CN111517813A - 一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料及制备方法 - Google Patents

一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料及制备方法 Download PDF

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CN111517813A
CN111517813A CN202010450866.8A CN202010450866A CN111517813A CN 111517813 A CN111517813 A CN 111517813A CN 202010450866 A CN202010450866 A CN 202010450866A CN 111517813 A CN111517813 A CN 111517813A
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董红芹
樊效乐
李建涛
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Zhengzhou Dongyu New Material Technology Co ltd
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Abstract

本发明涉及一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料，以微孔轻质球形骨料做关键原料制备出体密度较低的耐火材料，既能满足顶燃式热风炉对抗热震稳定性能要求，同时有效降低了炉体容重和炉顶壁面导热率，使顶燃式热风炉能够长期稳定节能运行。本发明还涉及一种制备上述中重质耐火材料的制备方法。

Description

一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料及制备 方法
技术领域
本发明涉及新型材料制备技术领域，尤其涉及一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料及制备方法。
背景技术
顶燃式热风炉的结构上部是燃烧器的预混室部位，工作温度通常在450至1000℃范围内上下波动，主要功能是空气和煤气在此混合后进一步在下方的燃烧室烧成。预混室的球顶位于炉子顶端，高度一般3米左右，该部位温度波动大、荷载低，同时对于耐火材料的抗热震稳定性能要求较高。
现有技术中通常采用重质矾土-莫来石-红柱石-堇青石质或其中任意组合的重质材料作为顶燃式热风炉炉顶的耐火材料，这种组分的重质材料其体密度大于2.3g/cm3，同时能够提供不低于1450℃的荷重软化温度。这种重质材料虽然可以满足顶燃式热风炉炉顶窑衬材料需求，但不低于1450℃的荷重软化温度实际大大超过顶燃式热风炉耐火材料的合适设计荷重软化温度1200℃，造成材料性能冗余浪费；同时由于材料体密度较大，明显增加了炉体的容重，且高密度材料也增大了热风炉炉顶壁面的整体导热率，使大量热量传导至外界环境，即不利于热风炉的节能运行，也降低了热风炉的使用寿命。
发明内容
为解决现有技术的不足，本发明提出一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料及制备方法，以微孔轻质球形骨料做关键原料制备出体密度较低的耐火材料，既能满足顶燃式热风炉对抗热震稳定性能要求，同时有效降低了炉体容重和炉顶壁面导热率，使顶燃式热风炉能够长期稳定节能运行。
为实现以上目的，本发明所采用的技术方案包括：
一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料，其特征在于，所述耐火材料的组成包括合计质量占比为100％的微孔轻质球形骨料组分、重质耐火骨料组分、细粉氧化铝组分和结合剂组分，且所述微孔轻质球形骨料组分在所述耐火材料中的质量占比大于等于10％，特别是可以优选的在所述耐火材料中的质量占比大于20％。
进一步地，所述微孔轻质球形骨料组分包括粒径规格0.3毫米至1毫米的微孔轻质球形莫来石骨料。
进一步地，所述微孔轻质球形莫来石骨料为Al2O3含量大于等于68％且体密度小于等于1.5g/cm3的骨料。
进一步地，所述重质耐火骨料组分包括粒径规格1毫米至3毫米的红柱石、粒径规格小于等于0.088毫米的红柱石、粒径规格大于等于150目的蓝晶石、粒径规格1毫米至3毫米的莫来石以及粒径规格小于等于0.088毫米的堇青石中任意一种或任意多种的组合。
进一步地，所述红柱石的Al2O3含量大于等于55％；所述蓝晶石的Al2O3含量大于等于53％；所述堇青石的Al2O3含量范围为33％至35％，且所述堇青石的MgO含量范围为13％至15％。
进一步地，所述细粉氧化铝组分包括粒径规格小于等于5微米的氧化铝微粉、白刚玉粉、板状刚玉粉中任意一种或任意多种的组合，以及还可以选用粒径规格适合的其他高氧化铝含量细粉物料作为细粉氧化铝组分，且所述细粉氧化铝组分在所述耐火材料中的质量占比小于等于10％。
进一步地，所述氧化铝微粉、白刚玉粉和板状刚玉粉的Al2O3含量大于等于99％。
进一步地，所述结合剂组分包括粒径规格大于等于150目的苏州土，且所述结合剂组分在所述耐火材料中的质量占比小于等于10％。
本发明还包括一种用于制备上述顶燃式热风炉炉顶的耐热震中重质耐火材料的制备方法，其特征在于，包括以下步骤：
S1、将微孔轻质球形骨料组分、重质耐火骨料组分、细粉氧化铝组分和结合剂组分混合并添加相当于所述微孔轻质球形骨料组分、重质耐火骨料组分、细粉氧化铝组分和结合剂组分相加总质量8％的纸浆，使用搅拌机搅拌5至20分钟形成充分混合均匀的泥料；
S2、使用液压机轻压泥料，使所述泥料厚度减小至其单重等于体密度范围2.0至2.1g/cm3对应单重，得到半成品胚体；
S3、将半成品胚体置于1380℃的恒温炉中烧制6至16小时，得到耐火材料成品。
进一步地，所述纸浆为比重1.2的纸浆。
本发明的有益效果为：
采用本发明所述用于顶燃式热风炉炉顶的耐热震中重质耐火材料通过添加微孔轻质球形骨料组分降低了材料体密度作为顶燃式热风炉炉顶的炉衬材料，能够显著降低炉体容重，同时降低炉体壁面的导热系数，减少炉内热量外溢，从而减少热风炉燃料消耗，起到节能的目的；炉内热量外溢减少也有助于降低炉顶外层温度，减缓炉体外部材料的热损耗，有助于提升热风炉使用寿命。
具体实施方式
为了更清楚的理解本发明的内容，将结合实施例详细说明。
本发明通过在原有重质耐火骨料组分的基础上加入质量占比不少于10％的微孔轻质球形骨料组分从而有效降低了炉顶材料的体密度，同时通过引入微孔材料加强了炉顶整体的隔热保温性能。
本发明所述中重质耐火材料是由微孔轻质球形骨料组分、重质耐火骨料组分、细粉氧化铝组分和结合剂组分混合机压成型后高温烧制，所形成的耐火材料具有铝含量一般不小于50％、气孔率不大于40％、体密度范围1.8-2.0g/cm3、荷重软化温度为1400度左右、抗热震稳定性不小于50次且350度导热率范围0.9～1.5w/m.k的优异性能。
本发明还包括一种制备上述中重质耐火材料的制备方法，优选的包括：
S1、将微孔轻质球形骨料组分、重质耐火骨料组分、细粉氧化铝组分和结合剂组分依据设定配比混合，使用行星式搅拌机搅拌10分钟并在搅拌过程中添加相当于所述微孔轻质球形骨料组分、重质耐火骨料组分、细粉氧化铝组分和结合剂组分相加总质量8％的比重为1.2的纸浆，形成充分混合均匀的泥料；
S2、使用液压机轻压泥料，使所述泥料厚度减小至体密度等于2.1g/cm3对应单重，得到半成品胚体；
S3、将半成品胚体置于1380℃的恒温炉中烧制8小时，得到耐火材料成品。
如下所示为本发明的典型实施例：
实施例1如表1所示：
表1
材料名称 规格 配比(％)
红柱石 1-3mm 38
微孔轻质球形骨料组分 0.3-1mm 22
蓝晶石 150目以上 14
红柱石 0.088mm以下 10
氧化铝微粉 5μm以下 8
苏州土 180目以上 8
实施例1中采用如表1所示的组分配比，其中微孔轻质球形骨料组分优选采用0.3-1mm粒径尺寸的微孔轻质球形莫来石骨料；重质耐火骨料组分采用1-3mm规格红柱石搭配150目以上的蓝晶石和0.088mm以下的红柱石形成致密堆积；细粉氧化铝组分采用5μm以下氧化铝微粉作为基质中的氧化铝成分；结合剂组分采用180目以上的苏州土。使用如上所述优选的制备方法加工上述材料，获得的耐火材料成品性质如表2所示：
表2
检测项目 单位 结果
Al<sub>2</sub>O<sub>3</sub> ％ 58
显气孔率 ％ 36
体密度 g/cm<sup>3</sup> 1.78
常温耐压强度 Mpa 32
荷重软化开始温度 ℃ 1360
导热率，350℃ w/m.k 1.4
热震稳定性，950℃，水冷 次 ＞50
实施例2如表3所示：
表3
材料名称 规格 配比(％)
红柱石 1-3mm 20
莫来石 1-3mm 25
微孔轻质球形骨料组分 0.3-1mm 15
蓝晶石 150目以上 8
红柱石 0.088mm以下 8
堇青石 0.088mm以下 8
氧化铝微粉 5μm以下 8
苏州土 180目以上 8
实施例2中采用如表3所示的组分配比，其中微孔轻质球形骨料组分优选采用0.3-1mm粒径尺寸的微孔轻质球形莫来石骨料；重质耐火骨料组分采用1-3mm规格红柱石、1-3mm规格莫来石搭配150目以上的蓝晶石、0.088mm以下的红柱石以及0.088mm以下的堇青石形成致密堆积；细粉氧化铝组分采用5μm以下氧化铝微粉作为基质中的氧化铝成分；结合剂组分采用180目以上的苏州土。使用如上所述优选的制备方法加工上述材料，获得的耐火材料成品性质如表4所示：
表4
Figure BDA0002507457400000051
Figure BDA0002507457400000061
实施例3如表5所示：
表5
材料名称 规格 配比(％)
红柱石 1-3mm 30
莫来石 1-3mm 20
微孔轻质球形骨料组分 0.3-1mm 10
红柱石 0.088mm以下 16
堇青石 0.088mm以下 8
氧化铝微粉 5μm以下 8
苏州土 180目以上 8
实施例3中采用如表5所示的组分配比，其中微孔轻质球形骨料组分优选采用0.3-1mm粒径尺寸的微孔轻质球形莫来石骨料；重质耐火骨料组分采用1-3mm规格红柱石搭配150目以上的蓝晶石和0.088mm以下的红柱石形成致密堆积；细粉氧化铝组分采用5μm以下氧化铝微粉作为基质中的氧化铝成分；结合剂组分采用180目以上的苏州土。使用如上所述优选的制备方法加工上述材料，获得的耐火材料成品性质如表6所示：
表6
Figure BDA0002507457400000062
Figure BDA0002507457400000071
对比例：一种现有技术的重质耐火材料成分配比如表7所示：
表7
Figure BDA0002507457400000072
采用如表7所示配比制得的重质耐火材料具有如表8所示性质：
表8
检测项目 单位 结果
Al<sub>2</sub>O<sub>3</sub> ％ 62
体密度 g/cm<sup>3</sup> 2.3
常温耐压强度 Mpa 40
荷重软化开始温度 ℃ 1450
导热率，350℃ w/m.k 2.5
热震稳定性，950℃，水冷 次 ＞30
相较对比例的材料性质，实施例1至实施例3在较低体密度的情况下实现了更佳的热震稳定性，能够有效提高炉体使用寿命；同时显著降低了材料导热率，表面采用如实施例1至实施例3的耐火材料能够大幅提高炉顶隔热性能，避免炉顶温度过高现象，实现热风炉的节能运行效果。
以上所述仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到的变化或替换等都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应该以权利要求书的保护范围为准。

Claims (10)

1.一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料，其特征在于，所述耐火材料的组成包括合计质量占比为100％的微孔轻质球形骨料组分、重质耐火骨料组分、细粉氧化铝组分和结合剂组分，且所述微孔轻质球形骨料组分在所述耐火材料中的质量占比大于等于10％。
2.如权利要求1所述的耐火材料，其特征在于，所述微孔轻质球形骨料组分包括粒径规格0.3毫米至1毫米的微孔轻质球形莫来石骨料。
3.如权利要求2所述的耐火材料，其特征在于，所述微孔轻质球形莫来石骨料为Al2O3含量大于等于68％且体密度小于等于1.5g/cm3的骨料。
4.如权利要求1或2所述的耐火材料，其特征在于，所述重质耐火骨料组分包括粒径规格1毫米至3毫米的红柱石、粒径规格小于等于0.088毫米的红柱石、粒径规格大于等于150目的蓝晶石、粒径规格1毫米至3毫米的莫来石以及粒径规格小于等于0.088毫米的堇青石中任意一种或任意多种的组合。
5.如权利要求4所述的耐火材料，其特征在于，所述红柱石的Al2O3含量大于等于55％；所述蓝晶石的Al2O3含量大于等于53％；所述堇青石的Al2O3含量范围为33％至35％，且所述堇青石的MgO含量范围为13％至15％。
6.如权利要求1或2所述的耐火材料，其特征在于，所述细粉氧化铝组分包括粒径规格小于等于5微米的氧化铝微粉、白刚玉粉、板状刚玉粉中任意一种或任意多种的组合，且所述细粉氧化铝组分在所述耐火材料中的质量占比小于等于10％。
7.如权利要求6所述的耐火材料，其特征在于，所述氧化铝微粉、白刚玉粉和板状刚玉粉的Al2O3含量大于等于99％。
8.如权利要求1或2所述的耐火材料，其特征在于，所述结合剂组分包括粒径规格大于等于150目的苏州土，且所述结合剂组分在所述耐火材料中的质量占比小于等于10％。
9.一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料的制备方法，其特征在于，包括以下步骤：
S1、将微孔轻质球形骨料组分、重质耐火骨料组分、细粉氧化铝组分和结合剂组分混合并添加相当于所述微孔轻质球形骨料组分、重质耐火骨料组分、细粉氧化铝组分和结合剂组分相加总质量8％的纸浆，使用搅拌机搅拌5至20分钟形成充分混合均匀的泥料；
S2、使用液压机轻压泥料，使所述泥料厚度减小至其单重等于体密度范围2.0至2.1g/cm3对应单重，得到半成品胚体；
S3、将半成品胚体置于1380℃的恒温炉中烧制6至16小时，得到耐火材料成品。
10.如权利要求9所述的方法，其特征在于，所述纸浆为比重1.2的纸浆。
CN202010450866.8A 2020-05-25 2020-05-25 一种用于顶燃式热风炉炉顶的耐热震中重质耐火材料及制备方法 Withdrawn CN111517813A (zh)

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