CN113121259A - 一种轻质隔热耐火材料及其制备方法 - Google Patents
一种轻质隔热耐火材料及其制备方法 Download PDFInfo
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Abstract
本发明属于无机材料技术领域，提供了一种轻质隔热耐火材料及其制备方法。其技术方案是：以20‑50wt%的高岭土粉体和30‑65wt%的硅线石粉体为基体，并以5‑25wt%的石墨粉体和5‑20wt%的木屑为复合造孔剂；再将上述粉体混合、球磨、烘干、碾碎、过筛；然后，造粒、成型，并在1300‑1400℃条件下煅烧1‑2h，得到隔热耐火材料。本发明提供了一种新型的制备隔热耐火材料的途径，通过在陶瓷基体中加入复合造孔剂以获得协同效应，具有成本低、工艺简单的特点，所制备的隔热耐火材料轻质、高强，易于工业化生产。
Description
技术领域
本发明属于无机材料技术领域，具体涉及一种轻质隔热耐火材料及其制备方法。
背景技术
工业窑炉是高耗能设备，特别是中高温窑炉，烧成温度高达1000-1800℃。如何有效降低工业窑炉的能耗，不仅对节能和环保具有重要意义，而且对于提升企业的竞争力也十分必要。目前，隔热耐火材料的轻质化是窑炉节能的主要技术途径之一。
现有的代表性轻质多孔材料主要有：氧化铝空心球材料、氧化铝基（含莫来石）轻质隔热材料和陶瓷纤维材料等。当前使用最广泛的氧化铝基轻质隔热材料使用温度为1000-1500℃，气孔率为40-80%，具有良好的节能特性。但这种隔热材料在轻质化的同时，其机械强度也在不断下降。就现有技术而言，常温下气孔率为80%的陶瓷材料的抗压强度一般为2MPa左右，使其在诸多应用中受到限制。此外，在生产莫来石基隔热材料时，原料中加入的大量造孔剂使材料无法干压成型，而通常是采用湿法挤出成型，由于无法控制挤出坯体体积的膨胀，尺寸无法精确控制，烧成后的产品需要进一步加工处理，成本高、损耗大。传统的添加造孔剂法，一般只引入一种造孔剂，而且不同的造孔剂在气孔率、强度、甚至加工方法等方面都有各自的局限性。
为了解决上述技术缺陷，本发明公开了一种轻质隔热耐火材料及其制备方法，通过在基体中引入复合造孔剂木屑和石墨，以获得协同效应，制备了高强的轻质隔热耐火材料。
发明内容
本发明的目的是针对现有技术中的添加单一造孔剂法存在的各种局限性，提供了一种轻质隔热耐火材料及其制备方法。通过在基体中引入复合造孔剂石墨和木屑，以获得协同效应，复合造孔剂的协同效应对隔热材料的性能起到了重要的作用，木屑和石墨在基体中分别起到了成孔和强化的作用，弥补了添加单一造孔剂时容重大或强度低的局限性。石墨在高温下形成的液相可以扩散到基体中形成一层致密层，对木屑引起的连续孔隙起到了一定的愈合和阻隔作用。并且，木屑烧失后形成了微观孔，基体烧失后形成了纳米孔，即进一步引入了烧失孔和堆积孔等多级别孔隙。最终，制备获得了高强的轻质隔热耐火材料。
为实现上述目的，本发明采用的技术方案是：
（a）以20-50wt%的高岭土粉体和30-65wt%的硅线石粉体为基体，以5-25wt%的石墨粉体和5-20wt%的木屑为复合造孔剂；
（b）将上述适量的各种粉体与球和去离子水按1:2:3的质量比混合，并在300r/min的球磨机上球磨8h，然后取出并烘干、碾碎、过80目筛；
（c）在得到的粉料中加入质量分数5%的聚乙烯醇（PVA）造粒，并干压成型，然后在高温炉中煅烧，烧成后的样品随炉冷却至室温后取出，制得隔热耐火材料。
优选的，所述高岭土粉体中的Al2O3含量为33-40wt%、SiO2含量为38-52wt%，自由水含量≤15wt%，所述高岭土粉体的粒径小于400μm。
优选的，所述硅线石粉体中的Al2O3含量为58-60wt%、SiO2含量为37-40wt%，所述硅线石粉体的粒径小于400μm。
优选的，石墨粉体纯度＞96%，木屑纯度＞96%。
优选的，样品的煅烧温度为1300-1400℃，煅烧时间为1-2h。
与现有技术相比，本发明的有益效果是：
(1)本发明采用的原料易得，其制备方法只需将粉料混合均匀，成型，干燥后烧成，成本低廉和工艺简单。
(2)本发明通过在基体中引入复合造孔剂获得协同效应，复合造孔剂的协同效应对隔热耐火材料的性能起到了重要的作用，最终制得了高强的轻质隔热耐火材料。
附图说明
图1是本发明实施例1中添加10wt%石墨（a）、10wt%木屑（b）、10wt%石墨和10wt%木屑复合造孔剂（c）的断面SEM图。
图2是本发明实施例1中造孔剂组成对隔热耐火材料容重和抗弯强度的影响对比图。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合实施例，对本发明进行进一步详细说明；应当理解，此处所描述的具体实施例仅用以解释本发明，并不用于限定本发明；除非特别说明，本发明采用的原料、方法和设备为本技术领域常规原料、方法和设备。
实施例1
本实施例提供一种轻质隔热耐火材料及其制备方法：
（a）以35wt%的高岭土粉体和45wt%的硅线石粉体为基体，以10wt%的石墨粉体和10wt%的木屑为复合造孔剂；
（b）将上述各种粉体与球和去离子水按1:2:3的质量比混合，并在300r/min的球磨机上球磨8h，然后取出并烘干、碾碎、过80目筛；
（c）在得到的粉料中加入质量分数5%的PVA造粒，并干压成型，然后在1400℃下煅烧2h，烧成后的样品随炉冷却至室温后取出，制得隔热耐火材料。
上述高岭土粉体中的Al2O3含量为38wt%、SiO2含量为50wt%，自由水含量为12wt%，高岭土粉体的粒径为350μm。
上述硅线石粉体中的Al2O3含量为59.5wt%、SiO2含量为38wt%，硅线石粉体的粒径为300μm。
上述石墨粉体纯度为98%，木屑纯度为98%。
对本实施例制备的隔热耐火材料进行SEM表征，图1为单一添加10wt%石墨（a）、单一添加10wt%木屑（b）、添加10wt%石墨和10wt%木屑复合造孔剂（c）的断面SEM图。由图1a可见，单一添加石墨时，陶瓷孔隙结构基本为球型，孔径分布在几微米到几百微米之间，较大的孔隙主要是由于部分石墨在高温烧成时发生“并孔”现象；单一添加木屑时（图1b），样品内形成了多处连续孔隙，如图中白色箭头所示；添加复合造孔剂时（图1c），样品依然保持着类似于图1a中的球型孔隙结构，没有形成明显的连续孔隙。
对本实施例制备的隔热耐火材料进行容重和抗弯强度测试，图2是造孔剂组成对隔热耐火材料容重和抗弯强度影响的对比图。由图可见，单一使用石墨时，隔热耐火材料的容重高达1.71 g/cm3，单一使用木屑时，隔热耐火材料的抗弯强度仅为0.5MPa。然而，使同复合造孔剂时，隔热耐火材料具有最低的容重1.05g/cm3和相对较高的抗弯强度5.7MPa。因此，复合造孔剂的添加效果明显优于添加单一造孔剂，使同复合造孔剂可以获得兼备轻质、高强两个优良性能的隔热耐火材料。
以上结果表明，添加复合造孔剂可以获得轻质高强的隔热耐火材料。
实施例2
本实施例提供一种轻质隔热耐火材料及其制备方法：
（a）以30wt%的高岭土粉体和35wt%的硅线石粉体为基体，以15wt%的石墨粉体和20wt%的木屑为复合造孔剂；
（b）将上述各种粉体与球和去离子水按1:2:3的质量比混合，并在300r/min的球磨机上球磨8h，然后取出并烘干、碾碎、过80目筛；
（c）在得到的粉料中加入质量分数5%的PVA造粒，并干压成型，然后在1300℃下煅烧1h，烧成后的样品随炉冷却至室温后取出，制得隔热耐火材料。
上述高岭土粉体中的Al2O3含量为40wt%、SiO2含量为45wt%，自由水含量为15wt%，高岭土粉体的粒径为400μm。
上述硅线石粉体中的Al2O3含量为59wt%、SiO2含量为36wt%，硅线石粉体的粒径为300μm。
上述石墨粉体纯度为97%，木屑纯度为98%。
对本实施例制备的隔热耐火材料进行表征和测试，发现添加复合造孔剂时，出现了图1c中类似的形貌，陶瓷孔隙结构基本为球型，没有明显的连续孔隙。并且，使同复合造孔剂时，隔热耐火材料具有较低的容重1.2g/cm3和相对较高的抗弯强度5MPa。因此，使同复合造孔剂可以获得兼备轻质、高强两个优良性能的隔热耐火材料。
以上结果表明，添加复合造孔剂可以获得轻质高强的隔热耐火材料。
以上所述的实施例对本发明的技术方案和有益效果进行了详细说明，应理解的是以上所述仅为本发明的具体实施例，并不用于限制本发明，凡在本发明的原则范围内所做的任何修改和改进等，均应包含在本发明的保护范围之内。
Claims (5)
1.一种轻质隔热耐火材料及其制备方法，其特征在于：
（a）以20-50wt%的高岭土粉体和30-65wt%的硅线石粉体为基体，以5-25wt%的石墨粉体和5-20wt%的木屑为复合造孔剂；
（b）按配方量取各种原料后与球和去离子水按1:2:3的质量比混合，并在300r/min的球磨机上球磨8h，然后取出并烘干、碾碎、过80目筛；
（c）在得到的粉料中加入质量分数5%的聚乙烯醇造粒，并干压成型，然后在高温炉中煅烧，烧成后的样品随炉冷却至室温后取出，制得隔热耐火材料。
2.根据权利要求1所述的一种轻质隔热耐火材料及其制备方法，其特征在于，所述高岭土粉体中的Al2O3含量为33-40wt%、SiO2含量为38-52wt%，自由水含量≤15wt%，所述高岭土粉体的粒径小于400μm。
3.根据权利要求1所述的一种轻质隔热耐火材料及其制备方法，其特征在于，所述硅线石粉体中的Al2O3含量为58-60wt%、SiO2含量为37-40wt%，所述硅线石粉体的粒径小于400μm。
4.根据权利要求1所述的一种轻质隔热耐火材料及其制备方法，其特征在于，石墨粉体纯度＞96%，木屑纯度＞96%。
5.根据权利要求1所述的一种轻质隔热耐火材料及其制备方法，其特征在于，样品的煅烧温度为1300-1400℃，煅烧时间为1-2h。
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