# US 12,006,268 B2 · Method for preparing ecological foamed ceramic from lepidolite filter mud whole waste

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- Number: US 12,006,268 B2
- Document ID: US12006268B2
- Status: Granted
- Kind: B2
- Application number: 18/500,592
- Filed: 2023-11-02
- Published: 2024-02-22
- Granted: 2024-06-11
- Earliest claimed: 2022-05-09
- Assignees: Beijing University of Technology
- Applicants: Beijing University of Technology
- Inventors: Dean Pan; Xiaoguang Zhang; Ruhao Kong; Qijun Zhang; Zhe Tan; Wei Wang
- Web page: https://patentgrep.com/patent/US12006268B2

## CPC

- C04B 33/132: Waste materials; Refuse {; Residues} (C04B33/16 takes precedence)
- C04B 38/10: by using foaming agents (C04B38/02 takes precedence){or by using mechanical means, e.g. adding preformed foam}
- C04B 35/18: rich in aluminium oxide
- C04B 35/19: Alkali metal aluminosilicates, e.g. spodumene
- C04B 35/62204: {using waste materials or refuse (clay-wares containing waste materials C04B33/132)}
- C04B 35/6261: {Milling}
- C04B 35/62655: {Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying}
- C04B 38/02: by adding chemical blowing agents
- C04B 41/0072: {Heat treatment}
- C04B 2111/00017: {Aspects relating to the protection of the environment}
- C04B 2235/3201: Alkali metal oxides or oxide-forming salts thereof
- C04B 2235/3472: Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite
- C04B 2235/3826: Silicon carbides
- C04B 2235/442: Carbonates
- C04B 2235/606: Drying
- C04B 2235/77: Density
- C04B 2235/96: Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- Y02P 40/60: Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method for preparing an ecological foamed ceramic from lepidolite filter mud whole waste belongs to the field of environmental protection and resource reuse. The ecological foamed ceramic with excellent properties can be prepared by using lepidolite filter mud as the main raw materials, including ball milling, homogenization, drying, material distribution, and heat treatment. The amount of lepidolite filter mud in the present invention accounts for more than 90%, which is a whole waste utilization and can achieve high-value utilization of bulk lepidolite filter mud. The present invention uses a composite foaming agent combined with a foaming technology and has the advantages of rapid foaming and controllable pore size compared with a single foaming agent. The ecological foamed ceramic prepared by the present invention meets the industrial standard of CJ/T 299-2008 “Artificial ceramic filter material for water treatment” and has potential application value in domestic sewage treatment.

## Claims

### Claim 1

A method for preparing an ecological foamed ceramic from lepidolite filter mud whole waste, comprising the steps of (1) ball milling: subjecting a weighed lepidolite filter mud and a composite foaming agent to ball milling to obtain a ball abrasive, wherein sodium carbonate and silicon carbide are used as the composite foaming agent, wherein sodium carbonate accounts for 1%-8% of a dry weight of the lepidolite filter mud, and silicon carbide accounts for 0.5%-2% of a dry weight of the lepidolite filter mud; wherein a particle size of the lepidolite filter mud is less than 200 meshes; ball milling is performed in a wet milling manner; a mass ratio of ball-to-material is 1:1-1.2:1, a mass ratio of water-to-material is 0.8:1-1.2:1; a ball milling time is 4-8 h; and an 8-mesh grid is used in a discharging process of the ball milling; the mass of a material is the total mass of a dry weight of the lepidolite filter mud and the composite foaming agent;
(2) homogenization: subjecting the ball abrasive obtained in the step (1) to homogenizing to obtain a homogenized material; wherein a stirring speed of a homogenization process is 0.5-2 r/min, and a homogenization time is 6-12 h; after homogenization, a material is passed through a 60-mesh sieve;
(3) drying: subjecting the homogenized material obtained in the step (2) to spray drying to obtain a dried material;
(4) material distribution: subjecting the dried material obtained in the step (3) to material distribution to obtain a green body; and
(5) heat treatment: subjecting the green body obtained in the step (4) to heat-treating to obtain the ecological foamed ceramic, wherein the ecological foamed ceramic meets an industrial standard of CJ/T 299-2008;
wherein the heat treatment comprises: increasing a temperature from room temperature at a temperature rising rate of 8-15° C./min to 500-700° ° C., holding for 20-60 min, increasing the temperature at a temperature rising rate of 3-8° C./min to 1050-1200° C., holding for 30-60 min, decreasing the temperature at a cooling rate of 5-10° C./min to 700-800° C., holding for 10-30 min, and cooling for 80-120 min with a furnace to room temperature after an end of the firing.