High-performance green environment-friendly electric porcelain material and manufacturing method thereof

Abstract

The invention relates to the technical field of electric porcelain production, and particularly discloses a high-performance green environment-friendly electric porcelain material, which is prepared from the following raw materials: 17 to 27 parts of Jiangjin soil, 1 to 3 parts of Yongchuan soil, 10 to 20 parts of quartz powder, 12 to 22 parts of Dongsheng soil, 7 to 17 parts of Jingyang soil, 1 to 5 parts of bauxite, 2 to 6 parts of potassium feldspar and 21 to 31 parts of waste water reclaimed materials. The wastewater reclaimed material is derived from a solid obtained after solid-liquid separation of sewage in electrical porcelain manufacturing, and the wastewater reclaimed material contains 44-50 parts of SiO2, 38-44 parts of AI2O3 and 2.6-2.9 parts of K2O. The invention further provides a manufacturing method of the high-performance green and environment-friendly electric porcelain material, burdening is performed according to the high-performance green and environment-friendly electric porcelain material, and the burdening is treated according to the flow of ball milling, sieving for iron removal, filter pressing, rough refining, aging and vacuum pugging to obtain the electric porcelain material. The scheme is used for solving the problem that the wastewater reclaimed material of the current electric porcelain sewage station cannot be used for producing disc-shaped suspension type high-voltage electric porcelain.

Description

Technical Field

[0001] The present invention relates to the technical field of electric porcelain production, and in particular to a high-performance green and environmentally friendly electric porcelain material and a manufacturing method thereof. Background Art

[0002] With the development of the national economy, the level of electrification is also improving, the status of electricity in the energy field is becoming more and more prominent, and electricity security has gradually become one of the core elements of the new energy security strategy.

[0003] In the current high-voltage power transmission, insulators are indispensable parts in the transmission line. A large amount of wastewater will be generated in the production of insulators. The wastewater will enter the factory's industrial wastewater treatment station for solid-liquid separation. The separated wastewater will enter the sewage treatment station, and the separated solid will be mud. After precipitation, this type of mud will be regularly transported away and treated as waste by professional environmental protection companies. The treatment of waste mud is also a considerable expense for production companies.

[0004] In the prior art, there is a patent announcement number CN102718467B, which is a line porcelain material formula and its manufacturing process. This public patent mentions that the sludge in the sewage during the porcelain manufacturing process is recycled and reused, and the sludge is mixed with Guangdong white mud, Zuoyun clay, and Houxi porcelain clay to produce porcelain as a porcelain material. However, the performance parameters reflected in this patent are mechanical damage of 30KN and 40KN, and the insulators verified in its test are PS-15 / 300 and SL-15 / 30. One of these two insulators is a post insulator / pin insulator, and the other is a double iron head porcelain rod insulator. These two types of insulators are solid in structure, so this type of insulator is more suitable for large current occasions, can support heavy-loaded cables and leads, and do not require high mechanical strength. Therefore, the requirements for porcelain materials are not high, and sludge with complex components can also be used in this type of porcelain.

[0005] However, for disc suspension insulators used in high-voltage transmission lines, due to the special structure of the disc suspension, its anti-pollution flashover performance can be met, so it has high requirements for mechanical strength and creepage distance, and can still maintain good insulation performance under high voltage levels. This places high demands on porcelain materials. At present, there is a lack of wastewater recycling materials after sewage treatment applied to disc suspension porcelain; and for manufacturers who focus on the production of disc suspension insulators, the discarded wastewater recycling materials can only be transported away for treatment on a regular basis, and resource recycling has not been achieved. Summary of the invention

[0006] The present invention aims to provide a high-performance green and environmentally friendly insulator material to solve the problem that the wastewater recycled from the insulator sewage station cannot be used for the production of disc-shaped suspended high-voltage insulators.

[0007] In order to achieve the above object, the present invention adopts the following technical scheme:

[0008] A high-performance green environmentally friendly electric porcelain material comprises the following raw materials: 17-27 parts of Jiangjin soil, 1-3 parts of Yongchuan soil, 10-20 parts of quartz powder, 12-22 parts of Dongsheng soil, 7-17 parts of Jingyang soil, 1-5 parts of bauxite, 2-6 parts of potassium feldspar, and 21-31 parts of sewage station wastewater recycling material.

[0009] Preferably, the wastewater recycling material also includes: 0.8-1.2 parts of Fe2O3, 0.6-0.8 parts of TiO2, 0.5-0.8 parts of CaO, 0.3-0.5 parts of MgO, and 0.4-0.6 parts of Na2O.

[0010] Preferably, the wastewater recovery material in the raw material is 21-26 parts.

[0011] Preferably, the raw material contains 4-6 parts of potassium feldspar.

[0012] Preferably, the raw materials include 18-21 parts of Jiangjin soil, 15-20 parts of Dongsheng soil, and 10-13 parts of Jingyang soil.

[0013] Preferably, the raw material contains 15-18 parts of quartz.

[0014] The present invention also provides a method for preparing a high-performance green and environmentally friendly insulator material, wherein ingredients are prepared according to the high-performance green and environmentally friendly insulator material, and the ingredients are processed according to the process of ball milling - screening for iron removal - filter pressing - coarse refining - aging - vacuum mud refining to obtain the insulator material.

[0015] Beneficial effects: Iron impurities and coarse particles in sewage and wastewater recycling materials can be removed by screening, and the rough smelting of mud cakes can ensure the uniformity of wastewater recycling materials, improve the process performance of raw materials, and increase the process qualification rate; in addition, aging can make the electric porcelain body made of electric porcelain materials reach the best molding moisture to reduce the deformation of the blank and ensure the dimensional accuracy of the blank after porcelainization.

[0016] Preferably, during ball milling, the ratio of material: ball: water is 1:2:1.2, and after ball milling, the material is sieved with a sieve of not less than 250 meshes.

[0017] Preferably, before batching, the wastewater recycled materials are stored and weathered until they turn white. In this solution, harmful substances in the wastewater recycled materials are naturally removed through microbial decomposition and air oxidation during the storage of the wastewater recycled materials, which is beneficial to improving the quality of the wastewater recycled materials. The wastewater recycled materials that turn white after natural weathering have higher green body dry strength than the newly squeezed wastewater recycled materials after solid-liquid separation.

[0018] The present invention recycles and reuses the wastewater recovery material obtained after solid-liquid separation of sewage in the mud making workshop during the manufacture of electrical porcelain, and under the ratio of the wastewater recovery material to other raw materials, electrical porcelain materials with higher quality than C120 medium-strength porcelain can be obtained, which not only realizes the transformation of waste into treasure, but also reduces the use of expensive alumina, and can reduce the use of flux raw materials (such as Jingyang clay) and barren raw materials (bauxite, potassium feldspar, quartz powder), leaving a lot of room for reducing the cost of billets.

[0019] The product obtained by the present invention has a pure porcelain flexural strength of more than 100Mpa (in this industry, flexural strength is also called bending strength), and a flexural strength after glazing of more than 130MPa, or even more than 140MPa. It is a medium-strength porcelain material obtained by applying wastewater recycling materials from sewage stations, and medium-strength porcelain material is a good material for making high-voltage insulators such as U70B and U120B insulators. The U70B insulator made by the present invention can withstand a mechanical damage load of more than 90KN, which not only ensures the excellent and stable performance of the insulator, but also breaks the situation in the prior art that wastewater recycling materials in sewage dare not be used for high-voltage disc-shaped suspension insulators.

[0020] In addition, since the wastewater recycled material in the sewage is the solid particles in the sewage generated by the electric porcelain mud making workshop, the particles of the wastewater recycled material are very fine. When all the raw materials are mixed and batched for ball milling, the proportion of fine particles in the entire mixture is relatively large. Especially when the wastewater recycled material itself is used in a large number of portions, the ball milling time can be shortened, thereby greatly reducing the ball milling time and energy consumption compared to the existing technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 The present invention is a flowchart of a method for producing a high-performance green and environmentally friendly electrical porcelain material according to an embodiment of the present invention. DETAILED DESCRIPTION

[0022] The following is further described in detail through specific implementation methods:

[0023] Example

[0024] A high-performance green and environmentally friendly insulator material comprises the following raw materials: 17-27 parts of Jiangjin soil, 1-3 parts of Yongchuan soil, 10-20 parts of Yichun quartz powder, 12-22 parts of Dongsheng soil, 7-17 parts of Jingyang soil, 1-5 parts of bauxite, 2-6 parts of potassium feldspar, and 21-31 parts of wastewater recycling material, wherein the wastewater recycling material is derived from the solid obtained after solid-liquid separation of sewage in a mud making workshop during insulator manufacturing, and the chemical composition of the wastewater recycling material is shown in Table 1 below.

[0025] Table 1 Chemical composition of wastewater recycling materials (mass percentage)

[0026] <![CDATA[SiO2]]> <![CDATA[AI2O3]]> <![CDATA[Fe2O3]]> <![CDATA[TiO2]]> CaO MgO <![CDATA[K2O]]> <![CDATA[Na2O]]> IL ％ ％ ％ ％ ％ ％ ％ ％ ％ 44～50 38～44 0.8～1.2 0.6～0.8 0.5～0.8 0.3～0.5 2.6～2.9 0.4～0.6 4.8～6.9

[0027] This embodiment provides a method for manufacturing a high-performance green and environmentally friendly insulator material, comprising the following steps:

[0028] S1. Ingredients: Take 17-27 parts of Jiangjin soil, 1-3 parts of Yongchuan soil, 10-20 parts of quartz powder, 12-22 parts of Dongsheng soil, 7-17 parts of Jingyang soil, 1-5 parts of bauxite, 2-6 parts of potassium feldspar, and 21-31 parts of wastewater recycling materials, and mix all the raw materials evenly;

[0029] S2, ball milling, material: ball: water = 1:2:1.2 during ball milling, sieve to remove iron after ball milling, remove iron impurities and coarse particles in the ingredients, specifically, use a sieve of not less than 250 mesh for filtering;

[0030] S3, filter press;

[0031] S4, rough smelting → aging → vacuum smelting → head cutting, rough smelting of mud cake can ensure the uniformity of wastewater recycled materials, improve the process performance of wastewater recycled materials, and improve the process qualification rate; aging can make the electric porcelain body made of electric porcelain materials reach the best molding moisture to reduce the deformation of the blank and ensure the dimensional accuracy of the blank after porcelainization; and vacuum smelting can improve the density of the center of the blank mud section in the later process;

[0032] S5. Blank forming → shade drying → polished blank forming → shade drying → drying → dry blank inspection. Blanks that do not require glazing are directly fired in the kiln. Blanks that require glazing are glazed first and then fired.

[0033] Before the batching in S1, the wastewater recycled material is stored and weathered until the wastewater recycled material turns white.

[0034] In order to verify the specific effect of the above-mentioned insulator materials, the formula was adjusted several times. After each adjustment, the technical parameters were recorded. In the specific formula test, the main chemical composition of the raw materials used is shown in Table 2 below:

[0035] Table 2 Main chemical composition of raw materials (%)

[0036]

[0037] The specific test formula is shown in Table 3 below. This embodiment takes 7 formulas in the test. Among the raw materials used this time, the parts are expressed as percentages.

[0038] Table 3 Details of the 7-times formula

[0039]

[0040]

[0041] The above formula and method are used for production and test verification. The test method is carried out in accordance with the "Test Methods for Inspection of Raw Materials and Process Control of Electrical Ceramics" of Xi'an Electrical Ceramics Research Institute. The test is uniformly carried out with a 50kg ball mill in the pilot room. The ball milling process adopts a single feed, and the material: ball: water = 1:2:1.2. The ball milling fineness is controlled to 250 mesh (≥0.063mm) and the sieve residue is 0.1-0.5%.

[0042] The following is the test data of formula 1:

[0043] Formula 1 Experimental Process Performance Test Data

[0044]

[0045] Formula 1 Test Porcelain Performance Test Data

[0046]

[0047] Mechanical strength test data of formula 1

[0048]

[0049]

[0050] The following is the test data of formula 2:

[0051] Formula 2 test process performance test data

[0052]

[0053] Formula 2 Test Porcelain Performance Test Data

[0054]

[0055] Mechanical strength test data of formula 2

[0056]

[0057]

[0058] The following is the test data of formula three:

[0059] Formula 3 test process performance test data

[0060]

[0061] Formula 3 test porcelain performance test data

[0062]

[0063] Mechanical strength test data of formula 3

[0064]

[0065]

[0066] The following is the test data of formula 4:

[0067] Formula 4 Experimental Process Performance Test Data

[0068]

[0069] Formula 4 Test Porcelain Performance Test Data

[0070]

[0071] Mechanical strength test data of formula 4

[0072]

[0073]

[0074] The following is the test data of formula 5:

[0075] Formula 5 Experimental Process Performance Test Data

[0076]

[0077] Formula 5 Test Porcelain Performance Test Data

[0078]

[0079] Mechanical strength test data of formula 5

[0080]

[0081]

[0082] The following is the test data of formula six:

[0083] Formula 6 test process performance test data

[0084]

[0085] Formula 6 Test Porcelain Performance Test Data

[0086]

[0087] Mechanical strength test data of formula six test

[0088]

[0089]

[0090] The following is the test data of formula seven:

[0091] Formula 7 Experimental Process Performance Test Data

[0092]

[0093] Formula 7 Test Porcelain Performance Test Data

[0094]

[0095] Mechanical strength test data of formula seven test

[0096]

[0097]

[0098] Note: In the above 7 formulas, each judgment standard has been verified through multiple tests, and can be used with the same standards as the insulator materials designed without wastewater recycling in the production of enterprises, thereby reducing the difficulty of production management. And these standards cover the key indicators in each production process, among which the porcelain performance and mechanical strength directly determine the quality of insulator products, while the process performance affects the qualified rate in the production process, which can ensure that the qualified rate of the final production is stable at more than 92%.

[0099] In formula 1, in terms of process performance, the plasticity index, plasticity index and dry bending strength of the blank are all low, and slight red absorption occurs in the porcelain porosity test. The mechanical strength of the final product is still far from that of C120 medium-strength porcelain material.

[0100] In order to improve Formula 1, the inventors conducted experiments on Formula 2 in combination with the various test parameters of Formula 1, reducing the amounts of Jiangjin clay and potassium feldspar and increasing the amount of Dongsheng clay. It was found that the process performance of the blank was greatly improved on the basis of Formula 1, especially the dry bending strength of the blank could reach 7.28MPa, the porcelain performance was also greatly improved, and the porcelain porosity test did not absorb red. However, the final mechanical strength after firing was still far from the mechanical strength required for C120 medium-strength porcelain.

[0101] Compared with Formula 2, Formula 3 reduces the amount of Jiangjin clay, Yongchuan clay, and potassium feldspar, and slightly reduces the amount of Dongsheng clay, and increases the amount of quartz powder, bauxite and wastewater recycled materials. It is found that except for the significant decrease in plasticity index and dry bending strength of the blank, the other process properties are not very different from the overall porcelain properties, but there is a big difference in mechanical strength. The prepared products can meet the flexural strength requirements of C120 medium-strength porcelain of not less than 90MPa for pure porcelain and not less than 110MPa after glazing, and the white-glazed products can exceed 120MPa in bending strength, which meets the company's requirements for electrical porcelain materials used for high-voltage insulators.

[0102] Compared with Formula 3, Formula 4 continues to reduce the amount of Jiangjin soil, Yongchuan soil, and Dongsheng soil, and reduces the amount of Jingyang soil, and boldly increases the amount of wastewater recycled materials. Under this formula, although the dry bending strength of the green body is reduced again, its final mechanical properties can reach a flexural strength of more than 100MPa for pure porcelain, and the flexural strength of both white glaze and brown glaze exceeds 140MPa, which fully meets the company's high standards for medium-strength porcelain and can be put into production.

[0103] In order to ensure the stability of production process and product quality, it is necessary to verify the adaptability of the formula. Therefore, we conducted a fine-tuning test on the formula based on Formula 4, and conducted multiple tests including Formula 5, Formula 6 and Formula 7. All performances were still qualified, indicating that the formula has strong adaptability and high qualified rate, which is conducive to the production of disc-shaped suspended insulator products.

[0104] After the above research, Formula 4 was used as a representative to produce a batch of U70BP / 146D and U120BP / 146D products, and 8 samples were randomly selected from the same batch of products for product performance tests in accordance with GB / T 1001.1-2021. The test results are shown in Tables 4 and 5 below:

[0105] Table 4 U70BP / 146D spot check test report

[0106]

[0107] From the test of 8 randomly selected samples, it can be seen that the U70BP / 146D product made of formula 4 can achieve an average mechanical destructive load of 101KN on the basis of simultaneous electromechanical destructive tests, which is far more than 3 times the standard deviation requirement.

[0108] Table 5 U120BP / 146D spot check test report

[0109]

[0110] From the tests of the 8 samples randomly selected, it can be known that the U120BP / 146D product made by formula 4 can still achieve an average mechanical destruction load of 151.19KN on the basis of simultaneous electromechanical destruction tests, which is far more than 3 times the standard deviation requirement. U70BP / 146D and U120BP / 146D are very typical disc-shaped suspension insulators used in high-voltage transmission lines. Therefore, it can be explained that the application of the porcelain material of this embodiment in high-voltage porcelain breaks the situation in the prior art that wastewater recycled materials in sewage dare not be used for high-voltage porcelain.

[0111] The above is only an embodiment of the present invention, and the common knowledge such as the known specific technical solutions and / or characteristics in the solution is not described in detail here. It should be pointed out that for those skilled in the art, without departing from the technical solution of the present invention, several modifications and improvements can be made, which should also be regarded as the protection scope of the present invention, and these will not affect the effect of the implementation of the present invention and the practicality of the patent. The scope of protection required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.

Claims

1. A high-performance green and environmentally friendly electric porcelain material, characterized in that: Including the following ingredients: 17-27 parts of Jiangjin soil, 1-3 parts of Yongchuan soil, 10-20 parts of quartz powder, 12-22 parts of Dongsheng soil, 7-17 parts of Jingyang soil, 1-5 parts of bauxite, 2-6 parts of potassium feldspar, 21-31 parts of wastewater recycling materials, the wastewater recycling materials are derived from the solids obtained after solid-liquid separation of wastewater in electrical porcelain manufacturing, and the wastewater recycling materials contain 44-50 parts of SiO2, 38-44 parts of AI2O3 and 2.6-2.9 parts of K2O.

2. A high-performance green and environmentally friendly electrical porcelain material according to claim 1, characterized in that: The wastewater recycling material also includes: 0.8-1.2 parts of Fe2O3, 0.6-0.8 parts of TiO2, 0.5-0.8 parts of CaO, 0.3-0.5 parts of MgO, and 0.4-0.6 parts of Na2O.

3. A high-performance green and environmentally friendly electrical porcelain material according to claim 2, characterized in that: The wastewater recovery material in the raw material is 21-26 parts.

4. A high-performance green and environmentally friendly electrical porcelain material according to claim 2, characterized in that: The raw material contains 4-6 parts of potassium feldspar.

5. The high-performance green and environmentally friendly electrical porcelain material according to claim 2, characterized in that: The raw materials include 18-21 parts of Jiangjin soil, 15-20 parts of Dongsheng soil, and 10-13 parts of Jingyang soil.

6. The high-performance green and environmentally friendly electrical porcelain material according to claim 2, characterized in that: The raw material contains 15-18 parts of quartz.

7. A method for producing a high-performance green and environmentally friendly electrical porcelain material, characterized in that: The high-performance green and environmentally friendly electric porcelain material is prepared according to any one of claims 1 to 6, and the prepared ingredients are processed according to the process of ball milling - screening for iron removal - filter pressing - rough smelting - aging - vacuum slurry smelting to obtain the electric porcelain material.

8. The method for producing a high-performance green and environmentally friendly electrical porcelain material according to claim 7, characterized in that: During ball milling, material: ball: water = 1:2:1.

2. After ball milling, use a sieve of not less than 250 meshes for sieving.

9. The method for producing a high-performance green and environmentally friendly electrical porcelain material according to claim 7, characterized in that: Before batching, the wastewater recycled material is stockpiled and weathered until the wastewater recycled material turns white.

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