C120 porcelain body and method for producing the same

Abstract

This invention relates to the field of electrical porcelain production technology, specifically disclosing a C120 porcelain blank, comprising the following components and weights: 20-30 parts high-quality clay, 15-25 parts silica powder, 15-25 parts kaolin, 12-22 parts illite, 2-6 parts potassium microcline, and 5-15 parts clay. This invention also provides a method for preparing the C120 porcelain blank, comprising batching the C120 porcelain blank according to the above-mentioned proportions, and then processing it according to a ball milling-pressure filtration-aging process to obtain the porcelain blank material. This solution aims to address the problems of low cost-effectiveness and high product dispersion in current porcelain insulators when achieving the required mechanical strength for medium-strength porcelain.

Description

Technical Field

[0001] This invention relates to the field of electrical porcelain production technology, specifically to a C120 porcelain blank and its preparation method. Background Technology

[0002] With the rapid development of the power industry, the demand for porcelain insulators is increasing, and the performance requirements for porcelain insulators are also becoming higher. Among them, improving the mechanical strength performance of porcelain insulators has become the key performance indicator for insulators to maintain their dominant position.

[0003] The current industry practice is to use large quantities of expensive aluminum oxide raw materials to increase the density and strength of electrical porcelain, as follows: Formulation design stage: Large-scale introduction of alumina raw materials → Reduction in the use of siliceous raw materials and local clay → Significant increase in billet formulation cost → Completion of billet formulation design.

[0004] This approach, for example, is exemplified by a raw material formula and method for manufacturing high-alumina porcelain insulators, as disclosed in patent publication number CN110922171B. This technology discloses the use of 35 parts bauxite, 20 parts kaolinite, 20 parts feldspar, 15 parts mullite, 15 parts illite, 10 parts clay, 10 parts tungsten clay, 8 parts pearlite clay, 4 parts garnet, and 5 parts fumed silica to produce high-alumina porcelain insulators. The amount of bauxite used in this disclosed technology is typical of cases with high aluminum oxide content. Although this method can enable the insulator to achieve a bending strength of over 108.6 MPa after glazing, the cost is still high.

[0005] Another patent, CN102838343B, discloses a formula for a medium-strength electrical porcelain blank made of high silica. This formula mentions the use of 20-22 parts of Dongsheng clay, 16-20 parts of Jiangjin clay, 16-20 parts of Jingyang clay, 3-6 parts of bauxite, 16-20 parts of Yongchuan clay, and 24-26 parts of quartz powder. The electrical porcelain made with this formula has properties that exceed the GB8411 standard for medium-strength porcelain, including a bending strength of ≥110 MPa. Although this formula reduces the amount of bauxite used, it still requires bauxite, so the cost is still relatively high.

[0006] In addition, to reduce raw material costs and improve the utilization rate of waste materials, the inventors have proposed a high-performance, green, and environmentally friendly electrical porcelain material and its manufacturing method, as disclosed in patent publication number CN119683968A. This electrical porcelain material uses 17-27 parts of Jiangjin clay, 1-3 parts of Yongchuan clay, 10-20 parts of quartz powder, 12-22 parts of Dongsheng clay, 7-17 parts of Jingyang clay, 1-5 parts of bauxite, 2-6 parts of potassium feldspar, and 21-31 parts of wastewater recovery material from sewage treatment plants as its formula. This technology can realize the reuse of wastewater recovery material. However, the acquisition of this wastewater recovery material requires strict pretreatment processes such as sieving and iron removal to remove iron impurities and coarse particles. Moreover, since this waste comes from the electrical porcelain production process, its production volume is limited and it is difficult to meet the raw material supply needs of large-scale industrial production. Therefore, there is an urgent need to develop a product that uses less alumina raw materials, achieves a significant reduction in cost, and has high mechanical strength. Summary of the Invention

[0007] The present invention aims to provide a C120 ceramic blank and its preparation method to solve the problems of low cost performance and high product dispersion in current ceramic insulators when they meet the mechanical strength requirements of medium-strength ceramics.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: A C120 porcelain blank comprises the following components and weight groups: 20-30 parts of high clay, 15-25 parts of silica powder, 15-25 parts of kaolin, 12-22 parts of illite, 2-6 parts of potassium microcline, and 5-15 parts of clay.

[0009] Preferably, as an improvement, it also includes 0-2 parts of calcined kaolin.

[0010] Preferably, as an improvement, it also includes 0-4 parts of hard soil.

[0011] Preferably, as an improvement, the high-clay is Dongsheng high-clay.

[0012] Preferably, as an improvement, the illite is Lushan illite.

[0013] Preferably, as an improvement, the clay is cloud platform clay.

[0014] Preferably, as an improvement, the high clay comprises 24-27 parts, silica powder 18-23 parts, and illite 14-17 parts.

[0015] The present invention also provides a method for preparing C120 porcelain blank, wherein the C120 porcelain blank is prepared by batching the ingredients, and after the batching of each group is completed, the porcelain blank material is obtained by processing it according to the process of ball milling-squeezing mud-aging.

[0016] Preferably, as an improvement, the ball milling process is carried out in at least two stages, with a set ball milling time after each stage, and a fineness test after each stage. The ball milling process is only carried out again or proceeds to the next process after the set requirements are met.

[0017] Preferably, as an improvement, a particle size distribution test is performed on the ball milling during the last loading. If the particle size distribution is acceptable, the ball milling proceeds to the next process of pressure filtration. If the particle size distribution is unacceptable, the ball milling is repeated until the particle size distribution is acceptable.

[0018] Preferably, as an improvement, the passing conditions for particle size distribution testing are: the proportion of particles smaller than 20 μm is >80% and the particle fineness D50 is controlled between 3 and 9 μm; to avoid the mud material being too fine (D50). 50 If the clay is <3μm, the drainage rate of the blank will be too slow, and the blank will shrink too much. These two factors directly lead to internal cracks in the blank, making it unusable. If the clay is too coarse (D... 50 If the micrometer is greater than 6μm, the internal density of the porcelain will be low, resulting in poor microstructure and ultimately reducing the electromechanical strength of the porcelain.

[0019] The principles and advantages of this invention are as follows: 1. This invention uses a large amount of low-cost clay (such as Yongchuan Guanyin clay, Yuntai clay, and Dongsheng high-alumina clay), while using a small amount of relatively expensive calcined kaolin and does not use high-priced raw materials such as bauxite. This allows the raw material cost to be controlled to no more than 650 yuan / ton. Compared with the raw material formula for making high-alumina porcelain insulators disclosed in CN110922171B, the raw material formula for making high-alumina porcelain insulators in CN110922171B has a higher cost than this invention because it uses a large proportion of expensive components. The electric porcelain blank formula disclosed in CN102838343B is also more than 20% higher than this patent.

[0020] 2. This invention uses silicon micro powder with uniform particle size, which solves the problem of large dispersibility of ceramic materials caused by coarse particles in conventional quartz powder.

[0021] 3. This invention employs multi-stage ball milling, which reduces the difficulty of single-stage ball milling, helps to grind coarse particles into finer particles more quickly, and allows for control of the particle size distribution of the mud after multi-stage ball milling. This invention ensures that the particle size distribution is optimal by controlling the particle ratio to: >80% of particles smaller than 20μm and the particle size D50 is controlled between 3 and 9μm. It also avoids the impact on the mud caused by excessive wear of the grinding media during single-stage ball milling that goes undetected. Attached Figure Description

[0022] Figure 1 This is a flowchart of the preparation method according to an embodiment of the present invention. Detailed Implementation

[0023] The following detailed description illustrates the specific implementation method: A C120 porcelain blank contains the following components and their weight ratios: 20-30 parts high clay, 0-2 parts calcined kaolin, 15-25 parts silica powder, 15-25 parts kaolin, 12-22 parts illite, 0-4 parts hard clay, 2-6 parts potassium microcline, and 5-15 parts clay.

[0024] The high clay used is Dongsheng high clay, the Guanyin clay is Yongchuan Guanyin clay, the illite is Lushan illite, the hard soil is Yongchuan hard soil, and the clay is Yuntai clay.

[0025] The preferred composition is 24-27 parts of Dongsheng high clay, 1-2 parts of calcined kaolin, 18-23 parts of silica powder, 17-25 parts of Yongchuan Guanyin clay, 14-17 parts of Lushan illite, 1-3 parts of Yongchuan hard soil, 4-6 parts of potassium microcline, and 6-12 parts of Yuntai clay.

[0026] A method for preparing C120 ceramic blank includes the following steps: The C120 porcelain blank material was prepared according to the above-mentioned batching process. After the batching of each group was completed, it was processed according to the process of ball milling, pressing mud and aging to obtain C120 porcelain blank material.

[0027] In this embodiment, the ball milling process is carried out in two stages, that is, the ingredients to be ball milled are divided into two batches and ball milled separately. After the first loading, the ball milling time is set, for example, 3 hours. After the ball milling is completed, the fineness is tested. If the fineness test is qualified, the second loading is carried out. If it is not qualified, the ball milling is carried out again until the fineness test is qualified. After the second loading, the ball milling time is set. The second ball milling time is shorter than the first ball milling time. In this embodiment, the ball milling time after the second loading is 1 hour. The particle size distribution of the raw material after the ball milling is tested. If the particle size distribution is qualified, it enters the next process of pressure filtration. If the particle size distribution is not qualified, the ball milling time is set again for the second loading until the particle size distribution is qualified.

[0028] The qualified conditions for particle size distribution test are: the proportion of particles smaller than 20μm is >80% and the particle fineness D50 is controlled between 3 and 9μm.

[0029] This embodiment also provides a method for manufacturing electrical porcelain, including forming an electrical porcelain blank using the C120 porcelain blank material obtained above, drying the blank after forming, firing the blank after drying, and conducting product testing on the obtained electrical porcelain after firing.

[0030] For cases requiring glazing for testing, the glaze is applied first and then fired after the porcelain blank is formed. After firing, the glazed porcelain is then subjected to product testing.

[0031] To screen for the optimal formula, the inventors designed numerous exploratory experiments. The following are seven representative C120 porcelain body formulas, the specific composition of which is shown in Table 1. The experimental methods for the seven formulas are exactly the same.

[0032] Table 1 - Details of Multi-Round Formulations

[0033] The specific requirements for the components in the above table are as follows: 1. Dongsheng high-clay clay requires a bonding strength of over 2.5 MPa, a hydration rate of over 60%, a silica content of over 50%, an alumina content of over 18%, and an iron oxide content of less than 2.5%. 2. Calcined kaolin requires an alumina content of less than 44% and greater than 35%, a silica content of greater than 50%, an iron oxide content of less than 1.5%, and a mechanical iron content of less than 0.01%. 3. The silica powder must have a fineness of less than 5% residue on a 250-mesh sieve, a mechanical iron content of less than 0.02%, a silica content of greater than 95%, and an iron oxide content of less than 0.8%. 4. Yongchuan Guanyin soil requires a hydration rate greater than 60%, a binding strength greater than 0.8 MPa, a silica content greater than 60%, an alumina content greater than 15%, and an iron oxide content less than 1.80%. 5. Lushan illite requires a potassium oxide content greater than 6%, a silicon dioxide content greater than 35%, an aluminum oxide content greater than 30%, an iron oxide content less than 2.0%, and a mechanical iron content less than 0.015%. 6. Yongchuan hard soil requires an iron oxide content of less than 1.2%, an aluminum oxide content of more than 12%, a silicon dioxide content of more than 60%, a binding strength of more than 0.6 MPa, and a hydration rate of more than 10%. 7. Potassium microcline requires a potassium oxide to sodium oxide content greater than 13%, an iron oxide content less than 0.7%, a mechanical iron content less than 0.005%, and a fineness of less than 15% residue on a 250-mesh sieve. 8. The requirements for Yuntai clay are: alumina content greater than 20%, silica content greater than 60%, iron oxide content less than 1.6%, hydration rate greater than 10%, and bonding strength greater than 0.8 MPa.

[0034] The above formula shows the mass percentage of each raw material, and the cost of the above formula is between 600 and 650 yuan / ton.

[0035] For each of the above formulations, process performance tests, ceramic performance tests, and mechanical strength tests were conducted. The specific results are shown in Table 2 - Process Performance Test Table, Table 3 - Ceramic Performance Test Table, and Table 4 - Mechanical Strength Test Table, respectively.

[0036] Table 2 - Process Performance Test Table for Multi-Round Formulations

[0037] Table 3 - Test Table of Porcelain Performance for Multi-Round Formulations

[0038] Table 4 - Mechanical Strength Test Table for Multi-Round Formulations

[0039] The test data above shows that Formula 1 is relatively low in terms of plasticity and ceramic body specific gravity. In the mechanical strength test, except for the flexural strength of the ceramic in the upper firing position which does not meet the performance requirements of GB / T8411 for C120 ceramic insulation materials (not less than 90MPa for unglazed and not less than 110MPa for glazed), the mechanical strength of the middle and lower firing positions meets the national standard requirements. However, compared with the other formulas, the mechanical strength is slightly worse.

[0040] Compared with Formula 1, Formula 2 has improved plasticity and ceramic body specific gravity. The strength after glazing can meet the national standard requirements. However, the flexural strength of the ceramic at the medium firing position (89MPa) is close to the national standard requirements.

[0041] All mechanical strength tests of formulas 3 to 7 met the national standard requirements of no less than 90 MPa for unglazed and no less than 110 MPa for glazed. In particular, formulas 4 and 6 can exceed 110 MPa and even reach 118 MPa in terms of porcelain bending strength, which is equivalent to the bending strength of ordinary C120 porcelain material after glazing. Furthermore, the mechanical strength of formulas 4 to 7 after glazing can reach or even exceed 130 MPa, far exceeding the requirements of conventional C120.

[0042] Compared to formula 3, formula 4 increases the amount of Dongsheng clay and potassium feldspar, resulting in excellent performance in terms of processing properties, porcelain properties, and mechanical strength. Moreover, the mechanical properties, whether white or brown glaze, exceed 120 MPa in flexural strength.

[0043] In addition, in this embodiment, due to the large amount of low-cost Sichuan Guanyin clay and Yuntai clay used, and the small amount of high-cost calcined kaolin used, the cost is reduced from the original (780-800) yuan / ton to (600-650) yuan / ton, which greatly reduces the enterprise's production and manufacturing costs.

[0044] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A C120 porcelain body characterized in that, The components and weights include: high clay 20-30 parts, silica powder 15-25 parts, guanyin clay 15-25 parts, illite 12-22 parts, potassium microcline 2-6 parts and clay 5-15 parts.

2. A C120 biscuit according to claim 1, characterised in that: It also includes calcined kaolin 0-2 parts.

3. A C120 biscuit according to claim 2, characterised in that: It also includes hard soil 0-4 parts.

4. A C120 biscuit according to claim 1, characterized in that: The high clay is Dongsheng high clay.

5. A C120 biscuit according to claim 1, characterized in that: The illite is Lushan illite.

6. A C120 porcelain body according to claim 1, characterized in that: The clay is Yunta clay.

7. A C120 porcelain body according to claim 1, characterized in that: The high clay is 24-27 parts, the silica powder is 18-23 parts, and the illite is 14-17 parts.

8. A method of making a C120 porcelain body characterized by: According to any one of claims 1-7, the C120 porcelain body material is prepared by ball milling, squeezing and aging.

9. A method of producing a C120 biscuit according to claim 8, characterised in that: In the ball milling process, the loading is carried out at least twice, and after each loading, the ball milling is carried out for a set time, and after each completion, the fineness is detected, and after each ball milling reaches the set requirement, the next ball milling or the next process is carried out.

10. A method of producing a C120 biscuit according to claim 9, characterised in that: The particle size distribution test is carried out on the last ball milling, and if the particle size distribution is qualified, it enters the next process of pressure filtration, and if the particle size distribution is unqualified, it is ball milled again until the particle size distribution is qualified.

Images