CN112321285A - 一种耐渣蚀轻量矾土熟料及其制备方法 - Google Patents
一种耐渣蚀轻量矾土熟料及其制备方法 Download PDFInfo
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- 238000005260 corrosion Methods 0.000 title claims abstract description 68
- 229910001570 bauxite Inorganic materials 0.000 title claims abstract description 38
- 238000002360 preparation method Methods 0.000 title claims abstract description 26
- 239000002994 raw material Substances 0.000 claims abstract description 57
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 55
- 239000002893 slag Substances 0.000 claims abstract description 51
- 230000007797 corrosion Effects 0.000 claims abstract description 40
- 238000000034 method Methods 0.000 claims abstract description 26
- 239000006229 carbon black Substances 0.000 claims abstract description 21
- 239000000843 powder Substances 0.000 claims abstract description 17
- 238000001035 drying Methods 0.000 claims abstract description 15
- 238000003825 pressing Methods 0.000 claims abstract description 14
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 13
- 238000002156 mixing Methods 0.000 claims abstract description 12
- 239000002245 particle Substances 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 4
- 235000012054 meals Nutrition 0.000 claims description 2
- 229910052593 corundum Inorganic materials 0.000 claims 1
- 229910001845 yogo sapphire Inorganic materials 0.000 claims 1
- 239000011148 porous material Substances 0.000 description 20
- 238000002474 experimental method Methods 0.000 description 10
- 230000035699 permeability Effects 0.000 description 10
- 238000002791 soaking Methods 0.000 description 10
- 239000007791 liquid phase Substances 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 8
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 description 6
- 229910001950 potassium oxide Inorganic materials 0.000 description 6
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 5
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 4
- 239000012535 impurity Substances 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
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- 239000000377 silicon dioxide Substances 0.000 description 4
- 238000004134 energy conservation Methods 0.000 description 3
- 235000012239 silicon dioxide Nutrition 0.000 description 3
- 238000005245 sintering Methods 0.000 description 3
- 238000001238 wet grinding Methods 0.000 description 3
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 238000006555 catalytic reaction Methods 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
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- 230000035515 penetration Effects 0.000 description 2
- 230000008092 positive effect Effects 0.000 description 2
- 229910052700 potassium Inorganic materials 0.000 description 2
- 239000011591 potassium Substances 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 239000000654 additive Substances 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明涉及一种耐渣蚀轻量矾土熟料及其制备方法。其技术方案是:以89~97wt%的矾土生料微粉、1~9wt%的炭黑和0.1~4wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,然后在100~200MPa条件下机压成型,得到生坯;然后将所述生坯在110~200℃条件下干燥12~36小时,在1550~1750℃和埋碳条件下保温3~8小时,制得耐渣蚀轻量矾土熟料。本发明成本低和工艺简单,所制备的耐渣蚀轻量矾土熟料具有孔径小、强度高和抗熔渣能力强的特点。
Description
技术领域
本发明属于轻量矾土熟料技术领域。具体涉及一种耐渣蚀轻量矾土熟料及其制备方法。
背景技术
冶金、水泥、玻璃、化工、电力等高温工业是全球工业领域的耗能大户,实现高温工业节能减排对于促进资源和能源节约、实现可持续发展有重要意义。工作层耐火材料轻量化是高温工业节能减排的重要方向,开发可直接用于工作层的轻量耐火材料已成为本领域所关注的重要课题,其关键在于制备孔径小、高强、耐渣蚀的轻量耐火骨料。
矾土熟料是全球耐火材料消耗量最大的耐火原料之一,被广泛地用于高温工业炉用耐火材料。目前国内外针对轻量矾土熟料制备开展了一定的研究。“一种微孔轻量矾土耐火骨料及其制备方法”(ZL 201410447797.X)专利技术,以矾土生料、有机聚合物和添加剂为原料,外加水,在行星球磨机湿磨、固化、干燥、高温烧成,虽制得微孔轻量矾土耐火骨料,但采用的湿磨工艺较复杂和成本高,且所制备的微孔轻量矾土耐火骨料孔径较大,抗熔渣能力有待提高。“一种轻量微闭孔矾土耐火骨料及其制备方法”(ZL 201610903975.4)专利技术,以3~10℃/分钟的升温速率,将块状矾土生料分段升温至最终温度,虽制得轻量微闭孔矾土耐火骨料,但制备的轻量微闭孔矾土耐火骨料平均孔径高达2μm,孔径较大,机械力学性能和抗熔渣能力不佳。Fu等(Fu,et al.Role of liquid phase amounts in the poreevolution of lightweight bauxite_Experimental and thermal simulation studies[J].Ceramics International,2019,45:6216-6222.)采用湿磨法虽制得轻量矾土骨料;但湿磨工艺较复杂、成本高,且所制备的轻量矾土骨料平均孔径达5.03μm,抗熔渣能力不佳。
发明内容
本发明旨在克服现有技术缺陷,任务是提供一种成本低和工艺简单的耐渣蚀轻量矾土熟料的制备方法;用该方法制备的耐渣蚀轻量矾土熟料孔径小、强度高和抗熔渣能力强。
为实现上述任务,本发明所采用的技术方案是:以89~97wt%的矾土生料微粉、1~9wt%的炭黑和0.1~4wt%的草木灰为原料,先将所述原料在行星球磨机中混合均匀,再于100~200MPa条件下机压成型,得到生坯;然后将所述生坯在110~200℃条件下干燥12~36小时,在1550~1750℃和埋碳条件下保温3~8小时,即得耐渣蚀轻量矾土熟料。
所述矾土生料微粉的Al2O3含量≥60wt%,粒径D50为1~10μm。
所述炭黑的C含量≥99wt%,粒径≤100nm。
所述草木灰的粒径≤10μm。
由于采用上述技术方案,本发明与现有技术相比具有如下积极效果:
(1)本发明以矾土生料微粉、炭黑和草木灰为原料,在行星球磨机中混匀后机压成型,经干燥及埋碳高温热处理,即得耐渣蚀轻量矾土熟料,故工艺简单;本发明以矾土生料为主要原料,矾土生料是一种来源广泛的天然原料,价格较低;此外,本发明采用的其他原料也来源广泛,价格较低。因此,制备耐渣蚀轻量矾土熟料的生产成本低。
(2)本发明引入的草木灰在热处理过程中分解为氧化钾和二氧化碳,氧化钾能够在高温下与矾土中的二氧化硅组分及其他杂质形成液相,这些液相能够分割及堵塞大气孔。因此,经高温烧成后,所制备的耐渣蚀轻量矾土熟料孔径较小。
(3)本发明引入的草木灰分解的氧化钾能够在高温下与矾土中的二氧化硅及其他杂质快速形成液相,由于炭黑的存在且处于埋碳环境,液相中的钾组分会转变为气态挥发,铁和硅会以小颗粒的形式析出。在析出的铁催化作用下,析出的硅会与炭黑发生反应,原位生成碳化硅晶须。一方面,碳化硅晶须具有增强作用,可以提升材料强度;另一方面,在与熔渣反应过程中,碳化硅晶须可以阻碍熔渣的侵蚀和渗透,使耐渣蚀轻量矾土熟料的抗熔渣能力显著提升。
本发明所制备的耐渣蚀轻量矾土熟料经检测:体积密度为2.7~3.2g/cm3;平均孔径为100~500nm;1600℃浸泡法抗渣实验侵蚀指数为1~5%,渗透指数为5~15%。
因此,本发明成本低和工艺简单,所制备的耐渣蚀轻量矾土熟料具有孔径小、强度高和抗熔渣能力强的特点。
具体实施方式
下面结合具体实施方式对本发明作进一步的描述,并非对保护范围的限制:
一种耐渣蚀轻量矾土熟料及其制备方法。以89~97wt%的矾土生料微粉、1~9wt%的炭黑和0.1~4wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于100~200MPa条件下机压成型,得到生坯;然后将所述生坯在110~200℃条件下干燥12~36小时,在1550~1750℃和埋碳条件下保温3~8小时,即得耐渣蚀轻量矾土熟料。
本具体实施方式中:
所述矾土生料微粉的Al2O3含量≥60wt%,粒径D50为1~10μm。
所述炭黑的C含量≥99wt%,粒径≤100nm。
所述草木灰的粒径≤10μm。
实施例中不再赘述。
实施例1
一种耐渣蚀轻量矾土熟料及其制备方法。本实施例的制备方法是:
以89wt%的矾土生料微粉、7wt%的炭黑和4wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于200MPa条件下机压成型,得到生坯;然后将所述生坯在200℃条件下干燥12小时,在1550℃和埋碳条件下保温8小时,即得耐渣蚀轻量矾土熟料。
本实施例所制备的耐渣蚀轻量矾土熟料经检测:体积密度为2.71g/cm3;平均孔径为495nm;1600℃浸泡法抗渣实验侵蚀指数为5%,渗透指数为15%。
实施例2
一种耐渣蚀轻量矾土熟料及其制备方法。本实施例的制备方法是:
以90wt%的矾土生料微粉、9wt%的炭黑和1wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于160MPa条件下机压成型,得到生坯;然后将所述生坯在160℃条件下干燥24小时,在1650℃和埋碳条件下保温6小时,即得耐渣蚀轻量矾土熟料。
本实施例所制备的耐渣蚀轻量矾土熟料经检测:体积密度为2.84g/cm3;平均孔径为426nm;1600℃浸泡法抗渣实验侵蚀指数为5%,渗透指数为14%。
实施例3
一种耐渣蚀轻量矾土熟料及其制备方法。本实施例的制备方法是:
以94wt%的矾土生料微粉、4wt%的炭黑和2wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于150MPa条件下机压成型,得到生坯;然后将所述生坯在150℃条件下干燥18小时,在1600℃和埋碳条件下保温5小时,即得耐渣蚀轻量矾土熟料。
本实施例所制备的耐渣蚀轻量矾土熟料经检测:体积密度为2.94g/cm3;平均孔径为316nm;1600℃浸泡法抗渣实验侵蚀指数为3%,渗透指数为12%。
实施例4
一种耐渣蚀轻量矾土熟料及其制备方法。本实施例的制备方法是:
以93wt%的矾土生料微粉、5wt%的炭黑和2wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于180MPa条件下机压成型,得到生坯;然后将所述生坯在140℃条件下干燥24小时,在1550℃和埋碳条件下保温7小时,即得耐渣蚀轻量矾土熟料。
本实施例所制备的耐渣蚀轻量矾土熟料经检测:体积密度为2.98g/cm3;平均孔径为368nm;1600℃浸泡法抗渣实验侵蚀指数为4%,渗透指数为13%。
实施例5
一种耐渣蚀轻量矾土熟料及其制备方法。本实施例的制备方法是:
以95wt%的矾土生料微粉、2wt%的炭黑和3wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于120MPa条件下机压成型,得到生坯;然后将所述生坯在140℃条件下干燥30小时,在1600℃和埋碳条件下保温5小时,即得耐渣蚀轻量矾土熟料。
本实施例所制备的耐渣蚀轻量矾土熟料经检测:体积密度为3.01g/cm3;平均孔径为278nm;1600℃浸泡法抗渣实验侵蚀指数为2%,渗透指数为10%。
实施例6
一种耐渣蚀轻量矾土熟料及其制备方法。本实施例的制备方法是:
以96.5wt%的矾土生料微粉、3wt%的炭黑和0.5wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于130MPa条件下机压成型,得到生坯;然后将所述生坯在130℃条件下干燥30小时,在1650℃和埋碳条件下保温4小时,即得耐渣蚀轻量矾土熟料。
本实施例所制备的耐渣蚀轻量矾土熟料经检测:体积密度为3.04g/cm3;平均孔径为264nm;1600℃浸泡法抗渣实验侵蚀指数为3%,渗透指数为9%。
实施例7
一种耐渣蚀轻量矾土熟料及其制备方法。本实施例的制备方法是:
以95wt%的矾土生料微粉、4.9wt%的炭黑和0.1wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于150MPa条件下机压成型,得到生坯;然后将所述生坯在180℃条件下干燥16小时,在1700℃和埋碳条件下保温3小时,即得耐渣蚀轻量矾土熟料。
本实施例所制备的耐渣蚀轻量矾土熟料经检测:体积密度为3.09g/cm3;平均孔径为158nm;1600℃浸泡法抗渣实验侵蚀指数为1%,渗透指数为6%。
实施例8
一种耐渣蚀轻量矾土熟料及其制备方法。本实施例的制备方法是:
以97wt%的矾土生料微粉、1wt%的炭黑和2wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于100MPa条件下机压成型,得到生坯;然后将所述生坯在110℃条件下干燥36小时,在1750℃和埋碳条件下保温3小时,即得耐渣蚀轻量矾土熟料。
本实施例所制备的耐渣蚀轻量矾土熟料经检测:体积密度为3.18g/cm3;平均孔径为106nm;1600℃浸泡法抗渣实验侵蚀指数为2%,渗透指数为5%。
本具体实施方式与现有技术相比具有如下积极效果:
(1)本具体实施方式以矾土生料微粉、炭黑和草木灰为原料,在行星球磨机中混匀后机压成型,经干燥及埋碳高温热处理,即得耐渣蚀轻量矾土熟料,故工艺简单;本具体实施方式以矾土生料为主要原料,矾土生料是一种来源广泛的天然原料,价格较低;此外,本具体实施方式采用的其他原料也来源广泛,价格较低。因此,制备耐渣蚀轻量矾土熟料的生产成本低。
(2)本具体实施方式引入的草木灰在热处理过程中分解为氧化钾和二氧化碳,氧化钾能够在高温下与矾土中的二氧化硅组分及其他杂质形成液相,这些液相能够分割及堵塞大气孔。因此,经高温烧成后,所制备的耐渣蚀轻量矾土熟料孔径较小。
(3)本具体实施方式引入的草木灰分解的氧化钾能够在高温下与矾土中的二氧化硅及其他杂质快速形成液相,由于炭黑的存在且处于埋碳环境,液相中的钾组分会转变为气态挥发,铁和硅会以小颗粒的形式析出。在析出的铁催化作用下,析出的硅会与炭黑发生反应,原位生成碳化硅晶须。一方面,碳化硅晶须具有增强作用,可以提升材料强度;另一方面,在与熔渣反应过程中,碳化硅晶须可以阻碍熔渣的侵蚀和渗透,使耐渣蚀轻量矾土熟料的抗熔渣能力显著提升。
本具体实施方式所制备的耐渣蚀轻量矾土熟料经检测:体积密度为2.7~3.2g/cm3;平均孔径为100~500nm;1600℃浸泡法抗渣实验侵蚀指数为1~5%,渗透指数为5~15%。
因此,本具体实施方式成本低和工艺简单,所制备的耐渣蚀轻量矾土熟料具有孔径小、强度高和抗熔渣能力强的特点。
Claims (5)
1.一种耐渣蚀轻量矾土熟料的制备方法,其特征在于所述制备方法是:以89~97wt%的矾土生料微粉、1~9wt%的炭黑和0.1~4wt%的草木灰为原料;先将所述原料在行星球磨机中混合均匀,再于100~200MPa条件下机压成型,得到生坯;然后将所述生坯在110~200℃条件下干燥12~36小时,在1550~1750℃和埋碳条件下保温3~8小时,制得耐渣蚀轻量矾土熟料。
2.根据权利要求1所述的耐渣蚀轻量矾土熟料的制备方法,其特征在于所述矾土生料微粉的Al2O3含量≥60wt%,粒径D50为1~10μm。
3.根据权利要求1所述的耐渣蚀轻量矾土熟料的制备方法,其特征在于所述炭黑的C含量≥99wt%,粒径≤100nm。
4.根据权利要求1所述的耐渣蚀轻量矾土熟料的制备方法,其特征在于所述草木灰的粒径≤10μm。
5.一种耐渣蚀轻量矾土熟料,其特征在于所述的耐渣蚀轻量矾土熟料是根据权利要求1~4项中任一项所述的耐渣蚀轻量矾土熟料的制备方法所制备的耐渣蚀轻量矾土熟料。
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