CN110590329A - Foamed ceramic and preparation method thereof - Google Patents
Foamed ceramic and preparation method thereof Download PDFInfo
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- CN110590329A CN110590329A CN201910761831.3A CN201910761831A CN110590329A CN 110590329 A CN110590329 A CN 110590329A CN 201910761831 A CN201910761831 A CN 201910761831A CN 110590329 A CN110590329 A CN 110590329A
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- 239000000919 ceramic Substances 0.000 title claims abstract description 73
- 238000002360 preparation method Methods 0.000 title abstract description 20
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 40
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 39
- 229910001845 yogo sapphire Inorganic materials 0.000 claims abstract description 39
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 36
- 239000004927 clay Substances 0.000 claims abstract description 22
- 239000002994 raw material Substances 0.000 claims abstract description 19
- 239000004088 foaming agent Substances 0.000 claims abstract description 17
- 239000003381 stabilizer Substances 0.000 claims abstract description 16
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 14
- 238000010521 absorption reaction Methods 0.000 claims abstract description 7
- 238000010304 firing Methods 0.000 claims description 31
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 29
- 238000005245 sintering Methods 0.000 claims description 29
- NUJOXMJBOLGQSY-UHFFFAOYSA-N manganese dioxide Chemical group O=[Mn]=O NUJOXMJBOLGQSY-UHFFFAOYSA-N 0.000 claims description 28
- 239000002002 slurry Substances 0.000 claims description 28
- 238000005406 washing Methods 0.000 claims description 23
- 239000000843 powder Substances 0.000 claims description 22
- 239000000203 mixture Substances 0.000 claims description 17
- 238000000034 method Methods 0.000 claims description 15
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 13
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 13
- 238000005469 granulation Methods 0.000 claims description 11
- 230000003179 granulation Effects 0.000 claims description 11
- 239000002689 soil Substances 0.000 claims description 11
- 238000000498 ball milling Methods 0.000 claims description 10
- 239000004576 sand Substances 0.000 claims description 10
- 239000007921 spray Substances 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 8
- 238000002156 mixing Methods 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- 238000002485 combustion reaction Methods 0.000 claims description 4
- 238000000227 grinding Methods 0.000 claims description 4
- 239000011159 matrix material Substances 0.000 abstract 1
- 239000000463 material Substances 0.000 description 14
- 230000008569 process Effects 0.000 description 10
- 239000010438 granite Substances 0.000 description 9
- 230000006872 improvement Effects 0.000 description 8
- 239000011734 sodium Substances 0.000 description 8
- 239000002699 waste material Substances 0.000 description 8
- 239000002585 base Substances 0.000 description 7
- 238000005265 energy consumption Methods 0.000 description 7
- 239000002245 particle Substances 0.000 description 6
- 239000010433 feldspar Substances 0.000 description 5
- 239000011449 brick Substances 0.000 description 4
- 229910052500 inorganic mineral Inorganic materials 0.000 description 4
- 239000011707 mineral Substances 0.000 description 4
- 238000005498 polishing Methods 0.000 description 4
- 239000002910 solid waste Substances 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 3
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000005187 foaming Methods 0.000 description 3
- 239000010445 mica Substances 0.000 description 3
- 229910052618 mica group Inorganic materials 0.000 description 3
- 229910052863 mullite Inorganic materials 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000003292 glue Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000005065 mining Methods 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 239000004575 stone Substances 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 230000002195 synergetic effect Effects 0.000 description 2
- 239000004604 Blowing Agent Substances 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000002734 clay mineral Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000010881 fly ash Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
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- C04B33/00—Clay-wares
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- C04B33/13—Compounding ingredients
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- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
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- C04B33/1324—Recycled material, e.g. tile dust, stone waste, spent refractory material
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
- C04B38/063—Preparing or treating the raw materials individually or as batches
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Abstract
The invention discloses a foamed ceramic which is mainly prepared from the following raw materials in parts by weight: 90-95 parts of Luoyuan red tailings, 1-9 parts of clay, 0.1-3 parts of foaming agent and 0.1-1 part of stabilizer; the Luoyuan red tailings mainly comprise the following components in percentage by weight: SiO 22 68～73％，Al2O3 12～15％，Fe2O3 1.2～2％，CaO 0.5～1.5％，MgO 0.2～0.5％，K2O 4～5.5％，Na23-5% of O and 0.5-3% of LOI. The invention also discloses a preparation method of the foamed ceramic. According to the invention, the Rouyan red tailings are used as the main matrix material to prepare the foamed ceramic tile, so that the resource utilization of the Rouyan red tailings is effectively realized;the prepared foamed ceramic tile has high compressive strength, low water absorption and low heat conductivity coefficient.
Description
Technical Field
The invention relates to the field of inorganic non-metallic materials, in particular to foamed ceramic and a preparation method thereof.
Background
Luoyuan red is granite produced in Luoyuan county, Fuzhou, Fujian province, has bright color and outstanding decorative performance, and is widely used as a material for plates, pavements, table tops, sculptures, various buildings and garden stones. In the process of Luoyuan red mining, a large amount of Luoyuan red tailings are generated, and huge pressure is caused on the local ecological environment. Therefore, how to utilize the resource of the Rousian red tailings is an urgent problem to be solved.
Chinese patent CN108558359A discloses a technical scheme for preparing water permeable bricks by utilizing Rouyan red, which adopts 80-100 parts of crushed stone materials, 3-12 parts of bonding base materials and 3-12 parts of liquid glue to prepare the sintered water permeable bricks. However, the water permeable brick (square brick) has low added value; and because the plasticity of the Rouyaoyuan red is poor, a large amount of bonding base materials and liquid glue are added in the formula, so that the use amount of the Rouyaoyuan red is reduced. Therefore, large-scale resource utilization and high-added-value utilization of the Roots Red tailings cannot be realized.
On the other hand, the existing foamed ceramics for construction mostly adopt polishing waste materials or other waste materials (such as granite waste materials, fly ash and the like) of a tile factory as base materials; among them, polishing waste and the like are greatly affected by regionality. The polishing waste residue of different production areas and different products has different components, and the stability of the slag charge is poor. The traditional granite waste material is low in utilization rate due to the specificity of components. For example, in chinese patent CN106187087A, a facing composite foamed ceramic based on granite tailings is disclosed, wherein a base material comprises 60-90% of granite tailings, 10-25% of clay, 1-10% of fluxing agent, 1-10% of foaming agent, 0.5-2% of stabilizer, and 0-2% of debonder, and the utilization efficiency of granite waste residue is low, and the additive amount is high, the firing cycle is long, and the energy consumption is high, so that the production cost is high.
Disclosure of Invention
The invention aims to solve the technical problems of providing a foamed ceramic which has high utilization rate of solid wastes, low energy consumption for firing and low production cost; and the foamed ceramic has low water absorption, high strength and small heat conductivity coefficient.
The invention also aims to provide a preparation method of the foamed ceramic.
In order to solve the technical problems, the invention provides a foamed ceramic which is mainly prepared from the following raw materials in parts by weight:
90-95 parts of Luoyuan red tailings, 1-9 parts of clay, 0.1-3 parts of foaming agent and 0.1-1 part of stabilizer;
the sum of the weight parts of the raw materials is 100 parts;
the Luoyuan red tailings mainly comprise the following components in percentage by weight: SiO 22 68～73％，Al2O312～15％，Fe2O3 1.2～2％，CaO 0.5～1.5％，MgO 0.2～0.5％，K2O 4～5.5％，Na2O 3～5％，LOI 0.5～3％。
As an improvement of the technical scheme, the clay is one or more of Rouyuan sand-coated soil, washing mud, black mud, port mud or sea mud.
As an improvement of the technical scheme, the Rouyuan sand-coated soil mainly comprises the following components in percentage by weight: SiO 22 70～75％，Al2O3 12～16％，Fe2O3 0.5～1.5％，CaO 0.3～0.5％，MgO 0.01～0.1％，K2O 4～6％，Na2O 3～5％，LOI 1～5％；
The washing mud mainly comprises the following components in percentage by weight: SiO 22 45～50％，Al2O3 32～36％，Fe2O3 2～3％，CaO 0.01～0.1％，MgO 0.3～0.5％，K2O 2～3％，Na2O 0.3～0.8％，LOI 8～12％；
The black mud mainly comprises the following components in percentage by weight: SiO 22 61～65％，Al2O3 20～24％，Fe2O3 1.5～3％，CaO 0.3～1％，MgO 0.3～0.5％，K2O 1～2％，Na2O 0.2～0.6％，LOI 5～10％；
The port mud mainly comprises the following components in percentage by weight: SiO 22 68～72％，Al2O3 12～15％，Fe2O3 2～3％，CaO 3～5％，MgO 1.5～3％，K2O 3.5～5％，Na2O 1.5～3.5％，LOI 1～8％；
The sea mud mainly comprises the following components in percentage by weight: SiO 22 68～72％，Al2O3 11～14％，Fe2O3 3～4％，CaO 2～3.5％，MgO 1.5～2.5％，K2O 3～5％，Na2O 1～3％，LOI 3～10％。
As an improvement of the technical scheme, the clay is selected from one or more of washing mud, harbor mud and sea mud.
As an improvement of the technical scheme, the foaming agent is one or more of silicon carbide, carbon powder or ceramic grinding block reclaimed materials; the stabilizing agent is manganese dioxide.
As an improvement of the technical scheme, the foaming agent is silicon carbide, and the stabilizing agent is manganese dioxide.
As an improvement of the technical scheme, the compressive strength of the foamed ceramic is not less than 7MPa, and the volume density of the foamed ceramic is 200-400 kg/m3The heat conductivity coefficient is less than or equal to 0.13W/m ℃, the fire resistance limit is more than or equal to 1h, the combustion grade is A1 grade, the water absorption rate is less than or equal to 0.5 percent, IRa≤1.0，Ir≤1.0。
Correspondingly, the invention also discloses a preparation method of the foamed ceramic, which comprises the following steps:
(1) uniformly mixing various raw materials according to a formula to obtain a mixture;
(2) performing ball milling on the mixture to obtain slurry;
(3) carrying out spray granulation on the slurry to obtain powder;
(4) distributing the powder into a high-temperature sagger;
(5) placing the high-temperature sagger in a kiln for sintering to obtain a finished foamed ceramic product;
wherein the fineness of the slurry is that the screen residue of a 250-mesh screen is less than 0.5%.
As an improvement of the technical scheme, in the step (5), a roller kiln is adopted for firing; the firing temperature is 1150-1180 ℃, and the firing period is 6-10 h.
As an improvement of the technical scheme, in the step (5), a tunnel kiln is adopted for firing, the firing temperature is 1150-1180 ℃, and the firing period is 10-15 hours.
The implementation of the invention has the following beneficial effects:
1. the invention adopts the Royuan red tailings as the main raw material to prepare the foamed ceramic, the ratio of the Royuan red tailings reaches 90-95 percent, the resource utilization and high value-added utilization of the Royuan red tailings are realized, the energy is saved, the environment is protected, and the production cost of the foamed ceramic is reduced.
2. K in the Rouyan red tailings of the invention2O、Na2The content of O is high, namely the content of potassium feldspar components is high; the firing temperature of the foamed ceramic using the Rouyan red tailings as the main raw material is low, and the foamed ceramic is suitable for quick firing, so that the firing energy consumption is greatly reduced, and the production cost is saved.
3. The invention effectively eliminates the defect of poor plasticity of the Rouyan red tailings by adjusting the proportion of the Rouyan red tailings and the clay in the formula and by cooperatively controlling the preparation method, ensures that slurry has good suspension property in the ball milling process and powder has good fluidity in the powder preparation process, and ensures that the preparation process is smoothly carried out.
4. The volume density and the heat conductivity coefficient of the foamed ceramic are reduced by controlling the foaming agent and the stabilizer, so that the foamed ceramic has good heat insulation performance and heat preservation performance.
Drawings
FIG. 1 is a flow chart of a method for preparing a foamed ceramic according to the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings. It is only noted that the invention is intended to be limited to the specific forms set forth herein, including any reference to the drawings, as well as any other specific forms of embodiments of the invention.
The existing utilization technology of the Luoyuan red tailings has low utilization rate and low added value. Therefore, the invention provides a foaming ceramic tile which is mainly prepared from the following raw materials in parts by weight:
90-95 parts of Luoyuan red tailings, 1-9 parts of clay, 0.1-3 parts of foaming agent and 0.1-1 part of stabilizer;
wherein the sum of the weight parts of the raw materials is 100 parts;
the Luoyuan red tailings mainly comprise the following components in percentage by weight: SiO 22 68～73％，Al2O312～15％，Fe2O3 1.2～2％，CaO 0.5～1.5％，MgO 0.2～0.5％，K2O 4～5.5％，Na23-5% of O and 0.5-3% of LOI. In addition, the components may contain small amounts of TiO2And the like, but the total amount thereof does not exceed 2 wt%. The Luoyuan red tailings are leftover materials left after Luoyuan red mining, some sawdust and the like. The composition is the same as the mineral phase homogeneous Rouyuan Red. From the mineralogy perspective, Luoyuan red belongs to granite, and granite mainly comprises mica, quartz and feldspar; in particular, in the Roots Red tailings, the content of potassium and sodium is high (K)2O+Na2O is more than or equal to 8.5wt percent), so compared with the common granite, the feldspar has relatively higher component content, which is more beneficial to quick firing and shortens the firing period; meanwhile, the sintering temperature of the foamed ceramic can be effectively reduced under the condition of not adding other fluxing agents, and the sintering energy consumption is greatly reduced. In general, when the common foamed ceramics of solid waste base (tailings and polishing slag) are sintered in a roller kiln, the sintering period is about 9-14h, but the invention only needs 6-10 h; when the foamed ceramics are sintered in a tunnel kiln, the sintering period of the common solid waste base foamed ceramics is 24-28h, but the invention only needs 10-15 h. This greatly reduces the energy consumption of firing.
In the Rouyan red tailings of the invention, Al2O312-15 wt% of Al2O3Mainly from feldspar and mica; the mica can be gradually converted into mullite in the high-temperature sintering process, so that the strength is provided for the foamed ceramic; the feldspar mineral can promote the crystallization transformation of mullite and improve the strength. Preferably, Al2O3The ratio of (A) to (B) is 14 to 15 wt%.
In addition, the existing amount of the Rouyan red tailings is rich, and the chemical components are stable, so that the addition amount of the Rouyan red tailings in the foamed ceramic is increased; meanwhile, the Rouyan red tailings do not need to be accumulated and homogenized for a large amount of time like traditional ceramic manufacturers, and the production efficiency is improved to a certain extent.
The method adopts the Luoyuan red tailings as a main base material to produce the foamed ceramic (the percentage is 90-95%), but because the Luoyuan red tailings belong to ridge minerals, the Luoyuan red tailings cannot be well suspended in the ball milling and ageing processes, and the homogenization effect is poor; in addition, a large amount of the Roots red tailings cannot form larger particles in the process of spray granulation, and the obtained powder is poor in flowability and difficult to distribute. Therefore, 1-9 parts of clay is added in the formula, so that the plasticity can be provided, and the process requirements in the ball milling and powder making processes are met. Preferably, the weight part of the clay is 1-5 parts. It should be noted that, because the clay used in the invention is a strong plastic clay, the average particle size is small, and the slurry is often difficult to dispergate, on the basis of considering the strength of molding, dispergation, powder making and foamed ceramics, the clay is added in 1-5 parts by weight.
Specifically, the clay is one or more of Rouyuan sand-coated soil, washing mud, black mud, harbor mud or sea mud.
Wherein, the Luoyuan sand-coated soil refers to sand on the surface layer of Luoyuan red mine, and mainly comprises the following components in percentage by weight: SiO 22 70～75％，Al2O3 12～16％，Fe2O3 0.5～1.5％，CaO 0.3～0.5％，MgO 0.01～0.1％，K2O 4～6％，Na23-5% of O and 1-5% of LOI; the contents of clay mineral phase and feldspar mineral phase in the Luoyuan sand coated soil are high, certain plasticity can be provided, and the firing temperature can be further reduced.
Wherein the washing mud is waste mud obtained by washing the Luoyuan sand-covered soil, and the average grain size of the washing mud is extremely small (D50 is less than 1 mu m); the plasticity is extremely strong. The washing mud mainly comprises the following components in percentage by weight: SiO 22 45～50％，Al2O3 32～36％，Fe2O32～3％，CaO 0.01～0.1％，MgO 0.3～0.5％，K2O 2～3％，Na2O 0.3～0.8 percent and LOI 8-12 percent; the content of alumina in the washing mud is up to 32-36%, and the washing mud can be converted into mullite in the high-temperature sintering process, so that the strength of the foamed ceramic is improved.
Wherein the black mud mainly comprises the following components in percentage by weight: SiO 22 61～65％，Al2O3 20～24％，Fe2O3 1.5～3％，CaO 0.3～1％，MgO 0.3～0.5％，K2O 1～2％，Na2O 0.2～0.6％，LOI 5～10％。
Wherein, the harbour mud is the mud between the Luo Yuan bay and the river; the paint mainly comprises the following components in percentage by weight: SiO 22 68～72％，Al2O3 12～15％，Fe2O3 2～3％，CaO 3～5％，MgO 1.5～3％，K2O 3.5～5％，Na21.5-3.5% of O and 1-8% of LOI. The Hongkong pottery has a small average particle size (D50 < 1 μm) and good plasticity.
Wherein the sea mud is sea mud of a Rouyuan gulf; the paint mainly comprises the following components in percentage by weight: SiO 22 68～72％，Al2O3 11～14％，Fe2O3 3～4％，CaO 2～3.5％，MgO 1.5～2.5％，K2O 3～5％，Na21-3% of O and 3-10% of LOI. The sea mud has small average particle size (D50 < 1 μm) and good plasticity.
The invention selects the Royuan red tailings, the Royuan sand-coated soil, the washing mud, the harbor mud and the sea mud as main raw materials (the ratio is more than or equal to 97 percent), realizes the comprehensive resource utilization of a large amount of solid wastes in the Royuan area, and is energy-saving and environment-friendly.
Preferably, in the present invention, the clay is one or more selected from washing mud, harbor mud or sea mud. Further preferably, the clay in the invention is a mixture of washing clay and harbor mud, and the washing clay: 2-3 of port road mud: 1; the washing mud and the port mud have strong plasticity, and the port mud contains high alkali metal and alkaline earth metal contents, so that the firing energy consumption is reduced.
The formula of the invention also contains 0.1-3 parts of foaming agent; the foaming agent is selected from one or more of silicon carbide, carbon powder or ceramic grinding block reclaimed materials (the main components are silicon carbide and resin); preferably, silicon carbide is selected. The foaming agent can be decomposed to generate gas in the high-temperature sintering process, and the volume density and the heat conductivity coefficient of the foamed ceramic are reduced. Preferably, the addition weight part of the foaming agent is 0.1-1 part, and the foaming agent in the range has a better foaming effect.
In addition, in order to optimize the foaming effect and reduce the thermal conductivity and the volume density, a small amount of stabilizer needs to be added into the formula. Specifically, in the invention, the addition amount of the stabilizer is 0.1-1 part, and the stabilizer is manganese dioxide. Manganese dioxide decomposes at about 900 ℃ to release oxygen, promoting decomposition of the blowing agent. Preferably, the addition weight part of the stabilizer is 0.5-1 part.
Preferably, the foamed ceramic is prepared from the following raw materials in parts by weight: 92-95 parts of Luoyuan red tailings, 2-4.5 parts of washing mud, 0.5-2 parts of Hongkong mud, 0.5-1.5 parts of silicon carbide and 0.5-1 part of manganese dioxide; the foamed ceramic in the proportion range has higher compressive strength, lower water absorption, heat conductivity coefficient and volume density.
In order to improve various properties of the foamed ceramic of the present invention, a specific preparation method needs to be matched, and specifically, referring to fig. 1, the preparation method of the foamed ceramic of the present invention includes the following steps:
s1: uniformly mixing various raw materials according to a formula to obtain a mixture;
s2: performing ball milling on the mixture to obtain slurry;
wherein the fineness of the slurry is that the screen residue of a 250-mesh screen is less than 0.5%. It is noted that in the production process of general foamed ceramics, the fineness is controlled to be about 3-5% of the sieve residue of a 250-mesh sieve. The invention reduces the content of clay, thereby improving the suspension property of the slurry and the fluidity of the powder after granulation by reducing the fineness of the slurry.
S3: carrying out spray granulation on the slurry to obtain powder;
specifically, after the slurry is aged in a slurry tank for 24-48 hours, pumping the slurry to a spray tower for spray drying and granulation; the proportion of particles with more than 40 meshes in the powder obtained by granulation is more than or equal to 20 wt%, and the powder with the particle grading has better fluidity and is beneficial to the subsequent material distribution process.
S4: distributing the powder into a high-temperature sagger;
s5: and sintering the high-temperature sagger in a kiln to obtain a finished foamed ceramic product.
When the roller kiln is used for firing, the firing temperature is 1150-1180 ℃, and the firing period is 6-10 hours. Preferably, the firing temperature is 1160-1180 ℃, and the firing period is 6-8 h.
When a tunnel kiln is adopted for firing, the firing temperature is 1150-1180 ℃, and the firing period is 10-15 hours; preferably, the firing period is 1160-1180 ℃ and 12-15 h. The invention effectively reduces the sintering temperature, shortens the sintering period and reduces the sintering energy consumption through a reasonable formula structure.
Under the synergistic effect of the formula and the preparation method, the foamed ceramic obtained by the invention comprises the following components in parts by weight: the compressive strength is more than or equal to 7MPa, and the volume density is 200-400 kg/m3The heat conductivity coefficient is less than or equal to 0.13W/m ℃, the fire resistance limit is more than or equal to 1h, the combustion grade is A1 grade, the water absorption rate is less than or equal to 0.5 percent, IRa≤1.0，Ir≤1.0。
The invention is further illustrated by the following specific examples:
example 1
The embodiment provides a foamed ceramic, which comprises the following components in percentage by weight: 90 parts of Luoyuan red tailings, 9 parts of sand-coated soil, 0.1 part of foaming agent and 0.9 part of stabilizing agent;
the Luoyuan red tailings comprise the following components: SiO 22 72.8％，Al2O3 13.1％，Fe2O3 1.9％，CaO 1.0％，MgO 0.2％，K2O 4.0％，Na2O 4.8％，LOI 2.2％；
The sand-coated soil consists of the following components: SiO 22 74.1％，Al2O3 12.4％，Fe2O3 1.2％，CaO 0.4％，MgO 0.08％，K2O 4.52％，Na2O 4.3％，LOI 3％；
Carbon powder is selected as the foaming agent, and manganese dioxide is selected as the stabilizing agent.
The preparation method comprises the following steps:
(1) uniformly mixing various raw materials according to a formula to obtain a mixture;
(2) performing ball milling on the mixture to obtain slurry;
wherein the fineness of the slurry is that the screen residue of a 250-mesh screen is 0.5%.
(3) Carrying out spray granulation on the slurry to obtain powder;
(4) distributing the powder into a high-temperature sagger;
(5) and sintering the high-temperature sagger in a kiln to obtain a finished foamed ceramic product.
Wherein, when the roller kiln is adopted for sintering, the sintering temperature is 1180 ℃, and the sintering period is 6 hours.
Example 2
The embodiment provides a foamed ceramic, which comprises the following components in percentage by weight: 95 parts of Luoyuan red tailings, 1 part of black mud, 3 parts of ceramic grinding block reclaimed materials and 1 part of manganese dioxide;
the Luoyuan red tailings comprise the following components: SiO 22 70.7％，Al2O3 13.6％，Fe2O3 1.2％，CaO 1.4％，MgO 0.4％，K2O 5.2％，Na2O 4.5％，LOI 3％；
The black mud comprises the following components: SiO 22 64.6％，Al2O3 23.4％，Fe2O3 2.8％，CaO 0.6％，MgO 0.4％，K2O 1.7％，Na2O 0.3％，LOI 6.2％。
The preparation method comprises the following steps:
(1) uniformly mixing various raw materials according to a formula to obtain a mixture;
(2) performing ball milling on the mixture to obtain slurry;
wherein the fineness of the slurry is that the screen residue of a 250-mesh screen is 0.3%.
(3) Carrying out spray granulation on the slurry to obtain powder;
(4) distributing the powder into a high-temperature sagger;
(5) and sintering the high-temperature sagger in a kiln to obtain a finished foamed ceramic product.
Wherein, when the tunnel kiln is adopted for sintering, the sintering temperature is 1160 ℃, and the sintering period is 8 h.
Example 3
The embodiment provides a foamed ceramic, which comprises the following components in percentage by weight: 92 parts of Luoyuan red tailings, 5.8 parts of sea mud, 1.2 parts of silicon carbide and 1 part of manganese dioxide;
the Luoyuan red tailings comprise the following components: SiO 22 72.4％，Al2O3 13.1％，Fe2O3 1.3％，CaO 1.2％，MgO 0.5％，K2O 5.2％，Na2O 4.3％，LOI 2.1％；
The sea mud comprises the following components: SiO 22 68.7％，Al2O3 13.2％，Fe2O3 3.6％，CaO 2.8％，MgO 2.1％，K2O 4.25％，Na2O 2.15％，LOI 3.2％。
The preparation method comprises the following steps:
(1) uniformly mixing various raw materials according to a formula to obtain a mixture;
(2) performing ball milling on the mixture to obtain slurry;
wherein the fineness of the slurry is that the screen residue of a 250-mesh screen is 0.3%.
(3) Carrying out spray granulation on the slurry to obtain powder;
(4) distributing the powder into a high-temperature sagger;
(5) and sintering the high-temperature sagger in a kiln to obtain a finished foamed ceramic product.
Wherein, the sintering is carried out by adopting a roller kiln, the sintering temperature is 1170 ℃, and the sintering period is 7 h.
Example 4
The embodiment provides a foamed ceramic, which comprises the following components in percentage by weight: 94 parts of Luoyuan red tailings, 3.6 parts of harbor mud, 1.8 parts of silicon carbide and 0.6 part of manganese dioxide;
wherein, the Rouyuan red tailings consist ofThe components are as follows: SiO 22 72.4％，Al2O3 13.1％，Fe2O3 1.3％，CaO 1.2％，MgO 0.5％，K2O 5.2％，Na2O 4.3％，LOI 2.1％；
The port mud comprises the following components: SiO 22 70.9％，Al2O3 13.1％，Fe2O3 2.5％，CaO 3.2％，MgO 1.6％，K2O 3.2％，Na2O 1.5％，LOI 4.0％。
The preparation method is the same as in example 3.
Example 5
The embodiment provides a foamed ceramic, which comprises the following components in percentage by weight: 92 parts of Luoyuan red tailings, 4 parts of water washing mud, 2 parts of harbor mud, 1.4 parts of silicon carbide and 0.6 part of manganese dioxide;
the Luoyuan red tailings comprise the following components: SiO 22 72.4％，Al2O3 13.1％，Fe2O3 1.3％，CaO 1.2％，MgO 0.5％，K2O 5.2％，Na2O 4.3％，LOI 2.1％；
The washing mud comprises the following components: SiO 22 49.8％，Al2O3 34.3％，Fe2O3 2.8％，CaO 0.08％，MgO 0.42％，K2O 2.8％，Na2O 0.7％，LOI 9.1％。
The port mud comprises the following components: SiO 22 70.9％，Al2O3 13.1％，Fe2O3 2.5％，CaO 3.2％，MgO 1.6％，K2O 3.2％，Na2O 1.5％，LOI 4.0％。
The preparation method is the same as in example 3.
Example 6
The embodiment provides a foamed ceramic, which comprises the following components in percentage by weight: 92 parts of Luoyuan red tailings, 4.3 parts of water washing mud, 1.7 parts of harbor mud, 1.4 parts of silicon carbide and 0.6 part of manganese dioxide;
the Luoyuan red tailings comprise the following components: SiO 22 72.4％，Al2O3 13.1％，Fe2O3 1.3％，CaO 1.2％，MgO 0.5％，K2O 5.2％，Na2O 4.3％，LOI 2.1％；
The washing mud comprises the following components: SiO 22 48.1％，Al2O3 35.9％，Fe2O3 2.4％，CaO 0.02％，MgO 0.42％，K2O 2.46％，Na2O 0.6％，LOI 10.1％。
The port mud comprises the following components: SiO 22 68.5％，Al2O3 14.5％，Fe2O3 2.2％，CaO 3.6％，MgO 2.8％，K2O 4.1％，Na2O2.5％，LOI 1.8％。
The preparation method is the same as in example 3.
Example 7
This example provides a foamed ceramic having the same formulation as in example 6;
the preparation method comprises the following steps:
(1) uniformly mixing various raw materials according to a formula to obtain a mixture;
(2) performing ball milling on the mixture to obtain slurry;
wherein the fineness of the slurry is that the screen residue of a 250-mesh screen is 0.05%.
(3) Carrying out spray granulation on the slurry to obtain powder;
(4) distributing the powder into a high-temperature sagger;
(5) and sintering the high-temperature sagger in a kiln to obtain a finished foamed ceramic product.
Wherein, the sintering is carried out by adopting a roller kiln, the sintering temperature is 1165 ℃, and the sintering period is 7.5 h.
Example 8
The embodiment provides a foamed ceramic, which comprises the following components in percentage by weight: 93 parts of Luoyuan red tailings, 3.5 parts of water washing mud, 2.5 parts of harbor mud, 1.2 parts of silicon carbide and 0.8 part of manganese dioxide;
the Luoyuan red tailings comprise the following components: SiO 22 72.4％，Al2O3 13.1％，Fe2O3 1.3％，CaO 1.2％，MgO 0.5％，K2O 5.2％，Na2O 4.3％，LOI 2.1％；
The washing mud comprises the following components: SiO 22 48.1％，Al2O3 35.9％，Fe2O3 2.4％，CaO 0.02％，MgO 0.42％，K2O 2.46％，Na2O 0.6％，LOI 10.1％。
The port mud comprises the following components: SiO 22 68.5％，Al2O3 14.5％，Fe2O3 2.2％，CaO 3.6％，MgO 2.8％，K2O 4.1％，Na2O2.5％，LOI 1.8％。
The preparation method is the same as in example 3.
The foamed ceramics of examples 1-8 were tested by the method specified in JGT 511-2017; the test results are shown in the following table:
as shown in the table above, through the synergistic effect of the Royuan Red tailings, clay and other raw materials and the formula, the compressive strength of the material prepared by the invention is more than or equal to 7MPa, and the volume density of the material is 200-500 kg/m3The heat conductivity coefficient is less than or equal to 0.13W/m ℃, the fire resistance limit is more than or equal to 1h, the combustion grade is A1 grade, the water absorption rate is less than or equal to 0.5 percent, IRa≤1.0，IrThe foamed ceramic is less than or equal to 1.0.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.
Claims (10)
1. The foamed ceramic is characterized by being mainly prepared from the following raw materials in parts by weight:
90-95 parts of Luoyuan red tailings, 1-9 parts of clay, 0.1-3 parts of foaming agent and 0.1-1 part of stabilizer;
the sum of the weight parts of the raw material components is 100 parts;
wherein, theThe Luoyuan red tailings mainly comprise the following components in percentage by weight: SiO 22 68～73％，Al2O3 12～15％，Fe2O3 1.2～2％，CaO 0.5～1.5％，MgO 0.2～0.5％，K2O 4～5.5％，Na2O 3～5％，LOI 0.5～3％。
2. The foamed ceramic of claim 1, wherein the clay is selected from one or more of luo yuan sand-covered soil, water washed mud, black mud, harbor mud, or sea mud.
3. The foamed ceramic of claim 2, wherein the luoyuan sand-coated soil consists essentially of the following components in percentage by weight: SiO 22 70～75％，Al2O3 12～16％，Fe2O3 0.5～1.5％，CaO0.3～0.5％，MgO 0.01～0.1％，K2O 4～6％，Na2O 3～5％，LOI 1～5％；
The washing mud mainly comprises the following components in percentage by weight: SiO 22 45～50％，Al2O332～36％，Fe2O32～3％，CaO 0.01～0.1％，MgO 0.3～0.5％，K2O 2～3％，Na2O0.3～0.8％，LOI 8～12％；
The black mud mainly comprises the following components in percentage by weight: SiO 22 61～65％，Al2O3 20～24％，Fe2O31.5～3％，CaO 0.3～1％，MgO 0.3～0.5％，K2O 1～2％，Na2O 0.2～0.6％，LOI5～10％；
The port mud mainly comprises the following components in percentage by weight: SiO 22 68～72％，Al2O312～15％，Fe2O32～3％，CaO 3～5％，MgO 1.5～3％，K2O 3.5～5％，Na2O 1.5～3.5％，LOI 1～8％；
The sea mud mainly comprises the following components in percentage by weight: SiO 22 68～72％，Al2O3 11～14％，Fe2O3 3～4％，CaO 2～3.5％，MgO 1.5～2.5％，K2O 3～5％，Na2O 1～3％，LOI 3～10％。
4. The foamed ceramic of claim 3, wherein the clay is selected from one or more of a wash mud, a harbor mud, or a sea mud.
5. The foamed ceramic of claim 1, wherein the foaming agent is selected from one or more of silicon carbide, carbon powder, or reclaimed ceramic grinding block; the stabilizing agent is manganese dioxide.
6. The foamed ceramic of claim 1, wherein said foaming agent is silicon carbide and said stabilizer is manganese dioxide.
7. The foamed ceramic of any one of claims 1-6, wherein the foamed ceramic has a compressive strength of 7MPa or more and a bulk density of 200-400 kg/m3The heat conductivity coefficient is less than or equal to 0.13W/m ℃, the fire resistance limit is more than or equal to 1h, the combustion grade is A1 grade, the water absorption rate is less than or equal to 0.5 percent, IRa≤1.0，Ir≤1.0。
8. A method of preparing a foamed ceramic according to any one of claims 1 to 7, comprising:
(1) uniformly mixing various raw materials according to a formula to obtain a mixture;
(2) performing ball milling on the mixture to obtain slurry;
(3) carrying out spray granulation on the slurry to obtain powder;
(4) distributing the powder into a high-temperature sagger;
(5) placing the high-temperature sagger in a kiln for sintering to obtain a finished foamed ceramic product;
wherein the fineness of the slurry is that the screen residue of a 250-mesh screen is less than 0.5%.
9. The method for producing a foamed ceramic according to claim 8, wherein in the step (5), firing is performed by a roller kiln; the firing temperature is 1150-1180 ℃, and the firing period is 6-10 h.
10. The method for preparing foamed ceramic according to claim 8, wherein in the step (5), the firing is performed by using a tunnel kiln, the firing temperature is 1150-1180 ℃, and the firing period is 10-15 h.
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| CN111116223A (en) * | 2019-12-31 | 2020-05-08 | 江西中材新材料有限公司 | Preparation method of foamed ceramic and foamed ceramic |
| CN115572176A (en) * | 2022-09-30 | 2023-01-06 | 广西欧神诺陶瓷有限公司 | Light ceramic tile prepared from metal tailings and preparation method thereof |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111116223A (en) * | 2019-12-31 | 2020-05-08 | 江西中材新材料有限公司 | Preparation method of foamed ceramic and foamed ceramic |
| CN115572176A (en) * | 2022-09-30 | 2023-01-06 | 广西欧神诺陶瓷有限公司 | Light ceramic tile prepared from metal tailings and preparation method thereof |
| CN115572176B (en) * | 2022-09-30 | 2023-06-20 | 广西欧神诺陶瓷有限公司 | Light ceramic tile prepared from metal tailings and preparation method thereof |
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