Study on Preparation of Lightweight Ceramsite with High Blending Capacity using Low Silicon Iron Tailings
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摘要:
为解决低硅铁尾矿大量堆存且利用难度大等问题，以杨家湾尾矿库低硅铁尾矿为主要原料，掺入了某铜尾矿和市售煤粉，通过烧结法制备轻质烧结陶粒，并考察了原料配比、水料比、尾矿粒度、烧结条件等因素对陶粒性能的影响。结果表明，质量配比为m(铁尾矿)∶m(铜尾矿)∶m(煤粉)=8∶1∶1（即铁尾矿掺量80%）、水料比1∶5、烧结温度1 120 ℃、烧结时间20 min的条件下制备出堆积密度为873.2 kg/m3、筒压强度5.13 MPa、1 h吸水率为7.65%的轻质陶粒，结合陶粒形貌、物相及热重分析，陶粒烧结过程中产生了起增强强度作用且呈致密网状结构的透辉石。该研究为低硅铁尾矿的资源化利用提供了新的利用途径。
Abstract:In response to the challenges of large amount of low silicon iron tailings and great difficulty in utilization, light weight sintered ceramsite was prepared using the low silicon iron tailings from Yangjiawan tailings pond as the main raw material, which was combined with copper tailings and pulverized coal commercially available. The effects of ingredient ratio, mass ratio of water and material, particle size, sintering conditions and other factors on the properties of ceramsite were investigated in details. The results showed that the lightweight ceramsite possessed a bulk density of 873.2 kg/m3, cylinder pressure strength of 5.13 MPa and water absorption of 7.65% in 1 h, under the condition of a mass ratio of m(iron tailings)∶m(copper tailings)∶m(coal powder) = 8∶1∶1 (i.e. 80% of iron tailings), water to material ratio of 1∶5, sintering temperature of 1120 ℃, and sintering time of 20 min. According to the morphology, phase and thermogravimetric analyses of ceramsite, diopside with dense network structure was formed and could improve the pressure of ceramsite during the sintering process. It therefore provides a novel way for the resource utilization of low silicon iron tailings.
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Key words:
- low-silicon /
- iron tailings /
- copper tailings /
- high dosage /
- lightweight ceramsite
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表 1 主要原料化学成分
Table 1. Chemical composition of main raw materials
/% 原料 SiO2 CaO Fe2O3 Al2O3 SO3 K2O MgO Na2O MnO TiO2 铁尾矿3 35.10 20.00 11.96 12.93 7.59 4.62 4.21 1.74 0.24 0.69 铁尾矿6 25.29 26.87 16.26 9.68 9.63 2.79 6.96 0.78 0.3 0.65 铁尾矿9 26.24 25.94 15.40 10.17 9.52 2.98 7.32 0.84 0.29 0.56 铜尾矿 27.70 35.78 25.23 5.85 0.10 0.83 2.53 0.51 0.66 0.32 
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表 2 正交配比设计表
Table 2. Orthogonal ratio design table
因素 单位 水平 1 2 3 A 铁尾矿 g 60 70 80 B 铜尾矿 g 5 10 15 C 煤粉 g 0 5 10
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表 3 正交试验测试数据汇总表
Table 3. Summary of orthogonal test data
试验序号 因素 表观密度/（kg·m−3） 1 h吸水率/% A B C 1 1 1 1 1965.2 3.27 2 1 2 2 2054.5 9.73 3 1 3 3 2200.1 5.04 4 2 1 3 1817.1 16.28 5 2 2 1 1879.8 14.42 6 2 3 2 2220.0 11.71 7 3 1 2 2252.2 3.17 8 3 2 3 1701.5 13.16 9 3 3 1 1938.2 12.40
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表 4 正交试验极差分析结果
Table 4. Range analysis results of orthogonal test
因素 指标 各水平下指标的平均值(k) 极差(R) 较优水平 k1 k2 k3 A 表观密度 2073.3 1972.3 1964.0 109.3 3 吸水率 6.01 14.14 9.58 8.12 1 B 表观密度 2011.5 1878.6 2119.4 240.8 2 吸水率 7.57 12.44 9.72 4.86 1 C 表观密度 1927.8 2175.6 1906.7 268.9 3 吸水率 10.03 8.20 11.49 3.29 2
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表 5 不同粒度陶粒性能测试结果
Table 5. Summary of ceramsite properties with different particle sizes
组别 采样点 配料比 堆积密度/(kg·m−3) 表观密度/(kg·m−3) 1 h吸水率/% 24 h吸水率/% 筒压强度/MPa 1 3 8∶1∶1 1021.3 1950.1 17.46 17.82 3.72 2 6 8∶1∶1 916.3 1776.5 7.65 7.73 7.63 3 9 8∶1∶1 912.0 1739.1 16.77 17.28 2.69
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表 6 不同烧结温度下的陶粒性能
Table 6. Summary of ceramsite performance tests at different sintering temperatures
组别 温度/℃ 堆积密度/(kg·m−3) 表观密度/(kg·m−3) 1 h吸水率/% 24 h吸水率/% 筒压强度/MPa 1 1100 953.2 1823.3 6.72 6.91 1.73 2 1120 916.3 1776.5 7.65 7.73 7.63 3 1140 1170.5 2278.8 1.01 1.07 11.07
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表 7 不同烧结时间下的陶粒性能
Table 7. Summary of ceramsite performance tests at different sintering times
组别 烧结时间/min 堆积密度/(kg·m−3) 表观密度/(kg·m−3) 1h吸水率/% 24h吸水率/% 筒压强度/MPa 1 10 816.2 1593.5 16.72 16.94 3.78 2 20 873.2 1650.2 9.42 9.76 5.13 3 30 916.3 1776.5 7.65 7.73 7.63
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表 8 最优条件下烧结陶粒的元素组成表
Table 8. Elemental composition of sintered ceramsite under optimal conditions
/% Na2O MgO Al2O3 SiO2 P2O5 SO3 K2O CaO TiO2 MnO Fe2O3 1.776 5.214 10.673 41.916 0.433 1.283 2.411 20.597 0.727 0.199 13.565 Co3O4 CuO ZnO As2O3 Rb2O SrO Y2O3 ZrO2 BaO PbO 0.047 0.085 0.018 0.007 0.014 0.07 0.002 0.031 0.135 0.007
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