CN111958762A - Method for manufacturing ceramic body by using ceramic waste - Google Patents
Method for manufacturing ceramic body by using ceramic waste Download PDFInfo
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- CN111958762A CN111958762A CN202010917959.7A CN202010917959A CN111958762A CN 111958762 A CN111958762 A CN 111958762A CN 202010917959 A CN202010917959 A CN 202010917959A CN 111958762 A CN111958762 A CN 111958762A
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/003—Pressing by means acting upon the material via flexible mould wall parts, e.g. by means of inflatable cores, isostatic presses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
-
- 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
- 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
- C04B2235/3208—Calcium oxide or oxide-forming salts thereof, e.g. lime
-
- 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
-
- 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
- C04B2235/34—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
- C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
-
- 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
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3839—Refractory metal carbides
- C04B2235/3843—Titanium carbides
-
- 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
Abstract
The invention discloses a method for manufacturing a ceramic body by using ceramic waste, which takes ceramic waste, alumina, kaolin, calcium carbonate, titanium carbide powder, ethylene glycol and hydroxyethyl cellulose as raw materials. Compared with the prior art, the method for producing the ceramic body by using the polishing waste mud, the waste residues, the waste powder and the waste blank generated in the ceramic production as the main raw materials not only solves the problem of waste treatment of industrial enterprises, protects the environment, but also saves the production cost and has good economic benefit; the shrinkage rate of the ceramic blank body before sintering and after high-temperature sintering is very low, the sintered ceramic has high compressive strength, namely very strong hardness, the technical problem of deformation of ceramic waste during sintering is solved, and the obtained ceramic blank body has good toughness and is resistant to falling and not easy to break.
Description
Technical Field
The invention relates to the technical field of ceramic materials, in particular to a method for manufacturing a ceramic body by using ceramic waste.
Background
The ceramic product generally comprises a functional ceramic coating and a ceramic blank, wherein the ceramic blank is a matrix structure of the ceramic product and directly influences subsequent processes of forming, drying, sintering and the like, and the mechanical properties of the ceramic blank, such as expansion coefficient, toughness, strength, high temperature resistance and the like, can all have important influence on the properties of the finally obtained ceramic product.
With the development of technology, ceramics are increasingly applied to the construction industry, and ceramic products are widely applied to public facilities, the construction industry and families. Various waste materials such as waste mud, waste slag, waste powder or waste blanks and the like are inevitably generated in the production process of ceramic products, the waste mud contains more impurities and pigments and is difficult to use in high-grade polished bricks, and the common method is landfill; the waste blank is a rotten blank generated in the production processes of pressing bricks, drying, printing and the like, or an unqualified blank with flowers lacking and the like, and is difficult to use in high-grade polished bricks due to more impurities and pigments, and the common method is landfill; the waste powder is usually sold as base powder; the waste slag is solid waste generated in the processing procedures of edging, chamfering and the like after the brick body is fired, and the waste slag cannot be recycled because of containing too much harmful substances, and the common method is landfill.
If the waste materials are reused, not only the cost can be reduced, but also natural resources can be protected.
Disclosure of Invention
The invention aims to solve the defects in the prior art and provides a method for manufacturing a ceramic body by using ceramic waste.
In order to achieve the purpose, the invention is implemented according to the following technical scheme:
a method for manufacturing a ceramic body by using ceramic waste comprises the following steps:
s1, pouring 100 parts by weight of ceramic waste, 20-30 parts by weight of alumina, 20-35 parts by weight of kaolin and 5-10 parts by weight of calcium carbonate into a ball mill for ball milling to prepare mixed powder after ball milling;
s2, adding 3-10 parts by weight of titanium carbide powder, 2-7 parts by weight of ethylene glycol and 3-10 parts by weight of hydroxyethyl cellulose into the mixed powder, and uniformly mixing to obtain mixed slurry for later use;
s3, adding the mixed slurry into an inlet of a centrifugal sprayer, and rotating a sprayer nozzle of the sprayer at the frequency of 16-18Hz/RPM to obtain powder with the particle size of 95-230 microns;
s4, forming by using an isostatic pressing method, placing the sprayed powder into a mold, placing the mold into an isostatic pressing machine, and gradually pressurizing by a pressurizing system to obtain a ceramic blank;
and S5, manufacturing the ceramic blank into a required shape by using a lathe.
As a preferable technical solution of the present invention, in S1, the ceramic waste includes polishing waste mud, waste residue, waste powder, and waste blank generated in ceramic production, wherein a mass ratio of the polishing waste mud, the waste residue, the waste powder, and the waste blank is 1:1: 1.
As a preferred technical scheme of the invention, in S1, the mass ratio of the raw materials to the ball stones in the ball mill is 3-5:1, the ball milling is carried out for 22-24 hours, and the rotating speed of the ball mill is 30-33 r/min.
In a preferred embodiment of the present invention, the titanium carbide in S2 has a particle size of 1 to 4 μm.
As a preferred technical scheme of the invention, in the S4, the pressure of the isostatic pressing machine is controlled at 220-240 MPa.
In addition, the invention also provides a ceramic blank prepared by the method for preparing the ceramic blank by utilizing the ceramic waste.
Compared with the prior art, the invention utilizes the polishing waste mud, waste residue, waste powder and waste blank generated in the ceramic production as main raw materials to produce the ceramic body, thereby not only solving the problem of waste treatment of industrial enterprises, protecting the environment, but also saving the production cost and having good economic benefit.
The shrinkage rate of the ceramic blank body before sintering and after high-temperature sintering is very low, the sintered ceramic has high compressive strength, namely very strong hardness, the technical problem of deformation of ceramic waste during sintering is solved, and the obtained ceramic blank body has good toughness and is resistant to falling and not easy to break.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. The specific embodiments described herein are merely illustrative of the invention and do not limit the invention.
Example 1
S1, pouring 100g of ceramic waste, 20g of alumina, 20g of kaolin and 5g of calcium carbonate into a ball mill for ball milling, wherein the mass ratio of the raw materials to ball stones in the ball mill is 3:1, the ball milling is carried out for 22 hours, and the rotating speed of the ball mill is 30 r/min; preparing mixed powder after ball milling; the ceramic waste comprises polishing waste mud, waste residues, waste powder and waste blanks generated in ceramic production, wherein the mass ratio of the polishing waste mud, the waste residues, the waste powder and the waste blanks is 1:1:1: 1;
s2, adding 3g of titanium carbide powder with the particle size of 1 mu m, 2g of ethylene glycol and 3g of hydroxyethyl cellulose into the mixed powder, and uniformly mixing to obtain mixed slurry for later use;
s3, adding the mixed slurry into an inlet of a centrifugal sprayer, and rotating a sprayer nozzle of the sprayer at the frequency of 16Hz/RPM to obtain powder with the particle size of 95 microns;
s4, forming by using an isostatic pressing method, placing the sprayed powder into a mold, then placing the mold into an isostatic pressing machine, controlling the pressure of the isostatic pressing machine to be 2200Mpa, and gradually pressurizing by a pressurizing system to obtain a ceramic blank;
and S5, manufacturing the ceramic blank into a required shape by using a lathe.
Then the ceramic green body is put into a tunnel kiln to be sintered, the sintering temperature is 1100 ℃, and the sintering period is 20 hours. The drying properties and the properties after firing were measured, and the results are shown in Table I.
Example 2
S1, pouring 100g of ceramic waste, 30g of alumina, 35g of kaolin and 10g of calcium carbonate into a ball mill for ball milling, wherein the mass ratio of the raw materials to the ball stones in the ball mill is 5:1, the ball milling is carried out for 24 hours, and the rotating speed of the ball mill is 33 r/min; preparing mixed powder after ball milling; the ceramic waste comprises polishing waste mud, waste residues, waste powder and waste blanks generated in ceramic production, wherein the mass ratio of the polishing waste mud, the waste residues, the waste powder and the waste blanks is 1:1:1: 1;
s2, adding 10g of titanium carbide powder with the particle size of 4 mu m, 7g of ethylene glycol and 10g of hydroxyethyl cellulose into the mixed powder, and uniformly mixing to obtain mixed slurry for later use;
s3, adding the mixed slurry into an inlet of a centrifugal sprayer, and rotating a sprayer nozzle of the sprayer at the frequency of 18Hz/RPM to obtain powder with the particle size of 230 microns;
s4, forming by using an isostatic pressing method, placing the sprayed powder into a mold, then placing the mold into an isostatic pressing machine, controlling the pressure of the isostatic pressing machine at 240Mpa, and gradually pressurizing by a pressurizing system to obtain a ceramic blank;
and S5, manufacturing the ceramic blank into a required shape by using a lathe.
Then the ceramic green body is put into a tunnel kiln to be sintered, the sintering temperature is 1100 ℃, and the sintering period is 20 hours. The drying properties and the properties after firing were measured, and the results are shown in Table I.
Example 3
S1, pouring 100g of ceramic waste, 20g of alumina, 35g of kaolin and 10g of calcium carbonate into a ball mill for ball milling, wherein the mass ratio of the raw materials to ball stones in the ball mill is 3:1, the ball milling is carried out for 24 hours, and the rotating speed of the ball mill is 33 r/min; preparing mixed powder after ball milling; the ceramic waste comprises polishing waste mud, waste residues, waste powder and waste blanks generated in ceramic production, wherein the mass ratio of the polishing waste mud, the waste residues, the waste powder and the waste blanks is 1:1:1: 1;
s2, adding 10g of titanium carbide powder with the particle size of 4 mu m, 7g of ethylene glycol and 3g of hydroxyethyl cellulose into the mixed powder, and uniformly mixing to obtain mixed slurry for later use;
s3, adding the mixed slurry into an inlet of a centrifugal sprayer, and rotating a sprayer nozzle of the sprayer at the frequency of 16Hz/RPM to obtain powder with the particle size of 200 microns;
s4, forming by using an isostatic pressing method, placing the sprayed powder into a mold, then placing the mold into an isostatic pressing machine, controlling the pressure of the isostatic pressing machine to be 220Mpa, and gradually pressurizing by a pressurizing system to obtain a ceramic blank;
and S5, manufacturing the ceramic blank into a required shape by using a lathe.
Then the ceramic green body is put into a tunnel kiln to be sintered, the sintering temperature is 1100 ℃, and the sintering period is 20 hours. The drying properties and the properties after firing were measured, and the results are shown in Table I.
Example 4
S1, pouring 100g of ceramic waste, 25g of alumina, 30g of kaolin and 7g of calcium carbonate into a ball mill for ball milling, wherein the mass ratio of the raw materials to the ball stones in the ball mill is 4:1, the ball milling is carried out for 23 hours, and the rotating speed of the ball mill is 32 r/min; preparing mixed powder after ball milling; the ceramic waste comprises polishing waste mud, waste residues, waste powder and waste blanks generated in ceramic production, wherein the mass ratio of the polishing waste mud, the waste residues, the waste powder and the waste blanks is 1:1:1: 1;
s2, adding 6g of titanium carbide powder with the grain size of 3 mu m, 5g of ethylene glycol and 6g of hydroxyethyl cellulose into the mixed powder, and uniformly mixing to obtain mixed slurry for later use;
s3, adding the mixed slurry into an inlet of a centrifugal sprayer, and rotating a sprayer nozzle of the sprayer at the frequency of 17Hz/RPM to obtain powder with the particle size of 150 μm;
s4, forming by using an isostatic pressing method, placing the sprayed powder into a mold, then placing the mold into an isostatic pressing machine, controlling the pressure of the isostatic pressing machine at 230Mpa, and gradually pressurizing by a pressurizing system to obtain a ceramic blank;
and S5, manufacturing the ceramic blank into a required shape by using a lathe.
Then the ceramic green body is put into a tunnel kiln to be sintered, the sintering temperature is 1100 ℃, and the sintering period is 20 hours. The drying properties and the properties after firing were measured, and the results are shown in Table I.
Watch 1
As can be seen from the table I, the ceramic green body of the invention has very low shrinkage before sintering and after high-temperature sintering, and the sintered ceramic has high compressive strength, i.e. very strong hardness.
In summary, the ceramic waste is fully utilized, the ceramic blank is further manufactured by taking the ceramic waste as the main material, the purpose of fully utilizing the waste is achieved, and the manufactured ceramic blank has excellent structural performance.
The technical solution of the present invention is not limited to the limitations of the above specific embodiments, and all technical modifications made according to the technical solution of the present invention fall within the protection scope of the present invention.
Claims (6)
1. A method for manufacturing a ceramic body by using ceramic waste is characterized by comprising the following steps:
s1, pouring 100 parts by weight of ceramic waste, 20-30 parts by weight of alumina, 20-35 parts by weight of kaolin and 5-10 parts by weight of calcium carbonate into a ball mill for ball milling to prepare mixed powder after ball milling;
s2, adding 3-10 parts by weight of titanium carbide powder, 2-7 parts by weight of ethylene glycol and 3-10 parts by weight of hydroxyethyl cellulose into the mixed powder, and uniformly mixing to obtain mixed slurry for later use;
s3, adding the mixed slurry into an inlet of a centrifugal sprayer, and rotating a sprayer nozzle of the sprayer at the frequency of 16-18Hz/RPM to obtain powder with the particle size of 95-230 microns;
s4, forming by using an isostatic pressing method, placing the sprayed powder into a mold, placing the mold into an isostatic pressing machine, and gradually pressurizing by a pressurizing system to obtain a ceramic blank;
and S5, manufacturing the ceramic blank into a required shape by using a lathe.
2. The method of claim 1, wherein the ceramic waste comprises polishing waste mud, waste slag, waste powder and waste blank generated in ceramic production in S1, wherein the mass ratio of the polishing waste mud, the waste slag, the waste powder and the waste blank is 1:1:1: 1.
3. The method for manufacturing a ceramic body by using the ceramic waste according to claim 1, wherein in S1, the mass ratio of the raw materials to the ball stones in the ball mill is 3-5:1, the ball mill is used for milling for 22-24 hours, and the rotation speed of the ball mill is 30-33 r/min.
4. The method for manufacturing a ceramic body using ceramic waste according to claim 1, wherein the grain size of the titanium carbide in S2 is 1-4 μm.
5. The method for manufacturing a ceramic body using ceramic waste as claimed in claim 1, wherein the pressure of the isostatic press is controlled at 220-240Mpa in S4.
6. A ceramic body produced by the method for producing a ceramic body using the ceramic waste according to any one of claims 1 to 5.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010917959.7A CN111958762A (en) | 2020-09-03 | 2020-09-03 | Method for manufacturing ceramic body by using ceramic waste |
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| CN202010917959.7A CN111958762A (en) | 2020-09-03 | 2020-09-03 | Method for manufacturing ceramic body by using ceramic waste |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114634351A (en) * | 2022-03-28 | 2022-06-17 | 醴陵华鑫电瓷科技股份有限公司 | Method for preparing ceramic grinding ball for electroceramic production by using non-calcined porcelain waste mud |
| CN117383911A (en) * | 2023-12-12 | 2024-01-12 | 苏州芯合半导体材料有限公司 | Ceramic magnetic disk prepared from ceramic chopper waste and production granulating waste powder and preparation method thereof |
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| CN117383911A (en) * | 2023-12-12 | 2024-01-12 | 苏州芯合半导体材料有限公司 | Ceramic magnetic disk prepared from ceramic chopper waste and production granulating waste powder and preparation method thereof |
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