RU2283818C1 - Method of manufacturing products based on silica-containing binder - Google Patents

Abstract

FIELD: manufacture of building materials.

SUBSTANCE: invention relates to manufacture of a variety of different-destination building products such as bricks, wall blocks, footway materials, face wall and floor tiles as well as various heat-insulation and structural heat-insulation units like slabs, blocks, shells, and segments showing elevated strength and heat-insulation characteristics based on silica-containing binder using non-expensive mineral raw material and production wastes. Method involves preparing silica-containing binder with density 1.1-2.1 g/cc from mixture composed of inorganic bonding material, silica-containing component, and water under vigorous stirring in high-speed mixer at stirring speed 1500-2500 rpm, stirred particle vibration frequency2000-35000 Hz, and heating to 80-90^°C followed by cooling at stirring with speed 40-100 rpm for 10-12 h to 15-25^°C. Preparation of molding blend is accomplished by blending 9.0-13.5% of silica-containing binder with silica-containing aggregate, homogenizing the blend, and heat treatment of molded products at 400-950^°C. When combustible aggregates are used heat treatment is carried out at 90^°C.

EFFECT: simplified process, enlarged assortment of products, and improved strength and heat-insulation characteristics thereof.

8 cl, 1 dwg, 5 tbl, 3 ex

Description

The invention relates to the production of various building products, materials for various purposes, including, in particular, piece materials such as bricks, wall blocks, paving, facade and floor tiles, and various heat-insulating and structural-heat-insulating products in the form of plates, blocks, shells , segments with high strength and heat insulation properties based on silica binder using cheap mineral raw materials and waste from various industries.

At its core, this technology is based on the junction of concrete technology using traditional binders (cement, alkaline silicates, etc.) and ceramic technology (creating a durable product by sintering). In the production of a large group of building products (bricks, tiles, blocks), it can be an alternative to the production of traditional materials based on mineral binders or ceramics. In some cases, it allows the production of high-quality materials and products using unconventional fillers, for example, agricultural processing waste, to obtain various materials with higher performance characteristics (strength, frost resistance, thermal conductivity, porosity, acid and alkali resistance, resistance to evaporation, etc.) .d.) compared with those produced by traditional technologies.

A known method of manufacturing building products based on liquid glass by preparing a mixture containing liquid glass (91-96 wt.%), Hydrofluoric acid (hardening accelerator) (0.7-1.5 wt.%), Filler (perlite) (3 -7 wt.%) And water (0.3-0.6 wt.%), Drying it to a residual moisture content of 35-40%, grinding the resulting material, molding products from it and heating them to 200-400 ° C followed by holding them at this temperature and cooling (SU 643461, 03/14/1977).

The material obtained by this method has increased strength, but does not have sufficient water resistance (water absorption 11%, hydroscopicity 1.2%), acid resistance.

A known method for the production of insulating products from liquid glass, converted by heating into a finely porous mass, in which liquid glass is crushed into pieces of the desired size, these pieces are stuffed into metal collapsible forms and heated to 300-350 ° C for several hours (3-4 hours).

According to this method, it is possible to obtain a water-resistant material by first mixing liquid soluble glass with dry mineral additives (chalk, lime, calcium chloride), drying the mass, crushing, and subsequent processing. Get the material, as described in the description of this known method, with great mechanical strength. The method is technologically complex enough, does not allow to obtain a wide range of construction products.

Water resistance data are not given (SU 4332431, 05.1935).

A known method for producing chemically resistant concrete based on a silicate binder, in which high siliceous alkaline glass of a fraction of 0.315-1.25 mm containing 8-40 wt.% High silica alkaline glass of dust fraction up to 0.315 mm, ground quartz sand with a specific surface of 4500 cm ^{2 is} mixed / g, ordinary quartz sand with a particle size of 1.4, quartzite crushed stone fractions 5-20 mm and water. The mixture is then molded, pressed and heat treated at 187 ° C and a pressure of 12 atm for 21 hours. A material is obtained having an acid absorption of 1.5-2.0 wt.%, A compressive strength of 112.5 MPa (SU 1025688, 06/30/1983).

However, using these known methods, it is not possible to obtain products having both high strength properties and increased water resistance.

A known method of producing aluminosilicate material comprising preparing a raw mix of natural, clay material and water, molding the mixture, drying and firing. According to the invention, inorganic glaze-forming substances are additionally introduced into the raw material mixture, and the molding of the product is carried out by filling with the raw mixture the form in which gas-permeable gaskets are installed. When drying, a predetermined part of the surface of the molded product is left open, and drying is carried out in a stream of infrared radiation with a wavelength of 5-10 μm with forced extraction. Preferably, glaze-forming substances are substances selected from the series: alumina, barium oxide, iron oxide, calcium oxide, magnesium oxide, sodium oxide, zinc oxide, silicon dioxide. Enter them into the mixture in an amount of 5-10%. The resulting materials have high monoporosity, but are mainly used as carriers in catalytic and sorption processes in the chemical industry (RU 2197424, 01.27.2003).

A known method of manufacturing heat-insulating products based on a composition containing in wt.%: Silicon-containing component - tripoli 42.0-50.0; sodium hydroxide 4.5-12.0; metal additive - aluminum hydroxide 3.0-7.0; water glass 8.0-15.0; the rest of the water (RU 2148046, 04/27/2000).

The manufacture of heat-insulating products (shells, plates, bricks, blocks, etc.) is as follows. An aqueous solution of sodium hydroxide with a density of ρ = 1.3 g / cm ^{3 is} loaded into the CA 400/300 V mixer-activator, aluminum hydroxide is gradually added in portions, a known amount of water glass with a density of ρ = 1.2 g / cm ³ is added thereto. and stirred for 10-20 minutes Then Tripoli is added and mixed with a stirrer with a speed of 400-450 rpm. The mixture is heated to a temperature of 65 ± 5 ° C due to the interaction of chemical components, the mixture is stirred until the temperature of the mass begins to decrease.

The finished mixture is poured into molds of various types and sizes and incubated for 24 hours, then the molds are stacked in a furnace at a temperature of 300 ± 25 ° C and kept in an oven for 2.5-3.5 hours, then they are taken out and stored in a receiver ( thermos), at a temperature of 60-70 ° C, incubated for 18 hours. Then the molds are taken out and folded out. Finished products are stored.

According to this invention, acid-resistant materials are obtained with increased water and fire resistance, but not possessing simultaneously increased strength and heat-insulating properties.

The closest in technical essence and the achieved result is a known method for the manufacture of building products (RU 2206536, 06/20/2003), including the preparation of a molding material from a silicate binder, silica filler, hardening accelerator and water, molding from the resulting mixture of products and drying them, use silicate a binder selected from the group of liquid glass, silicate block, sodium hydrosilicate, silica gel, silica filler with a moisture content of not more than 20% and a dispersion of 4-50 microns and 0.1-2.5 mm, preparation A washing mass with a moisture content of 6-10% is carried out with vigorous stirring to a homogeneous state by first co-grinding the specified silicate binder with 2-5 wt.% the specified filler to its dispersion of 4-50 microns, then introducing water and adding to the resulting activated mixture 20, 0-46.5 wt.% The specified filler with a dispersion of 4-50 microns and 24.5-63.9 wt.% Pigment and hardening accelerator, molding is carried out by pressing at a pressure of from 1.0 to 150 kg / cm ² and drying - at 25-400 ° C in the following ratio of components, wt.%: specified silicate binder - 0.5-15.5; the specified siliceous filler is 75.9-85.9; hardening accelerator - 0.5-5.0; water, 8.1-13.3; pigment - 0-5.0. Moreover, liquid glass is used, preferably in an amount of 0.5-15.5 wt.%, A silicate block with a dispersion of 4-20 microns, preferably in an amount of 0.5-3.0 wt.%, Sodium hydrosilicate with a dispersion of 4-20 microns is preferably in an amount of 3.0-4.0 wt.%, silica gel with a dispersion of 4-20 microns, preferably in an amount of 2.0-4.0 wt.%, and after drying, annealing is additionally carried out at 600-1000 ° C for 15- 90 min

The disadvantage of this method is primarily its complexity due to the need to introduce special curing additives, the need for a stage of drying of products, as well as insufficiently high strength properties of the obtained products.

The technical task of the claimed invention is to simplify the method, expand the range of products, increase their strength and thermal insulation properties, expand the raw material base, both due to mineral raw materials and industrial wastes, cheaper products.

The stated technical problem is achieved in that a method of manufacturing products based on a silica-containing binder by preparing a molding composition from a silica-containing binder and silica-containing aggregate, molding the products from the obtained molding composition and subsequent heat treatment of the molded products includes preparing a binder with a density of 1.1-2.1 g / cm ³ from a mixture containing an inorganic binder, a silica-containing component (material) and water with intensive mixing at high speed The mixer with a stirring speed of 1500-2500 rpm, an oscillation frequency of the mixed particles of 2000-35000 Hz, heating to 80-90 ° C and then cooling it with stirring from 40 to 100 rpm for 10-12 hours at 15 -25 ° C, the preparation of the molding mass is carried out by mixing 9.0-13.5 wt.% The prepared silica binder and 86.5-91.0 wt.% Silica-containing aggregate in the mixer, homogenization of the molding mixture, and the heat treatment of molded products is carried out at 90 -950 ° С depending on the type of aggregate.

The method is characterized in that, as the inorganic binder, alkali metal or ammonium hydroxide is used (in the preparation of the binder), a silicate binder selected from the group consisting of sodium hydrosilicates, liquid glass (sodium, potassium), a silicate block, a cullet formed during production and application of glass (window, technical), silica sol, silica gel, aluminosilicates.

As the silica-containing component in the preparation of the inorganic binder in the method according to the invention, various sands (sea, river, quarry), quartz sand with a moisture content of not more than 6%, clays, for example quarry clays with a moisture content of more than 20%, calcined clay, loam, sandy loam, loess deposits, silica fume obtained from ferroalloy production wastes, stone processing or grinding waste, such as granite, or in the production of crushed granite, various hydromica, in particular, used in the production of Vermiculite or expanded perlite.

In the method according to the invention, a silica-containing material with a particle size of 0.5-20.0 mm or from 40 Å to 50 μm is used as a silica-containing component in the preparation of the binder.

In the method according to the invention, various water is used (if necessary purified by filtration from organic impurities, for example, algae residues, living organisms), for example, river, sea, and mineralized.

As a silica-containing aggregate in the preparation of the molding material in the method according to the invention, various sands (river, marine, quarry), granite, basalt, vermiculite, expanded perlite sand, expanded clay, hydromica, metallurgical slag, coal slag and ash, waste clay, stone waste are used and stone processing; a mixture of amorphous silica with wood processing waste (sawdust, shavings) or crop processing waste, such as, in particular, bonfire from processing flax, straw, sunflower husk, etc.

A silica-containing aggregate is used with different fineness (particle size), for example, with a fineness of 4-50 microns or 60-120 microns, or 0.4-2.5 mm, or mixtures thereof in various combinations.

A silica-containing aggregate with a moisture content of not more than 10% is used.

According to the method according to the invention, the molding of products is carried out, for example, by semi-dry pressing directly on pallets (on presses equipped with a dosing and feeding system for pallets), for example, with a pressing force of 1.0 to 400 kg / cm ² .

The molding of products by the method according to the invention can also be carried out, for example, by casting (vibration casting) or vibropressing.

So, in the method according to the invention in the preparation of an inorganic silicon-containing binder as an inorganic binder, use:

- sodium hydrosilicates in the form of semi-aqueous sodium hydrosilicate (Na ₂ Si ₂ O ₅ · 0.5H ₂ O), three-water hydrosilicate (Na ₂ Si ₂ O ₅ · 3H ₂ O), nine-water hydrosilicate (Na ₂ Si ₂ O ₅ · 9H ₂ O), sodium hydro polysilicate (Na ₂ O · 18SiO ₂ · 4H ₂ O), sodium hydrometasilicate (monovalent Na ₂ SiO ₃ H ₂ O, two-, three-, four-water and further, up to fourteen-sodium sodium gyrometadivicate);

- liquid glass (sodium, potassium, etc.) with a module of 2.3-4.0;

- a silicate block (an anhydrous glassy mass of various colors in powder form or in the form of pieces from 0.1 to 25 mm. Get it, for example, by fusing a mixture of quartz sand with soda or potam (soda can be replaced with sodium sulfate) until a homogeneous liquid The melt discharged from the furnace, when slowly cooled in air, solidifies in the form of a solid monolith.

The next group of silicate binders used in the method according to the invention include silica gels (silica) - colloidal silica with high values of silica modulus (with a module of 25 and above). For example, silica gel (as a waste of metallurgical production) of the following composition can be used: SiO ₂ - 88.2 wt.%, H ₂ O - 1.7 wt.%, Pp - 8.3 wt.% (Impurities); Fe ₂ O ₃ - 0.035 wt.%, Al ₂ O ₃ - 0.16 wt.%, Na ₂ O - 1.86 wt.%, SO ₄ - 0.12 wt.% (SU 1724638) and others, for example silica gel, which is a waste product of the production of aluminum fluoride (SU 1121233).

In the method according to the invention are used as silicate alkaline glass and waste from the production and use of window and technical glass, for example, with a SiO ₂ content _of 71.2-72.8% (for example, SU 1112724).

The method uses a dry silicate binder (in the form of hydrated powders, amorphous and crystalline), crushed with a dispersion of 4 microns to 20 microns.

- aluminosilicates, which use natural mineral raw materials, for example, clay, loam, sandy loam, (whether or not burnt), forest deposits, clay brick bricks and industrial wastes, for example, metallurgical slags and ashes, and TZ slags formed as a result burning coal (black or brown, or peat), with an Al content (in the form of oxides or salts) ≥0.5% (by weight of dry matter).

So, to obtain a silica-containing binder in the implementation of the method according to the invention, various silica-containing components (materials) with a SiO ₂ content _of at least 40% are used, such as, for example, silica sand, silica flour, with a SiO ₂ content _of up to 99 wt%, diatomite, tripoli, marshalite (amorphous silicas), flasks, for example, chemical composition: SiO ₂ - 69-89, Al ₂ O ₃ - 3.94-11.6, TiO ₂ - 0.16-0.55, Fe ₂ O ₃ + FeO - 1 , 44-3.6, CaO - 0.2-0.9, MgO - 0.5-1.2, Na ₂ O - 0.08-1.1, K ₂ O - 0.7-1.53 , Mn <0.01 (% by weight of dry matter), silica fume obtained industrially, waste from stone processing, n example, granite, siliceous minerals were formed by volcanic activity (scoria, pumice, etc.), glass of different chemical composition, for example, packaging for food and non-food products.

The humidity of the silica-containing material (component for preparing an inorganic binder), as a rule, for example, when using crushed material, for example quartz sand, is not more than 6%, when using for example quarry clay it is more than 6% to 100%, and when using, for example, sawing waste or grinding granite with a moisture content of more than 20%, up to a water suspension.

The fractional composition (dispersion) of a silica-containing material used as a silica-containing component in the preparation of a silica-containing binder in the method according to this invention is in the range from 20 μm (waste of sawing and grinding granite, hydromica for the production of perlite sand of the Magadan deposit) to 20 mm (brick fight, expanded clay production waste, cullet); silica-containing materials, such as various sands, waste, screening during the production of crushed granite, are also preliminarily crushed to a size of less than 60 microns.

In this case, the mixing time of a silicon-containing material - a component to obtain a binder, with an inorganic binder depending on the dispersion of the silica-containing component is selected, for example, 10-30 minutes when using a material with a dispersion of less than 30 mm (expanded clay production waste, cullet, brick fight, tuffs, amorphous silicas, Tripoli, etc.), as well as for pre-crushed material with a dispersion of 60 μm or less (for example, quartz sand); and for silica-containing material without prior grinding (various sands, granite screenings, metallurgical slag, coal ash and slag of the CHP plant) it is 1-8 hours.

Mixing the inorganic binder with a silica-containing component (material) during the preparation of the binder is carried out at 80-90 ° C, and this temperature is maintained throughout the preparation of the binder.

Subsequent cooling of the prepared binder is also carried out with constant stirring at a speed of 40 to 100 rpm, for example, using a propeller type device or using air aeration for 10-12 hours at an ambient temperature of 15-25 ° C. Under such conditions, the preparation of the binder is an increase in the density of the binder. For example, a binder prepared using silica sand as a silica-containing material (component) and sodium hydroxide (alkali metal hydroxide) as an inorganic binder, first has a density of 1.49 g / cm ³ and after cooling under the above conditions, its density increases up to 1.57 g / cm ³ . The tank used to cool the binder can be equipped with a defoaming device, as during its preparation, in some cases, foam is formed (for example, when ferroalloys, artificial silica fume, metallurgical slags are used as a silica-containing component).

Mixing the inorganic binder with a silica-containing component (material) in the preparation of the binder used in the method according to the invention is carried out in various mixers at a mixing speed of 1500-2500 rpm and a vibration frequency of the mixed particles of 2000-35000 Hz.

A binder is obtained with a density of 1.1-2.1 g / cm ³ , which has a fluidity of water, a high wetting ability, and does not coagulate upon further addition of a silica-containing aggregate (ground sand, vermiculite, perlite sand, etc.) according to the method of the invention , i.e. it is uniformly distributed throughout the entire volume of the charge - molding material, which contributes to the production of high-strength products.

In the method according to the invention, silica-containing aggregate with a dispersion in the range of 40 Å to 25 mm is used, in particular quartz sand — a fraction with a dispersion of 4-50 μm or a fraction with a dispersion of 0.4-2.5 mm, or a fraction with a dispersion of 60-120 microns or their various mixtures.

To implement the method according to the invention, various grinding devices and various mixing devices are used, which provide both preliminary grinding, if necessary, of silica-containing raw materials to the desired specified size, and effective mixing of the initial mixture in the preparation of an inorganic binder and its subsequent mixing with aggregate.

Such devices include wolf, shock-centrifugal and disk mills, various dissolvers, ball mills, bissors, forced-action mixers, disk mixers, disk-propeller and disk-paddle mixers, anchor mixers, high-speed rotor-stator mixer, planetary mixers, screw, planetary mixers with three-dimensional movement of spiral-tape working bodies, providing mixing at a mixing speed of from 1500 rpm to 2500 rpm

For the preparation of building products by this method, depending on their specific purpose, it is possible to introduce various pigments and dyes of inorganic and organic origin (silk-resistant and light-resistant) in the dry form, for example, titanium dioxide, zinc, iron, ferrophosphoric pigments, chalk, depending on their specific purpose in the composition of the mixture (mixture), ocher, crown orange, chromium oxide, mummy, red iron, Mars red and brown, ultramarine, etc.

The pigments are also introduced in powder form in an amount of preferably up to 5%.

The following are specific examples of the method of manufacturing building products according to the invention, which illustrate the method according to the invention, but do not limit it.

Example 1

According to the method of the invention, a silica-containing binder is first prepared based on a mixture containing an inorganic binder, water, a silica-containing component (material). Silica-containing raw materials, for example, sand, with a particle size (dispersion) of 0.5 to 2.0 mm or from a grinder (ball mill) pre-ground silica-containing raw materials with a particle size (dispersion) of 40 Å to 50, are loaded into a high-speed rotor-stator mixer microns; silicate bond or sodium hydroxide (in solid state or in the form of a solution) and water (fresh, marine or mineralized) are also loaded there. Intensive mixing of this mixture is carried out when heated to 90 ° C and at a stirring speed of at least 1500 rpm and a vibration frequency of the mixing particles of 2000-35000 Hz for a time sufficient to achieve the required density of 1.2 g / cm ³ , for example, within 10-30 minutes or 1-8 hours. As a result of this, the mixture is subjected to shock-shear action (deformation) and a homogeneous homogeneous product is obtained.

Next, the prepared binder is cooled in a container with constant stirring at a stirring speed of 100 rpm for 10 hours at 15-25 ° C.

The obtained inorganic binder has a density after cooling of 1.35 g / cm ³ . Then, the molding material is prepared by mixing in a planetary type mixer 9.0 wt.% Of the obtained binder and 91.0 wt.% Silica-containing aggregate, in particular a mixture of amorphous silica (Tripoli) with a dispersion of 50 μm with sawdust when they are contained in a mixture of 5- 15 wt.%. Next, the final homogenization of the molding material (mixture) is carried out, further mixing in a mixer, for example a screw type. The obtained molding material is fed to a press, where directly on pallets semi-dry pressing of products with a force of 2.5-5 kg / cm ^{2 is} carried out, and then the products are heat treated at 90 ° C.

Receive pre-insulating construction products having the properties shown in table 1.

Table 1.
Properties of products obtained by the method according to the invention using partially sawdust as filler. №№ pp Indicators Units meas. Material Sawdust Sawdust one. Dry material volume cm ³ 400 600 2. Volumetric weight of dry material kg / m ³ one hundred one hundred 3. Binder Consumption ml 60 60 four. Water consumption ml 0 0 5. The weight of the raw mix g 134.5 148.2 6. Pressing load kg / cm ² 2,5 5,0 7. Heat treatment temperature ° C 90 90 8. Heat treatment time at maximum temperature min 60 60 9. The volume of the sample after pressing cm ³ 176 1766 10. The volume of the sample after heat treatment cm ³ 176 176 eleven. Sample weight g 100.6 111.1 12. Compressive strength kg / cm ² 10 24 13. Bending strength kg / cm ² 9 15.4 fourteen. Thermal conductivity kcal / m · hour · city 0,071 0,081 fifteen. Shrinkage of the sample after heat treatment % 0 0 16. Sample density kg / m ³ 540 610

Example 2

Products are obtained using inland sand as a filler of a silica-containing and silica-containing component (material) in the preparation of an inorganic binder.

An example implementation of the method according to the invention is illustrated using an exemplary production flow chart (see drawing).

Sand is delivered to production by road or rail, which depends on the distance of its delivery to the place of production, production volume and transportation cost. Unloading of sand is carried out in the receiving hopper 1, equipped with a cultivator 2, which ensures the destruction of lumps, the formation of which is possible especially in winter, and a uniform supply of sand to the conveyor 3, feeding sand to the elevator 4. Elevator 4 sand is loaded into the receiving hopper 5 to the conveyor 6 s a system of unloading knives, which ensures uniform distribution of sand over the area of the sand storage warehouse 7. From a warehouse equipped with a feeding system for drying 8, for example, with a clamshell crane, sand is fed into the drying drum 10 s receiving hopper 9, which provides uniformity and continuity of its receipt by the drying drum. In the drying drum, not only drying of the sand occurs, but also possible organic inclusions, such as shells or algae, burn out. At the outlet of the dryer drum, sand through the hopper 11 enters the sieve system 12, where larger fractions, such as pebbles, are removed from the sand. The resulting screening conveyor 13 is sent to the dump. In the future, screening can be used as a large aggregate in the production of any products, such as blocks, as a bedding on roads or used for other purposes. Dry sand with a moisture content of not more than 6%, the screened sand is conveyed by the conveyor 14 to the storage hopper 15 for storage and further distribution along the production line. Through the feeder 16 of the storage hopper 15, sand is supplied to the grinder 17, for example, a centrifugal mill, in which it is crushed to the required dispersion with separation into fractions in classifiers, for example, fractions of 10-30 μm and 60-120 μm. The mill is equipped with an air filter, for example a bag filter. As it is filled with sand dust, it is used together with a fraction of 10-30 microns for the preparation of a silicon-containing binder. From the classifiers, through the feeder 20, a fraction of 10-30 μm is partially fed to the binder preparation department, and by the feeder 24 to the crushed sand storage bin 25, the charge preparation department. When using two-fraction crushed sand of 10-30 microns and 60-120 microns, as in this example, the storage hopper with a dispenser 25 is two-section. In the binder preparation department, crushed sand is stored in a raw material warehouse 21, which consists of containers for crushed sand, water and an inorganic binder - caustic soda. The warehouse can be made in various versions: in the form of a single block system with a dosing device for dry and liquid components and feeding them to the mixer 22 at the same time or as separate containers equipped with independent dispensers and systems for feeding components to the mixer 22 for preparing the binder. The mixer 22 consists of a direct mixing device, for example, a rotary pulsation apparatus, a container for cooling the binder, and a storage container for the binder 27 with a dispenser and a system for supplying it to the mixer 29 for the preliminary preparation of the raw material charge. In this case, the cooling capacity of the binder and the hopper for its storage are equipped with devices that ensure constant mixing of the binder, for example, propeller type or air aeration. The preparation of the binder is carried out in accordance with the method for preparing the silica-containing binder described in this application: at a stirring speed of 1500 rpm, heating to 80 ° C, a vibration frequency of the mixed particles of 35000 Hz, cooling with stirring at a speed of 100 rpm at 25 ° C. In the compartment for the preparation of the mixture of clean sand through the feeder 23 of the storage hopper 15 is fed into the hopper 26, equipped with a dispenser. From the silos 25 of crushed sand and 26 of pure sand, through the batchers, these components are sent to a conveyor 28, which feeds them to the preliminary mixer of the mixture 29, for example, of a planetary type, in which they are mixed until a homogeneous dry mass is obtained. Then, a binder is fed into the mixer 29 through the dispenser and the feed system of the hopper 27 and it is mixed with the dry components to obtain a homogeneous mass in which there are small lumpy inclusions. To obtain a homogeneous composition of the mixture from the mixer 29 through the storage hopper 30, the mixture is sent to the mixer 31 of the final preparation, for example a screw type. From the mixer 31, the finished homogenized mixture enters the storage hopper 32. From the hopper 32, the finished mixture is fed to the press 33, equipped with a system for its dosage and supply of pallets. The pressing of products with a force of 200-400 kg / cm ^{2 is} carried out directly on pallets, which are conveyed by the conveyor 34 to the heat treatment department, into a continuous furnace 35, in which at a temperature of 750-950 ° C, the products are fired without preliminary drying. As the energy carrier can be used gaseous, liquid fuel, infrared radiation or microwave radiation. After firing, the pallets with finished products by conveyor 36 are fed to the baler 37, where the products are stacked on pallets and they are sent to the finished goods warehouse 39. Pressed pallets freed from finished products by conveyor 38 are returned to the press equipment.

Table 2 presents the options for implementing the method according to the invention according to example 2 and the properties of the resulting products.

Table 2.
Examples, embodiments of the method of example 2 and product properties. Name of components, properties Compositions, ratios, in wt.% one 2 3 four 5 1. Quartz sand 91 89.5 88 86.5 86.5 - Fraction with a dispersion of 4 to 50 microns 23.0 22.0 20,0 25.0 - Fraction with a dispersion from 0.4 to 2.5 mm 91 66.5 55.0 46.5 36.5 - Fraction with a dispersion from 60 to 120 microns 11.0 20,0 25.0 2. Silica-containing binder with ρ = 1.5 g / cm ³ (based on hydroxide 9.0 10.5 12.0 13.5 13.5 sodium and silica sand) The pressing force, kg / cm ² 200 200 250 300 350 Drying conditions: 200 ° C - - - - Firing molded products, ° C 900 850 900 850 750 Drying time, min 10 - - - - Firing time, min 10 25 thirty twenty twenty Product Properties: The limit of compressive strength, kg / cm ² 300 600 900 1100 1150 Bending Strength, kg / cm 9 48 58 64 68 Water absorption,% fourteen eleven 8 four 2,5 Frost resistance cycles 25 fifty one hundred 150 150 Acid resistance 0.95 0.95 0.95 0.95 0.95

Example 3

The method according to the invention is carried out using a silica-containing component in the preparation of an inorganic binder of aluminosilicates.

When implementing the method according to the invention using aluminosilicate material, aluminosilicate raw materials, for example clay with a particle size (dispersion) of less than 1 micron, are loaded into a mixer with water (fresh, marine or mineralized). Mixing is carried out for a time sufficient to obtain a homogeneous (homogeneous) aqueous suspension, for example 5-20 minutes, in mixers with a rotational speed of the mixing device, for example from 1500 to 2000 rpm. Next, a silicate bond or sodium hydroxide (in solid or soluble form) is loaded into the mixture and the mixture is subsequently mixed while heating to 90 ° C, a stirring speed of 1500 rpm, an oscillation frequency of the mixed particles of 1500 Hz.

Next, the binder is cooled with stirring at a stirring speed of 100 rpm for 10 hours at 15-25 ° C. The ratio between the inorganic binder and the aluminosilicate material is 13.5 wt% and 86.5 wt%, respectively. Get a binder with a density of 1.75 g / cm ³ . Further, analogously to example 1, the molding material is prepared. Molded products and fired at 750-950 ° C. Heat-insulating products with increased fire resistance, strength properties, acid resistance are obtained.

In the production of heat-insulating and structural-heat-insulating products, a technological line, a set of necessary equipment can tolerate small changes. For example, in the manufacture of products from expanded perlite sand, there is no need to organize a drying department. The preparation of a binder in mixers, for example rotary-pulsation type, using, for example, as silica-containing components of expanded perlite sand or hydromica, from which it is obtained, there is no need for grinding equipment. The preparation of the molding sand is limited to the simultaneous mixing of filler, perlite sand and a binder in the mixer pre-preparation of the mixture. To ensure the transportation strength of the molded products during the preparation of the charge, it is possible to introduce 1-15 wt.% Of the volume of the filler, amorphous silica, for example tripoli or industrial silica fume. The molding force is limited to small values, for example, with a force of 1 kg / cm ² heat-insulating products are obtained with a compressive strength of up to 10 kg / cm ² and a thermal conductivity of 0.03 to 0.051 W / (m · K), which is better than similar indicators known mineral wool insulation. The heat treatment temperature is limited to 400-600 ° C.

When using fillers having the properties of increasing the volume of products after pressing, for example, wood sawdust, the products must be kept under load for 5-15 minutes, then sent to heat treatment. Since this filler belongs to fuels, the processing temperature is limited to 90 ° C, and the heat treatment time is 1-2 hours.

Coloring of products is carried out, if necessary, by introducing pigments, for example, of the oxide type or in the form of alkali metal salts, into the molding mass (mixture) or into an inorganic silicon-containing binder during its preparation.

Similarly, products are obtained by the method according to the invention using other silica-containing materials as fillers.

The following tables 3, 4, and 5 show the properties of products obtained by the method according to the invention using expanded clay (table 3), perlite (table 4) and vermiculite (table 5) as siliceous aggregates.

Using the semi-dry pressing method allows you to quickly switch to production from one product to another by replacing the dies and punches on the press equipment, adjusting the pressing force and, if necessary, the temperature regime of processing. For example, when switching production from brick to paving or wall blocks, it is enough to replace the matrix with the punch, because the composition of the charge, the pressing force and the heat treatment mode remain the same.

In the production of heat-insulating and structural-heat-insulating products (for example, based on vermiculite and perlite), this technology allows you to create a material with strength characteristics from 5 kg / cm ² to 40 kg / cm ² and a thermal conductivity from 0.030 to 0.051 W / (m · K )

Table 3.
Properties of thermal insulation products from expanded clay on a silica binder №№ pp Indicators Units meas. Material Expanded clay Expanded clay one. Dry material volume cm ³ 400 500 2. Volumetric weight of dry material kg / m ³ 450 450 3. Binder Consumption ml 90 90 four. Water consumption ml 0 0 5. The weight of the raw mix g 280 350 6. Pressing load g / cm ² 1000 2200 7. Heat treatment temperature ° C 750 750 8. Heat treatment time at maximum temperature min 0 0 9. The volume of the sample after pressing cm ³ 296 296 10. The volume of the sample after heat treatment cm ³ 296 296 eleven. Sample weight g 207.2 259 12. Compressive strength kg / cm ² 12.8 19.1 13. Bending strength kg / cm ² 4.2 6.5 fourteen. Thermal conductivity kcal / m · hour · city 0,068 0,079 fifteen. Shrinkage of the sample after heat treatment % 0 0 16. Sample density kg / m ³ 700 875

Table 4.
Properties of heat-insulating products made of perlite on a silica-containing binder №№ pp Indicators Units meas. Material Perlite Perlite Perlite one. Dry material volume cm ³ 400 500 600 2. Volumetric weight of dry material kg / m ³ fifty fifty fifty 3. Binder Consumption ml 35 40 35 four. Water consumption ml 0 0 0 5. The weight of the raw mix g 96.8 121 145.2 6. Pressing load g / cm ² 1000 2200 10,000 7. Heat treatment temperature ° C 700 700 600 8. Heat treatment time at maximum temperature min 0 0 0 9. The volume of the sample after pressing cm ³ 96 96 96 10. The volume of the sample after heat treatment cm ³ 96 96 96 eleven. Sample weight g 59 68.8 88.5 12. Compressive strength kg / cm ² 4.9 11,4 62,4 13. Bending strength kg / cm ² 5.2 9.7 14.1 fourteen. Thermal conductivity kcal / m · hour · city 0,062 0,071 0,079 fifteen. Shrinkage of the sample after heat treatment % 0 0 0 16. Sample density kg / m ³ 615 717 922

Table 5.
Properties of thermal insulation products from vermiculite on a silica binder №№ pp Indicators Units meas. Vermiculite material one 2 3 four 5 one. Dry material volume cm ³ 300 350 400 450 500 2. Volumetric weight of dry material kg / m ³ one hundred one hundred one hundred one hundred one hundred 3. Binder Consumption ml thirty 35 fifty 45 fifty four. Consumption of silica fume industrial g 10 fifteen twenty twenty twenty 5. Weight of raw mix g 110.9 132.9 154.5 171.3 188.2 6. Pressing load g / cm ² 350 380 400.6 1500 2200 7. Heat treatment temperature ° C 150 180 250 300 350 8. Heat treatment time at maximum temperature hour one one 2 2 2 9. The volume of the sample after pressing cm ³ 176 176 176 176 176 10. The volume of the sample after heat treatment cm ³ 176 176 176 176 176 eleven. Sample weight g 71.5 90.9 120.6 133.2 145.3 12. Compressive strength kg / cm ² 3,7 5.8 10 24.4 38 13. Bending strength kg / cm ² 1,5 3.4 10 13.8 17.4 fourteen. Thermal conductivity kcal / m · hour · city 0,03 0,041 0.051 0.056 0,061 fifteen. Heat resistance limit ° C 950 950 950 950 950 16. Shrinkage of the sample after heat treatment % 0 0 0 0 0 17 Density kg / m ³ 349 431 569 643 712

A list of the main technological areas and the equipment included in them.

(indicated on the drawing)

Reception Department:

1 receiving hopper

2 cultivator

3 sand conveyor

4 sand elevator

Sand Storage Unit:

5 receiving hopper from the elevator

6 conveyor with knife unloading system

7 sand warehouse

8 sand feeding system for drying

Sand drying department:

9 dryer hopper

10 tumble dryer

11 sand receiving hopper from the dryer drum

12 sieve

13 screening conveyor

14 conveyor for supplying clean sand to the storage bin

15 sand storage bin

Sand grinding unit:

16 sand feeder to the grinder

17 chopper with classifier system and filter

18 feeder feed crushed sand into the hopper drive

19 crushed sand storage bin

20 shredder sand feeder to the binder preparation department

Binder preparation department:

21 warehouse of raw materials

22 set of equipment for preparing a binder with a storage and supply system for charge preparation compartments

The charge preparation department:

23 sand feeder from the clean sand hopper to the storage hopper with a batcher for the charge preparation compartment

24 feeder feeding crushed sand into the storage hopper with a batcher for the preparation of the charge mixture

25 bunker store of crushed sand with a batcher

26 sand bunker with dispenser

27 bunker drive binder with a dispenser and a system for feeding it into the mixer

28 conveyor feed sand and crushed sand into the mixer

29 batch pre-mixer

30 hopper-receiver mixer final preparation of the mixture

31 mixer final preparation of the mixture

32 hopper drive finished charge

Claims (9)

1. A method of manufacturing building products based on a silica-containing binder by preparing a molding mass from a silica-containing binder and a silica-containing aggregate, molding from the obtained molding mass of the products and their subsequent heat treatment, characterized in that it comprises preparing a silica-containing binder with a density of 1.1-2.1 g / cm ³ from a mixture containing an inorganic binder, a silica-containing component and water when they are intensively mixed in a high-speed mixer at high speed their mixing at 1500-2500 rpm, the vibration frequency of the mixed particles 2000-35000 Hz, heating to 80-90 ° C and then cooling it with stirring at a speed of 40 to 100 rpm for 10-12 hours at 15- 25 ° C, and quartz sand with a moisture content of not more than 6%, quarry clays with a moisture content of more than 20%, burnt clays, loams, sandy loams, loess deposits, silica fume obtained from ferroalloy production waste, stone processing waste, are used as a silica-containing component in the preparation of the binder obtained by cutting in grinding or grinding, for example granite, or in the production of crushed granite, hydromica, in particular, used in the production of vermiculite or expanded perlite, the preparation of the molding mass is carried out by mixing 9.0-13.5 wt.% silica binder and 86.5-91, 0 wt.% Silica-based aggregate, which is used as river sand, sea sand, quarry sand, granite, basalt, vermiculite, expanded perlite sand, expanded clay, hydromica, metallurgical slag, coal slag and ash, waste from the production of kera mzita, stone and stone processing, a mixture of amorphous silica with wood processing waste or agricultural processing waste, such as bonfire from processing flax, straw, sunflower husk, heat treatment is carried out at a temperature of 400-950 ° C, and when using these combustible aggregates, heat treatment is carried out at 90 ° C. 2. The method according to claim 1, characterized in that as an inorganic binder in the preparation of the binder, alkali metal or ammonium hydroxide is used, a silicate bond selected from the group consisting of sodium hydrosilicates, water glass, a silicate block, a cullet formed during production or application of glass, silica sol, silica gel, aluminosilicates. 3. The method according to claim 1, characterized in that a silica-containing material with a particle size of 0.5-20.0 mm or from 40 A to 50 μm is used as a silica-containing component in the preparation of the binder. 4. The method according to claim 1, characterized in that the water used in the preparation of the binder uses fresh, marine or mineralized water. 5. The method according to claim 1, characterized in that they use a silica-containing aggregate with a dispersion of 4-50 microns or 60-120 microns, or 0.4-2.5 mm, or a mixture thereof. 6. The method according to claim 1, characterized in that a silica-based aggregate with a moisture content of not more than 10% is used. 7. The method according to claim 1, characterized in that the molding is carried out by semi-dry pressing with a force of from 1.0 to 400 kg / cm on a press equipped with a dosing system for feeding pallets. 8. The method according to claim 7, characterized in that the semi-dry pressing is carried out directly on pallets. 9. The method according to claim 1, characterized in that the molding of the products is carried out by vibrocasting.