CN108191395A - 一种轻质煤矸石烧结空心砖及其制备方法 - Google Patents
一种轻质煤矸石烧结空心砖及其制备方法 Download PDFInfo
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Abstract
本发明提供一种轻质煤矸石烧结空心砖及其制备方法,涉及建筑材料领域,包括以下重量份的组分:植物秸秆纤维2‑6%、碳纤维0.5‑2.5%、玻璃纤维0.5‑2.5%、陶瓷微粉3‑8%、海砂4‑10%、彩石砂4‑10%、紫砂5‑15%、硅酸锆1‑3%、硅酸铝1‑3%、海泡石4‑10%、膨润土1‑3%、黏土岩1‑3%、余量为煤矸石,本发明具有密度小,强度高,热惰性大而且保温隔热性好的优点,而且制备工艺简单,易于操作,适合大规模生产。
Description
技术领域
本发明涉及建筑材料领域,具体涉及一种轻质煤矸石烧结空心砖及其制备方法。
背景技术
在我国北方,每年冬季的供暖能耗几乎占总能耗的30-40%。因此降低供暖能耗是一个非常值得重视的问题,通常降低供暖能耗采用两种方法,一种是提高各种供暖设备的效率,另一种是提高建筑物的保温性能,增加阻热,减少热损失。一般来说,墙体屋面散出的热量达房屋散热的60-70%,而墙面面积比屋面面积要多出几倍,必须把建筑能耗的降低放在集中改善房屋外围结构保暖上。
煤矸石是在成煤过程中与煤共同沉积的有机化合物和无机化合物混合在一起的岩石,通常呈薄层和在煤层中或煤层顶、煤层底。煤矸石按主要矿物含量分为黏土岩类、砂石岩类、碳酸盐类、铝质岩类。按来源及最终状态,煤矸石可分为掘进矸石、选煤矸石和自然矸石三大类。煤矸石排放量根据煤层条件、开采条件和洗选工艺的不同有较大差异,一般掘进矸石占原煤产量的10%左右,选煤矸石占入选原煤量的12%-18%;煤矸石的无机成分主要是硅、铝、钙、镁、铁的氧化物和某些稀有金属,用煤矸石为原料制成的空心砖具有质轻、热惰性大而且保温隔热性好的优点,非常适合作为建筑材料使用。
发明内容
(一)解决的技术问题
针对现有技术的不足,本发明提供了一种轻质煤矸石烧结空心砖及其制备方法,具有密度小,强度高,热惰性大而且保温隔热性好的优点,而且制备工艺简单,易于操作,适合大规模生产。
(二)技术方案
为实现以上目的,本发明通过以下技术方案予以实现:
一种轻质煤矸石烧结空心砖,包括以下重量份的组分:植物秸秆纤维2-6%、碳纤维0.5-2.5%、玻璃纤维0.5-2.5%、陶瓷微粉3-8%、海砂4-10%、彩石砂4-10%、紫砂5-15%、硅酸锆1-3%、硅酸铝1-3%、海泡石4-10%、膨润土1-3%、黏土岩1-3%、余量为煤矸石。
优选地,包括以下重量份的组分:植物秸秆纤维3-4.5%、碳纤维1-2%、玻璃纤维1-1.5%、陶瓷微粉4-6%、海砂5-8%、彩石砂5-8%、紫砂7-12%、硅酸锆1.5-2.5%、硅酸铝1.5-2.5%、海泡石6-8%、膨润土1.5-2.5%、黏土岩1.5-2.5%、余量为煤矸石。
优选地,所述植物秸秆纤维的长度为0.3-0.5mm,碳纤维的长度为0.1-0.4mm,玻璃纤维的长度为0.2-0.4mm。
上述轻质煤矸石烧结空心砖的制备方法,包括以下步骤:
(1)将海砂、彩石砂、紫砂、海泡石、黏土岩和煤矸石混合粉碎,得到粒度为30-50μm的混合料,向混合料中依次加入硅酸锆、硅酸铝、陶瓷微粉,将膨润土加入到水中预混合后边搅拌边倒入,最后将植物秸秆纤维、碳纤维和玻璃纤维加入,搅拌30-50min后,覆盖上塑料薄膜避光陈化放置1-5d,期间每天揭开塑料薄膜洒水一次;
(2)将陈化后的混合物料送入制砖机中,挤压成型制成砖坯,控制砖坯水分10-13%,成型压力2MPa;
(3)将砖坯送入干燥窑中进行干燥,先一次升温至40-50℃,保温30-40min后,二次升温至110-120℃,保温3-5h后,降温至室温出窖;
(4)将干燥好的砖坯送入隧道焙烧窑中进行烧结,以70-80℃/h的速度升温至1000-1200℃烧结,烧结时间为40-60min。
优选地,所述步骤(1)中所加水的质量为原料总质量的1.2-1.5倍。
优选地,所述步骤(1)中陈化放置的温度为10-20℃。
优选地,所述步骤(3)中一次升温的速度为10℃/min,二次升温的速度为30℃/min,降温速度为5℃/min。
(三)有益效果
本发明提供了一种轻质煤矸石烧结空心砖及其制备方法,具有以下有益效果:
陶瓷微粉的分散性好、遮盖力高、悬浮性好、化学稳定性好、密度小、可提高空心砖的耐侯、耐久性、耐腐蚀,提高防火性能,硅酸锆可提高各组分的结合性能,提升空心砖的硬度和强度,而且硅酸锆的熔点高达2500℃,可以提升空心砖防火等级,膨润土和黏土岩可以作为混合粘结剂,海泡石具有良好的催化活化性能,其结构中的Si-OH配合可以与膨润土和黏土岩表面的活化基团形成络合物,强化空间稳定性的同时,也促进了粘结效果,抗裂性更佳,植物秸秆纤维、碳纤维和玻璃纤维可以在空心砖内形成相互交错的丝网结构,提升空心砖的抗震抗拉强度,三者复配使用有利于降低成本,而且本发明制备工艺简单,易于操作,适合大规模生产。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚,下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1:
一种轻质煤矸石烧结空心砖,包括以下重量份的组分:长度为0.4mm的植物秸秆纤维3%、长度为0.2mm的碳纤维1%、长度为0.3mm的玻璃纤维1%、陶瓷微粉4%、海砂5%、彩石砂5%、紫砂7%、硅酸锆1.5%、硅酸铝1.5%、海泡石6%、膨润土1.5%、黏土岩1.5%、余量为煤矸石。
上述轻质煤矸石烧结空心砖的制备方法,包括以下步骤:
(1)将海砂、彩石砂、紫砂、海泡石、黏土岩和煤矸石混合粉碎,得到粒度为40μm的混合料,向混合料中依次加入硅酸锆、硅酸铝、陶瓷微粉,将膨润土加入到水中预混合后边搅拌边倒入,所加水的质量为原料总质量的1.3倍,最后将植物秸秆纤维、碳纤维和玻璃纤维加入,搅拌40min后,覆盖上塑料薄膜避光陈化放置3d,陈化放置的温度为15℃,期间每天揭开塑料薄膜洒水一次;
(2)将陈化后的混合物料送入制砖机中,挤压成型制成砖坯,控制砖坯水分11%,成型压力2MPa;
(3)将砖坯送入干燥窑中进行干燥,先一次升温至45℃,一次升温的速度为10℃/min,保温35min后,二次升温至115℃,二次升温的速度为30℃/min,保温4h后,降温至室温出窖,降温速度为5℃/min;
(4)将干燥好的砖坯送入隧道焙烧窑中进行烧结,以75℃/h的速度升温至1100℃烧结,烧结时间为50min。
实施例2:
一种轻质煤矸石烧结空心砖,包括以下重量份的组分:长度为0.3mm的植物秸秆纤维4.5%、长度为0.1mm的碳纤维2%、长度为0.2mm的玻璃纤维1.5%、陶瓷微粉6%、海砂8%、彩石砂8%、紫砂12%、硅酸锆2.5%、硅酸铝2.5%、海泡石8%、膨润土2.5%、黏土岩2.5%、余量为煤矸石。
上述轻质煤矸石烧结空心砖的制备方法,包括以下步骤:
(1)将海砂、彩石砂、紫砂、海泡石、黏土岩和煤矸石混合粉碎,得到粒度为30μm的混合料,向混合料中依次加入硅酸锆、硅酸铝、陶瓷微粉,将膨润土加入到水中预混合后边搅拌边倒入,所加水的质量为原料总质量的1.2倍,最后将植物秸秆纤维、碳纤维和玻璃纤维加入,搅拌30min后,覆盖上塑料薄膜避光陈化放置1d,陈化放置的温度为10℃,期间每天揭开塑料薄膜洒水一次;
(2)将陈化后的混合物料送入制砖机中,挤压成型制成砖坯,控制砖坯水分10%,成型压力2MPa;
(3)将砖坯送入干燥窑中进行干燥,先一次升温至40℃,一次升温的速度为10℃/min,保温30min后,二次升温至110℃,二次升温的速度为30℃/min,保温3h后,降温至室温出窖,降温速度为5℃/min;
(4)将干燥好的砖坯送入隧道焙烧窑中进行烧结,以70℃/h的速度升温至1000℃烧结,烧结时间为40min。
实施例3:
一种轻质煤矸石烧结空心砖,包括以下重量份的组分:长度为0.5mm的植物秸秆纤维2%、长度为0.4mm的碳纤维0.5%、长度为0.4mm的玻璃纤维0.5%、陶瓷微粉3%、海砂4%、彩石砂4%、紫砂5%、硅酸锆1%、硅酸铝1%、海泡石4%、膨润土1%、黏土岩1%、余量为煤矸石。
上述轻质煤矸石烧结空心砖的制备方法,包括以下步骤:
(1)将海砂、彩石砂、紫砂、海泡石、黏土岩和煤矸石混合粉碎,得到粒度为50μm的混合料,向混合料中依次加入硅酸锆、硅酸铝、陶瓷微粉,将膨润土加入到水中预混合后边搅拌边倒入,所加水的质量为原料总质量的1.5倍,最后将植物秸秆纤维、碳纤维和玻璃纤维加入,搅拌50min后,覆盖上塑料薄膜避光陈化放置5d,陈化放置的温度为20℃,期间每天揭开塑料薄膜洒水一次;
(2)将陈化后的混合物料送入制砖机中,挤压成型制成砖坯,控制砖坯水分13%,成型压力2MPa;
(3)将砖坯送入干燥窑中进行干燥,先一次升温至50℃,一次升温的速度为10℃/min,保温40min后,二次升温至120℃,二次升温的速度为30℃/min,保温5h后,降温至室温出窖,降温速度为5℃/min;
(4)将干燥好的砖坯送入隧道焙烧窑中进行烧结,以80℃/h的速度升温至1200℃烧结,烧结时间为60min。
实施例4:
一种轻质煤矸石烧结空心砖,包括以下重量份的组分:长度为0.5mm的植物秸秆纤维6%、长度为0.1mm的碳纤维2.5%、长度为0.4mm的玻璃纤维2.5%、陶瓷微粉8%、海砂10%、彩石砂10%、紫砂15%、硅酸锆3%、硅酸铝3%、海泡石10%、膨润土3%、黏土岩3%、余量为煤矸石。
上述轻质煤矸石烧结空心砖的制备方法,包括以下步骤:
(1)将海砂、彩石砂、紫砂、海泡石、黏土岩和煤矸石混合粉碎,得到粒度为35μm的混合料,向混合料中依次加入硅酸锆、硅酸铝、陶瓷微粉,将膨润土加入到水中预混合后边搅拌边倒入,所加水的质量为原料总质量的1.2倍,最后将植物秸秆纤维、碳纤维和玻璃纤维加入,搅拌35min后,覆盖上塑料薄膜避光陈化放置4d,陈化放置的温度为18℃,期间每天揭开塑料薄膜洒水一次;
(2)将陈化后的混合物料送入制砖机中,挤压成型制成砖坯,控制砖坯水分11%,成型压力2MPa;
(3)将砖坯送入干燥窑中进行干燥,先一次升温至50℃,一次升温的速度为10℃/min,保温38min后,二次升温至120℃,二次升温的速度为30℃/min,保温5h后,降温至室温出窖,降温速度为5℃/min;
(4)将干燥好的砖坯送入隧道焙烧窑中进行烧结,以72℃/h的速度升温至1150℃烧结,烧结时间为55min。
实施例5:
一种轻质煤矸石烧结空心砖,包括以下重量份的组分:长度为0.5mm的植物秸秆纤维4%、长度为0.2mm的碳纤维2%、长度为0.2mm的玻璃纤维2.5%、陶瓷微粉8%、海砂6%、彩石砂5%、紫砂12%、硅酸锆3%、硅酸铝3%、海泡石4%、膨润土2%、黏土岩3%、余量为煤矸石。
上述轻质煤矸石烧结空心砖的制备方法,包括以下步骤:
(1)将海砂、彩石砂、紫砂、海泡石、黏土岩和煤矸石混合粉碎,得到粒度为50μm的混合料,向混合料中依次加入硅酸锆、硅酸铝、陶瓷微粉,将膨润土加入到水中预混合后边搅拌边倒入,所加水的质量为原料总质量的1.5倍,最后将植物秸秆纤维、碳纤维和玻璃纤维加入,搅拌30min后,覆盖上塑料薄膜避光陈化放置1d,陈化放置的温度为10℃,期间每天揭开塑料薄膜洒水一次;
(2)将陈化后的混合物料送入制砖机中,挤压成型制成砖坯,控制砖坯水分12%,成型压力2MPa;
(3)将砖坯送入干燥窑中进行干燥,先一次升温至42℃,一次升温的速度为10℃/min,保温40min后,二次升温至120℃,二次升温的速度为30℃/min,保温3h后,降温至室温出窖,降温速度为5℃/min;
(4)将干燥好的砖坯送入隧道焙烧窑中进行烧结,以80℃/h的速度升温至1200℃烧结,烧结时间为40min。
本发明实施例1-4所制煤矸石烧结空心砖与市售煤矸石烧结空心砖的对比结果如表1所示:
表1
综上,本发明实施例具有如下有益效果:抗压强度、抗折强度高,密度小,保温效果好,防火等级高。
需要说明的是,在本文中,诸如第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来,而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且,术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含,从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素,而且还包括没有明确列出的其他要素,或者是还包括为这种过程、方法、物品或者设备所固有的要素。在没有更多限制的情况下,由语句“包括一个……”限定的要素,并不排除在包括所述要素的过程、方法、物品或者设备中还存在另外的相同要素。
以上实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
Claims (7)
1.一种轻质煤矸石烧结空心砖,其特征在于,包括以下重量份的组分:植物秸秆纤维2-6%、碳纤维0.5-2.5%、玻璃纤维0.5-2.5%、陶瓷微粉3-8%、海砂4-10%、彩石砂4-10%、紫砂5-15%、硅酸锆1-3%、硅酸铝1-3%、海泡石4-10%、膨润土1-3%、黏土岩1-3%、余量为煤矸石。
2.如权利要求1所述的轻质煤矸石烧结空心砖,其特征在于,包括以下重量份的组分:植物秸秆纤维3-4.5%、碳纤维1-2%、玻璃纤维1-1.5%、陶瓷微粉4-6%、海砂5-8%、彩石砂5-8%、紫砂7-12%、硅酸锆1.5-2.5%、硅酸铝1.5-2.5%、海泡石6-8%、膨润土1.5-2.5%、黏土岩1.5-2.5%、余量为煤矸石。
3.如权利要求1所述的轻质煤矸石烧结空心砖,其特征在于,所述植物秸秆纤维的长度为0.3-0.5mm,碳纤维的长度为0.1-0.4mm,玻璃纤维的长度为0.2-0.4mm。
4.如权利要求1所述的轻质煤矸石烧结空心砖的制备方法,其特征在于,包括以下步骤:
(1)将海砂、彩石砂、紫砂、海泡石、黏土岩和煤矸石混合粉碎,得到粒度为30-50μm的混合料,向混合料中依次加入硅酸锆、硅酸铝、陶瓷微粉,将膨润土加入到水中预混合后边搅拌边倒入,最后将植物秸秆纤维、碳纤维和玻璃纤维加入,搅拌30-50min后,覆盖上塑料薄膜避光陈化放置1-5d,期间每天揭开塑料薄膜洒水一次;
(2)将陈化后的混合物料送入制砖机中,挤压成型制成砖坯,控制砖坯水分10-13%,成型压力2MPa;
(3)将砖坯送入干燥窑中进行干燥,先一次升温至40-50℃,保温30-40min后,二次升温至110-120℃,保温3-5h后,降温至室温出窖;
(4)将干燥好的砖坯送入隧道焙烧窑中进行烧结,以70-80℃/h的速度升温至1000-1200℃烧结,烧结时间为40-60min。
5.如权利要求4所述的轻质煤矸石烧结空心砖的制备方法,其特征在于,所述步骤(1)中所加水的质量为原料总质量的1.2-1.5倍。
6.如权利要求4所述的轻质煤矸石烧结空心砖的制备方法,其特征在于,所述步骤(1)中陈化放置的温度为10-20℃。
7.如权利要求4所述的轻质煤矸石烧结空心砖的制备方法,其特征在于,所述步骤(3)中一次升温的速度为10℃/min,二次升温的速度为30℃/min,降温速度为5℃/min。
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