CN110317049A - 一种低气孔率硅质预制件及制备方法 - Google Patents
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Abstract
本发明以熔融石英为主原料，提出了一种低气孔率的硅质预制件，其原料及质量百分比为：5.0mm≥粒径＞3.0mm 15%‑20%，3.0mm≥粒径＞1.0mm 25%‑30%，1.0mm≥粒径＞0.1mm 20%‑25%，88um≥粒径＞74um 5%‑10%，74um≥粒径＞44um 5%‑10%，硅灰13%‑18%，结合剂2%‑5%以及适量的分散剂。本发明采用传统的浇注成型工艺，加入高于常规量的硅灰，既改善了石英质瘠性料的不足，又可以与结合剂引入的Al2O3发生莫来石化反应，赋予材料更高的强度和更好的抗冲刷性能。同时体系的高纯化（结合剂除外）也进一步提升了材料抗酸性熔渣侵蚀的能力。
Description
技术领域
本发明涉及一种酸性不定形耐火浇注料的制备，具体涉及到一种低气孔率硅质预制件及制备方法。
背景技术
硅质原料主要包括硅石和熔融石英两大类，是制备酸性耐火材料的主要原料。以硅石为主原料制备的硅砖因为具有较高的高温强度、荷重软化温度高、热膨胀等性能，是焦炉、玻璃熔窑、高炉热风炉以及其它热工设备的常规产品。但其缺点是抗热震稳定性差、耐火度不高（仅为1690~1730℃）。以熔融石英为主原料，经粉碎、成型与烧成而制得的再结合制品称为熔融石英陶瓷，克服了硅砖的缺点，具有良好的热震稳定性和耐火度高等优点，除了可以应用于前述热工设备外，还可以制成高温钢铁冶炼行业用的长水口或浸入式水口。
但上述两大类材料都属于压制成型工艺，成型模具复杂，生产成本高，且仍不能满足一些具有特殊要求和特殊形状领域的应用场合。浇注成型工艺作为一种耐材传统工艺，具有施工简单、生产成本低廉的优势，已取代了大多数压制成型工艺成为耐材行业的发展趋势。然而由于硅质原料是一种瘠性料，不仅原料间的结合能力弱，且该原料和水的润湿性差，通过浇注工艺制得的不定形产品常常出现均匀性差、强度低、气孔率高的问题，甚至出现泌水现象，无法满足正常成型和使用需求。
发明内容
为解决上述问题，本发明的目的是提出一种低气孔率硅质预制件及制备方法。
本发明为完成上述目的采用如下技术方案：
一种低气孔率硅质预制件，预制件的原料及质量百分比为：
熔融石英颗粒 5.0mm≥粒径＞3.0mm 15%-20%
熔融石英颗粒 3.0mm≥粒径＞1.0mm 25%-30%
熔融石英颗粒 1.0mm≥粒径＞0.1mm 20%-25%
熔融石英细粉 88um≥粒径＞74um 5%-10%
熔融石英细粉 74um≥粒径＞44um 5%-10%
硅灰 13%-18%
结合剂 2%-5%
所述原料的总质量为100%；所述预制件的原料中还外加有分散剂和水；分散剂的加入量为原料总质量的0%-0.3%；水的加入量为原料总质量的7%-9%。
所述的熔融石英颗粒及细粉为SiO2含量大于99.5%的任何一种。
所述熔融石英在0~1000℃温度下的热膨胀系数为0.49~0.59×10-6℃-1，保障了材料为具有较好的抗热震性能。
所述的硅灰为SiO2含量大于95%的任何一种微粉。
所述的结合剂为为水合氧化铝（ρ-Al2O3或Alphabond）或者铝酸盐水泥中的一种。
所述的结合剂为水合氧化铝、铝溶胶或者铝酸盐水泥，它们在常温下均能与水反应生成聚合物，赋予材料一定的常温强度；中、高温下（1000~1450℃）前两者还可与体系中的硅灰反应发生莫来石化反应起到增强作用，或是水泥中引入的氧化钙也可以作为矿化剂，促进了稳态二氧化硅晶相的效果。
所述分散剂为三聚磷酸钠、六偏磷酸钠、聚羧酸盐FS-20中的一种或组合。
一种低气孔率硅质预制件的制备方法，以熔融石英为主原料，并加入高于常规用量的硅灰，利用硅灰微粉自身的高比表面积包裹所述的熔融石英并填充体系孔隙，改善熔融石英与水润湿性差以及自结合能力差的不足，利用硅灰微粉自身的粘性和团聚性改善浇注料体系易分散、均匀性差的问题，同时硅灰微粉由于粒度较小填充至体系孔隙，降低加水量；低粒度、高活性、大量的富集硅灰微粉促进了材料的烧结，提高材料的烧后强度；硅灰微粉与结合剂引入的氧化铝成份在中高温下发生莫来石化反应，赋予材料一定的强度；亦可在水泥中引入的氧化钙的作用下，转变为更稳态的二氧化硅物相。
一种低气孔率硅质预制件及制备方法，采用上述技术方案，具有如下有益效果：
(1) 本发明中采用浇注成型，工艺简单，成本低廉。
(2) 本发明中的技术方案采用低膨胀的熔融石英为原料，赋予材料更好的抗热震稳定性。
(3)本发明中采用高于常规加入量的高活性的硅灰充分包裹熔融石英原料，充分改善了原体系的瘠性料的不足，也可以结合剂引入的Al2O3发生莫来石化反应，赋予材料更高的强度和更好的抗冲刷性能。同时体系的高纯化（结合剂除外）也进一步提升了材料抗酸性熔渣侵蚀的能力。
具体实施方式
给出本发明的实施例，但不构成对本发明的任何限制。根据下述3个实施例中的方案将基质料（含分散剂）与骨料一起在搅拌机中先干混3~4分钟，然后边搅拌边加水，4~5分钟后形成浇注料，接着浇注在三联模中让其振动成型。最后测量其理化指标（见表1），若无说明周围环境温度均为25℃左右。
实施例1：
熔融石英颗粒 5.0mm≥粒径＞3.0mm 17%
熔融石英颗粒 3.0mm≥粒径＞1.0mm 30%
熔融石英颗粒 1.0mm≥粒径＞0.1mm 20%
熔融石英细粉 88um≥粒径＞74um 5%
熔融石英细粉 74um≥粒径＞44um 10%
硅灰 15%
ρ-Al2O3 3%
FS-20（外加） +0.15%
水（外加） +7.5%
实施例2：
熔融石英颗粒 5.0mm≥粒径＞3.0mm 15%
熔融石英颗粒 3.0mm≥粒径＞1.0mm 25%
熔融石英颗粒 1.0mm≥粒径＞0.1mm 20%
熔融石英细粉 88um≥粒径＞74um 10%
熔融石英细粉 74um≥粒径＞44um 7%
硅灰 13%
Alphabond 5%
三聚磷酸钠（外加） +0.15%
六偏磷酸钠（外加） +0.10%
水（外加） +8.5%
实施例3：
熔融石英颗粒 5.0mm≥粒径＞3.0mm 20%
熔融石英颗粒 3.0mm≥粒径＞1.0mm 26%
熔融石英颗粒 1.0mm≥粒径＞0.1mm 22%
熔融石英细粉 88um≥粒径＞74um 7%
熔融石英细粉 74um≥粒径＞44um 5%
硅灰 18%
铝酸盐水泥 2%
FS-20（外加） +0.20%
水（外加） +8.8%
表1 具体实施例的理化性能指标（1000℃）
Claims (8)
1.一种低气孔率硅质预制件，其特征在于：预制件的原料及质量百分比为：
熔融石英颗粒 5.0mm≥粒径＞3.0mm 15%-20%
熔融石英颗粒 3.0mm≥粒径＞1.0mm 25%-30%
熔融石英颗粒 1.0mm≥粒径＞0.1mm 20%-25%
熔融石英细粉 88um≥粒径＞74um 5%-10%
熔融石英细粉 74um≥粒径＞44um 5%-10%
硅灰 13%-18%
结合剂 2%-5%
所述原料的总质量为100%；所述预制件的原料中还外加有分散剂和水；分散剂的加入量为原料总质量的0%-0.3%；水的加入量为原料总质量的7%-9%。
2.如权利要求1所述的一种低气孔率硅质预制件，其特征在于：所述的熔融石英颗粒及细粉为SiO2含量大于99.5%的任何一种。
3.如权利要求1所述的一种低气孔率硅质预制件，其特征在于：所述熔融石英在0~1000℃温度下的热膨胀系数为为0.49~0.59×10-6℃-1，保障了材料具有较好的抗热震性能。
4.如权利要求1所述的一种低气孔率硅质预制件，其特征在于：所述的硅灰为SiO2含量大于95%的任何一种微粉。
5.如权利要求1所述的一种低气孔率硅质预制件，其特征在于：所述的结合剂为水合氧化铝或者铝酸盐水泥中的一种。
6.如权利要求1所述的一种低气孔率硅质预制件，其特征在于：所述的结合剂为水合氧化铝、铝溶胶或者铝酸盐水泥，它们在常温下均能与水反应生成聚合物，赋予材料一定的常温强度；中、高温下（1000~1450℃）前两者还可与体系中的硅灰反应发生莫来石化反应起到增强作用，或是水泥中引入的氧化钙也可以作为矿化剂，促进了稳态二氧化硅晶相的效果。
7.如权利要求1所述的一种低气孔率硅质预制件，其特征在于：所述分散剂为三聚磷酸钠、六偏磷酸钠、聚羧酸盐FS-20中的一种或组合。
8.制备权利要求1-7所述的一种低气孔率硅质预制件的制备方法，其特征在于：以熔融石英为主原料，并加入过量的硅灰微粉，过量的硅灰微粉利用硅灰微粉自身的高比表面积包裹所述的熔融石英并填充体系孔隙，改善熔融石英与水润湿性差以及自结合能力差的不足，利用硅灰微粉自身的粘性和团聚性改善浇注料体系易分散、均匀性差的问题，同时硅灰微粉由于粒度较小填充至体系孔隙，降低加水量；低粒度、高活性、大量的富集硅灰微粉促进了材料的烧结，提高材料的烧后强度；硅灰微粉与结合剂引入的氧化铝成份在中高温下发生莫来石化反应，赋予材料一定的强度；亦可在水泥中引入的氧化钙的作用下，转变为更稳态的二氧化硅物相。
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| CN116253574A (zh) * | 2023-02-16 | 2023-06-13 | 中钢集团洛阳耐火材料研究院有限公司 | 一种低铝超低气孔氯化炉用耐火材料的制备方法 |
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| CN116253574A (zh) * | 2023-02-16 | 2023-06-13 | 中钢集团洛阳耐火材料研究院有限公司 | 一种低铝超低气孔氯化炉用耐火材料的制备方法 |
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