CN113912382A - 一种轻质高铝隔热耐火砖及其制备方法 - Google Patents

一种轻质高铝隔热耐火砖及其制备方法 Download PDF

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CN113912382A
CN113912382A CN202111209957.3A CN202111209957A CN113912382A CN 113912382 A CN113912382 A CN 113912382A CN 202111209957 A CN202111209957 A CN 202111209957A CN 113912382 A CN113912382 A CN 113912382A
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refractory brick
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孙玉岩
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Tangshan Karen Thermal Insulation Material Co ltd
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Abstract

本发明涉及耐火材料技术领域，提出了一种轻质高铝隔热耐火砖，配料按照重量份包括以下组分：高铝矾土熟料30‑50份、粘结剂50‑60份、有机纤维1‑3份、减水剂0.1‑0.2份、发泡剂1.2‑1.6份、蓝晶石10‑15份，所述粘结剂包括高岭土、磷酸，质量比为(10‑12):1。本发明还提出一种轻质高铝隔热耐火砖的制备方法。通过上述技术方案，解决了现有技术中的轻质高铝隔热耐火砖强度低，寿命较短的问题。

Description

一种轻质高铝隔热耐火砖及其制备方法
技术领域
本发明涉及耐火材料技术领域，具体的，涉及一种轻质高铝隔热耐火砖及其制备方法。
背景技术
随着工业的快速发展，对耐火材料的需求越来越大，这主要是由于采用新型隔热耐火材料，可以减少工业窑炉和输热管道的热损失，热损失的减少可以从某一种程度上节约煤炭等资源。因此，大力发展隔热保温耐火材料对我国经济的发展和节约能源有着重要的意义。
工业窑炉热面衬里使用的耐火材料主要是耐火陶瓷纤维、轻质高铝砖、轻质莫来石砖和刚玉莫来石砖等。对于耐火陶瓷纤维，节能效果较好但是耐高温性能较差，刚玉莫来石砖使用温度虽然较高，但是体积密度较大，用其砌筑的炉衬蓄热量较大，炉体重量大，节能效果较差。高铝质耐火砖是以Al2O3为主要化学成分的定型耐火材料，具有耐温、耐磨、强度大的优势，广泛应用于工业窑炉的衬体中。
目前，市面上的轻质高铝隔热耐火砖存在强度不足，易于损坏，寿命较短的问题。
发明内容
本发明提出一种轻质高铝隔热耐火砖及其制备方法，解决了相关技术中轻质高铝隔热耐火砖强度低，寿命较短的问题。
本发明的技术方案如下：
一种轻质高铝隔热耐火砖，配料按照重量份包括以下组分：高铝矾土熟料30-50份、粘结剂50-60份、有机纤维1-3份、减水剂0.1-0.2份、发泡剂1.2-1.6份、蓝晶石10-15份；所述粘结剂包括高岭土、磷酸，质量比为(10-12):1。
作为进一步的技术方案，配料按照重量份包括以下组分：高铝矾土熟料42份、粘结剂55份、有机纤维2份、减水剂0.15份、发泡剂1.3份、蓝晶石12份。
作为进一步的技术方案，所述高岭土的粒度为250～340目。
作为进一步的技术方案，所述发泡剂包括聚苯乙烯球、十二烷基苯磺酸钠，质量比为(3-3.5)：1。
作为进一步的技术方案，所述减水剂包括聚羧酸减水剂、4-嘧啶乙烷磺酸盐，质量比为(8-9)：1。
作为进一步的技术方案，所述有机纤维包括玻璃纤维、聚丙烯腈纤维，质量比为(5-6)：1。
本发明还提出一种轻质高铝隔热耐火砖的制备方法，包括以下步骤：
S1、将高铝矾土熟料、蓝晶石、粘结剂、有机纤维、减水剂混合搅拌后加入水；
S2、加入发泡剂，再次搅拌得到泥料；
S3、泥料浇筑成型，制成砖坯；
S4、砖坯干燥后升温至1300-1350℃烧制即得耐火砖。
作为进一步的技术方案，所述步骤S1中，混合搅拌1-2min后加入水再次搅拌5-7min，所述步骤S2中，搅拌时间控制在2分钟以内，搅拌速度均为300-400r/min。
作为进一步的技术方案，所述步骤S1中，水占其他物料的总量的20％-25％
作为进一步的技术方案，所述干燥分两段进行，第一阶段控制干燥温度30-35℃，时间24-30h，第二阶段控制干燥温度100-110℃，时间18-24h。
本发明的有益效果为：
本发明中采用磷酸和高岭土混合作为粘结剂，4-嘧啶乙烷磺酸盐和聚羧酸减水剂混合作为复合减水剂，有机纤维添加聚丙烯腈纤维和玻璃纤维的混合物，制得的耐火砖轻质、高强、使用寿命高。磷酸与高岭土混合作为粘结剂，使得各个组分粘结性更好，得到的耐火砖抗热震性较好，提高耐火砖的使用寿命。本发明中使用4-嘧啶乙烷磺酸盐与聚羧酸减水剂复合缩短搅拌时间，可以改善原料之间的混合性能。本发明中采用聚丙烯腈纤维，经过高温烧制的聚丙烯腈纤维，可以保留原始纤维的低密度，使得制备的耐火砖更加轻质，而且经过高温烧制的聚丙烯腈纤维，在烧结过程中可以发生氧化碳化等反应，形成碳环网络结构，具有较高的力学性能。
具体实施方式
下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都涉及本发明保护的范围。
实施例1
一种轻质高铝隔热耐火砖，配料按照重量份包括以下组分：高铝矾土熟料42份、粘结剂55份、有机纤维2份、减水剂0.15份、发泡剂1.3份、蓝晶石12份；
粘结剂为高岭土、磷酸，质量比为11:1，发泡剂为聚苯乙烯球、十二烷基苯磺酸钠，质量比为3.2：1；减水剂为聚羧酸减水剂、4-嘧啶乙烷磺酸盐，质量比为8.5：1；有机纤维为玻璃纤维、聚丙烯腈纤维，质量比为5.6：1；
一种轻质高铝隔热耐火砖的制备方法，包括以下步骤：
S1、将高铝矾土熟料、蓝晶石、粘结剂、有机纤维、减水剂混合搅拌1min后加入水再次搅拌6min，搅拌速度为350r/min，水占其他物料的总量的23％；
S2、加入发泡剂，再次搅拌2min得到泥料，搅拌速度为350r/min；
S3、泥料浇筑成型，制成砖坯；
S4、砖坯干燥，第一段33℃干燥24h，第二段105℃干燥18h，后升温至1300-1350℃烧制即得耐火砖。
实施例2
一种轻质高铝隔热耐火砖，配料按照重量份包括以下组分：高铝矾土熟料30份、粘结剂50份、有机纤维3份、减水剂0.1份、发泡剂1.2份、蓝晶石15份；
粘结剂为高岭土、磷酸，质量比为10:1，发泡剂为聚苯乙烯球、十二烷基苯磺酸钠，质量比为3.5：1；减水剂为聚羧酸减水剂、4-嘧啶乙烷磺酸盐，质量比为8：1；有机纤维为玻璃纤维、聚丙烯腈纤维，质量比为5：1；
一种轻质高铝隔热耐火砖的制备方法，包括以下步骤：
S1、将高铝矾土熟料、蓝晶石、粘结剂、有机纤维、减水剂混合搅拌2min后加入水再次搅拌5min，搅拌速度为400r/min，水占其他物料的总量的20％；
S2、加入发泡剂，再次搅拌1min得到泥料，搅拌速度为400r/min；
S3、泥料浇筑成型，制成砖坯；
S4、砖坯干燥，第一段35℃干燥30h，第二段100℃干燥24h，后升温至1300-1350℃烧制得耐火砖。
实施例3
一种轻质高铝隔热耐火砖，配料按照重量份包括以下组分：高铝矾土熟料50份、粘结剂60份、有机纤维1份、减水剂0.2份、发泡剂1.6份、蓝晶石10份；
粘结剂为高岭土、磷酸，质量比为12:1，发泡剂为聚苯乙烯球、十二烷基苯磺酸钠，质量比为3：1；减水剂为聚羧酸减水剂、4-嘧啶乙烷磺酸盐，质量比为9：1；有机纤维为玻璃纤维、聚丙烯腈纤维，质量比为6：1；
一种轻质高铝隔热耐火砖的制备方法，包括以下步骤：
S1、将高铝矾土熟料、蓝晶石、粘结剂、有机纤维、减水剂混合搅拌2min后加入水再次搅拌7min，搅拌速度为300r/min，水占其他物料的总量的25％；
S2、加入发泡剂，再次搅拌2min得到泥料，搅拌速度为300r/min；
S3、泥料浇筑成型，制成砖坯；
S4、砖坯干燥，第一段35℃干燥30h，第二段100℃干燥18h，后升温至1300-1350℃烧制得耐火砖。
实施例4
一种轻质高铝隔热耐火砖，配料按照重量份包括以下组分：高铝矾土熟料35份、粘结剂53份、有机纤维2份、减水剂0.14份、发泡剂1.5份、蓝晶石14份；
粘结剂为高岭土、磷酸，质量比为10:1，发泡剂为聚苯乙烯球、十二烷基苯磺酸钠，质量比为3：1；减水剂为聚羧酸减水剂、4-嘧啶乙烷磺酸盐，质量比为9：1；有机纤维为玻璃纤维、聚丙烯腈纤维，质量比为6：1；
一种轻质高铝隔热耐火砖的制备方法，包括以下步骤：
S1、将高铝矾土熟料、蓝晶石、粘结剂、有机纤维、减水剂混合搅拌1min后加入水再次搅拌6min，搅拌速度为350r/min，水占其他物料的总量的22％；
S2、加入发泡剂，再次搅拌2min得到泥料，搅拌速度为350r/min；
S3、泥料浇筑成型，制成砖坯；
S4、砖坯干燥，第一段33℃干燥26h，第二段105℃干燥20h，后升温至1300-1350℃烧制即得耐火砖。
对比例1
与实施例1相比，粘结剂中的磷酸替换为等量的硼酸，其他与实施例1相同。
对比例2
与实施例1相比，将减水剂中的4-嘧啶乙烷磺酸盐替换为等量的聚羧酸减水剂，其他与实施例1相同。
对比例3
与实施例1相比，将聚丙烯腈纤维替换为等量的玻璃纤维，其他与实施例1相同。
实验例
根据《GB/T 2998-2015定形隔热耐火制品体积密度和真气孔率试验方法》测试耐火砖的体积密度，根据《GB/T3001-2007耐火材料常温抗折强度试验方法》和《GB/T 5072-2008耐火材料常温耐压强度试验方法》测试耐火砖常温抗折、耐压强度，按照《GB/T30873-2014耐火材料抗热震性试验方法》测试耐火砖的热震稳定性，测试结果如表1所示。
表1实施例和对比例耐火砖的性能
性能 体积密度g/cm<sup>3</sup> 抗折强度/MPa 耐压强度/MPa 循环25次质量损失率/％
实施例1 0.6 3.5 26.5 0.12
实施例2 0.8 3.4 25.4 0.16
实施例3 0.9 3.2 25.1 0.14
实施例4 0.7 3.3 26.1 0.13
对比例1 0.9 3.4 25.9 0.29
对比例2 0.7 3.2 26.2 0.22
对比例3 1.3 2.6 24.3 0.13
本发明的实施例1是综合性能较好的实施例，发明人通过限定各个组分之间的比例得到了最佳实施例。对比例1中用粘结剂用硼酸代替磷酸，得到的耐火砖抗热震性有所降低，本发明中采用磷酸作为粘结剂可以提高耐火砖的使用寿命。对比例2中，使用4-嘧啶乙烷磺酸盐可以改善原料之间的混合性能，如果只用聚羧酸减水剂则不如两者复配的效果，混合性能好，可以缩短搅拌时间，而对比例2中，抗热震性能有所降低发明人认为可能是由于前期搅拌混合效果不好，从而导致最终制得的耐火砖性能降低。对比例3中，使用玻璃纤维替代聚丙烯腈纤维，最终制得的耐火砖密度增大。
以上仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (9)

1.一种轻质高铝隔热耐火砖，其特征在于，配料按照重量份包括以下组分：高铝矾土熟料30-50份、粘结剂50-60份、有机纤维1-3份、减水剂0.1-0.2份、发泡剂1.2-1.6份、蓝晶石10-15份，所述粘结剂包括高岭土、磷酸，质量比为(10-12):1。
2.根据权利要求1所述的轻质高铝隔热耐火砖，其特征在于，所述高岭土的粒度为250～340目。
3.根据权利要求1所述的轻质高铝隔热耐火砖，其特征在于，所述发泡剂包括聚苯乙烯球、十二烷基苯磺酸钠，质量比为(3-3.5)：1。
4.根据权利要求1所述的轻质高铝隔热耐火砖，其特征在于，所述减水剂包括聚羧酸减水剂、4-嘧啶乙烷磺酸盐，质量比为(8-9)：1。
5.根据权利要求1所述的轻质高铝隔热耐火砖，其特征在于，所述有机纤维包括玻璃纤维、聚丙烯腈纤维，质量比为(5-6)：1。
6.一种如权利要求1-5任意一项所述的轻质高铝隔热耐火砖的制备方法，其特征在于，包括以下步骤：
S1、将高铝矾土熟料、蓝晶石、粘结剂、有机纤维、减水剂混合搅拌后加入水；
S2、加入发泡剂，再次搅拌得到泥料；
S3、泥料浇筑成型，制成砖坯；
S4、砖坯干燥后升温至1300-1350℃烧制即得耐火砖。
7.根据权利要求6所述的轻质高铝隔热耐火砖的制备方法，其特征在于，混合搅拌1-2min后加入水再次搅拌5-7min，所述步骤S2中，搅拌时间控制在2分钟以内，搅拌速度均为300-400r/min。
8.根据权利要求6所述的轻质高铝隔热耐火砖的制备方法，其特征在于，所述步骤S1中，水占其他物料的总量的20％-25％。
9.根据权利要求6所述的轻质高铝隔热耐火砖的制备方法，其特征在于，所述干燥分两段进行，第一阶段控制干燥温度30-35℃，时间24-30h，第二阶段控制干燥温度100-110℃，时间18-24h。
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