RU1780276C - Mass for article of building ceramics, mainly for large-sized ones - Google Patents

Abstract

FIELD: building materials. SUBSTANCE: mass has, %: low-melting clay 53-93; vermiculite or hydrophlogopite, or hydrobiotite (fraction is 2.0 mm, not more) 2-42; component from the group: ash, sand, slag of fraction 2.0 mm, not more 5-45. Components of mass were mixed, and specimens were formed from mass indicated which were roasted after drying. EFFECT: enhanced quality of mass proposed. 13 tbl

Description

 The invention relates to the industry of ceramic building materials and can be used for the production of wall materials: large-sized ceramic blocks and panels, ceramic stones, building bricks.

 The purpose of the invention is the expansion of the raw material base and the cheapening of the cost of production while maintaining quality.

This goal is achieved by the fact that in the composition of the ceramic mass on the basis of fusible clay and vermiculite - raw material, an additional detergent is introduced - a coarse-grained dense material with a particle size of not more than 2.0 mm with the following ratio of components, wt.%: Fusible clay 53-93
Hydrophlogopite, vermiculitis, hydrobiotitis 2-42
Component from the group of ash, sand, slag 5-45
When a coarsely dispersed component is added to the clay-vermiculite mass, the air and general shrinkage should naturally decrease. This helps to reduce the level of internal stresses and, as a result, increase the strength of the molded raw and burnt products.

 Experiments were carried out, confirming the effectiveness of introducing traditional cleansers into the clay-vermiculite mass. Graduated cupola slag, sand, fuel slag with a grain size of not more than 2.0 mm were used as a cleaner.

 The initial composition was taken clay-vermiculite mass, consisting of 98% clay and 2% vermiculite. From the materials of the application N 4716296/33 dated 06.06.89, keeping the amount of vermiculite unchanged, a detergent was added to this mass, respectively, reducing the clay content. Otoshitel - granulated cupola slag with a maximum particle size of 2.0 mm, waste iron foundry plant "Lentrublit". From these masses, plastic samples were formed, which, after drying, were calcined and tested. The results after the tests are presented in table 1.

 The results in the table. 1 show that the introduction of a sand scrubber up to 5% practically does not affect the properties of raw and calcined stone. An increase in the amount of a sanding agent, starting from 5% (compositions 3, 4, 5) and more, leads to a decrease in molding moisture, air and general shrinkage. Therefore, formulations with less than 5% sand detergent are not included in the claimed dosages. Ceramic mass (composition 6) was molded in a plastic way with difficulty - it was poorly connected. Therefore, the stone was obtained with high water absorption and low strength. T.O. Composition No. 6 goes beyond the limits claimed for the content of the healer.

 Table 2 shows the results of the effect of raw vermiculite in a three-component ceramic mass.

 From table 2 we can conclude that increasing the content of raw vermiculite can reduce the air and general shrinkage of samples of all compositions. The average density is also reduced, which will allow to obtain a less heat-conducting stone. The strength of the calcined stone is high in compositions 1.2 and naturally decreases in other compositions with an increase in the content of vermiculite. However, its value is sufficient for the production of bricks. Samples from composition 6 were hardly molded by the plastic method; therefore, the samples had high water absorption and relatively low strength. Therefore, the composition is beyond the scope of the claimed.

 To identify the effect of unexpanded vermiculite and a traditional sanding agent - sand on the properties of the calcined stone, experiments were carried out (by the same method), the results of which are presented in Tables 3 and 4.

 The results in table 3 show that the introduction of a sand detergent up to 5% practically does not affect the properties of raw and calcined stone. An increase in the amount of sand - starting agent, starting from 5% (compositions 3, 4, 5). Therefore, formulations with less than 5% sand detergent are not included in the claimed dosages. Ceramic mass (composition 6) was molded in a plastic way with difficulty - it was poorly connected. Therefore, the stone was obtained with high water absorption and low strength. T.O. Composition No. 6 goes beyond the limits claimed for the content of the healer.

 Table 4 shows the results of the effect of raw vermiculite in a three-component ceramic mass.

 From table 4 we can conclude that increasing the content of raw vermiculite can reduce the air and general shrinkage of samples of all compositions. The average density also decreases, which will make it possible to obtain a heat-conducting stone. The strength of the calcined stone is high in compositions 1, 2 and naturally decreases in other compositions with an increase in the content of vermiculite. However, its value is sufficient for the production of bricks. Samples from composition 6 were hardly molded by the plastic method; therefore, the samples had high water absorption and relatively low strength. Therefore, the composition is beyond the scope of the claimed.

 In addition, one of the claimed compositions of the clay-vermiculite raw sand system was tested during the production of an experimental batch of ceramic panels (300x600x3000 mm) at the Keramika non-ferrous industrial complex in Leningrad in 1989. The panels in the non-porous metallurgical complex were made of a mass consisting of 73% clay and 27% quartz sand. The experimental ceramic mass consisted of 66.6% clay, 28.6% quartz sand and 4.8% raw vermiculite from the Kovdor deposit. The composition and characteristics of raw and calcined stone are shown in table 5.

 These production experiments showed the obvious advantage of a three-component mass in all respects. Samples cut from experimental panels showed higher strength. But most importantly, the coefficient of variation of strength was determined, which turned out to be 0.153 for experimental panels versus 0.364 for panels of traditional mass without vermiculite. This indicates a smaller number of defects in the structure of the calcined stone due to the presence of vermiculite in it.

 To determine the effect of the ash-thinner on the properties of ceramic masses, experimental samples with ash from the Dubrovskaya state district power station in the city of Leningrad were molded and burned using the above method. The compositions of ceramic stone are given in table.6.

 From table 6 it follows that with an increase in the amount of added ash, the molding moisture content slightly decreases, and shrinkage slightly decreases. However, cracks that occurred in the drying of composition No. 6 gave a stone with cracks after firing as well, which explains the low strength. Therefore, the composition of No. 6 is beyond the scope of the claimed. The effect of raw vermiculite on an alumina ceramic mass is given in Table 7.

 From the table. 7 it follows that an increase in the content of vermiculite in the alumina mass contributes to a decrease in molding moisture, air and general shrinkage. The average density also decreases, which reduces the thermal conductivity of the calcined stone. However, a stone with low strength and high water absorption, which does not meet the requirements of the current standard, was obtained on composition No. 6. Therefore, the composition of No. 6 is beyond the scope of the claimed.

 The most promising is the use of vermiculite ores in ceramic mixtures, which consist of vermiculite and host minerals. In this case, vermiculite ore is a component in which there is vermiculite and a scavenger - containing minerals. The use of vermiculite ores in the manufacture of ceramic products greatly simplifies the technology (instead of a three-component mixture, a two-component one), and reduces the cost of production.

 To identify the effect of vermiculite ore on the properties of raw and calcined stone, the following compositions of ceramic masses were prepared, presented in Table 8.

 In these experiments, materials delivered from the Ural region were used - clay from the Revda deposit (Sverdlovsk region), vermiculite ore from the Potaninsky deposit. The ore contained 35% vermiculite, the rest were minerals pyroxenes, amphiboles, feldspars, etc. Composition No. 5 is pure Revdinsky clay for comparing the characteristics.

 The characteristics of raw and burnt stone are presented in table.9.

 Table materials 9 show (for compositions 1, 2, and 3) that the introduction of vermiculite ore into the ceramic mass positively affects the properties of raw and calcined stone. With an increase in the dosage of ore, molding properties improve - molding moisture, air and general shrinkage decrease. Strength in this case varies slightly. Artificial stone of composition N 4 is notable for its low strength. It is obvious that 50% of vermiculite ore in the mass adversely affects the molding properties. Despite the low values of air and general shrinkage, the stone obtained is loose and fragile. Such a composition of the ceramic mass is outside the scope of the claimed masses.

 Another promising option for using vermiculite-containing raw materials is the use of vermiculite ore dressing wastes, the so-called tailings. Such materials are ground during the enrichment process, which makes it possible to use them in ceramic technology without additional grinding. In addition, due to the imperfection of the enrichment technology, the waste contains unseparated vermiculite. So, for example, in the wastes of the Kovdor Vermiculite enrichment of the Kovdorslyud Association (Murmansk Region), the content of unrecovered vermiculite can reach 7-10%. The waste of the Potaninsky deposit is 10-15%.

 To identify the effect of wastes from the Vermiculite ore dressing of the Kovdorslyuda association on the properties of raw and fired stone, the following ceramic compositions were prepared, shown in Table 10.

 The enrichment waste of vermiculite ore from the Kovdorsky deposit contained 7% of unrecovered vermiculite. The rest of the minerals are scavengers, silicates and aluminosilicates of magnesium, calcium, and iron (forsterite, spodumene, etc.).

 The results of determining the characteristics of raw and calcined stone are presented in table 11.

 The materials of table 11 show that the compositions 1, 2 and 3 allow you to get raw with minimal shrinkage in the burnt stone of high strength. The composition of N 4 is practically not molded by the plastic method. The calcined stone, despite the low shrinkage, was obtained almost four times less durable. Thus, the composition of N 4 is not included in the boundaries of the claimed.

 Relative to the costs for each type of mixture.

 Let us give such a concrete example on the large-sized ceramic panels produced by us at the Ceramics Scientific and Production Association.

 Table 12 shows the compositions of the ceramic masses from which the experimental panels were made and, for comparison, the traditional mass of the Ceramics NPSO.

 Thus, it is obvious that the set goals are achieved in the case of using vermiculite ore, where vermiculite and host rocks will act as a cleanser.

 In addition, the use of vermiculite ore dressing wastes simultaneously solves the environmental problem. So, for example, the Kovdorslyud association accumulated more than 10 million tons of enrichment waste.

 When working on compositions containing cleaning agents, the heat consumption for drying and the total heat consumption will decrease. Only one percent reduction in molding moisture at industry enterprises saves 60 thousand tons of standard fuel.

 Thus, when using raw vermiculite in comparison with expanded vermiculite, a significant reduction in the cost of products is achieved by reducing the cost of raw materials, and environmental problems are also solved.

 In the claimed ceramic masses, vermiculite can be replaced by hydromicas — hydrophlogopite and hydrobiotite — products of the phlogopite genesis in vermiculite.

 The experiments showed the achievement of the goal when using them. The composition of the components is given in table.13.

Claims (1)

MASS FOR CONSTRUCTION CERAMICS PRODUCTS, PREVIOUSLY LARGE-SIZED, including low-melting clay, vermiculite or hydrophlogopite, or hydrobiotite fractions of more than 2.0 mm, characterized in that, in order to reduce the cost of production and expand the raw material base, while maintaining the quality, it additionally contains groups: ash, sand, slag fractions of not more than 2.0 mm in the following ratio of components, wt.%:
Fusible clay - 53 - 93
Vermiculite, or hydrophlogopite, or hydrobiotite fractions of not more than 2.0 mm - 2 - 42
Component from the group: ash, sand, slag fractions not exceeding 2.0 mm - 5 - 45

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