CN111517766A - 多孔陶瓷过滤板制造方法 - Google Patents
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Abstract
本发明涉及陶瓷过滤机技术领域,且公开了多孔陶瓷过滤板制造方法,包括以下步骤,准备去离子水100份,异丙醇铝分析纯1‑3份,纳米氧化铝粉2‑4份,10%HNO3溶液化学纯0.1‑0.5份,纳米陶瓷膜的原料组份中加入有机粘结剂聚乙烯醇。该多孔陶瓷过滤板制造方法,通过采用了优质电熔刚玉骨料和高纯纳米氧化铝微粉为配方主要组份,加入二氧化钛等作矿化剂和Y‑氧化铝或有机物做成孔剂,使得过滤板不仅具有较为理想的气孔率,合适的微孔孔径,较好的强度,而且还可以耐低含量的氢氟酸和PH值8~14的工作介质,从而可以提供一种能使用氢氟酸和强碱清洗且能用于含少量氢氟酸(<0.2g/l)的矿浆脱水过滤用的陶瓷过滤板,这是其它陶瓷过滤板所不能达到的。
Description
技术领域
本发明涉及陶瓷过滤机技术领域,具体为一种多孔陶瓷过滤板制造方法。
背景技术
陶瓷过滤机是一种新型、高效、节能的固液分离设备,主要由陶瓷过滤板、辊筒***、搅拌***、给排矿***、真空***、滤液排放***、刮料***、反冲洗***、联合清洗(超声波清洗、自动配酸清洗)***、全自动控制***、槽体和机架几部分组成。
作为过滤介质,陶瓷过滤机的陶瓷过滤板在使用过程中微孔会被堵塞,引起陶瓷过滤板堵塞的因素很多,其中最主要的因素之一是矿浆中含有的微细颗粒,会随着过滤的过程而进入陶瓷膜的过滤孔道中,从而引起陶瓷过滤板过滤能力大幅下降,为防止陶瓷过滤板过滤能力减弱,陶瓷过滤机会对它进行周期性地化学清洗及超声清洗,使它恢复到较高的过滤水平,但是,这个清洗不是彻底的,仍会有少部分的物质残留,所以随着堵塞物的积累,会将陶瓷板彻底堵死而报废,现有陶瓷过滤板均使用微米级陶瓷过滤膜,矿浆中的微细颗粒极易进入陶瓷膜的孔道中,从而引起上述的堵塞过程,一方面会严重影响陶瓷过滤板的使用寿命,现有陶瓷板平均的使用寿命为一年左右,另一方面限制了陶瓷板的使用领域,对一些颗粒度较细的矿浆,微米级的陶瓷膜就无法适用,故而提出一种多孔陶瓷过滤板制造方法来解决上述所提出的问题。
发明内容
(一)解决的技术问题
针对现有技术的不足,本发明提供了一种多孔陶瓷过滤板制造方法,具备在多孔陶瓷过滤板表面涂覆纳米陶瓷过滤膜,有效阻挡了矿浆中绝大部份细小颗粒,陶瓷板不易被堵塞,延长了陶瓷板的使用寿命,拓宽了陶瓷过滤机的优点,解决了清洗不是彻底的,仍会有少部分的物质残留,所以随着堵塞物的积累,会将陶瓷板彻底堵死而报废,现有陶瓷过滤板均使用微米级陶瓷过滤膜,矿浆中的微细颗粒极易进入陶瓷膜的孔道中,从而引起上述的堵塞过程,一方面会严重影响陶瓷过滤板的使用寿命,现有陶瓷板平均的使用寿命为一年左右,另一方面限制了陶瓷板的使用领域,对一些颗粒度较细的矿浆,微米级的陶瓷膜就无法适用的问题。
(二)技术方案
为实现上述在多孔陶瓷过滤板表面涂覆纳米陶瓷过滤膜,有效阻挡了矿浆中绝大部份细小颗粒,陶瓷板不易被堵塞,延长了陶瓷板的使用寿命,拓宽了陶瓷过滤机的目的,本发明提供如下技术方案:多孔陶瓷过滤板制造方法,包括以下步骤:
1)准备去离子水100份,异丙醇铝分析纯1-3份,纳米氧化铝粉2-4份,10%HNO3溶液化学纯0.1-0.5份,纳米陶瓷膜的原料组份中加入有机粘结剂聚乙烯醇,以100份去离子水为基准,聚乙烯醇的加入量为0.05-0.15份,按上述的配比将异丙醇铝水解后用10%HNO3溶液进行胶溶,然后回流老化形成铝溶胶,在铝溶胶中加入纳米氧化铝粉进行混合、分散,形成均匀一致的纳米膜凝胶,采用浸渍提拉法将纳米膜凝胶均匀涂覆于基板表面,经干燥、烧成而成;
2)铝盐的水解,将去离子水加热至80-90C,恒温加入异丙醇铝,磁力搅拌1.5h以上后静止,慢慢形成沉淀,胶溶,升温至85-95"C,挥发异丙醇后,恒温加入10%HNO3溶液作为胶溶剂,使沉淀重新分散,回流老化,把溶液倒入回流装置,在85~95'C下回流老化大于24h,储存备用;
3)基板的组份及重量配比为,电熔刚玉120目,Al2O3≥99%(60-70%),氧化铝粉60~400nm,Al2O3≥99.9%(7-15%),外加有机结合剂0.25~0.5%,水25~40%,陶瓷过滤膜的组份及重量配比为,电熔刚玉1~5um,Al2O3≥99.2%(60-73%),氧化铝粉60~400nm,Al2O3≥99.9%(7-13%),无硅成孔剂1~5um(0-10%),无硅陶瓷原料矿化剂≤44um(17-30%),外加有机结合剂0.25~0.5%,水25~40%;
4)按配比将原料混合均匀,压制成过滤板单片,干燥、粘合成中空结构,然后进入窑内进行烧成,烧成温度为1400~1580C,烧成后的基板经平面加工到要求尺寸,将步骤2)制成的胶溶剂涂覆在基板表面,100C以下干燥后,然后经1200C~1500C左右烧成,封接装配得成品,陶瓷过滤膜原料的混合采用球磨机磨6-8小时,涂覆在基板上的陶瓷膜厚0.1-0.4mm。
优选的,所述通过蒸发或加水改变铝溶胶浓度,即调节料液呈固含量为4~5%的可均匀分散的体系。
优选的,所述通过蒸发或加水改变铝溶胶浓度,即调节料液呈固含量为4~5%的可均匀分散的体系。
优选的,所述在纳米膜凝胶中加入PVA溶液,超声波分散2h以上,再用磁力搅拌器搅拌2h以上。
优选的,所述浸渍提拉法镀膜是:除去基板表面污染物,保持浸溃面的平整光滑和洁净,加入少量乙醇除去浆料中的气泡,再把基板浸入浆料中,浸渍一定时间后缓慢取出。
优选的,所述镀膜后制品的干燥是将制品于恒温40°C干燥6h以上,再升温至100C干燥2h以上。
优选的,所述干燥的制品进行烧成为将制品置于窑炉中,5-8小时内升温至450"C,然后在8-11小时升温至1200-1400C,保温2至3h,自然冷却至室温。
优选的,所述无硅陶瓷原料矿化剂是二氧化钛、碳酸盐、氟化镁的一种或几种组合,无硅成孔剂是γ-氧化铝或碳粉或组合,无硅成孔剂是Al2O3≥99.5%的Y-氧化铝,Y-氧化铝的加入量为5-10%,有机结合剂是糊精或PVA。
(三)有益效果
与现有技术相比,本发明提供了一种多孔陶瓷过滤板制造方法,具备以下有益效果:
该多孔陶瓷过滤板制造方法,通过采用了优质电熔刚玉骨料和高纯纳米氧化铝微粉为配方主要组份,加入二氧化钛等作矿化剂,还加入了Y-氧化铝或有机物做成孔剂,使得过滤板不仅具有较为理想的气孔率(30~50%),合适的微孔孔径(约2μm),较好的强度(30~50MPa),而且还可以耐低含量的氢氟酸(浓度<0.2g/1)和PH值8~14的工作介质,从而可以提供一种能使用氢氟酸和强碱清洗且能用于含少量氢氟酸(<0.2g/l)的矿浆脱水过滤用的陶瓷过滤板,这是其它陶瓷过滤板所不能达到的。
具体实施方式
下面将结合本发明的实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例一:
1)准备去离子水100份,异丙醇铝分析纯1-3份,纳米氧化铝粉2-4份,10%HNO3溶液化学纯0.1-0.5份,纳米陶瓷膜的原料组份中加入有机粘结剂聚乙烯醇,以100份去离子水为基准,聚乙烯醇的加入量为0.05-0.15份,按上述的配比将异丙醇铝水解后用10%HNO3溶液进行胶溶,然后回流老化形成铝溶胶,在铝溶胶中加入纳米氧化铝粉进行混合、分散,形成均匀一致的纳米膜凝胶,采用浸渍提拉法将纳米膜凝胶均匀涂覆于基板表面,经干燥、烧成而成;
2)铝盐的水解,将去离子水加热至80-90C,恒温加入异丙醇铝,磁力搅拌1.5h以上后静止,慢慢形成沉淀,胶溶,升温至85-95"C,挥发异丙醇后,恒温加入10%HNO3溶液作为胶溶剂,使沉淀重新分散,回流老化,把溶液倒入回流装置,在85~95'C下回流老化大于24h,储存备用;
3)基板的组份及重量配比为,电熔刚玉100目,Al2O3≥99%(65%),氧化铝粉60~400nm,Al2O3≥99.9%(15%),外加碳酸钡4份,氯化镁4份,0.2份糊精,水1.8份,陶瓷过滤膜的组份及重量配比为,电熔刚玉1~5um,Al2O3≥99.2%(60-73%),氧化铝粉60~400nm,Al2O3≥99.9%(7-13%),无硅成孔剂1~5um(0-10%),无硅陶瓷原料矿化剂≤44um(17-30%),外加有机结合剂0.25~0.5%,水25~40%;
4)按配比将原料混合均匀,压制成过滤板单片,干燥、粘合成中空结构,然后进入窑内进行烧成,烧成温度为1400~1580C,烧成后的基板经平面加工到要求尺寸,将步骤2)制成的胶溶剂涂覆在基板表面,100C以下干燥后,然后经1200C~1500C左右烧成,封接装配得成品,陶瓷过滤膜原料的混合采用球磨机磨6-8小时,涂覆在基板上的陶瓷膜厚0.1-0.4mm。
经充分混合后,压制成型为过滤单片,坯体经烘干后粘合成具有中空结构的过滤板基板,在1400C-1580C烧成,机械加工到所需尺寸。
实施例二:
1)准备去离子水100份,异丙醇铝分析纯1-3份,纳米氧化铝粉2-4份,10%HNO3溶液化学纯0.1-0.5份,纳米陶瓷膜的原料组份中加入有机粘结剂聚乙烯醇,以100份去离子水为基准,聚乙烯醇的加入量为0.05-0.15份,按上述的配比将异丙醇铝水解后用10%HNO3溶液进行胶溶,然后回流老化形成铝溶胶,在铝溶胶中加入纳米氧化铝粉进行混合、分散,形成均匀一致的纳米膜凝胶,采用浸渍提拉法将纳米膜凝胶均匀涂覆于基板表面,经干燥、烧成而成;
2)铝盐的水解,将去离子水加热至80-90C,恒温加入异丙醇铝,磁力搅拌1.5h以上后静止,慢慢形成沉淀,胶溶,升温至85-95"C,挥发异丙醇后,恒温加入10%HNO3溶液作为胶溶剂,使沉淀重新分散,回流老化,把溶液倒入回流装置,在85~95'C下回流老化大于24h,储存备用;
3)基板的组份及重量配比为,电熔刚玉65目,Al2O3≥99%(63%),氧化铝粉60~400nm,Al2O3≥99.9%(10%),外加纳米氧化铝8份,二氧化钛12份,碳酸钡7份,水32份,陶瓷过滤膜的组份及重量配比为,电熔刚玉1~5um,Al2O3≥99.2%(60-73%),氧化铝粉60~400nm,Al2O3≥99.9%(7-13%),无硅成孔剂1~5um(0-10%),无硅陶瓷原料矿化剂≤44um(17-30%),外加有机结合剂0.25~0.5%,水25~40%;
4)按配比将原料混合均匀,压制成过滤板单片,干燥、粘合成中空结构,然后进入窑内进行烧成,烧成温度为1400~1580C,烧成后的基板经平面加工到要求尺寸,将步骤2)制成的胶溶剂涂覆在基板表面,100C以下干燥后,然后经1200C~1500C左右烧成,封接装配得成品,陶瓷过滤膜原料的混合采用球磨机磨6-8小时,涂覆在基板上的陶瓷膜厚0.1-0.4mm。
再加入约0.4份的甲基纤维素,约32份的水,经球磨机混合球磨6-8小时后于基板上均匀涂覆0.1-0.4mm厚的陶瓷膜,经100'C以下烘干后在1200C-1500'C烧成,封接装配而得成品。
实施例三:
1)准备去离子水100份,异丙醇铝分析纯1-3份,纳米氧化铝粉2-4份,10%HNO3溶液化学纯0.1-0.5份,纳米陶瓷膜的原料组份中加入有机粘结剂聚乙烯醇,以100份去离子水为基准,聚乙烯醇的加入量为0.05-0.15份,按上述的配比将异丙醇铝水解后用10%HNO3溶液进行胶溶,然后回流老化形成铝溶胶,在铝溶胶中加入纳米氧化铝粉进行混合、分散,形成均匀一致的纳米膜凝胶,采用浸渍提拉法将纳米膜凝胶均匀涂覆于基板表面,经干燥、烧成而成;
2)铝盐的水解,将去离子水加热至80-90C,恒温加入异丙醇铝,磁力搅拌1.5h以上后静止,慢慢形成沉淀,胶溶,升温至85-95"C,挥发异丙醇后,恒温加入10%HNO3溶液作为胶溶剂,使沉淀重新分散,回流老化,把溶液倒入回流装置,在85~95'C下回流老化大于24h,储存备用;
3)基板的组份及重量配比为,电熔刚玉65目,Al2O3≥99%(60-70%),氧化铝粉60~400nm,Al2O3≥99.9%(7-15%),外加有机结合剂0.25~0.5%,水25~40%,陶瓷过滤膜的组份及重量配比为,电熔刚玉1~5um,Al2O3≥99.2%(60-73%),氧化铝粉60~400nm,Al2O3≥99.9%(7-13%),无硅成孔剂1~5um(0-10%),无硅陶瓷原料矿化剂≤44um(17-30%),外加有机结合剂0.25~0.5%,水25~40%;
4)按配比将原料混合均匀,压制成过滤板单片,干燥、粘合成中空结构,然后进入窑内进行烧成,烧成温度为1400~1580C,烧成后的基板经平面加工到要求尺寸,将步骤2)制成的胶溶剂涂覆在基板表面,100C以下干燥后,然后经1200C~1500C左右烧成,封接装配得成品,陶瓷过滤膜原料的混合采用球磨机磨6-8小时,涂覆在基板上的陶瓷膜厚0.1-0.4mm。
本发明的有益效果是:该多孔陶瓷过滤板制造方法,通过采用了优质电熔刚玉骨料和高纯纳米氧化铝微粉为配方主要组份,加入二氧化钛等作矿化剂,还加入了Y-氧化铝或有机物做成孔剂,使得过滤板不仅具有较为理想的气孔率(30~50%),合适的微孔孔径(约2μm),较好的强度(30~50MPa),而且还可以耐低含量的氢氟酸(浓度<0.2g/1)和PH值8~14的工作介质,从而可以提供一种能使用氢氟酸和强碱清洗且能用于含少量氢氟酸(<0.2g/l)的矿浆脱水过滤用的陶瓷过滤板,这是其它陶瓷过滤板所不能达到的。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (8)
1.多孔陶瓷过滤板制造方法,其特征在于,包括以下步骤:
1)准备去离子水100份,异丙醇铝分析纯1-3份,纳米氧化铝粉2-4份,10%HNO3溶液化学纯0.1-0.5份,纳米陶瓷膜的原料组份中加入有机粘结剂聚乙烯醇,以100份去离子水为基准,聚乙烯醇的加入量为0.05-0.15份,按上述的配比将异丙醇铝水解后用10%HNO3溶液进行胶溶,然后回流老化形成铝溶胶,在铝溶胶中加入纳米氧化铝粉进行混合、分散,形成均匀一致的纳米膜凝胶,采用浸渍提拉法将纳米膜凝胶均匀涂覆于基板表面,经干燥、烧成而成;
2)铝盐的水解,将去离子水加热至80-90C,恒温加入异丙醇铝,磁力搅拌1.5h以上后静止,慢慢形成沉淀,胶溶,升温至85-95"C,挥发异丙醇后,恒温加入10%HNO3溶液作为胶溶剂,使沉淀重新分散,回流老化,把溶液倒入回流装置,在85~95'C下回流老化大于24h,储存备用;
3)基板的组份及重量配比为,电熔刚玉120目,Al2O3≥99%(60-70%),氧化铝粉60~400nm,Al2O3≥99.9%(7-15%),外加有机结合剂0.25~0.5%,水25~40%,陶瓷过滤膜的组份及重量配比为,电熔刚玉1~5um,Al2O3≥99.2%(60-73%),氧化铝粉60~400nm,Al2O3≥99.9%(7-13%),无硅成孔剂1~5um(0-10%),无硅陶瓷原料矿化剂≤44um(17-30%),外加有机结合剂0.25~0.5%,水25~40%;
4)按配比将原料混合均匀,压制成过滤板单片,干燥、粘合成中空结构,然后进入窑内进行烧成,烧成温度为1400~1580C,烧成后的基板经平面加工到要求尺寸,将步骤2)制成的胶溶剂涂覆在基板表面,100C以下干燥后,然后经1200C~1500C左右烧成,封接装配得成品,陶瓷过滤膜原料的混合采用球磨机磨6-8小时,涂覆在基板上的陶瓷膜厚0.1-0.4mm。
2.根据权利要求1所述的多孔陶瓷过滤板制造方法,其特征在于:所述通过蒸发或加水改变铝溶胶浓度,即调节料液呈固含量为4~5%的可均匀分散的体系。
3.根据权利要求2所述的多孔陶瓷过滤板制造方法,其特征在于:所述通过蒸发或加水改变铝溶胶浓度,即调节料液呈固含量为4~5%的可均匀分散的体系。
4.根据权利要求2所述的多孔陶瓷过滤板制造方法,其特征在于:所述在纳米膜凝胶中加入PVA溶液,超声波分散2h以上,再用磁力搅拌器搅拌2h以上。
5.根据权利要求1所述的多孔陶瓷过滤板制造方法,其特征在于:所述浸渍提拉法镀膜是,除去基板表面污染物,保持浸溃面的平整光滑和洁净,加入少量乙醇除去浆料中的气泡,再把基板浸入浆料中,浸渍一定时间后缓慢取出。
6.根据权利要求1所述的多孔陶瓷过滤板制造方法,其特征在于:所述镀膜后制品的干燥是将制品于恒温40°C干燥6h以上,再升温至100C干燥2h以上。
7.根据权利要求1所述的多孔陶瓷过滤板制造方法,其特征在于:所述干燥的制品进行烧成为将制品置于窑炉中,5-8小时内升温至450"C,然后在8-11小时升温至1200-1400C,保温2至3h,自然冷却至室温。
8.根据权利要求1所述的多孔陶瓷过滤板制造方法,其特征在于:所述无硅陶瓷原料矿化剂是二氧化钛、碳酸盐、氟化镁的一种或几种组合,无硅成孔剂是γ-氧化铝或碳粉或组合,无硅成孔剂是Al2O3≥99.5%的Y-氧化铝,Y-氧化铝的加入量为5-10%,有机结合剂是糊精或PVA。
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