CN112408801A - Method for preparing light microlite plate by calendering process - Google Patents
Method for preparing light microlite plate by calendering process Download PDFInfo
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- CN112408801A CN112408801A CN202011381759.0A CN202011381759A CN112408801A CN 112408801 A CN112408801 A CN 112408801A CN 202011381759 A CN202011381759 A CN 202011381759A CN 112408801 A CN112408801 A CN 112408801A
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C10/00—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B13/00—Rolling molten glass, i.e. where the molten glass is shaped by rolling
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B13/00—Rolling molten glass, i.e. where the molten glass is shaped by rolling
- C03B13/12—Rolling glass with enclosures, e.g. wire, bubbles, fibres, particles or asbestos
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B19/00—Other methods of shaping glass
- C03B19/08—Other methods of shaping glass by foaming
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
- C03B5/16—Special features of the melting process; Auxiliary means specially adapted for glass-melting furnaces
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C11/00—Multi-cellular glass ; Porous or hollow glass or glass particles
- C03C11/007—Foam glass, e.g. obtained by incorporating a blowing agent and heating
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/50—Glass production, e.g. reusing waste heat during processing or shaping
- Y02P40/57—Improving the yield, e-g- reduction of reject rates
Abstract
A method for preparing a light microlite plate by a calendering process comprises the steps of preparing a light microlite facing layer melt and a light microlite foaming layer melt; calendering and molding the prepared light microlite finishing layer melt, extruding, extending and stretching the melt under the action of a calendering and molding machine to form a continuous flaky light microlite finishing layer melt with a certain thickness; covering the light microlite foaming layer melt on the surface of the flaky facing layer melt to form a composite melt; forming the composite melt into a continuous sheet-shaped composite melt with a certain thickness; and (3) carrying out a foaming process on the prepared continuous flaky composite melt, and carrying out steps of slitting, stress relieving and cooling on the prepared continuous flaky plate to finish the preparation. The scheme replaces the traditional process with the calendering process, realizes the preparation of the decorative integrated light microcrystalline stone plate, has simple process steps and stable product quality, greatly reduces the production energy consumption, shortens the firing period and improves the production efficiency.
Description
Technical Field
The invention relates to the technical field of light microlite production, in particular to a method for preparing a light microlite plate by a calendering process.
Background
In the prior art, the light microlite is produced by a traditional firing method, wherein materials are put into a prepared die, and the light microlite is produced by a sintering molding process. The prior art has the advantages that a large amount of heat is absorbed by the mold in the firing process, so that the production energy consumption is high, and a certain distance must be reserved between the front product and the rear product due to the existence of the mold, so that the front-rear temperature difference of the product in the motion direction is controlled, the abrasion caused by collision between the molds is reduced, and the production stability is guaranteed. In addition, the refractory material has limited ability of resisting rapid cooling and rapid heating, and cannot realize a rapid firing process, so that the firing period needs to be properly prolonged, and the productivity is not favorably improved.
In conclusion, under the common influence of high energy consumption and low productivity, the prior art can only realize the production process of the light microlite plate with the period of 20-24 hours, and the production is severely restricted, so that the industrial production-output ratio is low.
Disclosure of Invention
In order to solve the problems of high energy consumption and low production energy in the prior art, the invention aims to provide a method for preparing a light microcrystalline stone plate by using a rolling process, the rolling process is used for replacing the traditional process, the preparation of a decorative integrated light microcrystalline stone plate is realized, the process steps are simple, the product quality is stable, the production energy consumption is greatly reduced, the firing period is shortened, and the production efficiency is improved.
The technical scheme adopted by the invention is as follows: a method for preparing a light microcrystalline stone plate by a rolling process comprises the following steps:
s1, proportioning and uniformly mixing the raw materials forming the light microlite facing layer, and then feeding the prepared raw materials into a smelting furnace for smelting to prepare a light microlite facing layer melt for later use;
s2, proportioning and uniformly mixing the raw materials forming the light microlite foaming layer, and then feeding the prepared raw materials into a smelting furnace for smelting to prepare a light microlite foaming layer melt for later use;
s3, performing calendering molding on the prepared light microlite finish coat melt, and extruding, extending and stretching the melt under the action of a calendering molding machine to form a continuous flaky light microlite finish coat melt with a certain thickness;
s4, covering the prepared light microlite foaming layer melt on the surface of the flaky light microlite decorative layer melt to form a composite melt;
s5, carrying out calendering molding on the composite melt, and extruding, extending and stretching the composite melt under the action of a calendering molding machine to form a continuous sheet-shaped composite melt with a certain thickness;
s6, insulating the prepared continuous flaky composite melt to complete the foaming process of the foaming layer melt therein, and preparing a continuous flaky plate with a porous structure;
and S7, cutting, stress relieving and cooling the prepared continuous flaky board to finish the preparation.
Further optimizing, in the step S1, the smelting temperature of the light microlite facing layer raw material is 1500-.
Further optimized, in the step S2, the smelting temperature of the light microlite foaming layer raw material is 1250-.
Further preferably, in the steps of S1 and S2, the smelting furnace is a full electric energy smelting furnace or a natural gas smelting furnace.
Further optimized, in the step S3, the temperature of the light microlite facing layer melt calendering molding is above 1300-1450 ℃, and the thickness of the melt obtained after calendering molding is 0.6-0.8 cm.
Further optimized, in step S4, the preparation process of the composite melt is as follows: and (3) positioning the continuous flaky light microlite facing layer melt below a discharge hole of the smelting furnace, flowing the light microlite foaming layer melt to the surface of the smelting furnace until the light microlite facing layer melt completely covers the surface of the light microlite facing layer melt, and forming a composite melt by the light microlite facing layer melt and the light microlite facing layer melt in a high-temperature environment.
Further optimizing, in the step S5, in the calendering and molding of the composite melt, the temperature is controlled at 1000 ℃ and 1200 ℃, and the thickness of the continuous sheet-shaped composite melt obtained after calendering and molding is 4-6 cm.
Further optimization, in the step S6, the temperature in the heat preservation process is controlled at 1000-1200 ℃, and the temperature is maintained for a period of time, so that the foaming layer in the composite melt contacts with air in a high-temperature environment to start an oxidation-reduction reaction, and cellular pores are generated.
And further optimizing, in the step S7, in the step of stress relief and temperature reduction, the cut plate is sent into a multilayer roller kiln for processing.
Further optimally, in step S7, the slitting process is set after the stress relief and temperature reduction process.
The invention has the beneficial effects that:
firstly, the invention provides the method for preparing the light microlite plate by the calendering process through optimizing the process steps, the method adopts the smelting process and the calendering forming process as an auxiliary to prepare the light microlite plate, and abandons the refractory material as a forming die, thereby greatly reducing the production energy consumption and providing possibility for quick firing of the product.
In the scheme, a smelting furnace direct smelting mode is adopted in a smelting process, the light microlite decorative layer and the light microlite foaming layer are compounded in a high-temperature area, and then a foaming procedure is carried out to form the decoration integrated light microlite plate with honeycomb-shaped air holes; in the process, a die which is high in energy consumption, rapid cooling resistance and poor in rapid heating capacity is abandoned, and the original production time of only 20-25 square meters in 1 hour is increased to 60-80 square meters in 1 hour; the process for preparing the decorative integrated light microcrystal stone plate has extremely high economic benefit.
Thirdly, in the scheme, the light microlite is calendered, stretched and molded by adopting the melt through a calendering molding machine in the calendering molding process. The calendering and molding process abandons the use of a mold in the traditional mold molding process, can quickly produce continuous sheet products with specific specification and size according to actual requirements, and has high molding efficiency and strong operability of product specification.
And fourthly, the stress of the plate cooling section is eliminated and the temperature is reduced by adopting a multilayer roller kiln, so that the waste of heat energy is avoided, and the productivity is improved.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the scope of the present invention.
A method for preparing a light microlite plate by a rolling process adopts a smelting process and a rolling forming process, abandons a refractory material as a forming die, greatly reduces the production energy consumption, and provides possibility for quick firing of products.
The calendering molding process comprises the following steps: the method is characterized in that melt obtained by smelting is extruded, extended and stretched by a calendaring forming machine to form a continuous sheet product with certain specification and size requirements.
It should be noted that: the main innovation points of the scheme are as follows: the light microlite plate is prepared by combining a smelting process and a calendaring forming process, the composition and the proportion of the raw materials of the decorative layer and the foaming layer in the light microlite plate do not relate to the composition and the proportion, and the content does not belong to the improvement point of the scheme, and a person skilled in the art can adopt the existing mature formula to operate when implementing the scheme.
The specific steps of the scheme are described in detail as follows: a method for preparing a light microcrystalline stone plate by a rolling process comprises the following steps:
step one, proportioning and uniformly mixing raw materials for forming a light microlite facing layer, and then feeding the prepared raw materials into a smelting furnace for smelting, wherein the smelting temperature of the raw materials for the light microlite facing layer is 1500-;
step two, proportioning and uniformly mixing the raw materials for forming the light microlite foaming layer, and then sending the prepared raw materials into a smelting furnace for smelting, wherein the smelting temperature of the raw materials for the light microlite foaming layer is 1250-;
thirdly, performing calendering molding on the prepared light microlite facing layer melt, wherein the calendering molding temperature of the light microlite facing layer melt is above 1300 ℃ and 1450 ℃, and extruding, extending and stretching the melt under the action of a calendering molding machine to form a continuous flaky light microlite facing layer melt with the thickness of 0.6-0.8 cm;
covering the prepared light microlite foaming layer melt on the surface of the flaky light microlite finishing layer melt to form a composite melt;
step five, carrying out calendering molding on the composite melt, controlling the temperature at 1000-1200 ℃, and extruding, extending and stretching the composite melt under the action of a calendering molding machine to form a continuous sheet-shaped composite melt with the thickness of 4-6 cm;
step six, the prepared continuous flaky composite melt is subjected to heat preservation, the foaming process of the foaming layer melt is completed, and the continuous flaky plate with the porous structure is prepared;
and seventhly, cutting, stress relieving and cooling the prepared continuous flaky board to finish the preparation.
In the scheme, in the fourth step, the preparation process of the composite melt is as follows: and (3) positioning the continuous flaky light microlite facing layer melt below a discharge hole of the smelting furnace, flowing the light microlite foaming layer melt to the surface of the smelting furnace until the light microlite facing layer melt completely covers the surface of the light microlite facing layer melt, and forming a composite melt by the light microlite facing layer melt and the light microlite facing layer melt in a high-temperature environment.
In the sixth step, the temperature is controlled to be 1000-1200 ℃ in the heat preservation process, the temperature is kept for a period of time, the foaming layer in the composite melt contacts with air in a high-temperature environment to start oxidation-reduction reaction, and honeycomb-shaped air holes are generated.
In the seventh step, in the stress relieving and cooling step, the cut plate is sent into a multilayer roller kiln for processing. It should be noted that: the method comprises the following steps: the slitting process can be arranged after the stress relief and cooling process.
As another preferred embodiment of the present invention, the cooling process may employ a conventional single-layer roller kiln.
Examples 1,
A method for preparing a light microlite plate by a calendering process comprises the following preparation steps:
(1) preparing a light microlite facing layer material by mixing mineral raw materials and chemical raw materials according to mass percentage, wherein the raw material components are weighed according to the proportion of 73% of quartz, 8% of albite, 4% of kaolin, 4% of talc, 3% of dolomite, 3% of soda ash, 4% of barium carbonate and 1% of a clarifying agent, and the raw material components are crushed and added into a mixer to be uniformly mixed;
(2) preparing a light microlite foaming layer material by mixing mineral raw materials and chemical raw materials according to mass percentage, wherein raw material components of 50% of quartz, 20% of albite, 10% of calcite, 10% of glass powder, 3% of soda, 3.5% of barium carbonate, 3% of borax and 0.5% of silicon carbide are weighed, crushed and added into a mixer for uniform mixing;
(3) adding the material prepared in the step (1) into a smelting furnace I, and smelting at 1590 ℃ for 24 hours to fully melt the material to prepare a light microlite facing layer melt;
(4) adding the material obtained in the step (2) into a smelting furnace II, and smelting at 1300 ℃ for 24 hours to fully melt the material to prepare a light microlite foaming layer melt;
(5) the melt prepared in the step (3) is subjected to calendering molding at 1300 ℃ to prepare a continuous flaky light microcrystalline stone decorative layer melt with the thickness of 0.7 cm;
(6) covering the melt prepared in the step (4) on the surface of the continuous flaky light microlite finishing layer melt obtained in the step (5) to form a composite melt;
(7) the composite melt prepared in the step (6) is subjected to calendering molding at 1190 ℃ to prepare a continuous flaky composite melt with the thickness of 6 cm;
(8) and (4) preserving the heat of the continuous flaky composite melt prepared in the step (7) at 1120 ℃ for 60 minutes to obtain a continuous flaky plate with a porous structure.
(9) And (3) cutting the continuous sheet-shaped plate prepared in the step (8) when the temperature is reduced to 800 ℃ to obtain the light microlite plate with the specification of 1200 x 2400 x 110 mm.
(10) And (4) conveying the product obtained in the step (9) into a multilayer roller kiln through a lifting platform for cooling, cooling to 80 ℃, discharging from the kiln, polishing to a fixed thickness, and warehousing the product.
Examples 2,
A method for preparing a light microlite plate by a calendering process comprises the following preparation steps:
(1) preparing a light microlite facing layer material by mixing mineral raw materials and chemical raw materials according to mass percentage, wherein the raw material components are weighed according to the proportion of 73% of quartz, 8% of albite, 4% of kaolin, 4% of talc, 3% of dolomite, 3% of soda ash, 4% of barium carbonate and 1% of a clarifying agent, and the raw material components are crushed and added into a mixer to be uniformly mixed;
(2) preparing a light microlite foaming layer material by mixing mineral raw materials and chemical raw materials according to mass percentage, wherein raw material components of 50% of quartz, 20% of albite, 10% of calcite, 10% of glass powder, 3% of soda, 3.5% of barium carbonate, 3% of borax and 0.5% of silicon carbide are weighed, crushed and added into a mixer for uniform mixing;
(3) adding the material prepared in the step (1) into a smelting furnace I, and smelting at 1500 ℃ for 24 hours to fully melt the material to prepare a light microlite facing layer melt;
(4) adding the material obtained in the step (2) into a smelting furnace II, and smelting at 1250 ℃ for 24 hours to fully melt the material to prepare a light microlite foaming layer melt;
(5) the melt prepared in the step (3) is subjected to compression molding at 1350 ℃ to prepare a continuous flaky light microcrystalline stone decorative layer melt with the thickness of 0.6 cm;
(6) covering the melt prepared in the step (4) on the surface of the continuous flaky light microlite finishing layer melt obtained in the step (5) to form a composite melt;
(7) the composite melt prepared in the step (6) is subjected to calendering molding at the temperature of 1000 ℃ to prepare a continuous flaky composite melt with the thickness of 4 cm;
(8) and (4) preserving the heat of the continuous flaky composite melt prepared in the step (7) at 1200 ℃ for 60 minutes to obtain a continuous flaky plate with a porous structure.
(9) And (3) cutting the continuous sheet-shaped plate prepared in the step (8) when the temperature is reduced to 800 ℃ to obtain the light microlite plate with the specification of 1200 x 2400 x 110 mm.
(10) And (4) conveying the product obtained in the step (9) into a single-layer roller kiln through a lifting platform for cooling, cooling to 80 ℃, discharging from the kiln, polishing to a fixed thickness, and warehousing the product.
Examples 3,
A method for preparing a light microlite plate by a calendering process comprises the following preparation steps:
(1) preparing a light microlite facing layer material by mixing mineral raw materials and chemical raw materials according to mass percentage, wherein the raw material components are weighed according to the proportion of 73% of quartz, 8% of albite, 4% of kaolin, 4% of talc, 3% of dolomite, 3% of soda ash, 4% of barium carbonate and 1% of a clarifying agent, and the raw material components are crushed and added into a mixer to be uniformly mixed;
(2) preparing a light microlite foaming layer material by mixing mineral raw materials and chemical raw materials according to mass percentage, wherein raw material components of 50% of quartz, 20% of albite, 10% of calcite, 10% of glass powder, 3% of soda, 3.5% of barium carbonate, 3% of borax and 0.5% of silicon carbide are weighed, crushed and added into a mixer for uniform mixing;
(3) adding the material prepared in the step (1) into a smelting furnace I, and smelting at the high temperature of 1600 ℃ for 24 hours to fully melt the material to prepare a light microlite facing layer melt;
(4) adding the material obtained in the step (2) into a smelting furnace II, and smelting at 1350 ℃ for 24 hours to fully melt the material to prepare a light microlite foaming layer melt;
(5) the melt prepared in the step (3) is subjected to calendering molding at 1450 ℃ to prepare a continuous flaky light microcrystalline stone decorative layer melt with the thickness of 0.8 cm;
(6) covering the melt prepared in the step (4) on the surface of the continuous flaky light microlite finishing layer melt obtained in the step (5) to form a composite melt;
(7) the composite melt prepared in the step (6) is subjected to rolling molding at 1200 ℃ to prepare a continuous flaky composite melt with the thickness of 5 cm;
(8) and (4) preserving the heat of the continuous flaky composite melt prepared in the step (7) at 1200 ℃ for 60 minutes to obtain a continuous flaky plate with a porous structure.
(9) And (3) cutting the continuous sheet-shaped plate prepared in the step (8) when the temperature is reduced to 800 ℃ to obtain the light microlite plate with the specification of 1200 x 2400 x 110 mm.
(10) And (4) conveying the product obtained in the step (9) into a multilayer roller kiln through a lifting platform for cooling, cooling to 80 ℃, discharging from the kiln, polishing to a fixed thickness, and warehousing the product.
The above disclosure is only intended to illustrate a few specific embodiments of the present application, and should not be construed as limiting the scope of the invention. Any modification and decoration made by those skilled in the art on the basis of the present invention shall fall within the protection scope of the present invention.
Claims (10)
1. A method for preparing a light microlite plate by a calendering process is characterized by comprising the following steps: the method comprises the following steps:
s1, proportioning and uniformly mixing the raw materials forming the light microlite facing layer, and then feeding the prepared raw materials into a smelting furnace for smelting to prepare a light microlite facing layer melt for later use;
s2, proportioning and uniformly mixing the raw materials forming the light microlite foaming layer, and then feeding the prepared raw materials into a smelting furnace for smelting to prepare a light microlite foaming layer melt for later use;
s3, performing calendering molding on the prepared light microlite finish coat melt, and extruding, extending and stretching the melt under the action of a calendering molding machine to form a continuous flaky light microlite finish coat melt with a certain thickness;
s4, covering the prepared light microlite foaming layer melt on the surface of the flaky light microlite decorative layer melt to form a composite melt;
s5, carrying out calendering molding on the composite melt, and extruding, extending and stretching the composite melt under the action of a calendering molding machine to form a continuous sheet-shaped composite melt with a certain thickness;
s6, insulating the prepared continuous flaky composite melt to complete the foaming process of the foaming layer melt therein, and preparing a continuous flaky plate with a porous structure;
and S7, cutting, stress relieving and cooling the prepared continuous flaky board to finish the preparation.
2. The method for preparing the light microlite plate by the calendering process according to claim 1, wherein the calendering process comprises the following steps: in the step S1, the smelting temperature of the light microlite facing layer raw material is 1500-1600 ℃.
3. The method for preparing the light microlite plate by the calendering process according to claim 1, wherein the calendering process comprises the following steps: in step S2, the melting temperature of the raw material of the light microlite foaming layer is 1250-.
4. The method for preparing the light microlite plate by the calendering process according to claim 1, wherein the calendering process comprises the following steps: in the steps of S1 and S2, the smelting furnace is an all-electric energy smelting furnace or a natural gas smelting furnace.
5. The method for preparing the light microlite plate by the calendering process according to claim 1, wherein the calendering process comprises the following steps: in the step S3, the temperature for calendering and molding the light microlite decorative layer melt is above 1300-1450 ℃, and the thickness of the melt obtained after calendering and molding is 0.6-0.8 cm.
6. The method for preparing the light microlite plate by the calendering process according to claim 1, wherein the calendering process comprises the following steps: in step S4, the composite melt is prepared by: and (3) positioning the continuous flaky light microlite facing layer melt below a discharge hole of the smelting furnace, flowing the light microlite foaming layer melt to the surface of the smelting furnace until the light microlite facing layer melt completely covers the surface of the light microlite facing layer melt, and forming a composite melt by the light microlite facing layer melt and the light microlite facing layer melt in a high-temperature environment.
7. The method for preparing the light microlite plate by the calendering process according to claim 1, wherein the calendering process comprises the following steps: in the step S5, the composite melt is subjected to calendering molding, the temperature is controlled at 1000 ℃ and 1200 ℃, and the thickness of the continuous sheet-shaped composite melt obtained after calendering molding is 4-6 cm.
8. The method for preparing the light microlite plate by the calendering process according to claim 1, wherein the calendering process comprises the following steps: in the step S6, the temperature in the heat preservation process is controlled at 1000-1200 ℃, and the temperature lasts for a period of time, so that the foaming layer in the composite melt contacts with air under the high-temperature environment to start the redox reaction and generate honeycomb-shaped air holes.
9. The method for preparing the light microlite plate by the calendering process according to claim 1, wherein the calendering process comprises the following steps: in the step of S7, in the step of stress relief and temperature reduction, the cut plate is sent into a multilayer roller kiln for processing.
10. The method for preparing the light microlite plate by the calendering process according to claim 1, wherein the calendering process comprises the following steps: in step S7, a dicing process is provided after the stress relief and temperature reduction process.
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