目前我國生產巴彥淖爾合成鎂鈣砂所(suo)使用的(de)(de)(de)原料有菱(ling)鎂石(shi)(shi)(shi)、白云石(shi)(shi)(shi)和(he)石(shi)(shi)(shi)灰(hui)石(shi)(shi)(shi)。所(suo)采用的(de)(de)(de)工(gong)(gong)(gong)藝(yi)為二步煅(duan)燒(shao)(shao)(shao)(shao)(shao)、入(ru)工(gong)(gong)(gong)合成(cheng)工(gong)(gong)(gong)藝(yi)。即(ji)先將菱(ling)鎂石(shi)(shi)(shi)、白云石(shi)(shi)(shi)和(he)石(shi)(shi)(shi)灰(hui)石(shi)(shi)(shi)在(zai)較低(di)的(de)(de)(de)溫度下輕(qing)燒(shao)(shao)(shao)(shao)(shao)，生產(chan)出輕(qing)燒(shao)(shao)(shao)(shao)(shao)氧化(hua)鎂、輕(qing)燒(shao)(shao)(shao)(shao)(shao)白云石(shi)(shi)(shi)和(he)生石(shi)(shi)(shi)灰(hui)。然后(hou)進行配(pei)料、磨細、混(hun)料、成(cheng)型，最后(hou)經(jing)過高(gao)溫煅(duan)燒(shao)(shao)(shao)(shao)(shao)，煅(duan)燒(shao)(shao)(shao)(shao)(shao)出不同牌(pai)號的(de)(de)(de)合成(cheng)鎂鈣砂。具體的(de)(de)(de)煅(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)(gong)藝(yi)有半干法壓(ya)坯、隧(sui)道窯(yao)煅(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)(gong)藝(yi)；半干法壓(ya)球、焦炭(tan)豎窯(yao)煅(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)(gong)藝(yi)；干法壓(ya)球、高(gao)溫燃油豎窯(yao)和(he)回(hui)轉窯(yao)煅(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)(gong)藝(yi)。

1、半干法壓(ya)坯、隧道(dao)窯(yao)煅燒工藝該煅燒工藝

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、半干法壓球、焦炭豎(shu)窯煅(duan)燒工(gong)藝

該(gai)煅(duan)(duan)燒工(gong)藝(yi)生產(chan)合成(cheng)(cheng)鎂鈣砂是以(yi)輕(qing)燒白(bai)云石和(he)輕(qing)燒氧化鎂為(wei)(wei)原料(liao)(liao)(liao)。將(jiang)輕(qing)燒白(bai)云石和(he)輕(qing)燒氧化鎂分別磨成(cheng)(cheng)細粉，計量(liang)后(hou)(hou)按比(bi)例加入(ru)輪碾(nian)機中再加水混合，混好的合成(cheng)(cheng)料(liao)(liao)(liao)在雙輥壓球(qiu)(qiu)機上壓成(cheng)(cheng)料(liao)(liao)(liao)球(qiu)(qiu)，干(gan)燥后(hou)(hou)裝入(ru)以(yi)焦(jiao)炭(tan)(tan)或無(wu)煙煤(mei)為(wei)(wei)燃(ran)料(liao)(liao)(liao)的豎窯內煅(duan)(duan)燒。裝料(liao)(liao)(liao)方式是焦(jiao)炭(tan)(tan)或無(wu)煙煤(mei)和(he)料(liao)(liao)(liao)球(qiu)(qiu)分層裝入(ru)。我國(guo)遼寧省生產(chan)合成(cheng)(cheng)鎂鈣砂的企業中，大部(bu)分采用該(gai)煅(duan)(duan)燒工(gong)藝(yi)。所用豎窯的規(gui)格一(yi)般為(wei)(wei)3m×16m。該(gai)煅(duan)(duan)燒工(gong)藝(yi)簡單，產(chan)品(pin)成(cheng)(cheng)本低，但在煅(duan)(duan)燒過程中料(liao)(liao)(liao)球(qiu)(qiu)和(he)焦(jiao)炭(tan)(tan)混在一(yi)起，焦(jiao)炭(tan)(tan)燃(ran)燒產(chan)生的灰分有(you)一(yi)部(bu)分混入(ru)到料(liao)(liao)(liao)球(qiu)(qiu)中，增加了(le)產(chan)品(pin)的雜(za)質(zhi)含(han)量(liang)。

3、干法壓球、燃油(you)豎窯煅燒工(gong)藝(yi)

該煅(duan)燒(shao)(shao)(shao)工(gong)(gong)藝(yi)用(yong)于生(sheng)(sheng)產高純度(du)合成(cheng)鎂鈣(gai)砂。將高純度(du)輕(qing)燒(shao)(shao)(shao)氧化(hua)鎂和(he)輕(qing)燒(shao)(shao)(shao)白云石配料(liao)(liao)(liao)(liao)、混合磨細后(hou)，直接將干粉料(liao)(liao)(liao)(liao)送(song)入高壓壓球機中干壓成(cheng)球，然(ran)后(hou)再(zai)送(song)入高溫燃(ran)油(you)(you)(you)豎窯(yao)(yao)內(nei)煅(duan)燒(shao)(shao)(shao)。這種煅(duan)燒(shao)(shao)(shao)工(gong)(gong)藝(yi)的(de)優勢(shi)是燃(ran)料(liao)(liao)(liao)(liao)油(you)(you)(you)噴入到料(liao)(liao)(liao)(liao)層內(nei)，在(zai)料(liao)(liao)(liao)(liao)層內(nei)部燃(ran)燒(shao)(shao)(shao)，煅(duan)燒(shao)(shao)(shao)溫度(du)高，可達到1800℃以上(shang)；燃(ran)料(liao)(liao)(liao)(liao)燃(ran)燒(shao)(shao)(shao)后(hou)不產生(sheng)(sheng)灰分，對(dui)物(wu)料(liao)(liao)(liao)(liao)的(de)純度(du)沒有影響。目(mu)前，國內(nei)采用(yong)該煅(duan)燒(shao)(shao)(shao)工(gong)(gong)藝(yi)生(sheng)(sheng)產合成(cheng)鎂鈣(gai)砂的(de)企業，只(zhi)有南方一(yi)家公司。該公司燃(ran)油(you)(you)(you)豎窯(yao)(yao)的(de)規格為(wei)φ1.75m×11.5m，窯(yao)(yao)的(de)工(gong)(gong)作襯用(yong)高純度(du)堿性耐火制(zhi)品砌(qi)筑，厚(hou)度(du)為(wei)350mm。工(gong)(gong)作襯于窯(yao)(yao)體(ti)鋼殼(ke)之間(jian)用(yong)輕(qing)質保溫磚砌(qi)筑。以重柴(chai)油(you)(you)(you)為(wei)燃(ran)料(liao)(liao)(liao)(liao)，煅(duan)燒(shao)(shao)(shao)溫度(du)>1800℃。設(she)計(ji)(ji)4排(pai)燒(shao)(shao)(shao)嘴，上(shang)下布置，間(jian)距(ju)900mm。每排(pai)設(she)計(ji)(ji)16支(zhi)燒(shao)(shao)(shao)嘴，沿圓周均布。采用(yong)無冷卻(que)燒(shao)(shao)(shao)嘴，每支(zhi)燒(shao)(shao)(shao)嘴配一(yi)臺(tai)計(ji)(ji)量泵(beng)供油(you)(you)(you)，一(yi)次空氣(qi)由羅茨(ci)風機供應。實際生(sheng)(sheng)產中使用(yong)一(yi)排(pai)燒(shao)(shao)(shao)嘴。連續(xu)裝窯(yao)(yao)和(he)出窯(yao)(yao)，全(quan)部自動化(hua)控制(zhi)，生(sheng)(sheng)產能力。

4、干(gan)法壓球(qiu)、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。