Method for preparing unfired easy-to-clean glazed tile by recycling solid waste raw materials and product prepared by method

Abstract

The invention discloses a method for preparing an unfired easy-to-clean glazed tile by recycling solid waste raw materials and a product prepared by the method, building wastes, copper-zinc tailings, ceramic wastes and cement are used as main raw materials, a green brick body is obtained by forming and hardening, then mixed sol is coated and glazed on the surface of the green brick body, and the unfired easy-to-clean glazed tile is prepared. And the unfired glazed tile with rich glaze color is prepared by a thermocuring process. Solid waste raw materials are fully utilized, the production cost and energy consumption are reduced, environmental pollution is reduced, meanwhile, the glaze surface of the prepared unfired easy-to-clean glazed tile is easy to clean, the performance is excellent, and the application requirements can be well met. The preparation method is simple in production process, convenient for industrialization and low in cost, has a wide market prospect, and plays an important role in promoting the sustainable development of the industry.

Description

Technical Field

[0001] The invention relates to the technical field of building ceramic materials, and in particular to a method for preparing glazed tiles and the products obtained therefrom. Background Art

[0002] Building ceramics are a type of ceramic material used for building decoration and structural purposes, and are an important type of building material. Since building ceramics have to undergo high-temperature firing at 1180-1220°C during the production process, a large amount of fuel (natural gas, fuel oil, etc.) is consumed, and its cost accounts for about 1 / 4-1 / 3 of the total cost; secondly, a large amount of carbon dioxide, sulfur dioxide and other gases will be released during the firing process, causing environmental pollution and greenhouse effect problems; in addition, the mineral raw materials used in the blanks, such as clay and feldspar, require a large amount of high-quality mining raw materials to meet production requirements. Therefore, how to make full use of solid waste raw materials, reduce raw material costs, energy consumption and environmental pollution on the basis of realizing resource recycling, is of great significance to the industrial market prospects and the sustainable development of the industry. Summary of the invention

[0003] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a method for preparing unfired easy-to-clean glazed tiles by recycling solid waste raw materials. The method uses construction waste, copper-zinc tailings, ceramic waste, and cement as the main raw materials, and obtains a brick body through forming and hardening. The surface of the brick body is then coated with a mixed sol for glazing, and unfired glazed tiles with rich glaze colors are prepared through a thermal curing process, so as to make full use of solid waste raw materials, reduce production costs and energy consumption, and the impact on the environment, thereby promoting the sustainable development of the industry. Another object of the present invention is to use the above-mentioned method for preparing unfired easy-to-clean glazed tiles by recycling solid waste raw materials to obtain products.

[0004] The purpose of the present invention is achieved through the following technical solutions:

[0005] The present invention provides a method for preparing unfired and easy-to-clean glazed tiles by recycling solid waste raw materials, comprising the following steps:

[0006] (1) Preparation of unfired brick body

[0007] (1-1) Using 30-40wt% of construction waste, 10-22wt% of copper-zinc tailings, 10-20wt% of ceramic waste, and 28-38wt% of cement as raw materials, the construction waste, copper-zinc tailings, and ceramic waste are crushed, sieved, and mixed with cement to obtain a blank; adding water to the blank according to a mass ratio of blank: water = 1: 0.38-0.42 to obtain a slurry;

[0008] (1-2) pouring the slurry into a mold to form a shape, and demolding after hardening for 8 to 12 hours to obtain a green body; placing the green body in water at room temperature for curing for 7 to 10 days, and taking it out and drying it to obtain an unfired brick body;

[0009] (2) Preparation of unfired glaze

[0010] (2-1) The unfired glaze is composed of a glaze base material, aluminum oxide powder, and a colorant; the raw material composition of the glaze base material is 20-30wt% of resin and 70-80wt% of solvent; the amount of the aluminum oxide powder and the colorant is 0-20wt% and 0.1-0.3wt% of the glaze base material respectively; the composition of the resin is acrylic resin: epoxy resin = 3-2:1 according to the mass ratio, and the solvent is a mixture of dimethyl diacid, dipropylene glycol methyl ether and ethyl acetate;

[0011] (2-2) After the unfired glaze is prepared according to the formula, it is stirred in a water bath at 50 to 60° C. for 1.5 to 2 hours to obtain an unfired glaze slurry;

[0012] (3) Preparation of unfired and easy-to-clean glazed tiles

[0013] The unfired glaze slurry is glazed on the surface of the unfired brick body by using a spraying process, and then a heat curing treatment is carried out at 80-120° C. for 4-8 hours to obtain the unfired easy-to-clean glazed tile.

[0014] Furthermore, the flexural strength of the unfired brick body obtained in step (1) of the present invention is 9.5-13 MPa. The average particle size of the aluminum oxide powder in step (2) is 1-2 μm. The thickness of the glaze layer after glazing in step (3) is 0.25-0.35 mm. The colorant is silicon oxide carbon, iron oxide, vanadium zirconium blue, praseodymium yellow, or copper green.

[0015] In the above scheme, the construction waste described in the present invention comes from demolished buildings, and its main components are red bricks, waste cement and lime; the copper-zinc tailings come from the waste left over from the mining of copper and zinc metals, and its composition is 40-45wt% of quartz, 20-23wt% of feldspar, 10-15wt% of illite, 20-23wt% of pyrite, and the rest 1-3wt%; the ceramic waste is ceramic brick waste and sanitary ware waste.

[0016] The product obtained by utilizing the above-mentioned method for preparing unfired easy-to-clean glazed tiles by resource utilization of solid waste raw materials has a glaze surface with an impact resistance of 1.18 to 2.03 kgf, a glossiness of 40 to 80, and a contact angle of 115 to 135 degrees.

[0017] The present invention has the following beneficial effects:

[0018] (1) The present invention first uses construction waste, copper-zinc tailings, and ceramic waste as main raw materials, supplemented by cementitious material cement, and on the basis of forming and water curing, gives strength to the body through the hydration reaction of the cementitious material, thereby obtaining an unfired brick body; then, a mixed sol prepared by high-strength resin (such as acrylic resin, etc.), solvent (such as dimethyl diacid, etc.), reinforcing body (such as aluminum oxide, etc.) and colorant (such as black silicon oxide carbon, red iron oxide, vanadium zirconium blue, etc.) is used to glaze the surface of the unfired brick body by a coating process, and an unfired glazed tile with rich glaze color is prepared by a thermal curing process. Since the glaze uses a hydrophobic resin, the surface of the glazed tile has an easy-to-clean property.

[0019] (2) The present invention has a simple production process, is easy to industrialize, has low cost, is easy to clean the glaze, has excellent performance, can well meet application requirements, has broad market prospects, and plays an important role in promoting the sustainable development of the industry.

[0020] The present invention will be described in further detail below with reference to the embodiments. DETAILED DESCRIPTION

[0021] The present invention provides a method for preparing unfired and easy-to-clean glazed tiles by recycling solid waste raw materials, and the steps are as follows:

[0022] (1) Preparation of unfired brick body

[0023] (1-1) Using 30-40wt% of construction waste, 10-22wt% of copper-zinc tailings, 10-20wt% of ceramic waste, and 28-38wt% of cement as raw materials, the construction waste, copper-zinc tailings, and ceramic waste are crushed, passed through a 120-mesh sieve, and then mixed with cement to obtain a blank; adding water to the blank at a mass ratio of blank: water = 1: 0.38-0.42 to obtain a slurry;

[0024] (1-2) pouring the slurry into a mold to form a green body, and removing the mold after hardening for 8 to 12 hours to obtain a green body; placing the green body in water at room temperature for 7 to 10 days to further harden, and taking it out and drying it to obtain a green body of an unfired brick;

[0025] The raw material composition of the unfired brick blank of each embodiment is shown in Table 1; the process parameters and the flexural strength of the unfired brick blank tested by a material testing machine are shown in Table 2;

[0026] (2) Preparation of unfired glaze

[0027] (2-1) The unfired glaze is composed of a glaze base material, aluminum oxide powder (with an average particle size of 1 to 2 μm), and a colorant; the raw material composition of the glaze base material is 20 to 30 wt% of resin and 70 to 80 wt% of solvent; the amount of aluminum oxide powder and the colorant is 0 to 20 wt% and 0.1 to 0.3 wt% of the glaze base material, respectively; the composition of the above resin is acrylic resin: epoxy resin = 3 to 2:1 according to the mass ratio, and the composition of the solvent is dimethyl bis(2-acid): dipropylene glycol methyl ether: ethyl acetate = 2:1:1 according to the mass ratio;

[0028] (2-2) After the above-mentioned unfired glaze is prepared according to the formula, it is stirred in a water bath at 50-60° C. for 1.5-2 h to obtain an unfired glaze slurry; the raw material composition and process parameters of the unfired glaze of each embodiment are shown in Table 3;

[0029] (3) Preparation of unfired and easy-to-clean glazed tiles

[0030] The unfired glaze slurry is applied to the surface of the unfired brick body by spraying technology, the glaze layer thickness is 0.25-0.35mm, and then heat-cured in an oven at 80-120℃ for 4-8h to obtain unfired easy-to-clean glazed tiles.

[0031] The glazing and curing processes of each embodiment are shown in Table 4.

[0032] The spherical impact method was used to test the impact resistance of the glaze, the sessile drop method was used to test the contact angle (°) of water on the glaze, and the colorimeter was used to test the glossiness of the glaze. The obtained glaze properties are shown in Table 4.

[0033] Table 1 Raw material composition of the unfired brick body of each embodiment of the present invention (wt%)

[0034]

[0035]

[0036] Among them, construction waste comes from demolished buildings, and its main components are red bricks, waste cement and lime. Copper-zinc tailings come from the waste left over from mining copper and zinc metals, and its composition is quartz 43wt%, feldspar 21.3wt%, illite 13.5wt%, pyrite 20.5wt%, and the remaining 1.7% (a small amount of serpentine and organic matter, etc.). Ceramic waste comes from the waste of ceramic production process, such as ceramic brick waste, sanitary ware waste, etc.

[0037] Table 2 Processing parameters and flexural strength of the unfired brick blanks of various embodiments of the present invention

[0038]

[0039] Table 3 Raw material composition and process parameters of the unfired glazes of various embodiments of the present invention

[0040]

[0041] Remark:

[0042] The amount of aluminum oxide powder and colorant used is relative to the glaze base material.

[0043] In Examples 1 to 4, the composition of the resin is acrylic resin: epoxy resin = 3:1 in mass ratio; the average particle size of the aluminum oxide powder is 1 μm.

[0044] In Examples 5 to 7, the composition of the resin is acrylic resin: epoxy resin = 2.5:1 in mass ratio; the average particle size of the aluminum oxide powder is 1.5 μm.

[0045] In Examples 8 to 10, the composition of the resin is acrylic resin: epoxy resin = 2:1 in a mass ratio; the average particle size of the aluminum oxide powder is 2 μm.

[0046] Raw materials used for pigments: black is silicon oxide carbon pigment, red is ferric oxide pigment, blue is vanadium zirconium pigment. Other pigments, such as yellow can use praseodymium yellow, green can use copper green, etc.

[0047] Table 4 Glazing and curing process and glaze properties of various embodiments of the present invention

[0048]

Claims

1. A method for preparing unfired and easy-to-clean glazed tiles by recycling solid waste raw materials, characterized in that The following steps are involved: (1) Preparation of unfired brick body (1-1) Using 30-40wt% of construction waste, 10-22wt% of copper-zinc tailings, 10-20wt% of ceramic waste, and 28-38wt% of cement as raw materials, the construction waste, copper-zinc tailings, and ceramic waste are crushed, sieved, and mixed with cement to obtain a blank; adding water to the blank according to a mass ratio of blank: water = 1: 0.38-0.42 to obtain a slurry; (1-2) pouring the slurry into a mold to form a shape, and demolding after hardening for 8 to 12 hours to obtain a green body; placing the green body in water at room temperature for curing for 7 to 10 days, and taking it out and drying it to obtain an unfired brick body; (2) Preparation of unfired glaze (2-1) The unfired glaze is composed of a glaze base material, aluminum oxide powder, and a colorant; the raw material composition of the glaze base material is 20-30wt% of resin and 70-80wt% of solvent; the amount of the aluminum oxide powder and the colorant is 0-20wt% and 0.1-0.3wt% of the glaze base material respectively; the composition of the resin is acrylic resin: epoxy resin = 3-2:1 according to the mass ratio, and the solvent is a mixture of dimethyl diacid, dipropylene glycol methyl ether and ethyl acetate; (2-2) After the unfired glaze is prepared according to the formula, it is stirred in a water bath at 50 to 60° C. for 1.5 to 2 hours to obtain an unfired glaze slurry; (3) Preparation of unfired and easy-to-clean glazed tiles The unfired glaze slurry is glazed on the surface of the unfired brick body by using a spraying process, and then a heat curing treatment is carried out at 80-120° C. for 4-8 hours to obtain the unfired easy-to-clean glazed tile.

2. The method for preparing unfired and easy-to-clean glazed tiles by recycling solid waste materials according to claim 1, characterized in that: The unfired brick body obtained in step (1) has a flexural strength of 9.5 to 13 MPa.

3. The method for preparing unfired and easy-to-clean glazed tiles by recycling solid waste materials according to claim 1, characterized in that: The average particle size of the aluminum oxide powder in step (2) is 1 to 2 μm.

4. The method for preparing unfired and easy-to-clean glazed tiles by recycling solid waste materials according to claim 1, characterized in that: The thickness of the glaze layer after glazing in the step (3) is 0.25 to 0.35 mm.

5. The method for preparing unfired and easy-to-clean glazed tiles by recycling solid waste materials according to claim 1, characterized in that: The colorant is silicon oxide carbon, ferric oxide, vanadium zirconium blue, praseodymium yellow, or copper green.

6. The method for preparing unfired and easy-to-clean glazed tiles by recycling solid waste materials according to claim 1, characterized in that: The construction waste comes from demolished buildings, and its main components are red bricks, waste cement and lime; the copper-zinc tailings come from the waste left over from the mining of copper and zinc metals, and its composition is 40-45wt% of quartz, 20-23wt% of feldspar, 10-15wt% of illite, 20-23wt% of pyrite, and the rest 1-3wt%; the ceramic waste includes ceramic brick waste and sanitary ware waste.

7. Products obtained by utilizing the method for preparing unfired and easy-to-clean glazed tiles by recycling solid waste raw materials as described in any one of claims 1 to 6.

8. The product according to claim 7, characterized in that: The glaze surface of the unfired easy-to-clean glazed tile has an impact resistance of 1.18-2.03 kgf, a glossiness of 40-80, and a contact angle of 115-135 degrees.

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