CN113773062A - Preparation method of ceramsite sand for casting - Google Patents
Preparation method of ceramsite sand for casting Download PDFInfo
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- CN113773062A CN113773062A CN202111119148.3A CN202111119148A CN113773062A CN 113773062 A CN113773062 A CN 113773062A CN 202111119148 A CN202111119148 A CN 202111119148A CN 113773062 A CN113773062 A CN 113773062A
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- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
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- B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
- B22C5/06—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose by sieving or magnetic separating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
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Abstract
The invention relates to the technical field of ceramsite sand production, in particular to a preparation method of ceramsite sand for casting, which comprises the following preparation steps: (1) uniformly mixing the casting dedusting ash, the casting regeneration ash and the bauxite according to the proportion, and then carrying out air separation ball milling to obtain a mixture A; (2) weighing alumina powder and a binder according to a ratio, adding the weighed alumina powder and the binder into the mixture A, and uniformly mixing to obtain a mixture B; (3) and adding water into the mixture B for granulation, shaping, screening, drying, roasting and cooling to obtain ceramsite sand. The casting ceramsite sand prepared by the method takes the casting dedusting ash and the casting regeneration ash of solid wastes as main raw materials, so that the preparation cost of the casting ceramsite sand is reduced, the secondary utilization of solid waste resources is realized, the energy is saved, the environment is protected, and the additional value is higher; the ceramsite sand for casting prepared by the method has the advantages of regular shape, good compressive strength and heat resistance and higher quality grade.
Description
Technical Field
The invention relates to the technical field of ceramsite sand production, in particular to a preparation method of ceramsite sand for casting.
Background
Casting is a method in which liquid metal is cast into a casting cavity that conforms to the shape of a part, and after it is cooled and solidified, a part or a blank is obtained. The ceramsite sand is a common molding material used for preparing molding sand and core sand in modern casting production, and is prepared by sintering various raw materials such as various clays, slates, shales, coal gangue, industrial solid wastes and the like through ceramics. Most of ceramsite sand in the prior art is low in refractoriness or high in cost, is only suitable for small-piece production by taking precoated sand as a process, and cannot be widely applied to the casting industry.
Casting is one of the basic processes of modern device manufacturing industry, China is also a big casting country, a large amount of casting dust is generated due to casting every year, and according to statistics, 0.1-0.2 ton of casting dust is generated when each 1 ton of sand core castings are produced. A large amount of casting dust removal ash is used as solid waste to be buried every year in China, so that the treatment efficiency is low, and secondary pollution to the environment is easy to cause; a small part of the ceramsite is used for preparing sintering-free ceramsite to replace stone and for producing cement, but the added value of the ceramsite is low. Therefore, the utilization of the casting dust removal ash is an urgent problem to be solved in the casting industry.
Disclosure of Invention
In order to solve the problems, the invention provides a method for preparing casting ceramsite sand by using casting dedusting ash on the basis of preparing sintering-free ceramsite by using casting waste ash in the prior art, and provides a new way for recycling the casting waste ash.
The invention adopts the following technical scheme:
a preparation method of ceramsite sand for casting comprises the following steps:
(1) uniformly mixing the casting dedusting ash, the casting regeneration ash and the bauxite according to the proportion, and then carrying out air separation ball milling to obtain a mixture A;
(2) weighing alumina powder and a binder according to a ratio, adding the weighed alumina powder and the binder into the mixture A, and uniformly mixing to obtain a mixture B;
(3) and adding water into the mixture B for granulation, shaping, screening, drying, roasting and cooling to obtain the ceramsite sand for casting.
Further, the raw materials of the ceramsite sand for casting comprise the following components in parts by weight: 15-25 parts of casting dedusting ash, 15-30 parts of casting regeneration ash, 45-60 parts of bauxite, 10-25 parts of alumina powder and 1-3 parts of binder.
Further, the raw materials of the ceramsite sand for casting comprise the following components in parts by weight: 20 parts of casting dedusting ash, 20 parts of casting regeneration ash, 50 parts of bauxite, 10 parts of alumina powder and 2 parts of binder.
Further, the particle size of the alumina powder is higher than 600 meshes.
Furthermore, the binder comprises one or more of CMC rubber powder, polyvinyl alcohol rubber powder and bentonite.
Further, the particle size of the dust subjected to air separation in the step (1) is higher than 800 meshes.
Further, the content of the water added in the step (3) is 18-30% of the total amount of the mixture B.
Further, the rotation speed of the granulator in the granulation process in the step (3) is 4000-.
Further, the granularity of the ceramsite balls sieved in the step (3) is 40/140 meshes.
Further, the roasting in the step (3) is two-stage roasting, wherein the first-stage roasting is roasting at 850 ℃ of 700-1800 ℃ for 1-1.5h, and the second-stage roasting is roasting at 1800 ℃ of 1300-1800 ℃ for 1-4 h.
Compared with the prior art, the invention has the beneficial effects that:
1. the casting ceramsite sand prepared by the invention takes the casting dedusting ash and the casting regeneration ash of solid wastes as main raw materials, so that the preparation cost of the casting ceramsite sand is reduced, the secondary utilization of solid waste resources is realized, the energy is saved, the environment is protected, and the additional value is higher.
2. The ceramsite sand for casting prepared by the invention has higher quality grade, and the core indexes are as follows: the grain size of the ceramsite is 40/140 meshes, and the yield is 80-90%; the sphericity is more than or equal to 0.86; the cylinder pressure strength is more than or equal to 52 MPa; the heat-resistant temperature is more than or equal to 1600 ℃.
3. According to the invention, by regulating and controlling the mechanical granulation speed and the roasting temperature in a segmented manner, the maximization of energy utilization is realized on the premise of fully considering the ceramsite preparation process mechanism to carry out the maximum optimization on the ceramsite performance, and the energy waste caused by overhigh rotating speed or overhigh temperature is avoided.
4. The invention starts from the granulation speed and the ceramsite strength, fully considers the influence of the mechanical speed on the ceramsite strength in different stages, and adopts a sectional speed control method for granulation, wherein firstly, fine particles are rapidly prepared at a high-speed rotating speed of 4000 plus materials and 4800r/min to obtain initial ceramsite cores, and then the rotating speed is reduced to 2500 plus materials and 3500r/min to ensure that the initial ceramsite cores gradually grow up to form compact ceramsite. The ceramsite prepared by the method has high initial strength, and the yield of the prepared 40/140-mesh ceramsite is high and can reach 80-90%.
5. The invention combines the essence of ceramic particle roasting, fully considers the influence of different temperatures on the ceramic particles, maximizes the energy utilization, adopts a sectional temperature control roasting mode, and firstly dries at the low temperature of 100-120 ℃ to evaporate the water in the ceramic particles, thereby preventing the ceramic particles from cracking caused by directly sintering the ceramic particles at high temperature. After drying, carrying out two-stage roasting, wherein the temperature of the first-stage roasting is set to be 700 DEG F and 850 DEG F, so as to remove combustibles such as coal dust, organic rubber powder and the like in the ceramsite, and prevent the direct sintering from causing the unburnt combustibles in the ceramsite after the surface is vitrified, thereby influencing the strength and the refractoriness of the ceramsite; the second-stage roasting temperature is set to be 1300 ℃ and 1800 ℃, and the high-temperature roasting leads the prepared ceramsite to be ceramic, thereby forming compact ceramsite sand. The ceramsite sand prepared by the method has a compact structure and high compressive strength and refractoriness, and is suitable for casting.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to specific embodiments, and it should be understood 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 protection scope of the present invention.
Example 1
The ceramsite sand for casting comprises the following raw materials in parts by weight: 20 parts of casting dedusting ash, 20 parts of casting regeneration ash, 50 parts of bauxite, 10 parts of alumina powder and 2 parts of binder.
The ceramsite sand for casting in the embodiment is prepared by the following steps:
(1) uniformly mixing the casting dedusting ash, the casting regeneration ash and the bauxite according to a ratio, then carrying out air separation ball milling, and air separating high-activity mixed dust with the particle size of more than 800 meshes to obtain a mixture A;
(2) weighing alumina powder with the particle size of more than 600 meshes and a binder according to a ratio, adding the weighed alumina powder and the binder into the mixture A, and uniformly mixing to obtain a mixture B;
(3) and adding water into the mixture B, uniformly mixing, wherein the water content is 25% of the total amount of the mixture B, granulating, wherein the initial rotating speed of a granulator in the granulating process is 4800r/min, mixing for 2min, then adjusting the rotating speed to 3500/min, mixing for 3min, shaping for 2h after the granulation is finished, then screening out ceramsite balls with the granularity of 40/140 meshes from the shaped ceramsite, drying the screened ceramsite balls at 120 ℃ for 0.5h, then carrying out two-stage roasting, wherein the first-stage roasting is carried out for 1h at 800 ℃, the second-stage roasting is carried out for 1h at 1800 ℃, and finally cooling to obtain the ceramsite sand for casting.
Example 2
The ceramsite sand for casting comprises the following raw materials in parts by weight: 15 parts of casting dedusting ash, 15 parts of casting regeneration ash, 45 parts of bauxite, 10 parts of alumina powder and 1 part of binder.
The ceramsite sand for casting in the embodiment is prepared by the following steps:
(1) uniformly mixing the casting dedusting ash, the casting regeneration ash and the bauxite according to a ratio, then carrying out air separation ball milling, and air separating high-activity mixed dust with the particle size of more than 800 meshes to obtain a mixture A;
(2) weighing alumina powder with the particle size of more than 600 meshes and a binder according to a ratio, adding the weighed alumina powder and the binder into the mixture A, and uniformly mixing to obtain a mixture B;
(3) and adding water into the mixture B, uniformly mixing, wherein the water content is 18% of the total amount of the mixture B, granulating, wherein the initial rotation speed of a granulator in the granulating process is 4000r/min, mixing for 8min, then adjusting the rotation speed to 2500r/min, mixing for 2min, shaping after the granulation is finished, screening out ceramsite balls with the granularity of 40/140 meshes from the shaped ceramsite balls, drying the screened ceramsite balls at 100 ℃ for 0.5h, then carrying out two-stage roasting, wherein the first-stage roasting is carried out for 1.5h at 700 ℃, the second-stage roasting is carried out for 4h at 1300 ℃, and finally cooling to obtain the ceramsite sand for casting.
Example 3
The ceramsite sand for casting comprises the following raw materials in parts by weight: 18 parts of casting dedusting ash, 20 parts of casting regeneration ash, 50 parts of bauxite, 15 parts of alumina powder and 2 parts of binder.
The ceramsite sand for casting in the embodiment is prepared by the following steps:
(1) uniformly mixing the casting dedusting ash, the casting regeneration ash and the bauxite according to a ratio, then carrying out air separation ball milling, and air separating high-activity mixed dust with the particle size of more than 800 meshes to obtain a mixture A;
(2) weighing alumina powder with the particle size of more than 600 meshes and a binder according to a ratio, adding the weighed alumina powder and the binder into the mixture A, and uniformly mixing to obtain a mixture B;
(3) and adding water into the mixture B, uniformly mixing, wherein the water content is 22% of the total amount of the mixture B, granulating, wherein the initial rotation speed of a granulator in the granulation process is 4300r/min, mixing for 7min, adjusting the rotation speed to 2800r/min, mixing for 2min, shaping after granulation is finished, screening ceramsite balls with the granularity of 40/140 meshes from the shaped ceramsite, drying the screened ceramsite balls at 110 ℃ for 0.5h, then carrying out two-stage roasting, wherein the first-stage roasting is carried out for 1.3h at 750 ℃, the second-stage roasting is carried out for 3h at 1500 ℃, and finally cooling to obtain the casting ceramsite sand.
Example 4
The ceramsite sand for casting comprises the following raw materials in parts by weight: 25 parts of casting dedusting ash, 30 parts of casting regeneration ash, 60 parts of bauxite, 25 parts of alumina powder and 3 parts of binder.
The ceramsite sand for casting in the embodiment is prepared by the following steps:
(1) uniformly mixing the casting dedusting ash, the casting regeneration ash and the bauxite according to a ratio, then carrying out air separation ball milling, and air separating high-activity mixed dust with the particle size of more than 800 meshes to obtain a mixture A;
(2) weighing alumina powder with the particle size of more than 600 meshes and a binder according to a ratio, adding the weighed alumina powder and the binder into the mixture A, and uniformly mixing to obtain a mixture B;
(3) and adding water into the mixture B, uniformly mixing, wherein the water content is 30% of the total amount of the mixture B, granulating, wherein the initial rotation speed of a granulator in the granulation process is 4800r/min, mixing for 2min, then adjusting the rotation speed to 3500r/min, mixing for 3min, shaping after granulation is finished, screening out ceramsite balls with the granularity of 40/140 meshes from the shaped ceramsite balls, drying the screened ceramsite balls at 120 ℃ for 0.5h, then carrying out two-stage roasting, wherein the first-stage roasting is carried out for 1h at 850 ℃, the second-stage roasting is carried out for 1h at 1800 ℃, and finally cooling to obtain the ceramsite sand for casting.
Example 5
The ceramsite sand for casting comprises the following raw materials in parts by weight: 25 parts of casting dedusting ash, 28 parts of casting regeneration ash, 55 parts of bauxite, 20 parts of alumina powder and 3 parts of binder.
The ceramsite sand for casting in the embodiment is prepared by the following steps:
(1) uniformly mixing the casting dedusting ash, the casting regeneration ash and the bauxite according to a ratio, then carrying out air separation ball milling, and air separating high-activity mixed dust with the particle size of more than 800 meshes to obtain a mixture A;
(2) weighing alumina powder with the particle size of more than 600 meshes and a binder according to a ratio, adding the weighed alumina powder and the binder into the mixture A, and uniformly mixing to obtain a mixture B;
(3) and adding water into the mixture B, uniformly mixing, wherein the water content is 25% of the total amount of the mixture B, granulating, wherein the initial rotation speed of a granulator in the granulating process is 4000r/min, mixing for 8min, then adjusting the rotation speed to 3000r/min, mixing for 2min, shaping after granulation is finished, screening out ceramsite balls with the granularity of 40/140 meshes from the shaped ceramsite balls, drying the screened ceramsite balls at 110 ℃ for 0.5h, then carrying out two-stage roasting, wherein the first-stage roasting is carried out at 800 ℃ for 1.5h, the second-stage roasting is carried out at 1500 ℃ for 3h, and finally cooling to obtain the ceramsite sand for casting.
Comparative example 1
In the comparative example, the rotation speed in the granulation process is respectively controlled to 3800r/min for mixing 8min and 3500r/min for mixing 3min, and the rest raw materials and the preparation method are consistent with those in example 1.
Comparative example 2
In the comparative example, the rotation speed in the granulation process is respectively controlled to be 3000r/min, mixed for 2min and 2000r/min and mixed for 3min, and the rest raw materials and the preparation method are consistent with those in the example 1.
Comparative example 3
In the comparative example, the rotation speed in the granulation process is respectively controlled to be 3000r/min, 2min and 4500r/min, the mixing time is 3min, and the rest raw materials and the preparation method are consistent with those in the example 1.
Comparative example 4
In the comparative example, the temperature of the drying process is controlled to be 80 ℃ for drying 0.5h, the temperature of the sectional roasting process is respectively controlled to be 500 ℃ for roasting 1.5h and 1800 ℃ for roasting 1h, and the rest of the raw materials and the preparation method are consistent with those of the example 1.
Comparative example 5
In the comparative example, the temperature of the drying process is controlled to be 180 ℃ for 0.5h, the temperature of the sectional roasting process is respectively controlled to be 1000 ℃ for roasting 1h and 1800 ℃ for roasting 1h, and the rest raw materials and the preparation method are consistent with those of the example 1.
Comparative example 6
In the comparative example, the temperature in the drying process is controlled to be 120 ℃ for drying 0.5h, the temperature in the sectional roasting process is respectively controlled to be 800 ℃ for roasting 1h and 1000 ℃ for roasting 4h, and the rest raw materials and the preparation method are consistent with those in the example 1.
The following performance tests were carried out on the ceramsite sands for casting obtained in examples 1 to 5 and comparative examples 1 to 6, and the test results are shown in table 1.
TABLE 1 ceramsite sand Performance test results
As can be seen from table 1, the casting ceramsite sand prepared in the embodiments of the present application can withstand a high temperature of 1600 ℃ or more, and has a breaking rate of less than 3.5% under a closing pressure of 52Mpa and a sphericity of more than 85%, so that the casting ceramsite sand having a high temperature resistance, a high compressive strength and a high sphericity is obtained, the casting quality of the product is effectively improved, and the application range of the casting ceramsite sand is expanded.
Firstly, comparing example 1 with comparative examples 1-3, the difference is that comparative examples 1-3 adopt low-speed granulation, the rotating speed is slow, the granulation is not compact, the broken rate of the ceramsite sand is high, the rounding rate is low, and the use requirement of the ceramsite sand for casting can not be met. Comparing the example 1 with comparative examples 4-6, the difference is that the baking and roasting temperature is controlled, the comparative example 4 has moisture when being baked for half a hour at 80 ℃, the cracking phenomenon can occur when the temperature is rapidly increased to 500 ℃, and simultaneously, the coal dust in the fly ash at the interior of 500 ℃ can not be completely combusted; comparative example 5 has a cracking phenomenon when dried at 180 ℃, and at the same time, when baked at 1000 ℃, part of the surface reacts first, resulting in uneven internal sintering; comparative example 6 firing at 1000 ℃ did not cause ceramization reaction, and the obtained ceramsite sand had low compressive strength and was crushed upon pressing.
And the comparison with the comparative example shows that the invention improves the high temperature resistance, the compressive strength and the like of the ceramsite sand to a certain extent by controlling the granulation speed and the roasting temperature in a segmented manner, and the prepared ceramsite sand has compact structure, high compressive strength and refractoriness and is suitable for casting. Meanwhile, the invention realizes the secondary utilization of solid waste resources such as casting dedusting ash, casting regeneration ash and the like with high added value, saves energy, protects environment, reduces the production cost of the ceramsite sand for casting and has good economic benefit.
The present invention has been further described with reference to specific embodiments, but it should be understood that the detailed description should not be construed as limiting the spirit and scope of the present invention, and various modifications made to the above-described embodiments by those of ordinary skill in the art after reading this specification are within the scope of the present invention.
Claims (10)
1. The preparation method of the ceramsite sand for casting is characterized by comprising the following preparation steps of:
(1) uniformly mixing the casting dedusting ash, the casting regeneration ash and the bauxite according to the proportion, and then carrying out air separation ball milling to obtain a mixture A;
(2) weighing alumina powder and a binder according to a ratio, adding the weighed alumina powder and the binder into the mixture A, and uniformly mixing to obtain a mixture B;
(3) and adding water into the mixture B for granulation, shaping, screening, drying, roasting and cooling to obtain ceramsite sand.
2. The method for preparing ceramsite sand for casting according to claim 1, wherein raw materials of the ceramsite sand for casting comprise the following components in parts by weight: 15-25 parts of casting dedusting ash, 15-30 parts of casting regeneration ash, 45-60 parts of bauxite, 10-25 parts of alumina powder and 1-3 parts of binder.
3. The method for preparing ceramsite sand for casting according to claim 2, wherein the raw material of the ceramsite sand for casting comprises the following components in parts by weight: 20 parts of casting dedusting ash, 20 parts of casting regeneration ash, 50 parts of bauxite, 10 parts of alumina powder and 2 parts of binder.
4. The method for preparing ceramsite sand for casting according to claim 1, wherein the particle size of the alumina powder is higher than 600 mesh.
5. The preparation method of the ceramsite sand for casting according to claim 1, wherein the binder comprises one or more of CMC rubber powder, polyvinyl alcohol rubber powder and bentonite.
6. The method for preparing ceramsite sand for casting according to claim 1, wherein the particle size of the dust obtained after air classification in step (1) is higher than 800 meshes.
7. The method of preparing ceramsite sand for foundry as claimed in claim 1, wherein the content of water added in step (3) is 18-30% of the total amount of the mixture B.
8. The method as claimed in claim 1, wherein the rotation speed of the pelletizer in the pelletizing process of step (3) is 4000-4800r/min for mixing 2-8min, and then the rotation speed is adjusted to 2500-3500r/min for mixing 2-4 min.
9. The method for preparing ceramsite sand for casting according to claim 1, wherein the granularity of the ceramsite balls sieved in the step (3) is 40/140 meshes.
10. The method for preparing ceramsite sand for casting according to claim 1, wherein the calcination in step (3) is a two-stage calcination, the one-stage calcination is a calcination at 850 ℃ of 700-1800 ℃ for 1-1.5h, and the two-stage calcination is a calcination at 1800 ℃ of 1300-1800 ℃ for 1-4 h.
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| CN116081969A (en) * | 2022-11-30 | 2023-05-09 | 柳晶（溧阳）环保科技有限公司 | Novel water-retaining ceramsite and preparation method thereof |
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