CN110922197A

CN110922197A - Hollow sphere ultra-high temperature light refractory prepared by taking FCC waste catalyst as raw material and production process thereof

Info

Publication number: CN110922197A
Application number: CN201911197359.1A
Authority: CN
Inventors: 刘宝敏; 邢慧
Original assignee: Shandong Zhongguan Industry Co Ltd
Current assignee: Shandong Zhongguan Industry Co Ltd
Priority date: 2019-11-29
Filing date: 2019-11-29
Publication date: 2020-03-27

Abstract

The invention relates to an ultrahigh-temperature light refractory prepared by taking FCC (fluid catalytic cracking) waste catalyst as a raw material and a production process thereof, wherein the refractory is prepared from the following raw materials in parts by weight: 30-60 parts of zirconium-aluminum hollow spheres, 60-80 parts of aluminum trioxide powder, 10-20 parts of silicon dioxide powder, 0.5-1 part of foaming agent, 0.5-1 part of foam stabilizer, 4-8 parts of binder and 0.5-1 part of dispersing agent. The ultra-high temperature light refractory prepared by the method is a novel fire-resistant heat-insulating material newly developed and fills the gap at home and abroad. The ceramic matrix structure contains a large amount of micron-nanometer pores and has light weightMass (density 1.2-1.6 g/cm)³) The refractory brick has the advantages of high temperature resistance (over 1700 ℃), excellent heat insulation and preservation performance, high efficiency, energy conservation (over 80 percent of energy conservation compared with the traditional refractory brick), high strength, high surface hardness, no slag falling, good high temperature erosion resistance and the like.

Description

Hollow sphere ultra-high temperature light refractory prepared by taking FCC waste catalyst as raw material and production process thereof

Technical Field

The invention relates to a hollow ball ultra-high temperature light refractory prepared by taking FCC waste catalyst as a raw material and a production process thereof.

Background

The information in this background section is only for enhancement of understanding of the general background of the disclosure and is not necessarily to be construed as an admission or any form of suggestion that this information forms the prior art that is already known to a person of ordinary skill in the art.

The catalytic cracking (FCC) catalyst is an indispensable catalyst for modern petroleum refining process, and can crack and convert petroleum raw materials into cracked gas, gasoline and diesel oil, especially for domestic oil refining enterprises. In the use process of the FCC catalyst, heavy metal elements and other inorganic elements are deposited on the surface of the catalyst, so that the activity and selectivity of the catalyst are reduced, and even the catalyst is permanently inactivated. In order to ensure the normal operation of an industrial plant, fresh agents are constantly replenished during the normal operation of an FCC unit. Regardless of the make-up adjustment, the deactivated catalyst must be discharged and discarded to achieve the desired operating conditions of the commercial FCC unit, thereby achieving economic benefits.

Because the FCC spent catalyst contains a certain amount of toxic heavy metals such as Ni, V, Co and the like, if the FCC spent catalyst is not specially disposed, the FCC spent catalyst is discarded or buried at will, and is easy to be leached by rainwater to seriously pollute the environment, even cause carcinogenesis. Therefore, in 2016, 8 months and 1 day, FCC waste catalysts are classified as HW 50-type hazardous wastes (hazardous solid wastes) in the national hazardous waste records newly released in China. After the FCC spent catalyst is listed in the national list of dangerous wastes, the crude way of directly carrying out underground landfill treatment is not allowed by law.

At present, the catalytic cracking capability of China is second in the world, and the weight of the FCC waste catalyst generated every year is at least about 20-30 ten thousand tons. With the heavy and inferior petroleum resources, the replacement period of the FCC catalyst is obviously shortened, and the heavy metal pollution problem of the waste catalyst is increasingly prominent. How to effectively treat the FCC waste catalyst is one of the issues that the industry is concerned about.

Since the FCC spent catalyst contains a certain amount of toxic heavy metals such as Ni, V, Co and the like, if the catalyst is directly used as a raw material to prepare other products, secondary pollution is brought. Therefore, how to effectively utilize the FCC waste catalyst in a resource manner, and simultaneously, fundamentally solve the problem of hazardous waste disposal, and avoid the heavy metal pollution to the environment is a technical problem that needs to be solved urgently in the field.

The ultrahigh-temperature light refractory material is a refractory material with high porosity and low volume density, and mainly comprises clay light bricks, light silica bricks, high-aluminum light bricks, alkaline light bricks and the like. Domestic large-scale ultra-high temperature light refractory manufacturers such as Shandong Luyang, Shandong Red Yang, Shandong Min Ye and the like, but enterprises capable of providing ultra-high temperature energy-saving special-shaped plates or light energy-saving refractory materials are relatively rare.

Disclosure of Invention

Against the background above, the present inventors have studied the chemical composition of the FCC spent catalyst and found that the main component is Al₂O₃And SiO₂And the relative content is closer to that of the silicon-aluminum refractory heat-insulating material. Therefore, through earlier researches, a technology for resource utilization of the FCC spent catalyst is successfully developed, namely, the technology is used for directionally blending and optimizing the oxide component of the FCC spent catalyst, the temperature tolerance of the FCC spent catalyst is improved, and an energy-saving new material which can tolerate ultrahigh temperature is produced.

Specifically, the following technical scheme is adopted in the disclosure:

in a first aspect of the disclosure, a hollow sphere ultra-high temperature light refractory prepared by using FCC waste catalyst as raw material is provided, which is mainly characterized in that: the ultra-high temperature light refractory is prepared by taking zirconium-aluminum hollow spheres as raw materials; the zirconium-aluminum hollow sphere is prepared from the following raw materials in parts by weight:

70-85 parts of FCC spent catalyst, 0.5-3 parts of coal gangue, 2-4 parts of zirconium dioxide, 14-18 parts of aluminum oxide, 0.5-1.5 parts of silicon dioxide and 1-2 parts of sodium carboxymethylcellulose;

specifically, the ultrahigh-temperature light refractory material is prepared from the following raw materials in parts by weight:

30-60 parts of zirconium-aluminum hollow spheres, 60-80 parts of aluminum trioxide powder, 10-20 parts of silicon dioxide powder, 0.5-1 part of foaming agent, 0.5-1 part of foam stabilizer, 4-8 parts of binder and 0.5-1 part of dispersing agent.

In a second aspect of the present disclosure, a production process of the hollow sphere ultrahigh temperature lightweight refractory prepared from the FCC dead catalyst is provided, the production process includes a step of preparing a zirconium-aluminum hollow sphere, and includes the following steps:

(1) carrying out calcination pretreatment on the FCC spent catalyst: carrying out closed calcination treatment on the FCC waste catalyst at 1000-1500 ℃ by taking HCl gas as a chlorine source;

(2) uniformly mixing the pretreated FCC spent catalyst, coal gangue, zirconium dioxide, aluminum oxide and silicon dioxide according to the weight parts;

(3) taking an organic small ball with the diameter of 0.5-3.5 mm as a template, and soaking the organic small ball in a sodium carboxymethyl cellulose solution;

(4) placing the dipped organic small balls into a ball rolling machine for rolling, and then spraying the mixed powder in the step (2) to prepare polystyrene small balls wrapped with the mixed powder;

(5) continuously spraying the sodium carboxymethylcellulose solution on the polystyrene pellets wrapped with the mixed powder in the step (4), spraying the mixed powder in the step (2), and repeating the step until the surface of the polystyrene has the mixed powder with the required thickness, so as to prepare green pellets wrapped with the mixed powder with the required thickness;

(6) drying and sintering the green ball to obtain the zirconium-aluminum hollow ball.

In a third aspect of the disclosure, an application of the hollow sphere ultrahigh temperature light refractory prepared by using the FCC waste catalyst as a raw material as or in preparation of a refractory energy-saving thermal insulation material is provided.

In a fourth aspect of the present disclosure, a fire-resistant rotary or anisotropic plate is provided, which is characterized in that: is prepared from the hollow ball ultra-high temperature light refractory.

Compared with the related technology known by the inventor, one technical scheme of the present disclosure has the following beneficial effects:

the ultra-high temperature light refractory prepared by the method is a novel fire-resistant heat-insulating material newly developed and fills the gap at home and abroad. The matrix structure contains a large number of micron-nanometer-level pores and has light weight (density of 1.2-1.6 g/cm)³) The refractory brick has the advantages of high temperature resistance (over 1700 ℃), excellent heat insulation and preservation performance, high efficiency, energy conservation (over 80 percent of energy conservation compared with the traditional refractory brick), high strength, high surface hardness, no slag falling, good high temperature erosion resistance and the like.

The material can replace the traditional materials such as refractory bricks in the past, and has great application prospect in the fields of steel, petrifaction, cement, electric power, nuclear power, chemical industry, machinery, industrial kilns and the like.

According to preliminary statistics, the potential market demand is at least more than 10 ten thousand tons/year, and the method has great practicability.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate embodiments of the disclosure and, together with the description, serve to explain the disclosure and not to limit the disclosure.

Fig. 1 is an ultra high temperature lightweight refractory prepared from FCC spent catalyst in example 2 of the present disclosure.

Fig. 2 is an ultra high temperature lightweight refractory prepared from FCC spent catalyst in example 3 of the present disclosure.

Fig. 3 is an ultra high temperature lightweight refractory prepared from FCC spent catalyst in example 4 of the present disclosure.

Fig. 4 is a production flow chart of the ultra-high temperature lightweight refractory of the present disclosure.

Detailed Description

It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of the stated features, steps, operations, and/or combinations thereof, unless the context clearly indicates otherwise.

As described in the background art, there is still a shortage in the industry that can provide ultra-high temperature energy-saving special-shaped plates or light energy-saving refractory materials, in order to solve the above technical problems, in a first exemplary embodiment of the present disclosure, a hollow ball ultra-high temperature light refractory material prepared by using FCC waste catalyst as a raw material is provided, which is mainly characterized in that: the ultra-high temperature light refractory is prepared by taking zirconium-aluminum hollow spheres as raw materials; the zirconium-aluminum hollow sphere is prepared from the following raw materials in parts by weight:

70-85 parts of FCC spent catalyst, 0.5-3 parts of coal gangue, 2-4 parts of zirconium dioxide, 14-18 parts of aluminum oxide, 0.5-1.5 parts of silicon dioxide and 1-2 parts of sodium carboxymethylcellulose.

In one or more embodiments of the present disclosure, the main chemical components of the FCC spent catalyst include: al (Al)₂O₃50～52％，SiO₂40-42%, and other components including rare earth elements, heavy metal elements and the like.

The composition content of the zirconium-aluminum hollow spheres in the ultra-high temperature light-weight refractory is searched, and experiments prove that when the content of the zirconium-aluminum hollow spheres is between 20% and 35%, various performances of the ultra-high temperature light-weight refractory are excellent, and especially the requirements of high temperature resistance, light weight, high strength and the like can be met. Tests prove that if the content of the zirconium-aluminum hollow spheres is too high, the strength of the obtained ultrahigh-temperature light refractory is lower, and if the content of the zirconium-aluminum hollow spheres is lower, the volume density of the obtained material is higher.

In one or more embodiments of the present disclosure, according to the characteristics of each raw material for preparing the refractory material, the present disclosure finds out the additives required to be adopted, mainly needs low content of the foaming agent, the foam stabilizer, the binder and the dispersing agent, and can meet the requirements without adding other additives. According to the characteristics of various raw materials for preparing the refractory material and the performance requirement of the finally prepared refractory material, the foaming agent is selected to be carbonate, the foam stabilizer is carboxymethyl cellulose, the binder is sodium carboxymethyl cellulose, and the dispersing agent is polyacrylic acid.

In a second exemplary embodiment of the present disclosure, a process for producing the hollow sphere ultrahigh temperature lightweight refractory prepared from the FCC dead catalyst as a raw material is provided, the process comprises the following steps:

In one or more embodiments of the present disclosure, in the step (1), the closed calcination time is 1 to 3 hours.

Furthermore, the HCl gas concentration is 10-20 v/v%, the HCl gas is 10-20% by volume and 90-80% by volume of air, the calcination treatment effect is good, and the treated heavy metal content is low.

In order to ensure the performance and yield of the product, the raw material is firstly subjected to chlorine source closed calcination pretreatment, and the main pretreatment process adopts the mature and reliable rotary kiln process at present. The method comprises the steps of carrying out calcination pretreatment on the FCC waste catalyst by adopting a rotary kiln (closed calcination, after smoke needs to be collected, purification treatment is carried out, environmental protection is achieved, and the smoke is discharged after reaching the standard), wherein after the FCC waste catalyst is subjected to closed calcination pretreatment by a chlorine source, residual carbon, residual oil, adsorbed water and the like are completely burned out, and the color is changed from light gray to white and slightly yellowish green. The data of the test results of Shandong environmental science research institute in 2019, 9 months and 20 days show that only copper, cobalt, nickel, chromium and mercury are separated out of heavy metals after the process, and the separated-out amount is far lower than the national standard of 1000mg in 40-70 mg/kg.

In one or more embodiments of the present disclosure, in the step (2), the calcined FCC dead catalyst is pulverized to 300 mesh or less, and the particle sizes of the coal gangue, zirconia, alumina and silica are all 300 mesh or less.

In one or more embodiments of the present disclosure, in the step (2), a gas kiln is adopted to perform calcination pretreatment on the coal gangue, and the specific steps and process conditions of the calcination pretreatment are as follows: and (3) carrying out closed calcining treatment on the coal gangue at 1000-1500 ℃ by taking HCl gas as a chlorine source, wherein the calcining time is 1-2 h. The coal gangue calcination treatment by using the gas kiln is more energy-saving. Residual carbon, adsorbed water, volatile impurities and the like in the coal gangue are thoroughly removed, and the color can be changed into pure white. The data of the test results of Shandong environmental science research institute in 2019, 9 months and 20 days show that only copper, cobalt, nickel, chromium and mercury are separated out of heavy metals after the process, and the separated-out amount is far lower than the national standard of 1000mg in 40-70 mg/kg.

In one or more embodiments of the present disclosure, in step (3), the organic beads are polystyrene beads. The diameter of the polystyrene spheres is controlled to be 0.5-3.5 mm, so that the zirconium-aluminum hollow spheres with better performance can be obtained.

In one or more embodiments of the present disclosure, in the step (3), the mass of the organic pellet is 10 to 40% of the mass of the mixed powder in the step (2). The particle size and the shell thickness of the finally obtained hollow sphere are controlled.

In one or more embodiments of the present disclosure, in the step (3), the concentration of the sodium carboxymethyl cellulose solution is 1 to 2 wt.%. Tests prove that the sodium carboxymethyl cellulose has excellent bonding property to the mixed powder in the step (2) of the method and good dispersibility.

In one or more embodiments of the present disclosure, in the step (4), the roller machine continues to operate for 30-60 min after the mixed powder in the step (2) is sprayed, and polystyrene pellets wrapped with the mixed powder are prepared.

In one or more embodiments of the present disclosure, in the step (6), the drying condition is 90 to 100 ℃ for 8 to 10 hours.

In one or more embodiments of the present disclosure, in step (6), the sintering conditions are: 1000-1500 ℃ and 6-8 h. The method has high balling rate and does not need to carry out temperature gradient sintering

The zirconium-aluminum hollow sphere prepared by the method is white, the particle size is customized as required, the preferred particle size is 1-5 mm, and the particle size is uniform.

The zirconium-aluminum hollow sphere material prepared by the method has the advantages of light volume weight, high temperature resistance, good thermal stability, low thermal conductivity, small thermal capacity, good mechanical vibration resistance, small thermal expansion, good heat insulation performance, good sound insulation, electrical insulation, good chemical stability and the like. The novel material zirconium-aluminum hollow sphere with excellent performance is prepared by taking the FCC waste catalyst as a main raw material and adopting a proper raw material proportion, compared with a zirconium oxide hollow sphere, the novel material zirconium-aluminum hollow sphere does not need to be additionally added with a stabilizer yttrium oxide with high price, the bulk density is lower, and compared with a silicon-aluminum hollow sphere, the novel material zirconium-aluminum hollow sphere has low thermal conductivity and high strength. The coal gangue is added in the preparation process of the zirconium-aluminum hollow sphere, so that the compressive strength of the hollow sphere can be obviously improved, and the bulk density is reduced. The method takes the organic small balls as the template, adopts a layer-by-layer wrapping and sintering method, has high balling rate and low energy consumption, and can ensure uniform particle size distribution and uniform shell thickness.

Specifically, the production process of the hollow sphere ultrahigh-temperature light refractory comprises the following steps:

1) preparing zirconium-aluminum hollow spheres, which comprises the following specific steps;

2) uniformly mixing the zirconium-aluminum hollow spheres, the aluminum oxide powder, the silicon dioxide powder, the foaming agent, the foam stabilizer, the dispersing agent and a proper amount of water in a set weight part ratio, and carrying out physical molding, drying and sintering to obtain the ultra-high temperature light refractory material.

In one or more embodiments of the present disclosure, in step 2), extrusion molding is employed.

In one or more embodiments of the present disclosure, in the step 2), the drying condition is 90 to 100 ℃ for 12 to 24 hours.

In one or more embodiments of the present disclosure, in step 2), the conditions of the sintering are: 1000-1500 ℃ and 4-6 h.

In a third exemplary embodiment of the disclosure, the hollow sphere ultrahigh temperature lightweight refractory prepared by using the FCC waste catalyst as a raw material is used as or for preparing a refractory energy-saving thermal insulation material.

In a fourth exemplary embodiment of the present disclosure, a refractory transition or anisotropic sheet material is provided, characterized in that: is prepared from the hollow ball ultra-high temperature light refractory.

After the FCC waste catalyst powder is subjected to pre-calcination treatment, components are tested, and according to component detection results, the components are combined and blended with alumina powder, silica powder, hollow spheres, a foaming agent, a foam stabilizer and the like, and the mixture is subjected to forming, drying, high-temperature calcination and size fine machining to obtain the FCC waste catalyst ultra-high temperature resistant material, wherein the specific production process flow is shown in fig. 4.

In order to make the technical solutions of the present disclosure more clearly understood by those skilled in the art, the technical solutions of the present disclosure will be described in detail below with reference to specific embodiments.

The following examples are of spent FCC catalyst from large petrochemical enterprises.

Example 1

A zirconium-aluminum hollow sphere is prepared by taking an FCC waste catalyst as a raw material, and is prepared from the following raw materials in parts by weight:

75 parts of FCC spent catalyst, 2.5 parts of coal gangue, 4 parts of zirconium dioxide, 15 parts of aluminum oxide, 1.5 parts of silicon dioxide and 2 parts of sodium carboxymethylcellulose.

The preparation method of the zirconium-aluminum hollow sphere comprises the following steps:

(1) carrying out calcination pretreatment on the FCC spent catalyst:

putting the FCC waste catalyst into a pulverizer for pulverizing, wherein the pulverized particle size is less than or equal to 1 mm;

putting the crushed FCC waste catalyst into a rotary kiln for closed calcination treatment, wherein the gas environment is 15 v/v% HCl gas, and the calcination treatment is carried out for 1.5h at 1500 ℃;

(2) putting the coal gangue into a gas kiln for closed calcination treatment, wherein the gas environment is 15 v/v% HCl gas, and carrying out calcination treatment for 1h at 1500 ℃;

putting the calcined FCC spent catalyst and coal gangue into a grinder for grinding, wherein the granularity is less than or equal to 300 meshes;

controlling the grain diameters of the zirconium dioxide, the aluminum oxide and the silicon dioxide to be less than or equal to 300 meshes;

uniformly mixing the raw materials with the particle size of less than or equal to 300 meshes according to the set weight part for later use;

(3) soaking organic spheres in 2 wt.% sodium carboxymethyl cellulose solution for 20min by using polystyrene spheres with the diameter of 0.5mm as a template; after the impregnation is finished, filtering to obtain polystyrene spheres;

(4) putting the filtered polystyrene spheres into a ball rolling machine, wherein the rotating speed is 40r/min, so that the polystyrene spheres are turned and rolled, spraying a certain amount of the mixed powder in the step (2), and continuously operating the ball rolling machine for 30min after spraying to obtain the polystyrene spheres coated with the mixed powder with a certain thickness;

(5) continuously spraying 2 wt.% of sodium carboxymethylcellulose solution on the polystyrene pellets wrapped with the mixed powder with a certain thickness in the step (4), spraying a certain amount of the mixed powder in the step (2), continuously operating the ball rolling machine for 30min after spraying, repeating the step until the polystyrene surface has the mixed powder with a required thickness, and preparing green pellets wrapped with the mixed powder with the required thickness;

wherein in the steps (4) and (5), the mass ratio of the polystyrene pellets to the total mixed powder is 25: 80;

(6) drying the green balls obtained in the step (5) at 95 ℃ for 8 h;

(7) and sintering the dried green ball at 1500 ℃ for 6h, cooling to room temperature after sintering, and then screening to obtain the zirconium-aluminum hollow ball with uniform particle size, wherein the balling rate is more than 99%, the white zirconium-aluminum hollow ball with uniform particle size is obtained, the average particle size is 1.5mm, the average shell thickness is 1mm, and the specific performance indexes are shown in table 1. TABLE 1 hollow sphere Performance test

Example 2

A hollow sphere ultra-high temperature light refractory prepared by taking FCC spent catalyst as raw material is prepared from the following raw materials in parts by weight:

40 parts of zirconium-aluminum hollow spheres, 60 parts of aluminum oxide powder, 10 parts of silicon dioxide powder, 1 part of calcium carbonate, 1 part of carboxymethyl cellulose, 6 parts of sodium carboxymethyl cellulose and 1 part of polyacrylic acid in example 1.

The production process of the hollow sphere ultra-high temperature light refractory comprises the following steps:

uniformly mixing zirconium-aluminum hollow spheres, aluminum oxide powder, silicon dioxide powder, calcium carbonate, carboxymethyl cellulose, sodium carboxymethyl cellulose and polyacrylic acid in set parts by weight with a proper amount of water, carrying out extrusion forming, drying at 100 ℃ for 12h after forming, cutting according to requirements, and sintering at 1500 ℃ for 6h after cutting to obtain the ultrahigh-temperature light refractory, wherein the ultrahigh-temperature light refractory is shown in figure 1.

Example 3

45 parts of zirconium-aluminum hollow spheres, 55 parts of aluminum oxide powder, 15 parts of silicon dioxide powder, 1 part of calcium carbonate, 1 part of carboxymethyl cellulose, 6 parts of sodium carboxymethyl cellulose and 1 part of polyacrylic acid in example 1.

uniformly mixing zirconium-aluminum hollow spheres, aluminum oxide powder, silicon dioxide powder, calcium carbonate, carboxymethyl cellulose, sodium carboxymethyl cellulose and polyacrylic acid in set parts by weight with a proper amount of water, carrying out extrusion forming, drying at 100 ℃ for 18h after forming, cutting according to requirements, and sintering at 1500 ℃ for 6h after cutting to obtain the ultrahigh-temperature light refractory, wherein the ultrahigh-temperature light refractory is shown in figure 2.

Example 4

50 parts of zirconium-aluminum hollow spheres, 65 parts of aluminum oxide powder, 20 parts of silicon dioxide powder, 1 part of calcium carbonate, 1 part of carboxymethyl cellulose, 8 parts of sodium carboxymethyl cellulose and 1 part of polyacrylic acid in example 1.

uniformly mixing zirconium-aluminum hollow spheres, aluminum oxide powder, silicon dioxide powder, calcium carbonate, carboxymethyl cellulose, sodium carboxymethyl cellulose and polyacrylic acid in set parts by weight with a proper amount of water, carrying out extrusion forming, drying at 100 ℃ for 18h after forming, cutting according to requirements, and sintering at 1500 ℃ for 5h after cutting to obtain the ultrahigh-temperature light refractory, as shown in fig. 3.

Through tests, the volume density of the ultrahigh-temperature light refractory prepared by adopting the FCC dead catalyst in the embodiments 1-3 of the disclosure is 1.2-1.6 g/cm³The long-term use temperature is up to 1700 ℃ or above. The refractory material has excellent heat insulating performance and mechanical performance, good erosion resistance, high strength, no slag falling, heat conductivity coefficient (1000 ℃) of 0.205 w/m.k and normal-temperature compressive strength of 44MPa, is used as a refractory heat insulating material, has obvious energy-saving effect (more than 80 percent) compared with the traditional heavy refractory brick, has high cost performance and wide market prospect.

Comparative example 1

The difference from example 2 is that: 90 parts of zirconium-aluminum hollow spheres of example 1. The rest is the same as in example 2. The room-temperature compressive strength of the obtained refractory was 37 MPa.

Comparative example 2

The difference from example 2 is that: 20 parts of zirconium-aluminum hollow spheres of example 1. The rest is the same as in example 2. The bulk density of the obtained refractory was 2.0g/cm³。

The above embodiments are preferred embodiments of the present disclosure, but the embodiments of the present disclosure are not limited to the above embodiments, and any other changes, modifications, substitutions, combinations, and simplifications which do not depart from the spirit and principle of the present disclosure should be regarded as equivalent replacements within the scope of the present disclosure.

Claims

1. The hollow sphere ultrahigh-temperature light refractory prepared by taking the FCC spent catalyst as a raw material is characterized by being prepared from the following raw materials in parts by weight:

30-60 parts of zirconium-aluminum hollow spheres, 60-80 parts of aluminum trioxide powder, 10-20 parts of silicon dioxide powder, 0.5-1 part of foaming agent, 0.5-1 part of foam stabilizer, 4-8 parts of binder and 0.5-1 part of dispersing agent;

the zirconium-aluminum hollow ball is prepared from the following raw materials in parts by weight:

2. The durable material of claim 1, wherein the foaming agent is carbonate, the foam stabilizer is carboxymethyl cellulose, the binder is sodium carboxymethyl cellulose, and the dispersing agent is polyacrylic acid.

3. The production process of the hollow sphere ultrahigh-temperature lightweight refractory of claim 1 or 2, which is characterized by comprising the step of preparing zirconium-aluminum hollow spheres, and comprises the following steps:

4. The method of claim 3, wherein in the step (1), the closed calcination time is 1 to 3 hours;

further, in the step (1), the concentration of the HCl gas is 10-20 v/v%;

further, in the step (2), HCl gas is used as a chlorine source to carry out closed calcination treatment on the coal gangue at 900-950 ℃, wherein the calcination time is 1-2 h;

further, in the step (2), the concentration of the HCl gas is 10-20 v/v%.

5. The method according to claim 3, wherein in the step (3), the organic beads are polystyrene beads;

further, in the step (3), the mass of the organic small balls is 10-40% of that of the mixed powder in the step (2);

further, in the step (3), the concentration of the sodium carboxymethyl cellulose solution is 1-2 wt.%;

further, in the step (4), after the mixed powder in the step (2) is sprayed, the ball rolling machine continues to operate for 30-60 min to prepare polystyrene pellets wrapped with the mixed powder;

further, in the step (6), the drying condition is 90-100 ℃ and 8-10 h;

further, in the step (6), the sintering conditions are as follows: 900-1000 ℃ for 10-12 h.

6. The method as claimed in claim 3, wherein the production process of the hollow sphere ultra-high temperature lightweight refractory comprises the following steps:

1) preparing zirconium-aluminum hollow spheres;

7. The method as claimed in claim 6, wherein in step 2), extrusion is used.

8. The method as claimed in claim 6, wherein in the step 2), the drying condition is 90-100 ℃ for 12-24 h;

further, in step 2), the sintering conditions are as follows: 1000-1500 ℃ and 4-6 h.

9. Use of the refractory according to claim 1 or 2 as or in the preparation of a refractory energy-saving thermal insulation material.

10. A refractory transition or anisotropic plate, which is characterized in that the refractory transition or anisotropic plate is prepared from the hollow sphere ultrahigh-temperature lightweight refractory according to claim 1 or 2.