A method of pre-mixing expandable polystyrene particles and a sodium silicate solution

Abstract

A premixing method of expandable polystyrene particles and sodium silicate solution, characterized in that a premixing device is provided above a drying stirrer and is connected with an expandable polystyrene particle bin and a sodium silicate solution bin respectively, when it is needed to premix expandable polystyrene particles and sodium silicate solution, expandable polystyrene particles are provided, and according to the volume ratio, 0.3-0.4 times of the volume of the expandable polystyrene particles of sodium silicate solution, while spraying industrial sodium silicate solution in the cylinder by starting the atomizing nozzle, the expandable polystyrene particles are carried by the pressurized gas and sprayed to the sprayed sodium silicate solution, and the premixing of the expandable polystyrene particles and the sodium silicate solution is completed in the cylinder of the premixing device. The method provided by the application can greatly reduce the input amount of sodium silicate solution.

Description

Technical Field

[0001] This invention relates to the field of building materials, and more particularly to a method for premixing expandable polystyrene particles and sodium silicate solution in the process of preparing homogeneous self-insulating blocks. This invention is a divisional application; the original application was filed on May 9, 2022, with application number 202210499258.5, and is entitled "Homogeneous Self-Insulating Block and its Production Method". Background Technology

[0002] Homogeneous self-insulating blocks are increasingly used in China due to their combined insulation and wall-building functions. Compared to concrete walls, homogeneous self-insulating blocks are a developing technology, and currently, the national standards only specify performance indicators, such as the "Technical Standard for Application of Self-Insulating Blocks" (XJJ109-2019) issued by the Xinjiang Uygur Autonomous Region. However, there are no unified standards for production processes, and manufacturers typically develop their own production processes based on locally available materials. For example, Chinese patent CN105084840B provides "A Class A Fire-Resistant High-Efficiency Homogeneous Self-Insulating Block".

[0003] With technological advancements, expandable polystyrene (EPS) granules, a material with excellent thermal insulation properties, have been applied in homogeneous self-insulating blocks. For example, Guangzhou Hengde Construction Technology Co., Ltd., relying on German LUCA, provides an EPS self-insulating block technology and corresponding production equipment technology. However, because this technology requires the use of imported German ingredients and incurs considerable technical costs, the production cost remains relatively high. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention proposes a premixing method for expandable polystyrene particles and sodium silicate solution. This method enables the production of a lightweight, high-strength, low-density building material with excellent fire resistance (Class A), low thermal conductivity, good insulation performance, and low segregation at a lower cost. This results in a homogeneous, self-insulating block that can be directly used to construct walls, simultaneously meeting the requirements for wall strength, insulation, and fire resistance without the need for separate insulation materials on the exterior walls. This solves numerous problems associated with existing processes, such as complex construction, significant safety and fire hazards, and the inability of external insulation to last as long as the building. It aligns with government-promoted requirements for integrated insulation and structure, and possesses characteristics of energy conservation, environmental protection, improved construction efficiency, resource and cost savings, and ease of promotion.

[0005] Specifically, this invention provides a premixing method for expandable polystyrene granules and sodium silicate solution. The method includes a premixing device connected above a drying mixer to both an expandable polystyrene granule hopper and a sodium silicate solution hopper. The premixing device comprises a cylinder, a bottom plate, and a cover plate. The top diameter of the cylinder is larger than its bottom diameter, and its bottom surface is inclined to the axis. The cylinder's interior has multiple sets of annular protrusions. The cover plate has a hole at its axis through which a pipe for connecting an atomizing nozzle spraying industrial sodium silicate solution passes. The atomizing nozzle is detachably connected to the pipe at the cover plate's axis. The cover plate also has a hole on one side for connecting an L-shaped nozzle for spraying expandable polystyrene granules. The L-shaped nozzle's pipe is welded to the cover plate. The outlet of the L-shaped nozzle faces the axis of the cover plate. A reflector plate coaxial with the cylinder is located at the axis of the bottom plate. A feed pipe extending into the inner cavity of the drying mixer is detachably installed at the lower part of the bottom plate. When premixing expandable polystyrene granules and sodium silicate solution is required, expandable polystyrene granules and sodium silicate solution of 0.3-0.4 times the volume of the expandable polystyrene granules are provided. While the industrial sodium silicate solution is sprayed from the atomizing nozzle inside the cylinder, pressurized gas carries the expandable polystyrene granules and sprays them onto the sprayed sodium silicate solution, thus completing the premixing of the expandable polystyrene granules and sodium silicate solution inside the cylinder.

[0006] Preferably, the expansionable polystyrene particles are fed using a Venturi injector, and the air source is pressurized gas obtained by pressurizing the atmosphere using a blower, or compressed air is used as the air source.

[0007] Preferably, the pressurized gas is supplied at a pressure of 0.4-0.8 bar.

[0008] Preferably, the feeding rate of expandable polystyrene granules is set to about 80-120 liters / minute.

[0009] Preferably, the working flow rate of the atomizing nozzle is set to about 30-40 liters / minute.

[0010] Preferably, before atomization, approximately 10% water is added to the liquid sodium silicate for dilution at a volume ratio.

[0011] Preferably, the cylinder has a jar-shaped structure that is larger at the top and smaller at the bottom, with an internal volume controlled between 0.5 and 0.8 cubic meters.

[0012] The present invention provides a method for premixing expandable polystyrene particles and sodium silicate solution, which can greatly reduce the amount of sodium silicate solution required. Attached Figure Description

[0013] The following figures are intended only to illustrate and explain the invention and do not limit the scope of the invention.

[0014] Figure 1 This is a schematic diagram illustrating the structural principle of a premixing device according to a specific embodiment of the present invention;

[0015] Figure 2 for Figure 1 Schematic diagram of the structural principle of the midsole plate;

[0016] Figure 3 for Figure 1 A schematic diagram illustrating the three-dimensional exploded structure of the cover plate;

[0017] Figure 4 for Figure 1 A schematic diagram of the three-dimensional structure of a partial cross-section of the premixing equipment cylinder;

[0018] Figure 5 for Figure 1 A schematic diagram of the three-dimensional structure of the feeding pipe. Detailed Implementation

[0019] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments are now described with reference to the accompanying drawings. Identical components are denoted by the same reference numerals.

[0020] This invention provides a homogeneous self-insulating block, which is mainly composed of the following materials by weight percentage: silicate cement 20-40%; coke slag from thermal power plants 10-20%; slag from steel plants 20-32%; silica fume 4-9%; expandable polystyrene particles 1.7%-2.2%; non-fired desulfurized gypsum 8-11%; high-performance water-reducing agent 0.2-0.5%; activator 0.15-0.2%; binder 0.05-0.2%; and water 8-15%.

[0021] The silicate cement used can be ordinary silicate cement, such as P.O42.5 silicate cement, with a 28-day compressive strength of 43 MPa. Using ordinary silicate cement can reduce the proportion of silicate cement in the cementitious materials, thereby reducing costs and the concrete's density while ensuring concrete strength.

[0022] The coke slag from the thermal power plant is the tailings of the thermal power plant. In this embodiment of the invention, the coke slag with a fineness modulus of 0.7 to 1.5 obtained by screening the power plant tailings by Changji Guangrun Building Materials Co., Ltd. is honeycomb-shaped with 50-120 mm particles, which can better fill the cementitious system and improve the heat preservation effect.

[0023] The steel plant slag is a screened 10-20 mesh coarse sand particle, which can help improve the strength of concrete and contribute to thermal insulation. The main components of the steel plant slag include SiO2, Al2O3, Fe2O3, CaO, MgO, etc., and it can be obtained from various steel plants. For example, steel plant slag from Baosteel Group Bayi Steel Co., Ltd. can be selected.

[0024] The silica fume can be selected with a SiO2 content of 94% and a specific surface area of ​​25,000 m² / kg. Selecting silica fume with a large specific surface area can better fill the voids in the cementitious system, increase the density of concrete, and thus improve the strength of concrete.

[0025] The expandable polystyrene granules can be selected with a flame-retardant grade and a bulk density of 18-25 kg / m³. 3 For commercially available products, in order to facilitate allocation calculations, the preferred bulk density parameter in this invention is 20 kg / m³. 3 Expandable polystyrene particles.

[0026] Regarding the homogeneous self-insulating blocks involved in this invention, the inventors discovered in practice that expandable polystyrene granules can be processed using an automatic temperature-controlled vertical drying and mixing machine after adding industrial sodium silicate solution (using products meeting the liquid-2 to liquid-4 indicators in the Chinese national standard GB / T4209-2008) to remove moisture. This yields dried granules with a certain strength, effectively improving not only the strength of the expandable polystyrene granules themselves but also their adhesion to other cementitious materials in the concrete slurry during subsequent production processes. This method of pre-treating expandable polystyrene granules is not currently documented in relevant academic or technical literature. The inventors discovered this method accidentally in practice, considering that during the mixing and gradual drying process of the sodium silicate solution with the expandable polystyrene granules, the solid particles in the sodium silicate solution do not simply adhere to the outer surface of the polystyrene granules but can penetrate into the interior of the granules to a certain depth, forming a deep-adhesive coating. This results in increased strength of the dried, coated expandable polystyrene granules.

[0027] The high-performance water-reducing agent is a polycarboxylate-type high-performance water-reducing agent. Using this type of water-reducing agent can improve the slump and flowability of concrete.

[0028] The activator is one or more of triethanolamine, diethanolamine, and triisopropanolamine. Selecting such activators can fully activate the reactivity of coke slag from thermal power plants, slag from steel plants, silica fume, and gypsum, which can improve the strength of concrete and reduce the amount of silicate cement used, thereby reducing the density of concrete and achieving the purpose of lightweight, high-strength, homogeneous, and heat-insulating properties.

[0029] The adhesive is one or more of latex powder, polyacrylamide, and polyacrylic acid. Using this type of adhesive can effectively increase the viscosity of the concrete mixture and reduce the possibility of segregation in the concrete.

[0030] The present invention also provides a method for producing the above-mentioned homogeneous self-insulating blocks, the method comprising the following steps:

[0031] Step A (this is the preferred step) involves pretreating expandable polystyrene (EPS) granules by preparing high-strength granules using a sodium silicate solution. High-strength granules are obtained after the expandable polystyrene granules are mixed with and dried using the sodium silicate solution. Specifically, the process involves feeding the expandable polystyrene granule raw material and the sodium silicate solution into a drying mixer. For example, in one specific embodiment, a vertical drying mixer with a capacity of approximately two cubic meters can be prepared. This could be a vertical drying mixer produced by Shenyang Jinggong Huazhiyi Machinery Co., Ltd., or a vertical mixer similar to the one described in Chinese Patent CN103691359B (A Spiral Water Channel Constant Temperature Heating Vertical Mixer). Add 15-20 kg of expandable polystyrene granules and industrial sodium silicate solution (which can be liquid-2, liquid-3, or liquid-4 standard industrial sodium silicate products) to the vertical drying mixer. The two materials can be added simultaneously while stirring, or they can be added separately in sequence. In the latter case, a larger amount of sodium silicate solution is usually required to ensure uniform mixing. For example, based on volume ratio, the amount of sodium silicate solution usually needs to be about 0.6-0.8 times the volume of the expandable polystyrene granules.

[0032] The inventors discovered in production practice that this processing method requires a relatively large amount of sodium silicate solution to be added, thus requiring a longer time for stirring and drying. For example, when the temperature of the vertical drying mixer is controlled at around 50°C, it usually takes about 30-40 minutes of mixing and stirring to allow the expandable polystyrene particles to fully contact, fuse, and absorb the industrial sodium silicate solution to form high-strength particles.

[0033] The inventor modified the equipment to provide a premixing device. Figure 1 This is a schematic diagram illustrating the structural principle of a premixing device according to a specific embodiment of the present invention. Figure 2 for Figure 1 Schematic diagram of the structural principle of the midsole plate; Figure 3 for Figure 1 A schematic diagram illustrating the three-dimensional exploded structure of the cover plate. Figure 4 for Figure 1 A partial cross-sectional three-dimensional structural schematic diagram of the premixing equipment cylinder. Figure 5 for Figure 1A schematic diagram of the three-dimensional structure of the feeding pipe is shown below. Figures 1 to 5 As shown, the present invention provides a premixing device, which includes a cylinder 1, a bottom plate 2, and a cover plate 3. The top diameter of the cylinder 1 is larger than the bottom diameter, and the bottom surface is inclined to the axis. The interior of the cylinder 1 is provided with multiple sets of annular protrusions 11. The cover plate 3 is provided with an atomizing nozzle 32 at the axis for connecting to spray industrial sodium silicate solution. Figure 3 The atomizing nozzle 32 (not shown) has a hole through which the pipe passes. The atomizing nozzle 32 can be detachably connected to the pipe at the axis of the cover plate 3. The cover plate 3 has a hole on one side through which the pipe of an L-shaped nozzle 31 for spraying expandable polystyrene particles passes. The pipe of the L-shaped nozzle 31 can be welded to the cover plate 3. The outlet of the L-shaped nozzle 31 faces the axis of the cover plate 3. A reflector plate 21, coaxial with the cylinder 1, is located at the axis of the base plate 2. A feeding pipe 4, extending into the inner cavity of the drying mixer, is detachably installed at a lower position on the base plate 2.

[0034] The working principle of the premixing equipment provided by this invention is as follows: While the atomizing nozzle sprays industrial sodium silicate solution inside the cylinder 1, pressurized gas carries expandable polystyrene particles towards the sprayed sodium silicate solution. The annular protrusion 11 and the reflector plate 21 can eject the material entering the cylinder 1, thereby increasing the residence time of sodium silicate droplets and expandable polystyrene particles within the cylinder 1. Furthermore, the annular protrusion 11 and the reflector plate 21 can create turbulence in the airflow entering the cylinder 1, thereby enhancing the adhesion effect between the sodium silicate droplets and the expandable polystyrene particles. The expandable polystyrene particles coated with sodium silicate droplets finally enter the drying mixer via the feeding pipe 4. After the raw material has completely entered the drying mixer (usually about 15 minutes from the start of spraying), some of the moisture in the sodium silicate solution will evaporate under the blowing action of the airflow. Therefore, when the temperature is controlled at around 50°C, only about 5 minutes of mixing and stirring are usually needed to form high-strength particles. Compared to the previous method of mixing entirely in a drying mixer, this significantly reduces the workload of the drying mixer. Furthermore, by controlling the flow rate, the amount of sodium silicate solution required when using premixing equipment can be greatly reduced by volume ratio; for example, it can be only about 0.3-0.4 times the volume of expandable polystyrene granules. Practical experience has shown that when granules obtained through premixing and those obtained through soaking are processed into homogeneous self-insulating blocks using the same formulation and process, the performance of the two types of homogeneous self-insulating blocks is essentially the same, with differences in various performance parameters ranging from approximately 0.05%.

[0035] See Figure 1As shown, expandable polystyrene granules can be fed using commercially available Venturi injectors such as those from FOX Corporation in the United States or Shanghai Qianghan Machinery Equipment Co., Ltd. The air source can be pressurized gas obtained by pressurizing the atmosphere with a blower, or compressed air can be used as the air source. Under normal circumstances, a pressure of 0.4-0.8 bar is used to supply pressurized gas, which can be adjusted to meet the feeding requirements of expandable polystyrene granules. Specifically, the feeding rate of expandable polystyrene granules can be set to about 80-120 liters / minute.

[0036] The atomizing nozzle 32 can be a high-flow-rate air atomizing nozzle, such as that provided by Dongguan Bomei Spray System Co., Ltd. By adjusting the pressure of the sodium silicate solution and the supply air pressure, the working flow rate of the atomizing nozzle 32 can be set to about 30-40 liters / minute. Since commercially available sodium silicate solutions, such as liquid sodium silicate produced by Foshan Zhongfa Water Glass Factory, have a relatively high viscosity, a large pressure is required when using the atomizing nozzle for atomization. The inventors found in their work that adding about 10% water by volume to the liquid sodium silicate before atomization can facilitate the atomization process. As mentioned above, since most of the water will evaporate in the cylinder 1 and the remaining water will be dried in the subsequent drying and mixing machine, this added water will not have any impact on the subsequent working process. In other words, it does not belong to the "8-15% water" part of the homogeneous self-insulating block provided by this invention.

[0037] The cylinder 1 has a jar-shaped structure that is larger at the top and smaller at the bottom, and its internal volume can be controlled to be around 0.5-0.8 cubic meters, which can meet the space requirements for material mixing.

[0038] The shape of the reflector 21 can be set according to the spray range of the atomizing nozzle 32. The atomizing nozzle 32 can be a commercially available product from domestic companies such as Dongguan Bomei Spray System Co., Ltd. and Tianjin Bowei Industrial Nozzle Processing Co., Ltd. For example, when the atomizing nozzle 32 is a fan-shaped nozzle, see [reference needed]. Figure 2 As shown, the reflector 21 can be an inverted V-shaped structure. When the atomizing nozzle 32 is a conical nozzle, the reflector 21 can be a semi-circular structure. The reflector 21 is coaxially arranged with the cylinder 1, meaning that the reflector 21 faces the atomizing nozzle 32, thus reflecting the sprayed sodium silicate solution. The distance between the reflector 21 and the atomizing nozzle 32 can be approximately half the axial height of the cylinder 1, which achieves a better mixing effect.

[0039] The cylinder 1 can be formed by first pressing the raised strips out of the steel plate, and then bending and welding it. The height of the annular protrusion 11 protruding inward can be 3-5cm, and the arc of the cross section of the annular protrusion 11 can be an arc of a circle with a diameter of 30cm.

[0040] The outlet of the L-shaped nozzle 31 faces the axis of the cover plate 3. The outlet of the L-shaped nozzle 31 can be rectangular or circular. The distance between the outlet of the L-shaped nozzle 31 and the atomizing nozzle 32 in the axial direction of the cylinder 1 can be 5 cm. The distance between the outlet of the L-shaped nozzle 31 and the atomizing nozzle 32 in the horizontal direction can be 15-20 cm. The angle between the outlet axis of the L-shaped nozzle 31 and the horizontal plane can be 8-16 degrees. This allows the expandable polystyrene particles sprayed from the outlet of the L-shaped nozzle 31 to mix better with the sodium silicate solution sprayed from the atomizing nozzle 32.

[0041] To prevent expandable polystyrene particles with sodium silicate droplets adhering to the inside of the cylinder 1 from interfering with the material inside the drying mixer when they enter through the feeding pipe 4 using high-pressure gas, see [reference needed]. Figure 5 As shown, the side wall of the feeding pipe 4 can be provided with multiple vent holes 41. A screen (not shown in the figure), such as a 20-mesh screen, is then installed on the side wall of the feeding pipe 4. This allows gas to be discharged through the vent holes 41 during the material feeding process, while the material falls into the drying mixer. The screen can be a metal screen, welded to the inner side wall of the feeding pipe 4, or installed on the outer side wall of the feeding pipe 4 by binding or other methods.

[0042] Step B: Provide a container, add a certain amount of water, such as 10-12 kg of water, heat the water to a certain temperature, such as 40°C, add the required adhesive material to the water while stirring, for example, for 2 minutes, to fully dissolve it and prepare an adhesive solution.

[0043] Step C: Provide a container and add the high-performance water-reducing agent, activator and the adhesive solution obtained in step B to water while stirring to fully dissolve them and prepare an aqueous solution;

[0044] Step D involves providing a slurry mixer and feeding solid raw materials such as silicate cement, coke slag from thermal power plants, slag from steel plants, silica fume, and non-fired desulfurized gypsum into the mixer via an automatic metering and feeding device. Additionally, the aqueous solution obtained in step C and expandable polystyrene granules are added. The expandable polystyrene granules added in this step can be commercially available expandable polystyrene granules or high-strength expandable polystyrene granules obtained in step A, added to the slurry mixer in the order of their weight percentages. The mixer is then turned on and mixed until all materials are uniformly mixed, typically within about 5 minutes, to obtain a lightweight, high-strength, homogeneous, self-insulating concrete slurry.

[0045] Step E: The lightweight, high-strength, homogeneous, self-insulating concrete slurry obtained in step D is injected into molds of different shapes. After steam curing at 40-60℃ for 3 hours, the blocks are demolded and then cured at a constant temperature of 23-25℃ for 8 hours to obtain concrete blocks. The compressive strength can reach more than 3.0 MPa.

[0046] Step F involves cutting the cured concrete blocks into homogeneous self-insulating blocks of different sizes, specifications, and shapes using cutting machines of different sizes and shapes. After 14 days, the compressive strength reaches more than 5.5 MPa, and after 28 days, the compressive strength can reach more than 7.5 MPa.

[0047] This invention relates to homogeneous self-insulating blocks of different sizes and shapes, including cuboids and cubes, developed and configured by the inventor in accordance with the standards, specifications, parameters, etc., required by relevant documents and policies regarding self-insulating blocks, based on parameters such as compressive strength ≥5.0MPa, thermal conductivity <0.12, and fire resistance rating A.

[0048] The present invention will be further illustrated below with specific embodiments. It should be noted that those skilled in the art can make several modifications and improvements without departing from the principle of the present invention, and these should also be considered to fall within the protection scope of the present invention.

[0049] Example 1:

[0050] The raw material weight percentages are as follows:

[0051]

[0052] Among the above raw materials, the activator contains 0.1% triethanolamine (85% by mass) and 0.05% triisopropanolamine (85% by mass); the adhesive contains 0.05% latex powder, 0.03% polyacrylamide, and 0.02% polyacrylic acid.

[0053] The manufacturing method of the above-mentioned homogeneous self-insulating blocks is as follows:

[0054] (1) Provide a container, add 10-12 kg of water, heat the water to 40°C, add the required adhesive material to the water while stirring for 2 minutes to fully dissolve it and prepare an adhesive solution; then add the polycarboxylate high-performance water-reducing agent, activator and the above adhesive solution to 33-35 kg of water while stirring to fully dissolve it and prepare an aqueous solution.

[0055] (2) Add 5% by weight of water to the slurry mixer;

[0056] (3) Add 36% by weight of silicate cement, 12% of coke slag from thermal power plants, 21.67% of water slag from steel plants, 7% of silica fume and 11% of non-fired desulfurized gypsum to the above slurry mixer and stir for 2 minutes to make it evenly mixed.

[0057] (4) Add the aqueous solution obtained in step (1) to the above-mentioned slurry mixer;

[0058] (5) Add expandable polystyrene granules to the above slurry mixer;

[0059] (6) Turn on the slurry mixer and stir for 5 minutes to mix all the materials evenly and obtain the lightweight, high-strength, homogeneous, self-insulating concrete slurry.

[0060] (7) The mixed lightweight high-strength homogeneous self-insulating concrete slurry is injected into molds of different shapes. After steam curing at 40-60℃ for 3 hours, it is demolded and then cured at 23-25℃ for 8 hours. The compressive strength reaches 3.0 MPa.

[0061] (8) Cut the cured concrete blocks into homogeneous self-insulating blocks of different sizes, specifications and shapes using cutting machines of different sizes and shapes. The compressive strength reaches 6.5MPa after 28 days.

[0062] Example 2:

[0063] The raw material weight percentages are as follows:

[0064]

[0065] The above raw materials contain the following components: the activator contains 0.08% triethanolamine (85% by mass), 0.05% triisopropanolamine (85% by mass), and 0.02% diacetamide; the adhesive contains 0.05% latex powder, 0.03% polyacrylamide, and 0.02% polyacrylic acid.

[0066] The manufacturing method of the above-mentioned homogeneous self-insulating blocks is as follows:

[0067] (1) Provide a container, add 10-12 kg of water, heat the water to 40°C, add the required adhesive material to the water while stirring for 2 minutes to fully dissolve it and prepare an adhesive solution; then add the polycarboxylate high-performance water-reducing agent, activator and the above adhesive solution to 20.8-22.8 kg of water while stirring to fully dissolve it and prepare an aqueous solution.

[0068] (2) Add 5% by weight of water to the slurry mixer;

[0069] (3) Add 30% by weight of silicate cement, 15% coke slag from thermal power plants, 25.62% water slag from steel plants, 9% silica fume and 9% non-fired desulfurized gypsum to the above slurry mixer and stir for 2 minutes to make it evenly mixed.

[0070] (4) Add the aqueous solution obtained in step (1) to the above-mentioned slurry mixer;

[0071] (5) Add expandable polystyrene granules to the above slurry mixer;

[0072] (6) Turn on the slurry mixer and stir for 5 minutes to mix all the materials evenly and obtain the lightweight, high-strength, homogeneous, self-insulating concrete slurry.

[0073] (7) The mixed lightweight, high-strength, homogeneous, self-insulating concrete slurry is injected into molds of different shapes. After steam curing at 40-60℃ for 3 hours, it is demolded and then cured at a constant temperature of 23-25℃ for 8 hours. The compressive strength reaches 3.0 MPa.

[0074] (8) The cured concrete blocks are cut into homogeneous self-insulating blocks of different sizes, specifications and shapes using cutting machines of different sizes and shapes. The compressive strength reaches 5.3MPa after 28 days.

[0075] Example 3:

[0076] The raw material weight percentages are as follows:

[0077]

[0078] The above raw materials contain 0.1% triethanolamine (85% by mass) and 0.05% triisopropanolamine (85% by mass) as the activator; and 0.05% latex powder and 0.05% polyacrylamide as the adhesive.

[0079] The preparation method of the above homogeneous self-insulating blocks is as follows:

[0080] (1) Provide a container, add 10-12 kg of water, heat the water to 40°C, add the required adhesive material to the water while stirring for 2 minutes to fully dissolve it and prepare an adhesive solution; then add the polycarboxylate high-performance water-reducing agent, activator and the above adhesive solution to 11.4-13.4 kg of water while stirring to fully dissolve it and prepare an aqueous solution.

[0081] (2) Add 5% by weight of water to the slurry mixer;

[0082] (3) Add 30% by weight of silicate cement, 14% of coke slag from thermal power plants, 31.27% of water slag from steel plants, 6% of silica fume and 8% of non-fired desulfurized gypsum to the above slurry mixer and stir for 2 minutes to make it evenly mixed.

[0083] (4) Add the aqueous solution obtained in step (1) to the above-mentioned slurry mixer;

[0084] (5) Add expandable polystyrene granules to the above slurry mixer;

[0085] (6) Turn on the slurry mixer and stir for 5 minutes to mix all the materials evenly and obtain the lightweight, high-strength, homogeneous, self-insulating concrete slurry.

[0086] (7) The mixed lightweight high-strength homogeneous self-insulating concrete slurry is injected into molds of different shapes. After steam curing at 40-60℃ for 3 hours, it is demolded and then cured at 23-25℃ for 8 hours. The compressive strength reaches 3.0 MPa.

[0087] (8) The cured concrete blocks are cut into homogeneous self-insulating blocks of different sizes, specifications and shapes using cutting machines of different sizes and shapes. The compressive strength reaches 5.1MPa after 28 days.

[0088] Example 4:

[0089] The raw material weight percentages are as follows:

[0090]

[0091] The above raw materials contain 0.1% triethanolamine (85% by mass) and 0.08% triisopropanolamine (85% by mass) as the activator; and 0.05% latex powder and 0.05% polyacrylamide as the adhesive.

[0092] The manufacturing method of the above-mentioned homogeneous self-insulating blocks is as follows:

[0093] (1) Provide a container, add 10-12 kg of water, heat the water to 40°C, add the required adhesive material to the water while stirring for 2 minutes to fully dissolve it and prepare an adhesive solution; then add the polycarboxylate high-performance water-reducing agent, activator and the above adhesive solution to 24-26 kg of water while stirring to fully dissolve it and prepare an aqueous solution.

[0094] (2) Add 5% by weight of water to the slurry mixer;

[0095] (3) Add 36% by weight of silicate cement, 13% of coke slag from thermal power plants, 23.44% of water slag from steel plants, 8% of silica fume and 8% of non-fired desulfurized gypsum to the above slurry mixer and stir for 2 minutes to make it evenly mixed.

[0096] (4) Add the aqueous solution obtained in step (1) to the above-mentioned slurry mixer;

[0097] (5) Add expandable polystyrene granules to the above slurry mixer;

[0098] (6) Turn on the slurry mixer and stir for 5 minutes to mix all the materials evenly and obtain the lightweight, high-strength, homogeneous, self-insulating concrete slurry.

[0099] (7) The mixed lightweight, high-strength, homogeneous, self-insulating concrete slurry is injected into molds of different shapes. After steam curing at 40-60℃ for 3 hours, it is demolded and then cured at a constant temperature of 23-25℃ for 8 hours. The compressive strength reaches 3.0 MPa.

[0100] (8) Cut the cured concrete blocks into homogeneous self-insulating blocks of different sizes, specifications and shapes using cutting machines of different sizes and shapes. The compressive strength reaches 5.5MPa after 28 days.

[0101] Example 5:

[0102] The original weight percentage is as follows:

[0103]

[0104] The above raw materials include 0.1% triethanolamine (85% by mass) and 0.1% triisopropanolamine (85% by mass) as the activator; and 0.1% latex powder and 0.1% polyacrylamide as the adhesive.

[0105] The manufacturing method of the above-mentioned homogeneous self-insulating blocks is as follows:

[0106] (1) Provide a container, add 10-12 kg of water, heat the water to 40°C, add the required adhesive material to the water while stirring for 2 minutes to fully dissolve it and prepare an adhesive solution; then add the polycarboxylate high-performance water-reducing agent, activator and the above adhesive solution to 43-45 kg of water while stirring to fully dissolve it and prepare an aqueous solution.

[0107] (2) Add 5% by weight of water to the slurry mixer;

[0108] (3) Add 40% by weight of silicate cement, 10% of coke slag from thermal power plants, 20.52% of water slag from steel plants, 8% of silica fume and 8% of non-fired desulfurized gypsum to the above slurry mixer and stir for 2 minutes to make it evenly mixed.

[0109] (4) Add the aqueous solution obtained in step (1) to the above-mentioned slurry mixer;

[0110] (5) Add expandable polystyrene granules to the above slurry mixer;

[0111] (6) Turn on the slurry mixer and stir for 5 minutes to mix all the materials evenly and obtain the lightweight, high-strength, homogeneous, self-insulating concrete slurry.

[0112] (7) The mixed lightweight, high-strength, homogeneous, self-insulating concrete slurry is injected into molds of different shapes. After steam curing at 40-60℃ for 3 hours, it is demolded and then cured at a constant temperature of 23-25℃ for 8 hours. The compressive strength reaches 4.0 MPa.

[0113] (8) Cut the cured concrete blocks into homogeneous self-insulating blocks of different sizes, specifications and shapes using cutting machines of different sizes and shapes. The compressive strength reaches 7.0 MPa after 28 days.

[0114] Example 6:

[0115] The raw material weight percentages are as follows:

[0116]

[0117] The above raw materials include, as follows: the activator contains 0.1% triethanolamine (85% by mass) and 0.1% triisopropanolamine (85% by mass); the 0.05% adhesive contains 0.025% latex powder and 0.025% polyacrylamide.

[0118] The manufacturing method of the above-mentioned homogeneous self-insulating blocks is as follows:

[0119] (1) Provide a container, add 10-12 kg of water, heat the water to 40°C, add the required adhesive material to the water while stirring for 2 minutes to fully dissolve it and prepare an adhesive solution; then add the polycarboxylate high-performance water-reducing agent, activator and adhesive solution to 33-35 kg of water while stirring to fully dissolve it and prepare an aqueous solution.

[0120] (2) Add 10% by weight of water to the slurry mixer;

[0121] (3) Add 20% by weight of silicate cement, 20% of coke slag from thermal power plants, 30.77% of water slag from steel plants, 4% of silica fume and 8% of non-fired desulfurized gypsum to the above slurry mixer and stir for 2 minutes to make it evenly mixed.

[0122] (4) Add the aqueous solution obtained in step (1) to the above-mentioned slurry mixer;

[0123] (5) Add expandable polystyrene granules to the above slurry mixer;

[0124] (6) Turn on the slurry mixer and stir for 5 minutes to mix all the materials evenly and obtain the lightweight, high-strength, homogeneous, self-insulating concrete slurry.

[0125] (7) The well-mixed lightweight, high-strength, homogeneous, self-insulating concrete slurry is injected into molds of different shapes. After steam curing at 40-60℃ for 3 hours, it is demolded and then cured at a constant temperature of 23-25℃ for 8 hours. The compressive strength reaches 2.6 MPa.

[0126] (8) The cured concrete blocks are cut into homogeneous self-insulating blocks of different sizes, specifications and shapes using cutting machines of different sizes and shapes. The compressive strength reaches 4.9MPa after 28 days.

[0127] The physical and mechanical properties of the homogeneous self-insulating blocks prepared in Examples 1 to 6 are shown in the table below. The specific test methods are based on: Technical Standard for Application of Self-Insulating Blocks XJJ109-2019, Test Method Standard for Concrete Blocks and Bricks GB / T4111, and Standard for Determination, Calibration and Protective Heat Box Method of Thermal Insulation Steady-State Heat Transfer Properties GB / T 13475.

[0128]

[0129]

[0130] The test data obtained in the table above are for blocks produced using commercially available expandable polystyrene granules as raw materials. Practical experience shows that if the commercially available expandable polystyrene granules are coated with industrial sodium silicate solution using the method described in step A above, all technical indicators can be improved to some extent, especially the compressive strength, which can be increased by about 8%.

[0131] As can be seen from the table, the homogeneous self-insulating blocks prepared using this method have excellent working performance, low apparent density, high compressive strength, low segregation, low bulk density, high fire resistance, low thermal conductivity, excellent thermal insulation performance, good safety, and can last as long as the building.

[0132] Comparative experiment:

[0133] Example 7, compared with Example 1, the raw materials were changed as follows: silicate cement 42%; coke slag from thermal power plants 10%; steel plant slag 20.67%; silica fume 6%; non-fired desulfurized gypsum 9%, the rest remained unchanged. Performance test results: product strength ≥ 5.5 MPa, dry density > 1000 kg, which is considered overweight.

[0134] Example 8, compared with Example 2, the raw materials were changed as follows: 13% coke residue from thermal power plants; 4.83% (15kg) expandable polystyrene granules; the rest remained unchanged. Performance test results: product strength ≤3.8MPa, the strength does not meet the standard.

[0135] Example 9, compared with Example 3, the raw materials were changed as follows: ordinary silicate cement 29%; coke slag from thermal power plants 12%; water slag from steel plants 28.27%; non-fired desulfurized gypsum 13%, the rest remained unchanged. Performance test results: product strength ≤3.6MPa, water absorption rate close to 18%, low strength and high water absorption rate.

[0136] Example 10, compared with Example 4, the raw materials were changed as follows: 9% non-fired desulfurized gypsum; 1.1% binder (including 0.55% latex powder and 0.55% polyacrylamide); 8% water; the rest remained unchanged. Performance test results: The product slurry was too thick and difficult to solidify, affecting product quality and cutting process.

[0137] Example 11, compared with Example 5, the raw materials were changed as follows: 0.1% high-performance water-reducing agent; the rest remained unchanged. Performance test results: The product slurry mixing required a large amount of water, and the amount of cement also needed to be increased accordingly. The dry density was >1000kg, the product was overweight, and the water absorption rate tended to be between 18% and 20%.

[0138] Example 12, compared with Example 6, the raw materials were changed as follows: 40% steel plant slag; 0.5% activator (including 0.3% latex powder and 0.2% polyacrylamide); the rest remained unchanged. Performance test results: The cement exothermic effect in the product increased, which led to thermal cracking, and the product brittleness increased. The yield and compressive strength of the product decreased and did not meet the standards.

[0139] The homogeneous self-insulating block provided by this invention has the following advantages: (1) It reduces the weight of the structure; (2) Due to its good compressive strength, low density, high fire rating (Class A), low thermal conductivity, excellent insulation, and low segregation, it can have the same lifespan as the building; (3) By using this homogeneous self-insulating block to directly build the wall, it can simultaneously meet the requirements of the wall's strength, insulation, and fire resistance, and there is no need to construct separate insulation materials on the exterior wall, thus solving many problems such as the complexity of existing construction processes, significant safety and fire hazards, and the inability of external insulation to have the same lifespan as the building; (4) This homogeneous self-insulating block meets the relevant requirements of the government's promotion of integrated insulation and structure, and has the characteristics of energy saving, environmental protection, improved construction efficiency, resource and cost saving, and easy promotion.

[0140] Those skilled in the art should understand that although the present invention has been described with reference to multiple embodiments, not every embodiment contains only one independent technical solution. This description is merely for clarity; those skilled in the art should understand the specification as a whole and consider the technical solutions involved in each embodiment as being able to be combined with each other to form different embodiments to understand the scope of protection of the present invention. Any equivalent changes, modifications, and combinations made by those skilled in the art without departing from the concept and principles of the present invention should fall within the scope of protection of the present invention.

Claims

1. A method for premixing expandable polystyrene particles and sodium silicate solution, characterized in that, The device includes a premixing unit above the drying mixer, connected to both an expandable polystyrene granule hopper and a sodium silicate solution hopper. The premixing unit comprises a cylinder, a bottom plate, and a cover plate. The top diameter of the cylinder is larger than its bottom diameter, and the bottom surface is inclined to the axis. The interior of the cylinder has multiple sets of annular protrusions. The cover plate has a hole at its axis through which a pipe for connecting an atomizing nozzle spraying industrial sodium silicate solution passes. The atomizing nozzle is detachably connected to the pipe at the axis of the cover plate. The cover plate also has a hole on one side for connecting an L-shaped spray pipe for spraying expandable polystyrene granules. The L-shaped spray pipe is welded to the cover plate. The outlet of the pipe faces the axis of the cover plate. A reflector plate coaxial with the cylinder is provided at the center of the bottom plate. A feeding pipe extending into the inner cavity of the drying mixer is detachably provided at the lower part of the bottom plate. When it is necessary to premix expandable polystyrene granules and sodium silicate solution, expandable polystyrene granules and sodium silicate solution with a volume ratio of 0.3-0.4 times the volume of the expandable polystyrene granules are provided. While the atomizing nozzle is activated to spray industrial sodium silicate solution in the cylinder, pressurized gas is used to carry expandable polystyrene granules and spray them onto the sprayed sodium silicate solution. The premixing of expandable polystyrene granules and sodium silicate solution is completed in the cylinder.

2. The method according to claim 1, characterized in that, The expansionable polystyrene granules are fed using a Venturi injector, with the air source being pressurized gas obtained by pressurizing the atmosphere using a blower, or compressed air.

3. The method according to claim 2, characterized in that, The pressurized gas is supplied with a pressure of 0.4-0.8 bar.

4. The method according to claim 2, characterized in that, The feeding rate of expandable polystyrene granules is set to 80-120 liters / minute.

5. The method according to claim 4, characterized in that, The working flow rate of the atomizing nozzle is set to 30-40 liters / minute.

6. The method according to claim 5, characterized in that, Before atomization, dilute the liquid sodium silicate with approximately 10% water by volume.

7. The method according to claim 1, characterized in that, The cylinder has a jar-shaped structure that is wider at the top and narrower at the bottom, with an internal volume controlled between 0.5 and 0.8 cubic meters.

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