CN103319156A - Method for recycling waste porcelain in porcelain tile production - Google Patents
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Abstract
The invention discloses a method for recycling waste porcelain in porcelain tile production. The method comprises the steps of: firstly, manually crushing waste porcelain into porcelain pieces with sizes capable of allowing to enter a crusher, and further crushing the porcelain pieces by the crusher to obtain a product for later use; replacing gravel raw materials with waste porcelain, wherein the waste porcelain takes up 10-60% of total mass of basic materials, the gravels take up 20-70% of total mass of basic materials, and clay takes up 15-25% of total mass of basic materials; simultaneously adding deflocculants taking up 0.1-0.6% of total mass of the basic materials, and sodium carboxymethyl cellulose taking up 0.01-0.1% of total mass of the basic materials; ball-milling, pelletizing and aging the formula of porcelain tiles to obtain blanks; and conducting secondary distribution the blanks together with surface materials by taking the blanks as bed charge for producing the porcelain tiles, conducting dry pressing to obtain green bodies, drying the green bodies and putting the green bodies into a furnace for sintering. On the premise of ensuring the quality of the porcelain tiles, a scientific approach for treatment of waste porcelain is found, thus not only is the environment is protected, but also wastes are changed into valuables, and the cost of raw materials is reduced; and the method is beneficial to sustainable development of porcelain industry.
Description
Technical field
The present invention relates to the method that solid waste utilizes in a kind of Production of Ceramics, the method for useless porcelain recycling during a kind of porcelain brick is produced specifically belongs to ceramic waste material comprehensive utilization technique field.
Background technology
Porcelain brick enjoys favor with its low water absorption, high strength, wear-resisting, resistance to chemical attack, the advantage such as freeze proof in household and building decoration field, and its output increases year by year.Take in Guangdong Province as example, porcelain brick output was about 2,300,000,000 square metres in 2011, increased approximately 41% than the last year.Yet through exploitation for many years, enterprise's periphery high-quality ceramic raw material reduces gradually, often needs to cause the products production cost to increase from local transportation far away.
Useless porcelain is a kind of solid waste that produces in Production of Ceramics, is mainly burning till, polishes, producing in the operation such as carrying.Take polished tile production as example, the useless porcelain total amount that produces in each operation is about 3~5% of finished product, its huge amount.Production of Ceramics enterprise only has the useless porcelain of minority producer recycle small amount in prescription, and large multiple enterprises adopts dispatch from the factory landfill or for the production of the method processing of other goods of stackings, transportation to the processing mode of useless porcelain more.Publication number is that the application for a patent for invention of CN101948285A has disclosed the calcium silicate material that utilizes useless porcelain powder to make, and publication number is that the application for a patent for invention of CN102351508A has disclosed a kind of production method of utilizing useless porcelain colorful ceramic permeable brick; Patent of invention ZL200910169643.8 provides a kind of and has utilized useless porcelain to prepare method fire-resistant, wear-resisting, alkaline-resisting, acidproof building material made, patent of invention ZL201010154867.4 discloses a kind of production method of utilizing the porcelain that gives up to make the matt porcelain glaze, the porcelain that will give up is used in to be produced than in the high value-added product, but the useless porcelain of usefulness as improving the glaze performance, its consumption is lower, can not consume the useless porcelain of enormous quantity.
Traditional useless porcelain landfill disposal causes huge pressure to environment, and the porcelain that perhaps will give up is used in produces the lower goods of some added value, does not give full play to the utility value of useless porcelain, has also wasted a large amount of resources, is unfavorable for the Sustainable development of ceramic industry.
Study the porcelain that how will give up and be widely used in the higher porcelain brick production field of added value, the useless porcelain resource of rational and efficient use more, not only can solve the problem of environmental pollution that useless porcelain brings, save simultaneously a large amount of high-quality ceramic raw materials, can reduce production costs and improve the competitiveness of product in market.
Summary of the invention
The objective of the invention is many weak points of utilizing for overcoming existing useless porcelain, provide a kind of porcelain brick produce in the method for useless porcelain recycling, reach the useless porcelain resource of more reasonable efficient utilization, turn waste into wealth, eliminate the purpose of porcelain environmental pollution of giving up.
Purpose of the present invention is achieved through the following technical solutions:
The method of useless porcelain recycling during a kind of porcelain brick is produced may further comprise the steps and processing condition:
1, the method for useless porcelain recycling during a kind of porcelain brick is produced is characterized in that may further comprise the steps and processing condition:
(1) useless porcelain pre-treatment: the porcelain hand breaking of will giving up first is to the size that can enter crusher, and is for subsequent use after the further fragmentation of crusher;
(2) batching: substitute the sandstone raw material with useless porcelain, useless porcelain accounts for 10~60% of basic material total mass, and sandstone accounts for 20~70% of basic material total mass, and clay accounts for 15~25% of basic material total mass; Add simultaneously the liquefactent of basic material total mass 0.1~0.6% and 0.01~0.1% Xylo-Mucine and be the porcelain brick prescription; Described liquefactent is one or more in water glass, yellow soda ash, sodium phosphate and the tripoly phosphate sodium STPP;
(3) ball milling, granulation: above-mentioned porcelain brick prescription is carried out ball milling, and the water ratio of gained mud is 31~33%, 250 mesh screen residues 0.8~1.5% behind the control ball milling; Go out to grind mud and carry out mist projection granulating, pelletizing obtains blank behind old 24~48h;
(4) moulding: the blank that step (3) is made is as production porcelain brick bed material, and carries out secondary material distributing with fabric, dry-pressing formed green compact that obtain under 30~50MPa pressure then, green compact initial bed thickness 6~10mm, precoat thickness 1~4mm;
(5) dry, burn till, detect, pack: the green compact drying enters klining to water ratio after 0.5%, firing temperature is 1150~1220 ℃, and firing period is 50~70min; Can pack warehouse-in through follow-up edging, Check processing.
Preferably, by weight percentage, the chemical composition of described useless porcelain composed as follows: 63~78% SiO
2, 14~23% Al
2O
3, the Fe below 2%
2O
3+ TiO
2, the CaO+MgO below 3%, 3~8% K
2O+Na
2O, loss on ignition I.L<0.5%.Waste ceramic particle footpath≤10mm after crusher in crushing.Described useless porcelain accounts for 20~50% of basic material total mass.Described secondary material distributing is that bed material and fabric are configured respectively, the fabric after the configuration is placed on the process that forms double-layer structure on the bed material.By weight percentage, described fabric consists of: feldspar 35-40, quartzy 20-40, wollastonite 1-5, white clay 5-15, clay 10-20.
The particle diameter of the sandstone raw material that uses in the waste ceramic particle degree of the present invention after crusher in crushing and the basic material quite (≤10mm), can realize by the crusher parameter regulation.It is feldspar, quartz and clay that useless porcelain replace porcelain brick to produce to be used sandstone raw material, its main component.
The treatment process of relatively existing useless porcelain, the present invention has following advantage:
(1) the useless addition of porcelain in bed material is 10~60wt%, can be with during useless porcelain be produced for the production of the higher porcelain brick of added value in a large number and do not affect the porcelain brick decorative effect, not only effectively utilized useless porcelain resource, greatly alleviated the pressure that useless porcelain produces environment, save simultaneously natural mineral resource, when improving the competitiveness of product in market, also be beneficial to the Sustainable development of ceramic industry.
(2) do not change existing porcelain brick production technique, its technique is simple, is easy to produce, and introduces useless porcelain and played the ability of improving goods opposing high temperature deformation; In addition, owing to having introduced useless porcelain powder in the bed material, so that the finished product bottom water-intake rate is slightly high, under the prerequisite that does not affect surface property, product is easier to the paving of constructing.
(3) useless porcelain substitutes the sandstone raw material in bed material, granularity by adjusting useless porcelain after the crusher in crushing and the kind of replaced raw material, adjust fabric firing temperature etc. can reach control bed material sintering temperature and and fabric between the matching problem, thereby guaranteed the performance of the finished product.
Embodiment
For a better understanding of the present invention, the invention will be further described below in conjunction with specific embodiment, but the scope of protection of present invention is not limited to the scope that embodiment describes.
Embodiment 1
The first step: useless porcelain preparation.(Contents of Main Components is (wt%): SiO to a kind of useless porcelain that the polishing stage produced during Ceramics was produced
2: 75.19, Al
2O
3: 17.57, Fe
2O
3+ TiO
2: 0.63, CaO+MgO:0.78, K
2O+Na
2O:5.69, I.L:0.17), through jaw crusher be crushed to prepare burden in the suitable size of sandstone raw material granularity (≤10mm).For sake of convenience, this useless porcelain is called useless porcelain 0
#(lower same).
Second step: batching, ball milling.With useless porcelain 0
#Substitute the sandstone raw material in the basic material, useless porcelain accounts for 10% of basic material total mass, and sandstone accounts for 70% of basic material total mass, and clay accounts for 20% of basic material total mass, adds the water glass of basic material total mass 0.1% and 0.01% Xylo-Mucine; Raw material, ballstone, water by mass percentage 1:1.2:0.48 ratio add, ball milling after mixing, and the final fineness of control mud is 250 mesh screen residues 0.8%.The water ratio that finally obtains mud is 31%, is 35s in the Engler viscosimeter elution time, behind the 24h in the 10ml graduated cylinder natural subsidence distance be 0.1ml.
The 3rd step: granulation, moulding.The mud that second step is prepared carries out mist projection granulating.As bed material, dry-pressing formed through under 50MPa pressure, carrying out behind the secondary material distributing with fabric behind the old 48h of granulation powder, make initial bed thickness 8mm, precoat thickness 3mm, the length of side is the square green compact of 680mm.The chemical composition of fabric and useless porcelain are basic identical, mainly by SiO
2, Al
2O
3, Fe
2O
3, TiO
2, CaO, MgO, K
2O and Na
2O forms, loss on ignition I.L<3.5%; By percentage to the quality, the present embodiment fabric chemical composition consists of SiO
2: 72.07%, Al
2O
3: 18.34%, Fe
2O
3+ TiO
2: 0.26%, CaO+MgO:0.71%, K
2O+Na
2O:4.81%, loss on ignition I.L are 2.88%.
The 4th step: dry, burn till.The green compact that the 3rd step was obtained are dried to water ratio less than 0.5%, burn till at 1180 ℃ again, and firing period is 58min.
The 5th step: goods produce thickness 10.1mm(initial bed 7.3mm, precoat 2.8mm through the edging processing treatment after burning), the length of side is the square porcelain brick of 600mm.Measure the water-intake rate of porcelain brick according to boiling method among standard GB/T/T3810.3-2006, adopt the three-point bending resistance method to measure the breaking tenacity of porcelain brick.
After the aforesaid method test, its water-intake rate is 0.06%, and breaking tenacity is 51MPa, is higher than the requirement of dry-pressing ceramic tile standard GB/T/T4100-2006, and the large quality of production is stablized controlled, with the good in economic efficiency of porcelain alternative materials generation of giving up.
Embodiment 2
The first step: useless porcelain preparation.Used useless porcelain is the described useless porcelain 0 of the first step among the embodiment 1
#
Second step: batching, ball milling.With useless porcelain 0
#Substitute the sandstone raw material in the batching, useless porcelain accounts for 20% of basic material total mass, and sandstone accounts for 65% of basic material total mass, and clay accounts for 15% of basic material total mass.Add respectively 0.2% water glass, 0.1% yellow soda ash and 0.1% Xylo-Mucine in the above-mentioned basic material, raw material, ballstone, water by mass percentage 1:1.2:0.52 ratio add, ball milling after mixing, and the final fineness of control mud is 250 mesh screen residues 1.0%.The water ratio that finally obtains mud is 33%, is 40s in the Engler viscosimeter elution time, behind the 24h in the 10ml graduated cylinder natural subsidence distance be 0ml.
The 3rd step: granulation, moulding.The mud that second step is prepared carries out mist projection granulating.Be bed material behind the old 48h of granulation powder, dry-pressing formed through under 30MPa pressure, carrying out behind the secondary material distributing with fabric, make initial bed thickness 7mm, precoat thickness 4mm, the length of side is the square green compact of 680mm.By percentage to the quality, the present embodiment fabric chemical composition consists of SiO
2: 72.07%, Al
2O
3: 18.34%, Fe
2O
3+ TiO
2: 0.26%, CaO+MgO:0.71%, K
2O+Na
2O:4.81%, loss on ignition I.L are 2.88%.
The 4th step: repeat the 4th step among the embodiment 1.
The 5th step: goods produce thickness 9.9mm(initial bed 6.3mm, precoat 3.6mm through the edging processing treatment after burning), the length of side is the square porcelain brick of 600mm.Measure the water-intake rate of porcelain brick according to boiling method among standard GB/T/T3810.3-2006, adopt the three-point bending resistance method to measure the breaking tenacity of porcelain brick.
After the aforesaid method test, its water-intake rate is 0.06%, and breaking tenacity is 50MPa, is higher than the requirement of dry-pressing ceramic tile standard GB/T/T4100-2006, and the large quality of production is stablized controlled, with the good in economic efficiency of porcelain alternative materials generation of giving up.
Embodiment 3
Repeat the first step operation among the embodiment 1.
Second step: batching, ball milling.With useless porcelain 0
#Substitute the sandstone raw material in the batching, useless porcelain accounts for 40% of basic material total mass, and sandstone accounts for 40% of basic material total mass, and clay accounts for 20% of basic material total mass.Add respectively 0.4% water glass, 0.2% tripoly phosphate sodium STPP and 0.03% Xylo-Mucine in the above-mentioned basic material, raw material, ballstone, water by mass percentage 1:1.2:0.48 ratio add, ball milling after mixing, and the final fineness of control mud is 250 mesh screen residues 1.2%.The water ratio that finally obtains mud is 31%, is 36s in the Engler viscosimeter elution time, behind the 24h in the 10ml graduated cylinder natural subsidence distance be 0.1ml.
The 3rd step: granulation, moulding.The mud that second step is prepared carries out mist projection granulating.Be bed material behind the old 24h of granulation powder, dry-pressing formed through under 40MPa pressure, carrying out behind the secondary material distributing with fabric, make initial bed thickness 8mm, precoat thickness 3mm, the length of side is the square green compact of 680mm.By percentage to the quality, the present embodiment fabric chemical composition consists of SiO
2: 72.07%, Al
2O
3: 18.34%, Fe
2O
3+ TiO
2: 0.26%, CaO+MgO:0.71%, K
2O+Na
2O:4.81%, loss on ignition I.L are 2.88%.
The 4th step: dry, burn till.The green compact that the 3rd step was obtained are dried to water ratio less than 0.5%, burn till at 1200 ℃ again, and firing period is 70min.
The 5th step: goods produce thickness 9.9mm(initial bed 7.4mm, precoat 2.5mm through the edging processing treatment after burning), the length of side is the square porcelain brick of 600mm.Measure the water-intake rate of porcelain brick according to boiling method among standard GB/T/T3810.3-2006, adopt the three-point bending resistance method to measure the breaking tenacity of porcelain brick.
After the aforesaid method test, its water-intake rate is 0.05%, and breaking tenacity is 57MPa, is higher than the requirement of dry-pressing ceramic tile standard GB/T/T4100-2006, and the large quality of production is stablized controlled, with the good in economic efficiency of porcelain alternative materials generation of giving up.
Embodiment 4
Repeat the first step operation among the embodiment 1.
Second step: batching, ball milling.With useless porcelain 0
#Substitute the sandstone raw material in the batching, useless porcelain accounts for 60% of basic material total mass, and sandstone accounts for 15% of basic material total mass, and clay accounts for 25% of basic material total mass.Add respectively 0.1% water glass, 0.1% sodium phosphate and 0.04% Xylo-Mucine in the above-mentioned basic material, raw material, ballstone, water by mass percentage 1:1.2:0.5 ratio add, ball milling after mixing, and the final fineness of control mud is 250 mesh screen residues 1.5%.The water ratio that finally obtains mud is 32%, is 32s in the Engler viscosimeter elution time, behind the 24h in the 10ml graduated cylinder natural subsidence distance be 0.2ml.
The 3rd step: granulation, moulding.The mud that second step is prepared carries out mist projection granulating.Be bed material behind the old 48h of granulation powder, dry-pressing formed through under 45MPa pressure, carrying out behind the secondary material distributing with fabric, make initial bed thickness 7mm, precoat thickness 4mm, the length of side is the square green compact of 680mm.By percentage to the quality, the present embodiment fabric chemical composition consists of SiO
2: 72.07%, Al
2O
3: 18.34%, Fe
2O
3+ TiO
2: 0.26%, CaO+MgO:0.71%, K
2O+Na
2O:4.81%, loss on ignition I.L are 2.88%.
The 4th step: dry, burn till.The green compact that the 3rd step was obtained are dried to water ratio less than 0.5%, burn till at 1180 ℃ again, and firing period is 55min.
The 5th step: goods produce thickness 10.1mm(initial bed 6.5mm, precoat 3.6mm through the edging processing treatment after burning), the length of side is the square porcelain brick of 600mm.Measure the water-intake rate of porcelain brick according to boiling method among standard GB/T/T3810.3-2006, adopt the three-point bending resistance method to measure the breaking tenacity of porcelain brick.
After the aforesaid method test, its water-intake rate is 0.04%, and breaking tenacity is 57Mpa, is higher than the requirement of dry-pressing ceramic tile standard GB/T/T4100-2006, and the large quality of production is stablized controlled, with the good in economic efficiency of porcelain alternative materials generation of giving up.
Embodiment 5
The first step: (Contents of Main Components is (wt%): SiO to a kind of useless porcelain that produces to select certain construction site to construct
2: 73.73, Al
2O
3: 17.81, Fe
2O
3+ TiO
2: 0.56, CaO+MgO:0.75, K
2O+Na
2O:7.01, I.L:0.15), sandstone raw material granularity in jaw crusher is crushed to less than batching is controlled to be below the 5mm, (sandstone raw material granularity in the batching≤10mm).
Second step: batching, ball milling.With the sandstone raw material in the alternative batching of the described useless porcelain of the first step, useless porcelain accounts for 30% of basic material total mass, and sandstone accounts for 50% of basic material total mass, and clay accounts for 20% of basic material total mass.Add respectively 0.3% water glass and 0.04% Xylo-Mucine in the above-mentioned basic material, raw material, ballstone, water by mass percentage 1:1.2:0.5 ratio add, ball milling after mixing, and the final fineness of control mud is 250 mesh screen residues 1.0%.The water ratio that finally obtains mud is 32%, is 31s in the Engler viscosimeter elution time, behind the 24h in the 10ml graduated cylinder natural subsidence distance be 0.1ml.
The 3rd step: granulation, moulding.The mud that second step is prepared carries out mist projection granulating.Be bed material behind the old 48h of granulation powder, dry-pressing formed through under 40MPa pressure, carrying out behind the secondary material distributing with fabric, make initial bed thickness 8mm, precoat thickness 3mm, the length of side is the square green compact of 680mm.By percentage to the quality, the present embodiment fabric chemical composition consists of SiO
2: 72.07%, Al
2O
3: 18.34%, Fe
2O
3+ TiO
2: 0.26%, CaO+MgO:0.71%, K
2O+Na
2O:4.81%, loss on ignition I.L are 2.88%.
The 4th step: dry, burn till.The green compact that the 3rd step was obtained are dried to water ratio less than 0.5%, burn till at 1150 ℃ again, and firing period is 50min.
The 5th step: goods produce thickness 10.0mm(initial bed 7.4mm, precoat 2.6mm through the edging processing treatment after burning), the length of side is the square porcelain brick of 600mm.Measure the water-intake rate of porcelain brick according to boiling method among standard GB/T/T3810.3-2006, adopt the three-point bending resistance method to measure the breaking tenacity of porcelain brick.
After the aforesaid method test, its water-intake rate is 0.06%, and breaking tenacity is 53MPa, is higher than the requirement of dry-pressing ceramic tile standard GB/T/T4100-2006, and the large quality of production is stablized controlled, with the good in economic efficiency of porcelain alternative materials generation of giving up.
Claims (6)
1. the method for useless porcelain recycling during a porcelain brick is produced is characterized in that may further comprise the steps and processing condition:
(1) useless porcelain pre-treatment: the porcelain hand breaking of will giving up first is to the size that can enter crusher, and is for subsequent use after the further fragmentation of crusher;
(2) batching: substitute the sandstone raw material with useless porcelain, useless porcelain accounts for 10~60% of basic material total mass, and sandstone accounts for 20~70% of basic material total mass, and clay accounts for 15~25% of basic material total mass; Add simultaneously the liquefactent of basic material total mass 0.1~0.6% and 0.01~0.1% Xylo-Mucine and be the porcelain brick prescription; Described liquefactent is one or more in water glass, yellow soda ash, sodium phosphate and the tripoly phosphate sodium STPP;
(3) ball milling, granulation: above-mentioned porcelain brick prescription is carried out ball milling, and the water ratio of gained mud is 31~33%, 250 mesh screen residues 0.8~1.5% behind the control ball milling; Go out to grind mud and carry out mist projection granulating, pelletizing obtains blank behind old 24~48h;
(4) moulding: the blank that step (3) is made is as production porcelain brick bed material, and carries out secondary material distributing with fabric, dry-pressing formed green compact that obtain under 30~50MPa pressure then, green compact initial bed thickness 6~10mm, precoat thickness 1~4mm;
(5) dry, burn till, detect, pack: the green compact drying enters klining to water ratio after 0.5%, firing temperature is 1150~1220 ℃, and firing period is 50~70min; Can pack warehouse-in through follow-up edging, Check processing.
2. the method for useless porcelain recycling during porcelain brick according to claim 1 is produced is characterized in that: by weight percentage, and the chemical composition of described useless porcelain composed as follows: 63~78% SiO
2, 14~23% Al
2O
3, the Fe below 2%
2O
3+ TiO
2, the CaO+MgO below 3%, 3~8% K
2O+Na
2O, loss on ignition I.L<0.5%.
3. the method for useless porcelain recycling is characterized in that: the waste ceramic particle footpath≤10mm after crusher in crushing during porcelain brick according to claim 1 was produced.
4. the method for useless porcelain recycling during porcelain brick according to claim 1 is produced, it is characterized in that: described useless porcelain accounts for 20~50% of basic material total mass.
5. the method for useless porcelain recycling during porcelain brick according to claim 1 is produced, it is characterized in that: described secondary material distributing is that bed material and fabric are configured respectively, the fabric after the configuration is placed on the process that forms double-layer structure on the bed material.
6. the method for useless porcelain recycling during porcelain brick according to claim 1 is produced, it is characterized in that: by weight percentage, described fabric consists of: feldspar 35-40, quartzy 20-40, wollastonite 1-5, white clay 5-15, clay 10-20.
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