A method for preparing real stone paint that can utilize various solid wastes

Abstract

The present invention relates to the technical field of solid waste treatment, and discloses a method for preparing a true stone paint coating that can utilize multiple solid wastes. The method utilizes the differences in color and apparent density to separate glassy slag from slag, which is used as a component in the true stone paint to imitate feldspar microcrystals; the waste glass particles are subjected to a certain matte treatment and color adjustment using powder made from waste gypsum board, so that the waste glass particles of different colors have a similar appearance and a texture close to that of quartz particles; at the same time, the dark ash produced by the impurities in the waste gypsum board during the calcination process can just simulate the black spots in natural granite; and the inorganic colloid formed by gelling salt is used to adsorb / encapsulate the dye, thereby completing the dyeing of the slippery sand that is not easily combined with the dye while preventing the loss of the dye. The above points are combined, and a true stone paint with a granite texture can be prepared without using any natural stone powder, and waste gypsum board and waste glass that are difficult to recycle due to their high impurity content can be utilized.

Description

Technical Field

[0001] The present invention relates to the technical field of solid waste treatment, in particular to a method for preparing real stone paint that can utilize a variety of solid wastes. Background Art

[0002] During building renovations, large quantities of gypsum board (for ceilings and interior walls) and glass panels are used. After renovations, these building materials become construction waste. Furthermore, the food industry generates a significant amount of discarded glass bottles each year. While waste gypsum board and glass can be recycled as raw materials for gypsum board and glass, their use is limited due to color and impurities. Excessive contamination can affect product quality. Furthermore, not all waste gypsum board and glass can be recycled as raw materials for gypsum board and glass. The portion that cannot be recycled as raw materials for gypsum board and glass (such as waste glass classified as "miscellaneous") is difficult to handle, presenting various challenges, whether crushing it for roadbed material or disposing of it in landfills.

[0003] Real stone paint is an emerging high-end paint. Using a real stone paint emulsion, natural stone powder is bonded to exterior walls to form a coating layer. This layer mimics the texture of natural rock without the added structural load of dry-hanging stone. The texture of real stone paint is determined by the type and color of the stone powder, as well as the color of any dyes added. Due to cost and construction difficulties, most real stone paints mimic the texture of sandstone. Simulating the texture of high-end stone materials like marble and granite is difficult and expensive, requiring relatively expensive raw materials such as colored quartz sand, and the appearance differs significantly from natural stone. Even the lower-cost real stone paint with a sandstone texture still requires a large amount of colored natural stone powder, which consumes natural resources and is costly. Granite is primarily composed of microcrystals of quartz and feldspar (some granite also contains mica), while marble is composed of microcrystals of calcite. However, the inventors found in actual construction that even when using colored sand from these materials to formulate real stone paint, the actual effect still differs from that of natural stone. The inventors discovered that the presence of the latex film in stone paint causes the feldspar and quartz crystals to lose the crystalline texture found in natural stone, thus affecting the appearance of the paint. Furthermore, the production process of these colored sands inevitably produces a large amount of fine powder, which destroys the crystal structure of these powders and thus loses the crystalline texture, also affecting the appearance of the stone paint.

[0004] If waste glass and plasterboard could be incorporated into real stone paint, both issues would be addressed. However, the texture of waste glass differs significantly from that of colored natural stone powder. Glass is an amorphous material, but its appearance is more brilliant and translucent than the microcrystals of feldspar and quartz. Even with similar colors, the difference in appearance is noticeable (too "shiny"). Furthermore, the color difference between waste glass and feldspar is significant; there is no glass that resembles feldspar.

[0005] Glassy slag is a special slag produced during coal combustion or ore smelting (although glassy slag is also produced during glass production, glassy slag does not refer to the slag produced during glass production, but slag with a glass-like texture). It is also known as slag glass. Its main components include silicon oxide, calcium oxide, and magnesium oxide. It is usually dark green and has a glass-like texture. It can easily be mistaken for a glass meteorite.

[0006] Slag usually has obvious alkalinity in aqueous solution system (most "acidic slag" is actually also alkaline in aqueous solution system, and its "acidity" refers to its "ability to absorb oxygen ions" in the furnace). Gypsum will produce a certain amount of calcium oxide after high-temperature calcination (calcium sulfate decomposes at high temperature), which also has obvious alkalinity in aqueous solution system.

[0007] The inventors found in actual operation that after being disturbed by the real stone paint emulsion film and gypsum powder, the texture of the glass particles became close to that of quartz crystals, and the glassy slag itself had a texture similar to that of feldspar in granite. Summary of the Invention

[0008] The invention provides a method for preparing real stone paint which can utilize various solid wastes.

[0009] The technical problem to be solved is that waste gypsum board and waste glass cannot be completely recycled as raw materials for gypsum board and glass, and the unusable parts are difficult to handle; at the same time, real stone paint requires the consumption of a large amount of natural minerals.

[0010] To solve the above technical problems, the present invention adopts the following technical solutions: a method for preparing a real stone paint coating that can utilize a variety of solid wastes, using glossy solid waste particles as aggregate in the real stone paint, using white solid waste powder to whiten and matte the solid waste particles, and using inorganic colloids to dye solid waste particles that are not easily dyed;

[0011] The pH value of the real stone paint is 6-10, and it contains the following components in parts by mass:

[0012] Slip sand: 40-60 parts, wherein the slip sand is a mixture of glassy slag particles and waste glass particles, and the mass ratio of the glassy slag particles to the waste glass particles is 1:1-4;

[0013] Whitening powder: 10-15 parts, the whitening powder is formed by calcining and crushing waste gypsum board;

[0014] Real stone paint emulsion: 30 parts;

[0015] Gelling salt: 1-3 parts, the gelling salt is an inorganic salt that can form a white or colorless inorganic colloid at the pH value of the real stone paint;

[0016] Inorganic dye: 0-1 part, the inorganic dye is a dye that can be adsorbed or encapsulated in the inorganic colloid formed by the colloid-forming salt;

[0017] The preparation method comprises the following steps:

[0018] Step 1: Select glassy slag from the slag and rinse it, rinse the waste glass, and rinse the waste gypsum board;

[0019] Step 2: crushing the glassy slag and waste glass into particles, and calcining the waste gypsum board and crushing it into powder;

[0020] Step 3: Mix the slippery sand, whitening powder, gelling salt and inorganic dye according to the proportion in the real stone paint to obtain the real stone paint powder, and seal the real stone paint powder in a moisture-proof packaging bag or packaging container;

[0021] Step 4: Mix the real stone paint powder and real stone paint emulsion on site. If the real stone paint powder contains inorganic dyes, the stirring time should be no less than 20 minutes.

[0022] Furthermore, in step 1, glassy slag is selected from the slag in the following manner:

[0023] Screening the slag to remove slag agglomerates;

[0024] Slag agglomerates containing glassy slag are selected by manual screening or color sorting;

[0025] Preliminary crushing of slag agglomerates containing glassy slag into small pieces with a mesh size of not less than 1;

[0026] The porous small pieces in the small pieces obtained by initial crushing are removed by air separation or winnowing, and the remaining part is the glassy slag.

[0027] Furthermore, the calcination temperature of the whitening powder is 900-1000° C., and the whitening powder contains anhydrous gypsum, hemihydrate gypsum, calcium oxide, and dust formed after calcination of impurities in waste gypsum boards;

[0028] In step 2, natural gas is used as fuel, and the waste gypsum board is calcined in an internal firing continuous gypsum calcining kiln at an excess air coefficient of 1.3-1.4 for a calcination time of 0.5-1 hour.

[0029] Furthermore, in step three, the real stone paint powder is stored in a compacted state.

[0030] Furthermore, in the slippery sand, at least half of the particles are 20-40 mesh, and the largest particle size is no more than 20; the whitening powder has a mesh size of no less than 800.

[0031] Furthermore, the gel-forming salt is alum powder, and the inorganic dye is iron red.

[0032] Furthermore, the sliding surface sand is ellipsoidal particles or flat flake particles.

[0033] Furthermore, the real stone paint emulsion is a pure acrylic emulsion or a silicone acrylic emulsion doped with a thickener, a defoaming agent, and a film-forming aid.

[0034] Furthermore, the real stone paint also contains 1-3 parts of mica powder, and the mesh size of the mica powder is 10-30.

[0035] Compared with the prior art, the method for preparing a real stone paint coating that can utilize various solid wastes has the following beneficial effects:

[0036] In the present invention, the difference in color and apparent density is used to separate the glassy slag from the slag, which is used as a component of the real stone paint to imitate the feldspar crystallites;

[0037] The waste glass particles are matte-treated and color-adjusted using powder made from waste gypsum board, making the different colored waste glass particles similar in appearance and texture to quartz particles. At the same time, the dark ash produced by the impurities in the waste gypsum board during the calcination process can simulate the black spots in natural granite.

[0038] The use of gelling salt to form an inorganic colloid to absorb / encapsulate the dye, thereby preventing the loss of dye while completing the dyeing of the slippery sand that is not easy to combine with the dye (if only the slurry has color, the texture is very strange). At the same time, the gelling salt adjusts the pH value of the paint in the process of forming the colloid to avoid the pH value being too high and affecting the adhesion of the paint (vitreous slag and whitening powder are both obviously alkaline, and real stone paint will have difficulty in adhesion when the pH value is higher than 10);

[0039] By combining the above points, the texture of granite was simulated using three types of solid waste. No natural stone powder is needed, all aggregates are solid waste, and waste gypsum board and waste glass, which are difficult to recycle due to their high impurity content, can be utilized. DETAILED DESCRIPTION

[0040] A method for preparing a true stone paint that can utilize a variety of solid wastes, using glossy solid waste particles as aggregate in the true stone paint, using white solid waste powder to whiten and matte the solid waste particles, and using inorganic colloids to dye solid waste particles that are not easily dyed.

[0041] The pH value of real stone paint is 6-10, which is the pH value after the paint is mixed. The pH has been adjusted during the mixing process. And in parts by mass, it contains the following ingredients:

[0042] Smoothing sand: 40-60 parts. Smoothing sand is a mixture of vitreous slag particles and waste glass particles. The mass ratio of vitreous slag particles to waste glass particles is 1:1-4, simulating the different crystallites found in natural granite. The vitreous slag particles are used to simulate feldspar, while the waste glass particles are used to simulate quartz. The ratio of the two solid waste particles reflects the feldspar to quartz ratio in granite, with quartz generally being more prominent. Of course, the texture of the smoothing sand differs from the granite surface crystallites, which are more "brilliant." Therefore, some whitening powder is added later to achieve a matte effect. This also overcomes the color effects of the waste glass particles from different sources, ensuring that the different colors of waste glass particles have a similar appearance and a texture similar to quartz particles. This ensures that even colored glass, such as beer bottles, can be used.

[0043] Smooth sand is the absolute main component of the paint. The amount used is 40-60 parts because it is easier to mix at this amount. If it is too much or too little, it will affect the mixing of the paint. Of course, in actual construction, this range can be exceeded as needed, as long as it can be mixed smoothly. Glassy slag can be manually selected from the slag, or the slag can be broken into small pieces and floated based on density differences. Waste glass particles are not strictly required to be colorless glass. Colored glass like beer bottles can also be used because its color is not dark. After being beaten into sand, it has almost no color, and whitening powder is also used later.

[0044] Whitening powder: 10-15 parts, whitening powder is the powder formed by calcining and crushing waste gypsum board;

[0045] Abandoned gypsum board contains a variety of organic impurities, such as organic dirt contaminated during long-term use and glue used in the installation process of the gypsum board. In addition to organic impurities, there is also rust on some iron parts used to install the gypsum board. These impurities often need to be removed when they are recycled, but they do not need to be removed in the present invention because the dark gray formed by these impurities after high-temperature calcination can just simulate the black spots (biotite) in granite. Gypsum will produce a certain amount of calcium oxide during the high-temperature calcination process, and these calcium oxides will promote the subsequent hydrolysis of gelling salts to form inorganic colloids. The amount of whitening powder is determined according to the surface area of ​​the sliding sand, and it must be ensured that it can be wrapped on the surface of the sliding sand.

[0046] Real stone paint emulsion: 30 parts; the real stone paint emulsion here can be purchased directly from the market. During the mixing process, you can add some water to facilitate mixing if necessary.

[0047] Gelling salt: 1-3 parts. Gelling salts are inorganic salts that form white or colorless inorganic colloids at the pH of natural stone paint. The inorganic colloids serve two purposes. One is to prevent dye loss. Among the various dyes used in the dyeing process, organic dyes have poor weather resistance. While inorganic dyes have good weather resistance, they also have poor dispersibility and are typically fine, insoluble powders. These powders can remain within the natural stone paint emulsion for a short time, but over time, they bleed out, causing the paint to discolor. Therefore, a white or colorless inorganic colloid is used to capture these dyes, forming a colored colloid that then flocculates, preventing loss. It also acts as a binder for brightening powder. Another function of the inorganic colloid is to adjust the pH, as both vitreous slag and brightening powder are significantly alkaline, which can affect paint adhesion. Conventional natural stone paint requires alkaline ammonia to adjust the pH, but this requires an acidic gelling salt.

[0048] Inorganic dye: 0-1 part. Inorganic dye is a dye that can be adsorbed or encapsulated in an inorganic colloid formed by a colloid-forming salt.

[0049] The amount of inorganic dye used depends on the needs and is not necessarily required. However, if too much is added, it will affect the texture of the real stone paint, making it closer to sandstone. In actual use, it is found that when the inorganic dye exceeds 1 part, the gloss of the smooth sand is almost completely lost and it no longer looks like microcrystalline.

[0050] The preparation method comprises the following steps:

[0051] Step 1: Select glassy slag from the slag and rinse it, rinse the waste glass, and rinse the waste gypsum board;

[0052] While the dark ash formed by calcining impurities from discarded gypsum board can mimic the black spots found in granite, excessive dust is harmful, affecting paint adhesion and appearance. The composition of the ash formed by calcining impurities from discarded gypsum board is controllable, primarily consisting of oxides, which have little impact on paint adhesion and are difficult to separate, so they can be retained. However, various dust impurities adhering to the surface of slag, discarded glass, and discarded gypsum board are easy to remove, but their composition is uncontrollable, requiring rinsing.

[0053] Step 2: crushing the glassy slag and waste glass into particles, and calcining the waste gypsum board and crushing it into powder;

[0054] This is a very mature operation that uses crushers to break down the particles and then uses screens to control the particle size.

[0055] Step 3: Mix the slippery sand, whitening powder, gelling salt and inorganic dye according to the proportion in the real stone paint to obtain the real stone paint powder, and seal the real stone paint powder in a moisture-proof packaging bag or packaging container;

[0056] The gelling salt here cannot be affected by moisture. It will become ineffective after being affected by moisture and will cause the real stone paint powder to agglomerate, so it needs to be sealed and stored. In addition, the whitening agent can act as a desiccant.

[0057] Step 4: Mix the real stone paint powder and real stone paint emulsion on site.

[0058] Inorganic dyes are not necessary for real stone paint, because not all buildings require colorful real stone paint. The most commonly used is solid color. But even if inorganic dyes are not added, gelling salt should be added. It not only fixes the inorganic dyes, but also fixes the whitening powder and adjusts the pH value. However, if the real stone paint powder contains inorganic dyes, the stirring time should be extended to at least 20 minutes to ensure that the slip surface sand is fully dyed.

[0059] In step 1, glassy slag is selected from the slag in the following manner:

[0060] The slag is screened to screen out the slag agglomerates; the glassy slag is formed by melting various oxides in the slag, so it must exist in the slag agglomerates.

[0061] Slag agglomerates containing glassy slag are selected by manual screening or color sorting. Glassy slag has a very consistent dark green color and can be selected by color sorting or manual selection. In this embodiment, several large pieces of glassy slag were found by manual selection.

[0062] The slag agglomerates containing glassy slag are preliminarily crushed into small pieces with a mesh size of not less than 1; each slag agglomerate is not entirely glassy slag, and unnecessary parts thereof need to be removed.

[0063] Air separation or winnowing is used to remove porous fragments from the initial crushing process, leaving the remaining portion as vitreous slag. The apparent density of vitreous slag is greater than that of the remaining slag agglomerates, so the density difference can be exploited to remove unwanted portions. Winnowing, using a dustpan for separation, while inefficient, is easier to operate. In this example, air separation equipment was not yet available, so this method was used to obtain some raw materials.

[0064] Whitening powder is calcined at 900-1000°C. It contains anhydrous gypsum, hemihydrate gypsum, calcium oxide, and dust formed after the calcination of impurities from discarded gypsum board. This calcination temperature is the temperature required to prepare high-temperature calcined gypsum. It is high enough to generate free calcium oxide, which, when added with water, forms basic calcium sulfate, acting as a catalyst and improving the strength of the coating. However, the raw material here is not natural gypsum, but discarded gypsum board. The impurities in the discarded gypsum board, after calcination, produce dark fly ash that simulates the black spots found in natural granite. The purpose of calcination here is not to produce high-temperature calcined gypsum, but to remove impurities. Therefore, it is sufficient to burn away the impurities; calcination does not require generating a large amount of free calcium oxide. In order to ensure that no unexpected impurities are generated during calcination, it is necessary to avoid carbon deposits during calcination. Therefore, in step 2, natural gas is used as fuel, and the waste gypsum board is calcined in an internal continuous gypsum calcination kiln at an excess air coefficient of 1.3-1.4 for a calcination time of 0.5-1 hour.

[0065] In step three, the real stone paint powder is stored in a compacted state to avoid stratification due to density difference, which increases the difficulty of mixing.

[0066] In the smooth sand, no less than half of the particles are 20-40 mesh, and the largest particle size is no more than 20; this particle size is similar to the particle size of microcrystals in natural granite; the mesh number of whitening powder is not less than 800, so that it is mixed in the real stone paint emulsion film without showing obvious granularity.

[0067] In this embodiment, the gel-forming salt is alum powder, which is a very common flocculant that easily forms a colloid at a certain pH value and then flocculates the colloid. The inorganic dye is iron oxide red. In actual use, it is found that alum flocculation can fix the iron oxide red into the flocs.

[0068] In the present embodiment, the sliding surface sand is an ellipsoidal particle or a flat flaky particle. Particles of these shapes are more likely to occur during the crushing process than spherical particles (waste glass is usually first broken into strips or triangles during the crushing process, and subsequently forms an ellipsoidal shape during the collision grinding process; and glass slag is easy to form a sheet like peeling an onion during the crushing process), and it also has a larger surface area, better reflective / refractive effect, and is more firmly combined with the real stone paint emulsion. However, it should be noted that the real stone paint in the present embodiment is more likely to scratch the hands of construction workers during use, so it should be avoided to directly grasp and smear the real stone paint during use.

[0069] In this embodiment, the real stone paint emulsion is a pure acrylic emulsion or a silicone acrylic emulsion doped with a thickener, a defoaming agent, and a film-forming aid.

[0070] The thickener, defoamer and film-forming aid (used to ensure that the coating can be carried out normally when the temperature is low) here are all commonly used additives in real stone paint emulsion. The dosage and usage are already very mature. They are added according to actual needs and will not be described in detail. The reason why pure acrylic emulsion or silicone acrylic emulsion is selected and styrene acrylic emulsion is abandoned is because styrene acrylic emulsion will turn yellow after long-term use, which is not a problem for the real stone paint with sandstone texture, but it will affect the granite texture for the present invention. In addition, the thickener selected inside can be commonly used hydroxyethyl cellulose or sodium carboxymethyl cellulose. Sodium carboxymethyl cellulose is not commonly used in real stone paint, but in the experiment we found that it is also an available option.

[0071] The real stone paint also contains 1-3 parts of mica powder, and the mesh number of the mica powder is 10-30. Mica powder is a commonly used additive for embellishment in real stone paint. It is added as appropriate when the customer needs it. No mica powder is added in this embodiment.

[0072] The following is a paint formula that is closest to the texture of common granite stone:

[0073] 50 parts of skid sand, consisting of 36 parts of waste glass particles and 14 parts of glassy slag particles (this ratio is similar to the dark to light parts of natural granite);

[0074] 12 parts whitening powder;

[0075] 30 parts of real stone paint emulsion;

[0076] 1 part gelling salt;

[0077] The amount of inorganic dyes is adjusted according to color requirements and generally does not need to be added.

[0078] The embodiments described above are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should fall within the scope of protection determined by the claims of the present invention.

Claims

1. A method for preparing a true stone paint coating that can utilize a variety of solid wastes, characterized by: Use shiny solid waste particles as aggregates in real stone paint, use white solid waste powder to whiten and matte the solid waste particles, and use inorganic colloids to dye solid waste particles that are not easy to be dyed; The pH value of the real stone paint is 6-10, and it contains the following components in parts by mass: Slip sand: 40-60 parts, wherein the slip sand is a mixture of glassy slag particles and waste glass particles, and the mass ratio of the glassy slag particles to the waste glass particles is 1:1-4; Whitening powder: 10-15 parts. The whitening powder is formed by calcining and crushing waste gypsum board. Glassy slag particles are used to imitate feldspar in granite, while waste glass particles are used to imitate quartz in granite. The texture of smooth sand is different from the microcrystals on the surface of granite, so whitening powder is needed to achieve a matte effect and overcome the color influence of waste glass particles from different sources. Real stone paint emulsion: 30 parts; the real stone paint emulsion is a pure acrylic emulsion or silicone acrylic emulsion doped with a thickener, a defoaming agent, and a film-forming aid; Gelling salt: 1-3 parts, the gelling salt is alum powder; the gelling salt fixes the inorganic dye and brightening powder to prevent them from being lost from the real stone paint emulsion film; Inorganic dye: 0-1 part, the inorganic dye is a dye that can be adsorbed or encapsulated in the inorganic colloid formed by the colloid-forming salt; The preparation method comprises the following steps: Step 1: Select glassy slag from the slag and rinse it, rinse the waste glass, and rinse the waste gypsum board; Step 2: crushing the glassy slag and waste glass into particles, and calcining the waste gypsum board and crushing it into powder; Step 3: Mix the slippery sand, whitening powder, gelling salt and inorganic dye according to the proportion in the real stone paint to obtain the real stone paint powder, and seal the real stone paint powder in a moisture-proof packaging bag or packaging container; Step 4: Mix the real stone paint powder and real stone paint emulsion on site. If the real stone paint powder contains inorganic dyes, the stirring time should be no less than 20 minutes.

2. The method for preparing a true stone paint that can utilize a variety of solid wastes according to claim 1, characterized in that: In step 1, glassy slag is selected from the slag in the following manner: Screening the slag to remove slag agglomerates; Slag agglomerates containing glassy slag are selected by manual screening or color sorting; Preliminary crushing of slag agglomerates containing glassy slag into small pieces with a mesh size of not less than 1; The porous small pieces in the small pieces obtained by initial crushing are removed by air separation or winnowing, and the remaining part is the glassy slag.

3. The method for preparing a true stone paint that can utilize a variety of solid wastes according to claim 1, characterized in that: The calcination temperature of the whitening powder is 900-1000°C, and the whitening powder contains anhydrous gypsum, hemihydrate gypsum, calcium oxide, and dust formed after the impurities in the waste gypsum board are calcined; In step 2, natural gas is used as fuel, and the waste gypsum board is calcined in an internal firing continuous gypsum calcining kiln at an excess air coefficient of 1.3-1.4 for a calcination time of 0.5-1 hour.

4. The method for preparing a true stone paint that can utilize a variety of solid wastes according to claim 1, characterized in that: In step three, the real stone paint powder is stored in a compacted state.

5. The method for preparing a true stone paint that can utilize a variety of solid wastes according to claim 1, characterized in that: In the slippery sand, at least half of the particles are 20-40 mesh, and the mesh number of the largest particle is not greater than 20; the mesh number of the whitening powder is not less than 800.

6. The method for preparing a true stone paint that can utilize a variety of solid wastes according to claim 1, characterized in that: The inorganic dye is iron red.

7. The method for preparing a true stone paint that can utilize various solid wastes according to claim 1, characterized in that: The sliding surface sand is in the form of ellipsoidal particles or flat flake particles.

8. The method for preparing a true stone paint that can utilize various solid wastes according to claim 1, characterized in that: The real stone paint further comprises 1-3 parts of mica powder, and the mesh number of the mica powder is 10-30.