CN106699204B - 一种400kg级轻质莫来石砖及其制备工艺 - Google Patents

一种400kg级轻质莫来石砖及其制备工艺 Download PDF

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CN106699204B
CN106699204B CN201611183627.0A CN201611183627A CN106699204B CN 106699204 B CN106699204 B CN 106699204B CN 201611183627 A CN201611183627 A CN 201611183627A CN 106699204 B CN106699204 B CN 106699204B
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曾鲁举
陈磊
钱蛇大
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RUITAI TECHNOLOGY Co Ltd
YIXING RUITAI REFRACTORY MATERIAL Co Ltd
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Abstract

本发明公开了一种400kg级轻质莫来石砖及其制备工艺。该莫来石砖采用以下重量百分比组份:苏州泥10‑23%,α‑氧化铝微粉24‑34%,硅灰1‑4%,紫木节3‑8%,膨润土5‑10%,焦宝石8‑15%,氢氧化钙粉12‑17%和Secar71水泥10‑15%;此外,还额外添加了以上组份重量总和为计算基准的以下组份:发泡剂1‑4%,水70‑90%,稳定剂0.1‑0.3%。本发明的级轻质莫来石砖具有体积密度小、强度高、导热系数小、可成型大型砖等优点。

Description

一种400kg级轻质莫来石砖及其制备工艺
技术领域
本发明涉及轻质保温耐火材料,具体涉及一种400kg级轻质莫来石砖及其制备工艺。
背景技术
轻质莫来石砖以其纯度高、耐高温、强度大、导热系数低等优越性能,广泛应用于石化、电力等行业高温热工设备的保温层衬里,甚至工作衬里。根据体积密度不同,通常可将轻质莫来石砖分为23级(500kg/m3)、26级、28级、30级等等,体积密度最小的轻质莫来石砖为23级轻质莫来石砖。目前轻质莫来石砖的成型方法采用挤压成型方式。
随着热工设备对耐火材料越来越严苛的要求,以及节能减排的需求,保温材料向体积密度更轻、导热系数更小、能耐高温、具有足够强度的方向发展成为必然。根据对国外市场的了解,他们对超轻保温材料的需求欲望远远大于国内,而且国内尚无体积密度小于500kg/m3的轻质莫来石砖,因此,研究开发超轻莫来石保温砖有利于抢先占领国际和国内市场。
传统的挤压成型不能满足超轻莫来石砖成型工艺要求,体积密度500kg/m3已经达到极限值,不可能再降低。而且挤压成型对超轻砖成型有致命缺陷:由于配方中加入了锯末、聚丙乙烯球等烧失剂,挤压成型后砖坯有较大体积反弹过程,这个过程会在砖体内部形成大量宏观物理缺陷,即使高温烧成后这些缺陷也不会消失,从而导致超轻砖强度降低,大量贯穿的裂纹也会使导热系数增大,从而降低保温节能的效果。
发明内容
发明目的:本发明所要解决的技术问题是针对现有技术的不足,提供一种体积密度小、强度高、导热系数小的轻质莫来石砖的制备工艺。
为了解决上述技术问题,本发明提供的一种400kg级轻质莫来石砖配方,具体制备工艺为:
以上组分重量百分比之和为100%;
此外,额外添加以下组份,计算基准为上述组分总重量:
发泡剂 1-4%;
水 70-90%;
稳定剂 0.1-0.3%。
本发明中,苏州泥为200-500目,优选200目;α-氧化铝微粉为1000-1500目,优选1000目;硅灰为96硅灰;紫木节为500-700目,优选500目;膨润土为200-500目,优选200目;焦宝石为特级焦宝石,200-500目,优选200目;氢氧化钙粉为200-500目,优选200目;水泥为Secar71水泥;外加组份发泡剂为铝粉发泡剂,1500-2000目,优选1500目;外加组份稳定剂为PEPTAPON 5浆体悬浮稳定剂,保证浆体在使用期限内体系均匀,不分层。
一种400kg级轻质莫来石砖的制备工艺,包括如下步骤:
(1)湿态球磨均化混合制浆:将除水泥、发泡剂以外的所有原材料加入到湿态球磨机中,球磨均化30-60分钟,优选30分钟,出浆备用,0.5-1小时内用完;
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入水泥搅拌3-5分钟,然后再加入发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化36-48小时,优选36小时候拆模;
(5)养护:恒温恒湿养护2-3天,优选3天;
(6)烘干:40-60℃,优选60℃烘烤24-48小时,优选24小时;
(7)烧成:隧道窑1280-1350℃高温烧成,保温36-48小时,优选36小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
本发明中,湿态球磨均化混合制浆过程湿磨球采用氧化铝材质球,大球规格为中球规格为小球规格为大球、中球、小球按重量比(0.5-1.5):(1.8-2.3):(3.0-4.0)组合,优选重量比1:2:3.5。
有益效果:
1、采用本发明制备的轻质莫来石砖单位重量轻,体积密度小,达到400±20kg/m3左右,有利于减少窑体自重,降低耐火材料负荷过重对窑体造成损坏的可能性,延长使用寿命;导热系数低,540℃下导热系数≤0.130w/m·k,有效减少窑体热量损失,可提高能源利用率15%以上,节能环保;最高使用温度可达1250℃,可用于环境温度要求较高的热工设备保温层;常温耐压强度可达1.3MPa,解决了保温材料强度低的问题,有利于提高砖体称重和剪切能力,减少窑体损坏的可能性。
2、采用发泡浇注成型的方法,避免了传统挤压成型对砖体体积的限制。
3、可制作(特)大型、(特)异型砖,并且具有较大强度,可通过螺栓和铆钉拉钩的方式固定在炉壳上,施工难易程度和速度可媲美甚至优于纤维棉,使用寿命却远大于纤维棉。
具体实施方式
实施例1
工艺配方为:
具体步骤如下:
(1)湿态球磨均化混合制浆:将除Secar71水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化42分钟,出浆备用,0.6小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入Secar71水泥搅拌3-5分钟,然后再加入铝粉发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化44小时后拆模;
(5)养护:恒温恒湿养护3天;
(6)烘干:50℃烘烤30小时;
(7)烧成:隧道窑1280-1350℃高温烧成,保温42小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例2
工艺配方为:
(1)湿态球磨均化混合制浆:将除Secar71水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化60分钟,出浆备用,1小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入Secar71水泥搅拌3-5分钟,然后再加入铝粉发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化48小时后拆模;
(5)养护:恒温恒湿养护2天;
(6)烘干:40℃烘烤48小时;
(7)烧成:隧道窑1280-1350℃高温烧成,保温48小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例3
工艺配方为:
具体步骤如下:
(1)湿态球磨均化混合制浆:将除Secar71水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化40分钟,出浆备用,0.7小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入Secar71水泥搅拌3-5分钟,然后再加入铝粉发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化45小时后拆模;
(5)养护:恒温恒湿养护2天;
(6)烘干:45℃烘烤36小时;
(7)烧成:隧道窑1280-1350℃高温烧成,保温40小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例4
工艺配方为:
具体步骤如下:
(1)湿态球磨均化混合制浆:将除Secar71水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化30分钟,出浆备用,1小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入Secar71水泥搅拌3-5分钟,然后再加入铝粉发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化36小时候拆模;
(5)养护:恒温恒湿养护3天;
(6)烘干:60℃烘烤24小时;
(7)烧成:隧道窑1280-1350℃高温烧成,保温36小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例5
工艺配方为:
具体步骤如下:
(1)湿态球磨均化混合制浆:将除Secar71水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化45分钟,出浆备用,0.5小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入Secar71水泥搅拌3-5分钟,然后再加入铝粉发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化42小时后拆模;
(5)养护:恒温恒湿养护2.5天;
(6)烘干:45℃烘烤28小时;
(7)烧成:隧道窑1280-1350℃高温烧成,保温42小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例6
工艺配方为:
具体步骤如下:
(1)湿态球磨均化混合制浆:将除Secar71水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化30分钟,出浆备用,0.5小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入Secar71水泥搅拌3-5分钟,然后再加入铝粉发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化46小时候拆模;
(5)养护:恒温恒湿养护2天;
(6)烘干:50℃烘烤36小时;
(7)烧成:隧道窑1280-1350℃高温烧成,保温48小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例效果:
表1为实施例1-6所制备400kg级轻质莫来石砖的体积密度、耐压强度、导热系数值。
表1实施例1-6所制备的400kg级轻质莫来石砖性能参数
本发明提供了一种400kg级轻质莫来石砖及其制备工艺的思路及方法,具体实现该技术方案的方法和途径很多,以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。本实施例中未明确的各组成部分均可用现有技术加以实现。

Claims (2)

1.一种400kg级轻质莫来石砖,其特征在于,其配方组成包括:
苏州泥 10-23%;
α-氧化铝微粉 24-34%;
硅灰 1-4%;
紫木节 3-8%;
膨润土 5-10%;
焦宝石 8-15%;
氢氧化钙粉 12-17%;
水泥 10-15%;
以上组分重量百分比之和为100%;
此外,额外添加以下组份,计算基准为上述组分总重量:
发泡剂 1-4%;
水 70-90%;
稳定剂 0.1-0.3%;
所述苏州泥为200-500目;所述α-氧化铝微粉为1000-1500目;所述硅灰为96硅灰;所述紫木节为500-700目;所述膨润土为200-500目;所述焦宝石为特级焦宝石,200-500目;所述氢氧化钙粉为200-500目;所述水泥为Secar71水泥;所述发泡剂为铝粉发泡剂,1500-2000目;所述稳定剂为PEPTAPON 5浆体悬浮稳定剂;
所述的400kg级轻质莫来石砖通过如下步骤制备:
(1)湿态球磨均化混合制浆:将除水泥、发泡剂的所有原材料加入到湿态球磨机中,球磨均化30-60分钟,出浆备用,0.5-1小时内用完;
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入水泥搅拌3-5分钟,然后再加入发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化36-48小时后拆模;
(5)养护:恒温恒湿养护2-3天;
(6)烘干:40-60℃烘烤24-48小时;
(7)烧成:隧道窑1280-1350℃高温烧成,保温36-48小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
2.根据权利要求1所述的一种400kg级轻质莫来石砖,其特征在于,所述湿态球磨均化混合制浆过程湿磨球采用氧化铝材质球,大球规格为Ø1.5cm,中球规格为Ø0.8cm,小球规格为Ø0.3cm,大球、中球、小球按重量比(0.5-1.5):(1.8-2.3):(3.0-4.0)组合。
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