CN105601307B - 一种硅铝酸钾砖及其制备方法 - Google Patents

一种硅铝酸钾砖及其制备方法 Download PDF

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CN105601307B
CN105601307B CN201610075234.1A CN201610075234A CN105601307B CN 105601307 B CN105601307 B CN 105601307B CN 201610075234 A CN201610075234 A CN 201610075234A CN 105601307 B CN105601307 B CN 105601307B
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袁林
李沅锦
李全有
郑建立
曹伟
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ZHENGZHOU RUITAI REFRACTORY MATERIALS TECHNOLOGY Co Ltd
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Abstract

本发明属于耐火材料技术领域，公开一种硅铝酸钾砖及其制备方法。由骨料、粉料、高温增强剂外加结合剂制成；骨料、粉料、高温增强剂之和为100wt%，骨料占55‑65wt%，粉料占35‑45wt%，高温增强剂占3‑5wt%，结合剂占骨料、粉料、高温增强剂之和的3‑5wt%；所述骨料为：粒度0‑1mm的合成铝酸钾，粒度1‑3mm的碳化硅，粒度3‑5mm的碳化硅；所述粉料为：粒度＜0.074mm的合成铝酸钾，粒度＜0.074mm的碳化硅；所述高温增强剂为中国专利申请号201410488950.3公开的产品；所述结合剂为低钠硅溶胶。本发明产品耐磨性及耐碱侵蚀性大于高耐磨砖及硅莫砖，寿命延长1.5‑2倍。

Description

一种硅铝酸钾砖及其制备方法
技术领域
本发明属于耐火材料技术领域，具体涉及一种硅铝酸钾砖及其制备方法。
背景技术
目前市场上绝大部分热工设备易磨损部位衬砖多使用高耐磨砖或硅莫砖，随着热工设备技术发展，使用的燃料从以前的单纯煤粉到现在的固体有机物及垃圾等，变得多样性，因此衬砖受到的不仅仅为磨损，碱性侵蚀变得越加严重。已有十年历史的硅莫砖及高耐磨砖虽然耐磨性高，但它们弱酸性体质已经逐渐不适应现有热工设备的使用环境，使用过程中逐渐出现了急冷急热炸裂、侵蚀剥落等现象，影响到了热工设备的安全正常运转。
发明内容
为解决现有耐磨类衬砖热震不佳、抗侵蚀性能低的问题，本发明的目的在于提供一种硅铝酸钾砖及其制备方法。
为实现上述目的，本发明采取的技术方案如下：
一种硅铝酸钾砖：由骨料、粉料、高温增强剂外加结合剂制成；骨料、粉料、高温增强剂之和为100wt%，骨料占55-65wt%，粉料占35-45wt%，高温增强剂占3-5wt%，结合剂占骨料、粉料、高温增强剂之和的3-5wt%；
所述骨料为：粒度0-1mm的合成铝酸钾10-15wt%，粒度1-3mm的碳化硅15-30wt%，粒度3-5mm的碳化硅15-20wt%；
所述粉料为：粒度＜0.074mm的合成铝酸钾10-15wt%，粒度＜0.074mm的碳化硅20-35wt%；
所述高温增强剂为中国专利申请号201410488950.3公开的产品；
所述结合剂为低钠硅溶胶。
较好地，三种粒度规格的碳化硅中碳化硅含量为90-98wt%。
较好地，所述合成铝酸钾按下述方法制备获得：85-95wt%的氢氧化铝与5-15wt%的碳酸钾在1200-1400℃中保温12-24小时而成。
较好地，所述低钠硅溶胶中：Na2O＜0.006wt%，SiO2＞30 wt %。
制备方法，步骤如下：
第一步，先将骨料加入结合剂混匀，然后加入粉料和高温增强剂继续混匀，得半成品泥料；
第二步，将上述半成品泥料压制成砖坯；
第三步，将砖坯自然干燥后再进一步烘干；
第四步，将烘干后的砖坯以8-10℃/h的升温速度升温至1200-1400℃保温36-48h，即得硅铝酸钾砖。
为提高衬砖的抗急冷急热及耐磨性，本发明使用碳化硅为主原料，但碳化硅为酸性，不适合碱性热工环境，因此加入了部分合成铝酸钾颗粒及粉料，合成铝酸钾在高温形成的碱金属氧化物相可减缓碱性侵蚀，因此提高了制品整体抗碱侵蚀性能。
本发明产品抗热震稳定性能优异，可适用于温差大且频繁的高温环境，同时该产品抗碱侵蚀性能强，使用寿命同比环境下大于同类耐磨衬砖。
具体实施方式
下面结合具体实施例对本发明作进一步说明，但不限定本发明的保护范围。
以下实施例中，原料规格（以质量百分比计）：三种粒度规格的碳化硅中碳化硅含量为90-98wt%；所述低钠硅溶胶中：Na2O＜0.006wt%，SiO2＞30 wt %。
实施例1
一种硅铝酸钾砖，其原料配伍为：
由骨料、粉料、高温增强剂外加结合剂制成；骨料、粉料、高温增强剂之和为100wt%，骨料占55wt%，粉料占42wt%，高温增强剂占3wt%，结合剂占骨料、粉料、高温增强剂之和的3.5wt%；
所述骨料为：粒度0-1mm的合成铝酸钾10wt%，粒度1-3mm的碳化硅30wt%，粒度3-5mm的碳化硅15wt%；
所述粉料为：粒度＜0.074mm的合成铝酸钾10wt%，粒度＜0.074mm的碳化硅32wt%；
所述高温增强剂为中国专利申请号201410488950.3实施例1制备的产品；
所述结合剂为低钠硅溶胶；
所述合成铝酸钾按下述方法制备获得：95wt%的氢氧化铝与5wt%的碳酸钾在1400℃中保温12h而成。
硅铝酸钾砖的制备方法，步骤如下：
第一步，先将骨料放入混碾机内加入结合剂混碾5分钟，然后依次加入粉料和高温增强剂继续混碾10分钟，得半成品泥料；
第二步，将上述半成品泥料用630T压力机压制成砖坯；
第三步，将砖坯自然干燥24小时后，110℃烘干24小时；
第四步，将烘干后的砖坯取出后装窑，以8℃/h的升温速度升温至1350℃，保温36h后冷却，即得硅铝酸钾砖。
实施例2
一种硅铝酸钾砖，其原料配伍为：
由骨料、粉料、高温增强剂外加结合剂制成；骨料、粉料、高温增强剂之和为100wt%，骨料占60wt%，粉料占35.2wt%，高温增强剂占4.8wt%，结合剂占骨料、粉料、高温增强剂之和的4.5wt%；
所述骨料为：粒度0-1mm的合成铝酸钾15wt%，粒度1-3mm的碳化硅30wt%，粒度3-5mm的碳化硅15wt%；
所述粉料为：粒度＜0.074mm的合成铝酸钾15wt%，粒度＜0.074mm的碳化硅20.2wt%；
所述高温增强剂为中国专利申请号201410488950.3实施例1制备的产品；
所述结合剂为低钠硅溶胶；
所述合成铝酸钾按下述方法制备获得：85wt%的氢氧化铝与15wt%的碳酸钾在1200℃中保温24h而成。
硅铝酸钾砖的制备方法，步骤如下：
第一步，先将骨料放入混碾机内加入结合剂混碾5分钟，然后依次加入粉料和高温增强剂继续混碾10分钟，得半成品泥料；
第二步，将上述半成品泥料用630T压力机压制成砖坯；
第三步，将砖坯自然干燥24小时后，110℃烘干24小时；
第四步，将烘干后的砖坯取出后装窑，以10℃/h的升温速度升温至1250℃，保温48h后冷却，即得硅铝酸钾砖。
实施效果：
从上表可知：本发明产品热震稳定性远远大于1680硅莫砖，同时耐碱性大于硅莫砖数倍，使用在相同部位，使用寿命同比环境下比1680硅莫砖和硅莫砖可延长1.5-2倍，满足了现有水泥窑的生产需求。

Claims (5)

1.一种硅铝酸钾砖，其特征在于：由骨料、粉料、高温增强剂外加结合剂制成；骨料、粉料、高温增强剂之和为100wt%，骨料占55-65wt%，粉料占35-45wt%，高温增强剂占3-5wt%，结合剂占骨料、粉料、高温增强剂之和的3-5wt%；
所述骨料为：粒度0-1mm的合成铝酸钾10-15wt%，粒度1-3mm的碳化硅15-30wt%，粒度3-5mm的碳化硅15-20wt%；
所述粉料为：粒度＜0.074mm的合成铝酸钾10-15wt%，粒度＜0.074mm的碳化硅20-35wt%；
所述的高温增强剂由下述质量百分比的原料组成：粒度＜0.045mm的合成莫来石 15%、粒度＜0.045mm的氧化铝微粉55%、粒度＜ 0.045mm 的硅微粉 20%、羧甲基纤维素钠 10%；其中，以质量百分含量计，合成莫来石中：莫来石相80－90%、 Fe2O3 ＜0.8%、K2O+Na2O＜0.3%，氧化铝微粉中Al2O3 ＞99%，硅微粉中 SiO2 ＞ 92%；
所述结合剂为低钠硅溶胶。
2.如权利要求1所述的硅铝酸钾砖，其特征在于：三种粒度规格的碳化硅中碳化硅含量为90-98wt%。
3.如权利要求1所述的硅铝酸钾砖，其特征在于，所述合成铝酸钾按下述方法制备获得：85-95wt%的氢氧化铝与5-15wt%的碳酸钾在1200-1400℃中保温12-24小时而成。
4.如权利要求1所述的硅铝酸钾砖，其特征在于，所述低钠硅溶胶中：Na2O＜0.006wt%，SiO2＞30 wt %。
5.一种制备如权利要求1-4之任一项所述的硅铝酸钾砖的方法，其特征在于，步骤如下：
第一步，先将骨料加入结合剂混匀，然后加入粉料和高温增强剂继续混匀，得半成品泥料；
第二步，将上述半成品泥料压制成砖坯；
第三步，将砖坯自然干燥后再进一步烘干；
第四步，将烘干后的砖坯以8-10℃/h的升温速度升温至1200-1400℃保温36-48h，即得硅铝酸钾砖。
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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102391007A (zh) * 2011-08-17 2012-03-28 通达耐火技术股份有限公司 一种垃圾焚烧炉用碳化硅砖及其制备方法
CN102701764A (zh) * 2012-06-08 2012-10-03 安徽瑞泰新材料科技有限公司 一种烧结铝硅质耐火材料及其制备方法
CN104230361A (zh) * 2014-09-23 2014-12-24 郑州瑞泰耐火科技有限公司 一种耐火材料用高温增强剂及其制备方法
CN105198463A (zh) * 2015-10-21 2015-12-30 长兴中建耐火材料科技有限公司 一种耐腐蚀的碳化硅砖

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102391007A (zh) * 2011-08-17 2012-03-28 通达耐火技术股份有限公司 一种垃圾焚烧炉用碳化硅砖及其制备方法
CN102701764A (zh) * 2012-06-08 2012-10-03 安徽瑞泰新材料科技有限公司 一种烧结铝硅质耐火材料及其制备方法
CN104230361A (zh) * 2014-09-23 2014-12-24 郑州瑞泰耐火科技有限公司 一种耐火材料用高温增强剂及其制备方法
CN105198463A (zh) * 2015-10-21 2015-12-30 长兴中建耐火材料科技有限公司 一种耐腐蚀的碳化硅砖

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