CN116217251B - 铝工业用低密度低蓄热陶瓷纤维浇注料及其制备方法 - Google Patents
铝工业用低密度低蓄热陶瓷纤维浇注料及其制备方法 Download PDFInfo
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- 239000000835 fiber Substances 0.000 title claims abstract description 73
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 50
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 50
- 238000005338 heat storage Methods 0.000 title claims abstract description 34
- 238000002360 preparation method Methods 0.000 title claims abstract description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 48
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 31
- 239000005350 fused silica glass Substances 0.000 claims abstract description 25
- 229920000742 Cotton Polymers 0.000 claims abstract description 22
- 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 21
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 21
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 18
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- 238000000034 method Methods 0.000 claims abstract description 15
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 13
- 229910021487 silica fume Inorganic materials 0.000 claims abstract description 13
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims abstract description 10
- 239000004568 cement Substances 0.000 claims abstract description 10
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- 239000001509 sodium citrate Substances 0.000 claims description 12
- NLJMYIDDQXHKNR-UHFFFAOYSA-K sodium citrate Chemical compound O.O.[Na+].[Na+].[Na+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O NLJMYIDDQXHKNR-UHFFFAOYSA-K 0.000 claims description 12
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 12
- 235000010627 Phaseolus vulgaris Nutrition 0.000 claims description 11
- 244000046052 Phaseolus vulgaris Species 0.000 claims description 11
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- 238000004806 packaging method and process Methods 0.000 claims description 7
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- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 13
- 230000006872 improvement Effects 0.000 description 8
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Abstract
本发明揭示了一种铝工业用低密度低蓄热陶瓷纤维浇注料及其制备方法,所述铝工业用低密度低蓄热陶瓷纤维浇注料包括:各组分含量如下:电熔石英砂45~55%、低铝莫来石20~30%、硅灰5~8%、纯铝酸钙水泥13~15%、萤石粉2~5%、增稠剂0.15‑0.2%,减水剂0.2~0.3%,陶瓷纤维散棉8~35%;本发明提供的铝工业用低密度低蓄热陶瓷纤维浇注料,应用于铝铸造耐火组件的制造,可以获得低密度、低收缩的耐火组件制成品,在铝水流经的整个过程中蓄热量小、抗热震性优秀,能够降低热能损失、提高耐火组件寿命,降低生产成本。
Description
技术领域
本发明属于陶瓷纤维浇注料领域,具体涉及一种铝工业用低密度低蓄热陶瓷纤维浇注料及其制备方法。
背景技术
在铝铸造生产中,流槽、分流盘、浇包、过滤箱等耐火材料组件是必不可少的工具,这些耐火组件要直接接触高温(约750℃)铝水、经受化学侵蚀、物理冲刷和急冷急热冲击,因此用以制造耐火材料组件的浇注料要化学稳定性好、抗铝水冲刷性好、不易被铝水浸润、抗热震稳定性好;同时,各耐火材料组件在工作中要吸收大量热能以达到热平衡,而冷却后热量又散失到周围环境中,大量热能白白损失掉了,所以流槽、分流盘等耐火组件的低蓄热性能也成为铝铸造企业选择耐火浇注料时关注的一个重点。
目前,国内铝铸造生产中所用的耐火浇注料主要有三大类:熔融石英类、矾土基类和赛隆结合熔融石英类。
赛隆结合熔融石英类和熔融石英类浇注料组件加热线变化小,材料的体积稳定性好,从而材料的抗热震性能优秀,但是二者体积密度相对较大,导致各耐火材料组件在工作过程中蓄热量较大,对企业节能、降成本非常不利;矾土类耐火浇注料组件不但体积密度高,加热线变化也大,造成组件在工作中抗热震性差、蓄热量大,也不利于节能和降低成本。
综上,三类铝铸造用耐火浇注料制成品存在体积密度较大、高温工作过程中蓄热量大,同时加热线变化和抗粘铝、抗物理冲刷、抗热震等性能“长板和短板”都很突出,一方面造成某些功能浪费,另一方面使耐火组件在工作中造成蓄热量大,浪费能源或材料抗热冲击能力差、寿命变短。
发明内容
本发明的目的之一在于提供一种铝工业用低密度低蓄热陶瓷纤维浇注料,以解决现有技术中耐火浇注料体积密度大、蓄热量过高等技术问题。
本发明的目的之一在于提供一种铝工业用低密度低蓄热陶瓷纤维浇注料制备方法。
为实现上述发明目的之一,本发明一实施方式提供一种铝工业用低密度低蓄热陶瓷纤维浇注料,包括各组分含量如下:
电熔石英砂45~55%、低铝莫来石20~30%、硅灰5~8%、纯铝酸钙水泥13~15%、萤石粉2~5%、增稠剂0.15-0.2%,减水剂0.2~0.3%,陶瓷纤维散棉8~35%。
作为本发明一实施方式的进一步改进,所述电熔石英砂的粒级包括0.001mm~0.088mm,0.088mm~01mm,0.1mm~0.25mm中的一种或两种以上的组合。
作为本发明一实施方式的进一步改进,当所述电熔石英砂的粒级为三种时,三种电熔石英砂粒级由小至大的比例为2:1:1。
作为本发明一实施方式的进一步改进,所述增稠剂为豆儿胶。
作为本发明一实施方式的进一步改进,所述减水剂包括三聚磷酸钠与柠檬酸钠,所述三聚磷酸钠与柠檬酸钠加入比例为2:1。
作为本发明一实施方式的进一步改进,所述低铝莫来石组分含量包括:Al2O3含量为42~45%,Fe2O3含量为0.1~0.7%,K2O+Na2O含量为0.5~1.5%,填充料含量为45~53%。
作为本发明一实施方式的进一步改进,所述低铝莫来石粒度不大于0.075mm,体积密度不大于2.35g/cm3,吸水率小于1.8%。
作为本发明一实施方式的进一步改进,所述萤石粉粒径为0.045mm~0.088mm,所述萤石粉中包括含量不少于95%的CaF2。
为实现上述发明目的之一,本发明一实施方式提供一种铝工业用低密度低蓄热陶瓷纤维浇注料制备方法,应用于上述任一种技术方案所述的铝工业用低密度低蓄热陶瓷纤维浇注料;所述铝工业用低密度低蓄热陶瓷纤维浇注料制备方法包括如下步骤:
S1,将浇注料称重后加入强力搅拌机中进行混合搅拌,得到混合后的干料;
S2,向步骤S1中得到的干料中加入定量的陶瓷纤维散棉,进行二次搅拌,得到混料;
S3,判断步骤S2中得到的混料是否有纤维团;
若有,则增加搅拌时间,直至纤维团消失;
若没有,则进行出料,并将出料后的产品进行封装。
作为本发明一实施方式的进一步改进,所述步骤S1中“将浇注料称重后加入强力搅拌机中进行混合搅拌”,其中混合搅拌时间为3-5分钟。
与现有技术相比,本发明提供的铝工业用低密度低蓄热陶瓷纤维浇注料,应用于铝铸造耐火组件的制造,可以获得低密度、低收缩的耐火组件制成品,在铝水流经的整个过程中蓄热量小、抗热震性优秀,能够降低热能损失、提高耐火组件寿命,降低生产成本;本发明选用低铝莫来石由莫来石针状结晶和高硅氧玻璃相组成,无游离的结晶石英和刚玉晶相存在,热膨胀系数小且均匀,抗热震性很好,具有硬度大、低体积密度、耐磨性好的优点;此外低密度的特点能使耐火浇注料制成品的体积密度降低,降低单位体积的材料重量,起到低蓄热的效果;低膨胀系数的特点特点使材料体系的整体膨胀系数降低,体积稳定性好,抗热震性得到提升。
具体实施方式
以下将结合具体实施方式对本发明进行详细描述。但这些实施方式并不限制本发明,本领域的普通技术人员根据这些实施方式所做出的结构、方法、或功能上的变换均包含在本发明的保护范围内。
实施例1
本发明公开了一种铝工业用低密度低蓄热陶瓷纤维浇注料,包括各组分含量如下:
电熔石英砂45~55%、低铝莫来石20~30%、硅灰5~8%、纯铝酸钙水泥13~15%、萤石粉2~5%、增稠剂0.15-0.2%,减水剂0.2~0.3%,陶瓷纤维散棉8~35%。
具体的,电熔石英砂的粒级包括0.001mm~0.088mm,0.088mm~01mm,0.1mm~0.25mm中的一种或两种以上的组合,当电熔石英砂的粒级为三种时,三种电熔石英砂粒级由小至大的比例为2:1:1。
进一步的,电熔石英膨胀系数低、体积密度适中、纯度高、性能优良,不同粒级的组合可以获理想的堆积体系,能一定程度上提高铝铸造耐火组件的基体强度,硅灰的纯度大于97.0%,白色,非晶质;加入适量比例的硅灰可以提高浇注料的流动性,同时它的自结合特性可以提高耐火组件的强度,优选硅灰的含量为6%。
其中,纯铝酸钙水泥中Al2O3含量≥69.7%,其用来固化浇注料利于成型,同时提高浇注后耐火材料制成品的强度。
进一步的,通过喷吹法将陶瓷纤维散棉喷吹成丝,陶瓷纤维散棉的纤维直径2~3.5微米,优选的纤维直径为3微米。
具体的,陶瓷纤维散棉主晶相为微晶莫来石和高硅氧玻璃,直径大于0.15mm的渣球含量小于5%;陶瓷纤维散棉经强力搅拌后,成为大量长径比不等的针状短纤维,大量的针状短纤维对浇注后的耐火组件强度起到增强作用,同时由于针状短纤维在三维空间的大量分布,形成类似空间网络的结构,在施工中振动成型的激振力停止后立即定形,一定程度的降低了耐火组件的体积密度。
在一种具体示例中,在浇注料施工中,单独加入或以硅溶胶与水的混合液形式加入硅溶胶,浇注料加入硅溶胶或硅溶胶与水的混合液后,经强力搅拌均匀,浇注成型铝铸造耐火材料组件;硅溶胶和水的比例为1~2.5:0~1;优选的,硅溶胶与水的比例为1.5:0.5;加入部分水,一方面可以降低耐火组件制造成本,另一方面可以加速纯铝酸钙水泥的凝固,缩减凝固时间。
进一步的,硅溶胶的PH值为8~10,固含量25~30%,胶团直径为10~20nm;由于胶体粒子微细,具有较大的比表面积,容易吸附在其它物料颗粒表面;硅溶胶粘度很低,水能渗透的地方都能渗透;当硅溶胶水份蒸发时,胶体粒子牢固地附着在其它物料颗粒表面,粒子间形成硅氧结合,可以增强浇注成型后坯体的强度。
进一步的,硅溶胶胶体粒子尺寸为10~20nm。
优选的,硅溶胶胶体粒子尺寸为15nm。
在一种具体示例中,增稠剂为豆儿胶。
具体的,豆儿胶是一种优秀的天然增稠剂,少量的加入会提高浇注料的抗泌水性能,还能改善浇注料体系的均匀性,提高材料的整体均匀性,但是加多了会产生浇注料在施工中粘度过大、流动性差或丧失流动性问题,优选的,豆儿胶加入量为0.17%。
在一种具体示例中,减水剂包括三聚磷酸钠与柠檬酸钠,三聚磷酸钠与柠檬酸钠加入比例为2:1。
进一步的,减水剂包括三聚磷酸钠和柠檬酸钠组合,主要是在确保浇注料施工流动性的条件下,减少加水量和调整凝固时间,优选的,三聚磷酸钠和柠檬酸钠加入比例为2:1。
优选的,减水剂的含量为0.25%。
在一种具体示例中,低铝莫来石组分含量包括:Al2O3含量为42~45%,Fe2O3含量为0.1~0.7%,K2O+Na2O含量为0.5~1.5%,填充料含量为45~53%。
在一种具体示例中,低铝莫来石粒度不大于0.075mm,体积密度不大于2.35g/cm3,吸水率小于1.8%。
进一步的,低铝莫来石由莫来石针状结晶和高硅氧玻璃相组成,无游离的结晶石英和刚玉晶相存在,热膨胀系数小且均匀,抗热震性很好,具有硬度大、低体积密度、耐磨性好的优点;此外低密度的特点能使耐火浇注料制成品的体积密度降低,降低单位体积的材料重量,起到低蓄热的效果;低膨胀系数的特点特点使材料体系的整体膨胀系数降低,体积稳定性好,抗热震性得到提升。
在一种具体示例中,萤石粉粒径为0.045mm~0.088mm,萤石粉中包括含量不少于95%的CaF2。
进一步的,萤石粉粒径为0.045mm~0.088mm,其中CaF2含量≥95%;萤石粉是一种优秀的抗粘铝添加剂,可以显著增加材料的抗粘铝性能,优选的,萤石粉含量为3%。
实施例2
为实现上述发明目的之一,本发明一实施方式提供一种铝工业用低密度低蓄热陶瓷纤维浇注料制备方法,应用于上述任一种技术方案的铝工业用低密度低蓄热陶瓷纤维浇注料;铝工业用低密度低蓄热陶瓷纤维浇注料制备方法包括如下步骤:
S1,将浇注料称重后加入强力搅拌机中进行混合搅拌,得到混合后的干料;
S2,向步骤S1中得到的干料中加入定量的陶瓷纤维散棉,进行二次搅拌,得到混料;
S3,判断步骤S2中得到的混料是否有纤维团;
若有,则增加搅拌时间,直至纤维团消失;
若没有,则进行出料,并将出料后的产品进行封装。
在一种具体示例中,步骤S1中“将浇注料称重后加入强力搅拌机中进行混合搅拌”,其中混合搅拌时间为3-5分钟。
实施例3:
S1,将粒径为0.25~0.1mm,含量为11.25%的电熔石英砂;粒径0.1~0mm,含量11.25%的电容石英砂;粒径0.088mm、含量22.5%的电容石英砂;低铝莫来石29.56%、硅灰5%、纯铝酸钙水泥15%、萤石粉5%、豆儿胶0.2%,减水剂三聚磷酸钠0.16%、柠檬酸钠0.08%按重量比例称重后加入强力搅拌机中,干混合3~5分钟;
S2,加入前述干料总重量的8%的喷吹法陶瓷纤维散棉,再搅拌8-15分钟;
S3,待混合均匀、陶瓷纤维散棉成为不同长径比的针状短纤维时,可以出料;如果混合料中还有纤维团或片,就继续增加搅拌时间,直至合格;出料后,装入防潮的包装袋中,封口,即得低密度、低蓄热陶瓷纤维浇注料。
实施例4:
S1,将粒径0.25~0.1mm,含量12%的电熔石英砂;粒径0.1~0mm,含量12%的电熔石英砂;粒径0.088mm,含量24%的电熔石英砂、低铝莫来石27%、硅灰6.25%、纯铝酸钙水泥14.07%、萤石粉4.23%、豆儿胶0.15%,减水剂三聚磷酸钠0.2%、柠檬酸钠0.1%按重量比例称重后加入强力搅拌机中,干混合3~5分钟;
S2,加入前述干料总重量的25.5%的喷吹法陶瓷纤维散棉,再搅拌8-15分钟;
S3,待混合均匀、陶瓷纤维散棉成为不同长径比的针状短纤维时,可以出料;如果混合料中还有纤维团或片,就继续增加搅拌时间,直至合格;出料后,装入防潮的包装袋中,封口,即得低密度、低蓄热陶瓷纤维浇注料。
实施例5:
S1,将粒径0.25~0.1mm,含量12.75%的电熔石英砂;粒径0.1~0mm,含量12.75%的电熔石英砂;粒径0.088mm,含量25.5%的电熔石英砂;低铝莫来石24.65%、硅灰7.53%、纯铝酸钙水泥13.25%、萤石粉3.15%、豆儿胶0.15%,减水剂三聚磷酸钠0.18%、柠檬酸钠0.09%按重量比例称重后加入强力搅拌机中,干混合3~5分钟;
S2,加入前述干料总重量的33.5%的喷吹法陶瓷纤维散棉,再搅拌8-15分钟;
S3,待混合均匀、陶瓷纤维散棉成为不同长径比的针状短纤维时,可以出料;如果混合料中还有纤维团或片,就继续增加搅拌时间,直至合格;出料后,装入防潮的包装袋中,封口,即得低密度、低蓄热陶瓷纤维浇注料。
实施例6:
S1,将粒径0.25~0.1mm,含量13.75%的电熔石英砂、粒径0.1~0mm,含量13.75%的电熔石英砂;粒径0.088mm,含量27.5%的电熔石英砂;低铝莫来石21.15%、硅灰8%、纯铝酸钙水泥13%、萤石粉2.41%、豆儿胶0.2%,减水剂三聚磷酸钠0.16%、柠檬酸钠0.08%按重量比例称重后加入强力搅拌机中,干混合3~5分钟;
S2,加入前述干料总重量的35%的喷吹法陶瓷纤维散棉,再搅拌8-15分钟;
S3,待混合均匀、陶瓷纤维散棉成为不同长径比的针状短纤维时,可以出料;如果混合料中还有纤维团或片,就继续增加搅拌时间,直至合格;出料后,装入防潮的包装袋中,封口,即得低密度、低蓄热陶瓷纤维浇注料。
将上述实施例3~6获得的陶瓷纤维浇注料,按照各自标准加入硅溶胶或硅溶胶与水的混合液(41.5~62.5%),搅拌混合均匀后,振动浇注成型40×40×160mm尺寸标准试块和抗铝液侵蚀检测标准样杯,依据GB/T 3001-2007测试材料在不同条件下的抗折强度、依据GB/T 5072-2008测试材料在不同条件下的耐压强度、依据GB/T 2997-2000测试材料在不同条件下的体积密度和显气孔率、依据GB/T 5988-2004测试材料在不同条件下的加热线变化,依据YB/T4161-2007(2017)测试材料的抗铝液侵蚀和抗粘铝性能,测试结果如表1所示。
表1
表1中检测结果表明:实施例3-6中,在110℃×24h下的加热线变化率在-0.12~-0.14%,在850℃×3h下的加热线变化率在-0.14~-0.20%,两种条件下线变化率都不大,材料的体积稳定性优秀,抗热震性优秀;
实施实例3-6中,在110℃×24h下的体积密度在1.42~1.78g/cm3,在850℃×3h下的体积密度在1.35~1.73g/cm3,两种条件下体积密度都较小,材料的单位体积重量小,在工作温度下蓄热量较低;
实施例3-6中,在110℃×24h下的耐压强度在21.60~28.40MPa,在850℃×3h下的耐压强度在20.00~23.90Mpa;在110℃×24h下的抗折强度强度在8.00~10.70MPa,在850℃×3h下的耐压强度在8.30~11.00Mpa;材料的各强度指标均能满足铝铸造生产中耐火组件的使用要求。
实施例3-6中,浇注料样杯在850℃×72h下的熔蚀率均为零,抗铝液侵蚀效果较佳,浇注料样杯冷却至常温后均没有铝和杯壁的粘连,抗粘铝性能较佳。
综上所述,本发明提供的铝工业用低密度低蓄热陶瓷纤维浇注料,应用于铝铸造耐火组件的制造,可以获得低密度、低收缩的耐火组件制成品,在铝水流经的整个过程中蓄热量小、抗热震性优秀,能够降低热能损失、提高耐火组件寿命,降低生产成本。
应当理解,虽然本说明书按照实施方式加以描述,但并非每个实施方式仅包含一个独立的技术方案,说明书的这种叙述方式仅仅是为清楚起见,本领域技术人员应当将说明书作为一个整体,各实施方式中的技术方案也可以经适当组合,形成本领域技术人员可以理解的其他实施方式。
上文所列出的一系列的详细说明仅仅是针对本发明的可行性实施方式的具体说明,它们并非用以限制本发明的保护范围,凡未脱离本发明技艺精神所作的等效实施方式或变更均应包含在本发明的保护范围之内。
Claims (5)
1.一种铝工业用低密度低蓄热陶瓷纤维浇注料,其特征在于,包括各组分含量如下:
电熔石英砂45~55%、低铝莫来石20~30%、硅灰5~8%、纯铝酸钙水泥13~15%、萤石粉2~5%、增稠剂0.15-0.2%,减水剂0.2~0.3%,陶瓷纤维散棉8~35%;
所述电熔石英砂的粒级包括0.001mm~0.088mm,0.088mm~01mm,0.1mm~0.25mm中的一种或两种以上的组合;
所述增稠剂为豆儿胶;
所述减水剂包括三聚磷酸钠与柠檬酸钠,所述三聚磷酸钠与柠檬酸钠加入比例为2:1;
所述低铝莫来石组分含量包括:Al2O3含量为42~45%,Fe2O3含量为0.1~0.7%,K2O+Na2O含量为0.5~1.5%,填充料含量为45~53%;
所述低铝莫来石粒度不大于0.075mm,体积密度不大于2.35g/cm3,吸水率小于1.8%;
陶瓷纤维散棉的纤维直径2~3.5微米;
陶瓷纤维散棉主晶相为微晶莫来石和高硅氧玻璃。
2.根据权利要求1所述的铝工业用低密度低蓄热陶瓷纤维浇注料,其特征在于,当所述电熔石英砂的粒级为三种时,三种电熔石英砂粒级由小至大的比例为2:1:1。
3.根据权利要求1所述的铝工业用低密度低蓄热陶瓷纤维浇注料,其特征在于,所述萤石粉粒径为0.045mm~0.088mm,所述萤石粉中包括含量不少于95%的CaF2。
4.一种铝工业用低密度低蓄热陶瓷纤维浇注料制备方法,其特征在于,所述铝工业用低密度低蓄热陶瓷纤维浇注料制备方法应用于权利要求1-3中任一项所述的铝工业用低密度低蓄热陶瓷纤维浇注料;所述铝工业用低密度低蓄热陶瓷纤维浇注料制备方法包括如下步骤:
S1,将浇注料称重后加入强力搅拌机中进行混合搅拌,得到混合后的干料;
S2,向步骤S1中得到的干料中加入定量的陶瓷纤维散棉,进行二次搅拌,得到混料;
S3,判断步骤S2中得到的混料是否有纤维团;
若有,则增加搅拌时间,直至纤维团消失;
若没有,则进行出料,并将出料后的产品进行封装。
5.根据权利要求4所述的铝工业用低密度低蓄热陶瓷纤维浇注料制备方法,其特征在于,所述步骤S1中“将浇注料称重后加入强力搅拌机中进行混合搅拌”,其中混合搅拌时间为3-5分钟。
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