CN105777153A - 一种大尺寸耐火砖的制备方法 - Google Patents

一种大尺寸耐火砖的制备方法 Download PDF

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CN105777153A
CN105777153A CN201610114071.3A CN201610114071A CN105777153A CN 105777153 A CN105777153 A CN 105777153A CN 201610114071 A CN201610114071 A CN 201610114071A CN 105777153 A CN105777153 A CN 105777153A
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refractory brick
substrate
powder
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bonding agent
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冯志源
王晗
谭清华
石鹏坤
李坚强
张永治
范沐旭
方旭
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Sinosteel Luoyang Institute of Refractories Research Co Ltd
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Abstract

本发明属于耐火材料领域，提出一种大尺寸耐火砖的制备方法。提出的一种大尺寸耐火砖的制备方法采用球形造粒料作为基质、采用粒度为1～0.1mm的细颗粒作为骨料；球形造粒料与水、结合剂在搅拌机中制成料浆，料浆经离心式喷雾造粒机制备成含水量为0.2～0.5%的球形基质造粒料；球形基质造粒料与细颗粒在混料设备中干混，得到均匀的混合料；混合料直接装入模具在等静压机中经90～180MPa的压力成型得到具有足够强度的坯体；成型后坯体经120℃干燥24h后在1500℃～1650℃保温6～10小时即可获得大尺寸耐火砖。本发明所制备的大尺寸砖坯具有结构均匀、密度高、强度高，抗侵蚀性好的特点。

Description

一种大尺寸耐火砖的制备方法
技术领域
本发明属于耐火材料领域，具体涉及一种大尺寸耐火砖的制备方法。
背景技术
大尺寸的耐火砖因其结构均匀，整体性好、装配时砖缝少等优点，能够应用在玻璃窑等对耐火砖尺寸要求高的地方。
目前常用的耐火砖成型方式有机压成型和浇注成型，机压成型方式为单方向加压，压力在传递过程中随着砖坯厚度而逐渐减少，因此该方法不能够成型大尺寸的砖坯；浇注成型方式能够成型较大尺寸砖坯，但一方面所制备坯体中存在较大气泡不利于结构均匀性，另一方面该工艺半成品脱模、养护、干燥处理技术难度大，不易操作，同时由于含水量高，大尺寸坯体的养护和干燥时间长，生产周期长、效率低。
发明内容
本发明的目的是提出一种大尺寸耐火砖的制备方法，利用离心式喷雾造粒机将基质细粉制备成球形的造粒料，造粒料和细颗粒料混合后通过等静压成型技术成型出大尺寸的砖坯；所制备大尺寸耐火砖结构均匀、密度高、强度大，抗侵蚀性好的特点。
为了实现上述目的，本发明采取的技术方案如下：
一种大尺寸耐火砖的制备方法，耐火砖采用球形造粒料作为基质、采用粒度为1～0.1mm的细颗粒作为骨料；骨料与基质的加入量分别为10～30%、70～90%；所述的球形造粒料采用粒度＜0.044mm的基质细粉作为原料，并与水、结合剂在搅拌机中制成料浆，料浆经离心式喷雾造粒机制备成含水量为0.2～0.5%的球形基质造粒料；所述的球形基质造粒料与所述的细颗粒在混料设备中干混，得到均匀的混合料；混合料直接装入模具在等静压机中经90～180MPa的压力成型得到具有足够强度的坯体；成型后坯体经120℃干燥24h后在1500℃～1650℃保温6～10小时即可获得。
所述水的加入量为基质细粉重量的40～50%。
所述结合剂的加入量为基质细粉重量的4～10%。
所述的基质细粉为氧化铬粉、氧化铝粉、莫来石粉、氧化锆粉中的一种或几种。
所述的结合剂为硅溶胶、PVA中的一种，或两种的混合溶液。
所述的细颗粒为氧化铬颗粒、铬刚玉颗粒、刚玉颗粒、刚玉莫来石颗粒中的一种或几种。
所述的耐火砖为刚玉砖或刚玉莫来石砖或铬刚玉砖或高铬砖。
本发明提出的一种大尺寸耐火砖的制备方法，利用等静压成型方式避免了成型方式对大尺寸坯体的成型限制;本发明可制备大尺寸的耐火砖，长可达1200mm，宽可达600mm，高可达500mm；喷雾造粒工艺获得的球形造粒料具有很好的流动性和成型塑形，有利于大尺寸坯体的成型成品率；利用离心式喷雾造粒机将基质细粉制备成球形的造粒料，造粒料和细颗粒料混合后通过等静压成型技术成型出大尺寸的砖坯；颗粒料的引入能够降低烧成收缩保证烧成成品率，等静压成型方式和喷雾造粒技术保证了成型压力均匀、基质细粉混合均匀，所制备的大尺寸砖坯具有结构均匀、密度高、强度高，抗侵蚀性好的特点。
具体实施方式
结合下述实施例对本发明加以详细说明：
实施例1：一种大尺寸耐火砖的制备方法，耐火砖采用球形造粒料作为基质、采用粒度为1～0.1mm的细颗粒作为骨料；该实施例中骨料与基质的加入量分别为30%、70%；所述的细颗粒为刚玉颗粒；所述的球形造粒料采用粒度＜0.044mm的氧化铝粉作为原料，并与水、结合剂在搅拌机中制成料浆，结合剂PVA溶液加入量为上述氧化铝粉重量的4%；水的加入量上述氧化铝粉重量40%；料浆经离心式喷雾造粒机制备成含水量为0.2～0.5%的球形基质造粒料；所述的球形基质造粒料与所述的细颗粒在混料设备中干混，得到均匀的混合料；混合料直接装入模具在等静压机中经90MPa的压力成型得到具有足够强度的坯体；成型后坯体经120℃干燥24h后在1650℃保温6小时即可获得大尺寸刚玉砖；本实施例获得的一种大尺寸刚玉砖的气孔率为15~16%，化学成分，Al2O3含量98.6%。
实施例2：一种大尺寸耐火砖的制备方法，耐火砖采用球形造粒料作为基质、采用粒度为1～0.1mm的细颗粒作为骨料；该实施例中骨料与基质的加入量分别为20%、80%；所述的细颗粒采用莫来石颗粒；所述的球形造粒料采用粒度＜0.044mm的氧化铝粉和莫来石粉（氧化铝粉为87%，莫来石粉为13%）作为原料，并与水、结合剂在搅拌机中制成料浆，结合剂PVA溶液加入量为上述氧化铝粉重量的5%；水的加入量上述氧化铝粉重量40%；料浆经离心式喷雾造粒机制备成含水量为0.2～0.5%的球形基质造粒料；所述的球形基质造粒料与所述的细颗粒在混料设备中干混，得到均匀的混合料；混合料直接装入模具在等静压机中经120MPa的压力成型得到具有足够强度的坯体；成型后坯体经120℃干燥24h后在1650℃保温10小时即可获得大尺寸刚玉莫来石砖；本实施例获得的一种大尺寸刚玉莫来石砖的气孔率为15~16%，化学成分，Al2O3含量90%。
实施例3：
一种大尺寸耐火砖的制备方法，耐火砖采用球形造粒料作为基质、采用粒度为1～0.1mm的细颗粒作为骨料；该实施例中骨料与基质的加入量分别为20%、80%；所述的细颗粒采用刚玉颗粒；所述的球形造粒料采用粒度＜0.044mm的氧化铝粉、氧化铬粉和氧化锆粉（氧化铬粉17%，氧化铝粉80%，氧化锆粉3%）作为原料，并与水、结合剂在搅拌机中制成料浆，结合剂PVA溶液加入量为上述氧化铝粉重量的10%；水的加入量上述氧化铝粉重量50%；料浆经离心式喷雾造粒机制备成含水量为0.2～0.5%的球形基质造粒料；所述的球形基质造粒料与所述的细颗粒在混料设备中干混，得到均匀的混合料；混合料直接装入模具在等静压机中经120MPa的压力成型得到具有足够强度的坯体；成型后坯体经120℃干燥24h后在1650℃保温6小时即可获得大尺寸铬刚玉砖；本实施例获得的一种大尺寸铬刚玉砖的气孔率为16~17%，化学成分，Cr2O3含量在13.2%。
实施例4：
一种大尺寸耐火砖的制备方法，耐火砖采用球形造粒料作为基质、采用粒度为1～0.1mm的细颗粒作为骨料；该实施例中骨料与基质的加入量分别为25%、75%；所述的细颗粒采用铬刚玉颗粒；所述的球形造粒料采用粒度＜0.044mm的氧化铝粉、氧化铬粉和氧化锆粉（氧化铬粉40%，氧化铝粉55%，氧化锆粉5%）作为原料，并与水、结合剂在搅拌机中制成料浆，结合剂PVA溶液加入量为上述原料的5%，结合剂硅溶胶溶液加入量为上述原料的3%；加水量为上述原料的48%；料浆经离心式喷雾造粒机制备成含水量为0.2～0.5%的球形基质造粒料；所述的球形基质造粒料与所述的细颗粒在混料设备中干混，得到均匀的混合料；混合料直接装入模具在等静压机中经150MPa的压力成型得到具有足够强度的坯体；成型后坯体经120℃干燥24h后在1550℃保温8小时即可获得一种大尺寸铬刚玉砖；本实施例获得的一种大尺寸铬刚玉砖的气孔率为14~15%，化学成分，Cr2O3含量为32.5%。
实施例5：
一种大尺寸耐火砖的制备方法，耐火砖采用球形造粒料作为基质、采用粒度为1～0.1mm的细颗粒作为骨料；该实施例中骨料与基质的加入量分别为20%、80%；所述的细颗粒采用10%的铬刚玉颗粒和10%的刚玉砂；所述的球形造粒料采用粒度＜0.044mm的氧化铝粉、氧化铬粉和氧化锆粉（氧化铬粉50%，氧化铝粉45%，氧化锆粉5%）作为原料，并与水、结合剂在搅拌机中制成料浆，结合剂硅溶胶溶液加入量为上述的6%；加水量为上述原料的48%；料浆经离心式喷雾造粒机制备成含水量为0.2～0.5%的球形基质造粒料；所述的球形基质造粒料与所述的细颗粒在混料设备中干混，得到均匀的混合料；混合料直接装入模具在等静压机中经180MPa的压力成型得到具有足够强度的坯体；成型后坯体经120℃干燥24h后在1600℃保温10小时即可获得一种大尺寸铬刚玉砖；本实施例获得的一种大尺寸铬刚玉砖的气孔率为11~12%，化学成分，Cr2O3含量在48.5%。
实施例6
一种大尺寸耐火砖的制备方法，耐火砖采用球形造粒料作为基质、采用粒度为1～0.1mm的细颗粒作为骨料；该实施例中骨料与基质的加入量分别为10%、90%；所述的细颗粒采用氧化铬颗粒；所述的球形造粒料采用粒度＜0.044mm的氧化铝粉、氧化铬粉和氧化锆粉（氧化铬粉86%，氧化铝粉10%，氧化锆粉4%）作为原料，并与水、结合剂在搅拌机中制成料浆，结合剂PVA溶液的加入量为上述的8%；加水量为上述原料的45%；料浆经离心式喷雾造粒机制备成含水量为0.2～0.5%的球形基质造粒料；所述的球形基质造粒料与所述的细颗粒在混料设备中干混，得到均匀的混合料；混合料直接装入模具在等静压机中经180MPa的压力成型得到具有足够强度的坯体；成型后坯体经120℃干燥24h后在1550℃保温8小时即可获得一种大尺寸铬刚玉砖；本实施例获得的一种大尺寸高铬砖的气孔率为11~12%，化学成分，Cr2O3含量在86.5%。

Claims (6)

1.一种大尺寸耐火砖的制备方法，其特征在于：耐火砖采用球形造粒料作为基质、采用粒度为1～0.1mm的细颗粒作为骨料；骨料与基质的加入量分别为10～30%、70～90%；所述的球形造粒料采用粒度＜0.044mm的基质细粉作为原料，并与水、结合剂在搅拌机中制成料浆，料浆经离心式喷雾造粒机制备成含水量为0.2～0.5%的球形基质造粒料；所述的球形基质造粒料与所述的细颗粒在混料设备中干混，得到均匀的混合料；混合料直接装入模具在等静压机中经90～180MPa的压力成型得到具有足够强度的坯体；成型后坯体经120℃干燥24h后在1500℃～1650℃保温6～10小时即可获得大尺寸耐火砖。
2.如权利要求1所述的一种大尺寸耐火砖的制备方法，其特征在于：所述水的加入量为基质细粉重量的40～50%。
3.如权利要求1所述的一种大尺寸耐火砖的制备方法，其特征在于：所述结合剂的加入量为基质细粉重量的4～10%。
4.如权利要求1所述的一种大尺寸耐火砖的制备方法，其特征在于：所述的基质细粉为氧化铬粉、氧化铝粉、莫来石粉、氧化锆粉中的一种或几种。
5.如权利要求1所述的一种大尺寸耐火砖的制备方法，其特征在于：所述的结合剂为硅溶胶、PVA中的一种，或两种的混合溶液。
6.如权利要求1所述的一种大尺寸耐火砖的制备方法，其特征在于：所述的细颗粒为氧化铬颗粒、铬刚玉颗粒、刚玉颗粒、刚玉莫来石颗粒中的一种或几种。
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