CN105712698A - 工业废玻璃废料生产环保陶瓷釉面砖工艺 - Google Patents
工业废玻璃废料生产环保陶瓷釉面砖工艺 Download PDFInfo
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- CN105712698A CN105712698A CN201610136840.XA CN201610136840A CN105712698A CN 105712698 A CN105712698 A CN 105712698A CN 201610136840 A CN201610136840 A CN 201610136840A CN 105712698 A CN105712698 A CN 105712698A
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- Prior art keywords
- waste
- produced
- bricks
- ceramic
- glazed tile
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Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/131—Inorganic additives
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B33/00—Clay-wares
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Abstract
本发明公开了一种工业废玻璃废料生产环保陶瓷釉面砖工艺，是属于能释放元素负离子净化空气的环保陶瓷砖生产工艺技术领域。是由废液晶显示器玻璃或其他废玻璃，石油炼制的废催化剂，碱厂废渣生产碳酸化砖，碱厂废碱渣生产的元素抗菌功能性环保陶瓷釉面砖组成。这种陶瓷砖由工业废玻璃废料添加高岭土、黏土、麦饭石、奇冰石、沸石、电气石、甲壳素，壳聚糖等天然矿物成分，通过本工艺生产的陶瓷砖，既能达到废物利用，变废为宝又能恢复陶瓷自发不断地释放有益人体健康的元素、负离子、轴射远红外、抗电磁波污染的物质，有效地吸附，拮抗空气中的有毒有害金属及病毒细菌，净化空间，增强人体健康益寿，具有特效功效的陶瓷环保釉面砖。
Description
技术领域：
本发明公开了一种工业废渣玻璃废料生产功能环保陶瓷釉面砖工艺，是属于能释放元素负离子净化空气环保陶瓷釉面砖生产工艺技术领域。
背景技术：
瓷釉面砖按吸水率可分为瓷质砖、炻质砖、釉面砖、碳酸化砖、陶制砖。吸水率大于10％的称陶瓷砖，市场上一般称内墙砖，广泛用于居民住宅、宾馆饭店、公共场所等建筑物的墙面装饰，是室内装修的主要产品。吸水率小于0.5％的称瓷质砖，也就是通常所说的玻化砖，用于铺地的大多经过表面抛光处理的，因此又叫抛光砖。广泛用于各类建筑物的地面装饰，也是室内装修的主要产品。吸水率在0.5％～10％之间的陶瓷砖一部分用于外墙修饰，一部分主要用于室内地面的装饰，多用于卫生间，与内墙砖配套使用。釉面砖多作为内墙装饰用薄皮精陶建筑材料，也有作为耐酸槽用。
性质与规格：可分为正方形、矩形、异形配件砖等品种。按其组成可分为：硅灰石质、叶蜡石质、瓷石质及长石质等。其化学成分一般为：SiO260％～70％，Al2O315％～22％，CaO1.0～10％，MgO1.0％～3.0％，R2O小于1.0％。吸水率不大于22％，白度不小于78％，耐急冷急热性150℃，一次不裂。耐蚀性好。常用半干压法成型。可分为坯体素烧后施釉入窑釉烧的二次烧成法，前者要求高，质量常不及后者。GB/T4100.5-1999干压陶瓷砖(吸水率E＞10％)。
按照陶瓷砖的成型方法和吸水率进行分类，陶瓷砖分为挤压成型陶瓷砖和干压成型陶瓷砖。
标准GB/T4100-2006。
本工艺在陶瓷砖生产工艺配方中添加高岭土黏土，天然矿物麦饭石、奇冰石、沸石、电气石的矿物元素成分及天然的抗菌杀菌的甲壳素及壳聚糖达到既能使陶瓷砖释放多种微量元素有效补充，调节拮抗人体内元素平衡，辐射红外线，电磁波，自发不断地产生负离子及杀菌抗菌滤毒吸毒的电气石、沸石纳米粉末，又能达到人体健康益寿的多功能性功效性环保陶瓷釉面砖。
发明内容：
本发明的目的在于提供一种工业废玻璃废料生产功能性环保陶瓷釉面砖工艺。
其技术解决的方案是：
1、一种工业废玻璃废料生产环保陶瓷釉面砖工艺，其特征是：由废液晶显示器玻璃及其他废玻璃按下列配方与工艺流程
(1)按下列质量份配比组成％
废玻璃15-45；
高岭土20-60；
麦饭石纳米粉7.8-22.5；
电气石纳米粉7-21；
水加至100；
(2)废显示器玻璃及其他废玻璃制备陶瓷砖工艺流程
①将废弃的液晶显示器中的玻璃从显示器上剥离下来和其他废玻璃破碎球磨后过20目筛备用；然后，将高岭土烘干后破碎球磨至20目备用；麦饭石、电气石分别制成纳米粉；
②按质量分数取15％～45％的经破碎球磨后的废玻璃和20％～60％的高岭土。各7～21％麦饭石、电气石、纳米粉混合放入球磨罐中，再加入至100％的水，球磨混合均匀后形成配合料；
③将配合料放入磨具中，在5MPa的压力下干压成陶瓷砖胚体，然后将成型的陶瓷砖胚体在室温下放置24h后再放入烘箱中，于110～150℃烘制24h，再将烘制后的样品放入炉子中，按照以下工艺过程烧结：
预热阶段：以3～6℃％2Fmin的升温速率自室温升到110～130℃；
升温阶段：以5～10℃％2Fmin升到900～1250℃；
保温退火阶段，在900～1250℃保温6h后随炉冷却至室温，得陶瓷砖。
本工艺的制备方法制得的陶瓷砖结构强度好，吸水率低，硬度大，化学稳定性良好，使用温度高，应用范围广，具有良好的释放微量元素负离子清新空气功能性的环保型陶瓷砖。
见说明书附图1“废显示器玻璃及其他废玻璃制备陶瓷砖工艺流程”。
2、一种工业废玻璃废料生产环保陶瓷釉面砖工艺，其特征是：由石油炼制的废催化剂，按下列配方与工艺流程
(1)按下列质量份配比组成％
(2)废催化剂生产釉面砖工艺流程
工艺流程是将上述配方中物料用颚式破碎机破碎，再送入轮碾机粉碎成直径小于3mm的纳米材料加入球磨机内。球磨18～20h，细度为万孔筛筛余量在1％～2％以内，并经湿式吸铁器除铁后放入水泥池内。将由水泥池内取出的磨碎料包裹在棉布包里，放到挤压机上横向挤榨成饼状，使含水率降到12％～13％。把挤后的料饼送入干燥窑内干燥，稳度30～60℃，一般烘干约30h左右，使料饼水分降到7.5～8.5％。再将干燥后的料饼送入对辊机辊成粉状。在粉料中加入适量水并搅拌混合均匀，送进陈化池陈化约2d，使水分均匀地渗入料粉内，所得粉料水分为6％～7％
成型：成型压力58.8MPa，一次施压成型后，小心地将泥坯取出，再竖装至匣钵中。
烘干：将坯体放入烘干室内，在60～70℃的温度下烘干2～3d，即可存放到坯体室待烧。
成型的坯体修边后，经人工或自然烘干至水分小于2％，进入隧道窑焙烧。隧道窑焙烧是连续作业，烧成带控制，烧成温度为1140～1180℃。坯体刚进入烧成室时的温度要低，然后缓慢升温，以防止成品出现裂纹、爆裂而降低成品合格率。烧成周期一般为78h，坯料在焙烧完毕后即进入冷却带冷却。降温要缓慢，不可骤然降温，否则可能使砖坯出现裂纹或变形。
将装有挂釉面的砖的匣体放入烧成室，采用13.5m多孔推板窑进行釉烧，其烧成温度为1020～1060℃，烧成周期为16h，出窑即可得成品釉面砖。
本工艺利用废催化剂取代部分填料黏土生产釉面砖，工艺简单，降低了生产成本，具有较好的环境效益和经济效益。并能释放对人体有益能补充人体元素平衡的微量元素，及自发不断地产生对人体有益的净化空气的负离子滤毒拮抗空气中有害金属和有毒气体保护环境净化空间。
黏土是一类含铝、铁、镁等元素的具有层状结构的硅酸盐化合物，有的黏土物质包括高岭土类物质、蒙脱土、蛭石、黏土级云母、伊利石、绿泥石、海绿石、膨胀绿泥石，黏土抗菌剂中的膨润土，因其具有很强的吸附能力和离子交换能力，而成为无机抗菌剂的理想载体。膨胀土为典型的层状黏土矿物，其层间的阳离子易被交换，且有很大的离子交换容量。并具有广谱抗菌性，对革兰阴性菌、真菌和霉菌，尤其是对大肠杆菌和金黄色葡萄球菌的抗菌率可达到99.9％，而且该抗菌剂安全性高，无毒无刺激，抗菌持久。
见说明书附图2“废催化剂生产釉面工艺流程”。
3、一种工业废玻璃废料生产功能性环保陶瓷砖工艺，其特征是：由氨碱厂废渣生产碳酸化砖按下列配方与工艺流程
(1)按下列质量份配比组成％
(2)工艺流程：
碱厂废渣先用海水洗涤至其Cl-含量与海水一致时为止，然后用板框式压滤机压滤。当过滤压力为4.9X105Pa，时，恒压11min，滤饼水分含量为56％～59％，在100℃热风下干燥10h，粉碎后待用。
①配料比：通常采用废碱渣17-51％，生石灰5-15％，炉渣15-45％，奇冰石6-18％，石膏0.5-1.5％，沸石加至100％，水灰比为1。
②工艺条件：上述原料按配方比要求进行混合、消化，消化时间为60min，温度70～90℃，然后在成型压力19.6MPa下碾压3～5min，制得240mm×115mm×53mm成型砖坯。风干至水分含量为3％～3.5％，送入碳化窑内进行碳酸化，通入CO2浓度为38％～42％的窑气，碳酸化的温度为50～60℃，压力为(0.4～0.53)X105Pa，碳酸化时间为36h。
本工艺的特点是就地取材。
本工艺过程可行，设备简单，便于操作。产品碳酸化砖强度好。
见说明书附图3“氨碱厂废渣生产碳酸化砖工艺流程”。
4、一种工业废玻璃废料生产环保陶瓷釉面砖工艺，其特征是：由碱厂的废碱渣生产元素抗菌功能性环保陶瓷釉面砖按下列配方与工艺流程
(1)按下列质量份配比组成％
(2)工艺流程
①首先将碱厂碱渣研碎或经200目筛的细粉与甲壳素或壳聚糖研碎过200目筛的中心粒径0.5～10mm细粉按质量分数麦饭石细粉15～45、碱渣细粉取15～54％甲壳素壳聚糖各5～15％，将其两者混合后再加水至100％，在球磨机中充分研磨混合均匀后形成配合料。
②配合料放入模具中。在5MPa的压力下干压成元素杀菌陶体砖胚体，然后将成型的元素杀菌陶瓷砖胚体置室温下放置24h后，再放入烤箱中，于110-150℃烘制24小时，再将烘制后的样品放入炉子中，按以下工艺过程烧制，预热阶段以3～6℃/min的升温速率自室温升到110～130℃。
③升温阶段，以5～10℃/min升至900～1250℃，保温退火阶段，在900～1250℃保温6h随炉冷却至室温即得微量元素抗菌釉面砖。
见说明书附图4“元素抗菌功能环保陶瓷釉面砖工艺流程”。
本工艺制得的元素抗菌功能性环保陶瓷砖具结构强度好、光洁度好，吸水率低、硬度大，化学稳定性好，能自发不断地释放微量元素负离子天然抗菌杀菌消毒功效既环保又健康的元素陶瓷砖。
碱渣组分经科学分析：钙为31.44％，镁5.83％，钾4.02％，纳0.78％，铝0.51％，铁0.33％，锰446mg/kg，磷328.5mg/kg，钛293.9mg/kg，钒18.6mg/kg，钴13.51mg/kg，可溶硅11.6mg/kg，锶123.9mg/kg，锌220.5mg/kg，铬87.8mg/kg，还含有钙镁氯钠等常量元素，亦含有铁、锌、锰、钛、钒、铬、镍、锶、硼、铍、铜、钴、硅等植物和人体都必需的微量元素，而有害元素铅含量小于地壳克拉克值13mg/kg，其他的一些元素也属于正常的本底水平。所以用碱渣作基料配制元素功能陶瓷砖具有很好的应用价值经济效益值得推广应用。
以沸石和黏土为载体的抗菌材料制备的元素抗菌功能性环保陶瓷砖。沸石是一种架状的含水铝硅酸盐矿物，沸石是由硅氧四面体[SiO4]在三度空间呈骨架状无限排列构成具有立体结构的物质。由于硅原子可被铝原子置换而形成铝氧四面体[AlO4]而使四面体带负电荷，这种负电荷可通过引入金属离子加以平衡。而氧桥把四面体连接形成许多通道和微孔，沸石的离子交换便在此区域进行。不同沸石中铝置换硅的数量不同，所需平衡的负电荷也有所不同。同时这些为平衡负电荷进入沸石晶体中的金属离子(如Na+、K+、Ca2+等)可被其他的离子如Cu2+、Zn2+、Ag+、Cd2+、Hg2+等置换，并由此形成离子交换性。
将沸石微粉浸在金属可溶性盐的水溶液或熔盐中，使其中的钠离子被铜、银、锌等金属离子置换，即可获得具有抗菌功能的沸石，对大肠杆菌、金黄色葡萄球菌、粪肠球菌、黑曲霉菌，对短梗霉菌球毛壳霉菌其病毒细菌均有很明显的抑菌、抗毒、滤毒效果。
麦饭石又称奇冰石、沸石是以硅酸、氧化铝为主要成分，还含有人体必需的Fe、Ca、Mn、Mg等无机物，神奇的净水功效，主要的成分有：氧化亚铁1.29％、氧化铁1.40％，无水磷(磷酸酐)0.26％，氧化锰0.02％，镁3.55％，钾3.19％，氧化钙2.00％，纳3.16％，钛0.30％，吸附水1.10％，结合水0.90％(+)：重金属40ppm以下，均在允许值下限安全无毒通过电子显微镜观察麦饭石表面，呈蜂窝状海绵样凹凸凹不平样结构和藕断面样结构。后者出现在沿解埋面剥离的晶面上。多见大小不齐的无数小孔，具有无比巨大的表面积，对重金属铅、汞、砷箐和细菌病毒有较强的吸附作用，并遇水能很快地溶出有益人体健康并能散布空间的纳米微粒中的微量元素，通过人体呼吸吸收进入人体，促进人体内达到元素平衡，身体健康，并具有抗电磁波辐射污染功能因为含有Fe3O4、Fe2O3、FeO。
电气石是天然矿石成分和结构十分复杂的负离子发生体即负离子粉是由气石经焙烧研磨处理而得可将空气负离化添加在陶瓷釉砖制作工艺中，因为其经粉碎的电气石纳米粉，具有热电性和压电性即是在温度、压力其微小的变化下就能引起电气石纳米粉晶体之间的气热差，从而形成电热、高压电恢电填中的空气发生电离波击中的电子附着于附近的水和氧分子，恢其转化成空气中的负离子，研制含负离子的陶瓷釉面砖非常重要，砖体由散发出来的负离子纳米粉经人体呼吸吸收进入人体可对人体血液有一定的净化作用，恢受损的细胞复活和协调自律神经的作用。净化污染的空气能恢人体走到呼吸舒畅、心旷神怡、负离子具有较强的生物波发射功能以及防止人体的老化和早衰、防臭、滤毒功能，空气中的负离子，他就像食物和营养元素一样，对人体和其他生物的生命活动有着十分重要的影响被称为“空气中的维生素”“长青素”所以研制含负离子的功能性环保陶瓷釉面砖是一种具有非常重要作用的实质性突出性的发明。
甲壳素和壳聚糖均是来自天然贝壳、蟹壳、虾壳、鱼骨及昆虫等动物壳体非常坚硬的部分，甲壳素结构式中的N-乙醇基被脱去55％以上时，则成为甲壳素最重要的衍生物壳聚糖。甲壳素和壳聚糖具有良好的粘合性，生物相容性、生物降解性、无毒性，但有特殊的吸附性，它不溶于水、有机溶剂、烯酸和稀碱，可溶于浓硫酸、浓盐酸、85％磷酸，同时发生降解，它们的化学结构与纤维素相似，若将甲壳素或壳聚糖放在适当的溶剂中可以溶解，若配制成一定浓度、一定粘度就具有较好的柔韧强度，因此可以通过湿法或干法的方法制成长纤维或短纤维，即甲壳素纤维或壳聚糖纤维，它们均具有很强的抑菌和抗菌能力分别达到100％、70.43％和50.11％，作为添加剂制成的本发明，制成环保陶瓷釉面砖，既能降解、阻燃、安全、环保。抗菌杀菌，防电磁波污染又能释放多种微量元素负离子促进人体健康，多种特殊功能环保陶瓷釉面砖。
下面结合实施例对本发明进一步说明
具体实施方法：
实施例1：一种工业废玻璃废料生产环保陶瓷釉面砖工艺，其特征是：由废液晶显示器玻璃及其他废玻璃按下列质量份配比组成％
废玻璃15-45；
高岭土20-60；
麦饭石纳米粉7.8-22.5；
电气石纳米粉7-21；
水加至100；
实施例2：一种工业废玻璃废料生产环保陶瓷釉面砖工艺，其特征是：由石油炼制的废催化剂按下列质量配比组成％
实施例3：一种工业废玻璃废料生产功能性环保陶瓷砖工艺，其特征是：由氨碱厂废渣生产碳酸化砖按下列质量配比组成％
实施例4：一种工业废玻璃废料生产环保陶瓷釉面砖工艺，其特征是：由碱厂的废碱渣生产元素抗菌功能性环保陶瓷釉面砖按下列质量份配比组成％
Claims (4)
1.一种工业废玻璃废料生产环保陶瓷釉面砖工艺，其特征是：由废液晶显示器玻璃及其他废玻璃按下列质量份配比组成％
废玻璃15-45；
高岭土20-60；
麦饭石纳米粉7.8-22.5；
电气石纳米粉7-21；
水加至100。
2.一种工业废玻璃废料生产环保陶瓷釉面砖工艺，其特征是：由废催化剂生产釉面砖按下列质量配比组成％
黏土9-27；石英G-186-18；
麦饭石纳米粉8-24；电气石纳米粉6-18；
水玻璃0.2-0.6；石油炼制的废催化剂加至100。
3.一种工业废玻璃废料生产功能性环保陶瓷砖工艺，其特征是：由氨碱厂废渣生产碳酸化砖按下列质量配比组成％
4.一种工业废玻璃废料生产环保陶瓷釉面砖工艺，其特征是：由废碱渣生产元素抗菌功能环保陶瓷釉面砖按下列质量份配比组成％
碱渣18～54；麦饭石15～45；
负离子粉5～15；甲壳素5～15；
壳聚糖5～15；水加至100。
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