基于响应曲面法的除尘灰与粉煤灰冷固结工艺优化

Process optimization for dust removal ash and fly ash cold consolidation based on response surface methodology

为了实现除尘灰与粉煤灰的高附加值协同利用,提出了除尘灰与粉煤灰协同制备陶瓷纤维的方法。传统的矿粉造块工艺参数不适用于除尘灰与粉煤灰的混合料,因此选择落下强度作为评价指标,水分含量、黏结剂配比、成型压力为主要影响因素,采用响应曲面法对除尘灰与粉煤灰冷固结成型的工艺参数重新进行优化设计与分析。结果表明,水分含量和黏结剂配比对落下强度影响显著,而成型压力的影响较小;水分含量和黏结剂配比的交互作用明显。通过分析试验结果建立了此配料情况下的落下强度二项式模型,模型预测的最优工艺参数为水分含量(质量分数)7.68%、黏结剂配比5.91%、成型压力38.8 MPa,按此参数进行试验,得到的落下强度与模型预测的误差小于2%,可以作为预测模型使用。按此参数进行不同粉煤灰与除尘灰的配比试验,结果符合预期,可为后续高温还原试验提供合格冷固结压块。

In order to realize the high value-added synergistic utilization of dust remoral ash and fly ash,a method of preparing ceramic fiber by dust removal ash and fly ash was proposed.Because the traditional slag powder agglomeration process parameters were not suitable for the mixture of dust removal ash and fly ash,the drop strength was chosen as the evaluation index,and the water content,binder ratio and molding pressure as main influencing factors.The response surface methodology was used to optimize the design and analysis for process parameters of cold consolidation molding for dust removal ash and fly ash.The results show that the water content and binder ratio has significant effect on the drop strength,while the molding pressure has little effect.The interaction between water content and binder ratio is obvious.By analyzing the experimental results,a binomial model of the drop strength under this batching condition was established.The optimal process parameters predicted by the model are water mass fraction 7.68%,binder ratio 5.91%,and molding pressure 38.8 MPa.Experiments are conducted using these parameters,and the error between the drop strength obtained and the model prediction is less than 2%,which can be used as the prediction model.According to this parameter,the ratio test of different fly ash and dust removal ash is conducted,and the results meet the expectations,which can provide qualified cold consolidation press blocks for subsequent high-temperature reduction experiments.