CN106866126A - 一种刚玉‑尖晶石质耐火砖及其制备方法 - Google Patents

一种刚玉‑尖晶石质耐火砖及其制备方法 Download PDF

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CN106866126A
CN106866126A CN201710194338.9A CN201710194338A CN106866126A CN 106866126 A CN106866126 A CN 106866126A CN 201710194338 A CN201710194338 A CN 201710194338A CN 106866126 A CN106866126 A CN 106866126A
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refractory brick
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张寒
周艳焰
林诗艺
赵惠忠
李静捷
余俊
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Wuhan University of Science and Engineering WUSE
Wuhan University of Science and Technology WHUST
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Abstract

本发明涉及一种刚玉‑尖晶石质耐火砖及其制备方法。其技术方案是：以55~60wt%的棕刚玉颗粒为骨料，以20~25wt%的铝镁尖晶石细粉、15~20wt%的轻烧镁粉、1~2wt%的铝粉和1~4wt%的铁红粉为基质料；先将所述基质料混匀，再加入所述骨料，混合5~8分钟，然后加入占所述基质料与所述骨料之和3~6wt%的热固性酚醛树脂，混合10~15分钟，机压成型，在200~250℃条件下养护12~18小时；最后置于马弗炉中，在氮气气氛条件下升温至1500~1600℃，保温2~3小时，随炉冷却，制得刚玉‑尖晶石质耐火砖。本发明具有成本低和工艺简单的特点；所制备的刚玉‑尖晶石质耐火砖的烧结致密度高、高温抗折强度大和抗渣侵蚀性强。

Description

一种刚玉-尖晶石质耐火砖及其制备方法
技术领域
本发明属于刚玉-尖晶石质耐火材料技术领域。具体涉及一种刚玉-尖晶石质耐火砖及其制备方法。
背景技术
刚玉-尖晶石质耐火材料是指以刚玉和尖晶石为主要物相的耐火材料，由于刚玉和尖晶石的熔点较高，且二者化学性质稳定，因此，刚玉-尖晶石质耐火材料具有耐高温、耐化学侵蚀性能强和抵抗氧化-还原气氛变化能力强等优良特性，广泛应用于冶金、建材等高温工业领域。
目前，刚玉-尖晶石质耐火材料主要以板状刚玉或烧结刚玉等为骨料，以尖晶石细粉、α-Al2O3微粉和镁砂细粉为基质，以纸浆废液或溶胶等为结合剂，经混合、成型后高温烧成，如“一种镁铝尖晶石-刚玉-Sialon复相耐高温材料及其制备方法”(CN200910092571.1)和“一种不烧氮化硅铁-尖晶石-刚玉复合耐火材料及制备方法”(CN201310096899.7)专利技术。
由于刚玉与尖晶石(或原位反应形成的尖晶石)热膨胀系数差别较大，导致刚玉-尖晶石质耐火材料烧成过程中易产生大量微裂纹，难以烧结致密，进而大大降低了刚玉-尖晶石质耐火材料的烧结性能和抗熔渣侵蚀性能；同时，原料组分中杂质成分易形成低熔点物相而富集于晶界，导致刚玉相与尖晶石相晶界结合较弱，降低了刚玉-尖晶石质耐火材料的高温强度；此外，板状刚玉、尖晶石和α-Al2O3等原料成本较高，增大了刚玉-尖晶石质耐火材料的开发成本。
发明内容
本发明旨在克服现有技术缺陷，目的是提供一种工艺简单和成本低廉的刚玉-尖晶石质耐火砖的制备方法，用该方法制备的刚玉-尖晶石质耐火砖的烧结致密度高、高温抗折强度大和抗渣侵蚀性强。
为实现上述目的，本发明采用的技术方案是：以55～60wt％的棕刚玉颗粒为骨料，以20～25wt％的铝镁尖晶石细粉、15～20wt％的轻烧镁粉、1～2wt％的铝粉和1～4wt％的铁红粉为基质料；先将所述基质料混匀，再加入所述骨料，混合5～8分钟，然后加入占所述基质料与所述骨料之和3～6wt％的热固性酚醛树脂，混合10～15分钟，机压成型，在200～250℃条件下养护12～18小时；最后置于马弗炉中，在氮气气氛条件下升温至1500～1600℃，保温2～3小时，随炉冷却，制得刚玉-尖晶石质耐火砖。
所述棕刚玉颗粒的粒度为0.1～5mm；棕刚玉颗粒的主要化学成分是：Al2O3含量≥95wt％，SiO2含量≤1wt％。
所述铝镁尖晶石细粉的粒度为0.064～0.088mm；铝镁尖晶石细粉的主要化学成分是：MgO含量为18～20wt％，Al2O3含量为78～80wt％。
所述轻烧镁粉的粒度为0.064～0.088mm；轻烧镁粉的主要化学成分是：MgO含量≥97wt％，SiO2含量≤0.5wt％。
所述铝粉的粒度为0.064～0.088mm；铝粉的Al含量≥98wt％。
所述铁红粉的粒度为0.064～0.088mm；铁红粉的Fe2O3含量≥98wt％。
所述热固性酚醛树脂的残碳含量≥60wt％。
由于采取上述技术方案，本发明与现有技术相比具有如下积极效果：
1、本发明仅将所用原料混合，成型，在氮气气氛中烧成，工艺简单；所用原料成本低廉，无需特殊的制备设备和处理技术，节省劳动力资源，生产成本低。
2、本发明通过烧结过程中连续固溶反应，增强骨料-基质的晶界结合，提高刚玉-尖晶石质耐火砖的高温强度。
3、本发明采用碳热还原氮化法在基质料中形成陶瓷相直接结合，增强了刚玉-尖晶石质耐火砖的致密度，降低了材料的孔隙率，进而提高了材料的抗渣侵蚀性能。
本发明所制备的刚玉-尖晶石质耐火砖经测定：体积密度为3.15～3.20g/cm3；1400℃×3h静态坩埚法抗渣实验侵蚀指数为1～4％；高温(1400℃)抗折强度为5.5～6.0MPa。
因此，本发明具有成本低和工艺简单的特点；所制备的刚玉-尖晶石质耐火砖的烧结致密度高、高温抗折强度大和抗渣侵蚀性强。
具体实施方式
下面结合具体实施方式对本发明作进一步的描述，并非对其保护范围的限制。
为避免重复，先将本具体实施方式所涉及的原料统一描述如下，实施例中不再赘述：
所述棕刚玉颗粒的粒度为0.1～5mm；棕刚玉颗粒的主要化学成分是：Al2O3含量≥95wt％，SiO2含量≤1wt％。
所述铝镁尖晶石细粉的粒度为0.064～0.088mm；铝镁尖晶石细粉的主要化学成分是：MgO含量为18～20wt％，Al2O3含量为78～80wt％。
所述轻烧镁粉的粒度为0.064～0.088mm；轻烧镁粉的主要化学成分是：MgO含量≥97wt％，SiO2含量≤0.5wt％。
所述铝粉的粒度为0.064～0.088mm；铝粉的Al含量≥98wt％。
所述铁红粉的粒度为0.064～0.088mm；铁红粉的Fe2O3含量≥98wt％。
所述热固性酚醛树脂的残碳含量≥60wt％。
实施例1
一种刚玉-尖晶石质耐火砖及其制备方法。本实施例所述制备方法是：
以58～60wt％的棕刚玉颗粒为骨料，以23～25wt％的铝镁尖晶石细粉、15～17wt％的轻烧镁粉、1～1.4wt％的铝粉和1～3wt％的铁红粉为基质料；先将所述基质料混匀，再加入所述骨料，混合5～8分钟，然后加入占所述基质料与所述骨料之和3～5wt％的热固性酚醛树脂，混合10～15分钟，机压成型，在200～250℃条件下养护12～18小时；最后置于马弗炉中，在氮气气氛条件下升温至1500～1600℃，保温2～3小时，随炉冷却，制得刚玉-尖晶石质耐火砖。
本实施例制备的刚玉-尖晶石质耐火砖经测定：体积密度为3.15～3.17g/cm3；1400℃×3h静态坩埚法抗渣实验侵蚀指数为1～3％；高温(1400℃)抗折强度为5.5～5.7MPa。
实施例2
一种刚玉-尖晶石质耐火砖及其制备方法。本实施例所述制备方法是：
以57～59wt％的棕刚玉颗粒为骨料，以22～24wt％的铝镁尖晶石细粉、16～18wt％的轻烧镁粉、1.2～1.6wt％的铝粉和1～3wt％的铁红粉为基质料；先将所述基质料混匀，再加入所述骨料，混合5～8分钟，然后加入占所述基质料与所述骨料之和3～5wt％的热固性酚醛树脂，混合10～15分钟，机压成型，在200～250℃条件下养护12～18小时；最后置于马弗炉中，在氮气气氛条件下升温至1500～1600℃，保温2～3小时，随炉冷却，制得刚玉-尖晶石质耐火砖。
本实施例制备的刚玉-尖晶石质耐火砖经测定：体积密度为3.16～3.18g/cm3；1400℃×3h静态坩埚法抗渣实验侵蚀指数为1～3％；高温(1400℃)抗折强度为5.6～5.8MPa。
实施例3
一种刚玉-尖晶石质耐火砖及其制备方法。本实施例所述制备方法是：
以56～58wt％的棕刚玉颗粒为骨料，以21～23wt％的铝镁尖晶石细粉、17～19wt％的轻烧镁粉、1.4～1.8wt％的铝粉和2～4wt％的铁红粉为基质料；先将所述基质料混匀，再加入所述骨料，混合5～8分钟，然后加入占所述基质料与所述骨料之和4～6wt％的热固性酚醛树脂，混合10～15分钟，机压成型，在200～250℃条件下养护12～18小时；最后置于马弗炉中，在氮气气氛条件下升温至1500～1600℃，保温2～3小时，随炉冷却，制得刚玉-尖晶石质耐火砖。
本实施例制备的刚玉-尖晶石质耐火砖经测定：体积密度为3.17～3.19g/cm3；1400℃×3h静态坩埚法抗渣实验侵蚀指数为2～4％；高温(1400℃)抗折强度为5.7～5.9MPa。
实施例4
一种刚玉-尖晶石质耐火砖及其制备方法。本实施例所述制备方法是：
以55～57wt％的棕刚玉颗粒为骨料，以20～22wt％的铝镁尖晶石细粉、18～20wt％的轻烧镁粉、1.6～2wt％的铝粉和2～4wt％的铁红粉为基质料；先将所述基质料混匀，再加入所述骨料，混合5～8分钟，然后加入占所述基质料与所述骨料之和4～6wt％的热固性酚醛树脂，混合10～15分钟，机压成型，在200～250℃条件下养护12～18小时；最后置于马弗炉中，在氮气气氛条件下升温至1500～1600℃，保温2～3小时，随炉冷却，制得刚玉-尖晶石质耐火砖。
本实施例制备的刚玉-尖晶石质耐火砖经测定：体积密度为3.18～3.20g/cm3；1400℃×3h静态坩埚法抗渣实验侵蚀指数为2～4％；高温(1400℃)抗折强度为5.8～6.0MPa。
本具体实施方式与现有技术相比具有如下积极效果：
1、本具体实施方式仅将所用原料混合，成型，在氮气气氛中烧成，工艺简单；所用原料成本低廉，无需特殊的制备设备和处理技术，节省劳动力资源，生产成本低。
2、本具体实施方式通过烧结过程中连续固溶反应，增强骨料-基质的晶界结合，提高刚玉-尖晶石质耐火砖的高温强度。
3、本具体实施方式采用碳热还原氮化法在基质料中形成陶瓷相直接结合，增强了刚玉-尖晶石质耐火砖的致密度，降低了材料的孔隙率，进而提高了材料的抗渣侵蚀性能。
本具体实施方式所制备的刚玉-尖晶石质耐火砖经测定：体积密度为3.15～3.20g/cm3；1400℃×3h静态坩埚法抗渣实验侵蚀指数为1～4％；高温(1400℃)抗折强度为5.5～6.0MPa。
因此，本具体实施方式具有成本低和工艺简单的特点；所制备的刚玉-尖晶石质耐火砖的烧结致密度高、高温抗折强度大和抗渣侵蚀性强。

Claims (8)

1.一种刚玉-尖晶石质耐火砖的制备方法，其特征在于以55～60wt％的棕刚玉颗粒为骨料，以20～25wt％的铝镁尖晶石细粉、15～20wt％的轻烧镁粉、1～2wt％的铝粉和1～4wt％的铁红粉为基质料；先将所述基质料混匀，再加入所述骨料，混合5～8分钟，然后加入占所述基质料与所述骨料之和3～6wt％的热固性酚醛树脂，混合10～15分钟，机压成型，在200～250℃条件下养护12～18小时；最后置于马弗炉中，在氮气气氛条件下升温至1500～1600℃，保温2～3小时，随炉冷却，制得刚玉-尖晶石质耐火砖。
2.根据权利要求1所述的刚玉-尖晶石质耐火砖的制备方法，其特征在于所述棕刚玉颗粒的粒度为0.1～5mm；棕刚玉颗粒的主要化学成分是：Al2O3含量≥95wt％，SiO2含量≤1wt％。
3.根据权利要求1所述的刚玉-尖晶石质耐火砖的制备方法，其特征在于所述铝镁尖晶石细粉的粒度为0.064～0.088mm；铝镁尖晶石细粉的主要化学成分是：MgO含量为18～20wt％，Al2O3含量为78～80wt％。
4.根据权利要求1所述的刚玉-尖晶石质耐火砖的制备方法，其特征在于所述轻烧镁粉的粒度为0.064～0.088mm；轻烧镁粉的主要化学成分是：MgO含量≥97wt％，SiO2含量≤0.5wt％。
5.根据权利要求1所述的刚玉-尖晶石质耐火砖的制备方法，其特征在于所述铝粉的粒度为0.064～0.088mm；铝粉的Al含量≥98wt％。
6.根据权利要求1所述的刚玉-尖晶石质耐火砖的制备方法，其特征在于所述铁红粉的粒度为0.064～0.088mm；铁红粉的Fe2O3含量≥98wt％。
7.根据权利要求1所述的刚玉-尖晶石质耐火砖的制备方法，其特征在于所述热固性酚醛树脂的残碳含量≥60wt％。
8.一种刚玉-尖晶石质耐火砖，其特征在于所述刚玉-尖晶石质耐火砖是根据权利要求1～7项中任一项所述的刚玉-尖晶石质耐火砖的制备方法所制备的刚玉-尖晶石质耐火砖。
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CN109160807A (zh) * 2018-08-20 2019-01-08 洛阳科创新材料股份有限公司 一种金属基铝镁尖晶石滑板及其制备方法
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