CN109650882B - 一种纤维内衬用复合涂料及其制备方法 - Google Patents

一种纤维内衬用复合涂料及其制备方法 Download PDF

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CN109650882B
CN109650882B CN201811627677.2A CN201811627677A CN109650882B CN 109650882 B CN109650882 B CN 109650882B CN 201811627677 A CN201811627677 A CN 201811627677A CN 109650882 B CN109650882 B CN 109650882B
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王发现
王巍
王霄鑫
刘鹏
李文超
陈东辉
孙晓强
李红凌
王龙
张焱
朱新雨
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Boiler & Pressure Vessel Safety Inspection Institute Of Henan Province
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Abstract

本发明公开了一种纤维内衬用复合涂料及其制备方法，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉25%～35%、活性氧化铝微粉5%～10%、石英砂微粉15%～20%、堇青石粉3%～8%、莫来石粉3%～5%、硅粉2%～6%、辐射粉料15%～25%、结合剂8%～12%、分散剂0.1%～1%、消泡剂0.1%～1%；外加占上述原料总重25%～35%的溶剂。该纤维内衬用复合涂料的发射率高，红外发射率可达0.85以上，节能效果显著；而且，与纤维内衬的结合力强，结构致密，耐腐蚀能力强，涂层不龟裂、不脱落，在1000‑1500℃的高温下可长期稳定工作，使用寿命长。

Description

一种纤维内衬用复合涂料及其制备方法
技术领域
本发明属于节能涂料技术领域，具体涉及一种纤维内衬用复合涂料及其制备方法。
背景技术
高温工业窑炉行业为能耗消耗的主要行业，每年的能耗约占国家总能耗的25％-40％，但是，工业窑炉的平均热效率仅有32％左右。工业窑炉的能耗利用率低的主要原因一方面在于热量通过窑炉的炉衬和外壁向外散热，造成热量损失；另一方面在于工业窑炉内壁发射率较低，使得热量不能有效的辐射到炉膛中，导致加热效率低，热量利用率低。近年来，随着能源危机问题日益严重，节能降耗已经成为高温工业窑炉行业亟待的重要研究课题。耐火纤维由于其导热系数小，隔热性能好，易于施工，已被广泛作为高温工业窑炉的内衬材料使用。虽然耐火纤维作为窑炉内城在一定程度上能够减少热量通过内衬向外散失，但是，耐陶瓷纤维的热辐射率较低，导致热量不能有效的辐射到炉膛中，热量利用率低；而且，耐火纤维易粉化、耐腐蚀性能差，作为窑炉内衬使用寿命短。因此，急需研究一种适用于纤维内衬工业窑炉的复合涂料，以提高耐火纤维窑炉内衬的热辐射性能和耐腐蚀性能。
发明内容
为解决现有技术中存在的问题和不足，本发明的目的旨在提供一种纤维内衬用复合涂料及其制备方法。该纤维内衬用复合涂料的发射率高，红外发射率可达0.85以上，节能效果显著；而且，与纤维内衬的结合力强，结构致密，耐腐蚀能力强，涂层不龟裂、不脱落，在1000-1500℃的高温下可长期稳定工作，使用寿命长。
为实现发明目的，本发明采用的技术方案如下：
一种纤维内衬用复合涂料，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉25％～35％、活性氧化铝微粉5％～10％、石英砂微粉15％～20％、堇青石粉3％～8％、莫来石粉3％～5％、硅粉2％～6％、辐射粉料15％～25％、结合剂8％～12％、分散剂0.1％～1％、消泡剂0.1％～1％；外加占上述原料总重25％～35％的溶剂。
根据上述的纤维内衬用复合涂料，优选地，所述辐射粉料由以下重量份的原料组成：纳米碳化硅20～30份、氧化铁微粉10～15份、氧化镍微粉3～8份、氧化锰微粉4～6份、氧化钴微粉2～4份、二硼化钛微粉1～3份。
根据上述的纤维内衬用复合涂料，优选地，所述结合剂为铝溶胶。
根据上述的纤维内衬用复合涂料，优选地，所述分散剂为聚丙烯酸钠。
根据上述的纤维内衬用复合涂料，优选地，所述消泡剂为二甲基硅油。
根据上述的纤维内衬用复合涂料，优选地，所述溶剂为水。
根据上述的纤维内衬用复合涂料，优选地，所述堇青石粉的粒径为180～280目；所述莫来石粉的粒径为325～400目；所述辐射粉料的粒径为325-800目。
上述纤维内衬用复合涂料的制备方法，包括以下步骤：
(1)按所述纤维内衬用复合涂料的原料组成称取各组分，备用；
(2)将氧化锆微粉、活性氧化铝微粉、石英砂微粉、堇青石粉、莫来石粉、硅粉和辐射粉料混合后进行高速研磨，使其混合均匀，得到组分A；
(3)向溶剂中加入分散剂，搅拌，使其充分溶解，然后再加入结合剂、消泡剂，搅拌混合均匀，得到组分B；
(4)将B组分加入A组分中，搅拌混合均匀，制得纤维内衬用复合涂料。
上述纤维内衬用复合涂料的使用方法为：将所述耐腐蚀纳米涂料纤维内衬用复合涂料喷涂在基材表面，晾干后，在150～200℃烘烤3～4h。
与现有技术相比，本发明取得的积极有益效果为：
(1)本发明制备的纤维内衬用复合涂料喷涂在纤维内衬表面后，能够在纤维内衬表面形成一层致密的涂层，该涂层发射率高，红外发射率可达0.85以上，热量能够有效的辐射到炉膛中，极大的提高了纤维内衬工业窑炉的热量利用率，节能效果显著。
(2)本发明的纤维内衬用复合涂料具有高附着力，与纤维内衬的结合力强，能牢固地粘接在纤维炉衬上，固化后形成的涂层强度高，稳定性强，结构致密，能够有效填封纤维内衬表面的微孔，对纤维表面微孔进行封闭，起到隔离氧原子、酸碱物质的侵蚀，提高了纤维内衬窑炉耐气流冲刷、耐酸碱侵蚀的能力；而且涂层不龟裂、不脱落，在1000-1500℃的高温下可长期稳定工作，使用寿命大于5年，极大低提高了纤维内衬窑炉的使用寿命。
(3)本发明的纤维内衬用复合涂料具有高耐温性和高耐磨性，其最高使用温度可达1500℃，有抗冲击、抗擦伤能力强；而且，该涂料热震稳定性好，热导率低，能够减少热量的损失。本发明制备的纤维内衬用复合涂料的性能参数检测结果见表1。
(4)本发明纤维内衬用复合涂料的制备方法操作简单，对设备要求低，易于工业化生产，具有显著的经济效益。
表1本发明制备的纤维内衬用复合涂料的性能参数检测结果
检测参数 检测结果
抗压强度(1200℃) 4.0MPa～4.3MPa
导热系数 0.3W/(m·k)～0.4W/(m·k)
最高使用温度 1500℃
红外辐射率 0.84～0.91
涂层密度 3.5g/cm<sup>3</sup>～4.8g/cm<sup>3</sup>
线膨胀系数 5.5×10<sup>-6</sup>K～6.5×10<sup>-6</sup>K
具体实施方式
以下通过具体实施例对本发明作进一步详细说明，但并不限制本发明的范围。
实施例1：
一种纤维内衬用复合涂料，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉30％、活性氧化铝微粉8％、石英砂微粉18％、堇青石粉5％、莫来石粉3％、硅粉3％、辐射粉料22％、铝溶胶10％、聚丙烯酸钠0.6％、二甲基硅油0.4％；外加占上述原料总重30％的水。
所述辐射粉料由以下重量份的原料组成：纳米碳化硅26份、氧化铁微粉12份、氧化镍微粉6份、氧化锰微粉5份、氧化钴微粉3份、二硼化钛微粉2份。
上述纤维内衬用复合涂料的制备方法，包括以下步骤：
(1)按所述纤维内衬用复合涂料的原料组成称取各组分，备用；
(2)将氧化锆微粉、活性氧化铝微粉、石英砂微粉、堇青石粉、莫来石粉、硅粉和辐射粉料混合后进行高速研磨，使其混合均匀，得到组分A；
(3)向水中加入聚丙烯酸钠，搅拌，使其充分溶解，然后再加入铝溶胶、二甲基硅油，搅拌混合均匀，得到组分B；
(4)将B组分加入A组分中，搅拌混合均匀，制得纤维内衬用复合涂料。
实施例2：
一种纤维内衬用复合涂料，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉25％、活性氧化铝微粉5％、石英砂微粉18％、堇青石粉8％、莫来石粉5％、硅粉2％、辐射粉料25％、铝溶胶10％、聚丙烯酸钠1％、二甲基硅油1％；外加占上述原料总重35％的水。
所述辐射粉料的原料组成与实施例1相同。
上述耐腐蚀纳米涂料的制备方法与实施例1相同。
实施例3：
一种纤维内衬用复合涂料，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉35％、活性氧化铝微粉6％、石英砂微粉15％、堇青石粉6％、莫来石粉4％、硅粉6％、辐射粉料15％、铝溶胶12％、聚丙烯酸钠0.8％、二甲基硅油0.2％；外加占上述原料总重25％的水。
所述辐射粉料由以下重量份的原料组成：纳米碳化硅20份、氧化铁微粉15份、氧化镍微粉3份、氧化锰微粉6份、氧化钴微粉4份、二硼化钛微粉3份。
上述耐腐蚀纳米涂料的制备方法与实施例1相同。
实施例4：
一种纤维内衬用复合涂料，其特征在于，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉28％、活性氧化铝微粉10％、石英砂微粉20％、堇青石粉3％、莫来石粉3％、硅粉4％、辐射粉料20％、铝溶胶11％、聚丙烯酸钠0.3％、二甲基硅油0.7％；外加占上述原料总重30％的水。
所述辐射粉料由以下重量份的原料组成：纳米碳化硅30份、氧化铁微粉10份、氧化镍微粉8份、氧化锰微粉4份、氧化钴微粉2份、二硼化钛微粉3份。
上述耐腐蚀纳米涂料的制备方法与实施例1相同。
实施例5：
一种纤维内衬用复合涂料，其特征在于，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉32％、活性氧化铝微粉8％、石英砂微粉15％、堇青石粉8％、莫来石粉3％、硅粉5％、辐射粉料20％、铝溶胶8％、聚丙烯酸钠0.9％、二甲基硅油0.1％；外加占上述原料总重25％的水。
所述辐射粉料由以下重量份的原料组成：纳米碳化硅22份、氧化铁微粉14份、氧化镍微粉5份、氧化锰微粉4份、氧化钴微粉4份、二硼化钛微粉1份。
上述耐腐蚀纳米涂料的制备方法与实施例1相同。
实施例6：
一种纤维内衬用复合涂料，其特征在于，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉25％、活性氧化铝微粉10％、石英砂微粉20％、堇青石粉5％、莫来石粉4％、硅粉3％、辐射粉料22％、铝溶胶10％、聚丙烯酸钠0.1％、二甲基硅油0.9％；外加占上述原料总重28％的水。
所述辐射粉料的原料组成与实施例1相同。
上述耐腐蚀纳米涂料的制备方法与实施例1相同。
实施例7：
一种纤维内衬用复合涂料，其特征在于，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉30％、活性氧化铝微粉10％、石英砂微粉16％、堇青石粉6％、莫来石粉3％、硅粉5％、辐射粉料18％、铝溶胶10％、聚丙烯酸钠1％、二甲基硅油1％；外加占上述原料总重25％的水。
所述辐射粉料的原料组成与实施例4相同。
上述耐腐蚀纳米涂料的制备方法与实施例1相同。
以上所述仅为本发明的较佳实施例而已，但不仅限于上述实例，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (5)

1.一种纤维内衬用复合涂料，其特征在于，以重量百分含量表示，所述纤维内衬用复合涂料的原料组成为：氧化锆微粉25%～35%、活性氧化铝微粉5%～10%、石英砂微粉15%～20%、堇青石粉3%～8%、莫来石粉3%～5%、硅粉2%～6%、辐射粉料15%～25%、结合剂8%～12%、分散剂0.1%～1%、消泡剂0.1%～1%；外加占上述原料总重25%～35%的溶剂；
所述辐射粉料由以下重量份的原料组成：纳米碳化硅20～30份、氧化铁微粉10～15份、氧化镍微粉3～8份、氧化锰微粉4～6份、氧化钴微粉2～4份、二硼化钛微粉1～3份；所述结合剂为铝溶胶。
2.根据权利要求1所述的纤维内衬用复合涂料，其特征在于，所述分散剂为聚丙烯酸钠。
3.根据权利要求1所述的纤维内衬用复合涂料，其特征在于，所述消泡剂为二甲基硅油。
4.根据权利要求1所述的纤维内衬用复合涂料，其特征在于，所述溶剂为水。
5.一种权利要求1～4任一所述纤维内衬用复合涂料的制备方法，其特征在于，包括以下步骤：
（1）按所述纤维内衬用复合涂料的原料组成称取各组分，备用；
（2）将氧化锆微粉、活性氧化铝微粉、石英砂微粉、堇青石粉、莫来石粉、硅粉和辐射粉料混合后进行高速研磨，使其混合均匀，得到组分A；
（3）向溶剂中加入分散剂，搅拌，使其充分溶解，然后再加入结合剂、消泡剂，搅拌混合均匀，得到组分B；
（4）将B组分加入A组分中，搅拌混合均匀，制得纤维内衬用复合涂料。
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