CN117719218A - Refractory concrete composite ceramic fiber blanket and preparation method and application thereof - Google Patents
Refractory concrete composite ceramic fiber blanket and preparation method and application thereof Download PDFInfo
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- CN117719218A CN117719218A CN202311728827.XA CN202311728827A CN117719218A CN 117719218 A CN117719218 A CN 117719218A CN 202311728827 A CN202311728827 A CN 202311728827A CN 117719218 A CN117719218 A CN 117719218A
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- 239000000835 fiber Substances 0.000 title claims abstract description 224
- 239000000919 ceramic Substances 0.000 title claims abstract description 142
- 239000004567 concrete Substances 0.000 title claims abstract description 109
- 239000002131 composite material Substances 0.000 title claims abstract description 45
- 238000002360 preparation method Methods 0.000 title description 7
- 239000010410 layer Substances 0.000 claims abstract description 142
- 239000002344 surface layer Substances 0.000 claims abstract description 45
- 238000010276 construction Methods 0.000 claims abstract description 26
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 54
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- 238000005507 spraying Methods 0.000 claims description 24
- 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 21
- 239000004744 fabric Substances 0.000 claims description 21
- 239000011214 refractory ceramic Substances 0.000 claims description 16
- 239000011819 refractory material Substances 0.000 claims description 16
- 238000004873 anchoring Methods 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 12
- 239000000203 mixture Substances 0.000 claims description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 10
- 239000004927 clay Substances 0.000 claims description 10
- ZGUQGPFMMTZGBQ-UHFFFAOYSA-N [Al].[Al].[Zr] Chemical compound [Al].[Al].[Zr] ZGUQGPFMMTZGBQ-UHFFFAOYSA-N 0.000 claims description 8
- 239000003063 flame retardant Substances 0.000 claims description 8
- 239000011248 coating agent Substances 0.000 claims description 7
- 238000000576 coating method Methods 0.000 claims description 7
- 230000002209 hydrophobic effect Effects 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 7
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims description 6
- 238000009826 distribution Methods 0.000 claims description 6
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 5
- 239000011230 binding agent Substances 0.000 claims description 5
- 230000000149 penetrating effect Effects 0.000 claims description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- 239000004746 geotextile Substances 0.000 claims description 4
- 239000003365 glass fiber Substances 0.000 claims description 4
- 239000004814 polyurethane Substances 0.000 claims description 4
- 229920002635 polyurethane Polymers 0.000 claims description 4
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- 239000004800 polyvinyl chloride Substances 0.000 claims description 4
- 238000009941 weaving Methods 0.000 claims description 4
- QQHSIRTYSFLSRM-UHFFFAOYSA-N alumanylidynechromium Chemical compound [Al].[Cr] QQHSIRTYSFLSRM-UHFFFAOYSA-N 0.000 claims description 3
- 238000005266 casting Methods 0.000 claims description 3
- 238000011049 filling Methods 0.000 claims description 3
- 229920002367 Polyisobutene Polymers 0.000 claims description 2
- 150000004645 aluminates Chemical group 0.000 claims description 2
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims description 2
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- 238000007788 roughening Methods 0.000 claims description 2
- 239000005995 Aluminium silicate Substances 0.000 claims 2
- QRRWWGNBSQSBAM-UHFFFAOYSA-N alumane;chromium Chemical compound [AlH3].[Cr] QRRWWGNBSQSBAM-UHFFFAOYSA-N 0.000 claims 2
- DNXNYEBMOSARMM-UHFFFAOYSA-N alumane;zirconium Chemical compound [AlH3].[Zr] DNXNYEBMOSARMM-UHFFFAOYSA-N 0.000 claims 2
- 229910000323 aluminium silicate Inorganic materials 0.000 claims 2
- 235000012211 aluminium silicate Nutrition 0.000 claims 2
- 239000004411 aluminium Substances 0.000 claims 1
- 239000002245 particle Substances 0.000 claims 1
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- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 230000035939 shock Effects 0.000 description 5
- 229910052726 zirconium Inorganic materials 0.000 description 5
- 238000012423 maintenance Methods 0.000 description 4
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- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 108010081750 Reticulin Proteins 0.000 description 1
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- 229910052804 chromium Inorganic materials 0.000 description 1
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Landscapes
- Furnace Housings, Linings, Walls, And Ceilings (AREA)
Abstract
The invention discloses a refractory concrete composite ceramic fiber blanket which sequentially comprises a ceramic fiber layer, a water-resisting layer, a refractory concrete layer and a surface layer from bottom to top, and further comprises ceramic fiber bundles longitudinally connected with the ceramic fiber layer and the surface layer, wherein the ceramic fiber bundles penetrate through the water-resisting layer and the refractory concrete layer. The refractory concrete composite ceramic fiber blanket provided by the invention has the advantages of good refractory performance, heat preservation, heat insulation, high mechanical strength, small high-temperature shrinkage, long service life, convenience in storage and transportation, convenience in construction and environment friendliness.
Description
Technical Field
The invention belongs to the technical field of refractory materials, and particularly relates to a refractory concrete composite ceramic fiber blanket, and a preparation method and application thereof.
Background
In the use process of high-temperature industrial kilns and equipment, a large amount of heat-insulating refractory materials are often required to be used in order to improve the heat efficiency and reduce heat loss. The ceramic fiber has the characteristics of softness and good toughness of common fibers, and can be processed into various products such as belts, wires, ropes, carpets, felts and the like; the ceramic fiber blanket has the characteristics of light weight, small heat conductivity, small heat capacity, high temperature resistance, corrosion resistance, good thermal shock resistance and convenient construction, and is often used as a heat insulation material in a high-temperature furnace and thermal equipment, wherein the ceramic fiber blanket is more in use. The ceramic fiber blanket is often used for high-temperature kilns and thermal equipment in the form of coiled materials or folding blocks, and the two forms are suitable for large-area paving, have good integrity and strong adaptability to construction surfaces, can wrap the outer wall of a pipeline and pave and fill the inner wall of a channel pipeline, can pave a large-area wall surface, and are convenient to transport and simple and quick to construct; however, the ceramic fiber blanket has large fiber skeleton gap, large high-temperature shrinkage and no hard surface, and has lower wear resistance, compressive strength and tensile strength, thus influencing the service life.
The heat-insulating unshaped refractory material is also a heat-insulating material which uses more heat-insulating materials, has good integrity and thermal shock resistance, and has high strength and small high-temperature shrinkage compared with refractory fibers, but requires complex processes of formwork supporting, on-site stirring, pouring, maintenance, formwork removing and the like during construction, has more dust and is not environment-friendly.
At present, the field of refractory materials does not have a material with the advantages of both ceramic fiber blankets and heat insulation unshaped refractory materials, but cement blankets are developed in the field of building materials as construction materials, the cement blankets generally have a net-shaped structure consisting 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 a concrete-like structure is formed after the cement blanket is solidified when meeting water. However, when the cement blanket is applied with water after being paved, because the water application technology of construction workers is uneven, the water guide capability of the cement blanket in the transverse or longitudinal direction is possibly caused to be not ideal, so that the cement blanket has different hydration reaction time and hydration degree at different positions, partial areas are solidified, other partial areas are still in a dry powder slag state, the stress distribution of the hardened cement blanket is uneven, and the performance and the service life of the cement blanket are influenced.
Patent 202210196576.4 discloses a typical cement blanket and a manufacturing method thereof, wherein the cement blanket is divided into three layers from top to bottom, is formed by sandwiching a cement solidified layer by two layers of organic fiber fabrics, and is used for fixing an upper layer of fabric and a lower layer of fabric through longitudinal fiber bundles and playing a role in water guiding. This patent provides a related art for introducing water into the interior of a cement blanket to promote hydration of the cement, but the blanket is not suitable for use in the refractory field. The patent product has the following defects if applied to the field of refractory materials: (1) The essence of the patent is that the cement blanket is of a concrete-like structure after hardening, the used materials cannot resist high temperature, and even if the materials and the technology are replaced by related materials in the field of refractory materials, the ceramic fiber heat preservation and heat insulation effects cannot be achieved; (2) The cement blanket is longitudinally guided with fiber bundles, the transverse water is guided by virtue of the fiber fabrics on the surface, when the thickness of the cement blanket is too large, the water guiding is uneven at the place far away from the longitudinal fiber bundles and the surface layer, and the refractory material must have enough thickness to ensure safe use; (3) In the construction of refractory materials, if the heat-insulating fiber absorbs water, the heat-insulating property and the service life of the heat-insulating fiber can be greatly reduced, and the heat-insulating fiber has no relevant solving measures.
Patent 202120397655.2 discloses a quick-drying cement blanket which is mainly used for construction of river channels, provides a waterproof layer and a fixed mounting technology, but does not provide a better water guiding technology; the waterproof layer is made of PVC material with the thickness of 2mm, when the product is applied to the field of refractory materials, the PVC material can be digested at high temperature under a high-temperature environment to cause the main material to fall off; the essence of the technology is still a concrete-like structure, and the heat preservation and heat insulation effects of the fiber materials cannot be achieved through refractory materials and technology replacement.
The patent 201711274906.2 discloses a three-wave superposition type multifunctional cement blanket, solves the problem that fibers cannot be uniformly stirred, adopts small-aperture reticular fiber fabrics through external packaging fiber cloth, adopts wavy reinforcing fiber cloth for separation, has larger holes and is regularly distributed, so that different fibers form countless hoops on hydraulic cement dry-mixed mortar, a spatial toughening lattice system is formed, and the stress performance of the cement blanket is obviously improved. The essence of the technology is still a concrete-like structure, and when the technology is applied to the field of refractory materials through refractory materials and technology replacement, the fiber material cannot achieve the heat preservation and heat insulation effects, and the fiber material is easy to peel off from the layered structure at high temperature.
Therefore, the development of the novel refractory ceramic fiber blanket which has the advantages of high integrity, good thermal shock resistance, good fire resistance, heat preservation, high mechanical strength, small high-temperature shrinkage, long service life, convenient storage and transportation, convenient and environment-friendly construction and the like and has the advantages of the ceramic fiber blanket and the heat insulation unshaped refractory material has important significance.
Disclosure of Invention
The invention aims to solve the technical problems of the prior art and provides a refractory concrete composite ceramic fiber blanket, and a preparation method and application thereof.
The invention adopts the technical proposal for solving the problems that:
the refractory concrete composite ceramic fiber blanket comprises a ceramic fiber layer, a water-proof layer, a refractory concrete layer and a surface layer from bottom to top in sequence, and further comprises ceramic fiber bundles longitudinally connected with the ceramic fiber layer and the surface layer, wherein the ceramic fiber bundles penetrate through the water-proof layer and the refractory concrete layer; the ceramic fiber layer is a refractory ceramic fiber needled blanket; the waterproof layer is a hydrophobic coating sprayed on the upper surface of the ceramic fiber layer; the refractory concrete layer is a mixture of ceramic fibers and refractory concrete; the diameter of the ceramic fiber bundle is 20-100um, the length is 20-80mm, and the distribution density is 10-100 bundles/dm 2 The method comprises the steps of carrying out a first treatment on the surface of the The surface layer is made of water permeable fiber cloth.
In the scheme, the refractory ceramic fiber needled blanket is one of an aluminum silicate needled fiber blanket, an aluminum silicate zirconium needled fiber blanket and an aluminum silicate chromium needled fiber blanket; napping the fibers on the upper surface of the refractory ceramic fiber needled blanket; the thickness of the refractory ceramic fiber needled blanket is 20-150mm.
In the scheme, the hydrophobic coating in the water-resistant layer is made of one of waterborne polyurethane, polyacrylate, polyvinyl chloride and polyisobutylene, and the thickness of the water-resistant layer is not more than 5mm.
In the above scheme, the fiber used in the ceramic fiber bundles is one of aluminum silicate fiber, aluminum zirconium silicate fiber, aluminum chromium silicate fiber or quartz glass fiber.
In the scheme, in the refractory concrete layer, the mass content of ceramic fibers in the mixture of the ceramic fibers and the refractory concrete is not more than 2%, and the mass content of the refractory concrete is not less than 98%; the thickness of the refractory concrete layer is 10-50mm. Ceramic fibers in the refractory concrete layer mainly play roles in strengthening and toughening, guiding water into the deep layer of the concrete and promoting the hardening of the cement.
In the scheme, the refractory concrete in the refractory concrete layer is high-alumina castable or clay castable, and the granularity of the refractory concrete is not more than 3mm; the cement in the high-alumina castable or the clay castable is aluminate cement, and the addition amount is 5-50 wt%.
In the scheme, the ceramic fiber in the refractory concrete layer is one of aluminum silicate fiber, aluminum zirconium silicate fiber, aluminum chromium silicate fiber or quartz glass fiber, and the ceramic fiber has a diameter of 3-30 mu m and a length of 10-50mm.
In the scheme, the thickness of the surface layer is 0.1-1mm. The surface layer is permeable fiber cloth and is selected from one of flame-retardant geotextile and common fiber cloth. The surface layer is made of a proper material according to the use conditions; when the refractory concrete composite ceramic fiber blanket is used for the outer wall of a pipeline, the surface layer can use flame-retardant geotextile; when the refractory concrete composite ceramic fiber blanket is used for the inner wall of the working layer of the high-temperature equipment, the surface layer can use common fiber cloth. The surface layer is mainly used for wrapping the refractory concrete layer, and water can smoothly penetrate into the mixture of the ceramic fiber and the refractory concrete during construction, so that cement is hardened; meanwhile, the surface layer can absorb certain amount of water, so that the surface of the refractory concrete layer is kept moist and is beneficial to maintenance.
The invention also claims a preparation method of the refractory concrete composite ceramic fiber blanket, which comprises the following steps: paving the refractory ceramic fiber needled blanket at the lowest end to serve as a ceramic fiber layer, spraying a hydrophobic coating material on the surface of the refractory ceramic fiber needled blanket for 2-3 times to form a water-resisting layer after the surface of the refractory ceramic fiber needled blanket is napped, wherein the time interval between two adjacent spraying is 2-5 hours, and spraying the refractory ceramic fiber needled blanket for the next time after the hydrophobic coating sprayed in the previous time is dried; filling uniformly mixed ceramic fiber and refractory concrete mixture on the water-resisting layer to form a refractory concrete layer; paving water permeable fiber cloth on the refractory concrete layer to form a surface layer; and weaving two ends of the ceramic fiber bundles into the surface layer and the ceramic fiber layer respectively and longitudinally penetrating through the waterproof layer and the refractory concrete layer to obtain the refractory concrete composite ceramic fiber blanket.
The application of the refractory concrete composite ceramic fiber blanket in the field of refractory materials is specifically as follows: during construction, the ceramic fiber layer is fixed on a construction surface through a fiber binder or anchoring piece and spread; spraying water to the surface layer for two to three times, stopping when the water is sprayed to the upper surface of the water-resisting layer and mud is oozed out every time, wherein the time interval between two adjacent water spraying is 10-30min, and baking for use after natural curing for 2-3 days.
Compared with the prior art, the invention has the beneficial effects that:
(1) The refractory concrete composite ceramic fiber blanket provided by the invention is a ceramic fiber blanket when in construction, water is applied during use to harden cement into a hard integral protective layer, so that the advantages of strong ceramic fiber blanket integrity, good thermal shock resistance and good heat preservation and insulation performance are maintained, the advantages of high mechanical strength and small high-temperature shrinkage of refractory concrete are also maintained, meanwhile, the refractory concrete composite ceramic fiber blanket is convenient to store and transport, convenient and environment-friendly to construct, the defects of easiness in segregation during refractory concrete transportation, large stirring dust and need for formwork erection and stripping during construction are overcome, the service life of the ceramic fiber blanket is greatly prolonged, and the application range is expanded.
(2) The surface layer and the ceramic fiber layer of the refractory concrete composite ceramic fiber blanket are connected by the longitudinal ceramic fiber bundles, so that the refractory concrete composite ceramic fiber blanket has the functions of reinforcing and toughening, guiding water during water application, introducing water into the refractory concrete layer and promoting cement to be uniformly hydrated; when the refractory concrete composite ceramic fiber blanket is used as the inner wall of the working layer of high-temperature equipment, the ceramic fiber bundles and the refractory concrete are sintered at high temperature, so that the reinforcing and toughening effects can be achieved again.
(3) According to the refractory concrete composite ceramic fiber blanket, the waterproof layer is arranged between the ceramic fiber layer and the refractory concrete layer, so that water is prevented from leaking to the ceramic fiber layer when water is applied to the refractory concrete, and the heat insulation effect of the ceramic fiber layer is prevented from being influenced.
(4) According to the refractory concrete composite ceramic fiber blanket, after the refractory concrete layer is hardened in water, the protective layer is formed on the surface of the ceramic fiber blanket, so that the defects of low strength and large high-temperature shrinkage of ceramic fibers are overcome, and the service life of the ceramic fiber blanket is prolonged.
(5) When the refractory concrete composite ceramic fiber blanket provided by the invention is used as a pipeline or furnace body outer wall heat insulation material, the surface layer uses flame-retardant geotextile, so that the refractory concrete layer can play a role in reinforcement; when the refractory concrete composite ceramic fiber blanket is used as the inner wall of the working layer of high-temperature equipment, the surface layer can be made of common fiber cloth, and can be burnt and digested at high temperature, so that the cost is saved.
Drawings
Fig. 1 is a cross-sectional view of a refractory concrete composite ceramic fiber blanket of the present invention.
Reference numerals
1-a ceramic fiber layer; 2-a water-barrier layer; 3-a refractory concrete layer; 4-a surface layer; 5-ceramic fiber bundles; 6-anchoring parts; 7-a water baffle; 8-anchoring ends and 9-furnace wall bottom layers.
Detailed Description
The technical solutions of the present invention will be fully and clearly described below with reference to the embodiments, but the described embodiments are only some embodiments of the present invention, and all other embodiments obtained by persons skilled in the art without making any inventive effort based on the embodiments of the present invention are within the scope of protection of the present invention.
Example 1
The refractory concrete composite ceramic fiber blanket is used for insulating heat of outer walls of an air supply pipeline, a flue and the like, and sequentially comprises a ceramic fiber layer 1, a water-resisting layer 2, a refractory concrete layer 3 and a surface layer 4 from bottom to top, and further comprises ceramic fiber bundles 5 which are longitudinally connected with the ceramic fiber layer 1 and the surface layer 4, wherein the ceramic fiber bundles 5 penetrate through the water-resisting layer 2 and the refractory concrete layer 3; the ceramic fiber layer 1 is aluminum silicateThe thickness of the mass needle punched fiber blanket is 30mm; the water-resisting layer 2 is a water-based polyurethane coating sprayed on the upper surface of the ceramic fiber layer 1, and the thickness of the water-resisting layer is 3mm; the refractory concrete layer 3 is a mixture of ceramic fibers and light clay castable, wherein the addition of the ceramic fibers is 1%, cement in the light clay castable is CA50 high alumina cement, the addition of the light clay castable is 25%, the maximum granularity of the light clay castable is 3mm, the ceramic fibers are aluminum silicate refractory fibers, the diameter of the aluminum silicate refractory fibers is 5 mu m, the length of the aluminum silicate refractory fibers is 40mm, and the thickness of the refractory concrete layer 3 is 20mm; the fibers of the ceramic fiber bundles 5 are aluminum silicate refractory fibers, the diameter of the ceramic fiber bundles 5 is 50 um+/-10 um, the length is 50mm, and the distribution density is 40 bundles/dm 2 The method comprises the steps of carrying out a first treatment on the surface of the The surface layer 4 is made of flame-retardant polyester fiber cloth, the thickness of the surface layer 4 is 0.5mm, and the surface layer 4 is woven by 300g of polyester filament fiber and flame retardant, so that water can smoothly permeate.
The preparation method of the refractory concrete composite ceramic fiber blanket comprises the following steps: the method comprises the steps of paving an aluminum silicate needled fiber blanket at the lowest end to serve as a ceramic fiber layer 1, spreading the aluminum silicate needled fiber blanket after napping treatment, spraying 2 times of aqueous polyurethane on the upper surface of the aluminum silicate needled fiber blanket to form a water-resisting layer 2, wherein the time interval between two adjacent spraying is 3 hours, and spraying the aluminum silicate needled fiber blanket again after the aqueous polyurethane coating sprayed at the previous time is dried; a mixture of Tao Hunge uniform aluminum silicate refractory fibers and light clay castable is filled on the water-resistant layer to form a refractory concrete layer 3; a fire-retardant polyester fiber cloth is paved on the fire-retardant concrete layer 3 to form a surface layer 4; and weaving two ends of the ceramic fiber bundles 5 into the surface layer 4 and the ceramic fiber layer 1 respectively and longitudinally penetrating through the water-resisting layer 2 and the refractory concrete layer 3 to obtain the refractory concrete composite ceramic fiber blanket.
During construction, the outer wall of the construction surface is cleaned, a layer of fiber binder is coated, then the refractory concrete composite ceramic fiber blanket is unfolded, the ceramic fiber layer 1 is closely attached to the construction surface for paving construction, and the construction surface is obliquely rolled and attached along a pipeline. After the fiber binder is solidified after the paving is finished, spraying water on the surface layer 4 in a mist mode, stopping when water is applied to the upper surface of the water-resisting layer 2 and mud is oozed out, observing the surface layer, spraying water again after the surface layer is slightly dried, spraying water again, enabling the time interval between two adjacent water spraying times to be 30min, standing for natural maintenance after the two water spraying times, and enabling the surface layer to be put into use after baking after 72 hours.
The refractory concrete composite ceramic fiber blanket prepared in this example and the lightweight clay casting material used in this example were prepared into samples of the same specification, and the results are shown in table 1.
TABLE 1
Example 2
The refractory concrete composite ceramic fiber blanket is used for the inner wall working lining of medium and high temperature equipment such as a heating furnace, an electric furnace and the like, and sequentially comprises a ceramic fiber layer 1, a water-resisting layer 2, a refractory concrete layer 3 and a surface layer 4 from bottom to top, and further comprises a ceramic fiber bundle 5 longitudinally connected with the ceramic fiber layer 1 and the surface layer 4, wherein the ceramic fiber bundle 5 penetrates through the water-resisting layer 2 and the refractory concrete layer 3; the ceramic fiber layer 1 is an aluminum silicate zirconium needled fiber blanket with the thickness of 50mm; the water-resisting layer 2 is a water-based polyurethane coating sprayed on the upper surface of the ceramic fiber layer 1, and the thickness of the water-resisting layer is 3mm; the refractory concrete layer 3 is a mixture of ceramic fibers and compact high-alumina castable, wherein the addition of the ceramic fibers is 0.5%, cement in the compact high-alumina castable is CA70 high-alumina cement, the addition of the cement is 16%, the maximum granularity of the compact high-alumina castable is 3mm, the ceramic fibers are aluminum zirconium silicate fibers, the diameter of the aluminum zirconium silicate fibers is 5 mu m, the length of the aluminum zirconium silicate fibers is 30mm, and the thickness of the refractory concrete layer 3 is about 30mm; the fibers of the ceramic fiber bundles 5 are aluminum zirconium silicate fibers, the diameter of the ceramic fiber bundles 5 is 50 um+/-10 um, the length is 80mm, and the distribution density is 20 bundles/dm 2 The method comprises the steps of carrying out a first treatment on the surface of the The surface layer 4 is made of nylon fiber cloth, the thickness of the surface layer 4 is 0.1mm, and water can smoothly permeate.
The preparation method of the refractory concrete composite ceramic fiber blanket comprises the following steps: the aluminum silicate zirconium needled fiber blanket is paved at the lowest end to be used as a ceramic fiber layer 1, and Y-shaped anchoring pieces 6 are arranged to penetrate through the ceramic fiber layer 1 until the refractory concrete layer 3. The diameter of the Y-shaped anchoring piece 6 is 5mm, the height is 70mm, the lower end is straight rod-shaped, and the Y-shaped anchoring piece penetrates out of the ceramic fiber layer 1; the upper end is Y-shaped and is bifurcated in the refractory concrete layer 3. The Y-shaped anchoring piece 6 is provided with a lamellar water baffle 7 at the position of penetrating into the ceramic fiber layer 1, the diameter of the water baffle is 10mm, and the thickness of the water baffle is 0.5mm. Spreading the aluminum silicate zirconium needle punched fiber blanket after surface roughening treatment, spraying 2 times of aqueous polyurethane on the upper surface of the aluminum silicate zirconium needle punched fiber blanket to form a water-resisting layer 2, wherein the time interval between two adjacent spraying is 4 hours, and after the aqueous polyurethane coating sprayed in the previous time is dried, spraying the next time; filling a uniformly mixed mixture of aluminum zirconium silicate fibers and compact high-alumina castable on the water-resistant layer 2 to form a refractory concrete layer 3; paving nylon fiber cloth on the refractory concrete layer 3 to form a surface layer 4; and weaving two ends of the ceramic fiber bundles 5 into the surface layer 4 and the ceramic fiber layer 1 respectively and longitudinally penetrating through the water-resisting layer 2 and the refractory concrete layer 3 to obtain the refractory concrete composite ceramic fiber blanket.
During construction, the construction surface of the furnace wall 9 is cleaned, the anchoring end 8 is planted according to the distribution position of the refractory concrete composite ceramic fiber blanket anchoring parts 6, a layer of fiber binder is coated on the construction surface of the furnace wall 9, then the refractory concrete composite ceramic fiber blanket is unfolded, the bottom surface of the ceramic fiber layer 1 is closely adhered to the construction surface of the furnace wall 9, the lower end of the anchoring parts 6 are welded on the anchoring end 8 implanted into the furnace wall 9 while being paved, mist spraying is carried out on the surface layer 4 after the paving is finished, the construction is stopped when slurry seeps out from the upper surface of the water-resisting layer 2, the surface layer 4 is observed, later, spraying water is carried out again, the time interval between two adjacent spraying water is 20min, after two spraying water, standing for natural maintenance, and after 72 hours, baking according to a conventional baking furnace heating curve of equipment, until 1300 ℃, and preserving heat for 3 hours, so that the refractory concrete is sintered and then put into use.
The refractory concrete composite ceramic fiber blanket prepared in the embodiment of the invention and the compact high-alumina castable used in the embodiment are prepared into samples with the same specification, and the related performance test is carried out, and the results are shown in table 2.
TABLE 2
As can be seen from the detection results of the table 1 and the table 2, the refractory concrete composite ceramic fiber blanket provided by the invention combines the advantages of the castable and the fiber blanket, and has the advantages of good thermal shock resistance, good fire resistance, heat preservation and insulation, high mechanical strength, small high-temperature shrinkage and convenient construction.
The above description is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto. Any person skilled in the art, within the technical scope of the present disclosure, may apply to the present invention, and the technical solution and the improvement thereof are all covered by the protection scope of the present invention.
Claims (10)
1. The refractory concrete composite ceramic fiber blanket is characterized by sequentially comprising a ceramic fiber layer (1), a water-resistant layer (2), a refractory concrete layer (3) and a surface layer (4) from bottom to top, and further comprises ceramic fiber bundles (5) longitudinally connecting the ceramic fiber layer (1) and the surface layer (4), wherein the ceramic fiber bundles (5) penetrate through the water-resistant layer (2) and the refractory concrete layer (3); the ceramic fiber layer (1) is a refractory ceramic fiber needled blanket; the waterproof layer (2) is a hydrophobic coating sprayed on the upper surface of the ceramic fiber layer (1); the refractory concrete layer (3) is a mixture of ceramic fibers and refractory concrete; the ceramic fiber bundles (5) have a diameter of 20-100um, a length of 20-80mm and a distribution density of 10-100 bundles/dm 2 The method comprises the steps of carrying out a first treatment on the surface of the The surface layer (4) is made of water-permeable fiber cloth.
2. The refractory concrete composite ceramic fiber blanket according to claim 1, wherein the refractory ceramic fiber needled blanket is one of an aluminum silicate needled fiber blanket, an aluminum zirconium silicate needled fiber blanket, an aluminum chromium silicate needled fiber blanket; napping the fibers on the upper surface of the refractory ceramic fiber needled blanket; the thickness of the refractory ceramic fiber needled blanket is 20-150mm.
3. The refractory concrete composite ceramic fiber blanket according to claim 1, wherein the hydrophobic coating in the water-resistant layer (2) is made of one of aqueous polyurethane, polyacrylate, polyvinyl chloride and polyisobutylene, and the thickness of the water-resistant layer (2) is not more than 5mm.
4. Refractory concrete composite ceramic fibre blanket according to claim 1, wherein the fibres used for the ceramic fibre bundles (5) are one of aluminium silicate fibres, aluminium zirconium silicate fibres, aluminium chromium silicate fibres or quartz glass fibres.
5. Refractory concrete composite ceramic fibre blanket according to claim 1, characterised in that the mass content of ceramic fibres in the mix of ceramic fibres and refractory concrete in the refractory concrete layer (3) is not more than 2%; the thickness of the refractory concrete layer (3) is 10-50mm.
6. Refractory concrete composite ceramic fibre blanket according to claim 1, characterized in that the refractory concrete in the refractory concrete layer (3) is a high aluminium casting or clay casting, the particle size of the refractory concrete being not more than 3mm; the cement in the high-alumina castable or the clay castable is aluminate cement, and the addition amount is 5-50 wt%.
7. Refractory concrete composite ceramic fibre blanket according to claim 1, characterized in that the fibres used for the ceramic fibres in the refractory concrete layer (3) are one of aluminium silicate fibres, aluminium zirconium silicate fibres, aluminium chromium silicate fibres or quartz glass fibres; the ceramic fiber has a diameter of 3-30 μm and a length of 10-50mm.
8. Refractory concrete composite ceramic fibre blanket according to claim 1, characterized in that the thickness of the facing layer (4) is 0.1-1mm; the permeable fiber cloth is flame-retardant geotextile or common fiber cloth.
9. A method of making a refractory concrete composite ceramic fiber blanket according to any of claims 1-8, comprising the steps of: paving a refractory ceramic fiber needled blanket at the lowest end to serve as a ceramic fiber layer (1), and spraying a hydrophobic coating material on the surface of the refractory ceramic fiber needled blanket for 2-3 times to form a water-resisting layer (2) after the surface roughening treatment of the refractory ceramic fiber needled blanket, wherein the time interval between two adjacent spraying is 2-5 hours; filling uniformly mixed ceramic fiber and refractory concrete mixture on the water-resisting layer (2) to form a refractory concrete layer (3); paving water permeable fiber cloth on the refractory concrete layer (3) to form a surface layer (4); and weaving two ends of the ceramic fiber bundles (5) into the surface layer (4) and the ceramic fiber layer (1) respectively, and longitudinally penetrating through the waterproof layer (2) and the refractory concrete layer (3) to obtain the refractory concrete composite ceramic fiber blanket.
10. Use of a refractory concrete composite ceramic fibre blanket according to any of claims 1 to 8 in the field of refractory materials, characterised by the steps of: during construction, the ceramic fiber layer (1) is fixed on a construction surface through a fiber binder or anchoring piece (6) and spread; spraying water to the surface layer (4) for two to three times, stopping when water is sprayed to the upper surface of the water-resisting layer (2) and mud is oozed out each time, wherein the time interval between two adjacent water spraying is 10-30min, and baking for use after natural curing for 2-3 days.
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| CN202311728827.XA CN117719218A (en) | 2023-12-15 | 2023-12-15 | Refractory concrete composite ceramic fiber blanket and preparation method and application thereof |
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| CN202311728827.XA CN117719218A (en) | 2023-12-15 | 2023-12-15 | Refractory concrete composite ceramic fiber blanket and preparation method and application thereof |
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