CN101838140A - Thin porcelain brick and production method thereof - Google Patents

Abstract

The invention relates to a thin porcelain brick and a production method thereof, wherein the production method comprises the following steps: 1. mixing blank raw materials comprising 4.5 to 5 percent of ball clay, 5 to 6 percent of black mud, 6 to 8 percent of Yichun kaolin, 6 to 10 percent of Beihai kaolin, 6 to 13 percent of Dehua pyrophyllite, 4 to 10 percent of Paishan pyrophyllite, 12 to 16 percent of sodium-potassium feldspar powder, 12 to 15 percent of weathered potassium feldspar, 8 to 15 percent of superfine pottery stone, 8 to 16 percent of sodium-potassium feldspar, 5.5 to 6 percent of Zhuji porcelain sand and 0.8 to 1.3 percent of lignin and lignin derivative; 2. adding water accounting for 50 to 60 percent of the weight of a powder material, 0 to 0.1 percent of polymethyl cellulose sodium (CMC) and 0.1 to 1 percent of sodium tripolyphosphate (STPP), putting into a ball mill, and controlling the ball milling fineness to have 0.5 to 1 percent of sieve residue through a 325-mesh sieve; 3. preparing the powder material containing 5 to 7 percent of water through iron removal, sieving and spray drying of the obtained mud; 4. ageing the powder material for 24 hours, then molding through pressing, and drying at the temperature of 150 to 200 DEG C to enable the water content of a blank to be below 0.3 percent; and 5. placing into a kiln for sintering, wherein the early period time of sintering is 6 to 15 minutes, the high temperature time is 15 to 30 minutes ,and the cooling time is 5 to 10 minutes. In the invention, the thin porcelain brick can be produced under the condition of traditional process equipment, and each item of performance index reaches or exceeds a porcelain brick standard GB/T4100-2006.

Description

A kind of thin porcelain brick and production method thereof

Technical field

The invention belongs to the building ceramics production field, particularly relate to a kind of thin porcelain brick and production method thereof.

Background technology

The energy and shortage of resources are the century property difficult problems that current mankind faces jointly, and the energy that causes thus and crisis of resource have caused the extensive concern of countries in the world to energy-saving and cost-reducing and energy-saving and cost-reducing technology and low-carbon economy.Building Ceramics Industry is as the industry of high resource consumption, high energy gamma source consumption, high pollution, more acts in accordance with the trend of seasonable generation development, and the energy-saving and cost-reducing new technology of development advances that China is energy-conservation, the realization of material-saving, reduction of discharging target.Ceramic tile slimming, minimizing production are to lead the ceramic industry new development with the Scientific Outlook on Development, promote the only way of ceramic industry level comprehensively, are the practical ways that ceramic industry is realized saving energy, lowering energy consumption and reducing pollutants discharge, assurance Sustainable development.By research, the exploitation of ceramic tile slimming, minimizing, carrying forward vigorously to save energy and reduce the cost is the technology and the technological transformation of major objective, finally realizes the batch process of thin ceramic brick product, has great economic implications and social effect.

In the prior art, the research of a lot of this respects has been arranged, as:

CN 100469734C discloses and has a kind ofly consisted of feldspar flux 20-40% by raw material weight per-cent, one of clay raw materials 20-30%, the 0-8% of calcium magnesia raw material, anti-crisp dose of 10-30%, the ultrathin polished brick in porcelain character that base substrate toughener 0.1-1% produces.Wherein anti-crisp dose is one or more combination in aluminum oxide powder, calcining bauxitic clay, aluminium hydroxide, bauxitic clay, the zirconium white; Calcium magnesia raw material is the one or more combination of burning in talcum, magnesiumcarbonate, magnesite or the wollastonite; The base substrate toughener is the one or more combination in polyvinyl alcohol, carboxymethyl cellulose or the Sumstar 190.The cost of this kind scheme is higher, is unfavorable for industrialization promotion.

CN 101634184A discloses a kind of by introduce the 5-30% fiber enhancer in base substrate, adopts the large-sized ultra-thin stoneware-quality tiles of dry-pressing formed technology preparation.Wherein fiber enhancer is mineral fibre such as acicular wollastonite, basalt mineral fiber, or the one or more combination in synthesize ceramic fiber such as aluminum silicate fiber, sapphire whisker, kyanite fiber and other manmade inorganic fibre; And fiber enhancer and common raw material need again both to be carried out mechanically mixing behind the independent ball milling slurry.The production process of this kind scheme is comparatively complicated.

CN 200510020723.9 discloses a kind of processing method of producing ultrathin ceramic bricks, comprising: adopt ultra-fine equipment to carry out the ultra micro thinning processing raw material of production ceramic tile; Powder after the dry ultra micro refinement; Obtain finished product with burning till after the dried pressed by powder moulding, polishing.This invention beneficial technical effects is: take superfine powder machinery team ceramic raw material to handle, replace original ball mill and technology thereof, can fundamentally solve the high energy consumption problem that the ceramic industry powder prepares the aspect, simultaneously, the superfine powder raw material will bring revolutionary progress for subsequent technique and final ceramic product quality.But, the material choice prior art of this method production ceramic tile generally is used for making the various materials of ceramic tile, comprise kaolin and feldspar etc., also add white mica and sericite, and mineral such as lime carbonate and wollastonite, consistency is bad in these raw materials mixing and the sintering process, still exists under the molten state to be separated, even inadequately, influence The comprehensive performance.

It is that raw material adopts traditional technology to prepare the method for ultra-thin ceramic outside-wall brick with clay, binding agent, kaolin, albite, potassium felspar sand, quartzy feldspar tailings, lithium feldspar that CN 100453498C discloses a kind of, but it adopts through 700-900oC incinerating wilkinite as binding agent and lithium feldspar as fusing assistant, increase operation and cost, and needed to increase specific equipment.

Summary of the invention

The objective of the invention is to overcome the deficiencies in the prior art part, a kind of thin porcelain brick with better comprehensive performance is provided.

Another object of the present invention provides the production method of this kind thin porcelain brick.

For realizing first goal of the invention, the technical scheme that is adopted is such: a kind of thin porcelain brick, it is characterized in that: fire by the blank raw material of following ratio (weight part) and form: ball clay 4.5-5%, black mud 5-6%, Yichuan kaolin 6-8%, North Sea kaolin 6-10%, Dehua agalmatolite 6-13%, row mountain agalmatolite 4-10%, potassium albite in powder 12-16%, weathered potash feldspar 12-15%, superfine porcelain stone 8-15%, potassium albite 8-16%, Zhuji porcelain sand 5.5-6%, xylogen and lignin derivative 0.8-1.3%.

Through measuring and calculating, above-mentioned blank raw material, main chemical constitution is: SiO264-70%, A12O322-25%, Fe2O30-0.4%, CaO0-0.3%, MgO0-0.2%, K2O2-3.3%, Na2O2.1-3.3%, TiO20-0.1%, and xylogen and the lignin derivative of 0.8-1.3%.

Xylogen is the crosslinking net natural phenolic macromolecular compound of a kind of complexity of being formed by four kinds of alcohol monomers (to tonquinol, lubanol, 5-hydroxyl lubanol, sinapyl alcohol), owing to contain a large amount of phenolic hydroxyl groups and alcoholic extract hydroxyl group, general formula often is designated as R-OH.Xylogen is present in the lignum, accounts for 25% in xylophyta, is second organism the abundantest (Mierocrystalline cellulose is first) in the world, and main effect is to come the sclereid wall by the formation net that interweaves, and plays the resistance to compression effect between cellulosic fibre.Lignin derivative is the various reaction product that xylogen utilizes the replacement(metathesis)reaction of its hydroxyl reaction or ring phenyl hydrogen atom to obtain.Main lignin derivative be respectively by acetylize, methylate, halogenation and nitrated, the acetyl xylogen that obtains, methyl xylogen, halogenation xylogen and nitration of lignin etc.Xylogen and lignin derivative all can be used for improving in the ceramic green strength, reduce the plastic clay consumption, improve slip fluidity.

The technical scheme of the best of the present invention is: a kind of thin porcelain brick is characterized in that: fired by the blank raw material of following ratio (weight part) and form: ball clay 4.9%, black mud 5.9%, Yichuan kaolin 7.9%, North Sea kaolin 9.9%, Dehua agalmatolite 7.9%, row mountain agalmatolite 7.9%, potassium albite in powder 15.0%, weathered potash feldspar 14.0%, superfine porcelain stone 9.8%, potassium albite 9.8%, Zhuji porcelain sand 5.9%, xylogen R-OH 0.5%, lignin derivative 0.6%.

Thin porcelain brick is because the attenuate significantly of its thickness, will inevitably cause the reduction of product strength, therefore must the formula system of thin porcelain brick be redesigned, improve the modulus of rupture and strength at break and other technical performance index of product, to meet or exceed the regulation of national standard.The formula system that the present invention is directed to thin porcelain brick proposes innovation scheme, its guiding theory is such: the raw material of introducing high aluminium content in formula system, improve the aluminium content in the formula system, thereby improve the modulus of rupture and strength at break and other technical performance index of finished product; Introduce simultaneously contain potassium sodium many, do not contain or less the feldspar raw materials of calcic magnesium reduce the rising of the firing temperature that the raising owing to aluminium content brings and overcome the base substrate thickness problems such as high temperature deformation that cause of attenuate significantly, with the firing range of stabilized formulations system.Through preferred base substrate toughener and add-on thereof, the base substrate toughener to the tangible situation of the reinforced effects of green strength under, the fixedly kind of base substrate toughener and optimal addn thereof, and then test by design system, by the massive parallel experiment with the contrast experiment, different high aluminium content raw materials are introduced in exploratory development repeatedly, and under the situation of different feldspar raw materials and add-on thereof formula system mud property, green strength, burn till contraction and loss on ignition, product strength and outward appearance etc., therefrom optimize formula system of the present invention.

For realizing second goal of the invention, the technical solution adopted in the present invention is such:

The production method of thin porcelain brick may further comprise the steps:

1) blank raw material with aforementioned formula mixes;

2) water, the poly-sodium carboxymethylcellulose pyce (CMC) of 0-0.1% and the tripoly phosphate sodium STPP (STPP) of 0.1-1% of adding powder weight 50-60% drop into ball mill, and control ball milling fineness tails over 0.5-1% at 325 mesh sieves;

3) gained mud is through deironing is sieved, spraying drying makes moisture 5-7% powder;

4) pass through the compression moulding of conventional ceramic brick pressing machine behind the old 24h of powder, make the base substrate water ratio below 0.3% through the 150-200oC drying;

5) go into klining, wherein burning till is 6-15min for the previous period, and high-temperature time is 15-30min, and be 5-10min cooling time.

Present method because good blank raw material prescription and added poly-sodium carboxymethylcellulose pyce (CMC) and tripoly phosphate sodium STPP (STPP) as dispergator, make powder particle slyness, good fluidity, tap density is big; The dry tenacity of compacting back base substrate can reach 1.7-2.3MPa, can stand glazing line operation and back operation processing and not damaged cracking.Because base substrate is than thin many of it common porcelain brick, base substrate conducts heat fast, the temperature difference is little in the table, substantially the problem that does not have evil mind, so clinkering zone can be shortened for the previous period as far as possible,, can cool off fast during cooling to promote the generation of secondary mullite in the base substrate in high temperature firing zone proper extension soaking time.By above drying system and calcining system, can under the existing processes appointed condition, produce thin porcelain brick, every performance index all meet or exceed GB/T 4100-2006 ceramic tile standard.

Embodiment

The present invention is further illustrated below in conjunction with preferred embodiment

Embodiment 1

Form blank raw material by following components in part by weight: ball clay 4.9%, black mud 5.9%, Yichuan kaolin 7.9%, North Sea kaolin 9.9%, Dehua agalmatolite 13.0%, row mountain agalmatolite 9.9%, potassium albite in powder 12.0%, weathered potash feldspar 12.0%, superfine porcelain stone 8.8%, potassium albite 8.8%, Zhuji porcelain sand 5.9%, xylogen R-OH0.3%, lignin derivative 0.7%.Fire through the method for embodiment 6 and to form thin porcelain brick.

Embodiment 2

Form blank raw material by following components in part by weight: ball clay 5.0%, black mud 5.9%, Yichuan kaolin 6.9%, North Sea kaolin 8.9%, Dehua agalmatolite 7.9%, row mountain agalmatolite 7.8%, potassium albite in powder 15.0%, weathered potash feldspar 15.0%, superfine porcelain stone 9.8%, potassium albite 11.0%, Zhuji porcelain sand 5.8%, xylogen R-OH 0.5%, lignin derivative 0.5%.Fire through the method for embodiment 6 and to form thin porcelain brick.

Embodiment 3

Form blank raw material by following components in part by weight: ball clay 5.0%, black mud 5.0%, Yichuan kaolin 6.0%, North Sea kaolin 6.0%, Dehua agalmatolite 7.8%, row mountain agalmatolite 6.0%, potassium albite in powder 14.8%, weathered potash feldspar 14.8%, superfine porcelain stone 12.8%, potassium albite 15.0%, Zhuji porcelain sand 6.0%, lignin derivative 0.8%.Fire through the method for embodiment 6 and to form thin porcelain brick.

Embodiment 4

Form blank raw material by following components in part by weight: ball clay 4.9%, black mud 5.9%, Yichuan kaolin 7.9%, North Sea kaolin 9.9%, Dehua agalmatolite 7.9%, row mountain agalmatolite 7.9%, potassium albite in powder 15.0%, weathered potash feldspar 14.0%, superfine porcelain stone 9.8%, potassium albite 9.8%, Zhuji porcelain sand 5.9%, xylogen R-OH 0.5%, lignin derivative 0.6%.Fire through the method for embodiment 6 and to form thin porcelain brick.

Embodiment 5

Form blank raw material by following components in part by weight: ball clay 5.0%, black mud 5.0%, Yichuan kaolin 6.0%, North Sea kaolin 6.0%, Dehua agalmatolite 6.0%, row mountain agalmatolite 5.0%, potassium albite in powder 15.8%, weathered potash feldspar 14.8%, superfine porcelain stone 14.8%, potassium albite 14.8%, Zhuji porcelain sand 6.0%, xylogen R-OH0.3%, lignin derivative 0.5%.Fire through the method for embodiment 6 and to form thin porcelain brick.

Embodiment 6

The preparation method of thin porcelain brick:

1) gets the blank raw material of the arbitrary prescription of embodiment 1-5, mix;

2) add water, 0.1% poly-sodium carboxymethylcellulose pyce (CMC) and 0.4% the tripoly phosphate sodium STPP (STPP) of powder weight 55%, drop into ball mill, control the ball milling fineness and tail over 0.5-1% at 325 mesh sieves;

3) gained mud is through deironing is sieved, spraying drying makes moisture 5-7% powder;

4) pass through the compression moulding of conventional ceramic brick pressing machine behind the old 24h of powder, make the base substrate water ratio below 0.3% through 150-200 ℃ of drying;

5) go into klining, wherein burning till is 10min for the previous period, and high-temperature time is 30min, and be 10min cooling time.

Embodiment 7

The performance index of each embodiment and GB/T 4100-2006 ceramic tile standard compare:

Project	Embodiment 1	Embodiment 2	Embodiment 3	Embodiment 4	Embodiment 5	GB/T 4100-2006 ceramic tile standard
							Green strength/MPa	??2.2	??2.1	??1.8	??2.2	??2.3	??----
Product thickness/mm	??5.5	??5.4	??5.5	??5.3	??5.5	??±5％max
							Water-intake rate/%	??0.10	??0.11	??0.49	??0.28	??0.13	??≤0.5％
Strength at break/N	??953	??955	??917	??947	??972	More than the 700N
							The modulus of rupture/MPa	??57	??57	??55	??56	??58	More than the 35MPa

From last table as seen, various embodiments of the present invention have have all met or exceeded GB, can be applied aborning fully.

Claims (3)

1. thin porcelain brick is characterized in that: fired by the blank raw material of following ratio (weight part) and form: ball clay 4.5-5%, black mud 5-6%, Yichuan kaolin 6-8%, North Sea kaolin 6-10%, Dehua agalmatolite 6-13%, row mountain agalmatolite 4-10%, potassium albite in powder 12-16%, weathered potash feldspar 12-15%, superfine porcelain stone 8-15%, potassium albite 8-16%, Zhuji porcelain sand 5.5-6%, xylogen and lignin derivative 0.8-1.3%.

2. a kind of thin porcelain brick as claimed in claim 1 is characterized in that: fired by the blank raw material of following ratio (weight part) and form: ball clay 4.9%, black mud 5.9%, Yichuan kaolin 7.9%, North Sea kaolin 9.9%, Dehua agalmatolite 7.9%, row mountain agalmatolite 7.9%, potassium albite in powder 15.0%, weathered potash feldspar 14.0%, superfine porcelain stone 9.8%, potassium albite 9.8%, Zhuji porcelain sand 5.9%, xylogen R-OH 0.5%, lignin derivative 0.6%.

3. the production method of thin porcelain brick as claimed in claim 1 or 2 may further comprise the steps:

1) blank raw material with aforementioned formula mixes;

2) water, the poly-sodium carboxymethylcellulose pyce (CMC) of 0-0.1% and the tripoly phosphate sodium STPP (STPP) of 0.1-1% of adding powder weight 50-60% drop into ball mill, and control ball milling fineness tails over 0.5-1% at 325 mesh sieves;

3) gained mud is through deironing is sieved, spraying drying makes moisture 5-7% powder;

4) pass through the compression moulding of conventional ceramic brick pressing machine behind the old 24h of powder, make the base substrate water ratio below 0.3% through 150-200 ℃ of drying;

5) go into klining, wherein burning till is 6-15min for the previous period, and high-temperature time is 15-30min, and be 5-10min cooling time.