CN105669168A - 一种石膏磨用陶瓷研磨体的制备方法 - Google Patents

一种石膏磨用陶瓷研磨体的制备方法 Download PDF

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CN105669168A
CN105669168A CN201610032356.2A CN201610032356A CN105669168A CN 105669168 A CN105669168 A CN 105669168A CN 201610032356 A CN201610032356 A CN 201610032356A CN 105669168 A CN105669168 A CN 105669168A
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张国辉
王慧
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Abstract

本发明提供一种石膏磨用陶瓷研磨体的制备方法，主要包括配料、粉磨、抽滤、脱二次真空练泥后、陈腐、造粒、挤压成型、在一定温度下烧成制备而成。本发明的制备方法工艺简单，能耗低，应用范围广泛。制备的石膏磨用陶瓷研磨体自重轻，磨损率低，能大幅降低粉磨能耗，延长研磨体使用寿命，降低成本；研磨过程中没有杂质金属铁离子的掺入，不影响建筑石膏粉的白度及强度；陶瓷研磨体还能减少静电吸附，有利于提高粉磨效率。

Description

一种石膏磨用陶瓷研磨体的制备方法
技术领域
本发明涉及一种石膏磨用陶瓷研磨体的制备方法，属于功能陶瓷制备技术领域。
背景技术
石膏石或工业副产石膏是以二水硫酸钙形式存在，其分子式中有两个结晶水，只有脱去一个半结晶水生成半水硫酸钙才有胶凝性质。脱去结晶水的过程即为石膏煅烧。石膏煅烧成建筑石膏粉的物理力学性能与颗粒粒径及级配有很大关系。以工业副产脱硫石膏为例，脱硫石膏颗粒粒径分布较窄，级配较差，比表面积小，水化硬化过程中流变性能差，容易离析分层泌水，导致制品容重不均衡、强度低，故一般会在煅烧前或煅烧后增加粉磨工序，采用磨细手段增大比表面积改善煅烧石膏粉的性能。常用的粉磨设备为球磨机，研磨体为金属铁复合铬、锰等重金属制成的金属研磨体，具有体积密度大，磨机耗电大，磨损率高，增加金属离子的缺点。金属研磨体容易产生过度粉磨，过细的颗粒粒度及比表面积太大，会影响建筑石膏粉的强度；由于磨损掺入石膏粉中金属离子，比如Fe3+等，会影响建筑石膏粉的白度、抗折强度等。
因此，能耗低、自重小、磨损率低的低密度研磨体为越来越多的科研工作者所研究。申请号为201510077860.X、201510077859.7、2015100358580.8的中国发明专利给出不同的低密度研磨体的制备方法及生产工艺，主要应用于水泥磨中。在水泥磨中球磨工艺主要起到粉碎、研磨的双重功效，而石膏粉磨工艺中，由于煅烧后石膏粒径较小（一般大于50目），研磨功能起主要作用，所以具有强冲击力高密度的金属研磨体在使用中能耗、损耗巨大，发挥不出其更有力的效果。专用于石膏磨中的低密度陶瓷研磨体的研究较少。全国每年产出的工业副产石膏有上亿吨，占用大量的土地，给生态环境造成严重危害，煅烧成建筑石膏粉是处理工业副产石膏循环利用的主要途径，改善煅烧建筑石膏粉的性能，增大应用范围显得尤为重要。
因此，寻求一种适用、专用、性能优异的石膏磨研磨体具有重大的意义。
发明内容
本发明的目的在于提供一种耗能低、磨损率低的石膏磨用陶瓷研磨体的制备方法。
本发明的技术方案为：
一种石膏磨用陶瓷研磨体的制备方法，包括以下步骤：
（1）配料：按照以下物质重量百分比配制原料：Al2O3：62%~83%，SiO2：5%~8%，Cr2O3：0.5%~1.8%，TiO2：1%~1.45%，MnO：1.51%~1.75%，ZrO2：1.6%~3.4%，BaO：1%~3%，硅硼钙石：4.6%~7%，ZnO：2%~2.8%，纳米胶体硅：0.3%~1.1%，助溶剂2%~6%；其中所述的助溶剂为AlF3、CaF2、钠长石、NH4Cl、MgO的一种或几种的组合。
（2）粉磨：将配制好的物料进行粉磨，使粉磨后颗粒过250目筛，筛余＜2%；
（3）用压滤机抽去步骤（2）中料浆水分，脱水后经过二次真空练泥后，静置40~46小时进行陈腐；
（4）料浆喷雾造粒，采用挤压工艺挤压成型，制得坯体，然后将坯体在80~120℃下干燥29~32小时；
（5）成型坯体在1350~1400℃烧结，保温7小时，制得成品。
本发明技术方案有如下显著进步之处：
第一、本发明制备的石膏磨用陶瓷研磨体与金属研磨体比较，自重轻，磨损率低，能大幅降低粉磨能耗，延长研磨体使用寿命，降低成本；研磨过程中没有杂质金属铁离子的掺入，不影响建筑石膏粉的白度及强度；陶瓷研磨体还能减少静电吸附，有利于提高粉磨效率；
第二、本发明制备的陶瓷研磨体形成以刚玉、尖晶石、莫来石等为主要晶相结构晶相间由玻璃相结构连接，结构致密，ZrO2的加入改善陶瓷脆性，增强韧性；为了增大石膏用陶瓷研磨体的研磨功能性，在结构中置入磨削能力极强的SiO2、Cr2O3、BaO等微晶矿物质，强化对物料的磋磨作用，加大研磨能力，微晶矿物的加入，硬度高，使研磨体功能不会受腐蚀影响；助溶剂的加入，降低陶瓷的在低温烧结条件下致密烧结，降低耗能，提高生产效率；
第三、本发明制备石膏用陶瓷研磨体的方法简单，耗能低，利于大面积推广应用。
具体实施方式
实施案例1
一种石膏磨用陶瓷研磨体的制备方法，包括以下步骤：
（1）配料：按照以下物质重量百分比配制原料：Al2O3：73%，SiO2：5.7%，Cr2O3：1.55%，TiO2：1.3%，MnO：1.65%，ZrO2：2.4%，BaO：2.3%，硅硼钙石：5.4%，ZnO：2.4%，纳米胶体硅：0.7%，助溶剂3.6%；其中所述的助溶剂为NH4Cl。
（2）粉磨：将配制好的物料进行粉磨，使粉磨后颗粒过250目筛，筛余＜2%；
（3）用压滤机抽去步骤（2）中料浆水分，脱水后经过二次真空练泥后，静置45小时进行陈腐；
（4）料浆喷雾造粒，采用挤压工艺挤压成型，制得坯体，然后将坯体在80~100℃下干燥29~32小时；
（5）成型坯体在1350~1400℃烧结，保温7小时，制得成品。
制备的石膏磨用陶瓷研磨体，制备成的球形石膏磨用研磨体，体积密度3.72g/cm3，硬度达到莫氏硬度9级，磨耗为0.05‰。
使用制备的石膏磨用陶瓷研磨体，对煅烧后的脱硫石膏粉进行粉磨，磨机填充率为36.2%，粉磨后的脱硫石膏粉性能达到很多改善，各性能如下表所示：
其中，使用陶瓷研磨体的电耗为20.2kwh/t，使用金属研磨体的电耗为23.5kwh/t。
实施案例2
一种石膏磨用陶瓷研磨体的制备方法，包括以下步骤：
（1）配料：按照以下物质重量百分比配制原料：Al2O3：75.9%，SiO2：5.3%，Cr2O3：0.9%，TiO2：1.25%，MnO：1.55%，ZrO2：1.9%，BaO：1.6%，硅硼钙石：5.2%，ZnO：2.3%，纳米胶体硅：0.5%，助溶剂3.6%；其中所述的助溶剂为钠长石和MgO的组合，组分比例为钠长石35.5%，MgO为64.5%。
（2）粉磨：将配制好的物料进行粉磨，使粉磨后颗粒过250目筛，筛余＜2%；
（3）用压滤机抽去步骤（2）中料浆水分，脱水后经过二次真空练泥后，静置44小时进行陈腐；
（4）料浆喷雾造粒，采用挤压工艺挤压成型，制得坯体，然后将坯体在80~120℃下干燥31小时；
（5）成型坯体在1350~1400℃烧结，保温7小时，制得成品。
制备的石膏磨用陶瓷研磨体，制备成的球形石膏磨用研磨体，体积密度3.69g/cm3，硬度达到莫氏硬度9级，磨耗为0.09‰。
使用制备的石膏磨用陶瓷研磨体，对生产氢氟酸产出的氟石膏粉进行粉磨，磨机填充率为34.3%，粉磨后氟石膏的活性被激发，更有利于水化反应，各性能如下表所示：
其中，使用陶瓷研磨体的电耗为25.2kwh/t，使用金属研磨体的电耗为28.5kwh/t。
实施案例3
一种石膏磨用陶瓷研磨体的制备方法，包括以下步骤：
（1）配料：按照以下物质重量百分比配制原料：Al2O3：62%~83%，SiO2：6.2%，Cr2O3：1.6%，TiO2：1.35%，MnO：1.65%，ZrO2：3.2%，BaO：2.6%，硅硼钙石：5.9%，ZnO：2.5%，纳米胶体硅：0.8%，助溶剂3.5%；其中所述的助溶剂为AlF3和CaF2的组合，其比例为55%和45%。
（2）粉磨：将配制好的物料进行粉磨，使粉磨后颗粒过250目筛，筛余＜2%；
（3）用压滤机抽去步骤（2）中料浆水分，脱水后经过二次真空练泥后，静置40~46小时进行陈腐；
（4）料浆喷雾造粒，采用挤压工艺挤压成型，制得坯体，然后将坯体在80~120℃下干燥29~32小时；
（5）成型坯体在1350~1400℃烧结，保温7小时，制得成品。
制备的石膏磨用陶瓷研磨体，制备成的球形石膏磨用研磨体，体积密度3.86g/cm3，硬度达到莫氏硬度9级，磨耗为0.02‰。
使用制备的石膏磨用陶瓷研磨体，对天然石膏粉进行粉磨，天然石膏的粉磨包括块状石膏的粉碎，磨机填充率为38.6%，粉末后白度高于其中，使用陶瓷研磨体的电耗为23.2kwh/t，使用金属研磨体的电耗为25.7kwh/t，粉末后，使用陶瓷研磨体的的白度高于使用金属研磨体。

Claims (1)

1.一种石膏磨用陶瓷研磨体的制备方法，其特征在于包括以下步骤：
（1）配料：按照以下物质重量百分比配制原料：Al2O3：62%~83%，SiO2：5%~8%，Cr2O3：0.5%~1.8%，TiO2：1%~1.45%，MnO：1.51%~1.75%，ZrO2：1.6%~3.4%，BaO：1%~3%，硅硼钙石：4.6%~7%，ZnO：2%~2.8%，纳米胶体硅：0.3%~1.1%，助溶剂2%~6%；其中所述的助溶剂为AlF3、CaF2、钠长石、NH4Cl、MgO的一种或几种的组合；
（2）粉磨：将配制好的物料进行粉磨，使粉磨后颗粒过250目筛，筛余＜2%；
（3）用压滤机抽去步骤（2）中料浆水分，脱水后经过二次真空练泥后，静置40~46小时进行陈腐；
（4）料浆喷雾造粒，采用挤压工艺挤压成型，制得坯体，然后将坯体在80~120℃下干燥29~32小时；
（5）成型坯体在1350~1400℃烧结，保温7小时，制得成品。
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