CN111138165B - Brick with temperature for porcelain brick kiln and preparation method and application thereof - Google Patents
Brick with temperature for porcelain brick kiln and preparation method and application thereof Download PDFInfo
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- CN111138165B CN111138165B CN201911394140.0A CN201911394140A CN111138165B CN 111138165 B CN111138165 B CN 111138165B CN 201911394140 A CN201911394140 A CN 201911394140A CN 111138165 B CN111138165 B CN 111138165B
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- 239000011449 brick Substances 0.000 title claims abstract description 119
- 229910052573 porcelain Inorganic materials 0.000 title abstract description 19
- 238000002360 preparation method Methods 0.000 title abstract description 10
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 70
- 239000002699 waste material Substances 0.000 claims abstract description 56
- 239000000919 ceramic Substances 0.000 claims abstract description 35
- 238000010304 firing Methods 0.000 claims abstract description 35
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 35
- 239000010881 fly ash Substances 0.000 claims abstract description 30
- 239000000440 bentonite Substances 0.000 claims abstract description 19
- 229910000278 bentonite Inorganic materials 0.000 claims abstract description 19
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims abstract description 19
- BITYAPCSNKJESK-UHFFFAOYSA-N potassiosodium Chemical compound [Na].[K] BITYAPCSNKJESK-UHFFFAOYSA-N 0.000 claims abstract description 18
- 239000004576 sand Substances 0.000 claims abstract description 17
- 238000000034 method Methods 0.000 claims abstract description 13
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 11
- 239000000203 mixture Substances 0.000 claims description 26
- 238000001035 drying Methods 0.000 claims description 24
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 17
- 238000005245 sintering Methods 0.000 claims description 14
- 238000010521 absorption reaction Methods 0.000 claims description 13
- 239000000843 powder Substances 0.000 claims description 13
- 239000011230 binding agent Substances 0.000 claims description 12
- 239000002002 slurry Substances 0.000 claims description 12
- 238000000498 ball milling Methods 0.000 claims description 11
- 238000004519 manufacturing process Methods 0.000 claims description 11
- 238000002156 mixing Methods 0.000 claims description 10
- 229910052593 corundum Inorganic materials 0.000 claims description 9
- 239000001768 carboxy methyl cellulose Substances 0.000 claims description 8
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 7
- 238000001694 spray drying Methods 0.000 claims description 6
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 6
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 5
- 238000003825 pressing Methods 0.000 claims description 5
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 claims description 5
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 claims description 5
- 229910052681 coesite Inorganic materials 0.000 claims description 4
- 229910052906 cristobalite Inorganic materials 0.000 claims description 4
- 229920005610 lignin Polymers 0.000 claims description 4
- 239000002994 raw material Substances 0.000 claims description 4
- 239000000377 silicon dioxide Substances 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- 229910052682 stishovite Inorganic materials 0.000 claims description 4
- 229910052905 tridymite Inorganic materials 0.000 claims description 4
- 229920002134 Carboxymethyl cellulose Polymers 0.000 claims description 3
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 3
- 229920002472 Starch Polymers 0.000 claims description 3
- 235000010948 carboxy methyl cellulose Nutrition 0.000 claims description 3
- 239000008112 carboxymethyl-cellulose Substances 0.000 claims description 3
- 239000004927 clay Substances 0.000 claims description 3
- 239000013078 crystal Substances 0.000 claims description 3
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 3
- 239000008107 starch Substances 0.000 claims description 3
- 235000019698 starch Nutrition 0.000 claims description 3
- 230000035939 shock Effects 0.000 abstract description 11
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 abstract description 10
- 230000008569 process Effects 0.000 abstract description 10
- 229910052878 cordierite Inorganic materials 0.000 abstract description 7
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 abstract description 7
- 239000000853 adhesive Substances 0.000 abstract description 3
- 230000001070 adhesive effect Effects 0.000 abstract description 3
- 230000009286 beneficial effect Effects 0.000 abstract description 3
- 230000002035 prolonged effect Effects 0.000 abstract description 2
- 230000006872 improvement Effects 0.000 description 7
- 239000002689 soil Substances 0.000 description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 6
- 239000002245 particle Substances 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 239000011325 microbead Substances 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 239000010431 corundum Substances 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 241001391944 Commicarpus scandens Species 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 125000004122 cyclic group Chemical group 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000002734 clay mineral Substances 0.000 description 1
- 239000002817 coal dust Substances 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 230000002045 lasting effect Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 238000007517 polishing process Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 229910052572 stoneware Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 230000002277 temperature effect Effects 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
- C04B33/1324—Recycled material, e.g. tile dust, stone waste, spent refractory material
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/1305—Organic additives
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/131—Inorganic additives
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
- C04B2235/3206—Magnesium oxides or oxide-forming salts thereof
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3418—Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3427—Silicates other than clay, e.g. water glass
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
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- Combustion & Propulsion (AREA)
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Abstract
The invention discloses a brick with temperature for a ceramic brick kiln, which is prepared from roller waste, magnesia, bentonite, polished brick waste residue, fly ash, potassium sodium sand and an adhesive. Correspondingly, the invention also discloses a preparation method of the brick with the temperature and application of the brick with the temperature in the firing process of the porcelain brick. According to the brick with the temperature, the acicular mullite and the cordierite are generated by high-temperature firing through a reasonable formula structure, so that the breaking strength and the thermal shock resistance of the brick with the temperature are improved, and the service life of the brick with the temperature is prolonged. Meanwhile, the brick with the temperature is high in porosity, low in heat conductivity coefficient and high in heat capacity, and is beneficial to fully taking away heat of a kiln and maintaining the temperature curve of the kiln to be stable.
Description
Technical Field
The invention relates to the technical field of ceramic tiles, in particular to a brick with temperature for a ceramic brick kiln and a preparation method and application thereof.
Background
Most of the existing ceramic tile manufacturers use a roller kiln for drying and firing, and the roller kiln is continuously produced for 24 hours. In the continuous production process, in order to stabilize the quality of the product, the temperature, atmosphere and pressure of the kiln are required to be kept stable. However, with the development of the ceramic tile industry, the ceramic tile decoration is more and more diversified, so that more and more production is carried out in the production process, and more kiln empty phenomena are caused, namely, no brick enters the kiln, so that the kiln is empty; the empty kiln can directly generate great influence on the temperature, atmosphere and pressure of the kiln, the direct harm is that bricks are fed again after the empty kiln, and the bricks burnt under abnormal temperature, atmosphere and pressure basically cannot meet the quality control requirement, so that the defective rate is increased.
On the other hand, the kilns of ceramic manufacturers are divided into drying kilns and firing kilns; among them, in order to recycle energy, exhaust gas from a firing kiln is generally extracted into a drying kiln to dry a green compact. When the temperature curve and the atmosphere of the kiln are changed, the temperature curve and the atmosphere of the drying kiln are also changed correspondingly, so that the drying kiln is easy to generate edge cracks and other defects.
A better method is to put the brick with temperature when the kiln is empty, and take away certain heat through the brick with temperature, so as to achieve the effect of controlling the firing curve. The brick with temperature of the existing porcelain brick kiln is generally a blank body without glaze which is sintered by the same formula and the same kiln. The brick with temperature is high in strength, but is easy to break in the cyclic sintering process, and short in service life. In addition, the heat taken away by the porcelain brick with the temperature is less, and the stability of the whole kiln system is not good for maintenance.
Disclosure of Invention
The invention aims to solve the technical problem of providing a brick with temperature for a ceramic brick kiln, which has strong thermal stability and long service life.
The technical problem to be solved by the invention is to provide a preparation method of the brick with the temperature for the porcelain brick kiln.
The invention also aims to solve the technical problem of providing the application of the brick with the temperature for the porcelain brick kiln in the production of the porcelain brick.
In order to solve the technical problem, the invention discloses a brick with temperature for a porcelain brick kiln, which is mainly prepared from the following raw materials in parts by weight:
5-10 parts of roller waste, 10-25 parts of magnesia, 10-20 parts of bentonite, 1-5 parts of polished tile waste residue, 30-40 parts of fly ash, 5-15 parts of potassium sodium sand and 0.5-1.5 parts of binder.
As an improvement of the technical scheme, the content of MgO in the magnesia soil is 15-25 wt%, and SiO is255-70 wt% of Al2O3The content of (A) is 0.5-5 wt%;
al in the fly ash2O3The content of the CaO is 30-45 wt%, and the content of the CaO is 5-15 wt%.
As an improvement of the technical scheme, the roller bar waste is corundum mullite roller bar waste, and Al of the corundum mullite roller bar waste2O3The content is 50-80 wt%.
As an improvement of the technical scheme, the binder is one or more of carboxymethyl cellulose, sodium carboxymethyl cellulose, lignin, polyvinyl alcohol and starch.
As an improvement of the technical scheme, the water absorption rate of the brick with the temperature is 10-20%, the breaking strength is 25-45 MPa, and the average heat conductivity coefficient of the brick with the temperature at 1100-1300 ℃ is 0.8-1.8W/(m.K).
As an improvement of the technical scheme, the ceramic brick kiln comprises a drying kiln and a firing kiln;
the highest temperature of the drying kiln is 150-300 ℃;
the maximum temperature of the firing kiln is 1100-1300 ℃.
Correspondingly, the invention also discloses a preparation method of the brick with the temperature for the porcelain brick kiln, which is characterized by comprising the following steps:
(1) uniformly mixing 5-10 parts of roller waste, 10-25 parts of magnesia, 10-20 parts of bentonite and 5-15 parts of potassium sodium sand to obtain a first mixture;
(2) mixing 1-5 parts of polished tile waste residue, 30-40 parts of fly ash and 0.5-1.5 parts of binder to obtain a second mixture;
(3) ball-milling the first mixture for 5-8 h, adding the second mixture, and continuing ball-milling for 0.5-2 h to obtain slurry;
(4) spray drying the slurry to obtain powder;
(5) pressing the powder material to obtain a green body;
(6) and drying and sintering the green body to obtain a finished product of the brick with the temperature.
As an improvement of the technical scheme, in the step (6), the firing temperature is 1100-1300 ℃.
Correspondingly, the invention also discloses the application of the brick with the temperature for the porcelain brick kiln in the production process of the porcelain brick.
As an improvement of the technical scheme, the ceramic tile is a polished tile, a glazed tile, a polished crystal tile or an antique tile, and the water absorption rate of the ceramic tile is less than or equal to 1 percent; the firing temperature is 1100-1300 ℃.
The implementation of the invention has the following beneficial effects:
the invention provides a brick with temperature for a ceramic brick kiln, which is prepared from roller bar waste, magnesia, bentonite, polished brick waste residue, fly ash, potassium sodium sand and an adhesive; wherein, the magnesia provides Mg which can react with the roller bar waste with high aluminum content and the fly ash to form cordierite, thereby improving the thermal shock resistance of the brick with the temperature; in addition, mullite is generated in the firing process of the roller waste material with high aluminum content and the fly ash, so that the breaking strength and the thermal shock resistance of the brick with the temperature are improved; the combination of the two can prolong the service life of the brick with the temperature. The waste polished brick slag can increase the porosity of the brick with the temperature, improve the water absorption rate of the brick with the temperature, reduce the heat conductivity coefficient, improve the heat capacity, facilitate the full taking away of the heat of the kiln and maintain the stable temperature curve of the kiln.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be further described in detail with reference to the following examples.
The invention provides a brick with temperature for a ceramic brick kiln, which is mainly prepared from the following raw materials in parts by weight:
5-10 parts of roller waste, 10-25 parts of magnesia, 10-20 parts of bentonite, 1-5 parts of polished tile waste residue, 30-40 parts of fly ash, 5-15 parts of potassium sodium sand and 0.5-1.5 parts of binder.
Specifically, the roller bar waste is corundum-mullite roller bar waste; al thereof2O3The content is 50-80 wt%. The roller rod waste is one of the main wastes in the production process of ceramic factories, and is difficult to apply in the conventional ceramic tile formula due to high aluminum content, so the roller rod waste is often stockpiled as a waste after being damaged and replaced and is difficult to treat. According to the invention, the roller bar waste is introduced into the formula of the brick with the temperature, so that the thermal shock resistance of the brick with the temperature can be improved by utilizing the mullite phase of the roller bar waste; the corundum phase of the two can also react with magnesia and bentonite to form cordierite, so that the thermal shock resistance of the brick with the temperature is improved.
5-10 parts of roller waste; when the content of the roller bar waste is more than 10 parts, the formula contains too high aluminum, the firing degree is low, and the breaking strength of the brick with the temperature is reduced. Preferably, the weight part of the roller waste is 5-8 parts.
The magnesia clay is clay containing Mg, and can provide plasticity, maintain the stability of slurry and improve the strength of green bricks before the bricks with temperature are fired; in the firing process, the magnesia-based carbon brick can react with the roller bar waste, the fly ash and the bentonite to generate mullite and cordierite, so that the thermal shock resistance of the brick with the temperature is improved, and besides, the magnesia can promote firing and improve the breaking strength.
Specifically, in the invention, the content of MgO in the magnesia soil is 15-25 wt%, and SiO is255-70 wt% of Al2O3The content of (B) is 0.5-5 wt%.
The addition weight part of the magnesia is 10-25 parts, when the magnesia is less than 10 parts, the Mg content in the formula is too low, the firing degree is low, the cordierite content is low, and the thermal shock resistance is poor; when the content of the magnesia exceeds 25 parts, the firing degree is too high, and stoneware (the water absorption is 0.5-10%) or ceramic (less than 0.5%) bricks with temperature can be formed, so that the thermal shock resistance is weakened, and the heat capacity is reduced.
Bentonite is a commonly used clay mineral which further enhances the strength of the green body; mullite can be generated in high-temperature sintering, and the thermal shock resistance is improved. The bentonite is added in 10-20 parts by weight, preferably 15-20 parts by weight.
The fly ash is the waste generated by power plant combustion, and Al of the fly ash2O3The content of the CaO is 30-45 wt%, and the content of the CaO is 5-15 wt%. The alumina in the fly ash exists partially in a mullite form and partially in an activated vitreous form, has high reaction activity at high temperature, and can react with magnesia, bentonite and the like to form cordierite and mullite. The CaO in the fly ash exists mainly in a vitreous form, and can be melted to promote sintering when being sintered at high temperature.
In terms of micro morphology, the fly ash mostly exists in a micro-bead form; because the content of aluminum in the fly ash is high, and part of the microbeads with high aluminum content are not melted after being fired, but are embedded into the brick body in the form of the microbeads, the linear expansion coefficient of the microbeads is small, and the thermal shock stability of the brick with the temperature is favorably improved.
The potassium sodium sand is a potassium sodium feldspar mixture, which can further promote firing. In particular, K in K-Na sand2O and Na2The total content of O is more than or equal to 10 percent. Adding weight portions of potassium sodium sand5 to 15 portions.
The waste residue of the polished tile is waste residue generated in the production process of the polished tile, contains resin, SiC and the like, can generate gas in the sintering process, improves the porosity of the brick with the temperature, reduces the heat conductivity coefficient and improves the heat capacity. The polishing brick waste residue is added in 1-5 parts by weight, and when the weight is more than 5 parts, the brick with the temperature can generate excessive air holes, so that the thickness is greatly improved, and the polishing brick waste residue cannot be suitable for a ceramic brick kiln.
The adhesive has the main function of maintaining the suspension property of ridge raw materials such as roller waste, polished tile waste, fly ash, potassium sodium sand and the like in the slurry stage; and in the green body stage, the green strength of the green body is improved. Specifically, in the invention, the binder is one or more of carboxymethyl cellulose, sodium carboxymethyl cellulose, lignin, polyvinyl alcohol and starch.
At present, the porcelain brick (water absorption less than or equal to 1%) is a porcelain blank without glaze which is fired in the same formula and kiln. The brick with temperature is high in strength, but is easy to break in the cyclic sintering process, and short in service life. In addition, the heat taken away by the porcelain brick with the temperature is less, and the stability of the whole kiln system is not good for maintenance. In order to solve the problems, on one hand, the finished product of the brick with the temperature contains more mullite and cordierite through the adjustment of the formula, so that the thermal shock resistance and the breaking strength are improved, and the service life is prolonged; on the other hand, the formula of the invention is ceramic after being fired, the water absorption rate of the formula reaches 10-20%, the number of open pores is large, the thermal conductivity is low, the formula is more similar to a green body in the firing process, and more kiln heat can be taken away; furthermore, in order to improve the temperature effect, the waste polished tile slag is added into the formula, so that the porosity is improved.
Correspondingly, the invention also discloses a preparation method of the brick with the temperature for the porcelain brick kiln, which comprises the following steps:
(1) uniformly mixing 5-10 parts of roller waste, 10-25 parts of magnesia, 10-20 parts of bentonite and 5-15 parts of potassium sodium sand to obtain a first mixture;
the particle sizes of the roller waste and the potassium-sodium sand are larger (larger than 3 cm); the magnesia soil and the bentonite contain some larger soil blocks and/or mud blocks; therefore, the components are mixed and ball-milled at first, and the crushing efficiency is improved. A
(2) Mixing 1-5 parts of polished tile waste residue, 30-40 parts of fly ash and 0.5-1.5 parts of binder to obtain a second mixture;
the waste residue of the polished tile is waste residue generated in the polishing process of the polished tile, and the particle size of the waste residue is very small and is less than 200 meshes (74 mu m); the fly ash is a coal dust combustion product, and the particle size of the fly ash is smaller and is generally below 150 meshes (106 mu m). The binder is generally an organic substance soluble in water and easy to mix.
(3) Ball-milling the first mixture for 5-8 h, adding the second mixture, and continuing ball-milling for 0.5-2 h to obtain slurry;
the conventional method is difficult to mix uniformly due to the large difference of the particle size distribution of the first mixture and the second mixture; therefore, the first mixture is ball-milled for a period of time, the particle size of the first mixture is reduced, and then the second mixture with small particle size is added. Meanwhile, the grinding means is beneficial to reducing the energy consumed in the ball milling process.
(4) Spray drying the slurry to obtain powder;
specifically, after spray drying, the water content of the powder is controlled to be 7-8%.
(5) Pressing the powder material to obtain a green body;
specifically, the forming pressure is 20-30 MPa; if the molding pressure is more than 30MPa, the compact degree of the green body is too high, the water absorption rate after firing is greatly reduced, the heat conductivity coefficient of the brick with the temperature is greatly increased, and the heat capacity is reduced. If the molding pressure is less than 20MPa, the green strength is poor and the green body is easily damaged during drying and firing.
(6) And drying and sintering the green body to obtain a finished product of the brick with the temperature.
Specifically, the firing temperature is 1100-1300 ℃, and preferably 1150-1250 ℃. The production process of the brick with the temperature is similar to that of a porcelain brick, can be directly produced by adopting the original parameters, and is convenient and simple.
After the formula and the process are adopted, the prepared brick with the temperature has the water absorption of 10-20%, the flexural strength of 25-45 MPa and the average heat conductivity coefficient of 0.8-1.8W/(m.K) at 1100-1300 ℃; preferably, the water absorption rate is 15-20%, the breaking strength is 30-45 MPa, and the average thermal conductivity at 1150-1250 ℃ is 0.9-1.2W/(m.K).
Correspondingly, the invention also discloses the application of the brick with the temperature in the production process of the porcelain brick. Specifically, the ceramic tile is a polished tile, a glazed tile, a polished crystal tile or an antique tile, but is not limited thereto; the water absorption rate of the ceramic tile is less than or equal to 1%, and the firing temperature of the ceramic tile is 1100-1300 ℃; preferably, the water absorption rate is less than or equal to 0.5 percent, and the firing temperature is 1150-1250 ℃.
Specifically, the kiln in the production process of the porcelain tiles comprises a drying kiln and a firing kiln; wherein the highest temperature of the drying kiln is 150-300 ℃; the highest temperature of the sintering kiln is 1100-1300 ℃, preferably, the highest temperature of the drying kiln is 180-220 ℃, and the highest temperature of the sintering kiln is 1150-1250 ℃.
More specifically, the application of the brick with the temperature refers to that the brick with the temperature is placed into a firing kiln after the kiln is empty so as to achieve the purpose of adjusting the temperature system of the drying kiln and the firing kiln.
The invention is illustrated below in specific examples:
example 1
The embodiment provides a brick with temperature for a ceramic brick kiln, which comprises the following components in part by weight:
5 parts of roller waste, 20 parts of magnesia, 18 parts of bentonite, 3 parts of polished tile waste residues, 40 parts of fly ash and 14 parts of potassium sodium sand; 1 part of lignin;
wherein Al of the scrap roll bar2O3The content was 67.5 wt%; MgO content in the magnesia soil is 21.8 wt%, SiO2Is 67.3 wt% of Al2O3The content of (B) is 2.5 wt%; al in fly ash2O3The content was 34.28 wt%, and the CaO content was 5.4 wt%.
The preparation method comprises the following steps:
(1) uniformly mixing the roller waste, magnesia, bentonite and potassium-sodium sand to obtain a first mixture;
(2) mixing the polished tile waste residue, the fly ash and the binder to obtain a second mixture;
(3) ball-milling the first mixture for 6h, adding the second mixture, and continuing ball-milling for 0.5h to obtain slurry;
(4) spray drying the slurry to obtain powder;
wherein, the water content of the powder is 7.5 percent;
(5) pressing the powder material to obtain a green body;
wherein the molding pressure is 20 MPa;
(6) and drying and sintering the green body to obtain a finished product of the brick with the temperature.
Wherein the sintering temperature is 1150 ℃.
Example 2
The embodiment provides a brick with temperature for a ceramic brick kiln, which comprises the following components in part by weight:
8 parts of roller waste, 24 parts of magnesia, 15 parts of bentonite, 5 parts of polished tile waste residues, 38 parts of fly ash and 10 parts of potassium sodium sand; 1.2 parts of sodium carboxymethyl cellulose;
wherein Al of the scrap roll bar2O3The content was 58.6 wt%; MgO content in the magnesia soil is 23.2 wt%, SiO2Is 65.9 wt% of Al2O3Is 1.6 wt%; al in fly ash2O3The content was 31.7 wt%, and the CaO content was 12.4 wt%.
The preparation method comprises the following steps:
(1) uniformly mixing the roller waste, magnesia, bentonite and potassium-sodium sand to obtain a first mixture;
(2) mixing the polished tile waste residue, the fly ash and the binder to obtain a second mixture;
(3) ball-milling the first mixture for 7h, adding the second mixture, and continuing ball-milling for 0.8h to obtain slurry;
(4) spray drying the slurry to obtain powder;
wherein, the water content of the powder is 7 percent;
(5) pressing the powder material to obtain a green body;
wherein the molding pressure is 25 MPa;
(6) and drying and sintering the green body to obtain a finished product of the brick with the temperature.
Wherein the sintering temperature is 1210 ℃.
Example 3
The embodiment provides a brick with temperature for a ceramic brick kiln, which comprises the following components in part by weight:
7 parts of roller waste, 23 parts of magnesia, 17 parts of bentonite, 4 parts of polished tile waste residues, 36 parts of fly ash and 13 parts of potassium sodium sand; 1 part of sodium carboxymethyl cellulose;
wherein Al of the scrap roll bar2O3The content was 58.6 wt%; MgO content in the magnesia soil is 23.2 wt%, SiO2Is 65.9 wt% of Al2O3Is 1.6 wt%; al in fly ash2O3The content was 31.7 wt%, and the CaO content was 12.4 wt%.
The preparation method is the same as that of example 2.
Comparative example 1
The glazed polished green brick body is used as a brick with temperature. The formula is the same as that of normal production.
Comparative example 2
Unglazed tiles (ceramic tiles) are used as the brick with the temperature.
The brick with temperature in examples 1-3 and comparative example 1 were tested, and the data are shown in the following table 1:
TABLE 1 Performance test Table for brick with temp
Example 4 kiln Effect experiment
The blocks with temperature of example 3 and comparative example 1 were used separately for the experiment. The specific experimental method is as follows:
placing a batch of bricks with temperature into a firing kiln within 5min after the kiln is empty; lasting for two hours; the change in the temperature profile of the drying kiln and the firing kiln was recorded. Wherein, the temperature of the drying kiln is determined by reading a thermometer externally connected with the drying kiln; the temperature of the firing kiln is determined by a thermocouple in the kiln.
Specifically, the results of the kiln test are shown in table 2 below:
table 2 drying kiln temperature curve change table
| Number of joints | 2 | 12 | 20 | 25 | 30 | 42 | 50 | 60 |
| In front of empty kiln | 180 | 155 | 145 | 105 | 110 | 110 | 110 | 110 |
| Example 3 | 190 | 160 | 140 | 110 | 115 | 115 | 115 | 115 |
| Comparative example 1 | 195 | 165 | 155 | 125 | 120 | 115 | 140 | 145 |
| After 2 hours of empty kiln | 240 | 220 | 220 | 190 | 170 | 170 | 160 | 160 |
The effect of the firing kiln test is as follows 3:
TABLE 3 variation table of temperature curve of calcining kiln
As is apparent from tables 2 and 3, the brick with temperature of the present invention can maintain the temperature curves of the firing kiln and the drying kiln well.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.
Claims (9)
1. A brick with temperature for a ceramic brick kiln is characterized by being mainly prepared from the following raw materials in parts by weight:
5-10 parts of roll bar waste, 10-25 parts of magnesia, 10-20 parts of bentonite, 1-5 parts of polished tile waste residue, 30-40 parts of fly ash, 5-15 parts of potassium sodium sand and 0.5-1.5 parts of binder;
the brick with the temperature has the water absorption rate of 10-20%, the breaking strength of 25-45 MPa, and the average heat conductivity coefficient of 0.8-1.8W/(m.K) at 1100-1300 ℃.
2. The brick with temperature for ceramic brick kiln as claimed in claim 1, wherein the magnesia clay contains 15-25 wt% of MgO and SiO255-70 wt% of Al2O3The content of (A) is 0.5-5 wt%;
al in the fly ash2O3The content of the CaO is 30-45 wt%, and the content of the CaO is 5-15 wt%.
3. The warm brick for ceramic brick kilns as claimed in claim 1, characterized in that said roller scrap is corundum-mullite roller scrap, whose Al is2O3The content is 50-80 wt%.
4. The brick of claim 1, wherein the binder is selected from one or more of the group consisting of carboxymethylcellulose, sodium carboxymethylcellulose, lignin, polyvinyl alcohol, and starch.
5. A brick with temperature for ceramic brick kiln as claimed in claim 1, characterized in that the ceramic brick kiln comprises a drying kiln and a firing kiln;
the highest temperature of the drying kiln is 150-300 ℃;
the maximum temperature of the firing kiln is 1100-1300 ℃.
6. A method for preparing a brick with temperature for a ceramic brick kiln as claimed in any one of claims 1 to 5, characterized in that it comprises:
(1) uniformly mixing 5-10 parts of roller waste, 10-25 parts of magnesia, 10-20 parts of bentonite and 5-15 parts of potassium sodium sand to obtain a first mixture;
(2) mixing 1-5 parts of polished tile waste residue, 30-40 parts of fly ash and 0.5-1.5 parts of binder to obtain a second mixture;
(3) ball-milling the first mixture for 5-8 h, adding the second mixture, and continuing ball-milling for 0.5-2 h to obtain slurry;
(4) spray drying the slurry to obtain powder;
(5) pressing the powder material to obtain a green body;
(6) and drying and sintering the green body to obtain a finished product of the brick with the temperature.
7. The method for preparing a brick with temperature for a ceramic brick kiln as claimed in claim 6, wherein in the step (6), the firing temperature is 1100-1300 ℃.
8. Use of a brick according to any of claims 1 to 5 for use in a ceramic brick kiln in the production of ceramic bricks.
9. The use according to claim 8, wherein the ceramic tile is a polished tile, a glazed tile, a polished crystal tile or an antique tile, and has a water absorption of less than or equal to 1%; the firing temperature is 1100-1300 ℃.
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Effective date of registration: 20221125 Address after: 526200 Longwan Ceramic City, Xiamao Town, Sihui City, Zhaoqing City, Guangdong Province Patentee after: ZHAOQING LEHUA CERAMIC SANITARY WARE Co.,Ltd. Patentee after: Arrow Home Group Co.,Ltd. Address before: 526200 Longwan Ceramic City, Xiamao Town, Sihui City, Zhaoqing City, Guangdong Province Patentee before: ZHAOQING LEHUA CERAMIC SANITARY WARE Co.,Ltd. |