CN112745097A - Semi-dry production method for mechanically and continuously preparing phosphogypsum building blocks - Google Patents

Semi-dry production method for mechanically and continuously preparing phosphogypsum building blocks Download PDF

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Publication number
CN112745097A
CN112745097A CN202110104322.0A CN202110104322A CN112745097A CN 112745097 A CN112745097 A CN 112745097A CN 202110104322 A CN202110104322 A CN 202110104322A CN 112745097 A CN112745097 A CN 112745097A
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phosphogypsum
building block
semi
production method
block
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封信超
陈正强
杨方福
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Zunyi Hanfeng Decoration Material Co ltd
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Zunyi Hanfeng Decoration Material Co ltd
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Priority to CN202110104322.0A priority Critical patent/CN112745097A/en
Publication of CN112745097A publication Critical patent/CN112745097A/en
Priority to CN202110548212.3A priority patent/CN113461397B/en
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/142—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing synthetic or waste calcium sulfate cements
    • C04B28/143—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing synthetic or waste calcium sulfate cements the synthetic calcium sulfate being phosphogypsum
    • 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
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • 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
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/245—Curing concrete articles
    • 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
    • B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
    • B28B3/08—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form with two or more rams per mould
    • B28B3/086—The rams working in different directions
    • 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
    • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)

Abstract

The invention discloses a semi-dry production method for mechanically and continuously preparing phosphogypsum building blocks, belonging to the field of gypsum building materials. The method comprises the steps of material preparation, material mixing, press forming, forming maintenance and the like. The invention reduces the water consumption and the pressing forming time for producing the gypsum block, improves the block maintenance temperature by utilizing the heat of hydration reaction, does not need to be dried, and can be hoisted, transported and warehoused or delivered from a factory within 15-30 minutes. The quality strength of the produced gypsum block is improved, the production cost is obviously saved, and the production efficiency is improved.

Description

Semi-dry production method for mechanically and continuously preparing phosphogypsum building blocks
Technical Field
The invention belongs to the technical field of phosphogypsum chemical building materials, and particularly relates to a semi-dry production method for preparing a phosphogypsum building block by adopting full-process mechanized continuous high efficiency.
Background
By-product phosphogypsum (the main component is CaSO) discharged by high-temperature calcination wet-process phosphoric acid production4·2H2O) production of fried phosphogypsum powder (the main component is CaSO)4·1/2H2O, original P of phosphogypsum2O5、SiO2、Al2O3、Fe2O3MgO, F and other impurities are greatly reduced due to high-temperature burning loss,burn-out rate of about 14%) is a cement-like cement-friendly cementitious material because of the hemihydrate gypsum (CaSO)4·1/2H2O) dihydrate Gypsum (CaSO) produced in the presence of Water4·2H2And the crystals (crystal water) of O) are mutually linked, so that the strength of the phosphogypsum-like block is developed and developed. Therefore, the adoption of the fried phosphogypsum (powder) to manufacture the phosphogypsum building block becomes one of the important approaches for quickly and environmentally utilizing the phosphogypsum at home and abroad.
The fried phosphogypsum has two important chemical property characteristics: firstly, the gypsum dehydrates to form dihydrate gypsum (CaSO) when meeting water4·2H2O) and develops the strength of the block-like mass due to the inter-linkage between the dihydrate gypsum crystal waters. Therefore, the method for producing the phosphogypsum building blocks by using the fried phosphogypsum powder by adopting a pure dry method (namely, no water is added) is not feasible, the phosphogypsum building blocks need to be subjected to hydration reaction and develop the strength of the product in the production process of the product, and the building blocks which are forcibly formed by adopting the dry method can be subjected to hydration reaction when meeting water in the use process and inevitably cause the deformation of a building. Secondly, the fried phosphogypsum with the same quality has stable initial setting time (hydration reaction begins to occur to form crystal water) and final setting time (the hydration reaction stops, the crystal water is not formed any more), the initial setting time is 3-8 minutes generally, and the final setting time is 7-17 minutes. The block sample block at the beginning of initial setting has strength, and the strength of the block sample block is gradually developed along with gradual completion and proper maintenance of final setting.
The gypsum block produced at home and abroad is produced by manually pouring a flat mould at first, is produced by mechanically pouring a flat mould at present by generally adopting vertical mould jacking, is produced by utilizing the two chemical properties of fried phosphogypsum, and is called as a wet method because the water consumption generally reaches more than 90 percent of the consumption of fried phosphogypsum powder in order to be capable of uniformly stirring and pouring and forming. The mechanical casting and molding production of the vertical mold jacking adopts the principle of stirring, pouring, molding and jacking and demolding, the stirring time of raw and auxiliary material slurry is generally about 50 seconds, the slurry is poured into a mold cavity, the slurry needs to be kept still in the mold cavity until initial setting is hydrated to form certain strength, the slurry can be jacked and demolded, a clamp can be used for clamping and conveying the gypsum block to a product drying yard for airing or drying on a drying line when final setting is finished, the process generally takes 7-8 minutes, the moisture content of the gypsum block sample reaches more than 70%, the production efficiency is low, and the time for airing is long.
The semi-dry method for preparing the phosphogypsum building block is a new technology appearing in recent years, and the weight ratio of the used raw materials of the gypsum powder to water is about 1: 20% -30%, can reduce the production cycle of the phosphogypsum building block greatly, press forming only needs 3-5 minutes after mixing, the gypsum building block formed has low water content, the airing or oven drying can leave the factory for several hours, for example: chinese patent 'a semidry process high-strength gypsum product and its production method (publication No. CN 109400094A)'.
Although the traditional production period is greatly shortened by the existing technique for preparing the phosphogypsum building block by the semidry method, the press forming process still needs 3-5 minutes, the production efficiency is still restricted, continuous production cannot be carried out, and auxiliary drying is still needed after forming, so that the efficiency of the whole production line is reduced, and the production cost is increased.
Disclosure of Invention
The invention aims to overcome the difficulties of the background technology, firstly improve the production efficiency of the phosphogypsum building block, and secondly further reduce the production cost, and provides a semi-dry production method for mechanically and continuously preparing the phosphogypsum building block.
In order to achieve the purpose, the technical scheme is as follows: a semi-dry production method for preparing phosphogypsum building blocks in a mechanized and continuous manner comprises the following steps:
1) preparing materials: preparing 100 parts of fried phosphogypsum powder, 25-30 parts of water and a proper amount of auxiliary agent according to the weight part ratio;
2) mixing materials: adding the raw materials in proportion, uniformly mixing and stirring for 70-100 seconds;
3) and (3) pressing and forming: pouring the mixture into a forming machine, pressing the mixture into a shape with the pressure of 180 tons and the pressure of 18-23 MPa for 20-30 seconds, and ejecting the building blocks after the pressing is finished;
4) forming and maintaining: and (4) placing the pressed building blocks for 15-30 minutes and warehousing or leaving the factory.
The auxiliary agent comprises a water reducing agent, a dispersing agent, a retarder and a reinforcing agent, and the dosage of the auxiliary agent is as follows: 0.1 to 0.2 percent.
Further, the auxiliary agent comprises fibers in the following amount: 0.1 to 0.2 percent.
Furthermore, the mixing amount of each time is 3-6 times of the material amount for press forming, and a transition bin is arranged between the mixing bin and the press forming machine.
Further, in the step of press forming, the upper press head presses downwards with 180 tons of pressure, then the lower press head presses upwards with 230 tons of pressure, after the size of the building block is reached, the building block is kept static for pressing for 3 seconds, and finally the building block is ejected out.
And further, in the molding and curing step, the pressed building blocks are placed on a conveyor belt and slowly moved, and after 15-30 minutes, the building blocks are hoisted, transported and warehoused or delivered from a factory.
Further, in the molding and maintenance step, the pressed building blocks are placed in a factory building, and steam collecting covers are arranged around and above the building blocks.
Further, the phosphogypsum building block is in a porous hollow shape.
Further, the fiber is a chemical fiber or a biological fiber.
The beneficial effect who adopts above-mentioned scheme does: the semi-dry production method for mechanically and continuously preparing the phosphogypsum building block is not only suitable for producing the gypsum building block by utilizing natural gypsum, but also suitable for producing the gypsum building block by utilizing desulfurized gypsum or other industrial by-product gypsum. Compared with the traditional manual production of flat plate moulds and the existing mechanized production method of hydraulic jacking of vertical moulds, the method has the following advantages:
1. the invention can obviously reduce the water consumption by controlling the proportion of the fried phosphogypsum to the water consumption. The water consumption of the method is only 25-30% of that of the fried phosphogypsum powder, and is reduced by 60-65% compared with the water consumption of the traditional manual pouring production of a flat plate mould and the mechanized production method of hydraulic jacking of a vertical mould; the water consumption is reduced, the water resource can be saved, the production cost is reduced, and the production efficiency is improved.
2. According to the invention, by accurately controlling the pressing technical parameters, the pressing time is shortened to 20-30 seconds, the forming time is shortened by more than 14 times compared with the forming time of 7-8 minutes of the vertical die hydraulic jacking mechanical production, and the forming time is shortened by more than 5 times compared with the forming time of 3-5 minutes of the existing semi-dry method technology; the efficiency of the phosphogypsum building block prepared by mechanization and continuity can be obviously improved.
3. In the building block forming and curing stage, the heat release of the hydration reaction is fully utilized, the steam hood is utilized for steam curing to protect the building block, the temperature of a sample block of the building block is increased by about 5-10 ℃, the final setting reaction speed of the building block is accelerated, drying is not needed, the strength of the building block can be ensured within 15-30 minutes, and the building block can be directly hoisted and transported to be put in storage or leave a factory; the production cost can be further obviously reduced, and the production efficiency is improved.
4. The gypsum block produced by high-pressure forming and low water-cement ratio has high strength, the compressive strength is more than 4 MPa, the breaking load is more than 9000N, and the softening coefficient is more than 0.8; greatly improving the quality of the gypsum block.
Detailed Description
The technical solution of the present invention will be clearly and completely described below with reference to the specific embodiments of the present invention. The described embodiments are only some, not all embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The initial setting of the fried phosphogypsum powder is related to water absorption, and the hydration reaction is an exothermic reaction. The initial setting water absorption rate is 18-19% of the weight of the fried phosphogypsum powder (which is the basic water amount required for forming crystal water by the whole hydration), and the hydration reaction is accelerated and releases certain heat with the increase of the water absorption rate.
The material ratio and the compression molding parameters of the phosphogypsum building block are closely related to the mold stripping strength, the water content and the subsequent hydration reaction speed of the phosphogypsum building block. Repeated tests show that under the molding conditions of the pressure of 180-230 tons and the pressure of 18-23 MPa, when the water absorption rate reaches 25-30% of the weight of the fried phosphogypsum, the hydration reaction speed is remarkably accelerated, and the heat release is remarkably increased.
As the water consumption of the prior production process reaches about 90 percent, the exothermic heat of the reaction can not obviously raise the temperature of the building block, so that people almost ignore the exothermic reaction phenomenon. When the water consumption is reduced, the exothermic heat of the reaction can obviously raise the temperature of the building block, the building block can be obviously felt by touching with hands, and the gypsum sample block can emit a large amount of water vapor, and the surface temperature can reach more than 45 ℃ (the temperature of a pressing forming cavity is about 40 ℃).
The gypsum block produced at home and abroad is produced by manually pouring a flat mold at first, is generally produced by mechanically pouring and molding a vertical mold by jacking at present, and is called as a wet method because the water consumption generally needs to reach more than 90 percent of the consumption of fried phosphogypsum powder in order to be uniformly stirred and poured and molded. The mechanical casting and molding production of the vertical mold jacking adopts the principle of stirring, pouring, molding and jacking and demolding, the stirring time of raw and auxiliary material slurry is generally about 50 seconds, the slurry is poured into a mold cavity, the slurry needs to be kept still in the mold cavity until initial setting is hydrated to form certain strength, the slurry can be jacked and demolded, a clamp can be used for clamping and conveying the gypsum block to a product drying yard for airing or drying on a drying line when final setting is finished, the process generally takes 7-8 minutes, and the water content of a gypsum block sample block reaches more than 70%. Because the press forming equipment occupies a high cost ratio of the production line, only one production line is usually prepared, the time required by press forming of the ring joint obviously restricts the production efficiency of the whole line, and the building blocks need to be aired and dried in the later period.
Example 1
A semi-dry production method for preparing phosphogypsum building blocks in a mechanized and continuous manner comprises the following steps:
1) preparing materials: preparing 100 parts of fried phosphogypsum powder, 25-30 parts of water and a proper amount of auxiliary agent according to the weight part ratio. The auxiliary agents comprise a water reducing agent, a dispersing agent, a retarder, a reinforcing agent and the like, the reinforcing agent comprises fibers, and the total dosage of the auxiliary agents is as follows: 0.2 percent and the fiber dosage is 0.15 percent.
2) Mixing materials: adding the raw materials according to the proportion, uniformly mixing and stirring for 70-100 seconds. The raw and auxiliary material bin is arranged at the front end of the raw and auxiliary material mixing and stirring device, and is arranged at the upper position or the side position; the size of the auxiliary material is matched with the number of the film cavities of the forming device and the unit dosage of the raw and auxiliary materials, and the requirement of 24-hour continuous production on the raw and auxiliary materials per day at least needs to be met. Preparing a self-made special auxiliary agent and water mixed liquid. An accurate metering and conveying device is arranged between the self-made special auxiliary agent bin and the upper water tank or the side water tank. Before the production of each batch of products is started, 1/290 adjuvant of the total amount of water, and the mixed liquid of the adjuvant and the water are accurately added for standby according to the total amount of the water in the water tank. And (3) accurately metering and quickly conveying the mixed liquid of the fried phosphogypsum powder and the water and the auxiliary agent. Accurate metering and quick conveying devices for gypsum powder and water are arranged among a bin for frying the phosphogypsum, a water tank and a stirrer. According to the total amount and the proportion of the materials used in one time of the stirrer, the fried phosphogypsum powder and the mixed liquid of water and the auxiliary agent are accurately and quickly added into the stirrer, the fried phosphogypsum powder is firstly added, and then the mixed liquid is added. And (4) quickly and fully stirring and adding short fibers to prepare a mixture. Adding the fried phosphogypsum powder, adding short fiber while stirring, and finishing before injecting the mixed liquid. And (3) injecting a mixed solution of water and the auxiliary agent, rolling at a high speed, fully stirring for 75 seconds to obtain a uniformly stirred mixture, and entering a transition bin for later use.
3) And (3) pressing and forming: and pouring the mixture into a forming machine, pressing the mixture into a shape with the pressure of 180 tons and the pressure of 18-23 MPa for 20-30 seconds, and ejecting the building blocks after the pressing is finished. And conveying the stirred mixture to a mixture transition bin, and conveying the mixture to a distributing device for distributing through the transition bin. The uniform material distribution of the prefabricated molding die cavity is required to be rapid and finished within 8 seconds; after the uniform distribution is finished, the upper pressure head presses downwards with 180 tons per second of pressure, the movement stops after the travel path reaches 50mm, then the lower pressure head presses upwards with 230 tons per second of pressure until the size ensures the set height, the pressure is not pressed for 3 seconds (static pressure is 3 seconds), the upper pressure head releases the pressure, and the lower pressure head continues to push the building block upwards.
Keeping the same mixing proportion and time, adopting different pressing pressures to perform single-side advancing pressing, and obtaining the following effects by pressing for 25 seconds with the same material distribution amount and advancing distance:
pressing pressure Demolding strength of building block Rate of hydration reaction Quality of building block
150 ton of Difference (D) Slow Difference (D)
160 ton of Difference (D) Slow Difference (D)
170 ton of Is poor Is slower Is poor
180 ton of In In In
190 tons In In In
200 ton of Is stronger Is quicker Is stronger
210 ton of Is stronger Is quicker Superior food
220 ton of Is stronger Fast-acting toy Superior food
230 ton of High strength Fastest speed Superior food
240 tons High strength Is quicker Is superior to
250 tons High strength Slow In
And (3) demolding strength of the building block: poor standards are not transportable or mobile (large collapses), medium standards are smooth and barely transportable by a belt (small collapses), strong standards are smooth and substantially transportable by a belt (substantially no collapses), and strong standards are substantially transportable by a belt (substantially no collapses). The demoulding strength of the building block is related to the intervention of the next procedure, and the demoulding strength is insufficient, so that collapse and scattering in the transportation process can be caused.
During the pressing process, we have found that using a single side travel press results in the block being pressed tighter on one side and looser on the other. The pressing effect can be improved by adopting the step-by-step pressing from top to bottom. And the strength of the block before pressing is very low, and 100 percent of pressure is not necessary. And the 100% pressure is adopted in the later stage of pressing, so that the overall strength of the building block can be kept consistent, and the pressing effect is improved.
The block hydration reaction rate can be estimated by the amount of steam produced and the temperature, with faster reaction rates producing more steam and more temperature rise. The hydration reaction is fast, the block maintenance time can be shortened, the production inventory and the occupied area are saved, and the production efficiency is improved. The faster the hydration reaction, the faster the temperature of the block rises, the more steam is generated. The hollow gypsum block has large void ratio, and the surrounding steam can increase the contact area of gypsum and water, thereby further promoting the rapid reaction.
The quality of the building block is measured after the building block is placed for 30 days after production. Less than DB 52/T1038-2015 (breaking load less than 2000N) or softening coefficient less than 0.6 are poor, 2000N breaking load less than 4000N, 0.6 softening coefficient less than 0.8, 4000N breaking load and 0.8 softening coefficient are excellent.
According to the experimental data and theoretical analysis, the scheme of the application is the optimal scheme.
4) Forming and maintaining: and (4) placing the pressed building blocks for 15-30 minutes and warehousing or leaving the factory. And (3) conveying the demoulded gypsum block sample block by adopting a translation belt, conveying by using the translation belt for more than 15min, accelerating high-heat steam-curing sample block formed by deepening hydration reaction and evaporating moisture by using moderate water absorption and high-pressure extrusion, and obtaining the gypsum block sample block basically completing final setting. And (5) stacking the trays, and warehousing or leaving the factory. The gypsum block sample block which finishes the walking of the translation conveying belt is stacked by standard trays, the hydration reaction completion rate of the gypsum block sample block is more than 98 percent, the water content is about 12 percent generally, and the softening coefficient is more than 0.8 through gypsum trisection analysis. According to the conditions of production field, storage, user requirements and the like, the materials can be continuously piled, aired and maintained, and put in storage or conveyed to users.
The water-cement ratio of the gypsum block produced by the method is reduced from 90% to 29%, the produced product does not need airing or drying procedures, 90 kilograms of standard coal are needed for drying one cubic meter of gypsum block, and the time and capital cost of the production period are shortened, so that the production cost can be reduced by more than 80 yuan per cubic meter of gypsum block.
The gypsum block produced by the invention can reduce the factory construction investment and save land resources. Taking the embodiment of the applicant as an example, the land occupation is 37400 square meters, the factory construction investment reaches more than 6000 RMB, the natural airing period is long, the average time is about 30 days in spring and summer, the average time is about 60 days in autumn and winter, and the maximum amount of 5 ten thousand cubic meters of gypsum blocks can be produced every year. The gypsum block of 10 ten thousand cubic meters produced by the method occupies only 2000 square meters of land area, and the factory construction investment is only about 1000 ten thousand. By adopting the invention, more than 5 block product production lines can be built in the space.
Realize the massive utilization of the phosphogypsum and other industrial by-product gypsum solid wastes. As a wall material for a non-bearing inner partition wall, gypsum blocks are introduced into China from the 20 th century and the 80 th era, and are not widely applied like cement wall materials in recent 40 years, although the gypsum blocks are steadily developed, the main reason is that the traditional production method is low in input-output ratio, the number of factories is small, the number of large-scale factories is small, the capacity scale is small, and the requirement of engineering application cannot be met. According to statistics, the current gypsum block yield in China is only 2000 ten thousand square meters (calculated according to the thickness of 200 millimeters, 400 ten thousand cubic meters), and the amount of the gypsum powder to be fried is about 250 ten thousand tons. According to statistics, the annual industrial byproduct gypsum emission amount in China is about 5000 ten thousand tons, the production is carried out according to the method, 10 ten thousand cubic meters of gypsum block production lines are produced annually, 7.3 ten thousand tons of fried gypsum powder can be utilized in each production line annually, and 10 ten thousand tons of byproduct gypsum can be consumed according to the condition that 1.4 tons of byproduct gypsum are fried to one ton of gypsum powder. If the method is popularized and applied in regions with large discharge amount of industrial by-product gypsum in China, a feasible path can be found for the resource utilization of the industrial by-product gypsum in bulk, and the method makes positive contribution to the utilization of the industrial by-product gypsum in solid waste and the innovation of wall materials in China.
The technology of the invention can reduce the amount of labor and the labor intensity of production workers. The annual output is calculated by a production line of 10 million cubic meters, only 4 persons are needed in each shift, 14 persons are needed by a vertical mold jacking machine according to the same productivity calculation, and 48 persons are needed by manual production by a flat mold. The labor intensity of the airing or drying process produced by the traditional method is very high, the airing or drying is not needed in the production by the method, the robot can be stacked and packaged when the production line comes out, and the forklift is forked into a storehouse, so that the labor intensity of production workers is low.
Example 2
The initial setting time of the fried phosphogypsum powder, namely the building phosphogypsum powder, is required to be 3.5-5min (namely the initial setting is required to be a little earlier so as to be beneficial to forming certain strength in a die cavity through hydration reaction as soon as possible and quickly demould and leave the die cavity), the final setting time is more than 7min (namely the final setting is required to be slower so as to be beneficial to prolonging the time process of steam curing and water loss by utilizing hydration reaction to generate heat after demoulding), P2O5 is less than or equal to 1% (beneficial to reducing acidity so as to improve product quality), the standard consistency reaches about 70% (beneficial to forming higher compressive strength), the flexural strength reaches 2.8MPa or more in 2 hours, and the fried phosphogypsum powder is aged and homogenized as; the main component of the self-made special auxiliary agent is a material with high water absorption performance, which can quickly absorb and retain water and quickly release water under pressure (the patent application of the company: a semidry gypsum auxiliary agent and a preparation method thereof, application number: 2018108649085), can solve the problems of uniform water supply by stirring and emergency supply of water by quick hydration reaction in a die cavity; short fibers, such as polypropylene fibers, hair, bristles, palm fibers and other fibers without emitting substances, have certain strength and toughness, are similar to the action of 'reinforcing steel bars' in concrete, are beneficial to rapid forming and form certain strength and strengthen the breaking strength after maintenance; the proportion of water is 22.3 percent, which is equivalent to 28.79 percent of the weight of 77.45 percent of the fried phosphogypsum powder in the formula, and is an average value, and the proportion is controlled within about 22.3 percent and 0.2 percent due to different qualities of the fried phosphogypsum powder.
The raw material bin is arranged close to the front end of the stirring device, so that the conveying cost is reduced; the upper position or side position arrangement is beneficial to automatically adding raw and auxiliary materials and installing an intelligent metering device by utilizing natural gravity; the newly demolded gypsum block generally has a volume weight of 20.5 kg per block in a natural state, a production line with 5 molding cavity molding devices is adopted, the daily production capacity in 24-hour continuous production reaches 330 and 350 cubic meters, at least 330 tons of fried phosphogypsum powder are needed, and the minimum amount of a raw material bin for frying the phosphogypsum reaches 360 tons (180 tons/piece is multiplied by 2 or 120 tons/piece is multiplied by 3). Other auxiliary bins, including the water tank, should match according to the ratio, avoid lacking the material in the way of production to ensure the serialization production needs.
The metering requirement error of the fried phosphogypsum powder is less than 1 percent, and the metering error requirement of the mixed liquid of water and the self-made special auxiliary agent is less than 0.1 percent. The conveying time is required to be within 10-15 seconds, which is beneficial to ensuring continuous production and production efficiency by shortening the blanking time, and a pressurizing or pumping device is required to be arranged in the water tank for the purpose.
The high-speed grinding and full stirring are carried out, the revolution speed of the stirrer is required to be more than 180 revolutions per minute, a blade, a turning shovel and a wheel grinding device are arranged in the stirrer, and the rotating speed of the blade reaches more than 260 revolutions per minute so as to ensure that the inside of the stirrer is non-sticky and can work continuously. The mixture is required to be uniform, the surface has no clear water, and the mixture is moist and loose, can be kneaded into a ball by force and is scattered into a sand shape. The stirring time reaches 75 seconds, and the rapid stirring is beneficial to accelerating the water absorption of the fried phosphogypsum (semi-hydrated gypsum) to generate hydration reaction to reduce the fried phosphogypsum into the dihydrate gypsum. Because the stirring time of the mixture is 75 seconds, which is 2.27 times of the time of the next forming production process, the preparation amount of each batch of the mixture is required to reach 3-6 times of the required mixture amount for each batch of forming, and the stirrer is connected with the forming machine by using the transition bin, so that the continuous production of the forming machine can be ensured, and the mixture can not follow the forming requirement.
A certain number of 'mold cores' with certain size are required to be arranged according to the requirement of a product on reducing the volume weight so as to enable the gypsum block sample block to form hollow holes, the size of the block sample block is 600 × 200 mm, the central part of the block sample block is provided with 62.5 mm/6 hollow holes, the hollow holes are arranged in 2 rows, and each row of the 3 hollow holes can meet the requirement of the volume weight of 20.5 kg/block in demolding; the upper pressure head presses downwards by 180 tons per second, the pressure intensity unit is more than 18 MPa according to the conversion of the stress area of the upper pressure head, and the travel time is about 10 seconds; the lower pressure head 230 tons presses upwards and ejects out the block sample block, the pressure unit is converted into more than 20 MPa according to the stress area, and the time is about 12 seconds. The high-pressure static pressure for 3 seconds is beneficial to quickly releasing the moisture in the water-absorbing material in the self-made admixture, so that the hydration reaction of the mixture is accelerated to release the maximum heat, and the initial setting of the hydration reaction is accelerated to form a certain strength together with the short fibers without sticking a mold. The total time of the material distribution and the forming process is 33 seconds, namely the material distribution time length is 8 seconds, the pressing stroke time length of the upper press head is 10 seconds, the pressing stroke time length of the lower press head is 12 seconds, and the static pressure is 3 seconds. In order to ensure that the high-pressure extrusion forming of the mixture stirred each time is completed before the initial setting so as to ensure the strength of the block sample, the mixture prepared in each batch needs to complete the forming process within 4min (from the time of adding the mixed liquid of 'water + self-made special aid' to the time of completing the forming), so that the total amount of the mixture prepared in each batch is less than or equal to 6 times of the amount of the mixture required by each batch of forming.
The initial strength of the ardealite block sample block just demoulded from the die cavity of the forming machine is mainly formed by high-pressure extrusion and pulling short fibers such as polypropylene and the like, so the ardealite block sample block needs to travel on a translation belt, and the translation belt needs to have small vibration amplitude and slow rotation speed during traveling. The hydration strength of the just demoulded block sample reaches the peak value, so that the surface temperature of the sample reaches over 45 ℃, and a large amount of water vapor is emitted. The sealing cover which is matched with the forming machine and is provided with a certain distance is required to seal the water vapor for curing the block sample. The length of the translation conveying belt can meet the translation conveying time of more than 15min according to the translation speed calculation, so that the hydration reaction of the gypsum blocks can be basically completed in the process of moving on the translation conveying belt, the final setting is achieved, and partial water is evaporated by fully utilizing the heat released by the hydration reaction.
The auxiliary agent comprises fibers, and the dosage of the fibers is as follows: 0.1 to 0.2 percent. The mixing amount of each time is 3-6 times of the material amount for press forming, and a transition bin is arranged between the mixing bin and the press forming machine. In the step of press forming, the upper pressure head presses downwards with 180 tons of pressure, then the lower pressure head presses upwards with 230 tons of pressure, after the size of the building block is reached, the building block is kept static for pressing for 3 seconds, and finally the building block is ejected out. And in the molding and maintaining step, the pressed building blocks are placed on a conveyor belt and slowly moved, and the building blocks are hoisted and transported to be put in storage or leave a factory after 15-30 minutes. And in the molding and maintaining step, the pressed building blocks are placed in a workshop, and steam collecting covers are arranged around and above the building blocks. The phosphogypsum building block is in a porous hollow shape. The fiber is chemical fiber or biological fiber.
Example 3
Take an example of a phosphogypsum block product with dimensions of 600 x 200 mm produced continuously for 24 hours using a production line with 5 gypsum-like block-forming cavities.
1. Preparing raw and auxiliary materials:
the invention is adopted, the process links for determining the production efficiency lie in a high-pressure extrusion forming process link and the number of formed die cavities, all other process links serve the process link, the preparation of the feeding and the mixture is to ensure that the forming die cavities work uninterruptedly to realize continuous production, and the translation belt is to ensure that the time of occupying the forming die cavities is shortened as much as possible by the block sample blocks, so that the final setting process is completed in the walking process. A production line with 5 gypsum-like block-forming cavities was used to produce 600 x 200 mm phosphogypsum block products in 24 consecutive hours, the block typically having a bulk weight of 20.5 kg per block when demolded. Theoretically, the total amount of raw and auxiliary materials is 24 hours × 60 min/h × 60 s/min/33 s/1 batch, and the number of formed × 5 blocks/batch × 20.5 kg/block is 268.35 tons. Calculated according to the formula proportion of raw and auxiliary materials of 77.45% of fried phosphogypsum powder, 0.1% of self-made special auxiliary agent, 0.15% of short fiber and 22.3% of water, 207.84 tons of fried phosphogypsum powder, 268.35 kilograms of self-made special auxiliary agent, 402.53 kilograms of short fiber and 59.84 tons of water are needed. In the production practice, raw and auxiliary materials which are larger than the calculated raw and auxiliary materials are prepared respectively for standby.
2. Preparation of a mixed solution of an auxiliary agent and water:
the building gypsum powder is purchased at 360t (bulk vehicle is 40 t/vehicle), sampled by laboratory personnel to be used as raw materials, put in storage and detected (initial setting time is 4min, final setting time is 8min, water consumption of standard consistency is 69%, breaking strength is 2.8MPa after 2h, fineness is 100 meshes), and conveyed to A, B two bins by air flow for standby application (180 tons/vehicle is taken as an example for the two bins).
Preparation of auxiliary materials: dividing a 5-ton water tank into A, B bins, filling A, B bins with water (2.4 cubic meters per bin, the water outlet direction is connected by a gate valve and a tee joint and is controllable and communicated), weighing 16kg of auxiliary agent, respectively adding the auxiliary agent into A, B water tanks in equal amount, and stirring for 5min for later use. (after the storehouse A is used up, the storehouse B is opened for use).
0.5 kg/part of polypropylene fiber (high-strength yarn with the specification of 19mm to 25 mm) is weighed for standby (can be prepared in advance).
3. Arranging the personnel in place:
the equipment is positioned at 4 shifts/shift, (3 shifts for 12 people) in which: manually feeding fibers by a stirrer and patrolling 1 person; the host computer operates one man; a palletizing system is one person; one forklift worker can respectively locate each position according to the training requirement,
4. preparing equipment:
(1) according to the production process requirements, the following equipment is prepared: two 150t bins; two screw conveyors with the diameter of 320mm are arranged; 1000 planetary mixer with wheel roller, fly knife, turning shovel, and big arm with scraping wall; the mixture conveying belt is 600mm wide, 8000mm long and 160 r/min; 1.2m3A transition bin; a material distribution trolley; model 1300 static press (with mold); the hydraulic station can provide the power and the speed of the hydrostatic machine; an air compressor 11kw (cooling and drying machine); air cylinder (1.5 m)3) (ii) a A programmable PLC system; a power distribution cabinet; a translation flat belt steam curing system (a flat belt with the width of 1.5m and the length of 30m, a sealing cover and a negative pressure fan heating temperature and humidity sensor); a gantry type high-level stacker crane (which can grab a manipulator of 1.0m by 1.2m, has a height of 1m and stacks 5 layers of building blocks); a heavy chain plate discharging machine (with the length of 8m and the function of placing a supporting plate and with a stacking station and a packing station); 3t forklift one; 380V800A power supply; and assembling, connecting and debugging the equipment for standby.
5. Preparation before production:
(1) checking the oil levels of all lubricating oil and the positions of all sensors at all parts;
(2) and turning a control switch of the stirrer to a manual position, starting the stirrer, and operating the empty stirrer for one minute.
(3) And turning the control switch of the host to a manual position, starting the host and the air compressor, and enabling the components of the host and the like to act for a plurality of times after the pressure of the air compressor reaches 3.5 MPa.
(4) And the calibration metering system ensures that the raw and auxiliary materials are accurately metered and each feeding and discharging device is smooth.
(5) Programming (setting parameters):
raw material conveying time: 15 s;
measuring the blanking time of the metering barrel: 20 s;
pre-mixing time; 30s
Stirring time: 75s
Stirring weight: 500 kg;
additive solution added: 150 kg;
pressure of an upper pressure head: 180 t;
pressure of a lower pressure head: 230 t;
the product discharging speed is 25 s/time/5 blocks;
setting a batch: 700 batches are 3500 times;
compression ratio: 1.5: 1.0;
the product specification is as follows: 600*200*200
6. Turning the device control switch to the automatic direction:
(1) starting a feeding system and a metering system;
(2) starting a stirring system;
(3) starting a host;
(4) starting a translation maintenance system;
(5) starting a stacking system;
7. the gypsum block produced automatically is inspected by quality inspector and host operator for appearance size and performance, and the speed is calculated by stopwatch, and the product enters the translation maintenance system.
8. After 15min, the product is horizontally moved by a flat belt, and is cured by steam generated by spontaneous heat, and the strength is high
50 blocks are stacked, the beating is improved, the stacking system is started, and after ten blocks are stacked in each group, the stacked blocks are intelligently shaped, stacked or stored in a warehouse or loaded to leave a factory.
The building blocks 414.72m are continuously produced by 24h of circulation and reciprocation according to the method3The compressive strength of the produced building block can reach more than 4.0MPa, the breaking load is more than 9000N, and the softening coefficient is more than 0.8. The net profit per cubic meter is 60 yuan, and the production profit can achieve 24883.2 yuan in 24 h.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.

Claims (9)

1. A semi-dry production method for preparing phosphogypsum building blocks in a mechanized and continuous manner is characterized by comprising the following steps:
1) preparing materials: preparing 100 parts of fried phosphogypsum powder, 25-30 parts of water and a proper amount of auxiliary agent according to the weight part ratio;
2) mixing materials: adding the raw materials in proportion, uniformly mixing and stirring for 70-100 seconds;
3) and (3) pressing and forming: pouring the mixture into a forming machine, pressing the mixture into a shape with the pressure of 180 tons and the pressure of 18-23 MPa for 20-30 seconds, and ejecting the building blocks after the pressing is finished;
4) forming and maintaining: and (4) placing the pressed building blocks for 15-30 minutes and warehousing or leaving the factory.
2. The semi-dry production method for the mechanical continuous preparation of the phosphogypsum building block according to claim 1 is characterized in that: the auxiliary agent comprises a water reducing agent, a dispersing agent, a retarder and a reinforcing agent, and the dosage of the auxiliary agent is as follows: 0.1 to 0.2 percent.
3. The semi-dry production method for the mechanical continuous preparation of the phosphogypsum building block according to claim 1 is characterized in that: the auxiliary agent comprises fibers, and the dosage of the fibers is as follows: 0.1 to 0.2 percent.
4. The semi-dry production method for the mechanical continuous preparation of the phosphogypsum building block according to claim 1 is characterized in that: the mixing amount of each time is 3-6 times of the material amount for press forming, and a transition bin is arranged between the mixing bin and the press forming machine.
5. The semi-dry production method for the mechanical continuous preparation of the phosphogypsum building block according to claim 1 is characterized in that: in the step of press forming, the upper pressure head presses downwards with 180 tons of pressure, then the lower pressure head presses upwards with 230 tons of pressure, after the size of the building block is reached, the building block is kept static for pressing for 3 seconds, and finally the building block is ejected out.
6. The semi-dry production method for the mechanical continuous preparation of the phosphogypsum building block according to claim 1 is characterized in that: and in the molding and maintaining step, the pressed building blocks are placed on a conveyor belt and slowly moved, and the building blocks are hoisted and transported to be put in storage or leave a factory after 15-30 minutes.
7. The semi-dry production method for the mechanical continuous preparation of the phosphogypsum building block according to claim 1 is characterized in that: and in the molding and maintaining step, the pressed building blocks are placed in a workshop, and steam collecting covers are arranged around and above the building blocks.
8. The semi-dry production method for the mechanical continuous preparation of the phosphogypsum building block according to claim 1 is characterized in that: the phosphogypsum building block is in a porous hollow shape.
9. The semi-dry production method for the mechanical continuous preparation of the phosphogypsum building block according to claim 3, which is characterized in that: the fiber is chemical fiber or biological fiber.
CN202110104322.0A 2021-01-26 2021-01-26 Semi-dry production method for mechanically and continuously preparing phosphogypsum building blocks Pending CN112745097A (en)

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