CN108840692A - 一种低碳铝镁质耐火材料及其制备方法 - Google Patents

一种低碳铝镁质耐火材料及其制备方法 Download PDF

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CN108840692A
CN108840692A CN201810946462.0A CN201810946462A CN108840692A CN 108840692 A CN108840692 A CN 108840692A CN 201810946462 A CN201810946462 A CN 201810946462A CN 108840692 A CN108840692 A CN 108840692A
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杨振东
崔应武
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Anhui Niushan New Materials Technology Co Ltd
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Abstract

本发明提供了一种低碳铝镁质耐火材料，由如下重量份的组分制成：电熔镁砂颗粒45‑50份，电熔镁砂细粉12‑16份，高铝矾土颗粒15‑20份，刚玉细粉6‑10份，轻烧镁砂微粉3‑4份，ɑ‑Al2O3微粉5‑6份，锆英石细粉7‑10份，微纳米石墨烯2.5‑3.5份，鳞片石墨0.5‑1份，铝粉1‑2份，碳化硅细粉6‑8份，硅粉2‑3份和液态酚醛树脂3‑4份。本发明所述的低碳铝镁质耐火材料，通过各组分的合理配比和粒度级配，并将微纳米石墨烯引入到碳复合耐火材料中；不仅降低了碳含量，还兼具有强度高、热导率低、热震稳定性及抗渣侵蚀性优良的特点。本发明还提供了所述低碳铝镁质耐火材料的制备方法。

Description

一种低碳铝镁质耐火材料及其制备方法
技术领域
本发明涉及耐火材料技术领域，特别是涉及一种低碳铝镁质耐火材料及其制备方法。
背景技术
耐火材料是高温行业不可缺少的基础材料，对支撑国家基础行业工业安全和国民经济的可持续发展具有重大意义。20世纪70年代，碳复合耐火材料(镁碳砖、镁钙碳砖、铝碳砖、铝锆碳砖等)出现，使氧化物-非氧化物复合耐火材料得到迅速发展，然而，传统碳复合耐火材料具有抗氧化性差、强度低等特点；随着现代钢铁冶金技术的发展，冶炼超低碳钢和洁净钢技术要求钢中的碳含量降至极低水平，但碳含量降低后，其抗热震性和抗渣渗透性也都大幅下降，因此，如何在目前工艺的基础上，提高低碳耐火材料的抗热震性及抗渣渗透性具有重要的意义。
发明内容
针对上述技术问题，本发明的目的在于提供一种低碳铝镁质耐火材料，在耐火材料的碳含量降低的同时既兼顾低热导率又具有优良抗热震性和抗渣渗透性。
本发明采用的技术方案是：
一种低碳铝镁质耐火材料，由如下重量份的组分制成：电熔镁砂颗粒45-50份，电熔镁砂细粉12-16份，高铝矾土颗粒15-20份，刚玉细粉6-10份，轻烧镁砂微粉3-4份，ɑ-Al2O3微粉5-6份，锆英石细粉7-10份，微纳米石墨烯2.5-3.5份，鳞片石墨0.5-1份，铝粉1-2份，碳化硅细粉6-8份，硅粉2-3份和液态酚醛树脂3-4份。
本发明所述的低碳铝镁质耐火材料，其中，由如下重量份的组分制成：电熔镁砂颗粒45份，电熔镁砂细粉16份，高铝矾土颗粒15份，刚玉细粉10份，轻烧镁砂微粉4份，ɑ-Al2O3微粉6份，锆英石细粉7份，微纳米石墨烯3.5份，鳞片石墨0.5份，铝粉1份，碳化硅细粉8份，硅粉2份和液态酚醛树脂4份。
本发明所述的低碳铝镁质耐火材料，其中，所述刚玉细粉为板状刚玉细粉，所述板状刚玉细粉的化学成分及质量百分含量为Al2O3>99.0wt％，所述刚玉细粉的粒径为30-70μm。
本发明所述的低碳铝镁质耐火材料，其中，所述电熔镁砂颗粒的粒径为0.1-5mm；所述高铝矾土颗粒的粒径为2-5mm。
本发明所述的低碳铝镁质耐火材料，其中，所述ɑ-Al2O3微粉的粒径为7-15μm；所述轻烧镁砂微粉的粒径≤0.005mm。
本发明所述的低碳铝镁质耐火材料，其中，所述鳞片石墨的化学成分及质量百分含量为C≥94.0％，粒径为0.1-4.5mm。
本发明所述的低碳铝镁质耐火材料，其中，所述微纳米石墨烯的粒径为100nm～5μm。
本发明所述的低碳铝镁质耐火材料，其中，所述电熔镁砂细粉、铝粉、碳化硅细粉和硅粉的粒径均≤0.088mm。
本发明所述的低碳铝镁质耐火材料的制备方法，包括以下步骤：
(1)按配比准备原料，将镁砂颗粒、高铝矾土颗粒、轻烧镁砂微粉和ɑ-Al2O3微粉加入到高速混炼机中进行搅拌混合均匀，混合时间为4-5min，得到混合料；
(2)在步骤(1)中所述混合料中加入所述液态酚醛树脂，然后加入微纳米石墨烯和鳞片石墨，搅拌混合均匀，混合8-10min；
(3)然后再加入所述镁砂微粉、刚玉细粉、锆英石细粉、铝粉、碳化硅细粉和硅粉搅拌混合5-8min后出料，困料15-24h后，压制成生胚；
(4)然后步骤(3)中所述生胚置在220-240℃进行热处理，热处理时间为15-20h，得到低碳铝镁质耐火材料。
本发明有益效果：
本发明所述的低碳铝镁质耐火材料，通过各组分的合理配比和粒度级配，并将微纳米石墨烯引入到碳复合耐火材料中，部分替代普通鳞片石墨并均匀分散在耐火材料中，可以填充到细小的缝隙中，增加材料的密实度；不仅降低了碳含量，还兼具有强度高、热导率低、热震稳定性及抗渣侵蚀性优良的特点。
本发明所述的低碳铝镁质耐火材料的制备方法，通过对个原料组分的加入顺序及工艺参数的设定，制备出了性能优良的低碳铝镁质耐火材料，且该方法加热时间短，成本低。
下面将结合具体实施例对本发明作进一步说明。
具体实施方式
实施例1
一种低碳铝镁质耐火材料，由如下重量份的组分制成：电熔镁砂颗粒45份，电熔镁砂细粉16份，高铝矾土颗粒15份，刚玉细粉10份，轻烧镁砂微粉4份，ɑ-Al2O3微粉6份，锆英石细粉7份，微纳米石墨烯3.5份，鳞片石墨0.5份，铝粉1份，碳化硅细粉8份，硅粉2份和液态酚醛树脂4份；
所述刚玉细粉为板状刚玉细粉，所述板状刚玉细粉的化学成分及质量百分含量为Al2O3>99.0wt％，所述刚玉细粉的粒径为30-70μm；所述电熔镁砂颗粒的粒径为0.1-5mm；所述高铝矾土颗粒的粒径为2-5mm，所述ɑ-Al2O3微粉的粒径为7-15μm；所述轻烧镁砂微粉的粒径≤0.005mm；所述鳞片石墨的化学成分及质量百分含量为C≥94.0％，粒径为0.1-4.5mm；所述微纳米石墨烯的粒径为100nm～5μm；所述电熔镁砂细粉、铝粉、碳化硅细粉和硅粉的粒径均≤0.088mm。
本实施例所述的低碳铝镁质耐火材料的制备方法，包括以下步骤：
(1)按配比准备原料，将镁砂颗粒、高铝矾土颗粒、轻烧镁砂微粉和ɑ-Al2O3微粉加入到高速混炼机中进行搅拌混合均匀，混合时间为5min，得到混合料；
(2)在步骤(1)中所述混合料中加入所述液态酚醛树脂，然后加入微纳米石墨烯和鳞片石墨，搅拌混合均匀，混合8min；
(3)然后再加入所述镁砂微粉、刚玉细粉、锆英石细粉、铝粉、碳化硅细粉和硅粉搅拌混合8min后出料，困料15h后，压制成生胚；
(4)然后步骤(3)中所述生胚置在240℃进行热处理，热处理时间为15h，得到低碳铝镁质耐火材料。
本实施例所制得的低碳铝镁质耐火材料，其性能测试结果为：1400℃×30min埋碳下的高温抗折强度为10.1-11.8MPa；16000C×3h埋碳气氛下进行渣侵蚀试验，无明显侵蚀或渗透现象。
实施例2
一种低碳铝镁质耐火材料，由如下重量份的组分制成：电熔镁砂颗粒50份，电熔镁砂细粉12份，高铝矾土颗粒20份，刚玉细粉6份，轻烧镁砂微粉3份，ɑ-Al2O3微粉5份，锆英石细粉10份，微纳米石墨烯2.5份，鳞片石墨1份，铝粉2份，碳化硅细粉6份，硅粉3份和液态酚醛树脂3份；
所述刚玉细粉为板状刚玉细粉，所述板状刚玉细粉的化学成分及质量百分含量为Al2O3>99.0wt％，所述刚玉细粉的粒径为30-70μm；所述电熔镁砂颗粒的粒径为0.1-5mm；所述高铝矾土颗粒的粒径为2-5mm，所述ɑ-Al2O3微粉的粒径为7-15μm；所述轻烧镁砂微粉的粒径≤0.005mm；所述鳞片石墨的化学成分及质量百分含量为C≥94.0％，粒径为0.1-4.5mm；所述微纳米石墨烯的粒径为100nm～5μm；所述电熔镁砂细粉、铝粉、碳化硅细粉和硅粉的粒径均≤0.088mm。
本实施例所述的低碳铝镁质耐火材料的制备方法，包括以下步骤：
(1)按配比准备原料，将镁砂颗粒、高铝矾土颗粒、轻烧镁砂微粉和ɑ-Al2O3微粉加入到高速混炼机中进行搅拌混合均匀，混合时间为4min，得到混合料；
(2)在步骤(1)中所述混合料中加入所述液态酚醛树脂，然后加入微纳米石墨烯和鳞片石墨，搅拌混合均匀，混合10min；
(3)然后再加入所述镁砂微粉、刚玉细粉、锆英石细粉、铝粉、碳化硅细粉和硅粉搅拌混合5min后出料，困料24h后，压制成生胚；
(4)然后步骤(3)中所述生胚置在220℃进行热处理，热处理时间为20h，得到低碳铝镁质耐火材料。
本实施例所制得的低碳铝镁质耐火材料，其性能测试结果为：1400℃×30min埋碳下的高温抗折强度为9.8-10.5MPa；16000C×3h埋碳气氛下进行渣侵蚀试验，无明显侵蚀或渗透现象。
以上所述的实施例仅仅是对本发明的优选实施方式进行描述，并非对本发明的范围进行限定，在不脱离本发明设计精神的前提下，本领域普通技术人员对本发明的技术方案作出的各种变形和改进，均应落入本发明权利要求书确定的保护范围内。

Claims (9)

1.一种低碳铝镁质耐火材料，其特征在于：由如下重量份的组分制成：电熔镁砂颗粒45-50份，电熔镁砂细粉12-16份，高铝矾土颗粒15-20份，刚玉细粉6-10份，轻烧镁砂微粉3-4份，ɑ-Al2O3微粉5-6份，锆英石细粉7-10份，微纳米石墨烯2.5-3.5份，鳞片石墨0.5-1份，铝粉1-2份，碳化硅细粉6-8份，硅粉2-3份和液态酚醛树脂3-4份。
2.根据权利要求1所述的低碳铝镁质耐火材料，其特征在于：由如下重量份的组分制成：电熔镁砂颗粒45份，电熔镁砂细粉16份，高铝矾土颗粒15份，刚玉细粉10份，轻烧镁砂微粉4份，ɑ-Al2O3微粉6份，锆英石细粉7份，微纳米石墨烯3.5份，鳞片石墨0.5份，铝粉1份，碳化硅细粉8份，硅粉2份和液态酚醛树脂4份。
3.根据权利要求1所述的低碳铝镁质耐火材料，其特征在于：所述刚玉细粉为板状刚玉细粉，所述板状刚玉细粉的化学成分及质量百分含量为Al2O3>99.0wt％，所述刚玉细粉的粒径为30-70μm。
4.根据权利要求1所述的低碳铝镁质耐火材料，其特征在于：所述电熔镁砂颗粒的粒径为0.1-5mm；所述高铝矾土颗粒的粒径为2-5mm。
5.根据权利要求1所述的低碳铝镁质耐火材料，其特征在于：所述ɑ-Al2O3微粉的粒径为7-15μm；所述轻烧镁砂微粉的粒径≤0.005mm。
6.根据权利要求1所述的低碳铝镁质耐火材料，其特征在于：所述鳞片石墨的化学成分及质量百分含量为C≥94.0％，粒径为0.1-4.5mm。
7.根据权利要求1所述的低碳铝镁质耐火材料，其特征在于：所述微纳米石墨烯的粒径为100nm～5μm。
8.根据权利要求1-7任意一项所述的低碳铝镁质耐火材料，其特征在于：所述电熔镁砂细粉、铝粉、碳化硅细粉和硅粉的粒径均≤0.088mm。
9.权利要求1-8任意一项所述的低碳铝镁质耐火材料的制备方法，其特征在于：包括以下步骤：
(1)按配比准备原料，将镁砂颗粒、高铝矾土颗粒、轻烧镁砂微粉和ɑ-Al2O3微粉加入到高速混炼机中进行搅拌混合均匀，混合时间为4-5min，得到混合料；
(2)在步骤(1)中所述混合料中加入所述液态酚醛树脂，然后加入微纳米石墨烯和鳞片石墨，搅拌混合均匀，混合8-10min；
(3)然后再加入所述镁砂微粉、刚玉细粉、锆英石细粉、铝粉、碳化硅细粉和硅粉搅拌混合5-8min后出料，困料15-24h后，压制成生胚；
(4)然后步骤(3)中所述生胚置在220-240℃进行热处理，热处理时间为15-20h，得到低碳铝镁质耐火材料。
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