CN115925443B - Solid waste-based ceramic membrane support raw material with wide firing range and solid waste-based ceramic membrane support - Google Patents
Solid waste-based ceramic membrane support raw material with wide firing range and solid waste-based ceramic membrane support Download PDFInfo
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- CN115925443B CN115925443B CN202211730717.2A CN202211730717A CN115925443B CN 115925443 B CN115925443 B CN 115925443B CN 202211730717 A CN202211730717 A CN 202211730717A CN 115925443 B CN115925443 B CN 115925443B
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Abstract
The invention discloses a raw material of a solid waste-based ceramic membrane support body with a wide firing range and a solid waste-based ceramic membrane support body. The solid waste base ceramic membrane support body raw materials comprise high-aluminum solid waste raw materials, clay and a high-temperature bonding agent; the high-temperature bonding agent consists of potassium feldspar, dolomite, basic magnesium carbonate and borax. The solid waste of the raw material accounts for 90% at most, the resource utilization of the solid waste raw material can be realized, the cost is reduced, the firing temperature is relatively wide, the firing within 1170-1240 ℃ can be realized, the uniformity of the firing performance is good, the shrinkage difference is less than or equal to 1%, the strength is kept between 30 and 40MPa, and the porosity is 35-40%.
Description
Technical Field
The invention relates to a raw material of a ceramic membrane support, in particular to a raw material of a solid waste base ceramic membrane support with a wide firing range, and also relates to a solid waste base ceramic membrane support sintered and formed by the raw material, belonging to the technical field of ceramic materials.
Background
At present, the preparation methods of the ceramic flat membrane disclosed in the prior art are many, but the main raw materials are alumina, for example, chinese patent (CN 108246119A) discloses a ceramic flat membrane for sewage treatment and a preparation method thereof, wherein the main raw materials are alpha-alumina, titanium oxide and silica powder particles, and the sintering temperature reaches 1350 ℃; the chinese patent (CN 109851328A) discloses a process for preparing a high-performance ceramic flat membrane support, which uses alumina powder with a proportion of up to 60-80%, and sintering temperature up to 1200-1500 ℃, because pure commercial alumina is basically used to prepare the ceramic flat membrane in the existing process, on one hand, alumina itself is high in price, which results in high raw material cost, and on the other hand, sintering temperature required for sintering the ceramic flat membrane with alumina is high, which results in high sintering cost, and on the other hand, the existing ceramic flat membrane has the defects of high raw material cost, high sintering energy consumption and the like, which results in high product price, insufficient market competitiveness, and urgent need to solve the related problems.
Research shows that most industrial solid waste raw materials contain a large number of active silicon (aluminum) oxide tetrahedrons, abundant metal oxides and other useful components, and the application of the active silicon (aluminum) oxide tetrahedrons to the preparation of ceramic flat membranes can realize the efficient utilization of solid waste resources and greatly reduce the production cost of products. However, the solid waste raw materials have complex material composition and different phase melting temperatures, and in the material sintering process, the temperature points of liquid phases generated by components are different, so that the sample has a performance mutation in a certain temperature range, the sintering temperature range of a performance qualified interval is narrower, and the uniformity of the product is not easy to control in industrial production.
Disclosure of Invention
Aiming at the defects existing in the prior art, the first aim of the invention is to provide a solid waste ceramic membrane support raw material, wherein the solid waste ratio of the raw material is high and can reach 90%, the resource utilization of the solid waste raw material can be realized, the cost is reduced, the sintering temperature is wider, the sintering within 1170-1240 ℃ can be realized, the uniformity of the sintering performance is good, the shrinkage difference is less than or equal to 1%, the strength is kept between 30 and 40MPa, and the porosity is 35-40%.
The second object of the present invention is to provide a solid waste ceramic membrane support, which is formed by sintering the above raw materials, has good uniformity of performance, a shrinkage difference of less than or equal to 1%, strength of 30-40 MPa, and porosity of 35-40%, and has an absolute market competitive advantage as compared with the conventional ceramic membrane support prepared from alumina raw materials, which has similar performance and greatly reduced cost.
In order to achieve the technical aim, the invention provides a solid waste-based ceramic membrane support raw material with a wide firing range, which comprises a high-aluminum solid waste raw material, clay and a high-temperature bonding agent; the high-temperature bonding agent consists of potassium feldspar, dolomite, basic magnesium carbonate and borax.
The key of the solid waste ceramic membrane support body raw material in the technical scheme of the invention is that the special high-temperature adhesive is matched and used while the high-aluminum solid waste raw material is adopted. The high-alumina solid waste raw material has the advantages that the aluminum-silicon content is higher, the phase composition is relatively simple, the aluminum-containing component can be used as an inhibitor to prevent excessive migration of liquid phase, the sintering shrinkage of the support body can be effectively reduced, meanwhile, the silicon-aluminum ratio is higher, the mullite phase is generated in the sintering process, the mullite phase has excellent high-temperature creep resistance and high-temperature strength, the pinning effect is realized in the sintering process, the material diffusion speed among particles can be inhibited, the sintering shrinkage rate is reduced, and in addition, the expansion reaction of the mullite counteracts part of sintering shrinkage, so that the sintering temperature range can be expanded. On the basis, the special high-temperature bonding agent is matched for use, the sintering effect can be further improved, the sintering temperature range is enlarged, wherein potassium feldspar has higher high-temperature melt viscosity, meanwhile, the addition of dolomite can enable components to enter a eutectic region, the material sintering temperature is reduced, basic magnesium carbonate can be matched with a calcium-containing phase to increase the liquid-phase viscosity, the two high-melt viscosity liquid phases are added, so that the high-temperature viscosity of a sample is gradually increased along with the sintering temperature, the high-temperature viscosity change of a glass phase is small, the viscosity reduction speed is low, the high-temperature deformation resistance of the glass phase is high, the sintering range is enlarged, in addition, a small amount of borax is introduced, the melting temperature is only 800 ℃, the melting temperature of each component of aggregate can be reduced, the phase in the aggregate is promoted to be generated in advance, a large amount of liquid phase is not suddenly generated in a target sintering region to influence the performance, and the sintering stability is improved.
As a preferable scheme, the high-alumina solid waste raw material comprises at least one of high-alumina fly ash, primary alumina ash, high-alumina gangue, bauxite tailings, high-alumina gasification slag and combined red mud.
As a preferable scheme, the total mass percentage of silicon aluminum of the high-aluminum solid waste raw material is more than 75 percent, and the mass percentage of aluminum is more than 40 percent. The high-aluminum solid waste raw material has insufficient aluminum content, and a small amount of alpha-alumina powder can be properly added for blending. The invention adopts solid waste raw materials with higher silicon-aluminum mass content, which is mainly used for controlling the temperature range of the raw materials of the support body in the sintering process, thereby controlling the uniformity of the performance. If the aluminum content is too low, sintering shrinkage is larger, and the shrinkage difference of the low-aluminum solid waste is larger in the same temperature interval, which is not beneficial to control of product quality in industrial production.
As a preferred embodiment, the clay includes at least one of ball clay and kaolin. The clay is high in refractoriness, high in heat stability and high in plasticity, and components such as calcium, magnesium and silicon can be introduced into the clay, and eutectic melting can be carried out in multiple stages with the solid waste raw material at high temperature, so that a molten liquid phase is produced in a gradient manner, and mechanical strength is provided for the support body. Preferred clays are refractory virgin clays of relatively high purity and slightly less plastic having a refractoriness above 1300 ℃ and below 1580 ℃.
As a preferable scheme, the solid waste ceramic membrane support raw material further comprises a pore-forming agent, a low-temperature binder, a plasticizer, a lubricating water retention agent and a water reducing agent.
As a preferred scheme, the pore-forming agent comprises at least one of starch, calcium carbonate, silicon carbide and carbon black powder.
As a preferred embodiment, the plasticizer includes at least one of dibutyl phthalate, glycerin, and PVA.
As a preferred scheme, the lubricating water retention agent comprises at least one of fatty acid triglyceride and silicone resin;
as a preferred embodiment, the low temperature binder comprises cellulose.
As a preferred embodiment, the water reducing agent comprises sodium pyrophosphate.
As a preferred scheme, the composition comprises the following components in parts by mass: 65-90 parts of high-aluminum solid waste raw materials, 7-13 parts of clay, 5-8 parts of pore-forming agent, 2-6 parts of low-temperature binder, 2-5 parts of plasticizer, 5-10 parts of high-temperature binder, 2-4 parts of lubricating water-retaining agent and 0.5-1 part of water reducer. The high-aluminum solid waste raw materials mainly provide raw materials such as aluminum and silicon, so that the support body cannot generate larger sintering shrinkage in the high-temperature sintering process, the support body is ensured to have a certain sintering temperature range, the forming and mechanical strength of the support body are influenced if the proportion of the support body is too low, the mud state is poor if the proportion of clay is too low, the forming qualification rate is reduced, pores are blocked if the proportion is too high, and the sintering temperature is increased; if the addition ratio of the high-temperature binder is too low, the sintering effect is not obviously improved, and if the addition ratio of the high-temperature binder is too high, the sintering temperature range is also reduced.
As a preferable scheme, the high-temperature bonding agent consists of 3 to 4.5 parts by mass of potassium feldspar, 1 to 1.5 parts by mass of dolomite, 0.5 to 1.5 parts by mass of basic magnesium carbonate and borax. The borax in the high-temperature bonding agent mainly plays a role in fluxing, when the content is too high, sintering shrinkage is large, the size is not easy to control, the sintering aiding effect is weakened when the content is too low, the sintering temperature is not reduced, a potassium feldspar, dolomite and magnesium carbonate ternary eutectic system can be constructed, the melt viscosity can be regulated, liquid phase is produced in a gradient mode, further product shrinkage is controlled, the sintering temperature range can be reduced when the content of the borax, the dolomite and the magnesium carbonate is too low, and the sintering temperature can be increased when the content is too high.
The invention also provides a solid waste base ceramic membrane support body which is obtained by extrusion molding and sintering of the raw material composition.
Compared with the prior art, the technical scheme of the invention has the beneficial technical effects that:
the solid waste ceramic membrane support provided by the invention has the advantages that the solid waste ratio of the solid waste raw material can be up to 90%, the traditional high-purity alumina raw material is basically completely replaced, the resource utilization of the solid waste raw material can be realized, the raw material cost is greatly reduced, the sintering temperature is relatively wide, the sintering within 1170-1240 ℃ can be realized, the sintering performance uniformity is good, the shrinkage difference is less than or equal to 1%, the strength is kept between 30 and 40MPa, and the porosity is 35-40%.
The solid waste ceramic membrane support provided by the invention adopts high-aluminum solid waste raw materials, the aluminum-silicon content is higher, the phase composition is relatively simple, the aluminum-containing component can be used as a barrier agent to prevent excessive migration of liquid phase, the sintering shrinkage of the support can be effectively reduced, meanwhile, the silicon-aluminum ratio is higher, the mullite phase is generated in the sintering process, the mullite phase has excellent high-temperature creep resistance and high-temperature strength, the pinning effect is realized in the sintering process, the substance diffusion speed among particles can be blocked, the sintering shrinkage rate is reduced, and in addition, the expansion reaction of the mullite also counteracts partial sintering shrinkage, so that the sintering temperature range can be effectively expanded.
The solid waste ceramic membrane support provided by the invention adopts a special high-temperature adhesive, the high-temperature adhesive is formed by compounding potassium feldspar, dolomite, basic magnesium carbonate and borax, the components have a synergistic effect, the sintering process can be obviously modified, the sintering temperature is further enlarged, and the sintering stability is improved, wherein the potassium feldspar has higher high-temperature melt viscosity, meanwhile, the addition of the dolomite can enable the components to enter a eutectic interval, the material sintering temperature is reduced, the basic magnesium carbonate can be matched with a calcium-containing phase to increase the liquid phase viscosity, the addition of the two high-melt viscosity liquid phases is carried out, the sample gradually increases along with the sintering temperature, the high-temperature viscosity of the glass phase has little change, the viscosity reduction speed is low, the high-temperature deformation resistance of the glass phase is higher, the sintering range is enlarged, in addition, the melting temperature of the borax introduced in the auxiliary agent is only 800 ℃, the melting temperature of each component of the aggregate can be reduced, the aggregate phase is promoted to be generated in advance, and a large amount of liquid phase is not generated in the target sintering interval suddenly so as to influence the performance.
Drawings
FIG. 1 is a physical view of a ceramic membrane support prepared in example 1,
Detailed Description
The following specific examples are intended to further illustrate the present invention, but not to limit the scope of the claims.
The chemical reagents in the following examples are conventional commercial reagents unless otherwise specified.
Example 1
Step 1: according to the weight portion, each portion weighs 10g, 80 portions of 20 mu m gasification slag (aluminum content 46 percent and silicon content 35 percent) are weighed, 10 portions of 18 mu m ball clay are 10 portions, 8 portions of industrial grade calcium carbonate and 3 portions of cellulose are mixed for 25 minutes by using a counter-current mixer;
step 2: weighing 4 parts of potassium feldspar, 3.5 parts of dolomite, 1 part of basic magnesium carbonate and 1.5 parts of borax by weight, grinding and mixing for 8 minutes by a rapid mill, weighing 6 parts of the materials, adding the materials into a mixer, and mixing for 5 minutes;
step 3: 3 parts of dibutyl phthalate, 21 parts of water, 4 parts of fatty acid triglyceride and 0.7 part of 98% sodium pyrophosphate are weighed according to parts by weight, mixed for 20 minutes by using a stirrer, and then added into a mixer for 5 minutes;
step 4: and ageing the pug at 25 ℃ for 12 hours, and then pugging and forming by using an extruder.
Step 5: and (3) drying the obtained green body, and then, respectively carrying out heat preservation at 1170 ℃, 1190 and 1210 ℃ for 2 hours by using a muffle furnace to burn.
Example 2
Step 1: weighing 90 parts of 20-mu m bauxite (aluminum content 50% and silicon content 32%) and 13 parts of 18-mu m ball clay, 7 parts of industrial calcium carbonate and 3 parts of cellulose by weight, and mixing for 25 minutes by using a counter-current mixer;
step 2: weighing 5 parts of potassium feldspar, 3 parts of dolomite, 1.5 parts of basic magnesium carbonate and 1 part of borax by weight, grinding and mixing for 8min by a rapid mill, weighing 10 parts of the materials, adding the materials into a mixer, and mixing for 5min;
step 3: weighing 3 parts of glycerin, 21 parts of water, 3 parts of SCR-1011 organic silicon resin and 0.7 part of 98% sodium pyrophosphate by weight, mixing for 20min by using a stirrer, adding into a mixer, and mixing for 5min;
step 4: and ageing the pug at 25 ℃ for 12 hours, and then pugging and forming by using an extruder.
Step 5: and (3) drying the obtained green body, and then, respectively preserving heat for 2 hours at 1170 ℃, 1200 and 1220 ℃ by using a muffle furnace to burn.
Example 3
Step 1: weighing 70 parts of 15-mu m combined red mud (with 49% of aluminum content and 27% of silicon content) and 13 parts of 15-mu m kaolin, 8 parts of industrial calcium carbonate and 3 parts of cellulose by weight, and mixing for 30min by using a counter-current mixer;
step 2: weighing 3 parts of potassium feldspar, 3.5 parts of dolomite, 1.2 parts of basic magnesium carbonate and 1.5 parts of borax by weight, grinding and mixing for 8 minutes by a rapid mill, weighing 8 parts of the materials, adding the materials into a mixer, and mixing for 5 minutes;
step 3: weighing 3 parts of PVA, 21 parts of water, 3 parts of SCR-1011 organic silicon resin and 0.7 part of 98% sodium pyrophosphate by weight, mixing for 20 minutes by using a stirrer, adding into a mixer, and mixing for 5 minutes;
step 4: and ageing the pug at 25 ℃ for 12 hours, and then pugging and forming by using an extruder.
Step 5: and (3) drying the obtained green body, and then, respectively carrying out heat preservation at 1175, 1190, 1205 and 1220 ℃ for 2 hours by using a muffle furnace to burn.
Example 4
Step 1: weighing 90 parts of 20 mu m aluminum ash (aluminum content is 45% and silicon content is 32%) per 10g of the raw materials in parts by weight, taking 13 parts of 18 mu m ball clay as 7 parts of industrial grade calcium carbonate and 3 parts of cellulose, and mixing for 25 minutes by using a counter-current mixer;
step 2, weighing 3 parts of potassium feldspar, 3 parts of dolomite, 1 part of basic magnesium carbonate and 0.5 part of borax by weight, grinding and mixing for 8 minutes by a rapid mill, weighing 6 parts of the materials, adding the materials into a mixer, and mixing for 5 minutes;
step 3, weighing 3 parts of glycerin, 21 parts of water, 3 parts of fatty acid triglyceride and 0.7 part of 98% sodium pyrophosphate according to parts by weight, mixing for 20min by using a stirrer, and then adding into a mixer for mixing for 5min;
and 4, ageing the pug at 25 ℃ for 12 hours, and performing pugging and forming by using an extruder.
And 5, drying the obtained green body, and then, respectively preserving heat at 1200, 1220 and 1240 ℃ for 2 hours by using a muffle furnace to burn.
Comparative example 1
Step 1, weighing 80 parts of 20 mu m gasified slag (with the aluminum content of 46% and the silicon content of 35%) and 10 parts of 18 mu m ball clay, 8 parts of industrial calcium carbonate and 3 parts of cellulose in parts by weight, and mixing for 25 minutes by using a counter-current mixer;
step 2, weighing 3 parts of dibutyl phthalate, 21 parts of water, 4 parts of fatty acid triglyceride and 0.7 part of 98% sodium pyrophosphate according to parts by weight, mixing for 20 minutes by using a stirrer, and then adding into a mixer for mixing for 5 minutes;
and 3, ageing the pug at 25 ℃ for 12 hours, and performing pugging and forming by using an extruder.
And step 4, drying the obtained green body, and then, using a muffle furnace to heat-insulating the green body for 2 hours at 1170, 1190 and 1210 ℃ for sintering.
Table 1 shows the performance of the support materials of examples 1 to 4 and comparative example 1
| Project | Example 1 | Example 2 | Example 3 | Example 4 | Comparative example 1 |
| Temperature interval (DEG C) | 1170-1210 | 1170-1220 | 1175-1220 | 1200-1240 | 1180-1210 |
| Strength MPa | 31-33 | 33-34 | 30-34 | 30-32 | 18-19 |
| Shrinkage percentage% | 11±0.7 | 11.5±0.4 | 12±0.8 | 11±0.6 | 7±0.4 |
| Porosity% | 38-40 | 37-40 | 38-39 | 39-40 | 42-44 |
Claims (5)
1. A solid waste-based ceramic membrane support raw material with a wide firing range is characterized in that: comprises the following components in parts by mass: 65-90 parts of high-aluminum solid waste raw materials, 7-13 parts of clay, 5-8 parts of pore-forming agents, 2-6 parts of low-temperature binders, 2-5 parts of plasticizers, 5-10 parts of high-temperature binders, 2-4 parts of lubricating water-retaining agents and 0.5-1 part of water reducing agents;
the high-temperature bonding agent consists of 3-5 parts by mass of potassium feldspar, 3-4.5 parts by mass of dolomite, 0.5-1.5 parts by mass of basic magnesium carbonate and 0.5-1.5 parts by mass of borax;
the total mass percentage of silicon aluminum of the high-aluminum solid waste raw material is more than 75%, and the mass percentage of aluminum is more than 40%.
2. A solid waste-based ceramic membrane support raw material having a wide firing range according to claim 1, characterized in that: the high-aluminum solid waste raw material comprises at least one of high-aluminum fly ash, primary aluminum ash, high-aluminum coal gangue, bauxite tailings and high-aluminum gasification slag.
3. A solid waste-based ceramic membrane support raw material having a wide firing range according to claim 1, characterized in that: the clay comprises at least one of ball clay and kaolin.
4. A solid waste-based ceramic membrane support raw material having a wide firing range according to claim 1, characterized in that:
the pore-forming agent comprises at least one of starch, calcium carbonate, silicon carbide and carbon black powder;
the plasticizer comprises at least one of dibutyl phthalate, glycerol and PVA;
the lubricating water retention agent comprises at least one of fatty acid triglyceride and organic silicon resin;
the low temperature binder comprises cellulose;
the water reducing agent comprises sodium pyrophosphate.
5. The utility model provides a solid useless base ceramic membrane supporter which characterized in that: the raw material composition according to any one of claims 1 to 4, which is obtained by extrusion molding and sintering.
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