Device and method for impregnating foamed ceramic precursor for purifying aluminum-containing melt

Abstract

The invention discloses a foamed ceramic precursor dipping device and method for purifying aluminum-containing melt. The dipping device comprises a first conveying device, a first novel mud jacking conveying device, a first mud storage device, a second conveying device, an unpowered turnover device, a third conveying device, a second novel mud jacking conveying device, a second mud storage device, a fourth conveying device and a second slurry recovery device; the first conveying device, the first novel mud jacking conveying device, the second conveying device, the unpowered turnover device, the third conveying device, the second novel mud jacking conveying device and the fourth conveying device are connected in sequence. Full-automatic impregnation of the impregnation process is achieved, the interior of the foamed ceramic precursor is evenly impregnated with ceramic slurry, the problem that the porosity is reduced due to the fact that part of pores in a foamed ceramic finished product for aluminum melt purification are blocked is solved, and meanwhile the internal strength of the foamed ceramic for aluminum melt purification is high.

Description

Technical Field

[0001] The invention relates to the technical field of aluminum and aluminum alloy melt purification, and in particular to a foam ceramic filter plate impregnation device for aluminum and aluminum alloy melt purification. Background Art

[0002] Foam ceramic is a porous ceramic with a three-dimensional spatial network structure and high porosity (84%-94%). Due to its low density, low strength, high temperature resistance, acid and alkali corrosion resistance and good filtration and adsorption, it is widely used in metal melt filtration, automobile exhaust treatment, medical materials and other fields.

[0003] In recent years, the development of the third generation of filter materials, foam ceramic filters, has greatly increased the qualified rate of finished metal smelting products and greatly improved product performance. Casting is one of the industries where foam ceramic filters are most widely used, and foam ceramics for purifying aluminum and its aluminum alloy melts are an important branch of foam ceramics for casting. Its main function is to turn the turbulent and turbulent molten metal into a stable, uniform and clean molten metal after passing through the honeycomb holes of foam ceramics, thereby greatly reducing the scrap rate of castings caused by casting defects such as non-metallic inclusions and saving production costs.

[0004] The impregnation process is an important step in the preparation of the third generation of foam ceramics. In the past, the impregnation process was manual impregnation followed by slurry pressing, and the slurry holding capacity of the precursor was unstable, making it difficult to ensure product quality.

[0005] Therefore, how to invent an impregnation method to fully automate the impregnation process, eliminate the influence of human factors on product quality, achieve uniform impregnation of ceramic slurry inside the foam ceramic precursor without causing partial pore blockage inside the finished foam ceramic product for purifying aluminum melt, thereby reducing the porosity, and at the same time achieve high internal strength of the foam ceramic for purifying aluminum melt, has become a difficult problem that needs to be urgently solved in this field. Summary of the invention

[0006] The purpose of the present invention is to provide a foam ceramic precursor impregnation device for purifying aluminum-containing melts, which realizes full automation of the impregnation process, uniformly impregnates the ceramic slurry inside the foam ceramic precursor, and does not cause partial pore blockage inside the finished foam ceramic for purifying aluminum melts, thereby reducing the porosity. At the same time, the internal strength of the foam ceramic for purifying aluminum melts is high.

[0007] According to one aspect of the present invention, a foam ceramic precursor impregnation device for purifying aluminum-containing melt is provided, characterized in that the impregnation device includes a first conveying device, a first new grouting conveying device, a first slurry storage device, a second conveying device, an unpowered turning device, a third conveying device, a second new grouting conveying device, a second slurry storage device, a fourth conveying device, and a second slurry recovery device;

[0008] The first conveying device, the first new grouting conveying device, the second conveying device, the unpowered turning device, the third conveying device, the second new grouting conveying device, and the fourth conveying device are connected in sequence, so that the foam ceramic precursor passes through the first conveying device, the first new grouting conveying device, the second conveying device, the unpowered turning device, the third conveying device, the second new grouting conveying device, and the fourth conveying device in sequence;

[0009] The first conveying device, the first new grouting conveying device, and the second conveying device are located on the upper layer, the third conveying device, the second new grouting conveying device, and the fourth conveying device are located on the lower layer, the feeding end of the unpowered turning device is connected with the discharging end of the second conveying device, and the discharging end of the unpowered turning device is connected with the third conveying device;

[0010] The first slurry storage device is located above the first novel slurry conveying device;

[0011] The second slurry storage device is located above the second novel grouting and conveying device.

[0012] The beneficial effect of the present invention over the prior art is that, through the impregnation device including the first conveying device, the first new grouting conveying device, the first slurry storage device, the second conveying device unpowered turning device, the third conveying device, the second new grouting conveying device, the second slurry storage device, the fourth conveying device, the second slurry recovery device, and the second slurry storage device, the foam precursor ceramic body is transported to the first new grouting conveying device by the first conveying device, and the foam ceramic precursor is impregnated, squeezed, and rebounded multiple times during the conveying process by the first new grouting conveying device, and in this process, the foam ceramic precursor is impregnated with the first slurry output by the first slurry storage device, and because the ceramic precursor is impregnated, squeezed, and rebounded multiple times during the conveying process, the first slurry enters the central part of the foam ceramic precursor and is evenly distributed in the foam ceramic precursor;

[0013] The second conveying device conveys the foam ceramic precursor that has been impregnated once to the unpowered flipping device, and the unpowered flipping device automatically flips the foam ceramic precursor that has been impregnated once and falls into the lower layer and moves in the opposite direction of the original conveying direction to perform a second impregnation, thereby realizing continuous conveying and impregnation, saving equipment length, and being more conducive to use and promotion. At the same time, the foam ceramic precursor does not need to be clamped during the automatic flipping process, thereby avoiding the problem of damage to the foam ceramic substrate during the flipping process;

[0014] The flipped foam ceramic precursor is conveyed to the second new slurry conveying device by the third conveying device, so that the contact surface of the foam ceramic precursor with the first slurry faces downward during the first impregnation, and the side of the foam ceramic that is not directly impregnated faces upward, so that the first slurry in the second slurry storage device is output to the side of the foam ceramic that is not directly in contact with the first slurry for impregnation, and the foam ceramic precursor is impregnated, squeezed multiple times, and rebounded multiple times while being conveyed in the second new slurry conveying device, so as to achieve further uniform impregnation with the second slurry, so that the grid skeleton surface inside the foam ceramic precursor is uniformly attached to the first slurry and the second slurry in turn; thereby further enhancing the internal strength of the foam ceramic; achieving fully automated impregnation of the impregnation process, the interior of the foam ceramic precursor is uniformly impregnated with the ceramic slurry, and there will be no problem of partial pore blockage inside the foam ceramic product for aluminum melt purification, thereby reducing the porosity, and at the same time achieving high internal strength of the foam ceramic for aluminum melt purification.

[0015] Furthermore, the first novel grouting and conveying device comprises a first roller group and a second roller group arranged in parallel;

[0016] The first roller set is located above the second roller set;

[0017] The first roller group includes n first rotating rollers, and the second roller group includes m second rotating rollers; n<m;

[0018] The planes where the axes of the first rotating roller and the second rotating roller are located are arranged at an angle to the horizontal plane;

[0019] The distance between the first roller and the second roller is adjustable;

[0020] and / or

[0021] The second novel grouting and conveying device comprises a third roller group and a fourth roller group arranged in parallel;

[0022] The third roller set is located above the fourth roller set;

[0023] The third roller group includes j third rotating rollers, and the second roller group includes k fourth rotating rollers; j<k;

[0024] The axis of the third rotating roller and the axis of the fourth rotating roller are arranged at an angle to the horizontal plane;

[0025] The distance between the third roller and the fourth roller is adjustable;

[0026] Preferably, n=6-8, m=7-9; j=6-8, k=7-9.

[0027] The beneficial effect of adopting the previous step is that the first roller group is located above the second roller group; the first roller group includes n first rollers, and the second roller group includes m second rollers; n<m; the plane where the axis of the first roller and the axis of the second roller are located is set at an angle to the horizontal plane; the first new grouting and conveying device is used to immerse, extrude and rebound the foam ceramic precursor during the conveying process, so that the first slurry can enter the foam ceramic and be evenly distributed, and the first slurry will not accumulate in the foam ceramic to cause pore blockage, and there will be no problem of the first slurry not being attached to the tendons of some grids inside the foam ceramic precursor;

[0028] The second novel grouting and conveying device includes a third roller group and a fourth roller group arranged in parallel; the third roller group is located above the fourth roller group; the third roller group includes j third rotating rollers, and the second roller group includes k fourth rotating rollers; j<k; the axis of the third rotating roller and the plane where the axis of the fourth rotating roller is located are arranged at an angle to the horizontal plane; the second novel grouting and conveying device is used to immerse, extrude and rebound the foam ceramic precursor during the conveying process, which is conducive to the second slurry being able to enter the interior of the foam ceramic and be evenly distributed, and there will be no phenomenon of the second slurry accumulating inside the foam ceramic to cause pore blockage, and there will be no problem of the second slurry not adhering to the tendons of some grids inside the foam ceramic precursor.

[0029] Furthermore, the first slurry storage device includes a first container, and a plurality of first slurry outlets are provided at the bottom of the first container; the first slurry outlet is provided with a flow regulating valve;

[0030] The second slurry storage device comprises a second container, and a plurality of second slurry outlets are provided at the bottom of the second container; the second slurry outlet is provided with a flow regulating valve;

[0031] Preferably, the first container is provided with 3-4 first slurry discharge ports at the bottom; the second container is provided with 3-4 second slurry discharge ports at the bottom;

[0032] Preferably, the first slurry discharge port is located above the gap between two adjacent first rollers; and the second slurry discharge port is located above the gap between two adjacent third rollers.

[0033] The beneficial effect of adopting the previous step is that a plurality of first slurry discharge ports are provided at the bottom of the first container; the first slurry discharge port is provided with a flow regulating valve; it is possible to realize multi-point impregnation of the foam ceramics during the transportation process or to open different discharge ports at different time points to impregnate the foam ceramics, thereby facilitating uniform impregnation of the foam ceramic precursor.

[0034] Furthermore, the unpowered turning device comprises a fifth roller group and a sixth roller group which are arranged opposite to each other; the fifth roller group and the sixth roller group are arranged in a curved manner;

[0035] The fifth roller group includes a plurality of fifth rotating rollers, the plurality of fifth rotating rollers are arranged in a horizontal row, and the plurality of fifth rotating rollers surround a first arc;

[0036] The sixth roller group includes a plurality of sixth rollers, the plurality of the sixth rollers are arranged in a horizontal row, and the plurality of the sixth rollers surround a second arc;

[0037] The diameter of the circle where the first arc is located is 1350-1650 mm, and the central angle of the first arc is greater than or equal to 45°;

[0038] The diameter of the circle where the second arc is located is 1030-1500 mm, and the central angle of the second arc is greater than or equal to 45°;

[0039] Preferably, the second arc and the first arc are based on two concentric circles of φ1500mm and φ1180mm respectively, the second arc has 18 φ100mm*700mm sixth rollers evenly distributed on the semicircle of φ1180mm, and the first arc has 21 φ100mm*700mm fifth rollers evenly distributed on the semicircle of φ1500mm.

[0040] The beneficial effect of adopting the previous step is that, through the bending arrangement of the fifth roller group and the sixth roller group, when the foam ceramic precursor enters between the fifth roller group and the sixth roller group, it is affected by gravity and slides along the track between the fifth roller group and the sixth roller group to the next layer, and the foam ceramic precursor is turned over.

[0041] Furthermore, the second conveying device is arranged to be tilted downward along the conveying direction, and the angle between the second conveying device and the horizontal plane is α, 8°≤α≤15°;

[0042] The third conveying device (7) is arranged to be tilted downward along the conveying direction, and the angle between the second conveying device and the horizontal plane is β, 8°≤β≤15°.

[0043] The beneficial effect of adopting the previous step is that the second conveying device is tilted downward along the conveying direction, which is beneficial for the foam ceramic precursor that has been impregnated once to enter the unpowered turning device, that is, it is beneficial to increase a certain kinetic energy of the foam ceramic precursor before it enters the unpowered turning device, and at the same time, the outlet of the second conveying device is opposite to the inlet of the unpowered turning device.

[0044] Furthermore, the linear speed of the first roller, the linear speed of the second roller, the linear speed of the third roller and the linear speed of the fourth roller of the first novel grouting conveying device are all V1, the discharge flow rate of the first slurry storage device and the second slurry storage device are both Q, the belt speed of the second conveying belt of the second conveying device is V2, and the belt speed of the third conveying belt of the third conveying device is V3;

[0045] The s is the cross-sectional area of ​​the pulp outlet, V1 = γQ / s, γ = 0.35, V2 = δV1, V3 = V1,

[0046] δ = 1.1-1.3;

[0047] The s is the cross-sectional area of ​​the outlet of the first slurry storage device and the second slurry storage device; the γ is the flow rate control coefficient; the outlet flow rate of the first slurry storage device and the second slurry storage device is Q.

[0048] The beneficial effect of adopting the previous step is that by V1=γQ / s, 0.25≤γ≤0.5, the linear speed of the first roller of the first novel slurry pressing and conveying device, the linear speed of the second roller, the linear speed of the third roller of the second novel slurry pressing and conveying device, and the linear speed of the fourth roller V1 are controlled, and V1 and the cross-sectional area s of the slurry outlet and the flow rate of the outlet of the second slurry storage device are all satisfied with the above relationship, so that the first slurry and the second slurry are uniformly impregnated into the foam ceramic precursor;

[0049] The belt speed of the second conveyor belt passing through the second conveying device is V2, V2=δV1, δ=1.1-1.3, which is conducive to the relatively fast rate at which the impregnated foam ceramic precursor enters the unpowered turning device, and is conducive to the foam ceramic precursor entering the third conveying device along the track between the fifth roller group and the sixth roller group.

[0050] Furthermore, the second slurry storage device is located directly below the first new grouting and conveying device, and the second new grouting and conveying device is located directly below the second slurry storage device; and / or, the second slurry storage device includes a second container, the second container is provided with a first accommodating space and a second accommodating space, the first accommodating space is located above the second accommodating space, and the second accommodating space is connected to a plurality of first slurry discharge ports provided at the bottom of the first container.

[0051] The beneficial effect of the above step is that the first slurry flowing down during the first impregnation of the foam ceramic precursor can be collected by the second slurry storage device to avoid waste, and the second slurry can also be stored by the second slurry storage device to perform a second impregnation of the foam precursor;

[0052] The second slurry storage device includes a second container, and the second container is provided with a first accommodating space and a second accommodating space. When the first slurry and the second slurry are different, it is possible to recover the first slurry flowing out during the first impregnation, and store the second slurry for the second impregnation, and the first slurry and the second slurry will not be mixed or contaminated.

[0053] Further, the second slurry recovery device includes a fifth conveying device and a third container located below an end of the fifth conveying device away from the third conveying device;

[0054] The fifth conveying device comprises a fifth conveying belt having retractable baffles on both sides, and a fifth bracket supporting the fifth conveying belt;

[0055] and / or

[0056] The first conveying device includes a first conveying belt and a first bracket supporting the first conveying belt;

[0057] and / or

[0058] The second conveying device includes a second conveying belt and a second bracket supporting the second conveying belt;

[0059] and / or

[0060] The third conveying device includes a third conveying belt and a third bracket supporting the third conveying belt;

[0061] and / or

[0062] The fourth conveying device includes a fourth conveying belt and a fourth bracket supporting the fourth conveying belt.

[0063] The beneficial effect of adopting the previous step is that the second slurry recovery device includes a fifth conveying device and a third container located below one end of the fifth conveying device away from the third conveying device, so as to collect the second slurry flowing out during the secondary immersion, thereby saving costs.

[0064] Another aspect of the present invention provides a method for impregnating a foam ceramic precursor for purifying an aluminum-containing melt, wherein the impregnation is performed by using the foam ceramic precursor impregnation device for purifying an aluminum-containing melt; the method comprises the following steps:

[0065] The first slurry is stored in the first slurry storage device; the second slurry is stored in the second slurry storage device;

[0066] Placing a foam ceramic precursor on the surface of a first conveying device, and conveying the foam ceramic precursor to between a first roller group and a second roller group of a first novel slurry pressing device through the first conveying device for continuous multiple extrusions and rebounds;

[0067] The flow regulating valve of the first slurry storage device is opened to allow the first slurry to enter the foam ceramic precursor through the gap of the first roller group; the first rotating roller of the first roller group and the second rotating roller of the second roller group transport the foam ceramic precursor during the rotation and simultaneously perform a dipping;

[0068] The foam ceramic precursor is transported to the surface of the second transport device after being impregnated once, and then the foam ceramic precursor after being impregnated once is transported to between the fifth roller group and the sixth roller group of the unpowered turning device through the second transport device;

[0069] After the first dipping, the foam ceramic precursor slides between the fifth roller group and the sixth roller group to the surface of the third conveying device under the action of gravity;

[0070] After the first impregnation, the foam ceramic precursor is transported to between the third roller group and the fourth roller group of the second novel grouting and conveying device through the third conveying device for continuous multiple extrusion and rebound;

[0071] The flow regulating valve of the second slurry storage device is opened to allow the second slurry to enter the foam ceramic precursor after the primary impregnation through the gap of the third roller group; the third rotating roller of the third roller group and the fourth rotating roller of the fourth roller group convey the foam ceramic precursor after the primary impregnation during the rotation process, and simultaneously perform extrusion and secondary impregnation;

[0072] After the first impregnation, the foam ceramic precursor is impregnated twice and then transported to the surface of the fourth transport device, and the foam ceramic precursor after the second impregnation is transported to the next process through the fourth transport device;

[0073] After the second impregnation, the foam ceramic precursor is impregnated and squeezed once by the first novel slurry conveying device, and the slurry retention rate of the foam ceramic precursor is 10.13-11.8, that is, the slurry retention rate of each 1kg of the foam ceramic precursor before impregnation is 10.3-11.8kg after the first impregnation;

[0074] After the foam ceramic precursor is impregnated twice by the second novel slurry conveying device, the slurry retention rate of the foam ceramic precursor is 25.32-29.5, that is, the slurry retention rate of every 1kg of foam ceramic precursor before impregnation is 25.32-29.5kg after the first and second impregnations.

[0075] The beneficial effect of the present invention over the prior art is that, through the impregnation device including the first conveying device, the first new grouting conveying device, the first slurry storage device, the second conveying device unpowered turning device, the third conveying device, the second new grouting conveying device, the second slurry storage device, the fourth conveying device, the second slurry recovery device, and the second slurry storage device, the foam precursor ceramic body is transported to the first new grouting conveying device by the first conveying device, and the foam ceramic precursor is impregnated, squeezed, and rebounded multiple times during the conveying process by the first new grouting conveying device, and in this process, the foam ceramic precursor is impregnated with the first slurry output by the first slurry storage device, and because the ceramic precursor is impregnated, squeezed, and rebounded multiple times during the conveying process, the first slurry enters the central part of the foam ceramic precursor and is evenly distributed in the foam ceramic precursor;

[0076] The second conveying device conveys the foam ceramic precursor that has been impregnated once to the unpowered flipping device, and the unpowered flipping device automatically flips the foam ceramic precursor that has been impregnated once and falls into the lower layer and moves in the opposite direction of the original conveying direction to perform a second impregnation, thereby realizing continuous conveying and impregnation, saving equipment length, and being more conducive to use and promotion. At the same time, the foam ceramic precursor does not need to be clamped during the automatic flipping process, thereby avoiding the problem of damage to the foam ceramic substrate during the flipping process;

[0077] The flipped foam ceramic precursor is conveyed to the second new slurry conveying device by the third conveying device, so that the contact surface of the foam ceramic precursor with the first slurry faces downward during the first impregnation, and the side of the foam ceramic that is not directly impregnated faces upward, so that the first slurry in the second slurry storage device is output to the side of the foam ceramic that is not directly in contact with the first slurry for impregnation, and the foam ceramic precursor is impregnated, squeezed multiple times, and rebounded multiple times while being conveyed in the second new slurry conveying device, so as to achieve further uniform impregnation with the second slurry, so that the grid skeleton surface inside the foam ceramic precursor is uniformly attached to the first slurry and the second slurry in turn; thereby further enhancing the internal strength of the foam ceramic; achieving fully automated impregnation of the impregnation process, the interior of the foam ceramic precursor is uniformly impregnated with the ceramic slurry, and there will be no problem of partial pore blockage inside the foam ceramic product for aluminum melt purification, thereby reducing the porosity, and at the same time achieving high internal strength of the foam ceramic for aluminum melt purification.

[0078] Further, the first slurry is the same as the second slurry;

[0079] The first slurry comprises: a first alumina powder, a dispersant, a binder, and a solvent in a mass ratio of (60-70):(3-5):(6-8):(22-26);

[0080] The dispersant includes one or more of sodium tripolyphosphate, 9 yellow dextrin, and sodium humate; the binder includes one or more of polyacrylamide, polyvinyl alcohol, and white carbon black; the solvent includes water or ethanol; the particle size distribution D50 of the first alumina powder is 8-15 μm;

[0081] or,

[0082] The first slurry is different from the second slurry;

[0083] The first slurry comprises: a second alumina powder, a zirconium oxide powder, a silicon carbide fiber, a dispersant, a binder, and a solvent in a mass ratio of (16-20): (24-28): (22-26): (5-8): (7-9): (20-25);

[0084] The second slurry comprises:

[0085] The mass ratio of (66-70):(8-10):(20-25): of the third alumina powder, dispersant, and solvent;

[0086] The dispersant includes one or more of sodium tripolyphosphate, yellow dextrin, and sodium humate; the binder includes one or more of polyacrylamide, polyvinyl alcohol, and white carbon black; the solvent includes water or ethanol;

[0087] The particle size distribution D50 of the second alumina powder is 6-10 μm, and the particle size distribution D50 of the third alumina powder and zirconium oxide powder is 12-18 μm.

[0088] The beneficial effect of adopting the previous step is that the first slurry is the same as the second slurry, and the first slurry includes a first alumina powder, a dispersant, a binder, and a solvent in a mass ratio of (60-70): (3-5): (6-8): (22-26), which is conducive to achieving high strength of the rib ceramic structure in the foam ceramic, and the main component is alumina, and even if it falls off during use, it will not cause a significant impact on the filtered aluminum water;

[0089] By making the first slurry different from the second slurry, the rib ceramic structure inside the foam ceramic includes an inner ceramic structure and an outer ceramic structure, which is further beneficial to improving the strength and toughness of the foam ceramic, avoiding the problem that the rib ceramic structure inside the ceramic foam is easily broken or damaged and slags off, and is beneficial to improving the surface smoothness of the rib ceramic structure inside the foam ceramic;

[0090] The first slurry includes: a second alumina powder, a zirconium oxide powder, a silicon carbide fiber, a dispersant, a binder, and a solvent in a mass ratio of (16-20): (24-28): (22-26): (5-8): (7-9): (20-25); the second alumina powder, the zirconium oxide powder, and the silicon carbide fiber are attached to the rib surface of the ceramic foam precursor during one impregnation, and the silicon carbide fiber content is relatively high, thereby achieving high toughness of the inner ceramic structure inside the foam ceramic; the particle size distribution D50 of the third alumina powder and the zirconium oxide powder is 12-18 μm, thereby achieving a larger pore and rougher surface of the inner ceramic structure, which is conducive to high bonding strength with the outer ceramic structure;

[0091] By comprising the second slurry: a third alumina powder, a dispersant, and a solvent in a mass ratio of (66-70): (8-10): (20-25):, the outer ceramic structure contains only alumina ceramics and has high strength. By having the particle size distribution D50 of the second alumina powder of 6-10 μm, it is further beneficial to improve the strength of the outer ceramic structure and achieve a smooth surface of the outer ceramic structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0092] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required to be used in the embodiments of the present invention will be described below.

[0093] Figure 1 This is a schematic structural diagram of a foam ceramic precursor impregnation device according to Example 1 of the present invention;

[0094] Figure 2 This is a schematic structural diagram of the unpowered turning device according to Embodiment 1 of the present invention;

[0095] Figure 3 This is a schematic structural diagram of the first new grouting and conveying device according to Example 1 of the present invention.

[0096] Markings shown in the accompanying drawings:

[0097] 1. A first conveying device; 2. A foam ceramic precursor; 3. A first new type of grouting conveying device; 4. A first slurry storage device; 5. A second conveying device; 6. An unpowered turning device; 7. A third conveying device; 8. A second slurry storage device; 9. A fifth conveying device; 10. A second new type of grouting conveying device; 12. A third container; 11. A fourth conveying device; 13. A flow regulating valve at the slurry outlet of the first slurry storage device; 14. A flow regulating valve at the slurry outlet of the second slurry storage device; 15. A foam ceramic precursor after a single impregnation; 16. A foam ceramic precursor after a secondary impregnation. DETAILED DESCRIPTION

[0098] In order to better understand the technical solution of the present invention, the present invention is further described below in conjunction with specific embodiments and the accompanying drawings of the specification.

[0099] Embodiment 1:

[0100] In one aspect of the present embodiment, a foam ceramic precursor impregnation device for purifying aluminum-containing melt is provided, characterized in that the impregnation device comprises a first conveying device (1), a first new type of grouting conveying device (3), a first slurry storage device (4), a second conveying device (5), an unpowered turning device (6), a third conveying device (7), a second new type of grouting conveying device (10), a second slurry storage device (8), a fourth conveying device (11), and a second slurry recovery device;

[0101] The first conveying device (1), the first new grouting conveying device (3), the second conveying device (5), the unpowered turning device (6), the third conveying device (7), the second new grouting conveying device (10), and the fourth conveying device (11) are connected in sequence, so that the foam ceramic precursor (2) passes through the first conveying device (1), the first new grouting conveying device (3), the second conveying device (5), the unpowered turning device (6), the third conveying device (7), the second new grouting conveying device (10), and the fourth conveying device (11) in sequence;

[0102] The first conveying device (1), the first new grouting conveying device (3), and the second conveying device (5) are located on the upper layer, the third conveying device (7), the second new grouting conveying device (10), and the fourth conveying device (11) are located on the lower layer, the feed end of the unpowered turning device (6) is connected to the discharge end of the second conveying device (5), and the discharge end of the unpowered turning device (6) is connected to the third conveying device (7);

[0103] The first slurry storage device (4) is located above the first novel slurry conveying device (3);

[0104] The second grout storage device (8) is located above the second novel grouting and conveying device (10).

[0105] The first novel grouting and conveying device (3) comprises a first roller group and a second roller group arranged in parallel; the first roller group is located above the second roller group; the first roller group comprises n first rotating rollers, and the second roller group comprises m second rotating rollers; n<m; the plane where the axis of the first rotating roller and the axis of the second rotating roller are located is arranged at an angle to the horizontal plane; the distance between the first rotating roller and the second rotating roller is adjustable;

[0106] The second novel grouting and conveying device (10) comprises a third roller group and a fourth roller group arranged in parallel; the third roller group is located above the fourth roller group; the third roller group comprises j third rotating rollers, and the second roller group comprises k fourth rotating rollers; j<k; the axis of the third rotating roller and the plane where the axis of the fourth rotating roller is located are arranged at an angle to the horizontal plane; the distance between the third rotating roller and the fourth rotating roller is adjustable;

[0107] The n=6, the m=7; the j=6, the k=7.

[0108] The first slurry storage device (4) comprises a first container, and a plurality of first slurry outlets are provided at the bottom of the first container; the first slurry outlet is provided with a first slurry storage device outlet flow regulating valve (13);

[0109] The second slurry storage device (8) comprises a second container, and a plurality of second slurry outlets are provided at the bottom of the second container; the second slurry outlet is provided with a second slurry storage device outlet flow regulating valve (14);

[0110] The first container is provided with three first slurry discharge ports at the bottom; the second container is provided with three second slurry discharge ports at the bottom;

[0111] The first slurry discharge port is located above the gap between two adjacent first rollers; the second slurry discharge port is located above the gap between two adjacent third rollers.

[0112] The unpowered turning device (6) comprises a fifth roller group and a sixth roller group which are arranged opposite to each other; the fifth roller group and the sixth roller group are arranged in a curved manner;

[0113] The fifth roller group includes a plurality of fifth rotating rollers, the plurality of fifth rotating rollers are arranged in a horizontal row, and the plurality of fifth rotating rollers surround a first arc;

[0114] The sixth roller group includes a plurality of sixth rollers, the plurality of the sixth rollers are arranged in a horizontal row, and the plurality of the sixth rollers surround a second arc;

[0115] The central angle of the first arc is greater than or equal to 45°; the central angle of the second arc is greater than or equal to 45°;

[0116] The unpowered turning device, the second arc and the first arc are based on two concentric circles of φ1500mm and φ1180mm respectively, the second arc has 18 φ100mm*700mm sixth rollers evenly distributed on the semicircle of φ1180mm, and the first arc has 21 φ100mm*700mm fifth rollers evenly distributed on the semicircle of φ1500mm.

[0117] The second conveying device (5) is arranged to be tilted downward along the conveying direction, and the angle between the second conveying device (5) and the horizontal plane is α, α=10°;

[0118] The third conveying device (7) is arranged to be tilted downward along the conveying direction, and the angle between the second conveying device (5) and the horizontal plane is β, β=10°.

[0119] The second conveying device (5) is arranged to be tilted downward along the conveying direction, which is beneficial for the foam ceramic precursor (15) to enter the unpowered turning device (6) after a single impregnation, that is, it is beneficial for the foam ceramic precursor (15) to increase a certain kinetic energy before entering the unpowered turning device after a single impregnation, and at the same time, the outlet of the second conveying device is opposite to the inlet of the unpowered turning device.

[0120] The first roller linear speed and the second roller linear speed of the first novel grouting conveying device (3), the third roller linear speed and the fourth roller linear speed of the second novel grouting conveying device (10) are all V1, the discharge port flow rates of the first slurry storage device (4) and the second slurry storage device (8) are both Q, the belt speed of the second conveying belt of the second conveying device (5) is V2, and the belt speed of the third conveying belt of the third conveying device (7) is V3;

[0121] The s is the cross-sectional area of ​​the pulp outlet, V1 = γQ / s, γ = 0.35, V2 = δV1, V3 = V1,

[0122] δ = 1.2;

[0123] The s is the cross-sectional area of ​​the outlet of the first slurry storage device (4) and the second slurry storage device (8); the γ is the flow rate control coefficient; the outlet flow rates of the first slurry storage device (4) and the second slurry storage device (8) are both Q.

[0124] The second slurry storage device (8) is located directly below the first new slurry pressing and conveying device (3), and the second new slurry pressing and conveying device (10) is located directly below the second slurry storage device (8);

[0125] The fifth conveying device (9) comprises a fifth conveying belt having retractable baffles on both sides, and a fifth bracket supporting the fifth conveying belt;

[0126] The first conveying device (1) comprises a first conveying belt and a first bracket supporting the first conveying belt;

[0127] The second conveying device (5) comprises a second conveying belt and a second bracket supporting the second conveying belt;

[0128] The third conveying device (7) comprises a third conveying belt and a third bracket supporting the third conveying belt;

[0129] The fourth conveying device (11) comprises a fourth conveying belt and a fourth bracket supporting the fourth conveying belt.

[0130] Another aspect of the present invention provides a method for impregnating a foam ceramic precursor for purifying an aluminum-containing melt, wherein the impregnation is performed by using the foam ceramic precursor impregnation device for purifying an aluminum-containing melt; the method comprises the following steps:

[0131] The first slurry is stored in the first slurry storage device (4); and the second slurry is stored in the second slurry storage device (8);

[0132] Placing a foam ceramic precursor on the surface of a first conveying device (1), and conveying the foam ceramic precursor to between a first roller group and a second roller group of a first novel slurry pressing device (3) through the first conveying device (1) for continuous multiple extrusion and rebound;

[0133] The flow regulating valve of the first slurry storage device (4) is opened to allow the first slurry to enter the foam ceramic precursor through the gap of the first roller group; the first rotating roller of the first roller group and the second rotating roller of the second roller group transport the foam ceramic precursor and perform a single immersion during the rotation process;

[0134] The foam ceramic precursor is transported to the surface of the second transport device (5) after a single impregnation, and then the foam ceramic precursor (15) after a single impregnation is transported to between the fifth roller group and the sixth roller group of the unpowered turning device (6) through the second transport device (5);

[0135] After the first impregnation, the foam ceramic precursor (15) slides between the fifth roller group and the sixth roller group to the surface of the third conveying device (7) under the action of gravity;

[0136] After the first impregnation, the foam ceramic precursor (15) is transported to between the third roller group and the fourth roller group of the second novel grouting and conveying device (10) via the third conveying device (7) for continuous multiple extrusion and rebound;

[0137] The flow regulating valve of the second slurry storage device (8) is opened to allow the second slurry to enter the foam ceramic precursor (15) after the primary impregnation through the gap of the third roller group; the third rotating roller of the third roller group and the fourth rotating roller of the fourth roller group transport the foam ceramic precursor (15) after the primary impregnation during the rotation process, and simultaneously impregnate the foam ceramic precursor (15) after the primary impregnation;

[0138] After the primary impregnation, the foam ceramic precursor (15) is impregnated for a secondary time and then transported to the surface of a fourth transport device (11), and the second impregnated foam ceramic precursor (16) is transported to the next process via the fourth transport device (11);

[0139] After the foam ceramic precursor is impregnated and squeezed once by the first novel slurry conveying device (3), the slurry retention rate of the foam ceramic precursor is 11, that is, the slurry retention rate of every 1 kg of the foam ceramic precursor before impregnation is 11 kg after the first impregnation;

[0140] After the foam ceramic precursor is impregnated twice by the second novel slurry conveying device (10), the slurry retention rate of the foam ceramic precursor is 27.41, that is, the slurry retention rate of every 1 kg of foam ceramic precursor before impregnation is 27.41 kg after the first and second impregnations.

[0141] The first slurry is the same as the second slurry;

[0142] The first slurry includes: a first alumina powder, a dispersant, a binder, and a solvent in a mass ratio of 65:4:7:24;

[0143] The dispersant includes sodium tripolyphosphate; the binder includes polyacrylamide; the solvent includes water; and the particle size distribution D50 of the first alumina powder is 10 μm.

[0144] Embodiment 2:

[0145] The same contents as those in Example 1 are not described in detail here. The differences between this embodiment and Example 1 are as follows:

[0146] The second slurry storage device includes a second container, the second container is provided with a first accommodating space and a second accommodating space, the first accommodating space is located above the second accommodating space, and the second accommodating space is connected to a plurality of first slurry discharge ports provided at the bottom of the first container.

[0147] The second slurry recovery device comprises a fifth conveying device (9) and a third container (12) located below an end of the fifth conveying device (9) away from the third conveying device (7);

[0148] n=7, m=8; j=7, k=8, γ=0.38;

[0149] The first container is provided with four first slurry discharge ports at the bottom; the second container is provided with four second slurry discharge ports at the bottom;

[0150] The second conveying device (5) is arranged to be tilted downward along the conveying direction, and the angle between the second conveying device (5) and the horizontal plane is α, α=14°;

[0151] The third conveying device (7) is arranged to be tilted downward along the conveying direction, and the angle between the second conveying device (5) and the horizontal plane is β, β=14°.

[0152] V2=δV1, V3=V1, δ=1.2;

[0153] Another aspect of the present invention provides a method for impregnating a foam ceramic precursor for purifying an aluminum-containing melt, wherein the foam ceramic precursor after the first impregnation loses 2.5% of water after passing through a second conveying device (5);

[0154] After the foam ceramic precursor is impregnated and squeezed once by the first novel slurry conveying device (3), the slurry retention rate of the foam ceramic precursor is 11.4, that is, the slurry retention rate of every 1 kg of the foam ceramic precursor before impregnation is 11 kg after the first impregnation;

[0155] After the foam ceramic precursor is impregnated twice by the second novel slurry conveying device (10), the slurry retention rate of the foam ceramic precursor is 28.5, that is, the slurry retention rate of every 1 kg of the foam ceramic precursor before impregnation is 28.5 kg after the first and second impregnations.

[0156] The first slurry is different from the second slurry;

[0157] The first slurry includes: a second alumina powder, a zirconium oxide powder, a silicon carbide fiber, a dispersant, a binder, and a solvent in a mass ratio of 18:26:24:7:8:22;

[0158] The second slurry comprises: a third alumina powder, a dispersant, and a solvent in a mass ratio of 68:9:22:

[0159] The dispersant includes yellow dextrin and sodium humate; the binder includes polyvinyl alcohol; and the solvent includes ethanol;

[0160] The particle size distribution D50 of the third alumina powder and the zirconium oxide powder is 16 μm; the particle size distribution D50 of the second alumina powder is 8 μm.

[0161] The above description is only a preferred embodiment of the present application and an explanation of the technical principles used. Those skilled in the art should understand that the scope of the invention involved in the present application is not limited to the technical solution formed by a specific combination of the above technical features, but should also cover other technical solutions formed by any combination of the above technical features or their equivalent features without departing from the inventive concept. For example, the above features have similar functions to those disclosed in the present application (but not limited to).

Claims

1. A foam ceramic precursor impregnation device for purifying aluminum-containing melt, characterized in that: The impregnation device comprises a first conveying device (1), a first new type of grouting conveying device (3), a first slurry storage device (4), a second conveying device (5), an unpowered turning device (6), a third conveying device (7), a second new type of grouting conveying device (10), a second slurry storage device (8), a fourth conveying device (11), and a second slurry recovery device (8); The first conveying device (1), the first new grouting conveying device (3), the second conveying device (5), the unpowered turning device (6), the third conveying device (7), the second new grouting conveying device (10), and the fourth conveying device (11) are connected in sequence, so that the foam ceramic precursor (2) passes through the first conveying device (1), the first new grouting conveying device (3), the second conveying device (5), the unpowered turning device (6), the third conveying device (7), the second new grouting conveying device (10), and the fourth conveying device (11) in sequence; The first conveying device (1), the first new grouting conveying device (3), and the second conveying device (5) are located on the upper layer, the third conveying device (7), the second new grouting conveying device (10), and the fourth conveying device (11) are located on the lower layer, the feed end of the unpowered turning device (6) is connected to the discharge end of the second conveying device (5), and the discharge end of the unpowered turning device (6) is connected to the third conveying device (7); The first slurry storage device (4) is located above the first novel slurry conveying device (3); The second grout storage device (8) is located above the second novel grouting and conveying device (10).

2. The foam ceramic precursor impregnation device for purifying aluminum-containing melt according to claim 1, characterized in that: The first novel grouting and conveying device (3) comprises a first roller group and a second roller group arranged in parallel; The first roller set is located above the second roller set; The first roller group includes n first rotating rollers, and the second roller group includes m second rotating rollers; n<m; The planes where the axes of the first rotating roller and the second rotating roller are located are arranged at an angle to the horizontal plane; The distance between the first roller and the second roller is adjustable; and / or The second novel grouting and conveying device (10) comprises a third roller group and a fourth roller group arranged in parallel; The third roller set is located above the fourth roller set; The third roller group includes j third rotating rollers, and the second roller group includes k fourth rotating rollers; j<k; The axis of the third rotating roller and the axis of the fourth rotating roller are arranged at an angle to the horizontal plane; The distance between the third roller and the fourth roller is adjustable.

3. The foam ceramic precursor impregnation device for purifying aluminum-containing melt according to claim 2, characterized in that: The first slurry storage device (4) comprises a first container, and a plurality of first slurry outlets are provided at the bottom of the first container; the first slurry outlets are provided with flow regulating valves; The second slurry storage device (8) comprises a second container, and a plurality of second slurry outlets are provided at the bottom of the second container; the second slurry outlets are provided with flow regulating valves; Preferably, the first container is provided with 3-4 first slurry discharge ports at the bottom; the second container is provided with 3-4 second slurry discharge ports at the bottom; Preferably, the first slurry discharge port is located above the gap between two adjacent first rollers; and the second slurry discharge port is located above the gap between two adjacent third rollers.

4. The foam ceramic precursor impregnation device for purifying aluminum-containing melt according to claim 1, characterized in that: The unpowered turning device (6) comprises a fifth roller group and a sixth roller group which are arranged opposite to each other; the fifth roller group and the sixth roller group are arranged in a curved manner; The fifth roller group includes a plurality of fifth rotating rollers, the plurality of fifth rotating rollers are arranged in a horizontal row, and the plurality of fifth rotating rollers surround a first arc; The sixth roller group includes a plurality of sixth rollers, the plurality of the sixth rollers are arranged in a horizontal row, and the plurality of the sixth rollers surround a second arc; The diameter of the circle where the first arc is located is 1350-1650 mm, and the central angle of the first arc is greater than or equal to 45°; The diameter of the circle where the second arc is located is 1030-1500 mm, and the central angle of the second arc is greater than or equal to 45°.

5. The foam ceramic precursor impregnation device for purifying aluminum-containing melt according to claim 1, characterized in that: The second conveying device (5) is arranged to be tilted downward along the conveying direction, and the angle between the second conveying device (5) and the horizontal plane is α, 8°≤α≤15°; The third conveying device (7) is arranged to be tilted downward along the conveying direction, and the angle between the second conveying device (5) and the horizontal plane is β, 8°≤β≤15°.

6. The foam ceramic precursor impregnation device for purifying aluminum-containing melt according to claim 1, characterized in that: The first roller linear speed and the second roller linear speed of the first novel grouting conveying device (3), the third roller linear speed and the fourth roller linear speed of the second novel grouting conveying device (10) are all V1, the discharge flow rates of the first slurry storage device (4) and the second slurry storage device (8) are both Q, the belt speed of the second conveying belt of the second conveying device (5) is V2, and the belt speed of the third conveying belt of the third conveying device (7) is V3; Said s is the cross-sectional area of ​​the pulp outlet, V1=γQ / s, 0.25≤γ≤0.5, V2=δV1, V3=V1, δ=1.1-1.3; The s is the cross-sectional area of ​​the outlet of the first slurry storage device (4) and the second slurry storage device (8); the γ is the flow rate control coefficient; the outlet flow rates of the first slurry storage device (4) and the second slurry storage device (8) are both Q.

7. The foam ceramic precursor impregnation device for purifying aluminum-containing melt according to claim 1, characterized in that: The second slurry storage device (8) is located directly below the first new slurry pressing and conveying device (3), and the second new slurry pressing and conveying device (10) is located directly below the second slurry storage device (8); and / or The second slurry storage device (8) comprises a second container, the second container is provided with a first accommodating space and a second accommodating space, the first accommodating space is located above the second accommodating space, and the second accommodating space is connected to a plurality of first slurry discharge ports provided at the bottom of the first container.

8. The foam ceramic precursor impregnation device for purifying aluminum-containing melt according to claim 1, characterized in that: The second slurry recovery device comprises a fifth conveying device (9) and a third container (12) located below an end of the fifth conveying device (9) away from the third conveying device (7); The fifth conveying device comprises a fifth conveying belt having retractable baffles on both sides, and a fifth bracket supporting the fifth conveying belt; and / or The first conveying device (1) comprises a first conveying belt and a first bracket supporting the first conveying belt; and / or The second conveying device (5) comprises a second conveying belt and a second bracket supporting the second conveying belt; and / or The third conveying device (7) comprises a third conveying belt and a third bracket supporting the third conveying belt; and / or The fourth conveying device (11) comprises a fourth conveying belt and a fourth bracket supporting the fourth conveying belt.

9. A method for impregnating a foam ceramic precursor for purifying an aluminum-containing melt, characterized in that: The impregnation is performed by using the foam ceramic precursor impregnation device for purifying aluminum-containing melts as described in any one of claims 1 to 8; The following steps are involved: The first slurry is stored in the first slurry storage device (4); and the second slurry is stored in the second slurry storage device (8); Placing a foam ceramic precursor (2) on the surface of a first conveying device (1), and conveying the foam ceramic precursor (2) to between a first roller group and a second roller group of a first novel slurry pressing device (3) through the first conveying device (1) for continuous multiple extrusion and rebound; The flow regulating valve of the first slurry storage device (4) is opened to allow the first slurry to enter the foam ceramic precursor (2) through the gap of the first roller group; the first rotating roller of the first roller group and the second rotating roller of the second roller group transport the foam ceramic precursor (2) during the rotation process and simultaneously perform a single impregnation; The foam ceramic precursor (2) is transported to the surface of the second transport device (5) after being impregnated once, and then the foam ceramic precursor (15) after being impregnated once is transported to between the fifth roller group and the sixth roller group of the unpowered turning device (6) through the second transport device (5); After the first impregnation, the foam ceramic precursor (15) slides between the fifth roller group and the sixth roller group to the surface of the third conveying device (7) under the action of gravity; After the first impregnation, the foam ceramic precursor (15) is transported to between the third roller group and the fourth roller group of the second novel grouting and conveying device (10) via the third conveying device (7) for continuous multiple extrusion and rebound; The flow regulating valve of the second slurry storage device (8) is opened to allow the second slurry to enter the foam ceramic precursor (15) after the primary impregnation through the gap of the third roller group; the third rotating roller of the third roller group and the fourth rotating roller of the fourth roller group transport the foam ceramic precursor (15) after the primary impregnation during the rotation process, and simultaneously impregnate the foam ceramic precursor (15) after the primary impregnation; After the primary impregnation, the foam ceramic precursor (15) is impregnated for a secondary time and then transported to the surface of a fourth transport device (11), and the second impregnated foam ceramic precursor (16) is transported to the next process via the fourth transport device (11); After the foam ceramic precursor is impregnated and squeezed once by the first novel slurry conveying device (3), the slurry retention rate of the foam ceramic precursor is 10.13-11.8, that is, the slurry retention rate of each 1 kg of the foam ceramic precursor before impregnation is 10.3-11.8 kg after the first impregnation; After the foam ceramic precursor is impregnated twice by the second novel slurry conveying device (10), the slurry retention rate of the foam ceramic precursor is 25.32-29.5, that is, the slurry retention rate of each 1 kg of foam ceramic precursor before impregnation is 25.32-29.5 kg after the first and second impregnations.

10. The foam ceramic precursor impregnation device for purifying aluminum-containing melt according to claim 9, characterized in that: The first slurry is the same as the second slurry; The first slurry comprises: a first alumina powder, a dispersant, a binder, and a solvent in a mass ratio of (60-70):(3-5):(6-8):(22-26); The dispersant includes one or more of sodium tripolyphosphate, 9300, yellow dextrin, and sodium humate; the binder includes one or more of polyacrylamide, polyvinyl alcohol, and white carbon black; the solvent includes water or ethanol; the particle size distribution D50 of the first alumina powder is 8-15 μm; or, The first slurry is different from the second slurry; The first slurry comprises: a second alumina powder, a zirconium oxide powder, a silicon carbide fiber, a dispersant, a binder, and a solvent in a mass ratio of (16-20): (24-28): (22-26): (5-8): (7-9): (20-25); The second slurry comprises: The mass ratio of (66-70):(8-10):(20-25): first alumina powder, dispersant, solvent; The dispersant includes one or more of sodium tripolyphosphate, yellow dextrin, and sodium humate; the binder includes one or more of polyacrylamide, polyvinyl alcohol, and white carbon black; the solvent includes water or ethanol; The particle size distribution D50 of the second alumina powder and the zirconium oxide powder is 15-18 μm; the particle size distribution D50 of the first alumina powder is 8-15 μm.

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