粉煤灰基轻质泡沫多孔材料的制备及性能研究
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摘要
粉煤灰是火力发电厂排出的工业废渣,其排放量随着经济的快速发展而不断增加。目前,我国粉煤灰年排放量近2.0亿吨,而其利用率不足50%。粉煤灰的排放不但占用大量土地,而且还对空气、地下水产生恶劣影响。基于粉煤灰含有大量未燃尽的碳和高比表面积的特点,本论文以粉煤灰为原料,利用坯体发泡和浆料发泡两种方法制备了轻质泡沫多孔材料,并对发泡剂种类、发泡温度等工艺条件对产品性能的影响进行了研究。主要研究内容包括：
(1)坯体发泡法制备轻质材料的研究。以粉煤灰为主要原料,通过向坯体中添加不同造孔剂制备出性能不同的轻质材料,并对工艺条件对试样性能的影响进行了分析。当造孔剂添加量在5 wt.%～10 wt.%之间,烧结温度为1050℃时,制备出轻质材料性能达到GB5101-2003普通烧结砖MU10.0的要求。
(2)发泡剂复配的研究。利用稳泡剂与各种起泡剂的复配,通过正交试验,最后得出发泡剂复配的最佳配比为：m(稳泡剂)：m(起泡剂)=8：2.5,m(溶解用水)：m(自制发泡剂)=10：1。
(3)粉煤灰活化的研究。通过加入碱性物质对其进行了活化,并对碱激活过程进行了研究,结果表明,当激发剂添加量在3 wt.%时效果即达到最佳。
(4)浆料发泡法制备泡沫材料的研究。通过浆料发泡法制备出了具有较均匀孔道结构的泡沫材料,最终得出最佳原料配比为：m(粉煤灰)：m(氢氧化钠)=97：3,水灰比=0.40,烧结温度1050℃,泡沫加入量13 wt.%,产品性能能达到GB13545-2003烧结空心砖和空心砌块中MU5.0水平。
Coal fly ash is a kind of waste outcome from coal fired power stations and the total production is increasing with the development of economy. Currently, the total amount of discharge for coal fly ash is up to two hundreds million tons per year but less than 50% of coal fly ash is utilized in China. This represents a huge negative environmental impact mainly including the pollution of soils and groundwater. In this thesis, light-weight foam materials were prepared by pore-foaming agent method and slurry foaming method. The effects of various kinds of process conditions on performances of sample were investigated and high-quality foam agent was obtained by orthogonal test. In summary, this thesis is composed of three parts as follows:
(1) Light-weight material was prepared by pore-foaming method. The effects of agents on sample performance were studied. The results show that:when the dosage of the agents was between 5 wt.% and 10 wt.% and the sintered temperature is 1050℃, the samples prepared under the conditions above mentioned come up to the standard GB 5101-2003 MU10.0.
(2) The preparation of foam agent is the key step of the slurry foaming method. The results show that:the weight ratio of foam stabilizer, frothing agent were 8:2.5, respectively; the weight ratio of frothing agent, foaming agent were 10:1, respectively.
(3) The activation was studied. In this thesis, alkali was used to activate coal fly ash and the process was studied, too. The optimal dosage of alkali is 3 wt.%.
(4) The sample with homogenous microstructures of pores was prepared by slurry foaming method after alkali-activation. The related factors were optimized:the weight ratio of coal fly ash, sodium hydroxide were 97:3, respectively; water cement ratio was 0.40; the amount of foam was 13 wt.%; sintering temperature was 1050℃. The samples come up to the standard GB 13545-2003 MU5.0.
(1)坯体发泡法制备轻质材料的研究。以粉煤灰为主要原料,通过向坯体中添加不同造孔剂制备出性能不同的轻质材料,并对工艺条件对试样性能的影响进行了分析。当造孔剂添加量在5 wt.%～10 wt.%之间,烧结温度为1050℃时,制备出轻质材料性能达到GB5101-2003普通烧结砖MU10.0的要求。
(2)发泡剂复配的研究。利用稳泡剂与各种起泡剂的复配,通过正交试验,最后得出发泡剂复配的最佳配比为：m(稳泡剂)：m(起泡剂)=8：2.5,m(溶解用水)：m(自制发泡剂)=10：1。
(3)粉煤灰活化的研究。通过加入碱性物质对其进行了活化,并对碱激活过程进行了研究,结果表明,当激发剂添加量在3 wt.%时效果即达到最佳。
(4)浆料发泡法制备泡沫材料的研究。通过浆料发泡法制备出了具有较均匀孔道结构的泡沫材料,最终得出最佳原料配比为：m(粉煤灰)：m(氢氧化钠)=97：3,水灰比=0.40,烧结温度1050℃,泡沫加入量13 wt.%,产品性能能达到GB13545-2003烧结空心砖和空心砌块中MU5.0水平。
Coal fly ash is a kind of waste outcome from coal fired power stations and the total production is increasing with the development of economy. Currently, the total amount of discharge for coal fly ash is up to two hundreds million tons per year but less than 50% of coal fly ash is utilized in China. This represents a huge negative environmental impact mainly including the pollution of soils and groundwater. In this thesis, light-weight foam materials were prepared by pore-foaming agent method and slurry foaming method. The effects of various kinds of process conditions on performances of sample were investigated and high-quality foam agent was obtained by orthogonal test. In summary, this thesis is composed of three parts as follows:
(1) Light-weight material was prepared by pore-foaming method. The effects of agents on sample performance were studied. The results show that:when the dosage of the agents was between 5 wt.% and 10 wt.% and the sintered temperature is 1050℃, the samples prepared under the conditions above mentioned come up to the standard GB 5101-2003 MU10.0.
(2) The preparation of foam agent is the key step of the slurry foaming method. The results show that:the weight ratio of foam stabilizer, frothing agent were 8:2.5, respectively; the weight ratio of frothing agent, foaming agent were 10:1, respectively.
(3) The activation was studied. In this thesis, alkali was used to activate coal fly ash and the process was studied, too. The optimal dosage of alkali is 3 wt.%.
(4) The sample with homogenous microstructures of pores was prepared by slurry foaming method after alkali-activation. The related factors were optimized:the weight ratio of coal fly ash, sodium hydroxide were 97:3, respectively; water cement ratio was 0.40; the amount of foam was 13 wt.%; sintering temperature was 1050℃. The samples come up to the standard GB 13545-2003 MU5.0.
引文
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[7]朱新文,江东亮,谭寿洪.网眼多孔陶瓷浸渍成型工艺的研究[J],无机材料学报,2001,16(6)：1144-1150.
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[19]P. Chindaprasirt, K. Pimraksa, A study of fly ash-lime granule unfired brick, Powder Technology, 2008,182:33-41.
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[21]Fanor Mondragon, F.Rincon, L.Sierra et al. New perspectives for coal ash utilization:synthesis of zeolitic materials [J], Fuel,1990,69(2):263-266.
[22]Hidekazu Tanaka, Satoshi Fujimoto, Atsushi Fujii et al. Microwave assisted two-step process for rapid synthesis of Na-A zeolite from coal fly ash[J], Industrial and Engineering Chemistry Research,2008,47(1):226-230.
[23]K.S.Hui, C.Y.H.Chao, Synthesis of MCM-41 from coal fly ash by a green approach:Influence of synthesis Ph [J], Journal of Hazardous Materials B,2006,137:1135-1148.
[24]J.Davidovits. Society of plastic engineering, SPE PATEC'79, Brookfield, USA,1979.
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[27]Jianguo Zhang, John L. Provis, Dingwu Feng et al. Geopolymers for immobilization of Cr6+,Cd2+,and Pb2+[J], Journal of hazardous materials,2008,157:587-598.
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