Method for producing ceramic fiber from oxygen-controlled cracked coal gangue and production system thereof

Abstract

The present application relates to a kind of oxygen control coal gangue production ceramic fiber method and its production system, it is related to ceramic fiber production technical field, the present application will oxygen control coal gangue be applied to ceramic production in cracking technology, i.e., oxygen control coal gangue is transported to melting furnace after cracking reaction as the raw material of ceramic fiber generation, and the fuel gas generated after oxygen control cracking reaction is transported to drying furnace for ceramic fiber drying solidification, in addition, to further embody oxygen control coal gangue cracking technology in the application of ceramic fiber production, a kind of ceramic fiber production system is designed.The present application can further reduce the energy consumption of ceramic fiber production, reduce production cost, energy saving and environmental protection.

Description

Technical Field

[0001] The present invention belongs to the technical field of ceramic fiber production, and in particular relates to a method for producing ceramic fibers by oxygen-controlled cracking of coal gangue and a production system thereof. Background Art

[0002] Coal gangue is the largest solid waste in industrial production. Its main components are clay rock, sandstone, carbonate rock, aluminous rock, etc. Its chemical composition is mainly SiO2, Al2O3 and C, followed by Fe2O3, CaO, MgO, etc. In addition, it often contains a small amount of metal elements such as Ti and Ca. With the continuous increase in coal gangue emissions, the area occupied has further expanded, damaging the ecological environment and affecting human sustainable development. How to comprehensively utilize coal gangue and reduce its damage to the environment is of great research significance.

[0003] At present, the production process of ceramic fiber is to first use coal gangue as raw material, and prepare calcined kaolin through calcination. The calcination temperature is usually above 1100-1200℃, so that the moisture, volatile matter and residual carbon in the coal gangue are burned out. The calcined kaolin is then melted in a melting furnace (the temperature required for melting is generally above 1500℃), spun into fibers, collected into cotton, and needled into a blanket. Finally, the finished ceramic fiber is obtained through post-processing steps such as drying and curing (the treatment temperature is generally 550-850℃), cutting and rolling the blanket. It can be seen that the production of ceramic fiber consumes a lot of energy. However, with the increasing shortage of energy, seeking more energy-saving and low-energy ceramic fiber production lines and production processes is a technical problem that tends to be solved. To this end, we propose a method for producing ceramic fiber by oxygen-controlled cracking of coal gangue and its production system. Summary of the Invention

[0004] The purpose of the present invention is to provide a method and a production system for producing ceramic fibers by oxygen-controlled cracking of coal gangue in order to solve the above problems.

[0005] The present invention achieves the above-mentioned purpose through the following technical solutions:

[0006] As a first aspect of the present invention, the present invention provides a method for producing ceramic fibers by oxygen-controlled cracking of coal gangue, comprising the following steps:

[0007] S1. First, crush the coal gangue to control the particle size of the coal gangue to 5-10mm, then dry it for pretreatment and set aside;

[0008] S2, performing oxygen-controlled cracking on the coal gangue treated in step S1;

[0009] S3, after the oxygen-controlled cracking in step S2, the coal gangue is heated to 700-800°C, and is sent to a melting furnace for melting as a raw material for producing ceramic fibers, and then spun into fibers to complete fiberization, and then needle-punched to obtain a needle-punched blanket;

[0010] S4, conveying the needle-punched blanket obtained in step S3 to a drying furnace. Simultaneously, the purified fuel gas generated by the oxygen-controlled cracking in step S2 is conveyed to the drying furnace, and the drying furnace is heated to 550-850° C. to solidify the needle-punched blanket.

[0011] S5, cooling, cutting, and rolling the needle-punched blanket cured in step S4 to obtain finished ceramic fibers.

[0012] As a further optimization scheme of the present invention, in step S2, the process parameters of the oxygen-controlled pyrolysis are as follows: the temperature of the oxygen-controlled pyrolysis is 1000-1200°C, the atmosphere composition of the oxygen-controlled pyrolysis, by volume percentage, includes 80-90% N2 and 10-20% O2, and the atmosphere flow rate is 3000-4000 Nm 3 / h.

[0013] As a second aspect of the present invention, the present invention provides a ceramic fiber production system for implementing any of the above methods, comprising a melting furnace, a spinning unit, a cotton collection needling unit, a drying furnace and a post-processing unit connected in sequence, and further comprising a gangue oxygen-controlled cracking reactor, wherein the gas outlet of the gangue oxygen-controlled cracking reactor is connected to a cyclone separator via a pipeline, and the discharge port of the gangue oxygen-controlled cracking reactor is connected to a second screw conveyor via a discharging inclined hopper, and the second screw conveyor is arranged to penetrate the interior of the cyclone separator;

[0014] The air outlet of the cyclone separator is connected to a drying furnace for drying and curing ceramic fibers through a pipeline, and the discharge port of the second screw conveyor is connected to the feed port of the melting furnace;

[0015] The pretreated gangue is burned and cracked in the gangue oxygen-controlled cracking reactor and then transported to the melting furnace through the discharging inclined hopper and the second screw conveyor as the raw material for producing ceramic fibers. The gas generated by the combustion and cracking of the pretreated gangue in the gangue oxygen-controlled cracking reactor is purified by the cyclone separator and then transported to the drying furnace for drying and solidifying the ceramic fibers.

[0016] As a second aspect of the present invention, the present invention provides a ceramic fiber production system, comprising a melting furnace, a spinning unit, a cotton collection needling unit, a drying furnace and a post-processing unit connected in sequence, and also comprising a gangue oxygen-controlled cracking reactor as described above, wherein the gas outlet of the gangue oxygen-controlled cracking reactor is connected to a cyclone separator through a pipeline, and the discharge port of the gangue oxygen-controlled cracking reactor is connected to the feed port of a second screw conveyor by providing a discharge inclined hopper, and the second screw conveyor is arranged to penetrate the interior of the cyclone separator;

[0017] The air outlet of the cyclone separator is connected to a drying furnace for drying and curing ceramic fibers through a pipeline, and the discharge port of the second screw conveyor is connected to a melting furnace;

[0018] The pretreated gangue is burned and cracked in the gangue oxygen-controlled cracking reactor and then transported to the melting furnace through the discharging inclined hopper and the second screw conveyor as the raw material for producing ceramic fibers. The gas generated by the combustion and cracking of the pretreated gangue in the gangue oxygen-controlled cracking reactor is purified by the cyclone separator and then transported to the drying furnace for drying and solidifying the ceramic fibers.

[0019] As a further optimization solution of the present invention, the gangue oxygen-controlled cracking reactor includes a reactor body and an ignition combustion unit and an atmosphere control unit arranged in the reactor body, and also includes a grate arranged in the reactor body and driven to rotate by a driving device, and a hafnium carbide protective layer provided on the inner side wall of the reactor body, wherein the hafnium carbide protective layer is used to protect the reactor body from overheating;

[0020] A first screw conveyor extending from the lower end of the reactor body and penetrating the interior of the grate, the first screw conveyor being used to convey pretreated coal gangue; and

[0021] A material guide structure is provided directly above the grate, the material guide structure comprising a sliding sleeve slidingly provided along the outer side wall of the first screw conveyor, a material guide piece movably provided at the top of the sliding sleeve, a cylinder group evenly provided at the top of the grate, and a rotating sleeve rotatably provided on the outer side wall of the lower end of the sliding sleeve;

[0022] The pretreated gangue is conveyed into the reactor body by the first screw conveyor. At the same time, the cylinder group pushes the sliding sleeve to slide back and forth with the outer side of the first screw conveyor, and the guide piece swings relative to the sliding sleeve, thereby promoting the dispersion of the gangue. In the process of the gangue being dispersed from the guide piece to the grate, a material flow is formed. Under the reducing atmosphere provided by the atmosphere control unit, the material flow is ignited by the ignition combustion unit and then discharged onto the grate driven by the driving device to continue burning and generate gas.

[0023] As a further optimization scheme of the present invention, the sliding sleeve includes a vertical cylinder, the outer side wall of the vertical cylinder is evenly provided with four through grooves and the top of the vertical cylinder is provided with a circular ring, a sleeve shaft is provided at the position of each through groove on the circular ring, the inner side wall of the vertical cylinder is provided with multiple sliding grooves, and the outer side wall of the first screw conveyor is provided with sliders corresponding to the multiple sliding grooves.

[0024] As a further optimization scheme of the present invention, the guide piece is a conical cover structure formed by four unit sector pieces stacked in sequence, a connecting block is installed at one end of the unit sector piece, the connecting block is connected to the sleeve shaft, the connecting block is arranged in a circular arc surface towards the end of the sliding sleeve and a transmission tooth portion is arranged on the circular arc surface, and the outer wall of the first screw conveyor is provided with a transmission rack that cooperates with the transmission tooth portion.

[0025] As a further optimization scheme of the present invention, the reactor body is provided with a drainage unit above the material guiding structure, and the drainage unit includes an air collecting hood with a gas exhaust pipe on the outside, and a partition provided at the lower end of the air collecting hood. A rotating shaft coaxially arranged with the screw rod of the first screw conveyor is movably sleeved on the partition, and blades are evenly arranged on the outside of the rotating shaft, and a guide impeller is provided on the rotating shaft near the gas exhaust pipe.

[0026] As a further optimization scheme of the present invention, the ceramic fiber production system also includes a gangue pretreatment unit, which includes a gangue crushing unit, a gangue pulverizing unit, a gangue drying unit and a gangue storage bin connected in sequence.

[0027] As a further optimized solution of the present invention, the post-processing unit includes a needle punched blanket cooling unit, a cutting unit and a blanket rolling and packaging unit which are sequentially connected.

[0028] The beneficial effects of the present invention are:

[0029] (1) The present invention applies the coal gangue oxygen-controlled cracking technology to ceramic production, that is, the coal gangue after the oxygen-controlled cracking reaction is transported to a melting furnace as a raw material for producing ceramic fibers, and the fuel gas generated by the oxygen-controlled cracking reaction is transported to a drying furnace for drying and solidifying the ceramic fibers, which can further reduce the energy consumption of ceramic fiber production, reduce production costs, and save energy and protect the environment.

[0030] (2) When the gangue oxygen-controlled cracking reactor provided by the present invention performs oxygen-controlled cracking on the gangue, the gangue dispersion effect is good, and a material flow is formed in the process of the gangue being dispersed from the guide plate to the grate. At the same time, the gangue forming the material flow is preliminarily ignited under the action of the ignition combustion unit. The preliminarily ignited gangue will be evenly spread on the grate as the grate rotates. On the one hand, the gangue material is fully dispersed to avoid the prolonged burnout time and increased energy consumption caused by accumulation. On the other hand, the preliminarily ignited gangue is stacked with the unignited gangue material falling on the grate, and they ignite each other, thereby promoting the overall combustion effect of the gangue. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 A schematic diagram of the internal structure of the gangue oxygen-controlled cracking reactor provided by the present invention;

[0032] Figure 2 A top view of the material guiding structure provided by the present invention;

[0033] Figure 3 A structural stereogram of the connecting block provided by the present invention;

[0034] Figure 4 A structural stereogram of the sliding sleeve provided by the present invention;

[0035] Figure 5 A diagram showing the arrangement of the ceramic fiber production system provided by the present invention;

[0036] Figure 6 A simplified flowchart of the ceramic fiber production process provided by the present invention;

[0037] In the figure: 1. Reactor body; 2. First screw conveyor; 21. Drive rack; 22. Slider; 3. Grate; 4. Drive device; 5. Ignition combustion unit; 6. Material guide structure; 61. Sliding sleeve; 611. Vertical cylinder; 612. Ring; 613. Through groove; 614. Slide; 62. Material guide plate; 63. Rotating sleeve; 64. Cylinder group; 65. Sleeve shaft; 66. Connecting block; 67. Drive gear; 7. Drainage unit; 71. Wind hood; 72. Partition; 73. Rotating shaft; 74. Blade; 75. Guide impeller; 76. Gas discharge pipe; 8. Atmosphere control unit; 9. Discharge hopper; 10. Gangue pretreatment unit; 101. Gangue crushing unit; 102. Gangue pulverizer; 103. Gangue drying unit; 104. Gangue storage bin; 11. Second screw conveyor; 12. Cyclone separator; 13. Melting furnace; 14. Wire spinning unit; 15. Cotton collection and needling unit; 16. Drying furnace; 17. Post-processing unit; 171. Needle blanket cooling unit; 172. Cutting unit; 173. Blanket roll and baling unit; 18. Hafnium carbide protective layer. DETAILED DESCRIPTION

[0038] The present application is described in further detail below in conjunction with the accompanying drawings. It is necessary to point out that the following specific implementation methods are only used to further illustrate the present application and cannot be understood as limiting the scope of protection of the present application. Technicians in this field can make some non-essential improvements and adjustments to the present application based on the above application content.

[0039] Example 1

[0040] This embodiment also provides a method for producing ceramic fibers by oxygen-controlled cracking of coal gangue, comprising the following steps:

[0041] S1. First, crush the coal gangue to control the particle size of the coal gangue to 5-10mm, then dry it for pretreatment and set aside;

[0042] S2, performing oxygen-controlled cracking on the coal gangue treated in step S1;

[0043] S3, after the oxygen-controlled cracking in step S2, the coal gangue is heated to 700-800°C and used as a raw material for producing ceramic fibers. The coal gangue is first melted and then spun into fibers to complete fiberization, and then needle-punched to obtain a needle-punched blanket;

[0044] S4, conveying the needle-punched blanket obtained in step S3 to a drying furnace. Simultaneously, the purified fuel gas generated by the oxygen-controlled cracking in step S2 is conveyed to the drying furnace, and the drying furnace is heated to 550-850° C. to solidify the needle-punched blanket.

[0045] S5, cooling, cutting, and rolling the needle-punched blanket cured in step S4 to obtain finished ceramic fibers.

[0046] In specific applications, the process flow diagram is as follows Figure 6 As shown, first, the gangue ore is crushed to a particle size of 5-10mm. The crushed material with qualified particle size is dried to remove moisture and set aside, thus completing the pretreatment of the gangue. When crushing, a jaw crusher, hammer crusher, or a combination of the two can be selected according to the actual application.

[0047] Subsequently, the pretreated gangue is subjected to an oxygen-controlled cracking reaction. During the reaction, a reducing atmosphere is formed inside the gangue by controlling the oxygen supply. In this reducing atmosphere, the volatile organic matter is gasified and cracked. The specific process parameters of the oxygen-controlled cracking are as follows: a temperature of 1000-1200°C, an atmosphere composition of 80-90% N2 and 10-20% O2 by volume, and an atmosphere flow rate of 3000-4000 Nm 3 / h.

[0048] The coal gangue after oxygen-controlled cracking (temperature of 700-800℃) is used as the raw material for ceramic fiber production. The temperature of the coal gangue after oxygen-controlled cracking is raised to 1670℃ to melt the coal gangue material into liquid. The melted material is spun into fibers:

[0049] The spinning process utilizes a spinning machine. Molten gangue falls between the first and second rollers of the spinning machine. The high-speed rotation of the spinning rollers spins the material adhering to the second rollers into fibers, completing the fiberization process. A wind ring surrounds the spinning rollers, and compressed air is ejected from the nozzles of the wind ring to form a wind curtain. The cotton ejected by the spinning rollers is confined to a narrow, compact area by the wind curtain. The cotton formed by the spinning machine is evenly spread onto a collection belt under the negative pressure generated by the fan and then carried away by a variable frequency drive system, forming the semi-finished product—spun wadding. Driven by conveyor and pressure rollers, the wadding enters a needling machine for needle punching, producing a needled blanket. The needle punching frequency ranges from 70 to 140 times per minute. Approximately 350 needles are inserted in alternate rows to create a uniform, dense pattern of needle holes on the blanket. Needling stitches the cotton fibers together, increasing the product's tensile strength. A certain amount of softener is added during the spinning process to lubricate the cotton during needle punching, thus preventing the cotton fibers from being broken by the needles.

[0050] The needle-punched blanket is then conveyed to a drying furnace, typically at a temperature of 550-850°C. In the method provided in this embodiment, the combustion and cracking of coal gangue produces fuel gas that is then transported to the drying furnace. The high heat content of the fuel gas replaces the heat energy normally required to heat the drying furnace to nearly 600°C. The high-temperature drying of the needle-punched blanket causes the fibers within the blanket to microcrystallize, raising the product's operating temperature and preventing significant linear shrinkage that could affect product efficiency. This also allows the moisture in the fabric softener to evaporate. No adhesive spraying or bonding is required during the drying and solidification stage.

[0051] After the needle-punched blanket is cured at high temperature in a drying furnace, it is cooled, cut, and rolled. Once the temperature of the blanket drops to ambient temperature, it is easier to cut. According to the size requirements of different products, it is cut into different product lengths in a dust-free manner. Finally, the blanket is rolled after cutting and then packaged using an automatic baler to obtain the finished ceramic fiber.

[0052] In the existing technology, the production process of ceramic fiber is to first use coal gangue as raw material, and prepare calcined kaolin through calcination. The calcination temperature is usually above 1100-1200℃ to burn out the moisture, volatile matter and residual carbon in the coal gangue. The calcined kaolin is then melted in a melting furnace, spun into fibers, collected and needled into a blanket. Finally, the finished ceramic fiber is obtained through post-processing steps such as drying, curing, cutting and rolling.

[0053] The present application uses oxygen-controlled cracking technology to treat coal gangue instead of the coal gangue calcining process in the prior art, that is, the coal gangue is subjected to oxygen-controlled cracking. During the reaction, by controlling the oxygen supply, a reducing atmosphere is formed inside the coal gangue. In the reducing atmosphere, the organic matter is prompted to undergo gasification and cracking reactions, and high-grade fuel gas is produced and transported to the curing section of the ceramic fiber production line to provide heat energy for ceramic fiber curing, which can replace the nearly 600°C heat energy of the ceramic fiber curing section. At the same time, the coal gangue after oxygen-controlled cracking is transported to the melting section of the ceramic fiber production line as a catalyst for producing ceramic fibers. The raw material of the fiber, the temperature of the oxygen-controlled cracking of coal gangue is 700-800℃, and the cracked coal gangue is transported to the melting section of the ceramic fiber production line at a temperature of 700-800℃. The melting furnace only needs to increase the basic temperature from 700-800℃ to 1670℃ to melt the coal gangue material into a liquid temperature. It is known in the prior art that every 1℃ increase in the melting furnace requires 900 kcal of energy consumption, and 1 kilowatt-hour of electricity is equivalent to 800 kcal of energy consumption. It can be seen that the application of coal gangue oxygen-controlled cracking technology to ceramic fiber production in this application can further save energy consumption.

[0054] Example 2

[0055] In order to further demonstrate the application of coal gangue oxygen controlled cracking technology in ceramic fiber production, Figure 5 As shown, this embodiment provides a ceramic fiber production system, including a melting furnace 13, a spinning unit 14, a cotton collecting needling unit 15, a drying furnace 16 and a post-processing unit 17 connected in sequence. The melting furnace is a three-phase electrode heating furnace, and the inner wall of the furnace is also provided with a hafnium carbide protective layer 18.

[0056] The system also includes a gangue oxygen-controlled cracking reactor, the gas outlet of which is connected to a cyclone separator 12 via a pipeline, and the discharge port of the gangue oxygen-controlled cracking reactor is connected to a second screw conveyor 11 via a discharge hopper 9, and the second screw conveyor 11 is arranged to penetrate the interior of the cyclone separator 12;

[0057] The air outlet of the cyclone separator 12 is connected to a drying furnace 16 for drying and curing ceramic fibers through a pipeline, and the discharge port of the second screw conveyor 11 is connected to the feed port of the melting furnace 13;

[0058] The ceramic fiber production system further includes a gangue pre-processing unit 10, which includes a gangue crushing unit 101, a gangue pulverizing unit 102, a gangue drying unit 103, and a gangue storage bin 104, which are sequentially connected.

[0059] When the production system is used, the gangue ore is crushed and pulverized by the gangue crushing unit 101 and the gangue grinding unit 102 to obtain a particle size of 5-10 mm. The qualified crushed material is dried by the gangue drying unit 103 to remove moisture and then stored in the gangue storage bin 104, thus completing the pretreatment of the gangue. The gangue crushing unit 101 can be selected from a jaw crusher, a hammer crusher, or a combination of the two according to actual application conditions.

[0060] The gangue (temperature of 700-800°C) after oxygen-controlled cracking is discharged through the discharging hopper 9 and transported to the melting furnace 13 by the second screw conveyor 11 as raw material for ceramic fiber production. The melting furnace 13 only needs to use the temperature of the gangue after oxygen-controlled cracking as the basic temperature, and heat it to 1670°C to melt the gangue material into liquid. The melted material is discharged to the spinning unit 14 through the material discharge port of the melting furnace 13, and then transported to the melting furnace 13 through the discharging hopper 9 and the second screw conveyor 11 as raw material for ceramic fiber production. The pre-treated gangue is burned and cracked in the gangue oxygen-controlled cracking reactor to generate fuel gas, which is purified by the cyclone separator 12 and then transported to the drying furnace 16 for drying and solidification of ceramic fibers.

[0061] Furthermore, the spinning unit 14 uses a spinning machine, the cotton collecting needle punching unit 15 structure includes a cotton collecting net and a needle punching machine, and the post-processing unit 17 includes a needle blanket cooling unit 171, a cutting unit 172 and a blanket rolling and baling unit 173 which are connected in sequence through a feeding device. The needle blanket cooling unit 171 reduces the temperature of the needle blanket to the ambient temperature, which is conducive to cutting. According to the size requirements of different products, the cutting unit 172 cuts the blanket into different product lengths in a dust-free manner. Finally, after the needle blanket is cut, it is conveyed to the blanket rolling net of the blanket rolling and baling unit 173 for blanket rolling, and then packaged by the automatic baling machine of the blanket rolling and baling unit 173 to obtain the finished ceramic fiber.

[0062] Example 3

[0063] On the basis of Example 2, in order to further improve the overall combustion effect of coal gangue, in this example, Figure 1 As shown, the gangue oxygen-controlled cracking reactor includes a reactor body 1 and an ignition combustion unit 5 and an atmosphere control unit 8 arranged in the reactor body 1, and also includes a grate 3 arranged in the reactor body 1 and driven to rotate by a driving device 4; and

[0064] A first screw conveyor 2 extending from the lower end of the reactor body 1 and penetrating the interior of the grate 3, wherein the first screw conveyor 2 is used to convey pretreated coal gangue;

[0065] A material guide structure 6 is provided directly above the grate 3. The material guide structure 6 comprises a sliding sleeve 61 slidingly arranged along the outer side wall of the first screw conveyor 2, a material guide piece 62 movably arranged at the top of the sliding sleeve 61, a cylinder group 64 evenly arranged at the top of the grate 3, and a rotating sleeve 63 rotatably arranged on the outer side wall of the lower end of the sliding sleeve 61.

[0066] The interior of the reactor body 1 is functionally divided into a combustion layer, a reduction layer, and a dry distillation layer from bottom to top, and the ignition combustion unit 5 and the grate 3 are located in the combustion layer. In addition, whether the residual carbon in the gangue is completely burned during the oxygen-controlled cracking process will affect the quality of the ceramic fiber produced subsequently using it as a raw material. In order to control the amount of residual carbon after the gangue is burned, the atmosphere control unit 8 is specifically arranged at the bottom of the reactor body 1 so that it can supply air from below the grate 3, so that the direction of the gas and the direction of movement of the gangue particles are in a reverse running state, which helps to burn out the residual carbon when the gangue particles are burned, thereby ensuring the quality of the subsequent production of ceramic fibers.

[0067] In addition, in the prior art, the reactor body 1 is mostly cooled by a water jacket for overheating protection. However, this embodiment further provides a hafnium carbide protective layer 18 on the inner wall of the reactor body 1. Hafnium carbide, as a high-temperature resistant alloy material, can withstand temperatures of 3000°C. It replaces the traditional water jacket, which can protect the reactor body 1 from overheating and solve the problem of the traditional water jacket easily taking away heat and causing energy loss.

[0068] In this embodiment, the specific application process of the gangue oxygen-controlled cracking reactor is as follows:

[0069] The pre-treated gangue (in the form of particles with a particle size of 5-10 mm) is conveyed by the first screw conveyor 2 into the reactor body 1. At the same time, the cylinder group 64 pushes the sliding sleeve 61 to slide back and forth with the outer side of the first screw conveyor 2, and the guide piece 62 swings relative to the sliding sleeve 61, promoting the dispersion of the gangue.

[0070] Then the gangue is dispersed by the guide piece 62 and forms a material flow in the process of falling into the grate 3. Because the ignition and combustion unit 5 is usually set close to the grate 3, when the ignition and combustion unit 5 is started, the gangue is preliminarily ignited when the gangue forms a material flow, and because the grate 3 is driven to rotate by the driving device 4 in the process of the gangue falling to the grate 3, the preliminarily ignited gangue will be evenly spread on the grate 3 as the grate 3 rotates. On the one hand, the gangue material is fully dispersed to avoid the extension of the burnout time and the increase of energy consumption caused by accumulation. On the other hand, the preliminarily ignited gangue is stacked with the unignited gangue material falling on the grate 3, and ignites each other to promote the overall combustion effect of the gangue.

[0071] The gangue is oxygen-controlled combusted and cracked in a reducing atmosphere provided by the atmosphere control unit 8, and its internal volatile matter is decomposed into combustible gas, which is further formed into combustion gas in the reducing layer of the reactor body 1. The combustion gas is gathered from the top empty layer inside the reactor body 1 and discharged from the outlet of the reactor body 1 for further utilization.

[0072] Example 4

[0073] On the basis of Example 3, Figure 2-4 As shown, the sliding sleeve 61 includes a vertical cylinder 611, four through grooves 613 are evenly opened on the outer wall of the vertical cylinder 611, and a circular ring 612 is provided at the top of the vertical cylinder 611. A sleeve shaft 65 is provided on the circular ring 612 at the position corresponding to each through groove 613, and a plurality of sliding grooves 614 are opened on the inner wall of the vertical cylinder 611. The outer wall of the first screw conveyor 2 is provided with sliders 22 corresponding to the plurality of sliding grooves 614 respectively.

[0074] The guide piece 62 is a conical cover structure formed by four unit sector pieces stacked in sequence. A connecting block 66 is installed at one end of the unit sector piece. The connecting block 66 is sleeved with the sleeve shaft 65. The connecting block 66 is arranged in an arc surface at one end facing the sliding sleeve 61 and a transmission tooth portion 67 is arranged on the arc surface. The outer wall of the first screw conveyor 2 is provided with a transmission rack 21 that cooperates with the transmission tooth portion 67.

[0075] During application, as described in Example 3, the cylinder group 64 pushes the sliding sleeve 61 to slide back and forth with the outer side of the first screw conveyor 2, and the slider 22 on the outer wall of the first screw conveyor 2 slides in the slide groove 614 on the inner wall of the vertical cylinder 611. At the same time, the transmission rack 21 on the outer wall of the first screw conveyor 2 engages with the transmission tooth portion 67 for transmission. When the transmission tooth portion 67 rotates, the connecting block 66 and the sleeve shaft 65 rotate relative to the ring 612. At this time, the unit sector pieces connected to the connecting block 66 rotate relative to the ring 612. At the same time, since the four unit sector pieces are stacked in sequence, when each unit sector piece rotates relative to the ring 612, the guide piece 62 of the conical cover structure also swings in the vertical direction. When the coal gangue material transported by the first screw conveyor 2 falls on the guide structure 6, it is effectively broken up and dispersed in the swinging motion state of the guide piece 62.

[0076] The reactor body 1 is located above the material guiding structure 6 and is provided with a drainage unit 7. The drainage unit 7 includes a wind collecting hood 71 with a gas exhaust pipe 76 on the outside, and a partition 72 provided at the lower end of the wind collecting hood 71. A rotating shaft 73 coaxially arranged with the screw rod of the first screw conveyor 2 is movably sleeved on the partition 72. Blades 74 are evenly arranged on the outside of the rotating shaft 73, and a guide impeller 75 is provided on the rotating shaft 73 near the gas exhaust pipe 76.

[0077] When in use, the gas generated in the reactor body 1 enters the wind collecting hood 71 along the gap between the wind collecting hood 71 and the partition 72. Driven by the first screw conveyor 2, the rotating shaft 73 coaxially arranged with its screw rod also rotates accordingly. The blades 74 on the rotating shaft 73 rotate as the rotating shaft 73 rotates, driving the gas spiral up to the guide impeller 75, and under the rotation of the guide impeller 75, it is introduced into the gas exhaust pipe 76 and discharged out of the reactor body 1, which can guide the gas out of the reactor body 1 more quickly, and the efficiency of the device is further improved.

[0078] Example 5

[0079] The difference from the fourth embodiment is that the melting furnace 13 in this embodiment is a plasma heating furnace, and the inner wall of the plasma heating furnace is also provided with a hafnium carbide protective layer 18.

[0080] The plasma heater in the plasma heating furnace generates a plasma flame flow in the furnace, which comes into contact with the coal gangue (temperature of 700-800℃) that has undergone oxygen-controlled cracking, causing the coal gangue to heat up to about 1670℃ and melt to form a molten liquid. The molten liquid is discharged through the material discharge port of the plasma heating furnace and transported to the next process. Compared with traditional three-phase electrode heating furnaces, the plasma heating furnace has a faster heating speed, shortens the time required to melt the material, and has high energy utilization efficiency.

[0081] Example 6

[0082] The difference from the fourth embodiment is that the melting furnace 13 in this embodiment is a high-frequency heating furnace, and the inner wall of the high-frequency heating furnace is also provided with a hafnium carbide protective layer 18 .

[0083] The high-frequency heater installed inside the high-frequency heating furnace heats the conductor by utilizing the electromagnetic induction of the high-frequency heating coil and generates high-frequency eddy current in the conductor. With the high-frequency current as the heat source, it can heat the coal gangue (temperature is 700-800℃) after oxygen-controlled cracking to the melting point in a very short time, so that the coal gangue can be quickly melted to form a melt. The melt is discharged through the material discharge port of the high-frequency heating furnace and transported to the next process. Compared with the traditional three-phase electrode heating furnace, it has the characteristics of fast heating speed and high energy utilization efficiency.

[0084] The above-described embodiments merely illustrate several implementations of the present invention. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, and all such variations and improvements fall within the scope of protection of the present invention.

Claims

1. A ceramic fiber production system, applied to a method for producing ceramic fibers by oxygen-controlled cracking of coal gangue, characterized in that: The production system comprises a melting furnace (13), a spinning machine (14), a cotton collecting needle punching machine (15), a drying furnace (16) and a post-processing machine (17) which are sequentially connected, and is characterized in that it also comprises a gangue oxygen-controlled cracking reactor, the gas outlet of the gangue oxygen-controlled cracking reactor is connected to a cyclone separator (12) through a pipeline, and the discharge port of the gangue oxygen-controlled cracking reactor is connected to a second screw conveyor (11) through a discharge hopper (9), and the second screw conveyor (11) is arranged to penetrate the interior of the cyclone separator (12); The air outlet of the cyclone separator (12) is connected to a drying furnace (16) for drying and curing ceramic fibers through a pipeline, and the discharge port of the second screw conveyor (11) is connected to the feed port of the melting furnace (13); The pretreated gangue is burned and cracked in the gangue oxygen-controlled cracking reactor and then transported to the melting furnace (13) through the discharging inclined hopper (9) and the second screw conveyor (11) as a raw material for producing ceramic fibers, and the combustion and cracking of the pretreated gangue in the gangue oxygen-controlled cracking reactor to generate fuel gas is purified by the cyclone separator (12) and then transported to the drying furnace (16) for drying and solidifying the ceramic fibers; The method for producing ceramic fibers by oxygen-controlled cracking of coal gangue comprises the following steps: S1. First, crush the coal gangue to control the particle size of the coal gangue to 5-10mm, then dry it for pretreatment and set aside; S2, performing oxygen-controlled cracking on the coal gangue treated in step S1; S3, after the oxygen-controlled cracking in step S2, the coal gangue is heated to 700-800°C, and is sent to a melting furnace for melting as a raw material for producing ceramic fibers, and then spun into fibers to complete fiberization, and then needle-punched to obtain a needle-punched blanket; S4, conveying the needle-punched blanket obtained in step S3 to a drying furnace. Simultaneously, the purified fuel gas generated by the oxygen-controlled cracking in step S2 is conveyed to the drying furnace, and the drying furnace is heated to 550-850° C. to solidify the needle-punched blanket. S5, cooling, cutting, and rolling the needle-punched blanket cured in step S4 to obtain finished ceramic fibers.

2. A ceramic fiber production system according to claim 1, characterized in that: In step S2, the process parameters of the oxygen-controlled pyrolysis are as follows: the temperature of the oxygen-controlled pyrolysis is 1000-1200°C, the atmosphere composition of the oxygen-controlled pyrolysis is 80-90% N2 and 10-20% O2 by volume, and the atmosphere flow rate is 3000-4000 Nm 3 / h.

3. The ceramic fiber production system according to claim 1, characterized in that: The gangue oxygen-controlled cracking reactor comprises a reactor body (1), an ignition combustion unit (5) and an atmosphere control unit (8) arranged in the reactor body (1), and further comprises a grate (3) arranged in the reactor body (1) and driven to rotate by a driving device (4), and a hafnium carbide protective layer (18) arranged on the inner side wall of the reactor body (1), wherein the hafnium carbide protective layer (18) is used to protect the reactor body (1) from overheating; a first screw conveyor (2) extending from the lower end of the reactor body (1) and penetrating the interior of the grate (3), the first screw conveyor (2) being used to convey pretreated coal gangue; and a material guide structure (6) arranged directly above the grate (3), the material guide structure (6) comprising a sliding sleeve (61) slidingly arranged along the outer side wall of the first screw conveyor (2), a material guide piece (62) movably arranged at the top of the sliding sleeve (61), a cylinder group (64) evenly arranged at the top of the grate (3), and a rotating sleeve (63) rotatably arranged on the outer side wall of the lower end of the sliding sleeve (61); The pretreated gangue is conveyed by the first screw conveyor (2) into the reactor body (1). At the same time, the cylinder group (64) pushes the sliding sleeve (61) to slide back and forth with the outer side of the first screw conveyor (2), and the guide piece (62) swings relative to the sliding sleeve (61), thereby promoting the dispersion of the gangue. In the process of the gangue being dispersed from the guide piece (62) to the grate (3), a material flow is formed. Under the reducing atmosphere provided by the atmosphere control unit (8), the material flow is ignited by the ignition combustion unit (5) and then discharged onto the grate (3) driven by the driving device (4) to continue to burn and generate gas.

4. A ceramic fiber production system according to claim 3, characterized in that: The sliding sleeve (61) includes a vertical cylinder (611), the outer wall of the vertical cylinder (611) is evenly provided with four through grooves (613), and a circular ring (612) is provided at the top of the vertical cylinder (611), and a sleeve shaft (65) is provided at a position corresponding to each through groove (613) on the circular ring (612), the inner wall of the vertical cylinder (611) is provided with a plurality of chute grooves (614), and the outer wall of the first screw conveyor (2) is provided with sliders (22) corresponding to the plurality of chute grooves (614).

5. The ceramic fiber production system according to claim 3, characterized in that: The guide piece (62) is a conical cover structure formed by stacking four unit sector pieces in sequence. A connecting block (66) is installed at one end of the unit sector piece. The connecting block (66) is sleeved with the sleeve shaft (65). The connecting block (66) is arranged in an arc surface at one end facing the sliding sleeve (61) and a transmission tooth portion (67) is arranged on the arc surface. The outer side wall of the first screw conveyor (2) is provided with a transmission rack (21) that is in transmission cooperation with the transmission tooth portion (67).

6. A ceramic fiber production system according to claim 3, characterized in that: The reactor body (1) is located above the material guide structure (6) and is provided with a drainage unit (7). The drainage unit (7) includes a wind collecting hood (71) with a gas discharge pipe (76) provided on the outside, and a partition (72) provided at the lower end of the wind collecting hood (71). A rotating shaft (73) coaxially arranged with the screw rod of the first screw conveyor (2) is movably sleeved on the partition (72). Blades (74) are evenly arranged on the outside of the rotating shaft (73), and a guide impeller (75) is provided on the rotating shaft (73) near the gas discharge pipe (76).

7. The ceramic fiber production system according to claim 1, characterized in that: The ceramic fiber production system further comprises a gangue pretreatment unit (10), wherein the gangue pretreatment unit (10) comprises a gangue crushing unit (101), a gangue pulverizing unit (102), a gangue drying unit (103), and a gangue storage bin (104) which are sequentially connected.

8. The ceramic fiber production system according to claim 1, characterized in that: The post-processing unit (17) comprises a needle punched blanket cooling unit (171), a cutting unit (172), and a blanket rolling and packaging unit (173) which are sequentially connected.

9. The ceramic fiber production system according to claim 1, characterized in that: The melting furnace (13) is at least one of a plasma heating furnace, a high-frequency heating furnace, and a three-phase electrode heating furnace.

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