Technical process for producing mineral wool by surface treatment of sludge

Abstract

The invention relates to the technical field of slag wool treatment and application, in particular to a technical process for producing slag wool by surface treatment of sludge, which comprises the following steps: step 1, sludge pretreatment; 2, mixing the ingredients; 3, high-temperature melting; step 4, fibration; 5, forming and post-processing are carried out; 6, waste gas and waste residue treatment; the sludge is used as the raw material, so that the production cost of the slag wool is reduced; by optimizing ingredients and process parameters, the prepared slag wool product has excellent thermal insulation performance and mechanical strength.

Description

Technical Field

[0001] The present invention relates to the technical field of the application of slag wool, and specifically to the technical process for producing slag wool from surface treatment sludge. Background Art

[0002] Surface treatment sludge is a solid waste generated during surface treatment processes such as electroplating, painting, and anodic oxidation. It contains heavy metals, organic substances, and other harmful components, making it difficult to treat and posing a high environmental risk. Traditional treatment methods such as landfilling and incineration have problems of secondary pollution and resource waste; Slag wool is a highly efficient thermal insulation material widely used in fields such as construction, metallurgy, and chemical industry, and its main raw material is metallurgical slag. However, the production of slag wool has relatively high requirements for the composition of raw materials, and it is difficult for traditional processes to directly utilize surface treatment sludge. Therefore, we propose a technical process for producing slag wool from surface treatment sludge. Summary of the Invention

[0003] To achieve the above object, the present invention provides the following technical solution: A technical process for producing slag wool from surface treatment sludge, characterized by including the following steps: Step 1: Sludge pretreatment; Step 2: Batching and mixing; Step 3: High-temperature melting; Step 4: Fiberization; Step 5: Shaping and post-treatment; Step 6: Exhaust gas and waste residue treatment; Step 1: Dehydrate the surface treatment sludge to reduce its moisture content to below 30%, dry the dehydrated sludge to further reduce the moisture content to below 5%, crush and screen the dried sludge to obtain particles with a particle size less than 5 mm; Step 2: Mix the pretreated sludge with auxiliary raw materials such as blast furnace slag, quartz sand, and limestone in a certain proportion. The mixing ratio is: sludge 20% - 40%, blast furnace slag 40% - 60%, quartz sand 10% - 20%, limestone 5% - 10%; Add appropriate fluxes (such as borax) and regulators (such as alumina) to improve the melting performance and fiberization effect; Step 3: Feed the mixture into a high-temperature furnace and melt it at 1400°C - 1500°C to form a uniform melt. During the melting process, the heavy metals in the sludge are solidified in the glass phase of the melt, avoiding volatilization and secondary pollution; Step 4: Fiberize the melted melt through a centrifuge or a blowing device to form slag wool fibers. During the fiberization process, control the temperature and air flow rate to ensure that the fiber diameter and length meet the standards; Step 5: Make the fiberized slag wool into products such as felt, board, or pipe through a shaping device, and cool, cut, and package the shaped products; Step 6: The waste gas generated during the high-temperature melting process is purified through dust removal, desulfurization, etc. and discharged up to the standard. The waste residue generated during the fiberization process can be returned to the furnace for reuse, achieving zero waste discharge.

[0004] Preferably, in Step 1, 1000 kg of surface-treated sludge is taken, the moisture content is reduced to 25% after dehydration, 4% after drying, and particles with a particle size less than 5 mm are obtained through crushing and screening.

[0005] Preferably, in Step 2, 300 kg of the pretreated sludge is mixed with 500 kg of blast furnace slag, 150 kg of quartz sand, and 50 kg of limestone, and 10 kg of borax and 5 kg of alumina are added.

[0006] Preferably, in Step 3, the mixture is fed into a high-temperature furnace and melted at 1450 °C for 2 hours to form a uniform melt.

[0007] Preferably, in Step 4, the melt is fiberized by a centrifuge, and the fiber diameter is controlled to be 5-8 μm and the length is 50-100 mm.

[0008] Preferably, in Step 5, the fiberized slag wool is made into a felt, cooled and then cut and packaged.

[0009] Preferably, in Step 6, the waste gas is discharged up to the standard after dust removal and desulfurization, and the waste residue is returned to the furnace for reuse.

[0010] The present invention provides a technical process for producing slag wool from surface-treated sludge. It has the following beneficial effects: The present invention converts surface-treated sludge into high-value-added slag wool products, realizing the resource utilization of solid waste; heavy metals in the sludge are solidified at high temperatures, avoiding secondary pollution, and the waste gas is discharged up to the standard after purification treatment; using sludge as a raw material reduces the production cost of slag wool; through optimizing the formulation and process parameters, the prepared slag wool products have excellent heat insulation performance and mechanical strength. Brief Description of the Drawings

[0011] Figure 1 It is a flow chart of the preparation method of the present invention. Detailed Embodiments

[0012] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0013] Such as Figure 1As shown in the figure, the present invention provides a technical solution: a technical process for producing slag wool from surface treatment sludge, which is characterized by including the following steps: Step 1: Sludge pretreatment; Step 2: Batching and mixing; Step 3: High-temperature melting; Step 4: Fiberization; Step 5: Forming and post-treatment; Step 6: Exhaust gas and waste residue treatment; Step 1: Dehydrate the surface treatment sludge to reduce its moisture content to below 30%, dry the dehydrated sludge to further reduce the moisture content to below 5%, and crush and screen the dried sludge to obtain particles with a particle size of less than 5 mm; Step 2: Mix the pretreated sludge with auxiliary raw materials such as blast furnace slag, quartz sand, and limestone in proportion. The mixing ratio is: sludge 20%-40%, blast furnace slag 40%-60%, quartz sand 10%-20%, limestone 5%-10%; Add appropriate fluxes (such as borax) and regulators (such as alumina) to improve the melting performance and fiberization effect; Step 3: Feed the mixture into a high-temperature furnace and melt it at 1400°C - 1500°C to form a uniform melt. During the melting process, heavy metals in the sludge are solidified in the glass phase of the melt, avoiding volatilization and secondary pollution; Step 4: Fiberize the melted melt through a centrifuge or a blowing device to form slag wool fibers. During the fiberization process, control the temperature and air flow velocity to ensure that the fiber diameter and length meet the standards; Step 5: Make the fiberized slag wool into products such as felt, board, or tube through a forming device, and cool, cut, and package the formed products; Step 6: The exhaust gas generated during the high-temperature melting process is discharged up to standard after purification treatment such as dust removal and desulfurization. The waste residue generated during the fiberization process can be returned to the furnace for reuse to achieve zero waste discharge.

[0014] Preferably, in Step 1, 1000 kg of surface treatment sludge is taken, the moisture content is reduced to 25% after dehydration, and the moisture content is 4% after drying. Particles with a particle size of less than 5 mm are obtained after crushing and screening.

[0015] Preferably, in Step 2, 300 kg of the pretreated sludge is mixed with 500 kg of blast furnace slag, 150 kg of quartz sand, and 50 kg of limestone, and 10 kg of borax and 5 kg of alumina are added.

[0016] Preferably, in Step 3, the mixture is fed into a high-temperature furnace and melted at 1450°C for 2 hours to form a uniform melt.

[0017] Preferably, in Step 4, the melt is fiberized through a centrifuge, and the fiber diameter is controlled at 5 - 8 μm and the length is controlled at 50 - 100 mm.

[0018] Preferably, in step five, the fibered slag wool is made into a felt, which is cut and packaged after cooling. After the slag wool is fibered, the fibers can intertwine with each other to form a felt with certain strength and toughness. The felt not only has good heat insulation and sound insulation properties, but also can effectively absorb sound and reduce noise. It is suitable as a heat insulation and sound insulation material in fields such as buildings, industrial equipment, and transportation vehicles. The cooling process ensures the stability of the felt. After high-temperature fibration, rapid cooling can prevent the fibers from further pyrolyzing or deforming, thus maintaining the excellent properties of the felt. The cutting and packaging steps make the felt products more standardized. Cutting the felt into different sizes and shapes can meet the needs of different customers, and careful packaging can protect the felt from damage during transportation and storage, ensuring the stability of product quality.

[0019] Preferably, in step six, the waste gas is discharged up to the standard after dust removal and desulfurization, and the waste residue is returned to the furnace for reuse. The waste gas discharged up to the standard after dust removal and desulfurization can effectively reduce the content of pollutants such as particulate matter and sulfur dioxide in the atmosphere, improve air quality, reduce environmental pollution, and is beneficial to protecting human health and the ecological environment. This measure can also reduce environmental problems such as acid rain caused by pollutant emissions, and has a positive significance for maintaining ecological balance. Returning the waste residue to the furnace for reuse can not only reduce the stacking amount of the waste residue, save land resources, but also avoid secondary pollution of the environment by harmful substances in the waste residue. The recycling of the waste residue can also realize the reuse of resources, improve resource utilization rate, reduce production costs, and is of great significance for the sustainable development of enterprises.

[0020] In the present invention, surface-treated sludge is mixed with auxiliary raw materials (such as blast furnace slag, quartz sand, limestone, etc.) in a certain proportion, and through processes such as high-temperature melting and fibration, a qualified slag wool product is prepared. The heavy metals in the sludge are solidified in the glass phase of the slag wool at high temperature, avoiding secondary pollution.

[0021] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or also includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "comprising an..." does not exclude the existence of additional identical elements in the process, method, article or device comprising the element.

[0022] Although embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A technical process for producing slag wool from surface treatment sludge, characterized in that, It includes the following steps: Step 1: Sludge pretreatment; Step 2: Batching and mixing; Step 3: High-temperature melting; Step 4: Fibering; Step 5: Forming and post-treatment; Step 6: Exhaust gas and waste residue treatment; Step 1: Dehydrate the surface-treated sludge to reduce its moisture content to below 30%, dry the dehydrated sludge to further reduce the moisture content to below 5%, and crush and screen the dried sludge to obtain particles with a particle size less than 5 mm; Step 2: Mix the pretreated sludge with auxiliary raw materials such as blast furnace slag, quartz sand, and limestone in a certain proportion. The mixing ratio is: sludge 20%-40%, blast furnace slag 40%-60%, quartz sand 10%-20%, limestone 5%-10%; Add appropriate fluxes (such as borax) and regulators (such as alumina) to improve the melting performance and fibering effect; Step 3: Feed the mixture into a high-temperature furnace and melt it at 1400°C - 1500°C to form a uniform melt. During the melting process, heavy metals in the sludge are solidified in the glass phase of the melt, avoiding volatilization and secondary pollution; Step 4: Fiberize the molten melt through a centrifuge or a spraying device to form slag wool fibers. During the fibering process, control the temperature and air flow rate to ensure that the fiber diameter and length meet the standards; Step 5: Make the fiberized slag wool into products such as felt, board, or tube through a forming device, and cool, cut, and package the formed products; Step 6: The exhaust gas generated during the high-temperature melting process is discharged up to standard after purification treatment such as dust removal and desulfurization. The waste residue generated during the fibering process can be returned to the furnace for reuse to achieve zero waste discharge.

2. The technical process for producing slag wool from surface treatment sludge according to claim 1, characterized in that: In Step 1, 1000 kg of surface-treated sludge is taken. After dehydration, the moisture content is reduced to 25%, and after drying, the moisture content is 4%. After crushing and screening, particles with a particle size less than 5 mm are obtained.

3. The technical process for producing slag wool from surface treatment sludge according to claim 1, characterized in that: In Step 2, 300 kg of pretreated sludge is mixed with 500 kg of blast furnace slag, 150 kg of quartz sand, and 50 kg of limestone, and 10 kg of borax and 5 kg of alumina are added.

4. The technical process for producing slag wool from surface treatment sludge according to claim 1, characterized in that: In Step 3, the mixture is fed into a high-temperature furnace and melted at 1450°C for 2 hours to form a uniform melt.

5. The technical process for producing slag wool from surface treatment sludge according to claim 1 is characterized in that: In Step 4, the melt is fiberized through a centrifuge, and the fiber diameter is controlled to be 5 - 8 μm and the length is 50 - 100 mm.

6. The technical process for producing slag wool from surface treatment sludge according to claim 1, characterized in that: In Step 5, the fiberized slag wool is made into felt, cooled, cut, and packaged.

7. The technical process for producing slag wool from surface treatment sludge according to claim 1, characterized in that: In Step 6, the exhaust gas meets the discharge standard after dust removal and desulfurization, and the waste residue is returned to the furnace for reuse.

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