CN110256064A - 一种铁氧体预烧料制备方法 - Google Patents
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Abstract
本发明公开了一种铁氧体预烧料的制备方法,旨在如何降低回转窑供气能耗,具体步骤包括配料称量与湿磨,脱水,预烧,粉碎;通过在制备永磁铁氧体预烧粉料的过程中更改原料配比并更改预烧条件的方法来制备永磁铁氧体预烧粉料,降低回转窑的天然气能耗15%以上,从而减少了生产成本,提高市场竞争力。
Description
技术领域
本发明涉及磁性材料技术领域,尤其涉及一种铁氧体预烧料制备方法。
背景技术
为了减少燃煤产生的大气污染,亦可减少二氧化碳的排放,有利于全球气候保护,积极响应国家“煤改气”政策,大小企业燃烧能源纷纷由煤炭改为天然气,而天然气的经济成本明显大于煤炭的经济成本,在锶铁氧体预烧料生产中,回转窑部分是一个重要生产环节,锶铁氧体预烧料的两个主要原料铁红与碳酸锶需要在高温下进行固相反应,生成化学分子式为SrO·nFe2O3的物质,在锶铁氧体预烧料行业内,湿法回转窑为主流,直径一般在1.5~2.5米范围内,以直径2M的湿法回转窑为例,每生产1吨预烧料消耗天然气量基本在140M3以上,如何降低天然气的消耗量成为回转窑烧结过程中需要研究的课题。
发明内容
本发明目的就是为了弥补已有技术的缺陷,提供一种铁氧体预烧料制备方法。
本发明是通过以下技术方案实现的:
一种铁氧体预烧料制备方法,其特征在于:具体步骤如下:
(1)配料称量与湿磨
配料总量按1500kg配料,按氧化铁粉末与碳酸锶粉末的摩尔比为5.2~5.5的配比称量永磁铁氧体主相原材料,在所述的主相原材料粉中加入一次添加剂,所述的一次添加剂为轻质碳酸钙、白炭黑与硼酸,添加比例为主相原材料总重量每100份,加入轻质碳酸钙0.4~1.2份、白炭黑0.1~0.6份和硼酸0~0.3份;将混合物料投入到湿式球磨机中,球磨机内物料:水:球比例=1:1.4-1.6:10-12,磨桶转速20-45r/min,细磨1-3h,得到混合物料平均粒度不大于1.0 um;
(2)脱水
将步骤(1)得到的混合物料经过卧式离心机脱水后放入储存桶内等待进窑预烧,离心机转速为1500-3300r/min,按1-1.5T/h的进料量进脱水机脱水,得到料浆的含固量在70wt%;
(3)预烧
将步骤(2)获得的混合物料在直径1.5-2.5M回转窑中进行预烧,回转窑转速0.5-0.7r/min,物料通过速度3-3.7m/h,窑尾进料端有挡料板,降低窑内风流速,通过调节引风机频率使窑尾负压提高到3~15Pa,降低回转窑内风流速预烧温度为1100~1250℃;
(4)粉碎
将步骤(3)得到的预烧颗粒料通过干式粉碎机进行破碎研磨,转速20-39.7r/min ,物料按1-1.5T/h的进料量通过干式粉碎机,得到平均粒度4um的预烧粉料。
所述的碳酸锶粉末的纯度≥97wt%、颗粒的原始平均粒度1.5um。
所述的氧化铁粉末的纯度≥98wt%、颗粒的原始平均粒度1.2um。
所述的轻质碳酸钙的纯度≥98.0wt%、颗粒的原始平均粒度1.0 um。
所述的白炭黑的纯度≥98. 0wt%,颗粒的原始平均粒度1.0 um。
所述的硼酸的纯度≥99. 0wt%,颗粒的原始平均粒度2.0 um。
在所述的回转窑的窑尾进料端内侧设有挡料板,挡料板的尺寸使遮蔽窑内气流的效果达到70%~90%。
1、降低原料需求的预烧温度
1、在锶铁氧体预烧料制备过程中,一般原材料配制时铁红与碳酸锶的摩尔比为5.6~6.0,预烧温度一般在1220~1350℃,通过调整原材料配制时铁红与碳酸锶的摩尔比,来大幅度降低原料的预烧温度,而进一步降低摩尔比,原料不利于烧结,造成磁性能降低,本方案通过添加一次添加剂来改善此问题,可使铁红与碳酸锶的摩尔比降至5.2~5.5,预烧温度1100~1250℃,其中一次添加剂为轻质碳酸钙、白炭黑和硼酸,添加比例为每100kg原材料,加入0.4~1.2kg轻质碳酸钙,0.1~0.6kg白炭黑,0~0.3kg硼酸;轻质碳酸钙在预烧时起到促进结晶,利于烧结的作用,可进一步降低预烧温度,而硼酸、白炭黑在预烧时起到抑制结晶的作用,少量添加可减慢原料结晶的速度,增加产品密度,进而使性能Br提高;
2、实现回转窑高浓度进料
锶铁氧体预烧料生产中,湿法生产时,生料成分均匀,工艺稳定,烧成的熟料质量高,熟料强度等级高,粉磨过程中粉尘少,窑尾飞灰少。但湿法生产时蒸发35%~45%的料浆水分,需要消耗较大热量,调整卧式离心机液位板,并变频调节卧式离心机的运转频率,使料浆浓度达到65%~72%,来减少进窑料浆的含水量,使料浆在回转窑内更易于烘干,降低料浆烘干造球需求的温度,利于回转窑造球,达到降低热量消耗的目的;
3、降低回转窑内风流速
窑尾进料端有挡料板,改变挡料板的尺寸,使遮蔽窑内气流的效果达到70%~90%,加大挡料板前后风流速差距,降低窑内风流速,减少热量消耗,再通过变频调节窑尾引风机,使窑尾负压提高到3~15Pa,降低回转窑内风流速,减少热量的消耗,进而降低天然气消耗。
本发明的优点是:1、本发明通过调整原料配比和加入一次添加剂,大幅度降低原料需求的预烧温度50℃以上,极大的降低了天然气的消耗量,并保证性能的稳定性;
2、本发明通过回转窑的高浓进料,降低了回转窑造球需要的最低温度,减少了热量的消耗,为实现压缩回转窑高温区长度创造了条件;
3、本发明通过降低回转窑内风流速,减少热量消耗,来实现节能的效果;
4、本发明通过以上优化方案,可实现降低回转窑的天然气能耗20%以上,从而减少了生产成本,提高市场竞争力。
具体实施方式
实施例1:
本实施例提供一种永磁铁氧体预烧料的制备方法,具体如下步骤:
(1)配料称量与湿磨
本制备方法配料总量按1500kg配料,按分子式SrO·5.4Fe2O3的摩尔数配比称量永磁铁氧体主相原材料:由此称得碳酸锶粉末(纯度≥97wt%、颗粒的原始平均粒度1.5um)219kg,氧化铁粉末(纯度≥98wt%、颗粒的原始平均粒度1.2um)1281kg,在所述主相原材料粉中加入一次添加剂,所述一次添加剂为轻质碳酸钙与白炭黑,添加比例为主相原材料总重量每100份,加入轻质碳酸钙0.8份(纯度≥98.0wt%、颗粒的原始平均粒度1.0 um),白炭黑(纯度≥98. 0wt%,颗粒的原始平均粒度1.0 um)0.3份,硼酸(纯度≥99. 0wt%,颗粒的原始平均粒度2.0 um)0.2份;将混合物料投入到湿式球磨机中,球磨机内物料:水:球比例=1:1.6:12,磨桶转速35r/min,细磨2h,得到混合物料平均粒度不大于1.0 um;
(2)脱水
将步骤(1)得到的混合物料经过卧式离心机脱水后放入储存桶内等待进窑预烧,离心机转速为2300r/min,按1.5T/h的进料量进脱水机脱水,得到料浆的含固量在70wt%;
(3)预烧
将步骤(2)获得的混合物料在直径2M回转窑中进行预烧,回转窑转速0.7r/min,物料通过速度3.7m/h,窑尾进料端有挡料板,降低窑内风流速,挡料板遮蔽效果75%,再通过调节引风机频率使窑尾负压提高到6Pa,预烧温度1150℃;
(5)粉碎
将步骤(3)得到的预烧颗粒料通过干式粉碎机进行破碎研磨,转速29.7r/min ,物料按1.5T/h的进料量通过干式粉碎机,得到平均粒度4um的预烧粉料;
实施例1中,回转窑预烧温度1150℃,每生产1吨预烧料消耗天然气量116M3,与140M3相比,实现天然气降低能耗17%。
实施例2:
本实施例提供一种永磁铁氧体预烧料的制备方法,具体如下步骤:
(1)配料称量与湿磨
本制备方法配料总量按1500kg配料,按分子式SrO·5.3Fe2O3的摩尔数配比称量永磁铁氧体主相原材料:由此称得碳酸锶粉末(纯度≥97wt%、颗粒的原始平均粒度1.5um)223kg,氧化铁粉末(纯度≥98wt%、颗粒的原始平均粒度1.2um)1277kg,在所述主相原材料粉中加入一次添加剂,所述一次添加剂为轻质碳酸钙与白炭黑,添加比例为主相原材料总重量每100份,加入轻质碳酸钙0.6份(纯度≥98.0wt%、颗粒的原始平均粒度1.0 um),白炭黑(纯度≥98. 0wt%,颗粒的原始平均粒度1.0 um)0.4份,硼酸(纯度≥99. 0wt%,颗粒的原始平均粒度2.0 um)0.1份;将混合物料投入到湿式球磨机中,球磨机内物料:水:球比例=1:1.6:12,磨桶转速35r/min,细磨2h,得到混合物料平均粒度不大于1.0 um;
(2)脱水
将步骤(1)得到的混合物料经过卧式离心机脱水后放入储存桶内等待进窑预烧,离心机转速为2300r/min,按1.5T/h的进料量进脱水机脱水,得到料浆的含固量在70wt%;
(3)预烧
将步骤(2)获得的混合物料在直径2M回转窑中进行预烧,回转窑转速0.7r/min,物料通过速度3.7m/h,窑尾进料端有挡料板,降低窑内风流速,挡料板遮蔽效果75%,通过调节引风机频率使窑尾负压提高到6Pa,预烧温度1120℃;
(4)粉碎
将步骤(3)得到的预烧颗粒料通过干式粉碎机进行破碎研磨,转速29.7r/min ,物料按1.5T/h的进料量通过干式粉碎机,得到平均粒度4um的预烧粉料;
实施例2中,回转窑预烧温度1130℃,每生产1吨预烧料消耗天然气量112M3,与140M3相比,实现天然气降低能耗20%。
在所述的回转窑的窑尾进料端内侧设有挡料板,挡料板的尺寸使遮蔽窑内气流的效果达到70%~90%。
本领域的技术人员容易理解,以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。
Claims (7)
1.一种铁氧体预烧料制备方法,其特征在于:具体步骤如下:
(1)配料称量与湿磨
配料总量按1500kg配料,按氧化铁粉末与碳酸锶粉末的摩尔比为5.2~5.5的配比称量永磁铁氧体主相原材料,在所述的主相原材料粉中加入一次添加剂,所述的一次添加剂为轻质碳酸钙、白炭黑与硼酸,添加比例为主相原材料总重量每100份,加入轻质碳酸钙0.4~1.2份、白炭黑0.1~0.6份和硼酸0~0.3份;将混合物料投入到湿式球磨机中,球磨机内物料:水:球比例=1:1.4-1.6:10-12,磨桶转速20-45r/min,细磨1-3h,得到混合物料平均粒度不大于1.0 um;
(2)脱水
将步骤(1)得到的混合物料经过卧式离心机脱水后放入储存桶内等待进窑预烧,离心机转速为1500-3300r/min,按1-1.5T/h的进料量进脱水机脱水,得到料浆的含固量在70wt%;
(3)预烧
将步骤(2)获得的混合物料在直径1.5-2.5M回转窑中进行预烧,回转窑转速0.5-0.7r/min,物料通过速度3-3.7m/h,窑尾进料端有挡料板,降低窑内风流速,通过调节引风机频率使窑尾负压提高到3~15Pa,降低回转窑内风流速预烧温度为1100~1250℃;
粉碎
将步骤(3)得到的预烧颗粒料通过干式粉碎机进行破碎研磨,转速20-39.7r/min ,物料按1-1.5T/h的进料量通过干式粉碎机,得到平均粒度4um的预烧粉料。
2.根据权利要求1所述的一种铁氧体预烧料制备方法,其特征在于:所述的碳酸锶粉末的纯度≥97wt%、颗粒的原始平均粒度1.5um。
3.根据权利要求2所述的一种铁氧体预烧料制备方法,其特征在于:所述的氧化铁粉末的纯度≥98wt%、颗粒的原始平均粒度1.2um。
4.根据权利要求3所述的一种铁氧体预烧料制备方法,其特征在于:所述的轻质碳酸钙的纯度≥98.0wt%、颗粒的原始平均粒度1.0 um。
5.根据权利要求4所述的一种铁氧体预烧料制备方法,其特征在于:所述的白炭黑的纯度≥98. 0wt%,颗粒的原始平均粒度1.0 um。
6.根据权利要求5所述的一种铁氧体预烧料制备方法,其特征在于:所述的硼酸的纯度≥99. 0wt%,颗粒的原始平均粒度2.0 um。
7.根据权利要求1所述的一种铁氧体预烧料制备方法,其特征在于:在所述的回转窑的窑尾进料端内侧设有挡料板,挡料板的尺寸使遮蔽窑内气流的效果达到70%~90%。
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