RU2240294C2 - Method of manufacturing wall ceramic products - Google Patents

Abstract

FIELD: manufacture of building materials.

SUBSTANCE: manufacture of ceramic bricks, stones, and blocks comprises (i) preparation of charge containing brick clay, burning-down additive in amount of 20 to 56% on the volume of charge treated with 10% boiled-off liquor, (ii) drying, and (iii) firing. Charge is further supplemented by boiled-off liquor in amount of 1.3-1.7% on the weight of clay.

EFFECT: enabled manufacture of hollow porous ceramic bricks with density 1000 kg/m3 from middle-, moderate-, and low-plastic clays.

2 cl, 3 tbl

Description

The invention relates to the building materials industry and can be used for the production of ceramic bricks, stones and blocks, especially hollow-porous.

A known method of manufacturing wall ceramic materials [Sedliacek Z. Moznostivysokol ahcenytoholv SST, n.p.v. Zavoge Martin, Ahlarsky spravodaj. - 1988], in which, in order to reduce the average density and thermal conductivity as an exhaustive additive, sawdust is introduced, which is a secondary product of woodworking enterprises.

The disadvantage is that with an increase in the amount of sawdust in the mixture, there is a sharp decrease in the formability of the raw material and the strength of the porous shard, which does not allow to obtain a shard with a density of less than 1300 kg / m ³ and a hollow-porous brick (stone, block) with an apparent density of less than 1000 kg / m ³ .

A known method of manufacturing ceramic products [patent No. 2082692, publ. 06/27/97, Bull. No. 18], in which, in order to reduce the average density of the crock to 1300 kg / m ^{3, it is} proposed to introduce into the charge compositions based on low-plastic clay raw materials (ductility number = 7) a large amount of a mixture of burnable additives consisting of sawdust and activated sludge up to 50% in terms of dry matter in relation to clay raw materials. Here, the introduction of activated sludge increases the plasticity of the mixture, which is very important for low-plastic clays, since the introduction of wood sawdust, especially in large quantities, leads to a practically linear decrease in plasticity and to a reduction or complete elimination of brick formability.

The disadvantage of this method is the large amount of introduced sludge (up to 50% by weight) of the clay consumption. Sludge production is associated with significant costs for its development, transportation, the complexity of its production and subsequent drying. For this reason, the use of sludge in the ceramic industry has not found wide application, and practically this method is implemented, mainly, only in laboratory conditions. In addition, sludge is not uniform in composition and is not available in all regions of the country.

The prototype of the invention is a method of manufacturing a mixture for the production of ceramic products [Kulikov OL A method of increasing the strength of porous ceramic bricks // Building Materials, 1995, No. 11, p. 18-19], in which, in order to reduce the average density and thermal conductivity of bricks, wood sawdust is used as a burn-out additive, which is previously processed to increase the strength of the shard sodium-containing additive.

The disadvantage of this method is that it does not allow to obtain a crock with a density of less than 1300 kg / m ³ and hollow-porous ceramic products with an apparent density of less than 1000 kg / m ³ on medium, moderate and low-plastic brick clays, since when introduced a large number of burnable additives is a decrease in the plasticity of the mixture and it is impossible to form a raw brick from such a mixture due to the low plastic strength.

The invention is aimed at creating the possibility of obtaining hollow-porous bricks, stones and blocks with a density of less than 1000 kg / m ³ on the basis of medium, moderate and low plastic brick clays.

The result is achieved in that in a method of manufacturing ceramic wall products, including mixing a mixture containing brick clay and a sodium-treated component, a burn-out additive, plastic molding, drying and firing, buckwheat husk in an amount up to 20-56% of the charge volume is used as a burn-out additive as a sodium-containing component for the treatment of a burn-out additive, a 10% aqueous solution of soapy liquor (liquid by-product of soap manufacture) is used, in addition, Submandial lye is introduced in an amount of 1.3-1.7% by weight of clay in terms of dry matter.

The result is also achieved by the fact that up to 55-56% of the charge volume is introduced for medium-plastic clay, buckwheat husks, up to 40-43% for moderate-plastic clay, and up to 20-22% for low-plastic clay.

Brick clays of the Saray-Chekurchinsky, Shelangovsky and Koshchakovsky deposits of the Republic of Tatarstan were used as the main raw materials.

The medium plastic clay of the Saray-Chekurchinsky deposit in appearance is an earthy mass of light brown color. This clay is finely dispersed; with a low content of carbonate inclusions (slightly boils when exposed to a 10% HCl solution); highly sensitive (sensitivity to drying according to the Chizhsky method is 70 s); fusible (t = 1240 ° С); with career humidity of 20-25%.

The moderate plastic clay of the Shelangovskoye field in appearance is an earthy mass from light to dark brown in color. This clay is finely dispersed with a low content of carbonate inclusions (it boils weakly when exposed to a 10% HCl solution); highly sensitive (sensitivity to drying according to Chizhsky 56 s); fusible (t = 1300 ° С) with a career humidity of 20-25%.

The unplastic clay of the Koshchakovskoye field in appearance is an earthy mass of light brown color. This clay is finely dispersed with a low content of carbonate inclusions (it boils weakly when exposed to a 10% HCl solution); highly sensitive (sensitivity to drying according to the Chizhsky method is 60 s); fusible (t = 1330 ° С); with career humidity of 20-25%.

Clay properties are presented in table 1.

As additives, wastes from agricultural processing (husk of buckwheat) and soap production (soap lye) were used.

Buckwheat husk is a bulk material that is highly uniform in granule size and bulk density. For the manufacture of ceramic samples, a by-product of the Buinsky agricultural processing enterprise (Buinsk, RT) was used. The average bulk density in the natural state is 160-170 kg / m ³ . The grain size distribution of the buckwheat husk is presented in table 2.

Sub-soap liquor is a waste of soap production. For the manufacture of ceramic samples, a by-product of the chemical plant named after Vakhitova (Kazan). Consists of, wt.%: Fatty acids - not more than 1; NaCl - 15 ... 26; free caustic alkali - 1.2 ... 2.1; free carbonic soda - 1.5 ... 1.9; water is the rest.

A method of manufacturing wall ceramic materials is as follows. Buckwheat husk was preliminarily kept in a container with a 10% aqueous solution of soapstone liquor (PS) for 24-48 hours with periodic or constant stirring for uniform impregnation. After that, the buckwheat husk was removed from the container and kept for 12-24 hours on a sieve at a temperature of 35-80 ° C to remove excess PS, as well as its drying.

Then PS was introduced into the charge in an amount of 1.3-1.7% of the clay mass, and an activated burn-out additive (buckwheat husk) in an amount of up to 20-56% of the charge volume, depending on the ductility of brick clay. For unplastic clay, buckwheat husks were introduced in an amount up to 20-22% of the charge volume, moderately plastic - 40-43 and medium plastic - 55-56%. The mixture was moistened to a molding moisture content of 18-20%, mixed, aged for 72 hours, after which the plasticity of the mixture was determined and cubed samples 50 × 50 × 50 mm in size were formed, which were then dried for 12 hours and calcined at a temperature of 950 ° C. After firing, control samples were tested, the results of which are presented in table.3.

From table 3 it is seen that the average density of hollow bricks is less than 1000 kg / m ³ . An increase in the amount of sub-soap liquor introduced into the medium-plastic, moderate-plastic and low-plastic clay in the amount of up to 1.5% by weight of clay entails an increase in shard strength in the first case by 43%, in the second by 22%, and in the third - by 24% .

Claims (2)

1. A method of manufacturing ceramic wall products, comprising mixing a mixture containing brick clay and a burnable additive treated with a sodium-containing component, plastic molding, drying and firing, characterized in that buckwheat husks in the amount of 20-56% of the charge volume are used as a burnable additive as a sodium-containing component for the treatment of a burn-out additive, a 10% aqueous solution of soapy liquor (a liquid by-product of soap manufacture) is used, in addition, in addition to the charge t podmylny liquor in an amount of 1.3-1.7% by weight of clay. 2. The method according to claim 1, characterized in that for medium-plastic clay, buckwheat husks are introduced in an amount of 55-56% of the charge volume, for moderately plastic clay - 40-43%, and low-plastic clay - 20-22%.