CN105859261A - 一种水泥研磨机用陶瓷研磨段及其制备方法 - Google Patents
一种水泥研磨机用陶瓷研磨段及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种水泥研磨机用陶瓷研磨段及其制备方法,其按重量百分比计含有氧化铝92‑95%、氮化硅0.5‑2%、高岭土0.8‑3%、碳化钛0.2‑2%、纳米碳化硼1.5‑2%、氮化钛0.8‑1%、碳化钽0.3‑2%,形状为球柱结合体、边角倒圆的圆柱体或上下对称的正四棱台,采用压制成型后高温烧结的方法制备,包括配料、球磨、喷雾造粒、料仓陈腐、压型加工、高温烧结、清粉抛光、成品干燥等工序。本发明的水泥研磨机用陶瓷研磨段具有高硬度、高耐磨、耐高温等优点之外还具有极限的抗震、耐磨、抗冲击性能。
Description
技术领域
本发明涉及水泥加工领域,尤其涉及一种水泥研磨机用陶瓷研磨段及其制备方法。
背景技术
水泥研磨机具有对物料适应性强、能连续生产、破碎比大、易于控制粉磨产品的细度等特点。常用的水泥研磨机的工作原理为,物料由进料装置经入料中空轴螺旋均匀地进入磨机仓内,该仓内有阶梯衬板或波纹衬板,内装不同规格钢球或钢段,筒体转动产生离心力将钢球或钢段带到一定高度后落下,对物料产生冲击和研磨作用。水泥研磨机研磨段是水泥研磨机设备研磨物料介质,通过水泥研磨机研磨段、物料、衬板之间的碰撞摩擦产生磨削作用,从而将物料的粒径进一步减小。因此,研磨段在使用时的硬度和耐磨性是影响研磨整形效果的主要因素之一,同时因为被长时间不停地撞击,对于研磨球的抗冲击性能有极高要求。
现有技术中,水泥研磨机用研磨段的材质多为工具钢或高碳不锈钢,材料相互之间、与物料之间磨损较大,表面易剥蚀,损耗率大,更换快;同时,钢质的磨段质量大,工作时功耗高,带来的碳排放大,同时不锈钢材质中的铬污染对于水泥来说是非常不利的,影响能量效率和环保;另外有一部分采用硬质合金或陶瓷材料,该类材料能很好适应水泥研磨机的使用工况,但其成本高,易破碎、成型时尺寸不易控制、成型后表面不规整一致。
综上所述,如何提高水泥研磨机研磨段的硬度、耐磨性是研究的重点,水泥粉磨技术也向高效、节电方向快速发展。
陶瓷作为一种新型的水泥球磨机用陶瓷研磨球材料,具备高硬度、耐高温、耐腐蚀等显而易见的优点,能基本克服上述缺点。
本发明人同日申请的专利中,公开了一种水泥研磨机用陶瓷研磨段,其配方在传统的Al2O3-CaO-MgO-SiO2四元体系的基础上新增了碳化钨、氮化钛、氧化锆等添加剂,其具有较低的成本和能耗低、物耗低、减少碳排放、高硬度、耐高温、高寿命、易成型、韧性好、生产的水泥纯净度高等一系列优异的综合性能,但其在极限工作条件下的抗震、耐磨、抗冲击方面还稍有欠缺。
发明内容
针对现有技术中存在的上述缺陷,本发明旨在提供一种能耗低、物耗低、减少碳排放、高硬度、耐高温、高寿命、易成型、韧性好、生产的水泥纯净度高且比传统陶瓷材料具有更优良的抗震、耐磨、抗冲击性能的水泥研磨机用陶瓷研磨段。
为了实现上述目的,本发明采用以下技术方案:一种水泥研磨机用陶瓷研磨段,其按重量百分比计含有氧化铝92-95%、氮化硅0.5-2%、高岭土0.8-3%、碳化钛0.2-2%、纳米碳化硼1.5-2%、氮化钛0.8-1%、碳化钽0.3-2%。
上述的水泥研磨机用陶瓷研磨段,其形状为中间截面积最大、上下对称的正四棱台,边角处倒圆。
上述的水泥研磨机用陶瓷研磨段,其形状为圆柱体,边角处倒圆,截面尺寸优选为10mm×10mm,15mm×15mm,20mm×20mm,25mm×25mm中的一种。
上述的水泥研磨机用陶瓷研磨段,其形状为球柱结合体,中间为圆柱,两头分别为球状。
上述的水泥研磨机用陶瓷研磨段的制备方法,包括以下步骤:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=(7-10):100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:(0.7-0.75),至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:(2-3):(0.7-0.75),至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液9-12%,混磨0.5-1h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,压型粉料水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入高温匣钵,撒上隔离砂,送入高温窑内,温度1350-1700℃,烧成周期24-36h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。
上述的水泥研磨机用陶瓷研磨段的制备方法,其中:步骤(c)中加入PVA溶液的同时,还加入适量的消泡剂。
上述的水泥研磨机用陶瓷研磨段的制备方法,其中:步骤(e)用于压型成坯的粉料颗粒大小控制为30-80目。
上述的水泥研磨机用陶瓷研磨段的制备方法,其中:步骤(f)中所述隔离砂为40目以下的白刚玉。
上述的水泥研磨机用陶瓷研磨段的制备方法,其中:步骤(f)中所述高温窑为隧道窑,温度为1350-1550℃,烧成周期为24-30h。
上述的水泥研磨机用陶瓷研磨段的制备方法,其中:步骤(f)中所述高温窑为梭式窑,温度为1450-1700℃,烧成周期为30-36h。
与现有技术比较,本发明的水泥研磨机用陶瓷研磨段,由于采用了上述方案,区别于传统的Al2O3-CaO-MgO-SiO2四元体系,以氧化铝为主,氧化铝系列陶瓷天生具有机械强度高、硬度高、重量轻、耐高温、耐化学腐蚀、绝缘性能优良等优点。添加氮化硅、碳化钛、纳米碳化硼、氮化钛、碳化钽等作为添加剂,以高岭土作为粘接剂,其中氮化硅硬度高、耐磨性好、耐热冲击大,氮化钛熔点高、密度较低、抗热冲击性好,纳米碳化硼莫氏硬度极高达到9.3、密度低、强度大、高温和化学稳定性好,碳化钽、碳化钛硬度接近金刚石、耐极度高温,氮化钛熔点高、密度较低、抗热冲击性好,高岭土具有优良的粘接性且提供SiO2,这些材料的综合作用使制得的成品既具有传统的陶瓷材料的优点:密度低、高硬度、耐高温、耐腐蚀、运转能耗低、物耗低、结合力好、撞击能力强、抗冲击抗爆震、生产的水泥细度和后期强度高等,同时纳米碳化硼、氮化钛、碳化钛、碳化钽等材料在高岭土的粘合作用下,具有更优良的抗震、耐磨、抗冲击性能。形状可采用业界常用的边角倒圆的圆柱体,也可采用球柱结合体或上下对称的正四棱台,没有应力集中点,不易被撞碎,寿命更长。
同时,与现有技术比较,本发明中的水泥研磨机用陶瓷研磨段的制备方法,由于采用了初磨、细磨、混磨三道工序的球磨和逐级筛选,使浆料细度均匀一致;进行除铁工序,能有效去除浆料中的杂质,提高陶瓷制品纯净度;因为氧化铝陶瓷粉料属瘠性原料,为了压制成型的需要,需要加入粘接剂,如配方中的高岭土和在喷雾造粒中添加的PVA溶液,加入消泡剂是为了抑制泡沫产生,提高生产能力,降低生产成本;料仓陈腐工序能有效去除造粒粉中的水分;压型加工工序使粉料成型,干压成型的坯料水分少、压力大、坯体致密,因此能获得收缩小、形状准确、易于干燥的生坯;高温烧结工序中撒入隔离砂,能有效防止产品粘连,使烧成制品与高温匣钵容易分离;清粉抛光工序把烧成过程中粘附的隔离砂及毛刺除掉,使产品光洁;最后的干燥工序使产品完全达到出厂指标。
附图说明
图1是本发明的几种典型结构的示意图。
图中:上下对称且边角处倒圆的正四棱台1、边角处倒圆的圆柱体2、球柱结合体3。
具体实施方式
实施例1:
该水泥研磨机用陶瓷研磨段按重量百分比计含有氧化铝92%、氮化硅0.5%、高岭土1%、碳化钛2%、纳米碳化硼1.5%、氮化钛1%、碳化钽2%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=8:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水(初磨球石可采用Φ30-Φ50mm的92-高铝等静压球,下同),比例为料:球:水=1:2.5:0.7,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水(细磨球石可采用Φ15-Φ25mm的92-高铝等静压球,下同),比例为料:球:水=1:2:0.7,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液9%,混磨1h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,形状为边角倒圆的圆柱体,截面尺寸优选为10mm×10mm,15mm×15mm,20mm×20mm,25mm×25mm中的一种;压型粉料水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入高温匣钵,撒上40目白刚玉隔离砂,送入隧道窑内,温度1550℃,烧成周期24h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。
实施例2:
该水泥研磨机用陶瓷研磨段按重量百分比计含有氧化铝95%、氮化硅0.5%、高岭土0.8%、碳化钛0.6%、纳米碳化硼2%、氮化钛0.8%、碳化钽0.3%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=7:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.75,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:3:0.75,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液12%,混磨0.5h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液和适量的消泡剂,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,形状为球柱结合体,中间为圆柱,两头分别为球状;压型粉料水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入高温匣钵,撒上60目白刚玉隔离砂,送入梭式窑内,温度1450℃,烧成周期36h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。
实施例3:
该水泥研磨机用陶瓷研磨段按重量百分比计含有氧化铝92%、氮化硅2%、高岭土3%、碳化钛0.2%、纳米碳化硼1.5%、氮化钛0.8%、碳化钽0.5%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=10:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.72,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5: 0.75,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液9%,混磨0.5h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液和适量的消泡剂,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,压型粉料水份控制在0.5%以下;形状为中间截面积最大、上下对称的正四棱台,边角处倒圆;
(f)高温烧结:将步骤(e)得到的生坯放入高温匣钵,撒上80目白刚玉隔离砂,送入隧道窑内,温度1350℃,烧成周期30h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。
实施例4:
该水泥研磨机用陶瓷研磨段按重量百分比计含有氧化铝93%、氮化硅1.2%、高岭土2%、碳化钛1%、纳米碳化硼1.6%、氮化钛0.9%、碳化钽0.3%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=9:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.7,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:2:0.7,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液11%,混磨0.7h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液和适量的消泡剂,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,形状为球柱结合体,中间为圆柱,两头分别为球状;压型粉料水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入高温匣钵,撒上60目白刚玉隔离砂,送入梭式窑内,温度1700℃,烧成周期30h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。
实施例5:
该水泥研磨机用陶瓷研磨段按重量百分比计含有氧化铝94%、氮化硅0.6%、高岭土1.1%、碳化钛0.5%、纳米碳化硼1.8%、氮化钛1%、碳化钽1%,采用如下方法制备:
(a)配料:按重量百分比计取所有成分;同时配置PVA溶液,配比为PVA:水=8:100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.75,至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:0.75,至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液12%,混磨0.6h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液和适量的消泡剂,并打入高位浆罐,控制喷雾干燥塔的热风温度,出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,压型粉料水份控制在0.5%以下;形状为中间截面积最大、上下对称的正四棱台,边角处倒圆;
(f)高温烧结:将步骤(e)得到的生坯放入高温匣钵,撒上40目白刚玉隔离砂,送入梭式窑内,温度1550℃,烧成周期34h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。
对所公开的实施例的上述说明,仅为了使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下,在其它实施例中实现。因此,本发明将不会被限制于本文所示的这些实施例,而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (10)
1.一种水泥研磨机用陶瓷研磨段,其特征在于:其按重量百分比计含有氧化铝92-95%、氮化硅0.5-2%、高岭土0.8-3%、碳化钛0.2-2%、纳米碳化硼1.5-2%、氮化钛0.8-1%、碳化钽0.3-2%。
2.根据权利要求1所述的一种水泥研磨机用陶瓷研磨段,其特征在于:其形状为中间截面积最大、上下对称的正四棱台,边角处倒圆。
3.根据权利要求1所述的一种水泥研磨机用陶瓷研磨段,其特征在于:其形状为圆柱体,边角处倒圆,截面尺寸优选为10mm×10mm,15mm×15mm,20mm×20mm,25mm×25mm中的一种。
4.根据权利要求1所述的一种水泥研磨机用陶瓷研磨段,其特征在于:其形状为球柱结合体,中间为圆柱,两头分别为球状。
5.根据上述任一权利要求所述的一种水泥研磨机用陶瓷研磨段的制备方法,其特征在于,包括以下步骤:
(a)配料:按重量百分比计取所有成分,混合并搅拌均匀,制得混合物料;同时配置PVA溶液,配比为PVA:水=(7-10):100;
(b)球磨:
(b1)初磨:将步骤(a)中计取的配料加入初磨研磨设备,并加入球石和水,比例为料:球:水=1:2.5:(0.7-0.75),至浆料细度D90≤8微米停磨,过40目筛出磨;
(b2)细磨:将步骤(b1)得到的浆料加入细磨研磨设备,并加入球石和水,比例为料:球:水=1:(2-3):(0.7-0.75),至浆料细度D50≤1.5微米、D90≤3.2微米后停磨;
(b3)混磨:将步骤(b2)得到的浆料中按重量比加入步骤(a)中配置的PVA溶液9-12%,混磨0.5-1h,过150目筛出磨,并进行除铁;
(c)喷雾造粒:将步骤(b3)得到的浆料中加入适量步骤(a)中配置的PVA溶液,并打入高位浆罐,控制喷雾干燥塔的热风温度、出风温度及压差,选用合适的喷雾喷片直径,进行喷雾造粒,造粒粉过20目筛;
(d)料仓陈腐:将步骤(c)得到的造粒粉进行陈腐,陈腐时间不少于48h;
(e)压型加工:将步骤(d)得到的粉料通过模具压型成坯,压型粉料水份控制在0.5%以下;
(f)高温烧结:将步骤(e)得到的生坯放入高温匣钵,撒上隔离砂,送入高温窑内,温度1350-1700℃,烧成周期24-36h;
(g)清粉抛光:把产品在烧成过程中的粘附的隔离砂及毛刺除掉;
(h)成品干燥:对产品进行干燥,得到成品。
6.根据权利要求5所述的一种水泥研磨机用陶瓷研磨段的制备方法,其特征在于,步骤(c)中加入PVA溶液的同时,还加入适量的消泡剂。
7.根据权利要求6所述的一种水泥研磨机用陶瓷研磨段的制备方法,其特征在于,步骤(e)用于压型成坯的粉料颗粒大小控制为30-80目。
8.根据权利要求7所述的一种水泥研磨机用陶瓷研磨段的制备方法,其特征在于,步骤(f)中所述隔离砂为40目以下的白刚玉。
9.根据权利要求6或7或8所述的一种水泥研磨机用陶瓷研磨段的制备方法,其特征在于,步骤(f)中所述高温窑为隧道窑,温度为1350-1550℃,烧成周期为24-30h。
10.根据权利要求6或7或8所述的一种水泥研磨机用陶瓷研磨段的制备方法,其特征在于,步骤(f)中所述高温窑为梭式窑,温度为1450-1700℃,烧成周期为30-36h。
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