CN113173796A - 一种抗铝液侵蚀的耐火材料及其制备方法 - Google Patents
一种抗铝液侵蚀的耐火材料及其制备方法 Download PDFInfo
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 48
- 239000011819 refractory material Substances 0.000 title claims abstract description 42
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 39
- 238000005260 corrosion Methods 0.000 title claims abstract description 24
- 230000007797 corrosion Effects 0.000 title claims abstract description 24
- 239000007788 liquid Substances 0.000 title abstract description 15
- 238000002360 preparation method Methods 0.000 title abstract description 9
- 239000000463 material Substances 0.000 claims abstract description 48
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 31
- 238000000034 method Methods 0.000 claims abstract description 17
- 229910052751 metal Inorganic materials 0.000 claims abstract description 14
- 239000002184 metal Substances 0.000 claims abstract description 14
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 7
- SNAAJJQQZSMGQD-UHFFFAOYSA-N aluminum magnesium Chemical compound [Mg].[Al] SNAAJJQQZSMGQD-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000002131 composite material Substances 0.000 claims description 21
- 239000000843 powder Substances 0.000 claims description 13
- 229910052593 corundum Inorganic materials 0.000 claims description 11
- 239000010431 corundum Substances 0.000 claims description 8
- 238000005245 sintering Methods 0.000 claims description 6
- 238000001035 drying Methods 0.000 claims description 5
- 229910001570 bauxite Inorganic materials 0.000 claims description 4
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims description 3
- 239000004568 cement Substances 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 3
- 239000004411 aluminium Substances 0.000 claims 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 abstract description 12
- 230000035939 shock Effects 0.000 abstract description 9
- 230000000694 effects Effects 0.000 abstract description 8
- 238000010304 firing Methods 0.000 abstract description 7
- 235000012239 silicon dioxide Nutrition 0.000 abstract description 6
- 239000000377 silicon dioxide Substances 0.000 abstract description 6
- 230000035699 permeability Effects 0.000 abstract description 5
- 239000002893 slag Substances 0.000 abstract description 5
- 230000003628 erosive effect Effects 0.000 abstract description 4
- 239000000126 substance Substances 0.000 abstract description 3
- 238000011049 filling Methods 0.000 abstract description 2
- 229910001092 metal group alloy Inorganic materials 0.000 abstract description 2
- 230000001590 oxidative effect Effects 0.000 abstract description 2
- 239000002994 raw material Substances 0.000 description 6
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 4
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- 229910052791 calcium Inorganic materials 0.000 description 4
- 239000011575 calcium Substances 0.000 description 4
- 238000001723 curing Methods 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 3
- 229910052749 magnesium Inorganic materials 0.000 description 3
- 239000011777 magnesium Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 229910001845 yogo sapphire Inorganic materials 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 229920001353 Dextrin Polymers 0.000 description 1
- 239000004375 Dextrin Substances 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000007767 bonding agent Substances 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- RGPUVZXXZFNFBF-UHFFFAOYSA-K diphosphonooxyalumanyl dihydrogen phosphate Chemical compound [Al+3].OP(O)([O-])=O.OP(O)([O-])=O.OP(O)([O-])=O RGPUVZXXZFNFBF-UHFFFAOYSA-K 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000006386 neutralization reaction Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
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Abstract
本发明涉及一种抗铝液侵蚀的耐火材料及其制备方法。该耐火材料可选自包括以质量分数计的如下组分：30％～95％的AMC复相材料、0％～5％的金属铝粉或镁铝合金、0％～8％的氧化铝微粉、0％～4％的铝溶胶。该耐火材料充分利用AMC复相材料化学纯度高、二氧化硅含量微量、对铝液不润湿的优点，使耐火材料具备抗高温性能、耐侵蚀性好、较高热震稳定性的优点；在此基础上添加部分金属或金属合金，实现在烧成过程中氧化增重、填充气孔并降低孔径的技术效果，进而实现耐火材料的抗熔渣侵蚀性、高热震稳定性和抗渗透性的和谐统一的使用效果；且该耐火材料可以和其他烧成制品配合烧成，不需要单独调整烧成温度，属于生产友好型产品。
Description
技术领域
本发明涉及耐火材料技术领域，尤其涉及一种抗铝液侵蚀的耐火材料及其制备方法。
背景技术
目前熔铝炉用耐火材料主要以高铝矾土熟料为主要原料，添加硫酸钡等抗润湿剂，利用磷酸或磷酸二氢铝作为结合剂，其中铝含量要达到85％以上，氧化铁和二氧化硅含量要尽可能的低，以防止污染铝液，或者采用碳化硅，但碳化硅原料昂贵，市场应用很少。对于我国现有的高铝矾土，不可避免的含有一定量的二氧化硅，铝行业选用的矾土铝含量至少在85％以上，矾土的铝硅合量一般在93-94％之间，所以常用的88％含量的矾土的硅含量约6-7％，铁含量约1.5-2％。以此为原料制作的耐火材料，在使用过程中，金属铝液和耐材紧密接触，很难防止金属铝与氧化铁和二氧化硅的接触和反应，但是如果选用铝含量高的棕刚玉、亚白刚玉、白刚玉，最终材料的抗热震稳定性会显著降低，选用板状刚玉时，成本又难以控制。铝液对镁铝尖晶石和六铝酸钙不润湿，但单一的这些高纯原料价格昂贵，尤其在制作烧结材料时需要很高的烧成温度，能耗高，不符合目前国家的碳达峰、碳中和的发展理念；而且单一物相容易导致结构应力集中，基于这些原料的耐火材料很容易出现断砖、裂纹及结构剥落问题。
基于上述问题，本发明提出一种新型的抗铝液侵蚀的耐火材料，拟解决抗铝液侵蚀耐火材料耐腐蚀性差、热震稳定性差、抗压能力差、成本昂贵且不环保的缺点。
发明内容
为解决现有技术的不足，本发明提出一种抗铝液侵蚀的耐火材料及其制备方法。
为实现以上目的，本发明所采用的技术方案包括：
根据本发明的第一个方面，公开了一种抗铝液侵蚀的耐火材料，所述耐火材料可选自包括以质量分数计的如下组分：30％～95％的AMC复相材料、0％～5％的金属铝粉或镁铝合金、0％～8％的氧化铝微粉、0％～4％的铝溶胶。
进一步地，所述耐火材料还包括0％～50％的高铝矾土、板状刚玉或白刚玉中的一种或几种。
进一步地，所述AMC复相材料优选为包括质量分数大于等于85％的Al2O3、质量分数小于等于8％的MgO、质量分数小于等于7％的CaO、质量分数小于等于0.8％的Fe2O3、质量分数小于等于0.8％的SiO2。
进一步地，所述AMC复相材料优选为包括粒度小于等于8mm的混级料或分级料，还包括粒度小于等于0.09mm的细粉。
进一步地，所述铝溶胶优选为包括质量分数大于40％的Al2O3、质量分数小于25％的P。
进一步地，所述金属铝粉的粒度优选为小于等于0.075mm。
进一步地，所述耐火材料优选为包括以质量分数计的如下组分：质量分数为60％且粒度小于等于5mm的AMC复相材料、质量分数为29％且粒度小于等于0.09mm的AMC复相材料细粉、质量分数为2％且粒度小于等于0.075mm的金属铝粉、质量分数为5％且粒度小于等于0.005mm的氧化铝微粉、质量分数为4％的铝溶胶；所述AMC复相材料为混级料或分级料。
进一步地，所述耐火材料优选为包括以质量分数计的如下组分：质量分数为68％且粒度小于等于8mm的AMC复相材料、质量分数为18％且粒度小于等于0.09mm的AMC复相材料细粉、质量分数为2％且粒度小于等于0.075mm的金属铝粉、质量分数为5％且粒度小于等于0.005mm的氧化铝微粉、质量分数为3％且粒度小于等于0.002mm的氧化铝微粉、质量分数为4％的纯铝酸钙水泥；所述AMC复相材料为混级料或分级料。
进一步地，所述耐火材料优选为包括以质量分数计的如下组分：质量分数为60％且粒度小于等于5mm的AMC复相材料、质量分数为32％且粒度小于等于0.09mm的AMC复相材料细粉、质量分数为4％且粒度小于等于0.075mm的镁铝合金、质量分数为4％的水合氧化铝；所述AMC复相材料为混级料或分级料。
根据本发明的第二个方面，公开了一种如上所述的抗铝液侵蚀的耐火材料的制备方法，包括振动成型、固化干燥的工艺过程。
进一步地，所述方法还包括烧结的工艺过程，所述烧结工艺为在1450℃下保温6～8h。
本发明的有益效果为：
采用本发明所述抗铝液侵蚀的耐火材料及其制备方法，该耐火材料以AMC复相材料为基料，充分利用其化学纯度高、二氧化硅含量微量、对铝液不润湿的优点，使耐火材料具备抗高温性能、耐侵蚀性好、较高热震稳定性的优点；在此基础上添加部分金属或金属合金，实现在烧成过程中氧化增重、填充气孔并降低孔径的技术效果，进而实现耐火材料的抗熔渣侵蚀性、高热震稳定性和抗渗透性的和谐统一的使用效果；且该耐火材料可以和其他烧成制品配合烧成，不需要单独调整烧成温度，属于生产友好型产品。
具体实施方式
为了更清楚的理解本发明的内容，下文将结合具体实施例，具体阐述本发明，本发明的优点和各种效果将由此更加清楚地呈现。本领域技术人员应理解，这些具体实施例是用于说明本发明，而非限制本发明。
在整个说明书中，除非另有特别说明，本文使用的术语应理解为如本领域中通常所使用的含义。因此，除非另有定义，本文使用的所有技术和科学术语具有与本发明所属领域技术人员的一般理解相同的含义。若存在矛盾，本说明书优先。
除非另有特别说明，本发明中用到的各种原材料、试剂、仪器和设备等，均可通过市场购买得到或者可通过现有方法制备得到。
实施例1
一种抗铝液侵蚀的耐火材料，可选自包括以质量分数计的如下组分：质量分数为60％且粒度小于等于5mm的AMC复相材料、质量分数为29％且粒度小于等于0.09mm的AMC复相材料细粉、质量分数为2％且粒度小于等于0.075mm的金属铝粉、质量分数为5％且粒度小于等于0.005mm的氧化铝微粉、质量分数为4％的铝溶胶；
所述AMC复相材料为混级料或分级料；
所述铝溶胶优选为包括质量分数大于40％的Al2O3、质量分数小于25％的P，比重优选为大于等于1.5g/cm3，PH值优选为小于等于3。
优选的，上述抗铝液侵蚀的耐火材料的制备方法，包括将上述混合料混合均匀、振动成型、固化干燥，并在1450℃下保温烧结6～8h。
采用上述工艺得到的抗铝液侵蚀的耐火材料制品，铝含量大于等于75％，镁含量小于等于7％，钙含量小于等于7％，显气孔率小于等于13％,耐压强度大于等于80MP，该制品具有高抗熔渣侵蚀性、高热震稳定性和高抗渗透性的技术效果，具有很好的使用性能。
实施例2
一种抗铝液侵蚀的耐火材料，可选自包括以质量分数计的如下组分：质量分数为68％且粒度小于等于8mm的AMC复相材料、质量分数为18％且粒度小于等于0.09mm的AMC复相材料细粉、质量分数为2％且粒度小于等于0.075mm的金属铝粉、质量分数为5％且粒度小于等于0.005mm的氧化铝微粉、质量分数为3％且粒度小于等于0.002mm的氧化铝微粉、质量分数为4％的纯铝酸钙水泥，外加质量分数为0.2％的分散剂、质量分数为6％的水；所述AMC复相材料为混级料或分级料。
优选的，上述抗铝液侵蚀的耐火材料的制备方法，包括将上述混合料混合均匀、振动成型、固化干燥即可。
采用上述工艺得到的抗铝液侵蚀的耐火材料制品，铝含量大于等于75％，镁含量小于等于7％，钙含量小于等于9％，显气孔率小于等于12％,耐压强度大于等于50MP，该制品具有高抗熔渣侵蚀性、高热震稳定性和高抗渗透性的技术效果，具有很好的使用性能。
实施例3
一种抗铝液侵蚀的耐火材料，可选自包括以质量分数计的如下组分：质量分数为60％且粒度小于等于5mm的AMC复相材料、质量分数为32％且粒度小于等于0.09mm的AMC复相材料细粉、质量分数为4％且粒度小于等于0.075mm的镁铝合金、质量分数为4％的水合氧化铝，外加质量分数为6％的水、质量分数为2％的糊精；所述AMC复相材料为混级料或分级料。
优选的，上述抗铝液侵蚀的耐火材料的制备方法，包括将上述混合料混合均匀、振动成型、固化干燥，并在1450℃下保温烧结6～8h。
采用上述工艺得到的抗铝液侵蚀的耐火材料制品，铝含量大于等于75％，镁含量小于等于7％，钙含量小于等于7％，显气孔率小于等于13％,耐压强度大于等于80MP，该制品具有高抗熔渣侵蚀性、高热震稳定性和高抗渗透性的技术效果，具有很好的使用性能。
具体地，上述实施例1-3所述AMC复相材料的理化指标如表1所示。
表1 AMC复相材料的理化指标
| 项目 | Al2O3 | MgO | CaO | Fe2O3 | SiO2 | 体密 | 吸水率 | CA6 | MA | C2M2A14 |
| 单位 | ％ | ％ | ％ | ％ | ％ | g/cm<sup>3</sup> | ％ | ％ | ％ | ％ |
| 规格值 | ≥85 | ≤8 | ≤7 | ≤0.8 | ≤0.8 | ≥3.25 | ≤2.0 | 7-15 | 20-30 | 50-60 |
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 (10)
1.一种抗铝液侵蚀的耐火材料，其特征在于，可选自包括以质量分数计的如下组分：30％～95％的AMC复相材料、0％～5％的金属铝粉或镁铝合金、0％～8％的氧化铝微粉、0％～4％的铝溶胶。
2.如权利要求1所述的耐火材料，其特征在于，还包括0％～50％的高铝矾土、板状刚玉或白刚玉中的一种或几种。
3.如权利要求1所述的耐火材料，其特征在于，所述AMC复相材料包括质量分数大于等于85％的Al2O3、质量分数小于等于8％的MgO、质量分数小于等于7％的CaO、质量分数小于等于0.8％的Fe2O3、质量分数小于等于0.8％的SiO2。
4.如权利要求3所述的耐火材料，其特征在于，所述AMC复相材料包括粒度小于等于8mm的混级料或分级料，还包括粒度小于等于0.09mm的细粉。
5.如权利要求1所述的耐火材料，其特征在于，所述铝溶胶包括质量分数大于40％的Al2O3、质量分数小于25％的P。
6.如权利要求1至5任一项所述的耐火材料，其特征在于，可选自包括以质量分数计的如下组分：质量分数为60％且粒度小于等于5mm的AMC复相材料、质量分数为29％且粒度小于等于0.09mm的AMC复相材料细粉、质量分数为2％且粒度小于等于0.075mm的金属铝粉、质量分数为5％且粒度小于等于0.005mm的氧化铝微粉、质量分数为4％的铝溶胶；所述AMC复相材料为混级料或分级料。
7.如权利要求1至5任一项所述的耐火材料，其特征在于，可选自包括以质量分数计的如下组分：质量分数为68％且粒度小于等于8mm的AMC复相材料、质量分数为18％且粒度小于等于0.09mm的AMC复相材料细粉、质量分数为2％且粒度小于等于0.075mm的金属铝粉、质量分数为5％且粒度小于等于0.005mm的氧化铝微粉、质量分数为3％且粒度小于等于0.002mm的氧化铝微粉、质量分数为4％的纯铝酸钙水泥；所述AMC复相材料为混级料或分级料。
8.如权利要求1至5任一项所述的耐火材料，其特征在于，可选自包括以质量分数计的如下组分：质量分数为60％且粒度小于等于5mm的AMC复相材料、质量分数为32％且粒度小于等于0.09mm的AMC复相材料细粉、质量分数为4％且粒度小于等于0.075mm的镁铝合金、质量分数为4％的水合氧化铝；所述AMC复相材料为混级料或分级料。
9.一种如权利要求1至8任一项所述的抗铝液侵蚀的耐火材料的制备方法，其特征在于，包括振动成型、固化干燥的工艺过程。
10.如权利要求9所述的方法，其特征在于，还包括烧结的工艺过程，所述烧结工艺为在1450℃下保温6～8h。
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