CN114349472B - 一种低成本高抗热震低导热轻质隔热砖及其制备方法 - Google Patents
一种低成本高抗热震低导热轻质隔热砖及其制备方法 Download PDFInfo
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- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 112
- 239000000919 ceramic Substances 0.000 claims abstract description 57
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 56
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- 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 49
- 239000000843 powder Substances 0.000 claims abstract description 46
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- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 31
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- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 claims description 27
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- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound 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 8
- 238000000227 grinding Methods 0.000 claims description 8
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Abstract
本发明公开了一种低成本高抗热震低导热轻质隔热砖,其主要包含如下体积份数的组分:陶瓷辊棒废料50‑60份,氧化铝粉10‑20份,镁质粘土10‑20份,高岭土20‑30份,木屑30‑50份;所述陶瓷辊棒废料为低热膨胀陶瓷辊棒废料,其热膨胀系数≤4×10‑6/℃。相应地,本发明还提供了上述低成本高抗热震低导热轻质隔热砖的制备方法,其采用振动加压成型,效率高,废料少。所述低成本高抗热震低导热轻质隔热砖的抗热震性能好,导热系数低,体积密度低。本发明的隔热砖以辊棒废料为主要原料,有利于降低产品的成本,并且减少辊棒废料带来的环境污染。
Description
技术领域
本发明涉及隔热砖技术领域,尤其涉及一种低成本高抗热震低导热轻质隔热砖及其制备方法。
背景技术
在传统能源日益枯竭,新能源发展缓慢情况下,企业对工业窑炉的节能降耗非常重视。陶瓷企业常常采用快烧的方式提高产能、降低能耗。这样对窑车用砖是技术难点,即在高温隧道窑内,窑车快进快出,要求窑车用砖具有良好的抗热震性。国内现有的窑车用砖抗热震性不是太好,在使用一段时间后容易开裂、掉砖,造成维修频繁,增加生产成本。
发明内容
本发明所要解决的技术问题在于,提供一种低成本高抗热震低导热轻质隔热砖,其抗热震性能好,体积密度低。
本发明所要解决的技术问题还在于,提供一种低成本高抗热震低导热轻质隔热砖的制备方法,方法简单,其制备得到的隔热砖的抗热震性好。
为了解决上述技术问题,本发明提供了一种低成本高抗热震低导热轻质隔热砖,其主要由下述以体积份计的原料制成:
陶瓷辊棒废料50-60份,氧化铝粉10-20份,镁质粘土10-20份,高岭土20-30份,木屑30-50份;
所述陶瓷辊棒废料为低热膨胀陶瓷辊棒废料,其热膨胀系数≤4×10-6/℃。
优选地,所述陶瓷辊棒废料为低热膨胀率陶瓷辊棒生产过程中产生的废料和/或低热膨胀率陶瓷辊棒使用后产生的废料;
所述陶瓷辊棒废料的Al2O3的含量为50-66wt%,SiO2含量为26-32wt%,MgO含量为6-8wt%;
所述陶瓷辊棒废料的莫来石晶相含量为40~50%,堇青石晶相含量为50~60%;
所述陶瓷辊棒废料的最大粒度≤44μm。
优选地,所述木屑的粒度≤0.5mm。
优选地,所述氧化铝粉为γ-氧化铝粉和/或α-氧化铝粉;
所述α-氧化铝粉的Al2O3含量≥99wt%,所述α-氧化铝粉的粒度≤44μm;
所述γ-氧化铝粉的Al2O3含量≥97wt%,所述γ-氧化铝粉的粒度≤88μm。
优选地,所述镁质粘土的Al2O3含量≥20wt%,MgO含量≥22wt%;
所述镁质粘土的粒度≤88μm。
优选地,所述高岭土的Al2O3含量≥35wt%,Fe2O3含量≤0.8wt%;
所述高岭土的粒度≤88μm。
优选地,所述低成本高抗热震低导热轻质隔热砖的Al2O3含量为40-45wt%,SiO2含量为31-38wt%,MgO含量为4-6wt%。
所述低成本高抗热震低导热轻质隔热砖的体积密度为0.95-1.05g/cm3;耐压强度为6.0-8.0MPa;
在1350℃下保温24h后,其重烧线变化率为-0.2%~0.2%;
在350±25℃下导热系数为0.28-0.32W/(m·K);
1000℃空冷测量条件下抗热震次数大于70次。
为解决上述问题,本发明还提供了一种低成本高抗热震低导热轻质隔热砖的制备方法,包括以下步骤:
将陶瓷辊棒废料、氧化铝粉、镁质粘土、高岭土倒入研磨设备中,研磨后得到混合物;
向所述混合物中加入木屑和水,混合均匀后得到泥料;
将所述泥料倒进模具中,成型得到坯体;
将所述坯体干燥、烧成,得到成品。
优选地,所述坯体的干燥温度为80~120℃,干燥时间为24~72h。
优选地,所述泥料倒进模具中,通过振动加压成型得到多个坯体;所述振动加压成型的激振力为220KN,振动频率为1000-2800r/min,振幅为1-3mm。
优选地,所述坯体的烧成曲线为:由室温升温到150-200℃,升温时间为6-8h;
由150-200℃升温到600~800℃,升温时间为3-6h;
在600~800℃下保温1.0-2.2h;
从600~800℃升温到1100-1200℃,升温时间为4.5-5.5h;
在1100-1200℃下保温2-3h;
从1100-1200℃升温到1390-1400℃,升温时间为4-5h;
在1390-1400℃下保温8-10h。
实施本发明,具有如下有益效果:
1、本发明将低热膨胀率陶瓷辊棒生产过程中的产生的以及低热膨胀陶瓷辊棒在陶瓷厂使用后产生的废料应用于低成本高热震低导热莫来石隔热砖的生产,实现了资源的合理利用的资源化利用,节能环保。
2、本发明提供的低成本高抗热震低导热轻质隔热砖通过合理的配方结构,将陶瓷辊棒废料、氧化铝粉、镁质粘土、高岭土合理搭配,并加入木屑及造孔剂,使得制得的隔热砖具有兼具体积密度低、低导热、抗热震性能好的优点,同时实现了资源的合理利用的资源化利用,节能环保。本发明得到的一种低成本高抗热震低导热轻质隔热砖的体积密度为0.95-1.05g/cm3;耐压强度为6.0-8.0MPa;在1350℃下保温24h得到的重烧线变化率为-0.2~0.2%;导热系数为(350±25℃)0.28-0.32W/(m·K);1000℃抗热震次数大于70次,按照GBT30873-2014中的空气自然冷法测量。
3、本发明烧成的隔热砖中低热膨胀率陶瓷辊棒废料所含有的堇青石起到晶核的作用,并在合理的烧成制度下,使得反应合成堇青石含量高,从而使得隔热砖的抗热震性保持在较高水平。
4、本发明采用一次多模具振动加压成型的生产工艺,一次成型多个砖坯,能保证所得砖坯的外观尺寸规整,烧成后切、磨加工量少,生产效率高。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚,下面对本发明作进一步地详细描述。
为解决上述问题,本发明提供了一种低成本高抗热震低导热轻质隔热砖,其主要由下述以体积份计的原料制成:
陶瓷辊棒废料50-60份,氧化铝粉10-20份,镁质粘土10-20份,高岭土20-30份,木屑30-50份;
所述陶瓷辊棒废料为低热膨胀率陶瓷辊棒废料,其热膨胀系数≤4×10-6/℃。
本发明提供的低成本高抗热震低导热轻质隔热砖通过合理的配方结构,将低热膨胀率陶瓷辊棒废料、氧化铝粉、镁质粘土、高岭土合理搭配,并加入木屑,在一定烧成制度下,原位合成堇青石,使得制得的隔热砖具有兼具体积密度低、抗热震性能的优点,同时实现了资源的合理利用的资源化利用,节能环保。
针对以上原料进行具体说明:
所述陶瓷辊棒废料为低热膨胀率陶瓷辊棒生产过程中产生的废料和/或低热膨胀率陶瓷辊棒使用后产生的废料。优选地,所述陶瓷辊棒废料的Al2O3的含量为50-66wt%,SiO2含量为26-32wt%,MgO含量为6-8wt%。所述陶瓷辊棒废料的莫来石晶相含量为40~50%,堇青石晶相含量为50~60%。陶瓷辊棒废料中的堇青石晶相起到晶核的作用,在此条件下,制备得到的成品具有良好的热稳定性。而且,所述MgO、SiO2和Al2O3含量在此范围内可以使Al2O3与MgO充分反应生成镁铝比尖晶石,再与SiO2反应从而生成大量的堇青石,可以减少中间相的剩余,有利于主晶相堇青石的生成,从而使堇青石晶体生长完全,堇青石晶体分布相对均匀,从而提高成品力学强度,减少热膨胀系数。更佳地,所述陶瓷辊棒废料的粒度≤44μm。
木屑是一种长纤维状的有机物,在本发明中起到造孔剂的作用,它在砖坯内部产生的气孔是细小而不规则连续的。由于形成气孔的固体物质形状不规则,在传热过程中的路径延长,降低了热量传递速度。由于气孔空间小,空气在气孔内运动速度不高,对流传热速度不高。当木屑粒度大于0.5㎜时,木屑在骨料颗粒之间团聚,分散不均匀,容易产生许多大气孔,导致砖坯导热系数偏大,优选地,所述木屑的粒度≤0.5mm。
氧化铝粉可以提高成品的热稳定性和机械强度。优选地,所述氧化铝粉为γ-氧化铝粉和/或α-氧化铝粉;所述α-氧化铝粉的Al2O3含量≥99wt%,所述α-氧化铝粉的粒度≤44μm;所述γ-氧化铝粉的Al2O3含量≥97wt%,所述γ-氧化铝粉的粒度≤88μm。需要说明的是,所述α-氧化铝粉的粒度大于44μm或所述γ-氧化铝粉的粒度大于88μm时,参与合成堇青石的反应合成的反应不完全,堇青石合成率低,还会生成刚玉相和石英相,得到的轻质隔热砖的热稳定性不高。
镁质粘土是常用的耐火原料,优选地,所述镁质粘土的Al2O3含量≥20wt%,MgO含量≥22wt%,这样使得晶相更加地接近堇青石的组成。所述镁质粘土的粒度≤88μm,这样有利于原料更好地混合均匀。
高岭土为体系进一步补充氧化铝和二氧化硅,优选地,所述高岭土的Al2O3含量≥35wt%,Fe2O3含量≤0.8wt%;所述高岭土的粒度≤88μm。
综上,本发明通过特定的配方组合,得到了一种具有良好抗热震性能的轻质隔热砖。优选地,所述抗热震轻质隔热砖的Al2O3含量为40-45wt%,SiO2含量为31-38wt%,MgO含量为4-6wt%。所述MgO、SiO2和Al2O3含量在此范围内可以使Al2O3与MgO充分反应生成镁铝比尖晶石,再与SiO2反应从而生成大量的堇青石,从而使得隔热砖的抗热震性保持在较高水平。
所述低成本高抗热震低导热轻质隔热砖的体积密度为0.95-1.05g/cm3;耐压强度为6.0-8.0MPa;重烧线变化率-0.2~0.2%;导热系数为(350±25℃)0.28-0.32W/(m·K);1000℃空冷测量条件下抗热震次数大于70次。所述重烧线变化率在1350℃下保温24h下测得。所述低成本高抗热震低导热轻质隔热砖的抗热震性,按照GBT30873-2014中的空气自然冷法测量。
相应地,本发明还提供了上述低成本高抗热震低导热轻质隔热砖的制备方法,包括以下步骤:
(1)将陶瓷辊棒废料辊棒废料、氧化铝粉、镁质粘土、高岭土倒入研磨设备中,研磨后得到混合物;
(2)向所述混合物中加入木屑和水,混合均匀后得到泥料;
(3)将所述泥料倒进模具中,成型得到坯体;
(4)将所述坯体干燥、烧成,得到成品。
优选地,所述泥料倒进模具中,通过振动加压成型得到多个坯体。振动加压成型是物料在频率很高的振动作用下,相互撞击,在自重和外力作用下逐渐堆集填满模框的坯体。本发明采用一次多模具振动加压成型的生产工艺,一次成型多块块砖坯,砖坯外观尺寸规整,烧成后切、磨加工量少,生产效率高。优选地,所述振动加压成型的激振力为220KN,振动频率为1000-2800r/min,振幅为1-3mm。在此条件下成型的坯体密度较高且比较均匀,气空率较低,耐压强度高,外形规整。
优选地,所述坯体的干燥温度为80~120℃,干燥时间为24~72h。
在轻质隔热砖坯体烧成过程中,优选地,所述坯体的烧成曲线为:
由室温升温到150-200℃,升温时间为6-8h;
由150-200℃升温到600~800℃,升温时间为3-6h;
在600~800℃下保温1.0-2.2h;
从600~800℃升温到1100-1200℃,升温时间为4.5-5.5h;
在1100-1200℃下保温2-3h;
从1100-1200℃升温到1390-1400℃,升温时间为4-5h;
在1390-1400℃下保温8-10h。
更佳地,所述坯体的烧成曲线为:
由室温升温到150-200℃,升温时间为4-6h;
由150-200℃升温到700℃,升温时间为3-6h;
在700℃下保温1-2h;
从700℃升温到1100℃,升温时间为5h;
在1100℃下保温2h;
从1100℃升温到1390-1400℃,升温时间为4-5h;
在1390-1400℃下保温8-10h。
需要说明的是,由室温升温到150-200℃,升温时间为6-8h,有利于砖坯内部的自由水蒸发,防止砖坯发生烧裂;由150-200℃升温到600~800℃,升温时间为3-6h,有利于高岭土分解为偏高岭石,并且快速分离出结构水;从600~800℃升温到1100-1200℃,并在1100-1200℃下保温2-3h,有利于堇青石晶体核大量产生,从而提高成品的抗震性能;从1100-1200℃升温到1390-1400℃,并在1390-1400℃下保温8-10h,能够实现堇青石的合成反应,并有利于堇青石晶体长大。
综上,本发明通过合理的配方组合,并充分考虑到配方中各种用于合成堇青石的原料,在烧成过程中的各种物理和化学反应特性,以及堇青石晶体生长发育特点,制定合理的烧成制度,使得烧成的隔热砖中合成的堇青石含量高,从而使得隔热砖的抗热震性保持在较高水平。
下面以具体实施例进一步说明本发明:
实施例1
一种低成本高抗热震低导热轻质隔热砖及其制备方法
低成本高抗热震低导热轻质隔热砖配方,包括以下体积份原料:
低热膨胀率陶瓷辊棒废料50份,α-氧化铝粉20份,镁质粘土15份,高岭土25份,木屑40份。
其中,所述低热膨胀率陶瓷辊棒废料的Al2O3含量为50wt%,SiO2含量为30wt%,MgO含量为6wt%,莫来石晶相含量为50%,堇青石晶相含量为50%,最大粒度为44μm;
所述α-氧化铝粉的Al2O3含量为99.5%,粒度为40μm;
所述镁质粘土的Al2O3含量为23wt%,MgO的含量为23wt%,其粒度≤80μm;
所述高岭土的Al2O3含量为36wt%,Fe2O3含量为0.7wt%,其粒度≤76μm。
所述低成本高抗热震低导热轻质隔热砖的制备方法为:
(1)先将低热膨胀率陶瓷辊棒废料50份,α-氧化铝粉20份,镁质粘土15份,高岭土25份倒入球磨机中,球磨10分钟放出,并倒进搅拌机里,得到混合物;
(2)向所述混合物中加入木屑40份,并加入预设量水,混合均匀后得到泥料;
(3)将所述泥料倒进模具中,振动加压成型得到坯体;
(4)将所述成型后的坯体干燥、烧成,得到抗热震轻质隔热砖成品。
所述坯体的烧成制度为:
从室温到150℃,升温时间为4-6h;
从150℃到700℃,升温时间为4-6h;
在700℃保温1.0-2.2h;
从700℃到1100℃,升温时间为4.5-5.5h;
在1100℃保温3h;
从1100℃到1400℃,升温时间为4-5h;
在1400℃保温8-10h。
实施例2
一种低成本高抗热震低导热轻质隔热砖的制备方法
抗热震轻质隔热砖配方,包括以下体积份原料:
低热膨胀率陶瓷辊棒废料60份,α-氧化铝粉10份,镁质粘土15份,高岭土20份,木屑50份;
其中,所述低热膨胀率陶瓷辊棒废料的Al2O3含量为50wt%,SiO2含量为30wt%,MgO含量为6wt%,莫来石晶相含量为40%,堇青石晶相含量为60%,最大粒度为40μm;
所述α-氧化铝粉的Al2O3含量为99.5%,粒度为40μm;
所述镁质粘土的Al2O3含量为23wt%,MgO的含量为23wt%,其粒度≤75μm;
所述高岭土的Al2O3含量为36wt%,Fe2O3含量为0.7wt%,其粒度≤76μm。
所述低成本高抗热震低导热轻质隔热砖的制备方法为:
(1)先将低热膨胀率陶瓷辊棒废料60份,α-氧化铝粉10份,镁质粘土15份,高岭土20份倒入球磨机中,球磨10分钟放出,并倒进搅拌机里,得到混合物;
(2)向所述混合物中加入木屑50份,并加入预设量水,混合均匀后得到泥料;
(3)将所述泥料倒进模具中,振动加压成型得到坯体;
(4)将所述成型后的坯体干燥、烧成,得到抗热震轻质隔热砖成品。
所述坯体的烧成制度为:
从室温到200℃,升温时间为5h;
从200℃到700℃,升温时间为5h;
在700℃保温2h;
从700℃到1100℃,升温时间为5h;
在1100℃保温3h;
从1100℃到1395℃,升温时间为5h;
在1395℃保温9h。
实施例3
一种低成本高抗热震低导热轻质隔热砖及其制备方法
低成本高抗热震低导热轻质隔热砖配方,包括以下体积份原料:
低热膨胀率陶瓷辊棒废料60份,α-氧化铝粉20份,镁质粘土10份,高岭土20份,木屑30份;
其中,所述低热膨胀率陶瓷辊棒废料的Al2O3含量为60wt%,SiO2含量为32wt%,MgO含量为8wt%,莫来石晶相含量为45%,堇青石晶相含量为55%,最大粒度为40μm;
所述α-氧化铝粉的Al2O3含量为99.5%,粒度为30μm;
所述镁质粘土的Al2O3含量为30wt%,MgO的含量为25wt%,其粒度≤80μm;
所述高岭土的Al2O3含量为38wt%,Fe2O3含量为0.5wt%,其粒度≤76μm。
所述低成本高抗热震低导热轻质隔热砖的制备方法为:
(1)先将低热膨胀率陶瓷辊棒废料60份,α-氧化铝粉20份,镁质粘土10份,高岭土20份倒入球磨机中,球磨10分钟放出,并倒进搅拌机里,得到混合物;
(2)向所述混合物中加入木屑30份,并加入预设量水,混合均匀后得到泥料;
(3)将所述泥料倒进模具中,振动加压成型得到坯体;
(4)将所述成型后的坯体干燥、烧成,得到抗热震轻质隔热砖成品。
所述坯体的烧成制度为:
从室温到150℃,升温时间为5h;
从150℃到700℃,升温时间为5h;
在700℃保温2h;
从700℃到1100℃,升温时间为5h;
在1100℃保温3h;
从1100℃到1390℃,升温时间为4h;
在1390℃保温8h。
实施例4
一种低成本高抗热震低导热轻质隔热砖及其制备方法
低成本高抗热震低导热轻质隔热砖配方,包括以下体积份原料:
低热膨胀率陶瓷辊棒废料55份,α-氧化铝粉20份,镁质粘土20份,高岭土30份,木屑30份;
其中,所述低热膨胀率陶瓷辊棒废料的Al2O3含量为55wt%,SiO2含量为30wt%,MgO含量为6.2wt%,莫来石晶相含量为45%,堇青石晶相含量为55%,最大粒度为44μm;
所述α-氧化铝粉的Al2O3含量为99.5%,粒度为40μm;
所述镁质粘土的Al2O3含量为24wt%,MgO的含量为27wt%,其粒度≤80μm;
所述高岭土的Al2O3含量为36wt%,Fe2O3含量为0.7wt%,其粒度≤76μm。
所述低成本高抗热震低导热轻质隔热砖的制备方法为:
(1)先将低热膨胀率陶瓷辊棒废料55份,α-氧化铝粉20份,镁质粘土20份,高岭土30份倒入球磨机中,球磨10分钟放出,并倒进搅拌机里,得到混合物;
(2)向所述混合物中加入木屑30份,并加入预设量水,混合均匀后得到泥料;
(3)将所述泥料倒进模具中,振动加压成型得到坯体;
(4)将所述成型后的坯体干燥、烧成,得到抗热震轻质隔热砖成品。
所述坯体的烧成制度为:
从室温到150℃,升温时间为6h;
从150℃到700℃,升温时间为8h;
在700℃保温2.2h;
从700℃到1100℃,升温时间为5.5h;
在1100℃保温3h;
从1100℃到1390℃,升温时间为5h;
在1390℃保温10h。
对比例1
一种低成本高抗热震低导热轻质隔热砖及其制备方法,与实施例1不用之处在于:
低成本高抗热震低导热轻质隔热砖配方,包括以下体积份原料:
普通陶瓷辊棒废料50份,α-氧化铝粉20份,镁质粘土15份,高岭土25份,木屑40份。其中,普通陶瓷辊棒废料的热膨胀系数>4×10-6/℃;其余皆与实施例1相同。
对比例2
一种低成本高抗热震低导热轻质隔热砖及其制备方法,与实施例1不用之处在于:
所述坯体的烧成制度为:
由室温升温到300℃,升温时间为5h;
由300℃升温到500℃,升温时间为2.5h;
在500℃下保温3h;
从500℃升温到1000℃,升温时间为3;
在1000℃下保温1h;
从1000℃升温到1250℃,升温时间为3.5h;
在1250℃下保温6h。
其余皆与实施例1相同。
将实施例1~4和对比例1~2制得的低成本高抗热震低导热轻质隔热砖进行性能测试,数据见表1。
表1实施例1~4和对比例1~2制得的抗热震轻质隔热砖性能对比
测试结果表明,本发明实施例1~4制备的低成本高抗热震低导热轻质隔热砖,其体积密度为0.95-1.05g/cm3;常温耐压强度为6.0-8.0MPa;1350℃×24h重烧线变化率为±0.2%;平均温度1000℃时,导热系数为(350±25℃)0.28-0.32W/(m·K);1000℃空冷测量条件下热震次数大于70次。相比于对比例1~2,本发明制得的低成本高抗热震低导热轻质隔热砖具有更低的体积密度和更佳的隔热性能,并且抗热震性能明显优于对比例1~2所得的隔热砖,
比较实施例1和对比例1可知,相比于普通陶瓷辊棒废料,采用低热膨胀率陶瓷辊棒废料的抗热震轻质隔热砖的抗热震性能更佳。
比较实施例1和对比例2可知,在本发明提供的烧成制度下烧成,得到的隔热砖的抗热震性才能够保持在较高水平。
以上所述是发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也视为本发明的保护范围。
Claims (10)
1.一种低成本高抗热震低导热轻质隔热砖,其特征在于,包含如下体积份数的组分:
陶瓷辊棒废料50-60份,氧化铝粉10-20份,镁质粘土10-20份,高岭土20-30份,木屑30-50份;
所述陶瓷辊棒废料为低热膨胀陶瓷辊棒废料,其热膨胀系数≤4×10-6/℃;
所述低热膨胀陶瓷辊棒废料为低热膨胀率陶瓷辊棒生产过程中产生的废料和/或低热膨胀率陶瓷辊棒使用后产生的废料;
所述陶瓷辊棒废料的Al2O3的含量为50-66wt%,SiO2含量为26-32wt%,MgO含量为6-8wt%;
所述陶瓷辊棒废料的莫来石晶相含量为40~50%,堇青石晶相含量为50~60%;
所述低成本高抗热震低导热轻质隔热砖由下述方法制得:
将陶瓷辊棒废料、氧化铝粉、镁质粘土、高岭土倒入研磨设备中,研磨后得到混合物;
向所述混合物中加入木屑和水,混合均匀后得到泥料;
将所述泥料倒进模具中,成型得到坯体;
将所述坯体干燥、烧成,得到成品;
所述烧成的烧成曲线为:
由室温升温到150-200℃,升温时间为6-8h;
由150-200℃升温到600~800℃,升温时间为3-6h;
在600~800℃下保温1.0-2.2h;
从600~800℃升温到1100-1200℃,升温时间为4.5-5.5 h;
在1100-1200℃下保温2-3h;
从1100-1200℃升温到1390-1400℃,升温时间为4-5h;
在1390-1400℃下保温8-10h。
2.如权利要求1所述的低成本高抗热震低导热轻质隔热砖,其特征在于,所述陶瓷辊棒废料的粒度≤44μm。
3.如权利要求1所述的低成本高抗热震低导热轻质隔热砖,其特征在于,所述木屑的粒度≤0.5mm。
4.如权利要求1所述的低成本高抗热震低导热轻质隔热砖,其特征在于,所述氧化铝粉为γ-氧化铝粉和/或α-氧化铝粉;
所述α-氧化铝粉的Al2O3含量≥99 wt%,所述α-氧化铝粉的粒度≤44μm;
所述γ-氧化铝粉的Al2O3含量≥97 wt%,所述γ-氧化铝粉的粒度≤88μm。
5.如权利要求1所述的低成本高抗热震低导热轻质隔热砖,其特征在于,所述镁质粘土的Al2O3含量≥20 wt%,MgO含量≥22wt%;
所述镁质粘土的粒度≤88μm。
6.如权利要求1所述的低成本高抗热震低导热轻质隔热砖,其特征在于,所述高岭土的Al2O3含量≥35 wt%,Fe2O3含量≤0.8 wt%;
所述高岭土的粒度≤88 μm。
7.如权利要求1所述的低成本高抗热震低导热轻质隔热砖,其特征在于,所述低成本高抗热震低导热轻质隔热砖的Al2O3含量为40-45wt%, SiO2含量为31-38wt%,MgO含量为4-6wt%。
8.如权利要求1所述的低成本高抗热震低导热轻质隔热砖,其特征在于,所述低成本高抗热震低导热轻质隔热砖的体积密度为0.95-1.05g/cm3;耐压强度为6.0-8.0 MPa;
在1350℃下保温24h后,其重烧线变化率为-0.2~0.2%;
在350±25℃下导热系数为0.28-0.32 W/(m•K);
1000℃空冷测量条件下抗热震次数大于70次。
9.如权利要求1所述的低成本高抗热震低导热轻质隔热砖,其特征在于,所述坯体的干燥温度为80~120℃,干燥时间为24~72h。
10.如权利要求1所述的低成本高抗热震低导热轻质隔热砖,其特征在于,所述泥料倒进模具中,通过振动加压成型得到多个坯体;所述振动加压成型的激振力为220KN,振动频率为1000-2800r /min,振幅为1-3mm。
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