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GB2477848A - Production of bauxite based refractory material - Google Patents

Production of bauxite based refractory material Download PDF

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Publication number
GB2477848A
GB2477848A GB1102033A GB201102033A GB2477848A GB 2477848 A GB2477848 A GB 2477848A GB 1102033 A GB1102033 A GB 1102033A GB 201102033 A GB201102033 A GB 201102033A GB 2477848 A GB2477848 A GB 2477848A
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United Kingdom
Prior art keywords
bauxite
briquettes
pellets
furnace
production
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Granted
Application number
GB1102033A
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GB2477848B (en
GB201102033D0 (en
Inventor
Christoph Beyer
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ThyssenKrupp Industrial Solutions AG
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Polysius AG
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Publication of GB2477848A publication Critical patent/GB2477848A/en
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Publication of GB2477848B publication Critical patent/GB2477848B/en
Expired - Fee Related legal-status Critical Current
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/111—Fine ceramics
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/101—Refractories from grain sized mixtures
    • C—CHEMISTRY; METALLURGY
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/6261—Milling
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62625—Wet mixtures
    • C—CHEMISTRY; METALLURGY
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62645—Thermal treatment of powders or mixtures thereof other than sintering
    • C04B35/62655—Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62695—Granulation or pelletising
    • C—CHEMISTRY; METALLURGY
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/6303—Inorganic additives
    • C04B35/6306—Binders based on phosphoric acids or phosphates
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
    • C04B2235/661—Multi-step sintering
    • C—CHEMISTRY; METALLURGY
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/77—Density
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/95—Products characterised by their size, e.g. microceramics

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Processing Of Solid Wastes (AREA)
  • Fireproofing Substances (AREA)

Abstract

Bauxite containing starting material 2 is ground 1 to a fineness of d90≤ 50µm. The comminuted material 2' is formed or pressed 3, with the addition of liquid 6, to pellets 7 or briquettes 8. The pellets 7 or briquettes 8 are preheated and/or calcined in part 4' of a furnace 4 and then sintered in another zone 4" of the furnace, before being cooled 4"'. The preferred refractory raw material 9 has specific maximum porosity and minimum density. The sintering 4" preferably takes place in a shaft furnace at > 1500°C. Preferably the bauxite is heated to remove at least some of the water and an agglomeration aid 5 is added to the comminuted material 2'.

Description

Process and installation for the production of a refractory raw material of bauxite, and use of a product of bauxite as a refractory raw material The invention relates to a process and an installation for the production of a refractory raw material of bauxite, and to the use of a product of bauxite as a refractory raw material.
Bauxite-containing starting material, such as, for example, bauxite ore, can be used for very different products depending on the production process. DE 36 17 340 Al describes a proppant based on bauxite which is used, for example, in the hydraulic fracturing of subterranean formations in order to improve the recovery of oil and gas.
The proppant described therein is distinguished by very high permeability at formation pressures, very high compressive strength, low specific gravity and good acid resistance.
Production processes for proppants based on bauxite are also disclosed in US 2006/0 081 371 Al and DE 29 48 584 Al.
Us 3 079 243 A relates to the production of abrasive grains of bauxite.
This starting material can, however, also be used, for example, in the production of refractory bauxite, which is used, for example, as lining material for industrial furnaces.
The object underlying the invention is to provide a process and a device for the production of a refractory material of bauxite as well as a novel use of a product of bauxite, the resulting refractory material being distinguished by a high density and low porosity.
The object is achieved according to the invention by the features of claims 1, 9, 10 and 11.
In the process according to the invention for the production of a refractory raw material of bauxite, the following process steps are carried out: a. grinding a bauxite-containing starting material to a fineness of d9° «= 50 rim, b. forming or pressing the comminuted material, with the addition of liquid, to pellets or briquettes, c. introducing the pellets or briquettes into a furnace, where the pellets or briquettes are preheated and/or calcined in a preheating and/or calcining zone, sintered in a sintering zone and cooled in a cooling zone.
The invention additionally comprises the use of a product of bauxite as a refractory raw material, the product of bauxite being obtainable by means of the process steps described above.
The installation according to the invention for carrying out this process consists essentially of a. a mill for grinding a bauxite-containing starting material to a fineness of d9° «= 50 m, b. a pelletising and/or briquetting device for forming or pressing the comminuted material, with the addition of liquid, to pellets or briquettes, and c. a furnace having at least one preheater and/or calcining zone, one sintering zone and one cooling zone for the heat treatment of the pellets or briquettes.
A fineness of d9° «= 50 im is to be understood as being a fineness at which at least 90% of the starting material has a particle size of «= 50 pm.
The sintering of bauxite is conventionally carried out in rotary furnaces. However, in the tests underlying the invention it has been shown that, by using a furnace which comprises a preheater and/or calcining zone, a sintering zone and a cooling zone, as is the case in a shaft furnace, for example, a refractory material having a higher density and lower porosity can be obtained. This is mainly attributable to the fact that the mechanical load on the pellets/briquettes in that type of furnace is substantially smaller than in a rotary furnace. In a rotary furnace, the relatively sensitive briquettes are easily destroyed, so that sintering cannot be carried out to the desired degree.
As compared with a rotary furnace, a shaft furnace also has the additional advantage that it requires less energy for production. An additional installation for cooling the sintered pellets/briquettes is likewise unnecessary.
Moreover, the loss of material via the gas duct, which can easily amount to 30% of the fed mass flow in a rotary furnace, is minimised or avoided completely, which means a further advantage in terms of energy and economy.
Further embodiments of the invention are the subject-matter of the dependent claims.
According to a preferred embodiment of the invention, the pellets or briquettes are sintered in the shaft furnace at temperatures of more than 1500°C. Advantageously, the pellets are formed beforehand with a diameter of from 7 mm to 50 mm. If briquettes are pressed from the comminuted material, they should advantageously have a length or a diameter of from 7 mm to 80 mm.
It can further be expedient to add an agglomeration aid to the comminuted starting material on forming of the pellets or on pressing of the briquettes so that the form is better retained on sintering. In order further to increase the stability of the pellets/briquettes, the comminuted material can be heated and at least some of the water can be removed before and/or after the grinding operation.
The resulting refractory material has a porosity of less than 10%, preferably a porosity of less than 6%. The porosity is the ratio of the void volume to the total volume of the sintered pellets/briquettes.
The sintered pellets/briquettes can further have a density of at least 3.3 g/cm3, preferably a density of more than 3.4 g/cm3. The indicated densities relate to measurement with the aid of a so-called mercury pycnometer.
Further advantages and embodiments of the invention are explained in greater detail hereinbelow with reference to
the description and the drawing.
In the drawing, an installation for the production of a refractory material of bauxite is shown diagrammatically.
The installation consists essentially of a mill 1 for grinding a bauxite-containing starting material 2, a pelletising and/or briquetting device 3 and a furnace 4 having at least one preheater and/or calcining zone 4', one sintering zone 4U and one cooling zone 4!v The furnace 4 is preferably formed by a shaft furnace but can also be, for example, in the form of a multi-stage furnace. The starting material 2 to be ground is especially uncalcined bauxite ore which, where appropriate, can previously be subjected to further treatment steps, such as, for example a washing process.
The mill 1 is in such a form that the starting material 2 can be ground to a fineness of d9° «= 50 rim. In the pelletising and/or briquetting device 3, the comminuted material 2', with the addition of liquid 6, is formed or pressed to pellets 7 or briquettes 8. In order to assist forming, water and/or oil or an oil mixture can be used as the liquid 6. For the forming of the pellets 7, at least 10% liquid is added. In the pressing of briquettes 8, at least 3% liquid is advantageous. In order to facilitate forming and/or to maintain the form of the pellets 7 or briquettes 8, a suitable agglomeration aid 5, such as, for example, phosphoric acid, can further be added to the pelletising and/or briquetting device 3 in addition to the liquid 6.
The pelletising and briquetting device 3 is so adjusted that the comminuted material 2' is pelletised to a size having a diameter of from 6 mm to 50 mm. If briquettes are pressed, their length or their diameter should preferably be from 7 mm to 80 mm.
The pellets 7 or briquettes 8 are subsequently introduced into the furnace 4 from above and then travel through the preheater and/or calcining zone 4', the sintering zone 4U and the cooling zone 4!T At the bottom end, the sintered pellets or sintered briquettes are removed as refractory raw material 9, which has a porosity of less than 10%, preferably a porosity of less than 6%. In addition, it has a density of at least 3.3 g/cm3, preferably a density of more than 3.4 g/cm3. This can be achieved especially in that the pellets 7 or briquettes 8 can be sintered in the furnace 4 at temperatures above 1500°C without the structure of the pellets or briquettes being destroyed.
GB1102033.6A 2010-02-08 2011-02-07 Process for the production of a porous material from bauxite Expired - Fee Related GB2477848B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102010007176A DE102010007176A1 (en) 2010-02-08 2010-02-08 Method for producing a refractory material from bauxite

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GB201102033D0 GB201102033D0 (en) 2011-03-23
GB2477848A true GB2477848A (en) 2011-08-17
GB2477848B GB2477848B (en) 2012-07-04

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CN (1) CN102190504A (en)
BR (1) BRPI1101777A8 (en)
DE (1) DE102010007176A1 (en)
GB (1) GB2477848B (en)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB315856A (en) * 1928-07-21 1930-07-03 Hartford Empire Co Improvements in or relating to the manufacture of refractory articles
GB1155783A (en) * 1965-07-26 1969-06-18 Carborundum Co Barrel Finishing Media
GB2203142A (en) * 1987-04-03 1988-10-12 Comalco Alu Hot filter media
WO2007016268A2 (en) * 2005-07-29 2007-02-08 Carbo Ceramics Inc. Sintered spherical pellets useful for gas and oil well proppants
WO2009134159A1 (en) * 2008-04-28 2009-11-05 Schlumberger Canada Limited Strong low density ceramics
CN101691486A (en) * 2009-09-21 2010-04-07 贵州鑫益能陶粒支撑剂有限公司 Porcelain granule propping agent with ultra strength and super-high density and manufacturing method thereof

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3079243A (en) * 1959-10-19 1963-02-26 Norton Co Abrasive grain
CA1117987A (en) * 1978-12-13 1982-02-09 Robert J. Seider Sintered high density spherical ceramic pellets for gas and oil well proppants and their process of manufacture
US4713203A (en) 1985-05-23 1987-12-15 Comalco Aluminium Limited Bauxite proppant
EP1799962A2 (en) * 2004-09-14 2007-06-27 Carbo Ceramics Inc. Sintered spherical pellets

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB315856A (en) * 1928-07-21 1930-07-03 Hartford Empire Co Improvements in or relating to the manufacture of refractory articles
GB1155783A (en) * 1965-07-26 1969-06-18 Carborundum Co Barrel Finishing Media
GB2203142A (en) * 1987-04-03 1988-10-12 Comalco Alu Hot filter media
WO2007016268A2 (en) * 2005-07-29 2007-02-08 Carbo Ceramics Inc. Sintered spherical pellets useful for gas and oil well proppants
WO2009134159A1 (en) * 2008-04-28 2009-11-05 Schlumberger Canada Limited Strong low density ceramics
CN101691486A (en) * 2009-09-21 2010-04-07 贵州鑫益能陶粒支撑剂有限公司 Porcelain granule propping agent with ultra strength and super-high density and manufacturing method thereof

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GB2477848B (en) 2012-07-04
DE102010007176A1 (en) 2011-08-11
BRPI1101777A8 (en) 2015-04-28
CN102190504A (en) 2011-09-21
GB201102033D0 (en) 2011-03-23
BRPI1101777A2 (en) 2012-07-31

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 20190207