CN113929433A - Low-clay system high-whiteness ceramic plate and preparation method thereof - Google Patents
Low-clay system high-whiteness ceramic plate and preparation method thereof Download PDFInfo
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Abstract
The invention provides a low-clay system high-whiteness ceramic plate and a preparation method thereof. The high-whiteness ceramic plate comprises a base mineral, an inorganic binder and micro-expanded alumina serving as a whitening agent; wherein the inorganic binder accounts for 3-8% of the basic mineral by mass, and the whitening agent accounts for 2-4% of the basic mineral by mass. The low-clay system high-white ceramic plate reduces impurity intervention, micro-expansion aluminum oxide cannot be melted in the firing process of a ceramic body, a plurality of interfaces can be formed in the ceramic with a glass phase, and light is reflected and refracted greatly at the interfaces, so that a good opacifying effect is achieved, and a large ceramic plate with the whiteness of over 80 degrees and the radioactivity index within the national standard range is obtained.
Description
Technical Field
The invention relates to a low-clay system high-whiteness ceramic plate and a preparation method thereof, and belongs to the field of building ceramics.
Background
With the improvement of living standard, people pay more and more attention to the pursuit of health and beauty. The high-whiteness ceramic plate is simple, attractive and large, can be used for traditional wall and ground decoration, and has wide market prospect in the fields of high-rise building curtain walls, household panels and the like. The whiteness of the existing ceramic plate is low and is usually more than 60 degrees, and the pursuit of people for high-grade products cannot be met. In order to realize whitening, zirconium silicate is generally introduced into a ceramic raw material, but the zirconium silicate has strong radioactivity, so that the radioactive index of a high-whiteness ceramic product exceeds the standard, and the development concept of green and health is not met. In addition, the clay belongs to non-renewable resources, and as clay resources are increasingly scarce along with the continuous development of the ceramic industry, the replaceable clay is increasingly difficult to obtain, which brings great difficulty to the stable production of ceramic products.
Disclosure of Invention
The invention provides a low-clay system high-whiteness ceramic plate and a preparation method thereof, aiming at solving the production fluctuation caused by low whiteness, overproof radioactive index and scarcity of clay resources of the ceramic plate. The low-clay system high-white ceramic plate reduces impurity intervention, micro-expansion aluminum oxide cannot be melted in the firing process of a ceramic body, a plurality of interfaces can be formed in the ceramic with a glass phase, and light is reflected and refracted greatly at the interfaces, so that a good opacifying effect is achieved, and a large ceramic plate with the whiteness of over 80 degrees and the radioactivity index within the national standard range is obtained.
In a first aspect, the invention provides a low clay system high-whiteness ceramic plate. The high-whiteness ceramic plate comprises a base mineral, an inorganic binder and micro-expanded alumina serving as a whitening agent; the chemical composition of the basic mineral comprises: to be provided withIn mass percent, SiO2 69.0～72.6％、Al2O3 15.5～17.0％、Fe2O3 0.18～0.20％、TiO2 0.03～0.05％、CaO 0.22～0.28％、MgO 0.51～0.65％、K2O 2.8～4.0％、Na23.0-4.5% of O; wherein the inorganic binder accounts for 3-8% of the basic mineral by mass, and the whitening agent accounts for 2-4% of the basic mineral by mass.
Preferably, the particle size of the micro-expanded alumina is 400 to 700 nm.
Preferably, the base mineral comprises: 9-12% of kaolin, 22-27% of water milled sand, 25-30% of white sand, 1.5-3.0% of calcined talc, 10-15% of water milled potassium feldspar, 15-21% of high-white albite, 1-5% of high-white clay and 2-6% of high-white bentonite in percentage by mass.
Preferably, the melting temperature of the basic mineral of the high-whiteness ceramic plate is 1180-1210 ℃.
Preferably, the inorganic binder is at least one of water glass and silica sol.
Preferably, an interface is formed between the micro-expanded alumina and a glass phase formed by the base mineral during the firing process of the ceramic plate, and light is reflected and refracted at the interface so as to opacify and whiten.
Preferably, the whiteness of the ceramic plate is more than 80 degrees.
In a second aspect, the present invention provides a method for preparing the low clay system high-whiteness ceramic plate. The preparation method comprises the following steps:
adding water into the basic mineral of the high-whiteness ceramic plate, an inorganic binder and micro-expanded alumina serving as a whitening agent, and uniformly ball-milling to obtain ceramic slurry;
removing iron from the ceramic slurry to control the content of iron element in the slurry to be below 0.1 wt%;
spraying powder to the slurry after iron removal and granulating to prepare blank powder;
and preparing the blank powder into a high-whiteness ceramic plate according to a conventional process.
Preferably, the ceramic slurry further comprises a suspending agent accounting for 0.2-0.4% of the base mineral by mass and a dispergator accounting for 0.3-0.5% of the base mineral by mass.
Preferably, the flow rate of the ceramic slurry is 30 to 65s, and the specific gravity is 1.75 to 1.86 g/mL.
Drawings
FIG. 1 is an SEM image of a micro-expanded alumina;
fig. 2 is an SEM image of the low clay system high white ceramic plate of example 1.
Detailed Description
The present invention is further illustrated by the following examples, which are to be understood as merely illustrative of, and not restrictive on, the present invention. Unless otherwise specified, each percentage means a mass percentage.
The following is an exemplary illustration of the low clay system high-whiteness ceramic plate and the preparation method thereof according to the present invention.
The high-whiteness ceramic plate comprises a base mineral, an inorganic binder and micro-expanded alumina as a whitening agent. Wherein the chemical composition of the base mineral comprises: by mass percent, SiO2 69.0～72.6％、Al2O3 15.5～17.0％、Fe2O3 0.18～0.20％、TiO2 0.03～0.05％、CaO 0.22～0.28％、MgO 0.51～0.65％、K2O 2.8～4.0％、Na23.0 to 4.5 percent of O. The content of the colored ferrotitanium element is far lower than that of the conventional ceramic body formula, so that the whiteness loss of the body caused by excessive ferrotitanium is avoided. In addition, the base mineral controls the content of silicon and aluminum within a proper range, and is beneficial to forming a blank body and maintaining the excellent mechanical properties of the blank body.
In some embodiments, the base mineral comprises: 9-12% of kaolin, 22-27% of water milled sand, 25-30% of white sand, 1.5-3.0% of calcined talc, 10-15% of water milled potassium feldspar, 15-21% of high-white albite, 1-5% of high-white clay and 2-6% of high-white bentonite in percentage by mass. Metakaolin refers to kaolin of high age having high whiteness, high strength and excellent plasticity. In some embodiments, the chemical composition of the metakaolin comprises: by mass percent, SiO2 55～65％、Al2O322～30％、Fe2O3 0.3～0.6％、TiO2 0.01～0.1％、CaO 0.01～0.04％、MgO 0.2～0.5％、K2O 1～3％、Na20.1 to 0.5 percent of O. By way of example, the chemical composition of the metakaolin includes: by mass percent, SiO2 59.88％、Al2O3 28.01％、Fe2O3 0.42％、TiO2 0.02％、CaO 0.06％、MgO 0.24％、K2O 1.55％、Na20.28 percent of O. The use of high-whiteness minerals is selected, the clay usage amount is reduced, and the introduction of coloring ions (particularly iron titanium ions) is limited to improve the whiteness of the blank body.
Different from the common calcined alumina, the micro-expanded alumina is light-calcined alumina, contains a small amount of organic components, can be gradually oxidized and release gas in the green body sintering process, so that the porosity of the green body is increased (for example, see fig. 2), the reflection and refraction of light at the air holes when the light passes through the green body are enhanced, the whiteness of the green body is further improved, and the density of the green body is slightly changed without obviously influencing the strength of the green body.
The melting temperature of the micro-expanded alumina is higher, and is above 2000 ℃ (usually about 2054 ℃). But the melting temperature of the basic mineral of the high-whiteness ceramic plate is 1180-1210 ℃. Therefore, the micro-expansion aluminum oxide can not be melted in the firing process of the ceramic body, and can form a plurality of interfaces with the glass phase in the ceramic, and light is reflected and refracted greatly at the interfaces, thereby achieving good opacifying effect and improving the whiteness of the body. Although ordinary alumina such as calcined alumina can also play a certain whitening role, the organic components of the micro-expanded alumina form micro pores in the system under the same using amount, so that the opacifying whitening effect on the ceramic body is more remarkable.
The particle size of the micro-expansion alumina is 400-700 nm. The particle size of the micro-expanded alumina is within the range of visible light (400-700 nm). Because the size of the barrier (micro-expanded alumina) is close to the wavelength of incident light, the barrier has stronger scattering effect on the light, the light transmission is reduced, and the reflection effect is further enhanced.
The mass percentage of the micro-expanded alumina in the basic mineral is 2-4%. The micro-expanded alumina accounts for less than 2 percent of the basic mineral by mass, and the whitening effect is not obvious; the micro-expansion alumina accounts for more than 4 percent of the basic mineral by mass, can greatly influence the firing temperature of a ceramic body, causes the body to be green fired under the current kiln firing system to influence the ceramic of the body, and causes the basic physical and chemical properties of the ceramic plate to be attenuated and not to meet the industrial standard.
The source of the micro-expanded alumina is not limited, and the micro-expanded alumina can be self-made through the existing patents, books, periodicals and the like, and can also be purchased through commercial routes. In a specific embodiment, a slightly expanded alumina, model PG-2-1, from Zibonoda chemical Co., Ltd, is used.
Clay is used as the main plastic aggregate in the ceramic formula. Low clay content can lead to insufficient plasticity of the formulation and thus affect green strength. By introducing the inorganic binder, the binding and combination among the raw materials of the basic mineral are promoted, and the green strength is improved to reduce the green body breakage rate. The inorganic binder includes but is not limited to at least one of water glass and silica sol. As an example, the solid content of the silica sol is 25-30%. In some embodiments, the silica in the silica sol has a particle size of 10 to 30 nm.
The inorganic binder accounts for 3-8% of the basic mineral by mass. The addition amount of the inorganic binder is too small, and the reinforcing effect of the green body is not obvious; after the addition amount of the inorganic binder is more than 8 percent, the strength of the green body is basically kept unchanged.
The invention also provides a preparation method of the low-clay system high-whiteness ceramic plate.
Respective raw materials of the ceramic slurry were prepared. Besides a base mineral, an inorganic binder and micro-expanded alumina serving as a whitening agent, the ceramic slurry also comprises a suspending agent accounting for 0.2-0.4% of the base mineral by mass and a dispergator accounting for 0.3-0.5% of the base mineral by mass. The composition of the suspending agent and the debonding agent is not limited. As an example, the suspending agent is at least one of sodium carboxymethyl cellulose and polyvinyl alcohol; the dispergator is at least one of sodium tripolyphosphate and sodium metasilicate.
And (5) ball-milling to obtain slurry. The ball mill is cleaned before feeding to reduce the influence of impurities on the purity of the slurry. Adding the raw materials into a ball mill according to the composition of the ceramic slurry, adding water, and ball-milling to a specified fineness to obtain the ceramic slurry. The order of addition of the raw materials does not substantially affect the properties of the slurry. The fineness of the slurry is 1.8-2.3 wt% of the residue of a 325-mesh screen.
Preferably, the ball lining used for ball milling is high-alumina ball lining with alumina content more than 90%. Thus, the ball milling loss can be reduced, and the intervention of abrasion impurities is avoided. In the ball milling process, the mass ratio of the raw materials of the ceramic slurry, the ball stone ball lining and the water can be adjusted according to actual needs.
The flow rate of the ceramic slurry is 30-65 s, and the specific gravity is 1.75-1.86 g/ml. The flow rate test method comprises the following steps: leveling the flow velocity cup, wiping the flow velocity cup with a wet rag to slightly moisten the inner surface of the flow velocity cup, pressing the outlet of the flow velocity cup with a middle finger, slowly pouring the pulp into the flow velocity cup until the surface of the pulp forms a convex liquid surface, leveling the pulp until the pulp surface and the mouth of the flow velocity cup are on the same plane, then loosening the middle finger, pressing on the stopwatch while pressing on the stopwatch, and pressing the stopwatch in time when the pulp flows to drip, wherein the reading on the stopwatch is the pulp flow velocity. The inner diameter of the mouth of the flow cup is 68mm, and the outer diameter is 75 mm.
And removing iron from the slurry. The magnetic induction intensity reaches more than 15000Gs and the electromagnetic iron remover with uniform and stable magnetic field is used for removing iron from the ceramic slurry. The number of iron removal operations can be adaptively adjusted as desired. The iron content in the ceramic slurry after iron removal is controlled to be below 0.1 wt%. And the ceramic slurry after iron removal enters a large tank for aging.
And (4) spray granulation. And (4) carrying out spray granulation on the ceramic slurry subjected to iron removal and aging homogenization. The energy source used by the spray tower uses natural gas to replace coal water slurry so as to further reduce the introduction of impurities. And putting the blank powder obtained by spray granulation into a storage bin for further aging and homogenizing for later use.
And preparing the ceramic plate by using the blank powder. For example, the green body powder is pressed into a shape, glazed, ink-jet printed, fired and polished to obtain the high-whiteness ceramic plate. The glazing, ink-jet printing, firing and polishing procedures are all conventional operations in the field and are not the creation of the invention. In the embodiment, the maximum firing temperature is 1180-1210 ℃, and the firing period is 58-80 min.
The whiteness of the low-clay system high-white ceramic plate exceeds 80 degrees.
Chinese patent CN113087508A mentions the introduction of alpha-alumina and silica sand to react the silica-alumina at high temperature to form mullite phase and simultaneously react with the magnesium in the formulation to form cordierite phase; the cordierite phase in the green body improves the whiteness and the toughness of the green body and reduces the expansion coefficient of the green body. Although the technical scheme can obtain a high-whiteness and high-transparency green body, the green body is easy to deform because the high-temperature liquid phase viscosity is slightly low in the sintering process due to excessive flux materials. Particularly, the proportion of the high-temperature material quartz sand to the alpha-alumina is equivalent, and the flux type raw material consisting of a large amount of talc and feldspar is contained, so that the variety of the raw material is few, and the fluctuation of the whole formula is large. Unlike the scheme in which alpha-alumina participates in the formation of the ceramic crystalline phase, micro-expanded alumina has a different role in the formulation system of the present invention. The micro-expansion alumina has a small addition amount which only accounts for 2-4% of the basic mineral, and the addition amount of the flux material in the formula is also low, so that the micro-expansion alumina is not melted in the sintering process, and a large amount of alumina crystallites (the alumina crystallites are presented in a corundum form in an XRD (X-ray diffraction) diagram) can be formed in a ceramic phase and a glass phase by keeping the original phase. Due to the non-uniformity of the refractive index of alumina and other phases (especially glass phases), light is refracted and reflected when passing through, macroscopically manifested as an increase in the whiteness of the green body.
In some embodiments, the high-whiteness ceramic plate of the present invention has a width (600 to 900) mm, a length (900 to 1800) mm, and a thickness (11.5 to 13.5) mm.
It is also stated that zirconium silicate is commonly used in the prior art as a whitening opacifier, for example, zirconium silicate is used in the whitening glaze of porcelain tiles to produce fine zircon grains, which scatter light to produce opaque white glaze. Besides causing the radioactivity of ceramic products to exceed the standard, the size and precipitation of zircon grains have great influence on the whitening effect, the size of the zircon grains is difficult to control in the actual production process, and the zirconium silicate is dispersed on the surface of a glaze layer due to the use of the zirconium silicate in the glaze, so that the scattering degree of light at each part of the surface is inconsistent, and the whiteness fluctuation of the glaze surface is large. The invention adds the micro-expansion alumina into the blank, which is beneficial to realizing uniform whitening. In addition, although the addition of the micro-expanded alumina slightly increases the firing temperature of the green body, the firing temperature can adapt to the current firing system through the blending of basic minerals, particularly low-temperature flux, and the method has industrial universality.
The present invention will be described in detail by way of examples. It is also to be understood that the following examples are illustrative of the present invention and are not to be construed as limiting the scope of the invention, and that certain insubstantial modifications and adaptations of the invention by those skilled in the art may be made in light of the above teachings. The specific process parameters and the like of the following examples are also only one example of suitable ranges, i.e., those skilled in the art can select the appropriate ranges through the description herein, and are not limited to the specific values exemplified below.
Example 1
The preparation method of the low-clay system high-whiteness ceramic plate comprises the following steps:
s1: respective raw materials of the ceramic slurry were prepared. The raw materials comprise a base mineral of a high-whiteness ceramic plate, an inorganic binder and micro-expanded alumina as a whitening agent. The basic minerals of the high-white ceramic plate include: 9-12% of kaolin, 22-27% of water milled sand, 25-30% of white sand, 1.5-3.0% of calcined talc, 10-15% of water milled potassium feldspar, 15-21% of high-white albite, 1-5% of high-white fine clay and 2-6% of high-white bentonite by mass percentage. The inorganic binder accounts for 3-8% of the basic mineral by mass. The micro-expansion alumina accounts for 2-4% of the mineral by mass. The particle size of the micro-expansion alumina is 400-700 nm. The raw materials also comprise a suspending agent accounting for 0.2-0.4% of the mass percent of the basic minerals and a dispergator accounting for 0.3-0.5% of the mass percent of the basic minerals.
S2: the raw materials are ball-milled and sieved to obtain ceramic slurry. Cleaning the ball mill, adding the raw materials into the ball mill, adding water, and ball-milling to a specified fineness. The used ball lining is high alumina ball lining with alumina content over 90 wt%. The flow rate of the ceramic slurry is 30-65 s, the specific gravity is 1.75-1.86 g/mL, and the screen residue of a 325-mesh net reaches 1.8-2.3 wt%.
S3: and removing iron from the ceramic slurry to control the content of iron element in the slurry after iron removal to be below 0.1 wt%. An electromagnetic iron remover with the magnetic induction intensity of more than 15000Gs and uniform and stable magnetic field is adopted to remove iron from the ceramic slurry, and then the ceramic slurry enters a tank for aging.
S4: spraying powder on the slurry subjected to iron removal and granulating to prepare blank powder. Spraying and granulating the ceramic slurry subjected to iron removal and aging homogenization, and putting the ceramic slurry into a storage bin for further aging homogenization. The energy used by the spray tower is natural gas to replace coal water slurry so as to further reduce impurity intervention.
S5: and preparing the blank powder into a high-whiteness ceramic plate according to a conventional process. And pressing and molding the blank powder, spraying glaze, ink-jet printing, sintering and polishing to obtain the high-whiteness ceramic plate.
The whiteness of the ceramic plate is detected according to a whiteness detection method of a GB/T5950-2008 building material and a nonmetal mineral product, and the water absorption is detected according to the measurement of water absorption, apparent porosity, apparent relative density and volume weight of GB/T3810.3-2006; modulus of rupture was measured according to the determination of modulus of rupture and breaking strength 3810.4-2006. The whiteness of the low-clay system high-whiteness ceramic plate obtained in example 1 was 80 degrees or more, the water absorption was 0.08 wt%, and the modulus of rupture was 43.5 MPa.
Comparative example 1
The preparation method of the high-whiteness ceramic plate comprises the following steps:
s1: respective raw materials of the ceramic slurry were prepared. The raw materials comprise a base mineral of a high-whiteness ceramic plate, an inorganic binder and micro-expanded alumina as a whitening agent. The basic minerals of the high-white ceramic plate include: 9-12% of kaolin, 22-27% of water milled sand, 25-30% of white sand, 1.5-3.0% of calcined talc, 10-15% of water milled potassium feldspar, 15-21% of high-white albite, 1-5% of high-white fine clay and 2-6% of high-white bentonite by mass percentage. The inorganic binder accounts for 3-8% of the basic mineral by mass. The micro-expanded alumina accounts for 5 percent of the mineral by mass. The particle size of the micro-expansion alumina is 400-700 nm. The raw materials also comprise a suspending agent accounting for 0.2-0.4% of the mass percent of the basic minerals and a dispergator accounting for 0.3-0.5% of the mass percent of the basic minerals.
S2: the raw materials are ball-milled and sieved to obtain ceramic slurry. Cleaning the ball mill, adding the raw materials into the ball mill, adding water, and ball-milling to a specified fineness. The used ball lining is high alumina ball lining with alumina content over 90 wt%. The flow rate of the ceramic slurry is 30-65 s, the specific gravity is 1.75-1.86 g/mL, and the screen residue of a 325-mesh net reaches 1.8-2.3 wt%.
S3: and removing iron from the ceramic slurry to control the content of iron element in the slurry after iron removal to be below 0.1 wt%. An electromagnetic iron remover with the magnetic induction intensity of more than 15000Gs and uniform and stable magnetic field is adopted to remove iron from the ceramic slurry, and then the ceramic slurry enters a tank for aging.
S4: spraying powder on the slurry subjected to iron removal and granulating to prepare blank powder. Spraying and granulating the ceramic slurry subjected to iron removal and aging homogenization, and putting the ceramic slurry into a storage bin for further aging homogenization. The energy used by the spray tower is natural gas to replace coal water slurry so as to further reduce impurity intervention.
S5: and preparing the blank powder into a high-whiteness ceramic plate according to a conventional process. And pressing and molding the blank powder, spraying glaze, ink-jet printing, sintering and polishing to obtain the high-whiteness ceramic plate.
The ceramic plate of comparative example 1 had a whiteness of 78.5 degrees, a water absorption of 0.63 wt%, and a modulus of rupture of 28.25mpa. Because the content of the micro-expansion alumina is too high, the firing temperature of the green body formula is higher, the green body is fired, the water absorption of the ceramic plate is increased, and the strength is reduced.
Comparative example 2
The preparation method of the ceramic plate comprises the following steps:
s1: respective raw materials of the ceramic slurry were prepared. The raw materials comprise a base mineral of a high-whiteness ceramic plate, an inorganic binder and micro-expanded alumina as a whitening agent. The basic minerals of the high-white ceramic plate include: 9-12% of kaolin, 22-27% of water milled sand, 25-30% of white sand, 1.5-3.0% of calcined talc, 10-15% of water milled potassium feldspar, 15-21% of high-white albite, 1-5% of high-white fine clay and 2-6% of high-white bentonite by mass percentage. The inorganic binder accounts for 3-8% of the basic mineral by mass. The micro-expansion alumina accounts for 2-4% of the mineral by mass. The particle size of the micro-expansion alumina is 800-1200 nm. The raw materials also comprise a suspending agent accounting for 0.2-0.4% of the mass percent of the basic minerals and a dispergator accounting for 0.3-0.5% of the mass percent of the basic minerals.
S2: the raw materials are ball-milled and sieved to obtain ceramic slurry. Cleaning the ball mill, adding the raw materials into the ball mill, adding water, and ball-milling to a specified fineness. The used ball lining is high alumina ball lining with alumina content over 90 wt%. The flow rate of the ceramic slurry is 30-65 s, the specific gravity is 1.75-1.86 g/mL, and the screen residue of a 325-mesh net reaches 1.8-2.3 wt%.
S3: and removing iron from the ceramic slurry to control the content of iron element in the slurry after iron removal to be below 0.1 wt%. An electromagnetic iron remover with the magnetic induction intensity of more than 15000Gs and uniform and stable magnetic field is adopted to remove iron from the ceramic slurry, and then the ceramic slurry enters a tank for aging.
S4: spraying powder on the slurry subjected to iron removal and granulating to prepare blank powder. Spraying and granulating the ceramic slurry subjected to iron removal and aging homogenization, and putting the ceramic slurry into a storage bin for further aging homogenization. The energy used by the spray tower is natural gas to replace coal water slurry so as to further reduce impurity intervention.
S5: and preparing the blank powder into a high-whiteness ceramic plate according to a conventional process. And pressing and molding the blank powder, spraying glaze, ink-jet printing, sintering and polishing to obtain the high-whiteness ceramic plate.
The whiteness of the ceramic plate of comparative example 2 was 75 degrees. The particle size of the micro-expanded alumina is not in the visible light range, so that the scattering effect on visible light is weakened, and the whiteness of the blank cannot reach more than 80 ℃.
Comparative example 3
The preparation method of the ceramic plate comprises the following steps:
s1: respective raw materials of the ceramic slurry were prepared. The raw materials include the basic minerals of the high-whiteness ceramic plate, the inorganic binder and the calcined alumina. The basic minerals of the high-white ceramic plate include: 9-12% of kaolin, 22-27% of water milled sand, 25-30% of white sand, 1.5-3.0% of calcined talc, 10-15% of water milled potassium feldspar, 15-21% of high-white albite, 1-5% of high-white fine clay and 2-6% of high-white bentonite by mass percentage. The inorganic binder accounts for 3-8% of the basic mineral by mass. The calcined alumina accounts for 2-4% of the mineral by mass. The raw materials also comprise a suspending agent accounting for 0.2-0.4% of the mass percent of the basic minerals and a dispergator accounting for 0.3-0.5% of the mass percent of the basic minerals.
S2: the raw materials are ball-milled and sieved to obtain ceramic slurry. Cleaning the ball mill, adding the raw materials into the ball mill, adding water, and ball-milling to a specified fineness. The used ball lining is high alumina ball lining with alumina content over 90 wt%. The flow rate of the ceramic slurry is 30-65 s, the specific gravity is 1.75-1.86 g/mL, and the screen residue of a 325-mesh net reaches 1.8-2.3 wt%.
S3: and removing iron from the ceramic slurry to control the content of iron element in the slurry after iron removal to be below 0.1 wt%. An electromagnetic iron remover with the magnetic induction intensity of more than 15000Gs and uniform and stable magnetic field is adopted to remove iron from the ceramic slurry, and then the ceramic slurry enters a tank for aging.
S4: spraying powder on the slurry subjected to iron removal and granulating to prepare blank powder. Spraying and granulating the ceramic slurry subjected to iron removal and aging homogenization, and putting the ceramic slurry into a storage bin for further aging homogenization. The energy used by the spray tower is natural gas to replace coal water slurry so as to further reduce impurity intervention.
S5: and preparing the blank powder into a high-whiteness ceramic plate according to a conventional process. And pressing and molding the blank powder, spraying glaze, ink-jet printing, sintering and polishing to obtain the high-whiteness ceramic plate.
The whiteness of the ceramic plate of comparative example 3 was 76 degrees. Because of the lack of a micro-pore structure formed inside organic components in the micro-expanded alumina, the reflection and refraction effects of the ceramic plate on light are weakened, and the whiteness is less than 80 degrees.
Claims (10)
1. The low clay system high-white ceramic plate is characterized in that the high-white ceramic plateComprises a base mineral, an inorganic binder and micro-expanded alumina as a whitening agent; the chemical composition of the basic mineral comprises: by mass percent, SiO269.0~72.6%、Al2O3 15.5~17.0%、Fe2O3 0.18~0.20%、TiO2 0.03~0.05%、CaO 0.22~0.28%、MgO 0.51~0.65%、K2O 2.8~4.0%、Na23.0-4.5% of O; wherein the inorganic binder accounts for 3-8% of the basic mineral by mass, and the whitening agent accounts for 2-4% of the basic mineral by mass.
2. The low-clay system high-whiteness ceramic plate according to claim 1, wherein the particle size of the micro-expanded alumina is 400-700 nm.
3. The low clay system high white ceramic plate according to claim 1 or 2, wherein the base minerals comprise: 9-12% of kaolin, 22-27% of water milled sand, 25-30% of white sand, 1.5-3.0% of calcined talc, 10-15% of water milled potassium feldspar, 15-21% of high-white albite, 1-5% of high-white clay and 2-6% of high-white bentonite in percentage by mass.
4. The low clay system high-white ceramic plate according to any one of claims 1 to 3, wherein a melting temperature of a base mineral of the high-white ceramic plate is 1180-1210 ℃.
5. The low clay system high-white ceramic plate according to any one of claims 1 to 4, wherein the inorganic binder is at least one of water glass and silica sol.
6. The low clay system high-white ceramic plate according to any one of claims 1 to 5, wherein an interface is formed between the micro-expanded alumina and a glass phase formed by a base mineral during firing of the ceramic plate, and light is reflected and refracted at the interface to opacify and whiten the ceramic plate.
7. The low clay system high white ceramic plate according to any one of claims 1 to 6, wherein the whiteness of the ceramic plate is 80 degrees or more.
8. The preparation method of a low clay system high-white ceramic plate according to any one of claims 1 to 7, wherein the preparation method comprises the following steps:
adding water into the basic mineral of the high-whiteness ceramic plate, an inorganic binder and micro-expanded alumina serving as a whitening agent, and uniformly ball-milling to obtain ceramic slurry;
removing iron from the ceramic slurry to control the content of iron element in the slurry to be below 0.1 wt%;
spraying powder to the slurry after iron removal and granulating to prepare blank powder;
and preparing the blank powder into a high-whiteness ceramic plate according to a conventional process.
9. The preparation method according to claim 8, wherein the ceramic slurry further comprises 0.2-0.4% by mass of a suspending agent and 0.3-0.5% by mass of a dispergator based on the base mineral.
10. The method according to claim 8 or 9, wherein the flow rate of the ceramic slurry is 30 to 65 seconds, and the specific gravity is 1.75 to 1.86 g/mL.
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