CN112341221A - Re-sintered electric-melting mullite brick and preparation method and application thereof - Google Patents
Re-sintered electric-melting mullite brick and preparation method and application thereof Download PDFInfo
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Abstract
The invention discloses a re-sintered electric cast mullite brick and a preparation method and application thereof, and the re-sintered electric cast mullite brick comprises the following raw materials in percentage by weight: 20-40% of crude fused mullite, 8-35% of middle fused mullite, 8-35% of fine fused mullite, 3-35% of fused mullite ball powder, 1.5-20% of fused mullite micropowder, 0-6% of alpha alumina micropowder, 0-8% of kaolin, 1-2% of solid bonding agent and 1-2% of liquid bonding agent, and the re-sintered fused mullite brick has small porosity and good quality, can prolong the service life of the brick, and has low creep rate at high temperature.
Description
Technical Field
The invention relates to the technical field of refractory materials, in particular to a re-sintered electric-melting mullite brick and a preparation method and application thereof.
Background
Mullite is a high-quality refractory material and has the characteristics of uniform expansion, excellent thermal shock stability, high refractoriness under load, small high-temperature creep value, high hardness, excellent chemical corrosion resistance and the like. The method can be divided into two types of sintered mullite bricks and fused mullite bricks according to the synthesis method. Compared with sintered mullite, the fused mullite has perfect crystal growth, large crystal grains, few defects and hundreds of times of crystal size of the sintered mullite, so the high-temperature mechanical property and the erosion resistance are better. The electric melting mullite brick is mainly applied to the upper structure of a thermotechnical kiln and parts with large thermal stress, such as an E-glass, borosilicate glass melting kiln breast wall, an arch crown, an arch foot brick and the like.
The porosity is one of the indexes of the service life of the refractory brick, and a small porosity indicates a high degree of densification, good quality and a long service life of the refractory brick. However, the traditional electrofused mullite generally has the problem of overhigh porosity, and the further application of the mullite is limited.
Disclosure of Invention
Based on the above, there is a need for a re-sintered mullite brick with reduced porosity, and a preparation method and applications thereof.
The re-sintered electrically-fused mullite brick comprises the following raw materials in percentage by weight:
the grain size specification of the crude material of the electric cast mullite is 3 mm-5 mm, the grain size specification of the medium material of the electric cast mullite is 1 mm-3 mm, the grain size specification of the fine material of the electric cast mullite is less than 1mm, the grain size specification of the ball powder of the electric cast mullite is D50 ═ 15 +/-2 mu m, the grain size specification of the micro powder of the electric cast mullite is D50 ═ 5 +/-1 mu m, the grain size specification of the alpha alumina micro powder is D50 ═ 2 +/-1 mu m, and the grain size specification of the kaolin is D50 ═ 5 +/-1 mu m.
In one embodiment, the composition comprises the following raw materials in percentage by weight:
in one embodiment, the chemical composition of the electrofused mullite is as follows: al (Al)2O375-77% of SiO222 to 24 percent of Fe2O3Mass fraction of not more than 0.1 percent, TiO2The mass fraction is less than or equal to 0.1 percent, and Na2O and K2The total mass fraction of O is less than or equal to 0.25 percent.
In one embodiment, the chemical composition of the alpha alumina micropowder is required to be as follows: al (Al)2O3With a mass fraction of > 98.5%, SiO2Is less than 0.1 percent, Fe2O3The mass fraction is less than or equal to 0.2 percent, and Na2O and K2The total mass fraction of O is less than or equal to 0.35 percent.
In one embodiment, the chemical composition of the kaolin is as follows: al (Al)2O3The mass fraction of the Fe content is more than or equal to 35 percent, and the Fe content is2O3Mass fraction of TiO is less than or equal to 1 percent2The mass fraction is less than or equal to 0.5 percent, and Na2O and K2The total mass fraction of O is less than or equal to 1 percent, and the total mass fraction of CaO and MgO is less than or equal to 0.3 percent.
In one embodiment, the solid bonding agent is peach gum powder, the liquid bonding agent is peach gum, and the peach gum is composed of the peach gum powder and water in a mass ratio of 1: 3.
The invention also provides a preparation method of the re-sintered mullite brick, which comprises the following steps:
s1, mixing the fused mullite ball powder, the fused mullite micro powder, the alpha alumina micro powder, the kaolin and the peach gum powder in a conical mixer for 1.5-2.5 hours to obtain mixed powder;
s2, sequentially putting the fused mullite coarse material, the fused mullite coarse material and the fused mullite coarse material into an inclined mixer, adding the peach gum water, putting the mixed powder after 1-2 min, and sealing and ageing after mixing for about 5-8 min to obtain a mixed material;
s3, placing the mixture in a friction press machine for molding to obtain a molding material;
and S4, placing the molding material in a tunnel kiln to be sintered, and preserving heat for 10-12 h.
In one embodiment, the mass fraction of the water in the molding material is 1-1.5%, and the time for bagging and ageing is 12-24 h.
In one embodiment, the firing temperature is 1700 ℃ to 1710 ℃.
The invention also provides a refractory material which comprises the re-sintered electric-melting mullite brick.
The research on the selection and the content of the raw materials of the electric-melting mullite with different grain diameters reduces the content of the raw material of the kaolin or does not add the kaolin so as to optimize the grain size distribution of the raw materials and combine the sintering process, and finally the high-purity re-sintered electric-melting mullite brick with low porosity and high density is obtained, and the electric-melting mullite brick has lower creep rate at high temperature.
Detailed Description
The present invention may be embodied in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Of course, they are merely examples and are not intended to limit the present invention. Furthermore, the present invention may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the invention, "a plurality" means at least two, e.g., two, three, etc., unless explicitly specified otherwise. In the description of the present invention, "a plurality" means at least one, e.g., one, two, etc., unless specifically limited otherwise.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
The invention provides a re-sintered electric cast mullite brick, which comprises the following raw materials in percentage by weight: 20 to 40 percent of fused mullite coarse material, 8 to 35 percent of fused mullite middle material, 8 to 35 percent of fused mullite fine material, 3 to 35 percent of fused mullite ball powder, 1.5 to 20 percent of fused mullite micro powder, 0 to 6 percent of alpha alumina micro powder, 0 to 8 percent of kaolin, 1 to 2 percent of solid bonding agent and 1 to 2 percent of liquid bonding agent.
Furthermore, the grain size specification of the crude material of the fused mullite is 3 mm-5 mm, the grain size specification of the medium material of the fused mullite is 1 mm-3 mm, the grain size specification of the fine material of the fused mullite is less than 1mm, the grain size specification of the ball powder of the fused mullite is D50 ═ 15 +/-2 mu m, the grain size specification of the micro powder of the fused mullite is D50 ═ 5 +/-1 mu m, the grain size specification of the micro powder of the alpha alumina is D50 ═ 2 +/-1 mu m, and the grain size specification of the kaolin is D50 ═ 5 +/-1 mu m.
Specifically, the re-sintered mullite brick comprises the following raw materials in percentage by weight: 25 to 35 percent of fused mullite coarse material, 11 to 31 percent of fused mullite middle material, 11 to 26 percent of fused mullite fine material, 5 to 20 percent of fused mullite ball powder, 6.5 to 16.5 percent of fused mullite micro powder, 0 to 6 percent of alpha alumina micro powder, 0 to 4 percent of kaolin, 1.2 to 1.6 percent of solid bonding agent and 1.2 to 1.6 percent of liquid bonding agent.
In a specific embodiment, the chemical composition of the electrofused mullite is as follows: al (Al)2O375-77% of SiO222 to 24 percent of Fe2O3Mass fraction of not more than 0.1 percent, TiO2The mass fraction is less than or equal to 0.1 percent, and Na2O and K2The total mass fraction of O is less than or equal to 0.25 percent.
In a specific embodiment, αThe chemical composition requirements of the alumina micro powder are as follows: al (Al)2O3With a mass fraction of > 98.5%, SiO2Is less than 0.1 percent, Fe2O3The mass fraction is less than or equal to 0.2 percent, and Na2O and K2The total mass fraction of O is less than or equal to 0.35 percent.
In one particular example, the chemical composition of the kaolin is required to be as follows: al (Al)2O3The mass fraction of the Fe content is more than or equal to 35 percent, and the Fe content is2O3Mass fraction of TiO is less than or equal to 1 percent2The mass fraction is less than or equal to 0.5 percent, and Na2O and K2The total mass fraction of O is less than or equal to 1 percent, and the total mass fraction of CaO and MgO is less than or equal to 0.3 percent.
In a specific embodiment, the solid binder is peach gum powder, the liquid binder is peach gum powder, and specifically, the peach gum powder is composed of peach gum powder and water in a mass ratio of 1: 3.
The invention also provides a preparation method of the re-sintered electric cast mullite brick, which comprises the following steps of S1-S4.
Step S1: and mixing the fused mullite sphere powder, the fused mullite micropowder, the alpha alumina micropowder, the kaolin and the peach gum powder in a conical mixer for 1.5 to 2.5 hours to obtain mixed powder.
Specifically, the above-mentioned mixing time in the conical mixer may be, for example, 1.5h, 1.8h, 2h, 2.2h, or 2.5 h.
Step S2: putting the fused mullite coarse material, the fused mullite coarse material and the fused mullite coarse material into an inclined mixer in sequence, adding peach glue, putting the mixed powder after 1-2 min, mixing for about 5-8 min, and sealing the bag for ageing to obtain a mixture.
Specifically, the mixing time may be, for example, 5min, 6min, 7min, or 8 min.
In a specific embodiment, the mass fraction of the water in the molding material is 1.0-1.5%, and the time for bagging and ageing is 12-24 h.
Step S3: and (3) placing the mixture into a friction press for molding to obtain a molding material.
Step S4: and (3) placing the molding material into a tunnel kiln for sintering, and keeping the temperature for 10-12 h.
In a specific example, the firing temperature in step S4 is 1700 ℃ to 1710 ℃, and specifically, the firing temperature may be 1700 ℃, 1701 ℃, 1702 ℃, 1703 ℃, 1704 ℃, 1705 ℃, 1706 ℃, 1707 ℃, 1708 ℃, 1709 ℃ or 1710 ℃, for example.
Further, the holding time may be, for example, 10 hours, 10.5 hours, 11 hours, 11.5 hours, or 12 hours.
According to the invention, by researching the selection and content of the raw materials of the fused mullite with different grain diameters and optimizing the grain size distribution of the raw materials in combination with the sintering process, the high-purity re-sintered fused mullite brick with low porosity and high density is finally obtained, and the fused mullite brick has lower creep rate at high temperature.
The concrete examples provided below are intended to explain in further detail the re-sintered electrically fused mullite brick of the present invention and the process for producing the same. Unless otherwise specified, each raw material and equipment in the following examples are commercially available. The crude materials, the medium materials, the fine materials, the ball powders and the micro powders of the electric-melting mullite are purchased from special high-new resistant materials, Inc. in the great wall of Henan, and the micro powders of the alpha alumina are purchased from the Anmai aluminum industry (Qingdao), Inc.
Example 1
This example provides a re-sintered fused mullite brick having the raw material powder ratios as shown in table 1.
And mixing the fused mullite sphere powder, the fused mullite micropowder, the alpha alumina micropowder, the kaolin and the peach gum powder in a conical mixer for 2 hours to obtain mixed powder.
And sequentially feeding the fused mullite coarse material, the fused mullite coarse material and the fused mullite coarse material into an inclined mixer, adding peach glue, feeding the mixed powder after 2min, mixing for about 5min, sealing and ageing, and keeping the time for sealing and ageing for 12h to obtain the mixture.
And (3) placing the mixture into a friction press for molding to obtain a molding material, wherein the mass fraction of water in the molding material is 1.13%.
And sintering the molding material in a tunnel kiln at the sintering temperature of 1700 ℃, and preserving heat for 10 hours.
Example 2
This example provides a re-sintered fused mullite brick having the raw material powder ratios as shown in table 1.
And mixing the fused mullite sphere powder, the fused mullite micropowder, the alpha alumina micropowder, the kaolin and the peach gum powder in a conical mixer for 2 hours to obtain mixed powder.
And sequentially feeding the fused mullite coarse material, the fused mullite coarse material and the fused mullite coarse material into an inclined mixer, adding peach glue, feeding the mixed powder after 2min, mixing for about 5min, sealing and ageing, and keeping the time for sealing and ageing for 12h to obtain the mixture.
And (3) placing the mixture into a friction press for molding to obtain a molding material, wherein the mass fraction of water in the molding material is 1.29%.
And sintering the molding material in a tunnel kiln at the sintering temperature of 1700 ℃, and preserving heat for 10 hours.
The raw materials of the fused mullite bricks of the embodiments 3-21 are fed according to the table 1, part of experimental parameters are experimental condition parameters according to the table 2, and other experimental parameters are consistent with those of the embodiment 1.
Table 1 examples 1-21 raw material contents of each component
Table 2 examples 1-21 experimental condition parameters
Table 3 properties of the fused mullite bricks of examples 1-21
The embodiment shows that the research on the selection and the content of the raw materials of the fused mullite with different grain diameters is carried out, the grain size distribution of the raw materials is optimized and the sintering process is combined, so that the obtained re-sintered fused mullite brick with low porosity is obtained, in addition, the high-purity fused mullite brick obtained by not adding the components of the kaolin in the raw materials is kept low, the purity is high, the volume weight is small, the volume density is reduced, the service life of the brick can be prolonged, and in addition, the creep rate of the fused mullite brick at high temperature is also low.
The technical features of the embodiments described above may be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the embodiments described above are not described, but should be considered as being within the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (10)
1. The re-sintered electric cast mullite brick is characterized by comprising the following raw materials in percentage by weight:
the grain size specification of the crude material of the electric cast mullite is 3 mm-5 mm, the grain size specification of the medium material of the electric cast mullite is 1 mm-3 mm, the grain size specification of the fine material of the electric cast mullite is less than 1mm, the grain size specification of the ball powder of the electric cast mullite is D50 ═ 15 +/-2 mu m, the grain size specification of the micro powder of the electric cast mullite is D50 ═ 5 +/-1 mu m, the grain size specification of the alpha alumina micro powder is D50 ═ 2 +/-1 mu m, and the grain size specification of the kaolin is D50 ═ 5 +/-1 mu m.
2. The re-sintered fused mullite brick of claim 1, wherein the composition comprises the following raw materials in percentage by weight:
3. the re-sintered fused mullite brick of claim 1 wherein the fused mullite brick has the following chemical composition requirements: al (Al)2O375-77% of SiO222 to 24 percent of Fe2O3Mass fraction of not more than 0.1 percent, TiO2The mass fraction is less than or equal to 0.1 percent, and Na2O and K2The total mass fraction of O is less than or equal to 0.25 percent.
4. The re-sintered fused mullite brick of claim 1, wherein the chemical composition of said alpha alumina micropowder is as follows: al (Al)2O3With a mass fraction of > 98.5%, SiO2Is less than 0.1 percent, Fe2O3The mass fraction is less than or equal to 0.2 percent, and Na2O and K2The total mass fraction of O is less than or equal to 0.35 percent.
5. The re-sintered fused mullite brick of claim 1 wherein the kaolin has the following chemical composition requirements: al (Al)2O3The mass fraction of the Fe content is more than or equal to 35 percent, and the Fe content is2O3Mass fraction of TiO is less than or equal to 1 percent2The mass fraction is less than or equal to 0.5 percent, and Na2O and K2The total mass fraction of O is less than or equal to 1 percent, and the total mass fraction of CaO and MgO is less than or equal to 0.3 percent.
6. The re-sintered mullite brick as claimed in claim 1, wherein said solid binder is peach gum powder, said liquid binder is peach gum powder, and said peach gum powder is composed of said peach gum powder and water in a mass ratio of 1: 3.
7. A method of making a re-sintered fused mullite brick according to any one of claims 1 to 6, comprising the steps of:
s1, mixing the fused mullite ball powder, the fused mullite micro powder, the alpha alumina micro powder, the kaolin and the peach gum powder in a conical mixer for 1.5-2.5 hours to obtain mixed powder;
s2, sequentially putting the fused mullite coarse material, the fused mullite coarse material and the fused mullite coarse material into an inclined mixer, adding the peach glue, adding the mixed powder after 1-2 min, and sealing and ageing after mixing for about 5-8 min to obtain a mixed material;
s3, placing the mixture in a friction press machine for molding to obtain a molding material;
and S4, placing the molding material in a tunnel kiln to be sintered, and preserving heat for 10-12 hours to obtain the material.
8. The method for preparing a re-sintered fused mullite brick as claimed in claim 7, wherein the moisture mass fraction of the molding material is 1-1.5%, and the time for bagging and ageing is more than 12-24 h.
9. The method of making a re-sintered fused mullite brick of claim 7 wherein the firing temperature is 1700 ℃ to 1710 ℃.
10. A refractory material comprising the re-sintered fused mullite brick according to any one of claims 1 to 6.
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