| The raw materials of coal gangue sintered perorated bricks are coal gangue waste residues. The coal gangue sintered perorated bricks are energy saving, earth saving, environmental protecting, light weighted and have excellent properties such as high strength, heat insulation and sound insulation. All these properties guarantee the impotent position of coal gangue sintered perorated bricks in the wall materials area. With the increasing realization of environment protection and the state limitation to the use of the earth, the coal gangue sintered perorated bricks are paid much more attention on nowadays. How to take the advantages of low price of the raw materials and energy saving characteristics of waste residues is an important topic.In this thesis, the raw materials are coal gangues from Kailuan coal mine and Jinggezhuang coal mine in Tangshan and Kailuan shale. The effects of the compositions and process on the properties of the coal gangue perorated bricks products are researched and the production line of 60 million coal gangue perorated bricks annually is also designed in this essay.High quality coal gangue sintered perorated bricks can be produced by-different combinations of coal gangues with different plasticity and calorific values. The best composition of coal gangue perorated brick is 60% 1#, 20% 2# and 20% shale.The effects of the raw materials particle sizes, the grain gradings of particles, aging time, aging temperature and the water content on the properties of the final products are studied. It is shown that particles with diameters from 1 to 2mm account for 15% and the rest of the materials with diameters less than 1 millimeter meet the production demands. The best grain grading of coal gangue raw materials is 15% powders with diameters from 1 to 2mm, 19% from 0.5 to 1mm, 13% from 0.25 to 0.5mm, 21% from 0.1 to 0.25mm and 32% with diameters less than 0.1mm. The aging of mixture materials can significantly increase the strength of green bodies and decrease the water absorption of products. The optimum aging time is 3 to 4 days. Aging at higher temperature can markedly increase the plasticity index of raw materials. It is shown that the best drying program of the coal gangue perorated brick is that the drying temperature range is 120-150℃, the velocity of hot gases is 1.5～4.5m/s and the drying period is 12～48 hours. The best sintering program is that the sintering temperature is 1050℃, the sintering period is 47～52 hours and the holding time is 4-8 hours.The phase compositions of coal gangue sintered perorated bricks are analyzed by the XRD analysis. It is shown that the compositions of the crystals are quartz, hematite, spinel, leucite, calcium aluminum yellow feldspar and cyanite. The microstructure of the coal gangue sintered perorated brick with different particle sizes are analyzed by the SEM analysis. It is shown that the sintered bricks with finer particles are much denser and more uniform.It is believed that hammer crusher and cage crusher can meet the demands for the shattering of raw materials. Big cross section double channels tunnel dry kiln and big cross section flat-suspended top tunnel kiln are fit for the drying of green bodies and the sintering of coal gangue perorated brick.Two typical production lines which can produce 60million coal gangue perorated bricks annually are designed in this thesis, which have already been used in Tangshan Kailuan New Building Materials Corporation and Shandong Luzhong House Property Building Materials Ltd. The production capacities of the two companies are more than 70million bricks annually and the properties of the sintered bricks reach the quality demands of sintered perorated bricks GB13545-92. It is proved by production practice that equipments of the production lines are appropriate and that the process is fluent and the design is reasonable. All these features guarantee the property to meet the demands for the production of high quality coal gangue perorated bricks. |
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