Ceramic production process flow

The main process of ceramic tile production:

1, ball milling pulping of raw materials:

Ball milling is a process of grinding different granular raw materials into slurry according to a certain proportion. It requires the slurry after ball milling to reach the specified technological parameters such as fineness, moisture and fluidity; The main equipment includes various tonnage ball mills, pulp tanks, etc.

2, spray tower pulverizing:

Crushing is a process in which high-pressure atomized mud exchanges heat in a spray tower through hot air provided by a hot blast stove, so that the mud becomes powder. The main control parameters are powder moisture, particle gradation, bulk density and so on. The main equipment is the spray tower. The milling process is very important, and the quality of powder is usually distinguished by the size of "mesh".

3. Staleness and storage of silos:

The prepared powder is stored in the silo, and some organic substances in it corrode to make it have a certain viscosity and uniform moisture, so that the physical properties of this batch of powder are basically the same to meet the requirements of molding, drying and firing. The main equipment is several silos. Among them, Fujian produces the largest number of storage tanks for exterior wall tiles, and some reach dozens.

4, press forming:

Molding is mainly to press the powder into a blank with a certain specification with a large tonnage press. It determines the specification and thickness of the product, and the key point of control is the molding pressure, thickness and thickness difference to prevent delamination, corner crack, big head, big waist and cracked brick defects; The main equipment includes printing presses and various types of power distribution equipment.

At present, compression molding not only refers to compression molding, but also has important functions such as product surface decoration (antique bricks are not involved at present). At present, the largest press tonnage for producing ceramic plates in China has reached 1.68 million tons.

5, drying:

After the molded blank enters the drying kiln, the process of evaporating the excess water brought by the powder to the specified range is called drying, which is used to improve the strength of semi-finished products and meet the strength requirements of glaze line operation and printing process. Because water is easy to crack when it evaporates, it is very important to control the evaporation speed and running speed of water. The main equipment is drying kiln.

6, printing process (polishing brick adopts cloth technology):

Inorganic pigments are printed on the surface of dried bricks through screen after technological treatment (blending and dissolving according to the formula), and the process of achieving surface decoration effect is called printing. The key point of this link is to control the temperature of the blank before printing and the amount of water spray after printing, otherwise it is easy to have defects such as yin and yang color, blooming, lack of flowers and color difference. The main equipment includes flower machine, glaze cabinet and its auxiliary equipment. Some antique bricks are also printed with rollers.

7. Ignition:

Bricks with preliminary surface decoration do not have performance, and physical indexes such as strength need to be further improved. Calcined in a kiln at high temperature (about 1200℃). Roller kiln is often used in the production of polished tiles, which uses producer gas, heavy oil or diesel oil as fuel, which is a qualitative process of products. Defects such as deformation, hole burning, color difference, contamination and secondary deformation are easy to occur in the production process. The main equipment is a firing kiln.

8. Polishing:

Polishing, as the name implies, is the process of polishing the surface of semi-finished products calcined in the kiln to make their surfaces have a certain luster, and the products are formed in this process. It needs to control the cutting amount, which depends on the product. Brick penetration is generally about 0.6 mm, and the gloss of polished products is required to be above 95 degrees.

The defects in production mainly include diagonal line, bending edge, uneven or dull luster, corner collapse and edge collapse. In addition to conventional polishing, soft polishing technology has appeared in recent years.

Extended data

As a socialized mass production, the ceramic production process has the following characteristics compared with other industries:

1. Ceramic production process is a low continuous flow production process. Ceramic raw materials are put into production from one end of the factory, continuously processed in sequence, and finally become finished products. The whole process is complex and the continuity between processes is low.

2. The degree of mechanization and automation in the ceramic production process is low.

3. The ceramic production cycle is long. The production cycle of ceramic products refers to the total calendar time from the input of raw materials to the production of finished products through various processes.

4. In the process of ceramic production, the consumption of auxiliary materials such as gypsum model, sagger and boron plate is large.

5. Ceramic production needs to consume a lot of energy, such as coal, natural gas and electric energy.

6. Transportation is an important link in the production process of ceramic enterprises. There are many kinds of raw materials used in the production of ceramics, and the semi-finished products and finished products, as well as the surplus materials and wastes produced, have the characteristics of large quantity and large transportation volume.

7. Flue gas, dust, solid waste and industrial wastewater produced in the process of ceramic production seriously pollute the environment. At present, most kilns used in China's ceramic industry use coal and heavy oil as energy sources, which will emit a lot of flue gas. Enterprises should strictly control the concentration of flue gas and sulfur dioxide to meet the national emission standards. Strive to use resistance tunnel kiln or gas kiln to reduce air pollution.

8. The degree of specialization and cooperation in ceramic production process is low. For a long time, the level of mutual cooperation between ceramic industry enterprises is not high, the proportion of "all-round" factories is large or small, and the degree of specialization and socialization of auxiliary services is low.

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