CN116330437A - Production process and equipment of ceramic fiber lengthened filter tube - Google Patents
Production process and equipment of ceramic fiber lengthened filter tube Download PDFInfo
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- CN116330437A CN116330437A CN202310082383.0A CN202310082383A CN116330437A CN 116330437 A CN116330437 A CN 116330437A CN 202310082383 A CN202310082383 A CN 202310082383A CN 116330437 A CN116330437 A CN 116330437A
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- 239000000835 fiber Substances 0.000 title claims abstract description 369
- 239000000919 ceramic Substances 0.000 title claims abstract description 184
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 48
- 238000003756 stirring Methods 0.000 claims abstract description 143
- 239000000463 material Substances 0.000 claims abstract description 92
- 238000009987 spinning Methods 0.000 claims abstract description 87
- 239000007788 liquid Substances 0.000 claims abstract description 70
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims abstract description 69
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 claims abstract description 55
- 239000002639 bone cement Substances 0.000 claims abstract description 54
- 239000002002 slurry Substances 0.000 claims abstract description 54
- 238000001035 drying Methods 0.000 claims abstract description 53
- 238000002156 mixing Methods 0.000 claims abstract description 52
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 33
- 238000010009 beating Methods 0.000 claims abstract description 28
- 238000000034 method Methods 0.000 claims abstract description 16
- 238000005086 pumping Methods 0.000 claims abstract description 16
- 230000008569 process Effects 0.000 claims abstract description 13
- 230000007246 mechanism Effects 0.000 claims description 166
- 238000010438 heat treatment Methods 0.000 claims description 16
- 238000001816 cooling Methods 0.000 claims description 15
- 238000007599 discharging Methods 0.000 claims description 4
- 230000001105 regulatory effect Effects 0.000 abstract 1
- 230000000052 comparative effect Effects 0.000 description 41
- 238000005336 cracking Methods 0.000 description 37
- 239000000047 product Substances 0.000 description 20
- 238000012360 testing method Methods 0.000 description 17
- 238000001914 filtration Methods 0.000 description 12
- 230000006872 improvement Effects 0.000 description 7
- 229910001220 stainless steel Inorganic materials 0.000 description 6
- 239000010935 stainless steel Substances 0.000 description 6
- 239000000428 dust Substances 0.000 description 5
- 230000001965 increasing effect Effects 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 238000000967 suction filtration Methods 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
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- 238000009472 formulation Methods 0.000 description 3
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- 239000000203 mixture Substances 0.000 description 3
- 230000002968 anti-fracture Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000003638 chemical reducing agent Substances 0.000 description 2
- 210000000078 claw Anatomy 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 238000009776 industrial production Methods 0.000 description 2
- 210000001503 joint Anatomy 0.000 description 2
- 230000007935 neutral effect Effects 0.000 description 2
- 238000004537 pulping Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000006477 desulfuration reaction Methods 0.000 description 1
- 230000023556 desulfurization Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 201000004356 excessive tearing Diseases 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/0001—Making filtering elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/02—Conditioning the material prior to shaping
- B28B17/026—Conditioning ceramic materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B21/00—Methods or machines specially adapted for the production of tubular articles
- B28B21/02—Methods or machines specially adapted for the production of tubular articles by casting into moulds
- B28B21/08—Methods or machines specially adapted for the production of tubular articles by casting into moulds by slip-casting; Moulds therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B21/00—Methods or machines specially adapted for the production of tubular articles
- B28B21/76—Moulds
- B28B21/82—Moulds built-up from several parts; Multiple moulds; Moulds with adjustable parts
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Physics & Mathematics (AREA)
- Geometry (AREA)
- Filtering Materials (AREA)
Abstract
The invention relates to a production process and equipment of a ceramic fiber lengthened filter tube, wherein the process comprises the following steps: s1, putting ceramic fibers and water into a beating machine, and mixing and beating to obtain a fiber base material; the mass ratio of the ceramic fiber to the water is 1.2-2.7:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.1-1.3; s2, pumping the fiber base material into a batching tank, setting the stirring speed to be 70-90rpm, and slowly adding sodium hydroxide until the pH value is 7.4-7.8; s3, adding liquid aluminum sulfate and bone glue into a material mixing tank, regulating the stirring speed to 140-200rpm, and stirring for 18-35min to obtain fiber slurry; the mass ratio of the liquid aluminum sulfate to the ceramic fiber is 3.2-5.8:100; the mass ratio of the bone glue to the ceramic fiber is 1.5-2.5:100; s4, pumping the fiber slurry into production equipment to prepare a lengthened wet pipe blank; s5, drying the lengthened wet tube blank to obtain the ceramic fiber lengthened filter tube. The fiber slurry can meet the strength requirement of the ceramic fiber filter tube with the length of more than 3m, and the prepared ceramic fiber lengthened filter tube has excellent tensile and flexural strength.
Description
Technical Field
The present invention relates generally to the technical field of ceramic fiber filter tubes. More particularly, the invention relates to a production process and equipment of a ceramic fiber lengthened filter tube.
Background
The ceramic fiber pipe can replace a dust removing bag in the bag type dust remover to filter dust, and has good high temperature resistance compared with the dust removing bag, and various industrial kilns in industries such as metallurgy, building materials, chemical industry, electric power, machinery and the like can discharge a large amount of high-temperature dust-containing harmful gas in the modern industrial production process, so that the environment is seriously polluted, and the ceramic fiber pipe with good high temperature resistance can be more suitable for the requirements of the industrial production. The structure of ceramic fiber tubes generally comprises: the tubular body, one end of tubular body is sealed, and the other end is open for giving vent to anger and admitting air. The forming process of the ceramic fiber pipe comprises the steps of firstly preparing ceramic fiber slurry, then pouring the ceramic fiber slurry into a die, vacuumizing the die to suck out liquid in the ceramic fiber slurry, attaching the rest substances on the inner wall of a grinding tool to form a wet pipe blank, taking the wet pipe blank out of the die, and then performing a drying process to harden and form the wet pipe blank.
Along with the wide application of ceramic fiber filter tubes in desulfurization, denitrification and dedusting waste gas treatment projects, the ceramic fiber filter tubes have the advantages of obtaining good environmental benefits and simultaneously meeting new problems: the ceramic fiber filter tube is limited by the constraint of the existing ceramic fiber filter tube manufacturing raw materials (ceramic fiber slurry) and manufacturing equipment, the length of the ceramic fiber filter tube is only 3m at present, the product specification is single, but the occupied area of a ceramic fiber filter tube bin needs to be further reduced due to the limited sites of more items, so that the length of the ceramic fiber filter tube needs to be further lengthened.
However, the existing ceramic fiber slurry is insufficient to meet the strength requirement of the ceramic fiber filter tube with the length of more than 3 m; meanwhile, when the wet pipe blank is taken out from the die, the length and the size of the wet pipe blank and the die are increased, so that a plurality of persons are often required to cooperatively work to draw out the die, the labor force is wasted, and the production efficiency is affected. The traditional Chinese patent application number 201510757555.5, named ceramic fiber tube suction filtration forming device, when the suction filtration system completes the suction filtration process, the end cover is automatically opened, the claw moves to the end opening of the roller and clamps the tubular mold, then the claw moves backwards to draw out the tubular mold, the whole production process does not need manual operation, the labor force is saved, and the production efficiency is improved. However, the jaws clamp the tubular mould and draw it out horizontally, which results in a whole device with a length dimension at least twice that of the tubular mould, a large footprint and a high production field requirement.
Disclosure of Invention
The invention provides a production process of a ceramic fiber lengthened filter tube, which aims to solve the technical problem that the fiber slurry in the prior art is insufficient to meet the strength requirement of the ceramic fiber filter tube with the size of more than 3 m. Meanwhile, the invention also provides production equipment of the ceramic fiber lengthened filter tube, so as to solve the technical problems of large occupied area and high requirements on production sites of the production equipment in the prior art.
In order to solve the problems, the production process of the ceramic fiber lengthened filter tube provided by the first aspect of the invention adopts the following technical scheme:
a production process of a ceramic fiber lengthened filter tube comprises the following steps:
s1, putting ceramic fibers and water into a beating machine, starting up and stirring, and carrying out mixed beating treatment to obtain a fiber base material;
the mass ratio of the ceramic fiber to the water is 1.2-2.7:100;
the ceramic fiber comprises a spinning fiber and a spinning fiber, wherein the mass ratio of the spinning fiber to the spinning fiber is 1:1.1-1.3;
s2, pumping the fiber base material obtained in the step S1 into a material mixing tank, starting a stirring device of the material mixing tank, setting the stirring speed to be 70-90rpm, slowly adding a sodium hydroxide tablet, detecting the pH in real time, and stirring until the pH value is 7.4-7.8;
S3, sequentially adding liquid aluminum sulfate and bone glue into a material mixing tank, then adjusting the stirring speed to 140-200rpm, and continuously stirring for 18-35min to obtain fiber slurry;
the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2-5.8:100;
the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5-2.5:100;
s4, pumping the fiber slurry obtained in the S3 into an elongated die mechanism of production equipment, discharging liquid in the fiber slurry through a discharge pipe of the elongated die mechanism, and forming the rest materials into an elongated wet pipe blank in the elongated die mechanism;
s5, drying the lengthened wet tube blank obtained in the step S4 to obtain the ceramic fiber lengthened filter tube.
As a further improvement, in S1, the length of the yarn throwing fiber is 180-250mm, and the diameter of the yarn throwing fiber is 3.0-5.0 mu m;
the length of the spinning fiber is 100-180mm, and the diameter of the spinning fiber is 2.0-3.0 mu m.
As a further improvement, in S1, firstly, ceramic fibers are put into a beating machine, then water is poured into the beating machine, stirring is carried out in two stages, the stirring speed in the first stage is 100-120rpm, and the stirring time is 15-20min;
The stirring speed in the second stage is 150-220rpm, and the stirring time is 10-15min.
In S2, the pH value of the fiber base material in the batching tank is detected, the dosage of the sodium hydroxide tablet is converted according to the mass of the fiber base material in the batching tank, and then the sodium hydroxide tablet is slowly added into the batching tank.
As a further improvement, in S5, the drying process includes three stages:
the first stage is a heating drying stage, the heating rate is 40-60 ℃/h, and the temperature is raised to 115-125 ℃;
the second stage is a constant temperature drying stage, the constant temperature is kept between 115 and 130 ℃, and the drying time is 8 to 10 hours;
the third stage is a cooling and drying stage, the cooling rate is 30-50 ℃/h, and the temperature is reduced to 20-25 ℃.
The production equipment of the ceramic fiber lengthened filter tube provided by the second aspect of the invention adopts the following technical scheme:
the utility model provides a production facility of ceramic fiber extension type filter tube, includes the frame, install diaphragm pump mechanism, post mechanism, mould device and slide rail mechanism in the frame, diaphragm pump mechanism is connected with post mechanism and is used for pumping into mould device with the fibre thick liquids in, mould device and slide rail mechanism sliding connection, and the liquid in the fibre thick liquids discharges mould device, and remaining material forms into wet pipe in mould device, still includes the elevating gear with slide rail mechanism sliding connection, mould device includes lower mould mechanism and is located the last mould mechanism of lower mould mechanism top, last mould mechanism is connected with elevating gear, elevating gear is used for driving the mould mechanism and removes along vertical direction to make mould mechanism and lower mould mechanism fold or separate, when last mould mechanism and lower mould mechanism are in the state of folding, in the fibre thick liquids flow into the cavity between mould mechanism and the lower mould mechanism, and then the shaping obtains wet pipe, when last mould mechanism and lower mould mechanism are in the state of separating, directly take out wet pipe from the lower mould mechanism.
As a further improvement, a locking component is detachably arranged between the upper die mechanism and the lower die mechanism, so that the upper die mechanism and the lower die mechanism are firmly connected when in a closed state.
As a further improvement, the upper die mechanism comprises an upper half cylinder die, the lower die mechanism comprises a lower half cylinder die, the folding state of the upper half cylinder die and the lower half cylinder die is tubular, at least two upper convex rings are uniformly and fixedly sleeved on the outer side wall of the upper half cylinder die, two upper epitaxial plates are uniformly and fixedly connected to the two ends of the upper convex rings, at least two lower convex rings are uniformly and fixedly sleeved on the outer side wall of the lower half cylinder die, the lower convex rings correspond to the upper convex rings, two ends of the lower convex rings are fixedly connected with the lower epitaxial plates, when the upper half cylinder die and the lower half cylinder die are in the folding state, the upper epitaxial plates are in butt joint with the lower epitaxial plates, and the locking assembly is detachably assembled between the upper epitaxial plates and the lower epitaxial plates.
As a further improvement, the locking assembly comprises a hanging ring, a tightening bolt and a locking device, wherein one end of the hanging ring is hinged with the lower extension plate and is movably sleeved on the upper extension plate, and the tightening bolt is in threaded connection with the other end of the hanging ring and is used for tightening the upper extension plate.
As a further improvement, the hanging ring is fixedly connected with a threaded cylinder, the jacking bolt is sleeved in the threaded cylinder in a threaded mode, one end, far away from the upper extension plate, of the jacking bolt is fixedly connected with the rotating plate, the jacking bolt can be driven to rotate through rotating the rotating plate, and the edge of the rotating plate is smooth and radian.
The beneficial effects are that:
in the production process, ceramic fibers and water are mixed and pulped to prepare the fiber base material, wherein the ceramic fibers comprise spinning fibers and spinning fibers, the spinning fibers are superior to the spinning fibers in tensile breaking strength because of thicker fibers, the prepared product is not easy to damage and is more durable, and the spinning fibers are relatively easier to break and tear; in the aspect of fine compactness, the spinning fiber is superior to the spinning fiber because of finer and shorter fiber, and the volume density of the manufactured product is higher, and the filtering performance is better; the spinning fiber and the spinning fiber are proportioned according to the mass ratio of 1:1.1-1.3, and the prepared product has balanced and excellent filtration performance and tensile breaking strength performance;
in the production process, the ceramic fibers are firstly put into the beating machine, and then water is injected into the beating machine, so that the water can be ensured to quickly submerge the ceramic fibers in the beating machine, and the subsequent stirring and beating efficiency is ensured to be higher; stirring is carried out in two stages, wherein the stirring speed in the first stage is 100-120rpm, the stirring time is 15-20min, the stirring speed in the second stage is 150-220rpm, the stirring time is 10-15min, the stirring is carried out at a low speed of 100-120rpm, and the ceramic fibers are prevented from being damaged by transition caused by excessive tearing force of water on the ceramic fibers due to sudden high speed before the ceramic fibers are approximately uniformly dispersed in the water, so that the product performance is influenced; the stirring speed is properly increased to 150-220rpm, the mixing and beating efficiency of water and ceramic fibers is accelerated, the stirring speed in the whole mixing and beating process is not more than 220rpm, the mixing and beating efficiency is ensured, the ceramic fibers are not excessively damaged, and the filtering performance and tensile and flexural strength performance of the product are further ensured to be balanced and excellent;
In the production process, the liquid aluminum sulfate is added into the fiber slurry, so that the precipitation stability of the dispersed particles in the water can be reduced or eliminated, the fine and loose combination body can be produced quickly, the wet pipe blank can be molded quickly, and the fine compactness of the product can be improved; the addition of the bone glue can utilize the strong adsorption and bridging effects of the bone glue, so that the fine and loose combination body becomes thick and dense, and the tensile and bending resistance of the product is improved; sodium hydroxide is used as a pH environment conditioner to adjust the pH value of the liquid environment to 7.4-7.8, which is more beneficial to the action of liquid aluminum sulfate;
in the production process, when the lengthened wet pipe blank is subjected to drying treatment, the drying treatment comprises three stages: the first stage is a heating drying stage, the heating rate is 40-60 ℃/h, and the temperature is raised to 115-125 ℃; the second stage is a constant temperature drying stage, the constant temperature is kept between 115 and 130 ℃, and the drying time is 8 to 10 hours; the third stage is a cooling and drying stage, wherein the cooling rate is 30-50 ℃/h, and the temperature is reduced to 20-25 ℃; the method comprises the steps of firstly, slowly heating up and drying, then continuously keeping constant temperature and finally slowly cooling and drying until the drying temperature is reduced to be close to the room temperature, stopping the drying treatment, and effectively avoiding secondary cracking of the wet tube blank in the drying treatment process, and guaranteeing the yield of the ceramic fiber lengthened filter tube of the final product;
The production equipment comprises a lifting device which is in sliding connection with a slide rail mechanism, wherein the die device comprises a lower die mechanism and an upper die mechanism positioned above the lower die mechanism, the upper die mechanism is connected with the lifting device, and the lifting device is used for driving the upper die mechanism to move along the vertical direction so as to fold or separate the upper die mechanism from the lower die mechanism; the wet pipe blank with the length of more than 3m can be formed only by the mold device with the length of more than 3m, and then the ceramic fiber lengthening filter pipe with the length of more than 3m is obtained; the lifting device can drive the upper die mechanism to move upwards along the vertical direction, so that the upper die mechanism is separated from the lower die mechanism, the wet pipe blank is exposed, the wet pipe blank is conveniently taken out, the wet pipe blank is not required to be horizontally pulled out from one end, and the equipment occupation length requirement is reduced;
the production equipment also comprises a locking component which is detachably arranged, so that the upper die mechanism and the lower die mechanism are firmly connected when in a closed state; the locking assembly comprises a hanging ring, a tightening bolt and a tightening bolt, wherein one end of the hanging ring is hinged with the lower extension plate and is movably sleeved on the upper extension plate, the tightening bolt is in threaded connection with the other end of the hanging ring and is used for tightening the upper extension plate, when the upper die mechanism and the lower die mechanism are folded, the hanging ring is sleeved on the upper extension plate only by rotating the hanging ring, and then the tightening bolt is screwed, so that the bottom end of the tightening bolt is tightly propped against the top of the upper extension plate, the effect of firm connection between the upper die mechanism and the lower die mechanism can be achieved, and the locking assembly is convenient and fast to operate and reliable to fasten.
Drawings
The above, as well as additional purposes, features, and advantages of exemplary embodiments of the present invention will become readily apparent from the following detailed description when read in conjunction with the accompanying drawings. In the drawings, embodiments of the invention are illustrated by way of example and not by way of limitation, and like reference numerals refer to similar or corresponding parts and in which:
FIG. 1 is a schematic diagram of an embodiment of a production facility for a ceramic fiber lengthened filter tube according to the present invention;
FIG. 2 is a top view of FIG. 1;
FIG. 3 is a schematic view of the mold apparatus of FIG. 1;
FIG. 4 is a right side view of FIG. 3;
FIG. 5 is a top view of FIG. 3;
fig. 6 is a perspective view of the die apparatus of fig. 1.
Reference numerals illustrate:
1. a diaphragm pump mechanism;
2. a motor rotation mechanism;
3. a lower die mechanism; 31. a lower half cylinder mold; 32. a lower convex ring; 33. a lower epitaxial plate; 34. a pin shaft; 35. hanging rings; 36. a thread cylinder; 37. a jack bolt; 38. a rotating plate;
4. a first lifting mechanism;
5. a second lifting mechanism;
6. an upper die mechanism; 61. an upper half cylinder mold; 62. an upper convex ring; 63. an upper epitaxial plate;
7. a frame; 8. a slide rail mechanism; 9. a drag chain; 10. an electric control box.
Detailed Description
The following description of the embodiments of the present invention will be made more complete and clear to those skilled in the art by reference to the figures of the embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The ceramic fiber filter tube is limited by the constraint of the existing ceramic fiber filter tube manufacturing raw materials (ceramic fiber slurry) and manufacturing equipment, the length of the ceramic fiber filter tube is only 3m at present, the product specification is single, but the occupied area of a ceramic fiber filter tube bin needs to be further reduced due to the limited sites of more items, so that the length of the ceramic fiber filter tube needs to be further lengthened. However, the existing ceramic fiber slurry is insufficient to meet the strength requirement of the ceramic fiber filter tube with the length of more than 3m, so that a production process of the ceramic fiber lengthened filter tube is needed to enable the fiber slurry to meet the strength requirement of the ceramic fiber filter tube with the length of more than 3m, so that the prepared ceramic fiber lengthened filter tube has excellent tensile and flexural strength and can meet the use requirement.
The production process of the ceramic fiber lengthened filter tube comprises the following steps:
s1, firstly, putting ceramic fibers into a beating machine, then, injecting water into the beating machine, and then, starting up and stirring to perform mixed beating. Stirring is carried out in two stages, wherein the stirring speed in the first stage is 100-120rpm, and the stirring time is 15-20min; the stirring speed in the second stage is 150-220rpm, and the stirring time is 10-15min; and (5) after the stirring is finished, obtaining the fiber base material.
Wherein the mass ratio of the ceramic fiber to the water is 1.2-2.7:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.1-1.3; the length of the spun fiber is 180-250mm, and the diameter of the spun fiber is 3.0-5.0 mu m; the length of the spinning fiber is 100-180mm, and the diameter of the spinning fiber is 2.0-3.0 mu m.
S2, pumping the fiber base material obtained in the step S1 into a material mixing tank, starting a stirring device of the material mixing tank, setting the stirring speed to be 70-90rpm, detecting the pH value of the fiber base material in the material mixing tank, converting the dosage of sodium hydroxide tablets according to the mass of the fiber base material in the material mixing tank, slowly adding the sodium hydroxide tablets into the material mixing tank, detecting the pH in real time, and stirring until the pH value is 7.4-7.8.
S3, sequentially adding liquid aluminum sulfate and bone glue into the material mixing tank, then adjusting the stirring speed to 140-200rpm, and continuously stirring for 18-35min to obtain the fiber slurry.
Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2-5.8:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5-2.5:100.
S4, pumping the fiber slurry obtained in the step S3 into a lengthened die mechanism of production equipment, discharging liquid in the fiber slurry through a discharge pipe of the lengthened die mechanism, and forming the rest materials into a lengthened wet pipe blank in the lengthened die mechanism.
S5, drying the lengthened wet pipe blank obtained in the step S4, wherein the drying process comprises three stages: the first stage is a heating drying stage, the heating rate is 40-60 ℃/h, and the temperature is raised to 115-125 ℃; the second stage is a constant temperature drying stage, the constant temperature is kept between 115 and 130 ℃, and the drying time is 8 to 10 hours; the third stage is a cooling and drying stage, wherein the cooling rate is 30-50 ℃/h, and the temperature is reduced to 20-25 ℃; thus obtaining the ceramic fiber lengthened filter tube.
Having described the basic principles of the present invention, various non-limiting embodiments of the invention are described in detail below. Any number of elements in the figures are for illustration and not limitation, and any naming is used for distinction only and not for any limiting sense.
The principles and spirit of the present invention are explained in detail below with reference to several representative embodiments thereof.
Example 1
A production process of a ceramic fiber lengthened filter tube comprises the following steps:
s1, firstly, putting ceramic fibers into a beating machine, then, injecting water into the beating machine, and then, starting up and stirring to perform mixed beating. Stirring is carried out in two stages, wherein the stirring speed in the first stage is 100rpm, and the stirring time is 15min; the stirring speed in the second stage is 150rpm, and the stirring time is 10min; and (5) after the stirring is finished, obtaining the fiber base material.
Wherein the mass ratio of the ceramic fiber to the water is 1.2:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.1; the length of the spun fiber is 180-250mm, and the diameter of the spun fiber is 3.0-5.0 mu m; the length of the spinning fiber is 100-180mm, and the diameter of the spinning fiber is 2.0-3.0 mu m.
S2, pumping the fiber base material obtained in the step S1 into a material mixing tank, starting a stirring device of the material mixing tank, setting the stirring speed to be 70rpm, detecting the pH value of the fiber base material in the material mixing tank, converting the dosage of sodium hydroxide tablets according to the mass of the fiber base material in the material mixing tank, slowly adding the sodium hydroxide tablets into the material mixing tank, detecting the pH in real time, and stirring until the pH value is 7.4-7.8.
And S3, sequentially adding liquid aluminum sulfate and bone glue into the material mixing tank, then adjusting the stirring speed to 140rpm, and continuously stirring for 18min to obtain the fiber slurry.
Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
S4, pumping the fiber slurry obtained in the step S3 into a lengthened die mechanism of production equipment, discharging liquid in the fiber slurry through a discharge pipe of the lengthened die mechanism, and forming the rest materials into a lengthened wet pipe blank in the lengthened die mechanism.
S5, drying the lengthened wet pipe blank obtained in the step S4, wherein the drying process comprises three stages: the first stage is a heating drying stage, the heating rate is 40-60 ℃/h, and the temperature is raised to 120 ℃; the second stage is a constant temperature drying stage, the constant temperature is kept between 115 and 130 ℃, and the drying time is 9 hours; the third stage is a cooling and drying stage, wherein the cooling rate is 30-50 ℃/h, and the temperature is reduced to 24 ℃; thus obtaining the ceramic fiber lengthened filter tube.
The production equipment used in the step S3 can be directly a ceramic fiber pipe suction filtration forming device disclosed in China patent application No. 201510757555.5, and the fiber slurry prepared in the production process can be used for producing a lengthened wet pipe blank only by increasing the length of a forming die to be more than 3m, so that a ceramic fiber lengthened filter pipe is produced.
The production equipment used in the step S3 can also be used for producing the ceramic fiber lengthening type filter tube.
As shown in fig. 1 and 2, the production equipment of the ceramic fiber lengthened filter tube comprises a frame 7, wherein a diaphragm pump mechanism 1, a pole mechanism 11, a die device and a sliding rail mechanism 8 are arranged on the frame 7. The diaphragm pump mechanism 1 includes a diaphragm pump, which is an existing commercial device, and a person skilled in the art can select a brand and a model according to actual needs, which will not be further described herein. The inlet end of the diaphragm pump is connected with a liquid inlet pipe for entering fiber slurry.
The diaphragm pump mechanism 1 is connected with the pole mechanism 11 and is used for pumping the fiber slurry into a die device, the die device is in sliding connection with the slide rail mechanism 8, liquid in the fiber slurry is discharged out of the die device, and the rest material is formed into a wet pipe blank in the die device. The die device comprises a lower die mechanism 3 and an upper die mechanism 6 positioned above the lower die mechanism 3, wherein the upper die mechanism 6 is connected with the lifting device, and the lifting device is used for driving the upper die mechanism 6 to move along the vertical direction so as to enable the upper die mechanism 6 to be folded or separated from the lower die mechanism 3.
When the upper die mechanism 6 and the lower die mechanism 3 are in the closed state, the fiber slurry flows into the cavity between the upper die mechanism 6 and the lower die mechanism 3, and the wet pipe blank is formed. When the upper die mechanism 6 and the lower die mechanism 3 are in the separated state, the wet pipe blank is directly taken out from the lower die mechanism 3. The wet pipe blank with the length of more than 3m can be formed only by the mold device with the length of more than 3m, and then the ceramic fiber lengthening filter pipe with the length of more than 3m is obtained; the lifting device can drive the upper die mechanism 6 to move upwards along the vertical direction, so that the upper die mechanism 6 is separated from the lower die mechanism 3, the wet pipe blank is exposed, the wet pipe blank is conveniently taken out, the wet pipe blank is not required to be horizontally pulled out from one end, and the equipment occupation length requirement is reduced.
As shown in fig. 3-4, a locking assembly is detachably mounted between the upper die mechanism and the lower die mechanism, so that the upper die mechanism and the lower die mechanism are firmly connected when in a closed state. The upper die mechanism comprises an upper half cylinder die 61, the lower die mechanism comprises a lower half cylinder die 31, the upper half cylinder die 61 and the lower half cylinder die 31 are in a tubular shape, two upper convex rings 62 are uniformly sleeved and welded on the outer side wall of the upper half cylinder die 61, two upper epitaxial plates 63 are uniformly sleeved and welded on the outer side wall of the lower half cylinder die 31, two lower convex rings 32 respectively correspond to the two upper convex rings 62, two lower epitaxial plates 33 are uniformly welded on the two ends of the lower convex rings 32, when the upper half cylinder die 61 and the lower half cylinder die 31 are in a closed state, the upper epitaxial plates 63 are in butt joint with the lower epitaxial plates 33, and the locking assembly is detachably arranged between the upper epitaxial plates 63 and the lower epitaxial plates 33.
As shown in fig. 5 to 6, the locking assembly includes a hanging ring 35 having one end opened and hinged to the lower extension plate 33 through a pin 34 and capable of being movably sleeved on the upper extension plate 63, and a tightening bolt 37 screwed to the other end closed end of the hanging ring 35 and used for tightening the upper extension plate 63. The hanging ring 35 is penetrated and welded with the threaded cylinder 36, the jacking bolt 37 is sleeved in the threaded cylinder 36 in a threaded manner, the threaded cylinder 36 plays a role in stabilizing and guiding the jacking bolt 37, and the situation that the jacking bolt 37 deflects and cannot jack the upper extension plate 63 is avoided. The rotating plate 38 is welded at one end of the jacking bolt 37 far away from the upper extension plate 63, and the jacking bolt 37 can be driven to rotate by manually rotating the rotating plate 38, so that the use is more convenient. The edge of the rotating plate 38 is smooth and radian, so that the user can be prevented from being scratched accidentally due to sharp edges and corners, and the safety is better. When the upper die mechanism and the lower die mechanism are folded, the hanging ring 35 is sleeved on the upper extension plate 63 only by rotating the hanging ring 35, then the jacking bolt 37 is screwed, the bottom end of the jacking bolt 37 is jacked on the top of the upper extension plate 63, the effect of firm connection of the upper die mechanism and the lower die mechanism can be achieved, the operation is convenient, and the fastening is reliable.
More specifically, the mast mechanism 11 includes a motor rotation mechanism 2, and the motor rotation mechanism 2 includes a motor and a speed reducer, and is also connected with a connection pipe and a rotary joint. Stainless steel filter screens and liquid discharge pipes are also arranged in the upper die mechanism 6 and the lower die mechanism 3, a multi-position double-stroke cylinder is also arranged in the lower die mechanism 3, and a thimble device is connected to the cylinder shaft. The first lifting mechanism 4 and the second lifting mechanism 5 all comprise a guide rail slide block, a lifting screw rod, a motor, a speed reducer and a universal coupling, which are of the prior art and are not described again. The slide rail mechanism 8 comprises a guide rail, a slide block and a driving assembly, the driving assembly comprises a gear motor, a stainless steel gear and a rack, the slide rail mechanism 8 is fixed on the frame 7, the electric appliance control components are installed in the electric cabinet 10, and the cable is placed in the drag chain 9.
The diaphragm pump mechanism 1 conveys the fiber slurry into a cavity between the upper die mechanism 6 and the lower die mechanism 3 in a closed state through the rotary post rod mechanism 11, the fiber slurry is continuously accumulated in the die device, and when the fiber slurry is accumulated to a certain degree, the multi-position double-stroke cylinder at the first position acts to the second position to drive the thimble device to be separated from the post rod mechanism 11; the liquid in the slurry is discharged through a discharge pipe, and the remaining material is formed into a wet pipe blank in a die apparatus.
After the wet pipe blank is formed, the diaphragm pump stops working, the post rod mechanism 11 continues to rotate, and the multi-position double-stroke cylinder at the second position acts to the third position to drive the thimble device to separate from the stainless steel filter screen. The upper die mechanism 6 and the lower die mechanism 3 in the closed state slide on the slide rail mechanism 8, gradually separate from the rotating post rod mechanism 11, and after the separation is completed, the post rod mechanism 11 stops rotating, meanwhile, the upper die mechanism 6 and the lower die mechanism 3 in the closed state stop sliding, then the first lifting mechanism 4 and the second lifting mechanism 5 act to drive the upper die mechanism 6 to lift, the formed wet pipe blank is separated, a stainless steel filter screen and the wet pipe blank are taken out from the lower die mechanism 3 to a workbench by a tool, the stainless steel filter screen and the wet pipe blank are separated, the wet pipe blank is placed in a curing furnace to enter a next heating and drying process, and the stainless steel filter screen is placed back into the lower die mechanism 3.
Then the gear motor in the slide rail mechanism 8 is reversed to drive the upper die mechanism 6 and the lower die mechanism 3 to reversely slide on the slide rail mechanism 8, and the slide is stopped after the slide is in place, at the moment, the post rod mechanism 11 is completely entered into the cavity of the lower die mechanism 3, and meanwhile, the multi-position double-stroke cylinder at the third position acts to the first position to drive the thimble device to prop against the post rod mechanism 11. Then the first lifting mechanism 4 and the second lifting mechanism 5 drive the upper die mechanism 6 to descend, the upper die mechanism 6 and the lower die mechanism 3 are folded and reinforced by the locking component, the diaphragm pump mechanism 1 conveys the fiber slurry into a cavity between the upper die mechanism 6 and the lower die mechanism 3 in a folded state through the rotating post rod mechanism 11, and the steps are repeated.
It is to be understood that the use of the terms "first" or "second" and the like in this specification is for descriptive purposes only and is not to be construed as an explicit or implicit indication of relative importance or number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In the description of the present specification, the meaning of "plurality" means at least two, for example, two, three or more, etc., unless explicitly defined otherwise.
Those skilled in the art will also appreciate from the foregoing description that terms such as "upper," "lower," "front," "rear," "left," "right," "length," "width," "thickness," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," "circumferential," "center," "longitudinal," "transverse," "clockwise," or "counterclockwise" and the like are used herein for the purpose of facilitating description and simplifying the description of the present invention only, and do not necessarily require that the particular orientation, configuration and operation be construed or implied by the terms of orientation or positional relationship shown in the drawings of the present specification, and therefore the terms of orientation or positional relationship described above should not be interpreted or construed as limiting the scope of the present invention.
Example 2
The differences from example 1 are mainly that: in S1, in the mixing and pulping process, the stirring speed and the stirring time of the two stages are different.
In embodiment 1, S1, ceramic fibers are put into a beater, water is injected into the beater, and then the beater is started up and stirred to perform mixed beating. Stirring is carried out in two stages, wherein the stirring speed in the first stage is 100rpm, and the stirring time is 15min; the stirring speed in the second stage is 150rpm, and the stirring time is 10min; and (5) after the stirring is finished, obtaining the fiber base material.
In this embodiment, S1, ceramic fibers are put into a beater, water is injected into the beater, and then the beater is started up and stirred to perform mixed beating. Stirring is carried out in two stages, wherein the stirring speed in the first stage is 110rpm, and the stirring time is 18min; the stirring speed in the second stage is 190rpm, and the stirring time is 12min; and (5) after the stirring is finished, obtaining the fiber base material.
Example 3
The differences from example 1 are mainly that: in S1, in the mixing and pulping process, the stirring speed and the stirring time of the two stages are different.
In embodiment 1, S1, ceramic fibers are put into a beater, water is injected into the beater, and then the beater is started up and stirred to perform mixed beating. Stirring is carried out in two stages, wherein the stirring speed in the first stage is 100rpm, and the stirring time is 15min; the stirring speed in the second stage is 150rpm, and the stirring time is 10min; and (5) after the stirring is finished, obtaining the fiber base material.
In this embodiment, S1, ceramic fibers are put into a beater, water is injected into the beater, and then the beater is started up and stirred to perform mixed beating. Stirring is carried out in two stages, wherein the stirring speed in the first stage is 120rpm, and the stirring time is 20min; the stirring speed in the second stage is 220rpm, and the stirring time is 15min; and (5) after the stirring is finished, obtaining the fiber base material.
Example 4
The differences from example 1 are mainly that: in S1, the mass ratio of the spinning fiber to the spinning fiber is different.
In the embodiment 1, the mass ratio of S1 to ceramic fiber to water is 1.2:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.1.
In the embodiment, the mass ratio of the S1 to the ceramic fiber to the water is 1.2:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.2.
Example 5
The differences from example 1 are mainly that: in S1, the mass ratio of the spinning fiber to the spinning fiber is different.
In the embodiment 1, the mass ratio of S1 to ceramic fiber to water is 1.2:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.1.
In the embodiment, the mass ratio of the S1 to the ceramic fiber to the water is 1.2:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.3.
Example 6
The differences from example 1 are mainly that: in S3, the mass ratio of the liquid aluminum sulfate to the ceramic fibers fed into the beater in S1 is different.
In example 1, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
In the embodiment, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain the fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 4.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
Example 7
The differences from example 1 are mainly that: in S3, the mass ratio of the liquid aluminum sulfate to the ceramic fibers fed into the beater in S1 is different.
In example 1, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
In the embodiment, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain the fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 5.8:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
Example 8
The differences from example 1 are mainly that: in S3, the mass ratio of the bone glue to the ceramic fiber put into the beater in S1 is different.
In example 1, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
In the embodiment, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain the fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 2:100.
Example 9
The differences from example 1 are mainly that: in S3, the mass ratio of the bone glue to the ceramic fiber put into the beater in S1 is different.
In example 1, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
In the embodiment, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain the fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 2.5:100.
Comparative example 1
The differences from example 1 are mainly that: in S1, in the mixing and beating process, the stirring speeds of the two stages are different.
In embodiment 1, S1, ceramic fibers are put into a beater, water is injected into the beater, and then the beater is started up and stirred to perform mixed beating. Stirring is carried out in two stages, wherein the stirring speed in the first stage is 100rpm, and the stirring time is 15min; the stirring speed in the second stage is 150rpm, and the stirring time is 10min; and (5) after the stirring is finished, obtaining the fiber base material.
In this embodiment, S1, ceramic fibers are put into a beater, water is injected into the beater, and then the beater is started up and stirred to perform mixed beating. Stirring is carried out in two stages, wherein the stirring speed in the first stage is 120rpm, and the stirring time is 15min; the stirring speed in the second stage is 250rpm, and the stirring time is 100min; and (5) after the stirring is finished, obtaining the fiber base material.
Comparative example 2
The differences from example 1 are mainly that: in S1, the mass ratio of the spinning fiber to the spinning fiber is different.
In the embodiment 1, the mass ratio of S1 to ceramic fiber to water is 1.2:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.1.
In the embodiment, the mass ratio of the S1 to the ceramic fiber to the water is 1.2:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.4.
Comparative example 3
The differences from example 1 are mainly that: in S1, the mass ratio of the spinning fiber to the spinning fiber is different.
In the embodiment 1, the mass ratio of S1 to ceramic fiber to water is 1.2:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.1.
In the embodiment, the mass ratio of the S1 to the ceramic fiber to the water is 1.2:100; the ceramic fiber comprises a spinning fiber and a spinning fiber, and the mass ratio of the spinning fiber to the spinning fiber is 1:1.
Comparative example 4
The differences from example 1 are mainly that: in S2, the amount of sodium hydroxide tablets varies.
In the embodiment 1, S2, pumping the fiber base material obtained in S1 into a material mixing tank, starting a stirring device of the material mixing tank, setting the stirring speed to be 70rpm, detecting the pH value of the fiber base material in the material mixing tank, converting the dosage of sodium hydroxide tablets according to the mass of the fiber base material in the material mixing tank, slowly adding the sodium hydroxide tablets into the material mixing tank, detecting the pH in real time, and stirring until the pH value is 7.4-7.8.
In this embodiment, S2, the fiber base material obtained in S1 is pumped into a formulation tank, a stirring device of the formulation tank is started, the stirring speed is set to be 70rpm, the pH value of the fiber base material in the formulation tank is detected, the pH value is detected to be 7.05, the fiber base material is neutral, and no sodium hydroxide tablet is added.
Comparative example 5
The differences from example 1 are mainly that: in S2, the amount of sodium hydroxide tablets varies.
In the embodiment 1, S2, pumping the fiber base material obtained in S1 into a material mixing tank, starting a stirring device of the material mixing tank, setting the stirring speed to be 70rpm, detecting the pH value of the fiber base material in the material mixing tank, converting the dosage of sodium hydroxide tablets according to the mass of the fiber base material in the material mixing tank, slowly adding the sodium hydroxide tablets into the material mixing tank, detecting the pH in real time, and stirring until the pH value is 7.4-7.8.
In this embodiment, S2, pumping the fiber base material obtained in S1 into a batch tank, starting a stirring device of the batch tank, setting a stirring speed to 70rpm, detecting the pH value of the fiber base material in the batch tank, converting the dosage of sodium hydroxide tablets according to the mass of the fiber base material in the batch tank, slowly adding the sodium hydroxide tablets into the batch tank, detecting the pH in real time, and stirring until the pH value is 8.0.
Comparative example 6
The differences from example 1 are mainly that: in S3, the mass ratio of the liquid aluminum sulfate to the ceramic fibers fed into the beater in S1 is different.
In example 1, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
In the embodiment, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain the fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 2.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
Comparative example 7
The differences from example 1 are mainly that: in S3, the mass ratio of the liquid aluminum sulfate to the ceramic fibers fed into the beater in S1 is different.
In example 1, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
In the embodiment, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain the fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 6.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
Comparative example 8
The differences from example 1 are mainly that: in S3, the mass ratio of the bone glue to the ceramic fiber put into the beater in S1 is different.
In example 1, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
In the embodiment, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain the fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1:100.
Comparative example 9
The differences from example 1 are mainly that: in S3, the mass ratio of the bone glue to the ceramic fiber put into the beater in S1 is different.
In example 1, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5:100.
In the embodiment, S3, liquid aluminum sulfate and bone glue are sequentially added into a material mixing tank, and then the stirring speed is adjusted to 140rpm, and the stirring is continued for 18min, so as to obtain the fiber slurry. Wherein the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2:100; the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 3:100.
Comparative example 10
The differences from example 1 are mainly that: in S5, the drying conditions are different.
In example 1, the elongated wet pipe blank obtained in S5 is subjected to a drying process comprising three stages: the first stage is a heating drying stage, the heating rate is 40-60 ℃/h, and the temperature is raised to 120 ℃; the second stage is a constant temperature drying stage, the constant temperature is kept between 115 and 130 ℃, and the drying time is 9 hours; the third stage is a cooling and drying stage, wherein the cooling rate is 30-50 ℃/h, and the temperature is reduced to 24 ℃; thus obtaining the ceramic fiber lengthened filter tube.
In this embodiment, S5, the elongated wet pipe blank obtained in S4 is subjected to a drying process, and the drying process includes three stages: the first stage is a rapid heating and drying stage, the heating rate is 100-120 ℃/h, and the temperature is raised to 120 ℃; the second stage is a constant temperature drying stage, the constant temperature is kept between 115 and 130 ℃, and the drying time is 9 hours; the third stage is a rapid cooling and drying stage, the cooling rate is 60-80 ℃/h, and the temperature is reduced to 24 ℃; thus obtaining the ceramic fiber lengthened filter tube.
Comparative example 11
Ceramic fiber filter tubes with a length of less than 3m are commercially available.
Test example 1
Test object: examples 1 to 5, comparative examples 1 to 3 and comparative example 11;
test item: 1. bulk density-filtration performance; 2. tensile and bending resistance;
the test is based on: 1. testing the volume density of the ceramic fiber lengthened filter tube by referring to a GB/T17911-2018 method; 2. tensile properties-interlaminar bond strength TAPPI-UM403; anti-fracture performance-fold-look at fracture;
test results: see table 1.
| Bulk Density (kg/m) 3 ) | Folding cracking condition | Interlayer bond Strength (J/m) 2 ) | |
| Example 1 | 195 | No cracking and no surface cracking | 86 |
| Example 2 | 192 | No cracking and no surface cracking | 84 |
| Example 3 | 194 | No cracking and no surface cracking | 83 |
| Example 4 | 194 | No cracking and no surface cracking | 85 |
| Example 5 | 196 | No cracking and no surface cracking | 86 |
| Comparative example 1 | 188 | Surface cracking | 75 |
| Comparative example 2 | 193 | Surface cracking | 77 |
| Comparative example 3 | 176 | Does not crack | 84 |
| Comparative example 11 | 190 | No cracking and no surface cracking | 82 |
Table 1.
Conclusion: as can be seen from Table 1, the ceramic fiber lengthened filter tube prepared by the invention has excellent filtering performance and tensile and fracture resistance, and is not lower than the performance of the existing ceramic fiber filter tube with the commercial length of less than 3 m;
the stirring speed of the comparative example 1 reaches 250rpm, so that the ceramic fiber is excessively destroyed, and the tensile and fracture resistance are obviously reduced;
the mass ratio of the spinning fiber to the spinning fiber in comparative example 2 is 1:1.4, and compared with the mass ratio of the spinning fiber to the spinning fiber in the range of 1:1.1-1.3, the spinning fiber occupies too small amount, so that the tensile and fracture resistance of the product is obviously reduced;
the mass ratio of the spinning fiber to the spinning fiber in comparative example 3 is 1:1, and compared with the mass ratio of the spinning fiber to the spinning fiber in the range of 1:1.1-1.3, the spinning fiber has an excessively small proportion, so that the bulk density (filtering performance) of the product is obviously reduced.
Test example 2
Test object: examples 1, examples 6-9, comparative examples 4-9 and comparative example 11;
Test item: 1. bulk density-filtration performance; 2. tensile and bending resistance;
the test is based on: 1. testing the volume density of the ceramic fiber lengthened filter tube by referring to a GB/T17911-2018 method; 2. tensile properties-interlaminar bond strength TAPPI-UM403; anti-fracture performance-fold-look at fracture;
test results: see table 2.
| Bulk Density (kg/m) 3 ) | Folding cracking condition | Interlayer bond Strength (J/m) 2 ) | |
| Example 1 | 195 | No cracking and no surface cracking | 86 |
| Example 6 | 193 | No cracking and no surface cracking | 85 |
| Example 7 | 193 | No cracking and no surface cracking | 83 |
| Example 8 | 194 | No cracking and no surface cracking | 83 |
| Example 9 | 195 | No cracking and no surface cracking | 84 |
| Comparative example 4 | 181 | Surface cracking | 79 |
| Comparative example 5 | 177 | Surface cracking | 78 |
| Comparative example 6 | 166 | Does not crack | 81 |
| Comparative example 7 | 182 | Does not crack | 81 |
| Comparative example 8 | 191 | Surface cracking | 74 |
| Comparative example 9 | 190 | Does not crack | 79 |
| Comparative example 11 | 190 | No cracking and no surface cracking | 82 |
Table 1.
Conclusion: as can be seen from Table 1, the ceramic fiber lengthened filter tube prepared by the invention has excellent filtering performance and tensile and fracture resistance, and is not lower than the performance of the existing ceramic fiber filter tube with the commercial length of less than 3 m;
in comparative example 4, the fiber base material had a neutral pH of 7.05, and no sodium hydroxide tablet was added; in comparative example 5, the sodium hydroxide tablet was added in relative excess to bring the pH of the fibrous base to 8.0; the pH value environment of the fiber base material in the two comparative examples is not good for the liquid aluminum sulfate to exert the effect, so that the filtration performance and the tensile and fracture resistance of the product are reduced;
In comparative example 6, the mass ratio of the liquid aluminum sulfate to the ceramic fibers fed into the beater in S1 was 2.2:100, and compared with the mass ratio of the liquid aluminum sulfate to the ceramic fibers fed into the beater in S1, which is in the range of 3.2-5.8:100, the use amount of the liquid aluminum sulfate is too small, resulting in a significant reduction in the filtration performance of the product; in the comparative example 7, the mass ratio of the liquid aluminum sulfate to the ceramic fibers fed into the beater in the S1 is 6.2:100, and compared with the mass ratio of the liquid aluminum sulfate to the ceramic fibers fed into the beater in the S1 in the range of 3.2-5.8:100, the liquid aluminum sulfate is used in a larger amount, so that the cost is increased, the product filtering performance is not improved, and the product filtering performance is slightly reduced;
the mass ratio of the bone glue to the ceramic fiber put into the beater in the comparative example 8 is 1:100, and compared with the mass ratio of the bone glue to the ceramic fiber put into the beater in the comparative example 1 which is 1.5-2.5:100, the use amount of the bone glue is too small, so that the tensile and fracture resistance of the product is obviously reduced; in the comparative example 9, the mass ratio of the bone glue to the ceramic fibers put into the beater in the S1 is 3:100, and compared with the mass ratio of the bone glue to the ceramic fibers put into the beater in the S1 which is in the range of 1.5-2.5:100, the use amount of the bone glue is larger, so that the cost is increased, the tensile property of the product is not improved, and the interlayer bonding strength of the product is slightly reduced.
Test example 3
Test object: example 1 and comparative example 10;
test item: comparing the cracking conditions of the products;
the test is based on: after the wet pipe blank is dried, visually observing the cracking condition of the product;
test results: the results of 10 times of the ceramic fiber lengthening filter pipes prepared in the example 1 and the comparative example 10 show that the ceramic fiber lengthening filter pipes prepared in the example 10 have no cracking condition, and the ceramic fiber lengthening filter pipes prepared in the comparative example 10 have cracking conditions with different degrees;
conclusion: the setting mode of slowly gradual change of the drying temperature in the drying treatment stage of the wet pipe blank in the production process effectively avoids secondary cracking of the wet pipe blank in the drying treatment process, and ensures the yield of the ceramic fiber lengthened filter pipe as a final product;
the comparative example 10 adopts a setting mode of rapid temperature rise and temperature reduction, which saves a small amount of production time, but directly results in greatly reduced yield.
While various embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Many modifications, changes, and substitutions will now occur to those skilled in the art without departing from the spirit and scope of the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. The appended claims are intended to define the scope of the invention and are therefore to cover all module forms, equivalents, or alternatives falling within the scope of the claims.
Claims (10)
1. The production process of the ceramic fiber lengthened filter tube is characterized by comprising the following steps of:
s1, putting ceramic fibers and water into a beating machine, starting up and stirring, and carrying out mixed beating treatment to obtain a fiber base material;
the mass ratio of the ceramic fiber to the water is 1.2-2.7:100;
the ceramic fiber comprises a spinning fiber and a spinning fiber, wherein the mass ratio of the spinning fiber to the spinning fiber is 1:1.1-1.3;
s2, pumping the fiber base material obtained in the step S1 into a material mixing tank, starting a stirring device of the material mixing tank, setting the stirring speed to be 70-90rpm, slowly adding a sodium hydroxide tablet, detecting the pH in real time, and stirring until the pH value is 7.4-7.8;
s3, sequentially adding liquid aluminum sulfate and bone glue into a material mixing tank, then adjusting the stirring speed to 140-200rpm, and continuously stirring for 18-35min to obtain fiber slurry;
the mass ratio of the liquid aluminum sulfate to the ceramic fiber put into the beater in the S1 is 3.2-5.8:100;
the mass ratio of the bone glue to the ceramic fiber put into the beater in the S1 is 1.5-2.5:100;
s4, pumping the fiber slurry obtained in the S3 into an elongated die mechanism of production equipment, discharging liquid in the fiber slurry through a discharge pipe of the elongated die mechanism, and forming the rest materials into an elongated wet pipe blank in the elongated die mechanism;
S5, drying the lengthened wet tube blank obtained in the step S4 to obtain the ceramic fiber lengthened filter tube.
2. The process for producing a ceramic fiber lengthened filter tube according to claim 1, wherein in S1, the length of the fiber is 180-250mm, and the diameter of the fiber is 3.0-5.0 μm;
the length of the spinning fiber is 100-180mm, and the diameter of the spinning fiber is 2.0-3.0 mu m.
3. The process for producing a ceramic fiber lengthened filter tube according to claim 1 or 2, wherein in S1, ceramic fibers are firstly put into a beater, then water is injected into the beater, stirring is carried out in two stages, the stirring speed in the first stage is 100-120rpm, and the stirring time is 15-20min;
the stirring speed in the second stage is 150-220rpm, and the stirring time is 10-15min.
4. The process for producing a ceramic fiber lengthened filter tube according to claim 1, wherein in S2, the pH value of the fiber base material in the batch tank is detected, and the sodium hydroxide tablet is slowly added into the batch tank after the dosage of the sodium hydroxide tablet is converted according to the mass of the fiber base material in the batch tank.
5. The process for producing a ceramic fiber extension filter tube according to claim 1, wherein the drying process in S5 comprises three stages:
The first stage is a heating drying stage, the heating rate is 40-60 ℃/h, and the temperature is raised to 115-125 ℃;
the second stage is a constant temperature drying stage, the constant temperature is kept between 115 and 130 ℃, and the drying time is 8 to 10 hours;
the third stage is a cooling and drying stage, the cooling rate is 30-50 ℃/h, and the temperature is reduced to 20-25 ℃.
6. A production facility for a production process of a ceramic fiber lengthened filter tube according to any one of claims 1-5, comprising a frame, wherein a diaphragm pump mechanism, a post rod mechanism, a die device and a slide rail mechanism are arranged on the frame, the diaphragm pump mechanism is connected with the post rod mechanism and is used for pumping fiber slurry into the die device, the die device is slidingly connected with the slide rail mechanism, liquid in the fiber slurry is discharged from the die device, the rest materials are formed into a wet pipe blank in the die device, the production facility is characterized by further comprising a lifting device slidingly connected with the slide rail mechanism, the die device comprises a lower die mechanism and an upper die mechanism positioned above the lower die mechanism, the upper die mechanism is connected with the lifting device, the lifting device is used for driving the upper die mechanism to move along the vertical direction, so that the upper die mechanism is folded or separated from the lower die mechanism, when the upper die mechanism and the lower die mechanism are in a folded state, the fiber slurry flows into a cavity between the upper die mechanism and the lower die mechanism, the wet pipe blank is further formed, and when the upper die mechanism and the lower die mechanism are in a separated state, the wet pipe blank is directly taken out from the lower die mechanism.
7. The apparatus of claim 6, wherein a locking assembly is removably disposed between the upper and lower mold mechanisms to secure the upper and lower mold mechanisms in the closed position.
8. The production device according to claim 7, wherein the upper die mechanism comprises an upper half cylinder die, the lower die mechanism comprises a lower half cylinder die, the upper half cylinder die and the lower half cylinder die are in a tubular shape in a folding state, at least two upper convex rings are uniformly and fixedly sleeved on the outer side wall of the upper half cylinder die, two ends of each upper convex ring are fixedly and fixedly connected with an upper epitaxial plate, at least two lower convex rings are uniformly and fixedly sleeved on the outer side wall of the lower half cylinder die, the lower convex rings correspond to the upper convex rings, two ends of each lower convex ring are fixedly connected with a lower epitaxial plate, the upper epitaxial plate is abutted against the lower epitaxial plate when the upper half cylinder die and the lower half cylinder die are in a folding state, and the locking assembly is detachably assembled between the upper epitaxial plate and the lower epitaxial plate.
9. The production facility of claim 8, wherein the locking assembly includes a link having one end hinged to the lower extension plate and movably mounted to the upper extension plate, and a jack bolt threadably connected to the other end of the link and adapted to jack the upper extension plate.
10. The production facility of claim 9, wherein the fixedly connected thread cylinder is located to the link, the jack screw thread cover is located in the thread cylinder, the one end fixed connection of jack screw remote from the upper extension board changes the board, can drive the jack screw rotation through rotating the board, the edge of board is slick and sly radian.
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