CN114890808B - 一种三明治结构煤矸石海绵砖的制备方法 - Google Patents
一种三明治结构煤矸石海绵砖的制备方法 Download PDFInfo
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Abstract
本发明公开了一种三明治结构煤矸石海绵砖的制备方法,采用煤矸石、废瓷、低温粘结剂、高温粘结剂、着色剂为原料,经制备颗粒料、混合配料、压制成型、干燥、烧成后获得海绵砖产品。本发明将占用土地和污染环境的大量煤矸石作为主要原料,通过陶瓷科技手段制成建设海绵城市的海绵砖,从污染环境的废弃物变成为改善环境的高科技产品,同时采用三明治结构的海绵砖,有效地解决了中温烧成时煤矸石颗粒强度偏低的问题。本发明制备的煤矸石海绵砖具有结构新颖、成本低、强度高、透水性好、保水性适中等显著优点,因此具有广阔的市场前景。
Description
技术领域
本发明属于无机非金属材料(陶瓷)领域,具体涉及一种三明治结构煤矸石海绵砖的制备方法。
背景技术
煤矸石是煤矿开采过程中的废弃物,主要化学成分是氧化铝和二氧化硅,含有少量的碳,主要矿物组成是高岭石,堆积的煤矸石山不仅占用土地资源,而且对环境也会造成污染,同时煤矸石堆积储存还是对资源的一种浪费。
随着我国海绵城市概念的提出,海绵砖(也叫透水砖)的研究和生产出现了一段时期的热潮。主要分为免烧海绵砖和烧结海绵砖两大类,其中烧结海绵砖的性能更优。目前烧结海绵砖的主要原料大致可分为四大类:粉煤灰类废料、矿渣类废料、淤泥类废料、陶瓷废料。煤矸石是一种矿渣类废料,在作为制备海绵砖的主要骨料时,遇到了一些问题,一些含杂质较少的煤矸石颗粒不能烧结致密,导致海绵砖结构强度很低,局部出现颗粒松散脱落现象,极大地限制了煤矸石在海绵砖中的使用量。
发明内容
本发明的目的在于克服现有技术的不足,提供一种工艺简单、成本低廉、便于规模化生产的三明治结构煤矸石海绵砖的制备方法。
为解决以上技术问题,本发明的技术方案是:一种三明治结构煤矸石海绵砖的制备方法,其特征在于:采用煤矸石、废瓷、低温粘结剂、高温粘结剂、着色剂为原料,经制备颗粒料、配料混合、压制成型、干燥、烧成后获得海绵砖产品。
所述制备颗粒料工序步骤为:
步骤一:将煤矸石用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的煤矸石颗粒料;进一步过20目筛,分别得到8~20目的筛上煤矸石颗粒料和20~40目的筛下煤矸石颗粒料;
步骤二:将废瓷用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的废瓷颗粒料;进一步过20目筛,分别得到8~20目的筛上废瓷颗粒料和20~40目的筛下废瓷颗粒料。
所述混合配料工序步骤为:
步骤一:将制备好的煤矸石颗粒料、废瓷颗粒料、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.5~1小时,使其混合均匀,得到底层混合料A,其中20~40目煤矸石颗粒料的含量为0~30wt%、8~20目或20~40目废瓷颗粒料为70~100wt%,外加低温粘结剂为5~8wt%、高温粘结剂为3~6wt%;
步骤二:将制备好的煤矸石颗粒料、废瓷颗粒料、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.5~1小时,使其混合均匀,得到主体层混合料B;其中8~20目或20~40目煤矸石颗粒料的含量为60~80wt%、8~20目或20~40目的废瓷颗粒料为20~40wt%,外加低温粘结剂为5~8wt%、高温粘结剂为3~6wt%;
步骤三:将制备好的煤矸石颗粒料、废瓷颗粒料、着色剂、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.5~1小时,使其混合均匀,得到面层混合料C;其中20~40目的煤矸石颗粒料的含量为0~30wt%、8~20目或20~40目的废瓷颗粒料为70~100wt%,外加着色剂为1~5wt%、低温粘结剂为5~8wt%、高温粘结剂为3~6wt%。
所述压制成型工序步骤为:
按海绵砖产品性能参数要求加入一定量的底层混合料A装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,再加入一定量的主体层混合料B装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,最后加入一定量的面层混合料C装入压制成型的钢制模具内,摊平,按预定的成型工艺参数进行压制成型,成型压力为5MPa,保压时间为15s,然后脱模,得到三明治结构形式的海绵砖生坯。
所述干燥工序步骤为:将海绵砖生坯送入干燥器内进行干燥,所述干燥温度按0.5~1℃/min,从20℃升高至80℃。
所述烧成工序步骤为:将干燥后的海绵砖坯体送入隧道窑或梭式窑进行烧成,烧成温度为1200~1320℃,升温速率为30~120℃/h。
上述低温粘结剂是水玻璃、2~4wt%的羧甲基纤维素钠水溶液、8~10wt%的聚乙烯醇水溶液中的任意一种。
上述高温粘结剂由70~90wt%的钾长石或/和钠长石、1~2wt%的石灰石或方解石、1~2wt%的烧滑石、0.1~2wt%的玻璃粉、2~5wt%的高岭土、0~10wt%的石英、0~4wt%的氧化锌组成。
上述着色剂是指含有过渡金属元素铬、铁、钴、锰等的金属氧化物或不溶于水的盐类,或者各种人工合成的中高温陶瓷色料。
所述海绵砖产品的透水系数为2×10-2cm/s以上,抗折强度达到5MPa以上,吸水率高于15%。
将上述煤矸石、废瓷颗粒料筛分为8~20目和20~40目,是因为这两个粒度范围的颗粒对海绵砖的透水率和强度有较明显的影响。颗粒粗的海绵砖透水率较高但强度较低,反之,颗粒细的海绵砖透水率较低而强度较高,但都符合国家标准GB/T 25993-2010《透水路面砖和透水路面板》的性能要求。而8~20目、20~40目的颗粒粒度分布已经较窄,不需再进一步细化粒度分布。
按照国家标准GB/T 25993-2010《透水路面砖和透水路面板》要求的测试方法对上述海绵砖产品进行测试,产品的透水系数、抗折强度、吸水率均达到或超过GB/T 25993-2010要求的高级标准。扫描电子显微镜观察表明,上述海绵砖样品中含有大量尺寸1mm以上的大孔隙,也有很多尺寸在0.1mm以下的小孔隙。
本发明具有以下有益效果:
(1)变废为宝。本发明将占用土地和污染环境的大量煤矸石作为主要原料,
通过陶瓷科技手段制成建设海绵城市的海绵砖,从污染环境的废弃物变成为改善环境的高科技产品。
(2)提高强度。本发明采用三明治结构的海绵砖,有效地解决了中温烧成时煤矸石颗粒强度偏低的问题。
(3)降低燃耗。通过利用煤矸石本身可燃物提供部分烧成时所需热量,减少烧成时的燃耗。
(4)优化孔结构。通过颗粒级配形成的大孔和煤矸石颗粒本身可燃物燃烧形成的微孔组成复合的孔结构,可以提高砖体的透水性和保水性,有效解决了海绵砖的强度、透水性和保水性相互制约的矛盾。
以上优点,使得本发明制备的煤矸石海绵砖具有结构新颖、成本低、强度高、透水性好、保水性适中等显著优点。
附图说明
图1为本发明采用的工艺流程图;
图2为实施例一制得海绵砖产品的扫描电子显微镜检测图。
具体实施方式
为更进一步阐述本发明为达成预定发明目的所采取的技术手段及功效,以下结合较佳实施例,对依据本发明提出的一种三明治结构煤矸石海绵砖制备的具体实施方式、方法、步骤、特征及其功效,详细说明如下:
实施例一:
本实施例一种三明治结构海绵砖的制备方法,其步骤如下:
1. 制备颗粒料。
将煤矸石用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的煤矸石颗粒料;进一步过20目筛,分别得到8~20目的筛上料颗粒和20~40目的筛下料颗粒。
将陶瓷废品用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的废瓷颗粒料;进一步过20目筛,分别得到8~20目的筛上料颗粒和20~40目的筛下料颗粒。
2. 称料混合
将制备好的废瓷颗粒、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.5小时,使其混合均匀,得到混合料A。其中20~40目的煤矸石颗粒的含量为30wt%,8~20目的废瓷颗粒为70wt%,外加低温粘结剂水玻璃为8wt%,自制的高温粘结剂为6wt%。
将制备好的煤矸石颗粒、废瓷颗粒、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.5小时,使其混合均匀,得到混合料B。其中8~20目的煤矸石颗粒的含量为60wt%,8~20目的废瓷颗粒为40wt%,外加低温粘结剂水玻璃为5wt%、自制的高温粘结剂为3wt%。
将制备好的废瓷颗粒、着色剂、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.5小时,使其混合均匀,得到混合料C。其中8~20目的废瓷颗粒为100wt%,外加着色剂氧化钴为1wt%,低温粘结剂水玻璃为5wt%,自制的高温粘结剂为3wt%。
上述高温粘结剂由60wt%的钾长石和30wt%的钠长石、1wt%的石灰石、1wt%的烧滑石、0.1wt%的玻璃粉、2wt%的高岭土组成。
3. 压制成型
按制品规格要求称取上述混合料A适量装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,再称取混合料B适量装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,最后再称取上述混合料C适量装入压制成型的钢制模具内,摊平,按预定的成型工艺参数进行压制成型,成型压力为5MPa,保压时间为15s,然后脱模,得到三明治结构形式的生坯。
4. 干燥
将上述生坯送入干燥器进行充分干燥,干燥温度按0.5℃/min,逐步从20℃升高至80℃,要注意避免升温太快或温度太高导致坯体变形或开裂。
5. 烧成
将上述充分干燥后的坯体送入隧道窑或梭式窑进行烧成,烧成温度为1200℃,升温速率为30℃/h。
按照国家标准GB/T 25993-2010《透水路面砖和透水路面板》要求的测试方法测试用上述配方和工艺方法制备的三明治结构海绵砖的透水系数为2.5×10-2cm/s,抗折强度为5.2MPa,吸水率为17.6%。
实施例二:
本实施例一种三明治结构海绵砖的制备方法,其步骤如下:
1. 制备颗粒料。
将煤矸石用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的煤矸石颗粒料;进一步过20目筛,分别得到8~20目的筛上料颗粒和20~40目的筛下料颗粒。
将陶瓷废品用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的废瓷颗粒料;进一步过20目筛,分别得到8~20目的筛上料颗粒和20~40目的筛下料颗粒。
2. 称料混合
将制备好的废瓷颗粒、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合1小时,使其混合均匀,得到混合料A。其中20~40目的废瓷颗粒为100wt%,外加低温粘结剂浓度为2.5wt%的CMC溶液6.5wt%,自制的高温粘结剂为3wt%。
将制备好的煤矸石颗粒、废瓷颗粒、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合1小时,使其混合均匀,得到混合料B。其中8~20目的煤矸石颗粒的含量为80wt%,20~40目的废瓷颗粒为20wt%,外加低温粘结剂浓度为2.5wt%的CMC溶液8wt%、自制的高温粘结剂为6wt%。
将制备好的废瓷颗粒、着色剂、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合1小时,使其混合均匀,得到混合料C。其中20~40目的煤矸石颗粒的含量为30wt%,8~20目的废瓷颗粒为70wt%,外加着色剂包裹红色料为4wt%,低温粘结剂浓度为2.5wt%的CMC溶液7wt%、,自制的高温粘结剂为5wt%。
上述高温粘结剂由55wt%的钾长石和20wt%钠长石、2wt%的方解石、2wt%的烧滑石、2wt%的玻璃粉、5wt%的高岭土、10wt%的石英、4wt%的氧化锌组成。
3. 压制成型
按制品规格要求称取上述混合料A适量装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,再称取混合料B适量装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,最后再称取上述混合料C适量装入压制成型的钢制模具内,摊平,按预定的成型工艺参数进行压制成型,成型压力为5MPa,保压时间为15s,然后脱模,得到三明治结构形式的生坯。
4. 干燥
将上述生坯送入干燥器进行充分干燥,干燥温度按1℃/min,逐步从20℃升高至80℃,要注意避免升温太快或温度太高导致坯体变形或开裂。
5. 烧成
将上述充分干燥后的坯体送入隧道窑或梭式窑进行烧成,烧成温度为1320℃。升温速率为120℃/h。
按照国家标准GB/T 25993-2010《透水路面砖和透水路面板》要求的测试方法测试用上述配方和工艺方法制备的三明治结构海绵砖的透水系数为2.0×10-2cm/s,抗折强度为6.5MPa,吸水率为15.1%。
实施例三:
本实施例一种三明治结构海绵砖的制备方法,其步骤如下:
1. 制备颗粒料。
将煤矸石用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的煤矸石颗粒料;进一步过20目筛,分别得到8~20目的筛上料颗粒和20~40目的筛下料颗粒。
将陶瓷废品用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的废瓷颗粒料;进一步过20目筛,分别得到8~20目的筛上料颗粒和20~40目的筛下料颗粒。
2. 称料混合
将制备好的废瓷颗粒、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.7小时,使其混合均匀,得到混合料A。其中20~40目的煤矸石颗粒的含量为15wt%,20~40目的废瓷颗粒为85wt%,外加低温粘结剂浓度为10wt%的PVA溶液6.5wt%,自制的高温粘结剂为4.5wt%。
将制备好的煤矸石颗粒、废瓷颗粒、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.7小时,使其混合均匀,得到混合料B。其中8~20目的煤矸石颗粒的含量为70wt%,8~20目的废瓷颗粒为30wt%,外加低温粘结剂浓度为10wt%的PVA溶液8wt%、自制的高温粘结剂为5wt%。
将制备好的废瓷颗粒、着色剂、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.7小时,使其混合均匀,得到混合料C。其中8~20目的煤矸石颗粒的含量为15wt%,20~40目的废瓷颗粒为85wt%,外加着色剂包裹黄色料为4wt%,低温粘结剂浓度为10wt%的PVA溶液6.5wt%、,自制的高温粘结剂为4.5wt%。
上述高温粘结剂由85wt%的钾长石、1.5wt%的方解石、1wt%的烧滑石、0.5wt%的玻璃粉、4wt%的高岭土、6wt%的石英、2wt%的氧化锌组成。
3. 压制成型
按制品规格要求称取上述混合料A适量装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,再称取混合料B适量装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,最后再称取上述混合料C适量装入压制成型的钢制模具内,摊平,按预定的成型工艺参数进行压制成型,成型压力为5MPa,保压时间为15s,然后脱模,得到三明治结构形式的生坯。
4. 干燥
将上述生坯送入干燥器进行充分干燥,干燥温度按0.8℃/min,逐步从20℃升高至80℃,要注意避免升温太快或温度太高导致坯体变形或开裂。
5. 烧成
将上述充分干燥后的坯体送入隧道窑或梭式窑进行烧成,烧成温度为1260℃,升温速率为70℃/h。
按照国家标准GB/T 25993-2010《透水路面砖和透水路面板》要求的测试方法测试用上述配方和工艺方法制备的三明治结构海绵砖的透水系数为2.2×10-2cm/s,抗折强度为5.8MPa,吸水率为16.2%。
以上所述,仅为本发明在实验室或小规模生产时的较佳的具体实施方式,但本发明保护范围并不局限于此,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。例如大生产时的压制成型压力采用20~100MPa,混料时间为1~4小时,干燥温度为50~120℃,这些改变都是在本发明的合理范围。
Claims (5)
1.一种三明治结构煤矸石海绵砖的制备方法,其特征在于:采用煤矸石、废瓷、低温粘结剂、高温粘结剂、着色剂为原料,经制备颗粒料、混合配料、压制成型、干燥、烧成后获得海绵砖产品;
所述制备颗粒料工序步骤为:
步骤一:将煤矸石用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的煤矸石颗粒料;进一步过20目筛,分别得到8~20目的筛上煤矸石颗粒料和20~40目的筛下煤矸石颗粒料;
步骤二:将废瓷用颚式破碎机破碎,过8目筛,将筛下料再过40目筛,得到8~40目的废瓷颗粒料;进一步过20目筛,分别得到8~20目的筛上废瓷颗粒料和20~40目的筛下废瓷颗粒料;
所述混合配料工序步骤为:
步骤一:将制备好的煤矸石颗粒料、废瓷颗粒料、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.5~1小时,使其混合均匀,得到底层混合料A,其中20~40目煤矸石颗粒料的含量为0~30wt%、8~20目或20~40目废瓷颗粒料为70~100wt%,外加低温粘结剂为5~8wt%、高温粘结剂为3~6wt%;
步骤二:将制备好的煤矸石颗粒料、废瓷颗粒料、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.5~1小时,使其混合均匀,得到主体层混合料B;其中8~20目或20~40目煤矸石颗粒料的含量为60~80wt%、8~20目或20~40目的废瓷颗粒料为20~40 wt%,外加低温粘结剂为5~8wt%、高温粘结剂为3~6wt%;
步骤三:将制备好的煤矸石颗粒料、废瓷颗粒料、着色剂、低温粘结剂和高温粘结剂按配方比例准确称量,并在混料机中混合0.5~1小时,使其混合均匀,得到面层混合料C;其中20~40目的煤矸石颗粒料的含量为0~30wt%、8~20目或20~40目的废瓷颗粒料为70~100wt%,外加着色剂为1~5wt%、低温粘结剂为5~8wt%、高温粘结剂为3~6wt%;
所述压制成型工序步骤为:
按海绵砖产品性能参数要求加入一定量的底层混合料A装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,再加入一定量的主体层混合料B装入压制成型的钢制模具内,摊平,在液压成型机上施加1MPa压力进行轻压,最后加入一定量的面层混合料C装入压制成型的钢制模具内,摊平,按预定的成型工艺参数进行压制成型,成型压力为5MPa,保压时间为15s,然后脱模,得到三明治结构形式的海绵砖生坯;
所述烧成工序步骤为:将干燥后的海绵砖坯体送入隧道窑或梭式窑进行烧成,烧成温度为1200~1320℃,升温速率为30~120℃/h;
所述海绵砖产品的透水系数为2×10-2cm/s以上,抗折强度达到5MPa以上,吸水率高于15%。
2.根据权利要求1所述的制备方法,其特征在于,所述干燥工序步骤为:将海绵砖生坯送入干燥器内进行干燥,所述干燥温度按0.5~1℃/min,从20℃升高至80℃。
3.根据权利要求1所述的制备方法,其特征在于,所述低温粘结剂是水玻璃、2~4wt%的羧甲基纤维素钠水溶液、8~10wt%的聚乙烯醇水溶液中的任意一种。
4.根据权利要求1所述的制备方法,其特征在于,所述高温粘结剂由70~90wt%的钾长石或/和钠长石、1~2wt%的石灰石或方解石、1~2wt%的烧滑石、0.1~2wt%的玻璃粉、2~5wt%的高岭土、0~10wt%的石英、0~4wt%的氧化锌组成。
5.根据权利要求1所述的制备方法,其特征在于,所述着色剂是指含有过渡金属元素铬、铁、钴、锰的金属氧化物或不溶于水的盐类。
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