CN108164276A - 一种隔热耐火材料及其制备方法 - Google Patents
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Abstract
本发明公开了一种隔热耐火材料及其制备方法,涉及耐高温材料领域,该耐火材料包括以下原料:黑龙江五大连池火山泥、三氧化二硼、锆英石、氮化铝、海泡石纤维、粉煤灰、微斜长石粉、耐火粘接剂和碱性激发剂。其制备方法是通过对原料的混合、成型、养护、烧结制得的。本发明的耐火材料制备简单方便,生产能耗低,具有优良的抗压强度、抗热震性、耐火隔热性以及理化稳定性,使用寿命长,应用领域宽泛,具有广阔的市场前景。
Description
技术领域
本发明涉及耐高温材料领域,具体涉及一种隔热耐火材料及其制备方法。
背景技术
耐火材料是工业领域的重要基础性材料,目前钢铁的冶炼、炉焦、机械热处理系统的工业炉窑及其内衬都需耐火材料,炉窑内及内衬需要使用大量的耐火砖,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(25%~50%)、玻璃相(25%~60%)和方石英及石英(最高可达30%)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。基主要应用于高炉、热风炉、加热炉、动力锅炉、石灰窑、回转窑、玻璃窑、陶瓷和耐火砖烧成窑中。该种粘土性耐火砖制备所需温度高、能耗大、燃烧时间长,生产成本高,制得的成品耐火砖导热系数高、抗压强度低,尤其是随温度的升高,其抗压强度逐渐降低,抗热震性能不足,进而影响耐火砖的使用寿命及使用领域。
发明内容
针对现有技术中存在的问题,本发明提供了一种隔热耐火材料及其制备方法,该种耐火材料制备简单方便,生产能耗低,具有优良的抗压强度、抗热震性、耐火隔热性以及理化稳定性,使用寿命长,应用领域宽泛,具有广阔的市场前景。
为了达到上述目的,本发明通过以下技术方案来实现的:
一种隔热耐火材料,包括以下按重量份计的原料:黑龙江五大连池火山泥200-300份、三氧化二硼8-14份、锆英石5-15份、氮化铝4-8份、海泡石纤维10-20份、粉煤灰20-30份、微斜长石粉15-25份、耐火粘接剂15-25份、发泡剂3-5份、稳泡剂1-3份和碱性激发剂1-5份;
上述的耐火粘接剂通过以下步骤制得:
步骤1:按重量份称取如下成分:纳米氟化石墨6-8份、硅凝胶3-5份、高分散白炭黑4-6份和液态磷酸二氢铝2-6份;
步骤2:将硅凝胶加热至220-240℃软化,保温20-30min;再边搅拌边加入纳米氟化石墨,保温继续搅拌40-50min;将温度升至280-320℃,依次加入液态磷酸二氢铝以及高分散白炭黑,保温搅拌20-30min后研磨分散处理,得混合粘液;
步骤3:将混合熔液输送至反应釜中,在真空、工作温度为140-160℃条件下混合反应2.5-3.5h即得。
进一步地,上述的耐火材料包括以下按重量份计的原料:黑龙江五大连池火山泥250份、三氧化二硼11份、锆英石10份、氮化铝6份、海泡石纤维15份、粉煤灰25份、微斜长石粉20份、耐火粘接剂20份、发泡剂4份、稳泡剂2份和碱性激发剂3份。
进一步地,上述的耐火粘接剂通过以下步骤制得:
步骤1:称取如下成分:纳米氟化石墨7份、硅凝胶4份、高分散白炭黑5份和液态磷酸二氢铝4份;
步骤2:将硅凝胶加热至230℃软化,保温25min;再边搅拌边加入纳米氟化石墨,保温继续搅拌45min;将温度升至300℃,依次加入液态磷酸二氢铝以及高分散白炭黑,保温搅拌25min后研磨分散处理,得混合粘液;
步骤3:将混合熔液输送至反应釜中,在真空、工作温度为150℃条件下混合反应3h即得。
优选地,上述的发泡剂采用碳酸氢钠。
优选地,上述的稳泡剂采用硅树脂聚醚乳液、聚丙烯酰胺或聚乙烯醇中任一种。
碱性激发剂采用硅酸盐、铝酸盐、磷酸盐、硫酸盐中任意两种组合的混合物。
上述的一种隔热耐火材料的制备方法,按照以下步骤进行:
(1)按所述重量份配比获取原料;
(2)向发泡剂中加入其10-12倍、温度为50-60℃的水,搅拌混匀,再加入稳泡剂继续搅拌5-15min,得发泡液备用;
(3)将所有原料及发泡液共同输送至搅拌机中搅拌6-8h,搅拌转速不低于60r/min,得混合物料;
(4)将混合物料浇筑至模具中压制成型,自然养护3-4天,得坯料;
(5)将坯料输送至烧结炉中,在温度为280-320℃条件下烧结2-3h即制得本发明的隔热耐火材料。
进一步地,上述搅拌机的搅拌转速控制在80-120r/min。
本发明具有如下的有益效果:
(1)本发明的隔热耐火材料生产原料来源广泛,绿色环保,制备简单方便,弃之不会造成环境的污染,且可对其进行简单加工,循环利用;制备过程中烧结所需温度低,能耗成本小,具体的相比现有的砖坯烧结或煅烧温度降低了4-6倍;
(2)本发明的隔热耐火材料通过对生产原料及工艺的改进优化,以黑龙江五大连池火山泥作为主料,加入三氧化二硼、锆英石、氮化铝等成分,再协同激发剂及发泡剂等外加助剂的辅助,使砖体结构中出现大量闭合结实微孔,具有牢固的骨架结构,制备过程中,再通过特制的耐火粘接剂对结构的稳固增强,显著地提高了耐火产品的抗压强度和抗热震性,大大降低了砖体的导热系数,隔热效果明显,耐火等级高,且随着环境温度的升高,该种耐火材料的产品结构趋于稳定,整体性能保持不变,提高了耐火材料的使用可靠性,延长了该种耐火材料制得的产品的使用寿命;
(3)本发明的耐火材料理化稳定性优良,具有耐腐蚀、耐老化、防水抗冻、阻音抗冲击等特性,大大拓宽了该种耐火材料的应用范围,具有广阔的市场前景。
具体实施方式
下面结合实施例对本发明的具体实施方式作进一步描述,以下实施例仅用于更加清楚地说明本发明的技术方案,而不能以此来限制本发明的保护范围。
实施例1
一种隔热耐火材料,称取以下原料:黑龙江五大连池火山泥200kg、三氧化二硼8kg、锆英石5kg、氮化铝4kg、海泡石纤维10kg、粉煤灰20kg、微斜长石粉15kg、耐火粘接剂15kg、发泡剂:碳酸氢钠3kg、稳泡剂:聚乙烯醇1kg和碱性激发剂1kg;上述的碱性激发剂由0.6kg的硅酸盐和0.4kg的铝酸盐组成。
上述的耐火粘接剂的制备:
步骤1:称取如下成分:纳米氟化石墨6kg、硅凝胶3kg、高分散白炭黑4kg和液态磷酸二氢铝2kg;
步骤2:将硅凝胶加热至220℃软化,保温20min;再边搅拌边加入纳米氟化石墨,保温继续搅拌40min;将温度升至280℃,依次加入液态磷酸二氢铝以及高分散白炭黑,保温搅拌20min后研磨分散处理,得混合粘液;
步骤3:将混合熔液输送至反应釜中,在真空、工作温度为140℃条件下混合反应2.5h即得。
上述的一种隔热耐火材料的制备方法如下:
(1)发泡液的制备:先向发泡剂中加入其10倍、温度为50℃的水,搅拌混匀,再加入稳泡剂继续搅拌5min,得发泡液备用;
(2)混料:将所有原料及发泡液共同输送至搅拌机中搅拌6h,搅拌转速为80r/min,得混合物料;
(3)耐火产品成型:将混合物料浇筑至砖体模具中压制成型,自然养护3天,得砖坯;
(4)产品烧结:将砖坯输送至烧结炉中,在温度为280℃条件下烧结2h即制得本发明的隔热耐火材料。
实施例2
一种隔热耐火材料,称取以下原料:黑龙江五大连池火山泥250kg、三氧化二硼11kg、锆英石10kg、氮化铝6kg、海泡石纤维15kg、粉煤灰25kg、微斜长石粉20kg、耐火粘接剂20kg、发泡剂:碳酸氢钠4kg、稳泡剂:硅树脂聚醚乳液2kg和碱性激发剂3kg;上述的碱性激发剂由1.5kg的铝酸盐和1.5kg的磷酸盐组成。
上述的耐火粘接剂的制备:
步骤1:称取如下成分:纳米氟化石墨7kg、硅凝胶4kg、高分散白炭黑5kg和液态磷酸二氢铝4kg;
步骤2:将硅凝胶加热至230℃软化,保温25min;再边搅拌边加入纳米氟化石墨,保温继续搅拌45min;将温度升至300℃,依次加入液态磷酸二氢铝以及高分散白炭黑,保温搅拌25min后研磨分散处理,得混合粘液;
步骤3:将混合熔液输送至反应釜中,在真空、工作温度为150℃条件下混合反应3h即得。
上述的一种隔热耐火材料的制备方法如下:
(1)发泡液的制备:先向发泡剂中加入其11倍、温度为55℃的水,搅拌混匀,再加入稳泡剂继续搅拌10min,得发泡液备用;
(2)混料:将所有原料及发泡液共同输送至搅拌机中搅拌7,搅拌转速为120r/min,得混合物料;
(3)耐火产品成型:将混合物料浇筑至砖体模具中压制成型,自然养护4天,得砖坯;
(4)产品烧结:将砖坯输送至烧结炉中,在温度为300℃条件下烧结2.5h即制得本发明的隔热耐火材料。
实施例3
一种隔热耐火材料,称取以下原料:黑龙江五大连池火山泥300kg、三氧化二硼14kg、锆英石15kg、氮化铝8kg、海泡石纤维20kg、粉煤灰30kg、微斜长石粉25kg、耐火粘接剂25kg、发泡剂:碳酸氢钠5kg、稳泡剂:聚丙烯酰胺3kg和碱性激发剂5kg;上述的碱性激发剂由2.5kg的磷酸盐和2.5kg的硫酸盐组成。
上述的耐火粘接剂的制备:
步骤1:称取如下成分:纳米氟化石墨8kg、硅凝胶5kg、高分散白炭黑6kg和液态磷酸二氢铝6kg;
步骤2:将硅凝胶加热至240℃软化,保温30min;再边搅拌边加入纳米氟化石墨,保温继续搅拌50min;将温度升至320℃,依次加入液态磷酸二氢铝以及高分散白炭黑,保温搅拌30min后研磨分散处理,得混合粘液;
步骤3:将混合熔液输送至反应釜中,在真空、工作温度为160℃条件下混合反应3.5h即得。
上述的一种隔热耐火材料的制备方法如下:
(1)发泡液的制备:先向发泡剂中加入其12倍、温度为60℃的水,搅拌混匀,再加入稳泡剂继续搅拌15min,得发泡液备用;
(2)混料:将所有原料及发泡液共同输送至搅拌机中搅拌8h,搅拌转速为100r/min,得混合物料;
(3)耐火产品成型:将混合物料浇筑至砖体模具中压制成型,自然养护4天,得砖坯;
(4)产品烧结:将砖坯输送至烧结炉中,在温度为320℃条件下烧结3h即制得本发明的隔热耐火材料。
性能检测
对上述实施例1-3制得的耐火砖料进行性能检测,与下列对比例4中的耐火砖料进行比较,两组砖料规格相同,皆为长230×宽114×高65(单位:mm);具体的检测项目及数据结果见下表1所示;
对比例4的耐火砖料包括以下按重量百分比计的原料:耐火水泥(铝酸盐)40%-60%、镁砂粒15%~25%、莫来石粉15%~25%、硅微粉0%~10%。
表1:
以上所述仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (8)
1.一种隔热耐火材料,其特征在于,包括以下按重量份计的原料:黑龙江五大连池火山泥200-300份、三氧化二硼8-14份、锆英石5-15份、氮化铝4-8份、海泡石纤维10-20份、粉煤灰20-30份、微斜长石粉15-25份、耐火粘接剂15-25份、发泡剂3-5份、稳泡剂1-3份和碱性激发剂1-5份;
所述耐火粘接剂通过以下步骤制得:
步骤1:按重量份称取如下成分:纳米氟化石墨6-8份、硅凝胶3-5份、高分散白炭黑4-6份和液态磷酸二氢铝2-6份;
步骤2:将硅凝胶加热至220-240℃软化,保温20-30min;再边搅拌边加入纳米氟化石墨,保温继续搅拌40-50min;将温度升至280-320℃,依次加入液态磷酸二氢铝以及高分散白炭黑,保温搅拌20-30min后研磨分散处理,得混合粘液;
步骤3:将混合熔液输送至反应釜中,在真空、工作温度为140-160℃条件下混合反应2.5-3.5h即得。
2.根据权利要求1所述的一种隔热耐火材料,其特征在于,包括以下按重量份计的原料:黑龙江五大连池火山泥250份、三氧化二硼11份、锆英石10份、氮化铝6份、海泡石纤维15份、粉煤灰25份、微斜长石粉20份、耐火粘接剂20份、发泡剂4份、稳泡剂2份和碱性激发剂3份。
3.根据权利要求1所述的一种隔热耐火材料,其特征在于,所述耐火粘接剂通过以下步骤制得:
步骤1:称取如下成分:纳米氟化石墨7份、硅凝胶4份、高分散白炭黑5份和液态磷酸二氢铝4份;
步骤2:将硅凝胶加热至230℃软化,保温25min;再边搅拌边加入纳米氟化石墨,保温继续搅拌45min;将温度升至300℃,依次加入液态磷酸二氢铝以及高分散白炭黑,保温搅拌25min后研磨分散处理,得混合粘液;
步骤3:将混合熔液输送至反应釜中,在真空、工作温度为150℃条件下混合反应3h即得。
4.根据权利要求1所述的一种隔热耐火材料,其特征在于,所述发泡剂为碳酸氢钠。
5.根据权利要求1所述的一种隔热耐火材料,其特征在于,所述稳泡剂为硅树脂聚醚乳液、聚丙烯酰胺或聚乙烯醇中任一种。
6.根据权利要求1所述的一种隔热耐火材料,其特征在于,所述碱性激发剂为硅酸盐、铝酸盐、磷酸盐、硫酸盐中任意两种组合的混合物。
7.一种根据权利要求1-6任一项所述的隔热耐火材料的制备方法,其特征在于,包括以下步骤:
(1)按所述重量份配比获取原料;
(2)向发泡剂中加入其10-12倍、温度为50-60℃的水,搅拌混匀,再加入稳泡剂继续搅拌5-15min,得发泡液备用;
(3)将所有原料及发泡液共同输送至搅拌机中搅拌6-8h,搅拌转速不低于60r/min,得混合物料;
(4)将混合物料浇筑至模具中压制成型,自然养护3-4天,得坯料;
(5)将坯料输送至烧结炉中,在温度为280-320℃条件下烧结2-3h即可。
8.根据权利要求7所述的一种隔热耐火材料的制备方法,其特征在于,所述搅拌机的搅拌转速为80-120r/min。
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