CN113061021A - 一种用于顶燃式热风炉的高热震砖及其制备方法 - Google Patents
一种用于顶燃式热风炉的高热震砖及其制备方法 Download PDFInfo
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Abstract
本发明涉及一种用于顶燃式热风炉的高热震砖及其制备方法，所述高热震砖选自包括以质量分数计的如下组分：92％～95％的熔融石英、5％～8％的硅微粉、1％～1.5％的磷酸、3％～3.5％的结合剂。利用一级熔融石英本身纯度高、高温状态下成玻璃态结构、热膨胀系数非常小的优点，进而提高高热震砖的抗热震稳定性，大大提高热风炉燃烧器预混室的使用寿命，同时一级熔融石英特殊的粒度分布有助于提高高热震砖的强度；采用SiO2质量分数为30％的碱性硅溶胶作为结合剂以及磷酸的复合作用，在烧结的过程中产生较强的结合强度，也大大增大高热震砖制品的强度；且该高热震砖的烧结温度远低于常规材料，有利于节能环保。
Description
技术领域
本发明涉及高热震砖制备技术领域，尤其涉及一种用于顶燃式热风炉的高热震砖及其制备方法。
背景技术
顶燃式热风炉由于其占地小、投资低、温度均匀、高风温等优点，近十年来在国内得到了长足的发展，许多国内的内燃式和外燃式热风炉也相继改造为顶燃式热风炉。但顶燃式热风炉的寿命还不能与国外等同，制约热风炉寿命的关键耐火材料为陶瓷燃烧器的预混室。该部位处于热风炉的顶端，工作温度虽然不高，一般在1100℃以下，但温度波动频繁。燃烧期，煤气温度较低(200-300℃)，助燃空气也低(500-600℃)，所以预混室的温度为500-600℃。送风期，上窜的热风和高温(1350-1420℃)拱顶的热辐射，使预混室的温度可达1000-1100℃。因此，预混室内衬砌体的温度波动大约为500℃。故对预混室耐材的热震稳定性要求较高，目前国内要求热震稳定性1100℃，水冷≥70次或100次；随着高炉容积增大，热风炉的容积也增大，致使预混室砌体高度增大，承受压力也随之增大，因此该部位用砖的高温性能也必须考虑。目前国内热风炉的预混室的材料为采用红柱石、莫来石、堇青石为主要原料的铝硅系材料，但实践证明，这些铝硅系材料的抗热震稳定性不能满足使用要求，在使用一段时间之后，就会出现因铝硅系材料的热震和热膨胀造成的结构开裂和掉块现象，不得不终止停炉进行大修，严重影响高炉的产量。
本发明的高热震砖主要应用于热风炉的陶瓷燃烧器的预混室，该高热震砖具有超级的抗热震性能，可以达到抗热震稳定性200次以上不碎裂，并具有较高的高温使用性能，荷重软化开始温度可达到1700℃以上，其导热率也远低于红柱石、莫来石、堇青石为主要原料的铝硅系材料，有利于节能。
发明内容
为解决现有技术的不足，本发明提出一种用于顶燃式热风炉的高热震砖及其制备方法，利用熔融石英本身纯度高、高温状态下成玻璃态结构、热膨胀系数非常小的优点，进而提高高热震砖的抗热震稳定性。
为实现以上目的，本发明所采用的技术方案包括：
一种用于顶燃式热风炉的高热震砖，选自包括以质量分数计的如下组分：92％～95％的熔融石英、5％～8％的硅微粉、1％～1.5％的磷酸、3％～3.5％的结合剂。
进一步地，所述熔融石英优选为粒度小于等于8mm、SiO2质量分数不低于99.99％的一级熔融石英。
进一步地，所述一级熔融石英的粒度分布优选包括如下范围：粒径为5～8mm的质量百分比为0～8％；粒径为3～5mm的质量百分比为0～20％；粒径为2～3mm的质量百分比为14～18％；粒径为1～2mm的质量百分比为15～19％；粒径为0.5～1mm的质量百分比为10～16％；粒径为0.08～0.5mm的质量百分比为9～15％；粒径为0.075～0.08mm的质量百分比为12～15％；粒径为0.045mm的质量百分比为12～14％；粒径为0.002mm的质量百分比为5～7％。
进一步地，所述硅微粉优选为粒度小于等于2μm、SiO2质量分数不低于98％的高纯硅微粉。
进一步地，所述磷酸的体积浓度优选为85％。
进一步地，所述结合剂优选为碱性硅溶胶，所述碱性硅溶胶中SiO2质量分数为30％。
进一步地，所述高热震砖优选应用于焦炉或热风炉。
进一步地，所述高热震砖优选应用于热风炉的陶瓷燃烧器的预混室。
本发明还涉及一种如上所述的用于顶燃式热风炉的高热震砖的制备方法，包括烧结过程，所述烧结过程的温度变化如下：
预升温阶段：在30min内，升温至200℃；
升温阶段：以5℃/min的升温速率，升温至终点温度，所述终点温度的范围为950℃～1150℃；
保温阶段：在所述终点温度保温4～6h。
本发明的有益效果为：
采用本发明所述用于顶燃式热风炉的高热震砖及其制备方法，利用一级熔融石英本身纯度高、高温状态下成玻璃态结构、热膨胀系数非常小的优点，进而提高高热震砖的抗热震稳定性至200次以上，大大提高热风炉的使用寿命，同时一级熔融石英特殊的粒度分布有助于提高高热震砖的强度；采用SiO2质量分数为30％的碱性硅溶胶作为结合剂以及磷酸的复合作用，在烧结的过程中产生较强的结合强度，也大大增大高热震砖制品的强度；且该高热震砖的烧结温度远低于常规材料，有利于节能环保。
具体实施方式
本发明以熔融石英为主要原料，熔融石英原料本身具有很低的热膨胀系数，但熔融石英在高温状态下具有析晶反应，熔融石英原料越纯、粒度越粗越不容易析晶，在较低温度下烧成的产品才持续具有优良的抗热震稳定性。所以在以熔融石英为原料开发制作产品时，原料的临界粒度、级配、烧成温度和杂质元素的避免引入是控制产品质量的关键因素。本发明采用的结合剂为硅溶胶，单纯的硅溶胶作为结合剂随温度的升高而固化，产生的结合强度很低，为此本发明采用SiO2质量分数为30％的碱性硅溶胶作为结合剂，同时加入磷酸，在二者复合作用下促进固化，以增大产品的强度，二者的质量分数、粒度等参数及复合作用对材料的强度有决定性影响。
为了更清楚的理解本发明的内容，将结合实施例详细说明。
实施例1
一种用于顶燃式热风炉的高热震砖，其特征在于，可选自包括以质量分数计的如下组分：92％～95％的一级熔融石英、5％～8％的高纯硅微粉、1％～1.5％的磷酸、3％～3.5％的碱性硅溶胶。所述一级熔融石英为SiO2质量分数不低于99.99％的一级熔融石英，其粒度分布为粒径为2～3mm的质量百分比为18％；粒径为1～2mm的质量百分比为19％；粒径为0.5～1mm的质量百分比为16％；粒径为0.075～0.5mm的质量百分比为15％；粒径为0.075mm的质量百分比为12％；粒径为0.045mm的质量百分比为14％；粒径为0.002mm的质量百分比为6％。所述高纯硅微粉为粒度小于等于2μm、SiO2质量分数不低于98％的高纯硅微粉。所述磷酸的体积浓度为85％。所述碱性硅溶胶中SiO2质量分数为30％。
上述用于顶燃式热风炉的高热震砖的制备方法，包括烧结过程，所述烧结过程的温度变化如下：
预升温阶段：在30min内，自由升温至200℃；
升温阶段：以5℃/min的升温速率，升温至终点温度950℃；
保温阶段：在终点温度950℃处保温6h。
实施例2
一种用于顶燃式热风炉的高热震砖，其特征在于，可选自包括以质量分数计的如下组分：92％～95％的一级熔融石英、5％～8％的高纯硅微粉、1％～1.5％的磷酸、3％～3.5％的碱性硅溶胶。所述一级熔融石英为SiO2质量分数不低于99.99％的一级熔融石英，其粒度分布为粒径为3～5mm的质量百分比为12％；粒径为2～3mm的质量百分比为14％；粒径为1～2mm的质量百分比为15％；粒径为0.5～1mm的质量百分比为13％；粒径为0.08～0.5mm的质量百分比为12％；粒径为0.08mm的质量百分比为15％；粒径为0.045mm的质量百分比为14％；粒径为0.002mm的质量百分比为5％。所述高纯硅微粉为粒度小于等于2μm、SiO2质量分数不低于98％的高纯硅微粉。所述磷酸的体积浓度为85％。所述碱性硅溶胶中SiO2质量分数为30％。
上述用于顶燃式热风炉的高热震砖的制备方法，包括烧结过程，所述烧结过程的温度变化如下：
预升温阶段：在30min内，自由升温至200℃；
升温阶段：以5℃/min的升温速率，升温至终点温度1050℃；
保温阶段：在终点温度1050℃处保温5h。
实施例3
一种用于顶燃式热风炉的高热震砖，其特征在于，可选自包括以质量分数计的如下组分：92％～95％的一级熔融石英、5％～8％的高纯硅微粉、1％～1.5％的磷酸、3％～3.5％的碱性硅溶胶。所述一级熔融石英为SiO2质量分数不低于99.99％的一级熔融石英，其粒度分布为粒径为5～8mm的质量百分比为8％；粒径为3～5mm的质量百分比为20％；粒径为1～3mm的质量百分比为17％；粒径为0.5～1mm的质量百分比为10％；粒径为0.08～0.5mm的质量百分比为9％；粒径为0.08mm的质量百分比为15％；粒径为0.045mm的质量百分比为14％；粒径为0.002mm的质量百分比为7％。所述高纯硅微粉为粒度小于等于2μm、SiO2质量分数不低于98％的高纯硅微粉。所述磷酸的体积浓度为85％。所述碱性硅溶胶中SiO2质量分数为30％。
上述用于顶燃式热风炉的高热震砖的制备方法，包括烧结过程，所述烧结过程的温度变化如下：
预升温阶段：在30min内，自由升温至200℃；
升温阶段：以5℃/min的升温速率，升温至终点温度1150℃；
保温阶段：在终点温度1150℃处保温4h。
上述实施例得到的高热震砖产品，主要应用于热风炉的陶瓷燃烧器的预混室，也可用于焦炉修补用，该高热震砖具有超级的抗热震性能，可以达到抗热震稳定性200次以上不碎裂，远高于现有材料的抗震稳定性，大大提高热风炉的使用寿命；并具有较高的高温使用性能，荷重软化开始温度可达到1700℃以上；其导热率也远低于红柱石、莫来石、堇青石为主要原料的铝硅系材料，有利于保温节能；且该高热震砖的烧结温度远低于常规材料，有利于节能环保。所述高热震砖产品的理化检测结果如表1所示。
表1高热震砖的性能指标
以上所述仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到的变化或替换等都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应该以权利要求书的保护范围为准。
Claims (9)
1.一种用于顶燃式热风炉的高热震砖，其特征在于，选自包括以质量分数计的如下组分：92％～95％的熔融石英、5％～8％的硅微粉、1％～1.5％的磷酸、3％～3.5％的结合剂。
2.如权利要求1所述的高热震砖，其特征在于，所述熔融石英为粒度小于等于8mm、SiO2质量分数不低于99.99％的一级熔融石英。
3.如权利要求2所述的高热震砖，其特征在于，所述一级熔融石英的粒度分布包括如下范围：粒径为5～8mm的质量百分比为0～8％；粒径为3～5mm的质量百分比为0～20％；粒径为2～3mm的质量百分比为14～18％；粒径为1～2mm的质量百分比为15～19％；粒径为0.5～1mm的质量百分比为10～16％；粒径为0.08～0.5mm的质量百分比为9～15％；粒径为0.075～0.08mm的质量百分比为12～15％；粒径为0.045mm的质量百分比为12～14％；粒径为0.002mm的质量百分比为5～7％。
4.如权利要求1所述的高热震砖，其特征在于，所述硅微粉为粒度小于等于2μm、SiO2质量分数不低于98％的高纯硅微粉。
5.如权利要求1所述的高热震砖，其特征在于，所述磷酸的体积浓度为85％。
6.如权利要求1所述的高热震砖，其特征在于，所述结合剂为碱性硅溶胶，所述碱性硅溶胶中SiO2质量分数为30％。
7.如权利要求1至6任一项所述的高热震砖，其特征在于，所述高热震砖应用于焦炉或热风炉。
8.如权利要求7所述的高热震砖，其特征在于，所述高热震砖应用于热风炉的陶瓷燃烧器的预混室。
9.一种如权利要求1至8任一项所述的用于顶燃式热风炉的高热震砖的制备方法，其特征在于，包括烧结过程，所述烧结过程的温度变化如下：
预升温阶段：在30min内，升温至200℃；
升温阶段：以5℃/min的升温速率，升温至终点温度，所述终点温度的范围为950℃～1150℃；
保温阶段：在所述终点温度保温4～6h。
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