目前我國生產長寧合成鎂鈣砂所使用的原料有(you)菱鎂石(shi)(shi)(shi)、白(bai)(bai)云石(shi)(shi)(shi)和石(shi)(shi)(shi)灰(hui)石(shi)(shi)(shi)。所采用的工(gong)(gong)(gong)藝(yi)為二步(bu)煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)、入工(gong)(gong)(gong)合(he)成(cheng)工(gong)(gong)(gong)藝(yi)。即先將菱鎂石(shi)(shi)(shi)、白(bai)(bai)云石(shi)(shi)(shi)和石(shi)(shi)(shi)灰(hui)石(shi)(shi)(shi)在較低的溫(wen)度下輕(qing)(qing)燒(shao)(shao)(shao)(shao)(shao)，生(sheng)產(chan)出輕(qing)(qing)燒(shao)(shao)(shao)(shao)(shao)氧化鎂、輕(qing)(qing)燒(shao)(shao)(shao)(shao)(shao)白(bai)(bai)云石(shi)(shi)(shi)和生(sheng)石(shi)(shi)(shi)灰(hui)。然后(hou)進(jin)行配料、磨細、混料、成(cheng)型，最后(hou)經(jing)過高溫(wen)煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)，煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)出不同牌號(hao)的合(he)成(cheng)鎂鈣砂(sha)。具體的煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)(gong)藝(yi)有(you)半(ban)干(gan)法壓坯、隧道窯(yao)(yao)煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)(gong)藝(yi)；半(ban)干(gan)法壓球、焦炭豎窯(yao)(yao)煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)(gong)藝(yi)；干(gan)法壓球、高溫(wen)燃油(you)豎窯(yao)(yao)和回轉窯(yao)(yao)煅(duan)(duan)(duan)燒(shao)(shao)(shao)(shao)(shao)工(gong)(gong)(gong)藝(yi)。

1、半干法(fa)壓坯、隧(sui)道窯(yao)煅(duan)燒(shao)工(gong)(gong)藝(yi)該(gai)煅(duan)燒(shao)工(gong)(gong)藝(yi)

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(jiao)炭(tan)豎窯煅(duan)燒工藝

該(gai)(gai)煅(duan)燒(shao)(shao)(shao)工(gong)藝生(sheng)產合成鎂(mei)鈣(gai)砂(sha)是(shi)以(yi)輕燒(shao)(shao)(shao)白云石和(he)輕燒(shao)(shao)(shao)氧化鎂(mei)為(wei)原料(liao)。將輕燒(shao)(shao)(shao)白云石和(he)輕燒(shao)(shao)(shao)氧化鎂(mei)分(fen)別磨成細(xi)粉，計量(liang)后(hou)按比例加入輪(lun)碾機(ji)中(zhong)(zhong)再加水(shui)混合，混好的(de)(de)合成料(liao)在(zai)雙(shuang)輥壓(ya)球機(ji)上壓(ya)成料(liao)球，干燥后(hou)裝(zhuang)入以(yi)焦(jiao)炭(tan)或無煙煤(mei)為(wei)燃(ran)料(liao)的(de)(de)豎(shu)(shu)窯(yao)內煅(duan)燒(shao)(shao)(shao)。裝(zhuang)料(liao)方(fang)式是(shi)焦(jiao)炭(tan)或無煙煤(mei)和(he)料(liao)球分(fen)層裝(zhuang)入。我國遼寧(ning)省生(sheng)產合成鎂(mei)鈣(gai)砂(sha)的(de)(de)企(qi)業中(zhong)(zhong)，大部(bu)分(fen)采用該(gai)(gai)煅(duan)燒(shao)(shao)(shao)工(gong)藝。所用豎(shu)(shu)窯(yao)的(de)(de)規格一(yi)般為(wei)3m×16m。該(gai)(gai)煅(duan)燒(shao)(shao)(shao)工(gong)藝簡單，產品成本(ben)低(di)，但在(zai)煅(duan)燒(shao)(shao)(shao)過程中(zhong)(zhong)料(liao)球和(he)焦(jiao)炭(tan)混在(zai)一(yi)起，焦(jiao)炭(tan)燃(ran)燒(shao)(shao)(shao)產生(sheng)的(de)(de)灰分(fen)有一(yi)部(bu)分(fen)混入到料(liao)球中(zhong)(zhong)，增加了(le)產品的(de)(de)雜質含量(liang)。

3、干法壓球、燃油豎窯煅(duan)燒工藝(yi)

該煅(duan)燒(shao)(shao)(shao)工(gong)藝用(yong)(yong)(yong)于生產(chan)高(gao)(gao)純(chun)度(du)(du)(du)合(he)(he)成(cheng)(cheng)(cheng)鎂鈣砂。將高(gao)(gao)純(chun)度(du)(du)(du)輕(qing)燒(shao)(shao)(shao)氧化鎂和(he)輕(qing)燒(shao)(shao)(shao)白云石(shi)配料(liao)(liao)、混合(he)(he)磨細后，直接將干粉料(liao)(liao)送(song)(song)入高(gao)(gao)壓(ya)(ya)壓(ya)(ya)球機(ji)中干壓(ya)(ya)成(cheng)(cheng)(cheng)球，然后再送(song)(song)入高(gao)(gao)溫(wen)燃(ran)(ran)油(you)(you)豎(shu)窯內煅(duan)燒(shao)(shao)(shao)。這種煅(duan)燒(shao)(shao)(shao)工(gong)藝的(de)優勢是燃(ran)(ran)料(liao)(liao)油(you)(you)噴入到料(liao)(liao)層(ceng)內，在料(liao)(liao)層(ceng)內部燃(ran)(ran)燒(shao)(shao)(shao)，煅(duan)燒(shao)(shao)(shao)溫(wen)度(du)(du)(du)高(gao)(gao)，可達(da)到1800℃以(yi)上；燃(ran)(ran)料(liao)(liao)燃(ran)(ran)燒(shao)(shao)(shao)后不產(chan)生灰分，對物料(liao)(liao)的(de)純(chun)度(du)(du)(du)沒有影響(xiang)。目(mu)前(qian)，國內采用(yong)(yong)(yong)該煅(duan)燒(shao)(shao)(shao)工(gong)藝生產(chan)合(he)(he)成(cheng)(cheng)(cheng)鎂鈣砂的(de)企業，只有南方一家(jia)公(gong)司(si)。該公(gong)司(si)燃(ran)(ran)油(you)(you)豎(shu)窯的(de)規格為(wei)φ1.75m×11.5m，窯的(de)工(gong)作(zuo)襯(chen)用(yong)(yong)(yong)高(gao)(gao)純(chun)度(du)(du)(du)堿性耐火制品砌筑(zhu)，厚度(du)(du)(du)為(wei)350mm。工(gong)作(zuo)襯(chen)于窯體鋼殼之間用(yong)(yong)(yong)輕(qing)質保(bao)溫(wen)磚砌筑(zhu)。以(yi)重柴油(you)(you)為(wei)燃(ran)(ran)料(liao)(liao)，煅(duan)燒(shao)(shao)(shao)溫(wen)度(du)(du)(du)>1800℃。設計4排(pai)燒(shao)(shao)(shao)嘴(zui)(zui)，上下布置(zhi)，間距(ju)900mm。每(mei)排(pai)設計16支燒(shao)(shao)(shao)嘴(zui)(zui)，沿圓周均(jun)布。采用(yong)(yong)(yong)無冷卻燒(shao)(shao)(shao)嘴(zui)(zui)，每(mei)支燒(shao)(shao)(shao)嘴(zui)(zui)配一臺計量泵供油(you)(you)，一次空氣(qi)由羅茨風機(ji)供應(ying)。實際生產(chan)中使用(yong)(yong)(yong)一排(pai)燒(shao)(shao)(shao)嘴(zui)(zui)。連續裝窯和(he)出窯，全(quan)部自動化控制，生產(chan)能力。

4、干法(fa)壓球、回轉窯煅(duan)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。