CN104403210B - 有色金属化学选矿设备用耐强酸橡胶辊胶料及制备方法 - Google Patents
有色金属化学选矿设备用耐强酸橡胶辊胶料及制备方法 Download PDFInfo
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Abstract
本发明涉及一种不仅具有耐强酸腐蚀、耐磨耗，而且具有高弹性（压缩永久变形低）、力学性能好，以及具有良好的自粘性和互粘性的有色金属化学选矿设备用耐强酸橡胶辊胶料及制备方法，三元乙丙橡胶100份、母胶10‑25份、N‑33炭黑29‑31份、N‑770炭黑49‑51份、防老剂RD 1.9‑2.1份、防老剂MB 1.4‑1.6份、2280#石蜡油24‑26份、双2，5 4.4‑4.6份、三烯丙基异氰脲酸酯1.4‑1.6份。优点：一是本申请的橡胶辊料不仅能够很好地承受矿浆流体磨蚀，橡胶在酸浸出液的作用下不会氧化裂解、热老化，不会加快橡胶辊的损坏，使用寿命长，而且具有高可靠的耐磨性；二是力学性能良好，并具有良好的自粘性和互粘性。
Description
技术领域
本发明涉及一种不仅具有耐强酸腐蚀、耐磨耗，而且具有高弹性（压缩永久变形低）、力学性能好，以及具有良好的自粘性和互粘性的有色金属化学选矿设备用耐强酸橡胶辊胶料及制备方法，属耐强酸橡胶辊胶料制造领域。
背景技术
化学选矿是基于矿物和矿物组分化学性质的差异，采用化学方法改变矿物组成，然后用相应方法使有用组分富集的矿物加工工艺。化学选矿的处理对象一般为目前技术条件下用物理选矿法或传统冶炼法无法处理或处理不经济的难选矿物原料，如：低品位难选原矿、表外矿、物理选矿的难选粗精矿、成分复杂的共生矿等，尤其是一些贵金属的提取和富集基本需要用化学方法来实现。因此，化学选矿的适应性较物理选矿强，应用范围较广。
酸浸出选矿设备用耐强酸橡胶辊工作介质为强酸矿浆，工作温度60～80℃。胶辊在这样的工作环境下要长期承受矿浆物料的磨蚀以及其他配件（摩擦副）的磨损。通常耐强酸的橡胶配件是由丁基胶、氟橡胶、乙丙胶、氯磺化聚乙烯或者硬质天然橡胶制造的，但是,选择橡胶牌号还不足以满足要求。因为只有综合考虑了硫化胶的强度、疲劳强度、弹性性能和硫化胶的结构特点以及加工工艺性,针对选矿设备的耐磨、耐腐蚀工作环境科学设计橡胶配方和加工工艺，才能提高橡胶辊在强酸矿浆中的使用寿命。实际上作为酸浸出选矿设备用耐强酸橡胶辊，承受矿浆流体磨蚀以及与其他配件之间的摩擦磨损破坏是必然的，但橡胶在酸浸出液的作用下氧化裂解、热老化等介质的腐蚀作用都会明显加快橡胶辊的破坏。
发明内容
设计目的：设计一种不仅具有耐强酸腐蚀、耐磨耗，而且具有高弹性（压缩永久变形低）、力学性能好，以及具有良好的自粘性和互粘性的有色金属化学选矿设备用耐强酸橡胶辊胶料及制备方法。
设计方案：酸浸出工艺是化学选矿常用并且有效的选矿和精矿富集浓缩手段，例如：铁、锰、铅、铜、锌、钨、铝、锡、金、银、钽、铌、钴、镍、铀、钍、等矿物的选矿和富集浓缩。酸浸出工艺中所用的酸类浸出剂通常是一些强酸混合物的水溶液，例如：15%HNO3+5%HF溶液就是一种酸浸出剂。所以，酸浸出选矿设备中的一些部件就需要耐强酸，橡胶辊是酸浸出选矿设备中的一个关键部件，它长期与含有酸浸出液的矿浆接触，工作温度60～80℃。根据有色金属化学选矿设备用耐强酸橡胶辊的工作环境来看，其必须具有耐强酸腐蚀、耐磨耗、高弹性（压缩永久变形低）、力学性能良好以及良好的自粘性和互粘性等。
由于酸浸出选矿设备用耐强酸橡胶辊工作介质为强酸矿浆，工作温度60～80℃，胶辊在这样的工作环境下要长期承受矿浆物料的磨蚀以及其他配件（摩擦副）的磨损，要求其橡胶材料必须具有优异的耐冲刷磨损和耐腐蚀性，同时作为酸浸出选矿设备用耐强酸橡胶辊必须弹性好、与金属辊芯粘合好、具有良好的挤出缠绕工艺性能等。因此本发明在辊胶料的设计上：
1、双环戊二烯为第三单体的三元乙丙橡胶（DCPD型EPDM），具有更宽的分子量分布，其不饱和度比乙叉降冰片烯类三元乙丙橡胶（ENB型EPDM）低，其混炼、挤出加工性能和化学稳定性更好。为此，本发明将以DCPD型EPDM为酸浸出选矿设备用耐强酸橡胶辊胶料的基体材料，以满足该产品的力学性能、耐强酸、耐高温、耐磨以及混炼、挤出缠绕加工工艺性能。
2、鳞片石墨具有耐高温、耐腐蚀、抗辐照、密封性能好、抗蠕变等特性，市面上有橡胶改性专用的产品。如果通过混炼工艺技术的研究，将其与尼龙短纤维、三元乙丙橡胶组成复合材料，将会发挥各自的优势，制备成一种具有良好力学性能、耐强酸、耐高温、耐磨并满足胶辊挤出缠绕加工工艺的胶料。
首先，将鳞片石墨与尼龙短纤维进行预分散处理，使其起到相互隔离作用，以避免混炼时，鳞片石墨、尼龙短纤维在橡胶基体中的结团，影响混炼性能；然后在125℃下将氯磺化聚乙烯橡胶和鳞片石墨/尼龙短纤维预混料在密炼机中混炼成母胶；再将三元乙丙橡胶、母胶、补强填充剂、硫化活性剂、硫化剂及助硫化剂混炼成混炼胶。
技术方案1：一种有色金属化学选矿设备用耐强酸橡胶辊胶料，三元乙丙橡胶100份、母胶10-25份、N-33炭黑29-31份、N-770炭黑49-51份、防老剂RD 1.9-2.1份、防老剂MB1.4-1.6份、2280#石蜡油24-26份、双2，5 4.4-4.6份、三烯丙基异氰脲酸酯1.4-1.6份。
技术方案2：一种有色金属化学选矿设备用耐强酸橡胶辊胶料制备方法，（1）母炼胶的制备：在常温下将20份尼龙短纤维、80份200目的鳞片石墨粉加入万能粉碎机中，通过固定刀片和高速旋转刀片使鳞片石墨粉预分散在尼龙短纤维绒毛表面，制成鳞片石墨/尼龙短纤维预分散混合料，通过尼龙短纤维和鳞片石墨粉的相互隔离作用，防止混炼时尼龙短纤维和鳞片石墨粉被挤压成团难于均匀分散在橡胶基体中，然后在125℃下将30份氯磺化聚乙烯橡胶和70份鳞片石墨/尼龙短纤维预混料在密炼机中混炼成母胶；（2）胶料混炼：一段混炼：采用90立升全自动密炼生产线进行，依次将生胶、防老剂加入密炼机，然后将软化剂与炭黑加入，混炼5-10分钟，在120～130℃下排胶；主要操作要点如下：按顺序依次称好生胶、小料，通过输送带将其投入密炼机；投炭黑完毕，上顶栓下降，将转速调至35，混炼约120秒后升栓，注入软化剂，上顶栓下降，混炼150秒； 打开下顶栓，上顶栓升栓，排胶，30秒后关闭下定栓；二段混炼：将密炼机排料放入开炼机拉片冷却，待胶料冷却至60℃以下时，将硫化剂、促进剂加入，翻捣均匀，放厚辊距5～7mm下片，投入硬脂酸锌水溶液冷却，悬挂风干进入下一工序；停放和过滤：上述混炼胶冷却后在室温下停放8小时以上，重新返炼出条，用滤胶机进行过滤，滤网为100目，滤胶温度为80℃以下；切割下片：过滤好的胶料在开炼机上出成5～7mm胶片，并切割成300×400mm的胶片，冷却后叠放入塑料袋、包裹后装箱。
本发明与背景技术相比，一是本申请的橡胶辊料不仅能够很好地承受矿浆流体磨蚀，橡胶在酸浸出液的作用下不会氧化裂解、热老化，不会加快橡胶辊的损坏，使用寿命长，而且具有高可靠的耐磨性；二是力学性能良好，并具有良好的自粘性和互粘性。
具体实施方式
实施例1：一种有色金属化学选矿设备用耐强酸橡胶辊胶料，重量配比份是：三元乙丙橡胶100份、母胶10-25份、N-33炭黑29-31份、N-770炭黑49-51份、防老剂RD 1.9-2.1份、防老剂MB 1.4-1.6份、2280#石蜡油24-26份、双2，5 4.4-4.6份、三烯丙基异氰脲酸酯1.4-1.6份。所述双2，5是指2,5-二甲基-2，5-双-（叔丁基过氧）己烷。所述母胶是由20份尼龙短纤维、80份200目的鳞片石墨粉、30份氯磺化聚乙烯橡胶构成。所述氯磺化聚乙烯橡胶生胶牌号为Hypalon-20，氯含量为29%，ML1+4 100℃=30。
根据上述胶料性能要求，本申请一是将以DCPD型EPDM（K520）为酸浸出选矿设备用耐强酸橡胶辊胶料的基体材料，以满足该产品的力学性能、耐强酸、耐高温、耐磨以及混炼、挤出缠绕加工工艺性能；二是将鳞片石墨（200目，橡胶改性专用）与尼龙短纤维（市售品）进行预分散处理，使其起到相互隔离作用，以避免混炼时，鳞片石墨、尼龙短纤维在橡胶基体中的结团，影响混炼性能；然后在125℃下将氯磺化聚乙烯橡胶（生胶牌号为Hypalon-20，氯含量为29%，ML1+4 100℃=30）和鳞片石墨/尼龙短纤维预混料在密炼机中混炼成母胶；再将三元乙丙橡胶、母胶、补强填充剂、硫化活性剂、硫化剂及助硫化剂混炼成混炼胶；三是采用高耐磨炭黑和半补强炭黑并用，以兼顾胶料的力学性能和弹性要求；四是采用过氧化物硫化剂（双2，5）和助硫化剂（TAIC）组成硫化体系；五是采用高粘度石蜡油（2280#）作为增塑剂。
实施例2：在实施例1的基础上，三元乙丙橡胶100份、母胶10-25份、N-33炭黑30份、N-770炭黑50份、防老剂RD 2份、防老剂MB 1.5份、2280#石蜡油25份、双2，5 4.5份、三烯丙基异氰脲酸酯1.5份。
实施例3：在实施例1的基础上，三元乙丙橡胶100份、母胶10份、N-33炭黑29份、N-770炭黑49份、防老剂RD 1.9份、防老剂MB 1.4份、2280#石蜡油24份、双2，5 4.4份、三烯丙基异氰脲酸酯1.4份。
实施例4：在实施例1的基础上，三元乙丙橡胶100份、母胶25份、N-33炭黑31份、N-770炭黑51份、防老剂RD 2.1份、防老剂MB 1.6份、2280#石蜡油26份、双2，5 4.6份、三烯丙基异氰脲酸酯1.6份。
实施例5：在实施例1的基础上，三元乙丙橡胶100份、母胶20份、N-33炭黑30份、N-770炭黑50份、防老剂RD 2份、防老剂MB 1.5份、2280#石蜡油25份、双2，5 4.5份、三烯丙基异氰脲酸酯1.5份。
实施例6：在实施例1的基础上，三元乙丙橡胶100份、母胶22份、N-33炭黑29份、N-770炭黑51份、防老剂RD 1.95份、防老剂MB 1.45份、2280#石蜡油24-26份、双2，5 4.5份、三烯丙基异氰脲酸酯1.5份。
实施例7：在实施例1的基础上，一种有色金属化学选矿设备用耐强酸橡胶辊胶料制备方法， （1）母炼胶的制备：在常温下将20份尼龙短纤维、80份200目的鳞片石墨粉加入万能粉碎机中，通过固定刀片和高速旋转刀片使鳞片石墨粉预分散在尼龙短纤维绒毛表面，制成鳞片石墨/尼龙短纤维预分散混合料，通过尼龙短纤维和鳞片石墨粉的相互隔离作用，防止混炼时尼龙短纤维和鳞片石墨粉被挤压成团难于均匀分散在橡胶基体中，然后在125℃下将30份氯磺化聚乙烯橡胶和70份鳞片石墨/尼龙短纤维预混料在密炼机中混炼成母胶；（2）胶料混炼：一段混炼：采用90立升全自动密炼生产线进行，依次将生胶、防老剂加入密炼机，然后将软化剂与炭黑加入，混炼5-10分钟，在120～130℃下排胶；主要操作要点如下：按顺序依次称好生胶、小料，通过输送带将其投入密炼机；投炭黑完毕，上顶栓下降，将转速调至35，混炼约120秒后升栓，注入软化剂，上顶栓下降，混炼150秒； 打开下顶栓，上顶栓升栓，排胶，30秒后关闭下定栓；二段混炼：将密炼机排料放入开炼机拉片冷却，待胶料冷却至60℃以下时，将硫化剂、促进剂加入，翻捣均匀，放厚辊距5～7mm下片，投入硬脂酸锌水溶液冷却，悬挂风干进入下一工序；停放和过滤：上述混炼胶冷却后在室温下停放8小时以上，重新返炼出条，用滤胶机进行过滤，滤网为100目，滤胶温度为80℃以下；切割下片：过滤好的胶料在开炼机上出成5～7mm胶片，并切割成300×400mm的胶片，冷却后叠放入塑料袋、包裹后装箱。
需要理解到的是：上述实施例虽然对本发明的设计思路作了比较详细的文字描述，但是这些文字描述，只是对本发明设计思路的简单文字描述，而不是对本发明设计思路的限制，任何不超出本发明设计思路的组合、增加或修改，均落入本发明的保护范围内。
Claims (3)
1. 一种有色金属化学选矿设备用耐强酸橡胶辊胶料，其特征重量配比份是：三元乙丙橡胶100份、母胶10-25份且所述母胶是由20份尼龙短纤维、80份200目的鳞片石墨粉、30份氯磺化聚乙烯橡胶构成、N-33炭黑29-31份、N-770炭黑49-51份、防老剂RD 1.9-2.1份、防老剂MB 1.4-1.6份、2280#石蜡油24-26份、二甲基-2，5-双-（叔丁基过氧）己烷 4.4-4.6份、三烯丙基异氰脲酸酯1.4-1.6份；
硬度 75～80
拉伸强度 ≥12
扯断伸长率 ≥300
撕裂强度 ≥40
DIN磨耗 ≤80
压缩永久变形 120℃×168h ≤8
15%HNO3+5%HF， 70℃×10d，ΔW≤2，ΔV≤1。
2.根据权利要求1所述的有色金属化学选矿设备用耐强酸橡胶辊胶料，其特征是：所述氯磺化聚乙烯橡胶生胶牌号为Hypalon-20，氯含量为29%，ML1+4 100℃=30。
3.一种有色金属化学选矿设备用耐强酸橡胶辊胶料制备方法，其特征是：
（1）母炼胶的制备：在常温下将20份尼龙短纤维、80份200目的鳞片石墨粉加入万能粉碎机中，通过固定刀片和高速旋转刀片使鳞片石墨粉预分散在尼龙短纤维绒毛表面，制成鳞片石墨/尼龙短纤维预分散混合料，通过尼龙短纤维和鳞片石墨粉的相互隔离作用，防止混炼时尼龙短纤维和鳞片石墨粉被挤压成团难于均匀分散在橡胶基体中，然后在125℃下将30份氯磺化聚乙烯橡胶和70份鳞片石墨/尼龙短纤维预混料在密炼机中混炼成母胶；
（2）胶料混炼：
一段混炼：采用90立升全自动密炼生产线进行，依次将生胶、防老剂加入密炼机，然后将软化剂与炭黑加入，混炼5-10分钟，在120～130℃下排胶；主要操作要点如下：按顺序依次称好生胶、小料，通过输送带将其投入密炼机；投炭黑完毕，上顶栓下降，将转速调至35，混炼约120秒后升栓，注入软化剂，上顶栓下降，混炼150秒； 打开下顶栓，上顶栓升栓，排胶，30秒后关闭下定栓；
二段混炼：将密炼机排料放入开炼机拉片冷却，待胶料冷却至60℃以下时，将硫化剂、促进剂加入，翻捣均匀，放厚辊距5～7mm下片，投入硬脂酸锌水溶液冷却，悬挂风干进入下一工序；
停放和过滤：上述混炼胶冷却后在室温下停放8小时以上，重新返炼出条，用滤胶机进行过滤，滤网为100目，滤胶温度为80℃以下；
切割下片：过滤好的胶料在开炼机上出成5～7mm胶片，并切割成300×400mm的胶片，冷却后叠放入塑料袋、包裹后装箱。
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| 氯磺化聚乙烯对三元乙丙橡胶耐热老化性能的影响;黄明璐等;《橡胶科技》;20131231(第10期);第21-23页 * |
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| CN104403210A (zh) | 2015-03-11 |
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