CN111606692A - 一种工业废弃物气化炉渣制备的陶粒支撑剂及制备工艺 - Google Patents

一种工业废弃物气化炉渣制备的陶粒支撑剂及制备工艺 Download PDF

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CN111606692A
CN111606692A CN202010363767.6A CN202010363767A CN111606692A CN 111606692 A CN111606692 A CN 111606692A CN 202010363767 A CN202010363767 A CN 202010363767A CN 111606692 A CN111606692 A CN 111606692A
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furnace slag
mass
shale
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肖国庆
种小川
丁冬海
付鹏程
任耘
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Xian University of Architecture and Technology
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Abstract

本发明属于陶瓷材料领域，主要涉及一种工业废弃物气化炉渣制备的陶粒支撑剂及制备工艺，所述的陶粒支撑剂由气化炉渣、粘土、页岩和/或烧结助剂为原料，进行混料、造粒、筛分和烧结即得，由以下质量分数的原料制成，气化炉渣：20％～50％，粘土：10％～40％，页岩：20％～50％，烧结助剂：0％～10％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。本发明制备的陶粒支撑剂，性能符合SY/T 5108‑2014行业标准，原料中加入气化炉渣，增加了固体废弃物利用率，解决气化炉渣堆放对土地资源的浪费，提高气化炉渣附加值，原料成本低，制备方法简单，利于资源循环和环境保护，为气化炉渣的综合利用提供新的思路。

Description

一种工业废弃物气化炉渣制备的陶粒支撑剂及制备工艺
技术领域
本发明属陶瓷材料领域，特别涉及提出一种工业废弃物气化炉渣制备的陶粒支撑剂及制备工艺。
背景技术
气化炉渣是在煤气化工业中产生的废渣，主要为煤在煤气化炉中不完全燃烧产生的废渣。我国是煤资源生产大国，而煤气化又是提高其产值的重要工艺，因此近年来我国煤气化废渣产量急剧增大，而主要处理手段为填埋和堆放。这导致形成了环境污染、用地紧张、资源过度消耗的尖锐矛盾和紧张局面。因此，为实现环境保护和提高固废附加值，在我国现有资源严重匮乏的情况下，开发含气化炉渣的资源化综合利用技术，对促进循环经济和可持续发展及环境保护具有重要的战略意义和现实意义。陶粒支撑剂是具有不同规格、能够满足一定性能指标，可用于石油工业深处支撑作业的一种高强度的陶瓷颗粒。对于陶粒的研制，我国所采用的主要原料为高品位的矿产资源，通过添加烧结助剂采用烧结法制备而成。传统的陶粒制备主要以高铝矾土、页岩、粘土等不可再生自然资源为原料经加工而成，随着环境保护和资源综合利用政策的执行，寻找适宜的替代不可再生自然资源制备陶粒的原料成为重要任务。目前为止未发现利用气化炉渣作为制备陶粒支撑剂原料的报道。
发明内容
本发明提出一种工业废弃物气化炉渣制备的陶粒支撑剂及制备工艺。用以解决传统的陶粒制备存在的原料资源紧张、环境污染、可持续发展问题。
为了实现上述任务，本发明采取如下技术方案：
一种工业废弃物气化炉渣制备的陶粒支撑剂，所述的陶粒支撑剂由气化炉渣、粘土、页岩和/或烧结助剂为原料，进行混料、造粒、筛分和烧结即得。
具体的，由以下质量分数的原料制成，气化炉渣：20％～50％，粘土：10％～40％，页岩：20％～50％，烧结助剂：0％～10％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。
可选的，由以下质量分数的原料制成，气化炉渣质量分数为50％，原料中粘土质量分数为15％，原料中页岩质量分数为25％，原料中烧结助剂质量分数为10％，所述的烧结助剂为锰矿粉。
具体的，所述的陶粒支撑剂体积密度≤1.7g/cm3，视密度≤3g/cm3，69MPa应力条件下破碎率≤9％，圆度和球度≥0.8，酸溶解度≤5wt％，浊度≤100FTU。
本发明所述的高炉气化炉渣制备的陶粒支撑剂的制备工艺，包括以下步骤：
步骤一：对气化炉渣、页岩进行破碎，并将气化炉渣、粘土、页岩、烧结助剂分别进行粉磨；
步骤二：将气化炉渣、粘土、页岩和烧结助剂分别按以下质量分数称量，并混合；然后添加结合剂在造粒机中使原料混合成球；
步骤三：将球粒分别进行烘干，筛分、烧结即得；
所述的气化炉渣：20％～50％，粘土：10％～40％，页岩：20％～50％，烧结助剂：0％～10％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。
进一步的，所述的结合剂为聚乙烯醇、糊精、羧甲基纤维素中单一组分或者复合组分所得溶液，溶液中聚乙烯醇、糊精、羧甲基纤维素总质量占溶液总质量的0～5％。
进一步的，所述的烧结助剂为钾长石、白云石、方解石、锰矿粉、氧化铁中单一组分或者复合组分。
进一步的，所述的原料中气化炉渣质量分数为40％，粘土质量分数为25％，页岩质量分数为30％，烧结助剂质量分数为5％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％；
所述的烧结助剂为白云石、方解石组成的复合组分，以质量百分比计，烧结助剂中白云石和方解石的质量比为1:1。
进一步的，所述的原料中气化炉渣质量分数为45％，粘土质量分数为20％，页岩质量分数为30，烧结助剂质量分数为5％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％；
原料中烧结助剂为钾长石与氧化铁组成的复合组分，其中钾长石和氧化铁的质量比为1:4。
具体的，所述的烘干干燥温度为80℃～120℃，烧结温度为1100℃～1400℃，保温时间为1.0h～3.0h。
本发明与现有技术相比具有以下优点：
(1)本发明提出了一种陶粒支撑剂，该陶粒支撑剂使用废弃气化炉渣作为原料，实现资源循环利用和环境保护；提高气化炉渣附加值、降低制备成本，制备过程简单经济、快速节能；所制备的陶粒支撑剂性能满足行业标准要求。
(2)本发明提出了一种陶粒支撑剂的制备工艺，该工艺过程简单、经济节能，制备工艺成本低。
附图说明
附图是用来提供对本公开的进一步理解，并且构成说明书的一部分，与下面的具体实施方式一起用于解释本公开，但并不构成对本公开的限制。
在附图中：
图1为本发明的制备工艺流程图；
以下结合附图和实施例对本发明作进一步的详细说明。
具体实施方式
下面结合具体实施例对本发明进行说明，但本发明不限于以下的实施例，对于本发明所属技术领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干简单推演或替换，均能制备出符合要求的陶粒支撑剂，都应当视为属于本发明的保护范围。以下如无特殊说明，物质的用量均为质量百分含量。
本发明中的气化炉渣是指在煤气化工业中产生的废渣，主要为煤在煤气化炉中不完全燃烧产生的废渣。本发明中的气化炉渣可取自煤气化工厂，其余试剂均为市售可得。
本发明的陶粒支撑剂由气化炉渣、粘土、页岩和/或烧结助剂为原料，进行混料、造粒、筛分和烧结即得。
由以下质量分数的原料制成，气化炉渣：20％～50％，粘土：10％～40％，页岩：20％～50％，烧结助剂：0％～10％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。
本发明的高炉气化炉渣制备的陶粒支撑剂的制备工艺，包括以下步骤：
步骤一：对气化炉渣、页岩进行破碎，并将气化炉渣、粘土、页岩、烧结助剂分别进行粉磨；
步骤二：将气化炉渣、粘土、页岩和烧结助剂分别按以下质量分数称量，并混合；然后添加结合剂在造粒机中使原料混合成球；
步骤三：将球粒分别进行烘干，筛分、烧结即得；
所述的气化炉渣：20％～50％，粘土：10％～40％，页岩：20％～50％，烧结助剂：0％～10％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。
所述的烘干干燥温度为80℃～120℃，烧结温度为1100℃～1400℃，保温时间为1.0h～3.0h。
所述的结合剂为聚乙烯醇、糊精、羧甲基纤维素中单一组分或者复合组分所得溶液，溶液中聚乙烯醇、糊精、羧甲基纤维素总质量占溶液总质量的0～5％。
所述的烧结助剂为钾长石、白云石、方解石、锰矿粉、氧化铁中单一组分或者复合组分。
实施例1
本实施例提出一种工业废弃物气化炉渣制备陶粒支撑剂。陶粒支撑剂由以下原料制成：气化炉渣、粘土、页岩和/或烧结助剂。气化炉渣中主要物相为铝硅酸盐。
本实施例陶粒支撑剂由以下质量分数的原料制成，气化炉渣质量分数为50％，原料中粘土质量分数为15％，原料中页岩质量分数为25％，原料中烧结助剂质量分数为10％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。原料中烧结助剂为单一的锰矿粉。
本实施例还公开了一种工业废弃物气化炉渣制备陶粒支撑剂的制备工艺，包括以下步骤：
步骤一：对气化炉渣、页岩进行破碎，并将气化炉渣、粘土、页岩、烧结助剂分别进行粉磨；所述的原料粉磨后均过200目筛，即粉体粒度均小于0.074mm。
步骤二：将气化炉渣、粘土、页岩和烧结助剂分别按以下质量分数称量，并混合；然后添加结合剂在造粒机中使原料混合成球；
具体是将称量好的原料在球磨机里进行混合，然后将混合均匀的粉料放入糖衣造粒机中，以糊精为单一组分配成溶液作为结合剂，使粉料混合成球；以质量百分比计，结合剂溶液中糊精占溶液总质量的5％。
步骤三：将球粒分别进行烘干，筛分、烧结即得；
具体是：将球粒进行烘干，利用标准筛对烘干球料进行初次筛分；最后在高温炉中进行烧结；
筛分检测：将烧结后的陶粒进行二次筛分后对性能进行检测，最终得到性能符合SY/T 5108-2014行业标准的陶粒支撑剂。
陶粒生坯的干燥温度为90℃，烧结温度为1150℃，保温时间为2h。
烧结后的陶粒支撑剂体积密度1.42g/cm3，视密度2.81g/cm3，69MPa应力条件下破碎率6.4％，圆度和球度0.8，酸溶解度3.6wt％，浊度85FTU，其性能满足行业标准要求，可用于压裂作业。
实施例2：
同实施例1，但与实施例1不同的是，本实施例陶粒支撑剂由以下质量分数的原料制成，原料中气化炉渣质量分数为40％，原料中粘土质量分数为25％，原料中页岩质量分数为30％，原料中烧结助剂质量分数为5％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。
原料中烧结助剂为白云石、方解石组成的复合组分，以质量百分比计，烧结助剂中白云石和方解石的质量比为1:1。
以质量百分比计，所述的结合剂溶液中聚乙烯醇、糊精、羧甲基纤维素总质量占溶液的0％。
陶粒生坯的干燥温度为80℃，烧结温度为1200℃，保温时间为2h。
将烧结后的陶粒进行二次筛分后对性能进行检测，烧结后的陶粒支撑剂体积密度1.46g/cm3，视密度2.85g/cm3，69MPa应力条件下破碎率6.8％，圆度和球度0.8，酸溶解度4.0wt％，浊度90FTU，其性能满足行业标准要求，可用于压裂作业。最终得到性能符合SY/T5108-2014行业标准的陶粒支撑剂。
实施例3
同实施例1，但与实施例1不同的是，本实施例陶粒支撑剂由以下质量分数的原料制成，原料中气化炉渣：30％，粘土：30％，页岩：40％，烧结助剂：0％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。
陶粒生坯的干燥温度为80℃，烧结温度为1300℃，保温时间为2h。
以质量百分比计，聚乙烯醇溶液单一组分作为结合剂，结合剂聚乙烯醇的浓度为1％。
经检测，烧结后的陶粒支撑剂体积密度1.44g/cm3，视密度2.83g/cm3，69MPa应力条件下破碎率6.2％，圆度和球度0.8，酸溶解度3.8wt％，浊度90FTU，其性能满足行业标准要求，可用于压裂作业。最终得到性能符合SY/T 5108-2014行业标准的陶粒支撑剂。
实施例4
同实施例1，但与实施例1不同的是，本实施例陶粒支撑剂由以下质量分数的原料制成，原料中气化炉渣质量分数为45％，原料中粘土质量分数为20％，原料中页岩质量分数为30，原料中烧结助剂质量分数为5％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。
原料中烧结助剂为钾长石与氧化铁组成的复合组分，其中钾长石和氧化铁的质量比为1:4。
陶粒生坯的干燥温度为90℃，烧结温度为1200℃，保温时间为3h。
以质量百分比计，所述的结合剂选择羧甲基纤维素为单一组分配成溶液作为结合剂，以质量百分比计，结合剂溶液中羧甲基纤维素占溶液总质量的2％。
烧结后的陶粒支撑剂体积密度1.48g/cm3，视密度2.87g/cm3，69MPa应力条件下破碎率6.6％，圆度和球度0.8，酸溶解度3.9wt％，浊度90FTU，其性能满足行业标准要求，可用于压裂作业。最终得到性能符合SY/T 5108-2014行业标准的陶粒支撑剂。

Claims (10)

1.一种工业废弃物气化炉渣制备的陶粒支撑剂，其特征在于，所述的陶粒支撑剂由气化炉渣、粘土、页岩和/或烧结助剂为原料，进行混料、造粒、筛分和烧结即得。
2.根据权利要求1所述的高炉气化炉渣制备的陶粒支撑剂，其特征在于，由以下质量分数的原料制成，气化炉渣：20％～50％，粘土：10％～40％，页岩：20％～50％，烧结助剂：0％～10％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。
3.根据权利要求1所述的高炉气化炉渣制备的陶粒支撑剂，其特征在于，由以下质量分数的原料制成，气化炉渣质量分数为50％，原料中粘土质量分数为15％，原料中页岩质量分数为25％，原料中烧结助剂质量分数为10％，所述的烧结助剂为锰矿粉。
4.根据权利要求1所述的高炉气化炉渣制备的陶粒支撑剂，其特征在于，所述的陶粒支撑剂体积密度≤1.7g/cm3，视密度≤3g/cm3，69MPa应力条件下破碎率≤9％，圆度和球度≥0.8，酸溶解度≤5wt％，浊度≤100FTU。
5.权利要求1～4任一所述的高炉气化炉渣制备的陶粒支撑剂的制备工艺，其特征在于，包括以下步骤：
步骤一：对气化炉渣、页岩进行破碎，并将气化炉渣、粘土、页岩、烧结助剂分别进行粉磨；
步骤二：将气化炉渣、粘土、页岩和烧结助剂分别按以下质量分数称量，并混合；然后添加结合剂在造粒机中使原料混合成球；
步骤三：将球粒分别进行烘干，筛分、烧结即得；
所述的气化炉渣：20％～50％，粘土：10％～40％，页岩：20％～50％，烧结助剂：0％～10％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％。
6.权利要求5所述的高炉气化炉渣制备的陶粒支撑剂的制备工艺，其特征在于，所述的结合剂为聚乙烯醇、糊精、羧甲基纤维素中单一组分或者复合组分所得溶液，溶液中聚乙烯醇、糊精、羧甲基纤维素总质量占溶液总质量的0～5％。
7.权利要求5所述的高炉气化炉渣制备的陶粒支撑剂的制备工艺，其特征在于，所述的烧结助剂为钾长石、白云石、方解石、锰矿粉、氧化铁中单一组分或者复合组分。
8.权利要求5所述的高炉气化炉渣制备的陶粒支撑剂的制备工艺，其特征在于，所述的原料中气化炉渣质量分数为40％，粘土质量分数为25％，页岩质量分数为30％，烧结助剂质量分数为5％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％；
所述的烧结助剂为白云石、方解石组成的复合组分，以质量百分比计，烧结助剂中白云石和方解石的质量比为1:1。
9.权利要求5所述的高炉气化炉渣制备的陶粒支撑剂的制备工艺，其特征在于，所述的原料中气化炉渣质量分数为45％，粘土质量分数为20％，页岩质量分数为30，烧结助剂质量分数为5％，气化炉渣、粘土、页岩和烧结助剂质量百分比之和为100％；
原料中烧结助剂为钾长石与氧化铁组成的复合组分，其中钾长石和氧化铁的质量比为1:4。
10.权利要求5所述的高炉气化炉渣制备的陶粒支撑剂的制备工艺，其特征在于，所述的烘干干燥温度为80℃～120℃，烧结温度为1100℃～1400℃，保温时间为1.0h～3.0h。
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