化煉鋁爐渣為高級耐火材料商業化生產技術開發

Development of Commercial Production Technique for Reclaiming Aluminum Dross and Ash as High-Quality Refractory Materials

楊昇府(S. F. Yang) ； 王多美(T. M. Wang) ； 蔣世傑(S. J. Jiang) ； 劉雅萍(Y. P. Liu) ； 林憲平(X. P. Lin)

《鑛冶：中國鑛冶工程學會會刊》 58卷4期 (2014/12) Pp. 93-109

https://doi.org/10.30069/MM.201412_58(4).0009

摘要

鋁金屬冶煉爐渣與集塵灰無論從質與量來看，都具有相當之再利用經濟價值，應該從零廢棄和資源再利用觀點，發展以其為原料，來發展綠色材料化再利用技術，製作高級耐火材料。試驗所使用的鋁金屬冶煉爐渣與集塵灰樣品，先進行化學成份、毒性特性溶出程序和戴奧辛分析，其結果顯示煉鋁爐渣和集塵灰的主要化學組成為氧化鋁，有毒重金屬溶出和戴奧辛檢測結果符合管制標準。因此，進一步依據配比設計，以鋁金屬冶煉爐渣與集塵灰為原料，製作高級耐火材料。試驗結果顯示，建議羧甲基纖維素水溶液添加量大於7 wt%，可使粉體造粒均勻，耐火材料的生胚試體順利壓製成型且無缺陷，煅燒溫度則以大於1200℃為最佳。以煅燒溫度1200℃為例，高鋁耐火磚的真密度、體密度、視孔隙率和孔隙率分別為3.5 g/cm^3、1.8 g/cm^3、14% 和50%； 抗壓強度和抗彎強度分別可達391 kgf/cm^2和68kgf/cm^2；耐火材料的化學組成主要以氧化鋁為主，所佔的百分比為76.6 wt%；經由毒性特性溶出程序測試後並無重金屬溶出的疑慮。目前已完成230×114×65 mm的商業化尺寸開發，現有製作程序每批次至少可以生產1000塊以上的高級耐火材料。

關鍵字

鋁金屬冶煉爐渣 ； 鋁集塵灰 ； 耐火材料

並列摘要

We developed a commercial production technique that can reclaim aluminum dross and ash as high-quality refractory materials. The chemical composition, toxicity characteristic of leaching procedure (TCLP) and dioxins of aluminum dross and ash were analyzed to make sure the toxicity levels are within the legal limits. Then, we investigated the effects of aluminum dross and ash to carboxyl methyl cellulose (CMC) solution ratio on the properties of the refractory materials to optimize the production technique. The best sintering temperature is 1200℃ or higher and the amount of CMC solution added should be 7 wt % minimum. Test results showed that the refractory products when manufactured using 8% (V/W) CMC solution and sintered at 1200℃ has 3.5 g/cm^3 true density, 1.8 g/ cm^3 bulk density, 14 % open porosity, 50% porosity, 391 kgf/ cm^2 compressive strength, 68 kgf/cm^2 bending strength and 76.6 % Al_2O_3 concentration. The manufactured refractory material is proved to be environmentally friendly. The commercial size of refractory is 230×114×65 mm. The capacity of commercial manufacturing process for producing refractory material is higher than 1000 pieces/batch.