A method for improving the production efficiency and fiber performance of continuous basalt fibers by raw material multi-component compounding

Abstract

The application belongs to the field of inorganic nonmetallic materials, and particularly relates to a method for improving the production efficiency and fiber performance of continuous basalt fiber by multi-element mixing of raw materials. The application adjusts the percentage content of main oxides of the raw material minerals, i.e. the percentage content of network formers, network intermediates and network changers, and the ratio of FeO / (Fe2O3+FeO) of the main mineral raw materials, and corrects the spinnability defects of the single mineral raw material, such as the imbalance of the ratio of 2+ valence iron to 3+ valence iron, the slightly low content of main oxides such as SiO2 and Al2O3, and the imbalance of the content of alkaline earth oxides such as CaO and MgO, so that the homogeneity and thermal conductivity of the glass liquid in the drawing production process are greatly improved, the basalt fiber drawing operation stability is improved, the fiber drawing rate and full barrel rate are improved, and the basalt fiber performance is stabilized synchronously.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of inorganic non-metallic materials, and particularly relates to a method for improving the production efficiency and fiber performance of continuous basalt fiber by multi-element mixing of raw materials. BACKGROUND

[0002] As an inorganic high-performance fiber with excellent physical and chemical properties, basalt fiber has shown a wide application prospect in many fields such as national defense and military industry, transportation, fire prevention and heat insulation, electric power and new energy, national infrastructure construction, ocean and maritime affairs, dielectric materials, automobile manufacturing, etc., and has shown great potential for industrial development.

[0003] A large number of production practices have proved that the ore raw material of continuous basalt fiber is not limited to basalt, and many magmatic rocks including diabase, gabbro, basaltic andesite, andesite, gray-green diorite, pyroxene diorite, diorite, etc. can be used for continuous basalt fiber production. In the existing basalt fiber preparation method in China, a single ore raw material is used for continuous basalt fiber production. Due to its natural nature, the single basalt ore has defects in spinnability, and the natural ore inevitably has fluctuation in mineral and chemical composition. The defects in spinnability of the raw material and the fluctuation in composition seriously affect the production efficiency and fiber performance of continuous basalt fiber. Under the premise of maintaining the natural nature and green environmental protection of continuous basalt fiber, in order to obtain higher production efficiency and stable fiber quality, it is necessary to design ideal raw material minerals and chemical composition contents to improve the difficult basalt fiber drawing and poor drawing effect, and to improve the production efficiency and fiber performance of continuous basalt fiber. SUMMARY

[0004] In order to overcome the defects in spinnability of single basalt fiber ore raw material and the influence of mineral and chemical composition fluctuation on production, the present application improves the stability of continuous basalt fiber drawing operation by multi-element mixing of raw materials, thereby improving the fiber formation rate and full barrel rate, and simultaneously stabilizing the performance of basalt fiber.

[0005] Specifically, the technical scheme adopted by the present application is as follows: a method for improving the production efficiency and fiber performance of continuous basalt fiber by multi-element mixing of raw materials, the method comprising the following steps:

[0006] (1) Raw material selection: selecting one or more basic-neutral magmatic rocks with SiO2 mass percentage content greater than or equal to 52% and less than 54% as the main material, selecting one or more neutral magmatic rocks with SiO2 mass percentage content greater than or equal to 54% and less than 58% as the first ingredient, and optionally, selecting one or more basic magmatic rocks with SiO2 mass percentage content greater than or equal to 47% and less than 52% as the second ingredient;

[0007] (2) Material proportioning: the chemical component content of the main material selected in step (1) and the material is determined by material detection means, and the target component content of the mixed material is used to determine the proportion of the main material and the material;

[0008] (3) Mixing and processing: the mixed raw materials are crushed, ground, and the obtained powder is subjected to homogenization treatment;

[0009] (4) Fiber production: the mixed powder obtained in step (3) is subjected to fiber production to obtain continuous basalt fiber.

[0010] As used herein, basic magmatic rock, basic-intermediate magmatic rock, and intermediate magmatic rock refer to the conventional rock classification of magmatic rocks in the art according to the mass percentage content of silicon dioxide.

[0011] Further, the basic-intermediate magmatic rock includes basalt, basaltic andesite, gray-green andesite, or pyroxene andesite.

[0012] Further, the intermediate rock includes andesite or diorite.

[0013] Further, the basic rock includes basalt, diabase, or gabbro.

[0014] Further, the mass fraction of total iron of the main material is 8%-11%, and the mass fraction of total iron of the material (e.g., the first material or the second material) is 6%-13%. As used herein, total iron means the total mass fraction of Fe2O3 and FeO in the ore.

[0015] Further, the mineral fabric of the main material is dense or oblique porphyritic, and the mineral fabric of the material (e.g., the first material or the second material) is dense or oblique porphyritic.

[0016] Further, the loss on ignition of the main material and the material is ≤2.0%.

[0017] Further, the target content of each chemical component in the mixed material of the main material and the material in step (2) is: 52%-55% of SiO2, 15%-17% of Al2O3, 7%-10.5% of Fe2O3+FeO, 11%-16% of MgO+CaO, 3%-6% of K2O+Na2O, and 1%-4% of TiO2 by mass percentage.

[0018] Further, in the target component content of the mixed material, FeO / (Fe2O3+FeO) = 0.4-0.8 by mass.

[0019] Further, in the target component content of the mixed material, the mass fraction of plagioclase+pyroxene is ≥70%.

[0020] Further, in step (3), the powder has a particle size of 80-100 mesh.

[0021] As used herein, the drawing of the compounded powder is produced using conventional processes well known in the art, for example, the drawing can be produced using the processes of melting, drawing forming, and dip coating.

[0022] In other aspects, the present application also provides continuous basalt fibers produced by the method described herein.

[0023] Advantages of the application

[0024] The present application adjusts the mass percentage content of the main oxides of the raw material minerals, i.e. the mass percentage content of network formers, network intermediates, and network modifiers, and the ratio of FeO / (Fe2O3+FeO) of the main raw materials, by compounding different raw materials, thereby correcting the spinnability defects of single mineral raw materials, such as the imbalance between 2+ valence iron and 3+ valence iron, the slightly low content of main oxides such as SiO2 and Al2O3, and the imbalance of alkaline earth oxides such as CaO and MgO, thereby greatly improving the homogeneity and thermal conductivity of the glass liquid during the drawing process, and thereby improving the production efficiency and fiber performance of continuous basalt fibers. DETAILED DESCRIPTION

[0025] The present application will be further described in conjunction with specific examples, but the examples do not limit the present application in any form. Unless otherwise specified, the reagents, methods, and equipment used in the present application are conventional reagents, methods, and equipment in the technical field.

[0026] Example:

[0027] The present application provides a method for improving the production efficiency and fiber performance of continuous basalt fibers by compounding multiple raw materials, comprising:

[0028] (1) Raw material selection: In this example, the basalt ore from Weixian County, Hebei Province, produced by Sichuan Torch Original Basalt Fiber Technology Co., Ltd., is selected as the main material, and the ores from several representative basalt mine sites in Sichuan Province are selected as the ingredients. See Table 1 for specific information.

[0029] Table 1: Multiple compounding raw material reference points

[0030] No. Ore site Rock type Note 1# Suluo basalt mine in Meigu County, Sichuan Province Basalt Batch 2 2# Basalt mine in Weixian County, Hebei Province Basalt Main material 3# Xiangzhangping basalt mine in Hanxian County, Sichuan Province Basanite Batch 1-1 4# Zengheba diorite in Jin'kou River District, Sichuan Province Diorite Batch 1-2

[0031] (2) Determine the content of each component in each reference ore. See Table 2.

[0032] Table 2: Content of each component in the reference ore

[0033]

[0034] (3)Batching: According to the target content (i.e., > 70% of the oblique feldspar + pyroxene; 52%-55% of SiO2, 15%-17% of Al2O3, 7%-10.5% of Fe2O3+FeO, 11%-16% of MgO+CaO, 3%-6% of K2O+Na2O, 1%-4% of TiO2, FeO / (Fe2O3+FeO) = 0.4-0.8), the mass percentage of each mixed batch is calculated according to the content of each component in Table 2. As shown in Table 3, 28 parts of 1# batch, 32 parts of 2# main material, and 40 parts of 3# batch are weighed according to the mass percentage for mixing in Example 1; 12 parts of 1# batch, 21 parts of 2# main material, 28 parts of 3# batch, and 39 parts of 4# batch are weighed for mixing in Example 2. The comparative example is only composed of the main material.

[0035] Table 3: Weight percentage of the mixed ore

[0036] Ore site Example 1 Example 2 Comparative example 1# (batch) 28 12 0 2# (main) 32 21 100 3# (batch) 40 28 0 4# (batch) 0 39 0

[0037] (4) The mixed material of Example 1 and Example 2 is ground into powder, mixed uniformly, sieved (80-100 mesh), and sampled for testing to ensure that the content of each component of the mixed batch is within the required range (if not, secondary mixing is required). The mixed powder is obtained. The test results of the content of each component in each example are shown in Table 4.

[0038] Table 4: Test results of the content of each component in the mixed powder of each example

[0039] Component (%) Example 1 Example 2 Comparative example SiO2 52.32 54.05 52.52 Al2O3 16.31 16.30 16.35 Fe2O3 4.25 3.87 3.01 FeO 5.13 4.51 6.44 [K2O] 0.87 0.84 0.68 Na2O 2.58 2.57 2.48 CaO 9.05 7.77 8.55 MgO 6.80 7.08 6.88 TiO2 1.83 1.81 2.22 L.O.I 0.85 1.20 0.89

[0040] (5) Fiber drawing production: The mixed powder obtained in the previous step is gradually added to the pool kiln, and after the raw materials in the pool kiln are completely replaced, the melting, fiber drawing forming, and immersion coating process are used for fiber drawing production, and the production parameters are recorded to obtain continuous basalt fibers.

[0041] (6) The production efficiency and fiber performance of the basalt fibers are tested, and the results are shown in Table 5.

[0042] Table 5: Production efficiency and fiber performance of basalt fibers in each example

[0043] Example 1 Example 2 Comparative example Melting T 1436℃ 1468℃ 1458℃ Molding T 1208℃ 1278℃ 1267℃ Liquidus T 1118℃ 1162℃ 1178℃ Fiber φ 13 μm 13 μm 13 μm Fiber yield rate 94％ 92％ 83％ Full bucket rate 94.4％ 88.8％ 27.8％ Tensile strength 2580 MPa 2820 MPa 2464 MPa Tensile elastic modulus 84 GPa 90 GPa 81 GPa

[0044] As can be seen from Table 5, in Example 1, by mixing, the mass percentage content of the network former, network intermediate, and network modifier oxides of the single main ore raw material is moderately adjusted, and the ratio of FeO / (Fe2O3+FeO) of the main ore raw material is greatly reduced, that is, the ratio of 2 + valent iron and 3+ The two spinnability defects—an imbalance in the valence iron ratio and a CaO imbalance—significantly improve the homogeneity and thermal conductivity of the molten glass during the fiber drawing process. This results in reduced gas and electricity consumption, increased fiber filamentation rate, and, in particular, a geometric increase in fiber fill rate. Furthermore, the properties of some fibers (tensile strength and tensile modulus) are also improved. The fiber drawing effect is significantly better than the comparative example.

[0045] In Example 2, by mixing, the mass percentage content of the framework oxide SiO2 in the comparative example was moderately increased, and the ratio of FeO / (Fe2O3+FeO) was significantly reduced, thus correcting the 2% content in the comparative example. + Price of iron and 3 + The two spinnability defects—an imbalance in the valence iron ratio and an imbalance in the skeletal oxides—are addressed by improving the homogeneity and thermal conductivity of the molten glass during production. This results in significantly enhanced fiber tensile strength, increased filamentation rate, and a geometric increase in fiber fill rate. Simultaneously, some fiber properties (tensile strength and tensile modulus) are also substantially improved. The fiber drawing effect is significantly better than the comparative example.

[0046] It should be noted that while the preferred embodiments of the present invention are provided in this specification, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are not intended to impose additional limitations on the content of the present invention; their purpose is to provide a more thorough and comprehensive understanding of the disclosure of the present invention. Furthermore, the above-described technical features can be combined with each other to form various embodiments not listed above, all of which are considered to be within the scope of the present invention. Moreover, those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A method for improving the production efficiency and fiber properties of continuous basalt fibers by raw material polyblending, characterized in that, The method comprises the following steps: (1) raw material selection: selecting one or more basic-neutral magmatic rocks with a SiO2 mass percentage content greater than or equal to 52% and less than 54% as a main material, selecting one or more neutral magmatic rocks with a SiO2 mass percentage content greater than or equal to 54% and less than 58% as a first ingredient, and optionally, selecting one or more basic magmatic rocks with a SiO2 mass percentage content greater than or equal to 47% and less than 52% as a second ingredient; (2) raw material proportioning: determining the chemical component content of the main material and the ingredients selected in step (1) through a material detection means, and determining the proportioning of the main material and the ingredients according to the target component content of the mixed ingredients; the target component content of the mixed ingredients is: 52%-55% of SiO2, 15%-17% of Al2O3, 7%-10.5% of Fe2O3+FeO, 11%-16% of MgO+CaO, 3%-6% of K2O+Na2O, and 1%-4% of TiO2, and in the target component content of the mixed ingredients, FeO / (Fe2O3+FeO)=0.4-0.55 by mass; (3) mixing processing: mixing the proportioned raw materials, crushing and grinding, and homogenizing the obtained powder; (4) fiber production: drawing the mixed powder obtained in step (3) to produce continuous basalt fibers.

2. The method of claim 1, wherein, The basic-neutral magmatic rock includes basalt, basaltic andesite, gray-green andesite or pyroxene andesite; The neutral magmatic rock includes andesite or diorite; The basic magmatic rock includes basalt, diabase or gabbro.

3. The method of claim 1, wherein, The total iron content of the main material is 8%-11%, and the total iron content of the ingredient is 6%-13%.

4. The method of claim 1, wherein, The mineral fabric of the main material and the ingredient is dense or porphyritic.

5. The method of claim 1, wherein, The loss on ignition of the main material and the ingredient is ≤2.0%.

6. The method of claim 1, wherein, In the target component content of the mixed ingredients, the mass fraction of plagioclase+pyroxene is ≥70%.

7. The method of claim 1, wherein, In step (2), the main material, the first ingredient and the optional second ingredient are proportioned at 20%-80%:10%-50%:0%-30%.

8. The method of claim 1, wherein, In step (3), the powder is a powder with a particle size of 80-100 mesh.

9. A continuous basalt fiber produced by the method of any one of claims 1-8.

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