CN110950558A - Application of ceramic waste in preparation of high-strength lightweight aggregate and high-strength lightweight aggregate prepared from ceramic waste - Google Patents
Application of ceramic waste in preparation of high-strength lightweight aggregate and high-strength lightweight aggregate prepared from ceramic waste Download PDFInfo
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
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Abstract
The invention belongs to the technical field of environment-friendly building, building material and solid waste treatment and resource utilization, and particularly relates to application of ceramic waste to preparation of high-strength lightweight aggregate, further discloses high-strength lightweight aggregate prepared from the ceramic waste and fly ash, and further discloses a preparation method of the high-strength lightweight aggregate. The lightweight aggregate of the invention takes fly ash and solid wastes such as ceramic waste and the like generated in each stage in the ceramic production process as raw materials; the high-strength lightweight aggregate is prepared from different additives by utilizing the characteristic interaction of ceramic wastes generated in different stages, and better performance advantages are obtained, so that the production cost of the lightweight aggregate is reduced, the utilization of solid wastes is maximized, and the building ceramsite with light weight, high strength, low heat conductivity coefficient, high refractoriness, good chemical stability, good durability and good heat and sound insulation performance is obtained.
Description
Technical Field
The invention belongs to the technical field of environment-friendly building, building material and solid waste treatment and resource utilization, and particularly relates to application of ceramic waste to preparation of high-strength lightweight aggregate, further discloses high-strength lightweight aggregate prepared from the ceramic waste and fly ash, and further discloses a preparation method of the high-strength lightweight aggregate.
Background
Aggregates, also called aggregates, are granular loose materials used for the preparation of concrete or mortar, the majority of common aggregates being natural aggregates, and a part of them being industrial waste aggregates (such as metallurgical slag, etc.). With the development of energy conservation, environmental protection, light weight and heat insulation of the current building materials, the light aggregate gradually replaces the common aggregate to become the preferred aggregate material in the building industry. Lightweight aggregates, generally having a bulk volume weight of less than 1000kg/m3The porous aggregate of (2), wherein the natural lightweight aggregate has the advantages of low density and convenient exploitation, but has the problems of common performance and difficulty in meeting the performance requirements which are improved day by day. Nowadays, the preparation of lightweight aggregates with low cost and high performance using industrial waste materials is a major direction in the development of building materials.
With the rapid development of social economy and ceramic industry, the increasing amount of waste materials in the ceramic industry not only causes great pressure on urban environment, but also limits the development of urban economy and the sustainable development of the ceramic industry, so that the treatment and utilization of the waste materials in the ceramic industry are very important. At present, most of the ceramic industrial waste in China is treated in a landfill mode, so that manpower and material resources are consumed, underground water quality is polluted, and the secondary utilization degree of the ceramic industrial waste is very low. In addition, the shortage of waste treatment funds causes a large amount of waste residues to occupy the farmland, and causes great pollution to water and air. Particularly, the ceramic industry has been developed at a high speed for 20 years, and the quantity of ceramic waste is increased along with the continuous increase of the ceramic yield. According to incomplete statistics, the yield of various ceramic wastes produced in the Foshan ceramic production area exceeds 400 ten thousand tons, and the annual yield of the national ceramic wastes is estimated to be about 1000 ten thousand tons. The problem that a large amount of ceramic waste can be solved without simple landfill is how to change waste into valuable and change the waste into resources, which is a urgent affair in the ceramic industry.
In addition, in the existing ceramic industry, the yield of polished tiles in China reaches 8 hundred million square meters, and in the grinding and polishing process of the polished tiles, a surface layer of 0.5-0.7mm, sometimes even 1-2mm, needs to be removed from the surface of a green tile, namely, about 1.5 kilograms of tile chips are formed in each square meter of polished tiles, and meanwhile, the loss of the grinding tool is about 0.6 kilograms. In short, the production of polished tiles per square meter results in approximately 2.1 kg of polishing waste per square meter, as is the case with the prior art. According to the calculation, the output of polished tile polishing waste in China can reach 170 ten thousand tons every year. If the polishing waste is not effectively recycled, it will cause serious damage to the surrounding environment. The disposal of polishing wastes has been a worldwide problem that disturbs the production of polishing bricks, and the effective utilization of polishing wastes has become the most urgent subject for the production of polishing bricks.
Therefore, how to change the waste of the fertilizer into valuable in the ceramic industry is an important problem to be solved urgently in the ceramic industry, and the method has positive significance for the development of the ceramic industry.
Disclosure of Invention
Therefore, the invention aims to provide a high-strength light aggregate prepared based on ceramic waste to solve the problem of low treatment and utilization degree of the waste in the ceramic industry in the prior art;
the second technical problem to be solved by the invention is to provide a preparation method of the high-strength lightweight aggregate.
In order to solve the technical problem, the invention discloses application of ceramic waste in preparation of high-strength lightweight aggregate.
Specifically, the ceramic waste comprises a mixture of ceramic body waste residues and/or waste products generated before the ceramic sintering step, a mixture of ceramic body waste residues and/or waste products generated during and after the ceramic sintering step, ceramic polishing waste generated by a ceramic polishing brick, and waste glaze generated in the ceramic production.
The invention also discloses a high-strength lightweight aggregate prepared based on the ceramic waste, and the preparation raw materials of the lightweight aggregate comprise: 30-50 parts of fly ash, 1-12 parts of pelletizing core material, 10-40 parts of biscuit waste fine powder, 5-10 parts of plasticizer, 2-10 parts of foaming agent and 0-5 parts of fluxing agent.
Preferably, the high-strength lightweight aggregate prepared based on ceramic waste has the grain size of less than or equal to 150 microns.
The balling core material is a mixture of ceramic body waste residues and/or waste products generated in and after ceramic sintering, and the grain diameter of the balling core material is 1-3 mm.
The biscuit waste fine powder is a mixture of ceramic body waste residues and/or waste products generated in and after ceramic sintering, and fine powder particles with the particle size of less than or equal to 150 mu m are obtained after ball milling treatment of a crusher.
The plasticizer is a mixture of waste residues and/or waste products of a ceramic blank generated before the ceramic sintering step, and particles with the particle size of less than or equal to 150 mu m are obtained after ball milling treatment of a crusher. The ceramic waste has good plasticity because the main component of the ceramic waste is clay and the ceramic waste is not subjected to firing treatment.
The foaming agent is ceramic polishing waste generated in the production process of the ceramic polishing brick, and fine powder particles with the particle size of less than or equal to 150 mu m are obtained after ball milling treatment of a crusher. The ceramic polishing waste is prepared by mixing polishing brick ceramic powder, SiC powder, MgO, MgCl and organic resin as main components, wherein the content of SiC is 5-15%, and the ceramic polishing waste can be used as a foaming agent.
The fluxing agent is waste glaze generated in the ceramic manufacturing process, and fine powder particles with the particle size of less than or equal to 150 mu m are obtained after ball milling treatment by a crusher. The waste glaze material is mainly composed of feldspar, diopside, wollastonite, talc and other mineral raw materials which can be used as a fluxing agent.
The invention also discloses a method for preparing the high-strength lightweight aggregate prepared based on the ceramic waste, which comprises the following steps:
(1) crushing and ball-milling the raw materials according to the selected particle size range for later use;
(2) mixing the fly ash, the pelletizing core material, the biscuit waste fine powder, the plasticizer, the foaming agent and the fluxing agent according to the selected proportion;
(3) continuously granulating the obtained mixed material by using a disc granulator, and continuously adding water, wherein the water addition amount is 18-22 wt% of the mixed material amount, so as to obtain a ceramsite blank;
(4) drying the obtained ceramsite blank at the temperature of 200 ℃ and 600 ℃ until the water content in the ceramsite blank is below 5 wt%;
(5) sintering the dried ceramsite blank at the temperature of 1000-1200 ℃, cooling, slowly cooling at the temperature of above 700 ℃, wherein the cooling speed is not more than 20 ℃/min, and quickly cooling below 700 ℃ to room temperature to obtain the required lightweight aggregate.
During the preparation process, the disc angle of the disc granulator is preferably 48-52 degrees, and the sintering process is carried out in a chain grate or a rotary kiln.
The lightweight aggregate of the invention takes fly ash and solid wastes such as ceramic waste and the like generated in each stage in the ceramic production process as raw materials; the waste particles with the particle size of 1-3mm generated in the ceramic sintering process are taken as the nucleating material, so that the granulation nucleation stage is removed in the preparation process of the ceramsite, the particle size and the quantity of the ceramsite are basically controllable, the customization of the ceramsite is realized, the granulation efficiency is increased, and the reduction of energy consumption is facilitated; meanwhile, by utilizing the mutual action of the characteristics of the ceramic waste materials generated in different stages, the high-strength light aggregate is prepared from different additives, better performance advantages are obtained, the production cost of the light aggregate is favorably reduced, and the utilization of solid waste is maximized, so that the building ceramsite with light weight, high strength, low heat conductivity coefficient, high refractoriness, good chemical stability, good durability and good heat and sound insulation performance is obtained.
The preparation process of the light aggregate of the invention carries out granulation of the light aggregate by a disc, powder particles are agglomerated together under the action of a liquid bridge and capillary particles in the granulation process to form micro-nuclei (the formation rate and the quantity of the micro-nuclei are difficult to control), and the agglomerated micro-nuclei continuously rotate and grow in a powder layer under the action of friction and rolling impact force generated by low-speed rotation in a container, and finally become spherical particles with certain size; the addition of the 'core' of the balling core material in the raw materials can directly replace the micronucleus, and the agglomerated powder is balling, and under the condition of fixed quantity of the cores, the more the powder is added, the larger the particle size of the ceramsite is, so that the particle size and the quantity of the ceramsite are basically controllable, the customization of the ceramsite is realized, the pelleting efficiency is increased, and the reduction of energy consumption is facilitated.
The raw materials for preparing the lightweight aggregate have wide sources, and a large amount of ceramic waste and fly ash waste generated by different production processes can be effectively treated; the whole raw material of the product is made of industrial solid wastes, is not suitable for other mineral raw materials, and effectively saves the production cost. The density grade of the light aggregate prepared by the invention is 700-3The cylinder pressure strength can reach 6-12MPa, the water absorption rate is 4-8%, and the composite material has the advantages of light weight and high strength and is not easy to damage. The lightweight aggregate prepared by the method can be used for effectively preparing lightweight aggregate high-performance concrete which can be used as a load-bearing structure and can be applied to building wallboards, bridges, pipelines and the like; the method can also be used for preparing light aggregate concrete, and has the advantages of low shrinkage, low creep, high elastic modulus and the like. Therefore, the high-strength lightweight aggregate has better performance advantage and wide market prospect.
Drawings
In order that the present disclosure may be more readily and clearly understood, the following detailed description of the present disclosure is provided in connection with specific embodiments thereof and the accompanying drawings, in which,
FIG. 1 is a process flow chart of the present invention for preparing the high strength lightweight aggregate based on ceramic waste.
Detailed Description
In the following embodiments of the invention, the loss on ignition of the selected fly ash material is 2-10%, and the content of each component is determined as follows: SiO 2230％-70％、Al2O310％-50％、CaO1％-15％、Fe2O31％-18％、MgO0.01％-8％、TiO20.01% -3%, pulverizing the fly ash, and screening the fly ash with the grain diameter less than or equal to 150 mu m for use.
In the following embodiment of the invention, the selected balling core material is one of ceramic waste materials, in particular to a mixture waste material of unqualified fired waste residue and/or waste product which has defects in the ceramic firing process or after firing, and the balling core material is screened and used by screening granular materials with the grain size range of 1-3 mm.
In the following embodiment of the invention, the selected biscuit waste fine powder is one of ceramic wastes, in particular to a mixture waste of unqualified fired waste residue and/or waste product with defects in the ceramic firing process or after firing, and the mixture waste is crushed, ball-milled, screened and used after screening fine powder particles with the particle size of less than or equal to 150 mu m.
In the following embodiment of the invention, the selected plasticizer is one of ceramic wastes, and specifically refers to a mixture waste of ceramic body waste residues and/or waste products which are generated by carrying and the like before a ceramic sintering step (after granulation and forming processes), and particles with the particle size of less than or equal to 150 micrometers are obtained after ball milling treatment by a crusher. The ceramic waste has good plasticity because the main component of the ceramic waste is clay and the ceramic waste is not subjected to firing treatment.
In the following embodiment of the invention, the selected foaming agent is one of ceramic wastes, in particular to ceramic polishing wastes generated in the production process of ceramic polished tiles, and fine powder particles with the particle size of less than or equal to 150 mu m are obtained after ball milling treatment by a crusher. The ceramic polishing waste is prepared by mixing polishing brick ceramic powder, SiC powder, MgO, MgCl and organic resin as main components, wherein the content of SiC is 5-15%, and the ceramic polishing waste can be used as a foaming agent.
In the following embodiment of the invention, the fluxing is one of ceramic wastes, in particular to waste glaze produced in the ceramic manufacturing process, and fine powder particles with the particle size of less than or equal to 150 mu m are obtained after ball milling treatment by a crusher. The waste glaze material is mainly composed of feldspar, diopside, wollastonite, talc and other mineral raw materials which can be used as a fluxing agent.
Example 1
The preparation raw materials of the high-strength lightweight aggregate comprise: 30kg of fly ash, 12kg of balling core material, 38kg of biscuit waste fine powder, 5kg of plasticizer, 10kg of foaming agent and 5kg of fluxing agent.
As shown in the process flow chart of fig. 1, the preparation method of the high-strength lightweight aggregate of the embodiment includes the following steps:
(1) crushing and ball-milling the raw materials according to the selected particle size range for later use;
(2) mixing the fly ash, the pelletizing core material, the biscuit waste fine powder, the plasticizer, the foaming agent and the fluxing agent according to the selected proportion;
(3) continuously granulating the obtained mixed material by using a disc granulator, and continuously adding water, wherein the water addition amount is 18 wt% of the mixed material amount, so as to obtain a ceramsite blank;
(4) drying the obtained ceramsite blank at 400 ℃ until the moisture content in the ceramsite blank is below 5 wt%;
(5) sintering the dried ceramsite blank at 1200 ℃, cooling, slowly cooling at the temperature of over 700 ℃, wherein the cooling speed is not more than 20 ℃/min, and quickly cooling to room temperature below 700 ℃, thus obtaining the required lightweight aggregate.
Example 2
The preparation raw materials of the high-strength lightweight aggregate comprise: 34kg of fly ash, 9kg of balling core material, 40kg of fine powder of biscuit waste, 5kg of plasticizer, 8kg of foaming agent and 4kg of fluxing agent.
The preparation method of the high-strength lightweight aggregate comprises the following steps:
(1) crushing and ball-milling the raw materials according to the selected particle size range for later use;
(2) mixing the fly ash, the pelletizing core material, the biscuit waste fine powder, the plasticizer, the foaming agent and the fluxing agent according to the selected proportion;
(3) continuously granulating the obtained mixed material by using a disc granulator, and continuously adding water, wherein the water addition amount is 22 wt% of the mixed material amount, so as to obtain a ceramsite blank;
(4) drying the obtained ceramsite blank at 200 ℃ until the moisture content in the ceramsite blank is below 5 wt%;
(5) sintering the dried ceramsite blank at the temperature of 1000 ℃, cooling, slowly cooling at the temperature of over 700 ℃, wherein the cooling speed is not more than 20 ℃/min, and quickly cooling to room temperature at the temperature of below 700 ℃ to obtain the required lightweight aggregate.
Example 3
The preparation raw materials of the high-strength lightweight aggregate comprise: 49kg of fly ash, 3kg of balling core material, 38kg of biscuit waste fine powder, 5kg of plasticizer, 2kg of foaming agent and 3kg of fluxing agent.
The preparation method of the high-strength lightweight aggregate comprises the following steps:
(1) crushing and ball-milling the raw materials according to the selected particle size range for later use;
(2) mixing the fly ash, the pelletizing core material, the biscuit waste fine powder, the plasticizer, the foaming agent and the fluxing agent according to the selected proportion;
(3) continuously granulating the obtained mixed material by using a disc granulator, and continuously adding water, wherein the water addition amount is 20 wt% of the mixed material amount, so as to obtain a ceramsite blank;
(4) drying the obtained ceramsite blank at 400 ℃ until the moisture content in the ceramsite blank is below 5 wt%;
(5) sintering the dried ceramsite blank at 1100 ℃, cooling, slowly cooling at the temperature of over 700 ℃, wherein the cooling speed is not more than 20 ℃/min, and quickly cooling to room temperature below 700 ℃ to obtain the required lightweight aggregate.
Example 4
The preparation raw materials of the high-strength lightweight aggregate comprise: 46kg of fly ash, 5kg of balling core material, 40kg of fine biscuit waste powder, 5kg of plasticizer, 2kg of foaming agent and 2kg of fluxing agent.
The preparation method of the high-strength lightweight aggregate comprises the following steps:
(1) crushing and ball-milling the raw materials according to the selected particle size range for later use;
(2) mixing the fly ash, the pelletizing core material, the biscuit waste fine powder, the plasticizer, the foaming agent and the fluxing agent according to the selected proportion;
(3) continuously granulating the obtained mixed material by using a disc granulator, and continuously adding water, wherein the water addition amount is 22 wt% of the mixed material amount, so as to obtain a ceramsite blank;
(4) drying the obtained ceramsite blank at 600 ℃ until the moisture content in the ceramsite blank is below 5 wt%;
(5) sintering the dried ceramsite blank at 1200 ℃, cooling, slowly cooling at the temperature of over 700 ℃, wherein the cooling speed is not more than 20 ℃/min, and quickly cooling to room temperature below 700 ℃, thus obtaining the required lightweight aggregate.
Example 5
The preparation raw materials of the high-strength lightweight aggregate comprise: 50kg of fly ash, 1kg of balling core material, 20kg of biscuit waste fine powder, 10kg of plasticizer and 5kg of foaming agent.
The preparation method of the high-strength lightweight aggregate described in this example is the same as that of example 1.
Example 6
The preparation raw materials of the high-strength lightweight aggregate comprise: 40kg of fly ash, 7kg of balling core material, 10kg of biscuit waste fine powder, 8kg of plasticizer, 5kg of foaming agent and 5kg of fluxing agent.
The preparation method of the high-strength lightweight aggregate described in this example is the same as that of example 1.
Experimental examples the lightweight aggregates prepared in the above examples 1 to 6 were tested for their relevant properties according to the conventional method of the prior art, and the test data are recorded in table 1 below.
Table 1 results of the performance test data of the lightweight aggregates
| Numbering | Ceramsite with grain diameter/mm | Bulk density/kg/m3 | Water absorption/%) | Barrel pressure strength/MPa |
| Example 1 | 4±1 | 725 | 4.3 | 6.5 |
| Example 2 | 6±1 | 886 | 5.2 | 7.9 |
| Example 3 | 8±1 | 962 | 6.8 | 10.3 |
| Example 4 | 10±1 | 1053 | 7.4 | 11.8 |
| Example 5 | 12±1 | 826 | 5.5 | 7.2 |
| Example 6 | 5±1 | 924 | 7.2 | 9.6 |
As can be seen from the data in the table above, the lightweight aggregate prepared by using the ceramic waste and the fly ash as raw materials has the advantages of light weight and high strength, and simultaneously has low water absorption rate, thereby meeting the requirements of production performance.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications therefrom are within the scope of the invention.
Claims (10)
1. Use of ceramic waste for the preparation of high strength lightweight aggregates.
2. Use according to claim 1, characterized in that said ceramic wastes comprise mixtures of ceramic body wastes and/or rejects generated before the ceramic sintering step, mixtures of ceramic body wastes and/or rejects generated during and after the ceramic sintering, ceramic polishing wastes generated by ceramic polishing bricks, and waste glazes generated in the ceramic production.
3. The high-strength lightweight aggregate prepared based on the ceramic waste is characterized in that the lightweight aggregate is prepared from the following raw materials: 30-50 parts of fly ash, 1-12 parts of pelletizing core material, 10-40 parts of biscuit waste fine powder, 5-10 parts of plasticizer, 2-10 parts of foaming agent and 0-5 parts of fluxing agent.
4. The high-strength lightweight aggregate prepared based on ceramic waste according to claim 3, characterized in that the particle size of the fly ash is 150 μm or less.
5. The high-strength lightweight aggregate prepared based on ceramic waste according to claim 3 or 4, characterized in that the balling core material is a mixture of waste residues and/or waste products of ceramic green bodies generated in and after ceramic sintering, and the grain size of the balling core material is 1-3 mm.
6. The high-strength lightweight aggregate prepared based on ceramic wastes according to any one of claims 3 to 5, characterized in that the biscuit waste fine powder is a mixture of ceramic body waste residues and/or wastes generated in and after ceramic sintering, and is subjected to ball milling treatment by a crusher to obtain fine powder particles with the particle size of less than or equal to 150 μm.
7. The high-strength lightweight aggregate prepared based on ceramic wastes according to any one of claims 3 to 6, characterized in that the plasticizer is a mixture of waste residues and/or waste products of ceramic body generated before the ceramic sintering step, and is subjected to ball milling treatment by a crusher to obtain particles with a particle size of 150 μm or less.
8. The high-strength lightweight aggregate prepared based on ceramic waste according to any one of claims 3 to 7, wherein the foaming agent is ceramic polishing waste generated in the production process of ceramic polished tiles, and is subjected to ball milling treatment by a crusher to obtain fine powder particles with the particle size of less than or equal to 150 μm.
9. The high-strength lightweight aggregate prepared based on ceramic waste according to any one of claims 3 to 8, characterized in that the fluxing agent is waste glaze generated in the ceramic manufacturing process and is treated by a crusher through ball milling to obtain fine powder particles with the particle size of less than or equal to 150 μm.
10. A method for preparing high-strength lightweight aggregate prepared based on ceramic waste according to any one of claims 3 to 9, characterized by comprising the steps of:
(1) crushing and ball-milling the raw materials according to the selected particle size range for later use;
(2) mixing the fly ash, the pelletizing core material, the biscuit waste fine powder, the plasticizer, the foaming agent and the fluxing agent according to the selected proportion;
(3) continuously granulating the obtained mixed material by using a disc granulator, and continuously adding water, wherein the water addition amount is 18-22 wt% of the mixed material amount, so as to obtain a ceramsite blank;
(4) drying the obtained ceramsite blank at the temperature of 200 ℃ and 600 ℃ until the water content in the ceramsite blank is below 5 wt%;
(5) sintering the dried ceramsite blank at the temperature of 1000-1200 ℃, cooling, slowly cooling at the temperature of above 700 ℃, wherein the cooling speed is not more than 20 ℃/min, and quickly cooling below 700 ℃ to room temperature to obtain the required lightweight aggregate.
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Application publication date: 20200403 |