A method for producing porcelain clay from waste porcelain powder

Abstract

The application discloses a production method of porcelain mud made of waste porcelain powder, and belongs to the technical field of ceramic materials. The method comprises the following steps: step 1, adding waste porcelain powder, sodium feldspar, potassium feldspar, ball clay, high-white primary ore, modified kaolin and calcined talc into a ball mill according to weight parts, adding water, ball-milling and mixing for 24-36 hours to obtain mud; and step 2, screening the mud obtained in step 1 to remove iron, pressure filtering, and refining the mud to obtain porcelain mud. The modified kaolin in the application has high dispersing performance and is not prone to agglomeration, and the mixing effect is excellent. The porcelain mud made of waste porcelain powder in the application has high plasticity and is not prone to cracking, dry shrinkage and other phenomena in the use process; the application not only effectively utilizes the waste porcelain powder generated by the ceramic industry, but also widens the production method of porcelain mud, and has great significance for the ceramic industry.

Description

Technical Field

[0001] This invention belongs to the field of ceramic materials technology, specifically relating to a method for producing porcelain clay from waste porcelain powder. Background Technology

[0002] Because waste ceramics have already undergone high-temperature sintering or firing, they cannot degrade under natural environmental conditions, causing serious environmental pollution. Previously, the recycling of waste ceramics only targeted porcelain waste, leaving a large amount of earthenware waste unused. Moreover, the technology was not widespread, and the processing cost of waste ceramics was high, leading most ceramic production enterprises to discard waste ceramics, resulting in resource waste and serious environmental pollution.

[0003] Currently, some ceramic manufacturers and research institutions are utilizing waste ceramics in the production of porcelain clay: after grinding and crushing, ceramic waste is added to the porcelain clay formula in a certain proportion, turning waste into treasure and meeting the requirements of sustainable development. However, due to the poor plasticity of waste ceramic powder, adding a large proportion of waste ceramic powder will result in insufficient plasticity of the porcelain clay, leading to cracking and deformation of the finished product during molding. In summary, how to efficiently utilize waste ceramic powder to prepare porcelain clay with high plasticity while ensuring its performance and economic cost is an urgent environmental and technical problem to be solved. Summary of the Invention

[0004] The purpose of this invention is to provide a method for producing porcelain clay from waste porcelain powder, so as to solve the problem of low plasticity of porcelain clay prepared from waste porcelain powder.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] A method for producing porcelain clay from waste porcelain powder includes the following steps:

[0007] Step 1: Add waste porcelain powder, sodium feldspar, potassium feldspar, ball clay, high whiteness raw ore, modified kaolin and calcined talc to a ball mill according to the weight parts, add water, and ball mill and mix for 24-36 hours to obtain mud.

[0008] Modified kaolin is prepared through the following steps:

[0009] Pretreated kaolin was added to deionized water and heated and stirred. Under a nitrogen atmosphere, an initiator was added and stirred for a period of time. Hydroxyethyl acrylate was added and stirring continued. The mixture was cooled to room temperature, washed and filtered, and dried to constant weight to obtain modified kaolin.

[0010] Step 2: The clay obtained in Step 1 is sieved to remove iron, filtered, and kneaded to obtain porcelain clay.

[0011] As a preferred embodiment of the present invention, the ratio of the amount of pretreated kaolin, deionized water, initiator and hydroxyethyl acrylate is 1.0-1.1 g: 30 mL: 0.15-0.20 g: 0.25-0.3 mL.

[0012] In a preferred embodiment of the present invention, the initiator is one of potassium persulfate and ammonium persulfate.

[0013] As a preferred embodiment of the present invention, the pretreated kaolin preparation steps are as follows:

[0014] Kaolin and dopamine were added to Tris buffer, sonicated, stirred, centrifuged, filtered, washed, and vacuum dried to obtain pretreated kaolin.

[0015] As a preferred embodiment of the present invention, the ratio of kaolin, dopamine and Tris buffer is 0.3 g: 0.3 g: 300 mL.

[0016] As a preferred embodiment of the present invention, the weight ratio of waste porcelain powder, sodium feldspar, potassium feldspar, clay, high whiteness ore, modified kaolin, calcined talc and water in step 1 is 13-16:12-14:15-17:4-6:10-12:14-18:1-3:80-150.

[0017] As a preferred embodiment of the present invention, the fineness of the waste ceramic powder is ≥300 mesh.

[0018] In a preferred embodiment of the present invention, the water content of the mud material in step 1 is 22%-24%.

[0019] As a preferred embodiment of the present invention, the sieve mesh size in step 2 is 150-250 mesh.

[0020] The above technical solution uses calcined talc. After calcination, the density of talc decreases, its specific surface area increases, and its wear resistance and thermal stability are greatly improved. This also improves the reactivity of porcelain clay after calcination.

[0021] The beneficial effects of this invention are:

[0022] This invention utilizes waste porcelain powder generated in the ceramic industry as the main raw material. Through batching, ball milling, sieving to remove iron, pressure filtration, and kneading, a porcelain clay with high plasticity and high solid content is prepared. This not only effectively utilizes the waste porcelain powder generated in the ceramic industry, but also broadens the production method of porcelain clay, which is of great significance to the ceramic industry.

[0023] The modified kaolin in this invention is prepared by chemically reacting dopamine with hydroxyethyl acrylate. The layered kaolin, after being coated with dopamine, introduces more active sites, improving its dispersion performance and reducing agglomeration. After grafting with hydroxyethyl acrylate, the interlayer spacing increases, enhancing the dispersion performance and wear resistance of the kaolin. It also has certain water retention and slow-release functions, increasing the water content of the porcelain clay and thus effectively reducing cracking.

[0024] In the raw material formula of this invention, traditional quartz is replaced with ceramic industrial waste—waste porcelain powder. Waste porcelain powder contains a certain amount of mullite, resulting in fewer physicochemical changes during firing compared to quartz. This reduces cracking defects caused by quartz crystal transformation, improving product qualification rate and thermal shock resistance. Simultaneously, the use of waste porcelain powder improves the fluidity and permeability of the grouting material, reduces viscosity, thixotropy, and dry shrinkage, thus minimizing drying cracking and deformation of the product. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0026] In the embodiments and comparative examples of this invention, the albite used has a mesh size of 80-100 mesh; the potassium feldspar has a mesh size of 80-100 mesh; and the clay used has a mesh size of 80 mesh.

[0027] The preparation steps of the Tris buffer used in the examples and comparative examples are as follows:

[0028] Dissolve 0.55 g of tris(hydroxymethyl)aminomethane hydrochloride in 450 mL of distilled water, and then adjust the pH of the solution to 8.5 with 0.1 mol / L NaOH to obtain Tris buffer.

[0029] Example 1

[0030] This embodiment provides a modified kaolin, and the preparation steps are as follows:

[0031] 0.3 g of kaolin and 0.3 g of dopamine were added to 300 mL of Tris buffer, sonicated for 1.5 h, stirred at room temperature for 22 h, centrifuged and filtered, washed three times with deionized water, and vacuum dried at 35 °C for 10 h to obtain pretreated kaolin.

[0032] Add 1.0 g of pretreated kaolin to 30 mL of deionized water, heat to 40 °C, add 0.15 g of ammonium persulfate under nitrogen atmosphere, stir for 20 min, add 0.25 mL of hydroxyethyl acrylate, continue stirring for 7 h, cool to room temperature, wash with deionized water and anhydrous ethanol respectively, filter, and dry to constant weight to obtain modified kaolin.

[0033] Example 2

[0034] This embodiment provides a modified kaolin, and the preparation steps are as follows:

[0035] 0.3 g of kaolin and 0.3 g of dopamine were added to 300 mL of Tris buffer, sonicated for 1.5 h, stirred at room temperature for 21 h, centrifuged and filtered, washed three times with deionized water, and vacuum dried at 35 °C for 11 h to obtain pretreated kaolin.

[0036] Add 1.05 g of pretreated kaolin to 30 mL of deionized water, heat to 42 °C, add 0.15 g of ammonium persulfate under nitrogen atmosphere, stir for 20 min, add 0.27 mL of hydroxyethyl acrylate, continue stirring for 8 h, cool to room temperature, wash with deionized water and anhydrous ethanol respectively, filter, and dry to constant weight to obtain modified kaolin.

[0037] Example 3

[0038] This embodiment provides a modified kaolin, and the preparation steps are as follows:

[0039] 0.3 g of kaolin and 0.3 g of dopamine were added to 300 mL of Tris buffer, sonicated for 1.5 h, stirred at room temperature for 20 h, centrifuged and filtered, washed three times with deionized water, and vacuum dried at 35 °C for 12 h to obtain pretreated kaolin.

[0040] 1.1 g of pretreated kaolin was added to 30 mL of deionized water, heated to 45 °C, and 0.16 g of initiator was added under a nitrogen atmosphere. The mixture was stirred for 20 min, then 0.3 mL of hydroxyethyl acrylate was added, and stirring was continued for 8 h. The mixture was cooled to room temperature, washed with deionized water and anhydrous ethanol respectively, filtered, and dried to constant weight to obtain modified kaolin.

[0041] Comparative Example 1

[0042] Compared to Example 1, only the kaolin was pretreated:

[0043] Add 0.3 g of kaolin and 0.3 g of dopamine to 300 mL of Tris buffer, sonicate for 1.5 h, stir at room temperature for 22 h, centrifuge and filter, wash three times with deionized water, and vacuum dry at 35 °C for 10 h to obtain pretreated kaolin, which is modified kaolin.

[0044] Example 4

[0045] A method for producing porcelain clay from waste porcelain powder includes the following specific steps:

[0046] Step 1: Add 15 parts waste porcelain powder, 12 parts sodium feldspar, 16 parts potassium feldspar, 5 parts ball clay, 10 parts high whiteness raw ore, 15 parts modified kaolin from Example 1 and 1 part calcined talc to a ball mill according to the following weight: add 100 parts water, and ball mill and mix for 26 hours to obtain mud.

[0047] Step 2: The clay obtained in Step 1 is sieved to remove iron, filtered, and kneaded to obtain porcelain clay.

[0048] Example 5

[0049] A method for producing porcelain clay from waste porcelain powder includes the following specific steps:

[0050] Step 1: Add 15 parts waste porcelain powder, 12 parts sodium feldspar, 16 parts potassium feldspar, 5 parts ball clay, 10 parts high whiteness raw ore, 15 parts modified kaolin from Example 2 and 1 part calcined talc to a ball mill according to the following weight: add 100 parts water, and ball mill and mix for 26 hours to obtain mud.

[0051] Step 2: The clay obtained in Step 1 is sieved to remove iron, filtered, and kneaded to obtain porcelain clay.

[0052] Example 6

[0053] A method for producing porcelain clay from waste porcelain powder includes the following specific steps:

[0054] Step 1: Add 15 parts waste porcelain powder, 12 parts sodium feldspar, 16 parts potassium feldspar, 5 parts ball clay, 10 parts high whiteness raw ore, 15 parts modified kaolin from Example 3 and 1 part calcined talc to a ball mill according to the following weight: add 100 parts water, and ball mill and mix for 26 hours to obtain mud.

[0055] Step 2: The clay obtained in Step 1 is sieved to remove iron, filtered, and kneaded to obtain porcelain clay.

[0056] Example 7

[0057] A method for producing porcelain clay from waste porcelain powder includes the following specific steps:

[0058] Step 1: Add 15 parts waste porcelain powder, 12 parts sodium feldspar, 16 parts potassium feldspar, 5 parts ball clay, 10 parts high whiteness raw ore, 18 parts modified kaolin from Example 3 and 1 part calcined talc to a ball mill according to the following weight: add 100 parts water, and ball mill and mix for 26 hours to obtain mud.

[0059] Step 2: The clay obtained in Step 1 is sieved to remove iron, filtered, and kneaded to obtain porcelain clay.

[0060] Comparative Example 2

[0061] Compared to Example 4, the modified kaolin from Comparative Example 1 was used:

[0062] A method for producing porcelain clay from waste porcelain powder includes the following specific steps:

[0063] Step 1: Add 15 parts waste porcelain powder, 12 parts sodium feldspar, 16 parts potassium feldspar, 5 parts ball clay, 10 parts high whiteness raw ore, 15 parts modified kaolin from Comparative Example 1 and 1 part calcined talc to a ball mill according to the following weight: add 100 parts water, and ball mill and mix for 26 hours to obtain mud.

[0064] Step 2: The clay obtained in Step 1 is sieved to remove iron, filtered, and kneaded to obtain porcelain clay.

[0065] Comparative Example 3

[0066] Compared to Example 5, no modified kaolin was added:

[0067] A method for producing porcelain clay from waste porcelain powder includes the following specific steps:

[0068] Step 1: Add 15 parts waste porcelain powder, 12 parts sodium feldspar, 16 parts potassium feldspar, 5 parts ball clay, 10 parts high whiteness raw ore and 1 part calcined talc to a ball mill according to the weight, add 100 parts water, and ball mill and mix for 26 hours to obtain mud.

[0069] Step 2: The clay obtained in Step 1 is sieved to remove iron, filtered, and kneaded to obtain porcelain clay.

[0070] The porcelain clays prepared in Examples 4-7 and Comparative Examples 2-3 were tested for plasticity index and solid content (wt%) based on the diameter (μm) of the largest particles. The test results are shown in Table 1.

[0071]

[0072] As can be seen from Table 1, compared with Comparative Examples 2-3, Examples 4-7 have excellent plasticity index and solid content, indicating that the porcelain clay prepared in this invention has high plasticity and high solid content. It not only effectively utilizes the waste porcelain powder generated by the ceramic industry, but also broadens the production method of porcelain clay, which is of great significance to the ceramic industry.

[0073] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0074] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A production method of porcelain clay made of waste porcelain powder, characterized in that, It comprises the following steps: Step 1, by weight parts, waste porcelain powder, albite, potassium feldspar, ball clay, high white primary ore, modified kaolin and calcined talc are added into a ball mill, water is added, and the mixture is ball milled for 24-36 hours to obtain a body; The modified kaolin is prepared by the following steps: The kaolin and dopamine are added into Tris buffer solution, ultrasonic treatment, stirring, centrifugal filtration, washing, vacuum drying to obtain pretreated kaolin; The pretreated kaolin is added into deionized water and heated and stirred, an initiator is added under nitrogen atmosphere and stirred for a period of time, hydroxyethyl acrylate is added and continued to stir, cooled to room temperature, washed and filtered, and dried to constant weight to obtain modified kaolin; Step 2, the body obtained in step 1 is screened to remove iron, pressure filtered, and the body is refined to obtain porcelain clay.

2. The production method of ceramic slurry using waste ceramic powder according to claim 1, wherein, The amount ratio of the pretreated kaolin, deionized water, initiator and hydroxyethyl acrylate is 1.0-1.1 g: 30 mL: 0.15-0.20 g: 0.25-0.3 mL.

3. The production method of ceramic slurry using waste ceramic powder according to claim 1, wherein, The initiator is one of potassium persulfate and ammonium persulfate.

4. The production method of ceramic slurry using waste ceramic powder according to claim 1, wherein, The amount ratio of kaolin, dopamine and Tris buffer solution is 0.3 g: 0.3 g: 300 mL.

5. The method of claim 1, wherein the ceramic slurry is produced by mixing the waste ceramic powder with water, and the waste ceramic powder is mixed with the water in a ratio of 1: 1 to 1:

3. The weight ratio of waste porcelain powder, albite, potassium feldspar, ball clay, high white primary ore, modified kaolin, calcined talc and water in step 1 is 13-16: 12-14: 15-17: 4-6: 10-12: 14-18: 1-3: 80-150.

6. The production method of ceramic slurry using waste ceramic powder according to claim 1, wherein, The fineness of the waste porcelain powder is ≥300 mesh.

7. The method of producing ceramic slurry from waste ceramic powder according to claim 1, wherein The moisture content of the body in step 1 is 22%-24%.

8. The method of claim 1, wherein the ceramic slurry is produced by mixing the waste ceramic powder with water, and the waste ceramic powder is mixed with the water in a ratio of 1: 1 to 1:

3. The mesh size in the screening process in step 2 is 150-250 mesh. The fineness of the waste porcelain powder is ≥300 mesh. The moisture content of the body in step 1 is 22%-24%. The mesh size in the screening process in step 2 is 150-250 mesh.

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