CN106904939B - 一种掺杂煤矸石高强度陶瓷地砖及其制备工艺 - Google Patents

一种掺杂煤矸石高强度陶瓷地砖及其制备工艺 Download PDF

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CN106904939B
CN106904939B CN201710186140.6A CN201710186140A CN106904939B CN 106904939 B CN106904939 B CN 106904939B CN 201710186140 A CN201710186140 A CN 201710186140A CN 106904939 B CN106904939 B CN 106904939B
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王维
陈位杰
李玉芝
刘伟
刘海洋
朱雁风
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Henan University of Science and Technology
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Abstract

本发明涉及一种掺杂煤矸石高强度陶瓷地砖及其制备工艺，陶瓷地砖以煤矸石、锅炉渣和三氧化钼为原料烧制而成，煤矸石占陶瓷地砖原料的重量百分数为：55‑70%，锅炉渣占陶瓷地砖原料的重量百分数为：26‑40%，三氧化钼占陶瓷地砖原料的重量百分数为：4‑6%。本发明在制备过程中利用了煤矸石和锅炉渣的二氧化硅和三氧化二铝在催化剂作用下高温烧制过程形成莫来石，在陶瓷地砖烧制过程中，煤矸石和锅炉渣中所含的氧化镁、氧化钾和氧化钠可作为烧结反应的助烧剂，提供了大量液相物质，促进了原料中传质，使固溶反应完全，使固相和玻璃相互充分粘结在一起。陶瓷地砖密度为1.6g/cm3，抗弯强度达到165Mpa，显气孔率低于0.5%，吸水率低于0.04%，达到了成品质轻高强度的目的。

Description

一种掺杂煤矸石高强度陶瓷地砖及其制备工艺
技术领域
本发明涉及建筑陶瓷技术领域，具体涉及一种掺杂煤矸石高强度陶瓷地砖及其制备工艺。
背景技术
煤矸石是一种在煤炭开采和洗选过程中产生的固体废弃物，排放量大约占煤炭产量的10%~15%，随着工业的飞速发展，我国每年约有4亿吨煤矸石堆存在环境中，不仅占用了大量的良田，而且对生态环境破坏很大，尤其不利于动植物生长。近几年来，国内对煤矸石的利用主要集中在做胶凝材料生产轻质建筑材料，但产品的附加值较低而限制了煤矸石的利用率。提高煤矸石的综合利用价值及利用率成为困扰科技界的一个新的难题。随着人们生活水平的不断提高，我国建筑陶瓷砖年产量已接近40亿m2，同时对陶瓷砖的各种性能提出了更严格的要求，譬如，陶瓷地砖的抗弯强度就是其中一项力学性能指标。莫来石是Al2O3-SiO2体系中无固定组成计量型化合物，其成分介于3Al2O3·2SiO2和2Al2O3·SiO2之间，具有热膨胀系数小、热震稳定性好、荷重软化点高、抗蠕变强度高、体积稳定性好、抗化学腐蚀性好等特点，近几年广泛应用于磨料、陶瓷领域。
发明内容
本发明的目的是为解决上述技术问题的不足，提供一种掺杂煤矸石高强度陶瓷地砖及其制备工艺，以煤矸石和锅炉渣为陶瓷地砖的主要原料，用三氧化钼做催化剂，促进煤矸石和锅炉渣的二氧化硅和三氧化二铝生产莫来石，使得烧制的陶瓷地砖烧成温度较低、密度较小，抗弯强度较高。
本发明为解决上述技术问题的不足，所采用的技术方案是：一种掺杂煤矸石高强度陶瓷地砖，该陶瓷地砖以煤矸石、锅炉渣和三氧化钼为原料烧制而成，其中，煤矸石占陶瓷地砖原料的重量百分数为：55-70%，锅炉渣占陶瓷地砖原料的重量百分数为：26-40%，三氧化钼占陶瓷地砖原料的重量百分数为：4-6%。
作为本发明一种掺杂煤矸石高强度陶瓷地砖的进一步优化：所述煤矸石的化学成份为CaO 15-20%、SiO2 40-50%、Al2O3 25-35%、Fe2O3 2-5%、MgO 2-3%、K2O 1-2%、Na2O 1-2%。
作为本发明一种掺杂煤矸石高强度陶瓷地砖的进一步优化：所述锅炉渣的化学成份为CaO 2-5%、SiO2 60-65%、Fe2O3 2-3%、Al2O3 20-25%、MgO 2-3% 其它5-10%。
上述陶瓷地砖的制备工艺，包括以下步骤：
（1）粗碎：将煤矸石和锅炉渣在150℃下烘烤4h，后分别经过破碎机粗碎成10mm以下的颗粒；
（2）细磨和筛分：将煤矸石和锅炉渣颗粒分别在球磨机球墨8h，然后过250目筛，得到细粉；
（3）混匀：按配方要求称取煤矸石细粉、锅炉渣细粉和三氧化钼放在三维立体混料机中混合10h，得到混合料；
（4）制坯：取混合料，加入蒸馏水，用油压机在20-25MPa压力下，压制得到生坯，并置于150℃下烘干；
（5）烧制：在150℃下烘干的生坯放入马弗炉内按下列程序进行升温：
25-650℃，升温速率为2℃/min，650℃保温60min；
650℃-900℃，升温速率为1℃/min，900℃保温60min；
900℃-1120℃，升温速率为1℃/min，1120℃，保温60min；
（6）冷却：1120℃-800℃，以1℃/min降温速率降温，800℃以下自然冷却，250℃以下出炉即可得到陶瓷地砖成品。
有益效果
1、本发明在制备过程中利用了煤矸石和锅炉渣的二氧化硅和三氧化二铝在催化剂作用下高温烧制过程形成莫来石，在陶瓷地砖烧制过程中，煤矸石和锅炉渣中所含的氧化镁、氧化钾和氧化钠可作为烧结反应的助烧剂，提供了大量液相物质，促进了原料中传质，使固溶反应完全，使固相和玻璃相充分粘结在一起。陶瓷地砖密度为1.6g/cm3，抗弯强度达到165Mpa，显气孔率低于0.5%，吸水率低于0.04%，达到了成品质轻高强度的目的；
2 、本发明制备陶瓷地砖用煤矸石和锅炉渣代替了以前主要原料优质高岭土，减轻了建筑陶瓷行业对高岭土的依赖，有效地缓解了工业迅速发展带来的优质高岭土匮乏的危机。煤矸石和锅炉渣中所含的氧化镁、氧化钾和氧化钠可作为烧结过程助烧剂，降低了烧结温度，比原陶瓷地砖烧成温度降低了100℃左右，实现了陶瓷地砖低碳生产，节约了能源。
附图说明
图1为本发明实施例1制得陶瓷地砖的微观结构图。
具体实施方式
下面结合较佳实施例详细说明本发明的具体实施方式。
实施例1
一种掺杂煤矸石高强度陶瓷地砖的制备工艺：
（1）粗碎：将煤矸石和锅炉渣在150℃下烘烤4h，后分别经过破碎机粗碎成10mm以下的颗粒；
（2）细磨和筛分：将煤矸石和锅炉渣颗粒分别在球磨机球墨8h，然后过250目筛，得到细粉；
（3）混匀：按重量百分比称取煤矸石细粉62%、锅炉渣细粉34%和三氧化钼（工业级三氧化钼）4%，放在三维立体混料机中混合10h，得到混合料；
（4）制坯：取混合料，加入蒸馏水，用油压机在20MPa压力下，压制得到生坯，并置于150℃下烘干；
（5）烧制：在150℃下烘干的生坯放入马弗炉内按下列程序进行升温：
25-650℃，升温速率为2℃/min，650℃保温60min；
650℃-900℃，升温速率为1℃/min，900℃保温60min；
900℃-1120℃，升温速率为1℃/min，1120℃，保温60min；
（6）冷却：1120℃-800℃，以1℃/min降温速率降温，800℃以下自然冷却，250℃以下出炉即可得到陶瓷地砖成品。陶瓷地砖性能参数经检测如下：抗弯强度167MPa，显气孔率0.5%，吸水率0.03%，磨损体积110mm2，破坏强度3500.3 N，光泽度66，各项性能检测均达到了国家标准要求，且大大降低了成本。
实施例2
一种掺杂煤矸石高强度陶瓷地砖的制备工艺：
（1）粗碎：将煤矸石和锅炉渣在150℃下烘烤4h，后分别经过破碎机粗碎成10mm以下的颗粒；
（2）细磨和筛分：将煤矸石和锅炉渣颗粒分别在球磨机球墨8h，然后过250目筛，得到细粉；
（3）混匀：按重量百分比称取煤矸石细粉69%、锅炉渣细粉26%和三氧化钼（工业级三氧化钼）5%，放在三维立体混料机中混合10h，得到混合料；
（4）制坯：取混合料，加入蒸馏水，用油压机在25MPa压力下，压制得到生坯，并置于150℃下烘干；
（5）烧制：在150℃下烘干的生坯放入马弗炉内按下列程序进行升温：
25-650℃，升温速率为2℃/min，650℃保温60min；
650℃-900℃，升温速率为1℃/min，900℃保温60min；
900℃-1120℃，升温速率为1℃/min，1120℃，保温60min；
（7）冷却：1120℃-800℃，以1℃/min降温速率降温，800℃以下自然冷却，250℃以下出炉即可得到陶瓷地砖成品。
实施例3
一种掺杂煤矸石高强度陶瓷地砖的制备工艺：
（1）粗碎：将煤矸石和锅炉渣在150℃下烘烤4h，后分别经过破碎机粗碎成10mm以下的颗粒；
（2）细磨和筛分：将煤矸石和锅炉渣颗粒分别在球磨机球墨8h，然后过250目筛，得到细粉；
（3）混匀：按重量百分比称取煤矸石细粉56%、锅炉渣细粉38%和三氧化钼（工业级三氧化钼）6%，放在三维立体混料机中混合10h，得到混合料；
（4）制坯：取混合料，加入蒸馏水，用油压机在25MPa压力下，压制得到生坯，并置于150℃下烘干；
（5）烧制：在150℃下烘干的生坯放入马弗炉内按下列程序进行升温：
25-650℃，升温速率为2℃/min，650℃保温60min；
650℃-900℃，升温速率为1℃/min，900℃保温60min；
900℃-1120℃，升温速率为1℃/min，1120℃，保温60min；
（6）冷却：1120℃-800℃，以1℃/min降温速率降温，800℃以下自然冷却，250℃以下出炉即可得到陶瓷地砖成品。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发明，任何熟悉本专业的技术人员，在不脱离本发明技术方案范围内，当可利用上述揭示的技术内容做出出些许更动或修饰为等同变化的等效实施例，但凡是未脱离本发明技术方案内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (1)

1.一种掺杂煤矸石高强度陶瓷地砖，其特征在于：该陶瓷地砖以煤矸石、锅炉渣和三氧化钼为原料烧制而成，其中，煤矸石占陶瓷地砖原料的重量百分数为：55-70%，锅炉渣占陶瓷地砖原料的重量百分数为：26-40%，三氧化钼占陶瓷地砖原料的重量百分数为：4-6%；所述煤矸石的化学成份为CaO 15-20%、SiO2 40-50%、Al2O3 25-35%、Fe2O3 2-5%、MgO 2-3%、K2O1-2%、Na2O 1-2%；所述锅炉渣的化学成份为CaO 2-5%、SiO2 60-65%、Fe2O3 2-3%、Al2O3 20-25%、MgO 2-3% 、其它5-10%；
其制备工艺，包括以下步骤：
（1）粗碎：将煤矸石和锅炉渣在150℃下烘烤4h，后分别经过破碎机粗碎成10mm以下的颗粒；
（2）细磨和筛分：将煤矸石和锅炉渣颗粒分别在球磨机球磨 8h，然后过250目筛，得到细粉；
（3）混匀：按配方要求称取煤矸石细粉、锅炉渣细粉和三氧化钼放在三维立体混料机中混合10h，得到混合料；
（4）制坯：取混合料，加入蒸馏水，用油压机在20-25MPa压力下，压制得到生坯，并置于150℃下烘干；
（5）烧制：在150℃下烘干的生坯放入马弗炉内按下列程序进行升温：
25-650℃，升温速率为2℃/min，650℃保温60min；
650℃-900℃，升温速率为1℃/min，900℃保温60min；
900℃-1120℃，升温速率为1℃/min，1120℃，保温60min；
（6）冷却：1120℃-800℃，以1℃/min降温速率降温，800℃以下自然冷却，250℃以下出炉即可得到陶瓷地砖成品。
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