CN102297588A - Composite insulating brick for kiln liner of rotary kiln and manufacturing method of brick - Google Patents
Composite insulating brick for kiln liner of rotary kiln and manufacturing method of brick Download PDFInfo
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- CN102297588A CN102297588A CN2010102105423A CN201010210542A CN102297588A CN 102297588 A CN102297588 A CN 102297588A CN 2010102105423 A CN2010102105423 A CN 2010102105423A CN 201010210542 A CN201010210542 A CN 201010210542A CN 102297588 A CN102297588 A CN 102297588A
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Abstract
The invention relates to a composite insulating brick for the kiln liner of a rotary kiln and a preparation method of the brick. The invention firstly provides a composite insulating brick which is provided with four adjacent joint surfaces, a working surface and a non-working surface opposite to the working surface, wherein the four adjacent joint surfaces are two first opposite joint surfaces and two opposite second joint surfaces; the first opposite joint surfaces and the second joint surfaces are respectively coincided with the axial direction and the radial direction of a kiln body when the kiln liner is built; the composite insulating brick is composed of a heavy fireclay material brick body made from a heavy fireclay material the volume density of which is 1.7-3.2g/cm<3> and a light fireclay insulating material brick body made from a light fireclay insulating refractory material the volume density of which is 0.13-1.7g/cm<3>; the light fireclay insulating material brick body is located at a region of the composite insulating brick, close to one end of the non-working surface, and penetrates through the brick body between the first joint surfaces or the second joint surfaces of the composite insulating brick; and on the joint surfaces, the area of the light fireclay insulating material brick body accounts for 50-6%. The invention also provides a manufacturing method of the composite insulating brick.
Description
Technical field
The present invention relates to a kind of refratory insulating brick and preparation method who is used for kiln, relate to compound heat-insulation brick that a kind of rotary kiln liner uses and preparation method thereof specifically.
Background technology
Building by laying bricks or stones of rotary kiln liner is to utilize the heavy refractory material at present, because rotary kiln liner is to work under dynamic condition, kiln lining not only needs to have good heat-blocking action, also should bear the concentrated mechanical stress of generation and the acting in conjunction of thermal stress down in working order of kiln body, so the refractory brick that is used to build by laying bricks or stones rotary kiln at present is the refractory brick with specific dimensions that the heavy refractory material is made.In order to build rotary kiln by laying bricks or stones, the shape of this heavy fire proof material brick is generally the not wide wedge type brick in two ends, is commonly called as " concentric reducer " in the industry, and working face is the microcephaly, build by laying bricks or stones the back along the width on the kiln body circumferencial direction less than relative non-working surface.This refractory brick forms for utilizing heavy material to fire.
The problem that is used for the heavy fire proof material brick existence of rotary kiln liner at present is, at first, the thermal conductivity factor of heavy fire proof material brick is bigger, thermal loss under the condition of work is also bigger, the total thermal loss of kiln body accounts for fuel and discharges about 18% of total amount of heat, the loss of kiln body heat content accounts for 2/3rds of cement rotary kiln system thermal evapotranspiration, and the heat insulating effect that improves the rotary kiln body is the key problem that this area presses for solution for many years; Secondly, under the equal volume situation, because the problem of weight produces bigger heavy load by the kiln lining that the heavy fire proof material brick is built by laying bricks or stones for the rotary kiln body fully, the also corresponding energy consumption that has improved in working; Again on the one hand, rotary kiln uses certain hour, the damage of brick body can cause the furnace lining working face greater loss to occur, generally speaking, the working face loss reaches about 50% of brick length, just whole furnace lining need be removed, again with qualified brick building, adopting the replacement cycle of the refractory brick that the heavy refractory material fires fully, also is to influence the key factor that rotary kiln has enterprise's production cost at present.
Solve the big problem of heavy refractory material kiln lining thermal loss and be listed in country " eight or five " brainstorm project, numerous cement rotary kilns have producer and liner fireproof material manufacturer has mostly dropped into great amount of manpower and financial resources, developed cement rotary kiln kiln lining insulation composite brick, method mostly is to adopt by the working face fire resistant materials of attaching most importance to form, and (bulk density is greater than 1.7g/cm for light thermal-shield refractory material composition by non-working surface
3The fire resistant materials of attaching most importance to, bulk density is at 1.7g/cm
3Following is the light thermal-shield refractory material, two kinds of refractory materials join compound composition heavy insulation composite brick, on probation through on cement rotary kiln, building by laying bricks or stones, though have good heat insulating effect, but its life cycle is shorter, reason is that cement rotary kiln is when working under hot conditions, kiln lining is owing to be subjected under the acting in conjunction of mechanical stress and elevated temperature heat stress, the heat insulation composite brick of weight quality guarantee temperature takes place by following two kinds of destructions: one: the heat insulating effect of the light thermal-shield refractory material of weight matter handing-over composite brick is good, but the deadly defect that its intensity is lower causes the cracked of non-working surface light thermal-shield refractory material, finally causes the damage of weight matter composite brick; Two: the heavy refractory material combines with the handing-over of light thermal-shield refractory material, under hot conditions,, make the junction of two kinds of refractory materials that shear fracture take place because the difference of the thermal coefficient of expansion of two kinds of refractory materials is bigger, cause the heavy composite brick to take out skewer and fall brick, final kiln lining damage.
Though process numerous cement rotary kilns of more than ten years have producer and kiln lining manufacturer has made painstaking efforts to the cement rotary kiln thermal and insulating performance, but it is mostly short with the life cycle of kiln lining, the use cost of kiln lining is higher and abandon, and the use cost of kiln lining is much larger than energy-conservation cost, simultaneously owing to stop the kiln maintenance frequently, cause cement output to descend, have a strong impact on the economic benefit of cement production enterprise, finally undesirable and come to an end with weight matter composite brick result of use.
Summary of the invention
The stack compound heat-insulation brick that provides a kind of rotary kiln liner to use is provided technical problem underlying solved by the invention, this compound heat-insulation brick is a kind of composite construction brick of being made by big heavy refractory material of thermal conductivity factor and the little light thermal-shield refractory material of thermal conductivity factor with combining structure, combination by two kinds of fire proof material brick bodies, reach and improve the rotary kiln heat insulating effect, simultaneously can reduce the weight loading of kiln body, thereby can effectively reduce energy consumption and prolong kiln body service life.
Technical problem solved by the invention also is to provide the preparation method of the compound heat-insulation brick that above-mentioned rotary kiln liner uses, by the mode of inlaying heavy fire proof material brick body and light thermal-shield refractory material brick body are combined, obtain meeting the compound heat-insulation brick that the rotary kiln liner of instructions for use is used.
Technical problem solved by the invention also is to provide the another kind of preparation method of the compound heat-insulation brick that above-mentioned rotary kiln liner uses, mode by cast combines heavy refractory material and light thermal-shield refractory material, obtains meeting the compound heat-insulation brick that the rotary kiln liner of instructions for use is used.
Technical problem solved by the invention also is to provide the another kind of preparation method of the compound heat-insulation brick that above-mentioned rotary kiln liner uses, by one-time formed mode heavy refractory material and light thermal-shield refractory material are combined, obtain meeting the compound heat-insulation brick that the rotary kiln liner of instructions for use is used.
For solving the problems of the technologies described above, the invention provides the compound heat-insulation brick that a kind of rotary kiln liner is used, it has four adjacent faying faces, a working face and the non-working surface relative with it, four adjacent faying faces are two or two relative first faying face and second faying faces, consistent with the axial and radial direction of kiln body respectively when building kiln lining by laying bricks or stones, wherein, this compound heat-insulation brick is greater than 1.7g/cm by bulk density
3Heavy refractory material the heavy fire proof material brick body and the bulk density 1.7g/cm that make
3The light thermal-shield refractory material brick body that following light thermal-shield refractory material is made combines, light thermal-shield refractory material brick body is positioned at this compound heat-insulation brick near the zone of non-working surface one end and run through brick body between first or second faying face of this compound heat-insulation brick, and on this faying face, the area of light thermal-shield refractory material brick body accounts for 50-6%.
In technique scheme provided by the invention, preferably, the bulk density of described heavy refractory material is 1.7-3.2g/cm
3, the bulk density of described light thermal-shield refractory material is 0.13-1.7g/cm
3
In technique scheme provided by the invention, preferably, the thermal conductivity factor of heavy refractory material is more than or equal to 0.6w/mk, and the thermal conductivity factor of light thermal-shield refractory material is less than 0.6w/mk.
In technique scheme provided by the invention, preferably, described light thermal-shield refractory material brick body is arranged at the compound heat-insulation brick in non-working surface 80-5mm zone.
Different with the special-purpose insulating brick that generally uses in the present rotary kiln, compound heat-insulation brick provided by the invention is the kiln lining special brick of the composite construction of two kinds of different refractory material brick body combinations, promptly, in the zone of this kiln lining with close non-working surface one end of brick, be provided with light thermal-shield refractory material brick body, this light thermal-shield refractory material brick body is to adopt density≤1.7g/cm
3The light thermal-shield refractory material make; Other parts of this compound heat-insulation brick then are the heavy fire proof material brick bodies of being made by the heavy refractory material, can be referred to as body, and in heavy fire proof material brick body, corresponding open-work and/or groove can be set, and light thermal-shield refractory material (perhaps light thermal-shield refractory material brick body) can pass through variety of way (for example cast, inlay, splicing etc.) be compound to (groove is arranged on the non-working surface) in above-mentioned open-work and/or the groove, perhaps make heavy refractory material and light thermal-shield refractory material carry out pressure forming simultaneously and (for example utilize friction press, static pressure forcing press etc. carries out mechanical pressing) or moulding by casting, i.e. one-shot forming prepares the compound heat-insulation brick.
In technique scheme provided by the invention, heavy refractory material that is adopted and light thermal-shield refractory material can be at present to be used for the fireclay insulating refractory that the insulating brick (refractory brick) of rotary kiln liner is adopted in manufacturing, heavy refractory material and light thermal-shield refractory material are distinguished with its bulk density, preferably, described heavy refractory material comprises one or more the combination in magnesia series, high alumina matter series, clay matter series, silicon-carbide series and the semi silica series heavy refractory material etc.
In technique scheme provided by the invention, preferably, described light thermal-shield refractory material comprises one or more the combination in siliceous series, clay matter series, high alumina matter series, diatomaceous series, vermiculite matter series, pearl series of rocks and the alumina hollow ball series light thermal-shield refractory material etc.
In technique scheme provided by the invention, preferably, in the compound heat-insulation brick that above-mentioned rotary kiln liner is used, described light thermal-shield refractory material brick body and heavy fire proof material brick body are inlayed and are combined into one, and being made of heavy fire proof material brick body to the small part non-working surface of this compound heat-insulation brick.
Particularly, the inlaying compound mode and can comprise of light thermal-shield refractory material brick body and heavy fire proof material brick body: light thermal-shield refractory material brick body is embedded in the one or more open-work that heavy fire proof material brick body is provided with; And/or described light thermal-shield refractory material brick body is embedded in the one or more groove that heavy fire proof material brick body offers on non-working surface, and the non-working surface of this compound heat-insulation brick is provided with at interval by two kinds of brick bodies and constitutes.In the above scheme, described open-work or groove shapes (shape of cross section) are preferably circle, ellipse, triangle, quadrangle and/or polygon etc.
The global shape of compound heat-insulation brick of the present invention can be identical with brick with present rotary kiln liner with size, for example has the concentric reducer structure, that is, the working face of this compound heat-insulation brick is less than non-working surface.
In technique scheme provided by the invention, preferably, the working face of compound heat-insulation brick and/or non-working surface can be plane or cambered surface.
In technical scheme provided by the invention, preferably, the compound heat-insulation brick can be rectangular tiles or radial brick, and when being rectangular tiles, light thermal-shield refractory material brick body is set to run through the brick body between first faying face; During for radial brick, light thermal-shield refractory material brick body is set to run through the brick body between second faying face.
The present invention also provides preparation method's (calling inlaying process in the following text) of the compound heat-insulation brick that a kind of above-mentioned rotary kiln liner uses, and this method is a kind of method of post forming, and it may further comprise the steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, prepare heavy fire proof material brick body and light thermal-shield refractory material brick body;
Heavy fire proof material brick body and light thermal-shield refractory material brick body are combined as a whole by the mode of inlaying.
According to concrete technical scheme of the present invention, preferably, above-mentioned preparation method (inlaying process) can comprise following concrete steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, prepare heavy fire proof material brick body and light thermal-shield refractory material brick body, and in this heavy fire proof material brick body, reserve one or more open-work and/or on non-working surface, offer one or more groove according to the shape of light thermal-shield refractory material brick body;
Light thermal-shield refractory material brick body is embedded in the open-work and/or groove in the heavy fire proof material brick body.
In the present invention, for the selection of heavy refractory material and light thermal-shield refractory material, be that leading indicator is carried out with the bulk density.Simultaneously, in actual production, also can consider concrete kiln lining service condition requirement, in the various refractory materials that the present invention provides, select proper material for the selection of refractory material.Concrete kiln lining service condition requires to generally comprise: aggressivity power, material coefficient of friction height etc. in kiln temperature height, kiln temperature fluctuation size, kiln atmosphere, the kiln, for corresponding which material of actual conditions, can carry out with reference to prior art.
In order to improve the bond strength between heavy fire proof material brick body and the light thermal-shield refractory material brick body, the intensity of the compound heat-insulation brick for preparing with raising, preferably, before above-mentioned preparation method also is included in and inlays, the step of smearing bond at the contact-making surface of light thermal-shield refractory material brick body and heavy fire proof material brick body;
And/or, toast or low sintering step inlaying the light thermal-shield refractory material brick body and the heavy fire proof material brick body that are combined as a whole, wherein, baking and low sintering temperature are controlled at 25-600 ℃.
The bond that is adopted in inlaying process can be a compound cementing agent, preferably, this bond can be thermosetting property cementing agent, hydraulicity cementing agent or its combination, wherein, the thermosetting property cementing agent can be phosphate (for example phosphoric acid aluminum dihydrogen, six acid phosphoric acid sodium, sodium phosphate trimer etc.) or waterglass etc., and the hydraulicity cementing agent can be alumina cement or pure calcium aluminate cement etc.Composite brick with cementing agent needs heating curing, low-temperature sintering maintenance, or adds water curing, also can reach the purpose that improves intensity at normal temperatures.
The present invention also provides preparation method's (calling casting in the following text) of the compound heat-insulation brick that another kind of above-mentioned rotary kiln liner uses, and this method also is a kind of method of post forming, and it may further comprise the steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, the heavy refractory material is made heavy fire proof material brick body, and in this heavy fire proof material brick body, reserve one or more open-work and/or on non-working surface, offer one or more groove according to the shape of light thermal-shield refractory material brick body;
The light thermal-shield refractory material is poured in the open-work and/or groove in the heavy fire proof material brick body, and carries out vibrating forming and demoulding maintenance is handled, obtain the compound heat-insulation brick.
The bond strength that can improve between heavy fire proof material brick body and the light thermal-shield refractory material brick body is handled in above-mentioned demoulding maintenance, thereby improve the intensity of the compound heat-insulation brick for preparing, preferably, in above-mentioned preparation method (casting), the compound heat-insulation brick adobe that described maintenance is treated to finishing cast and vibrating forming adds water curing or heating curing.Wherein, when adding the water curing processing, preferably add temperature at the water more than 5 ℃, and after finishing maintenance, the compound heat-insulation brick is carried out drying.
The present invention also provides preparation method's (calling once moulding method in the following text) of the compound heat-insulation brick that another kind of above-mentioned rotary kiln liner uses, and it may further comprise the steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, make heavy refractory material pug and light thermal-shield refractory material pug respectively;
Heavy refractory material pug and light thermal-shield refractory material pug are injected the relevant position of compound heat-insulation bricks die respectively, and carry out forming processes, obtain compound heat-insulation brick base just;
The first base of compound heat-insulation brick is carried out maintenance handle, obtain the compound heat-insulation brick.
In above-mentioned preparation method (once moulding method), by light, heavy refractory material pug are poured into simultaneously and carry out vibrating forming and maintenance in the compound heat-insulation bricks die, can just obtain compound heat-insulation brick of the present invention by one-shot forming, preferably, above-mentioned maintenance be treated to the compound heat-insulation brick just base carry out drying and sintering, heating curing or add processing such as water curing; Wherein, when adding the water curing processing, preferably add temperature at the water more than 5 ℃, and after finishing maintenance, the compound heat-insulation brick is carried out drying.
Rotary kiln liner of the present invention compared with prior art has following advantage with the compound heat-insulation brick:
One, the working face of compound heat-insulation brick partly adopts the heavy refractory material to form, has the intensity height, antiscour and anti-wear performance are good, heat resistanceheat resistant spalling resistance and thermal shock resistance are strong, the characteristics of heavy material such as high temperature resistant property and chemical resistance of concrete function admirable, and lean on non-working surface partly is light thermal-shield refractory material and two kinds of compound compositions of material of heavy refractory material, this part also has higher intensity, to concentrating mechanical stress and the coefficient resistivity of thermal stress strong, the cracked of non-working surface zone can not take place to lean under two kinds of stress actings in conjunction;
Two, two kinds of materials compound has anti-shear performance preferably, and be less with the difference of thermal expansion coefficient by the non-working surface zone by the working face zone under hot conditions, can not make two parts under hot conditions shear fracture take place;
Three, owing to adopted the combination of light thermal-shield refractory material brick body and heavy fire proof material brick body, under equal volume, weight than present heavy brick can reduce more than 20%, and the kiln lining after building by laying bricks or stones has reduced the heavy load effect to the rotary kiln body, and the energy consumption under the condition of work can obviously reduce;
Four, because the combination of light thermal-shield refractory material brick body and heavy fire proof material brick body, under the identical situation of (with common refractory brick) working face material, the thermal conductivity factor of this compound heat-insulation brick is low, thermal loss also significantly reduces (can reduce about 70%) under the kiln body running condition after building by laying bricks or stones, in the rotary kiln course of work, can save raw coal more than 10% when calcination condition is identical, waste gas and discharge of harmful gases amount also reduce thereupon, are beneficial to the pollution of reduction to environment;
Five, because light thermal-shield refractory material brick body is arranged on non-working surface one end, and on combined area and position, all make up with scientific and reasonable ratio with heavy fire proof material brick body, the interior thermograde of working lining of heavy composite is reduced, improved the heat insulating effect in the rotary kiln use, make the thermal shock resistance and the antistrip performance of kiln lining improve the life cycle that has prolonged kiln lining;
The compound heat-insulation brick is built by laying bricks or stones on cement rotary kiln when using, and under hot conditions, the Weight reduction, heat insulating effect of kiln lining also can be protected big kiln cylinder body, and the temperature of kiln surface is reduced, and alleviates the effect of elevated temperature heat load to the kiln body, the life cycle that has prolonged the kiln body greatly.
Description of drawings
Figure 1A and Figure 1B are in the compound heat-insulation brick used of rotary kiln liner provided by the invention, and light thermal-shield refractory material brick body is the embodiment schematic diagram of circular complex method, and wherein Figure 1B is the side schematic view of this compound heat-insulation brick among Figure 1A.
Fig. 2 A and Fig. 2 B are that working face provided by the invention and non-working surface are that the rotary kiln liner of cambered surface is with in the fan-shaped compound heat-insulation brick, light thermal-shield refractory material brick body is the embodiment schematic diagram of the complex method of circle, and wherein Fig. 2 B is the schematic bottom view of this compound heat-insulation brick among Fig. 2 A.
Fig. 3 A and Fig. 3 B are that light thermal-shield refractory material brick body is the embodiment schematic diagram of foursquare complex method in the compound heat-insulation brick used of rotary kiln liner provided by the invention, and wherein Fig. 3 B is the side schematic view of this compound heat-insulation brick among Fig. 3 A.
Fig. 4 A and Fig. 4 B are that light thermal-shield refractory material brick body is the embodiment schematic diagram of the complex method of circle and multirow in the compound heat-insulation brick used of rotary kiln liner provided by the invention, and wherein Fig. 4 B is the side schematic view of this compound heat-insulation brick among Fig. 4 A.
Fig. 5 A and Fig. 5 B are that working face provided by the invention and non-working surface are that the rotary kiln liner of cambered surface is with in the fan-shaped compound heat-insulation brick, light thermal-shield refractory material brick body is the embodiment schematic diagram of the complex method of circle and multirow, and wherein Fig. 5 B is the schematic bottom view of this compound heat-insulation brick among Fig. 5 A.
Fig. 6 A and Fig. 6 B are that working face provided by the invention and non-working surface are that the rotary kiln liner of cambered surface is with in the fan-shaped compound heat-insulation brick, light thermal-shield refractory material brick body is the embodiment schematic diagram of square complex method, and wherein Fig. 6 B is the schematic bottom view of this compound heat-insulation brick among Fig. 6 A.
Fig. 7 A and Fig. 7 B are in the compound heat-insulation brick used of rotary kiln liner provided by the invention, the embodiment schematic diagram in the groove of light thermal-shield refractory material brick bluk recombination on non-working surface, and wherein Fig. 7 B is the side schematic view of this compound heat-insulation brick among Fig. 7 A.
Fig. 8 A and Fig. 8 B are that working face provided by the invention and non-working surface are that the rotary kiln liner of cambered surface is with in the fan-shaped compound heat-insulation brick, embodiment schematic diagram in the groove of light thermal-shield refractory material brick bluk recombination on non-working surface, wherein Fig. 8 B is the schematic bottom view of this compound heat-insulation brick among Fig. 8 A.
Fig. 9 A and Fig. 9 B are in the compound heat-insulation brick used of rotary kiln liner provided by the invention, the embodiment schematic diagram in the arc groove of light thermal-shield refractory material brick bluk recombination on non-working surface, and wherein Fig. 9 B is the side schematic view of this compound heat-insulation brick among Fig. 9 A.
Figure 10 A and Figure 10 B are that working face provided by the invention and non-working surface are that the rotary kiln liner of cambered surface is with in the fan-shaped compound heat-insulation brick, embodiment schematic diagram in the semi-circular recesses of light thermal-shield refractory material brick bluk recombination on non-working surface, wherein Figure 10 B is the schematic bottom view of this compound heat-insulation brick among Figure 10 A.
The specific embodiment
In order to make the purpose, technical solutions and advantages of the present invention clearer,, the present invention is described in further details below in conjunction with concrete embodiment and accompanying drawing.At this, the schematic specific embodiment of the present invention and explanation thereof are used to explain the present invention, but not as a limitation of the invention.
The present invention is to provide a kind of rotary kiln liner specific complex insulating brick, is greater than 1.7g/cm by bulk density
3(be preferably greater than 1.7, smaller or equal to 3.2g/cm
3) heavy refractory material heavy fire proof material brick body and the bulk density made be 1.7g/cm
3Below (preferred 0.13-1.7g/cm
3) the light thermal-shield refractory material brick body made of light thermal-shield refractory material combine.This compound heat-insulation brick comprises common rectangular tiles and radial brick.
In the building by laying bricks or stones of rotary kiln liner, the set-up mode of rectangle compound heat-insulation brick is that working face is towards kiln body center, what it was relative is outside non-working surface, in all the other four adjacent faying faces, two bigger faces are consistent to direction with the kiln axon, and the present invention claims first faying face; Two less faces are consistent with kiln body radial direction, the present invention claims second faying face, modal rectangle compound heat-insulation brick with Figure 1A and Figure 1B signal is an example, among Figure 1A, length of side M is first faying face with plane (being called for short the MN face) and relative face thereof that N surrounds, Figure 1B is the side view of this compound heat-insulation brick, relative two is the second alleged faying face of the present invention among the figure, be called for short the ANB face, the end face that length of side A and M surround is working face (also claiming the AM face), correspondingly, the BM face is the non-working surface that outwards is provided with.These definition are applicable to the rectangle compound heat-insulation brick among following all embodiment.
Referring to Figure 1A and Figure 1B, be a kind of rectangular tiles, have working face AM face and relative non-working surface BM face, all the other four adjacent faces are first and second faying faces, concrete explanation as the front.Working face and near the zone of the working face fire resistant materials brick body 1 of attaching most importance among the figure, dash area zone near non-working surface is a light thermal-shield refractory material brick body 2, and this light thermal-shield refractory material brick body is the brick body between the MN face that runs through relative, among this embodiment, light-weight brick body 2 is combined with each other with heavy brick body 1 becomes described compound heat-insulation brick, at MN face (referring in two relative rectangle first faying faces any one), the area of light thermal-shield refractory material brick body 2 accounts for 50-6%, concrete size difference according to this compound heat-insulation brick, light thermal-shield refractory material brick body 2 is positioned at the zone towards last 5-80mm from BM, i.e. a=5-80mm among the figure, among this embodiment, light thermal-shield refractory material brick body 2 has occupied the whole zone that this compound heat-insulation brick non-working surface plays 5-80mm.Anticipate as shown in FIG., this compound heat-insulation brick is actually arch brick, and at ANB face in echelon, the width of working face one end is less than non-working surface, that is, working face divides another name microcephaly and major part less than non-working surface.Build employed this compound heat-insulation brick by laying bricks or stones for rotary kiln liner, most cases all is this planform with working face for the microcephaly, so following examples are example with the structure of this brick all.
In the building by laying bricks or stones of rotary kiln liner, the set-up mode of fan-shaped compound heat-insulation brick is, working face is towards kiln body center, what it was relative is outside non-working surface, in all the other four adjacent faying faces, two less faces are consistent to direction with the kiln axon, the present invention claims first faying face, two bigger faces are consistent with kiln body radial direction, and the present invention claims second faying face, and this faying face is fan-shaped, modal fan-shaped compound heat-insulation brick with Fig. 2 A and Fig. 2 B signal is an example, Fig. 2 A, among the 2B, length of side M is first faying face with plane (being called for short the MN face) and relative face thereof that N surrounds, among Fig. 2 A, length of side A, N is second faying face with fan-shaped plan (being called for short the ANB face) and relative face thereof that B surrounds, the cambered surface that length of side A and M surround is working face (also claiming the AM cambered surface), and correspondingly, the cambered surface that length of side B and M surround is non-working surface (also claiming the BM cambered surface).These definition are applicable to the fan-shaped compound heat-insulation brick among following all embodiment.
With reference to Fig. 2 A and Fig. 2 B, be a kind of radial brick, have working face AM cambered surface and relative non-working surface BM cambered surface, all the other four adjacent faces are first and second faying faces, concrete explanation as the front.Working face and near the zone of the working face fire resistant materials brick body 1 of attaching most importance among the figure, dash area zone (border circular areas) near non-working surface is a light thermal-shield refractory material brick body 2, and this light thermal-shield refractory material brick body is the brick body between the ANB face (second faying face) that runs through relative, among this embodiment, light-weight brick body 2 is combined with each other with heavy brick body 1 becomes the compound heat-insulation brick, at ANB face (referring in two relative fan-shaped faying faces any one), the area of light thermal-shield refractory material brick body 2 accounts for 50-6%, concrete size difference according to the compound heat-insulation brick, light thermal-shield refractory material brick body 2 is positioned at from the zone of BM cambered surface to cambered surface center 5-80mm, i.e. a=5-80mm among the figure, among this embodiment, light thermal-shield refractory material brick body 2 has occupied the whole zone that compound heat-insulation brick non-working surface plays 5-80mm.As promptly showing among the figure, this composite brick is a radial brick, is becoming fan-shaped ANB face, and the arc length of working face one end is less than non-working surface, that is, working face divides another name microcephaly and major part less than non-working surface.
Figure 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B, 5A, 5B and 6A, 6B have illustrated the structural representation that light thermal-shield refractory material brick body 2 and heavy fire proof material brick body 1 are mutually compound, and promptly light thermal-shield refractory material brick body 2 is compound in the open-work that runs through brick body between the MN face that heavy fire proof material brick body 1 is provided with.The cross sectional shape (open-work shape) of light thermal-shield refractory material brick body 2 can be the circle of different size, square, also can be other shapes (irregular polygons for example, ellipse etc.), overall dimensions and needs according to this compound heat-insulation brick, light thermal-shield refractory material brick body 2 can be set to a plurality of and be provided with at interval, as shown in above-mentioned figure, the outermost light thermal-shield refractory material brick body 2 of close ANB face is d apart from the Edge Distance of insulating brick, the diameter of circular light thermal-shield refractory material brick body 2 or the length of side (width) of square light thermal-shield refractory material brick body 2 are b, apart from the non-working surface Edge Distance is f, spacing c between the adjacent light-weight brick body 2, the shape and size of these light thermal-shield refractory material brick bodies 2 do not require necessarily identical, referring to described accompanying drawing, it is in the zone of a (a=5-80mm) that determined more than one light thermal-shield refractory material brick body 2 all is arranged on from the non-working surface distance, the distance of seeing from the ANB face is e, and these sizes all can be adjusted in proportion for the compound heat-insulation brick of different size.In these topology examples, compound heat-insulation brick non-working surface BM face is formed by the light thermal-shield refractory material, and working face and non-working surface can be the planes, also can be cambered surfaces.
Certainly, compound light thermal-shield refractory material brick body 2 also can have only a large-size among these embodiment, is compounded in the above-mentioned appropriate area.
As another kind of embodiment of the present invention, referring to the compound heat-insulation brick shown in accompanying drawing 7A, 7B, 8A, 8B, 9A, 9B and 10A and the 10B, light thermal-shield refractory material brick body 2 is compound in heavy fire proof material brick body 1 in the groove that non-working surface is offered, like this, non-working surface is provided with at interval with heavy fire proof material brick body 1 by light thermal-shield refractory material brick body 2 and forms.About the size design and the set-up mode of light thermal-shield refractory material brick body, symbol of anticipating shown in each accompanying drawing and implication are all identical with previous embodiment, no longer repeat.Be appreciated that among these embodiment that with reference to above-mentioned accompanying drawing light thermal-shield refractory material brick body 2 can be plane or right angle with the combination interface of heavy fire proof material brick body 1, also can be cambered surface or fillet.
In the above-mentioned compound heat-insulation brick provided by the invention, heavy refractory material and light thermal-shield refractory material compound can be by a pressure forming or moulding by casting, secondary is inlayed or manufacture such as moulding by casting is carried out, and compound heat-insulation brick promptly provided by the invention prepares by inlaying process or casting etc.
Wherein, above-mentioned inlaying process can comprise following steps:
1, selects heavy refractory material and light thermal-shield refractory material according to bulk density,, prepare heavy fire proof material brick body and light thermal-shield refractory material brick body with corresponding construction according to the different structure of compound heat-insulation brick; For example: reserving the cross section in the heavy fire proof material brick body is the open-work and/or the groove of shapes such as circle or triangle, and light thermal-shield refractory material brick body is correspondingly made the shape such as cylindrical or triangular prism shaped that adapts with above-mentioned open-work and/or groove;
2, light thermal-shield refractory material brick body is mounted to the corresponding position (open-work and/or groove) of heavy fire proof material brick body, the two is combined as a whole.
In above-mentioned inlaying process, can improve the bond strength between heavy fire proof material brick body and the light thermal-shield refractory material brick body by the mode that the contact-making surface of counterweight fire resistant materials brick body and light thermal-shield refractory material brick body is smeared adhesive and/or the heavy fire proof material brick body inlaying, be combined as a whole finishing and light thermal-shield refractory material brick body carry out heated baking or low-temperature sintering (temperature range is generally at 25-600 ℃).
Compound heat-insulation brick shown in Figure 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B, 5A, 5B, 6A, 6B, 7A, 7B, 8A, 8B, 9A, 9B and 10A and the 10B all can obtain by the inlaying process preparation, for the step of heavy refractory material and light thermal-shield refractory material being made corresponding brick body, can existing method carry out.
Above-mentioned compound heat-insulation brick shown in the drawings also can prepare by once moulding method, and wherein, this method can comprise following concrete steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, make heavy refractory material pug and light thermal-shield refractory material pug respectively; The process of preparation pug can be carried out according to existing method;
According to the difference of compound heat-insulation brick structure, select corresponding mould, heavy refractory material pug and light thermal-shield refractory material pug are injected the relevant position of compound heat-insulation bricks die respectively, and carry out pressure forming, obtain compound heat-insulation brick base just; Concrete method for implanting can carry out according to existing pouring procedure;
The first base (semi-finished product adobe) of compound heat-insulation brick is carried out sintering or maintenance processing, obtain the compound heat-insulation brick.
Compound heat-insulation brick shown in Figure 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B, 5A, 5B and 6A, the 6B preferably adopts casting to prepare, compound heat-insulation brick shown in Fig. 7 A, 7B, 8A, 8B, 9A, 9B and 10A, the 10B also can adopt casting to prepare, wherein, this casting can comprise following steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, the heavy refractory material is made heavy fire proof material brick body, and in this heavy fire proof material brick body, reserve one or more open-work and/or groove according to the shape of light thermal-shield refractory material brick body;
The light thermal-shield refractory material is poured in the open-work and/or groove in the heavy fire proof material brick body, and carries out demoulding maintenance and handle, obtain the compound heat-insulation brick.
In above-mentioned casting, can also comprise that the compound heat-insulation brick to finishing after the cast, the demoulding adds water curing or heat-cured step, wherein, need carry out drying processing after adding water curing the compound heat-insulation brick, can conventional method carry out, for example be statically placed in and carry out drying in the air.
In casting, concrete pouring operation can adopt conventional pouring procedure to carry out.
In preparation method's (comprising inlaying process and casting) of compound heat-insulation brick provided by the invention, the preparation of open-work and groove (or reservation) all can be by conventional technology realization, for example die methods.
More specifically, the preparation method of compound heat-insulation brick provided by the invention is divided into production and processing manufacture method and secondary production and processing manufacture method two classes, wherein:
A production and processing preparation method (once moulding method) can carry out according to following concrete steps:
1, batching: according to manufacturing technique requirent, the raw material of the raw material of counterweight fire resistant materials and light thermal-shield refractory material carry out pick, break processing such as pulverize, prepare burden, mix respectively, obtain heavy refractory material pug and light thermal-shield refractory material pug;
2, moulding: adopt pressure forming or vibration casting moulding to carry out forming processes, wherein:
The employing pressure forming is meant: light thermal-shield refractory material and heavy refractory material are in the same place by pressure forming (as passing through mechanical pressing) straight forming, obtain the compound heat-insulation brick, concrete method can be: with good heavy refractory material pug and the light thermal-shield refractory material pug of mixing respectively, press shared respectively area ratio of two kinds of refractory materials of weight and concrete shape and structure, in the compound heat-insulation bricks die, add a certain amount of heavy refractory material pug and light thermal-shield refractory material pug respectively; Can adopt thin plate that two kinds of pugs are separated, after adding way-board be taken out, and carry out extrusion forming, can obtain compound heat-insulation brick semi-finished product.The half-finished working face of compound heat-insulation brick (being the microcephaly) the zone fire resistant materials of attaching most importance to, non-working surface (being major part) zone is most of to be the light thermal-shield refractory material;
Adopt the vibration casting moulding to be meant: light thermal-shield refractory material and heavy refractory material are in the same place by the moulding by casting straight forming, concrete method can be: the pug that preparation is obtained, adopt forced mixer to stir respectively, then heavy refractory material pug and light thermal-shield refractory material pug are pressed two kinds of shared area ratios of material of weight, in mould, add a certain amount of heavy refractory material pug and light thermal-shield refractory material pug respectively, when in mould, feeding in raw material, with thin plate two kinds of pugs are separated, the working face of compound heat-insulation brick (being the microcephaly) zone adds heavy refractory material pug, its non-working surface (being major part) zone adds light thermal-shield refractory material pug, take out thin plate then, adopt the bumper vibrating forming, promptly can obtain compound heat-insulation brick semi-finished product.
3, compound heat-insulation brick semi-finished product can obtain compound heat-insulation brick finished product by following three kinds of modes:
(1) according to manufacturing technique requirent, compound heat-insulation brick semi-finished product are carried out drying, and (baking temperature is generally in 25 ℃ of-110 ℃ of scopes, dried residual moisture should be less than 1wt%), loading of kiln, (sintering temperature is generally at 180-1650 ℃ for sintering, sintering time is generally at 24-240 hour), step such as kiln discharge, pick, obtain rotary kiln liner compound heat-insulation brick;
(2),, obtain rotary kiln liner compound heat-insulation brick to steps such as the heating of compound heat-insulation brick semi-finished product (the heating curing temperature is generally at 25-110 ℃, and the heat-cured time is generally at 24-72 hour), maintenance, picks according to manufacturing technique requirent;
(3) according to manufacturing technique requirent, compound heat-insulation brick semi-finished product are added water curing (to be added the water curing minimum temperature and is not less than 5 ℃, be higher than most 40 ℃, the time that adds water curing is generally at 4-72 hour), step such as drying, pick, obtain rotary kiln liner compound heat-insulation brick.
Secondary production and processing preparation method comprises inlaying process and casting, can carry out in such a way:
The heavy refractory material is carried out processing and manufacturing by the requirement of production technology, face shaping (rectangle or fan-shaped) and compound with it light thermal-shield refractory material brick shape, be processed into qualified heavy refractory material pug or heavy fire proof material brick body;
The light-weight refractory heat-barrier material is carried out processing and manufacturing by the requirement of production technology and planform, be processed into qualified light-weight refractory heat-barrier material brick body, perhaps the light thermal-shield refractory material is made light thermal-shield refractory material pug;
Heavy fire proof material brick body and light thermal-shield refractory material brick body are combined by the mode of inlaying, perhaps light thermal-shield refractory material pug is poured into the relevant position in the heavy fire proof material brick body, handle by moulding and/or demoulding maintenance then, obtain the compound heat-insulation brick;
When inlaying, can also on the contact-making surface of heavy fire proof material brick body and light thermal-shield refractory material brick body, smear binding agent, thermosetting property series cementing agent and hydraulicity series cementing agent etc. for example is to improve bond strength.
Particularly, secondary production and processing preparation method can comprise following concrete mode or steps:
1, the processing and manufacturing of heavy fire proof material brick body: according to different manufacturing technique requirents, the raw material of counterweight fire resistant materials carry out pick, the broken pulverizing, batching, step such as mix, carry out the processing and manufacturing of mould simultaneously, the shape of mould is determined according to the heavy refractory material part in the compound heat-insulation brick and the planform of light thermal-shield refractory material part, by working face (microcephaly) the zone fire resistant materials part of attaching most importance to, difform open-work and/or groove are reserved according to the shape of light thermal-shield refractory material part in its non-working surface (major part) zone, the moulding of heavy fire proof material brick body can be adopted mechanical pressing equipment (friction press, the hydrostatic pressure machine, the vibrations forcing press, fly press etc.) extrusion forming, heavy fire proof material brick body semi-finished product after the moulding can be processed according to following four kinds of manufacturing technique requirents, obtain heavy fire proof material brick body finished product:
(1) according to different manufacturing technique requirents, the heavy fire proof material brick body semi-finished product after the moulding are advanced steps such as drying, loading of kiln, sintering, kiln discharge, pick, can obtain making the needed heavy fire proof material brick of compound heat-insulation brick body finished product;
(2) according to different manufacturing technique requirents, the heavy fire proof material brick body semi-finished product after the moulding are carried out steps such as heating curing, pick, can obtain making the needed heavy fire proof material brick of compound heat-insulation brick body finished product;
(3) according to different manufacturing technique requirents, the heavy fire proof material brick body semi-finished product after the moulding are added steps such as water curing, drying, pick, can obtain making the needed heavy fire proof material brick of compound heat-insulation brick body finished product; In the above-mentioned processing mode related technological parameter can production according to existing conventional in related technological parameter carry out;
(4) add water or bond etc. in the heavy refractory material pug after batching, adopt forced mixer that pug is stirred, while is according to the shape mfg. moulding die of the heavy refractory material part and the light thermal-shield refractory material part of compound heat-insulation brick, formwork and pouring into a mould then, adopt the bumper vibrating forming, obtain heavy fire proof material brick body semi-finished product behind the moulding by casting, its non-working surface (major part) zone is reserved with the open-work or the groove of the multiple shape that is fit to light thermal-shield refractory material brick body, serial semi-finished product heavy fire resistive material product behind the moulding by casting, according to different manufacturing technique requirents, can take to add water (or heating) maintenance respectively, dry, steps such as pick can obtain making the needed heavy fire proof material brick of compound heat-insulation brick body finished product.
2, the processing and manufacturing of light thermal-shield refractory material brick body: according to different manufacturing technique requirents, raw material to the light thermal-shield refractory material carry out pick, the broken pulverizing, batching, step such as mix, carry out the processing and manufacturing of mould simultaneously, the shape of mould according to the shape of light thermal-shield refractory material part in the compound heat-insulation brick determine (promptly with heavy fire proof material brick body in open-work or the groove reserved adapt), and the employing machine is pressed the equipment extrusion forming, open-work or groove shapes that non-working surface (the being major part) zone of half-finished shape of light thermal-shield refractory material brick body after the moulding and heavy fire proof material brick body is reserved match, and the light thermal-shield refractory material brick body semi-finished product after the moulding can be processed according to following manufacturing technique requirent, obtain light thermal-shield refractory material brick body:
(1) according to different manufacturing technique requirents, the light thermal-shield refractory material brick body semi-finished product after the moulding are carried out steps such as drying, loading of kiln, sintering, kiln discharge, pick, can obtain making the needed light thermal-shield refractory material of compound heat-insulation brick brick body finished product;
(2) according to different manufacturing technique requirents, the light thermal-shield refractory material brick body semi-finished product after the moulding are added steps such as water curing, drying, pick, can obtain making the needed light thermal-shield refractory material of compound heat-insulation brick brick body finished product;
(3) according to different manufacturing technique requirents, the light thermal-shield refractory material brick body semi-finished product after the moulding are carried out steps such as heating curing, pick, can obtain making the needed light thermal-shield refractory material of compound heat-insulation brick brick body finished product; In the above-mentioned processing mode related technological parameter can production according to existing conventional in related technological parameter carry out;
(4) add water or bond etc. in the light thermal-shield refractory material pug after batching, adopt forced mixer that pug is stirred, basis is selected mould with the open-work of the heavy fire proof material brick body portion of compound heat-insulation brick or the shape need of groove simultaneously, and pour into a mould, adopt bumper to carry out vibrating forming in the cast, open-work or the groove reserved in half-finished shape of light thermal-shield refractory material brick body behind the moulding by casting and the heavy fire proof material brick body match.Light thermal-shield refractory material brick body semi-finished product behind the moulding by casting, according to different manufacturing technique requirents, steps such as water (or heating) maintenance, drying, pick can be taked to add respectively, the needed light thermal-shield refractory material of compound heat-insulation brick brick body finished product can be obtained making.
3, the compound manufacturing of secondary operations of light thermal-shield refractory material brick body and heavy fire proof material brick body
(1) compound autofrettage is inlayed in gluing: the contact-making surface of counterweight fire resistant materials brick body and light thermal-shield refractory material brick body, smear cementing agent respectively, then light thermal-shield refractory material brick body is mounted in the open-work or groove in the non-working surface zone that heavy fire proof material brick body reserved, add steps such as water (or heating) maintenance, drying, pick then, obtain rotary kiln liner compound heat-insulation brick;
(2) directly inlay the manufacturing composite algorithm: with the light thermal-shield refractory material brick body finished product for preparing, through processing such as shearings, directly be mounted in the open-work or groove in the non-working surface zone that heavy fire proof material brick body reserved, pass through the steps such as binder-treatment on surface then, obtain rotary kiln liner compound heat-insulation brick;
(3) composite algorithm is made in cast: add entry or bond etc. in light thermal-shield refractory material pug, adopt forced mixer to stir, then the light thermal-shield refractory material pug that stirs is poured in the open-work or groove in the non-working surface zone that the heavy fire proof material brick body that has mould reserved, adopt the bumper vibrating forming then, pass through steps such as the demoulding, Jia Shui (or heating) maintenance, drying, pick again, obtain rotary kiln liner compound heat-insulation brick.
Related some concrete technological parameters (for example curing temperature, curing time, sintering temperature, sintering time etc.) can be used the preparation method of brick with reference to the kiln lining of existing heavy refractory material preparation in the above-mentioned the whole bag of tricks.
In preferred embodiment provided by the invention, the bulk density of the heavy refractory material that is adopted is 1.7-3.2g/cm
3, the bulk density of light thermal-shield refractory material is 0.13-1.7g/cm
3Preferably, the heavy refractory material that is adopted can be the various materials shown in the table 1, and the light thermal-shield refractory material that is adopted can be the various materials shown in the table 2, but the present invention the material that can adopt be not limited to this.
The main component content of table 1 heavy refractory material
The main component content of table 2 light heat-insulating material
| Title material | Clay matter series light thermal-shield refractory material | High alumina matter series light thermal-shield refractory material | Diatomaceous serial light thermal-shield refractory material | Vermiculite matter series light thermal-shield refractory material | Perlite series light thermal-shield refractory material | Alumina hollow ball series light thermal-shield refractory material |
| ?Al 2O 3(％) | 35-48 | 48-68 | 99 | |||
| ?SiO 2 | ||||||
| Bulk density g/cm 3 | 0.4-1.5 | 0.4-1.0 | 0.4-0.7 | 0.35-0.55 | 0.2-0.35 | 1.2-1.6 |
| Thermal conductivity factor n/mk | 0.2-0.7 | 0.2-0.5 | 0.13-0.2 | 0.09-0.14 | 0.056-0.087 | 0.93-1.16 |
When rotary kiln liner was built use by laying bricks or stones, the heat flow density of light thermal-shield refractory material and heavy refractory material was also different under the hot conditions.With Φ 4 * 60m cement rotary kiln transition belt is example, kiln lining adopts siliceous mullite brick (heavy fire proof material brick respectively, Comparative Examples) (the heavy refractory material is selected high alumina matter series fire proof material brick body for use with the compound heat-insulation brick, light thermal-shield refractory material selection high alumina matter fibrofelt, its preparation method is: according to reservation shape the heavy refractory material is made heavy fire proof material brick body, according to reservation shape the high aluminum fiber felt is cut into light thermal-shield refractory material brick body, then two kinds of brick bodies directly are embedded in the compound together compound heat-insulation brick of making) build by laying bricks or stones, kiln lining working face temperature is 1450 ℃, when adopting siliceous mullite brick to build by laying bricks or stones, the surface temperature of kiln body is 350 ℃, and the heat flow density of kiln body is 196974w/ms; When composite brick was not built by laying bricks or stones with silicon, the mean temperature of kiln surface was 170 ℃, and the heat flow density of kiln body is 34025w/ms.Can draw thus, when adopting silicon composite brick not being built kiln lining by laying bricks or stones, heat flow density loss reduction is 114065w/ms, and annual every meter can to save raw coal be 188.600 tons to rotary kiln transition belt, can reduce CO every year simultaneously
2691.533 tons of discharge capacitys, pernicious gas SO
2Discharge capacity will reduce 2.262 tons.Hence one can see that, and when the compound heat-insulation brick that all adopts this law invention to provide when the kiln body was built by laying bricks or stones, the effect of energy-saving and emission-reduction was apparent in view, to saving the energy and the protection environment also is very favourable.
Be example with Φ 4 * 60m (2500T/d) cement rotary kiln below, the beneficial effect that adopts rotary kiln liner provided by the present invention to be had with respect to existing heavy brick with the compound heat-insulation brick be described:
1, salband: the length of building by laying bricks or stones of kiln lining is generally 5m, adopts phosphoric acid block salt and PQ-1 composite brick (high alumina matter composite brick, heavy partly are high alumina matter brick bodies, and lightweight heat-proof partly is the high aluminum fiber felt) to build by laying bricks or stones respectively.The mean temperature of kiln lining working face is t=1150 ℃, and the mean temperature of kiln surface is t phosphorus=230 ℃, and t is compound=120 ℃, and mean heat flux is so: q phosphorus=171508w/s, and q is compound=30445w/s.Replace with the PQ-1 composite brick that phosphate is brick to be built, heat flow (every metre per second (m/s)) loss decreased average amount is: Q=98745w, can save raw coal every year and reach 816.400 tons approximately.
2, clinkering zone: the length of building by laying bricks or stones of kiln lining is generally 20m, adopts and directly builds by laying bricks or stones in conjunction with magnesite-chrome brick and GPQ-1 composite brick (modification high alumina matter composite brick, heavy partly are modification high alumina matter brick bodies, and lightweight heat-proof partly is the high aluminum fiber felt).The mean temperature of kiln lining working face is t=1450 ℃, and the mean temperature of kiln surface is t magnesium=350 ℃, and t is compound=170 ℃, and mean heat flux is q magnesium=93046w/s, q is compound=and 49478w/s.Replace directly building by laying bricks or stones in conjunction with magnesite-chrome brick with the GPQ-1 composite brick, heat flow (every metre per second (m/s)) loss decreased average amount is: Q=30499W, can save raw coal every year and reach 1008.300 tons approximately.
3, intermediate zone: the length of building by laying bricks or stones of kiln lining is 12m, adopts high aluminum silicon carbide brick and GLCQ-1 composite brick (extraordinary high alumina matter composite brick, heavy partly are extraordinary high alumina matter brick bodies, and lightweight heat-proof partly is the high aluminum fiber felt) to build by laying bricks or stones.The mean temperature of kiln lining working face is t=1350 ℃, and kiln surface mean temperature is t carbon=350 ℃, and t is compound=170 ℃, and mean heat flux is q carbon=196974w/s, q is compound=and 34025w/s.Replace high aluminum silicon carbide brick to build by laying bricks or stones with the GLCQ-1 composite brick, heat flow (every metre per second (m/s)) loss decreased average amount is: Q=114065w, can save raw coal every year and reach about 2263.200 tons.
4, branch ungirds: kiln lining is built length by laying bricks or stones and is generally 23m, adopts high-strength alkaline-resisting brick and GKNQ-1 composite brick (low pore high alumina matter composite brick, heavy partly are low pore high alumina matter brick bodies, and lightweight thermal insulation brick partly is the high aluminum fiber felt) to build by laying bricks or stones.The mean temperature of kiln lining working face is t=1100 ℃, and the mean temperature of kiln surface is t alkali=150 ℃, and t is compound=80 ℃, and mean heat flux is q alkali=148669w/s, q is compound=and 28623w/s.Replace high-strength alkaline-resisting brick building with GKNQ-1, heat flow (every metre per second (m/s)) loss decreased average amount is: Q=84033w, can save raw coal every year and reach 3196.000 tons approximately.
In sum, Φ 4 * 60m (2500T/d) cement rotary kiln kiln lining adopts that compound heat-insulation provided by the invention is brick to be built, and under the high temperature normal running conditions, the thermal loss of kiln body can reduce about 70%.Remove the big-and-middle light maintenance time, by 300 days operation working times of normal cement revolution, under the constant condition of cement output, Φ a 4 * 60m (2500T/d) cement rotary kiln can be saved raw coal and reach 7283.900 tons more than approximately, CO every year
2Discharge capacity can reduce about 26707.633 tons, can reduce SO simultaneously
2Reach 65.555 tons approximately etc. the discharge of harmful gases amount, and producing cement consumption raw coal amount per ton (5000cal) is dropped to about the 113kg/ ton by original 125kg/ ton, make and produce cement raw consumption of coal amount reduction per ton more than 10%, owing to saved raw coal, make and produce the CO that cement per ton produced simultaneously
2And SO
2Reduce etc. the discharge of harmful gases amount, waste gas environmental protection treatment qualified discharge expense is reduced, thereby economic benefit of enterprises is significantly improved, and obtain the good social benefit.
China in recent years, because industrial boom, the people's living standard improves constantly, constantly at double the growth of cement expense, cement output to the end of the year 2009 up to 2,000,000,000 tons about, (Φ 4 * 60m) calculates if manufacture of cement is all with the 2500t/d cement producing line, cement rotary kiln all adopts serial heat insulation composite brick to build by laying bricks or stones, and the annual operation working time by 300 days is under the constant condition of cement output, can save raw coal so every year and reach 1942.3733 ten thousand tons approximately, CO
2Discharge capacity can reduce about 7122.0355 ten thousand tons, can reduce SO simultaneously
2Reach 17.4813 ten thousand tons approximately etc. the discharge of harmful gases amount.Adopt that compound heat-insulation provided by the invention is brick builds the consumption that cement rotary kiln has not only reduced cement raw fuel per ton, saved a large amount of raw coal, reduced production cost, significantly improved economic benefit of enterprises, but also reduced CO
2, SO
2Deng the discharge capacity of pernicious gas in atmosphere, thereby protected environment.
Claims (15)
1. compound heat-insulation brick that rotary kiln liner is used, it has four adjacent faying faces, a working face and the non-working surface relative with it, four adjacent faying faces are two or two relative first faying face and second faying faces, consistent with the axial and radial direction of kiln body respectively when building kiln lining by laying bricks or stones, wherein, this compound heat-insulation brick is greater than 1.7g/cm by bulk density
3Heavy refractory material the heavy material brick body and the bulk density 1.7g/cm that make
3The light thermal-shield refractory material brick body that following light thermal-shield refractory material is made combines, described light thermal-shield refractory material brick body is positioned at this compound heat-insulation brick near the zone of non-working surface one end and run through brick body between first or second faying face of this compound heat-insulation brick, and on this faying face, described lightweight accounts for 50-6% every the area of fire-resistant hot material brick body.
2. compound heat-insulation brick as claimed in claim 1, wherein, the bulk density of described heavy refractory material is 1.7-3.2g/cm
3, the bulk density of described light thermal-shield refractory material is 0.13-1.7g/cm
3
3. compound heat-insulation brick as claimed in claim 1 or 2, wherein, the thermal conductivity factor of described heavy refractory material is more than or equal to 0.6w/mk, and the thermal conductivity factor of described light thermal-shield refractory material is less than 0.6w/mk.
4. compound heat-insulation brick as claimed in claim 1, wherein, described light thermal-shield refractory material brick body is arranged at this compound heat-insulation brick in non-working surface 80-5mm zone.
5. as claim 1 or 4 described compound heat-insulation bricks, wherein, described light thermal-shield refractory material brick body and heavy fire proof material brick body are inlayed and are combined into one, and being made of heavy fire proof material brick body to the small part non-working surface of this compound heat-insulation brick;
The described compound mode of inlaying comprises: light thermal-shield refractory material brick body is embedded in the more than one open-work of heavy fire proof material brick body setting; And/or described light thermal-shield refractory material brick body is embedded in the more than one groove that heavy composite brick body offers on non-working surface, and the non-working surface of this compound heat-insulation brick is provided with at interval by two kinds of brick bodies and constitutes.
6. compound heat-insulation brick as claimed in claim 1, wherein, described heavy refractory material comprises one or more the combination in magnesia series, high alumina matter series, clay matter series, silicon-carbide series and the semi silica series heavy refractory material.
7. compound heat-insulation brick as claimed in claim 1, wherein, described light thermal-shield refractory material comprises one or more the combination in siliceous series, clay matter series, high alumina matter series, diatomaceous series, vermiculite matter series, pearl series of rocks and the alumina hollow ball series light thermal-shield refractory material.
8. the preparation method of the compound heat-insulation brick used of each described rotary kiln liner of claim 1-7, it may further comprise the steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, prepare heavy fire proof material brick body and light thermal-shield refractory material brick body;
Heavy fire proof material brick body and light thermal-shield refractory material brick body are combined as a whole by the mode of inlaying.
9. preparation method as claimed in claim 8, wherein, this preparation method may further comprise the steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, prepare heavy fire proof material brick body and light thermal-shield refractory material brick body, and in this heavy fire proof material brick body, reserve more than one open-work and/or on non-working surface, offer more than one groove according to the shape of light thermal-shield refractory material brick body;
Described light thermal-shield refractory material brick body is embedded in the open-work and/or groove in the described heavy fire proof material brick body.
10. preparation method as claimed in claim 9, wherein, before this preparation method also is included in and inlays, the step of smearing bond at the contact-making surface of described light thermal-shield refractory material brick body and heavy fire proof material brick body.
11. as claim 9 or 10 described preparation methods, wherein, this preparation method also comprises and toasting or low sintering step inlaying the light thermal-shield refractory material brick body and the heavy fire proof material brick body that are combined as a whole.
12. the preparation method of the compound heat-insulation brick that each described rotary kiln liner of claim 1-7 is used, it may further comprise the steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, the heavy refractory material is made heavy fire proof material brick body, and in this heavy fire proof material brick body, reserve more than one open-work and/or on non-working surface, offer more than one groove according to the shape of light thermal-shield refractory material brick body;
The light thermal-shield refractory material is poured in the open-work and/or groove in the heavy fire proof material brick body, and carries out vibrating forming and demoulding maintenance is handled, obtain the compound heat-insulation brick.
13. preparation method as claimed in claim 12, wherein, the compound heat-insulation brick that described demoulding maintenance is treated to finishing after the cast carries out demoulding and adds water curing or demoulding heating curing.
14. the preparation method of the compound heat-insulation brick that each described rotary kiln liner of claim 1-7 is used, it may further comprise the steps:
Select heavy refractory material and light thermal-shield refractory material according to bulk density, make heavy refractory material pug and light thermal-shield refractory material pug respectively;
Heavy refractory material pug and light thermal-shield refractory material pug are injected the relevant position of compound heat-insulation bricks die respectively, and carry out pressure forming, obtain compound heat-insulation brick base just;
The first base of compound heat-insulation brick is carried out maintenance handle, obtain the compound heat-insulation brick.
15. preparation method as claimed in claim 14, wherein, described maintenance is treated to be carried out drying and sintering, heating curing or adds water curing the first base of compound heat-insulation brick.
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| Application Number | Priority Date | Filing Date | Title |
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| CN2010102105423A CN102297588A (en) | 2010-06-22 | 2010-06-22 | Composite insulating brick for kiln liner of rotary kiln and manufacturing method of brick |
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| Application Number | Priority Date | Filing Date | Title |
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| CN2010102105423A CN102297588A (en) | 2010-06-22 | 2010-06-22 | Composite insulating brick for kiln liner of rotary kiln and manufacturing method of brick |
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| CN102297588A true CN102297588A (en) | 2011-12-28 |
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| CN2010102105423A Pending CN102297588A (en) | 2010-06-22 | 2010-06-22 | Composite insulating brick for kiln liner of rotary kiln and manufacturing method of brick |
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Cited By (4)
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| CN102788497A (en) * | 2012-09-07 | 2012-11-21 | 厚波 | Special composite firebrick for rotary kiln and preparation method thereof |
| CN106352695A (en) * | 2016-09-08 | 2017-01-25 | 通达耐火技术股份有限公司 | Rotary kiln energy-saving method |
| CN107192268A (en) * | 2017-07-07 | 2017-09-22 | 浙江中茂耐火材料股份有限公司 | A kind of compound refractory brick |
| CN109405535A (en) * | 2018-10-15 | 2019-03-01 | 江苏宏大特种钢机械厂有限公司 | 4 points of fixed rotary kiln liner bricks |
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| CN102788497A (en) * | 2012-09-07 | 2012-11-21 | 厚波 | Special composite firebrick for rotary kiln and preparation method thereof |
| CN106352695A (en) * | 2016-09-08 | 2017-01-25 | 通达耐火技术股份有限公司 | Rotary kiln energy-saving method |
| CN107192268A (en) * | 2017-07-07 | 2017-09-22 | 浙江中茂耐火材料股份有限公司 | A kind of compound refractory brick |
| CN109405535A (en) * | 2018-10-15 | 2019-03-01 | 江苏宏大特种钢机械厂有限公司 | 4 points of fixed rotary kiln liner bricks |
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Application publication date: 20111228 |