CN105837168B - 一种高强度砌块的制备方法 - Google Patents
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Abstract
本发明公开了一种高强度砌块的制备方法，通过采用高温加压的方式制备砌块，大大提高了砌块的密度和耐压强度，减少了高温烧制的时间，在节能的同时，拓展了砌块的使用范围，该产品原材料来源广泛、生产工艺简单、产品质量和性能均比传统砌块有明显提升。
Description
技术领域
本发明涉及建筑材料技术领域，尤其涉及一种高强度砌块的制备方法。
背景技术
我国现在的墙体材料已经从传统的实心黏土砌块过渡到新型墙体材料，新型墙体材料从用途上可以分为砌块、砌块和板材三大类。目前国内常用的新型墙体材料中有一大类是非烧结的混凝土砌块，主要有陶粒混凝土砌块、普通混凝土砌块、石灰、水泥、矿渣粉加气混凝土砌块等。这些砌块要么安全性较差，特别是采用聚苯等有机高分子材料，其耐热温度低，易燃烧，要么工艺复杂，成本高。作为大规模应用的建筑砌块材料，必须要在保证其低成本的前提下，考虑其是否具备良好的力学性能和较高的使用安全性。同时随着砌块的应用日益广泛，如何在保证砌块轻质的前提下，兼顾高强度、承重的难点，日益受到业内人士的重视。
发明内容
基于背景技术存在的技术问题，本发明提出了一种原材料来源广泛、生产工艺简单、产品质量和性能稳定的高强度砌块的制备方法。本发明提出一种高强度砌块的制备方法，包括以下步骤：
各原料按比例混合后，在630T摩擦压砌块机上成块坯，在加压2-5T的条件下1150-1200℃高温烧结3-5小时，后升温至1300℃烧结1-2小时成砌块。所述的砌块，包括以下重量百分比的组分：
所述的目粒度200目，指的是将颗粒过200目筛，取筛下物。
广西维罗白泥是一种软质高岭土，也可以叫软质耐火粘土，1992年经我国粘土专家刘长龄在广西扶绥甄别后确认维罗白泥就是球粘土，所以现在也有人叫维罗球粘土。维罗白泥(球粘土)主要化学成分为SiO2(二氧化硅)含量45.3～51.6％，Al2O3(三氧化二铝)含量26～36.8％，Fe2O3(三氧化二铁)0.65～2.2％，K2O+Na2O<1.5％。广西白泥(广西维罗白泥球粘土)是我国目前所发现质量最好，质量最纯的软质耐火粘土，广西白泥(广西维罗白泥球粘土)具特有的物理性能：可塑性好、流动性好、结合性好、质很纯。Al2O3≥34％，Fe2O3<1.5耐火度大于1700℃可塑性指数>28。
工业上利用红柱石，主要是取其耐高温的特性。红柱石在常压下加热至1350℃以后，开始转化成与原晶体平行的针状莫来石。莫来石晶体是铝硅酸盐在高温作用下唯一稳定的形式，其理论转化率为87.64％。
红柱石在加热转化成莫来石的过程中，可以形成良好的莫来石网络，体积膨胀约4％。这是一种不可逆的晶体转化，一经转化，则具有更高的耐火性能，耐火度可达1800℃以上，且耐骤冷骤热，机械强度大，抗热冲击力强，抗渣性强，荷重转化点高，并具有极高的化学稳定性(甚至不溶于氢氟酸)和极强的抗化学腐蚀性。
珍珠岩是一种火山喷发的酸性熔岩，经急剧冷却而成的玻璃质岩石，因其具有珍珠裂隙结构而得名。珍珠岩矿包括珍珠岩，黑曜岩和松脂岩。三者的区别在于珍珠岩具有因冷凝作用形成的圆弧形裂纹，称珍珠岩结构，含水量2～6％；松脂岩具有独特的松脂光泽，含水量6～10％；黑曜岩具有玻璃光泽与贝壳状断口，含水量一般小于2％。珍珠岩的氧化与熔融温度为：开始收缩温度为1025℃，软化温度为1175℃，熔融温度大于1500℃，软化温度范围为150℃，熔化温度范围为325℃。珍珠岩开始收缩的温度比长石低120℃，软化温度低75℃，软化范围加宽95℃。由于这些特性，珍珠岩在陶瓷制品烧成中可以大大降低烧成温度，改进烧结的质量。通过进一步深入研究，珍珠岩还有一种特性，即含有珍珠岩的陶瓷坯体中，莫来石晶体形成较早，从而有利于烧结过程的展开。这样一来，含珍珠岩坯体除具有与长石-石英-黏土(高岭矿物)三元系坯体配方相同的工艺特性之外，还能降低烧成温度(从原来的1280℃降低为1180℃-1160℃)，并且具有良好的热稳定性。
粉煤灰，是从煤燃烧后的烟气中收捕下来的细灰，粉煤灰是燃煤电厂排出的主要固体废物。我国火电厂粉煤灰的氧化物组成为：SiO2、Al2O3及少量的FeO、Fe2O3、CaO、MgO、SO3、TiO2等。其中SiO2和Al2O3含量可占总含量的60％以上。
粉煤灰是我国当前排量较大的工业废渣之一，随着电力工业的发展，燃煤电厂的粉煤灰排放量逐年增加。大量的粉煤灰不加处理，就会产生扬尘，污染大气；若排入水系会造成河流淤塞，而其中的有毒化学物质还会对人体和生物造成危害。另外粉煤灰可作为混凝土的掺合料。
本发明的制备方法中与传统方法的不同之处在于：一是制备的过程中采用高温并加压的方式，而传统方式在制备块坯时会加压，高温时不会再加压；二是传统方式会在制备块坯以后先低温干燥，再高温烧制，而本发明直接使用高温加压烧制的方式，加压的目的是为了降低珍珠岩在反应时膨胀性能，减少形成的中空结构，在压力下使珍珠岩细粉与粉煤灰中的二氧化硅以及氧化铝成分反应更快，形成的莫来石结构更紧密。本发明的制备方法的设计思路为：珍珠岩有一种特性，在烧制过程中，莫来石晶体形成较早，从而有利于烧结过程的展开，本发明将烧制温度设立在1150-1200℃之间，珍珠岩和粉煤灰中的二氧化硅以及氧化铝成分反应，逐渐形成莫来石结构成分，加温至1300℃将红柱石也转化为莫来石结构，进一步加强砌块的密度。
加入广西白泥和丙二醇的目的是为了提高砌块块在高温烧结时的粘结力，砌块块在高温及压力下不会爆开。
实验证明，在加入广西白泥后，在高压下可以很顺利的压制成块坯，但是在压力下及1150-1200℃下加热不到5min，块坯很快会开裂，严重的会爆开，但是加入少量丙二醇后，砌块块的粘结效果会大大加强，不会再发生开裂现象，成砌块表面仅有细微的纹路。
本发明的砌块的主要为莫来石结构，具有良好的耐火性能。
本方案相比于传统方案的有益之处在于：本发明通过采用高温加压的方式制备砌块，大大提高了砌块的密度和耐压强度，减少了高温烧制的时间，在节能的同时，拓展了砌块的使用范围，该产品原材料来源广泛、生产工艺简单、产品质量和性能均比传统砌块有明显提升。
具体实施方式
实施例1
一种高强度砌块的制备方法，包括以下步骤：
各原料按比例混合后，在630T摩擦压砌块机上成块坯，在加压3T的条件下1180℃高温烧结3小时，后升温至1300℃烧结1.5小时成砌块。所述的砌块，包括以下重量百分比的组分：
实施例2
一种高强度砌块的制备方法，包括以下步骤：
各原料按比例混合后，在630T摩擦压砌块机上成块坯，在加压2-5T的条件下1150-1200℃高温烧结3-5小时，后升温至1300℃烧结1-2小时成砌块。所述的砌块，包括以下重量百分比的组分：
实施例3
一种高强度砌块的制备方法，包括以下步骤：各原料按比例混合后，在630T摩擦压砌块机上成块坯，在加压2-5T的条件下1150-1200℃高温烧结3-5小时，后升温至1300℃烧结1-2小时成砌块。所述的砌块，包括以下重量百分比的组分：
实施例4
一种高强度砌块的制备方法，包括以下步骤：各原料按比例混合后，在630T摩擦压砌块机上成块坯，在加压2-5T的条件下1150-1200℃高温烧结3-5小时，后升温至1300℃烧结1-2小时成砌块。所述的砌块，包括以下重量百分比的组分：
对实施例1-4进行检测：
此检测数据只针对上述检测样品。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，根据本发明的技术方案及其发明构思加以等同替换或改变，都应涵盖在本发明的保护范围之内。
Claims (4)
1.一种高强度砌块的制备方法，其特征在于，包括以下步骤：
将广西白泥、粉煤灰、红柱石、珍珠岩、丙二醇按比例混合后，在630T摩擦压砖机上成块坯，在加压2-5T的条件下1150-1200℃高温烧结3-5小时，后升温至1300℃烧结1-2小时成砖。
2.如权利要求1所述的高强度砌块的制备方法，其特征在于，所述砌块的原料包括以下重量百分比的组分：
。
3.如权利要求2所述的高强度砌块的制备方法，其特征在于，所述的各原料的纯度及粒径如下：细粉煤灰的粒径≤100微米，粗粉煤灰的粒径为：100微米＜粒径≤300微米；红柱石：纯度55％以上、粒度200目；珍珠岩：粒度200目。
4.如权利要求3所述的高强度砌块的制备方法，其特征在于，包括以下步骤：
各原料按比例混合后，在630T摩擦压砖机上成砖坯，在加压3T的条件下1180℃高温烧结3小时，后升温至1300℃烧结1.5小时成砖；
所述的砌块，包括以下重量百分比的组分：
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| CN101265076A (zh) * | 2008-04-17 | 2008-09-17 | 淄博嘉环耐火材料有限公司 | 蓄热式换热器用轻质镁砖及其制法 |
| CN104891953A (zh) * | 2015-05-07 | 2015-09-09 | 刘林 | 一种耐酸粉煤灰砖及其制作方法 |
| CN104891958A (zh) * | 2015-05-20 | 2015-09-09 | 合肥工业大学 | 一种热压有机粘土原位制备陶瓷/碳复合材料的方法 |
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| CN101265076A (zh) * | 2008-04-17 | 2008-09-17 | 淄博嘉环耐火材料有限公司 | 蓄热式换热器用轻质镁砖及其制法 |
| CN104891953A (zh) * | 2015-05-07 | 2015-09-09 | 刘林 | 一种耐酸粉煤灰砖及其制作方法 |
| CN104891958A (zh) * | 2015-05-20 | 2015-09-09 | 合肥工业大学 | 一种热压有机粘土原位制备陶瓷/碳复合材料的方法 |
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