CN113620659A - 一种利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法 - Google Patents
一种利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法 Download PDFInfo
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- 229910052918 calcium silicate Inorganic materials 0.000 title claims abstract description 51
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 title claims abstract description 51
- 239000010881 fly ash Substances 0.000 title claims abstract description 41
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- 238000000034 method Methods 0.000 title claims abstract description 26
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- 101150096185 PAAS gene Proteins 0.000 claims description 3
- 229920001131 Pulp (paper) Polymers 0.000 claims description 3
- ALVYUZIFSCKIFP-UHFFFAOYSA-N triethoxy(2-methylpropyl)silane Chemical compound CCO[Si](CC(C)C)(OCC)OCC ALVYUZIFSCKIFP-UHFFFAOYSA-N 0.000 claims description 3
- HXOGQBSDPSMHJK-UHFFFAOYSA-N triethoxy(6-methylheptyl)silane Chemical compound CCO[Si](OCC)(OCC)CCCCCC(C)C HXOGQBSDPSMHJK-UHFFFAOYSA-N 0.000 claims description 3
- NBXZNTLFQLUFES-UHFFFAOYSA-N triethoxy(propyl)silane Chemical compound CCC[Si](OCC)(OCC)OCC NBXZNTLFQLUFES-UHFFFAOYSA-N 0.000 claims description 3
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- MKTRXTLKNXLULX-UHFFFAOYSA-P pentacalcium;dioxido(oxo)silane;hydron;tetrahydrate Chemical compound [H+].[H+].O.O.O.O.[Ca+2].[Ca+2].[Ca+2].[Ca+2].[Ca+2].[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O MKTRXTLKNXLULX-UHFFFAOYSA-P 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
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- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 235000015334 Phyllostachys viridis Nutrition 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
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- UGGQKDBXXFIWJD-UHFFFAOYSA-N calcium;dihydroxy(oxo)silane;hydrate Chemical compound O.[Ca].O[Si](O)=O UGGQKDBXXFIWJD-UHFFFAOYSA-N 0.000 description 1
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- 239000012779 reinforcing material Substances 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
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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
- 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
- C04B28/02—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 hydraulic cements other than calcium sulfates
- C04B28/04—Portland cements
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- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
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- C04B14/043—Alkaline-earth metal silicates, e.g. wollastonite
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Abstract
本发明提供了一种利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,包括以下步骤:(1)将粉煤灰、氧化钙、氢氧化钠稀溶液和结构调节剂按一定比例混合在密闭反应器中进行一步动态水热反应,反应后将料浆过滤、洗涤得到水化硅酸钙湿渣;(2)将步骤(1)所得水化硅酸钙湿渣与水泥、纤维和有机硅防水剂按一定质量比例混合均匀,在20~60MPa压力下压制成型,成型后的坯体脱模,干燥后制得免蒸压疏水性纤维增强硅酸钙板。本发明以粉煤灰为原料,原料属大宗工业固体废弃物,廉价易得;无需蒸压养护工艺,设备投资少,生产工艺简单,能耗低,经济易行。
Description
技术领域
本发明涉及固体废弃物再利用领域,尤其涉及一种利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法。
背景技术
硅酸钙板是一种非常有潜力的新型建筑材料,因为它具有防火、隔热、隔音、防潮和高机械强度等优点,被广泛应用于外墙板、内墙板、吊顶板、装饰板、隔音板、家具衬板等领域。硅酸钙板通常是以石灰为钙源,以石英砂、高岭土或硅藻土为硅源,以纤维为增强物质,以硅酸钠或氢氧化钠为碱活化剂,在约200℃蒸汽中养护5-20h合成的,例如CN201010501474.6公开的复合纤维硅酸钙板及其制备方法和CN201310352902.7公开的一种轻质硅酸钙板及其制备工艺。但其存在如下问题:一是石英砂、高岭土或硅藻土都是需要被保护的自然资源;二是高温蒸压养护需要消耗大量能量,成本提高。
目前,环保和节能是建筑材料的发展趋势,已有报道利用固体废弃物来制备轻质和高强的硅酸钙板。例如CN201510014660.X公开的一种利用工业废渣生产的硅酸钙板,利用石英矿废渣、硅藻土、陶瓷抛光废料、水泥、电石渣、石灰竹浆纤维、纸浆增强材料、粉煤灰和珍珠岩为原料,但其需要将压制后的样品放入反应釜中在165~200℃蒸压养护10~48h,耗时长,能耗高;CN201410541415.X公开的一种粉煤灰综合利用方法,以粉煤灰为硅源,采用“两步凝胶化法”先转化成雪硅钙石,再转化为硬硅钙石型硅酸钙板,密度仅为0.2~0.3g/cm3,但其产品强度较低,并且“两步凝胶化法”操作复杂、能耗较大,尤其是第二步凝胶化反应温度高达220~280℃,压力为2~3MPa,设备要求较高,成本较高。
发明内容
本发明的目的在于提供一种利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,该方法以粉煤灰为原料,不需要加入其它自然硅质原料,原料廉价易得,无需蒸压养护工艺,方法简单,经济易行,适用于工业化生产。本发明可以缓解粉煤灰对环境的污染问题。
为达到上述目的,本发明提供了一种利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,该方法包括如下步骤:
(1)将粉煤灰、氧化钙、氢氧化钠稀溶液和结构调节剂按一定比例混合在密闭反应器中进行一步动态水热反应,反应后将料浆过滤、洗涤得到水化硅酸钙湿渣;
(2)将步骤(1)所得水化硅酸钙湿渣与水泥、纤维和有机硅防水剂按一定质量比例混合均匀,在20~60MPa压力下压制成型,成型后的坯体脱模,干燥后制得免蒸压疏水性纤维增强硅酸钙板;
进一步地,所述步骤(1)中氧化钙与粉煤灰按CaO与粉煤灰所含SiO2的摩尔比为0.8~1.2混合。
进一步地,所述步骤(1)中氢氧化钠稀溶液的质量百分数为1~10wt%。
进一步地,所述步骤(1)中氢氧化钠稀溶液与固体物料的液固比为10~30mL/g。
进一步地,所述步骤(1)中结构调节剂为P123(EO20PO70EO20)或F127(EO106PO70EO106)或聚丙烯酸钠(PAAS),添加量为1~5wt%。
进一步地,所述步骤(1)中动态水热反应的反应温度为140~190℃。
进一步地,所述步骤(1)中动态水热反应的反应时间为2~6h。
进一步地,所述步骤(1)中动态水热反应的搅拌速率为100~400r/min。
进一步地,将所述步骤(2)中水化硅酸钙湿渣与水泥、纤维的比例为60~90wt%:5~25wt%:5~15wt%,有机硅防水剂为异丁基三甲氧基硅烷、异丁基三乙氧基硅烷、异辛基三乙氧基硅烷、丙基三乙氧基硅烷中的一种或两种以上的混合物,添加量为1~5wt%。
进一步地,将所述步骤(2)中干燥温度60~105℃,干燥时间为6~24h。
进一步地,所述步骤(2)中水泥为强度等级42.5MPa的普通硅酸盐水泥。
进一步地,所述步骤(2)中纤维为纸浆纤维或者棉纤维。
本发明提供的一种利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法具有如下明显优越性:
(1)本发明以粉煤灰为原料,不需要加入其它自然硅质原料,原料廉价易得,成本较低,方法简单,不仅解决了粉煤灰大量堆积对环境的污染问题,还实现了粉煤灰的高值资源化利用;
(2)本发明制备的纤维增强硅酸钙板无需蒸压养护工艺,能耗低,无需大型蒸压养护釜,设备投资低,占地面积小,经济易行,适用于工业化生产;
(3)本发明提供的免蒸压疏水性纤维增强硅酸钙板具有密度低、强度高、防火隔热和防水等优异性能,其密度在0.95~1.20g/cm3,抗折强度在10MPa以上,导热系数小于0.25W/(m·K),吸水率小于5%,具有环保和经济双重价值,为粉煤灰高值资源化利用开辟了一种新途径。
附图说明
图1是本发明一种利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的工艺流程示意图。
具体实施方式
下面结合本发明几个具体实施例对本发明进一步详细说明,但以下实施例仅限于解释本发明,并不限制本发明的权利保护范围,本发明的权利范围以权利要求书为准。
实施例1
原料采用以内蒙某地的粉煤灰为例,其主要化学成分为57.09wt%的SiO2、21.39wt%的Al2O3和6wt%的CaO。
将粉煤灰与氧化钙以Ca/Si摩尔比为0.8混合,加入1wt%的氢氧化钠稀溶液混合成浆料,控制浆料的液固比即液体体积与固体质量的比值为10mL/g,添加1wt%的P123。将得到的浆料加入反应釜中,搅拌并加热到140℃,在此温度下反应6h,搅拌速率为200r/min。反应后将浆料进行抽滤,滤饼用水和乙醇多次洗涤,得到水化硅酸钙湿渣。将湿渣与水泥、纸浆纤维按90∶5∶5的质量比进行混合,添加1wt%异丁基三甲氧基硅烷,用选定的模具在20MPa压制成型得到湿坯,将湿坯在60℃干燥24h后得到免蒸压疏水性纤维增强硅酸钙板产品。硅酸钙板产品的密度为0.96g/cm3,导热系数为0.18W/(m·K),抗折强度为10.25MPa,吸水率为4.8%。
实施例2
将粉煤灰与氧化钙以Ca/Si摩尔比为1.0混合,加入3wt%的氢氧化钠稀溶液混合成浆料,控制浆料的液固比即液体体积与固体质量的比值为20mL/g添加3wt%的F127。将得到的浆料加入反应釜中,搅拌并加热到170℃,在此温度下反应3h,搅拌速率为100r/min。反应后将浆料进行抽滤,滤饼用水和乙醇多次洗涤,得到水化硅酸钙湿渣。将湿渣与水泥、棉纤维按70∶20∶10的质量比进行混合,添加5wt%的异丁基三甲氧基硅烷和异丁基三乙氧基硅烷混合物,用选定的模具在60MPa下压制成型得到湿坯,将湿坯在105℃干燥6h后得到免蒸压疏水性纤维增强硅酸钙板产品。硅酸钙板产品的密度为1.13g/cm3,导热系数为0.24W/(m·K),抗折强度为14.92MPa,吸水率为4.3%。
实施例3
将粉煤灰与氧化钙以Ca/Si摩尔比为1.2混合,加入10wt%的氢氧化钠稀溶液混合成浆料,控制浆料的液固比即液体体积与固体质量的比值为30mL/g,添加5wt%的PAAS。将得到的浆料加入反应釜中,搅拌并加热到190℃,在此温度下反应2h,搅拌速率为300r/min。反应后将浆料进行抽滤,滤饼用水和乙醇多次洗涤,得到水化硅酸钙湿渣。将湿渣与水泥、棉纤维按60∶25∶15的质量比进行混合,添加2wt%异辛基三乙氧基硅烷,用选定的模具在45MPa下压制成型得到湿坯,将湿坯在80℃干燥12h后得到免蒸压疏水性纤维增强硅酸钙板产品。硅酸钙板产品的密度为1.10g/cm3,导热系数为0.23W/(m·K),抗折强度为14.55MPa,吸水率为4.6%。
实施例4
将粉煤灰与氧化钙以Ca/Si摩尔比为0.9混合,加入5wt%的氢氧化钠稀溶液混合成浆料,控制浆料的液固比即液体体积与固体质量的比值为15mL/g,添加3wt%的P123。将得到的浆料加入反应釜中,搅拌并加热到150℃,在此温度下反应5h,搅拌速率为400r/min。反应后将浆料进行抽滤,滤饼用水和乙醇多次洗涤,得到水化硅酸钙湿渣。将湿渣与水泥、棉纤维按75∶20∶5的质量比进行混合,添加3wt%丙基三乙氧基硅烷,用选定的模具在35MPa下压制成型得到湿坯,将湿坯在95℃干燥10h后得到免蒸压疏水性纤维增强硅酸钙板产品。硅酸钙板产品的密度为1.03g/cm3,导热系数为0.20W/(m·K),抗折强度为10.40MPa,吸水率为4.5%。
最后所应说明的是,以上实施例仅用以说明本发明的技术方案而非限制。尽管参照实施例对本发明进行了详细说明,本领域的普通技术人员应该理解,对本发明的技术方案进行修改或者等同替换,都不脱离本发明技术方案的精神和范围,其均应涵盖在本发明的权利要求范围当中。
Claims (10)
1.一种利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于包括以下步骤:
(1)将粉煤灰、氧化钙、氢氧化钠稀溶液和结构调节剂按一定比例混合,在密闭反应器中进行一步动态水热反应,反应后将料浆过滤、洗涤得到水化硅酸钙湿渣;
(2)将步骤(1)所得水化硅酸钙湿渣与水泥、纤维和有机硅防水剂按一定质量比例混合均匀,在20~60MPa压力下压制成型,成型后的坯体脱模,干燥后制得免蒸压疏水性纤维增强硅酸钙板。
2.根据权利要求1所述的利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于:所述步骤(1)中氧化钙与粉煤灰按CaO与粉煤灰所含SiO2的摩尔比为0.8~1.2混合。
3.根据权利要求1所述的利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于:所述步骤(1)中氢氧化钠稀溶液的质量百分数为1~10wt%。
4.根据权利要求1所述的利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于:所述步骤(1)中氢氧化钠稀溶液与固体物料的液固比为10~30mL/g。
5.根据权利要求1所述的利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于:所述步骤(1)中结构调节剂为P123(EO20PO70EO20)或F127(EO106PO70EO106)或聚丙烯酸钠(PAAS),添加量为1~5wt%。
6.根据权利要求1所述的利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于:所述步骤(1)中动态水热反应的反应温度为140~190℃。
7.根据权利要求1所述的利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于:所述步骤(1)中动态水热反应的反应时间为2~6h。
8.根据权利要求1所述的利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于:所述步骤(2)中水化硅酸钙湿渣与水泥、纤维的比例为60~90wt%∶5~25wt%∶5~15wt%,有机硅防水剂为异丁基三甲氧基硅烷、异丁基三乙氧基硅烷、异辛基三乙氧基硅烷、丙基三乙氧基硅烷中的一种或两种以上的混合物,添加量为1~5wt%。
9.根据权利要求1所述的利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于:所述步骤(2)中水泥为强度等级42.5MPa的普通硅酸盐水泥。
10.根据权利要求1所述的利用粉煤灰制备免蒸压疏水性纤维增强硅酸钙板的方法,其特征在于:所述步骤(2)中纤维为纸浆纤维或者棉纤维。
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