CN106946585A - 一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法 - Google Patents
一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法 Download PDFInfo
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- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 title claims abstract description 70
- 239000011449 brick Substances 0.000 title claims abstract description 38
- 239000000395 magnesium oxide Substances 0.000 title claims abstract description 35
- 229910052596 spinel Inorganic materials 0.000 title claims abstract description 35
- 239000011029 spinel Substances 0.000 title claims abstract description 34
- 238000000034 method Methods 0.000 title claims abstract description 20
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 title claims abstract description 15
- 238000005245 sintering Methods 0.000 claims abstract description 22
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- 239000001095 magnesium carbonate Substances 0.000 claims description 6
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 claims description 6
- 235000014380 magnesium carbonate Nutrition 0.000 claims description 6
- 229910000021 magnesium carbonate Inorganic materials 0.000 claims description 6
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 4
- 239000000843 powder Substances 0.000 claims description 3
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- 229910052749 magnesium Inorganic materials 0.000 abstract description 7
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- -1 magnesium aluminate Chemical class 0.000 abstract description 6
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- 238000000465 moulding Methods 0.000 abstract description 3
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- 235000012245 magnesium oxide Nutrition 0.000 description 21
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- 229910003023 Mg-Al Inorganic materials 0.000 description 4
- 239000002994 raw material Substances 0.000 description 3
- 229910001051 Magnalium Inorganic materials 0.000 description 2
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- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910026161 MgAl2O4 Inorganic materials 0.000 description 1
- 229910003112 MgO-Al2O3 Inorganic materials 0.000 description 1
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Abstract
一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法,属于耐火材料技术领域。其特征在于制备步骤为:工业氧化铝和轻烧镁组成主原料与水和发泡剂,研磨得到泥浆;泥浆经滤水、真空挤出、干燥、烧结,即得微孔尖晶石;将重烧镁砂和微孔尖晶石按照一定的质量比干混后再加水以及结合剂进行湿混;然后使用压力机打压成半成品砖坯,在烘干窑内烘干后进入隧道窑在烧成。本发明以微孔尖晶石与重烧镁砂混炼,压机成型,烧结最终生成一种体密低,强度高,导热系数低的新型的镁铝尖晶石碱性耐火砖。
Description
技术领域
一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法,属于耐火材料技术领域。
背景技术
镁铝尖晶石(MgAl2O4)也被简称为尖晶石。尖晶石仅是MgO-Al2O3二元系统相图中的一个中间化合物,其熔点为2135℃。自然界中镁铝尖晶石的蕴藏量很少,目前工业应用上主要以合成原料为主。工业合成方法主要有:固相烧结法和电弧炉熔制法。因此,目前镁铝尖晶石主要用于重质致密耐火材料的研究和开发,而将其作为轻质耐火材料的应用还很少。作为重质的镁铝尖晶石具有体密大、热震稳定性好、抗侵蚀能力与抗渣性强的优点。广泛应用在大型水泥窑、中型水泥过渡带衬砖,但其导热系数大,容易造成筒体外壁温度高,散热损失打,既不节能,对筒体安全也不利。
发明内容
本发明要解决的技术问题是:克服现有技术的不足,提供一种强度高、导热系数低的低导热镁铝尖晶石耐火砖的制备方法。
本发明解决其技术问题所采用的技术方案是:该低导热镁铝尖晶石耐火砖的制备方法,其特征在于制备步骤为:
1)将重烧镁砂和微孔尖晶石按质量比50~99:1~50干混后再加水以及结合剂进行湿混;其中,微孔尖晶石体积密度为< 2.60 g/cm3,气孔率在 > 25 %,最可几气孔孔径在 < 2um;
2)然后使用压力机打压成半成品砖坯,在烘干窑内80 ℃~ 120 ℃条件下烘干后进入隧道窑在高于1460 ℃烧成。
本发明的发明人利用具有特定体积密度、特定气孔率和最可几气孔孔径的微孔尖晶石以原料的形式加入到耐火砖的配方中,配合先干混后湿混的工艺,最终制备成了低导热的镁铝尖晶石耐火砖。微孔尖晶石与重烧镁砂混炼,压机成型,烧结最终生成一种体密低,强度高,导热系数低的新型的镁铝尖晶石碱性耐火砖。
优选的,步骤1)所述的重烧镁砂和微孔尖晶石的粒度分布遵循安卓森方程,
,
式中,UDp为累计筛下百分数,%;Dpmax =4mm;q=1/2~1/3。安卓森方程是连续粒度体系紧密堆积方程。
重烧镁砂和微孔尖晶石的粒度级配影响耐火砖本身的原料分布和整体的强度。上述的优选颗粒级配能保证本发明的耐火砖原料分布均匀,从而能保证了具有更好的结构强度。
步骤1)所述的微孔尖晶石的比例在耐火砖成品中所占的质量比为1% ~50 %。
优选的,步骤1)所述的微孔尖晶石的比例在耐火砖成品中所占的质量比为17% ~22 %。优选的微孔尖晶石的比例能够得到性能最佳的耐火砖成品,砖体内气孔孔径大小均匀、细密,不但使耐火砖成品强度达到最大,体积密度也接近本发明所能达到的最小值。
所述的微孔尖晶石的制备工艺为:取主原料、主原料重量1.1~1.4倍的水、主原料重量0.5%~4%的发泡剂,研磨得到泥浆;泥浆经滤水、真空挤出、干燥、烧结,即得微孔尖晶石;所述主原料的重量份组成为:氧化铝50~70份、轻烧镁15~50份、菱镁矿0~15份。
本发明提供的微孔尖晶石的制备工艺中以轻烧镁全部或部分代替传统方法中的菱镁矿,能够制得与重烧镁砂适应性更好的微孔尖晶石,改善烧结后所得砖体的结晶形态,使同密度的砖体的高温抗折强度更高。
所述的烧结中烧结温度在1600 ℃~1680 ℃,保温时间30~45分钟。
本发明提供了一种湿法烧结的微孔尖晶石生产方法,将氧化铝、轻烧镁和菱镁矿加入一定的水进行湿混,由于水分子在研磨中沿着物料毛细管壁或微裂纹扩散至狭窄地区,对裂纹的四壁产生约0.1MPa的压力,使得物料更容易劈裂开,另外还可以促进各种原料和发泡剂分布均匀,使其中菱镁矿不粘磨机壁,从而所磨泥浆粒度更细;本发明采用的烧结法微孔尖晶石生产工艺所得的尖晶石体积密度可以< 2.60 g/cm3,气孔率在 > 25 %,最可几气孔孔径 < 2 um,而传统的致密烧结或者电熔尖晶石的最可几气孔孔径在 80~100 um。该湿法烧结生产的微孔尖晶石,由于加水共磨所得泥浆颗粒较细(典型值 500目),使得在制备微孔尖晶石时的烧结温度降低50℃~150℃,减少了保温时间,大大节约产品生产成本。所得该微孔尖晶石在本发明中降低了耐火砖的热导率,降低了热损耗,达到了更好的保温隔热性能;
步骤3)的干燥条件能够适应本发明工艺需求,提高砖体强度。
经过不断优化配置最终获得低导热镁铝尖晶石砖。所检测的典型物理性能与传统镁铝尖石砖进行了对比。
微孔尖晶石与重烧镁砂混炼,压机成型,烧结最终生成一种体密低,强度高,导热系数低的新型的镁铝尖晶石碱性耐火砖。本发明提供的湿法烧结的微孔尖晶石,将氧化铝、轻烧镁和菱镁矿加入一定的水进行湿混,可以促进各种原料和发泡剂分布均匀,使其中菱镁矿不粘磨机壁,从而所磨泥浆粒度更细;本发明采用真空挤泥机成型,可使微孔尖晶石泥料中孔径尺寸由原来的几十微米降低到几微米,同时也使泥料组成更加均匀,可塑性和密度均得到增加,保证了成型后坯体强度。本发明采用本发明烧结生产方法微孔尖晶石生产工艺所得的产品,体积密度大大减小,气孔率较传统工艺提高一个数量级,气孔孔径大小均匀细密。采用本发明湿法烧结生产方法生产微孔尖晶石,解决了传统干法生产环境差、劳动强度大等问题;采用本发明湿法烧结生产方法生产微孔尖晶石,由于加水共磨所得泥浆颗粒较细,大大降低烧结温度,大大节约产品成本,从而更具有市场竞争力。
附图说明
图1是本发明的低导热镁铝尖晶石耐火砖的显微镜观察照片;1 是方镁石; 2 是微孔尖晶石。
具体实施方式
下面结合具体实施例本发明做进一步说明,其中实施例1为最佳实施例。
实施例1
1)将重烧镁砂和制得的微孔尖晶石按照78:22的质量比干混后再加水以及结合剂进行湿混;其中,微孔尖晶石体积密度为2.45 g/cm3,气孔率在 26 %,最可几气孔孔径在 1.7um;重烧镁砂和微孔尖晶石的粒度级配包括粉料和颗粒料,粒度分布遵循安卓森方程,
,
式中,UDp为累计筛下百分数,%;Dpmax =4mm;q=1/2;
2)然后使用压力机打压成半成品砖坯,在烘干窑内80℃~120℃条件下烘干后进入隧道窑在 1480 ℃ 下烧成,微孔尖晶石的比例在耐火砖成品中所占的质量比为22 %。
实施例2
1)将重烧镁砂制得的微孔尖晶石按照83:17的质量比干混后再加水以及结合剂进行湿混;其中,微孔尖晶石体积密度为2.3g/cm3,气孔率在 28%,最可几气孔孔径在 1.5um;重烧镁砂和微孔尖晶石的粒度级配包括粉料和颗粒料,粒度分布遵循安卓森方程,
,
式中,UDp为累计筛下百分数,%;Dpmax =4mm;q=1/3;
2)然后使用压力机打压成半成品砖坯,在烘干窑内80℃~120℃条件下烘干后进入隧道窑在 1460℃ 下烧成,微孔尖晶石的比例在耐火砖成品中所占的质量比为17 %。
表1:各实施例和对比例物理性能
表2:将样品砖热面插入电炉炉膛内(温度1200 ℃)保温24小时,然后通过红外线测温仪测试耐火砖从热面传递到冷面的温度。可以看到传递到低导热镁铝尖晶石砖冷面温度比传统镁铝尖晶石砖低了大约 60 ℃左右。
从实施例与传统镁铝尖晶石砖的性能对比可以看出本发明实现了在低密度的情况下大大的提高高温抗折强度,并降低导热系数。
以上所述,仅是本发明的较佳实施例而已,并非是对本发明作其它形式的限制,任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以变更或改型为等同变化的等效实施例。但是凡是未脱离本发明技术方案内容,依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与改型,仍属于本发明技术方案的保护范围。
Claims (6)
1.一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法,其特征在于制备步骤为:
1)将重烧镁砂和微孔尖晶石按质量比50~99:1~50干混后再加水以及结合剂进行湿混;其中,微孔尖晶石体积密度< 2.60 g/cm3,气孔率> 25 %,最可几气孔孔径< 2 um;
2)使用压力机打压成半成品砖坯,在烘干窑内80 ℃~ 120 ℃条件下烘干后进入隧道窑在高于1460 ℃下烧成。
2.根据权利要求1所述的一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法,其特征在于:步骤1)所述的重烧镁砂和微孔尖晶石的粒度级配均包括粉料和颗粒料,粒度分布遵循安卓森方程,
,
式中,UDp为累计筛下百分数,%;Dpmax =4mm;q=1/2~1/3。
3.根据权利要求1所述的一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法,其特征在于:步骤1)所述的微孔尖晶石的比例在耐火砖成品中所占的质量比为1% ~50 %。
4.根据权利要求1所述的一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法,其特征在于:步骤1)所述的微孔尖晶石的比例在耐火砖成品中所占的质量比为17 % ~22 %。
5.根据权利要求1所述的一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法,其特征在于:所述的微孔尖晶石的制备工艺为:取主原料、主原料重量1.1~1.4倍的水、主原料重量0.5%~4%的发泡剂,研磨得到泥浆;泥浆经滤水、真空挤出、干燥、烧结,即得微孔尖晶石;所述主原料的重量份组成为:氧化铝50~70份、轻烧镁15~50份、菱镁矿0~15份。
6.根据权利要求5所述的一种利用人工合成的微孔尖晶石制备低导热镁铝尖晶石耐火砖的方法,其特征在于:所述的烧结中烧结温度在1600 ℃~1680 ℃,保温时间30~45分钟。
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