CN112047729B - 一种双重焙烧气氛烧制古建筑青瓦工艺 - Google Patents
一种双重焙烧气氛烧制古建筑青瓦工艺 Download PDFInfo
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Abstract
本发明公开了一种双重焙烧气氛烧制古建筑青瓦工艺,属于青瓦加工制造技术领域,包括如下步骤:(1)原料称取、(2)球磨处理、(3)坯体制备、(4)烘干处理、(5)焙烧处理、(6)冷却处理。本发明工艺各步骤搭配合理,生产成本低,绿色环保,利于推广应用,制得的青瓦力学品质好、耐腐耐候性强。
Description
技术领域
本发明属于青瓦加工制造技术领域,具体涉及一种双重焙烧气氛烧制古建筑青瓦工艺。
背景技术
传统工艺中青瓦是粘土烧制的,呈青灰色,给人以素雅,沉稳,古朴,宁静的美感,近年来成为设计师极力推荐的产品之一,由于烧制温度较高,具有一定的瓷化程度,具有抗折强度高、耐磨损、耐酸碱、寿命长等优点,故称之为瓷质青瓦。传统的烧制工艺如下:粘土经过造型后在阴凉处阴干,然后在土窑中烧制完成后,需要经过渗碳、保色等工艺后才能冷却出窑,整个工艺大概持续两周左右,使得生产效率很低,并且在此期间需要不断的消耗燃煤,不仅增加能源消耗,而且煤燃烧不充分导致废气排放造成环境污染;同时,由于青瓦完全采用粘土烧制,造成了大量土地的流失。因对于粘土产生过度使用,政府采取相关强制措施命令禁止以粘土为原料生产建材。
因此现有技术中摒弃了粘土的添加使用,而是采用了河沙、工业废弃物等进行加工制备,如申请号为:201310238704.8公开了一种蒸压青砖或青瓦,其由河沙或页岩、煤研石、石灰或水泥为原料制备而成,制得的青瓦具有不错的力学品质及耐候性等,但随着人们对于产品性能要求的不断提升,此类青瓦在寿命和使用稳定性上仍需要进一步的增强。
发明内容
本发明的目的是提供一种双重焙烧气氛烧制古建筑青瓦工艺。
本发明的上述技术目的是通过以下技术方案实现的:
一种双重焙烧气氛烧制古建筑青瓦工艺,包括如下步骤:
(1)原料称取:
按对应重量份称取下列原料:20~25份铝矾土、10~15份紫砂石、40~45份河沙、15~20份煤矸石、8~12份石灰、0.5~1.5份着色剂、2~4份纳米二氧化钛、5~8份石榴石、0.1~0.3份添加剂;
(2)球磨处理:
将步骤(1)称取的所有原料共同投入到球磨机内进行球磨处理,完成后取出得球磨粉碎料备用;
(3)坯体制备:
向步骤(2)所得的球磨粉碎料中加入清水,充分搅拌均匀调节整体的水含量至24~28%,然后再进行造型处理后得坯体备用;
(4)烘干处理:
对步骤(3)制得的坯体进行烘干处理,烘干至整体的水含量不大于10%后备用;
(5)焙烧处理:
a.将步骤(4)处理后的坯体放入到窑内,先进行加热升温处理,将窑内温度升至820~850℃;
b.将窑内温度进一步加热升温处理,控制窑内温度升至930~960℃,在此温度条件下焙烧处理3.5~4.5h后取出得半成品备用;
(6)冷却处理:
将步骤(5)所得的半成品放入到变温箱内进行冷却处理,待其降至常温后取出即得成品青瓦。
进一步的,步骤(1)中所述的着色剂为氧化铁黑;所述的添加剂为硝酸镧、氧化钇、二茂铁对应按照重量比4~6:2~3:1~3混合而成。
进一步的,步骤(2)中所述的球磨粉碎料的颗粒大小为200目。
进一步的,步骤(4)中所述的烘干处理时控制烘干的温度为100~110℃。
进一步的,步骤(5)操作a中所述的升温处理时控制加热升温的速度为130~140℃/h;在此期间持续向窑内通入过量的空气。
进一步的,步骤(5)操作b中所述的升温处理时控制加热升温的速度为170~180℃/h;在此期间持续向窑内通入高炉煤气。
进一步的,步骤(6)中所述的冷却处理时控制变温箱内的降温速度为240~250℃/h;所述的常温温度为23℃。
本发明相比现有技术具有以下优点:
本发明提供了青瓦的制备工艺,首先改变了传统粘土成分的添加使用,其次又变换了焙烧的气氛,采用双重焙烧气氛来进行烧制处理,显著提升了青瓦的使用品质;具体是在原料成分上,以铝矾土、紫砂石、河沙为主体成分,配以煤矸石、石灰作为辅料,保证了青瓦整体的低成本性和较好的强度品质等,为了进一步提升使用性能,又添加了纳米二氧化钛、石榴石和添加剂,其中纳米二氧化钛能够提升组织整体的致密性和强度,石榴石能够形成强度耐腐性更高的相结构,添加剂能够促进玻璃相等的形成,上述成分协同提高了青瓦的使用品质;此后在焙烧处理中,采用了双重焙烧的方式进行焙烧处理,更利于原料成分的性能发挥和增强,双重焙烧气氛是指青瓦的表层处于氧化气氛中,而内层处于还原气氛中,内层组织处于还原气氛中时将坯体内的三氧化二铁还原成了低价铁,产生了较强的助熔作用,使得产品的内层组织更为密实,配合纳米二氧化钛的添加,进一步增强了内部的致密性和强度;表层组织处于氧化气氛中,石榴石和添加剂的添加能够更快的促使表层有复杂的玻璃相液渗出,将青瓦表层的孔隙封闭,一方面利于内层组织在消耗掉氧气的情况下处于还原气氛中,另一方面可以在表层形成更为稳定的防护层来提升表面品质;此焙烧处理方式降低了焙烧的温度,相较于现有普遍1000℃以上的焙烧高温,有利于降低生产的成本;最后进行了冷却处理,严格控制降温的速率,消除了青瓦内部的应力,保证了青瓦的质量。本发明工艺各步骤搭配合理,生产成本低,绿色环保,利于推广应用,制得的青瓦力学品质好、耐腐耐候性强,极具市场竞争力和推广应用价值。
具体实施方式
实施例1
一种双重焙烧气氛烧制古建筑青瓦工艺,包括如下步骤:
(1)原料称取:
按对应重量份称取下列原料:20份铝矾土、10份紫砂石、40份河沙、15份煤矸石、8份石灰、0.5份着色剂、2份纳米二氧化钛、5份石榴石、0.1份添加剂;所述的着色剂为氧化铁黑;所述的添加剂为硝酸镧、氧化钇、二茂铁对应按照重量比4:2:1混合而成;
(2)球磨处理:
将步骤(1)称取的所有原料共同投入到球磨机内进行球磨处理,完成后取出过200目筛后得球磨粉碎料备用;
(3)坯体制备:
向步骤(2)所得的球磨粉碎料中加入清水,充分搅拌均匀调节整体的水含量至24~28%,然后再进行造型处理后得坯体备用;
(4)烘干处理:
对步骤(3)制得的坯体放入到温度为100℃的条件下进行烘干处理,烘干至整体的水含量不大于10%后备用;
(5)焙烧处理:
a.将步骤(4)处理后的坯体放入到窑内,先进行加热升温处理,控制加热升温的速度为130℃/h,将窑内温度升至820℃,在此期间持续向窑内通入过量的空气;
b.将窑内温度进一步加热升温处理,控制加热升温的速度为170℃/h,控制窑内温度升至930℃,在此温度条件下焙烧处理3.5h后取出得半成品备用,在此期间持续向窑内通入高炉煤气;
(6)冷却处理:
将步骤(5)所得的半成品放入到变温箱内进行冷却处理,控制变温箱内的降温速度为240℃/h,待其降至23℃的常温后取出即得成品青瓦。
实施例2
一种双重焙烧气氛烧制古建筑青瓦工艺,包括如下步骤:
(1)原料称取:
按对应重量份称取下列原料:20份铝矾土、13份紫砂石、42份河沙、15份煤矸石、8份石灰、0.5份着色剂、3份纳米二氧化钛、7份石榴石、0.2份添加剂;所述的着色剂为氧化铁黑;所述的添加剂为硝酸镧、氧化钇、二茂铁对应按照重量比5:2:1混合而成;
(2)球磨处理:
将步骤(1)称取的所有原料共同投入到球磨机内进行球磨处理,完成后取出过200目筛后得球磨粉碎料备用;
(3)坯体制备:
向步骤(2)所得的球磨粉碎料中加入清水,充分搅拌均匀调节整体的水含量至24~28%,然后再进行造型处理后得坯体备用;
(4)烘干处理:
对步骤(3)制得的坯体放入到温度为105℃的条件下进行烘干处理,烘干至整体的水含量不大于10%后备用;
(5)焙烧处理:
a.将步骤(4)处理后的坯体放入到窑内,先进行加热升温处理,控制加热升温的速度为135℃/h,将窑内温度升至820℃,在此期间持续向窑内通入过量的空气;
b.将窑内温度进一步加热升温处理,控制加热升温的速度为170℃/h,控制窑内温度升至930℃,在此温度条件下焙烧处理3.5h后取出得半成品备用,在此期间持续向窑内通入高炉煤气;
(6)冷却处理:
将步骤(5)所得的半成品放入到变温箱内进行冷却处理,控制变温箱内的降温速度为245℃/h,待其降至23℃的常温后取出即得成品青瓦。
实施例3
一种双重焙烧气氛烧制古建筑青瓦工艺,包括如下步骤:
(1)原料称取:
按对应重量份称取下列原料:23份铝矾土、12份紫砂石、44份河沙、18份煤矸石、10份石灰、1份着色剂、3份纳米二氧化钛、7份石榴石、0.2份添加剂;所述的着色剂为氧化铁黑;所述的添加剂为硝酸镧、氧化钇、二茂铁对应按照重量比5:2.6:2混合而成;
(2)球磨处理:
将步骤(1)称取的所有原料共同投入到球磨机内进行球磨处理,完成后取出过200目筛后得球磨粉碎料备用;
(3)坯体制备:
向步骤(2)所得的球磨粉碎料中加入清水,充分搅拌均匀调节整体的水含量至24~28%,然后再进行造型处理后得坯体备用;
(4)烘干处理:
对步骤(3)制得的坯体放入到温度为105℃的条件下进行烘干处理,烘干至整体的水含量不大于10%后备用;
(5)焙烧处理:
a.将步骤(4)处理后的坯体放入到窑内,先进行加热升温处理,控制加热升温的速度为135℃/h,将窑内温度升至840℃,在此期间持续向窑内通入过量的空气;
b.将窑内温度进一步加热升温处理,控制加热升温的速度为175℃/h,控制窑内温度升至950℃,在此温度条件下焙烧处理4h后取出得半成品备用,在此期间持续向窑内通入高炉煤气;
(6)冷却处理:
将步骤(5)所得的半成品放入到变温箱内进行冷却处理,控制变温箱内的降温速度为248℃/h,待其降至23℃的常温后取出即得成品青瓦。
实施例4
一种双重焙烧气氛烧制古建筑青瓦工艺,包括如下步骤:
(1)原料称取:
按对应重量份称取下列原料:25份铝矾土、15份紫砂石、45份河沙、20份煤矸石、12份石灰、1.5份着色剂、4份纳米二氧化钛、8份石榴石、0.3份添加剂;所述的着色剂为氧化铁黑;所述的添加剂为硝酸镧、氧化钇、二茂铁对应按照重量比6:3:3混合而成;
(2)球磨处理:
将步骤(1)称取的所有原料共同投入到球磨机内进行球磨处理,完成后取出过200目筛后得球磨粉碎料备用;
(3)坯体制备:
向步骤(2)所得的球磨粉碎料中加入清水,充分搅拌均匀调节整体的水含量至24~28%,然后再进行造型处理后得坯体备用;
(4)烘干处理:
对步骤(3)制得的坯体放入到温度为110℃的条件下进行烘干处理,烘干至整体的水含量不大于10%后备用;
(5)焙烧处理:
a.将步骤(4)处理后的坯体放入到窑内,先进行加热升温处理,控制加热升温的速度为140℃/h,将窑内温度升至850℃,在此期间持续向窑内通入过量的空气;
b.将窑内温度进一步加热升温处理,控制加热升温的速度为180℃/h,控制窑内温度升至960℃,在此温度条件下焙烧处理4.5h后取出得半成品备用,在此期间持续向窑内通入高炉煤气;
(6)冷却处理:
将步骤(5)所得的半成品放入到变温箱内进行冷却处理,控制变温箱内的降温速度为250℃/h,待其降至23℃的常温后取出即得成品青瓦。
对比实施例1
本对比实施例1与实施例4相比,区别仅在于,在步骤(1)原料称取中,省去了纳米二氧化钛成分的使用,除此外的方法步骤均相同。
对比实施例2
本对比实施例2与实施例4相比,区别仅在于,在步骤(1)原料称取中,省去了石榴石成分的使用,除此外的方法步骤均相同。
对比实施例3
本对比实施例3与实施例4相比,区别仅在于,在步骤(1)原料称取中,省去了添加剂成分的使用,除此外的方法步骤均相同。
对比实施例4
本对比实施例4与实施例4相比,区别仅在于,在步骤(5)焙烧处理中,省去了操作b的处理,直接将窑内温度升至960℃,并在此温度条件下焙烧处理4.5h,除此外的方法步骤均相同。
对比实施例5
本对比实施例5与实施例4相比,区别仅在于,在步骤(1)原料称取中,省去了纳米二氧化钛、石榴石和添加剂成分的使用,除此外的方法步骤均相同。
对比实施例6
申请号为:201310238704.8公开的一种蒸压青砖或青瓦,具体选用其实施例3的技术方案。
为了对比本发明效果,对上述实施例4、对比实施例1~6对应制得的青瓦进行性能测试,具体是将青瓦按照江南古建筑蝴蝶瓦(小青瓦)屋面用瓦的参考尺寸进行烧制,烧制成长宽为220mm×220mm的大号蝴蝶瓦,然后对其进行测试,具体对比数据如下表1所示:
表1
注:上表1中所述的抗折荷重指标对应的优等品标准值为≥1200N、合格品标准值为≥850N;所述的抗冻性能标准值是在-15~-20℃冰冻条件下经15次冻融循环后,不得出现开裂、分层、缺棱掉角和剥落等破坏现象,此处为出现上述现象的最低循环次数;所述的吸水率对应的优等品标准值为≤15.0%、合格品标准值为≤21.0%。
由上表1可以看出,本发明方法制得的青瓦的综合性能得到了显著的提升,其使用寿命及稳定性均得到了明显改善,极具推广应用价值和市场竞争力。
Claims (1)
1.一种双重焙烧气氛烧制古建筑青瓦工艺,其特征在于,包括如下步骤:(1)原料称取:按对应重量份称取下列原料:20~25份铝矾土、10~15份紫砂石、40~45份河沙、15~20份煤矸石、8~12份石灰、0.5~1.5份着色剂、2~4份纳米二氧化钛、5~8份石榴石、0.1~0.3份添加剂;(2)球磨处理:将步骤(1)称取的所有原料共同投入到球磨机内进行球磨处理,完成后取出得球磨粉碎料备用;(3)坯体制备:向步骤(2)所得的球磨粉碎料中加入清水,充分搅拌均匀调节整体的水含量至24~28%,然后再进行造型处理后得坯体备用;(4)烘干处理:对步骤(3)制得的坯体进行烘干处理,烘干至整体的水含量不大于10%后备用;(5)焙烧处理:a.将步骤(4)处理后的坯体放入到窑内,先进行加热升温处理,将窑内温度升至820~850℃;b.将窑内温度进一步加热升温处理,控制窑内温度升至930~960℃,在此温度条件下焙烧处理3.5~4.5h后取出得半成品备用;(6)冷却处理:将步骤(5)所得的半成品放入到变温箱内进行冷却处理,待其降至常温后取出即得成品青瓦;
步骤(1)中所述的着色剂为氧化铁黑;所述的添加剂为硝酸镧、氧化钇、二茂铁对应按照重量比4~6:2~3:1~3混合而成;
步骤(2)中所述的球磨粉碎料的颗粒大小为200目;
步骤(4)中所述的烘干处理时控制烘干的温度为100~110℃;
步骤(5)操作a中所述的升温处理时控制加热升温的速度为130~140℃/h;在此期间持续向窑内通入过量的空气;
步骤(5)操作b中所述的升温处理时控制加热升温的速度为170~180℃/h;在此期间持续向窑内通入高炉煤气;
步骤(6)中所述的冷却处理时控制变温箱内的降温速度为240~250℃/h;所述的常温温度为23℃。
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