CN108610019A - 一种利用抛光陶瓷废渣制备低容重、高强度保温材料的方法 - Google Patents

一种利用抛光陶瓷废渣制备低容重、高强度保温材料的方法 Download PDF

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CN108610019A
CN108610019A CN201611125988.XA CN201611125988A CN108610019A CN 108610019 A CN108610019 A CN 108610019A CN 201611125988 A CN201611125988 A CN 201611125988A CN 108610019 A CN108610019 A CN 108610019A
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waste residue
ceramic waste
ball
polishing ceramic
unit weight
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吴学坤
许壮志
薛健
张明
初小葵
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LIAONING FAKU COUNTY CERAMIC ENGINEERING TECHNOLOGY RESEARCH CENTER
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Abstract

一种利用抛光陶瓷废渣制备低容重、高强度保温材料的方法，由以下原料按重量份额经干燥处理、配料、混合、球磨、装模、烧成、修整等步骤制得保温材料。其原料由抛光陶瓷废渣、助熔剂、稳泡剂以80～90:7～10:3～5的比例构成。本发明可以替代现有外墙保温材料使用，具有很高的安全性，充分利用了抛光陶瓷废渣等废料资源，提高了固体废弃物的资源化利用，具有很好的经济价值和环保价值。

Description

一种利用抛光陶瓷废渣制备低容重、高强度保温材料的方法
技术领域
本发明涉及一种利用工业废渣，确切地说是一种利用抛光陶瓷废渣制备低容重、高强度保温材料的方法，属于建筑材料制造及应用技术领域。
背景技术
近十几年来，我国的建筑陶瓷工业得到迅猛发展，现有建筑陶瓷企业已经超过3500家，建筑陶瓷产品年产量在30亿平方米以上，占世界第一位。作为我国特色陶瓷产品的抛光砖产量约占建筑陶瓷产品的一半，在抛光砖生产的研磨抛光工艺过程中，会产生大量的固体废渣(以干料计，每生产1m2抛光砖即产生废粉2kg左右)，称为陶瓷抛光废渣(ceramic polishing waste,CPW)。据调查，每年抛光砖生产企业为处理抛光废渣的费用高达几百万甚至上千万元，很大程度上加重了企业的负担和影响企业的生产进度。目前对于抛光废渣的综合利用虽然进行了比较多的研究，但仍然缺乏对其进行大规模资源化利用的相关技术，故其处理多以填埋为主，对环境造成了严重影响。抛光废渣露天堆放也会对环境造成污染，不利于可持续发展。已知的抛光废渣利用技术较少，主要利用抛光废渣制备轻质保温材料。但是，现有的相关技术中所制备的保温材料的存在容重普遍较大、抗压强度较低、制品的绝热性能仍需进一步提高等一系列问题。目前，我国建筑外墙保温所用材料主要为用苯板、聚氨酯发泡材料等有机材料，以及岩棉板、玻璃棉等无机材料。其中，苯板最便宜，但其保温效果一般，使用过程中会发生吸水、变形等问题，做完保温层后还需采用相应的防水等措施；聚氨酯发泡材料的保温性能要高于苯板，尤其聚氨酯发泡材料的导热系数远低于苯板，但聚氨酯发泡材料的价格要明显高于苯板。此外，苯板、聚氨酯等有机材料在使用过程中具有耐热性和耐老化性能差及易燃烧。燃烧时会释放出大量热量、产生有毒烟气、加速火势蔓延等缺点。岩棉板、玻璃棉等无机保温材料既污染空气又易滋生细菌，对人身健康易造成危害。
发明内容
本发明的目的是针对上述现有技术的不足，而提供一种利用抛光陶瓷废渣制备低容重、高强度保温材料的方法。该方法主要以抛光陶瓷废渣为原料，很好地解决了抛光砖为主的陶瓷生产企业排放废料对环境的危害问题。同时也克服了传统外墙材料保温、耐腐蚀、防火及耐候性能差等缺点。
本发明的制备方法是通过下述工艺步骤实现的：
(1)将抛光陶瓷废渣在100～110℃进行干燥处理。
(2)将步骤(1)中获得的抛光陶瓷废渣与稳泡剂、助熔剂按重量份额配比，其中抛光陶瓷废渣、助熔剂、稳泡剂以80～90:7～10:3～5的比例进行混合，之后将混合物料装入球磨罐中进行干法球磨处理后过200目筛，取筛下部分。上述助熔剂采用玻璃粉、磷酸钠或硼砂中的一种或多种，稳泡剂采用工业碳酸钙、工业碳酸钠和碳化硅中的一种或多种，球磨介质球与物料的体积比为1:2～3。
(3)将步骤(2)中制得的物料放入组合好的模具中，模具呈方形盒子状，材质为堇青石莫来石材质。
(4)将步骤(3)中布置好的模具及待烧物料放入窑炉中，按以下工艺过程烧成：
先从室温以5～10℃/min的加热速度升温至1200～1250℃，保温50～60min；然后以15～20℃/min的冷却速度快速降温至1000℃，保温30～40min；最后，以3～5℃/min的速度降温至室温后即得轻体无机材料。
(5)将步骤(4)中制得的轻体无机材料切割、修整后可以作外墙保温材料使用。
上述步骤(1)中的除选择抛光陶瓷废渣，还可选用转炉渣、铁尾矿中的一种或多种。
本发明较好地解决了以抛光砖为主的陶瓷生产企业排放废料对环境的危害问题及现有利用工业废渣制备轻体无机材料技术中存在的容重大、抗压强度较低、制品的绝热性能等一系列技术问题。采用本方法制得的轻体无机材料容重小、耐腐蚀、耐高温、抗压强度高、保温性能优良、防火性能佳。能最大程度的降低因建筑物外墙保温施工及改造过程中的火灾发生机率，有效保障人民生命财产安全。可以替代现有外墙保温材料使用，具有很高的安全性，充分利用了抛光废渣等废料资源，提高了固体废弃物的资源化利用，具有很好的经济价值和环保价值。
具体实施方式
实施例一：
将各原料组分经过105℃干燥处理后，称取8.0kg废瓷、0.75kg玻璃粉、0.3kg工业碳酸钙，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具中。
将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1180℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
实施例二：
将各原料组分经过105℃干燥处理后，称取8.2kg废瓷、0.7kg玻璃粉、0.1kg硼砂、0.35kg工业碳酸钙，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具中。
将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1200℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
实施例三：
将各原料组分经过105℃干燥处理后，称取8.8kg废瓷、0.6kg玻璃粉、0.1kg硼砂、0.4kg工业碳酸钙，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具中。
将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1230℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
实施例四：
将各原料组分经过105℃干燥处理后，称取9kg废瓷、0.8kg玻璃粉、0.1kg硼砂、0.5kg工业碳酸钙，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具中。
将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1250℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
实施例五：
将各原料组分经过105℃干燥处理后，称取8.4kg废瓷、0.8kg玻璃粉、0.1kg硼砂、0.45kg工业碳酸纳，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具中。
将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1230℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
实施例六：
将各原料组分经过105℃干燥处理后，称取8.5kg废瓷、0.7kg玻璃粉、0.15kg工业碳酸钙、0.2kg工业碳酸纳，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具中。
将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1230℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
实施例七：
将各原料组分经过105℃干燥处理后，称取8.9kg废瓷、0.8kg玻璃粉、0.3kg工业碳酸纳，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具中。
将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1230℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
外墙保温材料的性能参数表
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改，等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (6)

1.一种利用抛光陶瓷废渣制备低容重、高强度保温材料的方法，其特征在于，包括下述步骤：
(1)将抛光陶瓷废渣在100～110℃进行干燥处理；
(2)将步骤(1)中获得的抛光陶瓷废渣与稳泡剂、助熔剂按重量份额配比，其中抛光陶瓷废渣、助熔剂、稳泡剂以80～90:7～10:3～5的比例进行混合，之后将混合物料装入球磨罐中进行干法球磨处理后过200目筛，取筛下部分，球磨介质球与物料的体积比为1:2～3。
(3)将步骤(2)中制得的物料放入组合好的模具中，模具呈方形盒子状，材质为堇青石莫来石材质。
(4)将步骤(3)中布置好的模具及待烧物料放入窑炉中，按以下工艺过程烧成：
先从室温以5～10℃/min的加热速度升温至1200～1250℃，保温50～60min；然后以15～20℃/min的冷却速度快速降温至1000℃，保温30～40min；最后，以3～5℃/min的速度降温至室温后即得轻体无机材料。
(5)将步骤(4)中制得的轻体无机材料切割、修整后可以作外墙保温材料使用。
2.如权利要求1所述的利用抛光陶瓷废渣制备低容重、高强度保温材料的方法，其特征在于：所述助熔剂采用玻璃粉、磷酸钠或硼砂中的一种或多种。
3.如权利要求1所述的利用抛光陶瓷废渣制备低容重、高强度保温材料的方法，其特征在于：所述稳泡剂采用工业碳酸钙、工业碳酸钠和碳化硅中的一种或多种。
4.如权利要求1所述的利用抛光陶瓷废渣制备低容重、高强度保温材料的方法，其特征在于：将各原料组分经过105℃干燥处理后，称取8.0kg废瓷、0.75kg玻璃粉、0.3kg工业碳酸钙，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具，将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1180℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
5.如权利要求1所述的利用抛光陶瓷废渣制备低容重、高强度保温材料的方法，其特征在于：将各原料组分经过105℃干燥处理后，称取8.5kg废瓷、0.7kg玻璃粉、0.15kg工业碳酸钙、0.2kg工业碳酸纳，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具，将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1230℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
6.如权利要求1所述的利用抛光陶瓷废渣制备低容重、高强度保温材料的方法，其特征在于：将各原料组分经过105℃干燥处理后，称取9kg废瓷、0.8kg玻璃粉、0.1kg硼砂、0.5kg工业碳酸钙，将以上物料装入球磨罐中球磨4h，控制介质球与待磨物料体积比为1:2.5，之后将物料取出过200目筛，取筛下部分装入组合模具，将模具和待烧物料置于窑炉中进行高温烧成，最高烧成温度为1250℃，即得轻体无机材料，经切割、修整后可作为外墙保温材料使用。
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