CN110981423A - 陶瓷原料纯净水制浆工艺 - Google Patents
陶瓷原料纯净水制浆工艺 Download PDFInfo
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 55
- 239000000919 ceramic Substances 0.000 title claims abstract description 31
- 239000002994 raw material Substances 0.000 title claims abstract description 27
- 238000000034 method Methods 0.000 title claims abstract description 18
- 238000004537 pulping Methods 0.000 title claims abstract description 14
- 239000002002 slurry Substances 0.000 claims abstract description 31
- 238000001914 filtration Methods 0.000 claims abstract description 19
- 239000008367 deionised water Substances 0.000 claims abstract description 14
- 229910021641 deionized water Inorganic materials 0.000 claims abstract description 14
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 12
- 239000008399 tap water Substances 0.000 claims abstract description 12
- 235000020679 tap water Nutrition 0.000 claims abstract description 12
- 239000000843 powder Substances 0.000 claims abstract description 11
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 10
- 238000002156 mixing Methods 0.000 claims abstract description 10
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims abstract description 9
- 235000019353 potassium silicate Nutrition 0.000 claims abstract description 8
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims abstract description 8
- 238000001035 drying Methods 0.000 claims abstract description 7
- 239000006004 Quartz sand Substances 0.000 claims abstract description 6
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 5
- 238000001223 reverse osmosis Methods 0.000 claims abstract description 5
- 239000003729 cation exchange resin Substances 0.000 claims abstract description 4
- 238000001816 cooling Methods 0.000 claims abstract description 4
- 238000000227 grinding Methods 0.000 claims abstract description 4
- 238000010438 heat treatment Methods 0.000 claims abstract description 4
- 238000002844 melting Methods 0.000 claims abstract description 4
- 230000008018 melting Effects 0.000 claims abstract description 4
- 238000012216 screening Methods 0.000 claims abstract description 4
- 238000003756 stirring Methods 0.000 claims abstract description 4
- 239000008213 purified water Substances 0.000 claims description 8
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 6
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 6
- 229910000029 sodium carbonate Inorganic materials 0.000 claims description 4
- 235000017550 sodium carbonate Nutrition 0.000 claims description 4
- NWUYHJFMYQTDRP-UHFFFAOYSA-N 1,2-bis(ethenyl)benzene;1-ethenyl-2-ethylbenzene;styrene Chemical compound C=CC1=CC=CC=C1.CCC1=CC=CC=C1C=C.C=CC1=CC=CC=C1C=C NWUYHJFMYQTDRP-UHFFFAOYSA-N 0.000 claims description 3
- 229910052582 BN Inorganic materials 0.000 claims description 3
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 3
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 3
- 239000003957 anion exchange resin Substances 0.000 claims description 3
- 150000001450 anions Chemical class 0.000 claims description 3
- 239000004917 carbon fiber Substances 0.000 claims description 3
- 239000004927 clay Substances 0.000 claims description 3
- 239000010438 granite Substances 0.000 claims description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 3
- 239000011022 opal Substances 0.000 claims description 3
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 3
- 239000010453 quartz Substances 0.000 claims description 3
- 239000004408 titanium dioxide Substances 0.000 claims description 3
- 239000011787 zinc oxide Substances 0.000 claims description 3
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 3
- 230000008901 benefit Effects 0.000 abstract description 5
- 239000003513 alkali Substances 0.000 abstract description 2
- 230000007797 corrosion Effects 0.000 abstract description 2
- 238000005260 corrosion Methods 0.000 abstract description 2
- 230000002194 synthesizing effect Effects 0.000 abstract 1
- 238000004519 manufacturing process Methods 0.000 description 9
- 239000000126 substance Substances 0.000 description 4
- 230000005611 electricity Effects 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
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Abstract
陶瓷原料纯净水制浆工艺，合成陶瓷原料，将陶瓷原料进行粉碎、研磨和筛分，得到陶瓷原料粉备用；自来水经过一级石英砂和活性碳的过滤，然后再经过阴阳离子交换树脂过滤，最后经过反渗透过滤，得到去离子水，将陶瓷原料粉与去离子水按照1:5的重量比混合成浆料，同时向浆料中加入水玻璃、纯碱和减水剂，搅拌均匀后静置8~12天；对浆料加热熔融，并将熔融后的浆料注入到成型模具中，然后对模具中的坯料进行快速降温使得坯料冷凝成型。本发明工艺得到的纯净水浆料的干燥收缩率有小幅度降低，干坯抗折强度有较明显提高，提升幅度达13.2%，而且本发明制浆工艺能显著减少水玻璃用量，减轻碱皮现象和对模具的腐蚀，有效提高了浆料干抗强度。
Description
技术领域
本发明涉及卫生陶瓷生产技术领域，具体涉及一种陶瓷原料纯净水制浆工艺。
背景技术
卫生陶瓷是卫生间、厨房和试验室等场所用的带釉陶瓷制品，也称卫生洁具。制浆是卫生陶瓷生产中的核心工序，目前制浆采用的都是自来水，自来水由于水质硬度过高，主要是钙、镁、氯离子和硫酸根离子影响，在很大程度上影响了泥浆的解凝过程，导致在球浆和调浆过程中加入较大比例的碱性解凝剂，从而坯体干燥过程中在表面析出大量可溶性晶体物质，在坯层内部也会残留较多，如果在下道工序不把表层物质砂洗干净，会直接影响雾化釉颗粒在坯体表面的吸附，并阻碍坯体在烧成过程的氧化反应，排气受阻。因此，制浆的水质不仅对外观实物质量造成影响，还会造成釉面缺陷，例如脱釉和毛孔等。
发明内容
本发明针对现有技术的不足，提供了一种陶瓷原料纯净水制浆工艺。
本发明解决其技术问题所采用的技术方案是：
一种陶瓷原料纯净水制浆工艺，首先对自来水进行三级过滤得到去离子水，然后与陶瓷原料粉混合制成浆料，具体工艺步骤如下：
（1）按照如下的成分和质量分数混合成陶瓷原料：粘土58~78份；石英30~40份；风化石20~25份；蛋白石13~20份；氧化锌14~20份；二氧化钛2~28份；氧化锆6~10份；氮化硼16~22份；碳纤维8~15份；
（2）将陶瓷原料进行粉碎、研磨和筛分，得到陶瓷原料粉备用；
（3）自来水经过一级石英砂和活性碳的过滤，然后再经过阴阳离子交换树脂过滤，最后经过反渗透过滤，得到去离子水；
（4）将陶瓷原料粉与去离子水按照1:5的重量比混合成浆料，同时向浆料中加入水玻璃、纯碱和减水剂，搅拌均匀后静置8~12天；
（5）对浆料加热熔融，并将熔融后的浆料注入到成型模具中，然后对模具中的坯料进行快速降温使得坯料冷凝成型；
（6）将成型后的坯料放在90~95℃的环境下进行干燥，直至坯料中的含水量低于2.3%。
本发明工艺得到的纯净水浆料的干燥收缩率有小幅度降低，大约0.2%左右，但干坯抗折强度有较明显提高，从3.253.68MPa提高到3.68MPa，提升幅度达13.2%，而且本发明制浆工艺能显著减少水玻璃用量，减轻碱皮现象和对模具的腐蚀，有效提高了浆料干抗强度。
具体实施方式
一种陶瓷原料纯净水制浆工艺，首先对自来水进行三级过滤得到去离子水，然后与陶瓷原料粉混合制成浆料，具体工艺步骤如下：
（1）按照如下的成分和质量分数混合成陶瓷原料：粘土58~78份；石英30~40份；风化石20~25份；蛋白石13~20份；氧化锌14~20份；二氧化钛2~28份；氧化锆6~10份；氮化硼16~22份；碳纤维8~15份；
（2）将陶瓷原料进行粉碎、研磨和筛分，得到陶瓷原料粉备用；
（3）自来水经过一级石英砂和活性碳的过滤，然后再经过阴阳离子交换树脂过滤，最后经过反渗透过滤，得到去离子水；
（4）将陶瓷原料粉与去离子水按照1:5的重量比混合成浆料，同时向浆料中加入水玻璃、纯碱和减水剂，搅拌均匀后静置8~12天；
（5）对浆料加热熔融，并将熔融后的浆料注入到成型模具中，然后对模具中的坯料进行快速降温使得坯料冷凝成型；
（6）将成型后的坯料放在90~95℃的环境下进行干燥，直至坯料中的含水量低于2.3%。
对本发明纯净水浆料和自来水浆料进行实验比对，结果如下：
浆料参数和物理性能对比检测
下球前检测印模纯净水电导率20-50μs/cm，自来水电导率800-1100μs/cm
化学成分
(1)
(2)在参数调到基本一致的情况下，纯净水浆的干燥收缩率有小幅度降低（0.2%左右），但干坯抗折强度有较明显提高（从3.25提高到3.68MPa，提升幅度达13.2%）；
(3)此次试验结果和前期试验结果基本吻合。纯净水浆综合性能优于自来水浆。其突出的性能优势是：能显著减少水玻璃用量，减轻碱皮现象和对模具的腐蚀，并且对浆料干抗强度的提升有一定帮助；
(4)成本增加不明显。在四条线满产的情况下，纯净水球浆需要的费用为3692.08+880.093=4572.17元/天。如果按照目前的产量，需要的费用为2286.085元/天。折合成浆料成本，大约增加4.3元/吨干料。以下是经济效益核算：
纯净水球浆的经济效益分析评估
以目前印模车间所使用的净化水装置进行核算如下：
1)印模车间水处理装置的处理能力为3立方/小时，每天处理10小时，一天处理30立方，处理效率是70%，无需人工成本；
2)一级过滤为石英砂和活性碳，每两年换一次，费用约1.5万元；折合每小时为15000÷660÷10=2.27元（一年按11个月算），则处理1立方水费用为2.27÷3=0.758元；
二级过滤为精密过滤器，每两个月换一次，费用150元左右；折合每小时为150÷60÷10=0.25元，则处理1立方水费用为0.25÷3=0.083元；
三级过滤为反渗透过滤，每7年换一次，费用约4万元；折合每小时为40000÷7÷330÷10=1.732元，则处理1立方水费用1.732÷3=0.577元；
3)因此，纯净水设备日产维护和辅材损耗费用为0.758+0.083+0.577=1.418元；
4)净化水设备每月的用电量为4000度，按平均电费0.82元/度，处理1立方水的电费为4000*0.82÷30÷10÷3=3.64元；
5)按照四条线满产核算，每天需球浆2.5+3.5+4+4=14球.每天化浆4+4+4.5+4.5=17池；则每天需水量为14*10+17*2=174方；
6)因此，如果用纯净水下球每天的水处理费用为(1.418+3.64)*174=880.093元。
7)使用纯净水球浆后水玻璃加入量有比较明显的降低，通过下40T大球试验，水玻璃加入量可以减少0.38%，纯碱减少0.13%，增加了0.105%减水剂。
算上水处理费用，在四条线满产的情况下，纯净水球浆需要的费用为3692.08+880.093=4572.17元/天。如果按照目前的产量，需要的费用为2286.085元/天。折合成浆料单位成本，大约增加4.3元/吨干料。
纯净水球浆对后期生产工艺的改善和对模具寿命的提升是必然的，这些无形成本目前还无法评估，但这些受益在生产过程中会逐渐凸显出来。
Claims (1)
1.一种陶瓷原料纯净水制浆工艺，其特征是首先对自来水进行三级过滤得到去离子水，然后与陶瓷原料粉混合制成浆料，具体工艺步骤如下：
（1）按照如下的成分和质量分数混合成陶瓷原料：粘土58~78份；石英30~40份；风化石20~25份；蛋白石13~20份；氧化锌14~20份；二氧化钛2~28份；氧化锆6~10份；氮化硼16~22份；碳纤维8~15份；
（2）将陶瓷原料进行粉碎、研磨和筛分，得到陶瓷原料粉备用；
（3）自来水经过一级石英砂和活性碳的过滤，然后再经过阴阳离子交换树脂过滤，最后经过反渗透过滤，得到去离子水；
（4）将陶瓷原料粉与去离子水按照1:5的重量比混合成浆料，同时向浆料中加入水玻璃、纯碱和减水剂，搅拌均匀后静置8~12天；
（5）对浆料加热熔融，并将熔融后的浆料注入到成型模具中，然后对模具中的坯料进行快速降温使得坯料冷凝成型；
（6）将成型后的坯料放在90~95℃的环境下进行干燥，直至坯料中的含水量低于2.3%。
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