CN101148343A - Gradient composite heat-insulating layer and manufacturing method thereof - Google Patents
Gradient composite heat-insulating layer and manufacturing method thereof Download PDFInfo
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- CN101148343A CN101148343A CNA2007100710335A CN200710071033A CN101148343A CN 101148343 A CN101148343 A CN 101148343A CN A2007100710335 A CNA2007100710335 A CN A2007100710335A CN 200710071033 A CN200710071033 A CN 200710071033A CN 101148343 A CN101148343 A CN 101148343A
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Abstract
The composite gradient heat insulating layer includes one hollow alumina ball layer with hollow alumina ball aggregate, one hollow corundum ball layer with hollow corundum ball aggregate, and one boulder layer with boulder aggregate compounded successively. It is produced through the following steps: 1. preparing materials through mixing powder ingredients in a ball mill, mixing aggregate and binding material, and adding mixed powder ingredients; and 2. forming through adding the materials separately into three separated material cavities in the mold, withdrawing the partition boards between the material cavities, vibrating and pressurizing to form, stoving and baking in a kiln. The composite gradient heat insulating layer has high fire resistance, high heat insulating performance, convenient construction and low cost. It is used in thermal equipment.
Description
Technical field
The invention belongs to technical field of refractory materials, relate in particular to a kind of novel gradient composite heat-insulating layer and manufacture method thereof.
Background technology
High temperature resistant heat insulation material is the key component of Thermal Equipment such as various kilns, and high temperature resistant heat insulation material directly contacts flame, requires not only high temperature resistant but also heat-insulating and energy-saving, and is high especially to the performance requriements of material.
Alumina hollow ball is used widely in the heat insulation field of fire resistant heat preserving, and hollow ball has utilized the big characteristics of enclosed cavity thermal resistance, good heat-insulation effect, and the intensity height, high temperature resistant, antistripping.The lightweight alumina hollow ball product has overcome that the foamed alumina product strength is low, the characteristics of high-temperature creep resistance difference, not only can directly contact flame, can also use as thermal insulation layer.This is for promoting traditional furnace construction transformation, and design novel kiln structure is laid a good foundation.The lightweight alumina hollow ball product is with alumina hollow ball and α-Al
2O
3Micro mist is basic composition, adds bond and adopts the vibration process for forming preparation, and alumina hollow ball product is a kind of spheroid interconnection network, and hollow ball provides skeleton function, α-Al
2O
3Micro mist is filled the space, strengthens the bond strength between the spheroid, further improves the compressive resistance of goods.The shortcoming that exists is: construction more complicated, energy consumption height, cost height.
Summary of the invention
For the construction more complicated that overcomes existing fire resistant heat preserving thermofin, energy consumption height, deficiency that cost is high, the invention provides a kind ofly have the refractoriness height, when thermal and insulating performance is good, can cut down the consumption of energy greatly and easy construction, the novel gradient composite heat-insulating layer and the manufacture method thereof of saving cost.
The technical solution adopted for the present invention to solve the technical problems is:
A kind of gradient composite heat-insulating layer, comprise the alumina hollow ball layer take alumina hollow ball as aggregate, corundum bollow ball layer take corundum bollow ball as aggregate, float the pearl layer to float pearl as aggregate, on the thermograde direction, alumina hollow ball layer, corundum bollow ball layer, to float the pearl layer successively compound, in alumina hollow ball, and Al
2O
3%＞99%, particle diameter are 0.2～5mm, natural packing density 0.7～1.0g/cm
3In corundum bollow ball,, Al
2O
3% is 92～96%, and particle diameter is 0.2～5mm, natural packing density 0.6～0.9; Al in floating pearl
2O
3%＞30%, SiO
2%＞50%, natural packing density＜0.4g/cm
3
Further, in described alumina hollow ball layer, the quality percentage composition of each component is: alumina hollow ball 45～65%, α-Al
2O
3Micro mist 35～55%, add phosphoric acid or the phosphate dihydrogen aluminum solution bond is α-Al
2O
330～35% of micro mist quality percentage composition, corresponding density are 1.3～1.6g/cm
3
Further, in described corundum bollow ball layer, the quality percentage composition of each component is: corundum bollow ball 40～60%, α-Al
2O
3Micro mist 40～60%, add phosphoric acid or the phosphate dihydrogen aluminum solution bond is α-Al
2O
330～35% of micro mist quality percentage composition, corresponding density are 1.2～1.5g/cm
3
Again further, float in the pearl layer described, the quality percentage composition of each component is: floating pearl 55～65%, alumina 20～35%, clay 10～15%, adding concentration is 20% yellow starch gum solution 15～20%, and corresponding density is 0.6～1.0g/cm
3
A kind of manufacture method of described novel gradient composite heat-insulating layer, described manufacture method may further comprise the steps:
(1) batching: powder mixes in ball mill, after particles of aggregates and wedding agent mixed, add the powder that mixes, it is standby to stir the back, particles of aggregates comprises alumina hollow ball, corundum bollow ball, floats pearl, and material comprises the heat insulation material of alumina hollow ball layer, the heat insulation material of corundum bollow ball layer, floats the heat insulation material of pearl layer;
(2) in mould, separate three heat insulation material chambeies of formation with dividing plate, in three heat insulation material chambeies, add respectively the heat insulation material of each layer; Extract dividing plate after reinforced out, adopt the vibration extrusion forming, the loading of kiln after 80～150 ℃ of oven dry of the base substrate after the moulding was burnt till in 1300～1350 ℃ of insulations in 3～5 hours.
Further, in described (2), described three heat insulation material chambeies add the heat insulation material of alumina hollow ball layer, the heat insulation material of corundum bollow ball layer respectively, float the heat insulation material of pearl layer, and the thickness ratio in three heat insulation material chambeies is 48: 96: 72～72: 128: 120.
Technical conceive of the present invention is: adopt 99 alumina hollow balls, corundum bollow ball and high-strength light float the pearl material, and to be that aggregate carries out stratiform on the thermograde direction compound, determine the thickness of differing materials according to the difference of differing materials thermal conductivity, vibratory compaction, width and thickness direction size can determine as required that the size on the thermograde direction is then carried out design decision according to the lagging material component.Composite insulating brick separates with dividing plate earlier when moulding is reinforced, adds respectively the heat insulation material of each layer, and the reinforced rear dividing plate of extracting out adopts the vibrations extrusion forming, and base substrate loading of kiln after 80～150 ℃ of oven dry was burnt till in 1300～1350 ℃ of insulations in 3～5 hours.
Corundum bollow ball alumina content 92～96%, crystal formation is with α-Al
2O
3Microcrystal is main, and this ball still can keep good physics and chemistry stability in temperature in up to 1700 ℃ kiln, is a kind of novel high temperature insulating material.As aggregate, introduce α-Al with it
2O
3Micro mist, mullite miropowder and bond etc. can prepare corundum bollow ball brick or the castable of various matrix, and its density is 1.2～1.6g/cm
3If, introduce polystyrene microsphere or sawdust or blowing agent etc., then its density can be lower than 0.6g/cm
3, adopt the product of this hollow ball preparation to have intensity height, serviceability temperature height, load softening point height, low the having a few of shrinkage factor.
Float pearl and be the broken glass body of the hollow that sorts out in heat power plant's flyash, have light weight, thermal conductivity is little, specific surface area is big, ultimate compression strength is high characteristics.The light cinder brick that pearl prepares excellent thermal insulation performance is floated in employing, is a kind of novel environmental protection and energy saving material.Therefore float the pearl light cinder brick and compare with alumina hollow ball product, the use temperature of floating bead brick is lower, and is cheap, satisfying requirement of strength, can the instead of alumina hollow ball product under the lower condition of use temperature.
Form structure as shown in Figure 1, the novel gradient composite insulating brick is made up of three parts: oxidation hollow ball brick partly bears 1600～1800 ℃ temperature, the corundum bollow ball brick partly bears 1200～1600 ℃ temperature, floating bead brick partly bears 600～1200 ℃, high temperature is 600 ℃ through top temperature outside after three heat insulation components in the kiln, the outside can be directly with rock wool or glass surface goods as thermofin.The size of insulating brick various piece thermograde direction is by the decision of its thermal conductivity,
In the construction application process, 99 alumina hollow balls are towards the high direction of temperature.The gradient composite insulating brick of the present invention preparation can be widely used in the various Thermal Equipments that need heat-insulation and heat-preservation, and it is big to have intensity, the refractoriness height, and characteristics such as thermal and insulating performance is good can cut down the consumption of energy greatly, and easy construction, help saving cost.Composite insulating brick alumina hollow ball and corundum bollow ball part realize sintering and improve intensity in the use of reality.
Beneficial effect of the present invention mainly shows: has the refractoriness height, when thermal and insulating performance is good, can reduce various Thermal Equipment energy consumptions greatly, and easy construction, saving cost.
Description of drawings
Fig. 1 is the structure iron of novel gradient composite heat-insulating layer.
Embodiment
Below in conjunction with accompanying drawing the present invention is further described.
Embodiment 1
With reference to Fig. 1, a kind of gradient composite heat-insulating layer, comprise alumina hollow ball layer 1 take alumina hollow ball as aggregate, the corundum bollow ball layer 2 take corundum bollow ball as aggregate, float pearl layer 3 to float pearl as aggregate, on the thermograde direction, alumina hollow ball layer 1, corundum bollow ball layer 2, to float pearl layer 3 successively compound, in alumina hollow ball, Al
2O
3%＞99%, particle diameter are 0.2～5mm, natural packing density 0.7～1.0g/cm
3In corundum bollow ball,, Al
2O
3% is 92～96%, and particle diameter is 0.2～5mm, natural packing density 0.6～0.9; Al in floating pearl
2O
3%＞30%, SiO
2%＞50%, natural packing density＜0.4g/cm
3
Present embodiment adopts alumina hollow ball, corundum bollow ball and floats the pearl material that to carry out stratiform on the thermograde direction compound existing, form structure as shown in Figure 1, the novel gradient composite insulating brick is made up of three parts: oxidation hollow ball brick partly bears 1600～1800 ℃ temperature, the corundum bollow ball brick partly bears 1200～1600 ℃ temperature, floating bead brick partly bears 600～1200 ℃, high temperature is 600 ℃ through top temperature outside after three heat insulation components in the kiln, the outside can be directly with rock wool or glass surface goods as thermofin.The size of insulating brick various piece thermograde direction sees table 1 for details: the relation of alumina bubble brick, corundum brick, floating bead brick density/thermal conductivity and thickness by its thermal conductivity decision.
| Material | Density, g/cm 3 | Proportioning forms | Thermal conductivity factor, W/ m.K | Thickness, mm | Thermograde, ℃ |
| Oxidation | 1.6 | Alumina hollow ball 45%, α-Al 2O 3Micro mist 55%, | 0.9 | 72 | 1600～ |
| The aluminium hollow ball | Adding phosphoric acid or phosphate dihydrogen aluminum solution bond is α-Al 2O 335% of micro mist | 1800 | |||
| 1.5 | Alumina hollow ball 52%, α-Al 2O 3Micro mist 48%, adding phosphoric acid or phosphate dihydrogen aluminum solution bond is α-Al 2O 333% of micro mist | 0.8 | 64 | ||
| 1.4 | Alumina hollow ball 58%, α-Al 2O 3Micro mist 42%, adding the phosphoric acid bond is α-Al 2O 331% of micro mist | 0.7 | 56 | ||
| 1.3 | Alumina hollow ball 65%, α-Al 2O 3Micro mist 35%, adding phosphoric acid or phosphate dihydrogen aluminum solution bond is α-Al 2O 330% of micro mist | 0.6 | 48 | ||
| Corundum bollow ball | 1.5 | Corundum bollow ball 40%, α-Al 2O 3Micro mist 60%, adding phosphoric acid or phosphate dihydrogen aluminum solution bond is α-Al 2O 335% of micro mist quality percentage composition, | 0.8 | 128 | 1200～1600 |
| 1.4 | Corundum bollow ball 47%, α-Al 2O 3Micro mist 53%, adding phosphoric acid or phosphate dihydrogen aluminum solution bond is α-Al 2O 333% of micro mist quality percentage composition | 0.7 | 112 | ||
| 1.3 | Corundum bollow ball 54%, α-Al 2O 3Micro mist 46%, adding phosphoric acid or phosphate dihydrogen aluminum solution bond is α-Al 2O 332% of micro mist quality percentage composition | 0.65 | 104 | ||
| 1.2 | Corundum bollow ball 60%, α-Al 2O 3Micro mist 40%, adding phosphoric acid or phosphate dihydrogen aluminum solution bond is α-Al 2O 330% of micro mist quality percentage composition | 0.6 | 96 | ||
| Float pearl | 1.0 | Float pearl 55%, alumina 35%, clay 10% adds | 0.5 | 120 | 600～1 |
| Concentration is 20% yellow starch gum solution 20% | 200 | ||||
| 0.8 | Float pearl 58%, alumina 35%, clay 12% adds concentration and is 20% yellow starch gum solution 18% | 0.4 | 96 | ||
| 0.7 | Float pearl 62%, alumina 35%, clay 13% adds concentration and is 20% yellow starch gum solution 17% | 0.35 | 84 | ||
| 0.6 | Float pearl 65%, alumina 20%, clay 15% adds concentration and is 20% yellow starch gum solution 15% | 0.3 | 72 |
Table 1
The novel gradient composite insulating brick of this embodiment preparation is high temperature resistant, antistrip performance is good, thermal conductivity is low, be directly used in Thermal Equipment around build by laying bricks or stones and can realize the effect that in the past adopted multilayer material to build by laying bricks or stones, easy construction adopts a composite insulating brick can realize from 1800 ℃ to 600 ℃ cooling-down effect on the thermograde direction.In use can keep the furnace temperature equilibrium, reduce heat lost by radiation, reduce energy expenditure greatly.
A kind of manufacture method of novel gradient composite heat-insulating layer, described manufacture method may further comprise the steps: (1) batching: powder mixes in ball mill, after particles of aggregates and wedding agent mixed, add the powder that mixes, it is standby to stir the back, particles of aggregates comprises alumina hollow ball, corundum bollow ball, floats pearl, and material comprises the heat insulation material of alumina hollow ball layer, the heat insulation material of corundum bollow ball layer, floats the heat insulation material of pearl layer; (2) in mould, separate three heat insulation material chambeies of formation, in three heat insulation material chambeies, add the heat insulation material of each layer respectively with dividing plate; Reinforced back is extracted dividing plate out, adopts the vibration extrusion forming, and the loading of kiln after 80～150 ℃ of oven dry of the base substrate after the moulding was burnt till in 1300～1350 ℃ of insulations in 3～5 hours.
In described (2), described three heat insulation material chambeies add the heat insulation material of alumina hollow ball layer, the heat insulation material of corundum bollow ball layer respectively, float the heat insulation material of pearl layer, and the thickness ratio in three heat insulation material chambeies is 48: 96: 72～72: 128: 120.
Tonnage and kiln wall thickness according to kiln require to carry out the composite brick design, and the tonnage of kiln is more big, and the kiln wall is more high then more high to the material withstand voltage properties, at this moment need select high density composite to build by laying bricks or stones; If require the kiln wall thin, it is compound then just to require to adopt the low-density heat-barrier material to carry out, and the size of each heat-insulation layer is determined according to table 1.When moulding is reinforced, separate with dividing plate earlier, add respectively the heat insulation material of each layer, the reinforced rear dividing plate of extracting out adopts the vibration extrusion forming, and base substrate loading of kiln after 80～150 ℃ of oven dry was burnt till in 1300～1350 ℃ of insulations in 3～5 hours.
Claims (7)
1. gradient composite heat-insulating layer, it is characterized in that: comprise the alumina hollow ball layer take alumina hollow ball as aggregate, corundum bollow ball layer take corundum bollow ball as aggregate, float the pearl layer to float pearl as aggregate, on the thermograde direction, alumina hollow ball layer, corundum bollow ball layer, to float the pearl layer successively compound, in alumina hollow ball, and Al
2O
3%＞99%, particle diameter are 0.2～5mm, natural packing density 0.7～1.0g/cm
3In corundum bollow ball, Al
2O
3% is 92～96%, and particle diameter is 0.2～5mm, natural packing density 0.6～0.9; Al in floating pearl
2O
3%＞30%, SiO
2%＞50%, natural packing density＜0.4g/cm
3
2. gradient composite heat-insulating layer as claimed in claim 1, it is characterized in that: in described alumina hollow ball layer, the quality percentage composition of each component is: alumina hollow ball 45～65%, α-Al
2O
3Micro mist 35～55%, add phosphoric acid or the phosphate dihydrogen aluminum solution bond is α-Al
2O
330～35% of micro mist quality percentage composition, corresponding density are 1.3～1.6g/cm
3
3. gradient composite heat-insulating layer as claimed in claim 1 or 2, it is characterized in that: in described corundum bollow ball layer, the quality percentage composition of each component is: corundum bollow ball 40～60%, α-Al
2O
3Micro mist 40～60%, add phosphoric acid or the phosphate dihydrogen aluminum solution bond is α-Al
2O
330～35% of micro mist quality percentage composition, corresponding density are 1.2～1.5g/cm
3
4. gradient composite heat-insulating layer as claimed in claim 1 or 2, it is characterized in that: float in the pearl layer described, the quality percentage composition of each component is: floating pearl 55～65%, alumina 20～35%, clay 10～15%, adding concentration is 20% yellow starch gum solution 15～20%, and corresponding density is 0.6～1.0g/cm
3
5. gradient composite heat-insulating layer as claimed in claim 3, it is characterized in that: float in the pearl layer described, the quality percentage composition of each component is: floating pearl 55～65%, alumina 20～35%, clay 10～15%, adding concentration is 20% yellow starch gum solution 15～20%, and corresponding density is 0.6～1.0g/cm
3
6. the manufacture method of a novel gradient composite heat-insulating layer as claimed in claim 1, it is characterized in that: described manufacture method may further comprise the steps:
(1) batching: powder mixes in ball mill, after particles of aggregates and wedding agent mixed, add the powder that mixes, it is standby to stir the back, particles of aggregates comprises alumina hollow ball, corundum bollow ball, floats pearl, and material comprises the heat insulation material of alumina hollow ball layer, the heat insulation material of corundum bollow ball layer, floats the heat insulation material of pearl layer;
(2) in mould, separate three heat insulation material chambeies of formation with dividing plate, in three heat insulation material chambeies, add respectively the heat insulation material of each layer; Extract dividing plate after reinforced out, adopt the vibration extrusion forming, the loading of kiln after 80～150 ℃ of oven dry of the base substrate after the moulding was burnt till in 1300～1350 ℃ of insulations in 3～5 hours.
7. the manufacture method of novel gradient composite heat-insulating layer as claimed in claim 6, it is characterized in that: in described (2), described three heat insulation material chambeies add the heat insulation material of alumina hollow ball layer, the heat insulation material of corundum bollow ball layer respectively, float the heat insulation material of pearl layer, and the thickness ratio in three heat insulation material chambeies is 48: 96: 72～72: 128: 120.
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|---|---|---|---|
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| CN100564307C CN100564307C (en) | 2009-12-02 |
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| CN101857451A (en) * | 2010-06-07 | 2010-10-13 | 浙江大学 | Heat-insulating integrated composite brick with alkaline structure and preparation method thereof |
| CN101863674A (en) * | 2010-06-07 | 2010-10-20 | 浙江大学 | Corundum hollow sphere structure heat-insulating integrated composite brick and preparation method thereof |
| CN101863673A (en) * | 2010-06-07 | 2010-10-20 | 长兴锅炉耐火器材厂 | Magnesia-alumina spinel structure heat insulation integral composite brick and preparation method thereof |
| CN101691295B (en) * | 2009-10-29 | 2012-02-01 | 冯维银 | Formula of high-purity alumina hollow ball product and low-temperature production method |
| CN110734042A (en) * | 2018-07-20 | 2020-01-31 | 淄博华庆耐火材料有限公司 | corundum-SiAlON-silicon nitride gradient brick for sulfur recovery reaction furnace and preparation process thereof |
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| CN101691295B (en) * | 2009-10-29 | 2012-02-01 | 冯维银 | Formula of high-purity alumina hollow ball product and low-temperature production method |
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| CN101857450A (en) * | 2010-06-07 | 2010-10-13 | 浙江大学 | Corundum structural heat-insulation integrative composite brick and preparation method |
| CN101857450B (en) * | 2010-06-07 | 2013-06-05 | 浙江大学 | Corundum structural heat-insulation integrative composite brick and preparation method |
| CN110734042A (en) * | 2018-07-20 | 2020-01-31 | 淄博华庆耐火材料有限公司 | corundum-SiAlON-silicon nitride gradient brick for sulfur recovery reaction furnace and preparation process thereof |
| CN112259841A (en) * | 2020-09-24 | 2021-01-22 | 沈阳化工大学 | Preparation method of heat-preservation and heat-insulation composite thermal battery shell |
| CN112225558A (en) * | 2020-10-30 | 2021-01-15 | 郑州方铭高温陶瓷新材料有限公司 | Gradient composite technology ceramic tile for glass kiln field and preparation method thereof |
| CN114507057A (en) * | 2022-03-01 | 2022-05-17 | 江苏佳核新能源科技有限公司 | High fire-resistant low heat conduction composite material |
| CN117362008A (en) * | 2023-10-13 | 2024-01-09 | 郑州金河源耐火材料有限公司 | Periclase-spinel and hollow sphere composite brick and preparation method thereof |
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