Method for preparing acid-proof brick from waste electroceramics

Abstract

The invention relates to the technical field of acid-proof brick manufacturing, and discloses a method for preparing an acid-proof brick by using waste electrical porcelain, and the method comprises the following steps: S1, preparing materials: Guangxi white mud, Yichun kaolin, half-shan mud, dark-bottom washing mud, Ningxian soil, waste electrical porcelain powder, Hengyang brand mud, Guangdong black mud and Wangxian stone; s2, after the raw materials are metered according to the weight percentage, adding the raw materials into a 15-ton ball mill for ball milling for 8 hours; according to the method for preparing the acid-proof brick by using the waste electroceramics, raw material preparation and pretreatment are basic links in acid-proof brick production, stability and consistency of product performance are ensured by accurately metering and proportioning various raw materials, excellent acid resistance is provided for the product by adding high-aluminum raw materials such as Guangxi white mud and Yichun kaolin, and meanwhile, the product quality is improved. Through the pretreatment steps of ball milling, iron removal, mud squeezing, pugging and the like, the uniformity and plasticity of the mud are effectively improved, and a solid foundation is laid for subsequent forming and sintering.

Description

Technical Field

[0001] The invention relates to the technical field of acid-resistant brick manufacturing, in particular to a method for preparing acid-resistant bricks by utilizing waste electrical porcelain. Background Art

[0002] The method of preparing acid-resistant bricks using waste electrical porcelain aims to convert discarded electrical porcelain materials into high-value acid-resistant bricks to achieve resource recycling. This method not only helps to reduce environmental pollution, but also saves raw materials and reduces production costs. Acid-resistant bricks, as a high-quality acid-resistant and alkali-resistant material, can withstand corrosion from various acidic or alkaline substances and are widely used in the fields of petroleum, chemical industry, and pharmaceuticals.

[0003] The workflow of preparing acid-resistant bricks from waste electrical porcelain mainly includes the steps of raw material processing, ingredient mixing, molding and pressing, drying, firing and quality inspection. First, the waste electrical porcelain materials are pre-treated by crushing, screening and washing to ensure the stable and pure quality of the raw materials. Then, according to production needs, the treated waste electrical porcelain is evenly mixed with other acid-resistant materials and pressed into acid-resistant bricks of a certain shape and size through a press. Next, the molded acid-resistant bricks are dried and fired at high temperature to improve their physical properties and acid and alkali resistance. Finally, the fired acid-resistant bricks are quality inspected to ensure that the products meet quality standards.

[0004] However, in the actual use of the above equipment, most of the manufacturing methods adopt wet forming, which has the disadvantages of low production efficiency, high energy consumption, and great environmental pollution. In view of this, we proposed a method for preparing acid-resistant bricks using waste electrical porcelain. Summary of the invention

[0005] The object of the present invention is to provide a method for preparing acid-resistant bricks using waste electrical porcelain, so as to solve the problems raised in the above-mentioned background technology.

[0006] To achieve the above object, the present invention provides the following technical solution: a method for preparing acid-resistant bricks using waste electrical porcelain, comprising the following steps:

[0007] S1. Material preparation: Guangxi white mud, Yichun kaolin, Banshan mud, Loudi washed mud, Ningxiang soil, waste electric porcelain powder, Hengyang Jiepai mud, Guangdong black mud, Wangxian stone;

[0008] S2. After the raw materials are measured by weight percentage, they are added into a 15-ton ball mill for 8 hours to reach a fineness of 2%-4%. The slurry is then sieved for iron removal, and the slurry in the refined slurry pool is aged for later use;

[0009] S3. After the mud is squeezed and smelted, the moisture content of the mud is 19%-20%, and it is ready for use after aging for 2 days;

[0010] S4. Use 350-type vacuum forming machine to form brick blanks, and use the robot to perform feeding, belt transportation, and blanking processes. Control the conveying rate, blank moisture, vacuum degree and process parameters to avoid defects such as stratification of the product.

[0011] S5. Put the formed green body into the drying room for drying. The temperature of the drying room is about 150 degrees.

[0012] S6. The dried blanks are refined. The refiner is adjusted according to the size of the semi-finished products. The refined blanks are carried out in an orderly manner. Unqualified products are refilled or scrapped.

[0013] S7. The dried green body is fired in a tunnel kiln at a temperature of about 1300 degrees.

[0014] Preferably, the method for preparing acid-resistant bricks using waste electrical porcelain comprises:

[0015] Raw material preparation and processing: Raw material preparation and pretreatment ensure that the raw materials required for acid-resistant brick production are accurately proportioned according to the formula, and improve the uniformity and plasticity of the mud through ball milling, iron removal, mud squeezing and mud kneading. This step is divided into raw materials and proportioning, ball milling and iron removal screening, and mud squeezing and mud kneading.

[0016] Wet pressing: The wet pressing step precisely controls the molding parameters to press the pretreated mud into acid-resistant bricks with regular shapes and precise sizes. This step is divided into molding preparation, pressing, and finishing and quality inspection.

[0017] Firing and post-processing: The firing and post-processing steps allow the bricks to be fully sintered at high temperatures to form acid-resistant bricks with dense structure and stable performance. This step is divided into drying and firing.

[0018] Preferably, the raw materials and proportions are precisely measured according to the formula composition, including 5%-9% Guangxi white mud, 14%-20% Banshan mud, 10%-12% Loudi washed mud, 9%-10% Yichun kaolin, 5%-8% Ningxiang soil, 12%-14% Hengyang Jiepai mud, 9%-12% Guangdong black mud, 5%-9% waste electrical porcelain powder and 5%-9% Wangxianshi.

[0019] Preferably, the ball milling and iron removal and screening are performed by adding the measured raw materials into a 15-ton ball mill and ball milling for 8 hours until a fineness of 2%-4% is reached. After slurrying, iron removal and screening are performed to ensure that there are no iron impurities in the mud, and the mud in the refined pulp pool is aged for standby use.

[0020] Preferably, the mud is squeezed and kneaded, the mud is squeezed to remove excess water, and the mud is kneaded to make the mud more uniform, and the moisture is controlled at 19%-20%, and the kneaded mud is aged for 2 days for subsequent use.

[0021] Preferably, the molding preparation includes preparing a 350-type vacuum molding machine and adjusting various parameters of the molding machine, such as conveying rate, body moisture, pressing pressure, etc.

[0022] Preferably, in the pressing and molding, the aged clay is placed into a molding machine, which is fed by a robot to ensure that the clay is evenly distributed, the molding machine is started, and a pressing operation is performed to form a brick blank, and the formed brick blank is sent out by a belt conveyor for subsequent processing.

[0023] Preferably, the refinement and quality inspection includes refining the formed brick blanks, adjusting the size and shape, conducting quality inspection, rejecting unqualified products, and performing repair or scrapping.

[0024] Preferably, the drying process is to send the refined bricks into a drying room for drying, and the temperature of the drying room is controlled at about 150 degrees to ensure that the bricks are dried evenly and avoid cracking or deformation.

[0025] Preferably, the firing process involves sending the dried bricks into a tunnel kiln for firing, with the firing temperature controlled at about 1300 degrees to ensure that the bricks are fully sintered. During the firing process, the temperature and time must be strictly controlled to avoid defects in the bricks.

[0026] Compared with the prior art, the present invention provides a method for preparing acid-resistant bricks using waste electrical porcelain, which has the following beneficial effects:

[0027] 1. The method of preparing acid-resistant bricks using waste electrical porcelain. Raw material preparation and pretreatment are the basic links in the production of acid-resistant bricks. The stability and consistency of product performance are ensured by accurately measuring and proportioning various raw materials. The addition of high-aluminum raw materials such as Guangxi white mud and Yichun kaolin provides the product with excellent acid resistance. At the same time, pretreatment steps such as ball milling, iron removal, mud squeezing and mud kneading effectively improve the uniformity and plasticity of the mud, laying a solid foundation for subsequent molding and firing.

[0028] 2. In the method of preparing acid-resistant bricks using waste electrical porcelain, the wet pressing step plays a vital role in the production of acid-resistant bricks. By precisely controlling the molding parameters, such as the conveying rate, the moisture content of the green body, the pressing pressure, etc., the shape of the bricks is regular and the size is accurate. This step not only improves the appearance quality of the product, but also enhances the structural strength of the product. At the same time, compared with wet molding, wet pressing has the advantages of high production efficiency, low energy consumption, and less environmental pollution.

[0029] 3. The method of preparing acid-resistant bricks using waste electrical porcelain, the firing and post-processing steps are the key links in the production of acid-resistant bricks, and their beneficial effects cannot be ignored. Through high-temperature firing, the organic matter in the brick blank is completely burned, and the inorganic matter forms a dense crystal structure, thereby giving the product excellent acid resistance. At the same time, the temperature and time control during the firing process ensure the stability and consistency of product performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 A schematic diagram of a method for preparing acid-resistant bricks using waste electrical porcelain according to the present invention;

[0031] Figure 2 This is a schematic diagram of the raw material preparation and processing module of the present invention;

[0032] Figure 3 It is a schematic diagram of a wet pressing molding module of the present invention;

[0033] Figure 4 It is a schematic diagram of the sintering and processing module of the present invention;

[0034] Figure 5 The figure is a flow chart of the method of the present invention. DETAILED DESCRIPTION

[0035] In order to enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only embodiments of a part of the present application, rather than all of the embodiments.

[0036] Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making any creative work should fall within the scope of protection of this application.

[0037] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so as to describe the embodiments of the present application described herein.

[0038] In the present application, the terms "upper", "lower", "left", "right", "front", "back", "top", "bottom", "inner", "outer", "middle", "vertical", "horizontal", "lateral", "longitudinal" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings. These terms are mainly used to better describe the present application and its embodiments, and are not used to limit the indicated devices, elements or components to have a specific orientation, or to be constructed and operated in a specific orientation.

[0039] In addition, some of the above terms may be used to express other meanings in addition to indicating orientation or positional relationship. For example, the term "on" may also be used to express a certain dependency or connection relationship in some cases. For those of ordinary skill in the art, the specific meanings of these terms in this application can be understood according to specific circumstances.

[0040] In addition, the terms "installed", "set", "provided with", "connected", "connected", and "socketed" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection, or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, elements, or components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0041] It should be noted that, in the absence of conflict, the embodiments in the present application and the features in the embodiments may be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0042] See also Figure 1-5 The present invention provides a technical solution: a method for preparing acid-resistant bricks using waste electrical porcelain, comprising the following steps:

[0043] S1. Material preparation: Guangxi white mud, Yichun kaolin, Banshan mud, Loudi washed mud, Ningxiang soil, waste electric porcelain powder, Hengyang Jiepai mud, Guangdong black mud, Wangxian stone;

[0044] S2. After the raw materials are measured by weight percentage, they are added into a 15-ton ball mill for 8 hours to reach a fineness of 2%-4%. The slurry is then sieved for iron removal, and the slurry in the refined slurry pool is aged for later use;

[0045] S3. After the mud is squeezed and smelted, the moisture content of the mud is 19%-20%, and it is ready for use after aging for 2 days;

[0046] S4. Use 350-type vacuum forming machine to form brick blanks, and use the robot to perform feeding, belt transportation, and blanking processes. Control the conveying rate, blank moisture, vacuum degree and process parameters to avoid defects such as stratification of the product.

[0047] S5. Put the formed green body into the drying room for drying. The temperature of the drying room is about 150 degrees.

[0048] S6. The dried blanks are refined. The refiner is adjusted according to the size of the semi-finished products. The refined blanks are carried out in an orderly manner. Unqualified products are refilled or scrapped.

[0049] S7. The dried green body is fired in a tunnel kiln at a temperature of about 1300 degrees.

[0050] In one embodiment of the present invention, raw material preparation and processing: raw material preparation and pretreatment ensure that the raw materials required for acid-resistant brick production are accurately proportioned according to the formula, and the uniformity and plasticity of the mud are improved through the steps of ball milling, iron removal, mud pressing and mud kneading. The steps are divided into raw materials and proportioning, ball milling and iron removal screening, and mud pressing and mud kneading;

[0051] Raw materials and proportions: according to Guangxi white mud 5%-9%, Banshan mud 14%-20%, Loudi washed mud 10%-12%, Yichun kaolin 9%-10%, Ningxiang soil 5%-8%, Hengyang Jiepai mud 12%-14%, Guangdong black mud 9%-12%, waste electric porcelain powder 5%-9%, Wangxian stone 5%-9%, accurately measure various raw materials according to the formula composition;

[0052] Ball milling and iron removal and screening: add the measured raw materials into a 15-ton ball mill and perform ball milling for 8 hours until the fineness reaches 2%-4%. After the slurry is discharged, iron removal and screening are performed to ensure that there are no iron impurities in the slurry, and the slurry in the refined slurry pool is aged for later use;

[0053] Mud squeezing and mud kneading: In the mud processing stage, the mud needs to be squeezed first to remove excess water through physical squeezing to make the mud more compact. Then, the mud is kneaded to make the mud more uniform and fine through repeated kneading and beating. The moisture content of the kneaded mud is controlled between 19% and 20%. Then it is left to stand for 2 days to allow the mud to fully mature so that it can show better performance in the subsequent molding and firing processes.

[0054] In one embodiment of the present invention, wet pressing and molding: the wet pressing and molding step presses the pre-treated mud into an acid-resistant brick blank with regular shape and precise size by precisely controlling the molding parameters. This step is divided into molding preparation, pressing and molding, and blank finishing and quality inspection;

[0055] Forming preparation: Before the operation begins, the 350-type vacuum forming machine must be prepared, fully inspected and debugged. Then, according to production requirements and product specifications, the key parameters of the forming machine, such as conveying rate, moisture content of the green body, and pressing pressure, must be adjusted to ensure that high-quality green bricks can be produced stably and efficiently during the forming process.

[0056] Pressing and molding: put the aged clay into the molding machine, feed it through the robot to ensure that the clay is evenly distributed, start the molding machine, perform the pressing operation to form the bricks, and send the formed bricks out through the belt conveyor for subsequent processing;

[0057] Refining and quality inspection: The formed bricks need to undergo fine refining processing, and their size and shape are adjusted by professional equipment to achieve the accuracy required by the design. Subsequently, each brick is subject to strict quality inspection to eliminate any defective and unqualified products, and these products are repaired or scrapped to ensure the high quality of the final product.

[0058] In one embodiment of the present invention, firing and treatment: The firing and treatment step allows the brick to be fully sintered at high temperature to form an acid-resistant brick with a dense structure and stable performance. This step is divided into drying and firing;

[0059] Drying: The bricks after finishing are sent to the drying room for further drying. The temperature in the drying room is precisely controlled at about 150 degrees, and the residual moisture in the bricks is gradually removed in a gentle way. This step not only ensures the uniformity of the drying of the bricks, but also effectively avoids cracking or deformation caused by too fast drying;

[0060] Firing: The dried bricks are sent to the advanced tunnel kiln for high-temperature firing. The temperature in the kiln is precisely controlled at around 1300 degrees to ensure that the bricks can be fully sintered at high temperature to form a dense crystal structure. During the firing process, the operator needs to strictly control the temperature and time to avoid cracks, deformation and other defects in the bricks to ensure the quality of the final product.

[0061] S1. Material preparation: Guangxi white mud (aluminum content 24%-26%) 5%-9%, Yichun kaolin (aluminum content 33%-35%, potassium and sodium content 2%-3%) 9%-10%, Banshan mud (aluminum content 15%-17%, potassium and sodium content 4%) 14%-20%, Loudi washed mud (aluminum content about 32%) 10%-12%, Ningxiang soil (aluminum content about 32%) 5%-8%, waste electric porcelain powder 5%-9%, Hengyang Jiepai mud 12%-14%, Guangdong black mud 9%-12%, Wangxianshi 5%-9%;

[0062] S2. The raw materials are weighed according to the precise weight percentage and put into a 15-ton ball mill. After 8 hours of continuous ball milling, the slurry reaches the required fineness of 2%-4%. Then, the slurry is discharged and screened for iron removal, and finally sent to the refined pulp pool for aging for subsequent use.

[0063] S3. The mud is squeezed to remove excess water, and then kneaded to make the mud more fine and uniform, with the moisture content controlled between 19% and 20%. Then it is left to stand for 2 days to allow the mud to fully mature for subsequent use.

[0064] S4, using 350-type vacuum forming machine, using precision manipulator automatic operation, complete the forming process from feeding to belt transportation to blanking. During this period, key process parameters such as conveying rate, blank moisture, vacuum degree, etc. need to be strictly controlled to ensure that the product has no defects such as stratification;

[0065] S5. Send the formed green body to the drying room for uniform drying. The temperature in the drying room is precisely controlled at about 150 degrees to ensure that the green body can lose moisture slowly and evenly.

[0066] S6. The dried blanks are sent to the finishing process. The operator accurately adjusts the finishing machine according to the actual size of the semi-finished product to ensure that each blank can be carefully processed. Under the orderly operation, unqualified products will be detected in time and refilled or scrapped;

[0067] S7. The dried green body is sent to the tunnel kiln for high-temperature firing. The temperature in the kiln is precisely controlled at around 1300 degrees to ensure that the green body can be fully sintered to form a dense crystal structure.

[0068] In the description of this specification, the terms "connect", "install", "fix", "set", etc. are understood in a broad sense. For example, "connection" can be a fixed connection or an indirect connection through an intermediate component without affecting the relationship between components and the technical effect. It can also be an integral connection or a partial connection. As in this example, for ordinary technicians in this field, the specific meanings of the above terms in the present invention or invention can be understood according to the specific circumstances.

[0069] The standard parts used can be purchased from the market, and can be customized according to the description and drawings. The specific connection methods of each part adopt conventional means such as bolts, rivets, welding, etc. in the prior art. The machinery, parts and equipment all adopt conventional models in the prior art, and the parts known to the technicians in this field, their structures and principles can be known by the technicians through technical manuals or through conventional experimental methods.

[0070] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing acid-resistant bricks using waste electrical porcelain, characterized in that: The following steps are involved: S1. Material preparation: Guangxi white mud, Yichun kaolin, Banshan mud, Loudi washed mud, Ningxiang soil, waste electric porcelain powder, Hengyang Jiepai mud, Guangdong black mud, Wangxian stone; S2. The raw materials are added to the ball mill for ball milling to reach the required fineness, and then the slurry is sieved for iron removal, and the slurry in the refined slurry pool is aged for standby use; S3. After the mud is squeezed and smelted, the moisture content of the mud is 19%-20%, and it is ready for use after aging for 2 days; S4. Use vacuum forming machine to form bricks, control the conveying rate, moisture content of the bricks, vacuum degree and process parameters to avoid defects such as stratification of the products; S5. Put the formed green body into the drying room for drying. The temperature of the drying room is about 150 degrees. S6. The dried blanks are refined. The refiner is adjusted according to the size of the semi-finished products. The refined blanks are carried out in an orderly manner. Unqualified products are refilled or scrapped. S7. The dried green body is fired in a tunnel kiln at a temperature of about 1300 degrees.

2. The method for preparing acid-resistant bricks using waste electrical porcelain according to claim 1, characterized in that: The method for preparing acid-resistant bricks using waste electrical porcelain comprises: Raw material preparation and treatment: Raw material preparation and pretreatment ensure that the raw materials required for acid-resistant brick production are accurately proportioned according to the formula, and improve the uniformity and plasticity of the mud through ball milling, iron removal, mud pressing and mud kneading. This step is divided into raw materials and proportion, ball milling and iron removal screening, mud pressing and mud kneading; Wet pressing: The wet pressing step presses the pre-treated mud into acid-resistant bricks with regular shapes and precise sizes by precisely controlling the molding parameters. This step is divided into molding preparation, pressing, and finishing and quality inspection. Firing and post-processing: The firing and post-processing steps allow the bricks to be fully sintered at high temperatures to form acid-resistant bricks with dense structure and stable performance. This step is divided into drying and firing.

3. The method for preparing acid-resistant bricks using waste electrical porcelain according to claim 2, characterized in that: The raw materials and proportions are accurately measured according to the formula composition, including 5% - 9% Guangxi white mud, 14% - 20% Banshan mud, 10% - 12% Loudi washed mud, 9% - 10% Yichun kaolin, 5% - 8% Ningxiang soil, 12% - 14% Hengyang Jiepai mud, 9% - 12% Guangdong black mud, 5% - 9% waste electrical porcelain powder and 5% - 9% Wangxianshi.

4. The method for preparing acid-resistant bricks using waste electrical porcelain according to claim 2, characterized in that: The ball milling and iron removal and screening are as follows: the measured raw materials are added into a 15-ton ball mill and ball milled for 8 hours until a fineness of 2%-4% is reached; after the slurry is discharged, the iron removal and screening are performed to ensure that there are no iron impurities in the slurry; and the slurry in the refined slurry pool is aged for standby use.

5. The method for preparing acid-resistant bricks using waste electrical porcelain according to claim 2, characterized in that: The mud squeezing and mud kneading are to squeeze the mud to remove excess water, perform mud kneading to make the mud more uniform, control the moisture content at 19%-20%, and age the kneaded mud for 2 days for subsequent use.

6. The method for preparing acid-resistant bricks using waste electrical porcelain according to claim 2, characterized in that: The molding preparation includes preparing a 350-type vacuum molding machine and adjusting various parameters of the molding machine, such as conveying rate, body moisture, pressing pressure, etc.

7. The method for preparing acid-resistant bricks using waste electrical porcelain according to claim 2, characterized in that: The pressing and molding process involves placing aged clay into a molding machine, feeding the clay through a robot to ensure that the clay is evenly distributed, starting the molding machine, performing a pressing operation to form a brick, and delivering the formed brick through a belt transport for subsequent processing.

8. The method for preparing acid-resistant bricks using waste electrical porcelain according to claim 2, characterized in that: The refinement and quality inspection are to refine the formed brick blanks, adjust the size and shape, conduct quality inspection, remove unqualified products, and carry out blank repair or scrapping.

9. The method for preparing acid-resistant bricks using waste electrical porcelain according to claim 2, characterized in that: The drying process is to send the refined bricks into a drying room for drying, and the temperature of the drying room is controlled at 150 degrees.

10. The method for preparing acid-resistant bricks using waste electrical porcelain according to claim 2, characterized in that: The firing process involves sending the dried green bricks into a tunnel kiln for firing, with the firing temperature controlled at about 1300 degrees to ensure that the green bricks are fully sintered.

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