CN115417682A - 一种工业窑炉用耐火砖及其制备方法 - Google Patents
一种工业窑炉用耐火砖及其制备方法 Download PDFInfo
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 34
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- 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 claims abstract description 23
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 23
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 20
- 239000010431 corundum Substances 0.000 claims abstract description 20
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- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims description 31
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Abstract
本发明公开了一种工业窑炉用耐火砖及其制备方法,以重量份计,所述耐火砖包括:莫来石细粉35‑55份、电熔刚玉粉15‑35份、碳化硅粉2‑10份、镁砂细粉2‑10份、α‑Al2O3粉1‑5份、二氧化锆粉1‑5份、ρ‑Al2O3粉2‑6份、有机纤维0.01‑0.2份和ABS/空心玻璃微珠复合材料0.1‑0.3份。本发明提出的一种工业窑炉用耐火砖及其制备方法,通过对所述耐火砖的配方组成进行设计,从而有效提升了所得耐火砖的强度和隔热保温性能。
Description
技术领域
本发明属于耐火砖技术领域,尤其涉及一种工业窑炉用耐火砖及其制备方法。
背景技术
工业窑炉炉衬用绝热材料的蓄热和散热损失一般占工业窑炉总能耗的20-45%。传统工业炉窑为达到保温节能的目的,通常在重质耐火砖砌体或重质不定形耐火材料施工体外增加保温层。由于需要两层砌体,导致施工的时间和费用增大,而且窑炉体积变得庞大、笨重。
近年来,莫来石保温隔热耐火砖是以莫来石(3Al2O3·2SiO2)为主晶相的轻质耐火材料,具有低导热、低热容、耐高温、抗热震性良好等优点,适用于冶金、石化、建材、陶瓷、机械等行业的各种工业炉热面衬里和背衬,可与火焰直接接触,是一种优异的隔热耐火材料。随着轻质隔热材料制备工艺的不断提高和改进,基于莫来石制备的保温隔热耐火砖的制备工艺逐渐成为研究的热门领域。
由于现在对工业窑炉的保温隔热要求越来越高,如何增强莫来石耐火砖的隔热保温效果显得尤为重要。
发明内容
基于上述技术问题,本发明提出了一种工业窑炉用耐火砖及其制备方法,通过对所述耐火砖的配方组成进行设计,从而有效提升了所得耐火砖的强度和隔热保温性能。
本发明提出的一种工业窑炉用耐火砖,以重量份计,包括:莫来石细粉35-55份、电熔刚玉粉15-35份、碳化硅粉2-10份、镁砂细粉2-10份、α-Al2O3粉1-5份、二氧化锆粉1-5份、ρ-Al2O3粉2-6份、有机纤维0.01-0.2份和ABS/空心玻璃微珠复合材料0.1-0.3份。
优选地,所述电熔刚玉粉中Al2O3≥90%、Fe2O3≤0.5%。
优选地,所述碳化硅粉中SiC≥95%。
优选地,所述α-Al2O3粉中Al2O3≥99%。
优选地,所述有机纤维为聚丙烯纤维、玻璃纤维或聚碳酸酯纤维中的至少一种。
优选地,所述ABS/空心玻璃微珠复合材料是将空心玻璃微珠和ABS树脂混匀后,熔融挤出得到;
优选地,空心玻璃微珠和ABS树脂的质量比为1:2-6。
本发明还提出一种工业窑炉用耐火砖的制备方法,包括如下步骤:
S1、按重量份将莫来石细粉35-55份、电熔刚玉粉15-35份、碳化硅粉2-10份、镁砂细粉2-10份、α-Al2O3粉1-5份、二氧化锆粉1-5份、ρ-Al2O3粉2-6份、有机纤维0.01-0.2份和ABS/空心玻璃微珠复合材料0.1-0.3份预混后,加水30-40份混匀,得到制砖浆料;
S2、将步骤S1所得制砖浆料加入到压砖机中,压制成型后,去水烘干,得到预制耐火砖;
S3、将步骤S2所得预制耐火砖再置于烧制窑中,高温烧结后,得到所述工业窑炉用耐火砖。
优选地,步骤S1中,所述混匀时间为10-30min。
优选地,步骤S2中,所述压制成型压力为300-400MPa;
优选地,所述去水烘干温度为100-120℃,时间为15-30h。
优选地,步骤S3中,所述高温烧结温度为1500-1600℃,时间为2-6h。
本发明提供的一种工业窑炉用耐火砖及其制备方法,莫来石细粉和电熔刚玉粉作为骨料,其烧结过后结构稳定、强度高、耐磨性好,既保证了耐火砖的基本耐火强度,又能大幅度降低生产成本;碳化硅粉红外辐射性能优越,使耐火砖在高温工作环境下更有效且均匀的对窑炉内的受热材料进行加热,从而降低耐火砖的受热量;α-Al2O3粉和镁砂细粉可以发生反应,因此能进一步提高耐火砖的耐压强度;有机纤维和ABS/空心玻璃微珠复合材料经烧结后,可以熔融形成微孔,既提高了耐火砖的抗热震性能,又降低了耐火砖的导热率;ρ-Al2O3粉作为结合剂,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α-Al2O3,并和莫来石细粉烧结熔融为一体,使耐火砖的耐压抗折强度等物理性能大大提高。
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
一种工业窑炉用耐火砖,以重量份计,包括:莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)45份、电熔刚玉粉25份、碳化硅粉(SiC≥95%)6份、镁砂细粉6份、α-Al2O3粉(Al2O3≥99%)3份、二氧化锆粉3份、ρ-Al2O3粉4份、聚丙烯纤维0.05份和ABS/空心玻璃微珠复合材料0.2份;
其中,所述ABS/空心玻璃微珠复合材料是通过下述方法制成:按重量比1:4将空心玻璃微珠和ABS树脂加入高速搅拌机中搅拌混合15min,所得混合料通过双螺杆挤出机熔融后挤出,双螺杆挤出机加工温度依次为185℃、190℃、190℃、190℃、190℃、200℃,经过上述温度熔融挤出的条状物料被牵引拉出,再经水冷和吹干之后,得到ABS/空心玻璃微珠复合材料。
上述工业窑炉用耐火砖的制备方法具体包括如下步骤:
S1、按重量份将莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)45份、电熔刚玉粉25份、碳化硅粉(SiC≥95%)6份、镁砂细粉6份、α-Al2O3粉(Al2O3≥99%)3份、二氧化锆粉3份、ρ-Al2O3粉4份、聚丙烯纤维0.05份和ABS/空心玻璃微珠复合材料0.2份预混后,加水35份搅拌混合20min,得到制砖浆料;
S2、将步骤S1所得制砖浆料加入到压砖机中,350MPa下压制成型后,再在110℃下去水烘干20h,得到预制耐火砖;
S3、将步骤S2所得预制耐火砖再置于烧制窑中,1550℃下高温烧结4h后,即得到所述工业窑炉用耐火砖。
实施例2
一种工业窑炉用耐火砖,以重量份计,包括:莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)35份、电熔刚玉粉35份、碳化硅粉(SiC≥95%)2份、镁砂细粉10份、α-Al2O3粉(Al2O3≥99%)1份、二氧化锆粉5份、ρ-Al2O3粉2份、玻璃纤维0.2份和ABS/空心玻璃微珠复合材料0.1份;
其中,所述ABS/空心玻璃微珠复合材料是通过下述方法制成:按重量比1:4将空心玻璃微珠和ABS树脂加入高速搅拌机中搅拌混合15min,所得混合料通过双螺杆挤出机熔融后挤出,双螺杆挤出机加工温度依次为185℃、190℃、190℃、190℃、190℃、200℃,经过上述温度熔融挤出的条状物料被牵引拉出,再经水冷和吹干之后,得到ABS/空心玻璃微珠复合材料。
上述工业窑炉用耐火砖的制备方法具体包括如下步骤:
S1、按重量份将莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)35份、电熔刚玉粉35份、碳化硅粉(SiC≥95%)2份、镁砂细粉10份、α-Al2O3粉(Al2O3≥99%)1份、二氧化锆粉5份、ρ-Al2O3粉2份、玻璃纤维0.2份和ABS/空心玻璃微珠复合材料0.1份预混后,加水30份搅拌混合30min,得到制砖浆料;
S2、将步骤S1所得制砖浆料加入到压砖机中,300MPa下压制成型后,再在120℃下去水烘干15h,得到预制耐火砖;
S3、将步骤S2所得预制耐火砖再置于烧制窑中,1600℃下高温烧结2h后,即得到所述工业窑炉用耐火砖。
实施例3
一种工业窑炉用耐火砖,以重量份计,包括:莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)55份、电熔刚玉粉15份、碳化硅粉(SiC≥95%)10份、镁砂细粉2份、α-Al2O3粉(Al2O3≥99%)5份、二氧化锆粉1份、ρ-Al2O3粉6份、聚碳酸酯纤维0.01份和ABS/空心玻璃微珠复合材料0.3份;
其中,所述ABS/空心玻璃微珠复合材料是通过下述方法制成:按重量比1:4将空心玻璃微珠和ABS树脂加入高速搅拌机中搅拌混合15min,所得混合料通过双螺杆挤出机熔融后挤出,双螺杆挤出机加工温度依次为185℃、190℃、190℃、190℃、190℃、200℃,经过上述温度熔融挤出的条状物料被牵引拉出,再经水冷和吹干之后,得到ABS/空心玻璃微珠复合材料。
上述工业窑炉用耐火砖的制备方法具体包括如下步骤:
S1、按重量份将莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)55份、电熔刚玉粉15份、碳化硅粉(SiC≥95%)10份、镁砂细粉2份、α-Al2O3粉(Al2O3≥99%)5份、二氧化锆粉1份、ρ-Al2O3粉6份、聚碳酸酯纤维0.01份和ABS/空心玻璃微珠复合材料0.3份预混后,加水40份搅拌混合10min,得到制砖浆料;
S2、将步骤S1所得制砖浆料加入到压砖机中,400MPa下压制成型后,再在100℃下去水烘干30h,得到预制耐火砖;
S3、将步骤S2所得预制耐火砖再置于烧制窑中,1500℃下高温烧结6h后,即得到所述工业窑炉用耐火砖。
实施例4
一种工业窑炉用耐火砖,以重量份计,包括:莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)40份、电熔刚玉粉30份、碳化硅粉(SiC≥95%)5份、镁砂细粉7份、α-Al2O3粉(Al2O3≥99%)2份、二氧化锆粉4份、ρ-Al2O3粉3份、聚丙烯纤维0.03份和ABS/空心玻璃微珠复合材料0.2份;
其中,所述ABS/空心玻璃微珠复合材料是通过下述方法制成:按重量比1:2将空心玻璃微珠和ABS树脂加入高速搅拌机中搅拌混合15min,所得混合料通过双螺杆挤出机熔融后挤出,双螺杆挤出机加工温度依次为185℃、190℃、190℃、190℃、190℃、200℃,经过上述温度熔融挤出的条状物料被牵引拉出,再经水冷和吹干之后,得到ABS/空心玻璃微珠复合材料。
上述工业窑炉用耐火砖的制备方法具体包括如下步骤:
S1、按重量份将莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)40份、电熔刚玉粉30份、碳化硅粉(SiC≥95%)5份、镁砂细粉7份、α-Al2O3粉(Al2O3≥99%)2份、二氧化锆粉4份、ρ-Al2O3粉3份、聚丙烯纤维0.03份和ABS/空心玻璃微珠复合材料0.2份预混后,加水36份搅拌混合10-30min,得到制砖浆料;
S2、将步骤S1所得制砖浆料加入到压砖机中,360MPa下压制成型后,再在110℃下去水烘干25h,得到预制耐火砖;
S3、将步骤S2所得预制耐火砖再置于烧制窑中,1550℃下高温烧结4h后,即得到所述工业窑炉用耐火砖。
对比例1
一种工业窑炉用耐火砖,以重量份计,包括:莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)45份、电熔刚玉粉25份、碳化硅粉(SiC≥95%)6份、镁砂细粉6份、α-Al2O3粉(Al2O3≥99%)3份、二氧化锆粉3份、ρ-Al2O3粉4份。
上述工业窑炉用耐火砖的制备方法具体包括如下步骤:
S1、按重量份将莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)45份、电熔刚玉粉25份、碳化硅粉(SiC≥95%)6份、镁砂细粉6份、α-Al2O3粉(Al2O3≥99%)3份、二氧化锆粉3份、ρ-Al2O3粉4份预混后,加水35份搅拌混合20min,得到制砖浆料;
S2、将步骤S1所得制砖浆料加入到压砖机中,350MPa下压制成型后,再在110℃下去水烘干20h,得到预制耐火砖;
S3、将步骤S2所得预制耐火砖再置于烧制窑中,1550℃下高温烧结4h后,即得到所述工业窑炉用耐火砖。
对比例2
一种工业窑炉用耐火砖,以重量份计,包括:莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)45份、电熔刚玉粉25份、碳化硅粉(SiC≥95%)6份、镁砂细粉6份、α-Al2O3粉(Al2O3≥99%)3份、二氧化锆粉3份、ρ-Al2O3粉4份、聚丙烯纤维0.05份和空心玻璃微珠0.2份。
上述工业窑炉用耐火砖的制备方法具体包括如下步骤:
S1、按重量份将莫来石细粉(Al2O3≥90%、Fe2O3≤0.5%)45份、电熔刚玉粉25份、碳化硅粉(SiC≥95%)6份、镁砂细粉6份、α-Al2O3粉(Al2O3≥99%)3份、二氧化锆粉3份、ρ-Al2O3粉4份、聚丙烯纤维0.05份和空心玻璃微珠0.2份预混后,加水35份搅拌混合20min,得到制砖浆料;
S2、将步骤S1所得制砖浆料加入到压砖机中,350MPa下压制成型后,再在110℃下去水烘干20h,得到预制耐火砖;
S3、将步骤S2所得预制耐火砖再置于烧制窑中,1550℃下高温烧结4h后,即得到所述工业窑炉用耐火砖。
实验测试:
将实施例和对比例所得耐火砖分别进行测试,结果见表1所示。
耐压强度(MPa、200℃×24h)、抗折强度(MPa、200℃×24h)、导热系数(W/m.K)、热震稳定性(次、1100℃-水冷)、线变化率(%、1500℃×3h);
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
实施例1 | 实施例2 | 实施例3 | 实施例4 | 对比例1 | 对比例2 | |
耐压强度 | 90 | 83 | 92 | 88 | 45 | 61 |
抗折强度 | 39 | 35 | 41 | 38 | 16 | 26 |
导热系数 | 1.2 | 1.4 | 1.7 | 1.9 | 6.5 | 4.6 |
热震稳定 | 13 | 10 | 11 | 10 | 4 | 6 |
线变化率 | 0.13 | 0.17 | 0.15 | 0.16 | 0.47 | 0.32 |
从上表中可以看出,实施例所述耐火砖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和更低的导热系数。
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)
1.一种工业窑炉用耐火砖,其特征在于,以重量份计,包括:莫来石细粉35-55份、电熔刚玉粉15-35份、碳化硅粉2-10份、镁砂细粉2-10份、α-Al2O3粉1-5份、二氧化锆粉1-5份、ρ-Al2O3粉2-6份、有机纤维0.01-0.2份和ABS/空心玻璃微珠复合材料0.1-0.3份。
2.根据权利要求1所述的工业窑炉用耐火砖,其特征在于,所述电熔刚玉粉中Al2O3≥90%、Fe2O3≤0.5%。
3.根据权利要求1或2所述的工业窑炉用耐火砖,其特征在于,所述碳化硅粉中SiC≥95%。
4.根据权利要求1-3任一项所述的工业窑炉用耐火砖,其特征在于,所述α-Al2O3粉中Al2O3≥99%。
5.根据权利要求1-4任一项所述的工业窑炉用耐火砖,其特征在于,所述有机纤维为聚丙烯纤维、玻璃纤维或聚碳酸酯纤维中的至少一种。
6.根据权利要求1-5任一项所述的工业窑炉用耐火砖,其特征在于,所述ABS/空心玻璃微珠复合材料是将空心玻璃微珠和ABS树脂混匀后,熔融挤出得到;
优选地,空心玻璃微珠和ABS树脂的质量比为1:2-6。
7.一种工业窑炉用耐火砖的制备方法,其特征在于,包括如下步骤:
S1、按重量份将莫来石细粉35-55份、电熔刚玉粉15-35份、碳化硅粉2-10份、镁砂细粉2-10份、α-Al2O3粉1-5份、二氧化锆粉1-5份、ρ-Al2O3粉2-6份、有机纤维0.01-0.2份和ABS/空心玻璃微珠复合材料0.1-0.3份预混后,加水30-40份混匀,得到制砖浆料;
S2、将步骤S1所得制砖浆料加入到压砖机中,压制成型后,去水烘干,得到预制耐火砖;
S3、将步骤S2所得预制耐火砖再置于烧制窑中,高温烧结后,得到所述工业窑炉用耐火砖。
8.根据权利要求7所述的工业窑炉用耐火砖的制备方法,其特征在于,步骤S1中,所述混匀时间为10-30min。
9.根据权利要求7或8所述的工业窑炉用耐火砖的制备方法,其特征在于,步骤S2中,所述压制成型压力为300-400MPa;
优选地,所述去水烘干温度为100-120℃,时间为15-30h。
10.根据权利要求7-9任一项所述的水工业窑炉用耐火砖的制备方法,其特征在于,步骤S3中,所述高温烧结温度为1500-1600℃,时间为2-6h。
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