High-strength and high-wear-resistance cylinder brick based on waste electroceramics and preparation method of high-strength and high-wear-resistance cylinder brick

Abstract

The invention discloses a high-strength and high-wear-resistance cylinder brick based on a waste electroceramic material and a preparation method of the cylinder brick, and belongs to the field of waste electroceramic recycling and reusing. The cylinder brick comprises the following components: a waste electric porcelain material, clinker clay, argil, white mud and feldspar powder, the electric porcelain waste material is used as a core raw material, and is combined with the clinker clay, the argil and the like, so that the high-quality cylinder brick with the characteristics of high compression strength, low porosity, good thermal shock resistance, excellent corrosion resistance, wear resistance and the like is manufactured; the characteristics of mechanical strength, high-density structure, excellent thermal shock stability, chemical stability and the like contained in the electroceramic waste are fully explored, and the purposes of improving the erosion resistance, wear resistance, high-temperature rapid change resistance and overall physical and mechanical properties of the cylinder brick are achieved, and the purposes of turning waste into wealth and achieving high value are achieved.

Description

Technical Field

[0001] The invention relates to the field of recycling and reuse of waste electrical porcelain, and in particular to a high-strength and high-wear-resistant cylinder brick based on waste electrical porcelain material and a preparation method thereof. Background Art

[0002] At present, the market demand for refractory materials is increasing, and its demand is very extensive in metallurgy, construction, cement and other industries. my country is a major ceramic country in the world. With the continuous development of the industry, a large amount of ceramic waste has been generated. Compared with other solid wastes, waste electrical porcelain is more complex and unstable in composition. The high-temperature resistant phase and the low-melting point component are closely combined and difficult to separate. Some manufacturers use waste electrical porcelain to prepare engineering ceramics, wall insulation materials and concrete, etc., but have not formed a large-scale. The vast majority of waste electrical porcelain is landfilled or piled up, which not only wastes resources but also pollutes the environment.

[0003] How to maximize the advantages and minimize the disadvantages in the recycling of waste electrical porcelain, fully utilize the granulation, high temperature resistance, high hardness, density and certain high temperature resistance of waste electrical porcelain, fully tap the potential for high-value utilization of waste electrical porcelain, and minimize the adverse effects of low-melting point components on product performance has become the key to "turning waste into treasure". Summary of the invention

[0004] Purpose of the invention: The first purpose of the present invention is to provide a high-strength and high-wear-resistant cylinder brick based on waste electrical porcelain materials that can achieve effective recycling of waste electrical porcelain materials. The second purpose of the present invention is to provide a method for preparing the above-mentioned cylinder brick based on waste electrical porcelain materials.

[0005] Technical solution: The high-strength and high-wear-resistant cylinder bricks based on waste electrical porcelain materials described in the present invention include the following components by mass percentage: 30-40% waste electrical porcelain materials, 7-15% clay clinker, 20-40% pottery clay, 10-20% white mud and 5-15% feldspar powder.

[0006] Furthermore, the waste electrical porcelain material includes granular materials with a particle size of 3-1 mm and a particle size of 1-0 mm, with a mass ratio of 2:1 to 3:1.

[0007] Furthermore, the clay clinker includes granular materials with a particle size of 3-1 mm and a particle size of 1-0 mm, with a mass ratio of 2:1.

[0008] Furthermore, the white mud is Shanghai white mud with a particle size of 325 meshes.

[0009] Furthermore, the clay particle size is 150 mesh.

[0010] Furthermore, the feldspar particle size is 200 mesh.

[0011] Among the above components, waste electrical porcelain is used as the main aggregate, clay clinker is used as aggregate to reduce shrinkage during firing, aggregate, clay is used to improve the plasticity of the material, white mud is used to increase the viscosity of the mud, and feldspar powder is used to promote the sintering process and improve the strength of the cylinder bricks.

[0012] The method for preparing the cylinder brick based on waste electrical porcelain material comprises the following steps:

[0013] (1) Pre-mixing the waste electrical porcelain material and clay clinker, adding water and continuing to stir, and then adding pottery clay, white mud and feldspar powder and mixing and grinding evenly to form a mud material;

[0014] (2) After the mud is trapped, it is pressed and formed into a cylinder brick embryo;

[0015] (3) After the cylinder brick embryo is dried, it is sintered in a weak reducing atmosphere to produce cylinder bricks based on waste electrical ceramic materials.

[0016] Furthermore, in step (1), the amount of the added water is 2.5%-3.5% by weight of the total components.

[0017] Furthermore, in step (2), the time of trapping the material is 12-24 hours.

[0018] Furthermore, in step (2), the compression molding conditions are: using a 400t friction press, a molding frequency of 1-2 times / second, a molding pressure of 100-120MPa, and a heavy pressing number of 3-4 times.

[0019] Furthermore, in step (3), the drying is carried out in a slow drying manner: drying in a drying oven at 40-50° C. for more than 48 hours.

[0020] Furthermore, in step (3), the weak reducing atmosphere is formed by adjusting the ratio of the fuel gas to the combustion-supporting gas.

[0021] Furthermore, in step (3), the sintering treatment conditions are: sintering at 1280°C-1310°C for 2.5-4 hours.

[0022] Principle of the invention: The present invention uses electrical porcelain waste as the core raw material, combined with clay clinker and pottery clay, white mud and feldspar powder, to create high-quality cylinder bricks with high compressive strength, low porosity, good thermal shock stability, excellent corrosion resistance, wear resistance and other characteristics. It fully explores the mechanical strength, high-density structure, excellent thermal shock stability and chemical stability contained in electrical porcelain waste, aiming to enhance the corrosion resistance, high-temperature rapid change resistance and overall physical and mechanical properties of cylinder bricks, so as to achieve the purpose of "turning waste into treasure" and high value.

[0023] The innovative features of the present invention are as follows:

[0024] Raw material innovation: high-value utilization of waste electrical porcelain materials: Traditionally, waste electrical porcelain materials are difficult to reuse due to the loss of plasticity. This invention successfully avoids the influence of low-melting-point components in waste electrical porcelain materials through specific proportions and processing techniques, and instead utilizes its good sintering properties to transform waste electrical porcelain materials into high-strength, high-wear-resistant cylinder bricks, thus achieving high-value utilization of waste electrical porcelain materials.

[0025] Process innovation: unique component and gradation design: through crushing, screening and other steps, waste electrical porcelain materials and hard clay are processed into granular materials suitable for molding, and appropriate amounts of clay, white mud and other raw materials are added and mixed evenly, laying a good foundation for the subsequent molding and sintering process.

[0026] Optimized sintering process: By precisely controlling the sintering temperature and time and adjusting the sintering atmosphere, the cylinder bricks are densified during the sintering process. During the sintering process, it is necessary to avoid excessively high temperatures that may cause glazing, melting holes and other defects on the surface of the cylinder bricks, and to avoid excessively low temperatures that may cause the strength and wear resistance of the cylinder bricks to fail to meet the design requirements.

[0027] Product performance innovation: combination of high strength and high wear resistance. Through the preparation method of the present invention, waste electrical porcelain materials are successfully converted into cylinder bricks with high strength and high wear resistance, meeting various use requirements and broadening the field of recycling waste electrical porcelain materials.

[0028] The key points of the present invention are as follows:

[0029] Raw material selection and proportion: The key point is to select the appropriate proportion of waste electrical porcelain materials as the main raw material, and combine it with auxiliary materials such as clay clinker to achieve the best proportion of raw materials. This proportion is the basis for preparing high-strength and high-wear-resistant cylinder bricks.

[0030] Raw material processing technology: Crushing and screening the particle size of waste electrical porcelain materials are key steps, which directly affect the subsequent molding and sintering effects. By accurately controlling the processing process, particles suitable for molding can be obtained, providing a strong guarantee for the subsequent steps.

[0031] Forming and sintering process: The uniformly mixed mud is formed into a cylinder brick body by pressing, and the sintering temperature and time are precisely controlled to adjust the sintering atmosphere. Under the reducing atmosphere, the low melting phase has a significant fluxing effect during the sintering process, and the densification degree of the cylinder brick is greatly improved during the sintering process, thereby improving the wear resistance and strength of the cylinder brick. This step is the core of preparing high-performance cylinder bricks.

[0032] Product performance optimization: Through the preparation method of the present invention, waste electrical porcelain materials are successfully converted into cylinder bricks with high strength and high wear resistance, meeting various usage requirements. This performance optimization is one of the important goals of the present invention.

[0033] The preparation method of the present invention includes the steps of formula design, raw material preparation, raw material processing, mixing and molding, sintering process, etc. The combination and order of these steps are specific, and the specific parameters in each step (such as raw material ratio and gradation, processing technology, sintering temperature and time, kiln atmosphere, etc.) are carefully designed and optimized. Therefore, the preparation method is one of the core protection points of the present invention.

[0034] The cylinder bricks prepared by the method of the present invention have high strength and high wear resistance, which are important characteristics that distinguish them from other cylinder brick products. Therefore, the product characteristics are also one of the protection points of the present invention.

[0035] Technological innovation: The present invention has made innovations in formula, raw material selection, molding and sintering process, and product performance optimization, etc. These innovations together constitute the technical protection scope of the present invention.

[0036] In summary, the key points and protection points of the present invention are mainly reflected in the selection and proportion of raw materials, particle grading, molding and sintering process, product performance optimization and technological innovation, etc. These key points and protection points together constitute the core value and competitiveness of the present invention.

[0037] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages: (1) Realization of resource recycling: The present invention uses waste electrical porcelain as the main raw material, realizes the effective recycling of waste and reduces resource waste; (2) High strength: Through reasonable raw material ratio and firing process, the prepared cylinder bricks have high strength; (3) High wear resistance: The low melting point phase in the electrical porcelain waste makes the fired cylinder bricks have extremely low porosity, which improves the wear resistance of the cylinder bricks; (4) It has both environmental protection and economic benefits, can reduce environmental pollution, and use waste electrical porcelain to prepare cylinder bricks, reduce waste emissions, reduce pollution to the environment, and conform to the concept of sustainable development; It can reduce production costs, and use waste electrical porcelain to prepare cylinder bricks. Through an efficient recycling process, the production cost of cylinder bricks is reduced and the economic benefits are improved; (5) Technical universality and scalability: The preparation method of the present invention is not only applicable to waste electrical porcelain, but can also be extended to other similar solid waste materials, providing new ideas and approaches for the recycling of solid waste. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 is a physical picture of the cylinder brick prepared in Example 1;

[0039] Figure 2 This is a physical picture of the cylinder brick prepared in Comparative Example 1;

[0040] Figure 3 This is a physical picture of the cylinder brick prepared in Comparative Example 2;

[0041] Figure 4This is a physical picture of the cylinder brick prepared in Comparative Example 3;

[0042] Figure 5 This is a physical picture of the cylinder brick prepared in Comparative Example 4. DETAILED DESCRIPTION

[0043] The technical solution of the present invention is further described below in conjunction with embodiments and drawings.

[0044] Example 1: The components and dosage of the cylinder bricks based on waste electrical porcelain provided in this example are shown in Table 1 below.

[0045] Table 1 Components and dosage of cylinder bricks based on waste electrical porcelain in Example 1

[0046]

[0047] The preparation method of the above cylinder brick is as follows:

[0048] (1) Mixing and molding:

[0049] Put waste electrical porcelain and clay clinker into a mixer according to the formula ratio and stir for 2 minutes, then add about 3% tap water and stir for 3 minutes, then add clay and other powders and mix for 15 minutes to make mud;

[0050] After the mud is trapped for 24 hours, a 400t friction press is used to press and shape the evenly mixed mud into cylinder brick bodies.

[0051] (2) Sintering:

[0052] Put the formed cylinder bricks into the dryer and slowly dry them for 48 hours;

[0053] The dried cylinder brick body is placed in a tunnel kiln, the atmosphere in the firing section of the kiln is adjusted to a weak reducing atmosphere, and sintered at a temperature of 1310°C for about 3.5 hours.

[0054] (3) Inspection: Samples of fired cylinder bricks are tested. The actual picture is as follows Figure 1 The indicators are shown in Table 2 below.

[0055] Table 2 Performance test table of cylinder bricks prepared in Example 1

[0056]

[0057] Compared with the current standards for high-strength and wear-resistant cylinder bricks, it is found that the cylinder bricks based on waste electrical porcelain materials of the present invention have strength and wear resistance far higher than the standards, and the water absorption rate is also very low, and the overall performance is very excellent.

[0058] Comparative Example 1: The components and dosage of the cylinder bricks provided in this comparative example are shown in Table 3 below.

[0059] Table 3 Components and dosage of cylinder bricks in comparative example 1

[0060]

[0061] The preparation method of the above cylinder brick is as follows:

[0062] (1) Mixing and molding:

[0063] Put waste electrical porcelain and clay clinker into a mixer according to the formula ratio and stir for 2 minutes, then add about 2.8% tap water and stir for 3 minutes, then add clay and other powders and mix for 15 minutes to make mud;

[0064] After the mud is trapped for 24 hours, a 400t friction press is used to press and shape the evenly mixed mud into cylinder brick bodies.

[0065] (2) Sintering:

[0066] Put the formed cylinder bricks into the dryer and slowly dry them for 48 hours;

[0067] The dried cylinder brick body is placed in a tunnel kiln, the atmosphere in the firing section of the kiln is adjusted to a weak reducing atmosphere, and sintered at a temperature of 1310°C for about 3.5 hours.

[0068] (3) Inspection: Samples of fired cylinder bricks are tested. The actual picture (cut surface) is as follows: Figure 2 The indicators are shown in Table 4 below.

[0069] Table 4 Performance test table of cylinder bricks prepared in comparative example 1

[0070]

[0071] Due to the special physical properties of waste electrical porcelain, the amount of waste electrical porcelain added has a significant impact on the molding of the green body and the performance of the finished brick. After the waste electrical porcelain is crushed, the particles are sharp and the surface is relatively smooth. The fine powder cannot fully wrap the aggregate, which is easy to cause defects such as segregation and layer cracking during the molding process, and it is difficult to compact it, resulting in a significant reduction in the performance of the finished brick. After a lot of research and comparison, it is determined that the amount of waste electrical porcelain added is 30%-40%, which can maximize the utilization of solid waste and ensure its performance.

[0072] Comparative Example 2: The components and dosage of the cylinder bricks provided in this comparative example are shown in Table 5 below.

[0073] Table 5 Components and dosage of cylinder bricks in comparative example 2

[0074]

[0075] The preparation method of the above cylinder brick is as follows:

[0076] (1) Mixing and molding:

[0077] Put waste electrical porcelain and clay clinker into a mixer according to the formula ratio and stir for 2 minutes, then add about 3% tap water and stir for 3 minutes, then add clay and other powders and mix for 15 minutes to make mud;

[0078] After the mud is trapped for 24 hours, a 400t friction press is used to press and shape the evenly mixed mud into cylinder brick bodies.

[0079] (2) Sintering:

[0080] Put the formed cylinder bricks into the dryer and slowly dry them for 48 hours;

[0081] The dried cylinder brick body is placed in a tunnel kiln, the atmosphere in the firing section of the kiln is adjusted to a weak reducing atmosphere, and sintered at a temperature of 1250°C for about 3.5 hours.

[0082] (3) Inspection: Samples of fired cylinder bricks are tested. The actual picture is as follows Figure 3 The indicators are shown in Table 6. When the firing temperature is lower than 1280℃, the surface color of the material is red and the size basically does not shrink. Its strength and wear resistance are significantly lower than the standard of high-strength wear-resistant cylinder bricks, and the apparent porosity is high.

[0083] Table 6 Performance test table of cylinder bricks prepared in comparative example 2

[0084]

[0085] Comparative Example 3: The components and dosage of the cylinder bricks provided in this comparative example are shown in Table 7 below.

[0086] Table 7 Components and dosage of cylinder bricks in comparative example 3

[0087]

[0088] The preparation method of the above cylinder brick is as follows:

[0089] (1) Mixing and molding:

[0090] Put waste electrical porcelain and clay clinker into a mixer according to the formula ratio and stir for 2 minutes, then add about 3% tap water and stir for 3 minutes, then add clay and other powders and mix for 15 minutes to make mud;

[0091] After the mud is trapped for 24 hours, a 400t friction press is used to press and shape the evenly mixed mud into cylinder brick bodies.

[0092] (2) Sintering:

[0093] Put the formed cylinder bricks into the dryer and slowly dry them for 48 hours;

[0094] The dried cylinder brick body is placed in a tunnel kiln, the atmosphere in the firing section of the kiln is adjusted to a weak reducing atmosphere, and sintered at a temperature of 1340°C for about 3.5 hours.

[0095] (3) Inspection: Sample preparation and inspection of fired cylinder bricks; the actual picture is as follows Figure 4 The indicators are shown in Table 8. When the firing temperature is higher than 1310°C, the strength and porosity of the brick body are excellent, but a large number of melt holes and protrusions appear on the surface of the brick body, and the brick body is deformed, which seriously affects the performance of the product.

[0096] Table 8 Performance test table of cylinder bricks prepared in comparative example 3

[0097]

[0098] Comparative Example 4: The components and dosage of the cylinder bricks provided in this comparative example are shown in Table 9 below.

[0099] Table 9 Components and dosage of cylinder bricks in comparative example 4

[0100]

[0101] The preparation method of the above cylinder brick is as follows:

[0102] (1) Mixing and molding:

[0103] Put waste electrical porcelain and clay clinker into a mixer according to the formula ratio and stir for 2 minutes, then add about 3% tap water and stir for 3 minutes, then add clay and other powders and mix for 15 minutes to make mud;

[0104] After the mud is trapped for 24 hours, a 400t friction press is used to press and shape the evenly mixed mud into cylinder brick bodies.

[0105] (2) Sintering:

[0106] Put the formed cylinder bricks into the dryer and slowly dry them for 48 hours;

[0107] The dried cylinder brick body is placed in a tunnel kiln, the atmosphere in the firing section of the kiln is adjusted to an oxidizing atmosphere, and sintered at a temperature of 1310°C for about 3.5 hours.

[0108] (3) Inspection: Sample preparation and inspection of fired cylinder bricks; the actual picture is as follows Figure 5 The indicators are shown in Table 9 below.

[0109] Table 9 Performance test table of cylinder bricks prepared in comparative example 4

[0110]

[0111] It can be seen that at the same temperature, different firing atmospheres have a significant impact on the performance and appearance of the product. When fired in an oxidizing atmosphere, the strength of the brick body decreases significantly, and the wear resistance is not ideal. The surface of the brick body is slightly reddish and there are melt holes.

[0112] In summary, by implementing the method of the present invention, the cylinder bricks prepared have high strength and high wear resistance, and can meet various usage requirements. At the same time, the method of the present invention realizes the effective reuse of waste electrical porcelain materials, reduces production costs, reduces environmental pollution, and has significant economic and social benefits.

Claims

1. A high-strength and high-wear-resistant cylinder brick based on waste electrical porcelain material, characterized in that: Calculated by mass percentage, the invention comprises the following components: 30-40% of waste electrical porcelain materials, 7-15% of clay clinker, 20-40% of pottery clay, 10-20% of white mud and 5-15% of feldspar powder.

2. The cylinder brick according to claim 1, characterized in that: The waste electrical porcelain material includes granular materials with a particle size of 3-1 mm and a particle size of 1-0 mm, with a mass ratio of 2:1 to 3:

1.

3. The cylinder brick according to claim 1, characterized in that: The clay clinker includes granular materials with a particle size of 3-1 mm and a particle size of 1-0 mm, with a mass ratio of 2:

1.

4. The cylinder brick according to claim 1, characterized in that: The clay particle size is 150 meshes, the white mud is Shanghai white mud with a particle size of 325 meshes, and the feldspar particle size is 200 meshes.

5. A method for preparing cylinder bricks based on waste electrical ceramic materials according to any one of claims 1 to 4, characterized in that: The following steps are involved: (1) Pre-mixing the waste electrical porcelain material and clay clinker particles, adding water and continuing to stir, and then adding pottery clay, white mud and feldspar powder and mixing and grinding evenly to form a mud material; (2) After the mud is trapped, it is pressed and formed into a cylinder brick embryo; (3) After the cylinder brick embryo is dried, it is sintered in a weak reducing atmosphere to produce cylinder bricks based on waste electrical ceramic materials.

6. The preparation method according to claim 5, characterized in that: In step (1), the amount of the added water is 2.5%-3.5% of the total component mass.

7. The preparation method according to claim 5, characterized in that: In step (2), the compression molding conditions are: using a 400t friction press, a molding frequency of 1-2 times / second, a molding pressure of 100-120MPa, and a heavy pressing number of 3-4 times.

8. The preparation method according to claim 5, characterized in that: In step (3), the drying is carried out in a slow drying manner: drying in a drying room at 40-50° C. for more than 48 hours.

9. The preparation method according to claim 5, characterized in that: In step (3), the weak reducing atmosphere is formed by adjusting the ratio of the fuel gas to the combustion-supporting gas.

10. The preparation method according to claim 5, characterized in that: In step (3), the sintering treatment conditions are: sintering at 1280°C-1310°C for 2.5-4 hours.

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