目前我國生產佳木斯合成鎂鈣砂所使用(yong)的原(yuan)料有(you)菱鎂石(shi)(shi)(shi)(shi)(shi)、白(bai)(bai)云石(shi)(shi)(shi)(shi)(shi)和(he)石(shi)(shi)(shi)(shi)(shi)灰石(shi)(shi)(shi)(shi)(shi)。所采(cai)用(yong)的工(gong)(gong)(gong)(gong)藝(yi)為二步煅(duan)(duan)(duan)燒(shao)(shao)、入工(gong)(gong)(gong)(gong)合成工(gong)(gong)(gong)(gong)藝(yi)。即先(xian)將菱鎂石(shi)(shi)(shi)(shi)(shi)、白(bai)(bai)云石(shi)(shi)(shi)(shi)(shi)和(he)石(shi)(shi)(shi)(shi)(shi)灰石(shi)(shi)(shi)(shi)(shi)在(zai)較低的溫(wen)度下輕燒(shao)(shao)，生產出(chu)輕燒(shao)(shao)氧化鎂、輕燒(shao)(shao)白(bai)(bai)云石(shi)(shi)(shi)(shi)(shi)和(he)生石(shi)(shi)(shi)(shi)(shi)灰。然后(hou)進行配料、磨(mo)細、混(hun)料、成型，最后(hou)經過高溫(wen)煅(duan)(duan)(duan)燒(shao)(shao)，煅(duan)(duan)(duan)燒(shao)(shao)出(chu)不同牌號的合成鎂鈣(gai)砂。具體(ti)的煅(duan)(duan)(duan)燒(shao)(shao)工(gong)(gong)(gong)(gong)藝(yi)有(you)半(ban)干(gan)法壓(ya)坯(pi)、隧道窯(yao)煅(duan)(duan)(duan)燒(shao)(shao)工(gong)(gong)(gong)(gong)藝(yi)；半(ban)干(gan)法壓(ya)球(qiu)(qiu)、焦炭豎(shu)窯(yao)煅(duan)(duan)(duan)燒(shao)(shao)工(gong)(gong)(gong)(gong)藝(yi)；干(gan)法壓(ya)球(qiu)(qiu)、高溫(wen)燃油豎(shu)窯(yao)和(he)回(hui)轉窯(yao)煅(duan)(duan)(duan)燒(shao)(shao)工(gong)(gong)(gong)(gong)藝(yi)。

1、半干法壓坯、隧(sui)道窯煅(duan)燒(shao)工藝(yi)該煅(duan)燒(shao)工藝(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(gan)法壓球、焦炭(tan)豎窯煅燒工(gong)藝

該煅(duan)燒(shao)(shao)(shao)(shao)工藝生(sheng)(sheng)產(chan)合(he)(he)成(cheng)(cheng)鎂(mei)鈣砂是以(yi)輕(qing)(qing)燒(shao)(shao)(shao)(shao)白云石和輕(qing)(qing)燒(shao)(shao)(shao)(shao)氧化(hua)(hua)鎂(mei)為(wei)原料(liao)(liao)。將輕(qing)(qing)燒(shao)(shao)(shao)(shao)白云石和輕(qing)(qing)燒(shao)(shao)(shao)(shao)氧化(hua)(hua)鎂(mei)分(fen)(fen)別磨成(cheng)(cheng)細粉，計(ji)量(liang)(liang)后按比例(li)加入輪碾(nian)機中(zhong)再加水混合(he)(he)，混好的(de)(de)(de)合(he)(he)成(cheng)(cheng)料(liao)(liao)在(zai)(zai)雙(shuang)輥壓球(qiu)(qiu)(qiu)機上壓成(cheng)(cheng)料(liao)(liao)球(qiu)(qiu)(qiu)，干(gan)燥后裝入以(yi)焦(jiao)炭或無煙煤為(wei)燃料(liao)(liao)的(de)(de)(de)豎窯(yao)內(nei)煅(duan)燒(shao)(shao)(shao)(shao)。裝料(liao)(liao)方式(shi)是焦(jiao)炭或無煙煤和料(liao)(liao)球(qiu)(qiu)(qiu)分(fen)(fen)層(ceng)裝入。我國遼(liao)寧省生(sheng)(sheng)產(chan)合(he)(he)成(cheng)(cheng)鎂(mei)鈣砂的(de)(de)(de)企業中(zhong)，大部分(fen)(fen)采(cai)用該煅(duan)燒(shao)(shao)(shao)(shao)工藝。所(suo)用豎窯(yao)的(de)(de)(de)規(gui)格一般為(wei)3m×16m。該煅(duan)燒(shao)(shao)(shao)(shao)工藝簡單，產(chan)品成(cheng)(cheng)本低(di)，但在(zai)(zai)煅(duan)燒(shao)(shao)(shao)(shao)過(guo)程中(zhong)料(liao)(liao)球(qiu)(qiu)(qiu)和焦(jiao)炭混在(zai)(zai)一起，焦(jiao)炭燃燒(shao)(shao)(shao)(shao)產(chan)生(sheng)(sheng)的(de)(de)(de)灰分(fen)(fen)有一部分(fen)(fen)混入到(dao)料(liao)(liao)球(qiu)(qiu)(qiu)中(zhong)，增加了(le)產(chan)品的(de)(de)(de)雜質(zhi)含量(liang)(liang)。

3、干法(fa)壓球(qiu)、燃油豎(shu)窯(yao)煅燒工藝

該(gai)煅(duan)(duan)燒工(gong)藝用(yong)于生產(chan)高(gao)純度(du)合(he)成(cheng)(cheng)鎂(mei)鈣砂(sha)。將高(gao)純度(du)輕(qing)(qing)燒氧化鎂(mei)和輕(qing)(qing)燒白云(yun)石配料(liao)(liao)(liao)、混合(he)磨細后，直接將干粉料(liao)(liao)(liao)送(song)(song)入高(gao)壓壓球機(ji)中干壓成(cheng)(cheng)球，然(ran)后再送(song)(song)入高(gao)溫(wen)燃(ran)(ran)油(you)豎窯(yao)內煅(duan)(duan)燒。這(zhe)種煅(duan)(duan)燒工(gong)藝的(de)(de)優勢是(shi)燃(ran)(ran)料(liao)(liao)(liao)油(you)噴入到料(liao)(liao)(liao)層內，在料(liao)(liao)(liao)層內部燃(ran)(ran)燒，煅(duan)(duan)燒溫(wen)度(du)高(gao)，可達到1800℃以上(shang)；燃(ran)(ran)料(liao)(liao)(liao)燃(ran)(ran)燒后不產(chan)生灰分，對(dui)物(wu)料(liao)(liao)(liao)的(de)(de)純度(du)沒(mei)有影響(xiang)。目前，國內采用(yong)該(gai)煅(duan)(duan)燒工(gong)藝生產(chan)合(he)成(cheng)(cheng)鎂(mei)鈣砂(sha)的(de)(de)企業，只有南方一(yi)(yi)家公司(si)。該(gai)公司(si)燃(ran)(ran)油(you)豎窯(yao)的(de)(de)規格為(wei)φ1.75m×11.5m，窯(yao)的(de)(de)工(gong)作襯用(yong)高(gao)純度(du)堿性耐火制品砌筑，厚(hou)度(du)為(wei)350mm。工(gong)作襯于窯(yao)體鋼殼之間用(yong)輕(qing)(qing)質保溫(wen)磚砌筑。以重(zhong)柴(chai)油(you)為(wei)燃(ran)(ran)料(liao)(liao)(liao)，煅(duan)(duan)燒溫(wen)度(du)>1800℃。設(she)計(ji)4排(pai)燒嘴(zui)，上(shang)下布(bu)置，間距900mm。每(mei)排(pai)設(she)計(ji)16支燒嘴(zui)，沿圓周均布(bu)。采用(yong)無冷(leng)卻燒嘴(zui)，每(mei)支燒嘴(zui)配一(yi)(yi)臺計(ji)量泵供油(you)，一(yi)(yi)次(ci)空氣由(you)羅茨(ci)風機(ji)供應(ying)。實際生產(chan)中使用(yong)一(yi)(yi)排(pai)燒嘴(zui)。連續裝窯(yao)和出窯(yao)，全(quan)部自動(dong)化控制，生產(chan)能力。

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。