An apparatus for producing a mullite-sapphire composite

Abstract

The utility model provides a kind of production device of mullite-corundum composite material, the production device of mullite-corundum composite material includes the reaction module, separation module and calcining module connected in sequence;The reaction module includes the magnetic separation unit, batching unit, heat exchange unit and reaction unit connected in sequence;The separation module includes the filter washing unit, slurry unit and filter unit connected in sequence;The calcining module includes the drying unit, calcining unit and cooling unit connected in sequence;And the magnetic separation unit of the reaction module is also connected with the slurry unit of the separation module;The production device can realize batch processing of fly ash, selectively removes amorphous silicon dioxide in fly ash, simultaneously converts amorphous alumina in fly ash into corundum, and prepares mullite-corundum composite material with aluminium silicon ratio ≥2.7.

Description

Technical Field

[0001] This utility model belongs to the field of mullite-corundum composite material preparation technology, and relates to a production device for mullite-corundum composite materials. Background Technology

[0002] Mullite is a binary solid solution compound composed of alumina and silicon dioxide, and is the most stable compound in the Al₂O₃-SiO₂ binary phase diagram. Mullite possesses many excellent physical properties, such as high fracture toughness, high temperature resistance, oxidation resistance, thermal shock resistance, creep resistance, low thermal conductivity, strong electrical insulation, and low dielectric constant. It can be used in various composite materials and has been widely researched and applied in chemical, energy, environmental, defense, power, and metallurgical fields. High-alumina fly ash itself is rich in mullite and is a potential raw material for preparing mullite products. However, in addition to containing a large amount of mullite and a small amount of corundum, high-alumina fly ash also contains a certain amount of amorphous silicon dioxide and amorphous alumina, as well as small amounts of impurities such as iron, calcium, and titanium, which seriously affect the performance and application of mullite. Therefore, designing a reasonable production process is crucial to solving these problems.

[0003] CN112707716A discloses a mullite-corundum composite ceramic, its preparation method, and its uses. The method includes the following steps: (1) mixing fly ash with an alkaline solution and performing alkaline activation treatment to obtain activated fly ash, and then classifying the activated fly ash by particle size to obtain activated fly ash of different particle sizes; (2) compounding the activated fly ash of different particle sizes to obtain compounded fly ash, and performing a molding process on the compounded fly ash to obtain a ceramic body; (3) sintering the ceramic body to obtain a mullite-corundum composite ceramic. This method uses a strong alkali for activation, which poses certain safety hazards, and does not fully utilize amorphous alumina (which is removed along with amorphous silica), and the removed amorphous silica cannot be utilized at a high value.

[0004] In summary, how to efficiently remove and transform impurities such as amorphous silica and amorphous alumina from high-alumina fly ash to prepare mullite-corundum composite materials is a key problem that urgently needs to be solved. Utility Model Content

[0005] To address the problems existing in the prior art, the purpose of this utility model is to provide a production device for mullite-corundum composite materials. The production device, through the optimized design of the overall process, selectively removes amorphous silica from fly ash and simultaneously converts amorphous alumina in fly ash into corundum, thereby obtaining a high-performance mullite-corundum composite material. The production device is highly efficient and energy-saving, and has good application prospects.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] In a first aspect, this utility model provides a production device for mullite-corundum composite materials, the production device for mullite-corundum composite materials comprising a reaction module, a separation module and a calcination module connected in sequence.

[0008] The reaction module includes a magnetic separation unit, a batching unit, a heat exchange unit, and a reaction unit connected in sequence.

[0009] The separation module includes a filtration and washing unit, a pulping unit, and a filtration unit connected in sequence.

[0010] The calcination module includes a drying unit, a calcination unit, and a cooling unit connected in sequence.

[0011] Furthermore, the magnetic separation unit of the reaction module is also connected to the pulping unit of the separation module.

[0012] The following are preferred technical solutions of this utility model, but are not intended to limit the technical solutions provided by this utility model. Through the following technical solutions, the technical objectives and beneficial effects of this utility model can be better achieved and realized.

[0013] As a preferred technical solution of this utility model, the magnetic separation unit includes a screening machine, a magnetic separator, and a first buffer chamber connected in sequence.

[0014] The first buffer chamber is connected to the batching unit via a first conveyor and to the pulping unit via a second conveyor.

[0015] In this invention, the screening machine is used to select large unburned coal particles and large impurities; the magnetic separator is used to remove magnetic iron compounds from fly ash and to realize the recycling of iron-containing compounds.

[0016] As a preferred technical solution of this utility model, the batching unit includes a batching tank.

[0017] The heat exchange unit includes a first heat exchanger.

[0018] The reaction unit includes a reaction vessel.

[0019] In this invention, the reactor is equipped with a heating jacket, and, exemplarily, is heated by saturated steam, hot water, heat transfer oil, or molten salt as a heat source.

[0020] As a preferred technical solution of this utility model, the filtration and washing unit includes a first filter press, a first filtrate tank and a washing liquid tank, wherein the first filter press is connected to the first filtrate tank and the first filter press and the washing liquid tank form a cyclic connection.

[0021] As a preferred technical solution of this utility model, the first filter press includes a plate and frame filter press.

[0022] The number of washing liquid tanks is at least two, such as two, three, four, five, six or seven, but is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0023] As a preferred technical solution of this utility model, the slurry unit includes a slurry tank, a first ball mill, and a buffer tank connected in sequence.

[0024] As a preferred embodiment of the present invention, the filtration unit includes a second filter press and a second filtrate tank connected in sequence.

[0025] The second filtrate tank is also connected to the first filter press.

[0026] In this invention, the filtration washing unit employs a multi-stage countercurrent washing method. For example, assuming the filtration washing unit includes three washing liquid tanks, named a primary washing liquid tank, a secondary washing liquid tank, and a tertiary washing liquid tank, the washing process is as follows: First, the washing liquid from the secondary washing liquid tank is used to perform a primary washing of the filter cake in the first filter press, and the washing liquid flows into the primary washing liquid tank. Then, the washing liquid from the tertiary washing liquid tank is used to perform a secondary washing of the filter cake in the first filter press, and the washing liquid flows into the secondary washing liquid tank. Finally, the filtrate from the second filter press is used to perform a tertiary washing of the filter cake in the first filter press, and the washing liquid flows into the tertiary washing liquid tank, thus completing the washing process.

[0027] As a preferred technical solution of this utility model, the drying unit includes a dryer.

[0028] As a preferred technical solution of this utility model, the calcination unit includes a low-temperature pyrolysis furnace and a high-temperature pyrolysis furnace connected in sequence.

[0029] In this invention, the low-temperature pyrolysis furnace can prevent the oxidation and decomposition of ammonia-containing gas at high temperatures, thus significantly improving the recovery rate of ammonia-containing gas. The high-temperature pyrolysis furnace can allow silicon-containing gas to fully volatilize, thereby increasing the removal rate of amorphous SiO2 from mullite. The combination of low-temperature and high-temperature pyrolysis furnaces can also effectively prevent the excessive decomposition of mullite in fly ash, thereby increasing the content of mullite, the main effective component in the product.

[0030] The low-temperature pyrolysis furnace is also connected to a first dust removal mechanism.

[0031] The high-temperature pyrolysis furnace is also connected to a second dust removal mechanism and a second heat exchanger.

[0032] In this invention, a suitable heat exchange medium (such as water, air, or thermal oil) is selected. After exchanging heat with the high-temperature gas from the high-temperature pyrolysis furnace in the second heat exchanger, it can be used to heat the ingredients in the first heat exchanger and to heat the reaction vessel, thereby achieving the rational utilization of energy.

[0033] As a preferred embodiment of this invention, the cooling unit includes a cooling machine.

[0034] The cooler is also connected in sequence to a second ball mill.

[0035] A second buffer chamber is also provided between the cooler and the second ball mill.

[0036] In this invention, the production apparatus also includes, but is not limited to, commonly used material conveying equipment (such as conveyors, gas pumps, and liquid pumps), flow meters, pneumatic valves, temperature sensors, and pH meters, which can be installed according to the process requirements.

[0037] In addition, the materials of the first heat exchanger and the parts of the reactor that come into direct contact with the materials are impregnated graphite or Monel alloy.

[0038] Secondly, this utility model provides a method for operating the production apparatus described in the first aspect, the method comprising:

[0039] Using fly ash as a solid raw material, a screening machine is used to remove large particles. The ash undersize is then subjected to a magnetic separator to remove iron compounds, yielding de-ironized ash. The obtained de-ironized ash enters the first buffer silo, and the de-ironized ash in the first buffer silo is fed into the batching tank according to the required weight, with a solution volume to solid mass ratio of 2-10 m³ / h. 3 The mixture is prepared in a ratio of / t and mixed with the reaction medium solution (ammonium salt solution). After the ingredients are prepared, the mixture is heated to 40-150℃ through a heat exchanger and then sent into the reactor for reaction. The gas generated during the reaction is discharged from the reactor and recycled.

[0040] After the reaction is complete, the reaction slurry is fed into a filter press for solid-liquid separation. The resulting filtrate is stored in the first filtrate tank. The filter cake is washed using filtrate from the second filter press in conjunction with a multi-stage washing tank to achieve multi-stage countercurrent washing. The mass ratio of washing liquid volume to filter cake (dry basis) is controlled at (0.5-10):1. The washed filter cake is fed into a slurry tank and mixed with water and de-ferroalloy ash from the first buffer tank to obtain a slurry with a solid content of 30%-60%, wherein the mass ratio of de-ferroalloy ash to filter cake (dry basis) is (0.01-3):1. The resulting slurry is fed into a ball mill to obtain solid material with a particle size ≤60μm (D90). The filter cake obtained after pressing the obtained solid material through the second filter press is the intermediate product.

[0041] The intermediate product is fed into a dryer to remove moisture, yielding a dried product with a moisture content ≤1wt%. The dried product is then fed into a low-temperature pyrolysis furnace, where it undergoes a low-temperature pyrolysis reaction at 150-400℃, yielding a low-temperature pyrolysis solid product and ammonia-containing flue gas. The ammonia-containing flue gas is purified by dust removal and then absorbed and utilized. The low-temperature pyrolysis solid product is fed into a high-temperature pyrolysis furnace, where it undergoes a high-temperature pyrolysis reaction at 450-1200℃, yielding a high-temperature pyrolysis solid product and silicon-containing flue gas. The silicon-containing flue gas is sequentially subjected to cyclone dust removal, heat exchange cooling, and bag filter dust removal before being absorbed and utilized. The high-temperature pyrolysis solid product is cooled to below 50℃ and then temporarily stored in a second buffer chamber. It is then further pulverized to a particle size ≤40μm (D90) to obtain a mullite-corundum composite material product.

[0042] In this invention, the mixing and pulping of the reaction filter cake and the de-ferroalloying ash can inhibit the excessive decomposition of mullite and increase the content of mullite, the main effective component in the product.

[0043] Compared with the prior art, the present invention has the following beneficial effects:

[0044] (1) The production device described in this utility model can realize the batch processing of fly ash, selectively remove the amorphous silica in the fly ash, fully expose the mullite whisker structure, and at the same time convert the amorphous alumina in the fly ash into corundum, so as to obtain a mullite-corundum composite material with an aluminum-silicon ratio ≥2.7.

[0045] (2) The production device described in this utility model can obtain ammonia-containing gas and silicon-containing gas respectively. By utilizing the two separately, high value-added products can be prepared.

[0046] (3) The production device described in this utility model realizes the rational use of energy, has good economic efficiency, and is suitable for large-scale production. Attached Figure Description

[0047] Figure 1 This is a schematic diagram of the reaction module in a mullite-corundum composite material production device provided in Embodiment 1 of this utility model.

[0048] Figure 2 This is a schematic diagram of the separation module in a mullite-corundum composite material production device provided in Embodiment 1 of this utility model.

[0049] Figure 3 This is a schematic diagram of the calcination module in a mullite-corundum composite material production device provided in Embodiment 1 of this utility model.

[0050] Among them, 1-screening machine, 2-magnetic separator, 3-first buffer tank, 31-first conveyor, 32-second conveyor, 4-batching tank, 5-first heat exchanger, 6-reaction vessel, 7-first filter press, 8-first filtrate tank, 9-first washing liquid tank, 10-secondary washing liquid tank, 11-tertiary washing liquid tank, 12-slurry tank, 13-first ball mill, 14-buffer tank, 15-second filter press, 16-second filtrate tank, 17-dryer, 18-low temperature pyrolysis furnace, 181-first cyclone dust collector, 182-first bag filter dust collector, 19-high temperature pyrolysis furnace, 191-second cyclone dust collector, 192-second bag filter dust collector, 193-second heat exchanger, 20-cooler, 21-second buffer tank, 22-second ball mill. Detailed Implementation

[0051] It should be understood that in the description of this utility model, the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used solely for the convenience of describing this utility model and for 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. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0052] It should be noted that, in the description of this utility model, unless otherwise explicitly specified and limited, the terms "set," "connected," and "linked" 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 connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0053] The technical solution of this utility model will be further described below through specific embodiments. Those skilled in the art should understand that the embodiments described are merely illustrative of this utility model and should not be considered as specific limitations thereof.

[0054] In one specific embodiment, the present invention provides a production device for mullite-corundum composite materials, the production device for mullite-corundum composite materials comprising a reaction module, a separation module and a calcination module connected in sequence.

[0055] The reaction module includes a magnetic separation unit, a batching unit, a heat exchange unit, and a reaction unit connected in sequence.

[0056] The separation module includes a filtration and washing unit, a pulping unit, and a filtration unit connected in sequence.

[0057] The calcination module includes a drying unit, a calcination unit, and a cooling unit connected in sequence.

[0058] Furthermore, the magnetic separation unit of the reaction module is also connected to the pulping unit of the separation module.

[0059] Furthermore, the magnetic separation unit includes a screening machine 1, a magnetic separator 2, and a first buffer chamber 3 connected in sequence; the first buffer chamber 3 is connected to the batching unit via a first conveyor 31 and to the pulping unit via a second conveyor 32.

[0060] Furthermore, the batching unit includes a batching tank 4; the heat exchange unit includes a first heat exchanger 5; and the reaction unit includes a reaction vessel 6.

[0061] Furthermore, the filtration and washing unit includes a first filter press 7, a first filtrate tank 8, and a washing liquid tank. The first filter press 7 is connected to the first filtrate tank 8, and the first filter press 7 and the washing liquid tank form a loop connection.

[0062] Furthermore, the first filter press 7 includes a plate and frame filter press.

[0063] Furthermore, there are at least two washing liquid tanks.

[0064] Furthermore, the slurry unit includes a slurry tank 12, a first ball mill 13, and a buffer tank 14 connected in sequence.

[0065] Furthermore, the filtration unit includes a second filter press 15 and a second filtrate tank 16 connected in sequence; the second filtrate tank 16 is also connected to the first filter press 7.

[0066] Furthermore, the drying unit includes a dryer 17.

[0067] Furthermore, the calcination unit includes a low-temperature pyrolysis furnace 18 and a high-temperature pyrolysis furnace 19 connected in sequence; the low-temperature pyrolysis furnace 18 is also connected to a first dust removal mechanism; the high-temperature pyrolysis furnace 19 is also connected to a second dust removal mechanism and a second heat exchanger 193.

[0068] Furthermore, the cooling unit includes a cooler 20; the cooler 20 is also connected in sequence to a second ball mill 22; a second buffer chamber 21 is also provided between the cooler 20 and the second ball mill 22.

[0069] Example 1:

[0070] This embodiment provides a production device for mullite-corundum composite materials. Based on the production device for mullite-corundum composite materials in the specific implementation, there are three washing liquid tanks, namely a primary washing liquid tank 9, a secondary washing liquid tank 10, and a tertiary washing liquid tank 11.

[0071] The first dust removal mechanism includes a first cyclone dust collector 181 and a first bag dust collector 182;

[0072] The second dust removal mechanism includes a second cyclone dust collector 191 and a second bag dust collector 192.

[0073] A schematic diagram of the reaction module of the mullite-corundum composite material production device is shown below. Figure 1 As shown, the structural diagram of the separation module is as follows: Figure 2 As shown in the diagram, the calcination module has the following structural schematic. Figure 3 As shown.

[0074] Example 2:

[0075] This embodiment provides a production apparatus for mullite-corundum composite materials. Based on the production apparatus for mullite-corundum composite materials in the specific implementation, there are four washing liquid tanks, namely a primary washing liquid tank 9, a secondary washing liquid tank 10, a tertiary washing liquid tank 11, and a quaternary washing liquid tank.

[0076] The first dust removal mechanism includes a first cyclone dust collector 181 and a first bag dust collector 182;

[0077] The second dust removal mechanism includes a second cyclone dust collector 191 and a second bag dust collector 192.

[0078] Application Example 1:

[0079] The method for producing mullite-corundum composite materials using the production apparatus described in Example 1 includes:

[0080] Using fly ash as a solid raw material, a screening machine 1 is used to remove large particles. The ash undersize is then subjected to a magnetic separator 2 to remove iron-containing compounds, resulting in de-ironized ash. The de-ironized ash enters the first buffer silo 3, and the de-ironized ash in the first buffer silo 3 is fed into the batching tank 4 according to the required weight, with a solution volume to solid mass ratio of 3m³. 3The mixture is prepared by mixing the ammonium salt solution with a concentration of 10wt% at a ratio of / t. After the mixture is prepared, it is heated to 90°C by a heat exchanger and then fed into reactor 6 for reaction. The ammonia-containing gas generated during the reaction is discharged from reactor 6 for recycling.

[0081] After the reaction is complete, the reaction slurry is sent to a filter press for solid-liquid separation. The resulting filtrate is stored in the first filtrate tank 8. The filter cake is washed in multiple stages of countercurrent washing using filtrate from the second filter press 15, combined with primary washing tank 9, secondary washing tank 10, and tertiary washing tank 11. The mass ratio of washing liquid to filter cake (dry basis) is controlled at 5:1. The washed filter cake is sent to a slurry tank 12 and mixed with water and deferroalloy ash from the first buffer tank 3 to obtain a slurry with a solid content of 60%, wherein the mass ratio of deferroalloy ash to filter cake (dry basis) is 1:1. The resulting slurry is sent to a ball mill to obtain solid material with a particle size ≤60μm (D90). The obtained solid material is then filtered by the second filter press 15, and the resulting filter cake is the intermediate product.

[0082] The intermediate product is fed into dryer 17 to remove moisture, resulting in a dried product with a moisture content of 1 wt%. The dried product is then fed into a low-temperature pyrolysis furnace 18, where a low-temperature pyrolysis reaction occurs at 200°C, yielding a low-temperature pyrolysis solid product and ammonia-containing flue gas. The ammonia-containing flue gas is purified by dust removal and then absorbed and utilized. The low-temperature pyrolysis solid product is fed into a high-temperature pyrolysis furnace 19, where a high-temperature pyrolysis reaction occurs at 500°C, yielding a high-temperature pyrolysis solid product and silicon-containing flue gas. The silicon-containing flue gas is sequentially subjected to cyclone dust removal, heat exchange cooling, and bag filter dust removal before absorption and utilization. The high-temperature pyrolysis solid product is cooled to below 50°C and then temporarily stored in a second buffer chamber 21. It is then further pulverized to a particle size ≤ 40 μm (D90) to obtain a mullite-corundum composite material product.

[0083] The aluminum-silicon ratio of the obtained mullite-corundum composite material is 2.7.

[0084] Application Example 2:

[0085] The method for producing mullite-corundum composite materials using the production apparatus described in Example 1 includes:

[0086] Using fly ash as a solid raw material, a screening machine 1 is used to remove large particles. The ash undersize is then subjected to a magnetic separator 2 to remove iron-containing compounds, resulting in de-ironized ash. The de-ironized ash enters the first buffer silo 3, and the de-ironized ash in the first buffer silo 3 is fed into the batching tank 4 according to the required weight, with a solution volume to solid mass ratio of 10m³. 3 The mixture is prepared by mixing the ingredients with an 8wt% ammonium salt solution at a ratio of / t. After the ingredients are prepared, the mixture is heated to 140°C by a heat exchanger and then fed into reactor 6 for reaction. The ammonia-containing gas generated during the reaction is discharged from reactor 6 for recycling.

[0087] After the reaction is complete, the reaction slurry is sent to a filter press for solid-liquid separation. The resulting filtrate is stored in the first filtrate tank 8. The filter cake is washed in multiple stages of countercurrent washing using filtrate from the second filter press 15, combined with primary washing tank 9, secondary washing tank 10, and tertiary washing tank 11. The volume ratio of washing liquid to filter cake (dry basis) is controlled at 10:1. The washed filter cake is sent to a slurry tank 12 and mixed with water and de-iron ash from the first buffer tank 3 to obtain a slurry with a solid content of 50%, wherein the mass ratio of de-iron ash to filter cake (dry basis) is 2:1. The resulting slurry is sent to a ball mill to obtain solid material with a particle size ≤60μm (D90). The obtained solid material is then filtered by the second filter press 15, and the resulting filter cake is the intermediate product.

[0088] The intermediate product is fed into dryer 17 to remove moisture, resulting in a dried product with a moisture content of 0.9 wt%. The dried product is then fed into a low-temperature pyrolysis furnace 18, where it undergoes a low-temperature pyrolysis reaction at 200°C to obtain a low-temperature pyrolysis solid product and ammonia-containing flue gas. The ammonia-containing flue gas is purified by dust removal and then absorbed and utilized. The low-temperature pyrolysis solid product is fed into a high-temperature pyrolysis furnace 19, where it undergoes a high-temperature pyrolysis reaction at 600°C to obtain a high-temperature pyrolysis solid product and silicon-containing flue gas. The silicon-containing flue gas is then subjected to cyclone dust removal, heat exchange cooling, and bag filter dust removal before being absorbed and utilized. The high-temperature pyrolysis solid product is cooled to below 50°C and then temporarily stored in a second buffer chamber 21. It is then further pulverized to a particle size ≤ 40 μm (D90) to obtain a mullite-corundum composite material product.

[0089] The aluminum-silicon ratio of the obtained mullite-corundum composite material is 2.9.

[0090] Application Example 3:

[0091] The method for producing mullite-corundum composite materials using the production apparatus described in Example 1 includes:

[0092] Using fly ash as a solid raw material, a screening machine 1 is used to remove large particles. The ash undersize is then subjected to a magnetic separator 2 to remove iron-containing compounds, resulting in de-ironized ash. The de-ironized ash enters the first buffer silo 3, and the de-ironized ash in the first buffer silo 3 is fed into the batching tank 4 according to the required weight, with a solution volume to solid mass ratio of 4m³ / 4m³. 3 The mixture is prepared by mixing the ingredients with an 8wt% ammonium salt solution at a ratio of / t. After the ingredients are prepared, the mixture is heated to 50°C by a heat exchanger and then fed into reactor 6 for reaction. The ammonia-containing gas generated during the reaction is discharged from reactor 6 for recycling.

[0093] After the reaction is complete, the reaction slurry is sent to a filter press for solid-liquid separation. The resulting filtrate is stored in the first filtrate tank 8. The filter cake is washed in multiple stages of countercurrent washing using filtrate from the second filter press 15, combined with primary washing tank 9, secondary washing tank 10, and tertiary washing tank 11. The volume ratio of washing liquid to filter cake (dry basis) is controlled at 7:1. The washed filter cake is sent to a slurry tank 12 and mixed with water and de-iron ash from the first buffer tank 3 to obtain a slurry with a solid content of 40%, wherein the mass ratio of de-iron ash to filter cake (dry basis) is 1.5:1. The resulting slurry is sent to a ball mill to obtain solid material with a particle size ≤60μm (D90). The obtained solid material is then filtered by the second filter press 15, and the resulting filter cake is the intermediate product.

[0094] The intermediate product is fed into dryer 17 to remove moisture, resulting in a dried product with a moisture content of 0.8 wt%. The dried product is then fed into low-temperature pyrolysis furnace 18, where it undergoes a low-temperature pyrolysis reaction at 250°C to obtain a low-temperature pyrolysis solid product and ammonia-containing flue gas. The ammonia-containing flue gas is purified by dust removal and then absorbed and utilized. The low-temperature pyrolysis solid product is fed into high-temperature pyrolysis furnace 19, where it undergoes a high-temperature pyrolysis reaction at 450°C to obtain a high-temperature pyrolysis solid product and silicon-containing flue gas. The silicon-containing flue gas is then subjected to cyclone dust removal, heat exchange cooling, and bag filter dust removal before being absorbed and utilized. The high-temperature pyrolysis solid product is cooled to below 50°C and then temporarily stored in the second buffer chamber 21. It is then further pulverized to a particle size ≤ 40 μm (D90) to obtain a mullite-corundum composite material product.

[0095] The aluminum-silicon ratio of the obtained mullite-corundum composite material is 2.8.

[0096] As can be seen from the above embodiments and application examples, the production device of this utility model can realize the batch processing of fly ash, selectively remove amorphous silica from fly ash, fully expose the mullite whisker structure, and at the same time convert amorphous alumina in fly ash into corundum, thereby obtaining a mullite-corundum composite material with an aluminum-silicon ratio ≥2.6.

[0097] The applicant declares that the detailed structure of this utility model is illustrated through the above embodiments, but this utility model is not limited to the above detailed structure, that is, it does not mean that this utility model must rely on the above detailed structure to be implemented. Those skilled in the art should understand that any improvements to this utility model, equivalent substitutions for the structure of this utility model, additions of auxiliary structures, selection of specific methods, etc., all fall within the protection scope and disclosure scope of this utility model.

Claims

1. A production apparatus for mullite-corundum composite materials, characterized in that, The production device for the mullite-corundum composite material includes a reaction module, a separation module, and a calcination module connected in sequence. The reaction module includes a magnetic separation unit, a batching unit, a heat exchange unit, and a reaction unit connected in sequence. The separation module includes a filtration and washing unit, a pulping unit, and a filtration unit connected in sequence. The calcination module includes a drying unit, a calcination unit, and a cooling unit connected in sequence. Furthermore, the magnetic separation unit of the reaction module is also connected to the pulping unit of the separation module.

2. The production apparatus for mullite-corundum composite materials according to claim 1, characterized in that, The magnetic separation unit includes a screening machine, a magnetic separator, and a first buffer chamber connected in sequence. The first buffer chamber is connected to the batching unit via a first conveyor and to the pulping unit via a second conveyor.

3. The production apparatus for mullite-corundum composite materials according to claim 1, characterized in that, The batching unit includes a batching tank; The heat exchange unit includes a first heat exchanger; The reaction unit includes a reaction vessel.

4. The production apparatus for mullite-corundum composite materials according to claim 1, characterized in that, The filtration and washing unit includes a first filter press, a first filtrate tank, and a washing liquid tank. The first filter press is connected to the first filtrate tank, and the first filter press and the washing liquid tank form a loop connection.

5. The production apparatus for mullite-corundum composite materials according to claim 4, characterized in that, The first filter press includes a plate and frame filter press; There are at least two washing solution tanks.

6. The production apparatus for mullite-corundum composite materials according to claim 1, characterized in that, The slurry unit includes a slurry tank, a first ball mill, and a buffer tank connected in sequence.

7. The production apparatus for mullite-corundum composite materials according to claim 4, characterized in that, The filtration unit includes a second filter press and a second filtrate tank connected in sequence. The second filtrate tank is also connected to the first filter press.

8. The production apparatus for mullite-corundum composite materials according to claim 1, characterized in that, The drying unit includes a dryer.

9. The production apparatus for mullite-corundum composite materials according to claim 1, characterized in that, The calcination unit includes a low-temperature pyrolysis furnace and a high-temperature pyrolysis furnace connected in sequence. The low-temperature pyrolysis furnace is also connected to a first dust removal mechanism; The high-temperature pyrolysis furnace is also connected to a second dust removal mechanism and a second heat exchanger.

10. The production apparatus for mullite-corundum composite materials according to claim 4 or 9, characterized in that, The cooling unit includes a cooling machine; The cooler is also connected in sequence to a second ball mill; A second buffer chamber is also provided between the cooler and the second ball mill.

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