A combined device for removing trace amounts of iron from ceramic raw materials

Abstract

This invention discloses a combined device for removing trace amounts of iron from ceramic raw materials. It includes a primary iron removal system and a secondary iron removal system. The secondary iron removal system includes an outer cylinder with a support cylinder that can rotate counterclockwise. A raw material distributor (4) is fixed on the inner wall of the outer cylinder between the support cylinder and the raw material feed pipe. Electromagnetic blocks are fixedly arranged at intervals on the surface of the support cylinder. The electromagnetic blocks are divided into abcd region and ad region on the cross section of the support cylinder. A wedge-shaped pressure block is arranged on the support cylinder at point a in the ad region. An arc-shaped contact plate is arranged on the end plate of the outer cylinder. The primary iron removal system includes two crushing and iron removal rollers that rotate vertically relative to each other. Each crushing and iron removal roller includes a rotating cylinder with comb teeth. A strong magnetic plate is fixedly arranged on the rotating cylinder between the comb teeth. This invention saves cleaning materials and labor time, reduces iron removal costs, and has a good iron removal effect, which can reduce iron content in raw materials by 60-70%.

Description

Technical Field

[0001] This invention relates to an iron removal device, and more particularly to an iron removal device specifically designed for removing trace amounts of iron from ceramic raw materials. Background Technology

[0002] Ceramic products are made primarily from clay, quartz (alumina), and feldspar, along with small amounts of various natural minerals, through crushing, mixing, molding, and firing. Because ceramic raw materials generally contain a certain amount of iron, ceramics with high iron content melt into a glassy substance during the sintering process. Not only does it easily form many tiny color spots on the ceramic surface This will increase the brittleness of ceramic products, making thin-walled ceramic products prone to deformation and cracking. This affects the internal and external quality of ceramics. To ensure the quality and performance of ceramic products, the iron content in various raw materials used in manufacturing ceramic products is subject to process limits. If the iron content in the raw materials exceeds the process requirements, iron removal is necessary. Currently, the main method for iron removal from ceramic raw materials is in the ceramic slurry stage, where a magnetic rod device is installed in the slurry tank for wet iron removal. This wet iron removal device has the following problems: First, after a certain period of use, a layer of slurry adheres to the surface of the magnetic rod, reducing its magnetic attraction and resulting in poor iron removal. Second, the magnetic rod needs to be cleaned after a certain period of use, which is troublesome, labor-intensive, and time-consuming, not only reducing the iron removal effect but also increasing labor costs. Summary of the Invention

[0003] To address the problems existing in the prior art, the present invention provides a ceramic raw material iron removal device that removes iron in a dry state, eliminates the need for cleaning of the magnet (magnetic block), and features a compact structure, good iron removal effect, and reduced labor intensity and time costs.

[0004] The technical solution adopted by this invention to solve the technical problem is: a combined device for removing trace amounts of iron from ceramic raw materials, comprising a primary iron removal body and a secondary iron removal body. The secondary iron removal body includes an outer cylinder, a raw material feed pipe with one end located at the upper part of the outer cylinder and communicating with the inner cavity of the outer cylinder, and a raw material discharge hopper and an iron discharge hopper respectively communicating with the lower end of the outer cylinder. A support cylinder that can rotate counterclockwise is provided on the outer cylinder via a rotating shaft. A raw material distributor fixed on the inner wall of the outer cylinder is provided between the support cylinder and the raw material feed pipe. The raw material distributor is arc-shaped and has a grid-like distribution on it. The raw material injection hole is provided. Electromagnetic blocks are fixedly arranged at intervals on the surface of the support cylinder. The electromagnetic blocks divide the cross-section of the support cylinder into an abcd region with a central angle of 280° and an ad region with a central angle of 80°. The electromagnetic blocks in the abcd region of the support cylinder are connected in series with wires, and the electromagnetic blocks in the ad region are connected in series with wires. The electromagnetic blocks in the abcd and ad regions are connected in parallel and pass through a rotating shaft tube to a rotary electrical connector mounted on one end of the rotating shaft tube. A wedge-shaped pressure block is provided on the support cylinder at a position relative to point a in the ad region. At the end point a corresponding to the ad region... An arc-shaped contact plate is fixedly installed on the end plate of the outer cylinder between the d and end points. When the pressure block rotates counterclockwise with the support cylinder and comes into contact with the arc-shaped contact plate at the a end point, it is compressed and displaced. The arc-shaped contact plate moves under pressure, squeezing the normally closed switch and opening it. At this time, the electromagnetic block in the ad region rotates counterclockwise and is de-energized and demagnetized. The iron material adhering to the electromagnetic block in the ad region falls off the electromagnet and enters the iron box through the iron material outlet. When the pressure block continues to rotate counterclockwise with the support cylinder and comes into contact with the arc-shaped contact plate at the d end point, it is compressed and displaced. The arc-shaped contact plate at the d end point moves under pressure, squeezing the normally open switch and closing it. At this time, the ad region... The electromagnetic blocks within the domain are charged and magnetized. A partition is provided at the lower end of the outer cylinder to separate the raw material discharge hopper and the iron material discharge hopper. The primary iron removal body is located inside the raw material feed pipe. The primary iron removal body includes two crushing and iron removal rollers that rotate relative to each other and are vertically distributed above and below the raw material input belt. The crushing and iron removal rollers include a rotating drum body. Several rows of comb teeth are arranged alternately or parallel on the drum body. Strong magnetic plates are fixedly installed on the drum body between the comb teeth. Magnetic strips are spaced apart on the strong magnetic plates. A raw material guide trough is provided between the raw material input belt and the crushing and iron removal rollers.

[0005] The working process of this invention is as follows: Ceramic raw materials are fed into two opposing rotating crushing and iron-removing rollers (50-100 rpm) via a raw material input belt. The comb teeth on the two rollers crush the raw materials into fine powder particles. The strong magnetic force of the strong magnetic plates with magnetic strips on the rollers removes iron from the raw materials for the first time. After the first iron removal, the raw materials are rotated and projected onto a raw material distributor, which then sprays them onto electromagnetic blocks within the abcd area of ​​the support cylinder. When the support cylinder rotates counterclockwise, the iron in the raw materials is adsorbed onto the electromagnetic blocks. The raw material falls onto the magnetic block, while the material falls into the cavity of region abcd between the support cylinder and the outer cylinder. It then enters the raw material discharge hopper through the raw material outlet and flows onto the raw material output belt. When the support cylinder rotates counterclockwise (40-60 rpm), the pressure block on it contacts the arc-shaped contact plate at end a. The arc-shaped contact plate is pressed and moves, then presses the normally closed switch to open it. The electromagnet in region ab is demagnetized, and the iron attracted to the electromagnet block in region ab falls from the support cylinder into the cavity of region ab and enters the iron material box through the iron material outlet, thus performing a second iron removal. When the support cylinder rotates counterclockwise, the pressure block on it contacts the arc-shaped contact plate at end d. The arc-shaped contact plate is pressed and moves, then presses the normally open switch to close it. The electromagnet in region ab is energized, and the electromagnet in region ab enters region abcd to contact the raw material. This cycle continues, continuously performing secondary iron removal on the raw material.

[0006] This invention employs a two-stage iron removal device to remove iron from dry ceramic raw materials. Firstly, it avoids the problems associated with removing iron in a wet state during ceramic slurry preparation, as is present in existing technologies. Secondly, the two-stage iron removal process improves the iron removal efficiency. The first-stage iron removal system uses two vertically oppositely rotating crushing and iron-removing rollers positioned above and below the raw material input belt, along with a rotating cylinder equipped with comb teeth and a strong magnetic plate on the crushing and iron-removing rollers. This process simultaneously crushes and adsorbs iron from the ceramic raw material, adsorbing approximately 20% of the iron. The second-stage iron removal system continuously adsorbs and separates the iron, adsorbing approximately 40-50% of the iron, cumulatively removing at least 60-70% of the iron. This ensures that the iron content of the ceramic raw material meets the technical requirements, thereby guaranteeing that the iron content in the ceramic slurry meets the required standards.

[0007] Technical requirements for the iron content (Fe2O3) of main raw materials in ceramic products:

[0008] 1. Grade I or Superior grade: Clay: ≤0.8-1%, Quartz: ≤0.1%, Feldspar: ≤0.15%, Alumina: ≤0.20%.

[0009] 2. Second-class product: Clay: ≤1.5%, Quartz: ≤0.15%, Feldspar: ≤0.25%, Alumina: ≤0.35%.

[0010] 3. Qualified product: Clay: ≤2%, Quartz: ≤0.25%, Feldspar: ≤0.5%, Alumina: ≤0.50%.

[0011] The main raw materials for preparing ceramic products are: 40-60% clay, 30-50% quartz and 5-10% feldspar.

[0012] Among existing clay minerals, kaolin, which has high industrial mining value, generally has an iron oxide content of 1.5-2.7%; quartz, which has high industrial mining value, generally has an iron oxide content of less than 1%; and bauxite, which has high industrial mining value, generally has an iron oxide content of 1-2%.

[0013] Compared with the prior art, the present invention has the following characteristics

[0014] 1. When removing iron in a dry state, no slurry residue or adhesion will remain on the magnets (magnetic blocks or rods). No cleaning is required for extended use, saving cleaning materials and time, and reducing iron removal costs.

[0015] 2. This invention has a compact structure, is easy to manufacture and maintain, and is stable and safe to use.

[0016] 3. This invention has a good iron removal effect, which can reduce the iron content in the raw material by 60-70%. It has a high iron removal efficiency, capable of removing iron from 3-5 tons of raw material per hour.

[0017] 4. In the secondary iron removal process of this invention, several charging magnetic blocks are arranged in parallel or staggered intervals on the side of the rotating support cylinder. The electromagnetic blocks in the two-thirds abc region, which are normally energized, adsorb the iron material of the raw material. The normally closed switches on the circuits in the intermittent ad region are turned on or off, causing the normally closed switches on the circuits in the ad region of the electromagnetic blocks adsorbing the iron material to be turned off. The electromagnetic blocks in the ad region are demagnetized, and the iron material falls off the electromagnetic blocks and separates into the iron storage area. The electromagnetic blocks leaving the ad region are quickly magnetized again after being powered on. This cycle can form a large-scale iron removal process. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the main cross-sectional structure of the present invention.

[0019] Figure 2 yes Figure 1 A schematic diagram of the AA cross-sectional structure in the diagram.

[0020] Figure 3 yes Figure 2 Enlarged schematic diagram of the XX local structure

[0021] Figure 4 This is a schematic diagram of the structure of the electromagnetic blocks in regions abcd connected in series according to the present invention.

[0022] Figure 5 This is a schematic diagram of the structure of the electromagnetic blocks in the ad region of this invention connected in series.

[0023] Figure 6 This is a schematic diagram of the end face structure of the iron removal roller of the present invention.

[0024] Figure 7 yes Figure 6 A schematic diagram of the B-direction structure.

[0025] Figure 8 This is a cross-sectional structural schematic diagram of the raw material distributor of the present invention.

[0026] In the diagram, 1. Raw material input belt; 2. Crushing and iron removal roller; 3. Raw material feed pipe; 4. Raw material distributor; 5. Outer cylinder; 6. Press block; 7. Electromagnetic block; 8. Support plate; 9. Wire; 10. Iron material outlet; 11. Iron material box; 12. Iron material discharge hopper; 13. Arc-shaped contact plate; 14. Raw material output belt; 15. Raw material discharge hopper; 16. Raw material outlet; 17. Roller body; 18. Magnetic strip; 19. Strong magnetic plate; 20. Comb teeth; 21. Primary rotating shaft; 22. Fastening screw I; 23. Wheel spoke; 24. Flange; 25. Bearing seat; 26. End plate; 27. Rotary tube shaft; 28. Transmission key; 29. ​​Rotary electrical connector; 30. Normally closed switch; 31. Partition plate; 32. Limit frame; 33. Support cylinder; 34. Fastening screw II; 35. Raw material injection hole; 36. Magnetic ring; 37. Guide trough; 38. Spring; 39. Normally open switch. Detailed Implementation

[0027] Example 1: Iron removal from Shulan clay (iron oxide content 2.2-2.5%) produced in Jilin City, Jilin Province. A combined device for removing trace amounts of iron from ceramic raw materials includes a primary iron removal body and a secondary iron removal body. The secondary iron removal body includes an outer cylinder 5 (the outer cylinder is connected to a support foot by a support plate 8), a raw material feed pipe 3 with one end located at the upper part of the outer cylinder and communicating with the inner cavity of the outer cylinder, a raw material discharge hopper 15 and an iron discharge hopper 12 respectively communicating with the lower end of the outer cylinder, end plates 26 are fixedly connected to both ends of the outer cylinder, a bearing seat 25 is provided in the middle of the end plate, and a rotating shaft 27 is movably arranged between the bearing seats. The right end of the rotating shaft extends out of the end plate and... A rotary electrical connector 29 and a transmission key 28 are connected to the outside of the bearing housing. The rotating tube shaft is connected to a servo motor (not shown in the figure) via the transmission key. The outer cylinder is provided with a support cylinder 33 that can rotate counterclockwise via the rotating tube shaft. A raw material distributor 4 is fixed on the inner wall of the outer cylinder between the support cylinder and the raw material feed pipe. The raw material distributor is arc-shaped and has horn-shaped raw material injection holes 35 arranged in a grid pattern on it. The inner cavity of the outer cylinder is connected to the raw material feed pipe through the raw material injection holes. Electromagnetic blocks 7 with magnetic rings 36 on their magnetic surfaces are fixedly fixed at intervals on the surface of the support cylinder by fastening screws II 34 (the magnetic rings increase the attraction force). The electromagnetic blocks are separated by limiting frame plates 32. The electromagnetic blocks are square (100-150×100-150 mm). The electromagnetic blocks divide the cross-section of the support cylinder into an abcd region with a central angle of 280° and an ad region with a central angle of 80° (the circumference of the support cylinder is divided into four points a, b, c, and d (ab, bc, and cd form the abcd region; the area between d and a forms the ad region). The electromagnetic blocks on the abcd region of the support cylinder are connected by wires 9. The two sets of wires of the electromagnetic blocks in the abcd and ad regions are connected in series. After passing through the rotating tube shaft 27, they are connected to the rotary electrical connector 29, which is connected to the mains power and mounted on one end of the rotating tube. A wedge-shaped pressure block 6 is set on the support cylinder at the position relative to point a in the ad region. An arc-shaped contact plate 13 is fixed on the end plate of the outer cylinder between the a and d endpoints corresponding to the ad region. The two ends of the arc-shaped contact plate are supported and fixed to the inner wall of the outer cylinder by springs 38. When the pressure block rotates counterclockwise with the support cylinder, it contacts the arc-shaped contact plate at the a endpoint and is compressed, resulting in displacement (maximum displacement 1-1).When the wedge-shaped pressure block is 5 mm high (i.e., the height of the inclined surface of the wedge-shaped pressure block), the arc-shaped contact plate at end a moves under pressure, squeezing the normally closed switch 30 at end a to open it. At this time, the electromagnetic block in the ad region is de-energized and demagnetized. When the pressure block comes into contact with the arc-shaped contact plate from end a to end d, the electromagnet on the support cylinder from end a to end d is de-energized, and the iron material adhering to the electromagnetic block in the ad region falls off the electromagnet and enters the iron material box through the iron material outlet. When the pressure block continues to rotate counterclockwise with the support cylinder until it comes into contact with the arc-shaped contact plate at end d and is compressed and displaced (pressure... When the block completely leaves the arc-shaped contact plate at endpoint a, the normally closed switch automatically returns to the closed state from open. The arc-shaped contact plate at endpoint d is pressed and moves, squeezing the normally open switch 39 at endpoint d to close. At this time, the electromagnetic block in region a and b is charged and magnetized. When the block leaves the arc-shaped contact plate at endpoint d and continues to rotate counterclockwise with the support cylinder (when the block completely leaves the arc-shaped contact plate at endpoint d, the normally open switch returns to the open state from closed), a partition 31 is provided between the raw material outlet 16 and the iron material outlet 10 at the lower end of the outer cylinder, thereby separating the raw material and the iron material. Material is discharged from the raw material discharge hopper 15 and the iron material discharge hopper 12. The raw material flows onto the raw material output belt 14 for output, while the ferrous material flows into the iron material box 11. The primary iron removal body is installed inside the trumpet-shaped raw material feed pipe 3. The primary iron removal body includes two crushing and iron removal rollers 2 that are vertically oppositely distributed at the upper and lower ends of the raw material input belt 1 and rotate relative to each other. The crushing and iron removal rollers include a rotating drum 17 connected to the primary rotating shaft 24 and capable of rotation. The rotating drum 17 is connected to the primary rotating shaft 21 through spokes 23 and flanges 24. The primary rotating shaft is connected to a motor. The cylinder body has several rows of staggered or parallel arrangement along its axial direction, with comb teeth 20 spaced apart on the cross-section of each row. A strong magnetic plate 19 is fixed to the rotating cylinder body with a fastening screw I22 at a radial angle (15-20°) between the comb teeth. The comb teeth are spaced 30-50 mm apart axially, with sharp angles on both sides. Magnetic strips 18 are spaced apart on the strong magnetic plate. A raw material guide trough 37 is provided between the raw material input belt 1 and the crushing and iron removal roller 2, allowing all the raw material coming down from the input belt to be fed between the two crushing and iron removal rollers. In the above embodiment, after 3 hours of operation, 10 tons of Shulan clay were tested five times (average Fe2O3 content: 0.81, 1.02, 0.92, 1.05, and 1.09%), and the result was 0.98%, meeting the requirements for excellent clay grade.

[0028] Example 2: Iron removal was performed on quartz sand minerals from Gongxian County, Henan Province (iron oxide content 0.6-1%). Using the combined device described in Example 1, with appropriate support cylinder and rotation speed adjusted to 30-40 rpm, 5 tons of Gongxian quartz sand were tested three times after 2 hours of operation (0.102, 0.17, and 0.11). The average iron content (Fe2O3) was 0.126%, meeting the grade requirements between first-class and second-class products.

[0029] In Example 3, similarly, after 2 hours of work, 5 tons of Kaifeng bauxite (iron oxide content 1.0-1.5%) was tested three times for iron removal (0.102, 0.17 and 0.11, average iron content Fe2O3 was 0.38.1%), which is close to the grade requirement of second-class product.

Claims

1. A combined device for removing trace amounts of iron from ceramic raw materials, characterized in that: It includes a primary iron removal system and a secondary iron removal system. The secondary iron removal system includes an outer cylinder (5), a raw material feed pipe (3) with one end located at the upper part of the outer cylinder and communicating with the inner cavity of the outer cylinder, a raw material discharge hopper (15) and an iron material discharge hopper (12) respectively connected to the lower end of the outer cylinder. The outer cylinder is provided with a support cylinder (33) that can be rotated counterclockwise by a rotating pipe shaft (27). A raw material distributor (4) fixed on the inner wall of the outer cylinder is provided between the support cylinder and the raw material feed pipe. The raw material distributor is arc-shaped and has raw material injection holes (35) arranged in a grid pattern at intervals on its surface. The support cylinder is fixedly provided with at intervals. An electromagnetic block (7) is divided into an abcd region with a central angle of 280° and an ad region with a central angle of 80° on the cross-section of the supporting cylinder. The electromagnetic blocks on the abcd region of the supporting cylinder are connected in series with wires (9), and the electromagnetic blocks on the ad region are connected in series with wires. The electromagnetic blocks in the abcd region and the ad region are connected in parallel and pass through the rotating tube shaft to be connected to the rotary electrical connector (29) mounted on one end of the rotating tube shaft. A wedge-shaped pressure block (6) is provided on the supporting cylinder at the position opposite to point a in the ad region. The end plate of the outer cylinder is fixed between the a end point and the d end point corresponding to the ad region. An arc-shaped contact plate (13) is provided. When the pressure block rotates counterclockwise with the support cylinder and contacts the arc-shaped contact plate at end a, it is pressed and displaced. The arc-shaped contact plate moves under pressure and squeezes the normally closed switch to open. At this time, the electromagnetic block in the ad area is de-energized and demagnetized. The iron material adhering to the electromagnetic block in the ad area falls off the electromagnet and enters the iron box (11) through the iron material outlet (10). When the pressure block continues to rotate counterclockwise with the support cylinder until it contacts the arc-shaped contact plate at end d, it is pressed and displaced. The arc-shaped contact plate at end d moves under pressure and squeezes the normally open switch to close. At this time, the electromagnetic block in the ad area is charged and magnetized. The lower end of the outer cylinder is provided with A partition (31) is provided to separate the raw material discharge hopper and the iron material discharge hopper. The primary iron removal body is set inside the raw material feed pipe. The primary iron removal body includes two crushing and iron removal rollers (2) that are vertically distributed and rotate relative to each other above and below the raw material input belt (1). The crushing and iron removal rollers include a rotating drum body (17). Several rows of comb teeth (20) are arranged alternately or parallel on the drum body. A strong magnetic plate (19) is fixedly arranged on the drum body between the comb teeth. Magnetic strips (18) are arranged at intervals on the strong magnetic plate. A raw material guide trough (37) is provided between the raw material input belt and the crushing and iron removal rollers.

2. The combined device for removing trace amounts of iron from ceramic raw materials according to claim 1, characterized in that: The raw material injection hole (35) is trumpet-shaped.

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