A solid sodium silicate preparation process based on controllable water quenching

Abstract

This invention discloses a process for preparing solid sodium silicate based on controllable particle size water quenching, belonging to the field of inorganic silicate chemical technology. The specific steps are as follows: S1: raw material melting and homogenization; S2: controllable particle size water quenching; S3: solid-liquid separation and online classification; S4: deep drying and packaging. This invention achieves innovation and simplification of the production process: through a one-step "atomization-cooling" forming method, the high-energy-consuming crushing and screening processes in traditional processes are completely eliminated, shortening the process flow and reducing equipment investment and maintenance costs; it significantly improves the overall quality of the product: directly generating solid particles with high sphericity and smooth surface, the product has good flowability, stable bulk density, high whiteness, and no tendency to agglomerate during subsequent dissolution, with a faster dissolution rate and superior application performance.

Description

Technical Field

[0001] This invention relates to the field of inorganic silicate chemical technology, specifically a process for preparing solid sodium silicate based on water quenching with controllable particle size, and particularly a method for directly preparing solid sodium silicate particles with specific particle size distribution and spherical morphology by precisely controlling the fluid dynamics and heat transfer parameters during the water quenching process. Background Technology

[0002] Sodium silicate, commonly known as sodium silicate, has the chemical formula Na2O·nSiO2. It is a soluble inorganic silicate with a wide range of applications.

[0003] Traditional solid sodium silicate production processes follow a fixed pattern of "forming first, then crushing." High-temperature melt is quenched in water (rapid cooling) to form amorphous glassy fragments of varying sizes. These fragments must undergo further processing using multiple crushing equipment, such as jaw crushers and roller crushers, as well as vibrating screens, to obtain commercially viable granular products. This process has the following drawbacks: High energy consumption: Crushing and screening are typically high-energy-consuming processes. Yield loss: The crushing process inevitably produces approximately 10%-20% of fine powder (<0.1mm) and large, substandard pieces, which must be remelted or treated as defective products, reducing the effective yield. Dust and noise pollution: The crushing and screening processes generate large amounts of silicate dust, posing a health hazard to employees and requiring a dust removal system, while also causing significant noise pollution. Irregular product shape: The crushed products are mostly angular flakes or blocks with poor flowability and large fluctuations in bulk density, affecting subsequent automatic metering and dissolution rates. Summary of the Invention

[0004] The purpose of this invention is to address the problems of long production processes, high energy consumption, poor product morphology, and pollution in existing solid sodium silicate production technologies. This invention provides a solid sodium silicate preparation process based on controllable particle size water quenching. By directly atomizing high-temperature melt into droplets and controllingly cooling and solidifying it, a "one-step forming" process from liquid to solid particles of the target particle size is achieved, resulting in products with high sphericity and good flowability, thereby enhancing product added value and user experience.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A process for preparing solid sodium silicate based on water quenching with controllable particle size, the specific steps of which are as follows:

[0007] S1: Raw material melting and homogenization: Quartz sand and soda ash are used as raw materials. The raw materials are prepared according to the molar ratio of SiO2 to Na2O and the modulus M is 2.0 to 3.3. The raw materials are melted at a high temperature of 1400℃~1500℃ to form sodium silicate melt. The melt is then subjected to static or bubble refining to obtain a homogeneous melt without bubbles.

[0008] S2: Controllable particle size water quenching: The sodium silicate melt obtained in step S1 is atomized, dispersed, and then instantaneously quenched and solidified to obtain solid particles within a specific particle size range;

[0009] S3: Solid-liquid separation and online classification: Using a hydrocyclone assembly, the mixture of quenched particles and water prepared in step S2 is subjected to efficient solid-liquid separation and online classification to obtain the mainstream product with the target particle size.

[0010] S4: Deep drying and packaging: The wet granules after grading in step S3 are deep dried to reduce their moisture content to less than 0.5%, and then packaged in a moisture-proof manner after cooling.

[0011] Furthermore, the controllable particle size water quenching described in step S2 specifically includes the following steps:

[0012] Step 1: Constant pressure and temperature conveying of melt: The melt is introduced into the heat-insulating buffer bag, and its outlet temperature is controlled within the range of 1250℃~1400℃. It is then conveyed to the atomizing device at a constant flow rate through a high-temperature resistant pump, with the flow rate fluctuation range controlled within ±3%.

[0013] Step 2, Melt atomization and dispersion: The melt is dispersed into uniform droplets using a centrifugal atomizing disc;

[0014] Step 3, Droplet Quenching and Solidification: Use room temperature deionized water or industrial soft water as the cooling medium, and control the mass ratio of water to melt between 5:1 and 15:1, so that the droplet is cooled to below its glass transition temperature and solidified within 1 second; wherein the quenching process is carried out under an inert gas protective atmosphere.

[0015] In step S1, the quartz sand has a SiO2 content of not less than 98.5% and a particle size range of 100 to 200 mesh; the soda ash has a Na2CO3 content of not less than 99.0%. Step S2 uses a one-step "atomization-cooling" forming method to directly obtain spherical solid particles from the melt, eliminating the traditional crushing and screening processes. In step S3, before online classification, the quenched particle-water mixture undergoes primary dehydration to separate most of the free water. In step S4, a fluidized bed dryer or belt dryer is used for deep drying.

[0016] As a further embodiment of the present invention: the hydrocyclone assembly includes a support column, a connecting pipe fixedly connected to the outer wall of the support column, a hydrocyclone body provided at one end of the connecting pipe, an underflow pipe and an overflow pipe installed inside the hydrocyclone body, a feed pipe connected to the connecting pipe fixedly connected to the top of the support column, a second collection tank fixedly connected above the support column, a second collection pipe fixedly connected to the outer wall of the second collection tank, a first collection tank provided on the outer wall of the support column, a first collection pipe fixedly connected to the outer wall of the first collection tank, a guide pipe installed above the hydrocyclone body, the guide pipe extending and suspended above the second collection tank, the underflow pipe and the overflow pipe being installed by an installation mechanism, and the hydrocyclone body being displaced by a displacement mechanism.

[0017] As a further embodiment of the present invention: the installation mechanism includes an underflow port, which is fixedly connected to the bottom end of the hydrocyclone body; an underflow pipe is slidably connected to the inner wall of the underflow port; a positioning ring is fixedly connected to the outer wall of the underflow pipe; a threaded sleeve is threadedly connected to the outer wall of the underflow port, the threaded sleeve being located on the outer wall of the underflow pipe; an overflow port is fixedly connected to the top end of the hydrocyclone body; a first docking plate is fixedly connected to the top end of the overflow port; a second docking plate is fixedly connected to the bottom end of the guide pipe; a circular groove is formed at the top end of the first docking plate; an annular plate is fixedly connected to the top end of the overflow pipe; and the overflow pipe is slidably connected to the inner wall of the overflow port.

[0018] As a further embodiment of the present invention: the installation mechanism further includes a first vertical groove, which is symmetrically opened on the outer wall of the first docking plate, and a second vertical groove is symmetrically opened on the outer wall of the second docking plate. A displacement ring is slidably connected to the outer wall of the overflow port, and a vertical rod is symmetrically fixedly connected to the top end of the displacement ring. A rotating rod is rotatably connected to the top end of the vertical rod, and a lower pressure plate is fixedly connected to the top end of the rotating rod.

[0019] As a further embodiment of the present invention: the displacement mechanism includes a mounting base, the mounting base being fixedly connected to the outer wall of the connecting pipe, a first motor being mounted on the top of the mounting base, a baffle being rotatably connected to the inner wall of the mounting base, the baffle being connected to the output end of the first motor, a limiting seat being fixedly connected to the outer wall of the connecting pipe, a gear being fixedly connected to the outer wall of the limiting seat, a displacement tube being fixedly connected to the outer wall of the hydrocyclone body, the displacement tube being slidably connected to the outer wall of the connecting pipe, a mounting frame being fixedly connected to the top of the displacement tube, a second motor being mounted on the top of the mounting frame, a connecting shaft being connected to the output end of the second motor, a spur gear being fixedly connected to the bottom end of the connecting shaft, and the spur gear contacting the gear.

[0020] As a further embodiment of the present invention: the displacement mechanism further includes a first bevel gear, which is fixedly connected to the outer wall of the connecting shaft. A second bevel gear is provided on the outer wall of the first bevel gear. A rotating shaft is fixedly connected to one end of the second bevel gear. A third bevel gear is fixedly connected to one end of the rotating shaft. A fourth bevel gear is provided on the outer wall of the third bevel gear. A threaded rod is fixedly connected to the top of the fourth bevel gear. A support frame and a limiting rod are fixedly connected to the top of the hydrocyclone body. The rotating shaft and the threaded rod are both rotatably connected to the support frame. The limiting rod and the threaded rod both pass through the displacement ring.

[0021] As a further embodiment of the present invention: the inner wall of the underflow port is in contact with the outer wall of the underflow pipe, the outer wall of the overflow pipe is in contact with the inner wall of the overflow port, the inner wall of the circular groove is in contact with the outer wall of the annular plate, and the outer wall of the vertical rod is in contact with the inner walls of both the first vertical groove and the second vertical groove.

[0022] As a further embodiment of the present invention: the outer wall of the gear is provided with a tooth groove, the tooth groove meshes with the spur gear, and the inner wall of the displacement tube is in contact with the outer wall of the connecting tube.

[0023] As a further embodiment of the present invention: the first bevel gear meshes with the second bevel gear, and the third bevel gear meshes with the fourth bevel gear.

[0024] As a further embodiment of the present invention: the outer wall of the displacement ring is provided with a limiting hole and a threaded hole, the inner wall of the limiting hole is in contact with the outer wall of the limiting rod, and the threaded hole is matched with the threaded rod.

[0025] Compared with the prior art, the beneficial effects of the present invention are:

[0026] 1. This invention achieves innovation and simplification of the production process by improving the process: through the one-step forming method of "atomization-cooling", the high-energy-consuming crushing and screening processes in the traditional process are completely eliminated, the process flow is shortened, and the equipment investment and maintenance costs are reduced.

[0027] 2. This invention significantly improves the overall quality of the product: it directly generates solid particles with high sphericity and smooth surface, resulting in good product flowability, stable bulk density, high whiteness, and no tendency to agglomerate during subsequent dissolution, with a faster dissolution rate and superior application performance.

[0028] 3. This invention has generated significant economic and environmental benefits: on the one hand, by avoiding breakage and loss, the product yield can be increased by more than 8%, while the overall energy consumption is greatly reduced; on the other hand, it eliminates dust and noise pollution from the source, realizes clean production, and is highly environmentally friendly.

[0029] 4. In conjunction with the improved production process, this invention also improves the hydrocyclone assembly. The hydrocyclone assembly is equipped with an installation mechanism and a moving mechanism. The baffle rotates to close the connecting pipe; the second motor drives the hydrocyclone body to move away from above the first collection pool, thus facilitating the operator's operation of the top and bottom of the hydrocyclone body; the displacement ring moves upward, automatically loosening the fixation between the first and second docking plates, facilitating the quick installation and disassembly of the underflow pipe and overflow pipe, thus facilitating the replacement of the underflow pipe and overflow pipe. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of the hydrocyclone assembly described in this invention;

[0031] Figure 2 This is a schematic diagram of the hydrocyclone body of the hydrocyclone assembly described in this invention;

[0032] Figure 3 This is a schematic diagram of the installation of the underflow pipe of the hydrocyclone assembly described in this invention;

[0033] Figure 4 This is a schematic diagram of the installation of the overflow pipe of the hydrocyclone assembly described in this invention;

[0034] Figure 5 This is a schematic diagram of the displacement tube of the hydrocyclone assembly described in this invention;

[0035] Figure 6 This is a schematic diagram of the internal structure of the connecting pipe of the hydrocyclone assembly described in this invention;

[0036] Figure 7 This is a schematic diagram of the installation of the displacement ring of the hydrocyclone assembly described in this invention.

[0037] In the diagram: 1. Support column; 2. Connecting pipe; 3. Hydrocyclone body; 4. Underflow pipe; 5. Overflow pipe; 6. Feed pipe; 7. Mounting mechanism; 701. Underflow port; 702. Positioning ring; 703. Threaded sleeve; 704. Overflow port; 705. First docking plate; 706. Second docking plate; 707. Circular groove; 708. Annular plate; 709. First vertical groove; 710. Second vertical groove; 711. Displacement ring; 712. Vertical rod; 713. Rotating rod; 714. Lower pressure plate; 8. Displacement mechanism; 801. Mounting base; 802. 803. First motor; 804. Baffle; 805. Limiting seat; 806. Gear rack; 807. Displacement tube; 808. Mounting bracket; 809. Second motor; 810. Connecting shaft; 811. Spur gear; 812. First bevel gear; 813. Second bevel gear; 814. Rotating shaft; 815. Third bevel gear; 816. Fourth bevel gear; 817. Threaded rod; 818. Support frame; 819. Limiting rod; 8000. First collection pool; 810. First collection pipe; 811. Second collection pool; 82. Second collection pipe; 83. Guide pipe. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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.

[0039] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of this invention, it should be noted that unless otherwise explicitly specified and limited, the terms "installed," "connected," "linked," and "set up" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. The following describes embodiments of the invention based on its overall structure.

[0040] Example 1: A method for preparing solid sodium silicate with a target modulus M=2.0 by water quenching with controllable particle size.

[0041] Raw materials and proportions: Quartz sand (SiO2≥98.5%, particle size 100 mesh) and soda ash (Na2CO3≥99.0%), precisely proportioned according to M=2.0.

[0042] In this embodiment of the invention, a process for preparing solid sodium silicate based on water quenching with controllable particle size is described in the following steps:

[0043] S1: Raw material melting and homogenization: High-temperature melting reaction is carried out in a gas-fired furnace at 1400℃. The melt is then subjected to static refining in a clarification zone to remove gases and impurities, resulting in a homogeneous, bubble-free sodium silicate melt.

[0044] S2: Water quenching with controllable particle size:

[0045] Step 1 (Constant Pressure and Temperature Melt Conveying): The homogeneous melt is introduced into an insulated buffer tank, and the outlet temperature is controlled at 1250℃. The melt flow rate is controlled at 100 kg / h using a high-temperature resistant gear pump, with a flow rate fluctuation of ≤±2.5%.

[0046] Step 2 (Melting and Dispersing): The melt is atomized and dispersed using a high-speed centrifugal atomizing disc (rotation speed of approximately 18,000 r / min) to form uniform droplets.

[0047] Step 3 (Droplet Quenching and Solidification): Using room temperature deionized water, a dense water mist field is formed through a ring-shaped water curtain generator. The water-to-melt mass ratio is controlled at 5:1, causing the droplets to be instantly cooled to below approximately 500°C within about 0.8 seconds, solidifying into solid glassy particles. Nitrogen gas is introduced into the quenching tower as a protective atmosphere.

[0048] S3: Solid-liquid separation and online classification: The quenched particle-water mixture is first dewatered by a high-frequency vibrating dewatering screen to remove most of the surface water, and then enters a hydrocyclone group for online classification to obtain mainstream products with a target particle size range of 0.1-0.3 mm.

[0049] S4: Deep Drying and Packaging: The graded wet granules are fed into a fluidized bed dryer and deep dried under 150°C hot air until the moisture content is 0.4%. After drying, they are cooled and then packaged with moisture protection.

[0050] In this embodiment, the production process is innovated and simplified: the "atomization-cooling" one-step forming method completely eliminates the energy-intensive crushing and screening processes in traditional processes, shortens the process flow, and reduces equipment investment and maintenance costs; it significantly improves the overall quality of the product: it directly generates solid particles with high sphericity and smooth surfaces, with good product flowability, stable bulk density, and high whiteness, and exhibits no tendency to agglomerate during subsequent dissolution, resulting in a faster dissolution rate and superior application performance; it generates significant economic and environmental benefits: on the one hand, by avoiding crushing losses, the product yield can be increased by more than 8%, while the overall energy consumption is significantly reduced; on the other hand, it eliminates dust and noise pollution at the source, achieving clean production and strong environmental friendliness.

[0051] Please refer to this carefully. Figures 1 to 7 The hydrocyclone assembly includes a support column 1, a connecting pipe 2 fixedly connected to the outer wall of the support column 1, a hydrocyclone body 3 at one end of the connecting pipe 2, an underflow pipe 4 and an overflow pipe 5 installed inside the hydrocyclone body 3, a feed pipe 6 connected to the connecting pipe 2 fixedly connected to the top of the support column 1, a second collection tank 11 fixedly connected above the support column 1, a second collection pipe 12 fixedly connected to the outer wall of the second collection tank 11, a first collection tank 9 set on the outer wall of the support column 1, a first collection pipe 10 fixedly connected to the outer wall of the first collection tank 9, a guide pipe 13 installed above the hydrocyclone body 3, the guide pipe 13 extending and suspended above the second collection tank 11, the underflow pipe 4 and the overflow pipe 5 being installed via an installation mechanism 7, and the hydrocyclone body 3 being displaced via a displacement mechanism 8.

[0052] In this embodiment: the material enters the connecting pipe 2 through the feed pipe 6, and then enters the hydrocyclone body 3 through the connecting pipe 2. It is classified by spiral flow in the hydrocyclone body 3. Large particles flow down along the underflow pipe 4 and enter the first collection tank 9 for collection, and are discharged through the first collection pipe 10. Small particles flow into the guide pipe 13 along the overflow pipe 5, and then flow into the second collection tank 11 for collection, and are discharged through the second collection pipe 12.

[0053] Please refer to this carefully. Figures 2 to 4The installation mechanism 7 includes an underflow port 701, which is fixedly connected to the bottom end of the hydrocyclone body 3. An underflow pipe 4 is slidably connected to the inner wall of the underflow port 701. A positioning ring 702 is fixedly connected to the outer wall of the underflow pipe 4. A threaded sleeve 703 is threadedly connected to the outer wall of the underflow port 701, and the threaded sleeve 703 is located on the outer wall of the underflow pipe 4. An overflow port 704 is fixedly connected to the top end of the hydrocyclone body 3. A first docking plate 705 is fixedly connected to the top end of the overflow port 704. A second docking plate 706 is fixedly connected to the bottom end of the guide pipe 13. The top end of the first docking plate 705 has a... The circular groove 707 has an annular plate 708 fixedly connected to the top of the overflow pipe 5. The overflow pipe 5 is slidably connected to the inner wall of the overflow port 704. The installation mechanism 7 also includes a first vertical groove 709, which is symmetrically opened on the outer wall of the first docking plate 705. The outer wall of the second docking plate 706 is symmetrically opened with a second vertical groove 710. The outer wall of the overflow port 704 is slidably connected with a displacement ring 711. The top of the displacement ring 711 is symmetrically fixedly connected with a vertical rod 712. The top of the vertical rod 712 is rotatably connected with a rotating rod 713. The top of the rotating rod 713 is fixedly connected with a lower pressure plate 714.

[0054] In this embodiment: when installing the underflow pipe 4, the underflow pipe 4 is connected to the inner wall of the underflow port 701, so that the positioning ring 702 contacts the bottom end of the underflow port 701. Then, the threaded sleeve 703 is threaded onto the outer wall of the underflow port 701, and the positioning ring 702 is pressed against the bottom end of the underflow port 701, thereby completing the installation of the underflow pipe 4. When disassembling the underflow pipe 4, the threaded sleeve 703 is removed from the underflow port 701, and then the underflow pipe 4 is moved out of the underflow port 701.

[0055] When installing the overflow pipe 5, it is connected to the inner wall of the overflow port 704. At this time, the annular plate 708 is connected into the circular groove 707 to limit the position of the overflow pipe 5. Then, the first docking plate 705 and the second docking plate 706 are aligned. The vertical rod 712 is connected to the first vertical groove 709 and the second vertical groove 710. The rotating rod 713 is rotated to a vertical position. Then, through the cooperation of the parts in the displacement mechanism 8, the displacement ring 711 is moved downward. The displacement of the displacement ring 711 causes the vertical rod 712 to move downward. The displacement of the vertical rod 712 causes the rotating rod 713 to move downward. The lower pressure plate 714 contacts the top of the second docking plate 706. The first docking plate 705 and the second docking plate 706 are pressed together, thereby completing the installation operation of the overflow pipe 5 and the guide pipe 13. When disassembling the overflow pipe 5, the displacement ring 711 is moved upward by the cooperation of the parts in the displacement mechanism 8. The displacement ring 711 moves the vertical rod 712, the rotating rod 713 and the lower pressure plate 714 upward, releasing the pressing operation between the first docking plate 705 and the second docking plate 706. Then, the rotating rod 713 is rotated, so that the rotating rod 713 and the lower pressure plate 714 are moved away from the top of the second docking plate 706, separating the second docking plate 706 from the first docking plate 705, thereby allowing the overflow pipe 5 and the guide pipe 13 to be disassembled.

[0056] During long-term operation, the underflow pipe 4 and the overflow pipe 5 are prone to wear due to particle impact and friction, resulting in a decrease in classification accuracy. Through the cooperation of the parts in the installation mechanism 7, it is easy to quickly install and disassemble the underflow pipe 4 and the overflow pipe 5, thereby facilitating the replacement of the underflow pipe 4 and the overflow pipe 5.

[0057] Please refer to this carefully. Figures 5 to 7The displacement mechanism 8 includes a mounting base 801, which is fixedly connected to the outer wall of the connecting pipe 2. A first motor 802 is mounted on the top of the mounting base 801. A baffle 803 is rotatably connected to the inner wall of the mounting base 801 and is connected to the output end of the first motor 802. A limit seat 804 is fixedly connected to the outer wall of the connecting pipe 2, and a gear 805 is fixedly connected to the outer wall of the limit seat 804. A displacement pipe 806 is fixedly connected to the outer wall of the hydrocyclone body 3. The displacement pipe 806 is slidably connected to the outer wall of the connecting pipe 2 through a silicone sealing ring. A mounting bracket 807 is fixedly connected to the top of the displacement pipe 806, and a second motor 808 is mounted on the top of the mounting bracket 807. A connecting shaft 809 is connected to the output end of the second motor 808, and a connecting shaft 809 is fixedly connected to the bottom end of the connecting shaft 809. The spur gear 810 contacts the rack 805. The displacement mechanism 8 also includes a first bevel gear 811, which is fixedly connected to the outer wall of the connecting shaft 809. A second bevel gear 812 is provided on the outer wall of the first bevel gear 811. A rotating shaft 813 is fixedly connected to one end of the second bevel gear 812. A third bevel gear 814 is fixedly connected to one end of the rotating shaft 813. A fourth bevel gear 815 is provided on the outer wall of the third bevel gear 814. A threaded rod 816 is fixedly connected to the top of the fourth bevel gear 815. A support frame 817 and a limiting rod 818 are fixedly connected to the top of the hydrocyclone body 3. The rotating shaft 813 and the threaded rod 816 are rotatably connected to the support frame 817. The limiting rod 818 and the threaded rod 816 both pass through the displacement ring 711.

[0058] In this embodiment: when replacing the underflow pipe 4 and overflow pipe 5 in a hydrocyclone, the first motor 802 can be started. The operation of the first motor 802 drives the baffle 803 to rotate, and the rotation of the baffle 803 closes the connecting pipe 2.

[0059] Then, the second motor 808 is started. The second motor 808 drives the connecting shaft 809 to rotate. The rotation of the connecting shaft 809 drives the spur gear 810 to rotate. The rotation of the spur gear 810 drives the rack 805 to move relative to the displacement tube 806, thereby causing the displacement tube 806 to slide on the outer wall of the connecting tube 2. The displacement of the displacement tube 806 causes the hydrocyclone body 3 to move away from the top of the first collection pool 9, thus facilitating the operator to operate the top and bottom of the hydrocyclone body 3.

[0060] Simultaneously, the rotation of the connecting shaft 809 drives the first bevel gear 811 to rotate, which in turn drives the second bevel gear 812 to rotate. The second bevel gear 812 then drives the rotating shaft 813 to rotate, which in turn drives the third bevel gear 814 to rotate. The third bevel gear 814 then drives the fourth bevel gear 815 to rotate, which in turn drives the threaded rod 816 to rotate. The threaded rod 816 then drives the displacement ring 711 to perform a displacement operation. When the hydrocyclone body 3 is removed from the first collection pool 9, the displacement ring 711 moves upward, automatically loosening the fixation between the first docking plate 705 and the second docking plate 706, thus facilitating the replacement of the overflow pipe 5. When the hydrocyclone body 3 moves above the first collection pool 9, the displacement ring 711 moves downward, and the lower pressure plate 714 presses the first docking plate 705 and the second docking plate 706 together, completing the automatic fixation.

[0061] Please refer to this carefully. Figures 2 to 4 The inner wall of the underflow outlet 701 is in contact with the outer wall of the underflow pipe 4, the outer wall of the overflow pipe 5 is in contact with the inner wall of the overflow outlet 704, the inner wall of the circular groove 707 is in contact with the outer wall of the annular plate 708, and the outer wall of the vertical rod 712 is in contact with the inner walls of the first vertical groove 709 and the second vertical groove 710.

[0062] In this embodiment: the underflow pipe 4 is connected to the inner wall of the underflow port 701, so that the positioning ring 702 contacts the bottom end of the underflow port 701. Then, the threaded sleeve 703 is threaded to the outer wall of the underflow port 701, and the positioning ring 702 is pressed tightly to the bottom end of the underflow port 701. The overflow pipe 5 is connected to the inner wall of the overflow port 704. At this time, the annular plate 708 is connected into the circular groove 707 to limit the position of the overflow pipe 5.

[0063] Please refer to this carefully. Figures 5 to 7 The outer wall of the rack 805 is provided with a tooth groove, which meshes with the spur gear 810. The inner wall of the displacement tube 806 is in contact with the outer wall of the connecting tube 2.

[0064] In this embodiment: the second motor 808 drives the connecting shaft 809 to rotate, the connecting shaft 809 rotates and drives the spur gear 810 to rotate, the spur gear 810 rotates and drives the rack 805 to move relative to the displacement tube 806, thereby causing the displacement tube 806 to slide on the outer wall of the connecting tube 2, and the displacement of the displacement tube 806 causes the hydrocyclone body 3 to move.

[0065] Please refer to this carefully. Figures 5 to 7 The first bevel gear 811 meshes with the second bevel gear 812, and the third bevel gear 814 meshes with the fourth bevel gear 815.

[0066] In this embodiment: the rotation of the connecting shaft 809 drives the first bevel gear 811 to rotate, the rotation of the first bevel gear 811 drives the second bevel gear 812 to rotate, the rotation of the second bevel gear 812 drives the rotating shaft 813 to rotate, the rotation of the rotating shaft 813 drives the third bevel gear 814 to rotate, the rotation of the third bevel gear 814 drives the fourth bevel gear 815 to rotate, and the rotation of the fourth bevel gear 815 drives the threaded rod 816 to rotate.

[0067] Please refer to this carefully. Figures 5 to 7 The outer wall of the displacement ring 711 is provided with a limiting hole and a threaded hole. The inner wall of the limiting hole fits with the outer wall of the limiting rod 818, and the threaded hole matches the threaded rod 816.

[0068] In this embodiment: the rotation of the threaded rod 816 drives the displacement ring 711 to move. At this time, the limiting rod 818 slides in the limiting hole to limit the displacement direction of the displacement ring 711.

[0069] Example 2: Preparation of solid sodium silicate with a target modulus M=2.5 based on controllable particle size and water quenching

[0070] Raw materials and proportions: Quartz sand (SiO2≥98.5%, particle size 150 mesh) and soda ash (Na2CO3≥99.0%), precisely proportioned according to M=2.5.

[0071] S1: Raw material melting and homogenization: High-temperature melting reaction is carried out in an electric melting furnace at 1450℃. The melt is then refined by bubbling in the clarification zone to remove gases and impurities, resulting in a homogeneous, bubble-free sodium silicate melt.

[0072] S2: Water quenching with controllable particle size:

[0073] Step 1 (Constant Pressure and Temperature Melt Conveying): The homogeneous melt is introduced into an insulated buffer tank, and the outlet temperature is controlled at 1320℃. The melt flow rate is controlled at 500 kg / h using a high-temperature resistant screw pump, with flow rate fluctuation ≤ ±2%.

[0074] Step 2 (Melting and Dispersing): The melt is atomized and dispersed using a high-speed centrifugal atomizing disc (rotation speed of approximately 15,000 r / min) to form uniform droplets.

[0075] Step 3 (Droplet Quenching and Solidification): Using room temperature industrial soft water, a dense water mist field is formed through a ring-shaped water curtain generator. The water-to-melt mass ratio is controlled at 10:1, causing the droplets to be instantly cooled to below approximately 550°C within about 0.5 seconds, solidifying into solid glassy particles. The quenching tower is filled with a nitrogen protective atmosphere.

[0076] S3: Solid-liquid separation and online classification: The quenched particle-water mixture is first dewatered by a high-frequency vibrating dewatering screen to remove most of the surface water, and then enters a hydrocyclone group for online classification to obtain mainstream products with a target particle size range of 0.2-0.8 mm.

[0077] S4: Deep Drying and Packaging: The graded wet granules are fed into a fluidized bed dryer and deep dried under 200℃ hot air until the moisture content is 0.35%. After drying, they are cooled and then packaged with moisture protection.

[0078] Example 3: Preparation of solid sodium silicate with a target modulus M=3.2 based on controllable particle size and water quenching

[0079] Raw materials and proportions: quartz sand (SiO2≥98.5%, particle size 200 mesh) and soda ash (Na2CO3≥99.0%), precisely proportioned according to M=3.2.

[0080] S1: Raw material melting and homogenization: High-temperature melting reaction is carried out in a gas-fired furnace at 1480℃. The melt is then refined in a clarification zone to obtain a homogeneous, bubble-free sodium silicate melt.

[0081] S2: Water quenching with controllable particle size:

[0082] Step 1 (Constant Pressure and Temperature Melt Conveying): The homogeneous melt is introduced into an insulated buffer tank, and the outlet temperature is controlled at 1380℃. The melt flow rate is controlled at 800 kg / h using a high-temperature resistant gear pump, with a flow rate fluctuation of ≤±2.5%.

[0083] Step 2 (Meltion Atomization and Dispersion): The melt is atomized and dispersed using a centrifugal atomizing disc (rotation speed of approximately 12000 r / min).

[0084] Step 3 (Droplet Quenching and Solidification): Using room temperature deionized water, the water-to-melt mass ratio is controlled at 12:1, allowing the droplets to be instantly cooled to below approximately 580°C within <1 second, completing the solidification process. Nitrogen gas is then introduced into the quenching tower.

[0085] S3: Solid-liquid separation and online classification: After primary dewatering by a high-frequency vibrating dewatering screen, the components are classified using a hydrocyclone to obtain mainstream products with a target particle size range of 0.1-0.5 mm.

[0086] S4: Deep Drying and Packaging: The graded wet granules are fed into a belt dryer and deep dried under 220℃ hot air until the moisture content is 0.28%. After drying, they are cooled and then packaged with moisture protection.

[0087] Comparative Example 1: Preparation of solid sodium silicate with a target modulus M=2.5 using a traditional water quenching-crushing process.

[0088] Raw materials and proportions: Same as in Example 2.

[0089] S1: Raw material melting and homogenization: Same as in Example 2.

[0090] S2: Water quenching: Homogeneous sodium silicate melt is directly poured into a water bath for rapid cooling, forming large, irregularly shaped glassy blocks.

[0091] S3: Crushing and Screening: The large glass blocks after water quenching are first coarsely crushed by a jaw crusher, then medium crushed by a double roll crusher, and finally screened by a vibrating screen to obtain products with the target particle size range (0.2-0.8 mm). Approximately 15% of fine powder (<0.1 mm) and unqualified large pieces (>0.8 mm) are generated during the crushing and screening process.

[0092] S4: Drying and packaging: Same as in Example 2.

[0093] Comparative Example 2: Preparation of solid sodium silicate with a target modulus M=2.5 using conventional water quenching process

[0094] Raw materials and proportions: Same as in Example 2.

[0095] S1: Raw material melting and homogenization: Same as in Example 2.

[0096] S2: Water quenching: Homogeneous sodium silicate melt is fed directly into a water quenching tank filled with room-temperature deionized water through a coarse nozzle in the form of a thin stream. The mass ratio of water to melt is approximately 10:1. Due to the lack of atomization, the melt breaks into particles and glass strips of varying sizes and highly irregular shapes under the impact of the water surface and its own surface tension.

[0097] S3: Solid-liquid separation and sieving: The water-quenched mixture is removed and dehydrated by a dewatering screen. It must then undergo multi-stage crushing and vibrating sieving to obtain a product with the target particle size range (0.2-0.8 mm). This process produces approximately 18% powder and non-conforming particles.

[0098] S4: Deep drying and packaging: Same as Example 2.

[0099] Comparative Example 3: Preparation of solid sodium silicate with a low mass ratio of water to melt (target modulus M=2.5)

[0100] Raw materials and proportions: Same as in Example 2.

[0101] S1: Raw material melting and homogenization: Same as in Example 2.

[0102] S2: Water quenching with controllable particle size:

[0103] Step 1 (Constant pressure and temperature conveying of melt): Same as Example 2.

[0104] Step 2 (Melting and Atomizing Dispersion): Same as Example 2.

[0105] Step 3 (Droplet Quenching and Solidification): The mass ratio of water to melt is controlled at 3:1. Due to insufficient cooling intensity, the droplets cannot be instantly cooled below the glass transition temperature during the falling process, and some droplets collide and stick together before solidification.

[0106] S3: Solid-liquid separation and online classification: Same as Example 2.

[0107] S4: Deep drying and packaging: Same as Example 2.

[0108] Product Testing and Data

[0109] To objectively evaluate the overall performance of the products prepared by the process of this invention, the mainstream products with the target particle size obtained in the above embodiments and comparative examples were uniformly tested. The test content, methods, and specific data are as follows:

[0110] 1. Testing Content and Methods

[0111] Sphericity: Using optical microscopy or dynamic image analysis, at least 200 particles were randomly selected, and the software was used to calculate the degree of closeness between their projection and the equivalent circle, and the average value was taken.

[0112] Bulk density: Determined using the graduated cylinder method according to GB / T 6286-2021 "Method for Determination of Bulk Density of Chemical Products".

[0113] Whiteness: Determined using a whiteness meter in accordance with GB / T 5950-2008 "Methods for measuring whiteness of building materials and non-metallic mineral products".

[0114] Solubility: Weigh 1.00g of sample and place it in a beaker containing 50mL of deionized water (25±1℃). Stir at a constant speed of 300r / min and record the time required from sample addition to complete dissolution and solution becoming clear and free of particulate matter.

[0115] Product yield: refers to the percentage of the mass of the target particle size mainstream product obtained after solid-liquid separation and online classification in step S3 relative to the total mass of the melt input in step S2 (based on the theoretical mass of the final solid product).

[0116] The specific test results for the above items are shown in the table below:

[0117] Test Result Statistics Table

[0118] The data in the table above shows that the sphericity of the products in all embodiments of the present invention is higher than 92%, and the bulk density is stable, indicating that the products have regular morphology and good uniformity. In contrast, the products in all comparative examples have extremely low sphericity, large fluctuations in bulk density, and irregular morphology. The whiteness of the products in all embodiments of the present invention is higher than 86%, superior to all comparative examples, indicating fewer impurities and better color. The dissolution time of all embodiments of the present invention is significantly shortened (38-55 seconds), and there is no clumping during the dissolution process. In contrast, the dissolution time of comparative examples 1 and 2 is longer than 110 seconds and there is severe clumping; comparative example 3 also has a prolonged dissolution time and slight clumping due to particle adhesion. The product yield of all embodiments of the present invention is higher than 95%, far exceeding the approximately 80% of comparative examples 1 and 2, and 88% of comparative example 3. This directly proves that the process of the present invention reduces material loss from the source, resulting in significant economic benefits.

[0119] In summary, the product testing and comparison above fully verify that the present invention, "Solid Sodium Silicate Preparation Process Based on Controllable Particle Size Water Quenching," has significantly outperformed traditional processes and defective alternatives in improving the overall quality of the product (morphology, uniformity, whiteness, and solubility) and increasing production yield.

[0120] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A process for preparing solid sodium silicate based on water quenching with controllable particle size, characterized in that, The specific steps are as follows: S1: Raw material melting and homogenization: Quartz sand and soda ash are used as raw materials. The raw materials are prepared according to the molar ratio of SiO2 to Na2O and the modulus M is 2.0 to 3.

3. The raw materials are melted at a high temperature of 1400℃~1500℃ to form sodium silicate melt. The melt is then subjected to static or bubble refining to obtain a homogeneous melt without bubbles. S2: Controllable particle size water quenching: The sodium silicate melt obtained in step S1 is atomized, dispersed, and then instantaneously quenched and solidified to obtain solid particles within a specific particle size range; S3: Solid-liquid separation and online classification: Using a hydrocyclone assembly, the mixture of quenched particles and water prepared in step S2 is subjected to efficient solid-liquid separation and online classification to obtain the mainstream product with the target particle size. S4: Deep drying and packaging: The wet granules after grading in step S3 are deep dried to reduce their moisture content to less than 0.5%, and then packaged in a moisture-proof manner after cooling. Step S2 specifically includes the following steps: Step 1: Constant pressure and temperature conveying of melt: The melt is introduced into the heat-insulating buffer bag, and its outlet temperature is controlled within the range of 1250℃~1400℃. It is then conveyed to the atomizing device at a constant flow rate through a high-temperature resistant pump, with the flow rate fluctuation range controlled within ±3%. Step 2, Melt atomization and dispersion: The melt is dispersed into uniform droplets using a centrifugal atomizing disc; Step 3, Droplet Quenching and Solidification: Use room temperature deionized water or industrial soft water as the cooling medium, and control the mass ratio of water to melt between 5:1 and 15:1, so that the droplet is cooled to below its glass transition temperature and solidified within 1 second; wherein the quenching process is carried out under an inert gas protective atmosphere. The hydrocyclone assembly includes a support column (1), a connecting pipe (2) fixedly connected to the outer wall of the support column (1), a hydrocyclone body (3) provided at one end of the connecting pipe (2), an underflow pipe (4) and an overflow pipe (5) installed inside the hydrocyclone body (3), a feed pipe (6) connected to the connecting pipe (2) fixedly connected to the top of the support column (1), and a second collection tank (11) fixedly connected above the support column (1). The outer wall of the second collection tank (11) is fixedly connected to the support column (1). A second collection pipe (12) is connected to the support column (1), and a first collection pool (9) is provided on the outer wall of the support column (1). A first collection pipe (10) is fixedly connected to the outer wall of the first collection pool (9). A guide pipe (13) is installed above the hydrocyclone body (3). The guide pipe (13) extends and is suspended above the second collection pool (11). The underflow pipe (4) and the overflow pipe (5) are installed through the installation mechanism (7). The hydrocyclone body (3) is displaced through the displacement mechanism (8). The installation mechanism (7) includes an underflow port (701), which is fixedly connected to the bottom end of the hydrocyclone body (3). The underflow tube (4) is slidably connected to the inner wall of the underflow port (701). A positioning ring (702) is fixedly connected to the outer wall of the underflow tube (4). A threaded sleeve (703) is threadedly connected to the outer wall of the underflow port (701). The threaded sleeve (703) is located on the outer wall of the underflow tube (4). An overflow port (704) is fixedly connected to the top of the device body (3). A first docking plate (705) is fixedly connected to the top of the overflow port (704). A second docking plate (706) is fixedly connected to the bottom of the guide pipe (13). A circular groove (707) is opened at the top of the first docking plate (705). An annular plate (708) is fixedly connected to the top of the overflow pipe (5). The overflow pipe (5) is slidably connected to the inner wall of the overflow port (704).

2. The solid sodium silicate preparation process based on controllable particle size water quenching according to claim 1, characterized in that, The installation mechanism (7) further includes a first vertical groove (709), which is symmetrically opened on the outer wall of the first docking plate (705). The outer wall of the second docking plate (706) is symmetrically opened with a second vertical groove (710). The outer wall of the overflow port (704) is slidably connected with a displacement ring (711). The top end of the displacement ring (711) is symmetrically fixedly connected with a vertical rod (712). The top end of the vertical rod (712) is rotatably connected with a rotating rod (713). The top end of the rotating rod (713) is fixedly connected with a lower pressure plate (714).

3. The solid sodium silicate preparation process based on controllable particle size water quenching according to claim 2, characterized in that, The displacement mechanism (8) includes a mounting base (801), which is fixedly connected to the outer wall of the connecting pipe (2). A first motor (802) is mounted on the top of the mounting base (801). A baffle (803) is rotatably connected to the inner wall of the mounting base (801). The baffle (803) is connected to the output end of the first motor (802). A limit seat (804) is fixedly connected to the outer wall of the connecting pipe (2). A rack (805) is fixedly connected to the outer wall of the limit seat (804). A displacement tube (806) is fixedly connected to the outer wall of the flow device body (3). The displacement tube (806) is slidably connected to the outer wall of the connecting tube (2). A mounting bracket (807) is fixedly connected to the top end of the displacement tube (806). A second motor (808) is installed at the top end of the mounting bracket (807). A connecting shaft (809) is connected to the output end of the second motor (808). A spur gear (810) is fixedly connected to the bottom end of the connecting shaft (809). The spur gear (810) is in contact with the rack (805).

4. The solid sodium silicate preparation process based on controllable particle size water quenching according to claim 3, characterized in that, The displacement mechanism (8) further includes a first bevel gear (811), which is fixedly connected to the outer wall of the connecting shaft (809). A second bevel gear (812) is provided on the outer wall of the first bevel gear (811). A rotating shaft (813) is fixedly connected to one end of the second bevel gear (812). A third bevel gear (814) is fixedly connected to one end of the rotating shaft (813). A fourth bevel gear (815) is provided on the outer wall of the third bevel gear (814). A threaded rod (816) is fixedly connected to the top of the fourth bevel gear (815). A support frame (817) and a limiting rod (818) are fixedly connected to the top of the hydrocyclone body (3). The rotating shaft (813) and the threaded rod (816) are rotatably connected to the support frame (817). The limiting rod (818) and the threaded rod (816) both pass through the displacement ring (711).

5. The solid sodium silicate preparation process based on controllable particle size water quenching according to claim 2, characterized in that, The inner wall of the underflow port (701) is in contact with the outer wall of the underflow pipe (4), the outer wall of the overflow pipe (5) is in contact with the inner wall of the overflow port (704), the inner wall of the circular groove (707) is in contact with the outer wall of the annular plate (708), and the outer wall of the vertical rod (712) is in contact with the inner walls of the first vertical groove (709) and the second vertical groove (710).

6. The solid sodium silicate preparation process based on controllable particle size water quenching according to claim 4, characterized in that, The outer wall of the rack (805) is provided with a tooth groove, which meshes with the spur gear (810). The inner wall of the displacement tube (806) is in contact with the outer wall of the connecting tube (2). The first bevel gear (811) meshes with the second bevel gear (812), and the third bevel gear (814) meshes with the fourth bevel gear (815).

7. The solid sodium silicate preparation process based on controllable particle size water quenching according to claim 4, characterized in that, The outer wall of the displacement ring (711) is provided with a limiting hole and a threaded hole. The inner wall of the limiting hole is in contact with the outer wall of the limiting rod (818), and the threaded hole is matched with the threaded rod (816).

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