Preparation method of low-temperature sintered ceramic water permeable brick

Abstract

The invention discloses a preparation method of a low-temperature sintered ceramic water permeable brick, which comprises the following steps: step 6, sintering: a brick blank passes through a 100-250 DEG C drying area at a heating speed of 2-5 DEG C / min; then passing through a firing zone of 250-850 DEG C at a heating speed of 5-10 DEG C / min; keeping the temperature for a period of time after the temperature reaches 850 DEG C; and then the temperature is slowly reduced to 300 DEG C at the cooling speed of 1 DEG C / min-5 DEG C / min, and natural cooling is carried out at the temperature of 300 DEG C or below. According to the invention, the sintering process is simple, the sintering temperature of the green brick is reduced from 1180-1250 DEG C to 850 DEG C or below, on the premise of ensuring that various physical properties of the product are not changed, the energy consumption is greatly reduced, the effective energy consumption can be reduced by 40-60%, the energy is saved, the sintering time is shortened, the cooling time is shortened, the production efficiency is improved, and batch production is facilitated.

Description

Technical Field

[0001] This invention relates to the field of permeable brick technology, and specifically to a method for preparing low-temperature sintered ceramic permeable bricks. Background Technology

[0002] Sintered permeable ceramic bricks have the following advantages: 1. Excellent permeability: Through their porous internal structure, rainwater quickly permeates, replenishing groundwater, alleviating urban flooding and the "heat island effect," and promoting water circulation. 2. High strength and durability: Made primarily from solid waste bricks and substandard bricks produced in ceramic factories, these bricks are fired to achieve high compressive and flexural strength, good wear resistance and frost resistance, and a long service life, suitable for various applications such as driveways and sidewalks. 3. Outstanding environmental performance: The raw materials are mainly industrial solid waste (such as ceramic slag, broken ceramic bricks, and substandard bricks), achieving resource reuse; the surface does not easily accumulate dust, and water does not easily accumulate after rain, reducing road dust and bacterial growth. 4. Good decorative properties: Rich colors and textures (various imitation granite and natural stone textures can be produced), and different specifications can be combined to create designs that combine functionality and aesthetics. 5. Easy maintenance: The pores are not easily clogged; even if minor blockage occurs, permeability can be restored through simple methods such as high-pressure water washing, resulting in low maintenance costs.

[0003] However, the sintering process of permeable ceramic bricks currently on the market mainly involves high-temperature sintering at 1180℃~1250℃, which results in a long sintering time, high energy consumption, and a long cooling time, making it unsuitable for mass production.

[0004] Therefore, in order to avoid the shortcomings of the existing technology, it is necessary to improve the existing technology. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings and deficiencies of the prior art and provide a method for preparing low-temperature sintered permeable ceramic bricks that reduces energy consumption and increases production efficiency.

[0006] This invention is achieved through the following technical solution: A method for preparing low-temperature sintered permeable ceramic bricks includes the following steps: Step 1: Crush the broken ceramic bricks into ceramic particles of different mesh sizes; Step 2: Weigh and mix ceramic particles of different mesh sizes according to the specified proportions; Step 3: Add water, stir well, then add auxiliary materials and stir well to obtain a mixture; Step 4: Place the well-stirred mixture into a storage silo for aging and homogenization; Step 5: Feed the mixture into a hydraulic press for high-pressure molding to form brick blanks; Step Six: Sintering. The brick blanks are passed through a drying zone at a heating rate of 2°C / min to 5°C / min, and then through a firing zone at a heating rate of 5°C / min to 10°C / min, and held at 850°C for a period of time. Then, the temperature is slowly reduced to 300°C at a cooling rate of 1°C / min to 5°C / min, and allowed to cool naturally below 300°C. Step 7: Sorting and packaging yields the finished product.

[0007] Furthermore, in step one, the broken ceramic bricks are crushed into ceramic particles of four mesh sizes: 5-10 mesh, 10-20 mesh, 20-40 mesh, and 40-120 mesh.

[0008] Furthermore, in step three, the auxiliary materials include bentonite, borosilicate, glass powder, sodium silicate, methylcellulose, potassium feldspar powder, sodium feldspar powder, iron oxide pigment, glass fiber, silicon dioxide, and aluminum oxide.

[0009] Furthermore, in step four, the aging and homogenization time is 50 to 70 minutes.

[0010] Furthermore, in step five, a 1500-ton hydraulic press is used for high-pressure molding.

[0011] Furthermore, in step six, the brick blanks are dried in the drying zone for 1 to 3 hours.

[0012] Furthermore, in step six, the brick blanks are fired in the firing zone for 1 to 3 hours.

[0013] Furthermore, in step six, the heat preservation time is 60 to 90 minutes.

[0014] Compared to existing technologies, this invention controls the heating rate in the drying zone, the heating rate in the firing zone, the holding temperature of the brick blank, the cooling rate of the brick blank, and the natural cooling temperature during the brick blank sintering process. This reduces the sintering temperature of the brick blank from 1180℃~1250℃ to below 850℃. While ensuring that the physical properties of the product remain unchanged, it significantly reduces energy consumption, with an effective energy consumption reduction of 40% to 60%. This saves energy, shortens the sintering time and cooling time, improves production efficiency, and facilitates mass production. Detailed Implementation

[0015] The technical solutions in the embodiments of the present invention will be clearly and completely described below. 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 skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] A method for preparing low-temperature sintered permeable ceramic bricks includes the following steps: Step 1: Crush the broken ceramic bricks into ceramic particles of different mesh sizes; Step 2: Weigh and mix ceramic particles of different mesh sizes according to the specified proportions; Step 3: Add water, stir well, then add auxiliary materials and stir well to obtain a mixture; Step 4: Place the well-stirred mixture into a storage silo for aging and homogenization; Step 5: Feed the mixture into a hydraulic press for high-pressure molding to form brick blanks; Step Six: Sintering. The brick blanks are passed through a drying zone at a heating rate of 2°C / min to 5°C / min, and then through a firing zone at a heating rate of 5°C / min to 10°C / min, and held at 850°C for a period of time. Then, the temperature is slowly reduced to 300°C at a cooling rate of 1°C / min to 5°C / min, and allowed to cool naturally below 300°C. Step 7: Sorting and packaging yields the finished product.

[0017] In step one, the broken ceramic bricks are crushed into ceramic particles of four mesh sizes: 5-10 mesh, 10-20 mesh, 20-40 mesh, and 40-120 mesh. The ceramic particles are easy to mix evenly and can be fully mixed and reacted with other raw materials, thereby improving the structural strength of the sintered permeable ceramic bricks.

[0018] The auxiliary materials include bentonite, borosilicate, glass powder, sodium silicate, methylcellulose, potassium feldspar powder, sodium feldspar powder, iron oxide pigment, glass fiber, silicon dioxide and aluminum oxide, which make the structure of sintered ceramic permeable bricks more stable.

[0019] In step four, the aging and homogenization time is 50 to 70 minutes, which allows the raw materials to be fully mixed and reacted, ensuring the stability of subsequent sintering.

[0020] In step five, a 1500-ton hydraulic press is used for high-pressure molding, resulting in a denser and more stable brick blank, which leads to more stable subsequent sintering.

[0021] In step six, the brick blanks are dried in the drying zone for 1 to 3 hours to fully remove moisture and reduce deformation.

[0022] In step six, the brick blanks are fired in the firing zone for 1 to 3 hours, allowing for a slow and thorough sintering process and a full reaction, thus improving sintering stability.

[0023] In step six, the heat preservation time is 60 to 90 minutes to sinter and stabilize the brick blank, ensuring the various physical properties of the product and improving structural stability.

[0024] Compared to existing technologies, this invention controls the heating rate in the drying zone, the heating rate in the firing zone, the holding temperature of the brick blank, the cooling rate of the brick blank, and the natural cooling temperature during the brick blank sintering process. This reduces the sintering temperature of the brick blank from 1180℃~1250℃ to below 850℃. While ensuring that the physical properties of the product remain unchanged, it significantly reduces energy consumption, with an effective energy consumption reduction of 40% to 60%. This saves energy, shortens the sintering time and cooling time, improves production efficiency, and facilitates mass production.

[0025] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing low-temperature sintered permeable ceramic bricks, characterized in that: Includes the following steps: Step 1: Crush the broken ceramic bricks into ceramic particles of different mesh sizes; Step 2: Weigh and mix ceramic particles of different mesh sizes according to the specified proportions; Step 3: Add water, stir well, then add auxiliary materials and stir well to obtain a mixture; Step 4: Place the well-stirred mixture into a storage silo for aging and homogenization; Step 5: Feed the mixture into a hydraulic press for high-pressure molding to form brick blanks; Step Six: Sintering. The brick blanks are passed through a drying zone at a heating rate of 2°C / min to 5°C / min, and then through a firing zone at a heating rate of 5°C / min to 10°C / min, and held at 850°C for a period of time. Then, the temperature is slowly reduced to 300°C at a cooling rate of 1°C / min to 5°C / min, and allowed to cool naturally below 300°C. Step 7: Sorting and packaging yields the finished product.

2. The method for preparing low-temperature sintered permeable ceramic bricks according to claim 1, characterized in that: In step one, the broken ceramic bricks are crushed into ceramic particles of four mesh sizes: 5-10 mesh, 10-20 mesh, 20-40 mesh, and 40-120 mesh.

3. The method for preparing low-temperature sintered permeable ceramic bricks according to claim 1, characterized in that: In step three, the auxiliary materials include bentonite, borosilicate, glass powder, sodium silicate, methylcellulose, potassium feldspar powder, sodium feldspar powder, iron oxide pigment, glass fiber, silicon dioxide, and aluminum oxide.

4. The method for preparing low-temperature sintered permeable ceramic bricks according to claim 1, characterized in that: In step four, the aging and homogenization time is 50 to 70 minutes.

5. The method for preparing low-temperature sintered permeable ceramic bricks according to claim 1, characterized in that: In step five, a 1500-ton hydraulic press is used for high-pressure molding.

6. The method for preparing low-temperature sintered permeable ceramic bricks according to claim 1, characterized in that: In step six, the brick blanks are dried in the drying zone for 1 to 3 hours.

7. The method for preparing low-temperature sintered permeable ceramic bricks according to claim 1, characterized in that: In step six, the brick blanks are fired in the firing zone for 1 to 3 hours.

8. The method for preparing low-temperature sintered permeable ceramic bricks according to claim 1, characterized in that: In step six, the heat preservation time is 60 to 90 minutes.