CN115385664A - 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 to 8 mass percent of the basic mineral, and the whitening agent accounts for 2 to 4 mass percent of the basic mineral. 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 base mineral comprises: in terms of mass percent, siO 2 69.0~72.6%、Al 2 O 3 15.5~17.0%、Fe 2 O 3 0.18~0.20%、TiO 2 0.03~0.05%、CaO 0.22~0.28%、MgO 0.51~0.65%、K 2 O 2.8~4.0%、Na 2 O3.0 to 4.5 percent; wherein, the inorganic binder accounts for 3 to 8 percent of the basic mineral by mass percent, and the whitening agent accounts for 2 to 4 percent of the basic mineral by mass percent.
Preferably, the particle size of the micro-expanded alumina is 400-700 nm.
Preferably, the raw material composition of the base mineral comprises: 9 to 12 percent of kaolin, 47 to 57 percent of sand, 1.5 to 3.0 percent of calcined talc, 10 to 15 percent of water mill potash feldspar, 15 to 21 percent of high white albite, 1 to 5 percent of high white mud and 2 to 6 percent of high white bentonite.
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, the interface is formed between the glass phase formed by the micro-expanded alumina and the base mineral during the firing process of the ceramic plate, and light is reflected and refracted at the interface so as to opalate 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 basic minerals of the high-whiteness ceramic plate, an inorganic binder and micro-expanded alumina serving as a whitening agent, and ball-milling uniformly 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 on the slurry subjected to 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 also comprises a suspending agent accounting for 0.2 to 0.4 percent of the mass of the base mineral and a dispergator accounting for 0.3 to 0.5 percent of the mass of the base mineral.
Preferably, the flow rate of the ceramic slurry is 30-65 s, and the specific gravity is 1.75-1.86 g/mL.
Drawings
FIG. 1 SEM image of 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 refers to 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: in terms of mass percent, siO 2 69.0~72.6%、Al 2 O 3 15.5~17.0%、Fe 2 O 3 0.18~0.20%、TiO 2 0.03~0.05%、CaO 0.22~0.28%、MgO 0.51~0.65%、K 2 O 2.8~4.0%、Na 2 O3.0 to 4.5 percent. 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 and maintaining a blank bodyExcellent mechanical properties.
In some embodiments, the feedstock composition of the base mineral comprises: 9 to 12 percent of kaolin, 47 to 57 percent of sand, 1.5 to 3.0 percent of calcined talc, 10 to 15 percent of water mill potash feldspar, 15 to 21 percent of high white albite, 1 to 5 percent of high white mud and 2 to 6 percent of high white bentonite. The raw material composition of the base mineral described above is merely an example, and the raw material composition of the base mineral of the present invention is not limited thereto, as long as the chemical composition of the base mineral described above is satisfied. In other words, the specific raw material of the base mineral can be selected appropriately according to the chemical composition of the base mineral.
The raw materials of the basic minerals can be purchased from commercial sources.
Metakaolin refers to kaolin of high age having high whiteness, high strength and excellent plasticity. Quantitative analysis by XRD showed that the phase composition of metakaolin included: by mass percentage, 25 to 30 percent of quartz, 50 to 55 percent of kaolin, 3 to 7 percent of muscovite, 4 to 10 percent of potash feldspar and 2 to 6 percent of amorphous phase. As an example, the phase composition of metakaolin includes: 28.53 percent of quartz, 52 percent of kaolin, 5.07 percent of muscovite, 9.93 percent of potash feldspar and 4.47 percent of amorphous phase by mass percentage. Unlike conventionally used hard kaolins, the phase composition of metakaolin has a reduced content of kaolin, but has a certain content of quartz, muscovite and potash feldspar. As an example, the phase composition of the hard kaolin includes: 77.42 percent of kaolin, 15.9 percent of diaspore and 6.39 percent of amorphous phase by mass percentage.
In some embodiments, the chemical composition of the metakaolin comprises: in terms of mass percent, siO 2 55~65%、Al 2 O 3 22~30%、Fe 2 O 3 0.3~0.6%、TiO 2 0.01~0.1%、CaO 0.01~0.06%、MgO 0.2~0.5%、K 2 O 1~3%、Na 2 0.1 to 0.5 percent of O. By way of example, the chemical composition of metakaolin includes: by mass percent, siO 2 59.88%、Al 2 O 3 28.01%、Fe 2 O 3 0.42%、TiO 2 0.02%、CaO 0.06%、MgO 0.24%、K 2 O 1.55%、Na 2 O 0.28%。
The sand material is sand (stone) material commonly used in the field. The chemical composition of the sand material comprises: 0.3 to 1.5 percent of ignition loss and SiO by mass percentage 2 75~79%、Al 2 O 3 11~17%、Fe 2 O 3 0.03~0.2%、CaO 0.1~0.2%、MgO 0.02~0.05%、K 2 O 3.5~4.5%、Na 2 0.4 to 5.0 percent of O. The whiteness of the sand material after being fired is more than 85 degrees. By controlling the content of silicon dioxide in the sand material to be more than 75%, the sand material replaces clay raw materials to become a main silicon source, and the whiteness of the product is favorably improved. In actual production, the sand material can be ground by water and the like.
Burnt talc is a silicate mineral. The chemical composition of the burned talc used in the examples included: calculated by mass percent, 0.11 percent of loss on ignition and SiO 2 64.53%、Al 2 O 3 2.08%、Fe 2 O 3 0.22%、TiO 2 0.09%、CaO 0.57%、MgO 31.67%、K 2 O 0.46%、Na 2 O 0.14%。
The water-milled potassium feldspar is a potassium-rich silicate mineral. The chemical composition of the water-milled potassium feldspar used in the examples comprises: calculated by mass percent, 0.25 percent of loss on ignition and SiO 2 71%、Al 2 O 3 14.91%、Fe 2 O 3 0.12%、TiO 2 0.03%、CaO 0.86%、MgO 0.22%、K 2 O 8.72%、Na 2 O 3.43%。
The high-white albite refers to albite with low content of colored element iron and titanium. The chemical composition of albite used in the examples included: calculated by mass percent, the loss on ignition is 1.11 percent, and SiO is 2 69%、Al 2 O 3 17.76%、Fe 2 O 3 0.12%、TiO 2 0.15%、CaO 0.82%、MgO 0.49%、K 2 O 0.32%、Na 2 O 9.97%。
The phase composition of the high white mud (high white refined mud) comprises: 32 to 36 percent of quartz, 16 to 19 percent of kaolin, 15 to 18 percent of muscovite, 12 to 15 percent of potassium feldspar and 5 to 8 percent of albite by mass percentage% and amorphous phase 2-4%. As an example, the phase composition of the high lime mud comprises: by mass percentage, 35.35 percent of quartz, 18.47 percent of kaolin, 16.04 percent of muscovite, 13.24 percent of potash feldspar, 7.88 percent of albite and 3.22 percent of amorphous phase. The chemical composition of the lime mud used in the examples included: calculated by mass percent, the loss on ignition is 5.91 percent and SiO 2 68.26%、Al 2 O 3 20.94%、Fe 2 O 3 0.25%、TiO 2 0.04%、CaO 0.14%、MgO 0.24%、K 2 O 2.91%、Na 2 O 1.13%。
The high-whiteness bentonite is bentonite with low content of nonferrous element iron and titanium. As an example, the chemical composition of high-whiteness bentonite includes: calculated by mass percent, loss on ignition is 7.05 percent, and SiO is 2 72.92%、Al 2 O 3 15.81%、Fe 2 O 3 1.05%、TiO 2 0.13%、CaO 0.64%、MgO 0.75%、K 2 O 1.06%、Na 2 O 0.41%。
Different from common calcined alumina, the micro-expanded alumina is light calcined alumina and contains a small amount of organic components. Therefore, the micro-expanded alumina forms a (micro) pore structure in the green body during firing. Referring to fig. 2, the micro-expanded alumina gradually oxidizes and releases gas during the firing of the green body, so that the porosity of the green body is increased, the reflection and refraction of light at the gas holes when the light passes through the green body are enhanced to further improve the whiteness of the green body, and the bulk density is slightly changed without obviously affecting 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, under the same using amount, the organic components of the micro-expanded alumina form micro pores in the system, so that the opalescence whitening effect on the ceramic body is more remarkable.
The grain diameter of the micro-expansion alumina is 400-700 nm. The particle diameter of the micro-expanded alumina is within the visible light band range (400 to 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 micro-expanded alumina accounts for 2 to 4 percent of the basic mineral by mass. 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 micro-expanded alumina, model PG-2-1, available from Zibonoda chemical Co., ltd, is used.
In ceramic formulations where clay-based raw materials are the main plastic materials, low clay content can lead to insufficient plasticity of the formulation and thus to 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 silica sol has a solids content of 25 to 30%. In some embodiments, the silica in the silica sol has a particle size of 10 to 30nm.
The inorganic binder accounts for 3 to 8 percent of the mass of the basic mineral. The addition amount of the inorganic binder is too small, and the blank reinforcing effect 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. In addition to a base mineral, an inorganic binder and micro-expanded alumina as a whitening agent, the ceramic slurry further includes a suspending agent in an amount of 0.2 to 0.4% by mass of the base mineral and a debonder in an amount of 0.3 to 0.5% by mass of the base mineral. 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 carboxymethylcellulose 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 75mm.
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 used by the spray tower is natural gas to replace coal water slurry, so as to further reduce the introduction of impurities. And feeding the blank powder obtained by spray granulation into a storage bin for further aging and homogenization 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 some embodiments, the maximum firing temperature is 1180 to 1210 ℃ and the firing period is 58 to 80min.
The whiteness of the low-clay system high-white ceramic plate exceeds 80 degrees.
Chinese patent CN113087508A mentions that α -alumina and quartz sand are introduced to react with silica-alumina at high temperature to form mullite phase, and react with 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 high-temperature liquid phase viscosity is slightly low in the sintering process due to excessive flux materials, and the green body is easy to deform. 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. In contrast to 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 of the invention has 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, which is not enough to melt the micro-expansion alumina in the sintering process, thus keeping the original phase in the ceramic phase and the glass phase to form a large amount of alumina microcrystals (the alumina microcrystals are presented in the form of corundum in an XRD pattern). Due to the non-uniformity of the refractive index of alumina and other phases, especially the glass phase, light is refracted and reflected when passing through, macroscopically manifested as an increase in the whiteness of the blank.
In some embodiments, the high white ceramic plate of the present invention has a specification of width (600 to 900) mm x length (900 to 1800) mm x thickness (11.5 to 13.5) mm.
It is also noted 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 ceramic tiles to produce fine zircon grains which scatter light to produce opaque, opacified 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 further detail with reference to 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 insubstantial modifications and adaptations of the invention by those skilled in the art based on the foregoing description are intended to be included within the scope of the invention. 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 mineral composition of the high-whiteness ceramic plate comprises the following raw materials: 9 to 12 percent of environmental kaolin, 22 to 27 percent of water mill sand, 25 to 30 percent of national white sand, 1.5 to 3.0 percent of calcined talc, 10 to 15 percent of water mill potassium feldspar, 15 to 21 percent of high white albite, 1 to 5 percent of high white mud and high white clay2 to 6 percent of white bentonite. The chemical composition of the water sanding comprises: calculated by mass percentage, 0.32 percent of loss on ignition and SiO 2 77.46%、Al 2 O 3 13.47%、Fe 2 O 3 0.05%、CaO 0.15%、MgO 0.02%、K 2 O 3.77%、Na 2 And 4.7 percent of O. The chemical composition of the national white sand comprises: calculated by mass percent, loss on ignition is 1.41 percent, and SiO is 2 77.86%、Al 2 O 3 15.19%、Fe 2 O 3 0.18%、TiO 2 0.16%、CaO 0.15%、MgO 0.05%、K 2 O 4.19%、Na 2 And O is 0.74 percent. The inorganic binder accounts for 3 to 8 percent of the basic mineral by mass. The micro-expansion alumina accounts for 2 to 4 percent of the mineral by mass. The grain diameter of the micro-expansion alumina is 400-700 nm. The raw materials also comprise a suspending agent accounting for 0.2 to 0.4 percent of the mass percent of the basic mineral and a dispergator accounting for 0.3 to 0.5 percent of the mass percent of the basic mineral.
S2: and ball-milling and sieving the raw materials 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 stone lining is high-alumina ball stone lining with the alumina content of more than 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 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 uses natural gas to replace coal water slurry so as to further reduce the introduction of impurities.
S5: and preparing the blank powder into a high-white 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 GB/T5950-2008 building materials and non-metal mineral products, and the water absorption is detected according to the determination of GB/T3810.3-2006 water absorption, apparent porosity, apparent relative density and volume weight; modulus of rupture was measured according to the determination of modulus of rupture and breaking strength from 3810.4-2006. The whiteness of the low-clay system high-white ceramic plate obtained in example 1 is 80 degrees or more, the water absorption is 0.08wt%, and the modulus of rupture is 43.5MPa.
Example 2
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 mineral composition of the high-whiteness ceramic plate comprises the following raw materials: the high-whiteness bentonite comprises, by mass, 10% of kaolin, 53% of water mill sand, 2% of calcined talc, 12% of water mill potassium feldspar, 18% of high-whiteness albite, 1% of high-whiteness clay and 4% of high-whiteness bentonite. The chemical composition of the water sanding comprises: calculated by mass percent, 0.32 percent of loss on ignition and SiO 2 77.46%、Al 2 O 3 13.47%、Fe 2 O 3 0.05%、CaO 0.15%、MgO 0.02%、K 2 O 3.77%、Na 2 And 4.7 percent of O. The inorganic binder accounts for 5 percent of the mass of the basic mineral. The micro-expanded alumina accounts for 3 percent of the mineral by mass. The grain diameter of the micro-expansion alumina is 400-700 nm. The raw materials also comprise a suspending agent accounting for 0.3 percent of the mass of the basic mineral and a dispergator accounting for 0.4 percent of the mass of the basic mineral.
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 stone lining is high-alumina ball stone lining with the alumina content of more than 90 wt%. The flow rate of the ceramic slurry is 48s, the specific gravity is 1.81g/mL, and the screen residue of a 325-mesh net reaches 2.9wt%.
S3: and removing iron from the ceramic slurry to control the content of iron element in the iron-removed slurry 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 after 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-white 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 GB/T5950-2008 building material and nonmetal mineral product whiteness detection method, and the water absorption is detected according to the measurement of the 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 from 3810.4-2006. The whiteness, water absorption and modulus of rupture of the low clay system high-white ceramic plate prepared in example 2 were comparable to those of example 1.
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 to 12 percent of environmental kaolin, 22 to 27 percent of water mill sand, 25 to 30 percent of national white sand, 1.5 to 3.0 percent of calcined talc, 10 to 15 percent of water mill potassium feldspar, 15 to 21 percent of high white albite, 1 to 5 percent of high white fine clay and 2 to 6 percent of high white bentonite. The inorganic binder accounts for 3 to 8 percent of the basic mineral by mass. The micro-expanded alumina accounts for 5 percent of the mineral by mass. The grain diameter of the micro-expansion alumina is 400-700 nm. The raw materials also comprise a suspending agent accounting for 0.2 to 0.4 percent of the mass percent of the basic minerals and a dispergator accounting for 0.3 to 0.5 percent of the mass percent of the basic minerals.
S2: the raw materials are ball-milled and sieved to obtain ceramic slurry. Cleaning a 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 iron-removed slurry to be below 0.1 wt%. An electromagnetic iron remover with 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, water absorption of 0.63wt%, and a fracture modulus of 28.25MPa. Due to the fact that the content of the micro-expansion aluminum oxide is too high, the firing temperature of the blank formula is high, the blank is green and fired, the water absorption rate 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 to 12 percent of kaolin, 22 to 27 percent of water mill sand, 25 to 30 percent of national white sand, 1.5 to 3.0 percent of calcined talc, 10 to 15 percent of water mill potassium feldspar, 15 to 21 percent of high-white albite, 1 to 5 percent of high-white fine clay and 2 to 6 percent of high-white bentonite. The inorganic binder accounts for 3 to 8 percent of the basic mineral by mass. The micro-expansion alumina accounts for 2 to 4 percent of the mineral by mass. The grain diameter of the micro-expansion alumina is 800-1200 nm. The raw materials also comprise a suspending agent accounting for 0.2 to 0.4 percent of the mass percent of the basic mineral and a dispergator accounting for 0.3 to 0.5 percent of the mass percent of the basic mineral.
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 feeding 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-white 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 to 12 percent of environmental kaolin, 22 to 27 percent of water mill sand, 25 to 30 percent of national white sand, 1.5 to 3.0 percent of calcined talc, 10 to 15 percent of water mill potassium feldspar, 15 to 21 percent of high white albite, 1 to 5 percent of high white fine clay and 2 to 6 percent of high white bentonite. The inorganic binder accounts for 3 to 8 percent of the basic mineral by mass. The calcined alumina accounts for 2 to 4 percent of the mineral by mass. The raw materials also comprise a suspending agent accounting for 0.2 to 0.4 percent of the mass percent of the basic mineral and a dispergator accounting for 0.3 to 0.5 percent of the mass percent of the basic mineral.
S2: the raw materials are ball-milled and sieved to obtain ceramic slurry. Cleaning a ball mill, adding the raw materials into the ball mill, adding water, and ball-milling to a specified fineness. The used ball stone lining is high-alumina ball stone lining with the alumina content of more than 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 feeding 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-white 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 ℃.
Claims (10)
1. A low clay system high white ceramic plate, characterized in that it comprises a base mineral, an inorganic binder and a micro-expanded alumina as a whitening agent; the chemical composition of the basic mineral comprises: by mass percent, siO 2 69.0~72.6%、Al 2 O 3 15.5~17.0%、Fe 2 O 3 0.18~0.20%、TiO 2 0.03~0.05%、CaO 0.22~0.28%、MgO 0.51~0.65%、K 2 O 2.8~4.0%、Na 2 O3.0 to 4.5 percent; wherein the inorganic binder accounts for 3 to 8 mass percent of the basic mineral, and the whitening agent accounts for 2 to 4 mass percent of the basic mineral.
2. The low clay system high-whiteness ceramic board according to claim 1, wherein the particle size of the micro-expanded alumina is 400 to 700nm.
3. The low clay system high white ceramic plate according to claim 1 or 2, wherein the raw material composition of the basic mineral comprises: 9 to 12 percent of kaolin, 47 to 57 percent of sand, 1.5 to 3.0 percent of burning talc, 10 to 15 percent of water-milled potassium feldspar, 15 to 21 percent of albite, 1 to 5 percent of white clay and 2 to 6 percent of high-white bentonite by mass percentage.
4. The low clay system high-white ceramic board according to any one of claims 1 to 3, wherein the melting temperature of the basic mineral of the high-white ceramic board 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 of claim 8, wherein the ceramic slurry further comprises 0.2 to 0.4 mass percent of a suspending agent and 0.3 to 0.5 mass percent of a dispergator based on the base mineral.
10. The method for preparing the ceramic slurry according to claim 8 or 9, wherein the flow rate of the ceramic slurry is 30 to 65s, and the specific gravity is 1.75 to 1.86g/mL.
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