目前我國生產鶴崗合成鎂鈣砂所使用的(de)原料有(you)菱(ling)鎂石(shi)(shi)(shi)、白云石(shi)(shi)(shi)和(he)石(shi)(shi)(shi)灰石(shi)(shi)(shi)。所采用的(de)工(gong)(gong)(gong)(gong)藝(yi)(yi)為二步煅(duan)燒、入(ru)工(gong)(gong)(gong)(gong)合(he)成(cheng)工(gong)(gong)(gong)(gong)藝(yi)(yi)。即先將菱(ling)鎂石(shi)(shi)(shi)、白云石(shi)(shi)(shi)和(he)石(shi)(shi)(shi)灰石(shi)(shi)(shi)在較低的(de)溫(wen)度下輕燒，生(sheng)產出輕燒氧化(hua)鎂、輕燒白云石(shi)(shi)(shi)和(he)生(sheng)石(shi)(shi)(shi)灰。然后(hou)進行配料、磨細、混料、成(cheng)型，最后(hou)經過高(gao)溫(wen)煅(duan)燒，煅(duan)燒出不(bu)同牌號的(de)合(he)成(cheng)鎂鈣砂。具體(ti)的(de)煅(duan)燒工(gong)(gong)(gong)(gong)藝(yi)(yi)有(you)半(ban)干(gan)法壓坯、隧道窯煅(duan)燒工(gong)(gong)(gong)(gong)藝(yi)(yi)；半(ban)干(gan)法壓球(qiu)、焦(jiao)炭豎窯煅(duan)燒工(gong)(gong)(gong)(gong)藝(yi)(yi)；干(gan)法壓球(qiu)、高(gao)溫(wen)燃油豎窯和(he)回(hui)轉窯煅(duan)燒工(gong)(gong)(gong)(gong)藝(yi)(yi)。

1、半(ban)干法壓坯、隧道(dao)窯煅燒工藝(yi)該煅燒工藝(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、焦炭豎窯(yao)煅燒工(gong)藝

該(gai)煅(duan)燒(shao)(shao)工(gong)(gong)藝生(sheng)(sheng)產(chan)(chan)合(he)成(cheng)鎂鈣砂(sha)是以輕燒(shao)(shao)白云(yun)石(shi)和輕燒(shao)(shao)氧化鎂為原料。將輕燒(shao)(shao)白云(yun)石(shi)和輕燒(shao)(shao)氧化鎂分(fen)別磨成(cheng)細粉，計量后(hou)按(an)比例加(jia)(jia)入(ru)輪碾機(ji)中(zhong)(zhong)再加(jia)(jia)水混合(he)，混好的(de)(de)合(he)成(cheng)料在(zai)雙輥壓球(qiu)機(ji)上壓成(cheng)料球(qiu)，干燥后(hou)裝(zhuang)入(ru)以焦炭(tan)或(huo)(huo)無(wu)煙(yan)(yan)煤為燃料的(de)(de)豎(shu)窯(yao)內(nei)煅(duan)燒(shao)(shao)。裝(zhuang)料方式是焦炭(tan)或(huo)(huo)無(wu)煙(yan)(yan)煤和料球(qiu)分(fen)層裝(zhuang)入(ru)。我國遼寧省(sheng)生(sheng)(sheng)產(chan)(chan)合(he)成(cheng)鎂鈣砂(sha)的(de)(de)企業中(zhong)(zhong)，大部(bu)分(fen)采(cai)用(yong)該(gai)煅(duan)燒(shao)(shao)工(gong)(gong)藝。所用(yong)豎(shu)窯(yao)的(de)(de)規格一(yi)般(ban)為3m×16m。該(gai)煅(duan)燒(shao)(shao)工(gong)(gong)藝簡單，產(chan)(chan)品成(cheng)本低，但在(zai)煅(duan)燒(shao)(shao)過程中(zhong)(zhong)料球(qiu)和焦炭(tan)混在(zai)一(yi)起，焦炭(tan)燃燒(shao)(shao)產(chan)(chan)生(sheng)(sheng)的(de)(de)灰分(fen)有一(yi)部(bu)分(fen)混入(ru)到料球(qiu)中(zhong)(zhong)，增加(jia)(jia)了(le)產(chan)(chan)品的(de)(de)雜(za)質含量。

3、干法壓球、燃油豎窯煅燒工藝

該(gai)煅(duan)(duan)燒(shao)(shao)(shao)(shao)工(gong)藝(yi)用(yong)于生(sheng)(sheng)(sheng)產高(gao)純(chun)(chun)(chun)度合成(cheng)鎂鈣砂(sha)。將高(gao)純(chun)(chun)(chun)度輕(qing)燒(shao)(shao)(shao)(shao)氧(yang)化鎂和輕(qing)燒(shao)(shao)(shao)(shao)白云(yun)石配料(liao)(liao)、混合磨細后，直接將干(gan)粉料(liao)(liao)送入高(gao)壓(ya)壓(ya)球(qiu)機(ji)(ji)中干(gan)壓(ya)成(cheng)球(qiu)，然(ran)后再送入高(gao)溫燃(ran)(ran)(ran)油(you)豎窯(yao)(yao)內煅(duan)(duan)燒(shao)(shao)(shao)(shao)。這種煅(duan)(duan)燒(shao)(shao)(shao)(shao)工(gong)藝(yi)的(de)(de)(de)優勢是(shi)燃(ran)(ran)(ran)料(liao)(liao)油(you)噴入到料(liao)(liao)層內，在料(liao)(liao)層內部燃(ran)(ran)(ran)燒(shao)(shao)(shao)(shao)，煅(duan)(duan)燒(shao)(shao)(shao)(shao)溫度高(gao)，可(ke)達到1800℃以上；燃(ran)(ran)(ran)料(liao)(liao)燃(ran)(ran)(ran)燒(shao)(shao)(shao)(shao)后不產生(sheng)(sheng)(sheng)灰分，對(dui)物料(liao)(liao)的(de)(de)(de)純(chun)(chun)(chun)度沒(mei)有(you)影響。目前，國內采用(yong)該(gai)煅(duan)(duan)燒(shao)(shao)(shao)(shao)工(gong)藝(yi)生(sheng)(sheng)(sheng)產合成(cheng)鎂鈣砂(sha)的(de)(de)(de)企(qi)業，只(zhi)有(you)南方一家公(gong)(gong)司。該(gai)公(gong)(gong)司燃(ran)(ran)(ran)油(you)豎窯(yao)(yao)的(de)(de)(de)規格為φ1.75m×11.5m，窯(yao)(yao)的(de)(de)(de)工(gong)作(zuo)襯(chen)用(yong)高(gao)純(chun)(chun)(chun)度堿性(xing)耐(nai)火(huo)制品砌(qi)筑，厚度為350mm。工(gong)作(zuo)襯(chen)于窯(yao)(yao)體鋼殼(ke)之(zhi)間(jian)用(yong)輕(qing)質保溫磚砌(qi)筑。以重柴(chai)油(you)為燃(ran)(ran)(ran)料(liao)(liao)，煅(duan)(duan)燒(shao)(shao)(shao)(shao)溫度>1800℃。設(she)計4排燒(shao)(shao)(shao)(shao)嘴(zui)(zui)，上下布置，間(jian)距900mm。每(mei)排設(she)計16支燒(shao)(shao)(shao)(shao)嘴(zui)(zui)，沿圓周均(jun)布。采用(yong)無冷卻燒(shao)(shao)(shao)(shao)嘴(zui)(zui)，每(mei)支燒(shao)(shao)(shao)(shao)嘴(zui)(zui)配一臺計量泵供(gong)油(you)，一次空氣由羅茨(ci)風機(ji)(ji)供(gong)應。實際(ji)生(sheng)(sheng)(sheng)產中使用(yong)一排燒(shao)(shao)(shao)(shao)嘴(zui)(zui)。連續裝(zhuang)窯(yao)(yao)和出窯(yao)(yao)，全部自動化控制，生(sheng)(sheng)(sheng)產能力(li)。

4、干法壓(ya)球、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。