CN111210167B - Regulation and control method of alumina fiber blanket blank - Google Patents
Regulation and control method of alumina fiber blanket blank Download PDFInfo
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- CN111210167B CN111210167B CN202010104404.0A CN202010104404A CN111210167B CN 111210167 B CN111210167 B CN 111210167B CN 202010104404 A CN202010104404 A CN 202010104404A CN 111210167 B CN111210167 B CN 111210167B
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- 239000000835 fiber Substances 0.000 title claims abstract description 217
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 title claims abstract description 195
- 238000000034 method Methods 0.000 title claims abstract description 39
- 239000002243 precursor Substances 0.000 claims abstract description 202
- 238000002360 preparation method Methods 0.000 claims abstract description 24
- 238000009987 spinning Methods 0.000 claims description 35
- 229920000742 Cotton Polymers 0.000 claims description 26
- 238000005520 cutting process Methods 0.000 claims description 5
- 230000003750 conditioning effect Effects 0.000 claims 1
- 238000010438 heat treatment Methods 0.000 abstract description 27
- 230000001276 controlling effect Effects 0.000 abstract description 20
- 230000001105 regulatory effect Effects 0.000 abstract description 9
- 239000002699 waste material Substances 0.000 abstract description 9
- 239000000243 solution Substances 0.000 description 20
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
- 238000004364 calculation method Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 239000004372 Polyvinyl alcohol Substances 0.000 description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 3
- 238000006116 polymerization reaction Methods 0.000 description 3
- 229920002451 polyvinyl alcohol Polymers 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 239000011550 stock solution Substances 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 1
- 239000001267 polyvinylpyrrolidone Substances 0.000 description 1
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
- 238000003079 width control Methods 0.000 description 1
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- G—PHYSICS
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- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
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- G06Q10/063—Operations research, analysis or management
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- G06Q10/06393—Score-carding, benchmarking or key performance indicator [KPI] analysis
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- G06Q10/00—Administration; Management
- G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
- G06Q10/063—Operations research, analysis or management
- G06Q10/0639—Performance analysis of employees; Performance analysis of enterprise or organisation operations
- G06Q10/06395—Quality analysis or management
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The invention provides a regulating and controlling method of an alumina fiber blanket blank, which comprises the following steps: a) Calculating the allowable deviation range of the specification index of the precursor alumina fiber blanket blank according to the standard requirement of the alumina fiber blanket product to obtain the control range of the specification index of the precursor; the specification indexes comprise width, surface density and thickness; b) According to the control range of the specification index of the precursor obtained in the step a), parameter data of the corresponding specification index of the precursor alumina fiber blanket blank obtained in actual preparation is matched, and then the parameter data which is not in the control range is adjusted to be in the control range by improving the preparation method. The invention firstly provides that the quality of the finished product is controlled by measuring and adjusting the width, the surface density and the thickness of the precursor in real time, and solves the problems of a large number of waste products caused by the thickness, the width and the volume density change before and after heat treatment, longer heat treatment time and difficult control of the specification of the product.
Description
Technical Field
The invention relates to the technical field of alumina fibers, in particular to a regulating and controlling method of an alumina fiber blanket blank.
Background
The alumina fiber has the characteristics of good high-temperature stability, chemical corrosion resistance, low heat conductivity coefficient, low slag ball content, low specific heat capacity, good high-temperature rebound resilience and the like, and is widely applied to the fields of high-temperature kiln, automobile exhaust treatment, aerospace and the like as a heat insulation or sealing material. The alumina fiber is prepared by preparing spinning solution through a sol-condensation chemical method, preparing an alumina fiber precursor through a centrifugal spinning or blowing spinning process, accumulating fiber cotton blanks to a certain thickness by utilizing cotton collecting or lapping equipment, then interweaving the fiber cotton blanks into a blanket through needling, and finally carrying out high-temperature heat treatment. Because the alumina fiber blanket blank is decomposed and volatilized in the process of high-temperature heat treatment (generally requiring 2-6 h for a long time) and has 40-60% weight loss and 20-45% size shrinkage in all directions, the problems of delay exist when the production process parameters are adjusted according to the specification requirements of the alumina fiber blanket product, the production of the alumina fiber blanket product cannot meet the requirements of the product standard and a large amount of waste products are generated, and the prior art does not have a method for completely regulating and controlling the alumina fiber blanket blank.
Disclosure of Invention
In view of the above, the invention provides a method for regulating and controlling an alumina fiber blanket blank, which can accurately control the specification of an alumina fiber blanket product further obtained by the alumina fiber blanket blank, thereby reducing the rejection rate.
The invention provides a regulating and controlling method of an alumina fiber blanket blank, which comprises the following steps:
a) Calculating the allowable deviation range of the specification index of the precursor alumina fiber blanket blank according to the standard requirement of the alumina fiber blanket product to obtain the control range of the specification index of the precursor alumina fiber blanket blank; the specification indexes comprise width, surface density and thickness;
b) According to the control range of the specification index of the precursor alumina fiber blanket blank obtained in the step a), parameter data of the corresponding specification index of the precursor alumina fiber blanket blank obtained in the actual preparation is matched, and then the parameter data which are not in the control range are adjusted to be in the control range by improving the preparation method.
Preferably, the alumina fiber blanket product standard requirements in step a) include a range of dimensional tolerances and/or a range of bulk density tolerances.
Preferably, the calculating method of the allowable deviation range of the width in the specification index in the step a) specifically includes:
target value of width W Precursor target value ＝K W ×(W Target value of product +2×W Leftover bits and pieces )；
Lower limit value W of width allowable deviation Lower limit of precursor ＝K W ×(W Lower limit value of product +2×W Leftover bits and pieces )；
Upper limit value W of width allowable deviation Upper limit of precursor ＝K W ×(W Upper limit of product +2×W Leftover bits and pieces )；
Wherein K is W Is the proportionality coefficient of the width of the precursor alumina fiber blanket blank and the width of the alumina fiber blanket product, W Leftover bits and pieces The cutting leftover width required to be reserved for one side.
Preferably, the K W Is 1.10 to 1.70, W Leftover bits and pieces 20 mm-200 mm.
Preferably, the calculating method of the allowable deviation range of the surface density in the specification index in the step a) specifically includes:
target areal density value Sd Precursor target value ＝K Sd ×Sd Target value of product ；
Lower limit Sd of allowable deviation of surface density Precursor lower limit value ＝K Sd ×Sd Target value of product ；
Upper limit Sd of permissible deviation of surface density Precursor upper limit value ＝K Sd ×Sd Target value of product ；
Wherein K is Sd Is the proportionality coefficient of the surface density of the precursor alumina fiber blanket blank and the surface density of the alumina fiber blanket product.
Preferably, the K Sd 0.70 to 1.20.
Preferably, the calculating method of the allowable deviation range of the thickness in the specification index in the step a) specifically includes:
target value T of thickness Precursor target value ＝K T ×T Target value of product ；
Lower limit value T of thickness allowable deviation Precursor lower limit value ＝K T ×T Lower limit value of product ；
Upper limit value T of thickness allowable deviation Precursor upper limit value ＝K T ×T Upper limit value of product ；
Wherein K is T Thickness of precursor alumina fiber blanket blank and thickness of alumina fiber blanket productScale factor of degree.
Preferably, the K T 1.35 to 1.60.
Preferably, the calculation method of the surface density parameter data in the specification index of the precursor alumina fiber blanket blank actually prepared in the step b) specifically includes:
precursor alumina fiber blanket blank surface Density Sd Precursor body ＝m Spinning solution ×K/(W Precursor target value ×L Precursor body )；
Wherein m is Spinning solution The flow rate of the spinning solution in unit time is K which is the fiber forming coefficient, W Precursor target value L is the width target value of precursor alumina fiber blanket blank Precursor body Is the delivery distance of the precursor fiber per unit time;
the K is 0.4-0.7.
Preferably, the specific procedure of the improved preparation method in step b) comprises:
parameter data of an allowable deviation range of the width which is not in the specification index is controlled by adjusting the cotton collecting width of the cotton collector or the swing of the lapping machine;
controlling parameter data of an allowable deviation range of the surface density which is not in the specification index by adjusting the flow rate of the spinning solution or the conveying line speed of the precursor fiber;
parameter data of an allowable deviation range of the thickness which is not in the specification index is controlled by adjusting the needling frequency or the needling mode.
The invention provides a regulating and controlling method of an alumina fiber blanket blank, which comprises the following steps: a) Calculating the allowable deviation range of the specification index of the precursor alumina fiber blanket blank according to the standard requirement of the alumina fiber blanket product to obtain the control range of the specification index of the precursor alumina fiber blanket blank; the specification indexes comprise width, surface density and thickness; b) According to the control range of the specification index of the precursor alumina fiber blanket blank obtained in the step a), parameter data of the corresponding specification index of the precursor alumina fiber blanket blank obtained in the actual preparation is matched, and then the parameter data which are not in the control range are adjusted to be in the control range by improving the preparation method. According to the invention, a corresponding relation between the specification of the alumina fiber blanket blank (precursor) and the specification of the alumina fiber blanket finished product is obtained through a large amount of experimental study data and production experience and data, and the problems that the precursor alumina fiber blanket blank is subjected to real-time measurement and adjustment of width, surface density and thickness, the quality of the alumina fiber blanket finished product is controlled, and a large amount of waste products are caused due to the fact that the parameters such as thickness, width and volume density are changed before and after heat treatment, the heat treatment time is long, and the specification of the product is not easy to control are solved for the first time. Experimental results show that the regulation and control method of the alumina fiber blanket blank provided by the invention has the technical effects that under the same conditions, 70kg of unqualified products are reduced to 8kg, 61kg of rim charge is reduced to 52kg, 229kg of products are increased to 300kg, and the rejection rate is reduced to 16.7% from 36.4%.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in conjunction with the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention provides a regulating and controlling method of an alumina fiber blanket blank, which comprises the following steps:
a) Calculating the allowable deviation range of the specification index of the precursor alumina fiber blanket blank according to the standard requirement of the alumina fiber blanket product to obtain the control range of the specification index of the precursor alumina fiber blanket blank; the specification indexes comprise width, surface density and thickness;
b) According to the control range of the specification index of the precursor alumina fiber blanket blank obtained in the step a), parameter data of the corresponding specification index of the precursor alumina fiber blanket blank obtained in the actual preparation is matched, and then the parameter data which are not in the control range are adjusted to be in the control range by improving the preparation method.
According to the standard requirements of alumina fiber blanket products, the allowable deviation range of the specification index of the precursor alumina fiber blanket blank is calculated, and the control range of the specification index of the precursor alumina fiber blanket blank is obtained. In the present invention, the alumina fiber blanket product standard requirements preferably include a range of dimensional tolerances and/or a range of bulk density tolerances, more preferably a range of dimensional tolerances and/or a range of bulk density tolerances; the size allowable deviation range specifically comprises a thickness allowable deviation range, a length allowable deviation range and a width allowable deviation range.
In the present invention, the specification index includes a width, an areal density, and a thickness.
In the present invention, the method for calculating the allowable deviation range of the width in the specification index preferably specifically includes:
target value of width W Precursor target value ＝K W ×(W Target value of product +2×W Leftover bits and pieces )；
Lower limit value W of width allowable deviation Lower limit of precursor ＝K W ×(W Lower limit value of product +2×W Leftover bits and pieces )；
Upper limit value W of width allowable deviation Upper limit of precursor ＝K W ×(W Upper limit of product +2×W Leftover bits and pieces )；
Wherein K is W Is the proportionality coefficient of the width of the precursor alumina fiber blanket blank and the width of the alumina fiber blanket product, W Leftover bits and pieces Cutting leftover material width which is reserved for a single side; w (W) Precursor target value Is the target value of the width control of the precursor alumina fiber blanket blank, W Target value of product Is the target value of the width of the alumina fiber blanket product, W Lower limit of precursor Is the lower limit value of the allowable deviation of the width of the precursor alumina fiber blanket blank, W Lower limit value of product Lower limit value of allowable deviation of width of alumina fiber blanket product, W Upper limit of precursor Is the upper limit value of the allowable deviation of the width of the precursor alumina fiber blanket blank, W Upper limit value of product Is the upper limit value of the allowable deviation of the width of the alumina fiber blanket product.
In the present invention, the K W Preferably 1.10 to 1.70, more preferably 1.30 to 1.45; the W is Leftover bits and pieces Preferably 20mm to 200mm, more preferably 30mm to 100mm.
In the present invention, the method for calculating the allowable deviation range of the surface density in the specification index is preferably specifically:
target areal density value Sd Precursor target value ＝K Sd ×Sd Target value of product ；
Lower limit Sd of allowable deviation of surface density Precursor lower limit value ＝K Sd ×Sd Target value of product ；
Upper limit Sd of permissible deviation of surface density Precursor upper limit value ＝K Sd ×Sd Target value of product ；
Wherein K is Sd The ratio coefficient of the surface density of the precursor alumina fiber blanket blank to the surface density of the alumina fiber blanket product; sd (Sd) Precursor target value Sd is the target value of the surface density control of the precursor alumina fiber blanket blank Target value of product Target value for controlling the surface density of the alumina fiber blanket product, which is formed by Bd Target value of product (target value of bulk Density of alumina fiber blanket product) and T Target value of product (target value of alumina fiber blanket product thickness) and Sd Precursor lower limit value Is the lower limit value of the allowable deviation of the surface density of the precursor alumina fiber blanket blank, sd Lower limit value of product The lower limit value of the allowable deviation of the surface density of the alumina fiber blanket product is Bd Lower limit value of product (lower limit value of allowable deviation of volume density of alumina fiber blanket product) and T Lower limit value of product (lower limit value of allowable deviation of thickness of alumina fiber blanket product), sd Precursor upper limit value Sd is the upper limit value of the allowable deviation of the surface density of the precursor alumina fiber blanket blank Upper limit value of product An upper limit value of the allowable deviation of the surface density of the alumina fiber blanket product, which is Bd Upper limit value of product (upper limit value of allowable deviation of volume density of alumina fiber blanket product) and T Upper limit value of product (upper limit value of allowable deviation of thickness of alumina fiber blanket product).
In the present invention, the K Sd Preferably 0.70 to 1.20, more preferably 0.80 to 1.00.
In the present invention, the calculation method of the allowable deviation range of the thickness in the specification index preferably specifically includes:
target value T of thickness Precursor target value ＝K T ×T Target value of product ；
Lower limit value T of thickness allowable deviation Precursor lower limit value ＝K T ×T Lower limit value of product ；
Upper limit value T of thickness allowable deviation Precursor upper limit value ＝K T ×T Upper limit value of product ；
Wherein K is T The ratio coefficient of the thickness of the precursor alumina fiber blanket blank to the thickness of the alumina fiber blanket product; t (T) Precursor target value T is the target value of the thickness control of the precursor alumina fiber blanket blank Target value of product T is the target value of the thickness of the alumina fiber blanket product Precursor lower limit value T is the lower limit value of the allowable deviation of the thickness of the precursor alumina fiber blanket blank Lower limit value of product T is the lower limit value of the allowable deviation of the thickness of the alumina fiber blanket product Precursor upper limit value T is the upper limit value of the allowable deviation of the thickness of the precursor alumina fiber blanket blank Upper limit value of product Is the upper limit value of the allowable deviation of the thickness of the alumina fiber blanket product.
In the present invention, the K T Preferably 1.35 to 1.60, more preferably 1.35 to 1.60.
After the control range of the specification index of the precursor alumina fiber blanket blank is obtained, the invention matches the parameter data of the corresponding specification index of the precursor alumina fiber blanket blank which is actually prepared according to the control range of the specification index of the precursor alumina fiber blanket blank, and then adjusts the parameter data which is not in the control range to the control range by improving the preparation method.
In the invention, the parameter data of the width of the precursor alumina fiber blanket blank obtained in actual preparation is preferably measured by a meter ruler under the condition of not damaging the precursor alumina fiber blanket blank; after matching, the parameter data of the allowable deviation range of the width in the specification index of the precursor alumina fiber blanket blank is preferably controlled by adjusting the cotton collecting width of a cotton collector or the swing of a lapping machine so as to be adjusted to be within the allowable deviation range of the width in the specification index of the precursor alumina fiber blanket blank.
In the invention, the parameter data of the surface density of the precursor alumina fiber blanket blank which is actually prepared is preferably measured and calculated under the condition of not damaging the precursor alumina fiber blanket blank, and the calculation method is preferably specifically as follows:
precursor alumina fiber blanket blank surface Density Sd Precursor body ＝m Spinning solution ×K/(W Precursor target value ×L Precursor body )；
Wherein m is Spinning solution The flow rate of the spinning solution in unit time is K which is the fiber forming coefficient, W Precursor target value L is the width target value of precursor alumina fiber blanket blank Precursor body The conveying distance of the precursor fiber in unit time (calculated by conveying speed and conveying time); sd (Sd) Precursor body The surface density of the precursor alumina fiber blanket blank obtained in practice.
In the present invention, K is preferably 0.4 to 0.7, more preferably 0.5 to 0.65.
After the parameter data of the surface density of the precursor alumina fiber blanket blank obtained by actual preparation is matched, the parameter data of the allowable deviation range of the surface density in the specification index of the precursor alumina fiber blanket blank is preferably controlled by adjusting the flow rate of the spinning solution or the conveying line speed of the precursor fiber, so that the parameter data is adjusted to be within the allowable deviation range of the surface density in the specification index of the precursor alumina fiber blanket blank.
In the invention, the parameter data of the thickness of the precursor alumina fiber blanket blank obtained in practice is preferably measured by a needle thickness gauge under the condition of not damaging the fiber blanket; after matching, the parameter data of the allowable deviation range of the thickness in the specification index of the precursor alumina fiber blanket blank is preferably controlled by adjusting the needling frequency or the needle distribution mode so as to be adjusted to be within the allowable deviation range of the thickness in the specification index of the precursor alumina fiber blanket blank.
In the present invention, the bulk density of the precursor alumina fiber blanket blank is calculated by dividing the areal density by the thickness, and the thickness of the precursor alumina fiber blanket blank is also a variation, so that the bulk density is controlled by controlling the product of the bulk density and the target value of the thickness, that is, by controlling the areal density of the precursor alumina fiber blanket blank.
According to the invention, a corresponding relation between the specification of the alumina fiber blanket blank (precursor) and the specification of the finished alumina fiber blanket is obtained through a large amount of experimental study data and production experience and data, and the problems that the specification of the product is difficult to control and a large amount of waste products are caused by the fact that the precursor alumina fiber blanket blank is subjected to real-time measurement and adjustment of width, surface density and thickness (under the condition of not damaging the precursor alumina fiber blanket blank) to control the quality of the finished alumina fiber blanket product are solved, and the heat treatment time is long due to the change of parameters such as thickness, width and volume density before and after the heat treatment; all specifications of the obtained alumina fiber blanket product meet the requirements, and the rejection rate is reduced to below 20% from the original 35% -40%; the regulation and control method is simple, effective and feasible.
In the invention, the preparation method of the alumina fiber blanket product preferably comprises the following steps:
according to the mass content of alumina and silica in the product of (70-75): uniformly mixing an aluminum source with the aluminum oxide content of 25-35 wt% and a silicon source with the mass fraction of 15-25 wt%, adding an organic textile auxiliary (polyvinyl alcohol or polyvinylpyrrolidone) according to the proportion of 5-15 wt%, and carrying out polymerization reaction for 2-4 h at 80-100 ℃ to obtain spinning stock solution with the viscosity of 1000-5000 cP (at 50 ℃); forming fibers by using a spinning machine, wherein the viscosity of the spinning solution is 3000-5000 cP (at 25 ℃), the rotating speed of the spinning machine is 1000-4000 r/min, the spinning flow rate of the spinning solution per hour is 40-60 kg, further drying cotton collecting in a cotton collector, controlling the temperature of the cotton collector at 40-80 ℃ and the humidity at 10-20 RH%, controlling the conveying speed of a needling and cotton collecting net bag at 0.2-0.4 m/min, collecting cotton blanks with accumulated thickness of 150-400 mm, and curing for 15-25 min at 80-120 ℃ and 30-50 RH% relative humidity to obtain precursor fibers; finally, needling the precursor fiber by a needling machine at a needling frequency of 8 Hz-35 Hz to obtain a precursor alumina fiber blanket blank;
and finally, carrying out heat treatment on the obtained precursor alumina fiber blanket blank to obtain an alumina fiber blanket product.
More preferably:
according to the mass content of alumina and silica in the product of 72:28, uniformly mixing a polyaluminium chloride solution (aluminum source) with the aluminum oxide content of 30wt% with a silica sol (silicon source) with the mass fraction of 20wt%, adding polyvinyl alcohol according to the proportion of 10wt%, and carrying out polymerization reaction for 3 hours at 90 ℃ to obtain a spinning stock solution with the viscosity of 2000cP (at 50 ℃); using a spinning machine described in a patent CN102465358B for forming fibers, wherein the viscosity of spinning solution is 5000cP (at 25 ℃), the rotating speed of the spinning machine is 3000r/min, the spinning flow rate of the spinning solution per hour is 50kg, further drying cotton collecting in a cotton collector, controlling the temperature of the cotton collector to be 50-55 ℃, controlling the humidity to be 10-15 RH%, controlling the conveying speed of needling and a cotton collecting net bag to be 0.3m/min, collecting cotton blanks with accumulated thickness of 180mm, and curing for 20min at 100 ℃ and 40RH% relative humidity to obtain precursor fibers; finally, needling the precursor fiber by a needling machine at the needling frequency of 16Hz to obtain a precursor alumina fiber blanket blank;
and finally, conveying the obtained precursor alumina fiber blanket blank to a high-temperature heat treatment furnace for heat treatment to obtain an alumina fiber blanket product.
In the invention, the high-temperature heat treatment furnace preferably increases the temperature in the furnace to the highest calcination temperature and then reduces the temperature along the conveying direction of the precursor alumina fiber blanket blank, and specifically comprises the following steps: a low temperature zone, a medium temperature zone, a high temperature zone and a cooling zone; the temperature of the low temperature zone is preferably 0-600 ℃ so as to volatilize most of moisture, organic matters and acid components in the zone; the medium temperature zone is preferably 600-1100 ℃; the high temperature zone is preferably 1100-1300 ℃ in order to allow the crystallization process of the alumina fibers to proceed in this zone.
In the invention, the conveying speed of the precursor alumina fiber blanket blank in the high-temperature heat treatment furnace is preferably reduced along with the shrinkage of the precursor alumina fiber blanket blank in the heat treatment process, and specifically comprises the following steps:
the speed of the precursor alumina fiber blanket blank at the outlet of the high-temperature heat treatment furnace is preferably 0.60-0.80, more preferably 0.65-0.75, of the speed of the precursor alumina fiber blanket blank at the inlet of the high-temperature heat treatment furnace.
The invention provides a regulating and controlling method of an alumina fiber blanket blank, which comprises the following steps: a) Calculating the allowable deviation range of the specification index of the precursor alumina fiber blanket blank according to the standard requirement of the alumina fiber blanket product to obtain the control range of the specification index of the precursor alumina fiber blanket blank; the specification indexes comprise width, surface density and thickness; b) According to the control range of the specification index of the precursor alumina fiber blanket blank obtained in the step a), parameter data of the corresponding specification index of the precursor alumina fiber blanket blank obtained in the actual preparation is matched, and then the parameter data which are not in the control range are adjusted to be in the control range by improving the preparation method. According to the invention, a corresponding relation between the specification of the alumina fiber blanket blank (precursor) and the specification of the alumina fiber blanket finished product is obtained through a large amount of experimental study data and production experience and data, and the problems that the precursor alumina fiber blanket blank is subjected to real-time measurement and adjustment of width, surface density and thickness, the quality of the alumina fiber blanket finished product is controlled, and a large amount of waste products are caused due to the fact that the parameters such as thickness, width and volume density are changed before and after heat treatment, the heat treatment time is long, and the specification of the product is not easy to control are solved for the first time. Experimental results show that the regulation and control method of the alumina fiber blanket blank provided by the invention has the technical effects that under the same conditions, 70kg of unqualified products are reduced to 8kg, 61kg of rim charge is reduced to 52kg, 229kg of products are increased to 300kg, and the rejection rate is reduced to 16.7% from 36.4%.
In order to further illustrate the present invention, the following examples are provided. The preparation method of the precursor alumina fiber blanket blank used in the following embodiment of the invention specifically comprises the following steps:
according to the mass content of alumina and silica in the product of 72:28, uniformly mixing a polyaluminium chloride solution (aluminum source) with the aluminum oxide content of 30wt% with a silica sol (silicon source) with the mass fraction of 20wt%, adding an organic textile auxiliary polyvinyl alcohol according to the proportion of 10wt%, and carrying out polymerization reaction for 3 hours at 90 ℃ to obtain a spinning stock solution with the viscosity of 2000cP (at 50 ℃); using a spinning machine described in a patent CN102465358B for forming fibers, wherein the viscosity of spinning solution is 5000cP (at 25 ℃), the rotating speed of the spinning machine is 3000r/min, the spinning flow rate of the spinning solution per hour is 50kg, further drying cotton collecting in a cotton collector, controlling the temperature of the cotton collector to be 50-55 ℃, controlling the humidity to be 10-15 RH%, controlling the conveying speed of needling and a cotton collecting net bag to be 0.3m/min, collecting cotton blanks with accumulated thickness of 180mm, and curing for 20min at 100 ℃ and 40RH% relative humidity to obtain precursor fibers; and finally, needling the precursor fiber by a needling machine at the needling frequency of 16Hz to obtain a precursor alumina fiber blanket blank.
TABLE 1 dimensional and bulk Density tolerance ranges for alumina fiber blanket product Standard requirements
Examples
The preparation width is 610mm, the thickness is 12.5mm, and the volume density is 96kg/m 3 Is a blanket product of alumina fibers.
(1) According to the allowable deviation ranges of the size and the volume density required by the standard of the alumina fiber blanket product (table 1), the allowable deviation ranges of the width, the surface density and the thickness of the precursor alumina fiber blanket blank are calculated, and the specific process is as follows:
known proportionality coefficient K between precursor alumina fiber blanket blank and alumina fiber blanket product W =1.43, one side requires reserved scrap widthThe lower limit value of the width required by the product standard is 610mm which is equal to the target value, the upper limit value of the width required by the product standard is 615mm, and the control range of the width of the precursor alumina fiber blanket blank is calculated as follows:
W lower limit of precursor ＝W Precursor target value ＝K W ×(W Target value of product +2×W Leftover bits and pieces )＝1.43×(610+2×50)＝1015.3mm；
W Upper limit of precursor ＝K W ×(W Upper limit of product +2×W Leftover bits and pieces )＝1.43×(615+2×50)＝1022.5mm；
Known proportionality coefficient K between precursor alumina fiber blanket blank and alumina fiber blanket product Sd =0.89, the lower limit, target value and upper limit of the bulk density required by the product standard are 81kg/m respectively 3 、96kg/m 3 、111kg/m 2 The control range of the surface density of the precursor alumina fiber blanket blank is calculated as follows:
Sd precursor target value ＝K Sd ×Bd Target value of product ×T Target value of product ＝0.89×96×0.0125＝1.07kg/m 2 ；
Sd Precursor lower limit value ＝K Sd ×Bd Lower limit value of product ×T Target value of product ＝0.89×81×0.0125＝0.90kg/m 2 ；
Sd Precursor upper limit value ＝K Sd ×Bd Upper limit value of product ×T Target value of product ＝0.89×111×0.0125＝1.24kg/m 2 ；
Known proportionality coefficient K between precursor alumina fiber blanket blank and alumina fiber blanket product T The lower limit value, the target value and the upper limit value of the thickness required by the product standard are respectively 10.5mm, 12.5mm and 16.5mm, and the control range of the thickness of the precursor alumina fiber blanket blank is calculated as follows:
T precursor target value ＝K T ×T Target value of product ＝1.37×12.5＝17.13mm；
T Precursor lower limit value ＝K T ×T Lower limit value of product ＝1.37×10.5＝14.39mm；
T Precursor upper limit value ＝K T ×T Upper limit value of product ＝1.37×16.5＝22.61mm；
The control ranges of the three indexes of the width, the surface density and the thickness of the precursor alumina fiber blanket blank are shown in table 2 according to the calculation.
Table 2 control ranges for precursor alumina fiber blanket blank specification parameters in the examples
| Precursor alumina fiber blanket blank index control | Lower limit value | Target value | Upper limit value |
| Width (mm) | 1015.3 | 1015.3 | 1022.5 |
| Areal density (kg/m) 2 ) | 0.90 | 1.07 | 1.24 |
| Thickness (mm) | 14.39 | 17.13 | 22.61 |
(2) According to the control range of the three indexes of the width, the surface density and the thickness of the precursor alumina fiber blanket blank obtained in the step (1), matching the data of corresponding specification parameters (width, surface density and thickness) of the precursor alumina fiber blanket blank obtained in actual preparation, and then adjusting the specification parameter data which are not in the control range to be in the control range by improving the preparation method, wherein the specific process is as follows:
the width of the precursor alumina fiber blanket blank obtained by actual preparation is 1050mm, which is higher than the allowable upper limit value of the precursor alumina fiber blanket blank width in the control range, and the cotton collecting width of a cotton collector is adjusted, and the measurement is repeatedly carried out until the width is 1020mm;
according to a calculation formula of the surface density of the precursor alumina fiber blanket blank, the calculated surface density is as follows:
Sd precursor body ＝m Spinning solution ×K/(W Precursor target value ×L Precursor body )＝50×0.6/(1.0153×0.3×60)＝1.64kg/m 2 ；
And (3) the surface density of the precursor alumina fiber blanket blank is higher than the allowable upper limit value of the surface density of the precursor alumina fiber blanket blank in the control range, and for this purpose, the conveying speed of the precursor fiber is adjusted to 0.46m/min, and the surface density of the precursor alumina fiber blanket blank obtained through recalculation is as follows:
Sd precursor body ＝m Spinning solution ×K/(W Precursor target value ×L Precursor body )＝50×0.6/(1.0153×0.46×60)＝1.07kg/m 2 The target value of the surface density of the precursor alumina fiber blanket blank in the control range is met.
After the two parameters are adjusted, conveying the adjusted precursor fibers to a needling machine to complete needling to obtain precursor alumina fiber blanket blanks; and measuring the thickness of the precursor alumina fiber blanket blank by using a needle type thickness gauge, wherein the thickness of the precursor alumina fiber blanket blank is measured to be 22.8mm and is higher than the upper limit value allowed by the thickness of the precursor alumina fiber blanket blank in the control range, and the needling frequency is adjusted to 18Hz, so that the thickness of the precursor alumina fiber blanket blank is adjusted to be 17.5mm and basically accords with the target value of the thickness of the precursor alumina fiber blanket blank in the control range.
Finally, sequentially transmitting the regulated precursor alumina fiber blanket blank to a low-temperature section, a medium-temperature section, a high-temperature section and a cooling section of a blanket heating furnace for heat treatment; wherein, low temperature section entry line speed: 0.46m/min, temperature: the temperature is continuously increased along the material conveying direction at 200-600 ℃, and the heat treatment time is as follows: 1h, outlet line speed: 0.43m/min; medium temperature section inlet line speed: 0.43m/min, temperature: 600-1100 ℃, the temperature is continuously increased along the material conveying direction, and the heat treatment time is as follows: 1h, outlet line speed: 0.37m/min; high temperature section inlet line speed: 0.37m/min, heat treatment temperature: 1100-1300 ℃, and the heat treatment time is as follows: 1h, the outlet linear speed is 0.32m/min, the shrinkage of the fiber blanket is completed in the three sections, and the linear speed in the subsequent area is not continuously reduced; temperature of the cooling section: the temperature is between 1100 and 700 ℃ and is continuously reduced along the material conveying direction, and the heat treatment time is as follows: the line speed was maintained at 0.32m/min for 0.5 h. The fiber blanket blank after the heat treatment is trimmed by a cutter to obtain an alumina fiber blanket product; the size and surface density and volume density data of the obtained product are shown in the following table 3;
TABLE 3 data on the dimensions and areal density and bulk density of the alumina fiber blanket product produced
| Width (mm) | Areal density (kg/m) 2 ) | Thickness (mm) | |
| Precursor adjustment | 1050 | 1.64 | 20.8 |
| After precursor adjustment | 1020 | 1.07 | 17.5 |
| Adjusting the corresponding products (examples) | 713(610) | 1.20 (bulk density 94 kg/m) 3 ) | 12.77 |
| Unadjusted to the corresponding product (comparative example) | 734(610) | 1.84 | 16.64 |
| Standard required range | 610-615 | 0.9-1.24 | 10.5-14.5 |
As can be seen from Table 3, the indexes of the alumina fiber blanket product prepared by the embodiment of the invention are all within the range of the product requirement, the width before cutting is proper, the cutting requirement is met, and the waste caused by the too wide rim charge reservation does not exist; the total of 360kg of rim charge, product and waste products prepared in 24h is that the reject rate is 16.7% and the reject rate is 8kg of unqualified products, 52kg of rim charge and 300kg of product.
Comparative example (control of precursor alumina fiber blanket blank was not performed)
In the preparation process, if the width, the surface density and the thickness of the precursor alumina fiber blanket blank are not adjusted, the size, the surface density and the volume density data of the prepared product are shown in the table 3; the alumina fiber blanket product prepared in the comparative example can not meet the standard requirement of the product, the product produced in 3.5h in the heat treatment furnace can not reach the standard, and the reserved rim charge is too wide, so that a large amount of waste is caused; the total of 360kg of rim charge, product and waste products prepared in 24h is that the defective products are 70kg, the rim charge is 61kg, the product is 229kg and the rejection rate is 36.4%.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (9)
1. The regulation and control method of the alumina fiber blanket blank is characterized by comprising the following steps of:
a) Calculating the allowable deviation range of the specification index of the precursor alumina fiber blanket blank according to the standard requirement of the alumina fiber blanket product to obtain the control range of the specification index of the precursor alumina fiber blanket blank; the specification indexes comprise width, surface density and thickness;
b) According to the control range of the specification index of the precursor alumina fiber blanket blank obtained in the step a), matching the parameter data of the corresponding specification index of the precursor alumina fiber blanket blank obtained in the actual preparation, and then adjusting the parameter data which are not in the control range to be in the control range by improving the preparation method;
the specific process of the improved preparation method comprises the following steps:
parameter data of an allowable deviation range of the width which is not in the specification index is controlled by adjusting the cotton collecting width of the cotton collector or the swing of the lapping machine;
controlling parameter data of an allowable deviation range of the surface density which is not in the specification index by adjusting the flow rate of the spinning solution or the conveying line speed of the precursor fiber;
parameter data of an allowable deviation range of the thickness which is not in the specification index is controlled by adjusting the needling frequency or the needling mode.
2. The conditioning method according to claim 1, wherein the alumina fiber blanket product standard requirements in step a) include a size tolerance range and/or a bulk density tolerance range.
3. The method according to claim 1, wherein the calculating method of the allowable deviation range of the width in the specification index in step a) specifically includes:
target value of width W Precursor target value ＝K W ×(W Target value of product +2×W Leftover bits and pieces )；
Lower limit value W of width allowable deviation Lower limit of precursor ＝K W ×(W Lower limit value of product +2×W Leftover bits and pieces )；
Upper limit value W of width allowable deviation Upper limit of precursor ＝K W ×(W Upper limit of product +2×W Leftover bits and pieces )；
Wherein K is W Is the proportionality coefficient of the width of the precursor alumina fiber blanket blank and the width of the alumina fiber blanket product, W Leftover bits and pieces The cutting leftover width required to be reserved for one side.
4. A method of modulating according to claim 3, wherein K W Is 1.10 to 1.70, W Leftover bits and pieces 20 mm-200 mm.
5. The method according to claim 1, wherein the calculating method of the allowable deviation range of the surface density in the specification index in step a) specifically includes:
target areal density value Sd Precursor target value ＝K Sd ×Sd Target value of product ；
Permissible deviation of surface densityLower limit value Sd Precursor lower limit value ＝K Sd ×Sd Lower limit value of product ；
Upper limit Sd of permissible deviation of surface density Precursor upper limit value ＝K Sd ×Sd Upper limit value of product ；
Wherein K is Sd Is the proportionality coefficient of the surface density of the precursor alumina fiber blanket blank and the surface density of the alumina fiber blanket product.
6. The method according to claim 5, wherein the K is Sd 0.70 to 1.20.
7. The method according to claim 1, wherein the calculating method of the allowable deviation range of the thickness in the specification index in step a) specifically includes:
target value T of thickness Precursor target value ＝K T ×T Target value of product ；
Lower limit value T of thickness allowable deviation Precursor lower limit value ＝K T ×T Lower limit value of product ；
Upper limit value T of thickness allowable deviation Precursor upper limit value ＝K T ×T Upper limit value of product ；
Wherein K is T Is the proportionality coefficient of the thickness of the precursor alumina fiber blanket blank and the thickness of the alumina fiber blanket product.
8. The method of claim 7, wherein the K is T 1.35 to 1.60.
9. The method according to claim 1, wherein the method for calculating the surface density parameter data in the specification index of the precursor alumina fiber blanket blank actually prepared in step b) specifically comprises the following steps:
precursor alumina fiber blanket blank surface Density Sd Precursor body ＝m Spinning solution ×K/(W Precursor target value ×L Precursor body )；
Wherein m is Spinning solution The flow rate of the spinning solution in unit time is K which is the fiber forming coefficient, W Precursor target value L is the width target value of precursor alumina fiber blanket blank Precursor body Is the delivery distance of the precursor fiber per unit time;
the K is 0.4-0.7.
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