目前我國生產包頭合成鎂鈣砂所使用(yong)的(de)原(yuan)料有(you)菱(ling)鎂(mei)(mei)石(shi)(shi)(shi)(shi)、白(bai)(bai)云(yun)石(shi)(shi)(shi)(shi)和(he)石(shi)(shi)(shi)(shi)灰石(shi)(shi)(shi)(shi)。所采(cai)用(yong)的(de)工(gong)(gong)(gong)(gong)(gong)藝(yi)為二步煅(duan)燒(shao)、入工(gong)(gong)(gong)(gong)(gong)合成工(gong)(gong)(gong)(gong)(gong)藝(yi)。即(ji)先將菱(ling)鎂(mei)(mei)石(shi)(shi)(shi)(shi)、白(bai)(bai)云(yun)石(shi)(shi)(shi)(shi)和(he)石(shi)(shi)(shi)(shi)灰石(shi)(shi)(shi)(shi)在較低的(de)溫(wen)度(du)下輕(qing)燒(shao)，生產出輕(qing)燒(shao)氧化鎂(mei)(mei)、輕(qing)燒(shao)白(bai)(bai)云(yun)石(shi)(shi)(shi)(shi)和(he)生石(shi)(shi)(shi)(shi)灰。然后(hou)進行配(pei)料、磨(mo)細、混料、成型，最后(hou)經過(guo)高溫(wen)煅(duan)燒(shao)，煅(duan)燒(shao)出不同牌號的(de)合成鎂(mei)(mei)鈣砂。具體的(de)煅(duan)燒(shao)工(gong)(gong)(gong)(gong)(gong)藝(yi)有(you)半干法壓坯、隧(sui)道窯(yao)(yao)煅(duan)燒(shao)工(gong)(gong)(gong)(gong)(gong)藝(yi)；半干法壓球(qiu)、焦炭豎(shu)窯(yao)(yao)煅(duan)燒(shao)工(gong)(gong)(gong)(gong)(gong)藝(yi)；干法壓球(qiu)、高溫(wen)燃(ran)油(you)豎(shu)窯(yao)(yao)和(he)回轉窯(yao)(yao)煅(duan)燒(shao)工(gong)(gong)(gong)(gong)(gong)藝(yi)。

1、半干法壓坯、隧道窯(yao)煅燒(shao)工藝(yi)該(gai)煅燒(shao)工藝(yi)

生產合成鎂鈣砂是以生石灰和輕燒氧化鎂為原料。首先將生石灰加水消化成消石灰，然后將消石灰與輕燒氧化鎂配料，經過攪拌混合，入筒磨機內共同磨細、均化，再將磨細的合成料在輪碾機內加水混合成半干料，在摩擦壓力機上壓成具有一定外形尺寸的磚坯，經過干燥，裝于隧道窯車上，推入隧道窯內高溫煅燒成合成鎂鈣砂熟料。我國某公司煅燒合成鎂鈣砂使用的隧道窯規格為104.5m×2.0m×1.2m，共52個車位，以熱發生爐煤氣為燃料，設12對套管式煤氣燒嘴，煅燒溫度1620~1650℃，年產量1.5萬t。以隧道窯作為煅燒設備煅燒溫度均勻，保溫時間長，物料達到充分燒結。因此，可獲得高致密度的合成耐火原料。

2、半干法壓球(qiu)、焦炭豎窯煅(duan)燒工藝

該(gai)煅(duan)燒(shao)(shao)工(gong)藝(yi)生(sheng)產(chan)合(he)成(cheng)(cheng)(cheng)鎂鈣砂是以輕(qing)燒(shao)(shao)白(bai)云石和(he)(he)輕(qing)燒(shao)(shao)氧化鎂為原料。將輕(qing)燒(shao)(shao)白(bai)云石和(he)(he)輕(qing)燒(shao)(shao)氧化鎂分(fen)(fen)別(bie)磨成(cheng)(cheng)(cheng)細(xi)粉(fen)，計量后按(an)比例加(jia)入(ru)輪碾(nian)機中(zhong)(zhong)再(zai)加(jia)水(shui)混合(he)，混好的(de)合(he)成(cheng)(cheng)(cheng)料在雙輥壓球(qiu)機上壓成(cheng)(cheng)(cheng)料球(qiu)，干燥(zao)后裝入(ru)以焦(jiao)炭(tan)(tan)或無煙煤為燃料的(de)豎窯內煅(duan)燒(shao)(shao)。裝料方式是焦(jiao)炭(tan)(tan)或無煙煤和(he)(he)料球(qiu)分(fen)(fen)層裝入(ru)。我(wo)國遼寧省生(sheng)產(chan)合(he)成(cheng)(cheng)(cheng)鎂鈣砂的(de)企業(ye)中(zhong)(zhong)，大部(bu)分(fen)(fen)采用該(gai)煅(duan)燒(shao)(shao)工(gong)藝(yi)。所用豎窯的(de)規格一般為3m×16m。該(gai)煅(duan)燒(shao)(shao)工(gong)藝(yi)簡單(dan)，產(chan)品(pin)成(cheng)(cheng)(cheng)本低(di)，但(dan)在煅(duan)燒(shao)(shao)過程中(zhong)(zhong)料球(qiu)和(he)(he)焦(jiao)炭(tan)(tan)混在一起，焦(jiao)炭(tan)(tan)燃燒(shao)(shao)產(chan)生(sheng)的(de)灰分(fen)(fen)有一部(bu)分(fen)(fen)混入(ru)到料球(qiu)中(zhong)(zhong)，增加(jia)了產(chan)品(pin)的(de)雜質含(han)量。

3、干法(fa)壓球(qiu)、燃油(you)豎(shu)窯煅(duan)燒工藝

該煅(duan)燒(shao)(shao)(shao)工(gong)藝用(yong)(yong)于(yu)生(sheng)產(chan)高純(chun)(chun)度(du)(du)合成(cheng)鎂鈣(gai)砂。將高純(chun)(chun)度(du)(du)輕燒(shao)(shao)(shao)氧化鎂和輕燒(shao)(shao)(shao)白云石(shi)配(pei)料(liao)、混合磨細后，直接(jie)將干粉料(liao)送(song)入高壓(ya)壓(ya)球(qiu)機中(zhong)干壓(ya)成(cheng)球(qiu)，然(ran)后再送(song)入高溫燃(ran)油豎窯內煅(duan)燒(shao)(shao)(shao)。這(zhe)種煅(duan)燒(shao)(shao)(shao)工(gong)藝的優(you)勢(shi)是燃(ran)料(liao)油噴入到料(liao)層內，在料(liao)層內部燃(ran)燒(shao)(shao)(shao)，煅(duan)燒(shao)(shao)(shao)溫度(du)(du)高，可達(da)到1800℃以上；燃(ran)料(liao)燃(ran)燒(shao)(shao)(shao)后不(bu)產(chan)生(sheng)灰分，對物料(liao)的純(chun)(chun)度(du)(du)沒有(you)影響。目(mu)前(qian)，國內采用(yong)(yong)該煅(duan)燒(shao)(shao)(shao)工(gong)藝生(sheng)產(chan)合成(cheng)鎂鈣(gai)砂的企業，只(zhi)有(you)南方一(yi)(yi)家公司。該公司燃(ran)油豎窯的規格為φ1.75m×11.5m，窯的工(gong)作(zuo)(zuo)襯用(yong)(yong)高純(chun)(chun)度(du)(du)堿性耐火制(zhi)品砌(qi)筑(zhu)，厚度(du)(du)為350mm。工(gong)作(zuo)(zuo)襯于(yu)窯體鋼殼之間用(yong)(yong)輕質保溫磚砌(qi)筑(zhu)。以重柴油為燃(ran)料(liao)，煅(duan)燒(shao)(shao)(shao)溫度(du)(du)>1800℃。設計4排燒(shao)(shao)(shao)嘴(zui)(zui)，上下布置，間距900mm。每排設計16支燒(shao)(shao)(shao)嘴(zui)(zui)，沿圓周均布。采用(yong)(yong)無冷卻燒(shao)(shao)(shao)嘴(zui)(zui)，每支燒(shao)(shao)(shao)嘴(zui)(zui)配(pei)一(yi)(yi)臺計量泵供油，一(yi)(yi)次空氣(qi)由羅茨風(feng)機供應。實際生(sheng)產(chan)中(zhong)使用(yong)(yong)一(yi)(yi)排燒(shao)(shao)(shao)嘴(zui)(zui)。連續裝窯和出窯，全部自動化控制(zhi)，生(sheng)產(chan)能(neng)力。

4、干法壓(ya)球、回轉(zhuan)窯煅燒工藝

目前，國內有部分企業采用高溫回轉窯煅燒合成鎂鈣砂。其煅燒工藝為：將高純度輕燒氧化鎂和高純度輕燒白云石按比例配料后，經過攪拌昆合，磨成細粉，送入高壓壓球機中干壓成球，然后送入高溫回轉窯內煅燒。如某公司采用φ2.5m×60m超高溫回轉窯煅燒合成鎂鈣砂，以重油作燃料，采用機械霧化燒嘴，窯尾設煙氣換熱器，將一次空氣預熱到450~500℃，煅燒溫度>1850℃。煅燒CaO含量20%~30%合成鎂鈣砂，產量2~2.5t/h，油耗300kg/t。