CN117700245A - Flexible refractory concrete and application thereof - Google Patents
Flexible refractory concrete and application thereof Download PDFInfo
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- CN117700245A CN117700245A CN202311724651.0A CN202311724651A CN117700245A CN 117700245 A CN117700245 A CN 117700245A CN 202311724651 A CN202311724651 A CN 202311724651A CN 117700245 A CN117700245 A CN 117700245A
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- 239000004744 fabric Substances 0.000 claims abstract description 87
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- 239000000919 ceramic Substances 0.000 claims abstract description 35
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- 239000000843 powder Substances 0.000 claims description 67
- 239000002245 particle Substances 0.000 claims description 34
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 32
- 238000010276 construction Methods 0.000 claims description 30
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 25
- 239000004568 cement Substances 0.000 claims description 23
- 238000005507 spraying Methods 0.000 claims description 19
- 239000011449 brick Substances 0.000 claims description 18
- 238000010438 heat treatment Methods 0.000 claims description 18
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 17
- 239000000395 magnesium oxide Substances 0.000 claims description 16
- 239000002699 waste material Substances 0.000 claims description 16
- 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 description 11
- 229910052863 mullite Inorganic materials 0.000 claims description 11
- 235000019353 potassium silicate Nutrition 0.000 claims description 11
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 11
- 239000004927 clay Substances 0.000 claims description 10
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 claims description 9
- 229910052850 kyanite Inorganic materials 0.000 claims description 9
- 239000010443 kyanite Substances 0.000 claims description 9
- 238000000034 method Methods 0.000 claims description 9
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 claims description 8
- 239000000701 coagulant Substances 0.000 claims description 8
- 239000002994 raw material Substances 0.000 claims description 8
- 239000007787 solid Substances 0.000 claims description 8
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical group C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 7
- NACUKFIFISCLOQ-UHFFFAOYSA-N [Mg].[Cr] Chemical compound [Mg].[Cr] NACUKFIFISCLOQ-UHFFFAOYSA-N 0.000 claims description 7
- 239000011734 sodium Substances 0.000 claims description 7
- 229910052708 sodium Inorganic materials 0.000 claims description 7
- 238000004873 anchoring Methods 0.000 claims description 6
- 239000011651 chromium Substances 0.000 claims description 5
- 238000012423 maintenance Methods 0.000 claims description 5
- 239000002002 slurry Substances 0.000 claims description 5
- 239000000853 adhesive Substances 0.000 claims description 4
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- 230000008439 repair process Effects 0.000 claims description 4
- 239000000377 silicon dioxide Substances 0.000 claims description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 3
- 238000004140 cleaning Methods 0.000 claims description 3
- 230000000149 penetrating effect Effects 0.000 claims description 3
- 239000007921 spray Substances 0.000 claims description 3
- 229910052726 zirconium Inorganic materials 0.000 claims description 3
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- 229910052804 chromium Inorganic materials 0.000 claims description 2
- 239000003595 mist Substances 0.000 claims description 2
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- 239000002344 surface layer Substances 0.000 claims description 2
- 238000010304 firing Methods 0.000 claims 1
- 239000011819 refractory material Substances 0.000 abstract description 6
- 229910052782 aluminium Inorganic materials 0.000 description 10
- 238000005245 sintering Methods 0.000 description 8
- 150000004645 aluminates Chemical class 0.000 description 6
- 229910001570 bauxite Inorganic materials 0.000 description 6
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 5
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Abstract
The invention belongs to the technical field of refractory materials, and discloses flexible refractory concrete and application thereof. The flexible refractory concrete comprises an upper layer, a main material layer and a bottom layer from top to bottom in sequence; the upper layer and the bottom layer are ceramic fiber cloth which are arranged in parallel, two groups of glass fiber cloth which are inclined forwards and reversely are arranged between the upper layer and the bottom layer, and the intersecting line of the glass fiber cloth and the bottom layer is parallel to the length direction of the bottom layer; the two groups of glass fiber cloth are distributed in a crossed manner, the main material layer is divided into grids, refractory concrete is filled in the grids, ceramic fiber cloth is arranged at through holes at two ends of the grids to serve as inclined plane sealing openings, and the cross section of the sealing openings, which is perpendicular to the length direction of the flexible refractory concrete structure, is in a parallelogram or isosceles trapezoid shape. The flexible refractory concrete is a ceramic fiber blanket in appearance, the refractory concrete is filled in the inner grid, and uniform water guide is realized through the design of the inner structure, so that excellent strength and service life are obtained in application.
Description
Technical Field
The invention belongs to the technical field of refractory materials, and particularly relates to flexible refractory concrete and application thereof.
Background
The refractory concrete furnace lining used in high-temperature industrial kiln and equipment is mostly formed by transporting unshaped refractory materials to the site, and spraying or pouring construction is carried out after uniform stirring. The unshaped refractory material can segregate due to vibration during transportation; the stirring is needed on site, and the dust is too large to pollute the environment; and the casting material construction needs formwork supporting maintenance and form stripping, the working procedure is complex, and the time is long.
In the field of construction materials, cement carpets have been developed as construction materials for similar problems. The cement blanket is a reticular structure which is generally composed of a top layer, a bottom layer and a connecting layer, cement-based dry powder is filled in a cavity between the bottom layer and the top layer, and the cement blanket is solidified when meeting water after being constructed, so that a concrete-like structure is formed. However, the following problems exist when the structure is used in the field of refractory materials: firstly, the material of the cement blanket is not high-temperature resistant; secondly, the refractory material must have enough thickness to ensure safe use, and the existing structure can have the problem of uneven water guide after the thickness is increased, thereby affecting the hydration of the material and finally affecting the strength and the service life of the material.
Disclosure of Invention
The invention aims to solve the technical problems of the prior art, and provides flexible refractory concrete and application thereof, wherein the appearance of the flexible refractory concrete is a ceramic fiber blanket, the refractory concrete is filled in an internal grid, and uniform water guide is realized through the design of an internal structure, so that excellent strength and service life are obtained in application.
In order to solve the technical problem, the invention provides the flexible refractory concrete which comprises an upper layer, a main material layer and a bottom layer from top to bottom in sequence; the upper layer and the bottom layer are ceramic fiber cloth which are arranged in parallel, two groups of glass fiber cloth which are inclined forwards and reversely are arranged between the upper layer and the bottom layer, and the intersecting line of the glass fiber cloth and the bottom layer is parallel to the length direction of the bottom layer; the two groups of glass fiber cloth are distributed in a crossed manner, the main material layer is divided into grids, refractory concrete is filled in the grids, ceramic fiber cloth is arranged at through holes at two ends of the grids to serve as inclined plane sealing openings, and the cross section of the sealing openings, which is perpendicular to the length direction of the flexible refractory concrete structure, is in a parallelogram or isosceles trapezoid shape.
In the scheme, the ceramic fiber cloth is woven by one or more of aluminum silicate refractory fibers, zirconium-containing aluminum silicate refractory fibers and chromium-containing aluminum silicate refractory fibers.
In the scheme, the ceramic fiber cloth can enable water to smoothly pass through.
In the scheme, the thicknesses of the upper layer and the bottom layer are less than or equal to 3mm, and are preferably 0.5-1.5 mm.
In the scheme, the high alumina cement dry powder is filled in the fiber framework gaps of the ceramic fiber cloth of the upper layer and the bottom layer.
In the above scheme, the glass fiber cloth is silica glass fiber cloth or quartz glass fiber cloth.
Further, when the temperature of the application scene is lower than 1000 ℃, the glass fiber cloth is selected from high silica glass fiber cloth or quartz glass fiber cloth; when the temperature of the application scene is 1000 ℃ or above, the glass fiber cloth is quartz glass fiber cloth.
In the scheme, the thickness of the glass fiber cloth is less than or equal to 0.5mm, preferably 0.3-0.5 mm.
In the scheme, the mesh size of the glass fiber cloth is 0.2-0.8 mm.
In the scheme, the intersection angle of the glass fiber cloth and the bottom layer is 30-60 degrees.
In the scheme, the glass fiber cloth is arranged in the same group at equal intervals in parallel, the distance between two adjacent glass fiber cloth blocks is 10-50 mm, and the projections of the two adjacent glass fiber cloth blocks on the bottom layer are partially overlapped.
In the scheme, the refractory concrete comprises the following raw materials in percentage by mass: 45-55% of high-alumina particles with the particle size of 1-3 mm, 10-25% of high-alumina particles with the particle size of 0.1-1 mm, 10-15% of sintered mullite fine powder, 5-10% of alumina powder, 2-5% of kyanite powder, 2-6% of raw clay powder, 1-5% of waste magnesium-chromium brick powder, 1-5% of light burned magnesia powder and 2-8% of silica micropowder, wherein the sum of the mass percentages of the raw materials is 100%, and 4-8% of a bonding agent and 0-1% of a coagulant are added.
Further, al of the high-alumina particles 2 O 3 The content is 55 to 75 percent, fe 2 O 3 The content is less than 1.5%.
Further, the sintered mullite fine powder is Al 2 O 3 The content is 50 to 72 percent, fe 2 O 3 The content is less than 1 percent, and the grain diameter is less than or equal to 0.1mm.
Further, al of the alumina powder 2 O 3 The content is more than 99 percent, and the grain diameter is less than or equal to 325 meshes.
Further, the kyanite powder is Al 2 O 3 The content is 52-58%, and the grain diameter is less than or equal to 200 meshes.
Further, the raw clay powder is Al 2 O 3 The content is 26-35%, siO 2 The content is 45-54%, and the grain diameter is less than or equal to 200 meshes.
Further, the Cr of the waste magnesium-chromium brick powder 2 O 3 The content is 8-20%, the MgO content is 40-60%, and the grain diameter is less than or equal to 200 mesh.
Further, the MgO content of the light burned magnesia powder is 92-97%, and the grain size is less than or equal to 200 meshes.
Further, siO of the silicon micropowder 2 The content is 95-98%, and the median diameter D 50 ≤10μm。
Further, the binding agent is solid water glass with the modulus of 2.0-2.5.
Further, the coagulant is sodium fluosilicate, and the grain diameter is less than or equal to 200 meshes.
In the scheme, the thickness of the flexible refractory concrete is 20-150 mm.
The invention also provides application of the flexible refractory concrete, which can be used for the integral construction of the inner lining of the thermal equipment such as a high-temperature tunnel kiln, a heating furnace, a belt roasting machine, a shuttle kiln, a bell jar kiln, a blast furnace granulating tower and the like, and the repair of the inner lining of the thermal equipment such as the shuttle kiln, the bell jar kiln, the blast furnace granulating tower and the like.
In the above scheme, the application method specifically includes the following steps:
1) Cleaning the construction surface and controlling the temperature of the construction surface;
2) Fixing and paving the flexible refractory concrete on a construction surface by using anchoring pieces or fiber adhesives;
3) Spraying water on the surface of the upper layer of the flexible refractory concrete in a mist manner, transversely diffusing the water along the ceramic fiber cloth, penetrating the water to the main material layer through gaps of the ceramic fiber cloth, and simultaneously guiding the water to the deep layer of the flexible refractory concrete through glass fiber cloth until a small amount of slurry seeps out from the bottom layer of the flexible refractory concrete;
4) After the refractory concrete is initially set, uniformly spraying a layer of high alumina cement fine powder on the upper surface of the flexible refractory concrete, and spraying water to the upper surface fiber to saturate the water, so that the high alumina cement on the surface layer is permeated into the ceramic fiber cloth;
5) Standing for maintenance, heating for baking, and putting into use after baking is finished.
Further, the temperature of the working surface is 10 to 30 ℃, preferably 20 to 25 ℃.
Further, when the temperature of the construction surface is too low, auxiliary heating is carried out on the construction surface; when the temperature of the construction surface is too high, the construction surface is flushed or forced ventilation and cooling are carried out.
Further, the flexible refractory concrete can be cut or continuously paved during paving; cutting along the oblique direction of the glass fiber cloth when cutting along the length direction; when the flexible refractory concrete is continuously paved, two adjacent flexible refractory concrete blocks are mutually spliced by the inclined planes in the width direction or the inclined planes after being cut in the length direction, so that the vertical through seams or the protrusions during overlapping and lapping are avoided.
Further, the water temperature of the atomized water spray is 20-50 ℃, preferably 40-50 ℃, which is favorable for dissolving and infiltrating the concrete mixture by using water glass.
Further, in step 4), if the upper layer surface fiber dries within 1h after spraying water, the attached cement paste turns white, spraying water again to saturate the upper layer surface fiber with water.
Furthermore, the initial setting time of the refractory concrete is 0.5-2 hours when no coagulant is added, so that higher strength can be obtained; when the time is urgent, the initial setting time can be adjusted to be 10-30 min by using the coagulant, and when the initial setting time is less than 10min, the conditions of uneven water glass infiltration and dry material inclusion can occur in the interior.
Further, standing and curing are carried out for at least 24 hours after the refractory concrete is molded.
Further, the baking schedule is: when the temperature of the application scene is higher than 540 ℃, uniformly heating to 105 ℃ for 2-5 hours, preserving heat for 2-5 hours, heating to 540-600 ℃ within 4 hours, preserving heat for 2-5 hours to remove crystal water, and then rapidly heating to the application scene using temperature to be put into normal use; when the temperature of the application scene is less than 540 ℃, after the heat preservation at 105 ℃ is finished, the temperature is directly increased to the use temperature of the application scene, and the normal use is realized.
In the scheme, the compressive strength of the flexible refractory concrete after baking is more than or equal to 5MPa, the compressive strength after baking at 1400 ℃ for 3 hours is more than or equal to 20MPa, the linear change rate at 1400 ℃ for 3 hours is less than or equal to-0.5%, and the air cooling thermal shock stability at 1100 ℃ is more than 100 times.
Compared with the prior art, the invention has the beneficial effects that:
1) The appearance of the flexible refractory concrete is a ceramic fiber blanket, the refractory concrete is filled in grids formed by glass fiber cloth inside, glass fiber cloth which is obliquely crossed and partially overlapped in the vertical projection direction is used for enabling any section of the flexible concrete to be distributed with the glass fiber cloth, so that the effect of uniform water guide is achieved; meanwhile, the glass fiber cloth also plays a role of reinforcing ribs at low temperature, and serves as a lower melting point substance at high temperature to play a role of a sintering agent so as to promote sintering of the material.
2) The gaps between the ceramic fiber cloths of the upper layer and the bottom layer of the flexible refractory concrete are filled and hardened by high alumina cement, so that the strength and the wear resistance of the surface are enhanced, the applicable temperature range and the application position range are widened, and the service life of the fibers is prolonged under the condition of no sintering at medium and low temperatures; along with the temperature rise, the refractory concrete, the refractory ceramic fiber and the glass fiber are sintered together, and the refractory ceramic fiber becomes the reinforcing fiber of the sintered product.
3) In the invention, firstly, waste magnesia-chrome brick powder and raw clay powder are added as sintering agents, and light burned magnesia powder and MgO are added to inhibit Al in the component design of refractory concrete 2 O 3 Form large grains, and Cr 3+ With Al 3+ Similar structure, can form continuous solid solution, causes lattice distortion, thereby promoting sintering, and simultaneously, mgO can be combined with Al 2 O 3 And Cr (V) 2 O 3 Forming a spinel structure, generating certain volume expansion, compensating sintering shrinkage of the material, and keeping the overall volume stability; secondly, alumina powder is added to react with silicon dioxide in the glass fiber cloth at high temperature to generate mullite phase, and the mullite phase is distributed along the glass fiber cloth to form a grid structure, so that the strength of the material is improved; thirdly, adding water glass and cement slurry formed by high alumina cement in gaps of a fiber framework of ceramic fiber cloth when meeting water into the repairing material to promote the solidification of the water glass to generate early strength; fourthly, the refractory concrete is sealed in the small cells, and the fixed shape can not consider the influence of concrete slump and flow value, so that the addition of various additives is reduced, the cost is obviously reduced, and the influence of the addition of low-melting-point substances on the refractory performance can be reduced.
4) According to the invention, the glass fiber cloth is obliquely crossed to form the small lattices, and the refractory concrete is uniformly stirred and then filled into the small lattices to form the independent packaging units, so that the problem of material segregation in the transportation process is effectively avoided; when the construction method is used, the oblique glass fiber cloth is cut or spliced, so that complicated procedures such as formwork erecting and removing are reduced, the construction is quick, and meanwhile, vertical through seams during splicing or protrusions caused by overlapping and lapping are effectively avoided, and the construction surface is good in integrity.
Drawings
FIG. 1 is a schematic cross-sectional view of the flexible refractory concrete of example 1 of the present invention along the length direction after being cut out of glass fiber cloth.
Fig. 2 is a side view of the flexible refractory concrete of example 1 of the present invention.
In the figure: 1. an upper layer; 2. a main material layer; 3. a bottom layer; 4. glass fiber cloth; 5. a grid; 6. and (5) sealing by an inclined plane.
Detailed Description
For a better understanding of the present invention, the following examples are further illustrated, but are not limited to the following examples.
Example 1
As shown in fig. 1 and 2, a flexible refractory concrete comprises an upper layer 1, a main material layer 2 and a bottom layer 3 from top to bottom; the upper layer 1 and the bottom layer 3 are water permeable ceramic fiber cloth woven by zirconium-containing aluminum silicate refractory fibers which are arranged in parallel, and CA50 aluminate cement dry powder is filled in the gaps of the fiber framework of the ceramic fiber cloth; two groups of quartz glass fiber cloth 4 with the mesh size of 0.5mm, which are inclined forwards and reversely, are arranged between the upper layer 1 and the bottom layer 3, the intersecting line of the glass fiber cloth 4 and the bottom layer 3 is parallel to the length direction of the bottom layer 3, and the intersecting angle of the glass fiber cloth 4 and the bottom layer 3 is 45 degrees; the glass fiber cloth 4 in the same group is arranged in parallel at equal intervals, the distance between two adjacent blocks is 50mm, and the projections of the two adjacent blocks on the bottom layer are partially overlapped; two groups of glass fiber cloth 4 are distributed in a crossed way, the main material layer 2 is divided into grids 5, refractory concrete is filled in the grids 5, water-permeable ceramic fiber cloth is arranged at the through holes at two ends of the grids 5 to serve as inclined plane seals 6, and the cross section of the sealed glass fiber cloth, which is perpendicular to the length direction of the flexible refractory concrete structure, presents an isosceles trapezoid; the thickness of the upper layer 1, the bottom layer 3 and the inclined surface seal 6 is 1mm, the thickness of the glass fiber cloth is 0.3mm, and the thickness of the final flexible refractory concrete is 120mm.
The refractory concrete in the embodiment comprises the following raw materials in percentage by mass: 50% of high-aluminum waste brick particles with the particle size of 1-3 mm, 20% of high-aluminum bauxite particles with the particle size of 0.1-1 mm, 10% of sintered mullite powder with the particle size of less than or equal to 0.1mm and alpha-alumina with the particle size of less than or equal to 325 meshes5% of powder, 3% of kyanite powder with the grain size less than or equal to 200 meshes, 2% of raw clay powder with the grain size less than or equal to 200 meshes, 3% of waste magnesia chrome brick powder with the grain size less than or equal to 200 meshes, 1% of light burned magnesia powder with the grain size less than or equal to 200 meshes and the median grain size D 50 Silicon micropowder 6% of 5 μm, and additionally 5% of solid water glass and 0.24% of sodium fluorosilicate by total mass of the above raw materials.
Wherein, al of the high-aluminum waste brick particles 2 O 3 The content is 70%, fe 2 O 3 The content is less than 1.5 percent; al of high bauxite particles 2 O 3 The content is 70%, fe 2 O 3 The content is less than 1.5 percent; sintering Al of mullite fine powder 2 O 3 The content is 70%, fe 2 O 3 The content is less than 1 percent; al of alpha-alumina powder 2 O 3 The content is 99.3 percent; al of kyanite powder 2 O 3 The content is 55%; al of raw clay powder 2 O 3 The content is 35%, siO 2 The content is 46%; cr of waste magnesium-chromium brick powder 2 O 3 The content is 12 percent, and the MgO content is 50 percent; mgO content of the light burned magnesia powder is 95%; siO of silicon micropowder 2 The content is 96%; the modulus of the solid water glass is 2; the grain size of the sodium fluosilicate is less than or equal to 200 meshes.
The preparation and use method of the refractory concrete comprises the following steps: mixing sintered mullite fine powder, alpha-alumina powder, kyanite powder, raw clay powder, waste magnesium-chromium brick powder, light burned magnesia powder, silicon micropowder, solid water glass and sodium fluosilicate uniformly, and then adding high-aluminum waste brick particles and high-aluminum bauxite particles to mix uniformly to obtain refractory concrete; and filling the refractory concrete into the grids 5 from the through holes at the two ends of the grids 5, sealing the grids 5, and respectively spraying a layer of CA50 aluminate cement on the outer surfaces of the upper layer 1 and the bottom layer 3 to obtain the flexible refractory concrete.
The flexible refractory concrete of the embodiment is applied to repairing a shuttle kiln lining, and comprises the following steps of:
1) After the shuttle kiln is stopped, the kiln car is pulled out and cooled to 30 ℃, a cutting machine and an air pick are used for cleaning the nodulation and damage cracking parts of the kiln lining, a construction surface is cleaned, and a high-pressure air gun is used for blowing, so that dust and residues are cleaned;
2) Cutting or continuously paving the flexible refractory concrete according to the shape and the size of the construction surface to enable the shape and the size of the flexible refractory concrete to be matched with the construction surface, coating the bottom layer of the flexible refractory concrete with a fiber adhesive, and conveying the flexible refractory concrete to the construction surface by using a mechanical arm to fixedly pave the flexible refractory concrete;
3) Spraying 40 ℃ warm water on the upper layer of the flexible refractory concrete by using a spray can, wherein water is transversely diffused along the ceramic fiber cloth, permeates into the main material layer through gaps of the ceramic fiber cloth, and is simultaneously drained through the glass fiber cloth to deeply diffuse into the flexible refractory concrete until a small amount of slurry seeps out from the bottom layer of the flexible refractory concrete;
4) After the refractory concrete is initially set for 30min, uniformly spraying a layer of CA50 aluminate cement fine powder on the upper surface of the flexible refractory concrete, and spraying water to the upper surface fiber to saturate the water so that the surface high alumina cement permeates into the ceramic fiber cloth;
5) Standing and curing for 24 hours after the refractory concrete is formed, heating and baking, heating to 110 ℃ uniformly for 2 hours, preserving heat for 2 hours, heating to 560 ℃ within 4 hours, preserving heat for 2 hours to remove crystal water, and heating to the kiln use temperature rapidly, so that the refractory concrete can be put into normal use.
The construction time of the invention is counted from the temperature reduction to 30 ℃, the time is about 2 days, the formwork is not required to be opened, the maintenance time is short, and the construction time is saved by 3-5 days compared with the construction using casting materials or spraying materials.
According to detection, the volume density of the baked flexible refractory concrete of the embodiment is 2.62g/cm 3 The method comprises the steps of carrying out a first treatment on the surface of the The compressive strength after baking is 11.3MPa; the compressive strength after being burned for 3h at 1500 ℃ is 30.5MPa, the linear change rate of 3h at 1400 ℃ is-0.2%, the linear change rate of 3h at 1500 ℃ is-0.4%, and the air cooling thermal shock stability at 1100 ℃ is more than 100 times, thereby meeting the service requirement of the lining of the industrial kiln.
Example 2
A flexible refractory concrete comprises an upper layer 1, a main material layer 2 and a bottom layer 3 from top to bottom; the upper layer 1 and the bottom layer 3 are water permeable ceramic fiber cloth woven by aluminum silicate refractory fibers arranged in parallel, and CA50 aluminate cement dry powder is filled in the gaps of the fiber framework of the ceramic fiber cloth; two groups of high silica glass fiber cloth 4 with the mesh size of 0.4mm, which are inclined forwards and reversely, are arranged between the upper layer 1 and the bottom layer 3, the intersecting line of the glass fiber cloth 4 and the bottom layer 3 is parallel to the length direction of the bottom layer 3, and the intersecting angle of the glass fiber cloth 4 and the bottom layer 3 is 60 degrees; the glass fiber cloth 4 in the same group is arranged in parallel at equal intervals, the distance between two adjacent blocks is 40mm, and the projections of the two adjacent blocks on the bottom layer are partially overlapped; two groups of glass fiber cloth 4 are distributed in a crossed way, the main material layer 2 is divided into grids 5, refractory concrete is filled in the grids 5, water-permeable ceramic fiber cloth is arranged at the through holes at two ends of the grids 5 to serve as inclined plane seals 6, and the cross section of the sealed glass fiber cloth, which is perpendicular to the length direction of the flexible refractory concrete structure, presents an isosceles trapezoid; the thickness of the upper layer 1, the bottom layer 3 and the inclined surface sealing 6 is 1.5mm, the thickness of the glass fiber cloth is 0.5mm, and the thickness of the final flexible refractory concrete is 80mm.
The refractory concrete in the embodiment comprises the following raw materials in percentage by mass: 52% of high aluminum waste brick particles with the particle size of 1-3 mm, 8% of high aluminum bauxite particles with the particle size of 0.1-1 mm, 10% of sintered mullite powder with the particle size of less than or equal to 0.1mm, 6% of alumina powder with the particle size of less than or equal to 325 meshes, 2% of kyanite powder with the particle size of less than or equal to 200 meshes, 3% of raw clay powder with the particle size of less than or equal to 200 meshes, 2% of waste magnesium-chromium brick powder with the particle size of less than or equal to 200 meshes, 2% of light burned magnesia powder with the particle size of less than or equal to 200 meshes, and D of median particle size 50 5% of 5 μm silica fume, and in addition 7% of solid water glass and 0.3% of sodium fluosilicate by total mass of the above raw materials.
Wherein, al of the high-aluminum waste brick particles 2 O 3 The content is 55%, fe 2 O 3 The content is less than 1.5 percent; al of high bauxite particles 2 O 3 The content is 55%, fe 2 O 3 The content is less than 1.5 percent; sintering Al of mullite fine powder 2 O 3 The content is 55%, fe 2 O 3 The content is less than 1 percent; al of alumina powder 2 O 3 The content is 99.2 percent; al of kyanite powder 2 O 3 The content is 56%; al of raw clay powder 2 O 3 The content is 32%, siO 2 The content is 50%; cr of waste magnesium-chromium brick powder 2 O 3 10% of MgO and 56%; mgO content of the light burned magnesia powder is 92%; siO of silicon micropowder 2 The content is 97%; solid waterThe modulus of the glass is 2.3; the grain size of the sodium fluosilicate is less than or equal to 200 meshes.
The preparation and use method of the refractory concrete comprises the following steps: mixing sintered mullite fine powder, alumina powder, kyanite powder, raw clay powder, waste magnesia-chrome brick powder, light burned magnesia powder, silica micropowder, solid water glass and sodium fluosilicate uniformly, and then adding high-aluminum waste brick particles and high-aluminum bauxite particles to mix uniformly to obtain refractory concrete; and filling the refractory concrete into the grids 5 from the through holes at the two ends of the grids 5, sealing the grids 5, and respectively spraying a layer of CA50 aluminate cement on the outer surfaces of the upper layer 1 and the bottom layer 3 to obtain the flexible refractory concrete.
The flexible refractory concrete of the embodiment is applied to the integral construction of a lining of a tunnel kiln, and comprises the following steps:
1) The inner wall of the brick wall of the tunnel kiln is provided with anchoring pieces at intervals, and the distance between the anchoring pieces is 0.4m;
2) The flexible refractory concrete is stuck to the inner wall of the brick wall by using a fiber adhesive, and the length direction of the flexible refractory concrete extends along the length direction of the tunnel kiln and is fixed by using an anchoring piece; cutting and splicing according to the length and the height of the tunnel kiln and the length and the width of the flexible refractory concrete to form an integral lining; oblique angles of joint parts are overlapped to avoid forming a through seam, and overlapped parts are fixed by anchoring parts;
3) Spraying 40 ℃ warm water on the upper layer of the flexible refractory concrete by using a sprayer, transversely diffusing water along the ceramic fiber cloth, penetrating the ceramic fiber cloth to the main material layer through gaps of the ceramic fiber cloth, and simultaneously guiding the water to the deep layer of the flexible refractory concrete by using glass fiber cloth until a small amount of slurry seeps out from the bottom layer of the flexible refractory concrete;
4) After the refractory concrete is initially set for 30min, uniformly spraying a layer of CA50 aluminate cement fine powder on the upper surface of the flexible refractory concrete, and spraying water to the upper surface fiber to saturate the water so that the surface high alumina cement permeates into the ceramic fiber cloth;
5) Standing and curing for 24 hours after the refractory concrete is formed, heating and baking, heating to 110 ℃ uniformly for 2 hours, preserving heat for 2 hours, heating to 540 ℃ within 4 hours, preserving heat for 2 hours to remove crystal water, and heating to the kiln use temperature rapidly, so that the refractory concrete can be put into normal use.
The construction time of the invention is about 3 days, the formwork is not required to be disassembled, the maintenance time is short, 7-10 days are saved compared with the construction with casting materials or spray coating materials, and the lining has good integrity and is not easy to crack.
According to detection, the volume density of the baked flexible refractory concrete of the embodiment is 2.45g/cm 3 The method comprises the steps of carrying out a first treatment on the surface of the The compressive strength after baking is 8MPa; the compressive strength after being burned at 1400 ℃ for 3 hours is 25MPa, the linear change rate of the compressive strength at 1400 ℃ for 3 hours is-0.2%, the air cooling thermal shock stability at 1100 ℃ is more than 100 times, and the service requirement of an industrial kiln lining is met.
The above examples are presented for clarity of illustration only and are not limiting of the embodiments. Other variations or modifications of the above description will be apparent to those of ordinary skill in the art, and it is not necessary or exhaustive of all embodiments, and thus all obvious variations or modifications that come within the scope of the invention are desired to be protected.
Claims (10)
1. A flexible refractory concrete is characterized in that an upper layer (1), a main material layer (2) and a bottom layer (3) are sequentially arranged from top to bottom; the upper layer (1) and the bottom layer (3) are ceramic fiber cloth which is arranged in parallel, two groups of glass fiber cloth (4) which are inclined forwards and reversely are arranged between the upper layer (1) and the bottom layer (3), and the intersecting line of the glass fiber cloth (4) and the bottom layer (3) is parallel to the length direction of the bottom layer (3); two groups of glass fiber cloth (4) are distributed in a crossed mode, the main material layer (2) is divided into grids (5), refractory concrete is filled in the grids (5), ceramic fiber cloth is arranged at through holes at two ends of the grids (5) to serve as inclined plane sealing openings (6), and cross sections perpendicular to the length direction of the flexible refractory concrete structure after sealing are in a parallelogram or isosceles trapezoid shape.
2. The flexible refractory concrete according to claim 1, wherein the thickness of the upper layer (1) and the bottom layer (3) is less than or equal to 3mm, and the thickness of the flexible refractory concrete is 20-150 mm.
3. The flexible refractory concrete of claim 1, wherein the ceramic fiber cloth is woven from one or more of aluminum silicate refractory fibers, zirconium-containing aluminum silicate refractory fibers, chromium-containing aluminum silicate refractory fibers; the gaps of the fiber skeletons of the ceramic fiber cloth of the upper layer (1) and the bottom layer (3) are filled with high alumina cement dry powder.
4. The flexible refractory concrete according to claim 1, wherein the glass fiber cloth (4) is a high silica glass fiber cloth or a quartz glass fiber cloth, the mesh size is 0.2-0.8 mm, and the thickness is less than or equal to 0.5mm.
5. The flexible refractory concrete according to claim 1, characterized in that the glass fiber cloths (4) are arranged in parallel and equidistantly in the same group, the distance between two adjacent blocks is 10-50 mm, and the projections of the two adjacent blocks on the bottom layer are partially overlapped; the intersection angle of the glass fiber cloth (4) and the bottom layer (3) is 30-60 degrees.
6. The flexible refractory concrete according to claim 1, wherein the refractory concrete comprises the following raw materials in mass percent: 45-55% of high-alumina particles with the particle size of 1-3 mm, 10-25% of high-alumina particles with the particle size of 0.1-1 mm, 10-15% of sintered mullite fine powder, 5-10% of alumina powder, 2-5% of kyanite powder, 2-6% of raw clay powder, 1-5% of waste magnesium-chromium brick powder, 1-5% of light burned magnesia powder and 2-8% of silica micropowder, wherein the sum of the mass percentages of the raw materials is 100%, and 4-8% of a bonding agent and 0-1% of a coagulant are added.
7. The flexible refractory concrete of claim 6, wherein the binder is solid water glass having a modulus of 2.0 to 2.5; the coagulant is sodium fluosilicate, and the grain diameter is less than or equal to 200 meshes.
8. Use of the flexible refractory concrete according to any one of claims 1 to 7 for the repair and overall construction of linings for thermal equipment, characterized in that the method of application comprises the following steps:
1) Cleaning the construction surface and controlling the temperature of the construction surface;
2) Fixing and paving the flexible refractory concrete on a construction surface by using anchoring pieces or fiber adhesives;
3) Spraying water on the surface of the upper layer of the flexible refractory concrete in a mist manner, transversely diffusing the water along the ceramic fiber cloth, penetrating the water to the main material layer through gaps of the ceramic fiber cloth, and simultaneously guiding the water to the deep layer of the flexible refractory concrete through glass fiber cloth until a small amount of slurry seeps out from the bottom layer of the flexible refractory concrete;
4) After the refractory concrete is initially set, uniformly spraying a layer of high alumina cement fine powder on the upper surface of the flexible refractory concrete, and spraying water to the upper surface fiber to saturate the water, so that the high alumina cement on the surface layer is permeated into the ceramic fiber cloth;
5) Standing for maintenance, heating for baking, and putting into use after baking is finished.
9. The use of the flexible refractory concrete in the repair and overall construction of a thermal equipment liner according to claim 8, wherein the temperature of the construction surface is 10-30 ℃; the water temperature of the atomized water spray is 20-50 ℃; the initial setting time of the refractory concrete is 0.5-2 h when the coagulant is not added, and the initial setting time is 10-30 min when the coagulant is added.
10. The use of the flexible refractory concrete according to claim 8 for repair and overall construction of thermal equipment liners, wherein the firing schedule is: when the temperature of the application scene is higher than 540 ℃, uniformly heating to 105 ℃ for 2-5 hours, then heating to 540-600 ℃ for 2-5 hours within 4 hours, and then quickly heating to the application scene using temperature, and putting the application scene into normal use; when the temperature of the application scene is less than 540 ℃, the temperature is directly raised to the use temperature of the application scene after the heat preservation at 105 ℃ is finished, and the normal use is realized.
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