CN110723976A - Fly ash burnt-out ceramsite and energy-saving treatment method for fly ash - Google Patents
Fly ash burnt-out ceramsite and energy-saving treatment method for fly ash Download PDFInfo
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Abstract
The invention relates to a fly ash sintered-expanded ceramsite and an energy-saving treatment method for fly ash, in particular to an energy-saving treatment method for casting fly ash, which comprises the following steps: mixing main materials and the dedusting ash, adding clear water, and stirring into a mud-like substance, wherein the main materials are one or more of clay, shale, sludge and waste incineration substances; and granulating the mud-like material to generate raw material balls, heating the raw material balls to 500-600 ℃ for the first time, carrying out heat preservation treatment, continuing heating treatment for the second time, cooling, and entering a vibrating screen to obtain the fly ash burnt-out and expanded ceramsite with different particle sizes. The method utilizes a large amount of heat provided by the fly ash in the fly ash during firing, reduces the natural gas consumption of firing and expanding the ceramsite, saves the fuel cost, can improve the economic benefit compared with the common ceramsite, and has the advantages of low energy consumption, good performance, no harm, wide range, cyclic utilization and the like.
Description
Technical Field
The invention belongs to the field of solid waste treatment and environment-friendly regeneration, and particularly relates to fly ash burnt-out ceramsite and an energy-saving treatment method of fly ash.
Background
Along with the development of domestic economy, castings not only meet the requirements of domestic manufacturing industry, but also stably rise in the outlet of castings, the total production of the castings in China is close to 5000 ten thousand tons/year, the castings produced by sand molds account for more than 80% of the total amount, and 1.2 tons of waste sand and 0.3 ton of dust removal ash are produced in each 1 ton of castings. The amount of fly ash is seen to be very large.
The green sand is a molding material for producing castings, which is composed of silica sand, bentonite, coal powder and water according to a certain proportion, is the material with the largest application range in the traditional casting in China, and cannot be compared with any other molding materials (cold core sand, precoated sand and sodium silicate sand). The annual throughput is more than five million tons, and about 30 percent of fly ash is produced by the process and mainly comprises fine silica sand powder, clay, coal powder and the like.
The national policy increases the requirements on energy conservation and emission reduction, people in the domestic casting world pay more and more attention to the importance of old sand regeneration, the green casting strategy is adhered to, the reduction, recycling and reutilization are realized from the aspect of resource saving, the regeneration process of waste sand discharged by casting is mature in China, and the key is the effective utilization of 30% of dust removal ash. The fly ash can be used for manufacturing products with different properties, the purpose of changing waste into valuable is realized, the source of the cast fly ash can replace clay resources, the cost of raw materials is low, the performance of the prepared product is good, and the application range is wide.
At present, ceramsite is mainly prepared by processing and granulating clay, shale, sludge and the like serving as main raw materials, and then sintering or sintering at high temperature to swell. The clay material is mainly taken from cultivated land when the clay ceramsite is produced, the shale ceramsite needs to be mountain-opened to take stones when the shale ceramsite is produced, and the two ceramsite raw material obtaining modes can damage the ecological environment, do not accord with the sustainable development strategy and do not accord with the basic national policy of our country emphasizing environmental protection and energy saving.
Fly ash exists in the casting dust removal ash, the heat value is very high, and the fly ash can be fully utilized; the high-temperature-region fluxing agent is a good fluxing agent, and the toughness of the sintered ceramic particles is improved. The chemical composition elements in the fly ash are shown in table 1.
TABLE 1
| Element(s) | SiO2 | Al2O3 | Fe2O3 | MgO | C | CaO | NaO |
| Percentage of | 42-45 | 10-18 | 6-7 | 2-4 | 2-3.5 | 2-3 | 0.5-1.2 |
At present, effective utilization of casting dust removal ash is not disclosed, compared with conventional treatment methods, burying treatment can pollute water, soil and raise dust, and a series of environmental pollution is caused.
The present invention has been made in view of the above circumstances.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides the fly ash burnt-out ceramsite and the energy-saving treatment method of the fly ash.
In order to achieve the purpose, the invention adopts the following technical scheme:
an energy-saving treatment method for casting dust comprises the following steps:
(1) mixing main materials and the dedusting ash, adding clear water, and stirring into a mud-like substance, wherein the main materials are one or more of clay, shale, sludge and waste incineration substances;
(2) and granulating the mud-like material to generate raw material balls, heating the raw material balls to 500-600 ℃ for the first time, carrying out heat preservation treatment, continuing heating treatment for the second time, cooling, and entering a vibrating screen to obtain the fly ash burnt-out and expanded ceramsite with different particle sizes.
The coal powder for casting the fly ash provides a large amount of heat sources during firing, reduces the natural gas consumption for firing and expanding the ceramsite, saves the fuel cost, and can improve the economic benefit compared with the common ceramsite; the fly ash is very fine, gaps after the sintered and expanded ceramsite is prepared are in dispersed distribution, the porosity is good, the strength of the sintered and expanded ceramsite can be improved, and compared with the traditional sintered and expanded ceramsite, the sintered and expanded ceramsite is lighter and has better sound insulation and heat insulation effects; in the roasting process, the temperature is increased in a gradient manner, and metal ions in the fly ash can be solidified, so that the prepared fly ash ceramsite is harmless to use, acid-resistant and alkali-resistant.
The size of the raw material ball obtained by granulation in the invention is determined according to the requirements of ceramsite products, and can be generally 0.5-3 cm.
The main material is one or more of clay, shale, sludge and waste incineration; all the raw materials can be mixed in any proportion.
Further, in the step (1), 40-70 parts by weight of main materials, 30-60 parts by weight of dedusting ash and 15-25 parts by weight of water are used.
Further, 50-60 parts of main materials, 40-50 parts of dedusting ash and 18-22 parts of water.
Further, 55 parts by weight of main material, 45 parts by weight of dedusting ash and 20 parts by weight of water.
Further, in the step (2), the temperature is raised at a constant rate for the first time and the second time.
Furthermore, the heating rate is 5-10 ℃/min.
The invention adopts constant rate heating, the production efficiency is influenced by adopting over-low heating rate, if the heating rate is too high, the raw material balls are heated in and out inconsistently, and the raw material balls are easy to crack.
Further, the heat preservation time in the step (2) is 30-60 min.
The invention is used for heat preservation at the temperature of 500-600 ℃ for 30-60min, so that low-melting-point substances and fly ash are fully burnt in the temperature region to form pores, and if the temperature is too high, MgO and SiO are added2And the coal powder is not easy to burn, and the formation and distribution state of pores are influenced.
Further, in the step (2), the temperature is raised to 1100 ℃ for the second time, and then the temperature is maintained for 30-60 min.
The purpose of heat preservation after the second temperature rise is to improve the strength of the ceramsite, the strength can be correspondingly improved if the heat preservation time is longer, but the energy consumption is increased, and the heat preservation time is selected to be 30-60min according to various factors.
Further, air cooling is adopted in the step (2), and the cooling temperature is 60-120 ℃.
The air cooling method is simple and reliable in work, and the generated hot air can be collected to be used as a heat source for supplementing a heat source at the front section to heat the raw material balls. The screening and packaging of the product are affected by too high temperature of the cooled ceramsite, and the efficiency is affected by too low temperature.
The fly ash sintered-swelling ceramsite is prepared by the energy-saving treatment method for casting fly ash.
Compared with the prior art, the invention has the beneficial effects that:
(1) the method utilizes the characteristics of the fly ash to prepare the fly ash into the sintered ceramic particles, the fly ash with a heat value provides a heat source, the residual bentonite can reduce the requirement on a binder, the bentonite mutually permeates to make up for the deficiency, and the harmless treatment of the fly ash is realized by improving the final roasting temperature;
(2) the method of the invention has low energy consumption: the large amount of heat provided by the fly ash in the fly ash during firing is utilized, the natural gas consumption of the sintered and expanded ceramsite is reduced, the fuel cost is saved, and the economic benefit can be improved compared with that of the common ceramsite; the performance is good: the coal dust in the fly ash is very fine, gaps after the sintered and expanded ceramsite is prepared are in dispersed distribution, the porosity is good, the strength of the sintered and expanded ceramsite is improved, and compared with the traditional sintered and expanded ceramsite, the sintered and expanded ceramsite is lighter and has better sound insulation and heat insulation effects;
(3) in the roasting process, the roasting temperature adopts a gradient rising mode, and metal ions in the fly ash can be solidified, so that the prepared fly ash sintered ceramsite is harmless, and has good acid and alkali resistance;
(4) the method has the advantages of high yield, energy conservation, low investment cost and pressure and high economic benefit; meanwhile, due to the high efficiency of the ceramsite formula and the manufacturing process level, the investment of a unit product is smaller, and the obtained final benefit is also larger; the sintered ceramic particles have the advantages of small density, good acid and alkali resistance, high compressive strength, good chemical stability and the like.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be described in detail below. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the examples given herein without any inventive step, are within the scope of the present invention.
Example 1
The energy-saving treatment method for the casting dust removal ash comprises the following steps:
(1) mixing 40kg of clay and 45kg of fly ash, adding 15kg of clear water, and stirring to obtain a paste;
(2) extruding and granulating the sludge to generate raw material balls, setting the size of the raw material balls according to actual production requirements, heating the raw material balls from room temperature at a constant heating rate, wherein the heating rate is 5 ℃/min, heating to 500 ℃ for the first time, carrying out heat preservation treatment for 60min, continuing to heat to 1000 ℃ for the second time, carrying out heat preservation for 60min, flowing into a cooling pipeline for cooling, cooling the expanded high-temperature ceramsite sand by adopting air cooling, collecting generated hot air to be used for supplementing a heat source to the front section to heat the raw material balls, discharging the cooled ceramsite into a vibrating screen, and obtaining the dedusting ash expanded ceramsite with different particle sizes according to requirements, wherein the temperature of the cooled ceramsite is 60 ℃.
Example 2
The energy-saving treatment method for the casting dust removal ash comprises the following steps:
(1) mixing 50kg of shale and 32kg of fly ash, adding 18kg of clean water, and stirring into a mud-like substance;
(2) extruding and granulating the sludge to generate raw material balls, setting the size of the raw material balls according to actual production requirements, heating the raw material balls from room temperature at a constant heating rate, wherein the heating rate is 6 ℃/min, heating to 520 ℃ for the first time, carrying out heat preservation treatment for 50min, continuing to heat to 1020 ℃ for the second time, carrying out heat preservation for 50min, flowing into a cooling pipeline for cooling, cooling the expanded high-temperature ceramsite sand by adopting air cooling, collecting generated hot air to be used for supplementing a heat source to the front section to heat the raw material balls, discharging the cooled ceramsite into a vibrating screen, and obtaining the dedusting ash expanded ceramsite with different particle sizes according to requirements, wherein the temperature of the cooled ceramsite is 80 ℃.
Example 3
The energy-saving treatment method for the casting dust removal ash comprises the following steps:
(1) mixing 30kg of sludge, 25kg of shale and 45kg of fly ash, adding 20kg of clear water, and stirring into a mud-like substance;
(2) extruding and granulating the sludge to generate raw material balls, setting the size of the raw material balls according to actual production requirements, heating the raw material balls from room temperature at a constant heating rate, wherein the heating rate is 7.5 ℃/min, heating to 550 ℃ for the first time, carrying out heat preservation treatment for 45min, continuing to heat to 1050 ℃ for the second time, carrying out heat preservation for 45min, flowing into a cooling pipeline for cooling, cooling the expanded high-temperature ceramsite sand by air cooling, collecting generated hot air to be used for supplementing a heat source to the front section to heat the raw material balls, feeding the cooled ceramsite into a vibrating screen, and obtaining the dedusting and expanding ceramsite with different particle sizes according to requirements, wherein the temperature of the cooled ceramsite is 90 ℃.
Example 4
The energy-saving treatment method for the casting dust removal ash comprises the following steps:
(1) mixing 50kg of clay and 40kg of fly ash, adding 22kg of clean water, and stirring to obtain a paste;
(2) extruding and granulating the sludge to generate raw material balls, setting the size of the raw material balls according to actual production requirements, heating the raw material balls from room temperature at a constant heating rate, wherein the heating rate is 9 ℃/min, heating to 580 ℃ for the first time, carrying out heat preservation treatment for 40min, continuing to heat to 1080 ℃ for the second time, carrying out heat preservation for 40min, flowing into a cooling pipeline for cooling, cooling the expanded high-temperature ceramsite sand by adopting air cooling, collecting generated hot air to be used for supplementing a heat source to the front section to heat the raw material balls, feeding the cooled ceramsite into a vibrating screen, and obtaining the dedusting ash expanded ceramsite with different particle sizes according to requirements, wherein the temperature of the cooled ceramsite is 100 ℃.
Example 5
The energy-saving treatment method for the casting dust removal ash comprises the following steps:
(1) mixing 70kg of waste incineration material and 60kg of dust removal ash, adding 25kg of clean water, and stirring into mud;
(2) extruding and granulating the sludge to generate raw material balls, setting the size of the raw material balls according to actual production requirements, heating the raw material balls from room temperature at a constant heating rate, wherein the heating rate is 10 ℃/min, heating to 600 ℃ for the first time, carrying out heat preservation treatment for 30min, continuing to heat to 1100 ℃ for the second time, carrying out heat preservation for 30min, flowing into a cooling pipeline for cooling, cooling the expanded high-temperature ceramsite sand by adopting air cooling, collecting generated hot air to be used for supplementing a heat source to the front section to heat the raw material balls, discharging the cooled ceramsite into a vibrating screen, and obtaining the dedusting ash expanded ceramsite with different particle sizes according to requirements, wherein the temperature of the cooled ceramsite is 100 ℃.
Comparative example 1
This comparative example gives a fire-swollen ceramsite according to the method of example 3, except that no fly ash is added.
Comparative example 2
The energy-saving method for treating fly ash in this comparative example is the same as that in example 3, except that the temperature raising in step (2) is performed by one temperature raising treatment, and is not performed by two temperature raising treatments.
Test example 1
The properties of the sintered and expanded porcelain granules obtained by the methods of examples 1-5 and comparative examples 1-2 are shown in Table 2.
TABLE 2
As can be seen from Table 1, in comparative example 1, compared with examples 1-5, the energy consumption of the natural gas is remarkably increased, the bulk density is increased, the porosity is reduced, the cylinder pressure strength is reduced, and the water absorption is reduced without adding the fly ash, because the fly ash contains coal powder, the consumption of the natural gas is remarkably reduced, the porosity is improved, the pores are in dispersion distribution, the cylinder pressure strength of the ceramsite can be improved, and in comparative example 2, compared with examples 1-5, the porosity is remarkably reduced, the cylinder pressure strength is reduced, because the sectional roasting heat preservation and heat preservation are performed, and the energy consumption of the natural gas is remarkably increased, the bulk density is increasedTreating to remove MgO and SiO in the fly ash2And the like, a molten phase is formed, a connecting framework between pores is increased, and the characteristics of light weight and high strength are achieved.
Test example 2
The ceramsite prepared in example 1 is subjected to heavy metal substance detection, and the reference of the standard GB5085-3-2007 hazardous waste identification standard is quoted, and the specific detection results are shown in Table 3.
TABLE 3
| Chemical composition | Lead (II) | Chromium (III) | Barium salt | Arsenic (As) | Mercury |
| Identification standard mg/L | 5 | 1 | 100 | 5 | 0.1 |
| The detection result is mg/L | ND | 0.061 | ND | 2.88×10-3 | 2.65×10-3 |
Remarking: "ND" indicates not detected.
As can be seen from the table above, the ceramsite obtained by the method has the characteristics of safety and no toxicity, and can meet the application requirements of various occasions.
The inventors have also conducted the above experiments on other examples, and the results are substantially consistent and, due to the limited space, are not listed.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of the changes or substitutions within the technical scope of the present invention, and all the changes or substitutions should be covered within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the appended claims.
Claims (10)
1. An energy-saving treatment method for casting dust removal ash is characterized by comprising the following steps:
(1) mixing main materials and the dedusting ash, adding clear water, and stirring into a mud-like substance, wherein the main materials are one or more of clay, shale, sludge and waste incineration substances;
(2) and granulating the mud-like material to generate raw material balls, heating the raw material balls to 500-600 ℃ for the first time, carrying out heat preservation treatment, continuing heating treatment for the second time, cooling, and entering a vibrating screen to obtain the fly ash burnt-out and expanded ceramsite with different particle sizes.
2. The energy-saving treatment method for the casting dust removal ash according to claim 1, wherein in the step (1), 40-70 parts by weight of the main material, 30-60 parts by weight of the dust removal ash and 15-25 parts by weight of water are used.
3. The energy-saving treatment method for the casting dust removal ash according to claim 2, wherein the main material comprises 50-60 parts by weight, the dust removal ash comprises 40-50 parts by weight, and the water comprises 18-22 parts by weight.
4. The energy-saving treatment method for the casting dust removal ash according to claim 2 or 3, characterized in that 55 parts by weight of the main material, 45 parts by weight of the dust removal ash and 20 parts by weight of water are used.
5. The energy-saving treatment method for the casting dust removal ash according to claim 1, characterized in that the first temperature rise and the second temperature rise in the step (2) are both temperature rises at a constant rate.
6. The energy-saving treatment method for the casting dust removal ash according to claim 5, wherein the temperature rise rate is 5-10 ℃/min.
7. The energy-saving treatment method for the casting dust removal ash according to claim 1, wherein the heat preservation time in the step (2) is 30-60 min.
8. The energy-saving treatment method for the casting dust removal ash as claimed in claim 1, wherein the temperature is raised to 1000-1100 ℃ for the second time in the step (2) and then is preserved for 30-60 min.
9. The energy-saving treatment method for the casting dust removal ash as claimed in claim 1, wherein air cooling is adopted in the cooling in the step (2), and the cooling temperature is 60-120 ℃.
10. A fly ash sintered-expanded ceramsite, characterized by being prepared by the treatment method according to any one of claims 1 to 9.
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111763071A (en) * | 2020-06-30 | 2020-10-13 | 巢湖学院 | Light high-strength casting waste sand and waste ash ceramsite and preparation method thereof |
| CN112573900A (en) * | 2020-11-23 | 2021-03-30 | 南阳仁创再生资源有限公司 | Recycling method of casting dust and sludge |
| CN113426942A (en) * | 2021-06-24 | 2021-09-24 | 南阳仁创砂业科技有限公司 | Method for preparing precoated sand for cast steel from recycled material |
| CN114605165A (en) * | 2022-01-25 | 2022-06-10 | 河南郑矿机器有限公司 | Process method for preparing sintered and expanded ceramsite by using ceramic waste |
| CN114940624A (en) * | 2022-04-25 | 2022-08-26 | 徐州市正峰锌业有限公司 | Method for preparing heat-insulating foam material by utilizing blast furnace ash as resource |
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| CN112573900A (en) * | 2020-11-23 | 2021-03-30 | 南阳仁创再生资源有限公司 | Recycling method of casting dust and sludge |
| CN113426942A (en) * | 2021-06-24 | 2021-09-24 | 南阳仁创砂业科技有限公司 | Method for preparing precoated sand for cast steel from recycled material |
| CN114605165A (en) * | 2022-01-25 | 2022-06-10 | 河南郑矿机器有限公司 | Process method for preparing sintered and expanded ceramsite by using ceramic waste |
| CN114940624A (en) * | 2022-04-25 | 2022-08-26 | 徐州市正峰锌业有限公司 | Method for preparing heat-insulating foam material by utilizing blast furnace ash as resource |
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