CN113636851A - Corundum-mullite gel composite wear-resistant castable and baking and setting method thereof - Google Patents
Corundum-mullite gel composite wear-resistant castable and baking and setting method thereof Download PDFInfo
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- 239000002131 composite material Substances 0.000 title claims abstract description 77
- 229910052863 mullite Inorganic materials 0.000 title claims abstract description 35
- 238000000034 method Methods 0.000 title claims abstract description 23
- 239000000843 powder Substances 0.000 claims abstract description 62
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 43
- 239000011230 binding agent Substances 0.000 claims abstract description 25
- 238000005336 cracking Methods 0.000 claims abstract description 25
- 239000004568 cement Substances 0.000 claims abstract description 18
- 238000005266 casting Methods 0.000 claims abstract description 15
- JVTAAEKCZFNVCJ-UHFFFAOYSA-N lactic acid Chemical compound CC(O)C(O)=O JVTAAEKCZFNVCJ-UHFFFAOYSA-N 0.000 claims description 22
- VXYADVIJALMOEQ-UHFFFAOYSA-K tris(lactato)aluminium Chemical compound CC(O)C(=O)O[Al](OC(=O)C(C)O)OC(=O)C(C)O VXYADVIJALMOEQ-UHFFFAOYSA-K 0.000 claims description 22
- 229910052593 corundum Inorganic materials 0.000 claims description 16
- 238000007493 shaping process Methods 0.000 claims description 16
- 239000000654 additive Substances 0.000 claims description 14
- 230000000996 additive effect Effects 0.000 claims description 14
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 14
- 239000004088 foaming agent Substances 0.000 claims description 14
- 239000002245 particle Substances 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 13
- 239000011148 porous material Substances 0.000 claims description 12
- 235000014655 lactic acid Nutrition 0.000 claims description 11
- 239000004310 lactic acid Substances 0.000 claims description 11
- 238000004080 punching Methods 0.000 claims description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
- 239000000835 fiber Substances 0.000 claims description 8
- 229910052751 metal Inorganic materials 0.000 claims description 8
- 239000002184 metal Substances 0.000 claims description 8
- 150000004645 aluminates Chemical class 0.000 claims description 7
- 239000010431 corundum Substances 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 7
- 239000002518 antifoaming agent Substances 0.000 claims description 6
- 239000003638 chemical reducing agent Substances 0.000 claims description 6
- 239000000701 coagulant Substances 0.000 claims description 6
- 239000002274 desiccant Substances 0.000 claims description 6
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical group O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 6
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 5
- 229910052710 silicon Inorganic materials 0.000 claims description 5
- 239000010703 silicon Substances 0.000 claims description 5
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical group [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- IXPNQXFRVYWDDI-UHFFFAOYSA-N 1-methyl-2,4-dioxo-1,3-diazinane-5-carboximidamide Chemical compound CN1CC(C(N)=N)C(=O)NC1=O IXPNQXFRVYWDDI-UHFFFAOYSA-N 0.000 claims description 3
- 239000004964 aerogel Substances 0.000 claims description 3
- 229910052681 coesite Inorganic materials 0.000 claims description 3
- 229910052906 cristobalite Inorganic materials 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 235000010413 sodium alginate Nutrition 0.000 claims description 3
- 239000000661 sodium alginate Substances 0.000 claims description 3
- 229940005550 sodium alginate Drugs 0.000 claims description 3
- 229910052682 stishovite Inorganic materials 0.000 claims description 3
- 229910052905 tridymite Inorganic materials 0.000 claims description 3
- 230000008901 benefit Effects 0.000 abstract description 7
- 230000017525 heat dissipation Effects 0.000 abstract description 6
- 230000035939 shock Effects 0.000 abstract description 6
- 230000003628 erosive effect Effects 0.000 abstract description 5
- 238000005553 drilling Methods 0.000 abstract description 2
- 230000008569 process Effects 0.000 description 10
- 230000009172 bursting Effects 0.000 description 7
- 230000000694 effects Effects 0.000 description 6
- 239000011819 refractory material Substances 0.000 description 6
- 239000011449 brick Substances 0.000 description 4
- 238000001514 detection method Methods 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 238000007599 discharging Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000011159 matrix material Substances 0.000 description 3
- 239000004570 mortar (masonry) Substances 0.000 description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000008646 thermal stress Effects 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000001879 gelation Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000004574 high-performance concrete Substances 0.000 description 1
- 239000011372 high-strength concrete Substances 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 230000035772 mutation Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 239000013589 supplement Substances 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 230000001960 triggered effect Effects 0.000 description 1
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Classifications
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- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/48—Producing shaped prefabricated articles from the material by removing material from solid section preforms for forming hollow articles, e.g. by punching or boring
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/243—Setting, e.g. drying, dehydrating or firing ceramic articles
-
- 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
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/06—Aluminous cements
-
- 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
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
-
- 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
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
-
- 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
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
-
- 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
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Manufacturing & Machinery (AREA)
- Inorganic Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Ceramic Products (AREA)
Abstract
The invention belongs to the technical field of refractory castable, and particularly relates to a corundum-mullite gel composite wear-resistant castable and a baking and setting method thereof. The invention ensures that the compact castable can meet the use requirements of a kiln head cover part of a cement rotary kiln and a hot end part of a grate cooler by forming the castable by refractory aggregate, refractory powder, oxide micro powder, a composite binder and a composite explosion-proof agent and matching with the modes of drilling a casting body and low-temperature intermittent baking operation. The invention has the following advantages: firstly, the compact castable after baking forming has outstanding wear resistance, good thermal shock resistance, low heat dissipation, erosion resistance and outstanding overall high-temperature performance, and can effectively meet the use requirements of a kiln head cover part of a cement rotary kiln and a hot end part of a grate cooler; and secondly, the compact castable has outstanding anti-cracking capability and high cracking temperature, is not easy to crack after being used at high temperature for a long time in a kiln lining system, and has effective service life as long as 24 months.
Description
Technical Field
The invention belongs to the technical field of refractory castable, and particularly relates to a corundum-mullite gel composite wear-resistant castable and a baking and setting method thereof.
Background
The kiln head cover part of the cement rotary kiln and the hot end part of the grate cooler are considered as one of the weakest links in the whole kiln lining system. The kiln head cover part is taken as an example, the kiln head cover part is a blanking point of a clinker finished product, the temperature is up to more than 1150 ℃, alkali in the clinker can be separated out in the clinker cooling process, secondary and tertiary air inlets for the system are arranged at the part, and the service life of the kiln head cover part is only 6-8 months due to high temperature, large heat dissipation, wind erosion and alkali erosion in the operation process, the time is short, and the kiln head cover part is not uniform with the standard overhaul time of a cement kiln system, so that the kiln head cover part is required to be independently stopped for treatment.
Therefore, a good lining refractory material needs to be developed so that the kiln head cover part and the hot end part meet the requirements of sufficient wear resistance, hot state strength, thermal shock resistance and low heat dissipation capacity, which has important significance for the normal operation of the cement kiln.
The existing lining refractory materials of a kiln head cover part and a hot end part mainly comprise two types of shaping and unshaped materials, wherein the shaping refractory material is formed by hanging a layer of refractory hanging brick on the inner side of the part and then bonding two adjacent hanging bricks through refractory mortar so as to basically prevent flames from penetrating through gaps. However, this solution for shaping refractory materials has the following drawbacks: firstly, the hanging operation of the hanging brick is troublesome, the subsequent bonding operation of the refractory mortar is more troublesome and has higher requirements, the whole construction process is more complicated, and the cost is high; secondly, the development trend of the kiln head cover part and the hot end part is in a large-scale direction, so the hanging operation and the bonding operation are more difficult, and the conditions of great abrasion, cold and hot mutation and thermal shock on the hanging brick and the refractory mortar are more frequent, so the scheme for shaping the refractory material frequently falls off after less than six months of use, and the effect is poor.
Relatively further, the second scheme is that the unshaped refractory material is a refractory castable, while the existing refractory castable adopts a relatively low-grade natural alumina raw material, the difference of the types and the contents of impurities is large, the existing refractory castable is influenced by the traditional firing process and the manual sorting process, the overall quality is not stable enough, the processing is not fine enough, the uniformity is poor, the problems of unstable performance indexes and non-uniform damage rate of the refractory castable are finally caused, and the service life of the refractory castable at a kiln head cover part and a hot end part is seriously reduced.
Therefore, in summary, the refractory castable is urgently needed to be improved deeply so as to ensure that the refractory castable has enough wear resistance, thermal state strength, thermal shock resistance and low heat dissipation capacity, and the use requirements of a kiln head cover part of a cement rotary kiln and a hot end part of a grate cooler are met.
Chinese patent with patent publication No. CN108455974A and publication No. 2018.08.28 discloses a castable for a cement kiln head cover, which comprises aggregate and a matrix material, wherein the weight ratio of the aggregate to the matrix material is 7: 3, the particle size of the aggregate is 0.2-10 mm, and the particle size of the base material is 0.088-0.045 mm; the aggregate comprises 25-40 parts by weight of magnesium titanate, 28-48 parts by weight of titanium corundum, 10-15 parts by weight of silicon carbide and 10-16 parts by weight of aluminum oxynitride; the matrix comprises metal silicon micro powder, silicon oxide fine powder and aluminum oxide micro powder.
However, the castable for the kiln head cover of the cement kiln in the patent of the invention has good high-temperature performance, but the castable has the problems of too compact internal structure, too small pore size and too narrow pore size distribution after being formed, and finally the castable is relatively easy to crack in the baking forming and subsequent use processes.
Disclosure of Invention
The invention provides a corundum-mullite gel composite wear-resistant castable and a baking and shaping method thereof, wherein refractory aggregate, refractory powder, oxide micro powder, a composite binder and a composite explosion-proof agent form the castable, and the castable is matched with the modes of drilling a casting body and low-temperature intermittent baking operation, so that the compact castable can meet the use requirements of a kiln head cover part of a cement rotary kiln and a hot end part of a grate cooler.
The technical scheme adopted by the invention for solving the problems is as follows: a corundum-mullite gel composite wear-resistant castable comprises a refractory aggregate, refractory powder, oxide micro powder, a composite binder and a composite explosion-proof agent, wherein a compact castable is obtained after the castable is cast, baked and formed, the apparent porosity of the compact castable is 3.2-5.8%, and the bulk density of the compact castable is 2.4-2.6g/cm3。
In the prior art, the following two points are said to be anti-burst.
1. The thermal stress theory means that the thermal inertia of the casting body causes uneven internal heat conduction and causes a temperature gradient in the casting body, and the two-way or three-way thermal stress generated along with the temperature gradient causes the casting body to crack after reaching a certain value.
2. The steam pressure theory says that because the high-performance casting body has a compact structure and low permeability, in the temperature rise process, the compact internal structure and the non-through capillary pores prevent the rapid escape of water vapor condensed water, namely the function of a saturation barrier (saturation clog), the steam pressure is generated, and when the steam pressure reaches a certain value, the high-temperature bursting of the casting body is triggered.
However, many researchers believe that the bursting is the combination of the temperature stress theory and the steam pressure theory, and believe that the root cause of the high-strength and high-performance concrete is easy to burst is the compact pore structure of the concrete.
On the other hand, according to the prior art, it can be known that the apparent porosity is properly reduced, which can improve the mechanical strength of the castable, but if the apparent porosity is too low, the castable is easy to crack, i.e. the cracking temperature is reduced, and the cracking condition is common, which is very unfavorable.
Therefore, the invention determines the apparent porosity of 3.2-5.8% and combines the apparent porosity with 2.4-2.6g/cm3The pore opening degree in the compact castable is proper, and the internal water vapor is easy to discharge, so that the anti-burst performance is improved.
The further preferred technical scheme is as follows: the composite explosion-proof agent comprises a metal aluminum powder foaming agent, an azoamide foaming agent, a cracking agent aluminum lactate and explosion-proof fibers.
In the invention, the metal aluminum powder foaming agent and the azoamide foaming agent can reserve pores in the castable in the process of baking and forming the compact castable, so that the final explosion-proof and anti-burst performance is ensured.
In addition, the aluminum lactate serving as the cracking agent can ensure that enough cracks can be formed in the baking process through the thermal instability of the structure of the aluminum lactate, so that moisture in a subsequent castable can be discharged, and the aluminum lactate also has a gelling effect after heating and can supplement the bonding and curing effects of the composite binder.
And finally, the explosion-proof fiber is glass fiber, heat-resistant steel fiber or carbon fiber, so that the castable has a basic explosion-proof effect.
The further preferred technical scheme is as follows: in the cracking agent aluminum lactate, Al2O3The molar ratio to lactic acid was 1: (2.2-2.5).
In the prior art, Al is contained in aluminum lactate2O3The molar ratio to lactic acid can be up to 1:4 at most, whereas in the present invention, 1: (2.2-2.5), the determined aluminum lactate has relatively high crack generation capacity, and the moisture in the subsequent castable is ensured to be easily discharged, at the moment, the gel effect of the aluminum lactate is poor, and the bonding effect of the composite binder cannot be remarkably improved.
The further preferred technical scheme is as follows: in the cracking agent aluminum lactate, Al2O3The molar ratio to lactic acid was 1: (3.0-3.6).
In the invention, the lactic acid with relatively high content can ensure that the corresponding aluminum lactate has relatively low but enough crack generation capacity, and meanwhile, the bonding property of the composite binder can be obviously assisted to be improved, so that the final compact castable has the advantages of wear resistance, high hardness and outstanding mechanical properties.
More importantly, Al2O3The molar ratio to lactic acid was 1: (2.5-3.0) but excluding 1: 2.5 and 1: the aluminum lactate of 3.0 is not suitable for use in the castable composition of the present invention because neither of the crack-generating ability nor the ability to assist adhesion after gelation is outstanding.
The further preferred technical scheme is as follows: the composite binder comprises gel powder and aluminate cement, wherein the gel powder is silicon-aluminum gel powder, sodium alginate gel powder and SiO2Any one or a mixture of several of aerogel powders.
In the invention, the gel powder and the aluminate cement are compounded doubly, so that the high-temperature performance of the compact castable is improved, and the wear resistance of the compact castable is enhanced.
The further preferred technical scheme is as follows: the refractory aggregate is corundum particles with the particle size of 6-10mm, the refractory powder is mullite powder with the fineness of 200-325 meshes, and the oxide micropowder is any one or mixture of active silicon micropowder and alumina micropowder.
The further preferable technical scheme is that the composition comprises the following components by weight: 68-72% of refractory aggregate, 15-25% of refractory powder, 2-12% of oxide micropowder, 1-3% of composite binder and 0.1-0.5% of composite explosion-proof agent, and the rest is additive, wherein the additive comprises water reducing agent, coagulant, retarder, expanding agent, defoaming agent and quick drying agent.
The further preferable technical scheme is that the composition comprises the following components by weight: 70% of refractory aggregate, 19% of refractory powder, 7.5% of oxide micropowder, 2% of composite binder, 0.5% of composite explosion-proof agent and 1% of additive.
The baking and shaping method of the corundum-mullite gel composite wear-resistant castable sequentially comprises the following steps:
s1, punching the castable which is coated and poured to obtain the perforated castable;
s2, carrying out intermittent low-temperature baking operation on the open pore castable to obtain the final shaped castable,
in S2, the baking temperature of the intermittent low-temperature baking operation is 650-.
In the invention, the castable punching operation has the following two advantages: firstly, the castable can have relatively uniform heating degree; and secondly, the convenience degree of discharging the water gas in the casting material is improved, the discharging path is shorter, the vapor pressure in the casting material is relatively smaller, and the cracking is more difficult.
In addition, the intermittent low-temperature baking operation also has the two advantages that the heat can be ensured to have sufficient transmission time in the casting material, the baking pause time is also the time for discharging a large amount of internal moisture, and the relatively small vapor pressure in the casting material is ensured.
The further preferred technical scheme is as follows: s1, punching holes with diameter of 2-8mm and depth of 15-35% of the thickness of the poured casting material, and punching holes from the baking surface with density of 10-50 holes/m2。
In the invention, the relatively small and dense mode of punching the surface of the casting material can ensure relatively uniform heating condition and relatively small steam pressure in the interior on the premise of effective baking forming, so that the compact casting material has the advantage of relatively uneasy bursting in the baking forming and subsequent using processes.
The invention has the following advantages: firstly, the compact castable after baking forming has outstanding wear resistance, good thermal shock resistance, low heat dissipation, erosion resistance and outstanding overall high-temperature performance, and can effectively meet the use requirements of a kiln head cover part of a cement rotary kiln and a hot end part of a grate cooler; secondly, the compact castable has outstanding anti-cracking capability and high cracking temperature, is not easy to crack after being used at high temperature for a long time in a kiln lining system, and has effective service life as long as 24 months; thirdly, the baking forming method of the compact castable is scientific, reasonable, simple and efficient, and can further improve the anti-cracking capability of the compact castable.
Drawings
Fig. 1 shows technical specifications of 4 embodiments of the dense castable in the present invention.
Detailed Description
The following description is only a preferred embodiment of the present invention and is not intended to limit the scope of the present invention.
Example 1
The corundum-mullite gel composite wear-resistant castable comprises a refractory aggregate, refractory powder, oxide micro powder, a composite binder and a composite explosion-proof agent, wherein a compact castable is obtained after the castable is cast, baked and formed, the apparent porosity of the compact castable is 3.2%, and the bulk density of the compact castable is 2.5g/cm3。
The composite explosion-proof agent comprises a metal aluminum powder foaming agent, an azoamide foaming agent, a cracking agent aluminum lactate and explosion-proof fibers. In the cracking agent aluminum lactate, Al2O3The molar ratio to lactic acid was 1: 2.2.
the composite binder comprises gel powder and aluminate cement, wherein the gel powder is silicon-aluminum gel powder.
The refractory aggregate is corundum particles with the particle size of 6-7mm, the refractory powder is mullite powder with the fineness of 200-280 meshes, and the oxide micropowder is active silicon micropowder.
Specifically, the corundum-mullite gel composite wear-resistant castable comprises the following components in parts by weight: 70% of refractory aggregate, 19% of refractory powder, 7.5% of oxide micropowder, 2% of composite binder, 0.5% of composite explosion-proof agent and 1% of additive, wherein the additive comprises existing water reducing agent, coagulant, retarder, expanding agent, defoaming agent and quick drying agent.
A baking and shaping method of a corundum-mullite gel composite wear-resistant castable sequentially comprises the following steps:
s1, punching the castable which is coated and poured to obtain the perforated castable;
s2, carrying out intermittent low-temperature baking operation on the open pore castable to obtain the final shaped castable,
in S2, the baking temperature of the intermittent low-temperature baking operation is 650-.
In S1, the diameter of a single punch is 2.5mm, the depth of the punch is 18% of the thickness of the castable which is coated and poured, the punch is inwards punched from the baking surface, and the density of the punch is 30/m2。
And curing the obtained compact castable by baking and shaping at 20 ℃ for 2 hours, and finally carrying out test detection on five technical indexes of volume density, normal-temperature rupture strength, normal-temperature compressive strength, wear resistance and bursting temperature to obtain a data result shown in the attached figure 1.
Example 2
The corundum-mullite gel composite wear-resistant castable comprises a refractory aggregate, refractory powder, oxide micro powder, a composite binder and a composite explosion-proof agent, wherein a compact castable is obtained after the castable is cast, baked and formed, the apparent porosity of the compact castable is 5.6%, and the bulk density of the compact castable is 2.6g/cm3。
The composite explosion-proof agent comprises a metal aluminum powder foaming agent, an azoamide foaming agent, a cracking agent aluminum lactate and explosion-proof fibers. In the cracking agent aluminum lactate, Al2O3The molar ratio to lactic acid was 1: 2.5.
the composite binder comprises gel powder and aluminate cement, wherein the gel powder is sodium alginate gel powder.
The refractory aggregate is corundum particles with the particle size of 6-9mm, the refractory powder is mullite powder with the fineness of 240-300 meshes, and the oxide micropowder is alumina micropowder.
Specifically, the corundum-mullite gel composite wear-resistant castable comprises the following components in parts by weight: 69% of refractory aggregate, 20% of refractory powder, 7.5% of oxide micropowder, 2.5% of composite binder, 0.5% of composite explosion-proof agent and 0.5% of additive, wherein the additive comprises existing water reducing agent, coagulant, retarder, expanding agent, defoaming agent and quick drying agent.
A baking and shaping method of a corundum-mullite gel composite wear-resistant castable sequentially comprises the following steps:
s1, punching the castable which is coated and poured to obtain the perforated castable;
s2, carrying out intermittent low-temperature baking operation on the open pore castable to obtain the final shaped castable,
in S2, the baking temperature of the intermittent low-temperature baking operation is 700-.
S1, making holes on the baking surface with a hole density of 40 holes/m, wherein the diameter of each hole is 4mm, the depth of each hole is 25% of the thickness of the pouring material after coating and pouring2。
And curing the obtained compact castable by baking and shaping at 20 ℃ for 2 hours, and finally carrying out test detection on five technical indexes of volume density, normal-temperature rupture strength, normal-temperature compressive strength, wear resistance and bursting temperature to obtain a data result shown in the attached figure 1.
Example 3
The corundum-mullite gel composite wear-resistant castable comprises a refractory aggregate, refractory powder, oxide micro powder, a composite binder and a composite explosion-proof agent, wherein a compact castable is obtained after the castable is cast, baked and formed, the apparent porosity of the compact castable is 4.0%, and the bulk density of the compact castable is 2.6g/cm3。
The composite explosion-proof agent comprises a metal aluminum powder foaming agent, an azoamide foaming agent, a cracking agent aluminum lactate and explosion-proof fibers. In the cracking agent aluminum lactate, Al2O3The molar ratio to lactic acid was 1: 3.2.
the composite binder comprises gel powder and aluminate cement, wherein the gel powder is SiO2Aerogel powders.
The refractory aggregate is corundum particles with the particle size of 8-9mm, the refractory powder is mullite powder with the fineness of 300-320 meshes, and the oxide micropowder is alumina micropowder.
Specifically, the corundum-mullite gel composite wear-resistant castable comprises the following components in parts by weight: 68% of refractory aggregate, 21% of refractory powder, 6.5% of oxide micropowder, 3.5% of composite binder, 0.5% of composite explosion-proof agent and 0.5% of additive, wherein the additive comprises existing water reducing agent, coagulant, retarder, expanding agent, defoaming agent and quick drying agent.
A baking and shaping method of a corundum-mullite gel composite wear-resistant castable sequentially comprises the following steps:
s1, punching the castable which is coated and poured to obtain the perforated castable;
s2, carrying out intermittent low-temperature baking operation on the open pore castable to obtain the final shaped castable,
in S2, the baking temperature of the intermittent low-temperature baking operation is 760 and 790 ℃, the baking duration time is 5min each time, and the baking pause time is 4min each time.
S1, making holes on the baking surface with a hole density of 50 holes/m, wherein the diameter of each hole is 6mm, the depth of each hole is 15% of the thickness of the pouring material after coating and pouring2。
And curing the obtained compact castable by baking and shaping at 20 ℃ for 2 hours, and finally carrying out test detection on five technical indexes of volume density, normal-temperature rupture strength, normal-temperature compressive strength, wear resistance and bursting temperature to obtain a data result shown in the attached figure 1.
Example 4
The corundum-mullite gel composite wear-resistant castable comprises a refractory aggregate, refractory powder, oxide micro powder, a composite binder and a composite explosion-proof agent, wherein a compact castable is obtained after the castable is cast, baked and formed, the apparent porosity of the compact castable is 5.2%, and the bulk density of the compact castable is 2.5g/cm3。
The composite explosion-proof agent comprises a metal aluminum powder foaming agent, an azoamide foaming agent, a cracking agent aluminum lactate and explosion-proof fibers. In the cracking agent aluminum lactate, Al2O3The molar ratio to lactic acid was 1: 3.6.
the composite binder comprises gel powder and aluminate cement, wherein the gel powder is silicon-aluminum gel powder.
The refractory aggregate is corundum particles with the particle size of 9-10mm, the refractory powder is mullite powder with the fineness of 300-325 meshes, and the oxide micropowder is active silicon micropowder.
Specifically, the corundum-mullite gel composite wear-resistant castable comprises the following components in parts by weight: 70% of refractory aggregate, 19% of refractory powder, 8% of oxide micropowder, 2% of composite binder, 0.5% of composite explosion-proof agent and 0.5% of additive, wherein the additive comprises existing water reducing agent, coagulant, retarder, expanding agent, defoaming agent and quick drying agent.
A baking and shaping method of a corundum-mullite gel composite wear-resistant castable sequentially comprises the following steps:
s1, punching the castable which is coated and poured to obtain the perforated castable;
s2, carrying out intermittent low-temperature baking operation on the open pore castable to obtain the final shaped castable,
in S2, the baking temperature of the intermittent low-temperature baking operation is 770-800 ℃, the baking duration time is 5min each time, and the baking pause time is 6min each time.
S1, making holes with a diameter of 2mm and a depth of 35% of the thickness of the pouring material, and making holes from the baking surface with a hole density of 50 holes/m2。
And curing the obtained compact castable by baking and shaping at 20 ℃ for 2 hours, and finally carrying out test detection on five technical indexes of volume density, normal-temperature rupture strength, normal-temperature compressive strength, wear resistance and bursting temperature to obtain a data result shown in the attached figure 1.
Finally, from the data table of fig. 1, the following conclusions can be drawn.
The castable disclosed by the invention is sequentially poured, baked and formed and maintained to obtain a compact castable, and the compact castable has the comprehensive advantages of outstanding wear resistance, good thermal shock resistance, low heat dissipation, erosion resistance, outstanding overall high-temperature performance, good anti-cracking capability and higher cracking temperature, and can well meet the refractory use requirements of kiln head covers of rotary cement kilns and hot end parts of grate coolers.
While the embodiments of the present invention have been described in detail with reference to the drawings, the present invention is not limited to the above embodiments, and various modifications can be made within the knowledge of those skilled in the art without departing from the spirit of the present invention. These are non-inventive modifications, which are intended to be protected by patent laws within the scope of the claims appended hereto.
Claims (10)
1. A corundum-mullite gel composite wear-resistant castable is characterized in that: the composite castable comprises refractory aggregate, refractory powder, oxide micro powder, a composite binder and a composite explosion-proof agent, wherein the compact castable is obtained after the castable is cast, baked and formed, the apparent porosity of the compact castable is 3.2-5.8%, and the bulk density of the compact castable is 2.4-2.6g/cm3。
2. The corundum-mullite gel composite wear-resistant castable according to claim 1, characterized in that: the composite explosion-proof agent comprises a metal aluminum powder foaming agent, an azoamide foaming agent, a cracking agent aluminum lactate and explosion-proof fibers.
3. The corundum-mullite gel composite wear-resistant castable according to claim 2, characterized in that: in the cracking agent aluminum lactate, Al2O3The molar ratio to lactic acid was 1: (2.2-2.5).
4. The corundum-mullite gel composite wear-resistant castable according to claim 2, characterized in that: in the cracking agent aluminum lactate, Al2O3The molar ratio to lactic acid was 1: (3.0-3.6).
5. The corundum-mullite gel composite wear-resistant castable according to claim 1, characterized in that: the composite binder comprises gel powder and aluminate cement, wherein the gel powder is silicon-aluminum gel powder, sodium alginate gel powder and SiO2Any one or a mixture of several of aerogel powders.
6. The corundum-mullite gel composite wear-resistant castable according to claim 1, characterized in that: the refractory aggregate is corundum particles with the particle size of 6-10mm, the refractory powder is mullite powder with the fineness of 200-325 meshes, and the oxide micropowder is any one or mixture of active silicon micropowder and alumina micropowder.
7. The corundum-mullite gel composite wear-resistant castable according to claim 1, characterized by comprising the following components by weight: 68-72% of refractory aggregate, 15-25% of refractory powder, 2-12% of oxide micropowder, 1-3% of composite binder and 0.1-0.5% of composite explosion-proof agent, and the rest is additive, wherein the additive comprises water reducing agent, coagulant, retarder, expanding agent, defoaming agent and quick drying agent.
8. The corundum-mullite gel composite wear-resistant castable according to claim 7, characterized by comprising the following components by weight: 70% of refractory aggregate, 19% of refractory powder, 7.5% of oxide micropowder, 2% of composite binder, 0.5% of composite explosion-proof agent and 1% of additive.
9. The baking and shaping method of the corundum-mullite gel composite wear-resistant castable according to claim 1, characterized by comprising the following steps in sequence:
s1, punching the castable which is coated and poured to obtain the perforated castable;
s2, carrying out intermittent low-temperature baking operation on the open pore castable to obtain the final shaped castable,
in S2, the baking temperature of the intermittent low-temperature baking operation is 650-.
10. The baking and shaping method of the corundum-mullite gel composite wear-resistant castable according to claim 9, characterized in that: in S1, punching with a single punch hole diameter of 2-8mmThe depth of the holes is 15-35% of the thickness of the casting material which is coated and cast, holes are punched inwards from the baking surface, and the density of the holes is 10-50 holes/m2。
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| CN114380607A (en) * | 2022-01-26 | 2022-04-22 | 郑州金河源耐火材料有限公司 | Corundum-mullite gel composite wear-resistant castable and preparation method thereof |
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