CN106938923A - 硅钢玉耐磨复合砖 - Google Patents

硅钢玉耐磨复合砖 Download PDF

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CN106938923A
CN106938923A CN201710220756.0A CN201710220756A CN106938923A CN 106938923 A CN106938923 A CN 106938923A CN 201710220756 A CN201710220756 A CN 201710220756A CN 106938923 A CN106938923 A CN 106938923A
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powder
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insulation layer
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CN106938923B (zh
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裴长松
周海涛
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Zhengzhou Zhongjian Refractories Co., Ltd
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Abstract

本发明公开了一种硅钢玉耐磨复合砖，该砖体是由耐火工作层和非工作保温层经化学结合、低温烧制而成的产品，其耐磨性、热震稳定性、抗侵蚀性、低导热性等各项性能指标及使用效果均优于高温烧结的硅莫砖、抗剥落高铝砖、镁铝尖晶石砖的性能指标，由于是低温烧制，节约了大量的燃料和能源，大大降低了吨生产制造成本，真正达到了节能降耗的目的，提高了企业的经济效益。为降低砖体的热导率，使砌筑的窑筒体表面温度更低，本发明在砖体的保温层中加入了轻质多孔莫来石热材料，可使砌筑的窑筒体表面温度降低100~150℃，大幅度延长了回转窑的运行寿命，优越性远远超过硅莫砖、抗剥落高铝砖等高温制品，是新一代水泥回转窑、石灰窑最理想的更新换代的节能窑衬。

Description

硅钢玉耐磨复合砖
技术领域
本发明涉及耐火材料，尤其是涉及一种用于砌筑大型水泥回转窑、石灰窑窑体的硅钢玉耐磨复合砖。
背景技术
目前在大型水泥回转窑、石灰窑的过渡带多采用硅莫砖或抗剥落高铝砖、镁铝尖晶石砖砌筑窑体，其不足之处在于抗热震性和耐磨性能较差，虽然硅莫砖的抗热震性能较其他砖体有所提高，但硅莫砖的热导率较高（高达2.9W/m.K），当用在回转窑过渡带时，可造成窑筒体温度增高（筒体表面温度一般都在350℃~380℃），散热损失大，这样不仅易导致回转窑筒体变形，而且还易引起窑筒体向后膨胀，加大窑尾密封装置的磨蚀损坏；同时还会造成回转窑内衬砖体剥落、破损，掉砖，降低回转窑的使用寿命，从而使生产成本大幅度提高，消耗了燃料、人力及原材料，投入高产出低，企业经济效益受到严重影响。
由于硅莫砖是经1450℃高温烧结而成的产成品，燃料消耗大，制砖成本高，不能达到节能减排降耗的目的。
发明内容
本发明的目的在于提供一种硅钢玉耐磨复合砖，该砖体制造时无需高温烧结，节能降耗，且具有高强度、高耐磨、高荷软、高热震的性能，由于其导热系数低，用于砌筑回转窑时可大大延长窑体的使用寿命。
为实现上述目的，本发明可采取下述技术方案：
本发明所述的硅钢玉耐磨复合砖，该砖体是由工作层和保温层复合而成；其中
所述工作层所用原料的重量份配比为：特级高铝矾土颗粒料50～55份，电熔刚玉颗粒料5～10份，碳化硅粉10～15份，合成莫来石粉10～15份，蓝晶石粉5～7份，结合剂2～3份，添加剂3～5份，外加剂为比重1.6 g/cm3的磷酸溶液6～8份；
所述保温层所用原料的重量份配比为：轻质多孔莫来石颗粒料55～60份；高铝矾土熟料细粉20～25份； 氧化铝粉5～10份；结合剂10～15份；外加剂为密度1.4 g/cm3的酸二氢铝溶液8～10份。
所述砖体的加工方法为：
第一步，加工工作层泥料
将特级高铝矾土颗粒料和电熔刚玉颗粒料放入湿碾机中混合均匀，然后加入磷酸溶液继续混碾3~5分钟，最后加入碳化硅粉、合成莫来石粉、蓝晶石粉、结合剂、添加剂后，持续混碾10~15分钟出碾，困料20~24小时后，再将物料放入湿碾机中二次混碾10~15分钟，得到工作层泥料，出碾备用；
第二步，加工保温层泥料
将轻质多孔莫来石颗粒料放入湿碾机中，加入酸二氢铝溶液混碾3~5分钟，再加入高铝矾土熟料细粉、氧化铝粉和结合剂后持续混碾10~15分钟出碾，困料20~24小时后，再将物料放入湿碾机中二次混碾10~15分钟，得到保温层泥料，出碾备用；
第三步，成型、烧结
将曲面隔板放入成型模具内，在曲面隔板两侧的模具腔室内分别放入第一步混碾得到的工作层泥料和第二步混碾得到的保温层泥料，然后抽出曲面隔板，按设定的压力加压制得成型砖坯，成型砖坯的工作层厚度:保温层厚度=6~8:4~2；成型砖坯经150~180℃低温干燥15~20小时后再送入隧道窑内进行烧成，砖坯烧成温度600~650℃，保温8～10h，出窑后即为硅钢玉耐磨复合砖成品砖体。
为保证成品复合砖的质量要求，所述工作层泥料中的特级高铝矾土颗粒料粒度为0.1~10mm，所述电熔刚玉颗粒料的粒度为.01~5mm，所述合成莫来石粉料和碳化硅粉料的粒度为200目，所述蓝晶石粉料的粒度为100目；所述保温层泥料中的轻质多孔莫来石颗粒料粒度为0.1~10mm，所述高铝矾土熟料细粉粒度为180目，所述氧化铝粉料粒度为500目。
本发明所述工作层泥料中的结合剂为粒度200目的黏土粉料，所述添加剂为金属硅粉和锆硅微粉按45:55的重量份配制的混合粉料，其中金属硅粉的粒度为200目，锆硅微粉的粒度为10um；所述保温层泥料中的结合剂同样为粒度200目的黏土粉料。
实际生产时，本发明硅钢玉耐磨复合砖的工作层泥料中原料的重量份配比可以为：特级高铝矾土颗粒料50份，电熔刚玉颗粒料 10份，碳化硅粉15份，合成莫来石粉15份，蓝晶石粉5份，结合剂2份，添加剂3份，比重1.6 g/cm3的磷酸溶液6～8份；保温层泥料中原料的重量份配比为：轻质多孔莫来石颗粒料55份；高铝矾土熟料细粉25份； 氧化铝粉10份；结合剂10份；外加剂为密度1.4 g/cm3的酸二氢铝溶液8～10份。
所述工作层泥料中原料的重量份配比也可以为：特级高铝矾土颗粒料55份，电熔刚玉颗粒料10份，合成莫来石粉10份，蓝晶石粉7份，碳化硅粉10份，结合剂3份，添加剂5份，比重1.6 g/cm3的磷酸溶液6～8份；所述保温层泥料中原料的重量份配比为：轻质多孔莫来石颗粒料60份；高铝矾土熟料细粉20份； 氧化铝粉10份；结合剂10份；外加剂为密度1.4 g/cm3的酸二氢铝溶液8～10份。
所述工作层泥料中原料的重量份配比还可以为：特级高铝矾土颗粒料53份，电熔刚玉颗粒料9份，合成莫来石粉13份，蓝晶石粉6份，碳化硅粉13份，结合剂2份，添加剂4份，比重1.6 g/cm3的磷酸溶液6～8份；所述保温层泥料中原料的重量份配比为：轻质多孔莫来石颗粒料57份；高铝矾土熟料细粉23份； 氧化铝粉5份；结合剂15份；外加剂为密度1.4 g/cm3的酸二氢铝溶液8～10份。
经检测，本发明生产的硅钢玉耐磨复合砖成品的理化指标如下：
本发明硅钢玉耐磨复合砖是由耐火工作层和非工作保温层经化学结合、低温（600~650℃）烧制而成的产品，其耐磨性、热震稳定性、抗侵蚀性、低导热性等各项性能指标及使用效果均优于高温烧结的硅莫砖、抗剥落高铝砖、镁铝尖晶石砖（砖坯烧成温度1450～1550℃）的性能指标，由于是低温烧制，节约了大量的燃料和能源，大大降低了吨生产制造成本，真正达到了节能降耗的目的，提高了企业的经济效益。以生产同样一吨砖为例，生产一吨本发明的硅钢玉耐磨复合砖（烧成温度600-650℃）需用天然气30m3，每吨用电量70 度；而生产一吨硅莫砖及其它高温烧结砖（砖坯烧成温度1450～1550℃）需用天然气130 m3，每吨用电量 195度，按现行天然气价格每方2.9元，工业用电平均0.8元/度计算，每吨砖可节约天然气 100 m3，用电量 节约125度，保守按每年生产5000吨计算，一年可节约天然气 50万m3，资金145万元，节约用电62.5万度，资金50万元，再加上其它人工工资等费用，经济效益更为客观。
同时，本发明硅钢玉耐磨复合砖在耐火工作层泥料中以特级高铝矾土熟料和电熔刚玉为骨料，以合成莫来石粉、蓝晶石粉、SiC粉和结合黏土为基质，并加入了金属硅粉和锆硅微粉添加剂，利用锆硅微粉细小的粒径以及锆在一定温度下与氧化铝发生反应，形成莫来石和斜锆石，大大提高了砖体的抗热震性和耐剥落性，使砖体在回转窑内长期工作不剥落、不破损、不抽签掉砖，同时在原料中加入微粉还可以在烧成过程中产生大量的纳米级的封闭气孔，有效降低了砖体的热导率和气孔率，大大提高了砖体的烧结强度和耐磨性。
为降低砖体的热导率，使砌筑的窑筒体表面温度更低，本发明在砖体的非工作面—保温层中加入了轻质多孔莫来石热材料，可使砌筑的窑筒体表面温度降低100~150℃，从而大幅度延长了回转窑的运行寿命，优越性远远超过硅莫砖、抗剥落高铝砖等高温制品，是新一代水泥回转窑、石灰窑最理想的更新换代的节能窑衬。
附图说明
图1、图2是本发明硅钢玉耐磨复合砖的断面结构示意图。
具体实施方式
下面通过具体实施例对本发明做更加详细的说明。
实施例1
本发明的硅钢玉耐磨复合砖，该砖体是由工作层1和保温层2复合而成，为保证工作层1和保温层2之间的牢固性，工作层1和保温层2的结合面呈相互咬合的锯齿结构，如图1所示，或者呈相互咬合的燕尾式结构，如图2所示；
为满足复合砖体在大型水泥回转窑、石灰窑过渡带使用的性能要求：
本发明工作层1所用原料的重量百分配比为：特级高铝矾土颗粒料50%（粒度0.1~10mm），电熔刚玉颗粒料 10%（粒度.01~5mm），碳化硅粉15%（粒度200目），合成莫来石粉15%（粒度200目），蓝晶石粉5%（粒度100目），黏土结合剂2%（粒度200目或更细），由45%金属硅粉（粒度200目）和55%锆硅微粉（粒度10um或更细）配制的添加剂3%，外加剂采用比重1.6 g/cm3的磷酸溶液，用量为全部原料总量的6～8%；
保温层2所用原料的重量百分配比为：轻质多孔莫来石颗粒料55%（粒度0.1~10mm）；高铝矾土熟料细粉25%（粒度180目或更细）； 氧化铝粉10%（粒度500目或更细）；黏土粉料结合剂10%（粒度200目或更细）；外加剂采用密度1.4 g/cm3的酸二氢铝溶液，用量为全部原料总量的8～10%；
本发明硅钢玉耐磨复合砖的加工方法为：
第一步，加工工作层泥料
将按上述比例准确称量的特级高铝矾土颗粒料和电熔刚玉颗粒料放入湿碾机中混合均匀，然后加入磷酸溶液继续混碾3~5分钟，最后加入碳化硅粉、合成莫来石粉、蓝晶石粉、结合剂、添加剂后，持续混碾10~15分钟出碾，困料20~24小时后，再次将物料放入湿碾机中二次混碾10~15分钟，得到工作层泥料，出碾备用；
第二步，加工保温层泥料
将轻质多孔莫来石颗粒料放入湿碾机中，加入酸二氢铝溶液混碾3~5分钟，再加入高铝矾土熟料细粉、氧化铝粉和结合剂后持续混碾10~15分钟出碾，困料20~24小时后，再将物料放入湿碾机中二次混碾10~15分钟，得到保温层泥料，出碾备用；
第三步，成型、烧结
将曲面隔板放入成型模具内，在曲面隔板两侧的模具腔室内分别放入工作层泥料和保温层泥料，然后抽出曲面隔板，将装有泥料的成型模具在800T压力机上按设定的压力加压制得合格的成型砖坯，成型砖坯的工作层厚度:保温层厚度=6~8:4~2（一般情况下，工作层厚度为7/10，保温层厚度为3/10）；首先将成型砖坯送入隧道窑经150~180℃低温干燥15~20小时后再送入隧道窑内进行烧成，砖坯烧成温度600~650℃，保温8～10h，出窑后即为硅钢玉耐磨复合砖成品砖体。
实施例2
在实际烧制砖体时，本发明硅钢玉耐磨复合砖的工作层1和保温层2的原料还可以按照下述重量百分配比配制：
其中工作层1所用原料的重量百分配比为：特级高铝矾土颗粒料55%，电熔刚玉颗粒料10%，合成莫来石粉10%，蓝晶石粉7%，碳化硅粉10%，结合剂3%，添加剂5%，外加剂采用比重1.6 g/cm3的磷酸溶液，用量为全部原料总量的6～8%；
保温层2所用原料的重量百分配比为：轻质多孔莫来石颗粒料60%；高铝矾土熟料细粉20%； 氧化铝粉10%；结合剂10%；外加剂采用比重1.6 g/cm3的磷酸溶液，用量为全部原料总量的6～8%。
其砖体的生产方法同实施例1。
实施例3
实际烧制砖体时，本发明硅钢玉耐磨复合砖的工作层1和保温层2的原料还可以按照下述重量百分配比配制：
工作层1所用原料的重量百分配比为：特级高铝矾土颗粒料53%，电熔刚玉颗粒料9%，合成莫来石粉13%，蓝晶石粉6%，碳化硅粉13%，结合剂2%，添加剂4%，外加剂采用比重1.6 g/cm3的磷酸溶液，用量为全部原料总量的6～8%；
保温层2所用原料的重量百分配比为：轻质多孔莫来石颗粒料57%；高铝矾土熟料细粉23%； 氧化铝粉5%；结合剂15%；外加剂采用比重1.6 g/cm3的磷酸溶液，用量为全部原料总量的6～8%。
实际烧制砖体时，各原料之间的配比可以按照本申请公布的范围值进行合理调整。
为保证烧制成的硅钢玉耐磨复合砖的使用性能，本发明所用原料的主要成分为：
特级高铝矾土熟料中，Al2O3≥88%，Fe2O3≤1.5%，体积密度≥3.15 g/cm3；电熔刚玉中，Al2O3≥95%，Fe2O3≤1.0%，体积密度≥3.80 g/cm3；碳化硅粉中SiC≥97%；合成莫来石粉中Al2O3 ≥70%；蓝晶石粉中Al2O3 ≥56%；多孔莫来石中Al2O3≥62%，显气孔率≥48%；氧化铝粉中Al2O3≥98%；黏土粉料中Al2O3 31～32%，Fe2O3 ≤1.5%；金属硅粉中Si≥97%；锆硅微粉中ZrO2≥14%，SiO2≥83%。

Claims (6)

1.一种硅钢玉耐磨复合砖，其特征在于：该砖体是由工作层和保温层复合而成；其中
所述工作层所用原料的重量份配比为：特级高铝矾土颗粒料50～55份，电熔刚玉颗粒料5～10份，碳化硅粉10～15份，合成莫来石粉10～15份，蓝晶石粉5～7份，结合剂2～3份，添加剂3～5份，外加剂为比重1.6 g/cm3的磷酸溶液6～8份；
所述保温层所用原料的重量份配比为：轻质多孔莫来石颗粒料55～60份；高铝矾土熟料细粉20～25份； 氧化铝粉5～10份；结合剂10～15份；外加剂为密度1.4 g/cm3的酸二氢铝溶液8～10份；
所述砖体的加工方法为：
第一步，加工工作层泥料
将特级高铝矾土颗粒料和电熔刚玉颗粒料放入湿碾机中混合均匀，然后加入磷酸溶液继续混碾3~5分钟，最后加入碳化硅粉、合成莫来石粉、蓝晶石粉、结合剂、添加剂后，持续混碾10~15分钟出碾，困料20~24小时后，再将物料放入湿碾机中二次混碾10~15分钟，得到工作层泥料，出碾备用；
第二步，加工保温层泥料
将轻质多孔莫来石颗粒料放入湿碾机中，加入酸二氢铝溶液混碾3~5分钟，再加入高铝矾土熟料细粉、氧化铝粉和结合剂后持续混碾10~15分钟出碾，困料20~24小时后，再将物料放入湿碾机中二次混碾10~15分钟，得到保温层泥料，出碾备用；
第三步，成型、烧结
将曲面隔板放入成型模具内，在曲面隔板两侧的模具腔室内分别放入第一步混碾得到的工作层泥料和第二步混碾得到的保温层泥料，然后抽出曲面隔板，按设定的压力加压制得成型砖坯，成型砖坯的工作层厚度:保温层厚度=6~8:4~2；成型砖坯经150~180℃低温干燥15~20小时后再送入隧道窑内进行烧成，砖坯烧成温度600~650℃，保温8～10h，出窑后即为硅钢玉耐磨复合砖成品砖体。
2.根据权利要求1所述的硅钢玉耐磨复合砖，其特征在于：
所述工作层泥料中的特级高铝矾土颗粒料粒度为0.1~10mm，所述电熔刚玉颗粒料的粒度为.01~5mm，所述合成莫来石粉料和碳化硅粉料的粒度为200目，所述蓝晶石粉料的粒度为100目；
所述保温层泥料中的轻质多孔莫来石颗粒料粒度为0.1~10mm，所述高铝矾土熟料细粉粒度为180目，所述氧化铝粉料粒度为500目。
3.根据权利要求1所述的硅钢玉耐磨复合砖，其特征在于：所述工作层泥料中的结合剂为粒度200目的黏土粉料，所述添加剂为金属硅粉和锆硅微粉按45:55的重量份配制的混合粉料，其中金属硅粉的粒度为200目，锆硅微粉的粒度为10um；所述保温层泥料中的结合剂为粒度200目的黏土粉料。
4.根据权利要求1所述的硅钢玉耐磨复合砖，其特征在于：
所述工作层泥料中原料的重量份配比为：特级高铝矾土颗粒料50份，电熔刚玉颗粒料10份，碳化硅粉15份，合成莫来石粉15份，蓝晶石粉5份，结合剂2份，添加剂3份，比重1.6 g/cm3的磷酸溶液6～8份；
所述保温层泥料中原料的重量份配比为：轻质多孔莫来石颗粒料55份；高铝矾土熟料细粉25份； 氧化铝粉10份；结合剂10份；外加剂为密度1.4 g/cm3的酸二氢铝溶液8～10份。
5.根据权利要求1所述的硅钢玉耐磨复合砖，其特征在于：
所述工作层泥料中原料的重量份配比为：特级高铝矾土颗粒料55份，电熔刚玉颗粒料10份，合成莫来石粉10份，蓝晶石粉7份，SiC粉10份，结合剂3份，添加剂5份，比重1.6 g/cm3的磷酸溶液6～8份；
所述保温层泥料中原料的重量份配比为：轻质多孔莫来石颗粒料60份；高铝矾土熟料细粉20份； 氧化铝粉10份；结合剂10份；外加剂为密度1.4 g/cm3的酸二氢铝溶液8～10份。
6.根据权利要求1所述的硅钢玉耐磨复合砖，其特征在于：
所述工作层泥料中原料的重量份配比为：特级高铝矾土颗粒料53份，电熔刚玉颗粒料9份，合成莫来石粉13份，蓝晶石粉6份，SiC粉13份，结合剂2份，添加剂4份，比重1.6 g/cm3的磷酸溶液6～8份；
所述保温层泥料中原料的重量份配比为：轻质多孔莫来石颗粒料57份；高铝矾土熟料细粉23份； 氧化铝粉5份；结合剂15份；外加剂为密度1.4 g/cm3的酸二氢铝溶液8～10份。
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CN109336621A (zh) * 2018-10-12 2019-02-15 甘肃酒钢集团科力耐火材料股份有限公司 一种采用废旧热风炉球并引入回收塞棒生产铝碳包沿料的方法
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CN112010612A (zh) * 2020-09-07 2020-12-01 郑州四季火耐火材料有限公司 一种石灰窑预制砖及其制备方法
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CN108751959A (zh) * 2018-08-24 2018-11-06 宜兴瑞泰耐火材料有限公司 一种丙烷脱氢装置反应器用多孔砖及其制备方法
CN108751959B (zh) * 2018-08-24 2023-05-23 宜兴瑞泰耐火材料有限公司 一种丙烷脱氢装置反应器用多孔砖及其制备方法
CN109336621A (zh) * 2018-10-12 2019-02-15 甘肃酒钢集团科力耐火材料股份有限公司 一种采用废旧热风炉球并引入回收塞棒生产铝碳包沿料的方法
CN109336621B (zh) * 2018-10-12 2021-06-08 甘肃酒钢集团科力耐火材料股份有限公司 一种采用废旧热风炉球并引入回收塞棒生产铝碳包沿料的方法
CN109534796A (zh) * 2018-12-28 2019-03-29 瑞泰科技股份有限公司 一种水泥窑过渡带和烧成带结合部用刚玉碳化硅砖
CN112010612A (zh) * 2020-09-07 2020-12-01 郑州四季火耐火材料有限公司 一种石灰窑预制砖及其制备方法
CN112010612B (zh) * 2020-09-07 2022-07-05 郑州四季火耐火材料有限公司 一种石灰窑预制砖及其制备方法
CN112745110A (zh) * 2020-12-07 2021-05-04 北京金隅通达耐火技术有限公司 一种危险废物处置回转窑用高致密锆刚玉砖
CN116444256A (zh) * 2023-03-10 2023-07-18 安徽瑞泰新材料科技有限公司 一种莫硅刚玉耐磨砖及其制备工艺

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