CN114454332A - Ceramic dry-process powder making - Google Patents
Ceramic dry-process powder making Download PDFInfo
- Publication number
- CN114454332A CN114454332A CN202210065909.XA CN202210065909A CN114454332A CN 114454332 A CN114454332 A CN 114454332A CN 202210065909 A CN202210065909 A CN 202210065909A CN 114454332 A CN114454332 A CN 114454332A
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- Prior art keywords
- mud
- particles
- blocks
- drying
- ceramic
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- 239000000843 powder Substances 0.000 title claims abstract description 45
- 239000000919 ceramic Substances 0.000 title claims abstract description 30
- 238000001035 drying Methods 0.000 title claims abstract description 30
- 239000002245 particle Substances 0.000 claims abstract description 41
- 238000000034 method Methods 0.000 claims abstract description 40
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 19
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000002002 slurry Substances 0.000 claims abstract description 15
- 229910052742 iron Inorganic materials 0.000 claims abstract description 8
- 239000000706 filtrate Substances 0.000 claims abstract description 6
- 238000004064 recycling Methods 0.000 claims abstract description 5
- 238000007670 refining Methods 0.000 claims abstract description 4
- 238000010304 firing Methods 0.000 claims description 8
- 239000000779 smoke Substances 0.000 claims description 7
- 238000001816 cooling Methods 0.000 claims description 6
- 238000002360 preparation method Methods 0.000 claims description 4
- 239000002918 waste heat Substances 0.000 claims description 4
- 238000005520 cutting process Methods 0.000 claims description 3
- 238000001125 extrusion Methods 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims 1
- 238000005265 energy consumption Methods 0.000 abstract description 7
- 238000003912 environmental pollution Methods 0.000 abstract description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 abstract description 3
- 229910052799 carbon Inorganic materials 0.000 abstract description 3
- 230000003009 desulfurizing effect Effects 0.000 abstract description 3
- 238000001694 spray drying Methods 0.000 description 8
- 239000003245 coal Substances 0.000 description 4
- 239000000428 dust Substances 0.000 description 4
- 238000000227 grinding Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000000498 ball milling Methods 0.000 description 3
- 238000001556 precipitation Methods 0.000 description 3
- 238000005299 abrasion Methods 0.000 description 2
- 230000032683 aging Effects 0.000 description 2
- 239000010419 fine particle Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 238000004537 pulping Methods 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 241000510672 Cuminum Species 0.000 description 1
- 235000007129 Cuminum cyminum Nutrition 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000002354 daily effect Effects 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- 238000007602 hot air drying Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 239000011265 semifinished product Substances 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000003911 water pollution Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C1/00—Apparatus or methods for obtaining or processing clay
- B28C1/10—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants
- B28C1/14—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants specially adapted for homogenising, comminuting or conditioning clay in non-fluid condition or for separating undesired admixtures therefrom
- B28C1/22—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants specially adapted for homogenising, comminuting or conditioning clay in non-fluid condition or for separating undesired admixtures therefrom combined with means for conditioning by heating, humidifying, or vacuum treatment, by cooling, by sub-atmospheric pressure treatment
- B28C1/227—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants specially adapted for homogenising, comminuting or conditioning clay in non-fluid condition or for separating undesired admixtures therefrom combined with means for conditioning by heating, humidifying, or vacuum treatment, by cooling, by sub-atmospheric pressure treatment by heating, drying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C1/00—Apparatus or methods for obtaining or processing clay
- B28C1/10—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants
- B28C1/14—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants specially adapted for homogenising, comminuting or conditioning clay in non-fluid condition or for separating undesired admixtures therefrom
- B28C1/16—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants specially adapted for homogenising, comminuting or conditioning clay in non-fluid condition or for separating undesired admixtures therefrom for homogenising, e.g. by mixing, kneading ; forcing through slots
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C1/00—Apparatus or methods for obtaining or processing clay
- B28C1/10—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants
- B28C1/14—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants specially adapted for homogenising, comminuting or conditioning clay in non-fluid condition or for separating undesired admixtures therefrom
- B28C1/18—Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants specially adapted for homogenising, comminuting or conditioning clay in non-fluid condition or for separating undesired admixtures therefrom for comminuting clay lumps
Landscapes
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Processing Of Solid Wastes (AREA)
Abstract
The invention discloses a ceramic dry-method powder making method, which comprises the following steps: firstly, squeezing the homogenized slurry into a mud cake, and concentrating the filtrate into filtered slurry for recycling; secondly, refining and processing the mud cakes into mud blocks or mud particles, drying the mud blocks or mud particles to reach the water content meeting the subsequent processing requirement, and adding recycled filter pulp in the process; thirdly, the mud blocks or mud particles are smashed into mud powder by impact and then iron is removed. The ceramic dry-method powder making method changes the traditional powder making mode of the ceramic industry, greatly reduces the energy consumption, does not need to build a desulfurizing tower, solves the problem of environmental pollution and has the key point of effectively reducing the carbon emission.
Description
Technical Field
The invention relates to the technical field of ceramic production methods, in particular to a preparation method of ceramic powder.
Background
At present, the production process of the wall and floor tiles in the ceramic industry basically follows the following process route: raw material proportioning, ball milling and pulping, slurry homogenizing and deironing, spray drying and powder making, powder material ageing, press molding, drying, glazing, firing to obtain a semi-finished product, and further performing deep processing such as edge grinding, polishing, cutting and the like to finally obtain a finished product sold in the market.
The ball milling, spray drying, press forming and sintering are four key processes for producing the wall and floor tiles, and the energy consumption is high. Generally, the water content of slurry after ball milling is about 33-38%, and the water content of powder for press molding is about 7%, and the purpose of preparing powder from slurry is spray drying process, the heat energy consumed by this process is only second to the energy consumption of the firing process, and the second of the four processes is about 80% of the energy consumption of the firing process. Under normal operation conditions, 1 ton of powder is produced by spray drying, about 430kg of water needs to be evaporated, about 65kg of coal is consumed, the heat efficiency is about 45%, about 350 tons of powder are required for producing 1000 square meters of wall and floor tiles, about 23 tons of coal is consumed in the spray drying process, about 5000kwh of electricity is also required, and the conversion is about 130 yuan per ton of powder of RMB. Therefore, the energy consumption of spray drying powder preparation is quite large, and various ceramic manufacturers always pursue the energy-saving problem of the spray drying process with cumin. In addition, several tens of tons of coal are burned every day, which also brings about the problem of environmental pollution. The investment of the ceramic factory is also considerable in environmental governance. Therefore, it is necessary to develop a ceramic powder manufacturing method with energy saving, consumption reduction and emission reduction.
Disclosure of Invention
The invention aims to provide a ceramic powder making method for saving energy, reducing consumption and reducing emission.
The technical scheme adopted for solving the technical problems is as follows: a dry powder preparation method of ceramics is characterized by comprising the following steps:
firstly, squeezing the homogenized slurry into a mud cake, and concentrating the filtrate into filtered slurry for recycling;
secondly, refining and processing the mud cakes into mud blocks or mud particles, drying the mud blocks or mud particles to reach the water content suitable for the subsequent processing requirement, and adding recycled filter pulp in the process;
thirdly, the mud blocks or mud particles are smashed into mud powder by impact and then iron is removed.
Preferably, in step one, the cake is pressed using a filter press.
Preferably, in the second step, the mud cake is processed into mud blocks or mud particles through extrusion and cutting.
Preferably, in step two, the slurry is quantitatively sprayed onto the clods or grains during drying.
On the basis, in the second step, the mud blocks or mud particles are dried by at least two sections in sequence, wherein the front section of the mud particles is dried by using direct cold hot air at the tail of the ceramic firing roller kiln, and the tail section is dried by using waste heat of exhaust smoke at the head of the ceramic firing roller kiln.
The invention has the following beneficial effects: the ceramic dry-method powder making method changes the traditional powder making mode of the ceramic industry, greatly reduces the energy consumption, does not need to build a desulfurizing tower, solves the problem of environmental pollution and has the key point of effectively reducing the carbon emission.
Detailed Description
The pulping process in the early stage of the ceramic dry-method powder making method is the same as that of the traditional process, and the batching, ball glaze, iron removal and homogenization are all indispensable. The method comprises the following steps:
firstly, the homogenized slurry is squeezed into a mud cake, the squeezed filtrate is concentrated into a filter pulp for recycling, and the water content of the mud cake is about 18 percent. In this example, a conventional filter press was used to press the cake into a cake.
And secondly, refining and processing the mud cakes into mud blocks or mud particles, drying the mud blocks or mud particles to a water content suitable for the subsequent processing requirement, and adding recycled filter pulp in the process. The mud cake is processed into mud blocks or mud particles with smaller block diameter or particle size, so that the later drying is facilitated, and the smaller the block particles are, the faster the drying speed is. And (3) in the drying process, adding the filter slurry recycled in the step one, wherein the filter slurry contains effective components in the ceramic powder. In this example, the mud cake was extruded into strips and cut into mud pellets. Specifically, the mud cake can be extruded into a thin strip by adopting extrusion equipment such as a pug mill and the like, and then cut into mud blocks or mud particles.
The drying of the mud blocks or mud particles can adopt two-stage or more-stage drying, wherein the final-stage drying is precise control drying so as to control the water content required by the mud blocks or mud particles. In the embodiment, two-stage drying is adopted, wherein the front-stage drying utilizes direct cooling hot air drying at the tail of the ceramic-fired roller kiln, and the tail-stage drying utilizes waste heat of exhaust smoke at the head of the ceramic-fired roller kiln.
At present, almost all the direct cooling hot air at the tail of a roller kiln burnt by a ceramic factory is not utilized, the waste heat of the front-stage drying process is the direct cooling hot air, the temperature of the direct cooling hot air is not high and is about 15 to 20 ℃ higher than the ambient temperature, but the air is dry, the water content is low, the air quantity is large, and the direct cooling hot air of 10000 square meter burnt kiln is about 16 to 20 ten thousand meters3And the free enthalpy of the hot air is very large, the hot air is used for blowing mud blocks or mud particles on a conveying line, the mud blocks or mud particles can be quickly dried, and the water content of the mud blocks or mud particles can be reduced from 18% to about 13% within half an hour through FCD fluid simulation calculation.
The latter stage drying process can adopt proper higher temperature (below 350 ℃) for drying so as to realize the precise control drying of the water content of the mud blocks or mud particles. The drying equipment may employ a rotary dryer. In the embodiment, the best drying heat source is the heat energy of the exhaust smoke of the firing roller kiln head, and both direct heat exchange and indirect heat exchange are feasible. The direct heat exchange means that kiln head smoke exhaust air is directly input into a rotary dryer, and smoke directly contacts with mud blocks or mud particles for heat exchange and drying; the indirect heat exchange means that the smoke exhaust air of the kiln head and dry air are firstly subjected to heat exchange, then the dry air is pumped into the rotary dryer, and the dry air is contacted with mud blocks or mud particles for heat exchange. The hot air quantity entering the gyrator is adjustable, the drying temperature is adjustable, the speed of conveying mud blocks or mud particles is controllable, and the moisture of the discharged mud blocks or mud particles is controllable, and is generally controlled to be about 8%. Theoretically, every ton of powder is produced, about 64kg of water needs to be evaporated at the working section of the rotary dryer, the heat efficiency is 30 percent, the water consumption is reduced to about 7kg, which is close to one tenth of the coal consumption of spray drying, and the cost can be saved by more than 1000 ten thousand yuan per year for a wall and floor tile production line with daily output of 10000 square meters.
In the first step, the product is not only the mud cake, but also the muddy water as filtrate, namely, the fine mud with the size less than 300 meshes is extruded along with the water, and the fine mud contains the components necessary for the ceramic wall and floor tiles and must be utilized. And (3) feeding the filtrate into a precipitation container, obtaining filter pulp with the water content of about 40% by gravity settling, enabling clear water overflowing from the upper part of the precipitation container to flow into a water storage container, pumping into a ball mill for recycling, and avoiding the effluent from squeezing to precipitation, so that the problem of water pollution is solved. The filter pulp discharged from the lower part of the settling container regularly and quantitatively flows into the stirring container firstly, and is sprayed onto the mud blocks or mud particles dried at the front section through the quantitative pump, and the mud blocks or mud particles absorb the moisture and adsorb fine particles. The method can recycle all fine particle powder in the raw slurry to be mixed into the mud block or mud particles, thereby not influencing the sintering performance of the wall and floor tiles.
Thirdly, the mud blocks or mud particles are smashed into mud powder by impact and then iron is removed. The impact crushing process is to crush the dried mud blocks or mud particles in the previous step by using a mechanical component rotating at a high speed, wherein the impact crushing process is to crush the dried mud blocks or mud particles into powder particles by using mechanical powder crushing, and the impact force is used for crushing the dried mud blocks or mud particles into powder particles.
In fact, the dry clods or grains of mud generate a great deal of dust during the crushing process, and the dust can be sucked by a fan through a bag-type dust collector, so that the impact crushing equipment can keep good working condition.
The powder outlet of the impact crushing equipment can adopt an air-locking discharge valve, and only allows the powder to fall but not allow air flow to pass through.
And screening the ground mud powder, sending the qualified part to a grinding bin for ageing, returning the unqualified part to the inlet of the impact grinding equipment through lifting equipment, and grinding for the second time. In the impact crushing process, abrasion of mechanical crushing components is inevitably brought about, and the abrasion exists in the powder as impurity iron, so that the screened powder needs to be subjected to powder iron removal before being sent into a powder bin, and the fine powder recovered by the bag-type dust remover also needs to be subjected to iron removal.
The ceramic dry-method powder making method changes the traditional powder making mode of the ceramic industry, greatly reduces the energy consumption, does not need to build a desulfurizing tower, solves the problem of environmental pollution and has the key point of effectively reducing the carbon emission.
Claims (5)
1. A dry powder preparation method of ceramics is characterized by comprising the following steps:
firstly, squeezing the homogenized slurry into a mud cake, and concentrating the filtrate into filtered slurry for recycling;
secondly, refining and processing the mud cakes into mud blocks or mud particles, drying the mud blocks or mud particles to reach the water content suitable for the subsequent processing requirement, and adding recycled filter pulp in the process;
thirdly, the mud blocks or mud particles are smashed into mud powder by impact and then iron is removed.
2. The dry powder process method of ceramic according to claim 1, wherein: in step one, the mixture is pressed into a mud cake by a filter press.
3. The dry powder process method of ceramic according to claim 1, wherein: in the second step, the mud cake is processed into mud blocks or mud particles through extrusion and cutting.
4. The dry powder process method of ceramic according to claim 1, wherein: in the second step, the slurry is quantitatively sprayed to the mud blocks or mud particles in the drying process.
5. The dry powder process method of ceramic according to claim 1, wherein: in the second step, the mud blocks or mud particles are dried by at least two sections of drying in sequence, wherein the front section of drying of the mud particles is dried by using direct cooling hot air at the tail of the ceramic firing roller kiln, and the tail section of drying utilizes the waste heat of the exhaust smoke at the head of the ceramic firing roller kiln.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210065909.XA CN114454332A (en) | 2022-01-20 | 2022-01-20 | Ceramic dry-process powder making |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210065909.XA CN114454332A (en) | 2022-01-20 | 2022-01-20 | Ceramic dry-process powder making |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN114454332A true CN114454332A (en) | 2022-05-10 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210065909.XA Pending CN114454332A (en) | 2022-01-20 | 2022-01-20 | Ceramic dry-process powder making |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN114454332A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115448733A (en) * | 2022-09-19 | 2022-12-09 | 新郑市新佳欣环保工程有限公司 | Ceramic wet pulping process, pulping and pulverizing process and system |
| CN115745629A (en) * | 2022-10-31 | 2023-03-07 | 佛山市蓝之鲸科技有限公司 | Ceramic powder preparation method |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102260082A (en) * | 2011-05-18 | 2011-11-30 | 杭州诺贝尔集团有限公司 | Wet production process of ceramic tile |
| CN109928767A (en) * | 2019-03-22 | 2019-06-25 | 佛山市蓝之鲸科技有限公司 | Ceramic wet low temperature flouring technology |
| CN110407587A (en) * | 2019-09-24 | 2019-11-05 | 佛山市博晖机电有限公司 | A kind of architectural pottery wet-dry change flouring technology |
| CN112321303A (en) * | 2021-01-04 | 2021-02-05 | 佛山市蓝之鲸科技有限公司 | Ceramic powder making process and system thereof |
-
2022
- 2022-01-20 CN CN202210065909.XA patent/CN114454332A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102260082A (en) * | 2011-05-18 | 2011-11-30 | 杭州诺贝尔集团有限公司 | Wet production process of ceramic tile |
| CN109928767A (en) * | 2019-03-22 | 2019-06-25 | 佛山市蓝之鲸科技有限公司 | Ceramic wet low temperature flouring technology |
| CN110407587A (en) * | 2019-09-24 | 2019-11-05 | 佛山市博晖机电有限公司 | A kind of architectural pottery wet-dry change flouring technology |
| CN112321303A (en) * | 2021-01-04 | 2021-02-05 | 佛山市蓝之鲸科技有限公司 | Ceramic powder making process and system thereof |
Non-Patent Citations (1)
| Title |
|---|
| 同继锋编著: "《现代建筑卫生陶瓷技术手册》", 中国建材工业出版社, pages: 105 - 109 * |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115448733A (en) * | 2022-09-19 | 2022-12-09 | 新郑市新佳欣环保工程有限公司 | Ceramic wet pulping process, pulping and pulverizing process and system |
| CN115448733B (en) * | 2022-09-19 | 2023-03-03 | 新郑市新佳欣环保工程有限公司 | Ceramic wet pulping process, pulping and pulverizing process and system |
| CN115745629A (en) * | 2022-10-31 | 2023-03-07 | 佛山市蓝之鲸科技有限公司 | Ceramic powder preparation method |
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Application publication date: 20220510 |
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