Device for reducing content of ceramic fiber slag balls based on multistage separation

Abstract

The utility model discloses a device for reducing the content of ceramic fiber slag balls based on multi-stage separation, which comprises a three-stage airflow separation chamber which is internally divided into a first-stage airflow separation chamber, a second-stage airflow separation chamber, a third-stage airflow separation chamber and a fiber settling and collecting chamber, the first filter screen, the second filter screen and the third filter screen are arranged in the bottoms of the first-stage airflow separation chamber, the second-stage airflow separation chamber and the third-stage airflow separation chamber; the first, second and third centrifugal fans are arranged in the first, second and third-stage airflow separation chambers; the slag ball collecting box is arranged at the bottom of the third-stage airflow separation chamber; the bag-type dust collector is arranged at the top of the fiber settling and collecting chamber; the fiber conveying belt is used for conveying the pure ceramic fibers collected in the fiber settling and collecting chamber into the fiber collecting bin. According to the utility model, the combined use of multi-stage airflow separation and multi-stage screening is utilized, so that the content of slag balls in the ceramic fibers is obviously reduced, and the flexibility and the heat-insulating property of the ceramic fibers are obviously improved.

Description

A device for reducing ceramic fiber slag ball content based on multi-stage separation Technical Field

[0001] This utility model relates to the field of ceramic fiber production equipment technology, and in particular to a device for reducing the slag ball content of ceramic fibers based on multi-stage separation. Background Technology

[0002] Ceramic fiber is an important high-temperature insulation material, widely used in industrial furnace linings, high-temperature pipeline insulation, and other fields. However, during the production process of ceramic fiber, the presence of slag balls (incompletely fiberized particles; the national standard defines slag balls as unfiberized particles with a diameter > 0.212 mm) can seriously affect the quality and performance of the fiber. Excessive slag ball content can lead to decreased fiber flexibility, weakened insulation performance, and even affect its service life.

[0003] Currently, traditional ceramic fiber production processes mainly employ centrifugal spinning or blown fiber forming. The control of slag ball content relies primarily on raw material selection and optimization of the melting process. Slag ball separation efficiency is low and the effect is limited, making it difficult to meet the needs of high-end applications. Furthermore, the lack of a multi-stage collaborative separation system makes it difficult to precisely remove slag balls of different particle sizes.

[0004] Therefore, through beneficial exploration and research, the applicant has found a solution to the above problems, and the technical solution to be introduced below is the result of this research. Summary of the Invention

[0005] The technical problem to be solved by this utility model is to provide a device for reducing the slag ball content in ceramic fibers based on multi-stage separation, which addresses the shortcomings of the existing technology. By improving the slag ball separation technology, the slag ball content in ceramic fibers is significantly reduced (≤5%), thereby improving the quality and performance of the fibers.

[0006] The technical problem to be solved by this utility model can be achieved by the following technical solution:

[0007] A device for reducing the content of ceramic fiber slag balls based on multi-stage separation, comprising:

[0008] The three-stage airflow separation chamber has a feed inlet at the top. The three-stage airflow separation chamber is divided into a first-stage airflow separation chamber, a second-stage airflow separation chamber, a third-stage airflow separation chamber, and a fiber settling and collection chamber. The top opening of the first-stage airflow separation chamber is connected to the feed inlet on one side and to the top opening of the second-stage airflow separation chamber on the other side. The top opening of the third-stage airflow separation chamber is connected to the top opening of the second-stage airflow separation chamber on one side and to the top opening of the fiber settling and collection chamber on the other side.

[0009] A first filter screen, a second filter screen, and a third filter screen are installed at the bottom of the first-stage airflow separation chamber, the second-stage airflow separation chamber, and the third-stage airflow separation chamber;

[0010] A first centrifugal fan, a second centrifugal fan, and a third centrifugal fan are installed in the first-stage airflow separation chamber, the second-stage airflow separation chamber, and the third-stage airflow separation chamber, and located above the first filter screen, the second filter screen, and the third filter screen;

[0011] A slag ball collection box is installed at the bottom of the three-stage airflow separation chamber to collect the slag balls and short fibers screened out in the three-stage airflow separation chamber.

[0012] A bag filter, installed at the top of the fiber settling and collection chamber of the three-stage airflow separation chamber, is used to collect and separate fine fibers mixed in the exhaust gas; and

[0013] The fiber conveyor belt and the fiber collection bin are provided. The feed end of the fiber conveyor belt is located at the bottom of the fiber settling and collection chamber, and its discharge end extends to the fiber collection bin. The fiber conveyor belt is used to transport the pure ceramic fibers collected in the fiber settling and collection chamber to the fiber collection bin.

[0014] In a preferred embodiment of this utility model, the first filter screen, the second filter screen, and the third filter screen are respectively connected to a vibration motor.

[0015] In a preferred embodiment of this utility model, the apertures of the first filter screen, the second filter screen, and the third filter screen decrease progressively.

[0016] In a preferred embodiment of the present invention, the aperture of the first filter screen is 190-210 μm, the aperture of the second filter screen is 90-110 μm, and the aperture of the third filter screen is 40-60 μm.

[0017] In a preferred embodiment of this utility model, the first filter screen, the second filter screen and the third filter screen are made of wear-resistant alloy steel coated with a special coating.

[0018] In a preferred embodiment of this utility model, the wind speeds of the first centrifugal fan, the second centrifugal fan, and the third centrifugal fan decrease progressively.

[0019] In a preferred embodiment of the present invention, the wind speed of the first centrifugal fan is 8-12 m / s, the wind speed of the first centrifugal fan is 5-8 m / s, and the wind speed of the first centrifugal fan is 2-5 m / s.

[0020] Due to the adoption of the above technical solution, the beneficial effects of this utility model are as follows:

[0021] This invention utilizes a combination of multi-stage airflow separation and multi-stage sieving to significantly reduce the slag ball content in ceramic fibers, which can be reduced to below 5%. After reducing the slag ball content, the flexibility and thermal insulation performance of ceramic fibers are significantly improved. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 is a structural schematic diagram of this utility model.

[0024] Figure 2 is a schematic diagram of the airflow separation principle of this utility model.

[0025] Figure 3 is a schematic diagram of the screening principle of this utility model. Detailed Implementation

[0026] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below with reference to specific illustrations.

[0027] Referring to Figure 1, the figure shows a device for reducing the content of ceramic fiber slag balls based on multi-stage separation, including a three-stage airflow separation chamber 100, filter screens 200a, 200b, and 200c, centrifugal fans 300a, 300b, and 300c, a slag ball collection box 400, a bag filter 500, a fiber conveyor belt 600, and a fiber collection bin 700.

[0028] The top of the three-stage airflow separation chamber 100 has a feed inlet 101. The three-stage airflow separation chamber 100 is divided into a first-stage airflow separation chamber 110, a second-stage airflow separation chamber 120, a third-stage airflow separation chamber 130, and a fiber settling and collection chamber 140. The top opening of the first-stage airflow separation chamber 110 is connected to the feed inlet 101 on one side and to the top opening of the second-stage airflow separation chamber 120 on the other side. The top opening of the third-stage airflow separation chamber 130 is connected to the top opening of the second-stage airflow separation chamber 120 on one side and to the top opening of the fiber settling and collection chamber 140 on the other side.

[0029] Filter screens 200a, 200b, and 200c are disposed at the bottom of the first-stage airflow separation chamber 110, the second-stage airflow separation chamber 120, and the third-stage airflow separation chamber 130, respectively. Filter screens 200a, 200b, and 200c are connected to vibration motors 210a, 210b, and 210c, respectively. The pore size of filter screens 200a, 200b, and 200c decreases progressively. In this embodiment, the pore size of filter screen 200a is 190–210 μm, the pore size of filter screen 200b is 90–110 μm, and the pore size of filter screen 200c is 40–60 μm. c. Filter screens 200a, 200b, and 200c are made of wear-resistant alloy steel coated with a special coating to reduce fiber clogging.

[0030] Centrifugal fans 300a, 300b, and 300c are installed within the first-stage airflow separation chamber 110, the second-stage airflow separation chamber 120, and the third-stage airflow separation chamber 130, and are positioned above the filter screens 200a, 200b, and 200c. The air velocity of centrifugal fans 300a, 300b, and 300c decreases progressively. In this embodiment, the air velocity of centrifugal fan 300a is 8–12 m / s, the air velocity of centrifugal fan 300b is 5–8 m / s, and the air velocity of centrifugal fan 300c is 2–5 m / s.

[0031] The slag ball collection box 400 is located at the bottom of the three-stage airflow separation chamber 100 and is used to collect the slag balls and short fibers screened out in the three-stage airflow separation chamber 100.

[0032] The bag filter 500 is located at the top of the fiber settling and collection chamber 140 of the three-stage airflow separation chamber 100, and is used to collect and separate the fine fibers mixed in the exhaust gas.

[0033] The feed end of the fiber conveyor belt 600 is located at the bottom of the fiber settling and collection chamber 140 of the three-stage airflow separation chamber 100, and its discharge end extends to the fiber collection bin 700, which is used to transport the pure ceramic fibers collected in the fiber settling and collection chamber 140 to the fiber collection bin 700.

[0034] The working process of the device for reducing ceramic fiber slag ball content based on multi-stage separation of this invention is as follows:

[0035] 1. Raw materials (such as alumina, silicon dioxide, etc.) are melted at high temperature through the melting system 10 to form a uniform melt. The melt is then drawn into a mixture of fibers and slag balls through the fiberization system 20 using high-speed airflow or centrifugal spinning process. The mixture of fibers and slag balls is then fed into the feed port 101 of the three-stage airflow separation chamber 100.

[0036] 2. The mixture of fiber and slag balls first falls into the first-stage airflow separation chamber 110. The centrifugal fan 300a separates the mixture entering the first-stage airflow separation chamber 110. Some of the fiber passes through the airflow into the second-stage airflow separation chamber 120. Larger slag balls and short fibers settle onto the filter screen 200a for screening and are collected by the slag ball collection box 400.

[0037] 3. Centrifugal fan 300b separates the mixture entering the second-stage airflow separation chamber 120. Some fibers pass through the airflow into the third-stage airflow separation chamber 130. Medium-sized slag balls and short fibers settle onto the filter screen 200b for screening and are collected via the slag ball collection box 400.

[0038] 4. Centrifugal fan 300c separates the mixture entering the third-stage airflow separation chamber 130. The pure fibers enter the fiber settling and collection chamber 140 through the airflow. Smaller slag balls and short fibers settle onto the filter screen 200c for screening and are collected through the slag ball collection box 400.

[0039] 5. The bag filter 500 collects the fine fibers separated from the exhaust gas in the fiber settling and collection chamber 140. The pure fibers settle to the bottom of the fiber settling and collection chamber 140 and are transported to the fiber collection bin 700 via the fiber conveyor belt 600.

[0040] This invention employs airflow velocity control for separation. By adjusting the airflow velocity in stages, lighter fibers and heavier slag balls exhibit different trajectories within the airflow. Due to their light weight and large surface area, fibers are easily carried by the airflow and move upwards, undergoing step-by-step separation before entering the subsequent fiber collection stage. Slag balls, with their larger mass and coarser particle size, are more affected by gravity, making them difficult to carry by the airflow. They tend to settle downwards and enter the screening process from the bottom, as shown in Figure 2.

[0041] This invention features a multi-stage separation structure that achieves fine separation of slag balls and fibers of different particle sizes by adjusting the airflow velocity at each stage. The first stage has a high airflow velocity, separating larger slag balls; the second stage has a medium airflow velocity, separating medium-sized slag balls; and the third stage has a low airflow velocity, separating smaller slag balls.

[0042] After airflow separation, slag balls and some mixed short fibers first enter the filter screen. Simultaneously, a multi-stage filter screen is driven by mechanical vibration, utilizing particle size differences to achieve physical sieving. The screening device separates fibers and slag balls through the physical screen, further removing slag balls remaining after airflow classification. This invention employs a multi-stage filter screen, with the screen aperture selected according to the particle size distribution of fibers and slag balls within the airflow separation chamber at different gas flow rates. The filter screen of this invention is equipped with a vibration motor, which vibrates to ensure sufficient movement of fibers and slag balls on the filter screen, improving separation efficiency, as shown in Figure 3. Furthermore, the vibration frequency and amplitude can be adjusted according to production needs to ensure that fibers pass smoothly through the screen while large slag balls are retained.

[0043] The fibers, after passing through the final stage of gas separation, fall under gravity in the fiber settling chamber and are then transported by conveyor belt to the fiber collection bin. Fibers and slag balls that have passed through the filter screen, along with larger slag balls trapped on the screen, are collected separately in the slag ball collection bin 400. Based on diameter, they are sorted and reused. Larger slag balls can be reheated in the furnace to continue fiber production; smaller slag balls can be used as powder additives, etc.; the fibers can be collected again. A baghouse dust collector (such as one made of fiberglass) is installed at the gas outlet to trap ultrafine fibers in the exhaust gas through surface filtration. The filter bags are cleaned periodically using a back-flushing system.

[0044] This invention employs a multi-stage airflow separation chamber connected in series. In each stage, the airflow velocity gradually decreases, separating slag balls of different sizes from large to small diameter. Airflow separation utilizes the difference in the motion trajectories of slag balls and fibers in the airflow to achieve the separation of different particle sizes. Its working principle is as follows:

[0045] The fiber diameter should be 2–5 μm, the fiber length should be 150–250 mm, and the fiber should have internal pores. The slag balls are unfiberized, approximately spherical particles, with a diameter greater than 0.212 mm.

[0046] The airflow separation is divided into three stages. In each stage, gas with different flow rates is introduced, and the terminal settling velocity of the particles in the airflow is calculated according to Stokes' law:

[0047]

[0048] Where r is the particle radius, ρ p ρ is the particle density, ρf is the air density, and η is the air viscosity.

[0049] Heavier slag balls (r, ρ) pLarger particles (r) have a faster settling velocity (v), while fibers, being lighter (r), have a longer suspension time. When the settling velocity is greater than the horizontal gas flow velocity, the slag balls will settle to the bottom of the separation chamber; when the settling velocity is less than the horizontal gas flow velocity, the fibers will be carried by the airflow into the next separation chamber.

[0050] The slag balls have high density, large mass, and high inertia, so they are difficult to change direction with the airflow in high-speed airflow and tend to sink downwards; the fibers are light in mass and have a large surface area, so they are easily carried by high-speed airflow and rise with the airflow into the next stage of separation chamber.

[0051] In each stage of the airflow separation chamber, larger, denser slag particles settle first, while smaller particles follow the fibers into the next stage. The multi-stage airflow separation chambers gradually reduce the air velocity, allowing even smaller particles to settle and separate, precisely intercepting slag particles of different sizes. This achieves graded and batch-wise separation of large, medium, and small slag particles, resulting in higher separation efficiency and better separation effect compared to single-stage separation.

[0052] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A device for reducing the content of ceramic fiber slag balls based on multi-stage separation, characterized in that, include: A three-stage airflow separation chamber, the top of which has a feed inlet, is divided into a first-stage airflow separation chamber, a second-stage airflow separation chamber, a third-stage airflow separation chamber, and a fiber settling and collection chamber. The top opening of the first-stage airflow separation chamber communicates with both the feed inlet and the top opening of the second-stage airflow separation chamber. The top opening of the third-stage airflow separation chamber communicates with both the top opening of the second-stage airflow separation chamber and the top opening of the fiber settling and collection chamber. A first filter screen, a second filter screen, and a third filter screen are disposed at the bottom of the first, second, and third-stage airflow separation chambers. The third and second stage airflow separation chambers are located inside and above the first, second, and third filter screens, respectively. A slag ball collection box is located at the bottom of the third stage airflow separation chamber to collect the slag balls and short fibers separated in the chamber. A bag filter is located at the top of the fiber settling collection chamber in the third stage airflow separation chamber to collect the fine fibers separated from the exhaust gas. A fiber conveyor belt and a fiber collection bin are also present. The feed end of the fiber conveyor belt is located at the bottom of the fiber settling collection chamber, and its discharge end extends to the fiber collection bin to transport the pure ceramic fibers collected in the fiber settling collection chamber into the fiber collection bin.

2. The device for reducing ceramic fiber slag ball content based on multi-stage separation as described in claim 1, characterized in that, The first filter screen, the second filter screen, and the third filter screen are each connected to a vibration motor.

3. The device for reducing ceramic fiber slag ball content based on multi-stage separation as described in claim 1, characterized in that, The aperture of the first filter screen, the second filter screen, and the third filter screen decreases progressively.

4. The device for reducing ceramic fiber slag ball content based on multi-stage separation as described in claim 3, characterized in that, The first filter screen has a pore size of 190–210 μm, the second filter screen has a pore size of 90–110 μm, and the third filter screen has a pore size of 40–60 μm.

5. The device for reducing ceramic fiber slag ball content based on multi-stage separation as described in claim 1, characterized in that, The first, second, and third filter screens are made of wear-resistant alloy steel coated with a special coating.

6. The device for reducing ceramic fiber slag ball content based on multi-stage separation as described in claim 1, characterized in that, The wind speeds of the first centrifugal fan, the second centrifugal fan, and the third centrifugal fan decrease progressively.

7. The device for reducing ceramic fiber slag ball content based on multi-stage separation as described in claim 6, characterized in that, The wind speed of the first centrifugal fan is 8-12 m / s, the wind speed of the first centrifugal fan is 5-8 m / s, and the wind speed of the first centrifugal fan is 2-5 m / s.

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