3888results about "Ceramic materials production" patented technology

The invention provides a ceramic slurry preparation and 3D (three dimensional) printing light curing molding method. 25-85vol% of ceramic powder and 15-75vol% of an optical resin premix solution are mainly involved, and the method includes: A), preparation of the optical resin premix : namely stirring a low polymer, a reactive diluent, a photoinitiator, a dispersing agent, a photosensitizer and a sensitizer according to a certain proportion under intermediate speed for 0.5-3 hours to enable the components to be mixed evenly; B), placing the premix solution and the ceramic powder in a ball mill according to certain volume for ball-milling for 5-15 hours to prepare the ceramic slurry high in solid content and low in viscosity; subjecting the ceramic slurry to curing molding layer by layer gradually on a 3D light curing molding machine to obtain a ceramic green body prior to aftertreatment of drying, degreasing, sintering and the like to obtain ceramic part. The method is high in preparation molding precision and free of molds to prepare complex structure parts, the ceramic product can reach more than 92% in density, 320-1750MPa in flexural strength and 1800-4500MPa in compression strength.

The invention discloses spherical attapulgite flower ceramsite. The key points of the technical scheme are that the spherical attapulgite flower ceramsite consists of high-adhesion attapulgite clay powder, attapulgite clay tailing powder, red bentonite powder, sludge, diatomite tailing powder and rice husk powder. The spherical attapulgite flower ceramsite is produced by the following steps of mixing the ingredients, pelleting, roasting, cooling, screening and packaging. The spherical attapulgite flower ceramsite has a rough and porous surface, is light in weight, high in strength and water absorption rate, can be immersed in water throughout the year without cracking and can continuously and slowly release nutrition required by flowers. Moreover, the spherical attapulgite flower ceramsite is produced by comprehensively utilizing the sludge and tailings, so that the resource utilization rate is improved, waste is turned into wealth, and environment is protected. Besides, the cylindrical attapulgite flower ceramsite is applicable to cultivation of various flowers and vegetables.

A lightweight, high-strength proppant is disclosed, comprising the formation of finely dispersed ceramic precursors and sintering at low temperatures, causing the formation and retention of mesopores and micropores in pelletized ceramic. A method of manufacturing such a proppant is also disclosed, comprising the steps of manufacturing finely divided ceramic precursors and additives using grinding, milling, and preferably sol-gel processes, and dispersing the finely divided ceramic precursors and additives in a liquid, preferably water. The dispersion has a viscosity profile, which permits the shaping of spheres using conventional pelletizing techniques. Drying of the pellets and sintering at temperatures below 1,400.degrees. C. forms and retains mesopores and micropores in the ceramic. Preferred total pore volumes range from 0.05 to 0.7 cm.sup.3/g. The pelletized and porous ceramic is useful as lightweight and high-strength proppants.

A degreasing jig assembling apparatus includes a robot arm and a table or a conveyor on which a degreasing jig including a bottom plate and a cover member is placed. A ceramic molded body is mounted on the degreasing jig upon degreasing the ceramic molded body. The ceramic molded body is mounted on the degreasing jig on the table or the conveyor. The degreasing jig assembling apparatus further includes a molding body mounting mechanism and a cover member. The molding body mounting mechanism mounts the ceramic molded body at a predetermined position on the bottom plate placed on the table or the conveyor by using the robot arm. The cover member attaching mechanism attaches the cover member to the bottom plate in a manner so as to cover the ceramic molded body mounted on the bottom plate.

The invention provides novel aerated composite materials that possess excellent physical and performance characteristics of aerated concretes, and methods of production and uses thereof. These composite materials can be readily produced from widely available, low cost raw materials by a process suitable for large-scale production with improved energy consumption, desirable carbon footprint and minimal environmental impact.

The invention discloses a foamed ceramics energy saving and heat preservation decorative wall brick and a manufacture method thereof, including the steps of conducting ball milling on 15-65 percent wt of industrial residues, 10-45 percent wt of plastic clay, 15-60 percent wt of solvent, 10-45 percent wt of pore-forming agent with the fineness being 1-100mum and proper amount of water to form slurry; spray drying or dehydration and clay preparation, and forming powder material or clay segment through staleness; and implementing pressure forming to make billet which is burned under heat preservation at temperature of 1140-1240 DEG C to finally form the foamed ceramics wall brick. The wall brick can be used not only for the heat preservation and decoration of external walls, but also for indoor heat preservation and decoration, and the external wall and the indoor space can realize the organic combination of uniform heat preservation and decoration, which agrees with the development direction of heat preservation material industry of external walls. The wall brick has the advantages of: I. high temperature resistance, acid and alkali-resistance, good chemical stability, no ageing, strong durability, long service life, no generation of heat channel and good adhesive fixity; and II. difficult water seepage and crack, strong anti-corrosion capacity, uneasy deformation and damage, simplification of mounting, laying and sticking procedures, convenience for construction, relief of labor intensity and decrease of material consumption quantity.

A precursor composition for the production of granulated ceramic material, particularly for ceramic proppants, comprises 20 to 55% by weight of magnesium orthosilicate, 20 to 35% by weight of MgO, and 2.5 to 11% by weight of Fe₂O₃. The resulting lightweight proppant material shows high mechanical strength. To further decrease the specific density of the proppant, the formation of small pores can be increased by adding 0.3 to 2.4% carbon as a gas-forming agent.

The present invention discloses one kind of haydite produced with dewatered sludge, fly ash and clay as material and its production process, and belongs to the field of environment technology. The haydite is produced dewatered sludge, fly ash and clay as material, and through mixing and sintering at gradually raised temperature. It is yellow or brown spherical solid in the bulk specific weight of 650-750 kg/cu m, granular specific weight of 1050-1150 kg/cu m, water absorption of 5.80-10.8 %, and specific surface area of 2.29-5.56 sq m/g. The production process is simple and low in cost, and the haydite has light weight, high strength, small water absorption, great specific surface area and other features. The haydite has wide use in building, environment protection, metallurgy, chemical industry, and other industry.

The invention discloses porous ceramsite made of low-silicon iron tailings and a preparation method of the porous ceramsite. The porous ceramsite is prepared from, by weight, 75-90 parts of low-silicon iron tailing powder or low-silicon iron tailing pulp, 5-20 parts of pore-forming agents and 1-8 parts of clay, wherein the SiO2 content in the low-silicon iron tailing powder or low-silicon iron tailing pulp is lower than 40%. The method includes: weighing and mixing the iron tailings, the pore-forming agents and the clay, and granulating the mixture into green balls; and after the green balls are dried, calcinating the dried green balls for 40-60min at the temperature of 1100-1180 DEG C, so that the ceramsite made of the iron tailings is obtained. By the method, the porous ceramsite conforming to architecture application and water treatment application can be prepared respectively. The ceramsite prepared by the method has the advantages of high strength and apparent porosity, low density, good thermal insulation property, high cost performance and the like, and can be used for preparing various light, sound-insulation and thermal-insulation materials or used as light building aggregate, water treatment biological carriers and the like.

In one example of an embodiment of the invention, a method for producing an aggregate is disclosed comprising mixing sewage sludge from a waste water treatment facility with a non-coal combustion ash silicoaluminous waste material, agglomerating the mixture to form an agglomerate, and pyroprocessing the agglomerate to form an aggregate. The waste material may comprise municipal solid waste incinerator bottom ash, incinerator fly ash, incinerator filter dusts, cement kiln dusts, waste glass, blast furnace slag, kiln dusts, and/or granite sawing residues, for example. The method may further comprise milling the waste material prior to mixing. Preferably, the milling is wet milling. Pyroprocessing of the agglomerate may take place in a rotary kiln. The resulting aggregate may be a lightweight or a normal weight, sintered or vitrified aggregate. Aggregates and methods for making aggregates of high and low calcium silicoaluminous materials are also disclosed.

The invention provides municipal sludge expanded ceramsite and a preparation method thereof. The municipal sludge expanded ceramsite is prepared from the following materials by mass percentage: 20% to 45% of municipal sludge, 50% to 70% of shale, tailings or clay, 1% to 5% of organic matter and 1% to 5% of iron powder, wherein, the tailings is one of pyrite tailings, gold tailings, lead-zinc tailings and aluminum tailings; and the organic matter is sawdust. The preparation method comprises the following steps: feeding the shale, tailings or clay into a crusher, and carrying out the screening treatment; adding and mixing the municipal sludge, the organic matter and the iron powder, feeding into an ageing silo and stirring; then, feeding into a granulating machine, granulating and calcinating in a rotary kiln; and finally, cooling and stacking the calcinated ceramsite by classification. By using a great amount of municipal sludge, the invention is resource-saving and environment-friendly; compared with the original cost, the overall cost of a building is reduced by 5% to 10%; and the prepared expanded ceramsite has the advantages of light weight, fire resistance, sound absorption, good heat insulating and preserving performance, simple process and low cost, so that the invention is suitable for industrialized production.

The invention provides a ceramic material with a multi-stage duct structure and a manufacture method thereof. The ceramic material is characterized by being provided with a plurality of macropores with millimeter grade, tens of middle pores with millimeter grade exist on the walls of the macropores, micropores with sizes less than microns exist on the walls of the middle pores. The ceramic material is manufactured by using 10-50 percent by mass of waste and 20-60 percent by mass of natural porous mineral and matching with 10-30 percent by mass of clay through the steps of adding water for mixing, forming, drying, preheating and sintering at a temperature of 1000-1200 DEG C, wherein the waste can be expanded at high temperature or has large ignition lost and easy decomposition and volatilization. The ceramic material has excellent water-absorbing and water-retaining properties, better water permeability, excellent absorption and filtration and light weight, and can be used as a water-absorbing material, a water-retaining material, a water permeating material, a sound insulating material, a heat insulating material, an indoor deodorizing material, an absorbing material, a filtering material and the like to be widely applied to various fields.

The invention discloses a method for producing a ceramic brick by metallurgical steel slag, which comprises the following steps: crushing waste slag after metallurgical steel-making; adding clay, talc, quartz and other materials to the waste slag according to the requirement of formulation property to mold a blank by a dry pressing method through ball milling by a wet method, and powdering by slurry spraying; drying and placing the molded blank into a roller kiln for maturing; and producing the matured product into a finished product through edging, polishing, grading and packaging. The invention can be widely applied in decoration, has the characteristics of environmental production, high strength, corrosion resistance, good decoration effect and so on. The method provided by the invention is simple and feasible, and is beneficial to industrial production.

The invention discloses gravel attapulgite flower ceramsite. The key point of the technical scheme is that the gravel attapulgite flower ceramsite consists of high-viscosity attapulgite clay powder, attapulgite clay tailing powder, red bentonite powder, sludge, kieselguhr tailing powder and rice husk powder.t. The gravel attapulgite flower ceramsite is produced by the following steps of mixing the ingredients, pelleting, baking, cooling, smashing, sieving and packaging. The gravel attapulgite flower ceramsite is an irregularly-shaped granule, and has a rough and porous surface, light weight, high strength and high water absorption. The gravel attapulgite flower ceramsite can be soaked in water without being cracked and release nutrition required by flowers continuously and slowly. The gravel attapulgite flower ceramsite is produced by utilizing the sludge and tailings comprehensively, so that the utilization rate of resources is improved, waste materials are changed into wealth, and environment is protected. Besides, the gravel attapulgite flower ceramsite is suitable for planting the flowers and vegetables.

The invention discloses a method for preparing no-foaming and no-deformation ceramics by utilizing ceramic waste, comprising the following steps: all raw materials are mixed by weight percentage: 1-99percent of ceramic waste, 0-40 percent of ceramic clay, 0-30 percent of quartz, 0-35 percent of feldspar and 1-50 percent of aluminum oxide or aluminous rich matter; water is added by 50-150 percentof total weight of the raw materials, and 0.5-5 percent of grinding aids and 0.5-5 percent of binders are added to carry out ball-milling, the no-foaming and no-deformation ceramics can be prepared bydrying, formation and sintering. The technology provide by the invention not only solves the problem of the treatment of a great amount of ceramics in ceramic industry, but also solves excessive consumption problem of raw material resource in the ceramic industry, thereby greatly reducing the waste discharge in the ceramic industry and reducing environmental pollution caused by accumulation and land filling of the ceramic waste. The technology has the advantages of high waste utilization rate, simple process and low cost.

Sewage sludge shale ceramsite and a preparation method thereof are provided, which relates to the light energy-saving ceramsite of building materials and a preparation method thereof. The ceramsite of the invention consists of sewage sludge, shale and admixtures; the method of the invention uses the sewage sludge, the shale and the admixtures as raw materials; first, the shale is grinded into shale powder and then the sewage sludge, the shale and the admixtures are mixed and wedged to be granulated into round particles and then enter into a kiln; the products are obtained after going through drying, preheating, barking and being taken out of the kiln for cooling. The ceramsite employs the sewage sludge discharged directly from sewage treatment plants and the shale as major materials, which greatly saves land resource and partial shale mine resource and provides an extremely good way for the non-hazardous and reclaiming treatment of sewage sludge; the method of the invention is simple, energy-saving and resources-saving and the density rank of the ceramsite is 300-700. The ceramsite of the invention can be widely applied in lightweight aggregate bricks, lightweight aggregate sheet materials, lightweight aggregate concrete, etc. and can also be taken as the filter material of sewage treatment, the water-retaining agent in cultivation, etc.

The invention discloses architectural ceramic prepared from industrial solid waste through a dry method and a process for preparing the architectural ceramic. The architectural ceramic comprises the following components in percentage by mass: 30-60% of solid waste, 40-70% of ceramic raw material and 1-3% of ceramic additive, wherein the ceramic raw material is selected from one or a composition of multiple of clay raw material, feldspar raw material or talc, and the ceramic additive is one or a combination of multiple of sodium tripolyphosphate, sodium silicate, ammonium chloride, ammonium citrate, sodium humate, sodium lignin sulfonate sodium, ethylenediamine tetraacetic acid disodium and edetic acid. After being pretreated, the granules of the solid waste are fine and are mixed evenly in a dry mixing manner and a spray drying manner and are directly used for pressing of green bricks or stored in a bin for standby, so that the ball milling energy consumption and the peptization cost are reduced, the humidification pelleting and fluidized bed drying procedures are omitted, the formula can be quickly adjusted according to the functional characteristics of the architectural ceramic, the process is simple and convenient to control, and the architectural ceramic has such good properties as heat preservation, thermal insulation and high strength.

A combinatorial library includes a gelcast substrate defining a plurality of cavities in at least one surface thereof; and a plurality of gelcast test materials in the cavities, at least two of the test materials differing from the substrate in at least one compositional characteristic, the two test materials differing from each other in at least one compositional characteristic.

A lightweight high-strength ceramsite, comprising solid raw materials and activator as the raw materials, which can be respectively expressed in parts by weight, the solid raw materials: 100 parts, the activator: 1-15 parts; wherein said solid raw materials comprise fly ash: 100 parts, high-alumina fly ash, bauxite and red mud: 6-18 parts, silica fume: 1-5 parts, surfactant: 0.1-3 parts, plasticizer: 6-24 parts; and said activator comprises alkali metal hydroxide: 5-20 parts and alkali metal silicate: 80-95 parts. The lightweight high-strength ceramsite product prepared has a density level of 700-1100 kg/m3 and cylindrical compressive strength of 10-20 MPa, and thus is not susceptible to damage.

A method for automatically shaping the load-bearing hollow brick includes such steps as preparing concrete, stirring, filling in mould, inserting core mould while vibrating, hydraulic pressing, and demoulding. Its apparatus is composed of electric power control box, control mechanism, motor, concrete preparing system, shaping system, feeding unit, and discharging unit.

The invention relates to the technical field of harmlessness treatment of smelting wastes, and especially relates to a ceramsite prepared by using smelting wastes, and a preparation method thereof. The ceramsite comprises 10-90% of smelting waste powder, 5-40% of municipal sludge, 4-20% of fly ash, 0-20% of gangue and 0.1-10% of a curing agent. The preparation method of the ceramsite comprises the following steps: 1, crushing the smelting wastes by using a crusher to prepare the smelting waste powder; 2, weighing the smelting waste powder, the municipal sludge, the fly ash, gangue and the curing agent, mixing, and uniformly stirring to prepare ceramsite powder; 3, conveying the ceramsite powder to a ball forming granulation machine, and carrying out granulation molding to prepare ceramsite balls; 4, drying the ceramsite balls; and 5, calcining he dried ceramsite balls to prepare the finished ceramsite. The ceramsite prepared in the invention has the advantages of light weight, environmental protection and wide uses; and the preparation method recycles the smelting wastes, and has good economic and social benefits.

The invention discloses a method for producing lightweight ceramic bricks by comprehensively utilizing solid wastes from ceramics factories and sludge produced in sewage treatment plants as the raw materials. The method comprises the steps of: subjecting waste residues from polishing, fragmentation treated waste polished tiles, waste blank powder and waste mud powder reclaimed from blank making, recovered dust from dedusters, drainage silt from ceramics factories, fragmented waste abrading blocks for polishing, waste glazes, coal sintering residuals, waste kaolin, waste high temperature sand, sludge, a water reducer and a reinforcing agent to ball milling, deironing through sieving, decaying and homogenization in a wet bowl mill, spray drying the slurry into particle powder, then pressing and sintering the particle powder into bricks. By comprehensively utilizing solid wastes from ceramics factories and sludge produced in sewage treatment plants, the method of the invention reaches the purpose of waste recycling and realizes the effect of zero emission of architectural ceramics and polished tile factories.

The invention discloses a low-density ceramic proppant prepared from fly ash and a preparation method thereof. The proppant comprises the following components, by weight: 60%-80% of bauxite, 10%-30% of fly ash and 5%-10% of manganese powder. The fly ash mainly comprises Al2O3 and SiO2, and the Al2O3 and SiO2 have higher content and purity than coal gangue, so that quality of the fly ash will not be influenced; and the fly ash has low density, and is suitable to be used as a raw material for preparation of low-density ceramic. Fly ash has wide distribution, and can be used to replace bauxite resource, which is becoming more and more limited, so as to save non-renewable resources. Compared with ceramic proppant prepared from coal gangue, the low-density ceramic proppant prepared from raw material of fly ash has substantially reduced fracture rate, bulk density and turbidity, improved product quality and reduced cost, so as to solve environmental pollution caused by fly ash emission.

The invention relates to a ceramic rock plate and a preparation method thereof. A ceramic rock plate blank is composed of the following components in percentage by weight: 35-46.1% of mud; 50 to 60 percent of a water abrasive; 1-7% of a green body toughening material; 0.5 to 3 percent of a reclaimed material; and 0.1-0.8% of an additive. The preparation method comprises the following steps: preparing a green body, processing the green body, performing spray drying to prepare powder, performing dry pressing to form the green body (with a plane or concave-convex effect), drying, polishing the green body, blowing ash, spraying water, spraying white ink, spraying engobe, decorating patterns, decorating isolation glaze, decorating a transparent glaze layer, firing, polishing and edging.

The invention relates to a low-temperature fast-fired ceramic tile and a production process thereof. The blank material of the ceramic tile comprises at least one selected from the group consisting of fine granules produced during grinding and polishing in production of polished tiles, fine granule-containing waste water collected after polishing and a waste polishing material obtained after deposition and press filtration; the blank material of the ceramic tile is composed of, by weight, 48 to 73% of the waste polishing material, 5 to 20% of porcelain sand, 20 to 27% of clay and 2 to 5% of a mineralizer. The production process comprises the following steps: (1) collecting the waste polishing material, carrying out batching according to a formula and then carrying out wet ball milling so as to obtain slurry, wherein the waste polishing material stood for subsequent usage in press filtration and other raw materials are calculated on a dry basis; (2) subjecting the slurry to spray drying so as to obtain powder and carrying out dry-pressing so as to form a ceramic adobe; (3) drying the adobe, glazing the adobe and carrying out surface decoration; and (4) putting a decorated blank into a ceramic roller kiln for firing, wherein fast firing temperature is 1050 to 1140 DEG C, a firing period is 35 to 75 min, and the ceramic tile with a water absorption rate of less than 0.5% is sintered.

The invention discloses a method of baking ceramsite by using sludge. The method firstly executes sludge drying to the mechanically dehydrated sludge of sewage treatment plant or sludge dredged by rivers in a special sludge drying device, and respectively reduces the water ratio and volume of the sludge to less than 30% and less than one third. Then a special press presses the sludge into material ball, baking the sludge material ball under 1000 to 100 degrees centigrade, forming sludge ceramsite; the hot fume exhausted when bakes the sludge ceramsite is taken as the thermal resource. Compared with the method taking clay, sub-clay, shale as the raw materials to bake ceramsite, the method in the invention has less energy consumption and lower production cost, and starts a new route of treatment of wastes with processes of wastes against one another and sludge resource treatment of waste cyclic utilization.

A method and a production line for producing ceramic particles by using various hazardous wastes relate to complete treatment and permanent safety of the hazardous wastes and ceramic particle production, and in particular relate to the method and the production line for producing the ceramic particles by using the various hazardous wastes. A hazardous waste mixture formed by random types of all the various hazardous wastes listed in the national hazardous waste catalogue according to random proportions is ground into slurry by a wet method; the slurry is sufficiently stirred and mixed with clay ground by a dry method and an additive according to certain proportions; the obtained mixture is extruded by a vacuum stirring extruding machine to form high-intensity biscuit particles; the high-intensity biscuit particles are dried, preheated, burn-expanded, sintered and cooled to form the ceramic particles. The clay polluted by the hazardous wastes is adopted; in the mixture of the hazardous wastes, the clay and the additive, a ratio of (SiO2+Al2O3+Fe2O3) to (CaO+MgO) is greater than 2, and meanwhile, a ratio of SiO4 to MgO is greater than 4.

The present invention discloses one kind of stone powder sludge sintering brick and its production process. The stone powder sludge sintering brick is produced with stone powder sludge from stone material producing process as main material, sludge from river, lake or sea, building waste clay or clay as adhesive, slag, coal slack, fly ash or coal as inner material, and through crushing, stirring, forming adobe, drying, roasting and other steps. The present invention has the features of waste utilization, environment friendship, saving in soil, low power consumption, high compression strength, etc. It may be used in replacing sintered clay brick.

The invention provides a method for preparing a ceramic water permeable brick by virtue of a granulation process. The method comprises the following steps: pulverizing brick-making raw materials into brick-making powder; granulating the brick-making powder so as to obtain brick-making particles with similar particle sizes, wherein the ratio of the minimum particle size to the maximum particle size of the brick-making particles is 0.5 to 1; and forming a green body by virtue of the brick-making particles, and carrying out processes of ceramic sintering brick drying, sintering and the like on the green body, so as to obtain the ceramic water permeable brick. According to the method, a preparation process of the ceramic water permeable brick can be greatly simplified, the quality in the preparation process is relatively controllable, and the range of the raw materials of the water permeable brick is greatly extended to various waste, inferior raw mineral materials and the like; and the method has remarkable economic, environment-friendly and social benefits and wide application prospects.

The invention relates to a light ceramisite and a preparation method, comprising processes such as modification treatment of the raw material, the biological preparation, granulation, drying, baking and roasting etc. The invention is characterized in that the component and volume percent of the raw materials comprise: 30-70 percent of tailing of tungsten mine; 15-22.5 percent of cinder; 15-22.5 percent of fly ash; 10-14.5 percent of clay; 0.1-3 percent of pore-forming material; 0.2-1 percent of modified adhesive of biological material; the preparation technology is that after subject to modification treatment using 15-25 percent of HC1, the tailing of tungsten mine is prepared to be the ceramisite together with materials with different melting temperatures such as the cinder, the fly ash, the clay etc., as well as the pore forming agent and adhesive; then the tailing of tungsten mine is put into an oven below normal temperature for baking below 120 DEG C for 1 hour, and placed into a muffle furnace for gradually heating up to 500 DEG C within 1 hour; presintered after kept constant temperature for 10 min; then entered into a furnace up to 800 - 1120 DEG C for burning for 30 minutes, finally discharged to be naturally cooled down to normal temperature.