WO2022142082A1 - 一种适用于玄武岩纤维生产的气电混用熔制方法 - Google Patents

一种适用于玄武岩纤维生产的气电混用熔制方法 Download PDF

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WO2022142082A1
WO2022142082A1 PCT/CN2021/095085 CN2021095085W WO2022142082A1 WO 2022142082 A1 WO2022142082 A1 WO 2022142082A1 CN 2021095085 W CN2021095085 W CN 2021095085W WO 2022142082 A1 WO2022142082 A1 WO 2022142082A1
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basalt
gas
fiber production
melting method
method suitable
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PCT/CN2021/095085
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English (en)
French (fr)
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石钱华
张小玲
李堂
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四川谦宜复合材料有限公司
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Publication of WO2022142082A1 publication Critical patent/WO2022142082A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
    • C03B5/02—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture in electric furnaces, e.g. by dielectric heating
    • C03B5/027—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture in electric furnaces, e.g. by dielectric heating by passing an electric current between electrodes immersed in the glass bath, i.e. by direct resistance heating
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
    • C03B5/16—Special features of the melting process; Auxiliary means specially adapted for glass-melting furnaces
    • C03B5/235—Heating the glass
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
    • C03B5/16—Special features of the melting process; Auxiliary means specially adapted for glass-melting furnaces
    • C03B5/235—Heating the glass
    • C03B5/2356—Submerged heating, e.g. by using heat pipes, hot gas or submerged combustion burners
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
    • C03B5/16—Special features of the melting process; Auxiliary means specially adapted for glass-melting furnaces
    • C03B5/24—Automatically regulating the melting process
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C13/00—Fibre or filament compositions
    • C03C13/06—Mineral fibres, e.g. slag wool, mineral wool, rock wool

Definitions

  • the invention relates to the technical field of basalt fiber production, in particular to a gas-electric hybrid melting method suitable for basalt fiber production.
  • Basalt fiber has excellent high temperature resistance. Microfibers (average diameter ⁇ 3 ⁇ m) made from it are much better than glass wool and ordinary mineral rock wool in terms of ordinary physical properties and thermodynamic properties, and are widely used in aircraft. Insulation protection of engine, instrument compartment, cockpit, etc. It is the most ideal thermal insulation material for aircraft.
  • basalt continuous fiber Today, the production process of basalt continuous fiber is roughly as follows: natural basalt material is heated and melted as the raw material for producing basalt continuous fiber, and the basalt liquid formed by melting flows down from the leakage hole of the porous leakage plate, and is drawn into basalt continuous fiber by a wire drawing machine.
  • the existing basalt fiber production basically adopts the electric heating method to melt the basalt into the basalt liquid in the crucible kiln.
  • the quality of the basalt liquid produced by the all-electric heating method is poor, the production operation is not ideal, and there are many bubbles and impurities, which affect the production of continuous basalt fiber.
  • the purpose of the present invention is to provide a gas-electric hybrid melting method suitable for basalt fiber production, which can uniformly heat basalt and realize continuous basalt fiber production by pool kiln method.
  • a gas-electric hybrid melting method suitable for basalt fiber production using natural gas and flux electrodes to heat basalt at the same time;
  • the heat energy generated by the flux electrode accounts for 10-30% of the total heat energy.
  • the invention adopts natural gas and electric fluxing to heat the basalt at the same time.
  • the natural gas heating ensures the effective melting of the basalt.
  • the auxiliary heating of the electric fluxing is used to ensure the temperature of the basalt liquid at the bottom of the kiln. By selecting a specific ratio, the temperature is ensured.
  • the overall rationality of the system can effectively solve the problem that basalt fluid is difficult to obtain homogeneous basalt fluid due to low heat transfer efficiency, and the quality of basalt fiber produced is higher.
  • the application of the melting method of the present invention can break through the technical problem of uneven melting and inability to wire drawing by the pool kiln method, and realize the continuous basalt fiber production by the pool kiln method. At the same time, it can save energy and reduce production costs.
  • the heat energy generated by the flux electrode accounts for 20-25% of the total heat energy.
  • the bottom of the same kiln is heated by a fluxing electrode, and the top is heated by a natural gas combustion system.
  • the natural gas combustion system includes a combustion gun.
  • the nozzle of the combustion gun is aimed at the basalt liquid surface, and the basalt liquid can be heated up and down. , making the heating more sufficient.
  • the amount of natural gas input and the electricity consumption of electric booster are counted;
  • the operator adjusts the consumption of natural gas and electric booster in time so that the energy consumption of electric booster accounts for 10-30% of the total energy consumption.
  • DCS system refers to the distributed control system, which is a new generation of instrument control system based on microprocessor and adopts the design principles of decentralized control function, centralized display operation, taking into account the separation and autonomy and comprehensive coordination.
  • the DCS system of the present invention can make statistics on the amount of natural gas and the electricity consumption of electric booster, and display it in front of the operator intuitively. Using the DCS system can facilitate the operator to centrally monitor and control the real-time power consumption of natural gas and electric booster.
  • the current density of the flux electrode has been controlled below 0.5A/m 2 .
  • the increase of the current density can speed up the melting rate, but the increase of the current density will also accelerate the passivation of the electrode. It is very troublesome to replace the flux electrode in the basalt kiln, and it will affect the normal production. In order to ensure the electrode For long-term safe use, the current density of the flux electrode of the present invention cannot exceed 0.5A/m 2 .
  • a temperature sensor is set in the kiln, and the power used by the natural gas combustion system and the fluxing electrode is adjusted by the temperature of the basalt.
  • the specific detection method of the basalt liquid temperature by the DCS system is to set a temperature sensor in the kiln, and the measurement range of the temperature sensor should be above 1000-2000 °C, because the working temperature of the kiln is about 1500 °C.
  • the DCS system is provided with an upper limit alarm prompt for the proportion of power consumption and energy consumption.
  • the DCS system can issue an alarm prompt to remind the operator to adjust the energy consumption of the flux electrode, so as to avoid excessive energy consumption of the flux electrode and waste of energy.
  • the DCS system is provided with an alarm prompt for the lower limit of the proportion of power consumption and energy consumption.
  • the DCS system can issue an alarm prompt to remind the operator to increase the energy consumption of the fluxing electrode, so as to avoid the low energy consumption of the fluxing electrode and affect the melting effect of basalt. cause an impact.
  • the temperature sensor implements PID automatic control with the natural gas combustion system and the fluxing electrode.
  • Manual control can be assisted by PID automatic control.
  • the calculation is performed directly according to the real-time temperature of the basalt liquid, the combustion speed of the natural gas combustion system and the electric power of the fluxing electrode, and the signal is transmitted back to the natural gas combustion system and the electric power according to the set gas-to-electricity ratio.
  • the fluxing electrode can adjust the energy consumption of gas and electricity, reduce the manual workload, and make the control more accurate and timely.
  • the gas-electric hybrid melting method provided by the invention is suitable for the production of basalt fiber.
  • the gas-electric hybrid melting method is adopted, and the energy consumption of electric boosting is set to account for 10-30%, so as to ensure the overall rationality of the temperature system and effectively solve the problem. Due to the low heat transfer efficiency of basalt liquid, it is difficult to obtain homogeneous basalt liquid, which increases the precipitation of air bubbles during the basalt melting process, stabilizes the wire drawing production, and improves the quality of basalt fibers;
  • the application of the melting method of the present invention can break through the technical problem of uneven melting and inability to wire drawing by the pool kiln method, and realize the continuous basalt fiber production by the pool kiln method. It can also prolong the service life of bricks, ensure the stable operation of the kiln, save energy and reduce production costs.
  • Three pairs of fluxing electrodes are arranged at the bottom of the kiln, and two sets of natural gas combustion systems are arranged at the top of the kiln.
  • Each group of natural gas combustion systems is provided with two combustion guns, and the nozzles of the combustion guns are aimed at the liquid surface of the basalt.
  • the amount of electric boosting makes the energy consumption of electric boosting account for 30% of the total energy consumption.
  • the current density of the flux electrode has been controlled below 0.5A/m 2 .
  • a temperature sensor is installed in the kiln.
  • the temperature sensor monitors the temperature of the basalt liquid in the kiln, transmits the temperature signal to the controller, and automatically controls the energy consumption of electric boosting and the burning rate of natural gas through PID.
  • the DCS system is also equipped with upper and lower limit alarm prompts for the proportion of electric melting energy consumption.
  • Example 1 The only difference from Example 1 is that the power consumption of electric boosting accounts for 20% of the total power consumption.
  • Example 1 The only difference from Example 1 is that the power consumption of electric boosting accounts for 10% of the total power consumption.
  • Example 1 The only difference from Example 1 is that the power consumption of electric boosting accounts for 5% of the total power consumption.
  • Example 1 The only difference from Example 1 is that the power consumption of electric boosting accounts for 50% of the total power consumption.
  • Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 brushed effect Stable wire drawing Stable wire drawing Stable wire drawing can not be drawn can not be drawn
  • the basalt liquids melted by the methods of Examples 1 to 3 can be stably drawn; while the basalt liquids melted by the methods of Comparative Examples 1 to 2 cannot be stably drawn, indicating that the gas-electric hybrid suitable for the production of basalt fibers of the present invention is used.
  • the melting method can fully melt the basalt, and can produce high-quality homogeneous basalt liquid, so that the wire drawing is stable, and the produced basalt fiber wire is of good quality.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Combustion & Propulsion (AREA)
  • Electrochemistry (AREA)
  • Inorganic Fibers (AREA)

Abstract

本发明提供了一种适用于玄武岩纤维生产的气电混用熔制方法，使用天然气和助熔电极同时对玄武岩进行加热；助熔电极产生的热能占总热能的10～30％。能够对玄武岩进行均匀的加热，实现池窑法生产连续玄武岩纤维。

Description

一种适用于玄武岩纤维生产的气电混用熔制方法 技术领域
本发明涉及玄武岩纤维生产技术领域，具体而言，涉及一种适用于玄武岩纤维生产的气电混用熔制方法。
背景技术
玄武岩纤维具有优良的耐高温性能，以它为原料制得的微纤维(平均直径≤3μm)，从普通的物理性能到热力学性能均大大优于玻璃棉和普通矿岩棉，被广泛用于飞机发动机、仪表舱、座舱等部位的隔热保护。是飞行器最为理想的隔热材料。
现今，玄武岩连续纤维的生产流程大致是：天然的玄武岩石料作为生产玄武岩连续纤维的原料加热融化，熔化形成的玄武岩液从多孔漏板的漏孔中流下，由拉丝机拉成玄武岩连续纤维。
现有的玄武岩纤维生产，基本全采用电加热的方式，将玄武岩在坩埚窑中熔化成玄武岩液，但是由于玄武岩石料导热性能差，窑炉内的玄武岩熔液的温度及成分不均匀，这种全电加热的方式生产的玄武岩液的质量较差，生产作业不理想，气泡、杂质多，影响连续玄武岩纤维生产。
近年来，池窑法熔制玄武岩的工艺因其能够熔制的玄武岩量大而受到越来越广泛的关注。但是，池窑法的熔制空间大的同时也加重了玄武岩熔化不均匀的问题，难以制作出高质量的玄武岩液，玄武岩液的质量不好将会影响后续的拉丝工艺，无法稳定拉丝。
因此，如何使得窑炉内热场更加均匀，提高玄武岩石料的熔化速率，使得玄武岩熔液温度及成分更均匀，提高单台窑炉所产玄武岩连续纤维的产能与质量，更有利于实现玄武岩连续纤维的大规模工业化生产是目前本领域技术人员亟需解决的技术问题。
发明内容
本发明的目的在于提供一种适用于玄武岩纤维生产的气电混用熔制方法，其能够对玄武岩进行均匀的加热，实现池窑法生产连续玄武岩纤维。
本发明通过以下技术方案实现：
一种适用于玄武岩纤维生产的气电混用熔制方法，使用天然气和助熔电极同时对玄武岩进行加热；
助熔电极产生的热能占总热能的10～30％。
窑炉内空间大，玄武岩的导热性差，使用单一的电加热或者气加热都难以熔化均匀，而熔化效果不好，将很大程度影响到后续的拉丝过程，导致无法稳定拉丝。
本发明采用天然气和电助熔两种方式同时对玄武岩进行加热，天然气加热确保玄武岩的有效熔化，通过电助熔的辅助加热来保证窑内底部玄武 岩液的温度，通过选择特定的比例，确保温度制度的整体合理性，有效解决玄武岩液因传热效率低，难以获得均质玄武岩液的问题，生产出的玄武岩纤维质量更高。应用本发明的熔制方法，能够突破池窑法熔化不均匀无法拉丝的技术问题，实现池窑法生产连续玄武岩纤维。同时，又能够节省能源，降低生产成本。
作为优选的，助熔电极产生的热能占总热能的20～25％。
进一步地，在同一窑炉的底部采用助熔电极进行加热，顶部采用天然气燃烧系统进行加热。
在窑炉池底安插多对助熔电极，同时在窑炉顶部设置若干个天然气燃烧系统，天然气燃烧系统包括燃烧枪，燃烧枪的喷口对准玄武岩液面，在上下均可对玄武岩液进行加热，使得加热更加充分。
具体的，通过DCS集散系统，对投入的天然气量与电助熔用电量进行统计；
将统计的能耗比例在DCS系统主控画面进行即时显示；
操作人员及时调整天然气和电助熔的用量使得电助熔耗能占总耗能的10～30％。
DCS系统是指分散控制系统，是以微处理器为基础，采用控制功能分散、显示操作集中、兼顾分而自治和综合协调的设计原则的新一代仪表控制系统。本发明的DCS系统能够对天然气量和电助熔用电量进行统计，直观的展示在操作人员面前，使用DCS系统能够便于操作人员集中监测并控制天然气和电助熔的实时功耗。
进一步地，助熔电极的电流密度一直控制在0.5A/m 2以下。
电流密度增加能够加快熔化速率，但是电流密度在升高的同时也会加速电极的钝化，在玄武岩窑炉中更换助熔电极是十分麻烦的事情，并且会影响生产的正常进行，为了确保电极长期安全使用，本发明的助熔电极的电流密度不能超过0.5A/m 2。
进一步地，在窑炉中设置温度传感器，通过玄武岩的温度来调整天然气燃烧系统和助熔电极的使用功率。
具体的DCS系统对玄武岩液温度的检测方法是在窑炉内设置温度传感器，温度传感器的测量范围要在1000～2000℃以上，因为窑炉的工作温度在1500℃左右。
进一步地，DCS系统设置有电耗能占比上限报警提示。
当助熔电极的电耗能过高时，DCS系统能够发出报警提示，提醒操作人员对助熔电极的能耗进行调整，避免助熔电极能耗过高，造成能源的浪费。
进一步地，DCS系统设置有电耗能占比下限报警提示。
当助熔电极的电耗能过低时，DCS系统能够发出报警提示，提醒操作人员提高助熔电极的能耗，避免助熔电极能耗过低，影响玄武岩的熔化效果，进而对后续拉丝操作造成影响。
进一步地，温度传感器与天然气燃烧系统和助熔电极实行PID自动控制。
通过PID自动控制能够辅助人工控制，直接根据实时的玄武岩液的温度、天然气燃烧系统的燃烧速度和助熔电极的电功率来进行计算，并且根据设置的气电比例，将信号传输回天然气燃烧系统和助熔电极，对气电的耗能进行调整，减少人工工作量，控制更加精准和及时。
本发明的技术方案至少具有如下优点和有益效果：
本发明提供的适用于玄武岩纤维生产的气电混用熔制方法，采用气电混用的熔制方法，设置电助熔的耗能占比10～30％，确保温度制度的整体合理性，有效解决玄武岩液因传热效率低，难以获得均质玄武岩液的问题，增加玄武岩熔制过程中气泡析出，稳定拉丝生产，提高玄武岩纤维丝质量；
应用本发明的熔制方法，能够突破池窑法熔化不均匀无法拉丝的技术问题，实现池窑法生产连续玄武岩纤维。还能延长砖材的使用寿命，确保窑炉的稳定运行，节省能源，降低生产成本。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将对本发明实施例中的技术方案进行清楚、完整地描述。实施例中未注明具体条件者，按照常规条件或制造商建议的条件进行。所用试剂或仪器未注明生产厂商者，均为可以通过市售购买获得的常规产品。
实施例1
在窑炉的底部设置三对助熔电极，在窑炉的顶部设置两组天然气燃烧系统，每组天然气燃烧系统设置有两个燃烧枪，燃烧枪的喷口对准玄武岩液面。通过DCS集散系统对投入的天然气量和电助熔用电量进行统计，再将统计的能耗比例在DCS系统的主控画面进行即时显示，操作人员根据主控画面上的数据及时调整天然气和电助熔的用量使得电助熔耗能占总耗能的30％。调整过程中，助熔电极的电流密度一直控制在0.5A/m 2以下。窑炉中设置有温度传感器，温度传感器监测到窑炉内玄武岩液的温度，将温度信号传输到控制器中，通过PID自动控制电助熔的能耗和天然气的燃烧速度。DCS系统还设置有电助熔耗能占比的上下限报警提示。
实施例2
与实施例1的差别仅在于电助熔耗能占总耗能的20％。
实施例3
与实施例1的差别仅在于电助熔耗能占总耗能的10％。
对比例1
与实施例1的差别仅在于电助熔耗能占总耗能的5％。
对比例2
与实施例1的差别仅在于电助熔耗能占总耗能的50％。
实验例1
采用实施例1～3和对比例1～2的熔制方法进行玄武岩的熔制，并将熔制得到的玄武岩液通向多孔漏板进行拉丝，得到拉丝结果如下表所示：
表1不同熔制方法生产出的玄武岩液的拉丝效果
  实施例1 实施例2 实施例3 对比例1 对比例2
拉丝效果 稳定拉丝 稳定拉丝 稳定拉丝 不能拉丝 不能拉丝
根据表1的测试结果可知：
以实施例1～3的方法熔制的玄武岩液能够进行稳定的拉丝；而对比例1～2的方法熔制的玄武岩液不能进行稳定拉丝，说明本发明的适用于玄武岩纤维生产的气电混用熔制方法能够对玄武岩进行充分的熔化，能够制作出高质量的均质玄武岩液，使得拉丝稳定，制作出的玄武岩纤维丝品质优良。
以上仅为本发明的优选实施例而已，并不用于限制本发明，对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (8)

  1. 一种适用于玄武岩纤维生产的气电混用熔制方法，其特征在于，使用天然气和助熔电极同时对玄武岩进行加热；
    助熔电极产生的热能占总热能的10～30％。
  2. 根据权利要求1所述的适用于玄武岩纤维生产的气电混用熔制方法，其特征在于，在同一窑炉的底部采用助熔电极进行加热，顶部采用天然气燃烧系统进行加热。
  3. 根据权利要求1所述的适用于玄武岩纤维生产的气电混用熔制方法，其特征在于，通过DCS集散系统，对投入的天然气量与电助熔用电量进行统计；
    将统计的能耗比例在DCS系统主控画面进行即时显示；
    操作人员及时调整天然气和电助熔的用量使得电助熔耗能占总耗能的10～30％。
  4. 根据权利要求1所述的适用于玄武岩纤维生产的气电混用熔制方法，其特征在于，所述助熔电极的电流密度一直控制在0.5A/m 2以下。
  5. 根据权利要求2所述的适用于玄武岩纤维生产的气电混用熔制方法，其特征在于，在窑炉中设置温度传感器，通过玄武岩的温度来调整天然气燃烧系统和助熔电极的使用功率。
  6. 根据权利要求1所述的适用于玄武岩纤维生产的气电混用熔制方法，其特征在于，所述DCS系统设置有电耗能占比上限报警提示。
  7. 根据权利要求1所述的适用于玄武岩纤维生产的气电混用熔制方法，其特征在于，所述DCS系统设置有电耗能占比下限报警提示。
  8. 根据权利要求2所述的适用于玄武岩纤维生产的气电混用熔制方法，其特征在于，所述温度传感器与所述天然气燃烧系统和所述助熔电极实行PID自动控制。
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