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INVENTION
Patent of the Russian Federation RU2235698
RAW MIXTURE AND METHOD OF MANUFACTURE OF LIGHT-CERAMIC CERAMICS
The name of the inventor: Kosykh AV (RU); Lokhova N.A. (RU); Makarova I.A.
The name of the patent holder: Bratsk State Technical University
Address for correspondence: 665728, Irkutsk Region, Bratsk, ul. Makarenko, 40, Bratsk State Technical University, Patent Service
Date of commencement of the patent: 2002.08.06
The invention relates to the production of porous ceramic materials and can be used for the manufacture of building materials. The feed mixture contains the following components, by weight: clad loam 75.5 ... 83; Compacted microsilica 10 ... 15; A spill from the battle of the coal lining of electrolysers 5 ... 7; Sulphate soap 2 ... 2,5. The method for manufacturing lightweight ceramics from the above mixture comprises preparing the mixture by mixing a rotary mixer of clay slurry with compacted microsilica obtained by granulation by feeding an aqueous solution of 0.8-1% by weight of sulphate soap into the granulator, followed by introduction of a technical foam prepared by bubbling air with an aqueous A solution of 1.2-1.5% by weight of sulphate soap; Molding, drying and firing at a temperature of 1000 ° C. The invention allows expanding the raw material base by involving the carbonized raw material in the ceramic production, reducing the average density, thermal conductivity and material consumption of products.
DESCRIPTION OF THE INVENTION
The present invention relates to the production of porous ceramic products and can be used for the manufacture of building materials.
The raw material mixture closest to the proposed raw material for the technical essence and the effect achieved is, including: weight%: microsilica - 70-80, the spill from the battle of spent coal lining of electrolysers - 20-30 [patent RF 2167125, publ. 20.05.2001, C 04 B 35/14].
The disadvantages of this mixture are the high material consumption and the average density of the products, as well as the deteriorated heat-shielding properties of the material.
The technical result is the expansion of the raw material base by involving the carbonized raw material in the ceramic production, reducing the average density, heat conductivity and material consumption of the products.
The technical result is achieved by the fact that the raw material mixture for the manufacture of lightweight ceramics, including microsilica and spillage from the battle of spent carbon lining of cells, contains as a microsilica a compacted microsilica with a bulk density of up to 500 kg / m 3 , the mixture additionally contains a carbonized loam containing carbonates 20. .. 25%, and as the pore-forming additive - sulphate soap with the following ratio of components, mass%:
- Clay loam 75,5 ... 83
- Compacted microsilica 10 ... 15
- A spill from a coal fight
- Lining of pots 5 ... 7
- Sulphate soap 2 ... 2,5
The carbonized loam of the Anzebinsk deposit contains 20 ... 25% by weight of calcite and dolomite and has the following chemical composition, mass%: SiO 2 54.34; Al 2 O 3 12.44; TiO 2 0.71; Fe 2 O 3 3.84; FeO 1.43; CaO: 5.84; MgO 5.44; Na 2 O 2.0; K 2 O 2.66; Loss on ignition 10,36.
Microsilica is an ultradisperse waste of production of crystalline silicon with a high specific surface area of 25 ... 34 m 2 / g and a low bulk density of 150 ... 250 kg / m 3 . Chemical composition of microsilica, wt%: SiO 2 86 ... 93; Fe 2 O 3 0.14 ... 1.28; MgO 1.03 ... 1.2; Na 2 O 0.39 ... 0.46; K 2 O 0.28 ... 0.42; Al 2 O 3 0.7 ... 1.05; CaO 0.26 ... 0.44; Loss on ignition 3,7 ... 5,29. Due to the low bulk density, the silica fines are compacted to reduce transportation costs and reduce dusting.
The spill from the battle of spent coal lining of electrolysers is a fine-grained waste that accumulates during the crushing of the dismantled spent coal lining of aluminum electrolysis production.
The spent carbon lining of the cells is formed during the overhaul of the cells. After crushing and screening, large pieces of spent coal lining are disposed of in the metallurgical industry, and the crumbling (less than 5 mm) does not find any application and is taken to the dump.
The spill from the battle of the spent coal lining of the electrolysers has the following chemical composition, mass%: SiO 2 22.4; Al 2 O 3 15.01; Fe 2 O 3 2.05; CaO 2.6; MgO 1.58; F to 15; Na + up to 15; C to 67. The predominant particle size (more than 90%) is up to 1.25 mm. The bulk density is 760 kg / m 3 .
Sulphated soap is a by-product of sulphate-cellulose production. Sulphated soap contains (TU 13-0281078-28-118-88), by weight: fatty, resin acids and unsaponifiable substances - not less than 40-45; Water - no more than 35-50; Total alkali in terms of NaOH - no more than 9. The soap is contaminated with lignin, tannins and coloring substances, and mineral components. Sulphate soap is an ointment product from dark yellow to dark brown, removed from the surface of black liquors when cooking pulp from coniferous and hardwoods.
The introduction of microsilica and spillage from the battle of the carbon lining of the electrolysers ensures the enrichment of the mixture with amorphized and low-melting constituents, which contributes to early accumulation of the melt and mineral formation. The burning out of the organic matter contained in these additives intensifies the course of oxidation-reduction processes during roasting and additionally pores the crock.
Sulphate soap provides a developed, differentiated in size porosity, which forms a cellular structure of the crock.
The method closest to the proposed method for the technical essence and the effect achieved, including the preparation of a mixture, molding, drying and baking, is patent [RF patent No. 2167125, publ. 20.05.2001, C 04 B 35/14].
Disadvantages of this method are high values of average density, thermal conductivity and material consumption of products.
The technical result is a decrease in the average density, thermal conductivity and material consumption of products.
The technical result is achieved by the fact that when using a raw mix according to claim 1, the microsilica is compacted by granulation by feeding 0.8-1 wt.% Of a sulphate soap into the granulator, then the compacted microsilica is mixed with a rotary mixer with a clay slurry prepared from a clay loam and water , Followed by the introduction of 1.2-1.5% by weight of sulphate soap in the form of a technical foam obtained by bubbling air with an aqueous solution of sulphate soap.
Phased introduction of sulphate soap provides a combined pore formation by combining air entrainment and foaming. Air entrainment occurs with mixing of a clay slip and microsilica granulated with the addition of a part of sulphate soap, due to the action of surface-active properties of salts of fatty and resin acids of sulphate soap. The introduction of the rest of the sulphate soap in the form of a technical foam forms a large porosity in the finely porous mass obtained by air entrainment.
Example
Fabrication of the material is as follows. The microsilica is compacted by granulation when an aqueous solution of sulfate soap is fed into the granulator. The granulated microsilica is mixed with a rotary mixer with a clay slurry, prepared from zakarbonizovannogo loam and water. The resulting fine pulp is introduced with a technical foam made by bubbling air with an aqueous solution of sulphate soap.
Molding is carried out by pouring foam into lubricated molds. The semi-finished product dried at 60-80 ° C is calcined at 1000 ° C.
Formulations of mixtures and physical and mechanical characteristics of products on their basis are presented in Table. 1 and 2.
CLAIM
1. A raw material mixture for the manufacture of lightweight ceramics, including clay raw material, an otoscent and pore-forming additive, characterized in that clayey raw material is used with a clay loam with a carbonate content of 20 ... 25% and compacted microsilica with a bulk density of up to 500 kg / m 3 , As a lean additive - a spill from the battle of the coal lining of cells, as a pore-forming additive - sulfate soap with the following ratio of components, mass%:
Carbonized loam 75,5 ... 83
Compacted microsilica 10 ... 15
The spill from the battle of the coal lining of the electrolyzers 5 ... 7
Sulphated soap 2 ... 2,5
2. A method of manufacturing lightweight ceramics from a raw mixture comprising microsilica and a spill from the battle of the spent carbon lining of electrolysers, comprising preparing the mixture, molding, drying and calcining, characterized in that, when using the mixture according to claim 1, the microsilica is compacted by granulation when fed to an aqueous granulator A solution of 0.8-1% by weight of sulphate soap, then the compacted microsilica is mixed with a rotary mixer with a clay slurry prepared from a clay loam and water, after which 1.2-1.5% by weight of sulphate soap is introduced as a technical foam, Obtained by bubbling air with an aqueous solution of sulphate soap.
print version
Date of publication 06.04.2007гг
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