CN116161974B - 一种等离子熔融炉用改性致密耐火砖及制备方法 - Google Patents
一种等离子熔融炉用改性致密耐火砖及制备方法 Download PDFInfo
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- CN116161974B CN116161974B CN202310149314.7A CN202310149314A CN116161974B CN 116161974 B CN116161974 B CN 116161974B CN 202310149314 A CN202310149314 A CN 202310149314A CN 116161974 B CN116161974 B CN 116161974B
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- refractory brick
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- 239000011449 brick Substances 0.000 title claims abstract description 132
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- 238000002844 melting Methods 0.000 title claims abstract description 25
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- 238000000034 method Methods 0.000 claims abstract description 21
- 229940090961 chromium dioxide Drugs 0.000 claims abstract description 19
- IAQWMWUKBQPOIY-UHFFFAOYSA-N chromium(4+);oxygen(2-) Chemical compound [O-2].[O-2].[Cr+4] IAQWMWUKBQPOIY-UHFFFAOYSA-N 0.000 claims abstract description 19
- AYTAKQFHWFYBMA-UHFFFAOYSA-N chromium(IV) oxide Inorganic materials O=[Cr]=O AYTAKQFHWFYBMA-UHFFFAOYSA-N 0.000 claims abstract description 19
- 238000010304 firing Methods 0.000 claims abstract description 15
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- 239000010427 ball clay Substances 0.000 claims abstract description 14
- 229910021538 borax Inorganic materials 0.000 claims abstract description 14
- 229940105847 calamine Drugs 0.000 claims abstract description 14
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- 239000011787 zinc oxide Substances 0.000 claims abstract description 14
- 235000014692 zinc oxide Nutrition 0.000 claims abstract description 14
- CPYIZQLXMGRKSW-UHFFFAOYSA-N zinc;iron(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[O-2].[Fe+3].[Fe+3].[Zn+2] CPYIZQLXMGRKSW-UHFFFAOYSA-N 0.000 claims abstract description 14
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- 238000012545 processing Methods 0.000 claims abstract description 8
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 39
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims description 34
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 24
- 239000000178 monomer Substances 0.000 claims description 19
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- 229910001868 water Inorganic materials 0.000 claims description 19
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- DHAHRLDIUIPTCJ-UHFFFAOYSA-K aluminium metaphosphate Chemical compound [Al+3].[O-]P(=O)=O.[O-]P(=O)=O.[O-]P(=O)=O DHAHRLDIUIPTCJ-UHFFFAOYSA-K 0.000 claims description 12
- 239000000378 calcium silicate Substances 0.000 claims description 12
- 229910052918 calcium silicate Inorganic materials 0.000 claims description 12
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 claims description 12
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims description 11
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- CNCOEDDPFOAUMB-UHFFFAOYSA-N N-Methylolacrylamide Chemical compound OCNC(=O)C=C CNCOEDDPFOAUMB-UHFFFAOYSA-N 0.000 claims description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 6
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- 229910052845 zircon Inorganic materials 0.000 claims description 5
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 4
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- GWWPLLOVYSCJIO-UHFFFAOYSA-N dialuminum;calcium;disilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-] GWWPLLOVYSCJIO-UHFFFAOYSA-N 0.000 description 4
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- 229910052791 calcium Inorganic materials 0.000 description 2
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- 238000003763 carbonization Methods 0.000 description 2
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 description 2
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- 125000004029 hydroxymethyl group Chemical group [H]OC([H])([H])* 0.000 description 2
- 230000005764 inhibitory process Effects 0.000 description 2
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- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 description 1
- 125000005587 carbonate group Chemical group 0.000 description 1
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- WMJIEXXHUGKGQQ-UHFFFAOYSA-N n-hydroxy-n-methylprop-2-enamide Chemical compound CN(O)C(=O)C=C WMJIEXXHUGKGQQ-UHFFFAOYSA-N 0.000 description 1
- 125000002467 phosphate group Chemical group [H]OP(=O)(O[H])O[*] 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
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- C08F265/00—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00
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Abstract
本发明公开了一种等离子熔融炉用改性致密耐火砖及制备方法,改性致密耐火砖原料按重量份数计包括:颗粒料30~35份,硼砂12~15份,熟矾土12~16份,刚玉粉10~15份,球粘土10~15份,炉甘石9~14份,改性剂3~5份,二氧化铬8~10份,氧化铁1.0~1.5份;包括如下步骤:S1、细粉加工,S2、泥浆制备,S3、混碾加工,S4、困料成型,S5、烧成,通过上述原料及制备方法得到的改性致密耐火砖的密度较大,显气孔率较小,同时具有良好的隔热效果以及强度性能。
Description
技术领域
本发明涉及砖块制备技术领域,具体涉及一种等离子熔融炉用改性致密耐火砖及制备方法。
背景技术
等离子熔融技术主要分为炬技术和弧技术,前者主要依靠等离子火炬产生的高温气体对物料进行加热,后者通过阴阳极间产生的高温电弧对物料进行加热。由于等离子熔融技术具有能量效率高、生产过程清洁、不使用焦炭等优点,目前正受到越来越多的重视。等离子熔融炉是通过等离子电弧产生的高温(中心区可达7000℃)迅速将飞灰和底渣变成熔融状态的反应器,是将飞灰和底渣无害化处理和资源化利用的一种方式和装置。危险废物等离子熔融是利用等离子火炬将危险废物加热到1500℃以上,使危险废物在还原性气氛条件下熔融,有机成分以烟气形式经净化排出,无机成分以无害玻璃态排出,实现危险废物的彻底无害化。但是,现有等离子熔融炉存在熔池内壁容易凝结、受到腐蚀温度传导较快等缺陷。
对于等离子熔融炉来说,用于离子熔融炉的内部砖料需要使用具有较高的致密度以及较好的耐腐蚀形同时应当具有较好的隔热效果,常用的耐火砖使用了铝酸钙水泥、碳化硅等物质,导致材料在高温条件下形成钙长石、钙黄长石,导致热态强度大大降低,其中后者强度低,不适宜在等离子熔融炉中应用;此外用于垃圾处理的等离子熔融炉由于原料成分复杂多变,其烟气组成也随着不断改变,这对烟气管路的耐火衬里的耐腐蚀性提出了更高的要求。
发明内容
因此,本发明提供一种等离子熔融炉用改性致密耐火砖,所述改性致密耐火砖的原料按重量份数计包括:颗粒料30~35份,硼砂12~15份,熟矾土12~16份,刚玉粉10~15份,球粘土10~15份,炉甘石9~14份,改性剂3~5份,二氧化铬8~10份,氧化铁1.0~1.5份;
所述颗粒料按重量分数计,由粒度为2~3mm的锆英砂40~46%,2~5mm的二氧化硅20~22%,1~3mm的方解石15~18%,余量为水混料得到;
所述改性剂由丙烯酸酯聚合乳液、偏磷酸铝、硅酸钙、硅溶胶树脂以重量比为20~35:3:2~3:6~10混合配制得到。
说明:通过上述原料制备得到的改性致密耐火砖的密度较大,显气孔率较小,同时具有良好的隔热效果以及强度性能;通过颗粒料的添加,可以利用砂石粒度来增加砖体的强度,通过硼砂、熟矾土、刚玉粉、球粘土、炉甘石粉末的添加可以增加砖体的粘结力以及密度,同时可以具有较优的耐腐蚀性,通过添加改性剂,可以进一步增强砖体的表面性能以及耐腐蚀,从而避免砖体中的含钙物质在高温条件下形成钙长石等形态,导致热态强度大大降低,同时可以提高砖体的整体强度与耐高温性。
进一步地,所述改性剂混合配制为:取偏磷酸铝、硅酸钙粉末过300~400目筛,然后加入到硅溶胶树脂中在200r/min下搅拌分散1h,得到预混合液,再将丙烯酸酯聚合乳液加入到预混合液中,在40KHz下超声混合处理15~20min,得到改性剂。
说明:通过上述方法得到的改性剂,再高温环境下具有较为稳定的性质,同时与砖料混合后能增加各原料之间的结合强度,使得得到的砖块兼具强度与耐高温性,使制备得到的砖块的抗渗碳性改善,可有效延长使用寿命;通过丙烯酸酯聚合乳液能够粘接原料粘土,且具有一定的缓蚀作用;通过偏磷酸铝提供化学稳定性以及机械性能,通过硅酸钙能有效提高强度高,且具有保温隔热、抗腐蚀等的性质,通过硅溶胶树脂可以增强改性剂与各原料之间的紧密结合,可以减少原子迁移,能保障高温下的电性能。
进一步地,所述丙烯酸酯聚合乳液的制备方法为:
S1-1、取质量比为1:1:0.1~0.2:10的羟甲基丙烯酰胺单体、丙烯酸单体、缓冲剂以及去离子水加入到反应器中混合,在65~75℃下,以羟甲基丙烯酰胺单体:引发剂的质量比为1:0.15的比例,加入引发剂,混合反应80~100min,得到种子乳液聚合物;
S1-2、在氮气氛围下,以丙烯酸单体、引发剂、缓冲剂的质量比为1:0.1~0.2:0.1混合得到混合物,以混合物:种子乳液聚合物为1:2~3的重量比,将混合物滴加到步骤S1-1得到的所述种子乳液聚合物中,滴加速度为1~2滴/s的直至完成,然后升温至80~90℃并保温2h,得到丙烯酸酯聚合乳液。
说明:通过以上方法得到的丙烯酸酯聚合乳液,可以充当乳液粘结剂的作用,将原料粘接,提高砖料的结合强度以及防腐蚀性能,其中羰基共轭的双键和富有反应性的羟甲基产生交联,可对树脂加工进行改性加工,增强树脂的结合效果,同时可以充当表面处理剂,进一步增强砖料的防腐蚀性能。
进一步地,所述缓冲剂为碳酸盐、碳酸氢盐、磷酸盐、铵盐中的任意一种,所述步骤S1-1及步骤S1-2中的引发剂均为偶氮类引发剂、过氧化二酰类引发剂中的任意一种。
说明:通过上述缓冲剂以及引发剂的适用,能更优地把控制备过程,通过缓冲剂的使用,能保证反应中的酸碱值相对稳定,使得聚合反应能更加充分,通过上述引发剂的使用能够引发两个单体更好地进行聚合反应。
进一步地,所述硅溶胶树脂的制备方法为:向硅溶胶中加入水直至pH为3~3.5,然后以硅溶胶:硅烷的质量比为1:8~10加入硅烷,在40~45℃温度下,搅拌1.5h,得到硅溶胶树脂。
说明:通过上述方法得到的硅溶胶树脂,能够使砖料固化收缩率变小,对改性剂也起到了一定的补强作用,能有效的提高涂层的耐热性能,同时可以使各原料之间的紧密结合,可以减少原子迁移,能保障高温下的电性能。
一种等离子熔融炉用改性致密耐火砖的制备方法,包括以下步骤:
S1、细粉加工:
用球磨机将硼砂、熟矾土、刚玉粉、球粘土、炉甘石、二氧化铬研磨至300目的细粉;
S2、泥浆制备:
将熟矾土、刚玉粉、球粘土、炉甘石以及水加入高温搅拌器,持续搅拌3~5h,泥浆温度为80~85℃,得到泥浆预混物;其中,水的加入质量为熟矾土的3倍;
S3、混碾加工:
将颗粒料、硼砂混砂机以及50%的二氧化铬进行搅拌,然后加入50%的泥浆预混物,混合2~3min后,加入氧化铁、以及50%的改性剂,混合5~8min;混碾12~15min,再经过干燥、机压形成中心料;
S4、困料成型:
将剩余50%的泥浆预混物,混碾12~15min,再经24~48h的困料后,将困料后的泥浆预混物包裹中心料放入模具中,通过震动成型,得到成型砖坯,成型砖坯经自然干燥至水分小于1.5%后,入窑烧结;
S5、烧成:
将剩余50%的改性剂与二氧化铬混合形成砂料,均匀喷涂在成型砖坯表面,在1365~1550℃下,恒温烧成5~15h,随后冷却得到改性致密耐火砖。
说明:通过上述制备方法,对原料特性的利用程度达到最大,使得制备得到的改性致密耐火砖的密度较大,显气孔率较小,同时具有良好的隔热效果以及强度性能;通过两次加入改性剂与二氧化铬,能显著提升砖料表面的各项性能,通过中心料被包裹的设置,可以使得砖体中心与外表砖料具有性质差异,进而增强隔热效果。
进一步地,步骤S4中震动成型为:6000~8000次/min的频率下振动1~2h;困料条件为:在湿度为40~60%,温度为60~65℃的密封环境下放置。
说明:通过震动成型上述参数设置,增加砖块内部原料均一程度,同时增大砖体的致密效果,通过困料参数的设置,能够减少原料之间的显气孔率,更加易于砖料的后续加工操作。
进一步地,步骤S5中,喷涂及烧成的方法为:以8~10℃/min的升温速度,将温度升至500~550℃时,以12~14℃/min的速度升温,同时以成型砖坯的喷涂面作为向火面,将砂料喷涂至成型砖坯表面,控制喷涂速度,当温度升至1365~1550℃时,喷涂完成,然后恒温烧成5~15h,然后以8~12℃/min的速度进行降温冷却,得到改性致密耐火砖。
说明:通过上述烧成预计喷涂方法,可以使改性剂将二氧化铬牢固地结合在砖体表面,通过升温速度的设置,能够在砖体烧制成型的过程中,喷涂砂料增强砖体的表面性质,从而更好地将砖体改性,达到密度较大,显气孔率较小,强度性能较优的效果。
进一步地,砂料喷涂采用湿法喷涂、等离子喷涂或者火焰喷涂法的任意一种喷涂方法。
本发明的有益效果是:
(1)本发明通过上述原料制备得到的改性致密耐火砖的密度较大,显气孔率较小,同时具有良好的隔热效果以及强度性能;通过颗粒料的添加,可以利用砂石粒度来增加砖体的强度,通过硼砂、熟矾土、刚玉粉、球粘土、炉甘石粉末的添加可以增加砖体的粘结力以及密度,同时可以具有较优的耐腐蚀性,通过添加改性剂,可以进一步增强砖体的表面性能以及耐腐蚀,从而避免砖体中的含钙物质在高温条件下形成钙长石等形态,导致热态强度大大降低,同时可以提高砖体的整体强度与耐高温性。
(2)本发明使用的改性剂,再高温环境下具有较为稳定的性质,同时与砖料混合后能增加各原料之间的结合强度,使得得到的砖块兼具强度与耐高温性,使制备得到的砖块的抗渗碳性改善,可有效延长使用寿命;通过丙烯酸酯聚合乳液能够粘接原料粘土,且具有一定的缓蚀作用;通过偏磷酸铝提供化学稳定性以及机械性能,通过硅酸钙能有效提高强度高,且具有保温隔热、抗腐蚀等的性质,通过硅溶胶树脂可以增强改性剂与各原料之间的紧密结合,可以减少原子迁移,能保障高温下的电性能。
(3)本发明通过制备的丙烯酸酯聚合乳液,可以充当乳液粘结剂的作用,将原料粘接,提高砖料的结合强度以及防腐蚀性能,其中羰基共轭的双键和富有反应性的羟甲基产生交联,可对树脂加工进行改性加工,增强树脂的结合效果,同时可以充当表面处理剂,进一步增强砖料的防腐蚀性能。通过上述方法得到的硅溶胶树脂,能够使砖料固化收缩率变小,对改性剂也起到了一定的补强作用,能有效的提高涂层的耐热性能,同时可以使各原料之间的紧密结合,可以减少原子迁移,能保障高温下的电性能。
(4)本发明通过砖块的制备方法,对原料特性的利用程度达到最大,使得制备得到的改性致密耐火砖的密度较大,显气孔率较小,同时具有良好的隔热效果以及强度性能;通过两次加入改性剂与二氧化铬,能显著提升砖料表面的各项性能,通过中心料被包裹的设置,可以使得砖体中心与外表砖料具有性质差异,进而增强隔热效果。上述烧成预计喷涂方法,可以使改性剂将二氧化铬牢固地结合在砖体表面,通过升温速度的设置,能够在砖体烧制成型的过程中,喷涂砂料增强砖体的表面性质,从而更好地将砖体改性,达到密度较大,显气孔率较小,强度性能较优的效果。
具体实施方式
下面结合具体实施方式来对本发明进行更进一步详细的说明,以更好地体现本发明的优势。
实施例1:
一种等离子熔融炉用改性致密耐火砖,所述改性致密耐火砖的原料按重量份数计包括:颗粒料33份,硼砂13份,熟矾土14份,刚玉粉12份,球粘土13份,炉甘石11份,改性剂4份,二氧化铬90份,氧化铁1.2份;
所述颗粒料按重量分数计,由粒度为2~3mm的锆英砂44%,2~5mm的二氧化硅21%,1~3mm的方解石16%,余量为水混料得到;
所述改性剂由丙烯酸酯聚合乳液、偏磷酸铝、硅酸钙、硅溶胶树脂以重量比为30:3:2.5:8混合配制得到;
所述硅溶胶树脂的制备方法为:向硅溶胶中加入水直至pH为3.2,然后以硅溶胶:硅烷的质量比为1:9加入硅烷,在42℃温度下,搅拌1.5h,得到硅溶胶树脂;
所述改性剂混合配制为:取偏磷酸铝、硅酸钙粉末过350目筛,然后加入到硅溶胶树脂中在200r/min下搅拌分散1h,得到预混合液,再将丙烯酸酯聚合乳液加入到预混合液中,在40KHz下超声混合处理18min,得到改性剂;
所述丙烯酸酯聚合乳液的制备方法为:
S1-1、取质量比为1:1:0.15:10的羟甲基丙烯酰胺单体、丙烯酸单体、缓冲剂以及去离子水加入到反应器中混合,在70℃下,以羟甲基丙烯酰胺单体:引发剂的质量比为1:0.15的比例,加入引发剂,混合反应90min,得到种子乳液聚合物;
S1-2、在氮气氛围下,以丙烯酸单体、引发剂、缓冲剂的质量比为1:0.15:0.1混合得到混合物,以混合物:种子乳液聚合物为1:2.5的重量比,将混合物滴加到步骤S1-1得到的所述种子乳液聚合物中,滴加速度为1滴/s,滴加直至完成,然后升温至85℃并保温2h,得到丙烯酸酯聚合乳液;所述缓冲剂为碳酸盐,所述引发剂为偶氮类引发剂;
改性致密耐火砖制备方法包括以下步骤:
S1、细粉加工:
用球磨机将硼砂、熟矾土、刚玉粉、球粘土、炉甘石、二氧化铬研磨至300目的细粉;
S2、泥浆制备:
将熟矾土、刚玉粉、球粘土、炉甘石以及水加入高温搅拌器,持续搅拌4h,泥浆温度为83℃,得到泥浆预混物;其中,水的加入质量为熟矾土的3倍;
S3、混碾加工:
将颗粒料、硼砂混砂机以及50%的二氧化铬进行搅拌,然后加入50%的泥浆预混物,混合2.5min后,加入氧化铁、以及50%的改性剂,混合6min;混碾14min,再经过干燥、机压形成中心料;
S4、困料成型:
将剩余50%的泥浆预混物,混碾13min,再经30h的困料后,将困料后的泥浆预混物包裹中心料放入模具中,通过震动成型,得到成型砖坯,成型砖坯经自然干燥水分为1.2%时,入窑烧结;7000次/min的频率下振动1.5h;困料条件为:在湿度为50%,温度为63℃的密封环境下放置。
S5、烧成:
将剩余50%的改性剂与二氧化铬混合形成砂料,均匀喷涂在成型砖坯表面,在1450℃下,恒温烧成10h,随后冷却得到改性致密耐火砖。
实施例2
本实施例与实施例1不同之处在于,原料组分不同,按重量份数计包括:颗粒料30份,硼砂15份,熟矾土16份,刚玉粉10份,球粘土10份,炉甘石14份,改性剂5份,二氧化铬8份,氧化铁1.0份;所述颗粒料按重量分数计,由粒度为2~3mm的锆英砂40%,2~5mm的二氧化硅22%,1~3mm的方解石18%,余量为水混料得到。
实施例3
本实施例与实施例1不同之处在于,原料组分不同,按重量份数计包括:颗粒料35份,硼砂12份,熟矾土12份,刚玉粉15份,球粘土15份,炉甘石9份,改性剂3份,二氧化铬10份,氧化铁1.5份;所述颗粒料按重量分数计,由粒度为2~3mm的锆英砂46%,2~5mm的二氧化硅20%,1~3mm的方解石15%,余量为水混料得到。
实施例4
本实施例与实施例1不同之处在于,改性剂的原料组分不同,所述改性剂由丙烯酸酯聚合乳液、偏磷酸铝、硅酸钙、硅溶胶树脂以重量比为20:3:3:6混合配制得到;所述硅溶胶树脂的制备方法为:向硅溶胶中加入水直至pH为3,然后以硅溶胶:硅烷的质量比为1:8加入硅烷,在45℃温度下,搅拌1.5h,得到硅溶胶树脂。
实施例5
本实施例与实施例1不同之处在于,改性剂的原料组分不同,所述改性剂由丙烯酸酯聚合乳液、偏磷酸铝、硅酸钙、硅溶胶树脂以重量比为35:3:2:10混合配制得到;所述硅溶胶树脂的制备方法为:向硅溶胶中加入水直至pH为3.5,然后以硅溶胶:硅烷的质量比为1:10加入硅烷,在40℃温度下,搅拌1.5h,得到硅溶胶树脂。
实施例6
本实施例与实施例1
不同之处在于,改性剂混合配制条件参数不同,取偏磷酸铝、硅酸钙粉末过300目筛,然后加入到硅溶胶树脂中在200r/min下搅拌分散1h,得到预混合液,再将丙烯酸酯聚合乳液加入到预混合液中,在40KHz下超声混合处理20min,得到改性剂。
实施例7
本实施例与实施例1不同之处在于,改性剂混合配制条件参数不同,取偏磷酸铝、硅酸钙粉末过400目筛,然后加入到硅溶胶树脂中在200r/min下搅拌分散1h,得到预混合液,再将丙烯酸酯聚合乳液加入到预混合液中,在40KHz下超声混合处理15min,得到改性剂。
实施例8
本实施例与实施例1不同之处在于,步骤S2与S3中的混合搅拌时间不同,S2中持续搅拌3h;S3中加入泥浆预混物,混合3min后,加入氧化铁、以及50%的改性剂,混合5min;混碾15min。
实施例9
本实施例与实施例1不同之处在于,步骤S2与S3中的混合搅拌时间不同,S2中持续搅拌5h;S3中加入泥浆预混物,混合2min后,加入氧化铁、以及50%的改性剂,混合8min;混碾12min。
实施例10
本实施例与实施例1不同之处在于,步骤S4中困料成型的条件参数不同,将剩余50%的泥浆预混物,混碾12min,再经48h的困料后,将困料后的泥浆预混物包裹中心料放入模具中,通过震动成型,得到成型砖坯,成型砖坯经自然干燥水分为1.4%时,入窑烧结;6000次/min的频率下振动2h;困料条件为:在湿度为40%,温度为65℃的密封环境下放置。
实施例11
本实施例与实施例1不同之处在于,步骤S4中困料成型的条件参数不同,将剩余50%的泥浆预混物,混碾15min,再经24h的困料后,将困料后的泥浆预混物包裹中心料放入模具中,通过震动成型,得到成型砖坯,成型砖坯经自然干燥水分为1.0%时,入窑烧结;8000次/min的频率下振动1h;困料条件为:在湿度为60%,温度为65℃的密封环境下放置。
实施例12
本实施例与实施例1不同之处在于,步骤S5中条件参数不同,在1365℃下,恒温烧成15h,随后冷却得到改性致密耐火砖。
实施例13
本实施例与实施例1不同之处在于,步骤S5中条件参数不同,在1550℃下,恒温烧成5h,随后冷却得到改性致密耐火砖。
实施例14
本实施例与实施例1不同之处在于,丙烯酸酯聚合乳液的制备中的原料不同,S1-1、取质量比为1:1:0.1:10的羟甲基丙烯酰胺单体、丙烯酸单体、缓冲剂以及去离子水加入到反应器中混合;S1-2、在氮气氛围下,以丙烯酸单体、引发剂、缓冲剂的质量比为1:0.2:0.1混合得到混合物。所述缓冲剂为碳酸氢盐,所述引发剂为过氧化二酰类引发剂。
实施例15
本实施例与实施例1不同之处在于,丙烯酸酯聚合乳液的制备中的原料不同,S1-1、取质量比为1:1:0.2:10的羟甲基丙烯酰胺单体、丙烯酸单体、缓冲剂以及去离子水加入到反应器中混合;S1-2、在氮气氛围下,以丙烯酸单体、引发剂、缓冲剂的质量比为1:0.1:0.1混合得到混合物。所述缓冲剂为磷酸盐,所述引发剂为偶氮类引发剂。
实施例16
本实施例与实施例1不同之处在于,丙烯酸酯聚合乳液的制备中的条件参数不同,S1-1、在65℃下,混合反应100min,得到种子乳液聚合物;S1-2、混合物的滴加速度为2滴/s,升温至80℃并保温2h,得到丙烯酸酯聚合乳液。
实施例17
本实施例与实施例1不同之处在于,丙烯酸酯聚合乳液的制备中的条件参数不同,S1-1、在75℃下,混合反应80min,得到种子乳液聚合物;S1-2、升温至90℃并保温2h,得到丙烯酸酯聚合乳液。
实施例18
本实施例与实施例1不同之处在于,步骤S5中,喷涂及烧成的方法为:以9℃/min的升温速度,将温度升至530℃时,以13℃/min的速度升温,同时以成型砖坯的喷涂面作为向火面,将砂料喷涂至成型砖坯表面,控制喷涂速度,当温度升至1450℃时,喷涂完成,然后恒温烧成10h,然后以10℃/min的速度进行降温冷却,得到改性致密耐火砖;砂料喷涂采用等离子喷涂法。
实施例19
本实施例与实施例18不同之处在于,喷涂及烧成条件参数不同,以8℃/min的升温速度,将温度升至500℃时,以14℃/min的速度升温,同时以成型砖坯的喷涂面作为向火面,将砂料喷涂至成型砖坯表面,控制喷涂速度,当温度升至1365℃时,喷涂完成,然后恒温烧成5h,然后以8℃/min的速度进行降温冷却,得到改性致密耐火砖;砂料喷涂采用等离子喷涂法。
实施例20
本实施例与实施例18不同之处在于,喷涂及烧成条件参数不同,以10℃/min的升温速度,将温度升至550℃时,以12℃/min的速度升温,同时以成型砖坯的喷涂面作为向火面,将砂料喷涂至成型砖坯表面,控制喷涂速度,当温度升至1550℃时,喷涂完成,然后恒温烧成15h,然后以12℃/min的速度进行降温冷却,得到改性致密耐火砖;砂料喷涂采用等离子喷涂法。
实验例
一、分别对实施例1~3、实施例18得到的改性致密耐火砖进行体积密度、耐压强度、耐磨系数以及耐酸性测试,测试结果如下:
1、探究不同原料组分对改性致密耐火砖性能的影响;
对比例1:通过相同量的水代替改性剂,其余原料组分以及步骤处理与实施例1相同;
取实施例1、实施例2与实施例3、对比例1进行对比,如表1所示;
表1不同原料组分下的改性致密耐火砖的性能实验结果
从表1可以看出,实施例18的改性致密耐火砖各项性能较优,对比实施例1、实施例2与实施例3,可以发现,实施例1中的组分配比为最优,对比实施例1与实施例18,可以看出,通过实施例18的方法进行处理后,改性致密耐火砖的各项性能较佳,且对耐压强度提高较明显;对比实施例1与对比例1可以发现,改性剂对的改性致密耐火砖多项性能均有所影响,综合来看,实施例18较优。
二、分别对实施例1~20得到的改性致密耐火砖产品进行体积密度以及常温耐压强度测试,测试结果如下:
2、探究不同改性剂组分以及条件参数对改性致密耐火砖性能影响;
取实施例1、实施例4~7进行对比,如表2所示;
表2不同改性剂组分以及条件下的改性致密耐火砖性能实验结果
从表2可以看出,对比实施例1、实施例4与实施例5,可以发现,实施例1的改性剂原料组分较优选,对比实施例1、实施例6与实施例7,可以发现实施例1的改性剂混合参数较为优选。
3、探究制备过程中不同处理参数对改性致密耐火砖性能影响;
取实施例1,实施例8~13进行对比,如表3所示;
表3制备过程中不同处理参数得到的改性致密耐火砖性能实验结果
从表3可以看出,对比实施例1、实施例8与实施例9,可以发现,实施例1的混合搅拌时间较优选,对比实施例1、实施例10与实施例11,可以发现,实施例困料成型的参数较优选,对比实施例1、实施例12与实施例13,可以得出,实施例1的烧成参数较为优选。
4、探究丙烯酸酯聚合乳液的制备对改性致密耐火砖性能影响;
取实施例1、实施例14~17进行对比,如表4所示;
表4丙烯酸酯聚合乳液的制备对改性致密耐火砖性能实验结果
从表4可以看出,对比实施例1、实施例14、实施例15,可以得出,采用实施例1丙烯酸酯聚合乳液原料配比得到的改性致密耐火砖性能较优,通过对比实施例1、实施例16以及实施例17,可以看出实施例1设置的条件参数较优。
5、探究喷涂及烧成的方法对改性致密耐火砖性能影响;
对比例2:喷涂及烧成的方法为:以9℃/min的升温速度,将温度升至530℃时,以成型砖坯的喷涂面作为向火面,将砂料喷涂至成型砖坯表面,控制喷涂速度,当温度升至1450℃时,喷涂完成;其余处理与实施例19相同;
对比例3:喷涂及烧成的方法为:以9℃/min的升温速度,将温度升至1450℃时,以成型砖坯的喷涂面作为向火面,将砂料喷涂至成型砖坯表面直至喷涂完成;其余处理与实施例19相同;
取实施例18~20进行对比,如表5所示;
表5喷涂及烧成的方法对改性致密耐火砖的性能实验结果
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从表5可以看出,对比实施例18、实施例19与实施例20,可以发现,实施例18的喷涂及烧成的方法参数较优,对比实施例18、对比例2与对比例3,可以看出,对比例19喷涂及烧成的方法较为优选。
Claims (9)
1.一种等离子熔融炉用改性致密耐火砖,其特征在于,所述改性致密耐火砖的原料按重量份数计包括:颗粒料30~35份,硼砂12~15份,熟矾土12~16份,刚玉粉10~15份,球粘土10~15份,炉甘石9~14份,改性剂3~5份,二氧化铬8~10份,氧化铁1.0~1.5份;
所述颗粒料按重量分数计,由粒度为2~3mm的锆英砂40~46%,2~5mm的二氧化硅20~22%,1~3mm的方解石15~18%,余量为水混料得到;
所述改性剂由丙烯酸酯聚合乳液、偏磷酸铝、硅酸钙、硅溶胶树脂以重量比为20~35:3:2~3:6~10混合配制得到。
2.如权利要求1所述的一种等离子熔融炉用改性致密耐火砖,其特征在于,所述改性剂混合配制方法为:取偏磷酸铝、硅酸钙粉末过300~400目筛,然后加入到硅溶胶树脂中在200r/min下搅拌分散1h,得到预混合液,再将丙烯酸酯聚合乳液加入到预混合液中,在40KHz下超声混合处理15~20min,得到改性剂。
3.如权利要求1所述的一种等离子熔融炉用改性致密耐火砖,其特征在于,所述丙烯酸酯聚合乳液的制备方法为:
S1-1、取质量比为1:1:0.1~0.2:10的羟甲基丙烯酰胺单体、丙烯酸单体、缓冲剂以及去离子水加入到反应器中混合,在65~75℃下,以羟甲基丙烯酰胺单体:引发剂的质量比为1:0.15的比例,加入引发剂,混合反应80~100min,得到种子乳液聚合物;
S1-2、在氮气氛围下,以丙烯酸单体、引发剂、缓冲剂的质量比为1:0.1~0.2:0.1混合得到混合物,以混合物:种子乳液聚合物为1:2~3的重量比,将混合物滴加到步骤S1-1得到的所述种子乳液聚合物中,滴加速度为1~2滴/s,直至滴加完成,然后升温至80~90℃并保温2h,得到丙烯酸酯聚合乳液。
4.如权利要求3所述的一种等离子熔融炉用改性致密耐火砖,其特征在于,所述缓冲剂为碳酸盐、碳酸氢盐、磷酸盐、铵盐中的任意一种,所述步骤S1-1及步骤S1-2中的引发剂均为偶氮类引发剂、过氧化二酰类引发剂中的任意一种。
5.如权利要求1所述的一种等离子熔融炉用改性致密耐火砖,其特征在于,所述硅溶胶树脂的制备方法为:向硅溶胶中加入水直至pH为3~3.5,然后以硅溶胶:硅烷的质量比为1:8~10加入硅烷,在40~45℃温度下,搅拌1.5h,得到硅溶胶树脂。
6.如权利要求1所述的一种等离子熔融炉用改性致密耐火砖的制备方法,其特征在于,包括以下步骤:
S1、细粉加工:
用球磨机将硼砂、熟矾土、刚玉粉、球粘土、炉甘石、二氧化铬研磨至300目的细粉;
S2、泥浆制备:
将熟矾土、刚玉粉、球粘土、炉甘石以及水加入高温搅拌器,持续搅拌3~5h,泥浆温度为80~85℃,得到泥浆预混物;其中,水的加入质量为熟矾土的3倍;
S3、混碾加工:
将颗粒料、硼砂混砂机以及50%的二氧化铬进行搅拌,然后加入50%的泥浆预混物,混合2~3min后,加入氧化铁、以及50%的改性剂,混合5~8min;混碾12~15min,再经过干燥、机压形成中心料;
S4、困料成型:
将剩余50%的泥浆预混物,混碾12~15min,再经24~48h的困料后,将困料后的泥浆预混物包裹中心料放入模具中,通过震动成型,得到成型砖坯,成型砖坯经自然干燥至水分小于1.5%后,入窑烧结;
S5、烧成:
将剩余50%的改性剂与二氧化铬混合形成砂料,均匀喷涂在成型砖坯表面,在1365~1550℃下,恒温烧成5~15h,随后冷却得到改性致密耐火砖。
7.如权利要求6所述的一种等离子熔融炉用改性致密耐火砖的制备方法,其特征在于,步骤S4中震动成型为:6000~8000次/min的频率下振动1~2h;困料条件为:在湿度为40~60%,温度为60~65℃的密封环境下放置。
8.如权利要求6所述的一种等离子熔融炉用改性致密耐火砖的制备方法,其特征在于,步骤S5中,喷涂及烧成的方法为:以8~10℃/min的升温速度,将温度升至500~550℃时,以12~14℃/min的速度升温,同时以成型砖坯的喷涂面作为向火面,将砂料喷涂至成型砖坯表面,控制喷涂速度,当温度升至1365~1550℃时,喷涂完成,然后恒温烧成5~15h,然后以8~12℃/min的速度进行降温冷却,得到改性致密耐火砖。
9.如权利要求8所述的一种等离子熔融炉用改性致密耐火砖的制备方法,其特征在于,砂料喷涂采用湿法喷涂、等离子喷涂或者火焰喷涂法的任意一种喷涂方法。
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