CN108706962B - High-strength ceramic tile of coal gangue-fly ash-desulfurized gypsum system and preparation method thereof - Google Patents

High-strength ceramic tile of coal gangue-fly ash-desulfurized gypsum system and preparation method thereof Download PDF

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CN108706962B
CN108706962B CN201810855638.1A CN201810855638A CN108706962B CN 108706962 B CN108706962 B CN 108706962B CN 201810855638 A CN201810855638 A CN 201810855638A CN 108706962 B CN108706962 B CN 108706962B
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ceramic tile
fly ash
coal gangue
desulfurized gypsum
ceramic
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CN108706962A (en
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卢安贤
刘涛涌
杨琦峰
韩磊
刘建磊
李翠
桂花
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Hunan Bossco Environmental Protection Technology Co ltd
Central South University
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Hunan Bossco Environmental Protection Technology Co ltd
Central South University
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C04B33/135—Combustion residues, e.g. fly ash, incineration waste
    • C04B33/1352—Fuel ashes, e.g. fly ash
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
    • C04B2235/6562—Heating rate
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
    • C04B2235/6567—Treatment time
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/77—Density
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9669—Resistance against chemicals, e.g. against molten glass or molten salts
    • C04B2235/9692—Acid, alkali or halogen resistance
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes

Abstract

The invention discloses a high-strength ceramic plate or ceramic tile of a coal gangue-fly ash-desulfurized gypsum total waste residue composition system and a preparation method thereof. The method takes the coal gangue, the fly ash and the desulfurized gypsum as raw materials, and obtains the ceramic tile with excellent comprehensive performance through the preparation process of composition design, reasonable waste residue collocation and optimization, the waste residue utilization rate is high, the preparation process is simple, the cost is low, no sintering aid or binder is required to be added, the main phase of the ceramic tile is anorthite phase, and the ceramic tile has low density (1.475-2.013 g/cm)3) The high-strength stainless steel has the characteristics of high strength (107.8-346.5 MPa), good corrosion resistance (more than 99%), no secondary pollution and the like. The utilization rate of the solid waste reaches 100 percent, the pollution of the waste residue to the environment can be effectively reduced, and the cyclic utilization and the high value-added utilization of the solid waste are realized.

Description

High-strength ceramic tile of coal gangue-fly ash-desulfurized gypsum system and preparation method thereof
Technical Field
The invention relates to the field of recycling of solid waste materials and novel building ceramic materials, in particular to a high-strength ceramic tile of a coal gangue-fly ash-desulfurized gypsum system and a preparation method thereof.
Background
In recent years, resource and environmental problems caused by the mass stockpiling of solid wastes have been receiving more and more attention. The stockpiling of the industrial solid waste occupies a large amount of land, and on one hand, high waste residue maintenance cost is generated; on the other hand, the overflow or collapse of the waste residues directly damages the property and human life safety nearby the slag yard, and especially some waste residues often contain heavy metals and radioactive toxic and harmful substances which are lost everywhere under the weathering action of the nature, thus causing serious pollution to soil, water areas and atmosphere. How to scientifically utilize the waste slag is one of the major problems facing countries in the world.
Meanwhile, with the continuous development of the construction industry, the demand for building materials is also increasing, and the consumption of limited natural resources reaches a critical value. In order to protect natural resources and relieve a series of environmental stresses brought by solid wastes, the solid wastes are used as partial substitutes of raw materials for producing building materials to produce novel building engineering materials, and the method is an effective way for solving the problems. Ceramic tiles are commonly used building materials, and are plate-shaped or block-shaped ceramic products produced by using clay and other inorganic non-metallic materials as raw materials through processes of forming, sintering and the like. The preparation of the traditional ceramic tile needs to consume a large amount of natural resources, and excessive consumption of the traditional ceramic tile inevitably causes the problem of shortage of the natural resources. Most of the solid wastes contain a large amount of SiO2And Al2O3Substances, these are essential components for the preparation of ceramic tiles. Therefore, the solid waste can be used as raw materials for producing ceramic tiles. Currently, there is also much research on the use of solid waste to make ceramic tiles.
Patent CN 105272163B discloses a method for preparing an environment-friendly ceramic tile. The composition ratio and the process are as follows: 1) the composition ratio is as follows: 20-25 parts of dolomite clay, 35-56 parts of ceramic waste, 10-15 parts of limestone, 5-10 parts of aluminum ore and 8-15 parts of soft clay. Wherein the ceramic waste is one or more of ceramic polishing waste, ceramic leftover materials and ceramic crushed materials. 2) The process comprises the following steps: the prepared raw materials are ground, aged, molded, primarily fired, secondarily fired and processed to obtain the environment-friendly ceramic brick material. The patent takes ceramic waste as one of raw materials (35-56 parts%); adding various natural resources such as dolomite clay, limestone, aluminum ore and soft clay, wherein the using amount of the natural resources accounts for 44-65 parts; the green strength of the ceramic is more than or equal to 0.25MPa, the dry strength is more than or equal to 1.8MPa, the performance of the sintered ceramic tile is not related, and the ceramic tile with the system consisting of coal gangue, coal ash and desulfurized gypsum and the preparation method thereof are not related.
Patent CN 107793132A discloses a ceramic tile based on ceramic polishing slag and a preparation method thereof. The method comprises the steps of using 50-70% of ceramic polishing slag; 20-40% of clay raw materials; 10-20% of bauxite; wherein the clayey raw material is one or two of kaolin, clayey shale and bentonite. Bauxite was used as the foaming inhibitor. The ceramic tile material is obtained by carrying out pretreatment, grinding, aging, spray granulation, press molding and firing treatment on the raw materials. The patent takes ceramic polishing slag as a main raw material (50-70 wt%), clay raw material and bauxite account for 30-60 wt%, the compressive strength of a sintered ceramic product is 23-29MPa, and the patent does not relate to other properties of the sintered ceramic tile, and does not relate to a system ceramic tile consisting of coal gangue-fly ash-desulfurized gypsum total waste residue and a preparation method thereof.
Patent CN 108101485A discloses a preparation method of a coal gangue brick for construction, which comprises the following raw materials: 30-45 parts of coal gangue, 40-60 parts of coal ash, 60-70 parts of coal slag, 35-45 parts of ordinary portland cement, 15-26 parts of kaolin, 18-28 parts of ceramic sand, 22-34 parts of bentonite, 12-18 parts of zeolite powder, 1-5 parts of naphthalene water reducer, 5-8 parts of antifreezing agent, 2-4 parts of tricalcium aluminate, 11-18 parts of redispersible latex powder, 20-26 parts of desulfurized gypsum, 6-10 parts of cellulose ether, 4-8 parts of salt-resistant retarder, 1-6 parts of sodium aluminosilicate, 7-11 parts of emulsified asphalt and 60-75 parts of water. The specific process comprises the following steps: 1) weighing the raw material components according to the weight part ratio; 2) adding coal gangue, fly ash, coal cinder, kaolin, ceramic sand, bentonite, zeolite powder and desulfurized gypsum into a ball mill, adding water, and grinding until solid particles pass through a 180-mesh 210-mesh sieve to obtain a main mixed material; 3) adding the mixture obtained in the step 2) and ordinary portland cement into a stirrer, uniformly stirring for 8-12 minutes by the stirrer, adding the redispersible latex powder and emulsified asphalt, continuously stirring for 3-5 minutes, sequentially adding sodium aluminosilicate, a naphthalene water reducer, an antifreezing agent, tricalcium aluminate, cellulose ether and a salt-resistant retarder, and stirring for 6-8 minutes to obtain a bricking raw slurry; 4) pouring the primary slurry for laying bricks into a brick laying mold, and cooling and molding the primary slurry for laying bricks in the brick laying mold at normal temperature to obtain a brick laying blank; 5) and putting the bricklaying blank into a steam curing chamber for steam curing. Although the patent introduces raw materials such as coal gangue, fly ash and desulfurized gypsum, a large amount of other components are introduced at the same time, the introduction amount of the coal gangue, the fly ash and the desulfurized gypsum is greatly reduced, and a sample prepared by the patent is not subjected to high-temperature sintering treatment, so that the document does not relate to various performances of a sample after steam curing, and does not relate to a coal gangue-fly ash-desulfurized gypsum full waste residue composition system ceramic tile and a preparation method thereof.
Disclosure of Invention
The invention mainly utilizes the synergistic-complementary effect among the chemical compositions of the waste residues of coal gangue, fly ash and desulfurized gypsum to fully play the role of the internal components of each waste residue so as to obtain the ceramic tile which has the characteristics of high waste residue utilization rate, high strength, good corrosion resistance, no secondary pollution and the like, thereby effectively reducing the harm of solid waste to the environment.
The invention provides a high-strength ceramic tile of a coal gangue-fly ash-desulfurized gypsum system and a preparation method thereof, wherein the ceramic tile is prepared by blank making and sintering the following chemical composition raw materials in percentage by mass: 42.5-85.5% of coal gangue; 8.5-47.5% of fly ash; 5-15% of desulfurized gypsum, wherein the corresponding ceramic tile green body comprises the following chemical components in percentage by mass: SiO 22：45.64～51.24％；Al2O3：21.08～23.71％；CaO：8.16～12.79％；MgO：3.68～4.75％；Na2O：3.08～3.81％；Fe2O3: 4.79-5.46%, and the balance: 7.67 to 9.14 percent.
The coal gangue, the fly ash and the desulfurized gypsum in the ceramic tile account for 100 percent of the total mass of the raw materials, and any sintering aid and binder do not need to be added. Both the coal gangue and the fly ash contain a large amount of SiO2And Al2O3The components participate in the formation of a ceramic tile framework in the sintering process, so that the ceramic tile has excellent mechanical properties and chemical stability; and the main component of the desulfurized gypsumIs CaSO4A large amount of CaO may be provided. In the sintering process, the chemical compositions of the waste residue generate synergistic, complementary and coherent effects, wherein part of CaO and SiO2、Al2O3The components generate synergistic effect and generate anorthite CaAl through reaction2Si2O8The ceramic tile has high strength and high chemical stability. Due to SiO2、Al2O3Belongs to a high-melting point compound, and the alkali metal oxide and the alkaline earth metal oxide have the fluxing action, so that Na in the waste residue is utilized2O、K2Alkali metal oxides such as O, alkaline earth metal oxides such as CaO and MgO, and SiO2、Al2O3The reaction of the compound in the ceramic sintering process generates a liquid phase, thereby reducing the sintering temperature of the ceramic and promoting the sintering process (namely, complementary effect), and therefore, a sintering aid does not need to be added. Meanwhile, part of Na2O、K2O, CaO, MgO, etc. with SiO2、Al2O3Formation of a glassy phase, Si-O-、Al-O-Chemically bonding with heavy metal ions in the waste residue to form Si-O-Pb (Cr), Al-O-Pb (Cr) bonds, and solid dissolving with toxic and harmful components such as heavy metal ions to restrict the heavy metal ions; or the harmful components such as heavy metal ions, radioactive substances and the like are sealed in a physical embedding mode, so that the zero emission (namely the phaco effect) of toxic and harmful substances introduced from waste residues in the ceramic products is realized. Utilizing CaSO in desulfurized gypsum4The ceramic green body is dissolved with a small amount of water to generate a cementing effect similar to the property of cement, and the ceramic green body is endowed with certain mechanical strength after being formed under the action of certain mechanical pressure by utilizing the physical binding force among fine particles of the raw materials, thereby being beneficial to the sintering of samples. Therefore, no binder needs to be added.
The method provided by the invention comprises the steps of processing raw materials of coal gangue, fly ash and desulfurized gypsum into fine particles by a ball mill, obtaining powder with the granularity of 100-300 meshes by sieving, weighing various raw materials according to a pre-designed ratio, and mixing the weighed desulfurized gypsum powder and water according to a ratio of 5: 3-3: 1, then mixing with the weighed coal gangue and fly ash, uniformly mixing to obtain a batch mixture, then loading the batch mixture into a die, and performing compression molding to obtain a blank; and (3) naturally drying the obtained ceramic tile blank in the air, sintering at a high temperature, preserving heat for a certain time, and cooling to obtain the ceramic tile.
The high-strength ceramic tile adopting the coal gangue-fly ash-desulfurized gypsum system and the preparation method thereof also comprise the following preferred scheme:
in a preferred scheme, the addition of a small amount of water is used for wetting the waste slag and reacting the waste slag with CaSO4The cementing effect is generated under the action of the ceramic powder, so that the raw materials are pressed and formed, the ceramic blank is endowed with initial mechanical strength, and the sintering of a sample is facilitated.
In the preferable scheme, the ceramic tile blank body after being fully dried is placed in a gas furnace or a resistance furnace, heated to 1140-1180 ℃ at the heating rate of 5 ℃/min, and kept warm for 1-3 h.
In the preferable scheme, the pressing molding adopts a single-side pressing mode, and the molding pressure is 30-35 MPa.
In a preferred scheme, the cooling mode is furnace cooling.
The invention has the technical advantages that: according to the chemical composition of the material, the chemical composition in the waste residue is utilized to realize potential synergistic, complementary and coherent effects on the preparation process and performance of the material, the waste residue is scientifically combined and matched, and the solid waste residue is utilized to the maximum extent.
1) The chemical composition analysis of the waste residue shows that the coal gangue and the fly ash both contain a large amount of SiO2And Al2O3Substance, also containing Na2O、K2O, CaO, MgO, SrO and the like, and the desulfurized gypsum mainly contains CaSO4. On the one hand, during sintering, SiO2And Al2O3The components participate in the formation of the framework of the ceramic tile, so that the ceramic tile has excellent mechanical property and chemical stability; on the other hand, SiO2And Al2O3With Na in the waste residue2O、K2The components of O, CaO, MgO, SrO and the like react to form a liquid phase with a certain content at a lower temperature, so that the sintering temperature of the ceramic tile is effectively reduced without addingAnd (3) a sintering aid.
2)SiO2/Al2O3With Na2O、K2Silicate and aluminate glass phase formed by O, CaO, MgO, SrO and the like can be opposite to Na+、K+The ions and the heavy metal ions play a role of 'constraint', and the bound alkali metal ions and the heavy metal ions are difficult to discharge in the use process of the ceramic material, so that the problems of water quality, soil alkalization and heavy metal ion pollution can be solved; on the other hand, the formation of the glass phase can also seal toxic and harmful components, thereby realizing the zero emission of toxic and harmful substances introduced from waste residues in ceramic products and ensuring the safety of material use. In addition, other substances present in the slag raw material, such as P2O5、TiO2、Fe2O3MnO and the like can participate in the composition of the material, so that the pretreatment process of the raw material can be reduced, and the preparation cost can be reduced.
3) The introduction of a small amount of water can cause CaSO in the desulfurized gypsum4Dissolving to generate a cementing effect similar to the cement property, and endowing the ceramic body with certain mechanical strength, thereby ensuring that the sample has higher density and strength after being sintered. Therefore, no binder needs to be added.
In conclusion, the unique innovativeness and technical advantages of the invention bring particularly excellent technical effects:
1. the synergistic, complementary and coherent effects among the chemical compositions of the three industrial solid waste residues are fully utilized, the waste residue introduction amount in the product reaches 100%, sintering aids and binders do not need to be added, and the high-efficiency and maximum utilization of the solid waste residues is realized.
2. The prepared ceramic tile takes anorthite as a main crystal phase, and has the characteristics of high strength, good corrosion resistance, no secondary pollution and the like; the concrete is that the density of the ceramic tile is 1.956-2.013 g.cm-3The water absorption rate is 0.22-4.52%, the compressive strength is 82.8-346.5 MPa, the acid resistance is 98.93-99.97%, and the alkali resistance is 99.75-99.98. Wherein the compressive strength is 3.5 to 11.9 times of that of the product of the patent CN 107793132A.
Drawings
FIG. 1 is an XRD pattern of the ceramic prepared in example 2 of the present invention.
FIG. 2 is a drawing showing a real object of the ceramic prepared in example 2 of the present invention.
Detailed Description
The present invention is further illustrated by the following examples, which should not be construed as limiting the scope of the invention.
Example 1
Will design the chemical composition of SiO2：45.72％，Al2O3：21.21％，CaO：12.53％，MgO：4.19，Na2O：3.33％，Fe2O3: 4.87%, and the balance: 8.15 percent of the waste residue is converted into the waste residue amount, the waste residue raw materials are weighed and evenly mixed according to the mass percent of 68 percent of coal gangue, 17 percent of fly ash and 15 percent of desulfurized gypsum, water accounting for 3 percent of the total weight of the raw materials is added, the mixture is evenly mixed and then put into a metal mold, the mixture is pressed into a ceramic blank under the pressure of 30MPa, and the ceramic blank is naturally dried; and (3) placing the dried blank body in a resistance furnace, uniformly heating to 1160 ℃ at a constant speed at a speed of 5 ℃/min, preserving heat for 2h, and naturally cooling. The bulk density of the prepared ceramic tile is 1.963g/cm3The water absorption rate is 0.28%, the compressive strength is 289.9MPa, the acid resistance is 99.96%, and the alkali resistance is 99.91%.
Example 2
Will design the chemical composition of SiO2：45.72％，Al2O3：21.21％，CaO：12.53％，MgO：4.19，Na2O：3.33％，Fe2O3: 4.87%, and the balance: 8.15 percent of the waste residue is converted into the waste residue amount, each waste residue raw material is weighed and evenly mixed according to the mass percent of 68 percent of coal gangue, 17 percent of fly ash and 15 percent of desulfurized gypsum, water accounting for 5 percent of the total weight of the raw materials is added, the mixture is evenly mixed and then placed into a metal mold, a ceramic blank is pressed under the pressure of 35MPa and then placed into a drying oven for drying; and (3) placing the fully dried blank in a resistance furnace, uniformly heating to 1160 ℃ at a constant speed of 5 ℃/min, preserving heat for 1h, and naturally cooling. The bulk density of the prepared ceramic tile is 1.956g/cm3The water absorption rate is 4.52%, the compressive strength is 346.5MPa, the acid resistance is 99.93%, and the alkali resistance is 99.94%. FIG. 1 is an XRD pattern of the ceramic prepared in this example. FIG. 2 shows the present embodimentExample physical pictures of the prepared ceramics.
Example 3
Will design the chemical composition of SiO2：45.72％，Al2O3：21.21％，CaO：12.53％，MgO：4.19，Na2O：3.33％，Fe2O3: 4.87%, and the balance: 8.15 percent of the waste residue is converted into the waste residue amount, each waste residue raw material is weighed and evenly mixed according to the mass percent of 68 percent of coal gangue, 17 percent of fly ash and 15 percent of desulfurized gypsum, water accounting for 4 percent of the total weight of the raw materials is added, the mixture is evenly mixed and then placed into a metal mold, a ceramic blank is pressed under the pressure of 30MPa and then placed into a drying oven for drying; and (3) placing the fully dried blank in a resistance furnace, uniformly heating to 1160 ℃ at a constant speed at a speed of 5 ℃/min, preserving heat for 3h, and naturally cooling. The bulk density of the prepared ceramic tile is 1.962g/cm3The water absorption rate is 0.31 percent, the compressive strength is 124.2MPa, the acid resistance is 99.99 percent, and the alkali resistance is 99.88 percent.
Example 4
Will design the chemical composition of SiO2：45.90％，Al2O3：21.12％，CaO：12.01％，MgO：3.85，Na2O：3.16％，Fe2O3: 4.82%, and the balance: 9.14 percent of the raw materials of the waste residue is converted into the consumption of the waste residue, the raw materials of the waste residue are weighed and evenly mixed according to the mass percent of 51 percent of coal gangue, 34 percent of fly ash and 15 percent of desulfurized gypsum, water accounting for 5 percent of the total weight of the raw materials is added, the mixture is evenly mixed and then put into a metal mold, a ceramic blank is pressed under the pressure of 30MPa and then put into a drying oven for drying; and (3) placing the fully dried blank in a resistance furnace, uniformly heating to 1160 ℃ at a constant speed at a speed of 5 ℃/min, preserving heat for 2h, and then naturally cooling. The bulk density of the prepared ceramic tile is 2.013g/cm3The water absorption rate is 1.64%, the compressive strength is 217.5MPa, the acid resistance is 99.99%, and the alkali resistance is 99.89%.
Example 5
Will design the chemical composition of SiO2：45.98％，Al2O3：21.08％，CaO：11.75％，MgO：3.68，Na2O：3.08％，Fe2O3: 4.79%, and the balance: 9.64 percent of the raw material of each waste residue is converted into the consumption of the waste residue according to 42 percent of coal gangueWeighing 5 percent of fly ash, 42.5 percent of fly ash and 15 percent of desulfurized gypsum by mass percent, uniformly mixing, adding water accounting for 3 percent of the total weight of the raw materials, uniformly mixing, putting the mixture into a metal mold, pressing the mixture under the pressure of 35MPa to prepare a ceramic blank, and putting the ceramic blank into a drying oven for drying; and (3) placing the fully dried blank in a resistance furnace, uniformly heating to 1160 ℃ at a constant speed at a speed of 5 ℃/min, preserving heat for 2h, and then naturally cooling. The bulk density of the ceramic tile produced was 1.965g/cm3The water absorption rate is 3.44%, the compressive strength is 304.5MPa, the acid resistance is 99.97%, and the alkali resistance is 99.98%.
Example 6
Will design the chemical composition of SiO2：45.81％，Al2O3：21.16％，CaO：12.27％，MgO：4.02，Na2O：3.24％，Fe2O3: 4.84%, and the balance: converting 8.66% into the consumption of the waste residues, weighing and uniformly mixing 59.5% of waste residue raw materials, namely coal gangue, 25.5% of fly ash and 15% of desulfurized gypsum according to the mass percentage, adding water accounting for 4% of the total weight of the raw materials, uniformly mixing, putting the mixture into a metal mold, pressing the mixture under the pressure of 35MPa to prepare a ceramic blank, and naturally drying the ceramic blank; and (3) placing the dried blank in a resistance furnace, raising the temperature to 1160 ℃ at a constant speed at a speed of 5 ℃/min, preserving the temperature for 2h, and then naturally cooling. The bulk density of the prepared ceramic tile is 1.998g/cm3The water absorption rate is 1.19%, the compressive strength is 234.6MPa, the acid resistance is 99.99%, and the alkali resistance is 99.93%.
Example 7
Will design the chemical composition of SiO2：45.64％，Al2O3：21.25％，CaO：12.79％，MgO：4.35，Na2O：3.41％，Fe2O3: 4.89%, and the balance: 7.67 percent of the raw material is converted into the consumption of the waste residue, the raw materials of the waste residue are weighed and evenly mixed according to the mass percent of 76.5 percent of coal gangue, 8.5 percent of fly ash and 15 percent of desulfurized gypsum, water accounting for 5 percent of the total weight of the raw materials is added, the mixture is evenly mixed and then put into a metal mold, a ceramic blank is prepared by pressing under the pressure of 35MPa, and the ceramic blank is put into a drying oven for drying; and (3) placing the fully dried blank in a resistance furnace, uniformly heating to 1160 ℃ at a constant speed at a speed of 5 ℃/min, preserving heat for 2h, and then naturally cooling. The bulk density of the ceramic tile produced was 1.958g/cm3The water absorption rate is 0.34 percentThe compressive strength is 126.8MPa, the acid resistance is 99.99 percent, and the alkali resistance is 99.92 percent.
Example 8
Will design the chemical composition of SiO2：45.72％，Al2O3：21.21％，CaO：12.53％，MgO：4.19，Na2O：3.33％，Fe2O3: 4.87%, and the balance: converting 8.15% into the consumption of the waste residues, weighing 68% of waste residue raw materials, namely coal gangue, 17% of fly ash and 15% of desulfurized gypsum by mass percent, uniformly mixing, adding water accounting for 5% of the total weight of the raw materials, uniformly mixing, putting into a metal mold, pressing under 35MPa to prepare a ceramic blank, and putting into a drying oven for drying; and (3) placing the fully dried blank in a resistance furnace, uniformly heating to 1140 ℃ at a constant speed of 5 ℃/min, preserving heat for 2h, and then naturally cooling. The bulk density of the prepared ceramic tile is 1.811g/cm3The water absorption rate is 1.13%, the compressive strength is 107.8MPa, the acid resistance is 99.95%, and the alkali resistance is 99.75%.
Example 9
Will design the chemical composition of SiO2：45.72％，Al2O3：21.21％，CaO：12.53％，MgO：4.19，Na2O：3.33％，Fe2O3: 4.87%, other minor constituents: converting 8.15% into the consumption of the waste residues, weighing 68% of waste residue raw materials, namely coal gangue, 17% of fly ash and 15% of desulfurized gypsum by mass percent, uniformly mixing, adding water accounting for 5% of the total weight of the raw materials, uniformly mixing, putting into a metal mold, pressing under 35MPa to prepare a ceramic blank, and putting into a drying oven for drying; and (3) placing the fully dried blank in a resistance furnace, uniformly heating to 1180 ℃ at a constant speed of 5 ℃/min, preserving heat for 2h, and then naturally cooling. The bulk density of the prepared ceramic tile is 1.475g/cm3The water absorption rate is 0.22%, the compressive strength is 82.8MPa, the acid resistance is 99.92%, and the alkali resistance is 99.94%.
TABLE 1 Performance parameter indices for ceramic tiles prepared in examples 1-9
Figure BDA0001748454670000081
The water absorption and bending strength indexes of the unglazed ceramic tile are shown in table 1 and are tested under the same conditions according to the following test method: water absorption: GBT 3810.3-2006 determination of Water absorption, apparent porosity, apparent relative density and volume weight of ceramic brick test methods.

Claims (4)

1. The high-strength ceramic tile of the coal gangue-fly ash-desulfurized gypsum system is characterized in that the ceramic tile takes the coal gangue, the fly ash and the desulfurized gypsum as raw materials, no sintering aid or binder is required to be added, and the ceramic tile green body comprises the following raw materials in percentage by mass: 42.5-85.5% of coal gangue; 8.5-47.5% of fly ash; 5-15% of desulfurized gypsum, and generating anorthite CaAl through reaction2Si2O8The ceramic tile green body comprises the following chemical components in percentage by mass: SiO 22：45.64～51.24%；Al2O3：21.08～23.71%；CaO：8.16～12.79%；MgO：3.68～4.75%；Na2O：3.08～3.81%；Fe2O3: 4.79-5.46%, and the balance: 7.67 to 9.14 percent.
2. The preparation method of the high-strength ceramic tile with the coal gangue-fly ash-desulfurized gypsum system according to claim 1, characterized by comprising the following process steps:
1) processing coal gangue, fly ash and desulfurized gypsum raw materials into fine particles, and sieving to obtain powder with the particle size of 100-300 meshes;
2) weighing the powder obtained in the step 1) according to a pre-designed proportion, and then mixing the weighed desulfurized gypsum powder with water according to a ratio of 5: 3-3: 1, then mixing with the weighed coal gangue and fly ash, uniformly mixing to obtain a batch mixture, then loading the batch mixture into a die, and performing compression molding to obtain a blank;
3) placing the ceramic blank prepared in the step 2) in the air for natural drying, then sintering at high temperature, preserving heat for a certain time, and cooling to obtain the ceramic tile.
3. The preparation method of the coal gangue-fly ash-desulfurized gypsum system high-strength ceramic tile according to claim 2, wherein the forming pressure of the coal gangue-fly ash-desulfurized gypsum mixed powder is 30-35 MPa.
4. The preparation method of the high-strength ceramic tile with the coal gangue-fly ash-desulfurized gypsum system according to claim 2, wherein the ceramic tile blank after being fully dried is placed in a gas-fired kiln or a resistance furnace, heated to 1140-1180 ℃ at a heating rate of 5 ℃/min, and kept warm for 1-3 h.
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