CN112266230A - 一种高温微发泡的轻质隔热材料及其制备方法 - Google Patents

一种高温微发泡的轻质隔热材料及其制备方法 Download PDF

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CN112266230A
CN112266230A CN202011147311.2A CN202011147311A CN112266230A CN 112266230 A CN112266230 A CN 112266230A CN 202011147311 A CN202011147311 A CN 202011147311A CN 112266230 A CN112266230 A CN 112266230A
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insulating material
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powder
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马成良
潘孟博
戚文豪
杜浩然
吴晓鹏
詹学武
赵飞
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Zhengzhou University
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Abstract

本发明公开了一种高温微发泡的轻质隔热材料及其制备方法。该轻质隔热材料按质量百分比配料，包括：30～60％花岗岩废料，10～30％高温助熔剂，0～30％硅藻土，0～10％黏土，0.6～1.2％高温发泡剂。无需压制成型，经混料、造粒、干燥、烧成等步骤，最终得到具有闭口微孔结构的轻质隔热材料。其体积密度为320～840kg/m3、抗压强度为6～19MPa、常温导热系数≤0.09W/(m·K)，1000℃时的导热系数≤0.5W/(m·K)。本发明原料成本低廉，工艺简单，不仅满足作为高温窑炉保温层的性能要求，还符合当前社会可持续发展理念，是集高性能与绿色环保于一体的轻质隔热材料。

Description

一种高温微发泡的轻质隔热材料及其制备方法
技术领域
本发明涉及轻质隔热材料领域，具体涉及一种高温微发泡的轻质隔热材料及其制备方法。
背景技术
随着人类社会的进步和生活水平的提高，工业生产对于能源的依赖与日俱增，能源短缺与环境恶化问题愈加突出。高温材料行业在进行生产时，各种高温窑炉消耗的能源量十分巨大，作为工业部门的耗能大户，亟需一种可降低能源损耗的方法。轻质隔热材料作为当前流行的一种隔热保温材料，具有体积密度小、高温稳定性好、导热率低等优点；应用于高温窑炉保温层，可有效降低窑体的热量损失，节约大量能源，满足工厂对于节能降耗的要求。传统的烧结型隔热砖在发挥作用前需要堆砌，由于砖块之间很难保持大小形状完全一致，因此在堆砌时难免会产生大量的砖缝。砖缝的存在严重影响了保温砖的隔热性能，使其在实际工作时的隔热能力明显低于理论数值。
花岗岩作为一种常见的建筑装饰材料，其具有质地坚硬，外形美观等特点，受到人们的广泛青睐。伴随着花岗岩需求量的增加，我国对于花岗岩的加工利用率却始终较低。在生产制品过程中产生的大量边角料或碎料，堆积起来会对环境造成沉重负担。花岗岩废料属铝硅系固体废弃物，主要物相为石英和长石，其中长石在烧结时可产生低熔点物质，降低烧结温度，是制备发泡陶瓷的优良原料。因此，选择花岗岩废料为主要原料，不仅可以实现废料的资源化利用，还可以制备出理想的轻质隔热材料，创造可观的经济效益。综上所述，以花岗岩废料制备轻质隔热材料符合当今研发环境友好型的低密度、低导热、低成本、高强度的轻质隔热材料的主流方向。
“一种莫来石轻质隔热砖及其制备方法”(CN 106673678 B)专利，采用烧失技术，以40～48wt％的焦宝石，14～38wt％的蓝晶石，6～16wt％的粘土，14～24wt％的α-Al2O3微粉，15～20wt％的结合剂，45～60wt％的锯末和硅溶胶混合物为造孔剂经过混料、困料、成型、烘烤、烧结制备了轻质隔热砖。其体积密度0.5～0.8g·cm-3、烧后线收缩率小于1％，但是大量的锯末在高温下燃烧后会形成开口气孔，导致抗压强度为5～10MPa、常温导热系数为0.1～0.3W/(m·K)。
发明内容
本发明要解决的技术问题是：针对上述问题，提供一种成本低廉、工艺简单、隔热保温、绿色环保、轻质高强、可在1000℃使用的高温微发泡轻质隔热材料。
为实现上述目的，本发明采取的技术方案如下：
(1)按比例将花岗岩废料、高温助熔剂、硅藻土、黏土、高温发泡剂和水，放入球磨机进行混料，然后经干燥、破碎得到原料粉体；
(2)在步骤(1)的粉体中加入临时结合剂和水，使用造粒机造粒。取适量颗粒放入匣钵中，自然堆积并刮平表面，进行干燥；
(3)将步骤(2)中干燥后的混合料及匣钵一同放入高温窑炉中在1100℃～1300℃下进行烧结，冷却后加工处理得到所述轻质隔热材料。
作为上述方案的改进，所述步骤(1)中各原料的质量百分比为：花岗岩废料30～60％，高温助熔剂10～30％，硅藻土0～30％，黏土0～10％，高温发泡剂0.6～1.2％。
作为上述方案的改进，所述花岗岩废料、高温助熔剂、硅藻土和黏土均为细粉，其粒度小于200μm；所述高温发泡剂粒度小于45μm。
作为上述方案的改进，所述的花岗岩废料细粉由花岗岩边角料或碎块经破碎、球磨而成。
作为上述方案的改进，所述的高温助熔剂为钾长石、钠长石、钙长石、废玻璃粉的至少一种。
作为上述方案的改进，所述的黏土为黄泥、锰泥、高岭土中的至少一种。
作为上述方案的改进，所述的高温发泡剂为碳化硅、氮化硼、碳酸钙的至少一种。
作为上述方案的改进，所述的临时结合剂为淀粉、树脂、黄糊精的至少一种。
作为上述方案的改进，所述步骤(2)中造粒时，加入总质量比15％的水和3％的临时结合剂，得到的颗粒粒径为0.2mm～1.2mm。
作为上述方案的改进，所述步骤(3)中烧结温度为1100～1300℃，保温时间为10～60min。
作为上述方案的改进，所述烧成过程为：
(a)从0℃升温至900℃时的升温速率为10℃/min；
(b)从900℃升温至1100～1300℃时的升温速率为1～5℃/min，然后在最高烧成温度保温10～60min；
(c)缓慢降温，从1100～1300℃降温至300℃的降温速率为4～12℃/min，由300℃降至常温的降温速率为1～4℃/min。
相应的，本发明公开了一种高温微发泡的轻质隔热材料，其采用上述方法制得。用该方法制备的高温微发泡的轻质隔热材料体积密度小、抗压强度大、导热系数低。
与现在有技术相比，本发明的有益效果为：
本发明采用花岗岩废料作为主要原料，通过原料的合理搭配，制备出发泡均匀的轻质隔热材料。该轻质隔热材料烧结温度不超过1300℃，可减少能源消耗。
本发明制备流程较为简单，取消了压制成型过程，简化了发泡陶瓷的生产工艺，进一步降低了产品的生产成本。
本发明成本低廉，工艺简单，花岗岩废料利用率高。不仅促进了发泡陶瓷功能化、高性能化的发展，还促进了工业固废的资源化利用，对于环境保护方面也具有重要意义。
本发明轻质隔热材料的体积密度为320～840kg/m3，抗压强度6～19MPa，常温导热系数≤0.09W/(m·K)，1000℃时的导热系数≤0.5W/(m·K)。
附图说明
构成本发明的一部分的附图用来提供对本发明的进一步理解，并用于解释本发明，并不构成对本发明的不当限定。在附图中：
图1为本发明制备的高温微发泡的轻质隔热材料的发泡气孔结构。
图2为本发明制备的高温微发泡的轻质隔热材料的发泡气孔微观形貌图。
具体实施方式
为更好地说明本发明的制备方案、使用目的和产品优点，下面将结合具体实施例对本发明作进一步阐述。值得说明的是，此处所述实施例仅用以解释本发明，并不用于限定本发明。
实施例1
一种高温微发泡的轻质隔热材料包括如下组分：花岗岩废料60％，钾长石20％，硅藻土20％，D50＝6.5μm的高温发泡剂碳化硅0.8％。
一种高温微发泡的轻质隔热材料的制备方法，其步骤如下：
(1)按质量百分比取花岗岩废料、钾长石、硅藻土、碳化硅，按照原料：球：水＝2:1:2分别加入研磨球和研磨介质。在混料机中以260r/min混料2h，得到混合均匀的泥浆后干燥12h；
(2)将步骤(1)干燥后的料破碎、过筛得到粒径小于0.2mm的粉末；
(3)将步骤(2)得到的粉末加入15％的水和3％的黄糊精，经造粒、震动筛分得到粒径为0.2mm～0.8mm的颗粒，将颗粒干燥待用
(4)将步骤(3)得到的干燥颗粒堆放入高温窑炉中进行烧成。从室温升温900℃的升温速率为10℃/min；900℃～1200℃的升温速率为3℃/min；在1200℃下保温30min；然后缓慢降温至室温。
(5)将步骤(4)得到的冷却样品切割成板状作为窑炉隔热保温材料。
本实施例所制备的高温微发泡轻质隔热材料体积密度为0.78g/cm3，气孔率为68.28％，抗压强度为13.15MPa，1000℃时导热系数为0.47W/(m·K)。
实施例2
一种高温微发泡的轻质隔热材料包括如下组分：花岗岩废料60％，钠长石30％，黏土10％，D50＝6.5μm的高温发泡剂碳化硅1.0％。
一种高温微发泡的轻质隔热材料的制备方法，其步骤如下：
(1)按质量百分比取花岗岩废料、钠长石、碳化硅，按照原料：球：水＝2:1:2分别加入研磨球和研磨介质。在混料机中以260r/min混料2h，得到混合均匀的泥浆后干燥12h；
(2)将步骤(1)干燥后的料破碎、过筛得到粒径小于0.2mm的粉末；
(3)将步骤(2)得到的粉末加入15％的水和3％的淀粉，经造粒、震动筛分得到粒径为0.6mm～1.2mm的颗粒，将颗粒干燥待用。
(4)将步骤(3)得到的干燥颗粒堆放入高温窑炉中进行烧成。从室温升温900℃的升温速率为10℃/min；900℃～1220℃的升温速率为5℃/min；在1220℃下保温45min；然后缓慢降温至室温。
(5)将步骤(4)得到的冷却样品切割成板状作为窑炉隔热保温材料。
本实施例所制备的高温微发泡轻质隔热材料体积密度为0.45g/cm3，气孔率为82.16％，抗压强度为6.36MPa，1000℃时导热系数为0.38W/(m·K)。
以上实施例仅用以说明本发明的技术方案而非对本发明保护范围的限制。尽管参照了较佳实施例对本发明进行了较为详细的说明，本领域的技术工人应当理解，在不脱离本发明方案的实质和范围的基础上，对本方案的技术方案进行修改或者等同替换，均应包含在本发明权利要求的保护范围内。

Claims (11)

1.一种高温微发泡的轻质隔热材料的制备方法，其特征在于，包括以下步骤：
(1)按比例将花岗岩废料、高温助熔剂、硅藻土、黏土、高温发泡剂和水，放入球磨机进行混料，然后经干燥、破碎得到原料粉体；
(2)在步骤(1)的粉体中加入临时结合剂和水，使用造粒机造粒。取适量颗粒放入匣钵中，自然堆积并刮平表面，进行干燥；
(3)将步骤(2)中干燥后的混合料及匣钵一同放入高温窑炉中在1100℃～1300℃下进行烧结，冷却后加工处理得到所述轻质隔热材料。
2.如权利要求1所述的轻质隔热材料，其特征在于，所述步骤(1)中各原料的质量百分比为：花岗岩废料30～60％，高温助熔剂10～30％，硅藻土0～30％，黏土0～10％，高温发泡剂0.6～1.2％。
3.如权利要求1所述的轻质隔热材料，其特征在于，所述花岗岩废料、高温助熔剂、硅藻土和黏土均为细粉，其粒度小于200μm；所述高温发泡剂粒度小于45μm。
4.如权利要求1所述的轻质隔热材料，其特征在于，所述的花岗岩废料细粉由花岗岩边角料或碎块经破碎、球磨而成。
5.如权利要求1所述的轻质隔热材料，其特征在于，所述的高温助熔剂为钾长石、钠长石、钙长石、废玻璃粉的至少一种。
6.如权利要求1所述的轻质隔热材料，其特征在于，所述的黏土为黄泥、锰泥、高岭土中的至少一种。
7.如权利要求1所述的轻质隔热材料，其特征在于，所述的高温发泡剂为碳化硅、氮化硼、碳酸钙的至少一种。
8.如权利要求1所述的轻质隔热材料，其特征在于，所述的临时结合剂为淀粉、树脂、黄糊精的至少一种。
9.如权利要求1所述的轻质隔热材料，其特征在于，所述步骤(2)中造粒时，加入总质量比15％的水对粉体进行湿润，得到的颗粒粒径为0.2mm～1.2mm。
10.如权利要求1所述的轻质隔热材料，其特征在于，所述步骤(3)中烧结温度为1100～1300℃，保温时间为10～60min。
11.一种采用权利要求1～10任一项所述方法制备所得的轻质隔热材料，为闭口微孔轻质材料。
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