CN102007089B - 由基于锆石的填料生产的烧结制品 - Google Patents

由基于锆石的填料生产的烧结制品 Download PDF

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CN102007089B
CN102007089B CN2009801129873A CN200980112987A CN102007089B CN 102007089 B CN102007089 B CN 102007089B CN 2009801129873 A CN2009801129873 A CN 2009801129873A CN 200980112987 A CN200980112987 A CN 200980112987A CN 102007089 B CN102007089 B CN 102007089B
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sintered article
oxide compound
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CN102007089A (zh
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奥利弗·西蒂
朱利安·弗卡德
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Saint Gobain Centre de Recherche et dEtudes Europeen SAS
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Abstract

本发明涉及一种烧结制品，该烧结制品自以基于氧化物的重量百分数计含75-99％的锆石的始料制备并以基于氧化物的重量百分数计具有如下平均重量化学组成：60％≤ZrO2≤72.8％，27％≤SiO2≤36％，0.1％≤B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5，0.1％≤ZnO+PbO+CdO，B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5+ZnO+PbO+CdO≤5％，0％≤Al2O3+TiO2+MgO+Fe2O3+NiO+MnO2+CoO+CuO≤5％，其他氧化物≤1.5％，总共100％。特别地，涉及在玻璃熔炉中的用途。

Description

由基于锆石的填料生产的烧结制品
技术领域
本发明涉及自锆石生产的新型烧结材料，其制备方法及其在玻璃熔炉中的用途。
技术背景
在耐火制品当中，分为熔铸制品与烧结制品。
与烧结制品不同，熔铸制品最常含非常丰富的粒间玻璃相，该粒间玻璃相会填充结晶粒子的晶格。烧结制品和熔铸制品在其各自的应用中所遇到的问题及解决这些问题所采用的技术方案因此通常不同。此外，由于制备工艺间的显著差异，故为制备熔铸制品所开发的组合物不能先验地原样用于制备烧结制品，反之亦然。
通过混合适宜的原料、然后以生坯态使该混合物成型并在足够的温度下和足够的时间内烘烤所得生坯形式以获得该生坯形式的烧结，从而获得烧结制品。
烧结制品根据其化学组成及其制备方法而预期用于非常广泛的工业。
应用于特定应用的烧结制品因此不会先验地具有使其用于其中温度、腐蚀或磨损条件不同的另一应用中所需的性质。
例如，US 3,899,341描述了自锆石(50-90％)和自氧化锆制备的烧结制品。所述氧化锆被部分稳定化以限制制品的弹性变形，弹性变形将导致裂缝。但US3,899,341的制品设计用于与熔融钢接触，其因此并不先验地适用于与熔融玻璃接触。
在烧结制品当中，自锆石(硅酸锆：ZrO2·SiO2或ZrSiO4)和任选的氧化锆(游离氧化锆ZrO2)制备的致密制品可用于该致密制品直接接触熔融玻璃的应用中，特别是在非碱性玻璃的情况下。
EP 952 125因此描述了预期用于玻璃熔炉并自锆石制备(5-40％)和自氧化锆制备的烧结制品。这些制品还含钛、铝和钇氧化物，利用这些氧化物可形成很大的块而无任何裂缝。这些制品中的SiO2含量低于14％。其ZrO2含量高于82％。
WO 02/44102描述了用于制备玻璃板的“isopipes”。Isopipes含超过95％质量的锆石并呈现出不充分的徐变行为，除非Isopipes还含0.2-0.4％的氧化钛。为说明技术发展水平，WO 02/44102引用了US 5,124,287。
US 5,124,287描述了含75-95％的锆石和氧化钛的、预期用于接触熔融玻璃的组合物。该申请指出，氧化钛的存在有利于使烧结后获得的制品致密化。在最终制品中，氧化锆应是未稳定化的，因此优选在起始混合物中使用未稳定化氧化锆。但不是不可以使用利用氧化锆稳定剂如钇或钙氧化物稳定化的氧化锆，加热该混合物将导致氧化锆的去稳定化。
WO 2006/073841描述了预期用于玻璃工业的耐火材料。这些基于锆石的材料可能含Y2O3。这些材料总是含至少1％的P2O5或V2O5。
SU 1 020 404描述了一种预期用于涂布基于锆石的耐火制品的混合物。
新型玻璃如无碱玻璃的出现必然伴有玻璃的熔融和/或成型温度的提高。因此，基于锆石的常规材料出现性能降低。确实，当受到高于1550℃的温度时，基于锆石的常规材料将往往渗出。该渗出将随温度的升高及在这些温度下的暴露时间的增长而更加显著。这种现象由于可能然后伴随着在玻璃中形成缺陷、玻璃和鼓泡现象引起腐蚀增加而特别有害。
因此需要具有非常好的抗渗出性并可用于玻璃熔炉中的制品。本发明旨在满足这种需要。
发明内容
为此，本发明提出了一种烧结制品，该烧结制品自以占始料的质量百分数计含有75-99％的锆石的始料制备，并以基于氧化物的质量百分数计具有如下平均重量化学组成：
60％≤ZrO2≤72.8％，
27％≤SiO2≤36％，
0.1％≤B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5，
0.1％≤ZnO+PbO+CdO，
B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5+ZnO+PbO+CdO≤5％，
0％≤Al2O3+TiO2+MgO+Fe2O3+NiO+MnO2+CoO+CuO≤5％，
其他氧化物：≤1.5％，
总共100％。
该烧结耐火制品具有优异的抗渗出性，特别是相对于迄今所述的制品而言。有利地，该烧结耐火制品也具有很高的密度，与受试的已知制品相当或更高。
优选根据本发明的制品还具有如下任选特征中的一个或多个：
-以基于氧化物的质量百分数计，Ta2O5含量高于0.3％，优选高于0.5％，更优选高于0.8％。
-以基于氧化物的质量百分数计，Ta2O5含量低于3％，优选低于2.5％，更优选低于2％。
-以基于氧化物的质量百分数计，0.1％≤GeO2+P2O5+Nb2O5+Ta2O5，和/或
0.1％≤ZnO，和/或
GeO2+P2O5+Nb2O5+Ta2O5+ZnO≤5％，和/或
0％≤Al2O3+TiO2+MgO+Fe2O3+NiO+MnO2+CoO+CuO≤5％。
-以基于氧化物的质量百分数计，ZnO含量高于0.3％，优选高于0.5％，更优选高于0.8％。
-以基于氧化物的质量百分数计，ZnO含量低于3％，优选低于2.5％，更优选低于2％。
-根据本发明的制品含至少一种氧化物，优选至少两种氧化物，所述氧化物选自Al2O3、TiO2、MgO、Fe2O3、NiO、MnO2、CoO和CuO。以基于氧化物的质量百分数计，优选这些氧化物中的至少一种的含量、甚至这些氧化物中的至少两种中的每一种的含量高于0.05％，优选高于0.10％，更优选高于0.15％，还优选高于0.3％。以基于氧化物的质量百分数计，优选0.05％＜Al2O3+TiO2，优选0.9％＜Al2O3+TiO2，更优选1％＜Al2O3+TiO2。此外优选Al2O3+TiO2＜3％，优选Al2O3+TiO2＜2％。
-以基于氧化物的质量百分数计，所述制品具有如下平均重量化学组成：
60％≤ZrO2≤72.4％，
27％≤SiO2≤36％，
0.2％≤B2O3+Nb2O5+Ta2O5≤2.5％，
0.2％≤ZnO≤2.5％，
0.2％≤Al2O3+TiO2+MgO+NiO+MnO2+CoO+CuO≤3％，
其他氧化物：≤1.5％，
总共100％。
-以基于氧化物的质量百分数计，所述制品具有如下平均重量化学组成：
60％≤ZrO2≤72.4％，
27％≤SiO2≤36％，
0.2％≤Nb2O5+Ta2O5≤2.5％，
0.2％≤ZnO≤2.5％，
0.2％≤Al2O3+TiO2≤2％，
其他氧化物：≤1.5％，
总共100％。
-所述“其他氧化物”为杂质。以基于氧化物的质量百分数计，优选所述“其他氧化物”的含量低于1.2％，优选低于1％，更优选低于0.7％，优选低于0.5％，还优选低于0.2％。
-P2O5含量低于1％，优选低于0.5％。
-以基于氧化物的质量百分数计，氧化钇Y2O3含量低于0.5％，优选低于0.3％。
-以占始料的质量百分数计，始料中锆石的含量高于或等于80％。
-以基于氧化物的质量百分数计，制品中氧化锆的含量高于5％，优选高于10％，和/或低于15％。
-超过90％数量或甚至基本100％数量的粒子的尺寸小于50微米，优选小于30微米，优选小于20微米，甚至优选小于10微米。
-所述制品的表观孔隙率低于5％，优选低于2％，优选低于1％，优选低于0.5％。
-所述制品的表观密度高于4.0g/cm3，优选高于4.1g/cm3，优选高于4.2g/cm3。
-所述制品呈块形，质量优选高于5kg，优选高于10kg。
本发明还涉及一种制备烧结制品的方法，该方法包括如下步骤：
a)混合原料以形成始料，
b)自所述始料成型生坯，
c)烧结所述生坯以获得所述烧结制品，
值得一提的是，将所述始料确定为使得所述制品符合本发明。
优选地，根据本发明的方法可还具有如下任选特征中的一种或多种：
-在步骤a)中，以占始料的质量百分数计，以使得锆石和氧化锆的总含量占始料至少95％的量加入锆石和任选的氧化锆。
-自主地(即系统地和有方法地)加入氧化物Al2O3、TiO2、MgO、Fe2O3、NiO、MnO2、CoO、CuO、B2O3、GeO2、P2O5、Sb2O3、Nb2O5、Ta2O5、V2O5、PbO、ZnO和CdO中的一种或多种，加入的量应保证步骤c)中获得的烧结制品符合本发明。
-至少50％、优选至少80％、优选至少90％、更优选基本100％质量的锌以氧化物ZnO加入。
-磷酸含量低于1％，优选低于0.8％，甚至优选低于0.5％。
-步骤a)中使用的原料的中值尺寸(D50)小于50μm，或甚至小于40μm，或甚至小于20μm，或甚至小于5μm，或甚至小于4μm。
本发明还涉及根据本发明的方法制得或能根据本发明的方法制得的本发明耐火制品在玻璃熔炉中、特别是接触熔融玻璃的熔炉领域中的用途。本发明还涉及这样的玻璃熔炉。
定义
在本说明书中及根据习俗，在始料中或制品中，未与SiO2分子缔合形成锆石的ZrO2分子被称为“氧化锆”。同样，未与ZrO2分子缔合形成锆石的SiO2分子被称为“二氧化硅”。根据本发明的制品的ZrO2含量对应于锆石的ZrO2含量和氧化锆。根据本发明的制品的SiO2含量对应于锆石的SiO2含量和二氧化硅。
在一种化学组成中，氧化物含量涉及各个对应化学元素按行业惯例以最稳定的氧化物表达的总含量；因此包括前述元素的低价氧化物，任选地包括前述元素的氮化物、氮氧化物、碳化物、碳氧化物、碳氮化物或甚至金属物类。
在定义所述制品的化学组成而使用的氧化物Al2O3、TiO2、MgO、Fe2O3、NiO、MnO2、CoO、CuO、B2O3、GeO2、P2O5、Sb2O3、Nb2O5、Ta2O5、V2O5、PbO、ZnO和CdO的质量含量的总和中，可缺少一种或多种所提及的氧化物。
含氧化锆ZrO2的原料也含少量HfO2(1.5％-2％)。“ZrO2”通常指氧化锆ZrO2及随ZrO2引入的这些痕量HfO2。
除非另有指出，否则所有百分数均为基于氧化物的质量百分数。特别地，在始料中，锆石百分数基于始料的总质量表示。
“杂质”指必然随这些组分引入到原料中或自与这些组分的反应产生的不可避免的组分。在一个特别的实施方案中，P2O5为杂质。
一组颗粒的“中值尺寸”D50为将该集合的颗粒分成等质量的第一群体和第二群体的尺寸，所述第一群体和第二群体分别仅包含尺寸比所述中值尺寸大或小的颗粒。
粒子的尺寸为在抛光的切面中观察到的粒子的较大尺寸。
具体实施方式
所述锆石可由锆砂或由具有高锆石含量的致密耐火粘土制品提供。
根据本发明，绝对有必要的是始料含至少75％、优选至少80％的锆石。如果由根据本发明的锆石带有的SiO2和ZrO2的量由二氧化硅和氧化锆来提供，则确实将不能获得根据本发明的制品的有利性质。
优选地，锆石和氧化锆的总含量占始料的至少95％。
氧化锆由于其在高温下的结晶态转变而具有显著的膨胀变化。为限制这些膨胀变化，特别是在大块上，有必要限制氧化锆含量。始料因此应含低于25％的氧化锆，这由锆石含量至少为75％确保。
根据本发明，至少一种选自B2O3、GeO2、P2O5、Sb2O3、Nb2O5、Ta2O5和V2O5、特别是Ta2O5和Nb2O5、更特别是Ta2O5的氧化物与至少一种选自ZnO、PbO和CdO、特别是ZnO的氧化物的同时存在将改进基于锆石的耐火制品的抗渗出性。
如果必要，可加入至少一种选自Al2O3、TiO2、MgO、Fe2O3、NiO、MnO2、CoO、CuO的氧化物以改进根据本发明的制品的密度。在所述制品被置于腐蚀性环境中及显著接触熔融玻璃的应用中，加入这些氧化物因此特别有利。但本发明人已发现，在本发明的制品中，特别是在含Ta2O5的制品中，以基于氧化物的质量百分数计，当限制以低含量，特别是低于3％、低于2％、或甚至低于1％、或甚至低于0.5％加入这些氧化物、特别是加入Al2O3和TiO2时，可获得高密度。
优选向始料中加入至少1％的二氧化硅以促进在比致密化纯锆石所需的温度低的温度下开始致密化。
所述“其他氧化物”为诸如Na2O或Y2O3的氧化物。应使Na2O含量(其促进锆石的离解)最小化。优选地，这些氧化物为原料带来的杂质且其为不需要的组分而仅可容忍。在低于1.5％的含量下，认为这些“其他氧化物”的影响不会实质性改变所得结果。
以基于氧化物的质量百分数计，优选地，根据本发明的烧结制品中氧化物Na2O和Y2O3中的每一个的含量均低于0.5％，优选低于0.3％，更优选低于0.15％。
可按通常包括步骤a)-c)的方法来制备烧结耐火块。任选地，该方法在步骤a)之前包括碾磨锆石源及其他原料的步骤。使用该步骤，可获得对于材料的良好后续致密化所需的常规颗粒尺寸特征。特别地，由此制得的粉体的中值尺寸(D50)可小于50μm，或甚至小于40μm，或甚至小于20μm，或甚至小于5μm，或甚至小于4μm。
在步骤a)中，计量称取所有原料使得混合物具有所需的平均重量化学组成，然后在锆石烧结方法中常用的反絮凝剂和/或粘合剂如磷酸的存在下混合。
原料的混合物可任选地在步骤b)之前雾化。
在步骤b)中，混合物然后通过例如等静压制得以成型以形成所需尺寸的块。
可使用其他技术如粉浆浇铸、单轴向压制、凝胶浇铸、振动压铸或这些技术的组合。
在步骤c)中，生坯在空气中于大气压下在1,400℃到1700℃之间的温度下烧结以形成致密的耐火块。
当然，本发明不限于作为示例性和非限制性实施例提供的所述实施方案。
实施例
如下非限制性实施例为是为说明本发明而给出的。
在这些实施例中，选择使用如下原料，所给的百分数为质量百分数：
-具有如下平均化学分析数据(以重量计)的微粉化锆石：ZrO2+HfO2：66％，SiO2：33％，Al2O3：0.3％，P2O5：0.3％，Fe2O3：0.07％，TiO2：0.08％，以及低于0.2％的其他化合物如Y2O3。颗粒的中值尺寸(D50)为2.5μm。
-80％的磷酸H3PO4溶液。
-含超过99％的ZnO的氧化锌，其颗粒的中值尺寸(D50)为约3μm。
-含约95％的TiO2的氧化钛，其颗粒的中值尺寸为2.3μm。
-氧化铝，其颗粒的中值尺寸为约3μm。
-含约99％的GeO2的氧化锗，其颗粒的中值尺寸为约3μm。
-含约99.85％的Ta2O5的氧化钽，其颗粒的尺寸小于44μm。
烧结耐火块按通常包括如下步骤的方法制备：
a)混合原料以形成始料，
b)自所述混合物成型生坯，
c)烧结所述生坯。
在步骤a)中，计量称取所有原料使得混合物具有所需的平均重量化学组成，然后将原料在常用的烧结剂、反絮凝剂和/或粘合剂如磷酸的存在下混合。
原料的混合物可任选地在步骤a)之前雾化。
在步骤b)中，混合物然后通过等静压制得以成型以形成直径200mm、高约200mm的圆柱形生坯。
在步骤c)中，生坯然后在空气中于大气压和1600℃的烧结温度下烧结，平稳阶段保持20小时。
为测定渗出水平，取具有方形截面(边长25mm)、高75mm的条形制品样品并于1700℃加热24小时。在此过程结束时测定样品的体积。加热后样品的体积称为“Vm”，加热前样品的体积称为“Vi”，这两体积间的差“Va”(体积增量)Va＝Vm-Vi。比率Va/Vi称为“渗出指数”，在表1中标记为“Ie”。
所用原料的份数(质量百分数)以及所获得的结制品的表观孔隙率(％)、密度和“Ie”指数在表1中给出。
表1
  1   2   3   4   5   6(对比)   7(对比)
  锆石   98.75   98.5   97   97.3   97.33   98.5   98.6
  ZnO   0.25   0.5   2.5   2.5   2.5
  H3PO4   0.17
  Al2O3   0.8   0.3
  Ta2O5   1   1   0.5
  GeO2   0.2
  TiO2   0.7   1.1
  表观孔隙率   4.14   4.71   0.12   0.79   1.23   0.29   0.25
  表观密度(g/cm3)   4.11   4.10   4.31   4.28   4.28   4.32   4.39
  Ie   3％   6％   3％   5％   3％   12％   9％
表1清楚地示出了根据本发明的制品非常好的抗渗出性。这些制品的密度与保持受试已知样品的密度相当。
这些制品因此极适于用在玻璃熔炉中。

Claims (17)

1.一种烧结制品，自以基于氧化物的质量百分数计含有75-99％的锆石的始料制备，并且，其中原料为中值尺寸小于5μm的粉末，所述烧结制品以基于氧化物的质量百分数计具有如下平均重量化学组成：
60％≤ZrO2≤72.8％，
27％≤SiO2≤36％，
0.1％≤B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5，
0.1％≤ZnO+PbO+CdO，
B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5+ZnO+PbO+CdO≤5％，
0％≤Al2O3+TiO2+MgO+Fe2O3+NiO+MnO2+CoO+CuO≤5％，
其他氧化物：≤1.5％，
总共100％。
2.根据权利要求1所述的烧结制品，其中：
0.1％≤GeO2+P2O5+Nb2O5+Ta2O5，和/或
0.1％≤ZnO，和/或
GeO2+P2O5+Nb2O5+Ta2O5+ZnO≤5％。
3.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，其中Ta2O5含量高于0.3％、低于3％。
4.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，其中Ta2O5含量高于0.8％。
5.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，其中ZnO含量高于0.3％、低于3％。
6.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，其中ZnO含量高于0.8％。
7.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，所述烧结制品含有超过0.05％的至少一种选自Al2O3、TiO2、MgO、Fe2O3、NiO、MnO2、CoO和CuO的氧化物。
8.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，所述烧结制品含有超过0.3％的至少两种选自Al2O3、TiO2、MgO、Fe2O3、NiO、MnO2、CoO和CuO的氧化物。
9.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，所述烧结制品的化学组成使得0.05％＜Al2O3+TiO2＜3％。
10.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，所述烧结制品的化学组成使得0.9％＜Al2O3+TiO2。
11.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，所述烧结制品的平均重量化学组成为：
60％≤ZrO2≤72.4％，
27％≤SiO2≤36％，
0.2％≤B2O3+Nb2O5+Ta2O5≤2.5％，
0.2％≤ZnO≤2.5％，
0.2％≤Al2O3+TiO2+MgO+NiO+MnO2+CoO+CuO≤3％，
其他氧化物：≤1.5％，
总共100％。
12.根据权利要求1所述的烧结制品，以基于氧化物的质量百分数计，所述烧结制品的平均重量化学组成为：
60％≤ZrO2≤72.4％，
27％≤SiO2≤36％，
0.2％≤Nb2O5+Ta2O5≤2.5％，
0.2％≤ZnO≤2.5％，
0.2％≤Al2O3+TiO2≤2％，
其他氧化物：≤1.5％，
总共100％。
13.根据权利要求1所述的烧结制品，其中，以基于氧化物的质量百分数计，所述“其他氧化物”的含量低于0.5％。
14.根据权利要求1所述的烧结制品，其中，以基于氧化物的质量百分数计，氧化钇Y2O3含量低于0.5％。
15.根据权利要求1所述的烧结制品，其中，以基于氧化物的质量百分数计，锆石含量高于5％。
16.根据权利要求1所述的制品在所述制品接触熔融玻璃的玻璃熔炉领域中的用途。
17.根据权利要求16所述的用途用于提高抗渗出性。
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