CN113416084A - Ultrahigh-temperature ceramic roller for roller kiln and manufacturing method thereof - Google Patents

Ultrahigh-temperature ceramic roller for roller kiln and manufacturing method thereof Download PDF

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CN113416084A
CN113416084A CN202110879468.2A CN202110879468A CN113416084A CN 113416084 A CN113416084 A CN 113416084A CN 202110879468 A CN202110879468 A CN 202110879468A CN 113416084 A CN113416084 A CN 113416084A
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roller
kiln
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high temperature
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任立民
苏陶
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Jincheng Scien Fine Materials Co ltd
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Abstract

An ultra-high temperature ceramic roller for a roller kiln and a preparation method thereof, aiming at meeting the use condition of the ultra-high temperature of 1700 ℃; the stick comprises the following components in percentage by mass: 32-38% of alpha alumina and 46-52% of fused corundum ultrafine powder; 10-14% of silicon micropowder; 1-5% of active nano alumina micro powder; the roller is prepared by (1) mixing the raw materials, adding into a ball mill, and water-milling for 6 hours to obtain slurry; (2) dehydrating and filter-pressing by a filter press, and then preparing into a mud column by a vacuum pug mill; (3) installing a die by using a vacuum tube extruding machine and then extruding and molding; (4) placing on an aluminum alloy bracket, covering the roller bar blank with cotton cloth, and drying in the shade for 48 hours; (5) hot air drying at 65-70 deg.C for 24 hr; (6) heating in a well kiln for 36 hr to 1600 deg.C, maintaining the maximum temperature of 1600 deg.C for 24 hr, and cooling for 72 hr after stopping heating.

Description

Ultrahigh-temperature ceramic roller for roller kiln and manufacturing method thereof
Technical Field
The invention relates to an ultrahigh-temperature ceramic roller for a roller kiln and a manufacturing method thereof.
Background
The roller kiln is a high-efficiency energy-saving device, a ceramic roller rod replaces a kiln car of a tunnel kiln, the roller rod rotates on the kiln without taking away heat, and a fired product is subjected to displacement firing through the transmission of the roller rod. At present, the refractory materials used at home and abroad reach more than 1600 ℃, and only corundum products, zirconia products, recrystallized silicon carbide products and the like are few, and only recrystallized silicon carbide in a round tube shape can be produced, but when the silicon carbide products are used on a kiln, black silicon is separated out, the products are polluted, and the price is high. The production process of the corundum-mullite ceramic roller rod for the existing roller kiln is characterized in that the semi-finished product forming and vertical hanging firing production are completed by depending on the clay plasticity and sintering performance. Therefore, the maximum use temperature is within 1300 ℃, and the requirements of the roller kiln for firing products such as building ceramics, daily ceramics and the like can only be met. The research and development of the product can meet the requirements of roller kilns for firing products with higher temperature requirements at the use temperature of 1700 ℃, new materials are researched and developed, and the blank is filled.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides an ultrahigh-temperature ceramic roller rod for a roller kiln and a manufacturing method thereof. The ultra-high temperature ceramic roller can be used for firing alumina ceramic parts, electronic ceramic parts, transparent ceramic appliances, functional ceramics and other ultra-high temperature products in a roller kiln at the use temperature of 1700 ℃, and the application field of the roller kiln is widened.
The invention relates to an ultrahigh-temperature ceramic roller for a roller kiln, which comprises the following components in percentage by mass: 32-38% of alpha alumina and 46-52% of fused corundum ultrafine powder; 10-14% of silicon micropowder; 1-5% of active nano alumina micro powder; the sum of the above components is 100%.
The conversion rate of the alpha alumina is 93 percent, the content of the alumina is 99.4 percent, and the particle size is less than or equal to 1 mu m (12500 meshes). The alumina content of the fused corundum sand ultrafine powder is 99.3%, and the particle size is less than or equal to 2 mu m (8000 meshes). The silicon powder is produced by Norway, H series silicon powder, the content of silicon dioxide is larger than or equal to 97%, and the particle size is smaller than or equal to 0.3 μm. The particle size of the active nano alumina micro powder is less than or equal to 20nm, the specific surface area is not less than 230 square meters per gram, and the product can be used on a 1700 ℃ ultrahigh temperature roller kiln.
The invention discloses a method for manufacturing an ultrahigh-temperature ceramic roller for a roller kiln, which comprises the following steps:
(1) mixing the raw materials according to a certain proportion, adding the mixture into a ball mill, and grinding the mixture with water for 6 hours to prepare slurry, wherein the ratio of the raw materials to the water is 1: 1.2;
(2) after ball milling, putting the slurry into a slurry tank, adding methyl cellulose dry powder according to 0.15-0.2% of the dry weight of the mixed raw materials, dehydrating the uniformly stirred slurry through a plunger pump and a filter press, preparing filter-pressed cakes into mud columns through a vacuum pugging machine, wherein the water content of the mud columns is 15-16%, stacking the mud columns on a tray, sealing the mud columns with plastic bags, and aging for 10 days;
(3) installing a die by using a vacuum tube extruding machine, and then extruding and molding, wherein the water content of an extruded roller bar blank body is 13-14%;
(4) the extruded roller bar blank is flatly placed on an aluminum alloy bracket, and the diameter position of 10cm at one end of the just extruded wet blank is punched
Figure BDA0003191478370000021
Covering the round holes on the roller bar blank by cotton cloth and drying in the shade for 48 hours;
(5) inserting a soft silica gel tube at the punching end of the roller bar blank, feeding hot air at 65-70 ℃, and drying for 24 hours until the water content is less than or equal to 1%;
(6) loading the dried roller bar blanks with certain strength into a shaft kiln, vertically hanging each roller bar between two recrystallized silicon carbide beams, and perforating the roller bar blanks at the punched holes
Figure BDA0003191478370000022
Fixing silicon carbide pins, arranging the silicon carbide pins in a kiln in a row, and covering a kiln cover; heating for 36 hours to 1600 ℃, keeping the maximum temperature of 1600 ℃ for 24 hours, stopping heating, and cooling for 72 hours.
The ball mill adopts ceramic lining and ceramic balls with the content of 99 percent of alumina. When the mud column is manufactured by a vacuum pug mill, phenolic resin liquid or Arabic gum is added according to the proportion of 0.1 percent of the dry weight of the raw materials. When the hot air is dried, a heat exchanger is arranged in a kiln flue, and the hot air is dried by utilizing the residual heat in the kiln flue. The well type kiln is 90m with the depth of 6 m3A well-type kiln.
The active nano alumina micro powder plays roles of catalysis and seeding, promotes the accelerated reaction of the alumina micro powder and the silicon micro powder to generate a high-purity mullite reticular crystal structure, and is combined with the electric melting white corundum micro powder to generate a high-purity corundum mullite material product. The product is required to be fired at a lower temperature of 1600 ℃, the firing process is satisfied by vertically suspending and hanging in a kiln, and the straightness and ovality of the product are ensured. Synthesizing the high-purity mullite combined corundum ceramic roller product. The service temperature is 1700 ℃. The method breaks through the original thinking, uses full-ultrafine powder to increase the specific surface area, synthesizes high-purity materials at lower temperature, develops a new material, and greatly improves the service performance of the ceramic roller rod. The round tube shaped ceramic roller has special production process and needs to be solved: the raw material is high-purity ultrafine powder, clay is not used, and the technical key points of low-melting substances, semi-finished roller rod forming, vertical suspension kiln charging and low-temperature firing are reduced as far as possible.
After the ceramic roller rod is taken out of the kiln, the ceramic roller rod is subjected to detection, selection, processing and detection; detection indexes of the qualified ceramic roller are as follows: bulk density: ≧ 3.2 g/cm3(ii) a Water absorption: ≦ 0.3%, room temperature flexural strength: ≧ 70 PMa; high-temperature flexural strength: ≧ 50 PMa; straightness accuracy: 0.04% or less; ovality: 0.2mm ≦ dimensional tolerance: ≦ 0.5 mm; thermal shock performance: air cooling at 1300 ℃, and no cracking for 3 times; maximum use temperature: 1700 ℃.
The use temperature of the ultra-high temperature ceramic roller rod can be increased to 1700 ℃, the roller rod can bear a certain weight of products and the torque force of transmission rotation in a kiln, the bending degree of the roller rod is within 0.04% under the high-temperature use condition, the high-temperature bending strength is more than 50PMa, and the ultra-high temperature ceramic roller rod can be used for firing special products in an ultra-high temperature roller kiln. The product meets the preset requirements detected by national detection center Luoyang refractory research institute, can be used for firing alumina ceramic parts, electronic ceramic parts, transparent ceramic appliances, functional ceramics and other ultra-high temperature products, and widens the application field of roller kilns.
Detailed Description
The invention relates to an ultrahigh-temperature ceramic roller for a roller kiln, which comprises the following components in percentage by mass: 32-38% of alpha alumina and 46-52% of fused corundum ultrafine powder; 10-14% of silicon micropowder; 1-5% of active nano alumina micro powder; the sum of the above components is 100%.
The conversion rate of the alpha alumina is 93 percent, the content of the alumina is 99.4 percent, and the particle size is less than or equal to 1 mu m (12500 meshes). The alumina content of the fused corundum sand ultrafine powder is 99.3%, and the particle size is less than or equal to 2 mu m (8000 meshes). The silicon powder is produced by Norway, H series silicon powder, the content of silicon dioxide is larger than or equal to 97%, and the particle size is smaller than or equal to 0.3 μm. The particle size of the active nano alumina micro powder is less than or equal to 20nm, the specific surface area is not less than 230 square meters per gram, and the product can be used on a 1700 ℃ ultrahigh temperature roller kiln.
The invention discloses a method for manufacturing an ultrahigh-temperature ceramic roller for a roller kiln, which comprises the following steps:
(1) adding the raw materials into a ball mill which is already filled with water with a specified weight according to the weight of the formula, and carrying out water milling for 6 hours to prepare slurry, wherein the material-water ratio is 1: 1.2;
(2) putting the slurry subjected to ball milling into a slurry tank, adding methylcellulose dry powder according to 0.15-0.2% of the dry weight of the mixed raw materials, dehydrating the uniformly stirred slurry by using a plunger pump and a filter press, preparing filter cakes into mud columns by using a vacuum pugging machine, wherein the water content of the mud columns is 15-16%, stacking the mud columns on a tray, sealing the mud columns by using a plastic bag, and aging for 10 days;
(3) installing a die by using a vacuum tube extruding machine, and then extruding and molding, wherein the water content of an extruded roller bar blank body is 13-14%; the diameter enlargement size of the pipe extrusion die is that the size of the finished product is enlarged by 11-12%, and the length of the pipe extrusion blank is that the size of the finished product is enlarged by 700-900 mm;
(4) the extruded roller bar blank is flatly placed on an aluminum alloy bracket, and is punched at the diameter position of 10cm at one end of the just extruded wet blank body
Figure BDA0003191478370000041
Covering the round holes on the roller bar blank by cotton cloth and drying in the shade for 48 hours;
(5) inserting a soft silica gel tube at the punching end of the roller bar blank, feeding hot air at 65-70 ℃, drying for 24 hours, and loading into a kiln when the moisture content of the roller bar blank is less than or equal to 1%;
(6) loading the dried roller blank with certain strength into a shaft kiln, vertically hanging each roller between two recrystallized silicon carbide beams, and perforating the roller blank at the perforation
Figure BDA0003191478370000042
Silicon carbide pins are fixed and arranged in a kiln, and covers are arrangedA kiln cover is well covered; igniting and heating up to 1600 ℃ for 36 hours, keeping the maximum temperature of 1600 ℃ for 24 hours, and cooling down for 72 hours after stopping the fire. Opening the kiln cover product and taking out of the kiln;
the ball mill adopts ceramic lining and ceramic ball products with the content of 99 percent of alumina. When the mud column is manufactured by a vacuum pug mill, phenolic resin liquid or Arabic gum is added according to the proportion of 0.1 percent of the dry weight of the raw materials. During hot air drying, a heat exchanger is arranged in a well-type kiln waste gas discharge flue, waste heat in the kiln flue is utilized, natural air is input into the heat exchanger by using a blower for heating, the heated air at the outlet of the heat exchanger is matched with the natural air, the temperature of drying air is controlled to be 65-70 ℃, the hot air is input into a drying box by using a pipeline, hot air discharged from the drying box is respectively inserted into the punching end of each roller bar blank body through a silica gel hose, and the roller bar blank bodies are dried from inside to outside.
The well type kiln is 90m with the depth of 6 m3The pit kiln is 5.5 meters above the ground and-0.5 meter below the ground, the inside dimension of the kiln is a rectangle of 5 x 3 meters, the smoke outlet is arranged at the bottom of the kiln, the spray guns are arranged on the side vertical surfaces of two long sides of the kiln, the spray guns are arranged in a delta shape and an opposite inverted delta shape, 6 spray guns are arranged on each side, 2 spray guns are distributed in a delta shape with equal distance, and 12 spray guns are arranged on two sides. The product is vertically hung and loaded at the upper opening of the kiln, a kiln cover is covered, and the kiln is ignited for heating, heat preservation and cooling, so that the ceramic roller product is sintered.

Claims (10)

1. An ultrahigh-temperature ceramic roller for a roller kiln is characterized by comprising the following components in percentage by mass: 32-38% of alpha alumina and 46-52% of fused corundum ultrafine powder; 10-14% of silicon micropowder; 1-5% of active nano alumina micro powder; the sum of the mass of the components is 100 percent.
2. The method for manufacturing the ultra-high temperature ceramic roller for the roller kiln as claimed in claim 1, wherein:
(1) mixing the raw materials according to a certain proportion, adding the mixture into a ball mill, and grinding the mixture with water for 6 hours to prepare slurry, wherein the ratio of the raw materials to the water is 1: 1.2;
(2) after ball milling, putting the slurry into a slurry tank, adding methyl cellulose dry powder according to 0.15-0.2% of the dry weight of the mixed raw materials, dehydrating the uniformly stirred slurry through a plunger pump and a filter press, preparing filter-pressed cakes into mud columns through a vacuum pugging machine, wherein the water content of the mud columns is 15-16%, stacking the mud columns on a tray, sealing the mud columns with plastic bags, and aging for 10 days;
(3) installing a die by using a vacuum tube extruding machine, and then extruding and molding, wherein the water content of an extruded roller bar blank body is 13-14%;
(4) the extruded roller bar blank is flatly placed on an aluminum alloy bracket, and is punched at the diameter position of 10cm at one end of the just extruded wet blank body
Figure FDA0003191478360000011
Covering the round holes on the roller bar blank by cotton cloth and drying in the shade for 48 hours;
(5) inserting a soft silica gel tube at the punching end of the roller bar blank, feeding hot air at 65-70 ℃, and drying for 24 hours until the water content is less than or equal to 1%;
(6) loading the dried roller bar blanks with certain strength into a shaft kiln, vertically hanging each roller bar between two recrystallized silicon carbide beams, and perforating the roller bar blanks at the punched holes
Figure FDA0003191478360000012
Fixing silicon carbide pins, arranging the silicon carbide pins in a kiln in a row, and covering a kiln cover; heating for 36 hours to 1600 ℃, keeping the maximum temperature of 1600 ℃ for 24 hours, stopping heating, and cooling for 72 hours.
3. The ultra-high temperature ceramic roller for roller kilns according to claim 1, characterized in that said alpha alumina has a conversion of 93%, an alumina content of 99.4% and a particle size less than or equal to 1 μm (12500 mesh).
4. The ultra-high temperature ceramic roller for roller kilns as set forth in claim 1 or 3, wherein said fused corundum ultrafine powder has an alumina content of 99.3% and a particle size of ≦ 2 μm (8000 mesh).
5. The ultra-high temperature ceramic roller for roller kilns according to claim 1 or 3, characterized in that the silica powder is produced by Norwegian, H series silica powder, silica content is greater than or equal to 97%, particle size is less than or equal to 0.3 μm; the particle size of the active nano alumina micro powder is less than or equal to 20nm, the specific surface area is not less than 230 square meters per gram, and the product can be used on a 1700 ℃ ultrahigh temperature roller kiln.
6. The ultra-high temperature ceramic roller for roller kilns as set forth in claim 1 or 2, characterized by the following acceptable product indicators: bulk density: ≧ 3.2 g/cm3(ii) a Water absorption: ≦ 0.3%, room temperature flexural strength: ≧ 70 PMa; high-temperature flexural strength: ≧ 50 PMa; straightness accuracy: 0.04% or less; ovality: 0.2mm ≦ dimensional tolerance: ≦ 0.5 mm; thermal shock performance: air cooling at 1300 ℃, and no cracking for 3 times; maximum use temperature: 1700 ℃.
7. The method for manufacturing ultra-high temperature ceramic roller rods for roller kilns as claimed in claim 1 or 2, wherein said ball mill uses ceramic lining, ceramic balls with 99% alumina content.
8. The method as claimed in claim 1 or 2, wherein the phenolic resin solution or gum arabic is added in an amount of 0.1% by dry weight of the raw material when the pillars are formed by a vacuum pug mill.
9. The method for manufacturing an ultra-high temperature ceramic roller for a roller kiln as claimed in claim 1 or 2, wherein the hot air drying is performed by installing a heat exchanger in the flue of the kiln and using the residual heat in the flue of the kiln.
10. The manufacturing method of the ultra high temperature ceramic roller for roller kilns as claimed in claim 1 or 2, characterized in that said shaft kiln is 90m 6 m deep3The highest firing temperature of the well type kiln is 1650 ℃.
CN202110879468.2A 2021-08-02 2021-08-02 Ultrahigh-temperature ceramic roller for roller kiln and manufacturing method thereof Pending CN113416084A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114180978A (en) * 2021-12-27 2022-03-15 晋城市三英精细材料有限公司 Preparation method of high-temperature ceramic kiln tool and kiln tool manufactured by same

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102863226A (en) * 2011-07-07 2013-01-09 佛山市南海金刚新材料有限公司 Preparation process of ceramic roller rod

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102863226A (en) * 2011-07-07 2013-01-09 佛山市南海金刚新材料有限公司 Preparation process of ceramic roller rod

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* Cited by examiner, † Cited by third party
Title
《中国冶金百科全书》编辑部编,冶金工业出版社: "《无机非金属材料学》" *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114180978A (en) * 2021-12-27 2022-03-15 晋城市三英精细材料有限公司 Preparation method of high-temperature ceramic kiln tool and kiln tool manufactured by same

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Application publication date: 20210921