CN107382328A - 一种刚玉莫来石浇注料及其制备方法 - Google Patents

一种刚玉莫来石浇注料及其制备方法 Download PDF

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CN107382328A
CN107382328A CN201710419795.3A CN201710419795A CN107382328A CN 107382328 A CN107382328 A CN 107382328A CN 201710419795 A CN201710419795 A CN 201710419795A CN 107382328 A CN107382328 A CN 107382328A
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伊国民
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Zhejiang Deqing Weiye New Material Co Ltd
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Abstract

一种刚玉莫来石浇注料的制备方法，其特征在于所述制备方法包括如下步骤：基质粉料预混合：刚玉细粉、α‑Al2O3微粉、SiO2微粉、生石灰、氧化铁红、水泥、复合型外加剂按照设定的比例，放入球磨机中混合30‑50分钟，以使SiO2微粉和Al2O3微粉充分混合均匀，混好的基质粉料密封保存后待用；将称取好的刚玉颗粒、莫来石颗粒和预先混合好的基质粉料放入强制式搅拌机中混合5～15分钟，外加占物料总重量5～8％的水混合搅拌均匀后，注入清洁干净并固定好的模具中，放在振动台上震动成型或使用振动棒分层震动成型，待表面泛浆后即可。

Description

一种刚玉莫来石浇注料及其制备方法
技术领域
本发明涉及一种刚玉莫来石浇注料及其制备方法，用于新建或老窑炉修补、改造施工，广泛使用于冲天炉、矿热炉等各类工业窑炉，属于炉窑的浇注料技术领域。
背景技术
现有的低水泥耐火浇注制品是20世纪后期得到迅猛发展的新一代耐火材料，它集多种耐火浇注料的优点于一身，具有高密度、高强度、低气孔、耐磨损、耐热震、抗侵蚀和抗渗透等特点，同时还具有体积稳定性强和施工用水量低等特性被广泛应用，使用效果较好和社会经济效益显著。而且随着优质、高性能、高品味原料的不断涌现，高效减水剂、添加剂及结合剂等的引入，粒度分布范围的优化，新型混料设备、施工设备及先进施工方法的采用，不定性耐火材料在材质、品种、性能、施工、应用等方面的发展十分活跃，新产品层出不穷。
目前，以莫来石为原材料的水泥窑用浇注料存在高温强度比较低，热稳定性不好等缺点，以现有的浇注料为例，通常最高使用温度为1400～1600℃之间，耐压强度和抗折强度低，1100℃线变化率为-0.5％～-0.3％之间，抗热震性差，常温耐磨性≥4.8cc(经1100℃烧后)，使用时，加水量大，通常为 6％～7％，普遍无法满足水泥窑窑口、喷煤管等部位的长时间使用。
发明内容
本发明的目的在于克服现有技术存在的不足，而提供一种施工工期短，养护和烘烤操作简便，预制件整体性能好、强度高、耐磨损、易施工，使用寿命长的刚玉莫来石浇注料及其制备方法。
本发明的目的是通过如下技术方案来完成的，一种刚玉莫来石浇注料，所述的浇注料由以下组分组成：
粒度0.05-1mm的刚玉颗粒 55-70%
粒度小于0.06mm的刚玉细粉 7-15%
粒度小于1mm的莫来石颗粒 8-11%
粒度小于3μm的α-Al2O3微粉 6-10%
粒度小于1μm的SiO2微粉 1-3%
生石灰 2-4%
氧化铁红 2-4%
水泥 3-5%
复合型外加剂 0.5-1.5%，
以上各组分是以质量百分比的100%为准。
作为优选：所述的浇注料由以下组分组成：60%的刚玉颗粒，所述的刚玉颗粒粒度0.05-1mm；11%的刚玉细粉，所述刚玉细粉的粒度小于0.06mm；9%的莫来石颗粒，所述莫来石颗粒的粒度小于1mm；7%的α-Al2O3微粉，所述α-Al2O3微粉的粒度小于3μm；2%的SiO2微粉，所述SiO2微粉的粒度小于1μm；3%的生石灰；3%的氧化铁红；4%的水泥；1%的复合型外加剂。
作为优选：所述刚玉的化学成分要求为：Al2O3≥99.0％；莫来石化学成分要求为：Al2O3+SiO2≥97.0％；SiO2微粉采用的是进口微粉，其成分要求为：SiO2≥97.5％；所述的水泥为硅酸盐或铝酸钙水泥中的至少一种；所述的复合型外加剂由柠檬酸水溶液、化学纯磷酸三钠溶液以及木质素磺酸钙溶液按照2-3.5：1.25-1.5：1-2比例混合而成；
一种如上所述刚玉莫来石浇注料的制备方法，所述制备方法包括如下步骤 ：
(1) 基质粉料预混合：刚玉细粉、α-Al2O3微粉、SiO2微粉、生石灰、氧化铁红、水泥、复合型外加剂按照设定的比例，放入球磨机中混合30-50分钟，以使SiO2微粉和Al2O3微粉充分混合均匀，混好的基质粉料密封保存后待用；
(2) 将称取好的刚玉颗粒、莫来石颗粒和预先混合好的基质粉料放入强制式搅拌机中混合5～15分钟，外加占物料总重量5～8％的水混合搅拌均匀后，注入清洁干净并固定好的模具中，放在振动台上震动成型或使用振动棒分层震动成型，待表面泛浆后即可 ；
(3) 浇注成型后养护2～4天脱模，随后在100～120℃温度下干燥 不少于24 小时，待水分充分排出后，将制品在干窑中于1600℃烧成，烧后的制品经拣选和包装后即可使用。
本发明具有施工工期短，养护和烘烤操作简便，预制件整体性能好、强度高、耐磨损、易施工，使用寿命长等特点，可适应浇注施工和修补，广泛使用于冲天炉和矿热炉等各类工业窑炉的修补和改造施工。
具体实施方式
下面将结合具体实施例对本发明作详细的介绍：本发明所述的一种刚玉莫来石浇注料，所述的浇注料由以下组分组成：
粒度0.05-1mm的刚玉颗粒 55-70%
粒度小于0.06mm的刚玉细粉 7-15%
粒度小于1mm的莫来石颗粒 8-11%
粒度小于3μm的α-Al2O3微粉 6-10%
粒度小于1μm的SiO2微粉 1-3%
生石灰 3-5%
氧化铁红 3-5%
水泥 3-5%
复合型外加剂 0.5-1.5%，
以上各组分是以质量百分比的100%为准。
本发明所述刚玉的化学成分要求为：Al2O3≥99.0％；莫来石化学成分要求为：Al2O3+SiO2≥97.0％；SiO2微粉采用的是进口微粉，其成分要求为：SiO2≥97.5％；所述的水泥为硅酸盐或铝酸钙水泥中的至少一种；所述的复合型外加剂由柠檬酸水溶液、化学纯磷酸三钠溶液以及木质素磺酸钙溶液按照2-3.5：1.25-1.5：1-2比例混合而成；
本发明所述的复合型外加剂中配制的柠檬酸溶液的浓度0.075%，磷酸三钠溶液的浓度0.05%，木质素酸钙溶液的浓度0.03%。
复合型外加剂能够在一定程度上阻碍了水泥的水化，使得水泥水化更加有序，水化形成的结构更加密实，磷酸盐成分的加入在熟料相表面形成了不浮性磷酸盐，降低了开放孔的数量，增加了封闭孔的数量，因此可以提高混凝土，也即浇注料的抗渗性和抗冻融性。另外复合型外加剂中的木质素磺酸盐属于阴离子型高分子表面活性剂，具有半胶体性质，可以在水泥水化产物之间形成膜状胶结层，该胶结层可与水化产物相互填充，相互交织，使得硬化体的孔隙率减少，密实度增加，从而使浇注料的强度得到提高。
一种如上所述刚玉莫来石浇注料的制备方法，所述制备方法包括如下步骤 ：
(1) 基质粉料预混合：刚玉细粉、α-Al2O3微粉、SiO2微粉、生石灰、氧化铁红、水泥、复合型外加剂按照设定的比例，放入球磨机中混合30-50分钟，以使SiO2微粉和Al2O3微粉充分混合均匀，混好的基质粉料密封保存后待用；
(2) 将称取好的刚玉颗粒、莫来石颗粒和预先混合好的基质粉料放入强制式搅拌机中混合5～15分钟，外加占物料总重量5～8％的水混合搅拌均匀后，注入清洁干净并固定好的模具中，放在振动台上震动成型或使用振动棒分层震动成型，待表面泛浆后即可 ；
(3) 浇注成型后养护2～4天脱模，随后在100～120℃温度下干燥 不少于24 小时，待水分充分排出后，将制品在干窑中于1600℃烧成，烧后的制品经拣选和包装后即可使用。
实施例1：本发明所述的浇注料由以下组分组成：所述的浇注料由以下组分组成：60%的刚玉颗粒，所述的刚玉颗粒粒度0.05-1mm；11%的刚玉细粉，所述刚玉细粉的粒度小于0.06mm；9%的莫来石颗粒，所述莫来石颗粒的粒度小于1mm；7%的α-Al2O3微粉，所述α-Al2O3微粉的粒度小于3μm；2%的SiO2微粉，所述SiO2微粉的粒度小于1μm；3%的生石灰；3%的氧化铁红；4%的水泥；1%的复合型外加剂，其中0.5%柠檬酸水溶液、0.23%化学纯磷酸三钠以及0.27%木质素磷酸钙。
实施例2：本发明所述的浇注料由以下组分组成：70%的刚玉颗粒，其粒度0.05-1mm；8%的刚玉细粉，其粒度小于0.06mm；8%的莫来石颗粒，其粒度小于1mm；5.5%的α-Al2O3微粉，其粒度小于3μm；1%的SiO2微粉，其粒度小于1μm；2%的生石灰；2%的氧化铁红；3%的水泥；0.5%的复合型外加剂，其中0.3%柠檬酸水溶液、0.11%化学纯磷酸三钠以及0.09%木质素磷酸钙。
实施例3：本发明所述的浇注料由以下组分组成：55%的刚玉颗粒，其粒度0.05-1mm；13%的刚玉细粉，其粒度小于0.06mm；10%的莫来石颗粒，其粒度小于1mm；7.5%的α-Al2O3微粉，其粒度小于3μm；3%的SiO2微粉，其粒度小于1μm；3%生石灰；3%的氧化铁红；4%的水泥；1.5%的复合型外加剂，其中0.55%柠檬酸水溶液、0.4%化学纯磷酸三钠以及0.55%木质素磷酸钙。
本发明的其它实施例可以在上述实施例的基础上，通过数值的简单替换即可获得无数个实施例，且这种替换是本领域技术人员能够简单实现并实施的。

Claims (4)

1.一种刚玉莫来石浇注料，其特征在于在于所述的浇注料由以下组分组成：
粒度0.05-1mm的刚玉颗粒 55-70%
粒度小于0.06mm的刚玉细粉 7-15%
粒度小于1mm的莫来石颗粒 8-11%
粒度小于3μm的α-Al2O3微粉 6-10%
粒度小于1μm的SiO2微粉 1-3%
生石灰 2-4%
氧化铁红 2-4%
水泥 3-5%
复合型外加剂 0.5-1.5%，
以上各组分是以质量百分比的100%为准。
2.根据权利要求1所述的刚玉莫来石浇注料，其特征在于在于所述的浇注料由以下组分组成：
粒度0.05-1mm的刚玉颗粒 60%
粒度小于0.06mm的刚玉细粉 11%
粒度小于1mm的莫来石颗粒 9%
粒度小于3μm的α-Al2O3微粉 7%
粒度小于1μm的SiO2微粉 2%
生石灰 3%
氧化铁红 3%
水泥 4%
复合型外加剂 1%。
3.按照权利要求1或2所述的刚玉莫来石浇注料，其特征在于所述刚玉的化学成分要求为：Al2O3≥99.0％；莫来石化学成分要求为：Al2O3+SiO2≥97.0％；SiO2微粉采用的是进口微粉，其成分要求为：SiO2≥97.5％；所述的水泥为硅酸盐或铝酸钙水泥中的至少一种；所述的复合型外加剂由柠檬酸水溶液、化学纯磷酸三钠溶液以及木质素磺酸钙溶液按照2-3.5：1.25-1.5：1-2比例混合而成。
4.一种如权利要求1或2或3所述刚玉莫来石浇注料的制备方法，其特征在于所述制备方法包括如下步骤 ：
(1) 基质粉料预混合：刚玉细粉、α-Al2O3微粉、SiO2微粉、生石灰、氧化铁红、水泥、复合型外加剂按照设定的比例，放入球磨机中混合30-50分钟，以使SiO2微粉和Al2O3微粉充分混合均匀，混好的基质粉料密封保存后待用；
(2) 将称取好的刚玉颗粒、莫来石颗粒和预先混合好的基质粉料放入强制式搅拌机中混合5～15分钟，外加占物料总重量5～8％的水混合搅拌均匀后，注入清洁干净并固定好的模具中，放在振动台上震动成型或使用振动棒分层震动成型，待表面泛浆后即可；
(3) 浇注成型后养护2～4天脱模，随后在100～120℃温度下干燥不少于24 小时，待水分充分排出后，将制品在干窑中于1600℃烧成，烧后的制品经拣选和包装后即可使用。
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