CN107311633A - 一种用石英石废弃物制备的多孔陶瓷及其制备方法 - Google Patents
一种用石英石废弃物制备的多孔陶瓷及其制备方法 Download PDFInfo
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Abstract
本发明属于建筑材料技术和废弃物利用技术领域,尤其涉及一种用石英石废弃物制备的多孔陶瓷及其制备方法,按重量份比将50‑60份石英石废弃物、35‑45份飞灰、15‑20份碳酸氢钠、0.01‑0.03份外加剂和适量水混合制成固含量浓度为30%‑40%的料浆,将料浆加入1‑5份发泡剂发泡,烘干,在不高于800℃条件下低温烧结。本发明方法实现了废弃物的利用,降低环境负荷和多孔陶瓷的制造成本;制得的多孔陶瓷具有较好的抗折强度,隔热性好、密度小、自重轻。
Description
技术领域
本发明属于建筑材料技术和废弃物利用技术领域,尤其涉及一种用石英石废弃物制备的多孔陶瓷及其制备方法。
背景技术
石英石废弃物是生产石英石时产生的废弃物,其成分含有10%左右的树脂,一般树脂含有苯等化合物,而且这些有机物在自然环境中降解非常缓慢;废弃物中还含有一些碱性的无机添加物,重金属盐类等,这些化合物都会对环境产生严重的污染而且堆积占用了大量的土地。石英石加工的过程中需要湿磨,因此废弃物中含有大量的水分。由于废弃物中大量树脂和水分的存在,而且树脂燃烧产生的气体严重污染大气,因此对其无污染煅烧处理难以实现。石英石含水率高(一般在40%以上),但其表观含水少,难挥发,烘干困难是制约其工业化应用的根本原因,且其完全烘干后易出现颗粒团聚导致无法均匀分散,同时在烘干的过程中(70℃)树脂开始挥发出刺激性的气味,因此一般企业只能是不作处理任意排放、填埋。
目前石英石废弃物已经成为环境的一大威胁,小规模企业众多,产品质量良莠不齐;生产率和产品合格率较低,据不完全统计全国生产人造石板的企业一年所产生的废料是2000多万吨,由于废弃物中大量树脂和水分的存在,且树脂燃烧产生的气体严重污染大气,降解缓慢,因此对其无污染处理难以实现。
多孔陶瓷是一种新型的陶瓷材料,自19世纪70年代作为细菌过滤体被实用化以来,由于它具有均匀透过性,较大的比表面积,低密度以及耐高温、抗腐蚀、耐热冲击、机械强度高、原料来源广泛,使用寿命长等优良特性而越来越受到人们的重视,己被广泛应用于化工,能源、环保、冶金、电子及生物等各个部门,作为过滤、分离、布气、吸音、催化剂载体及生物陶瓷等材料,引起了材料学界的高度关注,成为一个非常活跃的研究领域。随着大量研究成果的取得,多孔陶瓷的应用范围仍在不断地进一步发展。多孔陶瓷是一种经高温烧成,材料中含有大量彼此相通并与材料表面相贯通的多孔结构的陶瓷材料,多孔陶瓷由于其特殊的材质及结构,具有以下一些共同特性:化学稳定性好;热学稳定性能好;几何表面积与体积比高;多孔陶瓷制品的孔道尺寸分布范围较宽。
用石英石固体废弃物,研究开发一种生产成本低,兼具轻质、保温、隔热功能的环保型多孔陶瓷,实现资源化综合利用,既可以解决环境污染问题,又使资源得到了有效利用,符合我国环境可持续发展战略实施的要求,具有广阔的应用前景。。
发明内容
本发明针对上述的问题,本发明提出一种用石英石废弃物制备的多孔陶瓷及其制备方法。
为了达到上述目的,本发明采用的技术方案为,本发明提供一种用石英石废弃物制备的多孔陶瓷,其特征在于,按照按重量份数包括以下成分:
石英石废弃物 50-60份;
飞灰 35-45份;
碳酸氢钠 15-20份;
外加剂 0.01-0.03份;
水 30-40份;
发泡剂 1-5份。
作为优选,所述石英石板废弃物,其重量百分比组成如下:SiO2 89.05%-90.18%、Al2O3 0.3%-0.4%、CaO 1.95%-1.97%、MgO 0.60%-0.67%、Fe2O3 0.55%-0.6%、K2O 0.14%-0.17%、Na2O 0.7%-0.9%、杂质余量;其中杂质为废弃物中含有的树脂和水分,废弃物粒度为10-100微米。
作为优选,所述飞灰按重量百分比组成如下:Al2O3 38.5%-40.3%、SiO2 33.5%-35.9%、CaO 10.1%-12.3%、杂质余量;杂质为其它氧化物或水分;飞灰粒度为1-100微米。
作为优选,所述外加剂由质量百分比为5%-10%的烷基醇酰胺、40%-50%的聚羧酸减水剂、10%-15%的焦磷酸钠和25%-35%的聚丙烯酸钠组成。
作为优选,所述发泡剂为双氧水。
此外,本发明还提供了一种用石英石废弃物制备的多孔陶瓷的制备方法,其特征在于,包括以下步骤:
(1)将石英石废弃物过筛;
(2)将50-60份石英石废弃物、35-45份飞灰、15-20份碳酸氢钠、0.01-0.03份外加剂和适量水混合,制成浓度为30%-40%的料浆;
(3)向料浆加入发泡剂发泡;
(4)发泡后进行烘干;并在不高于800℃条件下低温烧结6-10小时,制得成品多孔陶瓷。
作为优选,所述过筛筛目大小为140-200目。
作为优选,所述烘干优选在90℃±5℃的烘干设备中烘干3-5小时。
作为优选,所述发泡为搅拌自然发泡,发泡好的混合料在温度20±2℃,湿度大于等于50%的环境中放置8-10小时。
作为优选,所述低温烧结采用每分钟升温3℃,300℃保温30-40分钟,500℃保温60-80分钟, 800℃保温3小时的烧结工艺。
与现有技术相比,本发明的优点和积极效果在于,
1、本发明原料中石英石废弃物中含有的大量树脂高温下分解都会产生大量的气体形成多孔的结构,废料中的Al2O3、SiO2和CaO,形成陶瓷中需要的骨架莫来石相,双氧水发泡剂可以引入大量气孔,碳酸氢钠助熔剂的使用可以大幅降低多孔陶瓷的出现液相的温度,有利用低温烧成。
2、本发明外加剂的使用,可以有效的释放出人造石里面的吸附水转化成自由水,降低了外加水的用量,节约了成本;释放出的水所留下的空间,形成气孔;烷基醇酰胺在体系里面具有稳定和促进气泡的作用,聚羧酸减水剂和焦磷酸钠复合作用具有分散废弃物和释放吸附水的作用,聚丙烯酸钠作为体系稳定剂,防止沉淀。
3、本发明采用的烧结工艺可保证多孔陶瓷孔结构和陶瓷莫来石相的形成,防止温度过高结构坍塌。
4、本发明方法实现了废弃物的利用,利用大量工业垃圾,降低环境负荷和多孔陶瓷的制造成本。
5、本发明方法制得的多孔陶瓷具有较好的抗折强度,隔热性好、密度小、自重轻。
具体实施方式
为了能够更清楚地理解本发明的上述目的、特征和优点,下面结合实施例对本发明做进一步说明。需要说明的是,在不冲突的情况下,本申请的实施例及实施例中的特征可以相互组合。
在下面的描述中阐述了很多具体细节以便于充分理解本发明,但是,本发明还可以采用不同于在此描述的其他方式来实施,因此,本发明并不限于下面公开说明书的具体实施例的限制。
本发明提供一种用石英石废弃物制备的多孔陶瓷,其特征在于,按照按重量份数包括以下成分50-60份石英石废弃物、35-45份飞灰、15-20份碳酸氢钠、0.01-0.03份外加剂、30-40份水和1-5份发泡剂,其中石英石板废弃物按重量百分比组成如下:SiO2 89.05%-90.18%、Al2O3 0.3%-0.4%、CaO 1.95%-1.97%、MgO 0.60%-0.67%、Fe2O3 0.55%-0.6%、K2O0.14%-0.17%、Na2O 0.7%-0.9%、杂质余量;其中杂质为废弃物中含有的树脂和水分,废弃物粒度为10-100微米。飞灰按重量百分比组成如下:Al2O3 38.5%-40.3%、SiO2 33.5%-35.9%、CaO 10.1%-12.3%、杂质余量;杂质为其它氧化物或水分;飞灰粒度为1-100微米。外加剂由质量百分比为5%-10%的烷基醇酰胺、40%-50%的聚羧酸减水剂、10%-15%的焦磷酸钠和25%-35%的聚丙烯酸钠组成。发泡剂优选为双氧水。下面结合具体实施方式对本发明做进一步解释说明:
实施例1
(1)将石英石废弃物取出,过200目筛;
(2)配料:按重量份将50份石英石废弃物、45份飞灰、15份碳酸氢钠、0.01份外加剂和40份水按照混合均匀,制成固含量为30%-40%的料浆,外加剂为质量百分比组成:8% 烷基醇酰胺、45%聚羧酸减水剂、12%的焦磷酸钠和35%的聚丙烯酸钠。将上述浆料加入4份发泡剂,自然发泡,发泡好的混合料在温度20℃、湿度50%的环境中放置10小时,使得混合料中水份的分布趋于均匀化,同时也带动了混合料内部粘接剂等物质在混合料内部的均匀化。
(3)烘干:将发泡好的样品放在90℃左右的烘干设备中烘干4小时。
(4)烧结:为了保证多孔陶瓷孔结构和陶瓷莫来石相的形成,防止温度过高结构坍塌,采取低温长时间保温的烧结工艺,即采用每分钟升温3℃,300℃保温30-40分钟,500℃保温60-80分钟, 800℃保温3小时的烧结工艺。
实施例2
(1)将石英石废弃物取出,过200目筛;
(2)配料:按重量份将55份石英石废弃物、40份飞灰、17份碳酸氢钠、0.02份外加剂和42份水按照混合均匀,制成固含量为40%的料浆,外加剂质量百分比组成为:8% 烷基醇酰胺、45%聚羧酸减水剂、12%的焦磷酸钠和35%的聚丙烯酸钠。将上述浆料加入4份发泡剂,自然发泡,发泡好的混合料在温度20℃、湿度50%的环境中放置10小时,使得混合料中水份的分布趋于均匀化,同时也带动了混合料内部粘接剂等物质在混合料内部的均匀化。
(3)烘干:将发泡好的样品放在90℃左右的烘干设备中烘干4小时。
(4)烧结:为了保证多孔陶瓷孔结构和陶瓷莫来石相的形成,防止温度过高结构坍塌,采取低温长时间保温的烧结工艺,即采用每分钟升温3℃,300℃保温30-40分钟,500℃保温60-80分钟, 800℃保温3小时的烧结工艺。
实施例3
(1)将石英石废弃物取出,过200目筛;
(2)配料:按重量份将60份石英石废弃物、35份飞灰、20份碳酸氢钠、0.03份外加剂和45份水按照混合均匀,制成固含量为30%-40%的料浆,外加剂质量百分比组成为:8% 烷基醇酰胺、45%聚羧酸减水剂、12%的焦磷酸钠和35%的聚丙烯酸钠。将上述浆料加入4份发泡剂,自然发泡,发泡好的混合料在温度20℃、湿度50%的环境中放置10小时,使得混合料中水份的分布趋于均匀化,同时也带动了混合料内部粘接剂等物质在混合料内部的均匀化。
(3)烘干:将发泡好的样品放在90℃左右的烘干设备中烘干4小时。
(4)烧结:为了保证多孔陶瓷孔结构和陶瓷莫来石相的形成,防止温度过高结构坍塌,采取低温长时间保温的烧结工艺,即采用每分钟升温3℃,300℃保温30-40分钟,500℃保温60-80分钟, 800℃保温3小时的烧结工艺。
实施例4
(1)将石英石废弃物取出,过200目筛;
(2)配料:按重量份将60份石英石废弃物、35份飞灰、20份碳酸氢钠、0.03份外加剂和45份水按照混合均匀,制成固含量为30%-40%的料浆,外加剂质量百分比组成为:10% 烷基醇酰胺、50%聚羧酸减水剂、10%的焦磷酸钠和30%的聚丙烯酸钠。将上述浆料加入3份发泡剂,自然发泡,发泡好的混合料在温度20℃、湿度50%的环境中放置10小时,使得混合料中水份的分布趋于均匀化,同时也带动了混合料内部粘接剂等物质在混合料内部的均匀化;
(3)烘干:将发泡好的样品放在90℃左右的烘干设备中烘干4小时。
(4)烧结:为了保证多孔陶瓷孔结构和陶瓷莫来石相的形成,防止温度过高结构坍塌,采取低温长时间保温的烧结工艺,即采用每分钟升温3℃,300℃保温30-40分钟,500℃保温60-80分钟, 800℃保温3小时的烧结工艺。
根据上述实施例得到数据如下表所示:
实施例 | 表观密度/g.cm-3 | 吸水率/% | 抗折强度/MPa | 抗压强度/MPa |
1 | 0.74 | 19 | 1.5 | 10.1 |
2 | 0.81 | 18 | 1.8 | 12.5 |
3 | 0.66 | 21 | 1.3 | 11.6 |
4 | 0.72 | 20 | 1.4 | 12.2 |
普通 | 1.35 | 12 | 1.0 | 8.0 |
如上表所示,利用本发明制备方法制得的多孔陶瓷,相较于现有市面上的普通陶瓷来说,在利用废弃物成本更低的前提下,性能更加优越。
以上所述,仅是本发明的较佳实施例而已,并非是对本发明作其它形式的限制,任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以变更或改型为等同变化的等效实施例应用于其它领域,但是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、等同变化与改型,仍属于本发明技术方案的保护范围。
Claims (10)
1.一种用石英石废弃物制备的多孔陶瓷,其特征在于,按照按重量份数包括以下成分:
石英石废弃物 50-60份;
飞灰 35-45份;
碳酸氢钠 15-20份;
外加剂 0.01-0.03份;
水 30-40份;
发泡剂 1-5份。
2. 根据权利要求1所述一种用石英石废弃物制备的多孔陶瓷,其特征在于:所述石英石板废弃物,其重量百分比组成如下:SiO2 89.05%-90.18%、Al2O3 0.3%-0.4%、CaO 1.95%-1.97%、MgO 0.60%-0.67%、Fe2O3 0.55%-0.6%、K2O 0.14%-0.17%、Na2O 0.7%-0.9%、杂质余量;其中杂质为废弃物中含有的树脂和水分,废弃物粒度为10-100微米。
3. 根据权利要求1所述一种用石英石废弃物制备的多孔陶瓷,其特征在于:所述飞灰按重量百分比组成如下:Al2O3 38.5%-40.3%、SiO2 33.5%-35.9%、CaO 10.1%-12.3%、杂质余量;杂质为其它氧化物或水分;飞灰粒度为1-100微米。
4.根据权利要求1所述一种用石英石废弃物制备的多孔陶瓷,其特征在于:所述外加剂由质量百分比为5%-10%的烷基醇酰胺、40%-50%的聚羧酸减水剂、10%-15%的焦磷酸钠和25%-35%的聚丙烯酸钠组成。
5.根据权利要求1所述一种用石英石废弃物制备的多孔陶瓷,其特征在于:所述发泡剂为双氧水。
6.一种用石英石废弃物制备的多孔陶瓷的制备方法,其特征在于,包括以下步骤:
(1)将石英石废弃物过筛;
(2)将50-60份石英石废弃物、35-45份飞灰、15-20份碳酸氢钠、0.01-0.03份外加剂和适量水混合,制成浓度为30%-40%的料浆;
(3)向料浆加入发泡剂发泡;
(4)发泡后进行烘干;并在不高于800℃条件下低温烧结6-10小时,制得成品多孔陶瓷。
7.根据权利要求5所述一种用石英石废弃物制备的多孔陶瓷的制备方法,其特征在于:所述过筛筛目大小为140-200目。
8.根据权利要求5所述一种用石英石废弃物制备的多孔陶瓷的制备方法,其特征在于:所述烘干优选在90℃±5℃的烘干设备中烘干3-5小时。
9.根据权利要求5所述一种用石英石废弃物制备的多孔陶瓷的制备方法,其特征在于:所述发泡为搅拌自然发泡,发泡好的混合料在温度20±2℃,湿度大于等于50%的环境中放置8-10小时。
10. 根据权利要求5所述一种用石英石废弃物制备的多孔陶瓷的制备方法,其特征在于:所述低温烧结采用每分钟升温3℃,300℃保温30-40分钟,500℃保温60-80分钟, 800℃保温3小时的烧结工艺。
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