CN110835259A - Uniformly foamed light heat-insulating ceramic and preparation method thereof - Google Patents

Uniformly foamed light heat-insulating ceramic and preparation method thereof Download PDF

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CN110835259A
CN110835259A CN201911076350.5A CN201911076350A CN110835259A CN 110835259 A CN110835259 A CN 110835259A CN 201911076350 A CN201911076350 A CN 201911076350A CN 110835259 A CN110835259 A CN 110835259A
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ceramic
polishing slag
molybdate
additive
preparation
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税安泽
王聪
陈为为
李剑桥
蔡梅
连家伟
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Chongqing Zhongfu Kerui Industrial Technology Research Institute Co Ltd
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Chongqing Zhongfu Kerui Industrial Technology Research Institute Co Ltd
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B33/00Clay-wares
    • C04B33/02Preparing or treating the raw materials individually or as batches
    • C04B33/13Compounding ingredients
    • C04B33/132Waste materials; Refuse; Residues
    • C04B33/1324Recycled material, e.g. tile dust, stone waste, spent refractory material
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    • C04B33/00Clay-wares
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    • C04B33/00Clay-wares
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    • C04B2235/34Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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    • C04B2235/44Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
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    • Y02P40/60Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes

Abstract

The invention relates to a uniformly foamed light heat-insulating ceramic and a preparation method thereof. The preparation method of the ceramic comprises the following steps: (1) mixing ceramic polishing slag, an additive and water, and then performing ball milling, granulation and sieving to obtain raw material powder; wherein the additive comprises at least one of molybdate, phosphate and borax; (2) sequentially carrying out dry pressing forming and drying on the raw material powder obtained in the step (1) to obtain a ceramic green body; (3) and (3) sintering the ceramic green body obtained in the step (2) at the temperature of 700-1100 ℃ to obtain the ceramic. The ceramic polishing slag is used as the main raw material for preparing the ceramic, silicon carbide contained in the polishing slag is used as a foaming agent, magnesium oxychloride cement is used as a sintering aid, and under the condition that other foaming agents and sintering aids are not added, the liquid phase viscosity is reduced by introducing additives, so that the silicon carbide is promoted to be oxidized (foamed) as soon as possible, the ceramic firing temperature is low, and the internal pore structure is uniform.

Description

Uniformly foamed light heat-insulating ceramic and preparation method thereof
Technical Field
The invention relates to a ceramic and a preparation method thereof, in particular to a uniformly foamed light heat-insulating ceramic and a preparation method thereof.
Background
The ceramic polished tile has the excellent performances of antifouling, wear resistance, chemical corrosion resistance, high mechanical strength and the like, and is widely applied to building materials. In order to improve the requirements of ceramic products such as dimensional accuracy and smoothness, a series of deep processing such as scraping and milling, surface polishing and edging and chamfering are generally required to be carried out on the ceramic tiles. In the process, the grinding and polishing process usually needs to remove a surface layer with a thickness of about 0.4-0.8 mm, even 1-2 mm, from the surface of the tile, so that the surface gloss of the polished tile reaches 65-70%, and a large amount of ceramic polishing slag (1 m per production) is generated2The polishing brick can generate about 2.1kg of ceramic polishing slag), and the large accumulation of the landfill polishing slag not only causes great waste of mineral resources, but also brings serious environmental pollution and secondary disasters. Therefore, the high-efficiency resource utilization of the ceramic polishing slag has important social and economic significance.
At present, a plurality of patents are provided for resource utilization of ceramic polishing slag, but the utilization rate of the ceramic polishing slag in raw materials is not high. For example, patent CN105174905A discloses a method for manufacturing ceramic archaized brick by using various solid wastes, wherein the adding amount of ceramic polishing slag is less than 10 wt%; patent CN102060541A discloses a method for producing polished tiles by utilizing various solid wastes generated in the production process of the tilesPreparing a polished brick with the water absorption rate of less than 0.5 percent at the temperature of 1180-1250 ℃, wherein the adding amount of the ceramic polishing slag is less than 10 percent by weight; the patent CN103044009A discloses an antique brick produced by using waste materials of a polishing brick factory and a preparation method thereof, the method adopts ceramic polishing slag and clay, quartz, porcelain stone and other raw materials to prepare the antique brick at the sintering temperature of 1150-1200 ℃, and the adding amount of the polishing slag is 10 wt%. The method has low utilization rate of the ceramic polishing slag, and the main reason is that SiC impurities in the polishing slag can react with O during firing2React and release CO and CO2Gases which hinder the densification process of sintering, and excessive introduction of polishing slag can cause foaming and deformation of products.
In addition, although there is a patent for producing a lightweight heat insulating ceramic using polishing slag, the polishing slag is also low in utilization rate, uneven in foaming (resulting in unstable mechanical strength and uneven heat insulating performance of the product), and high in firing temperature (resulting in high energy consumption). For example, patent CN109516773A discloses a method for preparing a light wallboard and a multilayer light wallboard, the usage amount of polishing slag is not more than 70 wt%, the firing temperature is as high as 1180 ℃, and a foaming agent is added; the patent CN105175007A discloses a light insulating brick, wherein the main foaming agent is industrial coal slag (50-76 wt%), the usage amount of polishing slag is only 15 wt%, and the firing temperature is up to 1150-1250 ℃; the patent CN102887721A discloses a foamed ceramic insulation board and a preparation method thereof, wherein the usage amount of polishing slag is 40-75 wt%, but 1-3 wt% of silicon carbide is additionally added, and the firing temperature is as high as 1130-1180 ℃; patent CN108129131A discloses a low-temperature preparation method of light heat-insulating ceramic, the usage amount of polishing slag reaches 90 wt%, but the sintering temperature is up to 1150 ℃. Too high firing temperature tends to cause uneven foaming and product deformation, and too high liquid phase viscosity also tends to cause uneven foaming.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a uniformly foamed light heat-insulating ceramic and a preparation method thereof.
In order to achieve the purpose, the invention adopts the technical scheme that: a method of making a ceramic, comprising the steps of:
(1) mixing ceramic polishing slag, an additive and water, and then performing ball milling, drying, granulation and sieving to obtain raw material powder; wherein the additive comprises at least one of molybdate, phosphate and borax;
(2) sequentially carrying out dry pressing forming and drying on the raw material powder obtained in the step (1) to obtain a ceramic green body;
(3) and (3) sintering the ceramic green body obtained in the step (2) at the temperature of 700-1100 ℃ to obtain the ceramic.
The ceramic polishing slag contains silicon carbide and magnesia cement. According to the invention, ceramic is prepared by taking ceramic polishing slag as a main raw material, silicon carbide contained in the polishing slag is used as a foaming agent, magnesium oxychloride cement is used as a sintering aid, and under the condition that other foaming agents and sintering aids are not added, the viscosity of a liquid phase is reduced by introducing an additive, so that the silicon carbide is promoted to be oxidized (foamed) as soon as possible (at a low temperature), and the internal pore structure is uniform (foamed uniformly).
The method has high utilization rate of the ceramic polishing slag, and the content of the ceramic polishing slag in the raw materials can reach 85-99 wt%. In addition, the method has low sintering temperature and uniform foaming, and the prepared ceramic product has low density, low heat conductivity coefficient, high compressive strength and stable performance (due to uniform foaming).
In addition, the process conditions are easy to control, the comprehensive production cost is low, and the industrial popularization is facilitated.
As a preferred embodiment of the preparation method of the ceramic, the weight percentage of the ceramic polishing slag is 85-99% based on the total weight of the ceramic polishing slag and the additive.
As a preferred embodiment of the preparation method of the ceramic, the weight percentage of the ceramic polishing slag is 90-95% based on the total weight of the ceramic polishing slag and the additive. When the weight percentage of the ceramic polishing slag is 90-95%, the resource utilization rate of the polishing slag is high, the firing temperature is low, and the dosage of the additive is small.
As a preferable embodiment of the method for preparing the ceramic of the present invention, the ceramic polishing slag is in a powder form; preferably, the ceramic polishing slag is powder with a particle size of 40 meshes or less.
As a preferred embodiment of the method for preparing the ceramic of the present invention, the method for preparing the ceramic polishing slag comprises: and (3) putting the polishing slag generated in the ceramic industry into a ball mill for ball milling, and sieving by a sieve with less than 40 meshes to obtain powdery ceramic polishing slag.
As a preferred embodiment of the method for preparing the ceramic of the present invention, the molybdate is at least one of sodium molybdate, ammonium molybdate and magnesium molybdate; the phosphate is at least one of sodium phosphate, potassium phosphate and calcium phosphate.
As a preferred embodiment of the method for preparing the ceramic according to the present invention, the additive consists of sodium molybdate and potassium phosphate, or consists of magnesium molybdate, calcium phosphate and borax. When the additive is adopted, the firing temperature is lower.
As a preferred embodiment of the preparation method of the ceramic of the present invention, in the step (1), the ball milling time is 0.5 to 8 hours, and the mesh number of the screen is 20 to 200 meshes.
As a preferable embodiment of the method for preparing the ceramic of the present invention, in the step (2), the pressure for dry pressing is 5 to 150MPa, and the temperature for drying is 80 to 240 ℃.
As a preferred embodiment of the preparation method of the ceramic, in the step (3), the temperature rise rate is 1-15 ℃/min, and the heat preservation time is 0-5 h. The temperature rise may be started at normal temperature or at 200-300 ℃.
In addition, the invention also provides the ceramic prepared by the method. The ceramic obtained by the invention has low density, low heat conductivity coefficient and high compressive strength.
Compared with the prior art, the invention has the beneficial effects that:
(1) according to the invention, silicon carbide contained in the polishing slag is used as a foaming agent, magnesium oxychloride cement is used as a sintering aid, and under the condition that other foaming agents and sintering aids are not added, the liquid phase viscosity is reduced by introducing additives, so that the silicon carbide is promoted to be oxidized (foamed) as soon as possible (at a low temperature), and the internal pore structure is uniform (foamed uniformly).
(2) The method has the advantages of easily controlled process conditions, low cost and high utilization rate of the polishing slag, even up to 99 wt%, promotes high-efficiency and large-scale resource utilization of the ceramic polishing slag, and has important significance for functionalization and high performance of the ceramic and protection of ecological environment.
Drawings
FIG. 1 is a microscopic morphology of a ceramic obtained in example 1 of the present invention;
FIG. 2 is a micro-topography of the ceramic obtained in example 2 of the present invention;
FIG. 3 is a micro-topography of the ceramic obtained in example 3 of the present invention;
FIG. 4 is a micro-topography of the ceramic obtained in example 4 of the present invention;
FIG. 5 is a micro-topography of the ceramic obtained in example 5 of the present invention.
Detailed Description
To better illustrate the objects, aspects and advantages of the present invention, the present invention will be further described with reference to the accompanying drawings and specific embodiments.
Example 1
In an embodiment of the ceramic and the preparation method thereof of the present invention, the preparation method of the ceramic in this embodiment is:
(1) putting the ceramic polishing slag into a ball mill for ball milling, sieving the ceramic polishing slag by a 40-mesh sieve, and sieving to obtain ceramic polishing slag powder for later use;
(2) taking 95g of ceramic polishing slag powder, 5g of ammonium molybdate and 100ml of water, ball-milling and mixing the raw materials for 2 hours according to the proportion, drying the mixed slurry in an oven, granulating the dried powder, and sieving the granulated powder with a 120-mesh sieve to obtain raw material powder for later use;
(3) carrying out dry pressing molding on the raw material powder, wherein the molding pressure is 80MPa, and drying in a drying oven at 120 ℃ to obtain a ceramic green body;
(4) and (3) sintering the ceramic green body in a sintering furnace, wherein the sintering temperature is 1050 ℃, the heating speed is 5 ℃/min, and the heat preservation time is 2 h.
The density of the light heat-insulating ceramic prepared by the embodiment is 0.305g/cm3Withstanding pressureThe degree is 4.73MPa, and the thermal conductivity is 0.082W/m.k.
Example 2
In an embodiment of the ceramic and the preparation method thereof of the present invention, the preparation method of the ceramic in this embodiment is:
(1) putting the ceramic polishing slag into a ball mill for ball milling, sieving with a 40-mesh sieve, and carrying out sieving treatment to obtain ceramic polishing slag powder for later use;
(2) taking 90g of ceramic polishing slag powder, 10g of sodium phosphate and 100ml of water, ball-milling and mixing the raw materials for 6 hours according to the proportion, drying the mixed slurry in an oven, granulating the dried powder, and sieving the granulated powder with a 200-mesh sieve to obtain raw material powder for later use;
(3) carrying out dry pressing molding on the raw material powder, wherein the molding pressure is 150MPa, and drying in a drying oven at 240 ℃ to obtain a ceramic green body;
(4) and (3) sintering the ceramic green body in a sintering furnace, wherein the sintering temperature is 700 ℃, the heating rate is 1 ℃/min, and the heat preservation time is 5 h.
The density of the light heat-insulating ceramic prepared by the embodiment is 0.657g/cm3The compressive strength is 6.85MPa, and the thermal conductivity is 0.161W/m.k.
Example 3
In an embodiment of the ceramic and the preparation method thereof of the present invention, the preparation method of the ceramic in this embodiment is:
(1) putting the ceramic polishing slag into a ball mill for ball milling, sieving with a 40-mesh sieve, and carrying out sieving treatment to obtain ceramic polishing slag powder for later use;
(2) taking 99g of ceramic polishing slag powder, 1g of borax and 100ml of water, ball-milling and mixing the raw materials according to a ratio for 0.5h, drying the mixed slurry in an oven, granulating the dried powder, and sieving the granulated powder with a 20-mesh sieve to obtain raw material powder for later use;
(3) carrying out dry pressing molding on the raw material powder, wherein the molding pressure is 5MPa, and drying in an oven at 80 ℃ to obtain a ceramic green body;
(4) and (3) sintering the ceramic green body in a sintering furnace, wherein the sintering temperature is 1100 ℃, the heating speed is 3 ℃/min, and the heat preservation time is 0 h.
The lightweight insulation produced in this exampleCeramic with density of 0.558g/cm3The compressive strength is 5.72MPa, and the thermal conductivity is 0.146W/m.k.
Example 4
In an embodiment of the ceramic and the preparation method thereof of the present invention, the preparation method of the ceramic in this embodiment is:
(1) putting the ceramic polishing slag into a ball mill for ball milling, sieving with a 40-mesh sieve, and carrying out sieving treatment to obtain ceramic polishing slag powder for later use;
(2) taking 94g of ceramic polishing slag powder, 3g of sodium molybdate, 3g of potassium phosphate and 100ml of water, ball-milling and mixing the raw materials for 8 hours according to the proportion, drying the mixed slurry in an oven, granulating the dried powder, and sieving the granulated powder with a 150-mesh sieve to obtain raw material powder for later use;
(3) and (3) carrying out dry pressing molding on the raw material powder, wherein the molding pressure is 120MPa, and drying in a drying oven at 200 ℃ to obtain a ceramic green body.
(4) And (3) sintering the ceramic green body in a sintering furnace, wherein the sintering temperature is 850 ℃, the heating rate is 4 ℃/min, and the heat preservation time is 4 h.
The density of the light heat-insulating ceramic prepared by the embodiment is 0.473g/cm3The compressive strength is 4.81MPa, and the thermal conductivity is 0.107W/m.k.
Example 5
In an embodiment of the ceramic and the preparation method thereof of the present invention, the preparation method of the ceramic in this embodiment is:
(1) putting the ceramic polishing slag into a ball mill for ball milling, sieving with a 40-mesh sieve, and carrying out sieving treatment to obtain ceramic polishing slag powder for later use;
(2) taking 85g of ceramic polishing slag powder, 5g of magnesium molybdate, 6g of calcium phosphate, 4g of borax and 100ml of water, ball-milling and mixing the raw materials according to a ratio for 8 hours, drying the mixed slurry in an oven, granulating the dried powder, and sieving the granulated powder with a 200-mesh sieve to obtain raw material powder for later use;
(3) carrying out dry pressing molding on the raw material powder, wherein the molding pressure is 30MPa, and drying in a drying oven at 100 ℃ to obtain a ceramic green body;
(4) and (3) sintering the ceramic green body in a sintering furnace, wherein the sintering temperature is 800 ℃, the heating rate is 1 ℃/min, and the heat preservation time is 4 h.
The density of the light heat-insulating ceramic prepared by the embodiment is 0.526g/cm3The compressive strength is 5.45MPa, and the thermal conductivity is 0.128W/m.k.
Effect example 1
The effect example investigates the influence of the using amount of the ceramic polishing slag on the firing temperature in the ceramic preparation process. In this effect example, the ceramics of test groups 1 to 5 were prepared by the following method, and the firing temperatures thereof were compared, and the specific method for preparing the ceramics of test groups 1 to 5 was:
(1) putting the ceramic polishing slag into a ball mill for ball milling, sieving the ceramic polishing slag by a 40-mesh sieve, and sieving to obtain ceramic polishing slag powder for later use;
(2) taking ceramic polishing slag powder, ammonium molybdate and water, mixing the raw materials according to a ratio by ball milling for 2 hours, drying the mixed slurry in an oven, granulating the dried powder, and sieving the granulated powder with a 120-mesh sieve to obtain raw material powder for later use;
(3) carrying out dry pressing molding on the raw material powder, wherein the molding pressure is 80MPa, and drying in a drying oven at 120 ℃ to obtain a ceramic green body;
(4) and (3) putting the ceramic green body into a sintering furnace for sintering, wherein the heating rate is 10 ℃/min, and the heat preservation time is 0.5h, so as to obtain the ceramic.
In the above preparation method, the weight percentage of the ceramic polishing slag, the firing temperature in step (4), and the properties of the obtained ceramic, based on the total weight of the ceramic polishing slag and the additive, are shown in table 1.
TABLE 1
Figure BDA0002262576180000071
As can be seen from Table 1, when the weight percentage of the ceramic polishing slag is 90-95%, the firing temperature is relatively low.
Effect example 2
The effect example investigates the influence of the types of the additives on the firing temperature in the preparation process of the ceramic. In this effect example, the ceramics of test groups 6 to 12 were prepared by the following method, and the firing temperatures thereof were compared, and the specific method for preparing the ceramics of test groups 6 to 12 was:
(1) putting the ceramic polishing slag into a ball mill for ball milling, sieving the ceramic polishing slag by a 40-mesh sieve, and sieving to obtain ceramic polishing slag powder for later use;
(2) taking 95g of ceramic polishing slag powder, 5g of additive and 100ml of water, ball-milling and mixing the raw materials for 2 hours according to the proportion, drying the mixed slurry in an oven, granulating the dried powder, and sieving the granulated powder with a 120-mesh sieve to obtain raw material powder for later use;
(3) carrying out dry pressing molding on the raw material powder, wherein the molding pressure is 80MPa, and drying in a drying oven at 120 ℃ to obtain a ceramic green body;
(4) and (3) putting the ceramic green body into a sintering furnace for sintering, wherein the heating rate is 5 ℃/min, and the heat preservation time is 0.5h, so as to obtain the ceramic.
In the above production method, the kinds of additives, the firing temperature in the step (4), and the properties of the obtained ceramics are shown in table 2.
TABLE 2
Figure BDA0002262576180000081
As can be seen from table 2, the firing temperature is lower when the additive consists of sodium molybdate and potassium phosphate, or alternatively, magnesium molybdate, calcium phosphate and borax.
Finally, it should be noted that the above embodiments are only used for illustrating the technical solutions of the present invention and not for limiting the protection scope of the present invention, and although the present invention is described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications or equivalent substitutions can be made on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims (10)

1. The preparation method of the ceramic is characterized by comprising the following steps:
(1) mixing ceramic polishing slag, an additive and water, and then performing ball milling, drying, granulation and sieving to obtain raw material powder; wherein the additive comprises at least one of molybdate, phosphate and borax;
(2) sequentially carrying out dry pressing forming and drying on the raw material powder obtained in the step (1) to obtain a ceramic green body;
(3) and (3) sintering the ceramic green body obtained in the step (2) at the temperature of 700-1100 ℃ to obtain the ceramic.
2. The method of claim 1, wherein the ceramic polishing slag is 85% to 99% by weight based on the total weight of the ceramic polishing slag and the additive.
3. The method of claim 2, wherein the ceramic polishing slag is present in an amount of 90 wt% to 95 wt% based on the total weight of the ceramic polishing slag and the additive.
4. The method of preparing a ceramic according to claim 1, wherein the ceramic polishing slag is in a powder form; preferably, the ceramic polishing slag is powder with a particle size of 40 meshes or less.
5. The method for preparing ceramic according to claim 4, wherein the method for preparing the ceramic polishing slag comprises: and (3) putting the polishing slag generated in the ceramic industry into a ball mill for ball milling, and sieving by a sieve with less than 40 meshes to obtain powdery ceramic polishing slag.
6. The method of claim 1, wherein the molybdate is at least one of sodium molybdate, ammonium molybdate and magnesium molybdate; the phosphate is at least one of sodium phosphate, potassium phosphate and calcium phosphate.
7. The method of claim 6, wherein the additive consists of sodium molybdate and potassium phosphate, or consists of magnesium molybdate, calcium phosphate and borax.
8. The method of claim 1, wherein in the step (1), the ball milling time is 0.5 to 8 hours, and the mesh number of the screen is 20 to 200 mesh.
9. The method of preparing ceramic according to claim 1, wherein in the step (2), the pressure for dry press forming is 5 to 150MPa, and the temperature for drying is 80 to 240 ℃.
10. A ceramic produced by the method of any one of claims 1 to 9.
CN201911076350.5A 2019-11-06 2019-11-06 Uniformly foamed light heat-insulating ceramic and preparation method thereof Pending CN110835259A (en)

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Application publication date: 20200225