Ceramic tile as well as preparation method and application thereof

Abstract

The invention discloses a ceramic tile as well as a preparation method and application thereof. The ceramic tile comprises the following components in percentage by mass: 62-78% of ore weathered powder and 22-38% of bauxite. The mineral weathered powder and the bauxite are compounded to prepare the ceramic tile, recycling of the mineral weathered powder is achieved, the problem of stockpiling of the mineral weathered powder and the problem of shortage of raw materials in the brick making industry are solved, and the prepared ceramic tile meets the performance requirement of the optimal-grade first-class ceramic tile (the water absorption rate is lower than 3%) in the national standard (GB / T 4100-2015).

Description

Technical Field

[0001] The present invention relates to the technical field of solid waste construction material conversion, and in particular to a ceramic brick and a preparation method and application thereof. Background Art

[0002] As the urbanization rate of human society increases year by year, the demand for architectural ceramic tiles used to build houses and infrastructure has increased dramatically. At present, the annual global production of architectural ceramic tiles has reached 1.5 trillion pieces, of which Asia accounts for about 90%. The traditional raw materials for the preparation of architectural ceramic tiles are mainly siliceous aluminum clay, which is a non-renewable resource. The high production of architectural ceramic tiles has led to a sharp increase in the mining of clay resources in Asia in recent years, which has further led to the increasingly serious land ecological problems caused by the mining of clay resources in Asia, such as land erosion, soil erosion, and reduction of cultivated land area. In order to prevent the expansion and aggravation of this problem, the Chinese government has issued relevant regulations prohibiting the use of clay in the brick industry. Therefore, in order to meet market demand and solve the shortage of raw materials in the architectural ceramic tile industry after the ban on clay, it is urgent to find other raw materials for the preparation of architectural ceramic tiles.

[0003] Ore weathering powder is the weathered soil waste stripped from the surface of the ore when the machine-made sand industry mines natural ore. The current treatment method for this waste in the machine-made sand industry is mainly open-air storage. The machine-made sand industry is huge in size and has a large annual output, which has led to a surge in the stockpile of ore weathering powder. The stockpile situation is becoming increasingly serious, with the annual stockpile exceeding 1 billion tons. The stockpile of a large amount of ore weathering powder will not only cause a waste of land resources and disposal funds, but also cause environmental and safety problems such as dust, vegetation destruction, mudslides, and landslides. Therefore, in order to alleviate the series of problems caused by the stockpile of ore weathering powder, it is also urgent to recycle the ore weathering powder. The chemical composition of ore weathering powder is mainly silicon oxide and aluminum oxide. In addition, it also contains a small amount of iron oxide, magnesium oxide, manganese oxide and alkaline oxides. Silicon oxide and aluminum oxide can be used as raw materials for the preparation of building ceramic tiles. Iron oxide, magnesium oxide, manganese oxide and alkaline oxides can be used as fluxing substances to reduce the firing temperature of building ceramic tiles and save energy. Therefore, developing weathered ore powder to prepare building ceramic tiles is a good way to alleviate the shortage of raw materials in the ceramic tile industry and solve the problem of weathered ore powder storage.

[0004] At present, there are no relevant patents for preparing building ceramic tiles from weathered ore powder, and practical knowledge of similar technical solutions is extremely lacking. In the prior art, the patent with publication number CN118545978A provides a method for preparing building ceramic tiles using machine-made sand fines. The method is to mix machine-made sand fines with bauxite, press and shape them, and then burn them to obtain building ceramic tiles. The patent with publication number CN115215633A provides a method for preparing building ceramic tiles using stone powder, washed sand, and medium-temperature sand as raw materials. The method obtains building ceramic tiles by wet ball milling, spray drying, pressing and molding the raw materials, and then firing them. The patent with publication number CN111777404A provides a method for preparing building ceramic tiles using machine-made sand filter cakes. The method is to mix machine-made sand filter cakes with clay, and then burn them into building ceramic tiles after aging and molding.

[0005] Although the above technical scheme has made outstanding contributions to the application of solid waste from the machine-made sand industry in the field of building ceramic tile preparation, it still has the following shortcomings: (1) It only realizes the recycling of fine materials, stone powder and filter cake in the solid waste of the machine-made sand industry, and does not realize the recycling of weathered ore powder. (2) It does not completely avoid the use of non-renewable resources such as clay, and its industrial practice value is not high. (3) The utilization rate of solid waste, especially solid waste generated by the machine-made sand industry, is less than 60%, and a large amount of natural resources (such as bauxite) is still required as supplementary raw materials. (4) The preparation process has many steps, takes a long time, and is not simple enough. Summary of the invention

[0006] In view of the above-mentioned shortcomings, the purpose of the present invention is to provide a building ceramic tile and a preparation method thereof, so as to solve the technical problems of the prior art of using machine-made sand solid waste to prepare building ceramic tiles, which has complex process and low solid waste utilization rate.

[0007] To achieve the above object, the present invention is implemented through the following technical solutions: In one aspect, the present invention provides a ceramic tile, comprising, by mass percentage, 62-78% of weathered ore powder and 22-38% of bauxite.

[0008] Preferably, the weathered ore powder includes CaO, SiO2, Al2O3, Fe2O3, MnO, MgO, Na2O and K2O; the mass ratio of CaO, SiO2, Al2O3, Fe2O3, MnO, MgO, Na2O and K2O is (3~4): (50~55): (20~25): (10~15): (0.1~0.2): (4~5): (2~3): (1~1.2).

[0009] In a second aspect, the present invention provides a method for preparing a ceramic tile, comprising the following steps: (1) Evenly mixing the weathered ore powder and bauxite to obtain a raw material for bricks; (2) Mixing water and raw materials for bricks evenly, and pressing them into shape to obtain bricks; (3) Calcine the brick at 1120-1180°C for 100-140 min to obtain ceramic bricks.

[0010] Preferably, in step (2), the amount of water used is 7-9% of the mass of the brick raw material.

[0011] Preferably, in step (2), the pressure of the pressing molding is 13-17 MPa.

[0012] Preferably, in step (2), the pressing time is 1 to 3 minutes.

[0013] Preferably, in step (3), the calcination temperature is 1130-1150°C.

[0014] Preferably, in step (3), the calcination time is 110-120 min.

[0015] Preferably, in step (3), the brick is heated to the calcining temperature at a heating rate of 5-10 °C / min.

[0016] In a third aspect, the present invention further provides an application of the ceramic brick described in the first aspect in the field of construction.

[0017] The beneficial effects of the present invention are: 1. The present invention realizes the recycling of weathered ore powder, alleviates the problem of stockpiling of weathered ore powder and the shortage of raw materials in the brick-making industry, and brings high value-added products.

[0018] 2. The ceramic bricks provided by the present invention can achieve a solid waste utilization rate of up to 78%, significantly reducing the use of expensive natural resources (such as bauxite) as supplementary raw materials.

[0019] 3. The ceramic bricks prepared by the present invention respond to national policy requirements, completely avoid the use of non-renewable resources such as clay, and have a higher ecological effect.

[0020] 4. The mechanical properties of the solid waste-based building ceramic bricks provided by the present invention can reach 100 MPa, and the water absorption rate is only 1.33%, which meets the performance requirements of the best grade I ceramic bricks (water absorption rate less than 3%) in the national standard (GB / T 4100-2015). BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the technical solution of the embodiment of the present invention, the drawings of the embodiment are briefly introduced below.

[0022] Figure 1 This is a process flow chart of a ceramic tile preparation process of the present invention; Figure 2 These are actual pictures of the ceramic tiles made in Example 1, Comparative Example 2, Comparative Example 4 and Comparative Example 6. DETAILED DESCRIPTION

[0023] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0024] In view of the problem of stockpiling of weathered ore powder and the shortage of raw materials in the building ceramic tile industry, the present application provides a method for preparing ceramic tiles using weathered ore powder, such as Figure 1 As shown, the method comprises the following steps: (1) According to the mass percentage, 62-78% of the weathered ore powder and 22-38% of the bauxite are mixed evenly to obtain the raw material of the brick; (2) mixing water and the raw materials for the bricks evenly, wherein the amount of water is 7-9% of the mass of the raw materials for the bricks, and then pressing and molding at 13-17 MPa for 1-3 min to obtain the bricks; (3) Calcine the brick at 1120-1180°C for 100-140 min to obtain ceramic bricks.

[0025] Specifically, the amount of weathered ore powder in step (1) can be 62%, 65%, 68%, 70%, 72%, 74%, 75%, 78% or any value within the range of 62-78%.

[0026] In order to make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be described in further detail below.

[0027] The chemical compositions of the weathered ore powder and bauxite used in the following examples and comparative examples are shown in Table 1.

[0028] Table 1 Chemical composition of weathered ore powder and bauxite

[0029] Example 1 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: 73 wt% of weathered ore powder and 27 wt% of bauxite are mixed evenly to obtain the raw material for bricks.

[0030] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0031] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1150 °C, and a holding time of 120 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0032] Example 2 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: 66 wt% of weathered ore powder and 34 wt% of bauxite are mixed evenly to obtain the raw material for bricks.

[0033] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0034] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1150 °C, and a holding time of 120 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0035] Example 3 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: 73 wt% of weathered ore powder and 27 wt% of bauxite are mixed evenly to obtain the raw material for bricks.

[0036] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0037] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1130 °C, and a holding time of 110 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0038] Example 4 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: 73 wt% of weathered ore powder and 27 wt% of bauxite are mixed evenly to obtain the raw material for bricks.

[0039] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0040] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1170 °C, and a holding time of 130 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0041] Comparative Example 1 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: Mix 60 wt% of weathered ore powder and 40 wt% of bauxite evenly to obtain brick raw materials.

[0042] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0043] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1150 °C, and a holding time of 120 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0044] Comparative Example 2 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: 80 wt% of weathered ore powder and 20 wt% of bauxite are mixed evenly to obtain the raw material for bricks.

[0045] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0046] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1150 °C, and a holding time of 120 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0047] Comparative Example 3 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: 73 wt% of weathered ore powder and 27 wt% of bauxite are mixed evenly to obtain the raw material for bricks.

[0048] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0049] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1100 °C, and a holding time of 120 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0050] Comparative Example 4 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: 73 wt% of weathered ore powder and 27 wt% of bauxite are mixed evenly to obtain the raw material for bricks.

[0051] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0052] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1200 °C, and a holding time of 120 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0053] Comparative Example 5 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: 73 wt% of weathered ore powder and 27 wt% of bauxite are mixed evenly to obtain the raw material for bricks.

[0054] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0055] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1150 °C, and a holding time of 80 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0056] Comparative Example 6 A method for preparing a ceramic tile comprises the following steps: (1) Ingredients: 73 wt% of weathered ore powder and 27 wt% of bauxite are mixed evenly to obtain the raw material for bricks.

[0057] (2) Preparing a green brick: Add 8 wt% of water to the green brick raw material obtained in step (1) to moisten the raw material, and then use a molding machine to press the raw material into a green brick at a molding pressure of 15 MPa and a molding time of 2 min.

[0058] (3) Firing ceramic tiles: The bricks obtained in step (2) are placed in a high-temperature furnace for calcination. The calcination conditions are a heating rate of 5 °C / min, a calcination temperature of 1150 °C, and a holding time of 160 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain a finished ceramic tile.

[0059] The compressive strength and water absorption rate of the ceramic tiles obtained in Examples 1 to 4 and Comparative Examples 1 to 6 were tested respectively, and the results are shown in Table 2.

[0060] Table 2 Compressive strength and water absorption of ceramic tiles made in Examples and Comparative Examples

[0061] As can be seen from Table 2, the compressive strength of the ceramic bricks made in the embodiment of the present invention is greater than 90 MPa, and the water absorption rate is less than 3%, which meets the performance requirements of a type of ceramic bricks in the national standard (GB / T 4100-2015). Compared with the embodiment, the compressive strength of Comparative Examples 1, 3 and 5 is significantly lower, and the water absorption rate exceeds 3%, which no longer meets the performance requirements of a type of ceramic bricks. This is because the amount of ore weathering powder added is small (the amount of Fe, Mn, Mg, Na and other fluxing ions in the brick blank is small), the calcination temperature is low and the insulation time is short, which will lead to the failure to maximize the formation of the strong mineral phase and dense structure (liquid phase formation content) in the brick body during the sintering process. Although the water absorption rate of Comparative Examples 2, 4 and 6 is lower than that of the embodiment, the compressive strength is still significantly reduced, and the overall performance of the brick is poor.

[0062] Figure 2 The following are the actual pictures of the ceramic tiles made in Example 1, Comparative Example 2, Comparative Example 4 and Comparative Example 6. Figure 2 It can be seen that compared with Example 1, the bricks of Comparative Examples 2, 4 and 6 have melted significantly, or even have lost their brick appearance. This is because too much weathered ore powder is added (too many fluxing ions such as Fe, Mn, Mg and Na in the brick), the calcination temperature is too high and the insulation time is too long, all of which lead to the melting of the strength mineral phase and the collapse of the mechanical structure (too high liquid phase content) in the brick during the sintering process.

[0063] It should be noted that the above embodiments all belong to the same inventive concept, and the description of each embodiment has its own focus. For matters that are not described in detail in some embodiments, reference may be made to the description in other embodiments.

[0064] The above-mentioned embodiments only express the implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A ceramic tile, characterized in that: Calculated by mass percentage, it includes: 62~78% weathered ore powder, 22~38% bauxite.

2. The ceramic tile according to claim 1, characterized in that: The weathered ore powder includes CaO, SiO2, Al2O3, Fe2O3, MnO, MgO, Na2O and K2O; the mass ratio of CaO, SiO2, Al2O3, Fe2O3, MnO, MgO, Na2O and K2O is (3-4): (50-55): (20-25): (10-15): (0.1-0.2): (4-5): (2-3): (1-1.2).

3. A method for preparing a ceramic tile according to any one of claims 1 to 2, characterized in that: The following steps are involved: (1) Evenly mixing the weathered ore powder and bauxite to obtain a raw material for bricks; (2) mixing water and the raw materials for the bricks evenly, and pressing and molding the mixture to obtain bricks; (3) calcining the brick at 1120-1180° C. for 100-140 min to obtain the ceramic brick.

4. The method for preparing a ceramic tile according to claim 3, characterized in that: In step (2), the amount of water used is 7-9% of the mass of the brick raw material.

5. The method for preparing a ceramic tile according to claim 3, characterized in that: In step (2), the pressing pressure is 13-17 MPa.

6. The method for preparing a ceramic tile according to claim 3, characterized in that: In step (2), the pressing time is 1 to 3 minutes.

7. The method for preparing a ceramic tile according to claim 3, characterized in that: In step (3), the calcination temperature is 1130-1150°C.

8. The method for preparing a ceramic tile according to claim 3, characterized in that: In step (3), the calcination time is 110 to 120 min.

9. The method for preparing a ceramic tile according to claim 3, characterized in that: In step (3), the brick is heated to the calcination temperature at a heating rate of 5-10 °C / min.

10. Use of the ceramic tile according to any one of claims 1 to 2 in the field of construction.

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