Ceramic preparation method capable of recycling waste mud

Abstract

The invention relates to the technical field of ceramic preparation, in particular to a waste mud recycling ceramic preparation method, which comprises the following steps: dividing ceramic waste mud into plastic waste mud and barren waste mud, mixing according to a characteristic proportion, adding a sintering aid to obtain a mixture, forming into a green body, and performing sectional sintering to obtain a ceramic finished product; in the preparation process, the characteristic particle size and the actual moisture content are collected, the running time or the rotating speed of grinding equipment is adjusted according to the characteristic particle size, the preset moisture content corresponding to the current characteristic particle size is determined by combining a characteristic particle size-moisture content correlation model, and the characteristic proportion is adjusted based on comparison of the actual moisture content and the preset moisture content. Or predicting the sintering activity rate of the green body and adjusting the heating power of the sintering furnace in combination with the characteristic particle size and the actual water content. Waste mud with different properties can be distinguished, and the ceramic preparation process can be intelligently adjusted, so that performance fluctuation of regenerated products is reduced, and the success rate of the regenerated products is increased.

Description

Technical Field

[0001] This invention relates to the field of ceramic preparation technology, and in particular to a method for preparing ceramics by reusing waste mud. Background Technology

[0002] The ceramics industry is an important traditional industry and a basic raw material industry in my country, but it is also one of the sources of a large amount of solid waste. During ceramic production, approximately 5% to 10% of the raw materials become waste mud, slag, or waste porcelain due to processes such as shaping, trimming, and polishing. Traditionally, these wastes are mostly disposed of through landfill, which not only occupies a large amount of land resources, but the heavy metal ions and trace chemical components they contain can also seep into the soil and groundwater systems through rainwater leaching, causing serious environmental pollution. With tightening environmental policies and rising resource costs, how to achieve efficient and high-value recycling of ceramic waste mud has become a key common problem that the industry urgently needs to solve.

[0003] Chinese Patent Publication No. CN104211377A discloses a process for preparing ceramic handicrafts using ceramic waste sludge. The relevant technical solution involves recycling and mixing white porcelain sludge, red soil sludge, high-temperature sludge, polishing sludge, waste pottery sludge, edge grinding waste sludge, fine edge grinding waste sludge, and chamfering waste sludge, and adding new clay, glass glue, and water. The mixture is then thoroughly stirred and mixed. The resulting liquid is ball-milled, screened, magnetically filtered, and dehydrated by pressure filtration. It is then placed in a drying room and dried using the residual heat of the kiln, and finally bisque-fired to obtain new ceramics. This technical solution involves directly and simply mixing various waste muds with vastly different compositions and properties (white porcelain mud residue, red soil mud residue, high-temperature mud residue, polishing mud residue, etc.). These waste muds have significant differences in chemical composition (such as Al2O3, SiO2, Fe2O3, K2O, Na2O content), particle size, plasticity, and sintering activity. This "one-pot" mixing makes it difficult to ensure uniformity and stability between batches, directly leading to difficulties in precise control of subsequent processes (such as molding and sintering), resulting in fluctuations in the performance of the final product. Furthermore, the related technology requires the addition of "new mud" and "glass glue," but the addition of "new mud" dilutes the actual utilization rate of the waste mud. Summary of the Invention

[0004] Therefore, the present invention provides a ceramic preparation method for recycling waste sludge, which overcomes the problem of the extensive mixing of waste sludge in the prior art, resulting in complex composition and inconsistent properties of the waste sludge, thus leading to large fluctuations in the performance of recycled products.

[0005] To achieve the above objectives, the present invention provides a method for preparing ceramics using recycled waste sludge, comprising: Several ceramic waste sludge samples were classified into plastic waste sludge and barren waste sludge according to their properties, and pretreated separately. The pretreated plastic mud and barren mud are mixed in a characteristic ratio, and a composite low-temperature sintering aid is added to obtain a mixture. The characteristic ratio is determined according to the sintering characteristics of the waste mud. The composite low-temperature sintering aid includes waste glass powder, spodumene tailings and zinc oxide. The mixture is formed into a green body and sintered using a segmented sintering process. The segmented sintering process includes heating to 600±50℃ at a first heating rate in the first stage, and then heating to the final sintering temperature of 950~1050℃ at a second heating rate in the second stage and holding at that temperature for 1~3 hours. During the preparation process, the characteristic particle size of the barren waste sludge, the actual moisture content of the mixture, and the real-time sintering temperature of the second stage are collected in real time. The ceramic preparation process is compared with the characteristic particle size, the actual moisture content, and the corresponding preset threshold to determine whether the current process meets the standard, including: The running time or rotation speed of the grinding equipment during the pretreatment process is adjusted according to the comparison result between the characteristic particle size and the preset characteristic particle size, and the preset moisture content corresponding to the current characteristic particle size is determined according to the pre-configured characteristic particle size-moisture content correlation model. The characteristic ratio is adjusted based on the comparison result between the actual moisture content and the preset moisture content. Alternatively, the sintering activity rate of the green body can be predicted based on the characteristic particle size and the actual moisture content detected again after adjustment, and the heating power of the sintering furnace during the second stage of sintering can be adjusted based on the comparison result between the sintering activity rate and the expected sintering activity rate.

[0006] Furthermore, the process of adjusting the running time or rotation speed of the grinding equipment during pretreatment based on the comparison result between the feature granularity and the preset feature granularity includes: If the feature particle size is greater than the first preset feature particle size and less than or equal to the second preset feature particle size, the running time of the grinding equipment or the rotation speed is increased based on the particle size difference. The granularity difference is the difference between the feature granularity and the first preset feature granularity.

[0007] Furthermore, the process of determining whether to extend the operating time or increase the rotation speed of the grinding equipment based on the particle size difference includes: Based on the comparison result between the particle size difference and the preset particle size difference, the running time of the grinding equipment is extended or the rotation speed is increased, wherein the extension of the running time and the increase of the rotation speed are both positively correlated with the particle size difference.

[0008] Furthermore, the process of adjusting the characteristic ratio based on the comparison between the actual moisture content of the mixture and the preset moisture content includes: If the actual moisture content is less than or equal to the minimum value among the preset moisture contents, the proportion of increasing the characteristic is determined based on the moisture content difference. If the actual moisture content is greater than the maximum value among the preset moisture contents, the proportion of reducing the characteristic is determined based on the moisture content offset value; The preset moisture content is dynamically determined based on the feature granularity-moisture content correlation model and the current feature granularity. The moisture content difference is the difference between the minimum value of the preset moisture content and the actual moisture content. The moisture content offset is the difference between the actual moisture content and the maximum value of the preset moisture content.

[0009] Furthermore, the process of adjusting the characteristic ratio includes: The characteristic ratio is increased based on the comparison result between the moisture content difference and the preset moisture content difference, wherein the increase in the characteristic ratio is positively correlated with the moisture content difference. The characteristic ratio is reduced based on the comparison result between the moisture content offset value and the preset moisture content offset value, wherein the reduction in the characteristic ratio is positively correlated with the moisture content offset value.

[0010] Furthermore, the process of adjusting the heating power of the sintering furnace during the second stage of sintering based on the comparison result of the sintering activity rate and the expected sintering activity rate includes: If the sintering activity rate is less than or equal to the minimum value among the expected sintering activity rates, the heating power of the sintering furnace is increased based on the activity rate difference. If the sintering activity rate is greater than the maximum value among the expected sintering activity rates, the heating power of the sintering furnace is reduced based on the activity rate offset value. Wherein, the activity rate difference is the difference between the minimum value of the expected sintering activity rate and the sintering activity rate, and the activity rate offset is the difference between the sintering activity rate and the maximum value of the expected sintering activity rate.

[0011] Furthermore, the process of adjusting the heating power of the sintering furnace during the second stage of sintering includes: The heating power of the sintering furnace is increased based on the comparison result between the activity rate difference and the preset activity rate difference, wherein the increase in heating power is positively correlated with the activity rate difference. The heating power of the sintering furnace is reduced based on the comparison result between the activity rate offset value and the preset activity rate offset value, wherein the reduction in heating power is positively correlated with the activity rate offset value.

[0012] Furthermore, it also includes: While adjusting the heating power of the sintering furnace, the second heating rate corresponding to the second stage is simultaneously adjusted based on the change in heating power, wherein... If the heating power of the sintering furnace is increased, the second heating rate will be increased simultaneously. If the heating power of the sintering furnace is reduced, the second heating rate will be reduced simultaneously.

[0013] Furthermore, the plastic waste mud is a blanking mud with a moisture content higher than 30%, and the barren waste mud is a mixture of polishing waste residue and edge grinding waste residue in a ratio of 1:1 to 1:3. The pretreatment process for the plastic waste sludge includes, in sequence, crushing, dewatering, sludge kneading, and aging; The pretreatment process for the barren waste sludge includes crushing, grinding, sieving, and aging.

[0014] Furthermore, the composite low-temperature sintering aid in the mixture accounts for 1-5% by weight, wherein the waste glass powder accounts for 50-70% by weight, the spodumene tailings account for 20-40% by weight, and the zinc oxide accounts for 5-15% by weight.

[0015] Compared with existing technologies, the beneficial effects of the ceramic preparation method based on the reuse of waste sludge of the present invention are as follows: First, the ceramic waste sludge is divided into plastic waste sludge and lean waste sludge, and pre-treated separately to obtain plastic sludge and lean sludge materials. The mixing characteristics of the mixture are initially determined based on sintering characteristics. Then, a composite low-temperature sintering aid is added to obtain the mixture, which is then shaped into a green body. Finally, a segmented sintering process is used to obtain the finished ceramic product. The final sintering temperature is 950–1050℃ and held for 1–3 hours. During the preparation process, characteristic particle size, actual moisture content, and actual... The sintering temperature is set, and the running time or speed of the grinding equipment is adjusted according to the characteristic particle size. The preset moisture content corresponding to the current characteristic particle size is determined by combining the characteristic particle size-moisture content correlation model. The characteristic ratio is adjusted based on the comparison between the actual moisture content and the preset moisture content. Alternatively, the heating power of the sintering furnace is adjusted by combining the characteristic particle size and the actual moisture content to predict the sintering activity rate of the green body and comparing it with the expected sintering activity rate. In this way, it is possible to distinguish waste mud with different properties, reduce the performance fluctuation of recycled products, and intelligently regulate the ceramic preparation process to improve the success rate of recycled products.

[0016] Furthermore, the present invention also determines the operating time or speed of the grinding equipment by comparing the characteristic particle size with the preset characteristic particle size; and when it is necessary to extend the operating time or increase the speed, it can accurately extend the operating time or increase the speed based on the comparison of the particle size difference with the preset particle size difference, so that the particle size of the barren clay can be more accurately and stably controlled within the preset range for ceramic preparation.

[0017] Furthermore, this invention can dynamically and accurately determine the preset moisture content corresponding to the current mixture based on the real-time collected characteristic particle size, and determine the characteristic ratio of the mixture during mixing based on the comparison between the actual moisture content and the preset moisture content; it can also accurately increase the characteristic ratio based on the comparison between the moisture content difference and the preset moisture content difference, or accurately decrease the characteristic ratio based on the comparison between the moisture content offset value and the preset moisture content offset value, thereby ensuring that the actual moisture content of the mixed mud can be automatically adjusted to the optimal process window that matches its particle characteristics under any incoming particle size, and ensuring that the mud always has the best molding plasticity, bonding strength and fluidity, providing a blank with highly consistent quality for subsequent pressing and molding, fundamentally reducing defects such as cracking and delamination caused by fluctuations in the mud's process performance.

[0018] Furthermore, this invention combines characteristic particle size and actual moisture content to predict the sintering activity rate of the green blank, and the comparison result with the expected sintering activity rate can intelligently adjust the heating power in the second-stage sintering furnace to ensure sintering quality. It can also accurately increase the heating power based on the comparison between the activity rate difference and the preset activity rate difference, or accurately decrease the heating power based on the comparison between the activity rate offset value and the preset activity rate offset value, thereby significantly improving energy utilization efficiency, achieving energy saving and consumption reduction, and ensuring the sintering quality of the final product.

[0019] Furthermore, this invention synchronously controls the adjustment of the sintering furnace heating power and the second-stage heating rate, enabling the heat input curve in the sintering furnace to be dually adapted to the real-time activity prediction of the green body (based on the activity rate difference and activity rate offset). This design not only controls the final temperature but also optimizes the path to reach the final temperature. For green bodies with low activity, the heating power is increased while the second heating rate is accelerated simultaneously to provide sufficient energy to overcome the sintering barrier. For green bodies with high activity, the heating power and the second heating rate are reduced simultaneously, effectively suppressing defects such as abnormal grain growth, green body deformation, and inability to expel internal pores caused by excessively rapid heating, thereby obtaining ceramic products with more uniform structure and superior performance. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of a system module for a ceramic preparation method that utilizes waste sludge in this embodiment; Figure 2 This is a schematic flowchart of a ceramic preparation method using waste mud recycling in this embodiment; Figure 3 This is a schematic diagram illustrating the process of adjusting the corresponding parameters of the grinding equipment based on the comparison results between the feature granularity and the preset feature granularity in this embodiment. Figure 4This is a flowchart illustrating the process of adjusting the characteristic ratio based on the comparison between the actual moisture content and the preset moisture content in this embodiment. Figure 5 This is a schematic diagram illustrating the process of adjusting the heating power of the sintering furnace based on the comparison between the sintering activity rate and the preset sintering activity rate in this embodiment. Detailed Implementation

[0021] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0022] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0023] It should be noted that in the description of this invention, the terms "upper", "lower", "left", "right", "inner", "outer", etc., which indicate directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0024] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0025] Please see Figure 1 The diagram shown illustrates a system module schematic for a ceramic preparation method using waste sludge recycling in this embodiment. The system modules in this embodiment include a sorting module, a pretreatment module, a mixing and molding module, a sintering module, a data acquisition module, and a central processing module.

[0026] A sorting module is configured to classify ceramic waste mud into plastic waste mud and lean waste mud according to their properties; a pretreatment module is configured to perform different pretreatments on the plastic waste mud and lean waste mud separated by the sorting module to obtain plastic mud material and lean mud material respectively; a mixing and molding module is configured to initially mix the plastic mud material and lean mud material obtained by the pretreatment module at a characteristic ratio of 5:5, and add a composite low-temperature sintering aid to obtain a mixture, wherein the characteristic ratio is determined to be within the range of 4:6 to 6:4 according to the sintering characteristics of the ceramic waste mud. The mixture includes waste glass powder, spodumene tailings, and zinc oxide as low-temperature sintering aids; the mixture is then formed into green bodies; a sintering module is configured to sinter the green bodies using a segmented sintering process, wherein the segmented sintering process includes: in the first stage, heating to 600±50℃ at a first heating rate, and then in the second stage, heating to the final sintering temperature of 950~1050℃ at a second heating rate and holding for 1~3 hours; a data acquisition module includes: a laser particle size analyzer installed at the pretreatment module for real-time acquisition of the characteristic particle size corresponding to the barren waste sludge. A moisture meter is installed in the mixing and molding module to collect the actual moisture content of the mixture in real time; a thermocouple is installed in the sintering module to collect the real-time sintering temperature corresponding to the second stage; a central processing module is connected to the data acquisition module, preprocessing module, mixing and molding module, and sintering module, and is configured to: send a first control command to the grinding equipment in the preprocessing module to adjust its running time or speed based on the comparison result of the characteristic particle size and the preset characteristic particle size; and adjust the grinding equipment's running time or speed based on the pre-configured characteristic particle size-moisture content correlation model. The system determines the preset moisture content corresponding to the current characteristic particle size. Based on the comparison between the actual moisture content and the preset moisture content, a second control command is sent to the mixing equipment in the mixing and molding module to adjust the required characteristic ratio of the mixture. Alternatively, the sintering activity rate of the green body is predicted based on the characteristic particle size and the actual moisture content. Based on the comparison between the sintering activity rate and the expected sintering activity rate, a third control command is sent to the sintering furnace in the sintering module to adjust its heating power in the second stage. The real-time sintering temperature after the heating power adjustment does not exceed the range of 950-1050℃. The system in this embodiment is a closed-loop, intelligent, and adaptive control system based on real-time data feedback, used to improve the efficiency of successfully preparing ceramics from waste sludge. The sintering characteristics of waste sludge refer to the physicochemical behavior characteristics exhibited by ceramic waste sludge during high-temperature sintering. These characteristics directly affect its formability, shrinkage rate, density, and the performance of the final ceramic product. A characteristic ratio of the mixture is initially determined based on the sintering characteristics of the ceramic waste sludge.

[0027] Please see Figure 2 The diagram shown is a schematic flow chart of a ceramic preparation method utilizing waste sludge in this embodiment. The process in this embodiment includes at least the following steps: S1: Several ceramic waste muds were divided into plastic waste muds and barren waste muds according to their properties, and pre-treated separately; S2: The pretreated plastic mud and lean mud are mixed according to the characteristic ratio, and a composite low-temperature sintering aid is added to obtain a mixture. The characteristic ratio is determined according to the ceramic waste mud. The composite low-temperature sintering aid includes waste glass powder, spodumene tailings and zinc oxide. S3: The mixture is formed into a green body and sintered using a segmented sintering process. In the first stage of the segmented sintering process, the temperature is raised to 600±50℃ at a first heating rate, and then raised to the final sintering temperature of 950~1050℃ at a second heating rate in the second stage and held for 1~3 hours. S4: During the preparation process, the characteristic particle size of the barren waste mud, the actual moisture content of the mixture, and the real-time sintering temperature of the second stage are collected in real time. S5: Compare the characteristic particle size, actual moisture content and corresponding preset threshold to determine whether the current ceramic preparation process meets the standard; S61: Adjust the running time or speed of the grinding equipment during the pretreatment process according to the comparison results between the feature particle size and the preset feature particle size, and determine the preset moisture content corresponding to the current feature particle size according to the pre-configured feature particle size-moisture content correlation model, and adjust the characteristic ratio based on the comparison results between the actual moisture content and the preset moisture content. S62: Or predict the sintering activity rate of the green body based on the characteristic particle size and the actual moisture content after adjustment, and adjust the heating power of the sintering furnace during the second stage of sintering based on the comparison between the sintering activity rate and the expected sintering activity rate.

[0028] In this embodiment, ceramic waste sludge is classified into plastic waste sludge and barren waste sludge based on its plasticity. Plastic waste sludge is rich in clay minerals and has high plasticity; barren waste sludge has low clay mineral content and high content of quartz, feldspar, and other granular aggregates, resulting in poor plasticity. For example, a plasticity index threshold P can be set to 15. Waste sludge with a plasticity index less than or equal to P and a flowability index greater than 75% is classified as barren waste sludge, while waste sludge with a plasticity greater than P is classified as plastic waste sludge.

[0029] When obtaining the mixture, the plastic clay, the lean clay and the composite low-temperature sintering aid are stirred and homogenized to obtain the mixture. In the sintering process, the pre-firing is carried out in the first stage, and the temperature is continuously raised to 600±50℃ to complete the dehydration and impurity removal of the green body. In the second stage, the actual sintering is carried out, and the temperature is continuously raised to 950~1050℃ and held for 1~3 hours to complete the densification sintering of the green body.

[0030] Key monitoring points should be placed at the stages that have the greatest impact on product quality; monitoring should be carried out on the three most critical and volatile stages: pretreatment (characteristic particle size), batching (actual moisture content), and sintering (temperature).

[0031] At the pretreatment station, a laser particle size analyzer is used to monitor the ground powder in real time to obtain data on the characteristic particle size W. At the mixing station, a moisture meter is used to monitor the mixture in real time to obtain data on the actual moisture content K. At the sintering station, thermocouples are used to monitor the sintering furnace in real time to obtain the sintering temperature. All the collected data are transmitted to the central processing module for analysis and processing.

[0032] Furthermore, the running time or speed of the grinding equipment is adjusted by comparing the real-time collected feature particle size W with the corresponding threshold; then, the corresponding preset moisture content K0 is determined by combining the feature particle size-moisture content correlation model, and the characteristic ratio of the mixture is adjusted by comparing the real-time collected actual moisture content K; this ensures that the mixture entering the next process is always in a "standard state", eliminating most of the quality fluctuation factors from the source.

[0033] Furthermore, based on the characteristic particle size W and the actual moisture content K detected again after adjustment, the sintering behavior of the green body is judged in advance, and the heating power during the sintering process is dynamically adjusted. Under the premise of ensuring that the final sintering temperature does not exceed 950-1050℃, the heating power of the second heating stage is appropriately increased so that the green body reaches the target temperature more quickly, thereby effectively extending the holding time at the highest temperature; or the preset holding time is extended accordingly to ensure that different batches of green bodies can be sintered at the optimal sintering temperature.

[0034] Please see Figure 3 The diagram illustrates the process of adjusting the parameters of the grinding equipment based on the comparison result between the feature particle size and the preset feature particle size in this embodiment. The process of adjusting the running time or rotation speed of the grinding equipment during preprocessing according to the comparison result between the feature particle size and the preset feature particle size includes: if the feature particle size is greater than a first preset feature particle size and less than or equal to a second preset feature particle size, determining to extend the running time or increase the rotation speed of the grinding equipment based on the particle size difference; wherein, the particle size difference is the difference between the feature particle size and the first preset feature particle size.

[0035] In this embodiment, a ball mill can be used as the grinding equipment. A preset characteristic particle size W0 corresponding to the characteristic particle size W is set. To more accurately and precisely determine whether the grinding process for barren waste sludge in the pretreatment stage meets the standard, the preset characteristic particle size W0 can be divided into a first preset characteristic particle size W1 (ideal target value) and a second preset characteristic particle size W2 (upper limit value of qualified). Based on the common process characteristics of ceramic raw materials (especially barren waste sludge), W1 can be set to 45 micrometers and W2 to 75 micrometers. The process of determining whether the pretreatment in the ceramic preparation process meets the standard based on the comparison between the characteristic particle size W and the first preset characteristic particle size W1 and the second preset characteristic particle size W2 is as follows: If W is less than or equal to W1, it is determined that the characteristic particle size W has reached the optimal level, the specific surface area of ​​the clay is large, the sintering activity rate is high, which is conducive to low-temperature densification sintering. The grinding equipment speed is automatically reduced or the standby mode is started to prevent over-grinding.

[0036] If W is greater than W1 and less than or equal to W2, the feature particle size W is deemed acceptable but needs optimization. In this case, the difference between W and W1 can be calculated and recorded as the particle size difference R. Based on the particle size difference R, it is determined whether to extend the running time of the grinding equipment or increase the rotation speed of the grinding equipment to fully grind and reduce the current W.

[0037] If W is greater than W2, it will lead to low green strength, uneven microstructure of sintered body, decreased mechanical properties and rough surface. The characteristic particle size W is determined to be unqualified. The grinding equipment speed is immediately increased to the maximum and an alarm is triggered. At the same time, the operator is notified to investigate the abnormality.

[0038] In other embodiments, the barren clay and plastic clay can be mixed before testing to obtain the corresponding characteristic particle size W.

[0039] Specifically, the process of determining whether to extend the running time or increase the rotation speed of the grinding equipment based on the particle size difference includes: extending the running time or increasing the rotation speed of the grinding equipment based on the comparison result between the particle size difference and a preset particle size difference, wherein the extension of the running time and the increase of the rotation speed are both positively correlated with the particle size difference.

[0040] In this embodiment, the particle size difference R is the difference between the characteristic particle size W and the first preset characteristic particle size W1. When the particle size difference R is larger, the characteristic particle size W is larger and farther away from the first preset characteristic particle size W1. The larger the characteristic particle size W is, the less sufficient the grinding process is, and the greater the adjustment force needs to be applied. Therefore, the increase in the running time or the increase in the rotation speed of the grinding equipment is also greater. Thus, the increase in the running time and the increase in the rotation speed are both positively correlated with the particle size difference R.

[0041] In this embodiment, based on process experiments and initial process parameters expected to bring the material to or near the target particle size, the original running time baseline value is determined to be between 90 minutes and 160 minutes, and the original rotation speed baseline value is determined to be between 22 RPM and 29 RPM. When it is determined that the running time of the grinding equipment needs to be extended and the rotation speed of the grinding equipment needs to be increased, in order to more accurately determine the extension range of the running time or the increase range of the rotation speed, the preset particle size difference R0 can be divided into a first preset particle size difference R1 and a second preset particle size difference R2. For example, R1 = 5 micrometers and R2 = 10 micrometers are set. The process of determining the extension range of the running time or the increase range of the rotation speed based on the comparison results of R with R1 and R2 is as follows: If R is less than or equal to R1, the central processing module generates a corresponding first running time adjustment command or a first speed adjustment command. The grinding equipment extends the original running time by 5% based on the first running time adjustment command, or increases the original speed by 5% based on the first speed adjustment command. For example, if the original running time is set to 120 minutes, the adjusted running time will be 126 minutes. If the original speed is set to 25 RPM, the adjusted speed will be 26.25 RPM.

[0042] If R is greater than R1 and less than or equal to R2, the central processing module generates a corresponding second running time adjustment command or a second speed adjustment command. The grinding equipment extends the original running time by 10% or increases the original speed by 8% according to the second running time adjustment command.

[0043] If R is greater than R2, the central processing module generates a corresponding third running time adjustment command or a third speed adjustment command. The grinding equipment extends the original running time by 20% or increases the original speed by 15% based on the third running time adjustment command.

[0044] It is understandable that the adjustment range for extending the running time or increasing the speed can be other values ​​that meet the requirements. For example, when R is less than or equal to R1, the running time can be extended by 6% or the speed can be increased by 6%. It should be noted that neither the adjustment of extending the running time nor the adjustment of increasing the speed will have a negative impact on the use of the equipment.

[0045] Please see Figure 4The diagram illustrates the process of adjusting the characteristic ratio based on the comparison between the actual moisture content and the preset moisture content in this embodiment. The process involves sequentially preparing samples, testing and data acquisition, and data analysis and fitting to obtain the feature granularity-moisture content correlation model. Based on the feature granularity-moisture content correlation model and the current feature granularity, the corresponding preset moisture content is dynamically determined. The process of adjusting the characteristic ratio during mixing based on the comparison between the actual moisture content and the preset moisture content includes: if the actual moisture content is less than or equal to the minimum value among the preset moisture contents, the characteristic ratio is increased based on the moisture content difference; if the actual moisture content is greater than the maximum value among the preset moisture contents, the characteristic ratio is decreased based on the moisture content offset value. Wherein, the moisture content difference is the difference between the minimum value among the preset moisture contents and the actual moisture content, and the moisture content offset is the difference between the actual moisture content and the maximum value among the preset moisture contents.

[0046] In this embodiment, a feature granularity-moisture content correlation model is used to couple and correlate the feature granularity W and the actual moisture content K. The preset moisture content K0 is dynamically determined based on the real-time monitored changes in feature granularity W and the pre-configured feature granularity-moisture content correlation model.

[0047] Regarding the characteristic particle size-moisture content correlation model, it can be an empirical regression model; it can be established through the following experimental methods: (1) Sample preparation: Select several representative samples of barren waste sludge raw materials, and use the ultrafine grinding equipment to grind for different durations to prepare a series of powder samples with different particle size distributions (e.g., the characteristic particle size W values ​​range from 10 micrometers to 100 micrometers); (2) Testing and data acquisition: For each powder sample, during the humidification process of the humidification equipment, gradually adjust the atomized water volume until the mixing effect reaches the best (i.e., good particle sphericity, concentrated particle size, and good fluidity), and record the characteristic particle size W and the corresponding actual moisture content K of the mixture at this time; (3) Data analysis and fitting: Use conventional data analysis software (e.g., Origin, MATLAB, or simple Excel spreadsheets) to perform linear or nonlinear regression fitting on the multiple sets of (characteristic particle size W, actual moisture content K) data points collected in step (2) to obtain the characteristic particle size-moisture content correlation model. The feature particle size-moisture content correlation model is pre-configured in the central processing module, which is capable of data processing and analysis. Then, the central processing module determines the preset moisture content in the subsequent mixing stage based on the feature particle size obtained during the real-time preparation process.

[0048] In this embodiment, an extrusion molding process can be selected during ceramic preparation. A preset moisture content K0 = [12%, 18%] can be exemplarily set based on the real-time monitored characteristic particle size W. The process for determining whether to adjust based on the comparison between the actual moisture content K and the preset moisture content K0 is as follows: If K is less than or equal to 12%, it means that the water content in the current mixture is too low, which will lead to problems such as molding difficulties, green body defects and insufficient green body strength. At this time, it is necessary to increase the proportion of plastic clay to increase the characteristic ratio, thereby increasing the actual water content K, and thus enhancing plasticity. This can significantly reduce defects such as green body cracking and deformation. At this time, the difference between the minimum value in the preset water content K0 and the actual water content K can be calculated and recorded as the water content difference N. Based on the water content difference N, the adjustment range of the characteristic ratio is determined.

[0049] If K is greater than 12% and less than or equal to 18%, it means that the water content in the current mixture is sufficient to meet the needs of the subsequent preparation process, and there is no need to adjust the characteristic ratio.

[0050] If K is greater than 18%, it means that the water content in the current mixture is too high, which can easily lead to cracking or deformation, as well as difficulties in demolding. In this case, it is necessary to reduce the proportion of plastic clay to reduce the characteristic ratio, thereby reducing the actual water content K, which can prevent sticking and deformation, eliminate drying cracking, and save drying energy. At this time, the difference between the actual water content K and the maximum value of the preset water content K0 can be calculated and recorded as the water content offset value M. Based on the water content offset value M, the reduction adjustment range of the characteristic ratio can be determined.

[0051] Specifically, the process of determining to increase the characteristic ratio based on the moisture content difference includes increasing the characteristic ratio based on the comparison result between the moisture content difference and a preset moisture content difference, wherein the increase in the characteristic ratio is positively correlated with the moisture content difference; the process of determining to decrease the characteristic ratio based on the moisture content offset value includes decreasing the characteristic ratio based on the comparison result between the moisture content offset value and a preset moisture content offset value, wherein the decrease in the characteristic ratio is positively correlated with the moisture content offset value.

[0052] In this embodiment, the moisture content difference N is the difference between the minimum value of the preset moisture content K0 and the actual moisture content K. The larger the moisture content difference N is, the smaller the actual moisture content K is, indicating that the water content in the current mixture is smaller, and the more the characteristic ratio needs to be increased. Therefore, the increase in the characteristic ratio is positively correlated with the moisture content difference N.

[0053] Furthermore, based on the sintering characteristics of ceramic waste mud and considering material properties, process requirements, and equipment type, the characteristic ratio is comprehensively determined to be within the range of 4:6 to 6:4. In this embodiment, the characteristic ratio is initially set to 5:5. A preset moisture content difference N0 is set, corresponding to the moisture content difference N. To more accurately determine the increase in the characteristic ratio, the preset moisture content difference N0 can be divided into a first preset moisture content difference N1 and a second preset moisture content difference N2. For example, N1=3% and N2=5%. The process of determining the increase in the characteristic ratio based on the comparison between N and N1 and N2 is as follows: If N is less than or equal to N1, the central processing module generates a corresponding first characteristic ratio adjustment command, adding plastic clay to the original mixture to change the characteristic ratio from 5:5 to 5.4:4.6.

[0054] If N is greater than N1 and less than or equal to N2, the central processing module generates a corresponding second characteristic ratio adjustment command, adding plastic mud to the original mixture to change the characteristic ratio from 5:5 to 5.7:4.3.

[0055] If N is greater than N², the central processing module generates a corresponding third characteristic ratio adjustment command, adding plastic clay to the original mixture to change the characteristic ratio from 5:5 to 6:4. In this embodiment, the moisture content offset value M is the difference between the actual moisture content K and the maximum value of the preset moisture content K0. The larger the moisture content offset value M is, the larger the actual moisture content K is, indicating that the water content in the current mixture is greater, and the more the characteristic ratio needs to be reduced. Therefore, the reduction of the characteristic ratio is positively correlated with the moisture content offset value M.

[0056] Furthermore, a preset moisture content offset value M0 is set corresponding to the moisture content offset value M. To more accurately determine the reduction range of the characteristic ratio, the preset moisture content offset value M0 can be divided into a first preset moisture content offset value M1 and a second preset moisture content offset value M2. For example, M1=4% and M2=6%. The process of determining the reduction range of the characteristic ratio based on the comparison between M and M1 and M2 is as follows: If M is less than or equal to M1, the central processing module generates a corresponding fourth characteristic ratio adjustment command to reduce the plastic mud material on the basis of the original mixture so that the characteristic ratio changes from 5:5 to 4.6:5.4.

[0057] If M is greater than M1 and less than or equal to M2, the central processing module generates a corresponding fifth characteristic ratio adjustment command to reduce the plastic mud material on the basis of the original mixture so that the characteristic ratio changes from 5:5 to 4.3:5.7.

[0058] If M is greater than M2, the central processing module generates a corresponding sixth characteristic ratio adjustment command to reduce the plastic mud material on the basis of the original mixture so that the characteristic ratio changes from 5:5 to 4:6.

[0059] Please see Figure 5 The diagram illustrates the process of adjusting the heating power of the sintering furnace based on a comparison between the sintering activity rate and a preset sintering activity rate in this embodiment. The process of adjusting the heating power of the sintering furnace during the second stage of sintering based on the comparison between the sintering activity rate and the expected sintering activity rate includes: if the sintering activity rate is less than or equal to the minimum value among the expected sintering activity rates, determining to increase the heating power of the sintering furnace based on the activity rate difference; if the sintering activity rate is greater than the maximum value among the expected sintering activity rates, determining to decrease the heating power of the sintering furnace based on the activity rate offset value; wherein, the activity rate difference is the difference between the minimum value among the expected sintering activity rates and the sintering activity rate, and the activity rate offset is the difference between the sintering activity rate and the maximum value among the expected sintering activity rates.

[0060] In this embodiment, relevant parameters of several characteristic particle sizes collected during the historical preparation process (including finer end particle size D10, median particle size D50, and coarser end particle size D90), as well as several actual moisture contents K collected, are input into the machine learning model as input features. The expected sintering activity (such as sintering shrinkage rate, final density, etc.) is set as the target label, and a gradient boosting tree is used for training to obtain a regression model. After training is completed, the real-time collected characteristic particle size W and actual moisture content K can be input into the regression model to predict the sintering activity rate F corresponding to the current green body.

[0061] Furthermore, a target sintering activity rate F0 corresponding to the sintering activity rate F is set. Based on previous process experiments and combined with material characteristics, the optimal window for the characteristic particle size W and the actual moisture content K is determined. Then, the target sintering activity rate F0 is characterized by the sintering linear shrinkage rate. For example, F0 = [14%, 16%]. The process of determining the sintering furnace heating power adjustment based on the comparison between the sintering activity rate F and the target sintering activity rate F0 is as follows: If F is less than or equal to 14%, it is predicted that the sintering driving force of the current green body is insufficient. If sintering is carried out directly according to the original plan, it will lead to under-firing of the product. At this time, the heating power in the sintering furnace can be increased to raise the original sintering temperature (but it must not exceed the upper limit of 1050℃); or the holding time can be extended at the target temperature, for example, from the original plan of 1 hour to a maximum of 3 hours (not exceeding 3 hours). At this time, the difference between the minimum value of the expected sintering activity rate F0 and the sintering activity rate F can be calculated and recorded as the activity rate difference H. Based on the activity rate difference H, the increase in heating power or the extension of the holding time can be determined.

[0062] If F is greater than 14% and less than or equal to 16%, the sintering activity of the current green body is predicted to be in the good or optimal range. In this case, the heating power in the current sintering furnace is maintained; or dynamic fine-tuning is performed to achieve precise sintering, such as lowering the planned final sintering temperature by 5°C to save a small amount of energy, because the activity is sufficient and top-level sintering is not required.

[0063] If F is greater than 16%, it is predicted that the sintering activity of the current green body is too high. Directly sintering according to the original plan will easily lead to over-burning. At this time, the heating power in the sintering furnace can be reduced to decrease the planned final sintering temperature (but not less than the lower limit of 950℃); or the holding time can be shortened at the target temperature, for example, from the planned 2 hours to a maximum of 1 hour (not less than 1 hour). At this time, the difference between the sintering activity rate F and the maximum value of the expected sintering activity rate F0 can be calculated and recorded as the activity rate offset value Y. Based on the activity rate offset value Y, the reduction of heating power or the reduction of holding time can be determined.

[0064] Specifically, the process of determining to increase the heating power of the sintering furnace based on the activity rate difference includes increasing the heating power of the sintering furnace based on the comparison result of the activity rate difference and a preset activity rate difference, wherein the increase in heating power is positively correlated with the activity rate difference; the process of determining to decrease the heating power of the sintering furnace based on the activity rate offset value includes decreasing the heating power of the sintering furnace based on the comparison result of the activity rate offset value and a preset activity rate offset value, wherein the decrease in heating power is positively correlated with the activity rate offset value.

[0065] In this embodiment, the activity rate difference H is the difference between the minimum value of the expected sintering activity rate F0 and the sintering activity rate F. When the activity rate difference H is larger, the sintering activity rate F is smaller, and the heating power needs to be increased to make up for the lack of activity of the material itself. Therefore, the increase in heating power is positively correlated with the activity rate difference H.

[0066] Furthermore, based on the expected sintering activity rate F0, the final sintering temperature, and the holding time, the original heating power benchmark value is determined to be 40-80kW. A preset activity rate difference H0 corresponding to the activity rate difference H is set. To more accurately determine the increase in heating power, the preset activity rate difference H0 can be divided into a first preset activity rate difference H1 and a second preset activity rate difference H2. For example, H1=3.5% and H2=5.5%. The process of determining the increase in heating power based on the comparison of H with H1 and H2 is as follows: If H is less than or equal to H1, the central processing module generates a corresponding first heating power adjustment command, and the sintering furnace increases the original heating power by 10% based on the first heating power adjustment command; for example, if the original heating power is set to 60kW, then the adjusted heating power is 66kW.

[0067] If H is greater than H1 and less than or equal to H2, the central processing module generates a corresponding second heating power adjustment command, and the sintering furnace increases the original heating power by 18% based on the second heating power adjustment command.

[0068] If H is greater than H2, the central processing module generates a corresponding third heating power adjustment command, and the sintering furnace increases the original heating power by 30% based on the third heating power adjustment command.

[0069] It is understandable that the adjustment range for increasing the heating power can also be other values ​​that meet the requirements. For example, when H is greater than H2, the heating power can be increased by 25% based on the original heating power. It should be noted that the adjustment of increasing the heating power will not have a negative impact on the use of the equipment.

[0070] In the embodiment, the activity rate offset value Y is the difference between the maximum value of the sintering activity rate F and the expected sintering activity rate F0. The larger the activity rate offset value Y is, the larger the sintering activity rate F is, and the more the heating power needs to be reduced to prevent over-sintering and ensure the stability of the product shape and microstructure. Therefore, the reduction in heating power is positively correlated with the activity rate offset value Y.

[0071] Furthermore, a preset activity rate offset value Y0 is set corresponding to the activity rate offset value Y. To more accurately determine the reduction in heating power, the preset activity rate offset value Y0 can be divided into a first preset activity rate offset value Y1 and a second preset activity rate offset value Y2. For example, Y1=3% and Y2=6%. The process of determining the reduction in heating power based on the comparison of Y with Y1 and Y2 is as follows: If Y is less than or equal to Y1, the central processing module generates a corresponding fourth heating power adjustment command, and the sintering furnace reduces the original heating power by 10% according to the command; for example, if the original heating power is set to 63kW, the adjusted heating power is 56.7kW.

[0072] If Y is greater than Y1 and less than or equal to Y2, the central processing module generates a corresponding fifth heating power adjustment command, and the sintering furnace reduces the original heating power by 16% according to the command.

[0073] If Y is greater than Y2, the central processing module generates a corresponding sixth heating power adjustment command, and the sintering furnace reduces the original heating power by 23% according to the command.

[0074] It is understandable that the reduction in heating power can also be other values ​​that meet the requirements. For example, when Y is greater than Y2, the heating power can be reduced by 25% from the original value. It should be noted that the reduction in heating power will not have a negative impact on the use of the equipment.

[0075] Specifically, while adjusting the heating power of the sintering furnace, the second heating rate corresponding to the second stage is simultaneously adjusted based on the change in heating power. An increase in heating power corresponds to an increase in the second heating rate, and a decrease in heating power corresponds to a decrease in the second heating rate. The adjusted real-time sintering temperature does not exceed the range of 950–1050°C.

[0076] In this embodiment, while adjusting the heating power of the sintering furnace according to the activity rate difference or activity rate offset, the heating rate of the second stage is simultaneously and positively correlated with the same activity rate difference or activity rate offset. The reference value for the first heating rate corresponding to the original first stage can be set to 1–3 °C / min, and the reference value for the second heating rate corresponding to the original second stage can be set to 5–10 °C / min, based on the expected sintering activity rate F0, the final sintering temperature, and the holding time. The adjustment of the heating power is coupled and linked with the second heating rate, and the second heating rate is controlled in a coordinated manner. A third stage is included after the second stage: rapid cooling to room temperature at a cooling rate of 5–10 °C / min.

[0077] Furthermore, when the heating power of the sintering furnace is increased based on the activity rate difference H, the second heating rate can also be increased based on the activity rate difference H; when the heating power of the sintering furnace is decreased based on the activity rate deviation Y, the second heating rate can also be decreased based on the activity rate deviation Y.

[0078] In this embodiment, the process of determining the increase in the second heating rate based on the comparison between the activity rate difference H and the first preset activity rate difference H1 and the second preset activity rate difference H2 is as follows: If H is less than or equal to H1, the central processing module generates corresponding first and second heating rate adjustment commands, and the sintering furnace increases the original second heating rate by 15% based on the command; for example, if the original second heating rate is set to 7%, the adjusted second heating rate is 8.05%.

[0079] If H is greater than H1 and less than or equal to H2, the central processing module generates a corresponding second heating rate adjustment command, and the sintering furnace increases the original second heating rate by 20% based on the command.

[0080] If H is greater than H2, the central processing module generates a corresponding third heating rate adjustment command, and the sintering furnace increases the original third heating rate by 30% based on the command.

[0081] It is understandable that the adjustment range of the second heating rate can also be other values ​​that meet the requirements. For example, when H is greater than H2, the second heating rate can be increased by 28% based on the original second heating rate. It should be noted that the adjustment of the second heating rate will not have a negative impact on the use of the equipment.

[0082] In this embodiment, the process of determining the reduction in the second heating rate based on the comparison between the activity rate offset value Y and the first preset activity rate offset value Y1 and the second preset activity rate offset value Y2 is as follows: If Y is less than or equal to Y1, the central processing module generates a corresponding fourth second heating rate adjustment command, and the sintering furnace reduces the original second heating rate by 10% based on the command; for example, if the original second heating rate is set to 7.5%, the adjusted second heating rate is 6.75%.

[0083] If Y is greater than Y1 and less than or equal to Y2, the central processing module generates a corresponding fifth second heating rate adjustment command, and the sintering furnace reduces the original second heating rate by 20% based on the command.

[0084] If Y is greater than Y2, the central processing module generates a corresponding sixth second heating rate adjustment command, and the sintering furnace reduces the original second heating rate by 25% based on the command.

[0085] It is understandable that the reduction adjustment of the second heating rate can also be other values ​​that meet the requirements. For example, when Y is greater than Y2, the original second heating rate can be reduced by 28%. It should be noted that the reduction adjustment of the second heating rate will not have a negative impact on the use of the equipment.

[0086] Specifically, the plastic waste sludge is a shaping sludge with a moisture content higher than 30%, and the barren waste sludge is a mixture of polishing waste residue and edge grinding waste residue in a ratio of 1:1 to 1:3; the pretreatment process for the plastic waste sludge includes at least crushing, dewatering, kneading, and aging; the pretreatment process for the barren waste sludge includes at least crushing, grinding, sieving, and aging.

[0087] In this embodiment, the main components of the finishing clay are clay minerals such as kaolinite, montmorillonite, and illite, as well as water and organic matter, which inherently possess high fineness and plasticity. The goal of pretreatment is not primarily grinding, but rather "homogenization" and "crushing," that is, breaking down hard lumps and clumps through methods such as kneading and aging, removing air bubbles, making its composition and moisture uniform, and fully developing its plasticity; its natural particle size is already very fine, and excessive grinding will damage its particle morphology and affect its plasticity.

[0088] The main components of the barren waste sludge are quartz, feldspar, clinker, etc., with coarse particles, high hardness, and no plasticity. The goal of pretreatment is purely "grinding". It is crushed to the required fineness by mechanical grinding using grinding equipment to increase its specific surface area and reactivity, and to transform it into a stable powder raw material that is easy to sinter. Its initial particle size is very coarse and needs to be ground very finely to be effective.

[0089] The pretreatment process for plastic waste sludge includes, in sequence: crushing to a particle size of less than 0.5 mm, dewatering to a moisture content of 10–12%, kneading under a vacuum of not less than -0.08 MPa, and then aging in a constant humidity and temperature environment for 48–72 hours to obtain plastic sludge with a plasticity index greater than 15. The pretreatment process for barren waste sludge includes, in sequence: crushing to a particle size of less than 2 mm and grinding to a particle size at least smaller than the second preset characteristic particle size W2, followed by aging in an environment with a humidity of 70% ± 5% for 24–48 hours to obtain barren sludge with a fluidity index greater than 75% and a plasticity index less than or equal to 15.

[0090] Specifically, the composite low-temperature sintering aid in the mixture accounts for 1-5% by weight, wherein the waste glass powder accounts for 50-70% by weight, the spodumene tailings account for 20-40% by weight, and the zinc oxide accounts for 5-15% by weight.

[0091] To better illustrate the process of using waste mud to prepare ceramics, the present invention will be further described below with reference to specific embodiments. Example 1:

[0092] The sorting module classifies ceramic waste mud into plastic waste mud (repair mud) and lean waste mud (polishing waste and edge grinding waste mixed at a 1:2 ratio) based on a plasticity index threshold of P=15. The plastic waste mud is sequentially crushed (to a particle size <0.5mm), dehydrated (to a moisture content of 11%), kneaded under a vacuum of -0.09MPa, and aged in a constant humidity and temperature environment for 60 hours to obtain plastic mud material. The lean waste mud is sequentially crushed (to a particle size <2mm), ground, sieved, and aged in a 70% humidity environment for 36 hours to obtain lean mud material.

[0093] At the pretreatment module, the laser particle size analyzer collected the characteristic particle size W=50μm of the barren mud in real time.

[0094] The mixing and molding module mixes plastic clay and lean clay at an initial ratio of 5:5, and adds a composite low-temperature sintering aid (60% waste glass powder, 30% spodumene tailings, and 10% zinc oxide) at 3% of the total weight of the mixture to obtain the final mixture. At the mixing module, a moisture meter collects real-time data showing that the actual moisture content of the mixture, K=14%.

[0095] The central processing module determines the preset moisture content K0 corresponding to the current feature particle size W=50μm as [13%, 17%] based on the pre-configured feature particle size-moisture content correlation model. Since the actual moisture content K=14% is within the preset range, the feature ratio is not adjusted.

[0096] After the mixture is shaped into green bodies, it enters the sintering module. The central processing module predicts the sintering activity rate F of the green body to be 15.2% based on the characteristic particle size W=50μm and the actual moisture content K=14%. Since this sintering activity rate is within the expected sintering activity rate F0=[14%,16%] range, the sintering module adopts a standard segmented sintering regime: the first stage heats up to 600℃ at 2℃ / min, and the second stage heats up to the final sintering temperature of 1000℃ at 7℃ / min and holds for 2 hours. Example 2:

[0097] The sorting and pre-processing process is the same as in Example 1.

[0098] At the preprocessing module, the laser particle size analyzer collected the characteristic particle size W=60μm of the barren clay in real time.

[0099] The initial ratio of the mixing and molding modules was 5:5. At the mixing module, the moisture meter measured the actual moisture content of the mixture in real time, which was K=11%.

[0100] The central processing module determines the preset moisture content K0 corresponding to W=60μm as [12.5%, 16.5%] based on the feature particle size-moisture content correlation model. Since the actual moisture content K=11%<12.5%, the moisture content difference N=1.5% is calculated. Based on the fact that the moisture content difference N is less than or equal to the first preset moisture content difference N1=3%, the central processing module sends a first control command to the mixing equipment to adjust the characteristic ratio from 5:5 to 5.4:4.6.

[0101] The adjusted mixture is shaped into green bodies. Based on the adjusted operating conditions (characteristic particle size W=60μm, expected moisture content to approach the preset value), the central processing module predicts the sintering activity rate of the green bodies to be F=14.1%. Since this sintering activity rate is slightly lower than the expected minimum, the activity rate difference H=0%. Because H=0%, the central processing module determines that it is in a critical state, maintaining the heating power and second heating rate of the second stage of the sintering furnace unchanged, and finally completing sintering by holding at 1000℃ for 2 hours. Example 3:

[0102] The sorting and pre-processing process is the same as in Example 1.

[0103] At the preprocessing module, the laser particle size analyzer collects the characteristic particle size of the barren clay in real time: W=70μm (greater than the first preset characteristic particle size W1=45μm, and less than or equal to the second preset characteristic particle size W2=75μm). The particle size difference R=25μm is calculated. Based on the fact that R is greater than the second preset particle size difference R2=10μm, the central processing module sends a third control command to the grinding equipment, increasing its rotation speed by 15% from the baseline value of 25RPM.

[0104] After adjustment and retesting, the characteristic particle size W decreased to 48 μm. The initial characteristic ratio of the mixing and molding module was 5:5. At the mixing module, the moisture meter collected real-time data showing that the actual moisture content of the mixture, K=19%.

[0105] The central processing module determines the preset moisture content K0 corresponding to W=48μm as [13.5%, 17.5%] based on the feature particle size-moisture content correlation model. Since the actual moisture content K=19%>17.5%, the moisture content offset value M=1.5% is calculated. Based on the fact that M is less than or equal to the first preset moisture content offset value M1=4%, the central processing module sends a fourth control command to the mixing equipment to adjust the characteristic ratio from 5:5 to 4.6:5.4.

[0106] The adjusted mixture was shaped into green bodies. The central processing module predicted a sintering activity rate F of 16.8% for the green bodies based on the characteristic particle size W = 48 μm and the adjusted actual moisture content K (expected to approach the preset value). Since this sintering activity rate was greater than the maximum expected range, an activity rate offset value Y = 0.8% was calculated. Based on Y being less than or equal to the first preset activity rate offset value Y1 = 3%, the central processing module sent a fourth heating power adjustment command to the sintering furnace, reducing it by 10% from the baseline value of 60 kW, and simultaneously reducing the second heating rate by 10% from the baseline value of 7 °C / min. The final sintering temperature was stabilized at 995 °C and held for 2 hours.

[0107] Control group, Example 4: The difference between this and Example 1 is that after the central processing module detects that the actual moisture content K=14%, it does not perform verification according to the characteristic particle size-moisture content correlation model, and does not execute any characteristic ratio adjustment instructions. The mixing process strictly maintains the initial 5:5 ratio, and the rest is the same as Example 1.

[0108] Control group, Example 5: The difference between this and Example 2 is that after the central processing module detects the characteristic particle size W=60μm, it generates an adjustment command for the grinding equipment. However, after detecting the actual moisture content K=11%, it does not adjust the characteristic ratio according to the comparison results. Otherwise, it is the same as Example 2.

[0109] Control group, Example 6: The difference between this and Example 3 is that the central processing module performs adjustments to the grinding and mixing equipment, but after predicting the sintering activity rate of the green blank to be F=16.8%, it does not adjust the heating power and heating rate of the sintering furnace accordingly, and still performs sintering according to the original power and rate. The rest is the same as Example 3.

[0110] Testing and evaluation methods: Flexural strength: According to GB / T 4741-1999 "Test Method for Flexural Strength of Ceramic Materials", the fracture strength of sintered specimens was determined using the three-point bending method, and the unit is MPa.

[0111] Water absorption rate: According to GB / T 3810.3-2016 "Test methods for ceramic tiles - Part 3: Determination of water absorption, apparent porosity, apparent relative density and bulk density", the boiling method was used for determination, and the result is expressed as a percentage (%).

[0112] Linear shrinkage rate: Measure the length of the green body after drying (L0) and the length after sintering (L1), and calculate it according to the formula ((L0-L1) / L0×100%), expressed as a percentage (%).

[0113] Bulk density: determined by Archimedes' displacement method according to GB / T 3810.3-2016, in g / cm³.

[0114] Product performance fluctuation coefficient (CV%): This is a key indicator for measuring the performance fluctuation of recycled products. Five samples were prepared repeatedly under the same embodiment conditions, and the coefficients of variation (CV, standard deviation / mean × 100%) of their flexural strength and water absorption were calculated for each sample. The average of these two values ​​was taken as the overall performance fluctuation coefficient for that embodiment. The lower the CV%, the better the production consistency and stability.

[0115] Please see the table below for specific data.

[0116] Table 1. Experimental results of Examples 1-6

[0117] As can be seen from Table 1: The complete implementation of this invention (Examples 1-3) demonstrates its comprehensive performance advantages and production stability: In terms of product performance, Examples 1-3, through precise control of pretreatment and mixing ratios based on real-time data (characteristic particle size, real-time moisture content), combined with predictive control of sintering activity rate, resulted in recycled products with flexural strengths all exceeding 36 MPa, water absorption rates all below 6%, and bulk densities all exceeding 2.10 g / cm³, meeting the requirements for conventional ceramic products. In contrast, all control groups exhibited varying degrees of performance degradation due to the lack of control measures: Control group Example 4, due to failure to verify and adjust the real-time moisture content according to the model, resulted in unsuitable plasticity of the mixture, insufficient sintering densification, significantly reduced flexural strength, and high water absorption; Control group Example 5, due to failure to adjust the characteristic ratio after detecting abnormal moisture content, resulted in poor green body formability, numerous internal defects, leading to the lowest strength, highest water absorption, and extreme performance fluctuations; Control group Example 6, although properly adjusted in the initial stage, failed to suppress the predicted high sintering activity with heating power, resulting in slight overfiring, abnormally large linear shrinkage, failure to achieve optimal density and strength, and compromised performance consistency.

[0118] Regarding the performance fluctuation coefficient (CV%), a key indicator for measuring the "performance fluctuation of recycled products," Examples 1-3 all had CV% values ​​below 4.5%, demonstrating that the preparation process of this invention effectively offsets the inherent volatility of the raw material waste sludge, ensuring the stability and uniformity of the recycled product quality. In contrast, the performance fluctuation coefficients of all control groups exceeded 7%, with Control Group 5 reaching as high as 11.3%. This clearly exposes that in the absence of one or more closed-loop adjustment mechanisms, minute changes in the waste sludge raw material are amplified step by step, ultimately leading to a significant increase in product performance dispersion and uncontrollable recycled product quality.

[0119] In summary, among Examples 1-3 and Control Examples 4-6, Examples 1-3, which fully implemented the present invention, showed significantly better performance in absolute indicators and production stability (low fluctuation coefficient) of the ceramic recycled products than the control groups with control defects. This demonstrates the important role of multi-stage linkage regulation based on real-time data feedback in the high-value and stable recycling of ceramic waste mud in the present invention.

[0120] It is understood that no specific limitation is made to any preset parameter or critical parameter in the embodiments of the present invention, and the above values ​​are not limited thereto. Those skilled in the art can make corresponding adjustments to the preset parameters or critical parameters according to actual needs, analysis of historical data, or equipment usage.

[0121] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A method for preparing ceramics using recycled waste mud, characterized in that, include: Several ceramic waste sludge samples were classified into plastic waste sludge and barren waste sludge according to their properties, and pretreated separately. The pretreated plastic mud and barren mud are mixed according to a characteristic ratio, and a composite low-temperature sintering aid is added to obtain a mixture. The characteristic ratio is determined according to the sintering characteristics of ceramic waste mud. The composite low-temperature sintering aid includes waste glass powder, spodumene tailings and zinc oxide. The mixture is formed into a green body and sintered using a segmented sintering process. The segmented sintering process includes heating to 600±50℃ at a first heating rate in the first stage, and then heating to the final sintering temperature of 950~1050℃ at a second heating rate in the second stage and holding at that temperature for 1~3 hours. During the preparation process, the characteristic particle size of the barren waste sludge, the actual moisture content of the mixture, and the real-time sintering temperature of the second stage are collected in real time. The ceramic preparation process is compared with the characteristic particle size, the actual moisture content, and the corresponding preset threshold to determine whether the current process meets the standard, including: The running time or rotation speed of the grinding equipment during the pretreatment process is adjusted according to the comparison result between the characteristic particle size and the preset characteristic particle size, and the preset moisture content corresponding to the current characteristic particle size is determined according to the pre-configured characteristic particle size-moisture content correlation model. The characteristic ratio is adjusted based on the comparison result between the actual moisture content and the preset moisture content. The sintering activity rate of the green body is predicted based on the characteristic particle size and the actual moisture content detected after adjustment. The heating power of the sintering furnace during the second stage of sintering is adjusted based on the comparison between the sintering activity rate and the expected sintering activity rate.

2. The ceramic preparation method based on the reuse of waste sludge according to claim 1, characterized in that, The process of adjusting the running time or rotation speed of the grinding equipment during pretreatment based on the comparison result between the feature particle size and the preset feature particle size includes: If the feature particle size is greater than the first preset feature particle size and less than or equal to the second preset feature particle size, the running time of the grinding equipment or the rotation speed is increased based on the particle size difference. The granularity difference is the difference between the feature granularity and the first preset feature granularity.

3. The ceramic preparation method based on the reuse of waste sludge according to claim 2, characterized in that, The process of determining whether to extend the operating time or increase the rotation speed of the grinding equipment based on the particle size difference includes: Based on the comparison result between the particle size difference and the preset particle size difference, the running time of the grinding equipment is extended or the rotation speed is increased, wherein the extension of the running time and the increase of the rotation speed are both positively correlated with the particle size difference.

4. The ceramic preparation method based on the reuse of waste sludge according to claim 2, characterized in that, The process of adjusting the characteristic ratio based on the comparison between the actual moisture content of the mixture and the preset moisture content includes: If the actual moisture content is less than or equal to the minimum value among the preset moisture contents, the proportion of increasing the characteristic is determined based on the moisture content difference. If the actual moisture content is greater than the maximum value among the preset moisture contents, the proportion of reducing the characteristic is determined based on the moisture content offset value; The preset moisture content is dynamically determined based on the feature granularity-moisture content correlation model and the current feature granularity. The moisture content difference is the difference between the minimum value of the preset moisture content and the actual moisture content. The moisture content offset is the difference between the actual moisture content and the maximum value of the preset moisture content.

5. The ceramic preparation method based on the reuse of waste sludge according to claim 4, characterized in that, The process of adjusting the characteristic ratio includes: The characteristic ratio is increased based on the comparison result between the moisture content difference and the preset moisture content difference, wherein the increase in the characteristic ratio is positively correlated with the moisture content difference. The characteristic ratio is reduced based on the comparison result between the moisture content offset value and the preset moisture content offset value, wherein the reduction in the characteristic ratio is positively correlated with the moisture content offset value.

6. The ceramic preparation method based on the reuse of waste sludge according to claim 1, characterized in that, The process of adjusting the heating power of the sintering furnace during the second stage of sintering based on the comparison between the sintering activity rate and the expected sintering activity rate includes: If the sintering activity rate is less than or equal to the minimum value among the expected sintering activity rates, the heating power of the sintering furnace is increased based on the activity rate difference. If the sintering activity rate is greater than the maximum value among the expected sintering activity rates, the heating power of the sintering furnace is reduced based on the activity rate offset value. Wherein, the activity rate difference is the difference between the minimum value of the expected sintering activity rate and the sintering activity rate, and the activity rate offset is the difference between the sintering activity rate and the maximum value of the expected sintering activity rate.

7. The ceramic preparation method based on the reuse of waste sludge according to claim 6, characterized in that, The process of adjusting the heating power of the sintering furnace during the second stage of sintering includes: The heating power of the sintering furnace is increased based on the comparison result between the activity rate difference and the preset activity rate difference, wherein the increase in heating power is positively correlated with the activity rate difference. The heating power of the sintering furnace is reduced based on the comparison result between the activity rate offset value and the preset activity rate offset value, wherein the reduction in heating power is positively correlated with the activity rate offset value.

8. The ceramic preparation method based on the reuse of waste sludge according to claim 7, characterized in that, Also includes: While adjusting the heating power of the sintering furnace, the second heating rate corresponding to the second stage is simultaneously adjusted based on the change in heating power, wherein... If the heating power of the sintering furnace is increased, the second heating rate will be increased simultaneously. If the heating power of the sintering furnace is reduced, the second heating rate will be reduced simultaneously.

9. The ceramic preparation method based on the reuse of waste sludge according to claim 8, characterized in that, The plastic waste mud is a blanking mud with a moisture content higher than 30%, and the barren waste mud is a waste mud mixed with polishing waste residue and edge grinding waste residue in a ratio of 1:1 to 1:

3. The pretreatment process for the plastic waste sludge includes, in sequence, crushing, dewatering, sludge kneading, and aging; The pretreatment process for the barren waste sludge includes crushing, grinding, sieving, and aging.

10. The ceramic preparation method based on the reuse of waste sludge according to claim 8, characterized in that, The composite low-temperature sintering aid in the mixture accounts for 1-5% by weight, wherein the waste glass powder accounts for 50-70% by weight, the spodumene tailings account for 20-40% by weight, and the zinc oxide accounts for 5-15% by weight.

Images