CN108002859A - 一种利用污泥制作轻质多孔陶粒的工艺 - Google Patents
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Abstract
本发明公开一种利用污泥制作轻质多孔陶粒的工艺,包括以下步骤:步骤一:在100‑140℃下,干燥污泥至含水量为30‑40%;步骤二:将污泥、高岭土、膨胀剂和CaF2研磨成混合粉末;步骤三:将混合粉末挤压造粒成陶粒生料;步骤四:以5‑10℃/min的速率升温,200‑500℃预热30‑40min,500‑1000℃烘焙50‑70min,1000‑1300℃煅烧50‑60min。其中,所述膨胀剂由20‑24份CaCO3、13‑17份MgCO3、7‑11份Na2O和30‑34份Fe2O3组成。本发明实现污泥的无害化、减量化、稳定化、资源化再生利用,生产出的陶粒稳定性强、抗压强度高、孔隙率高、密度低,具有良好的保温、隔音及防渗透作用,可与混凝土共掺作建筑材料。
Description
技术领域
本发明涉及污泥建材化技术领域,具体涉及一种利用污泥制作轻质多孔陶粒的工艺。
背景技术
目前,堆肥化技术、好氧发酵技术和厌氧消化技术是治理污泥的主要途径,但是污泥的有效利用率较低,无法完全发掘出污泥的潜在价值,造成资源的浪费,且污泥中重金属难以固定,造成二次污染。污泥的建材化技术利用污泥烧结制砖、水泥和陶粒等建筑材料,但是污泥陶粒的微孔较少、强度较低及密度相对较大,因此其稳定性和保温性较差。申请号为CN201710055896.7的专利,将30-70%的污泥、20-60%黏土和10-15%铝土矿混合均匀,再进行陈化、干燥、造粒和煅烧制得污泥陶粒,该专利简化了生产工艺,提高了污泥的处理效率,但是生产出的污泥陶粒孔隙结构较少,保温隔热效果欠佳。本发明生产出的陶粒质轻、强度高、孔隙率高,具有良好的保温、隔热、抗渗、抗震、抗冻及耐火性能,是优良的建筑材料,使污泥实现无害化、减量化、稳定化、资源化再生利用,变废为宝。
发明内容
针对现有技术的不足之处,本发明的目的在于提供一种高强度污泥陶粒的制备方法。
本发明的技术方案概述如下:
一种利用污泥制作轻质多孔陶粒的工艺,包括以下步骤:
步骤一:在100-140℃下,干燥污泥,使含水量降至30-40%;
步骤二:将步骤一中的污泥与高岭土按照1:(0.4-0.6)的重量比混合均匀,再加入15-25wt%的膨胀剂和2-6wt%CaF2,研磨成混合粉末;
其中,所述膨胀剂以重量份数计,包括以下组分:
步骤三:将步骤二中的混合粉末挤压造粒成陶粒生料;
步骤四:以5-10℃/min的速率升温,200-500℃预热30-40min,500-1000℃烘焙50-70min,1000-1300℃煅烧50-60min,再以3-7℃/min的速率降至常温,制得所述轻质多孔陶粒。
优选的是,步骤二中混合粉末粒径为0.02-0.04mm。
优选的是,步骤三中挤压压强为55-65MPa。
本发明的有益效果
(1)本发明中的高岭土含有46.54%的SiO2和39.5%的Al2O3,提高陶粒的硬度和抗压强度,此外,SiO2和Al2O3又是天然助熔剂,降低陶粒生胚软化系数,提高陶粒纯度;
(2)本发明中的膨胀剂使陶粒加热煅烧过程中,不断产生气泡,提高陶粒内部的微孔数量和微孔孔容,从而降低陶粒密度,有效减少室内外的热量传递,加强陶粒的保温、隔音及防渗透功能,Na2O在常温下能与污泥中的水反应生成O2,疏松陶粒内部结构,降低污泥含水量,MgCO3在400-500℃热分解生成MgO和CO2,CaCO3在850-1000℃热分解CaO和CO2,CaO和MgO又可作为助熔剂,脱除陶粒中的杂质成分,Fe2O3在高温条件下能与污泥中C发生氧化还原反应放出CO2;
(3)本发明中的CaF2在900-1100℃时,与SiO2反应生成Ca3O5Si,加强了陶粒分子间的作用力,提高陶粒的抗张强度和硬度,此外,CaF2可作为助熔剂和助色剂,能有效降低陶粒烧结温度,减少燃料消耗,提高陶粒的金属色泽,并能够脱去高岭土中硫、磷和氮,降低环境污染。
具体实施方式
下面结合实施例对本发明做进一步的详细说明,以令本领域技术人员参照说明书文字能够据以实施。
实施例1
步骤一:在100℃下,干燥污泥,使含水量降至30%;
步骤二:将步骤一中的污泥与高岭土按照1:0.4的重量比混合均匀,再加入15wt%的由20份CaCO3、13份MgCO3、7份Na2O和30份Fe2O3制备的膨胀剂和2wt%CaF2,研磨成0.02mm粒径的混合粉末;
步骤三:将步骤二中的混合粉末在55MPa下挤压造粒成陶粒生料;
步骤四:以5℃/min的速率升温,200℃预热30min,500℃烘焙50min,1000℃煅烧50min,再以3℃/min的速率降至常温,制得所述轻质多孔陶粒。
实施例2
步骤一:在120℃下,干燥污泥,使含水量降至35%;
步骤二:将步骤一中的污泥与高岭土按照1:0.5的重量比混合均匀,再加入20wt%的由22份CaCO3、15份MgCO3、9份Na2O和32份Fe2O3制备的膨胀剂和4wt%CaF2,研磨成0.03mm粒径的混合粉末;
步骤三:将步骤二中的混合粉末在60MPa下挤压造粒成陶粒生料;
步骤四:以7.5℃/min的速率升温,350℃预热35min,750℃烘焙60min,1150℃煅烧55min,再以5℃/min的速率降至常温,制得所述轻质多孔陶粒。
实施例3
步骤一:在140℃下,干燥污泥,使含水量降至40%;
步骤二:将步骤一中的污泥与高岭土按照1:0.6的重量比混合均匀,再加入25wt%的由24份CaCO3、17份MgCO3、11份Na2O和34份Fe2O3制备的膨胀剂和6wt%CaF2,研磨成0.04mm粒径的混合粉末;
步骤三:将步骤二中的混合粉末在65MPa下挤压造粒成陶粒生料;
步骤四:以10℃/min的速率升温,500℃预热40min,1000℃烘焙70min,1300℃煅烧60min,再以7℃/min的速率降至常温,制得所述轻质多孔陶粒。
对比例:密度为550kg/m3超轻密度陶粒。
实施例1 | 实施例2 | 实施例3 | 对比例 | |
堆积密度/kg/m3 | 382 | 378 | 394 | 550 |
抗压强度/MPa | 28.3 | 32.6 | 33.2 | 18.4 |
孔隙率/% | 68 | 73 | 76 | 63 |
吸水率/% | 8.3 | 8.0 | 7.8 | 8.2 |
吸音系数/% | 69.3 | 72.5 | 74.2 | 63.7 |
导热系数W/(m·K) | 0.16 | 0.14 | 0.13 | 0.43 |
软化系数 | 0.84 | 0.82 | 0.83 | 0.87 |
本发明生产的污泥陶粒抗压强度高,稳定性强,具有良好的隔音、保温及防潮作用,可作为建筑材料被广泛应用。
尽管本发明的实施方案已公开如上,但其并不仅仅限于说明书和实施方式中所列运用,它完全可以被适用于各种适合本发明的领域,对于熟悉本领域的人员而言,可容易地实现另外的修改,因此在不背离权利要求及等同范围所限定的一般概念下,本发明并不限于特定的细节。
Claims (3)
1.一种利用污泥制作轻质多孔陶粒的工艺,其特征在于,包括以下步骤:
步骤一:在100-140℃下,干燥污泥,使含水量降至30-40%;
步骤二:将步骤一中的污泥与高岭土按照1:(0.4-0.6)的重量比混合均匀,再加入15-25wt%的膨胀剂和2-6wt%CaF2,研磨成混合粉末;
其中,所述膨胀剂以重量份数计,包括以下组分:
步骤三:将步骤二中的混合粉末挤压造粒成陶粒生料;
步骤四:以5-10℃/min的速率升温,200-500℃预热30-40min,500-1000℃烘焙50-70min,1000-1300℃煅烧50-60min,再以3-7℃/min的速率降至常温,制得所述轻质多孔陶粒。
2.根据权利要求1所述的一种利用污泥制作轻质多孔陶粒,其特征在于,步骤二中混合粉末粒径为0.02-0.04mm。
3.根据权利要求1所述的一种利用污泥制作轻质多孔陶粒,其特征在于,步骤三中挤压压强为55-65MPa。
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