1. Strict control of raw materials
The quality of raw materials is the basic factor affecting the batch stability of the modulus of liquid potassium silicate. Liquid potassium silicate is mainly composed of silicon dioxide (SiO₂), potassium oxide (K₂O) and other components. Therefore, the selection and inspection of raw materials must be strictly regulated.
Choose high-quality and stable suppliers. The supplier's production capacity, quality control system and credibility need to be fully evaluated. Tongxiang Hengli Chemical Co., Ltd has rich experience and strict standards in this regard. When purchasing raw materials, it will conduct on-site inspections of suppliers to ensure that the suppliers have stable production processes and perfect quality inspection methods to ensure the quality of raw materials from the source.
Each batch of raw materials must be strictly inspected. Inspection items include the content of silicon dioxide, the purity of potassium oxide, and the impurity content. For example, if potassium oxide contains impurities such as iron, it will affect the modulus of liquid potassium silicate, so the iron content must be controlled within the standard of ≤0.01%. Through advanced testing equipment and precise testing methods, such as chemical analysis, spectral analysis, etc., ensure that the various indicators of raw materials meet the production requirements. Only when the quality of raw materials is stable can the foundation be laid for the subsequent production of liquid potassium silicate with stable modulus.
2. Optimization and stabilization of production process
The production process is the key link to ensure the stability of the batch modulus of liquid potassium silicate. Reasonable production process parameter settings and strict process execution procedures can effectively control the reaction process and ensure the consistency of modulus.
(I) Control of reaction temperature and time
The reaction temperature and time have a significant impact on the modulus (M): 2.7-3.0 The modulus of liquid potassium silicate. During the production process, it is necessary to monitor the temperature in the reactor in real time through precise temperature control systems, such as thermocouples, temperature sensors, etc., and adjust them according to process requirements. Generally speaking, appropriate temperature can promote the reaction and improve the uniformity and stability of the reaction. For example, within a specific temperature range, silicon dioxide and potassium oxide can fully react to form a stable potassium silicate structure, thereby ensuring that the modulus is within the range of 2.7-3.0. At the same time, the reaction time must be strictly controlled. Too long or too short a reaction time may lead to a deviation in the modulus. Through multiple experiments and data analysis, the optimal reaction temperature and time range are determined and strictly implemented during the production process.
(II) Accurate calculation of raw material ratio
The raw material ratio is one of the core factors affecting the modulus of liquid potassium silicate. According to the definition of modulus (modulus = amount of silicon dioxide / amount of potassium oxide), the feeding ratio of silicon dioxide and potassium oxide needs to be accurately calculated. Before production, the amount of raw materials required for each batch should be calculated according to the production plan and product specifications, and accurate feeding should be carried out through high-precision metering equipment such as electronic scales and flow meters. Tongxiang Hengli Chemical Co., Ltd has a professional technical team that can accurately adjust the raw material ratio according to different product requirements to ensure that the modulus of each batch of products meets the requirements. At the same time, during the feeding process, attention should be paid to the feeding order and stirring speed to ensure that the raw materials are fully mixed and the reaction is uniform.
(III) Optimization of stirring speed and method
Stirring plays an important role in the production process of liquid potassium silicate with modulus (M): 2.7-3.0. Good stirring can make the raw materials fully contact, speed up the reaction speed, and improve the uniformity of the reaction. Too fast or too slow stirring speed may affect the reaction effect. Too fast stirring speed may cause material splashing, resulting in raw material loss and safety hazards; too slow stirring speed may cause uneven material mixing and incomplete reaction, thus affecting the stability of the modulus. Therefore, it is necessary to select the appropriate stirring speed and stirring method according to factors such as the volume of the reactor and the properties of the materials. For example, an anchor stirrer or a paddle stirrer is used, and the stirring speed is adjusted according to the different reaction stages to ensure that the materials can be quickly mixed in the early stage of the reaction, and a stable stirring state can be maintained in the later stage of the reaction to ensure that the reaction is fully carried out.
3. Management and maintenance of production equipment
The performance and stability of production equipment directly affect the execution of the production process and product quality. Therefore, strengthening the management and maintenance of production equipment and ensuring the normal operation of equipment are important guarantees for ensuring the stability of the batch of liquid potassium silicate modulus.
(I) Regular inspection and maintenance of equipment
Regular inspection and maintenance of production equipment can timely discover problems with the equipment and avoid the impact of equipment failure on production. The inspection content includes the mechanical parts, electrical system, control system, etc. of the equipment. For example, check the sealing performance of the reactor to prevent material leakage and external impurities from entering; check the accuracy of the metering equipment to ensure the accuracy of the raw material feeding amount; check the operating conditions of the temperature control system and the stirring system to ensure the stability of the reaction conditions. Tongxiang Hengli Chemical Co., Ltd has established a complete equipment management system, formulated a detailed equipment maintenance plan, regularly maintains and maintains the equipment, and keeps records to ensure that the equipment is always in good operating condition.
(II) Equipment update and upgrade
With the continuous development of science and technology, chemical production equipment is also constantly updated and upgraded. Timely introduction of advanced production equipment can improve production efficiency and product quality. For example, the use of intelligent reactor control system can achieve precise control of parameters such as reaction temperature, time, stirring speed, etc., and improve the automation level and stability of the production process; the use of high-precision online detection equipment can monitor key indicators such as the modulus of liquid potassium silicate in real time, adjust production process parameters in time, and ensure the stability of product quality.
4. Improvement of the quality inspection system
Establishing a complete quality inspection system is an important means to ensure the batch stability of the modulus of liquid potassium silicate. By strictly inspecting the semi-finished products and finished products in the production process, problems can be discovered in time and measures can be taken to adjust them to ensure that the product quality meets the requirements.
(I) Determination of inspection items and standards
Determine reasonable inspection items and standards based on the product specifications and application requirements of liquid potassium silicate. In addition to the modulus (2.7-3.0), it also includes Baume degree (20°C/°Be: 40.0-42.0), density (ρ/g/cm³: 1.385-1.405), silicon dioxide content (SiO₂%: ≥26), potassium oxide (K₂O%: ≥14), iron content (Fe%: ≤0.01) and other indicators. These indicators are interrelated and reflect the quality and performance of liquid potassium silicate.
(II) Selection of inspection equipment and methods
Selecting advanced inspection equipment and scientific inspection methods is the key to ensuring the accuracy of the inspection results. For example, use a hydrometer to measure Baume, a densimeter to measure density, a chemical analysis method to measure the content of silicon dioxide and potassium oxide, and an atomic absorption spectrometer to measure the iron content. At the same time, the testing equipment should be calibrated and maintained regularly to ensure the precision and accuracy of the equipment.
(III) Standardization of the testing process
Standardize the testing process to ensure the scientificity and fairness of the testing work. During the testing process, the test standards and operating procedures should be strictly followed, and the sample collection, preparation, and testing records should be done well. Each batch of semi-finished products and finished products must be sampled and tested, and the test results should be fed back to the production department in a timely manner so that the production department can adjust the production process parameters according to the test results. If the test finds that the modulus and other indicators do not meet the requirements, the reasons should be analyzed in time and measures should be taken to deal with them, such as adjusting the raw material ratio, extending the reaction time, etc., until the product quality is qualified.
5. Control of environmental factors
The temperature, humidity, air quality and other factors of the production environment will also have a certain impact on the production process and product quality of liquid potassium silicate. Therefore, it is necessary to effectively control the production environment to ensure that production is carried out under suitable environmental conditions.
(I) Temperature and humidity control
The temperature and humidity of the production workshop should be kept within a certain range to avoid the impact of too high or too low temperature, too high or too low humidity on production. For example, too high temperature may cause the material to volatilize faster, affecting the accuracy of the raw material ratio; too high humidity may cause the raw materials to get damp, affecting their quality and performance. The temperature and humidity of the production workshop can be adjusted and controlled by installing air conditioners, humidifiers, dehumidifiers and other equipment to ensure that the temperature and humidity meet the production process requirements.
(II) Air quality control
The air quality of the production workshop should be kept good to avoid dust, harmful gases and other impurities from polluting materials and products. Ventilation equipment, air purification equipment, etc. can be installed to timely discharge dust and harmful gases in the workshop, introduce fresh air, and ensure the air quality in the workshop. At the same time, the workshop should be cleaned and disinfected regularly to keep the workshop clean and hygienic.
6. Packaging and storage management
Although the packaging and storage links do not directly affect the production process of liquid potassium silicate, they also play an important role in the quality stability of the product. Reasonable packaging and storage methods can prevent the product from being affected by external factors during transportation and storage, and ensure the stability of product modulus and other indicators.
(I) Selection of packaging materials
Select appropriate packaging materials, such as corrosion-resistant plastic barrels, iron barrels, etc., to ensure that the packaging materials will not react chemically with liquid potassium silicate and affect product quality. At the same time, the packaging materials must have good sealing properties to prevent product leakage and external impurities from entering.
(II) Specifications of the packaging process
During the packaging process, operations must be strictly carried out in accordance with the packaging process requirements to ensure that the quality and quantity of the packaging meet the requirements. For example, when filling liquid potassium silicate, the filling speed must be controlled to avoid bubbles and splashes; the packaging container must be marked with product name, model, batch number, production date and other information for traceability and management.
(III) Management of the storage environment
The storage warehouse should be kept dry, ventilated, cool, and avoid direct sunlight and high temperature and humidity. The storage temperature should be controlled within an appropriate range to avoid excessively high temperatures that cause product volatilization or deterioration, and excessively low temperatures that cause product solidification or crystallization. At the same time, it is necessary to conduct regular inspections on stored products to check whether the packaging is intact and whether the products have any abnormalities, such as precipitation, discoloration, etc. If any problems are found, timely measures should be taken to deal with them.
English
عربى
Español
English
عربى
Español
