Lightweight high-strength building ceramic large plate and preparation method thereof

Abstract

The present application relates to the technical field of building materials, especially to the field of IPC C04B 33, and more particularly to a light high-strength building ceramic large plate and a preparation method thereof. The components of the ceramic large plate include: coal gangue 30-60 wt%, fly ash 10-20 wt%, clay 10-30 wt%, and a sintering aid to make up the balance. The fineness of the coal gangue is 20-300 mesh, and the proportion of particles with a size of more than 100 mesh in the coal gangue is not less than 40%, which can improve the compressive strength of the material. The weight ratio of the coal gangue, fly ash and clay is (40-60):(10-20):(15-25), which can effectively reduce the density of the material and improve the thermal shock resistance at the same time. The sintering temperature is 1230-1300 DEG C, which can reduce the density of the product and also improve the thermal insulation performance of the product.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of building materials, in particular to the field of IPC C04B 33, and more particularly to a light high-strength building ceramic large plate and a preparation method thereof. BACKGROUND

[0002] Ceramic matrix composites have low density, high specific strength, high specific stiffness, high hardness, high wear resistance, high use temperature, large thermal conductivity, small thermal expansion coefficient, strong oxidation resistance, good vibration absorption performance and other advantages, and have very wide application. The ceramic large plate is generally made of ceramic raw materials, metal tailings, solid waste and other raw materials, and is formed by foaming, semi-dry pressing or extrusion process, and then sintered at high temperature, but the current ceramic large plate has not excellent temperature resistance and compressive strength, which limits its application.

[0003] CN 107098683 B discloses a sintered coal gangue heat preservation brick, which is prepared according to the following formula: coal gangue powder 50% to 70%, fly ash 30% to 50%, and vitrified microbeads and / or expanded perlite 110% to 130%; the coal gangue powder and fly ash are in mass percentage, and the total mass of the two raw materials is 100%; the invention utilizes the rich mineral composition in coal gangue and fly ash, and after high-temperature baking, all kinds of minerals are fully melted, crystallized, and crystal type transformation occurs, generating a large amount of glassy gel, combining the characteristics of low thermal conductivity of expanded perlite and vitrified microbeads, and the fact that expanded perlite can be transformed into glass phase at high temperature and leave closed pores at the location, but the temperature resistance and compressive strength are not good. SUMMARY

[0004] The first aspect of the present application provides a light high-strength building ceramic large plate, which comprises, in percentage: coal gangue 30-60wt%, fly ash 10-20wt%, clay 10-30wt%, and sintering aid to make up the balance.

[0005] Preferably, the components include: coal gangue 40-60wt%, fly ash 10-20wt%, clay 15-25wt%, and sintering aid to make up the balance.

[0006] The fineness of the coal gangue is 20-300 mesh, and the proportion of particles above 100 mesh in the coal gangue is not less than 40%, which can improve the compressive strength of the material. If the particle size is too fine, it will cause the product to shrink too much during drying and sintering, resulting in deformation or cracking of the product. On the contrary, if the particle size is too coarse, the sintering temperature will be increased or the strength will be reduced.

[0007] The fineness of the coal gangue is 20-300 mesh, and the proportion of particles above 100 mesh in the coal gangue is not less than 40%.

[0008] Preferably, the fineness of the coal gangue is 50-200 mesh.

[0009] Preferably, the coal gangue includes low-temperature heat-treated coal gangue.

[0010] The low-temperature heat-treated coal gangue accounts for 50-100% of the total amount of coal gangue.

[0011] Preferably, the low-temperature heat-treated coal gangue is subjected to low-temperature (below 1000℃) dehydration and decarburization treatment.

[0012] Preferably, the dehydration and decarburization process includes: the coal gangue is crushed to a particle size of less than 5mm, loaded into a sagger, rapidly raised to 950-1000℃ in a high-temperature kiln, and then cooled to 25-40℃.

[0013] The fly ash is high-aluminum fly ash, and the content of aluminum oxide in the high-aluminum fly ash is not less than 30wt%.

[0014] The fineness of the fly ash is less than 100 mesh.

[0015] Preferably, the fineness of the fly ash is 100-200 mesh.

[0016] The clay includes at least one of knot soil, red soil and plastic white clay.

[0017] Preferably, the clay includes plastic clay.

[0018] The sintering aid includes feldspar and talc, and the content of feldspar is 70-85wt%.

[0019] Preferably, the content of feldspar is 75wt%.

[0020] Preferably, the total content of K2O and Na2O in the feldspar is not less than 11wt%.

[0021] The fineness of the sintering aid is less than 200 mesh.

[0022] Preferably, the fineness of the sintering aid is 200-3000 mesh.

[0023] The applicant has found that the weight ratio of the coal gangue, fly ash and clay is (40-60):(10-20):(15-25), which can effectively reduce the material density and improve the thermal shock resistance. When the amount of fly ash is too high, the water content in the product forming process is too high, which causes the deformation or cracking of the green body during drying. The addition of coal gangue can effectively balance the shrinkage rate of the sintering system, and the sintering temperature of 1230-1300℃ can reduce the product density and improve the heat preservation performance of the product. A large number of fine pores may be generated in the green body. Figure 2), reduce the product density, and improve the product thermal insulation performance, so that it is suitable for fabricated building.

[0024] Preferably, the weight ratio of the coal gangue, fly ash and clay is (40-60):(10-20):(15-25).

[0025] The second aspect of the application provides a preparation method of a light high-strength building ceramic large plate, comprising the following steps:

[0026] S1, mixing coal gangue, fly ash, clay and sintering aid to obtain mixture 1;

[0027] S2, adding water to mixture 1, and sequentially performing mixing kneading and room temperature aging to obtain mixture 2;

[0028] S3, extruding mixture 2 through a mold to obtain a ceramic body;

[0029] S4, drying the ceramic body and then firing, thereby obtaining the light high-strength building ceramic large plate.

[0030] Preferably, the preparation method of the light high-strength building ceramic large plate comprises the following steps:

[0031] S1, mixing coal gangue, fly ash, clay and sintering aid in a double-S ceramic kneader to obtain mixture 1;

[0032] S2, adding water to mixture 1, and sequentially performing mixing kneading for 30-60 min and room temperature aging for 20-30 h to obtain mixture 2;

[0033] S3, extruding mixture 2 through a multi-channel mold to obtain a 1000*500*100mm multi-channel ceramic body;

[0034] S4, placing the body on a multi-hole high-temperature pad plate covered with high-temperature filter cloth, and drying for 2-4 h by microwave-hot air drying until the water content of the body is less than 0.5wt%, and then firing in a high-temperature tunnel kiln, thereby obtaining the light high-strength building ceramic large plate.

[0035] Preferably, the weight of the added water accounts for 15-20% of the weight of mixture 1.

[0036] Preferably, the weight of the added water accounts for 16-18% of the weight of mixture 1.

[0037] Preferably, the pore size of the body is 30mm.

[0038] Preferably, the firing temperature is 1230-1300℃.

[0039] Preferably, the firing temperature is 1250-1300℃.

[0040] Preferably, the firing temperature is 1250-1300℃.Beneficial effects

[0041] 1. The fineness of the coal gangue is 20-300 mesh, and the proportion of particles above 100 mesh in the coal gangue is not less than 40%, which can improve the compressive strength of the material.

[0042] 2. The weight ratio of the coal gangue, fly ash and clay is (40-60):(10-20):(15-25), which can effectively reduce the material density and improve the thermal shock resistance.

[0043] 3. Using a sintering temperature of 1230-1300℃, the product density is reduced, and the product thermal insulation performance is improved.

[0044] 4. The sintering aid includes feldspar and talc, and the proportion of feldspar is 70-85wt%, which can improve the uniformity of pore distribution in the green body and further improve the compressive strength to 32MPa.

[0045] 5. Using coal gangue and fly ash solid waste as the main raw material, the raw material source is wide, and the calorific value of part of the coal gangue can be fully utilized, which effectively reduces the product sintering cost, is conducive to the implementation of energy saving and emission reduction, and realizes the resource utilization of solid waste. BRIEF DESCRIPTION OF DRAWINGS

[0046] Figure 1 The schematic diagram of the ceramic large plate structure prepared in Example 1.

[0047] Figure 2 The internal micrograph of the ceramic large plate structure prepared in Example 1. DETAILED DESCRIPTION

[0048] Example 1

[0049] A light-weight high-strength building ceramic large plate, the components of the ceramic large plate are: coal gangue 40wt%, fly ash 20wt%, plastic clay 25wt%, potassium feldspar 10wt%, talc 5wt%.

[0050] The fineness of the coal gangue is 50-200 mesh, and the proportion of particles above 100 mesh in the coal gangue is 70%.

[0051] The coal gangue is processed by the company through crushing of coal gangue raw materials, and the coal gangue raw materials are purchased from Bulonggou Coal Mine in Zhun Geer.

[0052] The fineness of the fly ash is 100-200 mesh.

[0053] The fly ash is processed by the company through crushing of fly ash raw materials, and the fly ash raw materials are purchased from Zhun Geer Huadeng Power Plant.

[0054] The clay is plastic clay, and the production place is Zhungeer banner red coal mine plastic clay.

[0055] The potassium feldspar is from Linxian, Shanxi, and the K2O content in the feldspar is greater than or equal to 9.5wt%

[0056] The talc is from Lingshou, Hebei, and the MgO content in the talc is 35.2wt%.

[0057] A preparation method of a light high-strength building ceramic large plate comprises the following steps:

[0058] S1, mixing coal gangue, fly ash, plastic clay, potassium feldspar and talc in a double-S ceramic kneader to obtain a mixture 1;

[0059] S2, adding water to the mixture 1, and sequentially mixing and kneading for 50 min, and aging at room temperature for 24 h to obtain a mixture 2;

[0060] S3, extruding the mixture 2 into a 1000*500*100mm multi-channel ceramic body by using a multi-channel mold to obtain a ceramic body;

[0061] S4, placing the body on a multi-hole high-temperature pad plate covered with high-temperature filter cloth, and drying by using microwave-hot air drying until the water content of the body reaches 0.5wt%, and then high-temperature firing in a high-temperature tunnel kiln, as shown in Figure 1 , to obtain the product.

[0062] The weight of the added water accounts for 18% of the weight of the mixture 1.

[0063] The pore size of the body is 30mm.

[0064] The drying time is 2h.

[0065] The firing temperature is 1250℃.

[0066] Example 2

[0067] The specific implementation is the same as that in example 1, except that the components of the ceramic large plate in example 2 are as follows: coal gangue 50wt%, fly ash 15wt%, plastic clay 20wt%, potassium feldspar 10wt%, and talc 5wt%.

[0068] The drying time is 3h.

[0069] The firing temperature is 1260℃.

[0070] Example 3

[0071] The specific implementation is the same as example 1, except that the components of the ceramic large plate in example 3 are: coal gangue 50wt%, fly ash 20wt%, plastic clay 15wt%, potassium feldspar 10wt%, and talc 5wt%.

[0072] The low-temperature heat-treated coal gangue accounts for 60% of the total amount of coal gangue.

[0073] The low-temperature heat-treated coal gangue is subjected to dehydration and decarburization treatment.

[0074] The dehydration and decarburization process is: the coal gangue is loaded into a sagger, rapidly raised to 950℃ in a high-temperature kiln, and then cooled to 25℃ after 3 hours of heat preservation.

[0075] The drying time is 3h.

[0076] The sintering temperature is 1260℃.

[0077] Example 4

[0078] The specific implementation is the same as example 1, except that the components of the ceramic large plate in example 4 are: coal gangue 60wt%, fly ash 10wt%, plastic clay 15wt%, potassium feldspar 10wt%, and talc 5wt%.

[0079] The low-temperature heat-treated coal gangue accounts for 50% of the total amount of coal gangue.

[0080] The low-temperature heat-treated coal gangue is subjected to dehydration and decarburization treatment.

[0081] The dehydration and decarburization process is: the coal gangue is loaded into a sagger, rapidly raised to 950℃ in a high-temperature kiln, and then cooled to 25℃ after 3 hours of heat preservation.

[0082] The weight of the added water accounts for 16% of the weight of the mixture 1.

[0083] The drying time is 3h.

[0084] The sintering temperature is 1260℃.

[0085] Example 5

[0086] The specific implementation is the same as example 1, except that the components of the ceramic large plate in example 5 are: coal gangue 50wt%, fly ash 20wt%, plastic clay 15wt%, potassium feldspar 10wt%, and talc 5wt%.

[0087] The coal gangue is a low-temperature heat-treated coal gangue.

[0088] The low-temperature heat-treated coal gangue is subjected to dehydration and decarburization treatment.

[0089] The dehydration and decarbonization process is as follows: the coal gangue is loaded into a sagger, and is rapidly raised to 950℃ in a high-temperature kiln, and is kept for 3 hours, and then is cooled to 25℃, and thus the product is obtained.

[0090] The drying time is 3h.

[0091] The sintering temperature is 1300℃.

[0092] Comparative Example 1

[0093] The specific implementation is the same as that of Example 1, except that the ceramic slab component in Comparative Example 1 is as follows: coal gangue 70wt%, plastic clay 15wt%, potassium feldspar 10wt%, and talc 5wt%.

[0094] In S1, the coal gangue, plastic clay, potassium feldspar, and talc are mixed in a double-S ceramic kneader to obtain a mixture 1.

[0095] The drying time is 3h.

[0096] Comparative Example 2

[0097] The specific implementation is the same as that of Example 1, except that the ceramic slab component in Comparative Example 2 is as follows: coal gangue 30wt%, fly ash 40wt%, plastic clay 15wt%, potassium feldspar 10wt%, and talc 5wt%.

[0098] The weight of the added water accounts for 25% of the weight of the mixture 1.

[0099] The drying time is 3h.

[0100] Comparative Example 3

[0101] The specific implementation is the same as that of Example 1, except that the ceramic slab component in Comparative Example 3 is as follows: coal gangue 40wt%, fly ash 20wt%, plastic clay 20wt%, potassium feldspar 15wt%, and talc 5wt%.

[0102] The weight of the added water accounts for 20% of the weight of the mixture 1.

[0103] The drying time is 3h.

[0104] Performance test method

[0105] The ceramic slabs in the examples and comparative examples are subjected to performance tests, and the test data are listed in Table 1.

[0106] 1) The compressive strength is tested according to GB / T 4740.

[0107] 2) The thermal conductivity is tested according to GB / T 5598.

[0108] 3) Density reference GB / T 2413 test.

[0109] 4) Fire resistance reference GB / T 7322-2007.

[0110] 5) Thermal shock resistance number of times reference GB / T 30873 2014.

[0111] Performance test data 0.23

[0112] Table 1

[0113]

[0114]

Claims

1. A lightweight high-strength architectural ceramic slab, characterized by, The components are as follows in percentage: coal gangue 50wt%, fly ash 20wt%, plastic clay 15wt%, potassium feldspar 10wt%, talc 5wt%; The fly ash is high-aluminum fly ash, the content of aluminum oxide in the high-aluminum fly ash is not less than 30wt%; the fineness of the coal gangue is 50-200 meshes, the proportion of particles above 100 meshes in the coal gangue is 70%; the coal gangue is processed by crushing coal gangue raw materials, the coal gangue raw materials are purchased from Bulonggou Coal Mine in Zhun Geqi; the coal gangue is low-temperature heat-treated coal gangue; the low-temperature heat-treated coal gangue is treated by dehydration and decarburization; the dehydration and decarburization process is as follows: the coal gangue is loaded into a sagger, and is quickly raised to 950℃ in a high-temperature kiln, and is kept for 3 hours, and then is cooled to 25℃, and is obtained; The fineness of the fly ash is 100-200 meshes; The fly ash is processed by crushing fly ash raw materials, and the fly ash raw materials are purchased from Huadian Power Plant in Zhun Geqi; The clay is plastic clay, and the origin is plastic clay from Hongran coal mine in Zhun Geqi; The potassium feldspar is from Linxian, Shanxi, and the content of K2O in feldspar is not less than 9.5wt% The talc is from Lingshou, Hebei, and the content of MgO in talc is 35.2wt%; The preparation method of the light high-strength building ceramic large plate is as follows: S1, the coal gangue, fly ash, plastic clay, potassium feldspar and talc are mixed in a ceramic kneader to obtain a mixture 1; S2, water is added to the mixture 1, and mixed and kneaded for 50min, and aged for 24h at room temperature to obtain a mixture 2; S3, the mixture 2 is extruded into a 1000*500*100mm multi-channel ceramic body by using a multi-channel mold to obtain a ceramic body; S4, the body is placed on a multi-space high-temperature pad plate covered with high-temperature filter cloth, and is dried by microwave-hot air drying until the water content of the body reaches 0.5wt%, and then is fired in a high-temperature tunnel kiln, and is obtained; The weight of the added water accounts for 18% of the weight of the mixture 1; The pore size of the body is 30mm; The drying time is 3h; The firing temperature is 1300℃.

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