CN107973619A - 莫来石-钙长石-刚玉复相微孔隔热材料及其制备方法 - Google Patents

莫来石-钙长石-刚玉复相微孔隔热材料及其制备方法 Download PDF

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CN107973619A
CN107973619A CN201711138004.6A CN201711138004A CN107973619A CN 107973619 A CN107973619 A CN 107973619A CN 201711138004 A CN201711138004 A CN 201711138004A CN 107973619 A CN107973619 A CN 107973619A
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anorthite
mullite
complex phase
raw material
barrier material
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赵飞
贾元平
封吉圣
朱波
郭玉涛
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SHANDONG REFRACTORY ENGINEERING RESEARCH CENTER
SHANDONG SHENGCHUAN CERAMICS CO Ltd
Zibo Luzhong Refractory Co Ltd
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SHANDONG REFRACTORY ENGINEERING RESEARCH CENTER
SHANDONG SHENGCHUAN CERAMICS CO Ltd
Zibo Luzhong Refractory Co Ltd
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Abstract

本发明涉及一种莫来石‑钙长石‑刚玉复相微孔隔热材料及其制备方法,属于无机隔热材料技术领域。本发明所述的莫来石‑钙长石‑刚玉复相微孔隔热材料,由以下重量百分含量的原料制成:40~70%的铝硅质天然原料、1~20%的氧化铝质原料、10~25%的膨胀剂、5~20%的碳酸钙质原料、5~10%的无机增孔剂。本发明所述的莫来石‑钙长石‑刚玉复相微孔隔热材料,原料来源广泛,成本低,使用温度高,隔热效果好;本发明同时提供了一种简单易行、节能环保的制备方法。

Description

莫来石-钙长石-刚玉复相微孔隔热材料及其制备方法
技术领域
本发明涉及一种莫来石-钙长石-刚玉复相微孔隔热材料及其制备方法,属于无机隔热材料技术领域。
背景技术
近年来,随着能源的日趋枯竭,节能、环保、减少能源消耗已受到到社会发展极大的重视。为进一步减少排放,高温隔热材料在高温工业中得到了大量的使用。传统的隔热材料多数使用温度较低,只能在隔热层和保温层使用,已经很难满足高温工业的应用要求。开发强度高、导热系数低、高温性能优良的隔热材料是当前最为迫切的任务。
高温隔热材料的生产工艺方法通常为加入燃烬物法和发泡法。加入燃尽物法是在原料中添加适量的有机物,如聚轻球、锯木屑、淀粉等;发泡法是加入松香、双氧水发泡,这两种方法存在着生产过程有污染或者生产成本高,所得到的材料气孔大小不均匀等问题。
目前,钙长石轻质隔热材料在制备方法上出现了一些新的工艺,如发明专利“钙长石轻质隔热耐火材料及其制备方法”(CN 102491766 A)和发明专利“钙长石轻质耐火砖及其制备方法”(CN 102942376 A)均采用浇注成型的方法制备,以水为成孔剂,未添加烧失物和发泡剂,但该方法工艺仍复杂,干燥时间长,煅烧后需要切割处理,增加了生产成本,制备的钙长石轻质耐火隔热材料以钙长石单相为主,使用温度相对较低。
发明内容
本发明的目的在于提供一种莫来石-钙长石-刚玉复相微孔隔热材料,其原料来源广泛,成本低,使用温度高,隔热效果好;本发明同时提供了一种简单易行、节能环保的制备方法。
本发明所述的莫来石-钙长石-刚玉复相微孔隔热材料,由以下重量百分含量的原料制成:40~70%的铝硅质天然原料、1~20%的氧化铝质原料、10~25%的膨胀剂、5~20%的碳酸钙质原料、5~10%的无机增孔剂。
制备所述的莫来石-钙长石-刚玉复相微孔隔热材料时,向上述所有原料中加入占比3~6wt%的结合剂。
优选的,结合剂为纸浆废液、糊精或硅溶胶中的一种或两种。
优选的,铝硅质天然原料为煤矸石、高岭石、焦宝石或铝矾土生矿中的一种或多种,原料粒径≤0.088mm。
优选的,氧化铝质原料为α-氧化铝、氢氧化铝或工业氧化铝中的一种或多种,原料粒径≤0.088mm。
优选的,膨胀剂为硅石、蓝晶石、硅线石或红柱石中的两种或两种以上的混合物,原料粒径≤0.088mm。
优选的,碳酸钙质原料为轻质碳酸钙、石灰石或纳米碳酸钙中的一种或多种。
优选的,无机增孔剂为空心玻璃微珠、人工合成漂珠、闭孔珍珠岩或玻化微珠中的一种或多种,原料粒径≤0.1mm。
所述的莫来石-钙长石-刚玉复相微孔隔热材料的制备方法,包括以下步骤:
(1)将铝硅质天然原料、氧化铝质原料、膨胀剂、碳酸钙质原料和无机增孔剂混合,再外加结合剂混炼;
(2)将步骤(1)混炼好的泥料在10~50MPa的条件下机压成型;
(3)将步骤(2)成型好的素坯在60~120℃的条件下干燥10~24小时,在1300~1500℃保温3~8小时的条件下进行煅烧,随炉冷却,制得所述的莫来石-钙长石-刚玉复相微孔隔热材料。
制得的所述的莫来石-钙长石-刚玉复相微孔隔热材料,平均孔径≦35μm,且分布均匀,体积密度为1.0~1.5g/cm3,耐压强度为15.5~63.8MPa,导热系数为0.21~0.35w/(m·K)。
本发明以铝硅质天然原料、氧化铝质原料、膨胀剂、碳酸钙质原料和无机增孔剂等常见的大宗原料为原料,采用机压成型的方式,一步制备成所述的莫来石-钙长石-刚玉复相微孔隔热材料,避免了生产轻质隔热材料二次加工过程,减少了能源消耗,提高了生产效率;所有原料在高温煅烧过程中进行原位反应形成莫来石相和钙长石相,弥补了单相钙长石耐火度过低的不利因素;同时利用了碳酸钙的原位分解和无机增孔剂的反应扩散成孔机理,避免了有机烧失物的引入,减少了CO2的排放,生产过程更加环保。
本发明与现有技术相比,具有以下有益效果:
(1)所述的莫来石-钙长石-刚玉复相微孔隔热材料,原料来源广泛,成本低;
(2)所述的莫来石-钙长石-刚玉复相微孔隔热材料,耐压强度高、隔热性能好、使用温度高、平均孔径小,能够满足高温窑炉工作层和隔热层使用的要求;
(3)所述的莫来石-钙长石-刚玉复相微孔隔热材料的制备方法,干燥时间快,生产效率高,简单易行,节能环保,适合大规模工业化生产。
附图说明
图1是本发明制得的莫来石-钙长石-刚玉复相微孔隔热材料的XRD衍射图谱。
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
按质量百分比将40%的铝硅质天然原料、20%的氧化铝质原料、10%的膨胀剂、20%的碳酸钙质原料、10%的无机成孔剂混合均匀,再外加占上述原料重量百分比之和6%的结合剂混炼,得到混合泥料;在10MPa的压力下机压成型得到坯体,将坯体干燥后放入高温窑炉中在1450℃保温6小时的条件下进行煅烧,随炉冷却,即得到一种莫来石-钙长石-刚玉复相微孔隔热材料。
所述的40%的铝硅质天然原料由12%的高岭石和28%的铝矾土生矿组成;
所述的20%的氧化铝质原料由5%的α-氧化铝和15%的氢氧化铝组成;
所述的10%膨胀剂为6%蓝晶石和4%的红柱石组成;
所述的碳酸钙质原料为轻质碳酸钙;
所述的10%的无机成孔剂由7%的闭孔珍珠岩和3%的玻化微珠组成;
所述的6%结合剂由3%的糊精和3%的硅溶胶组成。
本实施例所制备的莫来石-钙长石-刚玉复相微孔隔热材料技术指标为:
耐压强度为20.3MPa,体积密度为1.20g/cm3,导热系数为0.26w/(m·K)。
实施例2
按质量百分比将53%的铝硅质天然原料、15%的氧化铝质原料、15%的膨胀剂、10%的碳酸钙质原料、7%的无机成孔剂混合均匀,再外加占上述原料重量百分比之和4%的结合剂混炼,得到混合泥料;15MPa的条件下机压成型得到坯体,将坯体干燥后放入高温窑炉中在1410℃保温4小时的条件下进行煅烧,随炉冷却,即得到一种莫来石-钙长石-刚玉复相微孔隔热材料。
所述的53%的铝硅质天然原料由23%的焦宝石和30%的煤矸石组成;
所述的15%的氧化铝质原料由10%的氢氧化铝和5%的工业氧化铝组成;
所述的15%膨胀剂由8%的蓝晶石、4%的硅石和3%的硅线石组成;
所述的10%碳酸钙质原料为5%轻质碳酸钙和5%的纳米碳酸钙;
所述的无机成孔剂为人工合成漂珠;
所述的结合剂为纸浆废液。
本实施例所制备的莫来石-钙长石-刚玉复相微孔隔热材料技术指标为:
耐压强度为21.8MPa,体积密度为1.12g/cm3,导热系数为0.24w/(m·K)。
实施例3
按质量百分比将70%的铝硅质天然原料、1%的氧化铝质原料、16%的膨胀剂、6%的碳酸钙质原料、7%的无机成孔剂混合均匀,再外加占上述原料重量百分比之和4%的结合剂混炼,得到混合泥料;13MPa的条件下机压成型得到坯体,将坯体干燥后放入高温窑炉中在1460℃保温5小时的条件下进行煅烧,随炉冷却,即得到一种莫来石-钙长石-刚玉复相微孔隔热材料。
所述的70%的铝硅质天然原料由30%的铝矾土生矿和40%的煤矸石组成;
所述的氧化铝质原料为工业氧化铝;
所述的16%膨胀剂由6%的蓝晶石、6%的硅线石和4%的红柱石组成;
所述的碳酸钙质原料为石灰石;
所述的无机成孔剂为空心玻璃微珠;
所述的结合剂为糊精。
本实施例所制备的莫来石-钙长石-刚玉复相微孔隔热材料技术指标为:
耐压强度为21.8MPa,体积密度为1.08g/cm3,导热系数为0.21w/(m·K)。

Claims (10)

1.一种莫来石-钙长石-刚玉复相微孔隔热材料,其特征在于由以下重量百分含量的原料制成:40~70%的铝硅质天然原料、1~20%的氧化铝质原料、10~25%的膨胀剂、5~20%的碳酸钙质原料、5~10%的无机增孔剂。
2.根据权利要求1所述的莫来石-钙长石-刚玉复相微孔隔热材料,其特征在于:制备时向上述所有原料中加入占比3~6wt%的结合剂。
3.根据权利要求2所述的莫来石-钙长石-刚玉复相微孔隔热材料,其特征在于:结合剂为纸浆废液、糊精或硅溶胶中的一种或两种。
4.根据权利要求1所述的莫来石-钙长石-刚玉复相微孔隔热材料,其特征在于:铝硅质天然原料为煤矸石、高岭石、焦宝石或铝矾土生矿中的一种或多种,原料粒径≤0.088mm。
5.根据权利要求1所述的莫来石-钙长石-刚玉复相微孔隔热材料,其特征在于:氧化铝质原料为α-氧化铝、氢氧化铝或工业氧化铝中的一种或多种,原料粒径≤0.088mm。
6.根据权利要求1所述的莫来石-钙长石-刚玉复相微孔隔热材料,其特征在于:膨胀剂为硅石、蓝晶石、硅线石或红柱石中的两种或两种以上的混合物,原料粒径≤0.088mm。
7.根据权利要求1所述的莫来石-钙长石-刚玉复相微孔隔热材料,其特征在于:碳酸钙质原料为轻质碳酸钙、石灰石或纳米碳酸钙中的一种或多种。
8.根据权利要求1所述的莫来石-钙长石-刚玉复相微孔隔热材料,其特征在于:无机增孔剂为空心玻璃微珠、人工合成漂珠、闭孔珍珠岩或玻化微珠中的一种或多种,原料粒径≤0.1mm。
9.一种权利要求1-8任一所述的莫来石-钙长石-刚玉复相微孔隔热材料的制备方法,其特征在于包括以下步骤:
(1)将铝硅质天然原料、氧化铝质原料、膨胀剂、碳酸钙质原料和无机增孔剂混合,再外加结合剂混炼;
(2)将步骤(1)混炼好的泥料在10~50MPa的条件下机压成型;
(3)将步骤(2)成型好的素坯在60~120℃的条件下干燥10~24小时,在1300~1500℃保温3~8小时的条件下进行煅烧,随炉冷却,制得所述的莫来石-钙长石-刚玉复相微孔隔热材料。
10.根据权利要求9所述的莫来石-钙长石-刚玉复相微孔隔热材料的制备方法,其特征在于:制得的所述的莫来石-钙长石-刚玉复相微孔隔热材料,平均孔径≦35μm,体积密度为1.0~1.5g/cm3,耐压强度为15.5~63.8MPa,导热系数为0.21~0.35w/(m·K)。
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