CN111470879A - Preparation method of normal-temperature foamed high-temperature fired foamed ceramic - Google Patents
Preparation method of normal-temperature foamed high-temperature fired foamed ceramic Download PDFInfo
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Abstract
The invention provides a preparation method of foamed ceramic foamed at normal temperature and fired at high temperature, belonging to the technical field of preparation of novel building materials. The method comprises the steps of preparing a foaming plate or a foaming building block by taking a raw material of a low-density foaming cement insulation board which is foamed through oxidation-reduction reaction at normal temperature as a main raw material, matching an auxiliary raw material and an additive and adopting a foaming process of a traditional cement-based foaming material; after the foamed plate or the foamed building block is maintained, cutting according to the market specification requirement of foamed ceramics to form a foamed ceramic blank; and feeding the cut foamed ceramic blank into a drying kiln and a kiln for firing. The preparation method synergistically improves the flexural strength of the foamed ceramic, reduces the density, and avoids using supporting carriers such as a shed plate, a sagger and the like in the traditional production, thereby avoiding the material and heat consumption cost caused by the use of the supporting carriers; and the related process is mature, is suitable for industrial popularization and application, and has excellent environmental benefit, economic benefit and social benefit.
Description
Technical Field
The invention relates to a preparation method of foamed ceramic foamed at normal temperature and fired at high temperature, belonging to the technical field of preparation of novel building materials.
Background
The foamed ceramic is widely used for heat insulation of building walls. In order to prepare a foamed ceramic with good performance, the key point is the chemical reaction of the foaming agent. In order to meet different use requirements, the foamed ceramics can be prepared into various foamed ceramics with different pore diameters, pore distribution and physical and chemical properties by reasonably matching the base material with different foaming agents and randomly changing the types and the adding amounts of the foaming agents and the particle diameters of the foaming agents in the preparation process of the foamed ceramics. When pores are formed by a chemical reaction of a foaming agent, the foaming agent can be broadly classified into a combustible type, a pyrolysis type, and a redox type according to a foaming principle.
These blowing agents are, however, characterized in that: the foaming needs to be carried out under the high-temperature condition, and the pores which are required to be uniform and small are required to be formed under the reflow condition with a liquid phase, so that the control is difficult, the firing process is foamed gradually, the lower the heat conductivity coefficient is in the later foaming stage, the longer the heat preservation time is, and meanwhile, because the foaming process is in the reflow state, a shed plate is required to be used as a support, so that the product cost is increased. Therefore, there is a need for a foaming process that can obtain uniform fine cells even when foaming at low temperature, and the foaming process does not require a support material.
At present, in addition to foaming by oxidation-reduction reaction at high temperature, foaming by oxidation-reduction reaction at normal temperature is also a feasible method. The traditional cement foaming wall board, foaming concrete, light non-sintered ceramsite and the like are typical types of foaming at normal temperature.
In particular to a novel wall thermal insulation material which is obtained by adding foaming agent or foam into inorganic cementing material slurry, rapidly stirring and then casting and molding the inorganic cementing material slurry. According to the difference of inorganic cementing materials for manufacturing the foamed cement insulation board, the inorganic cementing materials can be divided into cement-based foamed cement insulation boards, gypsum-based foamed cement insulation boards, pozzolanic foamed cement insulation boards and the like. The raw materials for preparing the cement-based foamed cement insulation board mainly comprise: cement, fly ash, a foaming agent, water, a certain filler and an additive; common fillers are sand, slag, crushed rock and fly ash; common additives include water reducing agent, coagulant, early strength agent, foam stabilizer and the like.
However, although the density of the cement-based foamed cement insulation board is relatively low, the density requirement of the low-density insulation material is consistent with that of the foamed ceramic, but the strength of the cement-based foamed cement insulation board is low and is inversely related to the density, and the prepared cement-based foamed cement insulation board cannot be suitable for working conditions with high strength requirement and low density requirement.
Therefore, the existing cement-based foaming cement insulation board has the contradiction between density reduction and strength guarantee, and the problems of high cost, immature process and the like in the preparation of the low-density high-strength cement-based cementing material.
Disclosure of Invention
The technical problem to be solved by the invention is how to obtain the technical scheme for preparing the cement-based foaming material which meets the performance requirements of synergistically reducing the density and improving the strength of the foamed cement-based foaming cement insulation board.
The invention provides a preparation method of foamed ceramic foamed at normal temperature and fired at high temperature, which comprises the following specific steps:
s1, preparing a foaming board or a foaming building block by taking the raw material of the low-density foaming cement insulation board which is foamed through redox reaction at normal temperature as a main raw material, matching with an auxiliary raw material and an additive and adopting the foaming process of the traditional cement-based foaming material;
s2, after the foamed board or the foamed block is cured, the flexural strength reaches 0.05-2MPa, and the density reaches 0.2-1.3g/cm3Then cutting according to the market specification requirement of the foamed ceramics to form a foamed ceramic blank;
s3, feeding the cut foamed ceramic blank into a drying kiln and a kiln for firing, wherein the maximum firing temperature is 1050-1200 ℃, and the foamed ceramic obtained after firing is the foamed ceramic which is foamed at normal temperature and high temperature; the flexural strength of the foamed ceramic foamed at normal temperature and fired at high temperature reaches 1.0-8.0 MPa, and the density reaches 0.3-1.8g/cm3。
Preferably, the foaming plate or the foaming block comprises the following components in percentage by mass: SiO 2245.0％～65.0％，Al2O35.0％～22.0％，CaO 10.0％～30.0％，MgO 0.5％～8.0％，Fe2O30.5％～8.0％，Na2O+K21.0 to 10.0 percent of O and the balance of inevitable impurities.
Preferably, the raw material of the low-density foamed cement insulation board foamed by the redox reaction at normal temperature is one or more of fly ash, blast furnace slag, cement, tailings, talc, perlite and silica fume.
Preferably, the auxiliary raw material comprises one or more of stone processing saw mud, tailings, ceramic processing dust, fluidized bed power plant ash, slag, and other pozzolanic active raw materials or solid wastes.
Preferably, the foaming process of the traditional cement-based foaming material mainly comprises the following two methods: one method is a two-step stirring method with foaming and stirring separated, namely, firstly, preparing cement mortar, secondly, preparing foam, and finally, stirring, mixing, pouring and maintaining the mortar and the foam; another method is a mixing and stirring method in which stirring and foaming are performed simultaneously: firstly, preparing foaming agent cement mortar, secondly, pouring the prepared mortar, and statically stopping, foaming and maintaining the poured material.
Preferably, the additive is desulfurized gypsum and aluminum powder, or desulfurized gypsum, lime or aluminum powder, or a protein foaming agent.
Preferably, the maintenance finger carries out natural maintenance or oxygen evaporation on the foaming plate or the foaming block cast in the mold to achieve the flexural strength of not less than 0.05MPa, and then the mold is removed and taken out.
Preferably, the cut foamed ceramic body is plate-shaped.
Preferably, the step of feeding the ceramic blank into a drying kiln and a kiln for firing refers to the step of feeding the cut foamed ceramic blank into the drying kiln and the roller kiln or the tunnel kiln in sequence according to a firing process of the ceramic roller kiln or the tunnel kiln, and then firing the ceramic blank into a finished product.
Preferably, the cut foamed ceramic body is directly fired on a roller kiln in high-temperature firing without using a support carrier comprising a shelf plate and a sagger in the conventional production.
The technical scheme of the invention has the following beneficial effects:
(1) the invention provides a novel foamed ceramic process of normal-temperature foaming and high-temperature firing by applying a slurry casting molding method, aiming at the defects of long high-temperature foaming process time, high energy consumption and large material consumption caused by the need of a shed plate and a saggar for supporting in the prior foamed ceramic;
(2) the normal-temperature foaming process can realize the volume expansion process at normal temperature, and then the formed and cut ceramic is fired, and the cut thin foamed ceramic blank body obviously reduces a large amount of time and energy consumption in the traditional foamed ceramic high-temperature foaming and firing heat preservation processes due to the reduction of the thickness;
(3) the foamed ceramic body after cutting can be directly fired on a roller kiln in high-temperature firing, so that the use of supporting carriers such as a shed plate, a sagger and the like in the traditional production is avoided, and the material and heat consumption cost caused by the use of the supporting carriers is avoided;
(4) the invention is a novel foamed ceramic preparation method which combines the advantages of normal temperature foamed building blocks and high temperature sintered ceramics, solves the contradiction between low density and high strength of cement-based light heat-insulating foamed materials, and improves the strength of the cement-based light heat-insulating foamed materials by sintering under the condition of possible low density to realize low density and high strength products;
(5) the chemical composition of the foaming building block taking the fly ash and the like as main raw materials is close to that of the existing novel silicon-calcium ceramic, and the foaming building block can be fired at high temperature to form ceramic, so that the breaking strength of the foaming ceramic is improved in a synergistic manner, the density is reduced, and the required low-density high-strength foaming ceramic material is obtained;
(6) the ceramic slurry casting molding method is similar to the traditional cement-based lightweight heat insulation material molding method, so that the cement-based foaming material with the silicon-calcium ceramic component and the like are further sintered to form the foaming ceramic, the foaming ceramic is mature in the prior art, the normal-temperature foaming and high-temperature firing process preparation of the foaming ceramic can be realized, and the industrial large-scale production and popularization are facilitated.
Detailed Description
In order to make the technical problems, technical solutions and advantages to be solved by the present invention clearer, the following detailed description is given with reference to specific embodiments.
The technical problem to be solved by the invention is how to obtain the technical scheme for preparing the cement-based foaming material which meets the performance requirements of synergistically reducing the density and improving the strength of the foamed cement-based foaming cement insulation board.
In order to solve the technical problems, the invention provides a preparation method of foamed ceramic foamed at normal temperature and fired at high temperature, which comprises the following specific steps:
s1, preparing a foaming board or a foaming building block by taking the raw material of the low-density foaming cement insulation board which is foamed through redox reaction at normal temperature as a main raw material, matching with an auxiliary raw material and an additive and adopting the foaming process of the traditional cement-based foaming material;
s2, after the foamed board or the foamed block is cured, the flexural strength reaches 0.05-2MPa, and the density reaches 0.2-1.3g/cm3Then cutting according to the market specification requirement of the foamed ceramics to form a foamed ceramic blank;
s3, feeding the cut foamed ceramic blank into a drying kiln and a kiln for firing, wherein the maximum firing temperature is 1050-1200 ℃, and the foamed ceramic obtained after firing is the foamed ceramic which is foamed at normal temperature and high temperature; the flexural strength of the foamed ceramic foamed at normal temperature and fired at high temperature reaches 1.0-8.0 MPa, and the density reaches 0.3-1.8g/cm3。
Particularly, the foaming plate or the foaming building block comprises the following components in percentage by mass: SiO 2245.0％～65.0％，Al2O35.0％～22.0％，CaO 10.0％～30.0％，MgO 0.5％～8.0％，Fe2O30.5％～8.0％，Na2O+K21.0 to 10.0 percent of O and the balance of inevitable impurities.
Particularly, the raw material of the low-density foamed cement insulation board foamed by the redox reaction at the normal temperature is one or more of fly ash, blast furnace slag, cement, tailings, talc, perlite and silica fume.
In particular, the auxiliary raw material comprises one or more of stone processing saw mud, tailings, ceramic processing dust, fluidized bed power plant ash, slag, and other pozzolanic active raw materials or solid waste.
In particular, the foaming process of the conventional cement-based foaming material mainly comprises the following two methods: one method is a two-step stirring method with foaming and stirring separated, namely, firstly, preparing cement mortar, secondly, preparing foam, and finally, stirring, mixing, pouring and maintaining the mortar and the foam; another method is a mixing and stirring method in which stirring and foaming are performed simultaneously: firstly, preparing foaming agent cement mortar, secondly, pouring the prepared mortar, and statically stopping, foaming and maintaining the poured material.
Particularly, the additive is desulfurized gypsum and aluminum powder, or desulfurized gypsum, lime or aluminum powder, or a protein foaming agent.
Particularly, the maintenance finger carries out natural maintenance or oxygen evaporation on the foaming plate or the foaming block cast in the mold to achieve the flexural strength not lower than 0.05MPa, and then the mold is removed and taken out.
In particular, the foamed ceramic body after cutting is plate-shaped.
Particularly, the step of feeding the ceramic blank into a drying kiln and a kiln for firing refers to the step of feeding the cut foamed ceramic blank into the drying kiln and the roller kiln or the tunnel kiln in sequence according to a firing process of a ceramic roller kiln or a tunnel kiln, and then firing the ceramic blank into a finished product.
In particular, the cut foamed ceramic body is directly fired on a roller kiln in high-temperature firing without using a support carrier comprising a shelf plate and a sagger in the conventional production.
The specific method for preparing the normal-temperature-foamed high-temperature-fired foamed ceramic will be described with reference to the following examples:
in the following examples of the present invention,
the composition of the foamed board or foamed block is shown in table 1 below:
table 1 composition (wt.%) of the foamed boards or foamed blocks of examples 1-4
The first embodiment is as follows:
a preparation method of normal-temperature foamed high-temperature fired foamed ceramic comprises the following specific steps:
firstly, taking fly ash, blast furnace slag and cement as main raw materials, matching with desulfurized gypsum and aluminum powder, adopting a foaming process of a traditional cement-based foaming material, and adopting a mixing and stirring method to prepare a foaming plate or a foaming building block, wherein the composition of the foaming plate or the foaming building block is shown in example 1 in Table 1;
secondly, the foaming board or the foaming building block is taken out after being treated by the oxygen steaming process, the measured flexural strength reaches 1.21MPa, and the density reaches 0.70g/cm3；
Thirdly, cutting the foamed board or the foamed building block into thin boards according to the market specification of the foamed ceramic, then sending the thin boards or the foamed building blocks into a drying furnace and a kiln for firing, wherein the firing process does not need the use of supporting carrier materials including a shelf board and a sagger, the firing temperature is 1050 ℃, the flexural strength of the foamed ceramic obtained after firing reaches 3.08MPa, and the density reaches 1.08g/cm3。
Example two:
a preparation method of normal-temperature foamed high-temperature fired foamed ceramic comprises the following specific steps:
firstly, fly ash, tailings and cement are used as main raw materials, desulfurized gypsum, lime and aluminum powder are matched, a traditional foaming process of a cement-based foaming material is adopted, and a mixing and stirring method is adopted to prepare a foaming plate or a foaming building block, wherein the composition of the foaming plate or the foaming building block is shown in an example 2 in a table 1;
secondly, the foaming board or the foaming building block is taken out after being treated by the oxygen steaming process, the measured flexural strength reaches 0.92MPa, and the density reaches 0.77g/cm3；
Thirdly, cutting the foamed board or the foamed building block into a sheet shape according to the market specification of the foamed ceramics, then sending the sheet-shaped foamed board or the foamed building block into a drying furnace and a kiln for firing, wherein the firing process does not need the use of supporting carrier materials including a shelf board and a sagger, the firing temperature is 1160 ℃,the flexural strength of the foamed ceramic obtained after firing reaches 5.36MPa, and the density reaches 1.20g/cm3。
Example three:
a preparation method of normal-temperature foamed high-temperature fired foamed ceramic comprises the following specific steps:
firstly, blast furnace slag, talc, perlite and cement are used as main raw materials and are matched with a protein foaming agent, a foaming process of a traditional cement-based foaming material is adopted, and a mixing and stirring method is adopted to prepare a foaming plate or a foaming building block, wherein the composition of the foaming plate or the foaming building block is shown in an example 3 in a table 1;
secondly, the foamed board or the foamed building block is taken out after being treated by the curing process, the measured flexural strength reaches 0.60MPa, and the density reaches 1.30g/cm3；
Thirdly, cutting the foamed board or the foamed building block into thin boards according to the market specification of the foamed ceramic, then sending the thin boards or the foamed building blocks into a drying furnace and a kiln for firing, wherein the firing process does not need the use of supporting carrier materials including a shelf board and a sagger, the firing temperature is 1180 ℃, the flexural strength of the foamed ceramic obtained after firing reaches 2.0MPa, and the density reaches 1.55g/cm3。
Example four:
a preparation method of normal-temperature foamed high-temperature fired foamed ceramic comprises the following specific steps:
firstly, fly ash, talcum, perlite and cement are used as main raw materials and matched with a protein foaming agent, a foaming process of a traditional cement-based foaming material is adopted, and a mixing and stirring method is adopted to prepare a foaming plate or a foaming building block, wherein the composition of the foaming plate or the foaming building block is shown in an example 4 in a table 1;
secondly, the foaming board or the foaming building block is taken out after being treated by the oxygen steaming process, the measured flexural strength reaches 0.52MPa, and the density reaches 1.20g/cm3；
Thirdly, cutting the foaming board or the foaming block into thin plates according to the market specification of the foaming ceramic, and then sending the thin plates or the foaming blocks into a drying furnace and a kiln for firing, wherein the firing process does not need the use of supporting carrier materials including a shelf board and a sagger, and the firing does not need to use the supporting carrier materials including the shelf board and the saggerThe temperature is 1200 ℃, the breaking strength of the obtained foamed ceramic after firing reaches 2.3MPa, and the density reaches 1.67g/cm3。
In summary, the beneficial effects of the above technical solutions of the present invention are as follows:
(1) the invention provides a novel foamed ceramic process of normal-temperature foaming and high-temperature firing by applying a slurry casting molding method, aiming at the defects of long high-temperature foaming process time, high energy consumption and large material consumption caused by the need of a shed plate and a saggar for supporting in the prior foamed ceramic;
(2) the normal-temperature foaming process can realize the volume expansion process at normal temperature, and then the formed and cut ceramic is fired, and the cut thin foamed ceramic blank body obviously reduces a large amount of time and energy consumption in the traditional foamed ceramic high-temperature foaming and firing heat preservation processes due to the reduction of the thickness;
(3) the foamed ceramic body after cutting can be directly fired on a roller kiln in high-temperature firing, so that the use of supporting carriers such as a shed plate, a sagger and the like in the traditional production is avoided, and the material and heat consumption cost caused by the use of the supporting carriers is avoided;
(4) the invention solves the contradiction between low density and high strength of the cement-based light heat-insulating foaming material, and can improve the strength of the foaming material by sintering under the condition of possible low density, thereby realizing a low-density high-strength product;
(5) the chemical composition of the foaming building block taking the fly ash and the like as main raw materials is close to that of the existing novel silicon-calcium ceramic, and the foaming building block can be fired at high temperature to form ceramic, so that the breaking strength of the foaming ceramic is improved in a synergistic manner, the density is reduced, and the required low-density high-strength foaming ceramic material is obtained;
(6) the ceramic slurry casting molding method is similar to the traditional cement-based lightweight heat insulation material molding method, so that the cement-based foaming material with the silicon-calcium ceramic component and the like are further sintered to form the foaming ceramic, the foaming ceramic is mature in the prior art, the normal-temperature foaming and high-temperature firing process preparation of the foaming ceramic can be realized, and the industrial large-scale production and popularization are facilitated.
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 as defined in the appended claims.
Claims (10)
1. A preparation method of foamed ceramic foamed at normal temperature and fired at high temperature is characterized by comprising the following specific steps:
s1, preparing a foaming board or a foaming building block by taking the raw material of the low-density foaming cement insulation board which is foamed through redox reaction at normal temperature as a main raw material, matching with an auxiliary raw material and an additive and adopting the foaming process of the traditional cement-based foaming material;
s2, after the foamed board or the foamed block is cured, the flexural strength reaches 0.05-2MPa, and the density reaches 0.2-1.3g/cm3Then cutting according to the market specification requirement of the foamed ceramics to form a foamed ceramic blank;
s3, feeding the cut foamed ceramic blank into a drying kiln and a kiln for firing, wherein the maximum firing temperature is 1050-1200 ℃, and the foamed ceramic obtained after firing is the foamed ceramic which is foamed at normal temperature and high temperature; the flexural strength of the foamed ceramic foamed at normal temperature and fired at high temperature reaches 1.0-8.0 MPa, and the density reaches 0.3-1.8g/cm3。
2. The preparation method of the normal-temperature foaming high-temperature fired foamed ceramic according to claim 1, wherein the composition of the foamed board or the foamed block is as follows by mass percent: SiO 2245.0％～65.0％，Al2O35.0％～22.0％，CaO 10.0％～30.0％，MgO 0.5％～8.0％，Fe2O30.5％～8.0％，Na2O+K21.0 to 10.0 percent of O and the balance of inevitable impurities.
3. The method for preparing normal-temperature foaming high-temperature firing foamed ceramic according to claim 1, wherein the raw material of the low-density foamed cement insulation board foamed by the redox reaction at normal temperature is one or more of fly ash, blast furnace slag, cement, tailings, talc, perlite and silica fume.
4. The method of claim 1, wherein the auxiliary raw materials include one or more of stone processing saw mud, tailings, ceramic processing dust, fluidized bed power plant ash, slag, and other pozzolanic active materials or solid wastes.
5. The method for preparing normal-temperature foaming high-temperature firing foamed ceramic according to claim 1, wherein the foaming process of the traditional cement-based foaming material mainly comprises the following two methods: one method is a two-step stirring method with foaming and stirring separated, namely, firstly, preparing cement mortar, secondly, preparing foam, and finally, stirring, mixing, pouring and maintaining the mortar and the foam; another method is a mixing and stirring method in which stirring and foaming are performed simultaneously: firstly, preparing foaming agent cement mortar, secondly, pouring the prepared mortar, and statically stopping, foaming and maintaining the poured material.
6. The method for preparing normal-temperature foaming high-temperature firing foamed ceramic according to claim 1, wherein the additive is desulfurized gypsum and aluminum powder, or desulfurized gypsum, lime or aluminum powder, or a protein foaming agent.
7. The method for preparing normal-temperature-foamed high-temperature-fired foamed ceramic according to claim 1, wherein the curing means is to remove the foamed plate or foamed block cast in the mold after natural curing or oxygen evaporation to a flexural strength of not less than 0.05 MPa.
8. The method of claim 1, wherein the cut foamed ceramic body has a plate shape.
9. The method for preparing foamed ceramics foamed at normal temperature and fired at high temperature according to claim 1, wherein the step of feeding the foamed ceramics into a drying kiln and a kiln for firing is that the cut foamed ceramics are fed into the drying kiln and the roller kiln or the tunnel kiln in sequence according to a firing process of a ceramic roller kiln or a tunnel kiln and then fired into a finished product.
10. The method of claim 1, wherein the cut green foamed ceramic body is fired directly in a roller kiln in the high temperature firing without using a support carrier comprising a shelf board and a sagger in the conventional production.
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