CN106587931A - 一种轻质高强陶粒及其制备方法 - Google Patents

一种轻质高强陶粒及其制备方法 Download PDF

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Publication number
CN106587931A
CN106587931A CN201611163523.3A CN201611163523A CN106587931A CN 106587931 A CN106587931 A CN 106587931A CN 201611163523 A CN201611163523 A CN 201611163523A CN 106587931 A CN106587931 A CN 106587931A
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parts
light high
strength
granule
exciting agent
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CN201611163523.3A
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CN106587931B (zh
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贾屹海
王希宏
陈思颖
王川行
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Guangdong Datong Datong Environmental Protection Technology Co., Ltd.
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Tsinghua Innovation Center in Dongguan
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Priority to CN201611163523.3A priority Critical patent/CN106587931B/zh
Publication of CN106587931A publication Critical patent/CN106587931A/zh
Priority to US16/464,878 priority patent/US10954163B2/en
Priority to PCT/CN2017/085243 priority patent/WO2018107660A1/zh
Priority to JP2019522261A priority patent/JP7038708B2/ja
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Abstract

本发明现提供一种轻质高强陶粒，原料包括固体原料和激发剂，重量份数分别为：固体原料100份，激发剂1‑15份，所述固体原料包括：粉煤灰100份，高铝粉煤灰、铝矾土和赤泥6‑18份；硅灰1‑5份；表面活性剂0.1‑3份；增塑剂6‑24份；所述激发剂包括碱金属氢氧化物5‑20份，碱金属硅酸盐80‑95份。本发明的轻质高强陶粒产品强度轻质高强，密度等级为700‑1100kg/m3，筒压强度可达10‑20MPa，不易受损；可制备轻骨料高性能混凝土，作为一种承重结构，可应用于建筑墙板、桥梁、管道等，具有极大的应用价值。

Description

一种轻质高强陶粒及其制备方法
技术领域
本发明环保建筑、建材以及固体废弃物处理及资源化利用技术领域，具体涉及一种轻质高强陶粒及其制备方法。
背景技术
1、粉煤灰是燃煤发电的固体废弃物，我国年产粉煤灰约6亿吨，综合利用率约70％，每年都有大量积存，如果对这些粉煤灰不加以处理，会产生扬尘，直接污染大气，对人类的呼吸***带来威胁；此外，如果粉煤灰被排入水系中，其中的有毒化学物质会污染生活用水，进一步地威胁人体的健康，因此将粉煤灰资源化利用受到国家和各地方政府的大力支持。
2、陶粒是一种人造轻质骨料，具有优异的性能，如密度低、筒压强度高、软化系数高、抗冻性良好、抗碱集料反应性优异等，因而具有质轻，耐腐蚀，抗冻，抗震和良好的隔绝性等多功能特点。利用陶粒这些优异的性能，其可作为建材用基础材料，用于替代砂石作为混凝土原料生产轻质高强混凝土，或生产轻质墙板、陶粒自保温砌块、污水处理滤料、种植基质等，应用领域广泛。
3、传统陶粒生产大多采用粘土、页岩为主要原料经烧结而成，这势必会消耗大量的粘土等矿土，不利于保护山林植被和耕田，不符合可持续发展的原则。寻找一种废弃物作为原料来生产陶粒，成为当下研究的热点。
4、粉煤灰中含有较为丰富的SiO2、Al2O3、Fe203、CaO，与粘土中的化学成分相似，因此可烧制陶粒。如果利用粉煤灰作为原料来制备陶粒，能充分利用固体废弃物，变废为宝。
5、申请号为201510273757.2的中国专利《一种轻质高强陶粒及其制备工艺》中提出利用高岭土尾矿、煤矸石、粉煤灰作为原料制备轻质高强陶粒，其中粉煤灰用量为20-40份，筒压强度为10MPa以上，堆积密度为800-900g/cm3，但该方法粉煤灰用量低。
6、申请号为201410507652.4的中国专利《一种污泥粉煤灰高强陶粒及其制备方法》中提出利用污泥和粉煤灰为主要原料制备高强陶粒，其中粉煤灰用量为30-55份，筒压强度为3-6.3MPa，堆积密度为500-650kg/m3，该方法粉煤灰用量不高，且筒压强度较低。
7、申请号为200610086665.4的中国专利《轻质高强度粉煤灰陶粒配方》中提出由粉煤灰、粘结剂、外加剂制备轻质高强度粉煤灰陶粒，其中粉煤灰用量为55-70％，筒压强度可达7.3MPa，该方法粉煤灰用量较高，但筒压强度较低。
8、申请号为201510320491.2的中国专利《一种生物陶粒及其制备方法》中提出由粉煤灰、增塑剂、矿渣、造孔剂和液体激发剂制备生物陶粒，其中粉煤灰用量85％-95％，筒压强度为9-14MPa，该方法粉煤灰用量较高，但筒压强度较低，且液体激发剂具有强碱性，对设备和人体均会有不良影响。
目前高强陶粒存在的问题有：
1、筒压强度较低；
2、粉煤灰用量较低；
3、液体激发剂较为危险。
发明内容
本发明的目的提供一种筒压强度高，粉煤灰用量高的轻质高强陶粒及其制备方法。
为实现本发明的目的，本发明提供了以下技术方案：
一种轻质高强陶粒，原料包括固体原料和激发剂，重量份数分别为：固体原料100份，激发剂1-15份，所述固体原料包括：粉煤灰100份，高铝粉煤灰、铝矾土和赤泥6-18份；硅灰1-5份；表面活性剂0.1-3份；增塑剂6-24份；所述激发剂包括碱金属氢氧化物5-20份，重量百分比为60-95％的碱金属硅酸盐溶液80-95份。
所述粉煤灰的组分包括烧失量为2-10％，SiO230％-70％，Al2O310％-50％，CaO1％-15％，Fe2O31％-18％，MgO0.01％-8％，TiO20.01％-3％。
所述增塑剂为广东白泥、广东黑泥、高岭土、膨润土、PVA、纤维素的一种或多种。
所述高铝粉煤灰和铝矾土中的氧化铝含量不小于37％，赤泥和高铝粉煤灰、铝矾土的重量分数比为1：2-5。
所述固体原料还包括0.01-5份的铁尾矿和0.01-5份的方解石。
所述碱金属氢氧化物为氢氧化钠、氢氧化钾、氢氧化锂的一种或多种。
所述碱金属硅酸盐溶液中的碱金属硅酸盐为硅酸钠、硅酸钾、硅酸锂的一种或多种。
所述表面活性剂为木质素磺酸钠、Light Polymers公司的CT017的一种或两种混合。
所述表面活性剂为木质素磺酸钠和Light Polymers公司的CT017两种混合，重量份数比木质素磺酸钠：Light Polymers公司的CT017为2-5：1。
一种轻质高强陶粒制备方法，包括步骤如下：a、称取固体原料混合，并制备固体激发剂：将碱金属氢氧化物溶于碱金属硅酸盐溶液中，冷却至室温后，继续搅拌直到出现少量白色浑浊，将其倒入干净容器，室温下1-20min白色结晶形成结块，将结块进行粉碎，形成固体激发剂；b、混合：固体原料与固体激发剂进行充分混合，形成混合料；c、造粒：将混合料进行造粒，形成颗粒；d、固化：将颗粒在70-100℃的温度和70-90％的湿度条件下进行养护1-2小时，使其固化；e、烘干：对于固化了的颗粒进行烘干，烘干温度100-300℃；f、烧结：将烘干颗粒通过一定的烧结工艺，烧结60-90min；g、成品：烧结颗粒降温到室温，制成成品的轻质高强陶粒。
烧结工艺的具体步骤为：100-300℃温度时以速率20-40℃/min升温至500-700℃，然后以速率5-25℃/min升温至1050-1350℃。
本发明的优点在于：
1、原料无需球磨直接混合造粒，降低能耗，减少工序；
2、颗粒先固化后烧结，在烧结过程中不产生灰尘，污染小；
3、产品强度轻质高强，密度等级为700-1100kg/m3，筒压强度可达10-20MPa，不易受损；可制备轻骨料高性能混凝土，作为一种承重结构，可应用于建筑墙板、桥梁、管道等，；
4、本发明在固体原料中添加了含有高铝的高铝粉煤灰、铝矾土，提高了材料的强度。
5、本发明的固体原料中还加入了表面活性剂，会提高固体原料和固体激发剂的混合效果，制备的陶粒性能更加均匀，产品质量更稳定。
6、本发明采用固体激发剂，固体激发剂比液体激发剂易操作，液体激发剂具有强碱性，容易腐蚀设备，且对人体容易造成危害。
具体实施方式
为了更详细地说明本发明，给出下述制备实例。但本发明的范围并不局限于此。
实施例1
称取固体原料：粉煤灰850g，广东白泥20g，高铝粉煤灰100g，硅灰30g，木质素磺酸钠8g，将以上固体原料混合；
制备激发剂：称取氢氧化钠5g，80％钠水玻璃溶液40g，将氢氧化钠加入钠水玻璃溶液中，进行溶解，搅拌冷却至室温后，继续搅拌直到出现少量白色沉淀，将其倒入干净容器，室温下1-20min白色结晶形成结块，将结块进行粉碎，形成固体激发剂；
混合：固体原料与固体激发剂进行充分混合，形成混合料；
造粒：将混合料进行造粒，形成颗粒；
固化：将颗粒在室温-100℃温度和70-90％湿度条件下进行养护1-2小时，使其固化；
烘干：对于固化了的颗粒进行烘干，烘干温度120℃；
烧结：将烘干颗粒在1250℃温度下烧结，详细步骤为120℃温度时以速率25℃/min升温至600℃，然后以速率15℃/min升温至1250℃；
成品：烧结颗粒降温到室温，为实施例1的成品陶粒。
实施例2
称取固体原料：粉煤灰880g，铝矾土40g，木质素磺酸钠10g，膨润土70g，将以上固体原料混合；
制备固体激发剂：称取氢氧化钾15g，90％的钾水玻璃溶液87g，将氢氧化钾加入钾水玻璃溶液中，进行溶解，搅拌冷却至室温后，继续搅拌直到出现少量白色沉淀，将其倒入干净容器，室温下1-20min白色结晶形成结块，将结块进行粉碎，形成固体激发剂；
混合：固体原料与固体激发剂进行充分混合，形成混合料；
造粒：将混合料进行造粒，形成颗粒；
固化：将颗粒在室温-80℃和70-90％湿度条件下进行养护1-2小时，使其固化；
烘干：对于固化了的颗粒进行烘干2小时，烘干温度100℃；
烧结：将烘干颗粒在1300℃温度下烧结；详细步骤为100℃温度时以速率30℃/min升温至700℃，然后以速率10℃/min升温至1300℃；
成品：烧结颗粒降温到室温，为实施例2的成品陶粒。
实施例3
称取固体原料：粉煤灰860g，硅灰40g，铝矾土50g，纤维素20g，Light Polymers公司的的CT017 10g，将以上固体原料混合；
制备固体激发剂：称取氢氧化锂12g，92％的锂水玻璃溶液80g，将氢氧化锂加入锂水玻璃溶液中，进行溶解，搅拌冷却至室温后，继续搅拌直到出现少量白色沉淀，将其倒入干净容器，室温下1-20min白色结晶形成结块，将结块进行粉碎，形成固体激发剂；
混合：固体原料与固体激发剂进行充分混合，形成混合料；
造粒：将混合料进行造粒，形成颗粒；
固化：将颗粒一定温度和湿度条件下进行养护1-2小时，使其固化；
温度：室温-80℃；
湿度：70-90％；
烘干：对于固化了的颗粒进行烘干2个小时，烘干温度140℃；
烧结：将烘干颗粒在1200℃温度下烧结；详细步骤为140℃温度时以速率40℃/min升温至700℃，然后以速率10℃/min升温至1200℃；
成品：烧结颗粒降温到室温，为实施例3的成品陶粒。
实施例4
称取固体原料：粉煤灰800g，广东白泥30g，膨润土80g，木质素磺酸钠10g，高铝粉煤灰50g，将以上固体原料混合；
制备激发剂：称取氢氧化钠20g，75％的钠水玻璃溶液100g，将氢氧化钠加入钠水玻璃溶液中，进行溶解，搅拌冷却至室温后，继续搅拌直到出现少量白色沉淀，将其倒入干净容器，室温下1-20min白色结晶形成结块，将结块进行粉碎，形成固体激发剂；
混合：固体原料与激发剂进行充分混合，形成混合料；
造粒：将混合料进行造粒，形成颗粒；
固化：将颗粒一定温度和湿度条件下进行养护1-2小时，使其固化；
温度：室温-90℃；
湿度：70-90％；
烘干：对于固化了的颗粒进行烘干2个小时，烘干温度130℃；
烧结：将烘干颗粒在1250℃温度下烧结；详细步骤为130℃温度时以速率30℃/min升温至700℃，然后以速率10℃/min升温至1250℃；
成品：烧结颗粒降温到室温，为实施例4的成品陶粒。
实施例5
称取固体原料：粉煤灰750g，赤泥100g，硅灰10g，方解石50g，将以上固体原料混合；
制备激发剂：称取氢氧化钠15g，85％的钠水玻璃溶液80.5g，将氢氧化钠加入钠水玻璃溶液中，进行溶解，搅拌冷却至室温后，继续搅拌直到出现少量白色沉淀，将其倒入干净容器，室温下1-20min白色结晶形成结块，将结块进行粉碎，形成固体激发剂；
混合：固体原料与激发剂进行充分混合，形成混合料；
造粒：将混合料进行造粒，形成颗粒；
固化：将颗粒一定温度和湿度条件下进行养护1-2小时，使其固化；
温度：室温-70℃；
湿度：70-90％；
烘干：对于固化了的颗粒进行烘干2个小时，烘干温度150℃；
烧结：将烘干颗粒在1050℃温度下烧结；详细步骤为150℃温度时以速率20℃/min升温至700℃，然后以速率10℃/min升温至1050℃
成品：烧结颗粒降温到室温，为实施例5的成品陶粒。
对比例1
称取固体原料：粉煤灰850g，广东白泥20g，硅灰30g，将以上固体原料混合；
制备液体激发剂：称取氢氧化钠5g，钠水玻璃40g，水5g，将氢氧化钠加入钠水玻璃中，进行溶解，加水搅拌均匀，冷却至室温，制得液体激发剂；
混合：固体原料与液体激发剂进行充分混合，形成混合料；
造粒：将混合料进行造粒，形成颗粒；
固化：将颗粒一定温度和湿度条件下进行养护1-2小时，使其固化；
温度：室温-100℃；
湿度：70-90％；
烘干：对于固化了的颗粒进行烘干，烘干温度120℃；
烧结：将烘干颗粒程序升温至1250℃，烧结60min；
成品：烧结颗粒降温到室温，为对比例1的成品陶粒。
对比例2
称取固体原料：粉煤灰880g，膨润土70g，将以上固体原料混合；
制备液体激发剂：称取氢氧化钾15g，钾水玻璃87g，水8g，将氢氧化钾加入钾水玻璃中，进行溶解，加水搅拌均匀，冷却至室温，制得液体激发剂；
混合：固体原料与液体激发剂进行充分混合，形成混合料；
造粒：将混合料进行造粒，形成颗粒；
固化：将颗粒一定温度和湿度条件下进行养护1-2小时，使其固化；
温度：室温-80℃；
湿度：70-90％；
烘干：对于固化了的颗粒进行烘干2小时，烘干温度100℃；
烧结：将烘干颗粒在1300℃温度下，烧结60min；
成品：烧结颗粒降温到室温，为对比例2的成品陶粒。
对比例3
称取固体原料：粉煤灰800g，广东白泥30g，膨润土80g，木质素磺酸钠10g，高铝粉煤灰50g，将以上固体原料混合，加8g水搅拌均匀；
造粒：将加水的固体原料进行造粒，形成颗粒；
固化：将颗粒一定温度和湿度条件下进行养护1-2小时，使其固化；
温度：室温-90℃；
湿度：70-90％；
烘干：对于固化了的颗粒进行烘干2个小时，烘干温度130℃；
烧结：将烘干颗粒在1250℃温度下，烧结80min；
成品：烧结颗粒降温到室温，为对比例3的成品陶粒。
对比例4
称取固体原料：粉煤灰750g，赤泥100g，硅灰10g，方解石50g，将以上固体原料混合，加水搅拌均匀；
造粒：将加12g水的固体原料进行造粒，形成颗粒；
固化：将颗粒一定温度和湿度条件下进行养护1-2小时，使其固化；
温度：室温-70℃；
湿度：70-90％；
烘干：对于固化了的颗粒进行烘干2个小时，烘干温度150℃；
烧结：将烘干颗粒在1050℃温度下，烧结90min；
成品：烧结颗粒降温到室温，为对比例4的成品陶粒。
对以上实施例1-5和对比例1-4制备的成品陶粒进行测试，样品性能测试结果如下：
堆积密度(kg/m3) 筒压强度(MPa) 吸水率(％)
实施例1 908 15.3 6.4
实施例2 894 13.5 8.6
实施例3 960 17.1 5.2
实施例4 1056 19.7 3.6
实施例5 720 11.6 9.3
对比例1 1020 15.6 5.6
对比例2 980 14.1 4.0
对比例3 850 7.2 9.1
对比例4 730 6.8 10.3
通过以上数据可以看出，本发明的实施例1-5和对比例1-2相比，在堆积密度接近的情况下，筒压强度和吸水率方面，使用固体激发剂和使用液体激发剂效果接近甚至使用固体激发剂效果更具优势，实施例1-5和对比例3-4相比，对比例3-4没有采用激发剂，实施例1-5具有明显的优势。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本领域的技术人员在本发明揭露的技术范围内，可轻易想到的变化或替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应该以权利要求的保护范围为准。

Claims (10)

1.一种轻质高强陶粒，原料包括固体原料和固体激发剂，重量份数分别为：固体原料100份，固体激发剂1-15份，其特征在于：所述固体原料包括：粉煤灰100份，高铝粉煤灰、铝矾土和赤泥6-18份；硅灰1-5份；表面活性剂0.1-3份；增塑剂6-24份；所述固体激发剂包括碱金属氢氧化物5-20份，重量百分比为60-95%的碱金属硅酸盐溶液80-95份。
2.根据权利要求1所述的轻质高强陶粒，其特征在于：所述粉煤灰的组分包括烧失量为2-10%，SiO230%-70%，Al2O310%-50%，CaO1%-15%，Fe2O31%-18%，MgO0.01%-8%，TiO20.01%-3%。
3.根据权利要求1所述的轻质高强陶粒，其特征在于：所述增塑剂为广东白泥、广东黑泥、高岭土、膨润土、PVA、纤维素的一种或多种。
4.根据权利要求1所述的轻质高强陶粒，其特征在于：所述高铝粉煤灰和铝矾土中的氧化铝含量不小于37%，赤泥和高铝粉煤灰、铝矾土的重量分数比为1：2-5。
5.根据权利要求1所述的轻质高强陶粒，其特征在于：所述固体原料还包括0.01-5份的铁尾矿和0.01-5份的方解石。
6.根据权利要求1所述的轻质高强陶粒，其特征在于：所述碱金属氢氧化物为氢氧化钠、氢氧化钾、氢氧化锂的一种或多种；所述碱金属硅酸盐溶液中的碱金属硅酸盐为硅酸钠、硅酸钾、硅酸锂的一种或多种。
7.根据权利要求1所述的轻质高强陶粒，其特征在于：所述表面活性剂为木质素磺酸钠、Light Polymers公司的 CT017的一种或两种混合。
8.根据权利要求7所述的轻质高强陶粒，其特征在于：所述表面活性剂为木质素磺酸钠和Light Polymers公司的 CT017两种混合，重量份数比木质素磺酸钠：Light Polymers公司的 CT017为2-5：1。
9.一种轻质高强陶粒制备方法，其特征在于：包括步骤如下：a、称取固体原料混合，并制备固体激发剂：将碱金属氢氧化物溶于碱金属硅酸盐溶液中，冷却至室温后，继续搅拌直到出现少量白色浑浊，将其倒入干净容器，室温下1-20min白色结晶形成结块，将结块进行粉碎，形成固体激发剂；b、混合：固体原料与固体激发剂进行充分混合，形成混合料；c、造粒：将混合料进行造粒，形成颗粒；d、固化：将颗粒在70-100℃的温度和70-90%的湿度条件下进行养护1-2小时，使其固化；e、烘干：对于固化了的颗粒进行烘干，烘干温度100-300℃；f、烧结：将烘干颗粒通过一定的烧结工艺，烧结60-90min；g、成品：烧结颗粒降温到室温，制成权利要求1-8任一项所述的轻质高强陶粒。
10.根据权利要求9所述的轻质高强陶粒制备方法，其特征在于：烧结工艺的具体步骤为：100-300℃温度时以速率20-40℃/min升温至500-700℃，然后以速率5-25℃/min升温至1050-1350℃。
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