CN106518104A - 一种水泥回转窑烧成带用无铬耐火砖及其制备方法 - Google Patents

一种水泥回转窑烧成带用无铬耐火砖及其制备方法 Download PDF

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CN106518104A
CN106518104A CN201610885864.5A CN201610885864A CN106518104A CN 106518104 A CN106518104 A CN 106518104A CN 201610885864 A CN201610885864 A CN 201610885864A CN 106518104 A CN106518104 A CN 106518104A
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晋元龙
陈德全
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Ma'an Mountain Bao Long Building Material Co Ltd
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Abstract

本发明公开了一种水泥回转窑烧成带用无铬耐火砖及其制备方法，其由以下重量份的原料制成：海砂24‑38、硅酸盐水泥粉尘28‑42、轻烧粉17‑29、山卵石19‑31、高炉瓦斯灰24‑37、磷酸二氢钾9‑16、云母渣14‑26、高炉水淬渣12‑23、膨胀珍珠岩11‑19、β‑赛隆10‑15、γ‑聚谷氨酸5‑10、粉煤灰硅酸盐水泥40‑50、硅酸乙酯12‑19。本发明采用海砂、轻烧粉、山卵石为主要原料，并掺入一定比例的膨胀珍珠岩和β‑赛隆，使制得的无铬耐火砖具有优异的综合性能，不仅具有优异的力学性能，还具有优异的热稳定性、抗侵蚀能力和抗热震性，可以代替镁铬砖用于水泥回转窑烧成带，满足目前大型水泥窑的要求和发展。

Description

一种水泥回转窑烧成带用无铬耐火砖及其制备方法
技术领域
本发明涉及一种水泥回转窑烧成带用无铬耐火砖及其制备方法，属于耐火材料领域。
背景技术
耐火砖是用耐火黏土或其他耐火原料烧制成的具有一定形状和尺寸的耐火材料，能耐1580℃-1770℃的高温。按制备工艺方法来划分可分为烧成砖、不烧砖、电熔砖(熔铸砖)、耐火隔热砖；按形状和尺寸可分为标准型砖、普通砖、特异型砖等。耐火砖可用作建筑窑炉和各种热工设备的高温建筑材料和结构材料，并在高温下能经受各种物理化学变化和机械作用。
作为水泥窑的主要设备——回转窑，由于其使用条件的不同，所以使用各种不同的耐火砖。其中在使用条件最苛刻的烧成带，主要使用镁铬砖。但是随着近年来对环保要求的日益提高，迫切要求镁铬砖以外的耐火砖，即使用无铬耐火砖。
近年来，国内耐火砖生产工艺发展迅速，市场上出现了种类繁多、性能各异的耐火砖。中国专利号为：200710062457.5的发明专利公开了一种硅质隔热耐火砖，本发明耐火砖由硅石细粉81-85％，珍珠岩15-19％，外加占上述主原料总重的下列辅料：铁鳞粉0.45-0.55％，水泥0.9-1.1％，石灰乳6.5-7.5％，纸浆1.95-2.2％组成，制备工艺为：将硅石细粉、珍珠岩按比例加入湿碾内，然后加入铁鳞粉、水泥干碾1-2分钟后，加入占主原料总重的1.8-2.2％的水，然后加入石灰乳，碾压10-15分钟，最后加入纸浆，碾压10-15分钟，出碾，成型制坯。采用上述原料和工艺制得的耐火砖虽然解决了现有粘土质隔热耐火砖存在荷重变形温度低、高温下易收缩、导热率较大、保温效果不好等缺陷，但是其耐火性与国外耐火砖相比较，仍存在较大的差距，无法满足出口市场的需求。
发明内容
本发明所要解决的技术问题是提供一种综合性能优异的水泥回转窑烧成带用无铬耐火砖及其制备方法。
为了解决上述问题，本发明采用如下技术方案：
一种水泥回转窑烧成带用无铬耐火砖，由以下重量份的原料制成：海砂24-38、硅酸盐水泥粉尘28-42、轻烧粉17-29、山卵石19-31、高炉瓦斯灰24-37、磷酸二氢钾9-16、云母渣14-26、高炉水淬渣12-23、膨胀珍珠岩11-19、β-赛隆10-15、γ-聚谷氨酸5-10、粉煤灰硅酸盐水泥40-50、硅酸乙酯12-19。
一种水泥回转窑烧成带用无铬耐火砖的制备方法，由下列步骤组成：
(1)将硅酸盐水泥粉尘、高炉瓦斯灰、云母渣、高炉水淬渣混合均匀，粉碎，过80-100目筛，740-780℃煅烧3-4h，冷却至室温，450-650r/min干法球磨25-35min，然后按照固液比1：6-7将球磨后的粉末加入到质量分数为25％的硫酸溶液中，水浴加热至70-80℃，保温浸泡0.5-1.5h，静置冷却后过滤，滤渣用水洗涤至中性，按照固液比1：4-5将洗涤后的滤渣加入到质量分数为20％的氢氧化钠溶液中，加热至70-80℃，保温浸泡1.5-2.5h，静置冷却后过滤，滤液通入二氧化碳气体至pH为7.5-8时，关闭二氧化碳，静置陈化3-5h，过滤，滤渣洗涤干净，烘干，730-790℃温煅烧1-2h，冷却至室温，待用；
(2)按照质量比1:5-6将步骤(1)制得的原料与固含量为20％的铝溶胶混合，充分搅拌均匀，再加入相当于浆料质量10-15％的聚乙烯醇和8-12％的六偏磷酸钠，700-900r/min干法球磨8-14min，然后在真空度为1-2Pa、温度为-70～-80℃的条件下冷冻干燥22-28h，再在空气气氛下以3-5℃/min的速率升温至390-430℃，保温5-6h，再以4-6℃/min的速率升温至780-820℃，保温3-4h，再以7-9℃/min的速率升温至1370-1430℃，保温1.5-2.5h，再以10-12℃/min的速率降温至400-450℃，保温4-5h，冷却至室温，得到耐火料；
(3)将海砂、山卵石、膨胀珍珠岩混合均匀，粉碎，过100-120目筛后与步骤(2)制得的耐火料进行干混，混合4-8min，然后加入适量的水，并加入余下原料进行湿混，混合3-6min；
(4)将步骤(3)制得的混合料加入成型模具中压制成型，成型压力为17-23MPa，脱模后进行晒水养护，7-9h养护一次，养护8-12天，然后自然环养护即可。
本发明的有益效果：
(1)本发明通过从硅酸盐水泥粉尘、高炉瓦斯灰、云母渣、高炉水淬渣等原料中提取二氧化硅，然后配合铝溶胶进行冷冻干燥和高温煅烧，可以得到以莫来石为主要成分的耐火料，该耐火料加入到砖中，可以大大提高耐火砖的耐火性，使得耐火砖在高温下仍能保持优异的综合性能，同时实现了硅酸盐水泥粉尘、高炉瓦斯灰、云母渣、高炉水淬渣等固体废渣的再资源化利用，具有重要的经济效益和社会效益；
(2)本发明采用海砂、轻烧粉、山卵石为主要原料，并掺入一定比例的膨胀珍珠岩和β-赛隆，使制得的无铬耐火砖具有优异的综合性能，不仅具有优异的力学性能，还具有优异的热稳定性、抗侵蚀能力和抗热震性，可以代替镁铬砖用于水泥回转窑烧成带，满足目前大型水泥窑的要求和发展。
具体实施方式
一种水泥回转窑烧成带用无铬耐火砖，由以下重量(kg)的原料制成：海砂32、硅酸盐水泥粉尘36、轻烧粉23、山卵石24、高炉瓦斯灰31、磷酸二氢钾12、云母渣20、高炉水淬渣17、膨胀珍珠岩15、β-赛隆12、γ-聚谷氨酸8、粉煤灰硅酸盐水泥45、硅酸乙酯15。
一种水泥回转窑烧成带用无铬耐火砖的制备方法，由下列步骤组成：
(1)将硅酸盐水泥粉尘、高炉瓦斯灰、云母渣、高炉水淬渣混合均匀，粉碎，过90目筛，760℃煅烧3h，冷却至室温，550r/min干法球磨30min，然后按照固液比1：7将球磨后的粉末加入到质量分数为25％的硫酸溶液中，水浴加热至75℃，保温浸泡1h，静置冷却后过滤，滤渣用水洗涤至中性，按照固液比1：5将洗涤后的滤渣加入到质量分数为20％的氢氧化钠溶液中，加热至75℃，保温浸泡2h，静置冷却后过滤，滤液通入二氧化碳气体至pH为7.7时，关闭二氧化碳，静置陈化4h，过滤，滤渣洗涤干净，烘干，750℃温煅烧1.5h，冷却至室温，待用；
(2)按照质量比1:6将步骤(1)制得的原料与固含量为20％的铝溶胶混合，充分搅拌均匀，再加入相当于浆料质量12％的聚乙烯醇和10％的六偏磷酸钠，800r/min干法球磨11min，然后在真空度为1.5Pa、温度为-75℃的条件下冷冻干燥25h，再在空气气氛下以4℃/min的速率升温至410℃，保温5h，再以5℃/min的速率升温至800℃，保温3h，再以8℃/min的速率升温至1400℃，保温2h，再以11℃/min的速率降温至420℃，保温4h，冷却至室温，得到耐火料；
(3)将海砂、山卵石、膨胀珍珠岩混合均匀，粉碎，过110目筛后与步骤(2)制得的耐火料进行干混，混合6min，然后加入适量的水，并加入余下原料进行湿混，混合4min；
(4)将步骤(3)制得的混合料加入成型模具中压制成型，成型压力为21MPa，脱模后进行晒水养护，8h养护一次，养护10天，然后自然环养护即可。
上述实施例制得的耐火砖的的性能检测结果与国外耐火砖性能参数相比较如下表所示：
国外耐火砖 上述实施例生产的耐火砖
耐火度，℃ 1795 1845
耐压强度，MPa 82 105
抗折强度，MPa 13 21
热震稳定性，1100℃，水冷，(次) 41 58

Claims (2)

1.一种水泥回转窑烧成带用无铬耐火砖，其特征在于，由以下重量份的原料制成：海砂24-38、硅酸盐水泥粉尘28-42、轻烧粉17-29、山卵石19-31、高炉瓦斯灰24-37、磷酸二氢钾9-16、云母渣14-26、高炉水淬渣12-23、膨胀珍珠岩11-19、β-赛隆10-15、γ-聚谷氨酸5-10、粉煤灰硅酸盐水泥40-50、硅酸乙酯12-19。
2.一种如权利要求1所述的水泥回转窑烧成带用无铬耐火砖的制备方法，其特征在于，由下列步骤组成：
（1）将硅酸盐水泥粉尘、高炉瓦斯灰、云母渣、高炉水淬渣混合均匀，粉碎，过80-100目筛，740-780℃煅烧3-4h，冷却至室温，450-650r/min干法球磨25-35min，然后按照固液比1：6-7将球磨后的粉末加入到质量分数为25%的硫酸溶液中，水浴加热至70-80℃，保温浸泡0.5-1.5h，静置冷却后过滤，滤渣用水洗涤至中性，按照固液比1：4-5将洗涤后的滤渣加入到质量分数为20%的氢氧化钠溶液中，加热至70-80℃，保温浸泡1.5-2.5h，静置冷却后过滤，滤液通入二氧化碳气体至pH为7.5-8时，关闭二氧化碳，静置陈化3-5h，过滤，滤渣洗涤干净，烘干，730-790℃温煅烧1-2h，冷却至室温，待用；
（2）按照质量比1:5-6将步骤（1）制得的原料与固含量为20%的铝溶胶混合，充分搅拌均匀，再加入相当于浆料质量10-15%的聚乙烯醇和8-12%的六偏磷酸钠，700-900r/min干法球磨8-14min，然后在真空度为1-2Pa、温度为-70~-80℃的条件下冷冻干燥22-28h，再在空气气氛下以3-5℃/min的速率升温至390-430℃，保温5-6h，再以4-6℃/min的速率升温至780-820℃，保温3-4h，再以7-9℃/min的速率升温至1370-1430℃，保温1.5-2.5h，再以10-12℃/min的速率降温至400-450℃，保温4-5h，冷却至室温，得到耐火料；
（3）将海砂、山卵石、膨胀珍珠岩混合均匀，粉碎，过100-120目筛后与步骤（2）制得的耐火料进行干混，混合4-8min，然后加入适量的水，并加入余下原料进行湿混，混合3-6min；
（4）将步骤（3）制得的混合料加入成型模具中压制成型，成型压力为17-23MPa，脱模后进行晒水养护，7-9h养护一次，养护8-12天，然后自然环养护即可。
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