阅读说明：本技术 一种利用烧结矿物球团电熔法制备无机纤维的方法 (Method for preparing inorganic fibers by using sintered mineral pellets through electric melting method ) 是由 李晓光 谢诚 于 2020-11-26 设计创作，主要内容包括：本发明公开了一种利用烧结矿物球团电熔法制备无机纤维的方法包括将原料烧结成球得到烧结球团,再将烧结球团进行电熔熔化后纺丝即得无机纤维,所述的电熔熔化后的熔体粘度为0.2～1Pa.S；所述的无机纤维包括岩棉纤维和连续玄武岩纤维；所述的岩棉纤维的酸度系数为0.9～2.4；所述的连续玄武岩纤维的酸度系数为5.2～10。本发明通过多种调质原料之间的组合,提供了更加灵活的选择,可以根据需求在上述调质原料之间组合,以调质后无机纤维的酸度系数作为最终控制目标,调质方法更加经济、合理和灵活；过程简单易控制,提高无机纤维生产制备效率。(The invention discloses a method for preparing inorganic fibers by using a sintered mineral pellet electric melting method, which comprises the steps of sintering raw materials into pellets to obtain sintered pellets, and then spinning the sintered pellets after electric melting to obtain the inorganic fibers, wherein the melt viscosity after electric melting is 0.2-1 Pa.S; the inorganic fibers comprise rock wool fibers and continuous basalt fibers; the acidity coefficient of the rock wool fiber is 0.9-2.4; the acidity coefficient of the continuous basalt fiber is 5.2-10. According to the invention, through combination of various modified raw materials, more flexible selection is provided, the modified raw materials can be combined according to requirements, the acidity coefficient of the modified inorganic fiber is taken as a final control target, and the modification method is more economic, reasonable and flexible; the process is simple and easy to control, and the production and preparation efficiency of the inorganic fiber is improved.)

1. A method for preparing inorganic fibers by using a sintered mineral pellet electric melting method is characterized by comprising the steps of sintering raw materials into pellets to obtain sintered pellets, and then spinning the sintered pellets after electric melting to obtain the inorganic fibers, wherein the melt viscosity after the electric melting is 0.2-1 Pa.S; the inorganic fibers comprise rock wool fibers and continuous basalt fibers;

the acidity coefficient of the rock wool fiber is 0.9-2.4;

the acidity coefficient of the continuous basalt fiber is 5.2-10.

2. The method for preparing inorganic fibers by using sintered mineral pellets through electric melting as claimed in claim 1, wherein the raw materials include, by mass, 0 to 75% of natural ore, 0 to 80% of low-grade iron ore, 0 to 60% of blast furnace slag, 0 to 15% of alkaline solvent, and 10 to 25% of clay, wherein the amounts of the natural ore and the low-grade iron ore are not 0 at the same time, and the amounts of the blast furnace slag and the alkaline solvent are not 0 at the same time.

3. The method for preparing inorganic fibers by using the electric melting method of sintered mineral pellets as claimed in claim 2, wherein the natural ore includes one or more of basalt, diabase and serpentine.

4. The method of claim 2, wherein the low-grade iron ore comprises one or more of magnetite tailings waste rock, hematite tailings waste rock, limonite tailings waste rock, siderite tailings waste rock, and mixed iron ore waste rock.

5. The method for preparing inorganic fibers by using the electric smelting of sintered mineral pellets as claimed in claim 2, wherein the blast furnace slag is one or more of blast furnace iron-making slag and manganese slag.

6. The method for preparing inorganic fibers by using the electric melting method of sintered mineral pellets as claimed in claim 2, wherein the alkaline solvent is one or more of dolomite and limestone.

7. The method for preparing inorganic fibers by using the electric melting method of sintered mineral pellets as claimed in claim 2, wherein the binder is one or more of clay, cellulose and bentonite.

8. The method for preparing inorganic fibers by using the electric melting method of sintered mineral pellets as claimed in claim 2, wherein the sintering temperature is 800-1000 ℃ and the sintering time is 20-40 min.

9. The method for preparing inorganic fibers by using the sintered mineral pellet electric melting method as claimed in claim 2, which comprises the following steps:

step 1: putting the raw materials into a stirrer for stirring, preparing into spherulites with the particle size of 15-30 mm by a pelletizer under the condition of adding water, and sending the spherulites into a rotary kiln for preheating at room temperature-800 ℃, drying and sintering at 800-1000 ℃ to obtain sintered pellets;

step 2: and then sending the sintered pellets into an electric melting furnace for electric melting spinning to obtain the inorganic fibers, wherein the melt viscosity after electric melting is 0.2-1 Pa.S.

10. The inorganic fiber prepared by the method for preparing the inorganic fiber by using the sintered mineral pellet electric melting method as claimed in any one of claims 1 to 9, wherein the inorganic fiber comprises rock wool fiber and continuous basalt fiber.

Technical Field

The invention belongs to the field of inorganic fiber preparation and resource recycling, and particularly relates to a method for preparing inorganic fibers by using a sintered mineral pellet electric melting method.

Background

The inorganic mineral fiber is a fiber product prepared by taking substances consisting of specific minerals as raw materials and adopting a special production process. The main varieties are glass fiber, basalt fiber, rock wool fiber, aluminum silicate fiber and the like. Inorganic mineral fibers can be further classified into staple fibers and continuous fibers. The staple fiber is prepared with one or several kinds of ore in certain proportion and through high temperature melting and centrifugal fiber forming process, and is formed into fiber product through certain forming process. Common products include glass wool, rock wool, aluminum silicate and other plate felt products; the continuous fiber is also an ultra-long fiber prepared by melting one or more ores at high temperature in proportion and then drawing and bushing, and common products comprise continuous glass fiber, continuous basalt fiber and the like. In particular, the continuous basalt fiber is called the fourth largest high-quality fiber after carbon fiber, aramid fiber and ultra-high molecular weight polyethylene fiber.

The heat sources adopted for melting in the preparation of the rock wool fiber are coke and electricity respectively. The melting furnace types are respectively a coke cupola furnace and a resistance furnace. No matter the melting process of the rock wool fiber or the continuous basalt fiber adopts a coke oven or a resistance furnace for melting, the melting furnace has three important common characteristics: 1. the preparation of the fiber needs the batching process of different materials so as to meet the specific chemical composition required by the preparation of the fiber. In order to realize the aim, all blending materials are required to be fully and uniformly mixed so as to ensure that the high-temperature viscosity can be accurately controlled after the materials are melted and meet the requirement of fiber making. At present, raw materials used for burdening are all blocky and are put into a kiln after being cold-mixed and mixed; 2. the physical and chemical changes of the materials in the kiln are generated in a certain area along the axial direction of the furnace, and the materials are respectively (or alternately) subjected to the processes of temperature rise, dehydration, decomposition, sintering, melting and the like; 3. due to different dehydration and decomposition temperatures of materials, high-temperature melt is easy to generate foaming, and unbalance of chemical components and melting states of products is caused.

Numerous studies have shown that: only on the basis of ensuring the correct selection of the proportion of ingredients and the accurate chemical components of the melt, the fiber with good quality and performance can be prepared through a physicochemical process system, and the balanced and stable production process is ensured.

Because the batching process relates to a plurality of mineral raw materials, and the raw materials undergo different physical and chemical changes in the temperature rising process, when the fiber is prepared by utilizing various wastes with more complex chemical components, the problem that the melting belt material is difficult to homogenize is particularly obvious because the types of the materials to be batched are more and a small amount of 'tempering' material is possibly added, and the improvement of the quality of the fiber finished product is seriously restricted.

Disclosure of Invention

The invention provides a method for preparing inorganic fibers by using a sintered mineral pellet electric melting method, which solves the problems of inaccurate material preparation, high energy consumption, foaming of melt and large damage to a melting furnace caused by the fact that various raw materials are involved in the material preparation in the current production process of rock wool and continuous basalt fibers.

In order to realize the task, the invention adopts the following technical scheme:

a method for preparing inorganic fibers by using a sintered mineral pellet electric melting method comprises the steps of sintering raw materials into pellets to obtain sintered pellets, performing electric melting on the sintered pellets, and spinning to obtain the inorganic fibers, wherein the melt viscosity after the electric melting is 0.2-1 Pa.S; the inorganic fibers comprise rock wool fibers and continuous basalt fibers;

the acidity coefficient of the rock wool fiber is 0.9-2.4;

the acidity coefficient of the continuous basalt fiber is 5.2-10.

Further, the raw materials comprise, by mass, 0-75% of natural ore, 0-80% of low-grade iron ore, 0-60% of blast furnace slag, 0-15% of alkaline solvent and 10-25% of clay, wherein the addition amounts of the natural ore and the low-grade iron ore are not 0 at the same time, and the addition amounts of the blast furnace slag and the alkaline solvent are not 0 at the same time.

Further, the natural ore includes one or more of basalt, diabase and serpentine.

Furthermore, the low-grade iron ore comprises iron tailings and iron ore waste rocks, and specifically comprises one or more of magnetite tailings, hematite tailings waste rocks, limonite tailings waste rocks, siderite tailings waste rocks and mixed iron ore waste rocks.

Furthermore, the blast furnace slag is one or more of blast furnace ironmaking slag and blast furnace ironmaking manganese slag.

Further, the alkaline solvent is one or more of dolomite and limestone.

Further, the binder is one or more of clay, cellulose and bentonite.

Specifically, the sintering temperature is 800-1000 ℃, and the sintering time is 20-40 min;

preferably, the method specifically comprises the following steps:

step 1: putting the raw materials into a stirrer for stirring, preparing into spherulites with the particle size of 15-30 mm by a pelletizer under the condition of adding water, and sending the spherulites into a rotary kiln for preheating at room temperature to 800 ℃, drying and sintering at 800-1000 ℃ for 20-40 min to obtain sintered pellets;

step 2: and then sending the sintered pellets into an electric melting furnace for electric melting spinning to obtain the inorganic fibers, wherein the melt viscosity after electric melting is 0.2-1 Pa.S.

The inorganic fiber is prepared by a method for preparing inorganic fiber by using a sintered mineral pellet electric melting method, and comprises rock wool fiber and continuous basalt fiber.

Compared with the prior art, the invention has the following advantages:

compared with the traditional process, the preparation method of the invention can save energy more effectively by adopting a one-step fiber preparation process. By controlling the acidity coefficient of the rock wool fiber to be 0.9-2.4 and the acidity coefficient of the continuous basalt fiber to be 5.2-10, the purposes of low melting temperature of raw materials and high yield of inorganic fibers are achieved.

Through combination among various tempering raw materials, more flexible selection is provided, the tempering raw materials can be combined according to requirements, the acidity coefficient of the inorganic fiber after tempering is taken as a final control target, and the tempering method is more economical, reasonable and flexible; the process is simple and easy to control, and the production and preparation efficiency of the inorganic fiber is improved.

Detailed Description

The present invention is described below with reference to specific embodiments, but the present invention is not limited to the following embodiments, and those skilled in the art to which the present invention pertains can make several simple deductions or substitutions without departing from the spirit of the present invention, and all of them should be considered as belonging to the protection scope of the present invention.

Sintered pellets are one method of making artificial bulk materials. The method can convert powdery materials with different chemical compositions into bulk materials with the same physical and chemical properties through sintering and other thermal processes, meets the requirement of material homogenization, and provides qualified material guarantee for smoothly implementing subsequent processes. In the process of preparing the pellets, the powdery material is formed into raw material particles, raw material segments or raw material balls (collectively referred to as raw material particles) with different shapes through different forming processes such as extrusion, rolling and the like, and the powdery material has certain cohesion. The raw material particles are prepared by mixing different powdery raw materials and have uniform components. By performing chemical analysis on the powdery raw material, accurate batching can be performed according to the set chemical composition. The prepared raw material particles are put into a sintering kiln, and the raw material is calcined to generate sintering reaction to form sintered pellets with certain mechanical strength. The sintered pellets have balanced and stable chemical components and mechanical properties meeting the requirements of subsequent processes. In the process of preparing sintered pellets by using powder, the inside of the pellet is subjected to complicated physical properties, such as density, porosity, size, mechanical strength and the like, which are obviously changed.

In the instruments and medicines of the present invention, unless otherwise specified below, the amounts of the substances are all by mass and are commercially available.

The method for preparing the inorganic fiber by using the sintered mineral pellet electric melting method fully utilizes the advantage of particularly accurate sintered pellet ingredients, and sinters the powdery mineral into the sintered pellet with certain mechanical property by a pyrogenic process to form the rock wool fiber or basalt fiber secondary raw material (sintered pellet) required by electric furnace melting. Meanwhile, the pellets are put into the electric furnace quickly after being sintered, so that partial sensible heat is brought, energy can be effectively saved, and the load of a circuit is reduced.

Sintering the raw materials into balls to obtain sintered balls, and then spinning the sintered balls after electric melting to obtain inorganic fibers, wherein the melt viscosity after electric melting is 0.2-1 Pa.S; the inorganic fibers comprise rock wool fibers and continuous basalt fibers, and the acidity coefficient of the rock wool fibers is 0.9-2.4; the acidity coefficient of the continuous basalt fiber is 5.2-10.

All the raw materials are mixed and tempered to form tempered raw materials. Through combination among various tempering raw materials, more flexible selection is provided, the tempering raw materials can be combined according to requirements, the acidity coefficient of the inorganic fiber after tempering is taken as a final control target, and the tempering method is more economical, reasonable and flexible; the process is simple and easy to control, and the production and preparation efficiency of the inorganic fiber is improved.

Example 1

In this example, the raw materials include, by mass, 35% of natural ore, 0% of low-grade iron ore, 45% of blast furnace slag, 10% of alkaline solvent, and 15% of clay.

The natural ore is selected from basalt, the blast furnace slag is selected from blast furnace ironmaking slag, and the alkaline solvent is selected from dolomite.

The method comprises the following steps:

step 1: weighing the raw materials according to the formula, putting the raw materials into a stirrer, stirring and mixing the raw materials uniformly, preparing the raw materials into spherical particles with the particle size of 20mm by a pelletizer under the condition of adding water for wetting, and sending the spherical particles into a rotary kiln for preheating at room temperature to 800 ℃, drying and sintering at 800-1000 ℃ for 20-40 min to obtain sintered pellets;

step 2: and then sending the uncooled sintered pellets into an electric melting furnace for melting materials, wherein the melt viscosity after electric melting is 0.2-10 Pa.S, and completing fiber forming operation of the rock wool fibers by a four-roller high-speed centrifugal machine. The acidity coefficient of the prepared rock wool fiber is 2.1.

In this example, the chemical composition of basalt (natural ore) detected by an inorganic nonmetallic test instrument was as follows: SiO 2₂ 57.85％；Al₂O₃ 15.79％；CaO 4.22％；MgO 3.29％；K₂O2.38％；Na₂O 4.43％；TFe₂O₃7.04％。

The blast furnace ironmaking slag comprises the following chemical components: SiO 2₂ 33.95％；Al₂O₃ 13.49％；CaO36.69％；MgO 7.92％；TiO₂ 4.24％；TFe₂O₃0.4％；Na₂O 1.59％；K₂O0.71％；

The chemical composition of dolomite (basic solvent) is as follows: SiO 2₂ 4.54％；CaO 30.36％；MgO21.44％；Na₂O 0.81％。

The chemical components of the clay are as follows: SiO 2₂ 45.54％；Al₂O₃ 38.63％；K₂O1.42％。

The rest of the chemical components in each raw material are loss on ignition, such as carbon dioxide, crystal water, oxygen and the like.

Example 2

In the same way as in example 1, the difference from example 1 is: in the embodiment, the raw materials comprise, by mass, 0% of natural ore, 30% of low-grade iron ore, 55% of blast furnace slag, 0% of alkaline solvent and 15% of clay.

Blast furnace slag is selected from blast furnace ironmaking slag, and low-grade iron ore is magnetite tailing waste rock.

The chemical components of the magnetite tailings and the waste rocks are as follows: SiO 2₂ 42.9％；Al₂O₃ 12.66％；CaO 9.71％；MgO 5.38％；TiO₂ 4.24％；TFe₂O₃0.35％；Na₂O 4.82％。

The blast furnace ironmaking slag comprises the following chemical components: SiO 2₂ 33.95％；Al₂O₃ 13.49％；CaO 36.69％；MgO 7.92％；TiO₂ 4.24％；TFe₂O₃0.35％；Na₂O 1.59％；K₂O 0.71％。

The chemical components of the clay are as follows: SiO 2₂ 45.54％；Al₂O₃ 38.63％；K₂O1.42％。

The acidity coefficient of the prepared rock wool fiber is 1.9.

In the embodiment, the rock wool fiber can be successfully prepared by replacing natural ore with low-grade iron ore.

Example 3

The same as example 1, except for the difference from example 1, in this example, raw materials were, in mass percentage, 35% for natural ore, 40% for low-grade iron ore, 0% for blast furnace slag, 15% for alkaline solvent, and 10% for clay.

The natural ore is diabase, the blast furnace slag is manganese slag, and the low-grade iron ore is waste hematite tailings.

In the step 1, the particle size of the spherulites is 15mm, the sintering temperature is 800 ℃, and the sintering time is 40 min; the melt viscosity after electrofusion in step 2 is 0.5 pa.s. The acidity coefficient of the prepared rock wool fiber is 2.4.

Example 4

The same as example 1, except for the difference from example 1, in this example, the raw materials were, in mass percentage, 70% for natural ore, 0% for low-grade iron ore, 0% for blast furnace slag, 5% for alkaline solvent, and 25% for clay.

The natural ore is serpentine, the blast furnace slag is manganese slag, and the low-grade iron ore is limonite tailing waste rock.

In the step 1, the particle size of the spherulites is 25mm, the sintering temperature is 900 ℃, and the sintering time is 35 min; the melt viscosity after electrofusion in step 2 is 0.8 pa.s. The acidity coefficient of the prepared rock wool fiber is 2.0.

Example 5

The same as example 1, except for the difference from example 1, in this example, the raw materials were, in mass percentage, 0% natural ore, 20% low-grade iron ore, 60% blast furnace slag, 0% alkaline solvent, and 20% clay.

Basalt is selected as natural ore, low-grade iron ore is used as siderite tailing waste stone, and limestone is used as alkaline solvent.

In the step 1, the particle size of the spherulites is 30mm, the sintering temperature is 950 ℃, and the sintering time is 30 min; the melt viscosity after electrofusion in step 2 is 0.6 pa.s. The acidity coefficient of the prepared rock wool fiber is 1.8.

Comparative example 1

The comparative example is different from example 1 in that the raw materials, in mass percentage, are 0% for natural ore, 0% for low-grade iron ore, 60% for blast furnace slag, 15% for alkaline solvent, and 25% for clay.

The acidity coefficient of the prepared rock wool fiber is 0.8.

Comparative example 2

The comparative example is different from example 1 in that the raw materials, in mass percentage, are 10% for natural ore, 75% for low-grade iron ore, 0% for blast furnace slag, 0% for alkaline solvent, and 15% for clay.

The acidity coefficient of the prepared rock wool fiber is 3.0.

Example 6

In the same manner as in example 1, except for preparing the continuous basalt fiber in the same manner as in example 1, the raw materials in this example were, in mass percent, 0% natural ore, 50% low-grade iron ore, 35% blast furnace slag, 5% alkaline solvent, and 10% clay.

The natural ore is diabase, the blast furnace slag is manganese slag, and the low-grade iron ore is waste mixed iron ore. The acidity coefficient of the prepared continuous basalt fiber is 5.5.

This example replaces natural ore with low grade iron ore.

Example 7

In the same manner as in example 1, except for preparing the continuous basalt fiber in the same manner as in example 1, the raw materials in this example were, in mass percent, 5% natural ore, 60% low-grade iron ore, 15% blast furnace slag, 0% alkaline solvent, and 20% clay.

The natural ore is diabase, the blast furnace slag is manganese slag, and the low-grade iron ore is waste mixed iron ore. The acidity coefficient of the prepared continuous basalt fiber is 9.5.

Example 8

In the same manner as in example 1, except for preparing the continuous basalt fiber in the same manner as in example 1, the raw materials in this example were, in mass percent, 40% natural ore, 40% low-grade iron ore, 0% blast furnace slag, 8% alkaline solvent, and 12% clay.

The acidity coefficient of the prepared continuous basalt fiber is 8.3.

Comparative example 3

The comparative example is different from example 6 in that the raw materials, in mass percentage, are 0% for natural ore, 0% for low-grade iron ore, 60% for blast furnace slag, 15% for alkaline solvent, and 25% for clay.

The acidity coefficient of the prepared continuous basalt fiber is 11.

Comparative example 4

The comparative example is different from example 6 in that the raw materials, in mass percentage, are 20% for natural ore, 70% for low-grade iron ore, 0% for blast furnace slag, 10% for alkaline solvent and 10% for clay.

The acidity coefficient of the prepared continuous basalt fiber is 5.0.

According to the chemical composition requirements of rock wool fiber and continuous basalt fiber (as shown in the following table), the ingredients of basalt, diabase, serpentine, iron tailings or waste stone, blast furnace slag, dolomite, limestone, clay and the like are calculated, wherein the clay is used as a bonding agent, and the acidity coefficient value, the sintering temperature, the sintering time and the high-temperature viscosity value are determined.

The foregoing is only a preferred embodiment of the present invention, and it should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be construed as the protection scope of the present invention.