Ceramic production process, 9 technologies can save energy

The typical process flow of architectural ceramics is as follows: selection of raw materials → green body ingredients → ball milling → spray drying powder making → compression molding → semi-finished product drying → one-time firing (plain firing) → water spray → bottom glaze → top glaze → printing → Second firing (glaze firing) → wet edging → drying → grading → packaging.

In the process of building ceramics production, energy is mainly consumed in the steps of spray drying, powder drying, semi-finished product drying, and roller kiln firing (including biscuit firing and glaze firing). Therefore, improving the energy efficiency of these three links is building ceramics The main energy-saving approach for production enterprises, among which energy-saving in the firing link of roller kiln is the most critical. Let's talk about the energy-saving technology of building ceramics from the process.

(1) Choose raw materials

Raw materials are an important basis for the production of building ceramics. For large-scale industrial production, the properties of raw materials are required to meet the production needs, the quality is stable, and the price is reasonable. Therefore, new technical requirements are put forward for the source of raw materials, mining and processing.

① Research and develop new raw materials and new technologies for low-temperature fast burning, expand the sources of raw materials, reduce transportation costs, and achieve energy saving.

② Adopt specialized production and commercial supply, and develop technical equipment such as elutriation, sorting, pre-homogenization, high-efficiency crushing, variable-speed ball mill, and high-efficiency iron removal.

③Implement the standardization of raw materials, stabilize the physical and chemical properties of raw materials in a relatively small range for a long time, stabilize the supply, and increase the yield.

(2) Ball mill

①The ball mill adopts the inner lining with long life, small load, large effective volume, and large amount of material.

②Using high-efficiency water reducing agent to improve ball milling efficiency. The reduction of mud moisture increases the ratio of raw materials and the effective space in the ball mill, improves the efficiency of the ball mill, and at the same time, the output of the spray drying tower is greatly improved.

③ Formulate reasonable material, ball, water ratio and ball stone gradation.

④Using frequency conversion technology, the starting current can be 3-5 times smaller than the original, realizing a real soft start, eliminating the shock during starting, extending the service life of mechanical parts such as shafts, gears, belts, etc., reducing maintenance costs, and can be easily set Fixed grinding time, grinding time and automatic shutdown function make the operation more intelligent and humanized.

⑤Using a continuous ball mill, the discharging and discharging are fully automated during the ball milling, and there is no need to stop the machine. It is easy to make thick slurry, which saves energy in the subsequent spray drying process and can save energy consumption by 10%-35%.

(3) Spray drying powder

①Reduce the mud moisture, optimize the type and proportion of water reducing agent while optimizing the process formula.

② Reasonably use the recovered fine powder, and transport the fine powder collected by the cyclone dust collector and the powder made by the spray drying tower to the silo with a belt to achieve the purpose of uniform mixing, instead of discarding the fine powder or re-pulping.

③Using dry granulation, instead of the traditional two processes of ball milling and spray drying, can save fuel 70%-80%, save water 70%-75%, and save electricity 30%-50%. However, due to the high iron content in the dry powder and the poor fluidity of the dry powder, the performance of the prepared product is not as good as that of the traditional process. Therefore, the process needs to be improved.

(4) Press molding

①Using large-tonnage, energy-saving press. The large-tonnage press has high pressure, the pressed bricks are of good quality, and the qualified rate is high. Under the condition of the same output, the power consumption is low and the energy saving effect is obvious.

②The frequency conversion network technology is used in the cloth system to facilitate the operation and management personnel to better understand the operating status of the production site and automatic control equipment, and achieve the effects of optimizing production process parameters, shortening the troubleshooting time, reducing labor intensity, and improving production labor efficiency. It can not only save electricity, but also reduce waste.

(5) Drying of semi-finished products

①Adopting multi-layer drying technology can increase heat utilization rate, reduce floor space and increase production scale.

②Using forced convection rapid drying technology, the hot air is sprayed vertically to the upper and lower surfaces of the bricks through the blowing pipe to realize the forced convection drying of the bricks, and at the same time ensure the uniform heating, uniform drying and uniform temperature of the bricks.

③Using waste heat recycling technology, the hot air is circulated repeatedly in the equipment, maintaining constant temperature, constant humidity, small quantitative emissions, making full use of energy, reducing emissions, and achieving rapid drying of bricks.

(6) Firing process

①Using the primary firing process, compared with the secondary firing, the energy consumption of the primary firing is much smaller, but because the primary firing has high requirements on the composition of the green body and the glaze, this process has certain technology Difficulty.

②Using a low-temperature fast burning process can not only increase output, save energy, but also reduce costs.

③Using pre-sintering technology, after pressing and forming, the green body does not go through the drying process, but directly quickly dried and pre-sintered. The highest temperature is about 900 ℃. At this stage, the porcelain body is not sintered completely, but it has sufficient hardness and The strength is used to complete the glazing and other processes, and the final sintering of the blank and glaze is completed together, which only takes 10-15min. This process can use relatively cheap raw materials and can save 40% of the energy consumption in the manufacturing process.

(7) Glazing

① Choose advanced equipment to reduce glaze loss. In the entire process of glazing, there is generally a loss of 15%-20%, most of which are difficult to recycle, and measures should be taken to recycle.

②Using inkjet printing technology, this technology can realistically express the texture and color of the selected materials, present the design effect of the three-dimensional tile surface, and can meet the personalized aesthetic needs of consumers in a relatively short time, greatly shortening the production cycle .

(8) Wet edging

The semi-dry grinding and non-drying technology is adopted, and the water spray nozzle and grinding head of the grinding line are modified to reduce the water inhalation during the grinding process. The bricks are directly packed into the warehouse without subsequent drying treatment.

(9) Other energy-saving technologies

① Strengthen product structure adjustment, improve independent innovation capabilities, and increase product added value.

②Through optimizing the design, shorten the distribution line, select the appropriate cross-section conductor and the reasonable distribution equipment to reduce the distribution loss. Install power capacitors to improve power factor.

③ Actively promote the implementation of green lighting projects, and actively promote the use of new energy-saving lamps such as high-pressure sodium lamps and fluorescent lamps. Optimize the lighting design of the factory building and make full use of natural light to achieve lighting energy saving.

④ Strengthen enterprise energy conservation management work and formulate energy conservation reward and punishment system.

⑤Establish an energy management center.