Method for reducing flying dust in production of ceramic digital glue dry granules

Abstract

The invention discloses a method for reducing flying dust in ceramic digital glue dry particle production, dust emission reduction and product performance improvement are realized through a multi-dimensional cooperative control technology, the core is to establish a particle size distribution-fluidity-flying dust suppression linkage control system, and a gradient dust removal system is synchronously developed. A high-frequency mechanical vibration device is arranged at the front section to remove large particles, a high-voltage electrostatic dust collection module is arranged at the middle section to capture suspended dust, a nanofiber membrane is adopted at the tail end for filtration, according to actual measurement, after transformation, the PM10 concentration of a production line is reduced to 3 mg / m < 3 > from 25 mg / m < 3 >, the equipment failure interval is prolonged to 1200 hours, the natural transition performance of dry particles is remarkably improved, the product superior rate is improved, and the production cost is reduced. In order to greatly reduce raised dust in the production process, the technology provides a solution for the generation of a large amount of dust in the production of ceramic digital dry granules.

Description

Technical Field

[0001] This invention belongs to the field of digital adhesive technology, specifically relating to a method for reducing dust generation during the production of dry ceramic digital adhesive granules. Background Technology

[0002] Dust pollution in the production of ceramic digital adhesive granules has become a key bottleneck restricting the sustainable development of the industry. With the rapid popularization of ceramic digital printing technology, dry granules, as a core consumable, are increasingly accompanied by dust pollution during production, exhibiting a more severe trend. From raw material pretreatment to finished product packaging, dry granule powder with a particle size of 5-200 micrometers continuously disperses during crushing, sieving, and drying processes, forming visible dust clouds. This high concentration of dust not only reduces visibility in the production environment but also causes frequent blockages in key equipment components. More seriously, suspended PM2.5-PM10 particles, after settling in the respiratory system, can induce irreversible occupational injuries such as pneumoconiosis and chronic obstructive pulmonary disease with long-term exposure. Industry surveys show that the incidence of respiratory diseases among employees in dusty work environments is 4.3 times higher than in ordinary jobs, and the rate of abnormal lung function among those continuously exposed to dust for more than 5 years is as high as 42%. Although current processes are equipped with dust collection devices such as cyclone separators and pulse bag filters, the dust collection efficiency is generally below 75% due to the electrostatic adsorption characteristics of powder materials and the intermittent production nature. Furthermore, the collected dust experiences a 30%-45% resuspension rate due to electrostatic adsorption. The KN95 protective masks worn by workers only provide 2-3 hours of protection in continuous exposure to high concentrations of dust. This dual predicament forces the industry to accelerate technological innovation. Therefore, a method for reducing dust in the production of ceramic digital adhesive dry granules is proposed to address the aforementioned problem of high dust levels during production. Summary of the Invention

[0003] To overcome the drawback of excessive dust in existing production processes, embodiments of the present invention provide a method for reducing dust in the production of ceramic digital adhesive dry granules, solving the problems of low production efficiency and safety issues for production personnel caused by excessive dust during the production process.

[0004] To achieve the above objectives, the present invention provides the following technical solution: A method for reducing dust generation during the production of ceramic digital adhesive dry granules includes the following steps: S1: The ceramic digital adhesive slurry undergoes three-stage homogenization treatment, and the homogenization pressure is used to eliminate agglomeration, so that the viscosity of the liquid is suitable for high-pressure pumping requirements. S2: In the pressure spray drying tower, the slurry is pressure atomized by a dual-air-liquid-feeding atomizing nozzle, and a uniform droplet group is generated by a high-speed rotating atomizing disc. S3: Set the drying tower to high temperature hot air. When the droplets come into contact with the air in the opposite direction, instant drying is achieved, ensuring a stable outlet temperature and preventing the particles from becoming too dry and brittle. S4: By dynamically adjusting the angle of the hot air distributor to change the intensity of hot air turbulence, combined with SEM analysis, online monitoring by a laser particle size analyzer, and secondary classification by an air delivery system, the dry particle size can be controlled.

[0005] Preferably, the hollow microspheres formed by high-speed centrifugation via the atomizing disc in step S2 should have a flow index of 85 or higher to improve the stability of the material system.

[0006] Preferably, the gradient control of the hot air pressure spray in S2 at 280-320℃ enables the water evaporation rate to reach 1.1 kg / (m³). 2 This process (·h) shortens the drying cycle by 40% and prevents particles from clumping.

[0007] Preferably, surface oxidation modification is simultaneously achieved during the drying process described in S2, so that the volume resistivity of the microspheres is lower than 1×108Ω·cm, thereby reducing the adsorption of particles during transportation.

[0008] Preferably, controlling the dry particle size in the range of 80-300 micrometers as described in S3 can effectively reduce production dust while achieving a natural transition of dry particles.

[0009] Preferably, the angle of the hot air distributor in S3 is adjusted to 15-25° to achieve a controllable distribution of 80-300μm, ensuring the uniformity of the spread of ceramic digital adhesive dry granules.

[0010] Preferably, the hollow microspheres in S3 have an internal porosity of 35-45%, ensuring unobstructed gas emission during sintering and eliminating pinhole defects on the glaze surface.

[0011] Preferably, the high temperature mentioned in S3 is above 280°C, which is effective in inactivating microorganisms.

[0012] Preferably, the dry particles with a glass phase content of more than 82% as described in S4, screened by SEM analysis, can have their surface density increased by 30%, which can effectively suppress the escape of dry particles.

[0013] Preferably, the closed drying system described in S4 consists of a double-layer stainless steel shell and a nano-aerogel insulation layer, achieving a thermal efficiency of 67%. Combined with an airlock-sealed feed inlet and a cyclone separator-bag filter combination, the PM10 concentration is controlled below 3 mg / m³. 3 Compared with traditional processes, it can save 30% of energy and the dust emission rate is less than 0.05%.

[0014] The effects and advantages of the method for reducing dust in the production of ceramic digital adhesive dry granules according to the present invention: 1. This invention achieves dual optimization of dust suppression and product performance by controlling the dry particle size within the range of 80-300 micrometers. The distribution characteristics of particle size span coefficient <1.2 reduce the micro powder content to below 5%. Combined with surface modification technology, the amount of dust emission is reduced by 82% compared with traditional processes. The medium particle size of 80-300μm has both excellent flowability and classification efficiency. During sintering, it forms a gradient melting structure, which improves the naturalness of the glaze transition by 50%, realizing the synergistic development of efficient production and green manufacturing.

[0015] 2. The invention utilizes a 15-25° hot air distributor angle dynamic adjustment technology to precisely control the particle size of ceramic digital adhesive dry granules to 80-300μm, with a particle size span coefficient <1.2 and a spreading thickness deviation ≤3μm. Optimized control of the hot air turbulence intensity within this angle range ensures that the dry particle settling rate matches the drying efficiency, reducing the micro powder generation rate to below 2%, and reducing PM10 dust emissions by 85% compared to traditional processes. The uniform gradient particle size distribution enables a natural transition in glaze melting. The feeding speed reaches 15cm / s, the equipment jamming rate decreases by 50%, and the overall pass rate increases to 99.3%.

[0016] 3. This invention utilizes high-speed centrifugation technology with an atomizing disc at 18,000-22,000 rpm to form hollow microspheres with a sphericity ≥0.93, resulting in a flow index exceeding 85 and a 70% improvement in feeding stability. The unique hollow structure ensures a stable tap density of 0.88±0.03 g / cm³. 3 The surface nanoscale roughness is controlled within Ra ≤ 0.2μm, thereby enhancing the inter-particle meshing effect, reducing the silo wall adhesion rate by 85%, and the dust emission rate is <5mg / m³. 3 The overall product qualification rate has increased to 99.5%, which has extended the equipment maintenance cycle by 3 times.

[0017] 4. This invention, through a gradient hot air pressure spray technology of 280-320℃, precisely controls the temperature field distribution within the drying tower, achieving a water evaporation rate of 1.1 kg / (m³). 2 This technology shortens the drying cycle by 40% compared to traditional processes. The dynamic balance gradient temperature control system can achieve a synergistic effect of rapid dehydration and slow release of thermal stress, reducing the particle agglomeration rate to below 0.2%.

[0018] 5. This invention optimizes energy efficiency, reducing unit energy consumption by 25%, while ensuring the integrity of the microsphere structure. The surface microporous structure formed by the rapidly dried granules can significantly improve the melting activity during sintering, resulting in a glaze surface smoothness Ra≤0.06μm. This gives the dry granules the dual advantages of high-efficiency production and improved quality. Attached Figure Description

[0019] Figure 1 This is a flowchart of the dry pellet production process in this invention. Specific implementation methods

[0020] The technical solutions in the embodiments of the present invention will be described in detail below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. By increasing control over the size of dry particles, keeping them within the range of 80-300 micrometers, a suitable natural transition of dry particles can be achieved, while dry particles within this range can effectively reduce dust generation.

[0021] The technical solution of the present invention will be described in detail with reference to Embodiment 1. Experimental methods in each embodiment that do not specify specific conditions were implemented according to conventional conditions in the art or conditions recommended by the manufacturer. Examples 2 and 3 below describe in detail the production of dry ceramic digital adhesive granules in the current technology, and provide statistics on the PM10 and PM2.5 dust generated during the production process.

[0022] Example 1 A method for reducing dust generation during the production of ceramic digital adhesive dry granules is provided, including: Experimental objective: This reduces dust generated during the production of ceramic digital adhesive dry granules.

[0023] Experimental steps: (1) Weigh 40 parts of kaolin, 25 parts of quartz, 15 parts of calcined alumina, 0.5 parts of zinc oxide, 4 parts of spodumene, 4 parts of calcium magnesium carbonate, and 0.5 parts of hydroxypropyl methylcellulose, and feed them into a loss-in-weight feeder and a three-dimensional motion mixer. (2) The value monitored by the Brookfield viscometer is controlled at 1800-2200 mPa·s, and the slurry concentration is controlled at 55-60%. Then, 0.08% sodium polyacrylate is added as a dispersant. The mixture is then processed by a three-roll mill, and the online laser particle size analyzer monitors the target size in real time within the range of 80-300 micrometers. (3) Place the product in a pressure spray drying tower, control the inlet air temperature to 280-320℃ and the outlet temperature to 95-105℃, so that the atomizing disc speed reaches 18000-22000rpm to obtain hollow microspheres with a sphericity greater than 0.92. Finally, adjust the angle of the hot air distributor to 15-25°. (4) Place the product in a high-frequency mechanical vibration device to remove large particles larger than 300μm, then place the product in a high-voltage electrostatic dust removal module to capture 80-300μm particles, and finally filter it through a nanofiber membrane.

[0024] Experimental results: See Table 1 for details.

[0025] Table 1: Test Results of Example 1

[0026] Controlling the dry particle size to within the range of 80-300 micrometers effectively allows for a natural transition of the dry particles and also effectively reduces dust generation during production, with PM emission concentration reaching 3 mg / m³. 3 The emission rate of PM2.5 is less than 0.05%.

[0027] Example 2 A traditional method for producing dry ceramic digital adhesive granules is provided, including: Experimental objective: Production of ceramic digital adhesive granules Experimental steps: (1) The dry ceramic granules are evenly spread on the glue area using a dry granule spreading machine. The spreading machine needs to be used in conjunction with a negative pressure system to control dust. At the same time, the spreading speed and pressure roller pressure should be adjusted to ensure that the dry granule coverage density is 300-500g / m². 2 Unadhesive dry particles are recovered via a suction system; (2) Apply adhesive twice to fix the dry particles and prevent the dry particles from shifting due to the hot air suction in the kiln preheating zone. After the adhesive cures, a physical bonding layer is formed. The weight ratio of adhesive to dry particles should be controlled at 1:3 to balance the adhesion and permeability. (3) During the drying stage, a closed drying tower is used to remove residual moisture. The kiln temperature is adjusted according to the type of dry granules during sintering. The temperature of high-temperature dry granules is 1050-1230℃ to form a dense and transparent glaze layer. The temperature of low-temperature dry granules is 760-850℃, which is used for precious metal or colored dry granules in the three-stage firing process.

[0028] Experimental results: See Table 2 for details.

[0029] Table 2: Test Results of Example 2

[0030] The PM10 emission concentration during the production of ceramic digital adhesive dry granules using this technology is 150-300 mg / m³. 3 The emission rate of PM2.5 reaches 0.1-0.3%.

[0031] Example 3 A dry-grain metal aperture fabrication technique is provided, including: Experimental objective: Provides the application of fine dry granule metal aperture technology in the production of ceramic digital adhesive dry granules. Experimental steps: (1) The alumina content is 45-52 parts, the silica content is 30-35 parts, the potassium sodium feldspar content is 8-12 parts, the calcium oxide content is 5-8 parts, and 0.5-2 parts of zinc oxide is added as a flux. The dry particle size range is controlled at 250-125μm, and the D50 deviation is ±5μm by using a laser particle size detection system. (2) A five-axis linkage polishing machine is used, equipped with 100-500 mesh nylon diamond grinding discs, grinding head pressure of 0.2-0.5MPa, rotation speed of 800-1200rpm, and the contact angle between the grinding disc and the brick surface is controlled at 30-45°. Through reciprocating motion, a micron-level groove with a depth of 5-20μm is formed. Light undergoes total reflection and refraction at the groove interface, generating a metal halo effect with a radius of 2-5mm and a gloss level of ≥95°. (3) The fine dry particles are pre-fired at 800℃ for 2 hours to remove bound water and organic matter, reducing the LOI to 4-6.5%. 0.1-0.3% carboxymethyl cellulose is added as a suspending agent to reduce the risk of drying cracking. A negative pressure glazing system is used to ensure that the glaze slurry bubble content is ≤0.5%. Combined with gradient sintering, the glaze porosity is ≤0.3%. After polishing, micro-dust is intercepted through a nanofiber membrane, resulting in a PM2.5 emission concentration ≤5mg / m³. 3 .

[0032] Experimental results: See Table 3 for details. Table 3: Test Results of Example 3

[0033] This technology achieves a PM10 emission concentration of 15-25 mg / m³ during the production of ceramic digital adhesive dry granules. 3 The emission rate of PM2.5 reaches 0.1-0.3%.

[0034] In the above embodiment 1, the synergistic effect of cyclone separator and laser-guided airflow sorting increases the recycling rate of over 95% for ultra-large particles, while simultaneously intercepting fine powder from entering the bag filter dust collection system, thereby increasing the qualified rate of finished dry granules from 75% to 98%. Combined with CCD image analysis and PLC control system, the particle size distribution model is updated every 5 seconds, and the fabric parameters are automatically calibrated to ensure that the particle size distribution meets the process requirements of Stokes settling rate. Multi-wavelength laser detection technology is used in conjunction with gradient sintering process to increase the spheroidization rate of particles to over 90% and reduce the specific surface area by 15%, effectively reducing the porosity of the glaze.

[0035] In Example 1 above, the rotary belt dust distribution mechanism, in conjunction with the scraper, controls the dry particle coverage thickness error within ±0.02mm. This particle size range, combined with the Stokes settling principle, reduces the suspension time by 80%, suppressing PM2.5 formation at its source. The accompanying dry particle suction and circulation unit, including a cyclone separator and a bag filter canister, uses a -5kPa negative pressure to adsorb unattached dry particles, increasing the recovery rate to over 95%. Actual PM10 levels range from 150-300 mg / m³. 3 Reduced to ≤5mg / m 3 The PM2.5 emission rate is ≤0.05%, avoiding secondary dust caused by the spraying of moisturizing liquid in traditional processes. After sintering, a gradient polishing process is adopted, combined with nanofiber membrane filtration, which reduces the concentration of polishing dust by 90%.

[0036] In Example 2 above, when coarse-grained dry-particle fabric was used, the fabric spreading machine was not equipped with a sealing system, and the PM10 concentration could reach 150-300 mg / m³ in the untreated state. 3 PM2.5 accounts for 30-50%, with measured values ​​of approximately 45-150 mg / m³. 3 The levels of PM10 exceeded ambient air quality standards by hundreds of times. Due to insufficient equipment sealing during the raw material crushing and fabrication processes, fugitive emissions accounted for 5-15%, and the accompanying baghouse dust collectors could only reduce PM10 to ≤10mg / m³. 3 PM2.5 still remains at 5-15 mg / m³ 3 Traditional processes require two applications of adhesive, and inaccurate temperature control in the drying kiln leads to insufficient curing of the adhesive. The recovery rate of unadhesive dry granules is only 70-80%, and residual particles are disturbed by hot air in the kiln preheating zone, forming secondary dust. Compared with the nano-level dry granules and closed negative pressure system of digital adhesive processes, traditional processes have significant gaps in terms of environmental protection and safe operation requirements.

[0037] Although the improved process in Example 3 above reduces PM10 emissions from 150-300 mg / m³ using nanoscale dry particle and gradient sintering technology, it still achieves this reduction. 3 Reduced to 50-150 mg / m³ 3 However, it still exceeds the limit of 10 mg / m³, with actual PM2.5 emissions measured at approximately 15-45 mg / m³.3 Compared with traditional processes, the reduction is 60%, which is hundreds of times higher than the secondary limit of GB3095-2012 standard.

[0038] In Examples 1, 2, and 3 above, the increased surface area of ​​the dry particles raises their surface energy, accelerating gravitational settling and shortening the suspension time by more than 80%, thus suppressing PM2.5 formation at its source. Combined with a closed-loop negative pressure glazing system, the recovery rate of unattached dry particles is increased to 98%, preventing secondary dust generation of PM2.5. With the addition of pulse bag filters and a nanofiber membrane dual filtration system, the PM2.5 emission concentration is ≤3 mg / m³. 3 By combining online laser particle size monitoring with dynamic adjustment of spray parameters, the generation rate of raw material micro powder is controlled to <2%, thereby reducing dust generation from the front end of the process chain.

[0039] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0040] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0041] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of protection of the claims.

[0042] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for reducing dust generation during the production of ceramic digital adhesive dry granules, characterized in that, Includes the following steps: S1: The ceramic digital adhesive slurry undergoes three-stage homogenization treatment, and the homogenization pressure is used to eliminate agglomeration, so that the viscosity of the liquid is suitable for high-pressure pumping requirements. S2: In the pressure spray drying tower, the slurry is pressure atomized by a dual-air-liquid-feeding atomizing nozzle, and a uniform droplet group is generated by a high-speed rotating atomizing disc. S3: Set the drying tower to high temperature hot air. When the droplets come into contact with the air in the opposite direction, instant drying is achieved, ensuring a stable outlet temperature and preventing the particles from becoming too dry and brittle. S4: By dynamically adjusting the angle of the hot air distributor to change the intensity of hot air turbulence, combined with SEM analysis, online monitoring by a laser particle size analyzer, and secondary classification by an air delivery system, the dry particle size can be controlled.

2. The method for reducing dust generation in the production of ceramic digital adhesive dry granules as described in claim 1, characterized in that, The hollow microspheres formed by high-speed centrifugation via an atomizing disc, as described in S2, should have a flow index of 85 or higher to improve the stability of the material system.

3. The method for reducing dust generation in the production of ceramic digital adhesive dry granules as described in claim 1, characterized in that, The hot air pressure spray gradient control described in S2, at 280-320℃, enables a water evaporation rate of 1.1 kg / (m³). 2 This process (·h) shortens the drying cycle by 40% and prevents particles from clumping.

4. The method for reducing dust generation in the production of ceramic digital adhesive dry granules as described in claim 1, characterized in that, During the drying process described in S2, surface oxidation modification is simultaneously achieved for 10-20 minutes, reducing the volume resistivity of the microspheres to below 1×10⁻⁶. 8 Ω·cm, reducing particle adsorption during transportation.

5. The method for reducing dust generation in the production of ceramic digital adhesive dry granules as described in claim 1, characterized in that, The control of dry particle size in S3 within the range of 80-300 micrometers can effectively reduce production dust while achieving a natural transition of dry particles.

6. The method for reducing dust generation in the production of ceramic digital adhesive dry granules as described in claim 1, characterized in that, The hot air distributor in S3 can be adjusted at an angle of 15-25° to achieve a controllable distribution of 80-300μm, ensuring the uniformity of the spread of ceramic digital adhesive dry granules.

7. The method for reducing dust generation in the production of ceramic digital adhesive dry granules as described in claim 1, characterized in that, The hollow microspheres described in S3 have an internal porosity of 35-45%, ensuring unobstructed gas emission during sintering and eliminating pinhole defects on the glaze surface.

8. The method for reducing dust generation in the production of ceramic digital adhesive dry granules as described in claim 1, characterized in that, The high temperature mentioned in S3 refers to an effective inactivation of microorganisms at temperatures above 280°C.

9. The method for reducing dust generation in the production of ceramic digital adhesive dry granules as described in claim 1, characterized in that, As described in S4, the dry particles with a glass phase content of over 82% can be screened by SEM analysis, which can improve their surface density by 30% and effectively suppress the escape of dry particles.

10. The method for reducing dust generation in the production of ceramic digital adhesive dry granules as described in claim 1, characterized in that, The closed-loop drying system described in S4 consists of a double-layer stainless steel shell and a nano-aerogel insulation layer. The ratio of the aerogel layer thickness to the drying tower diameter is 1:50, resulting in a thermal efficiency of 67%. Combined with an airlock-sealed feed inlet and a cyclone separator-bag filter combination, the PM10 concentration is controlled below 3 mg / m³. 3 Compared with traditional processes, it can save 30% of energy and the dust emission rate is less than 0.05%.

Images