CN108424120A - 一种利用页岩废渣制备发泡陶瓷墙体材料的方法 - Google Patents
一种利用页岩废渣制备发泡陶瓷墙体材料的方法 Download PDFInfo
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- 229910010293 ceramic material Inorganic materials 0.000 title claims abstract description 23
- 238000000034 method Methods 0.000 title claims abstract description 22
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- 229910052593 corundum Inorganic materials 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 3
- 238000002791 soaking Methods 0.000 claims description 3
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 2
- 229910052708 sodium Inorganic materials 0.000 claims description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims 1
- 239000001569 carbon dioxide Substances 0.000 claims 1
- 229910002092 carbon dioxide Inorganic materials 0.000 claims 1
- 229910052698 phosphorus Inorganic materials 0.000 claims 1
- 239000011574 phosphorus Substances 0.000 claims 1
- 239000007787 solid Substances 0.000 claims 1
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- 239000003381 stabilizer Substances 0.000 description 2
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- UEZVMMHDMIWARA-UHFFFAOYSA-N Metaphosphoric acid Chemical compound OP(=O)=O UEZVMMHDMIWARA-UHFFFAOYSA-N 0.000 description 1
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- NIFIFKQPDTWWGU-UHFFFAOYSA-N pyrite Chemical compound [Fe+2].[S-][S-] NIFIFKQPDTWWGU-UHFFFAOYSA-N 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
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Abstract
一种利用页岩废渣制备发泡陶瓷墙体材料的方法，按以下步骤进行：(1)将页岩废渣粉碎至粒径<0.124mm；(2)采用长石、碳粉、偏磷酸钠、MgO和Na2CO3作为添加剂与原料混合；(3)加水用球磨机进行湿磨制成料浆；(4)将料浆继续搅拌均匀，注入喷雾干燥器中进行喷雾干燥，制成粉体；(5)粉体置于模具中，升温至200±10℃保温，以8～10℃/min的速度升温至1000±10℃，以2～4℃/min升温至1100～1200℃保温，随炉冷却至常温。本发明的方法制备工艺简洁，所用原料为矿业开采过程中的固体废弃物，得到的发泡陶瓷墙体材料隔热性好、防火、体积密度低，具备普通发泡陶瓷材料的优良性能。
Description
技术领域
本发明属于建筑材料技术领域，特别涉及一种利用页岩废渣制备发泡陶瓷墙体材料的方法。
背景技术
页岩是地球上最为常见的一种沉积岩，是指主要由粒度小于3.9微米的细颗粒碎屑(包括石英、长石、黄铁矿或岩屑)、黏土矿物、碳酸盐岩矿物和有机质组成的细粒沉积岩，一般发育有较细层状及近于平行层状剥离的页理构造；黏土矿物为页岩的主要组成部分，因此页岩具有黏土岩的一般特性，包括低渗透性、吸附性，吸水膨胀性、脆性等特性，页岩的抗风化能力较弱，在受到外力的作用时，一般会在较短时间内发生破裂；常见的页岩类型有黑色页岩、碳质页岩、硅质页岩、铁质页岩、钙质页岩等；煤矿、铁矿、页岩油、页岩气的开采过程，以及公路、高速铁路、机场等大规模基础设施建设过程，经常需要剥离采挖大量的页岩层，产生大量难以利用的页岩废渣，这些尾矿很难得到资源化利用，只能大量堆存，不仅占用大面积土地，还会破环生态，污染环境。
发明内容
本发明的目的是提供一种利用页岩废渣制备发泡陶瓷墙体材料的方法，以页岩废渣为原料，添加氧化镁、碳酸钠、偏磷酸钠、碳粉、长石等添加剂，在中温炉中一次焙烧，发泡成型，制备得到强度、隔音性、防火性符合要求，且保温性能优异的发泡陶瓷墙体材料。
1、将页岩废渣粉碎至粒径<0.124mm，作为原料；
2、采用长石、碳粉、偏磷酸钠、MgO和Na2CO3作为添加剂，将原料与添加剂混合制成混合物料；混合物料中按质量百分比页岩废渣占75～85％，长石占5～15％，碳粉占3～5％，偏磷酸钠占1～5％，MgO占1～5％，Na2CO3占1～5％；
3、将混合物料加水用球磨机进行湿磨制成料浆；料浆中水的质量百分比≤40％；
4、将料浆从球磨机中取出后继续搅拌均匀，然后注入喷雾干燥器中进行喷雾干燥，制成粉体；粉体的粒径≤0.5mm；
5、将粉体填充到模具中，然后置于加热炉内，先升温至200±10℃，保温至少10min烘干水分，再以8～10℃/min的速度升温至1000±10℃，最后以2～4℃/min升温至1100～1200℃进行焙烧发泡造孔，保温时间为50～90min，保温结束后随炉冷却至常温，制成发泡陶瓷墙体材料。
上述方法中，湿磨时水、混合物料和磨球的质量比为0.6:1:4。
上述的页岩废渣按质量百分比含SiO2 52～55％，Al2O3 18～20％，Fe2O3 8～10％，CaO1～1.5％，Na2O 0.2～0.3％，TiO2 0.8～1.0％，MgO 3～4％，K2O 6～7％，其余为烧失量。
上述的发泡陶瓷墙体材料的体积密度0.25～0.42g/cm3，抗压强度5～10MPa，导热系数0.04～0.075W/(m·K)。
本发明的方法使用页岩废渣为主原料，添加适量的助熔剂、发泡剂、稳泡剂，通过湿磨混匀和喷雾干燥后，得到的粉体配合料经过一次焙烧，即可得到气孔致密均匀，体积密度小，强度高，体积密度小的高性能发泡陶瓷墙体材料；发泡陶瓷是一粘土、石英、长石为主要原料，加入适量的高温发泡剂、稳泡剂、助熔剂等助剂，进球磨湿混、喷雾造粒、布料成型，并在适当温度下烧制发泡，产生大量闭合气孔，具有轻质、隔热、防火、吸音等性能的多孔陶瓷材料；原料在高温下熔融，形成具有适宜粘度的熔体，发泡剂则会在高温下发生分解反应，产生挥发气体，此时高粘度的熔体使气体无法逸散，封闭在材料内部，引起材料发泡膨胀，而随着温度降低，熔体逐渐冷却凝固，封闭在熔体中的气体在材料内部形成闭合气孔，得到发泡陶瓷材料；采用合理的配方和合理的烧成制度，即可控制发泡过程，最终得到体积密度低、强度高、隔热性好且防火的建筑物墙体材料；页岩分布广泛，且作为页岩气、页岩油和采矿等工业过程中产生的固体废弃物，对其进行资源化利用不仅可以节约资源，保护环境，还能扩大生产发泡陶瓷的原料选择范围；通过对页岩尾矿进行工艺矿物学分析，其中的矿物种类与含量符合制备发泡陶瓷原料的要求，使用其作为主要原料制备发泡陶瓷墙体材料即有利于工业领域的减排，又能推动建筑领域的节能。
本发明的方法具有以下优点：1)制备工艺简洁，没有复杂的操作过程；2)所用原料为矿业开采过程中的固体废弃物，实现了固体废弃物的资源化利用，添加助剂使用量小，成本低廉；3)得到的发泡陶瓷墙体材料隔热性好、防火、体积密度低，具备普通发泡陶瓷材料的优良性能，同时具有较高的强度，达到了国家标准规定的建筑墙体材料标准。
本发明提供的方法便于实现工业化，且得到的发泡陶瓷墙体材料各方面性能优异，使用固体废弃物为原料，符合绿色建材的要求；优异的保温隔热性能使建筑物更加节能；可在隧道窑中实现大面积一次烧成，按照要求任意切割，一次性安装到位，能够在模块化建筑领域得到广泛应用。
具体实施方式
本发明实施例中MgO、Na2CO3、偏磷酸钠、碳粉和长石均为工业级添加剂。
本发明实施例中页岩废渣按质量百分比含SiO2 54.61％，Al2O3 18.30％，Fe2O38.84％，CaO1.16％，Na2O 0.249％，TiO2 0.891％，MgO 3.01％，K2O 6.77％，其余为烧失量。
本发明实施例中页岩废渣在使用前先烘干去除水分，烘干温度选用80±2℃，时间至少3h。
本发明实施例中，料浆从球磨机中取出后继续搅拌是用磁力搅拌器进行搅拌均匀化，时间至少30min。
本发明实施例中检测体积密度试验按建材行业标准JC/T 641-2005进行。
本发明实施例中检测抗压试验按标准GB/T 5486.2-2001进行，采用的试件尺寸为100mm×100mm×40mm，数量五块。
本发明实施例中测试导热系数按GB/T 10294-1988进行，采用的试件厚度为20～25mm。
本发明实施例中料浆中水的质量百分比在30～40％。
本发明实施例中采用的加热炉为中温炉。
本发明实施例中的粉体的粒径≤0.5mm。
下面结合具体的实施方式对本发明的内容进一步说明和补充。
实施例1
将页岩废渣粉碎至粒径<0.124mm，然后加入添加剂长石、碳粉、偏磷酸钠、MgO和Na2CO3，制成混合物料，混合物料中按质量百分比页岩废渣占75％，长石占15％，碳粉占4％，偏磷酸钠占1.5％，MgO占2％，Na2CO3占2.5％；
将混合物料加水用球磨机进行湿磨制成料浆，其中水、混合物料和磨球的质量比为0.6:1:4；料浆中水的质量百分比≤40％；
将料浆从球磨机中取出后继续搅拌均匀，然后注入喷雾干燥器中进行喷雾干燥，制成粉体；
将粉体填充到耐火砖搭建的模具中，然后置于中温炉内，先升温至200±10℃，保温10min烘干水分，再以8℃/min的速度升温至1000±10℃，最后以2℃/min升温至1100℃进行焙烧发泡造孔，保温时间为90min，保温结束后随炉冷却至常温，制成发泡陶瓷墙体材料；发泡陶瓷墙体材料的体积密度0.275g/cm3，抗压强度5.04MPa，导热系数0.048W/(m·K)。
实施例2
方法同实施例1，不同点在于：
(1)混合物料中按质量百分比页岩废渣占80％，长石占10％，碳粉占3％，偏磷酸钠占5％，MgO占1％，Na2CO3占1％；
(2)200±10℃保温15min，以9℃/min的速度升温至1000±10℃，以3℃/min升温至1150℃，保温80min；
(3)发泡陶瓷墙体材料的体积密度0.301g/cm3，抗压强度6.2MPa，导热系数0.054W/(m·K)。
实施例3
方法同实施例1，不同点在于：
(1)混合物料中按质量百分比页岩废渣占85％，长石占5％，碳粉占5％，偏磷酸钠占1％，MgO占2％，Na2CO3占2％；
(2)200±10℃保温20min，以9℃/min的速度升温至1000±10℃，以3℃/min升温至1200℃，保温60min；
(3)发泡陶瓷墙体材料的体积密度0.411g/cm3，抗压强度7.6MPa，导热系数0.072W/(m·K)。
实施例4
方法同实施例1，不同点在于：
(1)混合物料中按质量百分比页岩废渣占81％，长石占8％，碳粉占3.5％，偏磷酸钠占2.5％，MgO占5％，Na2CO3占5％；
(2)200±10℃保温25min，以10℃/min的速度升温至1000±10℃，以4℃/min升温至1200℃，保温50min；
(3)发泡陶瓷墙体材料的体积密度0.354g/cm3，抗压强度9.3MPa，导热系数0.0629W/(m·K)。
Claims (4)
1.一种利用页岩废渣制备发泡陶瓷墙体材料的方法，其特征在于按以下步骤进行：
(1)将页岩废渣粉碎至粒径<0.124mm，作为原料；
(2)采用长石、碳粉、偏磷酸钠、MgO和Na2CO3作为添加剂，将原料与添加剂混合制成混合物料；混合物料中按质量百分比页岩废渣占75～85％，长石占5～15％，碳粉占3～5％，偏磷酸钠占1～5％，MgO占1～5％，Na2CO3占1～5％；
(3)将混合物料加水用球磨机进行湿磨制成料浆；料浆中水的质量百分比≤40％；
(4)将料浆从球磨机中取出后继续搅拌均匀，然后注入喷雾干燥器中进行喷雾干燥，制成粉体；粉体的粒径≤0.5mm；
(5)将粉体填充到模具中，然后置于加热炉内，先升温至200±10℃，保温至少10min烘干水分，再以8～10℃/min的速度升温至1000±10℃，最后以2～4℃/min升温至1100～1200℃进行焙烧发泡造孔，保温时间为50～90min，保温结束后随炉冷却至常温，制成发泡陶瓷墙体材料。
2.根据权利要求1所述的一种利用页岩废渣制备发泡陶瓷墙体材料的方法，其特征在于步骤(3)中湿磨时水、混合物料和磨球的质量比为0.6:1:4。
3.根据权利要求1所述的一种利用页岩废渣制备发泡陶瓷墙体材料的方法，其特征在于所述的页岩废渣按质量百分比含SiO2 52～55％，Al2O3 18～20％，Fe2O3 8～10％，CaO 1～1.5％，Na2O 0.2～0.3％，TiO2 0.8～1.0％，MgO 3～4％，K2O 6～7％，其余为烧失量。
4.根据权利要求1所述的一种利用页岩废渣制备发泡陶瓷墙体材料的方法，其特征在于所述的发泡陶瓷墙体材料的体积密度0.25～0.42g/cm3，抗压强度5～10MPa，导热系数0.04～0.075W/(m·K)。
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