Research On Gradient-functional Sludge Ceramsite Concrete Block

At present,a variety of ceramsite concrete blocks,hollow blocks and organic foam sandwich concrete hollow blocks have been developed and widely used at home and abroad.However,ceramsite concrete hollow blocks with low strength and organic foam sandwich structure have more complex production process and high cost.In the production of ceramsite,if the raw materials are mixed with sludge,it is not only conducive to environmental protection,but also to reduce the production cost of ceramsite.This study used two kinds of fly ash in a given area?high calcium fly ash FA-S FA-H?and low calcium fly ash,clay and printing and dyeing sludge as raw material,study the appropriate mixing with printing and dyeing sludge fired the feasibility of lightweight ceramsite,on this basis,further through raw material proportioning design and process optimization,research and development of EPS foam composite concrete ceramsite-gradient function block,study the relevant technical performance,the results show that:?1?The main chemical components of P&D sludge are Fe₂O₃ and CaO,and the crystal phases are mainly calcite and quartz,and there is almost no crystal phase containing iron.The results showed that the ceramsite mixture which can meet the reasonable chemical composition range of fired ceramsite in Riley phase diagram cannot be obtained when either FA-S or FA-H is combined with waste glass powder or clay or P&D sludge respectively,based on the calculation results.When P&D sludge is added,the content of flux component in the mixture will be increased obviously??2?As compared with the mixture with FA-S as the main raw materials,the water requirement of raw ceramsite pellets was lower and the sintering temperature was higher when FA-H and P&D sludge were used.The lightweight ceramsite can't be sintered with good swelling performance under the condition of continuous heating for both of them.However,when the green pellets are added after the high-temperature furnace was heated to the sintering temperature in advance,and then reheated to the predetermined temperature,the lightweight ceramsite with bulk density less than 1.0g/cm³ can be obtained,and the sintering temperature is 1245?Between 1270?when FA-H and P&D sludge are used as the main raw materials??3?A kind of ceramsite concrete block with component gradient distribution along the height direction can be prepared by vibration while using ceramsite concrete mixture with good fluidity.However,its high fluidity is not conducive to the immediate demoulding and unfavorable to the industrial production.A layered composite gradient function polyphenylene particles composite ceramsite concrete block was prepared by adding polystyrene particles into the ceramsite concrete mixture.The surface layer of the block is a color mortar facing layer,and the bottom layer is a polyphenylene particle ceramsite concrete insulation layer,which can realize the integration of thermal insulation and decoration??4?While using ceramsite and polyphenylene particles to prepare polyphenyl particles composite ceramsite concrete blocks,the deformation recovery of polyphenylene particles after compression molding leads to poor molding performance.By using ceramsite sand and polyphenyl particles composite,layered composite functionally graded ceramsite concrete blocks with good molding performance can be prepared.The molding performance can be further improved by adding appropriate amount of re-dispersible latex powder and cellulose.For the concrete block with design strength grade of MU10 with the size of 200×100×60mm produced by pilot production,the tested average strength is can meet the requirements of MU10.0 strength grade according to the test standard of sintered porous brick??5?For the masonry with the thickness of 60mm and 120mm built by using 200×100×60mm layered composite gradient function polyphenylene particles composite ceramsite concrete block,the measured heat transfer coefficients were0.823 W/m²·K and 1.02 W/m²·K respectively when they were converted into a240mm masonry,which can meet the requirements of the national standard"design standard for energy efficiency of residential buildings in hot summer and cold winter area"and 50%energy saving ratio.