CN110981432A - 一种镍渣保温陶瓷砖制备方法 - Google Patents
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Abstract
本发明提供了一种镍渣保温陶瓷砖制备方法,包括以下步骤:(1)将镍渣和助磨剂放入球磨机进行球磨,再过筛处理,得到镍渣粉;(2)称取镍渣粉、珍珠岩、高岭土,加入烧结助剂和发泡剂,加水研磨,造粒得到粉料;(3)将造粒后的粉料注入模具,压制成型,干燥后进行煅烧,即得到镍渣保温陶瓷砖。本发明镍渣保温陶瓷砖制备方法,可大规模利用镍渣,解决了镍渣的堆积和环境污染的问题,具有环保效益和经济效益;制备的陶瓷砖具有轻质保温功能,可应用于高层建筑的外墙保温,减轻高层建筑的自重,可以优化房屋结构设计、提高建筑的经济性。
Description
技术领域
本发明涉及一种保温陶瓷砖制备方法,特别涉及一种镍渣保温陶瓷砖制备方法。
背景技术
保温陶瓷砖是指体积密度小、具有保温性能,对热传递起到阻碍作用的陶瓷砖。作为陶瓷砖,既可用于夏季高温环境条件下防止热的流入,还可用于冬季低温环境下防止热的流出。统计数据表明,外墙热损失约占建筑总能耗的32.1%~36.2%,所以,建筑中必不可少的重要内容就是在建筑外墙结构上采用保温隔热处理,从而降低建筑能耗,能够减少因加热、制冷所使用的能源,减少CO2、SO2的排放,避免浪费不可再生资源,更重要的是提高居住舒适度,以此保护我们赖以生存的地球环境。
GB/T 33500-2017《外墙外保温泡沫陶瓷》要求外墙砖的吸水率≤2.0%,抗折强度≥0.4MPa,体积密度≤160kg/m3,导热系数≤0.1W/m*K。体积密度的要求使我们需要加入发泡剂来减小体积密度,气孔率过高会导致陶瓷砖抗折强度的下降和吸水率的增大,不利于陶瓷砖的生产。
公开号为CN201711326806.X的中国专利提出了一种镍铁渣陶瓷及其制备方法,经研磨、造粒、成型、烧结后得到镍铁渣陶瓷,其较优配比下的陶瓷砖抗折强度值超过100MPa,吸水率小于0.5%。该陶瓷砖单位质量较重,加重建筑的负重,不利于现代建筑业的使用。公开号为CN106866170 A的中国专利提出了一种赤泥轻质保温陶瓷砖、用途及其制备方法。陶瓷砖的原料包括赤泥、石英、长石、高岭土、石膏,发泡剂为铝粉和固体氢氧化钠,烧结后的陶瓷砖的体积密度≤4000kg/m3、热导率≤0.073W/m*℃。该轻质保温陶瓷砖采用固体氢氧化钠和铝粉作为发泡剂,原料价格较高且存在一定的安全风险,不利于工业生产。
镍渣是工业金属镍冶炼过程中排放出来的一种固体废弃物,主要是在金属镍冶炼过程中所形成的的以SiO2、Al2O3、CaO、MgO、Fe2O3等为主要化学成分的高温熔融物再经水淬后所形成的的粒化炉渣。随着我国不锈钢产量逐年增加,镍渣的产量也不断增长,大量的堆积侵占土地,对环境造成污染。目前我国的镍渣排量超过2000万吨,大量的堆积造成土地的浪费。目前镍渣的处理方式主要是填埋,既造成土壤污染,还会由于镍渣中的重金属离子的浸出导致水污染,造成严重的生态环境污染问题。镍铁渣内含有大量的铁氧化物,这会造成陶瓷砖含铁量较高,导致陶瓷砖颜色及性能受到影响。
发明内容
本发明的目的在于提供一种镍渣保温陶瓷砖制备方法,解决现有镍渣的回收利用,及陶瓷砖保温性能不足的技术问题。
本发明的目的,通过以下技术方案实现:
一种镍渣保温陶瓷砖制备方法,包括以下步骤:
(1)将镍渣和助磨剂放入球磨机进行球磨,再过筛处理,得到镍渣粉;
(2)称取镍渣粉、珍珠岩、高岭土,加入烧结助剂和发泡剂,加水研磨,造粒得到粉料;
(3)将造粒后的粉料注入模具,压制成型,干燥后进行煅烧,即得到镍渣保温陶瓷砖。
本发明制备保温陶瓷砖的作用机理为,镍渣为高镁质材料,在高温下和氧化铝组分生成堇青石相,堇青石相具有保温作用,耐压抗磨,耐冷热性能优异。在发泡剂的作用下形成气孔结构,降低了陶瓷砖质量,增强陶瓷砖的保温性能。珍珠岩作为富硅质原料,质轻价廉,是优异的高硅质原料。高岭土是高铝质原料,提高陶瓷砖的强度和坯体的可塑性。
本发明的一些实施方案中,所述助磨剂是十二烷基苯磺酸钠,添加量是镍渣质量的0.1%-0.5%。
本发明的一些实施方案中,所述过筛为过100目筛。
本发明方法可以做以下改进,镍渣球磨过筛后的镍渣粉进行除铁处理。降低原料内的含铁量,铁的存在会导致陶瓷砖性能降低。
本发明中,所述镍渣粉、珍珠岩、高岭土的质量分数配比分别为20-50%、20-50%、20-40%。
本发明的一些实施方案中,所述烧结助剂是富钾钠原料、氧化锂、B2O3、Li2CO3中的一种或者多种。烧结助剂可以降低陶瓷砖烧结温度和扩大堇青石相的烧结范围。
进一步地,所述烧结助剂的添加量是镍渣粉、珍珠岩、高岭土总质量的0.1%-1%。
本发明的一些实施方案中,所述发泡剂是碳酸盐、纤维素聚合物、SiC中的一种或多种。发泡剂可以使陶瓷砖体积膨胀,内部产生气泡。
进一步地,所述纤维素聚合物为羧甲基纤维素。
所述发泡剂的添加量是镍渣粉、珍珠岩、高岭土总质量的0.1%-1%。
本发明的一些实施方案中,粉料的含水率为5.4%-6.4%。
本发明的一些实施方案中,压制成型的压力为10MPa-40MPa。
本发明的一些实施方案中,煅烧温度为1000-1300℃,煅烧时间20-40min。
与现有技术相比,本发明具有以下有益效果:
(1)本发明镍渣保温陶瓷砖制备方法,可大规模利用镍渣,解决了镍渣的堆积和环境污染的问题,具有环保效益和经济效益;制备的陶瓷砖具有轻质保温功能,可应用于高层建筑的外墙保温,减轻高层建筑的自重,可以优化房屋结构设计、提高建筑的经济性。
(2)本发明的陶瓷砖制备方法,不需要更改现有陶瓷砖制备的流水线,且原材料成本低,适合大规模工业化生产。
具体实施方式
以下结合具体的实施例对本发明作进一步的说明,以便本领域技术人员更好理解和实施本发明的技术方案。
实施例1
本实施例提供了一种镍渣保温陶瓷砖制备方法,包括以下步骤:
(1)将镍渣和镍渣质量0.1%的十二烷基苯磺酸钠放入球磨机进行球磨,再过100目筛,得到镍渣粉,对镍渣粉进行除铁处理;
(2)将镍渣粉、珍珠岩、高岭土按照40:30:30的质量比放入球磨机,加入镍渣粉、珍珠岩、高岭土总质量的1%的Li2CO3和1%Na2CO3,加水进行球磨,干燥后喷雾造粒,得到粉料。
(3)将造粒后的粉料(含水率5.4%)注入模具,在20MPa下压制成型,干燥后放入高温炉烧结,烧成温度为1200℃,保温时间20min,即可制得镍渣保温陶瓷砖。
对上述步骤制得的镍渣保温陶瓷砖进行性能测试,结果表明,抗折强度=2MPa、吸水率=0.7%、体积密度=151kg/m3、热导率=0.034W/m*K,形成晶相为堇青石相、莫来石相和玻璃相。
实施例2
本实施例提供了一种镍渣保温陶瓷砖制备方法,包括以下步骤:
(1)将镍渣和镍渣质量0.1%的十二烷基苯磺酸钠放入球磨机进行球磨,再过100目筛,得到镍渣粉,对镍渣粉进行除铁处理;
(2)将镍渣粉、珍珠岩、高岭土按照50:30:20的质量比放入球磨机,加入镍渣粉、珍珠岩、高岭土总质量的0.5%的Li2CO3和1%Na2CO3,加水进行球磨,干燥后喷雾造粒,得到粉料。
(3)将造粒后的粉料(含水率6.3%)注入模具,在20MPa下压制成型,干燥后放入高温炉烧结,烧成温度为1200℃,保温时间20min,即可制得镍渣保温陶瓷砖。
对上述步骤制得的镍渣保温陶瓷砖进行性能测试,结果表明,抗折强度=1.5MPa、吸水率=0.7%、体积密度=138kg/m3、热导率=0.026W/m*K,形成晶相为堇青石相和莫来石相。
实施例3
本实施例提供了一种镍渣保温陶瓷砖制备方法,包括以下步骤:
(1)将镍渣和镍渣质量0.5%的十二烷基苯磺酸钠放入球磨机进行球磨,再过100目筛,得到镍渣粉,对镍渣粉进行除铁处理;
(2)将镍渣粉、珍珠岩、高岭土按照40:40:20的质量比放入球磨机,加入镍渣粉、珍珠岩、高岭土总质量的1%的Li2CO3和1%羧甲基纤维素,加水进行球磨,干燥后喷雾造粒,得到粉料。
(3)将造粒后的粉料(含水率6.1%)注入模具,在20MPa下压制成型,干燥后放入高温炉烧结,烧成温度为1200℃,保温时间20min,即可制得镍渣保温陶瓷砖。
对上述步骤制得的镍渣保温陶瓷砖进行性能测试,结果表明,抗折强度=1.8MPa、吸水率=0.4%、体积密度=129kg/m3、热导率=0.047W/m*K,形成晶相为堇青石相、莫来石相和玻璃相。
实施例4
本实施例提供了一种镍渣保温陶瓷砖制备方法,包括以下步骤:
(1)将镍渣和镍渣质量0.2%的十二烷基苯磺酸钠放入球磨机进行球磨,再过100目筛,得到镍渣粉,对镍渣粉进行除铁处理;
(2)将镍渣粉、珍珠岩、高岭土按照30:40:30:的质量比放入球磨机,加入镍渣粉、珍珠岩、高岭土总质量的1%的Li2CO3和1%Na2CO3进行球磨,干燥后喷雾造粒,得到粉料。
(3)将造粒后的粉料(含水率5.8%)注入模具,在20MPa下压制成型,干燥后放入高温炉烧结,烧成温度为1200℃,保温时间20min,即可制得镍渣保温陶瓷砖。
对上述步骤制得的镍渣保温陶瓷砖进行性能测试,结果表明,抗折强度=1.4MPa、吸水率=0.1%、体积密度=157kg/m3、热导率=0.037W/m*K,形成晶相为莫来石相和玻璃相。
实施例5
本实施例提供了一种镍渣保温陶瓷砖制备方法,包括以下步骤:
(1)将镍渣和镍渣质量0.4%的十二烷基苯磺酸钠放入球磨机进行球磨,再过100目筛,得到镍渣粉,对镍渣粉进行除铁处理;
(2)将镍渣粉、珍珠岩、高岭土按照30:50:20的质量比放入球磨机,加入镍渣粉、珍珠岩、高岭土总质量的1%的Li2CO3和1%羧甲基纤维素,加水进行球磨,干燥后喷水造粒,得到粉料。
(3)将造粒后的粉料(含水率6.4%)注入模具,在20MPa下压制成型,干燥后放入高温炉烧结,烧成温度为1100℃,保温时间40min,即可制得镍渣保温陶瓷砖。
对上述步骤制得的镍渣保温陶瓷砖进行性能测试,结果表明,抗折强度=1.3MPa、吸水率=1.7%、体积密度=148kg/m3、热导率=0.033W/m*K,形成晶相为堇青石相和莫来石相。
实施例6
本实施例提供了一种镍渣保温陶瓷砖制备方法,包括以下步骤:
(1)将镍渣和镍渣质量0.3%的十二烷基苯磺酸钠放入球磨机进行球磨,再过100目筛,得到镍渣粉,对镍渣粉进行除铁处理;
(2)将镍渣粉、珍珠岩、高岭土按照40:40:20的质量比放入球磨机,加入镍渣粉、珍珠岩、高岭土总质量的1%的B2O3和1%Na2CO3,加水进行球磨,干燥后喷水造粒,得到粉料。
(3)将造粒后的粉料(含水率6.2%)注入模具,在20MPa下压制成型,干燥后放入高温炉烧结,烧成温度为1100℃,保温时间40min,即可制得镍渣保温陶瓷砖。
对上述步骤制得的镍渣保温陶瓷砖进行性能测试,结果表明,抗折强度=1.6MPa、吸水率=1.3%、体积密度=156kg/m3、热导率=0.054W/m*K,形成晶相为堇青石相和莫来石相。
实施例7
本实施例提供了一种镍渣保温陶瓷砖制备方法,包括以下步骤:
(1)将镍渣和镍渣质量0.2%的十二烷基苯磺酸钠放入球磨机进行球磨,再过100目筛,得到镍渣粉,对镍渣粉进行除铁处理;
(2)将镍渣粉、珍珠岩、高岭土按照40:40:20的质量比放入球磨机,加入镍渣粉、珍珠岩、高岭土总质量的1%的B2O3和0.5%SiC,加水进行球磨,干燥后喷水造粒,得到粉料。
(3)将造粒后的粉料(含水率6.1%)注入模具,在20MPa下压制成型,干燥后放入高温炉烧结,烧成温度为1100℃,保温时间40min,即可制得镍渣保温陶瓷砖。
对上述步骤制得的镍渣保温陶瓷砖进行性能测试,结果表明,抗折强度=2.3MPa、吸水率=1.6%、体积密度=158kg/m3、热导率=0.044W/m*K,形成晶相为堇青石相和莫来石相。
实施例8
本实施例提供了一种镍渣保温陶瓷砖制备方法,包括以下步骤:
(1)将镍渣和镍渣质量0.2%的十二烷基苯磺酸钠放入球磨机进行球磨,再过100目筛,得到镍渣粉,对镍渣粉进行除铁处理;
(2)将镍渣粉、珍珠岩、高岭土按照40:40:20的质量比放入球磨机,加入镍渣粉、珍珠岩、高岭土总质量的1%Li2O和1%Na2CO3,加水进行球磨,干燥后喷水造粒,得到粉料。
(3)将造粒后的粉料(含水率5.9%)注入模具,在20MPa下压制成型,干燥后放入高温炉烧结,烧成温度为1100℃,保温时间40min,即可制得镍渣保温陶瓷砖。
对上述步骤制得的镍渣保温陶瓷砖进行性能测试,结果表明,抗折强度=1.7MPa、吸水率=1.2%、体积密度=130kg/m3、热导率=0.028W/m*K,形成晶相为堇青石相和莫来石相。
以上实施实例对本发明不同的实施过程进行了详细的阐述,但是本发明的实施方式并不仅限于此,所属技术领域的普通技术人员依据本发明中公开的内容,均可实现本发明的目的,任何基于本发明构思基础上做出的改进和变形均落入本发明的保护范围之内,具体保护范围以权利要求书记载的为准。
Claims (10)
1.一种镍渣保温陶瓷砖制备方法,其特征在于,包括以下步骤:
(1)将镍渣和助磨剂放入球磨机进行球磨,再过筛处理,得到镍渣粉;
(2)称取镍渣粉、珍珠岩、高岭土,加入烧结助剂和发泡剂,加水研磨,造粒得到粉料;
(3)将造粒后的粉料注入模具,压制成型,干燥后进行煅烧,即得到镍渣保温陶瓷砖。
2.根据权利要求1所述镍渣保温陶瓷砖制备方法,其特征在于,所述镍渣粉、珍珠岩、高岭土的质量分数配比分别为20-50%、20-50%、20-40%。
3.根据权利要求1或2所述镍渣保温陶瓷砖制备方法,其特征在于,所述烧结助剂是富钾钠原料、氧化锂、B2O3、Li2CO3中的一种或者多种。
4.根据权利要求3所述镍渣保温陶瓷砖制备方法,其特征在于,所述烧结助剂的添加量是镍渣粉、珍珠岩、高岭土总质量的0.1%-1%。
5.根据权利要求3所述镍渣保温陶瓷砖制备方法,其特征在于,所述发泡剂是碳酸盐、纤维素聚合物、SiC中的一种或多种。
6.根据权利要求5所述镍渣保温陶瓷砖制备方法,其特征在于,所述发泡剂的添加量是镍渣粉、珍珠岩、高岭土总质量的0.1%-1%。
7.根据权利要求6所述镍渣保温陶瓷砖制备方法,其特征在于,煅烧温度为1000-1300℃,煅烧时间20-40min。
8.根据权利要求7所述镍渣保温陶瓷砖制备方法,其特征在于,所述助磨剂是十二烷基苯磺酸钠,添加量是镍渣质量的0.1%-0.5%。
9.根据权利要求8所述镍渣保温陶瓷砖制备方法,其特征在于,所述过筛为过100目筛。
10.根据权利要求9所述镍渣保温陶瓷砖制备方法,其特征在于,镍渣球磨过筛后的镍渣粉进行除铁处理。
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