CN115124355A - Method for burning large-size ceramic spheres in buried mode - Google Patents
Method for burning large-size ceramic spheres in buried mode Download PDFInfo
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- CN115124355A CN115124355A CN202210858591.0A CN202210858591A CN115124355A CN 115124355 A CN115124355 A CN 115124355A CN 202210858591 A CN202210858591 A CN 202210858591A CN 115124355 A CN115124355 A CN 115124355A
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D5/00—Supports, screens, or the like for the charge within the furnace
- F27D5/0006—Composite supporting structures
- F27D5/0012—Modules of the sagger or setter type; Supports built up from them
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
- C04B2235/6567—Treatment time
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
- C04B2235/661—Multi-step sintering
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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
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
Abstract
The invention relates to a large-size ceramic ball body burying method, wherein corundum sand is filled in a sagger, a ceramic ball is buried in the central position of the corundum sand in the sagger, heat in a furnace is transferred to the corundum sand through the sagger, heat accumulated by the corundum sand forms a thermal field outside the ceramic ball, heat is transferred to the ceramic ball through heat transfer, the heat can be transferred to the center of the ceramic ball at a higher speed, the temperature of the center of the ceramic ball is quickly close to the external temperature, the balance of the internal temperature and the external temperature of the ceramic ball is realized, the cracking caused by overlarge internal temperature and external temperature difference is not easy to occur, the finished product rate of ceramic ball sintering is greatly improved, the loss is reduced, the yield of the large-size ceramic ball is improved, and the market demand is met.
Description
Technical Field
The invention relates to the field of ceramic products, in particular to a method for burying and burning large-size ceramic spheres.
Background
The alumina ceramic ball is widely used due to the characteristics of moderate density, abrasion resistance, low price and the like. The alumina ceramic ball is the most ideal high-efficiency grinding medium for grinding glaze, blank, chemical raw materials and various mineral powders, and compared with natural stone balls and common ceramic balls, the abrasive resistance of the alumina ceramic ball is improved by 20-40 times, and the grinding efficiency is improved by 40% -60%. In addition, the ceramic ball valve based on the processing of the alumina ceramic ball is widely applied to a plurality of fields of paper making, medicine, coal chemical industry, electric power, petroleum, aerospace and the like.
Although the alumina ceramic spheres are widely applied, the large-size alumina ceramic spheres (especially the ceramic spheres with the sphere diameter larger than 200 mm) have great molding difficulty and greater sintering difficulty. The reason that the sintering difficulty is large is that the alumina ceramic ball is a solid ball body, and more binders, water and various inorganic substances are added into a ceramic ball blank in order to ensure the forming stability of the large-size ceramic ball, so that moisture in the ball body cannot be discharged in time in the sintering temperature rise process, the ball body is easy to crack due to moisture gasification, and in addition, the large-size ceramic ball is directly contacted with flame in a furnace body in the temperature rise process, the external part of the ball body is rapidly heated up, the internal temperature rise is delayed, obvious temperature difference can occur, the internal and external heating is unbalanced, and the ball body is easy to crack; in the current industrial production, the firing yield of large-size ceramic balls is less than two, so that it is necessary to perfect each firing process to improve the firing yield of the ceramic balls.
Disclosure of Invention
In order to solve the problems, the invention provides a method for burying and burning large-size ceramic spheres.
The technical scheme of the invention is as follows: a large-size ceramic sphere burying method comprises the following steps:
firstly, placing a ceramic ball blank in a drying environment for natural drying in the shade, and then placing the ceramic ball blank in a drying box for drying;
secondly, preparing a corundum-mullite sagger in advance, paving a layer of corundum-mullite on the bottom of the sagger, placing the dried ceramic ball blank in the middle of the sagger, continuously filling corundum sand into the sagger, and burying the ceramic ball blank in the center of the corundum-mullite;
and thirdly, covering a sagger cover, putting the sagger into a kiln, gradually heating, and sintering at 1650 ℃.
Preferably, the temperature rise curve during high-temperature sintering is as follows:
(1) a temperature rising stage: heating from room temperature, raising the temperature from room temperature to 300 ℃ within 40 hours, raising the temperature from 300 ℃ to 600 ℃ within 30 hours, raising the temperature from 600 ℃ to 950 ℃ within 23 hours, and keeping the temperature at 950 ℃ for 2 hours; continuously heating, heating from 950 ℃ to 1250 ℃ within 10 hours, heating from 1250 ℃ to 1500 ℃ within 7 hours, heating from 1500 ℃ to 1650 ℃ within 6 hours, and keeping the temperature at 1650 ℃ for 5 hours;
(2) and (3) cooling: cooling from 1650 ℃ to 1350 ℃ within 10 hours, then cooling from 1350 ℃ to 950 ℃ within 7 hours, turning off fire at 950 ℃, naturally cooling to 200 ℃, opening the kiln door when 200 ℃, fully opening the kiln door when cooling to 150 ℃, pulling out the kiln car after 2 hours, and naturally cooling to normal temperature.
Preferably, the volume of the cavity in the sagger is two times larger than that of the ceramic ball blank, and the thicknesses of the sagger and the cover are 40-50 mm.
Preferably, the refractoriness of the corundum sand is more than or equal to 1800 ℃.
Preferably, the thickness of the corundum sand at the bottom of the sagger is more than one third of the diameter of the ceramic ball blank.
Preferably, a corundum brick pad with the thickness of 200mm is arranged on the bottom surface of the sagger in a pad mode, and arc-shaped fire blocking bricks are arranged on the periphery of the sagger.
Preferably, the drying time of the ceramic ball blank in the shade is 20-45 days, so as to remove 70-80 wt% of water in the ceramic ball blank; the drying temperature of the drying box is 100 ℃, and the drying time is 48 hours.
The beneficial technical effects of the invention are as follows:
(1) the sagger of the invention is filled with corundum sand, and the ceramic ball is buried in the corundum sand during firing
The central point puts, the heat that the flame produced in the kiln transmits for the corundum sand through the saggar, the heat that the corundum sand is accumulational forms the thermal field at ceramic ball outside, through heat-conduction mode to ceramic ball in the heat transfer heat, make the ceramic ball be heated evenly, and the heat can be with faster speed transmission to ceramic ball center, the temperature that makes ceramic ball center can be close outside temperature fast, realize the quick balance of the inside and outside temperature of ceramic ball, the difficult condition that appears the fracture because of the inside and outside difference in temperature is too big that appears, the yield that jumbo size ceramic ball burns is improved by a wide margin, the loss is reduced, the output of jumbo size ceramic ball is improved, satisfy market demand.
(2) Before the large-size ceramic balls are fired, the large-size ceramic balls are dried in the shade in a drying environment and steamed
70% -80% of water in the ceramic ball blank is removed, then the residual water in the ceramic ball blank is further dried in a low-temperature baking mode, and the ceramic ball after primary drying is placed into a sagger to be fired.
(3) The sintering process of the large-size ceramic balls adopts strict temperature rising and reducing curves, the temperature rising and reducing curves are designed according to the characteristics of the large-size ceramic balls, the cracking of the balls caused by the fact that the balls are heated unevenly inside and outside the balls due to too fast temperature rising in the temperature rising process is prevented, and the temperature reducing curves are beneficial to the balance of the temperature outside and inside the balls and the improvement of the sintering quality of the large-size ceramic balls.
(4) The diameter of the ceramic ball prepared by the method is more than 200mm and can reach 300mm, and the finished product rate of ceramic ball sintering is more than 90 percent, which is in the leading level in the industry.
Drawings
FIG. 1 is a schematic view of a ceramic ball green body of the present invention loaded into a sagger;
FIG. 2 is a schematic perspective view of a sagger and a green ceramic ball according to the present invention;
FIG. 3 is a schematic perspective view of the sagger with fire-blocking bricks arranged outside.
In the figure, 11 is a ceramic ball blank, 12 is a sagger, 13 is a cover, 14 is corundum sand, and 15 is an arc-shaped fire-blocking brick.
Detailed Description
In a first embodiment, referring to fig. 1-3, a method for embedding large-sized ceramic spheres comprises the following steps:
firstly, placing a ceramic ball blank body in a drying environment for natural drying in the shade, drying 70-80% (wt) of water in the ceramic ball blank body in the shade, and then placing the ceramic ball blank body in a drying box for further drying;
naturally drying the ceramic ball blank in the shade for 20-45 days, and properly adjusting according to seasons; for example, the drying time in the shade in summer is 15-20 days, 25-45 days in winter, and about 20 days in spring and autumn, so that the moisture in the ceramic balls can be dried by 70-80 (wt%); drying for 48 hours at 100 ℃ by adopting a drying box;
the mode of combining natural drying in the shade and drying can well control the loss speed of the water in the ceramic balls, the balls cannot crack due to too fast water loss, and the yield is improved.
Secondly, preparing a cylindrical corundum-mullite sagger in advance, paving a layer of corundum-mullite on the bottom of the sagger, placing the dried ceramic ball blank in the middle of the sagger, and continuously filling corundum into the sagger until the ceramic ball blank is embedded into the center of the corundum-mullite; the corundum sand is used as a medium for accumulating and transferring heat, and the corundum sand around the ceramic ball can uniformly transfer heat to the ceramic ball, so that the ball body is uniformly heated;
and thirdly, covering a sagger cover, putting the sagger into a kiln, gradually heating, and sintering at 1650 ℃.
The sintering is carried out according to the following temperature rising and reducing curves strictly:
a temperature rise stage, wherein heating is started from room temperature, the temperature is raised from the room temperature to 300 ℃ within 40 hours, the temperature is raised from 300 ℃ to 600 ℃ within 30 hours, the temperature is raised from 600 ℃ to 950 ℃ within 23 hours, the temperature is preserved at 950 ℃ for 2 hours, then the temperature is raised from 950 ℃ to 1250 ℃ within 10 hours, the temperature is raised from 1250 ℃ to 1500 ℃ within 7 hours, the temperature is raised from 1500 ℃ to 1650 ℃ within 6 hours, and the temperature is preserved at 1650 ℃ for 5 hours;
and in the temperature reduction stage, the temperature is reduced from 1650 ℃ to 1350 ℃ within 10 hours, the temperature is reduced from 1350 ℃ to 950 ℃ within 7 hours, the fire is turned off and the kiln is naturally cooled to 200 ℃, then the kiln door is opened for about 10 minutes, the kiln door is fully opened when the temperature is reduced to 150 ℃, the kiln car is pulled out after adapting to 2 hours, a sagger is opened after the kiln car is cooled to be convenient to take, the fired ceramic balls are taken out, the ceramic balls below 100 ℃ can adapt to the room temperature, and cracking caused by excessive temperature difference is avoided.
Preferably, the volume of the cavity in the sagger is at least two times of the volume of the ceramic ball blank, enough space is reserved between the ceramic ball and the sagger to contain the corundum sand, the thickness of the sagger and the cover is 40-50mm, the thickness has enough strength to support the corundum sand and the ceramic ball in the sagger, and the heat transfer is uniform.
The corundum sand adopted has the refractoriness of over 1800 ℃ and the type number of the corundum sand is 100# -120#, and the corundum sand has small granularity, good heat storage and heat transfer effects and is beneficial to heat transfer.
The thickness of the corundum sand paved at the bottom of the sagger is more than one third of the diameter of the ceramic ball body, so that the corundum sand with enough thickness is formed at the lower part of the ceramic ball body.
The bottom surface of the sagger is padded with corundum brick pads with the thickness of 200mm, arc-shaped fire blocking bricks are arranged around the sagger and are used for blocking flames in the furnace body, the flames are prevented from impacting the side wall of the sagger, the sagger can be protected, and the sagger is prevented from cracking and being damaged.
Claims (7)
1. A large-size ceramic sphere burial burning method is characterized by comprising the following steps:
firstly, placing a ceramic ball blank in a drying environment for natural drying in the shade, and then placing the ceramic ball blank in a drying box for drying;
secondly, preparing a corundum-mullite sagger in advance, paving a layer of corundum-mullite on the bottom of the sagger, placing the dried ceramic ball blank in the middle of the sagger, continuously filling corundum sand into the sagger, and burying the ceramic ball blank in the center of the corundum-mullite;
and thirdly, covering a sagger cover, putting the sagger into a kiln, gradually heating, and sintering at 1650 ℃.
2. The method for burying large-size ceramic spheres as claimed in claim 1, wherein: the temperature rise curve during high-temperature sintering is as follows:
(1) a temperature rising stage: heating from room temperature, raising the temperature from room temperature to 300 ℃ within 40 hours, raising the temperature from 300 ℃ to 600 ℃ within 30 hours, raising the temperature from 600 ℃ to 950 ℃ within 23 hours, and keeping the temperature at 950 ℃ for 2 hours; continuously heating, heating from 950 ℃ to 1250 ℃ within 10 hours, heating from 1250 ℃ to 1500 ℃ within 7 hours, heating from 1500 ℃ to 1650 ℃ within 6 hours, and keeping the temperature at 1650 ℃ for 5 hours;
(2) and (3) cooling: cooling from 1650 ℃ to 1350 ℃ within 10 hours, then cooling from 1350 ℃ to 950 ℃ within 7 hours, turning off fire at 950 ℃, naturally cooling to 200 ℃, opening the kiln door when 200 ℃, fully opening the kiln door when cooling to 150 ℃, pulling out the kiln car after 2 hours, and naturally cooling to normal temperature.
3. The method for burying large-size ceramic spheres as claimed in claim 1, wherein: the volume of the cavity in the sagger is larger than two times of the volume of the ceramic ball blank, and the thicknesses of the sagger and the cover are 40-50 mm.
4. The method for burying large-size ceramic spheres as claimed in claim 1, wherein: the refractoriness of the corundum sand is more than or equal to 1800 ℃.
5. The method for burying large-size ceramic spheres as claimed in claim 1, wherein: the thickness of the corundum sand at the bottom of the sagger is more than one third of the diameter of the ceramic ball blank.
6. The method for burying large-size ceramic spheres as claimed in claim 1, wherein: the bottom surface of the sagger is padded with corundum brick pads with the thickness of 200mm, and arc-shaped fire blocking bricks are arranged around the sagger.
7. The method for burying large-size ceramic spheres as claimed in claim 1, wherein: the drying time of the ceramic ball green body in the shade is 20-45 days to remove the ceramic ball green body
70-80 wt% moisture; the drying temperature of the drying box is 100 ℃, and the drying time is 48 hours.
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|---|---|---|---|
| CN202210858591.0A CN115124355B (en) | 2022-07-21 | 2022-07-21 | Method for burying and burning large-size ceramic spheres |
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| CN202210858591.0A CN115124355B (en) | 2022-07-21 | 2022-07-21 | Method for burying and burning large-size ceramic spheres |
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| CN115124355B CN115124355B (en) | 2023-09-01 |
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