A crystal flower dry grain glaze and a positioning crystal flower rock plate prepared by using the crystal flower dry grain glaze and a preparation method thereof
By mixing red mud with phosphogypsum to form mixture A, etching the surface of the brick blank and spraying it with crystal flower dry granule glaze, the problems of resource consumption and red mud treatment in the preparation of slabs are solved, realizing the production of environmentally friendly crystal flower slabs with good economic benefits and decorative effects.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ZHAOQING LINGHANG CERAMIC CO LTD
- Filing Date
- 2025-04-18
- Publication Date
- 2026-05-19
AI Technical Summary
Existing slab preparation processes rely on natural mineral raw materials, leading to resource consumption and environmental pollution, and the problem of red mud treatment has not been effectively solved.
Mixture A, made by mixing red mud and phosphogypsum, is used as the raw material for ceramic bricks. The surface of the brick blank is etched with a strong alkaline filtrate to form micropores. The crystalline dry granule glaze is then precisely applied using digital inkjet printing and a dry granulator. Finally, the crystalline slabs are fired in a kiln.
It realizes the resource utilization of red mud, reduces dependence on natural minerals, lowers production costs, enhances the bonding strength of the brick surface, and forms beautiful crystal patterns through various processes, thus having significant environmental and economic benefits.
Abstract
Description
Technical Field
[0001] This invention relates to the field of slab preparation technology, specifically to a crystal-flowered dry granule glaze, a positioning crystal-flowered slab prepared using the crystal-flowered dry granule glaze, and a method for preparing the same. Background Technology
[0002] Sintered stone slabs are a widely used material in architectural decoration, and their preparation process and decorative effects have always been a focus of industry research. Crystal-flower dry granule glaze is a unique ceramic glaze that, through specific preparation processes and firing regimes, can form beautiful crystal patterns on sintered stone slabs, adding a unique artistic aesthetic to ceramic products.
[0003] Traditional ceramic tiles and glazes typically rely on natural mineral raw materials such as feldspar, quartz, and kaolin. The mining and use of these raw materials not only consume a large amount of natural resources but also put pressure on the environment. In recent years, with the increasing awareness of environmental protection and the promotion of the concept of sustainable development, how to use industrial waste to replace some natural raw materials, reduce production costs, and reduce environmental pollution has become an important research direction in the ceramic industry.
[0004] Red mud is an industrial waste generated during alumina production, primarily composed of iron oxide, aluminum oxide, and silicon dioxide. Due to its high alkalinity and heavy metal content, its treatment and disposal have long been a challenge. Direct dumping not only occupies significant land resources but also risks polluting soil and water bodies. However, the silicon, aluminum, and iron in red mud are chemically similar to those found in ceramic raw materials. Therefore, using red mud as a raw material for ceramic brick production not only enables the resource utilization of industrial waste but also reduces dependence on natural minerals, resulting in significant environmental and economic benefits. Summary of the Invention
[0005] The purpose of this invention is to provide a crystal-flowered dry granule glaze, a positioning crystal-flowered rock slab made using the crystal-flowered dry granule glaze, and a method for preparing the same, so as to solve the problems existing in the prior art.
[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution:
[0007] A method for preparing a positioning crystallized rock slab includes the following steps:
[0008] (1) Mix red mud and pure water at a mass ratio of 1:(9-10), soak at 80-90℃ for 60-70 min, and filter to obtain primary dealkalized red mud and alkaline filtrate; mix primary dealkalized red mud, phosphogypsum and pure water at a mass ratio of 1:(0.4-0.6):(50-60) for 30-40 min, filter, wash and dry to obtain mixture A;
[0009] (2) After the green body powder is granulated by spray tower, it is spread by a material spreading system and formed into brick blanks by roller pressing or stamping; the alkaline filtrate is sprayed onto the surface of the green body, rinsed with running water after 60s, and dried at 180-220℃ for 60-70min to obtain pretreated brick blanks.
[0010] (3) Apply a base glaze to the surface of the pretreated brick blank. The process parameters for applying the base glaze are: specific gravity 1.89±0.02g / mL, glaze application amount 400-480g / m³. 2 ;
[0011] (4) After applying the base glaze, inkjet print the pattern on the base glaze surface and spray positioning adhesive;
[0012] (5) Apply crystal-like dry granule glaze using a dry granulator and recover excess crystal-like dry granule glaze; the process parameters for applying crystal-like dry granule glaze are: specific gravity 1.15-1.20 g / mL, glaze application amount 200-300 g / mL. 2 ;
[0013] (6) Spraying zircon sand;
[0014] (7) Finally, the slabs are fired in a kiln and polished using a full-polishing process to obtain the positioning crystal flower slabs. The firing temperature is 1150-1200℃ and the firing cycle is 40-60min.
[0015] Preferably, the red mud in step (1) is produced by the Bayer process.
[0016] Preferably, the green body powder in step (2) comprises, by mass percentage, 50%–60% potassium feldspar, 20%–25% mixture A, 5%–15% talc, 3%–6% wollastonite, 5%–8% quartz, 4%–8% kaolinite, and 4%–6% dolomite.
[0017] Preferably, the chemical composition of the green body powder in step (2) includes: by mass percentage, SiO 2: 65%~68%, Al2O3: 17%~19%, Fe2O3: 1.5%~1.6%, TiO2: 0.1%~0.2%, CaO: 2.2%~2.5%, MgO: 1.5%~ 1.8%, K2O: 3.0% to 3.2%, Na2O: 2.3% to 2.6%, P2O5: 0.1% to 0.3%, SO3: 0.1% to 0.3%, loss on ignition: 1.2% to 4.3%.
[0018] Preferably, the base glaze raw materials in step (3) include, by mass percentage: 40%–45% potassium feldspar, 5%–10% sodium feldspar, 8%–10% kaolin, 3%–5% calcined kaolin, 10%–15% quartz, 5%–15% nepheline, 8%–12% zirconium oxide, 2%–4% spodumene, and 4%–6% calcined talc.
[0019] Preferably, the chemical composition of the base glaze raw material in step (3) includes, by mass percentage: SiO2: 55%–60%, Al2O3: 16%–18%, Fe2O3: 0.3%–0.5%, TiO2: 0.2%–0.3%, CaO: 1.5%–2.5%, MgO: 1.5%–2.5%, K2O: 4.0%–5.0%, Na2O: 2.0%–3.0%, ZrO2: 8%–12%, Li2O: 0.3%–0.5%, and loss on ignition: 3.0%–5.0%.
[0020] Preferably, the preparation method of the crystal flower dry granule glaze in step (5) is as follows: the raw materials of crystal flower dry granule glaze are mixed according to the ratio and calcined at a temperature of 1300-1400℃, water quenched and then processed into dry granules of 30-100 mesh.
[0021] Preferably, the raw material for the crystal-flower dry granule glaze comprises, by mass percentage, 55%–60% potassium feldspar, 6%–8% sodium feldspar, 12%–15% quartz, 6%–8% dolomite, 5%–6% zinc oxide, 4%–5% calcium carbonate, and 4%–5% talc.
[0022] Preferably, the chemical composition of the crystal-like dry granule glaze raw material includes, by mass percentage: SiO2: 55%–60%, Al2O3: 14%–16%, K2O: 6%–7%, Na2O: 1.5%–2.5%, CaO: 6%–8%, MgO: 1.5%–2.5%, ZnO: 5%–6%, and loss on ignition: 2%–4%.
[0023] Preferably, the zircon sand in step (5) has a particle size of 80-150 mesh, and the mass percentage of its main components is ZrO2≧65%, Fe2O3≦0.03%, and TiO2≦0.03%.
[0024] The present invention also provides a positioning crystal flower rock slab prepared according to any one of the above preparation methods.
[0025] Compared with the prior art, the beneficial effects achieved by the present invention are:
[0026] The raw material composition of the positioning crystallized rock slab prepared by this invention includes mixture A; mixture A is obtained by mixing phosphogypsum and red mud. Red mud is an industrial waste generated during the alumina production process, and its main components are iron oxide, aluminum oxide, silicon dioxide, etc. Due to the high alkalinity and heavy metal content of red mud, its treatment and disposal has long been a difficult problem. If it is directly piled up, it will not only occupy a large amount of land resources, but may also pollute the soil and water bodies. However, the silicon, aluminum, iron and other elements rich in red mud are compatible with ceramic raw materials. With similar chemical compositions, using red mud as one of the raw materials for ceramic brick preparation can not only realize the resource utilization of industrial waste, but also reduce the dependence on natural minerals, resulting in significant environmental and economic benefits. First, mixing red mud with pure water can remove most of the free alkali in the red mud, and the filtrate obtained by filtration is a strongly alkaline filtrate. The red mud after water washing can be further mixed with phosphogypsum to remove the chemically bound alkali in the red mud. The red mud after alkali removal does not need to be separated from phosphogypsum, and the two can be used as a mixture to form the body powder of the slab.
[0027] After the raw material is made into brick blanks, the above-mentioned strong alkaline filtrate can be used as an etching solution to etch the surface of the brick blank, forming micropores on the surface, increasing roughness, and enhancing the bonding strength between the base glaze and the surface of the brick blank. This allows the strong alkaline filtrate to be reused instead of being directly discharged and causing pollution.
[0028] In addition, the ZrO2 in the base glaze creates an opaque effect to cover the base color of the body; high-definition patterns are printed using a digital inkjet printer, followed by the application of positioning adhesive and precise application of crystal flower dry granule glaze using a dry granule machine, and the unadhered dry granules are recycled to reduce losses; the spraying of zircon sand can produce a shimmering effect. Detailed Implementation
[0029] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.
[0030] The zircon sand described in the following examples and comparative examples has a particle size of 100 mesh, and its main components have a mass percentage of ZrO2≧65%, Fe2O3≦0.03%, and TiO2≦0.03%; the red mud is produced by the Bayer process.
[0031] Example 1:
[0032] A method for preparing a positioning crystallized rock slab, the method comprising the following preparation steps:
[0033] (1) Mix red mud and pure water at a mass ratio of 1:9, soak at 90℃ for 70 min, and filter to obtain primary dealkalized red mud and alkaline filtrate; mix primary dealkalized red mud, phosphogypsum and pure water at a mass ratio of 1:0.4:50 for 40 min, filter, wash and dry to obtain mixture A;
[0034] (2) Weigh the green body powder; the green body powder includes: by mass percentage, 55% potassium feldspar, and mixture A The raw material consists of 20% talc, 6% wollastonite, 4.5% wollastonite, 6.5% quartz, 5% kaolin, and 3% dolomite. The chemical composition of the raw material powder includes, by mass percentage: SiO2: 66.5%, Al2O3: 18.0%, Fe2O3: 1.55%, TiO2: 0.15%, CaO: 2.35%, MgO: 1.65%, K2O: 3.1%, Na2O: 2.45%, P2O5: 0.02%, SO3: 0.02%, and loss on ignition: 4.21%. The raw material powder is granulated using a spray tower, then distributed using a material distribution system, and formed into brick blanks by roll forming or stamping. An alkaline filtrate is sprayed onto the surface of the brick blanks. After 60 seconds, the blanks are rinsed with running water and dried at 220℃ for 70 minutes to obtain pretreated brick blanks.
[0035] (3) Apply a base glaze to the surface of the pretreated brick blank by spraying. The process parameters for applying the base glaze are: specific gravity 1.89 g / mL, glaze application amount 400 g / m³. 2 The raw materials for the base glaze include, by mass percentage: 42% potassium feldspar, 7% sodium feldspar, 9% kaolin, 4% calcined kaolin, 12% quartz, 9% nepheline, 10% zirconium oxide, 3% spodumene, and 4% calcined talc; the chemical composition of the base glaze raw materials includes, by mass percentage: 58.0% SiO2, 17.0% Al2O3, 0.4% Fe2O3, 0.25% TiO2, 2.0% CaO, 2.0% MgO, 4.5% K2O, 2.5% Na2O, 9.9% ZrO2, 0.4% Li2O, and a loss on ignition of 3.05%.
[0036] (4) After applying the base glaze, use a digital inkjet printer to print the pattern on the base glaze surface and use a digital glue dry granulator to spray positioning glue.
[0037] (5) Apply crystal-like dry granule glaze using a dry granulator and recover excess crystal-like dry granule glaze using a negative pressure recovery system; the process parameters for applying the crystal-like dry granule glaze are: specific gravity 1.15 g / mL, glaze application amount 220 g / mL. 2The raw materials for the crystal-flower dry granule glaze are mixed according to the specified ratio and calcined at 1400℃, then water-quenched and processed into 70-mesh dry granules. The raw materials for the crystal-flower dry granule glaze include, by mass percentage: potassium feldspar 58%, sodium feldspar 7.5%, quartz 13%, dolomite 7%, zinc oxide 5.5%, calcium carbonate 4.5%, talc 4.5%. The chemical composition of the raw materials for the crystal-flower dry granule glaze includes, by mass percentage: SiO2: 59.0%, Al2O3: 15.0%, K2O: 6.5%, Na2O: 2.0%, CaO: 7.0%, MgO: 2.0%, ZnO: 5.2%, and loss on ignition: 3.3%.
[0038] (6) Spraying zircon sand;
[0039] (7) Finally, the slabs are fired in a kiln and polished using a full-polishing process to obtain the positioning crystal flower slabs. The firing temperature is 1200℃ and the firing cycle is 60min.
[0040] Example 2:
[0041] A method for preparing a positioning crystallized rock slab, the method comprising the following preparation steps:
[0042] (1) Mix red mud and pure water at a mass ratio of 1:10, soak at 80℃ for 60 min, and filter to obtain primary dealkalized red mud and alkaline filtrate; mix primary dealkalized red mud, phosphogypsum and pure water at a mass ratio of 1:0.6:60 for 30 min, filter, wash and dry to obtain mixture A;
[0043] (2) Weigh the green body powder; the green body powder includes, by mass percentage: potassium feldspar 52%, mixture A 21%, talc 6%, wollastonite 5%, quartz 7%, kaolin 6%, dolomite 3%; the chemical composition of the green body powder includes, by mass percentage: SiO2 67.0%, Al2O3 6%, 2%... 3: 18.5%, Fe2O3:1.5%, TiO2:0.15%, CaO:2.4%, MgO:1.7%, K2O:3.1%, Na2O:2.5%, P2O5:0.2%, SO3:0.2%, Loss on ignition:2.75%; The green body powder is granulated by spraying in a spray tower, then distributed using a material distribution system, and formed into brick blanks by roll forming or stamping; Alkaline filtrate is sprayed onto the surface of the green body, rinsed with running water after 60 seconds, and dried at 180℃ for 70 minutes to obtain pretreated brick blanks;
[0044] (3) Apply a base glaze to the surface of the pretreated brick blank by spraying. The process parameters for applying the base glaze are: specific gravity 1.89 g / mL, glaze application amount 480 g / m³. 2The base glaze raw materials include, by mass percentage: 43% potassium feldspar, 8% sodium feldspar, 9% kaolin, 4% calcined kaolin, 11% quartz, 9% nepheline, 9% zirconium oxide, 3% spodumene, and 4% calcined talc; the chemical composition of the base glaze raw materials includes, by mass percentage: 58.0% SiO2, 18% Al2O3, 0.4% Fe2O3, 0.2% TiO2, 1.8% CaO, 2.2% MgO, 4.2% K2O, 2.5% Na2O, and 4% ZrO. 2: 8.5%, Li₂O: 0.5%, Loss on ignition: 3.7%;
[0045] (4) After applying the base glaze, use a digital inkjet printer to print the pattern on the base glaze surface and use a digital glue dry granulator to spray positioning glue.
[0046] (5) Apply crystal-like dry granule glaze using a dry granulator and recover excess crystal-like dry granule glaze using a negative pressure recovery system; the process parameters for applying the crystal-like dry granule glaze are: specific gravity 1.20 g / mL, glaze application amount 250 g / mL. 2 The raw materials for the crystal-flower dry granule glaze are mixed according to the specified ratio and calcined at 1350℃, then water-quenched and processed into 50-mesh dry granules. The raw materials for the crystal-flower dry granule glaze include, by mass percentage: 58% potassium feldspar, 6.5% sodium feldspar, 14% quartz, 7.5% dolomite, 5.5% zinc oxide, 4.5% calcium carbonate, and 4.5% talc. The chemical composition of the raw materials for the crystal-flower dry granule glaze includes, by mass percentage: SiO₂ 2: 57.0%, Al2O 3: 15.5%, K2O: 6.8%, Na2O: 2.2%, CaO: 7.5%, MgO: 2.2%, ZnO: 5.3%, Loss on ignition: 3.5%;
[0047] (6) Spraying zircon sand;
[0048] (7) Finally, the slabs are fired in a kiln and polished using a full-polishing process to obtain the positioning crystal flower slabs. The firing temperature is 1150℃ and the firing cycle is 40min.
[0049] Example 3:
[0050] A method for preparing a positioning crystallized rock slab, the method comprising the following preparation steps:
[0051] (1) Mix red mud and pure water at a mass ratio of 1:9.5, soak at 85℃ for 65 min, and filter to obtain primary dealkalized red mud and alkaline filtrate; mix primary dealkalized red mud, phosphogypsum and pure water at a mass ratio of 1:0.5:55 for 35 min, filter, wash and dry to obtain mixture A;
[0052] (2) Weigh the green body powder; the green body powder includes: by mass percentage, 52% potassium feldspar, and mixture A The raw material consists of 23% talc, 7% wollastonite, 4% quartz, 6% kaolin, and 3% dolomite. The chemical composition of the raw material powder includes, by mass percentage: SiO2: 67.5%, Al2O3: 18.2%, Fe2O3: 1.52%, TiO2: 0.16%, CaO: 2.38%, MgO: 1.68%, K2O: 3.15%, Na2O: 2.5%, P2O5: 0.15%, SO3: 0.15%, and loss on ignition: 3.8%. The raw material powder is granulated using a spray tower, then distributed using a material distribution system, and formed into brick blanks by roll forming or stamping. An alkaline filtrate is sprayed onto the surface of the brick blanks. After 60 seconds, the blanks are rinsed with running water and dried at 200℃ for 65 minutes to obtain pretreated brick blanks.
[0053] (3) Apply a base glaze to the surface of the pretreated brick blank by spraying. The process parameters for applying the base glaze are: specific gravity 1.89 g / mL, glaze application amount 440 g / m³. 2 The raw materials for the base glaze include, by mass percentage: 44% potassium feldspar, 6% sodium feldspar, 9% kaolin, 4% calcined kaolin, 13% quartz, 8% nepheline, 10% zirconium oxide, 3% spodumene, and 4% calcined talc; the chemical composition of the base glaze raw materials includes, by mass percentage: 58.5% SiO2, 17.5% Al2O3, 0.45% Fe2O3, 0.22% TiO2, 2.2% CaO, 2.1% MgO, 4.8% K2O, 2.4% Na2O, 9.5% ZrO2, 0.45% Li2O, and a loss on ignition of 3.2%.
[0054] (4) After applying the base glaze, use a digital inkjet printer to print the pattern on the base glaze surface and use a digital glue dry granulator to spray positioning glue.
[0055] (5) Apply crystal-like dry granule glaze using a dry granulator and recover excess crystal-like dry granule glaze using a negative pressure recovery system; the process parameters for applying the crystal-like dry granule glaze are: specific gravity 1.17 g / mL, glaze application amount 250 g / mL. 2 The raw materials for the crystal-flower dry granule glaze are mixed according to the specified ratio and calcined at 1350℃, then water-quenched and processed into 60-mesh dry granules. The raw materials for the crystal-flower dry granule glaze include, by mass percentage: potassium feldspar 56%, sodium feldspar 7%, quartz 14%, dolomite 6%, zinc oxide 5%, calcium carbonate 4%, talc 3%. The chemical composition of the raw materials for the crystal-flower dry granule glaze includes, by mass percentage: SiO2: 57.5%, Al2O3: 15.5%, K2O: 6.2%, Na2O: 2.1%, CaO: 6.5%, MgO: 2.3%, ZnO: 5.1%, and loss on ignition: 3.6%.
[0056] (6) Spraying zircon sand;
[0057] (7) Finally, the slabs are fired in a kiln and polished using a full-polishing process to obtain the positioning crystal flower slabs. The firing temperature is 1180℃ and the firing cycle is 50min.
[0058] Example 4:
[0059] A method for preparing a positioning crystallized rock slab, the method comprising the following preparation steps:
[0060] (1) Mix red mud and pure water at a mass ratio of 1:9, soak at 85℃ for 60 min, and filter to obtain primary dealkalized red mud and alkaline filtrate; mix primary dealkalized red mud, phosphogypsum and pure water at a mass ratio of 1:0.4:50 for 30 min, filter, wash and dry to obtain mixture A;
[0061] (2) Weigh the body powder; the body powder includes: by mass percentage, potassium feldspar 50%, mixture A 25%, talc 7%, wollastonite 3%, quartz 7%, kaolin 5%, dolomite 3%; the chemical composition of the body powder includes: by mass percentage, SiO2: 65%, Al2O3: 19%, Fe2O3: 1.6%, TiO2: 0.2%, CaO: 2.5%, MgO: 1.8%, K2O: 3.2%, Na2O: 2.6%, P2O5: 0.3%, SO3: 0.3%, loss on ignition: 4.3%; after granulation of the body powder through a spray tower, it is distributed using a material distribution system and formed into brick blanks by roll forming or stamping; the alkaline filtrate is sprayed onto the surface of the body; after 60s, it is rinsed with running water and dried at 180℃ for 70min to obtain pretreated brick blanks;
[0062] (3) Apply a base glaze to the surface of the pretreated brick blank by spraying. The process parameters for applying the base glaze are: specific gravity 1.89 g / mL, glaze application amount 480 g / m³. 2 The raw materials for the base glaze include, by mass percentage: 40% potassium feldspar, 10% sodium feldspar, 8% kaolin, 3% calcined kaolin, 15% quartz, 5% nepheline, 12% zirconium oxide, 2% spodumene, and 4% calcined talc; the chemical composition of the base glaze raw materials includes, by mass percentage: 60% SiO2, 16% Al2O3, 0.5% Fe2O3, 0.3% TiO2, 1.5% CaO, 2.5% MgO, 5.0% K2O, 3.0% Na2O, 8% ZrO2, 0.5% Li2O, and a loss on ignition of 5.0%.
[0063] (4) After applying the base glaze, use a digital inkjet printer to print the pattern on the base glaze surface and use a digital glue dry granulator to spray positioning glue.
[0064] (5) Apply crystal-like dry granule glaze using a dry granulator and recover excess crystal-like dry granule glaze using a negative pressure recovery system; the process parameters for applying the crystal-like dry granule glaze are: specific gravity 1.15 g / mL, glaze application amount 300 g / mL. 2 The raw materials for the crystal-flower dry granule glaze are mixed according to the specified ratio and calcined at 1400℃, then water-quenched and processed into 60-mesh dry granules. The raw materials for the crystal-flower dry granule glaze include, by mass percentage: 55% potassium feldspar, 8% sodium feldspar, 12% quartz, 6% dolomite, 6% zinc oxide, 4% calcium carbonate, and 5% talc. The chemical composition of the raw materials for the crystal-flower dry granule glaze includes, by mass percentage: 55% SiO2, 16% Al2O3, 6% K2O, 2.5% Na2O, 8% CaO, 2.5% MgO, 6% ZnO, and 4% loss on ignition.
[0065] (6) Spraying zircon sand;
[0066] (7) Finally, the slabs are fired in a kiln and polished using a full-polishing process to obtain the positioning crystal flower slabs. The firing temperature is 1200℃ and the firing cycle is 60min.
[0067] Example 5:
[0068] A method for preparing a positioning crystallized rock slab, the method comprising the following preparation steps:
[0069] (1) Mix red mud and pure water at a mass ratio of 1:10, soak at 90℃ for 70 min, and filter to obtain primary dealkalized red mud and alkaline filtrate; mix primary dealkalized red mud, phosphogypsum and pure water at a mass ratio of 1:0.6:60 for 40 min, filter, wash and dry to obtain mixture A;
[0070] (2) Weigh the body powder; the body powder includes: by mass percentage, potassium feldspar 53%, mixture A 22%, talc 6%, wollastonite 5%, quartz 7%, kaolin 4%, dolomite 3%; the chemical composition of the body powder includes: by mass percentage, SiO2: 67%, Al2O3: 18%, Fe2O3: 1.5%, TiO2: 0.15%, CaO: 2.4%, MgO: 1.7%, K2O: 3.1%, Na2O: 2.5%, P2O5: 0.2%, SO3: 0.2%, loss on ignition: 3.0%; after granulation of the body powder through a spray tower, it is distributed using a material distribution system and formed into brick blanks by roll forming or stamping; the alkaline filtrate is sprayed onto the surface of the body; after 60s, it is rinsed with running water and dried at 220℃ for 60min to obtain pretreated brick blanks;
[0071] (3) Apply a base glaze to the surface of the pretreated brick blank by spraying. The process parameters for applying the base glaze are: specific gravity 1.89 g / mL, glaze application amount 420 g / m³. 2The raw materials for the base glaze include, by mass percentage: 45% potassium feldspar, 5% sodium feldspar, 9% kaolin, 4% calcined kaolin, 14% quartz, 10% nepheline, 8% zirconium oxide, 3% spodumene, and 4% calcined talc; the chemical composition of the base glaze raw materials includes, by mass percentage: 56% SiO2, 18% Al2O3, 0.4% Fe2O3, 0.2% TiO2, 2.0% CaO, 2.2% MgO, 4.5% K2O, 2.0% Na2O, 8% ZrO2, 0.4% Li2O, and 3.5% loss on ignition.
[0072] (4) After applying the base glaze, use a digital inkjet printer to print the pattern on the base glaze surface and use a digital glue dry granulator to spray positioning glue.
[0073] (5) Apply crystal-like dry granule glaze using a dry granulator and recover excess crystal-like dry granule glaze using a negative pressure recovery system; the process parameters for applying the crystal-like dry granule glaze are: specific gravity 1.17 g / mL, glaze application amount 220 g / mL. 2 The raw materials for the crystal-flower dry granule glaze are mixed according to the specified ratio and calcined at 1300℃, then water-quenched and processed into 50-mesh dry granules. The raw materials for the crystal-flower dry granule glaze include, by mass percentage: 57% potassium feldspar, 6% sodium feldspar, 13% quartz, 7% dolomite, 5% zinc oxide, 4% calcium carbonate, and 3% talc. The chemical composition of the raw materials for the crystal-flower dry granule glaze includes, by mass percentage: 58% SiO2, 14% Al2O3, 6.5% K2O, 1.8% Na2O, 7.0% CaO, 2.0% MgO, 5.0% ZnO, and 3.2% loss on ignition.
[0074] (6) Spraying zircon sand;
[0075] (7) Finally, the slabs are fired in a kiln and polished using a full-polishing process to obtain the positioning crystal flower slabs. The firing temperature is 1150℃ and the firing cycle is 45min.
[0076] Example 6:
[0077] A method for preparing a positioning crystallized rock slab, the method comprising the following preparation steps:
[0078] (1) Mix red mud and pure water at a mass ratio of 1:9.5, soak at 80℃ for 65 minutes, and filter to obtain primary dealkalized red mud and alkaline filtrate; mix primary dealkalized red mud, phosphogypsum and pure water at a mass ratio of 1:0.5:55 for 35 minutes, filter, wash and dry to obtain mixture A;
[0079] (2) Weigh the green body powder; the green body powder includes: by mass percentage, 50% potassium feldspar, and mixture A The raw material consists of 24% talc, 9% wollastonite, 4% silica, 6% quartz, 5% kaolin, and 2% dolomite. The chemical composition of the raw material powder includes, by mass percentage: SiO2: 66%, Al2O3: 18.5%, Fe2O3: 1.55%, TiO2: 0.16%, CaO: 2.35%, MgO: 1.65%, K2O: 3.1%, Na2O: 2.45%, P2O5: 0.05%, SO3: 0.05%, and loss on ignition: 3.5%. The raw material powder is granulated using a spray tower, then distributed using a material distribution system, and formed into brick blanks by roll forming or stamping. An alkaline filtrate is sprayed onto the surface of the brick blanks. After 60 seconds, the blanks are rinsed with running water and dried at 210℃ for 65 minutes to obtain pretreated brick blanks.
[0080] (3) Apply a base glaze to the surface of the pretreated brick blank by spraying. The process parameters for applying the base glaze are: specific gravity 1.89 g / mL, glaze application amount 460 g / m³. 2 The raw materials for the base glaze include, by mass percentage: 43% potassium feldspar, 7% sodium feldspar, 10% kaolin, 3% calcined kaolin, 12% quartz, 8% nepheline, 9% zirconium oxide, 3% spodumene, and 4% calcined talc; the chemical composition of the base glaze raw materials includes, by mass percentage: 57% SiO2, 17.5% Al2O3, 0.4% Fe2O3, 0.25% TiO2, 2.2% CaO, 2.0% MgO, 4.8% K2O, 2.5% Na2O, 9% ZrO2, 0.5% Li2O, and a loss on ignition of 3.3%.
[0081] (4) After applying the base glaze, use a digital inkjet printer to print the pattern on the base glaze surface and use a digital glue dry granulator to spray positioning glue.
[0082] (5) Apply crystal-like dry granule glaze using a dry granulator and recover excess crystal-like dry granule glaze using a negative pressure recovery system; the process parameters for applying the crystal-like dry granule glaze are: specific gravity 1.17 g / mL, glaze application amount 280 g / mL. 2 The raw materials for the crystal-flower dry granule glaze are mixed according to the specified ratio and calcined at 1380℃, then water-quenched and processed into 50-mesh dry granules. The raw materials for the crystal-flower dry granule glaze include, by mass percentage: potassium feldspar 59%, sodium feldspar 5%, quartz 12%, dolomite 8%, zinc oxide 6%, calcium carbonate 4%, talc 2%. The chemical composition of the raw materials for the crystal-flower dry granule glaze includes, by mass percentage: SiO2: 56%, Al2O3: 14%, K2O: 6%, Na2O: 1.5%, CaO: 8%, MgO: 2.5%, ZnO: 6%, and loss on ignition: 3.5%.
[0083] (6) Spraying zircon sand;
[0084] (7) Finally, the slabs are fired in a kiln and polished using a full-polishing process to obtain the positioning crystal flower slabs. The firing temperature is 1190℃ and the firing cycle is 55min.
[0085] Test example:
[0086] The test standard for the abrasion resistance of the glaze is GB / T 3810.7-2016; the results are shown in Table 1.
[0087] The test standard for the stain resistance of the glaze is GB / T 3810.14-2016; the results are shown in Table 1.
[0088] The test standard for glaze gloss is GB / T13891-2008; the results are shown in Table 1.
[0089] Table 1. Statistical analysis of test results for abrasion resistance, stain resistance, and gloss.
[0090] abrasion resistance Stain resistance Glaze gloss after polishing Example 1 1500 RPM, Level 3 Level 4 95 degrees Example 2 1500 RPM, Level 3 Level 4 95 degrees Example 3 1500 RPM, Level 3 Level 4 94 degrees Example 4 1500 RPM, Level 3 Level 4 96 degrees Example 5 1500 RPM, Level 3 Level 4 95 degrees Example 6 1500 RPM, Level 3 Level 4 94 degrees
[0091] The experimental data in Table 1 show that the slab produced by this invention has good wear resistance, stain resistance and gloss.
[0092] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No markings in the claims should be construed as limiting the scope of the claims.
Claims
1. A method for preparing a positioning crystallized rock slab, characterized in that, Includes the following steps: (1) Mix red mud and pure water at a mass ratio of 1:(9-10), soak at 80-90℃ for 60-70 min, and filter to obtain primary dealkalized red mud and alkaline filtrate; mix primary dealkalized red mud, phosphogypsum and pure water at a mass ratio of 1:(0.4-0.6):(50-60) for 30-40 min, filter, wash and dry to obtain mixture A; (2) After the green body powder is granulated by spray tower, it is spread by a material spreading system and made into brick blanks by roller pressing or stamping; the alkaline filtrate is sprayed on the surface of the green body, rinsed with running water after 60s, and dried at 180-220℃ for 60-70min to obtain pretreated brick blanks; (3) Apply a base glaze to the surface of the pretreated brick blank. The process parameters for applying the base glaze are: specific gravity 1.89±0.02g / mL, glaze application amount 400-480g / m 2 ; (4) After applying the base glaze, inkjet print the pattern on the base glaze surface and spray positioning adhesive; (5) Apply crystal-flower dry granule glaze using a dry granulator and recycle excess crystal-flower dry granule glaze; the process parameters for applying crystal-flower dry granule glaze are: specific gravity 1.15-1.20 g / mL, glaze application amount 200-300 g / mL. 2 ; (6) Spraying zircon sand; (7) Finally, the slabs are fired in a kiln and polished using a full-polishing process to obtain the positioning crystal flower slabs. The firing temperature is 1150-1200℃ and the firing cycle is 40-60min. The green body powder in step (2) includes, by mass percentage, 50% to 60% potassium feldspar, 20% to 25% mixture A, 5% to 15% talc, 3% to 6% wollastonite, 5% to 8% quartz, 4% to 8% kaolinite, and 4% to 6% dolomite.
2. The preparation method according to claim 1, characterized in that, The red mud mentioned in step (1) is produced by the Bayer process.
3. The preparation method according to claim 1, characterized in that, The chemical composition of the green body powder in step (2) includes, by mass percentage: SiO2: 65%–68%, Al2O3: 17%–19%, Fe2O3: 1.5%–1.6%, TiO2: 0.1%–0.2%, CaO: 2.2%–2.5%, MgO: 1.5%–1.8%, K2O: 3.0%–3.2%, Na2O: 2.3%–2.6%, P2O5: 0.1%–0.3%, SO3: 0.1%–0.3%, and loss on ignition: 1.2%–4.3%.
4. The preparation method according to claim 1, characterized in that, The base glaze raw materials in step (3) include, by mass percentage, 40%–45% potassium feldspar, 5%–10% sodium feldspar, 8%–10% kaolin, 3%–5% calcined kaolin, 10%–15% quartz, 5%–15% nepheline, 8%–12% zirconium oxide, 2%–4% spodumene, and 4%–6% calcined talc.
5. The preparation method according to claim 1, characterized in that, The chemical composition of the base glaze raw material in step (3) includes, by mass percentage: SiO2: 55%–60%, Al2O3: 16%–18%, Fe2O3: 0.3%–0.5%, TiO2: 0.2%–0.3%, CaO: 1.5%–2.5%, MgO: 1.5%–2.5%, K2O: 4.0%–5.0%, Na2O: 2.0%–3.0%, ZrO2: 8%–12%, Li2O: 0.3%–0.5%, and loss on ignition: 3.0%–5.0%.
6. The preparation method according to claim 1, characterized in that, The preparation method of the crystal flower dry granule glaze in step (5) is as follows: the raw materials of the crystal flower dry granule glaze are mixed according to the formula and calcined at a temperature of 1300-1400℃, then water quenched and processed into dry granules of 30-100 mesh; the zircon sand has a particle size of 80-150 mesh, and the mass percentage of its main components is ZrO2≧65%, Fe2O3≦0.03%, TiO2≦0.03%.
7. The preparation method according to claim 6, characterized in that, The raw materials for the crystal-flower dry granule glaze include, by mass percentage, 55%–60% potassium feldspar, 6%–8% sodium feldspar, 12%–15% quartz, 6%–8% dolomite, 5%–6% zinc oxide, 4%–5% calcium carbonate, and 4%–5% talc.
8. The preparation method according to claim 7, characterized in that, The chemical composition of the crystal-like dry granule glaze raw material includes, by mass percentage: SiO2: 55%–60%, Al2O3: 14%–16%, K2O: 6%–7%, Na2O: 1.5%–2.5%, CaO: 6%–8%, MgO: 1.5%–2.5%, ZnO: 5%–6%, and loss on ignition: 2%–4%.
9. A positioning crystallized rock slab prepared by the preparation method according to any one of claims 1-8.