CN111925196B

CN111925196B - Ceramic tile taking green sand as raw material and preparation method thereof

Info

Publication number: CN111925196B
Application number: CN202011036720.5A
Authority: CN
Inventors: 李伟泉; 江楠; 王求平; 谢平; 吴河城; 刘守见; 唐振华; 钟保民
Original assignee: Foshan Dongpeng Ceramic Development Co Ltd
Current assignee: Chongqing Dongpeng smart home Co.,Ltd.; Foshan Dongpeng Ceramic Development Co Ltd
Priority date: 2020-09-28
Filing date: 2020-09-28
Publication date: 2021-01-15
Anticipated expiration: 2040-09-28
Also published as: CN111925196A

Abstract

The invention discloses a ceramic tile taking green sand as a raw material and a preparation method thereof. The preparation method comprises the steps A-D. The green brick of the ceramic tile of the invention takes green sand as a main raw material, is matched with superfine potassium feldspar, yellow sand and quartz to improve the whiteness of the green brick, and is matched with raw bauxite to reduce the brittleness of the green brick, so that the quality of the ceramic tile meets the standard. Because the green sand material has large storage capacity and is easy to obtain, the ceramic tile disclosed by the invention can greatly reduce the cost of raw materials by using a large amount of green sand materials. Meanwhile, in the preparation method of the ceramic tile, the green sand deironing efficiency is high, and the method is suitable for large-scale ceramic production.

Description

Ceramic tile taking green sand as raw material and preparation method thereof

Technical Field

The invention relates to the technical field of ceramic tiles, in particular to a ceramic tile taking green sand as a raw material and a preparation method thereof.

Background

The existing ceramic tile formula generally comprises a plastic raw material, a ridge raw material and a fluxed raw material, wherein the plastic raw material comprises clay, white mud and black mud, the plastic raw material mainly plays a plastic role in the ceramic raw material, the plasticity is high, and the forming of the ceramic tile is realized. Common for the present plastic raw materials are clays and slimes.

Green sand is a material of sand, which has output in Rongchang area and Yongchuan area in Chongqing city and is lower in price than clay and mud. The green sand comprises the chemical components of about 4 percent of sodium and more than 1 percent of potassium by mass percent, and can be used as a fluxed raw material; meanwhile, the green sand has certain plasticity, and the strength of the green brick can be improved. If the green sand is applied to the ceramic, the cost of the ceramic tile can be greatly reduced.

The prior art does not record green sand as a raw material of a ceramic tile. In view of the above, it is necessary to provide a ceramic tile using green sand as raw material.

Disclosure of Invention

The invention aims to provide a ceramic tile taking green sand as a raw material, which has the characteristic of low cost.

The invention also aims to provide a preparation method of the ceramic tile by taking the green sand as the raw material, which has the characteristics of suitability for large-scale production and low cost of the finished ceramic tile product.

In order to achieve the purpose, the invention adopts the following technical scheme:

the ceramic tile with green sand as material includes green tile blank, which is produced with green sand, superfine potash feldspar, yellow sand, quartz and bauxite.

Further, the green sand is processed into a green sand slurry finished product by removing iron, and the water content of the green sand slurry finished product is 41-43%.

Further, the formula of the green brick comprises the following raw materials in parts by weight:

5-10 parts of superfine potash feldspar, 3-5 parts of bentonite, 2-3 parts of clay, 2-5 parts of porcelain powder, 2-5 parts of waste green body powder, 16-30 parts of yellow sand, 0-5 parts of Jiangjin washing mud, 0-5 parts of magnesium mud, 1-6 parts of quartz, 18-22 parts of raw ore bauxite and 25-40 parts of green sand slurry finished product.

Further, the content of potassium in the bentonite is more than 4 percent by mass.

Further, the clay contains more than 18% of aluminum by mass percent.

Further, the yellow sand comprises yellow sand A and yellow sand B, wherein the whiteness of the yellow sand A is 48-52 degrees, and the whiteness of the yellow sand B is 44-46 degrees.

Further, the formula of the green brick comprises the following components in parts by weight: yellow sand A8-15 parts and yellow sand B8-15 parts.

A preparation method of a ceramic tile taking green sand as a raw material comprises the following steps:

step A, removing iron from green sand to prepare a green sand slurry finished product;

b, mixing and granulating the green sand slurry finished product and other raw materials according to a green brick formula to obtain powder;

step C, pressing the powder into a green brick;

d, firing the adobes into finished ceramic tiles;

in the step A, the preparation method of the green sand slurry finished product comprises the following steps:

(1) preparing materials: metering green sand and water according to a preset proportion;

(2) ball milling: feeding the weighed green sand and water into a ball mill to obtain green mortar A;

(3) iron removal: the green mortar A is processed by a permanent magnet deironing unit to obtain green mortar B, and the green mortar B is processed by a strong magnetic deironing unit to obtain green mortar C;

(4) and (3) dehydrating: dehydrating the green mortar C to obtain a green mortar finished product;

(5) and (3) storage: and (5) sending the green mortar finished product into a finished product slurry pond for storage.

Further, in the step (3), the water content of the green mortar B is 42-45%, and the iron content is 2-2.8%;

the water content of the green mortar C is 44-46%, the iron content is 1.5-1.8%, and the whiteness of the green mortar C is more than or equal to 30 ℃.

Further, in the step (4), the green mortar C passes through a primary dewatering cyclone and a secondary dewatering cyclone to obtain a green mortar finished product;

and the surface flow of the primary dewatering cyclone enters a secondary dewatering cyclone, the bottom flows of the primary dewatering cyclone and the secondary dewatering cyclone both enter a finished product slurry tank, and the bottom flows of the primary dewatering cyclone and the secondary dewatering cyclone are the finished green mortar product.

The invention has the beneficial effects that:

the green brick of the ceramic tile of the invention takes green sand as a main raw material, is matched with superfine potassium feldspar, yellow sand and quartz to improve the whiteness of the green brick, and is matched with raw bauxite to reduce the brittleness of the green brick, so that the quality of the ceramic tile meets the standard. Because the green sand material has large storage capacity and is easy to obtain, the ceramic tile disclosed by the invention can greatly reduce the cost of raw materials by using a large amount of green sand materials. Meanwhile, in the preparation method of the ceramic tile, the green sand deironing efficiency is high, and the method is suitable for large-scale ceramic production.

Drawings

FIG. 1 is a flow chart of a method for making a ceramic tile from green sand according to one embodiment of the present invention;

FIG. 2 is a schematic view of a green sand slurry processing system according to one embodiment of the present invention;

the device comprises a ball mill 1, an iron removal system 2, a dehydration system 3, a sewage treatment system 4, a finished product slurry tank 5, a vibrating screen 6, a batching system 7, a sewage tank 8, a storage bin 9, a permanent magnet iron removal unit 21, a strong magnet iron removal unit 22, a primary dehydration cyclone 31, a secondary dehydration cyclone 32, a concentration barrel 41, a dehydrator 42, a water tank 43, a water weighing part 71, an additive weighing part 72 and a green sand weighing part 73.

Detailed Description

The technical solution of the present invention is further described below with reference to the accompanying drawings and the detailed description.

The invention provides a ceramic tile taking green sand as a raw material, which comprises a green brick, wherein the raw material of the green brick comprises green sand, superfine potash feldspar, yellow sand, quartz and crude ore bauxite.

Green sand is a sand material, has output in Rongchang area and Yongchuan area in Chongqing city, is a local special ceramic raw material, has good sintering plasticity and large storage capacity, is easy to obtain, and can greatly reduce the raw material cost if being added in a large amount in a ceramic formula. However, because the green sand contains extremely high iron and has the original whiteness of about 3.5 degrees, if the green sand is used for ceramic raw materials, the whiteness of a blank body can be reduced; the green sand has high calcium content which can reach 1-1.5% by mass, so that the green body is difficult to oxidize and has high brittleness. The iron content, the calcium content, the aluminum content, the potassium content and the like mentioned in the invention are all chemical element contents in percentage by mass.

The green brick of the ceramic tile of the invention takes green sand as a main raw material, is matched with superfine potassium feldspar, yellow sand and quartz to improve the whiteness of the green brick, and is matched with raw bauxite to reduce the brittleness of the green brick, so that the quality of the ceramic tile meets the standard. Because the green sand material has large storage capacity and is easy to obtain, the ceramic tile disclosed by the invention can greatly reduce the cost of raw materials by using a large amount of green sand materials.

The green sand raw material is used for producing ceramic tiles after being subjected to an iron removal process, so that the iron content can be greatly reduced, and the color development influence of iron on the whiteness of a blank body is reduced. In the iron removal process, the green sand is prepared into slurry, the raw material particles in the slurry are small but uniform, the iron removal agent can be fully removed, the stability of the performance of the raw material can be improved, and the load of a ball mill can be reduced when the green sand slurry finished product is mixed with other ceramic raw materials for pulping. The water content of the green sand slurry finished product is set to be 41-43%, so that the green sand slurry finished product is prevented from layering during storage, and the storage stability of the green sand slurry is ensured.

Further, the formula of the green brick comprises the following raw materials in parts by weight: 5-10 parts of superfine potash feldspar, 3-5 parts of bentonite, 2-3 parts of clay, 2-5 parts of porcelain powder, 2-5 parts of waste green body powder, 16-30 parts of yellow sand, 0-5 parts of Jiangjin washing mud, 0-5 parts of magnesium mud, 1-6 parts of quartz, 18-22 parts of raw ore bauxite and 25-40 parts of green sand slurry finished product.

The superfine potassium feldspar is used for improving the potassium content in the green brick formula, improving the melting range of the green brick, playing a role in fluxing and improving the whiteness of the green brick. When the using amount of the superfine potassium feldspar is less than 5 parts, the blank body has low whiteness which cannot reach the production standard, and the blank body has low formula potassium content and poor fluxing effect. When the using amount of the superfine potassium feldspar is more than 10 parts, the strength of the dried green brick is reduced, the production loss is increased, and the formula cost is increased. The grain size of the superfine potassium feldspar is larger than 800 meshes.

The bentonite has plasticity and is used for improving the strength of dried green bricks. When the using amount of the bentonite is less than 3 parts, the strength of the dried green brick is low; when the amount of bentonite is more than 5 parts, pinholes are easily generated in the sintered green body, and the situation of poor oxidation occurs.

Clay is a plastic material used to increase the strength of the dried body. When the using amount of the clay is less than 2 parts, the strength of the dried green brick is low; when the clay amount is more than 3 parts, the blank body can be oxidized badly, and the black core phenomenon appears.

The porcelain powder is the powder after the unqualified products are crushed and ground after the ceramic tiles are fired. The waste green powder is waste product produced before the formed green body enters the kiln. Porcelain powder and waste green body powder are used for secondary utilization of fertilizers, so that the cost is saved and the waste is avoided.

The yellow sand has higher whiteness, and the whiteness of the green brick can be improved when a certain amount of the yellow sand is added. When the using amount of the yellow sand is less than 16 parts, the whiteness of the green brick is lower; when the usage amount of the yellow sand exceeds 30 parts, the firing temperature of the formula is increased, and the firing in a kiln is not facilitated.

Jiangjin water washed mud produced in Chongqing Jiangjin area has a low whiteness of about 20 ℃. The Jiangjin washing mud has plasticity and is used for improving the strength of dried green bricks; the Jiangjin washing mud has the aluminum content of about 22% by mass, and if the adding amount is more than 5 parts, the whiteness of a green brick is low, the formula temperature is increased, and the kiln firing is not facilitated.

The magnesium mud can improve the magnesium content of the formula and is used for reducing the firing temperature of the formula. The firing temperature range of the formula is narrowed along with the increase of the addition amount of the magnesium mud in the formula.

The quartz is used for improving the whiteness of the green bricks, the quartz in the formula is purchased from Yongchuan Chongqing, the material is called 'gaobaishi', and the whiteness is about 62 degrees. The hardness of quartz is higher, a proper amount of quartz is added in the formula to improve the whiteness of the green brick, and when the adding amount of the quartz is larger, the ball milling efficiency is lower during pulping.

The raw ore bauxite is blocky, is crushed into particles and then is added into the formula for ball milling and pulping, the solid raw ore bauxite is adopted for convenient weighing and proportioning, and the formula cost can also be reduced. The aluminum content of the raw ore bauxite is about 45 percent by mass percent, the ignition loss is about 13 percent by mass percent, and the aluminum content of the green brick is improved by the raw ore bauxite in the formula of the green brick.

The green sand contains about 4 percent of sodium and more than 1 percent of potassium by mass percent, and is a flux type raw material. The iron content of the green sand slurry finished product is less than 1.7 percent. The green sand has plasticity, can improve the strength of a dried blank, and reduces the amount of clay in the formula.

In the invention, the iron content is reduced by carrying out iron removal treatment on the green sand; the whiteness of the green brick is improved by adding superfine potassium feldspar, quartz and yellow sand, and the problem of difficult oxidation of the green brick caused by adding a large amount of green sand is solved by reducing the consumption of clay; the aluminum content of the formula is improved by adding raw ore bauxite, the magnesium content of the formula is improved by adding magnesia, the potassium content is properly improved by yellow sand and superfine potassium feldspar, and the brittleness of a green brick is reduced by properly adding bentonite and clay.

Further, the content of potassium in the bentonite is more than 4 percent by mass. The bentonite has stronger plasticity, and the bentonite with high potassium content can increase the potassium content in the formula and is beneficial to reducing the brittleness of green bricks.

Further, the clay contains more than 18% of aluminum by mass percent. The clay with larger aluminum content can improve the aluminum content in the formula and is beneficial to reducing the brittleness of the green brick.

Further, the yellow sand comprises yellow sand A and yellow sand B, wherein the whiteness of the yellow sand A is 48-52 degrees, and the whiteness of the yellow sand B is 44-46 degrees. The two kinds of yellow sand have higher whiteness, which is beneficial to improving the whiteness of green bricks. The two kinds of yellow sand are adopted, so that the production is stable, and the fluctuation caused by large using amount of a single material is avoided.

As shown in fig. 1, correspondingly, the present invention provides a method for preparing ceramic tiles using green sand as a raw material, for preparing the ceramic tiles, comprising the following steps:

step C, pressing the powder into a green brick;

and D, firing the green brick into a finished ceramic brick product.

The preparation method of the green sand slurry finished product comprises the steps of removing most of iron agents in the slurry after ball milling through secondary magnetic absorption and iron removal, and dehydrating the slurry after iron removal to obtain the finished product slurry. The processing method has the advantages that the permanent magnet iron remover is used for removing iron for the first time, and then the strong magnetic iron remover is used for removing iron for the second time, so that the processing method is high in iron removal efficiency, is suitable for large-scale ceramic production, and can be directly used as a raw material to be mixed with other raw materials for granulation without secondary processing to obtain finished slurry.

Specifically, in the step (1), the measured green sand is crushed green sand, the fineness of the crushed green sand is less than or equal to 30 multiplied by 30mm, the green sand essentially belongs to weathered sand, and is easy to grind, and the green sand is primarily crushed into particles with the fineness of less than 30 multiplied by 30mm, so that the requirement of ball milling can be met. The additive is metered according to a preset proportion, and is water glass and used for improving the flow rate of the slurry. And (3) feeding the green sand, water and water glass into a ball mill together.

In the step (2), according to the weight ratio, the water content of the green mortar A is 40-43%, the iron content of the total solid content of the green mortar A is 3-3.4%, the fineness of the green mortar A is 30 +/-5.0 of the residue of a 325-mesh sieve, and the whiteness is 3.2-3.7 degrees. Preferably, the water content of the green mortar A is 40-43%, the slurry with the water content has better fluidity, and green sand particles can be better dispersed in the slurry, so that the subsequent iron removal process is facilitated. The iron content of the slurry is related to the moisture content of the slurry, and as the iron content of the green sand raw material is relatively stable, the higher the moisture content of the slurry is, the lower the iron content of the slurry is.

In the preparation method of the ceramic tile with the green sand as the raw material, the steps B-D adopt the prior art, the green brick obtained in the step C is dried, glazed and dried, and then the step D is carried out, so that the ceramic tile with the surface decoration is obtained.

As shown in fig. 2, the method for processing green sand slurry of the present invention is based on a green sand slurry processing system, which includes a ball mill 1, an iron removal system 2, a dehydration system 3, a sewage treatment system 4, a finished slurry tank 5 and a batching system 7, wherein the ball mill 1, the iron removal system 2, the dehydration system 3 and the finished slurry tank 5 are sequentially connected, and the iron removal system 2 is further connected with the sewage treatment system 4;

the iron removal system 2 comprises a permanent magnet iron removal unit 21 and a strong magnet iron removal unit 22 which are connected, the permanent magnet iron removal unit 21 is communicated with the ball mill 1, the strong magnet iron removal unit 22 is connected with the dehydration system 3, and slurry obtained by ball milling of the ball mill 1 sequentially passes through the permanent magnet iron removal unit 21, the strong magnet iron removal unit 22 and the dehydration system 3 and then enters the finished product slurry tank 5. The output of the ball mill 1 is 80-100T/h. The output of the iron removal system 2 is more than or equal to 50T/h.

Batching system 7 links to each other with ball mill 1, and batching system 7 includes that water weighs portion 71, admixture weigh portion 72, blue or green sand weighs portion 73 and batch controller, and water weighs portion 71, admixture weigh portion 72 and blue or green sand weigh portion 73 all with batch controller electric connection, and water weighs portion 71, admixture weigh portion 72 and blue or green sand weigh portion 73 all with ball mill 1 and be connected, make water, admixture and blue or green sand all get into ball mill 1.

Each portion of weighing all adopts static weighing method, is about to transfer the material to the container, and this container bottom is provided with weighing equipment, and after weighing finishes, the material in the container is shifted out. The top of the container can be provided with a material placing pipeline or a material placing conveying belt, the bottom of the container is provided with a discharging mechanism, the discharging mechanism corresponds to the ball mill 1, and the materials in the container are directly conveyed into the ball mill 1.

Further, in the step (3), according to the weight ratio, the water content of the green mortar B is 42-45%, and the iron content of the total solid content of the green mortar B is 2-2.8%;

the water content of the green mortar C is 44-46%, the iron content of the total solid content of the green mortar C is 1.5-1.8%, and the whiteness of the green mortar C is more than or equal to 30 ℃.

When the green mortar A is subjected to primary iron removal through the permanent magnet iron removal unit 21, the iron content of the green mortar B after iron removal is lower than that of the green mortar A, and the solid content of the slurry is reduced due to the removal of the iron agent, so that the water content of the green mortar B is greater than that of the green mortar A. And (3) carrying out secondary iron removal on the green mortar B by using a strong magnetic iron removal unit 22, further reducing the iron content of the slurry after iron removal, wherein the iron content is as low as 1.5-1.8%, and the whiteness of the green mortar C is more than or equal to 30 ℃. The green mortar C subjected to secondary iron removal meets the standard of ceramic raw materials and can be used for ceramic production, but the green mortar C has high water content and can be layered during storage, so that the green mortar C needs to be dehydrated to obtain a green mortar finished product capable of being stably stored, and the water content of the green mortar finished product is 41-43%.

The permanent magnet iron removing unit 21 comprises 3-7 permanent magnet iron removing machines, and the 3-7 permanent magnet iron removing machines are arranged in parallel; the rotating speed of the permanent magnetic iron removing machine is 20-23r/min, and the magnetic induction intensity is 6000-10000 GS.

The rotating speed and the magnetic induction intensity of the permanent magnet iron remover are set, so that the iron agent in the slurry can be fully removed. The plurality of permanent magnet iron removers are arranged in parallel, so that the slurry in the ball mill 1 enters the plurality of permanent magnet iron removers simultaneously, the slurry treatment capacity is improved, and the yield is more than or equal to 50T/h.

Preferably, 5 permanent magnet iron removers are arranged in parallel; the rotating speed of the permanent magnet iron remover is 23r/min, and the magnetic induction intensity is 8000 GS. The parameter setting ensures the production speed and has lower production cost.

In the step (3), the strong magnetic iron remover unit 22 comprises 2-4 strong magnetic iron removers, and the 2-4 strong magnetic iron removers are arranged in parallel; 13000 and 17000GS magnetic induction of the strong magnetic iron remover.

The slurry discharged from the permanent magnet iron remover unit 22 enters a plurality of strong magnetic iron removers simultaneously, and the iron is removed by strong magnetic iron removal, so that most of the iron agents in the green mortar are removed, and the whiteness of the green mortar is more than or equal to 30 degrees.

Preferably, 3 strong magnetic iron removers are arranged in parallel; the magnetic induction intensity of the strong magnetic iron remover 15000 GS. The parameter setting ensures the production speed and has lower production cost.

In the step (3), the permanent magnet iron removal unit 21 and the strong magnet iron removal unit 22 are cleaned to generate iron-containing sewage, the iron-containing sewage is sent into the concentration barrel 41, and aluminum chloride is added into the concentration barrel 41, wherein the adding amount of the aluminum chloride is 600 plus 700 g/ton of green sand.

The iron adsorbed by the permanent magnetic iron removing unit 21 and the strong magnetic iron removing unit 22 is adhered with other non-iron-containing particles, so that the sewage generated by cleaning the iron removing units is turbid, and after aluminum chloride is added into the turbid sewage, the particles in the sewage can be promoted to be aggregated into clusters and settled, so that the water in the concentration barrel 41 forms a surface layer containing clear water and a bottom layer containing slurry. Specifically, the aluminum chloride is prepared into a solution and added into a concentration barrel to ensure that the aluminum chloride is uniformly dispersed. The adding amount of the aluminum chloride is 600-700g per ton of green sand, namely, 700g of the aluminum chloride is consumed for processing 1 ton of green sand. In the actual production, the generation of the iron-containing sewage and the iron removal of the slurry are alternately carried out, and the addition amount of the aluminum chloride is calculated according to the weight of the processed green sand, so that an operator can accurately calculate the addition amount of the aluminum chloride.

The iron-containing sewage forms a surface layer containing clear water and a bottom layer containing mud in the concentration barrel 41, the bottom layer containing mud generates clear water and tailings after being dehydrated, and the surface layer containing clear water of the concentration barrel 41 and the clear water generated by dehydrating the mud are used after being deironized again.

The working modes of the permanent magnet iron removing unit 21 are as follows: the pulp is fed for 0.5-2min, the water is flushed for 0.5-2min, and the pulp feeding and the pulp discharging are carried out simultaneously, namely, the cleaning operation is carried out once after each operation for a period of time. The strong magnetic iron removing unit 22 is cleaned once after being magnetized once. The sewage generated by the permanent magnet iron removing unit 21 contains a large amount of iron agents. And collecting the sewage containing the iron agent into a concentration barrel 41, wherein the sewage is layered into a surface layer and a bottom layer in the concentration barrel 41, the surface layer is clear water, and the bottom layer is slurry. The bottom layer slurry enters a dehydrator 42, and tailings generated by dehydration enter a storage bin 9 for storage and secondary utilization. The dehydrator 42 is a molecular film dehydrator, and the filter plate of the molecular film dehydrator is a molecular film filter plate.

The sewage generated by cleaning the permanent magnet iron removing unit 21 and the strong magnet iron removing unit 22 and the water removed from the dewatering system can be recycled, so that the internal recycling of the water is realized, and the zero discharge of the sewage is realized.

The sewage treatment system 4 of the green sand slurry processing system comprises a concentration barrel 41 and a dehydrator 42; an input port of the concentration barrel 41 is connected with the iron removal system 2, so that the concentration barrel 41 receives sewage generated by cleaning the iron removal system 2; the outlet of the thickening barrel 41 is connected to the dewatering machine 42, so that the bottom layer slurry of the thickening barrel 41 enters the dewatering machine 42.

The sewage treatment system 4 further comprises a water tank 43, the concentration barrel 41 and the dewatering machine 42 are both connected with the water tank 43, and the water tank 43 is used for receiving the clean water on the surface layer of the concentration barrel 41 and the clean water removed by the dewatering machine 42 and removing iron from the clean water. The water tank 43 collects the clear water generated by the concentration tub 41 and the dehydrator 42, and the iron in the clear water is removed again in the water tank 43, and then the water is sent to the ball mill 1 or other pulping processes for recycling.

The dewatering system 3 of the green sand slurry processing system comprises a primary dewatering cyclone 31 and a secondary dewatering cyclone 32 which are communicated, the surface flow of the primary dewatering cyclone 31 enters the secondary dewatering cyclone 32, the bottom flow of the primary dewatering cyclone 31 and the bottom flow of the secondary dewatering cyclone 32 both enter a finished slurry tank 5, and the surface flow of the secondary dewatering cyclone 32 enters a sewage tank 8. Further, in the step (4), the green mortar C passes through a primary dewatering cyclone and a secondary dewatering cyclone to obtain a green mortar finished product;

the surface flow of the primary dewatering cyclone 31 enters a secondary dewatering cyclone 32, the bottom flows of the primary dewatering cyclone 31 and the secondary dewatering cyclone 32 both enter a finished product slurry tank 5, and the bottom flows of the primary dewatering cyclone 31 and the secondary dewatering cyclone 32 are the finished product of the green mortar.

The surface flow of the secondary dewatering cyclone 32 enters the sewage tank 8, and the sewage tank 8 has the functions of storing sewage and buffering. The secondary dewatering cyclone 32 further dewaters the surface flow of the primary dewatering cyclone 31 to recover slurry, and the loss of raw materials is reduced.

The dehydration cyclone adopts the centrifugal sedimentation principle, and after slurry to be separated enters the cyclone tangentially from the periphery of the cyclone under certain pressure, strong three-dimensional elliptical strong-rotation shearing turbulent flow motion is generated. Because the particle size difference exists between the coarse particles and the fine particles, the coarse particles and the fine particles are subjected to different sizes of centrifugal force, centripetal buoyancy, fluid drag force and the like, and under the action of centrifugal sedimentation, most of the coarse particles are discharged through a bottom flow port of the cyclone, and most of the fine particles are discharged through an overflow pipe, so that the purposes of separation and classification are achieved. The invention adopts the secondary dehydration cyclone 32 to receive the surface flow of the primary dehydration cyclone 32, further recovers fine particles, reduces the system loss, generates less surface flow particles again, and can be recycled as clean water.

The surface flow water content of the secondary dewatering cyclone 32 is 94-96%, and the water in the sewage tank 8 is used for feeding into the ball mill 1. The solid particles in the surface flow with the water content of 94-96% are fine and difficult to recover again, and the surface flow is sent back to the ball mill 1 for utilization again, so that the sewage is prevented from being discharged outside, and the system loss can be further reduced.

The maximum cavity diameter of the primary dehydration cyclone 31 is 120-180mm, and the number of the primary dehydration cyclones 31 is 8-12 in parallel; the maximum cavity diameter of the secondary dewatering cyclones 32 is 70-80mm, and the number of the secondary dewatering cyclones 32 is 20-24 in parallel.

The slurry after iron removal enters a plurality of cyclones at the same time, and the cyclones work at the same time, so that large-scale production is realized. When one or more of the first-stage dehydration cyclones 31 need to be maintained, the residual cyclones can still meet the requirement of large-scale production. The diameter of the primary dewatering cyclone 31 is set to recover slurry with the particle size of 300-. The maximum cavity diameter of the dewatering cyclone refers to the maximum diameter of the inner cavity of the cone.

Preferably, the maximum cavity diameter of the primary dewatering cyclone 31 is 150mm, and the number of the primary dewatering cyclones 31 is 10.

The cavity diameter of the secondary dewatering cyclone 32 is set so that the slurry with the particle diameter of 500-800 meshes can be recycled, and the particles contained in the surface flow are greatly reduced and can be directly sent into the ball mill 1 for recycling. When one or more of the secondary dewatering cyclones 32 need to be maintained, the remaining cyclones can still meet the requirement of large-scale production. Preferably, the secondary dewatering cyclone 32 has a maximum chamber diameter of 75mm and a number of 22.

And (4) carrying out the step (3) after the green mortar A passes through a vibrating screen 6, wherein the screen of the vibrating screen 6 is a screen with 10-18 meshes. Preferably, the screen of the vibrating screen 6 is a 14-mesh screen. The purpose of the screen of the vibrating screen 6 is to separate the finely divided pebbles and fine sands flowing out together with the slurry to obtain a slurry of uniform fineness.

The invention is further illustrated by the following examples and comparative examples.

Embodiment group A is a method for preparing a ceramic tile by using green sand as a raw material, which comprises the following steps:

step C, pressing the powder into a green brick;

and D, firing the green brick into a finished ceramic brick product.

(3) iron removal: the green mortar A is processed by a permanent magnet deironing unit to obtain green mortar B, and the green mortar B is processed by a strong magnetic deironing unit to obtain green mortar C; the green mortar B has a water content of 42-45% and an iron content of 2-2.8%; the water content of the green mortar C is 44-46%, the iron content is 1.5-1.8%, and the whiteness of the green mortar C is more than or equal to 30 ℃;

the green mortar C passes through a primary dewatering cyclone and a secondary dewatering cyclone to obtain a green mortar finished product; and the surface flow of the primary dewatering cyclone enters a secondary dewatering cyclone, the bottom flows of the primary dewatering cyclone and the secondary dewatering cyclone both enter a finished product slurry tank, and the bottom flows of the primary dewatering cyclone and the secondary dewatering cyclone are the finished green mortar product.

In the method for producing the green sand-based ceramic tile of example group a, the green brick formulation is shown in table 1.

In table 1, the potassium content of bentonite is greater than 4% and the aluminum content of clay is greater than 18% by mass; the whiteness of the yellow sand A is 48-52 degrees, and the whiteness of the yellow sand B is 44-46 degrees. The different adobe formulations in the table 1 are made into ceramic tiles, the performance of the ceramic tiles is tested according to the national standard detection method of the ceramic tiles or the conventional detection method of the performance of the ceramic tiles, and the results are shown in the table 2.

In Table 2, the dry green strength means the strength of the green brick before it is dried in the kiln. According to the performance test result of the embodiment group A, the modulus of rupture of the ceramic tiles prepared by the embodiments is more than 38.8 MPa, the whiteness of the green tiles is more than 43 degrees, the dry green strength is more than 1.4 MPa, and the black core phenomenon is avoided. According to the test results, the whiteness of the green brick is adjusted by carrying out iron removal operation on the green sand and adjusting the using amounts of the superfine potassium feldspar, the yellow sand and the quartz in the formula, so that the whiteness of the green brick meets the production standard, namely the whiteness of the green brick reaches the degree of not influencing the color of a surface glaze layer; the problems of difficult oxidation and black heart are prevented by adjusting the dosage of bentonite and clay in the formula; the brittleness of the green brick is reduced by properly adding yellow sand, superfine potassium feldspar, bentonite and clay, and the fracture modulus of the ceramic brick can represent the brittleness of the green brick to a certain extent.

Preparation method of ceramic tile with comparative example group A and green sand as raw material

The amount of green mortar used in the green brick was varied according to the same preparation method as in example A1, as shown in Table 3 below:

the different adobe formulations in the above table 3 were made into ceramic tiles, and the performance of the ceramic tiles was tested according to the national standard testing method of ceramic tiles or the conventional testing method of ceramic tile performance, with the results shown in table 4.

As can be seen from the test data in Table 4, the ceramic tiles perform better when the amount of green sand slurry is reduced, but the formulation cost is not reduced to a sufficient extent. When the using amount of the green sand slurry is more than 40 parts, the performance of the ceramic tile is poor, even the modulus of rupture is reduced to the national standard, and the black core phenomenon appears. Therefore, the dosage of the green sand slurry in the green brick formula is more suitable between 25 and 40 parts, so that the ceramic brick has better performance and can meet the requirement of reducing the cost to the maximum extent.

Comparative example group B

According to the same preparation method conditions as in example A1, only the amounts of the ultra-fine potash feldspar and the yellow sand in the green brick were changed as shown in the following Table 5:

the different adobe formulations in the above table 5 were made into ceramic tiles, and the performance of the ceramic tiles was tested according to the national standard testing method of ceramic tiles or the conventional testing method of ceramic tile performance, with the results shown in table 6.

As can be seen from the test data in Table 6, when the usage amount of the yellow sand and the ultra-fine potassium feldspar is too small, the whiteness of the green brick is reduced; when the consumption of the yellow sand is excessive, the black core phenomenon occurs in the ceramic tile. When the consumption of the superfine potassium feldspar is too much, the strength of a dry blank is reduced, and the production loss is increased. When the yellow sand and the superfine potash feldspar are both in a reasonable dosage range, the whiteness of the green brick meets the requirement, and simultaneously, the high dry green strength of the green brick and the high modulus of rupture of the ceramic brick are ensured.

Comparative example set C

According to the same preparation process conditions as in example A1, only the amounts of bentonite and clay used in the green brick were varied, as shown in Table 7 below:

the different adobe formulations in table 7 above were made into ceramic tiles, and the performance of the ceramic tiles was tested according to the national standard testing method for ceramic tiles or the conventional testing method for ceramic tile performance, with the results shown in table 8.

As can be seen from the test data in table 8, bentonite and clay together affect the dry green strength. When the consumption of bentonite and clay is too small, the dry blank strength is reduced; when the consumption of bentonite and clay is excessive, the black core phenomenon occurs in the ceramic tile. Moreover, pinholes appeared on the green surfaces of the ceramic tiles of comparative examples C4 and C6, affecting the surface decoration effect. When both the bentonite and the clay are in a reasonable dosage range, the dry blank of the ceramic tile has higher hardness and no black core phenomenon after being fired.

The technical principle of the present invention is described above in connection with specific embodiments. The description is made for the purpose of illustrating the principles of the invention and should not be construed in any way as limiting the scope of the invention. Based on the explanations herein, those skilled in the art will be able to conceive of other embodiments of the present invention without inventive effort, which would fall within the scope of the present invention.

Claims

1. The ceramic tile with green sand as the raw material is characterized by comprising a green tile, wherein the green tile comprises the raw materials of green sand, superfine potash feldspar, yellow sand, quartz and raw ore bauxite;

the green sand is subjected to iron removal to prepare a green sand slurry finished product, the water content of the green sand slurry finished product is 41-43%, and the iron content of the total solid content of the green sand slurry finished product is less than 1.7%;

the formula of the green brick comprises the following raw materials in parts by weight:

2. The green sand-based ceramic tile as claimed in claim 1, wherein the bentonite has a potassium content of more than 4% by mass.

3. The green sand-based ceramic tile as claimed in claim 2, wherein the clay contains aluminum in an amount of more than 18% by mass.

4. The green sand-based ceramic tile according to claim 1, wherein the yellow sand comprises a yellow sand A and a yellow sand B, the whiteness of the yellow sand A is 48-52 degrees, and the whiteness of the yellow sand B is 44-46 degrees.

5. The green sand-based ceramic tile as claimed in claim 4, wherein the formulation of the green brick comprises the following components in parts by weight: 8-15 parts of yellow sand A and 8-15 parts of yellow sand B.

6. A method for preparing green sand-based ceramic tiles, according to any one of claims 1 to 5, comprising the steps of:

step C, pressing the powder into a green brick;

d, firing the adobes into finished ceramic tiles;

7. The method for preparing ceramic tiles by using green sand as a raw material according to claim 6, wherein in the step (3), the water content of the green mortar B is 42-45% by weight, and the iron content of the total solid content of the green mortar B is 2-2.8%;

8. The method for preparing the ceramic tile by using the green sand as the raw material according to the claim 6, wherein in the step (4), the green mortar C is subjected to a primary dewatering cyclone and a secondary dewatering cyclone to obtain a green mortar finished product;