环保型功能化传统建筑陶瓷高瘠性料成型机理及性能研究

The in-situ gel-casting consolidation forming with macromolecule amylase has been wildly used in the fabrication of advanced ceramics industry. But the similar foundational and applied research of this technology is still blank in the field of traditional architectural ceramic. To prepare an environmental infrared functional traditional architectural ceramics, a novel method to reduce the raw materials and energy consumption is supposed in this project. In-situ forming technique will be firstly applied to the molding of traditional architectural ceramics using large amount of poor plastic silicates such as fly ashes, deserts and other waste materials as raw materials, which meet the state requirement of the energy conservation and environmental protection. Various modified starch's gelatinized and dispersion mechanism of large amount of poor plastic material with the characteristic of multi-composition will be investigated here. The effects of pH values on the stabilities of macromolecule amylase and poor plastic silicate particles in the slurry is studied. Meanwhile, the influence of different mould materials on slurry's properties was also investigated.The main purpose of this proposed is to utilize large amount of waste materials,therefore,the effect of reasonable proportion of waste material to other poor plastic materials on the physical & chemical, mechanical and infrared properties of the as-fabricated products will thoughly be studied.The proposed work is able to overcome the dust pollution and reduce energy consumption from the spray granulation and traditional dry molding process,which leads to a new revolution in the molding process and production equipments, raises the market competition and promotes the developing to environmental friendly and multi-functional architectural ceramics.

高分子多糖凝胶注模原位凝固成型技术已广泛运用在特种陶瓷制备领域，但在传统建筑陶瓷领域未见相关基础及应用研究。本项目以制备环保型红外功能化传统建筑陶瓷为目的，研究降低原材料和能耗的新方法，以粉煤灰、沙漠沙等废料为主的硅酸盐高瘠性浆体为对象，创新地将原位凝固成型技术应用到建筑陶瓷成形工艺中，符合国家节能环保要求；研究具备多成分特点的以废料为主的高瘠性料浆体的分散机理、各类改性淀粉在该体系中的胶凝机理；研究了解PH值对浆体中硅酸盐瘠性料和高分子多糖颗粒稳定性能的影响、了解不同材质成型模具对该体系浆体性能的影响；研究废料与其它瘠性料的合理配比对制品理化、力学及红外性能的影响，以达到尽可能多的引入废料。本项目基础研究成果将会给传统建筑陶瓷生产带来成型工艺和生产装备上的新变革，克服干粉粉尘污染，减少喷雾造粒、大吨位压机成型等过程的高能耗，促进传统建筑陶瓷向更环保节能及多功能方向发展，提高市场竞争力。

本课题在四年研究期间，围绕硅酸盐废料在建筑陶瓷红外功能化领域开展了大量的基础应用性研究，同时以实现废料在建筑陶瓷生产领域的最大资源化利用为目的，创新性探索湿法浇注成型工艺在绿色环保建筑制瓷领域的相关应用，在国内及国际上的建筑陶瓷研究领域具有独创性。期间共计发表期刊论文8篇，会议论文3篇，申请并获得授权国家发明专利6项，正在审查中国家发明专利2项，先后派遣7名项目组成员和研究人员参加国内外学术会议3次，并培养了6名全日制研究生。. 本项目根据地区特色，首先提出以江西产量较大的发电厂废渣——粉煤灰工业废料作为传统环保建筑陶瓷基础配方的立足点和新意点。鉴于过多的粉煤灰瘠性废料引入会引起传统干压压制成型坯体性能不佳的工艺壁垒，为了达到较大量（≥85%）使用工业废料的目的，本课题突破传统的成型工艺思路，创新性地将湿法浇注成型法引入到传统建筑陶瓷生产中。利用高分子多糖为胶凝剂，探讨不同类型的高分子多糖引入下的湿法浇注成型工艺，解决高硅酸盐废料（粉煤灰、废瓷粉、花岗岩废料等）引入下对传统建筑陶瓷砖制备工艺的成形性能、结合性及干燥制度等的影响，通过对原料配方、胶体种类、添加量以及制备工艺的优化实现了陶瓷的原位凝固成型，大大改善了全瘠性坯料干粉压制后生坯强度不足1MPa的成型缺陷，有效地增强全瘠性料生坯强度，满足建筑陶瓷厂流水线生产对生坯强度的要求。