Vol.2 No.2 2009

59/98

Research paper : A strategy to reduce energy usage in ceramic fabrication (K. Watari et al.)−139−Synthesiology - English edition Vol.2 No.2 (2009) and the speed of R&D can be accelerated considerably. However, since the manufacturing process is composed of the accumulation of elemental technologies and linkage between the technologies, more time than expected is required for the extraction of core technology. To solve this problem, it is necessary to systematize the elemental technologies and extract the issues and core technology to maintain the succession of the process. This is to create a research scenario for industry. By doing this, we believe various issues in technological realization can be understood, plans to solve the issues can be created, and the speed of research can be further increased.However, information on the materials and the processes that we can learn from private companies are limited. Therefore, to engage in R&D while writing the scenario for industry, it is important to obtain human resources that have long years of experience and wide-ranging knowledge in the field, and to thoroughly understand the theme and its background.Also, we believe the public research institute of industrial technology is expected to have a “universal thinking” that does not weather over the years. This is one of the outcomes of the Type 2 Basic Research conducted by AIST. In our research, we set the objectives to reduction and elimination of the organic binder, and we obtained a general solution that water on the surface of the raw particle greatly affects the formation of ceramics. When working on research topics that arise from the site of production in joint research, most are technological contributions and one-shot service to a company, but the outcome of Type 2 Basic Research may become extremely meaningful by also considering the construction of concepts with scientific universality.The final target of this research is the complete elimination of organic binders. We succeeded in simple extruding using an inorganic binder. By achieving this technology, ceramic manufacturing without debinding and exhaust gas treatment became possible, and as a result the reduction in CO2 emission was about 70 % (see Fig. 2). Also, since the amount of the reactive binder was one to two digits less compared to the amount of binders in the ordinary process, the debinding and exhaust gas treatment steps can be eliminated in the future. The estimated reduction in CO2 will have an impact on the ceramics industry. However, in reality, the demands of industry cannot be met without conventional organic binders in members of certain size or complex shape. Therefore, the current practice is to add small amounts of organic binders to the newly developed inorganic binder.Since the developed technology can be used in the current ceramic production process, we are working actively to spread the technology. We have engaged in R&D based on materials and processes, and wish to continue the R&D while looking at the development of manufacturing equipment to improve the energy-saving property based on the findings from this research project. Particularly, we shall fuse the R&D of materials and process with the R&D of manufacturing equipment, bring about a synergy effect, and contribute further to the development of the energy-saving ceramic process.AcknowledgementWe are deeply grateful for the cooperation and advice of the researchers and engineers of the companies with whom we engaged in joint research, as well as many people including the researchers of AIST.The Institute of Energy Economics, Japan: Keizai Sangyosho/EDMC Suikei (EDMC Handbook of Energy and Economics Statistics), 62-13 (2003) (in Japanese).K. Watari: Recent trends in low-energy process technology in ceramics, Materiaru Integureshon (Material Integration), 19, 2-9 (2006) (in Japanese).Y. Hotta, C. Duran, K. Sato, T. Nagaoka and K. Watari: Densification and grain growth in BaTiO3 ceramics fabricated from nanopowders synthesized by ball-milling assisted hydrothermal reaction, J. Euro. Ceram. Soc., 28, 599-604 (2007).J. Qiu, Y. Hotta, K. Watari and T. Mitsuishi: Enhancement of densification and thermal conductivity in AlN ceramics by addition of nano-sized particles, J. Am. Ceram. Soc., 89, 377-80 (2006).K. Watari, M. C. Valecillos, M. E. Brito, M. Toriyama and S. Kanzaki: Processing and thermal conductivity of aluminum nitride ceramics with concurrent addition of Y2O3, CaO and Li2O, J. Am. Ceram. Soc., 79, 3103-8 (1996).T. Isobe, Y. Hotta and K. Watari: Preparation of Al2O3 sheets from nano-sized particles by aqueous tape casting of wet-jet milled slurry, J. Am. Ceram. Soc., 90, 3720-24 (2007).Y. Kinemuchi, R. Ito, H. Ishiguro, T. Tsugoshi and K. Watari: Binder burnout from layers of alumina ceramics under centrifugal force, J. Am. Ceram. Soc., 89, 805-809 (2006).K. Watari, K. Sato, T. Nagaoka and T. Ozaki: Binder process and energy-saving sintering technology, Shin Zairyo Series, Kankyo Taio-Gata Ceramics No Gijutsu To Oyo (New Material Series, Technology and Application of Environment-Friendly Ceramics), 13-27 (2007) (in Japanese).K. Sato, Y. Hotta, T. Nagaoka, K. Watari, M. Asai and S. Kawasaki: Mutual linkage of particles in a ceramic green body through potoreactive organic binders, J. Ceram. Soc. Japan, 113, 687-691 (2005).K. Sato, M. Kawai, Y. Hotta, T. Nagaoka and K. Watari: Production of ceramic green bodies using a microwave-reactive organic binder, J. Am. Ceram. Soc., 90, 1319-22 (2007).C. Duran, K. Sato, Y. Hotta and K. Watari: Covalently connected particles in green bodies fabricated by tape casting, J. Am. Ceram. Soc., 90, 279-282 (2007).T. Nagaoka, C. Duran, T. Isobe, Y. Hotta and K. Watari: Hydraulic alumina binder for extrusion of alumina ceramics, J. Am. Ceram. Soc., 90, 3998-4001 (2007).T. Nagaoka, K. Sato, Y. Hotta, T. Tsugoshi and K. Watari: Extrusion of alumina ceramics with hydraulic without [1][2][3][4][5][6][7][8][9][10][11][12][13]References

※このページを正しく表示するにはFlashPlayer9以上が必要です