PROCESS FOR PREPARING CERAMIC-LIKE MATERIALS AND THE CERAMIC-LIKE MATERIALS

Abstract: This invention is concerned with a process for preparing ceramic-like materials suitable for a wide range of application, by binding an inorganic filler of a grain size of up to 20 mu m, used in the form of phosphogypsum or phosphogypsum and magnetite, or phosphogypsum and glass-forming oxides, with epoxy resin or a mixture of epoxy resin and polyester resin, the latter amounting to 80 % by volume, with the volume ratio of the resin component to the filler being 1:0.45-2. The resultant ceramic-like materials are water resistant and can be easily formed, also by casting, and additionally by mechanical working, if required. The ceramic-like materials containing magnetite show magnetic properties, while those containing glass-forming oxides are able to absorb an X-radiation of 45-55 keV and a hard radiation of 0.6-1.25 MeV. The addition of an expanding agent such as butyl isocyanate to the raw composition makes it possible to prepare an expanded material with completely closed pores. Due to very good adhesion of the ceramic-like to metal, glass, plastics, concrete it can be easily joined with these materials both during the polymerization process and after its termination, also by using a prepolymerized composition as a binder.

Description: Process for preparing ceramic-like materials and the ceramic-like materials The present invention is concerned with a process for preparing ceramic-like materials and the ceramic-like ma¬ terials produced thereby with various properties useful in many branches of industry, and at the same time making it possible to utilize industrial waste products. it is known from several patents, including polish pa¬ tent specifications 113573 and 147 599, that the waste phosphogypsum, obtained in the wet process of producing phosphoric acid, can be used as a raw material to manufac- o ture flooring compositions, stuccoes or building binders, after being treated with carbamine or melamine resins. The drawback of these processes is that, besides toxicity of these resins, they require a long time to be poϋ erized αr cured and the resultant material is rather brittle and hy- groscopic due to its porous structure. There is also known from Polish patent application no, -P.283240 aprocess far manufacturing a ceramic composition by binding phosphogy¬ psum in a non-aqueous system with polyester resins inclu¬ ding an accelerant, a curing agent and acetone, if requi- red. The resultant material is suitable for producing va¬ rious articles with a good mechanical strength and low wa¬ ter and oil absorbabilities by extrusion or casting. It has unexpectedly turned out that the use ofphospho¬ gypsum being a by-product in the production of phosphoric acid, as an inorganic filler, preferably an apatite deri¬ ved phosphogypsum, by itself or, if required, in a compo- sition with other compounds, bonded with epoxy resins or their mixtures with polyester resins in a non-aqueous sys¬ tem, makes it possible to prepare ceramic-like materials suitable for a wide application, water-resistant, showing properties similar to those of sane metals, and at the same time being readily processable, particularly by casting, and then, if required, additionally by mechanical working. The process for preparing a ceramic-like material by binding an inorganic filler with a synthetic resin in a nαa- aqueous system according to the present invention consists in adding a waste phosphogypsum, preferably an apatite de¬ rived phosphogypsum, previously prepared by heating for at least 1.5 hours at a temperature of not lower than 167 °C, and grinding to obtain a fraction with a grain size of up to 20 p , on continuous stirring for 0,2-5.0 hours to a synthetic resin in an amount of 1 : 0,45-2.0 per the volume of the dry filler. As a synthetic resin, epoxy re¬ sin is used by itself or in a mixture with polyester resins both saturated and unsaturated modified ones, with a con- centration of 20-80 % by volume. In the case of using un¬ saturated polyester resins, beside an organic dilutant such as acetone or styrene in an amount of up to 12 volumeparts added to maintain the raw composition viscosity at a level not higher than 4150mPa«s, O.Oβ-0.55 volume parts ofan accelerant such as cobalt naphthenate is also added. The raw composition can be coloured as required with any pigment, and then there is added 8-20 volume parts of a curing a- gent such as triethylenetetraamine or, in the case of using a mixture of epoxy resin and unsaturated polyester resins, 2-16 volume parts of a curing agent such as triethylenete- traamine and 0.5-8.5 volume parts of a curing agent, pre¬ ferably in the form solution with a concentration of 20-40 % by volume of cyclohexanone or benzoyl peroxide in cibutyl phthalate. The ceramic-like material, containing synthetic resins, a curing agent and an inorg'v.ic filler, according to the present invention, per every 100 volume parts of phospho¬ gypsum contains 50 - 225 volume parts of epoxy resin, 8-20 volume parts of a curing agent such as triethylenetetraami- ne and up to 12 volume parts of an organic dilutant such as acetone or styrene. Also the ceramic-like material, containing synthetic resins, a curing agent and an inorganic filler, according to the present invention per every 100 volume parts of tiie phosphogypsum filler contains 10-180 volume parts of epoxy resin and 10-180 volume parts of a saturated po¬ lyester resin, 8-20 volume parts of a curing agent such as triethylenetetraamine and up to 12 volume parts of an organic dilutant such as acetone or styrene. Also the ceramic-like material, containing synthetic resins, a curing agent and an inorganic filler, according to the present invention per every 100 volume parts of the phosphogypsum filler contains 10-180 volume parts of e- poxy resin, 10-180 volume parts of an unsaturated modi- fied polyester resin, 0.06-0.55 volume parts of an acce¬ lerant, such as cobalt naphthenate, 2-16 volume parts of a curing agent such as triethylenetetraamine and 0.1 - 3»4 volume parts of benzoyl or cyclohexanone peroxide and 0.4-5.1 volume parts of dibutyl phthalate. Using the process in accordance with the present in¬ vention, beside the above mentioned ceramic-like materials, one can also prepare ceramic-like materials with specific properties, by using, as an inorganic filler, a dry co po- sition prev iously homogenized physically, containing phos¬ phogypsum and magnetic in the volume ratio 1 : 0,72-1.42 or phosphogypsum and glass-forming oxides in the volume ra¬ tio 1 : 0.83-1.39, while the glass-forming oxides consist mainly of lead oxide in an amount, of 81 % by weight, sili- con dioxide in an amount of 11,.5 by weight and barium o- xide in an amount of 2.6 % by weight. The grain size of the dry composition containing phosphogypsum and magnetite is 18jLim at most and that of the dry composition containin phosphogypsum and glass-forming oxides up to 16 jum. Furthermore the process in accordance with this in¬ vention makes it possible to prepare expanded ceramic-like materials with completely closed pores, by adding to the raw composition containing a curig agent, within 0,15 hours, an expanding agent, preferably butyl isocyanate. in an amount of up to 30 % by volume per the composition and water in an amount of 0,06-0,15 % by volume per the com¬ position. The ceramic-like material with magnetic properties, containing an inorganic filler, synthetic resins and a cu- ring agent, according to the present invention contains phosphogypsum and magnetite in the volume ratio 1 :<V72 -142. The ceramic-like material effective at absorbing an Σ-radiation of 45 - 55 keV and a hard radiation of 0.6-1.25 Me7, containing an inorganic filler, synthetic resins and a curing agent, according to the present inven¬ tion contains in the volume ratio 1 t 0.83-1.36, respe¬ ctively phosphogypsum and glass-forming oxides consisting mainly of lead oxide, silicon oxide and barium oxide. The ceramic-like materials is accordance with the present invention, depending on their composition, can be used in a v/ide range of application. Various articles can be made from them by casting or injection moulding, as well as by mechanical working such as machine cutting, grinding, turning. Moreover, the ceramic-like materials, according to the present invention, show perfect adhesion to metal, wood, concrete, glass and most plactics. Therefore, thay can be optionally joined with other materials either dire¬ ctly at the polymerization stage or after curing by means of a prepolymerized composition. At the same time the process according to the present invention makes it possible to utilize excessive quantities of the waste phosphogypsum obtained during the production of phosphoric acid by the wet process. This waste stored. at vast dumping grounds, bringc about a growing degrada¬ tion of the natural environment. Thus, the waste when uti¬ lized by the process in accordance with this invention, due to very good mechanical properties of the resultant cera¬ mic-like materials, as well as their good resistance to ex- ternal conditions such as moisture, corrosion, acids and alkalies, on the one hand will partly assist in reducing the environmental hazard, while on the other hand, they will make it possible in many cases to decrease the consum¬ ption of metals, calcareous ore output, gravel. The invention is further described by the following example without limiting the scope of its application. Example I • a To 2 dnr of epoxy resin, 2.8 dπr of an apatite derived phosphogypsum, previously heated at a temperature of 235-239 °C for 2.1 hours, with a grain size of 14-17 μ . is added for 2.1. hours on continous stirring along with 0.05 dnr of styrene, after with the whole is stirred for 30 minutes to obtain a composition with a viscosity of 3200 mPa.s. Then, 3 g of pigment blue B and 0.125 dπ of triethylenetetraamine are added. The resultant composition is casted into an appropriate mould to obtain, after 0.9 hours, a dish to be used as a sa¬ tellite antenna. > Example II To the composition containing 0.5 dnr of epoxy re- sin and 0.3 dπr of an saturated polyester resin modified with maleic anhydride on continuous stirring for 1 hour, previously homogenized dry mix with a grain size of up to 10 um, consisting of 0,4 m^ of phosphogypsum- prepared as in example I and 0.5 dπr of. magnetite- is added. Then 0.001 dπr of cobalt naphtenate, 0.13 dπr of acetone, O065 dnr of triethylenetetraamine and 0.012 dπr of a 27 solution, of benzoyl peroxide in dibutyl phthalate are added, the whole composition is thoroughly stirred and casted into prepared moulds to form furniture magnetic lock inserts. Example III To the composition containing 2 dnr of epoxy resin and 2.2 dπr of a saturated polyester resin, on continuous 1 stirring for 2.7 hours 4«8 dnr of a homogenized dry com¬ position with a grain size up to 8 μ , containing 45 % by volume of a waste apatite derived phosphogypsum previously heated for 3»5 hours at a temperature of 247 °C and 55% • a by volume of lead cullet, along with 0,05 dnr of acetone are added and stirred for further 0.5 hours. Then, to the 3 raw composition 0,47 dπr of triethylenetetraamine is added and the whole is casted to prepared moulds to form portable protective screens, useful at work with radioactive sub- stances. Example IV Proceeding as in example I, after the addition of triethylenetrβraamine, to the raw composition 0.97 dπr of butyl isocyanate and 0.25 dπr of water are added and the whole is casted into prepared moulds to form, after polymerisation, external insulating wall boards.

Claims: Claims 1. A process for preparing a ceramic-like material, bybin¬ ding an inorganic filler with a synthetic resin in a non- aqueous system, characterized in that to 100 volume parts of epoxy resin or its mixture with polyester resins with a concentration of 20-80% by volume, on condition thatwhen using unsaturated polyester resins, they have to be modi¬ fied, on continuous stirring for 0.2-5 hours there are added 45 - 200 volume parts of a waste phosphogypsum, pre¬ ferably an apatite derived phosphogypsum, previously hea- ted at least for 1 hour at a temperature of not lower than 167 °C, with a grain size of up to 20 um, and, ifre¬ quired, 0.06-0.55 volume parts of an accelerant such as cobalt naphthenate and up to 12volume parts of an orga¬ nic dilutant such as acetone or styrene to maintain the raw composition viscosity at a level not higher than 4150 mPa«s, after which there are added 8-20 volume parts of a curing agent, preferably in the form of tri¬ ethylenetetraamine or a mixture of 2-16 volume parts of triethylenetetraamine and 0.5-8.5 volume parts of a so- lution witch a concentration of 20-40 % by volume of cyclohexanone or benzoyl peroxide in dibutyl phthalate. 2. A process according to claim 1, wherein the inorganic filler consists of a previously physically homogenized dry composition with a grain size of up to 18 pm, con- taining phosphogypsum and magnetite in the volume ratio 1 : 0.72- 1.42. 3. A process according to claim 1, wherein the inorganic filler consists of a previously physically homogenized dry composition with a grain size of up to 16 um, containing in the volume ratio 1 t 0.83-1.39 phosphogypsum and glass-forming oxides consisting mainly of lead oxide in an amount of 81 % by weight, silicon dioxide in an amount of 11,5 % by weight and barium oxide in an amount of 2,6 % by weight. 4. A process according to claim 1, wherein after the addi- tion of the curing agent, an expanding agent is added for at least 10 minutes, preferably butyl isocyanate in an amount of up to 30% by volume per the whole composition, and also 0.06-0.15 % by volume of water is added. 5. A ceramic-like material, containing an inorganic filler, a synthetic resin and a curing agent, characterized in that per every 100 volume parts of phosphogypsum, used as an inorganic filler, contains 50 - 225 volume parts of - poxy resin, 8-20 volume parts of triethylenetetraamine and up to 12 volume parts of acetone or styrene. 6. A ceramic-like material, containing an inorganic filler, a synthetic resin and a curing agent, characterized in that pre every 100 volume parts of phosphogypsum used as am inorganic filler contains 10-180 volume parts of satu¬ rated, epoxy resin, 10-180 volume parts of saturated poly- ester resin, 8-20 volume parts of triethylenetetraamine and up to 12 volume parts of acetone or styrene. 7, A ceramic-like material, containing an inorganic filler, a synthetic resin and a curing agent, characterized in that per every 100 volume parts of phosphogypsum used as an inorganic filler, contains 10-180 volume parts of epoxy resin, 10-180 volume parts of an unsaturated modified po¬ lyester resin, 0.06-0.55 volume parts of cobalt naphthe- nate, 0.1 -3.4 volume parts of cyclohexanone or benzoyl peroxide, 0.4 volume parts of dibutyl phthalate and up to 12 volume parts of acetone or styrene. 8. A ceramic-like material according to claim 5 or claim 6 or claim 7, wherein per every 100 volume parts of phosphogypsum contains 72-142 volume parts of magnetite, 9. ceramic-like material according to claim 5 or claim 6 or claim 7, wherein per every 100 volume parts of phosphogypsum contains 83-139 volume parts of glass- forming oxiαes consisting mainly of lead oxide, silicon di¬ oxide and barium oxicte.

Inventors: CYRKIEWICZ MARCELI, HERLING ERWIN, KLESZCZEWSKI JACEK, CYRKIEWICZ, MARCELI, HERLING, ERWIN, KLESZCZEWSKI, JACEK
Applicants: CYRKIEWICZ MARCELI, HERLING ERWIN, KLESZCZEWSKI JACEK, CYRKIEWICZ, MARCELI, HERLING, ERWIN, KLESZCZEWSKI, JACEK
Application year: 1993
Main classification: C08L67
IPC codes: C08K3, C08L63, C08L67