Production process of self-heat-preservation building block by utilizing solid waste to synergistically foam

Abstract

The invention discloses a production process of a self-heat-preservation building block by utilizing solid wastes to cooperatively foam, and belongs to the technical field of building materials. The concrete comprises the following components in percentage by weight of dry materials: 14%-22% of cement, 6%-11% of lime and 6%-9% of perlite. The water-containing slurry comprises the following components in percentage by weight: 2.5%-5% of gypsum slurry, 18%-23% of waste slurry and 35%-56% of tailing slurry; the water-binder ratio is 0.65 to 0.98; the use amount of the aluminum powder accounts for 0.1-0.2% of the total mass. Wherein the perlite can effectively reduce the heat conductivity coefficient of the building block and improve the thermal insulation performance, and can achieve a synergistic effect with the silicon sludge to reduce the building energy consumption; a large amount of solid wastes such as waste slurry and tailing slurry are utilized, and the cutting wastes are recycled, so that the solid wastes are efficiently recycled, the environmental pollution is reduced, and the production cost is reduced; and aluminum powder foaming is combined with standing primary curing and autoclaved curing, so that a uniform pore structure is formed in the building block, and the building block has light weight and thermal insulation performance.

Description

Technical Field

[0001] This invention belongs to the field of building materials technology, specifically, it relates to a production process for self-insulating blocks that utilizes solid waste for co-foaming. Background Technology

[0002] Developing efficient and energy-saving building materials, especially new wall materials that combine load-bearing and thermal insulation functions, has become one of the key goals in promoting building energy conservation. Among the many wall materials, self-insulating blocks have received widespread attention from the industry because they can integrate the building envelope and thermal insulation functions into one, effectively avoiding problems such as hollowing, falling off, and fire hazards associated with external insulation systems, as well as the space occupied by internal insulation systems.

[0003] The raw materials for existing self-insulating blocks largely rely on natural aggregates (such as quartz sand and limestone) and high-quality cementitious materials (such as high-grade cement), which not only exacerbates the pressure on the extraction of natural mineral resources but also leads to persistently high production costs. On the other hand, my country generates massive amounts of solid waste annually during industrial production and urban construction, such as fly ash, slag, desulfurization gypsum, steel slag, tailings sand, and recycled construction waste powder. The accumulation of these solid wastes not only occupies a large amount of land resources but also poses potential pollution risks to soil, water, and air. How to achieve large-scale, high-value-added resource utilization has become an urgent social and environmental issue.

[0004] In summary, existing self-insulating block production processes still face challenges in terms of resource consumption, performance optimization, and environmental friendliness, while the need for large-scale solid waste resource utilization is extremely urgent. Therefore, there is a pressing need to develop an innovative production process to address these issues and meet the higher demands of the building materials technology field. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a production process for self-insulating blocks that utilizes solid waste for co-foaming.

[0006] The objective of this invention can be achieved through the following technical solutions: A process for producing self-insulating blocks using solid waste co-foaming includes the following steps: A1. Add cement, lime, perlite, gypsum slurry, waste slurry, tailings slurry and aluminum powder into a mixer and mix to make a mixed slurry; A2. The mixed slurry obtained in step A1 is fixedly poured into the mold. After pouring, the mold is slightly vibrated to remove large air bubbles and make the slurry level. It is then transferred to the static curing chamber for initial static curing to obtain the self-insulating block blank. A3. Position the self-insulating block blank obtained in step A2, cut the blank with a cutting machine, collect the waste, and then cure it to obtain a self-insulating block that utilizes solid waste for synergistic foaming.

[0007] As a further technical solution, the thermal insulation block is composed of the following components: by dry weight: 14%-22% cement, 6%-11% lime, and 6%-9% perlite; by weight of water-containing slurry: 2.5%-5% gypsum slurry, 18%-23% waste slurry, and 35%-56% tailings slurry; the water-cement ratio is 0.65-0.98.

[0008] As a further technical solution, the amount of aluminum powder used accounts for 0.1%-0.2% of the total mass.

[0009] As a further technical solution, the dry material in the tailings slurry includes tailings and silica mud.

[0010] As a further technical solution, the waste slurry is a mixture of waste materials and water, wherein the waste materials include gypsum, tailings, lime, cement and aluminum powder.

[0011] As a further technical solution, the stirring speed in step A1 is 800-1000 r / min, and the stirring time is 40-60 s.

[0012] As a further technical solution, the temperature of the mold in step A2 is 40-50℃.

[0013] As a further technical solution, the initial aging temperature in step A2 is 50-60℃, and the time is 1-2 hours.

[0014] As a further technical solution, the curing operation in step A3 is as follows: the billet is placed in a steam curing chamber, and under a pressure of 1.0-1.2MPa, it is first heated to 180-190℃ and cured at a constant temperature for 6-8 hours. Then, it is slowly cooled down to normal pressure for 2-3 hours, and after being taken out, it is naturally cured for 7 days.

[0015] The perlite in the formula, as a natural lightweight aggregate, effectively reduces the thermal conductivity of the blocks, enhancing their thermal insulation capabilities and achieving "self-insulation," thus reducing the building's reliance on additional insulation materials. Furthermore, the tailings mortar contains silica mud, a lightweight powder that, after reacting with cementitious materials, forms CSH gel, which refines the internal pore structure of the blocks (forming tiny, closed pores), reducing heat conduction channels. Combined with the low thermal conductivity of perlite, the silica mud synergistically enhances the thermal insulation effect of the blocks, further reducing thermal conductivity and building energy consumption. The extensive use of industrial solid waste such as gypsum slurry, waste slurry, and tailings mortar as raw materials transforms waste into valuable resources. This not only reduces production costs but also alleviates the environmental pressure of industrial solid waste, aligning with the requirements of green and sustainable development.

[0016] The beneficial effects of this invention are: Advantage 1: The addition of perlite can effectively reduce the thermal conductivity of the blocks, significantly improve the thermal insulation performance, and can work synergistically with silica mud to reduce building energy consumption; Advantage 2: It makes extensive use of solid waste such as waste slurry and tailings slurry, and recycles and reuses cutting waste, realizing efficient recycling of solid waste resources, reducing environmental pollution, and reducing the consumption of raw materials and production costs. Advantage 3: The combination of aluminum powder foaming and static curing and autoclaving creates a uniform pore structure inside the blocks, balancing lightweight and thermal insulation performance. Furthermore, the casting and precise cutting processes ensure product dimensional accuracy and improve quality stability. Advantage 4: The synergistic effect of multiple raw materials takes into account thermal insulation, mechanical properties and environmental benefits, which meets the development needs of green building materials and has a wide range of applications. Detailed Implementation

[0017] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Example 1 The raw materials for preparing the self-insulating blocks using solid waste co-foaming in this embodiment include the following components: by dry weight: 20.00% cement, 9.00% lime, and 6.19% perlite; by weight of water-containing slurry: 4.18% gypsum slurry, 20.07% waste slurry, and 40.56% tailings slurry; the water-cement ratio is 0.92; and the amount of aluminum powder accounts for 0.17% of the total mass. A process for producing self-insulating blocks using solid waste co-foaming includes the following steps: A1. Add cement, lime, perlite, gypsum slurry, waste slurry, tailings slurry and aluminum powder into a mixer and mix at 800 r / min for 40s to make a mixed slurry. A2. The mixed slurry obtained in step A1 is fixedly poured into the mold (the temperature of the mold is 40℃), the mold is slightly vibrated to remove large air bubbles and make the slurry smooth, and then transferred to the static curing chamber for static curing (temperature is 50℃, time is 1h) to obtain the self-insulating block blank. A3. Position the self-insulating block blank obtained in step A2, cut the blank with a cutting machine, collect the waste, and then cure it to obtain a self-insulating block that utilizes solid waste for synergistic foaming. The waste slurry is a mixture of waste materials and water, including gypsum, tailings, lime, cement and aluminum powder. The curing process in step A3 is as follows: the billet is placed in a steam curing chamber, heated to 180°C under a pressure of 1.0 MPa, and cured at a constant temperature for 6 hours. Then, it is slowly cooled down to normal pressure for 2 hours, removed, and cured naturally for 7 days.

[0019] Example 2 The raw materials for preparing the self-insulating blocks using solid waste co-foaming in this embodiment include the following components: by dry weight: 19.98% cement, 10.46% lime, and 8.09% perlite; by weight of water-containing slurry: 4.18% gypsum slurry, 20.05% waste slurry, and 37.25% tailings slurry; the water-cement ratio is 0.96; and the amount of aluminum powder accounts for 0.13% of the total mass. A process for producing self-insulating blocks using solid waste co-foaming includes the following steps: A1. Add cement, lime, perlite, gypsum slurry, waste slurry, tailings slurry and aluminum powder into a mixer and mix at 1000 r / min for 60s to make a mixed slurry. A2. The mixed slurry obtained in step A1 is fixedly poured into the mold (the temperature of the mold is 50℃), the mold is slightly vibrated to remove large air bubbles and make the slurry smooth, and then transferred to the static curing chamber for static curing (temperature is 60℃, time is 2h) to obtain the self-insulating block blank. A3. Position the self-insulating block blank obtained in step A2, cut the blank with a cutting machine, collect the waste, and then cure it to obtain a self-insulating block that utilizes solid waste for synergistic foaming. The waste slurry is a mixture of waste materials and water, including gypsum, tailings, lime, cement and aluminum powder. The curing process in step A3 is as follows: the billet is placed in a steam curing chamber, heated to 190°C under a pressure of 1.2 MPa, and cured at a constant temperature for 8 hours. Then, it is slowly cooled down to normal pressure for 3 hours, removed, and cured naturally for 7 days.

[0020] Example 3 The self-insulating blocks prepared by co-foaming of solid waste in this embodiment include the following raw materials: by dry weight: 19.97% cement, 8.99% lime, and 9.04% perlite; by weight of water-containing slurry: 4.18% gypsum slurry, 20.04% waste slurry, and 37.78% tailings slurry; the water-cement ratio is 0.96; and the amount of aluminum powder accounts for 0.18% of the total mass. A process for producing self-insulating blocks using solid waste co-foaming includes the following steps: A1. Add cement, lime, perlite, gypsum slurry, waste slurry, tailings slurry and aluminum powder into a mixer and mix at 1000 r / min for 60s to make a mixed slurry. A2. The mixed slurry obtained in step A1 is fixedly poured into the mold (the temperature of the mold is 40℃), the mold is slightly vibrated to remove large air bubbles and make the slurry smooth, and then transferred to the static curing chamber for static curing (temperature is 60℃, time is 2h) to obtain the self-insulating block blank. A3. Position the self-insulating block blank obtained in step A2, cut the blank with a cutting machine, collect the waste, and then cure it to obtain a self-insulating block that utilizes solid waste for synergistic foaming. The waste slurry is a mixture of waste materials and water, including gypsum, tailings, lime, cement and aluminum powder. The curing process in step A3 is as follows: the billet is placed in a steam curing chamber, heated to 190°C under a pressure of 1.2 MPa, and cured at a constant temperature for 8 hours. Then, it is slowly cooled down to normal pressure for 3 hours, removed, and cured naturally for 7 days.

[0021] Comparative Example The only difference between this comparative example and Example 3 is that perlite is not added in this comparative example to obtain self-insulating blocks.

[0022] The thermal conductivity of Examples 1, 2, and 3, and Comparative Example 1, was measured according to GB / T 10294-2008 standard; the results are shown in Table 1. Table 1 As can be seen from the measurement results in Table 1, the thermal conductivity of the blocks in Examples 1, 2, and 3 of the present invention decreased significantly with the increase of perlite content. Therefore, the blocks prepared by the present invention have good thermal insulation performance and have important application value in the field of building materials technology.

[0023] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

Claims

1. A production process for self-insulating building blocks utilizing solid waste co-foaming, characterized in that, Includes the following steps: A1. Add cement, lime, perlite, gypsum slurry, waste slurry, tailings slurry and aluminum powder into a mixer and mix to make a mixed slurry; A2. The mixed slurry obtained in step A1 is fixedly poured into the mold. After pouring, the mold is slightly vibrated to remove large air bubbles and make the slurry level. It is then transferred to the static curing chamber for initial static curing to obtain the self-insulating block blank. A3. Position the self-insulating block blank obtained in step A2, cut the blank with a cutting machine, collect the waste, and then cure it to obtain a self-insulating block that utilizes solid waste for synergistic foaming.

2. The self-insulating block production process utilizing solid waste for co-foaming as described in claim 1, characterized in that, The thermal insulation blocks are composed of the following components: by dry weight: 14%-22% cement, 6%-11% lime, and 6%-9% perlite; by weight of water-containing slurry: 2.5%-5% gypsum slurry, 18%-23% waste slurry, and 35%-56% tailings mortar; the water-cement ratio is 0.65-0.

98.

3. The self-insulating block production process utilizing solid waste for co-foaming as described in claim 1, characterized in that, The amount of aluminum powder used accounts for 0.1%-0.2% of the total mass.

4. The self-insulating block production process utilizing solid waste for co-foaming as described in claim 1, characterized in that, The dry materials in the tailings slurry include tailings and silica mud.

5. The self-insulating block production process utilizing solid waste for co-foaming as described in claim 1, characterized in that, The waste slurry is a mixture of waste materials and water, wherein the waste materials include gypsum, tailings, lime, cement and aluminum powder.

6. The self-insulating block production process utilizing solid waste for co-foaming as described in claim 1, characterized in that, In step A1, the stirring speed is 800-1000 r / min and the stirring time is 40-60 s.

7. The self-insulating block production process utilizing solid waste for co-foaming as described in claim 1, characterized in that, The temperature of the mold in step A2 is 40-50℃.

8. The self-insulating block production process utilizing solid waste for co-foaming as described in claim 1, characterized in that, In step A2, the initial aging temperature is 50-60℃ and the time is 1-2 hours.

9. The self-insulating block production process utilizing solid waste for co-foaming as described in claim 1, characterized in that, The curing process in step A3 is as follows: Place the billet in a steam curing chamber, and under a pressure of 1.0-1.2 MPa, first heat it to 180-190℃, and then maintain the temperature for 6-8 hours. After that, slowly cool it down to normal pressure for 2-3 hours, and then remove it and let it cure naturally for 7 days.

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