Sanitary ware ceramic material prepared by resource utilization of waste ceramic and preparation method of sanitary ware ceramic material

Abstract

The invention discloses a sanitary appliance ceramic material for resource utilization of waste ceramic and a preparation method of the sanitary appliance ceramic material. The ceramic material comprises a ceramic waste material, a plastic raw material, a lean raw material and a solvent raw material. The preparation process comprises the following steps: mechanically crushing ceramic waste of a sanitary ware factory into particles, drying, and screening by using an airflow classifier; soaking with a NaOH solution to obtain the pretreated ceramic waste; respectively grinding a plastic raw material, a lean raw material, a solvent raw material and the pretreated ceramic waste; mixing the ground ceramic waste with a solvent raw material, carrying out ball milling, adding a plastic raw material and a lean raw material, and continuously carrying out ball milling; and performing slip casting, and then performing segmented firing to obtain the sanitary ware ceramic material. According to the characteristics of the waste ceramic material, the formula is adjusted, and due to the fact that the proportion of the added waste ceramic particles is high, the green body formula, the firing curve and other process parameters are adjusted, so that the prepared product has high mechanical strength.

Description

Technical Field

[0001] This invention belongs to the field of ceramic resource utilization, specifically relating to a sanitary ware ceramic material for the resource utilization of waste ceramics and its preparation method. Background Technology

[0002] Sanitary ware ceramics are glazed ceramic products used in bathrooms, kitchens, and laboratories, encompassing toilets, washbasins, bathtubs, and other categories. They are categorized by material into ceramic (water absorption <18%), fine ceramic (<12%), semi-porcelain (<5%), and porcelain (<0.5%), with porcelain exhibiting the best performance. With the rapid development of my country's sanitary ware industry, the output of sanitary ware ceramic waste has surged year by year. Especially for manufacturers of sanitary ware ceramics, the accumulation and disposal of discarded waste is a significant problem. Excessive ceramic waste not only wastes production costs but also puts considerable pressure on the environment. This type of waste is hard and difficult to degrade; long-term landfilling not only occupies a large amount of land resources, but its resource recycling and utilization has become an important issue that the industry urgently needs to address.

[0003] Currently, although there have been initial explorations in the resource utilization of waste sanitary ware ceramics, its large-scale industrial application is still constrained by multiple technical bottlenecks. The main problems include the complex composition of waste ceramics and the difficulty of pretreatment; during the recycling process, the composition of recycled waste ceramics fluctuates greatly, leading to unstable sintering shrinkage and decreased mechanical properties, making it difficult to meet the production requirements of high value-added products. Through the applicant's research, improving the fluidity and compatibility of raw materials in the raw materials and preparation process can effectively overcome this defect. Summary of the Invention

[0004] This invention overcomes the shortcomings of existing technologies and provides a sanitary ware ceramic material for the resource utilization of waste ceramics and its preparation method. This invention adjusts the formula to address the characteristics of waste ceramic materials. Due to the high proportion of waste ceramic particles added, this invention adjusts process parameters such as the green body formula and firing curve, resulting in a product with high mechanical strength.

[0005] A sanitary ware ceramic material for the resource utilization of waste ceramics, comprising, by weight, 20-40 parts of ceramic waste, 30-50 parts of plastic raw material, 15-25 parts of lean raw material and 15-25 parts of solvent raw material;

[0006] The plastic raw materials include kaolin, bentonite, and clay;

[0007] The infertile raw materials include quartz and pyrophyllite;

[0008] The solvent raw materials include aegirine, enstatite, lithium aluminum phosphate, fluorite, barium carbonate, zincite, and talc.

[0009] Furthermore, the ingredients, by weight, include 25 parts ceramic waste, 40 parts plastic raw materials, 15 parts lean raw materials, and 20 parts solvent raw materials.

[0010] As a preferred example, the plastic raw material comprises, by mass percentage, 40-60% kaolin, 15-35% bentonite, and 15-35% clay.

[0011] Furthermore, the barren raw materials, by mass percentage, include 50-75% quartz and 25-50% pyrophyllite.

[0012] Furthermore, the solvent raw materials, by mass percentage, include 10-20% aegirine, 5-15% enstatite, 15-25% phosphogypsum, 10-15% fluorite, 5-8% strontium carbonate, 10-15% zincite, and 10-40% talc.

[0013] A method for preparing sanitary ware ceramic materials for the resource utilization of waste ceramics includes the following steps:

[0014] (1) Pretreatment of ceramic waste:

[0015] Ceramic waste from a sanitary ware factory is mechanically crushed to a particle size of 1-5mm, then dried, and sieved using an air classifier. This process removes the glaze material that falls off during crushing. The waste is then soaked in NaOH solution, filtered, washed, and naturally dried to obtain the pre-treated ceramic waste.

[0016] (2) Material grinding treatment:

[0017] Each of the plastic raw material, lean raw material, solvent raw material and the pretreated ceramic waste obtained in step (1) is ground to 300~400 mesh;

[0018] (3) Mix the ground ceramic waste with solvent raw materials, then ball mill, then add plastic raw materials and lean raw materials, and continue ball milling;

[0019] (4) The mixture is slurry-cast, then air-dried, and then fired in sections to obtain sanitary ware ceramic materials.

[0020] In the above method, in step (1), the concentration of the NaOH solution is 20~30wt%.

[0021] In the above method, in step (1), the soaking time is 5-10 hours; the number of times the washing is performed is 2-3 times.

[0022] In the above method, the ball milling time in step (3) is 2 to 6 hours.

[0023] In the above method, in step (4), the segmented firing is carried out at 250~350℃ for 1~2h; at 500~700℃ for 2~4h; and at 900~1000℃ for 2~4h.

[0024] Existing technologies suffer from significant fluctuations in the composition of recycled ceramic waste and unstable sintering shrinkage. The main reason for its limited recyclability is its poor compatibility with unsintered clay, kaolin, quartz, and other raw materials. Improving the flowability of ceramic waste, allowing it to mix uniformly with plastic and non-plastic raw materials, and simultaneously breaking the silicon-oxygen and aluminum-oxygen bonds in the waste, further enhancing its compatibility, would allow for a greater proportion of waste to be incorporated, thereby improving the molding effect and mechanical properties of the product.

[0025] In this invention, nephrite, enstatite, lithium aluminum phosphate, fluorite, and talc are used as fluxing agents to effectively enhance fluidity. Since ceramic waste is composed of sintered materials, the silicon-oxygen and aluminum-oxygen bonds increase product fluidity. The silicon-aluminum network structure hinders fluidity; without treatment, this can lead to different shrinkage rates and incompatibility with other raw materials, resulting in poor molding or even failure to form after sintering. The aforementioned fluxing agents effectively make ceramic waste compatible with both ductile and non-ductile raw materials while lowering the sintering temperature. The combination of barium carbonate and zinc ore with the aforementioned fluxing agents reduces the melting resistance of the ceramic waste, allowing the silicon-oxygen and aluminum-oxygen bonds in the silicon-aluminum network to break at lower temperatures during the first and second firing stages. This enhances fluidity, facilitates full integration with ductile and non-ductile raw materials, and minimizes the defects caused by different shrinkage rates due to the different raw materials in the ceramic waste, which can lead to material deformation or failure to form.

[0026] Compared with the prior art, the advantages of the present invention are:

[0027] (1) The formula is adjusted in this invention. Compared with the 10% proportion of ceramic waste added in the prior art, the proportion of waste ceramic particles added in this invention is higher, which effectively realizes the purpose of resource utilization of waste ceramics.

[0028] (2) The green body formula corresponding to the present invention can effectively improve the fluidity compatibility of waste ceramic materials with plastic raw materials and barren raw materials in the solvent raw material formula, so that the raw materials are compatible, the product after firing has high mechanical strength, and no open hole design appears.

[0029] (3) The present invention adjusts the process parameters such as the firing curve to adapt to the formula of the present invention, so that the firing temperature of the product is controlled within 1000℃. Attached Figure Description

[0030] Figure 1 Image of the sanitary ware ceramic material prepared in Example 1;

[0031] Figure 2 Image of the sanitary ware ceramic material prepared in Example 2;

[0032] Figure 3 Image of the sanitary ware ceramic material prepared in Example 3. Detailed Implementation

[0033] The technical solutions described below, in conjunction with specific illustrations, are presented to provide a full understanding of this application. However, this application can be implemented in many other ways different from those described herein, and similar extended embodiments made by those skilled in the art without inventive effort are all within the scope of protection of this invention.

[0034] Example 1

[0035] In this embodiment, 200g of kaolin, 100g of bentonite, and 100g of clay are used as plastic raw materials; 80g of quartz and 70g of pyrophyllite are used as barren raw materials; and 20g of aegirine, 10g of enstatite, 30g of lithium aluminum phosphate, 20g of fluorite, 16g of barium carbonate, 30g of zincite, and 74g of talc are used as solvent raw materials. 250g of ceramic waste from the sanitary ware factory is also used. In this embodiment, the ceramic waste from the sanitary ware factory mainly consists of waste ceramics, with the majority of the body and ligands being ceramic waste, including a small amount of glaze adhering to the surface of the ceramic waste.

[0036] (1) Take ceramic waste from sanitary ware factory, mechanically crush it to a particle size of 1~5mm, then dry it, and use an air classifier for screening. This process can remove the glaze material that falls off during crushing. Soak it in 25wt% NaOH solution at 40℃ for 10h to further remove the glaze material. Since the glaze material cannot be completely removed, filter and wash it 3 times, and then dry it naturally to obtain the pre-treated ceramic waste.

[0037] (2) Take plastic raw materials, lean raw materials, solvent raw materials and pre-treated ceramic waste obtained in step (1) and grind them to 325 mesh;

[0038] (3) Mix the ground ceramic waste with solvent raw materials, then ball mill, then add plastic raw materials and lean raw materials, and continue ball milling for 6 hours;

[0039] (4) The material is slurry-cast and then air-dried. It is then fired in stages: 350℃ for 2 hours; 700℃ for 3 hours; and 900℃ for 2 hours, yielding sanitary ware ceramic material #1, as shown in the image. Figure 1 As shown.

[0040] Example 2

[0041] 240g kaolin, 60g bentonite, and 100g clay were used as plastic raw materials; 187g quartz and 63g pyrophyllite were used as infertile raw materials; 15g aegirine, 7.5g enstatite, 37.5g phosphogypsum, 22.5g fluorite, 7.5g barium carbonate, 22.5g zincite, and 37.5g talc were used as solvent raw materials. 400g of ceramic waste was also used.

[0042] (1) Take ceramic waste from sanitary ware factory, mechanically crush it to a particle size of 1~5mm, then dry it, and use an air classifier for screening. This process can remove the glaze material that falls off during crushing. Soak it in 25wt% NaOH solution at 40℃ for 10h to further remove the glaze material. Since the glaze material cannot be completely removed, filter and wash it 3 times, and then dry it naturally to obtain the pre-treated ceramic waste.

[0043] (2) Take plastic raw materials, lean raw materials, solvent raw materials and pre-treated ceramic waste obtained in step (1) and grind them to 400 mesh;

[0044] (3) Mix the ground ceramic waste with solvent raw materials, then ball mill, then add plastic raw materials and lean raw materials, and continue ball milling for 6 hours;

[0045] (4) The material is slurry-cast and then air-dried. It is then fired in stages: 300℃ for 2 hours; 700℃ for 4 hours; and 1000℃ for 2 hours, yielding sanitary ware ceramic material #2, as shown in the image. Figure 1 As shown.

[0046] Example 3

[0047] 250g kaolin, 130g bentonite, and 120g clay were used as plastic raw materials; 150g quartz and 100g pyrophyllite were used as infertile raw materials; 30g aegirine, 20g enstatite, 30g phosphogypsum, 30g fluorite, 15g barium carbonate, 16g zincite, and 59g talc were used as solvent raw materials. 350g of ceramic waste was also used.

[0048] (1) Take ceramic waste from sanitary ware factory, mechanically crush it to a particle size of 1~5mm, then dry it, and use an air classifier for screening. This process can remove the glaze material that falls off during crushing. Soak it in 25wt% NaOH solution at 40℃ for 10h to further remove the glaze material. Since the glaze material cannot be completely removed, filter and wash it 3 times, and then dry it naturally to obtain the pre-treated ceramic waste.

[0049] (2) Take plastic raw materials, lean raw materials, solvent raw materials and pre-treated ceramic waste obtained in step (1) and grind them to 400 mesh;

[0050] (3) Mix the ground ceramic waste with solvent raw materials, then ball mill, then add plastic raw materials and lean raw materials, and continue ball milling for 6 hours;

[0051] (4) The material is slurry-cast and then air-dried. It is then fired in stages: 300℃ for 2 hours; 700℃ for 4 hours; and 1000℃ for 2 hours, yielding sanitary ware ceramic material #3, as shown in the image. Figure 1 As shown.

[0052] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A sanitary ware ceramic material for the resource utilization of waste ceramics, characterized in that, By weight, it includes 20-40 parts ceramic waste, 30-50 parts plastic raw materials, 15-25 parts lean raw materials and 15-25 parts solvent raw materials; The plastic raw materials include kaolin, bentonite, and clay; The infertile raw materials include quartz and pyrophyllite; The solvent raw materials include aegirine, enstatite, lithium aluminum phosphate, fluorite, barium carbonate, zincite, and talc.

2. The sanitary ware ceramic material for the resource utilization of waste ceramics according to claim 1, characterized in that, The ingredients, by weight, include 25 parts ceramic waste, 40 parts plastic raw materials, 15 parts lean raw materials, and 20 parts solvent raw materials.

3. The sanitary ware ceramic material for the resource utilization of waste ceramics according to claim 1, characterized in that, The plastic raw material comprises, by mass percentage, 40-60% kaolin, 15-35% bentonite, and 15-35% clay.

4. The sanitary ware ceramic material for the resource utilization of waste ceramics according to claim 1, characterized in that, The barren raw materials comprise, by mass percentage, 50-75% quartz and 25-50% pyrophyllite.

5. A sanitary ware ceramic material for the resource utilization of waste ceramics according to claim 1, characterized in that, The solvent raw materials, by mass percentage, include 10-20% aegirine, 5-15% enstatite, 15-25% phosphogypsum, 10-15% fluorite, 5-8% strontium carbonate, 10-15% zincite, and 10-40% talc.

6. A method for preparing a sanitary ware ceramic material for the resource utilization of waste ceramics as described in any one of claims 1 to 5, characterized in that, Includes the following steps: (1) Pretreatment of ceramic waste: Ceramic waste from a sanitary ware factory is mechanically crushed to a particle size of 1-5mm, then dried and sieved using an air classifier; it is then soaked in NaOH solution; filtered, washed, and naturally dried to obtain pre-treated ceramic waste. (2) Material grinding treatment: Each of the plastic raw material, lean raw material, solvent raw material and the pretreated ceramic waste obtained in step (1) is ground to 300~400 mesh; (3) Mix the ground ceramic waste with solvent raw materials, then ball mill, then add plastic raw materials and lean raw materials, and continue ball milling; (4) The mixture is slurry-cast, then air-dried, and then fired in sections to obtain sanitary ware ceramic materials.

7. The method for preparing sanitary ware ceramic materials for the resource utilization of waste ceramics according to claim 6, characterized in that, In step (1), the concentration of the NaOH solution is 20~30wt%.

8. The method for preparing sanitary ware ceramic materials for the resource utilization of waste ceramics according to claim 6, characterized in that, In step (1), the soaking time is 5-10 hours; the number of times the washing is performed is 2-3 times.

9. The method for preparing sanitary ware ceramic materials for the resource utilization of waste ceramics according to claim 6, characterized in that, In step (3), the ball milling time is 2 to 6 hours.

10. The method for preparing sanitary ware ceramic materials for the resource utilization of waste ceramics according to claim 6, characterized in that, In step (4), the segmented firing is carried out at 250~350℃ for 1~2 hours; at 500~700℃ for 2~4 hours; and at 900~1000℃ for 2~4 hours.

Images