CN106083086A - 一种利用SiC废弃匣钵制备碳化硅基匣钵的方法 - Google Patents
一种利用SiC废弃匣钵制备碳化硅基匣钵的方法 Download PDFInfo
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Abstract
本发明涉及一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,采用碳化硅和SiC废弃匣钵作为主原料,以玄武石、锆石英、纳米氧化锆、电熔镁砂、水玻璃、沥青、氮化硅和石棉纤维为辅料,同时,在制备过程中,采用水淬、油浸和后处理工艺,提高所制备产品的物化性能,所制备的匣钵热稳定性好,抗压能力强,耐腐蚀,且不易开裂的。
Description
技术领域
本发明属于耐火材料匣钵领域,特别涉及一种利用SiC废弃匣钵制备碳化硅基匣钵的方法。
背景技术
匣钵是窑具之一。在烧制陶瓷器过程中,为防止气体及有害物质对坯体、釉面的破坏及污损,将陶瓷器和坯体放置在耐火材料制成的容器中焙烧,这种容器即称匣钵,亦称匣子。
使用匣钵烧制陶瓷器,不仅可提高装烧量、制品不致粘结、提高成品率,而且匣钵还具有一定的导热性和热稳定性,可保证陶瓷质量。匣钵的形状,依器物形状而异。我国龙山文化时期烧制的蛋壳黑陶,已经使用专门的匣钵。在山东省诸城市杨家子遗址曾采集过两件烧制龙山文化蛋壳陶的匣钵,这是目前所知最早的匣钵。后世发现的匣钵,以盛装瓷器为主,隋代湘窑已有发现。
随着清洁能源的应用,匣钵作为承载体在日用陶瓷企业的使用越来越少。但是匣钵作为盛料器皿,在陶瓷色料企业的应用仍然非常普遍,近几年来,由于原料、燃料、人工等成本的不断上涨,匣钵的价格也大幅度提高,尽管这样,匣钵的使用寿命却在降低,匣钵使用破损率每窑达15~20%, 造成了严重的资源浪费和经济损失。如何提高匣钵使用次数,降低匣钵使用破损率,减少固体废物排放,提高企业效益,是现在亟待解决的问题。
废物回收利用是现在工业化生产必须面对的事情,CN103373192A公开了一种利用废弃匣钵生产匣钵制品的方法,包括以下生产步骤:(1)熟料加工;(2)生料加工;(3)制作匣钵生产用原料;(4)匣钵成型生产;(5)匣钵烧成。本发明可使SiC废弃匣钵加入量达到原料总量的50%,而且能够确保制成的匣钵制品质量稳定,符合相关标准的要求,但是其物化性能不够优越,尤其是在耐高温以及抗开裂等性能有待于提高。
本发明主要解决的技术问题是:针对现有技术的不足,提供一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,通过优化该碳化硅-SiC废弃匣钵复合匣钵的原料组成,采用碳化硅和SiC废弃匣钵作为主原料,以玄武石、锆石英、纳米氧化锆、电熔镁砂、水玻璃、沥青、氮化硅和石棉纤维为辅料,同时,在制备过程中,采用水淬、油浸和后处理工艺,提高所制备产品的物化性能,所制备的匣钵热稳定性好,抗压能力强,耐腐蚀,且不易开裂的。
发明内容
本发明的目的是针对上述问题,研制出一种利用SiC废弃匣钵制备碳化硅基匣钵的方法。
一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,包括如下制备步骤:
1)准备碳化硅-SiC废弃匣钵复合匣钵原料,该匣钵的原料组成为:碳化硅 70-147份;SiC废弃匣钵 20-45份;玄武石 7-10份;锆石英 7-10份;纳米氧化锆 7-10份;电熔镁砂 1-7份;水玻璃 1-3份;沥青 1-3份;氮化硅 1-3份;石棉纤维 1-3份;
2)将SiC废弃匣钵进行机械破碎,研磨成细粉,以及除铁处理,然后将其与其他原料混合,混合后进行湿法球磨,球磨后形成粉料过65目筛备用;
3)压坯成型,将球磨后粉料经造粒、压坯成型,在70Mpa压力下压制成型,保温2小时,脱模,得到匣钵坯体;
4)将坯体在500-700℃下预烧,随后进行水淬,将坯体快速放入水中,时间为20-45s;随后将水淬后的坯体放入50-60℃的油中,油浸20-45s;
5)将处理后的坯体在自然条件下干燥15h,放入窑炉内进行烧成,烧成温度为1200℃,烧成时间为12小时;
6)对烧成后的碳化硅-SiC废弃匣钵复合匣钵进行后处理,在侧面切割若干条膨胀缝,在膨胀缝处塞入陶瓷棉,即可获得碳化硅-SiC废弃匣钵复合匣钵。
作为优选,该匣钵的原料组成为:碳化硅 120份;SiC废弃匣钵 25份;玄武石 9份;锆石英9份;纳米氧化锆 9份;电熔镁砂 2份;水玻璃 2份;沥青 2份;氮化硅 2份;石棉纤维2份。
作为优选,步骤4)为将坯体在600℃下预烧,随后进行水淬,将坯体快速放入水中,时间为25s;随后将水淬后的坯体放入55℃的油中,油浸25s。
作为优选,步骤5)为将处理后的坯体在自然条件下干燥15h,放入窑炉内进行烧成,烧成温度为1200℃,烧成时间为12小时;升温过程为30-500℃升温速率为10℃/min;500-800℃升温速率为12℃/min;800-1200℃升温速率为8℃/min。
本发明还请求保护一种碳化硅-SiC废弃匣钵复合匣钵,其特征在于:其采用上述的利用SiC废弃匣钵制备碳化硅基匣钵的方法来制备。
本发明的有益效果:
整体而言,通过优化碳化硅-SiC废弃匣钵复合匣钵的组成,来提高匣钵的热稳定性、抗压能力、耐腐蚀性以及不易开裂等性能;在传统的以碳化硅和SiC废弃匣钵为主体的原料基础上,选择碳化硅的成分以大约3-7倍的量多于SiC废弃匣钵,可以使得坯体的耐压强度得到大大的提高;同时,将废物进行回收利用,将大大缩小原料的成本;同时,在辅料的选择上,玄武石、锆石英、纳米氧化锆和电熔镁砂以及少量的氮化硅不仅能够起到增强原料抗压能力以及热稳定效果,同时,在原料烧结过程中,其不仅与主料相反应,降低玻璃相,同时,优化烧结工艺,使得所制备的坯体具有更好的致密度以及热稳定性;而通过加入水玻璃和沥青的复合粘结剂,提高所制备的匣钵的结合性能以及可塑性能;而少量的石棉纤维通过在原料之间形成横向的剪切力,对于提高产品的抗压能力以及不易开裂等效果有非常重要的影响。
而从制备工艺来说,本发明在传统的制备工艺的基础上,开拓新的采用压坯-水淬-油浸-烧成-切割膨胀缝等工艺,通过充分的消除产品的内在应力,降低其热膨胀系数,整体制备工艺简单,但是对于优化产品的性能却产生重大的提高。所制备的匣钵抗压强度大于15 MPa,连续使用至少17次仍旧不会产生裂纹。
本发明采用的原料廉价,制备工艺简单绿色环保,可工业化实施。
具体实施方式
下面结合具体的实施例,并参照数据进一步详细描述本发明。应理解,这些实施例只是为了举例说明本发明,而非以任何方式限制本发明的范围。
实施例1:
一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,包括如下制备步骤:
1)准备碳化硅-SiC废弃匣钵复合匣钵原料,该匣钵的原料组成为:碳化硅 120份;SiC废弃匣钵 25份;玄武石 9份;锆石英9份;纳米氧化锆 9份;电熔镁砂 2份;水玻璃 2份;沥青 2份;氮化硅 2份;石棉纤维 2份;
2)将SiC废弃匣钵进行机械破碎,研磨成细粉,以及除铁处理,然后将其与其他原料混合,混合后进行湿法球磨,球磨后形成粉料过65目筛备用;
3)压坯成型,将球磨后粉料经造粒、压坯成型,在70Mpa压力下压制成型,保温2小时,脱模,得到匣钵坯体;
4)将坯体在600℃下预烧,随后进行水淬,将坯体快速放入水中,时间为25s;随后将水淬后的坯体放入55℃的油中,油浸25s;
5)将处理后的坯体在自然条件下干燥15h,放入窑炉内进行烧成,烧成温度为1200℃,烧成时间为12小时;升温过程为30-500℃升温速率为10℃/min;500-800℃升温速率为12℃/min;800-1200℃升温速率为8℃/min;
6)对烧成后的碳化硅-SiC废弃匣钵复合匣钵进行后处理,在侧面切割若干条膨胀缝,在膨胀缝处塞入陶瓷棉,即可获得碳化硅-SiC废弃匣钵复合匣钵。
所制备的匣钵抗压强度为16MPa,连续使用至少17次仍旧不会产生裂纹。
实施例2:
一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,包括如下制备步骤:
1)准备碳化硅-SiC废弃匣钵复合匣钵原料,该匣钵的原料组成为:碳化硅 90份;SiC废弃匣钵 45份;玄武石 9份;锆石英9份;纳米氧化锆 9份;电熔镁砂 2份;水玻璃 2份;沥青2份;氮化硅 2份;石棉纤维 2份;
2)将SiC废弃匣钵进行机械破碎,研磨成细粉,以及除铁处理,然后将其与其他原料混合,混合后进行湿法球磨,球磨后形成粉料过65目筛备用;
3)压坯成型,将球磨后粉料经造粒、压坯成型,在70Mpa压力下压制成型,保温2小时,脱模,得到匣钵坯体;
4)将坯体在600℃下预烧,随后进行水淬,将坯体快速放入水中,时间为25s;随后将水淬后的坯体放入55℃的油中,油浸25s;
5)将处理后的坯体在自然条件下干燥15h,放入窑炉内进行烧成,烧成温度为1200℃,烧成时间为12小时;升温过程为30-500℃升温速率为10℃/min;500-800℃升温速率为12℃/min;800-1200℃升温速率为8℃/min;
6)对烧成后的碳化硅-SiC废弃匣钵复合匣钵进行后处理,在侧面切割若干条膨胀缝,在膨胀缝处塞入陶瓷棉,即可获得碳化硅-SiC废弃匣钵复合匣钵。
所制备的匣钵抗压强度为17MPa,连续使用至少17次仍旧不会产生裂纹。
实施例3:
一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,包括如下制备步骤:
1)准备碳化硅-SiC废弃匣钵复合匣钵原料,该匣钵的原料组成为:碳化硅 140份;SiC废弃匣钵 25份;玄武石 7份;锆石英7份;纳米氧化锆 7份;电熔镁砂 1份;水玻璃 2份;沥青 2份;氮化硅 1份;石棉纤维 1份;
2)将SiC废弃匣钵进行机械破碎,研磨成细粉,以及除铁处理,然后将其与其他原料混合,混合后进行湿法球磨,球磨后形成粉料过65目筛备用;
3)压坯成型,将球磨后粉料经造粒、压坯成型,在70Mpa压力下压制成型,保温2小时,脱模,得到匣钵坯体;
4)将坯体在600℃下预烧,随后进行水淬,将坯体快速放入水中,时间为25s;随后将水淬后的坯体放入55℃的油中,油浸25s;
5)将处理后的坯体在自然条件下干燥15h,放入窑炉内进行烧成,烧成温度为1200℃,烧成时间为12小时;升温过程为30-500℃升温速率为10℃/min;500-800℃升温速率为12℃/min;800-1200℃升温速率为8℃/min;
6)对烧成后的碳化硅-SiC废弃匣钵复合匣钵进行后处理,在侧面切割若干条膨胀缝,在膨胀缝处塞入陶瓷棉,即可获得碳化硅-SiC废弃匣钵复合匣钵。
所制备的匣钵抗压强度为16MPa,连续使用至少17次仍旧不会产生裂纹。
实施例4:
一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,包括如下制备步骤:
1)准备碳化硅-SiC废弃匣钵复合匣钵原料,该匣钵的原料组成为:碳化硅 120份;SiC废弃匣钵 25份;玄武石 9份;锆石英9份;纳米氧化锆 9份;电熔镁砂 2份;水玻璃 2份;沥青 2份;氮化硅 2份;石棉纤维 2份;
2)将SiC废弃匣钵进行机械破碎,研磨成细粉,以及除铁处理,然后将其与其他原料混合,混合后进行湿法球磨,球磨后形成粉料过65目筛备用;
3)压坯成型,将球磨后粉料经造粒、压坯成型,在70Mpa压力下压制成型,保温2小时,脱模,得到匣钵坯体;
4)将坯体在700℃下预烧,随后进行水淬,将坯体快速放入水中,时间为20s;随后将水淬后的坯体放入50℃的油中,油浸20s;
5)将处理后的坯体在自然条件下干燥15h,放入窑炉内进行烧成,烧成温度为1200℃,烧成时间为12小时;升温过程为30-500℃升温速率为10℃/min;500-800℃升温速率为12℃/min;800-1200℃升温速率为8℃/min;
6)对烧成后的碳化硅-SiC废弃匣钵复合匣钵进行后处理,在侧面切割若干条膨胀缝,在膨胀缝处塞入陶瓷棉,即可获得碳化硅-SiC废弃匣钵复合匣钵。
所制备的匣钵抗压强度为17MPa,连续使用至少19次仍旧不会产生裂纹。
对比例1:
一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,包括如下制备步骤:
1)准备碳化硅-SiC废弃匣钵复合匣钵原料,该匣钵的原料组成为:碳化硅 120份;SiC废弃匣钵 25份;玄武石 9份;锆石英9份;纳米氧化锆 9份;电熔镁砂 2份;水玻璃 2份;沥青 2份;氮化硅 2份;石棉纤维 2份;
2)将SiC废弃匣钵进行机械破碎,研磨成细粉,以及除铁处理,然后将其与其他原料混合,混合后进行湿法球磨,球磨后形成粉料过65目筛备用;
3)压坯成型,将球磨后粉料经造粒、压坯成型,在70Mpa压力下压制成型,保温2小时,脱模,得到匣钵坯体;
4)将坯体在600℃下预烧,随后进行水淬,将坯体快速放入水中,时间为25s;
5)将处理后的坯体在自然条件下干燥15h,放入窑炉内进行烧成,烧成温度为1200℃,烧成时间为12小时;升温过程为30-500℃升温速率为10℃/min;500-800℃升温速率为12℃/min;800-1200℃升温速率为8℃/min;
6)对烧成后的碳化硅-SiC废弃匣钵复合匣钵进行后处理,在侧面切割若干条膨胀缝,在膨胀缝处塞入陶瓷棉,即可获得碳化硅-SiC废弃匣钵复合匣钵。
所制备的匣钵抗压强度为7MPa,连续使用9次产生裂纹。
对比例2:
一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,包括如下制备步骤:
1)准备碳化硅-SiC废弃匣钵复合匣钵原料,该匣钵的原料组成为:碳化硅 120份;SiC废弃匣钵 25份;玄武石 9份;锆石英9份;纳米氧化锆 9份;电熔镁砂 2份;水玻璃 2份;沥青 2份;氮化硅 2份;石棉纤维 2份;
2)将SiC废弃匣钵进行机械破碎,研磨成细粉,以及除铁处理,然后将其与其他原料混合,混合后进行湿法球磨,球磨后形成粉料过65目筛备用;
3)压坯成型,将球磨后粉料经造粒、压坯成型,在70Mpa压力下压制成型,保温2小时,脱模,得到匣钵坯体;
4)将坯体在600℃下预烧,随后进行水淬,将坯体快速放入水中,时间为25s;随后将水淬后的坯体放入55℃的油中,油浸25s;
5)将处理后的坯体在自然条件下干燥15h,放入窑炉内进行烧成,烧成温度为1200℃,烧成时间为12小时;升温过程为30-500℃升温速率为10℃/min;500-800℃升温速率为12℃/min;800-1200℃升温速率为8℃/min;即可获得碳化硅-SiC废弃匣钵复合匣钵。
所制备的匣钵抗压强度为8MPa,连续使用9次产生裂纹。
对于本领域技术人员而言,显然本发明不限于上述示范性实施例的细节,而且在不背离本发明的精神或基本特征的情况下,能够以其他的具体形式实现本发明。因此,无论从哪一点来看,均应将实施例看作是示范性的,而且是非限制性的,本发明的范围由所附权利要求而不是上述说明限定,因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内。
此外,应当理解,虽然本说明书按照实施方式加以描述,但并非每个实施方式仅包含一个独立的技术方案,说明书的这种叙述方式仅仅是为清楚起见,本领域技术人员应当将说明书作为一个整体,各实施例中的技术方案也可以经适当组合,形成本领域技术人员可以理解的其他实施方式。
Claims (5)
1.一种利用SiC废弃匣钵制备碳化硅基匣钵的方法,其特征在于:
包括如下制备步骤:
准备碳化硅基匣钵原料,该匣钵的原料组成为:碳化硅 60-146份;SiC废弃匣钵 20-45份;玄武石 6-10份;锆石英 6-10份;纳米氧化锆 6-10份;电熔镁砂 1-6份;水玻璃 1-3份;沥青 1-3份;氮化硅 1-3份;石棉纤维 1-3份;
将SiC废弃匣钵进行机械破碎,研磨成细粉,以及除铁处理,然后将其与其他原料混合,混合后进行湿法球磨,球磨后形成粉料过65目筛备用;
压坯成型,将球磨后粉料经造粒、压坯成型,在60Mpa压力下压制成型,保温2小时,脱模,得到匣钵坯体;
将坯体在500-600℃下预烧,随后进行水淬,将坯体快速放入水中,时间为20-45s;随后将水淬后的坯体放入50-60℃的油中,油浸20-45s;
将处理后的坯体在自然条件下干燥10-20h,放入窑炉内进行烧成,烧成温度为1100-1450℃,烧成时间为10-15小时;
对烧成后的碳化硅基匣钵进行后处理,在侧面切割若干条膨胀缝,在膨胀缝处塞入陶瓷棉,即可获得碳化硅基匣钵。
2.一种如权利要求2所述的利用SiC废弃匣钵制备碳化硅基匣钵的方法,其特征在于,该匣钵的原料组成为:碳化硅 120份;SiC废弃匣钵 25份;玄武石 9份;锆石英9份;纳米氧化锆 9份;电熔镁砂 2份;水玻璃 2份;沥青 2份;氮化硅 2份;石棉纤维 2份。
3.一种如权利要求1或2所述的利用SiC废弃匣钵制备碳化硅基匣钵的方法,其特征在于,步骤4)为将坯体在600℃下预烧,随后进行水淬,将坯体快速放入水中,时间为25s;随后将水淬后的坯体放入55℃的油中,油浸25s。
4.一种如权利要求1所述的利用SiC废弃匣钵制备碳化硅基匣钵的方法,其特征在于,步骤5)为将处理后的坯体在自然条件下干燥15h,放入窑炉内进行烧成,烧成温度为1200℃,烧成时间为12小时;升温过程为30-500℃升温速率为10℃/min;500-800℃升温速率为12℃/min;800-1200℃升温速率为8℃/min。
5.一种碳化硅基匣钵,其特征在于:其采用如权利要求1-4所述的利用SiC废弃匣钵制备碳化硅基匣钵的方法来制备。
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