CN106986660B - 一种无油蜂窝陶瓷蓄热体及其制备方法 - Google Patents

一种无油蜂窝陶瓷蓄热体及其制备方法 Download PDF

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CN106986660B
CN106986660B CN201710287380.5A CN201710287380A CN106986660B CN 106986660 B CN106986660 B CN 106986660B CN 201710287380 A CN201710287380 A CN 201710287380A CN 106986660 B CN106986660 B CN 106986660B
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朱立全
陈鑫
唐婕
梁海龙
赵春林
吴彦霞
黄瀚涛
王献忠
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Jiangxi Xinke Environment Protection Co ltd
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Abstract

本发明申请提供了一种无油蜂窝陶瓷蓄热体，由以下重量份数的组分制备而成：助挤剂混合溶液15～25份、羟丙基纤维素0.5～1.0份、莫来石粉90～110份、电气石粉20～30份、苏州土5～10份，所述助挤剂混合溶液由以下重量份数的组分组成：水90～110份、聚氧化乙烯1～5份、聚丙烯酰胺1～5份、铝溶胶5～15份，在生产过程中不产生黑烟，具有健康环保、机械强度高、耐磨损、成本低、生产周期短等特点，可广泛适应于蓄热式炉窑设备中。本发明申请还提供了一种无油蜂窝陶瓷蓄热体的制备方法。

Description

一种无油蜂窝陶瓷蓄热体及其制备方法
【技术领域】
本发明涉及工业陶瓷领域，具体涉及一种无油蜂窝陶瓷蓄热体及其制备方法。
【背景技术】
随着制造工业的快速发展，能源紧缺是21世纪国际社会所面临的最大问题之一。作为能量之首的热能，在工业生产中的浪费越来越引人注目。为了节约能源浪费，蓄热式燃烧技术在工业炉窑设备中的应用，为提高热能利用率和提高燃烧效率起到了至关重要的作用，可有效的节约大量的能源。在蓄热式燃烧技术当中，蜂窝陶瓷蓄热体直接影响到蓄热式炉窑设备的节能水平和燃烧效率。
目前在国内现有技术中生产蜂窝陶瓷蓄热体，传统的配方为：刚玉莫来石粉、高岭土、氧化铝微粉、氧化硅微粉、羟丙基甲基纤维素、水、桐油与菜籽油。其传统生产工艺为：混料、捏合、挤压成型、微波定型、烘箱或烘房干燥、切割、吹灰、装窑、烧成。传统的配方中的桐油或菜籽油作为助挤剂，在干燥和焙烧过重产生大量的黑烟，长期危害工人身体健康和车间空气质量。其工艺所生产的蜂窝陶瓷蓄热体所需能耗大，生产周期短，占产品制造成本的25％左右；而且生产过程消耗大量能源，焙烧产生大量黑烟，严重污染环境。
CN 101066882A公开了一种不用桐油少用纤维素的蜂窝陶瓷的生产方法，具体包括1)将糯米磨成粉，加水，加蒸汽煮熟；2)加入3～5％的面粉熬成面糊状；3)加入20～30％的铝溶胶或硅溶胶，放入球磨机中研磨；4)磨好的浆过80目筛，作为蜂窝陶瓷临时粘合剂；5)在配好的蜂窝陶瓷原料中加入18～23％的临时粘合剂，0.5～0.8％的羧甲基纤维素，进行捏合，真空练泥，挤压成型，干燥，烧制成蜂窝陶瓷。该方法可以有效的降低生产成本，但是粘合剂制备工序复杂。所以，目前陶瓷蓄热体缺乏节能环保、简便低廉的生产工艺。
【发明内容】
本发明所要解决的技术问题是，针对以上现有技术的缺点，提供一种无油蜂窝陶瓷蓄热体及其制备方法，能够在生产过程中不产生黑烟。
本发明的技术方案是：一种无油蜂窝陶瓷蓄热体，它由以下重量份数的组分制备而成：助挤剂混合溶液15～25份、羟丙基纤维素(HPC)0.5～1.0份、莫来石粉90～110份、电气石粉20～30份、苏州土5～10份。
优选地，所述助挤剂混合溶液由以下重量份数的组分组成：水90～110份、聚氧化乙烯(PEO)1～5份、聚丙烯酰胺(PAM)1～5份、铝溶胶5～15份。
优选地，所述铝溶胶的固含量为15～25％。
一种无油蜂窝陶瓷蓄热体的制备方法，它包括以下步骤：
1)制备助挤剂混合溶液；
2)按照质量配比，将羟丙基纤维素、莫来石粉、电气石粉、苏州土干混20～30min，得到干粉，然后向干粉中加入助挤剂混合溶液，捏合30～60min，得到捏合泥料；
3)将捏合泥料真空练泥2～3遍，挤出成型，得到胚体；
4)将胚体经过微波定型5～10min，干燥1～3h，切割；
5)将步骤4)切割好的胚体在1400～1600℃焙烧4～6h，即得成品。
优选地，所述助挤剂混合溶液通过如下方法制备：将水加热至60～100℃，向水中加入PEO，搅拌至PEO完全溶解，再向PEO溶液中缓慢加入PAM，搅拌至PAM完全成絮状粘稠溶液，然后加入铝溶胶，搅拌均匀后冷却至室温，即得助挤剂混合溶液。PEO具有润滑性，但因其有机挥发性烧结时造成损失，且成本高。PAM能使泥料之间结丝，提高泥料的可塑性。铝溶胶也具有润滑性，但不会挥发，且成本较低，与PEO、PAM结合可以高效的增加并保持泥料的润滑性和粘度，取代了传统配方的油。助挤剂混合溶液含有有机润滑性的PEO助挤剂和无机润滑性能的铝溶胶助挤剂以及使溶液呈现絮状粘稠性能的PAM，增加泥料的可塑性和润滑性，有助于挤出成型，不粘磨具。
优选地，所述步骤3)中挤出成型根据挤出磨具孔型，得到三角孔、四方孔、六方孔或圆孔的蜂窝状胚体。
优选地，所述步骤4)中干燥条件为红外干燥。物料内部分子吸收了远红外线辐射能量直接转变为热量，从而使蜂窝内、外升温均匀，样品不易开裂，速度快、节能、高效。微波定型与红外干燥联合干燥，干燥效果好，可连续性生产。
优选地，所述无油蜂窝陶瓷蓄热体的密度大于等于2.5g/cm3。密度大可保证蜂窝陶瓷蓄热体的结实，增加抗压强度。
本发明具有以下有益的技术效果：
1)配方中不含油，在生产过程中耗氧少，不会产生黑烟，不会对环境和人身造成影响，更加环保；
2)羟丙基纤维素粘度受pH与温度影响小，而且在焙烧过程中灰分极少；
3)微波定型与红外干燥联合干燥，生产更加连续、周期更短；
4)铝溶胶练泥时作为无机润滑剂，煅烧过程中作为无机烧结剂；铝溶胶可增加并保持泥料的润滑性和粘度，高温烧结时转化成Al2O3与莫来石粉和电气石粉结合，增加其稳定性和抗压强度；
5)电气石粉的添加，大大提高了蓄热体的强度，耐磨损，制备成本更低。
【具体实施方式】
以下结合具体实施例，对本发明做进一步描述。
以下所提供的实施例并非用以限制本发明所涵盖的范围，所描述的步骤也不是用以限制其执行顺序。本领域技术人员结合现有公知常识对本发明做显而易见的改进，亦落入本发明要求的保护范围之内。
实施例一
一种无油蜂窝陶瓷蓄热体，它由以下重量份数的组分制备而成：助挤剂混合溶液20份、羟丙基纤维素1份、莫来石粉100份、电气石粉30份、苏州土10份。
所述助挤剂混合溶液由以下重量份数的组分组成：水100份、聚氧化乙烯1份、聚丙烯酰胺1份、固含量为15％的铝溶胶15份。
一种无油蜂窝陶瓷蓄热体的制备方法，它包括以下步骤：
1)制备助挤剂混合溶液：将100kg水加热至65℃，向水溶液中缓慢加入1kg的PEO，搅拌至PEO完全溶解，再向PEO溶液中缓慢加入1kg的PAM，搅拌至PAM完全成絮状粘稠溶液，然后继续向溶液中加入15kg铝溶胶，搅拌均匀后冷却至室温；
2)按照质量配比，将羟丙基纤维素、莫来石粉、电气石粉、苏州土干混30min，得到干粉，然后向干粉中加入助挤剂混合溶液，捏合60min，得到捏合泥料；
3)将捏合泥料真空练泥3遍，挤出成型，得到四方孔的蜂窝状胚体；
4)将胚体经过微波定型10min，放入红外干燥网带窑干燥3h，切割；
5)将步骤4)切割好的胚体在1600℃焙烧6h，即得成品。
实施例二
一种无油蜂窝陶瓷蓄热体，它由以下重量份数的组分制备而成：助挤剂混合溶液20份、羟丙基纤维素0.8份、莫来石粉100份、电气石粉25份、苏州土10份。
所述助挤剂混合溶液由以下重量份数的组分组成：水100份、聚氧化乙烯2份、聚丙烯酰胺2份、固含量为25％的铝溶胶12份。
一种无油蜂窝陶瓷蓄热体的制备方法，它包括以下步骤：
1)制备助挤剂混合溶液：将100kg水加热至70℃，向水溶液中缓慢加入2kg的PEO，搅拌至PEO完全溶解，再向PEO溶液中缓慢加入2kg的PAM，搅拌至PAM完全成絮状粘稠溶液，然后继续向溶液中加入12kg铝溶胶，搅拌均匀后冷却至室温；
2)按照质量配比，将羟丙基纤维素、莫来石粉、电气石粉、苏州土干混30min，得到干粉，然后向干粉中加入助挤剂混合溶液，捏合50min，得到捏合泥料；
3)将捏合泥料真空练泥3遍，挤出成型，得到四方孔的蜂窝状胚体；
4)将胚体经过微波定型10min，放入红外干燥网带窑干燥3h，切割；
5)将步骤4)切割好的胚体在1550℃焙烧6h，即得成品。
实施例三
一种无油蜂窝陶瓷蓄热体，它由以下重量份数的组分制备而成：助挤剂混合溶液20份、羟丙基纤维素0.8份、莫来石粉100份、电气石粉20份、苏州土10份。
所述助挤剂混合溶液由以下重量份数的组分组成：水100份、聚氧化乙烯3份、聚丙烯酰胺3份、固含量为15％的铝溶胶10份。
一种无油蜂窝陶瓷蓄热体的制备方法，它包括以下步骤：
1)制备助挤剂混合溶液：将100kg水加热至75℃，向水溶液中缓慢加入3kg的PEO，搅拌至PEO完全溶解，再向PEO溶液中缓慢加入3kg的PAM，搅拌至PAM完全成絮状粘稠溶液，然后继续向溶液中加入10kg铝溶胶，搅拌均匀后冷却至室温；
2)按照质量配比，将羟丙基纤维素、莫来石粉、电气石粉、苏州土干混30min，得到干粉，然后向干粉中加入助挤剂混合溶液，捏合50min，得到捏合泥料；
3)将捏合泥料真空练泥2遍，挤出成型，得到六方孔或圆孔的蜂窝状胚体；
4)将胚体经过微波定型8min，放入红外干燥网带窑干燥2h，切割；
5)将步骤4)切割好的胚体在1500℃焙烧5h，即得成品。
实施例四
一种无油蜂窝陶瓷蓄热体，它由以下重量份数的组分制备而成：助挤剂混合溶液20份、羟丙基纤维素0.5份、莫来石粉100份、电气石粉20份、苏州土8份。
所述助挤剂混合溶液由以下重量份数的组分组成：水100份、聚氧化乙烯4份、聚丙烯酰胺4份、固含量为25％的铝溶胶8份。
一种无油蜂窝陶瓷蓄热体的制备方法，它包括以下步骤：
1)制备助挤剂混合溶液：将100kg水加热至85℃，向水溶液中缓慢加入4kg的PEO，搅拌至PEO完全溶解，再向PEO溶液中缓慢加入4kg的PAM，搅拌至PAM完全成絮状粘稠溶液，然后继续向溶液中加入8kg铝溶胶，搅拌均匀后冷却至室温；
2)按照质量配比，将羟丙基纤维素、莫来石粉、电气石粉、苏州土干混30min，得到干粉，然后向干粉中加入助挤剂混合溶液，捏合40min，得到捏合泥料；
3)将捏合泥料真空练泥2遍，挤出成型，得到圆孔的蜂窝状胚体；
4)将胚体经过微波定型5min，放入红外干燥网带窑干燥2h，切割；
5)将步骤4)切割好的胚体在1450℃焙烧5h，即得成品。
实施例五
一种无油蜂窝陶瓷蓄热体，它由以下重量份数的组分制备而成：助挤剂混合溶液20份、羟丙基纤维素0.5份、莫来石粉100份、电气石粉20份、苏州土5份。
所述助挤剂混合溶液由以下重量份数的组分组成：水100份、聚氧化乙烯5份、聚丙烯酰胺5份、固含量为20％的铝溶胶5份。
一种无油蜂窝陶瓷蓄热体的制备方法，它包括以下步骤：
1)制备助挤剂混合溶液：将100kg水加热至100℃，向水溶液中缓慢加入5kg的PEO，搅拌至PEO完全溶解，再向PEO溶液中缓慢加入5kg的PAM，搅拌至PAM完全成絮状粘稠溶液，然后继续向溶液中加入5kg铝溶胶，搅拌均匀后冷却至室温；
2)按照质量配比，将羟丙基纤维素、莫来石粉、电气石粉、苏州土干混30min，得到干粉，然后向干粉中加入助挤剂混合溶液，捏合40min，得到捏合泥料；
3)将捏合泥料真空练泥2遍，挤出成型，得到三角孔的蜂窝状胚体；
4)将胚体经过微波定型5min，放入红外干燥网带窑干燥2h，切割；
5)将步骤4)切割好的胚体在1400℃焙烧4h，即得成品。
产品测试：
孔型：三角孔、四方孔、六方孔；
孔尺寸：150×150×100mm、120×120×100mm、100×100×100mm、80×80×100mm；
密度：≧2.5g/cm3；
热膨胀系数(室温-1500℃):≦2.0×10-6·℃-1；
轴向抗压强度≥15Mpa、径向抗弯强度≥40Mpa。
Figure DEST_PATH_IMAGE001
热膨胀系数小说明高温条件下蜂窝不变形，焙烧收缩小，焙烧不易开裂。由于高温不变形，所以蜂窝陶瓷蓄热体的使用温度高。
密度大，抗压强，轴向抗压强度和径向抗弯强度都很大，说明该发明的无油蜂窝陶瓷蓄热体稳定耐压。

Claims (7)

1.一种无油蜂窝陶瓷蓄热体，其特征在于，它由以下重量份数的组分制备而成：助挤剂混合溶液15～25份、羟丙基纤维素0.5～1.0份、莫来石粉90～110份、电气石粉20～30份、苏州土5～10份；所述助挤剂混合溶液由以下重量份数的组分组成：水90～110份、聚氧化乙烯1～5份、聚丙烯酰胺1～5份、铝溶胶5～15份。
2.根据权利要求1所述的无油蜂窝陶瓷蓄热体，其特征在于，所述铝溶胶的固含量为15～25％。
3.一种如权利要求1所述的无油蜂窝蓄热体的制备方法，其特征在于，包括以下步骤：
1)制备助挤剂混合溶液；
2)按照质量配比，将羟丙基纤维素、莫来石粉、电气石粉、苏州土干混20～30min，得到干粉，然后向干粉中加入助挤剂混合溶液，捏合30～60min，得到捏合泥料；
3)将捏合泥料真空练泥2～3遍，挤出成型，得到坯 体；
4)将坯 体经过微波定型5～10min，干燥1～3h，切割；
5)将步骤4)切割好的坯 体在1400～1600℃焙烧4～6h，即得成品。
4.根据权利要求3所述的无油蜂窝蓄热体的制备方法，其特征在于，所述助挤剂混合溶液通过如下方法制备：将水加热至60～100℃，向水中加入聚氧化乙烯，搅拌至聚氧化乙烯完全溶解，再向聚氧化乙烯溶液中加入聚丙烯酰胺，搅拌至聚丙烯酰胺成絮状粘稠溶液，然后加入铝溶胶，搅拌均匀后冷却至室温，即得助挤剂混合溶液。
5.根据权利要求3所述的无油蜂窝蓄热体的制备方法，其特征在于，所述步骤3)中挤出成型可根据挤出磨具孔型，得到三角孔、四方孔、六方孔或圆孔的蜂窝状坯 体。
6.根据权利要求3所述的无油蜂窝陶瓷蓄热体的制备方法，其特征在于，所述步骤4)中干燥条件为红外干燥。
7.根据权利要求3所述的无油蜂窝陶瓷蓄热体的制备方法，其特征在于，所述无油蜂窝陶瓷蓄热体的密度大于等于2.5g/m3。
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