Porous non-fired artificial stone and method for producing the same

Abstract

The present application belongs to the field of solid waste resource utilization and green building material technology, and particularly relates to a porous non-burned artificial stone and a preparation method thereof. The method uses glass plant dust, glass kiln ash and multi-component waste glass as an alkaline excitation source, ceramic glaze waste residue as a silicon-aluminum skeleton source, and aluminum ash as a self-foaming agent. After pretreatment, the raw materials are mixed and watered into a slurry without adding NaOH and Na2SiO3. The alkali excitation of the ceramic waste residue is realized by using the glass solid waste, the polycondensation of the ceramic waste residue is formed into a gel, hydrogen gas is released by the reaction of the aluminum ash to realize in-situ foaming of the slurry, and the product is formed by wet heat curing and natural curing. The obtained product has a porosity of 10% to 45%, a dry density of 0.85 to 1.60 g / cm3, and high compressive strength, realizing low-energy consumption and high-value utilization of multiple types of solid waste.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of solid waste resource utilization and green building materials, and particularly relates to a porous non-burned artificial stone and a preparation method thereof. BACKGROUND

[0002] The glass, ceramic and metallurgical industries continuously generate a large amount of solid waste, such as glass plant dust, glass kiln ash, multi-component waste glass, ceramic glaze waste residue and aluminum ash. These solid wastes are difficult to dispose due to their complex composition: glass-based solid waste is strongly alkaline and can cause leachate pollution; waste glass containing harmful impurities has low recycling value; ceramic glaze waste residue is often abandoned; and aluminum ash contains metal aluminum and chloride salts, and improper disposal poses a safety risk. Current resource utilization approaches are limited, and most of them are mainly stored or filled at low value, which not only occupies land but also causes environmental hazards.

[0003] Traditional artificial stone or ceramic tiles mainly rely on high-temperature sintering process, which has high energy consumption and carbon emissions; resin-based artificial stone has problems such as organic volatilization and poor weather resistance. Alkali-activated cementitious materials can utilize solid waste to prepare building materials at room temperature, but they generally rely on additional strong alkali (such as NaOH and Na2SiO3) as an activator, which increases the cost, energy consumption and operation corrosion risk. In addition, in order to obtain a lightweight and porous structure, chemical foaming agents are usually added, which has problems such as uncontrollable pore structure, increased cost and chemical consumption.

[0004] Therefore, there is an urgent need to develop a new green building material technology that can synergistically and efficiently utilize multiple types of industrial solid waste without the need for additional strong alkali activators and chemical foaming agents, and can be prepared with low energy consumption. SUMMARY

[0005] The purpose of the embodiments of the present application is to provide a porous non-burned artificial stone and a preparation method thereof, which solves the disposal problem of multiple types of solid waste such as glass plant dust, waste glass, ceramic glaze waste residue and aluminum ash, improves the utilization rate and added value of solid waste, and realizes the unification of energy saving, emission reduction and green building material development, has significant technical progress and good industrialization promotion prospects, thereby solving at least one technical problem involved in the background art.

[0006] In order to solve the above technical problems, the present application is implemented as follows:

[0007] The embodiments of the present application provide a preparation method of a porous non-burned artificial stone, comprising the following steps:

[0008] Raw material pretreatment: drying and sieving the glass plant dust and / or glass kiln ash; grinding the multi-component waste glass; drying and grinding the ceramic glaze waste residue; drying, impurity removal and surface slow-release treatment of the aluminum ash;

[0009] Mixing and slurry preparation: the pretreated ceramic glaze waste residue, glass plant dust and / or glass kiln dust, multi-component waste glass and surface slow-release treated aluminum ash are mixed to obtain a mixed powder, wherein the ceramic glaze waste residue accounts for 40% to 70% of the total mass of the mixed powder, the glass plant dust and / or glass kiln dust accounts for 10% to 30% of the total mass of the mixed powder, the multi-component waste glass accounts for 10% to 35% of the total mass of the mixed powder, and the mass of metallic aluminum in the aluminum ash accounts for 0.10% to 1.20% of the total mass of the mixed powder; then, mixing water is added to control the water-binder ratio to 0.28 to 0.40, and the slurry is formed by stirring without additional NaOH or Na2SiO3;

[0010] Foaming and solidification: the slurry is poured into a mold, and the slurry is foamed in situ under the action of aluminum ash reacting with water to release hydrogen gas, and the alkaline oxides dissolved and released by the glass solid waste stimulate the ceramic glaze waste residue to generate a gel product through polycondensation reaction;

[0011] Curing: after the foamed slurry is cured under the condition of 30℃ to 70℃ and relative humidity ≥ 90%, the slurry is demolded and naturally cured to obtain a porous unburned artificial stone.

[0012] Optionally, in the step of pretreatment of raw materials:

[0013] The glass plant dust and / or glass kiln dust is dried at 105℃±5℃ and sieved through a 200-mesh screen;

[0014] The multi-component waste glass is ground to a median particle size D50 of 10 to 35μm;

[0015] The ceramic glaze waste residue is ground to a median particle size D50 of 5 to 25μm.

[0016] Optionally, the surface slow-release treatment of the aluminum ash is surface coating with mineral oil, paraffin emulsion or stearate, and the coating amount is 1% to 3% of the mass of the aluminum ash.

[0017] Optionally, the pouring volume of the slurry is 80% to 95% of the volume of the mold cavity, and a limiting cover plate is arranged on the top of the mold, and a gas permeable hole is formed in the limiting cover plate.

[0018] Optionally, the wet heat curing includes:

[0019] Initial curing: temperature 30℃ to 45℃, relative humidity ≥ 95%, curing for 2 to 4 hours;

[0020] Intensive curing: temperature 50℃ to 70℃, relative humidity ≥ 90%, curing for 8 to 24 hours.

[0021] Optionally, the temperature during demolding is controlled below 35 DEG C; after demolding, the product is continuously cured at normal temperature for at least 7 days.

[0022] The application further provides a porous unfired artificial stone prepared by the method, the porous unfired artificial stone having a porosity of 10% to 45%, a dry density of 0.85 to 1.60 g / cm3, and a 7-day compressive strength of 10 to 25 MPa.

[0023] Optionally, the porous unfired artificial stone has a water absorption of less than or equal to 12%, and a mass loss rate of less than or equal to 1.5% after 25 freeze-thaw cycles.

[0024] Optionally, the surface of the porous unfired artificial stone is polished by stepwise grinding with a 200-mesh to 1500-mesh grinding wheel.

[0025] Optionally, the surface layer of the porous unfired artificial stone is embedded with pre-embedded colored waste glass particles or ceramic chips to form decorative textures.

[0026] Compared with the prior art, the application has the following beneficial effects:

[0027] (1) Source cost reduction and efficiency improvement, green and safe: the alkali oxides (such as Na2O, K2O and CaO) in the glass plant dust, kiln dust and multi-component waste glass are used as built-in alkali sources to successfully activate the silicon-aluminum activity of the ceramic glaze waste, without the need for additional addition of external strong alkali activators such as NaOH and Na2SiO3. This significantly reduces the cost of raw materials, and completely avoids the corrosion risk and safety hazards in the storage and use of strong alkali, achieving green and collaborative disposal of waste.

[0028] (2) Self-foaming and structure controllable: the property of the metal aluminum in the aluminum ash to release hydrogen gas under alkaline conditions is creatively utilized to realize in-situ self-foaming of the slurry. This method does not need to introduce chemical foaming agents such as hydrogen peroxide and aluminum powder slurry, not only simplifying the process flow and reducing the cost, but also producing fine and uniform bubbles, and the pore wall is more dense under the synchronous solidification of the gelation reaction, thereby obtaining a lightweight porous structure with stable structure and controllable pore size distribution.

[0029] (3) Low-temperature forming, energy saving and environmental protection: the gelation reaction and structure setting in the whole preparation process are completed under the conditions of 30 DEG C to 70 DEG C and humid heat curing, without the high-temperature sintering process of traditional ceramics or sintered bricks, greatly reducing the energy consumption and carbon dioxide emissions, and meeting the development direction of low-carbon building materials.

[0030] (4) The product has excellent performance and wide application: through the coordination of solid waste and process control, the porosity of the artificial stone material prepared can be controlled in the range of 10% to 45%, the dry density is 0.85 to 1.60 g / cm3, the 7-day compressive strength reaches 10 to 25 MPa, and the product has low water absorption (less than or equal to 12%) and good freeze-thaw resistance (the mass loss is less than or equal to 1.5% after 25 cycles). The product has the properties of light weight, high strength and good thermal insulation performance, and the surface can be polished and modified or formed with decorative texture, and can be used as decorative board, light weight thermal insulation brick, wall block and other green building materials.

[0031] In summary, the present application not only solves the disposal problems of multiple types of solid waste such as glass plant dust, waste glass, ceramic glaze waste residue and aluminum ash, but also improves the utilization rate and added value of solid waste, realizes the unification of energy saving, emission reduction and green building material development, and has significant technical progress and good industrialization promotion prospects. BRIEF DESCRIPTION OF DRAWINGS

[0032] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0033] Figure 1 The flow chart of the preparation method of the porous unfired artificial stone material provided by the present application. DETAILED DESCRIPTION

[0034] The technical solutions in the embodiments of the present application will be described clearly and completely in combination with the drawings of the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0035] The terms "first", "second" and the like in the specification of the present application are used to distinguish similar objects, and are not used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged under appropriate circumstances, so that the embodiments of the present application can be implemented in an order other than those illustrated or described herein, and the objects distinguished by "first", "second" and the like are generally of one kind and do not limit the number of objects, for example, the first object can be one or more. In addition, "and / or" in the specification means at least one of the connected objects, and the character " / ", generally means that the front and rear associated objects are in an "or" relationship.

[0036] Please refer to Figure 1As shown, the embodiment of the present application provides a preparation method of porous sinterless artificial stone, comprising the following steps:

[0037] In step S1, raw material pretreatment, the glass factory dust and / or glass kiln ash are dried and sieved; the multi-component waste glass is ground; the ceramic glaze waste residue is dried and ground; the aluminum ash is dried, impurity-removed and surface-release treated;

[0038] In step S2, batching and slurry preparation, the pretreated ceramic glaze waste residue, glass factory dust and / or glass kiln ash, multi-component waste glass and surface-release treated aluminum ash are mixed to obtain a mixed powder, wherein the ceramic glaze waste residue accounts for 40% to 70% of the total mass of the mixed powder, the glass factory dust and / or glass kiln ash accounts for 10% to 30% of the total mass of the mixed powder, the multi-component waste glass accounts for 10% to 35% of the total mass of the mixed powder, and the mass of metallic aluminum in the aluminum ash accounts for 0.10% to 1.20% of the total mass of the mixed powder; then, mixing water is added, the water-binder ratio is controlled to be 0.28 to 0.40, and the slurry is formed by stirring without additional addition of NaOH or Na2SiO3;

[0039] In step S3, foaming and solidification, the slurry is poured into a mold, the slurry is in-situ foamed under the action of hydrogen gas released by the reaction of aluminum ash and water, and the alkaline oxide released by the dissolution of glass solid waste excites the ceramic glaze waste residue to generate a cementation product through polycondensation reaction;

[0040] In step S4, curing, after the foamed slurry is cured under the condition of 30℃ to 70℃ and relative humidity ≥90%, the slurry is demolded and naturally cured to obtain the porous sinterless artificial stone.

[0041] In step S1, in the step of raw material pretreatment,

[0042] The glass factory dust and / or glass kiln ash is dried at 105℃±5℃ for 4 to 6 hours and sieved through a 200-mesh sieve; the adsorbed water is removed through drying to avoid caking and ensure quick dispersion during subsequent mixing; the undersize is sieved through a 200-mesh sieve, which has high fineness to ensure quick dissolution of alkaline oxides when in contact with water and provide the initial pH.

[0043] The multi-component waste glass is ground to a median particle size D50 of 10 to 35μm. Specifically, before grinding, the multi-component waste glass such as CRT display glass and waste fluorescent lamp glass needs to be thoroughly cleaned to remove coatings, organic residues and metal impurities after collection, and then dried at 120℃. Subsequently, the glass is crushed by ball milling or vertical milling to a D50 of 10 to 35μm and a D90 of not more than 75μm, so that the glass phase exposure area is increased and the glass is easily dissolved in the alkaline pore liquid.

[0044] The ceramic glaze waste residue is ground to a median particle size D50 of 5-25 μm. Specifically, the ceramic glaze waste residue is generally obtained from a spray drying tower or glaze polishing dust in ceramic production, and the drying temperature needs to be controlled below 120°C to prevent structural changes of the glass phase, and then the ceramic glaze waste residue is lightly ground to a D50 of 5-25 μm to ensure that the glassy SiO2 and Al2O3 therein have sufficient reactivity in an alkaline environment.

[0045] It should be noted that in the present application, the glass plant dust and / or glass kiln dust, and multi-component waste glass are used as the alkaline activator, and the ceramic glaze waste residue is used as the silicon-aluminum skeleton source.

[0046] The aluminum ash is used as a self-foaming agent, and needs to be dried before entering the system, with the temperature controlled below 80°C to prevent premature reaction of the residual metallic aluminum therein, and magnetic separation is used to remove iron filings, and air separation is used to separate large particles and impurities, so as to obtain aluminum ash powder with uniform particle size and extremely low water content. Finally, the metallic aluminum content, Al2O3 and CaO content of the aluminum ash need to be detected to quantitatively evaluate the foaming capacity and reactivity thereof when designing the ratio.

[0047] The determination of the metallic aluminum content in the aluminum ash uses a sodium hydroxide dissolution-gas volume measurement method: a certain mass of dried aluminum ash sample is weighed, an excess of NaOH solution with a known concentration is added, and the mass percentage of metallic aluminum in the sample is calculated by measuring the hydrogen gas volume released in the reaction.

[0048] In step S2, the pretreated ceramic glaze waste residue, glass plant dust and / or glass kiln dust, multi-component waste glass and aluminum ash treated by surface release are mixed to obtain a mixed powder, which specifically includes:

[0049] First, the ceramic glaze waste residue and the multi-component waste glass are mixed in proportion and mechanically activated, and a planetary ball mill or a high-speed stirring mill is used for short-time treatment of 5-10 minutes to increase the specific surface area of the mixture to 400 m²·kg -1 Thus, the early dissolution rate and polycondensation reaction efficiency are significantly improved; then the glass plant dust and / or glass kiln dust is added and stirred uniformly to uniformly disperse the soluble Na2O and K2O contained therein, so as to facilitate rapid dissolution to form a uniform alkaline pore solution when water is added.

[0050] The surface release treatment of the aluminum ash is surface coating with mineral oil, paraffin emulsion or stearate, and the coating amount is 1%-3% of the mass of the aluminum ash; in this way, the direct contact of the aluminum ash with water is delayed, the reaction induction period of the aluminum ash can be controlled to 2-6 minutes, and the maximum hydrogen release rate is in the range of 0.5-2.0 L·min -1 ·kg -1 Thus, the pore formation is ensured to be sufficient, and structural instability caused by too fast reaction is avoided.

[0051] The surface coating treatment is carried out in a high-speed mixer, and the aluminum ash powder preheated to 50-60℃ is mixed with the atomized sprayed coating agent (mineral oil, paraffin emulsion or stearate ethanol solution) for 5-10 minutes to ensure uniform coating, and then dried at 80℃ to remove the solvent.

[0052] In step S2, mixing water is added to control the water-binder ratio to 0.28-0.40, and the slurry is stirred, specifically including:

[0053] The mixing water is added in two to three times, and most of the water (about 90% of the total amount) is used to dissolve the glass dust and alkaline oxides in the multi-component waste glass in advance, so that the pore liquid pH rapidly rises above 10.5, thereby triggering the dissolution reaction of SiO2 and Al2O3 in the ceramic glaze waste residue and polycondensation to form N–A–S–H or C–(A)–S–H gel. After the slurry is uniform, the aluminum ash treated by slow release is added with the remaining water and quickly stirred to be uniform. At this time, the slurry should exhibit moderate viscosity to facilitate the uniform generation and distribution of hydrogen gas in the slurry. If the slurry viscosity is too low, the bubbles will quickly float to the surface, resulting in uneven pores. If the slurry viscosity is too high, it is not conducive to bubble formation, so the slurry viscosity should be controlled in the range of 0.8 to 2.0 Pa·s.

[0054] In step S3, the volume of the slurry is 80%-95% of the volume of the mold cavity, and after pouring, a slight vibration of 10 to 20 seconds is required to remove large bubbles and ensure the density of the slurry. After the induction period of the aluminum ash reaction, the slurry begins to release hydrogen gas uniformly and gradually expands, with a volume up to 5% to 15% of the mold thickness. To avoid excessive expansion or collapse, the top of the mold is provided with a limiting cover plate, and the limiting cover plate is provided with a gas permeable hole to allow excess gas to escape without damaging the structure. If decorative artificial stone is needed, colored waste glass particles or ceramic chips can be pre-placed at the bottom of the mold. As the slurry foams and solidifies simultaneously, these particles will be fixed on the surface layer of the product, showing a texture and color similar to natural stone.

[0055] In step S4, the wet heat curing includes:

[0056] Initial curing: temperature 30-45℃, relative humidity ≥95%, curing for 2-4 hours, so that the foaming process and the initial gel reaction proceed simultaneously, and the pore wall can be solidified and shaped at the same time as the hydrogen gas is released;

[0057] Intensive curing: temperature 50-70℃, relative humidity ≥90%, curing for 8-24 hours, to promote the generation of N–A–S–H and C–(A)–S–H gel and the densification of the pore wall.

[0058] The temperature during demolding is controlled below 35 DEG C to avoid the shrinkage and cracking of the hole wall caused by sudden cooling; after demolding, the product is continuously cured at normal temperature for at least 7 days to ensure that the mechanical properties and durability are further improved.

[0059] Through the above steps, the glass industrial solid waste, ceramic glaze waste residue and aluminum ash are synergistically utilized to prepare lightweight porous, suitable strength and excellent durability unburned artificial stone without relying on external strong alkali. The process not only significantly reduces the energy consumption and carbon emission in the production process, but also solves the high value-added utilization problem of multiple types of industrial solid waste, and has important engineering application prospect and industrial popularization value.

[0060] The present application also provides a porous unburned artificial stone prepared by the method, the porosity of the porous unburned artificial stone is 10% to 45%, the dry density is 0.85 to 1.60 g / cm3, and the 7-day compressive strength is 10 to 25 MPa.

[0061] The water absorption of the artificial stone is less than or equal to 12%, and the mass loss rate after 25 freeze-thaw cycles is less than or equal to 1.5%.

[0062] The surface of the artificial stone is ground and polished by a 200-mesh to 1500-mesh grinding wheel in stages to obtain a smooth and dense surface, and optionally sprayed with a silane or siloxane hydrophobic agent with a mass concentration of 0.3% to 1.0% to form a hydrophobic coating without changing the alkalinity of the material. For the plate installed on the wall or the table, chamfering, grooving or back grooving treatment can also be carried out to meet the needs of construction and decoration.

[0063] The surface layer of the artificial stone is embedded with pre-embedded colored waste glass particles or ceramic chips to form decorative texture; the artificial stone is used for decorative artificial stone plate, light weight thermal insulation brick, wall block or indoor decorative surface material.

[0064] In order to make the purpose, technical scheme and advantages of the present application more clear, the present application will be further described in detail below with specific examples. It should be understood that the specific examples described herein are only used to explain the present application, and do not limit the scope of the present application.

[0065] Example 1: Preparation of dense artificial stone

[0066] This embodiment 1 aims to prepare a decorative artificial stone with dense structure, high strength and smooth surface.

[0067] Raw material preparation and pretreatment:

[0068] Ceramic glaze waste residue: 60% of the total powder mass, after low-temperature drying, the powder is ground to a median particle size D50=15um.

[0069] Glass plant dust: 20% of the total powder mass, dried at 105°C for 5 hours and sieved to 200 mesh.

[0070] Multi-component waste glass (CRT glass powder): 18% of the total powder mass, ball-milled to D50=25 μm.

[0071] Aluminum dross: 2% of the total powder mass, with a metallic aluminum content of 12.5% (hence 0.25% of the total mass of the powder), dried at 80°C and cleaned by magnetic separation, and then surface-coated with 1.5% of its mass of zinc stearate to delay the hydrogen release reaction.

[0072] Batching and slurry preparation:

[0073] The above pretreated ceramic glaze waste, glass plant dust and CRT glass powder were dry-mixed in a planetary ball mill for 2 minutes. Then, the mixing water was added according to a water-binder ratio of 0.30. About 90% of the water was added first, and the pH of the system was quickly increased to 10.8 by stirring. The coated aluminum dross was then added with the remaining 10% of the water, and the mixture was stirred rapidly for 1 minute to obtain a uniform slurry, with a viscosity of about 1.2 Pa·s.

[0074] Foaming and solidification:

[0075] The slurry was poured into a steel mold with a filling volume of 90% of the mold cavity, and was gently vibrated for 15 seconds to remove large bubbles. A limiting cover plate was added to the top of the mold with a vent hole. The aluminum dross started to release hydrogen uniformly after an induction period of about 3 minutes, and the volume of the slurry slowly increased by about 7%.

[0076] Curing:

[0077] The mold was moved to a curing box and subjected to initial curing at 35°C and a relative humidity of 95% for 3 hours. Then, it was transferred to an environment at 55°C and a relative humidity of 90% for intensive curing for 12 hours. After curing, the mold was removed when its temperature naturally decreased to below 35°C. The product after demolding was continuously wet-cured at room temperature for 7 days.

[0078] Post-processing and performance:

[0079] After curing, the surface of the product was ground and polished. The performance test results were as follows: dry density 1.55 g / cm³, porosity 12%, 7-day compressive strength 24 MPa, 28-day compressive strength 32 MPa, water absorption 5.8%, and mass loss after 25 freeze-thaw cycles less than 1%. The product had good surface gloss and a decorative effect similar to natural stone.

[0080] Example 2: Preparation of lightweight porous bricks

[0081] This example 2 aims to prepare a lightweight porous brick with good thermal insulation performance.

[0082] Raw material preparation and pretreatment:

[0083] Ceramic glaze waste residue: 50% of the total powder mass, dried at low temperature and ground to D50 = 10 μm.

[0084] Glass kiln dust: 25% of the total powder mass, dried at 105°C to constant weight and sieved through a 200 mesh screen.

[0085] Multi-component waste glass (fluorescent tube glass powder): 20% of the total powder mass, refined by ball milling to D50 = 18 μm.

[0086] Aluminum dust: 5% of the total powder mass, with a metal aluminum content of 20.0% (1.0% of the total mass of the powder is metal aluminum), dried at 80°C and physically mixed with a small amount of waste glass powder sieved through a 200 mesh screen to slow down the reaction rate.

[0087] Batching and slurry preparation:

[0088] The pretreated ceramic glaze waste residue, glass kiln dust, and fluorescent tube glass powder were mixed uniformly. Water was added at a water-binder ratio of 0.38, with about 80% of the water added to bring the pH of the system to 10.5. The aluminum dust combined with the waste glass powder and the remaining water were then added and stirred quickly until the slurry was uniform. After about 4 minutes, the slurry began to foam significantly.

[0089] Foaming and solidification:

[0090] The slurry was poured into a mold with a filling volume of 85% of the mold cavity and lightly vibrated for 10 seconds. The volume was raised by about 15% during the foaming process, and the final height was controlled by a limiting device on the top of the mold.

[0091] Curing:

[0092] The poured sample was cured at 40°C and 98% relative humidity for 4 hours, then transferred to a 60°C, 90% relative humidity environment for 18 hours. After cooling to room temperature, it was demolded and continued to be wet cured at room temperature for 7 days.

[0093] Performance:

[0094] The test results showed that the dry density of the porous brick was 0.95 g / cm³, the porosity was 38%, the 7-day compressive strength was 11 MPa, the 28-day compressive strength was 15 MPa, the water absorption was 10.5%, the mass loss after 25 freeze-thaw cycles was 1.3%, and the thermal conductivity was 0.28 W / (m·K), making it suitable for lightweight wall bricks and insulation boards.

[0095] It should be noted that, as used in this place, the terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can also include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element preceded by "comprises a" does not, without more constraints, foreclose the existence of additional identical elements in the process, method, article, or apparatus that comprises the recited element.

[0096] Further, it is to be noted that the scope of the methods and systems of the embodiments of the present application is not limited to performing functions in the order discussed or illustrated, and includes performing functions in other orders, in substantially simultaneous fashion, or in reverse order, such as described methods can be performed in other than the order described, and various steps can be added, omitted, or combined and additional or different steps can be added, omitted, or combined. Also, features described with respect to certain examples can be combined in other examples.

[0097] The embodiments of the present application described above with reference to the drawings are merely illustrative, and not restrictive, and the ordinary skilled in the art can make many forms under the inspiration of the present application without departing from the scope of the present application, which is protected by the purpose of the present application.

Claims

1. A method for preparing porous, non-fired artificial stone, characterized in that, Includes the following steps: Raw material pretreatment: Drying and screening glass factory dust and / or glass kiln ash; Grinding multi-component waste glass; The ceramic glaze waste is dried and ground; the aluminum ash is dried, impurities are removed, and surface slow-release treatment is applied. Ingredients and slurry preparation: Pretreated ceramic glaze waste residue, glass factory dust and / or glass kiln ash, multi-component waste glass, and surface-treated slow-release aluminum ash are mixed to obtain a mixed powder. The ceramic glaze waste residue accounts for 40% to 70% of the total mass of the mixed powder, the glass factory dust and / or glass kiln ash accounts for 10% to 30% of the total mass of the mixed powder, the multi-component waste glass accounts for 10% to 35% of the total mass of the mixed powder, and the aluminum ash contains 0.10% to 1.20% of the total mass of the mixed powder. Then, mixing water is added, and the water-cement ratio is controlled at 0.28 to 0.

40. The mixture is stirred to form a slurry, without adding any additional NaOH or Na2SiO3. Foaming and curing: The slurry is poured into a mold, and the slurry foams in situ under the action of hydrogen gas released by the reaction of aluminum ash and water. At the same time, the glass factory dust and / or glass kiln ash, as well as the alkaline oxides released by the dissolution of the multi-component waste glass, stimulate the ceramic glaze waste residue to undergo a condensation reaction to generate cementitious products. Curing: After the foamed slurry is cured in a humid heat at 30℃~70℃ and relative humidity ≥90%, it is demolded and then naturally cured to obtain porous non-fired artificial stone.

2. The method according to claim 1, characterized in that, In the raw material pretreatment step: The glass factory dust and / or glass kiln ash are dried at 105℃±5℃ and passed through a 200-mesh sieve. The multi-component waste glass is ground to a median particle size D50 of 10–35 μm; The ceramic glaze waste residue is ground to a median particle size D50 of 5–25 μm.

3. The method according to claim 1, characterized in that, The surface slow-release treatment of the aluminum ash is to use one or more of mineral oil, paraffin emulsion, and stearate for surface coating, with a coating amount of 1% to 3% of the mass of aluminum ash.

4. The method according to claim 1, characterized in that, The volume of the slurry poured is 80% to 95% of the mold cavity volume; the top of the mold is provided with a limit cover plate, and the limit cover plate is provided with ventilation holes.

5. The method according to claim 1, characterized in that, The aforementioned hot and humid curing includes: Initial curing: Temperature 30℃~45℃, relative humidity ≥95%, curing time 2~4 hours; Intensive maintenance: Temperature 50℃~70℃, relative humidity ≥90%, maintenance time 8~24 hours.

6. The method according to claim 1, characterized in that, The temperature during demolding should be controlled below 35℃; after demolding, the product should continue to be cured at room temperature for at least 7 days.

7. A porous, non-fired artificial stone prepared by the method of any one of claims 1 to 6, characterized in that, The porous, non-fired artificial stone has a porosity of 10%–45%, a dry density of 0.85–1.60 g / cm³, and a 7-day compressive strength of 10–25 MPa.

8. The porous, non-fired artificial stone according to claim 7, characterized in that, The porous, non-fired artificial stone has a water absorption rate of ≤12% and a mass loss rate of ≤1.5% after 25 freeze-thaw cycles.

9. The porous, non-fired artificial stone according to claim 7, characterized in that, The surface of the porous, non-fired artificial stone is progressively ground and polished using grinding wheels ranging from 200 mesh to 1500 mesh.

10. The porous, non-fired artificial stone according to claim 7, characterized in that, The porous, non-fired artificial stone has pre-embedded colored waste glass particles or ceramic fragments on its surface, forming a decorative texture.

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