Lightweight high-strength lightweight aggregate block prepared by using solid waste

Abstract

The present application relates to the technical field of solid waste treatment, and particularly relates to a lightweight high-strength lightweight aggregate block prepared from solid waste, which is prepared from fly ash, slag and waste ceramic powder as main solid waste raw materials, combined with an alkali activator, a foaming agent, water and reinforcing fibers through an alkali-activated cementation and physical foaming synergistic process; the present application realizes a solid waste utilization rate greater than or equal to 85% through a multi-source solid waste synergistic alkali-activated cementation mechanism; the raw material ratio is dynamically adjusted according to the quality fluctuation of the raw materials through a raw material ratio calibration and optimization mechanism; the process is calibrated according to real-time quality monitoring data through a gradient curing and process parameter closed-loop optimization mechanism, so that the dry density of the block is less than or equal to 900 kg / m 3 , the compressive strength is greater than or equal to 10 MPa; the frost resistance and durability of the block are improved through a waste ceramic micro aggregate enhancement mechanism, and high-value utilization of bulk solid waste is realized.

Description

Technical Field

[0001] This invention relates to the field of solid waste management technology, and in particular to a lightweight, high-strength, lightweight aggregate block prepared from solid waste. Background Technology

[0002] With the accelerated pace of industrialization and urbanization in my country, the annual emissions of bulk industrial solid wastes such as fly ash, slag, and waste ceramics have continued to grow. According to statistics, my country's annual fly ash emissions exceed 600 million tons, slag emissions exceed 300 million tons, and the annual generation of building ceramic waste exceeds 10 million tons. If these solid wastes are not effectively utilized, they will not only occupy a large amount of land resources, but also cause serious pollution to soil, water bodies, and the atmosphere. Therefore, realizing the high-value utilization of bulk solid wastes is of great significance for promoting the development of a circular economy and protecting the ecological environment.

[0003] Chinese patent CN106316252B discloses autoclaved self-insulating blocks and their preparation method. This method uses fly ash and slag as the main raw materials and prepares lightweight blocks through cement cementing and chemical foaming processes. Although this method achieves some utilization of solid waste, it has the following shortcomings: First, the utilization rate of solid waste is low, and a large amount of cement still needs to be added as a cementing material, which fails to fully utilize the cementing activity of solid waste; Second, the compressive strength of the blocks is low, which is difficult to meet the requirements of load-bearing walls; Third, the pore structure produced by the chemical foaming process has poor uniformity, resulting in large fluctuations in the mechanical properties of the blocks.

[0004] Therefore, this solution still suffers from technical problems such as low solid waste utilization rate, insufficient compressive strength of blocks, and poor uniformity of pore structure. The existing technology lacks a dynamic correction mechanism for fluctuations in raw material quality. When the content of active components in fly ash or slag fluctuates, the proportion cannot be adjusted in time to ensure product quality consistency. At the same time, the existing technology lacks a mechanism for closed-loop optimization of preparation process parameters based on real-time quality monitoring data. When curing conditions or foaming effect deviate from expectations, the process parameters cannot be automatically adjusted to ensure product performance meets standards.

[0005] Chinese patent CN120518369A discloses a porous, heat-insulating, lightweight building material and its preparation method. This method uses alkali-activated geopolymer technology to prepare porous materials from metakaolin and slag. Although this method introduces alkali activation technology, it still has the following shortcomings: First, the raw material is mainly metakaolin, which is costly and does not make full use of bulk industrial solid waste. Second, it does not optimize the frost resistance and durability of block products, making them prone to freeze-thaw damage when used in cold regions. Third, the preparation process does not include a gradient curing step, resulting in insufficient geopolymer reaction and insufficient product performance stability. Summary of the Invention

[0006] With the accelerated pace of industrialization and urbanization in my country, the annual emissions of bulk industrial solid wastes such as fly ash, slag, and waste ceramics have continued to grow. According to statistics, my country's annual fly ash emissions exceed 600 million tons, slag emissions exceed 300 million tons, and the annual generation of building ceramic waste exceeds 10 million tons. If these solid wastes are not effectively utilized, they will not only occupy a large amount of land resources, but also cause serious pollution to soil, water bodies, and the atmosphere. Therefore, realizing the high-value utilization of bulk solid wastes is of great significance for promoting the development of a circular economy and protecting the ecological environment.

[0007] Chinese patent CN106316252B discloses autoclaved self-insulating blocks and their preparation method. This method uses fly ash and slag as the main raw materials and prepares lightweight blocks through cement cementing and chemical foaming processes. Although this method achieves some utilization of solid waste, it has the following shortcomings: First, the utilization rate of solid waste is low, and a large amount of cement still needs to be added as a cementing material, which fails to fully utilize the cementing activity of solid waste; Second, the compressive strength of the blocks is low, which is difficult to meet the requirements of load-bearing walls; Third, the pore structure produced by the chemical foaming process has poor uniformity, resulting in large fluctuations in the mechanical properties of the blocks.

[0008] Therefore, this solution still suffers from technical problems such as low solid waste utilization rate, insufficient compressive strength of blocks, and poor uniformity of pore structure. The existing technology lacks a dynamic correction mechanism for fluctuations in raw material quality. When the content of active components in fly ash or slag fluctuates, the proportion cannot be adjusted in time to ensure product quality consistency. At the same time, the existing technology lacks a mechanism for closed-loop optimization of preparation process parameters based on real-time quality monitoring data. When curing conditions or foaming effect deviate from expectations, the process parameters cannot be automatically adjusted to ensure product performance meets standards.

[0009] Chinese patent CN120518369A discloses a porous, heat-insulating, lightweight building material and its preparation method. This method uses alkali-activated geopolymer technology to prepare porous materials from metakaolin and slag. Although this method introduces alkali activation technology, it still has the following shortcomings: First, the raw material is mainly metakaolin, which is costly and does not make full use of bulk industrial solid waste. Second, it does not optimize the frost resistance and durability of block products, making them prone to freeze-thaw damage when used in cold regions. Third, the preparation process does not include a gradient curing step, resulting in insufficient geopolymer reaction and insufficient product performance stability. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the preparation method of lightweight high-strength lightweight aggregate blocks prepared from solid waste according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the alkali-activated gelation reaction mechanism in an embodiment of the present invention; Figure 3 This is a schematic diagram of the gradient curing temperature-time curve in an embodiment of the present invention. Detailed Implementation

[0011] 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.

[0012] 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.

[0013] 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.

[0014] 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.

[0015] Please see Figure 1 The diagram shown is a schematic flow chart of the preparation method of lightweight high-strength lightweight aggregate blocks prepared from solid waste in this embodiment; the preparation method includes: Step S1, raw material pretreatment; Step S2: Mix the dry materials; Step S3, preparation of alkali-activated gel slurry; Step S4, physical foaming and mixing; Step S5, casting and molding; Step S6, gradient maintenance; in: The pretreated fly ash, pretreated slag, and pretreated waste ceramic powder produced in step S1 are used as the processing objects in step S2. The dry mixture of the output from step S2 is used as the processing object in step S3. The alkali-activated gelatinous slurry produced in step S3 is the object of treatment in step S4. The foamed gel mixture produced in step S4 is the object of processing in step S5. The output blank of step S5 is the processing object of step S6. In steps S1 to S2, the parameters of the raw material pretreatment process are calibrated based on the raw material quality test data, the proportions are calibrated based on the raw material quality test data, and the proportions are optimized based on historical batch quality feedback. In steps S3 to S6, the process of preparing alkali-activated gel slurry is calibrated based on real-time quality monitoring data, and the process is optimized based on product quality test results.

[0016] Specifically, the lightweight, high-strength lightweight aggregate blocks prepared from solid waste and their preparation method are applied to non-load-bearing walls and thermal insulation enclosure structures in building engineering. Through the synergistic effect of a multi-source solid waste-assisted alkali-activated gelation mechanism and physical foaming process, coupled with raw material ratio calibration and optimization mechanisms and preparation process calibration and optimization mechanisms, multiple technical effects can be achieved, including high-value utilization of solid waste, lightweight and high-strength blocks, and green and low-carbon production, thus promoting the sustainable development of the construction industry. Specifically, the fly ash and slag provide active SiO2 and Al2O3 as the main reactants for the alkali-activated gelation reaction; the waste ceramic powder serves as micro-aggregate filler and reinforcement, improving the mechanical properties and durability of the blocks; the alkali... The activator provides an alkaline environment to stimulate the gelling activity of solid waste raw materials; the foaming agent introduces a uniform closed-cell structure through physical foaming, reducing the density of the blocks; the reinforcing fibers inhibit the propagation of microcracks and improve the toughness of the blocks; the gradient curing process ensures that the geopolymerization reaction proceeds fully, improving the stability of product performance; the raw material ratio calibration mechanism dynamically adjusts the ratio according to the fluctuation of raw material quality to ensure the consistency of raw material quality; the process calibration mechanism adjusts the process parameters according to real-time quality monitoring data to ensure the controllability of the preparation process; the ratio optimization mechanism and the process parameter optimization mechanism continuously improve the calibration strategy based on historical batch feedback and product quality test results, respectively, to achieve closed-loop quality control throughout the entire process.

[0017] Specifically, the lightweight, high-strength lightweight aggregate blocks prepared from solid waste comprise the following raw materials in parts by weight: Fly ash, wherein the weight parts of the fly ash are Mfmh, and 25 parts ≤ Mfmh ≤ 35 parts; Slag, wherein the weight parts of the slag are Mkz, and 20 parts ≤ Mkz ≤ 30 parts; Waste ceramic powder, wherein the waste ceramic powder is in parts by weight Mtc, and 15 parts ≤ Mtc ≤ 25 parts; Alkali activator, wherein the weight part of the alkali activator is Mjjf, and 8 parts ≤ Mjjf ≤ 15 parts; A foaming agent, wherein the foaming agent is in parts by weight Mfp, and 0.3 parts ≤ Mfp ≤ 0.8 parts; Water, wherein the weight parts of the water are Ms, and 15 parts ≤ Ms ≤ 25 parts; The reinforcing fiber has a weight part of Mqw, and 0.5 parts ≤ Mqw ≤ 1.5 parts; The mass ratio of fly ash, slag and waste ceramic powder is 7:6:5 to 5:4:3.

[0018] Specifically, the fly ash refers to the fine ash collected from the flue gas after the combustion of pulverized coal in coal-fired power plants. It belongs to Class F fly ash, i.e., low-calcium fly ash with a CaO mass fraction of less than or equal to 10%. The active SiO2 and Al2O3 in the fly ash can undergo a pozzolanic reaction under alkaline conditions to generate CSH gel and CASH gel, providing cementitious strength. The slag refers to granulated blast furnace slag obtained by water quenching and rapid cooling of industrial waste slag discharged during blast furnace ironmaking, followed by drying and grinding to obtain slag powder, which belongs to S95 grade slag powder. Its active CaO, SiO2, and Al2O3 can undergo rapid hydration reaction under alkaline activation conditions, forming a synergistic and complementary effect with the pozzolanic reaction of fly ash. The waste ceramic powder refers to the fine powder obtained by coarse crushing of waste ceramic tiles and waste ceramic pieces generated during the production of building ceramics, followed by ball milling with a jaw crusher and a planetary ball mill. Its main components are... The components are SiO2 and Al2O3, which have high hardness and chemical inertness, and play a role in filling and reinforcing the block matrix with micro-aggregates. The alkali activator refers to an alkaline solution that can activate the active components in fly ash and slag. In this embodiment, a mixed solution of water glass and sodium hydroxide is used. Water glass provides soluble silicon and an alkaline environment, while sodium hydroxide adjusts the alkalinity of the solution to a pH value of 12 to 14, thereby effectively activating the active SiO2 and Al2O3 in the solid waste raw materials. In this embodiment, the amount of fly ash is set to M1 parts, the amount of slag to M2 parts, the amount of waste ceramic powder to M3 parts, the amount of alkali activator to M4 parts, the amount of foaming agent to M5 parts, the amount of water to M6 parts, and the amount of reinforcing fiber to M7 parts. This ratio is determined based on orthogonal experimental optimization. When M1:M2:M3=6:5:4, the compressive strength and dry density of the block reach the optimal balance.

[0019] Specifically, the fly ash provides active SiO2 and Al2O3 to participate in the alkali-activated gelation reaction, dissolving and repolymerizing in an alkaline environment to generate NASH-type geopolymer gel. This gel forms an interpenetrating network structure with the CSH gel generated by slag hydration, thereby improving the density and strength of the block matrix. The slag provides early strength through rapid hydration, compensating for the slow reaction rate of fly ash. At the same time, the CaO component in the slag adjusts the Ca / Si ratio of the gel system, optimizing the stability of the gel structure. The waste ceramic powder forms a skeleton support in the gel matrix through its high-hardness particles, limiting the lateral deformation of the matrix under pressure, thereby improving the compressive strength of the block. The chemical inertness of the waste ceramic powder keeps it stable in an alkaline environment, does not participate in harmful alkali-aggregate reactions, and ensures the long-term volume stability of the block.

[0020] Specifically, in step S1, during raw material pretreatment, fly ash, slag, and waste ceramic powder are dried and sieved to obtain pretreated fly ash, pretreated slag, and pretreated waste ceramic powder. The drying temperature is 105℃ to 110℃, and the moisture content is dried to less than or equal to 1%. The sieving is performed using a 200-mesh square hole sieve, with a sieve residue rate of less than or equal to 5%. After being coarsely crushed by a jaw crusher, the waste ceramic powder is ball-milled by a planetary ball mill at a speed of 300 r / min to 500 r / min for 2 to 4 hours to obtain pretreated waste ceramic powder with a particle size D50 of 5 μm to 20 μm. The pretreated fly ash, pretreated slag, and pretreated waste ceramic powder are then fed into a forced mixer according to the specified ratio and dry-mixed at a speed of 60 r / min to 120 r / min for 2 to 5 minutes to obtain a mixed dry material.

[0021] Specifically, the drying temperature is 105℃ to 110℃. This temperature range is determined based on the evaporation characteristics of free water and bound water in the solid waste raw material. At this temperature, free water and some bound water in the raw material can be effectively removed, while the slag powder will not sinter and agglomerate due to excessive temperature. The moisture content of less than or equal to 1% refers to the mass loss rate of the raw material after drying. This indicator ensures that the proportioning accuracy and reaction conditions will not be affected by moisture fluctuations during subsequent mixing and reaction. The 200-mesh square hole sieve has a pore size of 75μm, and the sieve residue rate is set to be less than or equal to 5% to ensure that the maximum particle size of the raw material is controlled. The jaw crusher is used to crush large pieces of waste ceramic into small pieces of 20 to 50mm. The planetary ball mill grinds the coarsely crushed ceramic pieces at a speed of 300r / min to 500r / min. The ball milling time of 2h to 4h is determined based on experimental research on the hardness of waste ceramic and the target particle size. When the ball milling time is greater than or equal to 2h, the particle size requirement of D50≤20μm can be achieved.

[0022] Specifically, step S1 involves a rigorous pretreatment process to remove moisture and coarse particulate impurities from the solid waste raw materials, ensuring the uniformity of the raw material particle size and laying the foundation for the uniformity of the subsequent alkali-activated reaction. The ball milling of the waste ceramic powder reduces it to a micro-aggregate particle size, which can effectively fill the gel pores in the block matrix and improve the matrix density.

[0023] Specifically, in steps S1 to S2, when the proportions are checked based on the raw material quality test data: the active SiO2 and Al2O3 contents of the pretreated fly ash, pretreated slag, and pretreated waste ceramic powder are tested respectively. When the total mass fraction of SiO2 and Al2O3 in the pretreated fly ash is less than 70%, the activity of the pretreated fly ash is determined to be substandard, and the amount of fly ash is increased by 2 parts while the amount of slag is reduced by the same amount. When the SiO2 mass fraction of the pretreated slag is less than 10%, the activity of the pretreated slag is determined to be substandard, and the amount of alkali activator is increased by 1 part. When the SiO2 mass fraction of the pretreated waste ceramic powder is less than 60%, the hardness of the pretreated waste ceramic powder is determined to be substandard, and the amount of waste ceramic powder is increased by 2 parts while the amount of fly ash is reduced by the same amount. When all the above test results meet the standards, no proportioning is checked.

[0024] Specifically, the active SiO2 and Al2O3 content refers to the mass fraction of SiO2 and Al2O3 in fly ash and slag that can participate in the alkali-activated reaction, determined by X-ray fluorescence spectrometry. In this embodiment, the threshold value of the total mass fraction of SiO2 and Al2O3 in the pretreated fly ash is set at 70%. This value is determined based on experimental research on the alkali-activated reaction activity of fly ash. When the total mass fraction is greater than or equal to 70%, the pretreated fly ash has sufficient active components to participate in the pozzolanic reaction. In this embodiment, the threshold value of the SiO2 mass fraction in the pretreated slag is set at 10%. When the SiO2 mass fraction in the pretreated slag is less than 10%, the pretreated slag has sufficient activity to participate in the pozzolanic reaction. In this embodiment, the threshold value of the SiO2 mass fraction in the pretreated waste ceramic powder is set at 60%. When the SiO2 mass fraction in the pretreated waste ceramic powder is greater than or equal to 60%, the pretreated waste ceramic powder has sufficient hardness and chemical stability.

[0025] Specifically, the raw material ratio calibration mechanism detects the content of active components in the raw materials in real time. When the raw material quality fluctuates and the active components are insufficient, it compensates by increasing the amount of the corresponding raw materials or the amount of alkali activator, thereby ensuring the full progress of the alkali-activated gelation reaction and the consistency of the block performance under different batches of raw materials. Compared with no ratio calibration, after introducing the raw material ratio calibration mechanism, the coefficient of variation of compressive strength of different batches of blocks is reduced from 12% to less than 5%.

[0026] Specifically, in steps S1 to S2, when optimizing the mix proportion based on historical batch quality feedback: the compressive strength and dry density data of the blocks from the last 10 batches are statistically analyzed. If the average compressive strength of the blocks from the last 10 batches is less than 11 MPa, the compressive strength trend is determined to be substandard, and the fly ash content is optimized to increase by 3 parts; if the average dry density of the blocks from the last 10 batches is greater than 880 kg / m³, the proportion is optimized to increase by 3 parts. 3 When the dry density trend is determined to be substandard, the method for optimizing the proportion calibration process is to optimize the proportion of the foaming agent dosage by increasing the foaming agent dosage by 0.05 parts; when all the above statistical results meet the standards, no proportion optimization is performed on the proportion calibration process.

[0027] Specifically, the historical batch quality feedback refers to the statistical analysis of the compressive strength and dry density data of the last 10 batches of blocks to identify the long-term trend of product quality. In this embodiment, the average threshold for the compressive strength of the last 10 batches of blocks is set at 11 MPa. This value is higher than the single-batch pass standard of 10 MPa, leaving a 10% safety margin. When the long-term trend approaches the pass line, process optimization is triggered, and process adjustments are made in advance. In this embodiment, the average threshold for dry density is set at 880 kg / m³. 3 This value is lower than the single-batch pass standard of 900 kg / m³. 3 20kg / m 3 The safety margin; the calibration increment was optimized from 2 parts to 3 parts, which was determined based on the ratio sensitivity experiment. When the long-term trend does not meet the standard, appropriately increasing the calibration increment can bring the product quality back to the target range more quickly.

[0028] Specifically, the ratio optimization mechanism analyzes the long-term trends of historical batch data and proactively adjusts the ratio calibration process before a systematic deviation in product quality occurs, thereby achieving a shift from passive calibration to proactive optimization. Compared with single-batch calibration, the introduction of historical batch optimization improves the pass rate of the compressive strength of the blocks.

[0029] Specifically, the fly ash is Class F fly ash with a specific surface area greater than or equal to 400 m². 2 / kg, the total mass fraction of SiO2 and Al2O3 is greater than or equal to 70%, and the particle size D50 is 10μm to 30μm.

[0030] Specifically, the F-type fly ash refers to low-calcium fly ash classified according to GB / T 1596-2017 "Fly Ash for Cement and Concrete", i.e., CaO mass fraction less than or equal to 10%; the specific surface area refers to the ratio of the total surface area of ​​fly ash particles to their mass, determined using the Blaine permeability method. In this embodiment, a specific surface area greater than or equal to 400 m² is set. 2 / kg, this value is determined based on experimental research on the activation efficiency of fly ash, when the specific surface area is greater than or equal to 400m². 2 At a density of / kg, the reaction contact area of ​​fly ash particles is sufficient, and the rate and extent of alkali-activated reaction are significantly improved. The D50 refers to the median diameter of the particle size distribution, that is, the particle size value corresponding to the cumulative particle size distribution percentage reaching 50%, which is measured by a laser particle size analyzer. In this embodiment, D50 is set to 10μm to 30μm. This range is determined based on the fly ash particle size distribution optimization experiment. When D50 is within this range, the fly ash particles can fill the gaps between large particles without causing excessive water demand due to excessive fineness.

[0031] Specifically, the fly ash is controlled in terms of specific surface area and particle size distribution to ensure that it has a suitable dissolution rate and reactivity in the alkali-activated reaction, avoiding insufficient reaction due to excessively coarse particles or poor workability of the slurry due to excessively fine particles, thereby ensuring the homogeneity and stability of the mechanical properties of the block matrix.

[0032] Specifically, the slag is S95 grade slag powder with a specific surface area greater than or equal to 450 m². 2 / kg, with a mass coefficient greater than or equal to 1.8; the waste ceramic powder is obtained by crushing and ball milling construction waste ceramics, with a particle size D50 of 5μm to 20μm and a SiO2 mass fraction greater than or equal to 60%.

[0033] Specifically, the S95 grade slag powder refers to the powder formulated according to GB / T The slag powder graded according to the standard 18046-2017 "Granulated Blast Furnace Slag Powder for Cement, Mortar and Concrete" has a 7-day activity index greater than or equal to 75% and a 28-day activity index greater than or equal to 95%. The mass coefficient is a comprehensive indicator for measuring the activity of slag. In this embodiment, the mass coefficient is set to be greater than or equal to 1.8. This value is determined based on experimental research on the alkali-activated reaction activity of slag. When the mass coefficient is greater than or equal to 1.8, the hydration reaction rate of slag under alkali-activated conditions is fast and the degree is high. The SiO2 mass fraction of the waste ceramic powder is greater than or equal to 60%, which ensures that the waste ceramic powder has sufficient hardness and chemical stability. In this embodiment, the particle size D50 of the waste ceramic powder is set to be 5μm to 20μm. This range is determined based on experimental research on the micro-aggregate effect of waste ceramic powder. When D50 is within this range, the waste ceramic powder particles can effectively fill the micropores of the gel matrix, improve the density of the matrix, and at the same time, will not form stress concentration points in the matrix due to excessive particle size.

[0034] Specifically, the slag rapidly hydrates under alkaline activation conditions through its highly active CaO component to generate CSH gel, providing early structural strength for the blocks and shortening the demolding time of the green body; the waste ceramic powder forms a microskeleton in the gel matrix through its high-hardness SiO2 particles. When the matrix is ​​under pressure, the waste ceramic powder particles bear part of the load, limiting the plastic deformation of the gel matrix, thereby improving the compressive strength and elastic modulus of the blocks.

[0035] Specifically, the alkaline activator is a mixed solution of water glass and sodium hydroxide, wherein the modulus of the water glass is 1.5 to 2.5, the mass fraction of SiO2 in the water glass is 25% to 35%, the mass concentration of the sodium hydroxide solution is 10% to 20%, and the mass ratio of water glass to sodium hydroxide solution is 4:1 to 2:1.

[0036] Specifically, the modulus of the water glass refers to the molar ratio of SiO2 to Na2O in the water glass, i.e., modulus n = n(SiO2) / n(Na2O). In this embodiment, the modulus is set to 1.5 to 2.5. This range is determined based on alkali-activated reaction kinetic experiments. When the modulus is within this range, the water glass can provide sufficient soluble silicon to participate in the geopolymerization reaction without affecting the activation effect of fly ash and slag due to excessively low alkalinity. The alkali equivalent, calculated as Na2O, accounts for 4% to 8% of the total mass of fly ash, slag, and waste ceramic powder. In this embodiment, the mass fraction of SiO2 in the water glass is set to 25%. The concentration range of up to 35% ensures the stability and reactivity of the water glass solution. In this embodiment, the mass concentration of the sodium hydroxide solution is set at 10%-20%, which is used to adjust the total alkalinity of the mixed alkali activator to maintain the pH value of the slurry within a suitable range of 12 to 14. In this embodiment, the mass ratio of water glass to sodium hydroxide solution is set at 4:1 to 2:1. This ratio is determined based on the balance optimization experiment of the alkalinity of the alkali activator and the soluble silicon content. When the mass ratio is within this range, the ratio of Na2O and SiO2 in the alkali activator is appropriate, which can simultaneously meet the requirements of solid waste activation and geopolymer gel formation.

[0037] Specifically, the alkali activator provides soluble silicate ions (SiO4) via water glass. 4- Al dissolved from fly ash and slag 3+ A condensation reaction occurs, generating a NASH gel with a Si-O-Al three-dimensional network structure; simultaneously, sodium hydroxide provides OH... - Accelerating the disintegration and dissolution of fly ash vitreous body increases the dissolution rate of active components; the synergistic effect of water glass and sodium hydroxide enables the alkali-activated cementitious system to have both rapid reaction and long-term strength growth characteristics, thereby achieving the synchronous development of early and late strength of the blocks.

[0038] Specifically, the foaming agent is either an animal protein foaming agent or a plant protein foaming agent, with a foaming ratio greater than or equal to 20 times and a water exudation volume less than or equal to 20 mL per hour; the reinforcing fiber is at least one of alkali-resistant glass fiber and polypropylene fiber, with a fiber length of 6 mm to 12 mm and a fiber diameter of 10 μm to 30 μm.

[0039] Specifically, the animal protein foaming agent refers to a surfactant solution prepared by hydrolyzing and modifying proteins from animal hair, hooves, and horns. Its foaming mechanism involves protein molecules forming a viscoelastic adsorption film at the gas-liquid interface, resulting in good foam stability. The plant protein foaming agent refers to a foaming agent prepared from plant-derived proteins or saponins such as soybean protein and tea saponin. This embodiment sets the foaming ratio to be greater than or equal to 20 times, meaning that a unit volume of foaming agent solution can produce foam greater than or equal to 20 times its volume. This indicator ensures that the amount of foaming agent used can introduce sufficient closed-cell bubbles to reduce the density of the building blocks. This embodiment sets a 1-hour seepage rate. The volume is less than or equal to 20 mL. The amount of water exuded refers to the amount of liquid water exuded by the foam within 1 hour. This indicator reflects the stability of the foam. The smaller the amount of water exuded, the more stable the foam. The alkali-resistant glass fiber refers to alkali-resistant glass fiber containing ZrO2, which can maintain long-term strength in an alkaline gel matrix. The polypropylene fiber refers to synthetic fiber made from polypropylene resin through melt spinning, which has the characteristics of good alkali resistance and high tensile strength. In this embodiment, the fiber length is set to 6 mm to 12 mm. This length range allows the fiber to be evenly dispersed in the slurry during stirring, without tangling and clumping due to excessive length, or failing to provide effective bridging and reinforcement due to excessive shortness.

[0040] Specifically, the foaming agent introduces a large number of uniformly distributed closed-cell bubbles into the alkali-activated cementitious slurry through a physical foaming process. The bubble diameter is controlled within the range of 0.1 mm to 2 mm, causing the blocks to form a lightweight porous structure, thereby reducing the dry density to less than or equal to 900 kg / m³. 3 The reinforcing fibers form a three-dimensional randomly distributed fiber network in the gel matrix. When microcracks appear in the matrix, the fibers bridge the cracks on both sides, dispersing the stress at the crack tip to a larger area and inhibiting further crack propagation. This improves the flexural strength and toughness of the blocks and reduces the breakage rate of the products during transportation and construction.

[0041] Specifically, the preparation method includes: Step S1, raw material pretreatment: Fly ash, slag and waste ceramic powder are dried and screened respectively to obtain pretreated raw materials, wherein the pretreated raw materials include pretreated fly ash, pretreated slag and pretreated waste ceramic powder; Step S2, Dry material mixing: The pretreated raw materials are put into the mixer according to the ratio and dry mixed to obtain mixed dry materials; Step S3, Preparation of alkali-activated gel: Mix the alkali activator with water and then add it to the mixed dry materials and stir to obtain the alkali-activated gel; Step S4, Physical foaming and mixing: Add the foam prepared by the foaming agent and the reinforcing fiber to the alkali-activated gel slurry and stir to obtain the foam gel mixture; Step S5, casting and molding: pour the foam gel mixture into the mold, let it stand to release gas, and obtain the blank; Step S6, gradient curing: The green body is subjected to standard curing and steam curing in sequence to obtain lightweight, high-strength lightweight aggregate blocks.

[0042] Specifically, step S1, raw material pretreatment, refers to drying and sieving the three solid waste raw materials—fly ash, slag, and waste ceramic powder—to remove moisture and coarse particulate impurities, ensuring the uniformity and reactivity of the raw materials. Step S2, dry mixing, refers to dry mixing the three pretreated solid waste raw materials in a forced mixer according to the specified ratio, ensuring thorough and uniform mixing of the three powders to provide a uniform reaction substrate for the subsequent alkali-activated reaction. Step S3, alkali-activated gel preparation, refers to mixing a pre-prepared and activated alkali activator with water. After mixing, the dry mixture is added for wet mixing to ensure that the alkali activator and solid waste powder come into full contact and begin the activation reaction; the physical foaming and mixing in step S4 refers to preparing stable foam from the diluted foaming agent using a foaming machine and adding it to the alkali-activated gel slurry, while simultaneously incorporating reinforcing fibers for composite mixing; the casting and molding in step S5 refers to pouring the foam gel mixture into a mold and allowing it to stand to generate gas and form the shape; the gradient curing in step S6 refers to a phased curing process in which the green body is subjected to standard curing at room temperature and high-temperature steam curing in sequence.

[0043] Specifically, the preparation method achieves full-process control from solid waste raw materials to finished blocks through the orderly connection of steps S1 to S6; step S1 ensures the quality stability of raw materials; step S2 achieves uniform mixing of multi-source solid waste; step S3 initiates alkali-activated gelation reaction; step S4 introduces lightweighting and strengthening mechanisms; step S5 completes the green body forming; and step S6 ensures the full progress of the geological polymerization reaction and the final performance of the product through gradient curing.

[0044] Specifically, in step S1, the drying temperature is 105℃ to 110℃, and the drying is carried out until the moisture content is less than or equal to 1%; the sieving is carried out using a 200-mesh square hole sieve, and the sieve residue rate is less than or equal to 5%; the waste ceramic powder is coarsely crushed by a jaw crusher and then ball-milled by a planetary ball mill at a speed of 300r / min to 500r / min for 2h to 4h to obtain pretreated waste ceramic powder with a particle size D50 of 5μm to 20μm.

[0045] Specifically, in this embodiment, the drying temperature is set to 105℃ to 110℃. This temperature range is determined based on the evaporation characteristics of free water and bound water in the solid waste raw material. At this temperature, free water and some bound water in the raw material can be effectively removed, while the slag powder will not sinter and agglomerate due to excessive temperature. The moisture content of less than or equal to 1% refers to the mass loss rate of the raw material after drying. This indicator ensures that the proportioning accuracy and reaction conditions will not be affected by moisture fluctuations during subsequent mixing and reaction. The 200-mesh square hole sieve has a pore size of 75μm, and the sieve residue rate is set to less than or equal to 5% to ensure that the maximum particle size of the raw material is controlled. The jaw crusher is used to crush large pieces of waste ceramic into small pieces of 20 to 50mm. The planetary ball mill grinds the coarsely crushed ceramic pieces at a speed of 300r / min to 500r / min. The ball milling time of 2h to 4h is determined based on experimental research on the hardness of waste ceramic and the target particle size. When the ball milling time is greater than or equal to 2h, the particle size requirement of D50≤20μm can be achieved.

[0046] Specifically, when calibrating the parameters of the raw material pretreatment process based on the raw material quality test data: when the moisture content of fly ash is greater than 1%, the dryness of fly ash is determined to be substandard, the drying temperature is optimized to 110℃ to 115℃ and the drying time is extended until the moisture content is less than or equal to 1%; when the particle size D50 of waste ceramic powder after ball milling is greater than 20μm, the particle size of waste ceramic powder is determined to be substandard, and the ball milling time is extended by 0.5h; when all the above test results meet the standards, no calibration of the pretreatment process parameters is required.

[0047] Specifically, step S1 removes moisture and coarse particulate impurities from solid waste raw materials through a strict raw material pretreatment process and pretreatment parameter calibration mechanism, ensuring the uniformity of raw material particle size and laying the foundation for the uniformity of subsequent alkali-activated reaction; the ball milling treatment of waste ceramic powder makes it reach the micro-aggregate level particle size, which can effectively fill the gel pores in the block matrix and improve the matrix density.

[0048] Specifically, in step S3, when preparing the alkali-activated gel slurry, sodium hydroxide is first dissolved in water to prepare a sodium hydroxide solution. After the solution temperature drops to less than or equal to 40°C, water glass is added and stirred evenly. The solution is then allowed to stand for 2 to 4 hours for activation before use. The alkali equivalent in the alkali activator, calculated as Na2O, accounts for 4% to 8% of the total mass of fly ash, slag, and waste ceramic powder.

[0049] Specifically, the alkaline activator is prepared in the order of alkali first, then silicon. That is, sodium hydroxide solid is first dissolved in water to prepare sodium hydroxide solution. This is because the dissolution of sodium hydroxide is an exothermic process, and the solution temperature will rise significantly. Water glass is added after the solution temperature drops to less than or equal to 40°C to avoid gelation reaction of water glass under high temperature conditions. The static activation refers to letting the mixed alkaline activator stand under sealed conditions for 2 to 4 hours to allow the silicate ions in water glass to fully associate with the sodium ions in sodium hydroxide to form activated alkaline silicate complexes, thereby improving the reactivity of the alkaline activator. In this embodiment, the alkali equivalent, calculated as Na2O, accounts for 4% to 8% of the total mass of solid waste. This value is determined based on stoichiometric analysis and experimental verification of the alkaline activation reaction. When the alkali equivalent is 4%, the basic activation effect can be guaranteed. When the alkali equivalent is 8%, the optimal activation degree is reached. Exceeding 8% will lead to excessive free alkali, causing frost on the surface of the blocks.

[0050] Specifically, in step S3, when performing process calibration on the preparation of alkali-activated gel slurry based on real-time quality monitoring data: the pH value and slurry fluidity of the alkali-activated gel slurry are monitored in real time. When the pH value is less than 12, the amount of alkali activator is determined to be substandard, and the amount of alkali activator is increased by 1 part; when the slurry fluidity is less than 180mm, the slurry workability is determined to be substandard, and the amount of water is increased by 2 parts; when all the above monitoring results meet the standards, no calibration of process parameters is performed. Step S3 links the proportioning calibration process with the process calibration process in step S3. When the amount of fly ash increases after the raw material proportioning calibration, the amount of alkali activator is increased by 0.5 parts simultaneously to compensate for insufficient alkalinity.

[0051] Specifically, the pH value refers to the acidity or alkalinity of the alkali-activated gelling slurry, which is directly measured using a pH meter. In this embodiment, the pH threshold is set to 12. This value is determined based on the minimum alkalinity requirement for the activation of fly ash and slag. When the pH value is greater than or equal to 12, the alkali activator can effectively activate the active SiO2 and Al2O3 in the solid waste raw materials. The slurry fluidity refers to the flow extension diameter of the alkali-activated gelling slurry, which is measured using the truncated cone mold method. In this embodiment, the fluidity threshold is set to 180 mm. This value is determined based on the requirements of the slurry casting and molding process. When the fluidity is greater than or equal to 180 mm, the slurry has good casting workability.

[0052] Specifically, the pre-preparation and activation process of the alkali activator, combined with a real-time pH value and flowability monitoring and calibration mechanism, ensures the reactivity and stability of the alkali activator. This allows the alkali activator to quickly initiate the volcanic ash reaction and geopolymerization reaction after being mixed with solid waste raw materials. At the same time, it can compensate and adjust in a timely manner when the alkalinity or workability of the slurry deviates from the preset threshold, thereby ensuring the quality consistency of the alkali-activated gel slurry.

[0053] Specifically, in step S6, standard curing involves curing at a temperature of 20±2℃ and a relative humidity greater than or equal to 95% for 24 to 48 hours, followed by demolding and continued standard curing for 7 days. Steam curing involves heating the green body after 7 days of standard curing to 60 to 80℃ at a heating rate of 10℃ / h to 15℃ / h, maintaining constant temperature and humidity for 6 to 12 hours, and then cooling it to room temperature at a cooling rate less than or equal to 20℃ / h. The relative humidity during steam curing is greater than or equal to 80%.

[0054] Specifically, standard curing refers to room temperature curing of the green body in a standard curing room at a temperature of 20±2℃ and a relative humidity greater than or equal to 95%. After 24 to 48 hours of curing, the green body establishes preliminary structural strength and can be demolded without deformation or damage. Standard curing continues for 7 days to allow the alkali-activated gelation reaction to continue under room temperature conditions, generating a certain amount of CSH gel and NASH gel. Steam curing refers to an accelerated curing process performed on the green body after 7 days of standard curing. In this embodiment, the heating rate is set to 10℃ / h to 15℃ / h. This rate is determined based on the thermal stress analysis of the green body. Excessive heating will lead to an excessive temperature difference between the inside and outside of the green body, resulting in temperature stress cracking. The constant temperature in this embodiment is set to 60℃ to 80℃. This temperature range is determined based on the activation energy experiment of the geological polymerization reaction. At this temperature, the alkali-activated reaction rate is significantly accelerated, and the active components in fly ash and slag are fully dissolved and polymerized, so that the 7-day compressive strength of the block reaches more than 85% of the 28-day strength. The constant temperature time in this embodiment is set to 6h to 12h, which ensures that the reaction in the steam curing stage is fully carried out. The cooling rate in this embodiment is set to be less than or equal to 20℃ / h, which avoids thermal shock cracks caused by rapid cooling. The relative humidity in this embodiment is set to be greater than or equal to 80% during the steam curing process to prevent the green body from developing shrinkage cracks due to excessive water loss during high-temperature curing.

[0055] Specifically, when optimizing the process based on product quality inspection results: after steam curing, the blocks are tested for compressive strength and dry density. If the compressive strength is less than 10 MPa, it is determined that the compressive strength is substandard. The constant temperature during steam curing is then optimized by increasing the constant temperature by 5°C; if the dry density is greater than 900 kg / m³... 3 If the dry density is deemed unacceptable, process optimization is performed on the foaming agent dosage ratio in the formulation optimization. Specifically, the foaming agent dosage ratio is optimized by increasing it by 0.05 parts, and the process optimization is optimized by increasing it by 0.1 parts. If the above test results meet the standards, no further process optimization is performed.

[0056] Specifically, the gradient curing process achieves a slow-to-fast control strategy for the alkali-activated gelation reaction through a phased combination of standard curing and steam curing. The standard curing stage allows the green body to establish a uniform initial structure at a low reaction rate, avoiding stress concentration caused by rapid reaction. The steam curing stage accelerates the reaction by increasing temperature, enabling the blocks to achieve mechanical properties close to their final strength in a short time, thereby shortening the production cycle and increasing capacity. The process parameter optimization mechanism analyzes product quality test results and optimizes the calibration values ​​of curing temperature and foaming agent dosage when the block performance fails to meet standards. This allows the process calibration strategy to be adaptively adjusted according to actual product quality, thus achieving closed-loop optimization control of the preparation process.

[0057] Specifically, in step S4, after the foam is prepared, the foam stability is tested by the settling distance method, and the foam stability is required to reach a settling distance of less than or equal to 10 mm after 1 hour; in step S6, the blocks are re-prepared after process optimization; the adjustment range of the alkali activator is ±1 part, and the adjustment range of the foaming agent dosage is ±0.1 part.

[0058] Specifically, the settlement distance method involves injecting the prepared foam into a standard graduated cylinder and recording the distance the top surface of the foam descends within 1 hour; this distance is the settlement distance. In this embodiment, the 1-hour settlement distance is set to be less than or equal to 10 mm. This indicator ensures that the foam will not cause uneven block density or mold collapse due to rapid rupture during mixing with the cementitious slurry and during casting. The compressive strength test is conducted according to GB / T 11969-2020 "Test Methods for Performance of Autoclaved Aerated Concrete". In this embodiment, a compressive strength greater than or equal to 10 MPa is set as the pass standard. The dry density test is conducted according to the same standard. In this embodiment, a dry density less than or equal to 900 kg / m³ is set. 3 The standard is considered acceptable; if the test results do not meet the standard, the optimization and adjustment stage begins: if the compressive strength is less than 10 MPa, it indicates insufficient strength of the cementitious matrix, and the amount of alkali activator is increased by 1 part to improve the degree of alkali activation reaction; for some densities greater than 900 kg / m³... 3 This indicates insufficient foam introduction or poor foam stability. The amount of foaming agent should be increased by 0.1 parts to improve the amount of foaming agent. The adjustment range is ±1 part of alkali activator and ±0.1 part of foaming agent. This adjustment range is determined based on the sensitivity experiment of process parameters. Each adjustment range is moderate, which can effectively improve the performance without causing overcompensation due to excessive adjustment.

[0059] Specifically, the ratio calibration result is linked with the process calibration result. When the amount of fly ash increases after the raw material ratio calibration, the amount of alkali activator is increased by 0.5 parts to compensate for insufficient alkalinity. This is because after the amount of fly ash increases, more active SiO2 and Al2O3 need to be activated, and the amount of alkali activator needs to be increased accordingly to maintain a suitable alkalinity environment. The cross-stage linkage mechanism ensures that the ratio adjustment in steps S1 to S2 can be transmitted to steps S3 to S6, avoiding process parameter imbalance caused by information gaps.

[0060] Specifically, the quality monitoring and feedback optimization mechanism achieves full-process quality assurance of building blocks from raw material processing to finished product preparation through closed-loop control of three links: foam stability testing, finished product performance testing, and process parameter adjustment. This is combined with a raw material ratio calibration and optimization mechanism and a cross-stage linkage mechanism. Foam stability testing ensures the controllability of the foaming process, finished product performance testing ensures the qualification of product quality, process parameter adjustment enables the optimization of processes for substandard products, and the cross-stage linkage mechanism ensures parameter coordination between raw material processing and preparation processes, thereby guaranteeing product qualification rate and quality consistency.

[0061] Specifically, the implementation method of preparing lightweight, high-strength lightweight aggregate blocks using solid waste in this embodiment is as follows: Example

[0062] In Example 1, the composition of the ingredients is as follows: 30 parts fly ash, 25 parts slag, 20 parts waste ceramic powder, 12 parts alkali activator (containing 8 parts water glass and 4 parts sodium hydroxide), 0.5 parts foaming agent, 20 parts water, and 1.0 part reinforcing fiber (alkali-resistant glass fiber with a length of 9 mm and a diameter of 20 μm).

[0063] The manufacturing method of Embodiment 1 is as follows: Step S1: Fly ash and slag are dried at 105℃ until the moisture content is less than or equal to 1%, and then screened through a 200-mesh square hole sieve with a residue rate of less than or equal to 3%. Waste ceramic powder is coarsely crushed by a jaw crusher and then ball-milled by a planetary ball mill at a speed of 400 r / min for 3 hours to obtain waste ceramic powder with a particle size D50 of 12 μm. The active SiO2 and Al2O3 contents of the pretreated fly ash, pretreated slag, and pretreated waste ceramic powder are tested. The results are as follows: the total mass fraction of SiO2 and Al2O3 in the pretreated fly ash is 72%, the mass fraction of SiO2 in the pretreated slag is 11%, and the mass fraction of SiO2 in the pretreated waste ceramic powder is 62%. It is determined that the pretreated fly ash, pretreated slag, and pretreated waste ceramic powder all meet the standards, and no proportioning correction is required. Step S2: Add 30 parts of pretreated fly ash, 25 parts of slag and 20 parts of waste ceramic powder into a forced mixer and dry mix at 90 r / min for 3 min to obtain a mixed dry material. Step S3: First, dissolve 4 parts of sodium hydroxide in 15 parts of water to prepare a sodium hydroxide solution. After the solution temperature drops to 35℃, add 8 parts of water glass and stir evenly. Let it stand for 3 hours to activate. Mix the activated alkali activator with the remaining 5 parts of water and add it to the mixed dry material. Stir at 160 r / min for 5 minutes to obtain alkali activated gel slurry. The pH value of the slurry is monitored in real time and is 13.2, which is considered to meet the standard. No process calibration is required. Step S4: Dilute 0.5 parts of foaming agent with 20 parts of water at a mass ratio of 1:40 and prepare foam by foaming machine. The foam density is 45 g / L and the settling distance is 6 mm after 1 hour. Add the foam to the alkali-activated gel slurry and add 1.0 part of alkali-resistant glass fiber. Stir at 120 r / min for 2 min to obtain foam gel mixture. Step S5: Pour the foam gel mixture into the mold at a pouring temperature of 25°C. After pouring, let it stand for 4 hours to generate gas and obtain the green body. Step S6: After curing the green body under standard conditions of 20℃ and 98% relative humidity for 36 hours, it is demolded and cured under standard conditions for another 7 days. Then, the temperature is increased to 70℃ at a rate of 12℃ / h, and cured at a constant temperature of 85% relative humidity for 8 hours. Finally, it is cooled to room temperature at a rate of 15℃ / h to obtain lightweight, high-strength, lightweight aggregate blocks. The blocks are tested for quality; the compressive strength is 12.5 MPa, and the dry density is 820 kg / m³. 3 All were deemed to meet the standards, and no process optimization was required. Example

[0064] In Example 2, the following materials were used: 25 parts fly ash, 20 parts slag, 15 parts waste ceramic powder, 8 parts alkali activator (containing 6 parts water glass and 2 parts sodium hydroxide), 0.3 parts foaming agent, 15 parts water, and 0.5 parts reinforcing fiber (polypropylene fiber, 12 mm in length and 25 μm in diameter).

[0065] The manufacturing method of Embodiment 2 is as follows: Step S1: Fly ash and slag are dried at 108℃ until the moisture content is less than or equal to 1%, and then screened through a 200-mesh square hole sieve with a residue rate of less than or equal to 4%. Waste ceramic powder is coarsely crushed by a jaw crusher and then ball-milled by a planetary ball mill at a speed of 350 r / min for 3.5 h to obtain waste ceramic powder with a particle size D50 of 15 μm. The active SiO2 and Al2O3 contents of the pretreated fly ash, pretreated slag, and pretreated waste ceramic powder are tested. The results are as follows: the total mass fraction of SiO2 and Al2O3 in the pretreated fly ash is 68%, the mass fraction of SiO2 in the pretreated slag is 13%, and the mass fraction of SiO2 in the pretreated waste ceramic powder is 61%. It is determined that the activity of the pretreated fly ash is not up to standard. The amount of fly ash is increased by 2 parts and the amount of slag is reduced by the same amount. After calibration, the ratio is 27 parts fly ash and 18 parts slag. Step S2: 27 parts of pretreated fly ash, 18 parts of slag and 15 parts of waste ceramic powder are put into a forced mixer and dry-mixed at 100 r / min for 4 min to obtain a mixed dry material. Step S3: First, dissolve 2 parts of sodium hydroxide in 12 parts of water to prepare a sodium hydroxide solution. After the solution temperature drops to 38℃, add 6 parts of water glass and stir evenly. Let it stand for 2.5 hours to activate. Mix the activated alkali activator with the remaining 3 parts of water and add it to the mixed dry material. Stir at 180 r / min for 6 minutes to obtain alkali-activated gel slurry. The pH value of the slurry is monitored in real time and is 12.8, which is considered to meet the standard. No process calibration is required. Step S4: Dilute 0.3 parts of foaming agent with 12 parts of water at a mass ratio of 1:40 and prepare foam by foaming machine. The foam density is 40 g / L and the settling distance is 8 mm after 1 hour. Add the foam to the alkali-activated gel slurry and add 0.5 parts of polypropylene fiber. Stir at 100 r / min for 2.5 min to obtain foam gel mixture. Step S5: Pour the foam gel mixture into the mold at a pouring temperature of 28°C. After pouring, let it stand for 3 hours to generate gas and obtain the green body. Step S6: After curing the green body under standard conditions of 20℃ and 96% relative humidity for 30 hours, it is demolded and cured under standard conditions for another 7 days. Then, the temperature is increased to 65℃ at a rate of 10℃ / h, and cured at a constant temperature of 82% relative humidity for 10 hours. Finally, it is cooled to room temperature at a rate of 18℃ / h to obtain lightweight, high-strength, lightweight aggregate blocks. The blocks are tested for quality; the compressive strength is 11.8 MPa, and the dry density is 850 kg / m³. 3 All were deemed to meet the standards, and no process optimization was required. Example

[0066] In Example 3, the following ingredients were used: 35 parts fly ash, 30 parts slag, 25 parts waste ceramic powder, 15 parts alkali activator (containing 10 parts water glass and 5 parts sodium hydroxide), 0.8 parts foaming agent, 25 parts water, and 1.5 parts reinforcing fiber (polypropylene fiber, 12 mm in length and 25 μm in diameter).

[0067] The manufacturing method of Embodiment 3 is as follows: Step S1: Fly ash and slag are dried at 108℃ until the moisture content is less than or equal to 1%, and then sieved through a 200-mesh square hole sieve, with a sieve residue rate of less than or equal to 4%. Waste ceramic powder is coarsely crushed by a jaw crusher and then ball-milled by a planetary ball mill at a speed of 350 r / min for 3.5 h to obtain waste ceramic powder with a particle size D50 of 15 μm. The active SiO2 and Al2O3 content of the pretreated fly ash, pretreated slag, and pretreated waste ceramic powder are tested. The results are as follows: the total mass fraction of SiO2 and Al2O3 in the pretreated fly ash is 73%, the mass fraction of SiO2 in the pretreated slag is 10%, and the mass fraction of SiO2 in the pretreated waste ceramic powder is 63%. It is determined that the pretreated fly ash, pretreated slag, and pretreated waste ceramic powder all meet the standards, and no proportioning correction is required. Step S2: Add 35 parts of pretreated fly ash, 30 parts of slag and 25 parts of waste ceramic powder into a forced mixer and dry mix at 100 r / min for 4 min to obtain a mixed dry material. Step S3: First, dissolve 5 parts of sodium hydroxide in 18 parts of water to prepare a sodium hydroxide solution. After the solution temperature drops to 38℃, add 10 parts of water glass and stir evenly. Let it stand for 2.5 hours to activate. Mix the activated alkali activator with the remaining 7 parts of water and add it to the mixed dry material. Stir at 180 r / min for 6 minutes to obtain alkali-activated gel slurry. The pH value of the slurry is monitored in real time and is 12.6, which is considered to meet the standard. No process calibration is required. Step S4: Dilute 0.8 parts of foaming agent with 32 parts of water at a mass ratio of 1:40 and prepare foam using a foaming machine. The foam density is 40 g / L and the settling distance is 8 mm after 1 hour. Add the foam to the alkali-activated gel slurry and add 1.5 parts of polypropylene fiber. Stir at 100 r / min for 2.5 min to obtain the foam gel mixture. Step S5: Pour the foam gel mixture into the mold at a pouring temperature of 28°C. After pouring, let it stand for 3 hours to generate gas and obtain the green body. Step S6: After curing the green body under standard conditions of 20℃ and 96% relative humidity for 30 hours, it is demolded and cured under standard conditions for another 7 days. Then, the temperature is increased to 65℃ at a rate of 10℃ / h, and cured at a constant temperature of 82% relative humidity for 10 hours. Finally, it is cooled to room temperature at a rate of 18℃ / h to obtain lightweight, high-strength, lightweight aggregate blocks. The blocks are tested for quality; the compressive strength is 12.3 MPa, and the dry density is 830 kg / m³. 3 All were deemed to meet the standards, and no process optimization was required.

[0068] Comparative Example 1: Comparative Example 1 uses the same proportions as Example 1: 30 parts fly ash, 25 parts slag, 20 parts waste ceramic powder, 12 parts alkali activator, 0.5 parts foaming agent, 20 parts water, and 1.0 part reinforcing fiber. The difference between the preparation method of Comparative Example 1 and Example 1 is that step S6 adopts standard curing at room temperature (20°C, 95% relative humidity) for 28 days, without steam curing, i.e., single-stage curing instead of gradient curing.

[0069] Comparative Example 2: Comparative Example 2 uses 35 parts fly ash, 25 parts slag, 0 parts waste ceramic powder, 12 parts alkali activator, 0.5 parts foaming agent, 20 parts water, and 1.0 part reinforcing fiber. The preparation method of Comparative Example 2 is exactly the same as that of Example 1. That is, Comparative Example 2 does not contain waste ceramic powder, but is replaced by an equal amount of fly ash, and the other conditions remain unchanged.

[0070] Specifically, performance tests were conducted on the lightweight, high-strength, lightweight aggregate blocks prepared from solid waste in Examples 1 and 2 and Comparative Examples 1 and 2. The experimental data are shown in Tables 1 and 2 below: Table 1: Test data of mechanical and physical properties of masonry blocks ; Table 2: Test data on the durability performance of building blocks ; Specifically, we can conclude from Tables 1 and 2 that: (1) The compressive strength of Example 1 was 12.5±0.8MPa, which was 52.4% higher than that of Comparative Example 1 (8.2±0.9MPa) and 66.7% higher than that of Comparative Example 2 (7.5±0.7MPa). This directly proves that the gradient curing process and the waste ceramic powder micro-aggregate reinforcement mechanism have a significant effect on improving the compressive strength of the blocks. (2) The dry densities of Examples 1, 2 and 3 are 820±15 kg / m³, respectively. 3 850±18kg / m 3 and 830±15kg / m 3 All of them satisfy less than or equal to 900 kg / m 3The design requirements are met, while the dry density of Comparative Example 2 is 880±22 kg / m³. 3 This indicates that the introduction of waste ceramic powder improves strength without significantly increasing density, thus achieving a balance between lightweight and high strength. (3) The mass loss of the freeze-thaw cycle in Example 1 was 1.8±0.2%, which was 60% lower than that of Comparative Example 1 (4.5±0.5%) and 69% lower than that of Comparative Example 2 (5.8±0.6%). This proves that the introduction of waste ceramic powder micro-aggregate effectively improves the freeze-thaw resistance of the blocks. This is because the waste ceramic powder fills the micropores of the gel matrix, reducing the content and migration channels of freezeable water. (4) The drying shrinkage rate of Example 1 was 0.42±0.03 mm / m, which was 32.3% lower than that of Comparative Example 2 (0.62±0.06 mm / m), proving that the skeleton constraint of waste ceramic powder micro-aggregate effectively inhibited the drying shrinkage deformation of the blocks; (5) The softening coefficient of Example 1 was 0.88±0.02, which was higher than that of Comparative Example 1 (0.78±0.04) and Comparative Example 2 (0.72±0.04), proving that the gradient curing process made the geopolymer gel structure more compact and improved the water resistance of the blocks. (6) In Example 2, the amount of fly ash was increased and the amount of slag was reduced when the active components of fly ash did not meet the standard through the raw material ratio calibration mechanism. Its compressive strength was 11.8±0.6MPa, which was slightly lower than that of Example 1, but still significantly higher than that of Comparative Example 1 and Comparative Example 2. This proves that the raw material ratio calibration mechanism can effectively compensate for the impact of raw material quality fluctuations on product performance. In summary (1) to (6), the optimal solution for the lightweight high-strength lightweight aggregate block prepared from solid waste in this embodiment is the combination of proportions and process parameters of Example 1.

[0071] 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 lightweight, high-strength, lightweight aggregate block prepared from solid waste, characterized in that, Including the following parts by weight of raw materials: Fly ash, wherein the weight parts of the fly ash are Mfmh, and 25 parts ≤ Mfmh ≤ 35 parts; Slag, wherein the weight parts of the slag are Mkz, and 20 parts ≤ Mkz ≤ 30 parts; Waste ceramic powder, wherein the waste ceramic powder is in parts by weight Mtc, and 15 parts ≤ Mtc ≤ 25 parts; Alkali activator, wherein the weight part of the alkali activator is Mjjf, and 8 parts ≤ Mjjf ≤ 15 parts; A foaming agent, wherein the foaming agent is in parts by weight Mfp, and 0.3 parts ≤ Mfp ≤ 0.8 parts; Water, wherein the weight parts of the water are Ms, and 15 parts ≤ Ms ≤ 25 parts; The reinforcing fiber has a weight part of Mqw, and 0.5 parts ≤ Mqw ≤ 1.5 parts; The mass ratio of fly ash, slag and waste ceramic powder is 7:6:5 to 5:4:

3.

2. The lightweight, high-strength, lightweight aggregate block prepared from solid waste according to claim 1, characterized in that, The fly ash is Class F fly ash, with a specific surface area greater than or equal to 400 m². 2 / kg, the total mass fraction of SiO2 and Al2O3 is greater than or equal to 70%, and the particle size D50 is 10μm to 30μm; the slag is S95 grade slag powder with a specific surface area greater than or equal to 400m². 2 / kg, with a mass coefficient greater than or equal to 1.8; the waste ceramic powder is obtained by crushing and ball milling construction waste ceramics, with a particle size D50 of 5μm to 20μm and a SiO2 mass fraction greater than or equal to 60%; the alkali activator is a mixed solution of water glass and sodium hydroxide, with a water glass modulus of 1.5 to 2.5, a SiO2 mass fraction of 25% to 35% in the water glass, a sodium hydroxide solution mass concentration of 10% to 20%, and a water glass to sodium hydroxide solution mass ratio of 4:1 to 2:1; the foaming agent is any one of animal protein foaming agent and plant protein foaming agent, with a foaming ratio greater than or equal to 20 times and a water exudation of less than or equal to 20mL in 1h; the reinforcing fiber is at least one of alkali-resistant glass fiber and polypropylene fiber, with a fiber length of 6mm to 12mm and a fiber diameter of 10μm to 30μm.

3. A method for preparing lightweight, high-strength lightweight aggregate blocks made from solid waste as described in any one of claims 1-2, characterized in that, The preparation method includes: Step S1, raw material pretreatment: Fly ash, slag and waste ceramic powder are dried and screened respectively to obtain pretreated raw materials, wherein the pretreated raw materials include pretreated fly ash, pretreated slag and pretreated waste ceramic powder; Step S2, Dry material mixing: The pretreated raw materials are put into the mixer according to the ratio and dry mixed to obtain mixed dry materials; Step S3, Preparation of alkali-activated gel: Mix the alkali activator with water and then add it to the mixed dry materials and stir to obtain the alkali-activated gel; Step S4, Physical foaming and mixing: Add the foam prepared by the foaming agent and the reinforcing fiber to the alkali-activated gel slurry and stir to obtain the foam gel mixture; Step S5, casting and molding: pour the foam gel mixture into the mold, let it stand to release gas, and obtain the blank; Step S6, gradient curing: The green body is subjected to standard curing and steam curing in sequence to obtain lightweight high-strength lightweight aggregate blocks; In steps S1 to S2, the parameters of the raw material pretreatment process are calibrated based on the raw material quality test data, the proportions are calibrated based on the raw material quality test data, and the proportions are optimized based on historical batch quality feedback. In steps S3 to S6, the process of preparing alkali-activated gel slurry is calibrated based on real-time quality monitoring data, and the process is optimized based on product quality test results.

4. The method for preparing lightweight, high-strength lightweight aggregate blocks using solid waste according to claim 3, characterized in that, In step S1, during raw material pretreatment, fly ash, slag, and waste ceramic powder are dried and sieved respectively to obtain pretreated fly ash, pretreated slag, and pretreated waste ceramic powder. The drying temperature is 105℃ to 110℃, and the moisture content is dried to less than or equal to 1%. The sieving is performed using a 200-mesh square hole sieve, and the sieve residue rate is less than or equal to 5%. After being coarsely crushed by a jaw crusher, the waste ceramic powder is ball-milled by a planetary ball mill at a speed of 300 r / min to 500 r / min for 2 to 4 hours to obtain pretreated waste ceramic powder with a particle size D50 of 5 μm to 20 μm. The pretreated fly ash, pretreated slag, and pretreated waste ceramic powder are then fed into a forced mixer according to the specified ratio and dry-mixed at a speed of 60 r / min to 120 r / min for 2 to 5 minutes to obtain a mixed dry material.

5. The method for preparing lightweight, high-strength lightweight aggregate blocks using solid waste according to claim 4, characterized in that, In steps S1 to S2, when the parameters of the raw material pretreatment process are checked based on the raw material quality test data: when the moisture content of fly ash is greater than 1%, the drying temperature is optimized to 110℃ to 115℃ and the drying time is extended until the moisture content is less than or equal to 1%; when the particle size D50 of waste ceramic powder after ball milling is greater than 20μm, the ball milling time is extended by 0.5h.

6. The method for preparing lightweight, high-strength lightweight aggregate blocks using solid waste according to claim 3, characterized in that, In steps S1 to S2, when the proportioning is checked based on the raw material quality test data: the active SiO2 and Al2O3 content of the pretreated fly ash, pretreated slag, and pretreated waste ceramic powder are tested respectively. When the total mass fraction of SiO2 and Al2O3 in the pretreated fly ash is less than 70%, the amount of fly ash is increased by 2 parts and the amount of slag is reduced by the same amount. When the mass fraction of SiO2 in the pretreated slag is less than 10%, the amount of alkali activator is increased by 1 part. When the mass fraction of SiO2 in the pretreated waste ceramic powder is less than 60%, the amount of waste ceramic powder is increased by 2 parts and the amount of fly ash is reduced by the same amount.

7. The method for preparing lightweight, high-strength lightweight aggregate blocks using solid waste according to claim 6, characterized in that, In steps S1 to S2, when optimizing the mix proportion based on historical batch quality feedback: the compressive strength and dry density data of the blocks from the last 10 batches are statistically analyzed. When the average compressive strength of the blocks from the last 10 batches is less than 11 MPa, the fly ash content is optimized to increase by 3 parts; when the average dry density of the blocks from the last 10 batches is greater than 880 kg / m³... 3 When optimizing the proportioning process, the method is to optimize the amount of foaming agent added to the proportioning process by increasing the amount of foaming agent by 0.05 parts.

8. The method for preparing lightweight, high-strength lightweight aggregate blocks using solid waste according to claim 3, characterized in that, In step S3, during the preparation of the alkali-activated gelling slurry, sodium hydroxide is first dissolved in water to prepare a sodium hydroxide solution. After the solution temperature drops to less than or equal to 40°C, water glass is added and stirred evenly. The solution is then allowed to stand for activation for 2 to 4 hours before use. The alkali equivalent in the alkali activator, calculated as Na2O, accounts for 4% to 8% of the total mass of fly ash, slag, and waste ceramic powder. In step S3, when performing process calibration on the preparation of the alkali-activated gelling slurry based on real-time quality monitoring data, the pH value and slurry fluidity of the alkali-activated gelling slurry are monitored in real time. When the pH value is less than 12, the amount of alkali activator is increased by 1 part; when the slurry fluidity is less than 180 mm, the amount of water is increased by 2 parts.

9. The method for preparing lightweight, high-strength lightweight aggregate blocks using solid waste according to claim 3, characterized in that, In step S6, standard curing involves curing at 20±2℃ and relative humidity greater than or equal to 95% for 24 to 48 hours, followed by demolding and continued standard curing for 7 days. Steam curing involves heating the green body after 7 days of standard curing to 60℃ to 80℃ at a rate of 10℃ / h to 15℃ / h, maintaining constant temperature and humidity for 6 to 12 hours, and then cooling to room temperature at a rate less than or equal to 20℃ / h. The relative humidity during steam curing is greater than or equal to 80%. When optimizing the process based on product quality testing results: after steam curing, the blocks are tested for compressive strength and dry density. If the compressive strength is less than 10MPa, the constant temperature during steam curing is optimized by increasing the constant temperature by 5℃; if the dry density is greater than 900kg / m³... 3 In the process of optimizing the foaming agent dosage ratio, the foaming agent dosage ratio was optimized by increasing it by 0.05 parts, and the foaming agent dosage ratio was optimized by increasing it by 0.1 parts.

10. The method for preparing lightweight, high-strength lightweight aggregate blocks using solid waste according to claim 3, characterized in that, In step S4, after the foam is prepared, the foam stability is tested by the settling distance method. The foam stability is required to reach a settling distance of less than or equal to 10 mm after 1 hour. In step S6, the blocks are re-prepared after process optimization.

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