粉煤灰用于橡胶的研究现状及展望

Research progress and prospect of pulverized fly ash in rubber

粉煤灰是一种火力发电厂的废弃粉体材料,炭黑是橡胶产品中所用的主要补强填料,一般来源于石油和煤炭相关产业,但从节约能源和保护环境的角度出发,必须要降低炭黑的生产量。由于粉煤灰和炭黑的性质相近,因而可采用粉煤灰替代部分炭黑用于橡胶补强材料中。笔者论述了粉煤灰填充橡胶补强材料的工艺研究进展,主要包括直接填充、物理分离、化学提取及表面活性剂改性等4个方式,同时指出了粉煤灰在橡胶填充材料中工业化应用现状,并对粉煤灰提取橡胶用补强材料的方法,用于填充橡胶的处理方法,以及实现工业化的研究方向进行了展望。结果表明,粉煤灰直接填充,分散效果差,掺量较少;化学提纯虽能提升产品质量,但提纯工艺复杂;物理改性方式获得的超细颗粒存在分散性难题;机械化学改性方式采用湿法改性方法效果较明显,但生产效率低,需干燥后使用,难以实现工业化。目前,粉煤灰填充在橡胶材料中的工业化应用主要有耐压橡胶管、阻燃橡胶、氯化聚乙烯胶管等方面,应用范围存在一定的局限性。为实现粉煤灰在橡胶制品中的大规模应用,还需针对上述应用难题,结合多种改性方法,提升改性效果和效率,如结合物理改性法时应减少球磨、超声时间,降低能耗;结合化学改性法时,可引入低成本偶联剂提升改性效果和效率,以寻找一种低成本、高附加值的改性粉煤灰方法。

Fly ash is a waste powder material for thermal power plants.Carbon black is the main reinforcing filler used in rubber products,which is derived from petroleum and coal related industries.But from the perspective of energy conservation and environmental protection,the production of carbon black must be reduced.Due to the similar properties of fly ash and carbon black,fly ash can be used as a substitute for part of carbon black in rubber reinforcements.In this paper,the research progress of fly ash filled rubber reinforcing materials was discussed,including direct filling,physical separation,chemical extraction and surfactant modification.At the same time,the industrial application of fly ash in rubber filling materials was pointed out.In addition,the method of extracting reinforcing materials from fly ash for rubber,the treatment method of filling rubber,and the research direction of industrialization were prospected.The results show that the direct filling of fly ash will result in poor dispersion and less dosage.Although the chemical purification can improve the product quality,the purification process is complicated.The ultra-fined particles obtained by the physical modification method have the problem of dispersion.The wet modification method in the mechanical chemical modification method is more effective,but the production efficiency is low.And it needs to be used after drying,which makes it difficult to achieve industrialization.At present,the industrial applications of fly ash filled in rubber materials mainly include pressure rubber tubes,flame retardant rubbers,chlorinated polyethylene hoses,etc.,and there are some limitations in the application range.In order to realize the large-scale application of fly ash in rubber products,it is necessary to solve the above application problems and combine various modification methods to improve the modification effect and efficiency.For example,when combined with physical modification method,ball milling,ultrasonic time and the energy consumption should be reduced.When combined with chemical modification,a low-cost coupling agent can be introduced to enhance the modification effect and efficiency to find a low-cost,high value-added modified fly ash method.