CN112321311A - 一种全纤维烧嘴砖及其制备方法 - Google Patents
一种全纤维烧嘴砖及其制备方法 Download PDFInfo
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- CN112321311A CN112321311A CN202011246915.2A CN202011246915A CN112321311A CN 112321311 A CN112321311 A CN 112321311A CN 202011246915 A CN202011246915 A CN 202011246915A CN 112321311 A CN112321311 A CN 112321311A
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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 claims description 3
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Abstract
本发明提供了一种全纤维烧嘴砖及其制备方法。本发明提供的全纤维烧嘴砖，将氧化铝晶体纤维和非晶体陶瓷纤维混配，且二者均由一定的不同长度级配的纤维搭配，同时再添加不同粒度级配的细粉填料，辅以其它添加剂，能够使产品内部结构更均匀一致，提高产品容重，还有利于纤维棉坯的吸滤性，帮助成型及提高坯体强度。砖体表面再配以涂层，能够有效保护砖体纤维棉纤维不受恶劣环境的侵蚀，提高其耐高温性，有利于延长烧嘴砖的使用寿命。
Description
技术领域
本发明涉及耐火材料领域，特别涉及一种全纤维烧嘴砖及其制备方法。
背景技术
目前，石化行业的乙烯裂解炉需用烧嘴的部位主要有底烧、侧烧、顶烧三种，所用的烧嘴砖大部分都是刚玉材质和重质浇注料材质的，虽然以上两种材质的烧嘴砖强度高，能够承受乙烯裂解炉内天然气烧嘴的高温下的强力冲涮，但是重质浇注料也有很很多缺点，总结如下：
①容重大，一套重质烧嘴砖的重量为270～300kg/套，增加了炉衬承重压力，，尤其是顶烧部位的烧嘴砖，非常难锚固，需要托板、支撑板、护板，预计18kg/套。
②由于高重量，需要分片安装，吊装难度极大，并且需要最少3个人同时安装，安装空间狭小，操作难度很大。
③不耐热震，烧嘴很容易裂纹开裂，高密度材料易掉落，伤人。
④热导率高，导致炉外壁烧嘴部位温度高。
为解决上述问题，行业提倡采用全纤维烧嘴砖，其容重轻，70～100kg/套，安装便捷，只需要六个拐角角钢，预计3kg/套，两个人就能完成全部安装工作。热导率低，热震性好，节能，而且使用寿命长。但是，现有全纤维烧嘴砖还存在如下问题：坯体强度达不到烧嘴燃气高温冲刷要求、湿坯吸滤性差、使用寿命短等问题。
发明内容
有鉴于此，本发明的目的在于提供一种全纤维烧嘴砖及其制备方法。本发明提供的烧嘴砖能够提高强度和耐高温性，有利于提高使用寿命。
本发明提供了一种全纤维烧嘴砖，包括全纤维砖体和涂覆于所述全纤维砖体表面的涂层；
所述全纤维砖体由包括以下质量比的组分的原料制得：
所述氧化铝晶体纤维由不同长度纤维搭配组成，不同长度纤维在所述氧化铝晶体纤维中的质量比为：
0.01mm≤长度＜0.05mm 25％～35％；
0.05mm≤长度＜0.1mm 35％～45％；
0.1mm≤长度＜1mm 25％～35％；
所述非晶体陶瓷纤维由不同长度纤维搭配组成，不同长度纤维在所述非晶体陶瓷纤维中的质量比为：
0.01mm≤长度＜0.05mm 25％～35％；
0.05mm≤长度＜0.1mm 35％～45％；
0.1mm≤长度＜1mm 25％～35％。
优选的，所述细粉填料为氧化铝细粉；
所述细粉填料由不同粒度的颗粒组成，不同粒度的细粉填料在所述原料中的质量比为：
200～325目的填料 10％～20％；
1000目的填料 10％～30％。
优选的，所述无机结合剂为硅溶胶和/或铝溶胶；
所述有机结合剂为淀粉。
优选的，所述絮凝剂为聚合氯化铝；
所述全纤维砖体的厚度为250～550mm；
所述涂层的厚度为5～10mm。
优选的，所述涂层由包括以下质量比组分的涂料形成：
所述耐高温无机纤维的长度为0.01～1mm。
优选的，所述涂料中：
所述纳米粉选自纳米二氧化硅和纳米氧化铝粉中的一种或几种；
所述耐高温无机纤维选自高铝纤维、含锆纤维和氧化铝晶体纤维中的一种或几种。
优选的，所述涂料中：
所述增强填料选自针状微硅粉和叶腊石粉中的一种或几种；
所述高温膨胀填料选自蓝晶石粉和硅线石中的一种或几种；
所述骨架填料选自氧化铝粉、莫来石粉、锆英粉和刚玉粉中的一种或几种。
优选的，所述涂料中：
所述无机悬浮剂为膨润土；
所述无机结合剂选自铝溶胶、磷酸二氢铝和硅溶胶中的一种或几种；
所述有机添加剂选自有机结合剂、防腐剂和防冻剂中的一种或几种。
本发明还提供了一种上述技术方案中所述的全纤维烧嘴砖的制备方法，包括以下步骤：
a)将氧化铝晶体纤维、非晶体陶瓷纤维、无机结合剂、细粉填料、有机结合剂与水混合，得到浆料；
b)将所述浆料与絮凝剂混合后，进行真空吸滤和压制，得到湿坯；
c)将所述湿坯干燥，得到干坯；
d)对所述干坯的表面施加涂料、干燥，得到全纤维烧嘴砖。
优选的，所述步骤a)中，所述浆料的质量浓度为1％～15％；所述步骤c)中，所述压制为使坯体厚度达到250～550mm。
本发明提供了一种全纤维烧嘴砖，将氧化铝晶体纤维和非晶体陶瓷纤维混配，且二者均由一定的不同长度级配的纤维搭配，同时再添加不同粒度级配的细粉填料，辅以其它添加剂，能够使产品内部结构更均匀一致，提高产品容重，还有利于纤维棉坯的吸滤性，帮助成型及提高坯体强度。砖体表面再配以涂层，能够有效保护砖体纤维棉纤维不受恶劣环境的侵蚀，提高其耐高温性，有利于延长烧嘴砖的使用寿命。
实验结果表明，本发明提供的烧嘴砖的常温抗折强度达到1.1MPa以上，常温耐压强度达到0.6MPa以上，高温耐压强度达到0.7MPa以上，加热线变量绝对值在0.8％以下。
具体实施方式
本发明提供了一种全纤维烧嘴砖，包括全纤维砖体和涂覆于所述全纤维砖体表面的涂层；
所述全纤维砖体由包括以下质量比的组分制得：
所述氧化铝晶体纤维由不同长度纤维搭配组成，不同长度纤维在所述氧化铝晶体纤维中的质量比为：
0.01mm≤长度＜0.05mm 25％～35％；
0.05mm≤长度＜0.1mm 35％～45％；
0.1mm≤长度＜1mm 25％～35％；
所述非晶体陶瓷纤维由不同长度纤维搭配组成，不同长度纤维在所述非晶体陶瓷纤维中的质量比为：
0.01mm≤长度＜0.05mm 25％～35％；
0.05mm≤长度＜0.1mm 35％～45％；
0.1mm≤长度＜1mm 25％～35％。
本发明中，上述各组分的质量比之和优选为100％。
本发明将氧化铝晶体纤维和非晶体陶瓷纤维混配，且二者均由一定的不同长度级配的纤维搭配，同时再添加不同粒度级配的细粉填料，辅以其它添加剂，能够使产品内部结构更均匀一致，提高产品容重，还有利于纤维棉坯的吸滤性，帮助成型及提高坯体强度。砖体表面再配以涂层，能够有效保护砖体纤维棉纤维不受恶劣环境的侵蚀，提高其耐高温性，大大延长烧嘴砖的使用寿命。
关于烧嘴砖的全纤维砖体：
本发明中，预先将氧化铝晶体纤维原料加工至特定长度，并将不同长度的纤维进行搭配。即所述氧化铝晶体纤维由不同长度纤维搭配组成，不同长度纤维在所述氧化铝晶体纤维中的质量比为：
0.01mm≤长度＜0.05mm 25％～35％；
0.05mm≤长度＜0.1mm 35％～45％；
0.1mm≤长度＜1mm 25％～35％。
在本发明的一些实施例中，所述氧化铝晶体纤维的搭配如下：
0.01mm≤长度＜0.05mm 30％；
0.05mm≤长度＜0.1mm 40％；
0.1mm≤长度＜1mm 30％。
本发明中，所述氧化铝晶体纤维优选为72氧化铝晶体纤维、80氧化铝晶体纤维和95氧化铝晶体纤维中的一种或几种。本发明中，所述氧化铝晶体纤维在原料中的质量比为20％～50％；在本发明的一些实施例中，所述质量比为20％、25％或30％。
本发明中，预先将非晶体陶瓷纤维原料加工至特定长度，并将不同长度的纤维进行搭配。即所述非晶体陶瓷纤维由不同长度纤维搭配组成，不同长度纤维在所述非晶体陶瓷纤维中的质量比为：
0.01mm≤长度＜0.05mm 25％～35％；
0.05mm≤长度＜0.1mm 35％～45％；
0.1mm≤长度＜1mm 25％～35％。
在本发明的一些实施例中，所述非晶体陶瓷纤维的搭配如下：
0.01mm≤长度＜0.05mm 30％；
0.05mm≤长度＜0.1mm 40％；
0.1mm≤长度＜1mm 30％。
本发明中，所述非晶体陶瓷纤维的原料优选为高铝喷吹纤维棉，即将高铝喷吹纤维棉加工成不同长度的纤维进行搭配。本发明中，所述非晶体陶瓷纤维在原料中的质量比为5％～20％；在本发明的一些实施例中，所述质量比为5％、10％或20％。
本发明中，所述细粉填料优选为氧化铝细粉。本发明中，所述细粉填料在所述全纤维砖体的原料中的质量比为20％～50％；在本发明的一些实施例中，所述质量比为20％或25％。
本发明中，所述细粉填料由不同粒度的颗粒组成，不同粒度的细粉填料在所述全纤维砖体的原料中的质量比优选为：
200～325目的填料 10％～20％；
1000目的填料 10％～30％。
本发明中，所述无机结合剂优选为硅溶胶和/或铝溶胶。本发明中，所述无机结合剂在所述全纤维砖体的原料中的质量比为30％～50％；在本发明的一些实施例中，所述质量比为30％、35％或40％。
本发明中，所述有机结合剂优选为淀粉。本发明中，所述淀粉在所述全纤维砖体的原料中的质量比为5％～15％；在本发明的一些实施例中，所述质量比为5％、6％、7％或8％。
本发明中，所述絮凝剂优选为聚合氯化铝。本发明中，所述絮凝剂在所述全纤维砖体的原料中的质量比为1％～5％；在本发明的一些实施例中，所述质量比为2％、3％、4％或5％。
关于烧嘴砖的表面涂层：
本发明提供的全纤维烧嘴砖，除全纤维砖体外，其表面还涂覆有涂层。本发明中，所述涂层由包括以下质量比组分的涂料形成：
所述耐高温无机纤维的长度为0.01～1mm。
本发明提供的高温纳米复合涂料，对纤维预处理控制纤维长度，引入高温增强填料、高温膨胀填料、纳米粉、无机悬浮剂、及其它添加剂，通过这些改进，得到的高温纳米复合结构涂料具有以下特点：①高温下具有超高强度和密实度，收缩小，高温下不会产生裂纹，能够抵御石化行业裂解炉超强的气流冲刷和气氛的侵蚀；②纳米粉的引入，使得涂料的粒度级配更丰富，喷施到纤维炉衬表面时渗透性更强，从而达到与纤维炉衬结合更牢固的目的；③通过对纤维长度及粉料粒度的级配控制，引入无机悬浮剂及其它添加剂，使涂料状态均匀稳定，细腻柔滑，挤压能达到类似牙膏的浆体流动状态，放置过程不会出现沉淀分层，可实现小包装方式，在纤维模块打孔底部锚固生根时能形成倒锤形；④涂料渗透性好，喷涂后与炉衬的结合性好，特殊的锚固生根性能，使涂料与炉衬结合双重牢固，有效的抵抗气流冲刷，延长炉衬使用寿命。
本发明中，所述耐高温无机纤维的原料优选为高铝纤维、含锆纤维和氧化铝晶体纤维中的一种或几种。其中，所述氧化铝晶体纤维优选为72氧化铝晶体纤维、80氧化铝晶体纤维和95氧化铝晶体纤维中的一种或几种。
本发明中，所述耐高温无机纤维为二次加工纤维，本发明通过加工处理控制纤维的长度。本发明中，所得耐高温无机纤维的长度为0.01～1mm；所述耐高温无机纤维的直径优选为1～6um。
本发明中，所述耐高温无机纤维在涂料中的质量百分比为10％～50％，优选为15％～30％；在本发明的一些实施例中，所述质量比为15％、20％、25％或30％。
本发明中，所述增强填料为耐高温增强填料，优选为针状微硅粉和叶腊石粉中的一种或几种。其中，所述针状微硅粉的长径比优选为(15～20)∶1。所述叶腊石粉的粒度优选为200～300目。本发明对所述高温增强填料的来源没有特殊限制，为一般市售品即可。
本发明中，所述增强填料在涂料中的质量百分比为10％～20％；在本发明的一些实施例中，所述质量比为10％、13％、15％或20％。
本发明中，所述高温膨胀填料优选为蓝晶石粉和硅线石中的一种或几种。本发明对所述高温膨胀填料的来源没有特殊限制，为一般市售品即可。本发明中，所述高温膨胀填料在涂料中的质量百分比为5％～15％；在本发明的一些实施例中，所述质量比为5％、8％或12％。
本发明中，所述骨架填料为耐高温骨架填料，优选为氧化铝粉、莫来石粉、锆英粉和刚玉粉中的一种或几种。本发明中，所述骨架填料的粒度优选为300～1000目。本发明对所述骨架填料的来源没有特殊限制，为一般市售品即可。
本发明中，所述骨架填料在涂料中的质量百分比为7％～30％；在本发明的一些实施例中，所述质量比为7％、10％或15％。
本发明中，所述纳米粉优选为纳米二氧化硅和纳米氧化铝粉中的一种或几种。本发明中，所述纳米粉的粒度优选为1～100nm。本发明对所述纳米粉的来源没有特殊限制，为一般市售品即可。
本发明中，所述纳米粉在涂料中的质量百分比为3％～10％；在本发明的一些实施例中，所述质量比为3％、5％或8％。
本发明中，所述无机悬浮剂优选为膨润土。本发明中，所述无机悬浮剂在涂料中的质量百分比为0％～20％；在本发明的一些实施例中，所述质量比为0％或5％。
本发明中，所述无机结合剂优选为铝溶胶、磷酸二氢铝和硅溶胶中的一种或几种。本发明中，所述无机结合剂在涂料中的质量百分比为10％～50％；在本发明的一些实施例中，所述质量比为25％、37％、40％或41％。
本发明中，所述有机添加剂优选为有机结合剂、防腐剂和防冻剂中的一种或几种；更优选为有机结合剂、防腐剂和防冻剂。其中，所述有机结合剂优选为淀粉、糊精和纤维素中的一种或几种。所述防腐剂优选为百杀得。所述防冻剂优选为乙二醇。
本发明中，所述有机添加剂在涂料中的质量百分比为3％～15％；在本发明的一些实施例中，所述质量比为3％或5％。
本发明中，上述耐高温无机纤维、增强填料、高温膨胀填料、骨架填料、纳米粉、无机悬浮剂、无机结合剂和有机添加剂的质量和优选为100％。除上述组分外，涂料体系还包括水；本发明中，所述水的用量为除水之外上述所有组分用量和的10％～50％；在本发明的一些实施例中，所述水的用量为15％、25％、30％或35％。
本发明提供的高温纳米复合涂料，采用特定长度的纤维，并引入特定增强填料和高温膨胀填料，使其在高温下既有超高强度又不会高温收缩而产生裂纹，同时引入一定的骨架填料和纳米结构的材料，上述材料之间协同作用，使涂料状态均匀稳定，放置过程中不会出现沉淀分层；高温使用过程中，与炉衬结合牢固，高温收缩小，并具有超高强度的硬壳屏障；高温烧后收缩小，不裂纹，与炉衬结合牢固，高温烧后强度大，其作用是能有效地抵挡底烧、侧烧和顶烧的气流冲涮和气氛侵蚀，从而保护纤维模块，使其不会受外部环境侵蚀而粉化变脆，还会阻挡窑炉在高温运行过程中的热量散失，从而实现延长炉衬使用寿命，降低炉外壁温度，达到节能降耗的目的。本发明提供的高温纳米复合涂料能够作为乙烯裂解炉全纤维结构专用涂料，具有超高强度，与纤维炉衬上牢固结合性，以及特殊的锚固状态，从而实现施工便捷性和全纤维结构替代砖墙的应用中起到关键性的作用。
本发明中，上述涂料可通过以下方法制得：
S1、将耐高温无机纤维、无机结合剂和水混合，得到纤维分散液；
S2、将所述纤维分散液与高温膨胀填料、增强填料及骨架填料混合，得到浆料；
S3、将所述浆料与纳米粉、无机悬浮剂和有机添加剂混合，得到涂料。
其中，步骤S1中，所述混合优选为搅拌混合；所述搅拌的时间优选为10～30min。所述步骤S2中，所述混合优选为搅拌混合；所述搅拌的时间优选为3～5min。所述步骤S3中，混料顺序优选为：向浆料中先加入纳米粉，搅拌混合3～5min；再加入无机悬浮剂，搅拌混合5～10min；最后加入有机添加剂搅拌混合10～20min，得到涂料。
本发明提供的全纤维烧嘴砖中，全纤维砖体的厚度优选为250～550mm；涂层的厚度优选为5～10mm。本发明中，所述涂层是涂在全纤维砖体的所有外表面上。
本发明还提供了一种上述技术方案中所述的全纤维烧嘴砖的制备方法，包括以下步骤：
a)将氧化铝晶体纤维、非晶体陶瓷纤维、无机结合剂、细粉填料、有机结合剂与水混合，得到浆料；
b)将所述浆料与絮凝剂混合后，进行真空吸滤和压制，得到湿坯；
c)将所述湿坯干燥，得到干坯；
d)对所述干坯的表面施加涂料、干燥，得到全纤维烧嘴砖。
关于步骤a)：
本发明首先将纤维在和毛机上进行预加工，控制纤维长度，再将纤维按不同长度进行一定的搭配，投入原料中使用。其中，氧化铝晶体纤维和非晶体陶瓷纤维的种类、长度及不同长度纤维的配比等均与上述技术方案中所述一致，在此不再赘述。其中，无机结合剂和细粉填料的种类及用量等均与上述技术方案中所述一致，在此不再赘述。
由于烧嘴砖的体积比较大，成型厚度在450mm以上，吸到一半厚，就很难再增加吸滤厚度，所以正常的吸滤很难达到效果；本发明对纤维长度和粉料力度进行了级配调整，增加了棉浆的吸滤性，在纤维湿法成型前，先进性预加工，将其加工到指定的长度范围，控制了纤维长度，使纤维长度有了特定的级配，解决了纤维长度在水中搅拌不好控制纤维长度，导致棉浆过细不好吸滤，过粗棉坯容重太小，使得成型过程中吸滤不均匀、棉坯内部结构不均匀的问题；控制了粉料填料的颗粒级配，也是有助于棉坯湿坯吸滤时好成型。
本发明中，将上述物料混合时，混料顺序优选为：将氧化铝晶体纤维、非晶体陶瓷纤维、无机结合剂、细粉填料和有机结合剂按比例依次加入水中混合均匀。本发明对混合的方式没有特殊限制，为本领域技术人员熟知的常规混料方式将物料混匀即可。本发明中，优选控制混合所得浆料的质量浓度为1％～15％。
关于步骤b)：
本发明中，将步骤a)所得浆料与絮凝剂混合，进行助滤。浆料中加入絮凝剂后，使纤维、细粉填料和无机结合剂絮凝到一起，使水变清澈。本发明中，加入絮凝剂进行絮凝的温度优选为5～40℃，时间优选为1～5min。将絮凝好的浆料放到成型池，然后进行真空吸滤，将多余液体去除。经上述吸滤成型后，得到湿坯。本发明在上述吸滤成型中，与现有技术有所区别，成型模具有改变，传统成型方式只能从上方进料成型，本发明还增加了侧吸，使得产品的坯体更均匀、密实。
本发明中，在成型过程中增加压制工序，增加成型模具的厚度，棉浆填满成型模具后，在最后吸干的过程中，增加压制工艺，一边吸滤一边压制，使得湿坯更密实、均匀，保证了棉坯的容重和强度。
关于步骤c)：
本发明中，所述干燥的温度优选为80～120℃，所述干燥的时间优选为30～120h。经干燥后，得到干坯。
关于步骤d)：
本发明中，所述施加涂料的方式优选为：先在所述干坯表面打孔，向孔中打胶进行涂料生根，再向干坯整个表面涂覆涂料。本发明对打孔和涂料生根的操作没有特殊限制，按照本领域常规操作进行即可。以矩形烧嘴砖(长500mm×宽500mm×高320mm)为例，其包括上下左右前后六个表面，打孔可具体在迎火和侧壁表面，沿着迎火面和侧壁表面垂直方向进行打孔，从迎火面的边缘起，50mm见方的地方开始打孔，每隔80mm打一个孔，每行5个，打5行，共打35个孔，侧壁也用该方法进行打孔，每个侧面大约打24个孔，共四个侧面，沿砖体均匀分布。打孔直径为10mm，打孔深度为20～50mm。经打孔后，向孔内打胶、进行涂料生根。所述涂料为上述技术方案中所述的涂料，在此不再赘述。之后，向干坯表面涂覆涂料并干燥，形成涂层。本发明中，所述干燥的温度优选为80～120℃，所述干燥的时间优选为10～48h；所形成的涂层的厚度优选为5～10mm。经上述处理，得到全纤维烧嘴砖。
传统的高温全纤维异形件产品都是用表面淋无机结合剂的表面施胶来增加棉坯的强度，并不能从根本上保护棉坯纤维不受恶劣环境的侵蚀，而表面涂涂料从根本上隔绝了外部恶劣环境与全纤维坯体的接触，从而大大延长了烧嘴砖的使用寿命。
本发明提供的全纤维烧嘴砖具有以下有益效果：砖体材料搭配能够提高产品容重及改善纤维棉坯的吸滤性，帮助成型及提高坯体强度。砖体表面再配以涂层，能够有效保护砖体纤维棉纤维不受恶劣环境的侵蚀，提高其耐高温性，作为乙烯裂解炉用烧嘴砖有利于延长烧嘴砖的使用寿命。
为了进一步理解本发明，下面结合实施例对本发明优选实施方案进行描述，但是应当理解，这些描述只是为进一步说明本发明的特征和优点，而不是对本发明权利要求的限制。
实施例1
1.1砖体原料配方
其中：
氧化铝晶体纤维的长度搭配为：0.01～0.05mm 30％，0.05～0.1mm 40％，0.1～1mm 30％。
非晶体陶瓷纤维高铝喷吹纤维，长度搭配为：0.01～0.05mm 30％，0.05～0.1mm40％，0.1～1mm 30％。
细粉填料为氧化铝细粉，粒度搭配为：200～325目10％，1000目10％。
1.2涂料配方
其中，耐高温无机纤维的原料纤维为高铝纤维，加工成短纤维，所得纤维的长度为0.01～1mm，直径为1～5um。
涂料制备：
秤取耐高温无机纤维加入搅拌机内，秤量无机结合剂和水加入，搅拌20min，使纤维充分润湿分散；再依次加入高温膨胀填料、增强填料、骨架填料，加完后搅拌5min，使其充分分散；再加入纳米粉，搅拌5min；加入无机悬浮剂，搅拌10min，使其充分膨胀，起到悬浮作用；最后加入有机添加剂，搅拌20min；得到涂料。
1.3烧嘴砖制备
S1、将一定长度级配的氧化铝晶体纤维、非晶体陶瓷纤维、无机结合剂、细粉填料和有机结合剂按比例依次加入水中混合均匀，得到质量浓度为5％的浆料。
S2、向浆料中加入絮凝剂，使其它材料絮凝，水变清澈，得到絮凝料。
S3、将絮凝料放入成型池中，进行真空吸滤，成型后将湿坯压制到厚度为350mm，输送至干燥室进行干燥，干燥温度为120℃，时间为120h，得到干坯。
S4、将干坯进行切割，使尺寸和外观规整，得到长490mm×宽480mm×高310mm的干坯。
S5、在干坯表面施加涂料，具体步骤如下：干坯表面大孔→涂料生根→干坯表面涂涂料→烘干。其中，打孔直径为10mm，深度为30mm。涂料涂覆厚度为10mm；烘干温度为120℃，时间为24h。经上述处理，得到烧嘴砖。
实施例2
1.1砖体原料配方
其中：
氧化铝晶体纤维的长度搭配为：0.01～0.05mm 30％，0.05～0.1mm 40％，0.1～1mm 30％。
非晶体陶瓷纤维高铝喷吹纤维，长度搭配为：0.01～0.05mm 30％，0.05～0.1mm40％，0.1～1mm 30％。
细粉填料为氧化铝细粉，粒度搭配为：200～325目15％，1000目10％。
1.2涂料配方
其中，耐高温无机纤维的原料纤维为含锆纤维，加工成短纤维，所得纤维的长度为0.01～1mm，直径为2～6um。
涂料制备：同实施例1。
1.3烧嘴砖制备：同实施例1。
实施例3
1.1砖体原料配方
其中：
氧化铝晶体纤维的长度搭配为：0.01～0.05mm 30％，0.05～0.1mm 40％，0.1～1mm 30％。
非晶体陶瓷纤维高铝喷吹纤维，长度搭配为：0.01～0.05mm 30％，0.05～0.1mm40％，0.1～1mm 30％。
细粉填料为氧化铝细粉，粒度搭配为：200～325目10％，1000目10％。
1.2涂料配方
其中，耐高温无机纤维的原料纤维为72氧化铝晶体纤维，加工成短纤维，所得纤维的长度为0.01～1mm，直径为3～6um。
涂料制备：同实施例1。
1.3烧嘴砖制备：同实施例1。
实施例4
1.1砖体原料配方
其中：
氧化铝晶体纤维的长度搭配为：0.01～0.05mm 30％，0.05～0.1mm 40％，0.1～1mm 30％。
非晶体陶瓷纤维高铝喷吹纤维，长度搭配为：0.01～0.05mm 30％，0.05～0.1mm40％，0.1～1mm 30％。
细粉填料为氧化铝细粉，粒度搭配为：200～325目10％，1000目10％。
1.2涂料配方
其中，耐高温无机纤维的原料纤维为95氧化铝晶体纤维，加工成短纤维，所得纤维的长度为0.01～1mm，直径为3～6um。
涂料制备：同实施例1。
1.3烧嘴砖制备：同实施例1。
实施例5
对实施例1～4所得烧嘴砖的性能进行检测，并将现有技术中的全纤维烧嘴砖产品(由奇耐联合纤维公司提供)作为对照样进行性能对比，结果参见表1：
表1实施例1-4的烧嘴砖性能
由以上测试结果可知，与现有全纤维烧嘴砖相比，本发明提供的烧嘴砖能够明显提高常温抗折强度、耐压强度、高温耐压强度及降低加热线变，大大提升烧嘴砖性能。
以上实施例的说明只是用于帮助理解本发明的方法及其核心思想。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (10)
1.一种全纤维烧嘴砖，其特征在于，包括全纤维砖体和涂覆于所述全纤维砖体表面的涂层；
所述全纤维砖体由包括以下质量比的组分的原料制得：
所述氧化铝晶体纤维由不同长度纤维搭配组成，不同长度纤维在所述氧化铝晶体纤维中的质量比为：
0.01mm≤长度＜0.05mm 25％～35％；
0.05mm≤长度＜0.1mm 35％～45％；
0.1mm≤长度＜1mm 25％～35％；
所述非晶体陶瓷纤维由不同长度纤维搭配组成，不同长度纤维在所述非晶体陶瓷纤维中的质量比为：
0.01mm≤长度＜0.05mm 25％～35％；
0.05mm≤长度＜0.1mm 35％～45％；
0.1mm≤长度＜1mm 25％～35％。
2.根据权利要求1所述的烧嘴砖，其特征在于，所述细粉填料为氧化铝细粉；
所述细粉填料由不同粒度的颗粒组成，不同粒度的细粉填料在所述原料中的质量比为：
200～325目的填料 10％～20％；
1000目的填料 10％～30％。
3.根据权利要求1所述的烧嘴砖，其特征在于，所述无机结合剂为硅溶胶和/或铝溶胶；
所述有机结合剂为淀粉。
4.根据权利要求1所述的烧嘴砖，其特征在于，所述絮凝剂为聚合氯化铝；
所述全纤维砖体的厚度为250～550mm；
所述涂层的厚度为5～10mm。
5.根据权利要求1所述的烧嘴砖，其特征在于，所述涂层由包括以下质量比组分的涂料形成：
所述耐高温无机纤维的长度为0.01～1mm。
6.根据权利要求5所述的烧嘴砖，其特征在于，所述涂料中：
所述纳米粉选自纳米二氧化硅和纳米氧化铝粉中的一种或几种；
所述耐高温无机纤维选自高铝纤维、含锆纤维和氧化铝晶体纤维中的一种或几种。
7.根据权利要求5所述的烧嘴砖，其特征在于，所述涂料中：
所述增强填料选自针状微硅粉和叶腊石粉中的一种或几种；
所述高温膨胀填料选自蓝晶石粉和硅线石中的一种或几种；
所述骨架填料选自氧化铝粉、莫来石粉、锆英粉和刚玉粉中的一种或几种。
8.根据权利要求5所述的烧嘴砖，其特征在于，所述涂料中：
所述无机悬浮剂为膨润土；
所述无机结合剂选自铝溶胶、磷酸二氢铝和硅溶胶中的一种或几种；
所述有机添加剂选自有机结合剂、防腐剂和防冻剂中的一种或几种。
9.一种权利要求1～8中任一项所述的全纤维烧嘴砖的制备方法，其特征在于，包括以下步骤：
a)将氧化铝晶体纤维、非晶体陶瓷纤维、无机结合剂、细粉填料、有机结合剂与水混合，得到浆料；
b)将所述浆料与絮凝剂混合后，进行真空吸滤和压制，得到湿坯；
c)将所述湿坯干燥，得到干坯；
d)对所述干坯的表面施加涂料、干燥，得到全纤维烧嘴砖。
10.根据权利要求9所述的制备方法，其特征在于，所述步骤a)中，所述浆料的质量浓度为1％～15％；
所述步骤c)中，所述压制为使坯体厚度达到250～550mm。
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| MYPI2022002501A MY197979A (en) | 2020-11-10 | 2021-11-09 | Full-fiber burner brick and preparation method thereof |
| JP2022527213A JP7381744B2 (ja) | 2020-11-10 | 2021-11-09 | 全繊維バーナタイル、及びその製造方法 |
| US17/780,561 US20220411329A1 (en) | 2020-11-10 | 2021-11-09 | Full-fiber burner brick and preparation method thereof |
| KR1020227017156A KR102612770B1 (ko) | 2020-11-10 | 2021-11-09 | 전섬유 버너 벽돌 및 이의 제조방법 |
| EP21870522.6A EP4026818B1 (en) | 2020-11-10 | 2021-11-09 | Full-fiber burner tile and manufacturing method therefor |
| PCT/CN2021/129448 WO2022100560A1 (zh) | 2020-11-10 | 2021-11-09 | 一种全纤维烧嘴砖及其制备方法 |
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| WO2022100560A1 (zh) * | 2020-11-10 | 2022-05-19 | 山东鲁阳节能材料股份有限公司 | 一种全纤维烧嘴砖及其制备方法 |
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| CN112280343B (zh) * | 2020-11-10 | 2022-07-19 | 山东鲁阳节能材料股份有限公司 | 一种高温纳米复合涂料及其制备方法，以及小袋软包装涂料 |
| CN115231936B (zh) * | 2022-07-12 | 2023-11-17 | 山东工业陶瓷研究设计院有限公司 | 一种复合隔热材料及其制备方法 |
| CN117303919B (zh) * | 2023-10-19 | 2024-03-08 | 郑州金河源耐火材料有限公司 | 一种免烧铬刚玉耐火砖及其制备方法 |
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- 2021-11-09 WO PCT/CN2021/129448 patent/WO2022100560A1/zh active Application Filing
- 2021-11-09 MY MYPI2022002501A patent/MY197979A/en unknown
- 2021-11-09 KR KR1020227017156A patent/KR102612770B1/ko active IP Right Grant
- 2021-11-09 EP EP21870522.6A patent/EP4026818B1/en active Active
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| JP7381744B2 (ja) | 2023-11-15 |
| KR20220090546A (ko) | 2022-06-29 |
| EP4026818B1 (en) | 2024-07-03 |
| CN112321311B (zh) | 2022-08-16 |
| EP4026818A4 (en) | 2023-01-25 |
| KR102612770B1 (ko) | 2023-12-13 |
| JP2023506376A (ja) | 2023-02-16 |
| WO2022100560A1 (zh) | 2022-05-19 |
| EP4026818A1 (en) | 2022-07-13 |
| MY197979A (en) | 2023-07-25 |
| US20220411329A1 (en) | 2022-12-29 |
| EP4026818C0 (en) | 2024-07-03 |
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