CN110963790A - Foaming ceramic plate produced without foaming agent and method - Google Patents
Foaming ceramic plate produced without foaming agent and method Download PDFInfo
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- CN110963790A CN110963790A CN201911233551.1A CN201911233551A CN110963790A CN 110963790 A CN110963790 A CN 110963790A CN 201911233551 A CN201911233551 A CN 201911233551A CN 110963790 A CN110963790 A CN 110963790A
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Abstract
The invention relates to a foaming ceramic plate produced without foaming agent and a method thereof. The invention has simple process and low cost, can realize the recycling of industrial dust and can produce plates with large thickness. A method for producing a foamed ceramic plate without using a foaming agent, comprising the steps of: and A, granulation: putting 60-90 parts of recovered dust powder with the silicon dioxide content of more than 50%, 10-20 parts of bentonite, 10-20 parts of glass powder, 25-35 parts of EPS particles and 2-3 parts of cellulose into balling equipment, adding water mist, mixing and stirring to prepare a 3-4mm sphere; b, cloth material: b, putting the ball body obtained in the step A into a heat-resistant steel die; c, sintering: sending the heat-resistant steel die subjected to material distribution into a heat treatment kiln for low-temperature, medium-temperature and high-temperature three-section sintering, and cooling to obtain a foamed ceramic plate; d, processing: and processing the foamed ceramic plate into a foamed ceramic plate with a required specification according to the requirement.
Description
Technical Field
The invention relates to a foaming ceramic plate produced without foaming agent and a method thereof.
Background
The foamed ceramic is prepared by adding high-temperature foaming agents such as silicon carbide or ferric oxide and the like into ceramic waste, industrial tailings or industrial waste residues according to a formula ratio, and sintering and foaming at the high temperature of 1100-plus 1200 ℃, so that the sintered and molded light ceramic material has the characteristics of heat preservation, heat insulation, fire prevention, moisture prevention, light weight and the like, and is widely applied to the fields of buildings and industrial heat insulation and preservation. Because the foaming agent needs a high-temperature liquid phase, the cost of the foamed ceramic is higher due to the influence of factors such as high firing temperature, high air consumption and the like in the process of producing the foamed ceramic in batches. The thickness of the existing foamed ceramic plate cannot be larger than 20cm, when the thickness of the existing foamed ceramic plate exceeds 20cm, the difference between the central temperature and the external temperature of the material is too large, the foaming inside and outside is uneven, and in the cooling process, because the temperature difference between the inside and the outside is too large, the distribution of thermal stress is uneven, so that the foamed ceramic plate is broken, the yield is too low, and the leftover materials are too much.
In order to solve the problems, the invention provides a foaming ceramic plate produced without a foaming agent and a method thereof.
In order to achieve the purpose, the invention adopts the technical scheme that: a foaming ceramic plate produced without a foaming agent comprises the following raw material components in percentage by weight: 60-90 parts of casting recycled dust powder, 10-20 parts of bentonite, 10-20 parts of glass powder, 25-35 parts of EPS particles and 2-3 parts of cellulose; the recovered dust powder is generated in the process of regenerating casting sand by using a casting sand mold, wherein the content of silicon dioxide is more than 50%; the diameter of the EPS particles is 1mm-2 mm; the fineness of the glass powder is 200-300 meshes; the cellulose is sodium carboxymethyl cellulose.
Further, the foamed ceramic plate produced without the foaming agent comprises the following raw material components in percentage by weight: 80 parts of dust collecting powder, 10 parts of bentonite, 10 parts of 200-mesh glass powder, 25 parts of EPS particles with the diameter of 2mm and 2 parts of sodium carboxymethylcellulose, wherein the dust collecting powder is generated in the process of regenerating casting sand by casting sand molds and contains more than 50% of silicon dioxide.
The dimension of the foamed ceramic plate is 2.4-3.0 meters long, 0.6-0.9 meters wide and 0.2-0.4 meters thick, and the foam holes are 3-4 millimeters.
A method for producing a foamed ceramic plate without using a foaming agent, comprising the steps of:
and A, granulation: putting 60-90 parts of recovered dust powder with the silicon dioxide content of more than 50%, 10-20 parts of bentonite, 10-20 parts of glass powder, 25-35 parts of EPS particles and 2-3 parts of cellulose into balling equipment, adding water mist, mixing and stirring to prepare a 3-4mm sphere;
b, cloth material: b, putting the ball body obtained in the step A into a heat-resistant steel die;
c, sintering: sending the heat-resistant steel die subjected to material distribution into a heat treatment kiln for low-temperature, medium-temperature and high-temperature three-section sintering, and cooling to obtain a foamed ceramic plate;
d, processing: and processing the foamed ceramic plate into a foamed ceramic plate with a required specification according to the requirement.
Further, the balling equipment in the step A comprises a planetary mixing stirrer and a disc type balling machine.
Further, the low-temperature, medium-temperature and high-temperature three-stage sintering in the step C is carried out, wherein the low-temperature stage is heated to 720 ℃ at the heating rate of 2 ℃/min, and the temperature is kept for 0.5 h; the medium temperature section is heated to 840 ℃ at the heating rate of 1 ℃/min and is kept for 0.5 h;
the high temperature section is heated to 950 ℃ or 1000 ℃ at the heating rate of 0.5 ℃/min, and the temperature is kept for 0.3 h.
Further, in the step C, the cooling comprises quenching to 500 degrees, keeping the temperature for 2 hours, slowly cooling for 5 hours to reduce the temperature from 500 degrees to 300 degrees, and cooling for 8 hours to reduce the temperature from 300 degrees to room temperature.
Advantageous effects of the invention
The invention adopts a planetary mixing stirrer to mix evenly, and then uses a disc type ball forming mill to prepare the raw material balls, the conventional wet ball milling and spray drying processes of a ceramic ball mill are not needed, the process is simple, and the preparation cost of the raw materials is saved; the raw materials do not use foaming agent, so that the cost of the raw materials is saved, and simultaneously, the production method is not limited by factors such as foaming agent in the prior art, can produce plates with large thickness, and can better meet the requirements of the building market.
Detailed Description
The foamed ceramic plate produced without using a foaming agent comprises the following raw material components in percentage by weight: 60-90 parts of casting recycled dust powder, 10-20 parts of bentonite, 10-20 parts of glass powder, 25-35 parts of EPS particles and 2-3 parts of cellulose; the recovered dust powder is generated in the process of regenerating casting sand by using a casting sand mold, wherein the content of silicon dioxide is more than 50%; the diameter of the EPS particles is 1mm-2 mm; the fineness of the glass powder is 200-300 meshes; the cellulose is sodium carboxymethyl cellulose (CMC). The dimension of the foamed ceramic plate is 2.4-3.0 meters long, 0.6-0.9 meters wide, 0.2-0.4 meters thick, and the foam holes are 3-4 millimeters. A method for producing a foamed ceramic plate without using a foaming agent, comprising the steps of: and A, granulation: putting 60-90 parts of recovered dust powder with the silicon dioxide content of more than 50%, 10-20 parts of bentonite, 10-20 parts of glass powder, 25-35 parts of EPS particles and 2-3 parts of cellulose into balling equipment, adding water mist, mixing and stirring to prepare a 3-4mm sphere; b, cloth material: b, putting the ball body obtained in the step A into a heat-resistant steel die; c, sintering: and (3) conveying the heat-resistant steel die subjected to material distribution into a heat treatment kiln for low-temperature, medium-temperature and high-temperature three-stage sintering, wherein the low-temperature stage comprises the following steps: heating to 720 ℃ at the heating rate of 2 ℃/min, keeping the temperature for 0.5h, and performing medium-temperature stage: heating at a heating rate of 1 ℃/min, keeping the temperature from 720 to 840 ℃ for 0.5 h; a high-temperature section: heating at a heating rate of 0.5 ℃/min, keeping the temperature from 840 to 950 ℃ or 1000 ℃, preserving the heat for 0.3h, then cooling down to 500 ℃ by quenching, preserving the heat for 2 h, slowly cooling down to 300 ℃ from 500 ℃ within 5h, and finally cooling down to room temperature from 300 ℃ within 8 h to obtain the foamed ceramic plate; d, processing: and processing the foamed ceramic plate into a foamed ceramic plate with a required specification according to a required size. The method is specifically illustrated below with reference to examples:
example 1
80 parts of dust collecting powder, 10 parts of 200-mesh glass powder, 10 parts of bentonite, 25 parts of EPS particles with the diameter of 2mm and 2 parts of sodium carboxymethylcellulose (CMC), which are generated in the process of regenerating casting sand by using a casting sand mold containing more than 50 percent of silicon dioxide, are put into a star mixer, added with water mist for mixing and stirring, and then a disc type granulator is used for preparing a 4mm raw material wrapped sphere after uniform mixing. Spraying a release agent into a heat-resistant steel mold with the length of 2.4 meters, the width of 0.6 meters and the thickness of 0.4 meter, wherein the release agent is alumina slurry, and then fully filling 4mm of raw materials to wrap the sphere. Sintering through a kiln, firstly heating to 720 ℃ at a heating rate of 2 ℃/min at a low-temperature section, preserving heat for 0.5h, volatilizing EPS particles in the process to form raw material hollow spheres, then heating to 840 ℃ at a heating rate of 1 ℃/min at a medium-temperature section, preserving heat for 0.5h, then sintering at a high-temperature section, heating to 1000 ℃ at a heating rate of 0.5 ℃/min, preserving heat for 0.3h, and in the process, bonding the glass powder liquid phase with the hollow sphere raw material. And finally, cooling, namely, rapidly cooling to 500 ℃, preserving heat for 2 hours, then slowly cooling, reducing the temperature from 500 to 300 ℃ within 5 hours, and then reducing the temperature from 300 ℃ to room temperature within 8 hours to obtain the light foamed ceramic plate with the thickness of 0.3 meter, the length of 2.4 meters and the width of 0.6 meter, wherein the diameter of 4mm of air holes is uniformly distributed, and the compressive strength is more than 7 MPa. And processing the light foamed ceramic plate into a required size according to the requirement of a client.
Example 2:
60 parts of dust collecting powder, 20 parts of 300-mesh glass powder, 20 parts of bentonite, 35 parts of EPS particles with the diameter of 1mm and 3 parts of carboxymethyl cellulose, which are generated in the process of regenerating casting sand by using a casting sand mold containing more than 50 percent of silicon dioxide, are mixed and stirred in balling equipment by adding water mist to prepare a 3mm raw material coated sphere. Spraying a release agent of alumina slurry into a heat-resistant steel mould with the length of 3.0 meters, the width of 0.9 meters and the thickness of 0.3 meters, and then fully filling 3mm of raw materials to wrap the ball body. Sintering through a kiln, firstly heating to 720 ℃ at a heating rate of 2 ℃/min by adopting a low-temperature section, preserving heat for 0.5h, volatilizing EPS particles in the process to form raw material hollow spheres, then heating to 840 ℃ at the heating rate of 1 ℃/min by adopting a medium-temperature section, preserving heat for 0.5h, then sintering at a high-temperature section, heating to 950 ℃ at the heating rate of 0.5 ℃/min, preserving heat for 0.3h, and in the process, bonding the glass powder liquid phase with the hollow sphere raw material. And finally, cooling, wherein the cooling process is the same as that of the example 1, so that the light foamed ceramic plate with the thickness of 0.2 meter, the length of 3.0 meters and the width of 0.9 meter is obtained, the diameter of 3mm of air holes of the light foamed ceramic plate is uniformly distributed, and the compressive strength of the light foamed ceramic plate is more than 6 MPa. And processing the mixture into a specified size according to the requirement of a client.
Claims (7)
1. A foaming ceramic plate produced without using a foaming agent is characterized by comprising the following raw material components in percentage by weight: 60-90 parts of casting recycled dust powder, 10-20 parts of bentonite, 10-20 parts of glass powder, 25-35 parts of EPS particles and 2-3 parts of cellulose; the recovered dust powder is generated in the process of regenerating casting sand by using a casting sand mold, wherein the content of silicon dioxide is more than 50%; the diameter of the EPS particles is 1mm-2 mm; the fineness of the glass powder is 200-300 meshes; the cellulose is sodium carboxymethyl cellulose.
2. A foamed ceramic sheet produced without using a foaming agent as claimed in claim 1, wherein the raw material components are in a weight ratio of: 80 parts of dust collecting powder, 10 parts of bentonite, 10 parts of 200-mesh glass powder, 25 parts of EPS particles with the diameter of 2mm and 2 parts of sodium carboxymethylcellulose, wherein the dust collecting powder is generated in the process of regenerating casting sand by casting sand molds and contains more than 50% of silicon dioxide.
3. A foamed ceramic sheet produced without using a foaming agent as claimed in claim 1 or 2, wherein the foamed ceramic sheet has a size of 2.4 to 3.0 m long, 0.6 to 0.9 m wide, 0.2 to 0.4 m thick and cells of 3 to 4 mm.
4. A method for producing a foamed ceramic plate without using a foaming agent, characterized by comprising the steps of:
and A, granulation: putting 60-90 parts of recovered dust powder with the silicon dioxide content of more than 50%, 10-20 parts of bentonite, 10-20 parts of glass powder, 25-35 parts of EPS particles and 2-3 parts of cellulose into balling equipment, adding water mist, mixing and stirring to prepare a 3-4mm sphere;
b, cloth material: b, putting the ball body obtained in the step A into a heat-resistant steel die;
c, sintering: sending the heat-resistant steel die subjected to material distribution into a heat treatment kiln for low-temperature, medium-temperature and high-temperature three-section sintering, and cooling to obtain a foamed ceramic plate;
d, processing: and processing the foamed ceramic plate into a foamed ceramic plate with a required specification according to the requirement.
5. A method of manufacturing a foamed ceramic plate without using a foaming agent as claimed in claim 4, wherein in the step A, said balling means comprises a planetary mixer and a pan-type balling machine.
6. The method for manufacturing a foamed ceramic plate without using a foaming agent as claimed in claim 4, wherein in the step C, the low, medium and high temperature three-stage sintering is performed, in which the low temperature stage is heated to 720 ℃ at a heating rate of 2 ℃/min and is maintained for 0.5 hour; the medium temperature section is heated to 840 ℃ at the heating rate of 1 ℃/min and is kept for 0.5 h; the high temperature section is heated to 950 ℃ or 1000 ℃ at the heating rate of 0.5 ℃/min, and the temperature is kept for 0.3 h.
7. A method of manufacturing a foamed ceramic plate without using a foaming agent as claimed in claim 4, wherein in the step C, said cooling includes quenching to 500 degrees, holding for 2 hours, slowly cooling for 5 hours to reduce the temperature from 500 degrees to 300 degrees, and cooling for 8 hours to reduce the temperature from 300 degrees to room temperature.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112341141A (en) * | 2020-10-28 | 2021-02-09 | 广东金意陶陶瓷集团有限公司 | Ceramic thick brick and preparation method thereof |
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| CN112341141A (en) * | 2020-10-28 | 2021-02-09 | 广东金意陶陶瓷集团有限公司 | Ceramic thick brick and preparation method thereof |
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Application publication date: 20200407 |