CN111662073A - 一种大流量管式陶瓷膜的陶瓷泥料及制备方法 - Google Patents
一种大流量管式陶瓷膜的陶瓷泥料及制备方法 Download PDFInfo
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Abstract
本发明提的一种大流量管式陶瓷膜的陶瓷泥料及制备方法,其陶瓷泥料包括以下原料:(1)固体原料为包括以下质量分数的原料:粒径为80~120μm的氧化铝粉:70%~80%,粒径为5~30μm的氧化铝粉:10%~20%,造孔剂:3%~7%,烧结助剂:5%~8%;(2)液体原料为包括以下质量分数的原料:分散剂:15%~25%,润滑剂:10%~15%,纯水:60%~75%;所述固体原料与所述液体原料的重量比为(3~6):1。本发明的方法工艺简单,设计合适的混料、挤出、干燥、烧成等关键工艺参数,有效提高大流量管式陶瓷膜的合格率;合格率可达到85%以上,降低了生产成本;产品具有占地面积小、渗透性能好。
Description
技术领域
本发明属于陶瓷膜生产技术领域,具体涉及一种大流量管式陶瓷膜的陶瓷泥料及制备方法。
背景技术
电厂冷凝水中含有金属氧化物及其它悬浮硅颗粒,这些颗粒有可能降低离子交换床的效能,污染和降低热交换器的热传导效率,侵蚀蒸汽发生装置,加大锅炉清洗频次和不正常的管路爆裂。这些冷凝水中颗粒粒径在1~5μm的含有80%,颗粒粒径在5~15μm的含有20%,因此制备孔径5μm左右大流量管式陶瓷膜在发电厂水系统中有较大应用前景。另外大流量(孔径5~10μm)管式陶瓷膜可用于保安过滤系统中,用于超滤与反渗透之间,对反渗透膜起一个保护作用。
现有的文献资料研究,例如:文献【韩火年,李强,等. 莫来石-刚玉多孔陶瓷膜支撑体的制备[J]. 功能材料,2011,42(3):425-428】采用挤出成型、烧结等方法制备的陶瓷膜支撑体流量低,烧结温度1550℃太高,制备成本高。文献【杨柯,常启兵,等. 高岭土为助烧剂制备多孔陶瓷膜支撑体[J]. 中国陶瓷,2012,48(9):24-27】通过调节高岭土、刚玉等量制备的陶瓷膜支撑体在1510℃烧成,温度高,制备成本高。而且,现有技术中制备大流量管式陶瓷膜滤芯存在合格率低、流量低等问题,各专利中没有提出有效的控制措施,本发明通过调整优化配比,确定合适的工艺参数制备出高合格率的大流量管式陶瓷膜。
发明内容
本发明的目的是提供一种大流量管式陶瓷膜的陶瓷泥料及制备方法,以解决现有技术中存在的烧成温度高、合格率低、制备成本高的问题。
本发明的技术方案如下:
一种大流量管式陶瓷膜的陶瓷泥料,其特征在于,包括以下原料:
(1)固体原料为包括以下质量分数的原料:粒径为80~120μm的氧化铝粉:70%~80%,粒径为5~30μm的氧化铝粉:10%~20%,造孔剂:3%~7%,烧结助剂:5%~8%;
(2)液体原料为包括以下质量分数的原料:分散剂:15%~25%,润滑剂:10%~15%,纯水:60%~75%;
所述固体原料与所述液体原料的重量比为(3~6):1;
所述造孔剂为淀粉、甲基纤维素或玉米粉的一种或几种,其平均粒径为100~150μm;所述烧结助剂为滑石粉、云母粉或石英石的一种或者几种,其平均粒径为2~5μm;所述分散剂为聚乙二醇或/和聚丙烯酸,所述聚乙二醇的分子量为400~600,所述聚丙烯酸的分子量为500~1000;所述润滑剂为甘油、硅油润滑剂或聚酯润滑剂的一种或者几种。
本发明所述的一种大流量管式陶瓷膜的制备方法,其特征在于,包括以下步骤:
(1)陶瓷泥料的制备:将所述固体原料和所述液体原料分别混合均匀;再将所述液体原料加入持续搅拌的所述固体原料中,混合均匀后密闭陈腐12~48h,得到陶瓷泥料;
(2)素坯的制备:采用两段螺杆挤出成型法,将所述陶瓷泥料投入螺杆挤出机中真空练泥并挤出成型,挤出速度为0.5~1.5m/min,挤出温度为15~25℃,挤出压力为4~13bar;切割得到湿素胚;
(3)素坯的干燥:将所述湿素坯置于常温下自然干燥12~24h,然后送入热风干燥窑中,在24~72h内从30℃缓慢升温至60~70℃干燥,得到干素胚;
(4)素坯的烧结:将所述干素坯送入梭式窑中烧结,升温速率为2~5℃/h,在1300~1500℃下烧结,保温时间2~5h后降温,降温速率为3~5℃/h,冷却后即可得到本发明所述的大流量管式陶瓷膜。
优选地,在所述步骤(1)中,将所述液体原料以喷洒的方式加入持续搅拌的所述固体原料中。
优选地,在所述步骤(2)中,采用红外线进行切割得到所述湿素胚,可以避免管式陶瓷膜素胚在挤出过程中变形的问题。
优选地,在所述步骤(3)中,所述热风干燥窑中,干燥温度的升温速率为1.5~3℃/h,通过平缓升温避免素坯因水分蒸发太快引起的开裂或者变形问题。
优选地,在所述步骤(4)中,采用U型陶瓷棍棒将所述干素坯送入梭式窑中烧结,可以减少管式陶瓷膜在烧成过程中的变形。
本发明与现有技术相比,有如下好处:
本发明的方法工艺简单,设计合适的混料、挤出、干燥、烧成等关键工艺参数,有效提高大流量管式陶瓷膜的合格率;合格率可达到85%以上,降低了生产成本;烧结时升温降温曲线严格控制缓慢升温降温,避免快速烧成,坯体开裂;所制成的大流量管式陶瓷膜用于保安过滤器、电厂冷凝水处理等领域,纯水通量可达30m3/(m2·h)以上,具有占地面积小、渗透性能好、运行成本低等优点。
具体实施方式
下面结合具体实施例,进一步阐述本发明。应理解,本实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解,在阅读了本发明讲授的内容之后,本领域技术人员可以对本发明作各种改动或修改,这些等价形式同样落于本申请所附权利要求书所限定的范围。
实施例1
一种大流量管式陶瓷膜的陶瓷泥料为:
(1)固体原料:平均粒径110μm的氧化铝粉体75wt%、平均粒径25μm的氧化铝粉体15wt%、淀粉4wt%、滑石粉6wt%,总质量120kg;
(2)液体原料:分子量为400的聚乙二醇20wt%、甘油15wt%、纯水65wt%,总质量为20kg;固体原料和液体原料的重量比为6:1。
一种大流量管式陶瓷膜的制备方法,包括以下步骤:
(1)陶瓷泥料的制备:将所述固体原料和所述液体原料分别混合均匀;再以喷雾的方式将所述液体原料加入持续搅拌的所述固体原料中,混合均匀后密闭陈腐12h,得到陶瓷泥料;
(2)素坯的制备:采用两段螺杆挤出成型法,将陶瓷泥料投入螺杆挤出机中真空练泥并挤出成型,挤出速度为1m/min,挤出温度为20℃,挤出压力为6bar,挤出素胚为通道19,将挤出成型的泥料送至传送带上,传输皮带的速度与挤出速度一致,采用红外线切割得到外径43mm,长度1.3m的湿素胚;
(3)素坯的干燥:通过V型槽将湿素胚放置在铺有海绵的多孔不钢板上,在常温下自然干燥18h;然后送入热风干燥窑中,在24h内从30℃缓慢升温至60℃干燥,得到干素胚;
(4)素坯的烧结:采用U型陶瓷棍棒将所述干素坯送入梭式窑中烧结,升温速率为4℃/h,在1400℃下烧结,保温时间3h后降温,降温速率为4℃/h,冷却后即可得到本发明所述的大流量管式陶瓷膜。
实施例1得到的大流量管式陶瓷膜的平均孔径5μm,纯水通量37m3/(m2·h),制备每批大流量管式陶瓷膜的合格率为86%。
实施例2
一种大流量管式陶瓷膜的陶瓷泥料为:
(1)固体原料:平均粒径85μm的氧化铝粉体72wt%、平均粒径10μm的氧化铝粉体18wt%、甲基纤维素3wt%、石英石粉7wt%,总质量100kg;
(2)液体原料:分子量为600的聚丙烯酸20wt%、甘油13.5wt%、纯水66.5wt%,总质量为20kg;固体原料和液体原料的重量比为5:1。
一种大流量管式陶瓷膜的制备方法,包括以下步骤:
(1)陶瓷泥料的制备:将所述固体原料和所述液体原料分别混合均匀;再以喷雾的方式将所述液体原料加入持续搅拌的所述固体原料中,混合均匀后密闭陈腐24h,得到陶瓷泥料;
(2)素坯的制备:采用两段螺杆挤出成型法,将陶瓷泥料投入螺杆挤出机中真空练泥并挤出成型,挤出速度为1.2m/min,挤出温度为22℃,挤出压力为8bar,挤出素胚为通道19,将挤出成型的泥料送至传送带上,传输皮带的速度与挤出速度一致,采用红外线切割得到外径43mm,长度1.3m的湿素胚;
(3)素坯的干燥:通过V型槽将湿素胚放置在铺有海绵的多孔不钢板上,在常温下自然干燥20h;然后送入热风干燥窑中,在36h内从30℃缓慢升温至65℃干燥,得到干素胚;
(4)素坯的烧结:采用U型陶瓷棍棒将所述干素坯送入梭式窑中烧结,升温速率为3℃/h,在1450℃下烧结,保温时间2.2h后降温,降温速率为3℃/h,冷却后即可得到本发明所述的大流量管式陶瓷膜。
实施例2得到的大流量管式陶瓷膜的平均孔径4μm,纯水通量30m3/(m2·h),制备每批大流量管式陶瓷膜的合格率为88%。
实施例3
一种大流量管式陶瓷膜的陶瓷泥料为:
(1)固体原料:平均粒径100μm的氧化铝粉体70wt%、平均粒径15μm的氧化铝粉体20wt%、玉米粉4wt%、云母粉6wt%,总质量80kg;
(2)液体原料:分子量为600的聚乙二醇17wt%、聚酯润滑剂13wt%、纯水70wt%,总质量为20kg;固体原料和液体原料的重量比为4:1。
一种大流量管式陶瓷膜的制备方法,包括以下步骤:
(1)陶瓷泥料的制备:将所述固体原料和所述液体原料分别混合均匀;再以喷雾的方式将所述液体原料加入持续搅拌的所述固体原料中,混合均匀后密闭陈腐48h,得到陶瓷泥料;
(2)素坯的制备:采用两段螺杆挤出成型法,将陶瓷泥料投入螺杆挤出机中真空练泥并挤出成型,挤出速度为1.5m/min,挤出温度为22℃,挤出压力为9bar,挤出素胚为通道19,将挤出成型的泥料送至传送带上,传输皮带的速度与挤出速度一致,采用红外线切割得到外径43mm,长度1.3m的湿素胚;
(3)素坯的干燥:通过V型槽将湿素胚放置在铺有海绵的多孔不钢板上,在常温下自然干燥24h;然后送入热风干燥窑中,在40h内从30℃缓慢升温至60℃干燥,得到干素胚;
(4)素坯的烧结:采用U型陶瓷棍棒将所述干素坯送入梭式窑中烧结,升温速率为2.5℃/h,在1350℃下烧结,保温时间4h后降温,降温速率为4.5℃/h,冷却后即可得到本发明所述的大流量管式陶瓷膜。
实施例3得到的大流量管式陶瓷膜的平均孔径4.5μm,纯水通量33m3/(m2·h),制备每批大流量管式陶瓷膜的合格率为92%。
实施例4
一种大流量管式陶瓷膜的陶瓷泥料为:
(1)固体原料:平均粒径100μm的氧化铝粉体75wt%、平均粒径15μm的氧化铝粉体10wt%、玉米粉7wt%、滑石粉8wt%,总质量100kg;
(2)液体原料:分子量为400的聚乙二醇25wt%、聚酯润滑剂15wt%、纯水60wt%,总质量为20kg;固体原料和液体原料的重量比为5:1。
一种大流量管式陶瓷膜的制备方法,包括以下步骤:
(1)陶瓷泥料的制备:将所述固体原料和所述液体原料分别混合均匀;再以喷雾的方式将所述液体原料加入持续搅拌的所述固体原料中,混合均匀后密闭陈腐35h,得到陶瓷泥料;
(2)素坯的制备:采用两段螺杆挤出成型法,将陶瓷泥料投入螺杆挤出机中真空练泥并挤出成型,挤出速度为1.2m/min,挤出温度为20℃,挤出压力为10bar,挤出素胚为通道19,将挤出成型的泥料送至传送带上,传输皮带的速度与挤出速度一致,采用红外线切割得到外径43mm,长度1.3m的湿素胚;
(3)素坯的干燥:通过V型槽将湿素胚放置在铺有海绵的多孔不钢板上,在常温下自然干燥20h;然后送入热风干燥窑中,在48h内从30℃缓慢升温至70℃干燥,得到干素胚;
(4)素坯的烧结:采用U型陶瓷棍棒将所述干素坯送入梭式窑中烧结,升温速率为3.5℃/h,在1300℃下烧结,保温时间5h后降温,降温速率为3℃/h,冷却后即可得到本发明所述的大流量管式陶瓷膜。
实施例4得到的大流量管式陶瓷膜的平均孔径5.1μm,纯水通量35m3/(m2·h),制备每批大流量管式陶瓷膜的合格率为90%。
Claims (7)
1.一种大流量管式陶瓷膜的陶瓷泥料,其特征在于,包括以下原料:
(1)固体原料为包括以下质量分数的原料:粒径为80~120μm的氧化铝粉:70%~80%,粒径为5~30μm的氧化铝粉:10%~20%,造孔剂:3%~7%,烧结助剂:5%~8%;
(2)液体原料为包括以下质量分数的原料:分散剂:15%~25%,润滑剂:10%~15%,纯水:60%~75%;
所述固体原料与所述液体原料的重量比为(3~6):1。
2.根据权利要求1所述的大流量管式陶瓷膜的陶瓷泥料,其特征在于,所述造孔剂为淀粉、甲基纤维素或玉米粉的一种或几种,其平均粒径为100~150μm;所述烧结助剂为滑石粉、云母粉或石英石的一种或者几种,其平均粒径为2~5μm;所述分散剂为聚乙二醇或/和聚丙烯酸,所述聚乙二醇的分子量为400~600,所述聚丙烯酸的分子量为500~1000;所述润滑剂为甘油、硅油润滑剂或聚酯润滑剂的一种或者几种。
3.一种采用权利要求1或2所述的陶瓷泥料制备的大流量管式陶瓷膜的制备方法,其特征在于,包括以下步骤:
(1)陶瓷泥料的制备:将所述固体原料和所述液体原料分别混合均匀;再将所述液体原料加入持续搅拌的所述固体原料中,混合均匀后密闭陈腐12~48h,得到陶瓷泥料;
(2)素坯的制备:采用两段螺杆挤出成型法,将所述陶瓷泥料投入螺杆挤出机中真空练泥并挤出成型,挤出速度为0.5~1.5m/min,挤出温度为15~25℃,挤出压力为4~13bar;切割得到湿素胚;
(3)素坯的干燥:将所述湿素坯置于常温下自然干燥12~24h,然后送入热风干燥窑中,在24~72h内从30℃缓慢升温至60~70℃干燥,得到干素胚;
(4)素坯的烧结:将所述干素坯送入梭式窑中烧结,升温速率为2~5℃/h,在1300~1500℃下烧结,保温时间2~5h后降温,降温速率为3~5℃/h,冷却后即可得到本发明所述的大流量管式陶瓷膜。
4.根据权利要求3所述的大流量管式陶瓷膜的制备方法,其特征在于,在所述步骤(1)中,将所述液体原料以喷洒的方式加入持续搅拌的所述固体原料中。
5.根据权利要求3所述的大流量管式陶瓷膜的制备方法,其特征在于,在所述步骤(2)中,采用红外线进行切割得到所述湿素胚。
6.根据权利要求3所述的大流量管式陶瓷膜的制备方法,其特征在于,在所述步骤(3)中,所述热风干燥窑中,干燥温度的升温速率为1.5~3℃/h。
7.根据权利要求3所述的大流量管式陶瓷膜的制备方法,其特征在于,在所述步骤(4)中,采用U型陶瓷棍棒将所述干素坯送入梭式窑中烧结。
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