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CN112759412A - Method for preparing foamed ceramic by using ceramic production waste - Google Patents

Method for preparing foamed ceramic by using ceramic production waste Download PDF

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Publication number
CN112759412A
CN112759412A CN201910999502.2A CN201910999502A CN112759412A CN 112759412 A CN112759412 A CN 112759412A CN 201910999502 A CN201910999502 A CN 201910999502A CN 112759412 A CN112759412 A CN 112759412A
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ceramic
temperature
section
foamed
waste
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江峰
张国涛
邓波
杨景琪
戴永刚
邓仕豪
彭双阳
陈林
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Foshan Jinyi Green Energy New Material Technology Co ltd
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Foshan Jinyi Green Energy New Material Technology Co ltd
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Abstract

The invention relates to the field of ceramic material production, in particular to a method for preparing foamed ceramic by using ceramic production waste. The method comprises the following steps: the method comprises the following steps: step 1: preparing materials; the method comprises the following steps of (1) taking known ceramic production waste as a main raw material, and adding a high-temperature foaming agent to prepare a foamed ceramic raw material; step 2: the cloth is burnt, the prepared raw materials are pressed and formed or directly spread in a refractory kiln furniture to be put into a kiln to be burnt; the sintering stage is provided with a transition cooling section which is positioned between the sintering section and the quenching section, the temperature range is the highest sintering temperature-1000 ℃, and the cooling rate of the transition cooling section is 2-8 ℃/min, and the step 3: and (3) polishing, grinding and cutting, wherein the foamed ceramic blank obtained after the firing in the step (2) is polished, ground and cut to obtain the required foamed ceramic product. Compared with the prior art, the scheme can ensure that the foamed ceramic has higher quality and high-quality product rate while greatly utilizing ceramic production waste.

Description

Method for preparing foamed ceramic by using ceramic production waste
Technical Field
The invention relates to the field of ceramic material production, in particular to a method for preparing foamed ceramic by using ceramic production waste.
Background
The foamed ceramic is a kind of porous ceramic, which has pores with a diameter of about 0.1mm to 3mm, and many pores are not connected. The foamed ceramic has the excellent characteristics of light weight, heat preservation, sound insulation, water resistance, flame retardance and the like, and is a good masonry heat-preservation material. Silicon carbide, carbon powder, ferric oxide, sulfate, carbonate, hydroxide, cyanide and the like are commonly used as foaming agent raw materials in the production of foamed ceramics, the raw materials can generate gas due to decomposition or oxidation under high temperature, the gas can form a cavity in a green body, porous ceramics are obtained after the sintering, and the proper sintering system is controlled, so that the pores can be more or less not communicated, and the foamed ceramic product with closed pores is formed.
The foamed ceramic has low requirement on basic raw materials, so waste materials generated in ceramic production, slag, river sludge and other wastes left after mining can be used as the basic raw materials for producing the foamed ceramic. For example, the residual polishing slag in the ceramic polishing line wastewater collection and recovery treatment, the tailing residue talc mud in the talc mining, the feldspar tailing material in the feldspar mining or in the raw materials of different batches, the waste tile powder obtained by crushing the waste ceramic tiles, and the pressed mud are obtained by filter pressing, have certain plasticity, and are generally obtained by processing and filter pressing the waste mud generated in the production process of the architectural ceramics. The production cost can be reduced by using the waste materials to produce the foamed ceramics, but the fluctuation of the chemical components of the raw materials is large, so that the foamed ceramics are easy to crack, have large pores and other defects, and further influence the product performance. In addition, slow cooling is needed in the process of firing the foamed ceramics, so that the foamed ceramics are frequently fired in a roller kiln or a tunnel kiln at present, which causes the production efficiency of the foamed ceramics to be lower and the energy consumption to be higher.
Disclosure of Invention
Aiming at the technical problems in the background art, the invention provides a method for preparing foamed ceramics by using ceramic production waste, which can reduce the production energy consumption and improve the high-quality product rate and the performance of the foamed ceramics by optimizing and adjusting the firing process.
A method for preparing foamed ceramics using ceramic production waste, comprising the steps of:
step 1: preparing materials; the method comprises the following steps of (1) taking known ceramic production waste as a main raw material, and adding a high-temperature foaming agent to prepare a foamed ceramic raw material;
step 2: the cloth is burnt, the prepared raw materials are pressed and formed or directly spread in a refractory kiln furniture to be put into a kiln to be burnt; the sintering stage is provided with a transition cooling section, the transition cooling section is positioned between the sintering section and the quenching section, the temperature range is the highest sintering temperature-1000 ℃, and the cooling rate of the transition cooling section is 2-8 ℃/min;
and step 3: and (3) polishing, grinding and cutting, wherein the foamed ceramic blank obtained after the firing in the step (2) is polished, ground and cut to obtain the required foamed ceramic product.
Ceramic production waste as known herein includes, but is not limited to: polishing slag, waste brick powder, feldspar tailings, waste pug (usually pressed into pressed mud through pressing treatment), talc mud, tailing slag and the like.
The foaming agent is usually silicon carbide, and of course, carbon powder, ferric oxide, sulfate, carbonate, hydroxide, cyanide and the like can be optionally matched. In industrial production, the foaming agent is mainly silicon carbide. At present, in the process of preparing the foamed ceramic by adopting the foaming agent, the firing temperature is 1050-1250 ℃, and is usually set between 1150-1200 ℃, and the temperature range is particularly suitable for silicon carbide foaming and is basically consistent with the firing temperature of the traditional architectural ceramic.
This scheme is through carrying out meticulous control to the firing process, alleviates because the unstable product defect that causes of ceramic manufacture waste material. In the production process of foamed ceramics, high-temperature decomposition components such as organic matters, carbonate, sulfate and the like in raw materials need to be well regulated and controlled in the decomposition process, otherwise, adverse effects are caused on foaming of a foaming agent, the size and the shape of air holes are influenced, and the performance of a product is further influenced. Meanwhile, the cooling process of the foamed ceramic is different from that of the conventional building ceramic, firstly, the volume of the sintered foamed ceramic expands for many times, and the ceramic material forming the hole wall is easy to crack because the phase change is not well controlled in the cooling process; secondly, the foaming process of the foaming agent is continuous, and a certain time is required for forming regular air holes. For the traditional building ceramic product firing, a rapid cooling zone is immediately fed for cooling after the sintering is finished, but for the production of foamed ceramics, the rapid cooling can be immediately carried out to rapidly solidify a liquid phase, and air bubbles in the foamed ceramics are rapidly shaped, so that irregular-shaped air holes are increased, and the product performance is adversely affected.
In the method provided by the invention, the cooling rate of the transition cooling section is preferably 3-5 ℃/min. The temperature of the transition cooling section needs to be slowly reduced, and the green body needs to be properly heated when necessary so as to ensure the slow cooling. In the transition cooling section, the foaming agent in the foamed ceramic can continue to react and foam, and along with the slow cooling process, the bubbles enclosed in the liquid phase gradually make the shape close to a circle, so that the obtained foamed ceramic has more uniform pores, and the performance of the foamed ceramic can be greatly improved.
Preferably, in the method provided by the invention, the transition cooling section controls the cooling rate by heating. The cooling process is slowed down by heating, the foaming agent which is not completely reacted in the raw materials is promoted to further react, and meanwhile, the gas sealed in the liquid phase is self-regulated, so that the holes are more regular.
Preferably, in the method provided by the invention, the maximum firing temperature is 1150-1200 ℃, a middle temperature section is also arranged in the firing stage, the temperature of the middle temperature section is 900-1150 ℃, and the heating rate of the middle temperature section is 1-15 ℃/min. At the temperature of above 900 ℃, most foaming agents begin to react, gas is discharged, and at the temperature of 900 ℃, the molten liquid phase of the foaming ceramic powder taking ceramic production waste as a main raw material begins to tend to fuse, and the gas generated by the foaming agents can be wrapped inside to form air holes along with the increase of the temperature. The ceramic production waste has large chemical component fluctuation, a slow temperature rise rate is adopted at the stage, the influence caused by the fluctuation of the chemical components of the raw materials can be reduced to the minimum, bubbles can grow slowly and repeatedly in the process, the gas quantity generated by the foaming agent is gradually increased along with the temperature rise, and small bubbles can grow gradually and are uniformly fused. Thus, the adverse effect of unstable components of the waste materials of ceramic production can be reduced, and the foamed ceramic products with uniform pore diameters can be obtained. In addition, for the mode of firing by using kiln furniture to load powder, the temperature is slowly increased in the middle temperature section, so that the adverse effect caused by the fire leaping in the gaps between the kiln furniture can be reduced. Further preferably, the temperature rise rate in the medium temperature zone is 2 to 4 ℃/min.
Preferably, in the method provided by the invention, the foaming agent contains silicon carbide, and the average grain diameter of the silicon carbide is 7-7.5 microns. The use of ultra-fine particle size silicon carbide allows for more uniform foaming. The polishing slag in the ceramic production waste contains silicon carbide, so that the amount of a silicon carbide foaming agent can be reduced when the polishing slag is contained in a large amount in the main raw material, and the amount of the silicon carbide foaming agent is usually 0.2-2% of the total mass.
Preferably, in the method provided by the invention, the foamed ceramic raw material further contains an oxygen increasing agent accounting for 0.2-2% of the total mass of the raw materials. The oxygen increasing agent is a substance which can be decomposed at the temperature of more than 900 ℃ to release oxygen or provide free oxygen, and ferric oxide or manganese oxide is usually selected. The silicon carbide foaming agent needs free oxygen to accelerate decomposition in the high-temperature decomposition reaction process, so the addition of the oxygen increasing agent can promote foaming of the silicon carbide foaming agent, and ferric oxide or manganese oxide is preferred because the ferric oxide or manganese oxide is a good oxygen increasing agent and can participate in solid phase reaction in the sintering process to enable the hole wall to be more stable.
Preferably, in the method provided by the present invention, the ceramic production waste is at least three combinations of polishing slag, waste brick powder, talc sludge, press sludge and feldspar tailings. The ceramic polishing slag and the waste brick powder are mainly ceramic clinker, and the phase composition of the ceramic polishing slag and the waste brick powder contains a certain amount of cordierite and mullite, secondary mullite is difficult to form in the firing process of the foamed ceramic, and the primary mullite phase introduced from the raw materials can ensure that the product has better strength; the talc mud is talc tailings or mixture of residual tailings of different batches of talc raw materials, has a fluxing effect and can promote formation of magnesium spinel, the pressed mud is mixture of waste mud materials in ceramic production, the pressed mud can be slurry obtained after ball milling of the raw materials and has good suspension property and fluidity, and the feldspar tailings are a fusing agent for adjusting sintering temperature. Through the combination of the raw materials, the performances of various raw materials can be organically combined, and the product quality is ensured.
Preferably, in the method provided by the invention, the maximum firing temperature is 1175-1195 ℃.
Preferably, in the method provided by the invention, the foamed ceramic raw material comprises the following components in percentage by mass:
polishing slag: 50-80%;
waste brick powder: 0 to 10 percent;
10-15% of feldspar tailings;
and (3) rubble mud: 0 to 5 percent;
pressing the mud: 10 to 15 percent of the total weight of the mixture,
foaming agent: 0.2 to 2 percent of the total weight of the mixture,
0.2 to 2 percent of oxygenation agent.
Compared with the prior art, the method has the advantages that the sintering process is optimized, so that the adverse effect caused by the component fluctuation of the ceramic production waste among different batches is reduced. The quality and the high-quality product rate of the foamed ceramics are ensured while a large amount of waste materials of ceramic production are utilized. Through tests, the performance of the foamed ceramic prepared by the method is shown in the following table 1, and the excellent rate of the product can be kept above 80% when the raw materials are adjusted or changed in batches. Higher production fault tolerance reduces waste and production pauses caused by raw material changes.
TABLE 1
Figure 542050DEST_PATH_IMAGE001
Drawings
FIG. 1 is a Scanning Electron Microscope (SEM) photograph of a foamed ceramic prepared according to a preferred embodiment of the present invention at a magnification of 100.
FIG. 2 is a Scanning Electron Microscope (SEM) photograph of a foamed ceramic prepared according to a preferred embodiment of the present invention at a magnification of 500.
FIG. 3 is a Scanning Electron Microscope (SEM) photograph of a foamed ceramic prepared according to a preferred embodiment of the present invention at 2000 Xmagnification.
Detailed Description
The invention is described in detail below with reference to the figures and the detailed description.
The ceramic production waste comprises polishing slag, waste bricks, waste mud, raw material tailings, production transfer excess materials and the like. Besides a small part of the raw materials can be reused as raw materials of wall and floor tile products, most of the raw materials need to be buried, which causes great damage to the environment. The production of foamed ceramics has low requirements on the grade of raw materials, so that a large amount of ceramic production waste can be recycled, but the ceramic production waste has unstable characteristics and certain randomness, and the production of foamed ceramics by using the foamed ceramics as the main raw materials is frequently accompanied with frequent process adjustment. Even in this case, the high-quality product rate can be guaranteed only at about 70%, and even at about 50% when the raw material is replaced. The material properties make it difficult to standardize and therefore manufacturing process tuning is a major direction. We analyzed that the effect of adjusting the firing stage was maximal, specifically:
a method for preparing foamed ceramics using ceramic production waste, comprising the steps of:
step 1: preparing materials; the method comprises the following steps of (1) taking known ceramic production waste as a main raw material, and adding a high-temperature foaming agent to prepare a foamed ceramic raw material;
step 2: the cloth is burnt, the prepared raw materials are pressed and formed or directly spread in a refractory kiln furniture to be put into a kiln to be burnt; the firing stage is provided with a transition cooling section which is positioned between the firing section and the quenching section, and the temperature range is the highest firing temperature of 1000 ℃;
and step 3: and (3) polishing, grinding and cutting, wherein the foamed ceramic blank obtained after the firing in the step (2) is polished, ground and cut to obtain the required foamed ceramic product.
Example 1
The formulation of this example was composed of the following: polishing slag: 59.5%, pressed mud: 13%, waste brick powder 6%, feldspar tailing waste material: 18%, talc sludge: 3 percent, silicon carbide 0.3 percent and manganese oxide 0.2 percent.
Wherein the polishing residue is obtained by polishing and grinding waste water treatment and squeezing of ceramic tiles of the golden ceramic group Limited company.
The pressed mud is various waste mud materials generated in the production process of ceramic wall and floor tiles of Jinyi pottery group Limited company and is obtained by ball milling and pressing treatment.
The waste brick powder is granular powder obtained by crushing waste materials of ceramic wall and floor tiles of Jinyi ceramic group Limited.
The residual tailings after the feldspar tailings waste feldspar raw material is mined.
The talc mud is tailing residue left after the talc ore is mined.
Silicon carbide and manganese oxide are commercially available, wherein the particle size of the silicon carbide is 7-7.5 mu m, and the particle size of the manganese oxide is 200-350 meshes.
Ball-milling the raw materials to prepare slurry, ageing, and then performing spray granulation to form granular powder. In the present embodiment, the foamed ceramic is produced by sintering powder, i.e. the powder obtained by spray granulation is spread in a refractory kiln furniture and scraped, and the thickness of the spread powder is preferably not more than 1/3 of the depth of the kiln furniture. Then the powder is sent into a kiln for sintering. The firing kiln uses a roller kiln, but a tunnel kiln can also be applicable.
The firing process comprises the following parts from the head to the tail of the kiln, namely a preheating exhaust section, a firing section, a transition cooling section, a quenching section and a slow cooling section. Wherein the preheating exhaust section, the sintering section, the quenching section and the slow cooling section are arranged conventionally, the transition cooling section is an additional stage which is arranged between the sintering section and the quenching section, the temperature range is between the highest sintering temperature and 1000 ℃, in the embodiment, the highest sintering temperature is 1195 ℃, namely, the temperature is reduced from the highest 1195 ℃ to 1000 ℃, in the stage, the cooling rate of the kiln is strictly controlled, preferably between 2 ℃ and 8 ℃, preferably between 3 ℃ and 5 ℃, and in the embodiment, the cooling rate is set to be 3.5 ℃/min. The quenching section adopts cold air extracted from the outside of the kiln to cool, and the slow cooling section is a natural cooling zone, namely a stage of naturally cooling the green body. In order to ensure that the cooling rate can be controlled within a required range in the transition cooling section, a certain number of spray guns are usually additionally arranged on the kiln, and when the cooling rate is too high, the kiln can be properly heated.
After the blank is taken out of the kiln, the blank is cooled to a processing temperature and then is polished and processed, and in the embodiment, the foamed ceramic plate with the thickness of 20mm is obtained.
Product performance was tested and the data is as follows:
density: 405kg/m3;
Compressive strength: 7.83MPa;
softening coefficient: 0.96
Drying shrinkage of 0.03 mm/m;
breaking strength: 4.5 MPa;
flexural failure load/plate dead weight multiple: 4.5;
combustion performance: a1;
the air sound and sound insulation performance is Rw (C; Ctr) =38 (-2; 4) dB;
whiteness: 42-45 degrees;
pore diameter: 0.5 mm-0.8 mm.
The rate of superior products of the products is as follows: 91 percent.
The product micro-morphology can be seen in fig. 1-3. As can be seen from FIG. 1, the foamed ceramic obtained by the present invention has approximately circular pore morphology and relatively uniform size, and as can be seen from further enlarged FIGS. 2 and 3, there are a small number of flaky cordierite phases, and these cordierite phases wrapped by the glass phase can improve the strength of the foamed ceramic. To further clarify the phase composition of the foamed ceramic article, we analyzed the phase composition of the foamed ceramic article using XRD and concluded that table 2 below.
TABLE 2
Figure 396873DEST_PATH_IMAGE002
It contains approximately 5% cordierite, the major sources of which are polishing slag and waste brick dust.
Comparative example 1
In the embodiment, the raw material formula components are not changed, but the sintering stage is changed to be consistent with the prior art, namely, a transition cooling section is not arranged, and the product directly enters a quenching zone for cooling after being sintered. The properties of the test products were as follows:
density: 416kg/m3;
compressive strength: 6.92MPA;
softening coefficient: 0.95
Drying shrinkage of 0.08 mm/m;
breaking strength: 4.0 MPa;
flexural failure load/plate dead weight multiple: 3.8 of the total weight of the mixture;
combustion performance: a1;
the air sound and sound insulation performance is Rw (C; Ctr) =33 (-2; 4) dB;
whiteness: 42-45 degrees;
pore diameter: 0.5 mm-1.2 mm.
The rate of superior products of the products is as follows: 75 percent.
The results show that the appearance uniformity of the foamed ceramic holes is improved by arranging the transition cooling section, the performance of the corresponding products is also improved, and in addition, the high-quality product rate of the products is also greatly improved.
To further illustrate the effect of the invention providing protocol, we simulated the change of stock for testing, see example 2 and comparative example 2.
Example 2
In the embodiment, raw materials are replaced, namely the formula proportion is unchanged, but the polishing slag is selected from residues obtained after polishing and grinding wastewater treatment by a ceramic tile polishing line of a production base of Jiangxi Jingdezhen of a company, and waste mud is also obtained from the production base of the Jiangxi Jingdezhen. The two raw materials are replaced, other process parameters are unchanged, and the obtained foamed ceramic has the following test performance:
density: 418kg/m3;
Compressive strength: 7.95MPA;
softening coefficient: 0.96
Drying shrinkage of 0.03 mm/m;
breaking strength: 4.8 MPa;
flexural failure load/plate dead weight multiple: 4.7;
combustion performance: a1;
the air sound and sound insulation performance is Rw (C; Ctr) =38 (-2; 4) dB;
whiteness: 43-45 °;
pore diameter: 0.5 mm-0.8 mm.
The high-quality product rate of the products in the process of transferring production: 89 percent.
From the test results, the scheme of the invention has the advantages that after the raw materials are replaced, the product quality is basically equal to the original product quality under the condition that other process parameters are not changed, the reduction range of the high-quality product rate is low, the production requirements of a workshop are met, and no adjustment is needed.
Comparative example 2
As in example 2 and comparative example 1, we changed the raw materials as in example 2 and produced the ceramic foam according to comparative example 1, and the performance test results of the foamed ceramic product were as follows:
density: 438kg/m3;
Compressive strength: 6.47MPA;
softening coefficient: 0.95
Drying shrinkage of 0.1 mm/m;
breaking strength: 3.8 MPa;
flexural failure load/plate dead weight multiple: 3.8 of the total weight of the mixture;
combustion performance: a1;
the air sound and sound insulation performance is Rw (C; Ctr) =32 (-2; 4) dB;
whiteness: 42-45 degrees;
pore diameter: 0.5 mm-1.5 mm.
The rate of superior products of the products is as follows: and 55 percent.
From the above test results, it can be seen that the product performance does not fluctuate much as compared with the comparative examples, but the product quality yield is only 55%. The major defect causing product degradation is cracking. Only 55% of the high-quality product rate has to be adjusted to the production process, which not only increases the production cycle but also causes great waste in the process.
Examples 3 to 5
In the three examples, the formulation components were further adjusted according to the principle that the firing temperature range of the foamed ceramic raw material included 1195 ℃.
The formulation of example 3 had the following composition: polishing slag: 69.5%, pressed mud: 10%, waste brick powder 6%, feldspar tailing waste material: 11%, talc sludge: 3 percent, silicon carbide 0.3 percent and manganese oxide 0.2 percent.
Example 4 the formulation components were as follows: polishing slag: 79.5%, pressed mud: 10 percent; 10% of feldspar tailings, 0.3% of silicon carbide and 0.2% of manganese oxide.
Example 5 formulation components were as follows: 54% of polishing slag, 10% of waste brick powder, 15% of feldspar tailings, 5% of talc mud, 15% of pressed mud, 0.5% of silicon carbide, 0.2% of manganese oxide and 0.3% of ferric oxide.
The highest sintering temperature is 1195 ℃, the sintering period is 15 hours, the temperature reduction rate of the transition temperature reduction section is 3.5 ℃/min in the sintering stage, and the interval is 1195-1000 ℃. The quenching stage uses cold air outside the kiln for heat exchange, but the cold air does not directly contact the hot foamed ceramic blank body, but flows in a cold air pipe in the kiln, and the heat is taken away by cooling the cold air pipe. And testing the performance and the high-quality product rate of the obtained foamed ceramic. It should be noted here that the production process is continuous, i.e. there is no gap between examples 3, 4 and 5, and the direct butt joint is completely performed. The test results are shown in table 3 below.
TABLE 3
Figure 176610DEST_PATH_IMAGE003
From the test results, even if the components of the formula are replaced, the performance of the product after conversion can still be basically stable, the high-quality product rate reaches more than 80%, and continuous production can be realized.
The cooling rate of the transition cooling section is preferably 2-8 ℃, more preferably 3-5 ℃, in order to ensure that the cooling rate can be accurately regulated, the kiln is properly improved, a combustion device (spray gun) is additionally arranged at a corresponding position, and the temperature control effect can be achieved by regulating the fuel supply quantity of the combustion device. For the cooling rate, the relationship between the power cost and the high-quality product rate needs to be considered. The cooling rate is small, the effect is good, but the sintering period is prolonged, more heat energy is needed to be supplied, and the power cost is increased correspondingly. And if the cooling rate is too high, the required effect is difficult to achieve, and through the balance of the two relations, the cooling rate is set to be 2-8 ℃, and preferably 3-5 ℃.
The scheme can be further optimized, namely, a middle temperature section is arranged in the sintering process, the temperature range of the middle temperature section is 900-1150 ℃, the heating rate in the middle temperature section is preferably 1-15 ℃, and preferably 2-4 ℃, and the slow heating rate is mainly set to ensure that the foaming agent can foam at a more stable rate, so that the shape of air holes is more regular.
At the temperature of over 900 ℃, the silicon carbide, ferric oxide and other common high-temperature foaming agents start to react, and at the temperature, the fusing agent in the blank also starts to melt to generate a liquid phase, gas generated by the foaming agent is wrapped by the molten liquid phase in the process, the viscosity of the liquid phase is reduced along with the increase of the temperature, and simultaneously, more gas is generated, and pores start to fuse and grow.
According to an embodiment of the invention, the foaming agent is a composition of silicon carbide and ferric oxide, free oxygen is needed in the silicon carbide foaming process, and oxygen is generated by the ferric oxide through foaming decomposition, so that the free oxygen can be provided, therefore, when the silicon carbide foaming process and the ferric oxide are mixed, the foaming process can be faster and more efficient, but the efficient foaming can cause irregular pores and influence the performance of the foamed ceramic, the problem can be well solved by setting a medium temperature section, the temperature is slowly increased in the medium temperature section, the generated foaming gas can be uniformly dispersed in a molten liquid phase, the process of pore fusion growth tends to be smooth, and sufficient foaming gas can ensure that the volume density of the product after being fired is smaller.
Example 6
The raw material formulation of this example had the following composition: 64% of polishing slag, 8% of waste brick powder, 12% of feldspar tailings, 3% of talc mud, 12% of pressing mud, 0.3% of silicon carbide, 0.2% of ferric oxide and 0.5% of manganese oxide.
Ball milling and granulating the raw materials, distributing the granules into a refractory kiln, and firing the granules in a roller kiln at a maximum firing temperature of 1195 ℃. The firing stage of the kiln comprises: preheating exhaust section, medium temperature section, sintering section, transition cooling section, quenching section and slow cooling section, wherein the preheating exhaust section is at the temperature of entering the kiln to 600 ℃, and the powder is mainly dried in the preheating exhaust section; the preheating exhaust section is 600-900 ℃, the organic matter, carbonate, nitrate and sulfate in the blank body are mainly decomposed in the preheating exhaust section, so that the generated gas is prevented from generating adverse effect on the subsequent foaming process of the foaming agent, the middle temperature section is 900-1150 ℃, the temperature rise rate in the preheating exhaust section is slow, preferably 1-15 ℃, and in the embodiment, the temperature rise rate is 2.5 ℃/min; the temperature of the sintering section is 1195 ℃ of 1150 ℃, the temperature rising rate of the stage is 8-25 ℃/min, and the temperature is kept for more than 30 minutes at the highest temperature of 1195 ℃; the temperature interval of the rapid cooling section is 1000-800 ℃, the temperature of the green body can be rapidly reduced by using external cold air in the stage, but a direct cold air blowing mode is not suitable, and cold air is introduced into a cold air pipe extending into the kiln for cooling; the slow cooling section is 800-400 ℃, and the blank is naturally cooled along with the transmission of the kiln at the stage.
After the blank is taken out of the kiln and is kept stand and cooled for a period of time, the blank can be cut, polished and processed, and the obtained product has the following properties:
density: 415kg/m3;
compressive strength: 9.74MPA;
softening coefficient: 0.96
Drying shrinkage of 0.03 mm/m;
breaking strength: 5.8 MPa;
flexural failure load/plate dead weight multiple: 5;
combustion performance: a1;
the air sound and sound insulation performance is Rw (C; Ctr) =38 (-2; 4) dB;
whiteness: 43-45 °;
pore diameter: 0.5 mm-0.6 mm.
The high-quality product rate of the products in the process of transferring production: 95 percent.
The excellent product rate of the embodiment reaches 95 percent, the raw materials are obtained under the condition of using a large amount of ceramic production waste, the product performance is particularly good, and the core indexes such as strength, volume density and the like are all superior to those of a foamed ceramic product prepared from the ceramic production waste.
Of course, besides all the ceramic production waste materials, other mineral raw materials can be properly used, for example, a proper amount of plastic clay can be added to improve the suspension property of the slurry after ball milling; other waste materials such as slag, river sludge, etc. may also be used and need not be described in further detail herein.
In order to obtain better exhaust passage of the powder during the preheating exhaust stage, a component with decomposition temperature gradient can be used, such as a combination of carbonates, and 0.5% of barium carbonate and 2% of calcium carbonate are added in the raw material in one embodiment of the invention, although ammonium carbonate and sodium carbonate can be used alternatively.
In order to improve the strength of the product, a component containing a large amount of primary mullite and primary cordierite can be added into the raw materials, for example, the cordierite-mullite refractory kiln furniture can be added as the raw materials after being scrapped, in addition, some toughened high-alumina fibers can also be selected and applied, the sintering temperature or the flux component is required to be adjusted when the above components are used, and for example, glass can be used as the flux.
The amount of the foaming agent is preferably 0.2 to 2 percent, the amount of the foaming agent can be reduced for a formula system using a large amount of polishing slag, and the foaming agent can be other known foaming agents besides silicon carbide and can be used in combination. The amount of the oxygen increasing agent is matched with that of the foaming agent, namely when the silicon carbide foaming agent is used in a large amount, the amount of the corresponding oxygen increasing agent needs to be increased properly, usually 0.2-2 percent is preferred, common oxygen increasing agents are manganese oxide and ferric oxide, and the common components which can be decomposed to obtain free oxygen under the high-temperature condition can be selected and applied properly.
The technical principle of the present invention is described above in connection with specific embodiments. The description is made for the purpose of illustrating the principles of the invention and should not be construed in any way as limiting the scope of the invention. Based on the explanations herein, those skilled in the art will be able to conceive of other embodiments of the present invention without inventive effort, which would fall within the scope of the present invention.

Claims (10)

1. A method for preparing foamed ceramics by using ceramic production waste is characterized by comprising the following steps:
step 1: preparing materials, namely taking known ceramic production waste as a main raw material, and adding a high-temperature foaming agent to prepare a foamed ceramic raw material;
step 2: the cloth is burnt, the prepared raw materials are pressed and formed or directly spread in a refractory kiln furniture to be put into a kiln to be burnt; the sintering stage is provided with a transition cooling section, the transition cooling section is positioned between the sintering section and the quenching section, the temperature range is the highest sintering temperature-1000 ℃, and the cooling rate of the transition cooling section is 2-8 ℃/min;
and step 3: and (3) polishing, grinding and cutting, wherein the foamed ceramic blank obtained after the firing in the step (2) is polished, ground and cut to obtain the required foamed ceramic product.
2. The method for preparing foamed ceramics using ceramic production wastes according to claim 1, wherein the temperature reduction rate of the transition temperature reduction stage is 3 to 5 ℃/min.
3. The method of claim 1, wherein the transition cooling section controls the cooling rate by heating.
4. The method for preparing foamed ceramic using ceramic production waste according to claim 1, wherein the maximum firing temperature is 1150 ℃ to 1200 ℃, a middle temperature section is further provided in the firing stage, the temperature of the middle temperature section is 900 ℃ to 1150 ℃, and the heating rate of the middle temperature section is 1 ℃ to 15 ℃/min.
5. The method for preparing foamed ceramics according to claim 1, wherein the foaming agent contains silicon carbide, and the average particle size of the silicon carbide is 7 to 7.5 μm.
6. The method for preparing foamed ceramics by using ceramic production wastes according to claim 1, wherein the foamed ceramic raw material further contains an oxygen increasing agent in an amount of 0.2 to 2% by mass of the raw material.
7. The method of claim 6, wherein the oxygen-increasing agent is at least one of ferric oxide or manganese oxide.
8. The method for preparing foamed ceramics according to claim 1, wherein the ceramic production waste is at least three combinations of polishing slag, waste brick powder, talc sludge, press sludge and feldspar tailings.
9. The method of claim 8, wherein the maximum firing temperature is 1175 ℃ to 1195 ℃.
10. The method for preparing foamed ceramics according to claim 8, wherein the foamed ceramic raw material comprises the following components in percentage by mass:
polishing slag: 50-80%;
waste brick powder: 0 to 10 percent;
10-15% of feldspar tailings;
and (3) rubble mud: 0 to 5 percent;
pressing the mud: 10 to 15 percent of the total weight of the mixture,
foaming agent: 0.2 to 2 percent of the total weight of the mixture,
0.2 to 2 percent of oxygenation agent.
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