CN106220210B - 基于聚氯化铝废渣的陶瓷纤维隔热材料及其制备方法 - Google Patents

基于聚氯化铝废渣的陶瓷纤维隔热材料及其制备方法 Download PDF

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CN106220210B
CN106220210B CN201610582037.9A CN201610582037A CN106220210B CN 106220210 B CN106220210 B CN 106220210B CN 201610582037 A CN201610582037 A CN 201610582037A CN 106220210 B CN106220210 B CN 106220210B
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waste residue
polyaluminium chloride
chloride waste
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ceramic insulation
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刘浩
陈少
陈少一
王周福
王玺堂
马妍
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Henan Ruida Purification Material Co ltd
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Wuhan University of Science and Engineering WUSE
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Abstract

本发明涉及一种基于聚氯化铝废渣的陶瓷纤维隔热材料及其制备方法。其技术方案是：将聚氯化铝废渣、含铝原料和添加剂混合，加水搅拌，过滤，即得过滤料。将过滤料、城市污泥和表面活性剂混匀，成型，还原气氛中热处理，研磨，筛分，得到A物料和B物料。将A物料、B物料、含硅原料和含铝原料混匀，造粒，于还原气氛中热处理，再于中性气氛中热处理，得到C物料和D物料。将A物料、C物料、D物料、陶瓷纤维、结合剂、无机增稠剂和有机增稠剂混匀，加水搅拌，成型；烘干，热处理，制得基于聚氯化铝废渣的陶瓷纤维隔热材料。本发明具有原料来源广泛和生产成本低的特点；所制得的基于聚氯化铝废渣的陶瓷纤维隔热材料体积密度小和导热系数低。

Description

基于聚氯化铝废渣的陶瓷纤维隔热材料及其制备方法
技术领域
本发明属于陶瓷纤维隔热材料技术领域。具体涉及一种基于聚氯化铝废渣的陶瓷纤维隔热材料及其制备方法。
背景技术
聚合氯化铝废渣是铝矾土和铝酸钙粉在一定条件下与盐酸或混合酸反应得到液体聚合氯化铝（PAC）后的残余固体形成的废渣。我国年产400kt液体PAC，每生产1t含10%氧化铝的液体PAC就会产生150kg废渣，每年将会产生60kt固体废渣。此类废渣呈粘稠状，具弱酸性，对环境有极大危害。
目前，国内外对PAC废渣的主要处理方式是填埋、堆弃、制砖或生产肥料等。填埋、堆弃等方式，处理成本高，污染环境，也占用土地资源。“一种以聚氯化铝废渣和赤泥为主料的免烧砖及其制备方法”(ZL 201310486365.5)专利技术，以赤泥、聚合氯化铝废渣、活性矿物材料、石灰和石膏为原料，经加水搅拌混合、压制成型、撒水养护制得免烧砖。“一种聚氯化铝滤渣再利用工艺”(CN 201410572881.4)专利技术，以聚合氯化铝滤渣为原料，回用于聚氯化铝生产***，减少了滤渣的排放量。然而，现有的技术并没有充分利用PAC废渣的特性，也未进行综合开发利用。
发明内容
本发明旨在克服现有技术的不足，目的是提供一种原料来源广泛和生产成本低的基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法；用该方法制备的基于聚氯化铝废渣的陶瓷纤维隔热材料体积密度小和导热系数低。
为实现上述目的，本发明采用的技术方案的具体步骤是：
第一步，将20~50wt%的聚氯化铝废渣、40~70wt%的含铝原料和0.1~10wt%的添加剂混合，即得混合料Ⅰ；外加所述混合料Ⅰ8~15倍质量的水，于50~90℃条件下搅拌3~6小时，静置，过滤，即得过滤料。
第二步，将60~80wt%的所述过滤料、10~30wt%的城市污泥和0.1~10wt%的表面活性剂混合均匀，在50~100MPa条件下压制成型；于还原气氛和600~900℃条件下热处理3~6小时，破碎，研磨，筛分，得到粒度小于0.088mm的A物料和粒度为0.088~1mm的B物料。
第三步，将20~40wt%的所述A物料、10~20wt%的所述B物料、10~20wt%的含硅原料和20~40wt%的所述含铝原料混合均匀，造粒，筛分；于还原气氛和400~800℃条件下热处理3~6小时，再于中性气氛和1000~1300℃条件下热处理3~6小时，即得粒度小于0.25mm的C物料和粒度为0.25~1.5mm的D物料。
第四步，将10~20wt%的所述A物料、10~20wt%的所述C物料、10~20wt%的所述D物料、30~50wt%的陶瓷纤维、10~20wt%的结合剂、1~10wt%的无机增稠剂和1~10wt%的有机增稠剂混合均匀，即得混合料Ⅱ；外加所述混合料Ⅱ10~30wt%的水，搅拌，挤压成型；于50~80℃条件下烘干12~24小时，再于900~1100℃条件下热处理3~6小时，制得基于聚氯化铝废渣的陶瓷纤维隔热材料。
所述聚氯化铝废渣的含水量小于30wt%，所述聚氯化铝废渣中Al的含量大于18wt%，所述聚氯化铝废渣的粒度小于0.088mm。
所述含铝原料为氢氧化铝或为氧化铝微粉，所述氢氧化铝中Al(OH)3的含量大于99wt%，所述氧化铝微粉中Al2O3的含量大于99wt%，所述含铝原料的粒度小于0.088mm。
所述城市污泥的含水量小于10wt%，所述城市污泥中SiO2含量大于30wt%，Fe2O3含量小于6wt%，Al2O3含量大于10wt%，所述城市污泥的粒度小于0.088mm。
所述含硅原料为石英砂或为熔石英，所述含硅原料中SiO2的含量大于98wt%，所述含硅原料的粒度小于0.088mm。
所述添加剂为山梨糖醇或为羟基硬脂精。
所述表面活性剂为椰油酸二乙醇酰胺或为烷基糖苷。
所述还原气氛为氢气气氛或为一氧化碳气氛。
所述中性气氛为氮气气氛或为氩气气氛。
所述陶瓷纤维为硅酸铝陶瓷纤维或为硅酸镁陶瓷纤维。
所述结合剂为水玻璃或为硅溶胶，所述水玻璃的模数为1.5~2，所述硅溶胶中SiO2的含量为25~30wt%。
所述无机增稠剂为硅藻土或为球粘土。
所述有机增稠剂为羟乙基纤维素或为改性淀粉。
由于采用上述技术方案，本发明与现有技术相比具有如下积极效果：
本发明所采用的原料来源广泛，生产成本低；本发明通过对各步骤中的气氛、粒度、成型及热处理等工序的严格控制，既有利于不同原料颗粒的均化及各种原料颗粒之间的紧密接触，也为微结构的形成提供了合理空间，因而所制备的基于聚氯化铝废渣的陶瓷纤维隔热材料体积密度小和导热系数低。
本发明制备的基于聚氯化铝废渣的陶瓷纤维隔热材料经检测：体积密度小于0.35g/cm3；200~1200℃的导热系数为0.05~0.12w/(m·K)。
因此，本发明具有原料来源广泛和生产成本低的特点；所制备的基于聚氯化铝废渣的陶瓷纤维隔热材料体积密度小和导热系数低。
具体实施方式
下面结合具体实施方式对本发明作进一步的描述，并非对其保护范围的限制。
为避免重复，先将本具体实施方式所涉及的物料统一描述如下，实施例中不再赘述：
所述聚氯化铝废渣的含水量小于30wt%，所述聚氯化铝废渣中Al的含量大于18wt%，所述聚氯化铝废渣的粒度小于0.088mm。
所述氢氧化铝中Al(OH)3的含量大于99wt%，所述氧化铝微粉中Al2O3的含量大于99wt%，所述含铝原料的粒度小于0.088mm。
所述城市污泥的含水量小于10wt%，所述城市污泥中SiO2含量大于30wt%，Fe2O3含量小于6wt%，Al2O3含量大于10wt%，所述城市污泥的粒度小于0.088mm。
所述含硅原料中SiO2的含量大于98wt%，所述含硅原料的粒度小于0.088mm。
所述水玻璃的模数为1.5~2，所述硅溶胶中SiO2的含量为25~30wt%。
实施例1
一种基于聚氯化铝废渣的陶瓷纤维隔热材料及其制备方法。本实施例所述制备方法是：
第一步，将20~35wt%的聚氯化铝废渣、55~70wt%的含铝原料和0.1~10wt%的添加剂混合，即得混合料Ⅰ；外加所述混合料Ⅰ8~13倍质量的水，于50~80℃条件下搅拌3~6小时，静置，过滤，即得过滤料。
第二步，将60~70wt%的所述过滤料、20~30wt%的城市污泥和0.1~10wt%的表面活性剂混合均匀，在50~100MPa条件下压制成型；于还原气氛和600~800℃条件下热处理3~6小时，破碎，研磨，筛分，得到粒度小于0.088mm的A物料和粒度为0.088~1mm的B物料。
第三步，将20~30wt%的所述A物料、10~20wt%的所述B物料、10~20wt%的含硅原料和30~40wt%的所述含铝原料混合均匀，造粒，筛分；于还原气氛和400~700℃条件下热处理3~6小时，再于中性气氛和1000~1200℃条件下热处理3~6小时，即得粒度小于0.25mm的C物料和粒度为0.25~1.5mm的D物料。
第四步，将10~15wt%的所述A物料、15~20wt%的所述C物料、10~15wt%的所述D物料、40~50wt%的陶瓷纤维、10~15wt%的结合剂、5~10wt%的无机增稠剂和1~6wt%的有机增稠剂混合均匀，即得混合料Ⅱ；外加所述混合料Ⅱ10~25wt%的水，搅拌，挤压成型；于50~70℃条件下烘干12~24小时，再于900~1100℃条件下热处理3~6小时，制得基于聚氯化铝废渣的陶瓷纤维隔热材料。
本实施例中：
所述含铝原料为氢氧化铝；
所述含硅原料为石英砂；
所述添加剂为山梨糖醇；
所述表面活性剂为椰油酸二乙醇酰胺；
所述还原气氛为氢气气氛；
所述中性气氛为氮气气氛；
所述陶瓷纤维为硅酸铝陶瓷纤维；
所述结合剂为水玻璃；
所述无机增稠剂为硅藻土；
所述有机增稠剂为羟乙基纤维素。
实施例2
一种基于聚氯化铝废渣的陶瓷纤维隔热材料及其制备方法。本实施例除下述物料外其余同实施例1：
所述含铝原料为氧化铝微粉；
所述含硅原料为熔石英；
所述添加剂为羟基硬脂精；
所述表面活性剂为烷基糖苷；
所述还原气氛为一氧化碳气氛；
所述中性气氛为氩气气氛；
所述陶瓷纤维为硅酸镁陶瓷纤维；
所述结合剂为硅溶胶；
所述无机增稠剂为球粘土；
所述有机增稠剂为改性淀粉。
实施例3
一种基于聚氯化铝废渣的陶瓷纤维隔热材料及其制备方法。本实施例所述制备方法是：
第一步，将35~50wt%的聚氯化铝废渣、40~55wt%的含铝原料和0.1~10wt%的添加剂混合，即得混合料Ⅰ；外加所述混合料Ⅰ10~15倍质量的水，于60~90℃条件下搅拌3~6小时，静置，过滤，即得过滤料。
第二步，将70~80wt%的所述过滤料、10~20wt%的城市污泥和0.1~10wt%的表面活性剂混合均匀，在50~100MPa条件下压制成型；于还原气氛和700~900℃条件下热处理3~6小时，破碎，研磨，筛分，得到粒度小于0.088mm的A物料和粒度为0.088~1mm的B物料。
第三步，将30~40wt%的所述A物料、10~20wt%的所述B物料、10~20wt%的含硅原料和20~30wt%的所述含铝原料混合均匀，造粒，筛分；于还原气氛和500~800℃条件下热处理3~6小时，再于中性气氛和1100~1300℃条件下热处理3~6小时，即得粒度小于0.25mm的C物料和粒度为0.25~1.5mm的D物料。
第四步，将15~20wt%的所述A物料、10~15wt%的所述C物料、15~20wt%的所述D物料、30~40wt%的陶瓷纤维、15~20wt%的结合剂、1~6wt%的无机增稠剂和5~10wt%的有机增稠剂混合均匀，即得混合料Ⅱ；外加所述混合料Ⅱ15~30wt%的水，搅拌，挤压成型；于60~80℃条件下烘干12~24小时，再于900~1100℃条件下热处理3~6小时，制得基于聚氯化铝废渣的陶瓷纤维隔热材料。
本实施例中：
所述含铝原料为氢氧化铝；
所述含硅原料为石英砂；
所述添加剂为山梨糖醇；
所述表面活性剂为椰油酸二乙醇酰胺；
所述还原气氛为氢气气氛；
所述中性气氛为氮气气氛；
所述陶瓷纤维为硅酸铝陶瓷纤维；
所述结合剂为水玻璃；
所述无机增稠剂为硅藻土；
所述有机增稠剂为羟乙基纤维素。
实施例4
一种基于聚氯化铝废渣的陶瓷纤维隔热材料及其制备方法。本实施例除下述物料外其余同实施例3：
所述含铝原料为氧化铝微粉；
所述含硅原料为熔石英；
所述添加剂为羟基硬脂精；
所述表面活性剂为烷基糖苷；
所述还原气氛为一氧化碳气氛；
所述中性气氛为氩气气氛；
所述陶瓷纤维为硅酸镁陶瓷纤维；
所述结合剂为硅溶胶；
所述无机增稠剂为球粘土；
所述有机增稠剂为改性淀粉。
本具体实施方式与现有技术相比具有如下积极效果：
本具体实施方式所采用的原料来源广泛，生产成本低；本具体实施方式通过对各步骤中的气氛、粒度、成型及热处理等工序的严格控制，既有利于不同原料颗粒的均化及各种原料颗粒之间的紧密接触，也为微结构的形成提供了合理空间，因而所制备的基于聚氯化铝废渣的陶瓷纤维隔热材料体积密度小和导热系数低。
本具体实施方式制备的基于聚氯化铝废渣的陶瓷纤维隔热材料经检测：体积密度小于0.35g/cm3；200~1200℃的导热系数为0.05~0.12w/(m·K)。
因此，本具体实施方式具有原料来源广泛和生产成本低的特点；所制备的基于聚氯化铝废渣的陶瓷纤维隔热材料体积密度小和导热系数低。

Claims (9)

1.一种基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法，其特征在于所述制备方法是：
第一步，将20～50wt％的聚氯化铝废渣、40～70wt％的含铝原料和0.1～10wt％的添加剂混合，即得混合料Ⅰ；外加所述混合料Ⅰ8～15倍质量的水，于50～90℃条件下搅拌3～6小时，静置，过滤，即得过滤料；
第二步，将60～80wt％的所述过滤料、10～30wt％的城市污泥和0.1～10wt％的表面活性剂混合均匀，在50～100MPa条件下压制成型；于还原气氛和600～900℃条件下热处理3～6小时，破碎，研磨，筛分，得到粒度小于0.088mm的A物料和粒度为0.088～1mm的B物料；
第三步，将20～40wt％的所述A物料、10～20wt％的所述B物料、10～20wt％的含硅原料和20～40wt％的所述含铝原料混合均匀，造粒，筛分；于还原气氛和400～800℃条件下热处理3～6小时，再于中性气氛和1000～1300℃条件下热处理3～6小时，即得粒度小于0.25mm的C物料和粒度为0.25～1.5mm的D物料；
第四步，将10～20wt％的所述A物料、10～20wt％的所述C物料、10～20wt％的所述D物料、30～50wt％的陶瓷纤维、10～20wt％的结合剂、1～10wt％的无机增稠剂和1～10wt％的有机增稠剂混合均匀，即得混合料Ⅱ；外加所述混合料Ⅱ10～30wt％的水，搅拌，挤压成型；于50～80℃条件下烘干12～24小时，再于900～1100℃条件下热处理3～6小时，制得基于聚氯化铝废渣的陶瓷纤维隔热材料；
所述聚氯化铝废渣的含水量小于30wt％，所述聚氯化铝废渣中Al的含量大于18wt％，所述聚氯化铝废渣的粒度小于0.088mm；
所述含铝原料为氢氧化铝或为氧化铝微粉，所述氢氧化铝中Al(OH)3的含量大于99wt％，所述氧化铝微粉中Al2O3的含量大于99wt％，所述含铝原料的粒度小于0.088mm；
所述城市污泥的含水量小于10wt％，所述城市污泥中SiO2含量大于30wt％，Fe2O3含量小于6wt％，Al2O3含量大于10wt％，所述城市污泥的粒度小于0.088mm；
所述含硅原料为石英砂或为熔石英，所述含硅原料中SiO2的含量大于98wt％，所述含硅原料的粒度小于0.088mm；
所述添加剂为山梨糖醇或为羟基硬脂精。
2.根据权利要求1所述基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法，其特征在于所述表面活性剂为椰油酸二乙醇酰胺或为烷基糖苷。
3.根据权利要求1所述基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法，其特征在于所述还原气氛为氢气气氛或为一氧化碳气氛。
4.根据权利要求1所述基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法，其特征在于所述中性气氛为氮气气氛或为氩气气氛。
5.根据权利要求1所述基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法，其特征在于所述陶瓷纤维为硅酸铝陶瓷纤维或为硅酸镁陶瓷纤维。
6.根据权利要求1所述基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法，其特征在于所述结合剂为水玻璃或为硅溶胶，所述水玻璃的模数为1.5～2，所述硅溶胶中SiO2的含量为25～30wt％。
7.根据权利要求1所述基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法，其特征在于所述无机增稠剂为硅藻土或为球粘土。
8.根据权利要求1所述基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法，其特征在于所述有机增稠剂为羟乙基纤维素或为改性淀粉。
9.一种基于聚氯化铝废渣的陶瓷纤维隔热材料，其特征在于所述基于聚氯化铝废渣的陶瓷纤维隔热材料是根据权利要求1～8项中任一项所述基于聚氯化铝废渣的陶瓷纤维隔热材料的制备方法所制备的基于聚氯化铝废渣的陶瓷纤维隔热材料。
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