CN214658385U - Foamed ceramic and high-strength foamed cement composite board - Google Patents
Foamed ceramic and high-strength foamed cement composite board Download PDFInfo
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- CN214658385U CN214658385U CN202023197286.7U CN202023197286U CN214658385U CN 214658385 U CN214658385 U CN 214658385U CN 202023197286 U CN202023197286 U CN 202023197286U CN 214658385 U CN214658385 U CN 214658385U
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Abstract
The utility model provides a foaming ceramic and foaming cement composite board that excels in, includes first foaming ceramic plate and second foaming ceramic plate, is equipped with the foaming cement board between second foaming ceramic plate and second foaming ceramic plate, is equipped with the structure reinforcement in the foaming cement board. The application provides a composite board of a foamed ceramic blank and high-strength foamed cement and a preparation method thereof, wherein the foamed ceramic composite board can effectively reduce the production cost of a foamed ceramic partition board; meanwhile, the foamed ceramic plate used in the invention is formed by dry pressing a blank body, the foamed ceramic is fired by a mould-free naked firing process, the upper surface and the lower surface of the blank are relatively flat, the blank can be used for a composite plate without surface cutting, the utilization rate of a finished product of the foamed ceramic material can be improved, and the cost of the foamed ceramic composite plate is reduced.
Description
Technical Field
The application relates to a foamed ceramic and high-strength foamed cement composite board.
Background
The foamed ceramic light board is a common wall material in the field of architectural decoration, is a high-porosity ceramic material which is prepared by firing solid wastes such as polished porcelain slag, waste stone tailings, stone saw mud and the like serving as main raw materials by adopting a high-temperature foaming technology, has the properties of light weight, high strength, heat preservation, sound insulation, fire resistance and moisture resistance, and has the limitation of wide application in the field of buildings due to higher production cost. The high-strength foamed cement is a high-strength light plate made of cement, foaming agent and reinforcing agent as main raw materials.
At present, foamed ceramic is generally produced by flatly paving foamed ceramic granulation powder in a mold frame made of refractory materials, cooling the foamed ceramic granulation powder after high-temperature foaming in a cutting workshop to remove the upper surface, the lower surface and the four sides of a blank plate, wherein the cut leftover materials are more, and the yield of the foamed ceramic is only about 70%. Therefore, the production cost of foamed ceramics is always high. The composite board formed by directly combining the foamed ceramic blank with the foamed cement has the excellent performance of the foamed ceramic and can effectively reduce the production cost.
SUMMERY OF THE UTILITY MODEL
In order to solve the above-mentioned problem, this application has proposed a foamed ceramic and high strength foamed cement composite board on the one hand, including first foamed ceramic board and second foamed ceramic board, be equipped with the foamed cement board between second foamed ceramic board and second foamed ceramic board, be equipped with the structural reinforcement in the foamed cement board. The application provides a composite board of a foamed ceramic blank and high-strength foamed cement and a preparation method thereof, wherein the foamed ceramic composite board can effectively reduce the production cost of a foamed ceramic partition board; meanwhile, the foamed ceramic plate used in the invention is formed by dry pressing a blank body, the foamed ceramic is fired by a mould-free naked firing process, the upper surface and the lower surface of the blank are relatively flat, the blank can be used for a composite plate without surface cutting, the utilization rate of a finished product of the foamed ceramic material can be improved, and the cost of the foamed ceramic composite plate is reduced.
Preferably, the structural reinforcement is a mesh reinforcement; a plurality of L-shaped hanging parts are hung on the reinforcing steel bar net, and a plurality of reinforcing fibers are arranged on the L-shaped hanging parts.
Preferably, the L-shaped hanging part is abutted against the first foamed ceramic plate or the second foamed ceramic plate, and the first foamed ceramic plate or the second foamed ceramic plate is provided with a clamping groove matched with the L-shaped hanging part; the clamping groove is an inclined groove which is obliquely arranged relative to the surface of the first foamed ceramic plate or the second foamed ceramic plate. The preparation method of the foamed ceramic and high-strength foamed cement composite board comprises the steps of filling high-strength foamed cement slurry between two foamed ceramic plates, and obtaining a composite board with a three-layer structure after a foamed cement layer is hardened; the composite board has the advantages that the upper surface and the lower surface of the foamed ceramic are utilized, the utilization rate of the foamed ceramic is improved to more than 85%, the composite board has the excellent performances of light weight, high strength, water resistance, moisture resistance, heat preservation and heat insulation of the foamed ceramic, and meanwhile, the production cost of the foamed ceramic and the high-strength foamed cement composite board is reduced; the application the foaming cement that the foaming ceramic composite board was filled uses graphite alkene, oxidation graphite alkene or polypropylene fiber as the reinforcing agent, has increased combined material's whole toughness when improving foaming cement intensity.
On the other hand, the manufacturing method of the foamed ceramic and high-strength foamed cement composite board is also disclosed, and comprises the following steps:
manufacturing foamed ceramics;
cutting the foamed ceramic to obtain a foamed ceramic plate;
and (3) foaming cement between the two layers of foamed ceramics by using a vertical die casting method, removing the die, and cutting and maintaining to obtain the foamed ceramic composite board. In the prior art, the sintered foamed ceramic is generally obtained by arranging powder with a certain thickness in a die frame made of refractory materials, and the die frame absorbs a large amount of heat, influences the heat dissipation rate of the foamed ceramic during annealing and prolongs the annealing time of the foamed ceramic. The invention utilizes the light filling agent to reduce the specific gravity of the green body and reduce the foaming expansion rate of the foamed ceramic, utilizes star kaolin or flint clay or bauxite as a formula to provide alumina as a foam stabilizer, improves the viscosity and the surface tension of the high-temperature melt of the foamed ceramic, ensures that the foamed ceramic uniformly expands and the green body keeps the shape in the foaming process, and promotes the mutual reaction of sheets with the same chemical composition by introducing the green body bonding agent with similar chemical components, thereby fusing a plurality of sheets into a whole at high temperature, and ensuring the firm combination among the sheets without chemical defects. According to the invention, the heat absorption of kiln furniture is reduced, the annealing time of the foamed ceramic is shortened, the energy consumption of the foamed ceramic at the sintering section is reduced to about 60% of that of the traditional process, and various properties of the foamed ceramic meet the use requirements, so that the economic benefit of producing the foamed ceramic product by taking granite saw mud as a main raw material is improved.
Preferably, the vertical die casting method comprises the following steps:
fixing two-layer foamed ceramic plates on two sides of a vertical mold, arranging a baffle at an opening at the edge end of the vertical mold, forming an upward open cavity in the middle, arranging a layer of steel wire mesh in the cavity, pouring high-strength foamed cement into the cavity between the two foamed ceramic plates, and dismantling the bottom plate and the baffle after curing the high-strength foamed ceramic plates.
Preferably, the foaming cement comprises the following raw materials in parts by weight: foaming cement: 60-80 parts; fly ash: 15-35 parts; reinforcing agent: 1-3 parts; foaming agent: 2-4 parts; the reinforcing agent is one or a combination of more than two of graphene, graphene oxide and polypropylene fibers in any proportion; the thickness of the foamed ceramic plate is 20-50mm, and the thickness of the composite plate is 60-240 mm.
Preferably, the foamed ceramic is prepared according to the following steps:
s1, material preparation: the foamed ceramic raw material comprises the following raw materials in parts by weight: granite sawing mud: 40-60 parts; foam stabilizer: 15-35 parts; fluxing agent: 5-15 parts; foaming agent: 0.2-1 part, green body reinforcing agent: 0.01-0.1 part; the green body binding agent raw material comprises the following raw materials in parts by weight: perlite powder: 60-80 parts; potassium feldspar: 5-20 parts of a solvent; quartz: 1-5 parts; kaolin: 5-15 parts; foaming agent: 0.2-1 part;
s2, wet grinding of a ball mill: the raw materials are as follows by mass ratio: ball: water 1: 2: 0.6, respectively putting the foamed ceramic and the green body binder raw materials into a ball milling tank, and wet milling the mixture by a ball mill, wherein the fineness is controlled to ensure that the residue of a ten thousand-hole sieve is not more than 5.0 wt%;
s3, granulation: carrying out spray granulation on the mixture obtained after wet grinding of the foamed ceramic to obtain granulated powder, controlling the particle size to be 40-80 meshes and not less than 80 wt%, and drying to obtain the water content of not more than 7 wt%; slurry obtained after wet grinding of the green body binding agent enters a slurry tank for later use;
s4, secondary mixing: uniformly paving 15-25 parts of light filler on a foamed ceramic granulation powder conveying belt according to the mass ratio, and uniformly mixing the light filler and the granulation powder through a secondary drum sieve to obtain a mixture;
s5, dry pressing and forming: conveying the foamed ceramic mixture to a press by a belt conveyor and a bucket elevator, and pressing into sheets of 15-25mm by a dry pressing method;
s6, drying the blank: drying the slices in a drying roller kiln for 80-240min at a drying temperature not higher than 220 ℃ until the water content of the dried slices is not higher than 0.5 wt%;
s7, green body superposition: spraying a layer of green body binding agent on the upper surfaces of the dried sheets, and mutually overlapping a plurality of sheets to form a green body;
s8, firing: coating a refractory coating on the bottom of the obtained blank, feeding the blank into a roller kiln, and sintering the blank into a foamed ceramic blank by adopting a dieless naked sintering high-temperature foaming process;
s9, cold processing: cutting, edging, chamfering and grooving, and color separating, grading and packaging the cold-processed product and transferring the product into a warehouse; the thickness of the foamed ceramic blank is as follows: 80-150 mm; the thickness of the green body binder is as follows: 0.1-0.5 mm; the refractory coating is composed of one or more than two of alumina, corundum and kaolin in any proportion; the foam stabilizer is one or more than two of star kaolin, flint clay or bauxite in any proportion; the light filler is one or two of vitrified micro bubbles and foamed ceramic leftover material particles in any proportion; the fluxing agent is one or more than two of potash feldspar, albite, talc, calcite, fluorite, lepidolite, zinc oxide, magnesium oxide, iron oxide and manganese oxide in any proportion, and the fluxing agent contains zinc oxide; the foaming agent is one or two of black silicon carbide and green silicon carbide in any proportion, and the granularity of the foaming agent is not less than 1000 meshes.
Preferably, the foamed ceramic is prepared according to the following steps:
s1, material preparation: the raw materials are taken as follows according to parts by weight: gold tailings: 35-50 parts; foam stabilizer: 12-35 parts; fluxing agent: 10-20 parts; foaming agent: 0.2-1 part, green body reinforcing agent: 0.01-0.1 part; the foamed ceramic is formed by stacking and sintering a plurality of sheets, wherein the base materials of the sheets are gold tailings, a foam stabilizer containing aluminum oxide and a light filler, the content of the aluminum oxide in the gold tailings is not lower than 6 wt%, and the content of the calcium oxide in the gold tailings is not higher than 2 wt%; the application utilizes SiO in gold tailings2And Al2O3Melting into a glass phase with certain viscosity at high temperature, promoting the mutual adhesion of the thin slices, and taking the gold tailing substances as a main body for foaming.
S2, wet grinding of a ball mill: the raw materials are as follows by mass ratio: ball: water 1: 2: 0.6, respectively putting the foamed ceramic and the green body binder raw materials into a ball milling tank, and wet milling the mixture by a ball mill, wherein the fineness is controlled to ensure that the residue of a ten thousand-hole sieve is not more than 5.0 wt%;
s3, granulation: carrying out spray granulation on the mixture obtained after wet grinding of the foamed ceramic to obtain granulated powder, controlling the particle size to be 40-80 meshes and not less than 80 wt%, and drying to obtain the water content of not more than 7 wt%;
s4, secondary mixing: uniformly and flatly paving 20-30 parts of light filler on a granulating powder conveying belt according to the mass ratio, and uniformly mixing the light filler and the granulating powder through a secondary drum sieve to obtain a mixture;
s5, dry pressing and forming: conveying the foamed ceramic mixture to a press by a belt conveyor and a bucket elevator, and pressing into sheets of 15-25mm by a dry pressing method;
s6, drying the blank: drying the slices in a drying roller kiln for 80-240min at a drying temperature not higher than 220 ℃ until the water content of the dried slices is not higher than 0.5 wt%;
s7, green body superposition: overlapping a plurality of sheets to form a blank;
s8, firing: coating a refractory coating on the bottom of the obtained blank, feeding the blank into a roller kiln, and sintering the blank into a foamed ceramic blank by adopting a dieless naked sintering high-temperature foaming process;
s9, cold processing: cutting, edging, chamfering and grooving, and color separating, grading and packaging the cold-processed product and transferring the product into a warehouse; the thickness of the foamed ceramic blank is as follows: 80-150 mm; the refractory coating is composed of one or more than two components of alumina, corundum and kaolin in any proportion; the light filler is one or two of vitrified micro bubbles and foamed ceramic leftover material particles in any proportion; the fluxing agent is one or more than two of potash feldspar, albite, talc, calcite, fluorite, lepidolite, zinc oxide, magnesium oxide, iron oxide and manganese oxide in any proportion; the foaming agent is one or two of black silicon carbide and green silicon carbide in any proportion, and the granularity of the foaming agent is not less than 1000 meshes; the blank reinforcing agent is one or more than two of CMA, HPMC and PVA in any proportion.
Preferably, the foamed ceramic is prepared according to the following steps: s1, material preparation: the foamed ceramic raw material comprises the following raw materials in parts by weight: polishing slurry: 30-50 parts; expanded perlite micropowder: 10-25 parts; foam stabilizer: 10-20 parts; fluxing agent: 5-20 parts of a solvent; foaming agent: 0.2-1 part, green body reinforcing agent: 0.01-0.1 part; the green body bonding agent is prepared from the following raw materials in parts by weight: perlite powder: 40-80 parts; potassium feldspar: 5-15 parts; kaolin: 5-15 parts; foaming agent: 0.1-1 part;
s2, wet grinding of a ball mill: the raw materials are as follows by mass ratio: ball: water 1: 2: 0.6, respectively putting the foamed ceramic and the green body binder raw materials into a ball milling tank, and wet milling the mixture by a ball mill, wherein the fineness is controlled to ensure that the residue of a ten thousand-hole sieve is not more than 5.0 wt%;
s3, granulation: carrying out spray granulation on the mixture obtained after wet grinding of the foamed ceramics, controlling the particle size to be 40-80 meshes and not less than 80 wt%, and drying to obtain the mixture with the water content of not more than 7 wt%; slurry obtained after wet grinding of the green body binding agent enters a slurry tank for later use;
s4, dry pressing and forming: conveying the foamed ceramic mixture to a press by a belt conveyor and a bucket elevator, and pressing into sheets of 15-25mm by a dry pressing method;
s5, drying the blank: drying the slices in a drying roller kiln for 80-240min at a drying temperature not higher than 220 ℃ until the water content of the dried slices is not higher than 0.5 wt%;
s6, blank body superposition: spraying a layer of green body binding agent on the upper surfaces of the dried sheets, and mutually overlapping a plurality of sheets to form a green body;
s7, firing: coating a refractory coating on the bottom of the obtained blank, feeding the blank into a roller kiln, and carrying out die-free naked firing and high-temperature foaming firing to obtain a foamed ceramic blank;
s8, cold machining: the method comprises the steps of cutting, edging, chamfering, slotting and the like, wherein the cold-processed product is subjected to color separation, grading, packaging and transferring into a warehouse; the thickness of the green body binder is as follows: 0.1-0.5 mm; the thickness of the foamed ceramic blank is as follows: 80-150 mm; the refractory coating is composed of one or more than two of alumina, corundum and kaolin in any proportion; the foam stabilizer is one or more than two of star kaolin, flint clay or bauxite in any proportion; the fluxing agent is one or more than two of potash feldspar, albite, talc, calcite, fluorite, lepidolite, zinc oxide, magnesium oxide, iron oxide and manganese oxide in any proportion, and the fluxing agent contains magnesium oxide; the foaming agent is one or two of black silicon carbide and green silicon carbide in any proportion, and the granularity of the foaming agent is not less than 1000 meshes; the blank reinforcing agent is one or more than two of CMA, HPMC and PVA in any proportion.
Preferably, the foamed ceramic is prepared according to the following steps:
s1, material preparation: the raw materials are taken as follows according to parts by weight: perlite tailings: 50-80 parts; foam stabilizer: 10-30 parts; fluxing agent: 5-15 parts; foaming agent: 0.2-1 part, green body reinforcing agent: 0.01-0.1 part;
s2, wet grinding of a ball mill: the raw materials are as follows by mass ratio: ball: water 1: 2: 0.6, respectively putting the raw materials into a ball milling tank, wet-milling the mixture by a ball mill, and controlling the fineness to control the residue of a ten thousand-hole sieve to be not more than 5.0 wt%;
s3, granulation: carrying out spray granulation on the mixture after wet grinding, controlling the particle size to be not less than 80 wt% in a range of 40-80 meshes, and drying to obtain granulated powder, wherein the water content is not more than 7 wt%;
s4, secondary mixing: uniformly spreading 15-25 parts of expanded perlite micro powder on a granulation powder conveying belt according to the mass ratio, and uniformly mixing the expanded perlite micro powder and the granulation powder through a secondary drum sieve to obtain a mixture;
s5, dry pressing and forming: conveying the foamed ceramic mixture to a press by a belt conveyor and a bucket elevator, and pressing the foamed ceramic mixture into sheets by a dry pressing method;
s6, drying the blank: drying the slices in a drying roller kiln for 80-240min at a drying temperature not higher than 220 ℃ until the water content of the dried slices is not higher than 0.5 wt%;
s7, green body superposition: overlapping a plurality of sheets to form a blank;
s8, firing: coating a refractory coating on the bottom of the obtained blank, feeding the blank into a roller kiln, and carrying out die-free naked firing and high-temperature foaming firing to obtain a foamed ceramic blank;
s9, cold processing: the cooling work comprises cutting, edging, chamfering and grooving, and the products after cold processing are subjected to color separation, grading and package transferring into a warehouse; the thickness of the foamed ceramic blank is as follows: 80-150 mm; the refractory coating is combined by one or more than two of alumina, corundum and kaolin in any proportion; the thickness of the thin sheet is 15-25 mm; the foam stabilizer is one or more than two of star kaolin, flint clay or bauxite in any proportion; the fluxing agent is one or more than two of potash feldspar, albite, talc, calcite, fluorite, lepidolite, zinc oxide, magnesium oxide, iron oxide and manganese oxide in any proportion; the fluxing agent contains zinc oxide; the foaming agent is one or two of black silicon carbide and green silicon carbide in any proportion, and the granularity of the foaming agent is not less than 1000 meshes; the blank reinforcing agent is one or more than two of CMA, HPMC and PVA in any proportion.
This application can bring following beneficial effect:
1. the invention utilizes the light filling agent to reduce the specific gravity of the green body and reduce the foaming expansion rate of the foamed ceramic, utilizes star kaolin or flint clay or bauxite as a formula to provide alumina as a foam stabilizer, improves the viscosity and the surface tension of the high-temperature melt of the foamed ceramic, ensures that the foamed ceramic uniformly expands and the green body keeps the shape in the foaming process, and promotes the mutual reaction of sheets with the same chemical composition by introducing the green body bonding agent with similar chemical components, thereby fusing a plurality of sheets into a whole at high temperature, and ensuring the firm combination among the sheets without chemical defects. According to the invention, the heat absorption of kiln furniture is reduced, the annealing time of the foamed ceramic is shortened, the energy consumption of the foamed ceramic at the sintering section is reduced to about 60% of that of the traditional process, and various properties of the foamed ceramic meet the use requirements, so that the economic benefit of producing a foamed ceramic product by taking granite saw mud as a main raw material is improved;
2. in the prior art, the sintered foamed ceramic is generally obtained by arranging powder with a certain thickness in a die frame made of refractory materials, and the die frame absorbs a large amount of heat, influences the heat dissipation rate of the foamed ceramic during annealing and prolongs the annealing time of the foamed ceramic. The invention utilizes the light filling agent to reduce the specific gravity of the green body and reduce the foaming expansion rate of the foamed ceramic, utilizes star kaolin or flint clay or bauxite as a formula to provide alumina as a foam stabilizer, improves the viscosity and the surface tension of the high-temperature melt of the foamed ceramic, ensures that the foamed ceramic uniformly expands and the green body keeps the shape in the foaming process, and promotes the mutual reaction of sheets with the same chemical composition by introducing the green body bonding agent with similar chemical components, thereby fusing a plurality of sheets into a whole at high temperature, and ensuring the firm combination among the sheets without chemical defects. According to the invention, the heat absorption of kiln furniture is reduced, the annealing time of the foamed ceramic is shortened, the energy consumption of the foamed ceramic at the sintering section is reduced to about 60% of that of the traditional process, and various properties of the foamed ceramic meet the use requirements, so that the economic benefit of producing the foamed ceramic product by taking granite saw mud as a main raw material is improved.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the application and together with the description serve to explain the application and not to limit the application. In the drawings:
fig. 1 is a schematic structural diagram of the present application.
Detailed Description
In order to clearly explain the technical features of the present invention, the present application will be explained in detail by the following embodiments in combination with the accompanying drawings.
In a first embodiment, as shown in fig. 1, a foamed ceramic and high strength foamed cement composite board comprises a first foamed ceramic plate 1 and a second foamed ceramic plate 2, a foamed cement plate 3 is arranged between the second foamed ceramic plate 2 and the second foamed ceramic plate 2, and a structural reinforcement 4 is arranged in the foamed cement plate 3. The structural reinforcing piece is a reinforcing mesh; a plurality of L-shaped hanging parts 5 are hung on the reinforcing steel bar net, and a plurality of reinforcing fibers are arranged on the L-shaped hanging parts 5. The L-shaped hanging part 5 is abutted against the first foamed ceramic plate 1 or the second foamed ceramic plate 2, and a clamping groove 6 matched with the L-shaped hanging part 5 is formed in the first foamed ceramic plate 1 or the second foamed ceramic plate 2; the clamping groove 6 is an inclined groove which is obliquely arranged relative to the surface of the first foamed ceramic plate 1 or the second foamed ceramic plate 2.
The preparation method of the foamed ceramic and high-strength foamed cement composite board comprises the steps of filling high-strength foamed cement slurry between two foamed ceramic plates, and obtaining a composite board with a three-layer structure after a foamed cement layer is hardened; the composite board has the advantages that the upper surface and the lower surface of the foamed ceramic are utilized, the utilization rate of the foamed ceramic is improved to more than 85%, the composite board has the excellent performances of light weight, high strength, water resistance, moisture resistance, heat preservation and heat insulation of the foamed ceramic, and meanwhile, the production cost of the foamed ceramic and the high-strength foamed cement composite board is reduced; the application the foaming cement that the foaming ceramic composite board was filled uses graphite alkene, oxidation graphite alkene or polypropylene fiber as the reinforcing agent, has increased combined material's whole toughness when improving foaming cement intensity.
In the 2 nd to 5 th embodiments, the foamed cement is formed by uniformly stirring according to a common method, and comprises the following raw materials in parts by mass: foaming cement: 60-80 parts; fly ash: 15-35 parts; reinforcing agent: 1-3 parts; foaming agent: 2-4 parts; the reinforcing agent is one or a combination of more than two of graphene, graphene oxide and polypropylene fibers in any proportion; the thickness of the foamed ceramic plate is 20-50mm, and the thickness of the composite plate is 60-240 mm. Examples 2-5 disclose the synthesis of foamed ceramics compounded therewith.
In a second embodiment, a method for synthesizing a foamed ceramic from granite saw mud comprises the following steps:
s1, material preparation: the foamed ceramic raw material comprises the following raw materials in parts by weight: granite sawing mud: 40-60 parts; foam stabilizer: 15-35 parts; fluxing agent: 5-15 parts; foaming agent: 0.2-1 part, green body reinforcing agent: 0.01-0.1 part; the green body binding agent raw material comprises the following raw materials in parts by weight: perlite powder: 60-80 parts; potassium feldspar: 5-20 parts of a solvent; quartz: 1-5 parts; kaolin: 5-15 parts; foaming agent: 0.2-1 part; the foam stabilizer is one or more than two of star kaolin, flint clay or bauxite in any proportion; the light filler is one or two of vitrified micro bubbles and foamed ceramic leftover material particles in any proportion; the fluxing agent is one or more than two of potash feldspar, albite, talc, calcite, fluorite, lepidolite, zinc oxide, magnesium oxide, iron oxide and manganese oxide in any proportion, and the fluxing agent contains zinc oxide; the foaming agent is one or two of black silicon carbide and green silicon carbide in any proportion, and the granularity of the foaming agent is not less than 1000 meshes; the blank reinforcing agent is one or more than two of CMA, HPMC and PVA in any proportion.
S2, wet grinding of a ball mill: the raw materials are as follows by mass ratio: ball: water 1: 2: 0.6, respectively putting the foamed ceramic and the green body binder raw materials into a ball milling tank, and wet milling the mixture by a ball mill, wherein the fineness is controlled to ensure that the residue of a ten thousand-hole sieve is not more than 5.0 wt%;
s3, granulation: carrying out spray granulation on the mixture obtained after wet grinding of the foamed ceramic to obtain granulated powder, controlling the particle size to be 40-80 meshes and not less than 80 wt%, and drying to obtain the water content of not more than 7 wt%; slurry obtained after wet grinding of the green body binding agent enters a slurry tank for later use;
s4, secondary mixing: uniformly paving 15-25 parts of light filler on a foamed ceramic granulation powder conveying belt according to the mass ratio, and uniformly mixing the light filler and the granulation powder through a secondary drum sieve to obtain a mixture; the specific raw material ratios of the foamed ceramic raw material and the green body binder are shown in table 1;
table 1:
s5, dry pressing and forming: conveying the foamed ceramic mixture to a press by a belt conveyor and a bucket elevator, and pressing into sheets of 15-25mm by a dry pressing method;
s6, drying the blank: drying the slices in a drying roller kiln for 80-240min at a drying temperature not higher than 220 ℃ until the water content of the dried slices is not higher than 0.5 wt%;
s7, green body superposition: spraying a layer of green body binding agent on the upper surfaces of the dried sheets, and mutually overlapping a plurality of sheets to form a green body; the thickness of the green body binder is as follows: 0.1-0.5 mm;
s8, firing: coating a refractory coating on the bottom of the obtained blank, feeding the blank into a roller kiln, and sintering the blank into a foamed ceramic blank by adopting a dieless naked sintering high-temperature foaming process; the thickness of the foamed ceramic blank is as follows: 80-150mm, wherein the refractory coating is composed of one or more than two of alumina, corundum and kaolin in any proportion;
s9, cold processing: the method comprises the steps of cutting, edging, chamfering, slotting and the like, and the products after cold machining are subjected to color separation, grading, packaging and transferring into a warehouse.
S10, performing product characterization on the obtained material, wherein specific parameters and measurement data are shown in a table 2.
Table 2:
note that: the compressive strength in Table 2 is equal to or greater than a value, which indicates that the measured value is between the value and the value + 1.
Therefore, the foamed ceramic prepared by using the granite saw mud as the main raw material by adopting the method has low volume weight and high strength, meets the use requirement of the partition board, has use value, avoids heat absorption of kiln furniture and can obviously reduce the energy consumption of products.
In a third embodiment, the synthesis of the foamed ceramic by using the gold tailings as raw materials comprises the following steps:
s1, material preparation: the raw materials are taken as follows according to parts by weight: gold tailings: 35-50 parts; foam stabilizer: 12-35 parts; fluxing agent: 10-20 parts; foaming agent: 0.2-1 part, green body reinforcing agent: 0.01-0.1 part; the foamed ceramic is formed by stacking and sintering a plurality of sheets, wherein the base materials of the sheets are gold tailings, a foam stabilizer containing aluminum oxide and a light filler, the content of the aluminum oxide in the gold tailings is not lower than 6 wt%, and the content of the calcium oxide in the gold tailings is not higher than 2 wt%;
s2, wet grinding of a ball mill: the raw materials are as follows by mass ratio: ball: water 1: 2: 0.6, respectively putting the foamed ceramic and the green body binder raw materials into a ball milling tank, and wet milling the mixture by a ball mill, wherein the fineness is controlled to ensure that the residue of a ten thousand-hole sieve is not more than 5.0 wt%;
s3, granulation: carrying out spray granulation on the mixture obtained after wet grinding of the foamed ceramic to obtain granulated powder, controlling the particle size to be 40-80 meshes and not less than 80 wt%, and drying to obtain the water content of not more than 7 wt%;
s4, secondary mixing: uniformly and flatly paving 20-30 parts of light filler on a granulating powder conveying belt according to the mass ratio, and uniformly mixing the light filler and the granulating powder through a secondary drum sieve to obtain a mixture, wherein the specific components are shown in Table 3;
table 3:
s5, dry pressing and forming: conveying the foamed ceramic mixture to a press by a belt conveyor and a bucket elevator, and pressing into sheets of 15-25mm by a dry pressing method;
s6, drying the blank: drying the slices in a drying roller kiln for 80-240min at a drying temperature not higher than 220 ℃ until the water content of the dried slices is not higher than 0.5 wt%;
s7, green body superposition: overlapping a plurality of sheets to form a blank;
s8, firing: and (2) feeding the bottom of the obtained blank body into a roller kiln, wherein the refractory coating is composed of one or more than two of alumina, corundum and kaolin in any proportion, a non-mold naked firing high-temperature foaming firing foaming ceramic blank is adopted, and the thickness of the foaming ceramic blank is as follows: 80-150 mm;
s9, cold processing: cutting, edging, chamfering and grooving, and color separating, grading and packaging the cold-processed product and transferring the product into a warehouse;
s10, performing product characterization on the obtained material, wherein specific parameters and measurement data are shown in a table 4.
Table 4:
note that: the compressive strength in Table 2 is equal to or greater than a value, which indicates that the measured value is between the value and the value + 1.
Therefore, the foamed ceramic prepared by using the gold tailings as the main raw material by adopting the method has low volume weight and high strength, meets the use requirement of the partition board, has use value, avoids the heat absorption of kiln furniture, can obviously reduce the energy consumption of products, fully utilizes the characteristics of substances in the gold tailings, and plays an important role in integrating the gold tailings after superposition roasting.
In a fourth embodiment, a method for synthesizing a foamed ceramic from a ceramic polishing slurry comprises the following steps:
s1, material preparation: the foamed ceramic raw material comprises the following raw materials in parts by weight: polishing slurry: 30-50 parts; expanded perlite micropowder: 10-25 parts; foam stabilizer: 10-20 parts; fluxing agent: 5-20 parts of a solvent; foaming agent: 0.2-1 part, green body reinforcing agent: 0.01-0.1 part; the green body bonding agent is prepared from the following raw materials in parts by weight: perlite powder: 40-80 parts; potassium feldspar: 5-15 parts; kaolin: 5-15 parts; foaming agent: 0.1-1 part;
s2, wet grinding of a ball mill: the raw materials are as follows by mass ratio: ball: water 1: 2: 0.6, respectively putting the foamed ceramic and the green body binder raw materials into a ball milling tank, and wet milling the mixture by a ball mill, wherein the fineness is controlled to ensure that the residue of a ten thousand-hole sieve is not more than 5.0 wt%;
s3, granulation: carrying out spray granulation on the mixture obtained after wet grinding of the foamed ceramics, controlling the particle size to be 40-80 meshes and not less than 80 wt%, and drying to obtain the mixture with the water content of not more than 7 wt%; slurry obtained after wet grinding of the green body binding agent enters a slurry tank for later use;
s4, dry pressing and forming: conveying the foamed ceramic mixture to a press by a belt conveyor and a bucket elevator, and pressing into sheets of 15-25mm by a dry pressing method; the specific components are shown in table 5:
table 5:
s5, drying the blank: drying the slices in a drying roller kiln for 80-240min at a drying temperature not higher than 220 ℃ until the water content of the dried slices is not higher than 0.5 wt%;
s6, blank body superposition: and spraying a layer of green body bonding agent on the upper surface of the dried sheet, wherein the thickness of the green body bonding agent is as follows: 0.1-0.5mm, and mutually overlapping a plurality of sheets to form a blank;
s7, firing: and (2) feeding the bottom of the obtained blank body into a roller kiln, wherein the refractory coating is composed of one or more than two of alumina, corundum and kaolin in any proportion, and a foamed ceramic blank is obtained by adopting mould-free naked firing high-temperature foaming firing, and the thickness of the foamed ceramic blank is as follows: 80-150 mm;
s8, cold machining:the method comprises the steps of cutting, edging, chamfering, slotting and the like, and the products after cold machining are subjected to color separation, grading, packaging and transferring into a warehouse. The compressive strength of the foamed ceramic obtained by the method is more than 5MPa, the volume weight is 300-500 kg/m3, the water absorption is less than 1%, the fire resistance limit is more than 1h, the heat conductivity coefficient is 0.1-0.14 w/(m.k), and the daily gas consumption of each cubic product in a sintering section is 40-60 Nm3。
And S9, performing product characterization on the obtained material, wherein specific parameters and measurement data are shown in a table 6.
Table 6:
note that: the compressive strength in Table 2 is equal to or greater than a value, which indicates that the measured value is between the value and the value + 1.
In a fifth embodiment, the synthesis of a foamed ceramic using perlite tailings as raw material comprises the following steps:
s1, material preparation: the raw materials are taken as follows according to parts by weight: perlite tailings: 50-80 parts; foam stabilizer: 10-30 parts; fluxing agent: 5-15 parts; foaming agent: 0.2-1 part, green body reinforcing agent: 0.01-0.1 part; under the condition that no special description is provided, the foam stabilizer is one or more than two of star kaolin, flint clay or bauxite in any proportion; the fluxing agent is one or more than two of potash feldspar, albite, talcum, calcite, fluorite, lepidolite, zinc oxide, magnesium oxide, iron oxide and manganese oxide in any proportion; the fluxing agent contains lepidolite; the foaming agent is one or two of black silicon carbide and green silicon carbide in any proportion, and the granularity of the foaming agent is not less than 1000 meshes; the blank reinforcing agent is one or more than two of CMA, HPMC and PVA in any proportion;
s2, wet grinding of a ball mill: the raw materials are as follows by mass ratio: ball: water 1: 2: 0.6, respectively putting the raw materials into a ball milling tank, wet-milling the mixture by a ball mill, and controlling the fineness to control the residue of a ten thousand-hole sieve to be not more than 5.0 wt%;
s3, granulation: carrying out spray granulation on the mixture after wet grinding, controlling the particle size to be not less than 80 wt% in a range of 40-80 meshes, and drying to obtain granulated powder, wherein the water content is not more than 7 wt%;
s4, secondary mixing: uniformly spreading 15-25 parts of expanded perlite micro powder on a granulation powder conveying belt according to the mass ratio, and uniformly mixing the expanded perlite micro powder and the granulation powder through a secondary drum sieve to obtain a mixture; specific raw material compositions are shown in table 7;
table 7:
s5, dry pressing and forming: conveying the foamed ceramic mixture to a press by a belt conveyor and a bucket elevator, and pressing the foamed ceramic mixture into sheets by a dry pressing method;
s6, drying the blank: drying the slices in a drying roller kiln for 80-240min at a drying temperature not higher than 220 deg.C, wherein the water content of the dried slices is not higher than 0.5 wt%, and the thickness of the slices is 15-25 mm;
s7, green body superposition: overlapping a plurality of sheets to form a blank;
s8, firing: feeding the bottom of the obtained blank body into a roller kiln, wherein the refractory coating is composed of one or more than two of alumina, corundum and kaolin in any proportion, and obtaining a foamed ceramic blank with the thickness of 80-150mm by adopting mould-free naked firing high-temperature foaming firing;
s9, cold processing: the cooling work comprises cutting, edging, chamfering, slotting and the like, and the products after cold processing are subjected to color separation, grading, packaging and transferring into a warehouse;
s10, performing product characterization on the obtained material, wherein specific parameters and measurement data are shown in a table 8.
Table 8:
note that: the compressive strength in Table 2 is equal to or greater than a value, which indicates that the measured value is between the value and the value + 1.
Therefore, the foamed ceramic prepared by using the perlite tailings as the main raw material by adopting the method has low volume weight and high strength, meets the use requirement of the partition board, has use value, avoids heat absorption of kiln furniture, and can obviously reduce the energy consumption of products.
Particularly, the selection of the foam stabilizer, the selection of the foaming agent, the addition mode of the expanded perlite micro powder and whether the modification treatment is carried out on the perlite, have important influence on the formation of the final foamed ceramic, the material property and the like.
The embodiments in the present specification are described in a progressive manner, and the same and similar parts among the embodiments are referred to each other, and each embodiment focuses on the differences from the other embodiments. In particular, for the system embodiment, since it is substantially similar to the method embodiment, the description is simple, and for the relevant points, reference may be made to the partial description of the method embodiment.
The above are merely examples of the present application and are not intended to limit the present application. Various modifications and changes may occur to those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the scope of the claims of the present application.
Claims (3)
1. The foamed ceramic and high-strength foamed cement composite board is characterized in that: including first foaming ceramic plate and second foaming ceramic plate, be equipped with the foaming cement board between second foaming ceramic plate and second foaming ceramic plate, be equipped with the structure reinforcement in the foaming cement board.
2. The foamed ceramic and high-strength foamed cement composite board as claimed in claim 1, wherein: the structural reinforcing piece is a reinforcing mesh; a plurality of L-shaped hanging parts are hung on the reinforcing steel bar net, and a plurality of reinforcing fibers are arranged on the L-shaped hanging parts.
3. The foamed ceramic and high-strength foamed cement composite board as claimed in claim 2, wherein: the L-shaped hanging part is abutted against the first foamed ceramic plate or the second foamed ceramic plate, and a clamping groove matched with the L-shaped hanging part is formed in the first foamed ceramic plate or the second foamed ceramic plate; the clamping groove is an inclined groove which is obliquely arranged relative to the surface of the first foamed ceramic plate or the second foamed ceramic plate.
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