CN105819838B - 一种水泥球磨机用耐磨陶瓷衬板及其制备方法 - Google Patents
一种水泥球磨机用耐磨陶瓷衬板及其制备方法 Download PDFInfo
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- 239000004568 cement Substances 0.000 title claims abstract description 35
- 239000000919 ceramic Substances 0.000 title claims abstract description 28
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- 238000002360 preparation method Methods 0.000 title abstract description 7
- 239000000463 material Substances 0.000 claims abstract description 40
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 36
- 238000000034 method Methods 0.000 claims abstract description 31
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- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims abstract description 18
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims abstract description 18
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- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 claims abstract description 9
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- 229910000831 Steel Inorganic materials 0.000 description 12
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- 239000011651 chromium Substances 0.000 description 5
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- 229910017970 MgO-SiO2 Inorganic materials 0.000 description 2
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- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 2
- 229910052721 tungsten Inorganic materials 0.000 description 2
- 239000010937 tungsten Substances 0.000 description 2
- 229910052720 vanadium Inorganic materials 0.000 description 2
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229910001339 C alloy Inorganic materials 0.000 description 1
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- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 241001062472 Stokellia anisodon Species 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
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- 238000010924 continuous production Methods 0.000 description 1
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- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
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- 229910052710 silicon Inorganic materials 0.000 description 1
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- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- -1 which is added Substances 0.000 description 1
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Abstract
本发明公开了一种水泥球磨机用耐磨陶瓷衬板及其制备方法,其成分按重量百分比计含有氧化铝92‑95%、碳酸钙0.8‑3%、碳酸镁0.8‑1%、二氧化钛0.2‑2%、立方氮化硼0.3‑2%、碳化钽0.5‑2%、高岭土或山西大同土1.5‑2%,工作面呈波浪形或齿形或斜齿形或正四棱锥状突起;采用压制成型后高温烧结的方法制备,包括配料、球磨、喷雾造粒、料仓陈腐、压型加工、高温烧结、清粉抛光、成品干燥等工序。本发明制得的水泥球磨机用耐磨陶瓷衬板具有耐磨、耐高温、耐腐蚀、耐冲击、经济性好、使用寿命长、物料不易粘附、可辅助加工物料且所制物料纯净度高的优点。
Description
技术领域
本发明涉及水泥加工领域,尤其涉及一种水泥球磨机用耐磨陶瓷衬板及其制备方法。
背景技术
水泥球磨机具有对物料适应性强、能连续生产、破碎比大、易于调速粉磨产品的细度等特点。常用的水泥球磨机的工作原理为,物料由进料装置经入料中空轴螺旋均匀地进入磨机仓内,该仓内有阶梯衬板或波纹衬板,内装不同规格钢球,筒体转动产生离心力将钢球带到一定高度后落下,对物料产生重击和研磨作用。球磨机衬板的主要作用是保护磨机和带动磨球对物料进行研磨和粉碎。球磨机衬板的主要失效形式是小能量多次冲击下的磨料磨损,据统计,我国每年在球磨机上消耗的钢铁达数百万吨。因此,如何提高球磨机衬板的耐磨性是研究的重点。
现常用衬板材料为高强度钢,但其耐磨性仍较差,使用寿命短,由于高强度钢一般的韧性差,衬板在使用过程中易发生开裂、崩碎,使得维修拆卸非常困难;而用低碳合金钢制造球磨机衬板,又存在强度和硬度低、耐磨性差的不足;为了提高合金钢的强韧性和耐磨性,通常都要加入钼、镍、铬、钨、钒等合金元素,随着合金资源的日益紧缺,钼、镍、铬、钨、钒等合金供应日趋紧张,价格飞速上涨,导致普通钢铁耐磨材料生产成本不断攀升;同时,目前主流衬板多为马氏体型钢,在250℃以上易发生相变,导致衬板性能下降,因此不适合在长时间、高强度的工况下工作。另外,现有衬板多只考虑衬板本身的强度、韧性和耐蚀性等,没有考虑衬板辅助加工物料的能力,且物料易粘附在衬板上;同时,不锈钢成本高且不耐磨,高强度钢耐磨但不耐腐蚀,均易由于磨损或腐蚀影响工作面,同时降低所制物料的纯净度,尤其是不锈钢衬板带来的铬污染对于水泥来说是非常有害的。
在国内已申请的相关专利中,专利《一种大型球磨机用衬板及其铸造方法》(申请号:201010294909.4,公开日:2011-01-26),公开了一种耐磨性能优异,硬度高,韧性好,强度高衬板的制备方法,向常规钢质衬板内添加硅、铬、钼、硼、铌等多种合金元素提升衬板的耐磨性和韧性,但该衬板不耐腐蚀;另外,仍然是马氏体型钢,不耐高温;同时,由于基体限制,其抗冲击能力仍较差,长时间工作易破损。专利《一种高耐磨性能的球磨机用衬板》(申请号:201410364512.6,公开日:2014-10-29),公开了一种本质高强度不锈钢作为基材的衬板,且采用的中温回火工艺,耐高温,但其大量采用了铬、钛等合金元素,原材料冶炼困难且昂贵,同时导致了该衬板可铸造性差,不能用于制造大型衬板,应用范围不广,与此同时,大量碳的加入也使该衬板无法完全奥氏体化,耐蚀性不佳。另外,上述两份专利均只考虑衬板本身的强度、韧性和耐蚀性等,没有考虑衬板辅助加工物料的能力,且物料易粘附在衬板上。
发明内容
针对现有技术中存在的上述缺陷,本发明旨在提供一种耐磨、耐高温、耐腐蚀、耐冲击、经济性好、使用寿命长、物料不易粘附、可辅助加工物料且所制物料纯净度高的水泥球磨机用耐磨陶瓷衬板。
为了实现上述目的,本发明采用以下技术方案:一种水泥球磨机用耐磨陶瓷衬板,其成分按重量百分比计含有氧化铝92-95%、碳酸钙0.8-3%、碳酸镁0.8-1%、二氧化钛0.2-2%、立方氮化硼0.3-2%、碳化钽0.5-2%、高岭土或山西大同土1.5-2%。其制备方法,包括以下步骤:
(a)配料:按重量百分比计取所有成分,混合并搅拌均匀,制得混合物料;同时配置PVA溶液,配比为PVA:水=(7-10):100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:(0.7-0.75),至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:(2-3):(0.7-0.75),至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液9-12%,混磨0.5-1h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液,并打入高位浆罐,控制喷雾干燥塔的热风温度、出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,压型粉料水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入小棚板,撒上隔离砂,送入高温窑内,架装裸烧,温度1500-1700℃,烧成周期24-36h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。
上述的水泥球磨机用耐磨陶瓷衬板,其工作面呈波浪形,波峰波谷高差为10-25mm。
上述的水泥球磨机用耐磨陶瓷衬板,其工作面呈齿形或斜齿形。
上述的水泥球磨机用耐磨陶瓷衬板,其工作面划分为多个边长为50-150mm的正方形区格,每个区格内呈正四棱锥状突起;该正四棱锥的侧面与底面所成的二面角为5-25°。
上述的水泥球磨机用耐磨陶瓷衬板,其中:制造方法的步骤(c)中加入PVA溶液的同时,还加入适量的消泡剂。
上述的水泥球磨机用耐磨陶瓷衬板,其中:制造方法的步骤(e)用于压型成坯的粉料颗粒大小控制为30-80目。
上述的水泥球磨机用耐磨陶瓷衬板,其中:制造方法的步骤(f)中所述隔离砂为40目以下的白刚玉。
上述的水泥球磨机用耐磨陶瓷衬板,其中:制造方法的步骤(f)中所述高温窑为隧道窑,温度为1500-1550℃,烧成周期为24-30h。
上述的水泥球磨机用耐磨陶瓷衬板,其中:制造方法的步骤(f)中所述高温窑为梭式窑,温度为1530-1700℃,烧成周期为30-36h。
与现有技术比较,本发明由于采用了上述方案,首先构建了Al2O3-CaO-MgO-SiO2四元体系,其中碳酸钙提供CaO、碳酸镁提供MgO、高岭土或山西大同土提供SiO2,并且在传统的Al2O3-CaO-MgO-SiO2四元体系的基础上新增了二氧化钛、立方氮化硼、碳化钽作为添加剂,其中碳化钽硬度接近金刚石、耐极度高温,立方氮化硼的耐热性、耐热冲击和高温强度都很高,并具有良好的润滑性和陶瓷材料中比重最小的优点,因此制得的陶瓷衬板工作面耐磨性极高,表面硬度在1300HV以上,远高于常规高强度钢700HV左右的硬度;抗冲击能力强,耐腐蚀,耐高温,所制物料的纯净度高;工作损耗低,适应性好,使用寿命长,经济性好。基材工作面为波浪形或齿形或斜齿形或正四棱锥状突起,可辅助切削水泥颗粒,且物料不易粘附,其中,波浪形顶面圆滑,辅助加工效率适中、寿命长;齿形和斜齿形顶面较尖锐,寿命适中、辅助加工效率很高;正四棱锥状突起,顶面虽有棱角但底部坚实可靠,既保证了较好的切削效率,又能实现超长的寿命,综合性能较优。
同时,与现有技术比较,本发明中的水泥球磨机用耐磨陶瓷衬板的制备方法,由于采用了初磨、细磨、混磨三道工序的球磨和逐级筛选,使浆料细度均匀一致;进行除铁工序,能有效去除浆料中的杂质,提高陶瓷制品纯净度;因为氧化铝陶瓷粉料属瘠性原料,为了压制成型的需要,需要加入粘接剂,因此在喷雾造粒中添加PVA溶液,加入消泡剂是为了抑制泡沫产生,提高生产能力,降低生产成本;料仓陈腐工序能有效去除造粒粉中的水分;压型加工工序使粉料成型;高温烧结工序中撒入隔离砂,能有效防止产品粘连,使烧成制品与高温匣钵容易分离;清粉抛光工序把烧成过程中粘附的隔离砂及毛刺除掉,使产品光洁;最后的干燥工序使产品完全达到出厂指标。
附图说明
图1是本发明基材的波浪形工作面的局部示意图;
图2是本发明基材的齿形或斜齿形工作面的局部示意图;
图3是本发明基材的正四棱锥状突起工作面的局部示意图。
具体实施方式
实施例1:
该水泥球磨机用耐磨衬板按重量百分比计含有氧化铝92%、碳酸钙1%、碳酸镁1%、二氧化钛2%、立方氮化硼2%、碳化钽0.5%、高岭土或山西大同土1.5%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=8:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水(初磨球石可采用Φ30-Φ50mm的92-高铝等静压球,下同),比例为料:球:水=1:2.5:0.7,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水(细磨球石可采用Φ15-Φ25mm的92-高铝等静压球,下同),比例为料:球:水=1:2:0.7,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液9%,混磨1h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,其工作面呈波浪形,波峰波谷高差为10-25mm,水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入小棚板,撒上40目白刚玉隔离砂,送入隧道窑内,架装裸烧,温度1550℃,烧成周期24h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。该成品工作面采用波浪形,顶面圆滑,在实际工况中辅助加工的效率适中,具有寿命长的优点,循环工作时间超过2万小时,波峰波谷高差小的成品寿命更优。
实施例2:
该水泥球磨机用耐磨衬板按重量百分比计含有氧化铝95%、碳酸钙0.8%、碳酸镁0.8%、二氧化钛0.6%、立方氮化硼0.3%、碳化钽0.5%、高岭土或山西大同土2%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=7:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.75,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:3:0.75,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液12%,混磨0.5h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液和适量的消泡剂,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,其工作面呈呈齿形,水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入小棚板,撒上60目白刚玉隔离砂,送入梭式窑内,架装裸烧,温度1530℃,烧成周期36h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。该成品工作面采用齿形,顶面较尖锐,在实际工况中寿命适中,循环工作时间超过7千小时;辅助加工的效率十分高,齿形越尖锐的辅助切削加工效率越优。
实施例3:
该水泥球磨机用耐磨衬板按重量百分比计含有氧化铝92%、碳酸钙3%、碳酸镁0.8%、二氧化钛0.2%、立方氮化硼0.5%、碳化钽2%、高岭土或山西大同土1.5%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=10:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.72,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5: 0.75,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液9%,混磨0.5h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液和适量的消泡剂,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,其工作面呈斜齿形,水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入小棚板,撒上80目白刚玉隔离砂,送入隧道窑内,架装裸烧,温度1500℃,烧成周期30h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。该成品工作面采用斜齿形,顶面较尖锐,与齿形相比具有更大的切削力和更高的切削效率,寿命基本保持一致;在实际工况中寿命适中,循环工作时间超过7千小时;辅助加工的效率十分高,齿形越尖锐的辅助切削加工效率越优。
实施例4:
该水泥球磨机用耐磨衬板按重量百分比计含有氧化铝93%、碳酸钙2%、碳酸镁0.9%、二氧化钛1%、立方氮化硼0.3%、碳化钽1.2%、高岭土或山西大同土1.6%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=9:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.7,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:2:0.7,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液11%,混磨0.7h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液和适量的消泡剂,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,水份控制在0.5%以下,其工作面划分为多个边长为50mm的正方形区格,每个区格内呈正四棱锥状突起;该正四棱锥的侧面与底面所成的二面角为5°;
(f)高温烧结:将步骤(e)得到的生坯放入小棚板,撒上60目白刚玉隔离砂,送入梭式窑内,架装裸烧,温度1700℃,烧成周期30h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。该成品工作面采用正四棱锥状突起,顶面虽有棱角但底部坚实可靠,既保证了较好的切削效率,又能实现超长的寿命,综合性能较优。在实际工况中循环工作时间超过2万8千小时;辅助加工的效率较高,突起部分的二面角越大的辅助切削加工效率越优。
实施例5:
该水泥球磨机用耐磨衬板按重量百分比计含有氧化铝94%、碳酸钙1.1%、碳酸镁1%、二氧化钛0.5%、立方氮化硼1%、碳化钽0.6%、高岭土或山西大同土1.8%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=8:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.75,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.75,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液12%,混磨0.6h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液和适量的消泡剂,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,水份控制在0.5%以下,其工作面划分为多个边长为150mm的正方形区格,每个区格内呈正四棱锥状突起;该正四棱锥的侧面与底面所成的二面角为25°;
(f)高温烧结:将步骤(e)得到的生坯放入小棚板,撒上40目白刚玉隔离砂,送入梭式窑内,架装裸烧,温度1550℃,烧成周期34h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。该成品工作面采用正四棱锥状突起,顶面虽有棱角但底部坚实可靠,既保证了较好的切削效率,又能实现超长的寿命,综合性能较优。在实际工况中这种边长为150mm的正方形区格、正四棱锥的侧面与底面所成的二面角为25°的组合形式的循环工作时间超过2万5千小时;辅助加工的效率很高,突起部分的二面角越大的辅助切削加工效率越优。
对所公开的实施例的上述说明,仅为了使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下,在其它实施例中实现。因此,本发明将不会被限制于本文所示的这些实施例,而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (9)
1.一种水泥球磨机用耐磨陶瓷衬板,其特征在于:其成分按重量百分比计含有氧化铝92-95%、碳酸钙0.8-3%、碳酸镁0.8-1%、二氧化钛0.2-2%、立方氮化硼0.3-2%、碳化钽0.5-2%、高岭土或山西大同土1.5-2%;其制造方法包括以下步骤:
(a)配料:按重量百分比计取所有成分,混合并搅拌均匀,制得混合物料;同时配置PVA溶液,配比为PVA:水=(7-10):100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:(0.7-0.75),至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:(2-3):(0.7-0.75),至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液9-12%,混磨0.5-1h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液,并打入高位浆罐,控制喷雾干燥塔的热风温度、出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,压型粉料水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入小棚板,撒上隔离砂,送入高温窑内,架装裸烧,温度1500-1700℃,烧成周期24-36h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。
2.根据权利要求1所述的一种水泥球磨机用耐磨陶瓷衬板,其特征在于:其工作面呈波浪形,波峰波谷高差为10-25mm。
3.根据权利要求1所述的一种水泥球磨机用耐磨陶瓷衬板,其特征在于:其工作面呈齿形或斜齿形。
4.根据权利要求1所述的一种水泥球磨机用耐磨陶瓷衬板,其特征在于:其工作面划分为多个边长为50-150mm的正方形区格,每个区格内呈正四棱锥状突起;该正四棱锥的侧面与底面所成的二面角为5-25°。
5.根据权利要求1-4任一权利要求所述的一种水泥球磨机用耐磨陶瓷衬板,其特征在于,制造方法的步骤(c)中加入PVA溶液的同时,还加入适量的消泡剂。
6.根据权利要求1-4任一权利要求所述的一种水泥球磨机用耐磨陶瓷衬板,其特征在于,制造方法的步骤(e)用于压型成坯的粉料颗粒大小控制为30-80目。
7.根据权利要求1-4任一权利要求所述的一种水泥球磨机用耐磨陶瓷衬板,其特征在于,制造方法的步骤(f)中所述隔离砂为40目以下的白刚玉。
8.根据权利要求1-4任一权利要求所述的一种水泥球磨机用耐磨陶瓷衬板,其特征在于,制造方法的步骤(f)中所述高温窑为隧道窑,温度为1500-1550℃,烧成周期为24-30h。
9.根据权利要求1-4任一权利要求所述的一种水泥球磨机用耐磨陶瓷衬板,其特征在于:制造方法的步骤(f)中所述高温窑为梭式窑,温度为1530-1700℃,烧成周期为30-36h。
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