Method for preparing building ceramic tiles from a mechanism sand fine material and application

Abstract

This invention discloses a method for preparing building ceramic bricks using manufactured sand fine powder and its application, comprising the following steps: mixing and stirring manufactured sand fine powder with bauxite to obtain raw material; adding water to the raw material and mixing well, then pressing and molding to obtain a mixture; calcining the mixture at a final temperature of 1100-1200℃ to obtain building ceramic bricks prepared from manufactured sand fine powder; the ceramic bricks prepared using manufactured sand fine powder and bauxite as raw materials have a linear shrinkage rate of 1.51-2.59%, a water absorption rate of 2.61-5.97%, and a density of 2296-2377 kg / m³. 3 The compressive strength is 93-180 MPa, and it has good mechanical properties and high economic benefits. The building ceramic bricks prepared in this application have a high content of fine manufactured sand, a high recycling rate, and can alleviate the problem of solid waste stockpiling of manufactured sand and save clay resources.

Description

Technical Field

[0001] This invention relates to the field of building technology, and in particular to a method for preparing building ceramic bricks using manufactured sand fine particles and its application. Background Technology

[0002] The wet-process production of manufactured sand generates a large amount of washing sludge through mechanical crushing and screening. Fine particles in this sludge constitute the larger particle size component of the manufactured sand, which cannot meet the demands of construction sand. Currently, there is no proper solution for utilizing these fine particles, and they are mostly simply stored in open-air stockpiles. This storage of fine manufactured sand not only occupies a large amount of land, placing additional economic pressure on enterprises, but also easily generates dust storms, landslides, and other disasters, posing extremely high safety hazards. Therefore, the proper handling of fine manufactured sand is an urgent problem to be solved in the manufactured sand industry.

[0003] Architectural ceramic tiles are ceramic products used for paving walls and floors, and their demand in the construction industry continues to grow. Therefore, the demand for raw materials for ceramic tile production is extremely high. Traditional raw materials for ceramic tile production are non-renewable resources such as clay, quartz, and feldspar. With the development of mineral resources, these mineral raw materials are becoming increasingly scarce. Therefore, to alleviate the shortage of raw materials, it is urgent to find substitutes for traditional raw materials. The chemical composition of manufactured sand fine particles contains a large amount of silicon dioxide and aluminum oxide, which can serve as a source of silica and alumina for ceramic tiles. Therefore, manufactured sand fine particles are extremely suitable as raw materials for the production of architectural ceramic tiles. However, existing methods for preparing building materials using manufactured sand fine particles have the following problems: low dosage of manufactured sand filter cake or fine particles, resulting in low waste resource utilization; a focus on fine-grained sludge with finer particle size and better plasticity, with less research on larger-particle fine particles; finished products are mostly ordinary sintered bricks with low compressive strength; and the process is complex, time-consuming, and energy-intensive.

[0004] Therefore, there is a need to provide a method for preparing building ceramic bricks using manufactured sand fines to improve the utilization rate of manufactured sand fines and ensure the mechanical properties of the finished ceramic bricks. Summary of the Invention

[0005] In view of this, this application provides a method and application for preparing building ceramic bricks using manufactured sand fine particles, which is used to solve the problem of how to improve the mechanical properties of ceramic bricks while increasing the content of manufactured sand fine particles.

[0006] To achieve the above technical objectives, this application adopts the following technical solution: In a first aspect, this application provides a method for preparing building ceramic bricks from fine materials, comprising the following steps: The manufactured sand fines are mixed and stirred with bauxite to obtain raw material; Water is added to the raw material and mixed well, then pressed into shape to obtain a mixture; The mixture is calcined at a final temperature of 1100-1200℃ to obtain the fine material of manufactured sand for preparing building ceramic bricks.

[0007] Preferably, the D50 of the manufactured sand fine material is 240-250μm; it contains the following components in parts by mass: 50-52 parts SiO2, 12-15 parts Al2O3, 10-12 parts Fe2O3, 7-8 parts CaO, and 6-7 parts MgO.

[0008] Preferably, the mass of the manufactured sand fine material is 45-65% of the mass of the raw material.

[0009] Preferably, the mass ratio of manufactured sand fines to bauxite is 1.2-1.8:1.

[0010] Preferably, the water content is 6-10% of the raw material mass.

[0011] Preferably, the molding pressure used during compression molding is 18-22 MPa, and the molding time is 2-3 minutes.

[0012] Preferably, the calcination time is 1-2 hours, and the final temperature rise rate is 5-10℃ / min.

[0013] Secondly, this application provides a method for preparing building ceramic bricks using manufactured sand fine materials to obtain ceramic bricks.

[0014] Preferably, its linear shrinkage rate is 1.51-2.59%, water absorption rate is 2.61-5.97%, and density is 2296-2377 kg / m³. 3 Its compressive strength is 93-180 MPa.

[0015] Thirdly, this application provides a method for preparing building ceramic bricks from manufactured sand fine particles, and its application in the field of building recycling.

[0016] The beneficial effects of this application are as follows: This application describes the preparation of building ceramic bricks using manufactured sand fine particles and bauxite as raw materials. The resulting ceramic bricks have a linear shrinkage rate of 1.51-2.59%, a water absorption rate of 2.61-5.97%, and a density of 2296-2377 kg / m³. 3 It has a compressive strength of 93-180 MPa, good mechanical properties, and high economic benefits.

[0017] The building ceramic bricks prepared in this application have a high content of finely ground manufactured sand, a high rate of recycling and resource utilization, which alleviates the problem of solid waste stockpiling of manufactured sand and saves clay resources. The method for preparing ceramic bricks in this application has a low sintering temperature and short sintering time, which saves energy and is easy to scale up for industrial production. Attached Figure Description

[0018] Figure 1 This is a process flow diagram of this method. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0020] This application provides a method for preparing building ceramic bricks from fine particles, comprising the following steps: The manufactured sand fines are mixed and stirred with bauxite to obtain raw material; Water is added to the raw material and mixed well. The mixture is then placed in a mold and pressed to form a shape, thus obtaining the mixture. The mixture is calcined in a muffle furnace at a final temperature of 1100-1200℃ to obtain the fine material of manufactured sand for preparing building ceramic bricks.

[0021] The manufactured sand fine material of this application is a solid waste with high silicon and aluminum content, and also contains ions such as Fe, Ca, and Mg. During high-temperature calcination, it is easier to form a liquid phase, which improves the strength of ceramic bricks. The presence of Fe and Mg ions can lower the formation temperature of strength mineral phases such as mullite, reduce the firing difficulty of ceramic tiles, and increase the content of strength mineral phases, thereby increasing compressive strength. Therefore, the resulting building ceramic bricks have good mechanical properties. At the same time, the raw materials of this application are simple, only using manufactured sand fine material and bauxite to prepare ceramic bricks through batching, pressing, and firing processes. This increases the upper limit of the amount of manufactured sand fine material, has a high recycling and resource utilization rate, alleviates the problem of manufactured sand solid waste stockpiling, and saves clay resources.

[0022] The manufactured sand fine particles have a D50 of 240-250 μm; their composition includes quartz, biotite, iron-calcium amphibole, and anorthite, containing the following components in parts by weight: 50-52 parts SiO2, 12-15 parts Al2O3, 10-12 parts Fe2O3, 7-8 parts CaO, and 6-7 parts MgO. The manufactured sand fine particles used in this application have large particle size and poor plasticity; using them as raw materials can improve resource utilization.

[0023] In some embodiments, the source of the fine material of manufactured sand is: according to common knowledge, after multiple crushing processes of coarse crushing, medium crushing and fine crushing, over-crushed products with small particle size that cannot meet the standard requirements of manufactured sand will be generated during the crushing process. These products are discharged through a water washing step to form waste residue. Then the waste residue is screened, and the waste residue with a mesh size of 200 or larger is the fine material of manufactured sand.

[0024] In some embodiments, the mass of the manufactured sand fines is 45-65% of the mass of the raw meal.

[0025] In some embodiments, the mass ratio of manufactured sand fines to bauxite is 1.2-1.8:1, which ensures that the content of manufactured sand fines in the raw meal is maintained at 45-65%.

[0026] In some embodiments, the water content is 6-10% of the raw material mass; too much or too little water will make it difficult to press and mold.

[0027] In some embodiments, the molding pressure used during compression molding is 18-22 MPa, and the molding time is 2-3 minutes. Under these conditions, it is beneficial to increase the density of the finished product.

[0028] In some embodiments, the calcination time is 1-2 hours, and the final temperature rise rate is 5-10℃ / min.

[0029] This application provides a method for preparing building ceramic bricks using manufactured sand fine materials.

[0030] In this application, the linear shrinkage rate of the ceramic tiles is 1.51-2.59%, the water absorption rate is 2.61-5.97%, and the density is 2296-2377 kg / m³. 3 Its compressive strength is 93-180 MPa.

[0031] Thirdly, this application provides a method for preparing building ceramic bricks from manufactured sand fine particles, and its application in the field of building recycling.

[0032] The following specific embodiments further illustrate this solution.

[0033] Source of raw materials Fine aggregate of manufactured sand: These are particles with a particle size of D50=242.867 μm from the sand washing sludge produced by the wet process of manufactured sand production. Their composition includes quartz, biotite, iron-calcium amphibole, and anorthite. X-ray fluorescence spectroscopy testing shows that the content of SiO2 is 51.041%, Al2O3 is 14.224%, Fe2O3 is 11.503%, CaO is 7.006%, and MgO is 6.667%.

[0034] Example 1 A method for preparing building ceramic bricks using fine particles includes the following steps: Ingredients: Mix the finely ground manufactured sand with bauxite at a mass ratio of 3:2 to obtain raw material; Molding: Add 6% municipal water by weight of raw material to the raw material and mix well. Place the mixture in a mold and press it into shape under a tablet press. The molding pressure is 20 MPa and the molding time is 2 min to obtain the mixture. Firing: The mixture is placed in a muffle furnace and calcined at a heating rate of 5℃ / min to 1150℃ for 1 hour to obtain the building ceramic bricks prepared from the fine material of the manufactured sand.

[0035] Example 2 A method for preparing building ceramic bricks using fine particles includes the following steps: Ingredients: Mix the finely ground manufactured sand with bauxite at a mass ratio of 3:2 to obtain raw material; Molding: Add 6% municipal water by weight of raw material to the raw material and mix well. Place the mixture in a mold and press it into shape under a tablet press. The molding pressure is 20 MPa and the molding time is 2 min to obtain the mixture. Firing: The mixture is placed in a muffle furnace and calcined at a heating rate of 5℃ / min to 1150℃ for 1.5h to obtain the building ceramic bricks prepared from the machined sand fine material.

[0036] Example 3 A method for preparing building ceramic bricks using fine particles includes the following steps: Ingredients: The finely ground manufactured sand and bauxite are mixed and stirred at a mass ratio of 13:7 to obtain raw material; Molding: Add 6% municipal water by weight of raw material to the raw material and mix well. Place the mixture in a mold and press it into shape under a tablet press. The molding pressure is 20 MPa and the molding time is 2 min to obtain the mixture. Firing: The mixture is placed in a muffle furnace and calcined at a heating rate of 5℃ / min to 1150℃ for 1.5h to obtain the building ceramic bricks prepared from the machined sand fine material.

[0037] Example 4 A method for preparing building ceramic bricks using fine particles includes the following steps: Ingredients: The finely ground manufactured sand and bauxite are mixed and stirred at a mass ratio of 11:9 to obtain raw material; Molding: Add 6% municipal water by weight of raw material to the raw material and mix well. Place the mixture in a mold and press it into shape under a tablet press. The molding pressure is 20 MPa and the molding time is 2 min to obtain the mixture. Firing: The mixture is placed in a muffle furnace and calcined at a heating rate of 5℃ / min to 1150℃ for 1 hour to obtain the building ceramic bricks prepared from the fine material of the manufactured sand.

[0038] Comparative Example 1 A method for preparing building ceramic bricks from fine materials is the same as in Example 1, except that the temperature is increased to 1050°C at a heating rate of 5°C / min.

[0039] Comparative Example 2 A method for preparing building ceramic bricks from fine materials, which is the same as in Example 1 except that the temperature is increased to 1250°C at a heating rate of 5°C / min.

[0040] Comparative Example 3 A method for preparing building ceramic bricks from fine materials, the other contents are the same as in Example 1, and the calcination time is 3h.

[0041] Testing and Evaluation The ceramic tiles obtained in the examples and comparative examples were subjected to performance tests. The linear shrinkage rate, water absorption rate, density, and compressive strength were tested according to the standard GB / T 4100-2015 "Ceramic Tiles". The results are shown in Table 1.

[0042] Table 1 Test Results Linear shrinkage rate / % Water absorption rate / % <![CDATA[Density / (kg / m 3 )]]> Compressive strength (MPa) Example 1 2.22 3.17 2306.496 180.33 Example 2 2.59 2.61 2377.075 148.37 Example 3 1.51 5.97 2296.176 98.67 Example 4 2.48 3.02 2327.348 93.1 Comparative Example 1 1.17 7.68 2247.572 88.45 Comparative Example 2 1.20 1.06 2085.325 48.16 Comparative Example 3 2.36 2.60 2333.454 51.84 As shown in Table 1, the building ceramic brick samples prepared in Examples 1-4 of this invention have high compressive strength, low water absorption, and no obvious defects in appearance. Comparative Example 1, compared to the examples, used a lower firing temperature. The compressive strength and water absorption of the prepared ceramic brick sample were lower than those of the examples, indicating that the higher firing temperature resulted in the formation of more strong mineral phases during firing, improving the compressive strength of the building ceramic brick. The higher firing temperature also promoted the formation of the liquid phase, filling the pores inside the ceramic brick, thus reducing its porosity, increasing its density, and decreasing its water absorption. Comparative Example 2, compared to the examples, used a higher firing temperature. The prepared ceramic brick sample showed significant melting and severe appearance defects. Comparative Example 3, compared to the examples, used a longer holding time. The sample had no obvious defects in appearance. Although it had a lower water absorption rate than the examples, its compressive strength was far lower than that of the examples. This may be because the extended firing time caused slight melting of the strong mineral phases in the building ceramic brick, leading to a decrease in compressive strength.

[0043] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for preparing building ceramic bricks from manufactured sand fines, characterized in that, Includes the following steps: The manufactured sand fines are mixed and stirred with bauxite to obtain raw material; Water is added to the raw material and mixed well, then pressed into shape to obtain a mixture; The mixture is calcined at a final temperature of 1100-1200℃ to obtain the manufactured sand fine material for preparing building ceramic bricks; the raw material in the method consists of manufactured sand fine material and bauxite; the D50 of the manufactured sand fine material is 240-250μm; it contains the following components in parts by mass: 50-52 parts SiO2, 12-15 parts Al2O3, 10-12 parts Fe2O3, 7-8 parts CaO, and 6-7 parts MgO; the calcination time is 1-2 hours; the mass of the manufactured sand fine material is 45-65% of the mass of the raw material.

2. The method for preparing building ceramic bricks from manufactured sand fine particles according to claim 1, characterized in that, The mass of the water is 6-10% of the mass of the raw material.

3. The method for preparing building ceramic bricks from manufactured sand fine particles according to claim 1, characterized in that, During the pressing process, the molding pressure is 18-22 MPa and the molding time is 2-3 minutes.

4. The method for preparing building ceramic bricks from manufactured sand fine particles according to claim 1, characterized in that, The heating rate to the final temperature is 5-10℃ / min.

5. A ceramic brick obtained by a method for preparing building ceramic bricks using the manufactured sand fine material as described in any one of claims 1-4.

6. The ceramic tile according to claim 5, characterized in that, Its linear shrinkage rate is 1.51-2.59%, water absorption rate is 2.61-5.97%, and density is 2296-2377 kg / m³. 3 Its compressive strength is 93-180 MPa.

7. The application of a method for preparing building ceramic bricks from manufactured sand fine particles as described in any one of claims 1-4 in the field of building recycling.

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