Method for repairing refractory slab of sintering workshop

Abstract

The invention relates to the technical field of ceramic production equipment, in particular to a sintering workshop refractory slab repairing method which comprises the steps that refractory slab pits are removed; preparing a repairing material, wherein the repairing material is prepared by mixing daub and ceramic powder; filling and compacting are conducted, specifically, the pits are filled with the repairing materials, and compacting is conducted; and performing high-temperature firing, namely firing the refractory slab in a kiln at 1200 + / -50 DEG C for 2 + / -0.5 hours to form a repairing layer which is consistent with the original refractory slab in performance. The refractory slab is directly repaired, the repaired refractory slab is flat in surface, stable support can be provided for ceramic products in the firing process, the product percent of pass can be increased, the replacement frequency of the refractory slab can be reduced, and the production cost can be reduced.

Description

Technical Field

[0001] The invention relates to the technical field of ceramic production equipment, in particular to a method for repairing a sintering workshop shelf. Background Art

[0002] In the firing process of ceramic products, especially sanitary ceramics, the slab, a crucial support, is directly impacting the product's firing quality. In actual firing processes, it has been found that the ribbed bottoms of products like ceramic toilets create constant friction between the ribs and the slab surface during high-temperature firing. After dozens of firing cycles, pits ranging in depth from 0.5 to 3 cm appear on the slab surface. These pits cause uneven stress on the ceramic products placed on the slab during firing, increasing the contact area between the ceramic body and the slab. This can easily cause the ceramic to stick to the slab pits, leading to chipping and chipping. Stress concentration can also cause cracking and deformation at the edges of ceramic products, increasing the rate of defective products.

[0003] Traditional repair methods mainly involve grinding or replacing the entire shed board. Grinding can only repair shallow pits, and each grinding will reduce the thickness of the shed board by 0.3-0.5mm. The heat capacity of the thinned shed board decreases, shortening its service life. The cost of replacing the entire shed board is as high as 2,000-3,000 yuan / square meter. Frequent replacement of shed boards will significantly increase production costs.

[0004] Based on the above problems, there is an urgent need for a shed board repair technology to extend the service life of the shed boards. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the purpose of the present invention is to provide a method for repairing shelf boards in a firing workshop, which can effectively repair shelf board pits, extend the service life of the shelf boards, reduce production costs, and ensure the quality of ceramic products.

[0006] The technical solution adopted by the present invention to solve its technical problem is: A method for repairing a slab in a firing workshop, comprising the following specific steps: Step 1: Clear the pits on the shed; Step 2: preparing the repair material, which is a mixture of clay and ceramic powder; Step 3: Filling and compacting: Fill the repair material into the pit and compact it; Step 4: High temperature firing: fire the slab in a kiln at 1200±50℃ for 2±0.5 hours to form a repair layer with the same performance as the original slab.

[0007] Compared with the prior art, the present invention has the following beneficial effects: The present invention directly repairs the shelf plate. The surface of the repaired shelf plate is smooth, which can provide stable support for ceramic products during the firing process, avoid product quality problems caused by the uneven surface of the shelf plate, and improve the qualified rate of products; it can also reduce the number of replacement times of the shelf plate, reduce production costs and repair difficulty.

[0008] Adding ceramic powder to the clay can Furthermore, the preferred embodiment of the present invention is: The clay in step 2 is one of silicate clay and aluminate clay; and the ceramic powder is one of alumina ceramic powder and mullite ceramic powder.

[0009] The mass ratio of clay to ceramic powder is 3:1.

[0010] In step 3, the repair material is filled to a height of 0.5mm-1mm above the surface of the shelf.

[0011] In step 4, during the high-temperature firing process, the firing temperature is increased at a rate of 5° C. / min-8° C. / min. DETAILED DESCRIPTION

[0012] The present invention will be further described below in conjunction with specific embodiments. The purpose is only to better understand the content of the present invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0013] A method for repairing a slab in a firing workshop is specifically carried out in the following steps: Step 1: Clear the pits in the shed board, use tools to clean up impurities, dust, etc. in the pits, ensure the surface of the shed board is clean, and provide a good foundation for the subsequent filling of repair materials.

[0014] Step 2: Prepare the repair material. The repair material is made by mixing the clay and ceramic powder in a uniform proportion. The mass ratio of the clay and ceramic powder is 3:1. During mixing, the clay can be one of silicate clay or aluminate clay, and the ceramic powder can be one of alumina ceramic powder or mullite ceramic powder.

[0015] When mixing, ensure that the putty and ceramic powder are evenly distributed to ensure the consistency of the performance of the repair material.

[0016] Step 3: Fill and compact. Fill the mixed repair material into the pit position of the shed board, and fill the repair material to 0.5mm above the surface of the shed board. When filling, ensure that the repair material is flush with the edge of the pit, and compact it appropriately to ensure that the repair material can fit tightly in the pit.

[0017] Step 4: High temperature firing. Place the shed board filled with the repair material into a high temperature kiln and fire it at 1200±50℃ for 2±0.5 hours. The firing temperature is increased at a rate of 5℃ / min-8℃ / min. Under the action of high temperature, the glue in the repair material is further solidified, and ceramic powder is added to form a repair layer with the same performance as the original material, thereby achieving the purpose of repairing the shed board.

[0018] Through the above-mentioned repair method, the pits of the shelf boards can be effectively repaired, the service life and replacement frequency of the shelf boards can be extended, and the production cost can be reduced. Example

[0019] The mortar is aluminate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of aluminate mortar and alumina ceramic powder is 2:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 2 hours, and the firing temperature is increased at a rate of 6°C / min. Example

[0020] The mortar is aluminate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of aluminate mortar and alumina ceramic powder is 2.8:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 2 hours, and the firing temperature is increased at a rate of 6°C / min. Example

[0021] The mortar is aluminate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of aluminate mortar and alumina ceramic powder is 3:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 2 hours, and the firing temperature is increased at a rate of 6°C / min. Example

[0022] The mortar is aluminate mortar, the ceramic powder is alumina ceramic powder, the mass ratio of aluminate mortar and alumina ceramic powder is 3.5:1, the two are fully stirred, mixed evenly and filled into the pits on the surface of the shed, fired at 1200 ° C for 2 hours, and the firing temperature is increased at a rate of 6 ° C / min. Example

[0023] The mortar is aluminate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of aluminate mortar and alumina ceramic powder is 4:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 2 hours, and the firing temperature is increased at a rate of 6°C / min.

[0024] The comparison of the bonding strength and high temperature recovery rate of the repair materials and the surface conditions after repair in Examples 1 to 5 with respect to controlling different ratios of the adhesive and ceramic powder is shown in the following table: Example Clay: Ceramic powder Firing temperature (℃) Firing time (h) Bond strength (MPa) High temperature (1200℃) shrinkage (%) Surface condition after repair 1 2：1 1200 2 3.2 1.8 Slight cracking, weak bonding 2 2.8：1 1200 2 5.3 1.1 Weak bonding 3 3：1 1200 2 8.5 0.3 Smooth surface and strong bonding 4 3.5:1 1200 2 7.0 1.2 Localized fine cracks 5 4:1 1200 2 4.2 2.1 Severe surface cracking Example

[0025] The mortar is silicate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of silicate mortar and alumina ceramic powder is 3:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 1 hour, and the firing temperature is increased at a rate of 6°C / min. Example

[0026] The mortar is silicate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of silicate mortar and alumina ceramic powder is 3:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 2 hours, and the firing temperature is increased at a rate of 6°C / min. Example

[0027] The mortar is silicate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of silicate mortar and alumina ceramic powder is 3:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 3 hours, and the firing temperature is increased at a rate of 6°C / min.

[0028] In Examples 6 to 8, regarding the control of the firing time of the repair material, the comparison of the sintering degree and hardness of the repair material in each example is shown in the following table: Example Clay: Ceramic powder Firing temperature (℃) Heating rate (℃ / min) Firing time (h) Sintering degree Hardness (Mohs hardness) 6 3：1 1200 6 1.0 Not fully sintered 4.0 7 3：1 1200 6 2.0 Fully sintered 7.5 8 3：1 1200 6 3.0 Overburning, material performance degradation 6.0 Example

[0029] The mortar is silicate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of silicate mortar and alumina ceramic powder is 3:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 2 hours, and the firing temperature is increased at a rate of 3°C / min.

[0030] Example 10: The mortar is silicate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of silicate mortar and alumina ceramic powder is 3:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 2 hours, and the firing temperature is increased at a rate of 6°C / min.

[0031] Example 11: The mortar is silicate mortar, and the ceramic powder is alumina ceramic powder. The mass ratio of silicate mortar and alumina ceramic powder is 3:1. The two are fully stirred, mixed evenly, and filled into the pits on the surface of the shed. They are fired at 1200°C for 2 hours, and the firing temperature is increased at a rate of 10°C / min.

[0032] In Examples 6 to 8, regarding the control of the heating rate of the repair material, the integrity of the internal structure and the thermal shock resistance of the repair material after firing in each example are compared as shown in the following table: Experimental group Clay: Ceramic powder Firing temperature (℃) Heating rate (℃ / min) Firing time (h) Internal structural integrity Thermal shock resistance (times) 9 3：1 1200 3 2.0 Dense structure, no obvious defects 15 10 3：1 1200 6 2.0 Uniform structure and good performance 22 11 3：1 1200 10 2.0 Tiny pores appear inside 12 The above description is only a preferred embodiment of the present invention and does not limit the scope of the present invention. Any equivalent changes made using the contents of the present invention specification are included in the scope of the present invention.

Claims

1. A method for repairing a sintering workshop shed, characterized in that: The specific steps are as follows: Step 1: Clear the pits on the shed; Step 2: preparing the repair material, which is a mixture of clay and ceramic powder; Step 3: Filling and compacting: Fill the repair material into the pit and compact it; Step 4: High temperature firing: fire the slab in a kiln at 1200±50℃ for 2±0.5 hours to form a repair layer with the same performance as the original slab.

2. The method for repairing a sintering workshop slab according to claim 1, characterized in that: The clay in step 2 is one of silicate clay and aluminate clay; and the ceramic powder is one of alumina ceramic powder and mullite ceramic powder.

3. The method for repairing a sintering workshop slab according to claim 2, characterized in that: The mass ratio of clay to ceramic powder is 3:

1.

4. The method for repairing a sintering workshop slab according to claim 1, characterized in that: In step 3, the repair material is filled to a height of 0.5mm-1mm above the surface of the shelf.

5. The method for repairing a sintering workshop slab according to claim 1, characterized in that: In step 4, during the high-temperature firing process, the firing temperature is increased at a rate of 5° C. / min-8° C. / min.