CN115650710A - High-strength anti-skinning refractory castable and preparation method thereof - Google Patents
High-strength anti-skinning refractory castable and preparation method thereof Download PDFInfo
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Abstract
The invention discloses a high-strength anti-skinning refractory castable and a preparation method thereof, relates to the technical field of refractory castable, and solves the problems that SiC is added into the refractory castable in the prior art, and SiO generated after SiC is oxidized 2 The gas can form partial air holes in the casting material, and the strength and the volume density of the casting material are influenced. The high-strength anti-skinning refractory castable disclosed by the invention comprises the following components in percentage by mass: 50-80% of waste high-alumina electric porcelain, 3-8% of high-alumina bauxite, 10-20% of silicon carbide, 2-8% of alpha alumina micro powder, 2-5% of silicon micro powder, 2-10% of aluminate cement, 0.05-0.1% of composite explosion-proof material, 0.2-0.5% of additive and 3-10% of biological capsule, wherein the biological capsule comprises a capsule membrane, bacillus and calcium lactate, and the bacillus and calcium lactate are positioned in the capsule membrane and are covered by the capsule membrane. Compared with the prior art, the high-strength anti-skinning refractory castable disclosed by the invention can improve the strength and the volume density of the refractory castable after being used in biological capsules.
Description
Technical Field
The invention relates to the technical field of refractory castable, in particular to a high-strength anti-skinning refractory castable and a preparation method thereof.
Background
The refractory castable is a main variety of unshaped refractory materials, is mainly used for producing cement materials, and is also applied to metallurgical industrial kilns, petroleum, chemical engineering, building materials, electric power, mechanical industrial kilns, thermal equipment and the like. The castable generally comprises refractory aggregate, powder, a bonding agent, an additive and a solvent, wherein the refractory aggregate is prepared from magnesia, marble, perlite, spinel and the like. The refractory castable is cast and molded by a casting, vibrating or tamping method, can be hardened without heating, and is convenient to construct, high in utilization rate and widely applied.
When the refractory castable is used, the R is 2 O、SO 3 And volatile components such as chloride and the like are recycled and enriched, so that the skinning of the refractory castable is easy to cause, the skinning of the refractory castable falls off to cause the problem of blockage, and the service life of working linings at the kiln opening, the kiln door cover and other parts of the cement kiln is seriously influenced. At present, in order to solve the problems, a generally adopted mode is to add a proper amount of silicon carbide into a cement-bonded aluminum-silicon refractory castable, and SiO is generated after SiC is oxidized 2 Gas, siO 2 With fine Al in the material 2 O 3 The reaction forms a glaze layer on the surface of the refractory material, and reduces the adhesion and erosion of cement clinker, so that the refractory material has the anti-skinning property, and the thermal shock resistance of the refractory material can be improved, and the castable is the high-strength anti-skinning silicon carbide castable. However, siO generated after oxidation of SiC 2 The gas can form partial air holes in the casting material, and the strength and the volume density of the casting material are influenced.
The new material is the key development field of the 21 st century, and the biological material is the key point of development as the interdisciplinary subject of life science and material science. The biological material is applied to the refractory castable, so that the strength and the volume density of the refractory castable are improved, the innovation of the refractory material can be realized, and the biological material refractory castable has important significance.
Disclosure of Invention
The invention aims to provide a high-strength anti-skinning refractory castable and a preparation method thereof, and solves the problems that SiC is added in the refractory castable in the prior art and is oxidized to generate SiCSiO of (2) 2 The gas can form partial air holes in the casting material, and the strength and the volume density of the casting material are influenced. The various technical effects that can be produced by the preferred technical solution of the present invention are described in detail below.
In order to achieve the purpose, the invention provides the following technical scheme:
the high-strength anti-skinning refractory castable comprises the following components in percentage by mass: 50-80% of waste high-alumina electric porcelain, 3-8% of high-alumina bauxite, 10-20% of silicon carbide, 2-8% of alpha alumina micro powder, 2-5% of silicon micro powder, 2-10% of aluminate cement, 0.05-0.1% of composite explosion-proof material, 0.2-0.5% of additive and 3-10% of biological capsule, wherein the biological capsule comprises a capsule membrane, bacillus and calcium lactate, and the bacillus and the calcium lactate are positioned in the capsule membrane and are wrapped and covered by the capsule membrane; the sum of the mass percentages of the waste high-alumina electric porcelain, the high-alumina bauxite, the silicon carbide, the alpha alumina micro powder, the silicon micro powder, the aluminate cement, the composite explosion-proof material, the additive and the biological capsule is 100%.
According to a preferred embodiment, in the biological capsule, the mass percent of the capsule membrane is 50-65%, the mass percent of the bacillus is 15-20%, the mass percent of the calcium lactate is 15-35%, and the sum of the mass percent of the capsule membrane, the mass percent of the bacillus and the mass percent of the calcium lactate is 100%.
According to a preferred embodiment, the capsule membrane is an active silicate-urea-formaldehyde resin compound, and the mass ratio of the active silicate to the urea-formaldehyde resin in the capsule membrane is 10-15: 1-3.
According to a preferred embodiment, the bacillus is one or more of bacillus thuringiensis, bacillus subtilis, bacillus licheniformis, paenibacillus polymyxa, bacillus coagulans, bacillus megaterium, bacillus laterosporus and bacillus mucilaginosus.
According to a preferred embodiment, the bacillus is bacillus subtilis.
According to a preferred embodiment, the grain size of the waste high-alumina electric porcelain is not more than 5mm, and the grain size of the silicon carbide is not more than 1mm.
According to a preferred embodiment, the composite explosion-proof material is one or two of explosion-proof fiber and metal aluminum powder.
According to a preferred embodiment, the additive is one or more of sodium tripolyphosphate, sodium hexametaphosphate, sodium citrate and polycarboxylic acid water reducer.
The preparation method of the high-strength anti-skinning refractory castable provided by any technical scheme of the invention comprises the following steps:
preparing a biological capsule;
premixing waste high-alumina electric porcelain, high-alumina bauxite, silicon carbide, alpha alumina micro powder, silicon micro powder, aluminate cement, a composite explosion-proof material and an additive according to a ratio, adding a biological capsule and water with the weight of 3-8% of the weight of the raw materials after uniformly stirring, and performing wet mixing to obtain refractory casting slurry;
filling the refractory pouring slurry into a mold and placing the refractory pouring slurry at room temperature for 8 to 24 hours, and spraying a normal butanol solution on the surface of the refractory pouring slurry every 1 to 2 hours in the placing process;
and demolding after the refractory pouring slurry is completely hardened.
According to a preferred embodiment, the preparation of the biocapsules comprises the following steps:
dissolving active silicate, urea and ammonium chloride in water to obtain a water phase;
dripping an oil phase mixed with bacillus and calcium lactate into the water phase, and emulsifying to form O/W emulsion;
adding formaldehyde, and reacting for 4-5 h to obtain the biological capsule.
The high-strength anti-skinning refractory castable and the preparation method thereof provided by the invention have at least the following beneficial technical effects:
the high-strength anti-skinning refractory castable disclosed by the invention comprises the following components in percentage by mass: 50-80% of waste high-alumina electric porcelain, 3-8% of high-alumina bauxite, 10-20% of silicon carbide, 2-8% of alpha alumina micropowder and 2% of silicon micropowder5 percent, 2 to 10 percent of aluminate cement, 0.05 to 0.1 percent of composite explosion-proof material, 0.2 to 0.5 percent of additive and 3 to 10 percent of biological capsule, wherein the biological capsule comprises a capsule film, bacillus and calcium lactate, the bacillus and the calcium lactate are positioned in the capsule film and are wrapped and covered by the capsule film, and because the refractory castable of the invention has silicon carbide, siO is generated after the silicon carbide is oxidized 2 Gas, on the one hand, siO 2 Al in gases and materials 2 O 3 The reaction forms a glaze layer on the surface of the refractory material, and the adhesion and erosion of cement clinker are reduced, so that the refractory material has the anti-skinning property and the thermal shock resistance of the refractory material can be improved; on the other hand, siO produced after oxidation of silicon carbide 2 The gas enables the refractory castable to form a large number of pores, the bacillus can be dormant in a stable and closed environment all year round, the bacillus and calcium lactate are implanted into a capsule film, the refractory castable is prepared by placing refractory castable slurry at room temperature for 8-24 h, in the placing process, n-butyl alcohol solution is sprayed on the surface of the refractory castable slurry every 1-2 h, the capsule film can be opened by spraying the n-butyl alcohol solution, the bacillus starts to germinate and proliferate and uses the calcium lactate, the bacillus combines calcium and carbonate ions through metabolism to form calcium carbonate, the calcium carbonate is compatible with the refractory castable, the pores in the refractory castable are filled to form a compact structure, and therefore the strength and the volume density of the refractory castable can be enhanced.
The invention relates to a high-strength anti-skinning refractory castable and a preparation method thereof, which solves the problems that SiC is added in the refractory castable in the prior art, and SiO generated after SiC is oxidized 2 The gas can form partial air holes in the casting material, and the strength and the volume density of the casting material are influenced.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be described in detail below. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the examples given herein without any inventive step, are within the scope of the present invention.
The high-strength anti-skinning refractory castable disclosed by the invention comprises the following components in percentage by mass: 50-80% of waste high-alumina electric porcelain, 3-8% of high-alumina bauxite, 10-20% of silicon carbide, 2-8% of alpha alumina micro powder, 2-5% of silicon micro powder, 2-10% of aluminate cement, 0.05-0.1% of composite explosion-proof material, 0.2-0.5% of additive and 3-10% of biological capsule, wherein the biological capsule comprises a capsule membrane, bacillus and calcium lactate, and the bacillus and the calcium lactate are positioned in the capsule membrane and are wrapped by the capsule membrane; the sum of the mass percentages of the waste high-alumina electric porcelain, the high-alumina bauxite, the silicon carbide, the alpha alumina micro powder, the silicon micro powder, the aluminate cement, the composite explosion-proof material, the additive and the biological capsule is 100 percent. The refractory castable of the invention has silicon carbide which is oxidized to generate SiO 2 Gas, on the one hand, siO 2 Al in gases and materials 2 O 3 The reaction forms a glaze layer on the surface of the refractory material, and reduces the adhesion and erosion of cement clinker, so that the refractory material has the anti-skinning property and the thermal shock resistance of the refractory material can be improved; on the other hand, siO produced after oxidation of silicon carbide 2 The gas enables the refractory castable to form a large number of pores, the bacillus can be dormant in a stable and closed environment all the year round, the bacillus and the calcium lactate are implanted into a capsule membrane, in the process of preparing the refractory castable, the refractory castable is placed at room temperature for 8-24 h, in the placing process, n-butyl alcohol solution is sprayed on the surface of the refractory castable every 1-2 h, the capsule membrane can be opened by spraying the n-butyl alcohol solution, the bacillus starts to germinate and proliferate and uses the calcium lactate, the bacillus combines calcium and carbonate ions through metabolism to form calcium carbonate, the calcium carbonate is compatible with the refractory castable, the pores in the refractory castable are filled to form a compact structure, and therefore the strength and the volume density of the refractory castable can be enhanced. The invention relates to a high-strength anti-skinning refractory castable and a preparation method thereof, which solves the problems that SiC is added in the refractory castable in the prior art, and SiO generated after SiC is oxidized 2 The gas can form partial air holes in the casting material, and the strength and the volume density of the casting material are influenced. The invention is provided withThe proportion of each component is screened, so that the refractory castable has excellent strength and volume density.
In addition, the refractory castable disclosed by the invention utilizes the waste high-alumina electric porcelain as a main aggregate, so that bauxite resources can be effectively saved, and the cost performance of the refractory castable can be improved; the waste high-aluminum electric porcelain also has the characteristics of low water absorption, high purity, less impurities and high conversion utilization rate, and can be used as the main aggregate of the refractory castable, thereby greatly reducing the production cost, improving the fluidity of the refractory castable, reducing the water addition amount of the refractory castable, and improving the spalling resistance, mechanical property and thermal shock stability of the refractory castable.
According to a preferred embodiment, in the biological capsule, the mass percent of the capsule membrane is 50-65%, the mass percent of the bacillus is 15-20%, the mass percent of the calcium lactate is 15-35%, and the sum of the mass percent of the capsule membrane, the mass percent of the bacillus and the mass percent of the calcium lactate is 100%. The formula of the biological capsule in the technical scheme is optimized, so that the biological capsule can fully exert the function of enhancing the strength and the volume density of the refractory castable.
According to a preferred embodiment, the capsule membrane is an active silicate-urea-formaldehyde resin compound, and the mass ratio of the active silicate to the urea-formaldehyde resin in the capsule membrane is 10-15: 1-3. More preferably, the silicate is sodium silicate. The capsule membrane of the preferred technical scheme of the invention is an active silicate-urea-formaldehyde resin compound, and in the mixing and stirring process, the active silicate-urea-formaldehyde resin compound can effectively protect the bacillus in the capsule membrane and prevent the bacillus from dying to influence the performance of the biological capsule. On the other hand, the capsule film of the preferred technical scheme of the invention is a compound of active silicate and urea-formaldehyde resin, the mass ratio of the active silicate to the urea-formaldehyde resin is 10-15: 1-3, and after the capsule film is opened, the strength and the volume density of the refractory castable can be further enhanced through the silicate.
According to a preferred embodiment, the bacillus is one or more of bacillus thuringiensis, bacillus subtilis, bacillus licheniformis, paenibacillus polymyxa, bacillus coagulans, bacillus megaterium, bacillus laterosporus and bacillus mucilaginosus. Preferably, the bacillus is bacillus subtilis. The bacillus of the preferred embodiment of the present invention may be a commercially available product. The bacillus has the advantages of high propagation speed, strong vitality, temperature, aerobic property, extrusion resistance, high temperature resistance and the like, and particularly the bacillus subtilis has better performance. The active microorganism in the preferred technical scheme of the invention selects bacillus, so that the active microorganism in the biological capsule has higher survival rate, and the function can be fully exerted.
According to a preferred embodiment, the grain size of the waste high-alumina electric porcelain is not more than 5mm, and the grain size of the silicon carbide is not more than 1mm. Preferably, the waste high-aluminum electric porcelain with the grain diameter of 3-5 mm is used in an amount of 20-30%, the waste high-aluminum electric porcelain with the grain diameter of 1-3 mm is used in an amount of 15-30%, and the waste high-aluminum electric porcelain with the grain diameter of 0-1 mm is used in an amount of 10-20%. Without being limited thereto, the used amount of the waste high-alumina electroceramic of different grain sizes may be the rest. Preferably, the amount of silicon carbide having a particle size of 0.088 to 1mm is 5 to 15% and the amount of silicon carbide having a particle size of 0 to 0.088mm is 2 to 10%. Without being limited thereto, the silicon carbide having different particle diameters may be used in the remaining proportion.
Preferably, the waste high-alumina electric porcelain is waste high-alumina high-pressure electric porcelain Al in the power industry 2 O 3 Is between 40 and 50 percent, fe 2 O 3 SiO content of less than 2.0% 2 The content is between 45 and 55 percent, R 2 O content is 2.0-2.5%, the rest trace elements are below 1.0%, water absorption is 0.7-1.0%, and volume density is 2.4-2.5 g/cm 3 In the meantime. Preferably, the SiC content of the silicon carbide is higher than 90%.
According to a preferred embodiment, the composite explosion-proof material is one or two of explosion-proof fiber and metal aluminum powder. The composite explosion-proof material is not limited to the above, and other materials can be selected.
According to a preferred embodiment, the admixture is one or more of sodium tripolyphosphate, sodium hexametaphosphate, sodium citrate and a polycarboxylic acid water reducing agent. The additive is not limited to this, and other materials can be used.
The preparation method of the high-strength anti-skinning refractory castable material in any technical scheme of the invention comprises the following steps:
s1: preparing the biological capsule. Preferably, the preparation of the bio-capsule comprises the steps of:
s11: dissolving active silicate, urea and ammonium chloride in water to obtain a water phase;
s12: dripping an oil phase mixed with bacillus and calcium lactate into the water phase, and emulsifying to form O/W emulsion;
s13: adding formaldehyde, reacting for 4-5 h, and obtaining the biological capsule.
S2: the method comprises the steps of premixing waste high-alumina electric porcelain, high-alumina bauxite, silicon carbide, alpha alumina micro powder, silicon micro powder, aluminate cement, a composite explosion-proof material and an additive according to a ratio, uniformly stirring, then adding biological capsules and water with the weight of 3-8% of the weight of the raw materials for wet mixing, and uniformly stirring to obtain the refractory casting slurry.
S3: filling the refractory pouring slurry into a mold and placing the refractory pouring slurry at room temperature for 8 to 24 hours, and spraying a normal butanol solution on the surface of the refractory pouring slurry every 1 to 2 hours in the placing process;
s4: and demolding after the refractory casting slurry is completely hardened.
In the process of preparing the refractory castable, the refractory castable slurry is filled into a mold and placed at room temperature for 8-24 hours, and in the placing process, the strength and the volume density of the refractory castable can be enhanced through the action of the biological capsule.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of the changes or substitutions within the technical scope of the present invention, and all the changes or substitutions should be covered within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the appended claims.
Claims (10)
1. The high-strength anti-skinning refractory castable is characterized by comprising the following components in percentage by mass:
50-80% of waste high-alumina electric porcelain, 3-8% of high-alumina bauxite, 10-20% of silicon carbide, 2-8% of alpha alumina micro powder, 2-5% of silicon micro powder, 2-10% of aluminate cement, 0.05-0.1% of composite explosion-proof material, 0.2-0.5% of additive and 3-10% of biological capsule, wherein the biological capsule comprises a capsule membrane, bacillus and calcium lactate, and the bacillus and the calcium lactate are positioned in the capsule membrane and are wrapped and covered by the capsule membrane;
the sum of the mass percentages of the waste high-alumina electric porcelain, the high-alumina bauxite, the silicon carbide, the alpha alumina micro powder, the silicon micro powder, the aluminate cement, the composite explosion-proof material, the additive and the biological capsule is 100%.
2. The high-strength anti-skinning refractory castable material according to claim 1, wherein the biocapsule comprises 50-65% by mass of the capsule film, 15-20% by mass of the bacillus, 15-35% by mass of the calcium lactate, and the sum of the mass percentages of the capsule film, the bacillus and the calcium lactate is 100%.
3. The high-strength anti-skinning refractory castable material according to claim 2, wherein the capsule film is an active silicate-urea-formaldehyde resin composite, and the mass ratio of the active silicate to the urea-formaldehyde resin in the capsule film is 10-15: 1-3.
4. The high-strength anti-skinning refractory castable material according to claim 2, wherein the bacillus is one or more of bacillus thuringiensis, bacillus subtilis, bacillus licheniformis, paenibacillus polymyxa, bacillus coagulans, bacillus megaterium, bacillus laterosporus and bacillus mucilaginosus.
5. The high-strength anti-skinning refractory castable material according to claim 4, wherein the bacillus is bacillus subtilis.
6. The high-strength anti-skinning refractory castable material according to claim 1, wherein the grain size of the waste high-alumina electroceramic is not more than 5mm, and the grain size of the silicon carbide is not more than 1mm.
7. The high-strength anti-skinning refractory castable material according to claim 1, wherein the composite anti-explosion material is one or both of an anti-explosion fiber and a metal aluminum powder.
8. The high-strength anti-skinning refractory castable material according to claim 1, wherein the additive is one or more of sodium tripolyphosphate, sodium hexametaphosphate, sodium citrate and polycarboxylic acid water reducer.
9. A method for preparing a high-strength anti-skinning castable refractory according to any one of claims 1 to 8, characterized by comprising the steps of:
preparing a biological capsule;
premixing waste high-alumina electric porcelain, high-alumina bauxite, silicon carbide, alpha alumina micro powder, silicon micro powder, aluminate cement, a composite explosion-proof material and an additive according to a ratio, adding a biological capsule and water with the weight of 3-8% of the weight of the raw materials after uniformly stirring, and performing wet mixing to obtain refractory casting slurry;
filling the refractory pouring slurry into a mold and placing the refractory pouring slurry at room temperature for 8 to 24 hours, and spraying a normal butanol solution on the surface of the refractory pouring slurry every 1 to 2 hours in the placing process;
and demolding after the refractory pouring slurry is completely hardened.
10. The method for preparing the high-strength anti-skinning refractory castable material according to claim 9, wherein the preparation of the biocapsule comprises the steps of:
dissolving active silicate, urea and ammonium chloride in water to obtain a water phase;
dripping an oil phase mixed with bacillus and calcium lactate into the water phase, and emulsifying to form O/W emulsion;
adding formaldehyde, and reacting for 4-5 h to obtain the biological capsule.
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| JP2010275120A (en) * | 2009-05-26 | 2010-12-09 | Ngk Insulators Ltd | SiC-CONTAINING CASTABLE REFRACTORY, METHOD OF PRODUCING PRECAST BLOCK USING SiC-CONTAINING CASTABLE REFRACTORY AND METHOD OF CONSTRUCTING SiC-CONTAINING CASTABLE REFRACTORY |
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