CN107344859A - 一种中密度高铝碳化硅浇注料及其制备方法 - Google Patents

一种中密度高铝碳化硅浇注料及其制备方法 Download PDF

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CN107344859A
CN107344859A CN201710467091.3A CN201710467091A CN107344859A CN 107344859 A CN107344859 A CN 107344859A CN 201710467091 A CN201710467091 A CN 201710467091A CN 107344859 A CN107344859 A CN 107344859A
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parts
aggregate
particle diameter
silicon carbide
high alumina
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CN107344859B (zh
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山国强
许高
王强
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CHANGXING XING YING BUILDING MATERIAL Co Ltd OF NEW FIRE-RESISTANT
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CHANGXING XING YING BUILDING MATERIAL Co Ltd OF NEW FIRE-RESISTANT
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Abstract

本发明公开了一种中密度高铝碳化硅浇注料，其组份按质量份包括：粒径3‑8mm的轻质莫来石骨料10‑20份，粒径为3‑5mm的轻质矾土骨料10‑20份，铁钩废料10‑20份，硅莫砖废骨料10‑20份，粒径小于0.088mm碳化硅粉5‑10份，粒径小于1μm的硅微粉5‑8份，粒径小于1.2μm的Al2O3 微粉3‑5份，铝酸盐水泥3‑8份，减水剂0.03‑0.5份以及直径小于0.3mm、长度20‑25mm的合金钢纤维1.5‑2.3份。本发明所述中密度高铝碳化硅浇注料具有良好的致密性、抗热震性、耐碱耐磨性以及抗侵蚀能力，不易开裂，并且能有效节省原料，降低成本。

Description

一种中密度高铝碳化硅浇注料及其制备方法
技术领域
本发明涉及耐火材料技术领域，特别涉及一种中密度高铝碳化硅浇注料及其制备方法。
背景技术
近年来，随着新型干法水泥技术的推广发展，新型干法水泥窑的使用在国内日益成熟，工艺技术日益完善，窑用配套耐火材料的性能和要求逐渐成为影响新型干法窑窑炉运转率的重要因素之一。虽然水泥厂家都根据自身的实际情况在不同部位选择不同性能要求（耐高温、耐磨损、抗侵蚀、抗结皮等）的耐火材料，但许多部位的耐火材料实际使用寿命还是比较短，如水泥回转窑窑头罩、三次风管弯头等部位，温度高，风速大，碱性成份重，工矿条件比较苛刻，长期受到粉尘颗粒冲刷、侵蚀，耐火材料损毁很严重，四五个月就要检修一次，严重影响了水泥窑的正常运转。
这些部位常用的浇注料要求具有较好的耐磨性，较高的使用温度，常用的材料为高铝碳化硅浇注料，但材料本身的热导系数较大，散热损耗大。采用轻质骨料可以降低导热系数，但会产生局部过热的现象，材料容易裂开。因此，如何使浇注料能耐受苛刻环境，同时具有良好的保温效果并且不易开裂，成为亟待解决的问题。
发明内容
本发明要解决上述技术问题从而提供一种中密度高铝碳化硅浇注料，所述中密度高铝碳化硅浇注料具有良好的致密性、抗热震性、耐碱耐磨性以及抗侵蚀能力，不易开裂，并且能有效节省原料，降低成本。
为达到上述目的，本发明采用的具体技术方案如下：
一种中密度高铝碳化硅浇注料，其组分按重量份包括：
骨料40-80份，粒径小于0.088mm碳化硅粉5-10份，粒径小于1μm的硅微粉5-8份，粒径小于1.2μm的Al2O3 微粉3-5份，铝酸盐水泥3-8份，减水剂0.03-0.5份以及直径小于0.3mm、长度20-25mm的合金钢纤维1.5-2.3份；所述骨料包括选自粒径3-8mm的轻质莫来石骨料10-20份、粒径为3-5mm的轻质矾土骨料10-20份、铁钩废料10-20份、硅莫砖废骨料10-20份。
优选的，所述轻质莫来石骨料的重量份为15-18份，轻质矾土骨料的重量份为12-15份，铁钩废料的重量份为13-16份，硅莫砖废骨料的重量份13-16份。
优选的，所述铝酸盐水泥为铝酸钙水泥或白云石水泥。
优选的，所述减水剂为三聚磷酸钠和三聚氰胺甲醛树脂按质量比2:1混合。
优选的，所述合金钢纤维化学组成（质量百分比）为：0.03-0.18%C，9-12%Cr，4-8%Ni，0.3-0.6%Mo，0.01-0.2%Nb，＜1%Si，＜0.7%Mn，B＜0.005%，余量为Fe和不可避免的杂质。
优选的，所述中密度高铝碳化硅浇注料的密度为2.2-2.7g/cm3。
一种中密度高铝碳化硅浇注料的制备方法，包括如下步骤：将上述原料混合，加入4-5%的水搅拌均匀，搅拌好的物料注入模具，震动成型，养护48h-72h后进行烘烧，温度达到100℃时保温8-16h，温度达到350℃时保温16-24h，升温至1000℃煅烧8-12h，冷却得到浇注料预制件。
本发明具有以下有益效果：
1、本发明以轻质莫来石、轻质矾土骨料作为基体，导热系数低、密度适中，特别适合应用于各种高抗热震性炉子，如水泥回转窑、石灰窑窑头和窑尾等位置处，使用过程中能够降低散热损失，减少能源和设备动力消耗，起到改善工作环境和节能减排的作用。以氧化硅微粉和氧化铝微粉作为复合基质，利用微粉与骨料间的莫来石反应在基质与骨料间形成莫来石网络结构，提高材料整体强度及抗热震性，材料抗侵蚀能力大大增强。采用多级颗粒级配，有效提高了填充密度，降低气孔率，增强了抗侵蚀能力，并达到最佳使用及施工性能。
2、本发明采用铁钩废料和硅莫砖废骨料作为部分骨料，引入高铝材料和碳化硅，节省原料，降低成本，并使产品具有良好的耐磨性；废硅莫砖中的部分杂质成份在回转窑工作温度下能产生一定量液相促进材料烧结，从而改善材料高温使用性能。
3、本发明采用铝酸盐水泥作为结合剂，将颗粒粘结为整体，并具有一定硬度和良好的耐磨性，凝结硬化速度快，具有较高的耐热耐碱性。将复合使用的三聚磷酸钠和三聚氰胺甲醛树脂作为减水剂配合铝酸盐水泥的使用，可降低铝酸盐水泥用量，节约水泥同时提高浇注料性能，该减水剂有效克服了单一组分时缓凝较重，减水效果差的缺陷。
4、本发明通过添加合金钢纤维提高温度分布的均匀性，采用轻质骨料得到了低导热系数，加强了保温效果，使用起来具有节能的特点，但不可避免地产生浇注料局部过热易开裂的问题，本发明采用的合金钢纤维通过合理配比C、Cr、Ni、Mo、Nb 等元素的量，具有耐热、高强、抗氧化的特性，通过在混合原料中的均匀分布实现对热量的分散作用从而解决易开裂的问题，使得产品不仅节能还具有良好的抗热震性能。
5、本发明提出的中密度高铝碳化硅浇注料的制备方法中烘烧阶段采用保温、升温再保温的方式，先通过加热保温使得各种物质在热运动下变成均相，各部位的属性基本达到均匀稳定的状态；然后进一步提高温度是在此基础上，进一步提高均匀性，使得对后期的降温环节产生有利影响，降低了对降温的高要求。
具体实施方式
下面结合实施例对本发明作进一步说明。
实施例1
一种中密度高铝碳化硅浇注料，其组分按重量份包括：粒径3-8mm的轻质莫来石骨料10份，粒径为3-5mm的轻质矾土骨料12份，铁钩废料13份，硅莫砖废骨料13份，粒径小于0.088mm碳化硅粉5份，粒径小于1μm的硅微粉5份，粒径小于1.2μm的Al2O3 微粉3份，铝酸钙水泥4份，三聚磷酸钠0.02份，三聚氰胺甲醛树0.01份，以及直径小于0.3mm、长度20-25mm的合金钢纤维1.5份。
按如下步骤制备浇注料：将上述浇注料的原料混合后加入4%的水搅拌均匀，搅拌好的物料注入模具，震动成型，养护48h后进行烘烧，温度达到100℃时保温10h，温度达到350℃时保温16h，升温至1000℃煅烧8h，冷却得到浇注料预制件。
实施例2
一种中密度高铝碳化硅浇注料，其组分按重量份包括：粒径3-8mm的轻质莫来石骨料15份，粒径为3-5mm的轻质矾土骨料14份，铁钩废料13份，硅莫砖废骨料14份，粒径小于0.088mm碳化硅粉6份，粒径小于1μm的硅微粉6份，粒径小于1.2μm的Al2O3 微粉3份，铝酸钙水泥5份，三聚磷酸钠0.18份，三聚氰胺甲醛树0.09份，以及直径小于0.3mm、长度20-25mm的合金钢纤维1.8份。
按如下步骤制备浇注料：将上述浇注料的原料混合后加入4%的水搅拌均匀，搅拌好的物料注入模具，震动成型，养护60h后进行烘烧，温度达到100℃时保温12h，温度达到350℃时保温18h，升温至1000℃煅烧8h，冷却得到浇注料预制件。
实施例3
一种中密度高铝碳化硅浇注料，其组分按重量份包括：粒径3-8mm的轻质莫来石骨料18份，粒径为3-5mm的轻质矾土骨料14份，铁钩废料13份，硅莫砖废骨料14份，粒径小于0.088mm碳化硅粉8份，粒径小于1μm的硅微粉7份，粒径小于1.2μm的Al2O3 微粉4份，白云石水泥5份，三聚磷酸钠0.2份，三聚氰胺甲醛树0.1份，以及直径小于0.3mm、长度20-25mm的合金钢纤维2.0份。
按如下步骤制备浇注料：将上述浇注料的原料混合后加入5%的水搅拌均匀，搅拌好的物料注入模具，震动成型，养护64h后进行烘烧，温度达到100℃时保温12h，温度达到350℃时保温20h，升温至1000℃煅烧10h，冷却得到浇注料预制件。
实施例4
一种中密度高铝碳化硅浇注料，其组分按重量份包括：粒径5-8mm的轻质莫来石骨料20份，粒径为3-5mm的轻质矾土骨料20份，铁钩废料16份，硅莫砖废骨料15份，粒径小于0.088mm碳化硅粉10份，粒径小于1μm的硅微粉8份，粒径小于1.2μm的Al2O3微粉5份，铝酸钙水泥7份，三聚磷酸钠0.32份，三聚氰胺甲醛树0.16份，以及直径小于0.3mm、长度20-25mm的合金钢纤维2.3份。
按如下步骤制备浇注料：将上述浇注料的原料混合后加入5%的水搅拌均匀，搅拌好的物料注入模具，震动成型，养护72h后进行烘烧，温度达到100℃时保温16h，温度达到350℃时保温24h，升温至1000℃煅烧12h，冷却得到浇注料预制件。
上述实施例所得浇注料技术性能指标如下：
以上所述实施例仅仅是对本发明的解释，并不是对本发明的限制，本领域技术人员根据本发明作出的等效变换与修改，都属于本发明的保护范围。

Claims (7)

1.一种中密度高铝碳化硅浇注料，其特征在于：包括以下组分原料及重量份：骨料40-80份，粒径小于0.088mm碳化硅粉5-10份，粒径小于1μm的硅微粉5-8份，粒径小于1.2μm的Al2O3 微粉3-5份，铝酸盐水泥3-8份，减水剂0.03-0.5份以及直径小于0.3mm、长度20-25mm的合金钢纤维1.5-2.3份；所述骨料包括3-8mm的轻质莫来石骨料10-20份、粒径为3-5mm的轻质矾土骨料10-20份、铁钩废料10-20份、硅莫砖废骨料10-20份。
2.根据权利要求1所述的中密度高铝碳化硅浇注料，其特征在于：所述轻质莫来石的重量份为15-18份，轻质矾土骨料的重量份为12-15份，铁钩废料的重量份为13-16份，硅莫砖废骨料的重量份13-16份。
3.根据权利要求1所述的中密度高铝碳化硅浇注料，其特征在于：所述铝酸盐水泥为铝酸钙水泥或白云石水泥。
4.根据权利要求1所述的中密度高铝碳化硅浇注料，其特征在于：所述减水剂为三聚磷酸钠和三聚氰胺甲醛树脂按质量比2:1混合。
5.根据权利要求1所述的中密度高铝碳化硅浇注料，其特征在于：所述合金钢纤维化学组成（质量百分比）为：0.03-0.18%C，9-12%Cr，4-8%Ni，0.3-0.6%Mo，0.01-0.2%Nb，＜1%Si，＜0.7%Mn，B＜0.005%，余量为Fe和不可避免的杂质。
6.根据权利要求1所述的中密度高铝碳化硅浇注料，其特征在于：所述中密度高铝碳化硅浇注料的密度为2.2-2.7g/cm3。
7.一种中密度高铝碳化硅浇注料的制备方法，其特征在于：包括如下步骤：将权利要求1所述的原料混合，加入4-5%的水搅拌均匀，搅拌好的物料注入模具，震动成型，养护48h-72h后进行烘烧，温度达到100℃时保温8-16h，温度达到350℃时保温16-24h，升温至1000℃煅烧8-12h，冷却得到浇注料预制件。
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