All-solid-waste-based ceramic rock plate based on low-value solid waste raw materials and preparation method of all-solid-waste-based ceramic rock plate

Abstract

The invention discloses an all-solid-waste-based ceramic rock plate based on low-value solid waste raw materials and a preparation method of the all-solid-waste-based ceramic rock plate. The ceramic rock plate is prepared from the following raw materials in percentage by mass: 40-80% of a first component, 20-30% of a second component and 0-30% of a third component, wherein the first component is prepared from the following raw materials in percentage by mass: 40-80% of the first component, 20-30% of the second component and 0-30% of the third component; the first component is engineering residue soil, the second component is polishing mud, and the third component is ion adsorption type rare earth tailings, the mineral and chemical components of the engineering residue soil, the polishing mud and the ion adsorption type rare earth tailings are reasonably utilized by adopting a full solid waste base form, the ceramic rock plate is prepared, the sintering temperature is reduced, and the service life of the ceramic rock plate is prolonged. The invention solves the dependence of the traditional ceramic industry on natural minerals, solves the technical problems of high cost and high energy consumption of the ceramic rock plate, and not only realizes the reasonable utilization of waste resources, but also realizes the technical purposes of energy conservation and low carbon.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of solid waste resource utilization and ceramic production, and particularly relates to a method for preparing a full-solid-waste-based ceramic rock plate based on low-value solid waste raw materials. BACKGROUND

[0002] In recent years, the amount of engineering muck generated by civil engineering activities such as building, road, and subway has increased year by year; and the existing disposal field has a serious shortage of processing capacity, resulting in environmental problems and safety hazards. The resource utilization rate of engineering muck is less than 10%, which causes waste of this urban mineral resource.

[0003] Polishing mud is a solid waste generated in the polishing process of ceramic tiles, and the main components are SiO2, Al2O3 and various fluxing agent oxides, and a small amount of silicon carbide (SiC) abrasive. According to statistics, the annual output of polishing mud in China exceeds 7 million tons, and the traditional treatment method is mainly landfill, which occupies land resources, and its resource utilization is very urgent. At present, there are few reports on the technical means of resource utilization of polishing mud.

[0004] Ceramic rock plate / plate is a new building decoration material, which has become the development trend of the industry due to its large size, high strength, energy saving and environmental protection and other advantages. However, its production still mainly relies on natural mineral resources such as kaolin and feldspar, and the annual output of ceramic rock plate in China has exceeded 6.7 billion square meters in 2022, and the cost of raw materials continues to rise, which restricts the sustainable development of the industry. The production capacity regulation, energy efficiency standard improvement, process flow reconstruction and green energy replacement of high-energy-consuming industries such as ceramic production all have strict requirements, and the energy saving, consumption reduction and cost reduction of the ceramic industry including ceramic rock plate preparation have become an important development direction of the whole industry.

[0005] Therefore, the use of solid waste or low-value raw materials to replace kaolin, feldspar and other mineral raw materials to produce ceramic products such as ceramic tiles has gradually attracted attention in recent years, and some patent technologies have appeared. For example, the Chinese invention patent with the patent number CN202011537274.6 discloses a coal gangue ceramic tile and its production process, which uses 57-70wt% of coal gangue and ironmaking slag solid waste to replace natural raw materials to prepare ceramic tiles with excellent mechanical strength and chemical corrosion resistance. The Chinese invention patent with the patent number CN201410031333.0 discloses a porcelain tile made of ceramic waste solid (ceramic polishing waste slag, waste powder, waste blank, and waste tile) and its preparation method, which uses ceramic waste solid and ordinary ceramic raw materials to prepare porcelain tiles, and the ceramic waste solid accounts for 20-80wt% of the raw materials.

[0006] CN2020109402922 discloses a ceramic tile made from solid waste. The green body is composed of the following raw materials, by weight: 30-35 parts of ceramic waste, 35-40 parts of kaolin tailings, 20-25 parts of fly ash, 20-25 parts of red mud, 10-15 parts of diatomaceous earth, and 5-10 parts of brown corundum. However, although it can process ceramic waste, kaolin tailings, etc., it is quite strict in the selection of waste. Luo et al. used alkali-activated pretreatment of high-alumina fly ash to prepare mullite ceramic tiles at a lower sintering temperature, replacing up to 10% of the feldspar raw material (Luo et al., Journal of Alloys and Compounds , 2017). Ozturk and Gultekin used blast furnace slag to partially replace limestone and kaolin in natural mixtures to prepare ceramic wall tiles, with the optimal dosage controlled between 20-30% (Ozturk and Gultekin, Ceramics International , 2015). Ke et al. used polishing mud instead of natural raw materials to prepare ceramic tiles that met the standards, and the performance was the best when 50% polishing mud was added (Ke et al. Journal of Cleaner Production , 2015).

[0007] The aforementioned patents or technologies utilize a single solid waste, leading to issues such as reduced product performance, a low upper limit on solid waste content, high sintering temperatures, and the need for pretreatment, which increases energy consumption. Ceramic rock slabs, in particular, have recently gained popularity and become a mainstream building and decorative material, but reports on their production using only solid waste as raw materials are rare.

[0008] Based on the above defects, the inventor proposed a ceramic rock slab based on low-value solid waste raw materials and a preparation method, aiming to solve the problems of harsh raw material selection, single solid waste utilization and insufficient performance of ceramic rock slabs in the process of preparing ceramic rock slabs using low-value solid waste raw materials in the existing technology. Summary of the Invention

[0009] The purpose of the present invention is to provide a fully solid waste-based ceramic rock slab based on low-value solid waste raw materials and a preparation method thereof to solve the problems existing in the above background.

[0010] In the first aspect, the present invention provides a fully solid waste-based ceramic rock plate based on low-value solid waste raw materials, which is prepared using the following raw materials: a first component, a second component and a third component: Preferably, the first component has the following chemical composition ratio: SiO2 56.00~66.00%, Al2O3 14.00~25.00%, Fe2O3 3.00~6.50%, CaO 0.10~6.50%, MgO 0.40~2.00%, K2O+Na2O 1.55~5.30%, loss on ignition 6.00~9.70%; Preferably, the second component has the following chemical composition ratio: SiO2 65.00~69.00%, Al2O3 17.00~21.00%, Fe2O3 1.00~2.50%, CaO 1.50~2.50%, MgO 1.50~3.00%, K2O+Na2O 3.00~5.00%, loss on ignition 2.00~3.50%; Preferably, the third component has the following chemical composition ratio: SiO2 59.00~65.00%, Al2O3 28.00~32.00%, Fe2O3 1.30~2.50%, CaO 0.01~0.10%, MgO 0.04~0.15%, K2O+Na2O 4.55~5.65%, loss on ignition 0.03~0.10%; Preferably, the first component accounts for 40~80% by mass, the second component accounts for 20~30% by mass, and the third component accounts for 0~30% by mass; Preferably, the third component accounts for 0~30% by mass, and the third component accounts for more than 0% by mass; Preferably, the first component accounts for 60~80% by mass, the second component accounts for 20~30% by mass, and the third component accounts for 20~30% by mass; Preferably, the first component, the second component, and the third component are all solid waste raw materials.

[0011] Preferably, the first component is engineering slag, the second component is polishing mud, and the third component is ion-adsorbed rare earth tailings.

[0012] Preferably, the engineering slag can contain illite, montmorillonite, quartz, hematite, albite, kaolinite, calcite, oligoclase, etc.

[0013] Preferably, the engineered soil has the following chemical composition ratio: SiO2 56.00~66.00%, Al2O3 14.00~25.00%, Fe2O3 3.00~6.50%, CaO 0.10~6.50%, MgO 0.40~2.00%, K2O+Na2O 1.55~5.30%, loss on ignition 6.00~9.70%. Preferably, the polishing mud has the following chemical composition ratio: SiO2 65.00~69.00%, Al2O3 17.00~21.00%, Fe2O3 1.00~2.50%, CaO 1.50~2.50%, MgO 1.50~3.00%, K2O+Na2O 3.00~5.00%, loss on ignition 2.00~3.50%. Preferably, the ion-adsorbed rare earth tailings have the following chemical composition ratio: SiO2 59.00~65.00%, Al2O3 28.00~32.00%, Fe2O3 1.30~2.50%, CaO 0.01~0.10%, MgO 0.04~0.15%, K2O+Na2O 4.55~5.65%, loss on ignition 0.03~0.10%. Preferably, the polishing mud is a water groove mud produced after the polishing and edge grinding processes in the preparation of ceramic rock plates, and the water groove mud is formed into a mud cake-shaped waste after pressure filtration.

[0014] Preferably, the full-solid-waste-based ceramic rock plate based on low-value solid waste raw materials has a bending strength ≥40 MPa and a water absorption rate ≤0.20%.

[0015] In a second aspect, the present application also claims a preparation method for the full-solid-waste-based ceramic rock plate based on low-value solid waste raw materials provided in the first aspect, which specifically includes the following steps in some embodiments: (1) weighing the solid waste raw materials in proportion, ball milling and drying to obtain a green body; (2) granulating the green body through a screen; (3) semi-dry pressing the granulated and aged green body to obtain a ceramic rock plate green body; (4) sintering the dried ceramic rock plate green body at 1120~1180℃ to obtain a ceramic rock plate; preferably, the aging time is 20-30h.

[0016] Preferably, the sintering temperature is 1120-1150℃.

[0017] Preferably, the proportion in step (1) is the mass percentage of the first component, the second component and the third component.

[0018] Preferably, the ball milling treatment in step (1) comprises: mixing the mixed raw materials, the water reducing agent and water in a mass ratio of (80-120):(0.1-1):(50-200), and then ball milling for 10-50 min at a ball milling speed of 200-600 rpm, and then passing the obtained slurry through a 100-mesh screen, and then drying to obtain the fine granular blank.

[0019] Preferably, the water reducing agent is sodium tripolyphosphate or water glass.

[0020] Preferably, the drying temperature in step (1) is 100-105 DEG C, and the drying time is 8-18 h.

[0021] Preferably, the granulation in step (2) comprises: mixing the blank and water in a mass ratio of (85-100):(5-15), and then passing through a 10-40-mesh screen, and then collecting the undersize product as the granulation.

[0022] Preferably, the semi-dry pressing in step (3) comprises: semi-dry pressing the granulation under a pressure of 20-50 MPa, and then maintaining the pressure for 10-30 s to obtain the ceramic rock plate green body.

[0023] Preferably, the drying temperature in step (4) is 150-250 DEG C, and the drying time is 20-60 min; preferably, the temperature rising and falling rate in the sintering process is 5-15 DEG C / min, and preferably, the holding time is 15-35 min.

[0024] Compared with the prior art, the present application has the following beneficial effects: (1) The present application uses low-value solid waste such as engineering slag, polishing mud and rare earth tailings as raw materials to completely replace natural mineral raw materials such as kaolin used in the ceramic industry to prepare ceramic rock plates, and the utilization rate of solid waste reaches 100%; the raw material cost of the ceramic rock plate can be greatly reduced, and the pressure of natural mineral raw material supply in the ceramic rock plate industry can be relieved. The ceramic rock plate prepared based on the present application has a bending strength of ≥40 MPa and a water absorption of ≤0.20%, which meets the standard GB / T 44309-2024.

[0025] (2) The method for preparing a full-solid-waste-based ceramic rock plate based on low-value solid waste raw materials according to the present application ingeniously utilizes the unique minerals and chemical compositions in the granite weathered soil type construction engineering slag, polishing mud of ceramic factories and ion-adsorbed rare earth tailings, and by controlling the formula composition, relatively low mullite and other ceramic crystal phases can be stably generated at a relatively low temperature, so that the sintering of the full-solid-waste-based ceramic rock plate can be completed at a relatively low temperature (1120-1180 DEG C), which has the advantages of low-temperature sintering and energy saving. Compared with the ceramic rock plate prepared by using minerals, the sintering temperature is reduced, and the purpose of energy saving is achieved while utilizing solid waste.

[0026] (3) The preparation process described in the present invention is simple and can be quickly adapted to existing ceramic production lines without the need for additional complex pretreatment and equipment, making it easy to promote. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is the XRD diffraction pattern of the all-solid waste-based ceramic rock plate sample obtained by sintering in Example 1; Figure 2 This is the appearance of the all-solid waste-based ceramic rock plate sample obtained by sintering in Example 3; Figure 3 This is the appearance of the all-solid waste-based ceramic rock plate sample obtained by sintering in Comparative Example 2; Figure 4 This is the appearance of the all-solid waste-based ceramic rock plate sample obtained by sintering in Comparative Example 3. DETAILED DESCRIPTION

[0028] In order to make the purpose, technical solutions and beneficial effects of the present invention more clear, the present invention is further described in detail with reference to the accompanying drawings and embodiments.

[0029] The engineering slag is taken from slag receiving / disposal sites in different regions, subway shield tunneling and road subgrade excavation, and is mainly composed of minerals such as quartz, clay minerals, hematite, etc.

[0030] The polishing mud is the mud cake-like waste material formed by filtration during the preparation of ceramic rock slabs, which is produced by ditch mud after polishing and edge grinding processes. Example 1

[0031] The construction waste soil is taken from the earthwork excavation of the Chongqing Science City construction project. The soil is yellow-brown and mainly contains minerals such as illite, montmorillonite, quartz, hematite, and albite.

[0032] The all-solid waste-based ceramic rock plate sample described in this Example 1, which is prepared based on low-value solid waste raw materials, uses a total of 2 kg of low-value solid waste raw materials and is composed of the following raw materials in terms of mass percentage: 80% construction slag, 20% polishing mud, and 0% ion-adsorption rare earth tailings.

[0033] in: The chemical composition of the engineering slag is: SiO2 65.96%, Al2O3 15.36%, Fe2O3 3.58%, CaO 1.46%, MgO 1.89%, K2O+Na2O 5.16%, and loss on ignition 6.59%.

[0034] The polishing mud has the following chemical composition: SiO2 67.48%, Al2O3 19.09%, Fe2O3 1.6%, CaO 2.12%, MgO 2.46%, K2O+Na2O 4.19%, and loss on ignition 2.15%.

[0035] A full solid waste-based ceramic rock plate sample prepared from low-value solid waste raw materials according to the present embodiment 1 is prepared in a laboratory under the following steps: (1) The raw materials are weighed according to the specified mass percentage, 0.3wt% of sodium tripolyphosphate is added to the raw materials, and then the mixed raw materials are ball milled for 35 min at a speed of 600 rpm. The obtained slurry is sieved through a 100-mesh screen, and the slurry is dried at 100℃ for 12 h to obtain fine granular blank; (2) The blank is manually granulated through a 40-mesh screen so as to contain 10% of water; (3) The granulated blank is semi-dry pressed under a pressure of 40 MPa after aging for 24 h, and a ceramic rock plate green body is obtained after maintaining the pressure for 20 s; (4) The green body is dried at 180℃ for 40 min, and then sintered in a muffle furnace at 1120℃ for 35 min at a heating rate of 10℃ / min. After cooling in the furnace, a full solid waste-based ceramic rock plate sample prepared from low-value solid waste raw materials is obtained.

[0036] The physical property test and phase analysis of the full solid waste-based ceramic rock plate sample prepared from low-value solid waste raw materials according to the present embodiment 1 are carried out, and the results are as follows: the bending strength is 47.87 MPa, the water absorption is 0.13%, and the phase results are shown in Figure 1 The sintered ceramic rock plate sample is mainly composed of a multiphase mixed melt of glass phase (47.30%), residual quartz (33.44%), and mullite (15.21%), which are the typical mineral compositions of the ceramic rock plate. Embodiment 2

[0037] The engineering slag is obtained from the excavation of a foundation pit in the Huahua Slag Soil Receiving Site in Guangming District, Shenzhen. The soil is yellow-brown in color, and the main components are kaolinite, illite, quartz, and hematite.

[0038] The full solid waste-based ceramic rock plate sample prepared from low-value solid waste raw materials according to the present embodiment 2 uses a total of 2 kg of low-value solid waste raw materials, which are composed of the following raw materials in mass percentage: engineering slag 60%, polishing mud 20%, and ion-adsorbed rare earth tailings 20%.

[0039] In the formula, the mass percentage of the engineering slag is 60%, the mass percentage of the polishing mud is 20%, and the mass percentage of the ion-adsorbed rare earth tailings is 20%. The engineering slag has the following chemical components: SiO2 64.76%, Al2O3 17.76%, Fe2O3 6.38%, CaO 0.16%, MgO 0.92%, K2O+Na2O 3.6%, and loss on ignition 6.42%.

[0040] The polishing mud has the following chemical components: SiO2 67.48%, Al2O3 19.09%, Fe2O3 1.6%, CaO 2.12%, MgO 2.46%, K2O+Na2O 4.19%, and loss on ignition 2.15%.

[0041] The ion-adsorbed rare earth tailings have the following chemical components: SiO2 62.38%, Al2O3 30.19%, Fe2O3 1.87%, CaO 0.02%, MgO 0.09%, K2O+Na2O 5.13%, and loss on ignition 0.04%.

[0042] A full solid waste-based ceramic rock plate sample prepared based on low-value solid waste raw materials according to the embodiment 2 is prepared under laboratory conditions according to the following steps: (1) The raw materials are weighed according to the specified mass percentage, 0.3wt% of sodium tripolyphosphate is added to the raw materials, and then the mixed raw materials are ball milled for 35min at a ball milling speed of 600rpm. The obtained slurry is sieved through a 100-mesh sieve, and the slurry is dried at 100℃ for 12h to obtain a fine granular blank; (2) The blank is manually granulated through a 40-mesh sieve so as to contain 10% of water; (3) The granulated blank is semi-dry pressed under a pressure of 40MPa after aging for 24h, and a ceramic rock plate green body is obtained after maintaining the pressure for 20s; (4) The green body is dried at 180℃ for 40min, and then sintered in a muffle furnace at 1120℃ for 35min at a sintering heating rate of 10℃ / min. After cooling in the furnace, a full solid waste-based ceramic rock plate sample prepared based on low-value solid waste raw materials is obtained.

[0043] The full solid waste-based ceramic rock plate sample prepared based on low-value solid waste raw materials according to the embodiment 2 is subjected to physical property testing and phase analysis, and the results are as follows: the bending strength is 46.16MPa, the water absorption is 0.18%, and the sintered ceramic rock plate sample is mainly a multiphase mixed melt composed of glass phase (44.50%), residual quartz (36.50%), and mullite (16.69%). Embodiment 3

[0044] The engineering slag is engineering slag taken from the engineering slag accumulated in the Jianlian disposal field in Huadu District, Guangzhou, and has a reddish brown color. The engineering slag mainly contains illite, kaolinite, quartz, hematite and other minerals.

[0045] A full solid waste-based ceramic rock plate sample prepared based on low-value solid waste raw materials according to the embodiment 3, a total of 2 kg of low-value solid waste raw materials is used, which consists of the following raw materials in mass percentage: engineering slag 50%, polishing mud 30%, ion adsorption type rare earth tailings 20%.

[0046] Wherein: The chemical composition of the engineering slag is: SiO2 64.16%, Al2O3 14.24%, Fe2O3 4.90%, CaO 4.27%, MgO 0.92%, K2O+Na2O 1.81%, loss on ignition 9.70%.

[0047] The chemical composition of the polishing mud is: SiO2 67.48%, Al2O3 19.09%, Fe2O3 1.60%, CaO 2.12%, MgO 2.46%, K2O+Na2O 4.19%, loss on ignition 2.15%.

[0048] The chemical composition of the ion adsorption type rare earth tailings is: SiO2 62.38%, Al2O3 30.19%, Fe2O3 1.87%, CaO 0.02%, MgO 0.09%, K2O+Na2O 5.13%, loss on ignition 0.04%.

[0049] A full solid waste-based ceramic rock plate sample prepared based on low-value solid waste raw materials according to the embodiment 3 is prepared under laboratory conditions according to the following steps: (1) The raw materials are weighed according to the specified mass percentage, 0.3wt% of sodium tripolyphosphate is added to the raw materials, then the mixed raw materials are ball milled for 25min at a speed of 600rpm, the obtained slurry is sieved through a 100 mesh screen, and the slurry is dried at 100℃ for 12h to obtain fine granular blank; (2) The blank is manually granulated through a 40 mesh screen, and the granulated blank contains 10% of water; (3) The granulated blank is aged for 24h and then semi-dry pressed at a pressure of 40MPa, and the green body is obtained after maintaining the pressure for 20s; (4) The green body is dried at 180℃ for 40min, then sintered in a muffle furnace at 1180℃ for 25min, the sintering heating rate is 10℃ / min, and after cooling in the furnace, a full solid waste-based ceramic rock plate sample prepared based on low-value solid waste raw materials is obtained.

[0050] A full solid waste based ceramic rock plate sample prepared based on low value solid waste raw materials prepared in Example 3 is subjected to physical property testing and phase analysis, and the results are as follows: the bending strength is 50.77 MPa, the water absorption is 0.03%, and the sintered ceramic rock plate sample is mainly a multi-phase mixed melt composed of glass phase (50.16%), residual quartz (32.19%), and mullite (15.60%), and the sample appearance is as shown in Figure 2 . Example 4

[0051] The engineering slag is a shield engineering slag taken from the Foshan section of the Guangzhan high-speed rail project, and has a gray color. It mainly contains minerals such as quartz, illite, kaolinite, calcite, and hematite.

[0052] The full solid waste based ceramic rock plate sample prepared based on low value solid waste raw materials in this Example 4 uses a total of 2 kg of low value solid waste raw materials, which consists of the following raw materials in mass percentage: engineering slag 40%, polished mud 30%, and ion adsorption type rare earth tailings 30%.

[0053] Among them: The chemical composition of the engineering slag is: SiO2 60.30%, Al2O3 14.50%, Fe2O3 4.23%, CaO 6.18%, MgO 1.91%, K2O+Na2O 4.24%, and loss on ignition 8.64%.

[0054] The chemical composition of the polished mud is: SiO2 67.48%, Al2O3 19.09%, Fe2O3 1.60%, CaO 2.12%, MgO 2.46%, K2O+Na2O 4.19%, and loss on ignition 2.15%.

[0055] The chemical composition of the ion adsorption type rare earth tailings is: SiO2 62.38%, Al2O3 30.19%, Fe2O3 1.87%, CaO 0.02%, MgO 0.09%, K2O+Na2O 5.13%, and loss on ignition 0.04%.

[0056] The full solid waste based ceramic rock plate sample prepared based on low value solid waste raw materials in this Example 4 is prepared under laboratory conditions according to the following steps: (1) The raw materials are weighed according to the specified mass percentage, 0.3wt% of sodium tripolyphosphate is added to the raw materials, and then the mixed raw materials are ball milled for 15 min at a speed of 600 rpm. The obtained slurry is sieved through a 100 mesh screen, and the slurry is dried at 100°C for 12h to obtain a fine particle blank; (2) The blank is manually granulated through a 40 mesh screen, and the granulated material contains 10% moisture; (3) The granulated material is semi-dry pressed at a pressure of 40 MPa after aging for 24 h, and a ceramic rock plate green body is obtained after maintaining the pressure for 20 s; (4) The green body is dried at 180 ℃ for 40 min, and then sintered in a muffle furnace at 1140 ℃ for 15 min, with a sintering heating rate of 10 ℃ / min, and then cooled in the furnace, to obtain a full solid waste-based ceramic rock plate sample prepared from low-value solid waste raw materials.

[0057] The physical property test and phase analysis of the full solid waste-based ceramic rock plate sample prepared from low-value solid waste raw materials in Example 4 are as follows: the bending strength is 47.78 MPa, the water absorption is 0.02%, and the sintered ceramic rock plate sample is mainly composed of a multiphase mixed melt of glass phase (45.74%), residual quartz (27.19%), anorthite (11.07%), and mullite (13.25%). Example 5

[0058] The engineering spoil is a roadbed excavation engineering spoil taken from the second passage of Guangzhou Conghua Horse Racecourse and the connecting line of the surrounding roads, and the soil is gray-orange, mainly containing minerals such as quartz, microcline, kaolinite, and hematite.

[0059] The full solid waste-based ceramic rock plate prepared from low-value solid waste raw materials in the present example 5 uses a total of 2 kg of low-value solid waste raw materials, which consists of the following raw materials in mass percentage: engineering spoil 70%, polished mud 20%, and ion-adsorbed rare earth tailings 10%.

[0060] Among them: The chemical composition of the engineering spoil is: SiO2 56.71%, Al2O3 24.84%, Fe2O3 4.84%, CaO 0.77%, MgO 0.40%, K2O+Na2O 3.96%, and loss on ignition 8.48%.

[0061] The chemical composition of the polished mud is: SiO2 67.48%, Al2O3 19.09%, Fe2O3 1.60%, CaO 2.12%, MgO 2.46%, K2O+Na2O 4.19%, and loss on ignition 2.15%.

[0062] The chemical composition of the ion-adsorbed rare earth tailings is: SiO2 62.38%, Al2O3 30.19%, Fe2O3 1.87%, CaO 0.02%, MgO 0.09%, K2O+Na2O 5.13%, and loss on ignition 0.04%.

[0063] A full solid waste-based ceramic rock plate prepared based on low-value solid waste raw materials according to the present embodiment 5 is prepared under the conditions of a ceramic rock plate factory according to the following steps: (1) The raw materials are weighed according to the specified mass percentage, 0.3wt% of sodium tripolyphosphate is added to the raw materials, and then the mixed raw materials are wet ball milled, the obtained slurry is passed through a 100 mesh screen, the ball flow rate is 35 m / s, and the fineness of the slurry is 0.5~1.5wt% (250 mesh screen residue); (2) The powder is granulated by a spray granulation tower, and the bulk density of the granulated powder is ≥900 kg / m 3 ; (3) The granulated and aged materials are semi-dry pressed at a pressure of 40 MPa to obtain a ceramic rock plate green body; (4) The green body is sintered in a roller kiln at 1180℃ to obtain a full solid waste-based ceramic rock plate with a size of 90cm×180cm×1cm prepared based on low-value solid waste raw materials.

[0064] The physical property test and phase analysis of the full solid waste-based ceramic rock plate prepared based on low-value solid waste raw materials according to the present embodiment 5 are carried out, and the results are as follows: the bending strength is 48.03 MPa, the water absorption is 0.11%, and the sintered ceramic rock plate is mainly a multi-phase mixed melt composed of glass phase (47.39%), residual quartz (29.50%) and mullite (19.27%). The physical properties and phase composition are basically consistent with the samples prepared under laboratory conditions. Comparative Example 1

[0065] The ceramic rock plate according to the present comparative example 1 is a certain commercially available ceramic rock plate of Chongqing Dongpeng Intelligent Home Furnishing Co., Ltd., and the preparation process is the same as that of the present embodiment 5, except that the raw materials for the green body are different, and the sintering temperature is 1250℃. The raw materials for the green body of the commercially available ceramic rock plate are natural minerals, which are composed of the following raw materials in mass percentage: quartz 32wt%, clay 42wt%, feldspar 19wt%.

[0066] The physical property test of the commercially available ceramic rock plate according to the present comparative example is carried out, and the results are as follows: the bending strength is 50.67 MPa, and the water absorption is 0.04%. It can be seen that the mechanical strength and water absorption of the ceramic rock plate product prepared by using solid waste raw materials in the present embodiment 5 are close to those of the commercially available ceramic rock plate product. Comparative Example 2

[0067] The present comparative example 2 is basically the same as the present embodiment 2, except that only one kind of engineering slag is used, and the appearance of the sintered sample is as Figure 3The physical property test was performed on the ceramic rock plate sample described in the comparative example, and the results were as follows: the bending strength was 22.59 MPa, and the water absorption was 4.78%. It can be seen that the ceramic rock plate sample fired by using the engineering slag alone is underfired, and the strength is low. Comparative Example 3

[0068] Comparative Example 3 is basically the same as Example 2, except that only the polishing mud is used as a raw material to fire the sample. Figure 4 The surface of the sample is covered with blisters / pinholes, and the body is deformed. It can be seen that the ceramic rock plate sample fired by using the polishing mud alone is overfired, and has appearance quality defects such as deformation and pinholes. Comparative Example 4

[0069] Comparative Example 4 refers to Example 1 in patent CN113788668A, which uses artificial quartz stone polishing slag and ceramic polishing slag pretreated by resin degelling agent for 27 hours, and the waste slag (accounting for 40%) is composed of ceramic processing slag, artificial quartz stone processing slag and press filter mud in a mass ratio of 6:1:1. The waste slag and other natural raw materials form a ceramic body (the chemical composition is similar to the ceramic body described in the present application), and the ceramic tile is fired at 1226°C. The bending strength is 41.8 MPa, and the water absorption is 0.06%. However, the present application does not need resin degelling agent pretreatment, and is fired at 1120-1180°C. The bending strength is increased to 46.16-50.77 MPa, which proves that the present application simplifies the process, reduces energy consumption, and further optimizes the mechanical properties and density.

[0070] The above provides a detailed introduction to the full solid waste-based ceramic rock plate prepared based on low-value solid waste raw materials and the preparation method thereof. In this paper, specific examples are applied to explain the principles and implementation methods of the present application. The above example is only used to help understand the method and core idea of the present application, including the best mode, and also enables any person skilled in the art to practice the present application, including manufacturing and using any device or system, and implementing any combined method.

[0071] It should be noted that, for those skilled in the art, without departing from the principles of the present application, the present application can be improved and modified in several ways. In particular, as long as there is no structural conflict, the features in the disclosed embodiments of the present application can be combined in any way. The present application is not limited to the specific embodiments disclosed in the specification, but includes all technical solutions falling within the scope of the claims.

Claims

1. A fully solid waste-based ceramic rock board based on low-value solid waste raw materials, characterized in that: The following raw materials are used for preparation: the first component, the second component and the third component: The first component has the following chemical composition ratio: SiO2 56.00-66.00%, Al2O3 14.00-25.00%, Fe2O3 3.00-6.50%, CaO 0.10-6.50%, MgO 0.40-2.00%, K2O+Na2O 1.55-5.30%, loss on ignition 6.00-9.70%; The second component has the following chemical composition ratio: SiO2 65.00-69.00%, Al2O3 17.00-21.00%, Fe2O3 1.00-2.50%, CaO 1.50-2.50%, MgO 1.50-3.00%, K2O+Na2O 3.00-5.00%, loss on ignition 2.00-3.50%; The third component has the following chemical composition ratio: SiO2 59.00-65.00%, Al2O3 28.00-32.00%, Fe2O3 1.30-2.50%, CaO 0.01-0.10%, MgO 0.04-0.15%, K2O+Na2O 4.55-5.65%, loss on ignition 0.03-0.10%; The first component is 40-80% by mass, the second component is 20-30% by mass, and the third component is 0-30% by mass; The first component, the second component and the third component are all solid waste raw materials.

2. The all-solid waste-based ceramic rock board based on low-value solid waste raw materials according to claim 1 is characterized in that: The first component is engineering slag, the second component is polishing mud, and the third component is ion adsorption type rare earth tailings.

3. The all-solid waste-based ceramic rock board based on low-value solid waste raw materials according to claim 2 is characterized in that: The engineering slag is a mixture of illite, montmorillonite, hematite, albite, kaolinite, quartz, calcite, and microcline, and the chemical composition ratio of the result of the mixture conforms to the chemical composition ratio of the first component described in claim 1.

4. The all-solid waste-based ceramic rock board based on low-value solid waste raw materials according to claim 2 is characterized in that: The polishing mud is ditch mud produced after polishing and edging processes during the preparation of ceramic rock slabs, and is a mud cake-like waste formed by filtration. The resulting chemical composition ratio of the polishing mud conforms to the chemical composition ratio of the second component described in claim 1.

5. A method for preparing a fully solid waste-based ceramic rock plate based on low-value solid waste raw materials according to any one of claims 1 to 4, characterized in that The steps include: (1) Weighing solid waste raw materials in proportion, milling and drying to obtain blanks; (2) Granulating the blank through a screen; (3) The granulated material is aged and semi-dry pressed to obtain a green ceramic slab; (4) The dried ceramic rock slab green body is sintered at 1120-1180°C to obtain a ceramic rock slab; preferably, the aging time is 20-30 hours.

6. The method for preparing a fully solid waste-based ceramic rock slab based on low-value solid waste raw materials according to claim 5, characterized in that: The ball milling treatment in step (1) comprises: mixing the mixed raw materials, the water reducing agent and water in a mass ratio of (80-120): (0.1-1): (50-200), ball milling for 10-50 minutes at a ball milling speed of 200-600 rpm, passing the obtained slurry through a 100-mesh sieve, and drying to obtain a fine-grained blank. Preferably, the water reducing agent is sodium tripolyphosphate or water glass.

7. The method for preparing a fully solid waste-based ceramic rock slab based on low-value solid waste raw materials according to claim 5, characterized in that: In the step (1), the drying temperature is 100-105°C and the drying time is 8-18 hours.

8. The method for preparing a fully solid waste-based ceramic rock slab based on low-value solid waste raw materials according to claim 5, characterized in that: The granulation in step (2) comprises: mixing the blank and water in a mass ratio of (85-100): (5-15), passing through a 10-40 mesh sieve, and the product under the sieve is the granulation.

9. The method for preparing a fully solid waste-based ceramic rock slab based on low-value solid waste raw materials according to claim 5, characterized in that: The semi-dry pressing in step (3) includes: semi-dry pressing the granules under a pressure of 20-50 MPa, and maintaining the pressure for 10-30 seconds to obtain a ceramic rock slab green body.

10. The method for preparing a fully solid waste-based ceramic rock slab based on low-value solid waste raw materials according to claim 5, characterized in that: The drying temperature in step (4) is 150-250°C, and the drying time is 20-60 min. Preferably, the heating and cooling rate during the sintering process in step (4) is 5-15°C / min, and preferably, the holding time is 15-35 min.

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