Method for preparing unfired easy-to-clean glazed tiles from solid waste raw materials and product prepared thereby

Abstract

The application discloses a kind of solid waste raw material resourceization preparation baking-free easy-to-clean glazed tile method and product prepared thereby, with building waste, copper-zinc tailings, ceramic waste, cement as main raw material, through shaping, hardening and obtaining brick body, then with mixed sol coating glazing on the surface of brick body, through heat curing process and preparation obtain baking-free glazed tile with rich color.The application makes full use of solid waste raw material, reduces production cost and energy consumption, reduces environmental pollution at the same time, and the baking-free easy-to-clean glazed tile prepared thereby has easy-to-clean glazed surface, excellent performance, and can well meet the application requirements.The application has simple production process, is easy to industrialize, low in cost, has broad market prospect, and plays an important role in promoting the sustainable development of industry.

Description

Technical Field

[0001] This invention relates to the field of building ceramic materials technology, and in particular to a method for preparing glazed tiles and the resulting product. Background Technology

[0002] Architectural ceramics are ceramic materials used for architectural decoration and structural purposes, and are an important type of building material. Because the production of architectural ceramics involves high-temperature firing at 1180–1220℃, it consumes a large amount of fuel (natural gas, fuel oil, etc.), accounting for approximately one-quarter to one-third of the total cost. Secondly, the firing process releases large amounts of carbon dioxide, sulfur dioxide, and other gases, causing environmental pollution and contributing to the greenhouse effect. Furthermore, the mineral raw materials used in the raw materials, such as clay and feldspar, require large-scale mining of high-quality minerals to meet production requirements. Therefore, how to fully utilize solid waste raw materials, achieving resource recycling while reducing raw material costs, energy consumption, and environmental pollution, is of great significance for the industrialization market prospects and the sustainable development of the industry. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a method for preparing non-fired, easy-to-clean glazed bricks using solid waste raw materials. The method utilizes construction waste, copper-zinc tailings, ceramic waste, and cement as main raw materials. These materials are formed and hardened to obtain a brick body. Then, a mixed sol is applied to the surface of the brick body to create a glaze, followed by a thermosetting process to produce non-fired glazed bricks with rich glaze colors. This method fully utilizes solid waste raw materials, reduces production costs and energy consumption, and minimizes environmental impact, thereby promoting the sustainable development of the industry. Another objective of this invention is to produce products using the aforementioned method for preparing non-fired, easy-to-clean glazed bricks from solid waste raw materials.

[0004] The objective of this invention is achieved through the following technical solution:

[0005] This invention provides a method for preparing non-fired, easy-to-clean glazed tiles from solid waste raw materials, comprising the following steps:

[0006] (1) Preparation of non-fired brick blanks

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

[0008] (1-2) The slurry is poured into a mold to form a shape. After hardening for 8-12 hours, it is demolded to obtain a green body. The green body is placed in water and cured at room temperature for 7-10 days. After drying, it is obtained as a non-fired brick body.

[0009] (2) Preparation of non-fired glaze

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

[0011] (2-2) After the non-fired glaze is prepared according to the formula, it is stirred in a water bath at 50-60℃ for 1.5-2 hours to obtain the non-fired glaze slurry;

[0012] (3) Preparation of non-fired easy-to-clean glazed tiles

[0013] The non-fired glaze slurry is applied to the surface of the non-fired brick body using a spraying process, and then heat-cured at 80-120℃ for 4-8 hours to obtain non-fired easy-to-clean glazed bricks.

[0014] Furthermore, the flexural strength of the unfired brick body obtained in step (1) of this invention is 9.5–13 MPa. The average particle size of the alumina 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 dioxide carbon, ferric oxide, vanadium zirconium blue, praseodymium yellow, or copper green.

[0015] In the above scheme, the construction waste mentioned in this invention comes from demolished buildings and mainly consists of 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 consist of quartz 40-45wt%, feldspar 20-23wt%, illite 10-15wt%, pyrite 20-23wt%, and the remainder 1-3wt%; the ceramic waste consists of ceramic brick waste and sanitary ware waste.

[0016] The product prepared by the above-mentioned method of resource utilization of solid waste raw materials to prepare non-fired easy-clean glazed bricks has an impact resistance of 1.18-2.03 kgf, a gloss of 40-80, and a contact angle of 115-135°.

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

[0018] (1) This invention first uses construction waste, copper-zinc tailings, and ceramic waste as the main raw materials, supplemented by cement as a binder. Based on forming and water curing, the strength of the green body is given by the hydration reaction of the binder, thus obtaining the green body of the non-fired brick. Then, a mixed sol prepared by high-strength resin (such as acrylic resin), solvent (such as dimethyl diacid), reinforcement (such as alumina), and colorant (such as black silica carbon, red ferric oxide, vanadium zirconium blue, etc.) is applied to the surface of the non-fired brick green body using a coating process. After a thermosetting process, a non-fired glazed brick with rich glaze colors is obtained. Because the glaze uses hydrophobic resin, the surface of the glazed brick has easy-to-clean properties.

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

[0020] The present invention will now be described in further detail with reference to embodiments. Detailed Implementation

[0021] This invention discloses a method for preparing non-fired, easy-to-clean glazed bricks from solid waste raw materials, comprising the following steps:

[0022] (1) Preparation of non-fired brick blanks

[0023] (1-1) Using 30-40 wt% construction waste, 10-22 wt% copper-zinc tailings, 10-20 wt% ceramic waste, and 28-38 wt% 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; water is added to the blank at a mass ratio of blank:water = 1:0.38-0.42 to obtain a slurry;

[0024] (1-2) Pour the above slurry into the mold to form it. After hardening for 8-12 hours, demold it to obtain a green body. Place the green body in water and cure it at room temperature for 7-10 days to further harden it. After drying, obtain the unfired brick body.

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

[0026] (2) Preparation of non-fired glaze

[0027] (2-1) The non-fired glaze is composed of glaze base material, alumina powder (average particle size of 1-2 μm), and colorant; the raw material composition of the glaze base material is 20-30 wt% resin and 70-80 wt% solvent; the amount of alumina powder and colorant is 0-20 wt% and 0.1-0.3 wt% of the glaze base material, respectively; the composition of the above resin is acrylic resin: epoxy resin = 3-2:1 by mass ratio, and the composition of the solvent is dimethyl diacid: dipropylene glycol methyl ether: ethyl acetate = 2:1:1 by mass ratio;

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

[0029] (3) Preparation of non-fired easy-to-clean glazed tiles

[0030] The non-fired glaze slurry is applied to the surface of the non-fired brick body using a spraying process, with a glaze layer thickness of 0.25-0.35mm. Then, it is heat-cured in an oven at 80-120℃ for 4-8 hours to obtain non-fired easy-to-clean glazed bricks.

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

[0032] The impact resistance of the glaze was tested by the ball impact method, the contact angle (°) of water on the glaze was tested by the seat drop method, and the gloss of the glaze was tested by a colorimeter. The glaze properties obtained are shown in Table 4.

[0033] Table 1. Raw material composition (wt%) of the unfired brick blanks in various embodiments of the present invention.

[0034]

[0035]

[0036] Construction waste originates from demolished buildings and mainly consists of red bricks, waste cement, and lime. Copper-zinc tailings are waste left over from copper and zinc mining, composed of 43 wt% quartz, 21.3 wt% feldspar, 13.5 wt% illite, 20.5 wt% pyrite, and the remainder 1.7% (a small amount of serpentine and organic matter, etc.). Ceramic waste comes from the ceramic production process, such as ceramic tile waste and sanitary ware waste.

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

[0038]

[0039] Table 3 Raw material composition and process parameters of the non-fired glaze in various embodiments of the present invention

[0040]

[0041] Remark:

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

[0043] In Examples 1-4, the resin composition was acrylic resin:epoxy resin = 3:1 by mass; the average particle size of the aluminum oxide powder was 1 μm.

[0044] In Examples 5-7, the resin composition was as follows: acrylic resin: epoxy resin = 2.5:1 by mass; the average particle size of the aluminum oxide powder was 1.5 μm.

[0045] In Examples 8-10, the resin composition was acrylic resin:epoxy resin = 2:1 by mass; the average particle size of the aluminum oxide powder was 2 μm.

[0046] Raw materials used for colorants: black is silicon-oxygen-carbon colorant, red is ferric oxide colorant, and blue is vanadium-zirconium colorant. Other colorants, such as praseodymium yellow for yellow and verdigris for green, etc.

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

[0048]

Claims

1. A method for preparing a baking-free easy-to-clean glazed tile from solid waste raw materials, characterized by Includes the following steps: (1) Preparation of unfired brick blanks (1-1) Using 30-40 wt% construction waste, 10-22 wt% copper-zinc tailings, 10-20 wt% ceramic waste, and 28-38 wt% cement as raw materials, the construction waste comes from demolished buildings and mainly consists of red bricks, waste cement, and lime; the copper-zinc tailings come from waste left over from the mining of copper and zinc metals and consist of 40-45 wt% quartz, 20-23 wt% feldspar, 10-15 wt% illite, 20-23 wt% pyrite, and the remainder 1-3 wt%; the ceramic waste consists of ceramic brick waste and sanitary ware waste; the construction waste, copper-zinc tailings, and ceramic waste are crushed, sieved, and mixed with cement to obtain a blank; water is added to the blank at a mass ratio of blank:water = 1:0.38-0.42 to obtain a slurry; (1-2) The slurry is poured into a mold to form a green body. After hardening for 8-12 hours, the green body is demolded to obtain a green body. The green body is placed in water and cured at room temperature for 7-10 days. After drying, a non-fired brick body with a flexural strength of 9.5-13 MPa is obtained. (2) Preparation of non-fired glaze slurry (2-1) The non-fired glaze is composed of glaze base material, alumina powder, and colorant; the raw material composition of the glaze base material is 20-30 wt% resin and 70-80 wt% solvent; the amounts of alumina powder and colorant are 2.2-20 wt% and 0.1-0.3 wt% of the glaze base material, respectively, and the average particle size of the alumina powder is 1-2 μm; the composition of the resin is acrylic resin:epoxy resin = 3-2:1 by mass ratio, and the solvent is a mixture of dimethyl diacid, dipropylene glycol methyl ether, and ethyl acetate; (2-2) After the non-fired glaze is prepared according to the formula, it is stirred in a water bath at 50-60℃ for 1.5-2 hours to obtain the non-fired glaze slurry; (3) Preparation of non-fired, easy-to-clean glazed tiles The non-fired glaze slurry is applied to the surface of the non-fired brick body using a spraying process to obtain a glaze layer with a thickness of 0.25 to 0.35 mm. Then, it is heat-cured at 80 to 120°C for 4 to 8 hours to obtain a non-fired easy-clean glazed brick. The impact resistance of the glaze is 1.18 to 2.03 kgf, the gloss is 40 to 80, and the contact angle is 115 to 135°.

2. The method for preparing the fired easy-to-clean glazed tiles from solid waste raw materials according to claim 1, characterized in that: The colorant is ferric oxide, vanadium zirconium blue, praseodymium yellow, or verdigris.

3. The product obtained by the method of preparing non-fired easy-to-clean glazed bricks using solid waste raw materials as described in claim 1 or 2.

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