CN109516822B - 高强度过滤陶瓷材料及其制备方法 - Google Patents

高强度过滤陶瓷材料及其制备方法 Download PDF

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CN109516822B
CN109516822B CN201710843691.5A CN201710843691A CN109516822B CN 109516822 B CN109516822 B CN 109516822B CN 201710843691 A CN201710843691 A CN 201710843691A CN 109516822 B CN109516822 B CN 109516822B
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刘绍辉
黄乃乔
袁明辉
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Pingxiang Putian Hi Tech Industrial Co ltd
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Abstract

本发明公开了一种高强度过滤陶瓷材料，其包括中心核和外壁，中心核和外壁主要组成以重量份数计均为骨料45‑60份、粘结剂20‑30份、助熔剂5‑10份、致孔剂15‑20份，所述中心核的骨料为α‑氧化铝，所述外壁的骨料为氮化铝；所述外壁部分材料内侧延伸入中心核内部形成骨架，所述中心核和外壁厚度之比为5‑1:1，所述骨料颗粒为球形或近球形。采用α‑氧化铝作为中心核主要成分，氮化铝作为外壁主要成分，利用外壁氮化铝的高强度和成孔性能好的特点包覆α‑氧化铝后能最大程度地提高过滤介质的耐磨性，并且(近)球形骨料颗粒，进一步有利于内部孔隙的形成，并且由于骨料颗粒为球形，各颗粒之间的接触面均一从而有利于材料本身的均匀性和结构的稳定性。

Description

高强度过滤陶瓷材料及其制备方法
技术领域
本发明涉及一种陶瓷材料，尤其是涉及一种高强度过滤陶瓷材料，同时涉及其制备方法。
背景技术
随着全球经济的快速发展，能源的不断消耗，电力、建材、冶金、钢铁、化工等工业产生的高温烟气粉尘对环境造成了严重的污染。在上述行业中，经过工艺作用后常余留高温含尘气体，为了满足不同工艺的需要和能量回收的要求，都需要对这些高温含尘气体进行除尘，常见的高温气体除尘技术有陶瓷过滤除尘技术、颗粒层过滤除尘技术、金属微孔过滤除尘技术、旋风除尘技术、静电除尘技术等。陶瓷过滤除尘技术因陶瓷材料具有优良的耐高温性能、热稳定性和化学稳定性，可在高达1200℃温度下进行工作，并且在氧化、还原等高温环境下具有很好的耐腐蚀性而成为最具有发展前途的除尘技术之一。多孔陶瓷是目前常用的过滤介质，其组成通常为以耐火原料为骨料，配以结合剂等经过高温烧结而制成的陶瓷过滤材料，其结构内部具有大量贯通的微细气孔。根据实际生产需求常常需要采用不同孔径的过滤介质，因此制备过程中如何获得孔径分布均匀，孔径范围符合要求的多孔陶瓷是亟须解决的问题。此外在高温除尘过程中由于过滤本身的特性，过滤介质往往需要长期承受高温气体的冲击，过滤介质本身必须能够耐受这种较高的温度，而且高温气体中的灰尘对于过滤介质的冲击极易造成过滤介质的磨损，而一旦过滤介质被磨损，不仅会破坏过滤介质的结构影响过滤效果，同时降低了过滤介质的使用寿命。
发明内容
为解决上述技术问题，本发明提供一种使用寿命长、过滤效果好的多孔陶瓷过滤介质。
本发明的技术方案是提供一种高强度过滤陶瓷材料，其包括中心核和外壁，中心核和外壁主要组成以重量份数计均为骨料45-60份、粘结剂20-30份、助熔剂5-10份、致孔剂15-20份，所述中心核的骨料为α-氧化铝，所述外壁的骨料为氮化铝；所述外壁内侧部分材料延伸入中心核内部形成骨架，所述中心核和外壁厚度之比为5-1:1，所述骨料颗粒为球形或近球形。
所述骨料颗粒的平均粒径为5-10nm，粒径分布为7-8nm的颗粒数占总量的90％。
所述致孔剂为微晶纤维素、聚乙烯微球、蛋清、改性淀粉中的一种或几种。
本发明还提供上述高强度过滤陶瓷材料的制备方法，步骤包括：
S1.将α-氧化铝骨料、粘结剂、助熔剂、致孔剂按照配比混合后，投入球磨机中球磨5-10min，制得混合料1；
S2.将混合料1放入柱形容器中，将柱形容器放入冷冻池，仅容器底部接触冷冻液，容器敞口放置，至混合料1冷冻完全；
S3.冷冻完全的柱形混合料1干燥后，烧制，烧制温度为1300-1400℃；
S4.将氮化铝骨料、粘结剂、助熔剂、致孔剂按照配比混合后，投入球磨机中球磨5-10min，制得混合料2，加入水，制成含混合料2的质量百分比为60-80％的浆液；
S5.步骤S3的柱形混合料1浸入步骤S4的浆液中，浸渍时间为6-18h，制得坯体；
S6.将步骤S5的坯体干燥后进行烧制，烧制温度为1550-1600℃。
所述步骤S2中冷冻速率为1-3℃/h。
所述步骤S3中烧制过程为以8～10℃/min升温至760～800℃，保温2～4h；再以8～10℃/min升温至1300～1400℃，保温8～12h后冷却至常温。
所述步骤S6中烧制参数为以8～10℃/min升温至800～900℃，保温3～6h；再以8～10℃/min升温至1550～1600℃，保温8～12h后冷却至常温。
本发明的优点和有益效果：采用α-氧化铝作为中心核主要成分，氮化铝作为外壁主要成分，利用外壁氮化铝的高强度和成孔性能好的特点包覆α-氧化铝后能最大程度地提高过滤介质的耐磨性，并且(近)球形骨料颗粒，进一步有利于内部孔隙的形成，并且由于骨料颗粒为球形，各颗粒之间的接触面均一从而有利于材料本身的均匀性和结构的稳定性；此外采用冷冻方法首先制备多孔陶瓷过滤介质的中心核，使中心核一部分形成大孔，同时在大孔内形成微孔，而通过浸渍外壁原料的浆液使外壁材料不仅包覆在中心核表面且能够浸入中心核的孔道并被孔道壁所吸附，一方面能够作为中心核的部分支撑骨架，另一方面能够使介质形成阶梯型孔径的孔道，有利于对烟气不同成分的过滤。
具体实施方式
下面结合具体实施方式对本发明作进一步说明。
实施例1
本发明提供一种高强度过滤陶瓷材料，其包括中心核和外壁，主要组成以重量份数计均为骨料45份、长石5份、微晶纤维素35份既作为粘结剂又作为致孔剂，所述中心核的骨料为α-氧化铝，所述外壁的骨料为氮化铝；所述外壁部分材料内侧延伸入中心核内部形成骨架，所述中心核和外壁厚度之比为5:1，所述骨料颗粒为球形或近球形，其平均粒径5-10nm，粒径分布为7-8nm的颗粒数占总量的90％。
本发明还提供上述高强度过滤陶瓷材料的制备方法，步骤包括：
S1.将α-氧化铝骨料、微晶纤维素、长石按照配比混合后，投入球磨机中球磨5min，制得混合料1；
S2.将混合料1放入柱形容器中，将柱形容器放入冷冻池，仅容器底部接触冷冻液，容器敞口放置，冷冻速率为1℃/h，至混合料1冷冻完全；
S3.冷冻完全的柱形混合料1干燥后，烧制，烧制过程为以8～10℃/min升温至760～800℃，保温2～4h；再以8～10℃/min升温至1300～1360℃，保温8～12h后冷却至常温；
S4.将氮化铝骨料、微晶纤维素、长石按照配比混合后，投入球磨机中球磨5min，制得混合料2，加入水，制成含混合料2的质量百分比为60％的浆液；
S5.步骤S3的柱形混合料1浸入步骤S4的浆液中，浸渍时间为6h，制得坯体；
S6.将步骤S5的坯体干燥后进行烧制，烧制参数为以8～10℃/min升温至800～900℃，保温3～6h；再以8～10℃/min升温至1550～1600℃，保温8～12h后冷却至常温。分阶段升温保温有利于消除内部应力，使陶瓷材料内部结构更加稳定。
实施例2
本发明提供一种高强度过滤陶瓷材料，其包括中心核和外壁，主要组成以重量份数计均为骨料50份、石灰石10份、改性淀粉40份既作为粘结剂又作为致孔剂，所述中心核的骨料为α-氧化铝，所述外壁的骨料为氮化铝；所述外壁内侧部分材料延伸入中心核内部形成骨架，所述中心核和外壁厚度之比为5:1，所述骨料颗粒为球形或近球形，其平均粒径5-10nm，粒径分布为7-8nm的颗粒数占总量的90％。
本发明还提供上述高强度过滤陶瓷材料的制备方法，步骤包括：
S1.将α-氧化铝骨料、微晶纤维素、长石按照配比混合后，投入球磨机中球磨10min，制得混合料1；
S2.将混合料1放入柱形容器中，将柱形容器放入冷冻池，仅容器底部接触冷冻液，容器敞口放置，冷冻速率为2℃/h，至混合料1冷冻完全；
S3.冷冻完全的柱形混合料1干燥后，烧制，烧制过程为以8～10℃/min升温至760～800℃，保温2～4h；再以8～10℃/min升温至1300～1360℃，保温8～12h后冷却至常温；
S4.将氮化铝骨料、微晶纤维素、长石按照配比混合后，投入球磨机中球磨10min，制得混合料2，加入水，制成含混合料2的质量百分比为80％的浆液；
S5.步骤S3的柱形混合料1浸入步骤S4的浆液中，浸渍时间为12h，制得坯体；
S6.将步骤S5的坯体干燥后进行烧制，烧制参数为以8～10℃/min升温至800～900℃，保温3～6h；再以8～10℃/min升温至1550～1600℃，保温8～12h后冷却至常温。分阶段升温保温有利于消除内部应力，使陶瓷材料内部结构更加稳定。
实施例3
本发明提供一种高强度过滤陶瓷材料，其包括中心核和外壁，主要组成以重量份数计均为骨料60份、白云石7份、水玻璃20份，聚乙烯微球15份，所述中心核的骨料为α-氧化铝，所述外壁的骨料为氮化铝；所述外壁内侧部分材料延伸入中心核内部形成骨架，所述中心核和外壁厚度之比为3:1，所述骨料颗粒为球形或近球形，其平均粒径5-10nm，粒径分布为7-8nm的颗粒数占总量的90％。
本发明还提供上述高强度过滤陶瓷材料的制备方法，步骤包括：
S1.将α-氧化铝骨料、微晶纤维素、长石按照配比混合后，投入球磨机中球磨8min，制得混合料1；
S2.将混合料1放入柱形容器中，将柱形容器放入冷冻池，仅容器底部接触冷冻液，容器敞口放置，冷冻速率为3℃/h，至混合料1冷冻完全；
S3.冷冻完全的柱形混合料1干燥后，烧制，烧制过程为以8～10℃/min升温至760～800℃，保温2～4h；再以8～10℃/min升温至1360～1400℃，保温8～12h后冷却至常温；
S4.将氮化铝骨料、微晶纤维素、长石按照配比混合后，投入球磨机中球磨8min，制得混合料2，加入水，制成含混合料2的质量百分比为70％的浆液；
S5.步骤S3的柱形混合料1浸入步骤S4的浆液中，浸渍时间为10h，制得坯体；
S6.将步骤S5的坯体干燥后进行烧制，烧制参数为以8～10℃/min升温至800～900℃，保温3～6h；再以8～10℃/min升温至1550～1600℃，保温8～12h后冷却至常温。分阶段升温保温有利于消除内部应力，使陶瓷材料内部结构更加稳定。
实施例4
本发明提供一种高强度过滤陶瓷材料，其包括中心核和外壁，主要组成以重量份数计均为骨料55份、珍珠岩8份、水玻璃25份，蛋清15份，所述中心核的骨料为α-氧化铝，所述外壁的骨料为氮化铝；所述外壁内侧部分材料延伸入中心核内部形成骨架，所述中心核和外壁厚度之比为4:1，所述骨料颗粒为球形或近球形，其平均粒径5-10nm，粒径分布为7-8nm的颗粒数占总量的90％。
本发明还提供上述高强度过滤陶瓷材料的制备方法，步骤包括：
S1.将α-氧化铝骨料、微晶纤维素、长石按照配比混合后，投入球磨机中球磨10min，制得混合料1；
S2.将混合料1放入柱形容器中，将柱形容器放入冷冻池，仅容器底部接触冷冻液，容器敞口放置，冷冻速率为1℃/h，至混合料1冷冻完全；
S3.冷冻完全的柱形混合料1干燥后，烧制，烧制过程为以8～10℃/min升温至760～800℃，保温2～4h；再以8～10℃/min升温至1360～1400℃，保温8～12h后冷却至常温；
S4.将氮化铝骨料、微晶纤维素、长石按照配比混合后，投入球磨机中球磨8min，制得混合料2，加入水，制成含混合料2的质量百分比为65％的浆液；
S5.步骤S3的柱形混合料1浸入步骤S4的浆液中，浸渍时间为18h，制得坯体；
S6.将步骤S5的坯体干燥后进行烧制，烧制参数为以8～10℃/min升温至800～900℃，保温3～6h；再以8～10℃/min升温至1550～1600℃，保温8～12h后冷却至常温。分阶段升温保温有利于消除内部应力，使陶瓷材料内部结构更加稳定。
本发明产品的性能检测结果如下：
Figure BDA0001411366890000051
表中数据说明本发明的产品具有良好的过滤性能和耐磨性能。
本发明实施例涉及到的材料、试剂和实验设备，如无特别说明，均为符合陶瓷材料领域的市售产品。
以上所述，仅为本发明的优选实施例，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明的核心技术的前提下，还可以做出改进和润饰，这些改进和润饰也应属于本发明的专利保护范围。与本发明的权利要求书相当的含义和范围内的任何改变，都应认为是包括在权利要求书的范围内。

Claims (6)

1.一种高强度过滤陶瓷材料的制备方法，其特征在于，包括中心核和外壁，中心核和外壁主要组成以重量份数计均为骨料45-60份、粘结剂20-30份、助熔剂5-10份、致孔剂15-20份，所述中心核的骨料为α-氧化铝，所述外壁的骨料为氮化铝；所述外壁内侧材料延伸入中心核内部形成骨架，所述中心核和外壁厚度之比为5-1:1，所述骨料颗粒为球形或近球形；
所述的制备方法，其特征在于包括如下步骤：
S1. 将α-氧化铝骨料、粘结剂、助熔剂、致孔剂按照配比混合后，投入球磨机中球磨5-10min，制得混合料1；
S2. 将混合料1放入柱形容器中，将柱形容器放入冷冻池，仅容器底部接触冷冻液，容器敞口放置，至混合料1冷冻完全；
S3. 冷冻完全的柱形混合料1干燥后，烧制，烧制温度为1300-1400℃；
S4. 将氮化铝骨料、粘结剂、助熔剂、致孔剂按照配比混合后，投入球磨机中球磨5-10min，制得混合料2，加入水，制成含混合料2的质量百分比为60-80％的浆液；
S5. 步骤S3的柱形混合料1浸入步骤S4的浆液中，浸渍时间为6-18h，制得坯体；
S6. 将步骤S5的坯体干燥后进行烧制，烧制温度为1550-1600℃。
2.根据权利要求1所述的高强度过滤陶瓷材料的制备方法，其特征在于，所述骨料颗粒的平均粒径为5-10nm，粒径分布为7-8nm的颗粒数占总量的90％。
3.根据权利要求1所述的高强度过滤陶瓷材料的制备方法，其特征在于，所述致孔剂为微晶纤维素、聚乙烯微球、蛋清、改性淀粉中的一种或几种。
4.根据权利要求1所述的高强度过滤陶瓷材料的制备方法，其特征在于，所述步骤S2中冷冻速率为1-3℃/h。
5.根据权利要求1所述的高强度过滤陶瓷材料的制备方法，其特征在于，所述步骤S3中烧制过程为以8～10℃/min升温至760～800℃，保温2～4h；再以8～10℃/ min升温至1300～1400℃，保温8～12h后冷却至常温。
6.根据权利要求1所述的高强度过滤陶瓷材料的制备方法，其特征在于，所述步骤S6中烧制参数为以8～10℃/min升温至800～900℃，保温3～6h；再以8～10℃/ min升温至1550～1600℃，保温8～12h后冷却至常温。
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