目前我國生產烏魯木齊合成鎂鈣砂所(suo)使用的(de)(de)原料有(you)菱鎂(mei)石(shi)(shi)(shi)、白(bai)云石(shi)(shi)(shi)和石(shi)(shi)(shi)灰(hui)石(shi)(shi)(shi)。所(suo)采用的(de)(de)工(gong)(gong)藝為二步煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)、入工(gong)(gong)合成工(gong)(gong)藝。即(ji)先將菱鎂(mei)石(shi)(shi)(shi)、白(bai)云石(shi)(shi)(shi)和石(shi)(shi)(shi)灰(hui)石(shi)(shi)(shi)在較(jiao)低的(de)(de)溫度下輕燒(shao)(shao)(shao)(shao)(shao)，生產出輕燒(shao)(shao)(shao)(shao)(shao)氧化鎂(mei)、輕燒(shao)(shao)(shao)(shao)(shao)白(bai)云石(shi)(shi)(shi)和生石(shi)(shi)(shi)灰(hui)。然后(hou)進行(xing)配料、磨細、混料、成型，最(zui)后(hou)經(jing)過高溫煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)，煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)出不同(tong)牌號的(de)(de)合成鎂(mei)鈣(gai)砂。具(ju)體的(de)(de)煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)藝有(you)半干法壓(ya)坯、隧道窯(yao)煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)藝；半干法壓(ya)球(qiu)、焦炭豎(shu)窯(yao)煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)藝；干法壓(ya)球(qiu)、高溫燃油豎(shu)窯(yao)和回(hui)轉窯(yao)煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)藝。

1、半(ban)干法壓(ya)坯、隧道窯(yao)煅(duan)燒(shao)工(gong)藝該煅(duan)燒(shao)工(gong)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)干法壓球、焦炭豎窯煅(duan)燒工(gong)藝(yi)

該煅(duan)(duan)燒(shao)(shao)(shao)工(gong)藝生產(chan)合成(cheng)鎂(mei)(mei)鈣砂是以輕(qing)燒(shao)(shao)(shao)白云石和輕(qing)燒(shao)(shao)(shao)氧化(hua)鎂(mei)(mei)為原料。將輕(qing)燒(shao)(shao)(shao)白云石和輕(qing)燒(shao)(shao)(shao)氧化(hua)鎂(mei)(mei)分(fen)別磨成(cheng)細粉，計量后(hou)按比例(li)加入輪碾機(ji)中(zhong)再加水混(hun)合，混(hun)好的合成(cheng)料在雙輥壓球機(ji)上(shang)壓成(cheng)料球，干燥后(hou)裝(zhuang)(zhuang)入以焦(jiao)炭(tan)或無(wu)煙煤為燃(ran)料的豎(shu)窯(yao)內煅(duan)(duan)燒(shao)(shao)(shao)。裝(zhuang)(zhuang)料方(fang)式(shi)是焦(jiao)炭(tan)或無(wu)煙煤和料球分(fen)層裝(zhuang)(zhuang)入。我(wo)國遼寧省生產(chan)合成(cheng)鎂(mei)(mei)鈣砂的企業中(zhong)，大部分(fen)采用該煅(duan)(duan)燒(shao)(shao)(shao)工(gong)藝。所用豎(shu)窯(yao)的規格一般為3m×16m。該煅(duan)(duan)燒(shao)(shao)(shao)工(gong)藝簡單(dan)，產(chan)品(pin)成(cheng)本低，但在煅(duan)(duan)燒(shao)(shao)(shao)過程中(zhong)料球和焦(jiao)炭(tan)混(hun)在一起(qi)，焦(jiao)炭(tan)燃(ran)燒(shao)(shao)(shao)產(chan)生的灰分(fen)有一部分(fen)混(hun)入到料球中(zhong)，增加了產(chan)品(pin)的雜質(zhi)含量。

3、干法壓球(qiu)、燃(ran)油豎窯(yao)煅燒工(gong)藝

該煅燒(shao)(shao)(shao)工(gong)藝(yi)用(yong)(yong)于生產(chan)(chan)高純(chun)(chun)度(du)(du)合成鎂鈣砂。將高純(chun)(chun)度(du)(du)輕燒(shao)(shao)(shao)氧化鎂和輕燒(shao)(shao)(shao)白云(yun)石(shi)配料(liao)、混合磨細后(hou)，直接將干粉(fen)料(liao)送(song)入(ru)(ru)高壓(ya)壓(ya)球(qiu)機中(zhong)干壓(ya)成球(qiu)，然后(hou)再送(song)入(ru)(ru)高溫燃(ran)(ran)油(you)(you)豎窯(yao)內煅燒(shao)(shao)(shao)。這種煅燒(shao)(shao)(shao)工(gong)藝(yi)的(de)(de)(de)優(you)勢(shi)是燃(ran)(ran)料(liao)油(you)(you)噴入(ru)(ru)到料(liao)層(ceng)內，在料(liao)層(ceng)內部(bu)燃(ran)(ran)燒(shao)(shao)(shao)，煅燒(shao)(shao)(shao)溫度(du)(du)高，可達到1800℃以上(shang)；燃(ran)(ran)料(liao)燃(ran)(ran)燒(shao)(shao)(shao)后(hou)不產(chan)(chan)生灰(hui)分，對物(wu)料(liao)的(de)(de)(de)純(chun)(chun)度(du)(du)沒有影響(xiang)。目(mu)前，國內采用(yong)(yong)該煅燒(shao)(shao)(shao)工(gong)藝(yi)生產(chan)(chan)合成鎂鈣砂的(de)(de)(de)企業，只有南方一家(jia)公司。該公司燃(ran)(ran)油(you)(you)豎窯(yao)的(de)(de)(de)規格為φ1.75m×11.5m，窯(yao)的(de)(de)(de)工(gong)作(zuo)襯(chen)用(yong)(yong)高純(chun)(chun)度(du)(du)堿性耐(nai)火制品砌筑，厚度(du)(du)為350mm。工(gong)作(zuo)襯(chen)于窯(yao)體鋼殼之間用(yong)(yong)輕質保溫磚砌筑。以重柴油(you)(you)為燃(ran)(ran)料(liao)，煅燒(shao)(shao)(shao)溫度(du)(du)>1800℃。設計4排燒(shao)(shao)(shao)嘴(zui)，上(shang)下布置，間距900mm。每排設計16支燒(shao)(shao)(shao)嘴(zui)，沿圓周均(jun)布。采用(yong)(yong)無冷卻燒(shao)(shao)(shao)嘴(zui)，每支燒(shao)(shao)(shao)嘴(zui)配一臺計量泵(beng)供(gong)油(you)(you)，一次空氣(qi)由羅茨風機供(gong)應(ying)。實(shi)際生產(chan)(chan)中(zhong)使用(yong)(yong)一排燒(shao)(shao)(shao)嘴(zui)。連續(xu)裝窯(yao)和出窯(yao)，全部(bu)自動化控制，生產(chan)(chan)能(neng)力。

4、干法壓球、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。