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Manufacture of ceramic tiles from industrial waste

A technology of bricks and tiles, ceramics, applied in applications, household appliances, other household appliances, etc., can solve the problems of unsuitable and insufficient organic materials and metallurgical pollutants, ceramic materials, economic rationality, etc., to achieve low cost, High value-added effects

Inactive Publication Date: 2000-12-06
沃特克有限公司 +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0012] Although these methods have been found to be useful for converting waste into usable end products, they do not adequately oxidize organic materials and metallurgical contaminants in the waste to produce ceramic materials of consistent quality
In addition, these methods are not suitable for using higher percentages of recycled waste as raw materials
Also, none of these methods can produce end products with high market demand and high added value
As a result, the economic justification of the investment and operating costs of implementing these methods for treating industrial waste will be questioned

Method used

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  • Manufacture of ceramic tiles from industrial waste
  • Manufacture of ceramic tiles from industrial waste
  • Manufacture of ceramic tiles from industrial waste

Examples

Experimental program
Comparison scheme
Effect test

Embodiment Embodiment 1

[0095] Glass frits are prepared from fly ash from coal-fired boilers, which are then processed into glass suitable for the production of brick bodies. The glass undergoes a devitrification process before it is ground into granular material and mixed with additives to form a powder for pressing tiles. The tiles are pressed and fired using standard industrial tile presses and roller kilns. The resulting tile body has machinability and final properties desired by the commercial tile industry.

[0096] The fly ash composition of the coal-fired boilers is given in Table 5.

[0097] Oxide

weight%

SiO 2

51.8

al 2 o 3

25.6

MgO

0.80

CaO

1.74

Na 2 o

0.40

K 2 o

2.68

Fe 2 o 3

10.3

C

6.18

[0098] Based on this analysis, a flux needs to be added to the fly ash to lower its melting temperature below 1500°C, and the fly ash is mixed ...

Embodiment 2

[0109] The glass is prepared from ashes from municipal waste incinerators ("MSW"), which are then processed into glass suitable for the production of adobe tiles. The glass used in this example was not devitrified before the tile was formed. Press bricks and tiles and fire with conventional bricks and tiles industrial equipment. The resulting tile body has machinability and final properties desired by the commercial tile industry.

[0110] The composition of the MSW ashes used in the vitrification process is given in Table 7.

[0111] Oxide

weight%

SiO 2

35.0

Al 2 o 3

9.68

MgO

5.25

CaO

18.8

Na 2 o

3.67

K 2 o

1.55

Fe 2 o 3

6.41

[0112] In order to make glasses from the composition, no glass-forming additives are required. The MSW ashes were melted in a cyclone-type glass melting furnace. The oxidizing atmosphere of this glass furnace i...

Embodiment 3

[0123] Glass was prepared from spent electrolyzers reduced by aluminum to produce dense ceramic bodies. The glass used in this example was not subjected to a devitrification process prior to tile formation. Samples are prepared on a test scale. The glass in the press body appeared to be completely devitrified during firing without deformation of the green body. The resulting ceramic body has properties required for use in the brick and tile industry.

[0124] Aluminum reduction spent pots ("SPL") consisted of a mixture of graphite blocks and refractory materials. Refractory bricks mainly include SiO 2 、Al 2 o 3 and CaO. In addition to carbon, graphite blocks also contain residual cryolite (Na 3 AlF 6 ), cyanides and metal aluminates. Typical oxide compositions for graphite block and refractory brick mixes are given in Table 9.

[0125] Oxide

weight%

SiO 2

16.5

Al 2 o 3

22.8

CaO

2.57

Na 2 o

...

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Abstract

The present inveniton relates to a process of forming ceramic tiles having the appearance of tiles produced from clays. The process includes melting a material to form a glass melt, treating the glass melt to produce a solid glass product, grinding the solid glass product to produce glass particles having a particle size of less than 200 microns, mixing the glass particles with a first additive to form a glass power mixture having a composition of 55 to 99 wt.% glass particles and 45-1 wt.% first additive, forming the glass powder mixture into tiles by dry pressing, where the tiles have a primary crystalline phase selected from the group consisting of nepheline, diopside, anorthite, wollastonite, melilite, merwinite, spinel, akermanite, gehlenite, crystalline phases based on iron substitutions in the crystalline phase, and mitures thereof. The process includes a devitrifying step where the solid glass product is devitrified prior tothe grinding step or the glass particles in the tile are devitrified after the forming step.

Description

[0001] This application is a continuation of US patent application US08 / 630156 (filed April 10, 1996). field of invention [0002] The present invention relates to the production of ceramic tiles which include the incorporation of a relatively high percentage of recycled glass into the tiles. Background of the invention [0003] Industrial waste, which accounts for the vast majority of all solid waste in the United States, such as boiler fly ash, automatic shredder residue, sewage slurry powder, ashes from municipal waste incinerators, spent electrolyzers for aluminum reduction, and electric arc furnace furnaces Ashes etc. are buried and thus become a major environmental problem. These solid wastes may contain heavy metal contaminants that require appropriate treatment to prevent leakage into water supplies. This has led to a focus on how to reduce landfill volumes and how to develop regulations to prevent release of toxic substances from disposed landfills. Accordingly, a...

Claims

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Application Information

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IPC IPC(8): C04B33/00C04B35/16C04B35/18C04B35/653
Inventor J·C·辛普森M·萨纳维亚J·G·赫纳特
Owner 沃特克有限公司
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