Chapter 3 Technology
3.1 Design principles
3.1.1 Using advanced and mature production technology and equipment, the degree of automation is relatively high, which can reduce labor intensity.
3.1.2 The process layout should be compact and reasonable, shorten the transportation distance, smooth the process, facilitate production and save investment.
3.1.3 Protect the health of workers and remove dust pollution sources.
3.1.4 Fully meet the process parameters provided by you. The process flow has been fully researched and determined by both parties.
3.2 Process flow
Hard raw material → coarse grinding →Moderate grinding → silo
↓
Soft raw materials → weathering → silo → ball mill → screening →
→ iron removal → slip stale → screening → iron removal → slip storage →
→ Casting → Green body Storage → Drying → Body Repair → Inspection
→ Glazing → Drying → Firing → Inspection → Packaging
← Drying ← Molding ← Tiremaking ← Development ← Product Selection
3.2.1 Process description:
3.2.1.1 Crushing of raw materials
The raw materials are transported into the factory, and the raw materials (feldspar, quartz) are stored in the leaky storage yard, and the degree of cleanliness is determined according to the actual situation. The hard raw materials mixed with foreign matter impurities should be checked and selected , and a jaw crusher and a fine crusher should be used for coarse crushing and secondary crushing, and the particle size is required to be below 5mm.
The soft raw material (clay) should be cleaned according to the situation. If it is mixed with foreign debris, it should be selected and weathered for 100 days (if it has been weathered in the shipping mine, this work is optional). ≤100mm.
3.2.1.2 Raw material storage and batching
The raw materials are transported from the raw material factory to the raw material workshop and distributed to various silos. The proportioning of raw materials is done on the weighing scale.
3.2.1.3 Preparation of blank and glaze paste
Slip: add the proportioned raw materials to the ball mill, then add constant water and a certain amount of electrolyte, body enhancer, and grinding aid. The ball milling cycle is 15 hours . ~3.5%. Particle size distribution: >32μm10%～13%; <10μm50%. After the slip is milled, it enters the first slurry storage tank through the vibrating screen, then is transported by the diaphragm pump, and sent to the second slurry storage tank through the iron removal and vibrating screen. The slip should be stored in the slurry storage tank.
Glaze: According to the formula of the glaze, it will be added to the ball mill in proportion. After 20-24 hours of grinding, the fineness of the glaze is 0.063μm, the sieve residue is 0.02%-0.05%, and the viscosity and fluidity of the glaze slurry should meet the technological requirements.
3.2.1.4 CastingCasting and drying
The slip is casted into a green body by micro-pressure grouting or high-pressure grouting , demoulded, dried, and then manually trimmed, and then sent to the fine blank warehouse.
3.2.1.5 Glazing and drying
Glazing process: blowing dust → spraying outer glaze → applying inner glaze → installing kiln car → drying (requires body moisture <1%) → entering the kiln.
3.2.1.6 Firing
For the large-scale production of toilets, to ensure the qualified rate of production, a high-efficiency tunnel kiln is used for the firing cycle of 16-18 hours.
3.2.1.7 Selection
After firing, it is manually selected. For some defective products, the method of re- glazing with resin or the method of secondary hot refilling and re-firing can be adopted to improve the qualification rate and reduce the cost. .
3.2.1.8 Edging
Grind the bottom surface of the toilet and the mounting surface of the basin.
3.2.1.9 Preparation of plaster mold
The gypsum automatic weighing and feeding system is selected. After the ingredients and stirring of the system, the gypsum slurry is poured into the master mold, and after a certain period of time, the mold is demolded, and then put into the drying room, and dried at 55 ° C ~ 75 ° C for 4 -5 days.
3.3 Main process indicators
3.3.1 Sanitary ceramics finished product rate and semi-finished product rate
serial number | product name | % of semi-finished products | Pass Rate% | |||
Casting | Drying | Glazing | Firing | |||
1 | One-piece toile | 70 | 98 | 98 | 93 | 60 |
2 | Close-coupled toilet | 80 | 98 | 98 | 95 | 75 |
3 | Wash Basin | 80 | 98 | 98 | 95 | 75 |
4 | Pedestal | 80 | 98 | 98 | 95 | 75 |
3.3.2 Process parameters
serial number. | project | index | unit | Remark |
1 | Raw material storage period | |||
1.1 | soft material | ≥ | ||
1.2 | hard material | ≥ | ||
2 | Raw material storage and transportation, picking loss | |||
2.1 | hard material | % | ||
2.1 | soft raw materials | % | ||
3 | Raw material natural moisture content (average) | |||
4 | Raw material processing and molding losses | % | ||
5 | Plaster mold usage | 100 | cycles | |
6 | Billet Milling Cycle | 15 | Hour | |
7 | glaze ball milling cycle | twenty four | Hour | |
8 | slip stale time | 12 | Day | |
9 | Slip moisture content | 25-30 | % | |
10 | Blank storage time | |||
10.1 | green body | 6 | Day | |
10.2 | white billet | 2 | Day | |
11 | slip temperature | 30 | °C | |
12 | Moisture content of glaze paste | 30-35 | % | |
13 | Average drying cycle | 10 | Day | |
14 | Average slip loss rate | 2 | % | |
15 | Average molding and drying pass rate | 98 | % | |
16 | Glazing pass rate | 98 | % | |
17 | Firing pass rate | 95 | % | |
18 | firing rate | 75-80 | % | |
19 | Tunnel kiln firing cycle | 16～18 | Hour | |
20 | Shuttle kiln firing cycle | 18 | Hour | |
twenty one | Maximum firing temperature | 1250 | °C | |
twenty two | Firing energy consumption | 1250 | Kcal/kg ceramicspcs | Tunnel Kiln |
twenty three | Refiring energy consumption | 1800 | Kcal/kg ceramicspcs | Shuttle Kiln |
3.3.3 Billet formula in Tangshan area (may be determined according to local raw material resource formula)
serial number | raw material name | Origin | Proportion |
1 | Quartz sand | ||
2 | Feldspar | ||
3 | Purple Wood Festival | ||
4 | Suzhou soil | ||
5 | Changwutu | ||
6 | Zhang village soil | ||
7 | Datong soil | ||
8 | talc | ||
9 | ball clay | ||
10 | Glazed Quartz | ||
11 | Glazed Feldspar | ||
12 | First-class Suzhou soil | ||
13 | ground calcium carbonate | ||
14 | burnt zinc oxide | ||
15 | Industrial alumina | ||
16 | water glass | ||
17 | soda ash | ||
18 | cellulose | ||
19 | Dedicated frit | ||
20 | Pigment | ||
twenty one | dolomite | ||
twenty two | Ultrafine Zirconium |
3.4 Work system and labor quota
serial number | Workshop section name | shift (class/day | operating hours | Capacity (Total number of people/class) | total (people) | ||
operating hours (hours/shift) | day/week | day/year | |||||
1 | Raw material section | ||||||
1.1 | director | ||||||
1.2 | technician | ||||||
1.3 | broken | ||||||
1.4 | Ingredients | ||||||
1.5 | Material selection | ||||||
2 | Clay making section | ||||||
2.1 | clay glaze | ||||||
2.2 | out, grinding | ||||||
2.3 | Physical inspection | ||||||
2.4 | substitute | ||||||
2.5 | overweight | ||||||
2.6 | dump truck | ||||||
2.7 | Slurry tank feeder | ||||||
3 | Casting section | ||||||
3.1 | Note repair | ||||||
3.2 | substitute | ||||||
3.3 | Sample Tube Manufacturing | ||||||
3.4 | Note repair blank worker | ||||||
3.5 | half inspection | ||||||
3.6 | Semi inspection billet | ||||||
4 | Glazing section | ||||||
4.1 | Glaze | ||||||
4.2 | Glazing for blanks | ||||||
4.3 | waste billet push slip | ||||||
4.4 | Semi-finished product count | ||||||
5 | Firing section | ||||||
5.1 | group leader | ||||||
5.2 | director | ||||||
5.3 | schedule | ||||||
5.4 | technology | ||||||
5.5 | firing director | ||||||
5.6 | firing schedule | ||||||
5.7 | Firing technology | ||||||
5.8 | kiln | ||||||
5.9 | Pull ceramics | ||||||
5.10 | Statistics | ||||||
5.11 | Ceramics | ||||||
5.12 | Ceramics grinding machine | ||||||
6 | mold workshop | ||||||
6.1 | Mold preparation | ||||||
6.2 | director | ||||||
6.3 | technician | ||||||
6.4 | Master mold staff | ||||||
6.5 | working mold maker | ||||||
6.6 | Mold Transport/Assembly and Disassembly | ||||||
6.7 | forklift driver | ||||||
7 | Finished product inspection section | ||||||
7.1 | director | ||||||
7.2 | test | ||||||
7.3 | test the water | ||||||
7.4 | repair | ||||||
8 | Finished product packaging section | ||||||
8.1 | Package | ||||||
8.2 | Transport handling | ||||||
8.3 | Ship | ||||||
8.4 | manage | ||||||
8.5 | statistics | ||||||
9 | Logistics management | ||||||
9.1 | factory manager | ||||||
9.2 | Deputy director | ||||||
9.3 | chief engineer | ||||||
9.4 | finance | ||||||
9.5 | statistics, labor | ||||||
9.6 | Production Plan | ||||||
9.7 | Sales | ||||||
9.8 | supply | ||||||
9.9 | library tube | ||||||
9.10 | logistics | ||||||
9.11 | bath | ||||||
9.12 | repair | ||||||
total | |||||||
*The personnel is a preliminary plan and can be adjusted according to the actual situation.
3.5 Process calculation
3.5.1 Annual output, kiln loading, glazing, drying, and molding of various products
serial number | product name | % of semi-finished products | Annual output (pcs/year) | |||
casting (pcs/year) | dry (pcs/year) | Glaze (pcs/year) | Loaded kiln (pcs/year) | |||
1 | One-piece | 479830 | 335881 | 329164 | 329164 | 300000 |
2 | Squatting Pan Pan | 131524 | 105219 | 103114 | 103114 | 96000 |
3 | Pedestal wash Basin | 139744 | 111795 | 107368 | 107368 | 102000 |
4 | Pedestal | 139744 | 111795 | 107368 | 107368 | 102000 |
total | 890842 | 664690 | 647014 | 647014 | 600000 | |
3.5.2 Raw material processing volume
Processing volume of raw materials and chemical materials for glaze:
serial number | raw material name | Origin | Proportion | Processing capacity (kg/day) | Processing capacity (kg/year) |
1 | Glazed Quartz | Liaoning | 20--30 | 661.5 | 198732 |
2 | Glazed Feldspar | Liaoning | 20--30 | 477 | 198732 |
3 | First-class Suzhou soil | Jiangsu | 2--6 | 95.4 | 39746 |
4 | ground calcium carbonate | Liaoning | 10--16 | 254.4 | 105990 |
5 | Ultrafine Zircon | Hebei | 8--15 | 238.5 | 99366 |
6 | dolomite | Liaoning | 2--10 | 195 | 66244 |
7 | burnt zinc oxide | Liaoning | 2--6 | 95.4 | 39746 |
8 | Industrial alumina | Shandong | 2--6 | 132.3 | 39745 |
9 | water glass | Hebei | 0.5 | 11 | 3311 |
10 | soda ash | Hebei | 0.3 | 6.6 | 1987 |
11 | cellulose | Liaoning | 0.2 | 4.4 | 1324 |
12 | Dedicated frit | Hebei | 1--4 | 88.2 | 26498 |
13 | Pigment | Shandong | 0--5 | 55.8 | 16561 |
total | 2840 | 840000 |
Processing volume of raw materials for blanks (may be determined according to the local raw material resource formula):
serial number | Raw material, chemical material name | Origin | Proportion | The daily processing volume of blanks (kg/day) | Annual processing volume of billets (kg/year) |
1 | Quartz sand | ||||
2 | Feldspar for billet | ||||
3 | Purple Wood Festival | ||||
4 | Suzhou soil | ||||
5 | Changwutu | ||||
6 | Zhang village soil | ||||
7 | Datong soil | ||||
8 | talc | ||||
9 | ball clay | ||||
10 | water glass | ||||
11 | soda ash | ||||
total |
3.5.3 Amount of gypsum mold, gypsum powder and kiln furniture
product type | Annual molding volume (pcs) | mold usage frequency | Mold gypsum powder quantity (kg) set | Number of molds required per year (sets) | Number of molds required per day (sets) | Annual quantity of gypsum powder (tons) |
One-pieceOne-piece Toilet | ||||||
Squatting Pan pan | ||||||
PedestalPedestal wash Basin | ||||||
PedestalPedestal | ||||||
Subtotal |
3.5.4 Fuel consumption
Tunnel Kiln
fuel Type | natural gas |
Calorific value (Kcal/m 3 ) | |
Daily consumption per kiln |
Shuttle Kiln
Fuel Type | natural gas |
Calorific value (Kcal/m 3 ) | |
consumption per kiln |
3.6 Selection of main equipment
3.6.1 Slip Making mill
Billet processing volume: 1xxxx tons/year
Ball mill specification: QM2700×4000P
Loading capacity: 10 tons/time
Ball milling cycle: 15 hours
Production shifts: three shifts
Annual working days: 300 days/year
600000×18×15
Number of units required: ----------------------------- = 3.125 units
300×10000×24×0.8×0.9
Number of selected units: 5 units (4 units for routain production, 1 unit standby for backup; consider peak power consumption)
3.6.2 Glaze grinding
Glaze: Ball Mill Mold: QM2200×2200P
Glaze processing volume: 867 tons/year
Glaze grinding cycle: 24 hours
Glaze grinding specifications: 2.5 tons/time
Annual working days: 300 days/year
600000×1.3×24
Number of glaze mills: ----------------------------- = 1.16
300×24×2500×0.9
The number of 2.5 ton ball mills selected: 3 sets (2 sets in operation while1 set standby)
3.6.3 Casting Slip Pressure tank
Daily actual pulp consumption: 50.4 tons
Semi-finished product rate: 0.9
Utilization: 0.9
Daily pulp utilization rate: 40%
50.4
Daily pulp supply: ----------------------------- = 86.4m 3
0.9×0.9×0.4×1.8
The volume of the pressure casting tank required:
pressure tanks of 20m3 5 sets , totaling 100m3
3.6.4 Casting and pouring machine production line
serial number | product type | Proportion | Annual output (K pcs) | annual working days (Day) | Pass rate | number of online molds (indivual) | Number of vertical casting lines (strip) | Remark |
1
| One-piece toilet | 50% | 300 | 300 | ||||
2 | Squatting Pan | 16% | 96 | 300 | ||||
3 | Pedestal Wash Basin | 17% | 102 | 300 | ||||
4 | Pedestal | 17% | 102 | 300 | ||||
total | 100% | 600 | 105 |
Note: It can be adjusted according to the specific product shape.
3.6.5 Box-type dryer : installed capacity of 24KW, rated heat: 80×10 4 Kcal/h, thermal efficiency ≥85%.
Work intermittently. Drying cycle is 5 days. The recycled heat of the kiln is used for the drying process and introduced into the molding workshop afterwards.
According to the needs of heat, 2 sets of HX series hot blast stoves are selected.
3.6.6 Glazing equipment:
Glazing pass rate: 98%
An average of 80 pcs of glazing are applied per person per day
Spray glaze production in two shifts
Therefore, the number of spray glaze cabinets selected is:
3.6.7 Firing tunnel kiln : According to the experience of Tangshan Huida, Guangdong Wrigley and other factories, D series tunnel kiln is selected. The specific parameters are as follows:
Kiln width: 2?00mm
Kiln length: 9?000mm
Effective height: 9?0 mm
Cars inside the kiln: 5? (22 outside the kiln)
Kiln car size: 1?00×2?00 (length×width)
Fuel: Natural Gas
Fuel calorific value: 8600Kcal/m 3
Firing cycle: 16-18 hours
Firing pass rate: ≥95%
ceramicsDaily Output: 2000 pcs/piece
Annual working days: 335 days
Maximum firing temperature: 1250℃
Energy consumption per unit product: 1250kcal/kg ceramics ±10%
Installed capacity: 178.5KW
Control mode: Fieldbus + man-machine interface + PLC (programmable)
Operation mode: automatic continuous feeding and output of the cars
3.6.8 The specific parameters of the refiring shuttle kiln are as follows:
Inner width: 4200mm
Kiln length: 13300mm
Inner height: 1800mm
Fuel: Natural Gas
Fuel calorific value: 8600Kcal/m 3
Average product weight: 15kg
Kiln car size: 1500 × 4000 (length × width) mm
Product loading quantity: 80 pcs/car 7.5t ceramics
Firing cycle: 1 kiln ceramics/day
Sunrise ceramics volume: 560 pcs
Annual working days: 300 days
Energy consumption per unit product: 1800 kcal/kg ceramics ±10%
Fuel consumption: 1500m 3 /kiln time±10%
Product loading form: One-piece 2 layers, close-coupled 3 layers
Control mode: single-point pulse + man-machine interface + PLC (programmable)
Fan control: variable frequency speed regulation
Kiln door opening form: double-leaf horizontal push hydraulic opening
3.6.8 Finished product inspection
The standards for finished product inspection are determined in accordance with national standards and in combination with customer requirements.
3.6.9 Plaster mold
The plaster of paris is purchased from outside, and the mold is made in the factory. In order to ensure the quality of the gypsum mold, a vacuum gypsum mixer was used to stir the gypsum powder with 10°C water.
Mold drying room dedicated HX series rapid dryer, drying room indoor temperature can reach 50 ℃ ~ 75 ℃. It can ensure uniform indoor temperature, and the circulating air device can ensure energy saving.
3.7 Process equipment table (see Table 1 for details)