CN107954740A - 耐腐蚀微孔高铝矾土轻质耐火砖及其制备方法 - Google Patents
耐腐蚀微孔高铝矾土轻质耐火砖及其制备方法 Download PDFInfo
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Abstract
本发明提供一种耐腐蚀微孔高铝矾土轻质耐火砖,包括耐火砖基体和涂覆在所述耐火砖基体表面的耐高温涂层;其中,所述耐火砖基体的制备原料包括:高铝矾土熟料20%~30%、偏高岭土超细粉17%~25%、空心玻璃微珠5%~10%、膨胀石墨0.1 %~0.15%、粉煤灰20%~25%、余量为纸浆水;所述耐高温涂层的制备原料包括:氮化硅微粉20%~25%、六钛酸钾晶须3%~5%、二氧化硅气凝胶25%~43%、氧化铝微粉3%~5%、余量为水。所述耐腐蚀微孔高铝矾土轻质耐火砖具有较好的热稳定性和较高的荷重软化温度。本发明还提供一种耐腐蚀微孔高铝矾土轻质耐火砖的制备方法,该方法步骤简单、易于自动化生产。
Description
技术领域
本发明属于耐火材料技术领域,具体的说,涉及了一种耐腐蚀微孔高铝矾土轻质耐火砖及其制备方法。
背景技术
耐火材料由于对高温介质良好的抗侵蚀性,以及具有保温隔热的性能, 在冶金、石化、玻璃等高温行业被广泛使用。随着我国对节能降耗的重视程度不断提高,具有良好保温隔热效果的轻质耐火材料得到了更多的研究与发展。不定形耐火材料由于具有施工便利、生产成本低,以及衬体的整体结构性好等优势,而受到了特别的关注,其中尤以耐火浇注料应用得最为广泛。
通常使用的耐火浇注料主要为Al2O3-SiO2质材料,但这类耐火材料在石化等行业使用时,由于所处还原气氛环境的影响,会导致耐火材料的损毁加剧,从而使得材料的使用寿命降低。另外,由于传统的耐火骨料中气孔尺寸较大,孔径多处于毫米级,这样当该材料在高温环境中使用时,由于通过气孔内气体辐射传热与对流传热的加剧,会使耐火材料的导热系数升高,进而降低了耐火材料的隔热保温效果,增大了热能的流失,导致能源成本的上升。
为了解决以上存在的问题,人们一直在寻求一种理想的技术解决方案。
发明内容
本发明的目的是针对现有技术的不足,从而提供一种具有较高的抗热震性、较好的隔热保温效果的耐腐蚀微孔高铝矾土轻质耐火砖。
为了实现上述目的,本发明所采用的技术方案是:一种耐腐蚀微孔高铝矾土轻质耐火砖,它包括耐火砖基体和涂覆在所述耐火砖基体表面的耐高温涂层;其中,所述耐火砖基体的制备原料包括:高铝矾土熟料20%~30%、偏高岭土超细粉17%~25%、空心玻璃微珠5%~10%、膨胀石墨0.1 %~0.15%、粉煤灰20%~25%、余量为纸浆水;所述耐高温涂层的制备原料包括:氮化硅微粉20%~25%、六钛酸钾晶须3%~5%、二氧化硅气凝胶25%~43%、氧化铝微粉3%~5%、余量为水。
基于上述,制得所述耐火砖基体的原料包括:高铝矾土熟料25%~30%、偏高岭土超细粉20%~23%、空心玻璃微珠8%~10%、膨胀石墨0.1%~0.15%、粉煤灰20%~23%、余量为纸浆水;制得所述耐高温涂层的原料包括:氮化硅微粉23%~25%、六钛酸钾晶须4%~5%、二氧化硅气凝胶30%~40%、氧化铝微粉4%~5%、余量为水。
基于上述,所述高铝矾土熟料的粒度为1 mm~3 mm。
基于上述,所述偏高岭土超细粉的粒度小于0.074 mm。
基于上述,所述空心玻璃微珠粒度小于0.074 mm。
本发明还一种耐腐蚀微孔高铝矾土轻质耐火砖的制备方法,包括以下步骤:
按照上述质量百分数的原料计算,将高铝矾土熟料、偏高岭土超细粉、空心玻璃微珠、膨胀石墨、粉煤灰和纸浆水进行混碾制得混碾泥料,将所述混碾泥料压制成砖坯并干燥;
将氮化硅微粉、六钛酸钾晶须、二氧化硅气凝胶氧化铝微粉和水混合制得耐高温涂料然后将干燥后的所述砖坯浸渍在所述耐高温涂料中制得涂覆砖坯,所述涂覆砖坯经干燥、煅烧后制得所述耐腐蚀微孔高铝矾土轻质耐火砖。
基于上述,将所述混碾泥料压制成砖坯,并将所述砖坯在自然干燥24小时后置于干燥窑内,在100℃~200℃的温度条件下干燥24小时~48小时;然后将干燥后的所述砖坯浸渍在所述耐高温涂料中制得涂覆砖坯,并在1100℃~1350℃的温度下对其进行煅烧10小时~24小时,从而制得所述耐腐蚀微孔高铝矾土轻质耐火砖。
本发明所提供的耐腐蚀微孔高铝矾土轻质耐火砖原料中各成分的性能作用如下:
高铝矾土熟料:是指铝矾土矿物经过煅烧后的物料,其主要成分为水铝石和高铝硅石,具有较高的耐烧性能,常用来制备各种高铝砖,是冶金工业和其它工业广泛使用的耐火或防腐材料。
偏高岭土超细粉:偏高岭土是高岭土在适当温度下脱水形成的无水硅酸铝。偏高岭土中原子排列顺序是不规则的,呈现热力学介稳状态,在适当激发下具有胶凝性。当温度升至925℃时开始结晶生成莫来石和方石英。晶体主要由硅氧四面体和氢氧八面体组成,其中硅氧四面体以共用顶角的方式沿着二维方向连结形成六方排列的网格层。高岭土具有强的耐酸性能、良好的电绝缘性和较高的耐火性能,耐火度与高岭土的化学组成有关,纯的高岭土的耐火度一般在1700℃左右,当水云母、长石含量多,钾、钠、铁含量高时,耐火度降低,偏高岭土的耐火度最低不小于1500℃。
空心玻璃微珠:空心玻璃微珠是近年来发展起来的一种用途广泛、性能优异的新型材料,该产品的主要成分是硼硅酸盐,粒度为10-250微米、壁厚为1-2微米的空心球体。该产品具有质轻、低导热、强度高和良好的化学稳定性等优点,还具有绝缘、自润滑、隔音、不吸水、耐火、耐腐蚀、防辐射、无毒等优异性能。空心玻璃微珠是由无机材料构成的,按化学成分有:二氧化硅、氧化铝、氧化锆、氧化镁、硅酸钠等。其粒径十到几百微米,为内部充斥CO2气体的封闭微型球体。空心玻璃微珠具有明显的减轻重量和隔音保温效果,使制品具有很好的抗龟裂性能和再加工性能,被广泛地使用在隔热涂料等领域。
膨胀石墨:膨胀石墨是由天然石墨鳞片经插层、水洗、干燥、高温膨化得到的一种疏松多孔的蠕虫状物质。其除了具备天然石墨本身的耐冷热、耐腐蚀、自润滑等优良性能以外,还具有天然石墨所没有的柔软、压缩回弹性、吸附性、生态环境协调性、生物相容性、耐辐射性等特性。膨胀石墨遇高温可瞬间体积膨胀150~300倍,由片状变为蠕虫状,从而结构松散,多孔而弯曲,表面积扩大、表面能提高、吸附鳞片石墨力增强,蠕虫状石墨之间可自行嵌合,这样增加了它的柔软性、回弹性和可塑性。
氮化硅微粉:相对密度3.18,熔点:1900℃,具有高强度、高弹性模量、低热膨胀率,以及优良的耐热性、电绝缘性、化学稳定性等特性。β型比α型在高温条件下稳定性更高,硬度大,莫氏硬度9,纤维直径0.1~0.6 μm,纤维长5~200 μm,常用作高温陶瓷复合材料和特殊金属复合材料,亦可作绝热材料使用,氮化硅微粉与氧化铝微粉在高温条件下会生成Sialon晶须。
六钛酸钾晶须:是精细钛酸钾纤维的商品名称,具有比玻璃纤维和石墨纤维更为优异的特性,具有质轻、低导热、强度高和良好的化学稳定性等优点。
二氧化硅气凝胶:是由若干Si-O-Si基团相互连接聚集形成的纳米三维网络骨架结构,由于近无穷多纳米孔的存在,固体热传递只能沿着孔壁传递,近无穷多气孔壁构成了近于“无穷长路径”效应,使得固体热导率降到几乎最低极限。其介孔尺寸为2~50nm,当材料中的气孔直径<70nm时,孔内的空气分子就失去了自由流动的能力,相对地附着在气孔壁上,此时,纳米孔处于近似真空状态,材料中的空气对流减弱到最小极限。由于空气的主要成分是氮气和氧气,局域热激发无法通过空气分子跨越凝胶表面进行对流作用,从而对热对流传热产生隔绝作用。
本发明相对现有技术具有突出的实质性特点和显著的进步,具体的说,本发明首先将不同粒度及长度的高铝矾土熟料、偏高岭土超细粉、空心玻璃微珠、膨胀石墨土、粉煤灰进行混合,使得制备的砖坯各个部位成分配比搭配一致,保证了煅烧所得的耐腐蚀微孔高铝矾土轻质耐火砖各部位性能的一致性,同时原料中含有大量棱角突出的粒度料,增大了临界粒度,为耐腐蚀微孔高铝矾土轻质耐火砖提供了牢固的骨架结构使其在使用过程中不易产生变形。同时,本发明将所述砖坯浸渍在由氮化硅微粉、氧化铝微粉、六钛酸钾晶须和二氧化硅气凝胶混合制备的耐高温涂料中,使得烧制后的砖坯表面形成一层耐高温层,提升了产品的耐高温和表面抗腐蚀性能。
本发明充分利用膨胀石墨与上述原料混合,使得材料内部在多时间内生产大量微小气孔,且所述微小气孔不会随烧结过程的进行而聚集长大,最终在产品中形成微米级且均匀分布的气孔,使得制备的耐腐蚀微孔高铝矾土轻质耐火砖具有高荷软、低蠕变、高抗热震性能。
具体实施方式
下面通过具体实施方式,对本发明的技术方案做进一步的详细描述。
实施例1
本实施例提供一种耐腐蚀微孔高铝矾土轻质耐火砖,它包括耐火砖基体和涂覆在所述耐火砖基体表面的耐高温涂层;其中,所述耐火砖基体的原料包括:高铝矾土熟料30%、偏高岭土超细粉20%、空心玻璃微珠9%、膨胀石墨0.1 %、粉煤灰20.9%、纸浆水20%;所述耐高温涂层的原料包括:氮化硅微粉25%、六钛酸钾晶须5%、二氧化硅气凝胶40%、氧化铝微粉5%、水25%。
其中,所述高铝矾土熟料的粒度为1 mm~3 mm、所述偏高岭土超细粉的粒度小于0.074 mm、所述空心玻璃微珠长度小于1mm。各原料中的化学成分如表1所示。
表1、各原料主要化学成分
本实施例还提供一种所述耐腐蚀微孔高铝矾土轻质耐火砖的制备方法,具体制备步骤包括:
(1)按照上述质量百分数的原料计算,将高铝矾土熟料、偏高岭土超细粉、空心玻璃微珠、膨胀石墨、粉煤灰和纸浆水进行混碾制得混碾泥料;将氮化硅微粉、六钛酸钾晶须、二氧化硅气凝胶、氧化铝微粉和水混合制得耐高温涂料;
(2)采用压力吨位大于315吨的制砖机将所述混碾泥料压制成砖坯,并将所述砖坯在自然干燥24小时后置于干燥窑内,在200℃的温度条件下干燥24小时;然后将干燥后的砖坯浸渍在所述耐高温涂料中制得涂覆砖坯,并在1100℃的温度下对其进行煅烧24小时,从而制得所述耐腐蚀微孔高铝矾土轻质耐火砖。经检测,本实施例制得的所述耐腐蚀微孔高铝矾土轻质耐火砖密度为0.8 g/cm3。
实施例2
本实施例提供一种耐腐蚀微孔高铝矾土轻质耐火砖,它包括耐火砖基体和涂覆在所述耐火砖基体表面的耐高温涂层;其中,所述耐火砖基体的原料包括:高铝矾土熟料20%、偏高岭土超细粉25%、空心玻璃微珠10%、膨胀石墨0.1 %、粉煤灰24.9%;所述耐高温涂层的原料包括:氮化硅微粉25%、六钛酸钾晶须5%、二氧化硅气凝胶35%、氧化铝微粉5%、水30%。
本实施例所述的耐腐蚀微孔高铝矾土轻质耐火砖的制备方法与实施例1中的制备方法相同。经检测,本实施例制得的所述耐腐蚀微孔高铝矾土轻质耐火砖密度为0.9 g/cm3。
实施例3
本实施例提供一种耐腐蚀微孔高铝矾土轻质耐火砖,它包括耐火砖基体和涂覆在所述耐火砖基体表面的耐高温涂层;其中,所述耐火砖基体的原料包括:高铝矾土熟料27%、偏高岭土超细粉23%、空心玻璃微珠9%、膨胀石墨0.15%、粉煤灰20.85%、纸浆水20%;所述耐高温涂层的原料包括:氮化硅微粉20%、六钛酸钾晶须3%、二氧化硅气凝胶20%、氧化铝微粉3%、水54%。
本实施例所述的耐腐蚀微孔高铝矾土轻质耐火砖的制备方法与实施例1中的制备方法相同。经检测,本实施例制得的所述耐腐蚀微孔高铝矾土轻质耐火砖密度为1.13 g/cm3。
耐腐蚀微孔高铝矾土轻质耐火砖性能检测
分别对实施例1~3制备的耐腐蚀微孔高铝矾土轻质耐火砖中的体积密度、平均孔径、耐火度、常温耐压强度和1350℃高温抗折强度性能进行检测,检测结果如表2所示。
表2、耐腐蚀微孔高铝矾土轻质耐火砖性能检测
从上表中可以看出:实施例1~3提供的耐腐蚀微孔高铝矾土轻质耐火砖的耐火软化点大于1750℃、常温耐压强度大于30MPa、平均孔径介于5微米~7微米之间、体积密度介于0.8g/cm3~1.2 g/cm3之间,因此所述耐腐蚀微孔高铝矾土轻质耐火砖各项性能指标符合GB/T3994-2013规定的指标,所述耐腐蚀微孔高铝矾土轻质耐火砖内部存在均匀分布的微米级气孔,同时该产品具有载荷软化温度高、高抗热震的性能的优点。
最后应当说明的是:以上实施例仅用以说明本发明的技术方案而非对其限制;尽管参照较佳实施例对本发明进行了详细的说明,所属领域的普通技术人员应当理解:依然可以对本发明的具体实施方式进行修改或者对部分技术特征进行等同替换;而不脱离本发明技术方案的精神,其均应涵盖在本发明请求保护的技术方案范围当中。
Claims (7)
1.一种耐腐蚀微孔高铝矾土轻质耐火砖,其特征在于,它包括耐火砖基体和涂覆在所述耐火砖基体表面的耐高温涂层;其中,所述耐火砖基体的制备原料包括:高铝矾土熟料20%~30%、偏高岭土超细粉17%~25%、空心玻璃微珠5%~10%、膨胀石墨0.1 %~0.15%、粉煤灰20%~25%、余量为纸浆水;所述耐高温涂层的制备原料包括:氮化硅微粉20%~25%、六钛酸钾晶须3%~5%、二氧化硅气凝胶25%~43%、氧化铝微粉3%~5%、余量为水。
2.根据权利要求1所述的耐腐蚀微孔高铝矾土轻质耐火砖,其特征在于,所述耐火砖基体的制备原料包括:高铝矾土熟料25%~30%、偏高岭土超细粉20%~23%、空心玻璃微珠8%~10%、膨胀石墨0.1%~0.15%、粉煤灰20%~23%、余量为纸浆水;所述耐高温涂层的制备原料包括:氮化硅微粉23%~25%、六钛酸钾晶须4%~5%、二氧化硅气凝胶30%~40%、氧化铝微粉4%~5%、余量为水。
3.根据权利要求1或2所述的耐腐蚀微孔高铝矾土轻质耐火砖,其特征在于,所述高铝矾土熟料的粒度为1 mm~3 mm。
4.根据权利要求3所述的耐腐蚀微孔高铝矾土轻质耐火砖,其特征在于,所述偏高岭土超细粉的粒度小于0.074 mm。
5.根据权利要求4所述的耐腐蚀微孔高铝矾土轻质耐火砖,其特征在于,所述空心玻璃微珠粒度小于0.074 mm。
6.一种耐腐蚀微孔高铝矾土轻质耐火砖的制备方法,包括以下步骤:
按照权利要求1~5任一项所述质量百分数的原料计算,将高铝矾土熟料、偏高岭土超细粉、空心玻璃微珠、膨胀石墨、粉煤灰和纸浆水进行混碾制得混碾泥料,将所述混碾泥料压制成砖坯并干燥;
将氮化硅微粉、六钛酸钾晶须、二氧化硅气凝胶氧化铝微粉和水混合制得耐高温涂料然后将干燥后的所述砖坯浸渍在所述耐高温涂料中制得涂覆砖坯,所述涂覆砖坯经干燥、煅烧后制得所述耐腐蚀微孔高铝矾土轻质耐火砖。
7.根据权利要求6所述的耐腐蚀微孔高铝矾土轻质耐火砖的制备方法,其特征在于,将所述混碾泥料压制成砖坯,并将所述砖坯在自然干燥24小时后置于干燥窑内,在100℃~200℃的温度条件下干燥24小时~48小时;然后将干燥后的所述砖坯浸渍在所述耐高温涂料中制得涂覆砖坯,并在1100℃~1350℃的温度下对其进行煅烧10小时~24小时,从而制得所述耐腐蚀微孔高铝矾土轻质耐火砖。
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CN109987952A (zh) * | 2019-04-25 | 2019-07-09 | 郑州振东科技有限公司 | 尖晶石质钢包保温衬砖 |
CN114105617A (zh) * | 2021-12-02 | 2022-03-01 | 郑州荣盛窑炉耐火材料有限公司 | 一种水泥回转窑用抗扭拉耐磨耐火砖及其制备方法 |
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CN109608210B (zh) * | 2018-12-21 | 2022-05-13 | 茂名高岭科技有限公司 | 一种偏高岭土基耐火材料及其制备方法 |
CN109987952A (zh) * | 2019-04-25 | 2019-07-09 | 郑州振东科技有限公司 | 尖晶石质钢包保温衬砖 |
CN114105617A (zh) * | 2021-12-02 | 2022-03-01 | 郑州荣盛窑炉耐火材料有限公司 | 一种水泥回转窑用抗扭拉耐磨耐火砖及其制备方法 |
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