CN110054484A - 一种陶瓷换热管及其制备方法 - Google Patents
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Abstract
本发明提供一种陶瓷换热管及其制备方法,涉及换热设备技术领域,包括以下质量分数的原料:氧化铝70‑90份、堇青石5‑25份、钛酸铝5‑10份、六偏磷酸钠0.2‑0.4份、MgO 2‑6份、ZrO2 1‑3份、MnO2 1‑3份、B2O3 1‑3份、CuO 1‑3份、TiO2 2‑6份。该陶瓷换热管的相对密度较大,抗热震性能好,常温热导率较高。其中,采用氧化铝和堇青石、钛酸铝作为主要原料,MgO、ZrO2、MnO2、B2O3、CuO、TiO2作为烧结助剂,六偏磷酸钠作为分散剂,可最大限度提升陶瓷换热管的综合性能。
Description
技术领域
本发明涉及换热设备技术领域,具体涉及一种陶瓷换热管及其制备方法。
背景技术
随着世界经济的不断发展,人类社会对于能源的需求越来越大。而石化能源的储备有限,核能和太阳能进展不多,能源的短缺一直是经济发展的瓶颈。在此背景下,节约能源,降低能耗,提高燃料的利用率,回收使用废烟气的余热成为工业生产中的热点。换热器又称为热交换器,它是将热流体的部分能量传递给冷流体的设备。换热器在工业生产中发挥着举足轻重的作用,因此,开发应用高效率低成本的新型换热器是尝试解决能源问题的一个良好举措,也是当今换热器研究领域的一个新焦点。陶瓷换热器耐温高、高温蠕变性好、热膨胀系数低、使用寿命长,已在生产中获得广泛应用。
陶瓷换热器用于高温燃气的热交换较金属换热器有更强的优势,当烟气温度为1310℃时,使用换热效率60%的陶瓷换热器可节能48%,而金属换热器仅节能24%。目前陶瓷换热器的材质有:Si3N4、SiC、刚玉、锆石英、钛酸铝、堇青石和莫来石等。国内产品性能与发达国家研发的陶瓷换热器相比差距较大。主要问题在于抗震性能不够理想,耐磨和抗弯强度不高从而导致使用寿命不够长,氧化铝陶瓷具有机械强度高、热导率好、高温蠕变性能好、高温化学稳定性好的优点,成本更低,但其抗热震性能较差。因此,如何提高陶瓷换热管的抗热震性能热导率,降低其烧结温度,是本领域目前发展的方向。
发明内容
(一)解决的技术问题
针对现有技术的不足,本发明提供了一种陶瓷换热管及其制备方法,该陶瓷换热管致密性好,常温热导率高,抗热震循环次数高,综合性能好。
(二)技术方案
为实现以上目的,本发明通过以下技术方案予以实现:
一种陶瓷换热管,包括以下质量分数的原料:氧化铝70-90份、堇青石5-25份、钛酸铝5-10份、六偏磷酸钠0.2-0.4份、MgO 2-6份、ZrO21-3份、MnO21-3份、B2O31-3份、CuO 1-3份、TiO22-6份。
优选的,包括以下质量分数的原料:氧化铝80-85份、堇青石15-20份、钛酸铝6-8份、六偏磷酸钠0.2-0.4份、MgO 3-4份、ZrO22-3份、MnO22-3份、B2O31-3份、CuO 1-3份、TiO23-5份。
优选的,包括以下质量分数的原料:氧化铝83份、堇青石18份、钛酸铝7份、六偏磷酸钠0.3份、MgO 3份、ZrO22份、MnO23份、B2O32份、CuO2份、TiO24份。
上述陶瓷换热管的制备方法包括以下步骤:
1)原料预处理:按比例取上述原料粉体混合,得混合料,将混合料加入球磨罐中,加入水和瓷球,进行湿法球磨,将球磨好的料将倒出,烘干,放入电炉中,在800-900℃温度下煅烧2-3h,冷却至室温,将粉体过260-300目筛,备用;
2)制备陶瓷料浆:将步骤1得到的粉体原料与水按照质量为1:1的比例,加入到球磨罐中,球磨5-6h,得陶瓷料浆;
3)成型:将陶瓷料浆陈腐20-24h后,采用注浆成型工艺将陶瓷料浆注入管状石膏模具中成型,坯体成型后,脱膜并干燥,得陶瓷换热管坯体;
4)烧结:将陶瓷换热管坯体放入加热炉中烧结,烧结温度为1200-1400℃,冷却至室温后,得陶瓷换热管。
进一步的,其制备方法步骤1)中,混合料与水和瓷球的质量比为1:1-2:1-2,球磨时间为20-24h。
进一步的,其制备方法步骤3)中,干燥温度为40-60℃,干燥时间为20-24h。
进一步的,其制备方法步骤4)中,具体烧结过程为:将温度升至400℃,升温速率为3℃/min,保温60min后升温至1000℃,升温速率为8℃/min,保温30min后,升温至烧结温度,升温速率为5℃/min,保温30-60min。
(三)有益效果
本发明提供了一种陶瓷换热管及其制备方法,该陶瓷换热管的相对密度较大,抗热震性能好,常温热导率较高。其中,采用氧化铝和堇青石、钛酸铝作为主要原料,MgO、ZrO2、MnO2、B2O3、CuO、TiO2作为烧结助剂,六偏磷酸钠作为分散剂,可最大限度提升陶瓷换热管的综合性能。
堇青石、钛酸铝,能与Al2O3形成固溶体,有利于缓解热应力和提高陶瓷的结合强度,增强抗热震性能;MgO和TiO2对晶粒的生长变大会产生抑制作用,能够在很大程度上减小各晶界之间的能量差异,降低晶粒生长的各向异性,使得陶瓷的微观结构细晶化,气孔减少且均匀分布,促进Al2O3陶瓷的烧结致密化进程,加快陶瓷的烧结速度,提高Al2O3陶瓷的抗热震性能。
在制备方法中,首先将粉体原料进行预处理,使之达到需要的粒度要求,防止产生气孔,使得到的成品致密度更高,利于提高陶瓷换热管的抗热震性能;陈腐可式料浆的粘度降低,提高注浆成型的效果;烧结温度的选择对陶瓷换热管的性能影响较大,本发明所选烧结温度可以提高陶瓷换热管的综合性能。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚,下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1:
一种陶瓷换热管,包括以下质量分数的原料:氧化铝83份、堇青石18份、钛酸铝7份、六偏磷酸钠0.3份、MgO 3份、ZrO22份、MnO23份、B2O32份、CuO2份、TiO24份。
上述陶瓷换热管的制备方法包括以下步骤:
1)原料预处理:按比例取上述原料粉体混合,得混合料,将混合料加入球磨罐中,加入水和瓷球,进行湿法球磨,将球磨好的料将倒出,烘干,放入电炉中,在800℃温度下煅烧3h,冷却至室温,将粉体过300目筛,备用,其中,混合料与水和瓷球的质量比为1:1:1.5,球磨时间为24h;
2)制备陶瓷料浆:将步骤1得到的粉体原料与水按照质量为1:1的比例,加入到球磨罐中,球磨6h,得陶瓷料浆;
3)成型:将陶瓷料浆陈腐24h后,采用注浆成型工艺将陶瓷料浆注入管状石膏模具中成型,坯体成型后,脱膜并干燥,得陶瓷换热管坯体,其中,干燥温度为50℃,干燥时间为24h;
4)烧结:将陶瓷换热管坯体放入加热炉中烧结,烧结温度为1300℃,具体烧结过程为:将温度升至400℃,升温速率为3℃/min,保温60min后升温至1000℃,升温速率为8℃/min,保温30min后,升温至烧结温度,升温速率为5℃/min,保温60min后冷却至室温,得陶瓷换热管。
实施例2:
一种陶瓷换热管,包括以下质量分数的原料:氧化铝70份、堇青石20份、钛酸铝5份、六偏磷酸钠0.4份、MgO 2份、ZrO23份、MnO21份、B2O33份、CuO 1份、TiO25份。
上述陶瓷换热管的制备方法包括以下步骤:
1)原料预处理:按比例取上述原料粉体混合,得混合料,将混合料加入球磨罐中,加入水和瓷球,进行湿法球磨,将球磨好的料将倒出,烘干,放入电炉中,在900℃温度下煅烧2h,冷却至室温,将粉体过280目筛,备用,其中,混合料与水和瓷球的质量比为1:2:2,球磨时间为20h;
2)制备陶瓷料浆:将步骤1得到的粉体原料与水按照质量为1:1的比例,加入到球磨罐中,球磨5h,得陶瓷料浆;
3)成型:将陶瓷料浆陈腐22h后,采用注浆成型工艺将陶瓷料浆注入管状石膏模具中成型,坯体成型后,脱膜并干燥,得陶瓷换热管坯体,其中,干燥温度为60℃,干燥时间为20h;
4)烧结:将陶瓷换热管坯体放入加热炉中烧结,烧结温度为1400℃,具体烧结过程为:将温度升至400℃,升温速率为3℃/min,保温60min后升温至1000℃,升温速率为8℃/min,保温30min后,升温至烧结温度,升温速率为5℃/min,保温30min后冷却至室温,得陶瓷换热管。
实施例3:
一种陶瓷换热管,包括以下质量分数的原料:氧化铝90份、堇青石15份、钛酸铝10份、六偏磷酸钠0.2份、MgO 6份、ZrO22份、MnO23份、B2O31份、CuO3份、TiO23份。
上述陶瓷换热管的制备方法包括以下步骤:
1)原料预处理:按比例取上述原料粉体混合,得混合料,将混合料加入球磨罐中,加入水和瓷球,进行湿法球磨,将球磨好的料将倒出,烘干,放入电炉中,在900℃温度下煅烧2h,冷却至室温,将粉体过260目筛,备用,其中,混合料与水和瓷球的质量比为1:1.5:2,球磨时间为22h;
2)制备陶瓷料浆:将步骤1得到的粉体原料与水按照质量为1:1的比例,加入到球磨罐中,球磨6h,得陶瓷料浆;
3)成型:将陶瓷料浆陈腐20h后,采用注浆成型工艺将陶瓷料浆注入管状石膏模具中成型,坯体成型后,脱膜并干燥,得陶瓷换热管坯体,其中,干燥温度为40℃,干燥时间为24h;
4)烧结:将陶瓷换热管坯体放入加热炉中烧结,烧结温度为1200℃,具体烧结过程为:将温度升至400℃,升温速率为3℃/min,保温60min后升温至1000℃,升温速率为8℃/min,保温30min后,升温至烧结温度,升温速率为5℃/min,保温60min后冷却至室温,得陶瓷换热管。
实施例4:
一种陶瓷换热管,包括以下质量分数的原料:氧化铝80份、堇青石25份、钛酸铝5份、六偏磷酸钠0.4份、MgO 3份、ZrO23份、MnO22份、B2O33份、CuO 1份、TiO26份。其制备方法同实施例1。
上述陶瓷换热管的制备方法包括以下步骤:
1)原料预处理:按比例取上述原料粉体混合,得混合料,将混合料加入球磨罐中,加入水和瓷球,进行湿法球磨,将球磨好的料将倒出,烘干,放入电炉中,在800℃温度下煅烧3h,冷却至室温,将粉体过300目筛,备用,其中,混合料与水和瓷球的质量比为1:1:1,球磨时间为22h;
2)制备陶瓷料浆:将步骤1得到的粉体原料与水按照质量为1:1的比例,加入到球磨罐中,球磨6h,得陶瓷料浆;
3)成型:将陶瓷料浆陈腐22h后,采用注浆成型工艺将陶瓷料浆注入管状石膏模具中成型,坯体成型后,脱膜并干燥,得陶瓷换热管坯体,其中,干燥温度为60℃,干燥时间为22h;
4)烧结:将陶瓷换热管坯体放入加热炉中烧结,烧结温度为1350℃,具体烧结过程为:将温度升至400℃,升温速率为3℃/min,保温60min后升温至1000℃,升温速率为8℃/min,保温30min后,升温至烧结温度,升温速率为5℃/min,保温60min后冷却至室温,得陶瓷换热管。
实施例5:
一种陶瓷换热管,包括以下质量分数的原料:氧化铝85份、堇青石5份、钛酸铝8份、六偏磷酸钠0.2份、MgO 4份、ZrO21份、MnO23份、B2O31份、CuO3份、TiO22份。其制备方法同实施例1。
实施例6:
一种陶瓷换热管,包括以下质量分数的原料:氧化铝75份、堇青石22份、钛酸铝10份、六偏磷酸钠0.4份、MgO 6份、ZrO22份、MnO22份、B2O32份、CuO3份、TiO25份。其制备方法同实施例1。
对上述实施例1-6制得的陶瓷换热管进行热学性能测试,其结果如表1所示。
表1:
相对密度% | 常温热导率W/m/K | 抗热震循环次数 | |
实施例1 | 83.24 | 35.685 | 15 |
实施例2 | 86.35 | 34.562 | 15 |
实施例3 | 79.26 | 31.986 | 16 |
实施例4 | 62.31 | 36.325 | 14 |
实施例5 | 85.22 | 34.989 | 17 |
实施例6 | 81.97 | 35.562 | 16 |
综上,本发明实施例具有如下有益效果:本发明实施例1-6制得的陶瓷换热管致密性好,常温热导率高,抗热震循环次数高,综合性能好。
需要说明的是,在本文中,诸如第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来,而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且,术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含,从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素,而且还包括没有明确列出的其他要素,或者是还包括为这种过程、方法、物品或者设备所固有的要素。在没有更多限制的情况下,由语句“包括一个……”限定的要素,并不排除在包括所述要素的过程、方法、物品或者设备中还存在另外的相同要素。
以上实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
Claims (7)
1.一种陶瓷换热管,其特征在于,包括以下质量分数的原料:氧化铝70-90份、堇青石5-25份、钛酸铝5-10份、六偏磷酸钠0.2-0.4份、MgO 2-6份、ZrO2 1-3份、MnO2 1-3份、B2O3 1-3份、CuO 1-3份、TiO2 2-6份。
2.如权利要求1所述的陶瓷换热管,其特征在于,包括以下质量分数的原料:氧化铝80-85份、堇青石15-20份、钛酸铝6-8份、六偏磷酸钠0.2-0.4份、MgO 3-4份、ZrO2 2-3份、MnO22-3份、B2O3 1-3份、CuO 1-3份、TiO2 3-5份。
3.如权利要求2所述的陶瓷换热管,其特征在于,包括以下质量分数的原料:氧化铝83份、堇青石18份、钛酸铝7份、六偏磷酸钠0.3份、MgO 3份、ZrO2 2份、MnO2 3份、B2O3 2份、CuO2份、TiO24份。
4.如权利要求1所述的陶瓷换热管,其特征在于,该陶瓷换热管的制备方法包括以下步骤:
1)原料预处理:按比例取上述原料粉体混合,得混合料,将混合料加入球磨罐中,加入水和瓷球,进行湿法球磨,将球磨好的料将倒出,烘干,放入电炉中,在800-900℃温度下煅烧2-3h,冷却至室温,将粉体过260-300目筛,备用;
2)制备陶瓷料浆:将步骤1得到的粉体原料与水按照质量为1:1的比例,加入到球磨罐中,球磨5-6h,得陶瓷料浆;
3)成型:将陶瓷料浆陈腐20-24h后,采用注浆成型工艺将陶瓷料浆注入管状石膏模具中成型,坯体成型后,脱膜并干燥,得陶瓷换热管坯体;
4)烧结:将陶瓷换热管坯体放入加热炉中烧结,烧结温度为1200-1400℃,冷却至室温后,得陶瓷换热管。
5.如权利要求4所述的陶瓷换热管,其特征在于,其制备方法步骤1)中,混合料与水和瓷球的质量比为1:1-2:1-2,球磨时间为20-24h。
6.如权利要求4所述的陶瓷换热管,其特征在于,其制备方法步骤3)中,干燥温度为40-60℃,干燥时间为20-24h。
7.如权利要求4所述的陶瓷换热管,其特征在于,其制备方法步骤4)中,具体烧结过程为:将温度升至400℃,升温速率为3℃/min,保温60min后升温至1000℃,升温速率为8℃/min,保温30min后,升温至烧结温度,升温速率为5℃/min,保温30-60min。
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