CN1077450C - 一种用于骤冷熔融陶瓷物料的方法 - Google Patents

一种用于骤冷熔融陶瓷物料的方法 Download PDF

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CN1077450C
CN1077450C CN96198558A CN96198558A CN1077450C CN 1077450 C CN1077450 C CN 1077450C CN 96198558 A CN96198558 A CN 96198558A CN 96198558 A CN96198558 A CN 96198558A CN 1077450 C CN1077450 C CN 1077450C
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P·J·阿什利
L·希利
C·E·纳普
R·G·德默斯
D·C·巴彻勒
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Abstract

本发明提供了一种方法，该方法能使熔融陶瓷物料快速骤冷，它是将熔融陶瓷物料流送入湍流的流体流中，使得熔融陶瓷物料流被击碎成液滴，然后，这些液滴在被送入经过旋风器时进行固化，最终从流体流中分离出来，以干燥的粒状陶瓷材料形式被收集。

Description

一种用于骤冷熔融陶瓷物料的方法
                      发明的背景
本发明涉及以制成细碎形式的熔融物料，尤其涉及制备这些细碎物料的方法，特别是这些物料是陶瓷材料的情况。
在本领域内，已知制成熔融状态的物料最好的是通过快速骤冷操作，使其温度降至更易控制的温度。为此，可以将熔化物倒入水中，但是这会产生相当大量的蒸汽，且需要大量额外的水。另外，水会引入杂质或者引起不适当的反应。为了克服这一问题，有人提出将熔融的物料滴在某种冷却介质(如钢球)上，或者滴入厚钢板之间的空腔内。将物料滴在作为冷却介质的钢球上，还有将产物从冷却介质上分离的问题。而将物料滴在钢板之间时，钢板会变质，需要时常更换。用空气或水骤冷解决了这两个问题，但是却存在着局限性，就是得不到能够被粉碎并分级成磨料工业所需全部范围内磨料粒度的粗料。
然而，对于陶瓷和耐火材料，较好的方法是用空气骤冷熔融物料。在该方法中，熔融物料流被注入到冷空气的高速流中。湍流则将熔融物料流分成液滴，这些液滴被空气冷却，使得起初在液滴的外表面形成壳层，其厚度逐渐增加，直至所有的液滴均被固化。基于此机理的方法描述于USP3,831,857；USP4,897,111(它使用湍流形式的液化气体来代替空气)和英国专利1,478,087(它使用惰性气体)中。用于熔融金属流的类似方法描述于英国专利申请2,146,662-A中。
然而，这一类方法也存在着问题，由于据估计，在壳具有层足够强硬以承受颗粒之间的相互接触之前，(此相互接触可能会使壳层破裂，导致碰撞的液滴/颗粒之间产生熔融)液滴/颗粒需要运动长达15英尺。另外，该方法还会产生许多粉尘，造成收集和污染的问题。
现在发明了一种新方法，用此方法熔融陶瓷物料可以被迅速固化得到较均匀的球状颗粒，而产生最少量的粉尘。该方法适用于制备各种陶瓷材料，包括氧化锆、氧化钇稳定的氧化锆、氧化铝、氧化铝/氧化锆、氧化镁等。
发明的概述
本发明提供了一种用于骤冷熔融陶瓷物料的方法，该方法包括将熔融陶瓷物料流加入到含有至少一种流体的湍流的流体流中，温度和流量是使得熔融物料流被击碎成物料液滴流，这些液滴被夹带在流体流中并进行冷却。然后，将经冷却的液滴在旋风分离器中进一步冷却并从流体中分离出来，流体是与旋风分离器侧壁相切地引入其中。
在较好的方法中，流体流包括水滴或夹带在空气中的水滴，尽管使用仅仅包含空气的流体流也可以。然而，水的存在是非常需要的，因为水滴可大大促进熔融陶瓷物料滴的有效冷却，还可以预见到，其它气体(如氮气和二氧化碳)可用来代替空气。但是，空气具有其明显的优点，就是成本低且容易得到，所以是最佳的选择。
在本发明的一个较佳实施方案中，经过一个弓形狭缝将空气或空气/水混合物注入，狭缝弓形的凹面向上。流体流的流速应使得被夹带的熔融物料不会穿透该流体流，该流体流形成一种通道，在其中熔融物料被夹带着一起运动。
旋风分离器是一个垂直取向的漏斗形容器，其切向流入口位于漏斗的上部，出口位于漏斗的下端。流体从流入口引入，绕着分离器的内壁以螺旋方式盘旋而下，然后从出口出去。在该方法中，空气和蒸汽(在流体含水的情况下，在熔融陶瓷物料冷却时产生的蒸气)从旋风器(cyclone)的上端流出。固化的物料滴，以及在流体流中含水的情况下未蒸发成汽的水则从旋风器的底部分离出去。然后对颗粒进行干燥。
通常需要在旋风器的内部装置一些隔板以消散(break up)流动中的漩涡，因为这些漩涡会产生振动效应，该振动效应会在整个时间范围内损害系统的结构统一性。
旋风器的顶部还可以装上一套排气系统，但是更通常的是，只要注入口上方的长度足够大，顶部可以是任其敞开的，不会有什么严重的问题。
因为在旋风器中发生热交换，所以通常需要使得至少一部分旋风器配备有冷却外套以吸收回收的热量。在该方法的注入相中使用水的情况下，得到的产物是湿的，需要经过干燥操作后才能装袋和运输。然而，在这些情况下，可以使回收的颗粒保持足够的热量用来干燥，无需单独的干燥步骤。在这种情况下，干燥可以通过仅仅是先令水排尽，然后让颗粒在传输机上呈一薄层风干来完成。
本发明特别适用于制备要求尽可能细的结晶形式的熔融物料。本发明在制备氧化锆耐火材料中有特殊的用途，此时在氧化环境下的快速骤冷减少了最终产物中氮化物和碳化物的含量。完全氧化的产物在耐火工业中被认为是有利的。本发明还可用于氧化铝/氧化锆磨料的骤冷，此时的快速固化往往会使四方形的氧化锆稳定，四方形的氧化锆被认为在研磨性能上具有有益的效果。另外，通过控制流动的湍流，有可能得到具有不同粒度分布的颗粒，它们可直接用作磨料，或者经过进一步粉碎或分级制成磨料。
                附图
图1表示本发明一个装置的垂直剖面图。
图2表示图1所示装置的旋风器部分的俯视图。
图3表示本发明另一个用水炮的实施方案。
             较佳实施方案的描述
现在结合附图中所示的装置详细描述本发明。
在图1中，熔炉1用来制备熔融的陶瓷物料。熔融物料从熔炉出来，经过喷口2，进入旋风器6的入口4。熔体流被夹带在经过输送喷管(entraining jet)3输入的空气流、水流或空气/水流中。额外的冷却水可通过位于入口4开口处的环5加入旋风器6中。输送喷管在高压下操作，在其喷口和通向旋风器的入口之间产生一湍流区，它有效地将熔融物料流击碎成许多细小的液滴，这些细小液滴在进入旋风器时固化并冷却。在物料进入旋风器的位置以上有一个延伸部分7，用于防止在操作时颗粒从旋风器中甩出。
旋风器中可装置一些隔板(图中未示出)，用于确保冷却更均匀并减少可能的振动。流体从旋风器中出来，沉积在设计用来收集固体颗粒的分离器装置9中。陶瓷物料从分离器出来，沉积在传送-收集器10上。
还可以在旋风器前头放置另一套冷却系统，这样所有的熔融产物在进入旋风器之前就被固化了，然后旋风器的作用是进行进一步的冷却，且最终从陶瓷产物中分离出所有的水，这种方式通常也是有利的。这种另一套冷却系统的一个例子是“水炮”(water cannon)，装备有该装置的设备的一个例子如图3所示。熔融产物从熔炉1中出来，经过喷口2，灌入来自雾化喷嘴3的流体流中，沿着这段水炮管14朝前流动，水炮管内配有许多喷水环(water rings)15，它们的喷口指向水炮内，沿其长度方向形成角度。在每个喷水环的前面有隔板挡住，以防止在喷水环上有产物聚集，而这会导致蒸汽爆炸。水炮的出口放置在旋风器的入口处。
该系统的优点是可以使用较大量的冷却水，如果需要的话进一步设计水炮，使其配有许多冷却环，每个冷却环配有关闭阀，这样就可以仔细控制所用的水量。水炮可以与旋风器分离，也可以接在旋风器上。
该装置可以使用完全是水、或完全是空气，或者是水和空气混合物的流体流。在特别好的一个实施方案中，通过一根半开的一英寸管，提供空气/水混合物，该混合物是压力90磅/英寸2(psi)的空气，加入压力约40磅/英寸2的水。由该装置得到的产物是氧化钇稳定的氧化锆(最多约含5重量％的氧化钇)，其粒度不小于100筛目，大多数由1/4英寸的粗颗粒组成。
在通常的用水雾化的方法(不含空气)中，得到的是几乎没有小于40筛目的大颗粒。单独使用空气，可得到细得多的粒度分布。若用水和空气的混合物，则得到中等的粒度分布。然而，一般来说，流经喷管3的雾化流体流的流速越高，雾化就越好，所得颗粒就越细。正如预期的那样，熔融陶瓷物料流也会影响颗粒的粗度。对于任何给定的流体流量而言，熔融陶瓷物料的流量越高，产物就越粗。
该装置的有效性通过使用含5％MgO和95％氧化铝的尖晶石物料进行了评定。通过喷管注入100磅/英寸2的水，并且让45磅/英寸2的水流经环的喷口产生水幕。如此制得的粗产物，其过40筛目的产物约少于3％(重量)。
当通过输送喷管注入80磅/英寸2的空气，且经过与上述相同的水幕时，得到产物的粒度细得多。
使用含10％氧化铝、5％二氧化硅、85％氧化锆的陶瓷物料，通过环的喷口喷射水，在输送喷管中只用空气，结果在70筛目的筛网上留下99.78％(重量)的产物，在30筛目的筛网上留下90.6％(重量)的产物，只有42.28％(重量)的产物粗于12筛目。
使用相同的陶瓷原料，但是关闭喷水环喷口，在输送喷管中提供空气/水混合物，发现类似的情况：在70筛目的筛网上留下99.79％(重量)的产物，约40.47％的产物粗于12筛目。
仅仅在输送喷管中使用空气，且不用喷水环，则粒度分布有一些变细：在70筛目的筛网上仅留下91.2％(重量)的产物，在30筛目的筛网上留下59.75％的产物，只有19.17％(重量)的产物粗于12筛目。

Claims (7)

1.一种用于骤冷熔融陶瓷物料的方法，该方法包括将熔融陶瓷物料流加入到含有至少一种流体的湍流的流体流中，使得熔融陶瓷物料流被击碎成物料液滴流，这些物料液滴被夹带在流体流中变成固化的颗粒，它们以与旋风器侧壁相切的流动方式被送入旋风器中。
2.如权利要求1所述的方法，其中陶瓷物料选自氧化镁、氧化铝、氧化锆、氧化铝/氧化锆混合物，以及用小部分氧化钇、二氧化硅、氧化镁和它们的混合物改性的氧化铝或氧化锆。
3.如权利要求1所述的方法，其中湍流的流体流选自空气、水、以及空气和水的混合物。
4.如权利要求1所述的方法，其中湍流的流体流夹带着熔融陶瓷物料经过水幕。
5.如权利要求1所述的方法，其中湍流的流体流被注入到在内表面周围具有多个高压喷水口的管子的开口处，所述喷水口沿管子指向并与管子轴向形成角度。
6.如权利要求1所述的方法，其中旋风器配有内部隔板，用以消散流体/陶瓷颗粒混合物的流动。
7.如权利要求1所述的方法，其中控制旋风器的温度，使得颗粒从旋风器中出来时保持足够的热量，而不需要单独应用加热步骤来使颗粒变得基本上干燥。
CN96198558A 1995-11-29 1996-11-18 一种用于骤冷熔融陶瓷物料的方法 Expired - Lifetime CN1077450C (zh)

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AU692120B2 (en) 1998-05-28
HU224247B1 (hu) 2005-07-28
TW401385B (en) 2000-08-11
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CA2234223C (en) 2001-10-30
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