CN107089839A - 一种轻质多孔莫来石骨料及其制备方法 - Google Patents

一种轻质多孔莫来石骨料及其制备方法 Download PDF

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CN107089839A
CN107089839A CN201710250585.6A CN201710250585A CN107089839A CN 107089839 A CN107089839 A CN 107089839A CN 201710250585 A CN201710250585 A CN 201710250585A CN 107089839 A CN107089839 A CN 107089839A
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light porous
porous mullite
aggregate
mullite aggregate
dry
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李远兵
罗瀚
李淑静
陈若愚
徐娜娜
向若飞
欧阳思
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Wuhan University of Science and Engineering WUSE
Wuhan University of Science and Technology WHUST
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Abstract

本发明具体涉及一种轻质多孔莫来石骨料及其制备方法。其技术方案是：以30~45wt%的玻璃粉、20~30wt%的硅线石族矿物、15~25wt%的高岭土和15~25wt%的α‑氧化铝微粉为原料，外加所述原料20~120wt%的干熄焦粉，干混6~8h，得到干混料；将所述干混料置入圆盘造粒机中，滚动造粒时喷入所述原料10~25wt%的结合剂，制得骨料生坯，自然干燥；然后在110~180℃条件下烘烤12~24h，再于1000~1300℃的条件下保温2~5h，即得轻质多孔莫来石骨料。本发明具有成本低、工艺简单、煅烧温度较低和粒径可控的特点；所制制品导热系数较低、体积密度低、显气孔率低而闭气孔率高、烧后体积变化小、耐压强度高、耐化学侵蚀性良好和抗热震性能优异。

Description

一种轻质多孔莫来石骨料及其制备方法
技术领域
本发明属于莫来石骨料技术领域。具体涉及一种轻质多孔莫来石骨料及其制备方法。
背景技术
近年来，随着建材业的发展，国内每年都会有5000万吨废弃玻璃被掩埋处理，扩展到世界范围这个数字更为惊人，然而玻璃的自然降解大约需要4000年，这对自然环境和人类活动造成了不可估计的危害。另外，随着炼铁技术的发展和对焦炭要求的提高以及环保意识的增强，国内大型焦化厂采用的熄焦技术每天将产生大量的干熄焦粉尘，如果肆意排放必然导致空气污染，不符合环保要求。因此，合理利用废弃玻璃粉和干熄焦粉尘，将其转化成其它性能优越的产品已经引起本领域技术人员的关注。
“一种废弃玻璃作为混凝土粗骨料掺入混凝土的制备方法”（CN105110670A）的专利技术，公开了一种以5~20mm废弃玻璃作为粗骨料掺入混凝土中代替5~15wt%天然粗骨料的技术，该方法虽技术简单、成本低和一定程度上回收利用了废弃玻璃，但其主要缺陷是：（1）应用范围受到较大的局限，无法同时满足常温和高温的工况；（2）单纯使用废弃玻璃作为骨料其理化性能较差。
“一种陶瓷防滑骨料的制备方法”（CN102910896A），该方法公开了以50~60wt%高岭土、20~30wt%长石粉、10~15wt%玻璃粉和1.5~8wt%色基为原料，加入20~40wt%的水作为结合剂，湿磨，陈腐，脱水烘干，碾细造粒后煅烧。所制得的骨料理化性能稳定，并且可以灵活调整骨料颗粒大小，但其主要缺陷是：（1）低融相加入量过多，导致骨料不适用恶劣的工况；（2）玻璃粉加入量少，无法对大量废弃物实现有效利用；（3）生产周期长。
“一种以碎玻璃为主要原料的建材用品的制造方法”（CN1358583A），该方法公开了以自制助剂、玻璃粉、粉煤灰和水玻璃制造人造轻骨料的技术。该技术将城市垃圾、工业废渣和水处理厂污泥等资源化，开发和生产各种建材产品，具有较好的社会和经济效益，但其主要缺陷是：（1）骨料整体粒径偏大，无法达到紧密堆积；（2）莫来石相生成较少，骨料理化性能较差；（3）低融相加入量过多，高温性能不理想。
“一种以高铝粉煤灰为单一铝源制备高铝质耐火砖用莫来石骨料的方法”（CN104557094A）该方法公开了以准格尔高铝粉煤灰为唯一原料，不添加额外的铝源，经预处理、球磨、成型和烧结，得到高铝质耐火砖用莫来石骨料。使用该方法制备的莫来石骨料吸水率低、显气孔率低和理化性能良好，但其主要缺陷是：（1）对原料的铝含量要求极高，变相提高了生产成本；（2）烧结温度高，导致莫来石骨料密度高，不适用于制造轻质隔热材料。
发明内容
本发明旨在克服现有技术缺陷，目的是提供一种成本低、工艺简单、煅烧温度较低和粒径可控的轻质多孔莫来石骨料的制备方法；所制得轻质多孔莫来石骨料导热系数较低、体积密度低、显气孔率低而闭气孔率高、烧后体积变化小、耐压强度高、耐化学侵蚀性良好和抗热震性能优异。
为实现上述目的，本发明所采用的技术方案是：以30~45wt%的玻璃粉、20~30wt%的硅线石族矿物、15~25wt%的高岭土和15~25wt%的α-氧化铝微粉为原料，外加所述原料20~120wt%的干熄焦粉，干混6~8h，得到干混料；将所述干混料置入圆盘造粒机中，滚动造粒时喷入所述原料10~25wt%的结合剂，制得骨料生坯，自然干燥；然后在110~180℃条件下烘烤12~24h，再于1000~1300℃的条件下保温2~5h，即得轻质多孔莫来石骨料。
所述玻璃粉的主要化学组分是：SiO2为65~75wt%，Al2O3为2~5wt%，B2O3为0.5~1wt%,，Fe2O3为0.5~1wt%，碱金属和碱土金属氧化物为20~30wt%，烧失为2~5wt%；所述玻璃粉粒径小于0.045mm。
所述硅线石族矿物为硅线石、红柱石和蓝晶石中的一种。
所述干熄焦粉粒的主要化学成分是：固定碳为80~90wt%，烧失为80~90wt%；所述干熄焦粉粒径小于0.045mm。
所述结合剂为磷酸二氢铝、铝溶胶、硅溶胶和水玻璃中的一种。
由于采用上述技术方案，本发明与现有技术相比具有如下积极效果：
本发明采用团聚滚动式造粒，然后在1000~1300℃的条件下煅烧2~5h，通过燃尽物法制得轻质多孔莫来石骨料，故煅烧温度较低、工艺简单和成本低。
本发明在原料中混入的干熄焦粉在450~700℃完全燃烧产生孔隙；随着温度的升高，废弃玻璃粉中含有的碱金属及碱土金属氧化物挥发形成碱蒸汽，待煅烧完成，温度降低到一定程度后，碱蒸汽会于骨料表面凝固形成光滑的釉层，故制得的内部疏松、外壳密实的轻质多孔莫来石骨料导热系数较低、体积密度低、显气孔率低而闭气孔率高、烧后体积变化小、耐压强度高、耐化学侵蚀性良好和抗热震性能优异。
本发明采用的废弃玻璃粉中的低熔点组分能在高温下形成液相，一方面堵住大孔，提高小孔所占的比例，有效地降低导热系数，减弱温度剧变产生的热应力；另一方面经过高温烧结冷却后会于骨料表面形成釉层，显著提升骨料的理化性能；干熄焦粉为焦化厂排放的主要污染物，将其作为轻质多孔莫来石骨料的造孔剂一方面可以减少污染物排放压力，具有良好的环保效果，另一方面其高烧失、高燃烧热和高化学活性都能使得制备的莫来石质骨料性能更为优异。
本方法制备的内部疏松、外壳密实的轻质多孔莫来石骨料相对于喷雾干燥生产出的空心球，导热系数低和耐压强度高；相对于天然骨料，不仅粒径可控，而且表面具有一层光滑的釉层，在堆放和使用过程中无明显的应力集中，具有优良的理化性质。并且其制备工艺简单，效率高产量大，能满足工业大批量生产要求。
本发明制备的轻质多孔莫来石骨料经检测：导热系数为0.1~0.25 W/(m·K)，体积密度为0.5~1.0g/cm3，烧后线收缩率小于2.5%，耐压强度为2.5~15MPa。
因此，本发明具有成本低、工艺简单、煅烧温度较低和粒径可控的特点；所制得的内部疏松、外壳密实的轻质多孔莫来石骨料导热系数较低、体积密度低、显气孔率低而闭气孔率高、烧后体积变化小、耐压强度高、耐化学侵蚀性良好和抗热震性能优异，可以广泛应用于建材、耐火材料。
具体实施方式
下面结合具体实施方式对本发明做进一步的描述，并非对本发明保护范围的限制。
为避免重复，先将玻璃粉和干熄焦统一描述如下，实施例中将不赘述：
所述的主要化学组分是：SiO2为65~75wt%，Al2O3为2~5wt%，B2O3为0.5~1wt%,，Fe2O3为0.5~1wt%，碱金属和碱土金属氧化物为20~30wt%，烧失为2~5wt%；所述玻璃粉粒径小于0.045mm。
所述干熄焦粉粒的主要化学成分是：固定碳为80~90wt%，烧失为80~90wt%；所述干熄焦粉粒径小于0.045mm。
实施例1
一种轻质多孔莫来石骨料及其制备方法。以30~35wt%的玻璃粉、25~30wt%的硅线石族矿物、15~20wt%的高岭土和20~25wt%的α-氧化铝微粉为原料，外加所述原料20~60wt%的干熄焦粉，干混6~8h，得到干混料；将所述干混料置入圆盘造粒机中，滚动造粒时喷入所述原料10~15wt%的结合剂，制得骨料生坯，自然干燥；然后在110~180℃条件下烘烤12~24h，再于1200~1300℃的条件下保温2~5h，即得轻质多孔莫来石骨料。
本实施例中：所述硅线石族矿物为红柱石；所述结合剂为磷酸二氢铝。
本实施例1所制备的轻质多孔莫来石骨料经检测：导热系数为0.15~0.2W/(m·K)；烧后线收缩率小于2.5%；体积密度0.52~0.7g/cm-3；耐压强度2.5~9MPa。
实施例2
一种轻质多孔莫来石骨料及其制备方法。除下述技术参数外，其余同实施例1：
本实施例中：所述硅线石族矿物为红柱石；所述结合剂为铝溶胶。
本实施例2所制备的轻质多孔莫来石骨料经检测：导热系数为0.12~0.18W/(m·K)；烧后线收缩率小于1.8%；体积密度0.55~0.8g/cm-3；耐压强度5~15MPa。
实施例3
一种轻质多孔莫来石骨料及其制备方法。以35~40wt%的玻璃粉、20~25wt%的硅线石族矿物、20~25wt%的高岭土和15~20wt%的α-氧化铝微粉为原料，外加所述原料50~90wt%的干熄焦粉，干混6~8h，得到干混料；将所述干混料置入圆盘造粒机中，滚动造粒时喷入所述原料15~20wt%的结合剂，制得骨料生坯，自然干燥；然后在110~180℃条件下烘烤12~24h，再于1100~1200℃的条件下保温2~5h，即得轻质多孔莫来石骨料。
本实施例中：所述硅线石族矿物为硅线石；所述结合剂为硅溶胶。
本实施例3所制备的轻质多孔莫来石骨料经检测：导热系数0.16~0.25W/(m·K)；烧后线收缩率小于2%；体积密度0.6~1g/cm-3；耐压强度4.3~11MPa。
实施例4
一种轻质多孔莫来石骨料及其制备方法。以40~45wt%的玻璃粉、20~25wt%的硅线石族矿物、15~20wt%的高岭土和15~20wt%的α-氧化铝微粉为原料，外加所述原料80~120wt%的干熄焦粉，干混6~8h，得到干混料；将所述干混料置入圆盘造粒机中，滚动造粒时喷入所述原料20~25wt%的结合剂，制得骨料生坯，自然干燥；然后在110~180℃条件下烘烤12~24h，再于1000~1100℃的条件下保温2~5h，即得轻质多孔莫来石骨料。
本实施例中：所述硅线石族矿物为蓝晶石；所述结合剂为水玻璃。
本实施例4所制备的轻质多孔莫来石骨料经检测：导热系数0.1~0.2 W/(m·K)；烧后线收缩率小于1.6%；体积密度0.5~0.8g/cm-3；耐压强度3.9~13MPa。
本具体实施方式与现有技术相比具有如下积极效果：
本具体实施方式采用团聚滚动式造粒，然后在1000~1300℃的条件下煅烧2~5h，通过燃尽物法制得轻质多孔莫来石骨料，故煅烧温度较低、工艺简单和成本低。
本具体实施方式在原料中混入的干熄焦粉在450~700℃完全燃烧产生孔隙；随着温度的升高，废弃玻璃粉中含有的碱金属及碱土金属氧化物挥发形成碱蒸汽，待煅烧完成，温度降低到一定程度后，碱蒸汽会于骨料表面凝固形成光滑的釉层，故制得的内部疏松、外壳密实的轻质多孔莫来石骨料导热系数较低、体积密度低、显气孔率低而闭气孔率高、烧后体积变化小、耐压强度高、耐化学侵蚀性良好和抗热震性能优异。
本具体实施方式采用的废弃玻璃粉中的低熔点组分能在高温下形成液相，一方面堵住大孔，提高小孔所占的比例，有效地降低导热系数，减弱温度剧变产生的热应力；另一方面经过高温烧结冷却后会于骨料表面形成釉层，显著提升骨料的理化性能；干熄焦粉作为焦化厂排放的主要污染物，将其为轻质多孔莫来石骨料的造孔剂一方面可以减少污染物排放压力，具有良好的环保效果，另一方面其高烧失、高燃烧热和高化学活性都能使得制备的莫来石质骨料性能更为优异。
本方法制备的内部疏松、外壳密实的轻质多孔莫来石骨料相对于喷雾干燥生产出的空心球，导热系数低和耐压强度高；相对于天然骨料，不仅粒径可控，而且表面具有一层光滑的釉层，在堆放和使用过程中无明显的应力集中，具有优良的理化性质。并且其制备工艺简单，效率高产量大，能满足工业大批量生产要求。
本具体实施方式制备的轻质多孔莫来石骨料经检测：导热系数为0.1~0.25 W/(m·K)，体积密度为0.5~1.0g/cm3，烧后线收缩率小于2.5%，耐压强度为2.5~15MPa。
因此，本具体实施方式具有成本低、工艺简单、煅烧温度较低和粒径可控的特点；所制得的内部疏松、外壳密实的轻质多孔莫来石骨料导热系数较低、体积密度低、显气孔率低而闭气孔率高、烧后体积变化小、耐压强度高、耐化学侵蚀性良好和抗热震性能优异，可以广泛应用于建材、耐火材料。

Claims (6)

1.一种轻质多孔莫来石骨料的制备方法，其特征在于以30～45wt％的玻璃粉、20～30wt％的硅线石族矿物、15～25wt％的高岭土和15～25wt％的α-氧化铝微粉为原料，外加所述原料20～120wt％的干熄焦粉，干混6～8h，得到干混料；将所述干混料置入圆盘造粒机中，滚动造粒时喷入所述原料10～25wt％的结合剂，制得骨料生坯，自然干燥；然后在110～180℃条件下烘烤12～24h，再于1000～1300℃的条件下保温2～5h，即得轻质多孔莫来石骨料。
2.根据权利要求1所述的轻质多孔莫来石骨料的制备方法，其特征在于所述玻璃粉的主要化学组分是：SiO2为65～75wt％，Al2O3为2～5wt％，B2O3为0.5～1wt％,，Fe2O3为0.5～1wt％，碱金属和碱土金属氧化物为20～30wt％，烧失为2～5wt％；所述玻璃粉粒径小于0.045mm。
3.根据权利要求1所述的轻质多孔莫来石骨料的制备方法，其特征在于所述硅线石族矿物为硅线石、红柱石和蓝晶石中的一种。
4.根据权利要求1所述的轻质多孔莫来石骨料的制备方法，其特征在于所述干熄焦粉粒的主要化学成分是：固定碳为80～90wt％，烧失为80～90wt％；所述干熄焦粉粒径小于0.045mm。
5.根据权利要求1所述的轻质多孔莫来石骨料的制备方法，其特征在于所述结合剂为磷酸二氢铝、铝溶胶、硅溶胶和水玻璃中的一种。
6.一种轻质多孔莫来石骨料，其特征在于所述轻质多孔莫来石骨料是根据权利要求1～5项中任一项所述的轻质多孔莫来石骨料的制备方法所制备的轻质多孔莫来石骨料。
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