CN108298993A - 陶瓷材料回转窑干法造粒方法 - Google Patents

陶瓷材料回转窑干法造粒方法 Download PDF

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CN108298993A
CN108298993A CN201810200015.0A CN201810200015A CN108298993A CN 108298993 A CN108298993 A CN 108298993A CN 201810200015 A CN201810200015 A CN 201810200015A CN 108298993 A CN108298993 A CN 108298993A
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吴赟
石飞飞
叶刚
叶丹
郭振刚
吴文海
韩永欢
李正
陈聪聪
陈丹丹
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Tianjin Chengjian University
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Abstract

本发明公开了一种陶瓷材料回转窑干法造粒方法,包括如下步骤:1)将质量分数为80~50%、粒度为50~1μm的不含结晶水的陶瓷粉料与质量分数20~50%、粒度为100~10μm含结晶水的矿物原料混合均匀,得到干粉状物料;2)将干粉状物料利用输送设备投入回转窑,其投入量利用如下公式进行计算3)回转窑工作参数为:窑头温度:室温~80℃;窑尾温度:50~120℃;转速:1.8/D,D为回转窑内径,单位m;窑内工作区温度:200~700℃;4)将回转窑中出来的粉料冷却、筛分,筛下产物即为产物。该方法仅需陶瓷原料自身水分,即能利用回转窑完成造粒,减少混合、干燥、排胶环节,显著提高生产效率,减少资源消耗。

Description

陶瓷材料回转窑干法造粒方法
技术领域
本发明涉及陶瓷材料领域,具体涉及一种陶瓷材料回转窑干法造粒方法。
背景技术
陶瓷材料的造粒是指将流动性较差的原料粉磨通过一定的工艺加工成流动性较好的粉体材料,以利于后续致密化成型要求,造粒工艺对陶瓷产品的质量有决定性的影响。目前陶瓷行业广泛采用的湿法造粒工艺已无法满足日益增长的环保和节能生产要求,而现有的陶瓷干法制粉造粒生产技术及工艺往往需要专用设备和添加剂,工艺过程相对复杂,不利于陶瓷行业生产推广。
专利CN102731099A公开了一种陶瓷辊棒胚料的喷雾造粒加工工艺,该专利技术需要将预先制备陶瓷浆料,并采用喷雾干燥的方式造粒;专利CN101480813A公开了一种陶瓷原料干粉造粒的清洁节能生产工艺,工艺过程中需要使用专用混合造粒机和流化床干燥,在造粒的过程中仍需要加入雾化水;专利CN103566818A公开了一种建筑陶瓷坯料干法造粒装置及其方法,该项干法造粒技术由专用造粒设备实施,在工艺过程中需要“配成质量浓度为3%~5%的造粒添加剂溶液;其中,所用的造粒添加剂是由质量比为(8~15):(18~26):(16~30):(20~48)的海藻酸钠、聚乙烯醇、聚丙烯酞胺以及聚甲基丙烯酸甲酷组成”,工艺和设备相对繁琐。
发明内容
为了解决上述技术问题,本发明提供一种陶瓷材料回转窑干法造粒方法,该方法仅需利用陶瓷原料自身水分,即能利用回转窑完成造粒,减少混合、干燥、排胶等环节,显著提高生产效率,减少资源消耗。
为此,本发明的技术方案如下:
一种陶瓷材料回转窑干法造粒方法,包括如下步骤:
1)将质量分数为80~50%、粒度为50~1μm的不含结晶水的陶瓷粉料与质量分数20~50%、粒度为100~10μm含结晶水的矿物原料混合均匀,获得干粉状物料;
2)将所述干粉状物料利用输送设备投入回转窑,所述干粉状物料的给料量G利用如下公式计算得到;
式中:G为给料量,单位t/h;D为回转窑内径,单位m;为物料在窑内的平均填充系数,取0.04~0.08;γ物料为物料的堆积密度,单位t/m3;ω物料为物料轴向移动速度,单位m/h,ω物料=5.78Dβn,其中β为回转窑的安装倾斜角,单位度;n为回转窑转速,单为r/min;
3)回转窑采用外热式加热,工作参数如下:
窑头温度:室温~80℃;窑尾温度:50~120℃;转速:1.8/D,D为回转窑内径,单位m;窑内工作区温度:200~700℃;优选,回转窑的工作区域长度不低于总窑长的50%;更优选,回转窑倾斜角度:3~5°;
4)将从窑头出来的粉料冷却、筛分,得到的筛下产物即为陶粒粒化料。
优选,步骤1)所述的干粉状物料若含水量大于8%,还需在低于100℃条件下烘干。
进一步,步骤4)的筛上产物经破碎球磨后重新输入输送设备,进行步骤2)~4)。
进一步,所述不含结晶水的陶瓷粉料为三氧化二铝粉末、碳化硅粉末、碳化硼粉末、氮化硅粉末、石英粉末、氮化硼粉末、石墨粉末和碳酸钙粉末中的任意一种或任意几种以任意比的混合物。
进一步,所述含结晶水的矿物原料为明矾、生石膏、硼砂、高岭石、光卤石和硼酸中的任意一种或任意几种以任意比的混合物。
该陶瓷材料回转窑干法造粒方法不需引入造粒添加剂和水等液体物质,仅利用陶瓷原料自身的水分,在回转窑中即可完成造粒,具有生产效率高,工艺环节少,能耗和污染低的特点,对陶瓷行业的转型升级,节能减排能起到一定的推动作用。
附图说明
图1为实施例1最终得到的陶粒粒化料的形貌图;
图2为实施例2最终得到的陶粒粒化料的形貌图;
图3为实施例3最终得到的陶粒粒化料的形貌图;
图4为实施例4最终得到的陶粒粒化料的形貌图;
图5为实施例5最终得到的陶粒粒化料的形貌图;
图6为实施例6最终得到的陶粒粒化料的形貌图。
具体实施方式
以下结合附图和实施例对本发明的技术方案进行详细描述。
实施例1
一种陶瓷材料回转窑干法造粒方法,包括如下步骤:
1)将质量分数为60%、粒度为10μm的不含结晶水的三氧化二铝粉料与质量分数40%粒度为20μm含结晶水的明矾均匀混合,并于80℃温度烘干,获得干粉状物料;
2)在内径为1m的回转窑中,按照以下公式计算得到给料量为1~1.5t/h,将所述干粉状物料利用输送设备控制给料量,均匀投入到回转窑内;
其中:D——回转窑内径为1m;——物料在窑内的平均填充系数,取0.06;γ——物料的堆积密度,为0.8t/m3;ω物料=5.78Dβn为物料轴向移动速度,单位m/h,式中β为安装倾斜角,取3°;n为回转窑转速,取1.5~2r/min;
3)回转窑工作参数如下:
窑头温度:50~70℃,窑尾温度:80~100℃,转速:1.5~2r/min,窑内工作区温度:500℃,工作区域长度占总窑长的60%,倾斜角度:3°;
4)将从窑头出来的粉料冷却、筛分,并将筛上产物(粗颗粒)破碎球磨后重新投入到输送设备中按上述步骤进行造粒,最终得到陶粒粒化料,形貌见图1所示。
实施例2
一种陶瓷材料回转窑干法造粒方法,包括如下步骤:
1)将质量分数为70%、粒度为5μm的不含结晶水的石英粉料与质量分数30%粒度为10μm含结晶水的高岭石均匀混合,获得干粉状物料;
2)在内径为3m的回转窑中,按照以下公式得到给料量为17~18t/h,将干粉状物料利用输送设备控制给料量,均匀投入到回转窑内;
其中:
D——回转窑内径,为3m;
——物料在窑内的平均填充系数,取0.07;
γ——物料的堆积密度,为0.85t/m3
ω物料=5.78Dβn为物料轴向移动速度,单位m/h,式中β为安装倾斜角,取4°;n为回转窑转速,取0.6r/min
3)回转窑工作参数如下
窑头温度:40~50℃,窑尾温度:90~110℃,转速:0.6r/min,窑内工作区温度:600℃,工作区域长度占总窑长的65%,倾斜角度:4°;
4)将从窑头出来的粉料冷却、筛分,并将筛上产物(粗颗粒)破碎球磨后重新投入到输送设备中按上述步骤进行造粒,最终得到陶粒粒化料,形貌见图2所示。
实施例3
一种陶瓷材料回转窑干法造粒方法,包括如下步骤:
1)将质量分数为50%、粒度为1μm的不含结晶水的氮化硅粉料与质量分数50%粒度为10μm含结晶水的硼酸均匀混合,获得干粉状物料;
2)在内径为2m的回转窑中,按照以下公式得到给料量为7.5~9t/h,将干粉状物料利用输送设备控制给料量,均匀投入到回转窑内;
其中:
D——回转窑内径,为2m;
——物料在窑内的平均填充系数,取0.05;
γ——物料的堆积密度,为1.6~1.8t/m3
ω物料=5.78Dβn为物料轴向移动速度,单位m/h,式中β为安装倾斜角,取3°;n为回转窑转速,取0.9r/min;
3)回转窑工作参数如下
窑头温度:60~80℃,窑尾温度:50~70℃,转速:0.9r/min,窑内工作区温度:600℃,工作区域长度占总窑长的55%,倾斜角度:3°;
4)将从窑头出来的粉料冷却,筛分,并将筛上产物(粗颗粒)破碎球磨后重新投入到输送设备中按上述步骤进行造粒,最终得到陶粒粒化料,形貌见图3所示。
实施例4
一种陶瓷材料回转窑干法造粒方法,包括如下步骤:
1)将质量分数为75%、粒度为15μm的不含结晶水的氮化硼粉料与质量分数25%粒度为30μm含结晶水的硼砂均匀混合,获得干粉状物料;
2)在内径为2m的回转窑中,按照公式得到给料量为7.5~9t/h,将干粉状物料利用输送设备控制给料量,均匀投入到回转窑内;
3)回转窑工作参数如下
窑头温度:45~65℃,窑尾温度:55~70℃,转速:0.9r/min,窑内工作区温度:400℃,工作区域长度占总窑长的75%,倾斜角度:3°;
4)将从窑头出来的粉料冷却,筛分,并将筛上产物(粗颗粒)破碎球磨后重新投入到输送设备中按上述步骤进行造粒,最终得到陶粒粒化料,形貌见图4所示。
实施例5
一种陶瓷材料回转窑干法造粒方法,包括如下步骤:
1)将质量分数为80%、粒度为20μm的不含结晶水的碳酸钙粉料与质量分数20%粒度为40μm含结晶水的生石膏均匀混合,获得干粉状物料;
2)在内径为4m的回转窑中,按照以下公式得到给料量为31~33t/h,将干粉状物料利用输送设备控制给料量,均匀投入到回转窑内;
其中:
D——回转窑内径,为4m;
——物料在窑内的平均填充系数,取0.07;
γ——物料的堆积密度,为0.9t/m3
ω物料=5.78Dβn为物料轴向移动速度,单位m/h,式中β为安装倾斜角,取4°;n为回转窑转速,取0.45r/min;
3)回转窑工作参数如下
窑头温度:40~55℃,窑尾温度:50~60℃,转速:0.45r/min,窑内工作区温度:400℃,工作区域长度占总窑长的70%,倾斜角度:4°;
4)将从窑头出来的粉料冷却,筛分,并将筛上产物(粗颗粒)破碎球磨后重新投入到输送设备中按上述步骤进行造粒,最终得到陶粒粒化料,形貌见图5所示。
实施例6
1)将质量分数为50%、粒度为5μm不含结晶水的三氧化二铝粉料,质量分数为10%、粒度为2μm不含结晶水的石英粉料以及质量分数为40%、粒度为15μm含结晶水的高岭石粉料均匀混合,获得干粉状物料;
2)在内径为4m的回转窑中,按照公式得到给料量为31~33t/h,将干粉状物料利用输送设备控制给料量,均匀投入到回转窑内;
3)回转窑工作参数如下
窑头温度:60~70℃,窑尾温度:80~110℃,转速:0.45r/min,窑内工作区温度:500℃,工作区域长度占总窑长的80%,倾斜角度:4°;
4)将从窑头出来的粉料冷却,筛分,并将筛上产物(粗颗粒)破碎球磨后重新投入到输送设备中按上述步骤进行造粒,最终得到陶粒粒化料,形貌见图6所示。

Claims (7)

1.一种陶瓷材料回转窑干法造粒方法,其特征在于包括如下步骤:
1)将质量分数为80~50%、粒度为50~1μm的不含结晶水的陶瓷粉料与质量分数20~50%、粒度为100~10μm含结晶水的矿物原料混合均匀,获得干粉状物料;
2)将所述干粉状物料利用输送设备投入回转窑,所述干粉状物料的给料量G利用如下公式计算得到;
式中:G为给料量,单位t/h;D为回转窑内径,单位m;为物料在窑内的平均填充系数,取0.04~0.08;γ物料为物料的堆积密度,单位t/m3;ω物料为物料轴向移动速度,单位m/h,ω物料=5.78Dβn,其中β为回转窑的安装倾斜角,单位度;n为回转窑转速,单为r/min;
3)回转窑采用外热式加热,工作参数如下:
窑头温度:室温~80℃;窑尾温度:50~120℃;转速:1.8/D,D为回转窑内径,单位m;窑内工作区温度:200~700℃;
4)将从窑头出来的粉料冷却、筛分,得到的筛下产物即为陶粒粒化料。
2.如权利要求1所述陶瓷材料回转窑干法造粒方法,其特征在于:步骤4)的筛上产物经破碎球磨后重新输入输送设备,进行步骤2)~4)。
3.如权利要求1或2所述陶瓷材料回转窑干法造粒方法,其特征在于:所述不含结晶水的陶瓷粉料为三氧化二铝粉末、碳化硅粉末、碳化硼粉末、氮化硅粉末、石英粉末、氮化硼粉末、石墨粉末和碳酸钙粉末中的任意一种或任意几种以任意比的混合物。
4.如权利要求1或2所述陶瓷材料回转窑干法造粒方法,其特征在于:所述含结晶水的矿物原料为明矾、生石膏、硼砂、高岭石、光卤石和硼酸中的任意一种或任意几种以任意比的混合物。
5.如权利要求1或2所述陶瓷材料回转窑干法造粒方法,其特征在于:步骤1)所述的干粉状物料若含水量大于8%,还需在低于100℃条件下烘干。
6.如权利要求1或2所述陶瓷材料回转窑干法造粒方法,其特征在于:所述回转窑的工作区域长度不低于总窑长的50%。
7.如权利要求1或2所述陶瓷材料回转窑干法造粒方法,其特征在于:所述回转窑的倾斜角度为3~5°。
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