RU2503647C1 - Method to produce construction material - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: method for production of a construction material includes mixing of an alkaline component, water and silica-containing component in the form of a mixture of zeolite rock and volcanic glass. Besides, components of raw mix prior to mixing with the alkaline component and water are exposed to separate grinding in a vibration mill to particle size of not more than 100 mcm. Then the zeolite rock is dried at 200-300°C for 0.25 hours, then the volcanic glass is dried at 315-335°C for 0.15 hour. After drying and grinding of the silicate mass they perform heating with delay at 40-60°C and 240-260°C, and then heating to 600-650°C with speed of not more than 7-8°C/min, afterwards it is heated with the speed of not more than 5-6°C/min to swelling temperature, which is in the range of 765-835°C. Then the swollen silicate mass is cooled, being exposed to stabilisation by means of dramatic swelling temperature reduction by 100-150°C, afterwards they perform baking to 60°C with speed of not more than 0.5-0.6°C/min.

EFFECT: improved physical and mechanical properties of items.

4 cl, 9 ex, 6 tbl

Description

The present invention relates to the field of the construction industry, and the resulting building material can be effectively used throughout the thermal circuit of buildings and structures, as well as for thermal insulation of production equipment, refrigeration units and pipelines, to carry load-bearing and self-supporting fences and lintels for the construction of low-rise residential, administrative and industrial buildings and structures.

The applicant knows analogues: A.S. No. 292909, C03C 11/00, publ. 1971 - bull. No. 5; A.S. No. 1073199, C03C 11/00, publ. 1984 - bull. No. 6; A.S. No. 1708784, IPC C03C 11/00, publ. 1992; Hovhannesova N.E., Eliazyan L.A., Darbinyan M.V. Obtaining heat-insulating materials such as foam glass from perlite of Armenia and waste "tails" of the Kajaran Copper-Molybdenum Combine // All-Union Materials Collection. conference "The use of non-deficient materials in glass production": M .: - 1971. - S.241-248); Patent No. 2167112, IPC C03C 11/00, publ. 2001; Patent No. 2164898, IPC C03C 11/00, publ. 2001; Patent No. 2051869, IPC C03C 11/00, publ. 1996; Patent No. 2272007, IPC C03c 11/00, publ. 2006; Ivanenko V.N. Building materials and products from siliceous rocks / Kiev: Budivelnik, 1978 - 120 p.

There is also a known method for producing foam glass, in which perlite rocks of hydrated, vitreous and crystallized varieties and blown glass are used. Pearlite rock and container glass are subjected to separate grinding in a ball mill to a powder state with S _beats = 300-350 m ² / kg. After mechanical activation of the glass charge, in order to reduce the foaming temperature of the foam glass, sodium hydroxide is added to the finished powder in the form of an aqueous solution providing the mixture with a moisture content of 16-19%. The mixture is mixed and pressed in the form of samples with a size of 2 × 2 × 2 cm. Foaming during firing is carried out at a temperature of 815-830 ° C. To increase the strength of the foam glass it is subjected to repeated heat treatment - volume crystallization in the temperature range 600-625 ° C for 15-25 minutes, followed by cooling with the furnace (see patent RU No. 2291845, IPC C03C 11/00, publ. 20.01 .2007).

The disadvantage of this method is the use of cullet in the compositions, which complicates the technology of foam glass by introducing an additional line for the preparation of cullet.

A known composition for the manufacture of heat-insulating material, which uses tripoli, diatomite or flask as a silica-containing component, oxide, sulfate or zinc chloride as a zinc-containing additive, sodium hydroxide and tap water. A method of obtaining material consists in mixing the components to obtain a homogeneous silicate mass. The obtained silicate mass is filled into the mold, heated to a temperature of 350-400 ° C, at which the mass swelling is observed, followed by cooling to ambient temperature and removing the finished material from the molds.

The resulting material has a density of 134-302 kg / m ³ , a thermal conductivity of 0.074-0.098 W / (m · ° C) and compressive strength from 2 to 10 kgf / cm ² (0.2-1 MPa) (see RF patent No. 2053984, C04B 38/02, 1996).

The disadvantage of the analogue is that the results were achieved with a high ratio of the alkaline component to the silica-containing component in the initial mixture (0.4-0.5), and the silicate mass of high humidity is subjected to expansion, which generally contributes to the cost of foam glass and low quality due to heterogeneous porosity.

The closest technical solution to the claimed invention according to the set of essential features and the achieved result is a method of obtaining a building material, comprising mixing a silica-containing component, an alkaline component and water at their indicated ratio. The ratio of the content of the alkaline component to the content of the silica-containing component is in the range from 0.08 to 0.40, and the ratio of the total content of silica-containing and alkaline components to the water content is in the range from 0.8 to 5.3. Before filling the mold, the mass is dried to a residual moisture content of less than 5 wt.%, Crushed to a particle size of not more than 100 μm, providing a pore size of less than 3 mm, and after filling the mold, it is heated to 600 ° C with partial dehydration in the temperature range up to 165 ° C, from 165 to 220 ° C, from 230 to 350 ° C, from 450 to 600 ° C in any sequence. After that, the mixture is heated to a swelling temperature of 650-900 ° C, cooling according to the mode: up to 580 ° C at a speed of no higher than 2 ° C / min, up to 250 ° C no higher than 8 ° C / min, up to 20 ° C no higher 1.5 ° C / min. Swelling is carried out due to the final removal of chemically bound water in the temperature range 650-900 ° C (see RU No. 2300506, IPC C03C 11/00, publ. 08.05.2007).

The disadvantages of the method of obtaining building material are:

- a significant variation in the values of the properties of the building material due to the difficulty in achieving the desired level of viscosity of the silicate mass expanded at temperatures of 650-700 ° C when using a wide range of rocks with different chemical compositions;

- high energy costs due to the enormous total duration of multi-stage heat treatment for 40-52 hours before expansion in the temperature range from 145 to 560 ° C, due to the lack of preliminary thermal preparation of the initial siliceous rocks;

- multistage and lengthy heat treatment before firing during the organization of production will require the placement of vast areas for thermal installations;

- the absence in the analogue of information on the water absorption index, which characterizes the pore structure of the building material and determines its most important properties, such as thermal conductivity and frost resistance.

The problem to be solved in the present invention is to simulate the composition of the mixture to obtain a building material based on silica-containing zeolite rock and volcanic glasses of the Mukhor-Talinsky deposit of the Republic of Buryatia.

The technical result of the invention is to increase the physico-mechanical and operational properties of the building material by increasing the uniformity of the phase composition and improving the structure of the material by optimizing the preparation conditions of the initial silica-containing rocks;

increasing the efficiency of the use of siliceous rocks due to the integrated use of zeolite rocks and volcanic glasses (hydrated, vitreous and crystallized perlites) of the Mukhor-Talinsky deposit;

reducing the consumption of the alkaline component due to the use of fluff in the form of volcanic glasses (perlites) in the charge mixture;

reducing energy costs and labor intensity of production by reducing the number of stages of heat treatment before expansion due to the use of drying of the initial silica-containing rocks.

The technical result of the invention is achieved by the fact that in the method of obtaining a building material, comprising mixing silica-containing and alkaline components and water at their indicated ratio, drying, grinding the mixture, filling with the crushed mass of the mold and cooling, according to the invention, a mixture of zeolite rock and volcanic glass, the components of which, before mixing with the alkaline component and water, are subjected to separate grinding in vibrats ion mill to a particle size of not more than 100 microns, after which the zeolite rock is dried at a temperature of 200-300 ° C for 0.25 hours, then the volcanic glass is dried at a temperature of 315-335 ° C for 0.15 hours, and after drying and grinding the silicate mass produce heating with aging at temperatures of 40-60 ° C and 240-260 ° C, and then heating to a temperature of 600-650 ° C at a speed of no more than 7-8 ° C / min, and then heated at a speed not more than 5-6 ° C / min to a swelling temperature in the range from 765 to 835 ° C, while the cooling of the expanded silicate weight is carried out by a sharp decrease in swelling temperature at 100-150 ° C, whereupon annealing temperature to 60 ° C at a rate not more than 0,5-0,6 ° C / min.

In addition, the technical result is also achieved by the fact that as a volcanic glass using hydrated perlite with a crystalline phase content of 5% and hygroscopic water of 0.6-3.2% in the following ratio of components, wt.%:

Zeolite rock 35-65 Hydrated perlite 18-50 Sodium hydroxide rest,

the ratio of the mass of sodium hydroxide to the mass of zeolite rock and hydrated perlite is in the range of 0.177-0.205, and the ratio of the total content of the silica-containing component and sodium hydroxide to the water content is 2.94-3.33, after which the resulting mixture is dried for 2 hours at a temperature of 50-60 ° C and for 3 hours at a temperature of 250-260 ° C, and after drying, a finely ground charge is placed in a mold and heated to a temperature of 650 ° C and maintained at this temperature for 1 hour, and then heated before firing temperature, which is in the range of 765-805 ° C, and swell at this temperature for 1 hour, after which the silicate mass swelled during firing is subjected to stabilization by drastically lowering the maximum firing temperature by 100-150 ° C to the stabilization temperature.

In addition, the technical result is also achieved by the fact that as a volcanic glass using glassy perlite with a crystalline phase content of 2-5% and hygroscopic water of 0.3-1.0% with the following components, wt.%:

Zeolite rock 22.5-61.5 Glass perlite 21.5-62.5 Sodium hydroxide rest,

the ratio of the mass of sodium hydroxide to the mass of zeolite rock and vitreous perlite is in the range of 0.177-0.205, and the ratio of the total content of the silica-containing component and sodium hydroxide to the water content is 2.94-3.33, after which the resulting mixture is dried for 2 hours at a temperature of 45-55 ° C and for 3 hours at a temperature of 245-255 ° C, and after drying, a finely ground charge is placed in a mold and heated to a temperature of 600 ° C and maintained at this temperature for 1 hour, and then heated to those firing perature which is in the range of 775-825 ° C and is expanded at this temperature for 1 hour, followed by calcination at exfoliated silicate mass is subjected to stabilization by drastically lowering the maximum firing temperature at 100-150 ° C to stabilize the temperature.

In addition, the technical result is also achieved by the fact that crystallized perlite is used as volcanic glass with a content of 20-40% of the vitreous phase, 60-80% of cryptocrystalline aggregates and hygroscopic water 0.3-1.3% in the following ratio of components, wt .%:

Zeolite rock 19-53 Perlite crystallized 28-64 Sodium hydroxide rest,

the ratio of the mass of sodium hydroxide to the mass of zeolite rock and crystallized perlite is in the range of 0.205-0.235, and the ratio of the total content of the silica-containing component and sodium hydroxide to the water content is 2.63-2.94, after which the resulting mixture is dried for 2 hours at a temperature of 40-50 ° C and for 3 hours at a temperature of 240-250 ° C, and after drying the finely ground charge is placed in a mold and subjected to heating to a temperature of 625 ° C and maintained at this temperature for 1 hour and then heating t to the firing temperature, that is in the range of 785-835 ° C and is expanded at this temperature for 1 hour, followed by calcination at exfoliated silicate mass is subjected to stabilization by drastically lowering the maximum firing temperature at 100-150 ° C to stabilize the temperature.

In the present invention, as well as in the prototype (see patent RU No. 2300506, IPC C03C 11/00, publ. 08.05.2007), a silica-containing component, alkali and water are used at their established ratio, but unlike the prototype a mixture of zeolite rock and volcanic glass is used as a silica-containing component, which helps to reduce the consumption of an expensive alkaline component. So, thanks to the introduction of varieties of volcanic glass (hydrated, vitreous and crystallized perlites) containing up to 12 wt.% Alkali metal oxides, the maximum ratio of the content of the alkaline component in the form of sodium hydroxide to the content of the silica-containing component in the present invention was 0.235 (in prototype 0 ,four).

The present invention differs from the prototype in that in the proposed method, the expanded silicate mass is stabilized in order to fix the volume, which consists in a sharp decrease in the maximum firing temperature of building material by 100-150 ° C. Without the use of this process, the foamed silicate mass, as a rule, continues to increase inertia in volume, while the cells in the glass mass coalesce and increase in volume at this time. As a result of this, a material is formed with unevenly distributed and interconnected pores, which is highly undesirable for a heat-insulating material.

The present invention differs from the prototype in that it proposes a new approach to the use of structural and morphological features of zeolite rocks and volcanic glasses (perlite), which have a unique ability to adsorb substances, due to the presence in them of channels, windows at the molecular level. Silica-containing rocks used in the prototype do not have this unique ion-exchange, sorption and catalytic ability inherent in zeolite rocks and volcanic glasses (perlite), and therefore are not able to absorb the alkaline component well, especially since the physically bound rocks are not removed from the structure of silica-containing rocks (hygroscopic and hydrated) water, since preliminary thermal preparation of the source rocks in the prototype is not provided.

It is this circumstance that serves as a prerequisite for the fact that in the structure of the silicate mass at the firing temperature in the claimed invention, a larger volume of the gas phase is created due to bound water in zeolite rock and in volcanic glass, as well as due to OH groups introduced with sodium hydroxide. Therefore, the expanded material obtained in the claimed invention has a complex of physico-mechanical and operational properties, the performance of which is superior to that of the prototype.

From the analysis of the prior art by the applicant, including a search by patent and scientific and technical sources of information and identification of sources containing information about analogues of the claimed invention, the applicant did not find analogues that are characterized by signs that are identical to all the essential features of the claimed method for obtaining building material. The definition from the list of identified analogues of the prototype as the closest in the set of essential features of the analogue allowed us to identify the set of essential distinguishing features set forth in the claims in relation to the perceived technical result: increase the physico-mechanical and operational properties of the building material, increase the efficiency of use of siliceous rocks, reduce consumption alkaline component, reducing energy costs and labor intensity of production.

In the claimed compositions of the proposed method for producing building material used zeolite-containing rock and volcanic glass (perlite) Mukhor-Talinsky deposits of the Republic of Buryatia, the chemical composition of which is shown in tables 1 and 2.

Zeolite rock refers to vitroclastic and agglomerate tuffs with a zeolite content of 40% (average) to 60-65% (maximum). Zeolites (from the Greek. Zeo - boil and lithos - stone) are aluminosilicates that can swell when heated. Their crystalline structure is formed by [SiO ₄ ] ^4- and [AlO ₄ ] ^5- tetrahedra, united by common vertices into a three-dimensional skeleton penetrated by cavities and channels. In the latter there are water molecules and metal cations (I and II groups of the periodic table), as well as ammonium, tetraalkylammonium, etc.

The main mineral forms of zeolites are mordenite and clinoptilolite. According to tests conducted at the Analytical Certification Testing Center (Moscow), the zeolite rock of the Muhor-Talinsky deposit contains clinoptilolite (Na, K, Ca, Mg) · Ca [Al ₆ Si ₂₀ O ₇₂ ] · 20H ₂ O (55 ± 3)%; mordenite Ca ₂ (Na, K) · Ca [Al ₅ Si ₄₀ O ₉₆ ] · 28H ₂ O (15 ± 1.5)%; montmorillonite (l / 2Ca, Na) _0.7 · (Al, Mg, Fe) ₄ (Si, Al) ₃ O ₂₀ (OH) ₄ ] · 28H ₂ O (12 ± 1)%; potassium feldspar KALSi ₂ O ₈ (3 ± 0.5)%; X-ray amorphous phase - the rest.

Perlite is an acidic water-containing volcanic glass, all types of which contain water and crystalline inclusions (see Mountain Encyclopedia, Volume 4, Moscow: Soviet Encyclopedia. - 1991. - p. 73). According to the classification of domestic perlite raw materials proposed by N.I. Sergeev, V.V. Nasedkin and others, perlites of the Mukhor-Talinsky deposit are classified as different varieties according to water content and crystalline inclusions. The main motivation for using volcanic glasses in the composition of the mixture to obtain the claimed building material is their phase and chemical compositions, namely the increased content of glass phases, alkali metal oxides in them and the presence of various types of water in the cavities and channels of perlite.

In the claimed invention to obtain building material used perlite Mukhor-Talinsky deposits, the chemical composition of which is presented in table 2.

Hydrated perlites in the claimed invention include highly hydrated massive perlites with a vitreous phase of at least 95% with a bulk density of 1.9-2.1 g / cm ³ , hygroscopic water content of 0.6-3.2% and p.p. . 6.5-11%. Vitreous perlites in the claimed invention include unchanged massive perlites without microlites and crystallites with a quantity of vitreous phase of at least 90-95%, with a bulk density of 2.2-2.3 g / cm ³ , hygroscopic water content of 0.3-1.0 % and pp 5.5-6.5%. Massive perlites with crystallites and microlites with a content of 20-40% vitreous phase and 60-80% cryptocrystalline aggregates, with a bulk density of 2.1-2.4 g / cm ³ and a hygroscopic water content of 0.3 are classified as crystallized perlites in the claimed invention. -1.3% and pp 4.3-6.6%.

In the present invention, the appropriateness of the above unit is based on the fact that their difference in water content can affect the modes of heat treatment of rocks and heat treatment of the mixture, and their difference in the content of crystalline inclusions on the duration of grinding and modes of firing silicate mass. The expansion of knowledge in this area allows us to outline ways of rational use of different from each other varieties of perlite raw materials in the production of effective building heat-insulating material. It is known that in the extraction of conditioned glassy perlites, hydrated perlites due to their high water content, and crystallized perlites due to weak swelling often do not fall into the sphere of material production, and thereby their efficiency is reduced.

The X-ray spectrum of crystallized perlite confirms the presence of structural motifs close to the minerals of the tridimite-cristobalite series and feldspars - sanidin and albite (see Glukhovsky V.D., Tsyrempilov A.D., Runova R.F., Merkin A.P. and others. Alkaline concrete based on effusive rocks. - Irkutsk: Publishing house Irkut. Un-ta, 1990. - 176 p.).

According to x-ray phase analysis carried out in the Analytical Certification Test Center ASIC SIMS (Moscow), in the Voronezh State University of Architecture and Civil Engineering, as well as in the laboratory of the Baikal Institute of Nature Management of the Siberian Branch of the Russian Academy of Sciences, the zeolite rock of the Mukhor-Talinsky deposit has a heterogeneity of the minerals composing it. Depending on the location of the sampling, zeolite mineral mordenite predominates in some samples, and clinoptilolite prevails in others. In the present invention, the problem of optimizing the phase composition of the mixture to obtain expanded building material with the desired structure and properties is solved by introducing an additional second component into the mixture, namely, volcanic glass (perlite). The undermining of zeolite rocks with perlite in the presence of an alkaline component made it possible to obtain a melt in the present invention at energetically favorable temperature conditions and a low content of an expensive alkaline component. As a result, during firing, a high-temperature averaging of the phase composition of the porous glass melt takes place, in which the zeolite minerals dissolve regardless of which mineral (mordenite or clinoptilolite) is in the zeolite-containing rock. It is also likely that the solubility of ballast minerals (feldspar, montmorillonite, quartz) present in the zeolite rock also increases (about 20%).

Due to the formation of uniformly distributed and fine porosity due to high-temperature averaging of the phase composition of the porous glass melt as a result of optimization of the conditions for preparing the mixture from zeolite rock, volcanic glass (perlite) and alkaline component (sodium hydroxide) by the proposed method, it was possible to create expanded building material with high physical and mechanical and operational properties.

To select the optimal composition of the charge were prepared compositions (see tables 3, 4, 5), differing from each other by the ratio of zeolite rock and volcanic glass (in% by weight): 20; 35; fifty; 65; 80 zeolite rocks and 66; fifty; 34; eighteen; 2 hydrated perlite (composition 1); 3; 22.5; 42; 61.5; 81 zeolite rocks and 83; 62.5; 42; 21.5; 1 vitreous perlite (composition 2); 2; 19; 36; 53; 70 zeolite rocks and 82; 64; 46; 28; 10 perlite crystallized (composition 3). The sodium hydroxide content in compositions 1 and 2 is in the range of 14-18%, and in composition 3 is in the range of 16-20%. The compositions 1, 2, and 3 we adopted are distinguished by the fact that, as volcanic glass, they contain perlites of three varieties with different swelling properties. The ratios in the charge of zeolite rock and volcanic glass for each composition are taken into account the differences in the morphology of perlite varieties.

The proposed method for producing building material based on zeolite rock and hydrated perlite (composition 1) is as follows. Of the dosed portions of the powders of zeolite rock and perlite make up a mixture that is thoroughly mixed. To the finished silicate mass, 14-18% NaOH is added in the form of an aqueous solution providing the ratio of the mass of sodium hydroxide to the mass of zeolite rock and hydrated perlite in the range 0.163-0.22, and the ratio of the total content of the silica-containing component and sodium hydroxide to the water content is in the range 2.78-3.57. The resulting mixture is stirred using a mixer until a homogeneous state, and then the mixture on a pallet is placed in a drying chamber and dried for 2 hours at a temperature of 50-60 ° C and for 3 hours at a temperature of 250-260 ° C to obtain a silicate mass with residual moisture content of 1 wt.%. Dry silicate mass is crushed using a crusher to a fraction of 2-3 mm, and then crushed in a vibration mill to the main fraction of not more than 50-60 microns. The crushed powdery silicate mass is poured into a metal mold, placed in a muffle furnace and heated to a temperature of 650 ° C, at which it is held for 1 hour. The indicated temperature range corresponds to endothermic effects on thermograms of zeolite and perlite rocks, which indicate the removal of firmly bound water from the rock structure. Swelling of the silicate mass is carried out in the temperature range from 745 to 825 ° C.

The proposed method for producing building material based on zeolite rock and vitreous perlite (composition 2) is as follows. Of the dosed portions of the powders of zeolite rock and perlite make up a mixture that is thoroughly mixed. To the finished silicate mass, 14-18% NaOH is added in the form of an aqueous solution providing the ratio of the mass of sodium hydroxide to the mass of zeolite rock and vitreous perlite in the range 0.163-0.22, and the ratio of the total content of the silica-containing component and sodium hydroxide to the water content is in the range 2.78-3.57. The resulting mixture is stirred using a mixer until a homogeneous state, and then the mixture on a tray is placed in a drying chamber and dried for 2 hours at a temperature of 45-55 ° C and for 3 hours at a temperature of 245-255 ° C to obtain a silicate mass with residual moisture content of 1 wt.%. Dry silicate mass is crushed using a crusher to a fraction of 2-3 mm, and then crushed in a vibration mill to the main fraction of not more than 50-60 microns. The crushed powdery silicate mass is poured into a metal mold, placed in a muffle furnace and heated to a temperature of 625 ° C, at which it is kept for 1 hour. The indicated temperature range corresponds to endothermic effects on thermograms of zeolite and perlite rocks, which indicate the removal of firmly bound water from the rock structure. The expansion of the silicate mass is carried out in the temperature range from 750 to 850 ° C.

The proposed method for producing building material based on zeolite rock and crystallized perlite (composition 3) is as follows. Of the dosed portions of the powders of zeolite rock and perlite make up a mixture that is thoroughly mixed. To the finished silicate mass, 16-20% NaOH is added in the form of an aqueous solution providing a ratio of the mass of sodium hydroxide to the mass of zeolite rock and crystallized perlite in the range 0.19-0.25, and the ratio of the total content of the silica-containing component and sodium hydroxide to the water content is in the range of 2.5-3.125. The resulting mixture is stirred using a mixer until a homogeneous state, and then the mixture on a tray is placed in a drying chamber and dried for 2 hours at a temperature of 40-50 ° C and for 3 hours at a temperature of 240-250 ° C to obtain a silicate mass with residual moisture content of 1 wt.%. Dry silicate mass is crushed using a crusher to a fraction of 2-3 mm, and then crushed in a vibration mill to the main fraction of not more than 50-60 microns. The crushed powdery silicate mass is poured into a metal mold, placed in a muffle furnace and heated to a temperature of 600 ° C, at which it is kept for 1 hour. The indicated temperature range corresponds to endothermic effects on thermograms of zeolite and perlite rocks, which indicate the removal of firmly bound water from the rock structure. Swelling of the silicate mass is carried out in the temperature range from 760 to 860 ° C.

In compositions 1, 2 and 3 of the present invention, the expanded material is annealed to relieve internal stresses, for which it is cooled together with the furnace to room temperature.

In the claimed invention in all three compositions 1, 2 and 3 to reduce energy consumption and simplify the technology of obtaining building material by reducing the number of steps from six (according to the prototype) to three (in the present invention) heat treatment of the mixture before firing, as well as improving the pore structure and properties The material proposed optimization of the conditions for the preparation of source rocks. This is as follows. Crushed pieces of zeolite rock and perlite are subjected to separate grinding in a vibration mill, and then heat treatment by separate drying in a drying chamber. Such preliminary preparation of the source rocks helps to remove hygroscopic moisture and loosely bound hydrated water from the rock structure.

In the present invention also to stabilize the foam and fix the volume of the expanded silicate mass, a rapid decrease in the maximum firing temperature by 100-150 ° C is carried out.

Examples confirming the receipt of building material based on zeolite rock and hydrated perlite (composition 1)

Example 1

Zeolite rock 65 Hydrated perlite eighteen Sodium hydroxide 17

Of the dosed portions of the powders of zeolite rock and hydrated perlite make up a mixture that is thoroughly mixed. To the finished mixture, 17% NaOH is added in the form of an aqueous solution, providing a ratio of the mass of sodium hydroxide to the mass of zeolite rock and hydrated perlite equal to 0.205, and the ratio of the total content of silica-containing components and sodium hydroxide to the water content is 2.94.

The resulting mixture is mixed with a mixer until it is homogeneous, and then the homogeneous mixture is placed on a tray in a drying chamber, in which physical water is removed and a silicate mass with a residual moisture content of 1 wt.% Is obtained. Dry silicate mass is crushed with a crusher to a fraction of 2-3 mm, and then crushed to a base fraction of not more than 50-60 microns with a vibration mill. The crushed powdery silicate mass is poured into a metal mold and placed in a muffle furnace. The silicate mass is dried for 2 hours at a temperature of 50-60 ° C and for 3 hours at a temperature of 250-260 ° C to obtain a silicate mass with a residual moisture content of 1 wt.%, And then heated at a speed of 7-8 ° C / min to a temperature of 650 ° C, at which they are incubated for 1 hour. After heating, the temperature in the furnace is increased at a rate of 5-6 ° C / min to 765 ° C, at which the silicate mass is expanded for 1 hour. In order to relieve internal stresses, they are annealed, for which it is cooled together with the furnace to room temperature.

To reduce energy consumption and simplify the technology of building material by reducing the number of stages of heat treatment of the mixture before firing, as well as improving the pore structure and properties of the building material in the present invention, crushed pieces of zeolite rock fractions of 3-5 mm and hydrated perlite fractions of 0.5-5 mm are subjected to separate grinding in a vibration mill: zeolite rock for 7-9 minutes, and hydrated perlite for 3-4 minutes to a particle size of not more than 100 microns, and then heat treatment by ears in the drying chamber: zeolite rock at a temperature of 200-300 ° C for 0.25 hours, hydrated perlite - at a temperature of 320 ° C for 0.15 hours.

To stabilize the foam and fix the volume of the expanded silicate mass at the maximum firing temperature before annealing, a sharp decrease in the firing temperature of the building material by 100-150 ° C is performed.

The average density of the obtained building material is 285 kg / m ³ , its compressive strength is 2.4 MPa, the structure is uniformly porous, and the pore diameter is less than 2.5 mm.

Example 2

Carried out analogously to example 1 with the following ratio of components:

Zeolite rock fifty Hydrated perlite 34 Sodium hydroxide 16

The addition to the silicate mass of 16% NaOH in the form of an aqueous solution provides a ratio of the mass of sodium hydroxide to the mass of zeolite rock and hydrated perlite, equal to 0.191, and the ratio of the total content of silica-containing components and sodium hydroxide to the water content of 3.125. Building material swelling is carried out at a temperature of 785 ° C.

The average density of the building material is 405 kg / m ³ , its compressive strength is 5.0 MPa, the structure is uniformly porous, and the pore diameter is less than 2.0 mm.

Example 3

Carried out analogously to example 1 with the following ratio of components:

Zeolite rock 35 Hydrated perlite fifty Sodium hydroxide fifteen

The addition of 15% NaOH to the silicate mass in the form of an aqueous solution provides a ratio of the mass of sodium hydroxide to the mass of zeolite rock and hydrated perlite, equal to 0.177, and the ratio of the total content of silica-containing components and sodium hydroxide to the water content of 3.33. Building material is expanded at a temperature of 805 ° C.

The average density of the building material is 515 kg / m ³ , its compressive strength is 12.0 MPa, the structure is uniformly porous, and the pore diameter is less than 1.5 mm.

Examples confirming the receipt of building material based on zeolite rock and vitreous perlite (composition 2)

Example 4

Carried out in the following ratio of components:

Zeolite rock 61.5 Glass perlite 21.5 Sodium hydroxide 17

From the dosed portions of the powders of zeolite rock and vitreous perlite make up a mixture that is thoroughly mixed. To the finished silicate mass, 17% NaOH is added in the form of an aqueous solution providing a ratio of the mass of sodium hydroxide to the mass of zeolite rock and vitreous perlite equal to 0.205, and the ratio of the total content of silica-containing components and sodium hydroxide to the water content of 2.94.

The resulting mixture is mixed with a mixer until it is homogeneous, and then the homogeneous mixture is placed on a tray in a drying chamber, in which physical water is removed and a silicate mass with a residual moisture content of 1 wt.% Is obtained. Dry silicate mass is crushed with a crusher to a fraction of 2-3 mm, and then crushed to a base fraction of not more than 50-60 microns with a vibration mill. The crushed powdery silicate mass is poured into a metal mold and placed in a muffle furnace. The silicate mass is dried for 2 hours at a temperature of 45-55 ° C and for 3 hours at a temperature of 245-255 ° C to obtain a silicate mass with a residual moisture content of 1 wt.%, And then heated at a rate of 7-8 ° C / min to a temperature of 600 ° C, at which they are incubated for 1 hour. After heating, the temperature in the furnace is increased at a rate of 5-6 ° C / min to 775 ° C, at which the silicate mass is expanded for 1 hour. In order to relieve internal stresses, they are annealed, for which it is cooled together with the furnace to room temperature.

To reduce energy consumption and simplify the technology of obtaining building material by reducing the number of stages of heat treatment of the mixture before firing, as well as improving the pore structure and properties of the building material in the present invention, crushed pieces of zeolite rock fraction 3-5 mm and glassy perlite fraction 0.5-5 mm are subjected separate grinding in a vibration mill: zeolite rock for 7-9 minutes, and vitreous perlite for 4-6 minutes to a particle size of not more than 100 microns, and then heat treatment drying it in a drying chamber: zeolite rock at a temperature of 200-300 ° C for 0.25 hours, vitreous perlite - at a temperature of 315 ° C for 0.15 hours.

To stabilize the foam and fix the volume of the expanded silicate mass at the maximum firing temperature before annealing, a sharp decrease in the firing temperature of the building material by 100-150 ° C is performed.

The average density of the obtained building material is 300 kg / m ³ , its compressive strength is 3.2 MPa, the structure is uniformly porous, and the pore diameter is less than 2.0 mm.

Example 5

Carried out analogously to example 4 with the following ratio of components:

Zeolite rock 42 Glass perlite 42 Sodium hydroxide 16

The addition to the silicate mass of 16% NaOH in the form of an aqueous solution provides a ratio of the mass of sodium hydroxide to the mass of zeolite rock and vitreous perlite, equal to 0.19, and the ratio of the total content of silica-containing components and sodium hydroxide to the water content of 3.13. The expansion of the building material is carried out at a temperature of 800 ° C.

The average density of the building material is 420 kg / m ³ , its compressive strength is 5.3 MPa, the structure is uniformly porous, and the pore diameter is less than 1.5 mm.

Example 6

Carried out analogously to example 4 with the following ratio of components:

Zeolite rock 22.5 Glass perlite 62.5 Sodium hydroxide 15.0

The addition of 15% NaOH to the silicate mass in the form of an aqueous solution provides a ratio of the mass of sodium hydroxide to the mass of zeolite rock and vitreous perlite, equal to 0.19, and the ratio of the total content of silica-containing components and sodium hydroxide to the water content of 3.33. Building material swelling is carried out at a temperature of 825 ° C.

The average density of the building material is 545 kg / m ³ , its compressive strength is 13 MPa, the structure is uniformly porous, and the pore diameter is less than 1 mm.

Examples confirming the receipt of building material based on zeolite rock and crystallized perlite (composition 3)

Example 7

Carried out in the following ratio of components:

Zeolite rock 53 Perlite crystallized 28 Sodium hydroxide 19

From the dosed portions of the powders of zeolite rock and crystallized perlite make up a mixture, which is thoroughly mixed. To the finished silicate mass, 19% NaOH is added in the form of an aqueous solution providing a ratio of the mass of sodium hydroxide to the mass of zeolite rock and crystallized perlite equal to 0.235, and the ratio of the total content of silica-containing components and sodium hydroxide to the water content of 2.63.

The resulting mixture is mixed with a mixer until it is homogeneous, and then the homogeneous mixture is placed on a tray in a drying chamber, in which physical water is removed and a silicate mass with a residual moisture content of 1 wt.% Is obtained. Dry silicate mass is crushed with a crusher to a fraction of 2-3 mm, and then crushed to a base fraction of not more than 50-60 microns with a vibration mill. The crushed powdery silicate mass is poured into a metal mold and placed in a muffle furnace. The silicate mass is dried for 2 hours at a temperature of 40-50 ° C and for 3 hours at a temperature of 240-250 ° C to obtain a silicate mass with a residual moisture content of 1 wt.%, And then heated at a speed of 7-8 ° C / min to a temperature of 625 ° C, at which they are incubated for 1 hour. After heating, the temperature in the furnace is increased at a rate of 5-6 ° C / min to 785 ° C, at which the silicate mass is expanded for 1 hour. In order to relieve internal stresses, they are annealed, for which it is cooled together with the furnace to room temperature.

To reduce energy consumption and simplify the technology of obtaining building material by reducing the number of stages of heat treatment of the mixture before firing, as well as improving the pore structure and properties of the building material in the present invention, crushed pieces of zeolite rock fraction 3-5 mm and glassy perlite fraction 0.5-5 mm are subjected separate grinding in a vibration mill: zeolite rock for 7-9 minutes, and crystallized perlite for 5-7 minutes to a particle size of not more than 100 microns, and then thermal preparation drying by drying in a drying chamber: zeolite rock at a temperature of 200-300 ° C for 0.25 hours, crystallized perlite at a temperature of 315 ° C for 0.15 hours.

To stabilize the foam and fix the volume of the expanded silicate mass at the maximum firing temperature before annealing, a sharp decrease in the firing temperature of the building material by 100-150 ° C is performed.

The average density of the building material is 440 kg / m ³ , its compressive strength is 5.4 MPa, the structure is uniformly porous, and the pore diameter is less than 2.0 mm.

Example 8

Carried out analogously to example 7 with the following ratio of components:

Zeolite rock 36 Perlite crystallized 46 Sodium hydroxide eighteen

The addition of 18% NaOH to the silicate mass in the form of an aqueous solution provides a ratio of the mass of sodium hydroxide to the mass of zeolite rock and crystallized perlite, equal to 0.22, and the ratio of the total content of silica-containing components and sodium hydroxide to the water content of 2.78. Building material swelling is carried out at a temperature of 810 ° C.

The average density of the building material is 490 kg / m ³ , its compressive strength is 4.7 MPa, the structure is uniformly porous, and the pore diameter is less than 1.5 mm.

Example 9

Carried out analogously to example 7 with the following ratio of components:

Zeolite rock 19 Perlite crystallized 64 Sodium hydroxide 17

The addition of 17% NaOH to the silicate mass in the form of an aqueous solution provides a ratio of the mass of sodium hydroxide to the mass of zeolite rock and crystallized perlite, equal to 0.205, and the ratio of the total content of silica-containing components and sodium hydroxide to the water content of 2.94. Building material swelling is carried out at a temperature of 835 ° C.

The average density of the building material is 570 kg / m ³ , its compressive strength is 11.0 MPa, the structure is uniformly porous, and the pore diameter is less than 1 mm.

Tables 3, 4, and 5 show the comparative characteristics of the properties of the building material obtained, respectively, using hydrated, vitreous, and crystallized perlites in combination with zeolite rock (compositions 1, 2, and 3).

Table 3   The influence of prescription and technological factors on the properties of the building material of composition 1 of the composition “zeolite rock-perlite hydrated” The composition of the mixture and the conditions for obtaining building material, wt.% (Composition 1) Composition numbers one 2 3 four 5 Zeolite rock 80 65 fifty 35 twenty Hydrated perlite 2 eighteen 34 fifty 66 Sodium hydroxide eighteen 17 16 fifteen fourteen The ratio of sodium hydroxide to rock 0.22 0.205 0.191 0.177 0.163 The ratio of the total content of silica-containing components and sodium hydroxide to the water content 2.78 2.94 3,125 3.33 3.57 Temperature of thermal preparation of rocks: - perlite, ° С 320 320 320 320 320 - zeolite rock, ° С 200-300 200-300 200-300 200-300 200-300 The temperature of the heat treatment of silicate mass, ° C 650 650 650 650 650 Building material firing temperature, ° С 745 765 785 805 825 The average density of the building material, kg / m ³ 443 285 405 515 640 Compressive strength of building material, MPa 5.5 2,4 5,0 12.0 6.3 Water absorption, wt.% 3 5 four 3 9 Heat conductivity coefficient, kW / m · ° С 0.11 0.08 0.09 0.12 0.15 Building material structure Dense Uniform finely porous structure, pore diameter up to 1.5-2.5 mm Pores are uneven

Table 4  The influence of prescription and technological factors on the properties of the building material of composition 2 of the composition “zeolite rock-perlite glassy” The composition of the mixture and the conditions for obtaining building material, wt.% (Composition 2) Composition numbers one 2 3 four 5 Zeolite rock 81 61.5 42 22.5 3.00 Glass perlite 1.00 21.5 42 62.5 83 Sodium hydroxide eighteen 17 16 fifteen fourteen The ratio of sodium hydroxide to rock 0.22 0.205 0.19 0.177 0.163 The ratio of the total content of silica-containing components and sodium hydroxide to the water content 2.78 2.94 3.13 3.33 3.57 Temperature of thermal preparation of rocks: - perlite, ° С 315 315 315 315 315 - zeolite rock, ° С 200-300 200-300 200-300 200-300 200-300 The temperature of the heat treatment of silicate mass, ° C 600 600 600 600 600 Building material firing temperature, ° С 750 775 800 825 850 The average density of the building material, kg / m ³ 450 300 420 545 630 Compressive strength of building material, MPa 5,6 3,1 5.3 13.0 4.1 Water absorption, wt.% 2 four 3 2 10 Heat conductivity coefficient, kW / m · ° С 0.12 0.09 0.10 0.13 0.15 Building material structure Dense Uniform finely porous structure, pore diameter up to 1-2.0 mm Pores uneven
ny

Table 5  The influence of prescription and technological factors on the properties of the building material of composition 3 of the composition “crystallized zeolite rock-perlite” The composition of the mixture and the conditions for obtaining building material, wt.% (Composition 3) Composition numbers one 2 3 four 5 Zeolite rock 70 53 36 19 2 Perlite crystallized 10 28 46 64 82 Sodium hydroxide twenty 19 eighteen 17 16 The ratio of sodium hydroxide to rock 0.25 0.235 0.22 0.205 0.19 The ratio of the total content of silica-containing components and sodium hydroxide to the water content 2,5 2.63 2.78 2.94 3,125 Temperature of thermal preparation of rocks: - perlite, ° С 335 335 335 335 335 - zeolite rock, ° С 200-300 200-300 200-300 200-300 200-300 The temperature of the heat treatment of silicate mass, ° C 625 625 625 625 625 Building material firing temperature, ° С 760 785 810 835 860 The average density of the building material, kg / m ³ 520 440 390 570 665 Compressive strength of building material, MPa 7.2 5,4 4.7 11.0 8.1 Water absorption, wt.% 2 3 3 2 6 Heat conductivity coefficient, kW / m · ° С 0.13 0.10 0.11 0.14 0.16 Building material structure Dense Uniform finely porous structure, pore diameter up to 1-1.5 mm Dense, uneven pores
measured

An analysis of the data in Tables 3, 4, and 5 shows that the results on the physicomechanical properties obtained for a new building material using hydrated, vitreous, and crystallized perlites in combination with zeolite rock change slightly in the series composition 1 → composition 2 → composition 3. This indicates that when using preliminary thermal preparation of rocks and optimizing the composition of the charge, differences in morphology and water content in the structure of the source rocks become not so significant that have a significant impact on the properties of the synthesized material. As a result of this, the reproducibility of the results and the reliability of the production technology of the new building material increases during the transition from one perlite variety to another in charge compositions.

It should also be noted that there are optimal compositions of the charge for the main components and the content of sodium hydroxide, as well as the firing temperature, which are preferable from the standpoint of saving an expensive alkaline component and reducing energy costs, contributing to the formation of an optimal pore structure of the synthesized building material, and, as a result, the growth of indicators of its physical and mechanical properties. So, for the building material of the composition “zeolite rock-perlite hydrated” (Table 3), the optimal content of zeolite rock is in the range of 65-35 wt.%, Hydrated perlite in the range of 18-50 wt.% And sodium hydroxide in the range of 15-17 wt.%. The specified content of sodium hydroxide provides the ratio of the mass of sodium hydroxide to the mass of zeolite rock and hydrated perlite in the range of 0.177-0.205 and the ratio of the total content of silica-containing components and sodium hydroxide to the water content in the range of 2.94-3.33. The optimum firing temperature of the building material of the composition "zeolite rock-perlite hydrated" is in the range of 765-805 ° C.

For the building material of the composition “zeolite rock-perlite glassy” (Table 4), the optimal content of zeolite rock is in the range of 22.5-61.5 wt.%, Vitreous perlite in the range of 21.5-62.5 wt.% And hydroxide sodium in the range of 15.0-17.0 wt.%. The specified content of sodium hydroxide provides the ratio of the mass of sodium hydroxide to the mass of zeolite rock and vitreous perlite in the range of 0.177-0.205 and the ratio of the total content of silica-containing components and sodium hydroxide to the water content in the range of 2.94-3.33. The optimum firing temperature of the building material of the composition "zeolite rock - glassy perlite" is in the range of 775-825 ° C.

For the building material of the composition “zeolite rock - perlite crystallized” (Table 5), the optimal content of zeolite rock is in the range of 19-53 wt.%, Perlite crystallized in the range of 28-64 wt.% And sodium hydroxide in the range of 17-19 wt. % The specified content of sodium hydroxide provides the ratio of the mass of sodium hydroxide to the mass of zeolite rock and crystallized perlite in the range of 0.205-0.235 and the ratio of the total content of silica-containing components and sodium hydroxide to the water content in the range of 2.63-2.94. The optimum firing temperature of the building material of the composition "zeolite rock - perlite crystallized" is in the range of 785-835 ° C.

Table 6 shows the conditions of production and comparative data on the physico-mechanical properties of building materials obtained according to the invention (compositions 1,2 and 3) in comparison with the prototype (see patent RU No. 2300506, IPC С03С 11/00, publ. 08.05 .2007).

Thus, from table 6 it follows that the proposed method for producing building material has the following advantages compared to the prototype (see RU patent No. 2300506 IPC, C03C 11/00, publ. 08.05.2007):

- improving the physico-mechanical and operational properties of the new building material (in structure and strength) by increasing the uniformity of the phase composition and improving the structure of the material, due to the optimization of the conditions for the preparation of the initial silica-containing rocks;

- increasing the efficiency of the use of siliceous rocks due to the integrated use of zeolite rocks and volcanic glasses (hydrated, vitreous and crystallized perlites) of the Mukhor-Talinsky deposit;

- reducing the consumption of alkaline component due to the use in the composition of the mixture of flux in the form of volcanic glasses (perlite);

- reducing energy costs and the complexity of production by reducing the number of stages of heat treatment before expansion, due to the use of drying of the original silica-containing rocks.

The proposed method for producing building material has been tested and can be used in the construction industry as a thermal insulation and structural material in building envelopes, as well as thermal insulation in the power system and thermal insulation of heat pipes. Based on the foregoing, it can be concluded that the obtained new building material based on zeolite-bearing rocks and volcanic glasses (hydrated, vitreous and crystallized perlites) is a durable building thermal insulation and construction material, which is advisable to use in the form of plates, small-piece blocks, shells for thermal insulation of building structures, thermal installations, as well as for self-supporting fencing elements.

Claims (4)

1. A method of obtaining a building material, comprising mixing silica-containing and alkaline components and water at their indicated ratio, drying, grinding the mixture, filling with a ground mass of the mold and cooling, characterized in that as a silica-containing component, a mixture of zeolite rock and volcanic glass, the components of which before mixing with the alkaline component and water, they are subjected to separate grinding in a vibration mill to a particle size of not more than 100 μm, and then carried out with zeolite rock eye at a temperature of 200-300 ° C for 0.25 hours, then volcanic glass is dried at a temperature of 315-335 ° C for 0.15 hours, and after drying and grinding of the silicate mass, heating is carried out at a temperature of 40- 60 ° C and 240-260 ° C, and then heated to a temperature of 600-650 ° C at a speed of not more than 7-8 ° C / min, after which they are heated at a speed of no more than 5-6 ° C / min to the expansion temperature, is in the range of 765-835 ° C, while the cooling of the expanded silicate mass is stabilized by a sharp decrease in the temperature of the expanded Nia at 100-150 ° C, whereupon annealing temperature to 60 ° C at a rate not more than 0,5-0,6 ° C / min. 2. The method according to claim 1, characterized in that hydrated perlite with a crystalline phase content of 5% and hygroscopic water of 0.6-3.2% is used as volcanic glass in the following ratio of components, wt.%:
zeolite rock - 35-65;
hydrated perlite - 18-50;
sodium hydroxide - the rest,
the ratio of the mass of sodium hydroxide to the mass of zeolite rock and hydrated perlite is in the range of 0.177-0.205, and the ratio of the total content of the silica-containing component and sodium hydroxide to the water content is 2.94-3.33, after which the resulting mixture is dried for 2 hours at a temperature of 50-60 ° C and for 3 hours at a temperature of 250-260 ° C, and after drying, a finely ground charge is placed in a mold and heated to a temperature of 650 ° C and maintained at this temperature for 1 hour, and then heated before firing temperature, which is in the range of 765-805 ° C, and swell at this temperature for 1 hour, after which the silicate mass swollen during firing is stabilized by drastically lowering the maximum firing temperature by 100-150 ° C. 3. The method according to claim 1, characterized in that glassy perlite with a crystalline phase content of 2-5% and hygroscopic water of 0.3-1.0% is used as volcanic glass in the following ratio, wt.%:
zeolite rock - 22.5-61.5;
glassy perlite - 21.5-62.5;
sodium hydroxide - the rest,
the ratio of the mass of sodium hydroxide to the mass of zeolite rock and vitreous perlite is in the range of 0.177-0.205, and the ratio of the total content of the silica-containing component and sodium hydroxide to the water content is 2.94-3.33, after which the resulting mixture is dried for 2 hours at a temperature of 45-55 ° C and for 3 hours at a temperature of 245-255 ° C, and after drying, a finely ground charge is placed in a mold and heated to a temperature of 600 ° C and maintained at this temperature for 1 hour, and then heated to those perature firing, which is in the range of 775-825 ° C and is expanded at this temperature for 1 hour, followed by calcination at exfoliated silicate mass is subjected to stabilization by drastically lowering the maximum firing temperature at 100-150 ° C. 4. The method according to p. 1, characterized in that crystallized perlite with a content of 20-40% vitreous phase, 60-80% cryptocrystalline aggregates and hygroscopic water 0.3-1.3% is used as volcanic glass, in the following ratio of components, wt. %:
Zeolite rock - 19-53;
Crystallized perlite - 28-64;
Sodium hydroxide - the rest,
the ratio of the mass of sodium hydroxide to the mass of zeolite rock and crystallized perlite is in the range of 0.205-0.235, and the ratio of the total content of the silica-containing component and sodium hydroxide to the water content is 2.63-2.94, after which the resulting mixture is dried for 2 hours at a temperature of 40-50 ° C and for 3 hours at a temperature of 240-250 ° C, and after drying the finely ground charge is placed in a mold and subjected to heating to a temperature of 625 ° C and maintained at this temperature for 1 hour and then heating t to the firing temperature, that is in the range of 785-835 ° C and is expanded at this temperature for 1 hour, followed by calcination at exfoliated silicate mass is subjected to stabilization by drastically lowering the maximum firing temperature at 100-150 ° C.