Design scheme of process equipment for granulation-process-free wet production of green brick

Abstract

A granulation-free wet production process for a green brick. A high-concentration ceramic slurry is distributed and formed by means of a digital ceramic slurry jet printing device and is then rapidly dehydrated into a mud cake green brick with a water content of 14-18% by means of a suction-filtration filter-pressing or stamping filter-pressing device; and the mud cake green brick is dried until the water content thereof is 6-13% and is then pressed at a high pressure to form a compact green brick.

Description

A design scheme for wet production equipment of granulation-free bricks Technical Field

[0001] The present invention belongs to the technical field of ceramic wall and floor tile production, and specifically relates to a wet low-carbon production process equipment for ceramic tile blanks that does not require dry granulation and wet granulation processes, in particular to a direct and efficient wet low-carbon production process equipment for full-textured rock slabs. Technical Background

[0002] Ball milling, spray drying, pressing, and firing are the four key processes in ceramic tile production, all of which are energy-intensive. Typically, the moisture content of the milled slurry is around 33-38%, while the moisture content of the powder used for pressing is around 7%. The spray drying process, which produces the powder from the slurry, consumes the second-highest amount of heat energy after firing, accounting for approximately 80% of the firing process. Under normal operating conditions, spray drying requires evaporating approximately 430 kg of water, approximately 40 cubic meters of standard natural gas, or approximately 70 kg of coal, per ton of powder, achieving a thermal efficiency of approximately 45%. Furthermore, it consumes approximately 40-45 kWh of electricity, equivalent to approximately RMB 130-150 per ton of powder. Therefore, spray drying is energy-intensive and also poses environmental risks. Ceramic factories invest significantly in environmental governance. There are two main types of existing ceramic dry powder production methods, such as patent document patent publication number CN115745629A "Ceramic Powder Preparation Method" and CN114454332A "Ceramic Dry Powder Production". The key steps of the process are: 1. The homogenized mud is pressed into a mud cake, and the filtrate is concentrated into filter pulp for reuse; 2. The mud cake is refined into mud blocks or mud particles and then dried to a moisture content suitable for subsequent processing requirements, and the reused filter pulp is added during the process; 3. The mud blocks or mud particles are impact-crushed into mud powder and then iron is removed. There are also dry pulverization processes similar to existing cement raw material grinding processes, using a vertical roller mill to grind the ceramic raw materials and then adding water to granulate and harden them into the desired particles. Representative companies include LB in Italy, Eirich in Germany, and Atotor in the UK. Patents include Patent Publication No. CN115890893A, "Method and Apparatus for Preparing Ceramic Tiles Using Dry Pulverization," and wet and dry pulverization processes, such as Patent Publication No. CN110407587A, "A Dry and Wet Pulverization Process for Architectural Ceramics." Existing dry and wet ceramic pulverization methods are also traditional pulverization methods in the ceramics industry. They also reduce energy consumption, eliminate the need for desulfurization towers, and significantly reduce carbon emissions. The main steps of existing ceramic plastic extrusion methods for forming blanks are: 1. Pressing the homogenized slurry into a cake; 2. Refining the cake into blocks or pellets, drying them to a moisture content suitable for subsequent processing, extruding the desired blanks using a vacuum extruder, and then drying and firing them.

[0003] The usual production of full-textured ceramic wall and floor tiles is done by grinding the ceramic raw materials into a slurry and then spray drying it to form powder particles of various colors, which are then passed through various rollers with various patterned fabrics to form ceramic blanks; or by using digital ceramic powder particles using digital powder spraying equipment to press patterned fabrics to form a full-textured ceramic blank. Technical issues

[0004] The main defects of this process are: 1. Spray drying powder production has high energy consumption and complicated process flow. The slurry with a moisture content of about 33-38% needs to be directly dried into powder with a moisture content of about 5-8% through a spray tower. In particular, digital ceramic powder has specific requirements for the moisture content and fluidity of the slurry, and requires extremely strict moisture content. It takes about 43 cubic meters of standard natural gas and about 75 kg of coal to obtain each ton of powder. This drying and dehydration process will consume a lot of heat energy and produce more carbon dioxide emissions; 2. The production process of powders manufactured by dry and wet methods is complicated. A natural stone has extremely rich colors, with at least three colors and as many as four, five, seven or eight colors and transition colors. If you want to get rich and colorful, naturally variable colors, you need to configure the corresponding color powder, which also makes the spray tower operation cumbersome and the production process of preparing various color powders complicated. 3. Since solid particle powder is pressed into shape for pattern forming The production process of ceramic plastic extrusion blanks is rough and the pattern and texture are difficult to change. It requires a large proportion of scarce plastic clay. The cost of high-quality plastic clay raw materials is high, and the density of the finished bricks is low. 5. The dry pulverizing and wet filter pressing pulverizing processes are cumbersome and complicated, the powder particle size distribution is uneven, the fluidity is poor, the particle density ratio fluctuates greatly, the brick quality rate is low, and the dust pollution is serious. The transportation between dry powders makes the working environment harsh, increases the management cost, and can only make ordinary coarse ore ceramic bricks.

[0005] Technical solution (content of the invention)

[0006] In response to the above production process defects, the applicant provides a wet production process equipment that directly manufactures brick blanks without dry granulation process and wet granulation process. This is also a new color-changeable, low-carbon, low-cost, full-body rock slab production process technology and equipment solution. The present invention provides a wet production process equipment design scheme for granulation-free brick blanks, which is characterized in that the equipment mainly includes a digital slurry printing device, a belt vacuum negative pressure suction filter device, a vacuum negative pressure high-pressure pressing and dehydration device, a flash drying kiln device, and a high-pressure pressing and molding device. The equipment operation process is to use a digital ceramic mud printing device to shape the slurry with a moisture content of about 25% to 38% on the filter belt or filter plate of the belt vacuum negative pressure suction filter device, and then pass through the belt vacuum negative pressure suction filter device under vacuum negative pressure. The water content of the wet bricks is dehydrated by suction filtration to form ultra-high wet bricks with a moisture content of about 16% to 22%, or the wet bricks are dehydrated to about 9% to 16% by a high-pressure filter press device under a vacuum negative pressure and a hydraulic cylinder oil pressure of 2.5 to 40 MPa. The water is then evaporated to 5% to 13% wet bricks by a flash drying kiln device. The wet bricks are then pressed into dense bricks under a high-pressure pressing molding device under a hydraulic cylinder oil pressure of 15 to 60 MPa according to the process requirements, and then dried and other conventional processes are carried out. The wet production process equipment design scheme of the granulation-free process bricks of the present invention can be used to perform multiple new process pattern decorations on the bricks with different moisture contents before and after the drying process in the wet production process of the ceramic brick body, such as cutting and splicing, spraying color powder slurry on the cracks, etc. The present invention provides a wet production process equipment design for granulation-free brick blanks, which is characterized in that the production of brick blanks includes the use of a horizontal belt vacuum filter press dehydration device, and also includes a more complicated process equivalent to replacing it with a centrifugal dehydrator, a screw stacker, a non-horizontal belt, or a plate vacuum filter press device, which can also dehydrate the mud into an ultra-high wet brick blank paste with a moisture content of about 16% to 22%. It also includes a more complicated process of using a vacuum extruder to extrude high-wet brick blanks of the required specifications and then using a flash drying kiln device to evaporate the moisture into 5-13% wet brick blanks, and then using a high-pressure pressing molding device to perform high-pressure pressing to form dense brick blanks according to process requirements at different pressure requirements.

[0007] The present invention proposes a wet-process production equipment design for granulation-free bricks. Its digital ceramic slurry printing device ensures precise production of each batch of bricks with precise thickness and pattern. Standardized color matching is achieved using three primary color slurries. The system includes different slurry hoppers and a non-uniform stirring and mixing device. It preferably consists of multiple identical jetting module package systems, enabling high-precision pattern and texture formation. A single jetting module package system primarily includes a fixed frame, a storage hopper for holding the printed ceramic slurry, a multi-unit module plate for discharging slurry at the bottom of the storage hopper, a striker that controls the opening and closing of the slurry outlet holes, and an electrical device for controlling the lift of the striker. The digital ceramic glaze printing device is mainly installed with multiple groups of fixed frames, on which a storage hopper for holding the printed ceramic slurry is installed, and multiple groups of slurry discharge unit orifice plate modules are installed at the bottom of the storage hopper. A ejector pin device for controlling the opening and closing of the slurry discharge unit hole is installed in the storage hopper, and a piezoelectric ceramic component or electromagnet group device for controlling the lifting of the ejector pin is installed on the top or side of the ejector pin. The piezoelectric ceramic and electromagnet circuit signals of each unit are controlled by an integrated circuit control panel. The device is characterized in that the storage hopper includes at least two slurry tanks, and the unit holes of the slurry discharge unit orifice plate at the bottom of the storage hopper include a multi-channel structure, at least a three-channel structure, or the unit holes of the slurry discharge unit orifice plate are a structure for receiving multiple slurry channels, at least a channel structure for receiving two types of slurries.

[0008] The present invention discloses a wet-process equipment design for producing granulation-free bricks. The horizontal belt vacuum filter device primarily comprises a filter belt or microporous filter plate, a vacuum filter box, a vacuum tank, a drive roller, a driven roller, a filter press roller, a filter cloth deviation correction device, a drive device, a filter cloth cleaning device, and a frame. This highly efficient device primarily utilizes material gravity and vacuum suction to achieve solid-liquid separation. Its operating principle is as follows: a motor, after deceleration, drives the active roller to rotate, thereby driving the filter belt or microporous filter plate to continuously operate. The filter cloth, held in close contact with the belt, operates synchronously with the belt under the action of the vacuum. The annular friction belt under the tape slides into contact with the vacuum filter box plate in the vacuum filter chamber (water forms a water seal between the vacuum filter box plate and the annular friction belt). When the vacuum filter box plate is connected to the vacuum system, the filter cloth or microporous filter plate forms a vacuum filtration zone, dehydrating the slurry. The ceramic slurry is evenly applied to the filter cloth or belt filter plate by a digital ceramic slurry printing device. Under the action of vacuum, the filtrate passes through the small holes of the filter cloth microporous filter plate and enters the vacuum negative pressure collection chamber. The ceramic solid particles are trapped and form filter cakes. The filtrate entering the vacuum negative pressure collection chamber is discharged through the gas and water separator. As the filter cloth and microporous filter plate move forward, the formed filter cakes enter the filter cake drying zone in turn. Finally, the filter cloth and microporous filter plate are removed, cleaned, and recycled. After passing through the redirecting roller and the correction device, they re-enter the filtration section. The ceramic filter cake mud bricks are horizontally moved at the unloading area and sent to the drying device. The belt filter plate and the vacuum adsorption box plate can be designed to move forward synchronously, and a motion seal structure is formed between the vacuum adsorption box plate and the belt filter plate, and solid-liquid separation is achieved by using vacuum negative pressure as the driving force.

[0009] The present invention provides a design scheme for wet production process equipment of granulation-free brick blanks, wherein the drying kiln device, the horizontal belt drying device or the vertical box drying device includes a conventional horizontal belt drying kiln device, a single-layer and multi-layer stick drying kiln device and a box vertical hanging basket and cage circulation drying device, wherein the belt drying device is composed of an insulating box, a conveyor chain and mesh belt, a chain and mesh belt tensioner, a dehumidification device, a transmission device, a conveyor belt, an indirect heating device, etc. The box vertical hanging basket and cage circulation drying device mainly includes a column, a connecting crossbeam, a connecting longitudinal beam, an electric control device, a synchronous moving device, a hanging cage, and a lifting device. The column is fixed to the connecting crossbeam and the connecting longitudinal beam, the electric control device is fixed to the side of the column, and the synchronous moving device is fixed to the column, so that the support plate in the hanging cage can be horizontally moved up and down inside the column through the electric control device and the synchronous moving device. The drying device is a relatively mature process drying equipment in this field. Those skilled in the art are familiar with its drying principle and drying heat source scheme. The drying process is indispensable in ceramic production, and the inventor will not make a detailed description.

[0010] The wet production process equipment design scheme of the present invention for granulation-free brick blanks is characterized by the following process and process pressing parameters: in the existing ceramic blank formula system (the ceramic mud raw material accounts for about 20-40% of the total formula composition), the mud is filtered to make the mud blank uniformly wet with a moisture content of 5-16%, preferably a uniform moisture content of 8-12%, and further preferably a uniform moisture content of 7.5-9.5%. Then, high-pressure pressing is performed under the condition of 20-60 MPa hydraulic cylinder oil pressure to form a dense brick blank. The high-pressure press pressing process characteristics used are static pressure pressing equipment and vibration pressing equipment, preferably static pressure pressing equipment such as the existing ceramic belt roller press, and sliding mold frame punching press. The sliding mold frame punching press equipment is characterized by a sunken upper and lower sliding mold frame, preferably a trapezoidal sliding mold frame with a large lower inner width. The high-pressure stamping and dense pressing preferably has a lower inner width that is 8-10 mm larger than the brick blank size, which is convenient for reducing the fitting accuracy and achieving rapid pressing. The characteristic of the stamping press machine with a sinking upper and lower sliding mold frame is that the sliding mold frame can accurately correct the position of the brick to be pressed and the overlap of the lower mold core when it descends, while also preventing damage to the brick. In contrast, the stamping press machine with a fixed mold frame has a tendency to get stuck in the fixed mold frame when the lower mold core descends, causing damage to the brick and making it difficult to accurately correct the position of the brick to be pressed and the overlap of the mold core.

[0011] The wet production process equipment design scheme of the granulation-free brick blank of the present invention is characterized in that: the mud is directly dehydrated by a mechanical pressing method and the brick blank is directly manufactured. It is a unique ceramic wall and floor tile brick blank production process method. Different equipment and different process means in ceramic production are specially transformed and modified and beneficially combined to form a new technical overall solution, which makes the entire ceramic production process extremely streamlined, abandons the traditional high-energy consumption evaporation dehydration, abandons the traditional high-energy consumption and high-pollution granulation, and abandons the traditional high-energy consumption and high-pollution dry powder pressing of brick blanks, thereby greatly improving production efficiency and significantly reducing production costs. The preferred production process and equipment features of the ceramic brick blanks of the present invention are: 1. The equipment mainly includes a digital slurry printing device, a belt vacuum suction filter press device, a horizontal drying kiln device or a vertical box drying kiln device, a high-pressure press, and a transmission device interconnected between the devices, such as a mechanical arm suction cup, a gripper, a guide connection transfer device, a cutting device, etc. between each device. The process flow is to use a digital ceramic mud printing device to apply and shape high-concentration ceramic slurry and paste, and then use a horizontal belt vacuum suction filter press and a punching filter press device to dehydrate them into wet brick blanks with different moisture contents of 9% to 22% under the hydraulic cylinder oil pressure conditions of 0.2 to 40Mpa, and then dry the wet brick blanks to make the wet brick blanks homogenized with a moisture content of 8 to 9%, and then further press them into dense brick blanks under the hydraulic cylinder oil pressure conditions of 10 to 60Mpa. 2. The high-concentration slurry is a high-concentration slurry with a moisture content of about 25% to 30%, preferably a high-concentration slurry with a moisture content of about 27% to 29%; the moisture content of the high-humidity brick body is about 14% to 18%, preferably 14% to 16%. 3. When the ceramic tile body has a high-precision marble texture throughout, its digital slurry printing device mainly includes a fixed frame, a storage hopper with at least two slurry tanks for holding the printed ceramic slurry, multiple groups of slurry discharge unit orifice plates at the bottom of the storage hopper, a pin device for controlling the opening and closing of the slurry discharge unit orifice, a device for controlling the lifting of the pin, and an integrated circuit control panel. The unit holes of the slurry discharge unit orifice plate at the bottom of the storage hopper include a multi-channel structure, at least a three-channel structure, or the unit holes of the slurry discharge unit orifice plate are a structure that receives multiple slurry channels, at least a channel structure that receives two types of slurries. 4. The horizontal belt vacuum suction filtration, filtration, and filter press device mainly includes a belt-type filter belt or a belt-type microporous filter plate, a lower vacuum adsorption box plate, a connecting hose, a vacuum tank, a driving roller, a driven roller, a filter cloth, a filter plate correction device, a driving device, a filter cloth microporous filter plate cleaning and washing device, a frame and other components, and further includes an upper belt-type filter press belt, an upper vacuum negative pressure water vapor adsorption box, a connecting hose, an upper driving roller, an upper driven roller, an upper filter press roller, etc.5. When the ceramic tile body has a full-body marble texture, before and after the suction filtration, pressure filtration, and drying processes, the mud, ultra-high-humidity brick body, and high-humidity brick body are subjected to multiple new process pattern decorations such as spraying color paste, spraying dry particles, cutting and splicing, and spraying pink paste on the cracks.

[0012] Further summarized, the equipment mainly includes digital slurry printing device, suction filtration, pressure filtration, punching filter press device and equivalent replacement dehydrator device, drying kiln device, high-pressure press, and transmission device connecting the equipment to each other; the process flow plan of the equipment is to use digital ceramic mud printing device to apply high-concentration ceramic slurry to form, and then use suction filtration and pressure filtration, under the condition of 0-15Mpa hydraulic cylinder oil pressure, punching filter press device to quickly dehydrate it into high-wet bricks with a moisture content of 12%-17%, and then dry the high-wet bricks to make the wet bricks uniform in moisture content. The water content is 8-10%, and then further high-pressure pressing is performed under the condition of 20-60 MPa hydraulic cylinder oil pressure to form dense bricks; or under the condition of 0-35 MPa hydraulic cylinder oil pressure, a punch filter press device is used to directly dehydrate it into wet bricks with a moisture content of about 8%-11%, or a horizontal belt vacuum suction filtration and ultra-high pressure roller filter press device is used to directly dehydrate it into wet bricks with a moisture content of about 8%-11%. The wet bricks are then dried and oven-dried without being pressed by a separate high-pressure press. The wet bricks are directly dried and subjected to other conventional processes such as glazing and high-temperature firing. The suction filtration, pressure filtration, and punch filter press device filter presses a high-concentration slurry with a moisture content of about 25%-38%, preferably a high-concentration slurry with a moisture content of about 27%-30%, into wet bricks with a moisture content of about 8.5%-22%, preferably a high-wet brick with a moisture content of about 14%-16%. The digital slurry printing device produces ceramic tile bodies with fine marble texture throughout the body. The digital slurry printing device mainly includes a fixed frame, a storage hopper with 6 slurry troughs for holding 6 colors (red slurry, yellow slurry, blue slurry, black slurry, zirconium white slurry, and transparent slurry) of printed ceramic slurry, a group of unit orifice plates for discharging slurry at the bottom of the storage hopper, a ejector pin device for controlling the opening and closing of the slurry unit holes, and an electric (pneumatic) device for controlling the lifting and lowering of the ejector pin, an integrated circuit control panel, and the unit holes of the slurry unit orifice plate at the bottom of the storage hopper include a 7-channel structure, or the unit holes of the slurry unit orifice plate are structures for receiving 6 types of slurry channels. The suction filtration, pressure filtration and punching filter press devices described therein mainly include horizontal belt vacuum filter devices and punching filter press devices, wherein the horizontal belt vacuum filter device is mainly composed of a belt filter belt tape or a belt microporous filter plate, a lower vacuum adsorption box plate, a connecting hose, a vacuum tank, a driving roller, a driven roller, a filter cloth, a filter plate correction device, a driving device, a filter cloth, a microporous filter plate cleaning and washing device, and a frame component, and further includes an upper belt filter belt or a belt microporous filter plate, an upper vacuum negative pressure water vapor adsorption box plate, a connecting hose, an upper driving roller, an upper driven roller, multiple sets of upper and lower filter rollers and a hydraulic pressure device, a high-frequency vibration device for assisting rapid dehydration, and a rapid air dehydration device.It further includes one or more independent upper belt filter belts or belt microporous filter plates, upper vacuum negative pressure water vapor adsorption box plates, connecting hoses, upper drive rollers, upper driven rollers, multiple groups of upper and lower filter rollers and hydraulic pressure devices, high-frequency vibration devices for auxiliary rapid dehydration, rapid wind dehydration devices, positive pressure air blowing bricks to separate from the filter belt and filter plate devices, and the air and water permeability and dehydration micropore size of the filter cloth and filter plate can be selected to be 0.1 to 8 microns, preferably about 0.3 to 1 micron; wherein the stamping filter press device is mainly composed of upper and lower sliding mold frames, an upper movable filter press mold core, a lower fixed filter press mold core, positive and negative pressure water vapor blowing and suction devices, a hydraulic system device, and a frame component. Its characteristic is the production of ceramic tile bodies with full marble texture. The process includes multiple new process methods for bricks with different humidity, mud, ultra-high humidity bricks, and high humidity bricks before and after suction filtration and filtration pressing, and before drying and drying. Pattern decoration, such as spraying color paste, spraying dry particles, cutting and splicing, and spraying pink paste on cracks. Its process design produces dense bricks through a high-pressure stamping and pressing process. The use of stamping presses to produce bricks further includes a wet brick storage device. When necessary, the wet bricks are stored in batches using box-type storage racks to keep them moist and cope with special production situations. Its characteristic is that a stamping filter press device, preferably a sliding mold frame stamping press, is used to produce brick blanks. The upper and lower filter press cores of the stamping filter press are close to the stamping surface and have a multi-hole mold core with densely staggered and interconnected grooves with a width of about 0.1 to 5 mm (depth of about 0.1 to 15 mm), and are connected to the filter press dehydration material on the stamping surface. The multi-hole mold core main port of the filter press core is connected by negative pressure and positive pressure pipes. The negative pressure and positive pressure pass through the main port of the multi-hole structure of the mold core, which has the effect of negative pressure water absorption and positive pressure blowing on the filter press dehydration material on the stamping surface. The filter press dehydration material on the stamping surface is a microporous, porous, breathable and water-permeable material such as a porous ceramic panel, an alloy panel, a high-pressure-resistant fiber mesh filter cloth, etc. The micropore size can be selected from 0.1 to 8 microns, preferably about 0.3 to 1 micron. Beneficial effects

[0013] The beneficial effects and advantages of the present invention are as follows: ① It eliminates the need for spray drying granulation and dry and wet granulation, and uses a mechanical pressing method to directly dehydrate the mud and directly manufacture bricks, which simplifies the production process and greatly reduces production costs; ② It can increase the slurry grinding concentration, increase the solid content, and improve production efficiency; ③ It can make the texture of ceramic rock slabs and the texture formation principle of natural stone exactly the same, so that the inside and outside of the body are consistent, which can make the product have better aesthetic effects, achieve natural and smooth, and can truly replace natural scarce stone; ④ Use mechanical methods to directly dehydrate and directly manufacture bricks, which greatly reduces electricity consumption and reduces carbon emissions; ⑤ Reduce water use and save water resources.

[0014] Figures in the specification

[0015] Figure 1 is a simplified diagram of the brick production process of horizontal belt vacuum filtration, filter pressing → drying → belt roller pressing.

[0016] Figure 2 is a simplified diagram of the brick production process from stamping and filtration → drying → high-pressure stamping.

[0017] Figure 3 is a simplified diagram of the brick production process of horizontal belt vacuum filtration, filter pressing → drying → high-pressure stamping.

[0018] In the figure: 1 slurry hopper; 2 slurry; 3 vacuum filter box plate; 3-1 lower pressure vacuum filter box plate; 4 filter belt; 5 negative pressure vacuum tank; 6 vacuum pump; 7 transmission roller; 8 negative pressure valve; 9 drying kiln; 10 high-pressure roller press belt; 11 vacuum negative pressure pipe; 12 slurry pipe; 13 press sliding mold frame; 14 press lower mold core; 15 synchronous cutter; 16 cleaner; 17 filter press roller. DETAILED DESCRIPTION

[0019] Example 1

[0020] The wet production process equipment design scheme of a granulation-free brick blank of the present invention is shown in Figure 3, wherein the ceramic mud raw material accounts for 30% of the total formula composition. The process feature is that a high-concentration slurry (2) with a water content of 31% is applied to a belt-type microporous filter plate through a slurry hopper (1) of a digital ceramic mud printing device, and reaches a slurry thickness of 22 mm required by the process, and then a vacuum filter device vacuum suction box plate (3) is used to adsorb the bottom of the belt-type microporous filter plate to quickly vacuum dehydrate the 22 mm slurry layer into an ultra-high wet brick blank with a water content of about 20%, and then the ultra-high wet brick blank with a water content of about 20% is squeezed horizontally downward by pressing the vacuum suction box plate (3-1) downward, and a 0.5-5.0 MPa hydraulic cylinder oil pressure is applied. Under the condition of pressure, the high-pressure roller pressing and vacuum filtration are gradually applied to quickly dehydrate the high-humidity brick blanks with a moisture content of about 16%. Then, the brick blanks are cut and moved to the support plate using a mechanical arm. Then, the brick blanks are dried in a drying kiln (9) to reduce the moisture content to 8.5-9.5%. Then, the low-humidity brick blanks with a moisture content of 8.5-9.5% are sent to the lower mold core (14) of the punching press of equal size using a mechanical arm and accurately positioned. The press sliding mold frame (13) with a lower inner width 10 mm larger than the size of the brick blank and the lower mold core is lowered to accurately frame the brick blank until the inner width is equal to the size of the brick blank. The upper mold core of the press is lowered and pressed, and two punching presses are performed under the oil pressure conditions of 10Mpa and 20Mpa hydraulic cylinders to form dense brick blanks. The pressing frequency is 18 bricks per minute.

[0021] Example 2

[0022] The wet production process equipment design scheme of a granulation-free brick blank of the present invention is shown in Figure 1, wherein the ceramic mud raw material accounts for 40% of the total formula composition. The process feature is that a digital ceramic mud slurry printing device is used to apply 6 colors of high-concentration color paste with a moisture content of 34% in multiple layers on a belt filter belt (4), and the slurry thickness of 25 mm required by the process is achieved. Then, a vacuum filter device vacuum suction box plate (3) slides and absorbs the bottom of the belt filter belt to quickly dehydrate the 25 mm slurry layer into an ultra-high wet brick blank with a moisture content of about 21%. The ultra-high wet brick blank is cut and pieced together multiple times, and color powder and color paste are sprayed on the cracks to form a new process pattern decoration, and then The high-humidity green bricks are quickly filtered and dehydrated under the hydraulic cylinder oil pressure of 0.5 to 3.0 MPa using multiple groups of multi-stage downward pressure vacuum filter boxes (3-1) and multiple groups of filter rollers (17) with a moisture content of about 17%. The green bricks are then moved horizontally to the stainless steel mesh belt of the drying kiln (9). The green bricks are then dried and dried in the horizontal drying kiln (9) to reduce the moisture content to 8.5 to 9.5%. The green bricks are then adjusted to the size and shaped to meet the specified requirements. The green bricks are then sent to the high-pressure roller press belt (10) for pressing under the hydraulic cylinder oil pressure of 0.5 to 35 MPa using the progressive high pressure and the hydraulic cylinder oil pressure of 35 to 0 MPa using the progressive high pressure to form dense green bricks. The pressing line speed is 10 meters per minute.

[0023] Example 3

[0024] The wet production process equipment design scheme of a granulation-free brick blank of the present invention is shown in Figure 2, wherein the ceramic mud raw material accounts for 25% of the total formula composition. The process feature is that a high-concentration slurry (2) with a water content of 32% is quantitatively applied through a slurry pipe (12) to a brick blank mold composed of a press lower mold core (14) and a press sliding mold frame (13) of a punching press having a filter press multi-hole mold core through a digital ceramic mud printing device, and then the bottom of the lower mold core (14) of the lower press is fixed by a vacuum device to quickly dehydrate the slurry layer, and at the same time, the movable filter press mold core on the punching press squeezes the slurry layer downward to perform progressive multi-stage downward high-pressure filtration under the condition of 0-9Mpa hydraulic cylinder oil pressure, and the vacuum negative pressure adsorbs the upper movable filter press mold core for rapid dehydration, so that high-humidity brick blanks with a water content of about 14% can be pressed, and the pressing frequency is 6 brick blanks per minute; or a high-concentration slurry (2) with a water content of 26% is passed through the press sliding mold frame (1 3) of the side wall pipeline high-pressure quantitative pump into the stamping press with a multi-channel filter press mold core lower fixed press core (14) and the press sliding mold frame (13) and the upper stamping filter press mold core formed by the closed cavity, and to achieve the process requirement of 35 mm slurry thickness, then through the vacuum device adsorption fixed press core (14) bottom to make the slurry layer quickly dehydrated, while the stamping press upper movable filter press mold core downward squeeze the slurry layer, the 0 ~ 20Mpa hydraulic cylinder oil pressure pressure Under the conditions of progressive multi-stage downward pressure high-pressure filtration, vacuum negative pressure adsorption of the upper movable filter press mold core for rapid dehydration, it can be pressed into high-humidity bricks with a moisture content of about 11%, and the pressing frequency is 8 bricks per minute. Then the positive pressure water vapor blowing device cooperates with the filter press mold core to demold, the lower filter press mold core is positively demolded, the upper filter press mold core and the sliding mold frame rise, positive pressure demolding, and then it is translated to the receiving pallet by the robotic arm suction cup, and then dried in the horizontal drying kiln to make the moisture content of 7.5-8.5%. Then the low-humidity bricks are sent to the lower mold core of the stamping press of equal size through the robotic arm suction cup and accurately positioned. The sliding mold frame with a lower inner width that is 10 mm larger than the brick and lower mold core size descends, accurately framing the brick until the inner width is equal to the brick size. The upper mold core of the press descends and performs two punching presses under the conditions of 10Mpa and 30Mpa hydraulic cylinder oil pressure to form dense bricks, and the pressing frequency is 13 bricks per minute.Alternatively, as shown in the stamping and filtration schematic diagram of FIG2 , two colors of high-concentration slurry (2) pastes with a water content of 26% are pumped from the side wall pipeline of the press sliding mold frame (13) through a pipeline uneven stirring and mixing device with inner spiral blades into the closed cavity formed by the lower fixed press lower mold core (14) with multiple air channels of the stamping press, the press sliding mold frame (13) and the upper stamping filter mold core, and the slurry thickness of 35 mm required by the process is reached. Then, the bottom of the lower press lower mold core (14) is fixedly adsorbed by a vacuum machine device to quickly dehydrate the slurry layer, and at the same time, the upper active press of the stamping press is pressed. The dynamic filter mold core squeezes the slurry layer downward, and performs progressive multi-stage downward high-pressure filtration under the condition of 0-35Mpa hydraulic cylinder oil pressure. The upper movable filter mold core is adsorbed by vacuum negative pressure for rapid dehydration, and can be pressed into wet bricks with a moisture content of about 8-9%. The pressing frequency is 10 bricks per minute. Then the positive pressure water vapor blowing device is combined with the filter mold core for demoulding. The lower filter mold core is positively demoulded, and the upper filter mold core and the sliding mold frame rise and are positively demoulded. Then, they are directly translated to a conventional roller drying kiln through the mechanical arm suction cup, dried to a moisture content of 1.5-2.5%, and then fired at 1200℃.

[0025] Example 4

[0026] The wet production process equipment design scheme of a granulation-free brick blank of the present invention is shown in the schematic diagram of partial filter pressing in FIG1, wherein the ceramic mud raw material accounts for 20% of the total formula composition. The process feature is that a digital ceramic mud slurry printing device is used to apply 6 colors of high-concentration color paste with a moisture content of 30% in multiple layers on a belt filter belt (4) with high tensile strength and high compressive strength, and the slurry thickness of 25 mm required by the process is achieved. Then, a vacuum filter device vacuum suction box plate (3) slides and absorbs the bottom of the belt filter belt to quickly dehydrate the 25 mm slurry layer into an ultra-high wet brick blank with a moisture content of about 20%, and the ultra-high wet brick blank is sprayed with color powder and color paste for new process pattern decoration, and then quickly Under the hydraulic pressure of 0.5-3.0 MPa, the bricks are pressed and dehydrated by multiple groups of multi-stage downward pressure vacuum filter boxes (3-1) and multiple groups of filter rollers (17) to form high-humidity bricks with a moisture content of about 17%. Then, multiple groups of filter rollers are pressed and dehydrated by high-pressure pressing under the hydraulic pressure of 3-15 MPa, and high-frequency vibration is used for rapid dehydration. Then, high-pressure pressing and rapid wind blowing are used to dehydrate the bricks to a dense size of about 9% under the hydraulic pressure of 15-35 MPa. Then, under the hydraulic pressure of 35-0 MPa, the high pressure is gradually released and the filter belt and the bricks are further rapidly blown to dehydrate. The positive air pressure is forced to blow to separate the filter belt from the bricks and demould. The pressing line speed is 10 meters per minute. Then, the bricks are synchronously cut and moved to a conventional roller drying kiln for drying and drying to a moisture content of 1.5-2.5%. Then, the bricks are fired at 1200°C.

[0027] The above descriptions are only some embodiments of the present invention and do not limit the patent scope of the present invention. All equivalent transformations made by using the contents of this specification and drawings under the concept of the present invention and the upward and downward adjustments of parameter data that do not cause essential changes are included in the patent protection scope of the present invention. Industrial Applicability

[0028] ① Eliminate the spray drying tower and powder storage bin, reduce and simplify the production process, save floor space, and significantly reduce production costs; ② High slurry concentration grinding can be performed, reducing water consumption and improving production efficiency; ③ The texture formation principle of ceramic rock slabs and natural stone is exactly the same, so that the inside and outside of the body are consistent, giving the product a better aesthetic effect and being able to truly replace natural scarce precious stone; ④ Reduce natural gas and coal energy consumption by about 50%, reduce electricity consumption by about 30%, and reduce carbon emissions by about 50%; ⑤ Reduce water consumption by about 70%, saving water resources.

Claims

1. A design scheme of wet production process equipment for ceramic tile blanks with a granulation-free process, characterized in that The equipment mainly includes digital slurry printing device, suction filter, pressure filter, punching filter press device, drying kiln device, high-pressure press, and transmission device connecting the equipment to each other; the process flow plan of the equipment is to use digital ceramic mud printing device to apply high-concentration ceramic slurry to form, and then use suction filter, pressure filter, punching filter press device to quickly dehydrate it into wet bricks with different moisture contents, and then dry the wet bricks to make the homogenized moisture content of the wet bricks 5-13%, and then further use high-pressure press to press it into dense bricks, or without being pressed by a separate high-pressure press, the wet bricks are directly dried for other conventional processes such as glazing and high-temperature firing.

2. The design scheme of a wet production process equipment for a granulation-free process ceramic tile blank as described in claim 1, characterized in that The suction filtration, pressure filtration and punching filter press device can filter the slurry with a moisture content of about 25% to 38%, preferably a high-concentration slurry with a moisture content of about 25% to 30%, into high-wet bricks with a moisture content of about 8% to 22%, preferably wet bricks with a moisture content of about 9% to 16%, under the condition of 0.2 to 40Mpa hydraulic cylinder oil pressure; the high-pressure press can press the wet bricks with a moisture content of 5 to 13% into dense bricks under high pressure under the condition of 15 to 60Mpa hydraulic cylinder oil pressure.

3. The design solution of a wet production process equipment for a granulation-free ceramic tile blank as described in claim 1, characterized in that The digital slurry printing device includes different slurry hoppers and uneven stirring and mixing devices. When producing high-precision marble-textured ceramic tile bodies throughout the body, it is preferably mainly composed of multiple groups of identical injection module package systems. The structure of the single injection module package system mainly includes a fixed frame, a storage hopper with at least two slurry tanks for holding printed ceramic slurry, multiple groups of slurry outlet unit orifice plates at the bottom of the storage hopper, a top impact pin device for controlling the opening and closing of the slurry outlet unit holes, and a device for controlling the top impact pin lifting and lowering, an integrated circuit control panel, and the unit holes of the slurry outlet unit orifice plate at the bottom of the storage hopper include a multi-channel structure, at least a three-way channel structure, or the unit holes of the slurry outlet unit orifice plate are structures for receiving multiple slurry channels, at least a channel structure for receiving two types of slurries.

4. The design scheme of the wet production process equipment for the ceramic tile blank with a granulation-free process as described in claim 1, characterized in that The suction filtration, pressure filtration and punching filter press devices mainly include horizontal belt vacuum filter devices and punching filter press devices, wherein the horizontal belt vacuum filter device is mainly composed of a belt filter belt tape or a belt microporous filter plate, a lower vacuum adsorption box plate, a connecting hose, a vacuum tank, a driving roller, a driven roller, a filter cloth, a filter plate correction device, a driving device, a filter cloth microporous filter plate cleaner and a washing device, and a frame component, and further includes an upper belt filter belt tape or a belt microporous filter plate, an upper vacuum negative pressure water vapor adsorption box plate, a connecting hose, an upper driving roller, an upper driven roller, and upper and lower filter rollers; wherein the punching filter press device is mainly composed of an upper and lower sliding mold frame, an upper movable filter press mold core, a lower filter press mold core, a positive pressure and negative pressure water vapor blowing and suction device, and a frame component; the high pressure press refers to a ceramic belt roller press and a sliding mold frame punching press.

5. The design scheme of a wet production process equipment for a granulation-free process ceramic tile blank as described in claim 1, characterized in that the production Full-body marble texture ceramic tile body. The process flow includes applying new process means for pattern decoration, such as spraying color paste, sprinkling dry particles, cutting and piecing together, and spraying color powder paste at the cracks, to the slurry, super-high humidity green brick, and high humidity green brick before and after the processes of suction filtration, pressure filtration, and drying and baking.

6. The design scheme of a wet production process equipment for a granulation-free process ceramic tile blank as described in claim 1, characterized in that The upper and lower pressure filtration die cores of the stamping pressure filter press have multi-channel die cores close to the stamping surface and are connected to the pressure filtration and dehydration material on the stamping surface. It has a structure for negative pressure water absorption and air suction and positive pressure air blowing and water blowing on the pressure filtration and dehydration material on the stamping surface. The pressure filtration and dehydration material on the stamping surface is a microporous and porous air and water permeable material such as a porous ceramic panel, alloy panel, or high-pressure resistant fiber mesh cloth filter cloth, and the micropore size can be selected from 0.1 to 8 microns, preferably about 0.3 to 1 micron; using the sliding die frame stamping press in its high-pressure press to produce green bricks, it further includes a green brick storage device.

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