CN113716971A - 一种以日用陶瓷废瓷为原料的透水砖及其制备方法 - Google Patents
一种以日用陶瓷废瓷为原料的透水砖及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种以日用陶瓷废瓷为原料的透水砖,由基料和低温有机粘结剂组成;所述基料的原料组成为粒度为0.1~0.5mm的废瓷粉10~20wt%、0.5~2mm的废瓷粉55~70wt%、粒度为2~4mm的废瓷粉2~6wt%、废红砖粉8~15wt%、淀粉2~6wt%;所述低温有机粘结剂的用量为基料的5~9wt%,其组成为浓度5wt%的聚乙烯醇溶液20~40wt%、聚乙二醇溶液20~40wt%、水30~50wt%;所述废瓷粉由烧结温度为1250~1320℃、表面釉层厚度为0.5~2.0mm的日用陶瓷废瓷破碎而成。此外,还公开了利用上述以日用陶瓷废瓷为原料的透水砖的制备方法。本发明通过配方设计,不仅提高了废瓷的利用率、减少了对高温粘结剂的使用,而且工艺简单,有利于高效、绿色、经济、环保地回收日用陶瓷废瓷。
Description
技术领域
本发明涉及建筑陶瓷材料技术领域,尤其涉及一种作为地面砖的透水砖及其制备方法。
背景技术
中国陶瓷产量占比全球54.17%,是全世界最大的产瓷和用瓷大国,同时也是最大的废瓷产生国,仅江西省景德镇市产区每年的废瓷产量就高达35万吨。由于陶瓷不可被降解,因此大部分废瓷都是通过倾倒和掩埋处理,从而对环境带来了极大的压力,因此废瓷的回收利用技术尤为关切。目前,现有的废瓷回收利用技术主要分为三个方面:一是直接作为环境陶艺、景观雕塑原材料,不仅丰富了环境装饰元素,还实现了变废为宝,但是这种回收利用方法最大的缺点就是用量低,对每年产生的废瓷量无异于杯水车薪;二是将陶瓷破碎成小粒作为混凝土骨料,这种方法可以大量使用废瓷粒,但是废瓷的利用价值太低,毕竟陶瓷的生产过程消耗了大量的能源和资源,相比之下这种回收方式过于简易;第三种就是直接将废瓷用于陶瓷的制备生产中,即以废瓷为原料制备卫生陶瓷、瓷质砖、亚光瓷釉等,但是现有技术中废瓷添加量一般在10~50wt%,回用量低;此外,废瓷回用必须添加高温粘结剂,还需要将多次破碎加工至0.02~0.5mm,工艺复杂,从而限制了废瓷的综合性利用效率。而且,尤其是对于具有高烧成温度(1280~1320℃)、釉色丰富、硬度高、深度加工破碎困难的景德镇日用陶瓷废瓷的回收利用,目前还没有成熟稳定、工艺简单的技术回收手段。
随着生态环境保护法律法规的逐渐完善,以及人们环保意识的增强,需要研究开发新型的高利用率、高附加值、绿色环保的废瓷回用处理技术,以更好地适应行业和经济社会发展的需要。
发明内容
本发明的目的在于克服现有技术的不足,提供一种以日用陶瓷废瓷为原料的透水砖,通过配方设计,以提高废瓷的利用率,减少对高温粘结剂的使用,从而有利于高效、绿色、经济、环保地回收日用陶瓷废瓷。本发明的另一目的在于提供上述以日用陶瓷废瓷为原料的透水砖的制备方法。
本发明的目的通过以下技术方案予以实现:
本发明提供的一种以日用陶瓷废瓷为原料的透水砖,由基料和低温有机粘结剂组成;所述基料的原料组成为粒度为0.1~0.5mm的废瓷粉10~20wt%、0.5~2mm的废瓷粉55~70wt%、粒度为2~4mm的废瓷粉2~6wt%、废红砖粉8~15wt%、淀粉2~6wt%;所述低温有机粘结剂的用量为基料的5~9wt%,其组成为浓度5wt%的聚乙烯醇溶液20~40wt%、聚乙二醇溶液20~40wt%、水30~50wt%;所述废瓷粉由烧结温度为1250~1320℃、表面釉层厚度为0.5~2.0mm的日用陶瓷废瓷破碎而成。
进一步地,本发明所述废红砖粉为烧制温度为850~950℃的建筑砖块破碎而成,其粒度为0.1~0.5mm。
本发明的另一目的通过以下技术方案予以实现:
本发明提供的上述以日用陶瓷废瓷为原料的透水砖的制备方法,包括以下步骤:
(1)将所述粒度为0.1~0.5mm、0.5~2mm、2~4mm的废瓷粉投入混料机中进行一次干式混合后,再将淀粉和废红砖粉投入混料机中一起进行二次干式混合,得到混合干粉;
(2)将所述低温有机粘结剂的各组成搅拌混合后,得到溶液状低温有机粘结剂;
(3)将所述混合干粉和溶液状低温有机粘结剂在搅拌机中进行搅拌混合,陈腐后得到待干压物料;
(4)将所述待干压物料置于模具中干压成型得到坯体;然后将坯体干燥后进行烧制,以2℃/min从室温升至500℃,然后以5℃/min从500℃升至1130~1165℃,保温0.5~2h,即制得透水砖。
上述方案中,本发明制备方法所述步骤(1)中一次干式混合的时间为1~2h,二次干式混合的时间为1~2h。所述步骤(2)中搅拌混合时间为1~2h。
进一步地,本发明制备方法所述步骤(3)中溶液状低温有机粘结剂的加入方式为在搅拌的同时将溶液状低温有机粘结剂均匀喷洒至混合干粉中;喷洒结束后继续搅拌混合2~3h,然后陈腐15~24h。
上述方案中,本发明制备方法所述步骤(4)中干压成型的压力为12~20MPa、保压时间为1~2min。
本发明具有以下有益效果:
本发明以日用陶瓷废瓷为原料的透水砖,废瓷粉制备工艺简单,只需要将日用陶瓷废瓷投入颚式破碎机进行破碎、分级筛分即可获得;此外,无需外加高温粘结剂,利用日用陶瓷表面附着的0.5~2.0mm釉层作为原生高温粘结剂即可实现颗粒在高温的粘结;废瓷利用率高,达到了80wt%以上,为日用陶瓷废瓷尤其是颜色丰富的景德镇日用陶瓷废瓷的回用提供了一种高利用率、高附加值的技术途径。
附图说明
下面将结合实施例和附图对本发明作进一步的详细描述:
图1是本发明实施例制备方法的工艺流程图(1#、2#、3#废瓷粉分别为粒度为0.1~0.5mm、0.5~2mm、2~4mm的废瓷粉);
图2是本发明实施例透水砖中颗粒之间的高温粘结示意图;
图3是本发明实施例制备得到的透水砖的外观图。
具体实施方式
实施例一:
1、本实施例一种以日用陶瓷废瓷为原料的透水砖,由基料和低温有机粘结剂组成;基料的原料组成为粒度为0.1~0.5mm的废瓷粉18wt%、0.5~2mm的废瓷粉62wt%、粒度为2~4mm的废瓷粉3wt%、废红砖粉12wt%、淀粉5wt%;低温有机粘结剂的用量为基料的6.25wt%,其组成为浓度5wt%的聚乙烯醇溶液30wt%、聚乙二醇溶液30wt%、水40wt%。
2、本实施例上述以日用陶瓷废瓷为原料的透水砖的制备方法,如图1所示,其步骤如下:
(1)将上述粒度为0.1~0.5mm、0.5~2mm、2~4mm的废瓷粉投入混料机中进行一次干式混合1h后,再将淀粉和废红砖粉投入混料机中一起进行二次干式混合2h,得到混合干粉;
(2)将上述低温有机粘结剂的各组成快速搅拌1h后,得到溶液状低温有机粘结剂;
(3)将上述混合干粉倒入敞口搅拌机中进行低速搅拌,搅拌的同时用喷壶将溶液状低温有机粘结剂均匀喷洒至混合干粉中,喷洒结束后将搅拌机口封闭继续进行低速搅拌2h后,陈腐24h,得到待干压物料;
(4)将上述待干压物料置于模具中在压力12MPa、保压时间为1min条件下干压成型得到坯体;然后将坯体干燥后进行烧制,以2℃/min从室温升至500℃,然后以5℃/min从500℃升至1130℃,保温1h,即制得透水砖。
实施例二:
1、本实施例一种以日用陶瓷废瓷为原料的透水砖,由基料和低温有机粘结剂组成;基料的原料组成为粒度为0.1~0.5mm的废瓷粉15wt%、0.5~2mm的废瓷粉68wt%、粒度为2~4mm的废瓷粉4wt%、废红砖粉10wt%、淀粉3wt%;低温有机粘结剂的用量为基料的8wt%,其组成为浓度5wt%的聚乙烯醇溶液35wt%、聚乙二醇溶液35wt%、水30wt%。
2、本实施例上述以日用陶瓷废瓷为原料的透水砖的制备方法,如图1所示,其步骤如下:
(1)将上述粒度为0.1~0.5mm、0.5~2mm、2~4mm的废瓷粉投入混料机中进行一次干式混合1.5h后,再将淀粉和废红砖粉投入混料机中一起进行二次干式混合1.5h,得到混合干粉;
(2)将上述低温有机粘结剂的各组成快速搅拌1.5h后,得到溶液状低温有机粘结剂;
(3)将上述混合干粉倒入敞口搅拌机中进行低速搅拌,搅拌的同时用喷壶将溶液状低温有机粘结剂均匀喷洒至混合干粉中,喷洒结束后将搅拌机口封闭继续进行低速搅拌2.5h后,陈腐18h,得到待干压物料;
(4)将上述待干压物料置于模具中在压力12MPa、保压时间为1.5min条件下干压成型得到坯体;然后将坯体干燥后进行烧制,以2℃/min从室温升至500℃,然后以5℃/min从500℃升至1150℃,保温1.5h,即制得透水砖。
实施例三:
1、本实施例一种以日用陶瓷废瓷为原料的透水砖,由基料和低温有机粘结剂组成;基料的原料组成为粒度为0.1~0.5mm的废瓷粉18wt%、0.5~2mm的废瓷粉67wt%、粒度为2~4mm的废瓷粉5wt%、废红砖粉8wt%、淀粉2wt%;低温有机粘结剂的用量为基料的7.5wt%,其组成为浓度5wt%的聚乙烯醇溶液25wt%、聚乙二醇溶液35wt%、水40wt%。
2、本实施例上述以日用陶瓷废瓷为原料的透水砖的制备方法,如图1所示,其步骤如下:
(1)将上述粒度为0.1~0.5mm、0.5~2mm、2~4mm的废瓷粉投入混料机中进行一次干式混合1.5h后,再将淀粉和废红砖粉投入混料机中一起进行二次干式混合1.8h,得到混合干粉;
(2)将上述低温有机粘结剂的各组成快速搅拌1.2h后,得到溶液状低温有机粘结剂;
(3)将上述混合干粉倒入敞口搅拌机中进行低速搅拌,搅拌的同时用喷壶将溶液状低温有机粘结剂均匀喷洒至混合干粉中,喷洒结束后将搅拌机口封闭继续进行低速搅拌2.8h后,陈腐15h,得到待干压物料;
(4)将上述待干压物料置于模具中在压力20MPa、保压时间为2min条件下干压成型得到坯体;然后将坯体干燥后进行烧制,以2℃/min从室温升至500℃,然后以5℃/min从500℃升至1165℃,保温1h,即制得透水砖。
本发明上述实施例中废瓷粉由烧结温度为1250~1320℃、表面釉层厚度为0.5~2.0mm的景德镇日用陶瓷废瓷破碎而成,在制备过程中利用日用陶瓷表面附着的0.5~2.0mm釉层作为原生高温粘结剂即可实现颗粒在高温的粘结(见图2)。废红砖粉为烧制温度为850~950℃的建筑砖块破碎而成,其粒度为0.1~0.5mm。
本发明实施例制备的透水砖(见图3),经国家建筑材料测试中心检测符合GB/T25993-2010中劈裂抗拉强度等级fst4.5、透水系数A级、耐磨性能的技术要求。其性能指标如表1所示。
表1 本发明实施例制备的透水砖的性能指标
Claims (7)
1.一种以日用陶瓷废瓷为原料的透水砖,其特征在于:由基料和低温有机粘结剂组成;所述基料的原料组成为粒度为0.1~0.5mm的废瓷粉10~20wt%、0.5~2mm的废瓷粉55~70wt%、粒度为2~4mm的废瓷粉2~6wt%、废红砖粉8~15wt%、淀粉2~6wt%;所述低温有机粘结剂的用量为基料的5~9wt%,其组成为浓度5wt%的聚乙烯醇溶液20~40wt%、聚乙二醇溶液20~40wt%、水30~50wt%;所述废瓷粉由烧结温度为1250~1320℃、表面釉层厚度为0.5~2.0mm的日用陶瓷废瓷破碎而成。
2.根据权利要求1所述的以日用陶瓷废瓷为原料的透水砖,其特征在于:所述废红砖粉为烧制温度为850~950℃的建筑砖块破碎而成,其粒度为0.1~0.5mm。
3.权利要求1或2所述以日用陶瓷废瓷为原料的透水砖的制备方法,其特征在于包括以下步骤:
(1)将所述粒度为0.1~0.5mm、0.5~2mm、2~4mm的废瓷粉投入混料机中进行一次干式混合后,再将淀粉和废红砖粉投入混料机中一起进行二次干式混合,得到混合干粉;
(2)将所述低温有机粘结剂的各组成搅拌混合后,得到溶液状低温有机粘结剂;
(3)将所述混合干粉和溶液状低温有机粘结剂在搅拌机中进行搅拌混合,陈腐后得到待干压物料;
(4)将所述待干压物料置于模具中干压成型得到坯体;然后将坯体干燥后进行烧制,以2℃/min从室温升至500℃,然后以5℃/min从500℃升至1130~1165℃,保温0.5~2h,即制得透水砖。
4.根据权利要求3所述的以日用陶瓷废瓷为原料的透水砖的制备方法,其特征在于:所述步骤(1)中一次干式混合的时间为1~2h,二次干式混合的时间为1~2h。
5.根据权利要求3所述的以日用陶瓷废瓷为原料的透水砖的制备方法,其特征在于:所述步骤(2)中搅拌混合时间为1~2h。
6.根据权利要求3所述的以日用陶瓷废瓷为原料的透水砖的制备方法,其特征在于:所述步骤(3)中溶液状低温有机粘结剂的加入方式为在搅拌的同时将溶液状低温有机粘结剂均匀喷洒至混合干粉中;喷洒结束后继续搅拌混合2~3h,然后陈腐15~24h。
7.根据权利要求3所述的以日用陶瓷废瓷为原料的透水砖的制备方法,其特征在于:所述步骤(4)中干压成型的压力为12~20MPa、保压时间为1~2min。
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