CN104261840B - 一种磷酸盐结合低铝硅莫砖及其制备方法 - Google Patents

一种磷酸盐结合低铝硅莫砖及其制备方法 Download PDF

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CN104261840B
CN104261840B CN201410444238.3A CN201410444238A CN104261840B CN 104261840 B CN104261840 B CN 104261840B CN 201410444238 A CN201410444238 A CN 201410444238A CN 104261840 B CN104261840 B CN 104261840B
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魏瀚
王杰曾
周严敦
胡建辉
徐如林
王俊涛
叶亚红
陈雪峰
刘锡俊
袁林
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Shandong Ruitai Gezer Engineering Co.,Ltd.
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Abstract

本发明涉及一种磷酸盐结合低铝硅莫砖及其制备方法，砖的配方为：3‑1mm高铝矾土30‑59％、1‑0.088mm高铝矾土11‑28％、0.044＜mm矾土微粉0‑20％、0.088＜mm氧化铝微粉0‑18％、0.088＜mm煅烧高岭土5‑19％、0.088＜mm碳化硅5‑16％、20‑15μm硅微粉8‑22％、磷酸盐结合剂3‑10％。砖的制备工艺为：将原料按配方比例混合再加入磷酸盐结合剂，进行困料、回碾、机压成型、干燥，干燥的砖坯加热至450℃‑600℃温度下保温2‑8小时。本发明可利用低品位原料，抗碱性能良好，提高了材料耐高温性。

Description

一种磷酸盐结合低铝硅莫砖及其制备方法
所属技术领域
本发明涉及耐火材料生产技术，特别是涉及一种磷酸盐结合低铝硅莫砖及制备方法。主要使用在水泥窑窑尾烟室，窑门罩，三次风管，分解炉和窑内分解带等内衬工作层部位。
背景技术
目前，使用在水泥窑窑尾烟室、三次风管等低温区工作层部位的耐火材料多采用普通耐碱砖。但随着新型干法水泥设备的大型化，燃料燃烧效率的提升，单位产量的增加使整个回转窑系统的温度有了很大的提升，如：窑尾烟室从以前的900℃提高到至1100℃；窑内分解带的气流温度从1000℃提高到1300℃。因为温度的升高，普通耐碱砖已不能胜任，被迫使用抗剥落砖和硅莫砖。此外随着水泥日产量的不断提升，预热器循环系统中碱浓度含量不断提高，普通黏土质耐碱砖不能承受着较高温度碱蒸汽的冲刷与侵蚀，导致材料耐碱能力的下降。由于普通的耐碱砖不能满足当前的使用条件，导致频繁地检修维护，增加了维护成本，被迫使用价格昂贵的耐火材料如硅莫砖，但这种做法弊大于利。虽然提高了使用区域耐火材料的使用寿命并减少了维修成本，但硅莫砖不仅是一种使用在水泥窑高温带的区域(1300℃-1400℃)昂贵材料，而且耐碱性也不稳定，如使用在低温区域不仅加重了水泥生产的经营成本，而且还常常可能导致事故。故水泥窑窑尾烟室、三次风管需要使用经济成本低的，使用性能好的耐火材料。
发明内容
本发明的目的在于，研究一种磷酸盐结合低铝硅莫砖及其制备方法，该产品使用铝含量较低的三级高铝矾土作为骨料，采用磷酸盐作为结合剂，产品不需高温烧结，生产成本远低于现有高温烧结的耐火材料，故具有较好的性能指标及经济利用价值。这种材料的氧化铝组分介于耐碱粘土砖与高铝砖之间，故耐高温性优于普通耐碱砖。此外，该材料基质中加入了碳化硅，可以明显改善材料的抗热震，抵抗碱蒸汽侵蚀的能力。因而，它可以取代现有的普通耐碱砖、抗剥落砖和常规硅莫砖，广泛应用于水泥窑窑尾烟室，窑门罩，三次风管，分解炉等内衬工作层部位。填补了水泥窑系统中从低温到高温的过渡区中，既具有耐碱性、又具有耐高温性，且价格低廉的材料空白。本发明可通过以下技术方案来实现：
本发明的原料组分重量百分比为：
所述3-1mm高铝矾土，是3-1mm的市售同名耐火原料其氧化铝含量为50-55％；1-0.088mm高铝矾土，是1-0.088mm的市售同名耐火原料其氧化铝含量为50-55％；0.044＜mm矾土微粉，是0.044＜mm的市售一级矾土微粉，氧化铝含量＞85％，氧化铁含量＜0.05％；0.088＜mm碳化硅，是0.088＜mm的市售同名耐火原料，碳化硅含量≥92％，氧化铁含量＜1.2％；0.088＜mm煅烧高岭土，是0.088＜mm的市售同名耐火原料，二氧化硅含量≥52％，氧化铁含量＜0.26％；20-15μm硅微粉，SiO2含量≥95％；磷酸盐结合剂为40-50％的磷酸或磷酸二氢铝水溶液，其比重1.46-1.48g/cm3，P2O5/Al2O3摩尔比1.4-1.5。
所述低铝硅莫砖的制备方法如下：1)将原料按配方比例混合再加入磷酸盐结合剂；2)进行困料、回碾、机压成型、干燥；3)干燥的砖坯加热至450℃-600℃温度下保温2-8小时。
相比于现有技术，本发明具有如下有益效果：1)采用了三级高铝矾土作为原料，减少了已经相当紧缺的特级和一级矾土资源的消耗。2)控制材料中的氧化铝含量为45-58％，且碳化硅含量≥92％，赋予材料良好的抗碱性。3)提高了材料耐高温性，如荷重软化温度与普通耐碱砖相比提高了100-200℃。4)与硅莫砖相比，大幅降低了材料的售价。
具体实施方式
本发明的典型但非限制性的实施例如下：
实施例1
(1)材料的制备
1)将原料按配方比例混合，再加入磷酸盐结合剂；2)进行困料、回碾、机压成型、干燥；3)干燥的砖坯加热至500℃的温度下保温3小时。
实施例2
(1)材料的制备
1)将原料按配方比例混合，再加入磷酸盐结合剂；2)进行困料、回碾、机压成型、干燥；3)干燥的砖坯加热至530℃的温度下保温3小时。
实施例3
(1)材料的制备
1)将三级高铝矾土骨料、微粉结合剂按比例混合，再加入磷酸盐结合剂；2)进行困料、回碾、机压成型、干燥；3)干燥的砖坯加热至530℃的温度下保温3小时。
取以上实施事例所制备的低铝硅莫砖进行常规实验分析，各成品的性能参数和普通耐碱砖参数对比见下表：

Claims (2)

1.一种磷酸盐结合低铝硅莫砖，其特征在于：所述磷酸盐结合低铝硅莫砖的原料组分重量百分比为：
所述3-1mm高铝矾土，是3-1mm的市售同名耐火原料，其氧化铝含量为50-55％；1-0.088mm高铝矾土，是1-0.088mm的市售同名耐火原料，其氧化铝含量为50-55％；＜0.044mm矾土微粉，是＜0.044mm的市售一级矾土微粉，氧化铝含量＞85％，氧化铁含量＜0.05％；＜0.088mm碳化硅，是＜0.088mm的市售同名耐火原料，碳化硅含量≥92％，氧化铁含量＜1.2％；＜0.088mm煅烧高岭土，是＜0.088mm的市售同名耐火原料，二氧化硅含量≥52％，氧化铁含量＜0.26％；20-15μm硅微粉，SiO2含量≥95％；磷酸盐结合剂为40-50％的磷酸二氢铝水溶液，其比重1.46-1.48，P2O5/Al2O3理论摩尔比3∶1。
2.一种制备权利要求1所述磷酸盐结合低铝硅莫砖的方法，其特征为：将原料按配方比例混合最后加入磷酸盐结合剂，进行困料、回碾、机压成型、干燥，干燥的砖坯加热至450℃-600℃温度下保温2-8小时。
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