Ceramic tile, method for the production thereof and use thereof

Abstract

The application discloses a ceramic tile and a preparation method and application thereof. The ceramic tile comprises, in percentage by mass, 62-78% of ore weathered powder and 22-38% of bauxite. The application utilizes the ore weathered powder and the bauxite to prepare the ceramic tile, realizes recycling of the ore weathered powder, alleviates the problems of ore weathered powder stockpiling and shortage of raw materials in the brick-making industry, and the prepared ceramic tile meets the performance requirement of the optimal level of the first-class ceramic tile (water absorption is less than 3%) in the national standard (GB / T 4100-2015).

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of solid waste building materials, in particular to a ceramic tile and a preparation method and application thereof. BACKGROUND

[0002] With the urbanization rate of human society rising year by year, the demand for building ceramic tiles used for building houses and infrastructure has increased dramatically. At present, the annual output of building ceramic tiles worldwide has reached 1.5 trillion, of which the output in the Asian region accounts for about 90%. The traditional raw material for the preparation of building ceramic tiles is silico-alumina clay, which is a non-renewable resource. The high output of building ceramic tiles has led to a sharp increase in the mining of clay resources in the Asian region in recent years, further leading to land ecological problems caused by clay resource mining in the Asian region, such as land erosion, soil erosion, and reduction of arable land, which are becoming increasingly serious. In order to prevent the expansion and severity of this problem, the Chinese government has issued relevant orders prohibiting the use of clay in the brick industry. Therefore, in order to meet market demand and solve the problem of raw material shortage in the building ceramic tile industry after the prohibition of clay, it is urgent to find other raw materials for the preparation of building ceramic tiles.

[0003] Ore weathered powder is weathered soil waste stripped from the surface of natural ore during the mining of machine-made sand industry. The main treatment method for this waste material in the machine-made sand industry is open-air storage. The machine-made sand industry has a huge volume, with a large annual output, resulting in a growing amount of ore weathered powder storage, with an annual storage amount exceeding 1 billion tons. The storage of a large amount of ore weathered powder not only causes waste of land resources and disposal costs, but also causes environmental and safety problems such as dust, vegetation damage, mudslides, and landslides. Therefore, in order to alleviate the series of problems caused by the storage of ore weathered powder, it is also urgent to utilize the ore weathered powder as a resource. The chemical composition of ore weathered powder is mainly silicon oxide and aluminum oxide, in addition to a small amount of iron oxide, magnesium oxide, manganese oxide, and alkaline oxides. Silicon oxide and aluminum oxide can be used as raw material resources 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 building ceramic tiles from ore weathered powder is a good way to alleviate the shortage of raw materials in the ceramic tile industry and solve the problem of ore weathered powder storage.

[0004] At present, there is no related patent for preparing building ceramic tiles with ore weathered powder, and the practical knowledge of similar technical solutions is also 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-forming and then firing to obtain building ceramic tiles. The patent with publication number CN115215633A provides a method for preparing building ceramic tiles using stone powder, water-washed sand and medium-temperature sand as raw materials. The method is to wet ball mill the raw materials, spray dry, press-forming and then firing to obtain building ceramic tiles. The patent with publication number CN111777404A provides a method for preparing building ceramic tiles using machine-made sand filter cake. The method is to mix machine-made sand filter cake with clay, aging-forming and then firing to obtain building ceramic tiles.

[0005] Although the above technical solutions have made outstanding contributions to the application of machine-made sand industry solid waste in the field of building ceramic tile preparation, there are still the following shortcomings: (1) only the recycling of micro-fines, stone powder and filter cake in machine-made sand industry solid waste is realized, and the recycling of ore weathered powder is not realized. (2) The use of non-renewable resource clay is not completely avoided, and the industrial practice value is not high. (3) The utilization rate of solid waste, especially the solid waste generated by machine-made sand industry, is less than 60%, and a large amount of natural resources (such as bauxite) still need to be consumed as supplementary raw materials. (4) The preparation process has many steps and takes a long time, which is not simple. SUMMARY

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

[0007] To achieve the above-mentioned purpose, the present application realizes the following technical solutions:

[0008] On the one hand, the present application provides a ceramic tile, which comprises, by mass percentage: 62-78% of ore weathered powder, and 22-38% of bauxite.

[0009] Preferably, the ore weathered powder comprises CaO, SiO2, Al2O3, Fe2O3, MnO, MgO, Na2O and K2O; and 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).

[0010] On the second aspect, the present application provides a preparation method of a ceramic tile, comprising the following steps:

[0011] (1) uniformly mixing the ore weathered powder with bauxite to obtain a brick blank raw material;

[0012] (2) uniformly mixing water with the brick blank raw material and then pressing to form to obtain a brick blank;

[0013] (3) calcining the brick blank at 1120-1180 DEG C for 100-140 min to obtain a ceramic brick.

[0014] Preferably, in step (2), the amount of water is 7-9% of the mass of the brick blank raw material.

[0015] Preferably, in step (2), the pressure of the pressing to form is 13-17 MPa.

[0016] Preferably, in step (2), the forming time of the pressing to form is 1-3 min.

[0017] Preferably, in step (3), the calcining temperature is 1130-1150 DEG C.

[0018] Preferably, in step (3), the calcining time is 110-120 min.

[0019] Preferably, in step (3), the brick blank is heated to the calcining temperature at a heating rate of 5-10 DEG C / min.

[0020] In a third aspect, the application also provides a use of the ceramic brick of the first aspect in the field of construction.

[0021] The application has the following beneficial effects:

[0022] 1. The application realizes recycling of ore weathered powder, alleviates the problems of ore weathered powder stockpiling and shortage of raw materials for brick making, and brings a high value-added product.

[0023] 2. The ceramic brick provided by the application has a solid waste utilization rate of up to 78%, significantly reducing the use amount of expensive natural resources (bauxite, etc.) as a supplementary raw material.

[0024] 3. The application of the application to prepare ceramic bricks responds to the requirements of national policies, completely avoids the use of non-renewable resources such as clay, and has a high ecological effect.

[0025] 4. The mechanical properties of the solid waste-based building ceramic brick provided by the application can reach 100 MPa, and the water absorption rate is only 1.33%, meeting the performance requirements of the best level of Class 1 ceramic bricks (water absorption rate less than 3%) in the national standard (GB / T 4100-2015). BRIEF DESCRIPTION OF DRAWINGS

[0026] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings of the embodiments will be briefly introduced as follows.

[0027] Figure 1 A flow chart of the preparation process of the ceramic tile according to the present application is shown in Fig. 1.

[0028] Figure 2 A physical picture of the ceramic tile prepared in Example 1, Comparative Example 2, Comparative Example 4 and Comparative Example 6 is shown in Fig. 2. DETAILED DESCRIPTION

[0029] The technical solutions in the embodiments of the present application will be described clearly and completely in combination with the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, but not all the embodiments. Based on the embodiments of the present application, all the other embodiments obtained by those skilled in the art without any creative effort fall within the scope of the present application.

[0030] In view of the problems of ore weathered powder stockpiling and raw material shortage in the building ceramic tile industry, the present application provides a method for preparing ceramic tile by using ore weathered powder, as shown in Fig. 1, which comprises the following steps: Figure 1

[0031] (1) 62-78% of ore weathered powder and 22-38% of bauxite are uniformly mixed according to the mass percentage to obtain a green body raw material;

[0032] (2) water is uniformly mixed with the green body raw material, wherein the amount of water is 7-9% of the mass of the green body raw material, and then, the green body is formed by pressing under 13-17 MPa for 1-3 min to obtain a green body;

[0033] (3) the green body is calcined at 1120-1180℃ for 100-140 min to obtain a ceramic tile.

[0034] Specifically, the amount of ore weathered powder in step (1) can be 62%, 65%, 68%, 70%, 72%, 74%, 75%, 78% or any value within the range of 62-78%.

[0035] In order to make the purpose, technical solutions and advantages of the present application more clear, the embodiments of the present application will be further described in detail.

[0036] The chemical compositions of the ore weathered powder and bauxite used in the following examples and comparative examples are shown in Table 1.

[0037] Table 1 Chemical compositions of ore weathered powder and bauxite

[0038]

[0039] ​Example 1

[0040] A method for preparing a ceramic tile, comprising the following steps:

[0041] (1) Mixing: 73 wt% of the weathered ore powder and 27 wt% of bauxite are mixed to obtain a green tile raw material.

[0042] (2) Preparing green tile: 8 wt% of water is added to the green tile raw material obtained in step (1) to wet the raw material, and then the raw material is pressed into a green tile by a molding machine under a molding pressure of 15 MPa and a molding time of 2 min.

[0043] (3) Firing ceramic tile: the green tile obtained in step (2) is placed in a high-temperature furnace for calcination, the calcination conditions are a heating rate of 5 ℃ / min, a calcination temperature of 1150 ℃, and a holding time of 120 min, and the ceramic tile product is obtained after the temperature is naturally cooled to room temperature after the calcination is completed.

[0044] Example 2

[0045] A method for preparing a ceramic tile, comprising the following steps:

[0046] (1) Mixing: 66 wt% of the weathered ore powder and 34 wt% of bauxite are mixed to obtain a green tile raw material.

[0047] (2) Preparing green tile: 8 wt% of water is added to the green tile raw material obtained in step (1) to wet the raw material, and then the raw material is pressed into a green tile by a molding machine under a molding pressure of 15 MPa and a molding time of 2 min.

[0048] (3) Firing ceramic tile: the green tile obtained in step (2) is placed in a high-temperature furnace for calcination, the calcination conditions are a heating rate of 5 ℃ / min, a calcination temperature of 1150 ℃, and a holding time of 120 min, and the ceramic tile product is obtained after the temperature is naturally cooled to room temperature after the calcination is completed.

[0049] Example 3

[0050] A method for preparing a ceramic tile, comprising the following steps:

[0051] (1) Mixing: 73 wt% of the weathered ore powder and 27 wt% of bauxite are mixed to obtain a green tile raw material.

[0052] (2) Preparing green tile: 8 wt% of water is added to the green tile raw material obtained in step (1) to wet the raw material, and then the raw material is pressed into a green tile by a molding machine under a molding pressure of 15 MPa and a molding time of 2 min.

[0053] (3) Firing the ceramic tile: the green tile obtained in step (2) is placed in a high-temperature furnace for calcination, the calcination conditions are a heating rate of 5 ℃ / min, a calcination temperature of 1130 ℃, and a holding time of 110 min, and the ceramic tile product is obtained after the temperature is naturally cooled to room temperature after the calcination is completed.

[0054] Example 4

[0055] A method for preparing a ceramic tile, comprising the following steps:

[0056] (1) Blending: 73 wt% of the ore weathered powder is uniformly mixed with 27 wt% of the bauxite to obtain a green tile raw material.

[0057] (2) Preparing the green tile: 8 wt% of water based on the green tile raw material is added to the green tile raw material obtained in step (1) to wet the raw material, and then the raw material is pressed into a green tile by a forming machine under a forming pressure of 15 MPa and a forming time of 2 min.

[0058] (3) Firing the ceramic tile: the green tile obtained in step (2) is placed in a high-temperature furnace for calcination, the calcination conditions are a heating rate of 5 ℃ / min, a calcination temperature of 1170 ℃, and a holding time of 130 min, and the ceramic tile product is obtained after the temperature is naturally cooled to room temperature after the calcination is completed.

[0059] Comparative Example 1

[0060] A method for preparing a ceramic tile, comprising the following steps:

[0061] (1) Blending: 60 wt% of the ore weathered powder is uniformly mixed with 40 wt% of the bauxite to obtain a green tile raw material.

[0062] (2) Preparing the green tile: 8 wt% of water based on the green tile raw material is added to the green tile raw material obtained in step (1) to wet the raw material, and then the raw material is pressed into a green tile by a forming machine under a forming pressure of 15 MPa and a forming time of 2 min.

[0063] (3) Firing the ceramic tile: the green tile obtained in step (2) is placed in a high-temperature furnace for calcination, the calcination conditions are a heating rate of 5 ℃ / min, a calcination temperature of 1150 ℃, and a holding time of 120 min, and the ceramic tile product is obtained after the temperature is naturally cooled to room temperature after the calcination is completed.

[0064] Comparative Example 2

[0065] A method for preparing a ceramic tile, comprising the following steps:

[0066] (1) Blending: 80 wt% of the ore weathered powder is uniformly mixed with 20 wt% of the bauxite to obtain a green tile raw material.

[0067] (2) Preparation of green bricks: The green brick raw material obtained in step (1) is wetted by adding 8 wt% of water based on the green brick raw material, and then the raw material is pressed into green bricks by a molding machine under a molding pressure of 15 MPa and a molding time of 2 min.

[0068] (3) Firing of ceramic tiles: The green bricks obtained in step (2) are placed in a high-temperature furnace for calcination under calcination conditions of a temperature rising rate of 5 ℃ / min, a calcination temperature of 1150 ℃, and a holding time of 120 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain the finished ceramic tiles.

[0069] Comparative Example 3

[0070] A method for preparing ceramic tiles, comprising the following steps:

[0071] (1) Proportioning: 73 wt% of mineral weathered powder and 27 wt% of bauxite are uniformly mixed to obtain a green brick raw material.

[0072] (2) Preparation of green bricks: The green brick raw material obtained in step (1) is wetted by adding 8 wt% of water based on the green brick raw material, and then the raw material is pressed into green bricks by a molding machine under a molding pressure of 15 MPa and a molding time of 2 min.

[0073] (3) Firing of ceramic tiles: The green bricks obtained in step (2) are placed in a high-temperature furnace for calcination under calcination conditions of a temperature rising rate of 5 ℃ / min, a calcination temperature of 1150 ℃, and a holding time of 120 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain the finished ceramic tiles.

[0074] Comparative Example 4

[0075] A method for preparing ceramic tiles, comprising the following steps:

[0076] (1) Proportioning: 73 wt% of mineral weathered powder and 27 wt% of bauxite are uniformly mixed to obtain a green brick raw material.

[0077] (2) Preparation of green bricks: The green brick raw material obtained in step (1) is wetted by adding 8 wt% of water based on the green brick raw material, and then the raw material is pressed into green bricks by a molding machine under a molding pressure of 15 MPa and a molding time of 2 min.

[0078] (3) Firing of ceramic tiles: The green bricks obtained in step (2) are placed in a high-temperature furnace for calcination under calcination conditions of a temperature rising rate of 5 ℃ / min, a calcination temperature of 1150 ℃, and a holding time of 120 min. After the calcination is completed, the temperature is naturally cooled to room temperature to obtain the finished ceramic tiles.

[0079] Comparative Example 5

[0080] A method for preparing ceramic tiles, comprising the following steps:

[0081] (1) Preparation of raw material: 73 wt% of weathered ore powder and 27 wt% of bauxite were mixed to obtain a green brick raw material.

[0082] (2) Preparation of green brick: The green brick raw material obtained in step (1) was wetted by adding water accounting for 8 wt% of the green brick raw material, and then the raw material was pressed into a green brick by a molding machine under a molding pressure of 15 MPa and a molding time of 2 min.

[0083] (3) Firing of ceramic tile: The green brick obtained in step (2) was calcined in a high-temperature furnace under a calcination condition of a temperature rising rate of 5 ℃ / min, a calcination temperature of 1150 ℃, and a holding time of 80 min, and a ceramic tile product was obtained after the temperature was naturally cooled to room temperature after the calcination was completed.

[0084] Comparative Example 6

[0085] A method for preparing a ceramic tile, comprising the following steps:

[0086] (1) Preparation of raw material: 73 wt% of weathered ore powder and 27 wt% of bauxite were mixed to obtain a green brick raw material.

[0087] (2) Preparation of green brick: The green brick raw material obtained in step (1) was wetted by adding water accounting for 8 wt% of the green brick raw material, and then the raw material was pressed into a green brick by a molding machine under a molding pressure of 15 MPa and a molding time of 2 min.

[0088] (3) Firing of ceramic tile: The green brick obtained in step (2) was calcined in a high-temperature furnace under a calcination condition of a temperature rising rate of 5 ℃ / min, a calcination temperature of 1150 ℃, and a holding time of 160 min, and a ceramic tile product was obtained after the temperature was naturally cooled to room temperature after the calcination was completed.

[0089] The compressive strength and water absorption of the ceramic tiles obtained in Examples 1 to 4 and Comparative Examples 1 to 6 were tested, and the results are shown in Table 2.

[0090] Table 2 Compressive strength and water absorption of ceramic tiles prepared in examples and comparative examples

[0091]

[0092] As shown in Table 2, the compressive strength of the ceramic tile prepared in the embodiment of the application is greater than 90 MPa, and the water absorption is less than 3 %, which meets the performance requirements of the first type of ceramic tile in the national standard (GB / T 4100-2015). Compared with the embodiment, the compressive strength of Comparative Example 1, Comparative Example 3 and Comparative Example 5 is significantly reduced, and the water absorption exceeds 3 %, which does not meet the performance requirements of the first type of ceramic tile. This is because the small amount of ore weathered powder (small amount of Fe, Mn, Mg, Na and other fluxing ions in the brick body), the low calcination temperature and the short holding time all cause the strength mineral phase and the dense structure (liquid phase content) in the brick body during the sintering process to be unable to be formed to the maximum extent. Although the water absorption of Comparative Example 2, Comparative Example 4 and Comparative Example 6 is small, the compressive strength is still significantly reduced, and the overall performance of the brick material is poor.

[0093] Figure 2 The physical map of the ceramic tile prepared in Example 1, Comparative Example 2, Comparative Example 4 and Comparative Example 6 is shown in Figure 1. Figure 2 As shown in Figure 1, compared with Example 1, the brick body of Comparative Example 2, Comparative Example 4 and Comparative Example 6 has been obviously melted, and even there is no image of the brick body. This is because the large amount of ore weathered powder (too much Fe, Mn, Mg, Na and other fluxing ions in the brick body), the high calcination temperature and the long holding time all cause the strength mineral phase in the brick body during the sintering process to be melted and the mechanical structure to be collapsed (too high liquid phase content).

[0094] It should be noted that each of the above embodiments belongs to the same inventive concept, and the description of each embodiment has its own emphasis. If the description is not exhaustive in an individual embodiment, the description in other embodiments can be referred to.

[0095] The above-described embodiments only express the implementation of the application, and the description is more specific and detailed, but it should not be understood as limiting the scope of the patent. It should be noted that for ordinary skilled persons in the art, without departing from the inventive concept, a number of modifications and improvements can be made, which are within the scope of protection of the application. Therefore, the protection scope of the patent of the application should be subject to the appended claims.

Claims

1. A ceramic tile, characterized in that, The material is composed of 62-78% weathered ore powder and 22-38% bauxite by mass percentage; 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); the weathered ore powder is weathered soil waste stripped from the surface of natural ore during the mining of natural ore in the manufactured sand industry; The preparation method of ceramic tiles includes the following steps: (1) Mix the weathered ore powder with bauxite evenly to obtain the raw material for brick blanks; (2) After mixing water and the brick blank raw material evenly, press them into shape to obtain a brick blank; (3) The brick blank is calcined at 1120~1180℃ for 100~140 min to obtain the ceramic brick.

2. A method for preparing ceramic tiles as described in claim 1, characterized in that, Includes the following steps: (1) Mix the weathered ore powder with bauxite evenly to obtain the raw material for brick blanks; (2) After mixing water and the brick blank raw material evenly, press them into shape to obtain a brick blank; (3) The brick blank is calcined at 1120~1180℃ for 100~140 min to obtain the ceramic brick; In step (2), the amount of water used is 7-9% of the mass of the brick blank raw material; in step (2), the pressing pressure is 13-17 MPa; in step (2), the pressing time is 1-3 min; in step (3), the brick blank is heated to the calcination temperature at a heating rate of 5-10 ℃ / min.

3. The method for preparing ceramic bricks according to claim 2, characterized in that, In step (3), the calcination temperature is 1130~1150 ℃.

4. The method for preparing ceramic bricks according to claim 2, characterized in that, In step (3), the calcination time is 110~120 min.

5. The application of ceramic tiles according to claim 1 in the construction field.

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