CN108017379A - 一种氧化铝质轻质隔热砖及其制备方法 - Google Patents
一种氧化铝质轻质隔热砖及其制备方法 Download PDFInfo
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- 239000011449 brick Substances 0.000 title claims abstract description 38
- 238000009413 insulation Methods 0.000 title claims abstract description 31
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 title claims abstract description 31
- 238000002360 preparation method Methods 0.000 title claims abstract description 17
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 36
- 239000003595 mist Substances 0.000 claims abstract description 35
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 34
- 239000000843 powder Substances 0.000 claims abstract description 31
- 239000000463 material Substances 0.000 claims abstract description 29
- 239000011148 porous material Substances 0.000 claims abstract description 26
- 239000000203 mixture Substances 0.000 claims abstract description 24
- 238000005245 sintering Methods 0.000 claims abstract description 18
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 17
- 239000004575 stone Substances 0.000 claims abstract description 14
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 9
- 239000010432 diamond Substances 0.000 claims abstract description 9
- 229910003460 diamond Inorganic materials 0.000 claims abstract description 9
- 239000002994 raw material Substances 0.000 claims abstract description 8
- 229910001845 yogo sapphire Inorganic materials 0.000 claims abstract description 8
- 239000005995 Aluminium silicate Substances 0.000 claims abstract description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 7
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 7
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000000758 substrate Substances 0.000 claims description 14
- 238000005266 casting Methods 0.000 claims description 9
- 238000000465 moulding Methods 0.000 claims description 8
- KLZUFWVZNOTSEM-UHFFFAOYSA-K Aluminum fluoride Inorganic materials F[Al](F)F KLZUFWVZNOTSEM-UHFFFAOYSA-K 0.000 claims description 7
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 claims description 7
- 235000007164 Oryza sativa Nutrition 0.000 claims description 7
- 240000004808 Saccharomyces cerevisiae Species 0.000 claims description 7
- 229920002472 Starch Polymers 0.000 claims description 7
- 239000002253 acid Substances 0.000 claims description 7
- 150000007513 acids Chemical class 0.000 claims description 7
- QDOXWKRWXJOMAK-UHFFFAOYSA-N chromium(III) oxide Inorganic materials O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 claims description 7
- 239000010903 husk Substances 0.000 claims description 7
- 229910001635 magnesium fluoride Inorganic materials 0.000 claims description 7
- 235000009566 rice Nutrition 0.000 claims description 7
- 150000003839 salts Chemical class 0.000 claims description 7
- 235000019698 starch Nutrition 0.000 claims description 7
- 239000008107 starch Substances 0.000 claims description 7
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 7
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 claims description 6
- 229910052849 andalusite Inorganic materials 0.000 claims description 6
- 229910052850 kyanite Inorganic materials 0.000 claims description 6
- 239000010443 kyanite Substances 0.000 claims description 6
- DGVVJWXRCWCCOD-UHFFFAOYSA-N naphthalene;hydrate Chemical compound O.C1=CC=CC2=CC=CC=C21 DGVVJWXRCWCCOD-UHFFFAOYSA-N 0.000 claims description 6
- 229910052851 sillimanite Inorganic materials 0.000 claims description 6
- 238000010792 warming Methods 0.000 claims description 6
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 2
- 229910052594 sapphire Inorganic materials 0.000 claims description 2
- 240000007594 Oryza sativa Species 0.000 claims 1
- 238000000034 method Methods 0.000 abstract description 16
- 238000010438 heat treatment Methods 0.000 abstract description 6
- 230000035939 shock Effects 0.000 abstract description 6
- 238000004519 manufacturing process Methods 0.000 abstract description 4
- 238000001354 calcination Methods 0.000 abstract 1
- 239000000919 ceramic Substances 0.000 description 7
- 241000209094 Oryza Species 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 5
- 239000002002 slurry Substances 0.000 description 5
- 239000000178 monomer Substances 0.000 description 3
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
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- 230000001737 promoting effect Effects 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 238000013019 agitation Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
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- 238000011065 in-situ storage Methods 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
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- 230000001988 toxicity Effects 0.000 description 1
- 231100000419 toxicity Toxicity 0.000 description 1
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Abstract
本发明公开了一种氧化铝质轻质隔热砖的制备方法，包括采用氧化铝细粉、板状刚玉、白刚玉细粉、α‑Al2O3微粉、高岭土、ρ‑Al2O3微粉和“三石”为原料，通过添加助烧剂、硅溶胶、凝胶粉、水、减水剂、造孔剂和泡沫混合，最后加热煅烧制成。同时，本发明公开了上述方法制备的氧化铝质轻质隔热砖。本发明具有固化速度快、工艺简单、环境友好和生产周期短的优点；所制备的氧化铝质轻质隔热砖热导率低、荷重软化温度高、热震稳定性好及加热永久线变化小。
Description
技术领域
本发明属于轻质隔热砖技术领域，具体涉及一种氧化铝质轻质隔热砖及其制备方法。
背景技术
随着经济的发展，能源的消耗与日俱增，节能降耗成为普遍关注的问题。各种工业窑炉的热损失不容小觑，工业窑炉通常采用轻质隔热耐火材料作为保温层砌筑窑炉，从而减少热耗，增加蓄热能力。氧化铝质轻质砖是一种密度小、强度高、热导率低的耐火材料。与普通隔热材料相比，具有荷重软化温度高、耐压强度高、加热永久线变化率低等特点；与致密耐火砖相比具有体积密度低、保温性能好、热容量低等特性，是高温窑炉理想的内衬结构材料。
氧化铝质轻质砖的制备方法很多，主要有添加造孔剂法、泡沫法、凝胶注模法等。添加造孔剂法是在陶瓷粉料中添加成孔剂，利用成孔剂在烧成过程中烧失而形成孔洞来制备多孔陶瓷。发泡法主要是首先通过物理搅拌或加入发泡剂等方式引入气体到料浆中，之后陶瓷料浆经过固化和干燥得到陶瓷生坯，最后生坯经过烧成即可获得泡沫陶瓷。如“一种氧化铝轻质砖及其制备方法” (CN101708997A)的专利技术，该方法以50~80wt%的Al2O3细粉、15~30wt%的α-Al2O3细粉、5~20wt%的α-Al2O3微粉和5~20wt%的ρ-Al2O3微粉为原料，外加0.1~1wt%的助烧剂、30~50wt%的水、0.1~1wt%的减水剂和0.1~2wt%的SiO2，混合3~5分钟，再外加0.2~0.4wt%的泡沫剂，混合均匀，浇注成型，干燥后在1450~1700℃的条件下烧成，保温3~5小时。该技术虽具有一定的优点，但亦存在以下缺点：(1) 加水量过多，导致脱模时间较长，干燥时间较长，不利于工业上推广；(2)微粉的加入量过多导致样品在烧成过程中收缩过大，影响样品性能；(3)未引入板状刚玉和电熔白刚玉，加之又属于微孔结构，可能导致样品可能热震稳定性不好。
凝胶注模法是将有机单体、交联剂、催化剂、引发剂等加入到料浆中，然后把陶瓷料浆注入到模具中，最后料浆由于单体发生聚合反应而原位固化成型，得到复杂形状的均匀坯体。如“一种利用凝胶-发泡法制备氧化铝多孔陶瓷”(CN102432332 A)的专利技术，该技术采用泡沫法结合凝胶注模成型的方法虽具有一定的优点，但亦存在以下缺点：(1)由于使用的有机单体、引发剂以及催化剂具有一定的毒性，对人体健康和环境不利；(2)使用的凝胶体系，提高了成本，限制了产品的推广使用。
发明内容
发明目的：本发明目的在于针对现有技术的不足，提供一种固化速度快、工艺简单、环境友好和生产周期短的氧化铝质轻质隔热砖的制备方法。
本发明的另一目的在于提供用该方法制备的热导率低、荷重软化温度高、热震稳定性好及加热永久线变化小的氧化铝质轻质隔热砖。
技术方案：为了达到上述发明目的，本发明具体是这样来实现的：一种氧化铝质轻质隔热砖的制备方法，包括以下步骤：
（1）以20~40wt%的粒度为0.044~0.147mm的煅烧氧化铝细粉、15~30wt%的粒度为0.074~0.147mm的板状刚玉、15~30wt%的粒度为0.074~0.147mm的白刚玉细粉、5~15wt%的粒度小于5μm的α-Al2O3微粉、0~10wt%的粒度为0.074~0.147mm 的高岭土、5~10wt%的粒度小于5μm的ρ-Al2O3微粉和0~10wt%的“三石”为原料，预混合3~5分钟，制得预混料；
（2）向预混料中外加所述预混料0.1~1wt%的助烧剂、0~30wt%的硅溶胶、0~15wt%的凝胶粉、20~35wt%的水和0.1~0.8wt%的减水剂，混合5~10分钟，得到混合料；
（3）向混合料中加入造孔剂和泡沫，混合5~10分钟，浇注成型，固化1~3小时，得到固化后的坯体；其中：每Kg混合料中泡沫的加入量为0.5~1L，造孔剂的加入量为2~15wt%；
（4）将固化后的坯体升温至1400~1800℃，保温3~9h，即得氧化铝质轻质隔热砖。
其中，所述高岭土的Al2O3≥33.0%，Fe2O3≤1.08%，R2O≤1.7%。
其中，所述“三石”为蓝晶石、硅线石和红柱石中的一种或两种，其粒度小于0.178mm。
其中，所述的助烧剂为TiO2微粉、MgO微粉、Cr2O3微粉、MgF2和AlF3微粉中的一种或两种。
其中，所述的减水剂为聚羧酸类减水剂、无机盐类减水剂、磺酸系减水剂和萘系减水剂中的一种或两种。
其中，所述的造孔剂为稻壳、淀粉、锯末和酵母粉中的一种或两种，其粒度小于0.3mm。
本申请所述的氧化铝质轻质隔热砖，由上述氧化铝质轻质隔热砖的制备方法所制备。
有益效果：本发明与传统技术相比，存在以下优点和效果：
1、固化速度快、工艺简单、环境友好和生产周期短的氧化铝质轻质隔热砖的制备方法；用该方法制备的氧化铝质轻质隔热砖热导率低、荷重软化温度高、热震稳定性好及加热永久线变化小；
2、本发明所制得的氧化铝质轻质砖的体积密度为0.9~1.3g/cm3，导热系数为0.36~0.6w/m.k，耐压强度达到3.50~8.2Mpa，线收缩为1~5%，加热永久线变化为-0.4~-1.6%、荷重软化温度为1500~1600℃，热震稳定性次数为15~25次；
3、本发明具有固化速度快、工艺简单、环境友好和生产周期短的优点；所制备的氧化铝质轻质隔热砖热导率低、荷重软化温度高、热震稳定性好及加热永久线变化小。
具体实施方式
实施例1：
以20wt%的粒度为0.044~0.147mm的煅烧氧化铝细粉、30wt%的粒度为0.074~0.147mm的板状刚玉、15wt%的粒度为0.074~0.147mm的白刚玉细粉、15wt%的粒度小于5μm的α-Al2O3微粉、5wt%的粒度为0.074~0.147mm 的高岭土、10wt%的粒度小于5μm的ρ-Al2O3微粉和5wt%的“三石”为原料，预混合3~5分钟，制得预混料；向预混料中外加所述预混料0.5wt%的助烧剂、15wt%的硅溶胶、7wt%的凝胶粉、25wt%的水和0.5wt%的减水剂，混合5~10分钟，得到混合料；向混合料中加入造孔剂和泡沫，混合5~10分钟，浇注成型，固化1~3小时，得到固化后的坯体；其中：每Kg混合料中泡沫的加入量为0.8L，造孔剂的加入量为10wt%；将固化后的坯体升温至1400~1800℃，保温3~9h，即得氧化铝质轻质隔热砖。
其中，所述“三石”为蓝晶石、硅线石和红柱石中的一种或两种，其粒度小于0.178mm；所述的助烧剂为TiO2微粉、MgO微粉、Cr2O3微粉、MgF2和AlF3微粉中的一种或两种；所述的减水剂为聚羧酸类减水剂、无机盐类减水剂、磺酸系减水剂和萘系减水剂中的一种或两种；所述的造孔剂为稻壳、淀粉、锯末和酵母粉中的一种或两种，其粒度小于0.3mm。
实施例2：
以25wt%的粒度为0.044~0.147mm的煅烧氧化铝细粉、25wt%的粒度为0.074~0.147mm的板状刚玉、30wt%的粒度为0.074~0.147mm的白刚玉细粉、5wt%的粒度小于5μm的α-Al2O3微粉、5wt%的粒度为0.074~0.147mm 的高岭土、5wt%的粒度小于5μm的ρ-Al2O3微粉和5wt%的“三石”为原料，预混合3~5分钟，制得预混料；向预混料中外加所述预混料0.1wt%的助烧剂、10wt%的硅溶胶、35wt%的水和0.8wt%的减水剂，混合5~10分钟，得到混合料；向混合料中加入造孔剂和泡沫，混合5~10分钟，浇注成型，固化1~3小时，得到固化后的坯体；其中：每Kg混合料中泡沫的加入量为1L，造孔剂的加入量为2wt%；将固化后的坯体升温至1400~1800℃，保温3~9h，即得氧化铝质轻质隔热砖。
其中，所述“三石”为蓝晶石、硅线石和红柱石中的一种或两种，其粒度小于0.178mm；所述的助烧剂为TiO2微粉、MgO微粉、Cr2O3微粉、MgF2和AlF3微粉中的一种或两种；所述的减水剂为聚羧酸类减水剂、无机盐类减水剂、磺酸系减水剂和萘系减水剂中的一种或两种；所述的造孔剂为稻壳、淀粉、锯末和酵母粉中的一种或两种，其粒度小于0.3mm。
实施例3：
以30wt%的粒度为0.044~0.147mm的煅烧氧化铝细粉、15wt%的粒度为0.074~0.147mm的板状刚玉、25wt%的粒度为0.074~0.147mm的白刚玉细粉、10wt%的粒度小于5μm的α-Al2O3微粉、5wt%的粒度为0.074~0.147mm 的高岭土、10wt%的粒度小于5μm的ρ-Al2O3微粉和5wt%的“三石”为原料，预混合3~5分钟，制得预混料；向预混料中外加所述预混料1wt%的助烧剂、20wt%的硅溶胶、15wt%的凝胶粉、30wt%的水和0.6wt%的减水剂，混合5~10分钟，得到混合料；向混合料中加入造孔剂和泡沫，混合5~10分钟，浇注成型，固化1~3小时，得到固化后的坯体；其中：每Kg混合料中泡沫的加入量为0.5L，造孔剂的加入量为15wt%；将固化后的坯体升温至1400~1800℃，保温3~9h，即得氧化铝质轻质隔热砖。
其中，所述“三石”为蓝晶石、硅线石和红柱石中的一种或两种，其粒度小于0.178mm；所述的助烧剂为TiO2微粉、MgO微粉、Cr2O3微粉、MgF2和AlF3微粉中的一种或两种；所述的减水剂为聚羧酸类减水剂、无机盐类减水剂、磺酸系减水剂和萘系减水剂中的一种或两种；所述的造孔剂为稻壳、淀粉、锯末和酵母粉中的一种或两种，其粒度小于0.3mm。
实施例4：
以35wt%的粒度为0.044~0.147mm的煅烧氧化铝细粉、20wt%的粒度为0.074~0.147mm的板状刚玉、20wt%的粒度为0.074~0.147mm的白刚玉细粉、10wt%的粒度小于5μm的α-Al2O3微粉、5wt%的粒度小于5μm的ρ-Al2O3微粉和10wt%的“三石”为原料，预混合3~5分钟，制得预混料；向预混料中外加所述预混料0.3wt%的助烧剂、25wt%的硅溶胶、10wt%的凝胶粉、25wt%的水和0.4wt%的减水剂，混合5~10分钟，得到混合料；向混合料中加入造孔剂和泡沫，混合5~10分钟，浇注成型，固化1~3小时，得到固化后的坯体；其中：每Kg混合料中泡沫的加入量为0.6L，造孔剂的加入量为12wt%；将固化后的坯体升温至1400~1800℃，保温3~9h，即得氧化铝质轻质隔热砖。
其中，所述“三石”为蓝晶石、硅线石和红柱石中的一种或两种，其粒度小于0.178mm；所述的助烧剂为TiO2微粉、MgO微粉、Cr2O3微粉、MgF2和AlF3微粉中的一种或两种；所述的减水剂为聚羧酸类减水剂、无机盐类减水剂、磺酸系减水剂和萘系减水剂中的一种或两种；所述的造孔剂为稻壳、淀粉、锯末和酵母粉中的一种或两种，其粒度小于0.3mm。
实施例5：
以40wt%的粒度为0.044~0.147mm的煅烧氧化铝细粉、15wt%的粒度为0.074~0.147mm的板状刚玉、15wt%的粒度为0.074~0.147mm的白刚玉细粉、15wt%的粒度小于5μm的α-Al2O3微粉、5wt%的粒度为0.074~0.147mm 的高岭土和10wt%的粒度小于5μm的ρ-Al2O3微粉预混合3~5分钟，制得预混料；向预混料中外加所述预混料0.8wt%的助烧剂、15wt%的凝胶粉、20wt%的水和0.1wt%的减水剂，混合5~10分钟，得到混合料；向混合料中加入造孔剂和泡沫，混合5~10分钟，浇注成型，固化1~3小时，得到固化后的坯体；其中：每Kg混合料中泡沫的加入量为0.8L，造孔剂的加入量为8wt%；将固化后的坯体升温至1400~1800℃，保温3~9h，即得氧化铝质轻质隔热砖。
其中，所述的助烧剂为TiO2微粉、MgO微粉、Cr2O3微粉、MgF2和AlF3微粉中的一种或两种；所述的减水剂为聚羧酸类减水剂、无机盐类减水剂、磺酸系减水剂和萘系减水剂中的一种或两种；所述的造孔剂为稻壳、淀粉、锯末和酵母粉中的一种或两种，其粒度小于0.3mm。
Claims (7)
1.一种氧化铝质轻质隔热砖的制备方法，其特征在于，包括以下步骤：
（1）以20~40wt%的粒度为0.044~0.147mm的煅烧氧化铝细粉、15~30wt%的粒度为0.074~0.147mm的板状刚玉、15~30wt%的粒度为0.074~0.147mm的白刚玉细粉、5~15wt%的粒度小于5μm的α-Al2O3微粉、0~10wt%的粒度为0.074~0.147mm 的高岭土、5~10wt%的粒度小于5μm的ρ-Al2O3微粉和0~10wt%的“三石”为原料，预混合3~5分钟，制得预混料；
（2）向预混料中外加所述预混料0.1~1wt%的助烧剂、0~30wt%的硅溶胶、0~15wt%的凝胶粉、20~35wt%的水和0.1~0.8wt%的减水剂，混合5~10分钟，得到混合料；
（3）向混合料中加入造孔剂和泡沫，混合5~10分钟，浇注成型，固化1~3小时，得到固化后的坯体；其中：每Kg混合料中泡沫的加入量为0.5~1L，造孔剂的加入量为2~15wt%；
（4）将固化后的坯体升温至1400~1800℃，保温3~9h，即得氧化铝质轻质隔热砖。
2.根据权利要求1所述的氧化铝质轻质隔热砖的制备方法，其特征在于，所述高岭土的Al2O3≥33.0%，Fe2O3≤1.08%，R2O≤1.7%。
3.根据权利要求1所述的氧化铝质轻质隔热砖的制备方法，其特征在于，所述“三石”为蓝晶石、硅线石和红柱石中的一种或两种，其粒度小于0.178mm。
4.根据权利要求1所述的氧化铝质轻质隔热砖的制备方法，其特征在于，所述的助烧剂为TiO2微粉、MgO微粉、Cr2O3微粉、MgF2和AlF3微粉中的一种或两种。
5.根据权利要求1所述的氧化铝质轻质隔热砖的制备方法，其特征在于，所述的减水剂为聚羧酸类减水剂、无机盐类减水剂、磺酸系减水剂和萘系减水剂中的一种或两种。
6.根据权利要求1所述的氧化铝质轻质隔热砖的制备方法，其特征在于，所述的造孔剂为稻壳、淀粉、锯末和酵母粉中的一种或两种，其粒度小于0.3mm。
7.一种氧化铝质轻质隔热砖，其特征在于，所述氧化铝质轻质隔热砖是根据权利要求1~6项中任意一项所述的氧化铝质轻质隔热砖的制备方法所制备的氧化铝质轻质隔热砖。
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