CN105732057A - 一种硅溶胶结合刚玉浇注料及其制备方法 - Google Patents
一种硅溶胶结合刚玉浇注料及其制备方法 Download PDFInfo
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- CN105732057A CN105732057A CN201610061988.1A CN201610061988A CN105732057A CN 105732057 A CN105732057 A CN 105732057A CN 201610061988 A CN201610061988 A CN 201610061988A CN 105732057 A CN105732057 A CN 105732057A
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- silicasol
- brown alundum
- combined corundum
- ludox
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- 229910052593 corundum Inorganic materials 0.000 title claims abstract description 38
- 239000010431 corundum Substances 0.000 title claims abstract description 36
- 238000002360 preparation method Methods 0.000 title claims abstract description 24
- RMAQACBXLXPBSY-UHFFFAOYSA-N Silicic acid Chemical compound 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O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 title abstract 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N AI2O3 Inorganic materials 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[O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 60
- 239000002994 raw material Substances 0.000 claims abstract description 23
- 239000007787 solid Substances 0.000 claims abstract description 18
- 238000003756 stirring Methods 0.000 claims abstract description 11
- 238000000034 method Methods 0.000 claims abstract description 10
- 239000000843 powder Substances 0.000 claims abstract description 10
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound 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O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 30
- 238000002156 mixing Methods 0.000 claims description 17
- 238000005266 casting Methods 0.000 claims description 9
- 238000004321 preservation Methods 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 7
- 229910003465 moissanite Inorganic materials 0.000 claims description 5
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 5
- 239000002245 particle Substances 0.000 claims description 4
- 238000005086 pumping Methods 0.000 claims description 4
- 230000001143 conditioned Effects 0.000 claims description 2
- 229910052594 sapphire Inorganic materials 0.000 claims description 2
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Inorganic materials 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Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/101—Refractories from grain sized mixtures
- C04B35/103—Refractories from grain sized mixtures containing non-oxide refractory materials, e.g. carbon
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
Abstract
本发明公开了一种硅溶胶刚玉结合浇注料及其制备方法，该浇注料由以下原料组成：棕刚玉0~1mm、棕刚玉1~3mm、棕刚玉3~5mm、棕刚玉5~8mm、棕刚玉8~12mm、白刚玉325目、97SiC、氧化铝粉，外加硅溶胶。本发明首先将上述原料中的固体原料粉碎、筛选、搅拌均匀，备用；然后在现场使用时根据需要加入硅溶胶进行搅拌，送入炉内模具、自然养生、烘烤即可。本发明制备浇注料时，硅溶胶在现场使用时加入，然后搅拌制备出流动性较好的浇注料，既保证了硅溶胶本身较好的粘接性能，也增加了浇注料的流动性、提高了产品强度，无需为了保证最终浇注料的流动性，在制备过程中加入其他试剂，降低了生产成本。
Description
技术领域
[0001] 本发明属于耐火材料技术领域，特别涉及一种硅溶胶结合刚玉浇注料及其制备方 法。
背景技术
[0002] 在高炉炼铁过程中，较高的铁水温度以及较快的流速对于炼铁高炉出口内壁的使 用性能具有较高的要求，在高炉出口内壁铸有耐火材料层，以防止高炉内壁的损坏，延长其 使用寿命。在高炉内壁耐火材料的制备中大部分使用水泥作为结合剂，使用水泥结合：1、必 须用水才能结合，结合速度慢;2、制备过程中需要自然养生阶段，耗时；3、不能直接进行高 温烘烤，必须从低温到中温再到高温，升温曲线复杂;4、烘烤时容易出现炸裂现象，不易控 制。
[0003] 硅溶胶是二氧化硅胶体微粒在水中均匀扩散形成的胶体溶液，具有粘结力强、耐 高温等特点，作为无水泥刚玉的结合剂，不会引入高温下产生低熔点相的杂质，能够改善刚 玉浇注料的热震稳定性。目前已有使用硅溶胶作为粘结剂的耐火材料的制备，但是在使用 过程中为了防止由硅溶胶作为粘结剂的耐火材料的快速凝固、影响其流动性，需要在所需 原料中加入其它试剂以保持原料的流动性，大大增加了生产成本及制备操作过程，同时也 给运输存放带来一定的困难。
发明内容
[0004] 为了解决上述问题，本发明提供了一种硅溶胶结合刚玉浇注料，本发明提供的浇 注料以硅溶胶作为结合剂，使用硅溶胶作为粘结剂结合：1.没有水分，能够快速结合;2.浇 筑完毕就可以高温烘烤，不会出现炸裂现象;3.高温烘烤之后强度高，能够使浇注料结构致 I_L| 〇
[0005] 本发明还提供了一种上述硅溶胶结合刚玉浇注料的制备方法，该方法首先将固体 浇注料粉碎、筛选、配料、搅拌均匀得到固体混合浇注料，保存备用，然后在现场使用过程中 根据需要加入硅溶胶，即避免了在开始时加入硅溶胶因硅溶胶失水造成的流动性下降，也 不需要其他试剂的加入，降低了生产成本，减少了操作过程，增加了产品流动性。
[0006] 本发明是通过以下技术方案实现的 一种硅溶胶结合刚玉浇注料，以重量百分比表示，浇注料配方含有以下原料： 掠刚玉 0~lmm 8~10% 棕刚玉 1~3mm 8~12% 棕刚玉 3~5mm 17-23% 棕刚玉 5~8mm 17-23% 棕刚玉 8~12_ 7-13% 白刚玉 325目 12~16% 97SiC 8-12% 氧化铝粉 3~4% 以及占上述原料总量5~6%的硅溶胶。 所述的娃溶胶结合刚玉饶注料，所述的棕刚玉中AI2O3的含量为95%。
[0007]所述的硅溶胶结合刚玉浇注料，所述的白刚玉中Al2〇3的含量为98%。
[0008]所述的硅溶胶结合刚玉浇注料，所述97SiC的粒径为200目，其中SiC的含量为97%。 [0009]所述的硅溶胶结合刚玉浇注料，所述的氧化铝粉为α_Α12〇3,粒径为800目，其中 Al2〇3的含量为99%。
[0010] 所述的硅溶胶结合刚玉浇注料，所述的硅溶胶中Si〇2的含量为20~30%。
[0011] 所述硅溶胶结合刚玉浇注料的制备方法，包括以下步骤： (1) 将固体原材料破粉碎，筛选，按上述比例配料，倒入搅拌机搅拌均匀即可得到固体 混合浇注料，备用； (2) 步骤（1)制备的固体混合浇注料，在现场浇筑时，按照上述重量百分比在混合浇注 料中加入硅溶胶进行粘结，每吨固体混合浇注料配比50~60Kg的硅溶胶，再进行搅拌，搅拌 均匀后，使用栗送机将浇注料送入炉内模具，自然养生，烘烤即得到产品。
[0012] 所述硅溶胶结合刚玉浇注料的制备方法，步骤(2)所述的自然养生，其养生时间为 2~3小时，所述的烘烤过程中，烘烤温度为900~1100°C、烘烤时间为22~26小时。
[0013] 与现有技术相比，本发明具有以下积极有益效果 (1)本发明制备的刚玉浇注料以刚玉作为主要原料，用硅溶胶结合，浇铸后经自然养 生、简单烘烤即可投入使用，能够抵抗高炉内部的复杂环境，同时可以保护高炉的出铁口， 为无水炮泥的使用环境做了极好的基础。
[0014] (2)本发明以硅溶胶作为粘结剂，结合时不需要加水，缩短了结合时间，而且在浇 铸完毕时可以直接进行高温烘烤，程序简单也不易炸裂，即用硅溶胶作为粘结剂大大缩短 了生产时间，提高了工作效率，也提高了产品质量，更有利于大规模工业化生产。
[0015] (3)本发明以SiC作为制备浇注料的原料之一，SiC本身具有很好的耐高温性能，较 强的耐磨性能、抗氧化性能，在本申请中，SiC通过与硅溶胶及刚玉的相互作用使制备的最 终浇注料具有较好的耐腐蚀性、抗热冲击性、耐磨性及较好的导热性，强度大大提高。
[0016] (4)高炉出铁口是整座高炉很重要的部位，也是高炉比较薄弱的部位，当炽热的铁 水从高炉出铁口流出时，出铁口经受很大的压力与冲刷力。使用本发明制备的浇注料可以 很好的保护铁口，使铁口通道加深，铁水流动稳定。本浇注料的使用寿命在两年以上。
[0017] (5)硅溶胶在作为粘结剂使用时，短时间内能够凝固，影响产品的流动性，无法顺 利进入模具，为了保证硅溶胶的粘结性及产品的流动性，需加入其他试剂进行调节，增加了 生产成本;本申请采用的制备方法为，首先将所用固体原料按配比混合、备用，然后在现场 使用时根据需要加入硅溶胶，然后搅拌制备出流动性较好的浇注料，既保证了硅溶胶本身 较好的粘接性能，也增加了浇注料的流动性，也无需为了保证最终浇注料的流动性，在制备 过程中加入其他试剂，降低了生产成本;本申请的制备方法操作简单、时间短。
具体实施方式
[0018] 下面通过实施例对本发明进行更加详细的说明，但是本发明的保护范围并不限于 以下实施例。
[0019] 实施例1 一种硅溶胶结合刚玉浇注料，以重量百分含量表示，浇注料配方含有以下原料： 掠刚玉 0~1mm 8% 棕刚玉 1~3mm 8% 棕刚玉 3~5mm 23% 棕刚玉 5~8mm 23% 棕刚玉 8~12_ 7% 白刚玉 325目 16% 97SiC 200目 12% 氧化铝粉 800目 3% 以及占上述原料总量5~6%的硅溶胶。
[0020] 实施例2 一种硅溶胶结合刚玉浇注料，以重量百分含量表示，浇注料配方含有以下原料： 掠刚玉 0~1mm 10% 棕刚玉 1~3mm 12% 掠刚玉 3~5mm 17% 掠刚玉 5~8mm 17% 棕刚玉 8~12mm 13% 白刚玉 325目 16% 97SiC 200@ 11% 氧化铝粉800目 4% 以及占上述原料总量5~6%的硅溶胶。
[0021] 实施例3 一种硅溶胶结合刚玉浇注料，以重量百分含量表示，浇注料配方含有以下原料： 掠刚玉 0~1mm 9% 棕刚玉 1~3_ 11% 掠刚玉 3~5mm 21% 棕刚玉 5~8_ 20% 棕刚玉 8~12mm 12% 白刚玉 325目 13% 97SiC 200目 10% 氧化铝粉800目 4% 以及占上述原料总量5~6%的硅溶胶。
[0022] 实施例4 一种硅溶胶结合刚玉浇注料，以重量百分含量表示，浇注料配方含有以下原料： 掠刚玉 0~1mm 10% 棕刚玉 1~3_ 11% 棕刚玉 3~5mm 22% 棕刚玉 5~8_ 20% 掠刚玉 8^12mm 9% 白刚玉 325目 15% 97SiC 200 目 9% 氧化铝粉800目 4% 以及占上述原料总量5~6%的硅溶胶。
[0023] 实施例5 一种硅溶胶结合刚玉浇注料，以重量百分含量表示，浇注料配方含有以下原料： 掠刚玉 0~1mm 8% 掠刚玉 1~3mm 10% 掠刚玉 3~5mm 21% 棕刚玉 5~8_ 20% 棕刚玉 8~12mm 12% 白刚玉 325目 14% 97SiC 200目 12% 氧化铝粉800目 3% 以及占上述原料总量5~6%的硅溶胶。
[0024] 上述实施例1~5制备的硅溶胶结合刚玉浇注料的性能如表1所示。
[0025]表1硅溶胶结合刚玉浇注料性能检测结果
实施例6 一种硅溶胶结合刚玉浇注料的制备方法之一，包括以下步骤： (1) 将固体原材料破粉碎，筛选，按上述比例配料，倒入搅拌机搅拌均匀即可得到固体 混合浇注料，备用； (2) 将步骤（1)制备的固体混合浇注料运输至所需现场，进行现场浇筑，在混合浇注料 中加入硅溶胶进行粘结，每吨固体混合浇注料配比50Kg的硅溶胶，再进行搅拌，搅拌均匀 后，使用栗送机将浇注料送入炉内模具，自然养生2小时，在900°C条件下烘烤26小时。
[0026] 实施例7 一种硅溶胶结合刚玉浇注料的制备方法之二，包括以下步骤： (1) 将固体原材料破粉碎，筛选，按上述比例配料，倒入搅拌机搅拌均匀即可得到固体 混合浇注料，备用； (2) 将步骤（1)制备的固体混合浇注料运输至所需现场，进行现场浇筑，在混合浇注料 中加入硅溶胶进行粘结，每吨固体混合浇注料配比60Kg的硅溶胶，再进行搅拌，搅拌均匀 后，使用栗送机将浇注料送入炉内模具，自然养生3小时，在1100°C条件下烘烤22小时。
Claims (8)
1. 一种硅溶胶结合刚玉浇注料，其特征在于，以重量百分含量表示，浇注料配方含有以 下原料： 掠刚玉 0~1mm 8~10% 掠刚玉 1~3mm 8~12% 棕刚玉 3~5mm 17-23% 棕刚玉 5~8mm 17~23% 棕刚玉 8~12_ 7-13% 白刚玉 325目 12~16% 97SiC 8-12% 氧化铝粉 3~4% 以及占上述原料总量5~6%的硅溶胶。
2. 根据权利要求1所述的硅溶胶结合刚玉浇注料，其特征在于，所述的棕刚玉中Al2〇3的 含量为95%。
3. 根据权利要求1所述的硅溶胶结合刚玉浇注料，其特征在于，所述的白刚玉中Al2〇3的 含量为98%。
4. 根据权利要求1所述的硅溶胶结合刚玉浇注料，其特征在于，所述97SiC的粒径为200 目，其中SiC的含量为97%。
5. 根据权利要求1所述的硅溶胶结合刚玉浇注料，其特征在于，所述的氧化铝粉为α_ Α12〇3,粒径为800目，其中Α12〇3的含量为99%。
6. 根据权利要求1所述的硅溶胶结合刚玉浇注料，其特征在于，所述的硅溶胶中Si02的 含量为20~30%。
7. -种权利要求1所述硅溶胶结合刚玉浇注料的制备方法，其特征在于，包括以下步 骤： (1) 将固体原材料破粉碎，筛选，按上述比例配料，倒入搅拌机搅拌均匀即可得到固体 混合浇注料，备用； (2) 步骤（1)制备的固体混合浇注料，在现场浇筑时按照上述重量百分比加入硅溶胶进 行粘结，再进行搅拌，搅拌均匀后，使用栗送机将浇注料送入炉内模具，自然养生，烘烤即 可。
8. 根据权利要求7所述的硅溶胶结合刚玉浇注料的制备方法，其特征在于，步骤(2)所 述的自然养生，其养生时间为2~3小时，所述的烘烤过程中，烘烤温度为900~1100°C、烘烤时 间为22~26小时。
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