CN115010470A - 一种利用陶瓷废料生产化工填料的方法 - Google Patents
一种利用陶瓷废料生产化工填料的方法 Download PDFInfo
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Abstract
本发明提供一种利用陶瓷废料生产化工填料的方法,涉及化工填料技术领域。该利用陶瓷废料生产化工填料的方法,包括以下步骤:S1、预处理原浆A;S2、预处理原浆B;S3、预处理原浆A和预处理原浆B混合进行压滤、真空练泥、陈腐、切片处理;S4、波纹挤压和叠加修整得到泥片坯件;S5、干燥脱水;S6、氮化烧成处理,冷却出炉的陶瓷化工填料。通过从原料、双料混合、压滤、真空练泥、陈腐、粉碎、波纹挤压叠加、干燥和烧成的整个制备流程中,使得化工填料的坯体收缩减少,干燥强度增加,改善泥料的黏性,提高其成型性能,同时进一步增加化工填料的强度和抗震性能,减少其质脆破碎现象,延长其使用寿命。
Description
技术领域
本发明涉及化工填料技术领域,具体为一种利用陶瓷废料生产化工填料的方法。
背景技术
陶瓷废料主要是指陶瓷制品在生产的过程中,经过成形、干燥、施釉、搬运、焙烧及贮存等工序后残留下来的废料,通常包括坯体废料、废釉料、烧成废料、匣钵废渣和砖屑等,遗留下来的陶瓷废料不易处理,堆积过多既造成空间利用率不足,也影响周边环境,因此为了保护环境和陶瓷工业的可持续发展,现今社会基本是将陶瓷废料当做化工填料制备用的原料之一,既能减少其空间占比,也能提高附加经济效益,而且在化工领域中,许多设备都是使用化工填料来进行一些生产活动,同时化工填料种类繁多,有竹木类、金属类、陶瓷类、塑料类等不同的填料类型,其形状结构各有不同,产生的作用也不相同,而其中陶瓷化工填料具有显著的通量大、压降低、传质效率高等突出特点,在化工、冶金、煤气、制氧等行业的干燥塔、吸收塔、冷却塔、再生塔内和有机废气装置中得到了广泛应用,是应用较广的新型高效化工填料。
现有的陶瓷化工填料基本都存在着耐压强度低,抗震性能差,且也较易发生破碎现象,造成其使用寿命短的问题,同时,制备陶瓷化工填料的方法流程都较为繁琐,而制作陶瓷化工填料的效率过低会使得单个陶瓷化工填料的生产成本过高,不利于大批量生产活动。
发明内容
针对现有技术的不足,本发明提供了一种利用陶瓷废料生产化工填料的方法,解决了现有的陶瓷化工填料耐压强度低,抗震性能差,且也较易发生破碎现象,造成其使用寿命短的问题,同时,制备陶瓷化工填料的方法流程都较为繁琐,制作单个陶瓷化工填料的生产成本过高,不利于大批量生产活动的问题。
为实现以上目的,本发明通过以下技术方案予以实现:一种利用陶瓷废料生产化工填料的方法,包括以下重量份的原料:刚玉50-65份、由长石15-19份、胡精4-7份、湿润剂5-8份、稳定剂9-12份、陶瓷废料10-40份、滑石16-35份、三氧化二铝50-71份、锆石英10-32份、氧化钇0.01-3份、羧甲基纤维素钠0.5-2份、次亚磷酸钠15-22份、碳酸钡6-27份、方解石8-12份、氧化镁0.9-7份。
优选的,一种利用陶瓷废料生产化工填料的方法,包括以下步骤:
S1、按配方重量份配比拿取刚玉、由长石、胡精、湿润剂和稳定剂,将刚玉、由长石和稳定剂均匀搅拌,再依次加入胡精和湿润剂拌和均匀,即得到预处理原浆A;
S2、按配方重量份配比将S1中未使用的陶瓷废料和剩余原料投入球磨机内,加入水和球石,然后进行球磨处理5-10h后,得到初始浆料,放浆进入过滤筛选装置,过100-120目筛网,即得预处理原浆B;
S3、将预处理原浆A和预处理原浆B依次倒入压滤机,压滤成料饼,然后放入真空练泥机揉练6-9h,再陈腐静置3-4天,得到处理完成的泥料,利用泥料切碎机进行切片,得到泥片料;
S4、将泥片料放入成型机挤压成波纹片,利用粘接料浆将波纹片依次叠加黏合,再将粘接好的波纹片送入模具中修整形状,得到泥片坯件;
S5、将泥片坯件放入烘房中干燥,在干燥温度为500-600℃,干燥5-8h,使其泥片坯件含水率在1-3%;
S6、将泥片坯件装坯烧结,采用氮化烧成处理工艺烧制,烧成温度在1430-1440℃,并在900-1350℃下保温1.5-2.5h,烧成周期为16-25h,冷却后出炉,即成陶瓷化工填料。
优选的,所述S1步骤中,首先将刚玉和由长石依次放入研磨机研磨至50-100目,再分筛3-5次,最后进行搅拌。
优选的,所述S2步骤中,其中剩余原料、球石和水的投放量分别为0.9:1.4:0.9,球石采用直径为30mm或40mm规格编号。
优选的,所述S3步骤中,泥片料的厚度为9-11mm,切边完成的泥片料放置在自然环境下晾干至含水率为18.5-19.5%。
优选的,所述S4步骤中,粘接料浆由水泥原浆、木炭灰、二氧化硅、粘合剂、促进剂原料配置而成,将水泥原浆、木炭灰和二氧化硅依次放入粉碎装置中,粉碎至60-120目,得到混料,将混料放入加热搅拌装置中,再依次放入剩余原料,即得到粘接料浆。
优选的,所述S4步骤中,泥片坯件出炉后进行打渣修整及检验,其泥片坯件的吸水率在0.1-0.5%。
优选的,所述S6步骤中,氮化烧成所需要的氮气由100m3制氮机组提供,两台“微氧分析仪”、一台“露点仪”检测,保证氮气纯度达到99.9995%以上。
本发明提供了一种利用陶瓷废料生产化工填料的方法。具备以下有益效果:
1、本发明通过制备预处理原浆A和预处理原浆B,将两者依次倒入压滤机进行压滤、再进行真空练泥使坯体收缩减少,干燥强度成倍增加,产品性能显著改善,随后通过陈腐处理将粘土颗粒充分水化和进行离子交换,从而提高可塑性,改善泥料的黏性,提高成型性能,增加坯体的强度,再经过切片和波纹挤压,增加叠加的接触面积,随后整修、干燥和烧成得到陶瓷化工填料,整个制备方法增加了化工填料的强度,抗震性能,减少其质脆破碎现象,延长其使用寿命。
2、本发明通过简化化工填料从原料、混合、压滤、真空练泥、陈腐、粉碎、波纹挤压叠加、干燥、烧成的操作方法,使得单个陶瓷化工填料的生产效率提高,减少经济成本,有利于大批量生产活动。
3、本发明通过使用陶瓷废料用于化工填料的制备,既提高的陶瓷废料的利用率,也提高了经济效益,同时通过对外形的不同修整,可能组合出不同的产品形态,提高化工填料的不同用途和使用领域,减少局限性。
具体实施方式
下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例一:
本发明实施例提供一种利用陶瓷废料生产化工填料的方法,包括以下重量份的原料:刚玉53份、由长石16份、胡精6份、湿润剂7份、稳定剂10份、陶瓷废料35份、滑石23份、三氧化二铝62份、锆石英20份、氧化钇0.09份、羧甲基纤维素钠1份、次亚磷酸钠16份、碳酸钡13份、方解石11份、氧化镁3份。
一种利用陶瓷废料生产化工填料的方法,包括以下步骤:
S1、按配方重量份配比拿取刚玉、由长石、胡精、湿润剂和稳定剂,将刚玉、由长石和稳定剂均匀搅拌,再依次加入胡精和湿润剂拌和均匀,即得到预处理原浆A;
S2、按配方重量份配比将S1中未使用的陶瓷废料和剩余原料投入球磨机内,加入水和球石,然后进行球磨处理6h后,得到初始浆料,放浆进入过滤筛选装置,过110目筛网,即得预处理原浆B;
S3、将预处理原浆A和预处理原浆B依次倒入压滤机,压滤成料饼,然后放入真空练泥机揉练7h,再陈腐静置3天,得到处理完成的泥料,利用泥料切碎机进行切片,得到泥片料;经过压滤机得到的料饼,其中含有的水分和固体颗粒分布很不均匀,会导致后续成型的坯体烧制收缩不均匀,引起干燥和烧成裂纹,通过真空练泥后,料饼中的空气的体积可降至0.6-0.9%,而且由于对料饼的揉练和挤压作用,使后续形成的泥料的定向结构更加完善,组分更加均匀,使坯体收缩减少,干燥强度成倍增加,产品性能显著改善,而陈腐处理的作用在于将粘土颗粒充分水化和进行离子交换,从而提高可塑性,改善泥料的黏性,提高成型性能,也可提高坯体的强度,减少烧成的变形机会;
S4、将泥片料放入成型机挤压成波纹片,利用粘接料浆将波纹片依次叠加黏合,再将粘接好的波纹片送入模具中修整形状,得到泥片坯件;
S5、将泥片坯件放入烘房中干燥,在干燥温度为500℃,干燥7h,使其泥片坯件含水率在1.5%;
S6、将泥片坯件装坯烧结,采用氮化烧成处理工艺烧制,烧成温度在1430℃,并在1000℃下保温1.5h,烧成周期为18h,冷却后出炉,即成陶瓷化工填料。
S1步骤中,首先将刚玉和由长石依次放入研磨机研磨至60目,再分筛3次,最后进行搅拌。
S2步骤中,其中剩余原料、球石和水的投放量分别为0.9:1.4:0.9,球石采用直径为30mm规格编号。
S3步骤中,泥片料的厚度为10mm,切边完成的泥片料放置在自然环境下晾干至含水率为18.5%。
S4步骤中,粘接料浆由水泥原浆、木炭灰、二氧化硅、粘合剂、促进剂原料配置而成,将水泥原浆、木炭灰和二氧化硅依次放入粉碎装置中,粉碎至80目,得到混料,将混料放入加热搅拌装置中,再依次放入剩余原料,即得到粘接料浆。
S4步骤中,泥片坯件出炉后进行打渣修整及检验,其泥片坯件的吸水率在0.2%。
S6步骤中,氮化烧成所需要的氮气由100m3制氮机组提供,两台“微氧分析仪”、一台“露点仪”检测,保证氮气纯度达到99.9995%以上,以氮气的消耗制定升温曲线,实行“低温长保”制度,在1350℃以下长时间保温,以便让制品达到最大的氮化率,烧成过程中抽真空、充氮气、氮气压力等由专业司炉工负责,并在技术人员的监督、指导下进行。
实施例二:
本发明实施例提供一种利用陶瓷废料生产化工填料的方法,包括以下重量份的原料:刚玉61份、由长石19份、胡精7份、湿润剂5份、稳定剂11份、陶瓷废料40份、滑石18份、三氧化二铝54份、锆石英30份、氧化钇2份、羧甲基纤维素钠1.5份、次亚磷酸钠21份、碳酸钡24份、方解石12份、氧化镁5份。
一种利用陶瓷废料生产化工填料的方法,包括以下步骤:
S1、按配方重量份配比拿取刚玉、由长石、胡精、湿润剂和稳定剂,将刚玉、由长石和稳定剂均匀搅拌,再依次加入胡精和湿润剂拌和均匀,即得到预处理原浆A;
S2、按配方重量份配比将S1中未使用的陶瓷废料和剩余原料投入球磨机内,加入水和球石,然后进行球磨处理9h后,得到初始浆料,放浆进入过滤筛选装置,过120目筛网,即得预处理原浆B;
S3、将预处理原浆A和预处理原浆B依次倒入压滤机,压滤成料饼,然后放入真空练泥机揉练8h,再陈腐静置4天,得到处理完成的泥料,利用泥料切碎机进行切片,得到泥片料;经过压滤机得到的料饼,其中含有的水分和固体颗粒分布很不均匀,会导致后续成型的坯体烧制收缩不均匀,引起干燥和烧成裂纹,通过真空练泥后,料饼中的空气的体积可降至0.6-0.9%,而且由于对料饼的揉练和挤压作用,使后续形成的泥料的定向结构更加完善,组分更加均匀,使坯体收缩减少,干燥强度成倍增加,产品性能显著改善,而陈腐处理的作用在于将粘土颗粒充分水化和进行离子交换,从而提高可塑性,改善泥料的黏性,提高成型性能,也可提高坯体的强度,减少烧成的变形机会;
S4、将泥片料放入成型机挤压成波纹片,利用粘接料浆将波纹片依次叠加黏合,再将粘接好的波纹片送入模具中修整形状,得到泥片坯件;
S5、将泥片坯件放入烘房中干燥,在干燥温度为600℃,干燥8h,使其泥片坯件含水率在2.5%;
S6、将泥片坯件装坯烧结,采用氮化烧成处理工艺烧制,烧成温度在1440℃,并在1220℃下保温2h,烧成周期为23h,冷却后出炉,即成陶瓷化工填料。
S1步骤中,首先将刚玉和由长石依次放入研磨机研磨至80目,再分筛5次,最后进行搅拌。
S2步骤中,其中剩余原料、球石和水的投放量分别为0.9:1.4:0.9,球石采用直径为40mm规格编号。
S3步骤中,泥片料的厚度为11mm,切边完成的泥片料放置在自然环境下晾干至含水率为19%。
S4步骤中,粘接料浆由水泥原浆、木炭灰、二氧化硅、粘合剂、促进剂原料配置而成,将水泥原浆、木炭灰和二氧化硅依次放入粉碎装置中,粉碎至110目,得到混料,将混料放入加热搅拌装置中,再依次放入剩余原料,即得到粘接料浆。
S4步骤中,泥片坯件出炉后进行打渣修整及检验,其泥片坯件的吸水率在0.4%。
S6步骤中,氮化烧成所需要的氮气由100m3制氮机组提供,两台“微氧分析仪”、一台“露点仪”检测,保证氮气纯度达到99.9995%以上,以氮气的消耗制定升温曲线,实行“低温长保”制度,在1350℃以下长时间保温,以便让制品达到最大的氮化率,烧成过程中抽真空、充氮气、氮气压力等由专业司炉工负责,并在技术人员的监督、指导下进行。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (8)
1.一种利用陶瓷废料生产化工填料的方法,其特征在于:包括以下重量份的原料:刚玉50-65份、由长石15-19份、胡精4-7份、湿润剂5-8份、稳定剂9-12份、陶瓷废料10-40份、滑石16-35份、三氧化二铝50-71份、锆石英10-32份、氧化钇0.01-3份、羧甲基纤维素钠0.5-2份、次亚磷酸钠15-22份、碳酸钡6-27份、方解石8-12份、氧化镁0.9-7份。
2.根据权利要求1所述的一种利用陶瓷废料生产化工填料的方法,其特征在于:包括以下步骤:
S1、按配方重量份配比拿取刚玉、由长石、胡精、湿润剂和稳定剂,将刚玉、由长石和稳定剂均匀搅拌,再依次加入胡精和湿润剂拌和均匀,即得到预处理原浆A;
S2、按配方重量份配比将S1中未使用的陶瓷废料和剩余原料投入球磨机内,加入水和球石,然后进行球磨处理5-10h后,得到初始浆料,放浆进入过滤筛选装置,过100-120目筛网,即得预处理原浆B;
S3、将预处理原浆A和预处理原浆B依次倒入压滤机,压滤成料饼,然后放入真空练泥机揉练6-9h,再陈腐静置3-4天,得到处理完成的泥料,利用泥料切碎机进行切片,得到泥片料;
S4、将泥片料放入成型机挤压成波纹片,利用粘接料浆将波纹片依次叠加黏合,再将粘接好的波纹片送入模具中修整形状,得到泥片坯件;
S5、将泥片坯件放入烘房中干燥,在干燥温度为500-600℃,干燥5-8h,使其泥片坯件含水率在1-3%;
S6、将泥片坯件装坯烧结,采用氮化烧成处理工艺烧制,烧成温度在1430-1440℃,并在900-1350℃下保温1.5-2.5h,烧成周期为16-25h,冷却后出炉,即成陶瓷化工填料。
3.根据权利要求1所述的一种利用陶瓷废料生产化工填料的方法,其特征在于:所述S1步骤中,首先将刚玉和由长石依次放入研磨机研磨至50-100目,再分筛3-5次,最后进行搅拌。
4.根据权利要求1所述的一种利用陶瓷废料生产化工填料的方法,其特征在于:所述S2步骤中,其中剩余原料、球石和水的投放量分别为0.9:1.4:0.9,球石采用直径为30mm或40mm规格编号。
5.根据权利要求1所述的一种利用陶瓷废料生产化工填料的方法,其特征在于:所述S3步骤中,泥片料的厚度为9-11mm,切边完成的泥片料放置在自然环境下晾干至含水率为18.5-19.5%。
6.根据权利要求1所述的一种利用陶瓷废料生产化工填料的方法,其特征在于:所述S4步骤中,粘接料浆由水泥原浆、木炭灰、二氧化硅、粘合剂、促进剂原料配置而成,将水泥原浆、木炭灰和二氧化硅依次放入粉碎装置中,粉碎至60-120目,得到混料,将混料放入加热搅拌装置中,再依次放入剩余原料,即得到粘接料浆。
7.根据权利要求1所述的一种利用陶瓷废料生产化工填料的方法,其特征在于:所述S4步骤中,泥片坯件出炉后进行打渣修整及检验,其泥片坯件的吸水率在0.1-0.5%。
8.根据权利要求1所述的一种利用陶瓷废料生产化工填料的方法,其特征在于:所述S6步骤中,氮化烧成所需要的氮气由100m3制氮机组提供,两台“微氧分析仪”、一台“露点仪”检测,保证氮气纯度达到99.9995%以上。
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CN102875133A (zh) * | 2012-10-23 | 2013-01-16 | 江苏红旗环保工程有限公司 | 抗震耐温波纹陶瓷填料及其制备方法 |
CN104371373A (zh) * | 2014-08-01 | 2015-02-25 | 崔家强 | 一种利用陶瓷废料制备化工填料的方法 |
CN106587945A (zh) * | 2016-11-21 | 2017-04-26 | 临沂大学 | 一种化工设备用陶瓷填料及其制备方法 |
CN111196715A (zh) * | 2020-01-09 | 2020-05-26 | 余干金石新材料科技有限公司 | 利用活性氧化铝球工业固废危废制备惰性氧化铝化工填料的方法 |
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