CN110857250A - Method for preparing ceramic tile by using fly ash as raw material - Google Patents
Method for preparing ceramic tile by using fly ash as raw material Download PDFInfo
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- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/132—Waste materials; Refuse; Residues
- C04B33/135—Combustion residues, e.g. fly ash, incineration waste
- C04B33/1352—Fuel ashes, e.g. fly ash
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/61—Mechanical properties, e.g. fracture toughness, hardness, Young's modulus or strength
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Abstract
The invention relates to a method for preparing a ceramic tile by only using fly ash as a raw material, which comprises the following steps: respectively carrying out mild alkaline activation and deep alkaline activation on the fly ash to obtain a clay-like material and a feldspar-like material; and mechanically mixing the fly ash, the clay-like material and the feldspar-like material, then carrying out pressure forming, and sintering a green blank obtained after forming to obtain the ceramic tile product. According to the invention, the fly ash is activated into the clay-like material and the long stone-like material through chemical modification to respectively replace the clay and feldspar minerals in the traditional ceramic, and through subsequent compounding of raw material components, the fly ash is only used as the raw material, namely, the traditional ceramic raw material is 100% replaced, so that the high-added-value utilization of the fly ash is realized, and the current situation that the ceramic production raw material is increasingly in short supply is relieved. The obtained ceramic tile has rich acicular mullite structure inside, low volume weight, breaking modulus far larger than the national standard, excellent comprehensive performance, and good economic benefit and application prospect.
Description
Technical Field
The invention relates to the field of comprehensive utilization of solid wastes and production of ceramic materials, in particular to a method for utilizing industrial solid wastes, and particularly relates to a method for preparing a ceramic tile by only using fly ash as a raw material.
Background
Fly ash is a solid waste produced in the production process of coal-fired power plants. As China still mainly uses thermal power generation at present, the emission of the fly ash is high, and as the fly ash is large in production amount, centralized in production place and insufficient in effective utilization, a large amount of fly ash is stockpiled, the current accumulated stock is nearly 30 hundred million tons, and the fly ash becomes the largest single solid pollution source in China. The disposal of fly ash is receiving increasing attention from the whole society.
In recent years, with the further promotion of urbanization, the real estate industry in China develops rapidly, and the associated ceramic tile production industry changes day by day. However, as the production of ceramic tiles is greatly increased, the main production raw materials of clay, feldspar and quartz are increasingly deficient. The contradiction between the supply and demand of raw materials in the ceramic tile production industry is increasingly prominent.
Aiming at the problems of low utilization added value of the fly ash and shortage of raw material resources for ceramic tile production, numerous scientific researchers and ceramic manufacturers carry out active research, successfully utilize the fly ash resources in the production process of the ceramic tiles and realize high added value resource utilization of the fly ash.
For example, CN103922699A discloses a method for preparing domestic ceramics by using fly ash, which is solid waste fly ash, clay and feldspar as raw materials to prepare a ceramic blank, wherein the doping amount of the fly ash is 10-60%. CN103951388A discloses a fly ash ceramic wine bottle and a preparation method thereof, wherein the mixing amount of fly ash is 45-65 wt%. CN103833330A discloses a method for preparing a ceramic brick from high-alumina fly ash, which comprises the steps of material preparation, ball milling, slurry discharge, drying, granulation, aging, molding, drying, sintering and the like, so as to prepare the ceramic brick meeting the national standard, wherein the mixing amount of the fly ash in the obtained ceramic brick reaches 30-75%. CN103833331A discloses a method for preparing a ceramic brick by using high-alumina fly ash, wherein the yield of the fly ash can reach 60-70%, and the firing period is 3-5 h.
The existing method is to simply and physically mix the fly ash with other raw materials, and the fly ash is not subjected to chemical activation treatment. The unactivated fly ash has low plasticity and high melting point, and can only replace quartz components in the ceramic raw materials to play a role in reducing the shrinkage of the ceramic in the firing process. The coal ash is difficult to replace clay and feldspar components in the ceramic raw material, so that the addition amount of the coal ash is limited when the coal ash is used for preparing ceramic, and the large application of the coal ash in the production of ceramic tiles is limited.
Disclosure of Invention
In view of the problems in the prior art, the invention aims to provide a method for preparing a ceramic tile by only using fly ash as a raw material, the fly ash is activated into a clay-like material and a long stone-like material through chemical modification to respectively replace the clay and feldspar minerals in the traditional ceramic, the fly ash is only used as the raw material, namely, the traditional ceramic raw material is 100% replaced, the high-added-value utilization of the fly ash is realized, and the current situation that the raw material for ceramic production is increasingly in short supply is relieved.
In order to achieve the purpose, the invention adopts the following technical scheme:
the invention provides a method for preparing a ceramic tile by only using fly ash as a raw material, which comprises the following steps:
(1) mixing 60-100g/L alkali liquor with fly ash, heating to 80-150 ℃ for mild alkaline activation reaction to obtain a clay-like material;
(2) mixing alkali liquor with the concentration of 105-500g/L with the fly ash, heating to 120-200 ℃ for deep alkaline activation reaction to obtain feldspar-like material;
(3) mechanically mixing fly ash with the clay-like material obtained in the step (1) and the feldspar-like material obtained in the step (2) to obtain a solid mixture;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) to obtain a green body;
(5) and (4) sintering the green body obtained in the step (4) to obtain a ceramic tile product after sintering.
According to the invention, the clay-like material is obtained by carrying out mild alkaline activation modification on the fly ash. Abundant crystal water and hydroxyl structures exist on the surface of the modified clay-like material, so that hydrogen bonds exist among particles, and the modified clay-like material can play a role of a clay mineral-like adhesive when being used as a ceramic raw material. Overcomes the difficult problem that the fly ash is unfavorable for ceramic molding as barren material, and the green strength of the fly ash completely meets the requirements of factory production. The chemical components of the obtained clay-like material are closer to those of mullite, and the obtained clay-like material has very high reaction activity. More acicular mullite can be generated in the novel ceramic body in the low-temperature sintering process than the traditional ceramic, and the acicular mullite can obviously improve the mechanical property of the ceramic.
The feldspar-like material is obtained after deep alkaline activation modification is carried out on the fly ash. Abundant alkali metal elements exist in the modified feldspar-like material structure, and the modified feldspar-like material can play a role of a fluxing agent similar to feldspar.
According to the invention, the prepared clay-like material, feldspar-like material and unactivated fly ash (quartz-like material) are compounded, so that the effects of clay (plasticizer, precipitated mullite), quartz (shrinkage-reducing filler) and feldspar (fluxing agent) can be simultaneously achieved, and the ceramic tile is prepared by only using the fly ash as a raw material, wherein the substitution amount of the fly ash for the traditional ceramic raw material can reach 100%.
For the present invention, the step (1) and the step (2) are not sequentially divided, and the present invention may also perform the step of preparing the long stone-like material in the step (2) first, and then prepare the clay-like material in the step (1), or perform both of them simultaneously, which should not be taken as a limitation to the present invention.
According to the invention, the concentration of the alkaline solution in the mild alkaline activation reaction of step (1) is 60-100g/L, for example, 60g/L, 65g/L, 70g/L, 75g/L, 80g/L, 85g/L, 90g/L, 95g/L or 100g/L, and the specific values therebetween are limited for the sake of brevity and are not exhaustive.
According to the present invention, the reaction temperature in the mild alkaline activation reaction of step (1) is 80-150 ℃, for example, 80 ℃, 90 ℃, 100 ℃, 110 ℃, 120 ℃, 130 ℃, 140 ℃ or 150 ℃, and the specific values therebetween are not exhaustive for brevity and conciseness.
According to the present invention, the concentration of the alkaline solution in the deep alkaline activation reaction of step (2) is 500g/L, such as 105g/L, 150g/L, 200g/L, 250g/L, 300g/L, 350g/L, 400g/L, 450g/L or 500g/L, and the specific values therebetween are not exhaustive for the sake of brevity and brevity.
According to the present invention, the temperature of the deep alkaline activation reaction in step (2) is 120-200 ℃, and may be, for example, 120 ℃, 130 ℃, 140 ℃, 150 ℃, 160 ℃, 170 ℃, 180 ℃, 190 ℃ or 200 ℃, and the specific values therebetween are limited by space and for brevity, and the present invention is not exhaustive.
According to the invention, the alkali liquor in the step (1) and the step (2) is sodium hydroxide solution and/or potassium hydroxide solution.
According to the invention, the ratio of the lye to the fly ash in step (1) is (2-10):1, and may be, for example, 2:1, 3:1, 4:1, 5:1, 6:1, 7:1, 8:1, 9:1 or 10:1, and the specific values therebetween are not exhaustive for the sake of brevity and simplicity.
According to the invention, the time of the mild alkaline activation reaction in step (1) is 0.5-20h, for example, 0.5h, 1h, 3h, 5h, 8h, 10h, 13h, 15h, 18h or 20h, and the specific values between the above values are not exhaustive for reasons of space and simplicity.
According to the invention, when the concentration of the alkali liquor in the step (1) is more than or equal to 80g/L, the temperature of the mild alkaline activation reaction is less than or equal to 120 ℃.
According to the invention, the temperature of the mild alkaline activation reaction is > 120 ℃ when the concentration of the lye in step (1) is < 80 g/L.
According to the invention, the ratio of the lye to the fly ash in step (2) is (2-10):1, and may be, for example, 2:1, 3:1, 4:1, 5:1, 6:1, 7:1, 8:1, 9:1 or 10:1, and the specific values therebetween are not exhaustive for the sake of brevity and simplicity.
The unit of the liquid-solid ratio is mL/g.
According to the invention, the time of the mild alkaline activation reaction in step (2) is 0.5-20h, for example, 0.5h, 1h, 3h, 5h, 8h, 10h, 13h, 15h, 18h or 20h, and the specific values between the above values are not exhaustive for reasons of space and simplicity.
According to the invention, when the concentration of the alkali liquor in the step (2) is more than or equal to 300g/L, the temperature of the severe alkaline activation reaction is less than or equal to 160 ℃.
According to the invention, the temperature of the severe alkaline activation reaction is > 160 ℃ when the concentration of the lye in step (2) is < 300 g/L.
According to the invention, the solid mixture in the step (3) comprises the following components in percentage by mass: 40-60% of clay-like material, 15-35% of feldspar-like material and 10-30% of fly ash.
According to the invention, the content of clay-like material in the solid mix is 40-60% by mass, and may be, for example, 40%, 43%, 45%, 48%, 50%, 52%, 55%, 58% or 60%, and the specific values between the above values, which are limited to space and for the sake of brevity, are not exhaustive.
According to the invention, the solid mix has a content of long stone-like material of 15-35% by mass, for example 15%, 18%, 20%, 23%, 25%, 28%, 30%, 33% or 35%, and the specific values between the above values, limited to space and for the sake of brevity, are not exhaustive.
According to the invention, the content of the fly ash in the solid mixture is 10-30% by mass, and may be, for example, 10%, 13%, 15%, 18%, 20%, 23%, 25%, 27% or 30%, and the specific values between the above values are not exhaustive for reasons of space and simplicity.
The fly ash in the solid mixture is unmodified fly ash, namely original fly ash.
According to the invention, the mechanical mixing mode in the step (3) is ball milling, and the particle size of the solid mixture obtained after ball milling is-250 meshes.
According to the invention, the pressure of the shaping in step (4) is 20-100MPa, and may be, for example, 20MPa, 30MPa, 40MPa, 50MPa, 60MPa, 70MPa, 80MPa, 90MPa or 100MPa, and the specific values therebetween are limited by space and for the sake of brevity and are not exhaustive.
According to the present invention, the sintering temperature in step (5) is 1000-1300 ℃, for example, 1000 ℃, 1050 ℃, 1100 ℃, 1150 ℃, 1200 ℃, 1250 ℃ or 1300 ℃, and the specific values therebetween are limited to the space and for brevity, and the present invention is not exhaustive.
According to the invention, the sintering time in step (5) is 0.2-3h, for example, 0.2h, 0.5h, 1h, 1.5h, 2h, 2.5h or 3h, and the specific values between the above values are limited by space and for the sake of brevity, and the invention is not exhaustive.
As a preferred technical scheme, the method for preparing the ceramic tile only by using the fly ash as the raw material comprises the following steps:
(1) mixing 60-100g/L alkali liquor and fly ash according to the liquid-solid ratio of (2-10) to 1, heating to 80-150 ℃, and carrying out mild alkaline activation reaction for 0.5-20h to obtain a clay-like material; the alkali liquor is a sodium hydroxide solution and/or a potassium hydroxide solution; when the concentration of the alkali liquor is more than or equal to 80g/L, the temperature of the mild alkaline activation reaction is less than or equal to 120 ℃, and when the concentration of the alkali liquor is less than 80g/L, the temperature of the mild alkaline activation reaction is more than 120 ℃;
(2) mixing alkaline liquor with the concentration of 105-500g/L and fly ash according to the liquid-solid ratio of (2-10):1, heating to 120-200 ℃ to carry out deep alkaline activation reaction for 0.5-20h to obtain an anorthite material; the alkali liquor is a sodium hydroxide solution and/or a potassium hydroxide solution; when the concentration of the alkali liquor is more than or equal to 300g/L, the temperature of the severe alkaline activation reaction is less than or equal to 160 ℃; when the concentration of the alkali liquor is less than 300g/L, the temperature of the severe alkaline activation reaction is more than 160 ℃;
(3) mixing 10-30% of fly ash, 40-60% of clay-like material and 15-35% of feldspar-like material according to the mass percentage, and then carrying out ball milling to obtain a solid mixture with the particle size of-250 meshes;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) under the pressure of 20-100MPa to obtain a green body;
(5) and (4) sintering the green body obtained in the step (4) at the temperature of 1000-1300 ℃ for 0.2-3h to obtain a ceramic tile product after sintering.
Compared with the prior art, the invention at least has the following beneficial effects:
(1) according to the invention, the fly ash is activated into the clay-like material and the long stone-like material through chemical modification to respectively replace the clay and feldspar minerals in the traditional ceramic, and through subsequent compounding of raw material components, the fly ash is only used as the raw material, namely, the traditional ceramic raw material is 100% replaced, so that the high-added-value utilization of the fly ash is realized, and the current situation that the ceramic production raw material is increasingly in short supply is relieved.
(2) The ceramic tile prepared by the invention has abundant acicular mullite structures inside, low volume weight, modulus of rupture far larger than the national standard, excellent comprehensive performance and more advantages than similar products in the current market.
Drawings
FIG. 1 is a process flow diagram provided by one embodiment of the present invention.
The present invention is described in further detail below. The following examples are merely illustrative of the present invention and do not represent or limit the scope of the claims, which are defined by the claims.
Detailed Description
The technical scheme of the invention is further explained by the specific implementation mode in combination with the attached drawings.
The present invention provides, in part, a method for making ceramic tiles using only fly ash as a raw material, as shown in fig. 1, which may be: mixing 60-100g/L alkali liquor with fly ash, heating to 80-150 ℃ for mild alkaline activation reaction to obtain a clay-like material; mixing alkali liquor with the concentration of 105-500g/L with the fly ash, heating to 120-200 ℃ for deep alkaline activation reaction to obtain feldspar-like material; mechanically mixing the unactivated fly ash (quartz-like material) with a clay-like material and a feldspar-like material to obtain a solid mixture; carrying out pressure forming on the obtained solid mixture to obtain a green body; and sintering the green body to obtain a ceramic tile product after sintering.
To better illustrate the invention and to facilitate the understanding of the technical solutions thereof, typical but non-limiting examples of the invention are as follows:
example 1
In the example, fly ash from a power plant of the union of Silibinoguole of inner Mongolia autonomous region is used as a raw material to prepare the ceramic tile according to the following method.
(1) Mixing 60g/L NaOH solution with fly ash according to a liquid-solid ratio of 10:1, heating to 150 ℃, and carrying out mild alkaline activation reaction for 20h to obtain a clay-like material;
(2) mixing 105g/L NaOH solution with fly ash according to a liquid-solid ratio of 10:1, heating to 200 ℃ and carrying out deep alkaline activation reaction for 20h to obtain feldspathic material;
(3) mixing 25% of fly ash, 50% of clay-like material and 25% of feldspar-like material according to the mass percentage, and then carrying out ball milling to obtain a solid mixture with the particle size of-250 meshes;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) to obtain a green body with the body strength of 2.50 Mpa;
(5) and (4) sintering the green body obtained in the step (4) at 1050 ℃ for 3h to obtain a ceramic tile product after sintering.
Example 2
In the example, fly ash from a certain Tianjin power plant is used as a raw material to prepare the ceramic tile according to the following method.
(1) Mixing NaOH solution with the concentration of 100g/L and fly ash according to the liquid-solid ratio of 5:1, heating to 80 ℃, and carrying out mild alkaline activation reaction for 10 hours to obtain a clay-like material;
(2) mixing NaOH solution with the concentration of 500g/L and fly ash according to the liquid-solid ratio of 5:1, heating to 120 ℃, and carrying out deep alkaline activation reaction for 10h to obtain feldspar-like material;
(3) mixing 10% of fly ash, 60% of clay-like material and 30% of feldspar-like material according to the mass percentage, and then carrying out ball milling to obtain a solid mixture with the particle size of-250 meshes;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) to obtain a green body with the body strength of 4.55 Mpa;
(5) and (4) sintering the green body obtained in the step (4) at 1250 ℃ for 1.5h to obtain a ceramic tile product after sintering.
Example 3
The preparation method adopts fly ash of a certain power plant in Renbell City of autonomous region of inner Mongolia as a raw material to prepare the ceramic tile according to the following method.
(1) Mixing NaOH solution with the concentration of 100g/L and fly ash according to the liquid-solid ratio of 10:1, heating to 90 ℃, and carrying out mild alkaline activation reaction for 0.5h to obtain a clay-like material;
(2) mixing NaOH solution with the concentration of 200g/L and fly ash according to the liquid-solid ratio of 4:1, heating to 200 ℃ and carrying out deep alkaline activation reaction for 0.5h to obtain feldspar-like material;
(3) mixing 30% of fly ash, 40% of clay-like material and 30% of feldspar-like material according to the mass percentage, and then carrying out ball milling to obtain a solid mixture with the particle size of-250 meshes;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) to obtain a green body with the body strength of 4.55 Mpa;
(5) and (4) sintering the green body obtained in the step (4) at 1150 ℃ for 2.5h to obtain a ceramic tile product after sintering.
Example 4
In the example, fly ash from a power plant of the union of Silibinoguole of inner Mongolia autonomous region is used as a raw material to prepare the ceramic tile according to the following method.
(1) Mixing NaOH solution with the concentration of 100g/L and fly ash according to the liquid-solid ratio of 2:1, heating to 110 ℃, and carrying out mild alkaline activation reaction for 20 hours to obtain a clay-like material;
(2) mixing 150g/L NaOH solution with fly ash according to a liquid-solid ratio of 5:1, heating to 200 ℃ and carrying out deep alkaline activation reaction for 10h to obtain feldspathic material;
(3) mixing 30% of fly ash, 55% of clay-like material and 15% of feldspar-like material according to the mass percentage, and then carrying out ball milling to obtain a solid mixture with the particle size of-250 meshes;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) to obtain a green body with the body strength of 2.40 Mpa;
(5) and (4) sintering the green body obtained in the step (4) at 1200 ℃ for 1h to obtain a ceramic tile product after sintering.
Example 5
In the embodiment, the fly ash of a certain power plant in the city of xi' an of Shaanxi province is used as a raw material to prepare the ceramic tile according to the following method.
(1) Mixing NaOH solution with the concentration of 90g/L and fly ash according to the liquid-solid ratio of 10:1, heating to 110 ℃, and carrying out mild alkaline activation reaction for 2h to obtain a clay-like material;
(2) mixing NaOH solution with the concentration of 120g/L and fly ash according to the liquid-solid ratio of 4:1, heating to 190 ℃ and carrying out deep alkaline activation reaction for 6h to obtain anorthite material;
(3) mixing 10% of fly ash, 55% of clay material and 35% of feldspar material according to the mass percentage, and then carrying out ball milling to obtain a solid mixture with the particle size of-250 meshes;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) to obtain a green body with the body strength of 5.72 Mpa;
(5) and (4) sintering the green body obtained in the step (4) at 1300 ℃ for 0.5h to obtain a ceramic tile product after sintering.
Example 6
In the example, fly ash from a power plant of the union of Silibinoguole of inner Mongolia autonomous region is used as a raw material to prepare the ceramic tile according to the following method.
(1) Mixing 80g/L NaOH solution with fly ash according to a liquid-solid ratio of 6:1, heating to 120 ℃, and carrying out mild alkaline activation reaction for 15h to obtain a clay-like material;
(2) mixing NaOH solution with the concentration of 300g/L and fly ash according to the liquid-solid ratio of 7:1, heating to 160 ℃, and carrying out deep alkaline activation reaction for 7h to obtain an anorthite material;
(3) mixing 25% of fly ash, 40% of clay material and 35% of feldspar material according to the mass percentage, and then carrying out ball milling to obtain a solid mixture with the particle size of-250 meshes;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) to obtain a green body with the green body strength of 4.00 Mpa;
(5) and (4) sintering the green body obtained in the step (4) at 1000 ℃ for 2h to obtain a ceramic tile product after sintering.
Example 7
In the example, fly ash from a power plant of the union of Silibinoguole of inner Mongolia autonomous region is used as a raw material to prepare the ceramic tile according to the following method.
(1) Mixing 60g/L NaOH solution with fly ash according to a liquid-solid ratio of 2:1, heating to 150 ℃, and carrying out mild alkaline activation reaction for 20h to obtain a clay-like material;
(2) mixing NaOH solution with the concentration of 400g/L and fly ash according to the liquid-solid ratio of 5:1, heating to 150 ℃, and carrying out deep alkaline activation reaction for 10h to obtain anorthite material;
(3) mixing 20% of fly ash, 50% of clay-like material and 30% of feldspar-like material according to the mass percentage, and then carrying out ball milling to obtain a solid mixture with the particle size of-250 meshes;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) to obtain a green body with the body strength of 3.88 MPa;
(5) and (4) sintering the green body obtained in the step (4) at 1100 ℃ for 3h to obtain a ceramic tile product after sintering.
The products obtained in each example and comparative example were subjected to a performance test in which the test standards for volume weight and modulus of rupture were GB/T3810.3 and GB/T3810.4, respectively, and the results are shown in Table 1.
TABLE 1
| Volume weight | Modulus of rupture | |
| Example 1 | 2.44 | 45.4 |
| Example 2 | 2.58 | 50.3 |
| Example 3 | 2.51 | 48.7 |
| Example 4 | 2.42 | 43.1 |
| Example 5 | 2.55 | 44.8 |
| Example 6 | 2.32 | 39.8 |
| Example 7 | 2.40 | 42.4 |
The preferred embodiments of the present invention have been described in detail, however, the present invention is not limited to the specific details of the above embodiments, and various simple modifications may be made to the technical solution of the present invention within the technical idea of the present invention, and these simple modifications are within the protective scope of the present invention.
It should be noted that the various technical features described in the above embodiments can be combined in any suitable manner without contradiction, and the invention is not described in any way for the possible combinations in order to avoid unnecessary repetition.
In addition, any combination of the various embodiments of the present invention is also possible, and the same should be considered as the disclosure of the present invention as long as it does not depart from the spirit of the present invention.
Claims (10)
1. A method for preparing a ceramic tile by using only fly ash as a raw material, which is characterized by comprising the following steps:
(1) mixing 60-100g/L alkali liquor with fly ash, heating to 80-150 ℃ for mild alkaline activation reaction to obtain a clay-like material;
(2) mixing alkali liquor with the concentration of 105-500g/L with the fly ash, heating to 120-200 ℃ for deep alkaline activation reaction to obtain feldspar-like material;
(3) mechanically mixing fly ash with the clay-like material obtained in the step (1) and the feldspar-like material obtained in the step (2) to obtain a solid mixture;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) to obtain a green body;
(5) and (4) sintering the green body obtained in the step (4) to obtain a ceramic tile product after sintering.
2. The method of claim 1, wherein the alkali solution in step (1) and step (2) is sodium hydroxide solution and/or potassium hydroxide solution.
3. The method of claim 1 or 2, wherein the liquid-solid ratio of the lye to the fly ash in step (1) is (2-10): 1;
preferably, the time of the mild alkaline activation reaction in the step (1) is 0.5-20 h.
4. The method as claimed in any one of claims 1 to 3, wherein the temperature of the mild alkaline activation reaction is 120 ℃ or less when the concentration of the alkali solution in the step (1) is 80g/L or more;
preferably, the temperature of the mild alkaline activation reaction is > 120 ℃ when the concentration of the lye in step (1) is < 80 g/L.
5. The method of any one of claims 1 to 4, wherein the ratio of the lye to the fly ash in step (2) is (2-10): 1;
preferably, the time of the mild alkaline activation reaction in the step (2) is 0.5-20 h.
6. The method of any one of claims 1 to 5, wherein the temperature of the severe alkaline activation reaction is 160 ℃ or less when the concentration of the alkali liquor in the step (2) is 300g/L or more;
preferably, the temperature of the severe alkaline activation reaction is > 160 ℃ when the concentration of the lye in step (2) is < 300 g/L.
7. The method of any one of claims 1-6, wherein the solid mix of step (3) comprises the following components in weight percent: clay material 40-60%, feldspar material 15-35%, and fly ash 10-30%;
preferably, the mechanical mixing in the step (3) is ball milling;
preferably, the particle size of the solid mixture obtained in the step (3) is-250 meshes.
8. The method according to any one of claims 1 to 7, wherein the pressure for the forming in step (4) is 20 to 100 MPa.
9. The method according to any one of claims 1 to 8, wherein the sintering temperature in step (5) is 1000-1300 ℃;
preferably, the sintering time in the step (5) is 0.2-3 h.
10. The method according to any one of claims 1 to 9, characterized in that it comprises the steps of:
(1) mixing 60-100g/L alkali liquor and fly ash according to the liquid-solid ratio of (2-10) to 1, heating to 80-150 ℃, and carrying out mild alkaline activation reaction for 0.5-20h to obtain a clay-like material; the alkali liquor is a sodium hydroxide solution and/or a potassium hydroxide solution; when the concentration of the alkali liquor is more than or equal to 80g/L, the temperature of the mild alkaline activation reaction is less than or equal to 120 ℃, and when the concentration of the alkali liquor is less than 80g/L, the temperature of the mild alkaline activation reaction is more than 120 ℃;
(2) mixing alkaline liquor with the concentration of 105-500g/L and fly ash according to the liquid-solid ratio of (2-10):1, heating to 120-200 ℃ to carry out deep alkaline activation reaction for 0.5-20h to obtain an anorthite material; the alkali liquor is a sodium hydroxide solution and/or a potassium hydroxide solution; when the concentration of the alkali liquor is more than or equal to 300g/L, the temperature of the severe alkaline activation reaction is less than or equal to 160 ℃; when the concentration of the alkali liquor is less than 300g/L, the temperature of the severe alkaline activation reaction is more than 160 ℃;
(3) mixing 10-30% of fly ash, 40-60% of clay-like material and 15-35% of feldspar-like material according to the mass percentage, and then carrying out ball milling to obtain a solid mixture with the particle size of-250 meshes;
(4) carrying out pressure forming on the solid mixture obtained in the step (3) under the pressure of 20-100MPa to obtain a green body;
(5) and (4) sintering the green body obtained in the step (4) at the temperature of 1000-1300 ℃ for 0.2-3h to obtain a ceramic tile product after sintering.
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| CN1760155A (en) * | 2005-08-18 | 2006-04-19 | 任渊 | Method for fabricating clinker brick with central blind hole made from full fly ash |
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| CN108190926A (en) * | 2018-01-18 | 2018-06-22 | 中国科学院过程工程研究所 | A kind of preparation method of desiliconization flyash |
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| CN1760155A (en) * | 2005-08-18 | 2006-04-19 | 任渊 | Method for fabricating clinker brick with central blind hole made from full fly ash |
| CN101279839A (en) * | 2008-03-03 | 2008-10-08 | 徐子芳 | Solid wall insulating brick made by calcining fly ash coal gangue |
| CN106977176A (en) * | 2016-01-18 | 2017-07-25 | 中国科学院过程工程研究所 | A kind of method of utilization high-calcium fly ass low-temperature sintering ceramic brick |
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