Raw material and method for producing mineral fiber from basalt rock

Abstract

The invention relates to the technical field of mineral fiber preparation, in particular to a raw material and a method for producing mineral fibers from basalt rocks, and the raw material is composed of 70%-95% of basalt alkaline magmatic rocks and 30%-5% of granite acid magmatic rocks. According to the invention, the raw material base for obtaining the mineral fiber is expanded, the temperature resistance and corrosion resistance environment are improved, and the application range of the fiber in reinforced glass plastics, cement and ceramic composite materials, filtration, electrical insulation and other products is expanded.

Description

Technical Field

[0001] The present invention relates to the technical field of mineral fiber preparation, and in particular to a raw material and method for producing mineral fiber from basalt rock. Background Art

[0002] Research interest in various rock fibers is growing worldwide. Numerous studies have shown that suitable melts for processing into fibers, especially continuous fibers, must possess rheological properties (such as viscosity, viscosity-temperature relationship, growth interval, and activation energy) and complex physicochemical characteristics (such as surface tension and wettability) consistent with certain parameters. The growth interval can be understood as the temperature interval within the viscosity-temperature relationship within which the melt has the potential to form fibers.

[0003] The most traditional and well-known method for producing continuous fibers from rock raw materials typically involves crushing the rock to 5-20 mm. The crushed basalt is then fed by a loader into a melting furnace, where it is melted at high temperatures (1400-1600°C). The molten basalt enters the furnace feeder and passes through the holes of a die feeder. From the die feeder, the raw basalt fiber is fed into an oiling machine, where a winder winds the continuous fiber onto bobbins. The resulting yarn is then wound into roving coils by a doubling machine (DD Dzhigiris, MF Makhova, "Principles of Basalt Fiber and Product Production," M.: Teploenergetik. - 2002. - 411 p.). Patent CN00110460.8, "Method for Producing Basalt Alkali-Resistant Continuous Fibers" (China), discloses the composition of basalt alkali-resistant continuous fibers, which are made from 85.0-90.0% basalt powder, 1.0-5.0% fluorite powder, and 3.0–10.0% zirconium. However, large-scale production of continuous fibers from rock using fluorite powder (melting point 1360°C) and zirconium powder (melting point 2715°C) results in high energy consumption and wear of furnace refractory materials.

[0004] Ukrainian Utility Model Patent No. 131803 (C03C 13 / 00, published on January 25, 2019) discloses a raw material for continuous aluminosilicate fibers containing 75%-95% by weight of basalt, an alkaline volcanic rock, and 5%-25% by weight of obsidian, an acidic volcanic rock. However, using obsidian to mass-produce continuous fibers from rock significantly increases the cost of the final product (untreated obsidian costs ≥ $5 / kg).

[0005] Patent No. RU2233810 uses biotite and rhyolite as raw materials and heats them to a temperature of 2105-2200°C to obtain a melt with an amorphous degree of at least 96%. The disadvantages of using these raw materials and the method for obtaining a melt from them are that the melting process of andesite, biotite, and rhyolite is energy-intensive, resulting in wear of the refractory material in the melting furnace and unstable operation of the die feeder.

[0006] It is known from existing technologies that fibers obtained from andesite melt have stronger acid resistance (Patent RF2120423 "Method for obtaining acid-resistant inorganic fibers from rocks", C03B37 / 02). However, achieving such fibers requires a higher melting temperature (1705-2100°C). Summary of the Invention

[0007] In order to solve the problems that currently available continuous mineral fibers are difficult to obtain from rock raw materials and the fibers have low acid and alkalinity resistance, the present invention provides a raw material and method for producing mineral fibers from basalt rocks.

[0008] The present invention is achieved through the following technical solutions: In a first aspect, the present invention provides a raw material for producing mineral fiber using basalt rock, which is composed of 70% to 95% basalt alkaline igneous rock and 30% to 5% granite acidic igneous rock.

[0009] As a further improvement of the raw material technical solution of the present invention, the basalt alkaline igneous rock includes one or any combination of basalt, diabase, andesite, diorite, diabase, and porphyry.

[0010] As a further improvement of the raw material technical solution of the present invention, the chemical components of the basalt alkaline igneous rock are: SiO2 45-61%, Al2O3 12-18%, Fe2O3 and FeO 5-14%, CaO 5-12%, MgO 3-7%, TiO2 0.5-2%; Na2O and K2O 0.5-6.2%, and the rest are impurities.

[0011] As a further improvement to the raw material technical solution of the present invention, the chemical components of the granite acidic igneous rock are: SiO2 68-73%; Al2O3 12.0-15.5%; Na2O 3.0-6.0%; CaO 1.5-4.0%; FeO 0.5-3.0%; Fe2O3 0.5-2.5%; K2O 0.5-5.0%; MgO 0.1-1.5%; TiO2 0.1-0.6%, and the rest are impurities.

[0012] As a further improvement to the raw material technical solution of the present invention, the content of the granite acidic igneous rock is at least 10%.

[0013] As a further improvement to the raw material technical solution of the present invention, the content of the granite acidic igneous rock is no more than 20%.

[0014] In a second aspect, the present invention provides a method for producing mineral fibers from basalt rock, wherein basalt alkaline igneous rock and granite acidic igneous rock are mixed and maintained at a temperature of 1330-1470°C to obtain a uniform melt, which is then fed into a feeder and further stretched or blown to form fibers.

[0015] The raw materials and methods for producing mineral fibers from basalt rock provided by the present invention have the following advantages over the prior art: The invention expands the raw material base for obtaining mineral fibers, improves temperature resistance, resistance to aggressive environments (i.e., acid resistance), and expands the fiber's application range in reinforcing glass plastics, cement and ceramic composites, filtration, electrical insulation, and other products. DETAILED DESCRIPTION

[0016] In order to more clearly understand the above-mentioned objectives, features and advantages of the present invention, the scheme of the present invention will be further described below. It should be noted that, in the absence of conflict, the embodiments of the present invention and the features therein can be combined with each other.

[0017] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein; it is obvious that the embodiments in the specification are only part of the embodiments of the present invention, rather than all the embodiments.

[0018] The present invention provides a specific embodiment of a raw material for producing mineral fiber using basalt rock, which is composed of 70% to 95% basalt alkaline igneous rock and 30% to 5% granite acidic igneous rock.

[0019] In one example provided herein, the basaltic alkaline igneous rock includes one or more of basalt, diabase, andesite, diorite, diabase, and porphyry. These rocks are formed by the solidification and crystallization of magma (eruptive volcanic rocks) and are complex silicate systems containing oxides of alkali and alkaline earth metals. The primary diagenetic minerals are feldspar (dolomite Na[AlSi3O8], anodic spar CaAl2Si2O8), gabbro (diopside CaMg[Si2O6], pyroxene Ca(Mg,Fe,Al)[(Si,Al)2O6]), and sometimes Fe3O4 (Bart T. Petrological Theory. M.: Izd. IL, 1956, p. 414).

[0020] The present invention studies the chemical composition of basaltic alkaline igneous rock, which is specifically: SiO2 45-61%, Al2O3 12-18%, Fe2O3 and FeO 5-14%, CaO 5-12%, MgO 3-7%, TiO2 0.5-2%; Na2O and K2O 0.5-6.2%, and the rest are impurities.

[0021] The present invention studies the average chemical composition of granite acidic igneous rocks, which is specifically: SiO2 68-73%; Al2O3 12.0-15.5%; Na2O 3.0-6.0%; CaO 1.5-4.0%; FeO 0.5-3.0%; Fe2O3 0.5-2.5%; K2O 0.5-5.0%; MgO 0.1-1.5%; TiO2 0.1-0.6%, and the rest are impurities.

[0022] Granitic acidic igneous rocks are primarily composed of quartz and feldspar. Potassium feldspar is the most common feldspar, supplemented by oligoclase or albite. Granitic acidic igneous rocks also contain elements such as magnetite, zircon, allanite, apatite, and titanite, but in very small quantities.

[0023] Granite-acid igneous rocks have higher silicon content and lower iron content than basalt-alkaline igneous rocks. The melting temperature of basalt-alkaline igneous rocks is about 984-1260°C, while the melting temperature of granite-acid igneous rocks is about 1215-1260°C (the melting point drops significantly to 650°C in the presence of water and pressure).

[0024] In an example provided by the present invention, the content of the granite acidic igneous rock is at least 10%.

[0025] In another example provided by the present invention, the content of the granite acidic igneous rock is no more than 20%.

[0026] The present invention further provides a method for producing mineral fibers from basalt rock, wherein basalt alkaline igneous rock and granite acidic igneous rock are mixed and maintained at a temperature of 1330-1470°C to obtain a uniform melt, which is then fed into a feeder and further stretched or blown to form fibers.

[0027] Analysis of the presented data indicates that amorphism increases with increasing melt temperature. Overheating the melt in the 1500-1600°C range significantly increases amorphism and fiber strength index. The 1500-1600°C melting temperature range allows for a more complete transition from a crystalline to an amorphous state in basaltic alkaline igneous rocks and granitic acidic igneous rocks, with melt amorphism reaching 81-96%.

[0028] The specific embodiments of the present invention are described in detail below.

[0029] Further examples of raw material charge compositions relevant to the present invention are given below, which should not be considered limiting.

[0030] Table 1 Examples of raw material mixture compositions

[0031] The present invention further analyzes the chemical components in each embodiment: Mineral fibers were obtained under laboratory conditions from pure basalt (Example 1) and different proportions of basalt alkaline igneous rocks and granite acidic igneous rocks (Examples 2-6). Example 1

[0032] Basaltic alkaline igneous rock with the following composition (by weight: SiO₂ 53.6%, TiO₂ 3.2%, Al₂O₃ 13.0%, Fe₂O₃ + FeO 13.1%, MgO 9.8%, CaO 10.3%, Na₂O + K₂O 4.8%, and the remainder as impurities) is ground into 10-20 mm particles. After mechanical sorting, it is fed into a melting furnace maintained at 1450 ± 10°C to produce a homogeneous melt. The melt is then fed into a feeder with a hole near the bottom end. The melt in the feeder is maintained at a temperature between 1350 and 1300°C before being drawn to form fibers. Example 2

[0033] Basaltic alkaline igneous rock, with the following composition (weight percentage: SiO2 53.6%, TiO2 3.2%, Al2O3 13.0%, Fe2O3 + FeO 13.1%, MgO 9.8%, CaO 10.3%, Na2O + K2O 4.8%, the rest are impurities), and granitic acidic igneous rock composition ( SiO2 72.0%; Al2O3 14.4%; K2O 4.12%; Na2O 3.69%; CaO 1.82%; FeO1.67%; Fe2O3 1.22%; MgO 0.7%; TiO2 0.30%; P2O5 0.05%; MnO 0.03%) in a ratio of 95:5, were ground into units of 5-10 Millimeter-sized pieces are mechanically sorted and then loaded into a melting furnace, where the temperature is maintained at 1450±20°C to produce a uniform melt. The melting temperature range of 1450-1500°C allows the charge basalt-granite to transition more completely from a crystalline state to an amorphous state, with the amorphous melt concentration reaching ≥90%. The melt is then fed into a feeder with a hole near the bottom end. The melt temperature in the feeder is maintained between 1350-1300°C, where it is subsequently drawn to form fibers. Example 3

[0034] Using the raw materials described in Example 2, conventional briquetting methods and equipment were used to form blocks of basalt alkaline igneous rock and granite acidic igneous rock in a weight ratio of 90:10. These blocks were then pressed into briquettes of appropriate shape and size. The briquettes may contain a binder, such as clay. The briquettes were heated in a furnace to 1450±20°C and maintained until completely homogenized, producing a melt with a viscosity of ≤10 Pa·s. The melt was then fed into a feeder for further stretching or blowing into short fibers. Example 4

[0035] Using the raw materials described in Example 2, conventional briquetting methods and equipment were used to form blocks of basaltic alkaline igneous rock and granite acidic igneous rock in a weight ratio of 80:20. The blocks were then pressed into briquettes of appropriate shape and size. The briquettes may contain a binder, such as clay. The briquettes were heated in a furnace to 1450±20°C and maintained until fully homogenized, resulting in a melt with a viscosity of 10-20 Pa·s. The melt was then fed to a feeder for further stretching to produce fibers and / or blown to produce staple fibers. Example 5

[0036] Using conventional briquetting methods and equipment, basalt and granite raw materials, in a weight ratio of 70:30, are lumped and pressed into briquettes of appropriate shape and size. Briquettes may contain a binder, such as clay. The briquettes are heated in a furnace to 1450-1500°C and maintained until fully homogenized, resulting in a melt with a viscosity of 20-90 Pa·s. This melt is then fed into a feeder for further stretching and / or blowing to produce fibers. Example 6

[0037] Using the raw materials described in Example 2, conventional briquetting methods and equipment were used to form lumps of basalt and granite in a 50:50 weight ratio and press them into blocks of appropriate shape and size. The briquettes may contain a binder, such as clay or a similar binder. The briquettes were heated in a furnace to 1600°C for 3 hours. Under laboratory conditions, heat treatment (melting) of this mixture and holding it at the maximum temperature for 180 minutes does not guarantee complete melting of the granite (which contains silica). Residual unmelted silica can reduce the quality of the fibers produced. Achieving a uniform glass phase requires higher temperatures.

[0038] When the glass melting temperature is ≤1550° C. and maintained at the highest temperature for 3 hours, the raw materials of Examples 1-5 can obtain uniform glass frit.

[0039] When the granite content in the charge increases (as in Example 6), the glass homogenization process becomes more difficult - unmelted inclusions, bubbles, and gas inclusions are formed in the glass melt, which has a negative impact on the technical parameters of fiber production.

[0040] The examples given in this invention do not limit the invention in any way.

[0041] The chemical compositions of the obtained fibers are as follows (Table 2).

[0042] Table 2 Chemical composition of the obtained fibers

[0043] The present invention corrects the initial chemical composition of basalt by adding granite with a large acidity coefficient, thereby obtaining a uniform melt with good molding performance, and on this basis obtains continuous and / or chemically stable short fibers.

[0044] The chemical stability of the obtained fibers was studied (Table 3).

[0045] Table 3 Chemical stability of fibers

[0046] In the above chemical stability test, the specific test methods for the H2O stability and HCl stability are as follows: To determine the chemical stability of the fibers, selected fiber samples were placed in glass barrels and dried in a desiccator at a temperature of 105 ± 5° C. Then, they were cooled in the desiccator and samples were taken from them.

[0047] The resulting fibers were exposed to different boiling etching media for three hours: in this example, H2O water and 2N HCl acid. The fiber stability was evaluated by the loss of fiber mass.

[0048] The results of chemical stability of basalt and glass fiber are the average of the test results of at least three samples.

[0049] Table 4 Temperature resistance of fibers

[0050] The method for determining heat resistance is: The specimen is placed in a furnace with an initial temperature of 20°C. A plate containing rods weighing 2 kg is placed on the specimen, equivalent to a specific load of 2000 N / m² (2000 Pa). The initial thickness of the specimen is measured using a ruler. The furnace temperature is raised at a rate of 5°C / minute. The temperature Ta (in units of 0°C) at which the specimen thickness decreases to 10% of its initial thickness is determined. The average of the applied temperatures for all samples tested is used as the measurement result.

[0051] The aforementioned certification tests were performed in accordance with the Ukrainian National Standard 3413.

[0052] As can be seen from the table above, the temperature stability of the fibers obtained according to the present invention is 10-20% higher than that of similar fibers obtained from pure basalt raw material.

[0053] The present invention expands the range of raw material possibilities to produce fibers with increased temperature and chemical resistance in aggressive environments, namely, acid resistance. The technical results achieved using the present invention are a broadening of the raw material base for continuous fibers derived from rock, improving their resistance to temperature and aggressive environments (i.e., acid resistance), and expanding the fiber's application range in applications such as reinforcing glass, plastics, cement, and ceramic composites, filtration, electrical insulation, and other products.

[0054] The above description is merely a specific embodiment of the present invention, which enables those skilled in the art to understand or implement the present invention. Although detailed descriptions have been made with reference to the aforementioned embodiments, those skilled in the art should understand that they may still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents; and such modifications or replacements do not deviate from the essence of the corresponding technical solutions within the scope of the technical solutions of the embodiments, and they should all be included in the scope of protection of the claims.

Claims

1. A raw material for producing mineral fiber from basalt rock, characterized in that: It is composed of 70% to 95% basalt alkaline igneous rocks and 30% to 5% granite acidic igneous rocks.

2. The raw material for producing mineral fiber from basalt rock according to claim 1, characterized in that: The basaltic alkaline igneous rock includes one or any combination of basalt, diabase, andesite, diorite, diabase, and porphyry.

3. The raw material for producing mineral fiber from basalt rock according to claim 2, characterized in that: The chemical components of the basalt alkaline igneous rock are: SiO2 45-61%, Al2O3 12-18%, Fe2O3 and FeO 5-14%, CaO 5-12%, MgO 3-7%, TiO2 0.5-2%; Na2O and K2O 0.5-6.2%, and the rest are impurities.

4. The raw material for producing mineral fiber from basalt rock according to claim 1, characterized in that: The chemical components of the granite acidic igneous rock are: SiO2 68-73%; Al2O3 12.0-15.5%; Na2O 3.0-6.0%; CaO 1.5-4.0%; FeO 0.5-3.0%; Fe2O3 0.5-2.5%; K2O 0.5-3.0%; MgO 0.1-1.5%; TiO2 0.1-0.6%, and the rest are impurities.

5. The raw material for producing mineral fiber from basalt rock according to claim 1, characterized in that: The content of the granite acidic igneous rock is at least 10%.

6. The raw material for producing mineral fiber from basalt rock according to claim 1, characterized in that: The content of the granite acidic igneous rock is not more than 20%.

7. The method for producing mineral fibers from basalt rock according to any one of claims 1 to 6, characterized in that: Basalt alkaline igneous rock and granite acidic igneous rock are mixed and the temperature is maintained at 1330-1470°C to obtain a uniform melt, which is then fed into a feeder and further stretched or blown to form fibers.

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