CN113045182A - Composite brick and preparation process thereof - Google Patents

Composite brick and preparation process thereof Download PDF

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Publication number
CN113045182A
CN113045182A CN202110358442.3A CN202110358442A CN113045182A CN 113045182 A CN113045182 A CN 113045182A CN 202110358442 A CN202110358442 A CN 202110358442A CN 113045182 A CN113045182 A CN 113045182A
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zirconium
brick
cast
composite
layer
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CN113045182B (en
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张红哲
谢永刚
张艺锋
杜林海
韩世杰
魏杰
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Henan Ruitaike Industrial Group Co ltd
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Henan Ruitaike Industrial Group Co ltd
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    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
    • C03B5/16—Special features of the melting process; Auxiliary means specially adapted for glass-melting furnaces
    • C03B5/42—Details of construction of furnace walls, e.g. to prevent corrosion; Use of materials for furnace walls
    • C03B5/43—Use of materials for furnace walls, e.g. fire-bricks
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/107—Refractories by fusion casting
    • C04B35/109—Refractories by fusion casting containing zirconium oxide or zircon (ZrSiO4)
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
    • C04B35/484—Refractories by fusion casting
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Composite Materials (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Abstract

The application relates to the technical field of fusion casting refractory materials, and particularly discloses a composite brick and a preparation process thereof. A composite brick comprises a base layer and a modified layer, wherein the base layer is step-shaped, the modified layer is positioned at the step of the base layer, the lower surface of the modified layer is connected with the step surface of the base layer, the base layer and the modified layer are bonded through a binder, the base layer is a cast zirconia-corundum brick, and the modified layer is a cast high-zirconium brick; the preparation process of the composite brick comprises the following steps: 1) preparing a mixture; 2) a fusion casting process; 3) a casting process; 4) a heat preservation annealing process; 5) a demoulding processing procedure; 6) and (5) preparing the composite brick. The composite brick is higher in erosion resistance and lower in cost, and is located at the liquid level of glass.

Description

Composite brick and preparation process thereof
Technical Field
The application relates to the technical field of fusion-cast refractory materials, in particular to a composite brick and a preparation process thereof.
Background
The fused cast zirconia-corundum refractory material is a unique variety in the field of refractory materials, has a series of excellent performances of compact structure, strong anti-erosion capability, small pollution to molten glass and the like, is widely applied to various glass melting furnaces in the industries of building materials, light industry, medicines, electronics and the like, and is an indispensable key furnace building material of the glass melting furnaces.
The fused cast zirconia corundum AZS refractory material is prepared with industrial alumina, zircon sand and desilicated zirconium as main material and small amount of Na20，Na20 is added in the form of alkali powder, and the mixture is cast into a formed refractory product after being fused and cast by an electric arc furnace. The fused cast AZS refractory material is generally divided into three varieties of No. 33 (AZS33#), No. 36 (AZS36#) and No. 41 (AZS41#) according to the content of zirconium. According to different casting modes, the fused cast zirconia-corundum refractory materials are roughly divided into four types of common casting, inclined casting, quasi-shrinkage-cavity-free casting and shrinkage-cavity-free casting.
The atmosphere chemical composition of the space in which the upper structure of the glass furnace belongs is greatly changed compared with the atmosphere chemical composition of the lower space of the glass furnace, wherein the volume concentration of water vapor is increased by about 3 times, and the volume concentration of alkali volatile matter is increased by 3-6 times, and the refractory material at the upper part of the glass furnace is seriously corroded. The eroded refractory material forms debris into the molten glass in the kiln, producing stones, striae and bubbles, which severely affect the quality of the glass.
In the practical use process of the AZS product in the part which contacts with the molten glass for a long time, the AZS product has the tendency of generating bubbles due to the reason of the material or the physical and chemical changes when the refractory material contacts with the molten glass, and in addition, the glass phase of the AZS product can seep out in a high-temperature environment to become a weak link in the casting refractory material and a channel in which erosion substances are easy to diffuse, so that the service life of the material is influenced, and the internal quality of the molten glass can also be influenced.
In view of the above-mentioned related art, the inventors considered that the fused cast zirconia-corundum bricks had low resistance to corrosion at the portion located at the glass liquid surface.
Disclosure of Invention
In order to improve the erosion resistance of the fused cast zirconia-corundum brick at the liquid level of glass, the application provides a composite brick and a preparation process thereof.
In a first aspect, the composite brick provided by the application adopts the following technical scheme:
the utility model provides a composite brick, includes basal layer and modified layer, the basal layer is the step form, the modified layer is located basal layer step department, the lower surface on modified layer is connected with the step face on basal layer, basal layer and modified layer pass through the binder and bond, the basal layer is founding zirconium corundum brick, the modified layer is founding high zirconium brick.
By adopting the technical scheme, in the related technology, the junction of the high-temperature glass melt line is formed by the coexistence of three phases of solid phase, liquid phase and gas phase, when the high-temperature molten glass flows, the chemical erosion and the mechanical erosion are serious, and the normal production of the kiln is influenced, the composite brick is prepared by two parts, namely a base layer and a modified layer, wherein the base layer is a common cast zirconia-alumina brick, the modified layer is a cast high-zirconium brick, and when in use, the fused cast high-zirconium brick is positioned at the glass liquid level position in the kiln, the crystal structure of the fused cast high-zirconium brick mainly comprises baddeleyite and has high-temperature corrosion resistance, meanwhile, the casting high-zirconium brick has lower foaming rate and calculus rate and very little glass phase, so the glass liquid flows less at high temperature, thereby reducing chemical erosion and mechanical erosion, and greatly increasing purchasing cost when being used alone due to higher cost of the casting high-zirconium brick;
however, if the fused cast high-zirconium brick and the fused cast zirconia-alumina brick are compounded, the purchase cost is greatly reduced, and the corrosion resistance of the composite brick at the liquid level of the high-temperature glass can be well improved.
Preferably, the fused cast high-zirconium brick is prepared from the following raw materials: the high-temperature-resistant: (35-25): (4-4.2): (0.8-1), wherein the fluxing agent is lithium tetraborate.
By adopting the technical scheme, the desiliconized zirconium and the zircon sand are main components for preparing the cast high-zirconium brick, and the zirconium component is an anti-corrosion main body of the cast high-zirconium brick and is provided by the desiliconized zirconium and the zircon sand. The desiliconized zirconium is prepared from zircon sand, and the desiliconized zirconium is higher in cost, so that the zircon sand and the desiliconized zirconium are mixed for use when the cast high-zirconium brick is prepared, and the desiliconized zirconium is used in the raw materials of the cast high-zirconium brick, so that the cast high-zirconium brick is better in quality, more stable in chemical composition and more uniform in particle distribution; silicon in the zircon sand forms a glass phase and absorbs deformation caused by thermal stress in the heat-preservation annealing process; the addition of the alkali powder ensures that the microscopic structure of the product is more stable; the addition of the fluxing agent can enhance the fusion casting of the mixed raw materials in the fusion casting process, thereby reducing the fusion casting time of the raw materials.
Preferably, the mass fraction of zirconium in the desilicated zirconium is not less than 98% in terms of zirconium dioxide.
By adopting the technical scheme, the higher the zirconium component in the desiliconized zirconium is, the stronger the high-temperature corrosion resistance of the casting high-zirconium brick is, the lower the foaming rate is and the lower the calculus rate is, so that the high-temperature corrosion resistance of the composite brick is stronger, and the corrosion condition of the liquid surface of the high-temperature glass is reduced.
Preferably, the mass fraction of zirconium in the desilicated zirconium is 98-99% in terms of zirconium dioxide.
By adopting the technical scheme, the zirconium content in the desiliconized zirconium is 98-99%, the erosion resistance of the casting high-zirconium brick can be further enhanced, and the bubble rate of the composite brick is reduced, so that the composite brick is more compact.
Preferably, the binder is a high temperature binder.
By adopting the technical scheme, the high-temperature binder has the characteristics of good fire resistance, high bonding strength, good bonding stability, wide application range, no free water and thin mortar joint, and can better bond the fused cast zirconia-alumina brick layer and the fused cast high-zirconium brick layer, thereby enhancing the anti-erosion performance of the liquid surface of the high-temperature glass.
Preferably, the ratio of the total height of the base layer to the height of the modified layer is (3-5): 1.
through adopting above-mentioned technical scheme, the total height of basal layer is greater than the height of modified layer, and modified layer performance is excellent founding high zirconium brick more, but the cost on modified layer is higher simultaneously, and modified layer and basal layer intermix can improve the erosion resistance intensity of composite brick on the one hand, can reduce the cost of composite brick preparation on the one hand.
Preferably, the raw materials of the fused cast high-zirconium brick further comprise an erosion resisting agent, and the mass ratio of the erosion resisting agent to the desilicated zirconium is (2-3): (60-70), wherein the erosion resisting agent is at least two of sillimanite fine powder, alumina micro powder and mullite powder.
By adopting the technical scheme, the erosion-resistant agent can improve the internal structure of the fused cast high-zirconium brick, improve the compactness of the fused cast high-zirconium brick and improve the erosion resistance, so that the erosion resistance of the fused cast high-zirconium brick at the liquid level of high-temperature glass is improved, mullite is a mineral produced by aluminosilicate at high temperature, and has the advantages of high temperature resistance, high strength, small heat conductivity coefficient, energy conservation and the like.
In a second aspect, the present application provides a preparation process of a composite brick, which adopts the following technical scheme:
a preparation process of a composite brick comprises the following steps:
1) preparing a mixture: mixing the raw materials of the cast high-zirconium brick, and uniformly mixing;
2) a fusion casting process: melting the uniformly mixed raw materials in the step 1) at 2700-3000 ℃ to obtain molten feed liquid;
3) a casting process: injecting the molten material liquid obtained in the step 2) into a casting mold, and casting and forming;
4) a heat preservation annealing process: annealing the cast and formed fused and cast high-zirconium brick in the step 3) at room temperature;
5) demoulding and processing procedures: demoulding and sand removing the cooled and annealed cast high-zirconium brick;
6) preparing a composite brick: and bonding the cast high-zirconium brick and the prepared cast zirconia-alumina brick by using a bonding agent at room temperature, so that the cast zirconia-alumina brick and the cast high-zirconium brick are compounded.
By adopting the technical scheme, the raw materials for preparing the modified layer are mixed for electric melting and casting molding, and then the prepared casting high-zirconium brick and the casting zirconium corundum brick are combined, so that the composite brick with high compressive strength and strong erosion resistance is prepared.
Preferably, the melting time in the step 2) is 3-5 h.
By adopting the technical scheme, when the melting time is 3-5 hours, the molten feed liquid can be more uniform, so that the prepared casting high-zirconium brick has fewer glass phases and lower bubble rate and calculus rate, and the high-temperature corrosion resistance of the casting high-zirconium brick is better.
Preferably, the annealing in the step 4) is carried out for 1-2 months.
By adopting the technical scheme, after the cast fusion-cast high-zirconium brick is kept at room temperature for 1-2 months, the obtained fusion-cast high-zirconium brick has a better material structure, larger volume density and smaller bubble rate, and the corrosion of the liquid surface of the high-temperature glass of the prepared composite brick is less.
In summary, the present application has the following beneficial effects:
1. the composite brick is characterized in that the composite brick is divided into a base layer and a modified layer, the base layer is a casting zirconium corundum brick, the modified layer is a casting high-zirconium brick, and the modified layer and the base layer are bonded through a bonding agent to form the composite brick.
2. The erosion-resistant agent is added into the composite brick, so that the compactness of the cast high-zirconium brick is improved, and the erosion resistance of the composite brick is improved.
Drawings
Fig. 1 is a schematic overall structure diagram of an embodiment of the present application.
Description of reference numerals: 1. a base layer; 2. and a modified layer.
Detailed Description
The present application will be described in further detail with reference to examples.
The base layer 1 and the modified layer 2 of the composite brick are bonded through the adhesive, preferably, the adhesive is 1600 types, and further preferably, the adhesive is an adhesive for a nano composite brick at a high temperature.
During preparation, the mass ratio of the binder to the desilicated zirconium is (15-25): (60-70).
The fused cast high-zirconium brick comprises the following raw materials by mass: the raw materials comprise raw materials and clinker, the raw materials and the raw material proportion of the raw materials and the clinker are the same, the clinker is a blocky substance with the grain diameter of 3-8cm, the raw materials are powder, the grain diameter of the raw materials is 0.05-1.5cm, and the clinker accounts for 10-30%, wherein the raw materials and the clinker are prepared from the following raw materials by mass: the high-temperature-resistant: (35-25): (4-4.2): (0.8-1), and the fluxing agent is lithium tetraborate. The fused cast high-zirconium brick can be prepared by mixing raw materials and clinker or raw materials in the preparation process. Further preferably, the fused cast high zirconium brick is made from raw materials.
In the preparation process of the composite brick, the fusion casting voltage in the step 2) is 200-380V, and the fusion casting current is 4000-7000A, and further preferably, the fusion casting voltage in the step 2) is 380V, and the fusion casting current is 7000A.
Preferably, in the preparation process of the composite brick, the bonding time of the fused cast zirconia-alumina brick and the fused cast high-zirconium brick in the step 6) is 2-3 h.
Preferably, in the preparation process of the composite brick, the mixed raw materials of the fused cast high-zirconium brick are added into a three-phase electric arc furnace in the step 2).
Preferably, the fused cast zirconia-corundum brick comprises the following raw materials by mass: the raw materials comprise raw materials and clinker, the raw materials and the raw material proportion of the raw materials and the clinker are the same, the clinker is a blocky substance with the grain diameter of 3-8cm, the raw materials are powder, the grain diameter of the raw materials is 0.05-1.5cm, and the clinker accounts for 10-30%, wherein the raw materials and the clinker are prepared from the following raw materials by mass: desiliconized zirconium, zircon sand, alkali powder and aluminum oxide; the mass ratio of the desiliconized zirconium to the zircon sand to the alkali powder to the alumina is (5-10): (10-15): (1-2): (40-45).
Preferably, the preparation process of the fused cast zirconia-corundum brick comprises the following steps: 1) preparation of raw materials and clinker: uniformly mixing the raw materials of the desiliconized zirconium, the zircon sand, the alkali powder and the alumina according to the raw material proportion of the raw material to obtain the raw material; uniformly mixing the raw materials of the desiliconized zirconium, the zircon sand, the alkali powder and the alumina according to the raw material proportion of the clinker, and obtaining the clinker after fusion casting, annealing, demoulding and crushing; 2) a fusion casting process: adding the clinker prepared in the step 1) into an automatically controlled three-phase electric arc furnace, and melting under the conditions that the melting voltage is 200-7000V and the current is 4000-7000A, wherein the melting temperature is 1900-2000 ℃, so as to obtain the feed liquid. Wherein 1/2-3/5 fused clinker is reserved in the furnace body, the clinker is directly led into the center of the furnace body through a hopper, and the raw material is delivered to one point or a plurality of points on the edge of the highest liquid level of the furnace body at the speed of 30-50kg/s after the clinker is poured; heating the raw materials before entering the furnace body, raising the temperature from room temperature to 600-1000 ℃, and the heating time is 1-5 min; 3) a casting process: injecting the molten material liquid into a prefabricated casting mold, and waiting for molding; 4) a heat preservation annealing process: annealing the cast and molded brick in a heat preservation box covered with a heat preservation material at room temperature to ensure that the cast zirconia-corundum brick forms an optimal crystalline phase structure; 5) demoulding and processing procedures: and demoulding and sand removing the cast zirconia-alumina brick after cooling and annealing, and processing the cast zirconia-alumina brick into a brick body with a specified size and surface precision.
Preferably, the raw meal in step 2) is heated by microwave before entering the furnace body, the heating time is 3min, and the heating temperature is 800 ℃.
Preferably, the lowest point of the raw meal entering the furnace body in the step 2) is above the highest liquid level in the furnace body, and the distance between the lowest point and the highest liquid level is 1/2-3/4 of the distance between the highest liquid level and the reserved liquid level.
Preferably, the heat insulating material in the step 4) is heat insulating aluminum powder.
Referring to fig. 1, the composite brick comprises a base layer 1 and a modified layer 2, wherein the base layer 1 comprises a base layer matrix, the base layer matrix is cuboid, a bearing bulge is arranged on the end face of one end of the base layer matrix in the length direction, and the bearing bulge and the base layer matrix are integrally arranged.
The bearing protrusions are also rectangular parallelepiped, the width of the bearing protrusions is the same as that of the base layer substrate, and the length of the bearing protrusions is 1/3-1/2 of the length of the base layer substrate.
The height of the load bearing projections is about 1/5-1/3 of the height of the base layer substrate.
One end face in the height direction of the bearing bulge is flush with one end face in the height direction of the base layer base body, so that the other end face in the height direction of the bearing bulge and the corresponding end face in the length direction of the base layer base body form a step.
The modified layer 2 is rectangular and is disposed on the step. The width of the modified layer 2 is equal to the width of the base layer matrix and the width of the bearing bulge, the length of the modified layer 2 is equal to the length of the bearing bulge, and the sum of the heights of the modified layer 2 and the bearing bulge is equal to the height of the base layer matrix.
Preferably, referring to fig. 1, due to the difference of production conditions, the molten glass erosion lines of different glasses are different, the lower end face of the modified layer 2 is always positioned at 100mm below each erosion line, and the ratio of the total height of the base layer 1 to the height of the modified layer 2 is (3-5): 1, respectively coating adhesives on the joints of the base layer 1 and the modified layer 2, then placing the base layer 1 and the modified layer 2 together, and bonding for 2-3h at room temperature to obtain the composite brick with high breaking strength and high-temperature erosion resistance.
Preferably, the particle size of the desilicated zirconium is 1-5mm, and the mass fraction of zirconium (calculated as zirconium dioxide) in the desilicated zirconium is not less than 98%.
Preferably, the particle size of the zircon sand is 0-1mm, the mass fraction of zirconium (calculated as zirconium dioxide) in the zircon sand is 65.5%, and the mass fraction of silicon (calculated as silicon dioxide) in the zircon sand is 34%.
Preferably, the particle size of the alumina is less than 0.044mm, and the alumina is alpha-Al 2O 3.
Preferably, the particle size of the sillimanite fine powder is 0.2-0.3mm, the sillimanite fine powder is yellow, the mass fraction of aluminum oxide in the sillimanite fine powder is 62.92%, and the mass fraction of silicon dioxide in the sillimanite fine powder is 37.08%.
Preferably, the fine alumina powder has a particle size of 0.5 to 5 μm.
Preferably, the grain diameter of the mullite powder is 0.2-0.3mm, the mass fraction of alumina in the mullite powder is 42-46%, and the density is more than 2.5kg/cm3And the mass fraction of the silicon dioxide is 51-53 percent.
The raw materials and the manufacturers involved in the present application are shown in Table 1.
TABLE 1 raw materials and manufacturers
Name of raw materials Manufacturer of the product
Desilicated zirconium Anhui Union-Tech New Material science and technology Co Ltd
Zircon sand Iluka Australia Co
Alkali powder HUBEI SHUANGHUAN SCIENCE AND TECHNOLOGY STOCK Co.,Ltd.
Alumina oxide China aluminum group Co., Ltd
Sillimanite fine powder Zhengzhou Zhongke New Material Co.,Ltd.
Alumina micropowder Zibo Ashi Innovative materials Co Ltd
Mullite powder Zhengzhou Weida refractory Co., Ltd
High temperature binder LUOYANG AUST ENERGY CONSERVATION TECHNOLOGY Co.,Ltd.
Lithium tetraborate Henan Yisen chemical products Co Ltd
Examples
Example 1
Referring to fig. 1, the composite brick of this embodiment includes basic layer 1 and modified layer 2, and basic layer 1 includes the basic layer base member, and the basic layer base member is the cuboid, is provided with on the terminal surface of the length direction's of basic layer base member and bears the weight of the arch, bears the weight of protruding and basic layer base member integrative setting.
The bearing protrusions are also rectangular, the width of the bearing protrusions is the same as that of the base layer substrate, and the length of the bearing protrusions is 1/3 the length of the base layer substrate.
The height of the load bearing bumps is 4/5 the height of the base layer.
One end face in the height direction of the bearing bulge is flush with one end face in the height direction of the base layer base body, so that the other end face in the height direction of the bearing bulge and the corresponding end face in the length direction of the base layer base body form a step.
The modified layer 2 is rectangular and is disposed on the step. The width of the modified layer 2 is equal to the width of the base layer matrix and the width of the bearing bulges, the length of the modified layer 2 is equal to the length of the bearing bulges, the sum of the heights of the modified layer 2 and the bearing bulges is equal to the height of the base layer matrix, and the ratio of the height of the base layer matrix to the height of the modified layer 2 is 5: 1.
The lower surface of the modified layer 2 is located 100mm below the erosion line. The base layer 1 and the modified layer 2 are bonded through a binder, the binder is 15kg, the base layer 1 is a casting zirconium corundum brick, the modified layer 2 is a casting high-zirconium brick, and the casting high-zirconium brick is prepared from the following raw materials in mass: 60kg of desilicated zirconium, 35kg of zircon sand, 4kg of alkali powder and 0.8kg of fluxing agent;
the mass fraction of zirconium (calculated by zirconium dioxide) in the desiliconized zirconium is 98%, the particle size of the desiliconized zirconium is 3mm, the particle size of the zircon sand is 0.8mm, the mass fraction of zirconium (calculated by zirconium dioxide) in the zircon sand is 65.5%, the mass fraction of silicon (calculated by silicon dioxide) in the zircon sand is 34%, and the fluxing agent is lithium tetraborate.
The fused cast zirconia-corundum brick comprises the following raw materials by mass: the raw materials comprise raw materials and clinker, the raw materials and the raw material proportion of the raw materials and the clinker are the same, the clinker is a blocky substance with the grain diameter of 3-8cm, the raw materials are powder, the grain diameter of the raw materials is 0.05-1.5cm, and the clinker accounts for 20%, wherein the raw materials and the clinker are both prepared from the following raw materials by mass: 8kg of desilicated zirconium; 13kg of zircon sand, 1.5kg of alkali powder and 43kg of alumina, wherein the mass fraction of zirconium (calculated by zirconium dioxide) in the desiliconized zirconium is 98%, the particle size of the desiliconized zirconium is 3mm, the particle size of the zircon sand is 0.8mm, the mass fraction of zirconium (calculated by zirconium dioxide) in the zircon sand is 65.5%, and the mass fraction of silicon (calculated by silicon dioxide) in the zircon sand is 34%.
The preparation process of the fused cast zirconia-corundum brick comprises the following steps: 1) preparation of raw materials and clinker: uniformly mixing the raw materials of the desiliconized zirconium, the zircon sand, the alkali powder and the alumina according to the raw material proportion of the raw material to obtain the raw material; uniformly mixing the raw materials of the desiliconized zirconium, the zircon sand, the alkali powder and the alumina according to the raw material proportion of the clinker, and obtaining the clinker after fusion casting, annealing, demoulding and crushing; 2) a fusion casting process: adding the clinker prepared in the step 1) into an automatically controlled three-phase electric arc furnace, and melting under the conditions that the fusion casting voltage is 380V and the current is 7000A, the melting temperature is 2000 ℃, so as to obtain a feed liquid. During specific operation, pre-melted clinker which occupies 1/2-3/5 of the volume of the furnace body is reserved in the furnace body, then the clinker is directly guided into the center of the furnace body through a hopper, and the raw material is conveyed to one point or a plurality of points on the edge of the highest liquid level of the furnace body at the speed of 30-50kg/s after the clinker is poured; microwave heating the raw material before it enters the furnace body for 3min at 800 deg.C, wherein the lowest point of the raw material entering the furnace body is above the highest liquid level in the furnace body, and the distance between the lowest point and the highest liquid level is 3/4 of the distance between the highest liquid level and the reserved liquid level; 3) a casting process: injecting the molten material liquid into a prefabricated casting mold, and waiting for molding; 4) a heat preservation annealing process: annealing the cast and molded brick in a heat preservation box covered with heat preservation aluminum powder at room temperature to ensure that the cast zirconia-corundum brick forms an optimal crystalline phase structure; 5) demoulding and processing procedures: and demoulding and sand removing the cast zirconia-alumina brick after cooling and annealing, and processing the cast zirconia-alumina brick into a brick body with a specified size and surface precision.
The preparation process of the fused cast zirconia-alumina brick-fused cast high-zirconium brick of the embodiment comprises the following steps:
1) preparing a mixture: mixing the preparation raw materials of the cast high-zirconium brick according to the proportion, and uniformly mixing;
2) a fusion casting process: adding the uniformly mixed raw materials of the fused and cast high-zirconium brick obtained in the step 1) into an automatically controlled three-phase electric arc furnace, and melting under 380V voltage and 7000A current at the melting temperature of 2700 ℃ for 5h to ensure that the raw materials are fully and uniformly melted to obtain molten feed liquid;
3) a casting process: injecting the molten material liquid into a prefabricated casting mold, and waiting for molding;
4) a heat preservation annealing process: carrying out thermal annealing on the cast and molded brick in an insulation box covered with insulation aluminum powder, wherein the annealing insulation time is 2 months, so that the high-zirconium brick forms an optimal crystalline phase structure;
5) demoulding and processing procedures: demoulding and sand-removing the cooled and annealed high-zirconium brick, and processing the high-zirconium brick into a brick body with a specified size and surface precision;
6) preparing a composite brick: and respectively coating a nano composite binder for high temperature on the cast high-zirconium brick and the cast zirconium corundum brick, placing the cast high-zirconium brick coated with the nano composite binder for high temperature and the cast zirconium corundum brick together, and timing for 2 hours, so that the cast high-zirconium brick and the cast zirconium corundum brick are compounded.
Example 2
The composite brick of the embodiment comprises a base layer 1 and a modified layer 2, the position relationship of the base layer 1 and the modified layer 2 is the same as that of the embodiment 1, wherein the height of the bearing protrusion is 3/4 of the height of the base layer base body, and the ratio of the height of the base layer base body to the height of the modified layer 2 is 4: 1.
The base layer 1 and the modified layer 2 are bonded through a binder, the binder is 18kg, the base layer 1 is a casting zirconium corundum brick, the modified layer 2 is a casting high-zirconium brick, and the casting high-zirconium brick is prepared from the following raw materials in mass: 65kg of desilicated zirconium, 30kg of zircon sand, 4.1kg of alkali powder and 0.9kg of fluxing agent;
the mass fraction of zirconium (calculated by zirconium dioxide) in the desiliconized zirconium is 99%, the particle size of the desiliconized zirconium is 3mm, the particle size of the zircon sand is 0.8mm, the mass fraction of zirconium (calculated by zirconium dioxide) in the zircon sand is 65.5%, the mass fraction of silicon (calculated by silicon dioxide) in the zircon sand is 34%, and the fluxing agent is lithium tetraborate.
Wherein, the raw material components of the fused cast zirconia-alumina brick are the same as those in the example 1;
wherein, the preparation process of the fused cast zirconia-alumina brick is the same as that of the embodiment 1;
the preparation process of the fused cast zirconia-alumina brick-fused cast high-zirconium brick of the embodiment comprises the following steps:
1) preparing a mixture: mixing the preparation raw materials of the cast high-zirconium brick according to the proportion, and uniformly mixing;
2) a fusion casting process: adding the uniformly mixed raw materials of the fused and cast high-zirconium brick obtained in the step 1) into an automatically controlled three-phase electric arc furnace, and melting at the voltage of 380V and the current of 7000A at the melting temperature of 2800 ℃ for 4 hours to ensure that the raw materials are fully and uniformly melted to obtain molten feed liquid;
3) a casting process: injecting the molten material liquid into a prefabricated casting mold, and waiting for molding;
4) a heat preservation annealing process: carrying out thermal annealing on the cast and molded brick in an insulation box covered with insulation aluminum powder, wherein the annealing insulation time is 1.5 months, so that the high-zirconium brick forms an optimal crystalline phase structure;
5) demoulding and processing procedures: demoulding and sand-removing the cooled and annealed high-zirconium brick, and processing the high-zirconium brick into a brick body with a specified size and surface precision;
6) preparing a composite brick: and respectively coating a nano composite binder for high temperature on the cast high-zirconium brick and the cast zirconium corundum brick, placing the cast high-zirconium brick coated with the nano composite binder for high temperature and the cast zirconium corundum brick together, and timing for 2.5 hours, so that the cast high-zirconium brick and the cast zirconium corundum brick are compounded.
Example 3
The composite brick of the embodiment comprises a base layer 1 and a modified layer 2, the position relationship of the base layer 1 and the modified layer 2 is the same as that of the embodiment 1, wherein the height of the bearing protrusion is 2/3 of the height of the base layer base body, and the ratio of the height of the base layer base body to the height of the modified layer 2 is 3: 1.
The base layer 1 and the modified layer 2 are bonded through a binder, the binder is 25kg, the base layer 1 is a cast zirconia corundum brick, the modified layer 2 is a cast high-zirconium brick, and the cast high-zirconium brick is prepared from the following raw materials of 70kg of desilicated zirconium, 25kg of zircon sand, 4.2kg of alkaline powder and 1kg of fluxing agent;
the mass fraction of zirconium (calculated by zirconium dioxide) in the desiliconized zirconium is 99.5%, the particle size of the desiliconized zirconium is 3mm, the particle size of the zircon sand is 0.8mm, the mass fraction of zirconium (calculated by zirconium dioxide) in the zircon sand is 65.5%, the mass fraction of silicon (calculated by silicon dioxide) in the zircon sand is 34%, and the fluxing agent is lithium tetraborate.
Wherein, the raw material components of the fused cast zirconia-alumina brick are the same as those in the example 1;
wherein, the preparation process of the fused cast zirconia-alumina brick is the same as that of the embodiment 1;
the preparation process of the fused cast zirconia-alumina brick-fused cast high-zirconium brick of the embodiment comprises the following steps:
1) preparing a mixture: mixing the preparation raw materials of the cast high-zirconium brick according to the proportion, and uniformly mixing;
2) a fusion casting process: adding the uniformly mixed raw materials of the fused and cast high-zirconium brick obtained in the step 1) into an automatically controlled three-phase electric arc furnace, and melting at the voltage of 380V and the current of 7000A at the melting temperature of 3000 ℃ for 3 hours to ensure that the raw materials are fully and uniformly melted to obtain molten feed liquid;
3) a casting process: injecting the molten material liquid into a prefabricated casting mold, and waiting for molding;
4) a heat preservation annealing process: carrying out thermal annealing on the cast and molded brick in an insulation box covered with insulation aluminum powder, wherein the annealing insulation time is 1 month, so that the high-zirconium brick forms an optimal crystalline phase structure;
5) demoulding and processing procedures: demoulding and sand-removing the cooled and annealed high-zirconium brick, and processing the high-zirconium brick into a brick body with a specified size and surface precision;
6) preparing a composite brick: and respectively coating a nano composite binder for high temperature on the cast high-zirconium brick and the cast zirconium corundum brick, placing the cast high-zirconium brick coated with the nano composite binder for high temperature and the cast zirconium corundum brick together, and timing for 3 hours, so that the cast high-zirconium brick and the cast zirconium corundum brick are compounded.
Example 4
The composite brick of the embodiment comprises a base layer 1 and a modified layer 2, the position relationship of the base layer 1 and the modified layer 2 is the same as that of the embodiment 1, wherein the height of the bearing protrusion is 2/3 of the height of the base layer base body, and the ratio of the height of the base layer base body to the height of the modified layer 2 is 3: 1.
The base layer 1 and the modified layer 2 are bonded through a binder, the binder is 15kg, the base layer 1 is a casting zirconium corundum brick, the modified layer 2 is a casting high-zirconium brick, and the casting high-zirconium brick is prepared from the following raw materials in mass: 60kg of desilicated zirconium, 35kg of zircon sand, 4kg of alkali powder and 0.8kg of fluxing agent;
the mass fraction of zirconium (calculated by zirconium dioxide) in the desiliconized zirconium is 98.4%, the particle size of the desiliconized zirconium is 3mm, the particle size of the zircon sand is 0.8mm, the mass fraction of zirconium (calculated by zirconium dioxide) in the zircon sand is 65.5%, the mass fraction of silicon (calculated by silicon dioxide) in the zircon sand is 34%, and the fluxing agent is lithium tetraborate.
Wherein, the raw material components of the fused cast zirconia-alumina brick are the same as those in the example 1;
wherein, the preparation process of the fused cast zirconia-alumina brick is the same as that of the embodiment 1;
the preparation process of the fused cast zirconia-alumina brick-fused cast high-zirconium brick is the same as that of the example 1.
Example 5
The composite brick of the embodiment comprises a base layer 1 and a modified layer 2, the position relationship of the base layer 1 and the modified layer 2 is the same as that of the embodiment 1, wherein the height of the bearing protrusion is 2/3 of the height of the base layer base body, and the ratio of the height of the base layer base body to the height of the modified layer 2 is 3: 1.
The base layer 1 and the modified layer 2 are bonded through a binder, the binder is 15kg, the base layer 1 is a casting zirconium corundum brick, the modified layer 2 is a casting high-zirconium brick, and the casting high-zirconium brick is prepared from the following raw materials in mass: 60kg of desilicated zirconium, 35kg of zircon sand, 4kg of alkali powder and 0.8kg of fluxing agent, wherein the mass fraction of zirconium (calculated as zirconium dioxide) in the desilicated zirconium is 98.8%, the particle size of the desilicated zirconium is 3mm, the particle size of the zircon sand is 0.8mm, the mass fraction of zirconium (calculated as zirconium dioxide) in the zircon sand is 65.5%, the mass fraction of silicon (calculated as silicon dioxide) in the zircon sand is 34%, and the fluxing agent is lithium tetraborate.
Wherein, the raw material components of the fused cast zirconia-alumina brick are the same as those in the example 1;
wherein, the preparation process of the fused cast zirconia-alumina brick is the same as that of the embodiment 1;
the preparation process of the fused cast zirconia-alumina brick-fused cast high-zirconium brick is the same as that of the example 1.
Example 6
The composite brick of the embodiment comprises a base layer 1 and a modified layer 2, the position relationship of the base layer 1 and the modified layer 2 is the same as that of the embodiment 1, wherein the height of the bearing protrusion is 2/3 of the height of the base layer base body, and the ratio of the height of the base layer base body to the height of the modified layer 2 is 3: 1.
The base layer 1 and the modified layer 2 are bonded through a binder, the binder is 15kg, the base layer 1 is a casting zirconium corundum brick, the modified layer 2 is a casting high-zirconium brick, and the casting high-zirconium brick is prepared from the following raw materials in mass: 60kg of desilicated zirconium, 35kg of zircon sand, 4kg of alkali powder and 0.8kg of fluxing agent;
the mass fraction of zirconium (calculated by zirconium dioxide) in the desiliconized zirconium is 99.8%, the particle size of the desiliconized zirconium is 3mm, the particle size of the zircon sand is 0.8mm, the mass fraction of zirconium (calculated by zirconium dioxide) in the zircon sand is 65.5%, the mass fraction of silicon (calculated by silicon dioxide) in the zircon sand is 34%, and the fluxing agent is lithium tetraborate.
Wherein, the raw material components of the fused cast zirconia-alumina brick are the same as those in the example 1;
wherein, the preparation process of the fused cast zirconia-alumina brick is the same as that of the embodiment 1;
the preparation process of the fused cast zirconia-alumina brick-fused cast high-zirconium brick is the same as that of the example 1.
Example 7
The composite brick of the embodiment comprises a base layer 1 and a modified layer 2, the position relationship of the base layer 1 and the modified layer 2 is the same as that of the embodiment 1, wherein the height of the bearing protrusion is 2/3 of the height of the base layer base body, and the ratio of the height of the base layer base body to the height of the modified layer 2 is 3: 1.
The base layer 1 and the modified layer 2 are bonded through a binder, the binder is 15kg, the base layer 1 is a casting zirconium corundum brick, the modified layer 2 is a casting high-zirconium brick, and the casting high-zirconium brick is prepared from the following raw materials in mass: 60kg of desiliconized zirconium, 35kg of zircon sand, 4kg of alkali powder, 0.8kg of fluxing agent and 2.5kg of anti-erosion agent;
the mass fraction of zirconium (calculated by zirconium dioxide) in the desiliconized zirconium is 98.5%, the particle size of the desiliconized zirconium is 3mm, the particle size of zircon sand is 0.8mm, the mass fraction of zirconium (calculated by zirconium dioxide) in the zircon sand is 65.5%, the mass fraction of silicon (calculated by silicon dioxide) in the zircon sand is 34%, the fluxing agent is lithium tetraborate, the anti-erosion agent is composed of sillimanite fine powder and alumina micro powder according to the mass ratio of 1:1, and the particle size of the alumina micro powder is 3 μm.
Wherein, the raw material components of the fused cast zirconia-alumina brick are the same as those in the example 1;
wherein, the preparation process of the fused cast zirconia-alumina brick is the same as that of the embodiment 1;
the preparation process of the fused cast zirconia-alumina brick-fused cast high-zirconium brick is the same as that of the example 1.
Example 8
The difference between the embodiment and the embodiment 7 is that the erosion resisting agent consists of sillimanite fine powder, alumina fine powder and mullite powder according to the mass ratio of 1:1:1, and the rest is the same as the embodiment 7.
Comparative example
Comparative example 1
The casting zirconia corundum brick of the comparative example consists of the following raw materials by mass: the raw materials comprise raw materials and clinker, the mixture ratio of the raw materials and the clinker is the same, the clinker is a blocky substance with the grain diameter of 3-8cm, the raw material is powder with the grain diameter of 0.05-1.5cm, and the clinker accounts for 20%, wherein the raw materials and the clinker are both prepared from the following raw materials by mass: 8kg of desilicated zirconium; 13kg of zircon sand, 1.5kg of alkali powder and 43kg of alumina; the mass fraction of zirconium (calculated by zirconium dioxide) in the desiliconized zirconium is 98%, the particle size of the desiliconized zirconium is 3mm, the particle size of the zircon sand is 0.8mm, the mass fraction of zirconium (calculated by zirconium dioxide) in the zircon sand is 65.5%, and the mass fraction of silicon (calculated by silicon dioxide) in the zircon sand is 34%.
The process for producing the fused cast zirconia-alumina brick of this comparative example was the same as in example 1.
Performance test
And testing the performance of the prepared composite brick.
Testing the performance of the composite brick: the composite bricks in examples 1 to 8 and the fused cast zirconia-corundum refractory brick in comparative example 1 are subjected to performance tests according to standard JC/T493-2015 < fused cast zirconia-corundum refractory product for glass melting furnaces >, wherein the tests of the volume density and the apparent porosity refer to national standard GB/T2997-.
Table 2 results of performance testing
Figure BDA0003004542580000121
The volume density is the average volume density, and the apparent porosity is the average apparent porosity.
Combining example 1 and comparative example 1, and table 2, it can be seen that the physical properties of the composite brick are superior to those of the fused cast zirconia-corundum brick. The composite brick comprises a base layer and a modification layer, wherein the modification layer is added on the original basis, the modification layer is a casting high-zirconium brick, and the brick formed by compounding the base layer and the modification layer has the advantages of large volume density, large compressive strength, low apparent porosity and increased refractoriness under load, so that the erosion resistance of the composite brick is enhanced.
With reference to examples 1-8 and table 2, it can be seen that in the composite brick, by increasing the ratio of the fused cast high-zirconium brick in the composite brick, the volume density, the apparent porosity, the compressive strength and the refractoriness under load of the prepared composite brick are changed, and with the increase of the ratio of the fused cast high-zirconium brick, the volume density of the composite brick is continuously increased, the apparent porosity is continuously decreased, and the compressive strength and the refractoriness under load are gradually increased, so that the erosion resistance of the composite brick is improved, and the erosion condition at the liquid level of the high-temperature glass is reduced.
It can be seen from the combination of example 6 and examples 7 to 8 and table 2 that when an erosion resistant agent is added to the preparation of the fused cast high-zirconium brick, the performance of the prepared fused cast high-zirconium brick is better, so that the volume density of the prepared composite brick is increased, the apparent porosity is reduced, the compressive strength and the refractoriness under load are increased, and the volume density of the prepared composite brick is increased, the apparent porosity is reduced, and the compressive strength and the refractoriness under load are increased along with the increase of the erosion resistant agent, so that the erosion resistance of the composite brick is improved.
The present embodiment is only for explaining the present application, and it is not limited to the present application, and those skilled in the art can make modifications of the present embodiment without inventive contribution as needed after reading the present specification, but all of them are protected by patent law within the scope of the claims of the present application.

Claims (10)

1. A composite brick is characterized in that: including basal layer (1) and modified layer (2), basal layer (1) is the step form, modified layer (2) are located basal layer (1) step department, the lower surface on modified layer (2) is connected with the step face on basal layer (1), basal layer (1) passes through the binder with modified layer (2) and bonds, basal layer (1) is founding zirconia corundum brick, modified layer (2) is founding high zirconium brick.
2. A composite brick according to claim 1, wherein: the casting high-zirconium brick is prepared from the following raw materials: the high-temperature-resistant: (35-25): (4-4.2): (0.8-1), wherein the fluxing agent is lithium tetraborate.
3. A composite brick according to claim 2, wherein: the mass fraction of zirconium in the desilicated zirconium is not less than 98 percent in terms of zirconium dioxide.
4. A composite brick according to claim 3, wherein: the mass fraction of zirconium in the desilicated zirconium is 98-99 percent based on zirconium dioxide.
5. A composite brick according to claim 1, wherein: the binder is a high temperature binder.
6. A composite brick according to claim 1, wherein: the ratio of the total height of the basic layer (1) to the height of the modified layer (2) is (3-5): 1.
7. a composite brick according to claim 2, wherein: the raw materials of the casting high-zirconium brick also comprise an erosion resisting agent, and the mass ratio of the erosion resisting agent to the desilicated zirconium is (2-3): (60-70), wherein the erosion resisting agent is at least two of sillimanite fine powder, alumina micro powder and mullite powder.
8. A process for the preparation of a composite brick according to claim 1, characterized in that: the method comprises the following steps:
1) preparing a mixture: mixing the raw materials of the cast high-zirconium brick, and uniformly mixing;
2) a fusion casting process: melting the uniformly mixed raw materials in the step 1) at 2700-3000 ℃ to obtain molten feed liquid;
3) a casting process: injecting the molten material liquid obtained in the step 2) into a casting mold, and casting and forming;
4) a heat preservation annealing process: annealing the cast and formed fused and cast high-zirconium brick in the step 3) at room temperature;
5) demoulding and processing procedures: demoulding and sand removing the cooled and annealed cast high-zirconium brick;
6) preparing a composite brick: and bonding the cast high-zirconium brick and the prepared cast zirconia-alumina brick by using a bonding agent at room temperature, so that the cast zirconia-alumina brick and the cast high-zirconium brick are compounded.
9. The process for preparing a composite brick according to claim 8, wherein: the melting time in the step 2) is 3-5 h.
10. The process for preparing a composite brick according to claim 9, wherein: and the annealing in the step 4) is carried out for 1-2 months.
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CN108164275A (en) * 2018-01-14 2018-06-15 江苏嘉耐高温材料有限公司 A kind of resistant to corrosion zirconium oxide nozzle brick and preparation method thereof
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PE01 Entry into force of the registration of the contract for pledge of patent right

Denomination of invention: A composite brick and its preparation process

Granted publication date: 20220830

Pledgee: China Postal Savings Bank Co.,Ltd. Henan Provincial Branch Direct Branch

Pledgor: Henan ruitaike Industrial Group Co.,Ltd.

Registration number: Y2024980017788