CN108017398A - 含偏高岭土的耐火砖及其制备方法 - Google Patents

含偏高岭土的耐火砖及其制备方法 Download PDF

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CN108017398A
CN108017398A CN201610960519.3A CN201610960519A CN108017398A CN 108017398 A CN108017398 A CN 108017398A CN 201610960519 A CN201610960519 A CN 201610960519A CN 108017398 A CN108017398 A CN 108017398A
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metakaolin
refractory brick
fine powder
granularity
containing metakaolin
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张微微
计富宝
吉飞虎
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Henan World Intellectual Property Operation Co Ltd
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Abstract

本发明提供一种含偏高岭土的耐火砖，它包括下述质量百分数的原料：镁铝尖晶石大颗粒19.5%～27%、红柱石小颗粒13%～25%、偏高岭土细粉15%～24.5%、氧化铬绿细粉3%～17%、高铝刚玉微粉7%～18%、煤矸石微粉11%～23%、镁质助烧剂2%～5%、膨胀石墨0.5%～2%、复合防渗剂4%～9%、复合粘结剂1%～4%、余量为纸浆水。所述含偏高岭土的耐火砖成分搭配合理、具有较高的耐腐蚀性、良好的尺寸稳定性和较高的荷重软化温度。本发明还提供一种上述含偏高岭土的耐火砖的制备方法，该方法步骤简单、易于工业化生产。

Description

含偏高岭土的耐火砖及其制备方法
技术领域
本发明属于耐火材料技术领域，具体的说，涉及了一种含偏高岭土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偏高岭土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：一种含偏高岭土的耐火砖，它包括下述质量百分数的原料：镁铝尖晶石大颗粒19.5%～27%、红柱石小颗粒13%～25%、偏高岭土细粉15%～24.5%、氧化铬绿细粉3%～17%、高铝刚玉微粉7%～18%、煤矸石微粉11%～23%、镁质助烧剂2%～5%、膨胀石墨0.5%～2%、复合防渗剂4%～9%、复合粘结剂1%～4%、余量为纸浆水。
基于上述，所述的含偏高岭土的耐火砖，它包括下述质量百分数的原料：镁铝尖晶石大颗粒20%～23%、红柱石小颗粒14%～20%、偏高岭土细粉17%～19%、氧化铬绿细粉4%～13.5%、高铝刚玉微粉9%～15%、煤矸石微粉13%～19%、镁质助烧剂3%～5%、膨胀石墨1.5%～2%、复合防渗剂5%～7%、复合粘结剂3%～4%、余量为纸浆水。
基于上述，所述复合粘结剂由质量比为（1～2）：1的磷酸盐水溶液和氧化硅溶胶组成。
基于上述，所述复合防渗剂由质量比为1：2：（2～3）的纳米碳酸锶、纳米硫酸锶和纳米硫酸钡组成。
基于上述，所述镁质助烧剂为轻烧镁砂粉、镁质粘土或六水氯化镁。
基于上述，所述镁铝尖晶石大颗粒的粒度为3 mm～4 mm；所述红柱石小颗粒的粒度为1 mm～2 mm。
基于上述，所述偏高岭土细粉的粒度小于0.074 mm、所述氧化铬绿细粉的粒度小于0.074 mm；所述高铝刚玉微粉的粒度小于0.043 mm、所述煤矸石微粉的粒度小于0.043mm。
本发明还一种含偏高岭土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、红柱石小颗粒、偏高岭土细粉、氧化铬绿细粉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高铝刚玉微粉、煤矸石微粉、膨胀石墨、复合防渗剂、复合粘结剂和镁质助烧剂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偏高岭土的耐火砖。
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，并将所述砖坯自然干燥12小时，然后置于干燥窑内，在80℃～120℃的温度下干燥18小时～24小时；然后将干燥后的所述砖坯在1150℃～1300℃的温度下进行煅烧15小时～24小时，从而制得所述含偏高岭土的耐火砖。
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，以红柱石小颗粒、偏高岭土细粉、氧化铬绿细粉、煤矸石微粉、膨胀石墨、高铝刚玉微粉为辅料，在镁质助烧剂、复合防渗剂和复合粘结剂的作用下，实现上述辅料在所述骨架原料内的致密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，所述骨架原料会产生体积收缩，但是由于辅料中含有的所述膨胀石墨使得所述砖坯内部在短时间内产生大量微小气孔。因此，通过对原料的合理搭配，从而保证了所述含锂辉石的耐火砖具有良好的尺寸稳定性。
另一方面，在高温煅烧过程中，所述高铝刚玉微粉会通过原位反应形成含SiO2的高粘度相，该高粘度相会与所述镁铝尖晶石大颗粒反应生成含CaO高熔点相的致密层，且所述煤矸石微粉与所述高铝刚玉微粉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，所述莫来石晶须对提高所述含偏高岭土的耐火砖的力学性能非常有利，既提高了所述含偏高岭土的耐火砖的耐高温强度又降低了其烧成温度。因此，所述含偏高岭土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偏高岭土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偏高岭土的耐火砖，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偏高岭土的耐火砖，它包括下述质量百分数的原料：镁铝尖晶石大颗粒27%、红柱石小颗粒13%、偏高岭土细粉15%、氧化铬绿细粉3%、高铝刚玉微粉7%、煤矸石微粉11%、轻烧镁砂粉2%、膨胀石墨0.5%、复合防渗剂4%、复合粘结剂3%、纸浆水14.5%。
其中，所述复合粘结剂由质量比为1：1的磷酸盐水溶液和氧化硅溶胶组成；所述复合防渗剂由质量比为1：2：2的纳米碳酸锶、纳米硫酸锶和纳米硫酸钡组成。所述镁铝尖晶石大颗粒的粒度为3 mm～4 mm；所述红柱石小颗粒的粒度为1 mm～2 mm；所述偏高岭土细粉的粒度小于0.074 mm、所 述氧化铬绿细粉的粒度小于0.074 mm；所述高铝刚玉微粉的粒度小于0.043 mm、所述煤矸石微粉的粒度小于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
本实施例还提供一种所述含偏高岭土的耐火砖的制备方法，具体制备步骤包括：
（1）按照上述质量百分数的原料计算，将镁铝尖晶石大颗粒、红柱石小颗粒、偏高岭土细粉、氧化铬绿细粉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高铝刚玉微粉、煤矸石微粉、膨胀石墨、复合防渗剂、复合粘结剂和轻烧镁砂粉并进行混碾制得混碾泥料；
（2）采用制砖机在80 MPa的压力下将所述混碾泥料压制成砖坯，并将所述砖坯在自然干燥12小时后置于干燥窑内，在120℃的温度条件下干燥24小时；然后将干燥后的所述砖坯在1300℃的温度下进行煅烧15小时，从而制得所述含偏高岭土的耐火砖。
实施例2
本实施例提供一种含偏高岭土的耐火砖，它包括下述质量百分数的原料：镁铝尖晶石大颗粒23%、红柱石小颗粒14%、偏高岭土细粉17%、氧化铬绿细粉4%、高铝刚玉微粉7%、煤矸石微粉11%、六水氯化镁3%、膨胀石墨0.5%、复合防渗剂4%、复合粘结剂1%、纸浆水15.5%。
其中，所述复合粘结剂由质量比为2：1的磷酸盐水溶液和氧化硅溶胶组成；所述复合防渗剂由质量比为1：2：3的纳米碳酸锶、纳米硫酸锶和纳米硫酸钡组成。所述镁铝尖晶石大颗粒的粒度为3 mm～4 mm；所述红柱石小颗粒的粒度为1 mm～2 mm；所述偏高岭土细粉的粒度小于0.074 mm、所述氧化铬绿细粉的粒度小于0.074 mm；所述高铝刚玉微粉的粒度小于0.043 mm、所述煤矸石微粉的粒度小于0.043 mm。
本实施例所述的含偏高岭土的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的压力下将所述混碾泥料压制成砖坯，并将所述砖坯自然干燥12小时后置于干燥窑内，在100℃的温度下干燥20小时；然后将干燥后的所述砖坯在1150℃的温度下进行煅烧24小时，从而制得所述含偏高岭土的耐火砖。
实施例3
本实施例提供一种含偏高岭土的耐火砖，它包括下述质量百分数的原料：镁铝尖晶石大颗粒20%、红柱石小颗粒20%、偏高岭土细粉15%、氧化铬绿细粉3%、高铝刚玉微粉9%、煤矸石微粉15%、镁质粘土2%、膨胀石墨0.5%、复合防渗剂4%、复合粘结剂1%、纸浆水10.5%。
其中，所述复合粘结剂由质量比为1：1的磷酸盐水溶液和氧化硅溶胶组成；所述复合防渗剂由质量比为1：2：2的纳米碳酸锶、纳米硫酸锶和纳米硫酸钡组成。所述镁铝尖晶石大颗粒的粒度为3 mm～4 mm；所述红柱石小颗粒的粒度为1 mm～2 mm；所述偏高岭土细粉的粒度小于0.074 mm、所述氧化铬绿细粉的粒度小于0.074 mm；所述高铝刚玉微粉的粒度小于0.043 mm、所述煤矸石微粉的粒度小于0.043 mm。
本实施例所述的含偏高岭土的耐火砖的制备方法与实施例1中的制备方法相同。
含偏高岭土的耐火砖性能检测
分别对实施例1～3制备的含偏高岭土的耐火砖的透气量、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、含偏高岭土的耐火砖性能检测
从上表中可以看出：实施例1～3提供的含偏高岭土的耐火砖的耐火软化点大于1700℃、常温耐压强度大于100MPa、抗折强度大于20MPa、体积密度大于3.0g/cm3、透气量小于0.6m3/h，因此所述含偏高岭土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 (10)

1.一种含偏高岭土的耐火砖，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19.5%～27%、红柱石小颗粒13%～25%、偏高岭土细粉15%～24.5%、氧化铬绿细粉3%～17%、高铝刚玉微粉7%～18%、煤矸石微粉11%～23%、镁质助烧剂2%～5%、膨胀石墨0.5%～2%、复合防渗剂4%～9%、复合粘结剂1%～4%、余量为纸浆水。
2.根据权利要求1所述的含偏高岭土的耐火砖，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%～23%、红柱石小颗粒14%～20%、偏高岭土细粉17%～19%、氧化铬绿细粉4%～13.5%、高铝刚玉微粉9%～15%、煤矸石微粉13%～19%、镁质助烧剂3%～5%、膨胀石墨1.5%～2%、复合防渗剂5%～7%、复合粘结剂3%～4%、余量为纸浆水。
3.根据权利要求1或2所述的含偏高岭土的耐火砖，其特征在于，所述复合粘结剂由质量比为（1～2）：1的磷酸盐水溶液和氧化硅溶胶组成。
4.根据权利要求1或2所述的含偏高岭土的耐火砖，其特征在于，所述复合防渗剂由质量比为1：2：（2～3）的纳米碳酸锶、纳米硫酸锶和纳米硫酸钡组成。
5.根据权利要求4所述的含偏高岭土的耐火砖，其特征在于，所述镁质助烧剂为轻烧镁砂粉、镁质粘土或六水氯化镁。
6.根据权利要求5所述的含偏高岭土的耐火砖，其特征在于，所述镁铝尖晶石大颗粒的粒度为3 mm～4 mm。
7.根据权利要求6所述的含偏高岭土的耐火砖，其特征在于，所述红柱石小颗粒的粒度为1 mm～2 mm。
8.根据权利要求7所述的含偏高岭土的耐火砖，其特征在于，所述偏高岭土细粉的粒度小于0.074 mm、所述氧化铬绿细粉的粒度小于0.074 mm；所述高铝刚玉微粉的粒度小于0.043 mm、所述煤矸石微粉的粒度小于0.043 mm。
9.一种含偏高岭土的耐火砖的制备方法，包括以下步骤：
（1）按照权利要求1～8任一项所述质量百分数的原料计算，将镁铝尖晶石大颗粒、红柱石小颗粒、偏高岭土细粉、氧化铬绿细粉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高铝刚玉微粉、煤矸石微粉、膨胀石墨、复合防渗剂、复合粘结剂和镁质助烧剂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偏高岭土的耐火砖。
10.根据权利要求9所述的含偏高岭土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12小时后置于干燥窑内，在80℃～120℃的温度下干燥18小时～24小时；然后将干燥后的所述砖坯在1150℃～1300℃的温度下进行煅烧15小时～24小时，从而制得所述含偏高岭土的耐火砖。
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Application publication date: 20180511