目前我國生產巴中合成鎂鈣砂所(suo)使用(yong)的(de)原料有(you)菱鎂石(shi)(shi)(shi)(shi)、白云(yun)石(shi)(shi)(shi)(shi)和(he)石(shi)(shi)(shi)(shi)灰石(shi)(shi)(shi)(shi)。所(suo)采用(yong)的(de)工(gong)(gong)(gong)(gong)(gong)藝(yi)為二步煅燒(shao)、入工(gong)(gong)(gong)(gong)(gong)合成工(gong)(gong)(gong)(gong)(gong)藝(yi)。即先(xian)將菱鎂石(shi)(shi)(shi)(shi)、白云(yun)石(shi)(shi)(shi)(shi)和(he)石(shi)(shi)(shi)(shi)灰石(shi)(shi)(shi)(shi)在(zai)較(jiao)低的(de)溫(wen)(wen)度(du)下輕(qing)(qing)燒(shao)，生產出輕(qing)(qing)燒(shao)氧化鎂、輕(qing)(qing)燒(shao)白云(yun)石(shi)(shi)(shi)(shi)和(he)生石(shi)(shi)(shi)(shi)灰。然后進行配料、磨細、混料、成型(xing)，最后經過高溫(wen)(wen)煅燒(shao)，煅燒(shao)出不(bu)同牌號的(de)合成鎂鈣砂。具(ju)體的(de)煅燒(shao)工(gong)(gong)(gong)(gong)(gong)藝(yi)有(you)半干法(fa)壓坯、隧道窯(yao)(yao)煅燒(shao)工(gong)(gong)(gong)(gong)(gong)藝(yi)；半干法(fa)壓球(qiu)、焦炭豎(shu)窯(yao)(yao)煅燒(shao)工(gong)(gong)(gong)(gong)(gong)藝(yi)；干法(fa)壓球(qiu)、高溫(wen)(wen)燃(ran)油豎(shu)窯(yao)(yao)和(he)回轉窯(yao)(yao)煅燒(shao)工(gong)(gong)(gong)(gong)(gong)藝(yi)。

1、半干法(fa)壓坯、隧道窯煅(duan)燒(shao)工藝該煅(duan)燒(shao)工藝

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(ban)干法壓(ya)球(qiu)、焦炭豎窯煅燒工藝

該煅燒(shao)(shao)工藝生(sheng)(sheng)產(chan)合成(cheng)鎂鈣(gai)砂是以(yi)輕燒(shao)(shao)白(bai)云(yun)石(shi)和(he)輕燒(shao)(shao)氧化鎂為原料。將輕燒(shao)(shao)白(bai)云(yun)石(shi)和(he)輕燒(shao)(shao)氧化鎂分(fen)(fen)別(bie)磨成(cheng)細粉(fen)，計量后按(an)比例加(jia)(jia)入(ru)輪碾機中再加(jia)(jia)水混(hun)(hun)合，混(hun)(hun)好的(de)(de)合成(cheng)料在(zai)(zai)雙輥壓球機上壓成(cheng)料球，干燥后裝(zhuang)入(ru)以(yi)焦(jiao)(jiao)炭(tan)或無煙煤為燃(ran)料的(de)(de)豎(shu)窯內(nei)煅燒(shao)(shao)。裝(zhuang)料方式是焦(jiao)(jiao)炭(tan)或無煙煤和(he)料球分(fen)(fen)層裝(zhuang)入(ru)。我(wo)國(guo)遼寧省生(sheng)(sheng)產(chan)合成(cheng)鎂鈣(gai)砂的(de)(de)企(qi)業中，大部分(fen)(fen)采用該煅燒(shao)(shao)工藝。所(suo)用豎(shu)窯的(de)(de)規格一(yi)(yi)般(ban)為3m×16m。該煅燒(shao)(shao)工藝簡單，產(chan)品成(cheng)本低，但(dan)在(zai)(zai)煅燒(shao)(shao)過(guo)程中料球和(he)焦(jiao)(jiao)炭(tan)混(hun)(hun)在(zai)(zai)一(yi)(yi)起(qi)，焦(jiao)(jiao)炭(tan)燃(ran)燒(shao)(shao)產(chan)生(sheng)(sheng)的(de)(de)灰分(fen)(fen)有一(yi)(yi)部分(fen)(fen)混(hun)(hun)入(ru)到料球中，增加(jia)(jia)了產(chan)品的(de)(de)雜質含量。

3、干法壓球、燃油豎窯煅燒工(gong)藝(yi)

該(gai)煅燒(shao)(shao)(shao)工(gong)(gong)藝用(yong)(yong)于生(sheng)產(chan)高純(chun)度合成鎂鈣(gai)砂。將(jiang)高純(chun)度輕(qing)燒(shao)(shao)(shao)氧化鎂和(he)(he)輕(qing)燒(shao)(shao)(shao)白(bai)云石配(pei)料(liao)(liao)、混合磨細后(hou)，直接將(jiang)干粉料(liao)(liao)送(song)入高壓壓球(qiu)機(ji)中(zhong)干壓成球(qiu)，然后(hou)再送(song)入高溫燃(ran)(ran)(ran)油豎(shu)窯(yao)(yao)(yao)(yao)內煅燒(shao)(shao)(shao)。這種(zhong)煅燒(shao)(shao)(shao)工(gong)(gong)藝的(de)優勢是燃(ran)(ran)(ran)料(liao)(liao)油噴(pen)入到料(liao)(liao)層(ceng)內，在(zai)料(liao)(liao)層(ceng)內部燃(ran)(ran)(ran)燒(shao)(shao)(shao)，煅燒(shao)(shao)(shao)溫度高，可達到1800℃以(yi)上；燃(ran)(ran)(ran)料(liao)(liao)燃(ran)(ran)(ran)燒(shao)(shao)(shao)后(hou)不(bu)產(chan)生(sheng)灰分，對物料(liao)(liao)的(de)純(chun)度沒有(you)影響。目前，國內采用(yong)(yong)該(gai)煅燒(shao)(shao)(shao)工(gong)(gong)藝生(sheng)產(chan)合成鎂鈣(gai)砂的(de)企(qi)業，只有(you)南方一家(jia)公司(si)。該(gai)公司(si)燃(ran)(ran)(ran)油豎(shu)窯(yao)(yao)(yao)(yao)的(de)規格為φ1.75m×11.5m，窯(yao)(yao)(yao)(yao)的(de)工(gong)(gong)作襯用(yong)(yong)高純(chun)度堿性耐火制品砌筑，厚度為350mm。工(gong)(gong)作襯于窯(yao)(yao)(yao)(yao)體(ti)鋼殼之間(jian)用(yong)(yong)輕(qing)質(zhi)保溫磚砌筑。以(yi)重柴油為燃(ran)(ran)(ran)料(liao)(liao)，煅燒(shao)(shao)(shao)溫度>1800℃。設(she)計4排(pai)燒(shao)(shao)(shao)嘴(zui)，上下布置，間(jian)距900mm。每(mei)排(pai)設(she)計16支燒(shao)(shao)(shao)嘴(zui)，沿圓周均布。采用(yong)(yong)無冷卻燒(shao)(shao)(shao)嘴(zui)，每(mei)支燒(shao)(shao)(shao)嘴(zui)配(pei)一臺(tai)計量(liang)泵供(gong)油，一次空氣由羅(luo)茨風機(ji)供(gong)應。實(shi)際生(sheng)產(chan)中(zhong)使用(yong)(yong)一排(pai)燒(shao)(shao)(shao)嘴(zui)。連(lian)續裝窯(yao)(yao)(yao)(yao)和(he)(he)出窯(yao)(yao)(yao)(yao)，全部自(zi)動化控(kong)制，生(sheng)產(chan)能力。

4、干法壓球、回轉窯煅燒工藝

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。