Anhydrous phosphogypsum-based foaming door core plate and preparation method thereof

Abstract

The invention provides an anhydrous ardealite-based foaming door core board and a preparation method thereof.The anhydrous ardealite-based foaming door core board is prepared from anhydrous ardealite, cement, fly ash, water, a foaming agent, short fibers and a modifier.The preparation method includes the steps that the water is added into a stirrer, the short fibers and the modifier are added, then the stirrer is started, dry powder is added, the foaming agent is added after the dry powder is evenly stirred, and the foaming agent is added; adjusting the foaming amount; pouring the slurry into a mold, curing for 2 hours, and demolding; after demolding, the foaming agent is arranged at intervals in a side-standing mode, heat and moisture are dissipated, the foaming agent leaves a factory after being naturally cured for 3-5 days or is dried after being naturally cured for 1 day so as to shorten the factory time, and the modifier promotes the foaming agent to form hundreds of millions of closed thick-wall small round hole structures in the slurry to strongly support the strength of door core plates. Meanwhile, erosion of water and carbon dioxide in air is isolated, excellent durability is kept, and the excellent performance of the gypsum-based fireproof door core plate can be guaranteed; the production process is simple, raw material cost is low, and comprehensive production cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of door production, in particular to a water-free phosphogypsum-based foaming door core plate and a preparation method thereof. BACKGROUND

[0002] With the comprehensive utilization of industrial by-product gypsum, the formula, process and equipment for preparing anhydrous gypsum from by-product gypsum such as desulfurization gypsum are continuously matured, and gypsum-based fireproof door core plates are developed. Compared with traditional door core plates, the gypsum-based fireproof door core plates have high production efficiency, no "returning halogen", good fire resistance, green environmental protection and other excellent performances. However, the existing preparation method of the gypsum-based fireproof door core plate has problems of unstable quality, low production efficiency and high cost. SUMMARY

[0003] In view of the defects of the existing preparation method of the gypsum-based fireproof door core plate, the technical problem to be solved by the present application is to provide a water-free phosphogypsum-based foaming door core plate and a preparation method thereof, which can reduce the production cost while ensuring the performance of the door core plate.

[0004] In order to achieve the above-mentioned purpose, according to one aspect of the present application, the water-free phosphogypsum-based foaming door core plate is prepared by the following technical measures: the raw materials include water-free phosphogypsum, cement, fly ash, water, foaming agent, short fiber and modifier.

[0005] Further, the water-cement ratio of the raw materials is 0.5, and the weight percentage of each component of the raw materials except water is: 63%-69% water-free phosphogypsum, 17%-23% cement, 9%-16% fly ash, 0.2% foaming agent, 0.3% short fiber and 1% modifier.

[0006] Further, the weight percentage of each component of the raw materials except water is: 66% water-free phosphogypsum, 20% cement, 12.5% fly ash, 0.2% foaming agent, 0.3% short fiber and 1% modifier.

[0007] Further, the cement is ordinary Portland cement, the fly ash is grade II fly ash, the foaming agent is an animal protein and high molecular compound foaming agent, the short fiber is polyester short fiber, and the modifier is ethylene glycol.

[0008] Further, the strength grade of the ordinary Portland cement is 42.5.

[0009] A preparation method of a water-free phosphogypsum-based foaming door core plate, the specific steps are as follows: S1, proportioning, then adding water into the mixer, starting the mixer after adding short fibers and modifier, S2, adding the mixed dry powder (water-free phosphogypsum, cement and fly ash) in proportion and stirring uniformly; S3, after adding, stirring for 1.5 minutes, then adding the foaming agent within 10 seconds; S4, adjusting the foaming amount, so that the foaming amount is 0.2% of the total dry powder amount, and the wet bulk density of the slurry is controlled at 350-380 kg / m 3 ; S5, quickly pouring the slurry after stirring into the mold which has been assembled and coated with a release agent for solidification; S6, demolding after 2h of solidification, and then curing, with side-by-side interval discharge, heat dissipation and moisture dissipation.

[0010] Further, the solidification temperature in S6 is set to about 30 DEG C, the curing temperature is 25-35 DEG C, the humidity is 60%, and the natural curing time is 3-5 days.

[0011] Further, the curing in S6 is natural curing for 1 day, followed by automatic ware drying for 24 hours, and the drying temperature is 60-80 DEG C.

[0012] Compared with the prior art, the application has the following advantages: 1. The modifier promotes the foaming agent to form a structure of hundreds of millions of closed thick-walled small holes inside the slurry to support the core plate of the door, and to isolate the water and carbon dioxide in the air to maintain excellent durability, thereby ensuring excellent performance of the gypsum-based fireproof door core plate. 2. The production process is simple, and the raw material cost is low. The phosphogypsum is an industrial waste residue, and the cost is much lower than that of traditional raw materials such as wood and mineral wool. The waste is turned into treasure, and the production of phosphogypsum building materials has low energy consumption and reduces the overall production cost. 3. Compared with ordinary anhydrous gypsum, the anhydrous phosphogypsum has a porous structure and a large amount of crystal water, and the anhydrous phosphogypsum-based foaming door core plate has a light weight, high strength, stable structure, significant sound insulation and noise reduction effect, outstanding fireproof and heat insulation performance, good water resistance, strong mold resistance, and strong construction operability. DETAILED DESCRIPTION

[0013] Hereinafter, the application will be described in detail with reference to the embodiments. It should be noted that the embodiments and features in the embodiments in the present application can be combined with each other without conflict.

[0014] In the description of the present application, it should be understood that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", "bottom", "top" and the like indicate the orientation or positional relationship only for the purpose of facilitating the description of the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. Embodiment 1

[0015] The embodiment provides a preparation method of an anhydrous phosphogypsum-based foamed door core plate, and the specific steps are as follows: S1, 189Kg anhydrous phosphogypsum, 69Kg cement, 37.5Kg fly ash are proportioned, then 150Kg water is added to a mixer, 0.9Kg polyester short fibers and 3Kg ethylene glycol are added, and then the mixer is started; S2, the mixed dry powder (anhydrous phosphogypsum, cement and fly ash) is added in proportion and stirred uniformly; S3, after the addition is completed, stirring is performed for 1.5 minutes, and then 0.6Kg animal protein and high-molecular compound foaming agent are added within 10 seconds; S4, the foaming amount is adjusted, the foaming amount is 0.2% of the total dry powder amount, and the wet bulk density of the slurry is controlled to be 350-380kg / m 3 ; S5, the slurry after stirring is quickly poured into a mold which has been assembled and coated with a release agent to solidify the slurry, and the reaction temperature in the mold is usually within 80℃, if the reaction temperature exceeds 80℃, air blowing cooling or opening of the mold is required; S6, the solidification temperature is set to be constant 30℃, the mold is removed after 2h of solidification, and then curing is performed, the curing temperature is 25-35℃, the humidity is 60%, the indoor curing is performed, the side stand is spaced, heat and moisture are dissipated, and natural curing is performed for 3-5 days, or after 1 day of natural curing, automatic ware drying is performed to shorten the factory delivery time, the drying time is 24 hours, and the drying temperature is 60-80℃.

[0016] The product prepared in the embodiment has a compressive strength of 0.45Mpa and a flexural strength of 0.3Mpa. Example 2

[0017] The preparation method of the anhydrous phosphogypsum-based foamed door core plate provided in the embodiment is different from the technical scheme of the embodiment 1, and the difference is as follows: in S1, 198Kg anhydrous phosphogypsum, 60Kg cement and 37.5Kg fly ash are proportioned, then 150Kg water is added to a mixer, 0.9Kg polyester short fibers and 3Kg ethylene glycol are added, and then the mixer is started, and the remaining steps are the same as those of the embodiment 1.

[0018] The product prepared in the embodiment has a compressive strength of 0.5Mpa and a flexural strength of 0.35Mpa. Example 3

[0019] The preparation method of anhydrous phosphogypsum-based foamed door core board provided in this embodiment differs from the technical solution of Embodiment 1 as follows: In S1, 207 kg of anhydrous phosphogypsum, 51 kg of cement, and 37.5 kg of fly ash are mixed in proportion, then 150 kg of water is added to the mixer, 0.9 kg of polyester short fiber and 3 kg of ethylene glycol are added, and the mixer is turned on. The remaining steps are the same as in Embodiment 1.

[0020] The product obtained in this embodiment has a compressive strength of 0.42 MPa and a flexural strength of 0.28 MPa.

[0021] This invention provides a method for preparing anhydrous phosphogypsum-based foamed door core board. The production process is simple and the raw material cost is low. Phosphogypsum, as an industrial waste residue, can replace natural gypsum in the production of gypsum products after harmless treatment, reducing the exploitation of natural resources. Moreover, its acquisition cost is far lower than that of traditional raw materials such as wood and mineral wool. This effectively solves the land occupation and environmental pollution problems caused by the stockpiling of solid waste from phosphorus chemical industry, turning waste into treasure. Furthermore, the energy consumption of phosphogypsum building material production is only 16.7% of that of cement, such as a calcination temperature of 200℃, while the production of ordinary gypsum requires high-temperature calcination. At approximately 1200℃, the reduction in timber consumption and carbon emissions is significant, effectively lowering overall costs. The anhydrous phosphogypsum-based foamed door core board prepared using the method described in this embodiment, due to the porous structure of the anhydrous phosphogypsum, reduces weight and effectively absorbs mid-to-high frequency sound waves, making it ideal for quiet environments such as hospitals, schools, and government office buildings. Furthermore, the cross-linking of anhydrous phosphogypsum crystals enhances overall strength, reducing the risk of cracking. It offers significant sound insulation and noise reduction, with low density but high strength (technical standards require fire-resistant door cores). The compressive strength is ≥0.4 MPa, and the flexural strength is ≥0.25 MPa. The anhydrous phosphogypsum-based foamed door core boards prepared in Examples 1-3 of this application have compressive and flexural strengths that exceed the technical standards. Anhydrous phosphogypsum has a much higher water content of crystallization than ordinary anhydrous gypsum, reaching approximately 20%. When exposed to fire, the water evaporates and absorbs heat, resulting in a fire resistance limit of over 2 hours (according to GB / T9978-2008 test standard). Its thermal conductivity is only 0.15-0.25 W / (mK), which is superior to that of ordinary anhydrous gypsum (1.5 W / (mK)). / (mK) makes the fire resistance and heat insulation performance of anhydrous phosphogypsum-based foamed door core board outstanding; it has excellent water resistance, and is not prone to cracking and peeling in humid environments, nor is it prone to dampness and mold growth, thus avoiding the reduction in strength of the door core board due to moisture; compared with ordinary anhydrous gypsum, anhydrous phosphogypsum has natural retarding properties, which means that it is not necessary to add a large amount of retarder during construction to meet the slump requirements as with ordinary anhydrous gypsum. The raw material cost is lower, and it has good dimensional stability, is easy to process and shape, and has a short product curing period, enabling rapid warehousing and turnover.

[0022] The above merely describes the preferred embodiments of the present application and is not used to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. An anhydrous phosphogypsum based foamed door core panel, characterized by: The raw materials include anhydrous phosphogypsum, cement, fly ash, water, foaming agent, short fiber and modifier, the water-cement ratio of the raw materials is 0.5, and the weight percentage of each component of the raw materials except water is: 63-69% anhydrous phosphogypsum, 17-23% cement, 9-16% fly ash, 0.2% foaming agent, 0.3% short fiber and 1% modifier, and the modifier is ethylene glycol.

2. The anhydrous phosphogypsum based foamed door core panel according to claim 1, characterized by: The weight percentage of each component of the raw materials except water is: 66% anhydrous phosphogypsum, 20% cement, 12.5% fly ash, 0.2% foaming agent, 0.3% short fiber and 1% modifier.

3. The anhydrous phosphogypsum-based foamed door core panel according to claim 1 or 2, characterized in that: The cement is ordinary Portland cement, the fly ash is grade II fly ash, the foaming agent is an animal protein and high molecular compound foaming agent, and the short fiber is polyester short fiber.

4. The anhydrous phosphogypsum based foamed door core panel according to claim 3, characterized by: The strength grade of the ordinary Portland cement is 42.

5.

5. A process for the preparation of anhydrous phosphogypsum based foamed door core panel based on claim 1 characterized by: The method comprises the following steps: S1, proportioning, then adding water into the mixer, starting the mixer after adding short fiber and modifier; S2, adding mixed dry powder in proportion and stirring uniformly, the dry powder being anhydrous phosphogypsum, cement and fly ash; S3, stirring for 1.5 minutes after adding, then adding foaming agent within 10 seconds; S4, adjusting the foaming amount, so that the foaming amount is 0.2% of the total dry powder amount, and the wet bulk density of the slurry is controlled at 350-380 kg / m3; S5, quickly pouring the slurry after stirring into the mold which has been assembled and coated with release agent for solidification; S6, demolding after solidification for 2 hours, and curing after demolding, discharging and heat dissipation and humidity dissipation at intervals.

6. The process for preparing anhydrous phosphogypsum based foamed door core panel as claimed in claim 5 wherein: The solidification temperature in S6 is set to be about 30℃, the curing temperature is 25-35℃, the humidity is 60%, and the natural curing time is 3-5 days.

7. The process for preparing anhydrous phosphogypsum based foamed door core panel as claimed in claim 5 wherein: The curing in S6 is automatic warehouse drying for 24 hours after natural curing for 1 day, and the drying temperature is 60-80℃.