CN106396623A - 抛光砖废渣的回收工艺 - Google Patents
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Abstract
本发明提供了一种抛光砖废渣的回收工艺,包括以下步骤:步骤一、抛光废水预处理;步骤二、干燥抛光废渣:将步骤一中过滤得到的抛光废渣铺于露天晒场上,晒抛光废渣5~6天;步骤三、均化处理:将步骤二得到的抛光废渣转运至室内使用仓,使经过步骤一和步骤二处理得到若干份抛光废渣混合;步骤四、球磨制粉;将步骤三得到的抛光废渣输送至球磨机中,对抛光废渣进行粗磨得到抛光粗粉;步骤五、研磨制粉:将抛光粗粉放入研磨机中研磨,对抛光粗粉进行细磨得到湿抛光粉料;步骤六、雾化干燥。本发明的有益效果:提高了抛光粉料在制造非发泡瓷砖中的运用量。
Description
技术领域
本发明涉及瓷砖生产领域,具体涉及一种抛光砖废渣的回收工艺。
背景技术
抛光砖是通体砖的表面经过打磨而成的一种光亮的砖,属通体砖的一种。相对于通体砖而言,抛光砖表面要光洁得多,而且更坚硬、耐磨。但抛光砖在研磨、抛光的过程中会产生大量的抛光废料,这种抛光废料粒度很细,风干后呈分散状态,极易随风飘落到各处,会严重威胁周围人群的身体健康,并造成周边土地的板结,导致严重的环境污染。而抛光废料的填埋,不但耗费人力、物力,还会污染地下水质,人们通常把这种现象称作“白色恐怖”。综上所述,抛光砖废渣的回收利用是需要解决的一个重要难题。
中国专利中公开了一种授权公告号为CN 101898900 B的瓷砖抛光废渣的回收利用方法,该方法包括:A,将抛光废渣按其是否接触抛光磨块分为两类;B,将接触过抛光磨块的抛光废渣均化后用于生产泡沫陶瓷;C,未接触过抛光磨块的抛光废渣中加入10-25%(重量比)的粘土,球磨制粉,得颗粒为Φ0.1-Φ2mm、40目筛上30%-40%的粉料,制得的粉料以不超过40%(重量比)的比例加入常规粉料中,用于生产微粉瓷质抛光砖。该方法虽然可以回收利用抛光废渣,以生产抛光砖或泡沫陶瓷,但是该方法存在的问题为:1)制造抛光砖时,加入抛光废渣粉料的重量比过大,由于抛光废渣粉料中的残存有碳化硅、碳酸盐、卤化物、有机物等,在加热过程中会产生大量的气体,从而降低制造得到的抛光砖的抗弯强度,故加入抛光废渣粉料40%(重量比)会使得抛光砖的抗弯强度不能满足国家标准,现有技术中在保证制造得到的抛光砖抗弯强度的情况下,仅能加入15%-25%(重量比)的抛光废渣粉料;2)在抛光过程中,抛光废渣是直接排入到生长瓷砖的废水中的,再加上抛光磨头的损耗,会使得得到的抛光废水中含有镁矿、氧化镁、硫酸镁、氢氧化镁等,这些成分会相互作用使得抛光废水的颗粒沉降速度很慢,同时5Mg(OH)2.MgCl2.8H2O、3Mg(OH)2.MgCl2.8H2O和Mg(OH)2形成也会胶凝体,胶凝体会影响到球磨制粉等制粉工作的正常运行。
发明内容
本发明提供了一种抛光砖废渣的回收工艺,提高了抛光粉料在制造非发泡瓷砖中的运 用量。
为实现上述目的,本发明采用了如下的技术方案:
一种抛光砖废渣的回收工艺,包括以下步骤:
步骤一、抛光废水预处理:首先,将原处于回收池中的抛光废水转移至污水处理的厌氧发酵装置中;然后,在厌氧发酵装置中加入有机高分子絮凝剂,加入有机高分子絮凝剂后,让抛光废水在厌氧发酵装置中静置4小时,以使得抛光废渣快速沉淀;再后,启动厌氧发酵装置,厌氧发酵3个月,且发酵完后厌氧发酵装置将抛光废渣排至过滤装置;最后,过滤装置过滤出来自厌氧发酵装置的抛光废渣;
步骤二、干燥抛光废渣:将步骤一中过滤得到的抛光废渣铺于露天晒场上,晒抛光废渣5~6天;
步骤三、均化处理:将步骤二得到的抛光废渣转运至室内使用仓,使经过步骤一和步骤二处理得到若干份抛光废渣混合;
步骤四、球磨制粉;将步骤三得到的抛光废渣输送至球磨机中,对抛光废渣进行粗磨得到抛光粗粉;
步骤五、研磨制粉:将抛光粗粉放入研磨机中研磨,对抛光粗粉进行细磨得到湿抛光粉料;
步骤六、雾化干燥:首先,控制雾化塔内气流温度在600℃~850℃;然后,雾化塔将湿抛光粉料喷上去与雾化塔内的高温气流相遇禅风涡流作用,以使抛光粉料中含水率仅为6%,同时抛光磨头的磨块屑在该温度环境下发生反应;最后,将雾化塔内得到的抛光粉料转移至待使用室内,以在制造非发泡瓷砖过程中并在研磨制粉时将抛光粉料与非发泡瓷砖的原材料一起输送至研磨装置中,其中,以质量百分比计抛光粉料含30%。
相比于现有技术,本发明具有如下有益效果:
通过将抛光废水连带抛光废渣一起输送至污水处理的厌氧发酵装置中,实现了将抛光废渣非常沉淀析出,并去除了加快抛光废渣中有机絮凝剂,避免了有机物在烧成过程中产生气体,为提高抛光粉料在制造非发泡瓷砖中的运用量提供了条件;同时,该工艺并不是以前的在步骤二中得到抛光废渣与原材料混合后直接开始制造瓷砖,而该工艺得到抛光粉料则是经过球磨制粉、研磨制粉以及雾化干燥后得到,是为了使得抛光废渣独自经过雾化干燥后除去其中的抛光磨头的磨块屑,得到的抛光粉料则是在原料经过球磨制粉后在研磨制粉时与原料混合,因为步骤六处理后还有大量气体残留在抛光粉料中,而在制造非发泡瓷砖时抛光粉料与原材料一起进入到研磨装置中,研磨装置中需要将抛光粉料和原材料中加入水才得以研磨均匀,此时,由于抛光粉料中的残留气体微溶于水,由于水对抛光粉料颗粒的冲刷,残留气体形成的假颗粒则会不存在,该残留气体在水中则会与抛光粉料脱离,从而避免因残留气体被带入砖坯中而影响砖坯的致密度,最终提高了抛光粉料在制造非发泡瓷砖中的运用量,减少抛光废渣给环境带来的污染,既经济又环保。
具体实施方式
本发明提出了一种抛光砖废渣的回收工艺,包括以下步骤:
步骤一、抛光废水预处理:首先,将原处于回收池中的抛光废水转移至污水处理的厌氧发酵装置中;然后,在厌氧发酵装置中加入有机高分子絮凝剂,加入有机高分子絮凝剂后,让抛光废水在厌氧发酵装置中静置4小时,以使得抛光废渣快速沉淀;再后,启动厌氧发酵装置,厌氧发酵3个月,且发酵完后厌氧发酵装置将抛光废渣排至过滤装置;最后,过滤装置过滤出来自厌氧发酵装置的抛光废渣;
步骤二、干燥抛光废渣:将步骤一中过滤得到的抛光废渣铺于露天晒场上,晒抛光废渣5~6天;
步骤三、均化处理:将步骤二得到的抛光废渣转运至室内使用仓,使经过步骤一和步骤二处理得到若干份抛光废渣混合;
步骤四、球磨制粉;将步骤三得到的抛光废渣输送至球磨机中,对抛光废渣进行粗磨得到抛光粗粉;
步骤五、研磨制粉:将抛光粗粉放入研磨机中研磨,对抛光粗粉进行细磨得到湿抛光粉料;
步骤六、雾化干燥:首先,控制雾化塔内气流温度在600℃~850℃;然后,雾化塔将湿抛光粉料喷上去与雾化塔内的高温气流相遇禅风涡流作用,以使抛光粉料中含水率仅为6%,同时抛光磨头的磨块屑在该温度环境下发生反应;最后,将雾化塔内得到的抛光粉料转移至待使用室内,以在制造非发泡瓷砖过程中并在研磨制粉时将抛光粉料与非发泡瓷砖的原材料一起输送至研磨装置中,其中,以质量百分比计抛光粉料含30%。
具体地,步骤一中,抛光废水预处理:首先,将原处于回收池中的抛光废水转移至污水处理厌氧发酵装置中;然后,在厌氧发酵装置中加入有机高分子絮凝剂(如水解丙烯酰胺、磺化聚丙烯酰胺、聚丙烯酰胺以及聚乙烯吡啶盐等),以加快抛光废渣的沉降速度,且此处不能加入无机絮凝剂(如硫酸铝和硫酸铁等),因为加入无机絮凝剂会导致带SO4 -等酸性离子的盐仍然残留在抛光废渣中,导致无法去除,而在瓷砖烧成时产生大量的气体,影响瓷砖的抗弯强度,相反,加入有机絮凝剂则在后续步骤中则可以去除,加入有机高分子絮凝剂后,让抛光废渣在厌氧发酵装置中静置4小时,以使得抛光废渣快速沉淀,此时 有机絮凝剂悬浮在抛光废水中;再后,启动厌氧发酵装置,厌氧发酵3个月,以使抛光废水中有机物(包括有机高分子絮凝剂)充分分解,达到去除有机物(包括有机高分子絮凝剂)的目的,防止有机物被抛光废渣带走,以避免有机物在烧成过程中发生反应产生气体,从而减少抛光粉料在烧成过程中的气体,为提高抛光粉料在制造非发泡瓷砖中的使用量提供条件,且发酵完后厌氧发酵装置将抛光废渣排至过滤装置;最后,过滤装置接收来自厌氧发酵装置的抛光废渣,以使水与抛光废渣分离。
步骤二中,干燥抛光废渣:将步骤一中过滤得到的抛光废渣铺于露天晒场上,以对抛光废渣进行干燥。
步骤三中,均化处理:将干燥得到的抛光废渣转运至室内使用仓,将步骤一和步骤二处理得到若干份抛光废渣混合,以防止每次得到的抛光废渣内各组分含量有很大差异。
步骤四中,球磨制粉;将均化处理得到的抛光废渣输送至球磨机中,以对抛光废渣进行粗磨得到抛光粗粉。
步骤五中,研磨制粉:将抛光粗粉放入研磨机中研磨,以对抛光粗粉进行细磨得到湿抛光粉料。
步骤六中,雾化干燥:首先,控制雾化塔内气流温度在600℃~850℃,由于会发生如下反应:
在温度在100℃~545℃条件下,第一阶段反应如下:
5Mg(OH)2.MgCl2.8H2O、和Mg(OH)2
3Mg(OH)2.MgCl2.8H2O→3Mg(OH)2.MgCl2.5H2O+3H2O↑
3Mg(OH)2.MgCl2.5H2O→3Mg(OH)2.MgCl2.2H2O+3H2O↑
5Mg(OH)2.MgCl2.8H2O→5Mg(OH)2.MgCl2.5H2O+3H2O↑
5Mg(OH)2.MgCl2.5H2O→3Mg(OH)2.MgCl2.2H2O+3H2O↑
3Mg(OH)2.MgCl2.2H2O→3MgO.MgCl2.2H2O+3H2O↑
3MgO.MgCl2.2H2O→3MgO.Mg(OH)Cl+H2O↑+HCl↑
在温度在100℃~545℃条件下,第二阶段反应如下:
3MgO.Mg(OH)Cl→4MgO+HCl↑
故此处雾化塔内温度设置仅是为了得到抛光粉料,便于存储该抛光粉料,并将抛光粉料中的抛光磨头的磨块屑除去,便于后续制造非发泡瓷砖时使用;然后,雾化塔将湿抛光粉料喷上去与雾化塔内的高温热风相遇禅风涡流作用,使得抛光粉料中含水率仅为6%,以便于存储,同时抛光磨头的磨块屑在该温度环境下发生反应,产生HCl等气体,由于短时间内难以排除,残留在抛光粉料颗粒中,形成假颗粒;最后,将雾化塔内得到的抛光粉 料转移至待使用室内,以在制造非发泡瓷砖时与非发泡瓷砖的原材料一起输送至研磨装置中。
在制造非发泡瓷砖过程中,首先,将原材料输送至球磨机中,以粗磨得到原材料粗粉;然后,将原材料粗粉与通过抛光砖废渣的回收工艺得到的抛光粉料,其中,抛光粉料含30%(质量百分比);最后,依次通过喷雾制粉、压制成型、烧成以及抛光工序,得到需要的非发泡瓷砖成品。
以下列为例,在制造非发泡瓷砖过程中,原材料由聚晶微分以及辅料,聚晶微分按照质量份计包括下列组分:SiO2 70-73份、AL2O3 16.5-17.5份、CaO 0.6-0.7份、MgO 0.4-0.5份、K2O 2.0-2.5份、Na2O 3.5-4.2份、Fe2O3 0.35-0.4份、TiO2 0.1-0.15份以及烧失量2.8-3.2份。通过上述方法,得到的非发泡瓷砖为聚晶抛光瓷砖。
为了验证得到的聚晶抛光瓷砖符合国家标准,需要对聚晶抛光瓷砖的烧成收缩率、抗弯强度、吸水率以及体积密度四项性能指标进行检测。各个性能测试方法如下:采用阿基米德定律测定多孔陶瓷的吸水率和体积密度;采用三点弯曲法,将试样至10KN微机控制挖能测试机上,测定试样的抗弯强度;烧成收缩率的测定:根据公式:烧成收缩率=(坯体宽度-初成品宽度)/坯体宽度,因此需要测定实施例1至实施例3中,普通瓷砖坯体的宽度、通体瓷砖坯体的宽度、普通瓷砖初成品的宽度以及通体瓷砖成品的宽度,再根据烧成收缩率的计算公式来得到需要的烧成收缩率。经过测量,聚晶抛光瓷的烧成收缩率7.18%、抗弯强度46.21MPa、吸水率0.112%以及体积密度2.371g/cm3,故符合国家标准。
最后说明的是,以上实施例仅用以说明本发明的技术方案而非限制,尽管参照较佳实施例对本发明进行了详细说明,本领域的普通技术人员应当理解,可以对本发明的技术方案进行修改或者等同替换,而不脱离本发明技术方案的宗旨和范围,其均应涵盖在本发明的权利要求范围当中。
Claims (1)
1.一种抛光砖废渣的回收工艺,其特征在于,包括以下步骤:
步骤一、抛光废水预处理:首先,将原处于回收池中的抛光废水转移至污水处理的厌氧发酵装置中;然后,在厌氧发酵装置中加入有机高分子絮凝剂,加入有机高分子絮凝剂后,让抛光废水在厌氧发酵装置中静置4小时,以使得抛光废渣快速沉淀;再后,启动厌氧发酵装置,厌氧发酵3个月,且发酵完后厌氧发酵装置将抛光废渣排至过滤装置;最后,过滤装置过滤出来自厌氧发酵装置的抛光废渣;
步骤二、干燥抛光废渣:将步骤一中过滤得到的抛光废渣铺于露天晒场上,晒抛光废渣5~6天;
步骤三、均化处理:将步骤二得到的抛光废渣转运至室内使用仓,使经过步骤一和步骤二处理得到若干份抛光废渣混合;
步骤四、球磨制粉;将步骤三得到的抛光废渣输送至球磨机中,对抛光废渣进行粗磨得到抛光粗粉;
步骤五、研磨制粉:将抛光粗粉放入研磨机中研磨,对抛光粗粉进行细磨得到湿抛光粉料;
步骤六、雾化干燥:首先,控制雾化塔内气流温度在600℃~850℃;然后,雾化塔将湿抛光粉料喷上去与雾化塔内的高温气流相遇禅风涡流作用,以使抛光粉料中含水率仅为6%,同时抛光磨头的磨块屑在该温度环境下发生反应;最后,将雾化塔内得到的抛光粉料转移至待使用室内,以在制造非发泡瓷砖过程中并在研磨制粉时将抛光粉料与非发泡瓷砖的原材料一起输送至研磨装置中,其中,以质量百分比计抛光粉料含30%。
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