Process and system for producing alumina-based high-temperature synthetic material

Abstract

The invention relates to the technology of refractory materials, in particular to a process and system for producing alumina-based high-temperature synthetic materials, the system comprises a crushing unit, a dry grinding unit, a wet grinding unit, a mixing unit, a press unit, a drying kiln and a tunnel kiln, the drying kiln is connected with the tunnel kiln through a track, the crushing unit is connected with the dry grinding unit and the wet grinding unit, and the mixing unit is connected with the dry grinding unit and the wet grinding unit. The dry grinding unit and the wet grinding unit are respectively connected with the material mixing unit, the material mixing unit is connected with the press unit, the manipulator is arranged between the press unit and the drying kiln, the press unit performs automatic pressing, material distribution and brick discharging, the manipulator performs brick stacking according to programming, and the brick stacking vehicle sequentially enters the drying kiln and the tunnel kiln through the track. According to the method, the water content and the mixing ratio of the dry grinding powder and the wet grinding slurry are finely controlled, and the mixing means of the original process is improved, so that the production cost is lower, the quality of the obtained product is better, and the production efficiency of the alumina-based high-temperature synthetic material is effectively improved on the premise of energy conservation and emission reduction.

Description

Technical Field

[0001] The invention relates to refractory material technology, in particular to a process and system for producing alumina-based high-temperature synthetic materials. Background Art

[0002] Alumina-based high-temperature synthetic materials refer to the use of high-alumina bauxite as raw material, through the homogenization process and appropriate high-temperature calcination, to prepare homogenized materials with stable and uniform structure, performance and quality. The production lines for producing alumina-based high-temperature synthetic materials basically adopt dry process or wet process. The specific routes of each process are as follows: Dry process: raw materials are pre-homogenized, crushed, finely ground, conveyed by belt or elevator, mixed with water or binder in mixer, pressed into shape, dried and fired.

[0003] Wet process (1): raw materials are pre-homogenized, crushed, wet-milled with water, spray granulated, pressed, dried, and fired in a tunnel kiln.

[0004] Wet process (2): raw materials are pre-homogenized, crushed, wet-milled with water, filtered, extruded by a slurry squeezer, dried by a mesh belt, and fired in a tunnel kiln or rotary kiln.

[0005] Dry process: Since the dry process is the most economical way to grind the raw materials to 325 mesh, further grinding will significantly increase the energy consumption, resulting in rising costs. Currently, major manufacturers all use the 325 mesh standard for fine grinding. However, during the firing process, compared with the fineness of wet grinding above 500 mesh, the specific surface area is small, the activity is small, and a high firing temperature is required. The volume density of the finished product is lower than that of the wet process (1).

[0006] Wet process (1): Due to the use of wet grinding technology, the material fineness of more than 500 mesh can be obtained compared with the dry process, the specific surface area is large, the firing temperature is 10°C lower than the dry process, the gas consumption during firing is reduced, and the volume density is better than the dry process. However, since the spray granulation process requires a large amount of heat energy, the average natural gas consumption per ton of product is about 40-50 cubic meters. At present, with the high price of natural gas, the economic benefits cannot be compared with the dry process. At the same time, due to the excessive fineness of the material, during the high-temperature performance test, the load softening temperature is 20-50°C lower than the dry process.

[0007] Wet process (2): Compared with wet process (1), the spray granulation step is eliminated and replaced by mesh belt drying. However, it also consumes a lot of heat energy, but less than spray granulation. It consumes about 20-35 cubic meters of gas per ton of product. It also has the problem of low load softening temperature.

[0008] At present, in order to respond to the national call for energy conservation and emission reduction, and also to improve product quality and reduce production costs, our company has proposed a low-carbon production method for preparing refined corundum mullite high-temperature materials (CN114249585A), which uses a combination of dry and wet processes to produce mullite corundum high-temperature materials. However, this preparation method still has a lot of room for improvement, and there is the possibility of further improving production efficiency. Summary of the invention

[0009] In response to the problems pointed out in the background technology, the purpose of the present invention is to propose a process and system for producing alumina-based high-temperature synthetic materials, which can reduce production costs and improve product quality by finely controlling the water content and mixing ratio of dry abrasive powder and wet abrasive and improving the mixing method of the original process. Under the premise of energy saving and emission reduction, the production efficiency of alumina-based high-temperature synthetic materials is effectively improved.

[0010] To achieve the above object, the present invention adopts the following technical solutions: A process for producing alumina-based high-temperature synthetic materials comprises the following steps: S1. Mixing raw materials according to product requirements; the raw materials include high-alumina bauxite, alumina particles and silica particles; S2, the raw materials are crushed and screened to obtain screened materials with a particle size of 0-8 mm; S3. The screening material is divided into material A and material B. The weight of material A is less than that of material B, and the weight of material A is 20-30% of the total weight of the screening material; S4, material A is wet-milled and ground with additives to obtain wet abrasive with a water content of 28-30%; material B is dry-milled and ground with additives to obtain dry abrasive with a water content of 5%; S5, the wet abrasive and the dry abrasive are simultaneously fed into a mixer for mixing at a weight ratio of 1:4 to obtain a mixture; S6, the mixed material is transported to a press for pressing and forming to obtain a primary product; S7, the primary product is sent to the drying kiln for drying to obtain the secondary product; S8, the secondary product is put into a high-temperature kiln for calcination to obtain a clinker product; S9. The clinker product is crushed to obtain homogenized clinker.

[0011] In the step S2, the raw material is crushed by two-stage crushing, which is jaw crushing and roller crushing in sequence. After roller crushing, screening is performed, and the unqualified materials screened out are returned to the roller crushing process for re-crushing.

[0012] In step S3, the weight of material A is 25% of the total weight of the screened material; In step S4, the additive added to material B is a powdered water reducer; the additive added to material A is a dispersed suspending water reducer, the wet grinding and refining equipment is a wet ball mill, and the mass percentages of the components during wet grinding and refining are: material A is 65%-80%, the dispersed suspending water reducer is 0.2%-1%, and water is 19.8%-34%.

[0013] In step S5, before the wet abrasive and the dry ground powder are fed into the mixer, the wet abrasive is homogenized in a slurry pool, and the dry ground powder is homogenized in a powder bin.

[0014] The present invention also provides a system for producing alumina-based high-temperature synthetic materials using the process as described above, comprising a crushing unit, a dry grinding unit, a wet grinding unit, a mixing unit, a press unit, a drying kiln and a tunnel kiln, wherein the drying kiln and the tunnel kiln are connected by rails, the crushing unit is respectively connected to the dry grinding unit and the wet grinding unit, the dry grinding unit and the wet grinding unit are respectively connected to the mixing unit, the mixing unit is connected to the press unit, a manipulator is provided between the press unit and the drying kiln, the press unit automatically presses, distributes and discharges bricks, the manipulator stacks bricks according to programming, and a brick stacking vehicle enters the drying kiln and the tunnel kiln in sequence via the rails.

[0015] The crushing unit includes a raw material bin, a jaw crusher feeder, a jaw crusher, a roller feeder, a roller crusher, a first belt conveyor, a first elevator, a drum screen, a feed bin and a second belt conveyor which are connected in sequence. The feed bin is connected to the dry grinding unit and the wet grinding unit respectively through the second belt conveyor.

[0016] The dry grinding unit includes a third belt conveyor, a second elevator, a vertical mill, a dust collector and a collection bin. One end of the third belt conveyor is connected to the second belt conveyor, and the other end is connected to the feed port of the vertical mill through the second elevator. The discharge port of the vertical mill is connected to the feed port of the dust collector, and the discharge port of the dust collector is connected to the collection bin. The collection bin is connected to the mixing unit through a first pipeline.

[0017] The wet grinding unit includes a fourth belt conveyor, a wet mill, a mud pool and a plunger pump. One end of the fourth belt conveyor is connected to the second belt conveyor, and the other end is connected to the feed port of the wet mill. The discharge port of the wet mill is connected to the mud pool through the second pipeline. The mud pool is connected to the mixing unit through the third pipeline, and the plunger pump is installed on the third pipeline.

[0018] The mixing unit comprises a mixer.

[0019] The beneficial effects of the present invention are as follows: the present invention reduces production costs and improves product quality by finely controlling the water content and mixing ratio of dry-grinded powder and wet-grinded slurry and improving the mixing means of the original process, thereby effectively improving the production efficiency of alumina-based high-temperature synthetic materials under the premise of energy conservation and emission reduction. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a process flow chart of the present invention.

[0021] Figure 2 It is a system block diagram of the present invention. DETAILED DESCRIPTION

[0022] The technical solution of the present invention will be described clearly and completely below in conjunction with the drawings of this specification. It should be noted that the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0023] like Figure 1 As shown, a process for producing alumina-based high-temperature synthetic materials comprises the following steps: S1. Mixing raw materials according to product requirements; the raw materials include high-alumina bauxite, alumina particles and silica particles; adjusting the composition of high-alumina bauxite by alumina particles and silica particles; S2, the raw materials are crushed and screened to obtain screened materials; the raw materials are crushed by two-stage crushing, namely jaw crusher and roller crusher, and the roller crusher is screened after the crushing, and the unqualified materials screened are returned to the roller crushing process for re-crushing; S3, the screened material is divided into material A and material B, the weight of material A is less than that of material B, and the weight of material A is 20-30% of the total weight of the screened material; in one embodiment of the present invention, the weight of material A is 25% of the total weight of the screened material; S4, material A is wet-milled with additives to obtain wet abrasives with a water content of 28-30%; material B is dry-milled with additives to obtain dry-milled powder with a water content of 5%; the main functions of the additives are to reduce water, enhance fluidity, increase green body strength, and aid sintering; the additive added to material B is a powdered water reducer; the additive added to material A is a dispersed suspension water reducer, the wet-milling equipment is a wet ball mill, and the mass percentages of the components during wet-milling are: material A is 65%-80%, dispersed suspension water reducer (sulfonic acid + carboxylic acid) is 0.2%-1%, and water is 19.8%-34%; S5. The wet abrasive and the dry abrasive powder are simultaneously fed into a mixer for mixing. Before the wet abrasive and the dry abrasive powder are fed into the mixer, the wet abrasive is homogenized in a slurry pool, and the dry abrasive powder is homogenized in a powder bin. The mixing ratio is 1:4 by weight to obtain a mixture. With the above mixing ratio, the water content of the mixture is 5-6%. S6, the mixed material is transported to a press for pressing and forming to obtain a primary product; S7. The primary product is sent to the drying kiln for drying, so that the moisture content of the primary product is less than 1%, which becomes the secondary product; S8, the secondary product is put into a high-temperature kiln for calcination to obtain a clinker product; the calcination temperature range applicable to the present invention is 1100-1700°C; S9. The clinker product is crushed to obtain homogenized clinker.

[0024] The present invention adopts a dry method + wet method mixed process route, the dry grinding powder obtained by dry fine grinding is used as the base material, and the slurry-like wet grinding material obtained by wet fine grinding plays the role of a molding binder, which reduces the amount of binder used by 30-50% compared with the dry method. Under the premise of ensuring the high temperature performance of the product (load softening temperature), the firing temperature is reduced by 5-8°C compared with the dry process, and the gas consumption is reduced by 25% per ton of product, and full-process automated production can be realized.

[0025] like Figure 2 As shown, the present invention also provides a system for producing alumina-based high-temperature synthetic materials using the above-mentioned process, including a crushing unit, a dry grinding unit, a wet grinding unit, a mixing unit, a press unit, a drying kiln and a tunnel kiln, wherein the drying kiln and the tunnel kiln are connected by rails, the crushing unit is connected to the dry grinding unit and the wet grinding unit respectively, the dry grinding unit and the wet grinding unit are connected to the mixing unit respectively, the mixing unit is connected to the press unit, a manipulator is arranged between the press unit and the drying kiln, the press unit automatically presses, lays, and produces bricks, the manipulator stacks bricks according to programming, and the brick stacking vehicle enters the drying kiln and the tunnel kiln in sequence through the rails. The above-mentioned system for producing alumina-based high-temperature synthetic materials is a fully automated production line.

[0026] The crushing unit includes a raw material bin, a jaw crusher feeder, a jaw crusher, a roller feeder, a roller crusher, a first belt conveyor, a first elevator, a drum screen, a feed bin and a second belt conveyor which are connected in sequence. The feed bin is connected to the dry grinding unit and the wet grinding unit respectively through the second belt conveyor.

[0027] The dry grinding unit includes a third belt conveyor, a second elevator, a vertical mill, a dust collector and a collection bin, one end of the third belt conveyor is connected to the second belt conveyor, and the other end is connected to the feed port of the vertical mill through the second elevator, the discharge port of the vertical mill is connected to the feed port of the dust collector, the discharge port of the dust collector is connected to the collection bin, and the collection bin is connected to the mixing unit through the first pipeline. In one embodiment of the present invention, the first pipeline is gas transported.

[0028] The wet grinding unit includes a fourth belt conveyor, a wet mill, a mud pool and a plunger pump. One end of the fourth belt conveyor is connected to the second belt conveyor, and the other end is connected to the feed port of the wet mill. The discharge port of the wet mill is connected to the mud pool through the second pipeline. The mud pool is connected to the mixing unit through the third pipeline, and the plunger pump is installed on the third pipeline.

[0029] The mixing unit comprises a mixer.

[0030] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

[0031] Parts of the present invention not described in detail are prior art.

Claims

1. A process for producing alumina-based high-temperature synthetic materials, characterized in that: The following steps are involved: S1. Mixing raw materials according to product requirements; the raw materials include high-alumina bauxite, alumina particles and silica particles; S2, the raw materials are crushed and screened to obtain screened materials with a particle size of 0-8 mm; S3. The screening material is divided into material A and material B. The weight of material A is less than that of material B, and the weight of material A is 20-30% of the total weight of the screening material; S4, material A is wet-milled and ground with additives to obtain wet abrasive with a water content of 28-30%; material B is dry-milled and ground with additives to obtain dry abrasive with a water content of 5%; S5, the wet abrasive and the dry abrasive are simultaneously fed into a mixer for mixing at a weight ratio of 1:4 to obtain a mixture; S6, the mixed material is transported to a press for pressing and molding to obtain a primary product; S7, the primary product is sent to the drying kiln for drying to obtain the secondary product; S8, the secondary product is put into a high-temperature kiln for calcination to obtain a clinker product; S9. The clinker product is crushed to obtain homogenized clinker.

2. A process for producing alumina-based high-temperature synthetic materials according to claim 1, characterized in that: In the step S2, the raw material is crushed by two-stage crushing, which is jaw crushing and roller crushing in sequence. After roller crushing, screening is performed, and the unqualified materials screened out are returned to the roller crushing process for re-crushing.

3. The process for producing alumina-based high-temperature synthetic materials according to claim 1, characterized in that: In step S3, the weight of material A is 25% of the total weight of the screened material.

4. The process for producing alumina-based high-temperature synthetic materials according to claim 1, characterized in that: In step S4, the additive added to material B is a powdered water reducer; the additive added to material A is a dispersed suspending water reducer, the wet grinding and refining equipment is a wet ball mill, and the mass percentages of the components during wet grinding and refining are: material A is 65%-80%, the dispersed suspending water reducer is 0.2%-1%, and water is 19.8%-34%.

5. The process for producing alumina-based high-temperature synthetic materials according to claim 1, characterized in that: In step S5, before the wet abrasive and the dry ground powder are fed into the mixer, the wet abrasive is homogenized in a slurry pool, and the dry ground powder is homogenized in a powder bin.

6. A system for producing alumina-based high-temperature synthetic materials using the process according to any one of claims 1 to 5, comprising a crushing unit, a dry grinding unit, a wet grinding unit, a mixing unit, a press unit, a drying kiln and a tunnel kiln, characterized in that: The drying kiln and the tunnel kiln are connected by rails, the crushing unit is respectively connected to the dry grinding unit and the wet grinding unit, the dry grinding unit and the wet grinding unit are respectively connected to the mixing unit, the mixing unit is connected to the press unit, a manipulator is arranged between the press unit and the drying kiln, the press unit automatically presses, distributes and discharges bricks, the manipulator stacks bricks according to programming, and the brick stacking vehicle enters the drying kiln and the tunnel kiln in sequence through the rails.

7. The system for producing alumina-based high-temperature synthetic materials according to claim 6, characterized in that: The crushing unit includes a raw material bin, a jaw crusher feeder, a jaw crusher, a roller feeder, a roller crusher, a first belt conveyor, a first elevator, a drum screen, a feed bin and a second belt conveyor which are connected in sequence. The feed bin is connected to the dry grinding unit and the wet grinding unit respectively through the second belt conveyor.

8. The system for producing alumina-based high-temperature synthetic materials according to claim 6, characterized in that: The dry grinding unit includes a third belt conveyor, a second elevator, a vertical mill, a dust collector and a collection bin. One end of the third belt conveyor is connected to the second belt conveyor, and the other end is connected to the feed port of the vertical mill through the second elevator. The discharge port of the vertical mill is connected to the feed port of the dust collector, and the discharge port of the dust collector is connected to the collection bin. The collection bin is connected to the mixing unit through a first pipeline.

9. The system for producing alumina-based high-temperature synthetic materials according to claim 6, characterized in that: The wet grinding unit includes a fourth belt conveyor, a wet mill, a mud pool and a plunger pump. One end of the fourth belt conveyor is connected to the second belt conveyor, and the other end is connected to the feed port of the wet mill. The discharge port of the wet mill is connected to the mud pool through the second pipeline. The mud pool is connected to the mixing unit through the third pipeline, and the plunger pump is installed on the third pipeline.

10. The system for producing alumina-based high-temperature synthetic materials according to claim 6, characterized in that: The mixing unit comprises a mixer.

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