CN110216777B - Production process of dry pressing ceramic tile blank - Google Patents
Production process of dry pressing ceramic tile blank Download PDFInfo
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- CN110216777B CN110216777B CN201910534221.XA CN201910534221A CN110216777B CN 110216777 B CN110216777 B CN 110216777B CN 201910534221 A CN201910534221 A CN 201910534221A CN 110216777 B CN110216777 B CN 110216777B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/02—Conditioning the material prior to shaping
- B28B17/026—Conditioning ceramic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
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- Press-Shaping Or Shaping Using Conveyers (AREA)
- Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)
Abstract
The invention discloses a production process of a dry-pressing ceramic tile blank, which comprises the following steps of S1, feeding, stacking and homogenizing; s2, blending; s3, grinding; s4, storing and homogenizing; s5, removing impurities and iron; s6, granulating; s7, storing the material particles; s8, pressing the material particles into a green body; and S9, drying the blank. According to the production process of the dry-pressing formed ceramic tile blank, the granules granulated by the dry powder making process have uniform internal and external moisture, so that the process that the granules are aged to achieve uniform internal and external moisture in the traditional wet granulation process is saved; meanwhile, through the homogenization in the factory, the storage and homogenization of the dry powder and the detection and feedback of the weight components, the problem of homogenization of various domestic ceramic raw materials is solved, and the balance and stability of the raw materials in the subsequent production link are ensured; and the cross-flow granulator is adopted to realize the dual-fluid cross-flow nucleation and then granulate by a multi-stage granulating disc, so that the sphericity and the fluidity of dry-method granulated granules are improved, and the problem of yield reduction caused by potential unsmooth flowing in the subsequent green pressing link is reduced.
Description
Technical Field
The invention relates to a ceramic tile production technology, in particular to a production process of a ceramic tile blank formed by dry pressing.
Background
The ceramic tile is a thin plate product which is made of clay and other inorganic non-metallic raw materials and used for covering wall surfaces and floors, and is formed by extruding or dry-pressing the raw materials at room temperature, wherein the extrusion forming generally adopts a wet-process powder-making process, and the dry-pressing forming generally adopts a dry-process powder-making process;
wherein, the raw material milling equipment of the wet powder process adopts an intermittent or continuous wet ball milling method, the water content of the ground slurry reaches about 35 percent, the ground slurry is dried and granulated by a spray drying tower, the water content of the granulated material is 5 to 7 percent, and then the granulated material enters an ageing bin to be aged for 24 to 36 hours and then enters a press molding machine to be pressed into a green body;
the raw material grinding equipment of the dry powder process adopts dry grinding equipment (such as a vertical mill, a Raymond mill and the like), the ground dry powder is granulated by granulation equipment (a disc granulator, a high-speed mechanical stirring granulator) by a granulation method, water is used as a binder, the dry powder ground by the dry method is agglomerated into granules with the water content of below 12 percent, the granules are dried by a dryer until the water content is about 7 percent, and then the granules enter a storage bin for storing for 6 to 24 hours and then enter a molding press to be pressed into blanks;
the dry pressed brick is formed by pressing mixed powder in a mould under certain pressure, and has the characteristics of high forming speed, high yield and high strength of semi-finished products, the comprehensive skill effect of the dry powder making process is more than 67% compared with the traditional wet powder making process, the number of operators in a raw material workshop can be reduced by 50% or more, the land used in the raw material workshop can be reduced by 60%, the exhaust emission is reduced by more than 80%, water is saved by 80%, electricity is saved by 50%, fuel is saved by 80%, and the dry pressed brick does not use pebbles, ball linings and water dissolving agents, so that the dry pressed brick can be widely adopted by the ceramic industry instead of the wet powder making process in the foreseeable future.
However, according to research, the global ceramic tile yield in 2017 reaches about 144 hundred million square meters, wherein China is the largest ceramic tile producing country (110 million square meters), and at present, China also has 1,452 ceramic enterprises and 3,621 production lines besides Beijing, Tianjin, hong Kong and Australia platforms, the daily ceramic tile yield is 4503.6 ten thousand square meters, but almost one hundred percent adopts the traditional wet process powder making process, and each square meter of ceramic tile needs about 20kg of raw materials, so the national ceramic raw material treatment amount is about 2 million tons per year, and the wet process has the characteristics of long forming time, slow speed and the like, thereby greatly reducing the production efficiency.
Meanwhile, as more than ten raw material ingredients exist in China, the traditional dry powder process has the following problems in production:
1) the homogenization of various raw materials is difficult, the foreign raw materials are only 2-3, but the domestic raw material ingredients are more than ten, the raw material components are extremely unstable, and the requirement on the stability of the formula is very high;
2) the accuracy of continuous metering and the accuracy of batching of more than ten raw materials in dry production are difficult to ensure;
3) the research of a system process is lacked, only granulation equipment for dry milling is researched, and series links of iron removal, impurity removal, feeding of a press, grinding tools of the press, a system of the press, blank drying and the like brought by the change of the milling process and the granulation process are not researched;
4) the mechanical stirring high-speed granulation method has the advantages that the hardness of granules is not uniform, the density of a green body after the green body is pressed is inconsistent, particularly, when ceramic tiles (porcelain tiles and stoneware tiles) with higher ceramic degree are produced, the subsequent defects are more obvious, the reduction range of the work merit rate and the wet production is too large, and the whole cost is not reduced and reversely increased;
5) the granules prepared by the suspended aggregate method ceramsite equipment have uniform hardness, but poor sphericity, reduced fluidity by more than 30 percent, serious pulverization after storage, further reduced fluidity and serious influence on the yield of a press.
Disclosure of Invention
The invention aims to provide a production process of a dry-pressing formed ceramic tile blank, wherein the inside and outside moisture of granules granulated by a dry powder making process is uniform, so that the procedure that the inside and outside moisture of the traditional wet granulation granules is uniform by ageing is saved; meanwhile, through the homogenization in the factory, the storage and homogenization of the dry powder and the detection and feedback of the weight components, the problem of homogenization of various domestic ceramic raw materials is solved, and the balance and stability of the raw materials in the subsequent production link are ensured; and the cross-flow granulator is adopted to realize the dual-fluid cross-flow nucleation and then granulate by a multi-stage granulating disc, so that the sphericity and the fluidity of dry-method granulated granules are improved, and the problem of yield reduction caused by potential unsmooth flowing in the subsequent green pressing link is reduced.
In order to realize the aim, the invention provides a production process of a dry-pressing ceramic tile blank, which comprises the following steps:
s1 stockpiling and homogenizing feed
Firstly, impurities in ceramic raw materials are pre-screened, lumps in the ceramic raw materials are broken, then the ceramic raw materials are stacked in a stacking area through a side type stacker, the materials are taken and homogenized from the stacking area through a side type scraper blade reclaimer, the ceramic raw materials are scraped to a rubber belt conveyor, the rubber belt conveyor conveys the ceramic raw materials to the top end of a storage bin, and the ceramic raw materials are discharged into the corresponding storage bin according to the flowability of the ceramic raw materials;
s2, preparing the ingredients
The ceramic raw materials are conveyed to a material grinding conveyor belt and are conveyed to the next procedure after being mixed by a conveying mechanism arranged at the bottom of a storage bin, the components of the mixed ceramic raw materials are detected by a material analyzer arranged on the material grinding conveyor belt, the detected components are transmitted to a central controller, the central controller compares the difference between the detected component values and the set component values and controls the motor rotating speed of the quantitative feeder according to the difference, and after the motor rotating speed is adjusted, the quantitative feeder feeds weighing signals back to the central controller through a weighing signal receiver until the detected component values are equal to the set component values;
s3, grinding
Conveying the mixed ceramic raw materials to a hopper lifter through a material grinding conveying belt, lifting the ceramic raw materials to the interior of a combined type powder concentrator through a feed inlet by the hopper lifter, drying the ceramic raw materials through a hot air port arranged at the feed inlet, falling the coarse-grain-diameter ceramic raw materials dried by the combined type powder concentrator into a roller press to be ground into dry powder, lifting the dry powder to the interior of the combined type powder concentrator again through the hopper lifter until the grain diameter of the ceramic raw materials reaches the set value of the combined type powder concentrator, pumping the ceramic raw materials to a bag type dust collector through the combined type powder concentrator, falling the bag type dust collector into a spiral conveyor, and conveying the ceramic raw materials to the next process through the spiral conveyor;
s4, storing and homogenizing dry powder
The ceramic raw materials conveyed by the screw conveyor are received by the air conveying chute, the ceramic raw materials are controlled by an electric throttle valve arranged at the discharge port of the air conveying chute to circularly feed the ceramic raw materials into the four homogenizing warehouses, the feeding time of the four homogenizing warehouses is controlled to be the same by the electric throttle valve, after the ceramic raw materials enter the homogenizing warehouses, three aeration points of thirty aeration points in five aeration areas evenly distributed at the bottom of the homogenizing warehouses are sequentially opened at the same time for homogenization, after the homogenization is finished, the unloading is started at the same time by an unloading electromagnetic valve arranged at the bottom of each aeration area, the opening time of each unloading electromagnetic valve is controlled to be sequentially reduced in one aeration period, and then the unloaded ceramic raw materials are conveyed to the next working procedure by the air conveying chute;
s5, removing impurities and iron
The ceramic raw material is subjected to impurity removal and iron removal through a strong magnetic rod type iron remover and a medium-frequency negative-pressure material distribution sieve in sequence, and then the next procedure is carried out;
s6, granulating
Conveying the ceramic raw materials to the inside of a cross-flow granulator through a hopper lifter and a dry powder accelerating tube in sequence to form a mother core, then falling into a granulation disc to perform rolling granulation, drying through a fluidized dryer, then entering a crushing and screening compound machine for screening, crushing and then entering the next process;
s7, storing the material particles
The ceramic raw materials sequentially pass through a storage bin and a suspension type vibration discharging cone arranged at the bottom end of the storage bin to fall onto a quantitative feeder, and then are sieved and crushed by a crushing and screening compound machine again to enter the next process;
s8, pressing the material particles into a green body
The ceramic raw material enters a press die to be pressed into a blank body and then enters the next working procedure;
s9, drying the green body
And drying the green body by a wide body type dryer.
Preferably, in step S1, the impurities in the ceramic raw material are pre-screened by a wave roller screen, and the agglomerates in the ceramic raw material are crushed by a hammer crusher.
Preferably, the ceramic raw materials in step S2 include paste-like ceramic raw materials, first ceramic raw materials having a powder flowability FF value of less than 2, second ceramic raw materials having a powder flowability FF value of 2 or more and less than 4, third ceramic raw materials having a powder flowability FF value of 4 or more and less than 10, and fourth ceramic raw materials having a powder flowability FF value of 10 or more, and the bins include a first bin, a second bin, a third bin, a fourth bin, and a fifth bin.
Preferably, in step S2, the transfer mechanism includes a double-shaft screw feeder disposed at the discharge port of the first bin, a plate feeder disposed at the discharge port of the second bin, a first bar valve disposed at the discharge port of the third bin, an activation cone disposed at the discharge port of the fourth bin, and a second bar valve disposed at the discharge port of the fifth bin.
Preferably, in step S3, the combined powder concentrator includes a bamboo hat type static powder concentrator and a dynamic powder concentrator, which are sequentially arranged from top to bottom, a discharge port of the bamboo hat type static powder concentrator is communicated with a feed port of the dynamic powder concentrator, and a discharge port of the dynamic powder concentrator is communicated with a feed port of the roller press.
Preferably, the on-off of the thirty inflation points in the step S4 are controlled by thirty inflation discharge solenoid valves respectively.
Preferably, in step S5, the ceramic raw material is further sequentially fed into a closed constant feeder through a powder hopper, an activated discharge cone and a rotary discharger before being fed into the strong magnetic rod type iron remover for metering.
Preferably, two spray guns are crosswise arranged below the feed inlet of the cross-flow granulator in the step S6, and the granulation disc comprises a first-stage granulation disc, a second-stage granulation disc and a third-stage granulation disc which are sequentially arranged from top to bottom.
Preferably, the cloth plate of the press die in step S8 is herringbone.
Therefore, the invention has the following advantages:
1. the granules after being granulated by the dry powder making process have uniform internal and external moisture, so that the process that the conventional wet granulation granules need to be aged to achieve uniform internal and external moisture is saved, a new process of directly pressing the blanks without aging is adopted, a large number of aging bins are saved, and the system investment is reduced;
2. through the homogenization in the factory, the storage and homogenization of the dry powder and the detection and feedback of the weight components, the homogenization problem of various domestic ceramic raw materials is solved, and the balance and stability of the raw materials in the subsequent production link are ensured;
3. the cross-flow granulator is adopted to realize the dual-fluid cross-flow nucleation and then granulation is carried out by a multi-stage granulation disc, so that the sphericity and the fluidity of dry granulation granules are improved, and the problem of yield reduction caused by potential unsmooth flow in the subsequent green pressing link is solved;
4. the operation workers in the raw material workshop can be reduced by 50 percent or more, the land consumption of the raw material workshop can be reduced by 60 percent, the exhaust emission is reduced by more than 80 percent, the water is saved by 80 percent, the electricity is saved by 50 percent, and the fuel is saved by 80 percent.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
FIG. 1 is a flow chart of a process for producing a green body of a dry-pressed ceramic tile according to an embodiment of the present invention;
FIG. 2 is a flowchart of the process S1 of the production process of the dry-pressed ceramic tile blank according to the embodiment of the present invention;
FIG. 3 is a flowchart of the process S2 of the production process of the dry-pressed ceramic tile blank according to the embodiment of the present invention;
FIG. 4 is a flowchart of the process S3 of the production process of the dry-pressed ceramic tile blank according to the embodiment of the invention;
FIG. 5 is a flowchart of the process S4 of the production process of the dry-pressed ceramic tile blank according to the embodiment of the present invention;
FIG. 6 is a flowchart of the process S5 of the production process of the dry-pressed ceramic tile blank according to the embodiment of the present invention;
FIG. 7 is a flowchart of the process S6 of the production process of the dry-pressed ceramic tile blank according to the embodiment of the present invention;
FIG. 8 is a flowchart of the process S7 of the production process of the dry-pressed ceramic tile blank according to the embodiment of the present invention;
fig. 9 is a flowchart of the process of S8 of the process for producing a green body of a dry-pressed ceramic tile according to the embodiment of the present invention;
fig. 10 is a flowchart of the process of S9 in the production process of the dry-pressed ceramic tile blank according to the embodiment of the present invention.
Reference numerals: 1. a wave roller screen; 2. a hammer crusher; 3. a belt conveyor; 4. a side stacker; 5. a side scraper reclaimer; 6. a first storage bin; 7. a second storage bin; 8. a third storage bin; 9. a fourth storage bin; 10. a fifth storage bin; 11. a discharge trolley; 12. a constant feeder; 13. a hopper elevator; 14. a bamboo hat type static powder concentrator; 15. a dynamic powder concentrator; 16. a roll squeezer; 17. a bag type dust collector; 18. a screw conveyor; 19. a homogenization silo; 20. an electric throttle valve; 21. an air delivery chute; 22. an inflation zone; 23. a discharge electromagnetic valve; 24. a strong magnetic rod type iron remover; 25. medium-frequency negative-pressure material distribution sieve; 26. a dry powder acceleration tube; 27. a cross-flow granulator; 28. a granulation disc; 29. a fluidized dryer; 30. a crushing and screening compound machine; 31. a material storage bin; 32. a suspension type vibration discharging cone; 33. a press; 34. wide body type drying machine.
Detailed Description
The present invention will be further described with reference to the accompanying drawings, and it should be noted that the present embodiment is based on the technical solution, and the detailed implementation and the specific operation process are provided, but the protection scope of the present invention is not limited to the present embodiment.
Fig. 1 is a flowchart of a dry-press forming ceramic tile green body production process according to an embodiment of the present invention, fig. 2 is a flowchart of S1 of the dry-press forming ceramic tile green body production process according to the embodiment of the present invention, fig. 3 is a flowchart of S2 of the dry-press forming ceramic tile green body production process according to the embodiment of the present invention, fig. 4 is a flowchart of S3 of the dry-press forming ceramic tile green body production process according to the embodiment of the present invention, fig. 5 is a flowchart of S4 of the dry-press forming ceramic tile green body production process according to the embodiment of the present invention, fig. 6 is a flowchart of S5 of the dry-press forming ceramic tile green body production process according to the embodiment of the present invention, fig. 7 is a flowchart of S6 of the dry-press forming ceramic tile green body production process according to the embodiment of the present invention, fig. 8 is a flowchart of S7 of the dry-press forming ceramic tile green body production process according to the embodiment of the present invention, fig. 9 is a flow layout diagram of S8 of a dry-pressed ceramic tile green body production process according to an embodiment of the present invention, and fig. 10 is a flow layout diagram of S9 of a dry-pressed ceramic tile green body production process according to an embodiment of the present invention, as shown in fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, fig. 8, fig. 9 and fig. 10, the process of the present invention includes the following steps:
s1 stockpiling and homogenizing feed
Firstly, impurities in ceramic raw materials are pre-screened, lumps in the ceramic raw materials are broken, then the ceramic raw materials are stacked in a stacking area through a side type stacker, the materials are taken and homogenized from the stacking area through a side type scraper blade reclaimer, the ceramic raw materials are scraped to a rubber belt conveyor, the rubber belt conveyor conveys the ceramic raw materials to the top end of a storage bin, and the ceramic raw materials are discharged into the corresponding storage bin according to the flowability of the ceramic raw materials;
in the step S1, impurities in the ceramic raw material are pre-screened through a wave roller screen, lumps in the ceramic raw material are crushed through a butt crusher, and the ceramic raw material is discharged into a corresponding bin through a discharge trolley arranged on a rubber belt conveyor and corresponding to a bin feeding hole, so that a large amount of labor force is saved;
and step S1, the rotating arm of the side type stacker is controlled to rotate to stack materials, then the materials are scraped by the side type scraper reclaimer, and the primary homogenization of the ceramic raw materials in the process of stacking and reclaiming in the factory is realized.
S2, preparing the ingredients
The ceramic raw materials are conveyed to a material grinding conveyor belt by a conveying mechanism arranged at the bottom of a storage bin and are conveyed to the next procedure after being mixed, the components of the mixed ceramic raw materials are detected by a material analyzer arranged on the material grinding conveyor belt, the detected components are transmitted to a central controller, the central controller compares the difference between the detected component values and the set component values and controls the motor rotating speed of the quantitative feeder according to the difference, after the motor rotating speed is adjusted, a weighing signal is fed back to the central controller by the quantitative feeder through a weighing signal receiver until the detected component values are equal to the set component values, compared with the traditional regulation control of a hysteresis mode (the control mode is grinding tail material taking, sample conveying, sample preparation, artificial chemical analysis, control and adjustment of a batching scale, the analysis mode is seriously lagged, generally, the time lags by 6-24 hours), the material analyzer can detect chemical components (such as CaO, SiO2, Al2O3, Fe2O3, MgO, NaO, K2O, SO3 and the like) of the in-and-out grinding mixture in 1-5 minutes on line, and then the material feeding proportion of each raw material is adjusted in real time through a central controller, SO that the proportion of SiO2, Al2O3, NaO and K2O of the primary grinding ceramic raw material is basically close to a set value, and the accuracy of the dry powder-making raw material proportioning is ensured;
in the step S2, the ceramic raw materials include a paste-like ceramic raw material, a first ceramic raw material having a powder fluidity FF value of less than 2, a second ceramic raw material having a powder fluidity FF value of 2 or more and less than 4, a third ceramic raw material having a powder fluidity FF value of 4 or more and less than 10, and a fourth ceramic raw material having a powder fluidity FF value of 10 or more, and the bins correspondingly include a first bin, a second bin, a third bin, a fourth bin, and a fifth bin; in the step S2, the transfer mechanism includes a double-shaft screw feeder disposed at the discharge port of the first bunker, a plate feeder disposed at the discharge port of the second bunker, a first bar valve disposed at the discharge port of the third bunker, an activation cone disposed at the discharge port of the fourth bunker, and a second bar valve disposed at the discharge port of the fifth bunker;
the domestic dry-pressing ceramic tile raw material types are generally classified as follows: the ceramic raw material comprises a plastic clay raw material, a non-plastic quartz (barren raw material) and a flux raw material, wherein main minerals in the clay comprise kaolinite, montmorillonite, illite (hydromica) and a small part of allophane, and the proportion of the clay minerals in the ceramic raw material is the largest; the quartz raw materials mainly comprise vein quartz, sandstone, quartzite and quartz sand; the flux is mainly prepared from feldspar, calcite and talcum; as the clay raw materials are used as plastic raw materials, certain consolidation strength can be generated after the clay raw materials are subjected to material pressing in the storage bin, the mobility is deteriorated after consolidation, unsmooth discharging, intermittent discharging and uneven discharging can be generated at the bin outlet, and further the accuracy of continuous batching can not be ensured, different bins are arranged according to the flow function aiming at the ceramic raw materials with different mobilities;
specifically, the paste-shaped ceramic raw material comprises paste-shaped materials such as polishing mud and high-moisture black mud generated in a ceramic tile polishing link, the corresponding bin wall of the first bin is vertically arranged at 90 degrees, the discharge port of the first bin is consistent with the feed port of the double-shaft screw feeder, bridging in the bin can be prevented, meanwhile, the double-shaft screw feeder is driven by a hydraulic power pack, constant torque can be provided when the quantitative feeder is fed, compared with the defects of the traditional motor drive (the torque is in wavy change, once the characteristics of the materials are changed, torque increase must be realized by increasing the rotating speed, and the torque of a hydraulic motor with the same power can be achieved only under the condition of one rotating speed during motor drive, once the rotating speed is exceeded, the torque rapidly decreases, the motor superflow is probably caused, the motor jumps and stops), constant torque can be provided when the characteristics of the materials are changed by adopting the hydraulic drive, the operation is more stable and reliable; the second storage bin body corresponding to the ceramic raw material with the powder mobility FF value smaller than 2 is cylindrical, and the bin opening is in a step shape; the length of a bin opening of a third bin corresponding to the second ceramic raw material with the powder fluidity FF value of more than or equal to 2 and less than 4 is the same as the diameter of the bin body, the bin wall is 90 degrees, the bin opening is funnel-shaped, the distance between the bin opening and the bin wall is more than or equal to 75 degrees, and an activated discharge cone is arranged at a bin opening of a fourth bin corresponding to the third ceramic raw material with the powder fluidity FF value of more than or equal to 4 and less than 10; the bottom of a fifth storage bin corresponding to four types of ceramic raw materials with the powder mobility FF value of more than or equal to 10 is of a conical structure, so that the materials can be prevented from bridging in the flowing process, and a suspension type vibration discharging cone is arranged at the bottom of the conical structure, so that the feeding continuity can be ensured; chain plate conveyors are arranged at the discharge holes of the third bin, the fourth bin and the fifth bin, so that the conveyor has the advantages of high rigidity, capability of bearing larger material pressure in the bins and the like, and meanwhile, the chain plates are arranged on the surfaces of the conveyor, so that materials in the bins can be taken out of the bins, and the problems of insufficient strength of a carrier roller during metering of a belt conveyor and slippage of the belt during material taking are solved;
s3, grinding
Conveying the mixed ceramic raw materials to a hopper lifter through a material grinding conveying belt, lifting the ceramic raw materials to the interior of a combined type powder concentrator through a feed inlet by the hopper lifter, drying the ceramic raw materials through a hot air port arranged at the feed inlet, falling the coarse-grain-diameter ceramic raw materials dried by the combined type powder concentrator into a roller press to be ground into dry powder, lifting the dry powder to the interior of the combined type powder concentrator again through the hopper lifter until the grain diameter of the ceramic raw materials reaches the set value of the combined type powder concentrator, pumping the ceramic raw materials to a bag type dust collector through the combined type powder concentrator, falling the bag type dust collector into a spiral conveyor, and conveying the ceramic raw materials to the next process through the spiral conveyor;
the combined powder concentrator in the step S3 comprises a bamboo hat type static powder concentrator and a dynamic powder concentrator which are sequentially arranged from top to bottom, wherein a discharge hole of the bamboo hat type static powder concentrator is communicated with a feed inlet of the dynamic powder concentrator, and a discharge hole of the dynamic powder concentrator is communicated with a feed inlet of the roller press;
has the following advantages:
the material is lifted by the lifter, and compared with the traditional vertical mill for lifting the material by airflow, the vertical mill has the advantages that the ventilation resistance is lower, and the power consumption of a fan is lower;
the combined type powder concentrator is provided with a hot air inlet near the position of the feed inlet, so that high-humidity materials can be dried in time, the problem of material bonding is solved, and meanwhile, the strong magnetic plate type iron remover on the lower side of the conical part of the bamboo hat type static powder concentrator can remove magnetic iron (simple substance iron and ferroferric oxide) in the dried materials and further protect the roll surface of the roller press from being damaged.
S4, storing and homogenizing dry powder
The ceramic raw materials conveyed by the screw conveyor are received by the air conveying chute, the ceramic raw materials are controlled by an electric throttle valve arranged at the discharge port of the air conveying chute to circularly feed the ceramic raw materials into the four homogenizing warehouses, the feeding time of the four homogenizing warehouses is controlled to be the same by the electric throttle valve, after the ceramic raw materials enter the homogenizing warehouses, three aeration points of thirty aeration points in five aeration areas evenly distributed at the bottom of the homogenizing warehouses are sequentially opened at the same time for homogenization, after the homogenization is finished, the unloading is started at the same time by an unloading electromagnetic valve arranged at the bottom of each aeration area, the opening time of each unloading electromagnetic valve is controlled to be sequentially reduced in one aeration period, and then the unloaded ceramic raw materials are conveyed to the next working procedure by the air conveying chute;
the opening and closing of the thirty inflation points in the step S4 are respectively controlled by thirty inflation discharging electromagnetic valves;
the cutting of the dry powder layer is realized through the control, and the aeration area arranged at the bottom of the homogenizing warehouse can effectively mix the dry powder at the lower position in the warehouse; meanwhile, the opening time of the discharging electromagnetic valve is controlled to be reduced in sequence, so that the dry powder retention time is different, the dry powder distribution of the homogenizing chamber entering 5 aeration areas is improved, the retention time is different, the material layer entering the homogenizing chamber in any assumed time is broken due to the fact that the dry powder moves downwards, any assumed material layer is mixed by a large amount of dry powder with different chemical components, the irregular change of the chemical components of the dry powder is greatly weakened, and the dry powder with balanced stability is obtained.
S5, removing impurities and iron
The ceramic raw material is subjected to impurity removal and iron removal through a strong magnetic rod type iron remover and a medium-frequency negative-pressure material distribution sieve in sequence, and then the next procedure is carried out;
in step S5, the ceramic raw material is fed into a closed constant feeder for metering through a powder hopper, an activated discharging cone and a rotary discharger in sequence before entering a strong magnetic rod type iron remover.
S6, granulating
Conveying the ceramic raw materials to the inside of a cross-flow granulator through a hopper lifter and a dry powder accelerating tube in sequence to form a mother core, then falling into a granulation disc to perform rolling granulation, drying through a fluidized dryer, then entering a crushing and screening compound machine for screening, crushing and then entering the next process;
two spray guns are arranged below the feed inlet of the cross-flow granulator in the step S6 in a cross mode, and the granulation disc comprises a first-stage granulation disc, a second-stage granulation disc and a third-stage granulation disc which are sequentially arranged from top to bottom;
the cross-flow granulator has the following advantages:
1. the powder is accelerated by a dry powder accelerating tube, and the accelerated dry powder is dispersed after colliding and decelerating with a three-layer disperser arranged at the top of the granulator, so that the dry powder can be uniformly distributed in a hemispherical upper shell of the granulator;
2. two spray guns are arranged below a feed inlet of the cross-flow granulator in a cross way, and spray heads of the spray guns are upward, so that sprayed atomized water or a solution of a particle assistant and dry powder sprayed from the upper part can flow in a cross collision way to form a mother nucleus;
3. the three-stage granulating disk is adopted below the granulating machine, and granules falling to the granulating disk are rounded and strengthened, so that the sphericity and strength of the granules are increased.
S7, storing the material particles
The ceramic raw materials sequentially pass through a storage bin and a suspension type vibration discharging cone arranged at the bottom end of the storage bin to fall onto a quantitative feeder, and then are sieved and crushed by a crushing and screening compound machine again to enter the next process;
the storage bin has the following advantages:
1. the storage bin is large in diameter and low in height, and is provided with double outlets, so that bin pressure is reduced, and the problem of agglomeration of the aggregates under the bin pressure can be solved;
2. the vibration activation blanking cones are respectively arranged at the double outlets, so that the problems of relatively poor flowability of the granules, unsmooth and intermittent discharging are solved.
Aiming at the characteristic that aggregate particles are easy to form powder balls by an aggregate method, a screening and crushing process suitable for storing the aggregate particles after dry pressing ceramic tile raw material granulation and then feeding the aggregate particles into a press is developed, the requirement of the press on the uniformity of the aggregate particles is met, the feed back amount of the powder balls is greatly reduced, and the production cost is reduced
S8, pressing the material particles into a green body
The ceramic raw material enters a press die to be pressed into a blank body and then enters the next working procedure;
in the step S8, the material distribution plate of the press die is in a herringbone shape, so that the phenomenon of hanging materials can be avoided.
S9, drying the green body
And drying the green body by a wide body type dryer.
Since the above-mentioned devices are only for realizing the above-mentioned functions, the structure and control principle thereof may have various forms, and are not the invention points of the present application, so that the detailed description thereof is omitted.
Therefore, according to the production process of the dry-pressing ceramic tile blank, the granules granulated by the dry powder making process have uniform internal and external moisture, and the process that the granules are aged to achieve uniform internal and external moisture in the traditional wet granulation process is saved; meanwhile, through the homogenization in the factory, the storage and homogenization of the dry powder and the detection and feedback of the weight components, the problem of homogenization of various domestic ceramic raw materials is solved, and the balance and stability of the raw materials in the subsequent production link are ensured; and the cross-flow granulator is adopted to realize the dual-fluid cross-flow nucleation and then granulate by a multi-stage granulating disc, so that the sphericity and the fluidity of dry-method granulated granules are improved, and the problem of yield reduction caused by potential unsmooth flowing in the subsequent green pressing link is reduced.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solutions of the present invention and not for limiting the same, and although the present invention is described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that: modifications and equivalents may be made to the invention without departing from the spirit and scope of the invention.
Claims (9)
1. A production process of a dry pressing ceramic tile blank is characterized by comprising the following steps: the method comprises the following steps:
s1 stockpiling and homogenizing feed
Firstly, impurities in ceramic raw materials are pre-screened, lumps in the ceramic raw materials are broken, then the ceramic raw materials are stacked in a stacking area through a side type stacker, the materials are taken and homogenized from the stacking area through a side type scraper blade reclaimer, the ceramic raw materials are scraped to a rubber belt conveyor, the rubber belt conveyor conveys the ceramic raw materials to the top end of a storage bin, and the ceramic raw materials are discharged into the corresponding storage bin according to the flowability of the ceramic raw materials;
s2, preparing the ingredients
The ceramic raw materials are conveyed to a material grinding conveyor belt and are conveyed to the next procedure after being mixed by a conveying mechanism arranged at the bottom of a storage bin, the components of the mixed ceramic raw materials are detected by a material analyzer arranged on the material grinding conveyor belt, the detected components are transmitted to a central controller, the central controller compares the difference between the detected component values and the set component values and controls the motor rotating speed of the quantitative feeder according to the difference, and after the motor rotating speed is adjusted, the quantitative feeder feeds weighing signals back to the central controller through a weighing signal receiver until the detected component values are equal to the set component values;
s3, grinding
Conveying the mixed ceramic raw materials to a hopper lifter through a material grinding conveying belt, lifting the ceramic raw materials to the interior of a combined type powder concentrator through a feed inlet by the hopper lifter, drying the ceramic raw materials through a hot air port arranged at the feed inlet, falling the coarse-grain-diameter ceramic raw materials dried by the combined type powder concentrator into a roller press to be ground into dry powder, lifting the dry powder to the interior of the combined type powder concentrator again through the hopper lifter until the grain diameter of the ceramic raw materials reaches the set value of the combined type powder concentrator, pumping the ceramic raw materials to a bag type dust collector through the combined type powder concentrator, falling the bag type dust collector into a spiral conveyor, and conveying the ceramic raw materials to the next process through the spiral conveyor;
s4, storing and homogenizing dry powder
The ceramic raw materials conveyed by the screw conveyor are received by the air conveying chute, the ceramic raw materials are controlled by an electric throttle valve arranged at the discharge port of the air conveying chute to circularly feed the ceramic raw materials into the four homogenizing warehouses, the feeding time of the four homogenizing warehouses is controlled to be the same by the electric throttle valve, after the ceramic raw materials enter the homogenizing warehouses, three aeration points of thirty aeration points in five aeration areas evenly distributed at the bottom of the homogenizing warehouses are sequentially opened at the same time for homogenization, after the homogenization is finished, the unloading is started at the same time by an unloading electromagnetic valve arranged at the bottom of each aeration area, the opening time of each unloading electromagnetic valve is controlled to be sequentially reduced in one aeration period, and then the unloaded ceramic raw materials are conveyed to the next working procedure by the air conveying chute;
s5, removing impurities and iron
The ceramic raw material is subjected to impurity removal and iron removal through a strong magnetic rod type iron remover and a medium-frequency negative-pressure material distribution sieve in sequence, and then the next procedure is carried out;
s6, granulating
Conveying the ceramic raw materials to the inside of a cross-flow granulator through a hopper lifter and a dry powder accelerating tube in sequence to form a mother core, then falling into a granulation disc to perform rolling granulation, drying through a fluidized dryer, then entering a crushing and screening compound machine for screening, crushing and then entering the next process;
s7, storing the material particles
The ceramic raw materials sequentially pass through a storage bin and a suspension type vibration discharging cone arranged at the bottom end of the storage bin to fall onto a quantitative feeder, and then are sieved and crushed by a crushing and screening compound machine again to enter the next process;
s8, pressing the material particles into a green body
The ceramic raw material enters a press die to be pressed into a blank body and then enters the next working procedure;
s9, drying the green body
And drying the green body by a wide body type dryer.
2. The process for producing a green body of a dry-pressed ceramic tile according to claim 1, wherein: in the step S1, impurities in the ceramic raw material are pre-screened through a wave roller screen, and agglomerates in the ceramic raw material are crushed through a hammer crusher.
3. The process for producing a green body of a dry-pressed ceramic tile according to claim 1, wherein: in the step S2, the ceramic raw materials include a paste-like ceramic raw material, a first type of ceramic raw material having a powder flowability FF value of less than 2, a second type of ceramic raw material having a powder flowability FF value of 2 or more and less than 4, a third type of ceramic raw material having a powder flowability FF value of 4 or more and less than 10, and a fourth type of ceramic raw material having a powder flowability FF value of 10 or more, and the bins include a first bin, a second bin, a third bin, a fourth bin, and a fifth bin.
4. The process for producing a green body of a dry-pressed ceramic tile according to claim 3, wherein: in the step S2, the transfer mechanism comprises a double-shaft screw feeder arranged at the discharge port of the first bin, a plate-type feeder arranged at the discharge port of the second bin, a first bar valve arranged at the discharge port of the third bin, an activation cone arranged at the discharge port of the fourth bin and a second bar valve arranged at the discharge port of the fifth bin.
5. The process for producing a green body of a dry-pressed ceramic tile according to claim 1, wherein: and step S3, the combined powder concentrator comprises a bamboo hat type static powder concentrator and a dynamic powder concentrator which are sequentially arranged from top to bottom, a discharge hole of the bamboo hat type static powder concentrator is communicated with a feed inlet of the dynamic powder concentrator, and a discharge hole of the dynamic powder concentrator is communicated with a feed inlet of the roller press.
6. The process for producing a green body of a dry-pressed ceramic tile according to claim 1, wherein: and in the step S4, the opening and closing of the thirty inflation points are respectively controlled by thirty inflation discharging electromagnetic valves.
7. The process for producing a green body of a dry-pressed ceramic tile according to claim 1, wherein: in step S5, the ceramic raw material is fed into a closed constant feeder for metering through a powder hopper, an activated discharging cone and a rotary discharger in sequence before entering a strong magnetic rod type iron remover.
8. The process for producing a green body of a dry-pressed ceramic tile according to claim 1, wherein: and step S6, two spray guns are arranged below the feed inlet of the cross-flow granulator in a cross mode, and the granulation disc comprises a first-stage granulation disc, a second-stage granulation disc and a third-stage granulation disc which are sequentially arranged from top to bottom.
9. The process for producing a green body of a dry-pressed ceramic tile according to claim 1, wherein: in step S8, the cloth plate of the press die is herringbone.
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| CN111037732A (en) * | 2019-12-17 | 2020-04-21 | 淄博松阳锆业科技有限公司 | Mixing device is used in zirconia production |
| CN111391100B (en) * | 2020-03-22 | 2021-12-14 | 河北金汇陶瓷有限公司 | Press feeding device for ceramic dry-process powder making process |
| CN111361000B (en) * | 2020-03-22 | 2021-12-28 | 河北金汇陶瓷有限公司 | Dry powder making device and method adopting roller press for milling |
| CN111375481B (en) * | 2020-03-23 | 2022-01-28 | 河北金汇陶瓷有限公司 | Integrated device and method for powder making, dust collection and impurity removal by ceramic dry method |
| CN115890893B (en) * | 2021-09-30 | 2023-11-24 | 北京喜诺德科技有限公司 | Method and device for preparing ceramic tile by dry powder process |
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