CN107954746A - 微孔焦宝石轻质耐火砖及其制备方法 - Google Patents
微孔焦宝石轻质耐火砖及其制备方法 Download PDFInfo
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Abstract
本发明提供一种微孔焦宝石轻质耐火砖,包括主料和纸浆水,所述主料包括下述质量百分数的物料:焦宝石大颗粒20%~30%、铝酸钙细粉18%~28%、铝硅酸盐耐火纤维25%~30%、六钛酸钾晶须5%~9%、膨胀石墨0.08%~0.12%、空心玻璃微珠3%~5%、二氧化硅气凝胶5%~9%,所述纸浆水的质量为所述主料质量的5%~8%。所述微孔焦宝石轻质耐火砖成分搭配合理、材料内部形成有均匀分布的微米级气孔,使得产品具有良好的抗热震性、较好的热稳定性和较高的荷重软化温度。本发明还提供一种上述微孔焦宝石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,涉及了一种微孔焦宝石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微孔焦宝石轻质耐火砖。
为了实现上述目的,本发明所采用的技术方案是:一种微孔焦宝石轻质耐火砖,包括主料和纸浆水,其中所述主料包括下述质量百分数的物料:焦宝石大颗粒20%~30%、铝酸钙细粉18%~28%、铝硅酸盐耐火纤维25%~30%、六钛酸钾晶须5%~9%、膨胀石墨0.08%~0.12%、空心玻璃微珠3%~5%、二氧化硅气凝胶5%~9%,所述纸浆水的质量为所述主料质量的5%~8%。
基于上述,所述主料包括下述质量百分数的物料:焦宝石大颗粒25%~28%、铝酸钙细粉22%~25%、铝硅酸盐耐火纤维26%~29%、六钛酸钾晶须6%~9%、膨胀石墨0.10%~0.12%、空心玻璃微珠3%~4%、二氧化硅气凝胶6%~9%。
基于上述,所述焦宝石大颗粒的粒度为1 mm~3 mm。
基于上述,所述铝酸钙细粉的粒度小于0.074 mm。
基于上述,所述铝硅酸盐耐火纤维长度小于1mm。
本发明还提供一种微孔焦宝石轻质耐火砖的制备方法,包括以下步骤:
(1)按照上述质量百分数的原料计算,将焦宝石大颗粒、铝酸钙细粉、铝硅酸盐耐火纤维、膨胀石墨和纸浆水进行混碾制得预制泥料;然后向所述预制泥料中加入空心玻璃微珠粉、六钛酸钾晶须和二氧化硅气凝胶并进行混碾制得混碾泥料;
(2)将所述混碾泥料压制成砖坯,所述砖坯经干燥煅烧后制得所述微孔焦宝石轻质耐火砖。
基于上述,所述步骤(2)包括: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在1100℃~1350℃的温度下进行煅烧10小时~24小时,从而制得所述微孔焦宝石轻质耐火砖。
本发明所提供的微孔焦宝石轻质耐火砖原料中各成分的性能作用如下:
焦宝石大颗粒:又称一级硬质粘土熟料,是多种含铝硅酸盐的混合物,主要化学成分为Al2O3 和SiO2,伴有少量Fe2O3和微量的Na2O、K2O,经高温煅烧后具有体积稳定、强度大及吸水率小等特性,其耐火度可达1750℃以上,从而使得制备的耐火砖具有较高的抗热震性能和较好的耐热性能。
铝酸钙细粉:铝酸钙是一系列由氧化钙和氧化铝在高温下烧结而成的无机化合物,由于其硬度大、熔点高的物理性质,被应用于水泥和灭火材料中,通式为mCaO·nAl2O3。
铝硅酸盐耐火纤维:硅酸盐中的SiO4四面体的一部分由AlO4四面体取代组成的铝硅酸盐,如正长石KAlSi3O8,也可写为K[(AlO2)(SiO2)3],表示四分之一的含氧四面体被铝原子所占据,还有钙长石CaAl2SiO8或Ca[(AlO2)2(SiO2)2],其中一半是AlO4四面体,另一半是SiO4四面体由其制成的铝硅酸盐耐火纤维具有性能稳定,纤维长、抗拉强度大,渣球少等特点。
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。
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。
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焦宝石大颗粒、铝酸钙细粉、铝硅酸盐耐火纤维、六钛酸钾晶须、膨胀石墨、空心玻璃微珠和二氧化硅气凝胶进行混合,使得制备的砖坯各个部位成分配比搭配一致,保证了煅烧所得的微孔焦宝石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,为微孔焦宝石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,本发明充分利用本身含有多孔结构的铝酸钙及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。同时,分别利用焦宝石大颗粒、铝酸钙细粉、铝硅酸盐耐火纤维、六钛酸钾晶须的耐烧特性和较好的成型性使得制备的微孔焦宝石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
本实施例提供一种微孔焦宝石轻质耐火砖,包括主料和纸浆水,其中所述主料包括下述质量百分数的物料:焦宝石大颗粒30%、铝酸钙细粉26%、铝硅酸盐耐火纤维25%、六钛酸钾晶须9%、膨胀石墨0.12%、空心玻璃微珠3.88%、二氧化硅气凝胶6%;所述纸浆水的质量为所述主料质量的5%。其中,所述焦宝石大颗粒的粒度为1 mm~3 mm、所述铝酸钙细粉的粒度小于0.074 mm、所述铝硅酸盐耐火纤维长度小于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
原料 | Al2O3 | Fe2O3 | K2O+NaO | CaO |
焦宝石大颗粒 | ≥45% | ≤1.0% | ≤1.0% | -- |
铝硅酸盐耐火纤维 | ≥80% | ≤1.5% | ≤0.6% | -- |
铝酸钙细粉 | ≥53% | -- | -- | 29%~31% |
空心玻璃微珠 | 34%~37% | ≤1.5% | ≤0.5% | -- |
本实施例还提供一种所述微孔焦宝石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,将焦宝石大颗粒、铝酸钙细粉、铝硅酸盐耐火纤维、膨胀石墨进行混碾制得预制泥料;然后向所述预制泥料中加入空心玻璃微珠粉、六钛酸钾晶须和二氧化硅气凝胶并进行混碾制得混碾泥料;
(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,然后置于干燥窑内,在200℃的温度条件下干燥24小时;然后将干燥后的所述砖坯在1350℃的温度下进行煅烧10小时,从而制得所述微孔焦宝石轻质耐火砖。经检测,本实施例制得的所述微孔焦宝石轻质耐火砖密度为1.2 g/cm3。
实施例2
本实施例提供一种微孔焦宝石轻质耐火砖,包括主料和纸浆水,其中所述主料包括下述质量百分数的物料:焦宝石大颗粒28%、铝酸钙细粉25%、铝硅酸盐耐火纤维29%、六钛酸钾晶须8%、膨胀石墨0.1%、空心玻璃微珠3.9%、二氧化硅气凝胶6%;所述纸浆水的质量为所述主料质量的8%。
本实施例所述的微孔焦宝石轻质耐火砖的制备方法与实施例1中的制备方法大致相同,不同之处在于:
将所述混碾泥料压制成砖坯,然后置于干燥窑内,在200℃的温度条件下干燥48小时;然后将干燥后的所述砖坯在1100℃的温度下进行煅烧24小时,从而制得所述微孔焦宝石轻质耐火砖。
经检测,本实施例制得的所述微孔焦宝石轻质耐火砖密度为1.0 g/cm3。
实施例3
本实施例提供一种微孔焦宝石轻质耐火砖,具体原料成分与实施例1大致相同,不同之处在于:
本实施例中,所述主料包括下述质量百分数的物料:焦宝石大颗粒20%、铝酸钙细粉28%、铝硅酸盐耐火纤维30%、六钛酸钾晶须9%、膨胀石墨0.08%、空心玻璃微珠3.92%、二氧化硅气凝胶9%。
本实施例所述的微孔焦宝石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微孔焦宝石轻质耐火砖密度为1.1 g/cm3。
微孔焦宝石轻质耐火砖性能检测
分别对实施例1~3制备的微孔焦宝石轻质耐火砖中Al2O3、Fe2O3、CaO含量、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、微孔焦宝石轻质耐火砖性能检测
从上表中可以看出:实施例1~3提供的微孔焦宝石轻质耐火砖的耐火软化点大于1700℃、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1.0 g/cm3~1.2 g/cm3之间,因此所述微孔焦宝石轻质耐火砖各项性能指标符合GB/T3994-2013规定的指标,所述微孔焦宝石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)
1.一种微孔焦宝石轻质耐火砖,包括主料和纸浆水,其特征在于,所述主料包括下述质量百分数的物料:焦宝石大颗粒20%~30%、铝酸钙细粉18%~28%、铝硅酸盐耐火纤维25%~30%、六钛酸钾晶须5%~9%、膨胀石墨0.08%~0.12%、空心玻璃微珠3%~5%、二氧化硅气凝胶5%~9%,所述纸浆水的质量为所述主料质量的5%~8%。
2.根据权利要求1所述的微孔焦宝石轻质耐火砖,其特征在于,所述主料包括下述质量百分数的物料:焦宝石大颗粒25%~28%、铝酸钙细粉22%~25%、铝硅酸盐耐火纤维26%~29%、六钛酸钾晶须6%~9%、膨胀石墨0.10%~0.12%、空心玻璃微珠3%~4%、二氧化硅气凝胶6%~9%。
3.根据权利要求1或2所述的微孔焦宝石轻质耐火砖,其特征在于,所述焦宝石大颗粒的粒度为1 mm~3 mm。
4.根据权利要求3所述的微孔焦宝石轻质耐火砖,其特征在于,所述铝酸钙细粉的粒度小于0.074 mm。
5.根据权利要求4所述的微孔焦宝石轻质耐火砖,其特征在于,所述铝硅酸盐耐火纤维长度小于1mm。
6.一种微孔焦宝石轻质耐火砖的制备方法,包括以下步骤:
(1)按照权利要求1~5任一项所述质量百分数的原料计算,将焦宝石大颗粒、铝酸钙细粉、铝硅酸盐耐火纤维、膨胀石墨和纸浆水进行混碾制得预制泥料;然后向所述预制泥料中加入空心玻璃微珠粉、六钛酸钾晶须和二氧化硅气凝胶并进行混碾制得混碾泥料;
(2)将所述混碾泥料压制成砖坯,所述砖坯经干燥煅烧后制得所述微孔焦宝石轻质耐火砖。
7.根据权利要求6所述的微孔焦宝石轻质耐火砖的制备方法,其特征在于,所述步骤(2)包括: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在1100℃~1350℃的温度下进行煅烧10小时~24小时,从而制得所述微孔焦宝石轻质耐火砖。
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EP4071125A1 (en) * | 2021-04-07 | 2022-10-12 | Vilniaus Gedimino technikos universitetas | Composition of heat-insulating lightweight composite material |
CN116217221A (zh) * | 2023-01-09 | 2023-06-06 | 中冶武汉冶金建筑研究院有限公司 | 一种高强隔热耐火泥浆的制备方法 |
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EP4071125A1 (en) * | 2021-04-07 | 2022-10-12 | Vilniaus Gedimino technikos universitetas | Composition of heat-insulating lightweight composite material |
CN116217221A (zh) * | 2023-01-09 | 2023-06-06 | 中冶武汉冶金建筑研究院有限公司 | 一种高强隔热耐火泥浆的制备方法 |
CN116217221B (zh) * | 2023-01-09 | 2024-04-09 | 中冶武汉冶金建筑研究院有限公司 | 一种高强隔热耐火泥浆的制备方法 |
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