CN111995411A - 一种高铝碳化硅耐火砖及其制备工艺 - Google Patents
一种高铝碳化硅耐火砖及其制备工艺 Download PDFInfo
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Abstract
本发明公开了一种高铝碳化硅耐火砖及其制备工艺,涉及耐火砖技术领域,具体为内芯和包覆在两侧的散热层,所述内芯的配料为高铝钒土料、碳化硅、填料、覆料和结合剂,按含量比计,高铝钒土料:碳化硅:填料:覆料:结合剂=10:1:1:0.5:7,所述散热层的配料为岩棉、铜铝合金、发泡剂和基质,按含量比计,岩棉:铜铝合金:发泡剂:基质=1:1:1:5。该高铝碳化硅耐火砖及其制备工艺,采用内芯加用作保护的散热层结构,既达到了耐火砖的强度、硬度、抗压性能、耐火、耐高温等标准,又使得耐火砖兼具防水、吸水、高散热等性能,极大地保证了耐火砖的产品质量,使得耐火砖在耐受高温时或在长期耐高温后,内部开裂延缓,不易碎开。
Description
技术领域
本发明涉及耐火砖技术领域,具体为一种高铝碳化硅耐火砖及其制备工艺。
背景技术
耐火砖简称火砖,是用耐火黏土或其他耐火原料烧制成的耐火材料,淡黄色或带褐色,主要用于砌冶炼炉,能耐1580℃—1770℃的高温,耐火砖广泛应用于建筑窑炉和各种热工设备的高温建筑材料和结构材料,是一款比较耐用结实的耐火性能砖。
根据耐火砖成分的不同,其可以分为五大类,即:硅铝系耐火砖、碱性系列耐火砖、含碳耐火砖、含锆耐火砖和隔热耐火砖。
现有的耐火砖用材多,质地重,不利于节省生产成本,且气透性不佳,在撤温后,耐火砖上温度不易散开,或散开缓慢,容易积留在耐火砖中,导致应力集中的问题,比较容易造成耐火砖出现开裂损伤。
发明内容
针对现有技术的不足,本发明提供了一种高铝碳化硅耐火砖及其制备工艺,解决了上述背景技术中提出的问题。
为实现以上目的,本发明通过以下技术方案予以实现:一种高铝碳化硅耐火砖,包括内芯和包覆在两侧的散热层,所述内芯的配料为高铝钒土料、碳化硅、填料、覆料和结合剂,按含量比计,高铝钒土料:碳化硅:填料:覆料:结合剂=10:1:1:0.5:7,所述散热层的配料为岩棉、铜铝合金、发泡剂和基质,按含量比计,岩棉:铜铝合金:发泡剂:基质=1:1:1:5。
可选的,所述填料具体由钢水、黄糊精和玻璃棉组成,其中钢水、黄糊精和玻璃棉之间的含量比为1:1:1。
可选的,所述覆料由水玻璃和聚丙烯酰胺组成,其中水玻璃和聚丙烯酰胺之间的含量比为1:2。
可选的,所述结合剂具体为水泥。
可选的,所述内芯的制作过程如下:
①加水,搅拌溶解水泥结合剂;
②将高铝钒土料和碳化硅加入到稀释的水泥中,搅拌均匀;
③制备填料:将黄糊精和玻璃棉加入到高温的钢水中,搅拌均匀;
④将制备好的填料加入到高铝钒土料、碳化硅及水泥体系中,搅拌均匀;
⑤取料入模,烧制成型,所得内芯基块取出模具后,静置放冷;
⑥制备覆料:将水玻璃和聚丙烯酰胺进行搅拌混合至均匀;
⑦将覆料均匀涂抹在成型的内芯基块外壁,厚度为2mm。
可选的,所述岩棉和铜铝合金均选用粉末态,且岩棉粉末和铜铝合金粉末均过100目筛。
可选的,所述发泡剂具体为碳酸钙、碳酸镁、碳酸氢钠、十二烷基硫酸钠、脂肪醇聚氧乙烯醚硫酸钠中的一种。
可选的,所述基质由细沙、水泥和水组成,按含量比计,细沙:水泥:水=1:3:5。
可选的,所述散热层的制备过程如下:
①制备基质:将水泥加入水中,搅拌混合后,加入细沙,搅拌至完全混合;
②加入发泡剂,高频搅拌30min;
③加入岩棉粉末,搅拌均匀;
④加入铜铝合金粉末,充分混合。
基于上述配料,本发明还公开了一种高铝碳化硅耐火砖的制备工艺。
可选的,该制备工艺具体步骤如下:
①将涂覆有覆料的内芯基块进行风干,形成完整内芯后,用细磨机打磨内芯外壁,至内芯外壁面光滑;
②将内芯放置在耐火砖烧制模具的正中间位置;
③在内芯两侧填充散热层基料,在填充的过程中,搅拌散热层基料,消除散热层基料与内芯外壁之间的间隙;
④压模,并回收多余的散热层基料;
⑤入炉烧结成型。
本发明提供了一种高铝碳化硅耐火砖及其制备工艺,具备以下有益效果:该高铝碳化硅耐火砖及其制备工艺,采用内芯加用作保护的散热层结构,既达到了耐火砖的强度、硬度、抗压性能、耐火、耐高温等标准,又使得耐火砖兼具防水、吸水、高散热等性能,极大地保证了耐火砖的产品质量,使得耐火砖在耐受高温时或在长期耐高温后,内部开裂延缓,不易碎开,延长了耐火砖的使用寿命,且耐火砖中的散热层采用了疏松多孔结构,质地轻,热穿透性良好,降低了耐火砖生产成本,减轻了耐火砖的重量,还提高了耐火砖的散热性能。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。
实施例1
一种高铝碳化硅耐火砖,包括内芯和包覆在两侧的散热层,所述内芯的配料为高铝钒土料、碳化硅、填料、覆料和结合剂,按含量比计,高铝钒土料:碳化硅:填料:覆料:结合剂=10:1:1:0.5:7,所述散热层的配料为岩棉、铜铝合金、发泡剂和基质,按含量比计,岩棉:铜铝合金:发泡剂:基质=1:1:1:5;
填料具体由钢水、黄糊精和玻璃棉组成,其中钢水、黄糊精和玻璃棉之间的含量比为1:1:1;
钢水冷却后具有高强度,且具有良好的抗压能力,间距韧性,黄糊精增强了钢水的粘稠度,使得填料在加入到内芯基料中后,融合更好,最终形成的内芯也具有良好的结构强度和硬度,玻璃棉内部多孔,具有一定的吸声效果,玻璃棉的加入,也使得内芯内部具有少量的细孔,有利于热量的发散;
覆料由水玻璃和聚丙烯酰胺组成,其中水玻璃和聚丙烯酰胺之间的含量比为1:2;
覆料中,以水玻璃作为粘合剂,以聚丙烯酰胺为吸水材料,故覆料可以吸水,使得内芯具有吸水性能,进而保证整个耐火砖内部不易积留水分,保证耐火砖的产品品质;
结合剂具体为水泥;
内芯的制作过程为:①加水,搅拌溶解水泥结合剂;②将高铝钒土料和碳化硅加入到稀释的水泥中,搅拌均匀;③制备填料:将黄糊精和玻璃棉加入到高温的钢水中,搅拌均匀;④将制备好的填料加入到高铝钒土料、碳化硅及水泥体系中,搅拌均匀;⑤取料入模,烧制成型,所得内芯基块取出模具后,静置放冷;⑥制备覆料:将水玻璃和聚丙烯酰胺进行搅拌混合至均匀;⑦将覆料均匀涂抹在成型的内芯基块外壁,厚度为2mm;
高铝钒土料、碳化硅和填料作为内芯的主基体部分,外覆覆料予以防水保护,极大地提高了内芯的产品质量和优越的隔水防水性能,有效避免少量水分进入内芯内部,对内芯内部的基体造成损伤影响;
岩棉和铜铝合金均选用粉末态,且岩棉粉末和铜铝合金粉末均过100目筛;
岩棉为纤维多孔吸声材料,利用其内部大量微小且连通的孔隙,可以减少散热层的用材,降低散热层的重量,同时使得散热层内部疏松多孔,有助于热量的快速排散,进而保证整个耐火砖的产品质量,延长耐火砖的使用寿命,而铜铝合金则用于增强散热层的散热效能,使得耐火砖所积聚的热量能够快速被引导出去,以进行发散;
发泡剂具体为碳酸钙、碳酸镁、碳酸氢钠、十二烷基硫酸钠、脂肪醇聚氧乙烯醚硫酸钠中的一种;
发泡剂用于发泡散热层,使得散热层内气孔较多,在烧制时比较稳定,成型后散热层内也具有较多细孔,用以散热;
基质由细沙、水泥和水组成,按含量比计,细沙:水泥:水=1:3:5;
基质作为散热层的主要组成部分,内含有细沙,取材方便,成本低,且细沙的加入也使得散热层对热量具有一定的吸收作用,从而能够更好更快速地降低内芯高温;
散热层的制备过程为:①制备基质:将水泥加入水中,搅拌混合后,加入细沙,搅拌至完全混合;②加入发泡剂,高频搅拌30min;③加入岩棉粉末,搅拌均匀;④加入铜铝合金粉末,充分混合。
实施例2
一种高铝碳化硅耐火砖的制备工艺,具体步骤如下:
①将涂覆有覆料的内芯基块进行风干,形成完整内芯后,用细磨机打磨内芯外壁,至内芯外壁面光滑;
②将内芯放置在耐火砖烧制模具的正中间位置;
③在内芯两侧填充散热层基料,在填充的过程中,搅拌散热层基料,消除散热层基料与内芯外壁之间的间隙;
④压模,并回收多余的散热层基料;
⑤入炉烧结成型。
综上,该高铝碳化硅耐火砖及其制备工艺,采用内芯加用作保护的散热层结构,既达到了耐火砖的强度、硬度、抗压性能、耐火、耐高温等标准,又使得耐火砖兼具防水、吸水、高散热等性能,极大地保证了耐火砖的产品质量,使得耐火砖在耐受高温时或在长期耐高温后,内部开裂延缓,不易碎开,延长了耐火砖的使用寿命,且耐火砖中的散热层采用了疏松多孔结构,质地轻,热穿透性良好,降低了耐火砖生产成本,减轻了耐火砖的重量,还提高了耐火砖的散热性能。
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,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。
Claims (10)
1.一种高铝碳化硅耐火砖,包括内芯和包覆在两侧的散热层,其特征在于:所述内芯的配料为高铝钒土料、碳化硅、填料、覆料和结合剂,按含量比计,高铝钒土料:碳化硅:填料:覆料:结合剂=10:1:1:0.5:7,所述散热层的配料为岩棉、铜铝合金、发泡剂和基质,按含量比计,岩棉:铜铝合金:发泡剂:基质=1:1:1:5。
2.根据权利要求1所述的一种高铝碳化硅耐火砖,其特征在于:所述填料具体由钢水、黄糊精和玻璃棉组成,其中钢水、黄糊精和玻璃棉之间的含量比为1:1:1。
3.根据权利要求1所述的一种高铝碳化硅耐火砖,其特征在于:所述覆料由水玻璃和聚丙烯酰胺组成,其中水玻璃和聚丙烯酰胺之间的含量比为1:2。
4.根据权利要求1所述的一种高铝碳化硅耐火砖,其特征在于:所述结合剂具体为水泥。
5.根据权利要求1所述的一种高铝碳化硅耐火砖,其特征在于:所述内芯的制作过程如下:
①加水,搅拌溶解水泥结合剂;
②将高铝钒土料和碳化硅加入到稀释的水泥中,搅拌均匀;
③制备填料:将黄糊精和玻璃棉加入到高温的钢水中,搅拌均匀;
④将制备好的填料加入到高铝钒土料、碳化硅及水泥体系中,搅拌均匀;
⑤取料入模,烧制成型,所得内芯基块取出模具后,静置放冷;
⑥制备覆料:将水玻璃和聚丙烯酰胺进行搅拌混合至均匀;
⑦将覆料均匀涂抹在成型的内芯基块外壁,厚度为2mm。
6.根据权利要求1所述的一种高铝碳化硅耐火砖,其特征在于:所述岩棉和铜铝合金均选用粉末态,且岩棉粉末和铜铝合金粉末均过100目筛。
7.根据权利要求1所述的一种高铝碳化硅耐火砖,其特征在于:所述发泡剂具体为碳酸钙、碳酸镁、碳酸氢钠、十二烷基硫酸钠、脂肪醇聚氧乙烯醚硫酸钠中的一种。
8.根据权利要求1所述的一种高铝碳化硅耐火砖,其特征在于:所述基质由细沙、水泥和水组成,按含量比计,细沙:水泥:水=1:3:5。
9.根据权利要求1所述的一种高铝碳化硅耐火砖,其特征在于:所述散热层的制备过程如下:
①制备基质:将水泥加入水中,搅拌混合后,加入细沙,搅拌至完全混合;
②加入发泡剂,高频搅拌30min;
③加入岩棉粉末,搅拌均匀;
④加入铜铝合金粉末,充分混合。
10.一种高铝碳化硅耐火砖的制备工艺,其特征在于:该制备工艺包含权利要求1-9所述的任意一项高铝碳化硅耐火砖,该制备工艺具体步骤如下:
①将涂覆有覆料的内芯基块进行风干,形成完整内芯后,用细磨机打磨内芯外壁,至内芯外壁面光滑;
②将内芯放置在耐火砖烧制模具的正中间位置;
③在内芯两侧填充散热层基料,在填充的过程中,搅拌散热层基料,消除散热层基料与内芯外壁之间的间隙;
④压模,并回收多余的散热层基料;
⑤入炉烧结成型。
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