CN101965318A - 处理火山灰质材料的方法 - Google Patents

处理火山灰质材料的方法 Download PDF

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CN101965318A
CN101965318A CN2008801157370A CN200880115737A CN101965318A CN 101965318 A CN101965318 A CN 101965318A CN 2008801157370 A CN2008801157370 A CN 2008801157370A CN 200880115737 A CN200880115737 A CN 200880115737A CN 101965318 A CN101965318 A CN 101965318A
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V·龙尼
I·龙尼
C·W·派克
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    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
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Abstract

用于制备砂浆和混凝土的包含粉煤灰例如F级和/或C级粉煤灰的火山灰质材料的处理方法，其特征在于，通过在研磨设备中进行研磨使该火山灰质材料经受高能机械处理，研磨至最终产物的细度为30微米筛余量少于5％，由此在火山灰质材料颗粒受到机械冲击的同时粗熔渣颗粒形式的非微珠被破碎，且由此微珠研磨颗粒的表面被活化。

Description

处理火山灰质材料的方法
技术领域
本发明涉及一种处理粉煤灰形式的火山灰质材料(pozzolans)的方法。
背景技术
粉煤灰用于生产混凝土、砂浆和其它含水泥混合物。粉煤灰是燃煤发电厂的副产物并且全世界每年以大量产生。
本方法消除了因煤化学组成和煤燃烧工艺参数的变化带来的粉煤灰品质的变动。依据本发明方法处理火山灰质材料即粉煤灰显著提高了混凝土的性能并且以更高水平取代标准波特兰水泥，这导致显著的经济和环境益处。
粉煤灰通常包含约85％的微珠(cenosphere)颗粒形式的玻璃质无定形组分。依据ASTM C 618，粉煤灰被分成两种类别：C类和F类。F类粉煤灰通常含有超过70重量％的氧化硅、氧化铝和铁氧化物，而C类通常含有50％至70％。F类粉煤灰是烟煤燃烧的副产物。C类粉煤灰具有较高的钙含量，其是亚烟煤燃烧的副产物。
根据美国煤灰协会，2006年在美国产生约7300万吨的粉煤灰形式的煤灰，且仅有约45％被用于不同的工业应用而其它部分大多以废物形式堆积在填埋场。在美国，目前混凝土中取代波特兰水泥的仅为约10％。
深入研究证实，与不含粉煤灰的波特兰水泥混凝土相比，波特兰水泥被粉煤灰以超过50％的程度取代的高粉煤灰含量混凝土表现出更高的长期强度发展，较低的水渗透性和气体渗透性，高的氯离子耐受性等等。
同时高粉煤灰含量混凝土存在明显的缺点。一个缺点是在0到28天时段期间非常长的固化时间和非常慢的强度发展，尤其是水/胶结材料的比率高于0.50时。这些负面效果将用以取代波特兰水泥的粉煤灰水平降低至平均为15-20％。
严重的问题还涉及粉煤灰品质的稳定性。通常所用煤的化学组成的变化和锅炉操作参数的频繁改变引起晶相和准晶相(所谓的熔渣)的形成，这导致粉煤灰反应性(所谓的凝硬活性)的降低。
为了改善高粉煤灰含量混凝土的性能，已经进行了若干努力，例如Malhotra，Concrete International J.，0ol.21，No 5，1999年5月，第61-66页。根据Malhotra，通过显著地增加粘结剂的含量(即水泥和微填料)以及大量降低水量能改善此类混凝土的强度发展，但此方法需要增加减水掺合料的剂量来保持混凝土混合物具有可接受的稠度，这将急剧增加混凝土的成本。
已经开发了许多涉及研磨粉煤灰的方法，以便通过研磨(这增加尺寸为约11微米的粉煤灰颗粒的数量)并同时引入氧化钙来改善其凝硬活性。美国专利6,818,058，6,038,987，5,714,002，5,714,003，5,383,521和5,121,795中描述了此类方法。所有上述已知方法要么不能使作为混凝土成分的粉煤灰性能显著提高，要么不能避免粉煤灰性能的波动和保证最终产品的恒定品质。
本发明解决了上述问题。
发明内容
本发明因此涉及一种处理包含粉煤灰例如F级和/或C级粉煤灰的火山灰质材料的方法，所述火山灰质材料用于制备砂浆和混凝土，其特征在于，通过在研磨设备中进行研磨使所述火山灰质材料经受高能机械处理，研磨至最终产物的细度为30微米筛余量(retention)少于5％，由此在火山灰质材料颗粒受到机械冲击的同时粗熔渣(scoria)颗粒形式的非微珠被破碎，且由此微珠研磨颗粒的表面被活化。
可使用等不同类型的研磨设备如介质球磨设备来实现本发明，例如搅拌式磨机、离心式磨机、翻滚球磨设备或无介质碾磨设备；例如将具有主要为剪切机械冲击的喷射、冲击、辊子应用于经受处理的颗粒并与空气分级相结合。
依据本发明的一个优选实施方案，火山灰质材料经受预分级以分离出45微米筛余量为至少90％的部分，并且这些过大颗粒被研磨至细度为30微米筛余量少于5％以达到依据火山灰质材料指标ASTM C 618规定的28天后强度≥75％。
依据本发明的另一个优选实施方案，火山灰质材料经受预分级以分离出45微米筛余量为至少95％的部分，并且这些过大颗粒被研磨至细度为30微米筛余量少于5％。
依据本发明又一个优选实施方案，火山灰质材料经受预分级以分离出45微米筛余量为至少99％的部分，并且这些过大颗粒被研磨至细度为30微米筛余量少于5％。
依据本发明的再一个优选实施方案，在所述预分级之后，火山灰质材料经受搭配粉磨(intergrinding)至细度为30微米筛余量少于5％。
依据本发明的更加优选的实施方案，火山灰质材料经受研磨，使得最终产物具有下列颗粒尺寸分布：
≤5微米15-25％，
≤10微米30-40％，
≤30微米90-95％。
依照本发明处理过的火山灰质材料可通过添加波特兰水泥进一步处理。依据本发明的一个优选实施方案，在火山灰质材料的所述处理期间或之后，以最高10重量％的量向所述火山灰质材料中加入波特兰水泥。
还优选在火山灰质材料的所述处理期间或之后，向所述火山灰质材料中加入粉末形式的减水剂、固化时间调节剂、和/或强度促进掺合料。
本发明的主要优点是所述的粉煤灰处理使得煤成分变化和锅炉条件对粉煤灰性能的影响最小化。另一个优点是有可能增加在混凝土中对波特兰水泥的取代量，这显著地减少与波特兰水泥生产相联系的温室气体排放和能量消耗。
具体实施方式
实施例
依照本发明对具有由表1和表2所示的化学组成和颗粒尺寸分布(PSD)的根据ASTM C的F级粉煤灰进行测试。
表1.化学组成
Figure BPA00001187591600031
表2.颗粒尺寸分布
Figure BPA00001187591600041
下表3显示了波特兰水泥(依据ASIM C 150的1型)与未处理的和依照本发明处理过的辅助胶粘材料(SCM)的按重量比50/50掺混物根据ASTM C 109的强度发展。
表3.抗压强度发展，MPa(psi)
Figure BPA00001187591600042
所得的测试结果表明本发明将粉煤灰中具有零凝硬活性的完全惰性的粗粒部分转化成对强度具有显著贡献的活性部分。含有50％波特兰水泥和50％依照本发明处理的粉煤灰的掺混水泥就28天的固化时间而言，表现出与I类水泥同高炉矿渣的50/50掺混物、以及I类水泥的平均强度(35MPa-40MPa)一致的强度。
除了如高耐久性等显著的性能益处之外，本发明还具有使低活性灰分(其通常被埋填)可用于混凝土生产的巨大环境影响。
上文已描述了本发明的几个实施方案。然而，本发明不限于上述示例性实施方案，而是可以在权利要求范围内进行改变。

Claims (8)

1.一种处理包含粉煤灰例如F级和/或C级粉煤灰的火山灰质材料的方法，所述火山灰质材料用于制备砂浆和混凝土，其特征在于，通过在研磨设备中进行研磨使该火山灰质材料经受高能机械处理，研磨至最终产物的细度为30微米筛余量少于5％，由此在火山灰质材料颗粒受到机械冲击的同时粗熔渣颗粒形式的非微珠被破碎，且由此微珠研磨颗粒的表面被活化。
2.如权利要求1所述的方法，其特征在于，使火山灰质材料经受预分级以分离出45微米筛余量为至少90％的部分，并且过大的颗粒被研磨至细度为30微米筛余量少于5％，从而达到依据火山灰质材料指标ASTM C 618规定的28天后强度≥75％。
3.如权利要求1所述的方法，其特征在于，使火山灰质材料经受预分级以分离出45微米筛余量为至少95％的部分，并且过大的颗粒被研磨至细度为30微米筛余量少于5％。
4.如权利要求1所述的方法，其特征在于，使火山灰质材料经受预分级以分离出45微米筛余量为至少99％的部分，并且过大的颗粒被研磨至细度为30微米筛余量少于5％。
5.如权利要求2、3或4所述的方法，其特征在于，在所述预分级之后，该火山灰质材料经受搭配粉磨至细度为30微米筛余量少于5％。
6.如权利要求1所述的方法，其特征在于，火山灰质材料经受研磨使得最终产物具有下列颗粒尺寸分布：
≤5微米15-25％，
≤10微米30-40％，
≤30微米90-95％。
7.如权利要求1-6任一项所述的方法，其特征在于，在火山灰质材料的所述处理期间或之后，以最高10重量％的量向所述火山灰质材料中加入波特兰水泥。
8.如权利要求1-7任一项所述的方法，其特征在于，在火山灰质材料的所述处理期间或之后，向所述火山灰质材料中加入粉末形式的减水剂、固化时间调节剂、和/或强度促进掺合料。
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