CN111995277A

CN111995277A - Tunnel kiln fired concrete aggregate and production method thereof

Info

Publication number: CN111995277A
Application number: CN202010913382.2A
Authority: CN
Inventors: 李国安
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-09-03
Filing date: 2020-09-03
Publication date: 2020-11-27

Abstract

The invention discloses a tunnel kiln baked concrete aggregate and a production method thereof, comprising the steps of preparing shale, coal gangue, peat, clay, sludge and industrial waste residues, and baking the concrete aggregate through seven steps; according to the invention, shale, industrial waste residues, clay, sludge, coal gangue, peat and other raw materials are used for being matched and sintered to generate minerals such as composite aluminate to form the high-strength compact building aggregate, so that the raw materials of a factory are close to the material selection range and can digest and treat the industrial waste residues, thereby being beneficial to environmental protection; the inferior fuel with low calorific value is used as the internal combustion fuel, so that the production cost of the fuel is greatly reduced, and the energy is saved; the construction aggregate is calcined by adopting the tunnel kiln, the process is simple, the production operation is reliable, a stable thermal regulation system is formed by adding a DCS control system, the product quality is stable, the yield is high, the application range to the fuel is wide, the kiln tail waste gas is used for drying, crushing and grinding the raw material, the unit energy consumption is further reduced, the investment is less and the income is high.

Description

Tunnel kiln fired concrete aggregate and production method thereof

Technical Field

The invention relates to the technical field of building materials, in particular to a concrete aggregate fired by a tunnel kiln and a production method thereof.

Background

The artificial building aggregate has been developed in China for more than half a century, the aggregate sintering technical method is mature day by day, and as the artificial lightweight aggregate has the characteristics of light weight, high strength and multiple functions and can absorb a large amount of solid wastes, sludge of rivers, lakes and seas, industrial sludge and domestic sludge in production, the rapid, continuous and healthy development is obtained in the construction of resource-saving type and environment-friendly type and the development of circular economy at present, the artificial building aggregate is produced by reasonably utilizing industrial wastes to replace natural resources to mine and produce sand and stone products, the industrial policy of the circular economy development in China is met, the mining of mine resources is reduced, and the natural environment is protected;

the existing artificial building aggregate has low strength and quality, high investment cost, complex production operation and higher production cost, and the existing production method of the artificial building aggregate is not suitable for countries and regions lacking in building aggregate resources, and has narrow application range, so the invention provides the tunnel kiln fired concrete aggregate and the production method thereof to solve the problems in the prior art.

Disclosure of Invention

In view of the above problems, the present invention aims to provide a tunnel kiln-fired concrete aggregate and a production method thereof, wherein the tunnel kiln-fired concrete aggregate and the artificial building aggregate produced by the production method thereof have high strength and guaranteed quality, are low in investment of factory construction equipment, simple in production operation and low in production cost, and are particularly suitable for construction and popularization of countries and regions where building aggregate resources are scarce and building materials depend on imports.

In order to realize the purpose of the invention, the invention is realized by the following technical scheme: a tunnel kiln burned concrete aggregate and its production method, is made up of shale, coal gangue, peat, clay, mud and industrial drog;

a production method for firing concrete aggregate by a tunnel kiln comprises the following steps:

step one, preparing raw materials:

s1, accumulating, storing and air-drying the industrial waste residue and the shale, respectively crushing the industrial waste residue and the shale, then feeding the crushed industrial waste residue and the shale into a drying mill for grinding, and respectively storing the crushed industrial waste residue and the crushed shale with the fineness of less than 0.1 MM;

s2, stacking, storing and air-drying the clay and the sludge, and conveying and storing the materials with the particle size less than or equal to 1.5mm after crushing and screening by a rotary screen;

s3, stacking, storing and air-drying the coal gangue, peat and coal, crushing the coal gangue, the peat and the coal, wherein the size of crushed particles is less than or equal to 5mm, and stacking and storing the crushed particles respectively;

step two, material preparation and homogenization aging: the prepared materials are proportioned according to the components of the raw materials and the product varieties, then enter a double-shaft stirrer, are added with water, stirred and mixed uniformly, enter a storage through a stacker-reclaimer, are layered, tiled and stacked, and are aged for 24-72 hours;

step three, sagger blank making: molding the ground, piled and aged clay into saggar adobes by a screw extruder under the high-strength pressurizing condition, stacking the saggar adobes on a kiln car by a robot stacker crane, pushing the saggar adobes into a tunnel kiln, sintering and calcining to form a pottery bowl with certain strength;

step four, granulation: extruding and granulating the ground, piled and aged clay by using a screw extruder under a high-strength pressurizing condition to form cylindrical particles with compact interior;

step five, calcining: loading the qualified extruded blank particles prepared in the fourth step into a kiln car, feeding the kiln car into a tunnel kiln, forming a earthenware bowl with certain strength after drying, preheating, decomposing and calcining, returning the earthenware bowl to an outlet of a granulator to bear the qualified extruded blank particles, loading the earthenware bowl into the kiln car, and feeding the earthenware bowl into the tunnel kiln to calcine and synthesize silicate mineral aggregate;

step six, cooling: carrying out heat exchange between the aggregate product in a high-temperature state and a large amount of cold air at the outlet of the tunnel kiln, rapidly cooling, feeding the cooled aggregate into a crusher along with the saggar for crushing, and screening and grading by a screening device;

step seven, screening and packaging: the aggregate is screened and graded by a grading sieve device, and is divided into products with different specifications of 3 mm-10 mm, 10 mm-25 mm, 25 mm-40 mm and 40 mm-50 mm for packaging.

The further improvement lies in that: the air drying degree in the first step is that the air is dried to be below 8% of moisture, high-temperature waste gas at the tail of the kiln is used as a main drying source when the drying is carried out in the step S1, and a fluidized bed furnace capable of burning inferior coal is used as a back-up and supplementary heat source.

The further improvement lies in that: and in the second step, a microcomputer batching scale is adopted for batching, and the material is vertically taken along the stacking section when the material is taken by the material taking machine in the second step.

The further improvement lies in that: and in the third step and the fourth step, under the high-strength pressurizing condition, the sagger adobe is subjected to plastic drawing and extrusion granulation by using the pressure of more than or equal to 8MPa in a vacuum state, the particle size and the length of the extrusion granulation in the fourth step are 10-50 mm in diameter and 10-100 mm in column length according to the product specification required by the market, and the required size is controlled by a shearing machine at the outlet of the extruding machine.

The further improvement lies in that: and fifthly, the temperature gradient of the drying preheating zone is 150-650 ℃, the moisture of the aggregate grain blank is thoroughly dried and evaporated, the temperature is gradually increased to 600-750 ℃, the compounds in the material gradually start to decompose to form a free ion shape, the material is a high-temperature calcining zone when the temperature is increased to 750-1000 ℃, the material forms a molten vitreous humour phase at the temperature, and the composite minerals such as aluminate and the like are sintered and compacted to form the solid granular aggregate product.

The further improvement lies in that: and (5) extracting the hot air generated in the fifth step from an air outlet cover at the upper part of the drying belt, conveying the hot air to a grinding system for preparing the raw materials under the action of a heat-resistant fan under negative pressure by using a pipeline, and discharging the redundant hot flue gas in the high altitude through a flue window after the hot flue gas is subjected to desulfurization and denitrification treatment.

The further improvement lies in that: and the grading sieve in the seventh step adopts a vibrating grading sieve, and the materials with the size of more than 50mm after being sieved in the seventh step are sieved again after being crushed.

The invention has the beneficial effects that: according to the invention, shale, industrial waste residues, clay, sludge, coal gangue, peat and other raw materials are used for being matched and sintered to generate minerals such as composite aluminate to form the high-strength compact building aggregate, so that the raw materials of a factory are close to the material selection range and can digest and treat the industrial waste residues, thereby being beneficial to environmental protection; the inferior fuel with low calorific value is used as the internal combustion fuel, so that the production cost of the fuel is greatly reduced, and the energy is saved; the construction aggregate is calcined by adopting the tunnel kiln, the process is simple, the production operation is reliable, a stable thermal regulation system is formed by adding a DCS control system, the product quality is stable, the yield is high, the application range to the fuel is wide, the kiln tail waste gas is used for drying, crushing and grinding the raw material, the unit energy consumption is further reduced, the investment is less and the income is high.

Drawings

FIG. 1 is a flow chart of the main steps of the present invention.

FIG. 2 is a flow chart of clay treatment according to the present invention.

FIG. 3 is a flow chart of the process of raw coal according to the present invention.

FIG. 4 is a flow chart of industrial waste treatment according to the present invention.

FIG. 5 is a flow chart of the batching and sagger blank making granulation process of the present invention.

FIG. 6 is a flow chart of calcination cooling and screening packages according to the present invention.

Detailed Description

In order to further understand the present invention, the following detailed description will be made with reference to the following examples, which are only used for explaining the present invention and are not to be construed as limiting the scope of the present invention.

Referring to fig. 1, 2, 3, 4, 5 and 6, the present embodiment provides a tunnel kiln burned concrete aggregate and a production method thereof, which is composed of shale, coal gangue, peat, clay, sludge and industrial waste residue;

step one, preparing raw materials:

s1, accumulating, storing and air-drying the industrial waste residue and the shale until the water content is below 8%, crushing the industrial waste residue and the shale respectively, then feeding the crushed industrial waste residue and the shale into a drying mill for grinding, controlling the fineness of the obtained powder to be below 0.1MM, and storing the powder respectively, wherein the high-temperature waste gas at the tail of a kiln is used as a main drying source during drying, and a fluidized bed furnace capable of burning inferior coal is added as a backup and supplementary heat source;

s2, stacking, storing and air-drying the clay and the sludge until the moisture content is below 8%, and conveying and storing the materials with the particle size being less than or equal to 1.5mm after crushing and screening by a rotary screen;

s3, stacking the coal gangue, peat and coal, airing until the moisture content is below 8%, crushing until the crushed particles are less than or equal to 5mm, and respectively stacking and storing;

step two, material preparation and homogenization aging: the prepared materials are proportioned by a microcomputer batching scale according to raw material components and product varieties, then enter a double-shaft stirrer to be added with water and stirred and mixed uniformly, enter a storage tank through a stacker-reclaimer to be layered, tiled and stacked, and aged for 24-72 h, so that organic matter components of the materials generate fermentation, large-particle materials are loosened, the moisture is uniform, and the materials are vertically taken along a stacking section to be homogenized when the materials are taken by the stacker-reclaimer, so that the components of the materials entering a kiln are uniform;

step three, sagger blank making: molding ground, piled and aged clay into saggar adobes by a screw extruder under the vacuum state by using pressure of more than or equal to 8MPa, stacking the saggar adobes on a kiln car by a robot stacker crane, pushing the saggar adobes into a tunnel kiln, sintering and calcining the saggar adobes to form a earthen bowl with certain strength;

step four, granulation: extruding and granulating the ground, piled and aged clay by using a screw extruder under the vacuum state by using the pressure of more than or equal to 8MPa to form internally compact cylindrical particles, wherein the particle size and the length of the extruded and granulated clay are 10-50 mm in diameter and 10-100 mm in column length according to the product specification required by the market, and the required size is controlled by a shearing machine at the outlet of the extruder;

step five, calcining: loading qualified extruded blank particles prepared in the fourth step into a kiln car, feeding the extruded blank particles into a tunnel kiln, forming a earthen bowl with certain strength after stages of drying, preheating, decomposing, calcining and the like, returning the earthen bowl to an outlet of a granulator to carry the qualified extruded blank particles, loading the extruded blank particles into the kiln car, feeding the extruded blank particles into the tunnel kiln, calcining the extruded blank particles into synthetic silicate mineral aggregate, wherein the temperature gradient of a drying preheating zone is 150-650 ℃, the moisture of an aggregate particle blank is completely dried and evaporated, the temperature is gradually increased to 600-750 ℃, compounds in the material are gradually decomposed to form a free ion shape, and the calcined blank particles are a high-temperature calcining zone when the temperature is increased to 750-1000 ℃, the material forms a molten glass fluid phase at the temperature, and composite minerals such as aluminate and the like are sintered and compacted to;

hot air generated during calcination is extracted from an air outlet cover at the upper part of the drying belt, the hot air is conveyed to a grinding system for preparing raw materials under the action of a heat-resistant fan under negative pressure, and the redundant hot flue gas is subjected to desulfurization and denitrification treatment and then is discharged in the upper air through a smoke window;

step seven, screening and packaging: aggregate is screened and classified by a vibration type classifying screen, the aggregate is divided into products with different specifications of 3 mm-10 mm, 10 mm-25 mm, 25 mm-40 mm and 40 mm-50 mm, the products are packaged, the materials with the size of more than 50mm are crushed after being screened and then screened again, and the materials with the size of less than 3mm can be sold in the market as mixed materials of cement plants or sand for buildings.

During production, firstly, conveying raw materials such as clay and the like to a clay crusher for crushing by using a bag type feeder through a feeding transport vehicle, conveying the crushed clay raw materials to a screening machine for screening through a belt conveyor, conveying qualified materials to a clay stacking part through a movable belt stacker, and returning unqualified raw materials to the crusher for crushing again; conveying raw coal into a hammer crusher for crushing by using a loader through a belt feeder, and conveying the crushed coal to a coal stacking position through a movable belt stacker; utilize the loader to industrial waste residue, carry and detach the metallics in the industrial waste residue through the magnetic force de-ironing separator simultaneously, then send the waste residue after handling to the hammer crusher through vibrating feeder and carry out the breakage in, then handle through band conveyer and magnetic force de-ironing separator once more, later carry to the mill of below through the storage silo, the steam that produces through the high temperature steam collocation coal burning of coming from the tunnel cave is dried and is ground simultaneously, the waste residue after the grinding passes through portable belt stacker and carries industrial waste residue windrow department, smash and carry on the collection of dust through the bag collector that sets up on the way and filter.

The method comprises the following steps of proportioning processed materials through a microcomputer proportioning scale, adding water into the proportioned materials through a double-shaft stirrer for mixing and stirring, stacking the stirred raw materials through a movable belt stacker for homogenizing and aging, manufacturing pot blanks and blank particles through a pot making machine and a granulator, stacking the materials on a kiln car by using a robot, sending the materials to a tunnel kiln for firing, unloading fired aggregates by using a sagger after firing, sending the fired aggregates to a crusher through a chain plate feeder, collecting dust and dust through a dust collecting hopper during the conveying process, conveying the crushed aggregates to a particle sorting vibrating screen through a belt conveyor, conveying the screened aggregate particles to a finished product warehouse for storage, and loading the aggregate particles into a factory transport vehicle through a bulk loader for delivery.

And the flue gas generated by the combustion of the tunnel kiln is treated by the smoke window and the desulfurization device therein and then is discharged.

According to the tunnel kiln fired concrete aggregate and the production method thereof, shale, industrial waste residues, clay, sludge, coal gangue, peat and other raw materials are matched and sintered to generate composite aluminate and other minerals to form the high-strength compact building aggregate, the raw materials of a factory are close to the material selection range and can digest and treat the industrial waste residues, and the tunnel kiln fired concrete aggregate is beneficial to environmental protection; the inferior fuel with low calorific value is used as the internal combustion fuel, so that the production cost of the fuel is greatly reduced, and the energy is saved; the construction aggregate is calcined by adopting the tunnel kiln, the process is simple, the production operation is reliable, a stable thermal regulation system is formed by adding a DCS control system, the product quality is stable, the yield is high, the application range to the fuel is wide, the kiln tail waste gas is used for drying, crushing and grinding the raw material, the unit energy consumption is further reduced, the investment is less and the income is high.

The foregoing illustrates and describes the principles, general features, and advantages of the present invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.

Claims

1. The tunnel kiln concrete aggregate firing method is characterized by comprising the following steps: the shale-coal-gangue-sludge-coal-fired boiler is composed of shale, coal gangue, peat, clay, sludge and industrial waste residues;

step one, preparing raw materials:

2. The production method of the tunnel kiln burned concrete aggregate as set forth in claim 1, characterized in that: the air drying degree in the first step is that the air is dried to be below 8% of moisture, high-temperature waste gas at the tail of the kiln is used as a main drying source when the drying is carried out in the step S1, and a fluidized bed furnace capable of burning inferior coal is used as a back-up and supplementary heat source.

3. The production method of the tunnel kiln burned concrete aggregate as set forth in claim 1, characterized in that: and in the second step, a microcomputer batching scale is adopted for batching, and the material is vertically taken along the stacking section when the material is taken by the material taking machine in the second step.

4. The production method of the tunnel kiln burned concrete aggregate as set forth in claim 1, characterized in that: and in the third step and the fourth step, under the high-strength pressurizing condition, the sagger adobe is subjected to plastic drawing and extrusion granulation by using the pressure of more than or equal to 8MPa in a vacuum state, the particle size and the length of the extrusion granulation in the fourth step are 10-50 mm in diameter and 10-100 mm in column length according to the product specification required by the market, and the required size is controlled by a shearing machine at the outlet of the extruding machine.

5. The production method of the tunnel kiln burned concrete aggregate as set forth in claim 1, characterized in that: and fifthly, the temperature gradient of the drying preheating zone is 150-650 ℃, the moisture of the aggregate grain blank is thoroughly dried and evaporated, the temperature is gradually increased to 600-750 ℃, the compounds in the material gradually start to decompose to form a free ion shape, the material is a high-temperature calcining zone when the temperature is increased to 750-1000 ℃, the material forms a molten vitreous humour phase at the temperature, and the composite minerals such as aluminate and the like are sintered and compacted to form the solid granular aggregate product.

6. The production method of the tunnel kiln burned concrete aggregate as set forth in claim 1, characterized in that: and (5) extracting the hot air generated in the fifth step from an air outlet cover at the upper part of the drying belt, conveying the hot air to a grinding system for preparing the raw materials under the action of a heat-resistant fan under negative pressure by using a pipeline, and discharging the redundant hot flue gas in the high altitude through a flue window after the hot flue gas is subjected to desulfurization and denitrification treatment.

7. The production method of the tunnel kiln burned concrete aggregate as set forth in claim 1, characterized in that: and the grading sieve in the seventh step adopts a vibrating grading sieve, and the materials with the size of more than 50mm after being sieved in the seventh step are sieved again after being crushed.