CN111574231A - 一种环保型镁碳砖及其制备方法 - Google Patents

一种环保型镁碳砖及其制备方法 Download PDF

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CN111574231A
CN111574231A CN202010459569.XA CN202010459569A CN111574231A CN 111574231 A CN111574231 A CN 111574231A CN 202010459569 A CN202010459569 A CN 202010459569A CN 111574231 A CN111574231 A CN 111574231A
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庞宝贵
庞舒楠
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Dashiqiao Baoding Refractory Co ltd
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Abstract

本发明属于耐火材料技术领域，具体涉及一种环保型镁碳砖及其制备方法，包括镁砂粗颗粒35‑40份，镁砂中颗粒35‑40份，镁砂细粉15‑20份，工业糖浆3‑5份，酚醛树脂1‑2份，石墨5‑8份，添加剂6‑10份。根据镁碳砖的配方，优化了混料过程和热处理工艺。本发明降低环境污染的同时还能保持现有的使用寿命，同时生产的过程中减少传统配方的混料时间短、发散、发干、无粘结性,或者粘度过大,搅料不容易混匀、成型困难等问题，降低结合剂、混料成本，提高成型率。

Description

一种环保型镁碳砖及其制备方法
技术领域
本发明属于耐火材料技术领域，具体涉及一种环保型镁碳砖及其制备方法。
背景技术
目前，酚醛树脂是镁碳砖制造过程中最常使用的结合剂，其优点包括可在室温下直接混练、成型，节约能源；产品可在未固化条件下处理；与焦油沥青结合剂相比，加热时无玻璃相产生；固定碳高，在还原气氛下能形成牢固的碳结合，增强抗磨损性和抗渣性；在高温下能使镁碳砖保持较高的热态强度等。但是，酚醛树脂在使用过程会有刺激性有害气体产生，造成空气污染和臭味，并对人体造成伤害。其它结合剂包括CMC、纸浆废液、糖浆、糊精或乙基纤维素等虽然在不同程度上改善了空气污染，但均会明显降低制品的使用寿命。目前尚无既能减少环境污染还能保持使用使用寿命的镁碳砖生产技术。
发明内容
为了解决上述技术问题，本发明提供一种环保型镁碳砖及其制备方法，降低环境污染的同时还能保持现有使用寿命，同时生产的过程中减少传统配方的混料时间短、发散、发干、无粘结性,或者粘度过大,搅料不容易混匀、成型困难等问题，降低结合剂、混料成本，提高成型率。
本发明是这样实现的，提供一种环保型镁碳砖，镁碳砖配方中的结合剂包括工业糖浆3-5份，酚醛树脂1-2份。
具体的，一种环保型镁碳砖，按重量份计，包括镁砂粗颗粒35-40份，镁砂中颗粒35-40份，镁砂细粉15-20份，工业糖浆3-5份，酚醛树脂1-2份，石墨5-8份，添加剂6-10份。
优选地，所述镁砂粗颗粒粒径范围3-5mm，所述镁砂中颗粒粒径范围1-3mm，所述镁砂细粉粒径范围0-1mm。
优选地，所述添加剂包括铝粉、硅粉、碳化硅。
本发明还提供了一种上述的环保型镁碳砖的制备方法，包括如下步骤：
1)混料：镁砂粗颗粒、镁砂中颗粒加入到混料机中，低速混合1-3分钟，缓慢加入酚醛树脂，低速混30秒，加入工业糖浆，低速混合1-2分钟，加入石墨，低速混合1-2分钟，加入镁砂细粉和添加剂，低速混1-2分钟后高速混10-12分钟或中速混20-25分钟，完成后出料；
2)成型：出料后，压制成型，将成型后的镁碳砖放置到窑车上，推进干燥窑进行热处理；
3)热处理：温度设定在170-200℃,保温时间8-16小时，至树脂完全固化；
4)验收：成品取样、验收，检测合格后出厂。
优选地，步骤1)中低速混合指混合速度为20～35转/分，中速混合指混合速度为35～50转/分，高速混合指混合速度为50～60转/分。
与现有技术相比，本发明的优点在于：
1)酚醛树脂加入量大量减少，降低环境污染，采用工业糖浆作为替代品，价格低廉，每吨结合剂降低成本5000元左右；
2)由于加入工业糖浆作为结合剂的一部分，可以延长泥料存放时间6个小时左右，传统酚醛树脂作为添加剂混的泥料存放4小时后结块无法生产；
3)热处理的温度降低，时间减少，平均每吨镁碳砖节约电费10元左右。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，下面结合实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用于解释本发明，并不用于限定本发明。
实施例1、
提供一种环保型镁碳砖的制备方法：
1)破碎：将镁砂用破碎机进行破碎，筛分，得到镁砂粗颗粒、镁砂中颗粒和镁砂细粉三种粒径的镁砂，镁砂粗颗粒粒径范围3-5mm，所述镁砂中颗粒粒径范围1-3mm，所述镁砂细粉粒径范围0-1mm；
2)称料：按如下重量份数称取原料：
镁砂粗颗粒35份、镁砂中颗粒35份、镁砂细粉15份、酚醛树脂0份、工业糖浆4份、石墨5份、添加剂6份；
上述配方中镁砂、石墨、酚醛树脂、工业糖浆、添加剂均为市售原料。
3)混料：先将粗颗粒和中颗粒镁砂投入混料机中，并在低速混1-3分钟后缓慢加入酚醛树脂，并在低速混30秒后加入糖浆，低速混1-3分钟后加入石墨，低速混1-2分钟后加入细粉和各种添加剂，低速混1-2分钟后高速混10-12分钟(或中速混20-25分钟)
4)成型：出料后，压制成型，将成型后的砖放置窑车上，推进干燥窑进行热处理。
5)热处理：温度设定在170℃,保温时间一般在8-16小时。
6)验收：成品的取样、验收按YB 367-75《耐火制品取样、验收、保管和运输规则》进行。随机取样做化学成分分析，检测合格后出厂。
实施例2、
与实施例1相比，区别在于镁碳砖的配方：
镁砂粗颗粒35份、镁砂中颗粒35份、镁砂细粉15份、酚醛树脂1份、工业糖浆3份、石墨5份、添加剂6份；
实施例3、
与实施例1相比，区别在于镁碳砖的配方：
镁砂粗颗粒35份、镁砂中颗粒35份、镁砂细粉15份、酚醛树脂2份、工业糖浆2份、石墨5份、添加剂6份；
实施例4、
与实施例1相比，区别在于镁碳砖的配方：
镁砂粗颗粒35份、镁砂中颗粒35份、镁砂细粉15份、酚醛树脂3份、工业糖浆1份、石墨5份、添加剂6份；
实施例5、
与实施例1相比，区别在于镁碳砖的配方：
镁砂粗颗粒35份、镁砂中颗粒35份、镁砂细粉15份、酚醛树脂4份、工业糖浆0份、石墨5份、添加剂6份；
对实施例1、实施例2、实施例3、实施例4和实施例5生产出来的镁碳砖进行检测，检测结果如下表格：
表1镁碳砖检测结果
Figure BDA0002510520000000041
从上表中可以知道，实施例1和实施例2生产的镁碳砖虽然没有刺激性气味，但是常温耐压、体积密度均较低，气孔率较高，实施例4、5生产的镁碳砖耐压强度、体积密度较高，气孔率最低，但是有强烈的刺激性气味，实施例3生产的镁碳砖各项指标均呈优良状态，并且刺激性气味较弱，符合环保型镁碳砖的标准。

Claims (6)

1.一种环保型镁碳砖，其特征在于，镁碳砖配方中的结合剂包括工业糖浆3-5份，酚醛树脂1-2份。
2.一种环保型镁碳砖，其特征在于，按重量份计，包括镁砂粗颗粒35-40份，镁砂中颗粒35-40份，镁砂细粉15-20份，工业糖浆3-5份，酚醛树脂1-2份，石墨5-8份，添加剂6-10份。
3.如权利要求2所述的环保型镁碳砖，其特征在于，所述镁砂粗颗粒粒径范围3-5mm，所述镁砂中颗粒粒径范围1-3mm，所述镁砂细粉粒径范围0-1mm。
4.如权利要求2所述的环保型镁碳砖，其特征在于，所述添加剂包括铝粉、硅粉、碳化硅。
5.一种如权利要求2或3或4所述的环保型镁碳砖的制备方法，其特征在于，包括如下步骤：
1)混料：镁砂粗颗粒、镁砂中颗粒加入到混料机中，低速混合1-3分钟，缓慢加入酚醛树脂，低速混30秒，加入工业糖浆，低速混合1-2分钟，加入石墨，低速混合1-2分钟，加入镁砂细粉和添加剂，低速混1-2分钟后高速混10-12分钟或中速混20-25分钟，完成后出料；
2)成型：出料后，压制成型，将成型后的镁碳砖放置到窑车上，推进干燥窑进行热处理；
3)热处理：温度设定在160-200℃,保温时间8-16小时，至树脂完全固化；
4)验收：成品取样、验收，检测合格后出厂。
6.如权利要求5所述的环保型镁碳砖的制备方法，其特征在于，步骤1)中低速混合指混合速度为20～35转/分，中速混合指混合速度为35～50转/分，高速混合指混合速度为50～60转/分。
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