CN114436629A - 一种轻质硅晶石墙板及制备方法 - Google Patents
一种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 48
- 239000000377 silicon dioxide Substances 0.000 title claims abstract description 23
- 238000002360 preparation method Methods 0.000 title claims abstract description 8
- 239000003245 coal Substances 0.000 claims abstract description 32
- 238000000034 method Methods 0.000 claims abstract description 28
- 238000005245 sintering Methods 0.000 claims abstract description 21
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000002994 raw material Substances 0.000 claims abstract description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 14
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 13
- 239000010703 silicon Substances 0.000 claims abstract description 13
- 239000000446 fuel Substances 0.000 claims abstract description 12
- 239000011230 binding agent Substances 0.000 claims abstract description 11
- 239000012744 reinforcing agent Substances 0.000 claims abstract description 11
- 239000011343 solid material Substances 0.000 claims abstract description 6
- 238000010438 heat treatment Methods 0.000 claims description 63
- 239000000463 material Substances 0.000 claims description 28
- 238000001035 drying Methods 0.000 claims description 21
- 239000000843 powder Substances 0.000 claims description 21
- 239000002699 waste material Substances 0.000 claims description 15
- 239000000919 ceramic Substances 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 14
- 238000001816 cooling Methods 0.000 claims description 12
- 239000002245 particle Substances 0.000 claims description 10
- 239000005995 Aluminium silicate Substances 0.000 claims description 8
- 235000012211 aluminium silicate Nutrition 0.000 claims description 8
- 238000000137 annealing Methods 0.000 claims description 8
- 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 8
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 7
- 230000032683 aging Effects 0.000 claims description 6
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- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 6
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- 229910000281 calcium bentonite Inorganic materials 0.000 claims description 5
- ONCZQWJXONKSMM-UHFFFAOYSA-N dialuminum;disodium;oxygen(2-);silicon(4+);hydrate Chemical compound O.[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Na+].[Na+].[Al+3].[Al+3].[Si+4].[Si+4].[Si+4].[Si+4] ONCZQWJXONKSMM-UHFFFAOYSA-N 0.000 claims description 5
- 238000010304 firing Methods 0.000 claims description 5
- 238000000265 homogenisation Methods 0.000 claims description 5
- 229910000280 sodium bentonite Inorganic materials 0.000 claims description 5
- 229940080314 sodium bentonite Drugs 0.000 claims description 5
- 239000002910 solid waste Substances 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 238000007670 refining Methods 0.000 claims description 3
- 239000002689 soil Substances 0.000 claims description 3
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 2
- 229960000892 attapulgite Drugs 0.000 claims description 2
- 238000007664 blowing Methods 0.000 claims description 2
- 239000011575 calcium Substances 0.000 claims description 2
- 229910052791 calcium Inorganic materials 0.000 claims description 2
- 239000003610 charcoal Substances 0.000 claims description 2
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- 229910052625 palygorskite Inorganic materials 0.000 claims description 2
- 239000010451 perlite Substances 0.000 claims description 2
- 235000019362 perlite Nutrition 0.000 claims description 2
- 239000012286 potassium permanganate Substances 0.000 claims description 2
- 239000010453 quartz Substances 0.000 claims description 2
- 238000010791 quenching Methods 0.000 claims description 2
- 230000000171 quenching effect Effects 0.000 claims description 2
- 229910021487 silica fume Inorganic materials 0.000 claims description 2
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- 238000005265 energy consumption Methods 0.000 abstract description 6
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- 239000011863 silicon-based powder Substances 0.000 description 3
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- 239000010802 sludge Substances 0.000 description 2
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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1:0.08~0.15的重量比例混合而成;按重量百分含量计,所述固体物料由75%~95%骨料、10%~40%燃料、2%~10%增强剂及3%~15%粘结剂组成。与现有技术相比,本发明在烧结的过程中,由于坯体中掺加了煤矸石或精煤等能够通过自身燃烧释放热量的原料,轻质硅晶石墙板可以利用自身产生的一部分热量来降低烧结能耗,将烧结温度降低50~100℃,有效节约了能耗;同时该方法制备出的轻质硅晶石墙板成品率达到90%以上,抗压强度超过20MPa,孔洞率低、防水性能好,其保温性和隔热性都得到显著提高。
Description
技术领域
本发明涉及绿色建筑材料技术领域,具体涉及一种轻质硅晶石墙板及制备方法。
背景技术
大多数建筑用烧结板材都是用粘土、页岩等自然矿物资源制成,但粘土和页岩都是取自地表的上层土,如果长期用自然矿物资源烧结板材,就会破坏耕地、造成耕地的大量荒废;目前市面上的普通烧结板材多为实心或孔洞率小于25%的烧结板材,使得烧结板材的体积密度偏高,不便于现场施工,另一方面实心烧结板材会造成高温烧结能耗较大,而且制得的烧结板材的抗压强度都比较低,难以满足建筑用墙材的性能需求。可见,开发一种新的性能更优、烧结温度更低、更环保的轻质轻质硅晶石墙板具有积极的意义。
发明内容
为解决背景技术中提到的问题,本发明提供一种轻质硅晶石墙板及制备方法,实现了可以利用自身产生的一部分热量来降低烧结能耗,降低烧结温度,并制备达到90%以上成品率,各项理化指标优异,符合装配式轻质墙体材料使用需求的轻质硅晶石墙板。
一方面,本发明提供一种轻质硅晶石墙板,关键在于:由固体物料与水按照1:0.08~0.15的重量比例混合而成;按重量百分含量计,所述固体物料的组成如下:
骨料75%~95%;
燃料10%~40%;
增强剂2%~10%;
粘结剂3%~15%;
所述燃料包括精煤粉、煤矸石、焦炭粉、或木炭粉中的一种或多种。
优选的,所述骨料为建筑渣土、陶瓷废渣、煤矸石、高锰酸钾尾渣等固体废物中的一种或多种。
优选的,所述增强剂包括轻钙粉、矿粉、硅灰、石英粉、滑石粉等中的一种或多种。
优选的,所述粘结剂包括钠基膨润土、钙基膨润土、凹凸棒土、珍珠岩原矿、生高岭土等中的一种或多种。
另一方面,本发明提供一种轻质硅晶石墙板的制备方法,其特征在于:
S1.将各原料进行均化处理,再将骨料进行破碎、过筛、粉磨,得到不同粒度级配的骨料;
S2.按照配方准确称量骨料、燃料、增强剂、粘结剂,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,陈腐时间为3-7d,经过陈腐合格的泥料经进行真空炼泥处理获得料性均匀的泥料;实际操作时,真空炼泥的真空度为0.095~0.1MPa;
S4.将陈腐练泥之后的泥料经真空挤出机挤压后,切割成坯体产品;
S5.将坯体产品水分控制为7~20%时,进入干燥器内进行干燥成型;实际操作时,干燥设备可以选用干燥烘房或干燥窑;
S6.将干燥的坯体放入窑炉中,在750--1050℃下按照工艺烧成曲线进行烧结,保温时间为1-5h,烧结后产品经急冷、缓冷两段窑炉退火工艺,得到成品。实际操作时,窑炉可以选用电窑、梭式窑、隧道窑、辊道窑。
优选的,S1中所述均化处理过程为将不同种类和不同地区的固体废弃物和矿物原料分别放在原料晾晒场,原料经过1~36个月的风吹、日晒、雨淋,然后机械研磨至均匀状态。
优选的,S2中,骨料的粒度为10~20目,燃料的粒度为20~40目,增强剂的粒度为40~300目,粘结剂的粒度为40~300目。
优选的,S5中干燥条件为:在80℃~115℃的温度下干燥3h~24h。
优选的,所述S6中工艺烧成曲线为:从室温升温至700~750℃,之后继续升温至800~850℃,最后升温至900~1050℃,保温1~5h。
优选的,从室温升温至700~750℃为:先以1~3℃/min的升温速率升温至300℃;再以2~5℃/min的升温速率升温至600℃;然后以3~9℃/min的升温速率升温至700~750℃;升温至800~850℃的升温速率为5~10℃/min;升温至900~1050℃的升温速率为5~10℃/min;退火工艺采用5~15℃/min的降温速率从烧成温度降至820℃,然后采用2~4℃/min的降温速率降至室温。
与现有技术相比,本发明提供的一种轻质硅晶石墙板及制备方法,具有以下有益效果:
(1)本申请以一般以页岩、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)通过向轻质硅晶石墙板的原料中加入燃料尤其优选为精煤粉或焦炭粉,经挤出成型、干燥和焙烧制成的、含有孔洞的预制空心条板。在烧结的过程中,由于坯体中掺加了精煤粉或焦炭粉等能够通过自身燃烧释放热量的原料以及特殊的挤出成型工艺,轻质硅晶石墙板可以利用自身产生的一部分热量来降低烧结能耗,将烧结温度降低50~100℃,有效节约了能耗;由于特殊的成型工艺使得轻质硅晶石墙板的体积密度比实心烧结板材低很多,且所得轻质硅晶石墙板在力学性能达到使用要求;
(3)采用本发明的工艺方法制备的轻质硅晶石墙板,成品率达到90%以上,抗压强度≥20MPa,产品体积密度为400~1100kg/m3,产品燃烧性能为A1级,产品的体积吸水率≤2%,孔洞率低防水性能好,其保温性和隔热性都得到显著提高。
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
选取均化处理调整后的陶瓷废渣、煤矸石、精煤粉、钙基膨润土、黑泥,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10~20目的陶瓷废渣70kg、20~40目的煤矸石10kg、20~40目的精煤粉10kg、40~300目的钙基膨润土3kg、40~300目的黑泥7kg的配方称取倒入混料机,然后加入8kg水进行高速搅拌;将混合均匀的物料陈腐3天,再通过练泥机练泥排出混合物料中的空气,然后将具有塑性的物料进行真空挤出成型,成型后坯体90℃下干燥3h;干燥完成后放入窑炉中烧结,采用3℃/min的升温速率,从室温升温至300℃;采用4℃/min的升温速率,从300℃升温至600℃;采用6℃/min的升温速率,从600℃升温至700℃;采用7℃/min的升温速率,从700℃升温至850℃;采用10℃/min的升温速率,从850℃升温至1050℃保温1h;退火工艺采用15℃/min的降温速率从烧成温度降至820℃,然后采用4℃/min的降温速率降至室温,得到轻质硅晶石墙板。
检测结果:轻质硅晶石墙板容重为690kg/m3,体积吸水率10%,抗压强度为22MPa。
实施例2
选取均化处理调整后的陶瓷废渣、煤矸石、焦炭粉、钠基膨润土、硅粉,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10~20目的陶瓷废渣70kg、20~40目的煤矸石10kg、20~40目的焦炭粉10kg、40~300目的钠基膨润土4kg、40~300目的硅粉6kg的配方称取倒入混料机,然后加入10kg水进行高速搅拌;将混合均匀的物料陈腐3天,再通过练泥机练泥排出混合物料中的空气,然后将具有塑性的物料进行真空挤出成型,成型后坯体90℃下干燥3h;干燥完成后放入窑炉中烧结,采用3℃/min的升温速率,从室温升温至300℃;采用4℃/min的升温速率,从300℃升温至600℃;采用6℃/min的升温速率,从600℃升温至700℃;采用7℃/min的升温速率,从700℃升温至850℃;采用10℃/min的升温速率,从850℃升温至1050℃保温1h;退火工艺采用15℃/min的降温速率从烧成温度降至820℃,然后采用4℃/min的降温速率降至室温,得到轻质硅晶石墙板。
检测结果:轻质硅晶石墙板容重为760kg/m3,体积吸水率6%,抗压强度为29MPa。
实施例3
选取均化处理调整后的陶瓷废渣、煤矸石、精煤粉、高岭土、滑石粉,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10~20目的陶瓷废渣60kg、20~40目的煤矸石15kg、20~40目的精煤粉15kg、40~300目的高岭土4kg、40~300目的滑石粉6kg的配方称取倒入混料机,然后加入10kg水进行高速搅拌;将混合均匀的物料陈腐3天,再通过练泥机练泥排出混合物料中的空气,然后将具有塑性的物料进行真空挤出成型,成型后坯体90℃下干燥3h;干燥完成后放入窑炉中烧结,采用3℃/min的升温速率,从室温升温至300℃;采用4℃/min的升温速率,从300℃升温至600℃;采用6℃/min的升温速率,从600℃升温至700℃;采用7℃/min的升温速率,从700℃升温至850℃;采用10℃/min的升温速率,从850℃升温至1050℃保温1h;退火工艺采用15℃/min的降温速率从烧成温度降至820℃,然后采用4℃/min的降温速率降至室温,得到轻质硅晶石墙板。
检测结果:轻质硅晶石墙板容重为950kg/m3,体积吸水率7%,抗压强度为32MPa。
实施例4
选取均化处理调整后的陶瓷废渣、煤矸石、精煤粉、高岭土、滑石粉,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10~20目的陶瓷废渣65kg、20~40目的煤矸石10kg、20~40目的精煤粉10kg、40~300目的高岭土7kg、40~300目的滑石粉8kg的配方称取倒入混料机,然后加入15kg水进行高速搅拌;将混合均匀的物料陈腐7天,再通过练泥机练泥排出混合物料中的空气,然后将具有塑性的物料进行真空挤出成型,成型后坯体115℃下干燥12h;干燥完成后放入窑炉中烧结,采用1℃/min的升温速率,从室温升温至300℃;采用2℃/min的升温速率,从300℃升温至600℃;采用3℃/min的升温速率,从600℃升温至700℃;采用5℃/min的升温速率,从700℃升温至850℃;采用5℃/min的升温速率,从850℃升温至1050℃保温1h;退火工艺采用5℃/min的降温速率从烧成温度降至820℃,然后采用2℃/min的降温速率降至室温,得到轻质硅晶石墙板。
检测结果:轻质硅晶石墙板容重为928kg/m3,体积吸水率6%,抗压强度为30MPa。
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)
1.一种轻质硅晶石墙板,其特征在于由固体物料与水按照1:0.08~0.15的重量比例混合而成;按重量百分含量计,所述固体物料的组成如下:
骨料75%~95%;
燃料10%~40%;
增强剂2%~10%;
粘结剂3%~15%;
所述燃料包括精煤粉、煤矸石、焦炭粉、或木炭粉中的一种或多种。
2.根据权利要求1所述的一种轻质硅晶石墙板,其特征在于:所述骨料为建筑渣土、陶瓷废渣、煤矸石、高锰酸钾尾渣等固体废物中的一种或多种。
3.根据权利要求1所述的一种轻质硅晶石墙板,其特征在于:所述增强剂包括轻钙粉、矿粉、硅灰、石英粉、滑石粉等中的一种或多种。
4.根据权利要求1所述的一种轻质硅晶石墙板,其特征在于:所述粘结剂包括钠基膨润土、钙基膨润土、凹凸棒土、珍珠岩原矿、生高岭土等中的一种或多种。
5.一种如权利要求1-4所述的轻质硅晶石墙板的制备方法,其特征在于:
S1.将各原料进行均化处理,再将骨料进行破碎、过筛、粉磨,得到不同粒度级配的骨料;
S2.按照配方准确称量骨料、燃料、增强剂、粘结剂,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,陈腐时间为3-7d,经过陈腐合格的泥料经进行真空炼泥处理获得料性均匀的泥料;
S4.将陈腐练泥之后的泥料经真空挤出机挤压后,切割成坯体产品;
S5.将坯体产品水分控制为7~20%时,进入干燥器内进行干燥成型;
S6.将干燥的坯体放入窑炉中,在750--1050℃下按照工艺烧成曲线进行烧结,保温时间为1-5h,烧结后产品经急冷、缓冷两段窑炉退火工艺,得到成品。
6.根据权利要求5所述的轻质硅晶石墙板的制备方法,其特征在于S1中所述均化处理过程为将不同种类和不同地区的固体废弃物和矿物原料分别放在原料晾晒场,原料经过1~36个月的风吹、日晒、雨淋,然后机械研磨至均匀状态。
7.根据权利要求5所述的轻质硅晶石墙板的制备方法,其特征在于S2中,骨料的粒度为10~20目,燃料的粒度为20~40目,增强剂的粒度为40~300目,粘结剂的粒度为40~300目。
8.根据权利要求5所述的轻质硅晶石墙板的制备方法,其特征在于S5中干燥条件为:在80℃~115℃的温度下干燥3h~24h。
9.根据权利要求5所述的轻质硅晶石墙板的制备方法,其特征在于所述S6中工艺烧成曲线为:从室温升温至700~750℃,之后继续升温至800~850℃,最后升温至900~1050℃,保温1~5h。
10.根据权利要求9所述的轻质硅晶石墙板的制备方法,其特征在于:从室温升温至700~750℃为:先以1~3℃/min的升温速率升温至300℃;再以2~5℃/min的升温速率升温至600℃;然后以3~9℃/min的升温速率升温至700~750℃;升温至800~850℃的升温速率为5~10℃/min;升温至900~1050℃的升温速率为5~10℃/min;退火工艺采用5~15℃/min的降温速率从烧成温度降至820℃,然后采用2~4℃/min的降温速率降至室温。
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