CN118005260A - Glass melting method - Google Patents
Glass melting method Download PDFInfo
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- CN118005260A CN118005260A CN202410172581.0A CN202410172581A CN118005260A CN 118005260 A CN118005260 A CN 118005260A CN 202410172581 A CN202410172581 A CN 202410172581A CN 118005260 A CN118005260 A CN 118005260A
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- 239000011521 glass Substances 0.000 title claims abstract description 103
- 238000002844 melting Methods 0.000 title claims abstract description 100
- 230000008018 melting Effects 0.000 title claims abstract description 99
- 238000000034 method Methods 0.000 title claims abstract description 44
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 55
- 239000002994 raw material Substances 0.000 claims abstract description 51
- 239000006004 Quartz sand Substances 0.000 claims abstract description 40
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims abstract description 32
- 235000019353 potassium silicate Nutrition 0.000 claims abstract description 28
- 238000002156 mixing Methods 0.000 claims abstract description 22
- 239000000919 ceramic Substances 0.000 claims abstract description 10
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 19
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 16
- 230000007246 mechanism Effects 0.000 claims description 15
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims description 6
- 235000011941 Tilia x europaea Nutrition 0.000 claims description 6
- 239000007789 gas Substances 0.000 claims description 6
- 239000004571 lime Substances 0.000 claims description 6
- 229910021532 Calcite Inorganic materials 0.000 claims description 4
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 4
- 238000000498 ball milling Methods 0.000 claims description 4
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- 238000005303 weighing Methods 0.000 claims description 4
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- 230000015572 biosynthetic process Effects 0.000 description 8
- 230000000694 effects Effects 0.000 description 8
- 229910000029 sodium carbonate Inorganic materials 0.000 description 8
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 7
- 239000000843 powder Substances 0.000 description 7
- 238000007789 sealing Methods 0.000 description 7
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- 235000012239 silicon dioxide Nutrition 0.000 description 6
- 238000003723 Smelting Methods 0.000 description 5
- 230000009471 action Effects 0.000 description 5
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- 238000010438 heat treatment Methods 0.000 description 5
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- 239000011707 mineral Substances 0.000 description 5
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- 238000011160 research Methods 0.000 description 5
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- 238000002474 experimental method Methods 0.000 description 4
- 238000000227 grinding Methods 0.000 description 4
- 238000000265 homogenisation Methods 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 239000006060 molten glass Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 229910004298 SiO 2 Inorganic materials 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical group [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
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- 238000007496 glass forming Methods 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- 230000002776 aggregation Effects 0.000 description 2
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- -1 bubbles Substances 0.000 description 2
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- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 1
- 229910020489 SiO3 Inorganic materials 0.000 description 1
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 1
- NCXOIRPOXSUZHL-UHFFFAOYSA-N [Si].[Ca].[Na] Chemical compound [Si].[Ca].[Na] NCXOIRPOXSUZHL-UHFFFAOYSA-N 0.000 description 1
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- JYYOBHFYCIDXHH-UHFFFAOYSA-N carbonic acid;hydrate Chemical compound O.OC(O)=O JYYOBHFYCIDXHH-UHFFFAOYSA-N 0.000 description 1
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Landscapes
- Glass Melting And Manufacturing (AREA)
Abstract
The invention relates to a glass melting method, which comprises the steps of firstly stirring various glass raw materials including superfine quartz sand by a rotary ceramic ball mill to obtain uniformly mixed batch materials with the temperature of more than 40 ℃, then pressing to obtain compacted batch material plates, conveying the compacted batch material covered with a cementing layer containing water glass solution with a certain concentration into a lengthened pre-melting pool through a stable conveying belt for pre-melting, and continuously entering a melting pool for melting. The invention utilizes the ceramic ball mill to grind the glass raw materials such as superfine quartz sand and the like, covers a cementing layer on the surface of the compacted batch, and then cooperates with premelting of the lengthened premelting pool, so that the superfine quartz sand which is abandoned in the traditional glass factory can be used for glass manufacture, the batch can be ensured not to be layered and fly in the conveying and melting processes without mixing with a binder, the glass quality is improved, the application cost of the glass batch briquette is effectively reduced, the melting rate and the melting quality are obviously improved, and the fuel consumption is reduced.
Description
Technical Field
The present disclosure relates to the technical field of glass production, and in particular to a glass melting method.
Background
The statements in this section merely provide background information related to the present disclosure and may constitute prior art. In carrying out the present invention, the inventors have found that at least the following problems exist in the prior art.
The glass is an amorphous inorganic nonmetallic material, and the main components are SiO 2 and other oxides, namely silicate double salts. The main raw material in the batch for melting glass is quartz sand, and the rest is sequentially composed of sodium carbonate, calcite, alumina and other auxiliary raw materials, and the raw materials of different types of glass are different. The SiO 2 is a framework of glass, is introduced from raw material quartz sand containing about 98% of SiO 2, generally accounts for about 70% of glass components, has a melting point of over 1700 ℃, belongs to refractory raw materials, and is mainly realized by wrapping fluxing raw materials in order to melt the refractory raw materials at a common melting temperature of about 1520 ℃. The process of forming a uniform bubble-free glass melt (i.e., reducing bubble streaks and stones to acceptable limits) by heating the batch at high temperature and meeting the molding requirements is known as glass melting.
Glass melting is a key element in glass production. Many defects in glass (e.g., bubbles, stones, streaks, etc.) are caused during the melting process. The yield, quality, qualification rate, production cost, fuel consumption, life of the tank furnace and the like of the glass are closely related to glass melting. Therefore, reasonable glass melting is an important guarantee that the whole production process can be smoothly carried out and high-quality glass products can be produced.
Melting of the glass batch is accomplished by five processes, silicate formation, glass formation, fining, homogenization, and cooling. The glass forming process is a heavy weight in melting, and the high fuel cost and melting quality and kiln life are largely dependent on this process. Glass batch involves the control of the particulate composition of the raw materials, a certain amount of moisture, a certain amount of gas content, and batch uniformity. These controls relate to the rate of melting of the molten glass, the uniformity of the molten glass, and the quality of melting of the molten glass.
The end of the glass forming process is measured and is characterized by the disappearance of the melting of the refractory raw quartz sand particles. The size and uniformity of the composition of the silica sand particles has a very important effect on the uniformity of the batch mixture, segregation, melting and homogenization rates of the glass melt, and on the reduction of appearance defects in the glass article. Practice proves that the sand grains are too large, can be difficult to melt, and can easily produce unmelted stones (pimples); when the particles are smaller and uniform, the sand grains and the fluxing component have sufficient contact area, are easy to mix uniformly, are not easy to delaminate, and are favorable for melting and homogenization. However, when the particles are too fine, although in general the minute time (t) required for the batch to melt into soda lime silica glass is proportional to the cubic square of the cm radius (r) of the silica sand particles, i.e. t=k×r 3, the finer the particles the easier the glass will melt. However, in the actual production of glass factories, the quartz sand particles are too fine, so that the larger the surface activity (namely the surface energy), the water is easily adsorbed to form clusters, and the batch preparation is difficult to mix uniformly, thereby affecting the melting and clarifying speed of glass and leading to the generation of glass defects (stones and stripes). Meanwhile, when the excessively fine quartz sand grains are fed into the furnace, the heated quartz sand grains are easily brought into the regenerator by combustion gas, so that the grid body is blocked, and the stability of the glass composition is affected. Therefore, the common glass factories still use practical experience for nearly hundred years, the grain size of quartz sand used for melting in a tank furnace is generally between 0.15 and 0.8mm, and the grain size of 0.25 to 0.5mm should not be lower than 90 percent, and the grain size below 0.1mm is not more than 5 percent as the standard.
In order to accelerate the formation of glass, the melting efficiency is improved. For this reason, research on batch granulation, i.e., briquetting and balling techniques, of glass batch materials was carried out abroad from the 30 th nineteenth century and reached a peak in the 80 th nineteenth century. The method has the advantages that the problems of layering and material flying of the batch during conveying and storing, particularly the material flying of sodium carbonate and the like during feeding into a smelting furnace are solved, the erosion of refractory materials and checker bricks of a regenerator is effectively avoided, and the influence on glass components, smelting quality and pollution to the atmosphere is effectively avoided. Meanwhile, the granulating (briquetting or balling) of the batch is beneficial to solid phase reaction because the contact area between particles is increased, the thermal conductivity (the thermal conductivity coefficient of powder is 0.235 and the time/degree of granularity is 0.37 kilocalories/meter) is increased, and the surface of finer quartz sand is covered with uniform liquid alkali, so that the formation of an initial liquid phase is accelerated. The batch granulating can adopt fine powder raw materials, can shorten the melting time by 30-40%, can improve the melting quality of glass at the same time according to experiments, and can reduce bubble stones in the glass, thereby increasing the yield of the glass and improving the melting rate by 30-40%.
In the batch granulating research process, pit pair roller compaction granulating, disc rolling granulating, cylinder whirl granulating, extrusion molding granulating of an extruding machine, granulating of smooth pair roller strips and the like are adopted. The several methods described above are the most studied and the most developed are the two methods of briquetting and balling. However, compaction granulation has high research value from the standpoint of economic efficiency and cost budget. Practice proves that the melting temperature of the granulated glass batch is reduced by 80-100 ℃ compared with that of the powdery batch, and the melting rate is improved by 10-20%. The research on the briquetting of glass batch materials was carried out in the period of 'sixty five' of nineteenth century in China and experiments were carried out on the float glass industry experiment line, but the granulated glass batch materials have low drying strength due to the fact that proper binders cannot be found, the batch materials are easy to loose and fly up to finally influence the quality of glass when the kiln is melted at high temperature, and the research is interrupted afterwards. Improving the glass batch manufacturing process is a significant long-term problem. The granulating or briquetting of glass batch is an important and promising method for energy conservation and emission reduction in the glass industry, and has attracted attention of many researchers at home and abroad. However, the granulation of glass batch materials still remains in the experimental stage so far, and large-scale industrial application has not been achieved yet, and many key technologies have not been broken through, so that further development of the technology is restricted.
The existing glass melting method adopting the binder adopts the process flow of 'a method for preparing microcrystalline glass from pyroxene tailings', which comprises the steps of raw material mixing, mixer stirring, binder addition to be pressed into compacted batch, feeding into a melting furnace to be melted through a conveying belt, and then carrying out product forming and the like. However, such schemes have the following bottlenecks.
The first bottleneck is the problem of uniform stirring of the batch. The mixing machine is always used for stirring the batch materials before granulation, and stirring the structural fine sand or the superfine sand uniformly is difficult, so that the superfine quartz sand cannot be used as the raw material for manufacturing the glass.
The second bottleneck is the sticking problem of the glass batch. Since the glass raw material itself does not have viscoplasticity, particularly, the problem of flying materials is caused by high-temperature loosening, the mixture of the batch materials before granulating or briquetting or the binder must be added or the drying or sintering must be carried out during the pelletization process. The cost of baking and sintering is too high to be used, and if a binder is used, it is desirable that the binder be inexpensive, non-toxic, non-corrosive, not contain components detrimental to glass, and achieve the desired dry strength of the granulated glass batch, and meet the high temperature, non-loosening requirements. Binders or granulation methods that meet these requirements at the same time have not been found.
The third is that the above-mentioned traditional granulating method is characterized by one-step forming or non-pressure rolling dipping forming, and the used adhesive is caustic soda, lime emulsion or water glass, so that it is difficult to obtain the required drying strength, and the problem of that the loosening and breaking rate is extremely high when it is processed, stored and transported, in particular heated in kiln, so that it can not be used.
In addition, in view of the fact that the glass batch granulating and briquetting method is an effective way capable of remarkably improving comprehensive benefits such as glass melting rate, how to reduce the manufacturing cost of pelletizing or briquetting and solve the difficult problems of cracking process is also a urgent need to solve popularization and application.
Disclosure of Invention
In view of the above, it is an object of the present invention to solve some of the problems of the prior art, or at least to alleviate them.
A glass melting method comprising the steps of:
Weighing various glass raw materials for standby;
Rotating the mixing mechanism, and adding various glass raw materials into the mixing mechanism to obtain a uniformly mixed batch with the temperature of more than 40 ℃;
rapidly adding the batch into a roller press or a ball press to prepare a compacted batch;
Stably feeding the compacted batch into a pre-melting pool of a kiln through a conveying belt to perform pre-melting; wherein, before being sent into the pre-melting pool, a layer of air hardening cementing layer is covered on the surface of the compacted batch;
And (5) feeding the premelted batch into a melting tank of the kiln for melting.
Optionally, the air-hardening cementing layer is composed of water glass or a mixed solution of water glass and lime milk.
The pre-melt pool is an elongated pre-melt pool to allow the compacted batch to be fully pre-melted.
Furthermore, the flue gas in the lengthened pre-melting pool is slightly positive pressure, has abundant CO 2 gas and has the temperature of more than 1200 ℃.
Preferably, the mixing mechanism is a ball mill.
Further, the ball mill is a ceramic ball mill.
Rotating the mixing mechanism, adding various glass raw materials into the mixing mechanism to obtain a uniformly mixed batch with the temperature of more than 40 ℃, and comprising the following steps:
Rotating the ball mill, adding quartz sand and aluminum-containing raw materials into the ball mill for the first time, and supplementing water;
then adding the calcined soda raw material for the second time;
thirdly, entering other raw materials when the ball milling reaches the set time;
when the raw materials in the ball mill are uniformly mixed and ball-milled properly, the batch is obtained.
Further, the quartz sand is ultrafine quartz sand; such other raw materials include, but are not limited to, calcite and dolomite.
The conveying belt is a stable sealing conveying belt.
Further, the sealing conveyer belt is a plate-shaped sealing conveyer belt.
The invention has the following beneficial effects:
1. According to the application, a mixing mechanism is adopted for stirring and mixing glass raw materials, a layer of gel layer of water-containing glass is covered on a compacted batch surface prepared by uniformly mixed batch with the temperature of more than 40 ℃, and then an elongated pre-melting pool is matched, so that the batch is loose in normal temperature conveying process on a conveying belt or in a high temperature environment of a kiln, layering and flying materials can be prevented, a binder is well replaced, the glass quality is improved, the application cost of a glass batch briquetting is effectively reduced, and the effects of pollution reduction and the like are achieved;
2. The ceramic ball mill is adopted, so that pollution to batch materials is less likely to be caused than the metal ball mill, alumina abrasive materials are utilized to grind and refine materials, and particularly, the batch materials which are particularly likely to agglomerate and have the problem of superfine quartz sand can achieve the effect of uniform mixing, so that the superfine quartz sand which is abandoned in a traditional glass factory can also be used for glass manufacture, glass stones and stripes are not generated due to influence on melting and clarification speeds of glass, and the situation that a checker is blocked and glass composition is stable due to the fact that combustion gas is brought into a regenerator during feeding and melting in a furnace is avoided;
3. And the superfine quartz sand is adopted as the raw material for glass melting, and the ball mill and the process for covering the gel layer are matched, so that the melting time of the batch can be greatly shortened compared with the current quartz sand or fine quartz sand, thereby obviously improving the melting rate, the melting quality and reducing the fuel consumption.
Drawings
FIG. 1 is a process flow diagram of the present invention.
Detailed Description
The present invention will be further described with reference to the accompanying drawings, wherein the embodiments of the present invention are for the purpose of illustrating the invention only and not for the purpose of limiting the same, and wherein various substitutions and modifications are made by the person of ordinary skill in the art without departing from the technical spirit of the present invention, and are intended to be included in the scope of the present invention.
As shown in fig. 1, a glass melting method includes the steps of:
Weighing various glass raw materials for standby;
Rotating the mixing mechanism, and adding various glass raw materials into the mixing mechanism to obtain a uniformly mixed batch with the temperature of more than 40 ℃;
rapidly adding the batch into a roller press or a ball press to prepare a compacted batch;
Stably feeding the compacted batch into a pre-melting pool of a kiln through a conveying belt to perform pre-melting; wherein, before being sent into the pre-melting pool, a layer of air hardening cementing layer is covered on the surface of the compacted batch;
The premelted batch material then enters a melting tank of the kiln to be melted. After melting, the glass product can be produced through clarifying, homogenizing and cooling.
The mixing mechanism is a ball mill, a mixer and the like can also be adopted. The roller press can be a high-pressure twin-roller machine and the like, and the batch is made into a compacted batch plate meeting the thickness and width requirements; the ball press may be a high-pressure ball press or the like, which produces pellets from the batch.
Air hardening refers to the property of gradual setting and hardening with weak carbon dioxide in the atmosphere at normal temperature, so that the air hardening has considerable strength. The air hardening cementing material comprises lime, gypsum and water glass. Preferably, the air-hardening gel layer is composed of water glass or a mixed solution of water glass and lime milk.
Sodium silicate, commonly known as sodium silicate, is an inorganic substance with a chemical formula of Na 2O·nSiO2 and a melting point of 1089 ℃, and an aqueous solution of sodium silicate, commonly known as water glass, is an ore binder and an air hardening material. It is a soluble inorganic silicate and has wide application. The characteristics of the mineral binder mainly include the following aspects:
1. Hydrophilicity: the mineral binder has good hydrophilicity and can be separated from water to form a stable structure.
2. Complexation: the mineral adhesive has strong complexing capability, can react with other substances chemically, and improves the adhesive force of the material.
3. Quick setting property: the mineral binder can harden in a short time, and is suitable for the requirement of rapid construction.
4. Hydrolytic reducibility: the mineral binder has a certain hydrolytic reducibility which contributes to its better functioning under specific conditions.
The cohesive hardening of water glass (sodium silicate) is a result of the aggregation of unstable silica gels by hydrolysis and even the formation of crystalline silica frameworks. When the gel formed in large amounts after drying is more compact, the strength of the bond is thus increased. In particular, when the compacted batch enters the pre-melting pool, the liquid water glass sprayed on the surface reacts with abundant carbon dioxide, so that the formation of amorphous silicic acid gel, drying and hardening can be accelerated to form a shell with quite high strength. Meanwhile, the water glass can become solid after evaporating water by heating at 200 ℃. The hardening time shows a positive correlation with temperature, i.e. the higher the temperature the faster the hardening speed. When the compacted batch enters the high temperature of the pre-melting pool, the sprayed water glass thin layer can be accelerated to harden to form a hard shell to cover the surface of the compacted batch, so that the problem of loose and flying materials after being heated can be effectively prevented.
The rate at which water glass solidifies depends on several factors including temperature, concentration and PH. At high temperatures, the rate of water glass solidification will be increased, while at low temperatures, the rate of water glass solidification will be decreased. The physical and chemical properties of the solidified water glass are changed, and the solidified water glass has higher hardness and strength. Water glass is hardly soluble in water after curing. This is because the curing process of water glass involves the combination of water molecules with sodium ions and silicate ions in the water glass.
Carbonization reaction formula of water glass and carbon dioxide:
Na2O·nSiO2+CO2+mH2O＝Na2CO3+nSiO2·mH2O
nSiO2·mH2O＝nSi2+mH2O
According to the invention, the ball mill is adopted when the glass raw materials are mixed, so that the raw materials can be uniformly stirred, the heating characteristic of the ball mill is utilized, the temperature of the batch obtained by grinding for a period of time is higher than that of the mixer at about 35 ℃, the adhesion state of the batch is increased, and good conditions are provided for compression molding. Therefore, the mixture can be put into a high-pressure twin-roll machine or a high-pressure ball machine in time when being hot to prepare a mixture or granular mixture which meets the pressing block with the required thickness and width. Because the wetting time of the mixed batch is increased along with the increase of the water/sodium carbonate ratio and the temperature, the compacted batch can reach a certain conveying strength and can not loose and fly at the normal temperature of conveying by a conveying belt. Meanwhile, a gel layer of water-containing glass is covered on the compacted batch surface conveyed on the conveying belt, and then the water-containing glass is continuously and stably conveyed into a pre-melting pool for pre-melting through the acting force conveyed by the conveying belt, and then enters a melting pool of a kiln. The method avoids the defects of the existing binder, and can practically prevent and remedy the problem of material flying caused by loosening of the compacted batch under the action of high temperature.
The pre-melt pool is an elongated pre-melt pool to allow the compacted batch to be fully pre-melted. Because the compacted batch with certain temperature has a small amount of water, has certain self-adhesiveness and certain strength after being pressed, and a cementing layer of water-containing glass is covered on the surface of the compacted batch during conveying, the conventional pre-melting pool can not fully pre-melt the surface of the compacted batch, so that an lengthened pre-melting pool is needed to increase the pre-melting time. The flue gas in the lengthened pre-melting pool is slightly positive pressure, has abundant CO 2 gas and has the temperature of more than 1200 ℃.
The air-setting gel layer is thin and can adhere to the compacted batch level. The gel liquid and a small amount of water in the batch are quickly evaporated from the front end of the pre-melting pool between the charging port of the kiln and the melting pool, and are discharged from the charging port by micro-positive pressure of the kiln. After carbonization reaction of the gel layer and abundant CO 2 in the furnace gas, amorphous silicic acid gel is formed, and meanwhile, the gel layer is quickly dried to form a crust under the action of high temperature, so that the coverage of loose batch materials under the action of high temperature before the silicate forming process can be kept, and the batch materials are not flying. On the other hand, water glass itself is a low-melting silicate, and when the silicate on the surface of the batch is formed to sinter, the gelled layer of this thin layer reacts with it chemically, and is melted and melted to disappear. The components of the cementing material are all oxides which form glass, and the cementing material enters the components of the glass after being melted, so that the quality of the glass is not affected.
Rotating the mixing mechanism, adding various glass raw materials into the mixing mechanism to obtain a uniformly mixed batch with the temperature of more than 40 ℃, and comprising the following steps:
Rotating the ball mill, adding quartz sand and aluminum-containing raw materials into the ball mill for the first time, and supplementing water according to the situation;
then adding the calcined soda raw material for the second time;
thirdly, entering other raw materials when the ball milling reaches the set time;
when the raw materials in the ball mill are uniformly mixed and ball-milled properly, the batch is obtained.
The raw materials are sequentially added in the sequence, so that quartz sand is wrapped with fluxing raw materials and other raw materials, the grinding time is ensured while the stirring is uniform, the temperature is more than 40 ℃, the strength of the compacted batch is convenient to convey, and the later manufactured compacted batch is prevented from loosening and flying in the conveying process. Such other raw materials include, but are not limited to, calcite and dolomite. Of course, the glass raw materials can also be added into the ball mill according to different raw materials and proportions in different sequences. And (5) weighing various qualified glass raw materials automatically in a group bin for later use.
The dry powder quartz sand is superfine quartz sand. The superfine quartz sand can be superfine dry powder quartz sand or agglomerated quartz sand with trace moisture. Because the adopted ball mill is stirred, the grinding mode of the ball mill can ensure that the superfine dry powder quartz sand and the agglomerated quartz sand can be uniformly mixed, thereby avoiding affecting the melting and clarifying speed of glass and leading to the generation of glass stones and stripes, and meanwhile, adopting the compacted matching material surface to spray and cover a water glass layer, and avoiding the conditions that the glass composition is blocked and the glass composition is stable due to the fact that combustion gas is brought into a regenerator when premelting and melting in a furnace. In addition, the glass batch adopts superfine quartz sand instead of conventional quartz sand or fine powder quartz sand, and besides the resource recycling and environmental protection factors, the minute time (t) required for melting the batch into soda-lime-silica glass is proportional to the cubic square of the centimeter radius (r) of the quartz particles, namely t=k.r 3, which indicates that the finer the quartz particles, the easier the glass is melted. The superfine quartz sand is matched with the ball mill and the cementing layer process, and compared with the existing quartz sand or fine powder quartz sand, the smelting time of the batch can be greatly shortened under the condition of preventing layering flying materials, so that the smelting rate and the smelting quality are obviously improved, and the fuel consumption is reduced. For example, the melting rate of sodium-calcium-silicon glass in the existing natural gas horseshoe flame glass tank furnace is generally about 1.6T/m 2.24 h. After improvement, the temperature can reach about 2.1T/m 2.24 hours.
Preferably, the ball mill is a ceramic ball mill. Compared with a metal ball mill, the ceramic ball mill is not easy to cause pollution to materials. When all the raw materials are completely and evenly mixed (and are subjected to proper ball milling), the high-quality batch materials which are crushed by the ceramic ball mill to the maximum limit can be discharged. Experiments indicate that after the whole batch is crushed to the maximum, the glass forming speed is increased by 3.5 times for the sodium carbonate batch, and is increased by 6 times for the sodium carbonate mirabilite batch (compared with the batch with the same common granularity).
The reason why the ceramic ball mill is used for replacing the gravity type or forced type mixer is that the quality of the uniformity of the batch materials influences the yield and quality of glass products, and the degree of mixing of the batch materials by the mixer required by textbooks is limited in glass factories until now, so that the batch materials with excellent uniformity are the precondition for melting uniform glass liquid. Particularly when the raw materials have strong agglomeration tendency, the uniform distribution of the materials is hindered, and the forced type is better than the gravity type. The ceramic ball mill has the remarkable advantages that the alumina abrasive is used for grinding and refining materials, and particularly, the effect of uniformly mixing the ingredients which are particularly easy to agglomerate and have the problem of excessively fine quartz sand can be achieved.
The conveyer belt is a stable sealing conveyer belt, so that the ash falling amount is small when the compacted batch is conveyed on the conveyer belt, and the ash falling is prevented. The sealing conveyor belt is a plate-shaped sealing conveyor belt, and other forms of conveyor belts can be adopted.
Working principle:
In order to prevent the compacted batch from loosening and flying under the action of high temperature, a layer of water glass solution with a certain concentration of cementing material is continuously sprayed or covered on a conveyer belt, and the water glass solution can be properly mixed on the surface of the batch with the composite cementing layer such as lime milk or magnesia according to the requirement, and the batch is stably fed into a furnace through the acting force conveyed by the conveyer belt. The flue gas is slightly positive pressure, has abundant CO2 gas, and in the process of lengthening the pre-melting pool at the high temperature of more than 1200 ℃, the compacted batch is changed into a loose state due to heating, and a part of the thickness of the compacted batch can sink into glass liquid and a part of the thickness of the compacted batch can float on the glass liquid. The batch floating on the glass liquid is dehydrated by heating, the adhesion disappears and the loosening occurs before 500 ℃, because the melting point of the water glass gel is more than 500 ℃, particularly, the gelatinization layer NaSiO 3 covered by the batch which enters a pre-melting pool and is heated and loosened is carbonized with CO 2 to form silicic acid gel and sodium carbonate, the gelatinization layer is quickly solidified to form a hard shell under the action of high temperature, and water vapor is discharged through micropores of a solidified layer, so that the loose batch cannot generate flyash; the batch sinking in the glass liquid can not fly due to the wrapping of the glass liquid; and due to the thin layer feeding, a trace amount of loose parts escape from the edge of the material layer, so that the flying materials are negligible because of no direct impact and premelting effect of flame. Although the melting point of the solidified layer Na 2SiO3 is 1088 ℃, the batch becomes opaque sinter at 800-900 ℃ due to intimate contact with the batch fusible component and the eutectic. Therefore, the premelting pool has the temperature of more than 1200 ℃ and can completely achieve the premelting effect of the batch. The lengthening pre-melting pool is adopted, so that the retention time of the batch in the pre-melting pool is longer, and the pre-melting effect is better. With the continuous formation of silicate gel and sodium carbonate and the increase of temperature, the formation of silicate opacity will continuously disappear as a thin coating layer, thereby making the thickness of the premelted batch layer thinner. For example, in a natural gas horseshoe flame tank furnace, the premelted batch immediately enters a negative pressure area of the intersection angle of the flame and the glass liquid surface of the melting tank, and the batch is not easy to be impacted by the flame to run off so as to stabilize the melting. Because the batch adopts the superfine quartz sand, the specific surface area of the fluxing raw material for wrapping the batch is greatly increased, and the melting capacity and the melting quality of the molten glass are greatly improved. The glass liquid which is thoroughly melted is more beneficial to the clarification and homogenization time shortening of the glass, and the quality of the high-quality glass liquid molded product cooled to the molding temperature can be greatly improved.
The width and thickness of the compacted batch conveyed by the conveying belt are set according to the size and the discharge amount of the kiln, and the speed is controlled by an automatic liquid level controller according to the real-time fluctuation condition of the liquid level. The batch is conveyed into the furnace by the conveying belt, so that the existing feeder equipment can be omitted, the sealing degree of the charging port is increased, and the high-temperature heat dissipation loss of the existing charging port is reduced.
Claims (10)
1. A glass melting method, comprising the steps of:
Weighing various glass raw materials for standby;
Rotating the mixing mechanism, and adding various glass raw materials into the mixing mechanism to obtain a uniformly mixed batch with the temperature of more than 40 ℃;
rapidly adding the batch into a roller press or a ball press to prepare a compacted batch;
Stably feeding the compacted batch into a pre-melting pool of a kiln through a conveying belt to perform pre-melting; wherein, before being sent into the pre-melting pool, a layer of air hardening cementing layer is covered on the surface of the compacted batch;
And (5) feeding the premelted batch into a melting tank of the kiln for melting.
2. The glass melting method according to claim 1, wherein the air-hardening gel layer is composed of water glass or a mixed solution of water glass and lime milk.
3. The glass melting method of claim 1 wherein the pre-molten pool is an elongated pre-molten pool to substantially pre-melt the compacted batch.
4. A method of melting glass as in claim 3 wherein the flue gas in the elongated pre-bath is at a slight positive pressure, has a sufficient amount of CO 2 gas, and has a temperature greater than 1200 ℃.
5. The glass melting method of claim 1, wherein the mixing mechanism is a ball mill.
6. The glass melting method according to claim 5, wherein the ball mill is a ceramic ball mill.
7. The glass melting method according to claim 5, wherein the rotating mixing mechanism, into which various glass raw materials are added to obtain a uniformly mixed batch having a temperature of more than 40 ℃, comprises the steps of:
Rotating the ball mill, adding quartz sand and aluminum-containing raw materials into the ball mill for the first time, and supplementing water;
then adding the calcined soda raw material for the second time;
thirdly, entering other raw materials when the ball milling reaches the set time;
when the raw materials in the ball mill are uniformly mixed and ball-milled properly, the batch is obtained.
8. The glass melting method according to claim 7, wherein the quartz sand is an excessively fine quartz sand; such other raw materials include, but are not limited to, calcite and dolomite.
9. The glass melting method of claim 1 wherein the conveyor is a stationary seal conveyor.
10. The glass melting method according to claim 9, wherein the seal conveyor is a plate-shaped seal conveyor.
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