CN114956797A - 一种等离子熔融炉耐火浇注料及制备方法 - Google Patents
一种等离子熔融炉耐火浇注料及制备方法 Download PDFInfo
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Abstract
本发明公开了一种等离子熔融炉耐火浇注料及制备方法，包括以下质量份的组分组成：矾土电熔刚玉40～60份，锐钛矿型TiO2 5～10份，电熔镁砂细粉1～5份，纳米氧化锌1～5份，氧化铝微粉1～5份，莫来石4～8份，改性氧化锆6～12份，粘合剂3～6份；所述矾土电熔刚玉粒度≤2.0mm，其中25～40％矾土电熔刚玉粒度≤0.5mm；所述改性氧化锆与所述莫来石的质量比为1.5:1。该耐火浇注料耐腐蚀性能好、使用寿命长，具有高强度高致密性的表面性质，长期使用表面裂纹的产生明显减少。
Description
技术领域
本发明涉及耐火浇注料技术领域，具体涉及一种等离子熔融炉耐火浇注料及制备方法。
背景技术
等离子熔融炉由于其出口烟气温度高，流速快的特点，定型的耐火浇注料作为烟气管道的耐火衬里在使用一段时间后容易变形、剥落,修补难度大。
不定型的耐火浇注料由具有一定粒度级配的耐火骨料和粉料、粘合剂、外加剂混合而成的耐火浇注料，又称散状耐火浇注料，用于热工设备衬里，不经烧成工序，直接烘烤使用。同耐火砖相比，因省去烧成工序，具有工艺简单、节约能源、成本低廉、便于机械化施工等特点。在等离子熔融炉上使用效果也比耐火砖好，具有成本低，使用方便，适用范围广，整体性及使用效果好的优点。但是常用的刚玉浇注料使用了铝酸钙水泥作为粘合剂并加入了氧化硅微粉，例如专利CN 201510298564.2公开的“一种铝酸钙水泥结合刚玉质浇注料”和专利CN 201310035589.4公开的“一种含碳酸钙微粉的铝酸钙水泥结合刚玉质浇注料及其制备方法”，两方案会导致材料在高温条件下形成钙长石、钙黄长石，导致浇注料热态强度大大降低，其中后者强度低，不适宜在等离子熔融炉中应用。
此外用于垃圾处理的等离子熔融炉由于原料成分复杂多变，其烟气组成也随着不断改变，这对烟气管路的耐火衬里的耐腐蚀性提出了更高的要求。
发明内容
针对上述存在的技术不足，本发明的目的是提供一种等离子熔融炉耐火浇注料及制备方法，该耐火浇注料耐腐蚀性能好、使用寿命长，具有高强度高致密性的表面性质，明显减少表面裂纹产生。
为解决上述技术问题，本发明采用如下技术方案：
本发明提供一种等离子熔融炉耐火浇注料，包括以下质量份的组分组成：矾土电熔刚玉40～60份，锐钛矿型TiO2 5～10份，电熔镁砂细粉1～5份，纳米氧化锌1～5份，氧化铝微粉1～5份，莫来石4～8份，改性氧化锆6～12份，粘合剂3～6份。
优选地，所述矾土电熔刚玉粒度≤2.0mm，其中25～40％矾土电熔刚玉粒度≤0.5mm。
优选地，所述改性氧化锆与所述莫来石的质量比为1.5:1。
优选地，所述粘合剂为缩合磷酸铝和硼酸聚合物的一种或两种组合。
本申请的另一个目的是提供一种等离子熔融炉耐火浇注料的制备方法，包括以下步骤：
S1：将氧化锆粉体加入到水和含己二酸的甲苯饱和液的混合溶液中，加入 KH580硅烷耦合剂制备改性氧化锆；
S2：将煤矸石破碎至400目以下，在1000～1200℃下煅烧2h，冷却后破碎成粒径在0.1mm以下的微粒制成莫来石；
S3：按质量百分比分别称取锐钛矿型TiO2、电熔镁砂细粉、纳米氧化锌、氧化铝微粉、莫来石和改性氧化锆混合均匀，按比例加入粘合剂和矾土电熔刚玉继续混合搅拌，再高速混练15～20min，即得熔融炉用耐火浇注料；
S4：将熔融炉用耐火浇注料振动浇注，浇注体经过养护、脱模、烘烤即可投入使用。
优选地，所述步骤S1中改性氧化锆的制备方法具体为：按体积比配置水和含己二酸的甲苯饱和液溶液，将氧化锆置于加入到混合溶液中超声0.5～2h，超声后取0.8wt％的KH580硅烷耦合剂与溶液混合搅拌10～30min后在 1500～1600℃条件下烧结3～6h，冷却后破碎成粒径在0.1mm以下的改性氧化锆；
优选地，所述混合溶液水和含己二酸的甲苯饱和液的混合体积比为3:1。
优选地，所述含己二酸的甲苯饱和液中己二酸与甲苯质量比为1：19。
本发明的有益效果在于：
1、在原有的骨料中加入TiO2和电熔镁砂细粉，氧化钛和镁砂细粉交联形成Mg2TiO4镁砂晶石并固溶在骨料中，与骨料中的电熔刚玉混合交联，增强原有骨料的稳定性，提高了材料的耐腐蚀性能，延长了使用寿命；
2、将氧化锆粉体加入到水和含己二酸的甲苯饱和液的溶液，通过乙二酸处理氧化锆，改善其表面性质，使其具备较优的表面稳定性，再经KH580处理形成高强度高致密性的物化性能，提高耐腐蚀性能，明显减少裂纹的产生。
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做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
本发明一种等离子熔融炉耐火浇注料，包括以下质量份的组分组成：矾土电熔刚玉40～60份，锐钛矿型TiO2 5～10份，电熔镁砂细粉1～5份，纳米氧化锌1～5份，氧化铝微粉1～5份，莫来石4～8份，改性氧化锆6～12份，粘合剂3～6 份。
所述矾土电熔刚玉粒度≤2.0mm，其中25～40％矾土电熔刚玉粒度≤0.5mm。
所述改性氧化锆与所述莫来石的质量比为1.5:1。
所述粘合剂为缩合磷酸铝和硼酸聚合物的一种或两种组合。
本发明一种等离子熔融炉耐火浇注料的制备方法，包括以下步骤：
S1：按体积比为3:1配置水和含己二酸的甲苯饱和液溶液，将氧化锆置于加入到混合溶液中超声0.5～2h，超声后取0.8wt％的KH580硅烷耦合剂与溶液混合搅拌10～30min后在1500～1600℃条件下烧结3～6h，冷却后破碎成粒径在0.1mm以下的改性氧化锆；
S2：将煤矸石破碎至400目以下，在1100℃下煅烧2h，冷却后破碎成粒径在0.1mm以下的微粒制成莫来石；
S3：按质量份分别称取锐钛矿型TiO2、电熔镁砂细粉、纳米氧化锌、氧化铝微粉、莫来石和改性氧化锆混合均匀，按质量份加入粘合剂和矾土电熔刚玉继续混合搅拌，再高速混练15～20min，即得熔融炉用耐火浇注料；
S4：将熔融炉用耐火浇注料振动浇注，浇注体经过养护、脱模、烘烤即可投入使用。
实施例1
按体积比为3:1配置水和含己二酸的甲苯饱和液溶液，将氧化锆置于加入到混合溶液中超声1h，超声后取0.8wt％的KH580硅烷耦合剂与溶液混合搅拌10min后在1500℃条件下烧结5h，冷却后破碎成粒径在0.1mm以下的改性氧化锆；
将煤矸石破碎至400目以下，在1100℃下煅烧2h，冷却后破碎成粒径在 0.1mm以下的微粒制成莫来石；
按质量百分比分别称取锐钛矿型TiO2 5份、电熔镁砂细粉2份、纳米氧化锌2份、氧化铝微粉1份、莫来石5份和改性氧化锆8份混合均匀，按质量份加入粘合剂3份和矾土电熔刚玉40份继续混合搅拌，再高速混练15min，即得熔融炉用耐火浇注料；
将熔融炉用耐火浇注料振动浇注，浇注体经过养护、脱模、烘烤即可投入使用。
实施例2
按体积比为3:1配置水和含己二酸的甲苯饱和液溶液，将氧化锆置于加入到混合溶液中超声1h，超声后取0.8wt％的KH580硅烷耦合剂与溶液混合搅拌10min后在1500℃条件下烧结5h，冷却后破碎成粒径在0.1mm以下的改性氧化锆；
将煤矸石破碎至400目以下，在1100℃下煅烧2h，冷却后破碎成粒径在 0.1mm以下的微粒制成莫来石；
按质量百分比分别称取锐钛矿型TiO2 10份、电熔镁砂细粉5份、纳米氧化锌5份、氧化铝微粉5份、莫来石8份和改性氧化锆10份混合均匀，按质量份加入粘合剂5份和矾土电熔刚玉55份继续混合搅拌，再高速混练15min，即得熔融炉用耐火浇注料；
将熔融炉用耐火浇注料振动浇注，浇注体经过养护、脱模、烘烤即可投入使用。
对比例1：
按体积比为3:1配置水和含己二酸的甲苯饱和液溶液，将氧化锆置于加入到混合溶液中超声1h，超声后取0.8wt％的KH580硅烷耦合剂与溶液混合搅拌10min后在1500℃条件下烧结5h，冷却后破碎成粒径在0.1mm以下的改性氧化锆；
将煤矸石破碎至400目以下，在1100℃下煅烧2h，冷却后破碎成粒径在 0.1mm以下的微粒制成莫来石；
按质量百分比分别称取纳米氧化锌3份、氧化铝微粉3份、莫来石8份和改性氧化锆8份混合均匀，按质量份加入粘合剂3份和矾土电熔刚玉40份继续混合搅拌，再高速混练15min，即得熔融炉用耐火浇注料；
将熔融炉用耐火浇注料振动浇注，浇注体经过养护、脱模、烘烤即可投入使用。
对比例1：
按体积比为3:1配置水和含己二酸的甲苯饱和液溶液，将氧化锆置于加入到混合溶液中超声1h，超声后取0.8wt％的KH580硅烷耦合剂与溶液混合搅拌10min后在1500℃条件下烧结5h，冷却后破碎成粒径在0.1mm以下的改性氧化锆；
将煤矸石破碎至400目以下，在1100℃下煅烧2h，冷却后破碎成粒径在 0.1mm以下的微粒制成莫来石；
按质量百分比分别称取纳米氧化锌3份、氧化铝微粉3份、莫来石8份和改性氧化锆8份混合均匀，按质量份加入粘合剂3份和矾土电熔刚玉40份继续混合搅拌，再高速混练15min，即得熔融炉用耐火浇注料；将熔融炉用耐火浇注料振动浇注，浇注体经过养护、脱模、烘烤即可投入使用。
对比例2：
将煤矸石破碎至400目以下，在1100℃下煅烧2h，冷却后破碎成粒径在 0.1mm以下的微粒制成莫来石；
按质量百分比分别称取纳米氧化锌3份、氧化铝微粉3份、莫来石8份和氧化锆8份混合均匀，按质量份加入粘合剂3份和矾土电熔刚玉40份继续混合搅拌，再高速混练15min，即得熔融炉用耐火浇注料；将熔融炉用耐火浇注料振动浇注，浇注体经过养护、脱模、烘烤即可投入使用。
对比例3：
对比例3为市面上普通耐火浇注料。
将上述实施例1～2和对比例1～3得到的耐火浇注料经耐腐蚀性测试，将各不定形耐火浇注料按照YB/T 5202.1制备成试样，通过GB T 8931-2007抗渣性实验方法中的回转渣蚀法在2000℃进行实验，结果如表1，试样尺寸为 230mm*114mm*65mm。
表1耐火浇注料的侵蚀深度和渗透深度测试结果
将上述实施例1～2和对比例1～3得到的耐火浇注料经抗热震性能测试、耐压强度测试，按照GB/T 30873-2014、GB/T 7322-2007等的规定的方法进行测试，得到如表2的测试结果。
表2耐火浇注料的其他性能
综上所述，本申请要求保护的技术方案制得的耐火浇注料，具有较强的耐腐蚀性及表面稳定性，如表1所示，实施例1～2与对比实施例1～3相比，侵蚀深度和渗透深度均较小，具有较强的耐腐蚀性能；如表2所示，实施例1～2与对比实施例1～3相比，保持较好的抗热震性能性能的同时，表面稳定性能明显提高。
施工一年半后，实施例1～2无裂纹，对比例1～3出现不同程度的裂纹，其中对比例1出现轻微裂纹，对比例2～3出现中度裂纹，甚至有局部脱落现象。
显然，本领域的技术人员可以对本发明进行各种改动和变型而不脱离本发明的精神和范围。这样，倘若本发明的这些修改和变型属于本发明权利要求及其等同技术的范围之内，则本发明也意图包含这些改动和变型在内。
Claims (8)
1.一种等离子熔融炉耐火浇注料，其特征在于，包括以下质量份的组分组成：
2.如权利要求1所述的一种等离子熔融炉耐火浇注料，其特征在于，所述矾土电熔刚玉粒度≤2.0mm，其中25～40％矾土电熔刚玉粒度≤0.5mm。
3.如权利要求1所述的一种等离子熔融炉耐火浇注料，其特征在于，所述改性氧化锆与所述莫来石的质量比为1.5:1。
4.如权利要求1所述的一种等离子熔融炉耐火浇注料，其特征在于，所述粘合剂为缩合磷酸铝和硼酸聚合物的一种或两种组合。
5.一种权利要求1所述的一种等离子熔融炉耐火浇注料的制备方法，其特征在于，包括以下步骤：
S1：将氧化锆粉体加入到水和含己二酸的甲苯饱和液的混合溶液中，加入KH580硅烷耦合剂制备改性氧化锆；
S2：将煤矸石破碎至400目以下，在1000～1200℃下煅烧1～3h，冷却后破碎成粒径在0.1mm以下的微粒制成莫来石；
S3：按质量百分比分别称取锐钛矿型TiO2、电熔镁砂细粉、纳米氧化锌、氧化铝微粉、莫来石和改性氧化锆混合均匀，按比例加入粘合剂和矾土电熔刚玉继续混合均匀，再高速混练15～20min，即得熔融炉用耐火浇注料；
S4：将熔融炉用耐火浇注料振动浇注，浇注体经过养护、脱模、烘烤即可投入使用。
6.根据权利要求5所述的一种等离子熔融炉耐火浇注料的制备方法，其特征在于，上述步骤S1中改性氧化锆的制备方法具体为：按体积比配置水和含己二酸的甲苯饱和液溶液，将氧化锆置于加入到混合溶液中超声0.5～2h，超声后取0.8wt％的KH580硅烷耦合剂与溶液混合搅拌10～30min后在1500～1600℃条件下烧结3～6h，冷却后破碎成粒径在0.1mm以下的改性氧化锆。
7.根据权利要求6所述的一种等离子熔融炉耐火浇注料的制备方法，其特征在于，所述混合溶液水和含己二酸的甲苯饱和液的混合体积比为3:1。
8.根据权利要求6所述的一种等离子熔融炉耐火浇注料的制备方法，其特征在于，所述含己二酸的甲苯饱和液中己二酸与甲苯质量比为1:19。
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