AU2020102253A4 - Lightweight and high-strength ceramsite and preparation method thereof - Google Patents
Lightweight and high-strength ceramsite and preparation method thereof Download PDFInfo
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- AU2020102253A4 AU2020102253A4 AU2020102253A AU2020102253A AU2020102253A4 AU 2020102253 A4 AU2020102253 A4 AU 2020102253A4 AU 2020102253 A AU2020102253 A AU 2020102253A AU 2020102253 A AU2020102253 A AU 2020102253A AU 2020102253 A4 AU2020102253 A4 AU 2020102253A4
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- ceramsite
- slag
- salt
- washing waste
- manganese
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Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62204—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
- C04B2235/5427—Particle size related information expressed by the size of the particles or aggregates thereof millimeter or submillimeter sized, i.e. larger than 0,1 mm
Abstract
The present invention provides a lightweight and high-strength ceramsite and a preparation
method thereof. The ceramsite of the present invention is spherical, and has a diameter of 3 mm to
20 mm, a compressive strength of 1.5 Mpa to 2 Mpa, a volume weight of 350 kg 30 kg/m3 , and X
< 0.10 w/m-k. The ceramsite of the present invention is produced from raw materials that include
various inorganic solid wastes accounting for more than 95% by a novel environmentally-friendly
process according to an optimized formula. During the preparation process, no exhaust gas, waste
water and waste residue are discharged. The additive provided in the present invention can ensure
the foaming and expansion of the ceramsite during the high-temperature sintering, thereby
effectively improving the supporting force of the network framework inside the ceramsite. The
obtained ceramsite has pressure resistance, energy conservation and sound insulation superior to
an ordinary ceramsite at the same volume-weight level.
DRAWINGS
FIG. 1
FIG. 2
Description
FIG. 1
FIG. 2
The present invention relates to a ceramsite and a preparation method thereof, and in particular, to a lightweight and high-strength ceramsite prepared from fully-digested inorganic solid wastes, and a preparation method thereof.
At present, as the exploitation of natural sand and stone in river courses is restricted, mountain sand is heavily exploited across the country, and during the exploitation, a large amount of sand washing waste is produced, which includes silicon and aluminum as the main components as detected, and is difficult to be disposed of. Moreover, a large amount of manganese tailings includes a certain amount of manganese carbonate, and iron-washing waste includes a lot of iron, which, if not modified and used, will pollute the environment, result in waste of resources, and even pose a safety hazard. With the higher and higher requirements for energy conservation in building, ordinary ceramsite produced in China can no longer meet the requirements of market products for a substrate. There is an urgent need for a lightweight and high-strength ceramsite used as a basic raw material on the market. Ceramsite is widely used in roof insulation; toilet backfilling; ceramsite concrete pillars, beam aggregates, and self-insulation blocks with a tongued joint in earthquake-prone areas; anacoustic zones on roads; sound insulation of high-speed rail ground and anacoustic zones along the line; sponge cities; sewage treatment; landscaping; and the like. However, most of the ceramsite products currently are produced by subjecting clay or shale, china clay and the like to sintering, which will cause serious damage to vegetation and clay resources. Moreover, most of the ceramsite products are produced by a coal-fired rotary kiln, which will cause air pollution due to the exhaust gas emitted from the high chimney. The heavy metals with a low boiling point in the raw materials, such as mercury and arsenic, are not recycled, and thus pose serious pollution to the surrounding area, which affects the human health and destroys the biological chain.
Based on the requirements of environmental protection, the inventors preferably prepare a novel lightweight and high-strength ceramsite using a variety of typical bulk inorganic solid wastes (sand-washing waste, iron-washing waste, manganese slag and the like) and a modifier that is added to change the chemical principle support of the internal network structure of ceramsite and the surface structure foundation.
In view of the problems that the lightweight ceramsite in the prior art tends to have low strength, and the production of the existing ceramsite has long relied on raw materials of clay or shale, the present invention provides a lightweight and high-strength ceramsite and a preparation method thereof.
The present invention has the following technical solution.
The present invention provides a lightweight and high-strength ceramsite, where, the ceramsite is spherical, and has a diameter of 3 mm to 20 mm, a strength > 1.5, a mass of 350 kg± kg/m 3, and X < 0.10 w/m-k; the raw materials for producing the ceramsite include inorganic solid wastes accounting for more than 95%; and the inorganic solid wastes include sand-washing waste, iron-washing waste and slag.
Further, the raw materials also include an additive accounting for less than 5%; and the additive is a mixture of one or two of sodium salt and potassium salt (namely, sodium salt and/or potassium salt) with manganese salt.
Further, the sodium salt and/or potassium salt and the manganese salt have the following contents in all raw materials, in mass percentage:
sodium salt and/or potassium salt: 0.5% to 1%, and manganese salt: 2% to 4%.
Further, the sodium salt is preferably sodium chloride; the potassium salt is preferably potassium chloride; and the manganese salt is preferably manganese carbonate.
Further, the sand-washing waste, iron-washing waste and slag in the inorganic solid wastes have a total mass accounting for more than 95%; and the sand-washing waste, iron-washing waste and slag have a mass ratio of (2.6-3.5):(1.8-2.1):(1.2-2.8).
Further, the sand-washing waste is sand-washing waste produced during the washing process of hill sands in areas without river sands, sewage treatment waste, or sludge in a lake/pond.
Further, the iron-washing waste is the iron-washing waste produced during the water separation for iron ores.
Further, the slag is one or more of kaolinite tailings, china clay slag and manganese slag. In the case where the slag is manganese slag, since the slag itself includes manganese salt, the manganese salt in the additive is added at an amount based on the amount of manganese salt in the slag, and if the amount of manganese salt in the slag is adequate, no additional manganese salt is added.
The present invention also provides a method for preparing the lightweight and high-strength ceramsite, including the following steps:
(1) preparing the raw materials according to the above ratio and drying the obtained mixture;
(2) stirring the mixture, and subjecting the mixture to ball-milling and then granulation; and
(3) conducting multi-step sintering.
Further, the method also includes exhaust gas recovery after the sintering.
Further, in step (1), the drying is conducted at 120°C to 150°C.
Further, in step (2), the ball-milling is conducted until the mixture has a fineness of 100 mesh to 150 mesh; and the granulation is conducted by sprinkling granulation, extrusion moulding or other moulding methods, and the process is fully automatic.
Further, in step (3), the multi-step sintering includes low-temperature sintering and high temperature sintering; the low-temperature sintering is conducted at 200°C to 400°C for 30 min to 33 min; and the high-temperature sintering is conducted at 950°C to 1,100°C for 10 min to 12 min.
The present invention has the following beneficial effects:
(1) The present invention adopts raw materials with inorganic solid wastes accounting for more than 95%, which realizes the comprehensive utilization of solid wastes, significantly reduces the production cost of ceramsite, and solves the problem that the production of the existing ceramsite has long relied on raw materials of clay or shale.
(2) The present invention solves issues, such as high fineness, heavy weight, and insufficient compressive strength for ceramsite.
(3) The present invention solves the problem that the small ceramsite used as a raw material for producing noise-absorbing boards of high speed rail is currently dependent on imports, resulting in high price and inconvenient transportation.
(4) The present invention sets an example for the modification and intensive utilization of various inorganic fine solid wastes in the Yangtze valley.
(5) The present invention provides a novel environmentally-friendly ceramsite-sintering process.
(6) The present invention seeks to achieve the recovery and utilization of heavy metals in exhaust gas.
(7) The present invention uses coal gas as a fuel, which can effectively decrease the energy consumption, lower the cost by 30% compared with the direct coal combustion, and efficiently reduce the emission of sulfur dioxide.
(8) The product of the present invention has X < 0.10 w/m-k, which can achieve effects of sound insulation and energy conservation, and thus can completely replace the imported products.
(9) The present invention can ensure the foaming and expansion of the ceramsite during the high-temperature sintering through the mutual coordination of all components and the addition of an appropriate amount of additive, thereby effectively improving the supporting force of the network framework inside the ceramsite, and providing a core basic raw material for high-quality self-insulation blocks.
FIG. 1 is a diagram illustrating a pile of iron-washing waste used in the present invention.
FIG. 2 is a diagram illustrating a pile of sand-washing waste used in the present invention.
FIG. 3 is a diagram illustrating a pile of manganese slag used in the present invention.
FIG. 4 is a diagram illustrating the construction site for the premixing procedure.
FIG. 5 is a diagram illustrating the construction site for the feeding procedure.
FIG. 6 is a diagram illustrating the construction site for the stirring procedure.
FIG. 7 is a diagram illustrating the construction site for the granulation procedure.
FIG. 8 is a diagram illustrating the construction site for the sintering procedure.
FIG. 9 is a diagram illustrating different states of the ceramsite obtained in the present invention.
The present invention is further described in detail below with reference to specific examples, but is not limited thereto.
Example 1
A lightweight and high-strength ceramsite was prepared using the following raw materials:
400 kg of sand-washing waste, 300 kg of iron-washing waste, 270 kg of kaolinite tailings, 8 kg of sodium chloride, and 22 kg of manganese carbonate.
Example 2
A lightweight and high-strength ceramsite was prepared using the following raw materials:
450 kg of sand-washing waste, 300 kg of iron-washing waste, 210 kg of kaolinite tailings, 7 kg of potassium chloride, and 33 kg of manganese carbonate.
Example 3
A lightweight and high-strength ceramsite was prepared using the following raw materials:
430 kg of sand-washing waste, 300 kg of iron-washing waste, 220 kg of kaolinite tailings, 6 kg of sodium chloride, 4 kg of potassium chloride, and 40 kg of manganese carbonate.
Example 4
A lightweight and high-strength ceramsite was prepared using the following raw materials:
440 kg of sand-washing waste, 310 kg of iron-washing waste, 200 kg of kaolinite tailings, 3 kg of sodium chloride, 3 kg of potassium chloride, and 45 kg of manganese carbonate.
The lightweight and high-strength ceramsite samples in the above examples were prepared by the following steps:
(1) the raw materials were prepared according to the ratio in the above example, and then the obtained mixture was dried at 120°C to 150°C;
(2) the mixture was stirred, subjected to ball-milling to have a fineness of 100 mesh to 150 mesh, and then granulated by sprinkling granulation or extrusion moulding; and
(3) the multi-step sintering was conducted, where, the low-temperature sintering was conducted at 200°C to 400°C for 30 min to 33 min; and the high-temperature sintering was conducted at 950°C to 1,100°C for 10 min to 12 min.
The products obtained in the above examples are all lightweight and high-strength ceramsite products with excellent performance. These products were tested. The test results for the product obtained in Example 1 are as follows: bulk density: 425 Kg/m 3 ; compressive strength of concrete cylinder: 1.6 Mpa; water absorption rate within 1 h: 6.8%; softening coefficient: 0.96; internal radiation index: 0.2; and external radiation index: 0.4.
The test results for the products obtained in other examples are as follows.
Test item Test Unit Remarks data
Grade 4-8 mm sphere
Type of the shape of the material expanded clay ball
Geometric properties
Particle size of aggregates 4-8 mm
Ash content 1.5 mm
Physical properties
Bulk density 350+30 Kg/cm
Apparent density 610±50 %
Water absorption rate within 1 h 12+4 % soaking in water for 60 min
Maximum water absorption rate 18+4 % soaking in water for 24 h
Compressive strength of concrete Comprssivstrenthof>1.5 n/mm 2 compacting by shaking and pesn cylinder pressing
Mass loss after a freezing-thawing cycle < 2.0 %
Chemical properties
Chloride <0.02 %
Soluble acid < 0.8 %
Total sulfur < 1.0 %
Chemical composition
Silicon dioxide 55+5 %
Aluminum oxide 24+5 %
Ferric oxide 14+5 %
Calcium oxide 5±5
% Trace element 2+2
% Other properties
Thermal conductivity 0.10 w/(m-k)
Refractoriness Al
Claims (5)
1. A lightweight and high-strength ceramsite, wherein, the ceramsite is spherical, and has a diameter of 3 mm to 20 mm, a strength > 1.5, a mass of 350 kg 30 kg/m3 , and X< 0.10 w/m-k; the raw materials for producing the ceramsite comprise inorganic solid wastes accounting for more than 95%; and the inorganic solid wastes comprise sand-washing waste, iron-washing waste and slag.
2. The lightweight and high-strength ceramsite according to claim 1, wherein, the raw materials further comprise an additive accounting for less than 5%; and the additive is a mixture of one or two of sodium salt and potassium salt (namely, sodium salt and/or potassium salt) with manganese salt; wherein, the sodium salt and/or potassium salt and the manganese salt have the following contents in all raw materials, in mass percentage:
sodium salt and/or potassium salt: 0.5% to 1%, and manganese salt: 2% to 4%; wherein, the sodium salt is sodium chloride; the potassium salt is potassium chloride; and the manganese salt is manganese carbonate.
3. The lightweight and high-strength ceramsite according to claim 1, wherein, the sand washing waste, iron-washing waste and slag in the inorganic solid wastes have a total mass accounting for more than 95%; and the sand-washing waste, iron-washing waste and slag have a mass ratio of (2.6-3.5):(1.8-2.1):(1.2-2.8);
wherein, the sand-washing waste is sand-washing waste produced during the washing process of hill sands in areas without river sands, sewage treatment waste, or sludge in a lake/pond; the iron-washing waste is the iron-washing waste produced during the water separation for iron ores; and the slag is one or more of kaolinite tailings, china clay slag and manganese slag, and in the case where the slag is manganese slag, since the slag itself comprises manganese salt, manganese salt in the additive is added at an amount based on the amount of manganese salt in the slag.
4. A method for preparing the lightweight and high-strength ceramsite according to any one of claims 1 to 3, comprising the following steps:
(1) preparing the raw materials according to the above ratio and drying the obtained mixture;
(2) stirring the mixture, and subjecting the mixture to ball-milling and then granulation; and
(3) conducting multi-step sintering.
5. The method for preparing the lightweight and high-strength ceramsite according to claim 4, wherein, the method also comprises exhaust gas recovery after the sintering; wherein, in step (1), the drying is conducted at 120°C to 150°C; in step (2), the ball-milling is conducted until the mixture has a fineness of 100 mesh to 150 mesh; and the granulation is conducted by sprinkling granulation, extrusion moulding or other moulding methods, and the process is fully automatic; wherein, in step (3), the multi-step sintering comprises low-temperature sintering and high temperature sintering; the low-temperature sintering is conducted at 200°C to 400°C for 30 min to 33 min; and the high-temperature sintering is conducted at 950°C to 1,100°C for 10 min to 12 min.
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| AU2020102253A AU2020102253A4 (en) | 2020-09-15 | 2020-09-15 | Lightweight and high-strength ceramsite and preparation method thereof |
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| AU2020102253A AU2020102253A4 (en) | 2020-09-15 | 2020-09-15 | Lightweight and high-strength ceramsite and preparation method thereof |
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| CN114368962A (en) * | 2022-01-27 | 2022-04-19 | 中钢集团马鞍山矿山研究总院股份有限公司 | Preparation method of iron tailing ceramsite filter material for wastewater treatment |
| CN115043625A (en) * | 2022-06-23 | 2022-09-13 | 潍坊纵横建材有限公司 | Porous high-expansion ceramic sand anti-cracking agent for concrete and preparation method thereof |
| CN115073206A (en) * | 2022-06-09 | 2022-09-20 | 昆明理工大学 | Preparation method of composite ceramsite capable of simultaneously preparing biochar and ceramsite |
| CN115093200A (en) * | 2022-06-07 | 2022-09-23 | 中化地质矿山总局地质研究院 | Reinforced electrolytic manganese slag sintered brick and preparation method thereof |
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| CN115043625A (en) * | 2022-06-23 | 2022-09-13 | 潍坊纵横建材有限公司 | Porous high-expansion ceramic sand anti-cracking agent for concrete and preparation method thereof |
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| CN115180972A (en) * | 2022-09-09 | 2022-10-14 | 山东高速环保科技有限公司 | Preparation method of light sewage treatment material |
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| CN115974525B (en) * | 2023-01-12 | 2023-10-27 | 重庆聚源塑料股份有限公司 | Light ceramsite and preparation method and application thereof |
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