CN113511881B - Formula and method for preparing foamed ceramic by using overhaul slag - Google Patents
Formula and method for preparing foamed ceramic by using overhaul slag Download PDFInfo
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- CN113511881B CN113511881B CN202110309264.5A CN202110309264A CN113511881B CN 113511881 B CN113511881 B CN 113511881B CN 202110309264 A CN202110309264 A CN 202110309264A CN 113511881 B CN113511881 B CN 113511881B
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- 239000000919 ceramic Substances 0.000 title claims abstract description 46
- 239000002893 slag Substances 0.000 title claims abstract description 44
- 238000000034 method Methods 0.000 title claims abstract description 38
- 239000002994 raw material Substances 0.000 claims abstract description 74
- 238000005245 sintering Methods 0.000 claims abstract description 14
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims abstract description 13
- 238000000498 ball milling Methods 0.000 claims abstract description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 10
- 238000005187 foaming Methods 0.000 claims abstract description 10
- 239000003381 stabilizer Substances 0.000 claims abstract description 8
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 7
- 230000008569 process Effects 0.000 claims description 25
- 238000004519 manufacturing process Methods 0.000 claims description 18
- 239000000203 mixture Substances 0.000 claims description 15
- 238000010304 firing Methods 0.000 claims description 14
- 239000002699 waste material Substances 0.000 claims description 14
- 239000000843 powder Substances 0.000 claims description 11
- 239000000047 product Substances 0.000 claims description 11
- 239000002910 solid waste Substances 0.000 claims description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- 238000002156 mixing Methods 0.000 claims description 8
- 239000002245 particle Substances 0.000 claims description 8
- 238000001354 calcination Methods 0.000 claims description 7
- 238000001816 cooling Methods 0.000 claims description 7
- 230000004907 flux Effects 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
- 229910052799 carbon Inorganic materials 0.000 claims description 5
- 230000008859 change Effects 0.000 claims description 5
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 4
- 239000011268 mixed slurry Substances 0.000 claims description 4
- 239000011265 semifinished product Substances 0.000 claims description 4
- 238000007873 sieving Methods 0.000 claims description 4
- 238000009966 trimming Methods 0.000 claims description 4
- 238000005868 electrolysis reaction Methods 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 238000007580 dry-mixing Methods 0.000 claims description 2
- 238000000227 grinding Methods 0.000 claims description 2
- 239000003795 chemical substances by application Substances 0.000 claims 1
- 239000003112 inhibitor Substances 0.000 abstract description 7
- 238000011068 loading method Methods 0.000 abstract description 4
- 238000004064 recycling Methods 0.000 abstract description 4
- 238000001035 drying Methods 0.000 abstract description 3
- 238000003912 environmental pollution Methods 0.000 abstract description 2
- 238000000265 homogenisation Methods 0.000 abstract 1
- 239000002904 solvent Substances 0.000 abstract 1
- 238000005261 decarburization Methods 0.000 description 8
- 239000007789 gas Substances 0.000 description 7
- 239000010433 feldspar Substances 0.000 description 4
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical compound [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 239000010881 fly ash Substances 0.000 description 3
- 239000011812 mixed powder Substances 0.000 description 3
- 239000011148 porous material Substances 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 238000001694 spray drying Methods 0.000 description 3
- 239000004411 aluminium Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000004566 building material Substances 0.000 description 2
- 239000004568 cement Substances 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 239000003245 coal Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000005065 mining Methods 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- 239000010453 quartz Substances 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 229910004261 CaF 2 Inorganic materials 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
- 239000010459 dolomite Substances 0.000 description 1
- 229910000514 dolomite Inorganic materials 0.000 description 1
- 238000009837 dry grinding Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 150000002222 fluorine compounds Chemical class 0.000 description 1
- 239000010436 fluorite Substances 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 239000002440 industrial waste Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000002427 irreversible effect Effects 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 235000014380 magnesium carbonate Nutrition 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 229910052901 montmorillonite Inorganic materials 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 235000012222 talc Nutrition 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 150000003568 thioethers Chemical class 0.000 description 1
- 239000002912 waste gas Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
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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
- 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
- C04B33/138—Waste materials; Refuse; Residues from metallurgical processes, e.g. slag, furnace dust, galvanic waste
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- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
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- 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
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- C04B33/13—Compounding ingredients
- C04B33/131—Inorganic additives
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- 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
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- 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
- C04B33/16—Lean materials, e.g. grog, quartz
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- C04B33/00—Clay-wares
- C04B33/24—Manufacture of porcelain or white ware
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- 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
- C04B2235/3427—Silicates other than clay, e.g. water glass
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
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- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
- C04B2235/6567—Treatment time
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- 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 provides a formula and a method for preparing foamed ceramics by using overhaul slag, wherein the raw materials for preparing the foamed ceramics comprise the following components in parts by weight: 10-60 parts of overhaul slag, 5-40 parts of barren raw materials, 5-35 parts of plastic raw materials, 0-20 parts of solvent raw materials, 2-10 parts of inhibitors, 0.1-0.5 part of silicon carbide and 2-5 parts of stabilizers, and is prepared through the steps of homogenization, ball milling, drying, kiln loading, sintering and cutting processing. The invention adopts the electrolytic aluminum overhaul slag as the main material to produce the foaming ceramic, thus producing the ceramic product with high quality; creates huge economic value, realizes the recycling treatment of the overhaul slag, reduces environmental pollution and provides technical support for sustainable development of the aluminum industry.
Description
Technical Field
The invention relates to the technical field of industrial solid waste recycling treatment, in particular to a formula and a method for preparing foamed ceramics by utilizing overhaul slag.
Background
At present, the production of products such as cement, wall materials and the like by using large amounts of industrial wastes such as wood chips, stone powder, slag, fly ash, coal gangue, byproduct gypsum, tailings and the like and construction wastes has become an irreversible great trend. Products (such as cement, various light composite walls and the like) manufactured by the waste processed by the traditional process have the defects of easy cracking, easy wind generation, poor durability, difficult on-site processing and installation and the like, are not ideal building materials in terms of single performance, are used for buildings, are often not assembled for use for the second time, and are still construction wastes which are difficult to dispose after being disassembled for the service life of the building. The foamed ceramic is a ceramic material which is prepared by using mine tailings, industrial solid waste and the like as main raw materials, adding a special foaming agent, and performing high-temperature sintering to form a large amount of uniform closed pore structures, and is different from the honeycomb ceramic which adopts an open pore technology. The foamed ceramic has the advantages of light weight, high strength, fire resistance, flame retardance, heat preservation, heat insulation, water resistance, moisture resistance, sound insulation, noise reduction and the like, has the characteristics of quick and tidy construction, building load reduction and recycling, and is a novel green environment-friendly building material in the fields of building heat preservation walls and inner and outer wall decoration. Meanwhile, the foaming ceramic has extremely strong applicability in actual production due to the formula and firing process characteristics of the foaming ceramic which can be changed according to the material composition change, and the used foaming ceramic can also be used as a raw material for producing the foaming ceramic for reutilization, thereby realizing a closed-loop material flow mode of 'resource consumption, product and renewable resource'.
The service life of the electrolytic cell used in the aluminum production industry is limited, and the removed waste (mainly the waste lining removed in the electrolytic cell) is called overhaul slag when the aluminum cell is overhauled. The yield of the original aluminum in China is improved, and the waste slot liners discharged outside the aluminum industry are also increased year by year.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a formula and a method for producing foamed ceramics by using the overhaul slag, which not only solve the problem of innocuous treatment of the overhaul slag, but also change waste into valuable, and produce foamed ceramic products with excellent performance by taking the overhaul slag as a raw material, thereby creating good economic benefits.
The technical scheme of the invention is as follows: a formula for preparing foamed ceramics by utilizing overhaul slag comprises the following raw materials in parts by weight: 10-50 parts of overhaul slag after decarburization treatment, 5-40 parts of barren raw materials, 5-35 parts of plastic raw materials, 0-20 parts of flux raw materials, 2-10 parts of inhibitors, 0.1-0.5 part of silicon carbide and 2-5 parts of stabilizers. When the part of the overhaul slag after the decarburization treatment in the formula is less than 10 parts, the purpose of rapidly and massively treating the overhaul slag cannot be realized, and when the part of the overhaul slag after the decarburization treatment is more than 50 parts, a high-quality foamed ceramic product cannot be produced.
Preferably, the raw materials comprise the following components in parts by weight: 10-50 parts of overhaul slag, 10-35 parts of barren raw materials, 10-30 parts of plastic raw materials, 5-20 parts of flux raw materials, 2-7 parts of inhibitors, 0.1-0.5 part of silicon carbide and 2-5 parts of stabilizers after decarburization treatment.
Preferably, 30 parts of overhaul slag, 30 parts of barren raw materials, 15 parts of plastic raw materials, 20 parts of flux raw materials, 2 parts of inhibitors, 0.35 part of silicon carbide and 3 parts of stabilizers after decarburization treatment;
further, the barren raw material is at least one of feldspar raw material, quartz raw material and clinker after clay raw material processing in the common ceramic raw material, or the barren raw material is one or a mixture of more than two of gold ore tailings, lithium ore tailings, fly ash and fluorite tailings in the solid waste, or the barren raw material is a mixture of the common ceramic raw material and the solid waste; the barren raw material acts as an aggregate in the foamed ceramic, which provides SiO during formation 2 、Al 2 O 3 And the like, thus not having too high a requirement for barren raw materials, essentially SiO 2 The content of Al is above 60% 2 O 3 Raw materials with the content of 9-35% or general solid waste can be adopted. So that the waste materials generated during the processing of the foamed ceramics can also be used as raw materials to reenter the production material circulation; secondary pollution is avoided; for example: 0-30% of waste foamed ceramic partition boards can be directly added into the formula. The common ceramic raw materials mainly comprise clay, quartz, feldspar and the like.
Further, the plastic raw material is at least one of white mud, black mud, montmorillonite and kaolin; or one or more than two of solid waste such as gangue, shale and mining tail mud, and the plastic raw material can be a mixture of common ceramic raw materials and solid waste; the chemical composition of the ceramic raw materials and the mining tailings meets the requirement of SiO 2 The content of Al is above 35% 2 O 3 The content is between 13% and 45%.
Further, the flux raw material is one or more of feldspar, talcum, dolomite and magnesite, wherein the feldspar can be used as a barren raw material or a flux raw material.
Further, the overhaul slag after decarburization treatment is aluminium cell overhaul slag with more than 60% of decarburization, and the concrete process is that the aluminium cell overhaul slag is separated after crushing treatment, and the waste slag obtained after more than 60% of carbon slag is selected; the remaining carbon residue can be used as an organic pore former in the preparation and can increase the overall porosity.
The invention also provides a specific process method for producing the foamed ceramic by using the formula, which comprises the following steps:
the first step, the raw materials are pretreated,
respectively pre-crushing the raw materials in the formula, and sieving the crushed raw materials with a 40-mesh sieve to ensure that the particle size of raw material powder is smaller than 40 meshes; over 60% of carbon slag is separated from the aluminum electrolysis cell overhaul slag.
In the second step, the raw materials are mixed,
weighing various raw materials according to the proportion of the formula, and processing by adopting a dry method or a wet method mixing process to obtain a mixture after processing;
thirdly, if a dry mixing process is adopted in the second step, powder particles with the particle size smaller than 325 meshes are screened out after ball milling, and the obtained mixture is directly stored for standby; if a wet mixing process is adopted in the second step, the obtained mixture is further subjected to drying treatment to form dry powder for later use;
fourth, the material is distributed,
and (3) loading the mixed material obtained after the third step of treatment into a container or a kiln car according to the thickness of the powder of the process instruction sheet.
Fifth, the calcination treatment is carried out,
placing the material treated in the previous step into a firing kiln for calcination to obtain a semi-finished product of the foaming ceramic plate;
and sixthly, sorting and trimming the semi-finished product of the foaming ceramic plate to finally obtain a finished product.
Further, in the second step (mixing of raw materials), in order to improve the uniformity of foaming, a water-adding ball grinding method is adopted, and the materials in the ball mill are: ball: the water ratio is 1:2:0.5-0.6, and the rotation speed of ball milling is 13-18 revolutions per minute; ball milling for 7-9 h, and sieving the mixed slurry after ball milling by adding water with a 100-mesh sieve.
Further, after the water ball milling is completed, the particles with the particle size of 20-100 meshes are prepared by spray drying, so that the water content of the particles is lower than 8%.
Further, the firing kiln used in the fifth step (firing) may be any one of a roller kiln, a tunnel kiln, and a drawer kiln.
Furthermore, a gas collecting device is added in the fifth step to collect and treat the gas generated in the processing process so as to avoid polluting the environment and realize the harmless production process.
Further, in the calcination step, the calcination temperature is 1000 to 1200 ℃, preferably 1050 to 1180 ℃.
Further, the temperature change mode during calcination is as follows: firstly, the temperature in a sintering kiln is from room temperature to 1000 ℃, the heating rate of 600-700 ℃/h is adopted, and the heating rate of 300-450 ℃/h is adopted from 1000 ℃ to the sintering temperature; preserving the temperature for 1-2 h at the firing temperature, and then adopting the cooling rate of 500-800 ℃/h from the firing temperature to 600 ℃; the temperature reduction rate of 300-500 ℃/h is adopted from 600 ℃ to room temperature.
Compared with the prior art, the invention has the beneficial effects that: the invention provides a method for preparing foamed ceramics by using electrolytic aluminum overhaul slag as a production material, which can produce high-quality ceramic products; creates huge economic value, is beneficial to the harmless treatment of the overhaul slag, reduces the environmental pollution and provides technical support for the sustainable development of the aluminum industry. Other solid wastes can be added in the formula, so that the recycling treatment of various solid wastes is realized, and waste materials or waste gases formed in the production process can be collected and put into the production material circulation again, so that the problem of secondary pollution is avoided.
Drawings
FIG. 1 is a flow chart of a process for producing foamed ceramics according to the present invention.
Detailed Description
The present invention will be described in further detail with reference to specific examples, and methods or processes not specifically described in the present examples are all prior art.
Example 1
As shown in fig. 1, in this embodiment, the method for preparing foamed ceramics by using the overhaul slag includes the following steps:
1) Pretreatment of raw materials
Respectively pre-crushing other raw materials, crushing the raw materials, and sieving the crushed raw materials with a 40-mesh sieve to ensure that the particle size of raw material powder is smaller than 40 meshes; and (3) after the aluminum electrolysis cell overhaul slag is crushed, more than 60% of carbon slag is separated.
Taking raw materials according to the weight parts, wherein 30 parts of overhaul slag, 30 parts of fly ash, 15 parts of coal gangue, 20 parts of potassium feldspar, 2 parts of inhibitor, 0.35 part of silicon carbide and 3 parts of stabilizer after 60% decarburization; wherein the stabilizer and the inhibitor are the existing products which are directly purchased in the market and used for producing the foamed ceramics;
2) Mixing the raw materials, putting the mixture into a ball mill, adding water according to the mass ratio of the raw materials to the water of 1:0.6, and performing ball milling for 7 hours;
3) Transferring the obtained mixed slurry to a spray drying tower for spray drying treatment, and drying the mixed slurry to prepare powder to obtain powder;
4) And (3) placing the powder in the last step into kiln furniture, placing the kiln furniture into a tunnel kiln for sintering at 1050 ℃, keeping the temperature for 2 hours, taking out the kiln furniture after waiting for natural cooling, and sorting and trimming to obtain the foamed ceramic finished product.
The temperature change mode during calcination is as follows: firstly, the temperature in a sintering kiln is from room temperature to 1000 ℃, the heating rate of 650 ℃/h is adopted, and the heating rate of 300 ℃/h is adopted from 1000 ℃ to the sintering temperature; and preserving the temperature for 2 hours at the firing temperature; then, adopting a cooling rate of 700 ℃/h from the firing temperature to 600 ℃; from 600 ℃ to room temperature, a cooling rate of 400 ℃/h is adopted.
In other embodiments, gas collection devices may be used in steps 3 and 4 of the process to collect the gases produced during the process to avoid ring alignmentThe environment is polluted; during the production process of the present invention, the evolved gas may contain fluorides, sulfides, etc.; therefore, the gas collection device can adopt lime water as the treatment liquid, and the reaction mechanism is as follows: ca (OH) 2 + SO 2 = CaSO 3 ↓+ H 2 O，2HF + Ca（OH） 2 = CaF 2 ↓+ 2H 2 The specific gas collection device is the prior art, and is not described here in detail.
Example 2
The main differences between this example and example 1 are the different proportions of the raw materials, the different mixing processes of the raw materials and the different process parameters during firing; a brief description of the steps in example 2 is as follows:
1) Taking 25 parts of overhaul slag, 26 parts of barren raw materials, 25 parts of plastic raw materials, 20 parts of flux raw materials, 2 parts of inhibitors, 0.25 part of silicon carbide and 2 parts of stabilizers as raw materials according to the parts by weight;
2) Mixing the above raw materials, loading into a ball mill, and dry grinding to obtain powder with 1% of the screen residue of 325 mesh sieve, to obtain mixed powder.
3) And (3) loading the mixed powder into a kiln car, putting the kiln car into a tunnel kiln for sintering at 1080 ℃ for 2 hours, taking out the mixed powder after waiting for natural cooling, and sorting and trimming to obtain the foamed ceramic finished product.
The above is only a part of embodiments of the present invention, and it is not intended to limit the present invention, and it is obvious to those skilled in the art that the present invention can be combined and modified in various technical features, and it is intended to include the present invention in the scope of the present invention without departing from the spirit and scope of the present invention.
Claims (4)
1. A method for producing foamed ceramics by using overhaul slag is characterized in that: the raw materials used in the production of the method comprise the following components in weight: 10-60 parts of overhaul slag, 5-40 parts of barren raw materials, 5-35 parts of plastic raw materials, 0-20 parts of flux raw materials and 2-10 parts of inhibitors0.1-0.5 part of silicon carbide and 2-5 parts of stabilizer; the overhaul slag is waste slag obtained by crushing and sorting overhaul slag of an aluminum electrolysis cell and then separating 60% carbon slag; and 40% of carbon slag is reserved in the overhaul slag as a pore-forming agent; the barren raw material is at least one of ceramic raw material and solid waste, and the chemical composition of the ceramic raw material and the solid waste meets the requirement of SiO 2 The content is above 60 percent, al 2 O 3 The content is between 9% and 25%; the plastic raw material is at least one of ceramic raw material and waste residue generated in the ore-collecting and dressing process, and the chemical composition of the ceramic raw material and the waste residue generated in the ore-collecting and dressing process meets the requirement of SiO 2 The content of Al is above 35% 2 O 3 The content is between 13% and 45%;
the specific production process comprises the following steps: firstly, crushing the raw materials respectively, and sieving the crushed raw materials with a 40-mesh sieve; step two, various raw materials are measured according to the proportion of the formula, and a dry method or a wet method mixing process is adopted for treatment, so that a mixture is finally obtained; thirdly, if a dry mixing process is adopted in the second step, directly storing the obtained mixture for later use; if a wet mixing process is adopted in the second step, the obtained mixture is dried to form dry powder for later use; fourthly, distributing, namely placing the materials obtained after the treatment in the third step into a container or a kiln car; fifthly, placing the material treated in the previous step into a firing kiln for firing to obtain a semi-finished product of the foaming ceramic plate; step six, sorting and trimming the semi-finished products of the foaming ceramic plates to finally obtain finished products;
the sintering temperature adopted in the sintering kiln is 1000-1200 ℃; the temperature change mode in the calcination process is as follows: firstly, the temperature in a sintering kiln is from room temperature to 1000 ℃, the heating rate of 600-700 ℃/h is adopted, and the heating rate of 300-450 ℃/h is adopted from 1000 ℃ to the sintering temperature; preserving the temperature for 1-2 h at the firing temperature, and then adopting the cooling rate of 500-800 ℃/h from the firing temperature to 600 ℃; a cooling rate of 300-500 ℃/h is adopted from 600 ℃ to room temperature;
in the second step, a water ball grinding process is adopted, and raw materials in a ball mill are: ball: the water ratio is 1:2:0.5-0.6; if a dry ball milling process is adopted, the particle size of the mixture obtained after ball milling is ensured to be below 325 meshes; if a wet ball milling process is adopted, the mixed slurry after ball milling is sieved by a 100-mesh sieve.
2. The method for producing foamed ceramics by using overhaul slag according to claim 1, wherein: and in the fifth step, a gas collecting device is added to collect and treat the gas generated in the processing process so as to avoid polluting the environment and realize harmless treatment in the production process.
3. The method for producing foamed ceramics by using overhaul slag according to claim 1, wherein: in the fifth step, the firing kiln is one of a roller kiln, a tunnel kiln and a drawer kiln.
4. The method for producing foamed ceramics by using overhaul slag according to claim 1, wherein: the sintering temperature adopted in the sintering kiln is 1050-1180 ℃.
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