CN107459338A - 废弃陶瓷基建筑外墙用保温发泡材料及其制备方法 - Google Patents
废弃陶瓷基建筑外墙用保温发泡材料及其制备方法 Download PDFInfo
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- 239000000919 ceramic Substances 0.000 title claims abstract description 70
- 239000002699 waste material Substances 0.000 title claims abstract description 67
- 239000000463 material Substances 0.000 title claims abstract description 48
- 239000002937 thermal insulation foam Substances 0.000 title claims abstract description 38
- 238000002360 preparation method Methods 0.000 title claims abstract description 23
- 239000002994 raw material Substances 0.000 claims abstract description 24
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 20
- 239000002002 slurry Substances 0.000 claims abstract description 14
- 150000004645 aluminates Chemical class 0.000 claims abstract description 13
- 238000000498 ball milling Methods 0.000 claims abstract description 13
- 239000004568 cement Substances 0.000 claims abstract description 13
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 13
- 239000000843 powder Substances 0.000 claims abstract description 13
- 239000006260 foam Substances 0.000 claims abstract description 9
- 238000005187 foaming Methods 0.000 claims abstract description 9
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- LZZYPRNAOMGNLH-UHFFFAOYSA-M Cetrimonium bromide Chemical compound [Br-].CCCCCCCCCCCCCCCC[N+](C)(C)C LZZYPRNAOMGNLH-UHFFFAOYSA-M 0.000 claims abstract description 6
- 239000002585 base Substances 0.000 claims description 35
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 8
- 229910052681 coesite Inorganic materials 0.000 claims description 6
- 229910052593 corundum Inorganic materials 0.000 claims description 6
- 229910052906 cristobalite Inorganic materials 0.000 claims description 6
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 6
- 239000002245 particle Substances 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 6
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- 239000000126 substance Substances 0.000 claims description 6
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- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 claims description 5
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 5
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 4
- 239000003513 alkali Substances 0.000 claims description 3
- 229910052783 alkali metal Inorganic materials 0.000 claims description 3
- 229910001413 alkali metal ion Inorganic materials 0.000 claims description 3
- 229910000272 alkali metal oxide Inorganic materials 0.000 claims description 3
- 150000001340 alkali metals Chemical class 0.000 claims description 3
- 229910001420 alkaline earth metal ion Inorganic materials 0.000 claims description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052573 porcelain Inorganic materials 0.000 claims description 2
- 238000000034 method Methods 0.000 abstract description 7
- 238000001354 calcination Methods 0.000 abstract description 6
- 238000009413 insulation Methods 0.000 description 8
- 238000012360 testing method Methods 0.000 description 6
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- 238000010276 construction Methods 0.000 description 4
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- SWLVFNYSXGMGBS-UHFFFAOYSA-N ammonium bromide Chemical compound [NH4+].[Br-] SWLVFNYSXGMGBS-UHFFFAOYSA-N 0.000 description 1
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- 229910000278 bentonite Inorganic materials 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000010883 coal ash Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000002498 deadly effect Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
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- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
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- 239000011368 organic material Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 125000000913 palmityl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
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- 239000002893 slag Substances 0.000 description 1
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Abstract
本发明具体涉及一种废弃陶瓷基建筑外墙用保温发泡材料的制备方法。其技术方案是:先以65~80wt%的废弃陶瓷粉、5~15wt%的铝酸盐水泥、5~15wt%的粘土和5~15wt%的赤泥为原料,加入所述原料0.1~0.3wt%的减水剂和150~400wt%的水,球磨4~6h,得到发泡料浆;再按所述发泡料浆∶十六烷基三甲基溴化铵的质量比为(2500~3500)∶1配料,搅拌2~5min,浇注成型,自然干燥24h,再于80~150℃条件下干燥12~24h;然后在900~1100℃的条件下保温2~5h,即得废弃陶瓷基建筑外墙用保温发泡材料。本发明具有成本低、工艺简单、能实现资源综合利用和煅烧温度低的特点,所制制品常温导热系数较低、体积密度低、烧后体积变化小和耐压强度高。
Description
技术领域
本发明属于建筑外墙用保温发泡材料技术领域。具体涉及一种废弃陶瓷基建筑外墙用保温发泡材料及其制备方法。
背景技术
当前“低碳经济”成为时代背景,建筑节能也成为研究热门。墙体保温尤其是外墙保温是建筑节能的关键因素,外墙保温由于其施工相对方便而成为建筑行业的首选。目前国内建筑保温材料市场几乎被有机保温材料占领。其优点主要是质轻和致密性好,但也存在诸如稳定性差、易燃烧、不耐老化、生态环保性差和成本高等缺点。
研究发现,属于无机保温材料的发泡陶瓷保温板产品具有性能稳定、防火阻燃、抗老化、生态环保性好、可与建筑物同寿命的优点。最重要的是这种产品的防火等级为A1级,能够克服有机材料怕明火、易老化的致命弱点,可作为理想的建筑保温隔热材料。但是,现有的发泡陶瓷板大都采用价格偏高的矿石和精细陶瓷作为主要原料,由此带来产品成本高昂的缺点,使发泡陶瓷保温板得的应用收到限制。
由于陶瓷产业的快速发展,废弃陶瓷(即陶瓷工业的废弃品)也日渐增多。目前,对废弃陶瓷的处理方式仍然主要采取填埋的方式,这样不仅对土地、矿产资源造成浪费,还破坏环境,影响了我国陶瓷工业的可持续发展。赤泥是拜耳法生产氧化铝过程中产生的废渣,每生产1吨氧化铝产出0.8~1.5吨赤泥。赤泥的堆存占用了大量土地,耗费较多的堆场建设和维护费用,其处置费用高达氧化铝生产费用的5%,赤泥堆存坝一旦发生事故,将造成巨大经济损失;并且赤泥中的碱性物质易造成地下水体和土壤污染;裸露赤泥形成的粉尘随风飞扬,污染大气,恶化生态环境。从近几年的研究成果看,对于同时利用废弃陶瓷和赤泥作为主要原料的研究未见公开。
“粉煤灰轻质隔热发泡陶瓷保温板及其制法和应用”(CN104744070A)专利技术,以粉煤灰为主要原料,辅助以除尘灰、膨润土、电厂炉渣和发泡剂等,在1150~1200℃和氧化气氛下保温0.5~3h,随炉冷却,制得发泡陶瓷保温版。该技术虽将粉煤灰等固体废弃物作为原料,变废为宝,但仍然存在以下不足之处:(1)制样周期较长;(2)发泡剂的价格仍然昂贵;(3)烧成温度对于中温烧成制品而言相对较高;(4)试样体积密度区间过小,应用面窄。
发明内容
本发明旨在克服现有技术缺陷,目的在于提供一种成本低、工艺简单、能实现资源综合利用、煅烧温度低和孔结构可控的废弃陶瓷基建筑外墙用保温发泡材料的制备方法;用该方法制备的废弃陶瓷基建筑外墙用保温发泡材料常温导热系数较低、体积密度低、闭气孔率高、烧后体积变化小和耐压强度高。
为实现上述目的,本发明所采用的技术方案是:先以65~80wt%的废弃陶瓷粉、5~15wt%的铝酸盐水泥、5~15wt%的粘土和5~15wt%的赤泥为原料,加入所述原料0.1~0.3wt%的减水剂和150~400wt%的水,球磨4~6h,得到发泡料浆;再按所述发泡料浆∶十六烷基三甲基溴化铵的质量比为(2500~3500)∶1配料,搅拌2~5min,浇注成型,自然干燥24h,再于80~150℃条件下干燥12~24h;然后在900~1100℃的条件下保温2~5h,即得废弃陶瓷基建筑外墙用保温发泡材料。
所述废弃陶瓷粉的主要化学成分是:SiO2为60~70wt%,Al2O3为10~20wt%,Fe2O3为3~5wt%,FeO为0.5~1wt%,碱金属和碱土金属氧化物为10~20wt%,烧失为5~8wt%;所述废弃陶瓷粉的粒径小于0.048mm。
所述铝酸盐水泥为CA-50、CA-60、CA-70、CA-80中的一种。
所述赤泥的主要化学成分是:Fe2O3为35~45wt%,Al2O3为20~30wt%,SiO2为10~20wt%,TiO2为5~10wt%,碱金属和碱金属氧化物为2~6wt%;所述赤泥粒径小于0.048mm。
所述减水剂为三聚磷酸钠、六偏磷酸钠中的一种或两种。
所述球磨的球磨介质与原料的质量比为(2~5)∶1。
由于采用上述技术方案,本发明具有如下积极效果:
本发明采用陶瓷工业废弃物作为原料,在900~1100℃条件下保温2~5h,通过发泡法制得废弃陶瓷基建筑外墙用保温发泡材料。本发明采用的赤泥助烧效果显著,在满足产品强度的条件下能降低烧成温度,节约资源;故本发明煅烧温度低、工艺简单和成本低。
本发明采用的废弃陶瓷和赤泥中的低熔点组分能在高温下形成液相,堵住大孔,提高小孔所占的比例,有效地降低了导热系数。所制备的废弃陶瓷基建筑外墙用保温发泡材料具有常温导热系数低、体积密度低、闭气孔率高、烧后体积变化小、耐压强度高等优良性能。不仅适用于建筑外墙,且应用于耐火材料领域。
本发明以废弃陶瓷和赤泥为主要原料,不仅减少了运输及堆积填埋废陶瓷和赤泥的成本,且将废料用于生产附加值较高的泡沫陶瓷保温材料,可以减少优质资源的使用,降低原料成本,从而提高经济效益。对解决废陶瓷和赤泥污染环境问题、实现资源综合利用、保护生态环境具有十分重要的意义。
本发明制备的废弃陶瓷基建筑外墙用保温发泡材料经检测:常温导热系数为0.04~0.15W/(m·K);体积密度为0.35~1.2g/cm3;烧后线收缩率为5~15%;耐压强度为3~35MPa。
因此,本发明具有成本低、工艺简单、能实现资源综合利用、煅烧温度低和孔结构可控的特点,所制得的废弃陶瓷基建筑外墙用保温发泡材料常温导热系数较低、体积密度低、烧后体积变化小和耐压强度高,不仅适用于建筑外墙,且应用于耐火材料领域。
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。
本具体实施方式中:
所述废弃陶瓷粉的主要化学成分是:SiO2为60~70wt%,Al2O3为10~20wt%,Fe2O3为3~5wt%,FeO为0.5~1wt%,碱金属和碱土金属氧化物为10~20wt%,烧失为5~8wt%;所述废弃陶瓷粉的粒径小于0.048mm。
所述赤泥的主要化学成分是:Fe2O3为35~45wt%,Al2O3为20~30wt%,SiO2为10~20wt%,TiO2为5~10wt%,碱金属和碱金属氧化物为2~6wt%;所述赤泥粒径小于0.048mm。
所述球磨的球磨介质与原料的质量比为(2~5)∶1。
实施例中不再赘述。
实施例1
一种废弃陶瓷基建筑外墙用保温发泡材料及其制备方法。本实施例所述制备方法是:
先以65~70wt%的废弃陶瓷粉、11~15wt%的铝酸盐水泥、9~13wt%的粘土和8~12wt%的赤泥为原料,加入所述原料0.1~0.3wt%的减水剂和150~210wt%的水,球磨4~6h,得到发泡料浆。再按所述发泡料浆∶十六烷基三甲基溴化铵的质量比为(2500~2750)∶1配料,搅拌2~5min,浇注成型,自然干燥24h,再于80~150℃条件下干燥12~24h。然后在900~950℃的条件下保温2~5h,即得废弃陶瓷基建筑外墙用保温发泡材料。
所述铝酸盐水泥为CA-50。
所述减水剂为三聚磷酸钠。
本实施例1所制备的废弃陶瓷基建筑外墙用保温发泡材料经检测:常温导热系数为0.04~0.08W/(m·K);烧后线收缩率5~8%;体积密度0.35~0.68g/cm3;耐压强度3~10MPa。
实施例2
一种废弃陶瓷基建筑外墙用保温发泡材料及其制备方法。本实施例所述制备方法是:
先以68~73wt%的废弃陶瓷粉、9~13wt%的铝酸盐水泥、5~9wt%的粘土和11~15wt%的赤泥为原料,加入所述原料0.1~0.3wt%的减水剂和2100~270wt%的水,球磨4~6h,得到发泡料浆。再按所述发泡料浆∶十六烷基三甲基溴化铵的质量比为(2750~3000)∶1配料,搅拌2~5min,浇注成型,自然干燥24h,再于80~150℃条件下干燥12~24h。然后在950~1000℃的条件下保温2~5h,即得废弃陶瓷基建筑外墙用保温发泡材料。
所述铝酸盐水泥为CA-60。
所述减水剂为六偏磷酸钠。
本实施例2所制备的废弃陶瓷基建筑外墙用保温发泡材料经检测:常温导热系数为0.05~0.10W/(m·K);烧后线收缩率6~10%;体积密度0.48~0.82g/cm-3;耐压强度6~15MPa。
实施例3
一种废弃陶瓷基建筑外墙用保温发泡材料及其制备方法。本实施例所述制备方法是:
先以72~77wt%的废弃陶瓷粉、7~11wt%的铝酸盐水泥、11~15wt%的粘土和5~9wt%的赤泥为原料,加入所述原料0.1~0.3wt%的减水剂和270~330wt%的水,球磨4~6h,得到发泡料浆。再按所述发泡料浆∶十六烷基三甲基溴化铵的质量比为(3000~3250)∶1配料,搅拌2~5min,浇注成型,自然干燥24h,再于80~150℃条件下干燥12~24h。然后在1000~1050℃的条件下保温2~5h,即得废弃陶瓷基建筑外墙用保温发泡材料。
所述铝酸盐水泥为CA-70。
所述减水剂为三聚磷酸钠和六偏磷酸钠的混合物。
本实施例3所制备的废弃陶瓷基建筑外墙用保温发泡材料经检测:常温导热系数为0.06~0.12W/(m·K);烧后线收缩率7~12%;体积密度0.62~1.04g/cm-3;耐压强度9~25MPa。
实施例4
一种废弃陶瓷基建筑外墙用保温发泡材料及其制备方法。本实施例所述制备方法是:
先以75~80wt%的废弃陶瓷粉、5~9wt%的铝酸盐水泥、7~11wt%的粘土和6~10wt%的赤泥为原料,加入所述原料0.1~0.3wt%的减水剂和330~400wt%的水,球磨4~6h,得到发泡料浆。再按所述发泡料浆∶十六烷基三甲基溴化铵的质量比为(3250~3500)∶1配料,搅拌2~5min,浇注成型,自然干燥24h,再于80~150℃条件下干燥12~24h。然后在1050~1100℃的条件下保温2~5h,即得废弃陶瓷基建筑外墙用保温发泡材料。
所述铝酸盐水泥为CA-80。
所述减水剂为三聚磷酸钠和六偏磷酸钠的混合物。
本实施例4所制备的废弃陶瓷基建筑外墙用保温发泡材料经检测:常温导热系数为0.08~0.15W/(m·K);烧后线收缩率8~15%;体积密度0.84~1.2g/cm-3;耐压强度15~35MPa。
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陶瓷工业废弃物作为原料,在900~1100℃条件下保温2~5h,通过发泡法制得废弃陶瓷基建筑外墙用保温发泡材料。本具体实施方式采用的赤泥助烧效果显著,在满足产品强度的条件下能降低烧成温度,节约资源;故本具体实施方式煅烧温度低、工艺简单和成本低。
本具体实施方式采用的废弃陶瓷和赤泥中的低熔点组分能在高温下形成液相,堵住大孔,提高小孔所占的比例,有效地降低了导热系数。所制备的废弃陶瓷基建筑外墙用保温发泡材料具有常温导热系数低、体积密度低、闭气孔率高、烧后体积变化小、耐压强度高等优良性能。不仅适用于建筑外墙,且应用于耐火材料领域。
本具体实施方式以废弃陶瓷和赤泥为主要原料,不仅减少了运输及堆积填埋废陶瓷和赤泥的成本,且将废料用于生产附加值较高的泡沫陶瓷保温材料,可以减少优质资源的使用,降低原料成本,从而提高经济效益。对解决废陶瓷和赤泥污染环境问题、实现资源的综合利用、保护生态环境具有十分重要的意义。
本具体实施方式制备的废弃陶瓷基建筑外墙用保温发泡材料经检测:常温导热系数为0.04~0.15W/(m·K);体积密度为0.35~1.2g/cm3;烧后线收缩率为5~15%;耐压强度为3~35MPa。
因此,本具体实施方式具有成本低、工艺简单、能实现资源综合利用、煅烧温度低和孔结构可控的特点,所制得的废弃陶瓷基建筑外墙用保温发泡材料常温导热系数较低、体积密度低、烧后体积变化小和耐压强度高,不仅适用于建筑外墙,且应用于耐火材料领域。
Claims (7)
1.一种废弃陶瓷基建筑外墙用保温发泡材料的制备方法,其特征在于:先以65~80wt%的废弃陶瓷粉、5~15wt%的铝酸盐水泥、5~15wt%的粘土和5~15wt%的赤泥为原料,加入所述原料0.1~0.3wt%的减水剂和150~400wt%的水,球磨4~6h,得到发泡料浆;再按所述发泡料浆∶十六烷基三甲基溴化铵的质量比为(2500~3500)∶1配料,搅拌2~5min,浇注成型,自然干燥24h,再于80~150℃条件下干燥12~24h;然后在900~1100℃的条件下保温2~5h,即得废弃陶瓷基建筑外墙用保温发泡材料。
2.根据权利要求1所述的废弃陶瓷基建筑外墙用保温发泡材料的制备方法,其特征在于所述废弃陶瓷粉的主要化学成分是:SiO2为60~70wt%,Al2O3为10~20wt%,Fe2O3为3~5wt%,FeO为0.5~1wt%,碱金属和碱土金属氧化物为10~20wt%,烧失为5~8wt%;所述废弃陶瓷粉的粒径小于0.048mm。
3.根据权利要求1所述的废弃陶瓷基建筑外墙用保温发泡材料的制备方法,其特征在于所述铝酸盐水泥为CA-50、CA-60、CA-70、CA-80中的一种。
4.根据权利要求1所述的废弃陶瓷基建筑外墙用保温发泡材料的制备方法,其特征在于所述赤泥的主要化学成分是:Fe2O3为35~45wt%,Al2O3为20~30wt%,SiO2为10~20wt%,TiO2为5~10wt%,碱金属和碱金属氧化物为2~6wt%;所述赤泥粒径小于0.048mm。
5.根据权利要求1所述的废弃陶瓷基建筑外墙用保温发泡材料的制备方法,其特征在于所述减水剂为三聚磷酸钠、六偏磷酸钠中的一种或两种。
6.根据权利要求1所述的废弃陶瓷基建筑外墙用保温发泡材料的制备方法,其特征在于所述球磨的球磨介质与原料的质量比为(2~5)∶1。
7.一种废弃陶瓷基建筑外墙用保温发泡材料,其特征在于所述废弃陶瓷基建筑外墙用保温发泡材料是根据权利要求1~6项中任一项所述废弃陶瓷基建筑外墙用保温发泡材料的制备方法所制备的废弃陶瓷基建筑外墙用保温发泡材料。
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