CN106986620A - 硅酸钠窑炉专用复合浇注料 - Google Patents
硅酸钠窑炉专用复合浇注料 Download PDFInfo
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- 239000004115 Sodium Silicate Substances 0.000 title claims abstract description 17
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 title claims abstract description 17
- 229910052911 sodium silicate Inorganic materials 0.000 title claims abstract description 17
- 235000019795 sodium metasilicate Nutrition 0.000 title claims abstract description 14
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 39
- 239000000843 powder Substances 0.000 claims abstract description 33
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 18
- 239000002994 raw material Substances 0.000 claims abstract description 12
- 239000004568 cement Substances 0.000 claims abstract description 11
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 10
- 239000010431 corundum Substances 0.000 claims abstract description 10
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 10
- 239000011863 silicon-based powder Substances 0.000 claims abstract description 10
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000004411 aluminium Substances 0.000 claims abstract description 8
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 8
- 239000010703 silicon Substances 0.000 claims abstract description 8
- 235000019832 sodium triphosphate Nutrition 0.000 claims abstract description 8
- 239000010439 graphite Substances 0.000 claims abstract description 7
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 7
- 239000003595 mist Substances 0.000 claims abstract description 6
- 239000002245 particle Substances 0.000 claims description 30
- 150000001875 compounds Chemical class 0.000 claims description 10
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 6
- 238000000034 method Methods 0.000 claims description 5
- FPAFDBFIGPHWGO-UHFFFAOYSA-N dioxosilane;oxomagnesium;hydrate Chemical compound O.[Mg]=O.[Mg]=O.[Mg]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O FPAFDBFIGPHWGO-UHFFFAOYSA-N 0.000 claims description 3
- 239000000395 magnesium oxide Substances 0.000 claims description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 3
- 238000012216 screening Methods 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 238000010334 sieve classification Methods 0.000 claims description 2
- 238000010792 warming Methods 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 17
- 229910052799 carbon Inorganic materials 0.000 abstract description 2
- 238000012360 testing method Methods 0.000 abstract description 2
- 229940125810 compound 20 Drugs 0.000 abstract 1
- JAXFJECJQZDFJS-XHEPKHHKSA-N gtpl8555 Chemical compound OC(=O)C[C@H](N)C(=O)N[C@@H](CCC(O)=O)C(=O)N[C@@H](C(C)C)C(=O)N[C@@H](C(C)C)C(=O)N1CCC[C@@H]1C(=O)N[C@H](B1O[C@@]2(C)[C@H]3C[C@H](C3(C)C)C[C@H]2O1)CCC1=CC=C(F)C=C1 JAXFJECJQZDFJS-XHEPKHHKSA-N 0.000 abstract 1
- 239000007788 liquid Substances 0.000 description 5
- 239000002131 composite material Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 3
- 238000012856 packing Methods 0.000 description 3
- 239000011734 sodium Substances 0.000 description 3
- 229910052708 sodium Inorganic materials 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- UNXRWKVEANCORM-UHFFFAOYSA-I triphosphate(5-) Chemical compound [O-]P([O-])(=O)OP([O-])(=O)OP([O-])([O-])=O UNXRWKVEANCORM-UHFFFAOYSA-I 0.000 description 3
- 238000004078 waterproofing Methods 0.000 description 3
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- RAHZWNYVWXNFOC-UHFFFAOYSA-N Sulphur dioxide Chemical compound O=S=O RAHZWNYVWXNFOC-UHFFFAOYSA-N 0.000 description 2
- 238000009835 boiling Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 238000010669 acid-base reaction Methods 0.000 description 1
- 230000003487 anti-permeability effect Effects 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000002817 coal dust Substances 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000011981 development test Methods 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 239000003546 flue gas Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 238000005215 recombination Methods 0.000 description 1
- 230000006798 recombination Effects 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- ORVGYTXFUWTWDM-UHFFFAOYSA-N silicic acid;sodium Chemical compound [Na].O[Si](O)(O)O ORVGYTXFUWTWDM-UHFFFAOYSA-N 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 229910052938 sodium sulfate Inorganic materials 0.000 description 1
- 235000011152 sodium sulphate Nutrition 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000010257 thawing Methods 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
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- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3418—Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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Abstract
一种硅酸钠窑炉专用复合浇注料，由如下重量份的原料组成：板刚玉40‑45份；复合矾土20‑25份；α氧化铝微粉2‑12份；拉法基水泥2‑10份；硅微粉1‑7份；石墨1‑5份；金属铝粉0.5‑1份；金属硅粉2‑5份；致密刚玉粉7‑10份；三聚磷酸钠0.2‑0.4份。本发明的硅酸钠窑炉专用复合浇注料，耐火度高达1790℃，在110℃时耐压强度大于10MPa，体密度达到2.85‑2.9g/cm3，抗侵蚀强度高，经工业化试验，其实际使用寿命达到12个月以上，较现有技术的同类材料使用寿命高4‑6个月。此外本发明的材料具有良好的流动性，易脱模，不会发生粘包等不良现象。
Description
技术领域
本发明涉及一种耐火材料组合物，具体涉及一种硅酸钠窑炉专用复合浇注料，用于窑具模内浇筑或浇筑预制砖砌筑或窑壁窑顶喷涂。
背景技术
硅酸钠窑炉中使用高速火焰冲击加热，高速火焰直接喷射到硅酸钠原料——石英砂、硫酸钠、煤粉等混合材料和融化沸腾的液面上，原料经1400℃高温发生酸碱反应从而产生很强的腐蚀液体沸腾冲击和大量的二氧化硫烟气冷却转换为强硫酸，对液池内壁、窑炉顶部形成腐蚀脱落，造成窑炉使用周期短、频繁停产大修的状况。现有技术的硅酸纳窑炉内使用的浇注料使用寿命短，通常炉龄在6-8个月左右，因此，需要频繁地大修更换炉料，导致生产效率低下，产品产量降低，生产成本增加等。
发明内容
鉴于上述现有技术状况，经反复研究试验，研发出一种硅酸钠窑炉专用复合浇注料。解决目前的浇注料抗侵蚀与抗渗透性差，炉龄短导致生产成本高的问题。
一种硅酸钠窑炉专用复合浇注料，其特征是由如下重量份的原料组成：板刚玉40-45份；复合矾土20-25份；α氧化铝微粉2-12份；拉法基水泥2-10份；硅微粉1-7份；石墨1-5份；金属铝粉0.5-1份；金属硅粉2-5份；致密刚玉粉7-10份；三聚磷酸钠0.2-0.4份。
所述的硅酸钠窑炉专用复合浇注料，其特征是所述的板刚玉与复合矾土为骨料，所述板刚玉的粒径小于等于8㎜；
所述的复合矾土由如下工艺制得：分别取如下重量份的原料：氧化镁粉料30份，氧化铝粉料50份，滑石粉20份，上述粉料取325目筛下物，加水5-8份混合搅拌并成型为块状，入炉升温至1500℃烧结3小时，经10小时逐渐降温至200℃以下出炉，继续冷却至室温后粉碎并过筛分级，其中：粒径小于等于1㎜的占25%;1㎜＜粒径≤3㎜的占15%；3㎜＜粒径≤5㎜的占25%；5㎜＜粒径≤8㎜的占15%；8㎜＜粒径≤15㎜的占20%。
所述的硅酸钠窑炉专用复合浇注料，其特征是所述的α氧化铝微粉粒径≤1.5µm，所述的硅微粉粒径≤5µm；所述的石墨、金属铝粉、金属硅粉、致密刚玉粉、三聚磷酸钠粒径≤325目；所述的拉法基水泥采用SECAR-71拉法基水泥。
本发明的硅酸钠窑炉专用复合浇注料，耐火度高达1790℃，在110℃时耐压强度大于10MPa，体密度达到2.85-2.9g/cm3，抗侵蚀强度高，经工业化试验，其实际使用寿命达到12个月以上，较现有技术的同类材料使用寿命高4-6个月。此外本发明的材料具有良好的流动性，易脱模，不会发生粘包等不良现象。本发明的复合浇注料利用复合刚玉、复合矾土作为骨料以提高耐火浇注料的强度，石墨的润滑性和硅微粉使得耐火浇注料的流动性增加，多种细粉料复合在一起可提高耐火浇注料的抗侵蚀抗渗透功能。同时石墨与多种细粉料复合后不会与液体硅酸钠发生反应，也不会污染硅酸钠液体，赛卡71水泥保证耐火浇注料浇筑过程中快速凝结定型，耐火浇注料在同时硅微粉、复合细粉中的氧化硅与氧化铝细粉在高温烧结过程中生成莫来石相与复合刚玉、复合矾土相结合，因此提高了耐火浇注料的强度和抗侵蚀、抗渗透性能。
具体实施方式
实施例1
步骤制作复合矾土，分别取氧化镁粉料300公斤；氧化铝粉料500公斤；滑石粉200公斤，上述粉料均取325目筛下料，加水50-80公斤并搅拌均匀，入成型机，加压10-15 MPa，成型为边长5-10cm立方体，入烧结炉升温8小时，温度达到1500℃时保持3小时，然后经10小时降温至200℃出炉，继续冷却至室温，将所得立方体复合矾土块料入磨料机粉碎并过筛，将筛下物按粒径分级：其中粒径小于等于1㎜的物料占比25%;1㎜＜粒径≤3㎜的物料占比15%；3㎜＜粒径≤5㎜的物料占比25%；5㎜＜粒径≤8㎜的物料占比15%；8㎜＜粒径≤15㎜的物料占比20%，将上述物料均匀混合备用；
步骤② 分别取如下原料：40公斤粒径小于或等于8㎜的板刚玉；25公斤复合矾土；粒径≤1.5µm的α氧化铝微粉5公斤；市售SECAR-71拉法基水泥2公斤；粒径≤5µm的硅微粉3公斤；325目筛下石墨粉1公斤；325目筛下金属铝粉0.5公斤；325目筛下金属硅粉3公斤；325目筛下致密刚玉粉10公斤；325目筛下三聚磷酸钠粉0.2公斤；
步骤③ 将步骤②所得各物料均匀混合，经防水包装后入库。
实施例2
分别取如下原料：45公斤粒径小于或等于8㎜的板刚玉；20公斤按实施例1中步骤所述方法制作的复合矾土；粒径≤1.5µm的α氧化铝微粉12公斤；市售SECAR-71拉法基水泥8公斤；粒径≤5µm的硅微粉1公斤；325目筛下石墨粉3公斤；325目筛下金属铝粉0.8公斤；325目筛下金属硅粉2公斤；325目筛下致密刚玉粉8公斤；325目筛下三聚磷酸钠粉0.3公斤；将上述各原料均匀混合，经防水包装后入库。
实施例3
分别取如下原料：43公斤粒径小于或等于8㎜的板刚玉；22公斤按实施例1中步骤所述方法制作的复合矾土；粒径≤1.5µm的α氧化铝微粉2公斤；市售SECAR-71拉法基水泥10公斤；粒径≤5µm的硅微粉7公斤；325目筛下石墨粉5公斤；325目筛下金属铝粉1公斤；325目筛下金属硅粉5公斤；325目筛下致密刚玉粉7公斤；325目筛下三聚磷酸钠粉0.4公斤；将上述各原料均匀混合，经防水包装后入库。
Claims (3)
1.一种硅酸钠窑炉专用复合浇注料，其特征是由如下重量份的原料组成：板刚玉40-45份；复合矾土20-25份；α氧化铝微粉2-12份；拉法基水泥2-10份；硅微粉1-7份；石墨1-5份；金属铝粉0.5-1份；金属硅粉2-5份；致密刚玉粉7-10份；三聚磷酸钠0.2-0.4份。
2.根据权利要求1所述的硅酸钠窑炉专用复合浇注料，其特征是所述的板刚玉与复合矾土为骨料，所述板刚玉的粒径小于等于8㎜；
所述的复合矾土由如下工艺制得：分别取如下重量份的原料：氧化镁粉料30份，氧化铝粉料50份，滑石粉20份，上述粉料取325目筛下物，加水5-8份混合搅拌并成型为块状，入炉升温至1500℃烧结3小时，经10小时逐渐降温至200℃以下出炉，继续冷却至室温后粉碎并过筛分级，其中：粒径小于等于1㎜的占25%;1㎜＜粒径≤3㎜的占15%；3㎜＜粒径≤5㎜的占25%；5㎜＜粒径≤8㎜的占15%；8㎜＜粒径≤15㎜的占20%。
3.根据权利要求1或2所述的硅酸钠窑炉专用复合浇注料，其特征是所述的α氧化铝微粉粒径≤1.5µm，所述的硅微粉粒径≤5µm；所述的石墨、金属铝粉、金属硅粉、致密刚玉粉、三聚磷酸钠粒径≤325目；所述的拉法基水泥采用SECAR-71拉法基水泥。
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