基于RSM的煤基充填胶凝材料强度演化规律及配比优化研究

Strength evolution law and ratio optimization of coal-based filling cementitious materials based on the response surface method

  • 摘要: 为探究脱硫石膏质量分数、粉煤灰质量分数和水胶比对胶凝材料性能影响,优化充填料浆胶凝材料配比,提高固废综合利用率,本研究基于响应面法开展胶凝材料净浆试块制备试验,通过极差分析探究不同龄期强度的影响因素排序及最优配比,结合总功效系数分析综合考虑多个龄期强度进行配比优化,构建以强度为响应值的回归模型,揭示单因素及交互作用对强度的影响规律. 研究结果表明,影响早中后期强度的主要因素分别为脱硫石膏质量分数、粉煤灰质量分数及水胶比;水胶比是综合三个龄期强度的主要影响因素,胶凝材料优化配比为脱硫石膏质量分数15%、粉煤灰质量分数50%、水胶比(质量比)0.32. 各龄期多元非线性二次响应面回归模型拟合效果显著,根据各龄期回归模型与主观权重得到的总目标函数有最大值48.3 MPa和最小值21.2 MPa;早中后期强度均对脱硫石膏质量分数和粉煤灰质量分数的交互作用最为敏感;粉煤灰–水泥–脱硫石膏基胶凝材料的主要水化产物为C–S–H凝胶、Ca(OH)2和钙钒石,粉煤灰质量分数过高会导致部分粉煤灰未参与水化反应,造成强度下降.

     

    Abstract: The safety and efficiency of mining operations depend on the strength of backfill, and cementitious materials play a key role in achieving high-strength backfill. The stockpiling of fly ash (FA) and desulfurization gypsum (DG) poses serious environmental pollution risks and urgently requires effective treatment to achieve sustainable resource utilization. This study develops a cementitious composite system that integrates FA, DG, and cement. It systematically investigates the effects of DG mass fraction, FA mass fraction and water-to-binder mass ratio (w/b) on the properties of cementitious materials to optimize the mix ratio of backfill slurry binders and enhance comprehensive utilization of solid waste. In this study, a three-factor, three-level orthogonal experiment was designed using the response surface methodology (RSM) to prepare cementitious paste test blocks and to test their compressive strength at 3, 7, and 28 d (hereafter denoted as 3 d, 7 d, and 28 d). Based on the experimental results, range analysis was employed to determine the ranking of influencing factors and to identify the optimal mix ratios for each curing age. Additionally, overall efficacy coefficient analysis was used to optimize the mix design by comprehensively considering the strengths across multiple curing ages. A multivariate nonlinear regression analysis was conducted to develop regression models with strength as the response variable, revealing the effects of individual factors and their interactions on strength at different curing ages. Meanwhile, a weighted objective function incorporating all three curing ages was established through the assignment of subjective weight coefficients. Finally, X-ray diffraction (XRD) and scanning electron microscopy with energy-dispersive spectroscopy (SEM–EDS) analyses were conducted to investigate the microstructural mechanisms underlying the consolidation of cementitious materials. The research results indicate that the compressive strengths of all specimen groups meet the engineering application requirements for cementitious materials. The primary factors influencing early- (3 d), medium- (7 d), and late-stage (28 d) strengths are mass fraction of DG, mass fraction of FA, and water-to-binder mass ratio, respectively. Range analysis reveals the optimal mix proportions as 10% DG, 50% FA, and w/b=0.32 for 3 d strength; 10% DG, 67% FA, and w/b=0.36 for 7 d strength; and 20% DG, 50% FA, and w/b=0.32 for 28 d strength. Considering all three ages, the water-to-binder mass ratio is the most influential factor, with the optimal composite mix determined to be 15% DG, 50% FA, and a w/b of 0.32. The regression coefficients (R2) of the multivariate nonlinear quadratic response surface models for each age are close to 1, indicating excellent fitting accuracy. The total objective function derived from the regression models and subjective weights yields a maximum value of 48.3 MPa and a minimum value of 21.2 MPa. Strength at all ages is most sensitive to the interaction between mass fraction of DG and FA. XRD and SEM analyses confirm that the primary hydration products of the FA–cement–DG system are C–S–H gel, Ca(OH)2, and ettringite (AFt, calcium aluminate ferrite trihydrate). With increasing curing age, enhanced hydration and increased product formation fill internal pores, leading to gradual strength development. Excessive mass fraction of FA reduces strength due to the incomplete participation of FA in hydration reactions. This research provides theoretical guidance for optimizing the mix design of FA-based cementitious materials in mine backfill applications, particularly regarding the rational allocation of DG mass fraction, FA mass fraction, and water-to-binder mass ratio to balance early and long-term strength requirements.

     

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