CN109206126B - 一种不烧耐火砖用复合结合剂及其制备方法 - Google Patents
一种不烧耐火砖用复合结合剂及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种不烧耐火砖用复合结合剂及其制备方法。该结合剂的组成成分及各组分的重量份数为:按重量份称量:氧化镁超细粉3~9份,聚合氯化铝3~4份,氯化镁4~8份,木质素磺酸钙4~8份,以及硅微粉8~9份。制备时,按重量份称量各组分,将氧化镁超细粉、聚合氯化铝和氯化镁混合后置于多功能搅合机中,然后搅拌均匀,再与木质素磺酸钙以及硅微粉搅拌均匀得到复合结合剂。本发明所述复合结合剂的含碳量较低,减少对钢水污染;制备不烧耐火砖时,无需高温烧成,仅需在160~200℃干燥处理24小时即可,可节能降本;制成的耐火砖的低温相极少,具有较高的常温和高温强度,并具有较好的抗水浸潮解性能;本发明所述结合剂制备方法,操作简便,易于控制,降低生产成本,适于工业化推广。
Description
技术领域
本发明涉及耐火材料技术领域,尤其涉及一种不烧耐火砖用复合结合剂及其制备方法。
背景技术
耐火材料的生产过程中,仅靠耐火骨料和粉料本身是难以达到成品耐火砖的质量要求,这其中必须依靠结合剂或外加剂与耐火材料的粘结。耐火材料结合剂是指在耐火材料生产过程中使散状耐火原料胶粘在一起并产生足够常温及高温强度的物质。用作耐火材料的结合剂,不但要求具有较好的冷态和热态结合强度,而且要求具有较好的成型性能和耐火性能。
耐火材料结合剂种类繁多,现在常用的已达六十余种,而且新产品还在不断出现。常用耐火材料结合剂包括铝酸钙水泥、水玻璃、磷酸及磷酸盐、木质素磺酸钙、酚醛树脂、硫酸铝、聚合氯化铝、ρ-Al2O3、硅溶胶、硅酸乙酯、纤维素以及沥青等。耐火材料结合剂共有六类结合方式:1)水化结合:借助于常温下结合剂与水发生水化反应生成水化产物而产生结合;2)化学结合:借助于结合剂与硬化剂,或结合剂与耐火材料之间在常温下发生化学反应,或加热时发生化学反应生成具有结合剂作用的化合物而产生结合;3)聚合结合:借助于加催化剂或交联剂,使结合剂发生缩聚形成网络状结构而产生结合强度;4)陶瓷结合:系指低温烧结结合,即在散状耐火材料中加入可降低烧结温度的助剂或金属粉末,以大大降低液相出现温度,促进低温下固一液反应而产生低温烧结结合;5)粘着结合:是借助于物理吸附作用、扩散作用和静电作用等而产生结合;6)凝聚结合:依靠加入凝聚剂使微粒子(胶体粒子)发生凝聚而产生结合。
单一的结合剂难以兼顾常温和高温性能;同时,有些结合剂易受潮,且水化分解,砖体的结合强度激剧下降。最近研发的各种复合结合剂,如酚醛树脂类,其在使用过程往往又会对钢水造成一定污染,引起增碳。
发明内容
为了解决上述问题,本发明提出一种不烧耐火砖用复合结合剂及其制备方法,该不烧耐火砖用复合结合剂由氧化镁超细粉、聚合氯化铝、氯化镁、木质素磺酸钙以及硅微粉组成,按照一定重量比例进行制备,其成分中含碳量较低,从而减少对钢水污染,可用于钢包、RH炉;利用本复合结合剂制备不烧耐火砖,无需高温烧成,仅需在160~200℃干燥处理24小时即可,可节能降本。
本发明的目的在于提供一种不烧耐火砖用复合结合剂,其组成成分及各组分的重量份数为:氧化镁超细粉3~9份,聚合氯化铝3~4份,氯化镁4~8份,木质素磺酸钙4~8份,以及硅微粉8~9份。
优选地,所述氧化镁超细粉中氧化镁≥97%,45μm筛余<5.0%。
优选地,所述聚合氯化铝为固体,其中三氧化二铝≥28.0%,水不溶物≤1.5%。
优选地,所述氯化镁为结晶体,其中氯化镁≥45.0%,硫酸根离子≤2.80%,碱金属氯化物(以Cl-计)≤0.90%。
优选地,所述木质素磺酸钙为粉末,其中木质素≥50~65%,水不溶物≤0.5~1.5%,水份≤8%。
优选地,所述硅微粉中二氧化硅≥94%,45μm筛余<2.4%。
本发明的另一目的在于提供一种不烧耐火砖用复合结合剂的制备方法,包括以下步骤:按重量份称量:氧化镁超细粉3~9份,聚合氯化铝3~4份,氯化镁4~8份,木质素磺酸钙4~8份,以及硅微粉8~9份;将氧化镁超细粉、聚合氯化铝和氯化镁混合得到一次混合料,然后将一次混合料置于多功能搅合机中,搅拌均匀得到二次混合料;再将二次混合料以及称量好的木质素磺酸钙和硅微粉都置于多功能搅合机,搅拌均匀得到不烧耐火砖用复合结合剂。
本发明的有益效果:1)本发明所述不烧耐火砖用复合结合剂的含碳量较低,从而减少对钢水污染,可用于钢包、RH炉;2)本发明所述不烧耐火砖用复合结合剂制备不烧耐火砖时,无需高温烧成,仅需在160~200℃干燥处理24小时即可,可节能降本;制成的不烧耐火砖低温相极少,具有较高的常温和高温强度,达到50MPa以上;在水中浸泡24h,强度下降轻微,并具有较好的抗水浸潮解性能,便于存放;3)本发明的不烧耐火砖用复合结合剂的制备方法,操作简便,易于控制,可大幅降低生产成本,适于工业化推广应用。
具体实施方式
首先,需要说明的是,以下将以示例方式来具体说明所述不烧耐火砖用复合结合剂的特点和优点等,然而所有的描述仅是用来进行说明的,而不应将其理解为对本发明形成任何限制。
为避免重复,先将实施例中涉及的有关原料技术参数或制作方法统一说明,实施例中不再赘述:
所述氧化镁超细粉中氧化镁≥97%,45μm筛余<5.0%。
所述聚合氯化铝为固体,其中三氧化二铝≥28.0%,水不溶物≤1.5%。
所述氯化镁为结晶体,其中氯化镁≥45.0%,硫酸根离子≤2.80%,碱金属氯化物(以Cl-计)≤0.90%。
所述木质素磺酸钙为粉末,其中木质素≥50~65%,水不溶物≤0.5~1.5%,水份≤8%。
所述硅微粉中二氧化硅≥94%,45μm筛余<2.4%。
实施例1
本实施例所述不烧耐火砖用复合结合剂,其组成成分及各组分的重量份数为:氧化镁超细粉9份,聚合氯化铝4份,氯化镁4份,木质素磺酸钙4份,以及硅微粉9份。
上述不烧耐火砖用复合结合剂的制备方法,包括以下步骤:按重量份称量:氧化镁超细粉9份,聚合氯化铝4份,氯化镁4份,木质素磺酸钙4份,以及硅微粉9份;将氧化镁超细粉、聚合氯化铝和氯化镁混合得到一次混合料,然后将一次混合料置于多功能搅合机中,搅拌均匀得到二次混合料;再将二次混合料以及称量好的木质素磺酸钙和硅微粉都置于多功能搅合机,搅拌均匀得到不烧耐火砖用复合结合剂。
将制得的复合结合剂用于制备不烧耐火砖,其中不烧耐火砖由以下重量百分含量的原料制成:粒度为5~3mm的特优铝矾土29%,粒度为3~1mm的板状刚玉18%,粒度为1~0mm的板状刚玉18%,粒度为180目的电熔刚玉24%,粒度为1~0mm的97电熔镁砂2%,粒度为200目的97电熔镁砂2%,粒度为5μm的α~Al2O36%,复合结合剂3%,水1%。
不烧砖制备:(1)按上述重量百分含量称取:粒度为5~3mm的特优铝矾土29%,粒度为3~1mm的板状刚玉18%,粒度为1~0mm的板状刚玉18%,粒度为180目的电熔刚玉24%,粒度为1~0mm的97电熔镁砂2%,粒度为200目的97电熔镁砂2%,粒度为5μm的α~Al2O36%,复合结合剂3%,水1%;
(2)将粒度为5~3mm的特优铝矾土,粒度为3~1mm的板状刚玉,粒度为1~0mm的板状刚玉,粒度为1~0mm的97电熔镁砂,混合并装入多功能搅和机,再加入复合结合剂和水,搅拌均匀;
(3)步骤(2)的多功能搅和机中加入粒度为180目的电熔刚玉,粒度为200目的97电熔镁砂,粒度为5μm的α~Al2O3,并搅拌均匀得到混合料;
(4)称取114g步骤(3)中混合料,以200MPa压力进行压制不烧砖的压块;
(5)将步骤(4)中制得的压块在烘箱中200℃下烘干24h,即可制得不烧砖1。
对本实施例制得的不烧砖1进行性能测试,结果如下:
常温下强度为:60.5MPa;浸水24h后,烘干后强度为:50.0MPa;在1600℃下3h,线性变化为:0.12%,强度为:66.2MPa。
实施例2
本实施例所述不烧耐火砖用复合结合剂,其组成成分及各组分的重量份数为:氧化镁超细粉3份,聚合氯化铝3份,氯化镁8份,木质素磺酸钙8份,以及硅微粉8份。
上述不烧耐火砖用复合结合剂的制备方法,包括以下步骤:按重量份称量:氧化镁超细粉3份,聚合氯化铝3份,氯化镁8份,木质素磺酸钙8份,以及硅微粉8份;将氧化镁超细粉、聚合氯化铝和氯化镁混合得到一次混合料,然后将一次混合料置于多功能搅合机中,搅拌均匀得到二次混合料;再将二次混合料以及称量好的木质素磺酸钙和硅微粉都置于多功能搅合机,搅拌均匀得到不烧耐火砖用复合结合剂。
将制得的复合结合剂用于制备不烧耐火砖,其中不烧耐火砖由以下重量百分含量的原料制成:粒度为5~3mm的98电熔镁砂16%,粒度为3~1mm的98电熔镁砂29%,粒度为1~0mm的98电熔镁砂36%,粒度为200目的97电熔镁砂8%,粒度为5μm的α~Al2O38%,复合结合剂3%,水1%。
不烧砖制备:(1)按上述重量百分含量称取:粒度为5~3mm的98电熔镁砂16%,粒度为3~1mm的98电熔镁砂29%,粒度为1~0mm的98电熔镁砂36%,粒度为200目的97电熔镁砂8%,粒度为5μm的α~Al2O38%,复合结合剂3%,水1%;
(2)将粒度为5~3mm的98电熔镁砂,粒度为3~1mm的98电熔镁砂,粒度为1~0mm的98电熔镁砂,混合并装入多功能搅和机,再加入复合结合剂和水,搅拌均匀;
(3)步骤(2)的多功能搅和机中加入粒度为200目的97电熔镁砂,粒度为5μm的α~Al2O3,并搅拌均匀得到混合料;
(4)称取114g步骤(3)中混合料,以200MPa压力进行压制不烧砖的压块;
(5)将步骤(4)中制得的压块在烘箱中1600℃下烘干24h,即可制得不烧砖2。
对本实施例制得的不烧砖2进行性能测试,结果如下:
常温下强度为:66.0MPa;浸水24h后,烘干后强度为:59.6MPa;在1600℃下3h,线性变化为:-0.25%,强度为:85.0MPa。
Claims (7)
1.一种不烧耐火砖用复合结合剂,其特征在于,其组成成分及各组分的重量份数为:氧化镁超细粉3~9份,聚合氯化铝3~4份,氯化镁4~8份,木质素磺酸钙4~8份,以及硅微粉8~9份;所述氧化镁超细粉45μm筛余<5.0%。
2.根据权利要求1所述不烧耐火砖用复合结合剂,其特征在于:所述氧化镁超细粉中氧化镁≥97.0%。
3.根据权利要求1所述不烧耐火砖用复合结合剂,其特征在于:所述聚合氯化铝为固体,其中三氧化二铝≥28.0%,水不溶物≤1.5%。
4.根据权利要求1所述不烧耐火砖用复合结合剂,其特征在于:所述氯化镁为结晶体,其中氯化镁≥45.0%,硫酸根离子≤2.80%,以Cl-计碱金属氯化物≤0.90%。
5.根据权利要求1所述不烧耐火砖用复合结合剂,其特征在于:所述木质素磺酸钙为粉末,其中木质素≥50~65%,水不溶物≤0.5~1.5%,水份≤8%。
6.根据权利要求1所述不烧耐火砖用复合结合剂,其特征在于:所述硅微粉中二氧化硅≥94.0%,45μm筛余<2.4%。
7.一种如权利要求1~6任意一项所述不烧耐火砖用复合结合剂的制备方法,其特征在于,包括以下步骤:按重量份称量:氧化镁超细粉3~9份,聚合氯化铝3~4份,氯化镁4~8份,木质素磺酸钙4~8份,以及硅微粉8~9份;将氧化镁超细粉、聚合氯化铝和氯化镁混合得到一次混合料,然后将一次混合料置于多功能搅合机中,搅拌均匀得到二次混合料;再将二次混合料以及称量好的木质素磺酸钙和硅微粉都置于多功能搅合机,搅拌均匀得到不烧耐火砖用复合结合剂。
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