CN107739193A - 采用三种粒度原料三层布料生产发泡陶瓷的工艺方法 - Google Patents

采用三种粒度原料三层布料生产发泡陶瓷的工艺方法 Download PDF

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CN107739193A
CN107739193A CN201711133800.0A CN201711133800A CN107739193A CN 107739193 A CN107739193 A CN 107739193A CN 201711133800 A CN201711133800 A CN 201711133800A CN 107739193 A CN107739193 A CN 107739193A
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杨继野
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Liaoning Hanwang Green Building Materials Co Ltd
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Abstract

本发明公开了采用三种粒度原料三层布料生产发泡陶瓷的工艺方法，涉及发泡陶瓷制备领域，首先制备三份混合物料，每份混合物料制备方法相同，先将粒度小于0.074mm的发泡陶瓷原料，干混一个小时后，喷发泡陶瓷原料质量5%的雾状水分后制成混合物料，将三份混合物料分别采用三种粒径的对辊造粒机分别采用半干法将原料分别直接压制成0‑1mm颗粒，1‑3mm颗粒，3‑5mm颗粒制成颗粒料，然后再分别利用三台布料机将颗粒料分别布在垫好陶瓷纤维纸的耐火模具中，进入辊道窑或隧道窑进行烧结，完成发泡陶瓷的烧制过程。此种工艺方法实现了快烧的目的。且节能减排效果明显，同时保证烧制的陶瓷内部发泡均匀。

Description

采用三种粒度原料三层布料生产发泡陶瓷的工艺方法
技术领域
本发明涉及采用三种粒度原料三层布料生产发泡陶瓷的工艺方法，属于发泡陶瓷制备领域。
背景技术
目前发泡陶瓷通常工艺是将各种工业固废，与长石、玻璃、发泡剂等物料按比例一起湿法球磨成泥浆，再经过喷雾干燥塔，制备成直径40-60目颗粒状的粉料，再经过高温烧结出现液相，并在高温状态下发泡剂氧化还原后出现气体，气体在高温液相中以气泡形式包裹，冷却后制得多孔陶瓷材料。
发泡陶瓷作为墙体材料要求具有一定厚度，产品一般在150--400mm厚度，通常需要40-60目的颗粒料布料的厚度达到70-200mm，进入窑炉烧结的低温阶段排气就会要求比较充分，否则会在高温阶段产生缺陷，因此需要在低温阶段长时间停留。烧结阶段也需要产时间保温，才可以保证例外温度一致，发泡均匀。
发明内容
针对上述问题，本发明要解决的技术问题是提出利用半干法压制3-5mm粒度的发泡陶瓷原料颗粒料，生产发泡陶瓷制品的方法，解决喷雾干燥制粉，容易出现粉尘排放的问题。且提供了物料进入窑炉烧结的低温阶段排气的通道，加快了热量的传递。
本发明的采用三种粒度原料三层布料生产发泡陶瓷的工艺方法为：首先需要制备三份混合物料，每份混合物料制备方法相同，先将粒度小于0.074mm的发泡陶瓷原料，干混一个小时后，喷发泡陶瓷原料质量5%的雾状水分后制成混合物料，将三份混合物料分别采用三种粒径的对辊造粒机分别采用半干法将原料分别直接压制成0-1mm，1-3mm，3-5mm粒径的颗粒料，然后再分别利用三台布料机将颗粒料分别布在垫好陶瓷纤维纸的耐火模具中，将0-1mm颗粒布在下层，布料厚度48-52mm，1-3mm颗粒布在中层，布料厚度50-100mm，3-5mm颗粒布在上层，布料厚度48-52mm，进入辊道窑或隧道窑进行烧结，完成发泡陶瓷的烧制过程。
进一步优选，所述的烧制制度为：首先以每小时180-220°C的升温速率将温度升温至1160°C，在1160-1180°C下保温1个小时后急冷降温到700°C，然后按照每小时95-105°C的降温速率降至室温完成发泡陶瓷的烧制过程。
进一步优选，所述的发泡陶瓷原料包含以下重量份成分：5-8份铁尾矿、0.5-2份钠长石、0.5-2份废玻璃、0.3-0.8份硼泥、0.2-0.5份硅酸碱、0.1-0.4份碳化硅。
本发明的有益效果：采用半干法方法压制发泡陶瓷原料制成三种粒度的颗粒料，且同时采用三层布料方式进行布料，提供了物料进入窑炉烧结的低温阶段排气的通道，同时加快了热量的传递，实现了快烧的目的。且节能减排效果明显，同时保证烧制的陶瓷内部发泡均匀。
具体实施方式：
本具体实施方式采用以下技术方案和实施例对发明进行进一步的详细说明。
本具体实施方式中三种粒度原料三层布料生产发泡陶瓷的工艺方法为：首先制备三份混合物料，每份混合物料制备方法相同，先将粒度小于0.074mm的发泡陶瓷原料，干混一个小时后，喷发泡陶瓷原料质量5%的雾状水分后制成混合物料，将三份混合物料分别采用三种粒径的对辊造粒机分别采用半干法将原料分别直接压制成0-1mm，1-3mm，3-5mm粒径的颗粒料，然后再分别利用三台布料机将颗粒料分别布在垫好陶瓷纤维纸的耐火模具中，将0-1mm颗粒布在下层，布料厚度48-52mm，1-3mm颗粒布在中层，布料厚度50-100mm，3-5mm颗粒布在上层，布料厚度48-52mm，进入辊道窑或隧道窑进行烧结，完成发泡陶瓷的烧制过程。
进一步优选，所述的烧制制度为：首先以每小时180-220°C的升温速率将温度升温至1160°C，在1160-1180°C下保温1个小时后，急冷降温到700°C，然后按照每小时95-105°C的降温速率降至室温完成发泡陶瓷的烧制过程。
进一步优选，所述的发泡陶瓷原料包含以下重量份成分：5-8份铁尾矿、0.5-2份钠长石、0.5-2份废玻璃、0.3-0.8份硼泥、0.2-0.5份硅酸碱、0.1-0.4份碳化硅。
实施例
首先制备三份混合物料，每份混合物料的制备方法为：取7份小于0.074mm铁尾矿、1份小于0.074mm钠长石、1份小于0.074mm废玻璃、0.5份小于0.074mm硼泥、0.3份小于0.074mm硅酸碱、0.2份小于0.074mm碳化硅,干混一个小时后，喷每份混合物料5%的雾状水分即可，将三份混合物料分别经过三台对辊造粒机，半干压制出的颗粒料为0-1mm、1-3mm、3-5mm粒径颗粒料，利用三台布料机将颗粒料分别布在垫好陶瓷纤维纸的耐火模具中,将0-1mm颗粒布在下层，布料厚度50mm，1-3mm颗粒布在中层，布料厚度50mm，3-5mm颗粒布在上层，布料厚度150mm，按照每小时200°C升温制度,升温到1180°C后保温1个小时，急冷降温到700°C，按照每个小时100°C的降温速度到室温完成烧制过程。产品厚度300mm，内部气泡均匀，无缺陷，体积密度为340kg/m3,抗压强度为5.8Mp，导热系数为0.075W/(m.0C)。
以上显示和描述了本发明的基本原理和主要特征和本发明的优点。本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。

Claims (3)

1.采用三种粒度原料三层布料生产发泡陶瓷的工艺方法，其特征在于：具体工艺步骤为：首先制备三份混合物料，每份混合物料制备方法相同，先将粒度小于0.074mm的发泡陶瓷原料，干混一个小时后，喷发泡陶瓷原料质量5%的雾状水分后制成混合物料，将三份混合物料分别采用三种粒径的对辊造粒机分别采用半干法将原料分别直接压制成0-1mm，1-3mm，3-5mm粒径的颗粒料，然后再分别利用三台布料机将颗粒料分别布在垫好陶瓷纤维纸的耐火模具中，将0-1mm颗粒布在下层，布料厚度48-52mm，1-3mm颗粒布在中层，布料厚度50-100mm，3-5mm颗粒布在上层，布料厚度48-52mm，进入辊道窑或隧道窑进行烧结，完成发泡陶瓷的烧制过程。
2.根据权利要求1制备的采用三种粒度原料三层布料生产发泡陶瓷的工艺方法，其特征在于：所述的烧制制度为：首先以每小时180-220°C的升温速率将温度升温至1160°C，在1160-1180°C下保温1个小时后，急冷降温到700°C，然后按照每小时95-105°C的降温速率降至室温完成发泡陶瓷的烧制过程。
3.根据权利要求1制备的采用三种粒度原料三层布料生产发泡陶瓷的工艺方法，其特征在于：所述的发泡陶瓷原料包含以下重量份成分：5-8份铁尾矿、0.5-2份钠长石、0.5-2份废玻璃、0.3-0.8份硼泥、0.2-0.5份硅酸碱、0.1-0.4份碳化硅。
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