A foamed ceramic precursor impregnation device and method for purifying an aluminum-containing melt

Abstract

The application discloses a kind of foamed ceramic precursor impregnation device and method for aluminum melt purification, the impregnation device includes first conveying device, first new type of slurry conveying device, first slurry storage device, second conveying device, unpowered turnover device, third conveying device, second new type of slurry conveying device, second slurry storage device, fourth conveying device, second slurry recovery device;The first conveying device, first new type of slurry conveying device, second conveying device, unpowered turnover device, third conveying device, second new type of slurry conveying device, fourth conveying device are sequentially linked;Realize that impregnation process is fully automated impregnation, foamed ceramic precursor internal uniform impregnation ceramic slurry and will not appear aluminum melt purification foamed ceramic product internal partial pore blockage thereby porosity reduction problem, simultaneously realize that aluminum melt purification foamed ceramic internal strength is high.

Description

Technical Field

[0001] This invention relates to the field of aluminum and aluminum alloy melt purification technology, specifically to a foam ceramic filter plate impregnation device for purifying aluminum and aluminum alloy melts. Background Technology

[0002] Foam ceramics are a type of porous ceramic with high porosity (84%-94%) and a three-dimensional spatial network structure. Due to their advantages such as low density, low strength, high temperature resistance, acid and alkali corrosion resistance, and good filtration and adsorption, they are widely used in fields such as molten metal filtration, automobile exhaust treatment, and medical materials.

[0003] In recent years, the development of third-generation filter materials—foam ceramic filters—has significantly improved the finished product qualification rate of metal smelting products and greatly enhanced product performance. Casting is one of the industries most widely using foam ceramic filters, and foam ceramics for purifying aluminum and aluminum alloy melts are an important branch of foam ceramics used in casting. Their main function is to transform turbulent, turbulent molten metal into a stable, uniform, and clean molten metal after passing through the honeycomb pores of the foam ceramic. This greatly reduces the scrap rate of castings caused by casting defects such as non-metallic inclusions, thus saving production costs.

[0004] Impregnation is a crucial step in the preparation of third-generation foam ceramics. Traditional impregnation processes involved manual impregnation followed by pressing, resulting in inconsistent precursor slurry holding capacity and difficulty in guaranteeing product quality.

[0005] Therefore, how to invent a fully automated 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 and reduced porosity in the finished foam ceramic product for aluminum melt purification, and at the same time achieve high internal strength of the foam ceramic for aluminum melt purification, has become a problem that urgently needs to be solved in this field. Summary of the Invention

[0006] The purpose of this invention is to provide an impregnation device for a foam ceramic precursor used in aluminum melt purification, which realizes fully automated impregnation process, uniformly impregnates the interior of the foam ceramic precursor with ceramic slurry, and avoids the problem of partial pore blockage and reduced porosity in the finished foam ceramic product for aluminum melt purification, while achieving high internal strength of the foam ceramic for aluminum melt purification.

[0007] According to one aspect of the present invention, a foam ceramic precursor impregnation device for purifying aluminum melt is provided, characterized in that the impregnation device comprises a first conveying device, a first novel grouting conveying device, a first slurry storage device, a second conveying device, a non-powered turning device, a third conveying device, a second novel 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 novel grouting conveying device, the second conveying device, the non-powered turning device, the third conveying device, the second novel grouting conveying device, and the fourth conveying device are connected in sequence to realize that the foam ceramic precursor passes through the first conveying device, the first novel grouting conveying device, the second conveying device, the non-powered turning device, the third conveying device, the second novel grouting conveying device, and the fourth conveying device in sequence.

[0009] The first conveying device, the first novel grouting conveying device, and the second conveying device are located on the upper layer, and the third conveying device, the second novel grouting conveying device, and the fourth conveying device are located on the lower layer. The inlet end of the non-powered turning device is connected to the outlet end of the second conveying device, and the outlet end of the non-powered turning device is connected to 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 slurry conveying device.

[0012] The beneficial effects of this invention compared to the prior art are as follows: the impregnation device includes a first conveying device, a first novel grouting conveying device, a first slurry storage device, a second conveying device with a non-powered turning device, a third conveying device, a second novel grouting conveying device, a second slurry storage device, a fourth conveying device, a second slurry recovery device, and a second slurry storage device. This allows the first conveying device to transport the foam ceramic precursor to the first novel grouting conveying device. The first novel grouting conveying device performs multiple impregnation, compression, and rebound processes on the foam ceramic precursor during transport. During this process, the first slurry output from the first slurry storage device impregnates the foam ceramic precursor. Because the ceramic precursor undergoes multiple impregnation, compression, and rebound processes during transport, the first slurry enters the central part of the foam ceramic precursor and is evenly distributed within it.

[0013] The second conveying device transports the foam ceramic precursor that has undergone one impregnation to the non-powered turning device. The non-powered turning device automatically turns the foam ceramic precursor that has undergone one impregnation, allowing it to fall into the lower layer and move in the opposite direction of the original conveying direction for a second impregnation. This achieves continuous conveying and impregnation, saves equipment length, and is more conducive to its use and promotion. At the same time, the foam ceramic precursor does not need to be clamped during the automatic turning process, thus avoiding the problem of damage to the foam ceramic matrix during the turning process.

[0014] The flipped foam ceramic precursor is conveyed to the second novel slurry conveying device via a third conveying device. During the first impregnation, the surface of the foam ceramic precursor in contact with the first slurry faces downwards, while the side of the foam ceramic not directly impregnated faces upwards. The first slurry from the second slurry storage device is then output to the side of the foam ceramic not in direct contact with the first slurry for impregnation. Simultaneously, the foam ceramic precursor undergoes impregnation, multiple compressions, and multiple rebounds while being conveyed in the second novel slurry conveying device, achieving further uniform impregnation with the second slurry. This results in the first and second slurries being uniformly adhered sequentially to the surface of the internal mesh skeleton of the foam ceramic precursor, thereby further enhancing the internal strength of the foam ceramic. The impregnation process is fully automated, ensuring uniform impregnation of the ceramic slurry inside the foam ceramic precursor without causing pore blockage and reduced porosity in the finished foam ceramic product used for aluminum melt purification. This also results in high internal strength for the foam ceramic used for aluminum melt purification.

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

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

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

[0018] The plane containing the axis of the first roller and the axis of the second roller is set at an angle to the horizontal plane;

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

[0020] and / or

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

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

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

[0024] The plane containing the axis of the third roller and the axis of the fourth roller is set at an angle to the horizontal plane.

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

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

[0027] The beneficial effect of the previous step is that, by positioning the first roller group above the second roller group; the first roller group includes n first rotating rollers, and the second roller group includes m second rotating rollers; n < m; the plane containing the axis of the first rotating roller and the axis of the second rotating roller is set at an angle to the horizontal plane; the first novel slurry conveying device impregnates the foam ceramic precursor multiple times, squeezes and rebounds multiple times during the conveying process, which is conducive to the first slurry entering the interior of the foam ceramic and being evenly distributed, and will not cause the first slurry to accumulate inside the foam ceramic, causing pore blockage, nor will it cause the problem that the first slurry is not attached to the ribs of some mesh 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 plane containing the axis of the third rotating roller and the axis of the fourth rotating roller is set at an angle to the horizontal plane; the second novel grouting and conveying device achieves multiple impregnation, compression, and rebound during the conveying process of the foam ceramic precursor, which is conducive to the second slurry entering the interior of the foam ceramic and being evenly distributed, and will not cause the second slurry to accumulate inside the foam ceramic and cause pore blockage, nor will it cause the problem of the second slurry not adhering to the ribs of some mesh inside the foam ceramic precursor.

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

[0030] The second slurry storage device includes a second container, the bottom of which is provided with a plurality of second slurry outlets; the second slurry outlets are equipped with flow regulating valves;

[0031] Preferably, the bottom of the first container is provided with 3-4 first slurry outlets; the bottom of the second container is provided with 3-4 second slurry outlets;

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

[0033] The beneficial effect of the previous step is that, since the bottom of the first container is provided with several first slurry outlets and the first slurry outlets are equipped with flow regulating valves, it is possible to impregnate the foam ceramics at multiple points during the conveying process or to impregnate the foam ceramics by opening different outlets at different times, thereby facilitating the uniform impregnation of the foam ceramic precursor.

[0034] Furthermore, the unpowered flipping device includes a fifth roller group and a sixth roller group arranged opposite to each other; the fifth roller group and the sixth roller group are bent.

[0035] The fifth roller group includes a plurality of fifth rotating rollers, which are arranged horizontally in a row and form a first arc shape.

[0036] The sixth roller group includes a plurality of sixth rotating rollers, which are arranged horizontally in a row and form a second arc shape.

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

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

[0039] In the preferred embodiment of the non-powered flipping device, the second arc and the first arc are based on two concentric circles of φ1500mm and φ1180mm respectively. The second arc has 18 sixth rollers of φ100mm*700mm evenly distributed on the semicircle of φ1180mm, and the first arc has 21 fifth rollers of φ100mm*700mm evenly distributed on the semicircle of φ1500mm.

[0040] The beneficial effect of the previous step is that, by bending the fifth and sixth roller groups, the foam ceramic precursor is able to slide along the track between the fifth and sixth roller groups to the next layer under the action of gravity when it enters between the fifth and sixth roller groups, and the foam ceramic precursor is able to flip over.

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

[0042] The third conveying device (7) is inclined 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 the previous step is that by setting the second conveying device to be inclined downward along the conveying direction, it is easier for the foam ceramic precursor that has been impregnated once to enter the non-powered turning device. That is, it is beneficial to increase the kinetic energy of the foam ceramic precursor before it enters the non-powered turning device, and at the same time, the outlet of the second conveying device is opposite to the inlet of the non-powered turning device.

[0044] Furthermore, the linear speeds of the first roller, the second roller, the third roller, and the fourth roller of the first novel grouting conveyor are all V1, the discharge flow rates of the first grout storage device and the second grout storage device are both Q, the belt speed of the second conveyor belt of the second conveyor device is V2, and the belt speed of the third conveyor belt of the third conveyor device is V3.

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

[0046] δ = 1.1 - 1.3;

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

[0048] The beneficial effect of the previous step is that, by controlling the linear speeds of the first and second rollers of the first novel grouting conveying device, the third and fourth rollers of the second novel grouting conveying device, and V1, the relationship between V1 and the cross-sectional area s of the grout outlet and the flow rate of the outlet of the second grouting device is satisfied, thereby achieving uniform impregnation of the foam ceramic precursor by the first and second grouts.

[0049] The belt speed of the second conveyor belt of the second conveying device is V2, V2=δV1, δ=1.1-1.3, which is conducive to achieving a relatively fast speed of the impregnated foam ceramic precursor entering the unpowered turning device, and 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 novel grouting conveying device, and the second novel grouting 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 having a first accommodating space and a second accommodating space, the first accommodating space being located above the second accommodating space, and the second accommodating space being connected to the bottom of the first container having a plurality of first slurry outlets.

[0051] The advantage of the previous 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 impregnate the foam precursor a second time.

[0052] The second slurry storage device includes a second container, which has a first accommodating space and a second accommodating space. This allows the first slurry that flows out during the first impregnation to be recovered when the first slurry and the second slurry are different, while the second slurry is stored for the second impregnation. The first slurry and the second slurry will not be mixed or contaminated.

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

[0054] The fifth conveying device includes a fifth conveyor belt with retractable baffles on both sides, and a fifth support for supporting the fifth conveyor belt.

[0055] and / or

[0056] The first conveying device includes a first conveyor belt and a first support bracket that supports the first conveyor belt;

[0057] and / or

[0058] The second conveying device includes a second conveyor belt and a second support for supporting the second conveyor belt;

[0059] and / or

[0060] The third conveying device includes a third conveyor belt and a third support for supporting the third conveyor belt;

[0061] and / or

[0062] The fourth conveying device includes a fourth conveyor belt and a fourth support for supporting the fourth conveyor belt.

[0063] The advantage of the previous step is that the second slurry recovery device, including the fifth conveying device and the third container located below the end of the fifth conveying device away from the third conveying device, can collect the second slurry flowing out during the secondary impregnation, thus saving costs.

[0064] In another aspect, the present invention provides a method for impregnating a foam ceramic precursor for purifying aluminum melt, wherein impregnation is performed using the aforementioned impregnation device for the foam ceramic precursor for purifying aluminum melt; comprising the following steps:

[0065] A first slurry is stored in a first slurry storage device; a second slurry is stored in a second slurry storage device;

[0066] The foam ceramic precursor is placed on the surface of the first conveying device, and the foam ceramic precursor is conveyed by the first conveying device to the first roller group and the second roller group of the first novel grouting device for continuous extrusion and rebound.

[0067] Open the flow regulating valve of the first slurry storage device 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 convey the foam ceramic precursor and perform one impregnation during the rotation process.

[0068] After being impregnated once, the foam ceramic precursor is conveyed to the surface of the second conveying device. Then, the impregnated foam ceramic precursor is conveyed by the second conveying device to the fifth and sixth roller groups of the non-powered turning device.

[0069] After one impregnation, the foam ceramic precursor slides between the fifth and sixth roller groups onto the surface of the third conveying device under the action of gravity.

[0070] After one impregnation, the foam ceramic precursor is conveyed by the third conveying device to the third and fourth roller groups of the second new type of grouting conveying device for continuous extrusion and rebound.

[0071] Open the flow regulating valve of the second slurry storage device and let the second slurry enter the foam ceramic precursor after one impregnation through the gap of the third roller group; the third roller of the third roller group and the fourth roller of the fourth roller group convey the foam ceramic precursor after one impregnation while extruding and impregnating it during the rotation process.

[0072] After the first impregnation, the foam ceramic precursor is impregnated a second time and then conveyed to the surface of the fourth conveying device. The fourth conveying device then conveys the impregnated foam ceramic precursor to the next process.

[0073] After the secondary impregnation, the foam ceramic precursor is impregnated and extruded once by the first novel slurry conveying device. The slurry holding rate of the foam ceramic precursor is 10.13-11.8, that is, the slurry holding capacity of 1 kg of unimpregnated foam ceramic precursor is 10.3-11.8 kg after one impregnation.

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

[0075] The beneficial effects of this invention compared to the prior art are as follows: the impregnation device includes a first conveying device, a first novel grouting conveying device, a first slurry storage device, a second conveying device with a non-powered turning device, a third conveying device, a second novel grouting conveying device, a second slurry storage device, a fourth conveying device, a second slurry recovery device, and a second slurry storage device. This allows the first conveying device to transport the foam ceramic precursor to the first novel grouting conveying device. The first novel grouting conveying device performs multiple impregnation, compression, and rebound processes on the foam ceramic precursor during transport. During this process, the first slurry output from the first slurry storage device impregnates the foam ceramic precursor. Because the ceramic precursor undergoes multiple impregnation, compression, and rebound processes during transport, the first slurry enters the central part of the foam ceramic precursor and is evenly distributed within it.

[0076] The second conveying device transports the foam ceramic precursor that has undergone one impregnation to the non-powered turning device. The non-powered turning device automatically turns the foam ceramic precursor that has undergone one impregnation, allowing it to fall into the lower layer and move in the opposite direction of the original conveying direction for a second impregnation. This achieves continuous conveying and impregnation, saves equipment length, and is more conducive to its use and promotion. At the same time, the foam ceramic precursor does not need to be clamped during the automatic turning process, thus avoiding the problem of damage to the foam ceramic matrix during the turning process.

[0077] The flipped foam ceramic precursor is conveyed to the second novel slurry conveying device via a third conveying device. During the first impregnation, the surface of the foam ceramic precursor in contact with the first slurry faces downwards, while the side of the foam ceramic not directly impregnated faces upwards. The first slurry from the second slurry storage device is then output to the side of the foam ceramic not in direct contact with the first slurry for impregnation. Simultaneously, the foam ceramic precursor undergoes impregnation, multiple compressions, and multiple rebounds while being conveyed in the second novel slurry conveying device, achieving further uniform impregnation with the second slurry. This results in the first and second slurries being uniformly adhered sequentially to the surface of the internal mesh skeleton of the foam ceramic precursor, thereby further enhancing the internal strength of the foam ceramic. The impregnation process is fully automated, ensuring uniform impregnation of the ceramic slurry inside the foam ceramic precursor without causing pore blockage and reduced porosity in the finished foam ceramic product used for aluminum melt purification. This also results in high internal strength for the foam ceramic used for aluminum melt purification.

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

[0079] The first slurry comprises: alumina powder, dispersant, binder, and 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-xanthodextrin, and sodium humate; the binder includes one or more of polyacrylamide, polyvinyl alcohol, and silica; the solvent includes water or ethanol; and 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: alumina powder, zirconium oxide powder, silicon carbide fiber, dispersant, binder, and solvent in a mass ratio of (16-20):(24-28):(22-26):(5-8):(7-9):(20-25);

[0084] The second slurry includes:

[0085] Alumina powder, dispersant, and solvent in a mass ratio of (66-70):(8-10):(20-25):

[0086] The dispersant includes one or more of sodium tripolyphosphate, xanthodextrin, and sodium humate; the binder includes one or more of polyacrylamide, polyvinyl alcohol, and silica; and 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 the previous step is that the first slurry is the same as the second slurry. The first slurry includes alumina powder, dispersant, binder and solvent in a mass ratio of (60-70):(3-5):(6-8):(22-26), which is conducive to achieving high strength of the ribbed ceramic structure in the foam ceramic. The main component is alumina. Even if it falls off during use, it will not have a significant impact on the filtered aluminum water.

[0089] By using different first and second slurries, the internal ribbed ceramic structure of the foam ceramic is realized, including an inner ceramic structure and an outer ceramic structure. This further improves the strength and toughness of the foam ceramic, avoids the problem of easy breakage or damage and flaking of the internal ribbed ceramic structure of the ceramic foam, and helps to improve the smoothness of the surface of the internal ribbed ceramic structure of the foam ceramic.

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

[0091] The second slurry comprises a third alumina powder, dispersant, and solvent in a mass ratio of (66-70):(8-10):(20-25):, thereby achieving an outer ceramic structure containing only alumina ceramic with high strength. The particle size distribution D50 of the second alumina powder is 6-10μm, which further enhances the strength of the outer ceramic structure and achieves a smooth surface. Attached Figure Description

[0092] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments of the present invention will be described below.

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

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

[0095] Figure 3 This is a schematic diagram of the structure of the first novel grouting and conveying device in Embodiment 1 of the present invention.

[0096] The markings shown in the attached figure:

[0097] 1. First conveying device; 2. Foam ceramic precursor; 3. First novel grouting conveying device; 4. First slurry storage device; 5. Second conveying device; 6. Non-powered turning device; 7. Third conveying device; 8. Second slurry storage device; 9. Fifth conveying device; 10. Second novel grouting conveying device; 12. Third container; 11. Fourth conveying device; 13. Slurry outlet flow regulating valve of the first slurry storage device; 14. Slurry outlet flow regulating valve of the second slurry storage device; 15. Foam ceramic precursor after primary impregnation; 16. Foam ceramic precursor after secondary impregnation. Detailed Implementation

[0098] To better understand the technical solution of the present invention, the present invention will be further described below in conjunction with specific embodiments and accompanying drawings.

[0099] Example 1:

[0100] In one aspect of this embodiment, a foam ceramic precursor impregnation device for purifying aluminum melt is characterized in that the impregnation device includes a first conveying device (1), a first novel grouting conveying device (3), a first slurry storage device (4), a second conveying device (5), a non-powered turning device (6), a third conveying device (7), a second novel 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 novel grouting conveying device (3), the second conveying device (5), the non-powered turning device (6), the third conveying device (7), the second novel grouting conveying device (10), and the fourth conveying device (11) are connected in sequence to realize that the foam ceramic precursor (2) passes through the first conveying device (1), the first novel grouting conveying device (3), the second conveying device (5), the non-powered turning device (6), the third conveying device (7), the second novel grouting conveying device (10), and the fourth conveying device (11) in sequence;

[0102] The first conveying device (1), the first novel grouting conveying device (3), and the second conveying device (5) are located on the upper layer, and the third conveying device (7), the second novel grouting conveying device (10), and the fourth conveying device (11) are located on the lower layer. The inlet end of the non-powered turning device (6) is connected to the outlet end of the second conveying device (5), and the outlet end of the non-powered turning device (6) is connected to the third conveying device (7).

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

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

[0105] The first novel grouting conveying device (3) includes 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 includes n first rotating rollers, and the second roller group includes m second rotating rollers; n < m; the plane containing the axis of the first rotating roller and the axis of the second rotating roller is set 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 conveying device (10) 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 plane containing the axis of the third rotating roller and the axis of the fourth rotating roller is set 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) includes a first container, and the bottom of the first container is provided with a plurality of first slurry outlets; the first slurry outlets are provided with a first slurry storage device outlet flow regulating valve (13);

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

[0110] The first container has three first slurry outlets at its bottom; the second container has three second slurry outlets at its bottom.

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

[0112] The unpowered flipping device (6) includes a fifth roller group and a sixth roller group arranged opposite to each other; the fifth roller group and the sixth roller group are bent.

[0113] The fifth roller group includes a plurality of fifth rotating rollers, which are arranged horizontally in a row and form a first arc shape.

[0114] The sixth roller group includes a plurality of sixth rotating rollers, which are arranged horizontally in a row and form a second arc shape.

[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 non-powered flipping device is based on two concentric circles of φ1500mm and φ1180mm respectively. The second arc has 18 sixth rollers of φ100mm*700mm evenly distributed on the semicircle of φ1180mm, and the first arc has 21 fifth rollers of φ100mm*700mm evenly distributed on the semicircle of φ1500mm.

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

[0118] The third conveying device (7) is inclined downward along the conveying direction, and the second conveying device (5) is at an angle of β with the horizontal plane, where β = 10°.

[0119] The second conveying device (5) is inclined downward along the conveying direction, which is conducive to the foam ceramic precursor (15) entering the non-powered turning device (6) after one impregnation. That is, it is conducive to the foam ceramic precursor (15) entering the non-powered turning device after one impregnation to increase a certain kinetic energy, and at the same time, the outlet of the second conveying device is opposite to the inlet of the non-powered turning device.

[0120] The linear speeds of the first and second rollers of the first novel grouting conveyor (3), the third and fourth rollers of the second novel grouting conveyor (10) are all V1, the discharge flow rates of the first grout storage device (4) and the second grout storage device (8) are all Q, the belt speed of the second conveyor belt of the second conveyor device (5) is V2, and the belt speed of the third conveyor belt of the third conveyor device (7) is V3.

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

[0122] δ = 1.2;

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

[0124] The second grout storage device (8) is located directly below the first novel grouting conveying device (3), and the second novel grouting conveying device (10) is located directly below the second grout storage device (8);

[0125] The fifth conveying device (9) includes a fifth conveyor belt with retractable baffles on both sides, and a fifth support for supporting the fifth conveyor belt.

[0126] The first conveying device (1) includes a first conveyor belt and a first support for supporting the first conveyor belt;

[0127] The second conveying device (5) includes a second conveyor belt and a second support for supporting the second conveyor belt;

[0128] The third conveying device (7) includes a third conveyor belt and a third support for supporting the third conveyor belt;

[0129] The fourth conveying device (11) includes a fourth conveyor belt and a fourth support for supporting the fourth conveyor belt.

[0130] In another aspect, the present invention provides a method for impregnating a foam ceramic precursor for purifying aluminum melt, wherein impregnation is performed using the aforementioned impregnation device for purifying aluminum melt; comprising the following steps:

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

[0132] The foam ceramic precursor is placed on the surface of the first conveying device (1), and the foam ceramic precursor is conveyed by the first conveying device (1) to the first roller group and the second roller group of the first novel grouting device (3) for continuous extrusion and rebound.

[0133] Open the flow regulating valve of the first slurry storage device (4) and let the first slurry 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 convey the foam ceramic precursor and impregnate it once during the rotation process.

[0134] After being impregnated once, the foam ceramic precursor is conveyed to the surface of the second conveying device (5), and then the impregnated foam ceramic precursor (15) is conveyed through the second conveying device (5) to the fifth and sixth roller groups of the non-powered turning device (6).

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

[0136] After one impregnation, the foam ceramic precursor (15) is conveyed by the third conveying device (7) to the third and fourth roller groups of the second new type of grouting conveying device (10) for continuous extrusion and rebound.

[0137] Open the flow regulating valve of the second slurry storage device (8) and let the second slurry enter the foam ceramic precursor (15) after one impregnation through the gap of the third roller group; the third roller of the third roller group and the fourth roller of the fourth roller group transport the foam ceramic precursor (15) after one impregnation and impregnate it for a second time during the rotation process.

[0138] After the first impregnation, the foam ceramic precursor (15) is impregnated a second time and then conveyed to the surface of the fourth conveying device (11). The fourth conveying device (11) then conveys the impregnated foam ceramic precursor (16) to the next process.

[0139] After the foam ceramic precursor is impregnated and squeezed once by the first novel grouting and conveying device (3), the slurry holding rate of the foam ceramic precursor is 11, that is, the slurry holding capacity of 1 kg of unimpregnated foam ceramic precursor is 11 kg after one impregnation.

[0140] After the foam ceramic precursor is impregnated twice by the second novel grouting and conveying device (10), the slurry holding rate of the foam ceramic precursor is 27.41, that is, the slurry holding capacity of 1 kg of unimpregnated foam ceramic precursor after one impregnation and two impregnations is 27.41 kg.

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

[0142] The first slurry comprises: alumina powder, dispersant, binder, and 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] Example 2:

[0145] The contents that are the same as in Example 1 will not be repeated here; the different aspects of this embodiment compared to Example 1 are as follows:

[0146] The second slurry storage device includes a second container, which has 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 the bottom of the first container by a plurality of first slurry outlets.

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

[0148] Where n = 7, m = 8; j = 7, k = 8, γ = 0.38;

[0149] The first container has four first slurry outlets at its bottom; the second container has four second slurry outlets at its bottom.

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

[0151] The third conveying device (7) is inclined downward along the conveying direction, and the second conveying device (5) is at an angle of β with the horizontal plane, where β = 14°.

[0152] V2=δV1, V3=V1, δ=1.2;

[0153] In another aspect of the present invention, a method for impregnating a foam ceramic precursor for purifying aluminum melt is provided, wherein the foam ceramic precursor after the first impregnation loses 2.5% of its moisture after passing through a second conveying device (5);

[0154] After the foam ceramic precursor is impregnated and extruded once by the first novel slurry conveying device (3), the slurry holding rate of the foam ceramic precursor is 11.4, that is, the slurry holding capacity of 1 kg of unimpregnated foam ceramic precursor is 11 kg after one impregnation.

[0155] After the foam ceramic precursor is impregnated twice by the second novel grouting and conveying device (10), the slurry holding rate of the foam ceramic precursor is 28.5, that is, the slurry holding capacity of 1 kg of unimpregnated foam ceramic precursor after one impregnation and two impregnations is 28.5 kg.

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

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

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

[0159] The dispersant includes xanthodextrin 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 zirconium oxide powder is 16 μm; the particle size distribution D50 of the second alumina powder is 8 μm.

[0161] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to the technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, the above-described features have similar functions to (but are not limited to) those disclosed in this application.

Claims

1. A foam ceramic precursor impregnation device for purifying aluminum-containing melts, characterized in that, The impregnation device includes a first conveying device (1), a first novel grouting conveying device (3), a first slurry storage device (4), a second conveying device (5), a non-powered turning device (6), a third conveying device (7), a second novel grouting conveying device (10), a second slurry storage device (8), a fourth conveying device (11), and a second slurry recovery device; The first conveying device (1), the first new type of grouting conveying device (3), the second conveying device (5), the non-powered turning device (6), the third conveying device (7), the second new type of grouting conveying device (10), and the fourth conveying device (11) are connected in sequence to realize that the foam ceramic precursor (2) passes through the first conveying device (1), the first new type of grouting conveying device (3), the second conveying device (5), the non-powered turning device (6), the third conveying device (7), the second new type of grouting conveying device (10), and the fourth conveying device (11) in sequence. The first conveying device (1), the first new type of grouting conveying device (3), and the second conveying device (5) are located on the upper layer, and the third conveying device (7), the second new type of grouting conveying device (10), and the fourth conveying device (11) are located on the lower layer. The inlet end of the non-powered turning device (6) is connected to the outlet end of the second conveying device (5), and the outlet end of the non-powered turning device (6) is connected to the third conveying device (7). The first slurry storage device (4) is located above the first novel grouting and conveying device (3); The second slurry storage device (8) is located above the second novel grouting conveying device (10); The first novel grouting conveying device (3) includes 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 consists of n first rotating rollers, and the second roller group consists of m second rotating rollers; n < m; The plane containing the axis of the first roller and the axis of the second roller is set at an angle to the horizontal plane; The distance between the first and second rotating rollers is adjustable; and / or The second novel grouting conveying device (10) 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 rollers, and the second roller group includes k fourth rollers; j < k; The plane containing the axis of the third roller and the axis of the fourth roller is set at an angle to the horizontal plane. The distance between the third and fourth rollers is adjustable.

2. The foam ceramic precursor impregnation device for purifying aluminum-containing melts according to claim 1, characterized in that, The first slurry storage device (4) includes a first container, and the bottom of the first container is provided with a plurality of first slurry outlets; the first slurry outlets are provided with flow regulating valves; The second slurry storage device (8) includes a second container, and the bottom of the second container is provided with a plurality of second slurry outlets; the second slurry outlets are provided with flow regulating valves.

3. The foam ceramic precursor impregnation device for purifying aluminum-containing melts according to claim 2, characterized in that, The first container has 3-4 first slurry outlets at the bottom; the second container has 3-4 second slurry outlets at the bottom.

4. The foam ceramic precursor impregnation device for purifying aluminum-containing melts according to claim 3, characterized in that, The first slurry outlet is located above the gap between two adjacent first rollers; the second slurry outlet is located above the gap between two adjacent third rollers.

5. The foam ceramic precursor impregnation device for purifying aluminum-containing melts according to claim 1, characterized in that, The unpowered flipping device (6) includes a fifth roller group and a sixth roller group arranged opposite to each other; the fifth roller group and the sixth roller group are bent. The fifth roller group includes a plurality of fifth rotating rollers, which are arranged horizontally in a row and form a first arc shape. The sixth roller group includes a plurality of sixth rotating rollers, which are arranged horizontally in a row and form a second arc shape. The diameter of the circle containing the first arc is 1350-1650mm, and the central angle of the first arc is greater than or equal to 45°. The diameter of the circle containing the second arc is 1030-1500mm, and the central angle of the second arc is greater than or equal to 45°.

6. The foam ceramic precursor impregnation device for purifying aluminum-containing melts according to claim 1, characterized in that, The second conveying device (5) is inclined downward along the conveying direction, and the angle between the second conveying device (5) and the horizontal plane is α, where 8°≤α≤15°; The third conveying device (7) is inclined downward along the conveying direction, and the second conveying device (5) is at an angle of β with the horizontal plane, where 8°≤β≤15°.

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

8. The foam ceramic precursor impregnation device for purifying aluminum-containing melts according to claim 2, characterized in that, The second grout storage device (8) is located directly below the first novel grouting conveying device (3), and the second novel grouting conveying device (10) is located directly below the second grout storage device (8); and The second slurry storage device (8) 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. The second accommodating space is connected to the bottom of the first container with a plurality of first slurry outlets.

9. The foam ceramic precursor impregnation device for purifying aluminum-containing melts according to claim 1, characterized in that, The second slurry recovery device includes a fifth conveying device (9) and a third container (12) located below the end of the fifth conveying device (9) away from the third conveying device (7). The fifth conveying device includes a fifth conveyor belt with retractable baffles on both sides, and a fifth support for supporting the fifth conveyor belt. and The first conveying device (1) includes a first conveyor belt and a first support for supporting the first conveyor belt; and The second conveying device (5) includes a second conveyor belt and a second support for supporting the second conveyor belt; and The third conveying device (7) includes a third conveyor belt and a third support for supporting the third conveyor belt; and The fourth conveying device (11) includes a fourth conveyor belt and a fourth support for supporting the fourth conveyor belt.

10. A method for impregnating a foamed ceramic precursor for purifying aluminum-containing melts, characterized in that, Impregnation is performed using the foam ceramic precursor impregnation apparatus for purifying aluminum-containing melts as described in any one of claims 1-9; Includes the following steps: The first slurry is stored in the first slurry storage device (4); the second slurry is stored in the second slurry storage device (8); The foam ceramic precursor (2) is placed on the surface of the first conveying device (1), and the foam ceramic precursor (2) is conveyed by the first conveying device (1) to the first roller group and the second roller group of the first new type of grouting conveying device (3) for continuous extrusion and rebound. Open the flow regulating valve of the first slurry storage device (4) and let the first slurry 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) and impregnate it once during the rotation process. After being impregnated once, the foam ceramic precursor (2) is conveyed to the surface of the second conveying device (5), and then the impregnated foam ceramic precursor (15) is conveyed through the second conveying device (5) to the fifth and sixth roller groups of the non-powered turning device (6). After one impregnation, the foam ceramic precursor (15) slides between the fifth and sixth roller groups under the action of gravity to the surface of the third conveying device (7); After one impregnation, the foam ceramic precursor (15) is conveyed by the third conveying device (7) to the third and fourth roller groups of the second new type of grouting conveying device (10) for continuous extrusion and rebound. Open the flow regulating valve of the second slurry storage device (8) and let the second slurry enter the foam ceramic precursor (15) after one impregnation through the gap of the third roller group; the third roller of the third roller group and the fourth roller of the fourth roller group transport the foam ceramic precursor (15) after one impregnation while impregnating it for the second time during the rotation process. After the first impregnation, the foam ceramic precursor (15) is impregnated a second time and then conveyed to the surface of the fourth conveying device (11). The fourth conveying device (11) then conveys the impregnated foam ceramic precursor (16) to the next process. After the foam ceramic precursor is impregnated and extruded once by the first novel grouting and conveying device (3), the slurry holding rate of the foam ceramic precursor is 10.13-11.8, that is, the slurry holding capacity of 1 kg of unimpregnated foam ceramic precursor after one impregnation is 10.3-11.8 kg. After the foam ceramic precursor is impregnated and extruded twice by the second novel grouting and conveying device (10), the slurry holding rate of the foam ceramic precursor is 25.32-29.5, that is, the slurry holding capacity of 1 kg of unimpregnated foam ceramic precursor after one impregnation and two impregnations is 25.32-29.5 kg.

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

Images