Orthogonal Experiment on Preparation of Lightweight Porous Ceramics from a Porphyry Copper Flotation Tailings in Mongolia
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摘要:
以蒙古国某典型斑岩型铜矿尾矿为主要原料，添加钠长石、高岭土、发泡剂SiC，制备轻质多孔陶瓷材料。通过正交实验研究了物料配比、粉磨时间、发泡剂种类、发泡剂用量和烧成温度对轻质多孔陶瓷表观密度和抗压强度的影响。当m（铜尾矿）∶m（钠长石）∶m（高岭土）为6.4∶2.7∶0.9、粉磨时间为15 min、发泡剂（SiC）掺量为0.1%、烧成温度为1180 ℃、保温时间为60 min时，获得的多孔陶瓷材料表观密度为580 kg/m3，抗压强度为4.90 MPa，软化系数为0.92。
Abstract:Lightweight porous ceramic materials is prepared from flotation tailings of a typical porphyry copper ore in Mongolia, albite, kaolin and foaming agent SiC. The effects of material ratio, grinding time, foaming agent type, foaming agent dosage and sintering temperature on the apparent density and compressive strength of lightweight porous ceramics are studied by orthogonal tests. When the ratio of m (copper tailings)∶m (albite)∶m (kaolin) is 6.4∶2.7∶0.9, the grinding time was 15min, the content of foaming agent (SiC) was 0.1%, the sintering temperature was 1180℃ and the holding time was 60min, the technological process was the best. At this time, the apparent density of porous ceramic material was 580 kg/m3, the compressive strength was 4.90 MPa and the softening coefficient was 0.92.
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表 1 主要原料的X射线荧光光谱分析结果
Table 1. X−ray fluorescence spectrum analysis of copper tailings
/% 化学成分 SiO2 Al2O3 CaO MgO K2O Na2O Fe2O3 SO3 Loss 铜尾矿 67.74 15.73 0.67 0.95 3.68 3.72 2.70 2.38 1.36 钠长石 77.50 11.98 0.61 1.52 0.36 7.15 0.32 0.02 0.45 高岭土 45.71 40.32 0.77 0.66 2.53 0.18 7.27 0.16 2.14 
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表 2 发泡剂种类实验结果
Table 2. Test results of foaming agent types
试验编号 发泡剂种类 发泡剂用量/% 多孔陶瓷材料
表观密度/(kg·m−3)1 炭粉 5.0 2320 2 煤矸石 7.0 2551 3 纯碱 2.0 1900 4 氧化铁 4.0 2156 5 SiC 0.5 614 注：不同的发泡剂发泡能力有差异，因此发泡剂的用量有差别。
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表 3 铜尾矿发泡陶瓷配方及工艺条件正交因素和水平
Table 3. Orthogonal factor and level table of formula and process conditions of copper tailings foamed ceramics
因素 铜尾矿
/%钠长石
/%高岭土
/%磨矿
时间/min发泡剂
掺量/%烧成
温度/℃1 50 20 5 10 0.1 1180 2 60 30 10 15 0.3 1200 3 70 40 15 20 0.5 1220
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表 4 正交实验表L18（36）
Table 4. Orthogonal Experiment Table L18（36）
因素 尾矿
/wt%钠长石
/wt%高岭土
/wt%发泡剂
掺量/wt%磨矿
时间/min烧成
温度/℃实验1 50 20 5 0.1 10 1180 实验2 50 30 10 0.3 15 1200 实验3 50 40 15 0.5 20 1220 实验4 60 20 5 0.3 15 1220 实验5 60 30 10 0.5 20 1180 实验6 60 40 15 0.1 10 1200 实验7 70 20 10 0.1 20 1200 实验8 70 30 15 0.3 10 1220 实验9 70 40 5 0.5 15 1180 实验10 50 20 15 0.5 15 1200 实验11 50 30 5 0.1 20 1220 实验12 50 40 10 0.3 10 1180 实验13 60 20 10 0.5 10 1220 实验14 60 30 15 0.1 15 1180 实验15 60 40 5 0.3 20 1200 实验16 70 20 15 0.3 20 1180 实验17 70 30 5 0.5 10 1200 实验18 70 40 10 0.1 15 1220
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表 5 发泡陶瓷材料配方及工艺正交实验结果
Table 5. Orthogonal experimental results of formula and process of foamed ceramic materials
水平 因素 性能测试结果 尾矿 钠长石 高岭土 发泡剂掺量 磨矿细度 烧成温度 表观
密度/(kg·m−3)抗压
强度/MPa1 1 1 1 1 1 1 204.01 0.47 2 1 2 2 2 2 2 301.79 2.29 3 1 3 3 3 3 3 188.53 0.29 4 2 1 1 2 2 3 319.36 1.60 5 2 2 2 3 3 1 980.43 4.58 6 2 3 3 1 1 2 729.63 7.29 7 3 1 2 1 3 2 571.47 8.39 8 3 2 3 2 1 3 404.44 1.41 9 3 3 1 3 2 1 279.34 1.07 10 1 1 3 3 2 2 199.65 0.63 11 1 2 1 1 3 3 707.03 3.82 12 1 3 2 2 1 1 315.73 2.42 13 2 1 2 3 1 3 432.99 2.32 14 2 2 3 1 2 1 825.35 15.59 15 2 3 1 2 3 2 382.71 1.51 16 3 1 3 2 3 1 337.09 4.04 17 3 2 1 3 1 2 430.02 3.74 18 3 3 2 1 2 3 756.98 13.78 表观密度 K1 319.46 344.09 387.08 632.41 419.47 490.32 K2 611.75 608.18 559.90 343.52 447.08 435.88 K3 463.22 442.15 447.45 418.49 527.88 468.22 极差 292.29 264.08 172.82 288.89 108.41 54.45 优方案 A1 B1 C1 D2 E1 F2 抗压强度 K1 1.65 2.91 2.03 8.22 2.94 4.70 K2 5.48 5.24 5.63 2.21 5.83 3.97 K3 5.41 4.39 4.88 2.11 3.77 3.87 极差 3.83 2.33 3.60 6.12 2.89 0.83 优方案 A2 B2 C2 D1 E2 F1
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表 6 优化的产品性能测试结果
Table 6. Test results of optimal product performance
项目 抗压强度/MPa 表观密度/(kg·m−3) 软化系数 产品性能 4.90 580 0.92 标准要求 ≥3.50 ≤900 ≥0.80
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