Formula and production process for producing glass fiber batch by using coal gangue
By using coal gangue to prepare glass fiber compound, the problem of high transportation costs in glass fiber production is solved, raw material costs are reduced and production stability is improved, while promoting sustainable development.
Patent Information
- Application Number
- CN202511206515.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-27
- Publication Date
- 2025-10-17
AI Technical Summary
In the existing glass fiber production, the use of mineral raw materials such as pyrophyllite and kaolin leads to high transportation costs, resulting in high costs for glass fiber batches.
Coal gangue is used as the main raw material. The formula includes calcined coal gangue powder, quartz powder, kaolin powder, quicklime and dolomite powder. After calcination and grinding, it is mixed with other ingredients to make glass fiber batch, and then melted at high temperature to make glass liquid for drawing and molding.
It effectively reduces the raw material cost of glass fiber production, reduces dependence on high-quality ores, improves production stability, reduces environmental pollution, and achieves sustainable development.
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Figure CN120794364A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of glass fiber production, and particularly relates to a glass fiber batch formula and production process using coal gangue. BACKGROUND
[0002] Glass fiber is a kind of inorganic non-metallic material with excellent performance, and its components are silicon dioxide, aluminum oxide, calcium oxide, boron oxide, magnesium oxide and sodium oxide. The basis of the components of glass fiber is SiO2, Al2O3 and CaO ternary system. The main components of the existing produced glass fiber are basically similar, and only some components and trace elements are adjusted. The change range is approximately SiO2: 53% to 65%; CaO: 16% to 25%; Al2O3: 10% to 17%; and MgO: 0 to 8%. Glass fiber has the characteristics of insulation, heat resistance, good corrosion resistance and high mechanical strength, and is mainly used as an insulating material and a raw material for glass steel.
[0003] At present, the silicon-aluminum batch for producing alkali-free glass fiber in China is mainly produced by using minerals such as pyrophyllite, kaolin and white bubble stone. With the expansion of the production capacity of glass fiber in China, high-quality minerals such as pyrophyllite and kaolin are becoming less and less in the mining process, and are unevenly distributed. For example, at present, the main producing areas of high-quality pyrophyllite in China are Inner Mongolia Autonomous Region, Zhejiang Province and Fujian Province. If other areas need to use it, the transportation cost is extremely high. The silicon-aluminum batch produced by white bubble stone also has the problem of high transportation cost because it is mainly produced in a small number of areas in southwest China such as Chongqing. In view of the above reasons, the current glass fiber batch has the problem of high use cost. SUMMARY
[0004] The purpose of the present application is to provide a glass fiber batch formula and production process using coal gangue to reduce the cost of the glass fiber batch for producing glass fiber.
[0005] To achieve the above purpose, in a first aspect, the present application provides a glass fiber batch formula using coal gangue, which comprises, by weight, 40 parts of calcined coal gangue powder, 32 parts of quartz powder, 7 parts of kaolin powder, 20 parts of quicklime, 12 parts of dolomite powder and 0.5 parts of anhydrous sodium sulfate.
[0006] The SiO2 content in the quartz powder is greater than or equal to 98%.
[0007] The SiO2 content in the kaolin powder is 40% to 50%, the Al2O3 content is 35% to 45%, the Fe2O3 content is less than 1.0%, the R2O content is less than 0.6%, and the chemical oxygen demand is less than 2000 ppm.
[0008] The preparation method of the calcined coal gangue powder comprises the following steps: The SiO2 content in the quartz powder is greater than or equal to 98%. The SiO2 content in the kaolin powder is 40% to 50%, the Al2O3 content is 35% to 45%, the Fe2O3 content is less than 1.0%, the R2O content is less than 0.6%, and the chemical oxygen demand is less than 2000 ppm.
[0009] The original coal gangue is uniformly sampled, and SiO2, Al2O3, CaO, MgO, Fe2O3, SO3 contained in the original coal gangue are detected, wherein Fe2O3 needs to be less than or equal to 0.8%, and the chemical oxygen demand is detected;
[0010] The original coal gangue is calcined in a kiln to obtain calcined coal gangue.
[0011] The calcined and completely cooled coal gangue is ground to obtain calcined coal gangue powder.
[0012] In the step of calcining the original coal gangue in a kiln to obtain calcined coal gangue,
[0013] The original coal gangue is calcined in a kiln, the calcination temperature is 600-750 DEG C, the calcination time is 2-4 hours, and the COD of the calcined coal gangue is controlled at 1000-1500 ppm.
[0014] In the step of calcining the original coal gangue in a kiln to obtain calcined coal gangue,
[0015] The calcined and completely cooled coal gangue is ground by a vertical mill, and is sieved through a 325 mesh sieve, and the 325 mesh sieve residue is controlled to be less than or equal to 2%.
[0016] In a second aspect, the application also provides a glass fiber production process using coal gangue, which adopts the glass fiber batch formula using coal gangue.
[0017] According to the glass fiber batch formula, 40 parts of calcined coal gangue powder, 32 parts of quartz powder, 7 parts of quartz powder, 20 parts of quicklime, 12 parts of dolomite powder and 0.5 parts of anhydrous sodium sulfate are prepared.
[0018] The glass fiber batch is mixed and homogenized, so that the uniformity is greater than or equal to 99%, and a mixed powder material is obtained.
[0019] The mixed powder material is sent into a glass kiln to melt to obtain high-temperature glass liquid, the melting temperature is 1580 DEG C, and the melting time is 48 h.
[0020] The high-temperature glass liquid is clarified and then enters a drawing channel, and flows out of a platinum-gold sieve plate with 1600-6000 holes, the temperature of the glass liquid flowing out of the platinum-gold sieve plate is controlled at 1250-1320 DEG C, and the glass fiber is prepared by using a drawing machine to wind and form after coating with a wetting agent.
[0021] The coal gangue used in the glass fiber batch formula and production process of the present application is a solid waste produced in the process of coal mining and washing, and accounts for a large proportion of industrial solid waste. Since the coal gangue usually contains 40%-60% of SiO2, 15%-30% of Al2O3, and components such as MgO, CaO, Fe2O3, TiO2, and S, the mineral phase thereof is relatively complex, which can effectively make up for the deficiency of the quartz ore with a relatively simple mineral phase added in the present formula in the aspect of melting, and is beneficial to the formation of glass. Compared with the existing glass fiber batch produced by using pyrophyllite, kaolin and white bubble stone, the present application can achieve the same effects of main chemical components such as SiO2, Al2O3 and COD, and since the iron content of the quartz ore is low, the total iron of the batch can be effectively controlled. Through calcination, the COD and S in the coal gangue can also be controlled according to actual requirements to achieve the required content. In addition, the quartz ore and coal gangue used in the present application are relatively more widely distributed in China, especially the quartz ore, which is basically distributed in most regions of China, and the ore dressing and processing technology is also relatively mature in China. Both the mineral cost itself and the transportation cost are reduced. Although the coal gangue will cost a certain amount in the calcination process, it is a waste material itself, and the cost will not increase additional cost. The present application has the advantages of being able to fully utilize natural resources, reducing the dependence on high-quality pyrophyllite, greatly reducing the raw material cost, stable production process, reducing environmental pollution, etc. in the production of glass fiber, and is also conducive to the sustainable development of glass fiber in the aspect of raw materials. BRIEF DESCRIPTION OF DRAWINGS
[0022] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced.
[0023] Figure 1 is a flow chart of the preparation method of the calcined coal gangue powder of the present application.
[0024] Figure 2 is a flow chart of the glass fiber production process using coal gangue of the present application. DETAILED DESCRIPTION
[0025] The embodiments of the present application will be described in detail below, and the examples of the embodiments are shown in the drawings. The embodiments described below by referring to the drawings are exemplary and are intended to explain the present application, and cannot be understood as a limitation of the present application.
[0026] In the first aspect, please refer to Figure 1 , wherein, Figure 1 is a flow chart of the preparation method of the calcined coal gangue powder of the present application.
[0027] The application provides a glass fiber batch formula prepared from coal gangue, which comprises, by weight, 40 parts of calcined coal gangue powder, 32 parts of quartz powder, 7 parts of kaolin powder, 20 parts of quicklime, 12 parts of dolomite powder and 0.5 part of anhydrous sodium sulfate.
[0028] In the formula, the SiO2 content in the quartz powder is greater than or equal to 98%. The SiO2 content in the kaolin powder is 40-50%, the Al2O3 content is 35-45%, the Fe2O3 content is less than 1.0%, the R2O content is less than 0.6%, and the chemical oxygen demand is less than 2000 ppm.
[0029] The chemical oxygen demand COD is detected by using JCT 2156-2012 Determination of COD value of raw materials and batch for fiber glass.
[0030] The preparation method of the calcined coal gangue powder comprises the following steps:
[0031] S101 uniformly sampling the original coal gangue, detecting the SiO2, Al2O3, CaO, MgO, Fe2O3 and SO3 contained in the original coal gangue, wherein the Fe2O3 content is less than or equal to 0.8%, and detecting the chemical oxygen demand;
[0032] S102 calcining the original coal gangue in a kiln to obtain calcined coal gangue;
[0033] In this step, the original coal gangue is calcined in the kiln, the calcination temperature is 600-750 DEG C, the calcination time is 2-4 hours, and the COD of the calcined coal gangue is controlled to be 1000-1500 ppm.
[0034] Specifically, the coal gangue with a suitable particle size is placed in the kiln and calcined at a temperature of 600-750 DEG C, and the specific calcination time is controlled according to the chemical oxygen demand, and the calcination time is usually 2-4 hours. If the COD of the original coal gangue is 40000 ppm, it needs to be calcined at a temperature of 650 DEG C for 2 hours, and the COD of the final product after calcination can be controlled to be 1000-1500 ppm. The kiln is a shaft kiln or a rotary kiln.
[0035] S103 grinding the calcined and completely cooled coal gangue to obtain the calcined coal gangue powder.
[0036] The specific steps include: using a vertical mill to grind the calcined and completely cooled coal gangue, and screening through a 325 mesh screen, and the 325 mesh screen residue is controlled to be less than or equal to 2%. The grinding method is vertical grinding or Raymond grinding.
[0037] The coal gangue used in the glass fiber batch formula of the application is a solid waste generated in the process of coal mining and washing, and accounts for a large proportion of industrial solid waste. Since the coal gangue usually contains 40%-60% of SiO2, 15%-30% of Al2O3, and components such as MgO, CaO, Fe2O3, TiO2 and S, the mineral phase thereof is relatively complex, which can effectively make up for the deficiency of the quartz ore with a relatively simple mineral phase added in the formula in melting, and is beneficial to the formation of glass. Compared with the existing glass fiber batch produced by using pyrophyllite, kaolin and white bubble stone, the same effects of main chemical components such as SiO2, Al2O3 and COD can be achieved, and since the iron content of the quartz ore is low, the total iron of the batch can be effectively controlled. Through calcination, the COD and S in the coal gangue can also be controlled according to actual requirements to achieve the required content. In addition, the quartz ore and coal gangue used in the application are relatively more widely distributed in China, especially the quartz ore, which is basically distributed in most regions of China, and the mineral processing and processing technology is also relatively mature in China. Whether the mineral cost itself or the transportation cost is reduced. Although the coal gangue will cost a certain cost in the calcination process, the cost will not increase additional cost because it is waste utilization. The application has the advantages of being able to fully utilize natural resources, reducing the dependence on high-quality pyrophyllite, greatly reducing the raw material cost, stable production process, reducing environmental pollution, etc. in glass fiber production, and is also conducive to the sustainable development of glass fiber in raw materials.
[0038] In the second aspect, please refer to Figure 2 , Figure 2 is a flow chart of the glass fiber production process using coal gangue of the application. The application also provides a glass fiber production process using coal gangue, comprising:
[0039] S201, according to the weight parts, prepare the calcined coal gangue powder 40 parts, quartz powder 32 parts, kaolin powder 7 parts, quicklime 20 parts, dolomite powder 12 parts, anhydrous sodium sulfate 0.5 parts according to the glass fiber batch formula;
[0040] S202, mix and homogenize the glass fiber batch to make the uniformity greater than or equal to 99%, and obtain the mixed powder material;
[0041] In this step, all the raw material powders in step S201 are mixed and homogenized for 150 seconds to make the uniformity greater than or equal to 99%.
[0042] S203, send the mixed powder material into the glass kiln to melt to obtain high-temperature glass liquid, the melting temperature is 1580℃, and the melting time is 48h;
[0043] S204 passes the high-temperature glass liquid into a drawing channel after refining, and flows out from a platinum-rhodium sieve plate with 1600-6000 holes, the temperature of the glass liquid flowing out from the platinum-rhodium sieve plate is controlled at 1250-1320 DEG C, after coating with an immersion agent, the glass liquid is wound into a shape by using a drawing machine, and glass fibers are prepared.
[0044] In this step, the high-temperature glass liquid is drawn into a shape to prepare the glass fibers.
[0045] The coal gangue is used to produce the glass fiber mixture, and the glass fiber production has the advantages of fully utilizing natural resources, reducing the dependence on high-quality leaf talc, greatly reducing the raw material cost, stable production process, reducing environmental pollution, and the like, and is beneficial to the sustainable development of the glass fiber in the raw material aspect.
[0046] The above only discloses one or more preferred embodiments of the application, and cannot limit the scope of the application, and those skilled in the art can understand that all or part of the above-mentioned embodiments can be implemented, and equivalent changes made according to the claims of the application still belong to the scope of the application.
Claims
1. A glass fiber batch formula produced by using coal gangue, characterized in that: Calculated by weight, it includes 40 parts of calcined coal gangue powder, 32 parts of quartz powder, 7 parts of kaolin powder, 20 parts of quicklime, 12 parts of dolomite powder and 0.5 parts of anhydrous sodium sulfate.
2. The glass fiber batch formulation for producing coal gangue according to claim 1, wherein: The SiO2 content in the quartz powder is ≥98%.
3. The glass fiber batch formulation using coal gangue as claimed in claim 2, characterized in that: The kaolin powder contains SiO2 content of 40-50%, Al2O3 content of 35-45%, Fe2O3 content less than 1.0%, R2O content less than 0.6%, and chemical oxygen demand less than 2000ppm.
4. The glass fiber batch formulation using coal gangue as claimed in claim 3, characterized in that: The preparation method of the calcined coal gangue powder comprises: Take samples evenly from the original gangue and test the SiO2, Al2O3, CaO, MgO, Fe2O3, SO3 contained in the original gangue, of which Fe2O3 must be ≤0.8%, and test the chemical oxygen demand; The raw gangue is placed in a kiln and calcined to obtain calcined gangue; The calcined and completely cooled coal gangue is ground to obtain calcined coal gangue powder.
5. The glass fiber batch formulation produced by using coal gangue as claimed in claim 4, characterized in that: In the step of calcining the raw gangue in a kiln to obtain calcined gangue, The original coal gangue is calcined in a kiln at a calcination temperature of 600-750°C for 2-4 hours. The COD of the calcined coal gangue is controlled at 1000-1500ppm.
6. The glass fiber batch formulation for producing glass fiber from coal gangue as claimed in claim 5, characterized in that: The specific steps of grinding the calcined and completely cooled coal gangue to obtain calcined coal gangue powder include: The calcined and completely cooled coal gangue is ground with a vertical mill and sieved through a 325-mesh sieve, and the 325-mesh sieve residue is controlled within 2%.
7. A process for producing glass fiber from coal gangue, using the batch material formula for producing glass fiber from coal gangue as claimed in any one of claims 1 to 6, characterized in that: include: Prepare 40 parts of calcined coal gangue powder, 32 parts of quartz powder, 7 parts of kaolin powder, 20 parts of quicklime, 12 parts of dolomite powder, and 0.5 parts of anhydrous sodium sulfate according to the glass fiber batch formula by weight; The glass fiber batch material is mixed and homogenized to achieve a uniformity greater than or equal to 99% to obtain a mixed powder material; The mixed powder material is fed into a glass furnace to be melted to obtain high-temperature glass liquid at a melting temperature of 1580°C for 48 hours; The high-temperature glass liquid enters the drawing channel after clarification and flows out through a platinum leak plate with 1600 to 6000 holes. The temperature of the glass liquid flowing out of the platinum leak plate is controlled at 1250 to 1320°C. After being coated with a wetting agent, it is wound into shape using a wire drawing machine to produce glass fiber.