Research and Development Technology of Imitation Ceramic Glass Bottles (I)
2019-08-11 04:02:43
In recent years, inorganic sprayed glass bottles look like ceramic bottles, so they are commonly referred to as pottery bottles. It has the advantages of non-bleeding and uniform appearance and size. However, domestic pottery bottles are mostly produced by hand, and their efficiency is very low, so it is difficult to meet the market demand. We have cooperated with the glaze expert of Beijing University of Technology and Shandong Institute of Light Industry to successfully develop the industrialized production line of pottery and have been operating stably for more than two years.
First, the imitation pottery process The imitation pottery team uses low-temperature glass imitation pottery coatings to carry out many experiments for industrialized production. In order to ensure the stability and continuity of industrial production, the following process is adopted:
1. Process flow chart Glass bottle → Cleaning → Drying → Bottle up → High-pressure electrostatic auxiliary spraying → Online hot air drying → Lower bottle → Turnover tank → Kiln firing → Out Kiln inspection → (Decal → Turnover box → Kiln baking → Out of the kiln inspection) → The process of combining roasted flowers is shown in the brackets.
First, the imitation pottery process The imitation pottery team uses low-temperature glass imitation pottery coatings to carry out many experiments for industrialized production. In order to ensure the stability and continuity of industrial production, the following process is adopted:
1. Process flow chart Glass bottle → Cleaning → Drying → Bottle up → High-pressure electrostatic auxiliary spraying → Online hot air drying → Lower bottle → Turnover tank → Kiln firing → Out Kiln inspection → (Decal → Turnover box → Kiln baking → Out of the kiln inspection) → The process of combining roasted flowers is shown in the brackets.
2. Process description The industrialized pottery production line consists of three parts: automatic spraying, on-line drying and firing systems. The entire production line adopts chain transmission. The clean bottles are bottled, sprayed in a single row in the spraying room, dried in the drying room, rolled off the line, put into the turnover box, sent to the kiln for sintering, and packaged after inspection. . According to the production situation, fired pottery-like glass bottles can be decaled and baked.
(1) The automatic spraying system utilizes high-pressure electrostatic spraying, adopts a multi-spray nozzle with a large chance of even spraying, and the glass bottle spins to ensure that the bottle is evenly affected by the slurry. Under the action of the electrostatic generator, the workpiece (glass bottle) is positively charged, and the principle of charge anisotropic attraction is used to realize the combination of the workpiece and the powder fog. The paint uses an improved low temperature glass glaze.
(2) On-line drying system, online drying after spraying bottle. After drying, the semi-finished products can be easily transported and the quality can be guaranteed.
(3) The roasted flowers are roasted in a standard kiln.
3. Description of the current imitation ceramic coating is low-temperature glass powder, which is similar to that used in the ceramic industry. Add water and a blending agent before spraying. However, because the glass surface is relatively smooth, the water absorption rate is very low, and the sag phenomenon is likely to occur when the slurry is hydrated. When the surface of the slurry is repeatedly sprayed, the slurry is uneven and the color is uneven after baking. It is necessary to make good use of high-voltage electrostatic equipment to successfully paint once.
Bottles entering the spraying room in a single row are mainly considering the simplification of the system and the spraying effect.
(1) The automatic spraying system utilizes high-pressure electrostatic spraying, adopts a multi-spray nozzle with a large chance of even spraying, and the glass bottle spins to ensure that the bottle is evenly affected by the slurry. Under the action of the electrostatic generator, the workpiece (glass bottle) is positively charged, and the principle of charge anisotropic attraction is used to realize the combination of the workpiece and the powder fog. The paint uses an improved low temperature glass glaze.
(2) On-line drying system, online drying after spraying bottle. After drying, the semi-finished products can be easily transported and the quality can be guaranteed.
(3) The roasted flowers are roasted in a standard kiln.
3. Description of the current imitation ceramic coating is low-temperature glass powder, which is similar to that used in the ceramic industry. Add water and a blending agent before spraying. However, because the glass surface is relatively smooth, the water absorption rate is very low, and the sag phenomenon is likely to occur when the slurry is hydrated. When the surface of the slurry is repeatedly sprayed, the slurry is uneven and the color is uneven after baking. It is necessary to make good use of high-voltage electrostatic equipment to successfully paint once.
Bottles entering the spraying room in a single row are mainly considering the simplification of the system and the spraying effect.
Second, the design of production capacity and process balance calculation
1. Production capacity The production capacity of Nissan ceramic pots (24 hours) is 20,000, and the annual production capacity is 6.6 million.
Production line transmission speed V=2m/min
Glass holder center distance B=100mm
Spray glass bottle per minute F=V/B=2000/100=20pcs/min Theoretical daily production Q theory=F×24×60=20×24×60=28800pcs/day considering production actual situation, daily operation There are replacement paints, mechanical troubleshooting, etc., and 95% sprayed qualified products are sprayed every day for 20 hours. The expected sprayed products are:
Q spray = Q Li * 20 ÷ 24 × 0.95 = 22800 / day firing qualified imitation pottery, according to the yield of 95%, after the pass rate of 95%.
Then the fired pottery pots with Q-shape = Q sprayed × 0.95 = 21,660 pieces / day Qualified bottle after baking Q baked = Q-burn × 0.95 = 20577 / day
2. Daily consumption of glass bottles for each process
Glass bottle daily dosage for each process
Process Before processing (one) Yield (%) After processing (one)
Cleaning and drying 24243 99 24000
Spraying 24000 95 22800
Fired 22800 95 21660
Applique decoration 21660 95 20577
3, paint consumption Industrial production, each 500ml glass bottle coating amount of 8g (dry basis).
The actual input of glass bottles per day is 24,000 (calculated on a daily basis for 20 hours).
The actual daily consumption of paint is Q=24000×8=192000g=192kg
The annual working day is calculated as 330 days, then the dry powder consumption of the paint is:
192×330=63360kg
4. Water consumption The main water consumption channels are:
(1) Slurry water required for coating Q1 occurs every day;
(2) replacement of paint cleaning water Q2, intermittent;
(3) Compressor cooling water demand Q3 occurs every day;
The daily water consumption Q water = Q1 + Q2 + Q3 = 0.040 + 0.020 + 0.020 = 0.080 m3 / d, the water quality can be ordinary tap water.
5, daily consumption of blender Q adjustment = 0.040m3/d
The annual consumption is 0.040m3/dx330=13.2m3, about 14 tons.
The total annual transportation volume of the entire line was 6,081.72 tons, 3,290.86 tons of glass bottles, 63.360 tons of powder coatings (calculated at an annual output of 6.6 million pieces, average weight of 450 grams), 14 tons of blending agent, and 6,401.48 tons of finished products.
6, the daily consumption of electricity The electricity consumption channels mainly include:
(1) Air compressor power 22Kw, load 70%, daily electricity Q1, continuous operation;
(2) mechanical transmission power 5kw +0.75kw, load 70%, daily electricity Q2, continuous operation;
(3) Hot air circulation fan 1.25kw, load 70%, daily power Q3, continuous operation;
(4) Dust blower 1.5kw, load 70%, daily electricity Q4, continuous operation;
(5) The slurry mixer motor 0.5kw, load 70%, daily electricity Q5, continuous operation;
(6) Electric heating drying furnace 24kw, load 70%, daily electricity Q6, continuous operation; Q electricity = Q1+Q2+Q3+Q4+Q5+Q6=
369.6+96.6+21+25.2+8.4+403.2=924 degrees/day Energy Consumption Table of the Imitation Pottery Line Project Day of the Month Year
Electricity 924Kwh 27720Kwh 337260Kwh
Water 0.080m3 2.4m3 29.2m3
Coating 192Kg 5760Kg 63360Kg
Reconciliation agent 0.04m3 1.2m3 13.2m3
7. Work System Three shifts.
8, Labor capacity (not including decals and roasted flowers)
Spraying operation: 1 person Imitation ceramic hanging bottle: 1 person Imitation ceramic unloading bottle: 1 person Shipping bottle: 1 person Total: 12 people
1. Production capacity The production capacity of Nissan ceramic pots (24 hours) is 20,000, and the annual production capacity is 6.6 million.
Production line transmission speed V=2m/min
Glass holder center distance B=100mm
Spray glass bottle per minute F=V/B=2000/100=20pcs/min Theoretical daily production Q theory=F×24×60=20×24×60=28800pcs/day considering production actual situation, daily operation There are replacement paints, mechanical troubleshooting, etc., and 95% sprayed qualified products are sprayed every day for 20 hours. The expected sprayed products are:
Q spray = Q Li * 20 ÷ 24 × 0.95 = 22800 / day firing qualified imitation pottery, according to the yield of 95%, after the pass rate of 95%.
Then the fired pottery pots with Q-shape = Q sprayed × 0.95 = 21,660 pieces / day Qualified bottle after baking Q baked = Q-burn × 0.95 = 20577 / day
2. Daily consumption of glass bottles for each process
Glass bottle daily dosage for each process
Process Before processing (one) Yield (%) After processing (one)
Cleaning and drying 24243 99 24000
Spraying 24000 95 22800
Fired 22800 95 21660
Applique decoration 21660 95 20577
3, paint consumption Industrial production, each 500ml glass bottle coating amount of 8g (dry basis).
The actual input of glass bottles per day is 24,000 (calculated on a daily basis for 20 hours).
The actual daily consumption of paint is Q=24000×8=192000g=192kg
The annual working day is calculated as 330 days, then the dry powder consumption of the paint is:
192×330=63360kg
4. Water consumption The main water consumption channels are:
(1) Slurry water required for coating Q1 occurs every day;
(2) replacement of paint cleaning water Q2, intermittent;
(3) Compressor cooling water demand Q3 occurs every day;
The daily water consumption Q water = Q1 + Q2 + Q3 = 0.040 + 0.020 + 0.020 = 0.080 m3 / d, the water quality can be ordinary tap water.
5, daily consumption of blender Q adjustment = 0.040m3/d
The annual consumption is 0.040m3/dx330=13.2m3, about 14 tons.
The total annual transportation volume of the entire line was 6,081.72 tons, 3,290.86 tons of glass bottles, 63.360 tons of powder coatings (calculated at an annual output of 6.6 million pieces, average weight of 450 grams), 14 tons of blending agent, and 6,401.48 tons of finished products.
6, the daily consumption of electricity The electricity consumption channels mainly include:
(1) Air compressor power 22Kw, load 70%, daily electricity Q1, continuous operation;
(2) mechanical transmission power 5kw +0.75kw, load 70%, daily electricity Q2, continuous operation;
(3) Hot air circulation fan 1.25kw, load 70%, daily power Q3, continuous operation;
(4) Dust blower 1.5kw, load 70%, daily electricity Q4, continuous operation;
(5) The slurry mixer motor 0.5kw, load 70%, daily electricity Q5, continuous operation;
(6) Electric heating drying furnace 24kw, load 70%, daily electricity Q6, continuous operation; Q electricity = Q1+Q2+Q3+Q4+Q5+Q6=
369.6+96.6+21+25.2+8.4+403.2=924 degrees/day Energy Consumption Table of the Imitation Pottery Line Project Day of the Month Year
Electricity 924Kwh 27720Kwh 337260Kwh
Water 0.080m3 2.4m3 29.2m3
Coating 192Kg 5760Kg 63360Kg
Reconciliation agent 0.04m3 1.2m3 13.2m3
7. Work System Three shifts.
8, Labor capacity (not including decals and roasted flowers)
Spraying operation: 1 person Imitation ceramic hanging bottle: 1 person Imitation ceramic unloading bottle: 1 person Shipping bottle: 1 person Total: 12 people
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