CN110372412A - 一种硅藻土功能材料及其制备方法 - Google Patents
一种硅藻土功能材料及其制备方法 Download PDFInfo
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Abstract
本发明提供一种硅藻土功能材料及其制备方法,属于硅藻土材料技术领域。该材料按照重量份数计,包括:硅藻土或硅藻土助滤剂中的一种或两种混合100份,无机多孔材料0‑25份,有机粘合剂0‑30份,无机粘合剂10‑30份,水100份,所述的硅藻土中SiO2含量大于60%。该功能材料是以硅藻土为基质,配以有机、无机粘合剂经混合、成型、煅烧、整型、雕刻或打印等工艺制成;本发明的制备方法简单、使用方便,应用范围广、过滤流量大、精度高、效果好、化学性质稳定、耐压抗腐强度高、使用寿命长等优点,材料中的SiO2含量大于80%,孔隙率大于70%,抗压强度为20‑30MPa。
Description
技术领域
本发明属于硅藻土材料技术领域,具体涉及一种硅藻土功能材料及其制备方法。
背景技术
在制酒、制药、制糖、制胶、食品、食油、饮水、工业用水、石油化工、工业用油等领域中,为了确保工业液体的纯度和质量,都必须由过滤机对其进行过滤。而过滤机在过滤前,需将过滤介质如硅藻土助滤剂、珍珠岩助滤剂(或纤维素)、活性炭、活性白土、粉末冶金等固体粉末状先与清液或净水混合,然后经15-30分钟的循环过滤过程把过滤介质涂敷在过滤机的过滤元件(可为板、盘、网或叶片等等)上,并形成2-3毫米的滤饼后才能进行过滤。当过滤原液进入过滤机后,其中的杂质被过滤介质截留,清液得以顺利通过,从而实现对工业液体的过滤。该技术在工业液体过滤净化中发挥着及其重要的作用。然而利用该技术在过滤前必须将过滤介质在过滤机内进行涂敷,不仅工艺复杂,浪费时间、清液或净水,产量降低,硅藻土只能一次性使用成本增大,污染严重,浪费硅藻土资源。而且在过滤中形成的滤饼受过滤压差和操作的影响,不可避免地会发生裂缝或脱落,以因为硅藻土的粒度分布很宽泛从而使过滤介质和原液中的微细颗粒穿透滤饼以及过滤板、过滤盘、过滤网或叶片等进入过滤清液中导致净液产品质量下降。与此同时,在每个过滤周期开始前为防止产品染菌,必须对过滤机乃至过滤介质进行高温蒸汽灭菌。由于过滤机中的过滤板、过滤布受温度影响变质较快,夏季里7-10天就得进行更换,使用寿命短,价格又昂贵,不更换又使产品质量无保证。不仅如此,在每个过滤同期结束后又必须拆卸开过滤机进行清洗(因过滤板、过滤布不能进行反冲洗,所以过滤工艺不能实现连续自动),将过滤机内的粉末状过滤介质和杂质全部冲洗掉。这样一来势必造成原液的进一步损失浪费导致成本的增加。因此所述过滤介质不能满足现代化工业精密过滤、超精密过滤自动化生产的技术要求。多年来该领域科技人员一直在进行探索性实验,积极寻求解决的途径,但尚未得到满意的结果。
现有的硅藻土装饰材料采用硅藻土和粘接剂(水泥、水性胶、粘土等)搅拌成涂料或压制成形。硅藻土含量较低一般不超过30%。孔隙率低一般不超过20%。产品表现出防火保温隔音性差、吸附性差、湿度调节效率很低。有的强度很差。日本进口的产品强度较高,但是吸附性差、隔音保温性不好。更难达到天然环保绿色安全的标准。
发明内容
本发明的目的是为了解决现有的硅藻土装饰材料中的硅藻土含量较低导致的产品性能差的问题,而提供一种硅藻土功能材料及其制备方法。
本发明首先提供一种硅藻土功能材料,按照重量份数计,包括:
硅藻土或硅藻土助滤剂中的一种或两种混合100份
无机多孔材料0-25份
有机粘合剂0-30份
无机粘合剂10-30份
水100份。
所述的硅藻土中SiO2含量大于60%。
优选的是,所述的硅藻土助滤剂为煅烧硅藻土或助熔煅烧硅藻土。
优选的是,所述的混合中,硅藻土和硅藻土助滤剂的质量比为1:9。
优选的是,所述的无机多孔材料为硅藻土或风选加工的碳粉或珍珠岩。
优选的是,所述的有机粘合剂为粉末聚乙烯或淀粉。
所述的无机粘合剂为高岭土、膨润土、硅灰石或玻璃粉。
本发明还提供一种硅藻土功能材料的制备方法,包括:
步骤一:按配比将各原料混合,然后放入模具中压制成型,得到成型体;
步骤二:将成型体置入干燥室或干燥窑干燥,所述的干燥温度为20-200℃,干燥时间为1.5-60h;
步骤三:干燥后成型体经整形放入煅烧设备中煅烧,所述的煅烧温度为700-1250℃,煅烧时间为30-60min,经煅烧后的成型体再经整形、雕刻或打印得到硅藻土功能材料。
优选的是,所述的步骤二的干燥温度为90-150℃。
优选的是,所述的步骤三的煅烧温度为950-1200℃。
本发明的有益效果
本发明提供一种硅藻土功能材料及其制备方法,该功能材料是以硅藻土为基质,配以有机、无机粘合剂经混合、成型、煅烧、整型、雕刻或打印等工艺制成,该功能材料利用硅藻土天然的微孔性生产出来的功能材料具有强度高、防火、保温、天然环保安全、隔音吸声、调节空气湿度等优点,并可根据用户需求个性化订制图案。本发明的制备方法简单、使用方便,应用范围广、过滤流量大、精度高、效果好、化学性质稳定、耐压抗腐强度高、使用寿命长等优点,材料中的SiO2含量大于80%,孔隙率大于70%,抗压强度为20-30MPa。
本发明的硅藻土功能材料与现有过滤机配套使用,过滤机在过滤前无须涂敷过滤介质、过滤过程中不必更换过滤元件,不存在过滤介质形成的滤饼脱落,过滤周期结束不必拆机进行清洗,不仅能减少工艺过程,有效提高产品质量,延长设备使用寿命,降低生产成本,并能满足现代化工业精密过滤、超精密过滤和连续自动化生产的需求的微孔陶瓷过滤元件。对于降低污染,节约硅藻土矿产资源有重要意义。
具体实施方式
本发明首先提供一种硅藻土功能材料,按照重量份数计,包括:
硅藻土或硅藻土助滤剂中的一种或两种混合100份
无机多孔材料0-25份
有机粘合剂0-30份
无机粘合剂10-30份
水100份。
按照本发明,所述的硅藻土为采用硅藻土原土进行干燥风选后得到的,所述的硅藻土中SiO2含量大于60%,粒度优选为1-100微米。
按照本发明,所述的硅藻土助滤剂为煅烧硅藻土或助熔煅烧硅藻土,所述的煅烧硅藻土或助熔煅烧硅藻土中SiO2含量大于85%,粒度优选为1-100微米,所述的产品来源为商购或自己经过水溶沉降分级精选,煅烧硅藻土优选为商品型号为821#,助熔煅烧硅藻土优选为商品型号为616#。
按照本发明,所述的混合中,硅藻土和硅藻土助滤剂的质量比优选为1:9,所述的硅藻土助滤剂中煅烧硅藻土和助熔煅烧硅藻土的质量比优选为2:7。
按照本发明,所述的对于硅藻土、煅烧硅藻土或助熔煅烧硅藻土的选择和配比,可以根据最终要得到的多功能材料渗透率和粒度分布进行选择,当采用煅烧硅藻土制备时,得到的功能材料渗透率最小,粒度分布最细,该功能材料适合用于小微孔隙的场合;当采用助熔煅烧硅藻土制备时,得到的功能材料渗透率最大,粒度分布最粗,该功能材料适合用于大孔隙的产品;当采用硅藻土、煅烧硅藻土和助熔煅烧硅藻土按照比例配合使用时,得到的功能材料渗透率居中,粒度分布粗细均匀,适合中等孔隙的产品。
按照本发明,所述的无机多孔材料为硅藻土或风选加工的碳粉或珍珠岩,所述的硅藻土要求经过水溶沉降分级出小于50微米以下粒度;
按照本发明,所述的有机粘合剂为粉末聚乙烯或淀粉;
按照本发明,所述的无机粘合剂为高岭土、膨润土、硅灰石或玻璃粉,要求微粉颗粒800目以上。
本发明还提供一种硅藻土功能材料的制备方法,包括:
步骤一:按配比将各原料混合,然后放入模具中压制成型,得到成型体;所述的成型过程是将混合料放入挤出设备或者压力设备中的模具进行压制,得到板状或者柱状的成型体;
步骤二:将成型体置入干燥室或干燥窑干燥,所述的干燥温度为20-200℃,优选为90-150℃,干燥时间为1.5-60h;所述的干燥时间根据成型品的大小而不同,当成型品较小时,干燥时间优选为1.5-4h,更优选为1.5-2.5h,当成型品较大时,干燥时间优选为30-60h,更优选为25-50h;
步骤三:干燥后成型体经整形放入加热液压机中直接热压成型或煅烧设备中煅烧,所述加热液压机的加热温度优选为200-300℃,所述的煅烧设备优选为倒焰窑或辊道窑,所述的煅烧温度为700-1250℃,优选为950-1200℃,煅烧时间为30-60min,所述的煅烧时间根据成型体的大小而不同,当成型品较小时,煅烧时间优选为30-40min,当成型品较大时,煅烧时间优选为60min,经煅烧后的成型体再经整形、雕刻或打印得到硅藻土功能材料。
下面结合具体实施例对本发明做进一步详细的描述。
实施例1
步骤一:按表1的配比将各原料混合,然后放入模具中压制成型,得到成型体;
步骤二:将成型体置入干燥室干燥,所述的干燥温度为120℃,干燥时间为2h;
步骤三:干燥后成型体经整形放入倒焰窑中煅烧,所述的煅烧温度为950℃,煅烧时间为30min,经煅烧后的成型体再经整形、雕刻或打印得到硅藻土功能材料。
实施例2
步骤一:按表1的配比将各原料混合,然后放入模具中压制成型,得到成型体;
步骤二:将成型体置入干燥室干燥,所述的干燥温度为150℃,干燥时间为12h;
步骤三:干燥后成型体经整形放入加热液压机中在250℃下直接热压成型,经热压后的成型体再经整形、雕刻或打印得到硅藻土功能材料。
实施例3
步骤一:按表1的配比将各原料混合,然后放入模具中压制成型,得到成型体;
步骤二:将成型体置入干燥室干燥,所述的干燥温度为160℃,干燥时间为14h;
步骤三:干燥后成型体经整形放入加热液压机中在260℃下直接热压成型,经热压后的成型体再经整形、雕刻或打印得到硅藻土功能材料。
实施例4
步骤一:按表1的配比将各原料混合,然后放入模具中压制成型,得到成型体;
步骤二:将成型体置入干燥室干燥,所述的干燥温度180℃,干燥时间为50h;
步骤三:干燥后成型体经整形放入倒焰窑煅烧,所述的煅烧温度为1200℃,煅烧时间为60min经煅烧后的成型体再经整形、雕刻或打印得到硅藻土功能材料。
表1
实验结果表明:实施例1选取煅烧硅藻土助滤剂100份,助熔煅烧硅藻土助滤剂0份。该组配方其渗透率是最小,粒度分布最细,在不加其他无机多孔材料的情况下,配无机粘合剂10份,水100份,由该组重量配比制成的本发明孔径<0.1微米,适用于小微孔隙的场合;
实施例2选取硅藻土原土10份,煅烧硅藻土20份,助熔煅烧硅藻土70份,总份100份,无机多孔材料珍珠岩(或其它有机多孔材料)12份,有机粘合剂聚乙烯(或其它有机粘合剂)6份,无机粘合剂膨润土15份(或其它无机粘合剂),水100份组成中等孔隙的产品,适用于中等孔隙的场合。
实施例3选取硅藻土原土10份,煅烧硅藻土20份,助熔煅烧硅藻土70份,总份100份,无机多孔材料珍珠岩(或其它有机多孔材料)20份,有机粘合剂聚乙烯(或其它有机粘合剂)10份,无机粘合剂膨润土20份(或其它无机粘合剂),水100份组成中等孔隙的产品,适用于中等孔隙的场合。
实施例4选取煅烧硅藻土助滤剂0份、助熔煅烧硅藻土助滤剂100份,而无硅藻土原土和煅烧硅藻土。该组所选用的两种助滤剂为渗透率最高,粒度分布最粗的,同时配以玻璃粉(或其他无机粘合剂)30份,水100份。该组重量配比制成的本发明适用于大孔隙产品。
Claims (9)
1.一种硅藻土功能材料,其特征在于,按照重量份数计,包括:
硅藻土或硅藻土助滤剂中的一种或两种混合100份
无机多孔材料0-25份
有机粘合剂0-30份
无机粘合剂10-30份
水100份。
所述的硅藻土中SiO2含量大于60%。
2.根据权利要求1所述的一种硅藻土功能材料,其特征在于,所述的硅藻土助滤剂为煅烧硅藻土或助熔煅烧硅藻土。
3.根据权利要求1所述的一种硅藻土功能材料,其特征在于,所述的混合中,硅藻土和硅藻土助滤剂的质量比为1:9。
4.根据权利要求1所述的一种硅藻土功能材料,其特征在于,所述的无机多孔材料为硅藻土或风选加工的碳粉或珍珠岩。
5.根据权利要求1所述的一种硅藻土功能材料,其特征在于,所述的有机粘合剂为粉末聚乙烯或淀粉。
6.根据权利要求1所述的一种硅藻土功能材料,其特征在于,所述的无机粘合剂为高岭土、膨润土、硅灰石或玻璃粉。
7.根据权利要求1所述的一种硅藻土功能材料的制备方法,其特征在于,包括:
步骤一:按配比将各原料混合,然后放入模具中压制成型,得到成型体;
步骤二:将成型体置入干燥室或干燥窑干燥,所述的干燥温度为20-200℃,干燥时间为1.5-60h;
步骤三:干燥后成型体经整形放入煅烧设备中煅烧,所述的煅烧温度为700-1250℃,煅烧时间为30-60min,经煅烧后的成型体再经整形、雕刻或打印得到硅藻土功能材料。
8.根据权利要求7所述的一种硅藻土功能材料的制备方法,其特征在于,所述的步骤二的干燥温度为90-150℃。
9.根据权利要求7所述的一种硅藻土功能材料的制备方法,其特征在于,所述的步骤三的煅烧温度为950-1200℃。
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