WO2023065897A1 - 一种高含水率废弃泥浆脱水-制砖一体化系统及实施方法 - Google Patents

一种高含水率废弃泥浆脱水-制砖一体化系统及实施方法 Download PDF

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WO2023065897A1
WO2023065897A1 PCT/CN2022/118697 CN2022118697W WO2023065897A1 WO 2023065897 A1 WO2023065897 A1 WO 2023065897A1 CN 2022118697 W CN2022118697 W CN 2022118697W WO 2023065897 A1 WO2023065897 A1 WO 2023065897A1
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mud
switch
brick
density
pipeline
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PCT/CN2022/118697
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English (en)
French (fr)
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吴思麟
郑齐
彭晓
李晓道
周爱兆
徐浩青
吴涛
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江苏科技大学
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Publication of WO2023065897A1 publication Critical patent/WO2023065897A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
    • C02F11/121—Treatment of sludge; Devices therefor by de-watering, drying or thickening by mechanical de-watering
    • C02F11/122—Treatment of sludge; Devices therefor by de-watering, drying or thickening by mechanical de-watering using filter presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/245—Curing concrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
    • B28B13/023—Feeding the moulding material in measured quantities from a container or silo by using a feed box transferring the moulding material from a hopper to the moulding cavities
    • B28B13/0235—Feeding the moulding material in measured quantities from a container or silo by using a feed box transferring the moulding material from a hopper to the moulding cavities the feed box being provided with agitating means, e.g. stirring vanes to avoid premature setting of the moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/008—Sludge treatment by fixation or solidification
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
    • C02F11/121—Treatment of sludge; Devices therefor by de-watering, drying or thickening by mechanical de-watering
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
    • C02F11/14—Treatment of sludge; Devices therefor by de-watering, drying or thickening with addition of chemical agents
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
    • C02F11/14—Treatment of sludge; Devices therefor by de-watering, drying or thickening with addition of chemical agents
    • C02F11/143—Treatment of sludge; Devices therefor by de-watering, drying or thickening with addition of chemical agents using inorganic substances
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N9/00—Investigating density or specific gravity of materials; Analysing materials by determining density or specific gravity
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2303/00—Specific treatment goals
    • C02F2303/06—Sludge reduction, e.g. by lysis

Definitions

  • the invention relates to a reduction and resource integration method of engineering waste mud, in particular to an integrated system and implementation method of dehydration and brick making of waste mud with high water content.
  • waste mud has high moisture content, high clay content, slow settlement, and lack of landfill in cities.
  • reduction methods there are currently some reduction methods (the waste mud treatment methods in traditional engineering are mostly related to plate and frame filter press, belt filter press, and centrifugal treatment), but the soil after mud reduction Due to the nature and unclear requirements of the product, it cannot be directly used as a resource. It is still necessary to modify the reduced soil product twice before reusing it. That is, there is currently a lack of one-step reduction and resources for waste mud. method of transformation.
  • the existing relevant patents can be divided into two categories, one is a method for reducing the amount of waste mud with a high water content, and the other is a method for recycling waste mud with a lower water content.
  • the Chinese invention patent with application number CN201911285683.9 discloses a method for dehydration of river and lake bottom mud by plate-and-frame filter press.
  • the secondary dehydration improves the concentration efficiency to a certain extent.
  • the properties of the products after mud reduction are not clear, and the way of resource utilization is not clear, it may be necessary to modify the processed products again before resource utilization.
  • the Chinese invention patent with the application number CN201110100300.3 discloses a kind of non-fired brick made of sludge and its production method, through the proportioning of different materials, by stirring Make it evenly mixed, and then put it into brick-making machine-made bricks, which greatly improves the resource utilization of sludge, but this method has the following defects:
  • the applicable object of this method is sludge with low water content. It cannot be directly applied to mud with high water content. The mud needs to be dehydrated and pre-treated, and then the patented method is used to make bricks. The scope of application is limited;
  • This invention patent cannot be applied to waste sludge with uneven moisture content. If the moisture content of sludge changes during continuous treatment, bricks with uneven quality and strength will be produced in the subsequent brick-making process;
  • Purpose of the invention In view of the fact that it is difficult to recycle mud after reduction or it is necessary to find another way to recycle after reduction, an integrated system and implementation method for dehydration of waste mud with high water content and brick making are invented.
  • the present invention provides an integrated system and implementation method for waste mud dehydration with high water content and brick making, including a mud pool, a real-time mud density detection system, a unified mud density processing system, a chemical addition system, and a dehydration filter press brick making system , the systems are connected by mud conveying pipelines.
  • the real-time detection system for mud density includes a mud delivery port, a mechanical sensor, a signal sensor, a signal receiver, a switch controller, a first switch, a second switch and a third switch.
  • the mud conveying pipeline is used to transport mud, and a mechanical sensor is installed 30cm away from the mud conveying port.
  • the mechanical sensor, signal sensor and switch controller are all located on the outer surface of the mud conveying pipeline; the mechanical sensor is used to detect the real-time density of the mud.
  • the sensor is connected; the signal receiver is connected with the switch controller, the mud density real-time monitoring system is connected with the mud density unified processing system through the mud conveying pipeline, and is controlled by the switch, and the switch controller controls the closing status of each switch, which is used to control the direction of mud flow.
  • the mechanical sensor detects the real-time impact force of the mud, and calculates the density of the mud in real time through the formula.
  • the signal sensor is responsible for transmitting the density of the mud to the signal receiver in the form of an electrical signal; when the mud density is received by the signal receiver, the switch controller Control the opening and closing of the second switch, the first switch and the third switch are closed, and the mud directly enters the next system through the mud conveying pipeline; when the signal received by the signal receiver is the mud density, the switch controller controls the opening and closing of the first switch, and the second The second switch and the third switch are closed, and the mud enters the mud settlement tank through the mud conveying pipeline; when the signal received by the signal receiver is the mud density, the switch controller controls the opening and closing of the third switch, the first switch and the second switch are closed, and the mud Enter the mud dilution tank through the mud conveying pipeline.
  • the mud density unified treatment system includes a mud settlement tank, a water level height measuring instrument, a cantilever agitator and a mud dilution tank, and the switch controller controls the first switch, the second switch and the third The opening and closing of the switch divides the system into three branches.
  • the mud settlement tank and the mud dilution tank are respectively located on both sides of the central mud conveying pipeline, and the mud settlement tank and the mud dilution tank are connected through the mud conveying pipeline;
  • the water level measuring instrument is respectively It is located beside the mud settlement tank and the mud dilution tank, and the cantilever beam agitator is suspended above the mud settlement tank and the mud dilution tank respectively.
  • the switch controller controls the opening and closing of the first switch, and when the second switch and the third switch are closed, the mud enters the mud settlement tank for settlement treatment, and the water level measuring instrument tests the water level in the mud pool in real time.
  • the density of the mud is , the water in the mud settling tank is pumped out with a water pump, and then the cantilever agitator starts to work at a speed of 60r/min, and the evenly stirred mud is transported to the next system through the mud conveying pipeline;
  • the switch controller controls the first The second switch is opened and closed, the first switch and the third switch are closed, that is, the density of the mud at this time, and the mud directly enters the next system through the mud conveying pipeline;
  • the switch controller controls the opening and closing of the third switch, the first switch and the second switch Closed, the mud enters the mud dilution tank through the mud conveying pipeline, injects water into the tank, and detects the water level in real time through the water level
  • the medicament adding system includes a curing agent adding device, a curing stabilizer adding device, a curing agent delivery pipeline, a curing stabilizer delivery pipeline and a serpentine pipeline.
  • the curing agent adding device is connected with the serpentine pipeline through the curing agent conveying pipeline;
  • the curing stabilizer adding device is connected with the serpentine pipeline through the curing stabilizer conveying pipeline;
  • the two ends of the serpentine pipeline are connected through the mud conveying pipeline.
  • the curing agent adopts early-strength cement (aluminum phosphate cement), and its dosage is , and the calculation formula is ;
  • the curing stabilizer uses ordinary Portland cement, and its dosage is , and the calculation formula is .
  • the serpentine pipeline here can fully and evenly mix the curing agent and curing stabilizer with the mud, and the mixed mud enters the next system through the mud conveying pipeline.
  • the dehydration filter press brick making system includes a filter press, a grouting hole, a brick making mold, a press and a baffle, the filter press is connected through a mud delivery pipeline, the press and the brick making The mold is connected, and the mud fully mixed with the agent enters the dehydration filter press brick system and enters the brick mold through the grouting hole.
  • the filter press is equipped with 10 brick molds, and the size of each brick mold is set to 240cm in length, width and height.
  • the press is responsible for providing the pressure, according to the small test experiment, the preferred value of the pressure to be provided is 10kN, and the volume of the mud is compressed to the size of an ordinary standard brick in a ratio of 6:1, which is 240cm*115cm*53cm.
  • the diameter of the drainage hole is 1mm, and the mud after brick formation has become soft soil with a particularly low moisture content. At this time, after waiting for 1 hour, the early-strength cement will fully play its role, and the strength of the brick will increase.
  • the brick will be taken out manually and placed in the curing box for 4 days of curing.
  • the strength of the brick meets the strength requirements of the unburned brick in the specification Flush the dewatering filter press brick making system immediately after removing the bricks from the filter press.
  • the mud delivery pipelines, serpentine pipelines, curing agent delivery pipelines and solidification stabilizer delivery pipelines used in the above various systems all adopt anti-corrosion pipelines
  • the cross-sectional area of the mud delivery pipelines is 25cm 2
  • the curing agent delivery pipelines Both adopt the steel pipe that cross-sectional area is 10cm with solidification stabilizer delivery pipeline, and the cross-sectional area of serpentine pipeline is 25cm Its effective length is 150cm.
  • multiple mud settling tanks and mud dilution tanks can be set in the unified mud density treatment system; multiple filter presses can be set to work alternately in the dehydration filter press brick making system.
  • the mud density real-time detection system of the present invention can detect the density of mud in real time, and make different processing modes respectively according to the difference of mud density;
  • the mud density uniform processing system the mud is diluted or settled to make the mud
  • the density is uniform, which is convenient for post-curing treatment and dehydration filter press brick processing, so as to form unfired bricks with uniform quality specifications;
  • the chemical addition system the chemical addition process is made according to the fixed mud moisture content, and in the serpentine pipeline, it can
  • the agent and the mud are fully and uniformly mixed, which further ensures the uniform density of the mud and the uniform addition of the agent in the mud, thereby ensuring the uniform strength of each brick in the dehydration filter press brick system; on the one hand, the dehydration filter press brick system plays a role in the mud
  • the effect of dehydration reduction makes the waste mud of the project reduce and directly treat it as unburned bricks, saving the process and completing it in one step.
  • Fig. 1 is a structural representation of the present invention
  • Figure 2 is a schematic diagram of the mud dilution tank
  • Fig. 3 is the schematic diagram of dehydration filter press brick making system
  • Fig. 4 is a schematic diagram of the dehydration filter press brick making system.
  • the high water content waste mud dehydration-brick making integrated system and implementation method of this embodiment include a mud pool 1, a mud density real-time detection system 2, a mud density unified processing system 3, a chemical addition system 4 and a dehydration pressure Filter brick system5.
  • the mud is pumped into the mud density real-time monitoring system 2 from the mud pool 1 through the mud delivery port 24 at a fixed flow rate through the mud delivery pipeline 6, and the force received by the mechanical sensor 9 is then calculated according to the real-time density of the mud according to the formula.
  • the signal sensor 10 is responsible for transmitting the density of the mud to the signal receiver 7 in the form of an electrical signal; when the mud density received by the signal receiver 7, the switch controller 8 controls the second The switch 12 is opened and closed, the first switch 11 and the third switch 13 are closed, and the mud directly enters the next system through the mud conveying pipeline 6; when the signal received by the signal receiver 7 is the mud density, the switch controller 8 controls the first switch 11 Open and close, the second switch 12 and the third switch 13 are closed, and the mud enters the mud settlement tank 15 through the mud delivery pipeline 6; when the signal received by the signal receiver 7 is the mud density, the switch controller 8 controls the third switch 13 to open and close , the first switch 11 and the second switch 12 are closed, and the mud enters the mud dilution tank 17 through the mud delivery pipeline 6 .
  • the bottom mud needs to be dredged.
  • the cutter suction dredging method is used for dredging, and the density of the waste mud produced is about 1.02g/cm 3 . quantity and resources.
  • the dredged mud is pumped from the mud pool into the mud conveying pipeline at a flow rate of 4m/s, and then enters the real-time detection system of mud density.
  • the switch controller 8 controls the opening and closing of the first switch 11, the second switch 12 and the second Three switches 13 are closed, and mud enters mud settlement tank 15 by mud delivery pipeline 6; 1.2 high water in the mud settling tank 15 is extracted out with a water pump, then the suspension beam type agitator 14 starts to work with a rotating speed of 60r/s, and the evenly stirred mud is transported to the medicament addition system 4 through the mud delivery pipeline 6;
  • the top and bottom of the brick-making mold 26 are provided with a plurality of small holes.
  • a geotextile is arranged on the surface to discharge the water from the filter press. After the filter press is completed, it is manually taken out after standing for 1 hour and placed in a curing box for curing. 4d Take it out and take out the baffle 28 to rinse the filter press 23; The unburned bricks at this time meet the strength requirements of the national norms. In order to consider the continuity of the process, as a supplement, the process can consider the actual situation.
  • Waste mud generated during the construction of a mud-water shield project needs to be disposed of.
  • the density of the waste mud produced by this project is about 1.10g/cm 3 , and the mud has no chemical pollution.
  • This system is used to treat the waste mud and make resource utilization into unburned bricks.
  • the mud is pumped from the mud tank into the mud conveying pipeline at a flow rate of 4m/s, and enters the real-time detection system of mud density.
  • the switch controller 8 controls the second switch 12 to open and close, and the first switch 11 and the second The three switches 13 are closed, and the mud directly enters the medicament addition system 4 through the mud delivery pipeline 6; aluminum phosphate cement and ordinary Portland cement are respectively housed in the curing agent addition device 19 and the solidification stabilizer addition device 21. pollution, so no need to add curing stabilizer.
  • the mud is fully mixed evenly in the serpentine pipeline 18, and the mud uniformly mixed with the medicament enters the dehydration filter press brick making system 5; the mud enters the filter press 23, enters the brick making mold 26 through the grouting hole 25, and the press 27 provides pressure,
  • the volume of the mud is compressed to 240cm*115cm*53cm according to the compression ratio of 6:1.
  • a plurality of small holes are arranged on the top and bottom of the brick making mold 26, and geotextiles are arranged on the upper and lower surfaces of the mold to discharge the mud from the mud.
  • the curing time of each batch of bricks in the filter press 23 is 1h; in order to consider the continuity of the process, as a supplement, the process can consider the actual situation, and increase in the unified mud density processing system 3
  • a large amount of waste mud is produced during the construction process of a construction site.
  • the density of the waste mud is about 1.18g/cm 3 .
  • the mud has no chemical pollution. Due to the lack of site stacking, this system is used to reduce the waste mud and make it into a free burnt bricks.
  • the mud is pumped from the mud tank into the mud conveying pipeline at a flow rate of 4m/s, and enters the real-time detection system of mud density.
  • the switch controller 8 controls the opening and closing of the third switch 13, and the first switch 11 and the second The two switches 12 are closed, and the mud enters the mud dilution tank 17 through the mud delivery pipeline 6; the water level measuring instrument 16 real-time tests the water level height in the dilution tank 17, and when the water level height of the mud is , the density of the mud at this time is , the cantilever beam type stirring
  • the device 14 starts to work at a rotating speed of 60r/s, and the uniformly stirred mud is transported to the agent adding system 4 through the mud conveying pipeline 6; the curing agent adding device 19 and the curing stabilizer adding device 21 are respectively equipped with aluminum phosphate cement and ordinary silicic acid For salt cement, at this time, since the mud is not polluted, it is not necessary to add a curing stabilizer.
  • the dosage of aluminum phosphate cement can be obtained through small-scale experiments.
  • the mud is fully mixed evenly in the serpentine pipeline 18, and the mud uniformly mixed with the medicament enters the dehydration filter press brick making system 5; the mud enters the filter press 23, enters the brick making mold 26 through the grouting hole 25, and the press 27 provides pressure, The volume of the mud is compressed to 240cm*115cm*53cm according to the compression ratio of 6:1.
  • a plurality of small holes are arranged on the top and bottom of the brick making mold 26, and geotextiles are arranged on the upper and lower surfaces of the mold to discharge the mud from the mud.
  • the mud in the mud tank enters the mud density real-time monitoring system through the mud delivery port at a fixed flow rate, and the mud density is monitored in real time.
  • the real-time impact force of the mud detected by the mechanical sensor is calculated according to the formula
  • the real-time density of the mud, and the closing of each switch of the signal receiver, controls the mud to enter different mud density processing devices.
  • the mud density unified processing system will make different processing methods according to the density of the mud:
  • the switch controller controls the opening and closing of the first switch.
  • the density of the mud at this time is .
  • the mud enters the mud settlement tank through the mud conveying pipeline for settlement treatment.
  • the water level height when the water level height of the mud is , that is, the density of the mud at this time is , the water in the mud settlement tank is pumped out with a pump, and then the cantilever type agitator starts to work at a speed of 60r/min, and the evenly stirred mud passes through the mud conveying pipeline to the next system;
  • the switch controller controls the opening and closing of the second switch.
  • the density of the mud at this time is , and the mud directly enters the next system through the mud conveying pipeline;
  • the switch controller controls the opening and closing of the third switch.
  • the density of the mud at this time is , and the mud enters the mud dilution tank through the mud conveying pipeline for dilution treatment.
  • the height of the water level, when the water level of the mud is , that is, the density of the mud at this time is , at this time the suspension beam mixer starts to work to stir the mud evenly, and then the mud enters the next system through the mud conveying pipeline.
  • the mud with a uniform density enters the chemical addition system, and the dosage of curing agent and curing stabilizer are calculated respectively according to the formula.
  • the serpentine pipeline can fully and evenly mix the curing agent and curing stabilizer with the mud.
  • the mud evenly mixed with the agent enters the dehydration filter press brick making system, and enters the brick making mold through the grouting hole.
  • the pressure is provided by the press, so that the volume of the mud is compressed according to the volume of 6:1, and the formed unburned brick After standing for a period of time, after the early-strength cement has fully acted, take it out and place it in a curing box for curing and flush the dehydration filter press brick making system.

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Abstract

一种高含水率废弃泥浆脱水-制砖一体化系统及实施方法，包括泥浆池(1)、泥浆密度实时检测系统(2)、泥浆密度统一处理系统(3)和药剂添加系统(4)以及脱水压滤制砖系统(5)，各系统通过泥浆输送管道(6)连接，系统工作模式：连续的将不同密度的工程废弃泥浆均一化处理，连续的将废弃泥浆脱水在减量化的同时制成免烧砖，该系统对泥浆的密度进行实时监测及均一化处理，处理后的泥浆在药剂添加系统进行加药混合处理，加药处理后的泥浆进入脱水压滤制砖系统(5)进行压滤脱水制砖处理，可实现在高效的对泥浆进行减量的同时，可进一步的将泥浆制成质量可控的免烧砖，整体装置简易并且操作方便，实现了高含水率废弃泥浆的高效减量化及资源化。

Description

一种高含水率废弃泥浆脱水-制砖一体化系统及实施方法 技术领域
本发明涉及工程废弃泥浆的减量化及资源化一体化的方法，特别涉及一种高含水率废弃泥浆脱水-制砖一体化系统及实施方法。
背景技术
各类工程中产生了大量废弃泥浆，例如泥水平衡顶管工程、盾构工程、河湖绞吸式疏浚工程等；废弃泥浆含水率高、粘粒含量高，沉降缓慢，城市缺乏土地堆填，亟需减量化的方法；目前存在一些减量化的方法(传统工程上的废弃泥浆处理方法多与板框压滤、带式压滤、以及离心处理有关)，然而泥浆减量后的泥土产物由于性质、需求不明确等问题，并不能直接进行资源化利用，仍然需要对减量后的泥土产物二次改性处理，再进行资源化利用，即目前缺少将废弃泥浆一步减量及资源化的方法。
现有的相关专利可以分为两类，一类是将高含水率废弃泥浆减量化的方法，另一类是将较低含水率的废弃泥资源化的方法。
对于将高含水率废弃泥浆减量化的方法，例如申请号为CN201911285683.9的中国发明专利公开一种河湖底泥板框压滤脱水方法，通过絮凝对泥水进行分离，然后通过板框压滤进行二次脱水，在一定程度上提升了浓缩效率。但是由于泥浆减量后的产物性质不明确，资源化利用的途径不明确，可能需要对处理后的产物进行再次改性处理，再进行资源化利用。
对于将较低含水率废弃泥资源化利用的方法，如申请号为CN201110100300.3的中国发明专利公开一种用污泥制作的免烧砖及其制作方法，通过不同材料的配比，通过搅拌使其混合均匀，然后装入制砖机制砖，极大程度上提高了对污泥的资源化利用,但该方法存在以下缺陷：
(1)该方法适用的对象为低含水率的污泥，对于含水率较高的泥浆无法直接应用，需要对泥浆进行脱水预先处理，再采用该专利方法进行制砖，适用范围具有局限性；
(2)该发明专利无法适用于含水率不均匀的废弃泥，若连续处理过程中污泥含水率发生变化，在后续制砖过程中会制成质量、强度不均一的砖体；
(3)该方法制取的免烧砖在制作成型后，需要脱模制成坯砖，将坯砖进行码垛，自然养护30d；养护周期长，占用场地资源大。
综上，工程上急需一种能够将高含水率废弃泥浆一次性减量并资源化利用的方法，更优的，该方法可以进一步优化，适用于各种泥浆初始含水率，并且资源化产物具有质量均一等特点,基于此提出了一种高含水率废弃泥浆脱水-制砖一体化系统及实施方法。
发明内容
发明目的：针对泥浆减量化后难以资源化或者减量化后需要另寻资源化出路，发明了一种高含水率废弃泥浆脱水-制砖一体化系统及实施方法。
技术方案：本发明提供一种高含水率废弃泥浆脱水-制砖一体化系统及实施方法， 包括泥浆池、泥浆密度实时检测系统、泥浆密度统一处理系统、药剂添加系统和脱水压滤制砖系统，各系统之间通过泥浆输送管道连接。
本发明的进一步改进在于：所述泥浆密度实时检测系统包括泥浆输送口、力学传感器、信号传感器、信号接收器、开关控制器、第一开关、第二开关和第三开关。泥浆输送管道用于输送泥浆，在距离泥浆输送口30cm处设置力学传感器，力学传感器、信号传感器和开关控制器均位于泥浆输送管道外表面；力学传感器用于检测泥浆的实时密度，力学传感器与信号传感器连接；信号接收器与开关控制器连接，泥浆密度实时监测系统与泥浆密度统一处理系统通过泥浆输送管道连接，并由开关控制，开关控制器控制各开关的闭合情况，用于控制不同密度的泥浆流向。
力学传感器检通过检测泥浆的实时冲击力，通过公式实时计算泥浆的密度，信号传感器负责将泥浆的密度以电信号的形式传递至信号接收器；当信号接收器接受的泥浆密度时，开关控制器控制第二开关开合，第一开关和第三开关闭合，泥浆通过泥浆输送管道直接进入下一系统；当信号接收器接收的信号为泥浆密度时，开关控制器控制第一开关开合，第二开关和第三开关闭合，泥浆通过泥浆输送管道进入泥浆沉降池；当信号接收器接收的信号为泥浆密度时，开关控制器控制第三开关开合，第一开关和第二开关闭合，泥浆通过泥浆输送管道进入泥浆稀释池。
本发明的进一步改进在于：所述泥浆密度统一处理系统包括泥浆沉降池、水位高度测量仪和悬梁式搅拌器以及泥浆稀释池，所述开关控制器通过控制第一开关、第二开关和第三开关的开合将该系统分为三个支路，泥浆沉降池与泥浆稀释池分别位于中心泥浆输送管道两侧，泥浆沉降池与泥浆稀释池两侧通过泥浆输送管道连接；水位高度测量仪分别位于泥浆沉降池和泥浆稀释池池边，悬梁式搅拌器分别悬于泥浆沉降池和泥浆稀释池上方。
当开关控制器控制第一开关开合，第二开关和第三开关闭合时，泥浆进入泥浆沉降池沉降处理，水位测量仪实时测试泥浆池中的水位高度，当泥浆的水位高度为时即此时泥浆的密度为，用抽水机将泥浆沉降池中的水抽出，接着悬梁式搅拌器以转速60r/min开始工作，搅拌均匀的泥浆经泥浆输送管道运至下一系统；当开关控制器控制第二开关开合，第一开关和第三开关闭合，即此时泥浆的密度，泥浆通过泥浆输送管道直接进入下一系统；当开关控制器控制第三开关开合，第一开关和第二开关闭合，泥浆通过泥浆输送管道进入泥浆稀释池，向池中注水，通过水位高度测量仪实时检测水位高度，当时，泥浆此时的密度为，此时悬梁式搅拌器开始工作，将泥浆搅拌均匀，然后泥浆通过泥浆输送管道进入下一系统。
本发明的进一步改进在于：所述药剂添加系统包括固化剂添加装置、固化稳定剂添加装置、固化剂输送管道、固化稳定剂输送管道和蛇形管道。其中固化剂添加装置通过固化剂输送管道与蛇形管道相连；固化稳定剂添加装置通过固化稳定剂输送管道与蛇形管道相连；蛇形管道两端通过泥浆输送管道相连。固化剂采用早强型水泥(磷酸铝水泥)，其掺量为，计算公式为；固化稳定剂采用普通的硅酸盐水泥，其掺量为，计算公式。此处的蛇形管道可以使固化剂与固化稳定剂与泥浆充分均匀混合，混合处理后的泥浆通过泥浆输送管道进入下一系统。
本发明的进一步改进在于：所述脱水压滤制砖系统包括压滤机、注浆孔、制砖模和压力机以及挡板，所述压滤机通过泥浆输送管道连接，压力机与制砖模相连，与药剂充分混 合的泥浆进入脱水压滤制砖系统并通过注浆孔进入砖模，压滤机设置10个制砖模，每个制砖模的尺寸的长宽高分别设置为240cm、115cm、265cm，压力机负责提供压力，根据小试实验得到所需提供的压力优选值为10kN，将泥浆的体积按照6:1的比例压缩至普通标准砖的尺寸即240cm*115cm*53cm，制砖模顶部和底部设置多个排水孔，模内上下表面设置土工布，负责将压滤的水分排出，排水孔的直径为1mm，成砖后的泥浆已经变成含水率特别低的软土，此时等待1h后早强型水泥完全发挥作用，砖的强度增加，再由人工取砖并放置养护箱中养护4d后取出，此时砖的强度满足规范中对免烧砖的强度要求，从压滤机中取出砖后，立即冲洗脱水压滤制砖系统。
更进一步地，上述各类系统所使用的泥浆输送管道、蛇形管道和固化剂输送管道以及固化稳定剂输送管道均采用防锈蚀管道，泥浆输送管道的横截面积为25cm 2，固化剂输送管道与固化稳定剂输送管道均采横截面积为10cm 2的钢管，蛇形管道的横截面积为25cm 2其有效长度为150cm。
作为补充地，考虑到整个系统的连续性，可以在泥浆密度统一处理系统中设置多个泥浆沉降池和泥浆稀释池；在脱水压滤制砖系统中可以设置多个压滤机交替工作。
有益效果：
本发明的泥浆密度实时检测系统可以实时的检测出泥浆的密度，根据泥浆密度的不同，分别做出不同的处理方式；在泥浆密度统一处理系统中，对泥浆进行稀释或沉降处理，使泥浆的密度统一，便于后期固化处理以及脱水压滤制砖处理，以便于形成质量规格统一的免烧砖；在药剂添加系统，根据固定的泥浆含水率做出药剂添加处理，在蛇形管道内，能够使药剂与泥浆充分均匀混合，进一步保证了泥浆的密度统一和泥浆中药剂添加的均匀，从而保证脱水压滤制砖系统每块砖的强度均匀；脱水压滤制砖系统一方面对泥浆起到脱水减量化的效果，另一方面，使工程废弃泥浆减量后直接处理为免烧砖，节省工艺，一步到位。
附图说明
图1为本发明的结构示意图；
图2为泥浆稀释池示意图；
图3为脱水压滤制砖系统示意图；
图4为脱水压滤制砖系统示意图。
具体实施方式
如图，本实施例的一种高含水率废弃泥浆脱水-制砖一体化系统及实施方法包括泥浆池1、泥浆密度实时检测系统2、泥浆密度统一处理系统3和药剂添加系统4以及脱水压滤制砖系统5。
首先，泥浆通过泥浆输送管道6以固定的流速，从泥浆池1经泥浆输送口24泵入泥浆密度实时监测系统2，力学传感器9接收到的力，然后根据公式计算泥浆的实时密度，此时，泥浆与力学传感器9的接触时间，体积；信号传感器10负责将泥浆的密度以电信号的形式传递至信号接收器7；当信号接收器7接受的泥浆密度时，开关控制器8控制第二开关12开合，第一开关11和第三开关13闭合，泥浆通过泥浆输送管道6直接进入下一系统；当信号接 收器7接收的信号为泥浆密度时，开关控制器8控制第一开关11开合，第二开关12和第三开关13闭合，泥浆通过泥浆输送管道6进入泥浆沉降池15；当信号接收器7接收的信号为泥浆密度时，开关控制器8控制第三开关13开合，第一开关11和第二开关12闭合，泥浆通过泥浆输送管道6进入泥浆稀释池17。
实施例1
某湖泊由于富营养化严重，并且底泥存在重金属污染，需要对底泥进行疏浚，采用绞吸式的疏浚方法进行疏浚，产生的废弃泥浆密度约为1.02g/cm 3，采用本发明进行减量及资源化。疏浚泥浆以4m/s的流速从泥浆池泵入泥浆输送管道，进入泥浆密度实时检测系统中。
当信号接收器7接受的泥浆密度为ρ n＝(122400×0.2)/(4×6000)＝1.02g/cm 3时，开关控制器8控制第一开关11开合，第二开关12和第三开关13闭合，泥浆通过泥浆输送管道6进入泥浆沉降池15；水位高度测量仪16实时测试所述泥浆沉降池15中的水位高度，当泥浆的水位高度为时，即此时泥浆的密度为，用抽水机将泥浆沉降池15中1.2高的水抽出，接着悬梁式搅拌器14以转速60r/s开始工作，搅拌均匀的泥浆经所述泥浆输送管道6运至所述药剂添加系统4；所述固化剂添加装置19和所述固化稳定剂添加装置21内分别装有磷酸铝水泥和普通的硅酸盐水泥，其掺加量可以通过小试实验获取，分别为q＝5％和q 0＝0.25％，根据公式和分别计算磷酸铝水泥和硅酸盐水泥的掺量为m＝5％×1.1×150×25＝206.25g和m 0＝0.25％×1.1×150×25＝10.31g，添加药剂后的泥浆在所述蛇形管道18中充分混合均匀，与药剂均匀混合的泥浆进入脱水压滤制砖系统5；泥浆进入所述压滤机23，由所述注浆孔25进入所述制砖模26，所述压力机27提供压力，将泥浆的体积按照6:1的压缩比压缩至240cm*115cm*53cm，制砖模26的顶部和底部设置多个小孔，模内上下表面设置土工布，用于排出从泥浆中压滤而出的水，压滤完成后，静置1h后人工取出并放置养护箱养护4d取出并将挡板28拿出，冲洗压滤机23；此时的免烧砖满足国家规范的强度要求，为考虑工艺的连续性，作为补充的，该工艺可以考虑实际情况，在所述泥浆密度统一处理系统3中增加的所述泥浆沉降池15和所述泥浆稀释池17以及所述脱水压滤制砖系统5的所述压滤机23。
实施例2
某泥水盾构工程施工过程中产生了废弃泥浆需要进行处置处理，该工程产生的废弃泥浆密度约为1.10g/cm 3，泥浆无化学污染，采用本系统对废弃泥浆进行处理，并资源化利用成免烧砖。泥浆以4m/s的流速从泥浆池泵入泥浆输送管道，进入泥浆密度实时检测系统中。
当信号接收器7接受的泥浆密度为ρ n＝(132000×0.2)/(4×6000)＝1.10g/cm 3时，开关控制器8控制第二开关12开合，第一开关11和第三开关13闭合，泥浆通过泥浆输送管道6直接进入药剂添加系统4；固化剂添加装置19和固化稳定剂添加装置21内分别装有磷酸铝水泥和普通硅酸盐水泥，此时由于泥浆没有被污染，故不需添加固化稳定剂。磷酸铝水泥的掺量可以通过小试实验获取，其掺量为q＝4.5％，根据公式计算磷酸铝水泥的掺量为m＝4.5％×1.1×150×25＝185.63g，添加药剂后的泥浆在蛇形管道18中充分混合均匀，与药剂均匀混合的泥浆进入脱水压滤制砖系统5；泥浆进入压滤机23，由注浆孔25进入制砖模26，压力机27提供压力，将泥浆的体积按照6:1的压缩比压缩至240cm*115cm*53cm，制砖模26的顶部和底部设置多个小孔，模内上下表面设置土工布，用于排出从泥浆中压滤而出的水，压滤完 成后，静置1h后人工取出并放置养护箱养护4d取出并将挡板28拿出，冲洗压滤机23；此时的免烧砖满足国家规范的强度要求；在处理此种泥浆时，由于工程泥浆不断产生，设置3个沉降池15和3个稀释池17，压滤机23采用4轮组工作模式，即4个压滤机23轮转工作，每15min处理压砖一批次，每批次砖在压滤机23中的养护时间为1h；为考虑工艺的连续性，作为补充的，该工艺可以考虑实际情况，在所述泥浆密度统一处理系统3中增加的所述泥浆沉降池15和所述泥浆稀释池17以及所述脱水压滤制砖系统5的所述压滤机23。
实施例3
某建筑工地施工过程中产生了大量的废弃泥浆，废弃泥浆的密度约为1.18g/cm 3，泥浆无化学污染，因缺乏场地堆置，采用本系统对废弃泥浆进行减量化并制成免烧砖。泥浆以4m/s的流速从泥浆池泵入泥浆输送管道，进入泥浆密度实时检测系统中。
当信号接收器7接受的泥浆密度为ρ n＝(141600×0.2)/(4×6000)＝1.18g/cm 3时，开关控制器8控制第三开关13开合，第一开关11和第二开关12闭合，泥浆通过泥浆输送管道6进入泥浆稀释池17；水位高度测量仪16实时测试稀释池17中的水位高度，当泥浆的水位高度为时即此时泥浆的密度为，悬梁式搅拌器14以转速60r/s开始工作，搅拌均匀的泥浆经泥浆输送管道6运至药剂添加系统4；固化剂添加装置19和固化稳定剂添加装置21内分别装有磷酸铝水泥和普通的硅酸盐水泥，此时由于泥浆没有被污染，故不需添加固化稳定剂。磷酸铝水泥的掺量可以通过小试实验获取，其掺量为q＝4.8％，根据公式计算磷酸铝水泥的掺量为m＝4.8％×1.1×150×25＝198.00g，添加药剂后的泥浆在蛇形管道18中充分混合均匀，与药剂均匀混合的泥浆进入脱水压滤制砖系统5；泥浆进入压滤机23，由注浆孔25进入制砖模26，压力机27提供压力，将泥浆的体积按照6:1的压缩比压缩至240cm*115cm*53cm，制砖模26的顶部和底部设置多个小孔，模内上下表面设置土工布，用于排出从泥浆中压滤而出的水，压滤完成后，静置1h后人工取出并放置养护箱养护4d取出并将挡板28拿出，冲洗压滤机23；此时的免烧砖满足国家规范的强度要求；为考虑工艺的连续性，作为补充的，该工艺可以考虑实际情况，在所述泥浆密度统一处理系统3中增加的所述泥浆沉降池15和所述泥浆稀释池17以及所述脱水压滤制砖系统5的所述压滤机23。
工作原理：
运行中的系统，首先，泥浆池中的泥浆以固定的流速通过泥浆输送口进入泥浆密度实时监测系统，对泥浆的密度进行实时监测，此处根据力学传感器检测的泥浆实时冲击力，根据公式计算泥浆的实时密度，并由信号接收器各个开关的闭合，控制泥浆进入不同的泥浆密度处理装置。
其次，泥浆密度统一处理系统会根据泥浆的密度不同做出不同的处理方式：
①开关控制器控制第一开关开合，第二开关和第三开关闭合时，此时泥浆的密度为，泥浆通过泥浆输送管道进入泥浆沉降池进行沉降处理，水位测量仪实时测试泥浆池中的水位高度，当泥浆的水位高度为时即此时泥浆的密度为，用抽水机将泥浆沉降池中的水抽出，接着悬梁式搅拌器以转速60r/min开始工作，搅拌均匀的泥浆经泥浆输送管道运至下一系统；
②开关控制器控制第二开关开合，第一开关和第三开关闭合时，此时泥浆的密度为，泥浆通过泥浆输送管道直接进入下一系统；
③开关控制器控制第三开关开合，第一开关和第二开关闭合时，此时泥浆的密度 为，泥浆通过泥浆输送管道进入泥浆稀释池进行稀释处理，水位测量仪实时测试泥浆池中的水位高度，当泥浆的水位高度为时即泥浆此时的密度为，此时悬梁式搅拌器开始工作，将泥浆搅拌均匀，然后泥浆通过泥浆输送管道进入下一系统。
再次，密度统一为的泥浆进入药剂添加系统，根据公式和分别计算固化剂和固化稳定剂的掺量，蛇形管道可以使固化剂和固化稳定剂与泥浆充分均匀混合。
最后，与药剂混合均匀的泥浆进入脱水压滤制砖系统，并通过注浆孔进入制砖模，压力机提供压力，使泥浆的体积按照6:1的体积进行压缩处理，成型的免烧砖静置一段时间后待早强型水泥充分作用后，取出放置养护箱养护并且对脱水压滤制砖系统进行冲洗。
显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得其他实施例，都属于本发明的保护范围。

Claims (6)

  1. 一种高含水率废弃泥浆脱水-制砖一体化系统，其特征在于：包括泥浆池(1)、泥浆密度实时检测系统(2)、泥浆密度统一处理系统(3)和药剂添加系统(4)以及脱水压滤制砖系统(5)，各系统通过泥浆输送管道(6)连接。
  2. 根据权利要求1所述的一种高含水率废弃泥浆脱水-制砖一体化系统，其特征在于：所述泥浆密度实时检测系统(2)包括泥浆输送口(24)、力学传感器(9)、信号传感器(10)、信号接收器(7)和开关控制器(8)以及开关组合，所述开关组合包括第一开关(11)、第二开关(12)和第三开关(13)，所述开关控制器(8)通过控制第一开关(11)、第二开关(12)和第三开关(13)的开合将该系统分为三个支路，所述力学传感器(9)与信号传感器(10)相连，信号接收器(7)与所述开关控制器(8)连接。
  3. 根据权利要求1所述的一种高含水率废弃泥浆脱水-制砖一体化系统，其特征在于：所述泥浆密度统一处理系统(3)包括泥浆沉降池(15)、水位高度测量仪(16)和悬梁式搅拌器(14)以及泥浆稀释池(17)，所述泥浆沉降池(15)与所述泥浆稀释池(17)分别位于中心泥浆输送管道(6)两侧，所述泥浆沉降池(15)与所述泥浆稀释池(17)两侧通过所述泥浆输送管道(6)连接，所述水位高度测量仪(16)分别位于所述泥浆沉降池(15)和所述泥浆稀释池(17)池边，所述悬梁式搅拌器(14)分别悬于所述泥浆沉降池(15)和所述泥浆稀释池(17)的上方。
  4. 根据权利要求1所述的一种高含水率废弃泥浆脱水-制砖一体化系统，其特征在于：所述药剂添加系统(4)包括固化剂添加装置(19)、固化稳定剂添加装置(21)、固化剂输送管道(20)和固化稳定剂输送管道(22)以及蛇形管道(18)，所述固化剂添加装置(19)通过所述固化剂输送管道(20)与所述蛇形管道(18)相连，所述固化稳定剂添加装置(21)通过所述固化稳定剂输送管道(22)与所述蛇形管道(18)相连，所述蛇形管道(18)两端通过泥浆输送管道(6)相连。
  5. 根据权利要求1所述的一种高含水率废弃泥浆脱水-制砖一体化系统，其特征在于：所述脱水压滤制砖系统(5)包括压滤机(23)、注浆孔(25)、制砖模(26)和压力机(27)以及挡板(28)，所述压滤机(23)通过所述泥浆输送管道(6)与所述脱水压滤制砖系统(5)连接，泥浆通过所述注浆孔(25)进入制砖模，所述压力机(27)与所述制砖模(26)相连，为所述压滤机(23)提供压力。
  6. 权利要求1-5任一项所述的高含水率废弃泥浆脱水-制砖一体化系统的实施方法，其特征在于：
    步骤一，将工程废弃泥浆以固定流速从所述泥浆池(1)泵入所述泥浆输送管道(6)；
    步骤二，进入泥浆密度实时检测系统(2)，测定泥浆的密度，并将信号传递至开关控制器(8)，当信号接收器(7)接受的泥浆密度时，开关控制器控(8)制第二开关(12)开合，第一开关(11)和第三开关(13)闭合，泥浆通过泥浆输送管道(6)直接进入下一系统；当信号接收器(7)接收的信号为泥浆密度时，开关控制器(8)控制第一开关(11)开合，第二开关(12)和第三开关(13)闭合，泥浆通过泥浆输送管道(6)进入泥浆沉降池(15)；当信号接收器(7)接收的信号为泥浆密度时，开关控制器(8)控制第三开关(13)开合，第一开关(11)和第二开关(12)闭合，泥浆通过泥浆输送管道(6)进入泥浆稀释池(17)；
    步骤三，当泥浆的密度统一处理至后，泥浆进入药剂添加系统(4)；泥浆的密度为，添加固化剂及固化稳定剂，并且通过蛇形管道(18)使药剂与泥浆混合均匀，均匀混合后的泥浆 进入脱水压滤制砖系统(5)；
    步骤四，泥浆通过注浆孔(25)进入制砖模(26)，压力机(27)提供压力，使制砖模(26)的体积按照6:1的体积进行压缩，制砖模(26)顶部和底部设置小孔，且上下表面设置土工布，使泥浆中的水分压滤排出；
    步骤五，压滤后的免烧砖静置1h后人工取出，并冲洗压滤机(23)，取出的免烧砖放置养护箱养护3-5d即可满足规范要求的免烧砖强度。
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