material, and floating fish reef. Using low-specific-gravity solidified body makes construction easier, thereby shortening the construction period for revetment and exterior wall construction.

[0022] Wood materials have high water absorption. Therefore, by using wood materials as the raw material for the solidified body, heat generation during the hydration reaction in the solidification step is suppressed, and the occurrence of cracks in the produced solidified body can be suppressed. Furthermore, by using wood materials as the raw material for the solidified body, drying shrinkage of the solidified body is also suppressed, so that a solidified body with excellent thermal insulation, sound insulation, and fire resistance, as well as moisture-regulating effects and excellent biocompatibility can be produced.

[0023] It is preferable that the wood material contains at least one of semi-carbonized and charred materials. Semi-carbonized and charred materials function as adsorbents, absorbing the lye contained in low-cost wood materials that causes a delay in solidification of the solidified body. Therefore, by using wood materials containing semi-carbonized or charred materials, it becomes possible to produce solidified bodies using low-cost wood materials. Semi-carbonized materials can be produced by heating wood materials in an oxygen-free or low-oxygen reducing atmosphere at temperatures between 200°C and 300°C. Charred materials can be produced by heating wood materials in an oxygen-free or low-oxygen reducing atmosphere at temperatures between 300°C and 1000°C.

[0024] The content of at least one of semi-carbides and carbides contained in the wood material is preferably 1% by mass or more. If the content of at least one of semi-carbides and carbides is less than 1% by mass, the effect of inhibiting solidification delay cannot be obtained, making it impossible to use low-cost wood materials. On the other hand, the higher the content of semi-carbides and carbides, the greater the effect of inhibiting solidification delay. Therefore, there is no need to set an upper limit for the content of semi-carbides and carbides.

[0025] In this way, a solidified body in which CO2 is fixed can be produced by using a wood material instead of carbonated steelmaking slag. The solidified body according to the second embodiment can also be produced by solidifying a binder and a wood material with a hydrate, so that it can be produced without carrying out a degassing process or a carbonation process in an airtight container.

[0026] [Embodiment 3] A solidified body containing a binder, a synthetic resin, and water will be described as embodiment 3. The binder and water are the same as those in embodiment 1, so a description thereof will be omitted.

[0027] The binder, which is the raw material for the solidified body, synthetic resin crushed to 4.75 mm or less, and water are kneaded together to form a mixture. This process is the kneading step. Synthetic resin of 4.75 mm or less is crushed synthetic resin that can be sieved through a 4.75 mm mesh sieve. Next, the mixture of binder, synthetic resin, and water is formed into a predetermined shape and cured in air, a humid atmosphere, or water for at least one day to solidify through a hydration reaction. This process is the solidification step. By solidifying the raw materials through a hydration reaction in this manner, the solidified body according to embodiment 3 can be produced.

[0028] The synthetic resin is mixed so that the synthetic resin content in the solidified body is 1% by mass or more and 90% by mass or less. The synthetic resin is, for example, one of solid synthetic polymer compounds such as synthetic rubber waste, waste tires, polystyrene foam waste, polyvinyl chloride waste, polyethylene waste, polystyrene waste, and synthetic fiber waste. It is preferable to use waste plastics such as polystyrene foam waste, polyvinyl chloride waste, polyethylene waste, polystyrene waste, and synthetic fiber waste as the synthetic resin. Using synthetic resin as the raw material for the solidified body improves the insulating properties of the solidified body. Furthermore, it becomes possible to produce lightweight solidified bodies and solidified bodies with elasticity.

[0029] In this way, a solidified body with fixed CO2 can be produced by using synthetic resin instead of carbonated steelmaking slag. The solidified body according to the third embodiment can also be produced by solidifying a binder and synthetic resin with a hydrate, so that it can be produced without carrying out a degassing process or a carbonation process in an airtight container.

[0030] [Embodiment 4] A solidified body containing a binder, natural fibers, and water will be described as embodiment 4. The binder and water are the same as those in embodiment 1, so a description thereof will be omitted.

[0031] The binder, which is the raw material for the solidified body, natural fibers cut to 4.75 mm or less, and water are kneaded together to form a mixture. This process is the kneading step. Next, the mixture of binder, natural fibers, and water is formed into a predetermined shape and cured in air, a humid atmosphere, or water for at least one day to solidify through a hydration reaction. This process is the solidification step. By solidifying the raw materials through a hydration reaction in this manner, the solidified body of embodiment 4 can be produced.

[0032] Natural fibers are mixed so that the natural fiber content in the solidified body is 1% by mass or more and 90% by mass or less. Natural fibers are, for example, plant fibers such as cotton, hemp, linen, rice husks, palm kernel shells, and banana peels, or animal fibers such as wool, cashmere, and silk. Using natural fibers as a raw material for the solidified body improves the strength of the solidified body. Furthermore, it becomes possible to produce lightweight solidified bodies and solidified bodies with elasticity.

[0033] In this way, a solidified body in which CO2 is fixed can be produced by using natural fibers instead of carbonated steelmaking slag. The solidified body according to the fourth embodiment can also be produced by solidifying a binder and natural fibers with a hydrate, so that it can be produced without carrying out a degassing process or a carbonation process in an airtight container.

[0034] In the first to fourth embodiments, the solidified body is described using an example of a solidified body containing a binder, carbonated steelmaking slag, a wood material, a synthetic resin or natural fiber, and water. However, this is not limiting. A solidified body may be produced using a wood material together with carbonated steelmaking slag, a synthetic resin together with carbonated steelmaking slag, or a natural fiber together with carbonated steelmaking slag. Furthermore, a solidified body may be produced using a wood material together with synthetic resin, a wood material together with natural fiber, or a synthetic resin together with natural fiber. That is, the solidified body according to the present embodiment includes a binder, at least one of carbonated steelmaking slag, a wood material, a synthetic resin, and natural fiber, and water, and the content of at least one of carbonated steelmaking slag, a wood material, a synthetic resin, and natural fiber is 1% by mass or more and 90% by mass or less.

[0035] Furthermore, the solidified body may contain a binder, carbonated steelmaking slag, wood material, synthetic resin or natural fiber, water, and fine aggregate, or a binder, carbonated steelmaking slag, wood material, synthetic resin or natural fiber, water, fine aggregate, and coarse aggregate. Even with such a solidified body, a CO2-fixed solidified body can be produced without a degassing process or a carbonation process in an airtight container.

[0036] In roadbed materials containing 1% or more by mass of the solidified material obtained in this embodiment, CO2 is fixed in the roadbed material. In addition to the solidified material obtained in this embodiment, the roadbed material may be mixed with at least one of carbonated steelmaking slag, wood material, synthetic resin, and natural fiber. When incorporating the solidified material into the roadbed material, the solidified material is crushed so that the entire roadbed material satisfies CS-40 specified in JIS A 5015:2018 "Iron and steel slag for roads." [Example]

[0037] Next, we will explain examples in which solidified bodies were produced by adjusting the mixing ratios of binder, carbonated steelmaking slag (containing calcium carbonate, a carbonate), wood material, synthetic resin, natural fiber, and water. Carbonated steelmaking slag powder with a particle size of 1 mm or less was used as the carbonated steelmaking slag. The wood material and synthetic resin were crushed to 4.75 mm or less using a crusher, and the natural fiber was cut to 4.75 mm or less using a cutter mill. The mixing ratios of these raw materials, the water binding ratio, whether or not solidification was performed, and the amount of CO2 fixed are shown in Table 3 below. The binder, carbonated steelmaking slag powder, wood material, synthetic resin, and natural fiber materials used in each of Invention Examples 1 to 17 and Comparative Examples 1 to 4 are shown in Table 4 below.

[0038] The raw materials for each solidified form shown in Table 3 were placed in a test room maintained at a temperature of 20±3°C and a relative humidity of 60% or higher. 15 L of raw materials were placed in a 20 L mortar mixer. After 30 seconds of dry mixing, water was added and the mixture was mixed at 100 rpm for 90 seconds. The raw materials were then filled into a cylindrical container (φ100 mm x 200 mm) and sealed and cured for up to 7 days to produce a solidified form.

[0039] The semi-carbonized material contained in the wood material was produced by treating wood flour with an average particle size of 1 mm at 250°C for 10 minutes using superheated steam. The charcoal contained in the wood material was produced by treating wood flour with an average particle size of 300 μm at 300°C for 20 minutes using superheated steam. The average particle size of wood flour is the volume mean diameter defined by the following equation (1):

[0040]

number

[0041] If the compressive strength of the solidified body was 1 MPa or more, the solidification was judged as "Good," and if the compressive strength of the solidified body was less than 1 MPa, the solidification was judged as "Poor." Measurement of the compressive strength of the solidified body was carried out in accordance with JIS A 1108:2018 "Test method for compressive strength of concrete."

[0042] [Table 3]

[0043] [Table 4]

[0044] As shown in Table 3, in Examples 1 to 17, the kneaded mixed raw materials were hydrated and solidified, and a solidified body with CO2 fixed was produced. These results confirmed that the solidified body according to this embodiment can be produced without performing a degassing process or a carbonation process in an airtight container. On the other hand, in Comparative Examples 1 and 2, although a solidified body was produced by hydration and solidification, the raw materials for the solidified body did not contain carbonated finely divided steelmaking slag, wood material, or synthetic resin, so the amount of CO2 fixed in the solidified body was zero, and a solidified body with CO2 fixed could not be produced. In Comparative Examples 3 and 4, the raw materials did not contain a binder, so the raw materials did not hydrate and solidify, and a solidified body could not be produced.

Claims

1. A binder; At least one of carbonated steelmaking slag, wood material, synthetic resin, and natural fiber; water, The binder is ground steel slag, The ground steelmaking slag powder is at least one of converter slag, secondary refining slag, hot metal pretreatment slag, and electric furnace slag, The wood material is at least one of wood flour, wood chips, wood wool, wood fiber, pulp, semi-carbonized charcoal, and charcoal; the synthetic resin is at least one of synthetic rubber scraps, waste tires, styrofoam scraps, polyvinyl chloride scraps, polyethylene scraps, and polystyrene scraps; A solidified body in which the content of at least one of the carbonated steelmaking slag, wood material, synthetic resin, and natural fiber is 1% by mass or more and 90% by mass or less.

2. The carbonated steelmaking slag, The carbonated steelmaking slag is finely powdered carbonated steelmaking slag having a particle size of 1 mm or less, 2. The solidified body according to claim 1, wherein the carbonate content of the ground carbonated steelmaking slag is 1 mass % or more.

3. A method comprising the steps of: The wood material includes at least one of semi-carbonized charcoal and charcoal, The solidified body according to claim 1 , wherein the content of at least one of the semi-carbonized charcoal and the charcoal contained in the wood material is 1% by mass or more.

4. A roadbed material having a content of the solidified body according to claim 1 of 1% by mass or more.

5. A method for producing a solidified body, comprising: a kneading step of kneading a binder, at least one of carbonated steelmaking slag, wood material, synthetic resin, and natural fiber, and water to form a mixture; and a solidification step of molding and solidifying the mixture, The binder is ground steel slag, The ground steelmaking slag powder is at least one of converter slag, secondary refining slag, hot metal pretreatment slag, and electric furnace slag, The wood material is at least one of wood flour, wood chips, wood wool, wood fiber, pulp, semi-carbonized charcoal, and charcoal; the synthetic resin is at least one of synthetic rubber scraps, waste tires, styrofoam scraps, polyvinyl chloride scraps, polyethylene scraps, and polystyrene scraps; In the kneading step, the carbonated steelmaking slag, wood material, synthetic resin, and natural fiber are mixed and kneaded so that the content of at least one of them is 1% by mass or more and 90% by mass or less.

6. The method for producing a solidified body according to claim 5 , wherein in the kneading step, the water and the binder are mixed and kneaded so that a mass ratio of the water to the binder is 0.1 or more and 0.7 or less.

7. A method for producing a solidified body as described in claim 5 or claim 6, wherein the water is at least one of fresh water, salt water, seawater, hot spring water, and aqueous sodium hydroxide solution.

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