CN1211313C - 矾土基活性α-Al2O3微粉及生产工艺 - Google Patents

矾土基活性α-Al2O3微粉及生产工艺 Download PDF

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CN1211313C
CN1211313C CN 01103553 CN01103553A CN1211313C CN 1211313 C CN1211313 C CN 1211313C CN 01103553 CN01103553 CN 01103553 CN 01103553 A CN01103553 A CN 01103553A CN 1211313 C CN1211313 C CN 1211313C
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micro mist
alumina
alpha
al2o3
described micro
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CN1305974A (zh
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王杰曾
刘锡俊
杨瑞莲
夏霞云
盛敏琪
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Ruitai Technology Co., Ltd.
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BEIJING RUITAI HIGH-TEMP MATERIAL SCIENCE AND TECHNOLOGY Co Ltd
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Abstract

本发明涉及一种α-Al2O3微粉,它由优质天然矾土经1200±200℃烧成和超细粉磨制得,所述微粉主要矿物相为α-Al2O3,平均粒度为1-20微米。产品具有价格低、活性高、耐火性好和化学纯度较高的特点,可广泛用于提高各类含矾土的耐火材料的性能,以取得显著的技术和经济效果。

Description

矾土基活性α-Al2O3微粉及生产工艺
本发明涉及一种α-Al2O3微粉及制造工艺。
α-Al2O3具有耐火度高、高温体积稳定性好、耐磨性强、对酸性和碱性炉料的化学侵蚀都有较强的抵抗力等的优点,是一种主要的耐火原料。微粉的使用增强了材料的密集堆积程度和烧结性,从而可以显著提高耐火材料的物理性能和抵抗化学侵蚀能力。
然而,Al2O3的生产工艺十分复杂。以我国常用的烧结法为例:矾土须经和碳酸钠、石灰石配合、磨细后烧结成熟料,再经溶出、分离、结晶、洗涤、煅烧等步骤制成氧化铝。氧化铝还需通过添加结晶促进剂经特殊的煅烧制成活性α-Al2O3,最后经超细磨制得α-Al2O3微粉。这样,α-Al2O3微粉的价格就十分昂贵。
高铝质耐火材料的主要物相为刚玉(α-Al2O3)、莫来石、钛酸铝固溶体和玻璃相。添加2-10%的α-Al2O3微粉对提高材料纯度的有限,但显著增加了成本。从而添加α-Al2O3所获的有益效果在很多情况下被抵销,产品的性能/价格比值和竞争力提高不多。
虽然,一些工厂利用矾土熟料生产的325目(45μm)的细粉,用于制造高铝质耐火材料。但这有三个问题:1)矾土熟料未经过精心选择,产品常常不能满足优质矾土的要求;2)矾土熟料经1600℃左右的高温烧成,α-Al2O3已发育成数十个微米大小的晶粒,材料既无活性,磨细时电耗又高;3)产品的细度不够,不能有效地发挥其有益作用。
本发明的目的在于直接利用矾土生料,经过低温烧结和超细粉磨工艺制得活性α-Al2O3微粉,从而生产出一种质优价廉的新型耐火原料。所述活性指得是:1)微粉可以在一定程度上参与水化,提高不定形耐火材料的脱模强度和110℃烘干强度;2)微粉具有良好的烧结性,可以提高不定形材料经800-1100℃热处理后的强度,以解决传统浇注料经中温强度热处理后强度降低的问题;3)微粉能与耐火材料中的过渡性低熔物快速反应,以提高耐火材料的高温性能。
附图为本发明所述的微粉之X光衍射图,其中A为α-Al2O3,T为金红石,α-SiO2为α石英。
精心选择矾土是制得优质微粉的先决条件。矾土和氧化铝的质量差异在于前者含有少量杂质。选择了优质矾上就减少了产品与高纯α-Al2O3的差别,在更多的情况下,低价格材料就可以表现出其优越性。发育不完善的晶粒含有的缺陷多;小晶粒疏松聚集体的易磨性比大晶粒致密烧结体好的多。根据矾土生料的煅烧特性,制定合适烧成制度就可以控制α-Al2O3晶粒的尺寸,获得高活性和易磨的原料。最后,原料必须经超细粉磨制成微粉,以起到提高材料成型性能、致密度、室温强度、高温物理性能和抗侵蚀性的作用。
因此,本发明意图避免先对矾土提纯,然后将花费很大代价获得的α-Al2O3掺入低纯度高铝质材料的不合理过程,以及先过度烧结使材料丧失活性和易磨性再进行磨细的不合理过程,意图直接利用矾土和合理工艺烧制和粉磨制成α-Al2O3微粉。
本发明的制作工艺如下:
1)本发明所述微粉的灼烧基成分应满足下述要求:
项目                 理想要求             最低要求
Al2O3              ≥90.0%             ≥85.0%
TiO2                ≤4.0%              ≤5.0%
Fe2O3              ≤2.0%              ≤3.0%
CaO+MgO              ≤0.4%              ≤0.6%
K2O+Na2O           ≤0.4%              ≤0.6%
SiO2+其它微量成分   ≥3.2%              ≥5.8%
2)产品的煅烧温度为1000-1400℃。如煅烧温度<1000℃,材料的需水量过大,不利于生产不定形耐火材料;如煅烧温度>1400℃刚玉晶粒过度成长,不利于产品的活性和粉磨。
3)由于活性α-Al2O3有一定的水化能力,故宜采用振动磨、气流磨和高速机械冲击式等干式超细粉碎设备进行粉磨。
实施例1:
选择矾土的化学成分(灼烧基)为:Al2O3=92.53%,SiO2=3.05%,Fe2O3=0.54%,TiO2=3.68%,CaO=0.08%,MgO=0.07%,K2O=0.03,Na2O=0.11%。上述矾土矿石在1200℃经4小时煅烧制得轻烧料。经X光检验,轻烧料的主要矿物相为α-Al2O3但含有少量金红石(TiO2)和α石英(SiO2)。上述轻烧料经破碎至<1mm,再经振动磨磨制4小时,即可获得最大粒径<20μm,平均粒径为4μm的矾土基α-Al2O3微粉。
将所述微粉用于制造钢包镁铝尖晶石浇注料。材料的配比和性能对比为:
组成/性能                   实施配方            对比配方
>8mm矾土熟料               23%                23%
8-1mm矾土熟料               39%               39%
1-0.1mm矾土熟料             10%               10%
<0.1mm矾土熟料粉           8%                11%
<0.1mm镁砂粉               8%                8%
纯铝酸钙水泥                1%                1%
<0.02mm矾土基尖晶石微粉    5%                5%
硅灰                        3%                3%
矾土α-Al2O3微粉         3%                0%
110℃烘干强度(MPa)
抗折                        3.2                1.8
耐压                        53                 43.6
1100℃烧后强度(MPa)
抗折                        3.0                0.8
耐压                        47                 23.1
从实施例1可知用本发明所制α-Al2O3微粉3%等量替代<0.1mm矾土熟料粉,在其它条件相同时可以提高所述材料的强度指标,特别是成功解决了材料1100℃烧后强度下降的问题。
实施例2:
按实施例1所述方法制得矾土基α-Al2O3微粉,用于铝硅系超低水泥浇注料的预制件。材料的配比为:
组成/性能                实施配方           对比配方
10-3mm粘土熟料           40                 40
3-0.1mm粘土熟料          30                 30
<0.1mm高铝熟料          20                 24
纯铝酸钙水泥             1                  1
硅灰                     5                  5
矾土基α-Al2O3微粉    4                  0
上述材料外加0.2%常规减水剂和适量水成型、脱模和干燥后,再经1300℃热处理后检测材料的荷重软化温度:实施配方为1430℃,而对比配方仅为1400℃。用4%矾土基α-Al2O3微粉替代等量常规矾土粉,在其它条件相同时,可以提高荷重软化温度30℃。
从实施例1和实施例2可知:本发明所制矾土基α-Al2O3微粉明显改善了所述耐火材料的性能。因此,矾土基α-Al2O3微粉是一种价格低廉而技术效果显著的新材料,在许多场合下可以有效提高含矾土的铝硅系和铝镁系耐火材料的性能/价格比值或竞争力。

Claims (2)

1.一种矾土基活性α-Al2O3微粉,其特征在于:所述微粉以优质天然矾土为原料制成,所述微粉的灼烧基化学组成为:
Al2O3≥88.0%
TiO2≤5.0%
Fe2O3≤3.0%
CaO+MgO≤0.6%
K2O+Na2O≤0.6%
SiO2+其它微量成分≥5.8%
以上各成分含量之和等于100%,所述微粉的主要矿物相为α-Al2O3,平均粒度为1-20μm。
2.一种权利要求1所述微粉的生产工艺,其特征在于:所述微粉经1200±200℃烧成和超细粉磨工艺制备,所述矾土原料的主要矿物相为α-Al2O3,平均粒度为1-20μm。
CN 01103553 2001-02-28 2001-02-28 矾土基活性α-Al2O3微粉及生产工艺 Expired - Lifetime CN1211313C (zh)

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