CN115180964A - 一种高强耐酸轻质浇注料及其制备方法 - Google Patents
一种高强耐酸轻质浇注料及其制备方法 Download PDFInfo
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- 239000002253 acid Substances 0.000 claims abstract description 39
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Abstract
本发明公开了一种高强耐酸轻质浇注料及其制备方法,按照重量百分比表示的配方组分:莫来石质轻骨料、莫来石质轻骨料、烧结板状刚玉、抗酸填充料、焦宝石、蓝晶石、二氧化硅微粉、锂辉石、工业氧化铝细粉、高铝水泥、一级高铝熟料粉、的耐火纤维、外加剂,按配方组分要求,经来料检验、原料破碎、混合、性能检验和打包步骤,制成不定型高强耐酸轻质浇注料,该产品具备体积密度小、抗酸性、耐磨性、易少烧结和抗热应力等优异性能,作为浇注料或者修补料都具备良好的应激功能,可以适用于大部分酸性工况下的浇筑使用,即使面对生产温度改变,也能减少高温下的体积收缩,很好地与炉身结合,并且有着优异的耐磨、抗腐蚀。
Description
技术领域
本发明涉及耐火浇注料技术领域,特别是一种高强耐酸轻质浇注料及其制备方法。
背景技术
耐火浇注料是目前生产与使用最广泛的一种不定形耐火材料,主要用于构筑各种加热炉内衬等整体构筑物。是一种由耐火物质制成的粒状和粉状材料,并加入一定量结合剂和水分共同组成。它具有较高的流动性,适宜用浇注方法施工,并无需加热即可硬化的不定形耐火材料。由耐火骨料、粉料、结合剂、外加剂、水或其他液体材料组成。一般在使用现场以浇注、震动或捣固的方法浇筑成型,也可以制成预制件使用。
一般用于冶金、医药、化工、石油等行业中的各种塔、炉、池、罐、槽等设施内衬的耐火浇注料,在使用一段时间后必定会损坏,尤其当生产的产品种类更换频繁时,可能导致其工况环境的变化,如温度变化导致的热应力、酸碱度变化导致的侵蚀,冲刷力变化导致的损伤,都会加速耐火浇注料的破坏,为了有效解决大部分工况环境变化对传统不定形耐火材料造成的过快损坏,本申请人提出一种高强耐酸轻质浇注料及其制备方法。
发明内容
本发明的目的在于提供一种高强耐酸轻质浇注料及其制备方法,以解决工况环境的变化,如温度变化导致的热应力、酸碱度变化导致的侵蚀,冲刷力变化导致的损伤,加速耐火浇注料的破坏的问题。
为解决上述的技术问题,本发明采用以下技术方案:
一种高强耐酸轻质浇注料,包括以下按照重量百分比表示的配方组分:粒度为5~3mm的莫来石质轻骨料10~15%、3~1mm的莫来石质轻骨料15~20%、粒度为3~1mm的烧结板状刚玉15%~20%、粒度为3~1mm的抗酸填充料18~20%、粒度为0.1~1mm的焦宝石6~8%、粒度为150目的蓝晶石3~6%、粒度为≤5mm的二氧化硅微粉5~8%、粒度为150目的锂辉石1~3%、粒度为≤5mm的工业氧化铝细粉5~8%、高铝水泥6~10%、一级高铝熟料粉8~10%、长度为5-10mm的耐火纤维2~4%、外加剂0.3~0.5%。
进一步的技术方案是:所述二氧化硅微粉由二氧化硅空心微球和高硅质废弃料粉末组成。
进一步的技术方案是:所述二氧化硅空心微球和高硅质废弃料粉末的料比重为1∶(1.5~2)。
进一步的技术方案是:所述外加剂为减水剂、结合剂、有机消泡剂和硅烷偶联剂。
进一步的技术方案是:所述结合剂为广西白泥和磷酸二氢铝固粉的混合物。
进一步的技术方案是:所述抗酸填充料为铸石粉、黏土熟料、煅烧蜡石粉或者煅烧安山岩中的至少一种。
进一步的技术方案是:所述铸石粉的耐酸度为98%以上,所述黏土熟料的耐酸度为96%以上,所述煅烧蜡石粉的耐酸度为95%以上,所述煅烧安山岩的耐酸度为94%以上。
一种高强耐酸轻质浇注料的制备方法,包括以下步骤:
S1、来料检验:对来料进行性能和质量检验,批料的抽检样品数量至少为10组,且合格率控制在90%以上;
S2、原料破碎:将S1中的合格原料按照配方组分要求,破碎为合适的粒度大小,并分区分库进行干储存;
S3、混合: 按照合适配比,将S2中处理后的各组分原料按多次交替的方式加入搅拌机内,干混3~5min,直至混合料无明显的色差;
S4、性能检验:将S3中的混合料进行取样,一次加足中性水,料水比为1∶(0.055~0.065),搅拌时间不低于5min,浇注进检测模板内振实,干燥后按照行业规定检测项目及方法进行性能检测;
S4、打包:将S4中检验合格的批料进行灌装打包、入库。
与现有技术相比,本发明至少能达到以下有益效果之一的是:
本发明提出的一种高强耐酸轻质浇注料,该产品具备体积密度小、抗酸性、耐磨性、易少烧结和抗热应力等优异性能,作为浇注料或者修补料都具备良好的应激功能,可以适用于大部分酸性工况下的浇筑使用,即使面对生产温度改变,也能减少高温下的体积收缩,很好地与炉身结合,并且有着优异的耐磨、抗腐蚀。
另外,该产品中的二氧化硅微粉替代传统的硅粉,起到促烧结和减少膨胀的效果,二氧化硅微粉由二氧化硅空心微球和高硅质废弃料粉末组成,一方面,二氧化硅空心微球具备特殊的力学、热学性质和良好的流动性,可用作轻质的隔热、保温、阻燃材料,同时空心微球也可作为微反应器,使烧结反应在限定的微小区域内进行,促进烧结;另外,高硅质废弃料粉末可以避免传统硅粉烧结是的热膨胀。
具体实施方式
为使本发明实施方式的目的、技术方案和优点更加清楚,下面将结合本发明实施例,对本发明实施方式中的技术方案进行清楚、完整地描述,显然,所描述的实施方式是本发明一部分实施方式,而不是全部的实施方式。
因此,以下对本发明的实施方式的详细描述并非旨在限制要求保护的本发明的范围,而是仅仅表示本发明的选定实施方式。基于本发明中的实施方式,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方式,都属于本发明保护的范围。
需要说明的是,在不冲突的情况下,本发明中的实施方式及实施方式中的特征可以相互组合。
实施例一:
本实施例示出了一种高强耐酸轻质浇注料,包括以下按照重量百分比表示的配方组分:粒度为5~3mm的莫来石质轻骨料10~15%、3~1mm的莫来石质轻骨料15~20%、粒度为3~1mm的烧结板状刚玉15%~20%、粒度为3~1mm的抗酸填充料18~20%、粒度为0.1~1mm的焦宝石6~8%、粒度为150目的蓝晶石3~6%、粒度为≤5mm的二氧化硅微粉5~8%、粒度为150目的锂辉石1~3%、粒度为≤5mm的工业氧化铝细粉5~8%、高铝水泥6~10%、一级高铝熟料粉8~10%、长度为5-10mm的耐火纤维2~4%、外加剂0.3~0.5%。二氧化硅微粉由二氧化硅空心微球和高硅质废弃料粉末组成。二氧化硅空心微球和高硅质废弃料粉末的料比重为1∶(1.5~2)。外加剂为减水剂、结合剂、有机消泡剂和硅烷偶联剂。结合剂为广西白泥和磷酸二氢铝固粉的混合物。抗酸填充料为铸石粉、黏土熟料、煅烧蜡石粉或者煅烧安山岩中的至少一种。铸石粉的耐酸度为98%以上,黏土熟料的耐酸度为96%以上,煅烧蜡石粉的耐酸度为95%以上,煅烧安山岩的耐酸度为94%以上。
本发明中高强耐酸轻质浇注料,以莫来石质轻骨料、烧结板状刚玉和抗酸填充料作为主料,有效提高产品的阻热保温性、耐热性、耐酸性能和耐磨性;焦宝石的加入,弥补了轻质料劣化的不足,以焦宝石优良的热震稳定性和高温性能,提高浇注料的综合使用性能;二氧化硅微粉替代传统的硅粉(石英砂),起到促烧结和减少膨胀的效果,二氧化硅微粉由二氧化硅空心微球和高硅质废弃料粉末组成,一方面,二氧化硅空心微球具备特殊的力学、热学性质和良好的流动性,可用作轻质的隔热、保温、阻燃材料,同时空心微球也可作为微反应器,使烧结反应在限定的微小区域内进行,促进烧结;另外,高硅质废弃料粉末(如废弃硅砖)经过在先烧制后,不会再发生热胀现象,使用时可以避免传统硅粉烧结是的热膨胀;这里的锂辉石主要起到高温促烧结作用,便于高温陶瓷结合相的生成;高铝水泥、工业氧化铝细粉与二氧化硅微粉在这里起到协同的凝结硬化效果;一级高铝熟料粉的加入进一步提高产品的耐火性;蓝晶石作文膨胀剂使用,抵消高温下产品的体积收缩;外加剂一方面提高浇注料的流动性,减少加水量,提升产品综合性能,另一方面,酸性结合剂在起到耐酸的同时,便于产品的浇筑成型。该产品具备体积密度小、热稳定性(抗热胀、抗热缩)、抗酸性、耐磨性、易少烧结和抗热应力等优异性能,作为浇注料或者修补料都具备良好的应激功能,可以适用于大部分酸性工况下的浇筑使用,即使面对生产温度改变,也能减少高温下的体积收缩,很好地与炉身结合,并且有着优异的耐磨、抗腐蚀。
一种高强耐酸轻质浇注料的制备方法,包括以下步骤:
S1、来料检验:对来料进行性能和质量检验,批料的抽检样品数量至少为10组,且合格率控制在90%以上;
S2、原料破碎:将S1中的合格原料按照配方组分要求,破碎为合适的粒度大小,并分区分库进行干储存;
S3、混合: 按照合适配比,将S2中处理后的各组分原料按多次交替的方式加入搅拌机内,干混3~5min,直至混合料无明显的色差;
S4、性能检验:将S3中的混合料进行取样,一次加足中性水,料水比为1∶(0.055~0.065),搅拌时间不低于5min,浇注进检测模板内振实,干燥后按照行业规定检测项目及方法进行性能检测;
S4、打包:将S4中检验合格的批料进行灌装打包、入库。
该制备方法结合配方组分生产出的浇注料性能稳定优异,并且S4中的料水比也对该产品的使用方法起到技术启示。
表一:S4中本发明产品高强耐酸轻质浇注料的性能数据
尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换,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 (8)
1.一种高强耐酸轻质浇注料,其特征在于,包括以下按照重量百分比表示的配方组分:粒度为5~3mm的莫来石质轻骨料10~15%、3~1mm的莫来石质轻骨料15~20%、粒度为3~1mm的烧结板状刚玉15%~20%、粒度为3~1mm的抗酸填充料18~20%、0.1~1mm的焦宝石6~8%、粒度为150目的蓝晶石3~6%、粒度为≤5mm的二氧化硅微粉5~8%、粒度为150目的锂辉石1~3%、粒度为≤5mm的工业氧化铝细粉5~8%、高铝水泥6~10%、一级高铝熟料粉8~10%、长度为5-10mm的耐火纤维2~4%、外加剂0.3~0.5%。
2.根据权利要求1所述的一种高强耐酸轻质浇注料,其特征在于:所述二氧化硅微粉由二氧化硅空心微球和高硅质废弃料粉末组成。
3.根据权利要求2所述的一种高强耐酸轻质浇注料,其特征在于:所述二氧化硅空心微球和高硅质废弃料粉末的料比重为1∶(1.5~2)。
4.根据权利要求1所述的一种高强耐酸轻质浇注料,其特征在于:所述外加剂为减水剂、结合剂、有机消泡剂和硅烷偶联剂。
5.根据权利要求3所述的一种高强耐酸轻质浇注料,其特征在于:所述结合剂为广西白泥和磷酸二氢铝固粉的混合物。
6.根据权利要求1所述的一种高强耐酸轻质浇注料,其特征在于:所述抗酸填充料为铸石粉、黏土熟料、煅烧蜡石粉或者煅烧安山岩中的至少一种。
7.根据权利要求6所述的一种高强耐酸轻质浇注料,其特征在于:所述铸石粉的耐酸度为98%以上,所述黏土熟料的耐酸度为96%以上,所述煅烧蜡石粉的耐酸度为95%以上,所述煅烧安山岩的耐酸度为94%以上。
8.根据权利要求1-7任一项所述的一种高强耐酸轻质浇注料的制备方法,其特征在于,包括以下步骤:
S1、来料检验:对来料进行性能和质量检验,批料的抽检样品数量至少为10组,且合格率控制在90%以上;
S2、原料破碎:将S1中的合格原料按照配方组分要求,破碎为合适的粒度大小,并分区分库进行干储存;
S3、混合: 按照合适配比,将S2中处理后的各组分原料按多次交替的方式加入搅拌机内,干混3~5min,直至混合料无明显的色差;
S4、检验:将S3中的混合料进行取样,一次加足中性水,料水比为1∶(0.055~0.065),搅拌时间不低于5min,浇注进检测模板内振实,干燥后按照行业规定检测项目及方法进行性能检测;
S4、打包:将S4中检验合格的批料进行灌装打包、入库。
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