CN109650939A - 隔热砖 - Google Patents

隔热砖 Download PDF

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Publication number
CN109650939A
CN109650939A CN201910149778.1A CN201910149778A CN109650939A CN 109650939 A CN109650939 A CN 109650939A CN 201910149778 A CN201910149778 A CN 201910149778A CN 109650939 A CN109650939 A CN 109650939A
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insulating brick
partial size
brick according
zirconium oxide
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林伟
范新晖
吴则昌
程贵生
廖花妹
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Heyuan Dongyuan Yingpai Ceramics Co Ltd
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Heyuan Dongyuan Yingpai Ceramics Co Ltd
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Abstract

本发明提供了一种隔热砖，属于材料领域。一种隔热砖，其原料以重量份数计，包括：刚玉20‑40份、莫来石30‑50份、纳米氧化锆粉末15‑25份、氧化钙3‑5份、氧化钇3‑5份、氧化镁1‑3份、聚苯乙烯球0.5‑1份、有机烧失物0.5‑1份、页岩粉末1‑3份、ZnFe2O41‑3份、NiFe2O42‑4份、FeMnCuO43‑7份。本申请提供的隔热砖，热震稳定性好、导热系数小、强度高、节能环保。

Description

隔热砖
技术领域
本发明涉及材料领域，具体而言，涉及一种隔热砖。
背景技术
在耐火材料行业，国内几个主要耐火材料生产基地约有隧道窑1127条，梭式窑649座，特种陶瓷以及石化等行业也有许多高温工业窑炉。这些窑炉炉衬一般采用重质致密砖或氧化铝空心球砖砌筑。但是重质致密砖体积密度大、蓄热多、热导率大，不节能；氧化铝空心球砖体积密度大，隔热效果不明显。有一些产品中大量使用硅藻土，利用其气孔结构构筑气相－固相传热通道格局，但是硅藻土的使用存在着强度不高，恰当的砖坯含水量不易获得，产品次品率高，成本高等问题。因此，解决体积密度大、导热率大、隔热效果差、强度低等问题所带来的高能耗、高成本困局，显得尤为重要。
有鉴于此，特提出本发明。
发明内容
本发明的目的在于提供一种隔热砖，所述隔热砖密度和导热系数小、强度高、次品率低、隔热效果好、成本低，节能环保。
为了实现本发明的上述目的，特采用以下技术方案：
一种隔热砖，其特征在于，其原料以重量份数计，包括：刚玉20-40份、莫来石30-50份、纳米氧化锆粉末15-25份、氧化钙3-5份、氧化钇3-5份、氧化镁1-3份、聚苯乙烯球0.5-1份、有机烧失物0.5-1份、页岩粉末1-3份、ZnFe2O41-3份、NiFe2O4 2-4份、FeMnCuO43-7份。
刚玉和莫来石作为砖体的主体和主晶相，可以提供良好的隔热基础和较高的强度；添加氧化锆的目的是：高温条件下，氧化锆单斜与四方相之间的可逆转变并伴随有体积效应，这种可逆转变和体积效应是有益于形成隔热需要的气相-固相通道的。此外，适量的CaO、Y2O3、MgO等阳离子半径与锆离子半径相差12％以内的氧化物，经高温稳定后可以形成固溶体，形成了部分稳定的氧化锆，降低四方相到单斜相的转变温度。固溶体不分解，而且具有很好的力学性能和较低的热膨胀系数，利用应力诱导相变使四方相氧化锆转变为单斜相氧化锆，起到相变增韧的作用。从实际的增韧效果看，四方相氧化锆只有一部分可以产生相变，所以实际的增韧效果与可相变的氧化锆成正比，对氧化锆相变机制的研究表明，相变往往从晶界开始，相邻晶粒间的结构紧密程度也影响相变的完全性。因此，氧化锆的使用，与氧化钙、氧化钇、氧化镁协同，合适的使用量使得氧化锆晶相转变处于一个较佳的范畴，隔热砖整体从而获得较佳的导热系数和热震性能；氧化钙、氧化钇、氧化镁除了保障隔热砖在制备过程中的可塑性和物理稳定性外，还会改变隔热砖的固相导热性能，从固相角度入手，进一步降低导热系数；聚苯乙烯球和有机烧失物，可以为使得砖体内部获得优异的、有利于降低导热系数的气孔结构分布和气体氛围。页岩粉末、ZnFe2O4、NiFe2O4、FeMnCuO4的添加，一方面是为了进一步优化固相传热通道，另一方面有利于提高强度。
优选地，所述纳米氧化锆粉末的粒径为40-50nm。
氧化锆采用纳米级物料并限定粒径，是为了将纳米增韧效应很好地应用到产品中去，降低导热系数的同时，减少微小撕裂和裂纹的产生，保证所建立的固相－气相传热通道可以有效保持，避免在高温使用过程中发生内部质变，保证使用寿命。
优选地，所述的隔热砖，其原料以重量份数计，还包括：硅藻土10-28份、铁鳞1-3份、糖蜜0.5-1.3份。
硅藻土的添加是为了进一步在固相传热通道内建立微小的气相传热通道，进一步降低导热系数；为了减少硅藻土使用过程中带来的副作用，加入铁鳞和糖蜜，提高强度，保证性能稳定。
更加优选地，所述糖蜜的含糖量为42-52wt％。
更为优选地，所述铁鳞为轧钢铁鳞粉末，粒径为20-50微米。
更加优选地，所述硅藻土的粒径为30-80微米。
为了进一步优化性能，对糖蜜的含糖量、铁鳞的类型和粒径、硅藻土的粒径进行优选。
优选地，所述聚苯乙烯球的粒径为1-3mm。
限制聚苯乙烯球的粒径，主要目的是优化基础的固相－气相传热通道构型。
可选地，所述有机烧失物选自木屑、稻谷壳、草木灰和焦炭粉中的一种或多种。
有机烧失物的选择，有益于保证与聚苯乙烯球一起构建气相传热通道。
优选地，所述隔热砖的烧成温度为1600-1640℃。
更加优选地，所述隔热砖的烧制时间为8-12h。
烧成温度和烧制时间的优选，是为了与原料相配合，获得最佳的产品性能。
与现有技术相比，本发明的有益效果为：
(1)热震稳定性好、强度高；
(2)导热系数低、隔热性能优异，有利于降低能耗，节能环保。
具体实施方式
下面将结合实施例对本发明的实施方案进行详细描述，但是本领域技术人员将会理解，下列实施例仅用于说明本发明，而不应视为限制本发明的范围。实施例中未注明具体条件者，按照常规条件或制造商建议的条件进行。所用试剂或仪器未注明生产厂商者，均为可以通过市售购买获得的常规产品。
实施例1
备料：取刚玉20份、莫来石50份、纳米氧化锆粉末15份、氧化钙5份、氧化钇3份、氧化镁3份、聚苯乙烯球0.5份、木屑1份、页岩粉末1份、ZnFe2O43份、NiFe2O4 2份、FeMnCuO47份和适量水加入搅拌机搅拌。其中，聚苯乙烯球的粒径为1mm；纳米氧化锆的粒径为40nm；
制坯：将搅拌好的泥料堆积在一起，陈腐24小时后加入到练泥机内挤压成型符合要求的砖坯；将成型后的砖坯放进干燥房干燥；
烧制：将干燥后的砖坯码在窑炉中进行烧制，烧制时间12h，控制烧成温度1600℃，然后切磨、检验、包装得到成品隔热砖。
实施例2
备料：取刚玉40份、莫来石30份、纳米氧化锆粉末25份、氧化钙3份、氧化钇5份、氧化镁1份、聚苯乙烯球1份、草木灰0.5份、页岩粉末3份、ZnFe2O41份、NiFe2O4 4份、FeMnCuO43份和适量水加入搅拌机搅拌。其中，聚苯乙烯球的粒径为3mm；纳米氧化锆的粒径为50nm；
制坯：将搅拌好的泥料堆积在一起，陈腐48小时后加入到练泥机内挤压成型符合要求的砖坯；将成型后的砖坯放进干燥房干燥；
烧制：将干燥后的砖坯码在窑炉中进行烧制，烧制时间8h，控制烧成温度1640℃，然后切磨、检验、包装得到成品隔热砖。
实施例3
备料：取刚玉30份、莫来石40份、纳米氧化锆粉末20份、氧化钙4份、氧化钇4份、氧化镁2份、聚苯乙烯球0.8份、稻谷壳和焦炭粉0.8份、页岩粉末2份、ZnFe2O42份、NiFe2O4 3份、FeMnCuO45份、硅藻土10份、轧钢铁鳞3份、糖蜜0.5份和适量水加入搅拌机搅拌。其中，聚苯乙烯球的粒径为2mm，纳米氧化锆的粒径为45nm，硅藻土的粒径为30微米，铁鳞的粒径为50微米，糖蜜的含糖量为42wt％；
制坯：将搅拌好的泥料堆积在一起，陈腐36小时后加入到练泥机内挤压成型符合要求的砖坯；将成型后的砖坯放进干燥房干燥；
烧制：将干燥后的砖坯码在窑炉中进行烧制，烧制时间10h，控制烧成温度1620℃，然后切磨、检验、包装得到成品隔热砖。
需要说明的是，铁鳞又称氧化铁皮、氧化皮。在钢材加热和轧制过程中，由于表面受到氧化而形成氧化铁层，剥落下来的鱼鳞状物。糖蜜是制糖工业的副产品，其中主要含有大量可发酵糖(主要是蔗糖)。
实施例4
备料：取刚玉35份、莫来石45份、纳米氧化锆粉末22份、氧化钙3.5份、氧化钇4.5份、氧化镁2.5份、聚苯乙烯球0.6份、稻谷壳0.6份、页岩粉末1.5份、ZnFe2O42.5份、NiFe2O43.5份、FeMnCuO46份、硅藻土28份、铁鳞1份、糖蜜1.3份和适量水加入搅拌机搅拌。其中，聚苯乙烯球的粒径为3mm；纳米氧化锆的粒径为40nm，硅藻土的粒径为80微米，铁鳞的粒径为20微米，糖蜜的含糖量为52wt％；
制坯：将搅拌好的泥料堆积在一起，陈腐30小时后加入到练泥机内挤压成型符合要求的砖坯；将成型后的砖坯放进干燥房干燥；
烧制：将干燥后的砖坯码在窑炉中进行烧制，烧制时间11h，控制烧成温度1625℃，然后切磨、检验、包装得到成品隔热砖。
实施例5
备料：取刚玉25份、莫来石35份、纳米氧化锆粉末18份、氧化钙4.5份、氧化钇3.5份、氧化镁1.5份、聚苯乙烯球0.7份、木屑和草木灰0.6份、页岩粉末2.5份、ZnFe2O41.5份、NiFe2O4 2.5份、FeMnCuO44份、硅藻土20份、铁鳞2份、糖蜜1份和适量水加入搅拌机搅拌。其中，聚苯乙烯球的粒径为1mm；纳米氧化锆的粒径为50nm，硅藻土的粒径为50微米，铁鳞的粒径为30微米，糖蜜的含糖量为48wt％；
制坯：将搅拌好的泥料堆积在一起，陈腐28小时后加入到练泥机内挤压成型符合要求的砖坯；将成型后的砖坯放进干燥房干燥；
烧制：将干燥后的砖坯码在窑炉中进行烧制，烧制时间9h，控制烧成温度1615℃，然后切磨、检验、包装得到成品隔热砖。
比较例1
与实施例1相比，原料中不含聚苯乙烯球。
比较例2
与实施例2相比，原料中不含有机烧失物。
比较例3
与实施例3相比，原料中不含氧化钙、氧化钇和氧化镁。
比较例4
与实施例4相比，纳米氧化锆的粒径为100nm。
比较例5
与实施例5相比，原料中不含ZnFe2O4、NiFe2O4、FeMnCuO4。
对实施例1-4和比较例1-5得到的产品各500组进行性能测试。具体测试结果如下表1所示：
表1测试结果
此外，实施例1-5的平均成品率为98.8％，比较例1-5的平均成品率为90.4％.
上述测试数据表明，本申请提供的隔热砖，成品率高、密度小、导热系数小、热震稳定性强、耐压强度大。
尽管已用具体实施例来说明和描述了本发明，然而应意识到，在不背离本发明的精神和范围的情况下可以作出许多其它的更改和修改。因此，这意味着在所附权利要求中包括属于本发明范围内的所有这些变化和修改。

Claims (10)

1.一种隔热砖，其特征在于，其原料以重量份数计，包括：刚玉20-40份、莫来石30-50份、纳米氧化锆粉末15-25份、氧化钙3-5份、氧化钇3-5份、氧化镁1-3份、聚苯乙烯球0.5-1份、有机烧失物0.5-1份、页岩粉末1-3份、ZnFe2O4 1-3份、NiFe2O4 2-4份、FeMnCuO43-7份。
2.根据权利要求1所述的隔热砖，其特征在于，所述纳米氧化锆粉末的粒径为40-50nm。
3.根据权利要求1所述的隔热砖，其特征在于，其原料以重量份数计，还包括：硅藻土10-28份、铁鳞1-3份、糖蜜0.5-1.3份。
4.根据权利要求3所述的隔热砖，其特征在于，所述糖蜜的含糖量为42-52wt％。
5.根据权利要求3所述的隔热砖，其特征在于，所述铁鳞为轧钢铁鳞粉末，粒径为20-50微米。
6.根据权利要求3所述的隔热砖，其特征在于，所述硅藻土的粒径为30-80微米。
7.根据权利要求1所述的隔热砖，其特征在于，所述聚苯乙烯球的粒径为1-3mm。
8.根据权利要求1-7任一项所述的隔热砖，其特征在于，所述有机烧失物选自木屑、稻谷壳、草木灰和焦炭粉中的一种或多种。
9.根据权利要求1所述的隔热砖，其特征在于，所述隔热砖的烧成温度为1600-1640℃。
10.根据权利要求9所述的隔热砖，其特征在于，所述隔热砖的烧制时间为8-12h。
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