CN111484341A - 无硅灰耐火自流浇注料用缓凝型复合减水剂及其制备方法 - Google Patents
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Abstract
本发明公开了一种无硅灰耐火自流浇注料用缓凝型复合减水剂,以三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸为原料制成,三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸的质量比为3:3:2~3:0.2~1。相比于单一三聚氰胺减水剂或萘系减水剂或聚羧酸减水剂减水剂,本发明复合减水剂明显提升了减水效率,同时引入无水柠檬酸,不仅改善了复合减水剂的分散性能,使减水剂具备良好的分散性,而且使得体系更加稳定、缓凝性能更优,同时无水柠檬酸也具备减水作用,通过无水柠檬酸和三聚氰胺类减水剂、萘系减水剂和聚羧酸系减水剂的复配,满足了无硅灰耐火自流浇注料的高减水效率和高温(30℃~50℃)缓凝的双重要求。
Description
技术领域
本发明耐火浇注料领域,涉及一种有机化学和有机高分子材料两个领域的综合产物,具体涉及一种无硅灰耐火自流浇注料用缓凝型减水剂及其制备方法,尤其是具体涉及一种无硅灰的耐火自流浇注料专用、具有高温缓凝作用的减水剂。
背景技术
减水剂是耐火浇注料完成施工及提供后期高温性能必不可少的一部分,对浇注料的加水量、流动值、致密度、纯铝酸钙水泥结合剂的水化凝结性能和高温性能的作用至关重要。耐火自流浇注料被广泛应用于二次精炼钢包包底、座砖与透气砖等功能耐火材料安装空隙区域,对钢包的砌筑和安全运行工作至关重要。
无硅灰耐火自流浇注料要求较好的流动性能,通常情况下含有较高含量的氧化铝微粉。氧化铝微粉通常含有较高的比表面积/比表面能,可以明显促进耐火浇注料中纯铝酸钙水泥的水化,大大缩短浇注料的可施工时间。但是,耐火自流浇注料较高含量的活性氧化铝微粉也会导致其难以分散、加水量较高、初凝时间较短等施工问题。
目前,无硅灰耐火自流浇注料使用的减水剂以聚羧酸系减水剂为主,但是这一类产品通常只具有分散减水作用,并没有缓凝作用,这就易导致自流浇注料出现施工时间短、尤其是夏季或热态修补较高温度情况下,更加难以控制可施工时间。为了保证浇注料的安全施工,本领技术人员往往在使用一种减水剂的同时,引入一种缓凝剂。然而,引入缓凝剂势必造成减水剂的减水效率下降,导致自流浇注料必须在高加水量的情况下才能完成施工,最终导致其高温性能的下降。
发明内容
本发明的目的是提供一种低成本、高减水效率、缓凝效果明显的复合高效减水剂及其制备方法,该复合减水剂适用于无硅灰的耐火自流浇注料体系。
本发明的目的是通过以下技术方案实现的:
一种无硅灰耐火自流浇注料用缓凝型复合减水剂,它是以三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸为主要原料制成的,所述的三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸的质量比为3:3:2~3:0.2~1。
优选的,所述的三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸的质量比为3:3:2~3:0.5~1。
本发明所述的三聚氰胺减水剂的指标如下所示:
表1.三聚氰胺类减水剂的指标要求
三聚氰胺类减水剂 | 指标 |
外观 | 粉体状或粒状 |
pH值(5%,水溶液,20℃) | 7~9 |
含水量(%) | ≤5.0 |
Cl<sup>-</sup>(%) | ≤1.0。 |
所述的萘系减水剂的指标如下所示:
表2.萘系减水剂的指标要求
萘系减水剂 | 指标 |
外观 | 粉体状或粒状 |
减水效率(%) | ≥18 |
泌水率(%) | ≤90 |
含气量(%) | ≤2。 |
所述的聚羧酸减水剂的指标如下所示:
表3.聚羧酸的指标要求
聚羧酸减水剂 | 指标 |
固含量(%) | ≥95 |
pH值 | 7~9 |
减水效率(%) | ≥25。 |
所述的无水柠檬酸的指标如下所示:
表4.无水柠檬酸指标要求
无水柠檬酸 | 指标 |
纯度(%) | ≥98。 |
本发明所述的无硅灰耐火自流浇注料用缓凝型复合减水剂的制备方法,包括以下步骤:
三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸按照质量比3:3:2~3:0.2~1进行配料,制得混合料;采用研磨工艺进行机械研磨,制得均匀的缓凝型复合减水剂。
机械研磨时,研磨球的直径为20mm,研磨球和混合料的质量比为1~5:1,机械研磨时间为20~50分钟。机械研磨过程中,控制研磨球的直径和球料比,能够避免过于严重研磨导致破坏分子结构。
本发明的有益效果:
本发明缓凝型复合减水剂的原料来源广泛,整体成本较低。本发明控制原料三聚氰胺减水剂中Cl-含量,能够避免复合减水剂使用时锈蚀模具,控制三聚氰胺的pH,避免影响后续浇注料的凝结;同时控制原料含水量,能够避免产品解块,确保缓凝型复合减水剂为粉体产品。
本发明采用复合的方式,综合三聚氰胺类减水剂、萘系减水剂和聚羧酸系减水剂三类材料的特点,相比于单一三聚氰胺减水剂或萘系减水剂或聚羧酸减水剂减水剂,明显提升了减水效率,同时引入特定配比的无水柠檬酸,无水柠檬酸不仅改善了复合减水剂的分散性能,使减水剂具备良好的分散性,而且使得体系更加稳定、缓凝性能更优,同时无水柠檬酸也具备减水作用,通过无水柠檬酸和三聚氰胺类减水剂、萘系减水剂和聚羧酸系减水剂的复配,满足了无硅灰耐火自流浇注料的高减水效率和高温(30℃~50℃)缓凝的双重要求。
除此之外,使用单一减水剂容易出现泌水现象和气孔分布不均匀等问题,本发明复合减水剂在提高减水效率和实现高温缓凝的同时也消除了泌水现象,使得浇注料浇注养护后,基质内气孔分布更加均匀,有利于提高其高温使用性能。
附图说明
图1为无硅灰耐火自流浇注料用缓凝型复合减水剂的制备的流程图。
具体实施方式
下面结合具体实施例对本发明的技术方案作进一步说明。
实施例1
三聚氰胺类减水剂(pH值=8.1,含水量=4.3%,Cl-含量=0.3%,江苏兆佳建材科技有限公司)、萘系减水剂(减水效率=20%,含气量=0.5%,济南聚亿利化工有限公司)、聚羧酸系减水剂(pH=8.3,减水效率=26%,固含量=98%,北京砼帮汇科技有限公司)和无水柠檬酸(纯度=98.2%,潍坊英轩实业有限公司)按照质量比3:3:3:1进行配料,制得混合料M-1;将混合料M-1置于高性能球磨机,球磨机的转速为40转/分,研磨球的直径为20mm,研磨球和混合料M-1的质量比为3:1,研磨时间为40分钟,制备出混合均匀的缓凝型复合减水剂。
将本实施例缓凝型复合减水剂作为配制刚玉-尖晶石质自流浇注料的原料之一,在35℃较高温度条件下测试浇注料的性能,具体测试方案如表5。
浇注料的流动值测试方法:1)使用跳桌测试浇注料的流动值。将配好的原料在大塑料袋中先预混1min,然后倒入水泥胶砂搅拌机,干混1min后加入一定量的去离子水,然后再湿混4min,然后将搅拌好的浇注料分两次填满锥形模具(上底面70mm和下底面100mm),用一定尺寸的钢棒捣实后移去模具,抹平上表面,移去模具,用游标卡尺分别测量各个振动周期后两个垂直相交的对角线方向上的浇注料的铺展直径,并计算出平均值,作为其振动流动值。2)采用测试浇注料的水化热曲线,判断浇注料的可流动时间和凝结时间。
表5.减水剂测试方案及结果
由表5可知,使用单一的三聚氰胺减水剂(对照组1)、萘系减水剂(对照组2)、聚羧酸减水剂(对照组3)时,浇注料加水量较高、施工时间较短;在35℃较高温度条件下,以本实施例缓凝型复合减水剂作为浇注料原料,浇注料施工时间达到了95分钟,且加水量明显低于使用单一减水剂的几组方案,综合施工性能达到了很好的效果。即使缓凝型复合高效减水剂降低至0.1%时,亦可达到很好的使用效果。使用单一减水剂均出现泌水现象和气孔分布不均匀等问题,本实施例复合减水剂消除了泌水现象,浇注料浇注养护后基质内气孔分布均匀。
实施例2
三聚氰胺类减水剂(同实施例1)、萘系减水剂(同实施例1)、聚羧酸系减水剂(同实施例1)和无水柠檬酸(同实施例1)按照质量比3:3:2:1进行配料,制得混合料M-2;将混合料M-2置于高性能球磨机,球磨机的转速为40转/分,研磨球的直径为20mm,研磨球和混合料M-2的质量比为3:1,研磨时间为40分钟,制备出混合均匀的复合减水剂。
参照实施例1考察高温条件下含有本实施例复合减水剂的浇注料的性能:35℃条件下,0.15%加入量时,浇注料加水量为4.0%,可施工时间为86分钟,综合施工性能良好。
实施例3
三聚氰胺类减水剂(同实施例1)、萘系减水剂(同实施例1)、聚羧酸系减水剂(同实施例1)和无水柠檬酸(同实施例1)按照质量比3:3:3:0.8进行配料,制得混合料M-3;将混合料M-3置于高性能球磨机,球磨机的转速为40转/分,研磨球的直径为20mm,研磨球和混合料M-3的质量比为3:1,研磨时间为40分钟,制备出混合均匀的复合减水剂。
参照实施例1考察高温条件下含有本实施例复合减水剂的浇注料的性能:35℃条件下,复合减水剂的加入量为0.15%时,浇注料加水量为3.8%,可施工时间为89分钟,综合施工性能良好。
Claims (8)
1.一种无硅灰耐火自流浇注料用缓凝型复合减水剂,其特征在于它是以三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸为主要原料制成的,所述的三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸的质量比为3:3:2~3:0.2~1。
2.根据权利要求1所述的无硅灰耐火自流浇注料用缓凝型复合减水剂,其特征在于所述的三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸的质量比为3:3:2~3:0.5~1。
3.根据权利要求1所述的无硅灰耐火自流浇注料用缓凝型复合减水剂,其特征在于所述的三聚氰胺类减水剂的指标如下所示:
4.根据权利要求1所述的无硅灰耐火自流浇注料用缓凝型复合减水剂,其特征在于所述的萘系减水剂的指标如下所示:
5.根据权利要求1所述的无硅灰耐火自流浇注料用缓凝型复合减水剂,其特征在于所述的聚羧酸减水剂的指标如下所示:
6.根据权利要求1所述的无硅灰耐火自流浇注料用缓凝型复合减水剂,其特征在于所述的无水柠檬酸的纯度≥98%。
7.权利要求1所述的无硅灰耐火自流浇注料用缓凝型复合减水剂的制备方法,其特征在于包括以下步骤:三聚氰胺类减水剂、萘系减水剂、聚羧酸系减水剂和柠檬酸按照质量比3:3:2~3:0.2~1进行配料,制得混合料;采用研磨工艺进行机械研磨,制得均匀的缓凝型复合减水剂。
8.根据权利要求7所述的无硅灰耐火自流浇注料用缓凝型复合减水剂的制备方法,其特征在于机械研磨时,研磨球的直径为20mm,研磨球和混合料的质量比为1~5:1,机械研磨时间为20~50分钟。
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