AU2020101723A4 - Foamed ceramics and preparation method thereof - Google Patents
Foamed ceramics and preparation method thereof Download PDFInfo
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- AU2020101723A4 AU2020101723A4 AU2020101723A AU2020101723A AU2020101723A4 AU 2020101723 A4 AU2020101723 A4 AU 2020101723A4 AU 2020101723 A AU2020101723 A AU 2020101723A AU 2020101723 A AU2020101723 A AU 2020101723A AU 2020101723 A4 AU2020101723 A4 AU 2020101723A4
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- 239000000919 ceramic Substances 0.000 title claims abstract description 77
- 238000002360 preparation method Methods 0.000 title claims description 8
- 239000002994 raw material Substances 0.000 claims abstract description 66
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 64
- 239000002002 slurry Substances 0.000 claims abstract description 38
- 238000001035 drying Methods 0.000 claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 22
- 238000005245 sintering Methods 0.000 claims abstract description 21
- 238000000227 grinding Methods 0.000 claims abstract description 20
- 238000002156 mixing Methods 0.000 claims abstract description 20
- 238000005187 foaming Methods 0.000 claims abstract description 14
- 239000000843 powder Substances 0.000 claims abstract description 14
- 239000007787 solid Substances 0.000 claims abstract description 13
- 238000001238 wet grinding Methods 0.000 claims abstract description 13
- 238000010791 quenching Methods 0.000 claims abstract description 3
- 239000000440 bentonite Substances 0.000 claims description 46
- 229910000278 bentonite Inorganic materials 0.000 claims description 46
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 46
- 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 description 28
- 239000005995 Aluminium silicate Substances 0.000 claims description 26
- 235000012211 aluminium silicate Nutrition 0.000 claims description 26
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 20
- 239000010931 gold Substances 0.000 claims description 20
- 229910052737 gold Inorganic materials 0.000 claims description 20
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 16
- 239000000203 mixture Substances 0.000 claims description 14
- 239000000454 talc Substances 0.000 claims description 14
- 229910052623 talc Inorganic materials 0.000 claims description 14
- 229910021532 Calcite Inorganic materials 0.000 claims description 12
- 239000003638 chemical reducing agent Substances 0.000 claims description 12
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 12
- 229910052681 coesite Inorganic materials 0.000 claims description 8
- 229910052906 cristobalite Inorganic materials 0.000 claims description 8
- 239000000377 silicon dioxide Substances 0.000 claims description 8
- 235000012239 silicon dioxide Nutrition 0.000 claims description 8
- 229910052682 stishovite Inorganic materials 0.000 claims description 8
- 229910052905 tridymite Inorganic materials 0.000 claims description 8
- 238000000967 suction filtration Methods 0.000 abstract description 11
- 239000004566 building material Substances 0.000 abstract description 2
- 238000011049 filling Methods 0.000 abstract 1
- 230000000052 comparative effect Effects 0.000 description 29
- 239000011449 brick Substances 0.000 description 10
- 239000006260 foam Substances 0.000 description 10
- 239000002245 particle Substances 0.000 description 10
- 238000005096 rolling process Methods 0.000 description 10
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 9
- 229910052901 montmorillonite Inorganic materials 0.000 description 9
- 150000001768 cations Chemical class 0.000 description 8
- 230000000694 effects Effects 0.000 description 8
- 238000009413 insulation Methods 0.000 description 7
- 229910052500 inorganic mineral Inorganic materials 0.000 description 6
- 239000011707 mineral Substances 0.000 description 6
- 239000010410 layer Substances 0.000 description 5
- 239000013078 crystal Substances 0.000 description 4
- 238000005342 ion exchange Methods 0.000 description 4
- 239000011148 porous material Substances 0.000 description 4
- 230000007423 decrease Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
- YAIQCYZCSGLAAN-UHFFFAOYSA-N [Si+4].[O-2].[Al+3] Chemical compound [Si+4].[O-2].[Al+3] YAIQCYZCSGLAAN-UHFFFAOYSA-N 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 229910000323 aluminium silicate Inorganic materials 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000002734 clay mineral Substances 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 2
- 239000011229 interlayer Substances 0.000 description 2
- 229910052622 kaolinite Inorganic materials 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 229910052700 potassium Inorganic materials 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 239000002910 solid waste Substances 0.000 description 2
- 230000002195 synergetic effect Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 239000004604 Blowing Agent Substances 0.000 description 1
- AFCARXCZXQIEQB-UHFFFAOYSA-N N-[3-oxo-3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)propyl]-2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidine-5-carboxamide Chemical compound O=C(CCNC(=O)C=1C=NC(=NC=1)NCC1=CC(=CC=C1)OC(F)(F)F)N1CC2=C(CC1)NN=N2 AFCARXCZXQIEQB-UHFFFAOYSA-N 0.000 description 1
- OBNDGIHQAIXEAO-UHFFFAOYSA-N [O].[Si] Chemical compound [O].[Si] OBNDGIHQAIXEAO-UHFFFAOYSA-N 0.000 description 1
- 239000004480 active ingredient Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 229910000272 alkali metal oxide Inorganic materials 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000007900 aqueous suspension Substances 0.000 description 1
- 238000000498 ball milling Methods 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910001423 beryllium ion Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- 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
- C04B38/0038—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by superficial sintering or bonding of particulate matter
- C04B38/0041—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by superficial sintering or bonding of particulate matter the particulate matter having preselected particle sizes
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62204—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
- C04B2235/3208—Calcium oxide or oxide-forming salts thereof, e.g. lime
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
- C04B2235/661—Multi-step sintering
- C04B2235/662—Annealing after sintering
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- 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
- C04B38/0067—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the density of the end product
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Inorganic Chemistry (AREA)
- Compositions Of Oxide Ceramics (AREA)
Abstract
The present invention relates to the field of building materials, and specifically provides a
method for preparing foamed ceramics, which includes the following steps: selecting raw
materials; grinding and mixing the raw materials: grinding the above-mentioned raw
materials and after adding water, wet grinding is performed to obtain a slurry; suction
filtration drying which is to filter out the moisture in the slurry to make it into a solid
compact, and drying to obtain a green body; billet filling which is to make the green body
into powder, pour the powdery billet into the mold; high temperature sintering that is to
place the mold with the billet in an electric furnace, adjust the foaming temperature at 1170
1200°C, hold for 60-90 minutes, and then quench it to 900°C-1000°C, and then cool it to
make foamed ceramics.
-1/3
Figure 1
Description
-1/3
Figure 1
PATENTS ACT 1990
Foamed ceramics and preparation method thereof
The invention is described in the following statement:-
Foamed ceramics and preparation method thereof
The invention relates to the field of green building materials, in particular to a foamed
ceramic and a preparation method thereof.
As a secondary resource with the largest amount of bulk solid waste and a low utilization
rate, tailings are an urgent resource utilization problem in my country. A large amount of
piled tailings occupies the land area, affects the water, soil, vegetation and ecological
environment of the mining area, and there are certain safety hazards such as collapse and
landslides. Foamed ceramic is a kind of building fireproof and thermal insulation material
with high porosity. With its light weight and thin body, heat and sound insulation,
moisture and fire resistance, high strength, good cold and heat stability, etc., it can be
used in exterior wall insulation, building interior partitions, fire barriers, etc. Its main raw
materials are silicon aluminum oxide and some alkali metal oxides and blowing agents.
According to its chemical composition characteristics, we can use gold tailings to replace
silicon aluminum oxide raw materials. In this way, the secondary utilization of tailings
resources can be realized, the resource utilization rate can be improved, and the stability
of foamed ceramics can also be enhanced. The use of gold tailings to prepare foamed
ceramic products can increase the utilization rate of tailings and the added value of the
product, thereby realizing the recycling and efficient use of mineral resources. However,
in view of the characteristics of gold tailings, the current use of gold tailings to prepare foamed ceramics has the problems of complex technology, long sintering time and high sintering temperature. In addition, the prepared foamed ceramic has the problems of low strength, heavy weight, and poor heat insulation effect.
The present invention solves the above-mentioned technical problems in the related art at
least to a certain extent. Therefore, the present invention proposes a foamed ceramic and
a preparation method thereof. On the one hand, when a large amount of gold tailings are
mixed, the sintering time is greatly shortened, the sintering temperature is lowered and
energy is saved. On the other hand, foamed ceramics with light weight, high strength and
good heat insulation effect are obtained.
In order to achieve the above objective, the first aspect of the present invention provides a
method for preparing foamed ceramics, which includes the following steps:
Selection of raw materials. In parts by weight, gold tailings are 55-80 parts, bentonite are
-20 parts, kaolin are 5-10 parts, talc are5-10 parts, calcite are 0-5 parts, silicon carbide
powder are 0.4-1.2 parts, water reducing agent are 0.4-1.2 parts;
Grinding and mixing of raw materials. Grind the above-mentioned raw materials, add
water and perform wet grinding to obtain slurry;
Suction drying. Filter out the moisture in the slurry to make it into a solid compact, and
obtain a green body after drying;
Load the billet into the mold. The green body is made into powder, and the powdered
billet is poured into the mold;
High-temperature sintering. Place the mold with the billet in an electric furnace, adjust
the foaming temperature at 1170°C-1200°C, keep it for 60-90min, then quench it to
900°C-1000C, and then cool it to make foamed ceramics.
The second aspect of the present invention provides a foamed ceramic prepared by the
above method.
In addition, the above-mentioned foamed ceramic preparation method according to the
present invention may also have the following additional technical features:
According to an embodiment of the present invention, the step of adjusting the foaming
temperature includes:
First, at room temperature, the temperature is raised to 300 0 C for 30 minutes, then to
600 0C for 60 minutes, then to 1030°C for 60 minutes, and finally to1170-1200 0 C for 30
minutes.
According to an embodiment of the present invention, the gold tailings include the
following components- by weight, 75-80 parts of SiO2, 9-13 parts of Al203, 2-6 parts of
K20, 0-1 parts of MgO, 0-1 parts of Na20 , 1-4 parts of Fe203 and 1-3 parts of CaO.
According to an embodiment of the present invention, the bentonite includes the
following components- in parts by weight, 68-72 parts of SiO2, 13-17 parts of Al203, 1-4
parts of K20, 1-3 parts of MgO, 0-1 parts of Na20, 1-3 parts of Fe203, 1-3 parts of CaO.
According to an embodiment of the present invention, the kaolin includes the following
components- by weight, 68-72 parts of SiO2, 13-17 parts of Al203, 2-6 parts of K20, 0-1
parts of MgO, 0-1 parts of Na20, 1-3 parts of Fe203, 0-1 parts of CaO.
According to an embodiment of the present invention, the talc includes the following
components- by weight, 15-20 parts of SiO2, 35-45 parts of MgO, 0-1 parts of A1203, 0-1
parts of K20, 0-1 parts of Na20, 0-1 parts of Fe203, 0-1 parts of CaO.
According to an embodiment of the present invention, in the step of grinding and mixing
the raw materials, after adding water, the water content of the mixture is 40%-50%.
According to an embodiment of the present invention, the mass ratio of the bentonite to
the kaolin is 2:1.
According to an embodiment of the present invention, the compressive strength of the
foamed ceramic is 7.0-7.6 MPa, the bulk density is 390.6-407.8 kg/m3 , and the thermal
conductivity is 0.067-0.068 W/(m-k).
Compared with the prior art, the present invention has the following beneficial effects:
1. Incorporating a large amount of gold tailings to improve the solid waste utilization rate.
2. By mixing proper amount of bentonite, the sintering time is shortened and energy is
saved; specifically, bentonite is a non-metallic mineral with montmorillonite as the main
mineral component. Montmorillonite will swell strongly when exposed to water and has strong water absorption. Montmorillonite is a 2:1 type clay mineral. It is composed of two silicon-oxygen tetrahedral sheet and an aluminum oxide octahedral sheet to form a structural unit layer. The sinterability of bentonite can increase the plasticity, bending resistance and strength of ceramics of ceramics, make products less prone to cracking and help reduce sintering time and energy consumption. In addition, the suspension and stability are greatly enhanced, so that the water suspension is stabilized in the paste, and at the same time, it can be used as a thickener to improve the viscosity of the raw material.
The incorporation of bentonite facilitates ball milling and has a lubricating effect during
the grinding process.
3. The mass ratio of bentonite to kaolin in this embodiment is 2:1, and ion exchange can
be carried out between bentonite and kaolin, which has a synergistic effect on the
performance of foamed ceramics. Specifically, Kaolin is a kind of water-containing
aluminosilicate, which is a triclinic crystal system, and there are no cations or water
molecules between the structural layers. Bentonite is a non-metallic mineral with
montmorillonite as the main mineral component. Montmorillonite, also known as
microcrystalline kaolinite, is a layered structure and plate-like crystalline silicate clay
mineral in monoclinic crystal system. There are cations or water molecules between the
structural layers. The cations of the interlayer structure such as Cu, Mg, Na, K, etc. are
easily exchanged by other cations, thus realizing the ion exchange between the two.
4. This application greatly reduces the foaming temperature.
5. The foamed ceramic prepared by the preparation method of the present application has
excellent properties of high strength, light weight and good heat insulation effect.
By reading the detailed description of the preferred embodiments below, various other
advantages and benefits will become clear to those of ordinary skill in the art. The
drawings are only used for the purpose of illustrating the preferred embodiments, and are
not considered as a limitation to the present invention. Also, throughout the drawings, the
same reference symbols are used to denote the same components. In the attached picture:
Figure 1 is a cross-sectional photograph of the foamed ceramic prepared in Examples 1-4;
Figure 2 is a cross-sectional photograph of the foamed ceramic prepared in Comparative
Example 1-2.
Figure 3 is a cross-sectional photograph of the foamed ceramic prepared in Comparative
Examples 3-5.
Hereinafter, exemplary embodiments of the present disclosure will be described in more
detail with reference to the accompanying drawings. Although the drawings show
exemplary embodiments of the present disclosure, it should be understood that the
present disclosure can be implemented in various forms and should not be limited by the
embodiments set forth herein. On the contrary, these embodiments are provided to enable
a more thorough understanding of the present disclosure and to fully convey the scope of
the present disclosure to those skilled in the art.
Example 1
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 58 parts of gold
tailings, 20 parts of bentonite, 9 parts of kaolin, 9 parts of talc, 4 parts of calcite, 0.4 parts
of silicon carbide powder and 0.4 parts of water reducing agent;
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh
with a rapid sample maker for 4 minutes, add water to make the water content of the
slurry be 42%, and use a planetary ball mill for wet grinding for 4 hours to obtain the
slurry. Mix the raw materials thoroughly;
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 10.5 hours to
obtain a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10cm
mold, wrap the mold with release paper around, and spread the powdered green body in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1175°C for 30 minutes. After holding for 60 min, it
is rapidly cooled to 900 °C and then cooled in the furnace.
Example 2
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 65 parts of gold
tailings, 17 parts of bentonite, 9 parts of kaolin, 9 parts of talc, 0 part of calcite, 0.9 parts of silicon carbide powder and 0.9 parts of water reducing agent;
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh
with a rapid sample maker for 4 minutes, add water to make the water content of the
slurry be 42%, and use a planetary ball mill for wet grinding for 6 hours to obtain the
slurry. Mix the raw materials thoroughly;
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 12 hours to obtain
a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10cm
mold, wrap the mold with release paper around, and spread the powdered green body in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1190°C for 30 minutes. After holding for 65 min, it
is rapidly cooled to 900 °C and then cooled in the furnace.
Example 3
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 70 parts of gold
tailings, 14 parts of bentonite, 6 parts of kaolin, 6 parts of talc, 4 part of calcite, 0.9 parts
of silicon carbide powder and 0.9 parts of water reducing agent. The raw materials used
are the same as those in embodiment 1;
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh with a rapid sample maker for 4 minutes, add water to make the water content of the slurry be 46%, and use a planetary ball mill for wet grinding for 5.5 hours to obtain the slurry. Mix the raw materials thoroughly;
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 12 hours to obtain
a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10cm
mold, wrap the mold with release paper around, and spread the powdered green body in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1185°C for 30 minutes. After holding for 75 min, it
is rapidly cooled to 900 °C and then cooled in the furnace.
Example 4
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 78 parts of gold
tailings, 12 parts of bentonite, 5 parts of kaolin, 5 parts of talc, 0 part of calcite, 1.2 parts
of silicon carbide powder and 1.2 parts of water reducing agent.
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh
with a rapid sample maker for 4 minutes, add water to make the water content of the
slurry be 46%, and use a planetary ball mill for wet grinding for 6 hours to obtain the
slurry. Mix the raw materials thoroughly;
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 12 hours to obtain
a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10
cm mold, wrap the mold with release paper around, and spread the powdered green body
in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1190°C for 30 minutes. After holding for 65 min, it
is rapidly cooled to 900 °C and then cooled in the furnace.
In order to verify the influence of bentonite on sintering time, foaming temperature and
bentonite content on the properties of foamed ceramics, the following pairs of
comparative examples are set in the application.
Comparative example 1
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 76 parts of gold
tailings, 0 parts of bentonite, 10 parts of kaolin, 10 parts of talc, 4 part of calcite, 1 part of
silicon carbide powder and 1 part of water reducing agent.
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh
with a rapid sample maker for 4 minutes, add water to make the water content of the
slurry be 46%, and use a planetary ball mill for wet grinding for 6.5 hours to obtain the slurry. Mix the raw materials thoroughly;
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 12 hours to obtain
a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10
cm mold, wrap the mold with release paper around, and spread the powdered green body
in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1185°C for 30 minutes. After holding for 100 min,
it is rapidly cooled to 900 °C and then cooled in the furnace.
Comparative example 2
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 65 parts of gold
tailings, 17 parts of bentonite, 9 parts of kaolin, 9 parts of talc, 0 parts of calcite, 0.9 parts
of silicon carbide powder and 0.9 parts of water reducing agent. The number of materials
used is the same as that in embodiment 2;
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh
with a rapid sample maker for 4 minutes, add water to make the water content of the
slurry be 42%, and use a planetary ball mill for wet grinding for 6 hours to obtain the
slurry. Mix the raw materials thoroughly;
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 12 hours to obtain
a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10cm
mold, wrap the mold with release paper around, and spread the powdered green body in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1165°C for 30 minutes. After holding for 60 min, it
is rapidly cooled to 900 °C and then cooled in the furnace.
Comparative example 3
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 65 parts of gold
tailings, 17 parts of bentonite, 9 parts of kaolin, 9 parts of talc, 0 parts of calcite, 0.9 parts
of silicon carbide powder and 0.9 parts of water reducing agent. The number of material
used is the same as that in embodiment 2;
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh
with a rapid sample maker for 4 minutes, add water to make the water content of the
slurry be 42%, and use a planetary ball mill for wet grinding for 6 hours to obtain the
slurry. Mix the raw materials thoroughly.
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 12 hours to obtain a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10cm
mold, wrap the mold with release paper around, and spread the powdered green body in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1205°C for 30 minutes. After holding for 60 min, it
is rapidly cooled to 900 °C and then cooled in the furnace.
Comparative example 4
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 65 parts of gold
tailings, 16 parts of bentonite, 8 parts of kaolin, 8 parts of talc, 0 parts of calcite, 0.9 parts
of silicon carbide powder and 0.9 parts of water reducing agent;
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh
with a rapid sample maker for 4 minutes, add water to make the water content of the
slurry be 42%, and use a planetary ball mill for wet grinding for 6 hours to obtain the
slurry. Mix the raw materials thoroughly;
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 12 hours to obtain
a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10cm mold, wrap the mold with release paper around, and spread the powdered green body in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1190°C for 30 minutes. After holding for 65 min, it
is rapidly cooled to 900 °C and then cooled in the furnace.
Comparative example 5
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 65 parts of gold
tailings, 17 parts of bentonite, 0 parts of kaolin, 9 parts of talc, 0 parts of calcite, 0.9 parts
of silicon carbide powder and 0.9 parts of water reducing agent;
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh
with a rapid sample maker for 4 minutes, add water to make the water content of the
slurry be 42%, and use a planetary ball mill for wet grinding for 6 hours to obtain the
slurry. Mix the raw materials thoroughly;
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 12 hours to obtain
a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10cm
mold, wrap the mold with release paper around, and spread the powdered green body in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1190°C for 30 minutes. After holding for 65 min, it
is rapidly cooled to 900 °C and then cooled in the furnace.
Comparative example 6
A method for preparing foamed ceramics includes the following steps:
(1) Selection of raw materials. By weight, raw materials comprise 65 parts of gold
tailings, 25 parts of bentonite, 9 parts of kaolin, 9 parts of talc, 0 parts of calcite, 0.9 parts
of silicon carbide powder and 0.9 parts of water reducing agent;
(2) Grinding and mixing of raw materials. Grind each raw material to below 200 mesh
with a rapid sample maker for 4 minutes, add water to make the water content of the
slurry be 42%, and use a planetary ball mill for wet grinding for 6 hours to obtain the
slurry. Mix the raw materials thoroughly;
(3) Suction filtration drying. Pour the slurry into a suction filter to filter out the water to
make it into a solid compact, and place it in a drying oven at 55°C for 12 hours to obtain
a dried green body;
(4) Load green body into mold. Use a rolling pin to crush the dried green body into a
powder with a particle size of less than 2mm. Use refractory bricks to enclose a 15x10cm
mold, wrap the mold with release paper around, and spread the powdered green body in it;
(5) High temperature sintering. In the electric furnace, at room temperature, the
temperature is raised to 300°C for 30 minutes, then to 600°C for 60 minutes, then to
1030°C for 60 minutes, and finally to 1190°C for 30 minutes. After holding for 65 min, it
is rapidly cooled to 900 °C and then cooled in the furnace.
The foamed ceramics prepared in Examples 1-4 and Comparative Examples 1-6 were cut and subjected to performance testing. The cut photos of the foamed ceramics of Examples
1-4 and Comparative Example 4 are shown in Figure 1. The cut photos of the foamed
ceramics of Comparative Examples 1-3 are shown in FIG. 2, and the cut photos of the
foamed ceramics of Comparative Examples 5-6 are shown in FIG. 3. The performance
test results are shown in Table 1:
Table 1: Performance comparison of foamed ceramics prepared in Examples 1-4 and
Comparative Examples 1-6
Example raw Percent Final Compre Bulk Therma Degr Is the
e mater age of foaming ssive density 1 ee of pore
ial bentoni tempera strength ( kg/ conducti foami size
te ture (MPa) M3 ) vity ng unifo
( 0 C) W/(m-k) rm
Example Adde 19.8% 1175 7.6 407.8 0.068 Fully Yes
1 d foam
bento ed
nite
Example Adde 16.7% 1190 7.1 422.9 0.067 Fully Yes
2 d foam
bento ed
nite
Example Adde 13.8% 1185 7.4 396.4 0.071 Fully Yes
3 d foam
bento ed
nite
Example Adde 11.7% 1190 7.0 390.6 0.074 Fully Yes
4 d foam
bento ed
nite
Compar No 0 1185 5.8 410.8 0.079 Not no
active added fully
example bento foam
1 nite ed
Compar Same 16.7% 1165 5.8 527.5 0.080 Not no
active as fully
example Exam foam
2 ple 2 ed
Compar Same 16.7% 1205 5.4 424.9 0.080 Not no
active as fully
example Exam foam
3 ple 2 ed
Compar Same 16.6% Same as 7.8 530.5 0.060 Fully Yes
active as Example foam
example Exam 2 ed
4 ple 2
Compar No 18.3% Same as 3.9 600.3 0.095 Not no
active kaolin Example fully
example added 2 foam
ed
Compar Same 22.7% Same as 5.3 528.6 0.082 Not no
active as Example fully
example Exam 2 foam
6 ple 2 ed
It can be seen from Table 1 that compared with the foamed ceramics in Comparative
Examples 1-3 and 5-6, the foamed ceramics in Examples 1-4 have excellent properties of
light weight, high strength, and heat insulation. Compared with the foamed ceramics of
Comparative Example 4, the foamed ceramics of Examples 1-4 have slightly inferior
properties.
It is worth mentioning that the mass ratio of bentonite to kaolin in Comparative Example
4 is 2:1, which makes the ion exchange effect between bentonite and kaolin better, so as
to achieve a synergistic effect on foamed ceramics. Specifically, the difference between
bentonite and kaolin lies in its spatial structure. Kaolin is a water-containing
aluminosilicate, which is a triclinic crystal system, and there are no cations or water
molecules between the structural layers. Montmorillonite, also known as microcrystalline
kaolinite, is a layered structure and plate-like crystalline silicate clay mineral. It is a
monoclinic crystal system with cations or water molecules between the structural layers.
Interlayer cations such as Cu, Mg, Na, K, etc. are easily exchanged by other cations, so
bentonite and kaolin can be ion exchanged.
And the foamed ceramic prepared in Comparative Example 5 without adding kaolin,
because of the bentonite failed to perform ion exchange, the performance of the foamed
ceramic was extremely poor.
Specifically, for the foamed ceramic prepared in Comparative Example 1 without adding
bentonite, on the one hand, the total sintering time is greatly increased, especially in the
high temperature insulation foaming stage, which in turn leads to increased production
costs. On the other hand, the foamed ceramic in Comparative Example 1 has low
compressive strength, high bulk density, and large thermal conductivity, that is, the
performance of the foamed ceramic in Comparative Example 1 is worse than that of the
foamed ceramic in Examples 1-4.
Compared with Example 2, Comparative Example 2 lowers the final foaming
temperature under the same proportioning conditions. Keeping the temperature for the
same time, the height of the foamed ceramic obtained is only 3cm, as shown in Figure 2.
The pore size of the foamed ceramic is obviously uneven, and there is a phenomenon that
the bottom is not completely foamed. It can be seen from Table 1 that the performance of
the foamed ceramic in Comparative Example 2 is worse than that in Example 2.
Compared with Example 2, Comparative Example 3 increases the final foaming
temperature under the same proportioning conditions, and the foaming state is different when the heat preservation time is different. The foamed ceramics did not increase significantly in the first 30 minutes but increased significantly within the time period of
-60 minutes of heat preservation. Under the condition of 1205°C, the foaming speed
was too fast, the pore size was obviously uneven, and a large number of connected pores
appeared. It can be seen from Table 1 that the foamed ceramics in Comparative Example
3 have poorer properties than Example 2. Through the above analysis, it can be found that
the control of foaming temperature and time plays a very important role in the
performance of foamed ceramics.
Comparative Examples 1 and 6 are to verify the effect of bentonite content on foamed
ceramics. Compared with Example 2, the blending amount of bentonite in Comparative
Example 1 is 0, and that in Comparative Example 6 is higher. It can be seen from Table 1
that the blending of bentonite too low or too high will cause the performance of foamed
ceramics to deteriorate. It should be noted that bentonite can absorb water and has a good
cohesive force to fully fuse the raw materials. As the temperature increases, the structure
of montmorillonite in bentonite will change, followed by a gradual decrease in the
bonding force of bentonite. As the temperature continues to increase to 600-700°C, the
structure of montmorillonite in the bentonite is completely destroyed; in this case, the
bentonite will no longer have cohesive force. The mixing amount of bentonite should not
be too high, otherwise the slurry viscosity is too high, which is not conducive to operation.
Since montmorillonite has a two-octahedral layered structure, after adding water for wet
grinding into the over-high bentonite mixture, part of the water will be absorbed by the
bentonite and become the bound water of its structural unit, causing the slurry to flow sex decline. The grinding time becomes longer, and the required grinding effect cannot be achieved, which also has a certain influence on the performance of foamed ceramic products. The blending amount of bentonite in Comparative Example 6 is too high. After fully absorbing water, the bentonite will produce a plasticizing reaction, resulting in a decrease in the strength of the foamed ceramic. Although bentonite contains a small amount of SiO2 and A1203, these two active ingredients account for a relatively low proportion, and their contribution to the strength of foamed ceramics is relatively small, and cannot change the adverse effects of the plasticizing effect of bentonite after water absorption.
The above-mentioned embodiments only express several embodiments of the present
invention, and the descriptions are more specific and detailed, but they should not be
interpreted as a limitation on the scope of the invention patent. It should be pointed out
that for those of ordinary skill in the art, without departing from the concept of the
present invention, several modifications and improvements can be made, and these all fall
within the protection scope of the present invention. Therefore, the protection scope of
the patent of the present invention should be subject to the appended claims.
Claims (10)
1. A method for preparing foamed ceramics is characterized by comprising the following
steps:
Selection of raw materials. By weight, raw materials comprise 55-80 parts of gold tailings,
-20 parts of bentonite, 5-10 parts of kaolin, 5-10 parts of talc, 0-5 parts of calcite, 0.4
1.2 parts of silicon carbide powder and 0.4-1.2 parts of water reducing agent;
Grinding and mixing of raw materials. Grind the above-mentioned raw materials, add
water and perform wet grinding to obtain slurry;
Suction drying. Filter out the moisture in the slurry to make it into a solid compact, and
obtain a green body after drying;
Load the billet into the mold. The green body is made into powder, and the powdered
billet is poured into the mold;
High-temperature sintering. Place the mold with the billet in an electric furnace, adjust
the foaming temperature at 1170°C-1200°C, keep it for 60-90min, then quench it to
900°C-1000C, and then cool it to make foamed ceramics.
2. The method for preparing foamed ceramics according to claim 1 is characterized in
that the step of adjusting the foaming temperature comprises that first, at room
temperature, the temperature is raised to 300 0C for 30 minutes, then to 6000 C for 60
minutes, then to 10300 C for 60 minutes, and finally to 1170-1200 0 C for 30 minutes.
3. The method for preparing foamed ceramics according to claim 1 is characterized in
that the gold tailings comprise the following components- by weight, 75-80 parts of Si0 2 ,
9-13 parts of A1203, 2-6 parts of K20, 0-1 parts of MgO, 0-1 parts of Na20 , 1-4 parts of
Fe203 and 1-3 parts of CaO.
4. The method for preparing foamed ceramics according to claim 1 is characterized in
that the bentonite comprises the following components- in parts by weight, 68-72 parts of
SiO2, 13-17 parts of A1203, 1-4 parts of K20, 1-3 parts of MgO, 0-1 parts of Na20 , 1-3
parts of Fe203 and 1-3 parts of CaO.
5. The method for preparing foamed ceramics according to claim 1 is characterized in
that the kaolin comprises the following components- in parts by weight, 68-72 parts of
SiO2, 13-17 parts of A1203, 2-6 parts of K20, 0-1 parts of MgO, 0-1 parts of Na20 , 1-3
parts of Fe203 and 0-1 parts of CaO.
6. The method for preparing foamed ceramics according to claim 1 is characterized in
that the talc comprises the following components- by weight, 15-20 parts of SiO2, 0-1
part of A1203, 0-1 part of K20, 35-45 parts of MgO, 0-1 parts of Na20 , 0-1 part of Fe203
and 0-1 part of CaO.
7. The method for preparing foamed ceramics according to claim 1 is characterized in
that in the step of grinding and mixing the raw materials, after adding water, the water
content of the mixture is 40%-50%.
8. The method for preparing foamed ceramics according to any one of claims 1-7 is
characterized in that the mass ratio of the bentonite to the kaolin is 2:1.
9. A foamed ceramic is characterized in that the foamed ceramic is prepared by the
foamed ceramic preparation method of any one of claims 1-8.
10. The foamed ceramic of claim 9 is characterized in that the foamed ceramic has a
compressive strength of 7.0-7.6MPa, a bulk density of 390.6-407.8kg/m 3 , and a thermal
conductivity of 0.067-0.068W/ (m-k).
-1/3-
Figure 1
-2/3-
Figure 2
-3/3
Figure 3
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