CN115010504B - 一种两步法制备高强矾土基莫来石均质料的方法 - Google Patents

一种两步法制备高强矾土基莫来石均质料的方法 Download PDF

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CN115010504B
CN115010504B CN202210508559.XA CN202210508559A CN115010504B CN 115010504 B CN115010504 B CN 115010504B CN 202210508559 A CN202210508559 A CN 202210508559A CN 115010504 B CN115010504 B CN 115010504B
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赵飞
麦海香
胡杨
刘新红
葛铁柱
许琳娜
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Xiaoyi Jingang Refractory Co ltd
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Abstract

本发明涉及一种两步法制备高强矾土基莫来石均质料的方法,涉及高温耐火材料技术领域。本发明主要包括以下两个步骤,步骤1:将块状高铝矾土生料在600~800℃温度下轻烧1~1.5h,放入水中淬冷至室温,破碎得到轻烧高铝矾土。步骤2:按质量百分比,将70~86%的轻烧高铝矾土、10~24%的高铝矾土生料、4‑6%的蓝晶石以及上述原料重量百分比之和1~4%的锆质添加剂混合后,经过湿法共磨、脱水、挤出或机压成型,在高温窑炉中1550~1600℃保温3~8小时煅烧,冷却后即得到高强矾土基莫来石均质料。本发明有效提高了矾土基莫来石均质料的均化程度;所合成的莫来石晶体长径比大并形成连续的网状结构,提高了矾土基莫来石均质料的强度和抗热震性。

Description

一种两步法制备高强矾土基莫来石均质料的方法
技术领域
本发明属于耐火材料技术领域,具体涉及一种两步法制备高强矾土基莫来石均质料的方法。
背景技术
高铝矾土是具有战略意义的耐火材料资源。我国高铝矾土资源丰富,但70%以上是中低品位矿。特别是中品位高铝矾土由于矿物分布不均匀、难烧结等因素导致其利用率非常低。随着我国高品位铝矾土矿的日趋匮乏,以中低品位高矾土为原料制备矾土基均质料的技术得到发展。公开号为CN1326804C的发明专利提供了一种制备矾土基莫来石均质料的方法,该方法以Ⅱ等高铝矾土和煤矸石为原料,外加稀土氧化物及MgO复合助烧结剂,制备出体积密度≥2.65g/cm3的莫来石材料。公布号为CN105503219A的发明专利以铝矾土生矿为原料,采用分级、均化、连续湿法细磨、高温煅烧的方式制备出矾土基烧结刚玉-莫来石材料。上述专利的实施大幅提高了高铝矾土的综合利用率。但是,中品位高铝矾土生料矿物组成非常复杂,通过细磨得到的原料均化程度低,结构不均匀,同时稀土氧化物、MgO等助烧结剂的引入会增加莫来石材料中玻璃相的含量。
我国的高铝矾土以一水硬铝石-高岭石型(DK型)为主。在中品位高铝矾土中,一水硬铝石和高岭石均是主晶相,且两者的分布不均匀。其中,部分一水铝石颗粒彼此紧密镶嵌构成粒径较大的鲕粒;高岭石为片状,常呈微粒聚合体产出;少量的水云母、铁矿物等杂质相也呈20-50μm的颗粒出现。将高铝矾土生料细磨均化后仍有大量的一水硬铝石和高岭石聚集颗粒;高温煅烧后,形成莫来石包裹刚玉颗粒、玻璃相铺展在晶体颗粒间的现象,造成莫来石晶体网络结构的连续性差;所合成的矾土基均质料显微结构不均匀,力学和抗热震性能差。张彦杰等(高铝熟料与高铝均化料的性能研究[J],耐火材料,2016,50: 448-451)研究发现,由于80高铝矾土均质料中晶相之间的结合程度低,其高温性能比直接煅烧的高铝矾土熟料还要弱。因此,需要一种新的均化技术来提升矾土基莫来石均质料的质量、产品档次和附加值。
发明内容
本发明目的正是针对上述现有技术中所存在的不足之处提供一种两步法制备高强矾土基莫来石均质料的方法,所制备的矾土基莫来石均质料具有结构均匀、致密度高和力学性能优异的特点。
为实现上述目的,本发明采用的技术方案为:
一种两步法制备高强矾土基莫来石均质料的方法,包括以下步骤:
步骤1:将块状高铝矾土生料在600~800℃温度下轻烧1~1.5h,然后放入水中淬冷至室温,破碎后得到轻烧高铝矾土;
步骤2:按质量百分比,将70~86%的轻烧高铝矾土、10~24%的高铝矾土生料、4~6%的蓝晶石和以及上述原料重量百分比之和1~4%的锆质添加剂混合,湿法共磨120min、脱水、挤出或机压成型,在高温窑炉中1550~1600℃保温3~8小时煅烧,冷却后即得到高强矾土基莫来石均质料。
进一步,所述高铝矾土生料的粒度≤100mm。
进一步,所述高铝矾土生料灼减后Al2O3含量为55~70wt%、SiO2含量为27~42wt%、TiO2≤3.0wt%、Fe2O3≤2.1wt%、K2O≤0.5wt%、Na2O≤0.2wt%。
进一步,所述蓝晶石中Al2O3含量为45~55wt%,原料粒径≤325目。
进一步,所述锆质添加剂为锆英石、单斜氧化锆、氧氯化锆中的一种或两种,原料粒径≤325目。
上述制备方法中,轻烧使高铝矾土的研磨性能得到改善,湿法球磨120min后混合原料的平均粒径≤12μm,步骤2中加入蓝晶石和锆质添加剂促进了莫来石晶体长径比的增大。
进一步,上述制备方法制备的矾土基莫来石均质料以莫来石为主晶相,莫来石晶体长径比大于20,并形成连续的网状结构;材料结构均匀、致密度高,体积密度≥2.95 g·cm-3,耐压强度≥320 MPa。
与现有技术相比,本发明的有益效果为:
本发明中块状高铝矾土生料在轻烧过程中发生脱结晶水反应,生成结构疏松的刚玉假相和偏高岭石;原料淬冷后,其研磨性能得到改善。轻烧高铝矾土经湿法球磨后,氧化铝和偏高岭石的聚集颗粒减少,烧结和反应活性增加,从而提高了矾土基莫来石均质料的致密度和均化程度。加入蓝晶石和锆质添加剂后,促进了莫来石晶体的各向异性生长,并形成连续的网络结构,优化了矾土基莫来石均质料的力学性能。
附图说明
图1为本发明所制备高强矾土基莫来石均质料的显微结构照片。
具体实施方式
下面结合附图和具体的实施例对本发明的技术方案及效果做进一步描述,但本发明的保护范围并不限于此。
实施例1
本实施例两步法制备高强矾土基莫来石均质料的方法,包括以下步骤:
步骤1:轻烧高铝矾土的制备
将块状高铝矾土生料放入回转窑中,在650℃温度下轻烧1.5h,放入水中淬冷至室温,破碎后得到轻烧高铝矾土;
步骤2:利用轻烧高铝矾土原料制备高强矾土基莫来石均质料
按质量百分比,将80%的轻烧高铝矾土、16%的高铝矾土生料、4%的蓝晶石和以及上述原料重量百分比之和3%的锆质添加剂混合,湿法共磨120min、脱水、挤出成型,在高温窑炉中1600℃保温6小时煅烧,冷却后即得到高强矾土基莫来石均质料。
本实施例所述高铝矾土生料灼减后Al2O3含量为68.5wt%、SiO2含量为27.2wt%、TiO2含量为2.3wt%、Fe2O3含量为1.3wt%、K2O含量为0.3wt%、Na2O含量为0.1wt%;步骤2中所述蓝晶石中Al2O3含量为52.3wt%,原料粒径≤325目;所述的锆质添加剂为锆英石,原料粒径≤325目。
本实施例所制备的高强矾土基莫来石均质料的技术指标为:莫来石晶体平均长度约40μm,长径比>20;体积密度为2.95g·cm-3,显气孔率为1.05%,常温耐压强度为403.88MPa,0.2MPa荷重软化开始温度为1605℃。
实施例2
本实施例两步法制备高强矾土基莫来石均质料的方法,包括以下步骤:
步骤1:轻烧高铝矾土的制备
将块状高铝矾土生料放入回转窑中,在700℃温度下轻烧1h,放入水中淬冷至室温,破碎后得到轻烧高铝矾土;
步骤2:利用轻烧高铝矾土原料制备高强矾土基莫来石均质料
按质量百分比,将75%的轻烧高铝矾土、20%的高铝矾土生料、5%的蓝晶石和以及上述原料重量百分比之和2%的锆质添加剂混合,湿法共磨120min、脱水、挤出成型,在高温窑炉中1580℃保温4小时煅烧,冷却后即得到高强矾土基莫来石均质料。
本实施例所述高铝矾土生料灼减后本实施例所述高铝矾土生料灼减后Al2O3含量为64.4wt%、SiO2含量为31.6wt%、TiO2含量为2.1wt%、Fe2O3含量为1.6wt%、K2O含量为0.2wt%、Na2O含量为0.1wt%;步骤2中所述蓝晶石中Al2O3含量为50.6wt%,原料粒径≤325目;所述锆质添加剂为锆英石,原料粒径≤325目。
本实施例所制备的高强矾土基莫来石均质料的技术指标为:莫来石晶体平均长度约42μm,长径比>22;材料的体积密度为2.98g·cm-3,显气孔率为0.94%,常温耐压强度为450.50MPa,0.2MPa荷重软化开始温度为1590℃。
实施例3
本实施例两步法制备高强矾土基莫来石均质料的方法,包括以下步骤:
步骤1:轻烧高铝矾土的制备
将块状高铝矾土生料放入回转窑中,在650℃温度下轻烧1h,放入水中淬冷至室温,破碎后得到轻烧高铝矾土;
步骤2:利用轻烧高铝矾土原料制备高强矾土基莫来石均质料
按质量百分比,将70%的轻烧高铝矾土、25%的高铝矾土生料、5%的蓝晶石和以及上述原料重量百分比之和1.5%的锆质添加剂混合,湿法共磨120min、脱水、120MPa下机压成型,在高温窑炉中1570℃保温4小时煅烧,冷却后即得到高强矾土基莫来石均质料。
本实施例所述高铝矾土生料灼减后Al2O3含量为本实施例所述高铝矾土生料灼减后Al2O3含量为57.5wt%、SiO2含量为38.2wt%、TiO2含量为1.9wt%、Fe2O3含量为1.5wt%、K2O含量为0.2wt%、Na2O含量为0.1wt%;;步骤2中所述蓝晶石中Al2O3含量为45.8wt%,原料粒径≤325目;所述锆质添加剂为氧氯化锆,原料粒径≤325目。
本实施例所制备的高强矾土基莫来石均质料的技术指标为:莫来石晶体平均长度约44μm,长径比>25;材料的体积密度为2.99g·cm-3,显气孔率为0.65%,常温耐压强度为460.80MPa,0.2MPa荷重软化开始温度为1560℃。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。

Claims (6)

1.一种两步法制备高强矾土基莫来石均质料的方法,其特征在于,该方法包括以下步骤:
步骤1:将块状高铝矾土生料在600~800℃温度下轻烧1~1.5h,然后放入水中淬冷至室温,破碎后得到轻烧高铝矾土;
步骤2:按质量百分比,将70~86%的轻烧高铝矾土、10~24%的高铝矾土生料、4~6%的蓝晶石和以及上述原料重量百分比之和1~4%的锆质添加剂混合,湿法共磨120min、脱水、挤出或机压成型,在高温窑炉中1550~1600℃保温3~8小时煅烧,冷却后即得到高强矾土基莫来石均质料。
2.根据权利要求1所述的两步法制备高强矾土基莫来石均质料的方法,其特征在于,所述高铝矾土生料的粒度≤100mm。
3.根据权利要求1所述的两步法制备高强矾土基莫来石均质料的方法,其特征在于,所述高铝矾土生料灼减后Al2O3含量为55~70wt%、SiO2含量为27~42wt%、TiO2≤3.0wt%、Fe2O3≤2.1wt%、K2O≤0.5wt%、Na2O≤0.2wt%。
4.根据权利要求1所述的两步法制备高强矾土基莫来石均质料的方法,其特征在于,所述蓝晶石中Al2O3含量为45~55wt%,原料粒径≤325目。
5.根据权利要求1所述的两步法制备高强矾土基莫来石均质料的方法,其特征在于,所述锆质添加剂为锆英石、单斜氧化锆、氧氯化锆中的一种或两种,原料粒径≤325目。
6.根据权利要求1所述的两步法制备高强矾土基莫来石均质料的方法,其特征在于,所述制备方法制备的矾土基莫来石均质料以莫来石为主晶相,莫来石晶体长径比大于20,并形成连续的网状结构;材料结构均匀、致密度高,体积密度≥2.95 g·cm-3,耐压强度≥320MPa。
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