CN110040995A - 一种高温用轻质韧性莫来石骨料制备方法 - Google Patents

一种高温用轻质韧性莫来石骨料制备方法 Download PDF

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CN110040995A
CN110040995A CN201910321786.XA CN201910321786A CN110040995A CN 110040995 A CN110040995 A CN 110040995A CN 201910321786 A CN201910321786 A CN 201910321786A CN 110040995 A CN110040995 A CN 110040995A
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魏瀚
尹超男
徐如林
赵洪亮
徐琳琳
王俊涛
胡建辉
闫昕
周严敦
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RUITAI TECHNOLOGY Co Ltd
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Abstract

一种高温用轻质韧性莫来石骨料制备方法。其技术方案是：按重量份，将40‑65份的莫来石粉，5‑25份质量分数为94.0%的硅微粉，20‑55份的软质黏土，0.3‑0.5份的减水剂后加水混合，搅拌速度为500rad/min,主要物料经充分混合成为均匀浆体。在均质泥浆中加入10‑40份的发泡剂，0.1‑0.6份的稳泡剂。本发明采用一步发泡的方式，并配合独特的搅拌流程，将发泡剂充分、均匀分布在料浆中，并最终形成泡沫浆体，生产流程简单易行。骨料坯体的体积密度在0.5kg/m3‑0.6 kg/m3;烧后骨料的体积密度0.3kg/m3‑0.4 kg/m3。

Description

一种高温用轻质韧性莫来石骨料制备方法
技术领域
本发明涉及耐火材料领域所使用的一种轻质韧性骨料，尤其涉及一种高温用超轻莫来石骨料及其制备方式。
技术背景
高温工业一向是高耗能，高污染产业。燃料能源的大量消耗给自然环境与社会生活造成了巨大的负面影响，热工窑炉的保温节能日渐受到行业的关注。
目前，轻质骨料制备方法主要有烧失法、化学法以及发泡剂法。其中专利CN108793911A公开了“一种利用发泡法制备镁质轻质骨料的方法”，该专利以油酸盐为发泡剂，硬脂酸钙为稳泡剂，氧化镁粉为料浆，采用单独制泡、制浆的方式制备镁质轻质骨料。由于采用了一次发泡，二次制浆，最后将泡浆混合后制备出发泡浆体，其制备过程过于繁杂；且制备出的轻质骨料体积密度≥1.0g·cm3，显气孔率＜70%，所制备的轻质骨料体积密度相比于导热性较好的材料如：硅酸钙板体积密度（200—1000 g·cm3）相差甚远。虽然骨料的力学强度高，但骨料的导热系数远大于硅酸钙板。专利CN107010968 公开了“一种高强轻量刚玉莫来石质耐火骨料及其制备方法”，采用增孔剂制造出材料中的孔洞，其制备的材料体积密度在1.2-1.9g/cm3。原料的体积密度依然不能够达到硅酸钙板体积密度的水平，虽然采用的增孔剂导热系数较低，但原料在烧成后，由于体积密度≥1g/cm3,骨料的隔热性能不佳。综上可见，现有技术所制备的轻质骨料虽然解决了骨料强度低的问题，但是骨料的体积密度仍然不能降到1.0g/cm3以下。
发明内容
本发明涉及一种高温用轻质韧性莫来石骨料，主要解决目前轻质骨料体积密度≤1.0g/cm3的问题。本发明专利包括主要物料：
莫来石粉，粒径7-10μm
硅微粉，粒度≤0.088μm
软质黏土，粒度4-8μm,Al2O3含量≥33%，Fe2O3≤1.5%
结合剂，选自硅溶胶、铝溶胶的一种或两种
短切硅酸钙耐火纤维，高温使用温度大于1300℃
发泡剂，选自YS-10、YS-80，TR-WLFP、FP-180、FP-186、茶皂素、月桂基硫酸三乙醇胺其中的一种或多种组合
稳泡剂，羧甲基纤维素
减水剂，选自柠檬酸、三聚磷酸钠、六偏磷酸钠其中的一种或多种组合。
上述高温用轻质韧性莫来石骨料的制备工艺如下：
(1)制备均质泥浆
按重量份，将40-65份的莫来石粉，5-25份质量分数为94.0%的硅微粉，20-55份的软质黏土，0.3-0.5份的减水剂后加水混合，搅拌速度为450r/min-600r/min,主要物料经充分混合成为均匀浆体。
(2)制备发泡均质泥浆
在均质泥浆中加入10-40份的发泡剂，0.1-0.6份的稳泡剂，搅拌步骤为：
第一步：搅拌速度为620r/min-800r/min,搅拌时间为8-10min；
第二步：搅拌速度为300r/min-400r/min,搅拌时间为2-4min；
(3)加入耐火纤维及外加剂
在发泡浆体制备好后，将搅拌速度控制在200r/min,加入5-15份短切耐火纤维与总质量份数为10-30的结合剂，后继续搅拌3-4min。
(4)烧结成型
将制备好的纤维复合泡沫浆体在模具中浇注成型，放置于70℃的干燥箱中干燥8h后，提高烘箱温度至110℃，干燥12h后脱模后，在电炉中以3℃/min的升温速度从室温升到1300℃-1400℃，保温60-180min。即得成品。
本发明相比于现有技术的有益效果主要在于：
（1）相比于现有的轻质骨料生产工艺，本发明采用一次发泡工艺手段就，取消了单独发泡的工序，并结合独特发泡工艺时间、搅拌速度参数，明显提高生产效率并降低生产成本。
（2）先比于现有工艺所生产出来的产品，通过在骨料中加入短切耐火纤维发泡速度提高了10%，且纤维在发泡浆体中可以充当骨架的作用，相比不加入纤维，稳泡时间延长1h，采用本工艺生产的产品体积密度骨料坯体的体积密度0.5kg/m3-0.6 kg/m3;烧后骨料的体积密度0.3kg/m3-0.4 kg/m3，远远低于现有专利中骨料的体积密度，有效降低了骨料的平均导热系数，显著提高骨料的保温隔热性能。
（3）采用的溶胶结合方式，硅溶胶在≥1200℃时下形成与硅灰成分相同的SiO2，铝溶胶形成活性氧化铝，且两种成分原位反应生成莫来石，与原料最大程度上减少杂质元素的引入，保证了骨料在≤1300℃的温度下使用。
（4）在骨料的桶压强度能够达到4-6MPa，在一定强度的基础上由于纤维的加入，使骨料具备了一定的韧性强度，有效避免骨料的脆性断裂。
具体实施方式
实施例1
按重量份，将45份的莫来石粉，15份质量分数为94.0%的硅微粉，40份的软质黏土，0.2份的减水剂后加水混合，搅拌速度为500r/min,主要物料经充分混合成为均匀浆体。
在均质泥浆中加入10份的TR-WLFP，0.3份的稳泡剂，搅拌步骤为：第一步：搅拌速度为700r/min,搅拌时间为8min；
第二步：搅拌速度为400r/min,搅拌时间为3min；
在发泡浆体制备好后，将搅拌速度控制在200r/min,加入10份短切耐火纤维与质量份数为15的硅溶胶，继续搅拌3min。将制备好的纤维复合泡沫浆体在模具中浇注成型，放置于70℃的干燥箱中干燥8h后，提高烘箱温度至110℃，干燥12h后脱模后，在电炉中以3℃/min的升温速度从室温升到1400℃，保温180min即得成品。
实施例2
按重量份，将45份的莫来石粉，15份质量分数为94.0%的硅微粉，40份的软质黏土，0.2份的减水剂后加水混合，搅拌速度为500r/min,主要物料经充分混合成为均匀浆体。
在均质泥浆中加入20份的TR-WLFP，0.2份的稳泡剂，搅拌步骤为：第一步：搅拌速度为700r/min,搅拌时间为8min；
第二步：搅拌速度为400r/min,搅拌时间为3min；
在发泡浆体制备好后，将搅拌速度控制在200rad/min,加入10份短切耐火纤维与质量份数为15的铝溶胶，继续搅拌3min。将制备好的纤维复合泡沫浆体在模具中浇注成型，放置于70℃的干燥箱中干燥8h后，提高烘箱温度至110℃，干燥12h后脱模后，在电炉中以3℃/min的升温速度从室温升到1400℃，保温180min即得成品。
实施例3
按重量份，将45份的莫来石粉，15份质量分数为94.0%的硅微粉，40份的软质黏土，0.2份的减水剂后加水混合，搅拌速度为500r/min,主要物料经充分混合成为均匀浆体。
在均质泥浆中加入25份的TR-WLFP，0.2份的稳泡剂，搅拌步骤为：第一步：搅拌速度为700r/min,搅拌时间为8min；
第二步：搅拌速度为400r/min,搅拌时间为3min；
在发泡浆体制备好后，将搅拌速度控制在200rad/min,加入10份短切耐火纤维与质量份数为10的铝溶胶与质量份数为5的硅溶胶，继续搅拌3min。将制备好的纤维复合泡沫浆体在模具中浇注成型，放置于70℃的干燥箱中干燥8h后，提高烘箱温度至110℃，干燥12h后脱模后，在电炉中以3℃/min的升温速度从室温升到1400℃，保温180min即得成品。
实施例4
按重量份，将50份的莫来石粉，20份质量分数为94.0%的硅微粉，30份的软质黏土，0.2份的减水剂后加水混合，搅拌速度为500r/min,主要物料经充分混合成为均匀浆体。
在均质泥浆中加入15份的TR-WLFP，0.2份的稳泡剂，搅拌步骤为：第一步：搅拌速度为700r/min,搅拌时间为8min；
第二步：搅拌速度为400r/min,搅拌时间为3min；
在发泡浆体制备好后，将搅拌速度控制在200r/min,加入10份短切耐火纤维与质量份数为5的铝溶胶与质量份数为10的硅溶胶，继续搅拌3min。将制备好的纤维复合泡沫浆体在模具中浇注成型，放置于70℃的干燥箱中干燥8h后，提高烘箱温度至110℃，干燥12h后脱模后，在电炉中以3℃/min的升温速度从室温升到1400℃，保温180min即得成品。
测试上述实例原料得体积密度、桶压强度、1350℃平均导热系数，对比样为轻量微闭孔黏土耐火骨料、硅酸钙板。
表1 本发明实施例1-4的产品性能与现有的铝硅质轻质骨料性能的对比
实验编号 体积密度（kg/m<sup>3</sup>） 桶压强度(MPa) 350℃平均导热系数(W/m·k)
铝硅质轻质骨料 2.0 1.0 1.69
实例1 0.52 4.5 0.098
实例2 0.45 4.6 0.083
实例3 0.53 5.0 0.071
实例4 0.55 4.9 0.077

Claims (8)

1.一种高温用轻质韧性莫来石骨料的制备方法，其特征在于包括以下工艺步骤：
制备均质泥浆
按重量份，将40-65份的莫来石粉，5-25份质量分数为94.0%的硅微粉，20-55份的软质黏土，0.3-0.5份的减水剂后加水混合，搅拌速度为450 r/min -600r/min,主要物料经充分混合成为均匀浆体；
制备发泡均质泥浆
在均质泥浆中加入10-40份的发泡剂，0.1-0.6份的稳泡剂，搅拌步骤为：
第一步：搅拌速度为620 r/min-800r/min,搅拌时间为8-10min；
第二步：搅拌速度为300r/min-400r/min,,搅拌时间为2-4min；
加入耐火纤维及外加剂
在发泡浆体制备好后，将搅拌速度控制在100-200r/min,加入5-15份短切耐火纤维与总质量份数为10-30的结合剂，后继续搅拌3-4min；
烧结成型
将制备好的纤维复合泡沫浆体在模具中浇注成型，放置于70℃的干燥箱中干燥8h后，提高烘箱温度至110℃，干燥12h后脱模后，在电炉中以3℃/min的升温速度从室温升到1300℃-1400℃，保温60-180min，即得成品。
2.根据权利要求1所述的制备方法，其特征在于，所述的莫来石粉的粒径为7-10μm，硅微粉的粒度≤0.088μm。
3.根据权利要求1所述的制备方法，其特征在于，所述的软质黏土的粒度4-8μm,Al2O3含量≥33%，Fe2O3≤1.5%。
4.根据权利要求1所述的制备方法，其特征在于，所述的结合剂选自硅溶胶、铝溶胶的一种或两种。
5.根据权利要求1所述的制备方法，其特征在于，所述的短切纤维为硅酸钙耐火纤维，高温使用温度大于1300℃。
6.根据权利要求1所述的制备方法，其特征在于，所述的发泡剂选自YS-10、YS-80，TR-WLFP、FP-180、FP-186、茶皂素、月桂基硫酸三乙醇胺其中的一种或多种组合。
7.根据权利要求1所述的制备方法，其特征在于，所述的稳泡剂为羧甲基纤维素。
8.根据权利要求1所述的制备方法，其特征在于，所述的减水剂选自柠檬酸、三聚磷酸钠、六偏磷酸钠其中的一种或多种组合。
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