CN115403401B - Method for preparing foamed ceramic wallboard based on high-temperature jet process - Google Patents
Method for preparing foamed ceramic wallboard based on high-temperature jet process Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 63
- 239000000919 ceramic Substances 0.000 title claims abstract description 50
- 230000008569 process Effects 0.000 title claims abstract description 29
- 238000005187 foaming Methods 0.000 claims abstract description 47
- 238000000137 annealing Methods 0.000 claims abstract description 39
- 239000004088 foaming agent Substances 0.000 claims abstract description 19
- 239000002994 raw material Substances 0.000 claims abstract description 18
- 239000011230 binding agent Substances 0.000 claims abstract description 14
- 229910010293 ceramic material Inorganic materials 0.000 claims abstract description 13
- 238000002156 mixing Methods 0.000 claims abstract description 13
- 239000010802 sludge Substances 0.000 claims abstract description 13
- 238000003490 calendering Methods 0.000 claims abstract description 12
- 238000007493 shaping process Methods 0.000 claims abstract description 12
- 238000000227 grinding Methods 0.000 claims abstract description 10
- 230000001174 ascending effect Effects 0.000 claims abstract description 8
- 238000011049 filling Methods 0.000 claims abstract description 8
- 230000033001 locomotion Effects 0.000 claims abstract description 8
- 229910052751 metal Inorganic materials 0.000 claims abstract description 8
- 239000002184 metal Substances 0.000 claims abstract description 8
- 238000007664 blowing Methods 0.000 claims abstract description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 15
- 229910052710 silicon Inorganic materials 0.000 claims description 8
- 239000010703 silicon Substances 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 7
- 238000005453 pelletization Methods 0.000 claims description 7
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical group [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 7
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 7
- 235000006040 Prunus persica var persica Nutrition 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 5
- 229910021487 silica fume Inorganic materials 0.000 claims description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 4
- 239000006004 Quartz sand Substances 0.000 claims description 4
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 claims description 4
- 239000001768 carboxy methyl cellulose Substances 0.000 claims description 4
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 claims description 4
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 claims description 4
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 4
- 229910052742 iron Inorganic materials 0.000 claims description 2
- 240000006413 Prunus persica var. persica Species 0.000 claims 1
- 239000004115 Sodium Silicate Substances 0.000 claims 1
- 229910052911 sodium silicate Inorganic materials 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 18
- 238000011161 development Methods 0.000 abstract description 5
- 230000009286 beneficial effect Effects 0.000 abstract description 4
- 230000001737 promoting effect Effects 0.000 abstract description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 11
- 229910052796 boron Inorganic materials 0.000 description 11
- 239000002585 base Substances 0.000 description 8
- 239000008188 pellet Substances 0.000 description 6
- 238000005096 rolling process Methods 0.000 description 6
- 238000005192 partition Methods 0.000 description 5
- 239000000377 silicon dioxide Substances 0.000 description 5
- 235000012239 silicon dioxide Nutrition 0.000 description 5
- 238000005245 sintering Methods 0.000 description 5
- 244000144730 Amygdalus persica Species 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 4
- 229910021538 borax Inorganic materials 0.000 description 4
- 230000001105 regulatory effect Effects 0.000 description 4
- 239000004328 sodium tetraborate Substances 0.000 description 4
- 235000010339 sodium tetraborate Nutrition 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 3
- 235000019353 potassium silicate Nutrition 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 2
- 239000004327 boric acid Substances 0.000 description 2
- 229910052878 cordierite Inorganic materials 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 2
- 238000003912 environmental pollution Methods 0.000 description 2
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 239000003513 alkali Substances 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- QYHKLBKLFBZGAI-UHFFFAOYSA-N boron magnesium Chemical compound [B].[Mg] QYHKLBKLFBZGAI-UHFFFAOYSA-N 0.000 description 1
- 229910052810 boron oxide Inorganic materials 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 210000000497 foam cell Anatomy 0.000 description 1
- 238000005469 granulation Methods 0.000 description 1
- 230000003179 granulation Effects 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002910 solid waste Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
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- C04B33/00—Clay-wares
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Abstract
The invention relates to a method for preparing a foamed ceramic wallboard based on a high-temperature jet process, which comprises the following steps of S1, mixing ceramic basic raw materials including boric sludge, a foaming agent and a batch, and grinding and uniformly mixing; s2, adding a binder into the uniformly mixed ceramic basic raw materials to pelletize; s3, filling the balls into a high-temperature jet flow bin for preheating, vertically blowing the balls into a high-temperature shaft furnace by adopting air pressure, adjusting spiral air flow, and enabling the balls to perform spiral ascending movement for foaming; s4, freely falling the foamed hollow spheres into a metal rod die, carrying out calendaring and shaping, and carrying out precise annealing on the formed foamed ceramic material to obtain the light foamed ceramic wallboard. The method adopts a vertical foaming process and a die-free annealing process, solves the bottleneck problems of large floor area, large equipment investment and high production cost of the foaming ceramic material production line, and is beneficial to promoting the development of the foaming ceramic industry.
Description
Technical Field
The invention relates to a method for preparing a foamed ceramic wallboard based on a high-temperature jet process, and belongs to the technical field of comprehensive utilization of boron mud resources and foamed ceramic building materials.
Background
The boric sludge is waste residue produced in the production of boric acid, borax and other products, is off-white and yellow-white powdery solid, is alkaline, contains boron oxide, magnesium oxide and other components, and is commonly called as the boric sludge. The boron-magnesium resource reserves in the northeast area are rich, and the boric acid and borax productivity is always the first place in the world for many years. Generally, about 4-5 tons of boron mud is discharged from 1 ton of borax, only the Dandong wide puddle and Fengcheng zone are produced for many years, and the boron mud storage capacity is over 2000 ten thousand tons. The stockpiling treatment of the boric sludge not only occupies a large amount of land, but also can alkalize the soil near the stockyard and cause migration and conversion of boron, thereby causing environmental pollution. The boron mud has higher alkali content, can not be simply used as cement or concrete filler, and the problem of comprehensive utilization of boron mud resources has increasingly obvious influence on the healthy development of borax industry.
The foamed ceramic wallboard is a novel and assembled inner partition wall slat material for buildings, which is prepared by taking a large amount of industrial solid waste as a main raw material and sintering and foaming at high temperature and has excellent performance. The traditional production process of the foamed ceramic wallboard mainly adopts a roller kiln and tunnel kiln horizontal sintering process, ceramic powder is required to be filled into a die for uniform sintering in the production process, the die consumption in the production process is huge, and the production cost is high. In addition, because the foamed ceramic material needs to be precisely annealed, the annealing process with a die is difficult to control, the occupied area of production equipment is large, the investment is high, and the development of the foamed ceramic material industry is greatly inhibited.
Disclosure of Invention
First, the technical problem to be solved
In order to solve the problems in the prior art, the invention provides a method for preparing a foamed ceramic wallboard based on a high-temperature jet process.
(II) technical scheme
In order to achieve the above purpose, the main technical scheme adopted by the invention comprises the following steps:
a method for preparing a foamed ceramic wallboard based on a high-temperature jet process comprises the following steps:
s1, weighing and mixing ceramic basic raw materials including boric sludge, foaming agent and batch, and grinding and uniformly mixing by adopting a vertical Raymond mill;
s2, adding a binder into the uniformly mixed ceramic basic raw materials, and pelletizing by adopting a roll disc method;
s3, filling the balls into a high-temperature jet flow bin for preheating, vertically blowing the balls into a high-temperature shaft furnace by adopting air pressure, adjusting spiral air flow, and enabling the balls to perform spiral ascending movement for foaming;
s4, freely falling the foamed hollow ball into a 310S metal rod die, and carrying out calendaring and shaping;
s5, sending the formed foamed ceramic material into a mesh belt annealing furnace for precise annealing to obtain the light foamed ceramic wallboard.
In the above method, preferably, in step S1, the boron mud is 10 to 30 parts by weight, the foaming agent is 0.5 to 5 parts by weight, and the batch is 70 to 90 parts by weight.
In the method described above, preferably, the foaming agent is silicon carbide, the batch is a high silicon component, and the high silicon component is any one or a mixture of any one of silica fume, quartz sand and high silicon iron tailings, wherein the high silicon refers to the content of silicon dioxide is more than or equal to 85%.
In the above method, in step S1, the time for grinding and mixing is preferably 30 to 80 minutes.
In the method as described above, preferably, in step S2, the binder is one or a mixture of several of peach gum, sodium carboxymethyl cellulose, and water glass.
In the method as described above, preferably, in step S2, the binder is added in an amount of 5 to 15% by weight of the ceramic base material.
In the method described above, preferably, in step S2, the pellet diameter of the pellet is 5mm or less.
In the above method, preferably, in step S3, the preheating temperature is 600 to 800 ℃ and the preheating time is 30 to 60 minutes.
In the above method, preferably, in step S3, the foaming temperature is 1000 to 1200 ℃ and the foaming time is 30 to 60 minutes.
In the above-described method, preferably, in step S4, the temperature of the calendaring and shaping is controlled to be 700 to 1100 ℃.
In the above method, preferably, in step S5, the maximum temperature of the annealing is up to 680 ℃, the annealing time is 30-120 min,680 ℃ is reduced to 100 ℃, and the annealing time is 10h.
(III) beneficial effects
The beneficial effects of the invention are as follows:
according to the method for preparing the foamed ceramic wallboard based on the high-temperature jet process, the high-temperature jet process and the vertical sintering process are adopted, the foaming process is completed in a free falling stage in a high-temperature thermal field, the thermal efficiency is greatly improved, the forming mode adopts a calendaring process, the dimensional accuracy is high, secondary cutting processing is not needed, the production cost of the foamed ceramic material can be greatly reduced, and the healthy and rapid development of the industry is promoted; meanwhile, a brand new utilization way is found for the boric sludge, the environmental pollution problem of the boric sludge discharge area is favorably solved, and the obtained foamed ceramic has the advantages of light weight, high strength, fire resistance, heat preservation, stability, durability, excellent water resistance, moisture resistance and mildew resistance, and is especially applied to an outer wall body. The method adopts a vertical foaming process and a die-free annealing process, solves the bottleneck problems of large floor area, large equipment investment and high production cost of the foaming ceramic material production line, and is beneficial to promoting the development of the foaming ceramic industry.
Drawings
FIG. 1 is a flow chart of the method of the present invention;
Detailed Description
theinventionprincipleisamethodforpreparingafoamedceramicwallboardbasedonahigh-temperaturejetprocess,whichcomprisesthestepsoffirstlyaddingafoamingagentandabatchintobulkindustrialsolidwastesuchasboricsludge,designingaformulaaccordingtoapresetbatchpointofaC-M-A-Ssystemproject,ensuringthatthemeltingtemperatureoftheformulacomponentsandthedecompositiontemperatureofthefoamingagentarebothinarangeof1050-1150℃,andensuringthattheconsistencyoftheformulacomponentsatthemeltingtemperatureisexactlysuitableforfoamingtoobtainaceramicbasicrawmaterial. And adding a binder into the ceramic base raw material, and performing high-temperature spray jet. And the ceramic basic raw material after jet flow freely falls under the high-temperature thermal field condition, foaming and crystal growth processes are completed in the falling process, the grown ceramic porous hollow spheres fall into a die, and then the rolling shaping and annealing processes are carried out, so that the light foamed ceramic wallboard is obtained.
The traditional process is that the raw materials are uniformly mixed and then are placed in a cordierite mold, and the cordierite mold is sintered by adopting a tunnel kiln or a roller kiln, so that the mold is heavier and can absorb much heat, and the tunnel kiln and the roller kiln have low heat efficiency and excessive investment, so that the production cost of the product is too high to be approved by the market. The invention combines the production experience of more than ten years, combines the spray granulation process and the steel rolling process, has no mould in the foaming process, has no restraint foaming in the air, adopts the similar rolling mode of steel rolling in the forming process, does not need cutting processing any more, has no leftover materials, and has low cost. And the equipment investment and the occupied area of the process are also much smaller than those of other current processes. The traditional foaming ceramic forming process is cutting and grinding after complete sintering, the wear is particularly large, the direct production cost of the foaming ceramic partition board is 700-800 yuan/cubic meter, and the direct production cost of the method is below 300 yuan/cubic meter, so that the cost is greatly reduced. The invention provides a method for preparing a foamed ceramic wallboard based on a high-temperature jet process, which is shown in figure 1 and comprises the following steps:
s1, mixing ceramic basic raw materials including boric sludge, a foaming agent and a batch, and grinding and uniformly mixing;
s2, adding a binder into the uniformly mixed ceramic basic raw material to pelletize, wherein the pelletization diameter is less than or equal to 5mm;
s3, filling the balls into a high-temperature jet flow bin for preheating, vertically blowing the balls into a high-temperature shaft furnace by adopting air pressure, adjusting spiral air flow, and enabling the balls to perform spiral ascending movement for foaming;
s4, the hollow ball after foaming freely falls into a metal rod die, and is rolled and shaped,
and S5, precisely annealing the formed foamed ceramic material to obtain the light foamed ceramic wallboard.
Preferably, in step S1, the weight portion of the boric sludge is 10-30 parts, the weight portion of the foaming agent is 0.5-5 parts, the weight portion of the batch is 70-90 parts, the foaming agent is silicon carbide, the batch is high silicon component such as silica fume, quartz sand, high silicon iron tailings and the like, and the grinding and mixing time is 30-80 minutes.
Preferably, in the step S2, the binder is one or a mixture of more than one of peach gum, sodium carboxymethyl cellulose and water glass, the addition amount of the binder is 5-15% of the ceramic base raw material, and the diameter of the ball after pelletizing is 1-5 mm.
Preferably, in step S3, the preheating temperature is 600-800 ℃ and the preheating time is 30-60 min; the foaming temperature is 1000-1200 ℃, and the foaming time is 30-60 min.
Preferably, in step S4, the temperature of the calendaring and shaping is controlled to be 700-1100 ℃.
Preferably, in step S5, the highest temperature of the annealing is up to 680 ℃, the annealing time is 30-120 min,680 ℃ is reduced to 100 ℃, and the annealing time is 10h.
thebatchinthemethodisdesignedstrictlyaccordingtotheC-M-A-Sphasediagram,otherwise,thebatchcannotbefoamed; the binder is generally added according to the material property of the batch, if too little, the binder cannot be balled, and if too much, the economical efficiency is poor; the amount of binder added is preferably 5 to 15% of the ceramic base material.
Proved by a large number of experimental researches, the foaming unevenness can be caused by the too low preheating temperature in the method, the product with the too high preheating temperature can be foamed to a certain extent, and the condition of overburning of the finished product can occur; too much burning can occur when the preheating time is long, and uneven foaming can occur when the preheating time is short; therefore, the preheating temperature is preferably 600 to 800 ℃, and the preheating time is preferably 30 to 60 minutes. The foaming temperature is controlled according to the decomposition temperature of the foaming agent and the state of the melt, the foaming temperature is low, foam cells cannot be formed, and the product is over-burned due to the fact that the foaming temperature is too high; the foaming temperature is preferably 1000 to 1200 ℃.
The temperature of the rolling in the method of the invention must be controlled above 700 ℃, and after the temperature is low, the product is solidified, so that the rolling is not realized. The roller is damaged when the temperature is too high, and the product can be foamed continuously when the temperature is high, so that the regular size cannot be obtained; therefore, the temperature of the calendaring and shaping is preferably 700-1100 ℃. If the highest temperature of annealing is not reached to 680 ℃, the annealing time is 30-120 min, the 680 ℃ is reduced to 100 ℃ and the annealing time is 10h, the annealing process controls annealing to generate quartz crystal form transformation, so that the volume expansion is caused, and the residual stress in the product is overlarge due to the volume expansion, so that the product is burst.
The present invention will be described in detail below with reference to specific embodiments for better explaining the present invention.
Example 1
Preparing ceramic basic raw materials by adopting a vertical Raymond mill to prepare boron mud, a foaming agent and a batch according to parts by weight: boron mud: 30 parts of foaming agent adopts silicon carbide: 5 parts of silica fume (the content of silicon dioxide is 93 percent) is adopted as the batch material: 65 parts of the components are ground and mixed uniformly for 60min; and then 10 weight percent of peach gum is added into the uniformly mixed ceramic base raw material, and the mixture is pelletized by adopting a roll disc method, wherein the diameter of the pellets is less than or equal to 5mm. Filling the balls into a high-temperature jet flow bin for preheating, wherein the preheating temperature is 800 ℃, the preheating time is 30-60min, air pressure is adopted to vertically blow into a high-temperature shaft furnace, and spiral air flow is regulated to enable the balls to perform spiral ascending motion for foaming, the foaming temperature is 1150 ℃, and the foaming time is 30-60 min. The hollow ball after foaming falls into a 310s metal rod die freely, and is subjected to calendaring and shaping, wherein the calendaring and shaping temperature is 1000 ℃. And (3) feeding the formed foamed ceramic material into a mesh belt annealing furnace for precise annealing, wherein the highest temperature is up to 680 ℃, the annealing time is 120min, the 680 ℃ is reduced to 100 ℃, and the annealing time is 10h, so that the foamed ceramic wallboard is obtained.
Example 2
Adopting a vertical Raymond mill to mix boron mud, a foaming agent and a batch according to parts by weight: 20. the foaming agent adopts silicon carbide: 5 parts of silica fume (content of silica is 93%): 75. grinding and uniformly mixing for 60min; and then adding 10 weight percent of peach gum into the uniformly mixed ceramic base raw material, pelletizing by adopting a roll disc method, wherein the diameter of the pellets is less than or equal to 5mm. Filling the balls into a high-temperature jet flow bin for preheating, wherein the preheating temperature is 600 ℃, the preheating time is 30min, air pressure is adopted to vertically blow into a high-temperature shaft furnace, and spiral air flow is regulated to enable the balls to do spiral ascending motion for foaming, the foaming temperature is 1200 ℃, and the foaming time is 45min. The hollow ball after foaming falls into a 310s metal rod die freely, and is subjected to calendaring and shaping at the temperature of 1000 ℃. And (3) feeding the formed foamed ceramic material into a mesh belt annealing furnace for precise annealing, wherein the highest temperature is up to 680 ℃, the annealing time is 120min, the 680 ℃ is reduced to 100 ℃, and the annealing time is 10h, so that the foamed ceramic wallboard is obtained.
Example 3
Adopting a vertical Raymond mill to mix boron mud, a foaming agent and a batch according to parts by weight: 15. the foaming agent adopts silicon carbide: 5 parts of quartz sand (the content of silicon dioxide is 88%): 80. grinding and uniformly mixing for 60min; and then adding 10 weight percent of sodium carboxymethylcellulose into the uniformly mixed ceramic base raw material, and pelletizing by adopting a roll disc method, wherein the diameter of the pellets is less than or equal to 5mm. Filling the balls into a high-temperature jet flow bin for preheating, wherein the preheating temperature is 600 ℃, the preheating time is 60min, air pressure is adopted to vertically blow into a high-temperature shaft furnace, and spiral air flow is regulated to enable the balls to do spiral ascending motion for foaming, and the foaming temperature is 1100 ℃, and the foaming time is 30min. The hollow ball after foaming falls into a 310s metal rod die freely, and is subjected to calendaring and shaping at the temperature of 1000 ℃. And (3) feeding the formed foamed ceramic material into a mesh belt annealing furnace for precise annealing, wherein the highest temperature is up to 680 ℃, the annealing time is 120min, the 680 ℃ is reduced to 100 ℃, and the annealing time is 10h, so that the foamed ceramic wallboard is obtained.
Example 4
Adopting a vertical Raymond mill to mix boric sludge, a foaming agent and a batch according to the weight percentage of the boric sludge: 20. the foaming agent adopts silicon carbide: 5 parts of high-silicon iron tailings (the silicon dioxide content of which is 85 percent): 75 parts of the components are ground and mixed uniformly for 60min; and adding 10 weight percent of water glass into the uniformly mixed ceramic base raw materials, and pelletizing by adopting a roll disc method, wherein the diameter of the pellets is less than or equal to 5mm. Filling the balls into a high-temperature jet flow bin for preheating, wherein the preheating temperature is 600 ℃, the preheating time is 50min, air pressure is adopted to vertically blow into a high-temperature shaft furnace, and spiral air flow is regulated to enable the balls to do spiral ascending motion for foaming, the foaming temperature is 1150 ℃, and the foaming time is 50min. The hollow ball after foaming falls into a 310s metal rod die freely, and is subjected to calendaring and shaping at the temperature of 1000 ℃. And (3) feeding the formed foamed ceramic material into a mesh belt annealing furnace for precise annealing, wherein the highest temperature is up to 680 ℃, the annealing time is 120min, the 680 ℃ is reduced to 100 ℃, and the annealing time is 10h, so that the foamed ceramic wallboard is obtained.
The performance parameters of the foamed ceramic wallboard prepared in the above example were tested according to GB/T23451-2009, and the test results are shown in Table 1 below.
TABLE 1
From the above, the foamed ceramic partition board prepared by the method meets the requirements of the current standard, but the direct production cost of the foamed ceramic partition board prepared in the prior art is 700-800 yuan/cubic meter, and the direct production cost of the foamed ceramic partition board is below 300 yuan/cubic meter, so that the production cost is greatly reduced.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and any person skilled in the art may make modifications or alterations to the above disclosed technical content to equivalent embodiments. However, any simple modification, equivalent variation and variation of the above embodiments according to the technical substance of the present invention still fall within the protection scope of the technical solution of the present invention.
Claims (4)
1. The method for preparing the foamed ceramic wallboard based on the high-temperature jet process is characterized by comprising the following steps of:
s1, mixing ceramic basic raw materials including boric sludge, a foaming agent and a batch, and grinding and uniformly mixing;
s2, adding a binder into the uniformly mixed ceramic basic raw materials to pelletize;
s3, filling the balls into a high-temperature jet flow bin for preheating, vertically blowing the balls into a high-temperature shaft furnace by adopting air pressure, adjusting spiral air flow, and enabling the balls to perform spiral ascending movement for foaming;
s4, the hollow ball after foaming freely falls into a metal rod die, and is rolled and shaped,
s5, precisely annealing the formed foamed ceramic material;
in the step S1, 10-30 parts by weight of boric sludge, 0.5-5 parts by weight of foaming agent and 70-90 parts by weight of batch; the foaming agent is silicon carbide, the batch is high-silicon component, and the high-silicon component is any one or a mixture of more of silica fume, quartz sand and high-silicon iron tailings;
in the step S2, the binder is one or more of peach gum, sodium carboxymethyl cellulose and sodium silicate;
in the step S3, the preheating temperature is 600-800 ℃, and the preheating time is 30-60 min; the foaming temperature is 1000-1200 ℃ and the foaming time is 30-60 min;
in the step S4, the temperature of calendaring and shaping is controlled to be 700-1100 ℃;
in the step S5, the highest temperature of the annealing is up to 680 ℃, the annealing time is 30-120 min,680 ℃ is reduced to 100 ℃, and the annealing time is 10h.
2. The method according to claim 1, wherein in step S1, the time for grinding and mixing is 30 to 80 minutes.
3. The method according to claim 1, wherein the binder is added in an amount of 5 to 15% by weight of the ceramic base material in step S2.
4. A method according to claim 1, wherein in step S2, the diameter of the balls after pelletizing is 1-5 mm.
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