CN107935562A - 一种干法水泥窑高温带用无铬砖及其制备方法 - Google Patents

一种干法水泥窑高温带用无铬砖及其制备方法 Download PDF

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CN107935562A
CN107935562A CN201711253611.7A CN201711253611A CN107935562A CN 107935562 A CN107935562 A CN 107935562A CN 201711253611 A CN201711253611 A CN 201711253611A CN 107935562 A CN107935562 A CN 107935562A
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张敦明
张敦新
张哲�
李珺琪
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SHANDONG LUQIAO NEW MATERIALS Co Ltd
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Abstract

一种干法水泥窑高温带用无铬砖及其制备方法，属于耐火材料技术领域。其特征在于，所用的原料重量份组成为：锆酸钙2.68~3.22份、锆料1.67~2.31份、镁铝尖晶石1.72~2.52份、镁质砖基础物料91~94份。工艺步骤包括配料、混炼、液压成型、干燥、烧制；干燥制度为出车端温度70℃~100℃，进车端温度：30℃~50℃；推车速度为1.5~2.5h/车，干燥后残余水分小于2.0%；所述的烧制步骤中的烧成制度为：室温升温至195℃~205℃，保温7.5 h~8.5h，继续升温至985℃~1004℃，二次保温3.5 h~4.5 h。本环境友好型无铬化碱性耐火砖具有优异的物化性能，特别是烧成带耐火砖的挂窑皮性，抗熟料侵蚀性改善明显。

Description

一种干法水泥窑高温带用无铬砖及其制备方法
技术领域
一种干法水泥窑高温带用无铬砖及其制备方法，属于耐火材料技术领域。
背景技术
目前国外水泥窑烧成带广泛使用的镁白云石砖虽然挂窑皮性能优异，但镁白云石砖在生产和使用过程中需采取严密的防水化措施， 还不符合国内水泥窑的运转现状，因此在国内很少使用；另外改进的镁铝尖晶石砖虽有良好的热震稳定性能，但抗水泥熟料侵蚀性能和挂窑皮性能仍较差。回转窑内的碱氯硫的渗透和侵蚀严重，过热现象频繁，传统的下过渡带用耐火砖寿命一般只有3~4 个月。
而镁铬砖在水泥窑高温带使用后会产生致癌物质六价铬盐化合物，西方发达国家已限制或禁止镁铬砖在水泥窑上使用，但国内由于没有合适的无铬砖替代镁铬砖， 所以镁铬砖仍在国内水泥窑高温带大量使用，加剧了我国环境保护的压力。现在缺少一种具有足够的抗熟料侵蚀性的环境友好型无铬化碱性耐火砖。
发明内容
本发明要解决的技术问题是：克服现有技术的不足，提供一种物化性能优异、抗熟料侵蚀性强的干法水泥窑高温带用无铬砖及其制备方法。
本发明解决其技术问题所采用的技术方案是：该干法水泥窑高温带用无铬砖，其特征在于，所用的原料重量份组成为：锆酸钙2.68~3.22份、锆料1.67~2.31份、镁铝尖晶石1.72~2.52份、镁质砖基础物料91~94份。
本发明分别将锆酸钙、含锆料、铁铝尖晶石、镁铝尖晶石作为辅助相引入到镁质制品中，研制的环境友好型无铬化碱性耐火砖具有优异的物化性能，特别是烧成带耐火砖的挂窑皮性，抗熟料侵蚀性改善明显，其中镁钙锆砖和新型镁铝尖晶石在新型干法水泥窑上使用取得了良好的实用效果。
优选的，所述的锆料为斜锆石或锆英石。在本发明中优选的锆料为上述两种天然矿石，能够在提供本发明所需的氧化锆，还包含对本发明有益的微量元素，使本产品的显气孔率更小，抗熟料侵蚀性更好。
优选的，所述的镁质砖基础物料为菱镁矿或镁砂。优选的镁质砖基础物料不但成本更小，而且能够满足本发明的性能需求，保证产品的体积密度大，显气孔率小，从而能更好的保证抗熟料侵蚀性。
无铬砖的体积密度为3.09 g/cm3 ~3.14g/cm3 ，显气孔率15.3%~16.8%，1000℃时热膨胀率1.07%~1.18% 。本发明的产品按照上述配方结合本发明的制备工艺能够达到此物化性能，此物化性能能充分的保证烧成带耐火砖的挂窑皮性，抗熟料侵蚀性。
一种上述干法水泥窑高温带用无铬砖的制备方法，其特征在于：工艺步骤包括按原料重量份组成进行配料、混炼、液压成型、干燥、烧制；
所述的干燥步骤中干燥制度为出车端温度70℃~100℃，进车端温度：30℃~50℃；推车速度为1.5~2.5h/车， 干燥后残余水分小于2.0%；
所述的烧制步骤中的烧成制度为：室温升温至195℃~205℃，升温速率为27℃/h ~33℃/h，在195℃~205℃首次保温7.5 h ~8.5h，然后继续升温至985℃~1004℃，升温速率为27℃/h ~33℃/h，在985℃~1004℃二次保温3.5 h ~4.5 h。
本发明的制备方法采用特定的物料配比后，改进烧成制度，本发明中的物料配比使得成型的坯体在不含铬的情况下能够在1000℃左右的低温下完成熔融烧制，烧制过程中因为没有达到过高的温度，使得本发明制备的无铬砖不但具有更小的热膨胀，还使体积密度大大的增加。而且优化干燥工艺，与物料配比相适应，能够防止干躁过程中出现坯体裂痕，保证干燥后的成品率。
优选的，所述的液压成型步骤中采用1000吨液压成型机压实成型。与普通的工业烧成带耐火砖相比本发明生产的无铬砖采用1000吨液压成型机压实成型，既维持了焦炉设计部门对砖型的原设计又提高了砖的使用寿命，能够更好的保证烧制的成品率。
优选的，优选的，所述的烧制步骤中的烧成制度中首次保温的温度为200℃，保温时间为8h。
所述的烧制步骤中的烧成制度中二次保温的温度为985℃，保温时间为3.5h。
优选的保温温度和时间能够更好的保证本产品具有小的热膨胀、更大的体积密度和更小的显气孔。且配合其它优选的工艺条可以在更低的温度下，更短的时间内二次保温完成。
与现有技术相比，本发明种干法水泥窑高温带用无铬砖及其制备方法所具有的有益效果是：本发明的新型干法水泥窑高温带用无铬砖（镁钙锆）砖，作为烧成带耐火砖的挂窑皮性、抗熟料侵蚀性得到了大大的提高，能够正常使用12个月以上。本干法水泥窑高温带用无铬砖（镁钙锆砖）具备优异的抗碱氯硫和水泥熟料液相的侵蚀性能，很适合在强碱侵蚀及过热现象频繁的水泥窑过渡带上使用。
具体实施方式
下面结合具体实施例对本发明做进一步说明，其中实施例1为最佳实施。
实施例1
配料，按原料的重量份组成：锆酸钙2.94份、锆英石2.02份、镁铝尖晶石2.14份、菱镁矿或镁砂92份；
混炼，将称量好的物料在混炼机中进行混炼；
液压成型，采用1000吨液压成型机压实成型为标准砖；
干燥，干燥制度为出车端温度85℃，进车端温度：40℃；推车速度为2.0h/车， 干燥后残余水分为1.6%；
烧制，烧成制度为：室温升温至200℃，升温速率为30℃/h，在200℃首次保温7.5 h ~8.5h8h，然后继续升温至985℃，升温速率为30℃/h，在985℃二次保温3.5h，冷却即得。
实施例2
配料，按原料的重量份组成：锆酸钙3.11份、锆英石1.78份、镁铝尖晶石2.32份、菱镁矿或镁砂92份；
混炼，将称量好的物料在混炼机中进行混炼；
液压成型，采用1000吨液压成型机压实成型为标准砖；
干燥，干燥制度为出车端温度80℃，进车端温度：45℃；推车速度为1.8h/车， 干燥后残余水分为1.7%；
烧制，烧成制度为：室温升温至202℃，升温速率为31℃/h，在202℃首次保温7.8h，然后继续升温至989℃，升温速率为31℃/h，在989℃二次保温3.8h，冷却即得。
实施例3
配料，按原料的重量份组成：锆酸钙2.82份、斜锆石2.18份、镁铝尖晶石1.89份、菱镁矿或镁砂93份；
混炼，将称量好的物料在混炼机中进行混炼；
液压成型，采用1000吨液压成型机压实成型为标准砖；
干燥，干燥制度为出车端温度90℃，进车端温度：35℃；推车速度为2.2h/车， 干燥后残余水分1.6%；
烧制，烧成制度为：室温升温至198℃，升温速率为29℃/h，在198℃首次保温8.2h，然后继续升温至993℃，升温速率为29℃/h，在993℃二次保温3.6h，冷却即得。
实施例4
配料，按原料的重量份组成：锆酸钙2.68份、锆英石2.31份、镁铝尖晶石1.72份、菱镁矿或镁砂94份；
混炼，将称量好的物料在混炼机中进行混炼；
液压成型，采用1000吨液压成型机压实成型为标准砖；
干燥，干燥制度为出车端温度70℃，进车端温度：30℃；推车速度为1.5h/车， 干燥后残余水分为2.0%；
烧制，烧成制度为：室温升温至195℃，升温速率为27℃/h，在195℃首次保温8.5h，然后继续升温至1004℃，升温速率为33℃/h，在1004℃二次保温4h，冷却即得。
实施例5
配料，按原料的重量份组成：锆酸钙3.22份、斜锆石1.67份、镁铝尖晶石2.52份、菱镁矿或镁砂91份；
混炼，将称量好的物料在混炼机中进行混炼；
液压成型，采用1000吨液压成型机压实成型为标准砖；
干燥，干燥制度为出车端温度100℃，进车端温度：50℃；推车速度为2.5h/车， 干燥后残余水分为1.4%；
烧制，烧成制度为：室温升温至205℃，升温速率为33℃/h，在205℃首次保温7.5 h，然后继续升温至985℃，升温速率为27℃/h，在985℃二次保温4.5 h，冷却即得。
对比例1
制备过程同实施例1，不同的是原料的重量份组成：锆酸钙2.94份、锆英石2.02份、镁铝尖晶石2.14份、菱镁矿或镁砂80份。
对比例2
制备过程同实施例1，不同的是出车端温度120℃，进车端温度：60℃；推车速度为2.0h/车， 干燥后残余水分为1.2%。
实施例和对比例的性能检测见表1
表1 实施例和对比例的性能检测结果
。
以上所述，仅是本发明的较佳实施例而已，并非是对本发明作其它形式的限制，任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以变更或改型为等同变化的等效实施例。但是凡是未脱离本发明技术方案内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与改型，仍属于本发明技术方案的保护范围。

Claims (8)

1.一种干法水泥窑高温带用无铬砖，其特征在于，所用的原料重量份组成为：锆酸钙2.68~3.22份、锆料1.67~2.31份、镁铝尖晶石1.72~2.52份、镁质砖基础物料91~94份。
2.根据权利要求1所述的一种干法水泥窑高温带用无铬砖，其特征在于：所述的锆料为斜锆石或锆英石。
3.根据权利要求1所述的一种干法水泥窑高温带用无铬砖，其特征在于：所述的镁质砖基础物料为菱镁矿或镁砂。
4.根据权利要求1所述的一种干法水泥窑高温带用无铬砖，其特征在于：无铬砖的体积密度为3.09 g/cm3 ~3.14g/cm3 ，显气孔率15.3%~16.8%，1000℃时热膨胀率1.07%~1.18% 。
5.一种权利要求1~4任一项所述的干法水泥窑高温带用无铬砖的制备方法，其特征在于：工艺步骤包括按原料重量份组成进行配料、混炼、液压成型、干燥、烧制；
所述的干燥步骤中干燥制度为出车端温度70℃~100℃，进车端温度：30℃~50℃；推车速度为1.5~2.5h/车， 干燥后残余水分小于2.0%；
所述的烧制步骤中的烧成制度为：室温升温至195℃~205℃，升温速率为27℃/h ~33℃/h，在195℃~205℃首次保温7.5 h ~8.5h，然后继续升温至985℃~1004℃，升温速率为27℃/h ~33℃/h，在985℃~1004℃二次保温3.5 h ~4.5 h。
6.根据权利要求5所述的一种干法水泥窑高温带用无铬砖的制备方法，其特征在于：所述的液压成型步骤中采用1000吨液压成型机压实成型。
7.根据权利要求5所述的一种干法水泥窑高温带用无铬砖的制备方法，其特征在于：所述的烧制步骤中的烧成制度中首次保温的温度为200℃，保温时间为8h。
8.根据权利要求5所述的一种干法水泥窑高温带用无铬砖的制备方法，其特征在于：所述的烧制步骤中的烧成制度中二次保温的温度为985℃，保温时间为3.5h。
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