CN118164779A - Light ceramic tile using red mud as base material and production process and application thereof - Google Patents
Light ceramic tile using red mud as base material and production process and application thereof Download PDFInfo
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- CN118164779A CN118164779A CN202410592531.8A CN202410592531A CN118164779A CN 118164779 A CN118164779 A CN 118164779A CN 202410592531 A CN202410592531 A CN 202410592531A CN 118164779 A CN118164779 A CN 118164779A
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- red mud
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- clay
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- 239000000919 ceramic Substances 0.000 title claims abstract description 106
- 239000000463 material Substances 0.000 title claims abstract description 69
- 238000004519 manufacturing process Methods 0.000 title abstract description 18
- 239000002994 raw material Substances 0.000 claims abstract description 164
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 53
- 239000004927 clay Substances 0.000 claims abstract description 38
- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 claims abstract description 34
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 28
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 26
- 239000004088 foaming agent Substances 0.000 claims abstract description 10
- 230000005484 gravity Effects 0.000 claims description 29
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 18
- 239000002245 particle Substances 0.000 claims description 15
- 238000010304 firing Methods 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 10
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 claims description 7
- 229910001950 potassium oxide Inorganic materials 0.000 claims description 7
- 238000002156 mixing Methods 0.000 claims description 6
- 238000001035 drying Methods 0.000 claims description 5
- 238000003825 pressing Methods 0.000 claims description 5
- 238000003756 stirring Methods 0.000 claims description 5
- 239000000440 bentonite Substances 0.000 claims description 4
- 229910000278 bentonite Inorganic materials 0.000 claims description 4
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 4
- 238000005034 decoration Methods 0.000 claims description 4
- 239000005995 Aluminium silicate Substances 0.000 claims description 3
- 235000012211 aluminium silicate Nutrition 0.000 claims description 3
- 239000010427 ball clay Substances 0.000 claims description 3
- 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 3
- 238000010521 absorption reaction Methods 0.000 abstract description 14
- 238000004064 recycling Methods 0.000 abstract description 7
- 230000009286 beneficial effect Effects 0.000 abstract description 6
- 238000005336 cracking Methods 0.000 abstract description 2
- 230000000052 comparative effect Effects 0.000 description 21
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 18
- 239000010703 silicon Substances 0.000 description 17
- 229910052710 silicon Inorganic materials 0.000 description 17
- 239000002585 base Substances 0.000 description 12
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 10
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 8
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 8
- 238000012360 testing method Methods 0.000 description 8
- 238000005245 sintering Methods 0.000 description 7
- 238000005516 engineering process Methods 0.000 description 6
- 235000012239 silicon dioxide Nutrition 0.000 description 6
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 5
- 229910052791 calcium Inorganic materials 0.000 description 5
- 239000011575 calcium Substances 0.000 description 5
- 229910052742 iron Inorganic materials 0.000 description 5
- 238000011084 recovery Methods 0.000 description 5
- 238000010998 test method Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- NDLPOXTZKUMGOV-UHFFFAOYSA-N oxo(oxoferriooxy)iron hydrate Chemical compound O.O=[Fe]O[Fe]=O NDLPOXTZKUMGOV-UHFFFAOYSA-N 0.000 description 4
- 239000004408 titanium dioxide Substances 0.000 description 4
- 239000002699 waste material Substances 0.000 description 4
- 238000004131 Bayer process Methods 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 3
- 239000000292 calcium oxide Substances 0.000 description 3
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 3
- 238000005187 foaming Methods 0.000 description 3
- 239000012535 impurity Substances 0.000 description 3
- 238000010348 incorporation Methods 0.000 description 3
- 239000000395 magnesium oxide Substances 0.000 description 3
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 3
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 3
- BITYAPCSNKJESK-UHFFFAOYSA-N potassiosodium Chemical compound [Na].[K] BITYAPCSNKJESK-UHFFFAOYSA-N 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 3
- 229910001948 sodium oxide Inorganic materials 0.000 description 3
- 239000002910 solid waste Substances 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910001570 bauxite Inorganic materials 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000010419 fine particle Substances 0.000 description 2
- 239000010438 granite Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000001502 supplementing effect Effects 0.000 description 2
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 229910000281 calcium bentonite Inorganic materials 0.000 description 1
- 238000003763 carbonization Methods 0.000 description 1
- 239000011153 ceramic matrix composite Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000006477 desulfuration reaction Methods 0.000 description 1
- 230000023556 desulfurization Effects 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical group O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229940072033 potash Drugs 0.000 description 1
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Substances [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 1
- 235000015320 potassium carbonate Nutrition 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 229910052604 silicate mineral Inorganic materials 0.000 description 1
- 239000011863 silicon-based powder Substances 0.000 description 1
- 239000010802 sludge Substances 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
Classifications
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- 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
- C04B38/08—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding porous substances
-
- 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
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/132—Waste materials; Refuse; Residues
- C04B33/1321—Waste slurries, e.g. harbour sludge, industrial muds
- C04B33/1322—Red mud
-
- 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
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/132—Waste materials; Refuse; Residues
- C04B33/1324—Recycled material, e.g. tile dust, stone waste, spent refractory material
-
- 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
- C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
-
- 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
- C04B2235/3418—Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
-
- 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
- C04B2235/3427—Silicates other than clay, e.g. water glass
- C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
- C04B2235/3472—Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite
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- 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
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/74—Physical characteristics
- C04B2235/77—Density
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- Dispersion Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
- Compositions Of Oxide Ceramics (AREA)
Abstract
The invention discloses a lightweight ceramic tile taking red mud as a base material and a production process and application thereof, and belongs to the technical field of ceramics, wherein the lightweight ceramic tile is prepared from a first raw material, a second raw material and a third raw material, the first raw material comprises 50-84% of red mud, 4-20% of clay, 8-15% of silica micropowder and 4-15% of potassium feldspar according to mass percentage, the second raw material is foamed ceramic crushed material, the third raw material is foaming agent, wherein the mass ratio of the second raw material to the first raw material is (0.15-0.3): 1, and the mass ratio of the third raw material to the first raw material is (0.001-0.002): 1. The invention uses red mud as main base material to prepare the light ceramic tile with certain water absorption capacity and no cracking deformation, which is beneficial to recycling red mud.
Description
Technical Field
The invention belongs to the technical field of ceramics, and particularly relates to a lightweight ceramic tile taking red mud as a base material, and a production process and application thereof.
Background
The red mud is extremely fine particle strong alkaline solid waste generated in the process of producing alumina by taking bauxite as a raw material, the output of the solid waste is different due to the different ore grade, production process and technical level, and at present, most manufacturers can additionally produce 0.8-1.5 t red mud every 1t of alumina production, and the content of ferric oxide is large generally, and the appearance is similar to that of red mud, so that the red mud is named. The red mud belongs to harmful waste residues, and the recycling of the red mud is a main idea for treating the red mud.
At present, the technology of Bayer process red mud deep dealkalization technology, desulfurization technology, bayer process 'calcification-carbonization' treatment technology and Bayer process red mud iron recovery technology are applied, but the technologies only treat red mud harmlessly or recover useful substances in the red mud, and a sludge part still cannot be treated or recovered for use.
There are also patents currently mentioning the recycling of red mud. For example, patent CN2017111776698 is a wave-absorbing ceramic matrix composite insulation board and a preparation method thereof, red mud, granite waste, clay tailings and the like are mixed and calcined, but the red mud is less in consumption and more in recycling of the granite waste. At present, the red mud recovery still has more problems, such as less recovery amount, complicated recovery steps and the like, and a new red mud recovery thought is necessary to be provided for solving the problems.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide a light ceramic tile taking red mud as a base material, a production process and application thereof, and the light ceramic tile which is not cracked and deformed and has a certain water absorption capacity is prepared by taking the red mud as a main base material, thereby being beneficial to recycling the red mud.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
In a first aspect of the invention, the invention provides a lightweight ceramic tile based on red mud, which is prepared from a first raw material, a second raw material and a third raw material, wherein the first raw material comprises 50-84% of red mud, 4-20% of clay, 8-15% of silica micropowder and 4-15% of potassium feldspar, the second raw material is foamed ceramic crushed material, the third raw material is foaming agent, the mass ratio of the second raw material to the first raw material is (0.15-0.3): 1, and the mass ratio of the third raw material to the first raw material is (0.001-0.002): 1.
Preferably, in the first raw material, the mass percentage of the red mud is 70-84%.
Preferably, the specific gravity of the foamed ceramic crushed material is less than or equal to 0.50 g/cm 3.
More preferably, the specific gravity of the foamed ceramic crushed material is 0.20-0.50 g/cm 3, and the particle size of the foamed ceramic crushed material is less than or equal to 20 meshes.
Preferably, the clay comprises one or more of ball clay, bentonite and kaolin, and the particle size of the clay is less than or equal to 200 meshes.
Preferably, the potassium feldspar has a potassium oxide content of not less than 4%.
Preferably, the particle size of the potassium feldspar is less than or equal to 100 meshes.
Preferably, the foaming agent comprises silicon carbide powder, and the particle size of the silicon carbide powder is less than or equal to 1200 meshes.
In a second aspect of the invention, the invention also provides a production process of the lightweight ceramic tile with red mud as a base material, which comprises the following steps:
drying the red mud in the first raw material, and controlling the water content of the red mud to be less than or equal to 5%;
Mixing the first raw material, the second raw material and the third raw material to form a mixed material, adding water, uniformly stirring, and pressing to form a blank, wherein the water addition amount is 3-6% of the mass of the mixed material;
and after the green body is dried, firing at 1120-1200 ℃ to obtain the light ceramic tile.
In a third aspect of the invention, the invention also provides an application of the light ceramic tile based on red mud, and the light ceramic tile is used in the field of architectural decoration.
The beneficial effects are that:
The invention takes red mud as a base material, occupies larger proportion in the raw materials, is beneficial to quickening the recycling of the red mud, solves the defects of the red mud by mixing with the raw materials such as foamed ceramic crushed materials, clay, potassium feldspar and the like, and solves the problems of light weight, water absorption and the like of the prepared ceramic tile and higher radioactivity of the red mud, and the product meets the requirements of B-class or even A-class building decorative materials and is beneficial to recycling of the red mud.
Detailed Description
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following description will explain the specific embodiments of the present invention. It is obvious that the following description is only some embodiments of the present invention and that other embodiments may be obtained from these embodiments by those skilled in the art without undue burden.
The invention provides a lightweight ceramic tile taking red mud as a base material, which is prepared from a first raw material, a second raw material and a third raw material, wherein the first raw material comprises 50-84% of red mud, 4-20% of clay, 8-15% of silica micropowder and 4-15% of potassium feldspar according to mass percentage, the second raw material is foamed ceramic crushed material, the third raw material is foaming agent, the mass ratio of the second raw material to the first raw material is (0.15-0.3): 1, preferably the mass ratio of the second raw material to the first raw material is (0.2-0.25): 1, and the mass ratio of the third raw material to the first raw material is (0.001-0.002): 1.
The red mud is extremely fine particle strong alkaline solid waste generated in the process of producing alumina by taking bauxite as a raw material, has the characteristics of high calcium content and high iron content, contains silicon aluminum, sodium potassium, titanium and the like.
The red mud contains silicon aluminum, so that the red mud is possible to be used as a ceramic raw material, but various chemical components in the red mud also have the characteristics of being remarkably unfavorable for producing ceramic products: firstly, the red mud has large loss on ignition, and a ceramic blank prepared by directly taking a large amount of red mud as a base material has large shrinkage, and the blank is easy to deform and crack; secondly, the iron content of the red mud is high and is between 10 and 20 percent, so that the firing temperature of a product taking a large amount of red mud as a base material is low, other materials in a green body cannot be completely melted, and the density and the strength of the product are reduced; thirdly, the silicon-aluminum content in the red mud is low, and generally, the silicon-aluminum content of the conventional red mud is lower than 30%, and for a green body framework, when the silicon dioxide content is lower than 65%, the green body framework is easy to cause low strength, and the green body is easy to collapse and deform; fourthly, the calcium content in the red mud is higher, and the foaming pore diameter of the product is difficult to control in the sintering process.
In the invention, the red mud dosage regulation range is larger, preferably, in the first raw material, the mass percentage of the red mud is 70-84%, more preferably, the mass percentage of the red mud is 80-84%. In order to solve the problem that red mud is used as a ceramic product base material, clay in the first raw material is soil which contains less sand particles and has viscosity after silicate minerals are weathered, so that the effect of improving the silicon-aluminum content of a green body is achieved; the silicon micropowder plays a role in improving the silicon content of the blank; the potassium feldspar is an aluminosilicate of alkali metal or alkaline earth metal, has the effect of improving the silicon-aluminum content of the blank, and more importantly, the potassium feldspar also has the effect of widening the sintering temperature range, has greater temperature control flexibility in the sintering process, and is beneficial to improving the sintering quality and the consistency of products.
The clay is a conventional commercial clay product, comprising one or more of ball clay, bentonite and kaolin, and the particle size of the clay is less than or equal to 200 meshes. It is easy to understand that clay with proper silicon-aluminum content is selected according to the red mud dosage and the content of each component in the red mud. Preferably, the clay is calcium bentonite.
The silicon micropowder is commercial silicon micropowder with the particle size less than or equal to 200 meshes. It is easy to understand that the purity of the silicon micropowder is high, the silicon micropowder is used as a raw material for supplementing silicon, the consumption of the silicon micropowder is related to the silicon content in the red mud, when the silicon content of the red mud is relatively low, the addition of the silicon micropowder is high, and when the silicon content of the red mud is relatively high, the addition of the silicon micropowder is low.
The potassium feldspar is a commercial potassium feldspar product, the grain size is less than or equal to 100, preferably, the potassium oxide content of the potassium feldspar is more than or equal to 4%, and more preferably, the potassium oxide content in the potassium feldspar is more than or equal to 10%.
In the present invention, the addition amount of clay, silica powder and potash feldspar is related to the content of each component in red mud. For example, the components and the contents of the conventional commercial clay and potassium feldspar products are known, after testing the contents of the components of the red mud, in order to increase the silicon aluminum content of the green body to a specific value and control the sodium potassium content and the titanium dioxide content within the required range, the potassium feldspar content can be determined firstly, then the clay content is determined, and finally the silicon powder is added to adjust the silicon dioxide content in the green body.
In the invention, the foamed ceramic crushed material is an important raw material, is particles formed by foamed ceramic waste, preferably, the specific gravity is 0.20-0.50 g/cm 3, the particle size is less than or equal to 20 meshes, the dry press forming is facilitated, the generation of cracks is avoided, if the particles of the foamed ceramic crushed material are too large, the raw materials are difficult to mix uniformly when mixed, and the generation of cracks when fired is difficult to avoid.
According to the invention, a large amount of red mud is used as a base material, and foamed ceramic crushed materials are used as aggregate, so that the problem of overlarge shrinkage of a green body caused by large loss on ignition of the red mud is solved. The foamed ceramic crushed material is clinker, does not participate in the reaction in the firing process, and can reduce the weight of the green body while maintaining the strength of the green body, so the invention limits the specific gravity of the foamed ceramic crushed material and does not require the components and the corresponding content of the foamed ceramic crushed material.
The third raw material is a foaming agent, and although the red mud has high calcium content and has the function similar to the foaming agent, the foaming is difficult to control in the sintering process. Preferably, the foaming agent comprises silicon carbide powder, such as commercially available silicon carbide powder, and silicon carbide fine powder with particle size less than or equal to 1200 meshes is selected.
In the invention, the problem of large blank shrinkage caused by large red mud loss on ignition is solved by adding the foamed ceramic crushed material; the iron content of the whole green body is reduced by adding other raw materials with low iron content, and the problems of low sintering temperature and difficult control of the sintering temperature are controlled by the sodium-potassium content of the potassium feldspar; adding raw materials containing silicon and aluminum such as clay, potassium feldspar and the like to increase the silicon and aluminum content of the green body, and supplementing the silicon dioxide content in the green body through silicon micropowder; the calcium content of the whole green body is reduced by adding other raw materials with low calcium content, and the foaming pore diameter is controlled by adding a foaming agent. Based on the method, the problems caused by high red mud content in the green body are solved, the defects of the red mud are overcome, and the prepared ceramic tile has the properties of light weight, water absorption and the like.
Based on the light ceramic tile with red mud as the base material, the invention also provides a corresponding preparation process, which comprises the following steps:
drying the red mud in the first raw material, and controlling the water content of the red mud to be less than or equal to 5%;
Mixing the first raw material, the second raw material and the third raw material to form a mixed material, adding water, uniformly stirring, and pressing to form a blank, wherein the water addition amount is 3-6% of the mass of the mixed material;
and after the green body is dried, firing at 1120-1200 ℃ to obtain the light ceramic tile.
In some embodiments, during firing, the firing profile is: the temperature is raised to 300 ℃ from normal temperature, the temperature raising time is 100-120 min, the temperature raising time is 50-60 min from 300 ℃ to 600 ℃, the temperature is kept at 50-60 min at 600 ℃, the temperature is raised to 900 ℃ from 600 ℃ to 50-60 min, the temperature is kept at 50-60 min at 900 ℃, the temperature is raised to 1120-1200 ℃, the temperature raising time is 50-60 min, and the temperature is kept at 10-30 min at 1120-1200 ℃.
The technical scheme of the invention is described in detail in the following by specific embodiments.
The red mud is Zhengzhou red mud, and in the embodiment, each component of the red mud in the batch and the content thereof are as follows: 23.93% of aluminum oxide, 21.27% of silicon dioxide, 11.52% of ferric oxide, 16.84% of calcium oxide, 0.92% of magnesium oxide, 1.42% of potassium oxide, 5.99% of sodium oxide, 4.43% of titanium dioxide, 11.37% of ignition loss and the balance of impurities.
The clay is bentonite, and the components and contents of the clay used in the examples are: 13.72% of aluminum oxide, 70.93% of silicon dioxide, 1.75% of ferric oxide, 1.52% of calcium oxide, 2.66% of magnesium oxide, 1.04% of potassium oxide, 2.01% of sodium oxide, 0.12% of titanium dioxide, 6.06% of ignition loss and the balance of impurities.
The potassium feldspar used in the examples comprises the following components in percentage by weight: 18.74% of aluminum oxide, 65.06% of silicon dioxide, 0.12% of ferric oxide, 0.23% of calcium oxide, 0.07% of magnesium oxide, 12.41% of potassium oxide, 2.66% of sodium oxide, 0.01% of titanium dioxide, 0.40% of ignition loss and the balance of impurities.
The silica content of the fine silica powder used in the examples was higher than 92%.
Example 1
In this example, the total mass of the first, second and third materials was 200 kg.
The first raw material comprises 82.8% of 20-mesh red mud, 4.3% of clay, 8.6% of silica micropowder and 4.3% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.2:1, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0013:1.
Drying the red mud, controlling the water content of the red mud to be less than or equal to 5%, mixing the dried red mud with clay, silicon micropowder, potassium feldspar, foamed ceramic crushed materials and silicon carbide powder to form a mixed material, adding water, uniformly stirring, and pressing to form a blank, wherein the water content is 3-6% of the mass of the mixed material.
And firing the green body after the green body is dried to obtain the light ceramic tile.
Wherein the firing profile is: the temperature is raised to 300 ℃ from normal temperature, the temperature raising time is 120 min, the temperature raising time is 60 min from 300 ℃ to 600 ℃, the temperature is kept at 60 min at 600 ℃, the temperature is raised to 900 ℃ from 600 ℃, the temperature raising time is 60 minutes, the temperature is kept at 60 min at 900 ℃, the temperature is raised to 1120-1200 ℃, the temperature raising time is 60 min, and the temperature is kept at 30 min at 1120-1200 ℃.
The specific gravity of the ceramic tile prepared by the embodiment is 1.43 g/cm 3, which meets the requirement of the light ceramic tile (the requirement of the industry on the light ceramic tile is less than or equal to 1.5 g/cm 3).
The specific gravity test method comprises the following steps: according to the third part of the ceramic tile test method of GB/T3810.3: the measurements of water absorption, apparent porosity, apparent relative density and volume weight were carried out in the manner described in the examples and comparative examples.
Example 2
In this example, the total mass of the first, second and third materials was 200 kg.
The first raw material comprises 70% of 20-mesh red mud, 10% of clay, 15% of silica micropowder and 5% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.25:1, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0012:1.
The manufacturing process of this embodiment is the same as that of embodiment 1.
The specific gravity of the ceramic tile prepared by the embodiment is 1.32g/cm 3, which meets the requirements of light ceramic tiles.
Example 3
In this example, the total mass of the first, second and third materials was 200 kg.
The first raw material comprises 60% of 20-mesh red mud, 15% of clay, 15% of silica micropowder and 10% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.25:1, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0012:1.
The manufacturing process of this embodiment is the same as that of embodiment 1.
The specific gravity of the ceramic tile prepared by the embodiment is 1.24 g/cm 3, which meets the requirements of light ceramic tiles.
Example 4
In this example, the total mass of the first, second and third materials was 200 kg.
The first raw material comprises 50% of 20-mesh red mud, 20% of clay, 15% of silica micropowder and 15% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.25:1, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0010:1.
The manufacturing process of this embodiment is the same as that of embodiment 1.
The specific gravity of the ceramic tile prepared by the embodiment is 1.35 g/cm 3, which meets the requirements of light ceramic tiles.
Example 5
In this example, the total mass of the first, second and third materials was 200 kg.
The first raw material comprises 80% of 20-mesh red mud, 5% of clay, 10% of silica micropowder and 5% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40g/cm 3, the mass ratio of the second raw material to the first raw material is 0.20:1, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0013:1.
The manufacturing process of this embodiment is the same as that of embodiment 1.
The specific gravity of the ceramic tile prepared by the embodiment is 1.44 g/cm 3, which meets the requirements of light ceramic tiles.
Example 6
In this example, the total mass of the first, second and third materials was 200 kg.
The first raw material comprises 50% of 20-mesh red mud, 20% of clay, 15% of silica micropowder and 15% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.15:1, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0012:1.
The manufacturing process of this embodiment is the same as that of embodiment 1.
The specific gravity of the ceramic tile prepared by the embodiment is 1.41 g/cm 3, which meets the requirements of light ceramic tiles.
Example 7
In this example, the total mass of the first, second and third materials was 200 kg.
The first raw material comprises 60% of 20-mesh red mud, 15% of clay, 15% of silica micropowder and 10% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.30:1, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0012:1.
The manufacturing process of this embodiment is the same as that of embodiment 1.
The specific gravity of the ceramic tile prepared by the embodiment is 1.20 g/cm 3, which meets the requirements of light ceramic tiles.
The properties of the lightweight ceramic tiles prepared in examples 1 to 7 are shown in Table 1.
TABLE 1 Water absorption and radioactivity of lightweight ceramic tiles of examples 1-7
Remarks: the water absorption test method comprises the following steps: according to the third part of the ceramic tile test method of GB/T3810.3-2016: the test sample is prepared according to the requirements of the fourth chapter in the measurement of water absorption, apparent porosity, apparent relative density and volume weight, the size of the test sample is required to be larger than 100 mm multiplied by 100 multiplied by mm multiplied by 80 mm, the test sample is placed in a vacuum container so that the test samples are not contacted with each other, and a sufficient amount of water is added to cover the test sample and the test sample is higher than 5 cm. The vacuum was pulled to 10 kPa.+ -. 1 kPa and kept at 30min, then the vacuum was stopped, the sample was immersed in 15 min, taken out, placed on a suspended rack, immediately weighed and recorded after 3 min was continuously blown with 0.8 kg of compressed air at a distance of 10 cm from the upper surface of the sample. The water absorption was calculated according to the method specified in GB/T3810.3-2016.
Radionuclide limit test method: the test was carried out in accordance with the specification of GB 6566 building material radionuclide.
As can be seen from the radioactivity of Zhengzhou red mud in Table 1, the radioactivity of red mud per se exceeds the internal and external irradiation index, and thus the red mud cannot be directly used for building decoration materials. The radioactivity of the red mud is reduced by controlling the consumption of the red mud and the consumption of the rest components, and the ceramic tile which is not cracked and deformed is prepared, has certain water absorption performance, and can be used as a class A or class B building decoration material. The light ceramic tile prepared by the invention has obvious moisture absorption and moisture absorption functions, which are related to the red mud ratio. The light ceramic tile with high water absorption rate is particularly suitable for humid weather in the south, and keeps certain space comfortable humidity.
Comparative example 1
In this comparative example, the first raw material comprised 82.8% of 20-mesh red mud, 4.3% of clay, 8.6% of fine silica powder and 4.3% of potassium feldspar, and the second and third raw materials were not added. The total mass of the first raw material is 200 kg.
Drying the red mud, controlling the water content of the red mud to be less than or equal to 5%, mixing the dried red mud with clay, silica micropowder and potassium feldspar to form a mixed material, adding water, uniformly stirring, and pressing to form a blank, wherein the water addition amount is 3-6% of the mass of the mixed material.
And firing the green body after the green body is dried to obtain the light ceramic tile.
Wherein the firing profile is: the temperature is raised to 300 ℃ from normal temperature, the temperature raising time is 120 min, the temperature raising time is raised to 600 ℃ from 300 ℃, the temperature raising time is 60min, the temperature is kept at 60min at 600 ℃, the temperature is raised to 900 ℃ from 600 ℃, the temperature raising time is 60 minutes, the temperature is kept at 60min at 900 ℃, the temperature is raised to 1120-1200 ℃ from 900 ℃, the temperature raising time is 60min, and the temperature is kept at 1120-1200 ℃ for 10-30 min.
The ceramic tile prepared in this comparative example had a water absorption of 21.59% and a specific gravity of 1.76 g/cm 3, and could not meet the requirements for lightweight ceramic tiles.
Comparative example 2
In this comparative example, the total mass of the first raw material, the second raw material, and the third raw material was 200 kg.
The first raw material comprises 82.8% of 20-mesh red mud, 4.3% of clay, 8.6% of silica micropowder and 4.3% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.13:1, namely the second raw material is insufficient, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0013:1.
The manufacturing process of this comparative example was the same as that of example 1.
The specific gravity of the ceramic tile prepared by the comparative example is greater than 1.50 g/cm 3, and the ceramic tile does not meet the requirements of light ceramic tiles.
Comparative example 3
In this comparative example, the total mass of the first raw material, the second raw material, and the third raw material was 200 kg.
The first raw material comprises 82.8% of 20-mesh red mud, 4.3% of clay, 8.6% of silica micropowder and 4.3% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.35:1, namely the second raw material is excessive, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0013:1.
The manufacturing process of this comparative example was the same as that of example 1.
The ceramic tile prepared by the comparative example has more obvious cracks and cannot be used normally.
Comparative example 4
In this comparative example, the total mass of the first raw material, the second raw material, and the third raw material was 200 kg.
The first raw material comprises 82.8% of 20-mesh red mud, 7.0% of clay and 10.2% of silica micropowder, namely potassium feldspar is not added, the second raw material is foamed ceramic crushed material, the specific gravity is 0.40 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.2:1, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0013:1.
The manufacturing process of this comparative example was the same as that of example 1.
The ceramic tile finished product prepared by the comparative example has unstable quality, narrow firing range and partial deformation of the finished product, and does not meet the requirements of light-weight tiles.
Comparative example 5
In this comparative example, the total mass of the first raw material, the second raw material, and the third raw material was 200 kg.
The first raw material comprises 82.8% of 20-mesh red mud, 4.3% of clay, 8.6% of silica micropowder and 4.3% of potassium feldspar, the second raw material is foamed ceramic crushed material, the specific gravity is 0.85 g/cm 3, the mass ratio of the second raw material to the first raw material is 0.2:1, the third raw material is silicon carbide powder, and the mass ratio of the third raw material to the first raw material is 0.0013:1.
The manufacturing process of this comparative example was the same as that of example 1.
The specific gravity of the ceramic tile prepared by the comparative example is 1.65 g/cm 3, which does not meet the requirements of light ceramic tiles.
As is clear from comparison of comparative examples 1 to 5 with examples 1 to 7, the incorporation of the foamed ceramic crushed material has an important meaning for producing lightweight ceramic tiles from red mud, but the incorporation amount of the foamed ceramic crushed material has a direct effect on the product performance, and excessive foamed ceramic crushed material can cause cracking of a green body, while insufficient foamed ceramic cannot form lightweight ceramic, the present invention controls the incorporation amount to 15 to 30% and limits the specific gravity of the foamed ceramic crushed material to be less than or equal to 0.50 g/cm 3, so as to achieve the purpose of producing lightweight ceramic tiles.
The embodiments of the present invention are described in detail above. The principles and embodiments of the present invention have been described herein with reference to specific examples, the description of which is intended only to facilitate an understanding of the core concepts of the invention. It should be noted that it will be apparent to those skilled in the art that the present invention may be modified and adapted without departing from the principles of the present invention, and that such modifications and adaptations are intended to be within the scope of the appended claims.
Claims (10)
1. The lightweight ceramic tile is characterized by being prepared from a first raw material, a second raw material and a third raw material, wherein the first raw material comprises 50-84% of red mud, 4-20% of clay, 8-15% of silica micropowder and 4-15% of potassium feldspar according to mass percentage, the second raw material is foamed ceramic crushed material, the third raw material is foaming agent, the mass ratio of the second raw material to the first raw material is (0.15-0.3): 1, and the mass ratio of the third raw material to the first raw material is (0.001-0.002): 1.
2. The lightweight ceramic tile according to claim 1, wherein the mass percentage of red mud in the first raw material is 70-84%.
3. The lightweight ceramic tile according to claim 1, wherein the foamed ceramic crushed material has a specific gravity of 0.50 g/cm 3 or less.
4. The lightweight ceramic tile according to claim 3, wherein the foamed ceramic crushed material has a specific gravity of 0.20 to 0.50 g/cm 3 and a particle size of 20 mesh or less.
5. The lightweight ceramic tile according to claim 1, wherein said clay comprises one or more of ball clay, bentonite clay and kaolin clay, said clay having a particle size of 200 mesh or less.
6. The lightweight ceramic tile according to claim 1, wherein the potassium feldspar has a potassium oxide content of 4% or more.
7. The lightweight ceramic tile according to claim 1, wherein the potassium feldspar has a particle size of 100 mesh or less.
8. The lightweight ceramic tile according to claim 1, wherein the foaming agent comprises silicon carbide powder having a particle size of 1200 mesh or less.
9. A process for producing a lightweight ceramic tile based on red mud, characterized in that the process comprises the steps of:
drying the red mud in the first raw material, and controlling the water content of the red mud to be less than or equal to 5%;
Mixing the first raw material, the second raw material and the third raw material to form a mixed material, adding water, uniformly stirring, and pressing to form a blank, wherein the water addition amount is 3-6% of the mass of the mixed material;
and after the green body is dried, firing at 1120-1200 ℃ to obtain the light ceramic tile.
10. Use of a red mud-based lightweight ceramic tile according to any one of claims 1 to 8 in the field of architectural decoration.
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