CN100595176C - Method of producing archaistic brick by low-temperature sintering - Google Patents
Method of producing archaistic brick by low-temperature sintering Download PDFInfo
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- CN100595176C CN100595176C CN200610037066A CN200610037066A CN100595176C CN 100595176 C CN100595176 C CN 100595176C CN 200610037066 A CN200610037066 A CN 200610037066A CN 200610037066 A CN200610037066 A CN 200610037066A CN 100595176 C CN100595176 C CN 100595176C
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- temperature sintering
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Abstract
The invention discloses a production method for archaizing bricks by low-temperature sintering. The method comprises using cullet as a major raw material, sodium tripolyphosphate (Na3P5O10) as a secondary raw material, and other other low-priced ceramic raw materials, and producing archaizing bricks suitable for one rapid firing (burning time of 55 minutes and firing temperature <= 900DEG C). Theraw materials comprise: waste glass 42-60%, cooked bauxite 18-25%, white mud 15-2%, bentonite 3-8%, sodium tripolyphosphate 5-8%, and pigment 3-4%. The method comprises proportioning the ingredients,ball-milling, sifting, removing iron, spray-drying, pressing and molding, drying, spraying water, proportioning glaze ingredients, ball-milling, sifting and removing iron, aging, spraying transparentglaze, washing edge, sintering, grinding edge, separating, and packaging. The invention has the advantages of low energy consumption and low cost.
Description
Technical field
The present invention relates to a kind of production method of polished tile modelled after an antique, specifically relate to adopt compound plasticising and low-temperature sintering to produce the Technology of polished tile modelled after an antique, this method is suitable for the brickwork technology modelled after an antique that roller kiln once burn till fast.
Background technology
At present, domestic and international mass production and widely used architectural pottery goods, firing temperature is all more than 1150 ℃ in its production process, the firing temperature of low water absorption product (as polished tile) especially up to 1200 ℃ about, brick firing temperature modelled after an antique before our company is 1180 ℃, Building Ceramics Industry has become one of big power consumer in the national economy. because over nearly 20 years, the price continuous rise of oil, electricity, combustion gas and coal is also suppressing developing rapidly of architectural pottery industry.Domestic many architectural pottery industries cause product price to raise up because energy consumption cost is high, have reduced the market competitiveness; Also have some enterprises owing to digesting have to dwindle the gradually production of architectural pottery of the surging cost problem of energy prices.Therefore, energy-saving and cost-reducing, control cost, seek profit margin and become Building Ceramics Industry mainly assault fortified position direction and top priority.
Analyze theoretically, the energy saving way that architectural pottery is produced is a lot, as improve the mill efficiency of ball mill, shorten the ball milling time to reduce power consumption, the sealing property of strengthening kiln reduces heat leakage, kiln inwall brush SPECIAL MATERIAL strengthens thermal radiation, make full use of the equal energy that can save preciousness such as waste heat of kiln, but the most basic, the simplest and the most direct, energy-conservation maximum method still reduces the firing temperature of product.We know the ways such as fineness that adopt effective flux or improve raw material, can be to a certain extent the firing temperature of base substrate be reduced, but can cause formulation cost sharply to raise up again simultaneously, and the processing power consumption sharply rises, and this method cooling extent is little.Because with existing sintering theory makes that blank Densification must make that each component in the base substrate is decomposed, complex physico-chemical such as chemical combination and fusion generate some amount liquid phase, fill the space in the base substrate, and the temperature that above-mentioned reaction takes place has all surpassed 1050 ℃, so the firing temperature of base substrate can not be lower than 1100 ℃.Although the various countries researchist reduces high temperature composition (SiO in the base substrate on development low temperature fast firing method in recent years as far as possible
2, Al
2O
3) content, increase flux content (RO, R
2O) content, so that in sintering process, produce enough liquid phases, allow the liquid phase adsorption particle, discharge pore, make extrudate density reach maximum, volume arrives minimum, and goods are able to tight burning, but the energy consumption of the ceramic tile per kilogram product that makes so still needs the 6-10 megajoule, if think significantly to reduce again firing temperature, cut down the consumption of energy, reduce production costs, shown unable to do what one wishes with existing sintering theory.
Summary of the invention
The object of the present invention is to provide a kind of can the reduction greatly to burn till energy consumption, the method that compound plasticising of the employing that reduces production costs and low temperature sintering technology are produced brick modelled after an antique.
The present invention realizes above-mentioned purpose by following technical solution:
A kind of method that adopts low-temperature sintering to produce brick modelled after an antique, it is characterized in that, this method is as main flux raw material with cullet, with tripoly phosphate sodium STPP as less important flux raw material, be aided with other ceramic raw material, once burn till fast during in firing temperature≤900 ℃ through roller kiln, prescription is formed as follows by weight percentage: cullet 42～60%, calcined bauxite 18～25%, white clay 15～20%, wilkinite 3～8%, tripoly phosphate sodium STPP 5～8%, colorant 3～4%; The concrete chemical constitution of its composition of raw materials comprises by weight percentage: Al
2O
352～60%, SiO
223～26%, Fe
2O
30～1%, CaO6～8%, MgO0.5～1.0%, KNaO8～10%;
Preparation technology's flow process of the present invention is: blank batching → ball milling → sieve, deironing → spraying drying → old → compression moulding → drying → water spray → glaze batching → ball milling → sieve, deironing → old → spray transparent → side washing → burn till → edging → sorting → packing.
Also can increase multiple softening agent and ionogen in the above-mentioned prescription, to increase the plasticity-of blank; The softening agent prescription is algae substances JA 0.05～0.2%, polysaccharide HS 0.1～0.3%, Sodium salts humic acids 0.1～0.3%.
Transparent in the described method steps, its prescription consists of: the wear-resisting clear frit 92～95% of low temperature, smart kaolin 5～8%, tripoly phosphate sodium STPP 0.3%, methyl 0.1%.
Described powder is old to be 1～3 day; Firing time is 55 minutes.
Adopt the technological merit of the production brick modelled after an antique of above-mentioned formula constituent and method to be,
1. it will reduce greatly and burn till energy consumption, reduce production costs.Introduce according to preceding former Soviet Union data, firing temperature is represented the available F formula of the influence of fuel consumption:
F＝100-0.13(t
2-t
1)
F is a temperature t in the formula
1The time unit burnup and t
2The time the ratio (%) of unit burnup, by following formula as can be known, when other condition is identical, 100 ℃ of the every reductions of temperature of combustion, the burnup of unit goods reduces about 13%.
Utilize the architectural pottery product of " accurate non-reaction " (low-temperature sintering) sintering theory production to reduce about 300 ℃ than existing like product firing temperature, according to the aforementioned calculation formula, according to conservative measuring and calculating, the burnup of unit goods can reduce by 39%.Producing architectural pottery per year with existing company industrial scale is example for 2,600,000 square metres, 3,300,000 liters of year oil consumptions, and the fuel oil unit price is 4 yuan/liter.After using the technology of the present invention, Spring Festival holidays oil mass is: ten thousand liters of 3,300,000 * 39%=128.7, and the computed monetary value of payments made in securities or in kind is ten thousand yuan of 128.7 ten thousand * 4=514.8, deducts and introduces the cost that softening agent increases in the prescription, annual full company actual reduction fuel cost is about 5,000,000 yuan.
In addition, the expenses such as replacing of the maintenance of kiln, maintenance, depreciation and kiln furnitures all will reduce greatly.
If the present invention is promoted the use of the Foshan City of ceramic industrial base, produce 1500000000 square metres of calculating of architectural pottery at present per year with the Foshan City, then can reduce cost is hundred million yuan of 1,500,000,000/260*500=28.8.So remarkable in economical benefits of the present invention.
2. because oil consumption reduces in a large number, reduced SO to the Nature discharging
2, CO
2, NO
2Deng waste gas, so the favourable urban environment that improves is obvious social benefit of the present invention.The cullet that accounts for domestic waste 5% is originally environmental sanitation departmental head pain thing.Because cullet both non-degradable also can't burn, environmental sanitation department can only landfill, and processing cost per ton reaches 300 yuan, its land occupation resource and destroy the environmental loss that Soil structure brought and more can't estimate.Adopt a large amount of cullet among the present invention, not only saved the processing cost of cullet, and saved a large amount of land resources, therefore, environmental benefit of the present invention is fairly obvious.
The technology of the present invention is fully to study development trend both domestic and external and domestic development status, develop according to domestic market demand, look into new demonstration through technology, market does not have similar technology and exists, belong to the technology that fills the domestic gaps, China's priority construction ceramic decoration industry has developing period faster, the present invention's success, can alleviate the problem of present energy scarcity, therefore have good popularizing application prospect.
Description of drawings
Fig. 1 is a process flow sheet of the present invention;
Fig. 2 is sintering curve figure of the present invention.
Embodiment
The characteristics of utilizing very low temperature flux can be melt into liquid phase under very low temperature match with suitable crystallization composition and make blank, its crystallization composition is except that the decomposition reaction that organic matter, carbonate take place, complicated chemical reaction such as chemical combination, fusion does not take place, so, blank sintering becomes the needed temperature of porcelain to reduce greatly.
The present invention just is being based on above-mentioned one-tenth porcelain mechanism, burn till the work of energy consumption expansion experimental study with regard to how developing very low temperature architectural pottery base substrate with reduction, at first be to carry out the research of very low temperature (≤900 ℃) ceramic formula under the guidance of " accurate non-" reaction (low-temperature sintering) sintering theory, we have by selected starting material: very low temperature flux, high-al clay, plasticity mud, inorganic, toner etc.These materials are played the part of different roles in prescription: very low temperature flux at low temperatures can fusion, forms glassy phase, plays the wedding agent effect; High-al clay provides Al in prescription
2O
3, help forming more mullite, play enhancement; Plasticity mud can increase base substrate plasticity, intensity; The inorganic generation that can promote glassy phase at low temperatures.Toner mainly is meant Cr
2O
3, Fe
2O
3, CoO etc., when easy fired, can form various colourful colors.Formulated multiple formulations by demonstration,, finally determined to adopt: very low temperature flux: 42-60% with after the professional and technical personnel carries out a plurality of shaker tests in the laboratory, high-al clay: 10-25%, plasticity mud: 18-28%, inorganic: 5-8%, the prescription scheme of toner: 3-4%.Because the poor material of introducing in this prescription (very low temperature flux and high-al clay) is up to 70%, the suspension of mud is poor, very easily precipitates, blank strength is lower, and billet yield is low.Can formulate rational technical process and processing parameter be this problem key of success.When the plasticising mechanism of research softening agent, we find: various softening agent have his own strong points based on self constitutional features and action principle, and therefore, certain softening agent of single interpolation is difficult to regulate the rheological property of pug.To improve the pug performance in order regulate comprehensively, to satisfy the later process needs, we make pilot scale smooth by introducing the softening agent and the ionogen of different sorts, different ratios.According to above-mentioned technical process, first batching ball milling, the blowing deironing of sieving again with the mud crushed after being dried, is pressed into ceramic tile, and burns till under 850-900 ℃ temperature, and the product regularity height after burning till, distortion are little.This product is detected at Institutes Of Technology Of Changsha's material laboratory, and the result is as follows: open porosity: 0%; Ultimate compression strength (no glaze): 600Mpa; Bending strength (no glaze): 122Mpa; Volume density: 2.45g/cm
3Water-intake rate≤0.5%.X ray diffracting spectrum shows that the microstructure of test ceramic tile is matrix with the glassy phase also, and contains a certain amount of mullite crystalline phase, glassy phase and a small amount of gas phase.The microstructure of the very low temperature porcelain that this explanation is manufactured experimently and the porcelain base of common building pottery is consistent, different is that crystalline size, quantity are variant slightly, be in particular in that the amount of crystals in the very low temperature ceramic body is many, crystal grain is tiny, thermal stresses between closed pore few and crystalline phase and the glassy phase is little, make this material have good machinery and heat physical properties, the plasticity material of introducing in the prescription is less in addition, the volumetric shrinkage of finished product is little, is particularly suitable for applying in the architectural pottery field.
Embodiment one:
Production method may further comprise the steps:
1) blank formulation:
According to existing apparatus and process layout, in conjunction with the practical situation of this area feed distribution, by the simultaneous test analysis to different material, final definite: cullet, calcined bauxite, white clay, wilkinite, colorant and tripoly phosphate sodium STPP are main raw material.Various bases are shown in Table 1 with the raw material consumption, shown in the base substrate Chemical Composition analysis in table 2.
Table 1, body recipe are formed (wt%)
| Cullet | Calcined bauxite | White clay | Wilkinite | Tripoly phosphate sodium STPP | Colorant |
| 50％ | 20％ | 18％ | 4％ | 5％ | 3％ |
Table 2, base substrate chemical constitution
| Chemical Composition | Al 2O 3 | SiO 2 | Fe 2O 3 | CaO | MgO | KNaO | Other |
| Content (%) | 56 | 24 | 1 | 7 | 1.0 | 8 | 3 |
2) composite elasticizer prescription (butt consumption)
| Title | Algae substances JA | Polysaccharide HS | Sodium salts humic acids |
| Content (%) | 0.15 | 0.2 | 0.2 |
The wear-resisting transparent prescription of 3 low temperature:
Table 3, glaze formula are formed
| The wear-resisting clear frit of low temperature | Smart kaolin | Tripoly phosphate sodium STPP | Methyl |
| 93％ | 6.6％ | 0.3％ | 0.1％ |
4) technical process (seeing accompanying drawing 1)
------sieving, deironing,------old------------------sieving, deironing,---old------side washing---burns till that---edging---sorting---is packed to the spray transparent to ball milling to glaze batching to water spray to drying to spraying drying to ball milling in compression moulding for blank batching.
5) sintering curve (seeing shown in Figure 2)
6) processing parameter
1. base is starched
Fineness: 2.0～2.5wt% (250 mesh screen residue)
Proportion: 1.72～1.75g/ml
Flow velocity: 30～50s
80 orders sieve in the transfer pond
2. powder
Moisture content: 6.5～7.1wt%
Grain composition:
More than 40 orders≤10wt%
40～80 orders 〉=60wt%
80～100 orders≤20wt%
Below 100≤10wt%
Old 1～3 day of powder
3. glaze slip
Fineness: 0.7～1.0wt% (100ml glaze slip, 325 mesh screen residue %)
Proportion: 1.70～1.75g/ml
Flow velocity: 20～30s
4. moulding
Forming pressure: 290 ± 10bar (SACMl PH1080)
Die size: 535*535mm
Molding thickness: 11 ± 0.25mm
Claims (5)
1, a kind of method that adopts low-temperature sintering to produce brick modelled after an antique, it is characterized in that, this method is as main flux raw material with cullet, with tripoly phosphate sodium STPP as less important flux raw material, be aided with other ceramic raw material, once burn till fast during in firing temperature≤900 ℃ through roller kiln, prescription consists of: cullet 42～60%, calcined bauxite 18～25%, white clay 15～20%, wilkinite 3～8%, tripoly phosphate sodium STPP 5～8%, colorant 3～4%; The concrete chemical constitution of its composition of raw materials comprises: Al
2O
352～60%, SiO
223～26%, Fe
2O
30～1%, CaO6～8%, MgO0.5～1.0%, KNaO8～10%; Its concrete processing step is, the blank batching, and------sieving, deironing,------old------------------sieving, deironing,---old------side washing---burns till that---edging---sorting---is packed to the spray transparent to ball milling to glaze batching to water spray to drying to spraying drying to ball milling in compression moulding.
2, the employing low-temperature sintering according to claim 1 method of producing brick modelled after an antique is characterized in that described powder is old to be 1～3 day.
3, the employing low-temperature sintering according to claim 1 method of producing brick modelled after an antique is characterized in that firing time is 55 minutes.
4, a kind of method that adopts low-temperature sintering to produce brick modelled after an antique, it is characterized in that, this method is as main flux raw material with cullet, with tripoly phosphate sodium STPP as less important flux raw material, be aided with other ceramic raw material, once burn till fast during in firing temperature≤900 ℃ through roller kiln, prescription consists of: cullet 42～60%, calcined bauxite 18～25%, white clay 15～20%, wilkinite 3～8%, tripoly phosphate sodium STPP 5～8%, colorant 3～4%, and softening agent and ionogen, the softening agent prescription is algae substances JA 0.05～0.2%, polysaccharide HS 0.1～0.3%, Sodium salts humic acids 0.1～0.3%; The concrete chemical constitution of its composition of raw materials comprises: Al
2O
352～60%, SiO
223～26%, Fe
2O
30～1%, CaO6～8%, MgO0.5～1.0%, KNaO8～10%; Its concrete processing step is, the blank batching, and------sieving, deironing,------old------------------sieving, deironing,---old------side washing---burns till that---edging---sorting---is packed to the spray transparent to ball milling to glaze batching to water spray to drying to spraying drying to ball milling in compression moulding.
5, the employing low-temperature sintering according to claim 4 method of producing brick modelled after an antique is characterized in that described softening agent prescription is: algae substances JA 0.15%, polysaccharide HS 0.2%, Sodium salts humic acids 0.2%.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN200610037066A CN100595176C (en) | 2006-08-17 | 2006-08-17 | Method of producing archaistic brick by low-temperature sintering |
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|---|---|---|---|
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| CN100595176C true CN100595176C (en) | 2010-03-24 |
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| CN102145983A (en) * | 2010-02-09 | 2011-08-10 | 黄庆丰 | Environmentally-friendly hollow material |
| CN105440796A (en) * | 2015-12-10 | 2016-03-30 | 广东道氏技术股份有限公司 | Low-temperature metal glaze printing ink for ink-jet printing of ceramics and preparation method thereof |
| CN107473722A (en) * | 2017-09-01 | 2017-12-15 | 安徽省德邦瓷业有限公司 | A kind of ceramic disk and preparation method thereof |
| CN108529884A (en) * | 2018-07-09 | 2018-09-14 | 界首市伟盛古窑彩陶制作发展有限公司 | A kind of preparation method of unleaded glaze |
| CN111847881A (en) * | 2020-07-17 | 2020-10-30 | 安阳贝利泰陶瓷有限公司 | Medical antibacterial and mildewproof ceramic tile and production technology thereof |
| CN113024227A (en) * | 2021-04-07 | 2021-06-25 | 麻建华 | High-temperature and low-temperature resistant anti-skid ceramic tile and preparation method thereof |
| CN113185262B (en) * | 2021-04-15 | 2022-08-16 | 邹平宏宇博鹰建材有限公司 | Glazed tile and preparation method thereof |
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Assignee: Foshan Royal Magnetic Ceramic Co., Ltd. Assignor: Zhong Xudong Contract record no.: 2010440000654 Denomination of invention: Method of producing archaistic brick by low-temperature sintering Granted publication date: 20100324 License type: Exclusive License Open date: 20070207 Record date: 20100608 |
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