TW202037576A - High-performance sludge-based light-weight pellet material, preparation method and manufacturing system thereof - Google Patents

Abstract

Provided is a high-performance sludge-based light-weight pellet material, a preparation method and a manufacturing system thereof. The method for manufacturing a high-performance sludge-based light-weight pellet material of the invention comprises mixing a raw material consisting of reservoir sediment, an additive containing carbonized silicon and the like in a measurement ratio, and then adding water to be granulated into a dry state a green pellet ball, and further fired it into a light-weight pellet material through a thermal processing in a rotary kiln. Because of utilizing the rotary kiln apparatus system and molten sintering curing process in the present invention, the green pellet ball of reservoir sediment and additive can be made into an aggregate material which is internally filled with independent closed small pores, so that the pellet material obtained sintering process is sludge-based light-weight pellet material having high-performance characteristics such as light weight, high strength and low water absorption.

Description

High-performance sludge lightweight material, its production method and its production system

The present invention relates to a high-performance sludge lightweight material, its production method and its manufacturing system, in particular to a high-performance silt lightweight material production method, which can make reservoir silt into high-performance and high-economic value Lightweight material.

Ceramic pellets made of clay, shale, slate, sludge, and slag are all called ceramsites, and Light weight Aggregate is the general term for ceramsites used in engineering. Its meaning is to take its light weight. In general classification, the particle size is above 5mm (#4 sieve), and the dry loose aggregate unit weight is not more than 1100kg/m ³ is called light coarse aggregate (according to the Japanese JISA5002 standard, the aggregate particle specific gravity is less than 2.0) If the particle size is less than 5mm and the unit weight of the aggregate loose is not more than 1200kg/m ³ , it is called lightweight fine aggregate (according to the Japanese JISA5002 standard, the specific gravity of aggregate particles is ≦2.3). The following is a detailed description of the types and characteristics of light pellets:

1. Types of light pellets

Lightweight pellets can be roughly divided into two types:

a. Natural light pellets: Most of these light pellets come from the eruptions of volcanic magma, among which pumice and foamed volcanic rocks are widely used, and can be used after simple jaw crushing and screening. .

b. Artificial light pellets: The types of artificial light pellets are quite diverse, which can be classified according to the nature of their raw materials. They are processed from natural materials, such as clay, slate, shale, and zeolite; those from industry or the environment Wastes are directly used or processed, such as bottom ash, blast furnace slag and sewage sludge, etc., which are made into lightweight materials by heat treatment or cold solidification.

The characteristics of light pellets will vary depending on the origin, raw materials and production methods, etc., and there are many differences. Generally speaking, whether it is natural or man-made lightweight material, its light weight is caused by the large number of pores inside and outside the light material, resulting in the light material also having high water absorption, low density, and low particle strength And low unit weight, and as the particle size of the aggregate increases, its strength and density also decrease. The characteristics of the above-mentioned lightweight aggregate have a great influence on the performance of concrete. It can be said that the strength, unit weight, thermal insulation and durability of lightweight aggregate concrete mainly depends on the lightweight aggregate used. nature.

2. Disadvantages and limitations of the existing technology:

The traditional artificial light-weight materials are still mainly made of expanded shale and expanded clay. The light-weight materials fired from such materials are due to their inherent foaming mechanism and specific The manufacturing process usually makes the internal pore structure of the aggregates poor. In addition to problems such as large pore size and uneven distribution, there are relatively more defects such as connected pores and cracks, so it has a large water absorption rate (24 hours Water absorption is generally greater than 12%).

From the point of view of on-site construction, this kind of lightweight material with high water absorption rate is extremely unfavorable to the construction performance of concrete mixing, transportation, pumping and pouring, and it is also very easy to cause the separation of concrete, resulting in the durability of concrete Sexual decrease. On the other hand, the above-mentioned various unfavorable factors also make the research, development and application of high-performance lightweight aggregate concrete more complicated and difficult compared to high-performance concrete with constant weight aggregates.

In order to respond to and solve the high water absorption characteristics of traditional lightweight materials, many foreign experts and scholars have also actively carried out research and development and transformation in recent years, hoping to produce high-strength and low-quality materials while maintaining a certain light-weight effect. High Performance Light Weight Aggregate (HPLWA) with water absorption. Among them, Japan’s R&D achievements are the most prominent, and they are also implemented in practical applications and production. Its typical high-performance lightweight aggregate products such as those of Pacific Cement Co., Ltd. have low water absorption rates for aggregates in 24 hours. It is capable of mixing lightweight concrete with a unit weight of 1800kg/m ³ and a compressive strength of 40-60MPa. According to the research report of the Japan Concrete Engineering Association, to improve the performance of lightweight aggregates, it is necessary to start from improving the internal pore structure of lightweight aggregates.

The pore structure of lightweight aggregates can be divided into connected pores and independent closed pores. The existence of connected pores will increase the water absorption rate of the aggregate and reduce the particle strength of the aggregate. On the contrary, adding independent closed pores can help reduce the water absorption rate of the aggregate and obtain a lightweight aggregate. The current development concept of high-performance lightweight aggregates is to use appropriate raw materials and use special processes (such as admixture use or firing condition design) to control the internal pore structure of the aggregate. For example, to produce lightweight, high-strength, and low-water absorption high-performance lightweight materials, it is necessary to reduce the content of connected pores, and at the same time increase the spherical pore-like independent closed pores. Its honeycomb-like structure can reduce the water absorption rate of the aggregate. In addition to particle density, it can also provide relatively high strength of the bone material. However, the current high-performance lightweight materials developed in Japan still have their limitations, as described below:

(1). The main raw materials need to be taken from mountains and rocks, which will destroy the ecological environment balance

The main raw material is acidic volcanic rock. The acidic volcanic rock includes rhyolite, trachyte, etc. It is a kind of light-colored volcanic rock, mostly white and pink, and its chemical composition is equivalent to granite. Because it is a rock mine, large mining machinery is required to take it, and the collection cost is high. On the other hand, collecting such rocks and mines usually requires digging and fetching rocks, which will destroy the ecological environment balance. In addition, acidic volcanic rocks usually only exist in areas with volcanic zones. For other areas without volcanic zones, it is not easy to obtain raw materials.

(2). High cost of raw material processing

In order to obtain high-performance lightweight particles with independent closed pores, the raw materials need to be processed into powders with a particle size of less than 7 microns (μm). Because it uses acidic volcanic rock mines, it takes a lot of cost and equipment and technology to crush and grind the raw materials.

(3). High heat treatment temperature

Since the main raw material is acidic volcanic rock, it is characterized by excellent fire resistance and heat resistance, so it needs to consume a lot of heat (heat treatment temperature ≧1200℃) to make it melt and suitable for expansion to produce high-performance lightweight Pellets. On the other hand, although admixtures of fluxing components can be added to reduce the heat treatment temperature, the effect is still limited, and the addition of admixtures also leads to increased costs.

In view of the existing high-performance lightweight material still has the problem of high production cost, the purpose of the present invention is to provide a high-performance silt lightweight material production method, which can use reservoir silt to produce aggregates with independent closed pores inside. In addition, it is a lightweight, high-strength, and low-hydraulic high-performance sludge lightweight aggregate material, which is used as a granular material for lightweight aggregate concrete mixing.

In order to achieve the above objectives, the high-performance sludge lightweight material preparation method of the present invention includes the following steps:

A method for producing high-performance sludge lightweight material, which is obtained by recycling reservoir sludge. The production method includes: master batch preparation steps: putting reservoir sludge and additives into a mixing unit and mixing uniformly to obtain master batch And then remove the water to make the interior present an anhydrous state; granulation step: put the master batch mixture into a granulation unit to form raw pellets with a particle size distribution of 2-20 mm; and firing step: The raw pellets are transported to a firing unit for low-temperature stage firing and high-temperature stage firing in order to obtain high-performance sludge lightweight materials; the cylinder pressure strength of the high-performance sludge lightweight materials is at least It is greater than or equal to 10.0MPa, or its particle density is 0.3 g/m ³ ~1.8 g/m ³ . The weight ratio of the reservoir sludge relative to the additive is in the range of 90 wt%: 10 wt% to 80 wt%: 20 wt%. In addition, the weight of the reservoir silt relative to the additive is preferably in the range of 90 wt%: 10 wt% to 79 wt%: 21 wt%; more preferably, it is in the range of 90 wt%: 10 wt% to 78 wt% : The range of 22 wt%; the best one is in the range of 90 wt%: 10 wt% to 77 wt%: 23 wt%.

According to an embodiment of the present invention, the conditions for the low-temperature stage firing are: in a first predetermined time interval (t1), the temperature is increased from the first temperature (T1) to the second temperature (T2), and the rotation speed is 2 The range of ~6rpm; the firing conditions of this high-temperature stage are: in the second predetermined time interval (t2), the temperature is raised from the third temperature (T3) to the fourth temperature (T4). In addition, according to an embodiment of the present invention, firing in the low temperature stage further includes maintaining Y at a second temperature (T2) for X minutes; and, firing in the high temperature stage further includes maintaining Y at a fourth temperature (T4). minute. Furthermore, X, and Y are not particularly limited, and the two may be the same or different; for example, X, and Y may be in the range of 5 to 30, preferably 5 to 28 More preferably, it is in the range of 5 to 25, and the best is in the range of 5 to 22.

According to an embodiment of the present invention, t1, t2, T1, T2, T3, and T4 meet the following relations: 15 min≦t1≦60 min, 25 min≦t2≦50 min, and 0.6≦t1/t2≦2.4; 40℃≦T1≦700℃, 40℃≦T2≦700℃, and T1≦T2; 600℃≦T3≦1250℃, 600℃≦T4≦1250℃, and T3≦T4.

According to an embodiment of the present invention, the first predetermined time interval (t1) and the second predetermined time interval (t2) may be the same or different, and are not particularly limited. For example, for example, the lower limit of t1 is preferably 15 min or more, more preferably 16 min or more, and the best is 17 min or more; on the other hand, the lower limit of t2 is preferably 25 min or more, and more The best is greater than or equal to 26 min, and the best is greater than or equal to 27 min.

Secondly, according to an embodiment of the present invention, the upper limit of the first predetermined time interval (t1) is preferably less than or equal to 60 min, more preferably less than or equal to 59 min, and most preferably less than or equal to 58 min; on the other hand, The upper limit of the second predetermined time interval (t2) is preferably less than or equal to 50 min, more preferably less than or equal to 49 min, and most preferably less than or equal to 48 min.

Furthermore, according to an embodiment of the present invention, the first predetermined time interval (t1) and the second predetermined time interval (t2) are not particularly limited. For example, for example, the first predetermined time interval (t1) and the second predetermined time interval (t2) should satisfy the relational expression of 0.6≦t1/t2≦2.4, and preferably satisfy the relationship of 0.6≦t1/t2≦2.35 The relational expression is better to satisfy the relational expression of 0.6≦t1/t2≦2.30, and the best one is to satisfy the relational expression of 0.6≦t1/t2≦2.25.

According to an embodiment of the present invention, the first temperature (T1) and the second temperature (T2) of the low-temperature stage are not particularly limited, and the two may be the same or different. For example, for example, the first temperature (T1) is preferably in the range of 40°C to 700°C, preferably in the range of 40°C to 690°C, more preferably in the range of 40°C to 680°C, most Preferably, it is in the range of 40°C to 670°C. On the other hand, the second temperature (T2) is preferably in the range of 40°C to 700°C, preferably in the range of 40°C to 690°C, more preferably in the range of 40°C to 680°C, and most preferably It is in the range of 40°C to 670°C. In addition, the temperature difference between the first temperature (T1) and the second temperature (T2) is not particularly limited. For example, for example, the value of (T2-T1) may be above 50°C, preferably 100 ℃, more preferably above 150℃, and most preferably above 200℃.

According to an embodiment of the present invention, the third temperature (T3) and the fourth temperature (T4) of the high temperature stage are not particularly limited, and the two may be the same or different. For example, for example, the third temperature (T1) is preferably in the range of 600°C to 1250°C, preferably in the range of 600°C to 1240°C, more preferably in the range of 600°C to 1230°C, most preferably Those are in the range of 600°C to 1220°C. On the other hand, the fourth temperature (T4) is preferably in the range of 600°C to 1250°C, preferably in the range of 600°C to 1240°C, more preferably in the range of 600°C to 1230°C, and most preferably In the range of 600°C to 1220°C. In addition, the temperature difference between the third temperature (T3) and the fourth temperature (T4) is not particularly limited. For example, for example, the value of (T4-T3) can be above 50°C, preferably 100°C. ℃, more preferably above 150℃, and most preferably above 200℃.

According to an embodiment of the present invention, the additive is any one of silicon carbide, sodium oxide, and combinations thereof. Furthermore, according to one of the technical ideas of the present invention, substances suitable for use as additives may also include at least aluminosilicate, aluminosilicate crystals, aluminosilicate precursors, alkali metal oxides, and Its source of raw materials. According to an embodiment of the present invention, the additive, for example, can be, for example, reservoir sludge, water purification sludge, stone processing sludge, clay, fly ash, furnace stone powder, river silt, kaolin, granite powder, brick powder, Marble powder or a combination of them; preferably a substance containing at least aluminosilicate, for example, it may be any one selected from the group consisting of reservoir sludge, water purification sludge, stone processing sludge, clay, and mixtures thereof .

According to an embodiment of the present invention, in the preparation step of the masterbatch mixture, a filter press unit and/or a drying unit are used to remove the moisture in the masterbatch mixture.

According to an embodiment of the present invention, after the firing step, a cooling step is further included: cooling and annealing the high-performance sludge lightweight material obtained in the firing step.

According to an embodiment of the present invention, after the cooling step, a screening and classification step is further included: the high-performance sludge lightweight material is based on the unit weight and particle size distribution.

According to an embodiment of the present invention, the high-performance silt lightweight material is used as a component of concrete for structural engineering.

According to an embodiment of the present invention, the mixing unit is a double-shaft mixer. Preferably, in the master batch preparation step, the reservoir sludge is transported by a scraper to the double-shaft mixer and mixed until uniform.

According to an embodiment of the present invention, it is preferable that in the preparation step of the master batch mixture, the reservoir sludge and additives are conveyed to the double-shaft mixer by a conveyor belt, and the reservoir sludge and additives are measured by an electronic scale attached to the conveyor belt , And then add water and mix to homogeneity by a double-shaft mixer.

According to an embodiment of the present invention, it is preferable that in the preparation step of the masterbatch mixture, the masterbatch mixture is transported to the filter press unit by a conveyor belt to filter water, and the water removed by the filter press Recycle and reuse.

According to an embodiment of the present invention, it is preferable that in the preparation of the master batch mixture, the preparation further includes conveying the master batch mixture to an oven for drying.

According to an embodiment of the present invention, it is preferable that in the granulation step, the master batch mixture is crushed and granulated by a jaw crusher, and the scraps and dust produced by the jaw crusher are recycled and reused.

Therefore, the present invention can also provide a high-performance sludge lightweight material manufacturing system, which at least includes: a mixing unit for mixing reservoir silt and additives to form a master batch mixture; a granulation unit, which is arranged at The downstream end of the mixing unit is used to receive the master batch mixture from the mixing unit and pelletize it to form a raw material ball; and a firing unit, which at least includes a double-tube rotary kiln and a monitoring device; wherein the The double-cylinder rotary kiln is made up of a drying and preheating kiln and a roasting kiln connected in series, and the drying and preheating kiln and the roasting kiln are independently provided with a temperature adjustment mechanism and a rotation speed adjustment mechanism; the drying The feed inlet of the preheating kiln is arranged at the downstream end of the granulation unit to receive the raw material balls from the granulation unit and burn them in a low temperature stage; the roasting kiln receives the raw material from the drying and preheating kiln The pellets are fired in a high-temperature stage to obtain high-performance sludge light pellets; and the monitoring device is electrically connected with the temperature adjustment mechanisms and the rotational speed adjustment mechanisms to detect and control the drying pre-drying Thermal kiln, and the temperature and speed in the roasting kiln.

The specific effects that the present invention can achieve include:

1. In the present invention, raw materials such as reservoir sludge, silicon carbide-containing additives, etc., are mixed according to the metered ratio, and water is added to granulate the raw material pellets in a dry state, and then the light pellets are fired in a rotary kiln through a heat treatment process. Since the preferred embodiment of the present invention uses the rotary kiln system equipment to sinter and solidify the raw material balls containing the silt of the reservoir and the additives, they are fired into aggregates with independent closed small pores inside. Aggregate is a high-performance lightweight material with lightweight, high strengthening and low water absorption characteristics.

2. The present invention is made by using reservoir silt, and because its treatment temperature does not need to be higher than 1200°C, the manufacturing cost can be greatly reduced, and the waste reservoir silt can also be effectively removed. The re-prepared lightweight material also has a relatively high Economic benefits.

In the following, different specific embodiments are listed and explained in more detail for the implementation of the present invention, so as to make the spirit and content of the present invention more complete and easy to understand; however, those with ordinary knowledge in this art should understand Of course, the present invention is not limited to these examples, and other same or equal functions and sequence of steps can also be used to achieve the present invention.

In this article, the scientific and technical terms used here have the same meanings as understood and used by those with ordinary knowledge in the technical field of the present invention. In addition, without conflict with context, the singular nouns used in this specification cover the plural nouns; and the plural nouns also cover the singular nouns.

In this article, the values and parameters used to define the scope of the present invention inevitably contain standard deviations due to individual test methods, and therefore are mostly expressed as approximate quantitative values. However, in specific embodiments, Relevant values presented as accurately as possible. In this article, "about" usually depends on the considerations of those with ordinary knowledge in the technical field of the present invention, and generally means that the actual value falls within the acceptable standard error of the average value. For example, the actual value is a Within ±10%, ±5%, ±1%, or ±0.5% of a specific value or range.

In the embodiment of the present invention, reservoir sludge and additives containing at least silicon carbide are used as raw materials. Reservoir silt is a reusable resource waste. Reservoirs in Taiwan accumulate more than 470 million cubic meters of silt. Therefore, reservoir silt has the advantage of being abundant and endless. Development of reservoir silt to produce high-performance and light-weight Granules can remove the sludge and help the sustainable use of the reservoir, which is of great benefit to the national economy, people's livelihood and environmental protection. In addition, the reservoir silt has a fine particle size, with a median diameter D _{50 of} about 3~5 microns (μm), which is free The jaw crushing and grinding process is conducive to the production of high-performance sludge lightweight materials. The silicon carbide-containing additive has a foaming effect.

Next, please refer to Figure 1, which is a standard step flow chart showing the production method of the high-performance sludge lightweight material of the present invention. The production method includes:

Masterbatch preparation step S1: Put the reservoir sludge and additives into a mixing unit and stir evenly to obtain a masterbatch mixture, and then remove the water to make the inside appear anhydrous.

Granulation step S2: Put the master batch mixture into a granulation unit to form raw pellets with a particle size distribution of 2-20 mm.

The firing step S3: transport the raw meal ball to a firing unit for firing in a low temperature stage and a high temperature stage in order to obtain a high-performance sludge lightweight material.

In the master batch preparation step S1, the reservoir sludge is uniformly mixed to form a homogenized powder. Preferably, the reservoir sludge is transported by a scraper to a twin-shaft mixer to mix until uniform, and finally The well-mixed reservoir sludge is placed in its own silo for the subsequent mixing and batching action. The homogenization process is used to ensure the homogeneity of the raw materials to ensure that the final product can be produced with stable quality and excellent performance. Plasmid material.

Then, measure and mix the uniformly mixed reservoir sludge with additives and water to form a mixture. The weight ratio of the reservoir sludge to the additive is 90 wt%: 10 wt% to 80 wt%: 20 wt% Within the scope of the range, the process of mixing ingredients can be conveyed to the double-shaft mixer by a conveyor belt, and the reservoir sludge and additives are measured by the electronic scale attached to the conveyor belt, and then mixed with water through the double-shaft mixer until homogeneous (the mixture is then Slurry) Obtain a masterbatch mixture for subsequent granulation steps.

According to the technical idea of the present invention, the masterbatch mixture uses a filter press unit and/or a drying unit to remove moisture from it. Preferably, the masterbatch mixture is transported to the filter press by a conveyor belt to filter the moisture until the moisture content in the masterbatch mixture is less than 35%. The moisture removed by the filter press is recycled and reused to ensure weight. Environmentally-friendly and clean production; and then transport the masterbatch mixture to an oven for drying to an anhydrous state.

Then, in the granulation step S2, the anhydrous master batch mixture is crushed into continuous gradation 5-20 mm of crushed raw material balls; preferably, the master batch mixture is crushed and granulated by a jaw crusher, The scraps and dust produced by the jaw crusher are recycled and reused to implement environmentally friendly clean production.

In the firing step S3, the raw material balls are transported to the firing unit to be fired into light pellets. The highest furnace temperature used for firing is between 1100 and 1200°C, which can vary according to different product requirements. The difference is different, and firing is performed according to the preset firing curve. The firing unit can be a rotary kiln, and the exhaust gas of the rotary kiln must be desulfurized and dust collected by air pollution prevention equipment, so that it can meet the national air pollution prevention standards. After desulfurization and dust collection, The recovered dust can also be reused in the production of lightweight materials, achieving the "zero waste" concept promoted by the Environmental Protection Agency.

According to the technical idea of the present invention, the raw material ball is fired in a low temperature stage and a high temperature stage in sequence; the condition of the low temperature stage firing is: the temperature is changed from the first temperature in the first predetermined time interval (t1) (T1) The temperature is raised to the second temperature (T2) and the rotation speed is in the range of 2-6 rpm; the conditions for firing in this high temperature stage are: the second predetermined time interval (t2) is used to change the temperature from the third temperature ( T3) increase to the fourth temperature (T4); and t1, t2, T1, T2, T3, and T4 respectively conform to the following relations: 15 min≦t1≦60 min, 25 min≦t2≦50 min, and 0.6≦t1/t2≦2.4; 40℃≦T1≦700℃, 40℃≦T2≦700℃, and T1≦T2; 600℃≦T3≦1250℃, 600℃≦T4≦1250℃, and T3≦T4.

In addition, in another embodiment of the present invention, after the firing step S3, a cooling step S4 is further included: cooling and annealing the light weight material obtained by firing; preferably, the light weight material system Use a cooler to cool and anneal according to the pre-set slow cooling curve. In addition, after the cooling step S4, it may further include screening and classification S5: the light-weight particles obtained by cooling are classified and stored according to their unit weight and particle size, etc., and become a finished product that can be sold at the factory. .

Corresponding to the above-mentioned high-performance sludge light-weight material manufacturing method, the present invention further provides a high-performance sludge light-weight material manufacturing system. Please refer to Figure 2, which shows the system architecture diagram of the high-performance sludge lightweight material manufacturing system of the present invention. The high-performance sludge lightweight material manufacturing system mainly includes a mixing unit 1, a filter press unit 2 , Drying unit 3, granulating unit 4 and firing unit 5.

The granulation unit 4 is arranged at the downstream end of the mixing unit 1, and the firing unit 5 is arranged at the downstream end of the granulation unit 4. The raw material sludge is mixed into a homogenized powder in the mixing unit 1. In this embodiment, the mixing unit 1 can be a dual-shaft mixer, and the sludge can be reservoir sludge or sludge dredged from a trench. The homogenized sludge, additives and water are then mixed in the mixing unit 1 to form a master batch mixture. The mixing unit 1 can also be of flat-wing turbine type, disc turbine type, wedge-shaped wing type, or spiral type. A form of mixing equipment. In this embodiment, the weight ratio of the reservoir silt to the additive is in the range of 90 wt%: 10 wt% to 80 wt%: 20 wt%, and the mixed material after mixing is in a slurry state. The process of mixing ingredients can be conveyed to the twin-shaft mixer by a conveyor belt, and the silt and additives in the reservoir can be measured by the electronic scale attached to the conveyor belt, and then mixed with water by the twin-shaft mixer until homogeneous, and then the pre-treatment of the granulation process .

The slurry-like master batch mixture is conveyed to a filter press unit 2, which is arranged at the downstream end of the mixing unit 1 to receive the master batch mixture from the mixing unit 1, and filter the master batch mixture to remove Most of the water forms the masterbatch mixture after press filtration. The press-filtered masterbatch mixture is transported to a drying unit 3, which is arranged at the downstream end of the filter press unit 2 to receive the press-filtered mixture from the filter press unit 2, and dry the press-filtered mixture , And a dry master batch mixture is formed, and the dry master batch mixture is transported to the granulation unit 4.

The granulation unit 4 is arranged at the downstream end of the drying unit 3 to receive the master batch mixture from the mixing unit 1 and granulate it to form raw pellets, and crush the dried mixture into a continuous gradation 5-20 Millimeters of crushed raw material balls; preferably, the mixture is crushed and granulated by a jaw crusher. The scraps and dust produced by the jaw crusher are recycled and reused. For example, the scraps and dust can be transported back to the mixing unit 1 Mix the sludge with additives and water after being evenly mixed. The raw material balls are transported to a firing unit 5.

The firing unit 5 includes a double-cylinder rotary kiln 51 and a monitoring device 52. The double-cylinder rotary kiln 51 includes a drying and preheating kiln 511 and a roasting kiln 512 connected in series in a plug-in manner, and the drying and preheating kiln 511 and the roasting kiln 512 are connected in series. The temperature adjustment mechanism and the rotation speed adjustment mechanism are independently set up to control the heating temperature and the rotation speed of the kiln body of the drying preheating kiln 511 and the roasting kiln 512 respectively.

The inlet of the drying and preheating kiln 511 is set at the downstream end of the granulation unit 4 to receive the raw material balls from the granulation unit 4 and perform low-temperature firing. The roasting kiln 512 receives the raw material from the drying and preheating kiln 511 The raw material pellets are burned in the second stage to obtain light pellets, that is, light pellets. The maximum temperature in the kiln is between 1100~1200℃, which can be different according to different product requirements. It is fired according to the preset firing curve. The exhaust gas of the rotary kiln must be desulfurized by air pollution prevention equipment The dust collection process makes it meet the national air pollution control standards. The recovered dust from the desulfurization dust collection can also be reused in the production of light particles. The monitoring device 52 is electrically connected with the temperature adjustment mechanism and the rotation speed adjustment mechanism, and is used to detect and control the temperature and rotation speed in the drying and preheating kiln and the roasting kiln.

The lightweight pellets fired by the firing unit 5 are transported to the cooling unit 6, where the fired lightweight pellets are cooled and annealed; preferably, the light pellets are cooled and annealed by the cooling machine. The pre-set slow cooling curve is cooled and annealed.

The cooled lightweight pellets are sent to the screening unit 7, where they are sorted and stored according to their unit weight and particle size, etc., and they become finished products that can be sold out.

In addition, the high-performance sludge lightweight material manufacturing system further includes a system information control center 8. The system information control center 8 is connected to the mixing unit 1, the filter press unit 2, the drying unit 3, the granulation unit 4, and the firing unit. Unit 5, cooling unit 6, and screening unit 7, and the system information control center 8 is connected to a cloud database 9 via a network, mixing unit 1, filter press unit 2, drying unit 3, granulation unit 4, burning The manufacturing parameters of the system unit 5, the cooling unit 6 and the screening unit 7 can be sent to the system information control center 8, and the system information control center 8 can send control signals to the mixing unit 1, the filter press unit 2, the drying unit 3, The granulation unit 4, the firing unit 5, the cooling unit 6 and the screening unit 7, and the cloud database 9 can analyze the data of each unit and provide the best control mode of the system information control center 8.

The following compares the commercially available traditional lightweight material with the high-performance sludge lightweight material prepared by the preferred embodiment of the present invention, and observes its water absorption, density and strength properties. "Example 1-2"

In Examples 1 and 2, the reservoir sludge, silicon carbide and sodium oxide as additives were mixed in the proportions shown in Table 1 below to obtain a master batch mixture. Then, the masterbatch mixture is subjected to water pressure filtration with a filter press until the moisture content in the masterbatch mixture is between 15% and 25%, and then the masterbatch mixture is dried to an anhydrous state in an oven.

The dried masterbatch mixture is crushed and granulated by a jaw crusher to form a continuous gradation of 5-15 mm of crushed raw material balls.

Then, put the raw pellets into a double-cylinder rotary kiln for low-temperature stage firing and high-temperature stage firing at the temperature, heating time, and rotation speed shown in Table 1, to obtain light pellets S1 and S2.

After cooling and annealing the lightweight materials V1 and V2, the product physical properties were analyzed, and the results obtained were recorded in Table 1, and then compared with the commercially available conventional lightweight materials V1, V2, and V3 in Comparative Examples 1 to 3 Compare.

Table 1 Example 1 Example 2 Comparative example 1 Comparative example 2 Comparative example 3 Light pellets S1 S2 V1 (commercially available product) V2 (commercially available product) V3 (commercially available product) Raw material ratio Reservoir silt (wt%) 90 80 - - - Silicon carbide (wt%) 5 15 - - - Sodium oxide (wt%) 5 5 - - - Water content of masterbatch mixture (%) 15~25 15~25 - - - Average particle size of raw meal (mm) 5~15 5~15 - - - Low-temperature firing The first temperature (℃) 60 60 - - - The second temperature (℃) 650 650 - - - Heating time (min) 15~25 20~35 - - - Speed (rpm) 4~6 2~4 - - - High-temperature firing The third temperature (℃) 650 650 - - - The fourth temperature (℃) 1150 1200 - - - Time (min) 25~40 25~50 - - - Speed (rpm) 2~3 1~2 - - - Product properties Loose unit weight (kg/m ³ ) 400~550 500~800 - - - Particle size (mm) 5~20 5~18 - - - Particle density (g/cm ³ ) 0.7~1.1 1.1~1.6 1.0 1.15 1.36 Pore diameter (μm) 30~50 2~30 Larger than 100μm Larger than 100μm Larger than 100μm Water absorption rate (%) 3 0 10.4 7.2 6.1 Vacuum water absorption (%) 5 2 47.9 38.5 32.4 Cylinder compression strength (Mpa) 10 15 3 7 8

From the results in Table 1, it can be found that the water absorption rates of the high-performance sludge lightweight materials S1 and S2 prepared in Examples 1 and 2 of the present invention are significantly lower than those of the commercially available traditional lightweight materials, and the cylinder pressure strength is higher. The commercially available traditional lightweight materials are high, which shows that the method of the present invention can produce high-performance sludge lightweight materials with low water absorption and high strength.

In addition, please refer to FIG. 3A, FIG. 3B, FIG. 4A, and FIG. 4B. Figures 3A and 3B are the physical photos and electron microscope images of traditional lightweight aggregates, respectively; Figures 4A and 4B are the physical photos and electron microscope images of the high-performance sludge lightweight material of the present invention, respectively.

Comparing Fig. 3A, Fig. 3B, Fig. 4A, and Fig. 4B, it can be seen that the traditional artificial lightweight aggregates are still mostly made of expanded shale and clay, and the lightweight aggregates fired from such materials are inherently The foaming mechanism and specific production procedures usually make the internal pore structure of the aggregates poor. In addition to the large pore size and uneven distribution, there are relatively more defects such as connected pores and cracks, so it has a large water absorption rate (generally Greater than 12%). From the point of view of on-site construction, such lightweight aggregates with high water absorption rate are extremely unfavorable for the construction of concrete mixing, transportation, pumping and pouring, and it is also very easy to cause the separation of concrete, resulting in the durability of concrete Sexual decrease. Compared with traditional lightweight aggregates, the high-performance silt lightweight aggregate of the present invention has a pore structure that is significantly better than that of traditional lightweight aggregates, so that it can maintain the characteristics of lightweight It has high strength and low water absorption performance, which is more conducive to the construction of super high-rise buildings and large collapsed structures, and because it is made of reservoir silt, the manufacturing cost can be greatly reduced.

In other words, the performance of the high-performance sludge lightweight material of the present invention has two major characteristics compared with the traditional lightweight material:

1. Lightweight and high strength: Under the medium particle density grade, the cylinder compressive strength of the high-performance sludge lightweight aggregate of the present invention is one grade higher than that of the traditional lightweight aggregate (according to the standard GB/T17431.1), and at least can be prepared Lightweight aggregate concrete for structures with a compressive strength of 40MPa (=400kg/cm ³ ) (can be used for the production of super high-rise buildings).

2. Small pores and low water absorption: The high-performance sludge lightweight material of the present invention contains a large number of independently closed spherical pores (diameter is less than or equal to 100μm, preferably about 2-50μm; traditional lightweight materials are larger than 100μm) . Moreover, the atmospheric water absorption rate of the high-performance sludge lightweight aggregate of the present invention can be controlled to be less than 5% (traditional lightweight aggregates are generally higher than 12%), and the water absorption rate grows less under the action of high water pressure, which can meet Work requirements for mixing or pumping high-performance concrete without pre-wetting.

In summary, the preferred embodiment of the present invention can effectively remove the waste reservoir silt, and the light-weight pellets obtained from it can also obtain substantial economic benefits, which is very beneficial to the people's livelihood, construction and environmental protection of the country. Positive meaning. However, as shown in the above description, drawings and table, it is one of the preferred embodiments of the present invention, and is not limited to the present invention. Therefore, all the structures, devices, features, etc. of the present invention are similar and similar All of them should fall within the creation purpose of the invention and the scope of the patent application.

S1~S5: steps 1: Mixing unit 2: Filter press unit 3: Drying unit 4: Granulation unit 5: Firing unit 6: Cooling unit 7: Screening unit 8: System Information Control Center 9: Cloud database 51: Double barrel rotary kiln 52: Monitoring device 511: Drying and preheating kiln 512: roasting kiln

Fig. 1 is a flow chart showing an embodiment of the method for preparing high-performance sludge lightweight material of the present invention. Fig. 2 is a system block diagram showing an embodiment of the high-performance sludge lightweight material manufacturing system of the present invention. Figures 3A and 3B are physical photographs and electron microscope images showing traditional lightweight aggregates, respectively. 4A and 4B are physical photographs and electron microscope images of the high-performance sludge lightweight material of the present invention, respectively.

S1~S5: steps

Claims (10)

A method for producing high-performance sludge lightweight material, which is obtained by recycling sludge from a reservoir. The production method includes: Master batch preparation steps: put the reservoir sludge and additives into a mixing unit and stir evenly to obtain the master batch mixture, and then remove the water to make the inside appear anhydrous; Granulation step: put the master batch mixture into a granulation unit to form raw pellets with a particle size distribution of 2-20 mm; and The firing step: transport the raw meal ball to a firing unit for firing in a low temperature stage and a high temperature stage in order to obtain a high-performance sludge lightweight material; The weight ratio of the reservoir silt to the additive is in the range of 90 wt%: 10 wt% to 80 wt%: 20 wt%; The additive is any one of silicon carbide, sodium oxide, and combinations thereof; The conditions for firing in this low-temperature stage are: in a first predetermined time interval (t1), the temperature is increased from the first temperature (T1) to the second temperature (T2); The conditions for firing in the high-temperature stage are: in the second predetermined time interval (t2), the temperature is increased from the third temperature (T3) to the fourth temperature (T4); and t1, t2, T1, T2, T3, and T4 respectively conform to the following relations: 15 min≦t1≦60 min, 25 min≦t2≦50 min, and 0.6≦t1/t2≦2.4; 40℃≦T1≦700℃, 40℃≦T2≦700℃, and T1≦T2; 600℃≦T3≦1250℃, 600℃≦T4≦1250℃, and T3≦T4. The method for preparing high-performance sludge lightweight material as described in claim 1, wherein in the master batch preparation step, a filter press unit and/or a drying unit are used to remove water in the master batch mixture. The method for producing a high-performance sludge lightweight material as described in claim 1, wherein after the firing step, a cooling step is further included: cooling and annealing the high-performance sludge lightweight material obtained in the firing step. The method for preparing the high-performance sludge lightweight material as described in claim 4, wherein after the cooling step, a screening and classification step is further included: the high-performance sludge lightweight material is based on the unit weight and particle size distribution. The method for producing high-performance sludge lightweight material as described in claim 1, wherein the high-performance sludge lightweight material is used as a component of concrete for structural engineering. A high-performance sludge lightweight material manufacturing system, which includes at least: Mixing unit for mixing reservoir silt and additives to form a master batch mixture; A granulation unit, which is arranged at the downstream end of the mixing unit, for receiving the master batch mixture from the mixing unit and granulating to form a raw material ball; and The firing unit includes at least a double-tube rotary kiln and a monitoring device; The double-cylinder rotary kiln is formed by a drying and preheating kiln and a roasting kiln connected in series in a plug-in manner, and the drying and preheating kiln and the roasting kiln are independently provided with a temperature adjustment mechanism and a rotation speed adjustment mechanism; The inlet of the intervention thermal kiln is set at the downstream end of the granulation unit to receive the raw material pellets from the granulation unit and perform low-temperature firing; the roasting kiln receives the raw material from the drying and preheating kiln Raw meal pellets are fired at a high temperature stage to obtain high-performance sludge lightweight pellets; and The monitoring device is electrically connected with the temperature adjustment mechanisms and the rotation speed adjustment mechanisms to detect and control the temperature and rotation speed in the drying and preheating kiln and the roasting kiln. The high-performance sludge lightweight material manufacturing system described in claim 6, which further includes: The filter press unit is arranged at the downstream end of the mixing unit to receive the masterbatch mixture from the mixing unit, and filter the masterbatch mixture to remove most of the moisture to form a filtered press Master batch mixture, the moisture filtered by the filter press unit is transported to the mixing unit; and The drying unit is arranged at the downstream end of the filter press unit to receive the filtered press mixture from the filter press unit, and dry the press filtered mixture to form a dry master batch mixture. The dried masterbatch mixture is transported to the granulation unit; The cooling unit is arranged at the downstream end of the firing unit for cooling the high-performance sludge lightweight material. The high-performance sludge lightweight material manufacturing system described in claim 6, wherein the double-cylinder rotary kiln is further provided with an angle adjusting mechanism, and the angle adjusting mechanism is electrically connected with the monitoring device to adjust the double-cylinder rotation The tilt angle of the kiln. A high-performance sludge lightweight material produced by the manufacturing method according to any one of claims 1 to 5 or the manufacturing system according to any one of claims 6 to 8, characterized in that: the high performance The cylinder compressive strength of the sludge lightweight material is at least greater than or equal to 10.0 MPa, or its particle density is 0.3 g/m ³ ~1.8 g/m ³ . The high-performance sludge lightweight material as described in claim 9, wherein the diameter of the independently closed spherical pores contained in the high-performance sludge lightweight material is less than or equal to 100 µm.

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