CN107162618A - 一种新型耐火材料的制备方法 - Google Patents
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Abstract
一种新型耐火材料的制备方法,包括以下制备步骤:a、将煤矸石、赤泥、稀土、膨润土、氧化镁、氧化锰、氧化钛、氧化铝和增韧纤维混合进行预烧,得到材料一;b、将材料一与无水乙醇混合球磨,再烘干得到材料二;c、将材料二干压成型,制得材料三;d、将材料三进行烧结,烧结后自然冷却至室温,即可。本发明制作的耐火材料具有耐火性能好的特点,添加了增韧纤维后,其断裂韧性和抗热震性能得到提高,并且其制备方法简单,容易在现有设备上进行大规模的生产。
Description
技术领域
本发明属于耐火材料技术领域,具体涉及一种新型耐火材料的制备方法。
背景技术
在传统意义上,耐火材料是指耐火度不低于1580℃的无机非金属材料,它是为高温技术服务的基础材料,是用作高温窑炉等热工设备的结构材料,以及工业高温容器和部件的材料,并且能够承受相应的物理化学变化及机械作用。
大部分耐火材料是以天然矿石(如耐火粘土、硅石、菱镁矿、白云石)为原料制造的,采用某些工业原料和人工合成原料(如工业氧化铝、碳化硅、合成莫来石、合成尖晶石等)也日益增多,因此,耐火材料的种类很多。耐火材料按照矿物组成可以分为氧化硅质、硅酸铝质、镁质、白云石质、橄榄石质、尖晶石质、含碳质、含锆质耐火材料及特殊耐火材料;按照制造方法可以分为天然矿石和人造制品;按其方式可分为块状制品和不定形耐火材料;按照热处理方式可分为不烧制品、烧成制品和熔铸制品;按照耐火度可分为普通、高级和特级耐火制品;按照化学性质可分为酸性、中性及碱性耐火材料;按照其密度可分为轻质及重质耐火材料;按照其制品的形状和尺寸可分为标准砖、异形砖、特异形砖、管和耐火器皿;还可以按其应用分为高炉用、水泥窑用、玻璃窑用、陶瓷窑用耐火材料等。
无机非金属材料的机械韧性较差是无机非金属和材料中普遍存在的一个问题,作为同属无机非金属材料的耐火材料,其机械韧性也较差,虽然在使用过程中耐火材料几乎不需要进行移动,但是其较差的机械韧性也影响到了其高温时候的抗热震性能,在急冷急热和使用的间隙由于较大的温差耐火材料极易在热胀冷缩作用下发生开裂、剥落等影响耐火材料完整性的情况,降低了耐火材料的使用寿命;同时对于那些需要经常进行移动的耐火材料制品,其较差的机械韧性则会大大增加耐火制品的损坏率,影响其日常使用。
综上所述,因此需要一种更好的耐火材料来改善现有技术的不足。
发明内容
本发明的目的是提供一种新型耐火材料的制备方法,本发明制作的耐火材料具有耐火性能好的特点,添加了增韧纤维后,其断裂韧性和抗热震性能得到提高,并且其制备方法简单,容易在现有设备上进行大规模的生产。
本发明提供了如下的技术方案:
一种新型耐火材料的制备方法,包括以下制备步骤:
a、将煤矸石、赤泥、稀土、膨润土、氧化镁、氧化锰、氧化钛、氧化铝和增韧纤维混合均匀后,进行预烧,得到材料一;
b、将材料一与无水乙醇混合,球磨40-50min,球磨后在80-100℃下烘干,得到材料二;
c、将材料二在120-200MPa压力下干压成型,制得材料三;
d、将材料三置于2400-2600℃下烧结3-5h,烧结完成后自然冷却至室温,即可得到成品。
优选的,所述新型耐火材料包括以下重量份的原料:煤矸石22-26份、赤泥18-20份、稀土16-19份、膨润土12-16份、氧化镁12-17份、氧化锰13-15份、氧化钛12-16份、氧化铝14-18份、增韧纤维20-28份和无水乙醇30-34份。
优选的,所述步骤a的煤矸石为高硅煤矸石,氧化硅含量为50-55wt%,氧化铝含量为10-15wt%。
优选的,所述步骤a的赤泥为高铝赤泥,氧化铝含量为25-30wt%,氧化硅含量为15-20wt%,氧化钙含量为25-35wt%。
优选的,所述步骤a的增韧纤维的制作步骤为:将赤泥在1200-1500rpm转速下进行球磨,然后用水进行清洗,之后在1.5-3.5mol/L的盐酸水溶液中浸泡4-5h,过滤后是用水清洗后干燥,将处理后的赤泥与氧化镁和氧化钙混合,将混合物加热至2000-2300℃下熔融,除去不熔物进行离心甩丝,裁切后制得增韧纤维。
优选的,所述步骤a的增韧纤维的直径在0.5-0.8mm,长度为2-4mm。
优选的,所述步骤c的干压成型前,向原料中均匀喷洒原料质量10-15%的2-5mol/L的碳酸钠水溶液。
优选的,所述步骤d的预烧步骤为:将原料混合后,再加入原料重量10-13wt%的煤粉,混合均匀后将混合粉末喷入回转窑中进行烧结,升温至400-500℃保温1-2h,升温至600-800℃保温1-2h,升温至900-1000℃烧结2-3h,烧结过程中不断回转窑不断转动。
本发明的有益效果是:
本发明制作的耐火材料具有耐火性能好的特点,添加了增韧纤维后,其断裂韧性和抗热震性能得到提高,并且其制备方法简单,容易在现有设备上进行大规模的生产。
本发明的步骤d预烧中加入少量煤粉,由于材料三中的可燃物质含量有限,因此需要加入少量煤粉进行助燃,可缩短反应时间,缩短制备周期。
本发明采用矿产资源利用后的废弃物煤矸石和赤泥作为耐火材料的原料,充分利用了矿产资源利用后的废弃物,增加了矿产资源废弃物的附加值,为解决因矿产资源利用废弃物所造成的环境污染和资源浪费问题作了贡献。
本发明的步骤c干压成型前加入碳酸钠水溶液,增进干压后的致密度,也防止耐火材料块在烧结过程中松散,使用碳酸钠水溶液,一来起到造粒的作用,二来可以在粉体中添加适量的碳酸钠,碳酸钠在高温下会分解使得耐火材料中产生一些细微孔道,减轻耐火材料的自身质量,也可以增加耐火材料的隔热保温性能。
具体实施方式
实施例1
一种新型耐火材料的制备方法,包括以下制备步骤:
a、将煤矸石、赤泥、稀土、膨润土、氧化镁、氧化锰、氧化钛、氧化铝和增韧纤维混合均匀后,进行预烧,得到材料一;
b、将材料一与无水乙醇混合,球磨50min,球磨后在100℃下烘干,得到材料二;
c、将材料二在120MPa压力下干压成型,制得材料三;
d、将材料三置于2600℃下烧结5h,烧结完成后自然冷却至室温,即可得到成品。
新型耐火材料包括以下重量份的原料:煤矸石26份、赤泥20份、稀土19份、膨润土16份、氧化镁12份、氧化锰15份、氧化钛16份、氧化铝18份、增韧纤维28份和无水乙醇30份。
步骤a的煤矸石为高硅煤矸石,氧化硅含量为55wt%,氧化铝含量为15wt%。
步骤a的赤泥为高铝赤泥,氧化铝含量为30wt%,氧化硅含量为20wt%,氧化钙含量为35wt%。
步骤a的增韧纤维的制作步骤为:将赤泥在1500rpm转速下进行球磨,然后用水进行清洗,之后在3.5mol/L的盐酸水溶液中浸泡5h,过滤后是用水清洗后干燥,将处理后的赤泥与氧化镁和氧化钙混合,将混合物加热至2300℃下熔融,除去不熔物进行离心甩丝,裁切后制得增韧纤维。
步骤a的增韧纤维的直径在0.8mm,长度为4mm。
步骤c的干压成型前,向原料中均匀喷洒原料质量10%的2mol/L的碳酸钠水溶液。
步骤d的预烧步骤为:将原料混合后,再加入原料重量13wt%的煤粉,混合均匀后将混合粉末喷入回转窑中进行烧结,升温至400℃保温2h,升温至600℃保温1h,升温至1000℃烧结2h,烧结过程中不断回转窑不断转动。
实施例2
一种新型耐火材料的制备方法,包括以下制备步骤:
a、将煤矸石、赤泥、稀土、膨润土、氧化镁、氧化锰、氧化钛、氧化铝和增韧纤维混合均匀后,进行预烧,得到材料一;
b、将材料一与无水乙醇混合,球磨40min,球磨后在100℃下烘干,得到材料二;
c、将材料二在120MPa压力下干压成型,制得材料三;
d、将材料三置于2400℃下烧结5h,烧结完成后自然冷却至室温,即可得到成品。
新型耐火材料包括以下重量份的原料:煤矸石26份、赤泥20份、稀土19份、膨润土12份、氧化镁12份、氧化锰13份、氧化钛12-16份、氧化铝14份、增韧纤维28份和无水乙醇34份。
步骤a的煤矸石为高硅煤矸石,氧化硅含量为55wt%,氧化铝含量为15wt%。
步骤a的赤泥为高铝赤泥,氧化铝含量为30wt%,氧化硅含量为15wt%,氧化钙含量为25wt%。
步骤a的增韧纤维的制作步骤为:将赤泥在1200rpm转速下进行球磨,然后用水进行清洗,之后在3.5mol/L的盐酸水溶液中浸泡4h,过滤后是用水清洗后干燥,将处理后的赤泥与氧化镁和氧化钙混合,将混合物加热至2300℃下熔融,除去不熔物进行离心甩丝,裁切后制得增韧纤维。
步骤a的增韧纤维的直径在0.5mm,长度为4mm。
步骤c的干压成型前,向原料中均匀喷洒原料质量10%的2mol/L的碳酸钠水溶液。
步骤d的预烧步骤为:将原料混合后,再加入原料重量13wt%的煤粉,混合均匀后将混合粉末喷入回转窑中进行烧结,升温至500℃保温2h,升温至800℃保温2h,升温至1000℃烧结3h,烧结过程中不断回转窑不断转动。
以上所述仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (8)
1.一种新型耐火材料的制备方法,其特征在于,包括以下制备步骤:
a、将煤矸石、赤泥、稀土、膨润土、氧化镁、氧化锰、氧化钛、氧化铝和增韧纤维混合均匀后,进行预烧,得到材料一;
b、将材料一与无水乙醇混合,球磨40-50min,球磨后在80-100℃下烘干,得到材料二;
c、将材料二在120-200MPa压力下干压成型,制得材料三;
d、将材料三置于2400-2600℃下烧结3-5h,烧结完成后自然冷却至室温,即可得到成品。
2.根据权利要求1所述的一种新型耐火材料的制备方法,其特征在于,所述新型耐火材料包括以下重量份的原料:煤矸石22-26份、赤泥18-20份、稀土16-19份、膨润土12-16份、氧化镁12-17份、氧化锰13-15份、氧化钛12-16份、氧化铝14-18份、增韧纤维20-28份和无水乙醇30-34份。
3.根据权利要求1所述的一种新型耐火材料的制备方法,其特征在于,所述步骤a的煤矸石为高硅煤矸石,氧化硅含量为50-55wt%,氧化铝含量为10-15wt%。
4.根据权利要求1所述的一种新型耐火材料的制备方法,其特征在于,所述步骤a的赤泥为高铝赤泥,氧化铝含量为25-30wt%,氧化硅含量为15-20wt%,氧化钙含量为25-35wt%。
5.根据权利要求1所述的一种新型耐火材料的制备方法,其特征在于,所述步骤a的增韧纤维的制作步骤为:将赤泥在1200-1500rpm转速下进行球磨,然后用水进行清洗,之后在1.5-3.5mol/L的盐酸水溶液中浸泡4-5h,过滤后是用水清洗后干燥,将处理后的赤泥与氧化镁和氧化钙混合,将混合物加热至2000-2300℃下熔融,除去不熔物进行离心甩丝,裁切后制得增韧纤维。
6.根据权利要求1所述的一种新型耐火材料的制备方法,其特征在于,所述步骤a的增韧纤维的直径在0.5-0.8mm,长度为2-4mm。
7.根据权利要求1所述的一种新型耐火材料的制备方法,其特征在于,所述步骤c的干压成型前,向原料中均匀喷洒原料质量10-15%的2-5mol/L的碳酸钠水溶液。
8.根据权利要求1所述的一种新型耐火材料的制备方法,其特征在于,所述步骤d的预烧步骤为:将原料混合后,再加入原料重量10-13wt%的煤粉,混合均匀后将混合粉末喷入回转窑中进行烧结,升温至400-500℃保温1-2h,升温至600-800℃保温1-2h,升温至900-1000℃烧结2-3h,烧结过程中不断回转窑不断转动。
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