CN105753505A - 一种多孔陶粒载体及其制备方法 - Google Patents
一种多孔陶粒载体及其制备方法 Download PDFInfo
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- CN105753505A CN105753505A CN201610101833.6A CN201610101833A CN105753505A CN 105753505 A CN105753505 A CN 105753505A CN 201610101833 A CN201610101833 A CN 201610101833A CN 105753505 A CN105753505 A CN 105753505A
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- 229910052573 porcelain Inorganic materials 0.000 title abstract description 12
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 22
- 238000005245 sintering Methods 0.000 claims abstract description 15
- 239000002994 raw material Substances 0.000 claims abstract description 14
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- 239000010881 fly ash Substances 0.000 claims abstract description 12
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 10
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 10
- 238000001816 cooling Methods 0.000 claims abstract description 10
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 10
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Abstract
本发明公开了一种多孔陶粒载体及其制备方法,该方法包括以下步骤:(1)按重量份,以市政污泥2060份、粘土1020份、高岭土1020份、粉煤灰1020份、硅源25份为原料;将原料中的各组分混匀,再经挤压得陶粒坯料;硅源为水玻璃、气相二氧化硅和硅粉中的一种或几种;(2)将陶粒坯料干燥后烧结,冷却,得到多孔陶粒载体;烧结是将干燥后的陶粒坯料先升温至300600℃下保温1040min,再升温至9501150℃,保温1040min。该多孔陶粒载体有以下特征:表面粗糙、疏松多孔,颗粒孔隙率高达4555%,比表面积达200400m2/g;化学性质稳定,1+1盐酸溶出率<1%;重金属浸出量在标准以下,无浸出毒性造成的二次污染;机械强度高,抗压强度达到2030MPa,可作为废水处理中的催化剂与吸附剂的载体材料。
Description
技术领域
本发明涉及一种多孔陶粒载体及其制备方法。
背景技术
调研结果显示我国污水处理厂所产生的污泥已经超过3000万吨/年,有80%没有得到妥善处理,如何实现污泥减量化、稳定化、无害化,最终达到资源化,已经成为深受关注的重大课题。目前污泥资源化方式包括厌氧发酵、焚烧发电、堆肥土地利用、建材使用等。
在建材使用领域,利用污泥制备陶粒是一个重要的研究方向。在烧制过程中,有机物燃烧产气膨胀成孔,并产生可利用热量,而无机物作为骨架填充原料,污泥中重金属被固定晶格化,不会产生二次污染。现有的污泥陶粒主要用作水泥填料、保温材料等。例如中国专利CN 103723999 A公布了“一种城市给水污泥制备花卉陶粒的方法”,将给水污泥、煤泥、焦宝石板栗壳和废玻璃等干燥研磨后,成球烧结成花卉陶粒。中国专利CN103864404 A公布了“一种利用石英砂尾矿和污泥制作的陶粒及其制备方法”,由石英砂尾矿粉、污泥、河道底泥及助剂烧结而成,使用污泥为含水率10%-20%的活性污泥,制得陶粒符合路基材料、混凝土骨料、轻质砖填充料及水泥生产的指标要求。这些陶粒制备工艺为:干燥-粉磨-混合造粒-烧结,工艺条件及控制比较简单,能耗较高,制得多孔陶粒多为为闭孔结构,强度高、质量轻,适合于建材使用。
利用污泥烧制多孔陶粒作为滤料/吸附剂成为目前污泥资源化一个重要研究方向。利用污泥与粘土作为主料,在配料中加入一定量的可燃尽物质(如木炭粉或砻糠)作为致孔剂,在低温下烧成时,使主体材料间造成孔隙;或者在高温下形成一定量的液相,在主体材料粘结的同时收缩而造成孔隙。污泥包括给水厂污泥、河道淤泥、市政污泥等。目前,用掺加污泥的方式制备的多孔陶粒多用于污水处理中的生物滤料,例如中国专利CN 103496946 A公开了“一种从水中滤除铬的陶粒滤料及其制备方法”,将工业污泥和粘土作为主料,配以木屑或者活性炭作为致孔剂,在还原气氛(N2、H2)中制备陶粒滤料以去除废水中的铬离子,六价铬离子从830mg/L降到5mg/L,吸附容量达到825mg/g。该发明中使用的是工业污泥,因此需额外添加了木屑,为了使得混合均匀,致孔剂需要经过粉磨处理;反应在还原氛围中,要求比较高,充N2、H2成本高;陶粒中添加铜盐/锌盐是吸附容量高的一个重要原因,添加量比较多,为5-10%。中国专利CN 104311128 A公布了“一种多孔隙发型陶粒及其制备方法”,利用市政污泥、丝瓜囊、水泥熟料与粉煤灰等热干馏制备多孔吸附性陶粒,制得陶粒孔隙率>35%,盐酸可溶率<2%,该发明为干馏+高温烧结工艺,工艺比较复杂,且要实现产业化,丝瓜囊来源有难度。
发明内容
本发明解决的技术问题是,对污水处理后产生的污泥进行处理,将其用于制成多孔陶粒材料,可应用于催化剂的载体。
本发明的技术方案是,提供一种多孔陶粒载体的制备方法,包括以下步骤:
(1)按重量份,以市政污泥20-60份、粘土10-20份、高岭土10-20份、粉煤灰10-20份、硅源2-5份为原料;将原料中的各组分混匀,再经挤压得陶粒坯料;所述硅源为水玻璃、气相二氧化硅和硅粉中的一种或几种;
(2)将所述陶粒坯料干燥后烧结,冷却,得到多孔陶粒载体;所述烧结是将干燥后的陶粒坯料先升温至300-600℃(优选350-500℃)下预烧10-40min,再升温至950-1150℃,保温10-40min。
进一步地,所述高岭土中含SiO240-60wt%、含Al2O320-40wt%。
进一步地,所述粉煤灰中含SiO240-60wt%、含Al2O320-50wt%。
进一步地,所述粘土、高岭土和粉煤灰的粒径在500目以下。
进一步地,将所述陶粒坯料在55-65℃下干燥3-5h。
进一步地,所述市政污泥的含水率为65-75wt%,市政污泥的固形物中有机物成分40-60wt%。
进一步地,低温时升温速率不超过10℃;高温时升温速率不超过5℃/min,优选2-5℃/min。
本发明进一步提供一种由上述制备方法制得的多孔陶粒载体。
多孔载体材料具有比表面积大、密度小、热导率小、相对密度小、孔隙率大等特点,主要用作催化剂、吸附剂、保温、绝热、填料,用于污水处理、废气处理、建筑材料。天然多孔材料中以硅藻土和沸石最具代表性。人工多孔材料有活性炭、多孔氧化铝、树脂、微孔玻璃、多孔陶粒、空心玻璃珠等。
目前污泥制备陶粒更多使用给水污泥、水底淤泥、或者第含水率污泥,含水市政污泥的粘性大,与物料的混合比较困难,使用比较少。而且目前制得陶粒开孔率不高,作为建材使用的附加值较低。针对该情况,本发明了利用市政污泥作为致孔剂制备多孔载体材料。本发明的市政污泥添加量大,可达60%,有机质含量高,可占固形物中的15-20%,不需额外添加致孔剂,市政污泥不经过干燥直接使用,可以节省能源。
普通多孔陶瓷的主要成分为硅铝酸盐,原料包括高岭土、硅藻土、粘土等,成孔剂为碳酸盐类、有机物等可在高温下挥发成气体的物质。添加市政污泥制备陶粒利用其中有机物作为致孔剂,无机物作为陶粒成分;有机物在300-600℃(预烧)时氧化分解,挥发产生气体,溢出形成孔隙;而污泥中无机物质以SiO2、Al2O3、CaO、Fe2O3元素为主,是硅铝酸盐陶瓷烧制的原材料。陶粒的原料以SiO2和Al2O3为主体成分,为陶粒形成强度和结构的主要结构基础,Al2O3占10-25%,SiO2占40-79%,本发明中适当添加硅源(水玻璃、气相二氧化硅和硅粉),以增加SiO2的含量,调整Al2O3与SiO2的比例;本发明的硅源还可以作为粘结剂,为陶粒胚料的形成提供结构强度,使胚料的强度提高,易于成型。
在污泥陶粒烧制建筑陶粒过程中,有机物预烧时分解,在陶粒内部形成细微通孔,当温度上升到一定程度后,原料中SiO2、Al2O3、CaO、Fe2O3开始相互熔融(冷却后会形成矿物),当烧结温度到达1200℃后或者烧结时间延长时,在颗粒表面形成一定厚度的玻璃相熔融体,冷却后成为闭孔陶粒,这种陶粒密度小、强度高。烧制多孔的载体陶粒(开孔)时,不能在颗粒表面形成玻璃体,造成闭孔;同时又要求内部各组分充分熔融,有足够的物理强度,因此对烧结温度及烧结时间的把握更加精确。CaO、Fe2O3等可以作为SiO2、Al2O3高温液化的助熔剂(不需要单独添加其他的助溶剂,如硼砂),降低形成玻璃体的温度,根据本研究中开孔陶粒的原料成分,烧制温度在950-1150℃,烧制温度为10-40min。在烧制过程中需要控制升温速率和冷却降温速率,升温速度过快使得颗粒表面与内部受热不均,表面容易熔融,易形成闭孔;降温速度快将使得颗粒的物理性质发生变化,容易形成裂缝。
综上所述,载体陶粒与建筑陶粒的最大区别在于:建筑陶粒要求强度高、质轻,内部多孔,表面封闭,无贯穿性空隙,对孔径没有要求。载体陶粒要求表面有贯穿性微孔,比表面积大,孔径均匀,对强度要求相对较低,因此,对温度的控制更加精确,需要经过大量的试验和包括相图分析在内的大量数据分析才能够确定。建筑陶粒对所构成的原材料成分没有严格要求,而载体陶粒对原材料的成分要求严格,需要外加硅源进行成分调整,微小的成分差别都会影响其性能,需要通过大量实验和包括表面扫描、孔径测量,结构分析等大量数据分析及应用试验才能够确定。
本发明的有益效果是,本发明制备的多孔陶粒载体有以下特征:表面粗糙、疏松多孔,颗粒孔隙率高达45-55%,比表面积达200-400m2/g;化学性质稳定,1+1盐酸溶出率<1%;重金属浸出量在标准以下,无浸出毒性造成的二次污染;机械强度高,抗压强度达到20-30MPa。可替代传统的天然多孔材料或者人工多孔材料,作为废水处理中的催化剂与吸附剂的载体材料。本发明利用污泥制备多孔陶粒材料,原料简单、价格便宜、性能优异、使用方便。
具体实施方式
实施例1
取污泥2.0kg、粘土0.6kg、高岭土0.6kg、粉煤灰0.6kg、水玻璃0.2kg,充分混合均匀,造成柱状陶粒坯料,在高温炉中以10℃温度升温至500℃,恒温预烧30min,再以5℃/min速率升温至1100℃,烧结20min,以10℃/min速率冷却至300℃以下,取出自然冷却,得多孔陶粒载体外观为砖红色短柱状固体颗粒。经检查无浸出毒性物质,拥有较好的表观密度与孔隙率,可用作无机载体材料。
实施例2
取污泥2.4kg、粘土0.5kg、高岭土0.5kg、粉煤灰0.4kg、气相二氧化硅0.15kg,充分混合均匀,造成柱状陶粒坯料,在高温炉中以10℃温度升温至500℃,恒温预烧40min,再以5℃/min速率升温至1100℃,烧结20min,以10℃/min速率冷却至300℃以下,取出自然冷却,烧得多孔陶粒载体外观为微黄短柱状固体颗粒。经检查无浸出毒性物质,拥有较好的表观密度与孔隙率,可用作无机载体材料。
实施例3
取污泥1.6kg、粘土0.8kg、高岭土0.8kg、粉煤灰0.6kg、硅粉0.2kg,充分混合均匀,造成柱状陶粒坯料,在高温炉中以10℃温度升温至500℃,恒温预烧20min,再以5℃/min速率升温至1150℃,烧结15min,以10℃/min速率冷却至300℃以下,取出自然冷却,得多孔陶粒载体外观为微黄短柱状固体颗粒。经检查无浸出毒性物质,拥有较好的表观密度与孔隙率,可用作无机载体材料。
实施例4
取污泥2.0kg、粘土0.8kg、高岭土0.8kg、粉煤灰0.6kg、水玻璃0.1kg,充分混合均匀,造成柱状陶粒坯料,在高温炉中以10℃温度升温至500℃,恒温预烧30min,再以5℃/min速率升温至1050℃,烧结20min,以10℃/min速率冷却至300℃以下,取出自然冷却,得多孔陶粒载体外观为微黄短柱状固体颗粒。经检查无浸出毒性物质,拥有较好的表观密度与孔隙率,可用作无机载体材料。
实施案例对比表
实施例5
用实施例2制得陶粒涂覆过硫酸钾催化剂,用于石化废水过硫酸钾催化氧化,经过10次实验,COD值由1050mg/L降到501-552mg/L,COD降低47-52%,相比沸石涂覆过硫酸钾催化剂COD降低43%,催化效果更好。
实施例6
用实施例2制得陶粒涂覆CuCl2,用于石化废水非均相芬顿氧化处理,经过10次实验,COD值由1050mg/L降到653-692mg/L,COD降低34-39%,相比沸石所制非均相芬顿催化剂处理的COD降低36%,效果相差不大。
Claims (8)
1. 一种多孔陶粒载体的制备方法,其特征在于,包括以下步骤:
(1) 按重量份,以市政污泥20-60份、粘土10-20份、高岭土10-20份、粉煤灰10-20份、硅源2-5份为原料;将原料中的各组分混匀,再经挤压得陶粒坯料;所述硅源为水玻璃、气相二氧化硅和硅粉中的一种或几种;
(2) 将所述陶粒坯料干燥后烧结,冷却,得到多孔陶粒载体;所述烧结是将干燥后的陶粒坯料先升温至300-600℃下保温10-40min,再升温至950-1150℃,保温10-40min。
2.如权利要求1所述的制备方法,其特征在于,所述高岭土中含SiO2
40-60wt%、含Al2O3 20-40wt%。
3. 如权利要求1所述的制备方法,其特征在于,所述粉煤灰中含SiO2 40-60wt%、含Al2O3
20-50wt%。
4. 如权利要求1所述的制备方法,其特征在于,所述粘土、高岭土和粉煤灰的粒径在500目以下。
5. 如权利要求1所述的制备方法,其特征在于,将所述陶粒坯料在55-65℃下干燥3-5h。
6.如权利要求1所述的制备方法,其特征在于,所述市政污泥的含水率为65-75wt%,市政污泥的固形物中有机物成分40-60wt%。
7.如权利要求1所述的制备方法,其特征在于,所述烧结过程中,升温速率不超过5℃/min。
8.一种多孔陶粒载体,其特征在于,由权利要求1-7之一所述的制备方法制得。
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