CN109279869B - Preparation method of alumina wear-resistant ceramic ball - Google Patents
Preparation method of alumina wear-resistant ceramic ball Download PDFInfo
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- CN109279869B CN109279869B CN201811007187.2A CN201811007187A CN109279869B CN 109279869 B CN109279869 B CN 109279869B CN 201811007187 A CN201811007187 A CN 201811007187A CN 109279869 B CN109279869 B CN 109279869B
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Abstract
The invention discloses a preparation method of an alumina wear-resistant ceramic ball, which comprises the following steps: weighing raw materials required for manufacturing the alumina wear-resistant ceramic balls; putting the raw materials into a ball mill for ball milling to obtain slurry, wherein the fluidity of the slurry is controlled within 20-40 seconds; stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment; conveying the slurry subjected to primary treatment to a spray drying tower for spray powder making treatment to obtain powder for manufacturing the alumina wear-resistant ceramic ball, wherein the particle size range of the powder is that D <40 meshes is less than 2%, D <40 meshes is less than or equal to 35-50%, D < 60 meshes is less than or equal to 25-40%, D < 100 meshes is less than 15%; putting the powder into a ball forming mill to roll into ceramic balls; and placing the ceramic ball in a kiln for firing at the temperature of 1200-1500 ℃ to obtain the alumina wear-resistant ceramic ball. By controlling the particle size proportion of the powder, the product has smooth surface, good sphericity, high size precision and little difference between balls.
Description
Technical Field
The invention relates to the technical field of ceramic balls, in particular to a preparation method of an alumina wear-resistant ceramic ball.
Background
The alumina wear-resistant ceramic ball is widely applied to industries such as ceramics, glass, enamel, pigment, chemical engineering and the like, is a grinding ball body in fine crushing equipment of various mills, and has the advantages of high strength, large density, small abrasion, corrosion resistance, strong applicability and high grinding efficiency.
The existing preparation method of the alumina wear-resistant ceramic ball comprises two methods:
firstly, taking alumina powder as a main raw material, and calcining the alumina powder. The alumina wear-resistant ceramic ball produced by calcining alumina powder has white appearance, good product quality, good adaptability, good wear resistance, less or no pollution to ground products, is mainly used for grinding ceramic glaze and other wear-resistant materials which need high efficiency and cleanness, but has large resource consumption and high production cost.
And secondly, using bauxite as a main raw material and calcining the bauxite. The alumina wear-resistant ceramic ball produced by calcining the bauxite has yellow appearance, relatively poor product quality, poor adaptability and general wear resistance, is only suitable for grinding occasions with low requirements on the appearance quality of the product, and has high resource consumption.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a preparation method of alumina wear-resistant ceramic balls, which is characterized in that the particle size ratio of powder is controlled, so that the product surface is smooth, the sphericity is good, the size precision is high, the difference between the balls is extremely small, and the ceramic balls prepared by adopting the ceramic stick waste as the main raw material have low cost, white appearance, good adaptability and good wear resistance.
In order to solve the technical problem, the invention provides a preparation method of an alumina wear-resistant ceramic ball, which comprises the following steps:
weighing raw materials required for manufacturing the alumina wear-resistant ceramic balls;
putting the raw materials into a ball mill for ball milling for 40-60 h to obtain slurry with the milling particle size D50 ≦ 5 μm and the moisture content of 25-40%, wherein the fluidity of the slurry is controlled within 20-40 seconds;
stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment;
conveying the slurry subjected to primary treatment to a spray drying tower for spray powder making treatment to obtain powder for manufacturing the alumina wear-resistant ceramic ball, wherein the particle size range of the powder is that D <40 meshes is less than 2%, D <40 meshes is less than or equal to 35-50%, D < 60 meshes is less than or equal to 25-40%, D < 100 meshes is less than 15%;
putting the powder into a ball forming mill to roll into ceramic balls;
and placing the ceramic ball in a kiln for firing at the temperature of 1200-1500 ℃ to obtain the alumina wear-resistant ceramic ball.
As an improvement of the above scheme, the raw materials comprise:
ceramic stick waste;
a source of zirconium;
alumina powder;
dolomite;
and (3) bentonite.
As an improvement of the scheme, the zirconium source is waste zirconium corundum brick or waste zirconium powder.
As an improvement of the scheme, the ceramic roller waste comprises the following components:
60-80% of alumina;
15-25% of silicon oxide;
2-6% of zirconium oxide;
0.2 to 0.8 percent of ferric oxide;
0.01 to 0.1 percent of calcium oxide;
0.01 to 0.1 percent of magnesium oxide;
0.1 to 0.9 percent of sodium oxide;
0.1 to 0.5 percent of potassium oxide;
the balance being impurities.
As a modification of the above, the moisture content of the powder is in the range of 5 to 7%.
As an improvement of the scheme, the iron content of the primarily treated slurry is less than or equal to 1%.
As an improvement of the scheme, the moisture content of the porcelain ball before the porcelain ball is fired in a kiln is less than or equal to 1 percent.
As an improvement of the scheme, the firing and heat preservation time of the porcelain balls in the kiln is 1-8 hours.
The implementation of the invention has the following beneficial effects:
1. the invention adopts the spray powder process technology to prepare the slurry into powder with different grain diameters, when the powder is rolled into the ceramic ball, the powder has higher bulk density and is easier to be uniformly mixed with other raw materials, the obtained product has the advantages of smoothness, good sphericity, high size precision, little difference between balls and ensured internal quality.
2. According to the invention, the ceramic roller waste and the zirconia-corundum brick waste are used as main raw materials, and a small amount of alumina powder and chemical raw materials are added, so that the waste is recycled, and the cost of the ceramic balls is reduced.
3. In addition, the wear-resistant alumina ceramic balls produced by using the ceramic roller waste and the zirconia-corundum brick waste as main raw materials have low wear, high whiteness and wide application range, and can be used for grinding high-end products and low-end products. The alumina wear-resistant ceramic ball has lower cost than a ceramic ball made of bauxite, and because the prices of ceramic roller bar waste and zirconia-corundum brick waste are lower than that of the bauxite, the alumina wear-resistant ceramic ball can replace the ceramic ball made of the bauxite and be used for grinding low-end products.
Drawings
FIG. 1 is a flow chart of the manufacturing process of an alumina wear-resistant ceramic ball of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings.
Fig. 1 is a flow chart of a preparation method of the present invention, and the preparation method of the alumina wear-resistant ceramic ball provided by the present invention comprises:
s101: raw materials required for manufacturing the alumina wear-resistant ceramic balls are weighed.
The formula of the main raw materials for manufacturing the alumina wear-resistant ceramic ball is as follows:
ceramic stick waste;
a source of zirconium;
alumina powder;
dolomite;
and (3) bentonite.
Wherein the zirconium source is waste zirconia-corundum brick or waste zirconium powder.
The main raw material formulas for manufacturing the alumina wear-resistant ceramic ball are two, wherein one raw material formula is mainly prepared from the following raw materials in percentage by weight;
70-90% of ceramic roller waste;
5-15% of zirconia-corundum brick waste;
1-10% of alumina powder;
2-8% of dolomite;
1-4% of bentonite.
According to the formula, the ceramic roller waste and the zirconia-corundum brick waste are used as main raw materials, and a small amount of alumina powder and chemical raw materials are added, so that the waste is recycled, and the cost of the ceramic balls is reduced.
In addition, the wear-resistant alumina ceramic balls produced by using the ceramic roller waste and the zirconia-corundum brick waste as main raw materials have low wear, high whiteness and wide application range, and can be used for grinding high-end products and low-end products. The alumina wear-resistant ceramic ball has lower cost than a ceramic ball made of bauxite, and because the prices of ceramic roller bar waste and zirconia-corundum brick waste are lower than that of the bauxite, the alumina wear-resistant ceramic ball can replace the ceramic ball made of the bauxite and be used for grinding low-end products.
The waste material of the ceramic roller contains alumina, silica and partial zirconia, and can be used for preparing high-wear-resistance ceramic balls with main crystal phases of mullite phase and zirconia crystal phase.
The rock phase structure of the zircon corundum brick consists of eutectoid bodies of corundum and zircon and a glass phase, and the zircon phase is eutectoid bodies of corundum phase and zircon phase in terms of phase, and the glass phase is filled between crystals of the corundum phase and the zircon phase. The zirconium corundum brick waste can improve the zirconium content of the alumina wear-resistant ceramic ball, and the toughening performance of the zirconia is utilized, so that the strength and the wear resistance of the alumina wear-resistant ceramic ball are improved. Therefore, the alumina wear-resistant ceramic ball of the invention can replace the ceramic ball made of alumina powder and be used for grinding high-end products, but the cost is lower than that of the ceramic ball made of alumina powder.
Preferably, the alumina wear-resistant ceramic ball comprises the following raw materials: 78-82% of ceramic roller waste; 7-10% of zirconia-corundum brick waste; 3-5% of alumina powder; 3.5 to 5 percent of dolomite; 1-2% of bentonite.
Wherein the ceramic roller waste consists of the following components: 60-80% of alumina; 15-25% of silicon oxide; 2-6% of zirconium oxide; 0.2 to 0.8 percent of ferric oxide; 0.01 to 0.1 percent of calcium oxide; 0.01 to 0.1 percent of magnesium oxide; 0.1 to 0.9 percent of sodium oxide; 0.1 to 0.5 percent of potassium oxide; the balance being impurities.
Preferably, the ceramic roller scrap material consists of the following components: 65-75% of alumina; 17-22% of silicon oxide; 2-5% of zirconium oxide; 0.3 to 0.6 percent of ferric oxide; 0.03-0.08% of calcium oxide; 0.03-0.08% of magnesium oxide; 0.3 to 0.7 percent of sodium oxide; 0.2 to 0.4 percent of potassium oxide; the balance being impurities.
More preferably, the ceramic roller waste material consists of the following components: 74.8 percent of alumina; 19.4% of silicon oxide; 4.2% of zirconium oxide; 0.43% of ferric oxide; 0.05 percent of calcium oxide; 0.05 percent of magnesium oxide; 0.51 percent of sodium oxide; 0.26% of potassium oxide; the balance being impurities.
The waste zirconia-corundum brick consists of the following components: 40-60% of alumina; 10-20% of silicon oxide; 20-40% of zirconium oxide; 0.1 to 0.8 percent of ferric oxide; 0.1 to 0.8 percent of calcium oxide; 0.07-0.2% of magnesium oxide; 0.7-2 parts of sodium oxide; 0.07-0.2% of potassium oxide; the balance being impurities.
Preferably, the waste zirconia-corundum brick consists of the following components: 45-55% of alumina; 13-18% of silicon oxide; 25-35% of zirconium oxide; 0.2 to 0.5 percent of ferric oxide; 0.1 to 0.5 percent of calcium oxide; 0.1 to 0.15 percent of magnesium oxide; 1-1.5 parts of sodium oxide; 0.1 to 0.18 percent of potassium oxide; the balance being impurities.
More preferably, the waste zirconia-corundum brick consists of the following components: 49.09% of aluminum oxide; 16.47% of silicon oxide; 30.89% of zirconium oxide; 0.32% of ferric oxide; 0.29 percent of calcium oxide; 0.12 percent of magnesium oxide; 1.24% of sodium oxide; 0.16 percent of potassium oxide; the balance being impurities.
The alumina wear-resistant ceramic ball prepared from the raw materials comprises the following components:
65-80% of alumina;
10-20% of silicon oxide;
3-10% of zirconium oxide;
0.1-1% of ferric oxide;
0.7-2% of alkali metal;
1.8 to 3.4 percent of alkaline earth metal;
0.1 to 0.5 percent of titanium oxide.
The ceramic roll waste, the zirconia corundum brick waste, the alumina powder, the dolomite and the bentonite are used as raw materials of the alumina wear-resistant ceramic ball, and the raw materials are reacted, wherein the alumina, the silica and the zirconia can be used for preparing the high wear-resistant ceramic ball with main crystal phases of mullite phase and zirconia crystal phase. The titanium oxide can stabilize the lattice phase of the alumina wear-resistant ceramic ball, and the alkali metal and the alkaline earth metal can increase the wear resistance of the ceramic ball.
The other raw material formula is mainly prepared from the following raw materials in percentage by weight;
40-60% of ceramic roller waste;
30-50% of alumina powder;
2-10% of waste zirconium powder;
2-6% of barium carbonate;
0.1 to 2 percent of dolomite;
1-4% of bentonite.
According to the invention, the ceramic roller waste is used as a main raw material, a certain amount of alumina powder and waste zirconium powder are added, and barium carbonate is used as a main fusing agent, so that the alumina wear-resistant ceramic ball has high strength, high wear resistance and toughness, is suitable for dry-grinding environments with high impact force and high temperature, and not only is the waste recycled, but also the cost of the ceramic ball is reduced.
In addition, the wear-resistant alumina ceramic balls produced by using the ceramic roller waste as the main raw material have low wear, high whiteness and wide application range, and can be used for grinding high-end products and low-end products.
Because the corundum phase and the zirconia phase in the roller rod waste have the characteristics of high strength and high wear resistance, the high-quality alumina wear-resistant ceramic balls are produced by adding the alumina powder and the zirconia waste and selecting the flux raw materials. The alumina wear-resistant ceramic ball has higher specific gravity and higher strength, and is particularly suitable for the dry grinding field of cement fine grinding and the like.
The zirconium content of the alumina wear-resistant ceramic ball can be improved by the zirconia waste, and the strength and the wear resistance of the alumina wear-resistant ceramic ball are improved by utilizing the toughening performance of the zirconia. Therefore, the alumina wear-resistant ceramic ball of the invention can replace the ceramic ball made of alumina powder and be used for grinding high-end products, but the cost is lower than that of the ceramic ball made of alumina powder.
Preferably, the alumina wear-resistant ceramic ball is mainly prepared from the following raw materials in percentage by weight: 45-55% of ceramic roller waste, 35-45% of alumina powder, 3-6% of waste zirconium powder, 3-5% of barium carbonate, 0.5-1.5% of dolomite and 1-2% of bentonite.
Wherein the ceramic roller waste comprises the following components: 60-80% of aluminum oxide, 15-25% of silicon oxide, 2-6% of zirconium oxide, 0.2-0.8% of ferric oxide, 0.01-0.1% of calcium oxide, 0.01-0.1% of magnesium oxide, 0.1-0.9% of sodium oxide, 0.1-0.5% of potassium oxide and the balance of impurities.
The waste material of the ceramic roller refers to the residual material of the raw materials for manufacturing the ceramic roller, and generally, the main raw materials for producing the ceramic roller comprise kaolin, refractory clay, refractory corundum aggregate and alpha-Al2O3And the like. The ceramic roller raw material is used for manufacturing ceramic rollers applied to roller kilns, and plays a role in transmission and bearing. Therefore, the ceramic roll rod scrap of the present invention contains a component, such as zirconia, which improves the wear resistance and hardness of the roll rod, as compared with the existing wear-resistant ceramic raw material. In addition, the main mineral compositions of the ceramic roller waste material are corundum phase and zirconia phase, which belong to high-strength and high-hardness crystal phases and are high-grade wear-resistant materials, the ceramic roller waste material contains less non-wear-resistant impurity raw materials such as glass, and the content of alumina powder and zirconia in the existing other ceramic roller waste materials is low due to cost, so that the ceramic roller waste material is difficult to be used for preparing wear-resistant ceramic balls. The waste material of the ceramic roller contains 60-80% of alumina suitable for manufacturing alumina wear-resistant ceramic balls, and the component proportion of the waste material of the ceramic roller is obtained through scientific calculation, so that the waste material of the ceramic roller is not only suitable for manufacturing ceramic rollers, but also suitable for manufacturing alumina wear-resistant ceramic balls through tests. The calcining temperature of the existing ceramic roller raw material is above 1550 ℃, otherwise the existing ceramic roller raw material is difficult to sinter. The calcining temperature of the alumina wear-resistant ceramic ball is only 1300-1500 ℃.
Preferably, the ceramic roller scrap comprises the following components: 65-75% of aluminum oxide, 17-22% of silicon oxide, 2-5% of zirconium oxide, 0.3-0.6% of ferric oxide, 0.03-0.08% of calcium oxide, 0.03-0.08% of magnesium oxide, 0.3-0.7% of sodium oxide, 0.2-0.4% of potassium oxide and the balance of impurities.
More preferably, the ceramic roller waste comprises the following components: 74.8% of aluminum oxide, 19.4% of silicon oxide, 4.2% of zirconium oxide, 0.43% of ferric oxide, 0.05% of calcium oxide, 0.05% of magnesium oxide, 0.51% of sodium oxide and 0.26% of potassium oxide, and the balance of impurities.
The waste zirconium powder comprises the following components: 0.1-1% of aluminum oxide, 0.1-0.5% of silicon oxide, 60-85% of zirconium oxide, 0.03-0.15% of ferric oxide, 1-5% of calcium oxide, 0.1-0.8% of magnesium oxide, 0.01-0.05% of sodium oxide, 0.01-0.05% of potassium oxide, 10-22% of yttrium oxide, 0.1-1% of titanium oxide and the balance of impurities.
The waste zirconium powder is added into the ceramic stick waste, so that the zirconium content in the formula is improved, and because the main components of the waste zirconium powder are yttrium oxide and zirconium oxide, the toughening performance of the zirconium oxide is utilized to improve the specific gravity, the strength and the wear resistance of the alumina ceramic ball.
The invention mainly uses the leftover materials in several industrial productions as main raw materials, and adds calcined alpha-alumina powder to exert the advantages of the respective raw materials, thereby producing the high wear-resistant alumina ceramic ball with good wear resistance, high strength, wide application range and certain zirconia component.
Preferably, the waste zirconium powder comprises the following components: 0.3 to 0.5 percent of alumina, 0.1 to 0.3 percent of silicon oxide, 66 to 80 percent of zirconium oxide, 0.06 to 0.12 percent of ferric oxide, 1.5 to 4 percent of calcium oxide, 0.2 to 0.6 percent of magnesium oxide, 0.01 to 0.04 percent of sodium oxide, 0.01 to 0.04 percent of potassium oxide, 13 to 20 percent of yttrium oxide, 0.2 to 0.7 percent of titanium oxide and the balance of impurities.
More preferably, the waste zirconium powder comprises the following components: 0.52% of aluminum oxide, 0.2% of silicon oxide, 71% of zirconium oxide, 0.09% of iron oxide, 2.37% of calcium oxide, 0.37% of magnesium oxide, 0.02% of sodium oxide, 0.03% of potassium oxide, 16.92% of yttrium oxide, 0.5% of titanium oxide and the balance of impurities.
The alumina wear-resistant ceramic ball prepared from the raw materials comprises the following components:
65-80% of alumina;
8-17% of silicon oxide;
3-10% of zirconium oxide;
0.1-1% of ferric oxide;
2 to 5 percent of barium oxide
0.7-2% of alkali metal;
1.8 to 3.4 percent of alkaline earth metal;
0.1 to 0.5 percent of titanium oxide.
The ceramic roll waste, the waste zirconium powder, the alumina powder, the dolomite and the bentonite are used as raw materials of the alumina wear-resistant ceramic ball, the barium carbonate is used as a main fusing agent to promote the reaction of various raw materials, wherein the alumina, the silica and the zirconia can be used for preparing the high wear-resistant ceramic ball with main crystal phases of mullite phase and zirconia crystal phase. The titanium oxide can stabilize the lattice phase of the alumina wear-resistant ceramic ball, and the alkali metal and the alkaline earth metal can increase the sintering property of the ceramic ball.
The invention mainly utilizes scrap materials in several industrial production as main raw materials, and simultaneously adds alumina powder to exert the advantages of the respective raw materials, thereby producing the alumina wear-resistant ceramic ball with good wear resistance, high strength, wide application range and certain zirconia content.
S102: and (3) putting the raw materials into a ball mill for ball milling for 40-60 h to obtain slurry with the milling particle size D50 ≦ 5 μm and the water content of 25-40%, wherein the fluidity of the slurry is controlled within 20-40 seconds.
As the main raw material of the invention is the ceramic stick waste which contains different components and impurities, in order to ensure the ball milling efficiency and the slurry performance, not only the slurry is prevented from settling, but also the fluidity of the slurry is ensured, and the water content of the slurry is especially important. Preferably, the moisture content of the slurry is 30-35%.
Preferably, the raw materials are put into a ball mill for ball milling for 55 hours, the grinding particle size is less than or equal to 4 μm, and the fluidity of the slurry is controlled to be about 35 seconds.
S103: and stirring the slurry by an iron remover to remove iron to obtain the slurry subjected to primary treatment.
The iron content of the slurry subjected to primary treatment is less than or equal to 1%.
Preferably, the iron content of the slurry subjected to primary treatment is less than or equal to 0.3%.
The iron impurities in the slurry are removed, so that the good sphericity and appearance of the alumina ceramic ball blank are kept when the alumina ceramic ball blank is formed.
S104: and conveying the slurry subjected to primary treatment to a spray drying tower for spray powder making treatment to obtain powder for manufacturing the alumina wear-resistant ceramic ball, wherein the particle size range of the powder is that D <40 meshes is less than 2%, D <40 meshes is less than or equal to 60 meshes and is 35-50%, D < 60 meshes is less than or equal to 80 meshes and is 25-40%, and D < 100 meshes is less than 15%.
The moisture content of the powder is 5-7%.
The slurry is prepared into powder with different grain diameters by adopting a spray powder preparation processing technology, when the powder is rolled into a ceramic ball, the powder has higher bulk density and is easier to be uniformly mixed with other raw materials, the obtained product is smooth, the sphericity is good, the size precision is high, the difference between the ball and the ball is very small, and the internal quality is also ensured.
When the powder material is rolled into ceramic ball in a ball-shaped machine, the specific gravity of the ceramic ball is controlled at 3.2-3.6g/cm by controlling the proportion of the powder material with different grain diameters3In the scope, the application fields of the ceramic balls with different specific gravities are different, the alumina wear-resistant ceramic ball is mainly used for replacing a ceramic ball made of bauxite applied to the field of grinding low-end products, and meanwhile, the performance of the alumina wear-resistant ceramic ball can also be applied to the field of grinding high-end products.
In addition, by controlling the proportion of the powder with different grain diameters, the surface stress of the porcelain ball is more uniform when the porcelain ball is rolled, so that the porcelain ball with good quality, accurate size and smooth outer surface is formed.
Furthermore, by controlling the proportion of the powder with different particle sizes, the yield of the ceramic ball during rolling forming can be improved, and the breakage rate of the ceramic ball is reduced. Because the binding force and the porosity of the powder materials with different grain diameters are different, the powder materials with different grain diameters can be better combined together during roll forming.
S105: the powder is put into a ball forming mill to be rolled into ceramic balls.
S106: and placing the ceramic ball in a kiln for firing at the temperature of 1200-1500 ℃ to obtain the alumina wear-resistant ceramic ball.
Before the porcelain balls are fired in the kiln, the moisture content is less than or equal to 1%, and the firing heat preservation time of the porcelain balls in the kiln is 1-8 hours.
The firing temperature of the kiln is 1370-1400 ℃ for the 75 alumina wear-resistant ceramic balls.
The firing temperature of the kiln is 1450-1480 ℃ for the 85 alumina wear-resistant ceramic balls.
The invention is illustrated by the following specific examples
Example 1
Weighing 70% of ceramic roller waste, 13% of zirconia-corundum brick waste, 8% of alumina powder, 6% of dolomite and 3% of bentonite;
putting the raw materials into a ball mill for ball milling for 40 hours to obtain slurry with the grinding particle size less than or equal to 5 mu m and the water content of 30%, wherein the fluidity of the slurry is controlled to be about 30 seconds;
stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment;
conveying the slurry subjected to primary treatment to a spray drying tower for spray powder making treatment to obtain powder for manufacturing the alumina wear-resistant ceramic balls, wherein the particle size range of the powder is that D is larger than 40 meshes and is 1%, D is larger than or equal to 40 meshes and is 37%, D is larger than or equal to 60 meshes and is equal to 38%, D is larger than or equal to 60 meshes and is equal to 80 meshes and is equal to 14%;
putting the powder into a ball forming mill to roll into ceramic balls;
and placing the ceramic ball in a kiln for firing at the temperature of 1200-1500 ℃ to obtain the alumina wear-resistant ceramic ball.
Example 2
Weighing 78% of ceramic roller waste, 8% of zirconia-corundum brick waste, 5% of alumina powder, 4% of dolomite and 2% of bentonite;
putting the raw materials into a ball mill for ball milling for 55 hours to obtain slurry with the grinding particle size less than or equal to 4 mu m and the water content of 35%, wherein the fluidity of the slurry is controlled to be about 35 seconds;
stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment;
conveying the slurry subjected to primary treatment to a spray drying tower for spray powder making treatment to obtain powder for manufacturing the alumina wear-resistant ceramic ball, wherein the particle size range of the powder is that D is larger than 40 meshes and is 0.5%, D is larger than or equal to 40 meshes and is 42%, D is larger than or equal to 60 meshes and is 33%, D is larger than 60 meshes and is smaller than or equal to 80 meshes and is 10%;
putting the powder into a ball forming mill to roll into ceramic balls;
and placing the ceramic ball in a kiln for firing at the temperature of 1200-1500 ℃ to obtain the alumina wear-resistant ceramic ball.
Example 3
Weighing 80% of ceramic roller waste, 10% of zirconia-corundum brick waste, 4% of alumina powder, 3% of dolomite and 2% of bentonite;
putting the raw materials into a ball mill for ball milling for 60 hours to obtain slurry with the grinding particle size less than or equal to 5 mu m and the water content of 40%, wherein the fluidity of the slurry is controlled to be about 40 seconds;
stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment;
conveying the slurry subjected to primary treatment to a spray drying tower for spray powder making treatment to obtain powder for manufacturing the alumina wear-resistant ceramic ball, wherein the particle size range of the powder is that D is larger than 40 meshes and is 0.8%, D is larger than or equal to 40 meshes and is 45%, D is larger than or equal to 60 meshes and is 30%, D is larger than or equal to 60 meshes and is smaller than or equal to 80 meshes and is 8%;
putting the powder into a ball forming mill to roll into ceramic balls;
and placing the ceramic ball in a kiln for firing at the temperature of 1200-1500 ℃ to obtain the alumina wear-resistant ceramic ball.
Example 4
Weighing 50% of ceramic roller waste, 41% of alumina powder, 4% of waste zirconium powder, 4% of barium carbonate, 0.8% of dolomite and 0.2% of bentonite;
putting the raw materials into a ball mill for ball milling for 40 hours to obtain slurry with the grinding particle size less than or equal to 5 mu m and the water content of 30%, wherein the fluidity of the slurry is controlled to be about 30 seconds;
stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment;
conveying the slurry subjected to primary treatment to a spray drying tower for spray powder making treatment to obtain powder for manufacturing 85 alumina ceramic balls, wherein the particle size range of the powder is that D is larger than 40 meshes and is 1.5%, D is larger than or equal to 40 meshes and is 48%, D is larger than or equal to 60 meshes and is smaller than or equal to 60 meshes and is 27%, and D is larger than 100 meshes and is 5%;
putting the powder into a ball forming mill to roll into ceramic balls;
and (3) placing the ceramic balls in a kiln for firing at 1450-1480 ℃ to obtain the 85 alumina ceramic balls.
Example 5
Weighing raw materials of 58% of ceramic roller waste, 32% of alumina powder, 2% of waste zirconium powder, 5% of barium carbonate, 0.2% of dolomite and 2.8% of bentonite;
putting the raw materials into a ball mill for ball milling for 45 hours to obtain slurry with the grinding particle size less than or equal to 4 mu m and the water content of 38%, wherein the fluidity of the slurry is controlled to be about 40 seconds;
stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment;
conveying the slurry subjected to primary treatment to a spray drying tower for spray powder making treatment to obtain powder for manufacturing 85 alumina ceramic balls, wherein the particle size range of the powder is that D is larger than 40 meshes and is 1.8%, D is larger than or equal to 40 meshes and is smaller than or equal to 40%, D is larger than or equal to 60 meshes and is smaller than or equal to 35%, D is larger than or equal to 60 meshes and is smaller than or equal to 80 meshes and is smaller than or equal to 35%, and D is larger than 100 meshes and is 11%;
putting the powder into a ball forming mill to roll into ceramic balls;
and (3) placing the ceramic balls in a kiln for firing at 1450-1480 ℃ to obtain the 85 alumina ceramic balls.
Comparative example 1
Weighing 84.69% of ceramic roller waste, 12% of alumina, 1% of kaolin, 1% of barium carbonate and 1% of dolomite;
putting the raw materials into a ball mill for ball milling for 50h to obtain slurry with the grinding particle size less than or equal to 5 mu m and the water content of 30%, wherein the fluidity of the slurry is controlled to be about 30 seconds;
stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment;
conveying the slurry subjected to primary treatment to a spray drying tower for spray powder preparation treatment to obtain powder for manufacturing the alumina wear-resistant ceramic balls;
putting the powder into a ball forming mill to roll into ceramic balls;
and placing the ceramic ball in a kiln for firing at the temperature of 1200-1500 ℃ to obtain the alumina wear-resistant ceramic ball.
Comparative example 2
Weighing 52 parts of alumina powder, 3 parts of kaolin, 3 parts of flint clay clinker, 2 parts of diopside, 1.5 parts of talc and 1.5 parts of dolomite;
putting the raw materials into a ball mill for ball milling for 40 hours to obtain slurry with the grinding particle size less than or equal to 5 mu m and the water content of 30%, wherein the fluidity of the slurry is controlled to be about 30 seconds;
stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment;
conveying the slurry subjected to primary treatment to a spray drying tower for spray powder preparation treatment to obtain powder for manufacturing the alumina wear-resistant ceramic balls, and sieving the powder in a double-layer rotary sieve by using a 40-mesh sieve and a 140-mesh sieve to obtain powder of 40-140 meshes;
rolling the sieved powder in a ball forming mill to prepare ceramic balls;
and placing the ceramic ball in a kiln for firing at the temperature of 1200-1500 ℃ to obtain the alumina wear-resistant ceramic ball.
Comparative example 3
Bauxite is adopted to prepare the alumina wear-resistant ceramic ball.
Table one shows the comparison of the diameters of the ceramic balls manufactured in examples 1 to 5 and comparative examples 1 and 2, in which the ceramic balls have the same size, the diameters of the ceramic balls are measured using a measuring tool such as a micrometer, and each set of data is measured in millimeters (mm) for two directions (i.e., horizontal and vertical directions) of the same ceramic ball.
As can be seen from the table I, the ceramic balls of the present invention according to embodiments 1-5 have the smallest size variance, which means the smallest deviation of the size from the mean, the best dimensional accuracy and the best sphericity.
The alumina abrasion resistant ceramic balls prepared in examples 1 to 5 and comparative examples 1 to 3 were subjected to the test, and the results are shown in table two:
| component (%) | Whiteness degree | Mohs hardness | Specific gravity (g/cm)3) | Equivalent abrasion (%) |
| Example 1 | 77 | 8 | 3.34 | 0.004 |
| Example 2 | 76 | 8 | 3.35 | 0.003 |
| Example 3 | 77 | 8 | 3.35 | 0.003 |
| Example 4 | 77 | 8 | 3.61 | 0.004 |
| Example 5 | 77 | 8 | 3.57 | 0.003 |
| Comparative example 1 | 75 | 7 | 3.21 | 0.007 |
| Comparative example 2 | 77 | 6 | 3.46 | 0.007 |
| Comparative example 3 | 40 | 5 | 3.01 | 0.024 |
As shown in Table two, the specific gravity of the alumina wear-resistant ceramic balls of the invention with the implementation range of 1-5 can reach 3.6g/cm3The whiteness is about 76, the wear resistance is good, the equivalent abrasion is less than 0.005 percent and is higher than the building material industry standard by 0.02 percent.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Claims (5)
1. The preparation method of the alumina wear-resistant ceramic ball is characterized by comprising the following steps:
weighing raw materials required for manufacturing the alumina wear-resistant ceramic ball, wherein the raw materials comprise ceramic stick waste, zirconia corundum brick waste, alumina powder, dolomite and bentonite, and the rock phase structure of the zirconia corundum brick consists of a eutectoid body of corundum and zircon clinoptilolite and a glass phase;
putting the raw materials into a ball mill for ball milling for 40-60 h to obtain slurry with the milling particle size D50 ≦ 5 μm and the moisture content of 25-40%, wherein the fluidity of the slurry is controlled within 20-40 seconds;
stirring the slurry by an iron remover to remove iron to obtain slurry subjected to primary treatment, wherein the iron content of the slurry is less than or equal to 1%;
conveying the slurry subjected to primary treatment to a spray drying tower for spray powder making treatment to obtain powder for manufacturing the alumina wear-resistant ceramic ball, wherein the particle size range of the powder is that D <40 meshes is less than 2%, D <40 meshes is less than or equal to 35-50%, D < 60 meshes is less than or equal to 25-40%, D < 100 meshes is less than 15%;
putting the powder into a ball forming mill to roll into ceramic balls;
and placing the ceramic balls in a kiln for firing at the temperature of 1200-1500 ℃ to obtain the alumina wear-resistant ceramic balls with equivalent wear of less than 0.005 percent.
2. The method of preparing alumina wear-resistant ceramic balls according to claim 1, wherein the ceramic roller scrap comprises the following components:
60-80% of alumina;
15-25% of silicon oxide;
2-6% of zirconium oxide;
0.2 to 0.8 percent of ferric oxide;
0.01 to 0.1 percent of calcium oxide;
0.01 to 0.1 percent of magnesium oxide;
0.1 to 0.9 percent of sodium oxide;
0.1 to 0.5 percent of potassium oxide;
the balance being impurities.
3. The method of preparing alumina abrasion-resistant ceramic balls according to claim 1, wherein the moisture content of the powder is in the range of 5-7%.
4. The method of claim 1, wherein the ceramic ball has a moisture content of less than or equal to 1% before firing in the kiln.
5. The method for preparing the alumina abrasion-resistant ceramic balls as claimed in claim 1, wherein the firing holding time of the ceramic balls in the kiln is 1-8 hours.
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| CN110202488A (en) * | 2019-05-10 | 2019-09-06 | 广东家美陶瓷有限公司 | Porcelain ceramic particle water knife sand and preparation method thereof |
| CN111196715B (en) * | 2020-01-09 | 2022-06-10 | 山东中和金石新材料科技股份有限公司 | Method for preparing inert alumina chemical filler by utilizing solid waste and hazardous waste of activated alumina ball industry |
| CN111574196A (en) * | 2020-06-02 | 2020-08-25 | 苏州电瓷厂股份有限公司 | Ball milling medium and preparation method and application thereof |
| CN112159211B (en) * | 2020-09-30 | 2024-02-06 | 武汉理工大学 | Preparation method of high-density high-hardness submillimeter-grade alumina ceramic balls |
| CN112486128B (en) * | 2020-12-07 | 2021-12-03 | 东莞市琅菱机械有限公司 | Powder raw material manufacturing control method and system based on MES system |
| CN112692968B (en) * | 2020-12-24 | 2022-04-15 | 佛山市东鹏陶瓷有限公司 | Novel press die structure |
| CN113800895A (en) * | 2021-08-24 | 2021-12-17 | 萍乡市金刚科技工业园有限公司 | Wear-resistant zirconium-aluminum composite ball and preparation method thereof |
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