Application of silica fume in light porcelain ball, light porcelain ball and preparation method of light porcelain ball

Abstract

The invention discloses application of silica fume in a light porcelain ball, the light porcelain ball and a preparation method of the light porcelain ball, and relates to the technical field of smelting solid waste treatment. According to the application of the silica fume in the light porcelain ball, the silica fume is used as a pore-forming agent for closed pore forming of the light porcelain ball. The light porcelain ball comprises a core layer, the core layer is mainly prepared from core materials of the following components: potassium feldspar, albite, kaolin, fly ash, methyl cellulose and silica fume, and closed pores with the pore diameter of 0.01-0.5 mm and the porosity of 40-60% are dispersed in the core layer. The invention creatively discovers the application of the silica fume in the light ceramic ball, and the silica fume is used as a pore-forming agent for closed pore forming of the light ceramic ball. The light porcelain ball prepared from the silica fume is low in density, high in compressive strength, low in water absorption and good in corrosion resistance.

Description

Technical Field

[0001] The present invention relates to the field of smelting solid waste treatment, and in particular to the application of silica fume in lightweight porcelain balls, the lightweight porcelain balls and a preparation method thereof. Background Art

[0002] Silica fume (also called silica fume or microsilica fume) is a powder material with amorphous silicon dioxide as the main component, obtained by collecting silicon vapor discharged through the flue during the smelting of ferrosilicon or silicon-based materials (including single crystal, polycrystalline, and metallic silicon). It usually appears as a gray or off-white powder with an apparent density of 200-250 kg / m 3 Its main components are SiO2 with a content of 90%-95%, as well as a small amount of iron oxide, aluminum oxide, etc. One of its main characteristics is light weight and large specific surface area. The average particle size is 0.1-0.2μm and the specific surface area is 20-28m 2 / g, which is about 50-100 times that of cement and 50-70 times that of fly ash.

[0003] In the early days, silica fume was disposed of entirely in landfills or spills, with no harmless resource recovery. With the advancement of technology and to reduce environmental pollution, processed silica fume is now widely used in cement production, high-performance concrete, refractory ceramics, and soil improvement. In cement concrete, silica fume, as an ultrafine powder, can fill the gaps between cement particles, increasing the density and strength of cement products. In the refractory industry, silica fume can be used as a silicon source to facilitate the formation of mullite, improving the refractoriness of ceramics.

[0004] However, it is not currently used as a pore-forming agent in lightweight porcelain balls. Therefore, the prior art still needs to be improved and developed. Summary of the Invention

[0005] In view of the above-mentioned deficiencies in the prior art, the purpose of the present invention is to provide the application of silica fume in lightweight porcelain balls, lightweight porcelain balls and their preparation method, aiming to solve the problems of low compressive strength and high water absorption of existing lightweight porcelain balls.

[0006] The technical solutions of the present invention are as follows:

[0007] In a first aspect, the present invention provides the use of silica fume in lightweight porcelain balls, wherein the silica fume is used as a pore-forming agent for closed-pore formation in lightweight porcelain balls.

[0008] In a second aspect, the present invention provides a lightweight porcelain ball comprising a core layer, wherein the core layer is mainly made of a core material composed of the following components: potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica fume, and closed pores with a pore size of 0.01-0.5 mm and a porosity of 40-60% are dispersed in the core layer.

[0009] Optionally, the mass ratio of potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica fume is 10-20 parts: 10-20 parts: 20-30 parts: 10-20 parts: 1-3 parts: 10-20 parts.

[0010] Optionally, the diameter of the core layer is 3-76 mm.

[0011] Optionally, it also includes an enamel layer wrapped around the core layer, and the enamel layer is mainly prepared from the following glazes: potassium feldspar, sodium feldspar, kaolin, fly ash, and methyl cellulose. The mass ratio of potassium feldspar, sodium feldspar, kaolin, fly ash, and methyl cellulose is 10-30 parts: 10-30 parts: 20-30 parts: 10-20 parts: 1-3 parts.

[0012] Optionally, the thickness of the enamel layer is 0.2-1 mm.

[0013] In a third aspect, the present invention provides a method for preparing a lightweight porcelain ball, comprising the following steps:

[0014] Mix the core materials evenly to make a green body of porcelain ball;

[0015] Then, the green ceramic ball is placed in a sintering device and heated to 1100° C.-1200° C. for sintering for 0.5-3 hours, followed by cooling to obtain the lightweight ceramic ball.

[0016] Optionally, before sintering, the green porcelain ball further comprises the following steps: soaking the green porcelain ball in a slurry containing glaze, then fishing it out and drying it.

[0017] Optionally, the slurry is prepared by mixing glaze and water in a mass ratio of 1.1-1.5:1, and the soaking time is 2-5 seconds.

[0018] Optionally, the drying temperature is 90-110° C., and the drying time is 3-4 hours.

[0019] Beneficial Effects: This invention pioneered the use of silica fume in lightweight porcelain balls. The silica fume acts as a pore-forming agent to create closed-cell pores in these balls. Lightweight porcelain balls made with silica fume have low density, high compressive strength, low water absorption, and excellent corrosion resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a physical picture of the lightweight porcelain ball prepared in Example 1 of the present invention.

[0021] Figure 2 This is an SEM image of the lightweight porcelain ball prepared in Example 1 of the present invention.

[0022] Figure 3 This is a SEM image of the cross-section of the lightweight porcelain ball prepared in Example 1 of the present invention after destruction. DETAILED DESCRIPTION

[0023] The present invention provides a pore-forming agent for lightweight porcelain balls, lightweight porcelain balls, and a method for preparing the same. To clarify the objectives, technical solutions, and effects of the present invention, the present invention is described in further detail below. It should be understood that the specific embodiments described herein are intended only to illustrate the present invention and are not intended to limit the present invention.

[0024] The embodiment of the present invention provides the application of silica fume in lightweight porcelain balls, wherein the silica fume is used as a pore-forming agent for closed-pore formation in the lightweight porcelain balls.

[0025] The silica fume can play a good role in closing pores and forming pores in the lightweight porcelain balls.

[0026] In the field of petrochemical industry, porcelain balls are often used as supporting layers and covering layers of catalysts in reactors, which can ensure that the reaction materials pass through the catalyst bed evenly, avoid the phenomenon of channel flow, and improve the reaction efficiency. With the development of technology, it is now urgent to prepare a lightweight porcelain ball with near-zero water absorption. Most of the existing porcelain balls are solid balls with high volume density, which are easy to damage the reactor. Some porcelain balls are hollow, but most of them are open-hole porcelain balls with high water absorption, relatively poor corrosion resistance, and are prone to insufficient strength. For example, CN 210752705U discloses a lightweight porcelain ball with abundant interconnected pores and an pore size of less than 50 microns. Under normal pressure, liquid cannot penetrate into the interior of the porcelain ball, but its compressive strength is only about 50N, which is difficult to meet the actual use requirements. For example, CN115385671B discloses a lightweight ceramic ball and a preparation method thereof. The ceramic ball is a double-shell structure ceramic ball with a dense high-strength enamel layer and a loose porous inner shell layer. Its volume density is still greater than 1.6. Once the outer shell is damaged, the loose inner shell structure is easily eroded. The process is complicated. The three-layer structure is first fired, and then the outer layer structure is cleaned to obtain a double-shell structure ceramic ball. This method wastes a lot of raw materials, is costly, and is difficult to achieve large-scale mass production.

[0027] Therefore, it is urgent to find a lightweight porcelain ball with near-zero water absorption and a preparation method thereof.

[0028] Based on this, an embodiment of the present invention also provides a lightweight porcelain ball, including a core layer, wherein the core layer is mainly made of core materials of the following components: potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica fume, and closed pores with a pore size of 0.01-0.5 mm and a porosity of 40-60% are dispersed in the core layer.

[0029] Silica fume effectively closes and creates pores in lightweight porcelain balls. Lightweight porcelain balls made by combining silica fume with potassium feldspar, sodium feldspar, kaolin, fly ash, and methyl cellulose have dispersed closed pores with pore sizes of 0.01-0.5mm and a porosity of 40-60%. This closed-cell structure maintains high mechanical strength, while the porosity of 40-60% effectively reduces the ball's bulk density.

[0030] In some embodiments, the mass ratio of the potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose, and silica fume is 10-20 parts: 10-20 parts: 20-30 parts: 10-20 parts: 1-3 parts: 10-20 parts, for example, the potassium feldspar: sodium feldspar: kaolin: fly ash: methyl cellulose: silica fume = 15 parts: 20 parts: 30 parts: 19 parts: 1 part: 15 parts; or the potassium feldspar: sodium feldspar: kaolin: fly ash: methyl cellulose: silica fume = 20 parts: 20 parts: 30 parts: 18 parts: 2 parts: 10 parts; or the potassium feldspar: sodium feldspar: kaolin: fly ash: methyl cellulose: silica fume = 18 parts: 20 parts: 30 parts: 15 parts: 1 part: 16 parts.

[0031] The above formula can produce closed-pore, lightweight ceramic balls. If silica fume is missing from the ingredients, lightweight, porous ceramic balls cannot be produced using the other ingredients in the above ratios. Too little silica fume will reduce the pores, while too much will increase the porosity and reduce the overall performance.

[0032] The core layer of the lightweight porcelain ball obtained in this embodiment is composed of a closed, uniform, circular pore structure, which provides good support strength for the lightweight porcelain ball. In addition, the lightweight porcelain ball in this embodiment has good waterproof and anti-corrosion effects.

[0033] In one embodiment, the diameter of the core layer is 3-76 mm, for example, 3 mm, 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 76 mm, etc., but is not limited to the above diameters. The diameter of the core layer can be set as needed and can be large or small.

[0034] In one embodiment, the lightweight porcelain ball comprises a core layer, wherein the core layer is mainly made of core materials of the following components: potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica fume;

[0035] The mass ratio of the potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica fume is 10-20 parts: 10-20 parts: 20-30 parts: 10-20 parts: 1-3 parts: 10-20 parts.

[0036] The invention also includes an enamel layer wrapped around the core layer, and the enamel layer is mainly prepared from the following glaze materials: potassium feldspar, sodium feldspar, kaolin, fly ash, and methyl cellulose. The mass ratio of potassium feldspar, sodium feldspar, kaolin, fly ash, and methyl cellulose is 10-30 parts: 10-30 parts: 20-30 parts: 10-20 parts: 1-3 parts, for example, potassium feldspar: sodium feldspar: kaolin: fly ash: methyl cellulose = 25 parts: 25 parts: 30 parts: 19 parts: 1 part; or 20 parts: 20 parts: 30 parts: 18 parts: 2 parts: 10 parts.

[0037] When used in petrochemical catalyst reactors, the dense enamel layer and closed-pore core layer of the present invention can prevent the solution from penetrating into the interior of the porcelain ball and corroding the porcelain ball, thereby achieving excellent properties of the porcelain ball such as near-zero water absorption, light weight, and high strength.

[0038] The glaze component of the glaze layer of the lightweight porcelain ball of the present invention should be substantially consistent with the core material component of the core layer (except for the silica fume component), otherwise the glaze cannot tightly cover the core layer to form a dense glaze layer during the molding and sintering process.

[0039] Using components within the above ranges, a closed-pore, lightweight ceramic ball with a hard enamel layer on the outer surface can be obtained. This embodiment adds a dense enamel layer to the closed, uniform, circular pore structure, further enhancing its waterproof and corrosion resistance while maintaining its strength, thereby achieving better waterproof and corrosion resistance.

[0040] In some embodiments, the thickness of the enamel layer is 0.2-1 mm, such as 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, but not limited thereto. The thickness of the enamel layer can enhance its waterproofness and corrosion resistance.

[0041] This embodiment also provides a method for preparing a lightweight porcelain ball, comprising the following steps: mixing the core material evenly to form a porcelain ball green body, then placing the green body in a sintering device and heating it to 1100°C-1200°C (for example, 1100°C, 1110°C, 1120°C, 1130°C, 1140°C, 1150°C, 1160°C, 1170°C, 1180°C, 1190°C, 1200°C), sintering it for 0.5-3h (for example, 0.5h, 1h, 1.5h, 2h, 2.5h, 3h), and then cooling it to obtain the lightweight porcelain ball.

[0042] It should be noted that the green porcelain balls are enameled in a ball enameling machine. The specific steps include: uniformly mixing potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose, and silica fume, and then enameling the balls. During the enameling process, the water spraying ratio is controlled to achieve a material-to-water ratio of 0.3-0.4. Since enameling is not a key feature of the present invention, it will not be described in detail here.

[0043] In some embodiments, the heating rate is 5-10°C / min, such as 5°C / min, 6°C / min, 7°C / min, 8°C / min, 9°C / min, and 10°C / min.

[0044] In one embodiment, before sintering, the green porcelain ball further comprises the following steps: soaking the green porcelain ball in a slurry containing the glaze, then fishing it out and drying it.

[0045] In some embodiments, the slurry is formed by mixing glaze and water in a mass ratio of 1.1-1.5:1 (eg, 1.1:1, 1.2:1, 1.3:1, 1.4:1, 1.5:1).

[0046] In some embodiments, the soaking time is 2-5 s (eg, 2 s, 3 s, 4 s, 5 s).

[0047] In some embodiments, the drying temperature is 90-110° C. (eg, 90° C., 95° C., 100° C., 105° C., 110° C.), and the drying time is 3-4 h (eg, 3 h, 3.5 h, 4 h).

[0048] The present invention is further described below with reference to specific embodiments.

[0049] Example 1

[0050] A lightweight porcelain ball includes a core layer, which is mainly prepared from the following components in parts by mass: potassium feldspar: sodium feldspar: kaolin: fly ash: methyl cellulose: silica fume = 15 parts: 20 parts: 30 parts: 19 parts: 1 part: 15 parts.

[0051] The invention also includes a glaze, which is mainly prepared from the following components in parts by mass: potassium feldspar: sodium feldspar: kaolin: fly ash: methyl cellulose = 25 parts: 25 parts: 30 parts: 19 parts: 1 part.

[0052] A method for preparing lightweight porcelain balls comprises uniformly mixing potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose, and silica fume, and then slurrying the mixture in a slurrying machine to obtain green porcelain balls with a particle size of 10 mm. The green porcelain balls are then immersed in a slurry containing the glaze for 3 seconds, removed, and dried at 110°C for 3 hours. The mixture is then placed in a sintering device, heated to 1180°C at a heating rate of 5°C / min, and sintered for 3 hours. The mixture is then cooled to obtain the lightweight porcelain balls.

[0053] The slurry is prepared by mixing glaze and water in a mass ratio of 1.5:1.

[0054] Example 2

[0055] A lightweight porcelain ball comprises a core layer, which is mainly prepared from the following components in parts by mass: potassium feldspar: sodium feldspar: kaolin: fly ash: methyl cellulose: silica fume = 20 parts: 20 parts: 30 parts: 18 parts: 2 parts: 10 parts.

[0056] The invention also includes a glaze, which is mainly prepared from the following components in parts by mass: potassium feldspar: sodium feldspar: kaolin: fly ash: methyl cellulose = 25 parts: 25 parts: 30 parts: 18 parts: 2 parts.

[0057] A method for preparing lightweight porcelain balls comprises uniformly mixing potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose, and silica fume, and then slurrying the mixture in a slurrying machine to obtain green porcelain balls with a particle size of 10 mm. The green porcelain balls are then immersed in a slurry containing the glaze for 4 seconds, removed, and dried at 110°C for 4 hours. The mixture is then placed in a sintering device, heated to 1150°C at a heating rate of 8°C / min, and sintered for 1 hour. The mixture is then cooled to obtain the lightweight porcelain balls.

[0058] The slurry is prepared by mixing glaze and water in a mass ratio of 1.3:1.

[0059] Example 3

[0060] The difference between this embodiment and embodiment 1 is that this embodiment only includes a core layer and does not include glaze.

[0061] The lightweight porcelain ball of this embodiment includes a core layer, which is mainly prepared from the following components in parts by mass: potassium feldspar: sodium feldspar: kaolin: fly ash: methyl cellulose: silica fume = 15 parts: 20 parts: 30 parts: 19 parts: 1 part: 15 parts.

[0062] A method for preparing lightweight porcelain balls comprises: uniformly mixing potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose, and silica fume; and sintering the mixture using a sintering machine to obtain porcelain ball green bodies with a particle size of 10 mm. The mixture is then placed in a sintering device and heated to 1120° C. at a heating rate of 8° C. / min, sintered for 1.5 hours, and then cooled to obtain the lightweight porcelain balls.

[0063] The performance of the lightweight ceramic balls prepared in the above examples was tested, and it was found that they all had near-zero water absorption. The physical properties of the lightweight ceramic balls of each example are shown in Table 1 below.

[0064] Table 1 Comparison of physical properties of various examples

[0065]

[0066] As shown in Table 1, the near-zero water absorption lightweight porcelain balls prepared in the present embodiment have a water absorption rate maintained below 1.0%, achieving near-zero water absorption. Furthermore, the bulk density is less than 1.20 g / cm³, which is half the bulk density of solid porcelain balls. The compressive strength of a single ball is greater than 850 N / ball (HGT 3683.1-2014 Industrial Porcelain Balls, inert porcelain balls, require a compressive strength of ≥850 N / ball for a 10 mm diameter porcelain ball). This is significantly higher than the compressive strength of 50 N of a lightweight porcelain ball disclosed in CN 210752705U.

[0067] Figure 1 This is a physical picture of the lightweight porcelain ball prepared in Example 1 of the present invention. Figure 2 This is an SEM image of the lightweight porcelain ball prepared in Example 1 of the present invention. Figure 3 This is a cross-sectional SEM image of the lightweight porcelain ball obtained in Example 1 of the present invention after destruction. Figure 1-3 As can be seen, the lightweight porcelain balls produced in this embodiment of the present invention have a dense, high-gloss enamel layer on the outside, and a large number of closed, uniform, circular pores dispersed within the balls. The core layer is covered by a dense enamel layer, and the enamel layer and the porous closed-pore structure of the core layer are tightly integrated, effectively preventing solutions from penetrating the interior of the porcelain ball and providing effective strength support.

[0068] In summary, the present invention provides a pore-forming agent for lightweight porcelain balls, lightweight porcelain balls and their preparation method, which is a pioneering discovery of a pore-forming agent for lightweight porcelain balls. The lightweight porcelain balls prepared using the pore-forming agent have low density, high compressive strength, good water resistance and good corrosion resistance.

[0069] It should be understood that the application of the present invention is not limited to the above examples. For those skilled in the art, improvements or changes can be made based on the above description. All these improvements and changes should fall within the scope of protection of the claims attached to the present invention.

Claims

1. The application of silica fume in lightweight porcelain balls is characterized by: The silica fume is used as a pore-forming agent for closed-pore pore formation in lightweight porcelain balls.

2. A lightweight porcelain ball, characterized in that: The core layer comprises a core material mainly made of the following components: potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica fume. Closed pores with a pore size of 0.01-0.5 mm and a porosity of 40-60% are dispersed in the core layer.

3. The lightweight porcelain ball according to claim 2, characterized in that: The mass ratio of the potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica fume is 10-20 parts: 10-20 parts: 20-30 parts: 10-20 parts: 1-3 parts: 10-20 parts.

4. The lightweight porcelain ball according to claim 2, characterized in that: The diameter of the core layer is 3-76 mm.

5. The lightweight porcelain ball according to any one of claims 2 to 4, characterized in that: It also includes an enamel layer wrapped around the core layer, which is mainly prepared from the following glaze materials: potassium feldspar, sodium feldspar, kaolin, fly ash, and methyl cellulose. The mass ratio of potassium feldspar, sodium feldspar, kaolin, fly ash, and methyl cellulose is 10-30 parts: 10-30 parts: 20-30 parts: 10-20 parts: 1-3 parts.

6. The lightweight porcelain ball according to claim 5, characterized in that: The thickness of the enamel layer is 0.2-1 mm.

7. A method for preparing a lightweight porcelain ball, characterized in that: The steps include: Mix the core materials evenly to make a green body of porcelain ball; Then, the green ceramic ball is placed in a sintering device and heated to 1100° C.-1200° C. for sintering for 0.5-3 hours, followed by cooling to obtain the lightweight ceramic ball.

8. The method for preparing a lightweight porcelain ball according to claim 7, characterized in that: Before sintering, the green body of the porcelain ball further comprises the following steps: soaking the green body of the porcelain ball in a slurry containing glaze, then taking it out and drying it.

9. The method for preparing a lightweight porcelain ball according to claim 8, characterized in that: The slurry is prepared by mixing glaze and water in a mass ratio of 1.1-1.5:

1.

10. The method for preparing a lightweight porcelain ball according to claim 8, characterized in that: The drying temperature is 90-110℃ and the drying time is 3-4h.

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