CN115259872B - 一种莫来石质高强耐酸免烧砖及其制备方法 - Google Patents
一种莫来石质高强耐酸免烧砖及其制备方法 Download PDFInfo
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- 239000011449 brick Substances 0.000 title claims abstract description 77
- 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 title claims abstract description 48
- 229910052863 mullite Inorganic materials 0.000 title claims abstract description 47
- 239000002253 acid Substances 0.000 title claims abstract description 34
- 238000002360 preparation method Methods 0.000 title abstract description 10
- 239000000463 material Substances 0.000 claims abstract description 36
- 238000005245 sintering Methods 0.000 claims abstract description 26
- 239000004927 clay Substances 0.000 claims abstract description 20
- 229910052851 sillimanite Inorganic materials 0.000 claims abstract description 17
- 229910052849 andalusite Inorganic materials 0.000 claims abstract description 16
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 15
- 239000010431 corundum Substances 0.000 claims abstract description 15
- 238000002156 mixing Methods 0.000 claims abstract description 13
- 238000001035 drying Methods 0.000 claims abstract description 12
- 238000000227 grinding Methods 0.000 claims abstract description 11
- 239000007767 bonding agent Substances 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims abstract description 7
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 39
- 239000000203 mixture Substances 0.000 claims description 25
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 23
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 21
- 239000011230 binding agent Substances 0.000 claims description 18
- 239000000843 powder Substances 0.000 claims description 13
- 239000002245 particle Substances 0.000 claims description 8
- 230000003750 conditioning effect Effects 0.000 claims description 7
- 229910052903 pyrophyllite Inorganic materials 0.000 claims description 7
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical class [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
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- 238000003756 stirring Methods 0.000 claims description 6
- 229910052581 Si3N4 Inorganic materials 0.000 claims description 4
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 claims description 4
- 239000000919 ceramic Substances 0.000 claims description 4
- 229910000423 chromium oxide Inorganic materials 0.000 claims description 4
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 4
- 238000005496 tempering Methods 0.000 claims description 4
- 241000276425 Xiphophorus maculatus Species 0.000 claims description 3
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- IXQWNVPHFNLUGD-UHFFFAOYSA-N iron titanium Chemical compound [Ti].[Fe] IXQWNVPHFNLUGD-UHFFFAOYSA-N 0.000 claims description 3
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- 238000005260 corrosion Methods 0.000 abstract description 12
- 238000004519 manufacturing process Methods 0.000 abstract description 8
- 239000000126 substance Substances 0.000 abstract description 6
- 229910052799 carbon Inorganic materials 0.000 abstract description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 abstract description 3
- 230000008569 process Effects 0.000 abstract description 3
- 238000009991 scouring Methods 0.000 abstract description 3
- 229910052570 clay Inorganic materials 0.000 description 15
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- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 6
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- 238000003723 Smelting Methods 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
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- 150000007524 organic acids Chemical class 0.000 description 2
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- 230000000171 quenching effect Effects 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 235000011121 sodium hydroxide Nutrition 0.000 description 2
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
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- 239000000428 dust Substances 0.000 description 1
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- 239000007789 gas Substances 0.000 description 1
- 125000000623 heterocyclic group Chemical group 0.000 description 1
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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 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
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- 239000000779 smoke Substances 0.000 description 1
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- 229910052861 titanite Inorganic materials 0.000 description 1
- 239000002912 waste gas Substances 0.000 description 1
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Abstract
本发明公开了一种莫来石质高强耐酸免烧砖及其制备方法，按照重量百分比表示的配方组分：粒度为1mm～3mm的烧结莫来石25%～35%、粒度为1mm～3mm的烧结板状刚玉15%～20%、粒度为0.1mm～1mm的调质料10%～15%、粒度为1mm～1.5mm的焦宝石10%～15%、粒度为0.1mm～1mm的红柱石8%～10%、粒度为0.1mm～1mm的硅线石6%～8%、助烧剂2%～3%、结合剂5%～8%。按配方组分要求，经过多次的混碾、困料、制坯、干燥和低温烘制等工艺制备而成。本发明中制成的耐火砖具备着良好的抗冲刷性、高强度和化学稳定性等性能，可以适应高炉等工况中的各种强酸腐蚀环境，而且低温烘制即可达到烧结目的，节约生产成本，降低碳排放量。
Description
技术领域
本发明涉及耐火免烧砖技术领域，特别是一种莫来石质高强耐酸免烧砖及其制备方法。
背景技术
随着工业的迅速发展和能源的大量使用，人们的能源危机意识越来越强，国家对环保、节能要求的不断提高，这就对耐火材料生产企业提出了新的任务，不但要满足耐火制品的各项指标稳定，同时还要满足国家对企业节能减排的要求，同时也能适应强酸腐蚀工况环境的的应用。
在化工、冶金、石油等行业中各种塔、炉、池、罐、槽的防腐内衬，都是采用耐高温、耐急冷、抗强酸腐蚀的材料。莫来石(3Al2O3·2SiO2)质耐火砖具有抗蠕变能力高、热膨胀系数和导热系数低、较好的抗热震性能和抗腐蚀性能好等优异的性能。常用于以上场合，作为耐火保温材料。
现有技术中，如公开号为CN 101633578 B，专利名称为特种复合低铝莫来石砖及其制备方法的发明专利，公开的是一种特种复合低铝莫来石砖及其制备方法，其原料由莫来石、焦宝石、硅线石或红柱石和锆粉组成，经混碾、困料、挤压成型，干燥和高温烧制而成，该特种复合低铝莫来石砖以其低显气孔率、低杂质、高强度、高荷重软化温度、制品微膨胀等优异性能，可以满足高炉、焦炉的使用要求。
但是以上的特种复合低铝莫来石砖，其制成砖坯质地比较松散，必须在高温(1000℃以上)烧结下才能形成密实的显微结构，这一步是比较消耗能源，提高了生产成本和时间，虽然市场上存在着一些不烧砖或者免高温烧制砖，但一般各组分很难结合紧密，达不到一定的强度和保温性；另外，在高炉(热风炉)的冶炼过程中，面对酸性高温废气和烟尘颗粒的冲刷，但该特种复合低铝莫来石砖的强度和耐酸性仍不够，砖体会由表向内逐层脱落，导致保温效果减弱，墙内面剥离，起不到节能效果，严重时，甚至导致炉体变形坍塌。
发明内容
本发明的目的在于提供一种莫来石质高强耐酸免烧砖及其制备方法，以解决一般的莫来石质耐火砖在生产时，需要消耗大量的时间和能源进行高温烧制，以及砖体的强度和耐酸性不够，会由表向内逐层脱落，导致保温效果减弱的问题。
为解决上述的技术问题，本发明采用以下技术方案：
一种莫来石质高强耐酸免烧砖，包括以下按照重量百分比表示的配方组分：粒度为1mm～3mm的烧结莫来石25％～35％、粒度为1mm～3mm的烧结板状刚玉15％～20％、粒度为0.1mm～1mm的调质料10％～15％、粒度为1mm～1.5mm的焦宝石10％～15％、粒度为0.1mm～1mm的红柱石8％～10％、粒度为0.1mm～1mm的硅线石6％～8％、助烧剂2％～3％、结合剂5％～8％。
进一步的技术方案是：所述烧结莫来石35％、所述烧结板状刚玉20％、所述调质料10％、所述焦宝石13％、所述红柱石8％、所述硅线石6％、所述助烧剂2％、所述结合剂6％。
进一步的技术方案是：所述烧结莫来石中的氧化铝含量至少为68％、所述烧结板状刚玉中的氧化铝含量至少为99.5％、所述调质料中的氧化铝含量至少为30％、所述焦宝石中的氧化铝含量至少为45％、所述红柱石中的氧化铝含量至少为58％、所述硅线石中的氧化铝含量至少为40％。
进一步的技术方案是：所述调质料由70％～75％的广西白泥、20％～25％的叶蜡石粉、3％～5％的煅烧钛铁矿粉组成。
进一步的技术方案是：所述结合剂包括以下按照重量百分比表示的：磷酸溶液60％～70％和改性酚醛树脂溶液30％～40％。
进一步的技术方案是：所述磷酸溶液中磷酸的浓度为1.50％～1.55％。
进一步的技术方案是：所述助烧剂为电熔氧化铬颗粒。
一种莫来石质高强耐酸免烧砖的制备方法，包括以下步骤：
S1、一次混碾：按配方组分，将烧结莫来石、烧结板状刚玉、调质料、焦宝石、红柱石、硅线石、助烧剂送入轮碾机，混碾10～15min；
S2、困料：将S1处理后的混合料加入部分的结合剂搅拌均匀后送入困料室，困料温度为20℃～30℃，困料时间为6h～8h；
S3、烘干：将S2的混合料在150℃～200℃条件下热处理6h～8h；
S4、二次混碾：将S3处理后的混合料再次送入轮碾机，混碾10～15min；
S5、困料：将S4处理后的混合料加入剩下的结合剂拌均匀后送入困料室，困料温度为30℃～50℃，困料时间为6h～8h；
S6、烘干：将S6的混合料在150℃～200℃条件下热处理6h～8h；
S7、三次混碾：将S6处理后的混合料再次送入轮碾机，混碾10～15min；
S8、制坯：压砖机将S7得到的湿料进行压制成型，得到砖胚，砖胚工作面附有硬质层；
S9、干燥：砖胚在150℃～250℃条件下热处理10h～12h，得到砖坯；
S10、低温烘制：砖坯在500℃～600℃条件下热处理6h～8h，得到免烧砖成品。
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：
本发明提出的一种莫来石质高强耐酸免烧砖，以烧结莫来石、烧结板状刚玉、调质料、焦宝石、红柱石、硅线石等为主要原料，辅以助烧剂和结合剂制备而成，该高强耐酸免烧砖在具有保温和耐高温的基础上更容易烧结，并且烧结温度低，不需要经高温烧制便可形成致密结构，显气孔率低，可以达到保温和高强度性能，烧成温度从原先的1410℃左右降低到500℃左右，达到节能降耗的目的，节约生产成本，降低碳排放量。利用结合剂和调质料，可以在形成以莫来石质为主的耐火结构，同时具备较好的耐酸性，以适应各种强酸腐蚀的工况环境。
本发明在砖坯制备时，砖坯的一个工作面利用耐火耐高温胶水(耐火泥)滚粘至少一层1-2mm厚的氮化硅陶瓷粉末，在干燥后，形成低密度、耐高温、耐磨损的硬质层，使得该砖具备较高的强度和抗冲击性，并且该砖用于高温工况条件时，受热不会收缩，有惊人的耐化学腐蚀性能，能耐几乎所有的无机酸和30％以下的烧碱溶液，也能耐很多有机酸的腐蚀。有效提高原有高强耐酸免烧砖的抗冲刷性、热稳定性和化学稳定性。
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，一种莫来石质高强耐酸免烧砖，包括以下按照重量百分比表示的配方组分：粒度为1mm～3mm的烧结莫来石25％～35％、粒度为1mm～3mm的烧结板状刚玉15％～20％、粒度为0.1mm～1mm的调质料10％～15％、粒度为1mm～1.5mm的焦宝石10％～15％、粒度为0.1mm～1mm的红柱石8％～10％、粒度为0.1mm～1mm的硅线石6％～8％、助烧剂2％～3％、结合剂5％～8％。
优选地，按照重量百分比表示：烧结莫来石35％、烧结板状刚玉20％、调质料10％、焦宝石13％、红柱石8％、硅线石6％、助烧剂2％、结合剂6％。
优选地，烧结莫来石中的氧化铝含量至少为68％、烧结板状刚玉中的氧化铝含量至少为99.5％、调质料中的氧化铝含量至少为30％、焦宝石中的氧化铝含量至少为45％、红柱石中的氧化铝含量至少为58％、硅线石中的氧化铝含量至少为40％。
在本发明中，具备莫来石质的烧结莫来石和烧结板状刚玉，以及在高温作用下可转化成莫来石质的焦宝石、红柱石和硅线石(也叫夕线石或者矽线石)，以上作为主要原料，辅以助烧剂和结合剂，可以在极低的温度下生成以莫来石为主晶相的高强耐酸砖。通过各种原料的使用和配比达到最佳的耐酸性，以适应各种强酸腐蚀的工况环境；另一方面是在保证产品各项指标的情况下，烧成温度从原先的1410℃左右降低到500℃左右，达到节能降耗的目的，节约生产成本，降低碳排放量。
其中，调质料由70％～75％的广西白泥、20％～25％叶蜡石粉、3％～5％的煅烧钛铁矿粉组成。结合剂包括以下按照重量百分比表示的：磷酸溶液60％～70％和改性酚醛树脂溶液30％～40％。磷酸溶液中磷酸的浓度为1.50％～1.55％。助烧剂为电熔氧化铬颗粒。
广西白泥实质上是一种软质高岭土，也可以叫软质耐火粘土，其特点在于：可塑性好、流动性好、结合性好、质很纯。作为耐火料的同时，一方面在混合时，将各物料粘接到一块；另一方面提供砖胚成型的可塑性。添加叶蜡石粉(叶蜡石也称叶腊石)，作为耐火材料成分的同时，以其自身的化学性能稳定，增强砖的绝热性和耐酸性，但是考虑其质地较软，需要控制其合适的添加量(在调质料中占20％～25％)。煅烧钛铁矿粉中会存在氧化钛颗粒，氧化钛在高温下促进烧结。
结合剂中的磷酸溶液，主要增加物料之间的粘接性，并且做出的免烧砖在高温使用下，还可以被进一步促进强度的增加，也可以起到耐酸性，因为磷酸没有氧化性，物料需要困料，所以本发明中为了减少磷酸溶液的使用量，促进结合和缩短困料时间，在大量实验和论证下，在组分中增加部分的改性酚醛树脂溶液(主要是酸性改性的酚醛树脂)，这里可以使用磷酸改性酚醛树脂溶液，低温烘制下，便可起到熔融结合作用，同时作为酸性结合剂，不会与磷酸发生反应，消耗磷酸，还可以对砖的耐酸性和后期高温下的强度都起到协同促进作用。
助烧剂采用电熔氧化铬颗粒，较传统的氧化钛助烧剂，砖坯在高温做用下，Cr2O3对氧化铝促进烧结，灼烧后，形成的结晶体极硬，砖体的耐高温、耐磨损、耐腐蚀更好，在起到助烧的同时，还可以促进砖的强度和硬度。
表一：本发明产品莫来石质高强耐酸免烧砖的性能数据(FM1为本产品，FM2为市面上同类产品)
实施例二：
本实施例示出了，一种莫来石质高强耐酸免烧砖的制备方法，包括以下步骤：
S1、一次混碾：按配方组分，将烧结莫来石、烧结板状刚玉、调质料、焦宝石、红柱石、硅线石、助烧剂送入轮碾机，混碾10～15min；
S2、困料：将S1处理后的混合料加入部分的结合剂搅拌均匀后送入困料室，困料温度为20℃～30℃，困料时间为6h～8h；
S3、烘干：将S2的混合料在150℃～200℃条件下热处理6h～8h；
S4、二次混碾：将S3处理后的混合料再次送入轮碾机，混碾10～15min；
S5、困料：将S4处理后的混合料加入剩下的结合剂拌均匀后送入困料室，困料温度为30℃～50℃，困料时间为6h～8h；
S6、烘干：将S6的混合料在150℃～200℃条件下热处理6h～8h；
S7、三次混碾：将S6处理后的混合料再次送入轮碾机，混碾10～15min；
S8、制坯：压砖机将S7得到的湿料进行压制成型，得到砖胚，砖胚工作面附有硬质层；
S9、干燥：砖胚在150℃～250℃条件下热处理10h～12h，得到砖坯；
S10、低温烘制：砖坯在500℃～600℃条件下热处理6h～8h，得到免烧砖成品。
优选地，S6中的砖胚外表面通过耐高温胶水或者耐火泥粘附至少一层氮化硅陶瓷粉末。
在上述实施例一的基础上，本发明产品的制备方法在工艺上进行多次混料，各物料分布更加均匀，结合剂配料组分的加入，也极大所大了困料时间，并且分两次添加结合剂、两次困料，结合剂作用更加充分，物料之间的结合更加充实紧密。这里所使用的磷酸改性酚醛树脂本身的热稳定性在600℃左右(最高不超过670℃)，当磷酸(来源于添加的磷酸溶液)多余时，磷酸中多余的质子对树脂起到催化作用，热稳定性就会下降到500℃～600℃左右，甚至更低，在此温度区间范围即可烧融，得到免烧砖成品，意味着砖体的烧成温度从原先的1410℃左右降低到500℃左右，达到节能降耗的目的，节约生产成本，降低碳排放量。在形成砖胚之后，可以利用耐火泥等或者直接在还比较湿润的砖面上粘附氮化硅陶瓷粉末形成硬质层，烧结时不收缩，强度很高，质地较硬，耐热冲击性极佳，骤热骤冷也不会破裂，极耐高温，强度一直可以维持到1200℃的高温而不下降，受热后不会熔成融体，一直到1900℃才会分解，并有惊人的耐化学腐蚀性能，能耐几乎所有的无机酸和30％以下的烧碱溶液，也能耐很多有机酸的腐蚀，用于高炉等环境时，完全可以达到要求使用，有助于防气体、颗粒等高温流体的冲刷。
在每次困料后，在在150℃～200℃条件下对物料热处理6h～8h，为了使结合剂和各物料更好的反应，密闭物料颗粒的气孔，在成砖时，物料更加充实紧密，显气孔率更低。
另外，当添加的磷酸溶液不多时，磷酸改性酚醛树脂中引入了键能较高的P—O—C和P＝O键，使酚醛树脂形成了热稳定性较高的杂环结构并提高了树脂的芳香性，降低了树脂在高温下的分解量，从而使其耐热性和力学性能得到改善。S8中的最高烧结温度要略微提高到670℃进行烘制。
值得注意的是：本发明中的免烧砖是指不用在工业中划分的高温下烧结成型，只需在低温环境下烘制而成。
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 (6)
1.一种莫来石质高强耐酸免烧砖，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1mm～3mm的烧结莫来石25％～35％、粒度为1mm～3mm的烧结板状刚玉15％～20％、粒度为0.1mm～1mm的调质料10％～15％、粒度为1mm～1.5mm的焦宝石10％～15％、粒度为0.1mm～1mm的红柱石8％～10％、粒度为0.1mm～1mm的硅线石6％～8％、助烧剂2％～3％、结合剂5％～8％；其中，
所述调质料由70％～75％的广西白泥、20％～25％叶蜡石粉、3％～5％的煅烧钛铁矿粉组成；
所述结合剂包括以下按照重量百分比表示的：磷酸溶液60％～70％和改性酚醛树脂溶液30％～40％；
所述助烧剂为电熔氧化铬颗粒。
2.根据权利要求1所述的一种莫来石质高强耐酸免烧砖，其特征在于，所述烧结莫来石35％、所述烧结板状刚玉20％、所述调质料10％、所述焦宝石13％、所述红柱石8％、所述硅线石6％、所述助烧剂2％、所述结合剂6％。
3.根据权利要求1所述的一种莫来石质高强耐酸免烧砖，其特征在于，所述烧结莫来石中的氧化铝含量至少为68％、所述烧结板状刚玉中的氧化铝含量至少为99.5％、所述调质料中的氧化铝含量至少为30％、所述焦宝石中的氧化铝含量至少为45％、所述红柱石中的氧化铝含量至少为58％、所述硅线石中的氧化铝含量至少为40％。
4.根据权利要求1所述的一种莫来石质高强耐酸免烧砖，其特征在于，所述磷酸溶液中磷酸的浓度为1.50％～1.55％。
5.根据权利要求1～4任一项所述的一种莫来石质高强耐酸免烧砖的制备方法，其特征在于，包括以下步骤：
S1、一次混碾：按配方组分，将烧结莫来石、烧结板状刚玉、调质料、焦宝石、红柱石、硅线石、助烧剂送入轮碾机，混碾10～15min；
S2、困料：将S1处理后的混合料加入部分的结合剂搅拌均匀后送入困料室，困料温度为20℃～30℃，困料时间为6h～8h；
S3、烘干：将S2的混合料在150℃～200℃条件下热处理6h～8h；
S4、二次混碾：将S3处理后的混合料再次送入轮碾机，混碾10～15min；
S5、困料：将S4处理后的混合料加入剩下的结合剂拌均匀后送入困料室，困料温度为30℃～50℃，困料时间为6h～8h；
S6、烘干：将S6的混合料在150℃～200℃条件下热处理6h～8h；
S7、三次混碾：将S6处理后的混合料再次送入轮碾机，混碾10～15min；
S8、制坯：压砖机将S7得到的湿料进行压制成型，得到砖胚，砖胚工作面附有硬质层；
S9、干燥：砖胚在150℃～250℃条件下热处理10h～12h，得到砖坯；
S10、低温烘制：砖坯在500℃～600℃条件下热处理6h～8h，得到免烧砖成品。
6.根据权利要求5所述的一种莫来石质高强耐酸免烧砖的制备方法，其特征在于，S8中的砖胚外表面通过耐高温胶水或者耐火泥粘附至少一层氮化硅陶瓷粉末。
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