CN108002848A - 含镁铝尖晶石的耐火砖及其制备方法 - Google Patents
含镁铝尖晶石的耐火砖及其制备方法 Download PDFInfo
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Abstract
本发明提供一种含镁铝尖晶石的耐火砖,它包括下述质量百分数的原料:镁铝尖晶石大颗粒20%~30%、六铝酸钙小颗粒12%~24%、煤矸石小颗粒14.5%~27%、粉煤灰10%~28%、空心玻璃微珠8%~18%、石英砂11%~28%、复合防渗剂1.6%~3.8%、二氧化硅气凝胶3%~5%、余量为纸浆水。所述含镁铝尖晶石的耐火砖成分搭配合理、具有较高的耐腐蚀性、良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含镁铝尖晶石的耐火砖的制备方法,该方法步骤简单、易于工业化生产。
Description
技术领域
本发明属于耐火材料技术领域,具体的说,涉及了一种含镁铝尖晶石的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。
现有的耐火砖大多为粘质隔热耐火砖,粘土砖主要由莫来石、玻璃相和方石英及石英所组成。通常以硬质粘土为原料,预先煅烧成熟料,然后配以软质粘土,以半干法或可塑法成型,温度在1300℃~1400℃烧成粘土砖制品,也可以加少量的水玻璃、水泥等结合剂制成不烧制品和不定形材料。还有这种耐火砖使用寿命短,不可再利用。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荷重软化温度、较高的耐腐蚀性的含镁铝尖晶石的耐火砖及其制备方法。
为了实现上述目的,本发明所采用的技术方案是:一种含镁铝尖晶石的耐火砖,它包括下述质量百分数的原料:镁铝尖晶石大颗粒20%~30%、六铝酸钙小颗粒12%~24%、煤矸石小颗粒14.5%~27%、粉煤灰10%~28%、空心玻璃微珠8%~18%、石英砂11%~28%、复合防渗剂1.6%~3.8%、二氧化硅气凝胶3%~5%、余量为纸浆水。
基于上述,所述含镁铝尖晶石的耐火砖包括下述质量百分数的原料:镁铝尖晶石大颗粒22.4%~26.7%、六铝酸钙小颗粒13%~22%、煤矸石小颗粒17%~21%、粉煤灰13%~22%、空心玻璃微珠10%~16%、石英砂13%~21.5%、复合防渗剂2%~3.5%、二氧化硅气凝胶3.5%~5%、余量为纸浆水。
基于上述,所述复合防渗剂由质量比为1:(2~3):5纳米碳酸锶、纳米硫酸锶和纳米硫酸钡组成。
基于上述,所述镁铝尖晶石大颗粒的粒度为2 mm~4 mm;所述六铝酸钙小颗粒的粒度为0 mm~1 mm;所述煤矸石小颗粒的粒度为0 mm~1 mm。
基于上述,所述石英砂的粒度小于0.074 mm、所述空心玻璃微珠的粒度小于0.074mm。
基于上述,所述粉煤灰的粒度小于0.043 mm。
本发明还一种含镁铝尖晶石的耐火砖的制备方法,包括以下步骤:
(1)按照上述质量百分数的原料计算,将镁铝尖晶石大颗粒、六铝酸钙小颗粒、煤矸石小颗粒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粉煤灰、空心玻璃微珠、石英砂、复合防渗剂、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含镁铝尖晶石的耐火砖。
基于上述,所述步骤(2)包括:采用50 MPa~80 MPa的压力将所述混碾泥料压制成砖坯,并将所述砖坯在自然干燥18小时后置于干燥窑内,在100℃~200℃的温度条件下干燥24小时~32小时;然后将干燥后的所述砖坯在1200℃~1280℃的温度下进行煅烧10小时~18小时,从而制得所述含镁铝尖晶石的耐火砖。
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,本发明以镁铝尖晶石大颗粒为骨架原料,以六铝酸钙小颗粒、煤矸石小颗粒、空心玻璃微珠、粉煤灰、石英砂为辅料,在二氧化硅气凝胶和复合防渗剂的作用下,实现上述辅料在所述骨架原料内的填充从而制得所述混碾泥料。由所述混碾泥料压制成的砖坯在高温烧结过程中,因为原料中包括具有多孔结构的所述六铝酸钙小颗粒,会使得所述砖坯内部在短时间内产生大量微小气孔,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。同时在高温烧结过程中,由于辅料中的所述煤矸石小颗粒与所述石英砂反应产生的体积膨胀会与骨架原料在高温烧结过程产生的体积收缩相冲抵,因此,通过对原料的合理搭配,从而保证了所述含镁铝尖晶石的耐火砖具有良好的尺寸稳定性。
另一方面,在对所述砖坯高温烧结过程中,所述煤矸石小颗粒与所述石英砂还可以生成类似纤维增韧补强作用的针状或柱状莫来石晶须及含SiO2的高粘度致密层,所述莫来石晶须对提高所述含镁铝尖晶石的耐火砖的力学性能非常有利,既提高了所述含镁铝尖晶石的耐火砖的耐高温强度又降低了其烧成温度。因此,所述含镁铝尖晶石的耐火砖具有较高的表面抗腐蚀性和较高的荷重软化温度。
本发明还提供一种上述含镁铝尖晶石的耐火砖的制备方法,它通过将上述原料混合形成混碾泥料,所述混碾泥料经压制形成砖坯,然后将所述砖坯在高温条件下进行烧结从而制得所述含镁铝尖晶石的耐火砖,该方法步骤简单、易于工业化生产。
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
本实施例提供一种含镁铝尖晶石的耐火砖,它包括下述质量百分数的原料:镁铝尖晶石大颗粒22%、六铝酸钙小颗粒13%、煤矸石小颗粒17%、粉煤灰13%、空心玻璃微珠10%、石英砂13%、复合防渗剂2%、二氧化硅气凝胶5%、纸浆水5%。所述复合防渗剂由质量比为1:3:5的纳米碳酸锶、纳米硫酸锶和纳米硫酸钡混合而成。
其中,所述镁铝尖晶石大颗粒的粒度为2 mm~4 mm、所述六铝酸钙小颗粒的粒度为0 mm~1 mm、所述煤矸石小颗粒的粒度为0 mm~1 mm、所述石英砂的粒度小于0.074 mm、所述空心玻璃微珠的粒度小于0.074 mm、所述粉煤灰的粒度小于0.043 mm。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
本发明还一种含镁铝尖晶石的耐火砖的制备方法,包括以下步骤:
(1)按照上述质量百分数的原料计算,将镁铝尖晶石大颗粒、六铝酸钙小颗粒、煤矸石小颗粒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粉煤灰、空心玻璃微珠、石英砂、复合防渗剂、二氧化硅气凝胶并进行混碾制得混碾泥料;
(2)采用制砖机在70 MPa的压力将所述混碾泥料压制成砖坯,并将所述砖坯自然干燥18小时后置于干燥窑内,在100℃的温度下干燥32小时;然后将干燥后的所述砖坯在1280℃的温度下进行煅烧10小时,从而制得所述含镁铝尖晶石的耐火砖。
实施例2
本实施例提供一种含镁铝尖晶石的耐火砖,它包括下述质量百分数的原料:镁铝尖晶石大颗粒23%、六铝酸钙小颗粒15%、煤矸石小颗粒17%、粉煤灰13.5%、空心玻璃微珠10%、石英砂13%、复合防渗剂2%、二氧化硅气凝胶3.5%、纸浆水3%。所述复合防渗剂由质量比为1:2:5的纳米碳酸锶、纳米硫酸锶和纳米硫酸钡混合而成。
其中,所述镁铝尖晶石大颗粒的粒度为2 mm~4 mm、所述六铝酸钙小颗粒的粒度为0 mm~1 mm、所述煤矸石小颗粒的粒度为0 mm~1 mm、所述石英砂的粒度小于0.074 mm、所述空心玻璃微珠的粒度小于0.074 mm、所述粉煤灰的粒度小于0.043 mm
本实施例所述的抗腐蚀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:
所述步骤(2)采用制砖机在60 MPa的压力将所述混碾泥料压制成砖坯,,经自然干燥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1200℃的温度下进行煅烧18小时,从而制得所述抗腐蚀耐火砖。
实施例3
本实施例提供一种含镁铝尖晶石的耐火砖,它包括下述质量百分数的原料:镁铝尖晶石大颗粒30%、六铝酸钙小颗粒12%、煤矸石小颗粒14.5%、粉煤灰10.5%、空心玻璃微珠8%、石英砂11%、复合防渗剂1.6%、二氧化硅气凝胶3%、纸浆水9.4%。所述复合防渗剂由质量比为1:3:5的纳米碳酸锶、纳米硫酸锶和纳米硫酸钡混合而成。
其中,所述镁铝尖晶石大颗粒的粒度为2 mm~4 mm、所述六铝酸钙小颗粒的粒度为0 mm~1 mm、所述煤矸石小颗粒的粒度为0 mm~1 mm、所述石英砂的粒度小于0.074 mm、所述空心玻璃微珠的粒度小于0.074 mm、所述粉煤灰的粒度小于0.043 mm
本实施例所述的含镁铝尖晶石的耐火砖的制备方法与实施例1中的制备方法相同。
含镁铝尖晶石的耐火砖性能检测
分别对实施例1~3制备的含镁铝尖晶石的耐火砖的透气量、体积密度、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,其中透气度测试条件为:耐火砖面积2×10-3m2、气体压力为0.3MPa。
表2、含镁铝尖晶石的耐火砖性能检测
从上表中可以看出:实施例1~3提供的含镁铝尖晶石的耐火砖的耐火软化点大于1650℃、常温耐压强度大于100MPa、抗折强度大于20MPa、体积密度大于2.5g/cm3、透气量小于0.6m3/h,因此所述含镁铝尖晶石的耐火砖各项性能指标符合GB/T3994-2013规定的指标,同时该产品具有较高的表面抗腐蚀性和较高的荷重软化温度的优点。
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 (9)
1.一种含镁铝尖晶石的耐火砖,其特征在于,它包括下述质量百分数的原料:镁铝尖晶石大颗粒20%~30%、六铝酸钙小颗粒12%~24%、煤矸石小颗粒14.5%~27%、粉煤灰10%~28%、空心玻璃微珠8%~18%、石英砂11%~28%、复合防渗剂1.6%~3.8%、二氧化硅气凝胶3%~5%、余量为纸浆水。
2.根据权利要求1所述的含镁铝尖晶石的耐火砖,其特征在于,它包括下述质量百分数的原料:镁铝尖晶石大颗粒22.4%~26.7%、六铝酸钙小颗粒13%~22%、煤矸石小颗粒17%~21%、粉煤灰13%~22%、空心玻璃微珠10%~16%、石英砂13%~21.5%、复合防渗剂2%~3.5%、二氧化硅气凝胶3.5%~5%、余量为纸浆水。
3.根据权利要求1或2所述的含镁铝尖晶石的耐火砖,其特征在于,所述复合防渗剂由质量比为1:(2~3):5纳米碳酸锶、纳米硫酸锶和纳米硫酸钡组成。
4.根据权利要求1或2所述的含镁铝尖晶石的耐火砖,其特征在于,所述镁铝尖晶石大颗粒的粒度为2 mm~4 mm。
5.根据权利要求4所述的含镁铝尖晶石的耐火砖,其特征在于,所述六铝酸钙小颗粒的粒度为0 mm~1 mm;所述煤矸石小颗粒的粒度为0 mm~1 mm。
6.根据权利要求5所述的含镁铝尖晶石的耐火砖,其特征在于,所述石英砂的粒度小于0.074 mm、所述空心玻璃微珠的粒度小于0.074 mm。
7.根据权利要求6所述的含镁铝尖晶石的耐火砖,其特征在于,所述粉煤灰的粒度小于0.043 mm。
8.一种含镁铝尖晶石的耐火砖的制备方法,包括以下步骤:
(1)按照权利要求1~7任一项所述质量百分数的原料计算,将镁铝尖晶石大颗粒、六铝酸钙小颗粒、煤矸石小颗粒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粉煤灰、空心玻璃微珠、石英砂、复合防渗剂、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含镁铝尖晶石的耐火砖。
9.根据权利要求8所述的含镁铝尖晶石的耐火砖的制备方法,其特征在于,所述步骤(2)包括:采用50 MPa~80 MPa的压力将所述混碾泥料压制成砖坯,并将所述砖坯自然干燥18小时后置于干燥窑内,在100℃~200℃的温度下干燥24小时~32小时;然后将干燥后的所述砖坯在1200℃~1280℃的温度下进行煅烧10小时~18小时,从而制得所述含镁铝尖晶石的耐火砖。
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