CN104529510A - Preparation method of foaming ceramic - Google Patents
Preparation method of foaming ceramic Download PDFInfo
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- CN104529510A CN104529510A CN201410767174.0A CN201410767174A CN104529510A CN 104529510 A CN104529510 A CN 104529510A CN 201410767174 A CN201410767174 A CN 201410767174A CN 104529510 A CN104529510 A CN 104529510A
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Abstract
The invention discloses a preparation method of a foaming ceramic. The preparation method is characterized by comprising the following steps: mixing coal powder into a foaming ceramic blank; preparing the foaming ceramic through the processes of dry milling, granulation, high-temperature sintering, foaming, cooling and the like. The preparation method disclosed by the invention can be used for determining the mixing amount of the coal powder according to the combustion heat value of the coal powder and sintering heat consumption needed by the foaming ceramic blank, thereby providing the heat needed by the high-temperature sintering and foaming of the foaming ceramic mainly through a coal powder internal combustion mode and reducing the production energy consumption and cost. The preparation method disclosed by the invention simplifies the process course by adopting a dry milling process without drying powder, can be used for greatly reducing the production cost by taking the low-cost coal powder as main fuel and belongs to a high-efficiency low-cost foaming ceramic firing technology.
Description
Technical field
The present invention relates to building material field, be specifically related to a kind of method preparing foamed ceramic in coal dust internal combustion mode.
Background technology
Foamed ceramic is using shale, potter's clay, feldspar etc. as main raw material, additional certain whipping agent, through the high porosity stupalith of high-temperature roasting, has lightweight, thermal conductivity is lower, fire protection flame retarding, anti-aging, stable performance, eco-environmental prote is good, with plinth course and float coat consistency good, safety and firmness is good, can with buildings with features such as life-spans.The fire-protection rating that the more important thing is foamed ceramic is A1 level, and overcome organic materials for wall and be afraid of naked light, easily aging deadly defect is a kind of novel inorganic building thermal insulation material.
The conventional processing routes preparing foamed ceramic is: wet grinding, homogenizing, spraying dry, powder process, compression moulding, enters klining, cooling, cutting, finished product.Prepare foamed ceramic due to Conventional processing methods and adopt wet grinding and spraying dry flouring technology, dry and sintering process is all fuel with Sweet natural gas, have that thermo-efficiency is low, energy consumption is high, the problems such as cost ratio shared by fuel is excessive, thus cause foamed ceramic cost high, hinder it in the promotion and application of building material industry.
Summary of the invention
The object of the invention is from foamed ceramic blank, grinding process, firing process angle, the preparation method of a kind of low cost, high efficiency foamed ceramic is provided, the foamed ceramic intensity that the method obtains is high, good heat insulating, meets the performance requriements of building thermal insulation material.
For achieving the above object, the technical solution used in the present invention is: a kind of preparation method of foamed ceramic, and coal dust directly mixes in foamed ceramic blank by the method, provides and burns till required heat, specifically comprise the following steps in coal dust internal combustion mode:
1) dry method powder process: coal dust, foamed ceramic blank and whipping agent are mixed, compound is placed in ball mill grinding, various raw material is mixed at grinding process;
2) granulation, die-filling: by step 1) in the compound that obtains through ball milling make granular powder by tablets press, and granular powder is spread in refractory-material dies;
3) sinter, foaming: by step 2) in granular powder is housed fireproof die send in kiln, first granular powder carries out heat exchange with the high-temperature flue gas from kiln clinkering zone, granular powder pre-heating temperature elevation, when temperature is raised to 450 ~ 650 DEG C, the coal dust be evenly mixed in powder produces internal combustion, for the sintering of foamed ceramic blank and foaming process provide heat, the burner postcombustion arranged by kiln clinkering zone, control kiln temperature and rise to blowing temperature 1150 ~ 1250 DEG C, heat-up rate is 2 ~ 8 DEG C/min, under blowing temperature, be incubated 30 ~ 90min obtain foam material,
4) cooling, the demoulding, cutting: by step 3) in the foam material that obtains cool in kiln, through the demoulding, cutting after kiln discharge, obtain foamed ceramic.
According to such scheme, the incorporation of described coal dust burns till hear rate according to the calorific value of coal dust and ceramic batch and determines, the heat that coal dust internal combustion is produced meets the high temperature sintering of foamed ceramic, the heat needed for foaming substantially, and burning till heat needed for every kilogram of foamed ceramic blank is 4000 ~ 7500kJ.
According to such scheme, in described foamed ceramic blank, each chemical composition and mass percent thereof are: SiO
250 ~ 70%, Al
2o
310 ~ 35%, CaO+MgO 3 ~ 12% (being any proportioning between CaO and MgO), K
2o+Na
2o 3 ~ 6% (K
2o and Na
2be any proportioning between O), Fe
2o
30.5 ~ 10%, TiO
20 ~ 1.5%, ZrO
20 ~ 1.5%.
According to such scheme, described whipping agent is that one or more in silicon carbide, ferric oxide, calcium sulfate mix by any proportioning, and addition content is 0.5 ~ 2% of foamed ceramic blank quality.
According to such scheme, the high-temperature flue gas produced when described high-temperature flue gas is fuel combustion in the high-temperature flue gas or kiln clinkering zone combustion equipment that in kiln, coal dust internal combustion produces, high-temperature flue-gas is 600 ~ 1200 DEG C.
According to such scheme, described grinding process adopts dry method grinding, and grinding, to fineness≤50 μm, for the reunion reducing the powder in grinding process improves the homogeneity of mixing of materials, can introduce dispersion agent.
According to such scheme, after granulation, the granularity of gained granular powder is 0.5 ~ 8mm.
According to such scheme, described fireproof die is made up of a base plate and four surrounding edge bars, can dimensional requirement independent assortment surrounding edge bar per sample, and composition rectangle is framed.
According to such scheme, described kiln is tunnel furnace or roller kiln, and kiln clinkering zone arranges burner, for make-up gas fuel or liquid fuel, and controls and regulates sintering, blowing temperature.Described fuel is geseous fuel or liquid fuel, and geseous fuel is Sweet natural gas or coal gas, and liquid fuel is LIGHT DIESEL OIL or heavy oil.
The heat that heat needed for sintering of the present invention, foaming process produces mainly through coal dust firing provides, insufficient section supplements a small amount of gas by the burner being arranged in clinkering zone or liquid fuel is regulated, and the heat supplemented by burner is coal dust is introduce heat 5 ~ 20%.
Compared with prior art, the invention has the beneficial effects as follows:
(1) dry method grinding process is adopted, can continuous seepage, without the need to carrying out powder drying, simplify preparation process, with short production cycle, efficiency is high.
(2) coal dust is mixed in foamed ceramic blank, and burn till the incorporation of hear rate determination coal dust according to the calorific value of coal dust and ceramic batch, the heat energy of efficiency utilization coal dust; In sintering process, coal dust is dispersed in foamed ceramic blank, the heat direct heating ceramic batch that coal dust firing produces, while raising heat transfer efficiency reduces energy consumption, make ceramic batch temperature consistent, be beneficial to bubble and be uniformly distributed, be applicable to the production of large size foamed ceramic articles; Coal dust, as a kind of cheap fuel, significantly can reduce production cost.In addition, the coal ash that coal dust firing produces becomes a part for foamed ceramic raw material, without the need to solving Treatment of Coal Ash problem.
(3) preparation technology of foamed ceramic of the present invention is simple, and powder directly spreads in fireproof die, high temperature once-firing.
Accompanying drawing explanation
Below in conjunction with accompanying drawing, the invention will be further described, in accompanying drawing:
Fig. 1 is the surface topography map of foamed ceramic obtained in the embodiment of the present invention 1.
Fig. 2 is the surface topography map of foamed ceramic obtained in the embodiment of the present invention 2.
Fig. 3 is the surface topography map of foamed ceramic obtained in the embodiment of the present invention 3.
Embodiment
In order to make object of the present invention, technical scheme and advantage clearly understand, below in conjunction with drawings and Examples, the present invention is further elaborated.Should be appreciated that specific embodiment described herein only in order to explain the present invention, be not intended to limit the present invention.
For making object of the present invention, technical scheme and advantage clearly understand, below in conjunction with specific embodiment, the present invention is further elaborated.Should be appreciated that specific embodiment described herein only in order to explain the present invention, be not intended to limit the present invention.
In following embodiment, the performance test methods preparing foamed ceramic is as follows: the testing method of ultimate compression strength is with reference to " multicellular glass insulating product " (JC/T647-2005); The testing method of thermal conductivity is with reference to " mensuration-Guarded hot plate of Technology of Steady State Thermal Resistance of Thermal Insulating Material and related characteristics " (GB/T10294-2008); The testing method of unit weight and water-intake rate is with reference to " porous ceramics performance test methods " (GB/T1966-1996).
Embodiment 1
A preparation method for foamed ceramic, selects a kind of bituminous coal, and calorific value is 23MJ/kg, needs the heat coal blending of 5600kJ by every kilogram of foamed ceramic blank, and every kilogram of foamed ceramic blank mixes coal dust 0.24kg; Foamed ceramic blank chemical component consists of (weight percent): SiO
270%, Al
2o
310%, CaO+MgO 12%, K
2o+Na
2o 3.0%, Fe
2o
34.2%, TiO
20.8%, ZrO
20%; Whipping agent is the mixture of silicon carbide and calcium sulfate, and volume is 0.8% of foamed ceramic blank quality, and the mass ratio of silicon carbide and calcium sulfate is 3:5, and its preparation method comprises the following steps:
1) each raw material is taken according to said ratio, the coal dust taken, foamed ceramic blank and whipping agent are loaded in ball mill jointly, adopt Ball Mill dry method grinding, add in grinding process account for solid material quality 0.01% trolamine as dispersion agent, grinding is to fineness≤50 μm.
2) compound after levigate is made the granular powder of 0.5 ~ 8mm by tablets press, the powder after granulation is spread into piecing assembly refractory-material dies.
3) fireproof die that granular powder is housed is sent in tunnel furnace, in tunnel furnace, the high-temperature flue gas that first granular powder produces with coal dust internal combustion in front powder in kiln carries out heat exchange, the temperature of high-temperature flue gas is 600 ~ 1200 DEG C, powder pre-heating temperature elevation, when temperature rises to about 450 DEG C, the coal dust be mixed in foamed ceramic blank produces internal combustion, the heat that coal dust firing provides can realize the high temperature sintering of foamed ceramic substantially, foaming, shortage of heat part by be arranged on the burner of clinkering zone in kiln spray into Sweet natural gas carry out supplement and control temperature rise to blowing temperature 1150 DEG C, in whole process, temperature rise rate is 4 ~ 8 DEG C/min, after blowing temperature insulation 60min, obtain foam material.
4) cooled in kiln by the foam material baked, the demoulding after kiln discharge, cutting, obtain foamed ceramic.
In the present embodiment, the heat that coal dust firing provides can realize high temperature sintering, the foaming process of foamed ceramic substantially, and the heat supplemented by Sweet natural gas is every kilogram of foamed ceramic blank 280kJ, for coal dust introduces 5% of heat.Obtained foamed ceramic is carried out performance test by above-mentioned standard, and test result shows, prepared foamed ceramic unit weight is 380kg/m
3, thermal conductivity is 0.12W/ (mk), and ultimate compression strength is 5.8MPa, and water-intake rate is 0.6%.
Embodiment 2
A preparation method for foamed ceramic, selects a kind of hard coal, and calorific value is 27MJ/kg, needs the heat coal blending of 7500kJ by every kilogram of foamed ceramic blank, and every kilogram of foamed ceramic blank mixes coal dust 0.277kg coal dust; Foamed ceramic blank chemical component consists of (weight percent): SiO
264.1%, Al
2o
322%, CaO+MgO 6%, K
2o+Na
2o 5.5%, Fe
2o
32.0%, TiO
20%, ZrO
20.4%.Mix the mixture that whipping agent is silicon carbide and calcium sulfate outward, volume is 1.5% of foamed ceramic blank quality, and the mass ratio of silicon carbide and calcium sulfate is 8:7, and its preparation method comprises the following steps:
1) each raw material is taken according to said ratio, the coal dust taken, foamed ceramic blank and whipping agent are loaded in ball mill jointly, adopt Ball Mill dry method grinding, add in grinding process account for solid material quality 0.01% trolamine as dispersion agent, grinding is to fineness≤50 μm.
2) compound after levigate is made the granular powder of 0.5 ~ 8mm by tablets press, the powder after granulation is spread into piecing assembly refractory-material dies.
3) fireproof die that granular powder is housed is sent in tunnel furnace, in tunnel furnace, the high-temperature flue gas that first granular powder produces with coal dust internal combustion in front powder in kiln carries out heat exchange, the temperature of high-temperature flue gas is 600 ~ 1200 DEG C, powder pre-heating temperature elevation, when temperature rises to about 600 DEG C, the coal dust be mixed in foamed ceramic blank produces internal combustion, the heat that coal dust firing provides can realize the high temperature sintering of foamed ceramic substantially, foaming, shortage of heat part by be arranged on the burner of clinkering zone in kiln spray into Sweet natural gas carry out supplement and control temperature rise to blowing temperature 1190 DEG C, in whole process, temperature rise rate is 2 ~ 5 DEG C/min, after blowing temperature insulation 90min, obtain foam material.
4) cooled in kiln by the foam material baked, the demoulding after kiln discharge, cutting, obtain foamed ceramic.
In the present embodiment, the heat that high temperature sintering, foaming process institute heat requirement provides primarily of coal dust firing provides, and the heat supplemented by Sweet natural gas is every kilogram of foamed ceramic blank 1100kJ, for coal dust introduces 14.7% of heat.The performance test results shows: foamed ceramic unit weight prepared by the present embodiment is 186Kg/m
3, thermal conductivity is 0.073W/ (mk), and ultimate compression strength is 1.38MPa, and water-intake rate is 1.6%.
Embodiment 3
A kind of preparation method of foamed ceramic, select a kind of low grade coal, calorific value is 13.5MJ/kg, the heat coal blending of 4200kJ is needed by every kilogram of foamed ceramic blank, every kilogram of foamed ceramic blank mixes coal dust 0.31kg coal dust, and foamed ceramic blank chemical component consists of (weight percent): SiO
250%, Al
2o
335%, CaO+MgO 5%, K
2o+Na
2o 4.6%, Fe
2o
33.3%, TiO
21.1%, ZrO
21.0%.Mixing whipping agent is outward single variety silicon carbide, and volume is 0.5% of foamed ceramic blank quality, and its preparation method comprises the following steps:
1) each raw material is taken according to said ratio, the coal dust taken, foamed ceramic blank and whipping agent are loaded in ball mill jointly, adopt Ball Mill dry method grinding, add in grinding process account for solid material quality 0.01% trolamine as dispersion agent, grinding is to fineness≤50 μm.
2) compound after levigate is made the granular powder of 0.5 ~ 8mm by tablets press, the powder after granulation is spread into piecing assembly refractory-material dies.
3) fireproof die that granular powder is housed is sent in tunnel furnace, in tunnel furnace, the high-temperature flue gas that first granular powder produces with coal dust internal combustion in front powder in kiln carries out heat exchange, the temperature of high-temperature flue gas is 600 ~ 1200 DEG C, powder pre-heating temperature elevation, when temperature rises to about 630 DEG C, the coal dust be mixed in foamed ceramic blank produces internal combustion, the heat that coal dust firing provides can realize the high temperature sintering of foamed ceramic substantially, foaming, shortage of heat part by be arranged on the burner of clinkering zone in kiln spray into Sweet natural gas carry out supplement and control temperature rise to blowing temperature 1250 DEG C, in whole process, temperature rise rate is 2 ~ 4 DEG C/min, after blowing temperature insulation 30min, obtain foam material.
4) cooled in kiln by the foam material baked, the demoulding after kiln discharge, cutting, obtain foamed ceramic.
In the present embodiment, the heat that high temperature sintering, foaming process institute heat requirement provides primarily of coal dust firing provides, and the heat supplemented by Sweet natural gas is every kilogram of foamed ceramic blank 840kJ, for coal dust introduces 20% of heat.The performance test results shows: foamed ceramic unit weight prepared by the present embodiment is 272Kg/m
3, thermal conductivity is 0.09W/ (mk), and ultimate compression strength is 3.7MPa, and water-intake rate is 0.8%.
The surface topography map of foamed ceramic prepared by embodiment 1 ~ 3 is shown in accompanying drawing 1 ~ 3 respectively.Foamed ceramic prepared by the present invention is closed pore, and even air hole distribution, aperture is little, air hole structure is regular, does not absorb water; The performance test results shows, obtained foamed ceramic has lower thermal conductivity and water-intake rate, and intensity is high, good heat insulating, both can be used as external-wall heat-insulation material, and can be used for self-insulation wall material again.
Comparative example
A preparation method for foamed ceramic, foamed ceramic blank chemical component consists of (weight percent): SiO
262.8%, Al
2o
318%, CaO+MgO 9%, K
2o+Na
2o4.8%, Fe
2o
34.2%, TiO
20.2%, ZrO
20.3%; Mixing whipping agent is outward single variety silicon carbide, and volume is 1.2% of foamed ceramic blank quality., its preparation method comprises the following steps:
The foamed ceramic blank taken and whipping agent are loaded in ball mill jointly, slip is prepared by wet milling process grinding, in solid material: water is the ratio external adding water of 1:0.5, grinding is to fineness≤50 μm, then slip is carried out spraying dry, obtained powder, gained powder directly loads in piecing assembly refractory-material dies, surface is struck off, then tunnel furnace is sent into, in tunnel furnace, the burner being arranged in kiln preheating section and the section of burning till in kiln provides the fuel needed for whole sintering process (Sweet natural gas), realize the preheating of foamed ceramic blank, sintering, foaming process.Temperature rise rate is 4 ~ 8 DEG C/min, and blowing temperature controls at 1160 DEG C, and insulation 90min, finally cool in kiln, the demoulding after kiln discharge, cutting, obtain foamed ceramic.
This comparative example adopts wet grinding, spraying dry, and dry consumption of calorie is every kilogram of ceramic batch 1800kJ; Whole sintering process consumption of calorie is every kilogram of ceramic batch 8300kJ, and the heat in dry and sintering process provides by supplemental natural gas.
Contrast with embodiment 1 ~ 3, illustrate that preparation method of the present invention effectively can reduce the usage quantity of Sweet natural gas, and without the need to carrying out the spray-drying process of powder, simplifying preparation technology and effectively reducing production energy consumption and cost, belonging to the foamed ceramic burning techniques of a kind of high-level efficiency, low cost.
Bound value, the interval value of each raw material that the present invention relates to can realize the present invention, and lower limit value and the interval value of processing parameter of the present invention (as temperature, time etc.) can realize the present invention, do not enumerate embodiment at this.
Claims (7)
1. a preparation method for foamed ceramic, is characterized in that, with coal dust, foamed ceramic blank and whipping agent for raw material, comprises the following steps:
1) dry method powder process: coal dust, foamed ceramic blank and whipping agent are mixed, compound is placed in ball mill grinding, various raw material is mixed at grinding process;
2) granulation, die-filling: by step 1) in the compound that obtains through ball milling make granular powder by tablets press, and granular powder is spread in refractory-material dies;
3) sinter, foaming: by step 2) in granular powder is housed fireproof die send in kiln, first granular powder carries out heat exchange with the high-temperature flue gas from kiln clinkering zone, granular powder pre-heating temperature elevation, when temperature is raised to 450 ~ 650 DEG C, the coal dust be evenly mixed in powder produces internal combustion, simultaneously by burner postcombustion that kiln clinkering zone is arranged, control kiln temperature and rise to blowing temperature 1150 ~ 1250 DEG C, heat-up rate is 2 ~ 8 DEG C/min, is incubated 30 ~ 90min and obtains foam material under blowing temperature;
4) cooling, the demoulding, cutting: by step 3) in the foam material that obtains cool in kiln, through the demoulding, cutting after kiln discharge, obtain described foamed ceramic.
2. the preparation method of foamed ceramic according to claim 1, is characterized in that, described coal dust is by burning till its incorporation of ratio-dependent that heat is 4000 ~ 7500kJ needed for every kilogram of foamed ceramic blank.
3. the preparation method of foamed ceramic according to claim 1, is characterized in that, in described foamed ceramic blank, each chemical composition and mass percent thereof are: SiO
250 ~ 70%, Al
2o
310 ~ 35%, CaO+MgO 3 ~ 12%, K
2o+Na
2o3 ~ 6%, Fe
2o
30.5 ~ 10%, TiO
20 ~ 1.5%, ZrO
20 ~ 1.5%.
4. the preparation method of foamed ceramic according to claim 1, is characterized in that, described whipping agent is that one or more in silicon carbide, ferric oxide, calcium sulfate mix by any proportioning, and addition content is 0.5 ~ 2% of foamed ceramic blank quality.
5. the preparation method of foamed ceramic according to claim 1, is characterized in that, described grinding process adopts dry method grinding, and grinding is to fineness≤50 μm.
6. the preparation method of foamed ceramic according to claim 1, is characterized in that, after granulation, the granularity of gained granular powder is 0.5 ~ 8mm.
7. the preparation method of the foamed ceramic according to any one of claim 1 ~ 6, is characterized in that, described kiln is tunnel furnace or roller kiln.
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107285802A (en) * | 2017-07-18 | 2017-10-24 | 佛山市溶洲建筑陶瓷二厂有限公司 | A kind of microvesicle ceramic wafer and preparation method thereof |
| CN107805051A (en) * | 2017-11-16 | 2018-03-16 | 辽宁罕王绿色建材有限公司 | With the method for three layers of cloth production sandwich type foamed ceramic building block of iron tailings raw material |
| CN107857565A (en) * | 2017-11-16 | 2018-03-30 | 辽宁罕王绿色建材有限公司 | A kind of technique of raw material semidry method grain production foamed ceramic |
| CN111875395A (en) * | 2020-07-07 | 2020-11-03 | 佛山市德力泰科技有限公司 | Energy-saving light foamed ceramic whole body refractory material, energy-saving light foamed ceramic whole body refractory plate and application thereof |
| CN111974508A (en) * | 2019-09-19 | 2020-11-24 | 昆明特康科技有限公司 | Ceramic powder granulating method |
| CN113307653A (en) * | 2021-05-08 | 2021-08-27 | 江西中材新材料有限公司 | Foamed ceramic and preparation method thereof |
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| CN102718547A (en) * | 2012-06-11 | 2012-10-10 | 中国钢研科技集团有限公司 | Foamed ceramic material and preparation method thereof |
| CN103387414A (en) * | 2013-08-16 | 2013-11-13 | 陈世友 | Closed-cell foamed ceramic insulation board and preparation method thereof |
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| CN102603357A (en) * | 2012-03-22 | 2012-07-25 | 江苏南瓷绝缘子有限公司 | Method for manufacturing foam ceramic heat-insulation plate with closed pores |
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN107285802A (en) * | 2017-07-18 | 2017-10-24 | 佛山市溶洲建筑陶瓷二厂有限公司 | A kind of microvesicle ceramic wafer and preparation method thereof |
| CN107805051A (en) * | 2017-11-16 | 2018-03-16 | 辽宁罕王绿色建材有限公司 | With the method for three layers of cloth production sandwich type foamed ceramic building block of iron tailings raw material |
| CN107857565A (en) * | 2017-11-16 | 2018-03-30 | 辽宁罕王绿色建材有限公司 | A kind of technique of raw material semidry method grain production foamed ceramic |
| CN111974508A (en) * | 2019-09-19 | 2020-11-24 | 昆明特康科技有限公司 | Ceramic powder granulating method |
| CN111875395A (en) * | 2020-07-07 | 2020-11-03 | 佛山市德力泰科技有限公司 | Energy-saving light foamed ceramic whole body refractory material, energy-saving light foamed ceramic whole body refractory plate and application thereof |
| CN113307653A (en) * | 2021-05-08 | 2021-08-27 | 江西中材新材料有限公司 | Foamed ceramic and preparation method thereof |
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