核壳结构固废基免烧陶粒的制备及性能研究

doi:10.16552/j.cnki.issn1001-1625.2026.0244

摘要/Abstract

摘要：

为实现工业固废的高值化大宗利用，解决传统烧结陶粒高能耗、高碳排放问题，本研究融合核壳结构设计与界面改性策略，以石材尾粉（STP）和脱硫石膏（FGDG）为主要原料，制备大掺量固废基免烧陶粒，揭示了改性剂Si—O—Si共价键锚固和羧基—Ca^2＋配位键桥接的双重键合界面强化机理。通过正交试验优化外壳配比与改性剂合成工艺，系统研究了改性剂掺量、水料比及养护龄期对陶粒性能的影响，并采用XRD、SEM、FT-IR进行微观表征。结果表明：最优配比下，脱硫石膏与矿粉质量比1∶2，石材尾粉60%（质量分数），水泥8%（质量分数），改性剂掺量2.0%（质量分数），水料比0.24，养护28 d，所制陶粒筒压强度达4.8 MPa，堆积密度为751.2 kg/m³，1 h吸水率降至7.1%，满足《轻集料及其试验方法第1部分：轻集料》（GB/T 17431.1—2010）要求。该陶粒在保温隔墙板和轻质混凝土中应用性能优异，为工业固废制备高性能轻集料提供了理论支撑与可行技术路径。

关键词: 脱硫石膏, 石材尾粉, 免烧陶粒, 核壳结构, 界面改性, 轻质混凝土

Abstract:

To realize the high-value and large-scale utilization of industrial solid wastes and address the high energy consumption and high carbon emission problems of traditional sintered ceramsite， this study integrates core-shell structure design with interface modification strategy. Using stone tailing powder （STP） and flue gas desulfurization gypsum （FGDG） as the main raw materials， this work prepares high-volume solid waste-based non-sintered ceramsite. The dual bonding interface strengthening mechanism anchored by Si—O—Si covalent bonds and bridged by carboxyl—Ca^2＋ coordination bonds of the modifier was revealed. The shell proportioning and modifier synthesis process were optimized via orthogonal tests. The effects of modifier dosage， water-to-material ratio and curing age on the properties of ceramsite were systematically investigated， and XRD， SEM， and FT-IR were adopted for microscopic characterization. The results show that under the optimal formulation， the mass ratio of flue gas desulfurization gypsum to mineral powder is 1∶2， the mass fraction of stone tailing powder is 60%， the cement content is 8%， the modifier dosage is 2.0%， the water-to-material ratio is 0.24， and the curing age is 28 d. The prepared ceramsite achieves a cylinder compressive strength of 4.8 MPa， a bulk density of 751.2 kg/m³， and the 1 h water absorption is reduced to 7.1%， which complies with “Lightweight aggregates and their test methods—part 1： Lightweight aggregates” （GB/T 17431.1—2010）. The ceramsite exhibits excellent application performance in thermal insulation partition boards and lightweight concrete， providing theoretical support and a feasible technical route for the preparation of high-performance lightweight aggregates from industrial solid wastes.

Key words: flue gas desulfurization gypsum, stone tailings powder, non-sintered ceramsite, core-shell structure, interfacial modification, lightweight concrete

中图分类号:

X705

朱森奥, 黄修林, 彭力, 曹攀攀. 核壳结构固废基免烧陶粒的制备及性能研究[J]. 硅酸盐通报, 2026, 45(8): 2817-2828.

ZHU Sen’ao, HUANG Xiulin, PENG Li, CAO Panpan. Preparation and Properties of Core-Shell Structured Solid Waste-Based Non-Sintered Ceramsite[J]. BULLETIN OF THE CHINESE CERAMIC SOCIETY, 2026, 45(8): 2817-2828.

图/表 21

表1 原材料的化学组成

Table 1 Chemical composition of raw materials

Material	Mass fraction/%
Material	SiO₂	Al₂O₃	Fe₂O₃	CaO	SO₃	MgO	Other
FGDG	3.21	1.05	0.58	32.56	46.82	0.32	15.46
STP	68.30	12.50	4.26	3.12	0.85	1.08	9.89
Cement	21.54	6.82	3.26	62.31	2.15	1.58	2.34
GGBS	38.62	18.54	0.98	32.15	0.68	6.21	2.82

图1 核壳结构陶粒剖面

Fig.1 Core-shell structure ceramsite section

图2 核壳结构陶粒成品

Fig.2 Finished core-shell structure ceramsite

表2 外壳配合比正交试验因素和水平

Table 2 Factors and levels of orthogonal test for shell mix proportion

Level	Factor
Level	m（FGDG）∶m（GGBS）	STP content/%	Cement content/%
1	2∶1	50	8
2	1∶1	60	12
3	1∶2	70	16

表3 自制界面改性剂正交试验因素和水平

Table 3 Factors and levels of orthogonal test for self-made interface modifier

Level	Factor
Level	m（MAH）∶m（KH550）	MAH hydrolysis temperature/℃	APS content/%
1	1.5∶1	70	0.8
2	1.6∶1	80	1.0
3	1.7∶1	90	1.2

表4 外壳配合比正交试验结果

Table 4 Results of orthogonal test for shell mix proportion

Ceramsite No.	m（FGDG）∶m（GGBS）	Mass fraction/%		Bulk density/（kg·m^-3）	Bulk crushing strength/MPa	Water absorption of 1 h/%
Ceramsite No.	m（FGDG）∶m（GGBS）	STP	Cement	Bulk density/（kg·m^-3）	Bulk crushing strength/MPa	Water absorption of 1 h/%
A1	2∶1	50	8	682.5	3.1	12.1
A2	2∶1	60	12	725.8	3.4	9.8
A3	2∶1	70	16	764.3	3.7	8.7
A4	1∶1	50	12	702.6	3.6	9.5
A5	1∶1	60	16	736.4	3.9	7.6
A6	1∶1	70	8	769.1	3.3	10.2
A7	1∶2	50	16	728.7	4.1	10.8
A8	1∶2	60	8	750.2	3.6	11.5
A9	1∶2	70	12	805.3	4.3	9.2

图3 样品A8的XRD谱

Fig.3 XRD pattern of sample A8

图4 样品A8在不同放大倍数下的SEM照片

Fig.4 SEM images of sample A8 at different magnifications

表5 改性剂正交试验结果

Table 5 Results of orthogonal test for modifier

Ceramsite No.	m（MAH）∶m（KH550）	MAH hydrolysis temperature/℃	APS content/%	Bulk crushing strength/MPa	Water absorption of 1 h/%
A10	1.5∶1	70	0.8	4.1	8.2
A11	1.5∶1	80	1.0	4.4	7.5
A12	1.5∶1	90	1.2	4.2	7.9
A13	1.6∶1	70	1.0	4.6	7.2
A14	1.6∶1	80	1.2	4.8	7.1
A15	1.6∶1	90	0.8	4.5	7.3
A16	1.7∶1	70	1.2	4.3	7.7
A17	1.7∶1	80	0.8	4.4	7.6
A18	1.7∶1	90	1.0	4.3	7.8

图5 样品A8的核壳界面SEM照片

Fig.5 SEM image of core-shell interface for A8

图6 样品A14的核壳界面SEM照片

Fig.6 SEM image of core-shell interface for A14

图7 未改性膨胀珍珠岩FT-IR谱

Fig.7 FT-IR spectrum of unmodified expanded perlite

图8 改性膨胀珍珠岩FT-IR谱

Fig.8 FT-IR spectrum of modified expanded perlite

图9 改性剂构建“分子桥”结构示意图

Fig.9 Schematic of molecular bridge structure formed by modifier

图10 不同改性剂掺量对陶粒物理性能的影响

Fig.10 Effects of different modifier dosages on physical properties of ceramsite

图11 不同水料比对陶粒物理性能的影响

Fig.11 Effects of different water-material ratios on physical properties of ceramsite

图12 不同养护龄期对陶粒物理性能的影响

Fig.12 Effects of different curing ages on physical properties of ceramsite

表6 保温隔墙板配合比

Table 6 Mix ratio for thermal insulation partition wall panels

Raw material	Cement	Fly ash	Ceramsite	Medium sand	Water reducing agent	Water
Dosage per cubic meter/（kg·m^-3）	350	50	550	720	7.3	170

表7 保温隔墙板性能对比

Table 7 Performance comparison of thermal insulation partition wall panels

Panel type	Dry apparent density/（kg·m^-3）	Compressive strength/MPa	Thermal conductivity coefficient/（W·m^-1·K^-1）
Thermal insulation partition wall panel in this study	812	7.6	0.24
Autoclaved aerated concrete panel	654	4.2	0.15
Ordinary ceramsite panel	1013	3.9	0.28

表8 LC30轻质混凝土基准配合比

Table 8 LC30 lightweight concrete reference mix proportion

Raw material	Cement	Fly ash	Ceramsite	Medium sand	Water reducing agent	Water
Dosage per cubic meter/（kg·m^-3）	320	80	550	720	7.1	170

表9 混凝土性能对比

Table 9 Concrete performance comparison

Concrete type	Lightweight concrete	Ordinary concrete
Dry apparent density/（kg·m^-3）	1 850	2 350
28 d compressive strength/MPa	34.2	38.8
Thermal conductivity coefficient/（W·m^-1·K^-1）	0.85	1.80
Elastic modulus/GPa	22.5	32.0

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