CN115321946A - 一种高寿命低成本耐火浇注料及其制备方法 - Google Patents
一种高寿命低成本耐火浇注料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种高寿命低成本耐火浇注料及其制备方法,以重量份计,所述耐火浇注料包括:粒径1‑8mm的废旧电瓷55‑78份、刚玉15‑32份、碳化硅粉4‑16份、α‑氧化铝粉3‑9份、硅微粉2‑8份、纯铝酸钙水泥2‑8份、金属铝粉@聚乙烯醇微胶囊2‑6份、有机纤维0.01‑0.5份和减水剂0.1‑0.3份。本发明提出的一种高寿命低成本耐火浇注料及其制备方法,通过利用废旧电瓷作为主要原料,从而获得一种高温耐压抗折强度高、热震稳定性好且寿命长的耐火材料。
Description
技术领域
本发明属于耐火材料技术领域,尤其涉及一种高寿命低成本耐火浇注料及其制备方法。
背景技术
我国是陶瓷生产与使用的大国,每年产生大量的陶瓷废弃物,但是与成熟的陶瓷生产工艺相对应的陶瓷废料回收再利用技术还处于起步阶段,仅有少量的陶瓷能够回收利用,大部分是填埋,甚至随意堆积,造成环境污染。电瓷是一种常用的陶瓷,它是应用于电力系统中主要起支持和绝缘作用的部件,具有良好的机械强度以及耐高温性能,随着电瓷使用日益广泛,废旧电瓷体量越来越大,造成环境污染,如何使废旧电瓷实现高值化利用引起广泛关注。
近年来,以锻烧铝矾土和工业氧化铝为主的高强度铝质瓷已逐步在各电瓷厂得到应用,由于高强度铝质瓷是在高温下烧结而成,废电瓷体积稳定、结构致密、耐磨损,具有较好的利用价值,比较适用于水泥窑用不定形耐火材料的生产。例如周治军等以废电瓷为骨料,高铝细粉为基质,纯铝酸钙水泥、SiO2微粉和Al2O3微粉作为结合剂,研制出一种性能良好的循环流化床锅炉耐磨浇注料,其施工性能达到工厂要求(周治军,2013)。
尽管国内外已经有研究人员陆续投入到废旧电瓷的相关研究中,但总结研究成果发现废旧电瓷的回收中利用率低,制得的耐火材料例如耐火浇注料高温耐压抗折强度低,热震稳定性较差。
发明内容
基于上述技术问题,本发明提出了一种高寿命低成本耐火浇注料及其制备方法,通过利用废旧电瓷作为主要原料,从而获得一种高温耐压抗折强度高、热震稳定性好且寿命长的耐火材料。
本发明提出的一种高寿命低成本耐火浇注料,以重量份计,包括:粒径1-8mm的废旧电瓷55-78份、刚玉15-32份、碳化硅粉4-16份、α-氧化铝粉3-9份、硅微粉2-8份、纯铝酸钙水泥2-8份、金属铝粉@聚乙烯醇微胶囊2-6份、有机纤维0.01-0.5份和减水剂0.1-0.3份。
优选地,所述刚玉的颗粒级配组成包括:粒径小于8mm且大于5mm的刚玉占比为10-20wt%,粒径小于5mm且大于3mm的刚玉占比为30-40wt%,粒径小于3mm且大于1mm的刚玉占比为30-40wt%,粒径小于1mm且大于0.088mm的刚玉占比为15-25wt%。
优选地,所述碳化硅粉中SiC含量不小于97wt%,且碳化硅粉的粒径不大于1mm。
优选地,所述α-氧化铝粉中Al2O3含量不小于99wt%,且α-氧化铝粉的粒径不大于3μm。
优选地,所述硅微粉中SiO2含量不小于92wt%,且硅微粉的粒径不大于1μm。
优选地,所述纯铝酸钙水泥中Al2O3含量不小于70wt%,且纯铝酸钙水泥的粒径不大于20μm。
优选地,所述金属铝粉@聚乙烯醇微胶囊是通过下述方法制备而成:将正硅酸乙酯进行水解缩聚后对金属铝粉进行包覆,形成金属铝粉@二氧化硅微胶囊;再利用聚乙烯醇所含有的羟基与二氧化硅表面的羟基进行缩合,即得到所述金属铝粉@聚乙烯醇微胶囊。
优选地,所述有机纤维为聚丙烯防爆纤维、碳纤维或石墨纤维中的至少一种。
优选地,所述减水剂为三聚磷酸钠、四聚磷酸钠或六偏磷酸钠中的至少一种。
本发明还提出一种高寿命低成本耐火浇注料的制备方法,其是将上述高寿命低成本耐火浇注料的原料混合并搅拌均匀后得到。
与现有技术相比,本发明提供的一种高寿命低成本耐火浇注料及其制备方法,废旧电瓷和刚玉作为骨料,由于废旧电瓷主晶相为刚玉和莫来石,其烧结过后结构稳定、强度高、耐磨性好,因此既保证了耐火浇注料的基本耐火强度,又能大幅度降低生产成本;碳化硅、α-氧化铝粉以及硅微粉作为细粉,由于碳化硅具有密度低、强度大、高温稳定性以及化学稳定性好的特点,因此可以有效改善耐火浇注料的抗热震稳定性;α-氧化铝粉和硅微粉可以发生反应,因此可以进一步提高所述耐火浇注料的耐压抗折强度;金属铝粉@聚乙烯醇微胶囊作为抗氧添加剂,一方面,聚乙烯醇对铝粉形成包覆,可以避免铝粉水化对浇注料施工产生负面影响;另一方面,聚乙烯醇的水化特性又能增强浇注颗粒的分散性,从而有利于铝粉在基质中分散并发挥抗氧化性,因此有助于铝粉后续与氧气结合形成氧化铝并在整个基质中的广泛分布,增强所得耐火浇注料的耐热抗折强度和热震稳定性;纯铝酸钙水泥作为结合剂,其具有快硬、高强度、耐火度高等特点,在高温使用过程中转化成刚玉,并和废旧电瓷烧结融为一体,获得高温工作强度;有机纤维在基质内分布形成微小网络气孔,它能打开水气通道,减轻内部应力,从而有效提升耐火浇注料的使用效果。
具体实施方式
下面,本发明通过具体实施例对所述技术方案进行详细说明,但是应该明确提出这些实施例用于举例说明,但是不解释为限制本发明的范围。
实施例1
一种高寿命低成本耐火浇注料,以重量份计,包括:粒径1-8mm的废旧电瓷66份、粒径5-8mm的刚玉3.5份,粒径3-5mm的刚玉8.5份,粒径1-3mm的刚玉8.5份,粒径0.088-1mm的刚玉4.5份、粒径不大于1mm的碳化硅粉10份、粒径不大于3μm的α-氧化铝粉6份、粒径不大于1μm的硅微粉5份、粒径不大于20μm的纯铝酸钙水泥5份、金属铝粉@聚乙烯醇微胶囊4份、聚丙烯防爆纤维0.1份和三聚磷酸钠0.2份;
其中,所述金属铝粉@聚乙烯醇微胶囊是通过下述方法制成:按重量比10:5将金属铝粉和正硅酸乙酯加入无水乙醇中,超声分散均匀后,向其中缓慢滴加3倍铝粉重量的氨水稀溶液(2wt%),在40℃下加热反应2h后,再加入5倍铝粉重量的聚乙烯醇水溶液(15wt%),在60℃下加热反应1h后,抽滤,洗涤,干燥,即得到所述金属铝粉@聚乙烯醇微胶囊。
上述高寿命低成本耐火浇注料的制备方法具体包括:按照上述重量份将各原料加入搅拌机中充分搅拌均匀,再加入水使之具有良好的流动性,所得混合料浇入40mm×40mm×160mm模具后振动均匀,在室温下自然养护24h,脱模后在110℃下干燥24h,即得到待测试试样。
实施例2
一种高寿命低成本耐火浇注料,以重量份计,包括:粒径1-8mm的废旧电瓷55份、粒径5-8mm的刚玉5份,粒径3-5mm的刚玉9.5份,粒径1-3mm的刚玉11份,粒径0.088-1mm的刚玉6.5份、粒径不大于1mm的碳化硅粉4份、粒径不大于3μm的α-氧化铝粉9份、粒径不大于1μm的硅微粉2份、粒径不大于20μm的纯铝酸钙水泥8份、金属铝粉@聚乙烯醇微胶囊2份、聚丙烯防爆纤维0.1份和三聚磷酸钠0.1份;
其中,所述金属铝粉@聚乙烯醇微胶囊是通过下述方法制成:按重量比10:5将金属铝粉和正硅酸乙酯加入无水乙醇中,超声分散均匀后,向其中缓慢滴加3倍铝粉重量的氨水稀溶液(2wt%),在40℃下加热反应2h后,再加入5倍铝粉重量的聚乙烯醇水溶液(15wt%),在60℃下加热反应1h后,抽滤,洗涤,干燥,即得到所述金属铝粉@聚乙烯醇微胶囊。
上述高寿命低成本耐火浇注料的制备方法具体包括:按照上述重量份将各原料加入搅拌机中充分搅拌均匀,再加入水使之具有良好的流动性,所得混合料浇入40mm×40mm×160mm模具后振动均匀,在室温下自然养护24h,脱模后在110℃下干燥24h,即得到待测试试样。
实施例3
一种高寿命低成本耐火浇注料,以重量份计,包括:粒径1-8mm的废旧电瓷78份、粒径5-8mm的刚玉2.5份,粒径3-5mm的刚玉4.5份,粒径1-3mm的刚玉5份,粒径0.088-1mm的刚玉3份、粒径不大于1mm的碳化硅粉16份、粒径不大于3μm的α-氧化铝粉3份、粒径不大于1μm的硅微粉8份、粒径不大于20μm的纯铝酸钙水泥2份、金属铝粉@聚乙烯醇微胶囊6份、聚丙烯防爆纤维0.1份和三聚磷酸钠0.3份;
其中,所述金属铝粉@聚乙烯醇微胶囊是通过下述方法制成:按重量比10:5将金属铝粉和正硅酸乙酯加入无水乙醇中,超声分散均匀后,向其中缓慢滴加3倍铝粉重量的氨水稀溶液(2wt%),在40℃下加热反应2h后,再加入5倍铝粉重量的聚乙烯醇水溶液(15wt%),在60℃下加热反应1h后,抽滤,洗涤,干燥,即得到所述金属铝粉@聚乙烯醇微胶囊。
上述高寿命低成本耐火浇注料的制备方法具体包括:按照上述重量份将各原料加入搅拌机中充分搅拌均匀,再加入水使之具有良好的流动性,所得混合料浇入40mm×40mm×160mm模具后振动均匀,在室温下自然养护24h,脱模后在110℃下干燥24h,即得到待测试试样。
对比例1
一种高寿命低成本耐火浇注料,以重量份计,包括:粒径1-8mm的废旧电瓷66份、粒径5-8mm的刚玉3.5份,粒径3-5mm的刚玉8.5份,粒径1-3mm的刚玉8.5份,粒径0.088-1mm的刚玉4.5份、粒径不大于1mm的碳化硅粉10份、粒径不大于3μm的α-氧化铝粉6份、粒径不大于1μm的硅微粉5份、粒径不大于20μm的纯铝酸钙水泥5份、金属铝粉4份、聚丙烯防爆纤维0.1份和三聚磷酸钠0.2份;
上述高寿命低成本耐火浇注料的制备方法具体包括:按照上述重量份将各原料加入搅拌机中充分搅拌均匀,再加入水使之具有良好的流动性,所得混合料浇入40mm×40mm×160mm模具后振动均匀,在室温下自然养护24h,脱模后在110℃下干燥24h,即得到待测试试样。
对比例2
一种高寿命低成本耐火浇注料,以重量份计,包括:粒径1-8mm的废旧电瓷66份、粒径5-8mm的刚玉3.5份,粒径3-5mm的刚玉8.5份,粒径1-3mm的刚玉8.5份,粒径0.088-1mm的刚玉4.5份、粒径不大于1mm的碳化硅粉10份、粒径不大于3μm的α-氧化铝粉6份、粒径不大于1μm的硅微粉5份、粒径不大于20μm的纯铝酸钙水泥5份、金属铝粉@二氧化硅微胶囊4份、聚丙烯防爆纤维0.1份和三聚磷酸钠0.2份;
其中,所述金属铝粉@二氧化硅微胶囊是通过下述方法制成:按重量比10:5将金属铝粉和正硅酸乙酯加入无水乙醇中,超声分散均匀后,向其中缓慢滴加3倍铝粉重量的氨水稀溶液(2wt%),在40℃下加热反应2h后,抽滤,洗涤,干燥,即得到所述金属铝粉@二氧化硅微胶囊。
上述高寿命低成本耐火浇注料的制备方法具体包括:按照上述重量份将各原料加入搅拌机中充分搅拌均匀,再加入水使之具有良好的流动性,所得混合料浇入40mm×40mm×160mm模具后振动均匀,在室温下自然养护24h,脱模后在110℃下干燥24h,即得到待测试试样。
实验测试:
将实施例和对比例所得待测试试样分别进行测试,结果见表1所示。
表1实施例和对比例所得高寿命低成本耐火浇注料的性能测试效果
抗折强度参照GB/T3001-2007检测,抗压强度参照GB/T5072-2008检测;热震稳定性是在1100℃水冷循环5次条件下检测的抗折强度保持率。
从上表中可以看出,实施例所述耐火浇注料相对对比例具有更高的高温耐压抗折强度,更优异的热震稳定性。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。
Claims (10)
1.一种高寿命低成本耐火浇注料,其特征在于,以重量份计,所述耐火浇注料包括:粒径1-8mm的废旧电瓷55-78份、刚玉15-32份、碳化硅粉4-16份、α-氧化铝粉3-9份、硅微粉2-8份、纯铝酸钙水泥2-8份、金属铝粉@聚乙烯醇微胶囊2-6份、有机纤维0.01-0.5份和减水剂0.1-0.3份。
2.根据权利要求1所述的高寿命低成本耐火浇注料,其特征在于,所述刚玉的颗粒级配组成包括:粒径小于8mm且大于5mm的刚玉占比为10-20wt%,粒径小于5mm且大于3mm的刚玉占比为30-40wt%,粒径小于3mm且大于1mm的刚玉占比为30-40wt%,粒径小于1mm且大于0.088mm的刚玉占比为15-25wt%。
3.根据权利要求1或2所述的高寿命低成本耐火浇注料,其特征在于,所述碳化硅粉中SiC含量不小于97wt%,且碳化硅粉的粒径不大于1mm。
4.根据权利要求1-3任一项所述的高寿命低成本耐火浇注料,其特征在于,所述α-氧化铝粉中Al2O3含量不小于99wt%,且α-氧化铝粉的粒径不大于3μm。
5.根据权利要求1-4任一项所述的高寿命低成本耐火浇注料,其特征在于,所述硅微粉中SiO2含量不小于92wt%,且硅微粉的粒径不大于1μm。
6.根据权利要求1-5任一项所述的高寿命低成本耐火浇注料,其特征在于,所述纯铝酸钙水泥中Al2O3含量不小于70wt%,且纯铝酸钙水泥的粒径不大于20μm。
7.根据权利要求1-6任一项所述的高寿命低成本耐火浇注料,其特征在于,所述金属铝粉@聚乙烯醇微胶囊是通过下述方法制备而成:将正硅酸乙酯进行水解缩聚后对金属铝粉进行包覆,形成金属铝粉@二氧化硅微胶囊;再利用聚乙烯醇所含有的羟基与二氧化硅表面的羟基进行缩合,即得到所述金属铝粉@聚乙烯醇微胶囊。
8.根据权利要求1-7任一项所述的高寿命低成本耐火浇注料,其特征在于,所述有机纤维为聚丙烯防爆纤维、碳纤维或石墨纤维中的至少一种。
9.根据权利要求1-8任一项所述的高寿命低成本耐火浇注料,其特征在于,所述减水剂为三聚磷酸钠、四聚磷酸钠或六偏磷酸钠中的至少一种。
10.一种高寿命低成本耐火浇注料的制备方法,其特征在于,其是将权利要求1-9任一项所述的高寿命低成本耐火浇注料的原料混合并搅拌均匀后得到。
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