CN107176828A - 一种防粘渣的耐火砖 - Google Patents
一种防粘渣的耐火砖 Download PDFInfo
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- 238000002803 maceration Methods 0.000 claims abstract description 20
- 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 abstract description 18
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- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明属于耐火材料技术领域，具体公开了一种防粘渣的耐火砖，由以下重量份组份制备而成：硅藻土100～120份、陶瓷砂60～80份、硅微粉25～30份、氮化硅6～8份、滑石粉10～15份、钛白粉6～8份、硼化锆10～12份、分散剂1～2份、粘合剂6～10份、水350～450份、防粘渣浸渍液100～200份，粘合剂为沥青或高岭土水泥中的一种，分散剂为三聚磷酸铵、木质磺酸钙或氧化铝粉末中的一种，防粘渣浸渍液由纳米级滑石粉、磷酸铝粘结剂、氧化铬微粉、碳化硅微粉、固化剂、水制备而成。本发明的防粘渣的耐火砖具有较强的防粘渣性能，结构致密，高温下长期使用的形变小。
Description
技术领域
本发明属于耐火材料技术领域，具体涉及一种防粘渣的耐火砖。
背景技术
耐火材料是指在无荷重情况下能够抵抗不低于1580℃而不发生软化的一类耐高温材料，被广泛应用于冶金、化工、石油、硅酸盐等工业领域。耐火材料按形态可以分为定形耐火材料与不定形耐火材料。其中定形耐火材料主要是指耐火砖，由耐火黏土或其他耐火原料烧制成，按制备工艺方法来划分可分为烧成砖、不烧砖、电熔砖、耐火隔热砖；按形状和尺寸可分为标准型砖、普通砖、特异型砖，可用作建筑窑炉和各种热工装置的高温建筑材料和结构材料，并在高温下能经受各种物理化学变化和机械作用。由于耐火砖的耐火温度一般为1558℃～1770℃，耐火砖在高温下长期使用导致整体性能下降，并且大部分耐火砖的品质低、变形大、荷重软化温度低造成耐火砖表面粘渣，导致窑炉或热工装置的内衬处严重挂渣，需要停产进行清理，导致能耗、维护成本与生产成本增加，因此要求耐火砖具有较强的防粘渣能力。中国专利CN2013103050046，专利名称一种用于铸坯加热炉内耐火材料的防粘渣涂料，公开了由叶蜡石粉、高温熔融石英粉、硅酸钠、三聚磷酸钠、膨润土、鳞片石墨粉、糊精粉制成的炉内衬的防粘渣耐火涂料，该涂料中使用膨润土减少固体物沉积，膨润土易变形膨胀，以该涂料作为原料制成的耐火砖使用后存在变形大、裂纹风险，从而加剧耐火砖粘渣。
发明内容
针对耐火砖的防粘渣性能弱的问题，本发明的目的在于提供一种防粘渣的耐火砖，具有较强的防粘渣性能，耐火砖的品质高，结构致密，高温下长期使用的形变小。
本发明提供如下的技术方案：
一种防粘渣的耐火砖，由以下重量份组份制备而成：硅藻土100～120份、陶瓷砂60～80份、硅微粉25～30份、氮化硅6～8份、滑石粉10～15份、钛白粉6～8份、硼化锆10～12份、分散剂1～2份、粘合剂6～10份、水350～450份、防粘渣浸渍液100～200份。
作为本发明的一种改进，所述粘合剂为沥青或高岭土水泥中的一种。
作为本发明的一种改进，所述分散剂为三聚磷酸铵、木质磺酸钙或氧化铝粉末中的一种。
作为本发明的一种改进，所述防粘渣浸渍液由以下重量份组份混合而成：纳米级滑石粉50～60份、磷酸铝粘结剂10～15份、氧化铬微粉6～8份、碳化硅微粉5～7份、固化剂0.4～0.8份、水300～400份。
一种防粘渣的耐火砖的制备方法，包括以下步骤：
(1)将硅藻土、陶瓷砂、滑石粉分别研磨、过筛，然后混合煅烧得到煅烧料；
(2)将煅烧料、与硅微粉、氮化硅、钛白粉、硼化锆混匀后加入分散剂、粘合剂、水并充分搅拌制成可流动的泥浆状料液；
(3)将泥浆状料液注入模具浇注成砖坯，然后干燥，然后装入窑炉中煅烧制成耐火砖半成品；
(4)在耐火砖半成品表面喷涂防粘渣浸渍液，然后置于鼓风环境中干燥得到耐火砖。
作为本发明方法的一种改进，步骤(1)中过筛所用筛网的规格为1200～1500目，煅烧温度为550℃～650℃，煅烧时间2～3小时。
作为本发明方法的一种改进，步骤(3)中的煅烧温度为1200℃～1300℃，煅烧时间2～3小时。
作为本发明方法的一种改进，步骤(4)中防粘渣浸渍液的pH值为6.5～6.8，喷涂密度为0.8mL/cm2～1.2mL/cm2。
作为本发明方法的一种改进，步骤(4)中的干燥温度为130℃～150℃，干燥时间60～90分钟，空气流动速度3m/s～5m/s。
本发明的防粘渣的耐火砖以硅藻土、陶瓷砂为主料，具有较高的耐高温、耐火性能，在硅微粉作用下防止耐火砖在高温下出现变形、裂纹，防止废渣粘附。钛白粉、滑石粉可以起到防止固体物沉积的作用，且避免出现膨胀或裂纹缺陷，硼化锆与氮化硅在高温作用下形成硼化锆陶瓷结构，使耐火砖内结构致密化，阻止废渣由耐火砖表面向耐火砖内部渗透。在耐火砖半成品表面喷涂防粘渣浸渍液可以使耐火砖上形成防粘渣浸渍液成膜，强化耐火砖的抗渣性能，而且提高耐火砖的耐火性能和耐热稳定性。防粘渣浸渍液的弱酸性使耐火砖半成品形成蚀刻痕迹，使防粘渣浸渍液成膜稳定附着在耐火砖表面。
本发明的有益效果如下：
本发明的防粘渣的耐火砖，具有较强的防粘渣性能，耐火砖的品质高，结构致密，高温下长期使用的形变小。
具体实施方式
下面就本发明的具体实施方式作进一步说明：
如无特别说明，本发明中所采用的原料均可从市场上购得或是本领域常用的，如无特别说明，下述实施例中的方法均为本领域的常规方法。
实施例1
一种防粘渣的耐火砖，由以下组份制备而成：硅藻土100g、陶瓷砂60g、硅微粉25g、氮化硅6g、滑石粉10g、分散剂1g、粘合剂6g、水350g、防粘渣浸渍液100g，其中粘合剂为沥青或高岭土水泥中的一种，分散剂为三聚磷酸钠、木质磺酸钙或氧化铝粉末中的一种，防粘渣浸渍液由以下组份混合而成：纳米级滑石粉50g、磷酸铝粘结剂10g、氧化铬微粉6g、碳化硅微粉5g、固化剂0.4g、水300g。
一种防粘渣的耐火砖的制备方法，包括以下步骤：
(1)将硅藻土、陶瓷砂、滑石粉分别研磨、经1200目筛网过筛，然后在550℃下混合煅烧2小时得到煅烧料；
(2)将煅烧料、与硅微粉、氮化硅混匀后加入三聚磷酸钠、分散剂、粘合剂、水并充分搅拌制成可流动的泥浆状料液；
(3)将泥浆状料液注入模具浇注成砖坯，然后干燥，然后装入窑炉中在1200℃下煅烧2小时制成耐火砖半成品；
(4)调节防粘渣浸渍液的pH值至6.5～6.8，然后喷涂在耐火砖半成品的表面，喷涂密度为0.8mL/cm2，然后将耐火砖半成品置于鼓风环境中干燥得到耐火砖，干燥温度为130℃，干燥时间60分钟，空气流动速度3m/s。
实施例2
一种防粘渣的耐火砖，由以下组份制备而成：硅藻土110g、陶瓷砂70g、硅微粉27.5g、氮化硅7g、滑石粉12.5g、分散剂1.5g、粘合剂8g、水400g、防粘渣浸渍液150g，其中粘合剂为沥青或高岭土水泥中的一种，分散剂为三聚磷酸钠、木质磺酸钙或氧化铝粉末中的一种，防粘渣浸渍液由以下组份混合而成：纳米级滑石粉55g、磷酸铝粘结剂12.5g、氧化铬微粉7g、碳化硅微粉6g、固化剂0.6g、水350g。
一种防粘渣的耐火砖的制备方法，包括以下步骤：
(1)将硅藻土、陶瓷砂、滑石粉分别研磨、经1350目筛网过筛，然后在600℃下混合煅烧2.5小时得到煅烧料；
(2)将煅烧料、与硅微粉、氮化硅混匀后加入三聚磷酸钠、分散剂、粘合剂、水并充分搅拌制成可流动的泥浆状料液；
(3)将泥浆状料液注入模具浇注成砖坯，然后干燥，然后装入窑炉中在1250℃下煅烧2.5小时制成耐火砖半成品；
(4)调节防粘渣浸渍液的pH值至6.5～6.8，然后喷涂在耐火砖半成品的表面，喷涂密度为1.0mL/cm2，然后将耐火砖半成品置于鼓风环境中干燥得到耐火砖，干燥温度为140℃，干燥时间75分钟，空气流动速度4m/s。
实施例3
一种防粘渣的耐火砖，由以下组份制备而成：硅藻土120g、陶瓷砂80g、硅微粉30g、氮化硅8g、滑石粉15g、分散剂2g、粘合剂10g、水450g、防粘渣浸渍液200g，其中粘合剂为沥青或高岭土水泥中的一种，分散剂为三聚磷酸钠、木质磺酸钙或氧化铝粉末中的一种，防粘渣浸渍液由以下组份混合而成：纳米级滑石粉60g、磷酸铝粘结剂15g、氧化铬微粉8g、碳化硅微粉7g、固化剂0.8g、水400g。
一种防粘渣的耐火砖的制备方法，包括以下步骤：
(1)将硅藻土、陶瓷砂、滑石粉分别研磨、经1500目筛网过筛，然后在650℃下混合煅烧3小时得到煅烧料；
(2)将煅烧料、与硅微粉、氮化硅混匀后加入三聚磷酸钠、分散剂、粘合剂、水并充分搅拌制成可流动的泥浆状料液；
(3)将泥浆状料液注入模具浇注成砖坯，然后干燥，然后装入窑炉中在1300℃下煅烧2～3小时制成耐火砖半成品；
(4)调节防粘渣浸渍液的pH值至6.5～6.8，然后喷涂在耐火砖半成品的表面，喷涂密度为1.2mL/cm2，然后将耐火砖半成品置于鼓风环境中干燥得到耐火砖，干燥温度为150℃，干燥时间90分钟，空气流动速度5m/s。
性能测试
选取六个窑炉1～6，在窑炉1～3内衬涂覆对比专利CN2013103050046中的涂料，涂层厚度依次为15mm、20mm、25mm，窑炉5～6内分别以实施例1～3所得耐火砖为内衬，1600℃下进行冶炼测试，观察窑炉连续使用1个月后窑炉内有无废铁粘渣，窑炉内侧有无裂纹。结果表1所示。
表1
Claims (9)
1.一种防粘渣的耐火砖，其特征在于，由以下重量份组份制备而成：硅藻土100～120份、陶瓷砂60～80份、硅微粉25～30份、氮化硅6～8份、滑石粉10～15份、钛白粉6～8份、硼化锆10～12份、分散剂1～2份、粘合剂6～10份、水350～450份、防粘渣浸渍液100～200份。
2.根据权利要求1所述的防粘渣的耐火砖，其特征在于，所述粘合剂为沥青或高岭土水泥中的一种。
3.根据权利要求2所述的防粘渣的耐火砖，其特征在于，所述分散剂为三聚磷酸铵、木质磺酸钙或氧化铝粉末中的一种。
4.根据权利要求1或2或3所述的防粘渣的耐火砖，其特征在于，所述防粘渣浸渍液由以下重量份组份混合而成：纳米级滑石粉50～60份、磷酸铝粘结剂10～15份、氧化铬微粉6～8份、碳化硅微粉5～7份、固化剂0.4～0.8份、水300～400份。
5.一种如权利要求1所述的防粘渣的耐火砖的制备方法，包括以下步骤：
（1）将硅藻土、陶瓷砂、滑石粉分别研磨、过筛，然后混合煅烧得到煅烧料；
（2）将煅烧料、与硅微粉、氮化硅、钛白粉、硼化锆混匀后加入分散剂、粘合剂、水并充分搅拌制成可流动的泥浆状料液；
（3）将泥浆状料液注入模具浇注成砖坯，然后干燥，然后装入窑炉中煅烧制成耐火砖半成品；
（4）在耐火砖半成品表面喷涂防粘渣浸渍液，然后置于鼓风环境中干燥得到耐火砖。
6.根据权利要求5所述的防粘渣的耐火砖的制备方法，其特征在于，步骤（1）中过筛所用筛网的规格为 1200～1500目，煅烧温度为550 ℃～650 ℃，煅烧时间2～3小时。
7.根据权利要求 5所述的防粘渣的耐火砖的制备方法，其特征在于，步骤（3）中的煅烧温度为1200 ℃～1300 ℃，煅烧时间2～3小时。
8.根据权利要求5所述的防粘渣的耐火砖的制备方法，其特征在于，步骤（4）中耐火浸渍液的pH值为6.5～6.8，喷涂密度为0.8 mL/cm2～1.2 mL/cm2。
9.根据权利要求5所述的防粘渣的耐火砖的制备方法，其特征在于，步骤（4）中的干燥温度为130 ℃～150 ℃，干燥时间60～90 分钟，空气流动速度3 m/s～5 m/s。
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