CN103415487A - 成形或未成形的耐火或窑具组合物 - Google Patents

成形或未成形的耐火或窑具组合物 Download PDF

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CN103415487A
CN103415487A CN201280010111XA CN201280010111A CN103415487A CN 103415487 A CN103415487 A CN 103415487A CN 201280010111X A CN201280010111X A CN 201280010111XA CN 201280010111 A CN201280010111 A CN 201280010111A CN 103415487 A CN103415487 A CN 103415487A
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熊小勇
M·维森拜彻
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Center for Abrasives and Refractories Research and Development CARRD GmbH
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Abstract

本发明涉及一种耐火组合物，其包含70重量%-98重量%的粒状耐火材料和2重量%-30重量%的粘结剂相，该粘结剂相包含反应性填料和粘结剂，所述粘结剂相基本包含反应性红柱石作为反应性填料的单独。

Description

成形或未成形的耐火或窑具组合物
技术领域
本发明涉及成形或未成形的耐火或窑具组合物，其包含70重量%-98重量%的粒状耐火材料和2重量%-30重量%的粘结剂相。本发明也涉及通过使用以上组合物所生产的成形或未成形的耐火或窑具产品。
背景技术
成形或未成形的耐火或窑具组合物一般由粗糙粒状耐火材料、一部分反应性材料、粘结剂和添加剂组成。反应相或所谓的粘结剂相或基体包含反应性填料连同粘结剂，且如果需要的话添加剂例如反絮凝剂、抑制剂和加速剂。在现代的高科技的可铸微粒硅或热解法氧化硅和反应性氧化硅经常用作反应性填料。该反应性填料影响粘结剂相的化学行为和浇注料（castable）的性质，特别是其高温性质。
WO2008/060161Al记载了用于耐火制品例如炉衬、桶衬和用于冶金容器的衬里的耐火组合物。根据以上发明申请的耐火组合物包含发热材料、细的粒状红柱石和细的粒状氧化铝以及无机粘结剂。细红柱石和细氧化铝在粘结剂相连同无机粘结剂中用作反应性填料。
红柱石，一种具有化学式Al2O3*SiO2的天然矿物，是一种广为人知的耐火材料。红柱石的化学组成包含约60重量%的氧化铝、约38重量%的氧化硅和额外的某些杂质，例如铁和碱性氧化物。表1中总结了典型的红柱石精矿的组成。
表1
Figure BDA0000370829300000021
在浇注料中，在烧结期间使用细红柱石来分别支持反应性氧化铝和热解法氧化硅反应性氧化铝和硅酸钠的莫来石形成（莫来石化）。
发明概述
本发明的一个目的是提供特别用于在700℃-1750℃的温度下的改善的耐火组合物。本发明的另一目的是提供特别是在1100℃-1750℃的温度下具有高强度的耐火浇注料。此外，本发明的另一目的是取代或代替在低水泥浇注料（LCC）和超低水泥浇注料（ULCC）基体中的作为填料的反应性氧化铝。
已发现通过使用包含70重量%-98重量%的粒状耐火材料和2重量%-30重量%的粘结剂相（其中粘结剂相包含反应性填料和粘结剂）的耐火组合物可获得在1100℃-1750℃的温度下具有不同寻常的高强度的耐火材料。根据本发明的耐火组合物的基体或粘结剂相基本包含具有平均颗粒尺寸d50为0.2μm-2.0μm的单独反应性红柱石作为反应性填料。
具体实施方式
红柱石为具有化学式Al2SiO5的岛状硅酸铝的矿物。根据以下反应的红柱石向莫来石的热诱导转化导致矿物性质随着升高的温度而变化。
3（Al2O3*SiO2）（红柱石）→（3Al2O3*2SiO2）（莫来石）+SiO2（玻璃）
在1000℃下约1%的热膨胀之后，杂质的熔化伴随着小的收缩而出现。在1250℃莫来石化开始且伴随温度上升继续进行。最终，质量比为约87重量%的莫来石和13重量%的玻璃。
因此，可直接使用红柱石作为没有任何预先热处理的未加工的耐火原材料，或作为在上述莫来石转化（莫来石化）之后的烧制耐火材料。在莫来石的形成期间，过量的SiO2转化为玻璃。将玻璃的主要部分嵌入莫来石相，而使其少量位于所产生的莫来石晶体的表面。在高温下嵌入在莫来石相中的玻璃软化或熔融，且在高温下吸收莫来石的体积变化。因此，由红柱石形成的该特殊种类的莫来石展现了比其他种类的莫来石更高的热稳定性，因为软化的玻璃可渗入裂缝组织作为一种焊接剂修复在使用期间受损的莫来石。通过研究随温度变化的微观组织，可揭示莫来石结合和热机械性能之间的关系。可确认莫来石化闭合了红柱石晶粒的表面缺陷和起始裂纹。基体完全再结晶为莫来石-玻璃网络，与部分莫来石化的大晶粒相互连接。
发现通过使用粘结剂相显著和未预料地改变了以上所述的性质，该粘结剂相基本包含具有平均颗粒尺寸d50为0.2μm-2.0μm，优选0.5μm-1.5μm的单独的反应性红柱石作为反应性填料。
下面通过实施例详细说明本发明。
实施例1（反应性红柱石）
通过使用由研磨具有2μm-5μm的平均颗粒尺寸的可商购红柱石所产生的反应性红柱石来实现以下所述的研究。使用高能搅拌研磨机（碾磨机），获得了具有平均颗粒尺寸d50=1.37μm、特征在于dl0=0.72μm且d90=2.53μm的非常窄的颗粒尺寸分布、和18.27m2/g的比表面积（BET）的反应性红柱石。图1显示了反应性红柱石的颗粒尺寸分布的mastersizer分析。
使用其他研磨方法或不同的原材料发现了用于反应性红柱石的可比较的值，其中平均颗粒尺寸为0.2μm-2.0μm，颗粒尺寸分布具有小于2.5μm的颗粒尺寸宽度，且比表面积(BET)为10m2/g-25m2/g。
通过测量测试件的收缩率（永久线性变化；PLC）来测试反应性红柱石与反应性氧化铝比较的反应性，所述测试件通过在50mm×10mm×10mm的模具中在700℃-1500℃的温度下使用1000kg/cm2的压力干压制没有任何添加剂的各自材料而制备。对于这些对比测试，使用了反应性氧化铝，其特征在于d10=0.28μm，d50=0.93μm，d90=2.81μm，和6.55m2/g的比表面积（BET）。在图2中以图片形式再现了测试结果。如图2中所示，在700℃-1500℃的温度范围内，测试件的收缩率（PLC）从700℃的约-0.3%上升到1500℃的约-17.0%。
通过根据EN1402-5测量在相同温度范围的相同测试件的冷破裂模量（CMOR）来测试与反应性氧化铝对比的反应性红柱石的机械强度。在图3中以图象形式再现了测试结果。如图3中所示，在约950℃的温度下，反应性红柱石的CMOR开始明显上升。CMOR的温度曲线从700℃下的约10MPa上升到1500℃下的约90MPa。该图表明莫来石形成在950℃开始，且在1350℃完成。温度曲线暗示在反应性红柱石的情况下，相比使用反应性氧化铝的常规组合物，莫来石形成在低出200℃下开始。
反应性红柱石可多方面的使用，且可有利地与选自以下的粒状耐火材料结合：氧化硅、碳化硅、氧化铝、铝土矿、尖晶石、煅烧白云石、铬镁矿、橄榄石、镁橄榄石、莫来石、蓝晶石、硅线石、红柱石、火泥、或这些材料的两种或更多种的混合物。
实施例2（反应性红柱石浇注料）
表2
Figure BDA0000370829300000051
在表2中总结了典型的浇注料组合物。在表2中的两种组合物是相同的，除了根据本发明的组合物包含作为反应性填料的反应性红柱石，而对比组合物包含反应性氧化铝。
使用纯氧化铝浇注料以便分别获得包含反应性红柱石和反应性氧化铝的组合物的结合效率的直接比较。图4和5中显示了表2的浇注料组合物就根据EN1402-5的冷破裂模量（CMOR）而言的机械强度和其根据1402-6的冷碎强度（CCS）的对比。
如图4和5中所示，在中等温度范围(800℃-1200℃)中，两浇注料的结合强度具有接近相同的水平（浇注料RAD=包含反应性红柱石；浇注料RA=包含反应性氧化铝）。在更高的温度下，反应性红柱石通过在红柱石-莫来石和煅烧氧化铝和白色熔融氧化铝的表面上的玻璃相之间的二次莫来石形成而产生了额外的结合。因此，包含反应性红柱石的浇注料的机械性质得到了改善。
可以认为对热机械性能是完成合适性能的关键参数的应用而言，反应性红柱石是用于1100℃-1750℃的温度范围有希望的反应性填料。
检查与反应性氧化铝比较的反应性红柱石不同的应用，发现通过使用在1100℃-1750℃温度范围烧结的根据发明的耐火组合物所生产的耐火浇注料或铸件一般具有根据EN1402-5测量的超过5MPa的CMOR和根据EN1402-6测量的超过30MPa的冷碎强度(CCS)。
在该上下文中，在低水泥浇注料（LCC）中使用的反应性红柱石具有约5重量%的水泥含量，及在超低水泥浇注料(ULCC)中具有约2重量%的水泥含量。
在表3中就其CMOR和CCS总结了根据本发明的组合物的更多应用。在1100-1750℃的温度范围内烧结在表1中总结的材料和产品。
表3
应用 CMOR CCS
耐火捣打材料 ＞5MPa ＞30MPa
耐火喷射材料 ＞3MPa ＞20MPa
烧制或未烧制的耐火砖 ＞8MPa ＞50MPa
窑具 ＞8MPa ＞50MPa
测试以上所述的应用，将典型耐火组合物用于根据本发明的组合物中，该组合物具有基本包含作为反应性填料的单独的反应性红柱石的粘结剂相。所有测量的CMOR和CCS值均为高于限定值，如表3中所示。
基于以上结果可得到结论，反应性红柱石是为了代替用于高温应用的反应性氧化铝的合适的反应性填料。除了在中温范围（1100℃-1400℃）内反应性红柱石的技术优点，反应性红柱石因与反应性氧化铝相比明显的成本优势也十分突出。

Claims (12)

1.一种成形或未成形的耐火或窑具组合物，其包含70重量%-98重量%的粒状耐火材料和2重量%-30重量%的粘结剂相，该粘结剂相包含反应性填料和粘结剂，其特征在于该粘结剂相基本包含具有平均颗粒尺寸d50为0.2μm－2.0μm的单独反应性红柱石作为反应性填料。
2.据权利要求1的组合物，其特征在于反应性红柱石具有0.5μm-1.5μm的平均颗粒尺寸d50。
3.根据权利要求1或2的组合物，其特征在于该反应性红柱石具有窄的颗粒尺寸分布，该尺寸分布具有小于2.5μm的范围内的颗粒尺寸宽度。
4.根据权利要求1-3的任一项的组合物，其特征在于该反应性红柱石具有10m2/g-25m2/g的比表面积(BET)。
5.根据权利要求1-4的任一项的组合物，其特征在于粒状耐火材料选自氧化硅、碳化硅、氧化铝、铝土矿、尖晶石、煅烧白云石、铬镁矿、橄榄石、镁橄榄石、莫来石、蓝晶石、硅线石、红柱石、火泥、或这些材料的两种或更多种的混合物。
6.通过使用根据权利要求1-6的任一项的耐火组合物所生产的耐火浇注料或铸件，其特征在于在1100℃-1400℃的温度范围内烧结的浇注料或铸件具有根据EN1402-5测量的超过5MPa的冷破碎模量（CMOR）和根据EN1402-6测量的超过30MPa的冷碎强度(CCS)。
7.根据权利要求7的耐火浇注料，其特征在于浇注料为具有约5重量%的水泥含量的低水泥浇注料(LCC)。
8.根据权利要求7的耐火浇注料，其特征在于该浇注料为具有约2重量%的水泥含量的超低水泥浇注料(ULCC)。
9.通过使用根据权利要求1-6的任一项的耐火组合物所生产的耐火捣打材料，其特征在于在1100℃-1750℃温度范围内烧结的该耐火捣打料具有根据EN1402-5测量的超过5MPa的冷破碎模量(CMOR)和根据EN1402-6超过30MPa的冷碎强度(CCS)。
10.通过使用根据权利要求1-6的任一项的耐火组合物所生产的耐火喷射材料，其特征在于在1100℃-1750℃温度范围内烧结的该耐火喷射材料具有根据EN1402-5测量的超过3MPa的冷破碎模量(CMOR)和根据EN1402-6超过20MPa的冷碎强度(CCS)。
11.通过使用根据权利要求1-6的任一项的耐火组合物所生产的烧制或未烧制耐火砖，其特征在于在1100℃-1750℃温度范围内烧结的烧制或未烧制耐火砖具有根据EN1402-5测量的超过8MPa的冷破碎模量(CMOR)和根据EN1402-6超过50MPa的冷碎强度(CCS)。
12.通过使用根据权利要求1-6的任一项的耐火组合物所生产的窑具，其特征在于在1100℃-1750℃温度范围内烧结的该窑具具有根据EN1402-5测量的超过8MPa的冷破碎模量(CMOR)和根据EN1402-6超过50MPa的冷碎强度(CCS)。
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