CN112225543A - Fusion-cast formed cylindrical ceramic tile applied to glass kiln regenerator and preparation method thereof - Google Patents
Fusion-cast formed cylindrical ceramic tile applied to glass kiln regenerator and preparation method thereof Download PDFInfo
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Abstract
The invention relates to a fusion casting forming cylindrical ceramic tile applied to a glass kiln regenerator and a preparation method thereof. Compared with the traditional material, the ceramic material has the advantages of higher use temperature, lower safe use temperature than 1800 ℃, higher use temperature, longer service life and lower use cost, and avoids the problems of production interruption and high cost caused by the problems of corrosion, cracking and the like at high temperature in the long-term continuous production of the traditional material.
Description
Technical Field
The invention relates to the field of glass kiln regenerator application, in particular to a fusion-cast cylindrical ceramic tile applied to a glass kiln regenerator and a preparation method thereof.
Background
At present, a regenerative furnace of a glass furnace is a main heat supply and heat exchange mode of the glass furnace, and outside the electric melting furnace and a direct-fired furnace, the glass furnace preheats combustion-supporting air through a regenerative chamber and burns the combustion-supporting air and fuel. The working principle is that hot flue gas heats a heat accumulator in the heat accumulator when passing through the heat accumulator, after reversing, air enters the heat accumulator, the heat accumulator transfers heat to the air, the air temperature rises, the temperature of the heat accumulator is reduced, and the heat exchange process is completed. In the process, the heat accumulator is not only subjected to the thermal stress load of temperature change, but also subjected to chemical corrosion of flue gas, so that the material performance requirement of the heat accumulator is high. Besides the glass kiln, part of the metallurgical kiln is also heat accumulating type.
At present, the regenerator of the glass kiln mainly comprises: strip brick checker, cross checker brick, and tubular brick. At present, the regenerator material of the glass kiln regenerator mainly comprises: sintered magnesia bricks, sintered magnesia-chrome bricks, sintered magnesia-zirconia bricks, sintered chrome-corundum bricks, sintered corundum-mullite bricks and cast alumina, wherein the former four types belong to alkaline materials, and the latter four types belong to neutral meta-acidic materials.
The failure mechanism of regenerator checker is essentially a function of three factors: the effects of the physical-chemical reaction of the erosion medium, the thermal shock impact of temperature change and the volume effect caused by atmosphere change all come from the melting furnace smoke and the burden dust carried by the melting furnace smoke.
For a melting furnace using petroleum coke as fuel, impurities brought by the petroleum coke bring serious influence on refractory materials. The high temperature zone V2O5 is an erosion element, while the condensation zone SO3 is an erosion element. V2O5 reacts with CaO in the magnesia brick to generate 3 CaO.V 2O5, so that on one hand, the ratio of CaO to SiO2 in the magnesia brick is changed, and the composition of a binding phase is changed; on the other hand, the liquid 3 CaO.V 2O5 can also invade the interior of the brick body to promote the recrystallization and growth of the periclase, so that the brick body is cracked and pulverized; in addition, V2O5 also catalyzes the oxidation of SO2 in flue gas to SO3, which reacts with periclase to form MgSO4, causing the brick to expand, crack and spall. The erosion effect of Na2SO4 or SO3 is mainly shown in the following aspects: 1. the Na2SO4 or SO3 steam mainly reacts with MgO and a binding phase C2S at the temperature of over 1050 ℃ to generate MgSO4 and CaSO4, and generates larger volume expansion to destroy the brick structure; 2. after the gaseous Na2SO4 enters the open pores of the brick body, a cyclic process of solidification-melting-resolublization gasification can be generated along with the periodic change of the temperature in the heat storage chamber, the checker bricks are damaged along with the volume effect, and simultaneously the checker bricks react with refractory materials to generate sulfate, SO that the structure of the brick body is damaged.
The expected service life of the lattice body is greatly reduced as a result of the erosion, particularly the damage speed of the top-layer lattice body is reduced, so that the service life of the alkaline lattice body is reduced to 2-3 years, and the hot repair and the replacement of the lattice body pay high cost. Meanwhile, under the condition that the current kiln age reaches 8-10 years, the lattice body also becomes a short plate, and huge cost difficulty is caused to glass product manufacturing enterprises.
Disclosure of Invention
The invention aims to provide a fusion-cast forming cylindrical ceramic tile applied to a glass kiln regenerator and a preparation method thereof so as to meet the requirement of integral high-efficiency production function.
The purpose of the invention is realized as follows:
a fusion casting forming cylindrical ceramic tile applied to a glass kiln regenerator comprises the following raw materials in percentage by weight: 1-89.5% of aluminum oxide, 0.5-35% of silicon dioxide, 5-94.5% of zirconium dioxide, 0.5-5% of yttrium oxide, 0.5-3% of cerium oxide and 0.5-2% of trace components.
The micro-components comprise sodium oxide, ferric oxide and titanium oxide, and the sum of the weight of the sodium oxide, the ferric oxide and the titanium oxide is 0.5-2% of the total weight.
A preparation method of a fusion casting forming cylindrical ceramic tile for a glass kiln regenerator is characterized by comprising the following steps: the method comprises the following steps: a. mixing materials: putting a certain amount of aluminum oxide, silicon dioxide, zirconium dioxide, ferric oxide, cerium oxide, sodium oxide, ferric oxide and titanium oxide into a material mixing device, and uniformly mixing the materials to obtain a mixed material; b. melting the mixed material in the step a, pouring and forming: firstly, placing the mixed material in the step a into a water-cooled electrode heating furnace or a medium-frequency and high-frequency induction furnace, heating the mixed material to 2500-; simultaneously, pouring the obtained mixed liquid into a membrane shell by adopting a continuous casting side-pouring process and cooling to obtain a ceramic brick product; c, preparing a membrane shell in the step b: b, forming the membrane shell by adopting a quartz sand material, wherein a main pouring gate of the membrane shell is vertically arranged, a branch pouring gate of the membrane shell is transversely arranged, pouring the mixed liquid obtained in the step b into the membrane shell, then pouring and forming, and cooling to obtain a ceramic brick product; d, demolding to obtain the formed ceramic tile: and d, stripping the membrane shell of the product obtained in the step c to obtain a cooled ceramic tile finished product.
And c, mixing for 12-24 hours in the step a, and uniformly mixing the raw materials in the step a to obtain a mixed material.
The invention has the beneficial effects that: according to the invention, by adopting the rare earth oxides such as zirconium dioxide, yttrium oxide, aluminum oxide, cerium oxide, silicon dioxide and the like, and adopting the continuous casting side-pouring process technology during the molding of the fused cast molded cylindrical ceramic tile, the process technologies of controlling the melting temperature in a reasonable interval and the like are adopted, the comprehensive advantages of enhanced heat storage capability, long service life, good thermal shock resistance, improved acid and alkali corrosion resistance and reduced energy consumption of a glass kiln regenerator of the fused cast cylindrical tile are achieved. Compared with the traditional material, the ceramic material has the advantages of higher use temperature, lower safe use temperature than 1800 ℃, higher use temperature, longer service life and lower use cost, and avoids the problems of production interruption and high cost caused by the problems of corrosion, cracking and the like at high temperature in the long-term continuous production of the traditional material.
Detailed Description
The invention is illustrated below with reference to the following examples:
example 1:
a fusion casting forming cylindrical ceramic tile applied to a glass kiln regenerator comprises the following raw materials in percentage by weight: 1% of aluminum oxide, 0.5% of silicon dioxide, 94.5% of zirconium dioxide, 3% of yttrium oxide, 0.5% of cerium oxide and 0.5% of trace component. The micro-components comprise sodium oxide, ferric oxide and titanium oxide, the sum of the weight of the sodium oxide, the ferric oxide and the titanium oxide is 0.5 percent of the total weight, the zirconium dioxide adopts zircon sand, powder or monoclinic zirconium hollow spheres with the purity of 60 to 98 percent, and the D50 granularity is 0.1 to 8 millimeters; the yttrium oxide adopts yttrium oxide powder or yttrium oxide particles with the purity of not less than 98% and the D50 particle size of 0.1-8 mm; the alumina powder has the purity of not less than 98 percent and the D50 granularity of 1um-20 um; the cerium oxide is cerium oxide powder with purity not lower than 98% and D50 particle size in 1-20 um range.
A preparation method of a fusion casting forming cylindrical ceramic tile for a glass kiln regenerator comprises the following steps: a. mixing materials: putting 1% of aluminum oxide, 0.5% of silicon dioxide, 94.5% of zirconium dioxide, 3% of yttrium oxide, 0.5% of cerium oxide and 0.5% of trace components into a material mixing device, mixing for 12-24 hours, wherein the trace components comprise sodium oxide, ferric oxide and titanium oxide, the sum of the weights of the sodium oxide, ferric oxide and titanium oxide is 0.5% of the total weight, and uniformly mixing the materials to obtain a mixed material; b. melting the mixed material in the step a, pouring and forming: firstly, placing the mixed material in the step a into a water-cooled electrode heating furnace or an intermediate frequency and high frequency induction furnace, heating the mixed material to 2500-; c. b, manufacturing a membrane shell: b, forming the membrane shell by adopting a quartz sand material, wherein a main pouring gate of the membrane shell is vertically arranged, a branch pouring gate of the membrane shell is transversely arranged, pouring the mixed liquid obtained in the step b into the membrane shell, then pouring and forming, and cooling to obtain a ceramic brick product; when the membrane shell receives the mixed liquid, heat is supplemented to the ceramic brick material at the later stage of ceramic brick cooling after the membrane shell is heated and stored at the initial stage, so that the heat preservation function of the ceramic brick is obtained, the temperature is delayed to be reduced, the solution temperature is 2500-; d. demoulding to obtain a formed ceramic tile: and d, stripping the membrane shell of the product obtained in the step c to obtain a cooled ceramic tile finished product.
The experimental data for the component contents and performance parameters of the product are shown in table 1:
TABLE 1
Example 2:
a fusion casting forming cylindrical ceramic tile applied to a glass kiln regenerator comprises the following raw materials in percentage by weight: 89.5% of aluminum oxide, 0.5% of silicon dioxide, 5% of zirconium dioxide, 3% of yttrium oxide, 1.5% of cerium oxide and 0.5% of trace component. The micro-components comprise sodium oxide, ferric oxide and titanium oxide, the sum of the weight of the sodium oxide, the ferric oxide and the titanium oxide is 0.5 percent of the total weight, the zirconium dioxide adopts zircon sand, powder or monoclinic zirconium hollow spheres with the purity of 60 to 98 percent, and the D50 granularity is 0.1 to 8 millimeters; the yttrium oxide adopts yttrium oxide powder or yttrium oxide particles with the purity of not less than 98% and the D50 particle size of 0.1-8 mm; the alumina powder has the purity of not less than 98 percent and the D50 granularity of 1um-20 um; the cerium oxide is cerium oxide powder with purity not lower than 98% and D50 particle size in 1-20 um range.
A preparation method of a fusion casting forming cylindrical ceramic tile for a glass kiln regenerator comprises the following steps: a. mixing materials: 89.5% of aluminum oxide, 0.5% of silicon dioxide, 5% of zirconium dioxide, 3% of yttrium oxide, 1.5% of cerium oxide and 0.5% of trace components are put into a material mixing device and mixed for 12-24 hours, the trace components comprise sodium oxide, ferric oxide and titanium oxide, the sum of the weight of the sodium oxide, the ferric oxide and the titanium oxide is 0.5% of the total weight, and the materials are uniformly mixed to obtain a mixed material; b. melting the mixed material in the step a, pouring and forming: firstly, placing the mixed material in the step a into a water-cooled electrode heating furnace or an intermediate frequency and high frequency induction furnace, heating the mixed material to 2500-; c. b, manufacturing a membrane shell: b, forming the membrane shell by adopting a quartz sand material, wherein a main pouring gate of the membrane shell is vertically arranged, a branch pouring gate of the membrane shell is transversely arranged, pouring the mixed liquid obtained in the step b into the membrane shell, then pouring and forming, and cooling to obtain a ceramic brick product; when the membrane shell receives the mixed liquid, heat is supplemented to the ceramic brick material at the later stage of ceramic brick cooling after the membrane shell is heated and stored at the initial stage, so that the heat preservation function of the ceramic brick is obtained, the temperature is delayed to be reduced, the solution temperature is 2500-; d. demoulding to obtain a formed ceramic tile: and d, stripping the membrane shell of the product obtained in the step c to obtain a cooled ceramic tile finished product.
The experimental data for the component content and performance parameters of the product are shown in table 2:
TABLE 2
Example 3:
a fusion casting forming cylindrical ceramic tile applied to a glass kiln regenerator comprises the following raw materials in percentage by weight: 51.5 percent of aluminum oxide, 15 percent of silicon dioxide, 28 percent of zirconium dioxide, 3 percent of yttrium oxide, 0.5 percent of cerium oxide and 2 percent of trace component. The micro-components comprise sodium oxide, ferric oxide and titanium oxide, the sum of the weight of the sodium oxide, the ferric oxide and the titanium oxide is 2 percent of the total weight, the zirconium dioxide adopts zircon sand, powder or monoclinic zirconium hollow spheres with the purity of the zirconium dioxide of 60 percent to 98 percent, and the D50 granularity is 0.1 to 8 millimeters; the yttrium oxide adopts yttrium oxide powder or yttrium oxide particles with the purity of not less than 98% and the D50 particle size of 0.1-8 mm; the alumina powder has the purity of not less than 98 percent and the D50 granularity of 1um-20 um; the cerium oxide is cerium oxide powder with purity not lower than 98% and D50 particle size in 1-20 um range.
A preparation method of a fusion casting forming cylindrical ceramic tile for a glass kiln regenerator comprises the following steps: a. mixing materials: putting 51.5% of aluminum oxide, 15% of silicon dioxide, 28% of zirconium dioxide, 3% of yttrium oxide, 0.5% of cerium oxide and 0.5% of trace components into a material mixing device, mixing for 12-24 hours, wherein the trace components comprise sodium oxide, ferric oxide and titanium oxide, the sum of the weight of the sodium oxide, the ferric oxide and the titanium oxide is 2% of the total weight, and uniformly mixing the materials to obtain a mixed material; b. melting the mixed material in the step a, pouring and forming: firstly, placing the mixed material in the step a into a water-cooled electrode heating furnace or an intermediate frequency and high frequency induction furnace, heating the mixed material to 2500-; c. b, manufacturing a membrane shell: b, forming the membrane shell by adopting a quartz sand material, wherein a main pouring gate of the membrane shell is vertically arranged, a branch pouring gate of the membrane shell is transversely arranged, pouring the mixed liquid obtained in the step b into the membrane shell, then pouring and forming, and cooling to obtain a ceramic brick product; when the membrane shell receives the mixed liquid, heat is supplemented to the ceramic brick material at the later stage of ceramic brick cooling after the membrane shell is heated and stored at the initial stage, so that the heat preservation function of the ceramic brick is obtained, the temperature is delayed to be reduced, the solution temperature is 2500-; d. demoulding to obtain a formed ceramic tile: and d, stripping the membrane shell of the product obtained in the step c to obtain a cooled ceramic tile finished product.
The experimental data for the component content and performance parameters of the product are shown in table 3:
TABLE 3
According to the invention, by adopting the rare earth oxides such as zirconium dioxide, yttrium oxide, aluminum oxide, cerium oxide, silicon dioxide and the like, and adopting the continuous casting side-pouring process technology during the molding of the fused cast molded cylindrical ceramic tile, the process technologies of controlling the melting temperature in a reasonable interval and the like are adopted, the comprehensive advantages of enhanced heat storage capability, long service life, good thermal shock resistance, improved acid and alkali corrosion resistance and reduced energy consumption of a glass kiln regenerator of the fused cast cylindrical tile are achieved. Compared with the traditional material, the ceramic material has the advantages of higher use temperature, lower safe use temperature than 1800 ℃, higher use temperature, longer service life and lower use cost, and avoids the problems of production interruption and high cost caused by the problems of corrosion, cracking and the like at high temperature in the long-term continuous production of the traditional material.
Claims (4)
1. A fusion casting forming cylindrical ceramic tile applied to a glass kiln regenerator is characterized in that: comprises the following raw materials in percentage by weight: 1-89.5% of aluminum oxide, 0.5-35% of silicon dioxide, 5-94.5% of zirconium dioxide, 0.5-5% of yttrium oxide, 0.5-3% of cerium oxide and 0.5-2% of trace components.
2. The fused cast shaped cylindrical ceramic tile for glass kiln regenerators as claimed in claim 1, wherein: the micro-components comprise sodium oxide, ferric oxide and titanium oxide, and the sum of the weight of the sodium oxide, the ferric oxide and the titanium oxide is 0.5-2% of the total weight.
3. A method for manufacturing ceramic tiles of fusion cast shape cylinder type for use in regenerators of glass kilns, as claimed in any one of claims 1 to 2, characterized in that: the method comprises the following steps: a. mixing materials: putting a certain amount of aluminum oxide, silicon dioxide, zirconium dioxide, yttrium oxide, cerium oxide, sodium oxide, ferric oxide and titanium oxide into a material mixing device, and uniformly mixing the materials to obtain a mixed material; b. melting the mixed material in the step a, pouring and forming: firstly, placing the mixed material in the step a into a water-cooled electrode heating furnace or a medium-frequency and high-frequency induction furnace, heating the mixed material to 2500-; simultaneously, pouring the obtained mixed liquid into a membrane shell by adopting a continuous casting side-pouring process and cooling to obtain a ceramic tile product; c. b, manufacturing a membrane shell: b, forming the membrane shell by adopting a quartz sand material, wherein a main pouring gate of the membrane shell is vertically arranged, a branch pouring gate of the membrane shell is transversely arranged, pouring the mixed liquid obtained in the step b into the membrane shell, then pouring and forming, and cooling to obtain a ceramic brick product; d, demolding to obtain the formed ceramic tile: and d, stripping the membrane shell of the product obtained in the step c to obtain a cooled ceramic tile finished product.
4. The method for preparing ceramic bricks in the form of fused cast tubes for the regenerators of glass kilns as claimed in claim 3, characterized in that: and c, mixing for 12-24 hours in the step a, and uniformly mixing the raw materials in the step a to obtain a mixed material.
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| CN202011083960.0A CN112225543A (en) | 2020-10-12 | 2020-10-12 | Fusion-cast formed cylindrical ceramic tile applied to glass kiln regenerator and preparation method thereof |
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Cited By (2)
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| CN113620704A (en) * | 2021-09-15 | 2021-11-09 | 郑州亿川复合新材料研究所有限公司 | Preparation process of high-zirconium ceramic for special glass molten pool |
| CN115894018A (en) * | 2023-01-05 | 2023-04-04 | 郑州方铭高温陶瓷新材料有限公司 | Glass kiln material flowing nozzle brick and preparation method thereof |
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| CN115894018A (en) * | 2023-01-05 | 2023-04-04 | 郑州方铭高温陶瓷新材料有限公司 | Glass kiln material flowing nozzle brick and preparation method thereof |
| CN115894018B (en) * | 2023-01-05 | 2023-09-22 | 郑州方铭高温陶瓷新材料有限公司 | Glass kiln material flow nozzle brick and preparation method thereof |
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