CN109516774B - Preparation method of artificial spherical ceramic composite sand - Google Patents
Preparation method of artificial spherical ceramic composite sand Download PDFInfo
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- CN109516774B CN109516774B CN201811606337.1A CN201811606337A CN109516774B CN 109516774 B CN109516774 B CN 109516774B CN 201811606337 A CN201811606337 A CN 201811606337A CN 109516774 B CN109516774 B CN 109516774B
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- 239000004576 sand Substances 0.000 title claims abstract description 161
- 239000000919 ceramic Substances 0.000 title claims abstract description 144
- 239000002131 composite material Substances 0.000 title claims abstract description 122
- 238000002360 preparation method Methods 0.000 title claims abstract description 31
- 239000000843 powder Substances 0.000 claims abstract description 75
- 229910001570 bauxite Inorganic materials 0.000 claims abstract description 43
- 238000005245 sintering Methods 0.000 claims abstract description 33
- 238000012216 screening Methods 0.000 claims abstract description 21
- 239000004927 clay Substances 0.000 claims abstract description 16
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 13
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 12
- 239000010881 fly ash Substances 0.000 claims abstract description 8
- 239000010431 corundum Substances 0.000 claims abstract description 6
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 6
- 239000002893 slag Substances 0.000 claims abstract description 6
- 239000002245 particle Substances 0.000 claims description 43
- 239000000463 material Substances 0.000 claims description 39
- 238000001035 drying Methods 0.000 claims description 36
- 239000008188 pellet Substances 0.000 claims description 36
- 239000002994 raw material Substances 0.000 claims description 35
- 238000005469 granulation Methods 0.000 claims description 31
- 230000003179 granulation Effects 0.000 claims description 31
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 26
- 238000000034 method Methods 0.000 claims description 25
- 239000000440 bentonite Substances 0.000 claims description 19
- 229910000278 bentonite Inorganic materials 0.000 claims description 19
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical group O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 19
- 229910052661 anorthite Inorganic materials 0.000 claims description 15
- GWWPLLOVYSCJIO-UHFFFAOYSA-N dialuminum;calcium;disilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-] GWWPLLOVYSCJIO-UHFFFAOYSA-N 0.000 claims description 15
- 238000005201 scrubbing Methods 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 13
- 238000002156 mixing Methods 0.000 claims description 11
- 239000011230 binding agent Substances 0.000 claims description 8
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 7
- 238000000889 atomisation Methods 0.000 claims description 7
- 238000001816 cooling Methods 0.000 claims description 7
- 238000001238 wet grinding Methods 0.000 claims description 7
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 7
- 238000009837 dry grinding Methods 0.000 claims description 6
- 239000010419 fine particle Substances 0.000 claims description 6
- 238000003801 milling Methods 0.000 claims description 6
- 238000007873 sieving Methods 0.000 claims description 6
- 239000007787 solid Substances 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 4
- 238000005096 rolling process Methods 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 2
- 238000000576 coating method Methods 0.000 claims description 2
- 238000005266 casting Methods 0.000 abstract description 27
- 239000012778 molding material Substances 0.000 abstract description 6
- 238000000498 ball milling Methods 0.000 abstract description 2
- 238000005495 investment casting Methods 0.000 abstract description 2
- 238000007528 sand casting Methods 0.000 abstract description 2
- 238000010112 shell-mould casting Methods 0.000 abstract description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 143
- 239000011162 core material Substances 0.000 description 27
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 16
- 239000000395 magnesium oxide Substances 0.000 description 12
- 239000000126 substance Substances 0.000 description 8
- 239000002699 waste material Substances 0.000 description 6
- 239000000377 silicon dioxide Substances 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 229910052681 coesite Inorganic materials 0.000 description 4
- 229910052906 cristobalite Inorganic materials 0.000 description 4
- 229910052682 stishovite Inorganic materials 0.000 description 4
- 229910052905 tridymite Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- 230000018109 developmental process Effects 0.000 description 3
- 239000011257 shell material Substances 0.000 description 3
- 239000005995 Aluminium silicate Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 235000012211 aluminium silicate Nutrition 0.000 description 2
- 229910052570 clay Inorganic materials 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000010891 electric arc Methods 0.000 description 2
- 238000009776 industrial production Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000005065 mining Methods 0.000 description 2
- 229910021652 non-ferrous alloy Inorganic materials 0.000 description 2
- 239000004482 other powder Substances 0.000 description 2
- 230000008929 regeneration Effects 0.000 description 2
- 238000011069 regeneration method Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 229910052634 enstatite Inorganic materials 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- BBCCCLINBSELLX-UHFFFAOYSA-N magnesium;dihydroxy(oxo)silane Chemical compound [Mg+2].O[Si](O)=O BBCCCLINBSELLX-UHFFFAOYSA-N 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000002910 solid waste Substances 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 230000004083 survival effect Effects 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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Abstract
The invention relates to the field of ceramic sand for casting, in particular to a preparation method of artificial spherical ceramic composite sand, which can be widely applied to molding materials in the industries of common sand casting, shell mold casting, precision casting and the like. The structure of the ceramic composite sand is mainly a double-layer structure of 'inner core + outer layer', and the inner core adopts powder with a relatively large grain diameter: one or more than two of low-grade bauxite, low-grade flint clay, nickel tailing slag and fly ash, wherein the outer layer adopts powder with smaller grain diameter: one or more of high-grade flint clay, high-grade bauxite and corundum powder. The ceramic composite sand is prepared by adopting the preparation process of burdening, ball milling, granulating, sintering and screening grading, and has the advantages of few open holes, good surface smoothness, high refractoriness and low breakage rate. The double-layer structure design of the ceramic composite sand not only has better performance than the ceramic sand with a single structure, but also reduces the cost and gives consideration to the economy.
Description
Technical Field
The invention relates to the field of ceramic sand for casting, in particular to a preparation method of artificial spherical ceramic composite sand, which can be widely applied to molding materials in the industries of common sand casting, shell mold casting, precision casting and the like.
Background
With the development of economic society in China, in order to meet the needs of industrial production, natural resources are exploited in large quantities, so that many natural resources are exhausted, and the nation starts to limit the exploitation of enterprises to some mineral resources, so that the prices of many raw materials are continuously raised, for example: although China is the world with the largest bauxite reserves, the existing reserves are greatly reduced after a large number of years of mining, bauxite ores in many places are exhausted, and the country starts to limit the mining of the bauxite ores in recent years, so that the bauxite market is continuously favored; meanwhile, the emission of waste from industrial production causes serious pollution to the environment, and in order to protect the natural environment on which we rely for survival, countries and society begin to dispute policies, regulations and standards, such as: the issuance of new environmental protection tax laws, the issuance of industry standards such as admission conditions of the casting industry and emission limits of casting solid wastes, etc. Under the large background of "saving resources, protecting the environment", many enterprises that originally relied heavily on resources become difficult to survive. On the other hand, with the rapid development of the casting industry in China, the casting yield is steadily increased, the demand on casting sand is more and more, and with the improvement of the casting quality, the traditional silica sand cannot meet the demand of the casting industry due to the characteristics of large angular coefficient, large thermal expansion rate, poor regeneration performance and the like. Therefore, in recent years, artificial spherical sand has come into the visual field of people, and the artificial spherical sand has excellent performance as casting raw sand, is easy to regenerate, saves resources and protects the environment.
In fact, researchers can study the artificial spherical sand in the last 60 years, the artificial spherical sand has a history of more than 50 years, and various artificial spherical sand products such as carbon sand, enstatite sand, sun beads and the like appear in the artificial spherical sand. In the beginning of the 21 st century, an artificial spherical sand product named 'Baozhu sand' is developed and popularized domestically, and enterprises apply for patents, such as: patent publication No. CN106862479A discloses a method for preparing foundry sand for casting molding materials: mixing Al2O3Adding more than 60% of aluminum ore into an electric arc furnace, heating to more than 2000 ℃ for melting, applying air pressure to molten liquid flowing out of the electric arc furnace, crushing and cooling the liquid raw material, and finally screening the Baozhu sand according to the particle size to obtain the Baozhu sand product. The ball-shaped Baozhu sand product obtained by the preparation method has sphericityGood fire resistance, but obvious defects, large energy consumption, heavy pollution and high requirement on the grade of bauxite. In recent years, some manufacturers in China begin to apply sintered ceramsite to casting molding materials, such as: flint clay ceramic sand produced by Shandong Diamond New materials GmbH. There is also a group of patents filed by enterprises and scientific institutions, for example: patent publication No. CN107324781A discloses a ceramic sand for casting molding materials, which is prepared by using three-grade bauxite and kaolin as main raw materials and adopting a preparation method of atomization granulation and high-temperature sintering. The method has the advantages that the low-grade three-grade bauxite and the kaolin are used as raw materials, the sintering temperature is lower, the resources are saved, and the production cost is reduced. But the defects are also obvious because the ceramic sand has low aluminum content and poor refractoriness and cannot be used for producing high-melting-point castings. In order to improve the refractoriness of the ceramic sand, patent document No. CN107298584A discloses a ceramic sand with relatively high aluminum content, but the sintering temperature is up to 1550-1700 ℃, the sintering time is 3.5-5.0 hours, the sintering temperature is too high, the heat preservation time is too long, the energy is wasted, the cost is increased, and the ceramic sand still completely depends on high-grade bauxite ore. Therefore, designing a method for preparing ceramic sand for casting, which can realize waste recycling, reduce the use amount of high-quality raw materials, has excellent performance and low cost, is an important development direction in the field of molding materials.
Disclosure of Invention
Aiming at the technical problems in the field of the existing ceramic sand for casting, the invention aims to provide a preparation method of artificial spherical ceramic composite sand, which can realize the reutilization of wastes, reduce the use amount of high-quality raw materials, replace the ceramic sand with a single structure with excellent performance and low cost and meet the requirement of actual casting production.
In order to realize the purpose of the invention, the technical scheme is as follows:
a preparation method of artificial spherical ceramic composite sand adopts a rolling granulation method for granulation and sintering in a rotary kiln, and comprises the following preparation steps:
(1) preparing materials: adding a binder which accounts for 3-5% of the weight of the core raw material into the core raw material, putting the core raw material into a ball mill, carrying out dry grinding for 1-3 h, fully mixing, and taking out the mixture to serve as the core raw material for preparing the ceramic composite sand;
(2) milling: adding the outer layer raw material powder, the binder and the sintering aid into a ball mill, adding water, and wet-milling to D50Taking out the powder with the particle size less than or equal to 13 mu m, drying and crushing the powder to be used as an outer layer raw material for preparing the ceramic composite sand;
(3) and (3) granulation: adding a core raw material of the ceramic composite sand into a round pot type granulator, adjusting the rotating speed to be 20-40 r/min, adding atomized water into the material by using an atomization sprinkling can in the rotating process to form green pellets, adding outer layer raw material powder with fine particle size when the particle size of most of the green pellets reaches 120-180 mu m, stopping the machine when the particle size of the green pellets reaches 150-380 mu m, and taking out the green pellets to obtain the ceramic composite sand green pellets, wherein the total water addition amount is 15-20% of the total weight of the ceramic composite sand green pellets, and the granulation time is 1-3 h;
(4) screening and grading: sieving the ceramic composite sand green balls obtained by granulation by using a screen to remove the parts with overlarge grain sizes and the parts with undersize grain sizes;
(5) drying: placing the qualified ceramic composite sand green balls in a drying oven for drying until the weight is constant, wherein the drying temperature is 100-200 ℃, and the drying time is 0.5-2 h;
(6) and (3) sintering: sintering the dried ceramic composite sand green balls in a rotary kiln at 1250-1500 ℃ for 1-5 h, and then cooling to room temperature;
(7) scrubbing: placing the sintered ceramic composite sand in scrubbing equipment, and scrubbing for 0.5-2 hours to remove burrs and attached small solid particle powder on the surface of the ceramic composite sand;
(8) screening and grading: and screening the washed ceramic composite sand to obtain finished ceramic composite sand with different granularity specifications.
The preparation method of the artificial spherical ceramic composite sand is characterized in that the structure of the ceramic composite sand is mainly a double-layer structure of 'inner core + outer layer', and the inner core adopts main powder with a larger grain diameter as follows: low grade bauxite and cokeOne or more than two of stone, nickel tailing slag and fly ash, wherein the outer layer adopts main powder with smaller grain size as follows: one or more than two of high-grade flint clay, high-grade bauxite and corundum powder; wherein the grain diameter of the core powder is required to be D50Less than or equal to 25 mu m, and the grain diameter of the powder material at the outer layer is required to be D50Less than or equal to 13 mu m; the main technical indexes of the low-grade bauxite, the low-grade flint clay, the high-grade flint clay and the high-grade bauxite are respectively as follows: al (Al)2O3＜40wt％、Al2O3＜38wt％、Al2O3≥60wt％、Al2O3≥46wt％。
Preferably, in the step (1), the binder in the powder material of the inner core is bentonite, and the bentonite accounts for 5% of the weight of the raw material of the inner core.
In the step (2), the binder in the outer powder is bentonite, and the sintering aid in the outer powder is MgO and anorthite; the powder material of the outer layer comprises the following components in percentage by weight: 80-90% of one or more of high-grade flint clay, high-grade bauxite and corundum powder, 1-5% of bentonite, 1-5% of MgO and 1-10% of anorthite.
The preparation method of the artificial spherical ceramic composite sand preferably comprises 2% of MgO and 10% of anorthite.
The preparation method of the artificial spherical ceramic composite sand comprises the following steps of (2) according to the weight ratio: water: and (3) wet grinding the material at a ratio of 1.5:1:1 for 3-5 h, and taking out.
Preferably, in the step (3), the rotating speed is 30r/min, the total water addition amount is 20% of the total weight of the green ceramic composite sand, and the granulation time is 2 hours.
In the preparation method of the artificial spherical ceramic composite sand, in the step (4), the part with the grain diameter larger than 380 mu m is crushed and then granulated again, and the part with the grain diameter smaller than 109 mu m is directly used for the next granulation process as a primer.
Preferably, in the step (6), the sintering temperature is 1300-1350 ℃, and the sintering time is 3-4 h.
The preparation method of the artificial spherical ceramic composite sand comprises two steps of granulation by a rolling granulation method: firstly, manufacturing an inner core into a sphere structure; and secondly, coating outer layer powder on the surface.
Compared with the prior preparation method and process, the invention has the following advantages and beneficial effects:
1. the preparation method of the ceramic composite sand is to provide a preparation process of the ceramic sand with a double-layer composite structure on the basis of the existing ceramic sand preparation method system, compared with the existing ceramic sand with a single structure, the ceramic composite sand has the advantages that the waste resource is adopted by the inner core of the ceramic composite sand, the waste is recycled, the pollution to the environment is reduced, the outer shell material adopts high-quality raw materials, the performance is improved, a proper amount of sintering aid is added, the refractoriness of the ceramic composite sand (the refractoriness can reach more than 1700 ℃) is improved, the surface appearance is improved, and meanwhile, the sintering temperature is reduced.
2. The bulk density of the ceramic composite sand prepared by the preparation method of the ceramic composite sand is only 1.4-1.6 g/cm3Compared with ceramic sand with a single structure, the ceramic sand has the advantages of further reduced density, excellent performance and good regeneration effect, and can be widely used for producing non-ferrous alloy castings, iron castings and steel castings.
3. The preparation method can realize the successful preparation of the ceramic composite sand with the double-layer structure, the ceramic composite sand prepared by the preparation method not only reduces the consumption of high-performance but expensive raw materials, but also well uses waste resources which are difficult to utilize originally, reduces the production cost while ensuring the service performance of the ceramic sand, and further saves resources and protects the environment. The ceramic composite sand has the advantages of lower density and thermal expansion coefficient, better sphericity, smooth surface, reduced resin addition and gas evolution, higher refractoriness and lower breakage rate.
Drawings
Fig. 1 is a schematic structural diagram of the ceramic composite sand. Wherein, (a) is an outline drawing, and (b) is a cross-sectional drawing.
Detailed Description
The present invention will be described in further detail below with reference to examples.
Example 1:
in the example, the core raw material of the ceramic composite sand is nickel tailing slag powder, the outer layer is bauxite such as second-grade bauxite, and the chemical components are as follows by weight percent: al (Al)2O3：60％，SiO2: 30%, other substances: the balance, the addition of MgO is 1 wt%, the addition of anorthite is 6 wt%, and the requirement of the grain diameter of the core powder is D50Less than or equal to 25 mu m, and the grain diameter of the powder material at the outer layer is required to be D50≤13μm。
The specific preparation process of the ceramic composite sand comprises the following steps:
(1) preparing materials: adding bentonite which accounts for 5 percent of the weight of the powder into the nickel tailing slag powder, putting the powder into a ball mill, performing dry grinding for 2 hours, fully mixing, and taking out the powder as a core raw material for preparing ceramic composite sand;
(2) milling: adding the material of the second-level bauxite powder such as B, bentonite, MgO and anorthite into a ball mill according to the weight ratio of 90:3:1:6, adding water, and mixing the materials in the ball mill according to the weight ratio of ball: water: wet grinding the material at a ratio of 1.5:1:1 for 4h, taking out, drying and crushing the material into particles with the particle size of D50Bauxite powder with the particle size less than or equal to 13 mu m;
(3) and (3) granulation: adding a core raw material of the ceramic composite sand into a round pot type granulator, adjusting the rotating speed to 40r/min, adding atomized water into the material by using an atomization sprinkling can in the rotating process to form green pellets, adding bauxite powder with fine particle size when the particle size of more than 60 wt% of the green pellets reaches about 150 mu m, stopping the machine when the particle size of the green pellets reaches about 212 mu m, and taking out the green pellets to obtain the ceramic composite sand green pellets, wherein the total water addition amount is 15% of the total weight of the ceramic composite sand green pellets, and the granulation time is 1 h;
(4) screening and grading: sieving the granulated ceramic composite sand green balls by using a screen, crushing the part with the particle size of more than 380 mu m, and then granulating again, wherein the part with the particle size of less than 109 mu m is used as a primer to be directly used in the next granulation process;
(5) drying: and (3) placing the qualified ceramic composite sand green balls in a drying oven for drying until the weight is constant, wherein the drying temperature is 150 ℃, and the drying time is 1 h.
(6) And (3) sintering: sintering the dried ceramic composite sand green balls in a rotary kiln at 1250 ℃ for 5h, and then cooling to room temperature;
(7) scrubbing: placing the sintered ceramic composite sand in scrubbing equipment to scrub for 1h, and removing burrs and attached small solid particle powder on the surface of the ceramic composite sand;
(8) screening and grading: and screening the washed ceramic composite sand to obtain finished ceramic composite sand with different granularity specifications.
In the present example, the performance index of the artificial spherical casting sand-ceramic composite sand was measured as follows:
TABLE 1 Performance index of the products of the invention
| Name (R) | Angular coefficient of shape | Degree of refractoriness | Bulk density | Coefficient of thermal expansion | Loss on ignition |
| Ceramic composite sand | Is close to 1 | >1700℃ | 1.40～1.50g/cm3 | 4.5～5.0×10-6/K | <0.1wt％ |
Example 2:
in the example, the core raw material of the ceramic composite sand is fly ash powder, the outer layer is second-level first-level bauxite, and the bauxite comprises the following chemical components in percentage by weight: al (Al)2O3：65％，SiO2: 28%, other substances: the balance, the addition of MgO is 2 wt%, the addition of anorthite is 8 wt%, and the requirement of the grain diameter of the core powder is D50Less than or equal to 25 mu m, and the grain diameter of the powder material at the outer layer is required to be D50≤13μm。
The specific preparation process of the ceramic composite sand comprises the following steps:
(1) preparing materials: adding bentonite into the fly ash powder, wherein the bentonite accounts for 5% of the weight of the powder, putting the powder into a ball mill, performing dry grinding for 2 hours, fully mixing, and taking out the powder as a core raw material for preparing the ceramic composite sand;
(2) milling: adding bauxite powder, bentonite, MgO and anorthite into a ball mill according to the weight ratio of 86:4:2:8, adding water, and mixing the materials in the ball mill according to the weight ratio of: water: wet grinding the material at a ratio of 1.5:1:1 for 4h, taking out, drying and crushing the material into particles with the particle size of D50Bauxite powder with the particle size less than or equal to 13 mu m;
(3) and (3) granulation: adding a core raw material of the ceramic composite sand into a round pot type granulator, adjusting the rotating speed to 35r/min, adding atomized water into the material by using an atomization sprinkling can in the rotating process to form green pellets, adding bauxite powder with fine particle size when the particle size of more than 60 wt% of the green pellets reaches about 150 mu m, stopping the machine when the particle size of the green pellets reaches about 212 mu m, and taking out the green pellets to obtain the ceramic composite sand green pellets, wherein the total water addition amount is 18% of the total weight of the ceramic composite sand green pellets, and the granulation time is 2 hours;
(4) screening and grading: sieving the granulated ceramic composite sand green balls by using a screen, crushing the part with the particle size of more than 380 mu m, and then granulating again, wherein the part with the particle size of less than 109 mu m is used as a primer to be directly used in the next granulation process;
(5) drying: and (3) placing the qualified ceramic composite sand green balls in a drying oven for drying until the weight is constant, wherein the drying temperature is 150 ℃, and the drying time is 1 h.
(6) And (3) sintering: sintering the dried ceramic composite sand green balls in a rotary kiln at 1300 ℃ for 2h, and then cooling to room temperature;
(7) scrubbing: placing the sintered ceramic composite sand in scrubbing equipment to scrub for 1h, and removing burrs and attached small solid particle powder on the surface of the ceramic composite sand;
(8) screening and grading: and screening the washed ceramic composite sand to obtain finished ceramic composite sand with different granularity specifications.
In the present example, the performance index of the artificial spherical casting sand-ceramic composite sand was measured as follows:
TABLE 2 Performance index of the product of the invention
| Name (R) | Angular coefficient of shape | Degree of refractoriness | Bulk density | Coefficient of thermal expansion | Loss on ignition |
| Ceramic composite sand | Is close to 1 | >1750℃ | 1.40～1.50g/cm3 | 4.5～5.0×10-6/K | <0.1wt％ |
Example 3:
in this example, the core material of the ceramic composite sand is low grade (Al)2O3Not more than 45 wt%) bauxite, and the shell is first-grade bauxite, and the chemical components are as follows in percentage by weight: al (Al)2O3：72％，SiO2: 20%, other substances: the balance, the addition of MgO is 2 wt%, the addition of anorthite is 10 wt%, and the requirement of the grain diameter of the core powder is D50Less than or equal to 25 mu m, and the grain diameter of the powder material at the outer layer is required to be D50≤13μm。
The specific preparation process of the ceramic composite sand comprises the following steps:
(1) preparing materials: adding bentonite which accounts for 5 percent of the weight of the powder into the low-grade bauxite powder, putting the low-grade bauxite powder into a ball mill, performing dry grinding for 2 hours, fully mixing, and taking out the bentonite as a core raw material for preparing the ceramic composite sand;
(2) milling: adding the first-grade bauxite powder, bentonite, MgO and anorthite into a ball mill according to the weight ratio of 85:3:2:10, adding water, and mixing the materials in the ball mill according to the weight ratio of: water: wet grinding the material at a ratio of 1.5:1:1 for 4h, taking out, drying and crushing the material into particles with the particle size of D50Bauxite powder with the particle size less than or equal to 13 mu m;
(3) and (3) granulation: adding a core raw material of the ceramic composite sand into a round pot type granulator, adjusting the rotating speed to 30r/min, adding atomized water into the material by using an atomization sprinkling can in the rotating process to form green pellets, adding bauxite powder with fine particle size when the particle size of more than 60 wt% of the green pellets reaches about 150 mu m, stopping the machine when the particle size of the green pellets reaches about 212 mu m, and taking out the green pellets to obtain the ceramic composite sand green pellets, wherein the total water addition amount is 20% of the total weight of the ceramic composite sand green pellets, and the granulation time is 2 hours;
(4) screening and grading: sieving the granulated ceramic sand green balls by using a screen, crushing the part with the particle size of more than 380 mu m, and granulating again, wherein the part with the particle size of less than 109 mu m is used as a primer to be directly used in the next granulation process;
(5) drying: and (3) placing the qualified ceramic composite sand green balls in a drying oven for drying until the weight is constant, wherein the drying temperature is 150 ℃, and the drying time is 1 h.
(6) And (3) sintering: sintering the dried ceramic composite sand green balls in a rotary kiln at 1350 ℃ for 3h, and then cooling to room temperature;
(7) scrubbing: placing the sintered ceramic composite sand in scrubbing equipment to scrub for 1h, and removing burrs and attached small solid particle powder on the surface of the ceramic composite sand;
(8) screening and grading: and screening the washed ceramic composite sand to obtain finished ceramic composite sand with different granularity specifications.
In the present example, the performance index of the artificial spherical casting sand-ceramic composite sand was measured as follows:
TABLE 3 Performance index of the products of the invention
| Name (R) | Angular coefficient of shape | Degree of refractoriness | Bulk density | Coefficient of thermal expansion | Loss on ignition |
| Ceramic composite sand | Is close to 1 | >1800℃ | 1.40～1.50g/cm3 | 4.5～5.0×10-6/K | <0.1wt％ |
Example 4:
in this example, the inner layer of the ceramic composite sand is made of fly ash and low grade (Al)2O3Less than or equal to 38wt percent) flint clay, the shell is special-grade bauxite, and the weight percentage of the chemical components is as follows: al (Al)2O3：80％，SiO2: 15%, other substances: the balance, the addition of MgO is 3 wt%, the addition of anorthite is 10 wt%, and the requirement of the grain diameter of the inner layer powder is D50Less than or equal to 25 mu m, and the grain diameter of the powder material at the outer layer is required to be D50≤13μm。
The specific preparation process of the ceramic composite sand comprises the following steps:
(1) preparing materials: adding bentonite into fly ash and low-grade flint clay powder in a weight ratio of 1:1, wherein the bentonite accounts for 5% of the weight of the powder, putting the mixture into a ball mill, performing dry grinding for 2 hours, fully mixing, and taking out the mixture as a core raw material for preparing ceramic composite sand;
(2) milling: adding special-grade bauxite powder, bentonite, MgO and anorthite into a ball mill according to the weight ratio of 82:5:3:10, adding water, and mixing the materials in the ball mill according to the weight ratio of ball: water: wet grinding the material at a ratio of 1.5:1:1 for 4h, taking out, drying and crushing the material into particles with the particle size of D50Bauxite powder with the particle size less than or equal to 13 mu m;
(3) and (3) granulation: adding a core raw material of the ceramic composite sand into a round pot type granulator, adjusting the rotating speed to 35r/min, adding atomized water into the material by using an atomization sprinkling can in the rotating process to form green pellets, adding bauxite powder with fine particle size when the particle size of more than 60 wt% of the green pellets reaches about 150 mu m, stopping the machine when the particle size of the green pellets reaches about 212 mu m, and taking out the green pellets to obtain the ceramic composite sand green pellets, wherein the total water addition amount is 25% of the total weight of the ceramic composite sand green pellets, and the granulation time is 2 hours;
(4) screening and grading: sieving the granulated ceramic composite sand green balls by using a screen, crushing the part with the particle size of more than 380 mu m, and then granulating again, wherein the part with the particle size of less than 109 mu m is used as a primer to be directly used in the next granulation process;
(5) drying: and (3) placing the qualified ceramic composite sand green balls in a drying oven for drying until the weight is constant, wherein the drying temperature is 150 ℃, and the drying time is 1 h.
(6) And (3) sintering: sintering the dried ceramic composite sand green balls in a rotary kiln at 1400 ℃ for 4h, and then cooling to room temperature;
(7) scrubbing: placing the sintered ceramic composite sand in scrubbing equipment to scrub for 1h, and removing burrs and attached small solid particle powder on the surface of the ceramic composite sand;
(8) screening and grading: and screening the washed ceramic composite sand to obtain finished ceramic composite sand with different granularity specifications.
In the present example, the performance index of the artificial spherical casting sand-ceramic composite sand was measured as follows:
TABLE 4 Performance index of the products of the invention
| Name (R) | Angular coefficient of shape | Degree of refractoriness | Bulk density | Coefficient of thermal expansion | Loss on ignition |
| Ceramic composite sand | Is close to 1 | >1840℃ | 1.40～1.50g/cm3 | 4.5～5.0×10-6/K | <0.1wt％ |
As shown in figure 1, the structure of the ceramic composite sand is mainly divided into an inner layer and an outer layer, and the inner core has a coarse grain diameter (D)50Less than or equal to 25 mu m), low-grade flint clay or bauxite, nickel tailing slag or fly ash and other powder with common performance, and the outer layer is finer grain diameter (D)50Not more than 13 mu m) of high-grade flint clay or bauxite, corundum powder and other powder materials with excellent performance, and a proper amount of sintering aids such as MgO, anorthite and the like are added to reduce the sintering temperature of the ceramic sand and improve the surface appearance of the ceramic sand, thereby ensuring the performance of the ceramic sand and simultaneously considering the economy. The ceramic composite sand is prepared by adopting the preparation process of batching, ball milling, granulating, sintering and screening grading, has few open holes, good surface smoothness, high refractoriness and low breakage rate, and can be widely used for producing nonferrous alloy castings, iron castings and steel castings. The double-layer structure design of the ceramic composite sand not only has better performance than the ceramic sand with a single structure, but also reduces the cost and gives consideration to the economy.
The above description is only an embodiment of the present invention, and is not intended to limit the present invention, and all technical solutions obtained by equivalent replacement or equivalent transformation fall within the protection scope of the present invention.
Claims (7)
1. A preparation method of artificial spherical ceramic composite sand is characterized in that granulation is carried out by adopting a rolling granulation method, and sintering is carried out by a rotary kiln, and the preparation steps are as follows:
(1) preparing materials: adding a binder which accounts for 3-5% of the weight of the core raw material into the core raw material, putting the core raw material into a ball mill, carrying out dry grinding for 1-3 h, fully mixing, and taking out the mixture to serve as the core raw material for preparing the ceramic composite sand;
(2) milling: the outer layer is treatedAdding the material powder, the binder and the sintering aid into a ball mill, adding water, and wet-milling to D50Taking out the powder with the particle size less than or equal to 13 mu m, drying and crushing the powder to be used as an outer layer raw material for preparing the ceramic composite sand;
(3) and (3) granulation: adding a core raw material of the ceramic composite sand into a round pot type granulator, adjusting the rotating speed to be 20-40 r/min, adding atomized water into the material by using an atomization sprinkling can in the rotating process to form green pellets, adding outer layer raw material powder with fine particle size when the particle size of most of the green pellets reaches 120-180 mu m, stopping the machine when the particle size of the green pellets reaches 150-380 mu m, and taking out the green pellets to obtain the ceramic composite sand green pellets, wherein the total water addition amount is 15-20% of the total weight of the ceramic composite sand green pellets, and the granulation time is 1-3 h;
(4) screening and grading: sieving the ceramic composite sand green balls obtained by granulation by using a screen to remove the parts with overlarge grain sizes and the parts with undersize grain sizes;
(5) drying: placing the qualified ceramic composite sand green balls in a drying oven for drying until the weight is constant, wherein the drying temperature is 100-200 ℃, and the drying time is 0.5-2 h;
(6) and (3) sintering: sintering the dried ceramic composite sand green balls in a rotary kiln at 1250-1500 ℃ for 1-5 h, and then cooling to room temperature;
(7) scrubbing: placing the sintered ceramic composite sand in scrubbing equipment, and scrubbing for 0.5-2 hours to remove burrs and attached small solid particle powder on the surface of the ceramic composite sand;
(8) screening and grading: screening the washed ceramic composite sand to obtain finished ceramic composite sand with different granularity specifications;
the structure of the ceramic composite sand is mainly a double-layer structure of 'inner core + outer layer', and the inner core adopts main powder with a coarser grain diameter as follows: one or more than two of low-grade bauxite, low-grade flint clay, nickel tailing slag and fly ash, wherein the outer layer adopts main powder with smaller grain size as follows: one or more than two of high-grade flint clay, high-grade bauxite and corundum powder; wherein the grain diameter of the core powder is required to be D50Less than or equal to 25 mu m, and the grain diameter of the powder material at the outer layer is required to be D50≤13μm; the main technical indexes of the low-grade bauxite, the low-grade flint clay, the high-grade flint clay and the high-grade bauxite are respectively as follows: al (Al)2O3＜40wt%、Al2O3＜38wt%、Al2O3≥60wt%、Al2O3≥46wt%；
In the step (1), the binder in the core powder is bentonite, and the bentonite accounts for 5% of the weight of the core raw material;
in the step (2), the binder in the outer layer powder is bentonite, and the sintering aid in the outer layer powder is MgO and anorthite; the powder material of the outer layer comprises the following components in percentage by weight: 80-90% of one or more of high-grade flint clay, high-grade bauxite and corundum powder, 1-5% of bentonite, 1-5% of MgO and 1-10% of anorthite.
2. The method for preparing artificial spherical ceramic composite sand according to claim 1, wherein MgO is 2% and anorthite is 10%.
3. The method for preparing artificial spherical ceramic composite sand according to claim 1, wherein in the step (2), the weight ratio of the balls: water: the material =1.5:1:1, and is taken out after being wet-milled for 3-5 h.
4. The method for preparing the artificial spherical ceramic composite sand according to claim 1, wherein in the step (3), the rotating speed is 30r/min, the total water addition amount is 20% of the total weight of the green ceramic composite sand, and the granulation time is 2 hours.
5. The method for preparing artificial spherical ceramic composite sand according to claim 1, wherein in the step (4), the part with the particle size of more than 380 μm is crushed and then re-granulated, and the part with the particle size of less than 109 μm is directly used as a 'primer' for the next granulation process.
6. The method for preparing the artificial spherical ceramic composite sand according to claim 1, wherein in the step (6), the sintering temperature is 1300-1350 ℃ and the sintering time is 3-4 h.
7. The method for preparing artificial spherical ceramic composite sand according to claim 1, wherein the granulation by the rolling granulation method is divided into two steps: firstly, manufacturing an inner core into a sphere structure; and secondly, coating outer layer powder on the surface.
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