CN109400126A - 一种铝溶胶结合浇注料的制备方法 - Google Patents
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 38
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 38
- 238000002360 preparation method Methods 0.000 title claims abstract description 14
- 239000004568 cement Substances 0.000 claims abstract description 12
- 238000000465 moulding Methods 0.000 claims abstract description 9
- 238000001035 drying Methods 0.000 claims abstract description 8
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000012423 maintenance Methods 0.000 claims abstract description 7
- 238000002156 mixing Methods 0.000 claims abstract description 5
- 229910052593 corundum Inorganic materials 0.000 claims description 21
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 20
- 239000010431 corundum Substances 0.000 claims description 13
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- 239000000126 substance Substances 0.000 claims description 9
- 239000000470 constituent Substances 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 8
- 238000003756 stirring Methods 0.000 claims description 8
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 8
- 229910052681 coesite Inorganic materials 0.000 claims description 6
- 229910052906 cristobalite Inorganic materials 0.000 claims description 6
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 6
- 229910052682 stishovite Inorganic materials 0.000 claims description 6
- 229910052905 tridymite Inorganic materials 0.000 claims description 6
- 229920005861 Castament® Polymers 0.000 claims description 4
- 239000003638 chemical reducing agent Substances 0.000 claims description 4
- 239000000463 material Substances 0.000 claims description 4
- 239000002253 acid Substances 0.000 claims description 2
- 238000005266 casting Methods 0.000 claims description 2
- 239000003595 mist Substances 0.000 claims description 2
- 238000005245 sintering Methods 0.000 claims description 2
- 239000007787 solid Substances 0.000 claims description 2
- 230000005611 electricity Effects 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims 1
- 238000010304 firing Methods 0.000 abstract description 6
- 239000007767 bonding agent Substances 0.000 abstract description 5
- 239000000693 micelle Substances 0.000 abstract description 3
- 239000000919 ceramic Substances 0.000 abstract description 2
- 238000011065 in-situ storage Methods 0.000 abstract description 2
- 238000007493 shaping process Methods 0.000 abstract 1
- 239000010432 diamond Substances 0.000 description 6
- 229910003460 diamond Inorganic materials 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000011449 brick Substances 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000004411 aluminium Substances 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 230000036314 physical performance Effects 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- -1 Silica sol compound Chemical class 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 238000003723 Smelting Methods 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 230000001112 coagulating effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 239000010977 jade Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/101—Refractories from grain sized mixtures
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B2235/3222—Aluminates other than alumino-silicates, e.g. spinel (MgAl2O4)
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/40—Metallic constituents or additives not added as binding phase
- C04B2235/402—Aluminium
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Abstract
本发明公开了一种铝溶胶结合浇注料的制备方法,包括以下步骤:混合、成型、养护和干燥。铝溶胶胶粒在成型后均匀分散于成型体中,在随后的养护、干燥过程中,被凝固的纯铝酸钙水泥原位固定于浇注料中;均分散的铝溶胶胶粒使浇注料具有较高的中低温强度,高温烧成后形成牢固的陶瓷结合,可有效降低浇注料的烧成温度,节能降耗显著;铝溶胶为不含硅的高纯结合剂,有利于提高浇注料的高温强度。
Description
技术领域
本发明属于耐火材料技术领域,具体涉及一种铝溶胶结合浇注料的制备方法。
背景技术
从不定形耐火材料的结合方式来看,有化学结合、水合结合、凝聚结合等多种结合形式,采用的结合剂也多式多样,但总的发展趋势是从可能引入高杂质的结合剂向可能引入低杂质、乃至无杂质的结合剂的方向发展,从而极大地提高了材料的纯度和高温服役性能。
硅溶胶结合浇注料在干燥性能、中低温强度、烧结性能等方面比其水泥结合浇注料具有明显的优势,因而获得了广泛应用,但也存在如下技术问题:不适合要求无硅的透气砖材料系统。
发明内容
本发明旨在克服现有技术缺陷,目的在于提供一种不含硅、适合制作透气砖的铝溶胶结合浇注料的制备方法。
为实现上述目的,本发明采用如下技术方案:
一种铝溶胶结合浇注料的制备方法,其特征在于包括下列步骤:
①混合:将25-35wt%的6-3mm刚玉,15-25wt%的3-1mm刚玉,15-25wt%的1-0mm刚玉,15-25wt%的325目刚玉,5-10wt%的325目尖晶石,1-5wt%的3μm氧化铝微粉,0.5-6wt%的纯铝酸钙水泥和0.05~0.25wt%的Castament FS65减水剂置入星式搅拌机,搅拌5-10分钟,制成均匀混合料;
②成型:向上述星式搅拌机中加入均匀混合料5~8wt%的铝溶胶,强力搅拌5-10分钟,然后注入模具,振动成型;
③养护:将上述成型体连同模具一起置入养护窑,于60~70℃养护5~8小时,脱模得到坯体;
④干燥:将上述坯体置入干燥窑,于180~210℃干燥12~24小时,制成铝溶胶结合浇注料。
所述刚玉为板状刚玉、白刚玉中的至少一种,板状刚玉和白刚玉化学组分的质量百分比为:Al2O3≥99%、SiO2≤0.2%、Fe2O3≤0.1%、R2O≤0.4%。
所述尖晶石为电熔尖晶石、烧结尖晶石中的至少一种,其化学组分的质量百分比为:Al2O3≥72%、MgO≤27%、Fe2O3≤0.1%、R2O≤0.3%。
所述氧化铝微粉为α-氧化铝微粉,其化学组分的质量百分比为:Al2O3≥99.3%、SiO2≤0.1%、Fe2O3≤0.1%、R2O≤0.3%。
所述纯铝酸钙水泥为安迈CA270水泥、安迈CA670水泥、凯诺斯SECAR-71水泥中的任意一种,其化学组分的质量百分比为:Al2O3≥68%、SiO2≤0.25%、CaO≤31%。
所述铝溶胶为酸性铝溶胶,固含量20-30%,粒径10-15nm,PH值4-5。
与现有技术相比,本发明带来的有益效果为:铝溶胶胶粒均匀分散于成型体中,在随后的养护、干燥过程中,被凝固的纯铝酸钙水泥原位固定于浇注料中;均分散的铝溶胶胶粒使浇注料具有较大的中低温强度,高温烧成后形成牢固的陶瓷结合,可有效降低浇注料的烧成温度,节能降耗显著;铝溶胶为不含硅的高纯结合剂,有利于提高刚浇注料的高温强度。
具体实施方式
以下结合具体实施例对本发明作进一步详细说明,并非对其保护范围的限制。
实施例1
①混合:将30wt%的6-3mm板状刚玉,20wt%的3-1mm板状刚玉,15wt%的1-0mm板状刚玉,23.9wt%的325目刚玉,5wt%的325目尖晶石,3wt%的3μm氧化铝微粉,3wt%的纯铝酸钙和0.1wt%的Castament FS65减水剂置入星式搅拌机,搅拌8分钟,制成均匀混合料;
②成型:向上述星式搅拌机中加入均匀混合料7wt%的铝溶胶,强力搅拌6分钟,然后注入模具,振动成型;
③养护:将上述成型体连同模具一起置入养护窑,于65℃养护6小时,脱模得到坯体;
④干燥:将上述坯体置入干燥窑,于200℃干燥15小时,制成铝溶胶结合浇注料。
本实施例所制备的铝溶胶结合浇注料,其主要物理性能是:显气孔率为15.6%,体积密度为3.22g/cm3,常温耐压强度73MPa,1450℃×3h烧成后耐压强度182MPa,1400℃×1h条件下高温抗折强度20.2MPa。
该铝溶胶结合浇注料经某钢厂200吨钢包透气砖使用,寿命达46次。
实施例2
①混合:将28wt%的6-3mm白刚玉,22wt%的3-1mm板状刚玉,16wt%的1-0mm板状刚玉,17.9wt%的325目刚玉,10wt%的325目尖晶石,4wt%的3μm氧化铝微粉,2wt%的纯铝酸钙和0.1wt%的Castament FS65减水剂置入星式搅拌机,搅拌7分钟,制成均匀混合料;
②成型:向上述星式搅拌机中加入均匀混合料7.5wt%的铝溶胶,强力搅拌7分钟,然后注入模具,振动成型;
③养护:将上述成型体连同模具一起置入养护窑,于68℃养护8小时,脱模得到坯体;
④干燥:将上述坯体置入干燥窑,于210℃干燥16小时,制成铝溶胶结合浇注料。
本实施例所制备的铝溶胶结合浇注料,其主要物理性能是:显气孔率为16.1%,体积密度为3.21g/cm3,常温耐压强度67MPa,1450℃×3h烧成后耐压强度169MPa,1400℃×1h条件下高温抗折强度19.3MPa。
该铝溶胶结合浇注料经某钢厂180吨钢包透气砖使用,寿命达45次。
从上述实施例可以看出,本发明提供一种体密大、气孔率低、常温耐压强度高、高温抗折强度高、服役寿命高的铝溶胶结合浇注料的制备方法。
Claims (7)
1.一种铝溶胶结合浇注料的制备方法,其特征在于包括下列步骤:
①混合:将25-35wt%的6-3mm刚玉,15-25wt%的3-1mm刚玉,15-25wt%的1-0mm刚玉,15-25wt%的325目刚玉,5-10wt%的325目尖晶石,1-5wt%的3μm氧化铝微粉,0.5-6wt%的纯铝酸钙水泥和0.05~0.25wt%的Castament FS65减水剂置入星式搅拌机,搅拌5-10分钟,制成均匀混合料;
②成型:向上述星式搅拌机中加入均匀混合料5~8wt%的铝溶胶,强力搅拌5-10分钟,然后注入模具,振动成型;
③养护:将上述成型体连同模具一起置入养护窑,于60~70℃养护5~8小时,脱模得到坯体;
④干燥:将上述坯体置入干燥窑,于180~210℃干燥12~24小时,制成铝溶胶结合浇注料。
2.根据权利要求1所述的铝溶胶结合浇注料的制备方法,其特征在于,所述刚玉为板状刚玉、白刚玉中的至少一种,其化学组分的质量百分比为:Al2O3≥99%、SiO2≤0.2%、Fe2O3≤0.1%、R2O≤0.4%。
3.根据权利要求1所述的铝溶胶结合浇注料的制备方法,其特征在于,所述尖晶石为电熔尖晶石、烧结尖晶石中的至少一种,其化学组分的质量百分比为:Al2O3≥72%、MgO≤27%、Fe2O3≤0.1%、R2O≤0.3%。
4.根据权利要求1所述的铝溶胶结合浇注料的制备方法,其特征在于,所述氧化铝微粉为α-氧化铝微粉,其化学组分的质量百分比为:Al2O3≥99.3%、SiO2≤0.1%、Fe2O3≤0.1%、R2O≤0.3%。
5.根据权利要求1所述的铝溶胶结合浇注料的制备方法,其特征在于,所述纯铝酸钙水泥为安迈CA270水泥、安迈CA670水泥、凯诺斯SECAR-71水泥中的任意一种,其化学组分的质量百分比为:Al2O3≥68%、SiO2≤0.25%、CaO≤31%。
6.根据权利要求1所述的铝溶胶结合浇注料的制备方法,其特征在于,所述铝溶胶为酸性铝溶胶,固含量20-30%,粒径10-15nm,PH值4-5。
7.根据权利要求1~6中任一项所述的铝溶胶结合浇注料的制备方法所制备的铝溶胶结合浇注料。
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CN113666720A (zh) * | 2021-07-26 | 2021-11-19 | 中国铝业股份有限公司 | 一种连续超高温炉炉盖及其浇注料 |
CN113666720B (zh) * | 2021-07-26 | 2023-11-28 | 中国铝业股份有限公司 | 一种连续超高温炉炉盖及其浇注料 |
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