Phosphogypsum non-sintered ceramsite light aggregate and preparation method thereof

Abstract

A phosphogypsum non-sintered ceramsite light aggregate composed of water and a mixture composed of phosphogypsum, mineral powder and cement. Raw materials of the mixture have weight percentages of phosphogypsum 80-90%, mineral powder 3.3-10%, cement 6.5-10%; the water has a weight of 17% of the total weight of the mixture. A method of preparing the phosphogypsum non-sintered ceramsite light aggregate. The phosphogypsum non-sintered ceramsite light aggregate is prepared by modification, granulation, curing, crushing, sieving and other processes by using phosphogypsum as a main material, cement as an alkaline activator, mineral powder as an active material.

Claims

1. A phosphogypsum non-sintered ceramsite light aggregate, wherein the phosphogypsum non-sintered ceramsite light aggregate is composed of water and a mixture composed of phosphogypsum, mineral powder and cement, raw materials of the mixture have weight percentages of phosphogypsum 80-90%, mineral powder 3.3-10%, cement 6.5-10%; the water has a weight of 17% of the total weight of the mixture.

2. The phosphogypsum non-sintered ceramsite light aggregate of claim 1, wherein the phosphogypsum has a pH value greater than 3.0, the phosphogypsum has fineness of 80 μm and a sieve residue not more than 20%, the mineral powder is S95 grade, and the cement is Portland cement PO42.5.

3. The phosphogypsum non-sintered ceramsite light aggregate of claim 2, wherein the raw materials of the mixture have weight percentages of phosphogypsum 80%, mineral powder 10%, cement 10%.

4. The phosphogypsum non-sintered ceramsite light aggregate of claim 2, wherein the raw materials of the mixture have weight percentages of phosphogypsum 85%, mineral powder 8.5%, cement 6.5%.

5. The phosphogypsum non-sintered ceramsite light aggregate of claim 2, wherein the raw materials of the mixture have weight percentages of phosphogypsum 88%, mineral powder 5.5%, cement 6.5%.

6. The phosphogypsum non-sintered ceramsite light aggregate of claim 2, wherein the raw materials of the mixture have weight percentages of phosphogypsum 90%, mineral powder 3.3%, cement 6.7%.

7. A method of preparing the phosphogypsum non-sintered ceramsite light aggregate of claim 2, wherein the method comprises the following steps: S1: putting phosphogypsum, mineral powder, cement, and water into a mixer according to the weight percentages and mixing uniformly; S2: granulating the above-mentioned uniformly mixed raw materials with adding water according to the weight percentage, wherein the granulation equipment has an inclination angle of 60-82°, and the water is added at a rate of 1.25-1.5 L/min; S3: performing initial setting and final setting of the phosphogypsum ceramsite balls produced in S2 at 15-30° C.; wherein the initial setting time is 12-20 h and the final setting time is 24-36 h; curing for 14-28 days by using water immersion or continuous sprinkling water after the initial setting and final setting; S4: transferring the phosphogypsum ceramsite balls produced in S3 to a site with dust-proof facilities for stacking, and drying naturally until the moisture content of the phosphogypsum ceramsite balls is not more than 8%; S5: crushing the phosphogypsum ceramsite balls to a particle size of 10-40 mm to obtain the phosphogypsum ceramsite balls light aggregate; S6: sieving and classifying the phosphogypsum ceramsite balls light aggregate, and storing according to classification.

8. The method of preparing the phosphogypsum non-sintered ceramsite light aggregate of claim 7, wherein the sieved and classified phosphogypsum ceramsite balls light aggregate has sizes of 37.5-26.5, 26.5-19.0, 19.0-9.5, 9.5-4.75, 0-4.75.

9. The method of preparing the phosphogypsum non-sintered ceramsite light aggregate of claim 7, wherein the water for curing the phosphogypsum ceramsite balls is reused after precipitation and/or filtration.

Description

DETAILED DESCRIPTION

[0019] The specific content of the present invention is described in detail below in conjunction with embodiments.

[0020] Example 1: phosphogypsum non-sintered ceramsite light aggregate, the main raw materials and their weight parts are as follows: 800 kg of phosphogypsum, 100 kg of mineral powder, 100 kg of cement, 170 kg of water.

[0021] Example 2: phosphogypsum non-sintered ceramsite light aggregate, the main raw materials and their weight parts are as follows: 850 kg of phosphogypsum, 85 kg of mineral powder, 65 kg of cement, 170 kg of water.

[0022] Example 3: phosphogypsum non-sintered ceramsite light aggregate, the main raw materials and their weight parts are as follows: 880 kg of phosphogypsum, 55 kg of mineral powder, 65 kg of cement, 170 kg of water.

[0023] Example 4: phosphogypsum non-sintered ceramsite light aggregate, the main raw materials and their weight parts are as follows: 900 kg of phosphogypsum, 33 kg of mineral powder, 67 kg of cement, 170 kg of water.

[0024] The production process of the phosphogypsum non-sintered ceramsite light aggregate in examples 1-4 is as follows:

[0025] S1: putting the above materials into a mixer and mixing uniformly;

[0026] S2: granulating the above mentioned uniformly mixed raw materials with adding water according to the weight percentage, wherein the granulation equipment has an inclination angle of 60°, and the water is added at a rate of 1.5 L/min;

[0027] S3: performing initial setting and final setting of the phosphogypsum ceramsite balls produced in S2 at 20° C.; wherein the initial setting time is 16 h and the final setting time is 30 h; curing for 15 days by using water immersion after the initial setting and final setting;

[0028] S4: transferring the phosphogypsum ceramsite balls produced in S3 to a site with dust-proof facilities for stacking, and drying naturally until the moisture content of the phosphogypsum ceramsite balls is 6%;

[0029] S5: crushing the phosphogypsum ceramsite balls to a particle size of 10-40 mm to obtain the phosphogypsum ceramsite balls light aggregate;

[0030] S6: sieving and classifying the phosphogypsum ceramsite balls light aggregate, and storing based on classification;

[0031] The detection results were shown in table 1:

TABLE-US-00001 TABLE 1 Statistical table of detection structures of examples 1-4 Cylindrical Water compress absorption Softening Example Bulk density strength for 1 h coefficient 1 998 kg/m.sup.3 6.8 MPa 4.1% 0.98 2 970 kg/m.sup.3 6 MPa 5.7% 0.90 3 965 kg/m.sup.3 5.1 MPa 7.9% 0.86 4 950 kg/m.sup.3 4.5 MPa 8.4% 0.82

[0032] All performance indicators of the above-mentioned phosphogypsum non-sintered ceramsite light aggregate exceed the performance standards for light aggregate in the national standard GB/T17431.2-20101. Wherein the phosphogypsum non-sintered ceramsite light aggregate of example 1 is applicable to phosphogypsum light aggregate for concrete and concrete products, the phosphogypsum non-sintered ceramsite light aggregate of examples 2-4 is applicable to phosphogypsum water-stable layer.

[0033] There are other preferred parameters of the process for preparing the phosphogypsum non-sintered ceramsite light aggregate of Example 1, which is described in detail in examples.

Example 5

[0034] The production process of the phosphogypsum non-sintered ceramsite light aggregate in example 1 is as follows:

[0035] S1: putting the above materials into a mixer and mixing uniformly;

[0036] S2: granulating the above mentioned uniformly mixed raw materials with adding water according to the weight percentage, wherein the granulation equipment has an inclination angle of 60°, and the water is added at a rate of 1.5 L/min;

[0037] S3: performing initial setting and final setting of the phosphogypsum ceramsite balls produced in S2 at 20° C.; wherein the initial setting time is 16 h and the final setting time is 30 h; curing for 20 days by using water immersion after the initial setting and final setting;

[0038] S4: transferring the phosphogypsum ceramsite balls produced in S3 to a site with dust-proof facilities for stacking, and drying naturally until the moisture content of the phosphogypsum ceramsite balls is 6%;

[0039] S5: crushing the phosphogypsum ceramsite balls to a particle size of 10-40 mm to obtain the phosphogypsum ceramsite balls light aggregate;

[0040] S6: sieving and classifying the phosphogypsum ceramsite balls light aggregate, and storing based on classification;

Example 6

[0041] The production process of the phosphogypsum non-sintered ceramsite light aggregate in example 1 is as follows:

[0042] S1: putting the above materials into a mixer and mixing uniformly;

[0043] S2: granulating the above mentioned uniformly mixed raw materials with adding water according to the weight percentage, wherein the granulation equipment has an inclination angle of 60°, and the water is added at a rate of 1.5 L/min;

[0044] S3: performing initial setting and final setting of the phosphogypsum ceramsite balls produced in S2 at 30° C.; wherein the initial setting time is 12 h and the final setting time is 24 h; curing for 14 days by using water immersion after the initial setting and final setting;

[0045] S4: transferring the phosphogypsum ceramsite balls produced in S3 to a site with dust-proof facilities for stacking, and drying naturally until the moisture content of the phosphogypsum ceramsite balls is 6%;

[0046] S5: crushing the phosphogypsum ceramsite balls to a particle size of 10-40 mm to obtain the phosphogypsum ceramsite balls light aggregate;

[0047] S6: sieving and classifying the phosphogypsum ceramsite balls light aggregate, and storing based on classification;

[0048] S7: classifying and inspecting in batches and identifying the phosphogypsum ceramsite balls light aggregate.

Example 7

[0049] The production process of the phosphogypsum non-sintered ceramsite light aggregate in example 1 is as follows:

[0050] S1: putting the above materials into a mixer and mixing uniformly;

[0051] S2: granulating the above mentioned uniformly mixed raw materials with adding water according to the weight percentage, wherein the granulation equipment has an inclination angle of 60°, and the water is added at a rate of 1.5 L/min;

[0052] S3: performing initial setting and final setting of the phosphogypsum ceramsite balls produced in S2 at 15° C.; wherein the initial setting time is 20 h and the final setting time is 36 h; curing for 28 days by using water immersion after the initial setting and final setting;

[0053] S4: transferring the phosphogypsum ceramsite balls produced in S3 to a site with dust-proof facilities for stacking, and drying naturally until the moisture content of the phosphogypsum ceramsite balls is 6%;

[0054] S5: crushing the phosphogypsum ceramsite balls to a particle size of 10-40 mm to obtain the phosphogypsum ceramsite balls light aggregate;

[0055] S6: sieving and classifying the phosphogypsum ceramsite balls light aggregate, and storing based on classification;

[0056] S7: classifying and inspecting in batches and identifying the phosphogypsum ceramsite balls light aggregate.

[0057] The detection results were shown in table 2:

TABLE-US-00002 TABLE 2 Statistical table of detection structures of examples 5-7 Cylindrical Water compress absorption Softening Example Bulk density strength for 1 h coefficient 5 998 kg/m.sup.3 6.8 MPa 4.1% 0.98 6 995 kg/m.sup.3 6.75 MPa 4.3% 0.95 7 996 kg/m.sup.3 6.72 MPa 4.4% 0.96

[0058] All performance indicators of the phosphogypsum non-sintered ceramsite light aggregate prepared using the above preparation process parameters exceed the performance standards for light aggregate in the national standard GB/T17431.2-20101.