CN100450967C - High strength calcium sulfate cotton fiber plate and its producing process - Google Patents

Abstract

The high strength calcium sulfate-cotton fiber plate is produced with calcium sulfate and cotton fiber as main material, and its material consists of calcium sulfate75-95 weight portions, waste cotton fiber 5-25 weight portions, water 20-30 weight portions, coagulating agent 0.1-1weight portion, retarder 0.1-1 weight portion, and waterproof agent 0.1-3 weight portions. The high strength calcium sulfate-cotton fiber plate has the production process includes the steps of: dry mixing fiber with gypsum powder, spraying compounded supplementary material, spreading, high pressure forming, cutting and hydration to settle. The present invention has waste material utilized, low production cost, and product performance similar to available gypsum plate.

Description

High strength calcium sulfate cotton fiber plate and manufacturing process thereof

Technical field

The present invention relates to calcium sulfate cotton fiber plate and manufacturing process thereof, belong to building material technical field.

Background technology

In the prior art, the partition wall that uses in the building, decorative stone cream fiberboard is numerous in variety, structure is different; Strengthen plasterboard and Thistle board etc. if any fibrous plaster, gypsum particle board, calcium silicate board, glass.Its market demand is quite big, but manufacturing enterprise's profit of sheet material is very low.Its reason is that existing gypsum board manufacture Technology almost also rests on the period fifties, and equipment manufacturing cost is constantly soaring; Article one gypsum particle board production line built up in Finland in 1986 in the world, and annual production is 4 ten thousand steres; Became to build up second gypsum particle board production line in the world moving in 1988, annual production is 6 ten thousand steres.China Shandong Province builds up the Cangshan County Chinese first hand gypsum particle board production line, and equipment is all introduced, about 200,000,000 yuan of gross investment, and Inner Mongol Dongsheng City adopts home equipment to build up the gypsum particle board and the cement-bonded wood chipboard combined production line of 1.5 ten thousand steres.1.5 hundred million yuan of equipment funds; Hubei Xiaogan victory is materials for wall company limited not, invests more than the 3000 ten thousand yuan of annual output of building up 3,000,000 square meter device fabrication lines, and the German striate gypsum board assembly line of introduction is the comparatively advanced production technology nineties; The production technology that it is above, employing still be natural matter and the traditional slurry wet method or the production method of semidrying, product cost is quite high, capital fund is surprisingly high;

At first, in the use of main raw material, do not change and innovation, the still plaster of paris that raw material adopts mostly is main, and it is main that auxiliary material adopts wood fibre mostly; Secondly slurry method production is particularly adopted in also not innovation on production technology, causes that energy consumption is big in process of production, the corresponding height of facility investment, but and the corresponding problems such as little of industrial scale have caused direct operating cost high for a long time.

More than various gypsum sheet materials, its production method has uses pouring forming technology, have with slurry flowing process compacting dehydration moulding process, the usefulness that has is copied the slurry method and is produced.The major cause that the board materials production expense is high; Slurry method (wet method) fiber pulp will consume a large amount of power and waters, and the drying power consumption, the particularly sewage of Chan Shenging of back operation exist secondary pollution to handle in addition; Therefore, there is the problem that many needs solve in existing production technology.

Now will have the technological line of gypsum fiber sheet material at present now, do following analysis:

A: produce the starting material aspect:

(1) plaster of paris is a basic raw material;

(2) be stiffening web with wood fibre or glass fibre, to improve intensity.

B: production method aspect:

After natural dihydrate gypsum calcining pulverizing, make semi-hydrated gypsum powder; Will (or) timber or cardboard be processed into fiber pulp; Additive with after water cooperates, is mixed with fiber pulp, again terra alba is put into, stir jointly; Adopt slurry flowing process or copy slurry method production (being wet production) and become base; Compacting dehydration moulding; After the dry evaporation of the water of affluence, obtain the product plasterboard.

C: product structure aspect:

(1) fiber mixes with terra alba is unordered; I.e. " fibrous plaster ";

(2) between glass fiber net interlayer or two between interlayer; I.e. " enhancing surface fiberglass gypsum plate ";

(3) gypsum and blending in of fibers are the middle layer, and paper is on the two sides; I.e. " Thistle board ";

Understand existing gypsum board manufacture technology, can find that there are following problems in prior art:

1, raw material problems:

All be to be raw material with the plaster of paris and wood fibre wood shavings or cardboard fiber, raw material is gathered and processed difficulty, and the cost height, and course of processing energy consumption is big; Do not utilize cheap chemical gypsum, the raw material valency is high;

2, the problem of board materials production making processes:

Problem 1): slurry method (wet method) is produced, and fiber pulp need consume a large amount of power and waters; The particularly cardboard slurrying of Hui Shouing must be soaked, be pulled an oar, cleans the silt in the fiber pulp, produces sewage and has secondary pollution;

Problem 2): be difficult to get hold of the concentration of fiber pulp, get hold of the flowability of slurry; Contain additive in the recirculated water of manufacturing processed, can influence and re-use quality;

Problem 3): when terra alba and fiber pulp stirring, can twine a lot of fibers on the stirrer, the dead angle meeting accumulation of stirrer is the raw material of saturation water too, must constantly clear up; Supplementary material can not accurately be filled a prescription, unstable product quality, and be unfavorable for continuous production;

Problem 4): fiber is after long bubble system, and its matter is soft, and intensity is influenced;

Problem 5): water saturated fiber, after mixing and stirring moulding, can influence the aquation of plasterboard with semi-hydrated gypsum, the intensity of plate reduces;

Problem 6): after semi-hydrated gypsum is met water in advance, can shift to an earlier date gelling, reduce the intensity of plate;

Problem 7): the plate of wet method compression moulding, its amount of moisture are the several times of whole level product plate aquation amount, must consume a large amount of heat energy, its evaporation drying could be fallen;

Problem 8): production unit is huge, and a year scale is produced 2,000,000 square meters, and the required equipment capital quantity is minimum at 2,000 ten thousand Renminbi; The installation electric weight is not less than 800-1200KW; The product direct operating cost is high naturally;

Problem 9): the cost of supplementary product height: as: 1100 yuan/ton of wooden bifurcation branch material valencys, reclaim the cardboard valency: 1200 yuan/ton.

Problem 10) plate structure influences intensity: fiber is unordered mixing in terra alba; Must influence intensity.

In addition, the patent application of disclosed relevant plaster board is a lot, such as Chinese patent 96118317.9; 01104166.8; 02202232.5; 00236591.X; 96192771.2; 97114128.2; 99118576.5; 98801196.4 or the like, all creativeness solves above-mentioned basic problem.

Summary of the invention

At the prior art above shortcomings, the objective of the invention is to propose that a kind of cost is low, intensity is high, manufacturing process is succinct and the high strength calcium sulfate cotton fiber plate of less investment and manufacture method thereof.

Can realize purpose of the present invention by the following technical solutions:

The formation of high strength calcium sulfate cotton fiber plate: by one of (1) main raw material is calcium sulfate (another name: gypsum): comprise chemical gypsum, the plaster of paris, desulfurated plaster, phosphogypsum, fluorgypsum etc.; Its industrial waste residue gypsum general designation chemical gypsum; (2) two of main raw material is cotton fibre: be to be used further to weaving in a kind of caused by spinning industrial production, i.e. and the workshop airborne dust that weaving is produced, waste cotton recycled fiber; Pulverize the conjugated fibre that reclaim the back with waste and old cotton spinning goods;

With retardant, setting accelerator, water-resisting agent and moisture content is composition; Its prescription is as follows: calcium sulfate 75-95 part, waste cotton fiber 5-25 part, moisture 20-30 part, setting accelerator 0.1-1%, retardant 0.1-1%, water-resisting agent 0.1-3%.

Its constructional feature is that calcium sulfate combines formation with cotton fibre; Its sheet material is by upper and lower thin top layer, and middle more coarse layer is formed, and the middle layer is made up of thick cotton fibre and thick sulfuric acid calcium powder, and upper and lower upper layer is to be made of fine-fibered and thin sulfuric acid calcium powder.

Perhaps, described sheet material is combined with cotton fibre by the sulfuric acid calcium powder of even thickness and forms, and makes that calcium sulfate and fibre orientation are equally distributed to be combined.

Or described sheet material is that the sulfuric acid calcium powder and the cotton fibre of thickness grading structure constitutes, the excessive naturally be combined into of combined type.

Further improving is that plate surface is provided with watermark wood grain or glue decorated surface woodgrained paper structure.

The present invention from what composition of raw materials, structure composition and processing method were innovated is: with calcium sulfate, waste cotton recycled fiber the like waste is main raw material, adopt absolutely dry method (promptly dried fiber dry gesso) to produce, solved the various difficult problems that aforementioned plasterboard wet production (slurry method) causes.

Compared to existing technology, the present invention has following advantage:

1, utilize refuse material such as calcium sulfate or chemical gypsum, waste cotton recycled fiber to make starting material, production cost is extremely low, and efficiently solves the problem that re-uses of refuse.

2, adopt " absolutely dry material working system " to produce, absolutely dry method production is that waste cotton or paper fiber are carried out dedusting and resolve into individuality, in cellulolytic while, with the dispersive individual fibers, quantitatively also transports equably to the dry gesso in the stirrer; And the aqueous solution of working good by matching, the stirring of spraying.What solved long-term puzzlement people is medium (wet method) by water, fiber dispersion is become a difficult problem of admixing again behind the individuality in the terra alba;

3, suppress closely knit plate continuously, the degree of compactness of its plate can reach 1.0-2.5 gram/CM3; And surfacing is smooth, thickness difference＜0.1mm; Its equipment is simple and direct, and is reliable.Solved in the plasterboard Fibreboard Production, with the large equipment interruption production problem of large flat press.

4, in the structure of product of the present invention, in the two top layer 1mm waterproof layer that adds water-resisting agent; Neither influence the intensity of plate, saved water-resisting agent again, solved in the plasterboard whole add water-resisting agent after, make the intensity of plate reduce problem.

5, production method of the present invention has discarded the dry again of back operation, also the sanding of operation afterwards.

6, the product that the present invention produced meets national every technical requirements and phosphogypsum building materials environmental protection requirement fully.

7, facility investment required for the present invention is few, and energy consumption is little, and the products production cost is extremely low, and production process is to the environment non-secondary pollution, and the product plate of producing all reaches the requirement of national environmental protection building materials.Help in medium-sized and small enterprises and private business, being developed.

Description of drawings

Fig. 1 is the first embodiment of the invention structural representation;

Fig. 2 is the second embodiment of the invention structural representation;

Fig. 3 is novel the 3rd embodiment structural representation of invention.

Embodiment

A: Production Flow Chart and equipment: be example here with the chemical gypsum;

1) handles the waste residue chemical gypsum: promptly handle with the air-flow tumble dryer;

2) cooling: promptly use the totally-enclosed water cooler; Cooling surface 250m ²

3) sub-sieve: three layers of reciprocating sieve;

4) all store up homogenizing: storage tank 25T-4 platform; Recycle;

5) fiber dispersion; With dried fiber dust removing, disperse and transport;

6) metering, stirring: post-type mixer, twin shaft material casting stirrer, electronics metering conveyer, electronics metering water conveying machine;

7) the Fixed width fixed structure is mated formation: two-way porcupine roller machinery subtend is mated formation;

8) compression moulding: double roller bevel-type continuous press, linear pressure is 50-500 kilogram/cm;

9) deburring cutting: portraitlandscape cutting machine;

10) the overlapping interlayer stacking that adds of machinery: in the mechanical stack plate, add sealing coat;

11) constant temperature aquation: the constant temperature stacking is quiet to be put;

12) packing warehouse-in: machinery is abandoned interlayer, overlapping 100 simultaneously/buttress warehouse-in;

This plate need not dry, sanding, can guarantee the thickness and the planeness of plate.

B: production technique: (following) by the flow sequence narration

1) processing of chemical gypsum raw material:

The two water chemistry gypsum of stacking (being phosphogypsum) are detected, promptly classify by calcium contents, moisture content, pH value, color etc., by a batch adjustment operation, calcine drying, (not washing with water) removed main detrimental impurity aborning and obtained raw material.Promptly under 160-500 ℃, discard attached water, thereupon oxidation and charing phosphorus, fluorine, acid; Crystal water is remained to the amount of 2/5-3/4;

2) water cooling: feeding temperature 160-200 ℃, drop temperature 25-45 ℃; Dry mash can not combine with the air that moisture is arranged when cooling, and is constant moving to guarantee the due crystallization water yield of dry powder;

3) reciprocating sieve: the i.e. double-deck hermetically sealed reciprocating sieve of 100 orders;

4) all storages: promptly in 25T * 4 jar, recycle, guarantee that powder finishes all storageizations.

5) fiber dispersion machine: the waste cotton fiber is carried out dedusting and resolves into individuality, simultaneously the individual fibers equal and quantitative is also synchronously transported to stirrer;

6) the siccative twin shaft stirs: be about to cotton fibre and chemical gypsum powder is quantitative stirs in stirrer, will spray stirring by the composition that retardant, setting accelerator, water prepare simultaneously.The ratio of retardant, setting accelerator, the two use is to allocate according to the time needs of production line processing.Concrete prescription: chemical gypsum powder 80-95 part; Waste cotton fiber 5-20 part; Retardant 0.1-2 part; Setting accelerator 0.1-3 part; Water 18-30 part;

7) slab of mating formation: the material that stirs through putting down, awards the following tape transport of constant speed again by the relative material casting of crosspointer roller under the condition of dosing, forms the loose slab of structure-type; The top layer water-resisting agent is the 0.1-3 part of using separately.By the independent comb deals base to paving, its top layer and bottom carry out the mode of surface spraying, and water-resisting agent evenly in the top layer of plate, is present among the 0.5-1.5mm on plate top layer, form folder powder waterproof layer.

8) compression moulding: the slab of formation is pressed and the pressure-sizing compacted under giving of double roller, and reaches required thickness, in thickness difference ± 0.1mm.Long is endless.

9) deburring and cutting: when the plate after the pressure-sizing when the pallet by deburring, be cut, its width, length guarantee in ± 0.1mm.

10) constant temperature aquation: quiet putting behind the overlapping interlayer stacking of machinery, temperature are controlled at 20 degree or 25 degree or 30 degree, and atmospheric moisture is under 10% condition, and wind speed must not be stablized the storehouse temperature faster than 1 meter/s, leaves standstill then; Time of repose must not be early than 12 hours.After treating that aquation is finished, descend operation again.

11) turnover panel packing: after last operation aquation is finished, under the work of plate turnover, remove the interlayer between plate, pack warehouse-in by 100/part.

C: concrete prescription:

Prescription	The sulfuric acid calcium powder	The waste cotton fiber	Retardant	Setting accelerator	Water
						Prescription 1	95	20	2	3	30
Prescription 2	86	18	1.6	2.5	26
						Prescription 3	80	15	0.5	0.6	22
Prescription 4	75	5	0.1	0.1	20.5

The top layer water-resisting agent is the 0.2-3 part of using separately.

Described calcium sulfate can be the plaster of paris, phosphogypsum, desulfurated plaster or fluorgypsum.

Retardant adopts polyvinyl alcohol solution; Setting accelerator adopts sodium formate solution; Water-resisting agent adopts the water-soluble metasilicate series product to get final product.

Embodiment 1: as shown in Figure 1, the high strength calcium sulfate cotton fiber plate is a base material with the industrial residue chemical gypsum, makes stiffening web with cotton fibre; Its sheet material is by upper and lower thin top layer 1, and the center is that more coarse layer 2 is formed, and middle layer 2 is to add condensing agent by thick cotton fibre and alligatoring terra alba to form, and upper and lower upper layer 1 is to be added to suppress after water-resisting agent adopts machinery to mat formation by fine-fibered and fine gypsum to form again.Described fineness degree is that 100-450 purpose raw material is a benchmark.Plate surface is covered with watermark wood grain or glue decorated surface woodgrained paper structure 3.

Its overall dimensions are made plurality of specifications as required, as: long 2400mm, wide 1220mm, thick 6-15mm; Or: long 3000mm, wide 1200mm, thick 6-15mm or the like.

Embodiment 2: as shown in Figure 2, as different from Example 1, its sheet material is combined with cotton fibre by the chemical gypsum powder of even thickness and forms 4, makes that gypsum and fibre orientation are equally distributed to be combined.

Embodiment 3: as shown in Figure 3, different with the foregoing description is that its sheet material is that the phosphogypsum powder and the cotton fibre of thickness grading structure constitutes 5, the excessive naturally be combined into of combined type.

The present invention adopts absolutely dry method automatic production process to realize.

In the time of with dried waste cotton or the pulverizing of waste and old cotton spinning goods, under the moving gaseouse medium effect, resolve into individuality, the dispersive individuality is quantitatively also transported to the dry gesso that moves in the stirrer by air-flow equably; And the aqueous solution by matching, promptly the water yield of Jia Ruing is the water yield of dihydrate gypsum aquation caking, does not have to give and the unnecessary water yield; The individual surface that makes composition and water adding fiber and terra alba is stirred in spraying, has fixed the position that concerns of fiber and terra alba.The material that stirs through putting down the following tape transport that awards constant speed again by the relative material casting of crosspointer roller, forms the loose slab of structure-type under the condition of dosing; The mode of drenching by the spraying of independent secondary evenly in the middle of the 0.5-1.5mm of the top layer of plate, forms folder powder waterproof layer with water-resisting agent; The slab that forms gives and pressing and the pressure-sizing compacted under, and reach required thickness at the continuous press of double roller, and is wide 1.4 meters in thickness difference ± 0.1mm, and long is endless; Plate after the pressure-sizing during through pallet by deburring, cutting; Quiet putting behind the overlapping interlayer stacking of machinery, temperature are controlled at 20 ℃-30 ℃, and atmospheric moisture is under 10% condition, and wind speed must not be stablized the storehouse temperature faster than 1 meter/s, leaves standstill then; Time of repose is greater than qualitative after 12 hours; Make the chemical gypsum cotton fiber plate closely knit hard.

Calcium sulfate cotton fiber plate must have the gradual change type structure, single layer structure and three-decker; Fiber and phosphogypsum powder in the whole plate are evenly also directed combinations; Thereby reached high strength and surpassed the relevant national standards index.

Its physical chemistry technical indicator after testing:

A: folding strength: e8 〉=15MPa;

B: screw withdrawal force: 〉=150N/mm;

C: density: 1.3g/Cm3

D: hygroexpansivity :≤0.025%

E: water ratio :≤10%

F: radioassay is: 0.25;

G: fluorine content is 0.8mg/L;

H: uninflammability: A level

I: thermal conductivity: 0.29W/M.K.

High strength calcium sulfate cotton fiber plate of the present invention, its facility investment needs only 1,200,000 Renminbi, and a year industrial scale is 3,000,000 square meters, total installed capacity electric weight 120KW, the technological process of production is succinct, all fronts facility compact, the level of automation height, stable.Product cost has only 5.50 yuan/, and (1220/mm * 2440/mm * 6-15), product cost is extremely low for specification; The capability and performance of product is more excellent;

Long 30 meters of equipment, wide 3 meters, equipment takes up an area of 200 square metres; Facility investment is 6% of an import equipment.

The present invention makes main raw material with industrial residue chemical gypsum and waste cotton fiber, replaces natural resources, has played the effect of protection Nonrenewable resources; And, promote the comprehensive utilization aspect of industrial residue in environment protection, can be widely used in building decorating industry, the sheet material of using plate and various furniture to use that internal partition for building and house decoration are decorated.Have tangible society, economic benefit.

Claims (6)

1, high strength calcium sulfate cotton fiber plate is characterized in that by calcium sulfate, cotton fibre be raw material, is composition with retardant, setting accelerator, water-resisting agent and water, the sheet material that combines;

Described calcium sulfate comprises chemical gypsum, the plaster of paris, desulfurated plaster, phosphogypsum or fluorgypsum;

Described cotton fibre is a kind of waste cotton fiber that can not be used further to yarn fabric, the production plant airborne dust of promptly weaving, and the waste cotton recycled fiber, or pulverize the composite cotton fabric fiber of back recovery by waste and old cotton textiles;

Its technical recipe is as follows: sulfuric acid calcium powder 75-95 part, cotton fibre 5-25 part, moisture content 20-30 part, setting accelerator 0.1-1%, retardant 0.1-1%, water-resisting agent 0.1-3%.

2, high strength calcium sulfate cotton fiber plate according to claim 1, it is characterized in that its sheet material is by upper and lower thin top layer (1), middle more coarse layer (2) is formed, and middle layer (2) are made up of thick cotton fibre and thick sulfuric acid calcium powder, and upper and lower upper layer (1) is made of fine-fibered and thin sulfuric acid calcium powder.

3, high strength calcium sulfate cotton fiber plate according to claim 1 is characterized in that described sheet material is combined with cotton fibre by the sulfuric acid calcium powder of even thickness to form, and makes that calcium sulfate and fibre orientation are equally distributed to be combined.

4, high strength calcium sulfate cotton fiber plate according to claim 1, described sheet material are that the sulfuric acid calcium powder and the cotton fibre of thickness grading structure constitutes, the excessive naturally be combined into of combined type.

5,, it is characterized in that described plate surface is provided with watermark wood grain or glue decorated surface woodgrained paper structure (3) according to claim 2,3 or 4 described high strength calcium sulfate cotton fiber plates.

6, high strength calcium sulfate cotton fiber plate manufacturing process is characterized in that adopting absolutely dry method production, comprises the steps:

1) calcium sulfate of stacking is detected, under 160-500 ℃, discard attached water, thereupon oxidation and charing phosphorus, fluorine, acid; Crystal water is remained to the amount of 2/5-3/4, send in the stirrer and stir;

2) in the time of with dried waste cotton or the pulverizing of old cotton spinning goods, under the moving gaseouse medium effect, resolve into individuality, dispersive is individual quantitatively also to be transported to dynamic dry gesso in the stirrer by air-flow equably; And filling is the aqueous solution of composition by retardant, setting accelerator, water-resisting agent and water, and water-soluble liquid measure is the 20-30% of calcium sulfate and the total deal of fiber, promptly just satisfies the aquation amount of fiberboard; Spraying is stirred and to be made composition and water join a fiber and a vitriolic surface, anchoring fiber and calcium sulfate concern the position;

3) material that stirs passes through the relative material casting of crosspointer roller to the following tape transport of constant speed again after putting down under the condition of dosing, form the loose slab of structure-type;

4) by independent secondary spraying mode, make water-resisting agent in the top layer of plate, be present in the degree of depth of plate top layer 0.5-1.5mm, form folder powder waterproof layer; The slab that forms is at the precompressed and the pressure-sizing compacted under of double roller, and reaches required thickness, in thickness difference ± 0.1mm;

5) plate after the pressure-sizing when the pallet by deburring, cutting;

6) quiet putting behind the overlapping interlayer stacking of machinery, temperature is controlled at 20 ℃-30 ℃, and atmospheric moisture is under 10% condition, and wind speed must not leave standstill then faster than 1 meter/s; Time of repose is greater than qualitative after 12 hours.

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