CN115353410B - Steel slag foamed ceramic decorative plate with groove-shaped glaze and preparation method thereof - Google Patents

Steel slag foamed ceramic decorative plate with groove-shaped glaze and preparation method thereof Download PDF

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CN115353410B
CN115353410B CN202210946624.7A CN202210946624A CN115353410B CN 115353410 B CN115353410 B CN 115353410B CN 202210946624 A CN202210946624 A CN 202210946624A CN 115353410 B CN115353410 B CN 115353410B
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foamed ceramic
glaze
steel slag
layer
blank
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CN115353410A (en
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徐晓虹
张嘉艺
吴建锋
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Chongqing Research Institute Of Wuhan University Of Technology
Wuhan University of Technology WUT
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Chongqing Research Institute Of Wuhan University Of Technology
Wuhan University of Technology WUT
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/001—Applying decorations on shaped articles, e.g. by painting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/044—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with glaze or engobe or enamel or varnish
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0438—Ornamental plaques, e.g. decorative panels, decorative veneers containing stone elements
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/131—Inorganic additives
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C04B33/138—Waste materials; Refuse; Residues from metallurgical processes, e.g. slag, furnace dust, galvanic waste
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B33/00—Clay-wares
    • C04B33/32—Burning methods
    • C04B33/34—Burning methods combined with glazing
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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
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
    • C04B38/063—Preparing or treating the raw materials individually or as batches
    • C04B38/0635—Compounding ingredients
    • C04B38/0645—Burnable, meltable, sublimable materials
    • C04B38/068—Carbonaceous materials, e.g. coal, carbon, graphite, hydrocarbons
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3418—Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
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    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
    • C04B2235/3472—Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite
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    • C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
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    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
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  • Chemical & Material Sciences (AREA)
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  • Dispersion Chemistry (AREA)
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Abstract

The invention relates to a steel slag foamed ceramic decorative plate with groove-shaped glaze and a preparation method thereof, wherein the steel slag foamed ceramic decorative plate comprises a base body and a glaze layer which are sequentially arranged from bottom to top, a plurality of grooves are formed in the upper surface of the base body, a plurality of protruding parts are formed in the lower surface of the glaze layer, and the protruding parts are in scarf joint with the grooves; the raw materials of the matrix comprise the following components in percentage by mass: (0.1-0.6) a main material and a foaming agent; the main materials comprise 80-90% of steel slag, 5-6% of quartz, 2-4% of kaolin and 2-10% of high-temperature flux according to weight percentage. The decorative layer of the foamed ceramic decorative plate is firmly combined with the matrix, and the decorative layer is not easy to fall off and peel off, so that the service life of the foamed ceramic decorative plate is longer; the heat preservation and insulation effects are good, the steel slag doping amount is high, solid waste can be effectively utilized, and the cost is reduced.

Description

Steel slag foamed ceramic decorative plate with groove-shaped glaze and preparation method thereof
Technical Field
The invention belongs to the field of foamed ceramics, and particularly relates to a steel slag foamed ceramic decorative plate with groove-shaped glaze and a preparation method thereof.
Background
The foamed ceramic is a porous ceramic material with high closed porosity, which is prepared by taking solid wastes such as red mud, steel slag, polishing mud, graphite tailings, gold tailings and the like and a small amount of silicate minerals as raw materials, adding a proper amount of high-temperature foaming agent, mixing, ball milling, drying, forming and the like, and sintering at a proper temperature. The foamed ceramic has the characteristics of light weight, high strength, heat preservation, heat insulation, fire resistance, water resistance, durability, rich decoration and the like, and is a novel wall material suitable for the masonry of the inner wall and the outer wall of an assembled building.
Steel slag is a solid waste produced in the steelmaking process, and has large stock quantity at present, pollutes the environment and occupies the land. At present, steel slag is mostly used for preparing cement concrete and road materials, and is also used for preparing foaming ceramics. As in the Chinese patent of invention (method for producing foamed ceramic building thermal insulation material by using lithium tailings and steel slag tailings) (CN 108840710A), 12-30 parts of steel slag tailings, 50-60 parts of lithium tailings, 20-30 parts of clay raw materials, 2-4 parts of foaming materials and 40-50 parts of water are adopted as raw materials to prepare the foamed ceramic; the Chinese patent (CN 111517819A) discloses a method for preparing foamed ceramics by using metallurgical high-temperature fluid steel slag, which comprises the following steps of 60-70 parts of steel slag, 8-15 parts of coal gangue, 10-15 parts of feldspar, 3-5 parts of quartz, 3-6 parts of frit and 0.5-1 part of foaming agent serving as raw materials to prepare the foamed ceramics. The steel slag blending amount in the patents is less than 75 weight percent.
The foamed ceramic decorative board is a foamed ceramic board with a decorative layer (glaze or microcrystalline glass or paint or pigment and the like) on the surface, can be directly used as an inner and outer wall material, and has higher added value than a foamed ceramic board without a decorative layer. The foamed ceramic insulation board prepared by the Chinese patent of the invention (a microcrystalline composite gangue-based foamed ceramic insulation board and a preparation method thereof) (CN 110395969A) comprises a foamed ceramic substrate layer and a decorative layer: the foaming ceramic matrix layer is prepared from 70-85 parts of gangue, 5-30 parts of ore material, 5-10 parts of additive, 0.03-0.07 part of silicon carbide and 5-8 parts of foam stabilizer; the decorative layer is made of 33-50 parts of microcrystalline frit, 5-30 parts of ore material and 5-15 parts of additive. The decorative layers of the foamed ceramic decorative plates and the vertical plate surface of the foamed ceramic matrix have low tensile strength, so that the surface layers of the foamed ceramic decorative plates are easy to fall off or peel, the attractiveness is affected, and the service life is short.
The thermal conductivity of the foamed ceramic is a parameter representing the thermal insulation performance of the foamed ceramic, and the smaller the thermal conductivity is, the better the thermal insulation performance of the foamed ceramic is. The light heat-insulating foamed ceramic heat-insulating board with the heat conductivity coefficient of 0.018-0.03W/(m.K) is prepared by taking fly ash as a main raw material in the Chinese patent of the invention (CN 104744070B); however, the thermal conductivity of the foamed ceramics in these patents is high.
Disclosure of Invention
The invention aims to overcome the technical defects, and provides a steel slag foamed ceramic decorative plate with groove-shaped glaze and a preparation method thereof, which solve the technical problems that a decorative layer of the foamed ceramic decorative plate is easy to fall off or peel and has poor heat preservation and heat insulation effects in the prior art.
In order to achieve the technical purpose, the technical scheme of the invention is as follows:
in a first aspect, the invention provides a steel slag foamed ceramic decorative board with groove-shaped glaze applied thereon, which comprises: the glaze layer is provided with a plurality of convex parts, and the convex parts are in scarf joint with the grooves;
the raw materials of the matrix comprise the following components in percentage by mass: (0.1-0.6) a main material and a foaming agent; the main materials comprise 80-90% of steel slag, 5-6% of quartz, 2-4% of kaolin and 2-10% of high-temperature flux according to weight percentage.
Further, the steel slag comprises SiO in weight percent 2 ：8.56～12.65％，MgO：1.59～8.10％，Fe 2 O 3 ：15.21～27.59％，Al 2 O 3 ：14.17～18.16％，CaO：34.87～52.21％，K 2 O is less than 2% and Na 2 O is less than 2%; ball milling quartz, kaolin and high-temperature flux for 4-6 h, and pre-treating by a 200-250 mesh sieve; the high-temperature flux is one or a mixture of two of potassium feldspar and albite in any proportion.
Further, the foaming agent comprises a mixture of two or three of silicon carbide, carbon powder and magnesite powder in any proportion.
Further, the silicon carbide is ball-milled for 7 to 12 hours and is subjected to pretreatment of 500 to 700 meshes of sieve; ball milling carbon powder for 4-8 hr, and sieving with 320-500 mesh sieve; ball milling the magnesite powder for 3-6 h, and sieving with 240-320 mesh sieve.
Further, the glaze layer comprises a ground glaze layer and a surface glaze layer, wherein the ground glaze layer is positioned between the substrate and the surface glaze layer;
the raw materials of the ground coat layer comprise the following components in percentage by weight: 40-50% of feldspar, 10-15% of quartz, 6-8% of Suzhou soil, 8-12% of calcium carbonate, 5-10% of zinc oxide, 4-6% of talcum and 5-10% of dolomite;
the surface glaze layer comprises the following raw materials in percentage by weight: 34-37% of feldspar, 28-31% of quartz, 2-5% of kaolin, 3-5% of calcined talcum, 10-14% of calcite, 10-13% of zirconium silicate, 0.8-2% of zinc oxide and 0.5-1.0% of barium carbonate.
Further, a decorative pattern layer is arranged between the ground glaze layer and the surface glaze layer.
In a second aspect, the invention provides a method for preparing a steel slag foamed ceramic decorative board with groove-shaped glaze, which comprises the following steps:
(1) Taking the raw materials of the matrix, adding water, and uniformly mixing to obtain blank slurry; granulating, homogenizing and ageing the blank slurry, performing compression molding and surface grooving to obtain a foamed ceramic green body with grooves;
(2) Applying glaze slurry on the foamed ceramic green body, and drying to obtain a foamed ceramic glaze blank;
(3) And (3) sintering the foamed ceramic glaze blank to obtain the steel slag foamed ceramic decorative plate with the groove-shaped glaze.
In the step (1), the raw materials of the matrix are mixed for 1-2 hours by a wet method under the condition of 40-44 wt% of water adding amount, and the mixture is sieved by a 180-mesh sieve to obtain blank slurry with the specific gravity of 1.40-1.44; the granulation is that the blank slurry is aged for 24 to 48 hours and then spray granulation is carried out to obtain the blank; homogenizing and ageing, namely placing the blank into a storage bin for homogenizing and ageing for 16-24 hours; the pressure of the compression molding is 45-50 MPa.
Further, in the step (2), the glaze slip comprises base glaze slip and surface glaze slip, wherein the base glaze slip is firstly applied on the foamed ceramic green body, and the upper surface of the foamed ceramic green body is completely covered and then is subjected to drying treatment; performing ink-jet printing to form a decorative pattern layer; finally spraying surface glaze slurry and drying to obtain the foamed ceramic glaze blank.
Further, in the step (3), the sintering temperature is 1100-1170 ℃ and the sintering time is 16-24 h.
Compared with the prior art, the invention has the beneficial effects that:
1. the decorative layer of the foamed ceramic decorative board is firmly combined with the matrix. The invention firstly processes the groove structure on the surface of the pressed foamed ceramic green body, then applies glaze slurry to enable a part of the glaze slurry to flow into the groove of the green body, and finally burns, so that the tensile strength of the vertical plate surface of the foamed ceramic substrate and the glaze layer reaches 2.02-2.30 MPa, the combination of the substrate and the decorative layer is firmer, the decorative layer is not easy to fall off and peel, and the service life of the foamed ceramic decorative plate is longer.
2. The foamed ceramic decorative board has good heat preservation and insulation effects and higher steel slag doping amount. The heat conductivity of the foamed ceramic decorative board is as low as 0.012-0.015W/(m.K), and the reason is that the higher iron content in the steel slag is effectively utilized, and the foamed ceramic decorative board is matched with a foaming agent for synergistic foaming, and the glaze decoration is beneficial to reducing the heat conductivity. In addition, the addition amount of the steel slag waste in the formula of the invention reaches 80-90 wt%, which has the significance of environmental protection, and can effectively utilize solid waste and reduce the cost.
Drawings
FIG. 1 is a schematic view of a steel slag foamed ceramic decorative board with groove-shaped glaze applied to the invention;
FIG. 2 is a microstructure (SEM. Times.50) of the steel slag foamed ceramic of the invention.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Referring to fig. 1, the foamed ceramic decorative board of the invention comprises a base body 1, a ground coat layer 2 and a cover coat layer 3 which are arranged in sequence; the invention is not limited by the fact that the foamed ceramic decorative board is horizontally arranged, the base body 1 is arranged at the lower side, and the overglaze layer 3 is arranged at the upper side to define the relevant direction, so that the structure of the decorative board is only described more clearly; the upper surface of the base body 1 is provided with a plurality of grooves 4, and the grooves 4 are preferably dovetail-shaped with wide lower side and narrow upper side, so that a stronger scarf joint effect can be achieved; the primer layer 2 comprises a flat part and a plurality of protruding parts arranged on the lower side of the flat part, wherein the protruding parts can be in joggle fit with the grooves 4.
Preferably, the total thickness h1 of the flat plate portions of the overglaze layer 3 and the under glaze layer 2 in the present invention is 0.1mm to 5mm, more preferably 0.1mm to 1mm, most preferably 0.2mm to 0.5mm, and other thinner or thicker thickness dimensions may be selected according to circumstances; a decorative pattern layer may be further disposed between the overglaze layer 3 and the flat plate portion of the under glaze layer 2, and is usually formed by inkjet printing, where the thickness of the decorative pattern layer is substantially negligible, that is, the total thickness of the overglaze layer 3, the decorative pattern layer, and the flat plate portion of the under glaze layer 2 is still h1, and for convenience of description, the overglaze layer 3, the decorative pattern layer, and the flat plate portion of the under glaze layer 2 are collectively referred to as a decorative layer.
Preferably, the depth h2 of the dovetail groove is less than h1. The thickness of the matrix can be set according to actual situation requirements.
The invention provides a preparation method of a steel slag foamed ceramic decorative plate with dovetail groove-shaped glaze, which comprises the following steps:
1. preparation of foamed ceramic matrix
1. And (3) raw material treatment: ball milling the steel slag for 10-15 h by a ball mill, and sieving the steel slag by a 270-320 mesh sieve to obtain powder for later use; ball milling the three materials of quartz, kaolin and high-temperature flux by a ball mill for 4-6 hours respectively, and sieving the materials by a 200-250 mesh sieve to obtain raw material powder for later use; ball milling the foaming agent silicon carbide for 7-12 h by a ball mill, and sieving the foaming agent silicon carbide with a 500-700 mesh sieve to obtain foaming agent powder for standby; ball milling the carbon powder of the foaming agent by a ball mill for 4-8 hours, and sieving the carbon powder of the foaming agent by a 320-500 mesh sieve to obtain the powder of the foaming agent for standby; ball milling the foaming agent magnesite powder for 3-6 hours by a ball mill, and sieving the mixture with a 240-320 mesh sieve to obtain foaming agent powder for later use;
2. the raw materials are as follows: the raw material powder and the foaming agent powder are mixed according to the weight percentage: 80 to 90 percent of steel slag, 5 to 6 percent of quartz, 2 to 4 percent of kaolin, 2 to 10 percent of high-temperature flux and 0.1 to 0.6 percent of additional foaming agent. Wherein, the chemical composition of the steel slag is as follows: siO (SiO) 2 ：8.56～12.65％；MgO：1.59～8.10％；Fe 2 O 3 ：15.21～27.59％；Al 2 O 3 ：14.17～18.16％；CaO：34.87～52.21％；K 2 O、Na 2 O is less than 2%. The high-temperature flux is any one or a mixture of any two of potassium feldspar and albite. The foaming agent is a mixture of two or three of silicon carbide, carbon powder and magnesite powder in any proportion;
3. ball milling and mixing: the ingredients are put into a ball mill to be mixed for 1 to 2 hours by a wet method (the water addition amount is 40 to 44 weight percent), and the mixture is sieved by a 180-mesh sieve after ball milling, so as to obtain blank slurry with the specific gravity of 1.40 to 1.44;
4. and (3) spray granulation: after ageing the blank slurry for 24-48 hours, placing the blank slurry into a spray drying tower, and carrying out spray granulation to obtain a blank;
5. homogenizing and ageing: placing the blank into a storage bin for homogenization and ageing for 16-24 hours to obtain a homogenized and ageing blank;
6. dry pressing and forming: placing the homogenized and aged blank into a press, and then performing dry press molding at 45-50 MPa to obtain a foamed ceramic green body;
7. and (3) green body processing: the surface of the foamed ceramic green body is processed into a dovetail groove structure, as shown in fig. 1. Thus, a preferable foamed ceramic body with dovetail grooves is obtained.
2. Preparation of decorative layer
The foamed ceramic blank with the dovetail groove needs to be coated with a ground coat and a surface coat, and then dried, decorated and burned, and the preparation method is as follows:
1. preparing ground glaze: the following raw materials are mixed according to the weight percentage: 40-50% of feldspar, 10-15% of quartz, 6-8% of Suzhou soil, 8-12% of calcium carbonate, 5-10% of zinc oxide, 4-6% of talcum and 5-10% of dolomite, and sieving with a 200-250 mesh sieve after water ball milling to obtain ground glaze;
2. preparing an overglaze: the following raw materials are mixed according to the weight percentage: 34-37% of feldspar, 28-31% of quartz, 2-5% of kaolin, 3-5% of calcined talcum, 10-14% of calcite, 10-13% of zirconium silicate, 0.8-2% of zinc oxide and 0.5-1.0% of barium carbonate, and sieving with a 250-320-mesh sieve after ball grinding by adding water to obtain overglaze;
3. glazing, decorating and drying: spraying water to wet the foamed ceramic blank with the dovetail groove after ash removal, firstly spraying a layer of ground coat (a layer of flat plate part which is added with the ground coat after filling the dovetail groove), putting into a drying roller kiln for drying for 5-8 hours, then performing ink-jet printing on the ground coat layer to obtain a required decorative pattern, finally spraying a layer of surface coat, and putting into the drying roller kiln again for drying for 5-8 hours to obtain a foamed ceramic glaze blank;
4. firing the glaze blank: and (3) putting the foamed ceramic glaze blank into a roller kiln for sintering, wherein the highest sintering temperature is 1100-1170 ℃, and the sintering period is 16-24 hours, so as to obtain the steel slag foamed ceramic decorative plate of the Shi Yanwei groove-shaped glaze.
The invention is further illustrated by the following specific examples.
Example 1
The steel slag foamed ceramic decorative board with dovetail groove-shaped glaze comprises two layers of structures, namely a foamed ceramic substrate layer and a decorative layer.
The foaming agent is silicon carbide and carbon powder, and the mass ratio of the silicon carbide to the carbon powder is 1:1.
The preparation process of the steel slag foamed ceramic decorative plate comprises the following steps:
1. and (3) raw material treatment: ball milling the steel slag for 10 hours by a ball mill, and sieving the steel slag by a 270-mesh sieve to obtain powder for standby; ball milling the three materials of quartz, kaolin and high-temperature flux by a ball mill for 4 hours respectively, and sieving the materials by a 200-mesh sieve to obtain raw material powder for later use; ball milling the foaming agent silicon carbide for 7 hours by a ball mill, and sieving the foaming agent silicon carbide with a 500-mesh sieve to obtain foaming agent powder for later use; ball milling the foaming agent carbon powder for 4 hours by a ball mill, and sieving the foaming agent carbon powder by a 320-mesh sieve to obtain foaming agent powder for standby;
2. the raw materials are as follows: the raw material powder and the foaming agent powder are mixed according to the weight percentage: 80% of steel slag, 6% of quartz, 4% of kaolin, 5% of potassium feldspar, 5% of albite and 0.4% of additional foaming agent;
3. ball milling and mixing: the ingredients are put into a ball mill to be mixed for 1h by a wet method (the water addition amount is 40wt percent), and the mixture is sieved by a 180-mesh sieve after ball milling, so as to obtain blank slurry with the specific gravity of 1.40;
4. and (3) spray granulation: after the blank slurry is aged for 24 hours, placing the blank slurry into a spray drying tower, and carrying out spray granulation to obtain a blank;
5. homogenizing and ageing: placing the blank into a storage bin for homogenization and ageing for 16 hours to obtain a homogenized and ageing blank;
6. dry pressing and forming: placing the homogenized and aged blank into a press, and then performing dry press molding at a molding pressure of 45MPa to obtain a foamed ceramic green body;
7. and (3) green body processing: and processing the surface of the foamed ceramic green body into a dovetail groove structure. Thus, a foamed ceramic body with a dovetail groove is obtained.
8. Preparing ground glaze: the following raw materials are mixed according to the weight percentage: 50% of feldspar, 10% of quartz, 8% of Suzhou soil, 12% of calcium carbonate, 10% of zinc oxide, 5% of talcum and 5% of dolomite, adding water, ball milling, and sieving with a 200-mesh sieve to obtain ground enamel;
9. preparing an overglaze: the following raw materials are mixed according to the weight percentage: 35% of feldspar, 30% of quartz, 5% of kaolin, 5% of calcined talcum, 10% of calcite, 13% of zirconium silicate, 1% of zinc oxide and 1% of barium carbonate, and sieving with a 250-mesh sieve after ball milling by adding water to obtain overglaze;
10. glazing, decorating and drying: spraying water to wet a foamed ceramic blank with a dovetail groove after ash removal, firstly spraying a layer of ground coat, filling the dovetail groove, then spraying a layer of ground coat, forming a flat plate part of the ground coat layer, putting the flat plate part into a drying roller kiln, drying for 5 hours, then performing ink-jet printing to obtain a required decorative pattern, finally spraying a layer of surface coat, wherein the total thickness of the decorative layer (the flat plate part of the ground coat layer, the ink-jet printing layer and the surface coat layer) is 0.2mm, and putting the flat plate part of the ground coat layer, the ink-jet printing layer and the surface coat layer into the drying roller kiln again for 5 hours to obtain a foamed ceramic glaze blank;
11. firing the glaze blank: and (3) putting the foamed ceramic glaze blank into a roller kiln for sintering, wherein the highest sintering temperature is 1150 ℃, the sintering period is 16 hours, and the steel slag foamed ceramic decorative plate of the Shi Yanwei groove-shaped glaze is obtained.
Example 2
The steel slag foamed ceramic decorative board with dovetail groove-shaped glaze comprises two layers of structures, namely a foamed ceramic substrate layer and a decorative layer.
The foaming agent is silicon carbide, carbon powder and magnesite, and the mass ratio of the silicon carbide to the carbon powder to the magnesite is 1:1:1.
The preparation process of the steel slag foamed ceramic decorative plate comprises the following steps:
1. and (3) raw material treatment: ball milling the steel slag for 10 hours by a ball mill, and sieving the steel slag by a 270-mesh sieve to obtain powder for standby; ball milling the three materials of quartz, kaolin and high-temperature flux by a ball mill for 4 hours respectively, and sieving the materials by a 200-mesh sieve to obtain raw material powder for later use; ball milling the foaming agent silicon carbide for 7 hours by a ball mill, and sieving the foaming agent silicon carbide with a 500-mesh sieve to obtain foaming agent powder for later use; ball milling the foaming agent carbon powder for 4 hours by a ball mill, and sieving the foaming agent carbon powder by a 320-mesh sieve to obtain foaming agent powder for standby; ball milling the foaming agent magnesite for 3 hours by a ball mill, and sieving the mixture by a 240-mesh sieve to obtain foaming agent powder for later use;
2. the raw materials are as follows: the raw material powder and the foaming agent powder are mixed according to the weight percentage: 80 parts of steel slag, 6 parts of quartz, 4 parts of kaolin, 5 parts of potassium feldspar, 5 parts of albite and 0.4 part of additional foaming agent;
3. ball milling and mixing: the ingredients are put into a ball mill to be mixed for 1h by a wet method (the water addition amount is 40wt percent), and the mixture is sieved by a 180-mesh sieve after ball milling, so as to obtain blank slurry with the specific gravity of 1.40;
4. and (3) spray granulation: after the blank slurry is aged for 24 hours, placing the blank slurry into a spray drying tower, and carrying out spray granulation to obtain a blank;
5. homogenizing and ageing: placing the blank into a storage bin for homogenization and ageing for 16 hours to obtain a homogenized and ageing blank;
6. dry pressing and forming: placing the homogenized and aged blank into a press, and then performing dry press molding at a molding pressure of 45MPa to obtain a foamed ceramic green body;
7. and (3) green body processing: and processing the surface of the foamed ceramic green body into a dovetail groove structure. Thus, a foamed ceramic body with a dovetail groove is obtained.
8. Preparing ground glaze: the following raw materials are mixed according to the weight percentage: 50% of feldspar, 10% of quartz, 8% of Suzhou soil, 12% of calcium carbonate, 10% of zinc oxide, 5% of talcum and 5% of dolomite, adding water, ball milling, and sieving with a 200-mesh sieve to obtain ground enamel;
9. preparing an overglaze: the following raw materials are mixed according to the weight percentage: 35% of feldspar, 30% of quartz, 5% of kaolin, 5% of calcined talcum, 10% of calcite, 13% of zirconium silicate, 1% of zinc oxide and 1% of barium carbonate, and sieving with a 250-mesh sieve after ball milling by adding water to obtain overglaze;
10. glazing, decorating and drying: spraying water to wet a foamed ceramic blank with a dovetail groove after ash removal, spraying a layer of ground coat, filling the dovetail groove, spraying a layer of ground coat again to form a flat plate part of the ground coat layer, drying in a drying roller kiln for 5 hours, performing ink-jet printing to obtain a required decorative pattern, spraying a layer of ground coat, spraying the ground coat with the total thickness of 0.2mm, and drying in the drying roller kiln for 5 hours again to obtain a foamed ceramic glaze blank;
11. firing the glaze blank: and (3) putting the foamed ceramic glaze blank into a roller kiln for sintering, wherein the highest sintering temperature is 1150 ℃, the sintering period is 16 hours, and the steel slag foamed ceramic decorative plate of the Shi Yanwei groove-shaped glaze is obtained.
Example 3
The steel slag foamed ceramic decorative board with dovetail groove-shaped glaze comprises two layers of structures, namely a foamed ceramic substrate layer and a decorative layer.
The foaming agent is silicon carbide, carbon powder and magnesite, and the mass ratio of the silicon carbide to the carbon powder to the magnesite is 1:1:1
The preparation process of the steel slag foamed ceramic decorative plate comprises the following steps:
1. ball milling the steel slag for 10 hours by a ball mill, and sieving the steel slag by a 270-mesh sieve to obtain powder for standby; ball milling the three materials of quartz, kaolin and high-temperature flux by a ball mill for 4 hours respectively, and sieving the materials by a 200-mesh sieve to obtain raw material powder for later use; ball milling the foaming agent silicon carbide for 7 hours by a ball mill, and sieving the foaming agent silicon carbide with a 500-mesh sieve to obtain foaming agent powder for later use; ball milling the foaming agent carbon powder for 4 hours by a ball mill, and sieving the foaming agent carbon powder by a 320-mesh sieve to obtain foaming agent powder for standby; ball milling the foaming agent magnesite for 3 hours by a ball mill, and sieving the mixture by a 240-mesh sieve to obtain foaming agent powder for later use;
2. the raw materials are as follows: the raw material powder and the foaming agent powder are mixed according to the weight percentage: steel slag 82, quartz 5%, kaolin 3%, potassium feldspar 5%, albite 5% and additional foaming agent 0.4%;
3. ball milling and mixing: the ingredients are put into a ball mill to be mixed for 2 hours by a wet method (the water addition amount is 40wt percent), and the mixture is sieved by a 180-mesh sieve after ball milling, so as to obtain blank slurry with the specific gravity of 1.44;
4. and (3) spray granulation: after the blank slurry is aged for 24 hours, placing the blank slurry into a spray drying tower, and carrying out spray granulation to obtain a blank;
5. homogenizing and ageing: placing the blank into a storage bin for homogenization and ageing for 16 hours to obtain a homogenized and ageing blank;
6. dry pressing and forming: placing the homogenized and aged blank into a press, and then performing dry press molding at a molding pressure of 45MPa to obtain a foamed ceramic green body;
7. and (3) green body processing: and processing the surface of the foamed ceramic green body into a dovetail groove structure. Thus, a foamed ceramic body with a dovetail groove is obtained.
8. Preparing ground glaze: the following raw materials are mixed according to the weight percentage: 50% of feldspar, 10% of quartz, 8% of Suzhou soil, 12% of calcium carbonate, 10% of zinc oxide, 5% of talcum and 5% of dolomite, adding water, ball milling, and sieving with a 200-mesh sieve to obtain ground enamel;
9. preparing an overglaze: the following raw materials are mixed according to the weight percentage: 35% of feldspar, 30% of quartz, 5% of kaolin, 5% of calcined talcum, 10% of calcite, 13% of zirconium silicate, 1% of zinc oxide and 1% of barium carbonate, and sieving with a 250-mesh sieve after ball milling by adding water to obtain overglaze;
10. glazing, decorating and drying: spraying water to wet a foamed ceramic blank with a dovetail groove after ash removal, spraying a layer of ground coat, filling the dovetail groove, spraying a layer of ground coat again to form a flat plate part of the ground coat layer, drying in a drying roller kiln for 5 hours, performing ink-jet printing to obtain a required decorative pattern, spraying a layer of ground coat, spraying the ground coat with the total thickness of 0.2mm, and drying in the drying roller kiln for 5 hours again to obtain a foamed ceramic glaze blank;
11. firing the glaze blank: and (3) putting the foamed ceramic glaze blank into a roller kiln for sintering, wherein the highest sintering temperature is 1150 ℃, the sintering period is 16 hours, and the steel slag foamed ceramic decorative plate of the Shi Yanwei groove-shaped glaze is obtained.
Example 4
The steel slag foamed ceramic decorative board with dovetail groove-shaped glaze comprises two layers of structures, namely a foamed ceramic substrate layer and a decorative layer.
The foaming agent is silicon carbide, carbon powder and magnesite, and the mass ratio of the silicon carbide to the carbon powder to the magnesite is 1:1:1
The preparation process of the steel slag foamed ceramic decorative plate comprises the following steps:
1. ball milling the steel slag for 10 hours by a ball mill, and sieving the steel slag by a 270-mesh sieve to obtain powder for standby; ball milling the three materials of quartz, kaolin and high-temperature flux by a ball mill for 4 hours respectively, and sieving the materials by a 200-mesh sieve to obtain raw material powder for later use; ball milling the foaming agent silicon carbide for 7 hours by a ball mill, and sieving the foaming agent silicon carbide with a 500-mesh sieve to obtain foaming agent powder for later use; ball milling the foaming agent carbon powder for 4 hours by a ball mill, and sieving the foaming agent carbon powder by a 320-mesh sieve to obtain foaming agent powder for standby; ball milling the foaming agent magnesite for 3 hours by a ball mill, and sieving the mixture by a 240-mesh sieve to obtain foaming agent powder for later use;
2. the raw materials are as follows: the raw material powder and the foaming agent powder are mixed according to the weight percentage: steel slag 82, quartz 5%, kaolin 3%, potassium feldspar 5%, albite 5% and additional foaming agent 0.4%;
3. ball milling and mixing: the ingredients are put into a ball mill to be mixed for 2 hours by a wet method (the water addition amount is 40wt percent), and the mixture is sieved by a 180-mesh sieve after ball milling, so as to obtain blank slurry with the specific gravity of 1.44;
4. and (3) spray granulation: after the blank slurry is aged for 24 hours, placing the blank slurry into a spray drying tower, and carrying out spray granulation to obtain a blank;
5. homogenizing and ageing: placing the blank into a storage bin for homogenization and ageing for 16 hours to obtain a homogenized and ageing blank;
6. dry pressing and forming: placing the homogenized and aged blank into a press, and then performing dry press molding at a molding pressure of 45MPa to obtain a foamed ceramic green body;
7. and (3) green body processing: and processing the surface of the foamed ceramic green body into a dovetail groove structure. Thus, a foamed ceramic body with a dovetail groove is obtained.
8. Preparing ground glaze: the following raw materials are mixed according to the weight percentage: 45% of feldspar, 15% of quartz, 8% of Suzhou soil, 12% of calcium carbonate, 9% of zinc oxide, 6% of talcum and 5% of dolomite, adding water, ball milling, and sieving with a 250-mesh sieve to obtain ground enamel;
9. preparing an overglaze: the following raw materials are mixed according to the weight percentage: 37% of feldspar, 28% of quartz, 5% of kaolin, 5% of calcined talcum, 13% of calcite, 10% of zirconium silicate, 1% of zinc oxide and 1% of barium carbonate, and sieving the mixture with a 320-mesh sieve after ball milling by adding water to obtain overglaze;
10. glazing, decorating and drying: spraying water to wet a foamed ceramic blank with a dovetail groove after ash removal, spraying a layer of ground coat, filling the dovetail groove, spraying a layer of ground coat again to form a flat plate part of the ground coat layer, drying in a drying roller kiln for 8 hours, performing ink-jet printing to obtain a required decorative pattern, spraying a layer of ground coat, spraying the ground coat with the total thickness of 0.5mm, and drying in the drying roller kiln for 5 hours again to obtain a foamed ceramic glaze blank;
11. firing the glaze blank: and (3) putting the foamed ceramic glaze blank into a roller kiln for sintering, wherein the highest sintering temperature is 1150 ℃, the sintering period is 24 hours, and the steel slag foamed ceramic decorative plate of the Shi Yanwei groove-shaped glaze is obtained.
Performance testing
The water absorption, volume density and compressive strength of a sample are tested according to the test method of inorganic hard heat insulation products (GB/T5486-2008), the tensile strength of the vertical plate surface of a foamed ceramic matrix and a glaze layer (namely a matrix and a decorative layer) is tested according to the technical specification of heat insulation and water prevention engineering of hard foam polyurethane (GB/T50404-2007), and the heat conductivity coefficient of the foamed ceramic is tested by using a QTM-500 heat conductivity coefficient tester. The results of the performance test of the steel slag foamed ceramic decorative boards of Shi Yanwei channel enamels obtained in the above examples 1 to 4 are shown in Table 1 below.
Table 1 results of Performance test of slag foamed ceramic decorative boards obtained in examples 1 to 4
Figure BDA0003787666480000151
As is clear from Table 1, the foamed ceramic decorative board of the present invention has a water absorption of 0.9% to 1.3% and a bulk density of 280～325kg/m 3 The heat conductivity coefficient reaches 0.012-0.015W/(m.K), the compressive strength reaches 3-4.1 MPa, and the requirements of industry standard foaming ceramic insulation board for building (JG/T511-2017) are met. The vertical plate surface tensile strength of the foamed ceramic matrix and the glaze layer reaches 2.02-2.30 MPa, and the decorative layer is not easy to fall off and peel, and has good decorative effect and long service life.
As can be seen from examples 1 and 2, the magnesite powder is added in example 2 on the basis of example 1, and other conditions are the same as those in example 1, and test results show that the thermal conductivity of the foamed ceramic decorative board obtained in example 2 is slightly improved compared with that of example 1, namely, the thermal insulation performance is slightly reduced; but the mechanical property is obviously improved, the volume density is reduced, and the material is favorable for being used as a decorative plate; it has been demonstrated that the invention adds multiple blowing agents of different particle sizes to produce synergistic foaming effects.
From the results of example 2 and example 3, example 3 further increases the amount of steel slag based on example 2, reduces the amount of quartz and kaolin, and increases the mixing time; the bulk density and water absorption of example 3 were increased relative to example 2, but the thermal conductivity was better than that of example 2, and the mechanical properties were further improved.
From examples 3 and 4, example 4 fine-adjusts the ratio of the base glaze to the surface glaze on the basis of example 3, adjusts the thickness of the flat plate part of the base glaze (from 0.2mm to 0.5mm, and increases the corresponding drying time), and increases the firing time; as a result, the overall performance of the embodiment 4 is obviously improved, and therefore, the invention shows that the substrate and the glaze layer formula, the thickness of the flat plate part of the base glaze as the transition layer, the firing time and the like have the matching effect in the preparation condition, and the performance of the obtained foamed ceramic decorative board can be effectively improved under the matching of proper parameters.
Referring to FIG. 2, the foamed ceramic matrix microstructure prepared by the invention shows good foaming effect, and the average pore diameter is between 200 and 500 mu m.
Compared with the prior art, the invention has the following advantages:
1. the decorative layer of the foamed ceramic decorative board is firmly combined with the matrix. According to the invention, the groove structure is firstly processed on the surface of the pressed foamed ceramic blank, then the ground glaze is applied, a part of ground glaze slip flows into the grooves of the blank, and finally the ground glaze is applied, so that the foamed ceramic decorative plate is prepared after one-time firing, the tensile strength of the vertical plate surface of the foamed ceramic matrix and the glaze layer reaches 2.02-2.50 MPa, the matrix and the decorative layer are combined more firmly, the decorative layer is not easy to fall off and peel, and the service life of the foamed ceramic decorative plate is longer.
2. The foamed ceramic decorative board has good heat preservation and insulation effects and higher steel slag doping amount. The heat conductivity of the foamed ceramic decorative board is as low as 0.010-0.015W/(m.K), and the reason is that the higher iron content in the steel slag is effectively utilized, and the foamed ceramic decorative board is matched with a plurality of foaming agents with different particle sizes for cooperative foaming, and two layers of decorative glaze materials are provided, so that the heat conductivity of the foamed ceramic decorative board is reduced. In addition, the addition amount of the steel slag waste in the formula of the invention reaches 80-90 wt%, and the invention has the meaning of environmental protection.
The above-described embodiments of the present invention do not limit the scope of the present invention. Any other corresponding changes and modifications made in accordance with the technical idea of the present invention shall be included in the scope of the claims of the present invention.

Claims (9)

1. The steel slag foamed ceramic decorative plate is characterized by comprising a base body and a glaze layer which are sequentially arranged from bottom to top, wherein the upper surface of the base body is provided with a plurality of dovetail-shaped grooves, the lower surface of the glaze layer is provided with a plurality of protruding parts, and the protruding parts are in scarf joint with the grooves;
the raw materials of the matrix comprise the following components in percentage by mass: (0.1-0.6) a main material and a foaming agent; the main materials comprise 80-90% of steel slag, 5-6% of quartz, 2-4% of kaolin and 2-10% of high-temperature flux according to weight percentage;
the foaming agent comprises two or three of silicon carbide, carbon powder and magnesite powder in any proportion.
2. The Shi Caoxing glazed steel slag foamed ceramic decorative board as claimed in claim 1, whereinCharacterized in that the steel slag comprises SiO by weight percent 2 ：8.56～12.65％，MgO：1.59～8.10％，Fe 2 O 3 ：15.21～27.59％，Al 2 O 3 ：14.17～18.16％，CaO：34.87～52.21％，K 2 O is less than 2% and Na 2 O is less than 2%; ball milling the quartz, kaolin and high-temperature flux for 4-6 hours, and pre-treating the quartz, the kaolin and the high-temperature flux by a 200-250 mesh sieve; the high-temperature flux is one or a mixture of two of potassium feldspar and albite in any proportion.
3. The Shi Caoxing glazed steel slag foamed ceramic decorative board according to claim 1, wherein the silicon carbide is ball-milled for 7-12 h and then is subjected to pretreatment of 500-700 mesh sieve; ball milling carbon powder for 4-8 hr, and sieving with 320-500 mesh sieve; ball milling the magnesite powder for 3-6 h, and sieving with 240-320 mesh sieve.
4. The Shi Caoxing glazed steel slag foamed ceramic decorative panel according to claim 1, wherein the glaze layer comprises a base glaze layer and a cover glaze layer, wherein the base glaze layer is located between the base and cover glaze layers;
the raw materials of the ground coat layer comprise the following components in percentage by weight: 40-50% of feldspar, 10-15% of quartz, 6-8% of Suzhou soil, 8-12% of calcium carbonate, 5-10% of zinc oxide, 4-6% of talcum and 5-10% of dolomite;
the raw materials of the overglaze layer comprise the following components in percentage by weight: 34-37% of feldspar, 28-31% of quartz, 2-5% of kaolin, 3-5% of calcined talcum, 10-14% of calcite, 10-13% of zirconium silicate, 0.8-2% of zinc oxide and 0.5-1.0% of barium carbonate.
5. The Shi Caoxing glazed steel slag foamed ceramic decorative board according to claim 4, wherein a decorative pattern layer is arranged between the base glaze layer and the top glaze layer.
6. A method for producing a Shi Caoxing glazed steel slag foamed ceramic decorative board as claimed in any one of claims 1 to 5, comprising the steps of:
(1) Taking the raw materials of the matrix, adding water, and uniformly mixing to obtain blank slurry; granulating, homogenizing and ageing the blank slurry, performing compression molding and surface grooving to obtain a foamed ceramic green body with grooves;
(2) Applying glaze slurry on the foamed ceramic green body, and drying to obtain a foamed ceramic glaze blank;
(3) And (3) sintering the foamed ceramic glaze blank to obtain the steel slag foamed ceramic decorative plate with the groove-shaped glaze.
7. The method for preparing the Shi Caoxing glazed steel slag foamed ceramic decorative plate according to claim 6, wherein in the step (1), the raw materials of the matrix are mixed for 1-2 hours by a wet method under the condition that the water addition amount is 40-44 wt%, and the mixture is sieved by a 180-mesh sieve to obtain blank slurry with the specific gravity of 1.40-1.44; the granulation is that the blank slurry is aged for 24 to 48 hours and then spray granulation is carried out to obtain the blank; homogenizing and ageing, namely placing the blank into a storage bin for homogenizing and ageing for 16-24 hours; the pressure of the compression molding is 45-50 MPa.
8. The method for producing a steel slag foamed ceramic decorative board with Shi Caoxing glaze according to claim 6, wherein in the step (2), the glaze slip comprises a base glaze slip and a surface glaze slip, wherein the base glaze slip is firstly applied on the foamed ceramic green body, and the upper surface of the foamed ceramic green body is completely covered and then dried; performing ink-jet printing to form a decorative pattern layer; finally spraying surface glaze slurry and drying to obtain the foamed ceramic glaze blank.
9. The method for producing a Shi Caoxing glazed steel slag foamed ceramic decorative board according to claim 6, wherein in the step (3), the firing temperature is 1100-1170 ℃ and the firing time is 16-24 hours.
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