CN116217221B - 一种高强隔热耐火泥浆的制备方法 - Google Patents

一种高强隔热耐火泥浆的制备方法 Download PDF

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CN116217221B
CN116217221B CN202310026089.8A CN202310026089A CN116217221B CN 116217221 B CN116217221 B CN 116217221B CN 202310026089 A CN202310026089 A CN 202310026089A CN 116217221 B CN116217221 B CN 116217221B
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陈金凤
程水明
蔡玮
丛培源
项冰
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China First Metallurgical Group Co Ltd
Wuhan Research Institute of Metallurgical Construction Co Ltd
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Abstract

本发明公开了一种高强隔热耐火泥浆的制备方法，将六铝酸钙细粉、焦宝石细粉、蓝晶石细粉、膨润土细粉、硅酸钙纤维、钛白粉按质量比100︰(35～40)︰(10～15)︰(5～8)︰(3～5)︰(1.2～1.5)加入行星式搅拌机中混合10～15分钟，得到预混细粉料；向所述预混细粉料中加入6～8wt％的液体石蜡，搅拌6～8分钟，即得高强隔热耐火泥浆；本发明所得高强隔热耐火泥浆制备工艺简单，易烧结，施工性能好，粘接强度大，荷重软化温度高，导热系数低，无毒害气体等组分产生，绿色环保，尤其适用于碱性耐火材料制品的砌筑。

Description

一种高强隔热耐火泥浆的制备方法
技术领域
本发明属于耐火材料技术领域，具体涉及一种高强隔热耐火泥浆的制备方法。
背景技术
耐火泥浆是定形耐火材料制品砌筑时所使用的接缝/填缝材料。与普通耐火材料不同，耐火泥浆一般仅由细粉料和结合剂(包括外加剂)组成，即耐火泥浆从粒度上而言属于均一体系，无大颗粒骨料或中颗粒(谢朝晖，葛山，刘志强，等.“对耐火泥浆性能研究的再思考”，《耐火材料》，2015，49(6)：pp475～478)，其浓度高，呈膏状浆体，具有宾汉流体的特性。
从服役条件来看，耐火泥浆需要在砖缝处起到衔接作用，因此需要与整体耐火材料形成良好的结合，故耐火泥浆需要具备如下主要优点：
(1)易烧结：耐火泥浆在低于服役环境的温度下即可快速烧结产生强度，从而将耐火砖整体衔接。
(2)粘接强度高：对耐火砖之间的粘接强度要高，使砖与砖之间粘接紧密，若粘接强度较低，则对高温窑炉内衬砖的整体性与安全性产生隐患(伍书军.“耐火泥浆抗剪粘接强度新试验方法的研究”，《耐火材料》，2016，50(2)：pp158～160)。
(3)荷重软化温度高：耐火泥浆涂抹于层砖之间，在高温荷重之下发生软化对窑炉内衬的密实性有显著影响。荷重软化点温度适当提高，其服役性能越好，但同时应该注意荷重软化温度过高，也容易产生层砖缝隙，不同组成的耐火泥浆荷重软化温度不同，一般黏土耐火泥浆荷重软化温度T0.6≥1200℃，高铝质耐火泥浆荷重软化温度T0.6≥1300℃(王洪永.“耐火泥浆荷重软化温度试验制样方法的改进”，《耐火材料》，2011，45(6)：pp479～480)。
(4)高温体积膨胀：耐火泥浆在高温下应产生适当的体积膨胀，这有利于“补偿”砖间缝隙，换言之，耐火泥浆的高温体积特性以微膨胀为优，但不能膨胀过大，否则导致内衬砖开裂损毁。
(5)成本低且易于获得：耐火泥浆作为定形耐火材料制品砌筑用辅材，要求成本较低，且易于获得和使用，施工便利(包括硬化速率、混合均匀程度等)。
目前，耐火泥浆按组分可分为硅质耐火泥浆、铝硅质耐火泥浆、碳化硅质耐火泥浆和碱性耐火泥浆等几类，主要针对不同材质的耐火材料制品。
硅质耐火泥浆由硅石粉、硅砖(包括废硅砖等)粉、黏土和结合剂组成，主要针对硅砖的砌筑，如高炉热风炉、焦炉炭化室等部位。硅质耐火泥浆原料来源广泛，成本低，可通过水系结合或化学结合(如水玻璃、磷酸盐等溶液)，如“一种热风炉用高强度硅质耐火泥浆及其制备方法，CN202111389576.8”，但硅质耐火泥浆的作业性能和结合强度还需要引入适当的矿化剂，如石灰乳、铁鳞或木质素磺酸盐等，导致硅质耐火泥浆的应用受限。
铝硅质耐火泥浆应用范围较广，包括黏土质、莫来石质、高铝质等，其原料可选用黏土熟料，高铝矾土熟料，莫来石等(如“一种热风炉用高强度粘土质耐火泥浆及其制备方法，CN202111433397.X”、)，结合剂以水玻璃或磷酸盐系列为主。铝硅质耐火泥浆属于典型的水系结合泥浆，还需引入一定量的减水剂(如聚磷酸盐、聚丙酸钠等)、稳定剂(甲基纤维素、羧甲基纤维素等)等，这阻碍了铝硅质耐火泥浆在碱性耐火材料制品中的应用。
碳化硅质耐火泥浆(又称为炭糊)主要用于SiC(或含SiC)质等非氧化物耐火材料制品的砌筑，包括高炉炭砖、混铁车或鱼雷罐用铝碳化硅炭砖。如“一种预砌筑的碳化硅质耐火泥浆，CN202111051469.4”，但碳化硅质耐火泥浆在氧化物耐火材料中应用较少，一方面由于SiC与氧化物耐火材料本体难以烧结形成有效结合，另一方面碳化硅的氧化也容易在砖缝间留下气孔。
碱性耐火泥浆是针对碱性耐火材料(如镁质耐火材料、镁钙质耐火材料或镁尖晶石质等耐火材料)制品砌筑所开发的一类泥浆，主要成分为MgO和Al2O3，如“一种钢包抗侵蚀镁质耐火泥浆及其制备方法，CN202110160817.5”，其原料来源大多为废镁砖、废镁尖晶石砖等破粉碎后制得的粉料，此类耐火泥浆存在的主要问题在于：一是废砖破粉碎后所得原料属于再生脊性料，其可塑性弱，施工性能较差，对砖缝的粘接质量产生显著的影响；二是作为碱性耐火泥浆而言，MgO本身反应活性较低，烧结性能较差；三是碱性耐火泥浆不宜选用水系结合或者酸性化学结合，这易于导致碱性耐火泥浆的瞬凝而失效。因此，在考虑碱性耐火泥浆的使用性能前提下，优化其组成与结构，进而提升其服役寿命则至关重要。
发明内容
本发明目的在于提供一种高强隔热耐火泥浆的制备方法，该高强隔热耐火泥浆制备工艺简单，易烧结，施工性能好，粘接强度大，荷重软化温度高，导热系数低，无毒害气体等组分产生，绿色环保，尤其适用于碱性耐火材料制品的砌筑。
为达到上述目的，采用技术方案如下：
一种高强隔热耐火泥浆的制备方法，包括以下步骤：
1)将六铝酸钙细粉、焦宝石细粉、蓝晶石细粉、膨润土细粉、硅酸钙纤维、钛白粉按质量比100︰(35～40)︰(10～15)︰(5～8)︰(3～5)︰(1.2～1.5)加入行星式搅拌机中混合10～15分钟，得到预混细粉料；
2)向所述预混细粉料中加入6～8wt％的液体石蜡，搅拌6～8分钟，即得高强隔热耐火泥浆。
按上述方案，所述六铝酸钙细粉的粒度为60～80μm，CaO含量为8～10wt％。
按上述方案，所述焦宝石细粉的粒度为60～80μm，Al2O3含量为40～45wt％，SiO2含量为45～50wt％。
按上述方案，所述蓝晶石细粉的粒度为60～80μm，真密度为3.4～3.5g/cm3，Al2O3含量为60～65wt％，SiO2含量为32～33wt％。
按上述方案，所述膨润土细粉的粒度为60～80μm，Al2O3含量为12～15wt％，SiO2含量为65～68wt％，K2O含量为1.5～2.0wt％。
按上述方案，所述硅酸钙纤维的CaO含量43～45wt％，SiO2含量为50～52wt％，长度为2～5mm，直径10～20μm。
按上述方案，所述钛白粉为工业纯。
按上述方案，所述液体石蜡为工业纯。
相对于现有技术，本发明有益效果如下：
(1)本发明所制备的高强隔热耐火泥浆属CaO-Al2O3-SiO2体系，其烧结活性高，服役过程中能够利用外界环境温度快速烧结，利于接缝并与耐火材料制品形成整体粘接。
(2)本发明通过高熵掺杂，利用氧化钛的固溶增大CaO-Al2O3-SiO2体系熵值，促进耐火泥浆高温下原位生成钙长石和钛铝酸钙相，提高了泥浆的荷重软化温度，降低泥浆的导热性能，防止高温窑炉内部热量从砖缝处扩散，节能的同时进一步提高了高温窑炉的服役安全性。
(3)本发明利用高温下体系中的液相及膨润土分解产生的气相形成莫来石晶须，并与硅酸钙纤维交叉互锁，产生体积膨胀的同时提高了耐火泥浆的高温粘接强度。
(4)本发明采用液体石蜡为结合剂，通过非水系结合避免钙铝硅质耐火泥浆破坏碱性耐火材料制品的结构，其保存周期长，无毒害组分，安全环保，施工性能好。
(5)本发明制备的高强隔热耐火泥浆经检测：110℃1121体积密度为2.14～2.22g/cm3；荷重软化温度(T0.6)＞1680℃；高温抗折强度(1400℃111)为6.8～7.2MPa；粘结抗折强度(1400℃131)为3.5～3.9MPa；1400℃131烧后导热系数为1.1～1.4W/(m·K)。
具体实施方式
以下实施例进一步阐释本发明的技术方案，但不作为对本发明保护范围的限制。
具体实施方式提供了一种高强隔热耐火泥浆的制备方法：
1)将六铝酸钙细粉、焦宝石细粉、蓝晶石细粉、膨润土细粉、硅酸钙纤维、钛白粉按质量比100︰(35～40)︰(10～15)︰(5～8)︰(3～5)︰(1.2～1.5)加入行星式搅拌机中混合10～15分钟，得到预混细粉料；
2)向所述预混细粉料中加入6～8wt％的液体石蜡，搅拌6～8分钟，即得高强隔热耐火泥浆。
具体地，所述六铝酸钙细粉的粒度为60～80μm，CaO含量为8～10wt％。
具体地，所述焦宝石细粉的粒度为60～80μm，Al2O3含量为40～45wt％，SiO2含量为45～50wt％。
具体地，所述蓝晶石细粉的粒度为60～80μm，真密度为3.4～3.5g/cm3，Al2O3含量为60～65wt％，SiO2含量为32～33wt％。
具体地，所述膨润土细粉的粒度为60～80μm，Al2O3含量为12～15wt％，SiO2含量为65～68wt％，K2O含量为1.5～2.0wt％。
具体地，所述硅酸钙纤维的CaO含量43～45wt％，SiO2含量为50～52wt％，长度为2～5mm，直径10～20μm。
具体地，所述钛白粉为工业纯。
具体地，所述液体石蜡为工业纯。
实施例1
一种高强隔热耐火泥浆的制备方法，其特征在于，具体步骤如下：
1)按六铝酸钙细粉、焦宝石细粉、蓝晶石细粉、膨润土细粉、硅酸钙纤维和钛白粉的质量比为100︰38︰14︰6︰3︰1.5，加入行星式搅拌机中混合15分钟，得到预混细粉料；
2)向所述预混料中加入占所述预混料8wt％的液体石蜡，搅拌8分钟，即得高强隔热耐火泥浆。
经检测：110℃1121体积密度为2.18g/cm3；荷重软化温度(T0.6)为1700℃；高温抗折强度(1400℃111)为7.1MPa；粘结抗折强度(1400℃131)为3.8MPa；1400℃131烧后导热系数为1.4W/(m·K)。
实施例2
一种高强隔热耐火泥浆的制备方法，其特征在于，具体步骤如下：
1)按六铝酸钙细粉、焦宝石细粉、蓝晶石细粉、膨润土细粉、硅酸钙纤维和钛白粉的质量比为100︰35︰15︰5︰5︰1.2，加入行星式搅拌机中混合12分钟，得到预混细粉料；
2)向所述预混料中加入占所述预混料7wt％的液体石蜡，搅拌6分钟，即得高强隔热耐火泥浆。
经检测：110℃1121体积密度为2.14g/cm3；荷重软化温度(T0.6)为1690℃；高温抗折强度(1400℃111)为6.9MPa；粘结抗折强度(1400℃131)为3.6MPa；1400℃131烧后导热系数为1.2W/(m·K)。
实施例3
一种高强隔热耐火泥浆的制备方法，其特征在于，具体步骤如下：
1)按六铝酸钙细粉、焦宝石细粉、蓝晶石细粉、膨润土细粉、硅酸钙纤维和钛白粉的质量比为100︰40︰10︰8︰4︰1.4，加入行星式搅拌机中混合10分钟，得到预混细粉料；
2)向所述预混料中加入占所述预混料6wt％的液体石蜡，搅拌8分钟，即得高强隔热耐火泥浆。
经检测：110℃1121体积密度为2.22g/cm3；荷重软化温度(T0.6)为1690℃；高温抗折强度(1400℃111)为7.2MPa；粘结抗折强度(1400℃131)为3.9MPa；1400℃131烧后导热系数为1.2W/(m·K)。
实施例4
一种高强隔热耐火泥浆的制备方法，其特征在于，具体步骤如下：
1)按六铝酸钙细粉、焦宝石细粉、蓝晶石细粉、膨润土细粉、硅酸钙纤维和钛白粉的质量比为100︰36︰13︰7︰3︰1.3，加入行星式搅拌机中混合10分钟，得到预混细粉料；
2)向所述预混料中加入占所述预混料7wt％的液体石蜡，搅拌7分钟，即得高强隔热耐火泥浆。
经检测：110℃1121体积密度为2.19g/cm3；荷重软化温度(T0.6)为1700℃；高温抗折强度(1400℃111)为6.8MPa；粘结抗折强度(1400℃131)为3.5MPa；1400℃131烧后导热系数为1.1W/(m·K)。
对比例1
重复实施例4，减去钛白粉成分的加入。
经检测：110℃1121体积密度为2.02g/cm3；荷重软化温度(T0.6)为1400℃；高温抗折强度(1400℃111)为3.1MPa；粘结抗折强度(1400℃131)为1.2MPa；1400℃131烧后导热系数为1.3W/(m·K)。

Claims (4)

1.一种高强隔热耐火泥浆的制备方法，其特征在于包括以下步骤：
1)将六铝酸钙细粉、焦宝石细粉、蓝晶石细粉、膨润土细粉、硅酸钙纤维、钛白粉按质量比100︰(35～40)︰(10～15)︰(5～8)︰(3～5)︰(1.2～1.5)加入行星式搅拌机中混合10～15分钟，得到预混细粉料；
2)向所述预混细粉料中加入6～8wt％的液体石蜡，搅拌6～8分钟，即得高强隔热耐火泥浆；
其中，所述六铝酸钙细粉的粒度为60～80μm，CaO含量为8～10wt％；
焦宝石细粉的粒度为60～80μm，Al2O3含量为40～45wt％，SiO2含量为45～50wt％；
所述硅酸钙纤维的CaO含量43～45wt％，SiO2含量为50～52wt％，长度为2～5mm，直径10～20μm；
所述膨润土细粉的粒度为60～80μm，Al2O3含量为12～15wt％，SiO2含量为65～68wt％，K2O含量为1.5～2.0wt％；
所述高强隔热耐火泥浆荷重软化温度＞1680℃。
2.如权利要求1所述高强隔热耐火泥浆的制备方法，其特征在于所述蓝晶石细粉的粒度为60～80μm，真密度为3.4～3.5g/cm3，Al2O3含量为60～65wt％，SiO2含量为32～33wt％。
3.如权利要求1所述高强隔热耐火泥浆的制备方法，其特征在于所述钛白粉为工业纯。
4.如权利要求1所述高强隔热耐火泥浆的制备方法，其特征在于所述液体石蜡为工业纯。
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