RU2443660C2 - Method to produce construction items based on silica-containing binder - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: method includes preparation of silica-containing binder with density of 1.3-2.4 g/cm³, module 15-30, from the mixture containing inorganic bond, a silica-containing component, a hydrofluoric acid salt in amount of 0.5-10.0 wt % of the mixture, and water, during their intensive mixing in a high-speed mixer at their mixing speed of 2600-6000 rpm, frequency of particle oscillations 3600-45000 rpm, heating at 80-90°C or under effect of electric current with intensity of 15-40 W and current force of up to 60 A, with subsequent cooling during mixing with speed from 40 to 100 rpm at 15-25°C within 10-12 hours or air aeration at 10-20°C within 6-11 hours, preparation of moulding material is carried out by mixing 9.0-13.5 wt % of this produced binder and 86.5-91.0 wt % of the silica-containing filler with moisture of not more than 6% and dispersion of 4-50 mcm or 60-150 mcm, or 0.2-25 mm, homogenisation of masses, formation by means of vibration casting or surface vibration compaction, or by means of vibration pressing, or semidry pressing with force from 1.0 to 400 kg/cm² on a press or on a conveyor with pressing force from 150 to 600 kg/cm², thermal treatment is carried out at the temperature of 400-950°C, and when hot fillers are used from the ones listed above, thermal treatment is carried out at 85-95°C. The invention is developed in dependent claims.

EFFECT: simplified method, expansion of produced articles assortment, higher strength and other operational properties, cheapening of produced articles.

3 cl, 6 tbl, 3 ex, 1 dwg

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, curbs, facade and floor tiles, and various products in the form of shells, segments, pipe rings, possessing increased strength and other properties, arrange paving and road monolithic coating, 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.), ceramic technology (the creation of a durable product by sintering) and a paving device. 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 non-traditional aggregates, for example, waste products from agricultural products, 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 (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 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 above. 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 332431, 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 area 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, including the preparation of 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 material mixture a 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, oxide, calcium, 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 tripoli component 42,0-50,0; sodium hydroxide 4.5-12.0; aluminum hydroxide metal additive 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 removed from the 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 the known invention receive acid-resistant materials with increased water resistance and fire resistance, but not possessing simultaneously increased strength and thermal insulation properties.

Another method for the manufacture of building products is known (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, using a silicate binder selected from the group of liquid glass , silicate block, sodium hydrosilicate, silica gel, siliceous filler with a moisture content of not more than 20% and a dispersion of 4-50 microns and 0.1-2.5 mm, the preparation of the molding mass with a moisture content of 6-10% is carried out with intensive alternating sewing to a homogeneous state by first co-grinding the specified silicate binder with 2-5 wt.% the specified filler to its fineness of 4-50 microns and 0.1-2.5 mm, then introducing water and adding 20.0- to the resulting activated mixture 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 1.0-150 kg / cm, and drying at 25 -400 ° C in the following ratio of components, wt.%: The specified silicate binder is 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 - 0-0.5. 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 3.0-4.0 wt.%, Silica gel with a dispersion of 4-20 microns, preferably in the amount of 2.0-4.0 wt.%, and after drying, annealing is additionally carried out at 600-1000 ° C for 15-90 minutes.

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 closest in technical essence to the claimed method according to the invention is a known method of manufacturing products based on a silica binder by preparing a molding mass from a silica binder and silica filler, molding products from the obtained molding mass and subsequent heat treatment of the molded products, includes preparing a binder with a density of 1.1 -2.1 g / cm ³ of a mixture containing inorganic binding, siliceous component (material) and water at their intensive mixing in a high-speed 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 its subsequent cooling with stirring from 40 to 100 rpm for 10-12 hours at 15-25 ° C, the preparation of the molding material is carried out by mixing 9.0-13.5 wt.% prepared silica binder and 86.5-91.0 wt.% silica filler in the mixer, homogenization of the molding mixture, and heat treatment of molded products carried out at 90-950 ° C depending ing on the type of filler (RU 2283818 20.09.2006).

However, due to the fact that for the preparation of products using a binder with a density of 1.1-2.1 g / cm ³ , this does not allow to obtain a wide range of products with increased strength and water resistance.

The technical task of the claimed invention is to simplify the method, expand the range of products, increase the strength and other operational properties of the products (frost resistance, abrasion resistance, water resistance, etc.), expanding the raw material base both due to mineral raw materials and industrial waste, cheaper products, environmentally friendly building products, as well as maintaining all the operational properties for a long time.

The stated technical problem is achieved in that in a method for producing building products based on a silica binder by preparing a molding mass from a silica binder and silica filler, molding from the resulting mass of products and subsequent heat treatment, a silica binder with a density of 1.3-2 is first prepared (prepared) , 4 g / cm ³ , module 15-30 from a mixture containing an inorganic binder, silica-containing component, water and a salt of hydrofluoric acid in an amount of 0 , 5-10.0 wt.% Based on the mixture, and when intensively mixed in a high-speed mixer at a mixing speed of 2600-6000 rpm, particle vibration frequency 3600-45000 rpm, heating 80-90 ° C or when exposed to an electric current with a voltage of 15-40 W and a current strength of 60 A, followed by cooling of the siliceous binder with constant stirring at a speed of 40 to 100 rpm at 15-25 ° C for 10-12 hours or using air aeration at 10-20 ° C for 6-11 hours, silica is used as a silica-containing component a soil-containing component with a particle size of 0.2 to 20.0 mm or pre-crushed to a particle size of 40 Å to 60 μm, selected from the group consisting of silica sand or quartz flour with a moisture content of not more than 4%, quarry clays with a moisture content of more than 10 %, calcined clay, loam, sandy loam, loess deposits, with a moisture content of about 4%, silica fume obtained from ferroalloy production waste, stone processing waste obtained from sawing or grinding, such as granite, or from granite crushed stone production, hydromica, such as they are used in the production of vermiculite or expanded perlite with a moisture content of about 4%, as well as amorphous silica-containing mineral raw materials from the group including tripoli, diatomite with a moisture content of 4-6%, the preparation of the molding mass is carried out by mixing 9.0-13.5 wt.% of this obtained silica-containing binder and 86.5-91.0 wt.% silica-containing aggregate with a moisture content of not more than 6% and a dispersion of 4-50 microns or 60-150 microns, or 0.2-25 mm, which use various sand, granite, basalt, vermiculite, expanded perlite sand, expanded clay, In the first place, metallurgical slag, coal slag and ash, expanded clay, stone and stone processing waste, a mixture of amorphous silica with wood processing waste or vegetable waste from agricultural processing, such as bonfire from flax processing, straw, sunflower husk, and the molding itself is carried out by vibration casting or surface vibration compaction, or by vibrocompression, or by semi-dry pressing with a force of 1.0 to 400 kg / cm ² on a press equipped with a pallet feed dosing system with or without pallets with a removable mechanism for supplying raw materials to the conveyor with a pressing force of 150 to 600 kg / cm ² ; and heat treatment is carried out at 400-950 ° C, and when using combustible aggregates from the above, heat treatment is carried out at 85-95 ° C.

To obtain a silica-containing binder with a density of 1.3-2.4 g / cm ³ and silicate by vibration casting or surface vibration compaction or by vibrocompression by module 15-30, in particular, the following mixture can be used (ratio of mixture components in wt.%):

Inorganic ligament - 5.0-30.0 Silica-containing component - 15, -65.0 Hydrofluoric acid salt - 0.5-10.0 Water - the rest.

The indicated ratios between the inorganic binder and the silicon-containing component relate to the well-known, traditional ratios commonly used in the preparation of similar binders, such as those used in RU 2236374, 09/20/2004, for subsequent use in the preparation of various building products. And it is determined by the choice of specific inorganic binders and silica-containing component, as well as by varying the quantitative content of hydrofluoric acid salt in the range of 0.5-10.0 wt.% According to the claims, which generally provides a silica-containing binder with a density of 1.3-2, 4 g / cm ³ and the module 15-30, as well as improved operational and strength characteristics that are preserved during its use.

The method according to the invention uses fresh, for example industrial water, sea water, mineralized water, which allows the method according to the invention to be carried out in various environmental conditions, as well as to utilize various industrial water, thereby improving the surrounding ecology.

To implement the method according to the invention, various grinding devices and various mixing devices are used, which provide preliminary grinding of silica-containing raw materials to the desired predetermined size and effective mixing of the initial mixture. These devices include roller and disc mills, various dissolvers, ball mills, bissors; high-speed - disk mixers, disk-propeller and disk-paddle mixers, mixers with an anchor mixer, 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 at least 2600 rpm and vibration frequency of the mixed particles 3600-45000 Hz.

In the case of mixing silica-containing raw materials with an inorganic binder and water without first grinding the silica-containing raw materials, the preferred mixing time is 8-10 hours, in the case of using pre-crushed silica-containing raw materials, the mixing time with inorganic binder and water is from 10 minutes to 0.5 hours. carried out as follows.

In a high-speed rotor-stator mixer load siliceous raw materials, such as sand, pre-crushed with silica-containing raw materials with a particle size (dispersion) of from 40 Å to 60 microns; silicate bond or sodium hydroxide (in solid state or in the form of a solution) and water (fresh, marine or mineralized) and a salt of hydrofluoric acid, for example, calcium fluoride, are also loaded there. Intensive mixing of this mixture is carried out at a stirring speed of at least 2600 rpm and an oscillation frequency of the mixing particles of 3600-45000 Hz, for example, for 10 minutes - 0.5 hours or 8-12 hours

Mixing can also be carried out under the influence of an electric field with an intensity of 15-40 W and a current strength of 60 A.

Next, the mixture is cooled with constant stirring at a speed of 40 to 100 rpm at 15-25 ° C for 10-12 hours or using air aeration at 10-20 ° C for 6-11 hours to obtain a binder with a density 1.3-2.4 g / cm ³ , which is a homogeneous homogeneous product having a fluidity similar to water, with a silicate module of 15-30.

Table 1 presents examples of a binder used in the claimed method for producing building products and its main characteristics.

In the manufacture of a binder using instead of heating an electric current, there is an increase in the volume of the finished binder by 2-3 times due to the formation of gas bubbles. During storage and use, they are not destroyed and make finished products more porous, which expands the range of these products.

After mixing the components used to prepare the silica-containing binder under the stirring conditions listed in table 1, the mixture is cooled with constant stirring at a speed of 49 to 100 rpm at 15-25 ° C for 12 hours or using air aeration at 10 -20 ° C for 6-11 hours to obtain a binder with the required density (1.3-2.4 g / cm ³ , which is a homogeneous homogeneous product having a fluidity similar to water, with silicate module 15-30, low water absorption acid resistant spine and environmentally friendly.

Table 1 Names of components The content of the components used in the method of the mixture, in wt.%, According to examples Conditions, properties one 2 3 four 5 6 1. Inorganic ligament: - liquid sodium glass, M = 3.2 11.8 - - - - 30,0 - silicate block - 6.3 - - - - - sodium hydroxide - - 11.8 16.6 18.6 - 2. Silica-containing raw materials (humidity 4%, SiO ₂ - 85%) silica sand (flour), anticipates. crushed, with a size of 40 Å - 60 microns 29.4 - - 27.8 40.7 50,0 - Tripoli, with disp. 0.5-2.0 μm (humidity 6%) - 31,2 29.4 - - - 3. Water: - fresh - 62.0 53.8 - - 16,0 - sea 56.3 - - - 30.7 - - mineralized - - - 52.6 - - 4. Hydrofluoric acid salt, CaF ₂ 2.5 0.5 5,0 3.0 10.0 4.0 - Mixing speed, rpm 3000 3600 4700 2600 6000 4000 - mixing time 0.5 h 10 h 8 h 10 min 0.5 h 0.5 h - Particle oscillation frequency, Hz 4000 3600 30000 8000 10,000 45000 - Mixing when exposed to electric current 20 W, 40 A - + + - + + - heating ° C 80 - - 90 - - Properties: - density, g / cm ³ 2,4 1,6 1.3 1.4 1,5 2,4 - siliceous (silicate) module fifteen 25 thirty twenty 25 fifteen Water resistance (water absorption.%) 0.2 0.1 0.15 0.2 0.1 0.05 Acid resistance + + + + + +

Note: similar results on the properties of the binder are obtained by mixing the components using an electric current of 15 W, 30 W and current strength of up to 60 A. Heating to 100 ° C occurs. Mechanical stirring 20-140 rpm

The obtained binder is used to obtain various building materials and products by subsequent molding of its mixture with various target additives, such as fillers, curing additives, pigment dyes, and other additives, depending on the specific purpose of the product, by simple compression molding or by shock-pressing method, further molded products are dried, if necessary, heat treated (firing). Products with its use are water-resistant, have little moisture absorption (almost 0%), are acid-resistant, weather-resistant, and have good strength properties.

The next group of silicate binders used in the method according to the invention include silica gels (silica sols) - colloidal silica with high values of silica modulus (with a module of 25 and above). Can be used, for example, silica gel (as a waste of metallurgical production) of the following composition:

(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, such as silica gel, which is a waste product of the production of aluminum fluoride (SU 1121233) .

In the method according to the invention is used as silicate alkaline glass, for example, with a SiO ₂ content _of 71.2-72.8 wt.% (SU 1112724).

The method uses a dry silicate binder (in the form of hydrated powders, amorphous and crystalline), crushed with a dispersion of 40 Å to 60 μm, aluminosilicates, which use natural mineral raw materials, for example clays, loams, sandy loam, calcined or unburnt clay, loess deposits, clay bricks and industrial waste, such as metallurgical slag and ash, and TPP slag formed by burning coal (black or brown, or peat), with an A1 content (in the form of oxides or salts) more than 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, SiO ₂ content _of up to 99 wt.%, Ditomite, tripoli , marshalite (amorphous silicas), flasks, silica fume obtained industrially, waste from stone processing, for example granite, silica-containing minerals formed as a result of volcanic activity (volcanic slag, pumice, etc.), glass wallpaper of various chemical composition, for example, containers 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 from 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 an aqueous suspension.

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 the processing of flax, straw, husk and sunflower, etc.

A silica-containing aggregate is used with different fineness (particle size), for example, with a fineness of 4-50 microns or 60-150 microns, or 0.2-25 mm, or mixtures thereof in various combinations.

A silica-containing aggregate with a moisture content of not more than 6% is used. According to the method according to the invention, the molding of products is carried out, for example, by the method of semi-dry pressing directly on pallets (on presses equipped with a dosing and feeding system for pallets) or without pallets with a removable feed mechanism for the conveyor, for example, with a pressing force of 150 to 600 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), vibrocompression or surface vibration compaction.

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

sodium hydrosilicates in the form of semi-aqueous sodium hydrosilicate,

three-water hydrosilicate, nine-water hydrosilicate, sodium hydro polysilicate, sodium hydrometasilicates (monovalent, two-, three-, four-water and further, up to the fourteenth sodium hydrometadivicate);

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

silicate block (anhydrous glassy mass of various colors in powder form or in the form of pieces from 0.05 to 10 mm. Get it, for example, by fusing a mixture of quartz sand with soda or potam (soda can be replaced by sodium sulfate) to form a homogeneous liquid melt The melt released from the furnace, when slowly cooled in air, solidifies in the form of a solid monolith.

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 5 μm (waste sawing and grinding of 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 the silicon-containing material 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 silica, tripoli, etc.), as well as for pre-crushed material with a dispersion of 60 microns 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 3-12 hours.

Mixing the inorganic binder with a silica-containing component in the preparation of the binder is carried out at 80-90 ° C, and this temperature is maintained throughout the entire preparation of the binder; mixing is carried out in the presence of a hydrofluoric acid salt (CaF ₂ , NaF; AlF ₃ and others), taken in an amount of 0.5-10.0 wt%.

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 8-12 hours at an ambient temperature of 10-20 ° C. Under such conditions, the preparation of the binder is an increase in the density of the binder. For example, a binder prepared using quartz sand as a silica-containing component and sodium hydroxide as an inorganic binder first has a density of 1.63 g / cm ³ and after cooling under the above conditions, its density increases to 1.71 g / cm ³ .

Mixing the inorganic binder with the silica-containing component 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 2600-6000 rpm and a particle vibration frequency of 3600-45000 Hz.

A binder is obtained with a density of 1.3-2.4 g / cm ³ , which has a fluidity of water, a high wetting ability, does not coagulate with the further addition of a silica-containing aggregate (ground sand, vermiculite, perlite sand, etc.), t. 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 roller, 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 2600 to 6000 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 (alkali-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, such as sand, with a particle size (dispersion) of 0.2 to 20 mm or a grinder (ball mill) pre-ground silica-containing raw materials with a particle size (dispersion) of 40 Å to 60 μm are loaded into a high-speed rotor-stator mixer; 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 2600 rpm and an oscillation frequency of the mixing particles of 3600-45000 Hz for a time sufficient to achieve the required density of 1.47 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 1.57 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 the 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.

Thermal insulating building products are obtained having the properties shown in Table 2.

table 2
Properties of products obtained by the method according to the invention using partially sawdust as filler No. p / p Indicators Material Sawdust Sawdust one. The volume of dry material, cm ³ 400 600 2. Volumetric weight of dry material, kg / m ³ one hundred one hundred 3. Binder consumption, ml 80 80 four. Water consumption, ml 0 0 5. The weight of the raw mix, g 145.2 157.2 6. The pressing load, g / cm ² 35 60 7. Heat treatment temperature, ° С 90 90 8. Heat treatment time at maximum 90 90 temperature, min 9. The volume of the sample after pressing, cm ³ 176 176 10. The volume of the sample after heat treatment, cm ³ 176 176 eleven. Sample weight, g 110.6 121.1 12. Compressive strength, kg / cm ² 13.7 29.6 13. Bending Strength, kg / cm ² 12 20,0 fourteen. Thermal conductivity, kcal / m- hour- hail 0.06 0,071 fifteen. Water absorption,% 1,2 1.4 16. Shrinkage of the sample after heat treatment,% 0 0 17. The density of the sample, kg / m ³ 540 610 eighteen. Frost resistance cycles 80 90 19. Resistance to abrasion, g / cm ² 0.1 0.08

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 technological scheme of production (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 ripper 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 drying drum, sand passes through a hopper 11 into a 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 10-30 and 60-120 microns. 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 1-30 μm is partially fed to the binder preparation compartment, and by the feeder 24 to the crushed sand storage bin 25, the charge preparation compartment. When using two-fraction crushed sand of 10-30 and 60-120 microns, as in this example, the storage hopper with 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 storage hopper 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 a silica-containing binder described in this application: at a stirring speed of 2600 rpm, heating to 80 ° C, a vibration frequency of the mixed particles of 45000 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. Compression of products with a force of 200-400 kg / cm ^{2 is} carried out directly on pallets, which are conveyed by conveyor 34 to the heat treatment department, into a continuous furnace 35, in which products are fired at a temperature of 750-950 ° C 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 3 presents the options for implementing the method according to the invention according to example 2 and the properties of the resulting products.

Table 3
Examples of 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 (humidity 6%) 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 of from 0.4 to 2.5 mm 91 66.5 55.0 46.5 36.5 - fraction with a dispersion of from 60 to 150 microns - - 11.0 20,0 25.0 2. Silica-containing binder with ρ = 1.63 g / cm ³ (based on sodium hydroxide and quartz sand) 9.0 10.5 12.0 13.5 13.5 The pressing force, kg / cm ² 200 200 300 400 500 Drying conditions, ° С 200 170 210 270 300 Firing molded products, ° C 900 850 900 850 750 Drying time, min 10 twenty twenty 25 25 Firing time, min 10 25 thirty twenty twenty Product Properties: - - - - The limit of compressive strength, kg / cm ² 500 700 950 1120 1200 Bending strength, kg / cm ² 10 49 60 69 73 Water absorption,% fourteen eleven 8 four 2.5 Frost resistance cycles 35 60 120 250 250 Abrasion, g / cm ² 0.1 0.08 0.06 0,07 0.1 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 μm, 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 2600 to 3000 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, the stirring speed is 2600 rpm, the vibration frequency of the mixed particles is 3600 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 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 may undergo small changes. For example, in the manufacture of products from expanded perlite sand, there is no need to organize a drying compartment. 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 in the manufacture 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 with a compressive strength of up to 10 kg / cm ² and a thermal conductivity of 0.03 to 0.051 W / m · K) are obtained, which is better than similar indicators of known mineral wool heaters. 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 is a fuel, the processing temperature is limited, for example, 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 inorganic silicon-containing binder.

The following tables 4, 5 and 6 show the properties of products obtained by the method according to the invention using expanded clay (table 4), perlite (table 5) and vermiculite (table 6) 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.

Table 4
Properties of thermal insulation products from expanded clay on a silica binder No. p / p Indicators Material Expanded clay Expanded clay one. The volume of dry material, cm ³ 400 500 2. Volumetric weight of dry material, kg / m ³ 450 450 3. Binder consumption, ml 60 60 four. Water consumption, ml 10 10 5. The weight of the raw mix, g 260 310 6. The pressing load, g / cm ² 1000 2200 7. Heat treatment temperature, ° С 250 250 8. Heat treatment time at maximum 0 0 temperature, min 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 197 230 12. Compressive strength, kg / cm ² 12,2 19,4 13. Bending Strength, kg / cm ² 8.2 12.9 fourteen. Thermal conductivity, kcal / m- hour- hail 0.05 0.05 fifteen. Shrinkage of the sample after heat treatment,% 0 0 16. The density of the sample, kg / m ³ 680 851 17. Water absorption,% 0 0 eighteen Frost resistance cycles one hundred 120 19. Abrasion, g / cm ² 0,07 0.1

Table 5 p / p Indicators Perlite Perlite Perlite one. The volume of dry material, 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 twenty 10 0 5. The weight of the raw mix, g 96.8 121 145.2 6. The pressing load, g / cm ² 1000 2200 10,000 7. Heat treatment temperature, ° С 780 700 600 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 61 70 90 12. Compressive strength, kg / cm ² 6.1 3.0 60,2 13. Bending Strength, kg / cm ² 3.8 7.8 16.1 fourteen. Thermal conductivity, kcal / m- hour- hail 0.051 0,060 0.051 fifteen. Shrinkage of the sample after heat treatment,% 0 0 0 16. The density of the sample, kg / m ³ 615 717 922 17. Water absorption,% 2.0 1,5 0,07 eighteen. Frost resistance cycles 160 170 180 19. Abrasion, g / cm ² 0.1 0.08 0,07

Table 6 Properties of thermal insulation products from vermiculite on a silica binder No. p / p Indicators Vermiculite material one 2 3 four 5 one. The volume of dry material, 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 eighteen 25 35 twenty 35 four. Water consumption, ml 10 10 fifteen twenty twenty 5. The weight of the raw mix, g 110.9 132.9 154.5 171.3 188.2 6. The pressing load, g / cm ² 350 380 400.6 1500 2200 7. Heat treatment temperature, ° С 150 150 200 250 250 8.
9. Heat treatment time at maximum temperature, min
The volume of the sample after pressing, cm ³ 0.5
176 one
176 1,5
176 1,5
176 1,5
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 6.2 10.8 12.9 29.8 45.0 13. Bending Strength, kg / cm ² 3,5 5,4 10.0 15.8 19.5 fourteen. Thermal conductivity, kcal / m- hour- hail 0.02 0,03 0,041 0.05 0.05 fifteen. The limit of heat resistance, ° C 950 950 950 950 950 16. Shrinkage of the sample after heat treatment,% 0 0 0 0 0 17. The density of the sample, kg / m ³ 349 431 569 643 12 eighteen. Water absorption,% 3.0 2.0 1.7 1,0 1,0 19. Frost resistance cycles 160 160 170 170 180 twenty. Abrasion, g / cm ² 0.1 0.1 0.08 0.08 0,07

The 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

7 - sand storage

8 - sand feed system for drying

Sand drying department:

9 - receiving hopper of the drying apparatus

10 - drying drum

11 - sand receiving hopper from the dryer drum

12 - sieve

13- screening conveyor

14 - conveyor for supplying clean sand to the storage hopper

15 - storage tank for clean sand

Sand grinding unit:

16 - sand feeder to the grinder

17 - chopper with classifier system and filter

18 - feeder feeding crushed sand into the storage hopper

19 - the hopper drive crushed sand

20 - feeding feeder crushed sand in the preparation of the binder

Binder preparation department:

21 - raw materials warehouse

22 - a 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 storage hopper of clean sand to the storage hopper with a batcher for the preparation of the charge

24 - a feeder for feeding crushed sand into a storage hopper with a batcher for preparing the charge

25 - the hopper drive crushed sand with a dispenser

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 - mixer pre-preparation of the mixture

30 - hopper-receiver mixer final preparation of the mixture

31 - mixer final preparation of the mixture

32 - storage hopper of the finished mixture.

Claims (3)

1. A method of obtaining building products based on a silica binder by preparing a molding mass from a silica binder and a silica filler, molding from the obtained molding mass of the products and subsequent heat treatment, characterized in that it includes the preparation of a silica binder with a density of 1.3-2.4 g / ^cm3 module 15-30 from a mixture containing inorganic binders, silica-component salt of hydrofluoric acid in an amount of 0.5-10.0 wt.% based on the mixture, and when they are intensively mixed in a high-speed mixer at a mixing speed of 2600-6000 rpm, particle vibration frequency of 3600-45000 rpm, heating at 80-90 ° C or when exposed to electric current with a voltage of 15-40 W and force current to 60 A, followed by cooling of the silica binder with constant stirring at a speed of 40 to 100 rpm at 15-25 ° C for 10-12 hours or using air aeration at 10-20 ° C for 6-11 h, as a silica-containing component using a silica-containing component NT with a particle size of 0.2 to 20.0 mm or pre-crushed to a particle size of 40 Å to 60 μm, selected from the group comprising quartz sand with a moisture content of not more than 4%, quarry clays with a moisture content of more than 10%, calcined clay , loams, sandy loam, loess deposits, with a moisture content of about 4%, as well as silica fume obtained from ferroalloy production waste, stone processing waste obtained during sawing or grinding, for example granite, or in the production of granite crushed stone, hydromica, such as vermicum ita or expanded perlite, with a moisture content of about 4%, as well as amorphous silica-containing mineral raw materials from the group including tripoli, diatomite, with a moisture content of 4-6%, the preparation of the molding mass is carried out by mixing 9.0-13.5 wt.% of this obtained silica-containing binder and 86.5-91.0 wt.% silica-containing aggregate with a moisture content of not more than 6% and a dispersion of 4-50 microns or 60-150 microns, or 0.2-25 mm, which is used as various sand, granite, basalt , vermiculite, expanded perlite sand, expanded clay, hydromica, metallurgical varnishes, coal slags and ashes, expanded clay, stone and stone processing waste, a mixture of amorphous silica with wood processing waste or agricultural processing waste, such as bonfire from processing flax, straw, sunflower husk, and the molding itself is carried out by vibration casting or surface vibration compaction, or by vibropressing or dry pressing with a force of 1.0 to 400 kg / cm ² in a press equipped with a metering system supplying pallets or without pallets with removable feed mechanism sy ca on the conveyor with a pressing force of 150 to 600 kg / cm ^2, the heat treatment is carried out at a temperature of 400-950 ° C, and when using a heat treatment of combustible fillers the above is carried out at 85-95 ° C. 2. The method according to claim 1, characterized in that as the inorganic binder in the preparation of the binder use sodium or ammonium hydroxide or silicate binder. 3. The method according to one of claims 1 and 2, characterized in that a silica-containing material with a particle size of from 0.2 to 20 mm or from 40 Å to 60 μm is used as a silica-containing component in the preparation of the binder.

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