CN108794021A - 一种工业窑炉用耐火修补剂 - Google Patents
一种工业窑炉用耐火修补剂 Download PDFInfo
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Abstract
本发明涉及高温耐火材料技术领域,具体涉及一种工业窑炉用耐火修补剂。该耐火修补剂中包括如下组分:氧化铝微粉、纳米二氧化硅、蓝晶石粉、纳米氧化锆、陶瓷纤维、聚乙烯醇、铝硅系溶胶、去离子水、金属量子点复合物、羟甲基纤维素钠、聚乙二醇和分散剂。其中,氧化铝微粉选择粒径为20‑40nm的α型氧化铝;分散剂为聚丙烯酸铵、三聚磷酸钠和六偏磷酸钠中的一种;陶瓷纤维选用高铝纤维、氧化铝多晶纤维和硅酸铝纤维中的一种,陶瓷纤维的纤维长度为2‑4mm。该型修补剂具有耐火度高,粘结性好,粘结强度大,热膨胀性好,耐冲蚀性能突出的优点。
Description
技术领域
本发明涉及高温耐火材料技术领域,具体涉及一种工业窑炉用耐火修补剂。
背景技术
工业窑炉是一种用耐火材料砌成的用以煅烧物料或烧成制品的设备。工业窑炉按使用热原的不同可分为火焰窑和电热窑;火焰窑的窑炉燃料多为重油,轻柴油或煤气、天然气;结构上由窑室、燃烧设备、通风设备,输送设备等四部分组成。电窑多半以电炉丝、硅碳棒或二硅化钼作为发热元件,其结构较为简单,主要结构为窑室。在具体行业,窑炉还有更多细分类型,如水泥回转窑、玻璃池窑、钢铁的高炉和转炉,化工行业的一些设备也可归为窑炉。但通常意义上的工业窑炉,范围主要指金属和无机材料的煅烧设备。
工业窑炉还有多种分类方法,例如,按热源面向坯体状况可分为明焰窑、隔焰窑和半隔焰窑;按坯体运载工具可分为有窑车窑、推板窑、辊道窑、输送带窑,步进梁式窑和气垫窑等;按通道数目可分为单通道窑、双通道窑和多通道窑。按操作方法可分为:连续窑(隧道窑)、半连续窑和间歇窑。
工业窑炉的工作温度范围宽泛,可以用于对包括200-2500℃温度范围内工业制品的加热,在应用中,可用于ZnO压敏电阻器、避雷器阀片、结构陶瓷、纺织陶瓷、PTC&NTC热敏电阻器、电子陶瓷滤波器、片式电容、瓷介电容、厚膜电路、片式电阻、磁性材料、粉末冶金、电子粉体、稀土化工、聚焦电位器、陶瓷基板、高铝陶瓷及其金属化,触头材料、硬质合金材料、钨钼材料等的烧成。
大型工业窑炉的窑室主要由耐材料砌筑加工,耐火材料长期使用后部分耐火砖会发生老化粉碎,或是在使用过程的由于金属或其他材料熔液的侵蚀作用而产生缝隙、缺口等,出现这种状况后要及时对窑炉进行修补,工业上对于窑炉的修补主要使用的材料是耐火火泥,这种材料具有较好的粘结效果,最重要的是材料的耐火度非常好,可以根据热窑工作温度的不同进行选择,使得修补后的窑炉依然可以保持良好的工作效能。
专利申请号CN200810049036.3提供的高铬质耐火泥浆是一种专用型修补剂,该型修补剂能与高铬砖良好匹配,提高德士古气化炉的整体寿命;但是该型修补剂的应用范围较窄,与铝质高温窑炉中耐火材料的相容性较差。专利申请号CN201010582755.9公开了一种碱性高温耐火泥浆,该泥浆由铝质粉料、水玻璃和黄糊精等材料制成,具有耐火度高、粘结强度高、体积稳定等优点,但是粘接剂与耐火砖等材料的相容性和结合强度不足,在流动性较强的工况下,容易脱落,耐液相侵蚀性能较差。
发明内容
针对现有技术中存在的问题,本发明提供了一种工业窑炉用耐火修补剂,该型修补剂具有耐火度高,粘结性好,粘结强度大,耐冲蚀性好的特点。
为了达到上述目的,本发明通过以下技术方案来实现的:
一种工业窑炉用耐火修补剂,按照质量份数,耐火修补剂中包括如下组分:氧化铝微粉75-80份,纳米二氧化硅40-45份,蓝晶石粉23-27份,纳米氧化锆5-9份,陶瓷纤维12-16份,聚乙烯醇15-18份,铝硅系溶胶43-47份,去离子水55-65份,金属量子点复合物4-8份,羟甲基纤维素钠2-5份,聚乙二醇1-3份,分散剂4-8份。
优选地,按照质量份数,耐火修补剂中包括如下组分:氧化铝微粉77-79,纳米二氧化硅42-44份,蓝晶石粉24-26份,纳米氧化锆6-8份,陶瓷纤维13-14份,聚乙烯醇16-18份,铝硅系溶胶44-45份,去离子水57-59份,金属量子点复合物6-7份,羟甲基纤维素钠3-4份,聚乙二醇1.5-2.3份,分散剂5-7份。
进一步优选地,按照质量份数,耐火修补剂中包括如下组分:氧化铝微粉78份,纳米二氧化硅43份,蓝晶石粉25份,纳米氧化锆7份,陶瓷纤维14份,聚乙烯醇17份,铝硅系溶胶44份,去离子水58份,金属量子点复合物6.3份,羟甲基纤维素钠3.5份,聚乙二醇2份,分散剂6份。
本发明中金属量子点复合物的制备方法为:将4份乙酸锌,6份油酸和100份壬基胺加入到真空反应釜中,以115-120℃的温度反应15-20min,然后充入氮气气氛保护,并加入2份三辛基膦和13份量子点,以180-190℃的温度继续反应15-20min,然后将产物冷却至室温,过滤用足量洗涤溶剂清洗,并离心、干燥得到所述金属量子点复合物。
优选地,金属量子点为AlN、AlP、ZnSe、ZnTe、ZnO、MgS和SiGe中的一种或任意多种的混合物。
优选地,氧化铝微粉选择粒径为20-40nm的α型氧化铝。
该材料具有耐火度高,惰性好,没有催化活性;化学性质非常稳定的优点,此外,该型材料还具有成型性好,晶相稳定、硬度高、尺寸稳定性好的特点;非常适合作为修补剂的粉质基料。
优选地,分散剂为聚丙烯酸铵、三聚磷酸钠和六偏磷酸钠中的一种。
分散剂的使用可以提高修补剂中各物料的分散效果,使得修补剂的性质更加均匀,从而使得产生的修补面各处性质均一,防止材料各处热稳定性和线性热膨胀率差异,导致的修补剂脱落、开裂、破损等问题。
优选地,陶瓷纤维选用高铝纤维、氧化铝多晶纤维和硅酸铝纤维中的一种,陶瓷纤维的纤维长度为2-4mm。
陶瓷纤维是一种具有极强的耐高温性能的材料,在修补剂中使用,可以提高料浆的机械强度,增强基料间的结合作用效果,避免修补剂形成的修复面开裂。
本发明提供的耐火修补剂的制备方法为:按照质量份数,将去离子水分成等质量的两份,第一份和铝硅系溶胶混合加入到分散釜中,以120-150r/min的转速搅拌得到稀释溶胶;第二份和金属量子点复合物、聚乙烯醇、分散剂混合,以200-250r/min的转速搅拌均匀得到分散液;然后将氧化铝微粉、纳米二氧化硅、蓝晶石粉、纳米氧化锆、陶瓷纤维预先混合均匀后投入到分散釜中,与稀释溶剂、分散液充分混合,并加入羟甲基纤维素钠和聚乙二醇,以550-600r/min的转速高速分散处理20-30min,得到的粘稠浆料即为所需的耐火修补剂。
该耐火修补剂用于修补工业窑炉时,将耐火修补剂填充于缺陷处,并保持耐火修补剂填充部位厚度高于缺陷处表面2-3mm,等待修补处自然硬化后,先升高炉温至350-450℃,保温,初步固化1.5-2h,再升高炉温至1500-1650℃,保温2-4h至耐火修补剂完全固化。
本发明具有如下的有益效果:
本发明提供耐火修补剂具有热稳定性好、耐火度高,粘结效果优秀的特点,非常适合用于工业热窑的窑室修补,提高工业热窑的使用寿命。该型修补剂还具有非常优秀的材料相容性,尤适合用于使用铝质耐火材料的热窑的修补,修补剂材料的性质均匀稳定,在各种温度状况下均不会出现开裂、粉化、膨胀鼓包的问题,具有极好的修补效果。
其中,耐火修补剂中添加了金属量子点复合物,该材料的使用,能够与硅铝系溶胶等材料产生协同作用,使得修补剂与热窑耐火材料间的粘结强度得到较大的提升,并提高修补剂的耐高温腐蚀性能;从而降低玻璃窑、冶金窑等窑炉使用过程中液相物质对修补面冲蚀作用产生的损害;进一步提高修补面的稳定性和整体的修复效果。
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
一种工业窑炉用耐火修补剂,按照质量份数,耐火修补剂中包括如下组分:氧化铝微粉75份,纳米二氧化硅40份,蓝晶石粉23份,纳米氧化锆5份,陶瓷纤维12份,聚乙烯醇15份,铝硅系溶胶43份,去离子水55份,金属量子点复合物4份,羟甲基纤维素钠2份,聚乙二醇1份,分散剂4份。
本发明中金属量子点复合物的制备方法为:将4份乙酸锌,6份油酸和100份壬基胺加入到真空反应釜中,以115℃的温度反应15min,然后充入氮气气氛保护,并加入2份三辛基膦和13份量子点,以180℃的温度继续反应15min,然后将产物冷却至室温,过滤用足量洗涤溶剂清洗,并离心、干燥得到所述金属量子点复合物。
其中,金属量子点为AlN。
组分中使用的氧化铝微粉选择粒径为20-40nm的α型氧化铝。
分散剂为聚丙烯酸铵。
陶瓷纤维选用高铝纤维;陶瓷纤维的纤维长度为2-4mm。
本实施例提供的耐火修补剂的制备方法为:按照质量份数,将去离子水分成等质量的两份,第一份和铝硅系溶胶混合加入到分散釜中,以120r/min的转速搅拌得到稀释溶胶;第二份和金属量子点复合物、聚乙烯醇、分散剂混合,以200r/min的转速搅拌均匀得到分散液;然后将氧化铝微粉、纳米二氧化硅、蓝晶石粉、纳米氧化锆、陶瓷纤维预先混合均匀后投入到分散釜中,与稀释溶剂、分散液充分混合,并加入羟甲基纤维素钠和聚乙二醇,以550r/min的转速高速分散处理20min,得到的粘稠浆料即为所需的耐火修补剂。
该耐火修补剂用于修补工业窑炉时,将耐火修补剂填充于缺陷处,并保持耐火修补剂填充部位厚度高于缺陷处表面2mm,等待修补处自然硬化后,先升高炉温至350℃,保温,初步固化1.5h,再升高炉温至1500℃,保温2h至耐火修补剂完全固化。
实施例2
一种工业窑炉用耐火修补剂,按照质量份数,耐火修补剂中包括如下组分:氧化铝微粉80份,纳米二氧化硅45份,蓝晶石粉27份,纳米氧化锆9份,陶瓷纤维16份,聚乙烯醇18份,铝硅系溶胶47份,去离子水65份,金属量子点复合物8份,羟甲基纤维素钠5份,聚乙二醇3份,分散剂8份。
本发明中金属量子点复合物的制备方法为:将4份乙酸锌,6份油酸和100份壬基胺加入到真空反应釜中,以120℃的温度反应20min,然后充入氮气气氛保护,并加入2份三辛基膦和13份量子点,以190℃的温度继续反应20min,然后将产物冷却至室温,过滤用足量洗涤溶剂清洗,并离心、干燥得到所述金属量子点复合物。
其中,金属量子点为AlP、ZnSe和SiGe的的质量比混合物。
组分中使用的氧化铝微粉选择粒径为20-40nm的α型氧化铝。
分散剂为三聚磷酸钠。
陶瓷纤维选用氧化铝多晶纤维,陶瓷纤维的纤维长度为2-4mm。
本实施例提供的耐火修补剂的制备方法为:按照质量份数,将去离子水分成等质量的两份,第一份和铝硅系溶胶混合加入到分散釜中,以150r/min的转速搅拌得到稀释溶胶;第二份和金属量子点复合物、聚乙烯醇、分散剂混合,以250r/min的转速搅拌均匀得到分散液;然后将氧化铝微粉、纳米二氧化硅、蓝晶石粉、纳米氧化锆、陶瓷纤维预先混合均匀后投入到分散釜中,与稀释溶剂、分散液充分混合,并加入羟甲基纤维素钠和聚乙二醇,以600r/min的转速高速分散处理30min,得到的粘稠浆料即为所需的耐火修补剂
该耐火修补剂用于修补工业窑炉时,将耐火修补剂填充于缺陷处,并保持耐火修补剂填充部位厚度高于缺陷处表面3mm,等待修补处自然硬化后,先升高炉温至450℃,保温,初步固化2h,再升高炉温至1650℃,保温4h至耐火修补剂完全固化。
实施例3
一种工业窑炉用耐火修补剂,按照质量份数,耐火修补剂中包括如下组分:氧化铝微粉78份,纳米二氧化硅43份,蓝晶石粉25份,纳米氧化锆7份,陶瓷纤维14份,聚乙烯醇17份,铝硅系溶胶44份,去离子水58份,金属量子点复合物6.3份,羟甲基纤维素钠3.5份,聚乙二醇2份,分散剂6份。
本发明中金属量子点复合物的制备方法为:将4份乙酸锌,6份油酸和100份壬基胺加入到真空反应釜中,以118℃的温度反应17min,然后充入氮气气氛保护,并加入2份三辛基膦和13份量子点,以185℃的温度继续反应17min,然后将产物冷却至室温,过滤用足量洗涤溶剂清洗,并离心、干燥得到所述金属量子点复合物。
其中,金属量子点为ZnTe、ZnO、MgS和SiGe按照1:2:3:1的质量比组合的混合物。
组分中使用的氧化铝微粉选择粒径为20-40nm的α型氧化铝。
分散剂为六偏磷酸钠。
陶瓷纤维选用高铝纤维、氧化铝多晶纤维和硅酸铝纤维中的一种,陶瓷纤维的纤维长度为2-4mm。
本实施例提供的耐火修补剂的制备方法为:按照质量份数,将去离子水分成等质量的两份,第一份和铝硅系溶胶混合加入到分散釜中,以140r/min的转速搅拌得到稀释溶胶;第二份和金属量子点复合物、聚乙烯醇、分散剂混合,以230r/min的转速搅拌均匀得到分散液;然后将氧化铝微粉、纳米二氧化硅、蓝晶石粉、纳米氧化锆、陶瓷纤维预先混合均匀后投入到分散釜中,与稀释溶剂、分散液充分混合,并加入羟甲基纤维素钠和聚乙二醇,以570r/min的转速高速分散处理25min,得到的粘稠浆料即为所需的耐火修补剂。
该耐火修补剂用于修补工业窑炉时,将耐火修补剂填充于缺陷处,并保持耐火修补剂填充部位厚度高于缺陷处表面2.5mm,等待修补处自然硬化后,先升高炉温至400℃,保温,初步固化1.8h,再升高炉温至1600℃,保温3h至耐火修补剂完全固化。
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 (10)
1.一种工业窑炉用耐火修补剂,其特征在于:按照质量份数,所述耐火修补剂中包括如下组分:氧化铝微粉75-80份,纳米二氧化硅40-45份,蓝晶石粉23-27份,纳米氧化锆5-9份,陶瓷纤维12-16份,聚乙烯醇15-18份,铝硅系溶胶43-47份,去离子水55-65份,金属量子点复合物4-8份,羟甲基纤维素钠2-5份,聚乙二醇1-3份,分散剂4-8份。
2.根据权利要求1所述的一种工业窑炉用耐火修补剂,其特征在于:按照质量份数,所述耐火修补剂中包括如下组分:氧化铝微粉77-79,纳米二氧化硅42-44份,蓝晶石粉24-26份,纳米氧化锆6-8份,陶瓷纤维13-14份,聚乙烯醇16-18份,铝硅系溶胶44-45份,去离子水57-59份,金属量子点复合物6-7份,羟甲基纤维素钠3-4份,聚乙二醇1.5-2.3份,分散剂5-7份。
3.根据权利要求1所述的一种工业窑炉用耐火修补剂,其特征在于:按照质量份数,所述耐火修补剂中包括如下组分:氧化铝微粉78份,纳米二氧化硅43份,蓝晶石粉25份,纳米氧化锆7份,陶瓷纤维14份,聚乙烯醇17份,铝硅系溶胶44份,去离子水58份,金属量子点复合物6.3份,羟甲基纤维素钠3.5份,聚乙二醇2份,分散剂6份。
4.根据权利要求1所述的一种工业窑炉用耐火修补剂,其特征在于:所述金属量子点复合物的制备方法为:将4份乙酸锌,6份油酸和100份壬基胺加入到真空反应釜中,以115-120℃的温度反应15-20min,然后充入氮气气氛保护,并加入2份三辛基膦和13份量子点,以180-190℃的温度继续反应15-20min,然后将产物冷却至室温,过滤用足量洗涤溶剂清洗,并离心、干燥得到所述金属量子点复合物。
5.根据权利要求4所述的一种工业窑炉用耐火修补剂,其特征在于:所述金属量子点为AlN、AlP、ZnSe、ZnTe、ZnO、MgS和SiGe中的一种或任意多种的混合物。
6.根据权利要求1所述的一种工业窑炉用耐火修补剂,其特征在于:所述氧化铝微粉选择粒径为20-40nm的α型氧化铝。
7.根据权利要求1所述的一种工业窑炉用耐火修补剂,其特征在于:所述分散剂为聚丙烯酸铵、三聚磷酸钠和六偏磷酸钠中的一种。
8.根据权利要求1所述的一种工业窑炉用耐火修补剂,其特征在于:所述陶瓷纤维选用高铝纤维、氧化铝多晶纤维和硅酸铝纤维中的一种,陶瓷纤维的纤维长度为2-4mm。
9.根据权利要求1所述的一种工业窑炉用耐火修补剂,其特征在于:所述耐火修补剂的制备方法为:按照质量份数,将去离子水分成等质量的两份,第一份和铝硅系溶胶混合加入到分散釜中,以120-150r/min的转速搅拌得到稀释溶胶;第二份和金属量子点复合物、聚乙烯醇、分散剂混合,以200-250r/min的转速搅拌均匀得到分散液;然后将氧化铝微粉、纳米二氧化硅、蓝晶石粉、纳米氧化锆、陶瓷纤维预先混合均匀后投入到分散釜中,与稀释溶剂、分散液充分混合,并加入羟甲基纤维素钠和聚乙二醇,以550-600r/min的转速高速分散处理20-30min,得到的粘稠浆料即为所需的耐火修补剂。
10.根据权利要求1所述的一种工业窑炉用耐火修补剂,其特征在于:所述耐火修补剂用于修补工业窑炉时,将耐火修补剂填充于缺陷处,并保持耐火修补剂填充部位厚度高于缺陷处表面2-3mm,等待修补处自然硬化后,先升高炉温至350-450℃,保温,初步固化1.5-2h,再升高炉温至1500-1650℃,保温2-4h至耐火修补剂完全固化。
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