Dry compression molding production process for acid-resistant and temperature-resistant bricks

Abstract

The invention relates to the technical field of industrial ceramic materials, and discloses an acid-resistant and temperature-resistant brick dry compression molding production process which comprises the following steps: S1, preparing materials: Guangxi white mud, Yichun kaolin, Henan flint clay, Guizhou kaolin, Ningxian soil, feldspar, zinc stearate and methyl cellulose; and S2, adding the mixture into a 15-ton ball mill, carrying out ball milling for 8 hours until the fineness reaches 2-4%, discharging the slurry, carrying out iron removal and sieving, and aging the slurry in a refined slurry pool for later use. According to the dry compression molding production process for the acid-resistant and temperature-resistant bricks, in the raw material preparation and pretreatment stage, various high-quality raw materials are carefully screened and proportioned, so that the accuracy and stability of raw material components are ensured, the uniformity of the raw materials is improved in the ball-milling refining process, and tight combination of particles in the subsequent molding process is promoted. Impurities are effectively removed through iron removal and sieving, and the purity of the product is improved.

Description

Technical Field

[0001] The invention relates to the technical field of industrial ceramic materials, in particular to a dry pressing and molding production process for acid-resistant and heat-resistant bricks. Background Art

[0002] The dry pressing and molding production process of acid-resistant and heat-resistant bricks is an efficient production technology developed to meet the needs of building materials in extreme environments. The process aims to produce bricks with excellent acid resistance and high temperature resistance through dry pressing and molding methods.

[0003] The workflow of the dry pressing production process of acid-resistant and heat-resistant bricks includes key steps such as raw material selection, mixing, dry pressing, drying, high-temperature firing and finished product processing. After strict screening, the raw materials are mixed in a specific proportion and directly pressed into shape using high-pressure mechanical force through dry pressing technology without adding additional water.

[0004] However, in the actual use of the above equipment, the acid-resistant and heat-resistant brick dry pressing production process may cause inconsistent density due to uneven pressure during the pressing process, which in turn affects the strength and corrosion resistance of the product. In view of this, we proposed a dry pressing production process for acid-resistant and heat-resistant bricks. Summary of the invention

[0005] The object of the present invention is to provide a dry pressing and forming production process for acid-resistant and heat-resistant bricks to solve the problems raised in the above-mentioned background technology.

[0006] To achieve the above object, the present invention provides the following technical solution: a dry pressing and molding production process for acid-resistant and heat-resistant bricks, comprising the following steps:

[0007] S1. Prepare materials: Guangxi white clay, Yichun kaolin, Henan coke gemstone, Guizhou kaolin, Ningxiang clay, feldspar, zinc stearate, methyl cellulose;

[0008] S2, add 15 tons of ball mill for 8 hours to reach 2%-4% fineness, then remove iron and sieve, and the slurry in the refined pulp pool is aged for standby use;

[0009] S3, the slurry is transported by a plunger pump and spray-dried into a powder with a certain fluidity and a moisture content of 5%-7%, and then aged for 2 days before use;

[0010] S4, mix the prepared powder with fused quartz and zinc stearate in a ratio of 1:12:0.1, pour into a mixer through a conveyor belt and stir for 15-20 minutes to mix evenly;

[0011] S5. Use a 1200-ton press to perform the processes of feeding, pressing, demoulding, and billet removal, and control the process parameters of gas phase, billet moisture, pressing times, pressing time, and pressure to avoid defects such as stratification of the product;

[0012] S6. Put the formed green body into the drying room for drying. The temperature of the drying room is about 150 degrees.

[0013] S7. The dried green body can be fired in a shuttle kiln or tunnel kiln at a firing temperature of about 1300 degrees.

[0014] Preferably, the acid-resistant and heat-resistant brick dry pressing molding production process comprises:

[0015] Raw material preparation and pretreatment: It is the basis for ensuring the quality of acid-resistant and heat-resistant bricks. Through material preparation and proportioning, fine ball milling, iron removal screening and aging, and spray granulation and aging processes, the uniformity, stability and plasticity of raw materials are improved, laying a solid foundation for subsequent molding and firing;

[0016] Powder mixing and pressing: used to evenly mix the components and form them. Through the powder mixing and pressing process, the green body structure is ensured to be tight and defect-free, creating conditions for subsequent firing of high-quality products;

[0017] Drying and firing: key steps for curing the acid-resistant and heat-resistant brick structure and improving performance. Through drying in an oven and high-temperature firing, the brick body is densified to obtain excellent acid-resistant, alkali-resistant and high-temperature resistant properties.

[0018] Preferably, the materials are prepared and proportioned according to the formula requirements, including Guangxi white mud, Guizhou kaolin, Henan jiaobaoshi, Yichun kaolin, Ningxiang soil and feldspar, and high-precision metering equipment is used to accurately measure according to the established proportions, providing solid guarantee for production.

[0019] Preferably, ball milling is used to slowly add the precisely measured raw materials into a high-efficiency ball mill, and through long-term fine grinding and stirring, the raw material fineness reaches the strict standard of 2%-4%, ensuring that each raw material particle is uniform and fine, laying a solid foundation for the subsequent molding and sintering process.

[0020] Preferably, after iron removal, screening and aging, after ball milling, the slurry is deeply purified by advanced iron removal equipment to completely remove iron and other magnetic impurities. Subsequently, it is filtered through a precision screen to ensure that all large particles are effectively removed, leaving only a fine and uniform slurry. Next, the mud in the refined slurry pool is placed in a specific environment for aging. This step not only promotes the further fusion of the internal components of the mud, but also significantly improves its uniformity and stability, laying a solid foundation for subsequent processes.

[0021] Preferably, spray granulation and aging, the finely treated mud is cleverly introduced into the plunger pump, and its powerful power is used to smoothly and efficiently transport it to the advanced spray drying equipment. During the spray drying process, the mud is finely atomized into tiny droplets, fully contacted with hot air, and the water is quickly evaporated until it is converted into dry powder with a moisture content strictly controlled between 5% and 7%. Subsequently, the powder is sent to a specific aging area, and after a period of standing and maturation, its plasticity and molding properties are further enhanced, creating the best conditions for subsequent molding processes.

[0022] Preferably, the powders are mixed, and after the powders are aged, the aged powders, selected fused quartz and an appropriate amount of zinc stearate are accurately mixed in a ratio of 1:12:0.1. Subsequently, these raw materials are smoothly fed into a high-efficiency mixer via an automated conveyor belt, and are deeply stirred for up to 15-20 minutes in a closed and temperature-controlled environment. During this process, the mixer uses an appropriate speed and angle to ensure that each grain of raw material is fully mixed and contacted until all components reach a perfectly uniform state, laying a solid foundation for subsequent molding processes.

[0023] Preferably, the pressing molding uses a 1200-ton large press to perform processes such as feeding, press molding, demolding, and billeting on the evenly mixed powder. During the pressing process, process parameters such as the gas phase, billet moisture, number of presses, pressing time and pressure must be strictly controlled to ensure the quality of the billet and avoid defects such as stratification.

[0024] Preferably, the blank is dried in a drying room. After precision pressing and forming, it is sent to a professionally designed drying room for critical drying treatment. The temperature in the drying room is precisely controlled at around 150 degrees. This temperature can not only effectively remove excess moisture remaining in the blank to avoid cracking or deformation, but also ensure that the blank maintains appropriate strength and stability during the drying process. After a period of constant temperature baking, the blank gradually reaches an ideal dry state, laying a solid foundation for the subsequent high-temperature firing process and ensuring the quality of the final product.

[0025] Preferably, high temperature firing is performed, and the dried green body is sent to a shuttle kiln or a tunnel kiln for high temperature firing. The firing temperature is controlled at about 1300 degrees. At high temperature, the components in the green body undergo physical and chemical reactions to form a dense crystal structure, thereby giving the acid-resistant and heat-resistant bricks excellent properties.

[0026] Compared with the prior art, the present invention provides a dry pressing and forming production process for acid-resistant and heat-resistant bricks, which has the following beneficial effects:

[0027] 1. In the dry pressing and molding production process of acid-resistant and heat-resistant bricks, the raw material preparation and pretreatment stage ensures the accuracy and stability of the raw material composition by carefully screening and proportioning various high-quality raw materials. The ball milling process not only improves the uniformity of the raw materials, but also promotes the close bonding between particles in the subsequent molding process. Iron removal and screening effectively remove impurities and improve the purity of the product.

[0028] 2. The dry pressing and molding production process of the acid-resistant and heat-resistant bricks, powder mixing and pressing are the core links in the production process of acid-resistant and heat-resistant bricks. Through precise proportioning and sufficient mixing, the uniform distribution of each component in the powder is ensured, which provides a basis for the stability of product performance. The molding technology ensures the density and defect-freeness of the green body structure, effectively avoiding cracking, peeling and other problems that may occur in the subsequent use of the product.

[0029] 3. The dry pressing and forming production process of the acid-resistant and heat-resistant bricks. Drying and firing are the key steps in the production of acid-resistant and heat-resistant bricks, which have a decisive influence on the final performance of the product. The drying process improves the density and stability of the product by removing excess moisture in the green body, laying a solid foundation for the subsequent firing process. The high-temperature firing promotes chemical reactions and physical changes between the raw materials, so that the product has excellent acid and alkali resistance and high temperature resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is a schematic diagram of a dry pressing and molding production process for acid-resistant and heat-resistant bricks of the present invention;

[0031] Figure 2 This is a schematic diagram of the raw material preparation and pretreatment module of the present invention;

[0032] Figure 3 This is a schematic diagram of the powder mixing and pressing molding module of the present invention;

[0033] Figure 4 This is a schematic diagram of the drying and sintering module of the present invention;

[0034] Figure 5 The figure is a flow chart of the method of the present invention. DETAILED DESCRIPTION

[0035] In order to enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only embodiments of a part of the present application, rather than all of the embodiments.

[0036] Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making any creative work should fall within the scope of protection of this application.

[0037] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so as to describe the embodiments of the present application described herein.

[0038] In the present application, the terms "upper", "lower", "left", "right", "front", "back", "top", "bottom", "inner", "outer", "middle", "vertical", "horizontal", "lateral", "longitudinal" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings. These terms are mainly used to better describe the present application and its embodiments, and are not used to limit the indicated devices, elements or components to have a specific orientation, or to be constructed and operated in a specific orientation.

[0039] In addition, some of the above terms may be used to express other meanings in addition to indicating orientation or positional relationship. For example, the term "on" may also be used to express a certain dependency or connection relationship in some cases. For those of ordinary skill in the art, the specific meanings of these terms in this application can be understood according to specific circumstances.

[0040] In addition, the terms "installed", "set", "provided with", "connected", "connected", and "socketed" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection, or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, elements, or components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0041] It should be noted that, in the absence of conflict, the embodiments in the present application and the features in the embodiments may be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0042] See also Figure 1-5 The present invention provides a technical solution: a dry pressing and forming production process for acid-resistant and heat-resistant bricks comprises the following steps:

[0043] S1. Prepare materials: Guangxi white clay, Yichun kaolin, Henan coke gemstone, Guizhou kaolin, Ningxiang clay, feldspar, zinc stearate, methyl cellulose;

[0044] S2, add 15 tons of ball mill for 8 hours to reach 2%-4% fineness, then remove iron and sieve, and the slurry in the refined pulp pool is aged for standby use;

[0045] S3, the slurry is transported by a plunger pump and spray-dried into a powder with a certain fluidity and a moisture content of 5%-7%, and then aged for 2 days before use;

[0046] S4, mix the prepared powder with fused quartz and zinc stearate in a ratio of 1:12:0.1, pour into a mixer through a conveyor belt and stir for 15-20 minutes to mix evenly;

[0047] S5. Use a 1200-ton press to perform the processes of feeding, pressing, demoulding, and billet removal, and control the process parameters of gas phase, billet moisture, pressing times, pressing time, and pressure to avoid defects such as stratification of the product;

[0048] S6. Put the formed green body into the drying room for drying. The temperature of the drying room is about 150 degrees.

[0049] S7. The dried green body can be fired in a shuttle kiln or tunnel kiln at a firing temperature of about 1300 degrees.

[0050] In one embodiment of the present invention, raw material preparation and pretreatment: the basis for ensuring the quality of acid-resistant and heat-resistant bricks, through material preparation and proportioning, fine ball milling, iron removal screening and aging, and spray granulation and aging processes, the uniformity, stability and plasticity of the raw materials are improved, laying a solid foundation for subsequent molding and firing;

[0051] Material preparation and proportioning: according to the formula requirements, Guangxi white clay, Guizhou kaolin, Henan coke gemstone, Yichun kaolin, Ningxiang clay, feldspar, and high-precision metering equipment are used to accurately measure according to the established ratio, providing a solid guarantee for production;

[0052] Ball milling: slowly add the precisely measured raw materials into the high-efficiency ball mill, and grind and stir them for a long time until the fineness of the raw materials reaches the strict standard of 2%-4%, ensuring that each raw material particle is uniform and fine, laying a solid foundation for the subsequent molding and sintering process;

[0053] Iron removal, screening and aging: After ball milling, the slurry is deeply purified by advanced iron removal equipment to completely remove iron and other magnetic impurities. Then, it is filtered through a precision screen to ensure that all large particles are effectively removed, leaving only fine and uniform slurry. Next, the slurry in the refined slurry pool is placed in a specific environment for aging. This step not only promotes the further integration of the internal components of the slurry, but also significantly improves its uniformity and stability, laying a solid foundation for subsequent processes.

[0054] Spray granulation and aging, the finely treated mud is cleverly introduced into the plunger pump, and its powerful power is used to smoothly and efficiently transport it to the advanced spray drying equipment. During the spray drying process, the mud is finely atomized into tiny droplets, fully contacted with hot air, and the water is quickly evaporated until it is converted into dry powder with a moisture content strictly controlled between 5% and 7%. Subsequently, the powder is sent to a specific aging area, and after a period of standing and maturation, its plasticity and molding properties are further enhanced, creating the best conditions for subsequent molding processes.

[0055] In one embodiment of the present invention, powder mixing and pressing molding: used to uniformly mix the components and perform molding, through the powder mixing and pressing molding process, ensure that the green body structure is tight and defect-free, creating conditions for subsequent firing of high-quality products;

[0056] Powder mixing: After the powder is aged, the aged powder, selected fused quartz and an appropriate amount of zinc stearate are accurately mixed in a ratio of 1:12:0.1. Then, these raw materials are smoothly sent to the high-efficiency mixer through an automated conveyor belt. In a closed and temperature-controlled environment, they are deeply stirred for 15-20 minutes. During this process, the mixer uses an appropriate speed and angle to ensure that each grain of raw material can be fully mixed and contacted until all components reach a perfect uniform state, laying a solid foundation for the subsequent molding process.

[0057] For pressing, a 1,200-ton large press is used to feed, press, demould, and discharge the evenly mixed powder. During the pressing process, process parameters such as gas phase, body moisture, number of presses, pressing time, and pressure must be strictly controlled to ensure body quality and avoid defects such as stratification.

[0058] In one embodiment of the present invention, drying and firing are key steps for curing the acid-resistant and heat-resistant brick structure and improving the performance. The brick body is densified by drying in an oven and firing at high temperature to obtain excellent acid-resistant, alkali-resistant and high-temperature resistant properties;

[0059] Drying in the drying room: After precision pressing and forming, the green body is sent to a professionally designed drying room for critical drying treatment. The temperature in the drying room is precisely controlled at around 150 degrees. This temperature can effectively remove excess moisture remaining in the green body to avoid cracking or deformation, and ensure that the green body maintains appropriate strength and stability during the drying process. After a period of constant temperature baking, the green body gradually reaches an ideal drying state, laying a solid foundation for the subsequent high-temperature firing process and ensuring the quality of the final product.

[0060] High temperature firing: the dried green body is sent into a shuttle kiln or tunnel kiln for high temperature firing. The firing temperature is controlled at about 1300 degrees. Under high temperature, the components in the green body undergo physical and chemical reactions to form a dense crystal structure, thus giving the acid-resistant and heat-resistant bricks excellent properties.

[0061] Working principle:

[0062] S1. Prepare materials: Guangxi white clay (aluminum content 24%-26%), Yichun kaolin (aluminum content 33%-35%, potassium and sodium content 2%-3%), Henan coke gemstone (aluminum content 37%-55%, potassium and sodium content 1%), Guizhou kaolin (aluminum content about 36%), Ningxiang clay (aluminum content about 32%), feldspar, zinc stearate, methyl cellulose (polyvinyl alcohol);

[0063] S2, add 15 tons of ball mill for 8 hours to reach 2%-4% fineness, then remove iron and sieve, and the slurry in the refined pulp pool is aged for standby use;

[0064] S3, the slurry is transported by a plunger pump and spray-dried into a powder with a certain fluidity and a moisture content of 5%-7%, and then aged for 2 days before use;

[0065] S4, mix the prepared powder with fused quartz and zinc stearate in a ratio of 1:12:0.1, pour into a mixer through a conveyor belt and stir for 15-20 minutes to mix evenly;

[0066] S5. Use a 1200-ton press to perform the processes of feeding, pressing, demoulding, and billet removal, and control the process parameters of gas phase, billet moisture, pressing times, pressing time, and pressure to avoid defects such as stratification of the product;

[0067] S6. The formed green body is sent to a drying room with precise temperature control. The uniform temperature of about 150 degrees slowly evaporates the internal moisture, ensuring uniform drying and avoiding cracking, laying a solid foundation for subsequent firing.

[0068] S7. The dried green body is carefully fired at a high temperature of about 1300 degrees in a shuttle kiln or tunnel kiln. The precisely controlled heating curve promotes material melting and crystallization, ensuring excellent product performance and significantly enhanced acid, alkali and high temperature resistance.

[0069] The above generally describes the present invention in detail, but it is obvious to a person skilled in the art that some modifications or improvements can be made to the present invention. Therefore, modifications or improvements that do not depart from the spirit of the present invention are within the scope of protection of the present invention.

Claims

1. A dry pressing and molding production process for acid-resistant and heat-resistant bricks, characterized in that: The following steps are involved: S1. Prepare materials: Guangxi white clay, Yichun kaolin, Henan coke gemstone, Guizhou kaolin, Ningxiang clay, feldspar, zinc stearate, methyl cellulose; S2, add the slurry to the ball mill for ball milling to reach a fineness of 2%-4%, then remove iron and sieve, and the slurry in the refined slurry pool is aged for standby use; S3, the slurry is transported by a plunger pump and spray-dried into a powder with a certain fluidity and a moisture content of 5%-7%, and then aged for 2 days before use; S4, mixing the prepared powder with fused quartz and zinc stearate in a ratio of 1:12:0.1, and then pouring them into a mixer through a conveyor belt for stirring; S5, using a 1200-ton press to carry out the processes of feeding - pressurizing - demoulding - blanking; S6. Put the formed green body into the drying room for drying. The temperature of the drying room is about 150 degrees. S7. The dried green body can be fired in a shuttle kiln or tunnel kiln at a firing temperature of about 1300 degrees.

2. The dry pressing and forming production process of acid-resistant and heat-resistant bricks according to claim 1 is characterized in that: The acid-resistant and heat-resistant brick dry pressing molding production process comprises: Raw material preparation and pretreatment: It is the basis for ensuring the quality of acid-resistant and heat-resistant bricks. Through material preparation and proportioning, fine ball milling, iron removal screening and aging, and spray granulation and aging processes, the uniformity, stability and plasticity of raw materials are improved, laying a solid foundation for subsequent molding and firing; Powder mixing and pressing: used to evenly mix the components and form them. Through the powder mixing and pressing process, the green body structure is ensured to be tight and defect-free, creating conditions for subsequent firing of high-quality products; Drying and firing: key steps for curing the acid-resistant and heat-resistant brick structure and improving performance. Through drying in an oven and high-temperature firing, the brick body is densified to obtain excellent acid-resistant, alkali-resistant and high-temperature resistant properties.

3. The dry pressing and forming production process of an acid-resistant and heat-resistant brick according to claim 2 is characterized in that: Prepare materials and proportions according to the formula requirements, including Guangxi white clay, Guizhou kaolin, Henan jiaobaoshi, Yichun kaolin, Ningxiang clay, and feldspar, and measure them accurately in the specified proportions.

4. The dry pressing and forming production process of acid-resistant and heat-resistant bricks according to claim 2 is characterized in that: Ball milling: add the measured raw materials into the ball mill and perform ball milling until the raw material fineness reaches 2%-4%, ensuring that the raw material particles are uniform and fine.

5. The dry pressing and forming production process of acid-resistant and heat-resistant bricks according to claim 2 is characterized in that: Deironing, screening and aging: the slurry after ball milling is passed through deironing equipment to remove impurities, and then sieved to remove large particles. The slurry in the refined slurry pool is then aged to improve the uniformity and stability of the slurry.

6. The dry pressing and forming production process of acid-resistant and heat-resistant bricks according to claim 2 is characterized in that: Spray granulation and aging: the slurry is transported to the spray drying equipment through a plunger pump, spray-dried into a powder with a moisture content of 5%-7%, and then the powder is aged to enhance its plasticity and molding properties.

7. The dry pressing and forming production process of acid-resistant and heat-resistant bricks according to claim 1 is characterized in that: Powder mixing: the aged powder is mixed with fused quartz and zinc stearate in a ratio of 1:12:0.1, and then sent into the mixer through a conveyor belt and fully stirred for 15-20 minutes to ensure that the components are evenly mixed.

8. The dry pressing and forming production process of acid-resistant and heat-resistant bricks according to claim 1 is characterized in that: Pressing molding uses a large press to feed, pressurize, demould, and produce the uniformly mixed powder. During the pressing process, it is necessary to strictly control process parameters such as gas phase, body moisture, number of presses, pressing time and pressure to ensure the quality of the body and avoid defects such as stratification.

9. The dry pressing and forming production process of acid-resistant and heat-resistant bricks according to claim 1 is characterized in that: Drying in the drying room: the pressed green body is sent to the drying room for drying. The temperature of the drying room is controlled at a moderate temperature to remove excess moisture in the green body and improve the strength and stability of the green body.

10. The dry pressing and forming production process of acid-resistant and heat-resistant bricks according to claim 1 is characterized in that: High temperature firing: the dried green body is sent to a shuttle kiln or tunnel kiln for high temperature firing. The firing temperature is controlled at a moderate temperature. At high temperature, the components in the green body undergo physical and chemical reactions. A dense crystal structure is formed, thus giving acid-resistant and heat-resistant bricks excellent properties.

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