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

Abstract

The application discloses application of silica ash in light ceramic balls, the light ceramic balls and a preparation method thereof, and relates to the technical field of smelting solid waste treatment. The application discloses application of silica ash in light ceramic balls, wherein the silica ash is used as a pore-forming agent for closed pore forming of the light ceramic balls. A light ceramic ball comprises a core layer which is mainly made of core material of the following components: potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica ash, and the core layer is dispersed with closed pores with a pore size of 0.01-0.5 mm and a porosity of 40-60%. The application discloses application of silica ash in light ceramic balls, wherein the silica ash is used as a pore-forming agent for closed pore forming of the light ceramic balls. The light ceramic ball prepared by using the silica ash has the advantages of low density, high compressive strength, low water absorption and good corrosion resistance.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of smelting solid waste treatment, in particular to application of silica ash in light ceramic ball, light ceramic ball and preparation method thereof. BACKGROUND

[0002] Silica ash (also called silica powder or microsilica) is a powder material with amorphous silica as the main component, which is obtained by collecting the silicon vapor discharged through the flue during the smelting of ferrosilicon or silicon-based materials (including single crystal, polycrystal, metallic silicon). The appearance is usually gray or off-white powder, and the apparent density is 200-250 kg / m 3 The main components are SiO2 with a content of 90%-95%, and a small amount of iron oxide and aluminum oxide, and one of the main characteristics is light weight and large specific surface area, with an average particle size of 0.1-0.2 μm and a specific surface area of 20-28 m 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 ash was disposed of by landfill or scattering, and no resource and harmless treatment was realized. With the development of science and technology, in order to reduce environmental pollution, the processed silica ash has been widely used in cement production, high-performance concrete and refractory ceramics, soil improvement and other aspects. In the field of cement and concrete, silica ash can be filled in the gap between cement particles to improve the density and strength of cement products; in the field of refractory materials, silica ash can be used as a silicon source to facilitate the formation of mullite and improve the refractoriness of ceramics.

[0004] However, it has not been used in light ceramic ball as a pore-forming agent. Therefore, the prior art still needs to be improved and developed. SUMMARY

[0005] In view of the shortcomings of the prior art, the purpose of the present application is to provide application of silica ash in light ceramic ball, light ceramic ball and preparation method thereof, aiming to solve the problems of low compressive strength and high water absorption of existing light ceramic ball.

[0006] The technical scheme of the present application is as follows:

[0007] In a first aspect of the present application, the application of silica ash in light ceramic ball is provided, and the silica ash is used as a pore-forming agent for closed pore-forming of light ceramic ball.

[0008] In a second aspect of the present application, a light ceramic ball is provided, which comprises a core layer made of core material mainly composed of potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica ash, and the core layer is dispersed with closed pores with a pore size of 0.01-0.5 mm and a porosity of 40-60%.

[0009] Optionally, the mass ratio of the potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica ash 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, the enamel layer is further wrapped outside the core layer, and the enamel layer is mainly prepared from the following enamel materials: potassium feldspar, sodium feldspar, kaolin, fly ash, and methyl cellulose, and the mass ratio of the 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 application provides a preparation method of the light ceramic ball, which comprises the following steps:

[0014] Mixing the core material uniformly to prepare a ceramic ball green body;

[0015] Then, the ceramic ball green body is placed into a sintering device and heated to 1100-1200 DEG C for 0.5-3 h, and then cooled to obtain the light ceramic ball.

[0016] Optionally, before sintering, the ceramic ball green body further comprises the following steps: soaking the ceramic ball green body in a slurry containing the enamel material, and then taking out and drying.

[0017] Optionally, the slurry is mixed from the enamel material and water according to a mass ratio of 1.1-1.5:1, and the soaking time is 2-5 s.

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

[0019] Beneficial effects: The application initiatively finds the application of silica ash in the light ceramic ball, and the silica ash is used as a pore-forming agent for the closed pore-forming of the light ceramic ball. The light ceramic ball prepared from the silica ash has low density, high compressive strength, low water absorption and good corrosion resistance. BRIEF DESCRIPTION OF DRAWINGS

[0020] Fig. 1 It is a physical picture of the light ceramic ball prepared in Example 1 of the application.

[0021] Fig. 2 It is an SEM picture of the light ceramic ball prepared in Example 1 of the application.

[0022] Fig. 3 It is an SEM picture of the cross section of the light ceramic ball prepared in Example 1 of the application after damage. DETAILED DESCRIPTION

[0023] The present application provides a pore-forming agent for light ceramic balls, light ceramic balls and a preparation method thereof. To make the purpose, technical scheme and effects of the present application clearer and more explicit, the present application is further described in detail below. It should be understood that the specific examples described herein are only used to explain the present application and do not limit the present application.

[0024] The present application provides the application of silica ash in light ceramic balls, and the silica ash is used as a pore-forming agent for closed pore-forming of light ceramic balls.

[0025] The silica ash can play a good closed pore-forming role in light ceramic balls.

[0026] Ceramic balls are often used as a support layer and a cover layer of catalysts in reactors in the field of petrochemical industry, which can ensure that reactants pass through the catalyst bed uniformly and avoid phenomena such as channeling, thereby improving the reaction efficiency. With the development of technology, there is an urgent need to prepare light ceramic balls with near-zero water absorption. Existing ceramic balls are mostly solid balls with high bulk density, which are easy to break the reactor. Some ceramic balls are hollow, but most of them are open-pored ceramic balls with high water absorption and relatively poor corrosion resistance, and are prone to insufficient strength. For example, CN210752705U discloses a light ceramic ball, which has a large number of connected pores with a pore size of less than 50 microns, and liquid cannot penetrate into the interior of the ceramic ball under normal pressure, but the compressive strength thereof is only about 50 N, which is difficult to meet the actual requirements. CN115385671B discloses a light ceramic ball and a preparation method thereof. The ceramic ball is a double-shell structure ceramic ball with a dense and high-strength glaze layer and a loose and porous inner shell layer. The bulk density thereof is still greater than 1.6. Once the outer shell is damaged, the loose inner shell structure is easily eroded. The process is complex, the three-layer structure is first fired, and then the outer structure is cleaned to obtain a double-shell structure ceramic ball. This method has large raw material waste and high cost, and is difficult to realize large-scale production.

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

[0028] Based on this, the present application further provides a light ceramic ball, which comprises a core layer made of core material mainly composed of potassium feldspar, sodium feldspar, kaolin, fly ash, methyl cellulose and silica ash. The core layer is dispersed with closed pores with a pore size of 0.01-0.5 mm and a porosity of 40-60%.

[0029] The silica ash can play a good closed pore forming effect in the light ceramic ball. The light ceramic ball prepared by the silica ash, the potash feldspar, the soda feldspar, the kaolin, the fly ash and the methyl cellulose has the closed pores with the pore size of 0.01-0.5mm and the porosity of 40-60%. The closed pore structure with the pore size of 0.01-0.5mm can make the ceramic ball maintain the high mechanical strength, and the porosity of 40-60% can effectively reduce the bulk density of the ceramic ball.

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

[0031] The light ceramic ball with the closed pores can be obtained by using the above-mentioned formula. If the silica ash is not included in the formula, the light porous ceramic ball cannot be prepared by using the other components in the above-mentioned formula. If the amount of the silica ash is too small, the pore size will be small, and if the amount of the silica ash is too large, the porosity will be high, and the comprehensive performance will be poor.

[0032] The core layer of the light ceramic ball obtained in the embodiment is composed of the closed, uniform and circular pore structure, which can provide good support strength for the light ceramic ball, and the light ceramic ball has good waterproof and corrosion resistance.

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

[0034] In one embodiment, the light ceramic ball comprises a core layer, and the core layer is mainly made of the core material of the following components: the potash feldspar, the soda feldspar, the kaolin, the fly ash, the methyl cellulose and the silica ash.

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

[0036] The enamel layer is prepared from the following enamel materials: potassium feldspar, sodium feldspar, kaolin, fly ash and methyl cellulose, and the mass ratio of the 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 applied to a petroleum chemical catalyst reactor, the dense enamel layer and the closed-pore structure core layer of the present application can both hinder the penetration of the solution into the inside of the porcelain ball to corrode the porcelain ball, thereby realizing the excellent properties of the porcelain ball, such as near-zero water absorption, light weight, high strength and the like.

[0038] The enamel material components of the enamel layer of the light-weight porcelain ball and the core material components (except the silica ash component) of the core layer should be substantially consistent, otherwise the enamel cannot tightly cover the core layer to form a dense enamel layer during the forming and sintering processes.

[0039] The components within the above range can all be used to obtain the closed-pore light-weight porcelain ball with a hard enamel layer wrapped on the outer surface. The embodiment adds a dense-structure enamel layer to the closed, uniform and circular pore structure, further enhances the waterproofness and corrosion resistance of the porcelain ball on the premise of ensuring the strength, so that the waterproofness and corrosion resistance of the porcelain ball are better.

[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 or 1 mm, but is not limited thereto. The thickness of the above enamel layer can all achieve the effect of enhancing the waterproofness and corrosion resistance of the porcelain ball.

[0041] The embodiment also provides a preparation method of the light-weight porcelain ball, which comprises the following steps: uniformly mixing the core material to prepare a porcelain ball green body, and then placing the porcelain ball green body into a sintering device to be sintered at 1100-1200 DEG C (such as 1100 DEG C, 1110 DEG C, 1120 DEG C, 1130 DEG C, 1140 DEG C, 1150 DEG C, 1160 DEG C, 1170 DEG C, 1180 DEG C, 1190 DEG C or 1200 DEG C) for 0.5-3 h (such as 0.5 h, 1 h, 1.5 h, 2 h, 2.5 h or 3 h), and then cooling to obtain the light-weight porcelain ball.

[0042] It should be noted that the porcelain ball green body is prepared by a balling machine, and the specific steps include: uniformly mixing potash feldspar, soda feldspar, kaolin, fly ash, methyl cellulose and silica ash, and then balling; the water spraying ratio is controlled during balling, and the water spraying ratio is 0.3-0.4. Since balling is not the protection point of the present application, it will not be described here.

[0043] In some embodiments, the temperature increase rate is 5-10℃ / min, such as 5℃ / min, 6℃ / min, 7℃ / min, 8℃ / min, 9℃ / min, 10℃ / min.

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

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

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

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

[0048] The present application is further described below in conjunction with specific examples.

[0049] Example 1

[0050] A light porcelain ball comprises a core layer, which is mainly prepared from components in the following mass fractions: potash feldspar: soda feldspar: kaolin: fly ash: methyl cellulose: silica ash = 15 parts: 20 parts: 30 parts: 19 parts: 1 part: 15 parts.

[0051] Further comprising a glaze, which is mainly prepared from components in the following mass fractions: potash feldspar: soda feldspar: kaolin: fly ash: methyl cellulose = 25 parts: 25 parts: 30 parts: 19 parts: 1 part.

[0052] A method for preparing a light ceramic ball, wherein potash feldspar, soda feldspar, kaolin, fly ash, methyl cellulose and silica ash are mixed uniformly, and then the mixture is put into a balling machine to obtain green ceramic balls with a particle size of 10 mm; the green ceramic balls are soaked in a slurry containing a glaze for 3 s, and then taken out and dried at a drying temperature of 110 ℃ for 3 h; then the green ceramic balls are put into a sintering device and sintered at a temperature of 1180 ℃ for 3 h with a temperature rising rate of 5 ℃ / min, and then cooled to obtain the light ceramic ball.

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

[0054] Example 2

[0055] A light ceramic ball comprises a core layer, which is prepared from the following components in a mass ratio of potash feldspar: soda feldspar: kaolin: fly ash: methyl cellulose: silica ash = 20 parts: 20 parts: 30 parts: 18 parts: 2 parts: 10 parts.

[0056] The light ceramic ball further comprises a glaze, which is prepared from the following components in a mass ratio of potash feldspar: soda feldspar: kaolin: fly ash: methyl cellulose = 25 parts: 25 parts: 30 parts: 18 parts: 2 parts.

[0057] A method for preparing a light ceramic ball, wherein potash feldspar, soda feldspar, kaolin, fly ash, methyl cellulose and silica ash are mixed uniformly, and then the mixture is put into a balling machine to obtain green ceramic balls with a particle size of 10 mm; the green ceramic balls are soaked in a slurry containing a glaze for 4 s, and then taken out and dried at a drying temperature of 110 ℃ for 4 h; then the green ceramic balls are put into a sintering device and sintered at a temperature of 1150 ℃ for 1 h with a temperature rising rate of 8 ℃ / min, and then cooled to obtain the light ceramic ball.

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

[0059] Example 3

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

[0061] The light ceramic ball of this embodiment comprises a core layer, which is prepared from the following components in a mass ratio of potash feldspar: soda feldspar: kaolin: fly ash: methyl cellulose: silica ash = 15 parts: 20 parts: 30 parts: 19 parts: 1 part: 15 parts.

[0062] A preparation method of light ceramic ball, wherein potash feldspar, soda feldspar, kaolin, fly ash, methyl cellulose and silica ash are uniformly mixed, and then the mixture is put into a balling machine to obtain green ceramic balls with a particle size of 10 mm, and then the green ceramic balls are put into a sintering device to be sintered at 1120 DEG C for 1.5 h at a heating rate of 8 DEG C / min, and then the light ceramic ball is obtained after cooling.

[0063] The light ceramic balls prepared in the above examples are detected for performance, and it is found that they all have a near-zero water absorption rate, and the physical properties of the light ceramic balls of each example are shown in Table 1.

[0064] Table 1 Comparison of physical properties of each example

[0065]

[0066] As shown in Table 1, the light ceramic ball prepared in the examples has a water absorption rate of less than 1.0%, achieving the effect of near-zero water absorption rate, and the bulk density is less than 1.20 g / cm3, which is half of the bulk density of the solid ceramic ball, and the single-ball compressive strength is more than 850 N / ball (HGT 3683.1-2014 Industrial Ceramic Ball Inert Ceramic Ball requires that the single-ball compressive strength of the ceramic ball with a diameter of 10 mm is greater than or equal to 850 N / ball), which is much higher than the compressive strength (50 N) of the light ceramic ball disclosed in CN 210752705U.

[0067] Fig. 1 It is a real object diagram of the light ceramic ball prepared in Example 1 of the present application. Fig. 2 It is a SEM diagram of the light ceramic ball prepared in Example 1 of the present application. Fig. 3 It is a SEM diagram of the cross section of the light ceramic ball prepared in Example 1 of the present application after being broken. Figs. 1-3 As can be seen, the light ceramic ball prepared in the examples has a dense glaze layer outside, high gloss, and a large number of closed, uniform and circular pore structure closed pores are dispersed in the inside of the ceramic ball. The core layer is covered by a dense glaze layer, and the glaze layer and the porous closed pore structure of the core layer of the ceramic ball are closely combined, which can effectively prevent the solution from penetrating into the inside of the ceramic ball, and can provide effective strength support for the ceramic ball.

[0068] In summary, the pore-forming agent for light ceramic ball, light ceramic ball and preparation method thereof provided by the present application, which has found a pore-forming agent for light ceramic ball, and the light ceramic ball prepared by using the pore-forming agent has low density, high compressive strength, good waterproofness and good corrosion resistance.

[0069] It should be understood that the application of the present application is not limited to the above examples, and those skilled in the art can make improvements or changes according to the above description, and all these improvements and changes shall belong to the protection scope of the appended claims of the present application.

Claims

1. The application of silica fume in lightweight ceramic balls, characterized in that, The silica fume is used as a pore-forming agent for creating closed-cell pores in lightweight ceramic balls. The lightweight ceramic ball includes a core layer and a glaze layer surrounding the core layer. The core layer is mainly made of potassium feldspar, sodium feldspar, kaolin, fly ash, methylcellulose and silica fume in a mass ratio of 10-20 parts: 10-20 parts: 20-30 parts: 10-20 parts: 1-3 parts: 10-20 parts. The core layer contains closed pores with a pore size of 0.01-0.5 mm and a porosity of 40-60%. The glaze layer is mainly prepared from the following glaze materials: potassium feldspar, sodium feldspar, kaolin, fly ash, and methylcellulose. The mass ratio of potassium feldspar, sodium feldspar, kaolin, fly ash, and methylcellulose is 10-30 parts: 10-30 parts: 20-30 parts: 10-20 parts: 1-3 parts.

2. The application of silica fume in lightweight ceramic balls according to claim 1, characterized in that, The diameter of the core layer is 3-76 mm.

3. The application of silica fume in lightweight ceramic balls according to claim 1, characterized in that, The thickness of the enamel layer is 0.2-1 mm.

4. The application of silica fume in lightweight ceramic balls according to claim 1, characterized in that, The lightweight ceramic spheres are prepared by the following method: The core material is mixed evenly to form a porcelain ball blank; then the porcelain ball blank is immersed in a glaze-containing slurry, and then taken out and dried; The ceramic ball blanks are then placed in a sintering apparatus and sintered at 1100℃-1200℃ for 0.5-3 hours, followed by cooling.

5. The application of silica fume in lightweight ceramic balls according to claim 4, characterized in that, The slurry is made by mixing glaze and water in a mass ratio of 1.1-1.5:

1.

6. The application of silica fume in lightweight ceramic balls according to claim 4, characterized in that, The drying temperature is 90-110℃, and the drying time is 3-4 hours.

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