CN117658652A - Fiber-reinforced air-hardening refractory mortar and preparation method thereof - Google Patents
Fiber-reinforced air-hardening refractory mortar and preparation method thereof Download PDFInfo
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- CN117658652A CN117658652A CN202311655942.9A CN202311655942A CN117658652A CN 117658652 A CN117658652 A CN 117658652A CN 202311655942 A CN202311655942 A CN 202311655942A CN 117658652 A CN117658652 A CN 117658652A
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- alumina
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- kaolin
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- 238000002360 preparation method Methods 0.000 title claims description 14
- 239000004570 mortar (masonry) Substances 0.000 title abstract description 42
- 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 81
- 239000000835 fiber Substances 0.000 claims abstract description 76
- 239000011449 brick Substances 0.000 claims abstract description 60
- 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 45
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 45
- 239000005995 Aluminium silicate Substances 0.000 claims abstract description 43
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 43
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 43
- 239000000463 material Substances 0.000 claims abstract description 43
- 239000004115 Sodium Silicate Substances 0.000 claims abstract description 42
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims abstract description 42
- 229910052911 sodium silicate Inorganic materials 0.000 claims abstract description 42
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 25
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 25
- 238000000034 method Methods 0.000 claims abstract description 22
- 230000008569 process Effects 0.000 claims abstract description 19
- 239000002994 raw material Substances 0.000 claims abstract description 17
- 239000002002 slurry Substances 0.000 claims description 72
- 239000000843 powder Substances 0.000 claims description 25
- 238000003756 stirring Methods 0.000 claims description 25
- 238000002156 mixing Methods 0.000 claims description 17
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 6
- 229910052710 silicon Inorganic materials 0.000 claims description 6
- 239000010703 silicon Substances 0.000 claims description 6
- 241000233855 Orchidaceae Species 0.000 claims description 3
- 239000004575 stone Substances 0.000 claims description 2
- 239000004927 clay Substances 0.000 claims 1
- 238000010276 construction Methods 0.000 abstract description 21
- 238000007711 solidification Methods 0.000 abstract description 8
- 230000008023 solidification Effects 0.000 abstract description 8
- 230000003993 interaction Effects 0.000 abstract description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 238000004898 kneading Methods 0.000 description 6
- 238000001035 drying Methods 0.000 description 5
- 229910019142 PO4 Inorganic materials 0.000 description 4
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 4
- 239000010452 phosphate Substances 0.000 description 4
- 238000007789 sealing Methods 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 150000004645 aluminates Chemical class 0.000 description 3
- 230000008439 repair process Effects 0.000 description 3
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 239000004568 cement Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 210000001015 abdomen Anatomy 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910001570 bauxite Inorganic materials 0.000 description 1
- 230000002301 combined effect Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005868 electrolysis reaction Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- UPKIHOQVIBBESY-UHFFFAOYSA-N magnesium;carbanide Chemical compound [CH3-].[CH3-].[Mg+2] UPKIHOQVIBBESY-UHFFFAOYSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005554 pickling Methods 0.000 description 1
- 239000004576 sand Substances 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
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
- C04B35/185—Mullite 3Al2O3-2SiO2
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
- C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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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
- C04B2235/44—Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
- C04B2235/442—Carbonates
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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
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/52—Constituents or additives characterised by their shapes
- C04B2235/5208—Fibers
- C04B2235/5216—Inorganic
- C04B2235/522—Oxidic
- C04B2235/5224—Alumina or aluminates
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
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Abstract
The invention provides fiber reinforced air hardening refractory mortar, which is prepared from the following raw materials: 28 to 32 weight parts of mullite brick return material; 10-15 parts of kaolin; 27-35 parts of high aluminum material; 23-34 parts of sodium silicate; 10 to 40 parts by weight of alumina fiber. Compared with the prior art, the fiber reinforced air hardening refractory mortar provided by the invention adopts specific components with specific content to realize better overall interaction, and the obtained fiber reinforced air hardening refractory mortar has better workability, and the bonding time is solidified within 2 minutes at normal temperature; and meets various performance requirements for use as refractory mud: the fiber reinforced air hardening refractory mortar mainly adopts sodium silicate, can be quickly combined with a masonry in the construction process, has normal-temperature flexural strength which can reach 4.0MPa after bonding, has good construction property and can also reduce the thermal conductivity of the mortar after solidification.
Description
Technical Field
The invention relates to the technical field of unshaped refractory materials, in particular to fiber-reinforced air-hardening refractory slurry and a preparation method thereof.
Background
The refractory mortar is a common refractory material and is widely applied to various industrial kilns built by high-alumina bricks; the hot blast stove is used for building furnace top, heat accumulating chamber, combustion chamber, etc. and is used in blast furnace bottom, hearth, furnace belly, furnace waist, etc. and may be also used in repairing furnace top, furnace wall, etc. of industrial furnace.
Refractory slurries can be classified into the following categories depending on the composition and use: (1) silicate-based refractory mortar: the main components of silicate refractory mud are silicate cement and silica sand; the slurry has excellent high temperature resistance and cold and hot circulation resistance, and is suitable for the construction of refractory linings such as high temperature kiln, hearth, chimney and the like. (2) aluminate refractory slurry: the aluminate refractory slurry takes aluminate cement and bauxite as main components; it has excellent fireproof performance and chemical corrosion resistance, and is used in fireproof lining of high temperature railway train, glass kiln and other high temperature equipment. (3) phosphate-based refractory mortar: the components of the phosphate refractory slurry mainly comprise phosphate cement and phosphate ore; the slurry has higher acid corrosion resistance, and is suitable for lining engineering of acid resistant environments such as chemical equipment, pickling tanks, storage tanks and the like. (4) alumina-based refractory mortar: the alumina-based refractory slurry contains alumina as a main component. It has good high temperature resistance and erosion resistance, and is commonly used for lining and repairing high temperature industrial equipment such as metallurgical equipment, aluminum electrolysis cell and the like. In addition to the above main classifications, there are also special refractory slurries, such as silicon carbide-based refractory slurries, magnesium carbide-based refractory slurries, etc., which are selected for use in accordance with specific application requirements and operating environments.
However, the refractory mortar in the prior art has the following technical problems: (1) poor workability and low bonding strength; (2) After the slurry is smeared on the bricks, the bricks are not built, and the slurry can lose the kneading property due to water loss, so that the construction quality defects of uneven brick joints, unsatisfied bricks and the like are caused; the problem of slurry flowing from the brick joints can also occur; (3) Because the slurry is easy to lose water, in the brickwork after being built, the slurry only loosely exists in the brick joints, and the brickwork cannot be bonded into a firm and compact whole; (4) The brick has strength after being dried at 110 ℃, and if the sintering is poor, the slurry is difficult to combine the bricks together well; thus, some countries (such as the United states, japan, etc.) develop air hardening refractory mortar after construction in succession, harden in room temperature, produce certain hardness, heat up and sinter and form firm bond with masonry in use; (5) After kiln construction is completed, cracking phenomenon easily occurs in the drying process of the baking furnace; and (6) the heat conductivity of the common refractory mortar after curing is high.
Disclosure of Invention
In view of the above, the invention aims to provide a fiber-reinforced air-hardening refractory mortar and a preparation method thereof, and the fiber-reinforced air-hardening refractory mortar provided by the invention has better workability and meets various performance requirements for use as a refractory mortar.
The invention provides fiber reinforced air hardening refractory mortar, which is prepared from the following raw materials:
28 to 32 weight parts of mullite brick return material;
10-15 parts of kaolin;
27-35 parts of high aluminum material;
23-34 parts of sodium silicate;
10 to 40 parts by weight of alumina fiber.
Preferably, the aluminum content of the mullite brick return is 54-60 wt%.
Preferably, the kaolin has an aluminum content of 32wt% to 38wt% and a silicon content of 48wt% to 52wt%.
Preferably, the aluminum content of the high aluminum material is 45wt% to 50wt%.
Preferably, the high alumina material is one or more of alumina powder, gangue powder and orchid crystal powder.
Preferably, the length of the alumina fiber is less than or equal to 5mm, and the diameter is less than or equal to 5 mu m.
The invention also provides a preparation method of the fiber-reinforced air hardening refractory slurry, which comprises the following steps:
mixing mullite brick returns, kaolin, high alumina material, sodium silicate and alumina fibers, and stirring to obtain fiber reinforced air hardening refractory slurry.
Preferably, the mixing process specifically comprises the following steps:
adding sodium silicate into a stirrer, adding mullite brick returns, kaolin and high-alumina materials, premixing, and adding alumina fibers to complete the mixing process;
or alternatively, the first and second heat exchangers may be,
adding half of sodium silicate into a stirrer, adding mullite brick returns, kaolin and half of high-alumina materials, premixing, adding the other half of sodium silicate and the other half of alumina powder, uniformly stirring, and adding alumina fibers to complete the mixing process;
or alternatively, the first and second heat exchangers may be,
adding sodium silicate into a stirrer, adding half of kaolin, mullite brick returns and high alumina materials, premixing, adding the other half of kaolin, mullite brick returns and high alumina materials, stirring uniformly, and adding alumina fibers to complete the mixing process.
Preferably, the premixing time is 10 min-30 min.
Preferably, the stirring time is 20 min-30 min.
The invention provides fiber reinforced air hardening refractory mortar, which is prepared from the following raw materials: 28 to 32 weight parts of mullite brick return material; 10-15 parts of kaolin; 27-35 parts of high aluminum material; 23-34 parts of sodium silicate; 10 to 40 parts by weight of alumina fiber. Compared with the prior art, the fiber reinforced air hardening refractory mortar provided by the invention adopts specific components with specific content to realize better overall interaction, and the obtained fiber reinforced air hardening refractory mortar has better workability, and the bonding time is solidified within 2 minutes at normal temperature; and meets various performance requirements for use as refractory mud: the fiber reinforced air hardening refractory mortar mainly adopts sodium silicate, can be quickly combined with a masonry in the construction process, can reach 4.0MPa (according to GB/T22459.4-2022) after normal-temperature flexural strength is bonded, can be applied for construction, repairs cracks of a kiln, improves the mortar strength in the kiln drying process, eliminates hidden danger of cracks, and can also reduce the thermal conductivity of the mortar after solidification.
In addition, the preparation method provided by the invention has the advantages of simple process, mild and easily controlled conditions, easily available raw materials, low cost and wide application prospect.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in conjunction with the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention provides fiber reinforced air hardening refractory mortar, which is prepared from the following raw materials:
28 to 32 weight parts of mullite brick return material;
10-15 parts of kaolin;
27-35 parts of high aluminum material;
23-34 parts of sodium silicate;
10 to 40 parts by weight of alumina fiber.
In the invention, the fiber reinforced air hardening refractory slurry is prepared from raw materials including mullite brick returns, kaolin, high alumina materials, sodium silicate and alumina fibers, preferably from mullite brick returns, kaolin, high alumina materials, sodium silicate and alumina fibers. The sources of the mullite brick feed back, the kaolin, the high alumina material, the sodium silicate and the alumina fiber are not particularly limited, and the mullite brick feed back, the kaolin, the high alumina material, the sodium silicate and the alumina fiber are commercially available products which are well known to those skilled in the art.
In the invention, the aluminum content of the mullite brick return is preferably 54-60 wt%, more preferably 56-58 wt%.
In the invention, the fiber reinforced air hardening refractory slurry comprises 28 to 32 parts by weight of mullite brick return.
In the present invention, the kaolin preferably has an aluminum content of 32wt% to 38wt%, more preferably 34wt% to 36wt%, and a silicon content of 48wt% to 52wt%, more preferably 49wt% to 51wt%. The invention adopts the kaolin with the silicon content, so that the strength of the refractory mortar can be increased.
In the present invention, the fiber-reinforced air-hardening refractory slurry includes 10 to 15 parts by weight of kaolin.
In the invention, the aluminum content of the high aluminum material is preferably 45-50 wt%; the high alumina material is preferably one or more of alumina powder, gangue powder and orchid stone powder, and more preferably alumina powder or gangue powder. In the invention, the high aluminum material can increase aluminum content, and after application (sintering), the high aluminum material forms firm bonding with masonry.
In the present invention, the fiber-reinforced air-hardening refractory slurry includes 27 to 35 parts by weight of a high alumina material.
In the present invention, the sodium silicate can increase the viscosity of the refractory mortar.
In the present invention, the fiber-reinforced air-hardening refractory slurry includes 23 to 34 parts by weight of sodium silicate, more preferably 23 to 31 parts by weight.
In the present invention, the length of the alumina fiber is preferably 5mm or less, and the diameter is preferably 5 μm or less; the alumina fibers can enhance the mud bond strength while reducing the mud thermal conductivity.
In the present invention, the fiber-reinforced air-hardening refractory slurry includes 10 to 40 parts by weight of alumina fiber, more preferably 15 to 25 parts by weight.
In the invention, the mullite brick feed back and the high aluminum material mainly provide aluminum sources; kaolin and sodium silicate primarily provide a source of silicon and increase viscosity; alumina fibers enhance the mud bond strength while reducing the mud thermal conductivity.
The fiber reinforced air hardening refractory mortar provided by the invention adopts specific components with specific content to realize better overall interaction, and the obtained fiber reinforced air hardening refractory mortar has better construction performance, and the bonding time is solidified within 2 minutes at normal temperature; and meets various performance requirements for use as refractory mud: the fiber reinforced air hardening refractory mortar mainly adopts sodium silicate, can be quickly combined with a masonry in the construction process, can reach 4.0MPa (according to GB/T22459.4-2022) after normal-temperature flexural strength is bonded, can be applied for construction, repairs cracks of a kiln, improves the mortar strength in the kiln drying process, eliminates hidden danger of cracks, and can also reduce the thermal conductivity of the mortar after solidification.
The invention also provides a preparation method of the fiber-reinforced air hardening refractory slurry, which comprises the following steps:
mixing mullite brick returns, kaolin, high alumina material, sodium silicate and alumina fibers, and stirring to obtain fiber reinforced air hardening refractory slurry.
In the present invention, the mullite brick return material, kaolin, high alumina material, sodium silicate and alumina fiber are the same as those in the above technical scheme, and will not be described here again.
In the present invention, the mixing process is preferably specifically:
adding sodium silicate into a stirrer, adding mullite brick returns, kaolin and high-alumina materials, premixing, and adding alumina fibers to complete the mixing process;
or alternatively, the first and second heat exchangers may be,
adding half of sodium silicate into a stirrer, adding mullite brick returns, kaolin and half of high-alumina materials, premixing, adding the other half of sodium silicate and the other half of alumina powder, uniformly stirring, and adding alumina fibers to complete the mixing process;
or alternatively, the first and second heat exchangers may be,
adding sodium silicate into a stirrer, adding half of kaolin, mullite brick returns and high alumina materials, premixing, adding the other half of kaolin, mullite brick returns and high alumina materials, stirring uniformly, and adding alumina fibers to complete the mixing process.
In the present invention, the pre-mixing time is preferably 10min to 30min, more preferably 20min; the technical scheme of stirring, which is well known to those skilled in the art, is adopted to ensure that the raw materials are uniformly mixed.
In the present invention, the stirring time is preferably 20 to 30 minutes, more preferably 25 minutes; the technical scheme of stirring, which is well known to those skilled in the art, is also adopted to ensure that the raw materials are uniformly mixed.
The preparation method provided by the invention has the advantages of simple process, mild and easily controlled conditions, easily available raw materials, low cost and wide application prospect.
The invention provides fiber reinforced air hardening refractory mortar, which is prepared from the following raw materials: 28 to 32 weight parts of mullite brick return material; 10-15 parts of kaolin; 27-35 parts of high aluminum material; 23-34 parts of sodium silicate; 10 to 40 parts by weight of alumina fiber. Compared with the prior art, the fiber reinforced air hardening refractory mortar provided by the invention adopts specific components with specific content to realize better overall interaction, and the obtained fiber reinforced air hardening refractory mortar has better workability, and the bonding time is solidified within 2 minutes at normal temperature; and meets various performance requirements for use as refractory mud: the fiber reinforced air hardening refractory mortar mainly adopts sodium silicate, can be quickly combined with a masonry in the construction process, can reach 4.0MPa (according to GB/T22459.4-2022) after normal-temperature flexural strength is bonded, can be applied for construction, repairs cracks of a kiln, improves the mortar strength in the kiln drying process, eliminates hidden danger of cracks, and can also reduce the thermal conductivity of the mortar after solidification.
In addition, the preparation method provided by the invention has the advantages of simple process, mild and easily controlled conditions, easily available raw materials, low cost and wide application prospect.
In order to further illustrate the present invention, the following examples are provided. The raw materials used in the following examples of the present invention are all commercially available; wherein, the aluminum content of the mullite brick return is 56 to 58 weight percent, the aluminum content of the kaolin is 34 to 36 weight percent, and the silicon content is 49 to 51 weight percent.
Example 1
An air hardening refractory slurry formula with the use temperature of 1000℃: 28 weight percent of mullite brick return, 14 weight percent of kaolin, 27 weight percent of alumina powder, 31 weight percent of sodium silicate and 20 percent of alumina fiber by total mass of the raw materials.
The preparation method comprises the following steps: adding sodium silicate into a stirrer according to a certain proportion, adding mullite brick returns, kaolin and alumina powder, stirring for 20min, adding alumina fibers with the length less than or equal to 5mm and the diameter less than or equal to 5 mu m after the slurry is uniformly stirred, stirring for 25min again, and placing the slurry into a barrel for sealing and warehousing after the slurry is uniformly stirred to obtain the fiber reinforced air hardening refractory slurry.
According to tests, the normal-temperature flexural strength is 3.6MPa (according to GB/T22459.4-2022) after bonding, the flexural strength of the slurry is detected, the thermal conductivity after curing is 0.25W/m.K (according to YB/T4130-2005), the moisture in the slurry is protected after fibers are added, the slurry is not easy to dehydrate, exposed parts of brick joints are rapidly solidified under the influence of air, the slurry in the brick joints is still moist, the water content of the slurry is detected within 2 minutes (according to GB/T3007-2006), the slurry has stronger bonding property and kneading property, and the overall appearance of the masonry after construction is clean and attractive.
Example 2
An air hardening refractory slurry formula with the use temperature of 1500℃: 32wt% of mullite brick return, 10wt% of kaolin, 35wt% of alumina powder, 23wt% of sodium silicate and 25% of alumina fiber by total mass of the raw materials.
The preparation method comprises the following steps: firstly adding half of sodium silicate into a stirrer according to a proportion, then adding mullite brick return, kaolin and half of alumina powder, fully stirring for 20min, then sequentially adding the other half of sodium silicate, adding the other half of alumina powder, uniformly stirring the slurry, then adding alumina fibers with the length of less than or equal to 5mm and the diameter of less than or equal to 5 mu m, stirring for 25min again, and after all the alumina fibers are uniformly stirred, placing the slurry into a barrel, sealing the barrel and warehousing to obtain the fiber reinforced air-hardening refractory slurry.
According to tests, the normal-temperature flexural strength is tested to be 2.6MPa (according to GB/T22459.4-2022) after bonding, the thermal conductivity after solidification is 0.28W/m.K (according to YB/T4130-2005), after fibers are added, the moisture in the slurry is protected, the exposed parts of the brick seams are not easy to dehydrate and are rapidly solidified under the influence of air, the slurry in the brick seams is still moist, the moisture content of the slurry is tested to be 33% within 2 minutes after masonry (according to GB/T3007-2006), and the mortar has stronger bonding property and kneading property, and the overall appearance of the masonry after construction is clean and attractive.
Example 3
An air hardening refractory slurry formula capable of being quickly solidified at normal temperature: 28wt% of mullite brick return, 15wt% of kaolin, 27wt% of Shanxi gangue powder, 30wt% of sodium silicate and 15% of alumina fiber by total mass of the raw materials.
The preparation method comprises the following steps: adding sodium silicate into a stirrer according to a proportion, adding half of kaolin, mullite brick returns and Shanxi gangue powder, fully stirring for 20min, adding the other half of kaolin, mullite brick returns and Shanxi gangue powder, uniformly stirring slurry, adding alumina fibers with the length of less than or equal to 5mm and the diameter of less than or equal to 5 mu m, stirring for 25min again, and putting the slurry into a barrel after all the alumina fibers are uniformly stirred, sealing the barrel and warehousing to obtain the fiber-reinforced air-hardening refractory slurry.
According to tests, the normal-temperature flexural strength is 1.9MPa (according to GB/T22459.4-2022) after bonding, the flexural strength of the slurry is detected, the thermal conductivity after curing is 0.25W/m.K (according to YB/T4130-2005), the moisture in the slurry is protected after fibers are added, the slurry is not easy to dehydrate, exposed parts of brick joints are rapidly solidified under the influence of air, the slurry in the brick joints is still moist, the water content of the slurry is detected within 2 minutes after masonry (according to GB/T3007-2006), the slurry has stronger bonding property and kneading property, and the overall appearance of the masonry after construction is clean and attractive.
Comparative example 1
A refractory mortar formulation which can be quickly solidified at normal temperature: 28 weight percent of mullite brick return, 15 weight percent of kaolin, 27 weight percent of Shanxi mullite powder, 30 weight percent of sodium silicate and 15 percent of alumina fiber by total mass of the raw materials.
The preparation method comprises the following steps: adding sodium silicate into a stirrer according to a proportion, adding half of kaolin, mullite brick returns and Shanxi mullite powder, fully stirring for 20min, adding the other half of kaolin, mullite brick returns and Shanxi mullite powder, uniformly stirring slurry, adding alumina fibers with the length of less than or equal to 5mm and the diameter of less than or equal to 5 mu m, stirring for 25min again, and putting the slurry into a barrel for sealing and warehousing after all the alumina fibers are uniformly stirred, thus obtaining refractory slurry.
According to tests, the normal-temperature flexural strength is tested to be 0.6MPa (according to GB/T22459.4-2022) after bonding, the thermal conductivity after solidification is 0.3W/m.K (according to YB/T4130-2005), the moisture in the slurry is protected after fibers are added, but the combined effect of the components is common, the components are easy to dehydrate, exposed parts of the brick joints are rapidly solidified under the influence of air, the slurry in the brick joints is still moist, the water content is tested to be 25% in 2 minutes after construction (according to GB/T3007-2006), the adhesive property and the kneading property are common, and the overall appearance of the constructed masonry is poor.
In conclusion, the fiber reinforced air hardening refractory mortar provided by the invention solves the construction quality defects of uneven and plump brick joints and the like caused by loss of kneading property of the refractory mortar due to water loss during construction; meanwhile, the coating is not required to be dried and hardened at room temperature, so that certain hardness is generated, and the construction period and the cost are reduced; the slurry is not easy to lose water, and the masonry can be bonded into a firm and compact whole in the built masonry; in addition, the slurry has higher hardness after solidification, the service temperature range is lower than 1500 ℃, the slurry strength in the kiln drying process is improved, and the hidden danger of cracks is eliminated; the coating construction can be carried out, and kiln cracks are repaired; and the thermal conductivity of the slurry after solidification can be reduced.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (10)
1. The fiber reinforced air hardening refractory slurry is characterized by being prepared from the following raw materials:
28 to 32 weight parts of mullite brick return material;
10-15 parts of kaolin;
27-35 parts of high aluminum material;
23-34 parts of sodium silicate;
10 to 40 parts by weight of alumina fiber.
2. The fiber reinforced air hardening refractory slurry according to claim 1, wherein the mullite brick return has an aluminum content of 54wt% to 60wt%.
3. The fiber reinforced air hardening refractory slurry according to claim 1, wherein the kaolin clay has an aluminum content of 32 wt.% to 38 wt.% and a silicon content of 48 wt.% to 52 wt.%.
4. The fiber reinforced air hardening refractory slurry according to claim 1, wherein the aluminum content of the high alumina material is 45wt% to 50wt%.
5. The fiber reinforced air hardening refractory slurry according to claim 1, wherein the high alumina material is one or more of alumina powder, gangue powder, and orchid stone powder.
6. The fiber reinforced air hardening refractory slurry of claim 1, wherein the alumina fibers have a length of 5mm or less and a diameter of 5 μm or less.
7. A method of preparing a fiber reinforced air hardening refractory slurry according to any one of claims 1 to 6, comprising the steps of:
mixing mullite brick returns, kaolin, high alumina material, sodium silicate and alumina fibers, and stirring to obtain fiber reinforced air hardening refractory slurry.
8. The preparation method according to claim 7, wherein the mixing process is specifically:
adding sodium silicate into a stirrer, adding mullite brick returns, kaolin and high-alumina materials, premixing, and adding alumina fibers to complete the mixing process;
or alternatively, the first and second heat exchangers may be,
adding half of sodium silicate into a stirrer, adding mullite brick returns, kaolin and half of high-alumina materials, premixing, adding the other half of sodium silicate and the other half of alumina powder, uniformly stirring, and adding alumina fibers to complete the mixing process;
or alternatively, the first and second heat exchangers may be,
adding sodium silicate into a stirrer, adding half of kaolin, mullite brick returns and high alumina materials, premixing, adding the other half of kaolin, mullite brick returns and high alumina materials, stirring uniformly, and adding alumina fibers to complete the mixing process.
9. The method of claim 8, wherein the pre-mixing time is from 10 minutes to 30 minutes.
10. The method according to claim 7, wherein the stirring time is 20 to 30 minutes.
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| CN202311655942.9A CN117658652A (en) | 2023-12-05 | 2023-12-05 | Fiber-reinforced air-hardening refractory mortar and preparation method thereof |
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