CN106348782B - 一种利用果壳粉制备建筑保温材料的方法 - Google Patents
一种利用果壳粉制备建筑保温材料的方法 Download PDFInfo
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Abstract
本发明公开了一种利用果壳粉制备建筑保温材料的方法，它由以下质量百分比的原料和掺合料混合搅拌制浆，经喷雾造粒、高温烧制而成；页岩50‑60％、长石10‑15％、砂岩10‑13％、石灰石0‑3％、菱镁土5‑8％以及果壳粉10‑16％。本发明提供的建筑保温材料制备方法不仅利用矿山原料和废弃的果壳粉实现资源综合利用，而且其制品具有较好的力学性能和保温性能，其制造成本低，环境污染小。
Description
技术领域
本发明属于建筑保温材料领域，最大限度地利用果壳粉等农业剩余物，添加低品味长石、页岩、砂岩、石灰石、菱镁土等矿山原料，将其混合烧结制备建筑保温材料，可用于城市化和新农村建筑节能建设需要。
背景技术
目前，果壳是果仁加工所残存的固体有机废弃物，已经成为一种典型的农业剩余物，广泛分布在我国华北地区，包括核桃壳、杏壳、樱桃壳、酸枣壳，果壳具有质地坚硬、硬度高、热值高。在我国果壳的综合利用尚不充分，例如过去核桃作为干果销售,其果壳难以回收利用,现在出现了核桃的深加工工艺,一是取仁或取仁后加工成饮料；二是制油,大量集中的核桃壳被丢弃或被焚烧,造成资源的极大浪费。近年来，人们对核桃壳的综合利用进行了深入的研究。研究表明，核桃壳的组成成分为：灰分0.663％，水分9.59％，苯醇抽出物3.71％，木质素38.05％，纤维素30.88％，半纤维素27.26％。利用不同组分、组成果壳，研究果壳作为不同用途加以综合利用。
将果壳的应用现状进行总结，现有利用途径主要作为过滤材料、活性炭加工、抗氧化剂等，为促进果壳的深加工利用提供了一定途径，但是这些利用途径等果壳原料纯度、粒度要求极高，相关利用途径如下：
1.制造活性炭：由于核桃壳的化学成分多为含碳物质,而活性炭是一种具有发达的孔隙结构、巨大的比表面积和优良的吸附性能的含碳物质：
(1)以山核桃壳为原料,采用水蒸气活化法制备不定型颗粒活性炭。试验结果表明,活性炭的综合得率为12％～16％。
(2)将核桃壳木炭粉碎至小于160目,加入黏结剂混合均匀后挤条成型、干燥,置于电热转炉中在氮气保护下炭化,加热条件为升温速率10℃/min、终温800℃、恒温时间30min,冷却后得到产品碳分子筛。
2.过滤材料:作为过滤器中的滤料，核桃壳滤料具有亲水疏油性能,处理含油污水后容易洗涤再生,特别是处理含油量低于100mg/L的污水,效果良好,因此已广泛应用于油田含油污水的处理。核桃壳过滤器已成为污水处理中的主要过滤设备。
3.生产抗氧化剂：在储存油脂及含油食品的过程中,油脂中的不饱和脂肪酸极易被氧化,造成食品色泽风味及质地发生改变,以至损害消费者的身体健康。试验结果表明,核桃壳提取物可有效地抑制亚油酸的脂质氧化,其中以正己烷和乙酸己酯提取物的抑制效果为好,可与同浓度的茶多酚相媲美
上述利用果壳制备多功能材料工艺复杂成本高，每年被利用的果壳数量相对有限，大部分遗弃在果仁加工厂周边露天堆放或填埋在周边坑池内，未能将其充分进行资源化处理。
随着我国城市建设和新农村发展，需要改善建筑节能水平，需要大量建筑节能产品。因此，利用果壳和低品位矿山原料，开发适用新农村建设用的无机烧结型保温建筑材料。
发明内容
本发明利用果壳和低品位矿山原料，开发适用新农村建设用的无机烧结型保温建筑材料。利用果壳和低品位矿山原料，开发适用新农村建设用的无机烧结型建筑保温材料。该建筑保温材料成型制备工艺将低品位矿山原料采用湿法研磨制浆、果壳破碎形成果壳粉，将两者混合，然后离心喷雾造粒，进行烧结和退火，形成多孔烧结建筑保温材料。
本发明使用的果壳包括核桃壳、杏壳、樱桃壳、酸枣壳等，
可以为一种或几种混合物，将其使用粉碎机将其破碎成果壳粉，其粒度达到40-200目。一般市场所售果壳粉一般是以核桃壳为主的多种果壳的混合物。
果壳粉作用分别为：(1)占位造孔剂，在高温烧结时，果壳粉分解和碳化，在无机原料内部形成孔穴，为制备多孔无机保温材料充当发泡剂和造孔剂作用。
(2)果壳粉为有机质材料，在加热过程中会释放大量热量，大约为煤炭发热量的40-60％，约为2800-4500Kcal/kg,是一种有机质燃料，在烧结过程释放热量，成为一种有机质燃料，促进烧结过程的能源节约。
本发明所使用的低品位矿山原料包括长石、页岩、砂岩、石灰石、菱镁土等，上述原料主要作为烧结原料，提供硅酸盐固相反应的基本物质，促进固相反应和液相形成。
砂岩主要提供SiO2，是硅酸反应的基础原料，长石主要提供SiO2、Al2O3、Na2O、K2O，是促进烧结和液相形成物质，页岩是一种沉积性层状粘土质原料，富含石英、长石、氧化铁，提供SiO2、Al2O3、Na2O、K2O、Fe2O3，是湿法制备过程中，泥浆悬浮和塑性物质提供者。石灰石主要提供CaCO3,是促进高温硅酸烧结反应物质，菱镁土主要提供MgCO3,既是促进高温硅酸烧结反应物质，又是促进堇青石相(2MgO·2Al2O3·5SiO2)形成，改善材料力学性能和热学性能。
通过上述原料，本发明制备一种烧结型多孔无机建筑保温材料，该建筑保温材料具有保温功能、防水功能、防火功能。其保温功能是通过内部的多孔疏松轻质结构来实现的，主要是果壳粉烧结占位形成的气腔；防火功能是该材料纯无机特性来保障的，不具有可燃性。防水功能是由其内部气孔的封闭性和烧结的液相(玻璃相)密实性来实现的。
本发明是利用果壳粉内用剩余物制备烧结型多孔无机建筑保温材料，重点在于实现该材料的保温隔热功能，同时兼顾具有较好力学、防火、防水、防腐功能。
本发明是基于果壳粉农业剩余物制备建筑保温材料的目的，促进农业废弃物的综合利用，在本发明中所使用果壳粉的体积百分比是相对较高的，体积占比可达到50-55％，充分考虑制品的实际配方和质量控制需要，因此在本发明中使用的配比按质量百分比进行陈述。
本发明利用果壳粉制备多孔建筑保温材料所使用的配比按质量百分比。
本发明是通过以下技术方案来实现的：一种利用果壳粉制备建筑保温材料的方法，生产工艺包括以下步骤
(1)原料预处理：首先将长石、页岩、砂岩、石灰石、菱镁土进行初级破碎处理，颗粒尺寸小于5cm；
(2)原料计量：将步骤(1)中已处理的主料按重量百分比进行计量称重；
(3)原料球磨：将步骤(2)中已计量的原料投入到球磨机中，按长石、页岩、砂岩、石灰石、菱镁土原料总质量的65-68％注入水，封盖球磨机进行湿法研磨，研磨时间8-12小时，浆体粒度达到200-400目；
(4)掺和料混合：将步骤(3)混合浆体排出球磨机，送入浆体池；再将果壳粉按配比投入到浆体池，开动搅拌机器，使果壳粉充分混合在主料浆体中，形成松散、均匀的湿混合浆料；
(5)喷雾造粒：将步骤(4)中湿混合浆料使用泥浆泵送至离心喷雾造粒塔进行造粒，颗粒直径1-3mm,水分含量小于8％，造粒粉核心基本为果壳粉，造粒粉流动性良好；
(6)将步骤(5)中造粒粉铺平置于耐火材料模具内，在加热炉进行预热、烧结、定型和退火，
(7)步骤(6)中温度曲线为：室温至650℃，时间0.75-1.0h,650℃至1050～1200℃，时间0.75-1.5h；保温0.5-1h；1050～1200℃至800℃，时间0.3-0.6h；800℃至60℃，时间15-20h，然后出炉冷却，得到多孔烧结保温材料。
经过上述原料配比、混磨、加热、烧结和退火形成多孔烧结型无机建筑保温材料毛坯块，需要进行切割形成外观形态完整的制品，分别参照GB/T 5486-2008《无机硬质绝热制品试验方法》制备100×100×100mm试样，进行密度和抗压强度测试；参照GB/T 10295-2008《绝热材料稳态热阻及有关特性的测定热流计法》制备300×300×30mm试样，进行导热系数测试；参照GB/T 10299-2011《绝热材料憎水性试验方法》制备300×150×30mm试样，进行憎水率测试。
本发明所用果壳粉烧结制备的建筑保温材料，可制备和切割成厚度为20-200mm的板材，规格尺寸最大可达1200×1800mm,可满足建筑墙体保温使用。
本发明与现有技术相比，具有以下有益效果:
(1)本发明在于可以大量消纳果壳粉这类农业剩余物和低品味的矿山原料等制备建筑保温材料，其具有良好的保温隔热功能，以及防火、防水以及轻质的特性，可满足城市化和新农村节能建设需要，可取得显著的技术效果和经济优势。
(2)本发明利用果壳粉烧结制备的建筑保温材料，充分利用了果壳粉农业剩余物和低品味的矿山原料，实现资源综合利用。
(3)本发明采用占位烧结工艺，使有机质果壳粉变成了占位物质和有机质燃料，避免了有机物质的发霉腐烂问题，果壳粉提供加热烧结过程的热量，减少燃料使用。既节约能源，又避免了燃料废料排放对环境的污染。
(4)本发明通过烧结工艺制备的建筑保温材料具有材料结构的稳定性和耐久性，可以满足建筑同寿命要求。通过上述技术创新和制备方法创新，制备性能优良的果壳粉烧结多孔无机建筑保温材料，果壳粉在建筑材料中体积使用量可达50-50％，实现了果壳粉的充分利用。
利用果壳粉制备的建筑保温材料制品性能达到：体积密度为183-392kg/m3,抗压强度为1.2-4.8MPa,导热系数0.068-0.121W/m·K，憎水率为96-99％，果壳粉烧结制备筑保温材料制品配比和产品综合性能见表1所示，表1配方是按质量百分比，在实际配料时，可转换成质量单位公斤。
具体实施方式
表1
以下结合实施实例对本发明进行阐述，然而本发明的保护范围并非仅仅局限于以下实施实例。所属技术领域的普通技术人员依据本发明公开的内容，均可实现本发明的目的。实施例中的果壳粉是市场采购的，市场所售果壳粉一般是以核桃壳为主的多种果壳的混合物，凡是市场上所售果壳粉都能适用本发明。
实施实例1
(1)配料：按表1配方1的配比进行称量配料，其配比分别为：长石粉15kg,页岩60kg，砂岩10kg，石灰石0kg,菱镁土5kg，水61.2kg，控制原料粒度小于5cm；
(2)球磨混料：将(1)中原料投入到200公斤级的刚玉陶瓷内衬的球磨机，球磨8h停机，将浆体排出，放入200L搅拌筒中，浆体200-400目，将40-120目果壳粉10kg投入到搅拌筒中搅拌，得到果壳分散均匀混合料浆；
(3)造粒：对(2)中混合料浆采用实验室级离心造粒机，将浆体进行造粒，造粒粉粒度范围1-3mm,水分含量8％；
(4)烧制：将(3)中造粒粉置于碳化硅耐火材料模具内，铺平展开，厚度30mm，在加热炉进行加热烧结和退火，预热、烧结、定型、退火工艺为：室温至650℃，时间0.75h,650℃至1200℃，时间1.5h；保温0.5h；1200℃至800℃，0.6h,800℃至60℃，15h。升温和降温都采用匀速，但实际生产不局限于匀速，以下例子都相同。
利用果壳粉制备的建筑保温材料制品性能为：体积密度为392kg/m3,抗压强度为4.80MPa,导热系数0.121W/m·K，憎水率为99％。
实施实例2
(1)配料：按表1配方2的配比进行称量配料，其配比分别为：长石粉13kg,页岩57kg，砂岩11kg，石灰石1kg,菱镁土6kg，水57.2kg，控制原料粒度小于5cm；
(2)球磨混料：将(1)中原料投入到200公斤级的刚玉陶瓷内衬的球磨机，球磨10h停机，将浆体排出，放入200L搅拌筒中，浆体200-400目筛余，将120-160目果壳粉12kg投入到搅拌筒中搅拌，得到果壳分散均匀混合料浆；
(3)造粒：对(2)中混合料浆采用实验室级离心造粒机，将浆体进行造粒，造粒粉粒度范围1-3mm,水分含量6％；
(4)烧制：将(3)中造粒粉置于碳化硅耐火材料模具内，铺平展开，厚度40mm，在加热炉进行加热烧结和退火，预热、烧结、定型、退火工艺为：室温至650℃，时间0.8h,650℃至1160℃，时间1.2h；保温0.75h,1160℃至800℃，0.3h,800℃至60℃，18h。
利用果壳粉制备的建筑保温材料制品性能为：体积密度为336kg/m3,抗压强度为3.13MPa,导热系数0.103W/m·K，憎水率为98％。
实施实例3
(1)配料：按表1配方3的配比进行称量配料，其配比分别为：长石粉13kg,页岩52kg，砂岩12kg，石灰石2kg,菱镁土7kg，水56.76kg，控制原料粒度小于5cm,
(2)球磨混料：将(1)中原料投入到200公斤级的刚玉陶瓷内衬的球磨机，球磨12h停机，将浆体排出，放入200L搅拌筒中，浆体200-400目，将120-200目果壳粉14kg投入到搅拌筒中，
(3)造粒：对(2)中混合料浆采用实验室级离心造粒机，将浆体进行造粒，造粒粉粒度范围1-1mm,水分含量5％。
(4)烧制：将(3)中造粒粉置于碳化硅耐火材料模具内，铺平展开，厚度50mm，在加热炉进行加热烧结和退火，预热、烧结、定型、退火工艺为：室温至650℃，时间1h,650℃至1050℃，时间1.5h；保温0.75h,1050℃至800℃，0.5h,800℃至60℃，19h。
利用果壳粉制备的建筑保温材料制品性能为：体积密度为241kg/m3,抗压强度为1.87MPa,导热系数0.086W/m·K，憎水率为97％。
实施实例4
(1)配料：按表1配方4的配比进行称量配料，其配比分别为：长石粉10kg,页岩50kg，砂岩13kg，石灰石3kg,菱镁土8kg，水56.28kg，控制原料粒度小于5cm；
(2)球磨混料：将(1)中原料到200公斤级的刚玉陶瓷内衬的球磨机，球磨12h停机，将浆体排出，放入200L搅拌筒中，浆体200-400目，将80-120目果壳粉16kg投入到搅拌筒中，
(3)造粒：对(2)中混合料浆采用实验室级离心造粒机，将浆体进行造粒，造粒粉粒度范围1-2mm,水分含量4％。
(4)烧制：将(3)中造粒粉置于碳化硅耐火材料模具内，铺平展开，厚度50mm，在加热炉进行加热烧结和退火，预热、烧结、定型、退火工艺为：室温至650℃，时间1.0h,650℃至1080，时间1.5h；保温1h；1080℃至800℃，0.6h,800℃至60℃，20h。
利用果壳粉制备的建筑保温材料制品性能为：体积密度为183kg/m3,抗压强度为1.20MPa,导热系数0.068W/m·K，憎水率为96％。
Claims (2)
1.一种利用果壳粉烧结制备建筑保温材料的方法，其特征是，它由以下质量配比的原料加水混合后高温发泡而成：
采用以下步骤：
(1)原料预处理：首先将长石、页岩、砂岩、石灰石、菱镁土进行初级破碎处理，颗粒尺寸小于5cm；
(2)原料计量：将步骤(1)中已处理的原料按重量百分比进行计量称重；
(3)原料球磨：将步骤(2)中已计量的原料投入到球磨机中，按上述原料总质量的65-68％注入水，封盖球磨机进行湿法研磨，研磨时间8-12小时，浆体粒度达到200-400目；
(4)掺和料混合：将步骤(3)得到的浆体排出球磨机，送入具有搅拌装置浆体池或容器；再将果壳粉投入到浆体池，开动搅拌机器，使果壳粉充分混合在浆体中，形成均匀的果壳粉湿浆混合料；
(5)喷雾造粒：将步骤(4)中湿浆混合料使用泥浆泵送至离心喷雾造粒塔进行造粒，颗粒直径1-3mm,水分含量小于8％；
(6)将步骤(5)中造粒粉铺平置于耐火材料模具内，在加热炉进行预热、烧结定型和退火，然后出炉冷却，得到多孔烧结保温材料；
预热、烧结、定型、退火工艺为：室温至650℃，时间0.75-1.0h,650℃至1050～1200℃，时间0.75-1.5h；保温0.5-1h；1050～1200℃至800℃，时间0.3-0.6h；800℃至60℃，时间15-20h。
2.根据权利要求1所述的方法，其特征是，所述的水的重量是所述长石、页岩、砂岩、石灰石、菱镁土干料总重量的65％～68％。
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