Full-process recyclable ceramic manufacturing method

Abstract

The invention relates to the technical field of recoverable ceramic preparation, in particular to a full-process recoverable ceramic manufacturing method which comprises the following steps: mixing recovered waste pug and ceramic raw materials, and performing ball milling through a ball mill; the slurry obtained after ball milling is sieved through a screen; the screened slurry is dried through a drying oven to reach the preset water content, and then pugging is conducted; sequentially forming and drying pug after pugging to obtain a porcelain body; the qualification of drying treatment is judged according to the surface quality coefficient of the porcelain body; finishing the dried and qualified porcelain body, and firing the porcelain body in an electric kiln to obtain a fired finished product; judging the qualification of firing according to whether the fired finished product has defects or not; the qualification of the ceramic finished product is judged according to the compressive strength under the condition that the firing is qualified, and the particle size of the ceramic raw material is reduced under the condition that the finished product is unqualified; and the recyclable ceramic is manufactured under the condition that the finished product is qualified, so that the quality of the ceramic finished product is improved.

Description

Technical Field

[0001] The invention relates to the technical field of recyclable ceramic preparation, and in particular to a full-process recyclable ceramic preparation method. Background Art

[0002] Ceramic materials are widely used in the fields of construction, electronics, medical treatment, aerospace, etc. due to their excellent mechanical properties, high temperature resistance, corrosion resistance and other characteristics. However, the traditional ceramic manufacturing process has problems such as high resource consumption, low energy utilization, and serious environmental pollution. Especially in the ceramic production process, a large number of discarded ceramic products and scraps are difficult to be effectively recycled, resulting in resource waste and environmental pollution. Chemical substances such as binders and glazes used in the traditional ceramic manufacturing process may contain harmful ingredients, further increasing the environmental burden. Therefore, the development of a full-process recyclable ceramic production method from raw material selection, molding, sintering to finished product recycling can not only improve resource utilization, but also reduce the impact on the environment, which has important economic and social significance.

[0003] Chinese patent application publication number: CN112979322A, discloses a ceramic part and a manufacturing method thereof, the ceramic part manufacturing method comprising: adding an adhesive to ceramic powder particles to form a ceramic green body; before the ceramic green body is completely solidified, using a template with a specified pattern to press into the surface to be processed of the ceramic green body to form a roughness pattern corresponding to the template on the surface to be processed; after a specified period of time, taking out the template; after the ceramic green body is completely solidified, processing and sintering the ceramic green body. However, there are the following problems in the prior art: the lack of detection of the ceramic manufacturing process in the prior art may result in a low qualified rate of ceramic finished products. Summary of the invention

[0004] To this end, the present invention provides a full-process recyclable ceramic production method to overcome the problem in the prior art of lack of detection of the ceramic production process resulting in a low qualified rate of ceramic finished products.

[0005] To achieve the above object, the present invention provides a full-process method for producing recyclable ceramics, comprising: The recycled waste mud is mixed with ceramic raw materials and then ball-milled in a ball mill; The ball-milled slurry is screened through a sieve; The sieved slurry is dried in an oven to a preset moisture content and then slurry is kneaded; The clay material after kneading is successively formed and dried to obtain a porcelain blank; Determine the eligibility of the drying process according to the surface quality coefficient of the porcelain blank, and adjust the temperature of the drying environment or the humidity of the drying environment if the drying process is unqualified; After the dried and qualified porcelain blanks are trimmed, they are fired in an electric kiln to obtain fired products; The quality of firing is determined based on whether the fired product has defects. If the firing is unqualified, the cause of the defect is determined based on the defect type, and the heating rate in the kiln is adjusted based on the overall deformation rate, or the clay kneading time is increased based on the defect area ratio; Under the condition of qualified firing, the qualification of the finished ceramic product is determined according to the compressive strength, and under the condition of unqualified finished product, the particle size of the ceramic raw material is reduced; The production of recyclable ceramics is completed under the condition that the finished product is qualified.

[0006] Furthermore, the process of determining the eligibility of the drying process includes: comparing the surface quality coefficient with the first preset quality coefficient and the second preset quality coefficient respectively; Based on the comparison result that the surface quality coefficient is less than the first preset quality coefficient, it is determined that the drying process is qualified, and the ceramic blank that has passed the drying process is fired; Determining that the drying process is unqualified based on the comparison result that the surface quality coefficient is greater than or equal to the first preset quality coefficient and less than the second preset quality coefficient, and adjusting the humidity of the drying environment according to the difference between the surface quality coefficient and the first preset quality coefficient; The drying process is determined to be unqualified based on the comparison result that the surface quality coefficient is greater than or equal to the second preset quality coefficient, and the temperature of the drying environment is adjusted according to the difference between the surface quality coefficient and the second preset quality coefficient.

[0007] Furthermore, the surface quality coefficient is determined by the surface crack size and edge warping of the ceramic blank.

[0008] Furthermore, different humidity adjustment methods are provided for the humidity in a dry environment, and each adjustment method has a different adjustment range for the humidity.

[0009] Furthermore, the temperature of the drying environment is positively correlated with the second quality coefficient difference, wherein the second quality coefficient difference is the difference between the surface quality coefficient and the second preset quality coefficient.

[0010] Furthermore, if there are defects in the fired product, the firing process is determined to be unqualified, and the cause of the defect is determined based on the defect type of the fired product.

[0011] Furthermore, if the defect type is an overall defect, the cause of the defect is determined to be the excessively fast heating rate in the kiln, and the heating rate in the kiln is adjusted according to the overall deformation rate; if the defect type is a local defect, the cause of the defect is determined to be the presence of pores inside the porcelain blank, and the clay kneading time is increased according to the proportion of the defect area.

[0012] Furthermore, if there are no defects in the fired product, the firing process is judged to be qualified, and the qualification of the ceramic product is judged based on the compressive strength of the fired product.

[0013] Furthermore, the finished ceramic product is determined to be unqualified when the compressive strength is less than a preset compressive strength, and the particle size of the ceramic raw material is reduced according to the difference between the preset compressive strength and the compressive strength.

[0014] Furthermore, the finished ceramic product is judged to be qualified under the condition that the compressive strength is greater than or equal to the preset compressive strength, and the production of the recyclable ceramic is completed.

[0015] Compared with the prior art, the beneficial effect of the present invention is that the present invention reduces production costs by recycling waste mud. At the same time, the ceramic raw materials are environmentally friendly and pollution-free materials that can be recycled and reused, which reduces resource consumption and ensures long-term production stability.

[0016] Furthermore, the present invention can timely discover and adjust problems existing in the production process through detection and control of the entire ceramic production process, thereby significantly improving the qualified rate of finished ceramic products.

[0017] Furthermore, the present invention introduces the surface quality coefficient as a criterion for determining the drying process, and combined with a comprehensive evaluation of the surface crack size and edge warping, can more accurately adjust the temperature and humidity of the drying environment to avoid ceramic defects caused by improper drying.

[0018] Furthermore, the present invention specifically adjusts the heating rate or clay kneading time in the kiln according to the defect type of the fired product, thereby effectively reducing the occurrence of defects during the firing process.

[0019] Furthermore, the present invention ensures the quality of the final product by detecting the compressive strength of the fired product and adjusting the particle size of the ceramic raw material when the compressive strength is unqualified. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 A flow chart of a method for making recyclable ceramics in the whole process of an embodiment of the present invention; Figure 2 A flow chart for determining the eligibility of a drying process according to an embodiment of the present invention; Figure 3 A flow chart for determining firing eligibility according to an embodiment of the present invention; Figure 4 The present invention is a flowchart for determining the cause of a defect according to an embodiment of the present invention. DETAILED DESCRIPTION

[0021] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0022] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the protection scope of the present invention.

[0023] It should be noted that, in the description of the present invention, terms such as "up", "down", "left", "right", "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the drawings. This is merely for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0024] See also Figures 1 to 4 As shown, they are respectively a flow chart of the whole process of the recyclable ceramic production method of an embodiment of the present invention; a flow chart of determining the eligibility of drying treatment according to an embodiment of the present invention; a flow chart of determining the eligibility of firing according to an embodiment of the present invention; and a flow chart of determining the cause of defects according to an embodiment of the present invention.

[0025] The full-process method for producing recyclable ceramics in the embodiment of the present invention includes: Step S1, mixing the recycled waste mud with the ceramic raw material and then ball milling the mixture in a ball mill; Step S2, sieving the ball-milled slurry through a sieve; Step S3, drying the screened slurry in an oven to a preset moisture content of 20% and then kneading the slurry; Step S4, forming and drying the clay material to obtain a ceramic blank; Step S5, judging the eligibility of the drying process according to the surface quality coefficient of the ceramic blank, and adjusting the temperature of the drying environment or the humidity of the drying environment if the drying process is unqualified; Step S6, trimming the ceramic blanks that have passed the drying treatment and firing them in an electric kiln to obtain fired products; Step S7, judging the eligibility of firing according to whether there are defects in the fired product, determining the cause of the defect according to the defect type if the firing is unqualified, and adjusting the heating rate in the kiln according to the overall deformation rate, or increasing the clay kneading time according to the defect area ratio; Step S8, if the firing is qualified, judging the qualification of the finished ceramic product according to the compressive strength, and if the finished product is unqualified, reducing the particle size of the ceramic raw material; Step S9, completing the production of recyclable ceramics under the condition that the finished product is qualified.

[0026] In the embodiment of the present invention, the mass ratio of the waste mud to the ceramic raw material is 1:9.

[0027] In the embodiment of the present invention, the ceramic raw materials and their mass proportions are 40% to 50% kaolin, 10% to 20% quartz, 20% to 30% feldspar, 5% to 10% talc, 5% to 10% zirconia, and 5% to 10% alumina. The preferred embodiment of the present invention is 40% kaolin, 15% quartz, 25% feldspar, 5% talc, 5% zirconia, and 10% alumina.

[0028] In the embodiment of the present invention, the mass ratio of the mixed raw materials, water and grinding balls in the ball mill is 1:0.8:1.5, the ball milling time is 12 hours, and after ball milling, the mixture is sieved using a 200-mesh screen.

[0029] In the embodiment of the present invention, the preset moisture content is 20%, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0030] Specifically, the moisture content is calculated by weighing method, and the moisture content is obtained by calculating the difference between the weight of the slurry before drying and the weight of the slurry after drying, and then comparing it with the mass of water added to the ball mill.

[0031] In the embodiment of the present invention, the oven temperature is set to 60° C., and the drying time is not specifically limited and can be adjusted according to the actual moisture content.

[0032] In the embodiment of the present invention, the drying process is shade drying, which is carried out in a drying room away from light and wind. The drying temperature in the drying room is set to 25°C and the drying humidity is set to 50%, but the above values ​​are not limited to this. Those skilled in the art can also adjust the values ​​according to actual needs.

[0033] In the embodiment of the present invention, the firing temperature is in the range of 1250° C. to 1350° C., but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0034] Specifically, there is no specific limit on the firing time, which can be determined based on the actual product conditions.

[0035] Specifically, the process of determining the eligibility of the drying process includes: The surface quality coefficient is compared with a first preset quality coefficient of 0.02 and a second preset quality coefficient of 0.03 respectively; Based on the comparison result that the surface quality coefficient is less than the first preset quality coefficient, it is determined that the drying process is qualified, and the ceramic blank that has passed the drying process is fired; Determining that the drying process is unqualified based on the comparison result that the surface quality coefficient is greater than or equal to the first preset quality coefficient and less than the second preset quality coefficient, and adjusting the humidity of the drying environment according to the difference between the surface quality coefficient and the first preset quality coefficient; The drying process is determined to be unqualified based on the comparison result that the surface quality coefficient is greater than or equal to the second preset quality coefficient, and the temperature of the drying environment is adjusted according to the difference between the surface quality coefficient and the second preset quality coefficient.

[0036] In the embodiment of the present invention, the first preset quality coefficient is set to 0.02, and the second preset quality coefficient is set to 0.03, but the above values ​​are not limited thereto, and those skilled in the art may also adjust the values ​​according to actual needs.

[0037] Specifically, the surface quality coefficient is determined by the surface crack size and edge warpage of the ceramic blank and is calculated by the following formula: , where l is the crack length, d is the crack depth, S is the surface area of ​​the ceramic blank, and λ 1 As the first evaluation coefficient, set λ 1 =0.68, C is the perimeter of the edge of the ceramic blank after drying, C0 is the perimeter of the edge of the ceramic blank before drying, λ 1 As the second evaluation coefficient, set λ 2 =0.25.

[0038] Specifically, the surface crack size of the ceramic blank is measured by a portable flaw detector to obtain the length and depth of the crack, and the edge curvature of the ceramic blank is calculated based on the edge circumference before and after the ceramic blank is dried, and the edge circumference is measured by a tape measure.

[0039] Specifically, different humidity adjustment methods are set for the humidity of the dry environment, and each adjustment method has a different adjustment range for the humidity. If the first quality coefficient difference is less than the first preset quality coefficient difference of 0.004, the first humidity adjustment coefficient of 1.01 is used to adjust the humidity of the dry environment to the corresponding value; If the first quality coefficient difference is greater than or equal to the first preset quality coefficient difference, adjusting the humidity of the dry environment to a corresponding value using a second humidity adjustment coefficient of 1.03; The first quality coefficient difference is a difference between the surface quality coefficient and the first preset quality coefficient.

[0040] In the embodiment of the present invention, the first preset quality coefficient difference value is 0.004, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0041] Specifically, the temperature of the drying environment is positively correlated with the second mass coefficient difference, wherein if the second mass coefficient difference is less than the second preset mass coefficient difference of 0.005, the temperature of the drying environment is adjusted to a corresponding value using the first temperature adjustment coefficient of 1.02; If the second quality coefficient difference is greater than or equal to the second preset quality coefficient difference, adjusting the temperature of the drying environment to a corresponding value using a second temperature adjustment coefficient of 1.05; The second quality coefficient difference is a difference between the surface quality coefficient and the second preset quality coefficient.

[0042] In the embodiment of the present invention, the second preset quality coefficient difference is 0.005, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0043] Specifically, if there are defects in the fired product, the firing process is judged to be unqualified, and the cause of the defect is determined based on the defect type of the fired product.

[0044] In an embodiment of the present invention, the defects and types of the fired product are determined by an optical machine vision defect detection method, and the surface image of the fired product is captured by a high-definition high-speed camera. The defects are then classified by image processing technology, wherein the image processing technology is a conventional technology and will not be described in detail here.

[0045] Specifically, if the defect type is an overall defect, the cause of the defect is determined to be the excessively fast heating rate in the kiln, and the heating rate in the kiln is adjusted according to the overall deformation rate; if the defect type is a local defect, the cause of the defect is determined to be the presence of pores inside the porcelain blank, and the kneading time is increased according to the proportion of the defect area.

[0046] Specifically, overall defects such as deformation of the fired product and local defects such as the presence of pits or bubbles are not specifically limited.

[0047] Specifically, the heating rate in the kiln is adjusted according to the overall deformation rate, wherein if the overall deformation rate is less than the preset deformation rate of 5%, the heating rate in the kiln is adjusted to the corresponding value using the first rate adjustment coefficient of 0.98; If the overall deformation rate is greater than or equal to the preset deformation rate, the heating rate in the kiln is adjusted to a corresponding value using a second rate adjustment coefficient of 0.95.

[0048] In the embodiment of the present invention, the overall deformation rate is measured by a three-coordinate measuring machine.

[0049] In the embodiment of the present invention, the preset deformation rate is 5%, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0050] In the embodiment of the present invention, the initial heating rate in the kiln is set to 5°C / min, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0051] Specifically, the clay training time is increased according to the defect area ratio, wherein, if the defect area ratio is less than 3% of the preset area ratio, the first time adjustment coefficient 1.01 is used to increase the clay training time to the corresponding value; If the defect area ratio is greater than or equal to the preset area ratio, the second duration adjustment coefficient 1.03 is used to increase the clay kneading time to a corresponding value.

[0052] In the embodiment of the present invention, the preset area ratio is 3%, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0053] In the embodiment of the present invention, the defect area ratio is measured by an industrial CT scanner.

[0054] Specifically, if there are no defects in the fired product, the firing process is judged to be qualified, and the qualification of the ceramic product is judged based on the compressive strength of the fired product.

[0055] Specifically, the finished ceramic product is judged as unqualified when the compressive strength is less than a preset compressive strength of 35 MPa, and the particle size of the ceramic raw material is reduced according to the difference between the preset compressive strength and the compressive strength.

[0056] Specifically, the finished ceramic product is judged to be qualified under the condition that the compressive strength is greater than or equal to the preset compressive strength, and the production of the recyclable ceramic is completed.

[0057] Specifically, the compressive strength is obtained by testing according to GB / T 4741-1999 "Test method for compressive strength of ceramic tiles".

[0058] In the embodiment of the present invention, the preset compressive strength value is 35 MPa, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0059] So far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

[0060] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A full-process method for producing recyclable ceramics, characterized in that: include: The recycled waste mud is mixed with ceramic raw materials and then ball-milled in a ball mill; The ball-milled slurry is screened through a sieve; The sieved slurry is dried in an oven to a preset moisture content and then slurry is kneaded; The clay material after kneading is successively formed and dried to obtain a porcelain blank; Determine the eligibility of the drying process according to the surface quality coefficient of the porcelain blank, and adjust the temperature of the drying environment or the humidity of the drying environment if the drying process is unqualified; After the dried and qualified porcelain blanks are trimmed, they are fired in an electric kiln to obtain fired products; The quality of firing is determined based on whether the fired product has defects. If the firing is unqualified, the cause of the defect is determined based on the defect type, and the heating rate in the kiln is adjusted based on the overall deformation rate, or the clay kneading time is increased based on the defect area ratio; Under the condition of qualified firing, the qualification of the finished ceramic product is determined according to the compressive strength, and under the condition of unqualified finished product, the particle size of the ceramic raw material is reduced; Complete the production of recyclable ceramics under the condition that the finished product is qualified; The process of determining the eligibility of the drying process includes: comparing the surface quality coefficient with the first preset quality coefficient and the second preset quality coefficient respectively; Based on the comparison result that the surface quality coefficient is less than the first preset quality coefficient, it is determined that the drying process is qualified, and the ceramic blank that has passed the drying process is fired; Determining that the drying process is unqualified based on the comparison result that the surface quality coefficient is greater than or equal to the first preset quality coefficient and less than the second preset quality coefficient, and adjusting the humidity of the drying environment according to the difference between the surface quality coefficient and the first preset quality coefficient; Determining that the drying process is unqualified based on the comparison result that the surface quality coefficient is greater than or equal to the second preset quality coefficient, and adjusting the temperature of the drying environment according to the difference between the surface quality coefficient and the second preset quality coefficient; The surface quality coefficient is determined by the surface crack size and edge warping of the ceramic blank.

2. The full-process recyclable ceramic production method according to claim 1, characterized in that: Different humidity adjustment methods are provided for the humidity in a dry environment, and each adjustment method has a different adjustment range for the humidity.

3. The full-process recyclable ceramic production method according to claim 1 is characterized in that: The temperature of the drying environment is positively correlated with the second quality coefficient difference, wherein the second quality coefficient difference is the difference between the surface quality coefficient and the second preset quality coefficient.

4. The full-process recyclable ceramic production method according to claim 1 is characterized in that: If there are defects in the fired product, the firing process is judged to be unqualified, and the cause of the defect is determined based on the defect type of the fired product.

5. The full-process recyclable ceramic production method according to claim 4 is characterized in that: If the defect type is an overall defect, the cause of the defect is determined to be the excessively fast heating rate in the kiln, and the heating rate in the kiln is adjusted according to the overall deformation rate; if the defect type is a local defect, the cause of the defect is determined to be the presence of pores inside the porcelain blank, and the kneading time is increased according to the proportion of the defect area.

6. The full-process recyclable ceramic production method according to claim 1, characterized in that: If there are no defects in the fired product, the firing process is judged to be qualified, and the qualification of the ceramic product is judged based on the compressive strength of the fired product.

7. The full-process recyclable ceramic production method according to claim 6, characterized in that: The finished ceramic product is judged as unqualified when the compressive strength is less than the preset compressive strength, and the particle size of the ceramic raw material is reduced according to the difference between the preset compressive strength and the compressive strength.

8. The full-process recyclable ceramic production method according to claim 6, characterized in that: The finished ceramic product is judged to be qualified under the condition that the compressive strength is greater than or equal to the preset compressive strength.

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