CN110436939A - 一种石墨尾矿基发泡墙体砌块的干法制备工艺 - Google Patents
一种石墨尾矿基发泡墙体砌块的干法制备工艺 Download PDFInfo
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Abstract
一种石墨尾矿基发泡墙体砌块的干法制备工艺,该工艺以石墨开采生产的废弃物石墨尾矿为主原料,辅以添加特定配方比例的矿物原料、化工原料和发泡剂SiC,多种物料协同配合,制备得到的发泡墙体砌块导热系数得到显著降低,为0.10w/(m▪k)以下,与现有技术中的发泡砌块相比具有优异的保温性能,且容重小,为0.45kg/m3以下,抗压强度可达5.12Mpa以上,具有保温、轻质、高强的特点。同时,以石墨尾矿为主原料的配方本身具有节能减排的优势,不仅降低了尾矿废料对土壤、环境的污染,提高了固体废弃物的再生利用率,还大大降低了砌块的生产成本,具有较好的经济效益。
Description
技术领域
本发明涉及砌块的生产技术领域,具体的说是一种利用石墨尾矿为主原料生产发泡墙体砌块的工艺方法。
技术背景
石墨是一种化学和电器工业必不可少的无机非金属原料,同时在国防工业和高科技产品中也发挥着不可替代的作用。但是,从石墨矿中选取石墨后里留下了大量的尾矿,其堆积不仅占用大量的土地,还严重污染生态环境。
随着建筑业的迅速发展以及墙体材料的革新与建筑节能的要求,发泡墙体因其特性受到广泛的重视。现有技术中的发泡墙体砌块大多保温性能较差,不能满足建筑节能中对于外墙保温的诉求。同时,现有的发泡陶瓷制备工艺在原料的处理上通常采用湿法工艺为主,其特点是将原料按配方完成配料后投入球磨机中进行研磨混料,再经过喷雾造粒过程得到所需混合料,之后压坯进行烧制。这种湿法工艺因为水分的添加和存在,造成耗水量大,步骤繁琐,耗能较高,不能满足现代节能减排的工艺生产要求。
目前,现有技术中还没有利用石墨尾矿进行干法制备发泡墙体砌块的相关报道出现,急需填补石墨尾矿在此领域的空白。
发明内容
本发明的技术目的为:通过发泡砌块原料的有效调配和不同物料之间粒径大小的精准把控,在不加水的前提下,利用干法,制备出一种保温性能得到显著提高,耐火能力强,且抗压强度较好的发泡墙体砌块,来克服现有技术中发泡陶瓷耗水量大,步骤繁琐,耗能高,保温性差的技术缺陷。
为实现上述技术目的,本发明所采用的技术方案为:一种石墨尾矿基发泡墙体砌块的干法制备工艺,包括以下步骤:
步骤一、按照重量份数,取60~85份石墨尾矿置于粉碎机中粉碎成粒径为300-350目的石墨尾矿微粉,备用;
步骤二、按照重量份数,取10~35份矿物原料、2~10份化工原料和0.2-0.6份SiC,分别置于粉碎机中粉碎成粒径为150-200目的矿物原料粉、粒径为200~250目的化工原料粉和粒径为500~800目的SiC粉,备用;
步骤三、将步骤一制得的石墨尾矿微粉,以及步骤二制得的矿物原料粉、化工原料粉和SiC粉转置于混料机中进行混合12-25min,制得混合料,备用;
步骤四、在辊道窑的辊轴上,利用棚板搭设一个中空的腔体状模具,之后,在中空腔体状模具的外侧布置挡板,并在中空腔体状模具的内表面铺设陶瓷纤维纸,然后,将步骤三制得的混合料铺设在陶瓷纤维纸上,之后,进行表面刮平成厚度为50~150mm的预制件,备用;
步骤五、控制辊道窑内温度不断升高至1160~1200℃,并在该温度下进行保温烧制60-80min,之后,自然冷却至窑内温度低于80℃后,出窑卸板,即得成品发泡墙体砌块。
进一步的,所述的矿物原料为钠长石、钾长石、黑泥、石英、锂云母、硅灰石、海泡石、滑石、方解石和瓷石中的至少一种。
进一步的,所述的化工原料为玻璃粉、碳酸钡和硝酸钠中的至少一种。
进一步的,在步骤四中,所述的棚板为堇青石或莫来石。
进一步的,在步骤五中,所述辊道窑的升温速率为5℃/min。
有益效果:
1、本发明的发泡墙体砌块,以石墨开采生产的废弃物石墨尾矿为主原料,辅以添加特定配方比例的矿物原料、化工原料和发泡剂SiC,多种物料协同配合,制备得到的发泡墙体砌块导热系数得到显著降低,为0.10w/(m▪k)以下,与现有技术中的发泡砌块相比具有优异的保温性能,且容重较小,为0.45kg/m3以下,抗压强度可达5.12Mpa以上,具有保温、轻质、高强的特点。能够较好的满足建筑材料领域对于节能、环保、高强、防火的要求。同时,以石墨尾矿为主原料的配方本身具有节能减排的优势,不仅降低了尾矿废料对土壤、环境的污染,提高了固体废弃物的再生利用率,还大大降低了砌块的生产成本,具有较好的经济效益。
2、本发明的制备工艺,在步骤中摒弃了现有技术常规操作中必备物料——水的添加,整个生产工艺过程均为干法工艺,从而大大节约了水源,减少了能耗,也精简了步骤。工艺流程中无需进行喷雾造粒、加水混料、坯体压制,坯料烧结脱水等繁琐步骤。而是利用不同功用物料在发泡陶瓷砌块烧制过程中所参与的化学反应,扮演的角色,自身的物化性质、分子结构等因素,通过不同原料之间特定粒径比例的调配和后续步骤中充分的混合,外加颗粒级配的方式来更好的把控混料的均匀度,使小颗粒自动填充至大颗粒的孔隙当中,并在后续的烧制过程中与大颗粒进行更好的接触、反应、融合,完成颗粒装配和微粒发泡作用过程,进而烧制熔融成容重小,内部多孔结构均匀、复杂,导热系数小,保温性好的石墨尾矿基发泡墙体砌块。
具体实施方式
下面将结合几个具体实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护范围。
本发明所要解决的主要是石墨尾矿带来的生态环境污染问题,为此发明出一种利用石墨尾矿制备发泡墙体砌块的方法。
一种石墨尾矿基发泡墙体砌块的干法制备工艺,包括以下步骤:
步骤一、按照重量份数,取60~85份石墨尾矿置于粉碎机中粉碎成粒径为300-350目的石墨尾矿微粉,备用;
步骤二、按照重量份数,取10~35份矿物原料、2~10份化工原料和0.2-0.6份SiC,分别置于粉碎机中粉碎成粒径为150-200目的矿物原料粉、粒径为200~250目的化工原料粉和粒径为500~800目的SiC粉,备用;
所述的矿物原料为钠长石、钾长石、黑泥、石英、锂云母、硅灰石、海泡石、滑石、方解石和瓷石中的至少一种。
所述的化工原料为玻璃粉、碳酸钡和硝酸钠中的至少一种。
步骤三、将步骤一制得的石墨尾矿微粉,以及步骤二制得的矿物原料粉、化工原料粉和SiC粉转置于混料机中进行混合12-25min,制得混合料,备用;
步骤四、在辊道窑的辊轴上,利用堇青石或莫来石棚板搭设一个中空的腔体状模具,之后,在中空腔体状模具的外侧布置挡板,并在中空腔体状模具的内表面铺设陶瓷纤维纸,然后,将步骤三制得的混合料铺设在陶瓷纤维纸上,之后,进行表面刮平成厚度为50~150mm的预制件,备用;
步骤五、控制辊道窑内温度不断升高至1160~1200℃,并在该温度下进行保温烧制60-80min,之后,自然冷却至窑内温度低于80℃后,出窑卸板,即得成品发泡墙体砌块。
进一步的,在步骤五中,所述辊道窑的升温速率为5℃/min。
本发明制备得到的发泡墙体砌块具有多孔结构。发泡墙体砌块体积密度0.3~0.6g/cm3,厚度可根据需求制备成50~150mm的规格。
通常,作为外墙建筑材料使用的发泡墙体砌块需要满足一定的强度要求,抗压强度保证在4Mpa以上才能保证安全使用。
本发明制备的发泡墙体砌块抗压强度可达5.12Mpa以上,具备一定的力学强度,能够保证建筑的安全可靠。可做装配式建筑围护材料,也可作为高层建筑中的隔墙板使用,砌块内部形成有细致、均匀的多孔结构,该多孔结构能够提供材料良好的保温性能,能够实现节能建筑的基本要求。
实施例 1
一种石墨尾矿基发泡墙体砌块的干法制备工艺,包括以下步骤:
(1)、称取石墨尾矿6.6kg、置于粉碎机中粉碎成粒径为350目的石墨尾矿微粉,备用;
(2)、称取钠长石0.9kg、钾长石0.8kg、黑泥0.6kg、海泡石0.5kg、锂云母0.3kg和滑石0.3kg置于粉碎机中粉碎成粒径为150目的矿物原料粉,备用;
(3)、称取碳酸钡1kg,置于粉碎机中粉碎成粒径为220目的化工原料粉,备用;
(4)、称取SiC 0.05kg,置于粉碎机中粉碎成粒径为500目的SiC粉,备用;
(5)、将上述石墨尾矿微粉、矿物原料粉、化工原料粉和SiC粉转置于混料机中进行混合15min,制得混合料,备用;
(6)、组装模具,并在内侧布置陶瓷纤维纸,将混合料平铺至模具内,之后,进行表面刮平成厚度为60m的预制件,备用;
(7)、控制辊道窑内温度不断升高至1180℃,并在该温度下进行保温烧制70min,之后,自然冷却至窑内温度低于80℃后,出窑卸板,即得成品石墨尾矿基发泡墙体砌块。
经测定,本实施例制得的石墨尾矿基发泡墙体砌块容重为0.44kg/m3,导热系数为0.094w/(m▪k),抗压强度为5.12Mpa。
实施例2
一种石墨尾矿基发泡墙体砌块的干法制备工艺,包括以下步骤:
(1)、称取石墨尾矿7.6kg、置于粉碎机中粉碎成粒径为300目的石墨尾矿微粉,备用;
(2)、称取钠长石0.9kg、黑泥0.6kg、锂云母0.3kg和方解石0.3kg置于粉碎机中粉碎成粒径为200目的矿物原料粉,备用;
(3)、称取玻璃粉0.2kg,置于粉碎机中粉碎成粒径为250目的化工原料粉,备用;
(4)、称取SiC 0.03kg,置于粉碎机中粉碎成粒径为600目的SiC粉,备用;
(5)、将上述石墨尾矿微粉、矿物原料粉、化工原料粉和SiC粉转置于混料机中进行混合15min,制得混合料,备用;
(6)、组装模具,并在内侧布置陶瓷纤维纸,将混合料平铺至模具内,之后,进行表面刮平成厚度为80m的预制件,备用;
(7)、控制辊道窑内温度不断升高至1180℃,并在该温度下进行保温烧制70min,之后,自然冷却至窑内温度低于80℃后,出窑卸板,即得成品石墨尾矿基发泡墙体砌块。
经测定,本实施例制得的石墨尾矿基发泡墙体砌块容重为0.41kg/m3,导热系数为0.087w/(m▪k),抗压强度为5.84Mpa。
实施例3
一种石墨尾矿基发泡墙体砌块的干法制备工艺,包括以下步骤:
(1)、称取石墨尾矿8.2kg、置于粉碎机中粉碎成粒径为350目的石墨尾矿微粉,备用;
(2)、称取瓷石0.9kg、锂云母0.3kg和硅灰石0.3kg置于粉碎机中粉碎成粒径为180目的矿物原料粉,备用;
(3)、称取玻璃粉0.2kg、碳酸钡0.1kg,置于粉碎机中粉碎成粒径为200目的化工原料粉,备用;
(4)、称取SiC 0.05kg,置于粉碎机中粉碎成粒径为500目的SiC粉,备用;
(5)、将上述石墨尾矿微粉、矿物原料粉、化工原料粉和SiC粉转置于混料机中进行混合20min,制得混合料,备用;
(6)、组装模具,并在内侧布置陶瓷纤维纸,将混合料平铺至模具内,之后,进行表面刮平成厚度为50m的预制件,备用;
(7)、控制辊道窑内温度不断升高至1180℃,并在该温度下进行保温烧制80min,之后,自然冷却至窑内温度低于80℃后,出窑卸板,即得成品石墨尾矿基发泡墙体砌块。
经测定,本实施例制得的石墨尾矿基发泡墙体砌块容重为0.39kg/m3,导热系数为0.079w/(m▪k),抗压强度为5.33Mpa。
实施例4
一种石墨尾矿基发泡墙体砌块的干法制备工艺,包括以下步骤:
(1)、称取石墨尾矿6.0kg、置于粉碎机中粉碎成粒径为320目的石墨尾矿微粉,备用;
(2)、称取钠长石0.4kg、钾长石0.3kg、黑泥0.4 kg、石英0.5 kg、瓷石0.9 kg、锂云母0.4kg、滑石0.3 kg、海泡石0.1 kg和硅灰石0.2 kg置于粉碎机中粉碎成粒径为150目的矿物原料粉,备用;
(3)、称取玻璃粉0.3 kg、碳酸钡0.3kg和硝酸钠0.2 kg置于粉碎机中粉碎成粒径为220目的化工原料粉,备用;
(4)、称取SiC 0.06kg,置于粉碎机中粉碎成粒径为800目的SiC粉,备用;
(5)、将上述石墨尾矿微粉、矿物原料粉、化工原料粉和SiC粉转置于混料机中进行混合25min,制得混合料,备用;
(6)、组装模具,并在内侧布置陶瓷纤维纸,将混合料平铺至模具内,之后,进行表面刮平成厚度为70m的预制件,备用;
(7)、控制辊道窑内温度不断升高至1160℃,并在该温度下进行保温烧制80min,之后,自然冷却至窑内温度低于80℃后,出窑卸板,即得成品石墨尾矿基发泡墙体砌块。
经测定,本实施例制得的石墨尾矿基发泡墙体砌块容重为0.42kg/m3,导热系数为0.097w/(m▪k),抗压强度为6.05Mpa。
实施例5
一种石墨尾矿基发泡墙体砌块的干法制备工艺,包括以下步骤:
(1)、称取石墨尾矿8.5kg、置于粉碎机中粉碎成粒径为350目的石墨尾矿微粉,备用;
(2)、称取黑泥0.3kg、海泡石0.4kg、锂云母0.2kg和方解石0.1kg置于粉碎机中粉碎成粒径为150目的矿物原料粉,备用;
(3)、称取硝酸钠0.2 kg置于粉碎机中粉碎成粒径为220目的化工原料粉,备用;
(4)、称取SiC 0.02kg,置于粉碎机中粉碎成粒径为500目的SiC粉,备用;
(5)、将上述石墨尾矿微粉、矿物原料粉、化工原料粉和SiC粉转置于混料机中进行混合12min,制得混合料,备用;
(6)、组装模具,并在内侧布置陶瓷纤维纸,将混合料平铺至模具内,之后,进行表面刮平成厚度为150m的预制件,备用;
(7)、控制辊道窑内温度不断升高至1200℃,并在该温度下进行保温烧制60min,之后,自然冷却至窑内温度低于80℃后,出窑卸板,即得成品石墨尾矿基发泡墙体砌块。
经测定,本实施例制得的石墨尾矿基发泡墙体砌块容重为0.47kg/m3,导热系数为0.095w/(m▪k),抗压强度为5.32Mpa。
以上公开的仅为本申请的几个具体实施例,但并非用于限定本发明的保护范围。任何熟悉本领域的技术人员,在本发明的基础上所做的改动与润饰,都应属于本发明的保护范围。
Claims (5)
1.一种石墨尾矿基发泡墙体砌块的干法制备工艺,其特征在于,包括以下步骤:
步骤一、按照重量份数,取60~85份石墨尾矿置于粉碎机中粉碎成粒径为300-350目的石墨尾矿微粉,备用;
步骤二、按照重量份数,取10~35份矿物原料、2~10份化工原料和0.2-0.6份SiC,分别置于粉碎机中粉碎成粒径为150-200目的矿物原料粉、粒径为200~250目的化工原料粉和粒径为500~800目的SiC粉,备用;
步骤三、将步骤一制得的石墨尾矿微粉,以及步骤二制得的矿物原料粉、化工原料粉和SiC粉转置于混料机中进行混合12-25min,制得混合料,备用;
步骤四、在辊道窑的辊轴上,利用棚板搭设一个中空的腔体状模具,之后,在中空腔体状模具的外侧布置挡板,并在中空腔体状模具的内表面铺设陶瓷纤维纸,然后,将步骤三制得的混合料铺设在陶瓷纤维纸上,之后,进行表面刮平成厚度为50~150mm的预制件,备用;
步骤五、控制辊道窑内温度不断升高至1160~1200℃,并在该温度下进行保温烧制60-80min,之后,自然冷却至窑内温度低于80℃后,出窑卸板,即得成品发泡墙体砌块。
2.根据权利要求1所述的一种石墨尾矿基发泡墙体砌块的干法制备工艺,其特征在于:所述的矿物原料为钠长石、钾长石、黑泥、石英、锂云母、硅灰石、海泡石、滑石、方解石和瓷石中的至少一种。
3.根据权利要求1所述的一种石墨尾矿基发泡墙体砌块的干法制备工艺,其特征在于:所述的化工原料为玻璃粉、碳酸钡和硝酸钠中的至少一种。
4.根据权利要求1所述的一种石墨尾矿基发泡墙体砌块的干法制备工艺,其特征在于:在步骤四中,所述的棚板为堇青石或莫来石。
5.根据权利要求1所述的一种石墨尾矿基发泡墙体砌块的干法制备工艺,其特征在于:在步骤五中,所述辊道窑的升温速率为5℃/min。
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