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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