Lightweight building material containing distillers' grains as well as preparation method and application of lightweight building material

Abstract

The invention relates to a lightweight building material containing distillers' grains as well as a preparation method and application thereof, and belongs to the technical field of lightweight building materials. The material comprises cement, composite activation powder, modified reinforced fibers, a composite foaming agent, graded expanded perlite, shale ceramsite, a weather-resistant reinforcing auxiliary agent, a waterproof plugging auxiliary agent, a thermal insulation stabilizing auxiliary agent, a polymer of methyl ethylene oxide and ethylene oxide dimethyl ether and the like. The composite activation powder is prepared by performing surface modification on a mixture of vinasse, slag powder, expandable graphite powder and nano silicon dioxide through a silane coupling agent KH-560. The modified reinforced fibers are short fibers prepared by melt extrusion of glass fiber reinforced PP particles, and the short fibers are subjected to surface modification with a silane coupling agent KH-550. The composite foaming agent is prepared by mixing vinasse protein liquid, ammonium bicarbonate, wood fiber and tween-80. All the components are matched for use, interface modification is optimized, lightweight of the material is achieved, and strength, waterproofness, impermeability and freezing resistance are improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of lightweight building materials, and particularly relates to a lightweight building material containing vinasse and a preparation method and application thereof. BACKGROUND

[0002] Traditional building materials such as bricks and concrete have the advantages of high strength and good durability, but have the significant defects of high density and high self-weight, which not only lead to the increase of building energy consumption, but also increase the construction difficulty and transportation cost. Under this background, lightweight building materials gradually replace traditional materials due to their comprehensive advantages of low density, high strength, thermal insulation, etc. The density of lightweight building materials is usually lower than that of traditional materials, and the application of lightweight building materials can significantly reduce the self-weight of buildings, reduce the consumption of structural materials, simplify the construction process and improve the construction efficiency. Lightweight materials can not only meet the safety requirements of structures, but also achieve the goal of energy saving and consumption reduction.

[0003] The research and development of lightweight building materials can be traced back to the early 20th century. In the early stage, porous materials such as aerated concrete and lightweight bricks were mainly used to reduce density by introducing pores, but they had problems such as insufficient strength and poor waterproof performance. With the progress of material science and preparation technology, lightweight building materials gradually develop in the direction of "high strength, multifunctional and composite". Modern lightweight materials achieve the balance between density and strength by optimizing the formula design, such as adding lightweight aggregates such as ceramsite and perlite, and improving the preparation process, such as foaming molding and fiber reinforcement technology. For example, lightweight concrete can reduce density while improving compressive strength by adding polystyrene particles and glass fibers, and has good thermal insulation performance; for example, fiber reinforced cement board is composed of carbon fiber, glass fiber and cement-based material, which reduces density, improves bending strength, and has fireproof, soundproof and other multifunctional properties.

[0004] In terms of market demand, the rapid development of prefabricated buildings has driven the growth of demand for lightweight partition boards and prefabricated lightweight components. At present, lightweight building materials have been widely used in wall, roof, floor and other building parts, covering residential, commercial buildings, industrial plants and other fields, and the market size continues to expand.

[0005] However, there are still some technical bottlenecks in existing lightweight building materials: most of the materials still have the problems of low strength, high water absorption, poor impermeability and poor frost resistance; therefore, it is necessary to further optimize the material formula and improve the preparation process to improve the performance and durability of lightweight building materials. SUMMARY

[0006] In view of the problems of low strength, high water absorption, poor impermeability and poor frost resistance of existing lightweight building materials, the present application provides a lightweight building material containing vinasse and its preparation method and application. Through precise selection of components such as cement, activated powder, reinforcing fiber, foaming agent, polymer foam stabilizer, lightweight aggregate, functional additive, interface modification optimization and process parameter matching, the core contradiction of strength and lightness balance, waterproofing and frost resistance of traditional lightweight building materials is effectively solved, and the synergy of lightweight and high performance is realized. The specific technical scheme is as follows:

[0007] A lightweight building material containing vinasse, comprising the following mass fractions of raw materials: 24-29 parts of ordinary Portland cement, 18-23 parts of composite activated powder, 2.5-3.5 parts of modified reinforcing fiber, 3.5-5.0 parts of composite foaming agent, 14-18 parts of graded expanded perlite, 9-13 parts of shale ceramsite, 3-5 parts of weather-resistant reinforcing additive, 2-3 parts of waterproof plugging additive, 2-3 parts of thermal stability additive, 0.6-1.0 parts of sodium sulfate, 0.8-1.2 parts of polycarboxylic acid water reducer, 0.1-0.15 parts of polymer of methyl oxirane and oxirane dimethyl ether, and 23-28 parts of water; The composite activated powder is a mixture of vinasse, slag powder, expandable graphite powder and nano silicon dioxide in a mass ratio of (4-6):(3-4):(0.1-0.3):(0.1-0.3), and is prepared by surface modification with silane coupling agent KH-560; the modified reinforcing fiber is a short fiber made by melting extrusion of glass fiber reinforced PP particles, and is further surface modified with silane coupling agent KH-550; the composite foaming agent is prepared by mixing vinasse protein solution, ammonium bicarbonate, wood fiber and Tween-80 in a mass ratio of (3-5):(1-1.5):(0.3-0.5):(0.1-0.2).

[0008] The preparation method of the composite activated powder comprises: uniformly mixing vinasse, slag powder, expandable graphite powder and nano silicon dioxide in a mass ratio of (4-6):(3-4):(0.1-0.3):(0.1-0.3) to obtain a mixture; preparing a 1.5wt%-2wt% silane coupling agent KH-560 solution with an ethanol aqueous solution to obtain a modifier; adding the mixture into the modifier in a solid-liquid mass ratio of 1:(2-3), stirring, drying, and crushing to pass through a 100-150 mesh sieve to obtain the composite activated powder.

[0009] The preparation method of the modified reinforcing fiber comprises the following steps: melting extruding, granulating, and making short fibers with a diameter of 0.3mm to 0.5mm and a length of 5mm to 8mm; preparing a 1.5wt% to 2.5wt% silane coupling agent KH-550 solution with an ethanol aqueous solution, adjusting the pH to 4 to 5, and pre-hydrolyzing by stirring to obtain a modified solution; and immersing the short fibers in the modified solution according to a material-to-liquid mass ratio of 1: (6 to 8), stirring, filtering, and drying the filter cake to obtain the modified reinforcing fiber.

[0010] The preparation method of the composite foaming agent comprises the following steps: preparing a composite foaming agent by mixing distiller's grains, ammonium bicarbonate, wood fiber, and Tween-80 according to a mass ratio of (3 to 5):(1 to 1.5):(0.3 to 0.5):(0.1 to 0.2), stirring at 50°C to 60°C and 300rpm to 350rpm for 1h to 1.5h.

[0011] The preparation method of the composite foaming agent comprises the following steps: preparing a composite foaming agent by mixing distiller's grains, ammonium bicarbonate, wood fiber, and Tween-80 according to a mass ratio of (3 to 5):(1 to 1.5):(0.3 to 0.5):(0.1 to 0.2), stirring at 50°C to 60°C and 300rpm to 350rpm for 1h to 1.5h.

[0012] The preparation method of the composite foaming agent comprises the following steps: preparing a composite foaming agent by mixing distiller's grains, ammonium bicarbonate, wood fiber, and Tween-80 according to a mass ratio of (3 to 5):(1 to 1.5):(0.3 to 0.5):(0.1 to 0.2), stirring at 50°C to 60°C and 300rpm to 350rpm for 1h to 1.5h.

[0013] The preparation method of the composite foaming agent comprises the following steps: preparing a composite foaming agent by mixing distiller's grains, ammonium bicarbonate, wood fiber, and Tween-80 according to a mass ratio of (3 to 5):(1 to 1.5):(0.3 to 0.5):(0.1 to 0.2), stirring at 50°C to 60°C and 300rpm to 350rpm for 1h to 1.5h.

[0014] The preparation method of the composite foaming agent comprises the following steps: preparing a composite foaming agent by mixing distiller's grains, ammonium bicarbonate, wood fiber, and Tween-80 according to a mass ratio of (3 to 5):(1 to 1.5):(0.3 to 0.5):(0.1 to 0.2), stirring at 50°C to 60°C and 300rpm to 350rpm for 1h to 1.5h.

[0015] The preparation method of the composite foaming agent comprises the following steps: preparing a composite foaming agent by mixing distiller's grains, ammonium bicarbonate, wood fiber, and Tween-80 according to a mass ratio of (3 to 5):(1 to 1.5):(0.3 to 0.5):(0.1 to 0.2), stirring at 50°C to 60°C and 300rpm to 350rpm for 1h to 1.5h.

[0016] The preparation method of the composite foaming agent comprises the following steps: preparing a composite foaming agent by mixing distiller's grains, ammonium bicarbonate, wood fiber, and Tween-80 according to a mass ratio of (3 to 5):(1 to 1.5):(0.3 to 0.5):(0.1 to 0.2), stirring at 50°C to 60°C and 300rpm to 350rpm for 1h to 1.5h. S1: according to the mass fraction of raw materials, ordinary portland cement, composite activated powder, graded expanded perlite, shale ceramsite, modified reinforcing fiber and sodium sulfate are mixed, then weather-resistant reinforcing additives, waterproof plugging additives, heat preservation stabilizing additives and polycarboxylic acid water reducing agent are added, continue to mix, then the mixed solution of premixed methyl oxirane and oxirane dimethyl ether polymer and water is added, continue to mix, finally the composite foaming agent is added and mixed to form a foam slurry with a gas content of 50vol%~60vol% to obtain a lightweight building material; S2: the lightweight building material is injected into a prefabricated component mold or a site pouring mold, the material is vibrated and compacted, the surface is covered with a plastic film, and natural curing is carried out for 10h~12h, demolding, water spray curing for 7d, and then natural curing until 28d.

[0017] The above lightweight building material is used for preparing non-load-bearing walls, prefabricated thermal insulation components, ground heating backfill layers or sound insulation and noise reduction components in building engineering.

[0018] The lightweight building material provided by the application has the beneficial effects of including: (1) The lightweight building material effectively solves the core contradiction between the strength and lightness of traditional lightweight building materials, the waterproofing and frost resistance, realizes the synergistic unity of lightness and high performance, and the core principle is to build a protective system of dense gel matrix and uniform microporous structure through sufficient reaction of active components, strengthening of interfacial adhesion and precise control of pore structure, which not only guarantees the low density characteristics of the material between 800kg / m 3 ~850kg / m 3 , but also makes up for the structural defects of traditional lightweight materials to meet the comprehensive performance requirements of non-load-bearing components in building engineering.

[0019] (2) The composite activated powder is reasonably proportioned by distiller's grains, slag powder, expandable graphite powder and nano silicon dioxide and modified by KH-560. The active components of distiller's grains and slag powder generate dense hydrates to fill the pores of the matrix; nano silicon dioxide and expandable graphite powder optimize the microstructure; KH-560 modification improves the interfacial compatibility of the powder and the cement-based material through chemical bonding, reduces the agglomeration defects, and strengthens the matrix density and mechanical properties.

[0020] (3) The high strength characteristics of glass fiber reinforced PP provide mechanical support for the material, and the short fiber form is convenient for uniform dispersion; KH-550 modification forms a chemical bond between the fiber and the matrix, improves the anchoring effect and load transfer efficiency, effectively inhibits crack initiation and propagation, and enhances the material's bending and compressive properties and structural stability.

[0021] Four, the composite foaming agent is prepared by mixing distiller's grains protein solution, ammonium bicarbonate, wood fiber and Tween-80 in a specific proportion. The distiller's grains protein solution promotes foaming and the formation of stable liquid film to prevent bubble rupture; the ammonium bicarbonate decomposes to generate uniform gas; the wood fiber and Tween-80 assist in stabilizing the foam, and cooperatively form a composite foaming agent, which cooperates with the polymer (a polymer of methyl oxirane and oxirane dimethyl ether) to stabilize the foam in the later stage, effectively forming a fine, uniform and closed pore structure, which not only reduces the material density, but also avoids the decline of waterproofness and mechanical properties caused by pore connectivity.

[0022] Five, the graded expanded perlite and shale ceramsite are reasonably configured, the coarse and fine graded expanded perlite optimizes the skeleton pore structure, and the shale ceramsite provides light support, so that the skeleton is dense and the micro-pores are uniform, and the lightness and mechanical bearing capacity are considered.

[0023] Six, the weather-resistant reinforcing additive includes silica ash, a composite anti-freezing agent and UV-328, which densifies the matrix through silica ash, inhibits frost heaving through the anti-freezing agent, and resists ultraviolet aging through UV-328, thereby improving the weather-resistant stability.

[0024] Seven, according to the comprehensive characteristics of each component of the material, a waterproof plugging additive is designed, which includes a specific proportion of a deep penetration crystalline sealing waterproof agent, a cetyl phosphate-cetyl phosphate diethanolamine and an expansion fiber anti-cracking waterproof agent, which cooperatively realizes internal crystalline plugging of pores, surface hydrophobic blocking of water, anti-cracking and inhibition of penetration channels, and comprehensively improves the waterproof performance, and has a good synergistic effect compared with a single component and an unreasonable proportion.

[0025] Eight, the heat preservation stabilizing additive includes montmorillonite and fluorocarbon surfactant, which optimizes the heat preservation structure, inhibits heat transfer and improves the system stability.

[0026] Nine, sodium sulfate accelerates the hydration reaction and promotes the generation of gel; polycarboxylic acid superplasticizer improves the fluidity of the slurry, reduces the water consumption and reduces the porosity; the polymer of methyl oxirane and oxirane dimethyl ether has the functions of dispersion and foam stabilization, and precise timing of addition can reduce the damage to the performance of the foaming agent, and optimize the particle dispersion and foam stability.

[0027] Ten, in the preparation steps: first mix the inorganic powder and the aggregate, then add the additive, and finally add the composite foaming agent to avoid mutual interference between the components; the stirring speed and time are designed to ensure uniform dispersion of the components and avoid high-speed stirring to damage the foam structure.

[0028] In summary, the composite activated powder of the material of the present application forms a multi-component active system with the vinasse, slag powder and cement-based material, the organic active components of the vinasse and the inorganic active components of the slag powder synergistically hydrate to generate more dense gel hydrates, while the nano-silicon dioxide and the expandable graphite powder fill the micro-pores to achieve dual improvement of reaction strengthening and structure densification. The micro-pores generated by the composite foaming agent and the skeleton structure of the graded lightweight aggregate of perlite and shale ceramsite form a macro and micro synergistic pore system, which not only ensures low density, but also avoids the deterioration of waterproof and mechanical properties caused by the connection of pores through the combination of closed micro-pores and dense skeleton. The KH-560 modification of the composite activated powder and the KH-550 modification of the modified reinforcing fiber form the interface strengthening of the powder, fiber and matrix, reduce the interface defects, improve the stress transfer efficiency, and simultaneously enhance the mechanical properties and structural stability of the material. The waterproof, weather-resistant and thermal insulation additives form a comprehensive protection system, the waterproof additive blocks the water penetration channel, the weather-resistant additive resists external erosion such as freeze-thaw and ultraviolet radiation, and the thermal insulation additive maintains the temperature stability, so that the material maintains long-term performance stability in complex building environment, and realizes the balanced optimization of mechanical properties, waterproof performance, weather resistance and thermal insulation performance. DETAILED DESCRIPTION

[0029] The present application will be further described in conjunction with specific implementation examples, but the present application is not limited to these examples.

[0030] Example 1 A lightweight building material containing vinasse, comprising the following raw materials in mass fraction: ordinary portland cement 26 parts, composite activated powder 20 parts, modified reinforcing fiber 3 parts, composite foaming agent 4.2 parts, graded expanded perlite 16 parts, shale ceramsite 11 parts, weather-resistant reinforcing additive 4 parts, waterproof blocking additive 2.5 parts, thermal insulation stabilizing additive 2.5 parts, sodium sulfate 0.8 parts, polycarboxylic acid water reducer 1 part, polymer of methyl oxirane and oxirane dimethyl ether 0.12 parts, and water 25 parts.

[0031] The preparation method of the composite activated powder comprises: drying the wheat vinasse to a water content of 3wt%, crushing to D50 of 32μm, and passing through a 100-mesh sieve. The slag is crushed and passed through a 150-mesh sieve. The vinasse, slag powder, expandable graphite powder and nano-silicon dioxide are mixed uniformly in a mass ratio of 5:3.5:0.2:0.2 to obtain a mixture. A 1.8wt% silane coupling agent KH-560 solution is prepared by using 22vol% ethanol aqueous solution, and a modifier is obtained. The mixture is added to the modifier in a solid-liquid mass ratio of 1:2.5, stirred at 55℃ for 0.5h, dried at 130℃ to a water content of 2.5wt%, crushed and passed through a 150-mesh sieve to obtain the composite activated powder.

[0032] The preparation method of the modified reinforcing fiber comprises: melting and extruding the glass fiber reinforced PP through an extruder, granulating, and making short fibers with a diameter of 0.4 mm and a length of 6 mm. A 2wt% silane coupling agent KH-550 solution is prepared with 22vol% ethanol aqueous solution, and a 6wt% acetic acid aqueous solution is used to adjust the pH to 4.5. The solution is stirred at 25℃ for 25min to obtain a modified solution. The short fibers are immersed in the modified solution at a material-to-liquid mass ratio of 1:7, stirred at 25℃ for 1.5h, filtered through a 200-mesh sieve, and the filter cake is dried at 85℃ for 5h to obtain the modified reinforcing fiber.

[0033] The preparation method of the composite foaming agent comprises: taking the distiller's grains protein waste liquid of wheat raw material, removing impurities by filtration, and adjusting the protein content to 18wt%. The distiller's grains protein liquid, ammonium bicarbonate, wood fiber, and Tween-80 are mixed at a mass ratio of 4:1.2:0.4:0.15, and stirred at 55℃ and 320rpm for 1h to obtain the composite foaming agent.

[0034] The graded expanded perlite comprises coarse expanded perlite with a particle size of 20-40 meshes and fine expanded perlite with a particle size of 60-80 meshes at a mass ratio of 2.5:1.2. The particle size of the shale ceramsite ranges from 3mm to 8mm. The weather-resistant reinforcing aid comprises silica fume, composite anti-freezing agent, and UV-328 at a mass ratio of 2.5:1:0.15. The composite anti-freezing agent comprises sodium nitrite and urea at a mass ratio of 1.5:1.2. The waterproof plugging aid comprises deep penetration crystalline sealing waterproof agent, cetyl phosphoric acid-cetyl phosphoric acid diethanolamine, and expanded fiber anti-cracking waterproof agent at a mass ratio of 1.8:0.7:0.4. The thermal insulation stabilizing aid comprises montmorillonite and fluorocarbon surfactant at a mass ratio of 1.2:0.15.

[0035] The preparation method of the above-mentioned lightweight building material containing distiller's grains comprises the following steps: S1: The ordinary portland cement, composite activated powder, graded expanded perlite, shale ceramsite, modified reinforcing fiber, and sodium sulfate are mixed at a mass ratio of 70rpm for 2.5min, then the weather-resistant reinforcing aid, waterproof plugging aid, thermal insulation stabilizing aid, and polycarboxylic acid water reducer are added and continue to mix at 70rpm for 2.5min, then the premixed mixture of methyl oxirane and oxirane dimethyl ether polymer and water is added and continue to mix at 70rpm for 1.5min, finally the composite foaming agent is added and mixed at 90rpm for 3min to form a foamed slurry, and the lightweight building material is obtained; S2: The lightweight building material is injected into a prefabricated component mold or a site pouring mold, vibrated and compacted at a frequency of 45Hz for 25s, covered with plastic film on the surface, naturally cured for 11h, demolded, and water sprayed (sprayed every 8h for 4.5L / m 2 ) for 7d, and then naturally cured for 28d.

[0036] In this embodiment, the test sample was cast using a precast component mold that meets the test specifications.

[0037] Example 2 A lightweight building material containing distiller's grains comprises the following raw materials in parts by weight: 24 parts ordinary silicate cement, 23 parts composite activated powder, 2.5 parts modified reinforcing fiber, 5.0 parts composite foaming agent, 14 parts graded expanded perlite, 13 parts shale ceramsite, 3 parts weather-resistant reinforcing agent, 3 parts waterproof sealing agent, 2 parts thermal insulation stabilizing agent, 1.0 part sodium sulfate, 0.8 parts polycarboxylate superplasticizer, 0.15 parts polymer of methyl ethylene oxide and ethylene oxide dimethyl ether, and 23 parts water.

[0038] The preparation method of the composite activated powder includes: drying barley lees to a moisture content of 4 wt%, pulverizing to a D50 of 10 μm, and passing through a 150-mesh sieve. Pulverizing slag and passing it through a 100-mesh sieve. Mixing the lees, slag powder, expandable graphite powder, and nano-silica at a mass ratio of 6:3:0.3:0.1 to obtain a mixture. Preparing a 1.5 wt% silane coupling agent KH-560 solution with a 25 vol% ethanol aqueous solution to obtain a modifier. Adding the mixture to the modifier at a solid-liquid mass ratio of 1:2, stirring at 50℃ for 1 h, drying at 120℃ to a moisture content of 2.8 wt%, pulverizing and passing through a 150-mesh sieve to obtain the composite activated powder.

[0039] The preparation method of the modified reinforced fiber includes: melt extruding glass fiber reinforced PP through an extruder, granulating it, and producing short fibers with a diameter of 0.3 mm and a length of 8 mm. A 2.5 wt% silane coupling agent KH-550 solution is prepared using a 20 vol% ethanol aqueous solution, and the pH is adjusted to 5 with a 5 wt% acetic acid aqueous solution. The solution is then stirred and pre-hydrolyzed at 20°C for 30 min to obtain a modified solution. The short fibers are immersed in the modified solution at a material-to-solution mass ratio of 1:6, stirred at 30°C for 1.5 h, filtered through a 200-mesh sieve, and the filter cake is dried in an air-drying environment at 80°C for 6 h to obtain the modified reinforced fiber.

[0040] The preparation method of the composite foaming agent includes: taking the waste liquor of barley raw material, filtering to remove impurities, and adjusting the protein content to 15wt%. The liquor is mixed according to the mass ratio of liquor liquor:ammonium bicarbonate:lignocellulose:Tween-80 = 5:1:0.5:0.1, and stirred at 60℃ and 300rpm for 1.5h to obtain the composite foaming agent.

[0041] The graded expanded perlite includes coarse expanded perlite with a particle size of 20-40 mesh and fine expanded perlite with a particle size of 60-80 mesh at a mass ratio of 2:1.5. The particle size of the shale ceramsite ranges from 3 mm to 8 mm. The weather-resistant reinforcing additive includes silica fume, composite anti-freezing agent, and UV-328 at a mass ratio of 2:1.2:0.1. The composite anti-freezing agent includes sodium nitrite and urea at a mass ratio of 2:1. The waterproof plugging additive includes deep penetration crystalline sealing waterproof agent, cetyl phosphate-cetyl phosphodiethanolamine, and expansion fiber anti-cracking waterproof agent at a mass ratio of 2.0:0.5:0.5. The heat preservation stabilizing additive includes montmorillonite and fluorocarbon surfactant at a mass ratio of 0.8:0.1.

[0042] The preparation method of the lightweight building material containing vinasse includes the following steps: S1: The ordinary portland cement, the composite activated powder, the graded expanded perlite, the shale ceramsite, the modified reinforcing fiber, and the sodium sulfate are mixed at 60 rpm for 3 min according to the mass fraction of the raw materials, and then the weather-resistant reinforcing additive, the waterproof plugging additive, the heat preservation stabilizing additive, and the polycarboxylic acid water reducing agent are continuously mixed at 60 rpm for 3 min, and then the mixed solution of the pre-mixed polymer of methyl oxirane and oxirane dimethyl ether and water is continuously mixed at 60 rpm for 2 min, and finally the composite foaming agent is mixed at 80 rpm for 4 min to form a foamed slurry, thereby obtaining the lightweight building material; S2: The lightweight building material is poured into a prefabricated component mold or a site pouring mold, and the material is vibrated and compacted at a frequency of 45 Hz for 30 s, the surface is covered with a plastic film, and the material is naturally cured for 10 h, demolded, and water sprayed (5 L / m 2 ) every 8 hours for 7 d, and then naturally cured for 28 d.

[0043] In this embodiment, the sample is poured into a prefabricated component mold that meets the detection specifications.

[0044] Example 3 A lightweight building material containing vinasse includes the following mass fractions of raw materials: ordinary portland cement 29 parts, composite activated powder 18 parts, modified reinforcing fiber 3.5 parts, composite foaming agent 3.5 parts, graded expanded perlite 18 parts, shale ceramsite 9 parts, weather-resistant reinforcing additive 5 parts, waterproof plugging additive 2 parts, heat preservation stabilizing additive 3 parts, sodium sulfate 0.6 parts, polycarboxylic acid water reducing agent 1.2 parts, polymer of methyl oxirane and oxirane dimethyl ether 0.1 parts, and water 28 parts.

[0045] The preparation method of the composite activated powder comprises the following steps: drying corn vinasse to a water content of 5wt%, crushing to a D50 of 50μm, and passing through a 100-mesh sieve; crushing the slag to pass through a 150-mesh sieve; uniformly mixing the vinasse, slag powder, expandable graphite powder and nano-silicon dioxide at a mass ratio of 4:4:0.1:0.3 to obtain a mixture; preparing a 2wt% silane coupling agent KH-560 solution with 20vol% ethanol water solution to obtain a modifier; adding the mixture into the modifier at a solid-liquid mass ratio of 1:3, stirring at 60℃ for 0.5h, drying at 150℃ until the water content is 3wt%, crushing to pass through a 100-mesh sieve, and obtaining the composite activated powder.

[0046] The preparation method of the modified reinforcing fiber comprises the following steps: melting and extruding the glass fiber reinforced PP through an extruder, pelletizing, and obtaining short fibers with a diameter of 0.5mm and a length of 5mm; preparing a 1.5wt% silane coupling agent KH-550 solution with 25vol% ethanol water solution, adjusting pH to 4 with 8wt% acetic acid water solution, and stirring at 30℃ for 20min to obtain a modified liquid; immersing the short fibers into the modified liquid at a material-liquid mass ratio of 1:8, stirring at 20℃ for 2h, filtering through a 150-mesh sieve, and drying the filter cake at 90℃ under ventilation for 4h to obtain the modified reinforcing fiber.

[0047] The preparation method of the composite foaming agent comprises the following steps: taking vinasse protein waste liquid of corn raw material, removing impurities by filtration, and adjusting the protein content to 20wt%; and preparing the composite foaming agent by mixing the vinasse protein liquid, ammonium bicarbonate, wood fiber and Tween-80 at a mass ratio of 3:1.5:0.3:0.2, and stirring at 50℃ and 350rpm for 1h.

[0048] The hierarchical expanded perlite comprises coarse expanded perlite with a particle size of 20-40 meshes and fine expanded perlite with a particle size of 60-80 meshes at a mass ratio of 3:1. The particle size of the shale ceramsite ranges from 3mm to 8mm. The weather-resistant reinforcing aid comprises silica fume, composite anti-freezing agent and UV-328 at a mass ratio of 3:0.8:0.2. The composite anti-freezing agent comprises sodium nitrite and urea at a mass ratio of 1:1.5. The waterproof plugging aid comprises deep penetration crystalline sealing waterproof agent, cetyl phosphate-cetyl phosphodiethanolamine and expanded fiber anti-cracking waterproof agent at a mass ratio of 1.5:0.8:0.3. The thermal insulation stabilizing aid comprises montmorillonite and fluorocarbon surfactant at a mass ratio of 1.5:0.2.

[0049] The preparation method of the lightweight building material containing vinasse comprises the following steps: S1: according to the mass fraction of raw materials, ordinary portland cement, composite activated powder, graded expanded perlite, shale ceramsite, modified reinforcing fiber and sodium sulfate are mixed at 80 rpm for 2 min, then weather-resistant reinforcing additives, waterproof plugging additives, heat preservation stabilizing additives and polycarboxylic acid water reducing agent are added, 80 rpm continues to mix for 2 min, then the mixed solution of premixed methyl oxirane and oxirane dimethyl ether polymer and water is added, 80 rpm continues to mix for 1 min, finally the composite foaming agent is added, 100 rpm mixes for 2 min, forms the foam slurry, and the light building material is obtained; S2: the light building material is injected into the prefabricated component mold or the site pouring mold, the material is vibrated and compacted at a frequency of 50 Hz for 20 s, the surface is covered with plastic film, and natural curing is carried out for 12 h, demolding, water spraying (spraying 4 L / m 2 ) every 8 hours, curing for 7 d, and then natural curing for 28 d.

[0050] The test sample of the embodiment is poured in a prefabricated component mold conforming to the detection specification.

[0051] The indicators and sources involved in the above embodiments are as follows: ordinary portland cement is ordinary portland cement P·O42.5R, which is from Tangshan Development Cement Co., Ltd. The slag powder is S95 mineral powder, which is from Taixing City Su Yete New Building Material Co., Ltd. The expandable graphite powder is 2000 mesh grade, which is from Shijiazhuang Huabang Mineral Products Co., Ltd. The nano-silicon dioxide is 12 nm grade, which is from Lingyuan County Shuanglong Mining Co., Ltd. The silane coupling agent KH-560 and the silane coupling agent KH-550 are both from Shandong Huachen New Material Co., Ltd. The glass fiber reinforced PP is 30 wt% glass fiber reinforced PP, which is from Dongguan Nabaichuan Plastic Co., Ltd. The ammonium bicarbonate has a purity of 99%. The wood fiber is from Lingyuan County Xingyuan Mineral Powder Processing Factory, and is building flocculent wood fiber with a model number of 089. The Tween-80 has a purity of 99%. The expanded perlite is from Guangzhou Wanjie Building Material Co., Ltd. The shale ceramsite is from Jinzhou Xinghong New Building Material Co., Ltd. The silica ash is 1250 mesh, which is from Lingyuan County Zanteng Mineral Product Processing Factory. The UV-328 is ultraviolet absorber UV-328 with a purity of 99%. The sodium nitrite has a purity of 99%. The urea has a purity of 99%. The deep penetration crystallization sealing waterproof agent is CM-DPS, which is from Henan Jue Nenghezhong Special Material Co., Ltd. The cetyl phosphoric acid-cetyl phosphoric acid diethanolamine has a purity of 99%, which is from Suzhou Senfeda Chemical Co., Ltd. The expanded fiber anti-cracking waterproof agent is SY-K, which is from Henan Jue Nenghezhong Special Material Co., Ltd. The montmorillonite is 325 mesh grade, which is from Lingyuan County Aotai Mineral Product Processing Factory. The fluorocarbon surfactant is FS-8500, which is from Guangzhou Huituo New Material Co., Ltd. The sodium sulfate has a purity of 99%. The polycarboxylic acid water reducer is PC8800, which is from Jiangsu Guanxiang Building Material Co., Ltd. The polymer of methyl oxirane and oxirane dimethyl ether is PEG / PPG-14 / 7 dimethyl ether, which is from Guangdong Wengjiang Chemical Reagent Co., Ltd., and has a purity of 99%.

[0052] Comparative Example 1 The difference from Example 1 is that in the preparation of the composite activated powder, the ratio of vinasse: slag powder: expandable graphite powder: nano-silicon dioxide is 2:6.5:0.2:0.2 by mass, and no surface modification with silane coupling agent KH-560 is performed.

[0053] Comparative Example 2 The difference from Example 1 is that in the material formula, the modified reinforcing fiber is directly replaced by short fibers, and no modification with silane coupling agent KH-550 is performed.

[0054] Comparative Example 3 The difference from Example 1 is that in the material formula, no polymer of methyl oxirane and oxirane dimethyl ether is added.

[0055] Comparative Example 4 The difference from Example 1 is that in the material formula, the polymer of methyl oxirane and oxirane dimethyl ether is mixed in the preparation of the composite foaming agent, and the composite foaming agent is stirred at 55℃ and 320rpm for 1h to obtain the composite foaming agent.

[0056] Comparative Example 5 The difference from Example 1 is that in the preparation of the composite foaming agent, the mass ratio of vinasse protein solution: ammonium bicarbonate: wood fiber: Tween-80 is 1.2:4:0.4:0.15.

[0057] Comparative Example 6 The difference from Example 1 is that the waterproof plugging aid is all deep penetration crystalline sealing waterproof agent.

[0058] Comparative Example 7 The difference from Example 1 is that the waterproof plugging aid is all cetyl phosphoric acid-cetyl phosphoric acid diethanolamine.

[0059] Comparative Example 8 The difference from Example 1 is that the waterproof plugging aid is all expanded fiber anti-cracking waterproof agent.

[0060] Comparative Example 9 The difference from Example 1 is that in the waterproof plugging aid, the mass ratio of deep penetration crystalline sealing waterproof agent: cetyl phosphoric acid-cetyl phosphoric acid diethanolamine: expanded fiber anti-cracking waterproof agent is 0.4:0.7:1.8.

[0061] 1. 28d compressive strength detection: Test block specification: 100mm×100mm×100mm, 28d curing.

[0062] The detection method includes: using a universal testing machine, loading at a constant speed until the test block is destroyed, and recording the maximum destruction load F (N). The compressive strength fc=F / A, wherein A is the compression area of the test block (mm 2 ).

[0063] 2. 28d flexural strength detection: Test block specification: 100mm×100mm×400mm, 28d curing.

[0064] The detection method includes: using a three-point bending method, with a span of 300mm, loading at a constant speed until the test block is broken, and recording the maximum destruction load F (N). The flexural strength ff= (3FL) / (2bh 2 ), wherein L is the span, b is the width of the test block, and h is the height of the test block.

[0065] 3. 24h water absorption rate detection: Test block specification: 100mm×100mm×100mm, 28d curing.

[0066] The detection method comprises: drying the test block to a constant weight, and weighing the dry mass md(g). The test block is completely immersed in 25℃ clean water, soaked for 24h, and during the period, it is ensured that the test block does not contact the bottom and side wall of the container. The test block is taken out, and the surface adhering moisture is wiped dry with a wet cloth. Immediately, the saturated mass mw(g) is weighed with a balance. The water absorption rate Wm= (mw-md) / md x 100%.

[0067] 4. Anti-permeability detection: The test block specification is a circular truncated cone test block with an upper opening of φ175mm x a lower opening of φ185mm x a height of 150mm.

[0068] The detection method comprises: the test block is cured for 26d (i.e. 2d in advance), the side surface of 6 test blocks is sealed with melted paraffin, and the test blocks are installed into the anti-permeability instrument film; the water pressure is increased by 0.1MPa every 8h, and the water pressure is continuously increased until water seepage appears in 3 test blocks, and the water pressure P (MPa) at this time is recorded.

[0069] 5. Anti-freezing detection: The test block specification is 100mm x 100mm x 100mm.

[0070] The detection method comprises: the test block is cured for 24d (i.e. 4d in advance), and is immersed in 20℃ water for 4d (to reach a total age of 28d) to serve as a freeze-thaw test block. At the same time, a normal curing 28d comparative test block is set, and the initial compressive strength f0 (MPa) of the comparative test block is tested. The freeze-thaw group test block is placed in a freeze-thaw test box, and one cycle is that the test block is frozen at-20℃ for 4h and is immersed in 20℃ clean water for 4h to melt, and the cycle is performed for 50 times. After the cycle is completed, the final compressive strength f1 (MPa) is tested. The strength loss rate Δfc= (f0-f1) / f0 x 100%.

[0071] The above detection items are set with 3 parallel tests, and the average value is taken, and the detection results are shown in Table 1 below.

[0072] Table 1. Detection results (average value) In the materials of Example 1 to Example 3, the composite activating powder, the composite foaming agent, the foam stabilizer, the lightweight aggregate, the waterproofing aid, the weather-resistant aid, etc. are all in the optimal proportion, which not only ensures that the active ingredients such as vinasse fully react to form dense hydrates, but also forms a uniform microporous structure through the classification of aggregates and the stabilization of foams, and takes into account the light weight and high strength. The composite activating powder is modified by KH-560, and the reinforcing fiber is modified by KH-550, which effectively improves the interfacial adhesion between the powder, the fiber and the cement-based material, reduces agglomeration and pore defects, and strengthens the mechanical properties and structural stability. According to the overall composition characteristics of the material, crystalline, hydrophobic and anti-cracking waterproofing aids are designed to cooperate with the heat preservation and weather-resistant aids, etc. to block capillary pores, inhibit cracks and block water intrusion; the precise control of the addition time of the polymer of methyl oxirane and oxirane dimethyl ether optimizes the dispersibility and foam stability, and further improves the structural density. The process and formula matching of stirring speed and curing method ensure that the components are fully mixed and the hydration reaction is complete, and finally achieve balanced optimization of strength, waterproofness and frost resistance.

[0073] In Comparative Example 1, the composite activating powder is not modified and the proportion is unbalanced. The synergistic effect of vinasse and slag powder in the composite activating powder depends on the reasonable proportion. The active components in vinasse need to fully react with the hydration products of slag powder to form dense hydrates. Unbalanced proportion will lead to lack of active ingredients and decrease of material structure density. At the same time, the modification of silane coupling agent improves the compatibility of powder and cement-based interface through chemical bonding. Unmodified powder will lead to powder agglomeration, weakened interfacial adhesion and increased porosity. Interface defects and increased porosity will cause a series of performance degradation. Loose interface will cause stress concentration and aggravate quality and strength loss in freeze-thaw cycle.

[0074] In Comparative Example 2, the glass fiber reinforced PP fiber is not modified by silane coupling agent. The reinforcing effect of the fiber depends on the interfacial adhesion between the fiber and the cement matrix. Silane coupling agent KH-550 can form chemical bonding between the fiber and the matrix, improve the anchoring effect and load transfer efficiency of the fiber, and effectively inhibit crack propagation; and promote uniformity. Without modification, the smooth surface of the fiber only has physical contact with the matrix, which cannot achieve efficient stress transfer and significantly weakens the inhibition effect on crack propagation, resulting in local defects, decreased compressive strength and flexural strength. At the same time, the loose interface will form small pores, providing a channel for water penetration, leading to increased water absorption and deteriorated frost resistance.

[0075] The polymer of Comparative Example 3 is not added with methyl oxirane and oxirane dimethyl ether. A high proportion of the polymer is added during the mixing of the material, which can have the functions of dispersion, foam stabilization and interface modification, can disperse cement particles and aggregates, reduce large pores caused by agglomeration, and can also optimize foam stability to make the bubbles uniform and small, and improve the structural density. The high proportion of the polymer is added in advance during the mixing of the material, rather than in the composite foaming agent, which can reduce the influence on the composition of the foaming agent and achieve appropriate foam stabilization performance. Without the addition, the cement-based material has poor dispersibility, and the foam is easy to break and form connected pores, which can increase the water absorption and deteriorate the impermeability; at the same time, the increase of interface defects can hinder the load transfer, resulting in a decrease in compressive and flexural strength; in the freeze-thaw cycle, the connected pores become water migration channels, and the frost heaving damage is intensified, further amplifying the strength loss.

[0076] In Comparative Example 4, a high proportion of the polymer is mixed with the composite foaming agent in advance. The best time for the polymer to act is in the later stage of the mixing of the cement-based slurry, and the excessive polymer mixed with the foaming agent too early will cause it to be adsorbed on the surface of the foaming agent molecules, especially affecting the foaming property of the distiller's grains protein, which can damage the foaming rate and stability of the foam, cause the bubbles to merge and become larger, and increase the porosity and uneven pore size distribution. At the same time, the dispersion of the polymer is weakened, and the agglomeration of the cement-based material is intensified, resulting in an increase in the internal structural defects of the material, a decrease in the compressive and flexural strength, an increase in the water permeability, and a significant deterioration in the impermeability and frost resistance, which can even be worse than the case without the addition of the polymer.

[0077] In Comparative Example 5, the proportion of the composite foaming agent is imbalanced. In the composite foaming agent, the distiller's grains protein solution plays a dual role in promoting foaming and stabilization, and can form a liquid film to prevent bubble collapse, and ammonium bicarbonate is used as a foaming agent to generate gas. The proportion of the two needs to be accurately matched. When the proportion is imbalanced, the lack of protein content can cause poor foam stability, and the bubbles can easily merge and collapse, forming a large number of large pores; and an excessive amount of ammonium bicarbonate can generate too much gas, resulting in a high internal porosity and uneven distribution of the material, and a significant decrease in the structural bearing capacity. Large pores and connected pores not only reduce the mechanical properties, but also provide convenience for water permeation, resulting in a significant increase in water absorption and a serious lack of impermeability, and the damage caused by water retention during freeze-thaw cycles is more severe.

[0078] The waterproof plugging aids in Comparative Examples 6 to 9 are single or imbalanced in proportion. The core function of the waterproof plugging aid relies on the synergistic effect of the three components. The waterproof agent with deep penetration and crystallization penetrates into the material and reacts with the hydration product to form crystals, plugging capillary pores; cetyl phosphoric acid-cetyl phosphoric acid diethanolamine forms a hydrophobic film on the surface to block water intrusion; the expansion fiber anti-crack waterproof agent inhibits the generation and expansion of cracks to avoid water penetration through the cracks. When a single component is used, the synergistic effect is lacking. When only the crystalline type aid is used, the amount of crystallization generated is limited and cannot completely cover all pores. When only the surface hydrophobic type aid is used, it cannot plug the internal capillary pores and small cracks. When only the anti-crack type aid is used, there is no obvious hydrophobic and crystalline plugging effect. And the inverted proportion will lead to insufficient crystalline plugging and surface hydrophobic effect, excessive anti-cracking effect but unable to make up for the waterproof defects, ultimately leading to an increase in water absorption, deterioration of impermeability and frost resistance.

Claims

1. A lightweight building material containing vinasse, characterized by, The material comprises raw materials in the following mass fractions: ordinary Portland cement 24-29 parts, composite activated powder 18-23 parts, modified reinforcing fiber 2.5-3.5 parts, composite foaming agent 3.5-5.0 parts, graded expanded perlite 14-18 parts, shale ceramsite 9-13 parts, weather-resistant reinforcing additive 3-5 parts, waterproof plugging additive 2-3 parts, heat preservation stabilizing additive 2-3 parts, sodium sulfate 0.6-1.0 parts, polycarboxylic acid water reducer 0.8-1.2 parts, polymer of methyl oxirane and oxirane dimethyl ether 0.1-0.15 parts, and water 23-28 parts; The composite activated powder is obtained by mixing distiller's grains, slag powder, expandable graphite powder and nano silicon dioxide in a mass ratio of (4-6):(3-4):(0.1-0.3):(0.1-0.3) and then modifying the surface with silane coupling agent KH-560; The modified reinforcing fiber is obtained by melt extruding PP particles reinforced with glass fiber into short fibers and then modifying the surface with silane coupling agent KH-550; The composite foaming agent is obtained by mixing distiller's grains protein liquid, ammonium bicarbonate, wood fiber and Tween-80 in a mass ratio of (3-5):(1-1.5):(0.3-0.5):(0.1-0.2).

2. A lightweight building material containing vinasse according to claim 1, characterized by that, The preparation method of the composite activated powder comprises the following steps: uniformly mixing distiller's grains, slag powder, expandable graphite powder and nano silicon dioxide in a mass ratio of (4-6):(3-4):(0.1-0.3):(0.1-0.3) to obtain a mixture; preparing a 1.5wt%-2wt% silane coupling agent KH-560 solution with an ethanol aqueous solution to obtain a modifier; adding the mixture into the modifier in a solid-liquid mass ratio of 1:(2-3), stirring, drying, crushing through a 100-150 mesh sieve, and obtaining the composite activated powder.

3. The lightweight building material containing vinasse according to claim 1, characterized by that, The preparation method of the modified reinforcing fiber comprises the following steps: melt extruding PP particles reinforced with glass fiber into short fibers with a diameter of 0.3-0.5 mm and a length of 5-8 mm; preparing a 1.5wt%-2.5wt% silane coupling agent KH-550 solution with an ethanol aqueous solution, adjusting the pH to 4-5, pre-hydrolyzing by stirring, and obtaining a modified liquid; immersing the short fibers into the modified liquid in a material-liquid mass ratio of 1:(6-8), stirring, filtering, and drying the filter cake to obtain the modified reinforcing fiber.

4. The lightweight building material containing vinasse according to claim 1, characterized by that, The preparation method of the composite foaming agent comprises the following steps: preparing a mixture of distiller's grains protein liquid, ammonium bicarbonate, wood fiber and Tween-80 in a mass ratio of (3-5):(1-1.5):(0.3-0.5):(0.1-0.2), stirring at 50-60°C and 300-350 rpm for 1-1.5 hours, and obtaining the composite foaming agent.

5. The lightweight building material containing vinasse according to claim 1, characterized by that, The graded expanded perlite comprises coarse expanded perlite with a particle size of 20-40 mesh and fine expanded perlite with a particle size of 60-80 mesh in a mass ratio of (2-3):(1-1.5); and the particle size of the shale ceramsite ranges from 3 mm to 8 mm.

6. The lightweight building material containing vinasse according to claim 1, characterized by that, The weather-resistant reinforcing aid comprises silica fume, composite anti-freezing agent and UV-328 in a mass ratio of (2-3):(0.8-1.2):(0.1-0.2); the composite anti-freezing agent comprises sodium nitrite and urea in a mass ratio of (1-2):(1-1.5).

7. The lightweight building material containing vinasse according to claim 1, characterized by that, The waterproof plugging aid comprises deep penetration crystalline sealing waterproof agent, cetyl phosphate-cetyl phosphoric acid diethanolamine and expansion fiber anti-cracking waterproof agent in a mass ratio of (1.5-2.0):(0.5-0.8):(0.3-0.5).

8. The lightweight building material containing vinasse according to claim 1, characterized by that, The heat preservation stabilizing aid comprises montmorillonite and fluorocarbon surfactant in a mass ratio of (0.8-1.5):(0.1-0.2).

9. The method of claim 1, wherein the method of preparing a lightweight building material containing vinasse is characterized by, The method comprises the following steps: S1: mixing ordinary portland cement, composite activated powder, graded expanded perlite, shale ceramsite, modified reinforcing fiber and sodium sulfate according to the mass fraction of raw materials, then adding weather-resistant reinforcing aid, waterproof plugging aid, heat preservation stabilizing aid and polycarboxylic acid water reducing agent, continuing to mix, then adding the premixed mixture of methyl oxirane and oxirane dimethyl ether polymer and water, continuing to mix, finally adding composite foaming agent, mixing to form a foamed slurry with a gas content of 50vol%-60vol%, thereby obtaining a lightweight building material; S2: injecting the lightweight building material into a prefabricated component mold or a site pouring mold, vibrating and compacting the material, covering the surface with plastic film, naturally curing for 10h-12h, demolding, water spraying curing for 7d, and then naturally curing for 28d.

10. Use of a lightweight building material containing vinasse according to claim 1, characterized by the fact that it is used in the construction of walls, floors, roofs, ceilings, partitions, and the like. The lightweight building material is used for preparing non-load-bearing walls, prefabricated thermal insulation components, floor heating backfill layers or sound insulation and noise reduction components in construction engineering.

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