CN111099880A - Heat-insulating composite brick for kiln and preparation method thereof - Google Patents
Heat-insulating composite brick for kiln and preparation method thereof Download PDFInfo
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Abstract
The invention relates to a heat-insulating composite brick for a kiln and a preparation method thereof, belonging to the technical field of building materials. According to the technical scheme, the coal gangue is used as a main raw material, the material structure is effectively bonded through the formed sol material, the prepared sol material is effectively bonded in the sintering process, and a three-dimensional space grid structure is formed in the material, so that the crystal reinforcing effect is achieved, the mechanical property and the strength of the material are further improved, and meanwhile, the sol material and the mullite fiber are selected and prepared to integrate the crystal material and the fiber material into a whole, so that the thermal shock stability and the elasticity are high, the thermal conductivity of the heat-insulating brick can be reduced, and the heat-insulating property of the heat-insulating brick is improved.
Description
Technical Field
The invention relates to a heat-insulating composite brick for a kiln and a preparation method thereof, belonging to the technical field of building materials.
Background
There is necessarily heat transfer wherever temperature differences exist. The function of the insulating brick is to reduce the degree of heat exchange and prevent the heat transfer. The heat-insulating brick is generally composed of solid particles, gaps, fibers and the like, so that the heat conduction process of the whole material is composed of four parts, namely heat transfer among solids, heat transfer between solid phases and gas phases, convection among the gas phases in the gaps, radiation among bubble films and the like. The effective thermal conductivity of the material should be the sum of the contributions of these four parts to the thermal conductivity. When the material is used at high temperatures, radiation is a major factor affecting the thermal conductivity. While radiation is converted to a secondary factor when used at ambient temperatures. The porous insulating brick has a good insulating capacity and a low thermal conductivity because of the large amount of gas contained in the material. The thermal conductivity of gases is much less than that of solids. A large gas content increases the convection between the gas phases in the voids, on the contrary the convective heat transfer decreases. Since porous insulating bricks often have a closed pore structure, the contribution of a flow of gas between interstitial spaces to the effective thermal conductivity becomes a secondary factor.
However, the existing heat-insulating brick material for kilns is prepared by adopting pore-forming agent in the preparation process, so that the porosity of the material is increased, the mechanical property of the material is obviously reduced, and the heat-insulating property of the material is not good, so that the property modification is particularly important.
Disclosure of Invention
The invention aims to provide a heat-insulating composite brick for a kiln and a preparation method thereof, and aims to solve the problems in the prior art.
In order to achieve the purpose, the invention provides the following technical scheme:
a heat insulation composite brick for a kiln comprises the following substances in parts by weight:
45-50 parts of clay;
25-30 parts of expanded perlite;
3-5 parts of mullite fiber;
6-8 parts of water;
10-15 parts of a bonding sol solution;
the adhesive sol solution is prepared by washing coal gangue with sulfuric acid, soaking the coal gangue in a sodium hydroxide solution, soaking the coal gangue with hydrochloric acid, collecting the soaking solution, and aging the soaking solution. According to the technical scheme, the coal gangue is used as a main raw material, acid leaching treatment is carried out on the coal gangue to remove impurities such as iron, the content of impurity iron in the coal gangue is effectively reduced, alkali fusion activation is carried out on the coal gangue to destroy the mineral crystal structure in the coal gangue, and the reaction activity of silicon and aluminum components is improved.
The clay is one or a mixture of more of kaolin, montmorillonite, vermiculite, illite and allophane. Through selecting clay, effectively improve the heat-proof quality of material.
The particle size of the clay is 500 meshes. The structural performance and the bonding strength of the material are improved by effectively limiting the grain diameter of the material.
The preparation method of the heat-insulating composite brick for the kiln comprises the following steps: respectively weighing 45-50 parts by weight of clay, 25-30 parts by weight of expanded perlite, 3-5 parts by weight of mullite fiber, 6-8 parts by weight of water and 10-15 parts by weight of bonding sol solution, placing the materials into a stirrer, stirring, mixing, standing, collecting standing slurry, placing the obtained standing slurry into a mold, pressing and molding, drying, carrying out temperature programming, carrying out heat preservation firing, standing, and cooling to room temperature to obtain the heat-insulating composite brick for the kiln.
The temperature programming and heat preservation firing is to heat the temperature to 1300-1500 ℃ at a speed of 10 ℃/min and heat preserve the temperature for 1-2 h.
The compression molding pressure is 5-10 MPa.
The preparation method of the adhesive sol solution comprises the following specific steps:
s1, taking coal gangue, crushing, grinding and sieving, collecting the sieved coal gangue particles, placing the particles in a resistance furnace, roasting, standing, cooling and washing to obtain impurity-removed coal gangue particles;
s2, stirring and mixing the impurity-removed coal gangue particles and a sodium hydroxide solution according to the mass ratio of 1:2, carrying out high-temperature heat preservation treatment, collecting an activated mixed solution, stirring and mixing deionized water and the activated mixed solution according to the mass ratio of 1:1, carrying out ultrasonic dispersion, standing, carrying out centrifugal separation, collecting lower-layer precipitates, washing with deionized water until a washing solution is neutral, and collecting washing particles;
s3, stirring and mixing the washing particles and hydrochloric acid with the mass fraction of 3% according to the mass ratio of 1:5, standing, filtering, collecting filtrate, placing the filtrate in a rotary evaporator, performing rotary evaporation treatment, adjusting the pH value to 7.0, standing, and aging to obtain the bonding sol solution. The material structure is effectively bonded through the formed sol material, and the prepared sol material is firstly effectively bonded in the sintering process and forms a three-dimensional space grid structure in the material, the material is filled with cavities and pore canals after the sol is dried, the cavities are filled with gas inclusions and water molecules, the pore-forming agent can play a role in pore-forming under the heating condition, and the sol sintering product has a crystal structure which cannot be damaged when gas is released at high temperature, so that the sol material remained in a sample can play a role in enhancing crystals, and the mechanical property and the strength of the material are further improved.
The particle size of the screened coal gangue particles in the step S1 is 0.12 mm. The structural performance and the bonding strength of the material are improved by effectively limiting the grain diameter of the material.
And S2, wherein the high-temperature heat preservation treatment temperature is 800-850 ℃.
The rotary evaporation treatment in the step S3 is vacuum concentration at 70-75 ℃ to 1/5 of the original volume.
Compared with the prior art, the invention has the beneficial effects that: (1) the technical scheme of the invention is that firstly, coal gangue is used as a main raw material, acid leaching treatment is firstly carried out on the coal gangue to remove impurities such as iron, the content of impurity iron in the coal gangue is effectively reduced, alkali fusion activation is carried out on the coal gangue to destroy the mineral crystal structure in the coal gangue, the reaction activity of silicon and aluminum components is improved, because Si-O-Si and Si-O-Al bonds in aluminosilicate glass bodies and mineral crystals are destroyed under the action of the alkali fusion activation, free SiO2 and Al2O3 with high reaction activity are formed and react with sodium hydroxide to generate sodium silicate, sodium aluminate and sodium aluminosilicate, the material structure is effectively bonded through the formed sol material, and because the prepared sol material forms effective bonding in the sintering process and forms a three-dimensional space grid structure in the material, cavities and pore canals are filled in the material after the sol is dried, the cavity is filled with gas inclusions and water molecules, the cavity can play a role of a pore-forming agent under the heating condition, and the sol sintered product has a crystal structure which cannot be damaged when gas is released at high temperature, so that the sol material remained in the sample can play a role of crystal enhancement, and the mechanical property and the strength of the material are further improved;
(2) according to the technical scheme, through selecting and preparing the sol material, the sol material has good adsorbability, countless network structure pores generated by micelle aggregation can generate certain adsorption effect on inorganic matters and organic matters, and the mullite fiber integrates the crystal material and the fiber material and has high thermal shock stability and elasticity.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Taking coal gangue, crushing and grinding the coal gangue, sieving the coal gangue by using a 0.12mm sieve, collecting sieved coal gangue particles, placing the sieved coal gangue particles in a resistance furnace, roasting the particles at 300-350 ℃ for 2-3 h, standing and cooling the particles to 60-70 ℃, washing the particles for 15-20 min by using sulfuric acid with the mass fraction of 1%, and washing the particles for 3-5 min by using deionized water to obtain impurity-removed coal gangue particles; stirring and mixing the impurity-removed coal gangue particles and 10% sodium hydroxide solution by mass according to the mass ratio of 1:2, carrying out heat preservation treatment at 800-850 ℃ for 1-2 h, collecting an activated mixed solution, stirring and mixing deionized water and the activated mixed solution according to the mass ratio of 1:1, carrying out ultrasonic dispersion at 200-300W for 1-2 h, standing for 10-12 h, carrying out centrifugal separation at 1200-1300 r/min, collecting a lower-layer precipitate, washing with deionized water until the washing solution is neutral, and collecting washing particles; according to the mass ratio of 1:5, stirring and mixing the washing particles with hydrochloric acid with the mass fraction of 3%, standing for 6-8 hours, filtering, collecting filtrate, placing the filtrate in a rotary evaporator, concentrating the filtrate at 70-75 ℃ under reduced pressure to 1/5 in the original volume, adjusting the pH to 7.0 with sodium hydroxide solution, standing for 20-24 hours, and aging for 3-5 hours at 45-55 ℃ to obtain a bonding sol solution; respectively weighing 45-50 parts by weight of clay, 25-30 parts by weight of expanded perlite, 3-5 parts by weight of mullite fiber, 6-8 parts by weight of water and 10-15 parts by weight of bonding sol solution, placing the mixture in a stirrer, stirring and mixing, standing for 10-12 hours, collecting standing slurry, placing the standing slurry in a mold, performing compression molding under the pressure of 5-10 MPa, drying at normal temperature for 48 hours, heating to 1300-1500 ℃ at the speed of 10 ℃/min, performing heat preservation firing for 1-2 hours, and standing and cooling to room temperature to obtain the heat-insulating composite brick for the kiln.
Example 1
Taking coal gangue, crushing and grinding the coal gangue, sieving the coal gangue by a 0.12mm sieve, collecting sieved coal gangue particles, placing the sieved coal gangue particles in a resistance furnace, roasting the particles at 300 ℃ for 2 hours, standing and cooling the particles to 60 ℃, washing the particles for 15min by using sulfuric acid with the mass fraction of 1%, and washing the particles for 3min by using deionized water to obtain impurity-removed coal gangue particles; stirring and mixing the impurity-removed coal gangue particles and 10% sodium hydroxide solution in parts by mass according to the mass ratio of 1:2, carrying out heat preservation treatment at 800 ℃ for 1h, collecting an activated mixed solution, stirring and mixing deionized water and the activated mixed solution according to the mass ratio of 1:1, carrying out ultrasonic dispersion at 200W for 1h, standing for 10h, carrying out centrifugal separation at 1200r/min, collecting lower-layer precipitates, washing with deionized water until the washing solution is neutral, and collecting washing particles; according to the mass ratio of 1:5, stirring and mixing the washing particles with hydrochloric acid with the mass fraction of 3%, standing for 6h, filtering, collecting filtrate, placing the filtrate in a rotary evaporator, concentrating the filtrate under reduced pressure at 70 ℃ to 1/5 in the original volume, adjusting the pH to 7.0 by using sodium hydroxide solution, standing for 20h, and aging for 3h at 45 ℃ to obtain a bonding sol solution; respectively weighing 45 parts of clay, 25 parts of expanded perlite, 3 parts of mullite fiber, 6 parts of water and 10 parts of bonding sol solution in parts by weight, placing the materials into a stirrer, stirring and mixing the materials, standing the materials for 10 hours, collecting standing slurry, placing the standing slurry into a mold, pressing the obtained product under the pressure of 5MPa to form a mold, drying the obtained product at normal temperature for 48 hours, heating the obtained product to 1300 ℃ at the speed of 10 ℃/min, carrying out heat preservation firing for 1 hour, standing the obtained product, and cooling the obtained product to the room temperature to obtain the heat-insulating.
Example 2
Taking coal gangue, crushing and grinding the coal gangue, sieving the coal gangue by a 0.12mm sieve, collecting sieved coal gangue particles, placing the sieved coal gangue particles in a resistance furnace, roasting the particles at 325 ℃ for 2 hours, standing and cooling the particles to 65 ℃, washing the particles for 17min by using sulfuric acid with the mass fraction of 1%, and washing the particles for 4min by using deionized water to obtain impurity-removed coal gangue particles; stirring and mixing the impurity-removed coal gangue particles and 10% sodium hydroxide solution in parts by mass according to the mass ratio of 1:2, carrying out heat preservation treatment at 825 ℃ for 1h, collecting an activated mixed solution, stirring and mixing deionized water and the activated mixed solution according to the mass ratio of 1:1, carrying out ultrasonic dispersion at 250W for 1h, standing for 11h, carrying out centrifugal separation at 1250r/min, collecting lower-layer precipitates, washing with deionized water until the washing solution is neutral, and collecting washing particles; according to the mass ratio of 1:5, stirring and mixing the washing particles with hydrochloric acid with the mass fraction of 3%, standing for 7h, filtering, collecting filtrate, placing the filtrate in a rotary evaporator, concentrating the filtrate under reduced pressure at 72 ℃ to 1/5 in the original volume, adjusting the pH to 7.0 by using sodium hydroxide solution, standing for 22h, and aging for 4h at 47 ℃ to obtain a bonding sol solution; respectively weighing 47 parts of clay, 27 parts of expanded perlite, 4 parts of mullite fiber, 7 parts of water and 12 parts of bonding sol solution by weight, placing the materials into a stirrer, stirring and mixing, standing for 11 hours, collecting standing slurry, placing the standing slurry into a mold, performing compression molding under 7MPa, drying at normal temperature for 48 hours, heating to 1400 ℃ at the rate of 10 ℃/min, performing heat preservation firing for 1 hour, standing and cooling to room temperature to obtain the heat-insulating composite brick for the kiln.
Example 3
Taking coal gangue, crushing and grinding the coal gangue, sieving the coal gangue by a 0.12mm sieve, collecting sieved coal gangue particles, placing the sieved coal gangue particles in a resistance furnace, roasting the particles at 350 ℃ for 3 hours, standing and cooling the particles to 70 ℃, washing the particles for 20min by using sulfuric acid with the mass fraction of 1%, and washing the particles for 5min by using deionized water to obtain impurity-removed coal gangue particles; stirring and mixing the impurity-removed coal gangue particles and 10% sodium hydroxide solution in parts by mass according to the mass ratio of 1:2, placing the mixture at 850 ℃ for heat preservation treatment for 2 hours, collecting an activated mixed solution, stirring and mixing deionized water and the activated mixed solution according to the mass ratio of 1:1, performing ultrasonic dispersion for 2 hours at 300W, standing the mixture for 12 hours, performing centrifugal separation at 1300r/min, collecting lower-layer precipitates, washing the precipitates with deionized water until the washing solution is neutral, and collecting washing particles; according to the mass ratio of 1:5, stirring and mixing the washing particles with hydrochloric acid with the mass fraction of 3%, standing for 8 hours, filtering again, collecting filtrate, placing the filtrate in a rotary evaporator, concentrating the filtrate under reduced pressure at 75 ℃ to 1/5 in the original volume, adjusting the pH to 7.0 by using sodium hydroxide solution, standing for 24 hours, and aging for 5 hours at 55 ℃ to obtain a bonding sol solution; respectively weighing 50 parts of clay, 30 parts of expanded perlite, 5 parts of mullite fiber, 8 parts of water and 15 parts of bonding sol solution in parts by weight, placing the materials into a stirrer, stirring and mixing, standing for 12 hours, collecting standing slurry, placing the standing slurry into a mold, pressing the slurry into a mold under the pressure of 10MPa, drying the slurry at normal temperature for 48 hours, heating the slurry to 1500 ℃ at the speed of 10 ℃/min, keeping the temperature, firing the slurry for 2 hours, standing and cooling the slurry to the room temperature to obtain the heat-insulating composite brick for the kiln.
Example 4
Respectively weighing 50 parts of clay, 30 parts of expanded perlite, 5 parts of mullite fiber and 8 parts of water in parts by weight, placing the materials in a stirrer, stirring, mixing, standing for 12 hours, collecting standing slurry, placing the slurry in a mold, pressing under 10MPa to form the product, drying at normal temperature for 48 hours, heating to 1500 ℃ at a speed of 10 ℃/min, keeping the temperature, firing for 2 hours, standing, and cooling to room temperature to obtain the heat-insulating composite brick for the kiln.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
The performance tests of the embodiment 1, the embodiment 2, the embodiment 3 and the embodiment 4 are carried out, wherein the embodiment 4 is an insulating composite brick prepared without adding the bonding sol solution:
the density, compressive strength and thermal conductivity of the material are tested, and the specific test results are shown in table 1.
TABLE 1 comparison of Properties
(1) Comparing the examples 1, 2, 3 and 4 of the invention, the thermal conductivity of the example 4 is far greater than that of the examples 1, 2 and 3, which shows that the thermal insulation brick material prepared in the embodiment 4 of the invention has poorer thermal insulation performance than the examples 1, 2 and 3, because the sol material has better adsorbability by selection and preparation, countless network structure pores generated by micelle aggregation can generate certain adsorption effect on inorganic matters and organic matters, and the mullite fiber integrates the crystal material and the fiber material into a whole and has higher thermal shock stability and elasticity, meanwhile, the sol prepared by the invention is decomposed and overflowed in a high temperature environment, and air with low thermal conductivity plays a good thermal insulation effect in pores, so that the material prepared by the invention has uniform pores to structures, the heat conductivity of the heat insulation brick can be reduced, and the heat insulation performance of the heat insulation brick can be improved.
(2) Compared with the embodiment 4 in the technical schemes 1, 2 and 3, the embodiment 4 has compressive strength far lower than that of the embodiment 1, 2 and 3, and the technical scheme of the invention is that the sol material prepared by taking coal gangue as a main raw material forms effective bonding in the sintering process and forms a three-dimensional space grid structure in the material, the material is filled with cavities and pore canals after the sol is dried, the cavities are filled with existing gas inclusions and water molecules and can play a role of pore-forming agent under the heating condition, and the sol sintering product has a crystal structure which cannot be damaged when releasing gas at high temperature, so that the sol material remained in a sample can play a role of crystal enhancement, and the mechanical property and the strength of the material are further improved.
Claims (10)
1. The heat-insulating composite brick for the kiln is characterized by comprising the following substances in parts by weight:
45-50 parts of clay;
25-30 parts of expanded perlite;
3-5 parts of mullite fiber;
6-8 parts of water;
10-15 parts of a bonding sol solution;
the adhesive sol solution is prepared by washing coal gangue with sulfuric acid, soaking the coal gangue in a sodium hydroxide solution, soaking the coal gangue with hydrochloric acid, collecting the soaking solution, and aging the soaking solution.
2. The insulating composite brick as claimed in claim 1, wherein the clay is a mixture of one or more of kaolin, montmorillonite, vermiculite, illite and allophane.
3. The heat-insulating composite brick for the kiln as claimed in claim 1, wherein the clay has a particle size of 500 meshes.
4. A preparation method of a heat insulation composite brick for a kiln is characterized by comprising the following preparation steps: respectively weighing 45-50 parts by weight of clay, 25-30 parts by weight of expanded perlite, 3-5 parts by weight of mullite fiber, 6-8 parts by weight of water and 10-15 parts by weight of bonding sol solution, placing the materials into a stirrer, stirring, mixing, standing, collecting standing slurry, placing the obtained standing slurry into a mold, pressing and molding, drying, carrying out temperature programming, carrying out heat preservation firing, standing, and cooling to room temperature to obtain the heat-insulating composite brick for the kiln.
5. The preparation method of the heat-insulating composite brick for the kiln as claimed in claim 4, wherein the temperature programming and heat-preserving firing is carried out at a temperature of 1300-1500 ℃ at a rate of 10 ℃/min for 1-2 h.
6. The preparation method of the heat-insulating composite brick for the kiln as claimed in claim 4, wherein the pressure of the compression molding is 5-10 MPa.
7. The preparation method of the heat-insulating composite brick for the kiln as claimed in claim 4, wherein the specific preparation steps of the bonding sol solution are as follows:
s1, taking coal gangue, crushing, grinding and sieving, collecting the sieved coal gangue particles, placing the particles in a resistance furnace, roasting, standing, cooling and washing to obtain impurity-removed coal gangue particles;
s2, stirring and mixing the impurity-removed coal gangue particles and a sodium hydroxide solution according to the mass ratio of 1:2, carrying out high-temperature heat preservation treatment, collecting an activated mixed solution, stirring and mixing deionized water and the activated mixed solution according to the mass ratio of 1:1, carrying out ultrasonic dispersion, standing, carrying out centrifugal separation, collecting lower-layer precipitates, washing with deionized water until a washing solution is neutral, and collecting washing particles;
s3, stirring and mixing the washing particles and hydrochloric acid with the mass fraction of 3% according to the mass ratio of 1:5, standing, filtering, collecting filtrate, placing the filtrate in a rotary evaporator, performing rotary evaporation treatment, adjusting the pH value to 7.0, standing, and aging to obtain the bonding sol solution.
8. The method for preparing the heat-insulating composite brick for the kiln as claimed in claim 7, wherein the particle size of the screened gangue particles in the step S1 is 0.12 mm.
9. The preparation method of the heat-insulating composite brick for the kiln as claimed in claim 7, wherein the high-temperature heat-preserving treatment temperature of step S2 is 800-850 ℃.
10. The method for preparing the heat-insulating composite brick for the kiln as claimed in claim 7, wherein the rotary evaporation treatment of step S3 is vacuum concentration at 70-75 ℃ to 1/5 of the original volume.
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