CN109111236A - 一种多孔高强莫来石耐火原料的制备方法 - Google Patents
一种多孔高强莫来石耐火原料的制备方法 Download PDFInfo
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- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 title claims abstract description 45
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 13
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Abstract
一种多孔高强莫来石耐火原料的制备方法，属于耐火原料技术领域。具体步骤为：以铝矾土生料和造孔剂为原料，外加上述原料10～40wt％的水，混磨混合均匀后成型，得到耐火原料生坯；生坯在烘烤条件为110℃的电热鼓风干燥箱中烘烤24h，再将干燥好的生坯放入烧结炉中，在1550℃下保温3h，升温速率3℃·min‑1，高温下原位反应烧结生成莫来石晶体；莫来石晶体烧成出窑冷却后分级破碎，即得到多孔高强莫来石耐火原料。优点在于，制备的多孔高强莫来石耐火原料气孔尺寸小、孔径分布均匀、体积密度小、导热系数低、热稳定性好、线收缩率低、耐压强度高。
Description
技术领域
本发明属于耐火原料技术领域，特别涉及一种多孔高强莫来石耐火原料的制备方法。
背景技术
随着国家对节能环保问题越来越重视，对节能减排的要求越来越高，低热导率、高强度的多孔均质铝矾土成为一种理想的节能型耐火原料，该原料具有良好的保温节能效果，其轻质化的特点能有效地达到降低窑炉负载、降低筒体温度、节能环保的目的，同时其内部的多孔化结构能有效的传导内部应力，提高铝矾土的抗热冲击性能。
目前，已经有一些关于轻质莫来石材料的文献报导。但是所描述的轻质莫来石材料大多气孔孔径大、材料强度低，只能作为一种保温隔热材料使用；材料的制备工艺过程复杂，工业生产成本高；而且一般添加一种或多种有机材料作为造孔剂，在煅烧过程中很可能会排出污染环境的气体。
专利技术“一种莫来石轻质隔热砖及其制备方法”(CN201611228577.3)中叙述了一种莫来石轻质隔热砖，该隔热砖以焦宝石、蓝晶石、粘土、氧化铝微粉、结合剂为原料，以一种自制的主要成分为锯末的材料作为造孔剂，通过机压成型的方式制备而成。该隔热砖体积密度小、导热系数低，但耐压强度不超过10MPa。
专利技术“莫来石轻质隔热耐火砖及其生产方法”(CN201410145534.3)中叙述了一种莫来石轻质隔热砖，该隔热砖以氢氧化铝、焦宝石、蓝晶石、结合剂为原料，该发明工艺过程简单，得到的耐火砖体积密度低，但耐压强度低、导热系数偏大。
专利技术“一种基于焦宝石的莫来石轻质隔热砖及其制备方法”(CN201510942152.2)中叙述了一种莫来石轻质隔热砖，该隔热砖以焦宝石、蓝晶石、粘土、氧化铝微粉、锯末、莫来石纤维和结合剂为原料，该隔热砖体积密度低，但是该隔热砖耐压强度降低，且在工业生产过程中容易出现莫来石纤维分散不均的问题。
专利技术“一种微孔莫来石陶瓷分离膜支撑体及其制备方法”(CN201510841038.6)中叙述了一种微孔莫来石陶瓷，该微孔莫来石陶瓷主要通过铝硅质原料、氧化铝原料、胶凝材料烧制而成。该微孔莫来石陶瓷耐压强度较高，但制备工艺过程复杂。
发明内容
本发明的目的在于提供一种多孔高强莫来石耐火原料的制备方法，解决了多孔高强莫来石耐火原料的制备工艺复杂的问题。该方法制备的多孔高强莫来石耐火原料气孔尺寸小、孔径分布均匀、体积密度小、导热系数低、热稳定性好、线收缩率低、耐压强度高。该发明产品将来应用在耐火材料中，能有效降低能耗和荷载，达到节能减排的效果。
一种多孔高强莫来石耐火原料的制备方法，具体步骤及参数如下：
1、多孔高强莫来石耐火原料是以70～95wt％的铝矾土生料、5～30wt％的造孔剂为原料，外加上述原料10～40wt％的水，混磨混合均匀后成型，得到耐火原料生坯；
2、生坯在烘烤条件为110℃的电热鼓风干燥箱中烘烤24h，再将干燥好的生坯放入烧结炉中，在1550℃下保温3h，升温速率3℃·min-1，高温下原位反应烧结生成莫来石晶体。
3、莫来石晶体烧成出窑冷却后分级破碎，即得到多孔高强莫来石耐火原料。
步骤1所述的铝矾土生料中的铝含量为50～95％，其粒径小于0.088mm。
步骤1所述的造孔剂的制备方法以轻漂珠、氢氧化铝、膨胀珍珠岩、淀粉、拟薄水铝石中的一种或多种为原料，以一定质量配比混合后混磨均匀，筛分后得到造孔剂。其中造孔剂化学成分中Al2O3和SiO2的合量大于80wt％。轻漂珠的主要化学成分为30～40wt％Al2O3、55～65wt％SiO2，其粒径小于0.05mm；所述氢氧化铝的主要化学成分为65～68wt％Al2O3，其粒径小于0.05mm；所述膨胀珍珠岩的主要化学成分为10～15wt％Al2O3、70～75wt％SiO2，其粒径小于0.05mm；所述淀粉的主要成分为C12H22O11，其粒径小于0.05mm；所述拟薄水铝石的主要化学成分为Al2O3·nH2O，其中n＝0.08～0.62；其粒径小于0.05mm。
所述造孔剂的中位径小于0.05mm。
步骤1中所述混磨混合均匀后成型的方式为半干法机压成型。
该耐火原料生坯的烘烤条件为90～120℃下烘烤24～48h。
该耐火原料的煅烧条件为1500～1700℃下保温3～12h，升温速率2～10℃·min-1。
采用上述的技术方案，本发明制备的多孔高强莫来石耐火原料与现有的技术产品相比具有以下优势：
本发明采用半干法机压成型的方式，制备工艺简单；主要原料为铝矾土生料，原料来源丰富；原料中不含任何有机成分，没有污染气体的排放；铝矾土生料和造孔剂原位生成的莫来石，发育形状良好，成网格状交错，含有大量的封闭气孔；通过调整原料配比，可以调整产品的体积体密、耐压强度、气孔率等各项物理指标，满足不同的环境要求。本发明制备的多孔高强莫来石耐火原料经检测：体积密度1.60g/cm3～2.2g/cm3。常温耐压强度50～120MPa；显气孔率20％～65％；气孔的平均孔径为10～100μm；重烧线膨胀(或收缩)系数0.1％～1％。1000℃导热系数导热系数≤1.30w/m·k。
本发明的优点在于，制备的多孔高强莫来石耐火原料气孔尺寸小、孔径分布均匀、体积密度小、导热系数低、热稳定性好、线收缩率低、耐压强度高，且产品的各项物理指标可以根据现场实际情况调整。
具体实施方式
以下将结合具体实施方式对本发明做进一步的描述：以下的具体实施案例中，铝矾土生料中的铝含量为80％，粒径小于0.088mm；轻漂珠的主要化学成分为35％Al2O3、60％SiO2，容重为450kg/m3，粒径小于0.05mm；氢氧化铝的主要化学成分为65～68wt％Al2O3，其粒径小于0.05mm；耐火原料生坯的成型方式为半干法机压成型。
实施例1
按重量百分比称取原料：90wt％铝矾土生料和10wt％轻漂珠。在混炼机中初步混合后，外加上述原料重量百分比21wt％的水，进一步碾压混合均匀后采用半干法机压成型得到耐火原料生坯；将生坯放入110℃的电热鼓风干燥箱中烘烤24h，再将干燥好的生坯放入烧结炉中，在1550℃下保温3h，升温速率3℃·min-1，冷却后得到多孔高强莫来石耐火原料。
经检测，通过本实施方案制备的多孔高强莫来石耐火原料的显气孔率为31.3％、平均孔径32μm、体积密度2.17g·cm-3、耐压强度106.2MPa，1000℃导热系数导热系数1.23w/m·k。
实施例2
按重量百分比称取原料：85wt％铝矾土生料、10wt％轻漂珠和8wt％氢氧化铝。先将轻漂珠和氢氧化铝在混炼机中混磨均与，筛分后取粒径小于0.05mm的混合料作为造孔剂；再将铝矾土生料和造孔剂混炼机中初步混合，之后外加上述原料重量百分比23wt％的水，进一步碾压混合均匀后采用半干法机压成型得到耐火原料生坯；将生坯放入110℃的电热鼓风干燥箱中烘烤24h，再将干燥好的生坯放入烧结炉中，在1550℃下保温3h，升温速率3℃·min-1，冷却后得到多孔高强莫来石耐火原料。
经检测，通过本实施方案制备的多孔高强莫来石耐火原料的显气孔率为40.1％、平均孔径12μm、体积密度1.89g·cm-3、耐压强度95.1MPa、1000℃导热系数导热系数1.08w/m·k。
实施例3
按重量百分比称取原料：85wt％铝矾土生料、10wt％轻漂珠和8wt％氢氧化铝。先将轻漂珠和氢氧化铝在混炼机中混磨均与，筛分后取粒径小于0.05mm的混合料作为造孔剂；再将铝矾土生料和造孔剂混炼机中初步混合，之后外加上述原料重量百分比23wt％的水，进一步碾压混合均匀后采用半干法机压成型得到耐火原料生坯；将生坯放入110℃的电热鼓风干燥箱中烘烤24h，再将干燥好的生坯放入烧结炉中，在1600℃下保温3h，升温速率3℃·min-1，冷却后得到多孔高强莫来石耐火原料。
经检测，通过本实施方案制备的多孔高强莫来石耐火原料的显气孔率为31.2％、平均孔径21μm、体积密度2.01g·cm-3、耐压强度124.7MPa，1000℃导热系数导热系数1.18w/m·k。
Claims (6)
1.一种多孔高强莫来石耐火原料的制备方法，其特征在于，具体步骤及参数如下：
1)多孔高强莫来石耐火原料是以70～95wt％的铝矾土生料、5～30wt％的造孔剂为原料，外加上述原料10～40wt％的水，混磨混合均匀后成型，得到耐火原料生坯；
2)生坯在烘烤条件为110℃的电热鼓风干燥箱中烘烤24h，再将干燥好的生坯放入烧结炉中，在1550℃下保温3h，升温速率3℃·min-1，高温下原位反应烧结生成莫来石晶体；
3)莫来石晶体烧成出窑冷却后分级破碎，即得到多孔高强莫来石耐火原料。
2.根据权利要求1所述的方法，其特征在于，步骤1)中所述的铝矾土生料中的铝含量为50～95％，其粒径小于0.088mm。
3.根据权利要求1所述的方法，其特征在于，步骤1)所述的造孔剂的制备方法以轻漂珠、氢氧化铝、膨胀珍珠岩、淀粉、拟薄水铝石中的一种或多种为原料，以一定质量配比混合后混磨均匀，筛分后得到造孔剂；其中造孔剂化学成分中Al2O3和SiO2的合量大于80wt％；轻漂珠的主要化学成分为30～40wt％Al2O3、55～65wt％SiO2，其粒径小于0.05mm；所述氢氧化铝的主要化学成分为65～68wt％Al2O3，其粒径小于0.05mm；所述膨胀珍珠岩的主要化学成分为10～15wt％Al2O3、70～75wt％SiO2，其粒径小于0.05mm；所述淀粉的主要成分为C12H22O11，其粒径小于0.05mm；所述拟薄水铝石的主要化学成分为Al2O3·nH2O，其中n＝0.08～0.62；其粒径小于0.05mm。
4.根据权利要求3所述的方法，其特征在于，所述造孔剂的中位径小于0.05mm。
5.根据权利要求1所述的方法，其特征在于，步骤1)中所述混磨混合均匀后成型的方式为半干法机压成型。
6.根据权利要求1所述的方法，其特征在于，所述耐火原料生坯的烘烤条件为90～120℃下烘烤24～48h；该耐火原料的煅烧条件为1500～1700℃下保温3～12h，升温速率2～10℃·min-1。
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