CN109553393A - 一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法 - Google Patents

一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法 Download PDF

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CN109553393A
CN109553393A CN201910031342.2A CN201910031342A CN109553393A CN 109553393 A CN109553393 A CN 109553393A CN 201910031342 A CN201910031342 A CN 201910031342A CN 109553393 A CN109553393 A CN 109553393A
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powder
waste slag
microwave sintering
foamed ceramic
melting waste
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侯雅军
曲冬雪
潘文凯
曹志明
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QUZHOU HUAYOU COBALT NEW MATERIAL CO Ltd
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Abstract

本发明属于固体废弃物资源化利用技术领域，特别涉及一种钴冶炼废渣资源化利用的方法。本发明提供一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，以钴冶炼废渣、填料、液相剂、增塑剂、发泡剂进行配料，经研磨、混料、造粒、入模压制或入模粉体堆积制得生胚，通过微波烧结制得发泡陶瓷。采用微波加热的方法，相比采用传统电加热或燃料加热的方式，大幅度降低了发泡温度和缩短了发泡时间，因此能耗大幅度降低。本发明解决了目前发泡陶瓷行业高能耗以及钴冶炼废渣的高附加值综合利用的问题。

Description

一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法
技术领域
本发明属于固体废弃物资源化利用技术领域，特别涉及一种钴冶炼废渣资源化利用的方法。
背景技术
目前，国内使用建筑外墙保温材料大都是有机材料如聚氨酯、聚苯乙烯、酚醛树脂等，燃烧性能最好也只能达到B级，满足不了防火阻燃A级的要求。个别无机材料如发泡水泥、泡沫玻璃、岩棉、膨胀珍珠岩等，燃烧性能虽然能达到A级，但存在吸水率大、强度低等一系列问题。
发泡陶瓷是一种以各种耐火原料为骨料，配以填料、增塑剂、液相剂、发泡剂等，经高温烧结而成的陶瓷材料。其特点是内部结构中具有大量孔径可控、分布均匀的闭口气孔。具有保温、隔热、吸音、装饰、防潮、防渗、耐腐蚀、耐老化、阻燃，且不危害人体健康等优点，完全能满足防火阻燃A级的要求。
钴冶炼废渣是提取各种钴生产过程中产生的一种固体废弃物，其产量巨大。其堆放既挤占土地，又影响当地空气的粉尘含量。长期以来，钴冶炼废渣的综合利用都是环境保护领域的一个重要课题，到现在为止，钴冶炼废渣的高附加值利用尚未大规模推广，资源化利用主要还是以作为填料加入水泥或者混凝土砌块中，或者做成陶粒，难以产生较大的经济效益。如果能用钴冶炼废渣生产出符合质量要求的发泡陶瓷，势必是一种高附加值利用且能大规模消耗掉钴冶炼废渣。
现有的发泡陶瓷板的制备方法一般采用各种燃料如天然气、发生炉煤气、焦炉气隧道窑或者辊道窑方法，烧成温度一般在1100-1250℃。由于多孔陶瓷材料本身的热导率较低，采用常规方法烧结容易导致材料局部烧结不均匀，且烧结时间过长造成极大的能源浪费。采用微波烧结的方式，利用微波烧结特有的内外同时加热的方式，可以快速的达到发泡的目的，从而大量的节省能耗。
发明内容
本发明的目的在于克服现有技术的不足，提供一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，解决了目前发泡陶瓷行业高能耗以及钴冶炼废渣的高附加值综合利用的问题。
为了达到上述目的，本发明的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，包括如下步骤：
1、按照如下重量百分比进行配料：钴冶炼废渣10-80%，填料10-80%，液相剂 0-10%，增塑剂0-5%，上述组分的重量百分比之和为100%，加入上述所有组分之和0.2-2.5%的发泡剂；
2、配料经研磨、喷雾造粒、入模压制得生坯；或经过研磨、喷雾造粒、入模粉体堆积；或经过研磨、强制混料、造粒、入模粉体堆积；所得生坯或入模粉体通过微波烧结制得发泡陶瓷。
进一步，所述钴冶炼废渣为湿法冶金提取钴后剩余的有色金属灰渣、氧压渣的一种或两种，其重量百分含量为30-70%。
进一步，所述填料为钾长石、钠长石、钙长石、锂长石、锂辉石、锂瓷石、珍珠岩尾矿粉、页岩的一种或一种以上。
进一步，所述液相剂为玻璃粉、陶瓷熔块、纯碱、硝酸钠、硫酸钠、碳酸钾、硝酸钾、硼砂、硼泥、硼酸、硅酸钠、碳酸钙、氧化钙、石灰石、大理石、白云石、碳酸镁、氧化镁、滑石、碳酸锂、萤石、氟化镁中的一种或一种以上。
进一步，所述增塑剂为粘土、膨润土、黑泥、白泥、高领土、紫木节、球土、叶蜡石、焦宝石、瓷石、瓷土、陶土中的一种或一种以上。
进一步，所述发泡剂为碳化硅、碳化硅收尘粉、碳化硅抛光粉、含碳化硅的研磨废料、石墨、碳粉、煤粉中的一种或一种以上，其粒度控制在150-4000目。
进一步，步骤2中配料研磨后的粒度控制在200-4000目；所述生坯或入模粉体直接进入微波炉进行干燥和发泡，微波烧结温度为1020-1200℃、微波保温时间为5-90 min。
进一步，步骤2中所述生坯或入模粉体先预热到1020-1120℃，再微波加热至1120℃-1200℃进行微波烧结5-40 min。
更进一步，所述步骤2具体如下：
(1)原料按步骤1配料入球进行湿法研磨混合均匀，研磨转速为10-15转/分钟，研磨时间为10-20小时；研磨后的粒度控制在200-300目；
(2)喷雾干燥制粉，控制粒径为20-80目，陈腐24h后入模平铺制得粉末生坯；
(3)粉末生坯直接微波加热至1120℃-1160℃进行微波烧结40-90 min，或者先预热到1020-1120℃，再微波加热至1120℃-1160℃进行微波烧结20-40 min，然后降温到室温，形成闭口气孔分布均匀的轻质发泡陶瓷板；
(4)经切割等冷加工制成所需规格的成品。
更进一步，所述步骤2具体如下：
(1) 原料按步骤1配料入球进行干法研磨混合均匀，研磨转速为10-20转/分钟，研磨时间为2-6小时；得到粉体经万孔筛余小于5%；
(2)得到的粉体通过对辊压机进行造粒，粒度大小为3-8目，入模平铺制得堆积粉料；
(3)堆积粉料直接微波加热至1120℃-1160℃进行微波烧结15-40 min，或者先预热到1020-1120℃，再微波加热至1120℃-1160℃进行微波烧结5-20min，然后降温到室温，形成闭口气孔分布均匀的轻质发泡陶瓷板；
(4)经切割等冷加工制成所需规格的成品。
本发明的有益效果是：
（1）本发明使得钴冶炼废渣得到了高附加值利用，且能大规模消耗掉钴冶炼废渣，解决环保难题；并且生产出符合质量要求的发泡陶瓷，不仅节约了紧缺的陶瓷原料，同时符合国家的节能减排政策，对资源保护和钴冶炼废渣的资源化利用都有重大意义。
（2）本发明在于原料创新，大量使用钴冶炼废渣，原料组成简单，操作性强。本发明制得的发泡陶瓷烧结均匀，质量高，满足保温、耐老化、阻燃性能要求。所制备的发泡陶瓷材料具有优异的性能，如密度小、强度高、吸水率低、热导率低、不燃烧、寿命长等。
（3）本发明采用微波加热烧结，相比采用传统电加热或燃料加热的方法，大幅度降低了发泡温度和缩短了发泡时间。微波烧结是利用微波具有的特殊波段与材料的基本细微结构耦合而产生热量，材料的介质损耗使其材料整体加热至烧结温度而实现致密化的方法。采用微波烧结技术不仅大幅度降低了烧结温度，还大大缩短了烧成时间。
具体实施方式
实施例1：
一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，包括如下步骤：
1、按照如下重量百分比进行配料：钴冶炼剩余的氧压渣 20％，页岩70％，废玻璃粉10％，碳化硅粉（200目）1％；
2、配料入球进行湿法研磨混合均匀，研磨介质为中铝瓷球，研磨转速为12转/分钟，研磨时间为15小时；得到粉体全部通过200目；
3、喷雾干燥制粉（粒径为20-80目），陈腐24h后入模平铺制得粉末生坯；
4、粉末生坯直接微波加热至1130℃进行微波烧结40min，或者先预热到1050℃，再微波加热至1130℃进行微波烧结30 min，然后降温到室温，形成闭口气孔分布均匀的轻质发泡陶瓷板；
(4)经切割等冷加工制成所需规格的成品。
本实施例制得的发泡陶瓷板，经检测容重为0.40g/cm3，导热系数为0.1W/m.k。
实施例2：
一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，包括如下步骤：
1、按照如下重量百分比进行配料：钴冶炼剩余的有色金属灰渣 40％，页岩60％，9水硅酸钠1％，碳化硅粉（2000目）0.8％；
2、配料入球进行干法研磨混合均匀，研磨介质为钢球，研磨转速为15转/分钟，研磨时间为4小时；得到粉体经万孔筛余小于5%；
3、得到的粉体通过对辊压机进行造粒，粒度大小为5目，入模平铺制得堆积粉料；
4、堆积粉料直接微波加热至1150℃进行微波烧结15min，或者先预热到1100℃，再微波加热至1150℃进行微波烧结10 min，然后降温到室温，形成闭口气孔分布均匀的轻质发泡陶瓷板；
(4)经切割等冷加工制成所需规格的成品。
本实施例制得的发泡陶瓷板，经检测容重为0.16g/cm3，导热系数为0.06W/m.k。

Claims (10)

1.一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：包括如下步骤：
（1）按照如下重量百分比进行配料：钴冶炼废渣10-80%，填料10-80%，液相剂 0-10%，增塑剂0-5%，上述组分的重量百分比之和为100%，加入上述所有组分之和0.2-2.5%的发泡剂；
（2）配料经研磨、喷雾造粒、入模压制得生坯；或经过研磨、喷雾造粒、入模粉体堆积；或经过研磨、强制混料、造粒、入模粉体堆积；所得生坯或入模粉体通过微波烧结制得发泡陶瓷。
2.根据权利要求1所述的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：所述钴冶炼废渣为湿法冶金提取钴后剩余的有色金属灰渣、氧压渣的一种或两种，其重量百分含量为30-70%。
3.根据权利要求1所述的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：所述填料为钾长石、钠长石、钙长石、锂长石、锂辉石、锂瓷石、珍珠岩尾矿粉、页岩的一种或一种以上。
4.根据权利要求1所述的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：所述液相剂为玻璃粉、陶瓷熔块、纯碱、硝酸钠、硫酸钠、碳酸钾、硝酸钾、硼砂、硼泥、硼酸、硅酸钠、碳酸钙、氧化钙、石灰石、大理石、白云石、碳酸镁、氧化镁、滑石、碳酸锂、萤石、氟化镁中的一种或一种以上。
5.根据权利要求1所述的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：所述增塑剂为粘土、膨润土、黑泥、白泥、高领土、紫木节、球土、叶蜡石、焦宝石、瓷石、瓷土、陶土中的一种或一种以上。
6.根据权利要求1所述的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：所述发泡剂为碳化硅、碳化硅收尘粉、碳化硅抛光粉、含碳化硅的研磨废料、石墨、碳粉、煤粉中的一种或一种以上，其粒度控制在150-4000目。
7.根据权利要求1所述的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：步骤2中配料研磨后的粒度控制在200-4000目；所述生坯或入模粉体直接进入微波炉进行干燥和发泡，微波烧结温度为1020-1200℃、微波保温时间为5-90 min。
8.根据权利要求1所述的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：步骤2中所述生坯或入模粉体先预热到1020-1120℃，再微波加热至1120℃-1200℃进行微波烧结5-40 min。
9.根据权利要求7或8所述的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：
(1)原料按步骤1配料入球进行湿法研磨混合均匀，研磨转速为10-15转/分钟，研磨时间为10-20小时；研磨后的粒度控制在200-300目；
(2)喷雾干燥制粉，控制粒径为20-80目，陈腐24h后入模平铺制得粉末生坯；
(3)粉末生坯直接微波加热至1120℃-1160℃进行微波烧结40-90 min，或者先预热到1020-1120℃，再微波加热至1120℃-1160℃进行微波烧结20-40 min，然后降温到室温，形成闭口气孔分布均匀的轻质发泡陶瓷板；
(4)经切割等冷加工制成所需规格的成品。
10.根据权利要求7或8所述的一种以钴冶炼废渣微波烧结制备发泡陶瓷的方法，其特征在于：
(1) 原料按步骤1配料入球进行干法研磨混合均匀，研磨转速为10-20转/分钟，研磨时间为2-6小时；得到粉体经万孔筛余小于5%；
(2)得到的粉体通过对辊压机进行造粒，粒度大小为3-8目，入模平铺制得堆积粉料；
(3)堆积粉料直接微波加热至1120℃-1160℃进行微波烧结15-40min，或者先预热到1020-1120℃，再微波加热至1120℃-1160℃进行微波烧结5-20min，然后降温到室温，形成闭口气孔分布均匀的轻质发泡陶瓷板；
(4)经切割等冷加工制成所需规格的成品。
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CN112645692A (zh) * 2020-12-28 2021-04-13 信阳师范学院 一种以低品位非金属伴生矿为主要原料制备的穿孔吸音陶瓷及其制备方法
US20240059619A1 (en) * 2022-05-09 2024-02-22 Beijing University Of Technology Method for preparing ecological foamed ceramic from lepidolite filter mud whole waste
US12006268B2 (en) * 2022-05-09 2024-06-11 Beijing University Of Technology Method for preparing ecological foamed ceramic from lepidolite filter mud whole waste
CN114799184A (zh) * 2022-05-12 2022-07-29 江西咏泰粉末冶金有限公司 一种高均匀大颗粒球形复合粉末的制备方法

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