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CN116675525A - 一种高强耐碱轻质耐火浇注料及其制备方法 - Google Patents

一种高强耐碱轻质耐火浇注料及其制备方法 Download PDF

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CN116675525A
CN116675525A CN202310433820.9A CN202310433820A CN116675525A CN 116675525 A CN116675525 A CN 116675525A CN 202310433820 A CN202310433820 A CN 202310433820A CN 116675525 A CN116675525 A CN 116675525A
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CN116675525B (zh
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范昌龙
殷波
毛旭敏
郑益锋
蒋旭
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Yixing Morgan Thermal Ceramics Co ltd
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Abstract

本发明公开了一种高强耐碱轻质耐火浇注料,包括原料,所述原料包括以下质量份数的骨料和基质料,所述骨料包括55~75份的轻质莫来石耐火颗粒,基质料包括12~18份耐火粘土细粉、3~6份碳酸钡细粉、3~6份锆英石细粉、4~8份的镁铝水滑石细粉、2~4份的硅溶胶和4~10份的纯铝酸钙水泥。本发明所制备的高强耐碱轻质耐火浇注料具有强度高、体积稳定性好和抗碱性介质侵蚀能力强的特点。

Description

一种高强耐碱轻质耐火浇注料及其制备方法
技术领域
本发明涉及浇注料领域,尤其涉及一种高强耐碱轻质耐火浇注料及其制备方法。
背景技术
耐碱浇注料被广泛应用于钢铁、有色、玻璃、机械、石化等行业的碱腐蚀工业窑炉。现有的耐碱浇注料中通常含有较高的二氧化硅含量。一方面,其耐碱原理就是利用二氧化硅在高温下与碱金属氧化物反应,形成高粘度液相,形成釉面保护层,防止碱金属熔融物的渗透和侵蚀。另一方面,耐碱浇注料通常采用纯铝酸钙水泥为结合剂,中温条件下水泥胶结构的破坏导致强度大幅下降,为提升其中温强度,通常会引入硅微粉。因此,现有的耐碱浇注料中二氧化硅含量通常高达40%以上,然而,过高的二氧化硅含量对于材料的高温性能不利,且容易导致材料烧成过程中收缩过大,废品率增高。例如:专利技术“一种基于废建筑陶瓷的耐碱浇注料及其制备方法”(CN 104804827 A)以废建筑陶瓷、废碳化硅硼板、矾土粉、硅灰、铝酸盐水泥为主要原料制备得到了基于废建筑陶瓷的耐碱浇注料,然而其二氧化硅含量高,最高使用温度偏低。专利技术“一种轻质耐火耐碱浇注料配方”(CN 101973770 A)以废陶器、轻质料、硅微粉、铝酸盐水泥为主要原料制备得到了一种轻质耐火耐碱浇注料,但是,其二氧化硅含量高达50%以上,高温性能不佳,使用温度偏低。专利技术“一种低铝低导热耐碱浇注料”(CN 106830958 B)以焦宝石、板状刚玉粉、氧化铝微粉、复合耐碱粉、二氧化硅微粉、微孔莫来石、镁铝尖晶石、钙钛矿、固体造孔剂、纯铝酸钙水泥为主要原料,所得到的低铝低导热耐碱浇注料具有较低的铝含量,因而导热率更低,但是也存在二氧化硅含量高、使用温度不高的缺陷。
发明内容
本发明的目的是提供一种高强耐碱轻质耐火浇注料。
本发明还提供了一种高强耐碱轻质耐火浇注料的制备方法。
本发明的创新点在于本发明所制备的高强耐碱轻质耐火浇注料具有强度高、体积稳定性好和抗碱性介质侵蚀能力强的特点。
为实现上述发明目的,本发明的技术方案是:一种高强耐碱轻质耐火浇注料,包括原料,所述原料包括以下质量份数的骨料和基质料,所述骨料包括55~75份的轻质莫来石耐火颗粒,基质料包括12~18份耐火粘土细粉、3~6份碳酸钡细粉、3~6份锆英石细粉、4~8份的镁铝水滑石细粉、2~4份的硅溶胶和4~10份的纯铝酸钙水泥。
进一步地,所述轻质莫来石耐火颗粒中Al2O3含量为70~80wt%;轻质莫来石耐火颗粒的粒径为0.088~8mm。
进一步地,所述耐火粘土细粉的Al2O3含量为30~45wt%;耐火粘土细粉的粒径≤0.088mm。
进一步地,所述碳酸钡细粉的粒径≤45μm。
进一步地,所述锆英石细粉中ZrO2含量≥63wt%;锆英石细粉的粒径≤74μm。
进一步地,所述镁铝水滑石细粉中MgO与Al2O3摩尔比为1.5~2.5;镁铝水滑石细粉的粒径≤45μm。
进一步地,所述硅溶胶的SiO2含量为25~35wt%;硅溶胶的pH值为9~11。
进一步地,所述纯铝酸钙水泥的Al2O3含量为70~80wt%,CaO含量为20~30wt%;纯铝酸钙水泥的粒径≤0.088mm。
一种高强耐碱轻质耐火浇注料的制备方法,包括以下步骤:按配方取料,先将基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;再加入3~10质量份的水,搅拌均匀,振动成型,室温条件下养护12~24小时;最后在110~200℃条件下保温12~36小时,制得成品。
本发明的有益效果是:
1、本发明基质料中引入的硅溶胶和镁铝水滑石细粉可以原位反应形成MgO-SiO2-Al2O3结合体系,该体系不仅可以加速纯铝酸钙水泥水化和硬化;而且,在中温条件下,还可以起到辅助结合剂的作用,提升浇注料中温强度。
2、本发明中引入的碳酸钡细粉在材料服役过程中,能够分解成为高活性的氧化钡,与纯铝酸钙水泥一起形成结合网络,不仅可以提升结合强度,还可以降低中温条件下水泥水化产物胶结结构发生裂解的概率,从而提升浇注料强度。
3、本发明中引入的镁铝水滑石细粉在浇注料服役过程中,一部分可以原位形成晶粒尺寸细小的镁铝尖晶石,一部分与基质中其他组分形成含MgO的液相。镁铝尖晶石本身具有较好的抗碱性能,同时,镁铝尖晶石晶相也可以在基质中起到支撑骨架的作用,提升浇注料强度和高温体积稳定性。此外,在常规耐碱浇注料中,莫来石物相容易在K2O、Na2O等碱性物质的侵蚀下而发生分解,从而导致结构坍塌。而镁铝水滑石细粉在基质中所形成的含MgO的液相能够促进基质中莫来石晶粒的形成、析出和发育,不仅抑制了莫来石的分解,还提升了浇注料中莫来石物相的含量,从而增加浇注料强度、高温体积稳定性和抗碱性能。
4、本发明引入的锆英石细粉能够在不影响浇注料高温性能的前提下,提升材料中液相的粘度;同时,本发明引入的碳酸钡细粉在服役过程中,能够在基质中形成钡长石,其也具有较好的抗碱和硫酸盐的侵蚀性能,进一步提升了浇注料的抗碱性能。
5、本发明中由于锆英石细粉、镁铝水滑石细粉和碳酸钡细粉的作用,制备的浇注料具有较高的固相含量和较低的玻璃相含量,同时,原位反应生成尖晶石、铝酸钙、莫来石、钡长石等过程中会伴随着体积膨胀,因此,其在烧成过程及服役过程中体积收缩比较小,体积稳定性优良。
6、本发明所制备的高强耐碱轻质耐火浇注料经检测:110℃条件下冷态抗折强度为5~8MPa;1100℃×3h烧后冷态抗折强度为7~9MPa;1100℃×3h烧后线变化率为-0.3%~-0.2%;使用温度超过1300℃;静态坩埚法抗碱性能测试后质量变化率小于0.3%。
实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述。
所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。
实施例1:一种高强耐碱轻质耐火浇注料,包括原料,原料包括以下质量份数的骨料和基质料,骨料包括55份的轻质莫来石耐火颗粒,基质料包括12份耐火粘土细粉、3份碳酸钡细粉、3份锆英石细粉、4份的镁铝水滑石细粉、2份的硅溶胶和4份的纯铝酸钙水泥;轻质莫来石耐火颗粒中Al2O3含量为70wt%;轻质莫来石耐火颗粒的粒径为0.088~8mm;耐火粘土细粉的Al2O3含量为30wt%;耐火粘土细粉的粒径≤0.088mm;碳酸钡细粉的粒径≤45μm;锆英石细粉中ZrO2含量为63wt%;锆英石细粉的粒径≤74μm;镁铝水滑石细粉中MgO与Al2O3摩尔比为1.5;镁铝水滑石细粉的粒径≤45μm;硅溶胶的SiO2含量为25wt%;硅溶胶的pH值为9;纯铝酸钙水泥的Al2O3含量为70wt%,CaO含量为30wt%;纯铝酸钙水泥的粒径≤0.088mm。
实施例2:一种高强耐碱轻质耐火浇注料,包括原料,原料包括以下质量份数的骨料和基质料,骨料包括65份的轻质莫来石耐火颗粒,基质料包括15份耐火粘土细粉、5份碳酸钡细粉、5份锆英石细粉、6份的镁铝水滑石细粉、3份的硅溶胶和7份的纯铝酸钙水泥;轻质莫来石耐火颗粒中Al2O3含量为75wt%;轻质莫来石耐火颗粒的粒径为0.088~8mm;耐火粘土细粉的Al2O3含量为37wt%;耐火粘土细粉的粒径≤0.088mm;碳酸钡细粉的粒径≤45μm;锆英石细粉中ZrO2含量为65wt%;锆英石细粉的粒径≤74μm;镁铝水滑石细粉中MgO与Al2O3摩尔比为2;镁铝水滑石细粉的粒径≤45μm;硅溶胶的SiO2含量为30wt%;硅溶胶的pH值为10;纯铝酸钙水泥的Al2O3含量为75wt%,CaO含量为25wt%;纯铝酸钙水泥的粒径≤0.088mm。
实施例3:一种高强耐碱轻质耐火浇注料,包括原料,原料包括以下质量份数的骨料和基质料,骨料包括75份的轻质莫来石耐火颗粒,基质料包括18份耐火粘土细粉、6份碳酸钡细粉、6份锆英石细粉、8份的镁铝水滑石细粉、4份的硅溶胶和10份的纯铝酸钙水泥;轻质莫来石耐火颗粒中Al2O3含量为80wt%;轻质莫来石耐火颗粒的粒径为0.088~8mm;耐火粘土细粉的Al2O3含量为45wt%;耐火粘土细粉的粒径≤0.088mm;碳酸钡细粉的粒径≤45μm;锆英石细粉中ZrO2含量≥63wt%;锆英石细粉的粒径≤74μm;镁铝水滑石细粉中MgO与Al2O3摩尔比为2.5;镁铝水滑石细粉的粒径≤45μm;硅溶胶的SiO2含量为35wt%;硅溶胶的pH值为11;纯铝酸钙水泥的Al2O3含量为80wt%,CaO含量为20wt%;纯铝酸钙水泥的粒径≤0.088mm。
实施例4:一种高强耐碱轻质耐火浇注料的制备方法,包括以下步骤:按实施例1的配方取料,先将基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;再加入3质量份的水,搅拌均匀,振动成型,室温条件下养护12小时;最后在110℃条件下保温12小时,制得成品。
本实施例所制备的高强耐碱轻质耐火浇注料经检测:110℃条件下冷态抗折强度为5MPa;1100℃×3h烧后冷态抗折强度为8MPa;1100℃×3h烧后线变化率为-0.28%;使用温度超过1300℃;静态坩埚法抗碱性能测试后质量变化率小于0.3%。
实施例5:一种高强耐碱轻质耐火浇注料的制备方法,包括以下步骤:按实施例2的配方取料,先将基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;再加入7质量份的水,搅拌均匀,振动成型,室温条件下养护18小时;最后在150℃条件下保温24小时,制得成品。
本实施例所制备的高强耐碱轻质耐火浇注料经检测:110℃条件下冷态抗折强度为6MPa;1100℃×3h烧后冷态抗折强度为7MPa;1100℃×3h烧后线变化率为-0.26%;使用温度超过1300℃;静态坩埚法抗碱性能测试后质量变化率小于0.3%。
实施例6:一种高强耐碱轻质耐火浇注料的制备方法,包括以下步骤:按实施例3的配方取料,先将基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;再加入10质量份的水,搅拌均匀,振动成型,室温条件下养护24小时;最后在200℃条件下保温36小时,制得成品。
本实施例所制备的高强耐碱轻质耐火浇注料经检测:110℃条件下冷态抗折强度为8MPa;1100℃×3h烧后冷态抗折强度为8MPa;1100℃×3h烧后线变化率为-0.25%;使用温度超过1300℃;静态坩埚法抗碱性能测试后质量变化率小于0.3%。
基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。

Claims (9)

1.一种高强耐碱轻质耐火浇注料,包括原料,其特征在于,所述原料包括以下质量份数的骨料和基质料,所述骨料包括55~75份的轻质莫来石耐火颗粒,基质料包括12~18份耐火粘土细粉、3~6份碳酸钡细粉、3~6份锆英石细粉、4~8份的镁铝水滑石细粉、2~4份的硅溶胶和4~10份的纯铝酸钙水泥。
2.根据权利要求1所述的高强耐碱轻质耐火浇注料,其特征在于,所述轻质莫来石耐火颗粒中Al2O3含量为70~80wt%;轻质莫来石耐火颗粒的粒径为0.088~8mm。
3.根据权利要求1所述的高强耐碱轻质耐火浇注料,其特征在于,所述耐火粘土细粉的Al2O3含量为30~45wt%;耐火粘土细粉的粒径≤0.088mm。
4.根据权利要求1所述的高强耐碱轻质耐火浇注料,其特征在于,所述碳酸钡细粉的粒径≤45μm。
5.根据权利要求1所述的高强耐碱轻质耐火浇注料,其特征在于,所述锆英石细粉中ZrO2含量≥63wt%;锆英石细粉的粒径≤74μm。
6.根据权利要求1所述的高强耐碱轻质耐火浇注料,其特征在于,所述镁铝水滑石细粉中MgO与Al2O3摩尔比为1.5~2.5;镁铝水滑石细粉的粒径≤45μm。
7.据权利要求1所述的高强耐碱轻质耐火浇注料,其特征在于,所述硅溶胶的SiO2含量为25~35wt%;硅溶胶的pH值为9~11。
8.根据权利要求1所述的高强耐碱轻质耐火浇注料,其特征在于,所述纯铝酸钙水泥的Al2O3含量为70~80wt%,CaO含量为20~30wt%;纯铝酸钙水泥的粒径≤0.088mm。
9.一种如权利要求1~9任一所述的高强耐碱轻质耐火浇注料的制备方法,其特征在于,包括以下步骤:按配方取料,先将基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;再加入3~10质量份的水,搅拌均匀,振动成型,室温条件下养护12~24小时;最后在110~200℃条件下保温12~36小时,制得成品。
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