CN116589289A - Acid-resistant castable and preparation method thereof - Google Patents
Acid-resistant castable and preparation method thereof Download PDFInfo
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- CN116589289A CN116589289A CN202310538855.9A CN202310538855A CN116589289A CN 116589289 A CN116589289 A CN 116589289A CN 202310538855 A CN202310538855 A CN 202310538855A CN 116589289 A CN116589289 A CN 116589289A
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- 239000002253 acid Substances 0.000 title claims abstract description 89
- 238000002360 preparation method Methods 0.000 title abstract description 12
- 239000000843 powder Substances 0.000 claims abstract description 64
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 43
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims abstract description 37
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 37
- 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 36
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 33
- 239000010431 corundum Substances 0.000 claims abstract description 33
- 239000004568 cement Substances 0.000 claims abstract description 30
- 239000004927 clay Substances 0.000 claims abstract description 29
- 150000004645 aluminates Chemical class 0.000 claims abstract description 28
- 239000000919 ceramic Substances 0.000 claims abstract description 27
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 20
- 239000000654 additive Substances 0.000 claims abstract description 10
- 230000000996 additive effect Effects 0.000 claims abstract description 10
- 239000000463 material Substances 0.000 claims description 57
- 239000000835 fiber Substances 0.000 claims description 30
- 239000002270 dispersing agent Substances 0.000 claims description 17
- 239000000395 magnesium oxide Substances 0.000 claims description 16
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 16
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 16
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 claims description 16
- 235000019982 sodium hexametaphosphate Nutrition 0.000 claims description 16
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 claims description 16
- 239000000701 coagulant Substances 0.000 claims description 15
- 239000002245 particle Substances 0.000 claims description 13
- 238000003756 stirring Methods 0.000 claims description 13
- 229910052710 silicon Inorganic materials 0.000 claims description 12
- 239000010703 silicon Substances 0.000 claims description 12
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 11
- 238000002156 mixing Methods 0.000 claims description 9
- 239000011230 binding agent Substances 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 7
- 239000007787 solid Substances 0.000 claims description 3
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 claims description 2
- 239000000347 magnesium hydroxide Substances 0.000 claims description 2
- 229910001862 magnesium hydroxide Inorganic materials 0.000 claims description 2
- 239000001509 sodium citrate Substances 0.000 claims description 2
- 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 2
- 235000011083 sodium citrates Nutrition 0.000 claims description 2
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 2
- 239000002699 waste material Substances 0.000 claims description 2
- 230000009286 beneficial effect Effects 0.000 abstract description 3
- 239000007767 bonding agent Substances 0.000 abstract description 2
- 238000005266 casting Methods 0.000 description 21
- 230000000052 comparative effect Effects 0.000 description 14
- 238000001035 drying Methods 0.000 description 12
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 10
- 238000001514 detection method Methods 0.000 description 10
- 238000005260 corrosion Methods 0.000 description 9
- 230000007797 corrosion Effects 0.000 description 9
- 238000010438 heat treatment Methods 0.000 description 8
- 238000010521 absorption reaction Methods 0.000 description 7
- 230000000704 physical effect Effects 0.000 description 7
- 239000002994 raw material Substances 0.000 description 6
- 238000000465 moulding Methods 0.000 description 5
- 239000011819 refractory material Substances 0.000 description 5
- 238000005303 weighing Methods 0.000 description 5
- 238000005299 abrasion Methods 0.000 description 4
- 238000006482 condensation reaction Methods 0.000 description 2
- 230000003628 erosive effect Effects 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 239000004480 active ingredient Substances 0.000 description 1
- CNLWCVNCHLKFHK-UHFFFAOYSA-N aluminum;lithium;dioxido(oxo)silane Chemical compound [Li+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O CNLWCVNCHLKFHK-UHFFFAOYSA-N 0.000 description 1
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- -1 calcium titanate aluminate Chemical class 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 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 description 1
- KPUWHANPEXNPJT-UHFFFAOYSA-N disiloxane Chemical class [SiH3]O[SiH3] KPUWHANPEXNPJT-UHFFFAOYSA-N 0.000 description 1
- 239000003814 drug Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910052850 kyanite Inorganic materials 0.000 description 1
- 239000010443 kyanite Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 239000005543 nano-size silicon particle Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 229910021487 silica fume Inorganic materials 0.000 description 1
- 239000003469 silicate cement Substances 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
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 229910052642 spodumene Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
- C04B2235/3206—Magnesium oxides or oxide-forming salts thereof
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3418—Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
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- C04B2235/44—Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
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- C04B2235/9669—Resistance against chemicals, e.g. against molten glass or molten salts
- C04B2235/9692—Acid, alkali or halogen resistance
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Abstract
The invention discloses an acid-resistant castable and a preparation method thereof. According to the invention, the recycled ceramics, corundum and flint clay are used as acid-resistant aggregate, the silica powder and the activated alumina powder are used as acid-resistant powder, the silica sol is used as a bonding agent, and the aluminate cement, the water and the additive are added on the basis, so that the prepared acid-resistant castable has the advantages of compact structure, high strength, excellent wear resistance, good permeation resistance, high thermal stability, good acid resistance and the like, can meet the use conditions of the lining of equipment, can effectively ensure safe and stable operation of the equipment, and is beneficial to obtaining good economic and social benefits.
Description
Technical Field
The invention relates to an acid-resistant castable and a preparation method thereof, and belongs to the field of refractory materials.
Background
The refractory material may be classified into a shaped refractory material and an unshaped refractory material. The most widely used of the unshaped refractories are castable materials. The castable mainly comprises refractory aggregate, powder, a binding agent and an additive, has higher fluidity, is generally constructed by a pouring method, and can be hardened without heating. However, refractory castable used for inner liners of various towers, furnaces, chimneys and other equipment in the industries of metallurgy, medicine, chemical industry, petroleum and the like can be damaged after being used for a period of time due to the effect of thermal stress and the erosion of acid water vapor.
Patent application publication number CN115180964A discloses a high-strength acid-resistant light castable, which comprises the following components: mullite lightweight aggregate, sintered plate-shaped corundum, acid-resistant filler, flint clay, kyanite, silica micropowder, spodumene, industrial alumina fine powder, high alumina cement, primary high alumina clinker powder, refractory fibers and an additive. The casting material can resist acid corrosion but has poor permeability and is easy to crack after being corroded by water vapor.
Patent application publication number CN112573909A discloses a ceramic abrasive resistance based on nano silica sol, which comprises the following components: wear-resistant aggregate, calcium titanate aluminate, silicon carbide, activated alumina powder, zirconium silica fume, A70 cement, silica sol and an additive. The ceramic wear-resistant material has excellent wear resistance but poor acid resistance, and is damaged too fast when being corroded by acid vapor, so that the service life of equipment is influenced.
Disclosure of Invention
The invention aims to solve the problems, and thus provides an acid-resistant castable. The invention takes reclaimed ceramics, corundum and flint clay as acid-proof aggregate, silica powder and active alumina powder as acid-proof powder, silica sol as bonding agent, and silicate cement, water and admixture are added on the basis. Preparing two formulas by using various materials according to the particle size and the physical properties of the materials, wherein one formula is mainly composed of large and medium particle materials, and the other formula is mainly composed of medium and small particle materials, so that two casting materials which are not suitable for single use are respectively prepared, and then the two casting materials are mixed to prepare the required acid-resistant casting material; the structure of the acid-resistant castable is optimized, and the acid-resistant castable prepared by the method has compact structure, high strength, excellent wear resistance, high thermal stability, good permeation resistance and good acid resistance, and can meet the use conditions of equipment linings, so that safe and stable operation of equipment is effectively ensured.
The technical scheme for solving the problems is as follows:
an acid-resistant castable comprises the following components in parts by weight: 45-75 parts of acid-resistant aggregate, 15-35 parts of acid-resistant powder, 5-10 parts of aluminate cement, 5-15 parts of binding agent, 5-7 parts of water and 3.02-6 parts of additive;
the acid-resistant aggregate is selected from one or more of recycled ceramics, corundum and flint clay;
the acid-resistant powder is one or more selected from silicon micropowder and activated alumina powder;
the binding agent is silica sol;
the additive comprises high temperature resistant fiber, dispersing agent and coagulant.
Preferably, the acid-resistant aggregate comprises the following components:
25-35 parts of granularity of 3-5 mm;
10-20 parts of particles with the granularity of 1-3 mm;
10-20 parts of particles with the granularity of 0.1-1 mm.
Preferably, the acid-resistant powder comprises the following components:
10-20 parts of silicon micropowder;
5-15 parts of active alumina powder.
Preferably, the additive comprises the following components:
3-5 parts of high-temperature resistant fibers;
0.01-0.5 parts of dispersing agent;
0.01-0.5 parts of coagulant.
Preferably, the alumina content of the reclaimed ceramic is greater than 90%.
Preferably, the corundum is sintered corundum.
Preferably, the fine silica powder is made of high siliceous waste powder.
Preferably, the silica sol is SiO 2 The solid content is more than or equal to 40 percent.
Preferably, the dispersing agent is at least one of sodium hexametaphosphate, sodium tripolyphosphate and sodium citrate.
Preferably, the accelerator is at least one of magnesium oxide and magnesium hydroxide.
The recycled ceramics mainly comprise alumina and silicon oxide, and can resist acid corrosion; is a product after high-temperature firing, and has excellent high-temperature resistance and abrasion resistance.
Corundum, the main component of which is alumina, can resist acid corrosion; high melting point and high temperature resistance; the hardness is high, and the wear resistance is high.
The flint clay has the characteristics of high temperature resistance, corrosion resistance and abrasion resistance, and can improve the acid resistance and the abrasion resistance of the acid-resistant castable.
The silicon micropowder can fill gaps among materials; and because the phase remains relatively stable through firing.
The active alumina powder can increase the performances of wear resistance, high temperature resistance, acid resistance and the like of the castable.
Aluminate cement can increase the acid resistance and the wear resistance of the castable.
Silica sol, when used as a castable binder, mainly undergoes a condensation reaction (-Si-oh+ho-Si- = -Si-O-Si- +h) between particles 2 The three-dimensional network structure formed by the O) provides initial strength for the castable, and nano silicon dioxide existing in the silica sol can react with active ingredients in the castable during heat treatment to improve the performance of the castable.
The high-temperature resistant fiber can maintain the general mechanical properties even at high temperature for a long time, is used as a reinforcing material of casting materials, and can enhance the structural strength of the casting materials.
The dispersing agent in the silica sol binder has the function of dispersing around sol particles, and the fluidity of the castable is regulated by increasing the Zeta potential of the matrix in the castable, regulating the distance between colloidal particles and improving the stability of the sol.
Accelerator capable of capturing H on the surface of silica sol particles + Promote the condensation reaction of silicon hydroxyl groups among silica sol particles, accelerate the formation of a siloxane network, promote the condensation speed of casting materials and improve the initial strength.
The preparation method of the acid-resistant castable comprises the following steps:
s1, uniformly stirring recycled ceramics, corundum, flint clay, silica micropowder, activated alumina powder, aluminate cement, water, silica sol, high-temperature resistant fibers, a dispersing agent and a coagulant in a stirrer to obtain a mixed material 1; in the step, the acid-resistant aggregate with the granularity of 0.1-5 mm accounts for 75-90% of the total acid-resistant aggregate, the acid-resistant powder accounts for 15-25% of the total acid-resistant powder, the aluminate cement accounts for 80-95% of the total aluminate cement, the silica sol accounts for 5-15% of the total silica sol, the high-temperature resistant fiber accounts for 70-85% of the total high-temperature resistant fiber, the dispersant accounts for 70-85% of the dispersant, the coagulant accounts for 70-85% of the total coagulant, and the water accounts for 40-60% of the total water;
s2, uniformly stirring corundum, flint clay, silica micropowder, activated alumina powder, aluminate cement, water, silica sol, high-temperature resistant fiber, dispersing agent and coagulant in a stirrer to obtain a mixed material 2; in the step, the dosages of acid-resistant aggregate, acid-resistant powder, aluminate cement, silica sol, high-temperature resistant fiber, dispersing agent, coagulant and water are the rest;
and S3, further uniformly mixing the mixed material 1 and the mixed material 2 to obtain the castable.
In the step S1, the recovered ceramics have a particle size of 3 to 5mm, and the amount of the recovered ceramics is 95% or more of the total amount of the recovered ceramics; the granularity of the corundum is 1-3 mm, and the usage amount of the corundum accounts for 75-85% of the total amount of the corundum; the granularity of the flint clay is 0.1-1 mm, and the usage amount of the flint clay accounts for 45-55% of the total amount of the flint clay; the usage amount of the silicon micro powder is 15-25% of the total amount of the silicon micro powder; the usage amount of the activated alumina powder is 15-25% of the total amount of the activated alumina powder.
The invention has the following beneficial effects:
1. the acid-resistant castable prepared by the invention has compact structure, high strength and excellent wear resistance, and can meet the use conditions of equipment liners;
2. the acid-resistant castable prepared by the invention has high thermal stability and can be attached to equipment when the production temperature is changed;
3. the acid-resistant castable prepared by the invention has low water absorption and good permeation resistance, can prevent the lining of the equipment from cracking, and prolongs the service life of the equipment;
4. the acid-resistant castable prepared by the method has good acid resistance, can resist acid gas erosion, and can effectively ensure safe and stable operation of equipment.
Detailed Description
Example 1
Acid-resistant castable is prepared by weighing the following raw materials in parts by weight: 25 parts of 3-5 mm recycled ceramic, 10 parts of 1-3 mm sintered corundum, 10 parts of 0.1-1 mm flint clay, 15 parts of active alumina powder, 20 parts of silica powder, 10 parts of aluminate cement, 10 parts of silica sol, 6 parts of water, 5 parts of high-temperature fiber, 0.06 part of sodium hexametaphosphate and 0.02 part of magnesium oxide.
The preparation method of the acid-resistant castable comprises the following steps:
s1, taking 25 parts of 3-5 mm recycled ceramic, 8 parts of 1-3 mm sintered corundum, 5 parts of 0.1-1 mm flint clay, 4 parts of silica powder, 3 parts of active alumina powder, 9 parts of aluminate cement, 3 parts of water, 1 part of silica sol, 4 parts of high temperature resistant fiber, 0.05 part of sodium hexametaphosphate and 0.015 part of magnesium oxide, and uniformly stirring in a stirrer to obtain a mixed material 1;
s2, taking 2 parts of 1-3 mm sintered corundum, 5 parts of 0.1-1 mm flint clay, 16 parts of silica micropowder, 12 parts of active alumina powder, 1 part of aluminate cement, 3 parts of water, 9 parts of silica sol, 1 part of high-temperature resistant fiber, 0.01 part of sodium hexametaphosphate and 0.005 part of magnesium oxide, and uniformly stirring in a stirrer to obtain a mixed material 2;
s3, further uniformly mixing the mixed material 1 and the mixed material 2 to obtain a castable;
s4, casting the casting material according to the requirement.
Pouring the castable into a mold with the thickness of 160mm multiplied by 40 mm multiplied by 40 mm, vibrating and molding, curing at normal temperature for 24h, demolding and curing for 24h, drying the castable in an electric furnace for 110 ℃ multiplied by 24 hours and heat-treating for 1100 ℃ multiplied by 3h, and testing physical properties according to GB/T4513.6-2017; acid resistance detection is carried out according to GB/T17401-2008.
The detection result is as follows: 110 ℃ x 24h drying: bulk Density 1.12g/cm 3 The flexural strength is 30.2Mpa, the compressive strength is 170.9Mpa,the volume water absorption rate is 4.2%;1100 ℃ x 3h heat treatment: line change-0.07%; sulfuric acid corrosion resistance: the mass loss ratio was 0.43%.
Example 2
Acid-resistant castable is prepared by weighing the following raw materials in parts by weight: 30 parts of 3-5 mm recycled ceramic, 15 parts of 1-3 mm sintered corundum, 15 parts of 0.1-1 mm flint clay, 10 parts of activated alumina powder, 15 parts of silica powder, 6 parts of aluminate cement, 9 parts of silica sol, 6 parts of water, 5 parts of high-temperature fiber, 0.06 part of sodium hexametaphosphate and 0.02 part of magnesium oxide.
The preparation method of the acid-resistant castable comprises the following steps:
s1, taking 30 parts of 3-5 mm recycled ceramic, 12 parts of 1-3 mm sintered corundum, 7.5 parts of 0.1-1 mm flint clay, 3 parts of silica powder, 2 parts of active alumina powder, 5 parts of aluminate cement, 3 parts of water, 1 part of silica sol, 4 parts of high temperature resistant fiber, 0.05 part of sodium hexametaphosphate and 0.015 part of magnesium oxide, and uniformly stirring in a stirrer to obtain a mixed material 1;
s2, taking 3 parts of 1-3 mm sintered corundum, 7.5 parts of 0.1-1 mm flint clay, 12 parts of silica powder, 8 parts of active alumina powder, 1 part of aluminate cement, 3 parts of water, 8 parts of silica sol, 1 part of high-temperature resistant fiber, 0.01 part of sodium hexametaphosphate and 0.005 part of magnesium oxide, and uniformly stirring in a stirrer to obtain a mixed material 2;
s3, further uniformly mixing the mixed material 1 and the mixed material 2 to obtain a castable;
s4, casting the casting material according to the requirement.
Pouring the castable into a mold with the thickness of 160mm multiplied by 40 mm multiplied by 40 mm, vibrating and molding, curing at normal temperature for 24h, demolding and curing for 24h, drying the castable in an electric furnace at the temperature of 110 ℃ multiplied by 24 hours and heat treating at the temperature of 1100 ℃ multiplied by 3h, and testing physical properties according to GB/T4513.6-2017; acid resistance detection is carried out according to GB/T17401-2008.
The detection result is as follows: 110 ℃ x 24h drying: bulk density 0.95g/cm 3 The flexural strength is 34.6Mpa, the compressive strength is 179.8Mpa, and the volume water absorption rate is 3.3 percent; 1100 ℃ x 3h heat treatment: line change-0.02%; sulfuric acid corrosion resistance: the mass loss ratio was 0.38%.
Example 3
Acid-resistant castable is prepared by weighing the following raw materials in parts by weight: 25 parts of 3-5 mm recycled ceramic, 20 parts of 1-3 mm sintered corundum, 20 parts of 0.1-1 mm flint clay, 5 parts of active alumina powder, 10 parts of silica powder, 10 parts of aluminate cement, 10 parts of silica sol, 6 parts of water, 5 parts of high-temperature fiber, 0.06 part of sodium hexametaphosphate and 0.02 part of magnesium oxide.
The preparation method of the acid-resistant castable comprises the following steps:
s1, taking 25 parts of 3-5 mm recycled ceramic, 16 parts of 1-3 mm sintered corundum, 10 parts of 0.1-1 mm flint clay, 2 parts of silica powder, 1 part of active alumina powder, 9 parts of aluminate cement, 3 parts of water, 1 part of silica sol, 4 parts of high temperature resistant fiber, 0.05 part of sodium hexametaphosphate and 0.015 part of magnesium oxide, and uniformly stirring in a stirrer to obtain a mixed material 1;
s2, taking 4 parts of 1-3 mm sintered corundum, 10 parts of 0.1-1 mm flint clay, 8 parts of silica micropowder, 4 parts of active alumina powder, 1 part of aluminate cement, 3 parts of water, 9 parts of silica sol, 1 part of high-temperature resistant fiber, 0.01 part of sodium hexametaphosphate and 0.005 part of magnesium oxide, and uniformly stirring in a stirrer to obtain a mixed material 2;
s3, further uniformly mixing the mixed material 1 and the mixed material 2 to obtain a castable;
s4, casting the casting material according to the requirement.
Pouring the castable into a mold with the thickness of 160mm multiplied by 40 mm multiplied by 40 mm, vibrating and molding, curing at normal temperature for 24h, demolding and curing for 24h, drying the castable in an electric furnace at the temperature of 110 ℃ multiplied by 24 hours and heat treating at the temperature of 1100 ℃ multiplied by 3h, and testing physical properties according to GB/T4513.6-2017; acid resistance detection is carried out according to GB/T17401-2008.
The detection result is as follows: 110 ℃ x 24h drying: bulk Density 1.09g/cm 3 The flexural strength is 32.1Mpa, the compressive strength is 174.2Mpa, and the volume water absorption is 3.8%;1100 ℃ x 3h heat treatment: line change-0.05%; sulfuric acid corrosion resistance: the mass loss ratio was 0.41%.
Comparative example 1
Acid-resistant castable is prepared by weighing the following raw materials in parts by weight: 30 parts of 3-5 mm recycled ceramic, 15 parts of 1-3 mm sintered corundum, 15 parts of 0.1-1 mm flint clay, 10 parts of activated alumina powder, 15 parts of silica powder, 6 parts of aluminate cement, 9 parts of silica sol, 6 parts of water, 5 parts of high-temperature fiber, 0.06 part of sodium hexametaphosphate and 0.02 part of magnesium oxide.
The preparation method of the acid-resistant castable comprises the following steps:
s1, taking 30 parts of 3-5 mm recycled ceramic, 15 parts of 1-3 mm sintered corundum, 15 parts of 0.1-1 mm flint clay, 5 parts of aluminate cement, 3 parts of water, 1 part of silica sol, 4 parts of high temperature resistant fiber, 0.05 part of sodium hexametaphosphate and 0.015 part of magnesium oxide, and uniformly stirring in a stirrer to obtain a mixed material 1;
s2, taking 15 parts of silica micropowder, 10 parts of activated alumina powder, 1 part of aluminate cement, 3 parts of water, 8 parts of silica sol, 1 part of high-temperature resistant fiber, 0.01 part of sodium hexametaphosphate and 0.005 part of magnesium oxide, and uniformly stirring in a stirrer to obtain a mixed material 2;
s3, further uniformly mixing the mixed material 1 and the mixed material 2 to obtain a castable;
s4, casting the casting material according to the requirement.
Pouring the castable into a mold with the thickness of 160mm multiplied by 40 mm multiplied by 40 mm, vibrating and molding, curing at normal temperature for 24h, demolding and curing for 24h, drying the castable in an electric furnace at the temperature of 110 ℃ multiplied by 24 hours and heat treating at the temperature of 1100 ℃ multiplied by 3h, and testing physical properties according to GB/T4513.6-2017; acid resistance detection is carried out according to GB/T17401-2008.
The detection result is as follows: 110 ℃ x 24h drying: bulk Density 1.23g/cm 3 The flexural strength is 26.8Mpa, the compressive strength is 162.2Mpa, and the volume water absorption rate is 4.5 percent; 1100 ℃ x 3h heat treatment: line change-0.10%; sulfuric acid corrosion resistance: the mass loss ratio was 0.54%.
Comparative example 2
Acid-resistant castable is prepared by weighing the following raw materials in parts by weight: 30 parts of 3-5 mm recycled ceramic, 15 parts of 1-3 mm sintered corundum, 15 parts of 0.1-1 mm flint clay, 10 parts of activated alumina powder, 15 parts of silica powder, 6 parts of aluminate cement, 9 parts of silica sol, 6 parts of water, 5 parts of high-temperature fiber, 0.06 part of sodium hexametaphosphate and 0.02 part of magnesium oxide.
The preparation method of the acid-resistant castable comprises the following steps:
s1, taking 30 parts of 3-5 mm recycled ceramic, 15 parts of 1-3 mm sintered corundum, 15 parts of 0.1-1 mm flint clay, 15 parts of silicon micropowder, 10 parts of active alumina powder, 6 parts of aluminate cement, 5 parts of high-temperature resistant fiber, 0.06 part of sodium hexametaphosphate and 0.02 part of magnesium oxide, and uniformly stirring in a stirrer to obtain a mixed material 1;
s2, adding a mixed material 2 consisting of 6 parts of water and 9 parts of silica sol into the mixed material 1, and uniformly mixing to obtain a castable;
s3, casting the casting material according to the requirement.
Pouring the castable into a mold with the thickness of 160mm multiplied by 40 mm multiplied by 40 mm, vibrating and molding, curing at normal temperature for 24h, demolding and curing for 24h, drying the castable in an electric furnace at the temperature of 110 ℃ multiplied by 24 hours and heat treating at the temperature of 1100 ℃ multiplied by 3h, and testing physical properties according to GB/T4513.6-2017; acid resistance detection is carried out according to GB/T17401-2008.
The detection result is as follows: 110 ℃ x 24h drying: bulk Density 1.35g/cm 3 Flexural strength 23.4Mpa, compressive strength 154.5Mpa, and volume water absorption 4.6%;1100 ℃ x 3h heat treatment: line change-0.14%; sulfuric acid corrosion resistance: the mass loss ratio was 0.68%.
Table 1: comparative table of partial Components of examples 1 to 3 and comparative examples 1 to 2
Table 2: performance comparison Table of examples 1 to 3 and comparative examples 1 to 2
As can be seen from Table 2, after the drying treatment at 110 ℃ for 24 hours, the bulk density, flexural strength and compressive strength of examples 1-3 are all better than those of comparative examples 1-2, and it is demonstrated that the strength and wear resistance of examples 1-3 are better than those of comparative examples 1-2.
As can be seen from Table 2, after the drying treatment at 110 ℃ for 24 hours, the volume water absorption of examples 1-3 is lower than that of the castable of comparative examples 1-2, which indicates that the permeation resistance and compactness of examples 1-3 are better than those of comparative examples 1-2.
As can be seen from Table 2, after heat treatment at 1100 ℃ for 3 hours, the line changes of examples 1 to 3 are better than those of comparative examples 1 to 2, and the heat stability of examples 1 to 3 is better than that of comparative examples 1 to 2.
As can be seen from Table 2, examples 1 to 3 were better in acid resistance than comparative examples 1 to 2.
As can be seen from Table 2, the strength, abrasion resistance, permeation resistance, compactibility, heat stability, acid resistance are all the best in example 2.
Compared with the preparation method of uniformly mixing large-grain-size materials and small-grain-size materials respectively and then preparing casting materials, which is adopted in comparative example 1, and the preparation method of uniformly mixing all solid raw materials and then humidifying materials, which is adopted in comparative example 2, the invention prepares two formulas according to grain size and physical properties of each material, wherein one formula is mainly composed of large-grain-size materials and medium-grain-size materials, the other formula is mainly composed of medium-grain-size materials, two casting materials which are not suitable for single use are respectively prepared, and then the two casting materials are mixed to prepare the required acid-resistant casting materials; the structure of the acid-resistant castable is optimized, so that the structure is more compact, and the performance of the acid-resistant castable is improved.
By combining the comparison data, the acid-resistant castable prepared by the invention has compact structure, high strength, excellent wear resistance, good permeation resistance, high thermal stability and good acid resistance, can well meet the service conditions of equipment linings, can effectively ensure safe and stable operation of equipment, and is beneficial to obtaining good economic and social benefits.
Claims (10)
1. An acid-resistant castable is characterized in that: comprises the following components in parts by weight: 45-75 parts of acid-resistant aggregate, 15-35 parts of acid-resistant powder, 5-10 parts of aluminate cement, 5-15 parts of binding agent, 5-7 parts of water and 3.02-6 parts of additive;
the acid-resistant aggregate is selected from one or more of recycled ceramics, corundum and flint clay;
the acid-resistant powder is one or more selected from silicon micropowder and activated alumina powder;
the binding agent is silica sol;
the additive comprises high temperature resistant fiber, dispersing agent and coagulant.
2. An acid resistant castable according to claim 1, wherein: the acid-resistant aggregate comprises the following components:
25-35 parts of granularity of 3-5 mm;
10-20 parts of particles with the granularity of 1-3 mm;
10-20 parts of particles with the granularity of 0.1-1 mm.
3. An acid resistant castable according to claim 1, wherein: the acid-resistant powder comprises the following components:
10-20 parts of silicon micropowder;
5-15 parts of active alumina powder.
4. An acid resistant castable according to claim 1, wherein: the additive comprises the following components:
3-5 parts of high-temperature resistant fibers;
0.01-0.5 parts of dispersing agent;
0.01-0.5 parts of coagulant.
5. An acid resistant castable according to claim 1, wherein: the content of alumina in the reclaimed ceramic is more than 90%; the corundum is sintered corundum; the silicon micropowder is made from high-siliceous waste powder.
6. An acid resistant castable according to claim 1, wherein: siO of the silica sol 2 The solid content is more than or equal to 40 percent.
7. An acid resistant castable according to claim 1, wherein: the dispersing agent is at least one of sodium hexametaphosphate, sodium tripolyphosphate and sodium citrate.
8. An acid resistant castable according to claim 1, wherein: the coagulant is at least one of magnesium oxide and magnesium hydroxide.
9. The method for preparing the acid-resistant castable according to any one of claims 1 to 8, wherein the method is characterized by comprising the following steps: the method comprises the following steps:
s1, uniformly stirring recycled ceramics, corundum, flint clay, silica micropowder, activated alumina powder, aluminate cement, water, silica sol, high-temperature resistant fibers, a dispersing agent and a coagulant in a stirrer to obtain a mixed material 1; in the step, the acid-resistant aggregate with the granularity of 0.1-5 mm accounts for 75-90% of the total acid-resistant aggregate, the acid-resistant powder accounts for 15-25% of the total acid-resistant powder, the aluminate cement accounts for 80-95% of the total aluminate cement, the silica sol accounts for 5-15% of the total silica sol, the high-temperature resistant fiber accounts for 70-85% of the total high-temperature resistant fiber, the dispersant accounts for 70-85% of the dispersant, the coagulant accounts for 70-85% of the total coagulant, and the water accounts for 40-60% of the total water;
s2, uniformly stirring corundum, flint clay, silica micropowder, activated alumina powder, aluminate cement, water, silica sol, high-temperature resistant fiber, dispersing agent and coagulant in a stirrer to obtain a mixed material 2; in the step, the dosages of acid-resistant aggregate, acid-resistant powder, aluminate cement, silica sol, high-temperature resistant fiber, dispersing agent, coagulant and water are the rest;
and S3, further uniformly mixing the mixed material 1 and the mixed material 2 to obtain the castable.
10. The method for preparing the acid-resistant castable according to claim 9, wherein: in the step S1, the granularity of the recovered ceramic is 3-5 mm, and the usage amount of the recovered ceramic is more than 95% of the total amount of the recovered ceramic; the granularity of the corundum is 1-3 mm, and the usage amount of the corundum accounts for 75-85% of the total amount of the corundum; the granularity of the flint clay is 0.1-1 mm, and the usage amount of the flint clay accounts for 45-55% of the total amount of the flint clay; the usage amount of the silicon micro powder is 15-25% of the total amount of the silicon micro powder; the usage amount of the activated alumina powder is 15-25% of the total amount of the activated alumina powder.
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