CN114409375A - 一种快速烧结轻质硅晶石墙板及制备方法 - Google Patents
一种快速烧结轻质硅晶石墙板及制备方法 Download PDFInfo
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 title claims abstract description 38
- 238000005245 sintering Methods 0.000 title claims abstract description 36
- 239000013078 crystal Substances 0.000 title claims abstract description 18
- 239000000377 silicon dioxide Substances 0.000 title claims abstract description 15
- 238000002360 preparation method Methods 0.000 title abstract description 7
- 239000000463 material Substances 0.000 claims abstract description 32
- 238000000034 method Methods 0.000 claims abstract description 29
- 238000001816 cooling Methods 0.000 claims abstract description 20
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 12
- 239000002245 particle Substances 0.000 claims abstract description 10
- 239000002689 soil Substances 0.000 claims abstract description 10
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 8
- 239000011343 solid material Substances 0.000 claims abstract description 8
- 239000011230 binding agent Substances 0.000 claims abstract description 7
- 239000003245 coal Substances 0.000 claims abstract description 7
- 239000002994 raw material Substances 0.000 claims abstract description 7
- 238000010438 heat treatment Methods 0.000 claims description 50
- 238000000137 annealing Methods 0.000 claims description 12
- 238000001035 drying Methods 0.000 claims description 12
- 238000010304 firing Methods 0.000 claims description 11
- 230000032683 aging Effects 0.000 claims description 10
- 239000006004 Quartz sand Substances 0.000 claims description 8
- 238000001125 extrusion Methods 0.000 claims description 7
- 239000000919 ceramic Substances 0.000 claims description 6
- 238000000227 grinding Methods 0.000 claims description 6
- 238000007670 refining Methods 0.000 claims description 6
- 238000012216 screening Methods 0.000 claims description 6
- 239000002699 waste material Substances 0.000 claims description 6
- 238000005303 weighing Methods 0.000 claims description 6
- 239000010427 ball clay Substances 0.000 claims description 5
- 239000000395 magnesium oxide Substances 0.000 claims description 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 5
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 5
- 238000004321 preservation Methods 0.000 claims description 5
- 229920002472 Starch Polymers 0.000 claims description 4
- CNLWCVNCHLKFHK-UHFFFAOYSA-N aluminum;lithium;dioxido(oxo)silane Chemical compound [Li+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O CNLWCVNCHLKFHK-UHFFFAOYSA-N 0.000 claims description 4
- 229910052642 spodumene Inorganic materials 0.000 claims description 4
- 239000008107 starch Substances 0.000 claims description 4
- 235000019698 starch Nutrition 0.000 claims description 4
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- 239000004375 Dextrin Substances 0.000 claims description 3
- 239000000440 bentonite Substances 0.000 claims description 3
- 229910000278 bentonite Inorganic materials 0.000 claims description 3
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 claims description 3
- 235000019425 dextrin Nutrition 0.000 claims description 3
- FPAFDBFIGPHWGO-UHFFFAOYSA-N dioxosilane;oxomagnesium;hydrate Chemical compound O.[Mg]=O.[Mg]=O.[Mg]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O FPAFDBFIGPHWGO-UHFFFAOYSA-N 0.000 claims description 3
- 229920003063 hydroxymethyl cellulose Polymers 0.000 claims description 2
- 229940031574 hydroxymethyl cellulose Drugs 0.000 claims description 2
- 239000002910 solid waste Substances 0.000 claims description 2
- 238000003756 stirring Methods 0.000 claims description 2
- 239000010456 wollastonite Substances 0.000 claims description 2
- 229910052882 wollastonite Inorganic materials 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 5
- 239000004566 building material Substances 0.000 abstract description 3
- 238000005265 energy consumption Methods 0.000 abstract description 3
- 239000010881 fly ash Substances 0.000 abstract description 3
- -1 river and lake silt Substances 0.000 abstract description 3
- 239000010802 sludge Substances 0.000 abstract description 3
- 239000000126 substance Substances 0.000 abstract description 3
- 238000002156 mixing Methods 0.000 abstract description 2
- 238000009825 accumulation Methods 0.000 abstract 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 13
- 229910052710 silicon Inorganic materials 0.000 description 13
- 239000010703 silicon Substances 0.000 description 13
- 239000004575 stone Substances 0.000 description 7
- 238000001514 detection method Methods 0.000 description 4
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- 238000005336 cracking Methods 0.000 description 1
- 238000013467 fragmentation Methods 0.000 description 1
- 238000006062 fragmentation reaction Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 238000010583 slow cooling Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000010257 thawing Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
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Abstract
本发明涉及绿色建筑材料技术领域,具体涉及一种快速烧结轻质硅晶石墙板及制备方法。墙板由固体物料与水按照1:0.1~0.2的重量比例混合而成;按重量百分含量计,所述固体物料由15%~40%骨料、55%~75%塑性料、15%~20%助熔剂、3%~15%粘结剂组成。与现有技术相比,本发明以页岩、煤矸石、粉煤灰、建筑渣土、江河湖淤泥、污泥等为主要原料,生产更加环保,通过调整颗粒骨料级配,形成致密均匀堆积,减少坯体内部结构间隙,降低产品在快速烧结及降温过程中出现各类裂纹的情况,烧结周期减少40%以上,降低单位产品的能源消耗,提升单线生产效率,制备的产品各项理化指标均满足实际需求,产品表观质量优异。
Description
技术领域
本发明涉及绿色建筑材料技术领域,具体涉及一种快速烧结轻质硅晶石墙板及制备方法。
背景技术
快速烧结轻质硅晶石墙板是以页岩、煤矸石、粉煤灰、建筑渣土、江河湖淤泥、污泥等为主要原料,经挤出成型、干燥和焙烧制成的、含有孔洞的预制空心条板。产品具有轻质高强、保温隔热、防水防潮、隔音降噪、防火耐久、抗冻融、易切割加工等优质性能,在装配式建筑背景下,产品可广泛应用在装配式墙体工程施工中,是一种新型环保绿色高端建材。
传统硅晶石烧结采用最快的辊道窑烧结周期为20h,由于产品的烧结周期长,导致单线产能低,投入产出比低,导致产品综合成本较高,影响产品在装配式领域大范围推广应用。
快速烧结轻质硅晶石墙板烧结需要经过预热、中温、高温、保温、急冷、缓冷、尾冷几个阶段完成烧结全部过程,其中预热、保温、和各段冷却需要严格控制,否则产品容易出现隐裂、开裂、通裂、碎裂等问题,因此亟需开发一种可以快速升温、降温的快速烧结轻质硅晶石墙板产品。
发明内容
为解决背景技术中提到的问题,本发明提供一种快速烧结轻质硅晶石墙板及制备方法,实现了降低单位产品的能源消耗,提升单线生产效率,降低产品在快速烧结及降温过程中出现各类裂纹的情况,各项理化指标均满足实际需求。
一方面,本发明提供一种快速烧结轻质硅晶石墙板,关键在于:由固体物料与水按照1:0.1~0.2的重量比例混合而成;按重量百分含量计,所述固体物料组成如下:
骨料15%~40%;
塑性料55%~75%;
助熔剂15%~20%;
粘结剂3%~15%;
所述助熔剂包括锂辉石、氧化镁、硅灰石、滑石粉等中的一种或多种。
优选的,所述骨料为建筑渣土、陶瓷废渣、石英砂尾渣等固体废物中的一种或多种。
优选的,所述塑性料包括煤矸石、膨润土、球粘土或页岩中的一种或多种;
优选的,所述粘结剂包括羟甲基纤维素、糊精、淀粉等中的一种或多种。
另一方面,本发明提供一种快速烧结轻质硅晶石墙板的制备方法,关键在于包括以下步骤:
S1.将各固体物料通过破碎机破碎、过筛、粉磨,得到不同粒度级配的各类物料;
S2.将各类物料按照配方准确称量并依次添加进入混料机,再向混料机里面加水,然后搅拌混匀;
S3.将混合均匀的原料进行陈腐,陈腐时间≥12h,经过陈腐合格的泥料经炼泥后获得料性均匀的泥料,泥料水分控制在10~20%;
S4.将陈腐练泥之后的塑性泥料经挤压、切割成坯体产品,挤出压力控制在1.5~3MPa;
S5.将坯体产品水分控制为10~18%时,进入干燥器内进行干燥,干燥后坯体水分控制在≤1%;
S6.将干燥的坯体放入窑炉中按照烧成工艺曲线进行烧成,在4h内从室温升至750℃,在2h内从750℃升至1020℃,在1020℃保温0-1h后,在3h内退火,得到成品。
优选的,S1中所述骨料的粒度为8~275目,所述塑性料的粒度为20~40目,所述助熔剂的粒度为40~300目,所述粘结剂的粒度为40~300目。
优选的,S5中干燥条件为:干燥最高温度为150℃,干燥速率为1~5℃/min,干燥保温时间3h~24h。
优选的,S6中从室温~750℃为:先以5~8℃/min的升温速率升温至300℃;再以4~6℃/min的升温速率升温至600℃;然后以3~5℃/min的升温速率升温至750℃。
优选的,S6中750℃~1020℃的升温速率为2.5~4.5℃/min。
优选的,S6中退火工艺采用8~15℃/min的降温速率从烧成温度降至200℃,然后采用5~8℃/min的降温速率降至室温。
与现有技术相比,本发明提供的一种快速烧结轻质硅晶石墙板及制备方法,具有以下有益效果:
(1)本申请中的快速烧结轻质硅晶石墙板以页岩、煤矸石、粉煤灰、建筑渣土、江河湖淤泥、污泥等为主要原料,生产更加环保;
(2)通过调整产品配方中的助熔剂原料的种类,降低硅晶石坯体的烧结温度,调整颗粒骨料级配,形成致密均匀堆积,减少坯体内部结构间隙,加快产品高温热传递同时配合提升配方中耐热振性能良好的原料,降低产品在快速烧结及降温过程中出现各类裂纹的情况,减少产品的烧成整体周期,从而实现产品在不增加设备的情况下快速烧结工艺得以实现;
(2)本发明的工艺方法使烧结周期减少40%以上,降低单位产品的能源消耗,提升单线生产效率,制备的产品各项理化指标均满足实际需求,产品表观质量优异,产品容重≤1000kg/m3,抗压强度超过4MPa,符合装配式轻质墙体材料的使用需求。
具体实施方式
为了使本发明的目的、技术方案和优点更加清楚,下面结合具体实施例对本发明进行详细描述。在此,还需要说明的是,为了避免因不必要的细节而模糊了本发明,在具体实施例中仅仅示出了与本发明的方案密切相关的结构和/或处理步骤,而省略了与本发明关系不大的其他细节。
另外,还需要说明的是,术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含,从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素,而且还包括没有明确列出的其他要素,或者是还包括为这种过程、方法、物品或者设备所固有的要素。
实施例1
首先选取均化处理调整后的建筑渣土、陶瓷废渣、石英砂尾矿分别装入破碎机进行破碎,然后再用雷蒙磨进行粉磨、筛分;将得到的不同碎石级配的物料按照配方称量:其中8~275目的混合渣土共计150kg,20~40目的煤矸石150kg、20~40目的膨润土400kg,40~300目的滑石粉150kg、40~300目的甲基纤维素100kg、40~300目的糊精50kg配方称取倒入混料机,然后加入150kg水进行高速搅拌;将混合均匀的物料陈腐14h,经过陈腐炼泥,得到具有均匀成分的泥料,然后将泥料送至真空挤出机中挤出成型,成型压力1.6MPa,成型后坯体在150℃下干燥5h;
将干燥合格的坯体放入辊道窑炉中按照烧成工艺曲线进行烧成,在3.5h内从室温升温至750℃,其中,先以5℃/min的升温速率升温至300℃;再以4℃/min的升温速率升温至600℃,然后以3℃/min的升温速率升温至750℃;然后在1.8h内以2.5℃/min的升温速率从750℃升温至1020℃,在1020℃保温1h后,在2.6h内退火冷却出窑,其中,退火工艺采用8~15℃/min的降温速率从烧成温度降至200℃,然后采用5℃/min的降温速率降至室温,产品整体烧结周期8.9h完成,得到快速烧结轻质硅晶石墙板成品。
检测结果:快速烧结轻质硅晶石墙板容重为890kg/m3,抗压强度为8MPa。
实施例2
首先选取均化处理调整后的建筑渣土、陶瓷废渣、石英砂尾矿分别装入破碎机进行破碎,然后再用雷蒙磨进行粉磨、筛分;将得到的不同碎石级配的物料按照配方称量:其中8~275目的混合渣土共计210kg,20~40目的煤矸石250kg、20~40目的球粘土300kg,40~300目的氧化镁180kg、40~300目的甲基纤维素60kg配方称取倒入混料机,然后加入170kg水进行高速搅拌;将混合均匀的物料陈腐16h,经过陈腐炼泥,得到具有均匀成分的泥料,然后将泥料送至真空挤出机中挤出成型,成型压力2.3MPa,成型后坯体在150℃下干燥8h;
将干燥合格的坯体放入辊道窑炉中按照烧成工艺曲线进行烧成,在3.8h从室温升温至750℃,其中,先以8℃/min的升温速率升温至300℃;再以6℃/min的升温速率升温至600℃,然后以5℃/min的升温速率升温至750℃;然后在1.6h内以4.5℃/min的升温速率从750℃~1020℃,1030℃保温0.8h,在2.8h内冷却退火出窑,其中,退火工艺采用15℃/min的降温速率从烧成温度降至200℃,然后采用8℃/min的降温速率降至室温,产品整体烧结周期9h完成,得到快速烧结轻质硅晶石墙板成品。
检测结果:快速烧结轻质硅晶石墙板容重为795kg/m3,抗压强度为6.8MPa。
实施例3
首先选取均化处理调整后的建筑渣土、陶瓷废渣、石英砂尾矿分别装入破碎机进行破碎,然后再用雷蒙磨进行粉磨、筛分;将得到的不同碎石级配的物料按照配方称量:其中8~275目的混合渣土共计220kg,20~40目的石英砂尾矿160kg、20~40目的球粘土390kg,40~300目的氧化镁80kg、40~300目的锂辉石80kg,40~300目的淀粉70kg配方称取倒入混料机,然后加入175kg水进行高速搅拌;将混合均匀的物料陈腐18h,经过陈腐炼泥,得到具有均匀成分的泥料,然后将泥料送至真空挤出机中挤出成型,成型压力2.6MPa,成型后坯体在150℃下干燥12h;
将干燥合格的坯体放入辊道窑炉中按照烧成工艺曲线进行烧成,在3.2h内从室温升温至750℃,其中,先以6℃/min的升温速率升温至300℃;再以5℃/min的升温速率升温至600℃,然后以4℃/min的升温速率升温至750℃;在1.8h内以3.5℃/min的升温速率从750℃升温至1050℃,1050℃保温0.9h,在3h内冷却退火出窑,其中,退火工艺采用10℃/min的降温速率从烧成温度降至200℃,然后采用6℃/min的降温速率降至室温,产品整体烧结周期8.9h完成,得到快速烧结轻质硅晶石墙板成品。
检测结果:快速烧结轻质硅晶石墙板容重为959kg/m3,抗压强度为13.6MPa。
实施例4
首先选取均化处理调整后的建筑渣土、陶瓷废渣、石英砂尾矿分别装入破碎机进行破碎,然后再用雷蒙磨进行粉磨、筛分;将得到的不同碎石级配的物料按照配方称量:其中8~275目的混合渣土共计220kg,20~40目的石英砂尾矿160kg、20~40目的球粘土390kg,40~300目的氧化镁80kg、40~300目的锂辉石80kg,40~300目的淀粉70kg配方称取倒入混料机,然后加入200kg水进行高速搅拌;将混合均匀的物料陈腐15h,经过陈腐炼泥,得到具有均匀成分的泥料,然后将泥料送至真空挤出机中挤出成型,成型压力3.0MPa,成型后坯体在150℃下干燥24h;
将干燥合格的坯体放入辊道窑炉中按照烧成工艺曲线进行烧成,在4h内从室温升温至750℃,其中,先以6℃/min的升温速率升温至300℃;再以5℃/min的升温速率升温至600℃,然后以4℃/min的升温速率升温至750℃;在2h内以3.5℃/min的升温速率从750℃升温至1050℃,1050℃保温1h,在3h内冷却退火出窑,其中,退火工艺采用10℃/min的降温速率从烧成温度降至200℃,然后采用6℃/min的降温速率降至室温,产品整体烧结周期10h完成,得到快速烧结轻质硅晶石墙板成品。
检测结果:快速烧结轻质硅晶石墙板容重为970kg/m3,抗压强度为14.7MPa。
最后说明的是,以上实施例仅用以说明本发明的技术方案而非限制,尽管参照较佳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当理解,可以对本发明的技术方案进行修改或者等同替换,而不脱离本发明技术方案的宗旨和范围,其均应涵盖在本发明的权利要求范围当中。
Claims (10)
1.一种快速烧结轻质硅晶石墙板,其特征在于由固体物料与水按照1:0.1~0.2(0.15、0.17)的重量比例混合而成;按重量百分含量计,所述固体物料组成如下:
骨料15%~40%;
塑性料55%~75%;
助熔剂15%~20%;
粘结剂3%~15%;
所述助熔剂包括锂辉石、氧化镁、硅灰石、滑石粉等中的一种或多种。
2.根据权利要求1所述的一种快速烧结轻质硅晶石墙板,其特征在于:所述骨料为建筑渣土、陶瓷废渣、石英砂尾渣等固体废物中的一种或多种。
3.根据权利要求1所述的一种快速烧结轻质硅晶石墙板,其特征在于:所述塑性料包括煤矸石、膨润土、球粘土或页岩中的一种或多种。
4.根据权利要求1所述的一种快速烧结轻质硅晶石墙板,其特征在于:所述粘结剂包括羟甲基纤维素、糊精、淀粉等中的一种或多种。
5.一种如权利要求1-4任一项所述的一种快速烧结轻质硅晶石墙板的制备方法,其特征在于包括以下步骤:
S1.将各固体物料通过破碎机破碎、过筛、粉磨,得到不同粒度级配的各类物料;
S2.将各类物料按照配方准确称量并依次添加进入混料机,再向混料机里面加水,然后搅拌混匀;
S3.将混合均匀的原料进行陈腐,陈腐时间≥12h,经过陈腐合格的泥料经炼泥后获得料性均匀的泥料,泥料水分控制在10~20%;
S4.将陈腐练泥之后的塑性泥料经挤压、切割成坯体产品,挤出压力控制在1.5~3MPa;(1.6、2.3)
S5.将坯体产品水分控制为10~18%时,进入干燥器内进行干燥,干燥后坯体水分控制在≤1%;
S6.将干燥的坯体放入窑炉中按照烧成工艺曲线进行烧成,在4h内从室温升至750℃,在2h内从750℃升至1020℃,在1020℃保温0-1h后,在3h内退火,得到成品。
6.根据权利要求5所述的快速烧结轻质硅晶石墙板的制备方法,其特征在于S1中所述骨料的粒度为8~275目,所述塑性料的粒度为20~40目,所述助熔剂的粒度为40~300目,所述粘结剂的粒度为40~300目。
7.根据权利要求5所述的快速烧结轻质硅晶石墙板的制备方法,其特征在于S5中干燥条件为:干燥温度为150℃,干燥保温时间3h~24h。
8.根据权利要求5所述的快速烧结轻质硅晶石墙板的制备方法,其特征在于S6中从室温~750℃为:先以5~8℃/min的升温速率升温至300℃;再以4~6℃/min的升温速率升温至600℃;然后以3~5℃/min的升温速率升温至750℃。
9.根据权利要求5所述的快速烧结轻质硅晶石墙板的制备方法,其特征在S6中750℃~1020℃的升温速率为2.5~4.5℃/min。
10.根据权利要求5所述的快速烧结轻质硅晶石墙板的制备方法,其特征在S6中退火工艺采用8~15℃/min的降温速率从烧成温度降至200℃,然后采用5~8℃/min的降温速率降至室温。
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