CN107935575A - 高纯低蠕变电熔莫来石砖及其制备方法 - Google Patents

高纯低蠕变电熔莫来石砖及其制备方法 Download PDF

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CN107935575A
CN107935575A CN201711146123.6A CN201711146123A CN107935575A CN 107935575 A CN107935575 A CN 107935575A CN 201711146123 A CN201711146123 A CN 201711146123A CN 107935575 A CN107935575 A CN 107935575A
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mullite
low creep
purity low
electric cast
electrofused
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CN107935575B (zh
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张晓峰
孙文礼
李玉强
张瑛
李志军
郑飞
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ZIBO INDUSTRIAL CERAMIC REFRACTORY MATERIAL Co Ltd
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Abstract

本发明涉及一种高纯低蠕变电熔莫来石砖及其制备方法，属于耐火材料技术领域。本发明所述的高纯低蠕变电熔莫来石砖，其原料组成如下：电熔莫来石3.35‑2mm，5‑15％；电熔莫来石2‑0.85mm，20‑30％；电熔莫来石0.85‑0.1mm，25‑35％；电熔莫来石≤0.045mm，20‑30％；α氧化铝微粉≤0.005mm，5‑8％；熔融石英微粉≤0.005mm，1‑4％；外加入的有机结合剂占上述原料总重量的0.1‑5％。本发明所述的高纯低蠕变电熔莫来石砖，杂质含量极低、荷重软化点温度高、高温下的体积稳定性好，高温蠕变率低；本发明同时提供了一种简单易行、节能环保的制备方法。

Description

高纯低蠕变电熔莫来石砖及其制备方法
技术领域
本发明涉及一种高纯低蠕变电熔莫来石砖及其制备方法，属于耐火材料技术领域。
背景技术
新一代的特种玻璃熔窑普遍采用了具有节能减排特点的全氧燃烧技术，窑炉火焰空间温度达到1600℃或以上，通常玻璃窑用的优质硅砖已无法安全使用。
中国专利申请201010171542.7(CN 101817676B)公开了一种低蠕变电熔莫来石砖及其制造方法，其制造方法为：使用高品质电熔莫来石原料与煅烧氧化铝原料和高岭土、水一起加入到研磨机进行细磨，过筛、烘干、磨碎和再次过筛，得到基质粉料；将60wt％-75wt％电熔莫来石颗粒料与40wt％-25wt％的基质粉料进行混练，再加入1.0wt％-2.0wt％的树胶液，混练，困料4-15小时后成型；烘干；和焙烧。其基质料使用高岭土，并与电熔莫来石原料和煅烧氧化铝原料进行细磨，过筛、烘干、磨碎和再次过筛。由于高岭土杂质含量较高，高温下产生较多的低温玻璃相，高温性能降低，高温蠕变量上升，对窑炉使用寿命降低较多。
中国专利申请201110285777.3(CN 102503447A)公开了一种电熔莫来石砖及其制备方法，其制备方法为：55-80％的≤3.5mm电熔莫来石颗粒，10-20％的≤0.1mm的兰晶石，10-20％的0.1-1.5mm的石英，0-5％的≤0.1mm的粘土，0-1％的2-10μm的二氧化钛；将兰晶石、石英、粘土、二氧化钛及部分电熔莫来石与油酸混合，球磨得到球磨料；将粘结剂溶解到水中，与剩余电熔莫来石混合，得到颗粒料；球磨料和颗粒料混合，混碾，陈腐，再次混练，经压力成型制成砖坯，干燥烧成。其基质料使用粘土、石英、兰晶石及二氧化钛等，引进促烧结剂以期得到较低的气孔率，较高的抗折强度和良好的抗热震性。但是，由于使用粘土、蓝晶石、氧化钛、天然石英原料，杂质含量很高，高温下产生大量的低温玻璃相，高温性能极大降低，荷重软化点降低到1350℃，高温下产生较大的蠕变，已经无法在1300℃以上的使用条件下使用。
发明内容
本发明的目的在于提供一种高纯低蠕变电熔莫来石砖，其杂质含量极低、荷重软化点温度高、高温下的体积稳定性好，高温蠕变率低；本发明同时提供了一种简单易行、节能环保的制备方法。
本发明所述的高纯低蠕变电熔莫来石砖，其组成原料的种类、粒度规格及重量百分含量如下：
外加入的有机结合剂占上述原料总重量的0.1-5％。
所使用的电熔莫来石的化学成分要求如下：Al2O3≥74％，Fe2O3≤0.1％，Na2O≤0.3％。
所述电熔莫来石的粒度规格要求如下：
(1)粒度为3.35-2mm的电熔莫来石中，≥3.35mm的重量含量≤5％，≤2mm的重量含量≤5％；
(2)粒度为2-0.85mm的电熔莫来石中，≥2mm的重量含量≤5％，≤0.85mm的重量含量≤5％；
(3)粒度为0.85-0.1mm的电熔莫来石中，≥0.85mm的重量含量≤5％，≤0.1mm的重量含量≤5％；
(4)粒度≤0.045mm的电熔莫来石中，≥0.045mm的重量含量≤3％。
所述α氧化铝微粉中化学成分要求如下：Al2O3≥99％，Fe2O3≤0.03％，Na2O≤0.2％；粒度规格要求为：D90≤5μm，D50≤2μm。
所述熔融石英微粉中化学成分的重量百分含量如下：SiO2≥99％，Fe2O3≤0.03％；粒度规格要求为：D90≤5μm，D50≤2μm。
所述有机结合剂为液体结合剂和固体结合剂的混合物，液体结合剂为聚乙烯醇或环氧树脂中的一种或两种。
所述的高纯低蠕变电熔莫来石砖的制备方法，包括以下步骤：
(1)将高温氧化铝微粉与熔融石英微粉湿法或干法共磨预混，得到预磨干粉，使用的研磨介质为氧化铝研磨球；
(2)半干法混料：使用轮碾式混料机，先将粒径为0.1mm以上的电熔莫来石颗粒料投入混料机混合均匀，再加入液体结合剂混合均匀，然后加入粒径≤0.045mm的电熔莫来石细粉、步骤(1)所得的预磨干粉、固体结合剂，混合10-20分钟，制得半干法泥料，放入成型压机料仓中困料4-5小时；
(3)成型，烘干；使用液压机或摩擦压力机成型或等静压成型；使用远红外烘干箱或其它设备烘干，烘干温度为80-120℃，保温12-48小时；
(4)烧成，使用隧道窑或梭式窑进行烧成，烧成温度为1600-1800℃，保温8-10小时，制得所述的高纯低蠕变电熔莫来石砖。
步骤(2)中，半干法混料制得的泥料的水分为2-4％，泥料的粒度规格为：大于1mm的质量占比为35-50％，小于0.08mm的质量占比为35-50％。
所述成型后所制得的生坯的密度为2.6-2.8g/cm3。
制得的高纯低蠕变电熔莫来石砖中的化学成分的重量百分含量如下：Al2O3≥75％，Fe2O3≤0.08％，Na2O≤0.2％，杂质含量≤0.8％；物理性能如下：气孔率≤14.5％，体积密度≥2.65g/cm3，常温耐压强度≥100MPa，荷重软化点温度(0.2MPa)T2≥1700℃，压蠕变率0.2MPa(1500℃×50h)的绝对值≤0.15％。
本发明与现有技术相比，具有以下有益效果：
(1)使用高纯电熔莫来石、高纯α氧化铝微粉和高纯熔融石英微粉，不使用高岭土等矿物原料，杜绝杂质引入，保证电熔莫来石砖的原料纯度；
(2)使用氧化铝微粉和熔融石英微粉，提高了充填密度和成型性能，高温烧结时通过氧化铝微粉和熔融石英微粉的莫来石化反应，提高材料的结合强度，形成了稳定的结构和良好的高温性能；
(3)通过对电熔莫来石进行颗粒级配调整，符合紧密堆积原理，减少成型时的层裂风险，提高成型合格率；
(4)采用半干法混料，使用有机结合剂替代粘土，保证成型性能和常温结合强度，摒弃传统使用粘土保证成型性能的方法；
(5)通过将氧化铝微粉与熔融石英微粉预先共磨，使两种微粉均匀混合，保证了氧化铝微粉与熔融石英微粉生成莫来石的均匀性，使电熔莫来石砖具有更优良的性能；
(6)制备的高纯低蠕变电熔莫来石砖，杂质含量极低、荷重软化点温度高、高温下的体积稳定性好，高温蠕变率低；
(7)制备方法简单易行，节能环保，利于大规模工业化生产，适用于普通燃烧和全氧燃烧无碱玻璃熔窑的火焰空间部位(大碹和窑墙)，和一般工业高温窑炉的高温内衬部位，其中用于全氧燃烧无碱玻璃窑炉碹顶部位可以使用两个窑期。
具体实施方式
下面结合实施例对本发明作进一步的说明，但其并不限制本发明的实施。
实施例1-7
所述的高纯低蠕变电熔莫来石砖，其组成原料的种类、粒度规格及重量百分含量如下：
表1
所述的高纯低蠕变电熔莫来石砖的制备方法，包括以下步骤：
(1)将高温氧化铝微粉与熔融石英微粉湿法共磨预混，得到预磨干粉，使用的研磨介质为氧化铝研磨球；
(2)半干法混料：使用轮碾式混料机，先将粒径为0.1mm以上的电熔莫来石颗粒料投入轮碾式混料机混合均匀，再加入PVA溶液混合均匀，然后向锥式混料机中加入粒径≤0.045mm的电熔莫来石细粉、步骤(1)所得的预磨干粉、纤维素干粉，混合10-20分钟，制得半干法泥料，放入成型压机料仓中困料4-5小时；
(3)成型，烘干；使用摩擦压力机成型；使用远红外烘干箱烘干，烘干温度为80-120℃，保温12-48小时；
(4)烧成，使用隧道窑或梭式窑进行烧成，烧成温度为1600-1800℃，保温8-10小时，制得所述的高纯低蠕变电熔莫来石砖。
实施例1-7制得的高纯低蠕变电熔莫来石砖的物理指标检测结果如下：
表2
实施例1-7制得的高纯低蠕变电熔莫来石砖中的化学成分组成如下：
表3
通过以上数据可以看出，实施例1制得的高纯低蠕变电熔莫来石砖的物理性能最优。

Claims (10)

1.一种高纯低蠕变电熔莫来石砖，其特征在于：其组成原料的种类、粒度规格及重量百分含量如下：
外加入的有机结合剂占上述原料总重量的0.1-5％。
2.根据权利要求1所述的高纯低蠕变电熔莫来石砖，其特征在于：所使用的电熔莫来石的化学成分要求如下：Al2O3≥74％，Fe2O3≤0.1％，Na2O≤0.3％。
3.根据权利要求1所述的高纯低蠕变电熔莫来石砖，其特征在于：电熔莫来石的粒度规格要求如下：
(1)粒度为3.35-2mm的电熔莫来石中，≥3.35mm的重量含量≤5％，≤2mm的重量含量≤5％；
(2)粒度为2-0.85mm的电熔莫来石中，≥2mm的重量含量≤5％，≤0.85mm的重量含量≤5％；
(3)粒度为0.85-0.1mm的电熔莫来石中，≥0.85mm的重量含量≤5％，≤0.1mm的重量含量≤5％；
(4)粒度≤0.045mm的电熔莫来石中，≥0.045mm的重量含量≤3％。
4.根据权利要求1所述的高纯低蠕变电熔莫来石砖，其特征在于：α氧化铝微粉中化学成分要求如下：Al2O3≥99％，Fe2O3≤0.03％，Na2O≤0.2％；粒度规格要求为：D90≤5μm，D50≤2μm。
5.根据权利要求1所述的高纯低蠕变电熔莫来石砖，其特征在于：熔融石英微粉中化学成分的重量百分含量如下：SiO2≥99％，Fe2O3≤0.03％；粒度规格要求为：D90≤5μm，D50≤2μm。
6.根据权利要求1所述的高纯低蠕变电熔莫来石砖，其特征在于：有机结合剂为液体结合剂和固体结合剂的混合物，液体结合剂为聚乙烯醇或环氧树脂中的一种或两种。
7.一种权利要求1-6任一所述的高纯低蠕变电熔莫来石砖的制备方法，其特征在于包括以下步骤：
(1)将高温氧化铝微粉与熔融石英微粉共磨预混，得到预磨干粉；
(2)半干法混料：先将粒径为0.1mm以上的电熔莫来石颗粒料投入混料机混合，再加入液体结合剂混合，然后加入粒径≤0.045mm的电熔莫来石细粉、步骤(1)所得的预磨干粉、固体结合剂，混合10-20分钟，制得半干法泥料，困料4-5小时；
(3)成型，烘干，烘干温度为80-120℃，保温12-48小时；
(4)烧成，烧成温度为1600-1800℃，保温8-10小时，制得所述的高纯低蠕变电熔莫来石砖。
8.根据权利要求7所述的高纯低蠕变电熔莫来石砖的制备方法，其特征在于：步骤(2)中，半干法混料制得的泥料的水分为2-4％，泥料的粒度规格为：大于1mm的质量占比为35-50％，小于0.08mm的质量占比为35-50％。
9.根据权利要求7所述的高纯低蠕变电熔莫来石砖的制备方法，其特征在于：成型后所制得的生坯的密度为2.6-2.8g/cm3。
10.根据权利要求7所述的高纯低蠕变电熔莫来石砖的制备方法，其特征在于：制得的高纯低蠕变电熔莫来石砖中的化学成分的重量百分含量如下：Al2O3≥75％，Fe2O3≤0.08％，Na2O≤0.2％，杂质含量≤0.8％；物理性能如下：气孔率≤14.5％，体积密度≥2.65g/cm3，常温耐压强度≥100MPa，荷重软化点温度(0.2MPa)T2≥1700℃，压蠕变率0.2MPa(1500℃×50h)的绝对值≤0.15％。
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