CN111662088A - 一种利用煤矸石制备的耐火浇注料及其制备方法 - Google Patents
一种利用煤矸石制备的耐火浇注料及其制备方法 Download PDFInfo
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- 238000002360 preparation method Methods 0.000 title claims description 6
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- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims abstract description 26
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- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 claims abstract description 8
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims abstract description 8
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- 235000019832 sodium triphosphate Nutrition 0.000 claims abstract description 6
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 5
- 239000010703 silicon Substances 0.000 claims abstract description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 22
- 239000000126 substance Substances 0.000 claims description 16
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- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 3
- 230000003628 erosive effect Effects 0.000 description 3
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Abstract
本发明涉及一种利用煤矸石制备的耐火浇注料，按重量份组分包括：5‑3mm煤矸石15～25份；3‑1mm煤矸石25～35份；1‑0.5mm煤矸石10～20份；180目蓝晶石5～10份；200目高铝矾土熟料17～27份；硅微粉3～7份；铝酸钙水泥3～8份；钛白粉2～5份；氧化铁黄0.1～1.6份；三聚磷酸钠0.08～0.35份。本产品气孔率高，体积密度小，具有隔热性能，对热能可以起屏蔽作用。用在高于环境温度条件下防止热能的流出损失，降低热工窑炉的能耗，降低炉体重量，增加保温性能。并且该产品有效降低成本，生产工艺简单、使用性能良好。
Description
技术领域
本发明涉及不定形耐火材料技术领域，特别是涉及一种利用煤矸石制备的耐火浇注料及其制备方法。
背景技术
煤矸石是采煤和洗煤过程中排放的岩石，是煤矿建设及煤炭生产过程中所排出的固体废弃物总称，全国有约2000座煤矸石山，累计堆存煤矸石50亿t以上，每年碳排放1400万t，长期、持续堆积与排放煤矸石不仅占用大量土地，污染环境、水资源、土地资源，而且随之产生的固体粉尘污染对生态环境造成了严重的危害。
发明内容
本发明所要解决的技术问题是提供一种利用煤矸石制备的耐火浇注料，产品为松散、干状、均匀集料，气孔率高，体积密度小，抗热震性好，抗侵蚀性强，具有隔热性能。
为实现上述目的，本发明采用以下技术方案实现：
一种利用煤矸石制备的耐火浇注料，按重量份组分包括：5-3mm煤矸石15～25份；3-1mm煤矸石25～35份；1-0.5mm煤矸石10～20份；180目蓝晶石5～10份；200目高铝矾土熟料17～27份；硅微粉3～7份；铝酸钙水泥3～8份；钛白粉2～5份；氧化铁黄0.1～1.6份；三聚磷酸钠0.08～0.35份。
所述的煤矸石化学成分要求：SiO2＜60％；Al2O3＞20％。
所述的高铝矾土熟料化学成分要求：Fe2O3≤2.0％；Al2O3≥80％；CaO+MgO≤0.5％；TiO2≤4.0％；K2O+Na2O≤0.50％；体积密度要求≥2.9g/cm3。
所述的铝酸钙水泥化学成分要求：SiO2≤8％；Fe2O3≤2.8％；Al2O3≥50％；K2O+Na2O≤0.4％。
所述的蓝晶石化学成分要求：灼减≤1.5％；Fe2O3≤1.0％；Al2O3≥50％；TiO2≤1.9％；K2O+Na2O≤0.80％。
所述的硅微粉化学成分要求：SiO2≥90％；Fe2O3≤2.0％；Al2O3≤1.5％；CaO+MgO≤2.0％；K2O+Na2O≤2.0％；
所述的钛白粉化学成分要求：TiO2≥98％。
所述的氧化铁黄化学成分要求：Fe2O3≥85.5％。
一种利用煤矸石制备的耐火浇注料的制备方法，包括以下步骤：
1)煤矸石破粉碎、筛选；各原料去磁处理；
2)混料：
a.预混料A：将二分之一的1-0.5mm煤矸石与蓝晶石、二分之一的高铝矾土熟料、硅微粉、铝酸钙水泥、三聚磷酸钠预混20-30分钟，备用；
b.预混料B：将剩余二分之一的1-0.5煤矸石与钛白粉、氧化铁黄、剩余的高铝矾土熟料预混20-30分钟，备用；
c.将预混料A、预混料B、5-3mm的煤矸石、3-1mm的煤矸石混合搅拌15-20分钟，出料；
3)包装出成品。
与现有的技术相比，本发明的有益效果是：
1.通过添加钛白粉在经高温使用中与煤矸石成分中的的Al2O3生成钛酸铝，其熔点1860℃，真密度为3.702g/cm3。钛酸铝具有耐高温，线膨胀系数低，和优良抗侵蚀性，而且耐碱腐蚀。
2.通过添加氧化铁黄与煤矸石主成分SiO2产生矿化剂，矿化剂在产品使用过程中形成一定数量的“流态”相，起到以下述作用：
2.1容易形成与SiO2石英材料有较大面积的接触层，促使较多的SiO2石英在高温时转变为低密度的变体(鳞石英或方石英)，但在无矿化剂的场合下，单靠温度与时间要达到这个程度十分困难，只有用矿化剂作为晶型转变的催化剂才行。
2.2矿化剂能将含SiO2石英材料在高温下粘结且不显著降低其耐火度；
2.3矿化剂高温时处在“流态”，且较均匀分布在SiO2石英材料之间，对SiO2石英材料产生的急剧膨胀具有可退让性，因而它能避免或减少显微裂纹；
2.4矿化剂的矿物结构能使产品表层的SiO2石英材料在高温下形成非晶质的玻璃体，使产品表层增加了抗侵蚀能力；
3.通过添加氧化铁黄与煤矸石中的残炭在高温状态下使部分Fe2O3还原为金属Fe液。在高温下与金属Fe平衡的氧化铁液即FeO，此时FeO与高铝矾土熟料中的Al2O3反应，生成铁铝尖晶石(FeO·Al2O3)。由于热失配在材料中存在一定量的微裂纹，其增韧作用改善了材料的抗热震性。
4.通过添加硅微粉在经过高温使用中与煤矸石成分中的Al2O3生成稳定的化合物(莫来石)，其熔点(1890±90)℃，莫来石出现改善产品一系列良好的性能，如高的热态强度，好的抗热震性，抗化学侵蚀性强等优点。
5.本产品气孔率高，体积密度小，具有隔热性能，对热能可以起屏蔽作用。用在高于环境温度条件下防止热能的流出损失，降低热工窑炉的能耗，降低炉体重量，增加保温性能。并且该产品有效降低成本，生产工艺简单、使用性能良好。
具体实施方式
下面结合实施例对本发明进一步说明：
以下实施例对本发明进行详细描述。这些实施例仅是对本发明的最佳实施方案进行描述，并不对本发明的范围进行限制。
浇注料实施例组分配比见表1；
表1：
煤矸石化学成分见表2；
表2：
浇注料制备方法，按以下步骤完成：
1)煤矸石破粉碎、筛选；各原料去磁处理；
2)混料：
a.预混料A：将二分之一的1-0.5mm煤矸石与蓝晶石、二分之一的高铝矾土熟料、硅微粉、铝酸钙水泥、三聚磷酸钠预混20-30分钟，备用；
b.预混料B：将剩余二分之一的1-0.5煤矸石与钛白粉、氧化铁黄、剩余的高铝矾土熟料预混20-30分钟，备用；
c.将预混料A、预混料B、5-3mm的煤矸石、3-1mm的煤矸石混合搅拌15-20分钟，出料；
3)包装出成品。
成品浇注料性能指标见表3：
表3：成品浇注料性能指标
利用煤矸石制备的耐火浇注料的使用方法，包括以下步骤：
1)把浇注料成品倒入搅拌机中，边搅拌边加水，加水量控制在浇注料重量的6.5～8.0％，湿混5分钟出料，混完料在15分钟内施工完成。混好的料加入胎模中，开动振动棒，边振动边加料，直到加料完毕；
2)脱模与养护：振动施工后静置24小时后脱模，脱模后再自然养护24小时；
3)加热烘烤温度控制220～280℃保温30小时，投入使用。
Claims (9)
1.一种利用煤矸石制备的耐火浇注料，其特征在于，按重量份组分包括：5-3mm煤矸石15～25份；3-1mm煤矸石25～35份；1-0.5mm煤矸石10～20份；180目蓝晶石5～10份；200目高铝矾土熟料17～27份；硅微粉3～7份；铝酸钙水泥3～8份；钛白粉2～5份；氧化铁黄0.1～1.6份；三聚磷酸钠0.08～0.35份。
2.根据权利要求1所述的一种利用煤矸石制备的耐火浇注料，其特征在于，所述的煤矸石化学成分要求：SiO2＜60％；Al2O3＞20％。
3.根据权利要求1所述的一种利用煤矸石制备的耐火浇注料，其特征在于，.所述的高铝矾土熟料化学成分要求：Fe2O3≤2.0％；Al2O3≥80％；CaO+MgO≤0.5％；TiO2≤4.0％；K2O+Na2O≤0.50％；体积密度要求≥2.9g/cm3。
4.根据权利要求1所述的一种利用煤矸石制备的耐火浇注料，其特征在于，所述的铝酸钙水泥化学成分要求：SiO2≤8％；Fe2O3≤2.8％；Al2O3≥50％；K2O+Na2O≤0.4％。
5.根据权利要求1所述的一种利用煤矸石制备的耐火浇注料，其特征在于，所述的蓝晶石化学成分要求：灼减≤1.5％；Fe2O3≤1.0％；Al2O3≥50％；TiO2≤1.9％；K2O+Na2O≤0.80％。
6.根据权利要求1所述的一种利用煤矸石制备的耐火浇注料，其特征在于，所述的硅微粉化学成分要求：SiO2≥90％；Fe2O3≤2.0％；Al2O3≤1.5％；CaO+MgO≤2.0％；K2O+Na2O≤2.0％。
7.根据权利要求1所述的一种利用煤矸石制备的耐火浇注料，其特征在于，所述的钛白粉化学成分要求：TiO2≥98％。
8.根据权利要求1所述的一种利用煤矸石制备的耐火浇注料，其特征在于，所述的氧化铁黄化学成分要求：Fe2O3≥85.5％。
9.根据权利要求1所述的一种利用煤矸石制备的耐火浇注料的制备方法，其特征在于，包括以下步骤：
1)煤矸石破粉碎、筛选；各原料去磁处理；
2)混料：
a.预混料A：将二分之一的1-0.5mm煤矸石与蓝晶石、二分之一的高铝矾土熟料、硅微粉、铝酸钙水泥、三聚磷酸钠预混20-30分钟，备用；
b.预混料B：将剩余二分之一的1-0.5煤矸石与钛白粉、氧化铁黄、剩余的高铝矾土熟料预混20-30分钟，备用；
c.将预混料A、预混料B、5-3mm的煤矸石、3-1mm的煤矸石混合搅拌15-20分钟，出料；
3)包装出成品。
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