CN109516774B - 一种人造球形陶瓷复合砂的制备方法 - Google Patents
一种人造球形陶瓷复合砂的制备方法 Download PDFInfo
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- 238000012216 screening Methods 0.000 claims abstract description 21
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- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 12
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- 239000010431 corundum Substances 0.000 claims abstract description 6
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 6
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- 239000002245 particle Substances 0.000 claims description 43
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- 229910000278 bentonite Inorganic materials 0.000 claims description 19
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical group O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 19
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- GWWPLLOVYSCJIO-UHFFFAOYSA-N dialuminum;calcium;disilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-] GWWPLLOVYSCJIO-UHFFFAOYSA-N 0.000 claims description 15
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Abstract
本发明涉及铸造用陶瓷砂领域,具体为一种人造球形陶瓷复合砂的制备方法,可广泛运用于普通砂型铸造、壳型铸造、精密铸造等行业的造型材料。陶瓷复合砂的结构主要为“内核+外层”双层结构,内核采用较粗粒径的粉料:低品位铝矾土、低品位焦宝石、镍尾矿矿渣、粉煤灰中的一种或两种以上,外层采用较细粒径的粉料:高品位焦宝石、高品位铝矾土、刚玉粉中的一种或两种以上。采用配料—球磨—造粒—烧结—筛分级配的制备工艺进行制备陶瓷复合砂,所得陶瓷复合砂的开放式孔洞少、表面光洁度好,耐火度高,破碎率低。陶瓷复合砂的双层结构设计,不仅较单一结构的陶瓷砂性能更优还降低成本,兼顾经济性。
Description
技术领域
本发明涉及铸造用陶瓷砂领域,具体为一种人造球形陶瓷复合砂的制备方法,可广泛运用于普通砂型铸造、壳型铸造、精密铸造等行业的造型材料。
背景技术
随着我国经济社会的发展,为了满足工业生产的需要,对自然资源进行大量的开采,导致许多自然资源面临枯竭,国家开始限制企业对某些矿产资源的开采,导致许多原材料的价格不断走高,例如:我国虽然是世界铝矾土储量最大的国家,经过多年的大量开采,现存储量已经大大减少,许多地方的铝矾土矿已经枯竭,国家近年来开始限制铝矾土矿的开采,导致铝矾土市场持续走俏;同时,工业生产带来的废弃物排放又对环境造成严重的污染,为了保护我们赖以生存的自然环境,国家和社会开始纷纷出台政策、法规和标准,例如:新环保税法的颁布、铸造行业准入条件和铸造固废排放限值等行业标准的颁布。在“节约资源,保护环境”的大背景下,许多原本严重依赖资源的企业变得难以生存。另一方面,随着我国的铸件行业的快速发展,铸件产量稳步上升,对铸造用砂的需求也越来越多,而且随着铸件质量的提高,传统硅砂由于角形系数大,热膨胀率大、再生性能差等特性,已经满足不了铸造行业的需要。因此,近年来人造球形砂逐渐进入人们的视野,人造球形砂作为铸造原砂不仅性能优异,而且再生容易,节约资源,保护环境。
其实,人造球形砂早在上世纪60年代就有研究人员对其进行研究,发展到如今已有50余年的历史,期间出现碳粒砂、顽辉石砂、“太阳珠”等多种人造球形砂产品。21世纪初,国内开发并推广一种名叫“宝珠砂”的人造球形砂产品,并有企业申请专利,例如:专利公开号为CN106862479A的专利文献公开一种用于铸造造型材料的宝珠砂的制备方法:将Al2O3质量分数在60%以上的铝矿加入到电弧炉中加热到2000℃以上熔融,对电弧炉中流出的熔融液体施加空气压,将液体原料破碎冷却,最后根据粒径对宝珠砂进行筛分得到宝珠砂产品。这种制备方法得到的宝珠砂产品球形度好、耐火度高,但缺点也十分明显,不仅能耗大,污染重,还对铝矾土的品位要求很高。近年来,国内开始有一些厂家开始将烧结陶粒运用于铸造造型材料,例如:山东金刚新材料股份有限公司生产的焦宝石陶瓷砂。也有一批企业和科研院所申请一部分专利,例如:专利公开号为CN107324781A的专利文献公开一种用于铸造造型材料的陶瓷砂,其主要原料为三级铝矾土和高岭土,采用雾化造粒和高温烧结的制备方法制备。其优点是采用低品位三级铝矾土和高岭土作为原材料,烧结温度较低,节约资源,降低生产成本。但其缺点也十分明显,因为陶瓷砂含铝量低,耐火度较差,不能用于高熔点铸件的生产。为了提高陶瓷砂的耐火度,专利公开号为CN107298584A的专利文献公开一种含铝量相对较高的陶瓷砂,但烧结温度高达1550℃~1700℃,烧结时间为3.5~5.0小时,烧结温度过高,保温时间过长,不但浪费能源,增加成本,而且这种陶瓷砂依然完全依赖高品位的铝矾土矿石。因此,设计一种能实现废弃物再利用、减少优质原料的使用量且性能优异、低成本的铸造用陶瓷砂的制备方法是造型材料领域的重要发展方向。
发明内容
针对现有铸造用陶瓷砂领域存在的技术问题,本发明的目的是提供一种人造球形陶瓷复合砂的制备方法,为了能够制备一种能实现废弃物再利用、减少优质原料的使用量且性能优异、低成本的铸造用陶瓷复合砂来取代单一结构的陶瓷砂,满足铸造实际生产的需要。
为了实现本发明的目的,采用的技术方案是:
一种人造球形陶瓷复合砂的制备方法,采用滚动造粒法造粒,经回转窑烧结,制备步骤如下:
(1)配料:在内核原料中添加占内核原料重量3~5%的粘结剂,放入球磨机中干磨1~3h进行充分混合,取出作为用来制备陶瓷复合砂的内核原料;
(2)制粉:将外层原料粉末、粘结剂和助烧剂加入到球磨机中,加入水,湿磨至D50≤13μm的粉末,取出烘干、破碎后作为制备陶瓷复合砂的外层原料;
(3)造粒:将陶瓷复合砂的内核原料加入圆锅式造粒机中,调整转速为20~40r/min,利用雾化喷壶在物料转动过程中加入雾化水形成生球,当大部分生球粒径达到120~180μm时,加入细粒径的外层原料粉末,待生球粒径达到150~380μm时停机取出,获得陶瓷复合砂生球,总加水量为陶瓷复合砂生球总重量的15~20%,造粒时间为1~3h;
(4)筛分分级:将造粒所得的陶瓷复合砂生球用筛网进行筛分,去除粒径过大的部分和粒径过小的部分;
(5)烘干:将合格的陶瓷复合砂生球放置在干燥箱中烘干,干燥至恒重,干燥温度为100~200℃,干燥时间0.5~2h;
(6)烧结:将干燥后的陶瓷复合砂生球放在回转窑中进行烧结,烧结温度为1250℃~1500℃,烧结时间为1~5h,随后冷却至室温;
(7)擦洗:将烧结得到的陶瓷复合砂放置在擦洗设备中经过0.5~2h的擦洗,去除陶瓷复合砂表面的毛刺和附着的固体小颗粒粉末;
(8)筛分分级:将擦洗后的陶瓷复合砂进行筛分,得到不同粒度规格的成品陶瓷复合砂。
所述的人造球形陶瓷复合砂的制备方法,陶瓷复合砂的结构主要为“内核+外层”双层结构,内核采用较粗粒径的主要粉料为:低品位铝矾土、低品位焦宝石、镍尾矿矿渣、粉煤灰中的一种或两种以上,外层采用较细粒径的主要粉料为:高品位焦宝石、高品位铝矾土、刚玉粉中的一种或两种以上;其中,内核粉料的粒径要求为D50≤25μm,外层粉料的粒径要求为D50≤13μm;低品位铝矾土、低品位焦宝石、高品位焦宝石、高品位铝矾土的主要技术指标分别为:Al2O3<40wt%、Al2O3<38wt%、Al2O3≥60wt%、Al2O3≥46wt%。
所述的人造球形陶瓷复合砂的制备方法,优选的,步骤(1)中,内核粉料中的粘结剂为膨润土,膨润土占内核原料重量的5%。
所述的人造球形陶瓷复合砂的制备方法,步骤(2)中,外层粉料中的粘结剂为膨润土,外层粉料中的助烧剂为MgO和钙长石;按重量百分比计,外层粉料的成分含量如下:高品位焦宝石、高品位铝矾土、刚玉粉中的一种或两种以上80~90%,膨润土1~5%,MgO 1~5%,钙长石1~10%。
所述的人造球形陶瓷复合砂的制备方法,优选的,MgO 2%,钙长石10%。
所述的人造球形陶瓷复合砂的制备方法,步骤(2)中,按重量比,球:水:物料=1.5:1:1,湿磨3~5h后取出。
所述的人造球形陶瓷复合砂的制备方法,优选的,步骤(3)中,转速为30r/min,总加水量为陶瓷复合砂生球总重量的20%,造粒时间为2h。
所述的人造球形陶瓷复合砂的制备方法,步骤(4)中,将粒径大于380μm的部分破碎后重新造粒,粒径小于109μm的部分作为“引子”直接用于下一次造粒过程。
所述的人造球形陶瓷复合砂的制备方法,优选的,步骤(6)中,烧结温度为1300~1350℃,烧结时间为3~4h。
所述的人造球形陶瓷复合砂的制备方法,滚动造粒法造粒分为两步:第一步造内核成球结构;第二步在表面包裹外层粉料。
与现有的制备方法与工艺相比,本发明具有如下优点及有益效果:
1、本发明的陶瓷复合砂制备方法是在现有陶瓷砂制备方法体系的基础上提出双层复合型结构陶瓷砂的制备工艺,相对于现有单一结构的陶瓷砂,陶瓷复合砂的内核采用的废弃物资源,实现废弃物的再利用,减少对环境的污染,其外壳材料采用优质原料,提高性能,并添加适量的助烧剂,在提高陶瓷复合砂的耐火度(其耐火度可达到1700℃以上)和改善表面形貌的同时降低烧结温度。
2、本发明的陶瓷复合砂制备方法制得的陶瓷复合砂的堆积密度仅为1.4~1.6g/cm3,相比于单一结构陶瓷砂,密度得到进一步下降,且其性能优异,再生效果好,可广泛用于有色合金铸件、铸铁件和铸钢件的生产。
3、本发明制备方法可实现具有双层结构的陶瓷复合砂的成功制备,这种制备方法制备的陶瓷复合砂不仅减少高性能但价格昂贵的原料的用量,还让原本难以利用的废弃物资源得到很好的使用,在保证陶瓷砂使用性能的同时降低生产成本,更做到节约资源、保护环境。这种陶瓷复合砂具有较低的密度和热膨胀系数,较好的球形度,表面光滑,可减少树脂加入量,减少发气量,有较高耐火度和较低的破碎率。
附图说明
图1为陶瓷复合砂的结构示意图。其中,(a)为外形图,(b)为剖面图。
具体实施方式
下面,通过实施例对本发明进一步详细阐述。
实施例1:
本实例中,陶瓷复合砂的内核原料为镍尾矿矿渣粉料,外层为二级乙等铝矾土,化学成分重量百分比如下:Al2O3:60%,SiO2:30%,其它物质:余量,MgO加入量为1wt%,钙长石加入量为6wt%,内核粉料的粒径要求为D50≤25μm,外层粉料的粒径要求为D50≤13μm。
所述陶瓷复合砂的具体制备过程,包括以下步骤:
(1)配料:在镍尾矿矿渣粉料中添加膨润土,膨润土占粉料重量的5%,放入球磨机中干磨2h进行充分混合,取出作为用来制备陶瓷复合砂的内核原料;
(2)制粉:将物料二级乙等铝矾土粉末、膨润土、MgO和钙长石按重量比90:3:1:6加入到球磨机中,加入水,按重量比,球:水:物料=1.5:1:1,湿磨4h后,取出烘干、破碎成粒径为D50≤13μm的铝矾土粉末;
(3)造粒:将陶瓷复合砂的内核原料加入圆锅式造粒机中,将转速调整至40r/min,利用雾化喷壶在物料转动过程中加入雾化水形成生球,当60wt%以上生球的粒径达到150μm左右时,加入细粒径的铝矾土粉末,待生球粒径达到212μm左右时停机取出,获得陶瓷复合砂生球,总加水量为陶瓷复合砂生球总重量的15%,造粒时间为1h;
(4)筛分分级:将造粒所得的陶瓷复合砂生球用筛网进行筛分,将粒径大于380μm的部分破碎后重新造粒,粒径小于109μm的部分作为“引子”直接用于下一次造粒过程;
(5)烘干:将合格的陶瓷复合砂生球放置在干燥箱中烘干,干燥至恒重,干燥温度为150℃,干燥时间为1h。
(6)烧结:将干燥后的陶瓷复合砂生球放在回转窑中进行烧结,烧结温度为1250℃,烧结时间为5h,随后冷却至室温;
(7)擦洗:将烧结得到的陶瓷复合砂放置在擦洗设备中擦洗1h,去除陶瓷复合砂表面的毛刺和附着的固体小颗粒粉末;
(8)筛分分级:将擦洗后的陶瓷复合砂进行筛分,得到不同粒度规格的成品陶瓷复合砂。
本实施例中,测得人造球形铸造用砂——陶瓷复合砂的性能指标达到如下:
表1本发明产品的性能指标
名称 | 角形系数 | 耐火度 | 堆积密度 | 热膨胀系数 | 灼烧减量 |
陶瓷复合砂 | 接近于1 | >1700℃ | 1.40~1.50g/cm<sup>3</sup> | 4.5~5.0×10<sup>-6</sup>/K | <0.1wt% |
实施例2:
本实例中,陶瓷复合砂的内核原料为粉煤灰粉料,外层为二级甲级铝矾土,铝矾土化学成分重量百分比如下:Al2O3:65%,SiO2:28%,其它物质:余量,MgO加入量为2wt%,钙长石加入量为8wt%,内核粉料的粒径要求为D50≤25μm,外层粉料的粒径要求为D50≤13μm。
所述陶瓷复合砂的具体制备过程,包括以下步骤:
(1)配料:在粉煤灰粉料中添加膨润土,膨润土占粉料重量的5%,放入球磨机中干磨2h进行充分混合,取出作为用来制备陶瓷复合砂的内核原料;
(2)制粉:将物料铝矾土粉末、膨润土、MgO和钙长石按重量比86:4:2:8加入到球磨机中,加入水,按重量比,球:水:物料=1.5:1:1,湿磨4h后,取出烘干、破碎成粒径为D50≤13μm的铝矾土粉末;
(3)造粒:将陶瓷复合砂的内核原料加入圆锅式造粒机中,将转速调整至35r/min,利用雾化喷壶在物料转动过程中加入雾化水形成生球,当60wt%以上生球的粒径达到150μm左右时,加入细粒径的铝矾土粉末,待生球粒径达到212μm左右时停机取出,获得陶瓷复合砂生球,总加水量为陶瓷复合砂生球总重量的18%,造粒时间为2h;
(4)筛分分级:将造粒所得的陶瓷复合砂生球用筛网进行筛分,将粒径大于380μm的部分破碎后重新造粒,粒径小于109μm的部分作为“引子”直接用于下一次造粒过程;
(5)烘干:将合格的陶瓷复合砂生球放置在干燥箱中烘干,干燥至恒重,干燥温度为150℃,干燥时间为1h。
(6)烧结:将干燥后的陶瓷复合砂生球放在回转窑中进行烧结,烧结温度为1300℃,烧结时间为2h,随后冷却至室温;
(7)擦洗:将烧结得到的陶瓷复合砂放置在擦洗设备中擦洗1h,去除陶瓷复合砂表面的毛刺和附着的固体小颗粒粉末;
(8)筛分分级:将擦洗后的陶瓷复合砂进行筛分,得到不同粒度规格的成品陶瓷复合砂。
本实施例中,测得人造球形铸造用砂——陶瓷复合砂的性能指标达到如下:
表2本发明产品的性能指标
名称 | 角形系数 | 耐火度 | 堆积密度 | 热膨胀系数 | 灼烧减量 |
陶瓷复合砂 | 接近于1 | >1750℃ | 1.40~1.50g/cm<sup>3</sup> | 4.5~5.0×10<sup>-6</sup>/K | <0.1wt% |
实施例3:
本实例中,陶瓷复合砂的内核原料为低品位(Al2O3≤45wt%)铝矾土,外壳为一级铝矾土,化学成分重量百分比如下:Al2O3:72%,SiO2:20%,其它物质:余量,MgO加入量为2wt%,钙长石加入量为10wt%,内核粉料的粒径要求为D50≤25μm,外层粉料的粒径要求为D50≤13μm。
所述陶瓷复合砂的具体制备过程,包括以下步骤:
(1)配料:在低品位铝矾土粉料中添加膨润土,膨润土占粉料重量的5%,放入球磨机中干磨2h进行充分混合,取出作为用来制备陶瓷复合砂的内核原料;
(2)制粉:将物料一级铝矾土粉末、膨润土、MgO和钙长石按重量比85:3:2:10加入到球磨机中,加入水,按重量比,球:水:物料=1.5:1:1,湿磨4h后,取出烘干、破碎成粒径为D50≤13μm的铝矾土粉末;
(3)造粒:将陶瓷复合砂的内核原料加入圆锅式造粒机中,将转速调整至30r/min,利用雾化喷壶在物料转动过程中加入雾化水形成生球,当60wt%以上生球的粒径达到150μm左右时,加入细粒径的铝矾土粉末,待生球粒径达到212μm左右时停机取出,获得陶瓷复合砂生球,总加水量为陶瓷复合砂生球总重量的20%,造粒时间为2h;
(4)筛分分级:将造粒所得的陶瓷砂生球用筛网进行筛分,将粒径大于380μm的部分破碎后重新造粒,粒径小于109μm的部分作为“引子”直接用于下一次造粒过程;
(5)烘干:将合格的陶瓷复合砂生球放置在干燥箱中烘干,干燥至恒重,干燥温度为150℃,干燥时间为1h。
(6)烧结:将干燥后的陶瓷复合砂生球放在回转窑中进行烧结,烧结温度为1350℃,烧结时间为3h,随后冷却至室温;
(7)擦洗:将烧结得到的陶瓷复合砂放置在擦洗设备中擦洗1h,去除陶瓷复合砂表面的毛刺和附着的固体小颗粒粉末;
(8)筛分分级:将擦洗后的陶瓷复合砂进行筛分,得到不同粒度规格的成品陶瓷复合砂。
本实施例中,测得人造球形铸造用砂——陶瓷复合砂的性能指标达到如下:
表3本发明产品的性能指标
名称 | 角形系数 | 耐火度 | 堆积密度 | 热膨胀系数 | 灼烧减量 |
陶瓷复合砂 | 接近于1 | >1800℃ | 1.40~1.50g/cm<sup>3</sup> | 4.5~5.0×10<sup>-6</sup>/K | <0.1wt% |
实施例4:
本实例中,陶瓷复合砂的内层原料为粉煤灰+低品位(Al2O3≤38wt%)焦宝石,外壳为特级铝矾土,化学成分重量百分比如下:Al2O3:80%,SiO2:15%,其它物质:余量,MgO加入量为3wt%,钙长石加入量为10wt%,内层粉料的粒径要求为D50≤25μm,外层粉料的粒径要求为D50≤13μm。
所述陶瓷复合砂的具体制备过程,包括以下步骤:
(1)配料:在重量比为1:1的粉煤灰和低品位焦宝石粉料中添加膨润土,膨润土占粉料重量的5%,放入球磨机中干磨2h进行充分混合,取出作为用来制备陶瓷复合砂的内核原料;
(2)制粉:将物料特级铝矾土粉末、膨润土、MgO和钙长石按重量比82:5:3:10加入到球磨机中,加入水,按重量比,球:水:物料=1.5:1:1,湿磨4h后,取出烘干、破碎成粒径为D50≤13μm的铝矾土粉末;
(3)造粒:将陶瓷复合砂的内核原料加入圆锅式造粒机中,将转速调整至35r/min,利用雾化喷壶在物料转动过程中加入雾化水形成生球,当60wt%以上生球的粒径达到150μm左右时,加入细粒径的铝矾土粉末,待生球粒径达到212μm左右时停机取出,获得陶瓷复合砂生球,总加水量为陶瓷复合砂生球总重量的25%,造粒时间为2h;
(4)筛分分级:将造粒所得的陶瓷复合砂生球用筛网进行筛分,将粒径大于380μm的部分破碎后重新造粒,粒径小于109μm的部分作为“引子”直接用于下一次造粒过程;
(5)烘干:将合格的陶瓷复合砂生球放置在干燥箱中烘干,干燥至恒重,干燥温度为150℃,干燥时间为1h。
(6)烧结:将干燥后的陶瓷复合砂生球放在回转窑中进行烧结,烧结温度为1400℃,烧结时间为4h,随后冷却至室温;
(7)擦洗:将烧结得到的陶瓷复合砂放置在擦洗设备中擦洗1h,去除陶瓷复合砂表面的毛刺和附着的固体小颗粒粉末;
(8)筛分分级:将擦洗后的陶瓷复合砂进行筛分,得到不同粒度规格的成品陶瓷复合砂。
本实施例中,测得人造球形铸造用砂——陶瓷复合砂的性能指标达到如下:
表4本发明产品的性能指标
名称 | 角形系数 | 耐火度 | 堆积密度 | 热膨胀系数 | 灼烧减量 |
陶瓷复合砂 | 接近于1 | >1840℃ | 1.40~1.50g/cm<sup>3</sup> | 4.5~5.0×10<sup>-6</sup>/K | <0.1wt% |
如图1所示,陶瓷复合砂的结构主要分为内外两层,内核为较粗粒径(D50≤25μm)的低品位焦宝石或铝矾土、镍尾矿矿渣或粉煤灰等性能一般的粉料,外层为较细粒径(D50≤13μm)的高品位焦宝石或铝矾土、刚玉粉等性能优异的粉料,并添加适量的MgO、钙长石等助烧剂,来降低陶瓷砂的烧结温度和改善陶瓷砂表面形貌,在保证陶瓷砂性能的同时兼顾经济性。采用配料—球磨—造粒—烧结—筛分级配的制备工艺进行制备陶瓷复合砂,所得陶瓷复合砂的开放式孔洞少、表面光洁度好,耐火度高,破碎率低,可广泛用于有色合金铸件、铸铁件和铸钢件的生产。陶瓷复合砂的双层结构设计,不仅较单一结构的陶瓷砂性能更优还降低成本,兼顾经济性。
以上所述仅为本发明的实施例,并不限制本发明,凡采用同等替换或等效变换的方式所获得的技术方案,均落在本发明的保护范围内。
Claims (7)
1.一种人造球形陶瓷复合砂的制备方法,其特征是,采用滚动造粒法造粒,经回转窑烧结,制备步骤如下:
(1)配料:在内核原料中添加占内核原料重量3~5%的粘结剂,放入球磨机中干磨1~3h进行充分混合,取出作为用来制备陶瓷复合砂的内核原料;
(2)制粉:将外层原料粉末、粘结剂和助烧剂加入到球磨机中,加入水,湿磨至D50≤13μm的粉末,取出烘干、破碎后作为制备陶瓷复合砂的外层原料;
(3)造粒:将陶瓷复合砂的内核原料加入圆锅式造粒机中,调整转速为20~40r/min,利用雾化喷壶在物料转动过程中加入雾化水形成生球,当大部分生球粒径达到120~180μm时,加入细粒径的外层原料粉末,待生球粒径达到150~380μm时停机取出,获得陶瓷复合砂生球,总加水量为陶瓷复合砂生球总重量的15~20%,造粒时间为1~3h;
(4)筛分分级:将造粒所得的陶瓷复合砂生球用筛网进行筛分,去除粒径过大的部分和粒径过小的部分;
(5)烘干:将合格的陶瓷复合砂生球放置在干燥箱中烘干,干燥至恒重,干燥温度为100~200℃,干燥时间0.5~2h;
(6)烧结:将干燥后的陶瓷复合砂生球放在回转窑中进行烧结,烧结温度为1250℃~1500℃,烧结时间为1~5h,随后冷却至室温;
(7)擦洗:将烧结得到的陶瓷复合砂放置在擦洗设备中经过0.5~2h的擦洗,去除陶瓷复合砂表面的毛刺和附着的固体小颗粒粉末;
(8)筛分分级:将擦洗后的陶瓷复合砂进行筛分,得到不同粒度规格的成品陶瓷复合砂;
陶瓷复合砂的结构主要为“内核+外层”双层结构,内核采用较粗粒径的主要粉料为:低品位铝矾土、低品位焦宝石、镍尾矿矿渣、粉煤灰中的一种或两种以上,外层采用较细粒径的主要粉料为:高品位焦宝石、高品位铝矾土、刚玉粉中的一种或两种以上;其中,内核粉料的粒径要求为D50≤25μm,外层粉料的粒径要求为D50≤13μm;低品位铝矾土、低品位焦宝石、高品位焦宝石、高品位铝矾土的主要技术指标分别为:Al2O3<40wt%、Al2O3<38wt%、Al2O3≥60wt%、Al2O3≥46wt%;
步骤(1)中,内核粉料中的粘结剂为膨润土,膨润土占内核原料重量的5%;
步骤(2)中,外层粉料中的粘结剂为膨润土,外层粉料中的助烧剂为MgO和钙长石;按重量百分比计,外层粉料的成分含量如下:高品位焦宝石、高品位铝矾土、刚玉粉中的一种或两种以上80~90%,膨润土1~5%,MgO 1~5%,钙长石 1~10%。
2.按照权利要求1所述的人造球形陶瓷复合砂的制备方法,其特征是,MgO 2%,钙长石10%。
3.按照权利要求1所述的人造球形陶瓷复合砂的制备方法,其特征是,步骤(2)中,按重量比,球:水:物料=1.5:1:1,湿磨3~5h后取出。
4.按照权利要求1所述的人造球形陶瓷复合砂的制备方法,其特征是,步骤(3)中,转速为30r/min,总加水量为陶瓷复合砂生球总重量的20%,造粒时间为2h。
5.按照权利要求1所述的人造球形陶瓷复合砂的制备方法,其特征是,步骤(4)中,将粒径大于380μm的部分破碎后重新造粒,粒径小于109μm的部分作为“引子”直接用于下一次造粒过程。
6.按照权利要求1所述的人造球形陶瓷复合砂的制备方法,其特征是,步骤(6)中,烧结温度为1300~1350℃,烧结时间为3~4h。
7.按照权利要求1所述的人造球形陶瓷复合砂的制备方法,其特征是,滚动造粒法造粒分为两步:第一步造内核成球结构;第二步在表面包裹外层粉料。
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