Ceramic roller based on high-aluminum solid waste and preparation method thereof

Abstract

The application discloses a ceramic roller based on zirconium-aluminum solid waste and a preparation method thereof, and relates to the field of refractory materials. The ceramic roller based on zirconium-aluminum solid waste is mainly prepared from the following raw materials in parts by weight: 30-40 parts of alumina, 20-30 parts of kaolin, 10-30 parts of zirconium-aluminum powder, 8-22 parts of zirconium-aluminum micro powder and 2-8 parts of a binder; the sum of the parts by weight of the alumina, the kaolin, the zirconium-aluminum powder and the zirconium-aluminum micro powder is 100 parts; the zirconium-aluminum powder and the zirconium-aluminum micro powder are obtained by crushing and grinding zirconium-aluminum ball stone solid waste; the average particle size of the zirconium-aluminum powder is 30-80 microns, and the content of ZrO2 in the zirconium-aluminum powder is less than or equal to 10 wt%; the average particle size of the zirconium-aluminum micro powder is 1-10 microns, and the content of ZrO2 in the zirconium-aluminum micro powder is greater than or equal to 25 wt%; and the content of RO in the kaolin is greater than or equal to 4 wt%. The ceramic roller has high bending strength and good thermal shock resistance.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of ceramic roller bars, in particular to a ceramic roller bar based on high-aluminum solid waste and a preparation method thereof. BACKGROUND

[0002] Zirconium-aluminum spheralite is the most widely used grinding medium at present, which will be worn out and cracks will be generated on the surface after long-term use, so it needs to be replaced frequently, thereby generating zirconium-aluminum spheralite solid waste. At present, the zirconium-aluminum spheralite solid waste is difficult to process and recycle, and the application range of the prepared product is narrow, and the added value and solid waste utilization rate are low. The most common practical way at present is to mix into refractory materials, but this has high requirements on the particle size distribution of high-aluminum spheralite solid waste, the early treatment process is complex, and the added value of the product is also not high.

[0003] On the other hand, the roller bars used by the current ceramic enterprises are mostly corundum-mullite ceramic roller bars, which have low strength and are difficult to meet the use requirements in some occasions. SUMMARY

[0004] The technical problem to be solved by the present application is to provide a ceramic roller bar based on zirconium-aluminum solid waste, which can realize mass utilization of zirconium-aluminum solid waste and has high strength.

[0005] The technical problem to be solved by the present application is to provide a ceramic roller bar based on zirconium-aluminum solid waste, which can realize mass utilization of zirconium-aluminum solid waste and has high strength.

[0006] In order to solve the above technical problems, the present application provides a ceramic roller bar based on zirconium-aluminum solid waste, which is mainly made of the following raw materials by weight:

[0007] alumina 30-40 parts, kaolin 20-30 parts, zirconium-aluminum powder 10-30 parts, zirconium-aluminum micro powder 8-22 parts, and binder 2-8 parts;

[0008] The sum of the weight parts of alumina, kaolin, zirconium-aluminum powder and zirconium-aluminum micro powder is 100 parts;

[0009] The zirconium-aluminum powder and the zirconium-aluminum micro powder are obtained by crushing and grinding zirconium-aluminum spheralite solid waste; the average particle size of the zirconium-aluminum powder is 30-80 microns, and the content of ZrO2 is ≤10wt%; the average particle size of the zirconium-aluminum micro powder is 1-10 microns, and the content of ZrO2 is ≥25wt%;

[0010] The content of RO in the kaolin is ≥4wt%.

[0011] As an improvement of the above technical solution, the content of Al2O3 in the zirconium-aluminum powder is ≥70wt%, and the total content of R2O, RO and Fe2O3 is ≥3wt%;

[0012] The content of Al2O3 in the zirconium-aluminum micro powder is less than or equal to 50 wt%, and the total content of R2O, RO and Fe2O3 is less than or equal to 3 wt%.

[0013] As an improvement of the above technical solution, the content of Al2O3 in the zirconium-aluminum powder is 70-80 wt%, the content of SiO2 is 6-10 wt%, the content of ZrO2 is 8-10 wt%, the content of Fe2O3 is 0.05-0.2 wt%, the content of K2O is 0.01-0.1 wt%, the content of Na2O is 2-3 wt%, and the LOI is 1-3 wt%.

[0014] The average particle size of the zirconium-aluminum powder is 45-55 mu m.

[0015] As an improvement of the above technical solution, the content of Al2O3 in the zirconium-aluminum micro powder is 40-50 wt%, the content of SiO2 is 18-25 wt%, the content of ZrO2 is 25-35 wt%, the content of Fe2O3 is 0.1-0.8 wt%, the content of K2O is 0.1-0.5 wt%, the content of Na2O is 1-2 wt%, and the LOI is 1-2.5 wt%.

[0016] The average particle size of the zirconium-aluminum powder is 3-5 mu m.

[0017] As an improvement of the above technical solution, the weight ratio of the zirconium-aluminum powder to the zirconium-aluminum micro powder is 1:1-2:1.

[0018] As an improvement of the above technical solution, the average particle size of the kaolin is 1-5 mu m, the content of Al2O3 is 28-35 wt%, the content of CaO is 1-5 wt%, and the content of MgO is 2-5 wt%.

[0019] The average particle size of the alumina is 5-10 mu m, and the content of Al2O3 is greater than or equal to 99 wt%.

[0020] As an improvement of the above technical solution, the binder is selected from one or more of polyvinyl alcohol, carboxymethyl cellulose and polyhydroxy cellulose.

[0021] Correspondingly, the application also discloses a preparation method of the ceramic roller based on the zirconium-aluminum solid waste.

[0022] The zirconium-aluminum ballstone solid waste is crushed, ground and classified to obtain zirconium-aluminum powder and zirconium-aluminum micro powder.

[0023] The alumina 30-40 parts, the kaolin 20-30 parts, the zirconium-aluminum powder 10-30 parts, the zirconium-aluminum micro powder 8-22 parts and the binder 2-8 parts are mixed to obtain a mixture.

[0024] 10-15 parts of water are mixed with the mixture to granulate and obtain a blank.

[0025] extruding and shaping the blank, and primary drying to obtain a roller blank body;

[0026] isostatic pressing the roller blank body under a pressure of 80-300 MPa;

[0027] secondary drying the roller blank body after isostatic pressing;

[0028] firing the roller blank body after secondary drying at 1300-1700 DEG C to obtain a ceramic roller product.

[0029] As an improvement of the above technical solution, the firing temperature is 1580-1610 DEG C, and the firing time is 28-32 h.

[0030] As an improvement of the above technical solution, in the step of extruding and shaping the blank, and primary drying to obtain a roller blank body, the blank is extruded and shaped, and then is aged for 20-50 h before primary drying at 80-120 DEG C for 35-40 h to obtain a roller blank body.

[0031] The present application has the following beneficial effects:

[0032] The ceramic roller based on zirconium-aluminum solid waste of the present application introduces zirconium-aluminum powder and zirconium-aluminum micro powder in the formula, which are obtained by crushing and grinding of zirconium-aluminum ball stone solid waste; the average particle size of the zirconium-aluminum powder is 30-80 μm, the content of ZrO2 is ≤10 wt%, and the average particle size of the zirconium-aluminum micro powder is 1-10 μm, the content of ZrO2 is ≥25 wt%. The present application introduces micro-crack reinforcement and strain-induced reinforcement in the ceramic roller after the above classification, effectively improves the strength of the ceramic roller, and also improves the thermal shock resistance of the ceramic roller. DETAILED DESCRIPTION

[0033] To make the purpose, technical solution and advantages of the present application clearer, the present application will be further described in detail below with reference to specific embodiments.

[0034] The present application provides a ceramic roller based on zirconium-aluminum solid waste, which is mainly made of the following raw materials by weight:

[0035] alumina 30-40 parts, kaolin 20-30 parts, zirconium-aluminum powder 10-30 parts, zirconium-aluminum micro powder 8-22 parts, and binder 2-8 parts; and the sum of the weight parts of alumina, kaolin, zirconium-aluminum powder and zirconium-aluminum micro powder is 100 parts;

[0036] The zirconium-aluminum powder and the zirconium-aluminum micro powder are obtained by crushing and grinding of the zirconium-aluminum ball stone solid waste. Specifically, some ZrO2 is introduced into the zirconium-aluminum ball stone to play a role of phase change toughening and reinforcement. Specifically, when the zirconium-aluminum ball stone is impacted, the tetragonal phase ZrO2 (t-ZrO2) stabilized by an alkaline earth metal or other elements (such as Y2O3) will induce a martensitic phase change and convert into monoclinic phase ZrO2 (m-ZrO2). The volume expansion accompanied by the lattice conversion will form a micro stress field and even a micro crack, thereby playing a role of phase change toughening and reinforcement. In order to sinter the zirconium-aluminum ball stone and stabilize the m-ZrO2 phase, some alkaline earth metals (such as CaO and MgO) are also introduced. However, during the action of the zirconium-aluminum ball stone as a grinding medium, the glass-like substances formed by the alkaline earth metals will be broken and worn out first due to their small hardness, resulting in some zirconium-rich areas in the waste zirconium-aluminum ball stone, which have many stress expansion sources and cracks and are easy to break. Therefore, the zirconium-aluminum ball stone solid waste can be effectively classified into zirconium-aluminum powder and zirconium-aluminum micro powder with different chemical compositions by crushing and grinding. Specifically, the average particle size of the zirconium-aluminum powder is 30-80 μm, and the content of ZrO2 is ≤10 wt%. The particle size of the zirconium-aluminum powder is larger, and the ZrO2 is mainly in the form of aggregate in the ceramic roller, which will form micro cracks before and after sintering, thereby playing a role of toughening and reinforcement, i.e. realizing micro crack reinforcement. The average particle size of the zirconium-aluminum micro powder is 1-10 μm, and the content of ZrO2 is ≥25 wt%. The particle size of the zirconium-aluminum micro powder is small, and the content of ZrO2 is high, and most of the ZrO2 is in the form of m-ZrO2. The zirconium-aluminum micro powder can be used as a matrix component and enter the corundum-mullite lattice of the ceramic roller, and then realize stability under the action of free alkaline earth metal (RO≥4 wt%) in kaolin at room temperature. When an external stress is applied, the zirconium-aluminum micro powder will produce a toughening and reinforcing effect, i.e. realizing strain-induced reinforcement, thereby effectively improving the strength of the ceramic roller. Through the above particle size classification, the zirconium-aluminum ball stone waste can be fully utilized, and the strength is improved from the aspects of micro crack reinforcement and strain-induced reinforcement.

[0037] Specifically, the average particle size of the zirconium-aluminum powder is relatively large, being 30-80 μm. If the average particle size is relatively small, a large amount of ball milling work is required, which can cause part of the m-Zr02 to transform into t-Zr02. The micro-cracks caused by the excessive t-Zr02 can reduce the strength. In addition, the ceramic roller is used at high temperature. The volume shrinkage caused by the transformation of excessive t-Zr02 into t-Zr02 during the heating process can also reduce the high-temperature strength of the ceramic roller. For example, the average particle size of the zirconium-aluminum powder is 35 μm, 39 μm, 44 μm, 49 μm, 52 μm, 57 μm, 64 μm, 72 μm or 77 μm, but is not limited thereto. Preferably, the average particle size of the zirconium-aluminum powder is 45-55 μm, and more preferably, 50-55 μm. The zirconium-aluminum powder has relatively large particles. The t-Zr02 in the zirconium-aluminum powder has a relatively large particle size. The m-Zr02 formed by the sintering and heating also has a relatively large particle size. Since the t-Zr02 mainly exists in the form of aggregate and has less contact with the alkaline earth metal in the kaolin, it is difficult to be effectively stabilized. Therefore, the t-Zr02 is more likely to transform into t-Zr02 during the cooling process (about 800-950 °C), thereby achieving micro-crack toughening.

[0038] Specifically, the content of Zr02 in the zirconium-aluminum powder is ≤10 wt%, preferably 5-10 wt%, and for example, 5.4 wt%, 5.8 wt%, 6.2 wt%, 6.6 wt%, 7 wt%, 7.4 wt%, 8 wt%, 8.4 wt%, 9 wt% or 9.5 wt%, but is not limited thereto. More preferably, the content of Zr02 in the zirconium-aluminum powder is 8-10 wt%, and further preferably, 9-10 wt%.

[0039] The content of Al203 in the zirconium-aluminum powder is ≥70 wt%, which mainly exists in the form of corundum and mullite phases and can be used as aggregate. Preferably, the content of Al203 in the zirconium-aluminum powder is 70-85 wt%, and for example, 70.5 wt%, 71.1 wt%, 71.8 wt%, 72.4 wt%, 73.3 wt%, 74.6 wt%, 75 wt%, 77 wt%, 79 wt%, 80.4 wt%, 81.8 wt%, 83 wt% or 84.5 wt%, but is not limited thereto. Preferably, the content of Al203 in the zirconium-aluminum powder is 70-80 wt%, and more preferably, 75-80 wt%.

[0040] The total content of R2O, RO and Fe2O3 in the zirconium-aluminum powder is greater than or equal to 3 wt%, wherein R2O is alkali metal oxide, such as Li2O, Na2O or K2O, but is not limited thereto. RO is alkaline earth metal compound, such as CaO, MgO, but is not limited thereto. Preferably, in one embodiment, the content of Fe2O3 in the zirconium-aluminum powder is 0.05-0.5 wt%, the content of K2O is 0.01-0.2 wt%, the content of Na2O is 2-4 wt%, the content of CaO is 0.1-1 wt%, and the content of MgO is 0.2-2 wt%. Preferably, the content of Fe2O3 in the zirconium-aluminum powder is 0.05-0.2 wt%, the content of K2O is 0.01-0.1 wt%, the content of Na2O is 2-3 wt%, the content of CaO is 0.1-1 wt%, and the content of MgO is 0.8-1.5 wt%.

[0041] The content of SiO2 in the zirconium-aluminum powder is 5-15 wt%, and is exemplarily 6.5 wt%, 8 wt%, 9.5 wt%, 11 wt%, 13.5 wt% or 14.5 wt%, but is not limited thereto. Preferably, the content of SiO2 is 6-10 wt%.

[0042] The LOI (loss on ignition) of the zirconium-aluminum powder under oxidation atmosphere at 1000°C is 1-4 wt%, preferably 1-3 wt%, and more preferably 1.5-2.5 wt%.

[0043] Specifically, the amount of the zirconium-aluminum powder is 10-30 parts, and is exemplarily 12 parts, 14 parts, 16 parts, 18 parts, 20 parts, 22 parts, 24 parts, 26 parts or 28 parts, but is not limited thereto. Preferably, the amount of the zirconium-aluminum powder is 15-25 parts.

[0044] Specifically, the average particle size of the zirconium-aluminum powder is small, and is 1-10 μm. If the average particle size is too large, it is difficult for the zirconium-aluminum powder to enter the ceramic roller bar matrix, to be stabilized by the free CaO and MgO in the kaolin, and to realize strain-induced strengthening. If the average particle size is too small, part of the m-ZrO2 is converted into t-ZrO2 during the grinding process, and the micro-cracks generated by excessive t-ZrO2 will reduce the strength. In addition, the ceramic roller bar is used at high temperature, and the volume shrinkage caused by the conversion of excessive t-ZrO2 into t-ZrO2 during the heating process will also reduce the high-temperature strength of the ceramic roller bar. Exemplarily, the average particle size of the zirconium-aluminum powder is 1.5 μm, 2.2 μm, 2.9 μm, 3.6 μm, 4.3 μm, 5.4 μm, 6.5 μm, 7.4 μm, 8.2 μm or 9.4 μm, but is not limited thereto. Preferably, the average particle size of the zirconium-aluminum powder is 3-5 μm, more preferably 3-4.5 μm, and further preferably 3-4 μm.

[0045] Specifically, the content of ZrO2 in the zirconium-aluminum micropowder is ≥25wt%, preferably 25-40wt%, and more preferably 25-35wt%, and even more preferably 28wt%-32wt%. For example, the content of ZrO2 is 27wt%, 28.5wt%, 29wt%, 30.5wt%, 33wt%, 34.5wt%, 36wt%, 37.5wt% or 39wt%, but is not limited thereto.

[0046] The content of Al2O3 in the zirconium-aluminum micropowder is ≤50wt%, preferably 40-55wt%, and more preferably 40-50wt%, and even more preferably 45-50wt%. For example, the content of Al2O3 is 40.5wt%, 42.1wt%, 44.5wt%, 46.3wt%, 47wt%, 48.5wt%, 50wt%, 52wt% or 54wt%, but is not limited thereto.

[0047] The total content of R2O, RO and Fe2O3 in the zirconium-aluminum micropowder is ≤3wt%. For example, the content of Fe2O3 is 0.05-1wt%, the content of K2O is 0.1-1wt%, the content of Na2O is 1-3wt%, the content of CaO is 0.1-1wt%, and the content of MgO is 0.1-1wt%. Preferably, the content of Fe2O3 is 0.1-0.8wt%, the content of K2O is 0.1-0.5wt%, the content of Na2O is 1-2wt%, the content of CaO is 0.1-0.5wt%, and the content of MgO is 0.1-0.8wt%.

[0048] The content of SiO2 in the zirconium-aluminum micropowder is 15-25wt%, and more preferably 18-25wt%. For example, the content of SiO2 is 16.5wt%, 18wt%, 19.5wt%, 21wt%, 23.5wt% or 24wt%, but is not limited thereto.

[0049] The LOI (loss on ignition, under an oxidizing atmosphere at 1000°C) of the zirconium-aluminum powder is 1-4wt%, preferably 1-2.5wt%, and more preferably 1-2wt%.

[0050] Specifically, the amount of the zirconium-aluminum micropowder is 8-22 parts, and more preferably 10-20 parts. For example, the amount of the zirconium-aluminum micropowder is 9 parts, 10.5 parts, 13 parts, 14.5 parts, 16 parts, 17.5 parts, 19 parts, 20.5 parts or 21 parts, but is not limited thereto.

[0051] Preferably, in one embodiment of the present application, the weight ratio of the zirconium-aluminum powder to the zirconium-aluminum micropowder is 1:1-2:1. Based on the above ratio, the strength of the ceramic roller can be further improved.

[0052] Specifically, the average particle size of the alumina is 2-10 mu m, and the content of Al2O3 is greater than or equal to 99 wt%. The amount of alumina is 30-40 parts, and the exemplary amount is 31 parts, 32 parts, 33 parts, 34 parts, 35 parts, 36 parts, 37 parts, 38 parts or 39 parts, but is not limited thereto. Preferably, the amount is 30-35 parts.

[0053] Specifically, the average particle size of the kaolin is 1-10 mu m, the content of Al2O3 is 25-35 wt%, the content of CaO is 0.5-5 wt%, and the content of MgO is 1-5 wt%; such kaolin can better stabilize t-ZrO2. Preferably, the average particle size of the kaolin is 1-5 mu m, the content of Al2O3 is 28-35 wt%, the content of CaO is 1-5 wt%, and the content of MgO is 2-5 wt%.

[0054] The amount of kaolin is 20-30 parts, and the exemplary amount is 21 parts, 22 parts, 23 parts, 24 parts, 25 parts, 26 parts, 27 parts, 28 parts or 29 parts, but is not limited thereto. Preferably, the amount is 25-30 parts.

[0055] Specifically, the binder can be selected from one or more of polyvinyl alcohol, carboxymethyl cellulose, and polyhydroxy cellulose, but is not limited thereto. The amount of the binder is 2-8 parts, and the exemplary amount is 2.5 parts, 3 parts, 4 parts, 4.5 parts, 6 parts, 6.5 parts, 7 parts or 7.5 parts, but is not limited thereto.

[0056] Correspondingly, the application also provides a preparation method of the ceramic roller based on zirconium-aluminum solid waste, which is used for preparing the ceramic roller described above, and specifically includes the following steps:

[0057] S1: crushing, grinding and grading the zirconium-aluminum ball stone solid waste to obtain zirconium-aluminum powder and zirconium-aluminum micro powder;

[0058] Specifically, the zirconium-aluminum ball stone solid waste can be first crushed by using a jaw crusher, a cone crusher or the like commonly used in the art, and then ground by using a ball mill, and then sieved and graded, but is not limited thereto. Preferably, the sieving is performed by using a sieve with a pore size of 10-20 mu m after grinding, but is not limited thereto.

[0059] S2: mixing 30-40 parts of alumina, 20-30 parts of kaolin, 10-30 parts of zirconium-aluminum powder, 8-22 parts of zirconium-aluminum micro powder, and 2-8 parts of a binder to obtain a mixture

[0060] S3: mixing 10-15 parts of water with the mixture to obtain a granulated blank;

[0061] S4: extruding and shaping the blank and drying it once to obtain a roller blank;

[0062] Specifically, a support rod is arranged inside the blank after extrusion molding to facilitate subsequent cold isostatic pressing. After aging (placed at 20-30℃, 80-100% RH) for 20-50h, the extrusion-molded body is dried at 80-120℃ for 35-40h to obtain a roller rod blank.

[0063] S5: isostatic pressing the roller rod blank at a pressure of 80-300MPa;

[0064] Preferably, the isostatic pressing is cold isostatic pressing, and the pressure is 100-250MPa. After the treatment is completed, the support rod is removed.

[0065] S6: secondary drying of the roller rod blank after isostatic pressing;

[0066] Specifically, the secondary drying is performed at a temperature of 80-120℃ for 10-20h.

[0067] S7: firing the roller rod blank after secondary drying at 1300-1700℃ to obtain a ceramic roller rod product.

[0068] Preferably, in one embodiment, the firing temperature is 1580-1610℃, and the firing time is 28-32h.

[0069] The application is further described below with specific examples:

[0070] Example 1

[0071] This example provides a ceramic roller rod based on zirconium aluminum solid waste, and the formula is as follows:

[0072] 40 parts of alumina, 20 parts of kaolin, 30 parts of zirconium aluminum powder, 10 parts of zirconium aluminum micro powder, and 8 parts of binder.

[0073] The alumina is α-alumina, the average particle size is 6.54μm, and the content of Al2O3 is 99.6wt%. The average particle size of the kaolin is 2.33μm, the content of Al2O3 is 30.3wt%, the content of CaO is 2.15wt%, and the content of MgO is 2.85wt%.

[0074] The average particle size of the zirconium aluminum powder is 60.42μm, and the chemical composition is as follows:

[0075] Al2O3 80.32wt%, SiO2 6.98wt%, ZrO2 5.74wt%, Fe2O3 0.16wt%, K2O 0.08wt%, Na2O 2.32wt%, CaO 0.85wt%, MgO 1.93wt%, and LOI 1.62wt%.

[0076] The average particle size of the zirconium-aluminum micro powder is 8.56 μm, and the chemical composition is as follows:

[0077] Al2O3 40.89wt%, SiO2 22.68wt%, ZrO2 32.79wt%, Fe2O3 0.14wt%, K2O 0.13wt%, Na2O 1.42wt%, CaO 0.15wt%, MgO 0.68wt%, and LOI is 1.12wt%.

[0078] The binder is carboxymethyl cellulose.

[0079] The preparation method of the ceramic roller rod based on zirconium-aluminum solid waste in this embodiment is as follows:

[0080] (1) The zirconium-aluminum spherulite solid waste is crushed, ground, and classified to obtain zirconium-aluminum powder and zirconium-aluminum micro powder;

[0081] Specifically, the zirconium-aluminum spherulite solid waste is crushed by a cone crusher, ball milled by a ball mill, and classified by sieving through a 15 μm sieve to obtain zirconium-aluminum powder and zirconium-aluminum micro powder;

[0082] (2) The alumina, kaolin, zirconium-aluminum powder, zirconium-aluminum micro powder, and binder are mixed to obtain a mixture

[0083] (3) 15 parts of water are mixed with the mixture to obtain a green body by granulation;

[0084] (4) The green body is extrusion molded, aged, and once dried to obtain a roller rod body;

[0085] The aging temperature is 25°C, the humidity is 88% RH, and the aging time is 36 h; the once drying temperature is 88°C, and the time is 36 h.

[0086] (5) The roller rod body is isostatic pressed at a pressure of 100 MPa;

[0087] (6) The roller rod body after isostatic pressing is secondarily dried;

[0088] The second drying temperature is 90°C, and the drying time is 15 h.

[0089] (7) The roller rod body after secondary drying is fired to obtain a ceramic roller rod product.

[0090] The firing temperature is 1600°C, and the firing time is 28 h.

[0091] Example 2

[0092] The embodiment provides a ceramic roller rod based on zirconium-aluminum solid waste, and the formula is as follows:

[0093] alumina 30 parts, kaolin 30 parts, zirconium-aluminum powder 18 parts, zirconium-aluminum micro powder 22 parts, and binder 2 parts;

[0094] The alumina is alpha-alumina, the average particle size of which is 6.54 μm, and the content of Al2O3 is 99.6 wt%; the average particle size of the kaolin is 2.33 μm, the content of Al2O3 is 30.3 wt%, the content of CaO is 2.15 wt%, and the content of MgO is 2.85 wt%.

[0095] The average particle size of the zirconium-aluminum powder is 60.42 μm, and the chemical composition of the zirconium-aluminum powder is as follows:

[0096] Al2O3 80.32 wt%, SiO2 6.98 wt%, ZrO2 5.74 wt%, Fe2O3 0.16 wt%, K2O 0.08 wt%, Na2O 2.32 wt%, CaO 0.85 wt%, MgO 1.93 wt%, and LOI 1.62 wt%.

[0097] The average particle size of the zirconium-aluminum micro powder is 8.56 μm, and the chemical composition of the zirconium-aluminum micro powder is as follows:

[0098] Al2O3 40.89 wt%, SiO2 22.68 wt%, ZrO2 32.79 wt%, Fe2O3 0.14 wt%, K2O 0.13 wt%, Na2O 1.42 wt%, CaO 0.15 wt%, MgO 0.68 wt%, and LOI 1.12 wt%.

[0099] The binder is polyhydroxy cellulose.

[0100] The preparation method of the ceramic roller in the embodiment based on zirconium-aluminum solid waste is as follows:

[0101] (1) The zirconium-aluminum ball stone solid waste is crushed, ground, and classified to obtain zirconium-aluminum powder and zirconium-aluminum micro powder;

[0102] Specifically, the zirconium-aluminum ball stone solid waste is crushed by a cone crusher, ground by a ball mill, and classified by sieving through a 15 μm sieve to obtain zirconium-aluminum powder and zirconium-aluminum micro powder;

[0103] (2) The alumina, kaolin, zirconium-aluminum powder, zirconium-aluminum micro powder, and binder are mixed to obtain a mixture

[0104] (3) 10 parts of water are mixed with the mixture to obtain a granulated blank;

[0105] (4) The blank is extrusion-molded, aged, and dried once to obtain a roller blank;

[0106] The aging temperature is 25°C, the humidity is 88% RH, and the aging time is 36 h.

[0107] (5) The roller bar blank is subjected to isostatic pressing at a pressure of 100 MPa.

[0108] (6) The roller bar blank subjected to isostatic pressing is subjected to secondary drying.

[0109] The secondary drying temperature is 90°C, and the drying time is 15 h.

[0110] (7) The roller bar blank subjected to secondary drying is fired to obtain a ceramic roller bar product.

[0111] The firing temperature is 1550°C, and the firing time is 30 h.

[0112] Example 3

[0113] This example provides a ceramic roller bar based on zirconium aluminum solid waste, and the formula is as follows:

[0114] 36 parts of alumina, 26 parts of kaolin, 19 parts of zirconium aluminum powder, 19 parts of zirconium aluminum micro powder, and 4.5 parts of a binder.

[0115] The alumina is α-alumina, the average particle size of which is 6.54 μm, and the content of Al2O3 is 99.6 wt%. The average particle size of the kaolin is 2.33 μm, the content of Al2O3 thereof is 30.3 wt%, the content of CaO is 2.15 wt%, and the content of MgO is 2.85 wt%.

[0116] The average particle size of the zirconium aluminum powder is 51.35 μm, and the chemical composition thereof is as follows:

[0117] Al2O3 76.41 wt%, SiO2 7.85 wt%, ZrO2 9.36 wt%, Fe2O3 0.18 wt%, K2O 0.02 wt%, Na2O 2.54 wt%, CaO 0.58 wt%, MgO 1.07 wt%, and LOI 1.99 wt%.

[0118] The average particle size of the zirconium aluminum micro powder is 3.98 μm, and the chemical composition thereof is as follows:

[0119] Al2O3 46.58 wt%, SiO2 20.07 wt%, ZrO2 29.02 wt%, Fe2O3 0.54 wt%, K2O 0.21 wt%, Na2O 1.36 wt%, CaO 0.33 wt%, MgO 0.51 wt%, and LOI 1.38 wt%.

[0120] The binder is polyhydroxy cellulose.

[0121] The preparation method of the ceramic roller rod based on zirconium aluminum solid waste in this embodiment is as follows:

[0122] (1) The zirconium aluminum ball stone solid waste is crushed, ground, and classified to obtain zirconium aluminum powder and zirconium aluminum micro powder;

[0123] Specifically, the zirconium aluminum ball stone solid waste is crushed by a cone crusher, ground by a ball mill, and classified by sieving through a 10 μm sieve to obtain zirconium aluminum powder and zirconium aluminum micro powder;

[0124] (2) The alumina, kaolin, zirconium aluminum powder, zirconium aluminum micro powder, and binder are mixed to obtain a mixture;

[0125] (3) 12 parts of water are mixed with the mixture to obtain a green body by granulation;

[0126] (4) The green body is extrusion molded, aged, and dried once to obtain a roller rod body;

[0127] The aging temperature is 25 °C, the humidity is 88% RH, and the aging time is 36 h; the first drying temperature is 88 °C, and the first drying time is 36 h.

[0128] (5) The roller rod body is subjected to isostatic pressing treatment under a pressure of 100 MPa;

[0129] (6) The roller rod body after isostatic pressing treatment is dried for the second time;

[0130] The second drying temperature is 90 °C, and the second drying time is 15 h.

[0131] (7) The roller rod body after the second drying is fired to obtain a ceramic roller rod product.

[0132] The firing temperature is 1580 °C, and the firing time is 28 h.

[0133] Example 4

[0134] The present embodiment provides a ceramic roller rod based on zirconium aluminum solid waste, and the formula is as follows:

[0135] Alumina 36 parts, kaolin 26 parts, zirconium aluminum powder 28 parts, zirconium aluminum micro powder 10 parts, and binder 4.5 parts;

[0136] The alumina is α-alumina, the average particle size of which is 6.54 μm, and the content of Al2O3 is 99.6 wt%; the average particle size of the kaolin is 2.33 μm, the content of Al2O3 thereof is 30.3 wt%, the content of CaO is 2.15 wt%, and the content of MgO is 2.85 wt%.

[0137] The average particle size of the zirconium-aluminum powder is 51.35 μm, and the chemical composition is as follows:

[0138] Al2O3 76.41wt%, SiO2 7.85wt%, ZrO2 9.36wt%, Fe2O3 0.18wt%, K2O 0.02wt%, Na2O 2.54wt%, CaO 0.58wt%, MgO 1.07wt%, and LOI is 1.99wt%.

[0139] The average particle size of the zirconium-aluminum micro powder is 3.98 μm, and the chemical composition is as follows:

[0140] Al2O3 46.58wt%, SiO2 20.07wt%, ZrO2 29.02wt%, Fe2O3 0.54wt%, K2O 0.21wt%, Na2O 1.36wt%, CaO 0.33wt%, MgO 0.51wt%, and LOI is 1.38wt%.

[0141] The binder is polyhydroxy cellulose.

[0142] The preparation method of the ceramic roller rod based on the zirconium-aluminum solid waste in the embodiment is as follows:

[0143] (1) The zirconium-aluminum spherulite solid waste is crushed, ground, and classified to obtain zirconium-aluminum powder and zirconium-aluminum micro powder;

[0144] Specifically, the zirconium-aluminum spherulite solid waste is crushed by a cone crusher, ground by a ball mill, and classified by sieving through a 10 μm sieve to obtain zirconium-aluminum powder and zirconium-aluminum micro powder;

[0145] (2) The alumina, kaolin, zirconium-aluminum powder, zirconium-aluminum micro powder, and binder are mixed to obtain a mixture;

[0146] (3) 12 parts of water are mixed with the mixture to obtain a green body by granulation;

[0147] (4) The green body is extrusion-molded, aged, and once-dried to obtain a roller rod body;

[0148] The aging temperature is 25°C, the humidity is 88% RH, and the aging time is 36 h; the once-drying temperature is 88°C, and the time is 36 h.

[0149] (5) The roller rod body is subjected to isostatic pressing treatment under a pressure of 100 MPa;

[0150] (6) The roller rod body after isostatic pressing treatment is subjected to secondary drying;

[0151] The secondary drying temperature is 90°C, and the drying time is 15 h.

[0152] (7) firing the roller blank after secondary drying to obtain a ceramic roller product.

[0153] The firing temperature is 1580℃ and the firing time is 28h.

[0154] Comparative Example 1

[0155] This comparative example provides a ceramic roller with the following formulation:

[0156] 40 parts of alumina, 20 parts of kaolin, 40 parts of zirconium-aluminum solid waste powder, and 8 parts of a binder;

[0157] The alumina is α-alumina with an average particle size of 6.54μm and an Al2O3 content of 99.6wt%; the kaolin has an average particle size of 2.33μm, an Al2O3 content of 30.3wt%, a CaO content of 2.15wt%, and a MgO content of 2.85wt%.

[0158] The zirconium-aluminum solid waste has an average particle size of 89.28μm and the following chemical composition:

[0159] Al2O3 61.34wt%, SiO2 18.51wt%, ZrO2 14.55wt%, Fe2O3 0.21wt%, K2O 0.24wt%, Na2O 2.13wt%, CaO 0.67wt%, MgO 0.76wt%, and LOI 1.59wt%.

[0160] The binder is carboxymethyl cellulose.

[0161] The method for preparing the ceramic roller based on zirconium-aluminum solid waste in this example is as follows:

[0162] (1) crushing and grinding the zirconium-aluminum ball stone solid waste to obtain zirconium-aluminum solid waste powder;

[0163] (2) mixing the alumina, kaolin, zirconium-aluminum powder, zirconium-aluminum micro powder, and binder to obtain a mixture

[0164] (3) mixing 15 parts of water with the mixture and granulating to obtain a blank;

[0165] (4) extruding the blank, aging, and primary drying to obtain a roller blank;

[0166] The aging temperature is 25℃, the humidity is 88%RH, and the aging time is 36h; the primary drying temperature is 88℃ and the time is 36h.

[0167] (5) isostatic pressing the roller blank under a pressure of 100MPa;

[0168] (6) the roller blank after isostatic pressing is dried again;

[0169] The temperature of the second drying is 90°C, and the drying time is 15h.

[0170] (7) the roller blank after the second drying is fired to obtain the finished ceramic roller.

[0171] The firing temperature is 1600°C, and the firing time is 28h.

[0172] Comparative Example 2

[0173] This comparative example provides a ceramic roller, which is different from Example 1 in that:

[0174] The average particle size of the kaolin is 5.35μm, the content of Al2O3 is 36.4wt%, the content of CaO is 0.15wt%, and the content of MgO is 0.53wt%.

[0175] The rest is the same as Example 1.

[0176] The ceramic rollers of Examples 1-4 and Comparative Examples 1-2 are tested, and the specific results are as follows:

[0177] Example 1 Example 2 Example 3 Example 4 Comparative Example 1 Comparative Example 2 coefficient of thermal expansion (x 10 -6 / °C) 6.32 6.38 6.11 6.14 6.52 6.44 Water absorption (%) 4.1 4.4 4.8 4.9 3.5 4.3 Cold modulus of rupture (MPa) 58 59 65 63 52 46 Thermal shock resistance (1350°C to 20°C, air cooling) 3 times not cracked 3 times not cracked 5 times not cracked 4 times not cracked 2 times not cracked 1 time not cracked

[0178] The above is the preferred embodiment of the application. It should be noted that those skilled in the art can make several improvements and refinements without departing from the principles of the application. These improvements and refinements are also considered within the scope of protection of the application.

Claims

1. A ceramic roller based on zirconium aluminum solid waste, characterized by, It is mainly made of the following raw materials by weight parts: alumina 30~40 parts, kaolin 20~30 parts, zirconium aluminum powder 10~30 parts, zirconium aluminum micro powder 8~22 parts, binder 2~8 parts; Among them, the sum of the weight parts of alumina, kaolin, zirconium aluminum powder and zirconium aluminum micro powder is 100 parts; The zirconium aluminum powder and the zirconium aluminum micro powder are both obtained by crushing and grinding zirconium aluminum ballstone solid waste; The average particle size of the zirconium aluminum powder is 30~80μm, the content of Al2O3 is 70~80wt%, the content of SiO2 is 6~10wt%, the content of ZrO2 is 8~10wt%, the content of Fe2O3 is 0.05~0.2wt%, the content of K2O is 0.01~0.1wt%, the content of Na2O is 2~3wt%, and the LOI is 1~3wt%; The average particle size of the zirconium aluminum micro powder is 1~10μm, the content of Al2O3 is 40~50wt%, the content of SiO2 is 18~25wt%, the content of ZrO2 is 25~35wt%, the content of Fe2O3 is 0.1~0.8wt%, the content of K2O is 0.1~0.5wt%, the content of Na2O is 1~2wt%, and the LOI is 1~2.5wt%; The content of RO in the kaolin is ≥4wt%, and the average particle size is 1~5μm, wherein RO is CaO and MgO.

2. The zirconia-alumina solid waste based ceramic roller as claimed in claim 1 wherein, The total content of R2O, RO and Fe2O3 in the zirconium aluminum powder is ≥3wt%. The total content of R2O, RO and Fe2O3 in the zirconium aluminum micro powder is ≤3wt%. Among them, R2O is K2O and Na2O.

3. The ceramic roller based on zirconium aluminum solid waste according to claim 1 or 2, characterized by, The average particle size of the zirconium aluminum powder is 45~55μm.

4. The ceramic roller based on zirconium aluminum solid waste according to claim 3, characterized by, The average particle size of the zirconium aluminum micro powder is 3~5μm.

5. The zirconia-alumina solid waste based ceramic roller as claimed in claim 4 wherein, The weight ratio of the zirconium aluminum powder to the zirconium aluminum micro powder is 1:1~2:

1.

6. The zirconium-aluminum solid waste based ceramic roller as claimed in claim 1 wherein, The content of Al2O3 in the kaolin is 28~35wt%, the content of CaO is 1~5wt%, and the content of MgO is 2~5wt%. The average particle size of the alumina is 5~10μm, and the content of Al2O3 is ≥99wt%.

7. The zirconia-alumina solid waste based ceramic roller as claimed in claim 1 wherein, The binder is selected from one or more of polyvinyl alcohol, carboxymethyl cellulose and polyhydroxy cellulose.

8. A method for producing a ceramic roller based on zirconium-aluminum solid waste according to any one of claims 1 to 7, characterized by, It comprises: Crushing, grinding and grading zirconium aluminum ballstone solid waste to obtain zirconium aluminum powder and zirconium aluminum micro powder; Mixing alumina 30~40 parts, kaolin 20~30 parts, zirconium aluminum powder 10~30 parts, zirconium aluminum micro powder 8~22 parts and binder 2~8 parts to obtain a mixture; Mixing 10~15 parts of water with the mixture to obtain a green body by granulation; Extruding the green body into a shape and drying it once to obtain a roller bar blank; Isostatic pressing the roller bar blank under a pressure of 80~300MPa; Secondary drying the roller bar blank after isostatic pressing; Firing the secondary dried roller bar blank at 1300~1700℃ to obtain a ceramic roller bar finished product.

9. The method of producing a ceramic roller bar based on zirconium-aluminum solid waste according to claim 8, characterized in that, The firing temperature is 1580~1610℃, and the firing time is 28~32h.

10. The method of producing a ceramic roller bar based on zirconium-aluminum solid waste according to claim 8, characterized in that, In the step of extruding and drying the blank once to obtain the roller bar blank body, the blank is extruded and dried once at 80-120°C for 35-40h after being left to stand for 20-50h to obtain the roller bar blank body. In the step of extruding and drying the blank once to obtain the roller bar blank body, the blank is extruded and dried once at 80-120°C for 35-40h after being left to stand for 20-50h to obtain the roller bar blank body.