CN106278299A - 红柱石复合耐火砖及其制备方法和应用 - Google Patents
红柱石复合耐火砖及其制备方法和应用 Download PDFInfo
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Abstract
本发明提供一种红柱石复合耐火砖,包括主料和添加剂,所述主料包括下述质量百分数的原料:铝矾土熟料大颗粒5%~10%、红柱石大颗粒10%~20%、莫来石大颗粒14%~20%、红柱石小颗粒14%~30%、红柱石细粉15%~35%、高岭土微粉5%~10%、硅微粉2%~5%;所述添加剂的质量为所述主料质量的4.5%~5.5%。本发明还提供一种上述红柱石复合耐火砖的制备方法和应用。所述红柱石复合耐火砖成分搭配合理且具有良好的热震性、较好的热稳定性和较高的荷重软化温度,从而提高了应用所述红柱石复合耐火砖砌筑火道墙的碳素焙烧炉使用寿命。
Description
技术领域
本发明属于耐火材料技术领域,具体的说,涉及了一种红柱石复合耐火砖及其制备方法和应用。
背景技术
在现代碳素工业中,用焙烧炉生产阳极碳块已经十分普遍,碳素焙烧炉的主要任务是焙烧电解铝用阳极碳块。现有技术的焙烧炉火道墙由粘土砖砌筑而成,燃料在火道内进行燃烧,并通过高载荷红柱石复合耐火砖材料将热量传递给临近料箱内的阳极碳块,阳极碳块在不接触火焰的气氛中焙烧。所以,耐火材料在阳极焙烧炉中除了要经受长期的高温、高压外,还要承受周期性的温度变化,因此,对耐火材料的要求是高温蠕变率低,荷重软化温度高、比较好的热震稳定性。
而在我国目前的市场上,碳素焙烧炉用耐火材料生产虽然已非常普遍,但是,无论是粘土质耐火材料还是高铝质耐火材料或一般的蠕变耐火材料都存在荷重软化点不高、热震稳定性差、长时间使用蠕变率大等缺点,会导致火道墙过早的出现变形,损坏,阳极碳块生产受到很大影响。
为了解决以上存在的问题,人们一直在寻求一种理想的技术解决方案。
发明内容
本发明的目的是针对现有技术的不足,从而提供一种具有较高的热震性、较高的荷重软化温度和较好的热稳定性的红柱石复合耐火砖。
为了实现上述目的,本发明所采用的技术方案是:一种红柱石复合耐火砖,包括主料和添加剂,所述主料包括下述质量百分数的原料:铝矾土熟料大颗粒5%~10%、红柱石大颗粒10%~20%、莫来石大颗粒14%~20%、红柱石小颗粒14%~30%、红柱石细粉15%~35%、高岭土微粉5%~10%、硅微粉2%~5%;所述添加剂的质量为所述主料质量的4.5%~5.5%。
基于上述,所述主料包括下述质量百分数的原料:铝矾土熟料大颗粒5%、红柱石大颗粒10%、莫来石大颗粒17%、红柱石小颗粒27%、红柱石细粉34%、高岭土微粉5%、硅微粉2%。
基于上述,所述铝矾土熟料大颗粒的粒度为1 mm~3 mm;所述莫来石大颗粒的粒度为1 mm~3 mm。所述红柱石大颗粒的粒度为1 mm~3 mm;
基于上述,所述红柱石小颗粒的粒度小于1 mm。
基于上述,所述红柱石细粉的粒度小于0.074 mm、所述高岭土微粉的粒度小于0.043 mm、所述硅微粉的粒度小于2微米。
基于上述,所述添加剂为纸浆水。
其中,所述主料包括骨料和细料,所述红柱石复合耐火砖以原料中的铝矾土熟料大颗粒、红柱石大颗粒、红柱石小颗粒、莫来石大颗粒为骨料,以红柱石细粉、高岭土微粉、硅微粉为细料,通过所述添加剂进行混合。
本发明还提供一种所述的红柱石复合耐火砖的制备方法,包括以下步骤:
(1)按照上述质量百分数计算,将铝矾土熟料大颗粒、红柱石大颗粒、莫来石大颗粒、红柱石小颗粒及添加剂进行混碾制得预制泥料;然后向所述预制泥料中加入红柱石细粉、高岭土微粉、硅微粉并进行混碾制得混碾泥料;
(2)将所述混碾泥料压制成砖坯,所述砖坯经干燥煅烧后制得所述红柱石复合耐火砖。
基于上述,所述步骤(2)包括:将所述混碾泥料压制成砖坯,将所述砖坯在温度为60℃~130℃条件下进行干燥时间24小时~36小时;然后将干燥后的所述砖坯在1450℃~1480℃的温度下进行煅烧10小时~24小时,从而制得所述红柱石复合耐火砖。
本发明还提供一种上述红柱石复合耐火砖的应用,所述红柱石复合耐火砖应用于碳素焙烧炉中。
本发明所提供的红柱石复合耐火砖原料中各成分的性能作用如下:
红柱石:晶体属正交(斜方)晶系的岛状结构硅酸盐矿物,红柱石在砖坯煅烧过程中会发生不可逆的晶体转化形成具有良好的莫来石网络的莫来石,从而使其具有1800℃以上的耐火性能,且耐骤冷骤热、机械强度大、抗热冲击力和抗渣性强、荷重转化点高,并具有极高的化学稳定性和极强的抗化学腐蚀性,从而使得制备的所述红柱石复合耐火砖具有高荷软、低蠕变、高抗热震性能。
高岭土:高岭土属于1:1型层状硅酸盐,晶体主要由硅氧四面体和铝氢氧八面体组成,具有强的耐酸性能和大于1700℃的耐烧性能从而增加了所述红柱石复合耐火砖的抗煅烧性,高岭土与水结合形成的泥料具有较高的可塑性,使得制备的所述砖坯具有较好的成型性。
铝矾土熟料:是指铝矾土矿物经过煅烧后的物料,其主要成分为水铝石和高铝硅石,具有较高的耐烧性能,常用来制备各种高铝砖,是冶金工业和其它工业广泛使用的耐火或防腐材料。
莫来石:是一系列铝硅酸盐组成的矿物统称,具有耐高温、强度高导热系数小,节能效果显著等特点,适用于石油裂介炉、冶金热风炉、陶瓷辊道窑、隧道窑、电瓷抽屉窑、玻璃坩埚窑及各种电炉的内衬,可直接接触火焰。
硅微粉:硅微粉是由天然石英或熔融石英经破碎、球磨、浮选、酸洗提纯、高纯水处理等多道工艺加工而成的微粉;是一种无毒、无味、无污染的无机非金属材料。它具有耐温性好、耐酸碱腐蚀、导热性差、高绝缘、低膨胀、化学性能稳定、硬度大等优良的性能。硅微粉不易与其他物质反应,与大部分酸、碱不起化学反应大颗粒级配合理,使用时能减少和消除沉淀、分层现象;可使固化物的抗拉、抗压强度增强,耐磨性能提高,并能增大固化物的导热系数,增加阻燃性能。硅微粉能够填充红柱石复合耐火砖原料大颗粒间的孔隙,同时与水化产物生成凝胶体,能显著提高红柱石复合耐火砖的抗压、抗折、抗渗、防腐、抗冲击、耐磨性能和致密性。并与Al2O3发应生成莫来石相,使红柱石复合耐火砖的高温强度,抗热振性增强。
本发明相对现有技术具有突出的实质性特点和显著的进步,具体的说,本发明将不同粒度的铝矾土熟料、红柱石、莫来石、高岭土、硅微粉和添加剂进行混合,使得制备的砖坯各个部位成分配比搭配一致,保证了煅烧所得的红柱石复合耐火砖各部位性能的一致性,同时原料中含有大量棱角突出的粒度料,增大了临界粒度,为红柱石复合耐火砖提供了牢固的骨架结构使其在使用过程中不易产生变形。同时,分别利用铝矾土熟料、莫来石、高岭土、硅微粉的耐烧特性和较好的成型性及红柱石在煅烧过程形成的具有抗热冲击力、抗渣性强、荷重转化点高的莫来石,使得制备的红柱石复合耐火砖具有高荷软、低蠕变、高抗热震性能,从而提高了应用所述红柱石复合耐火砖砌筑火道墙的碳素焙烧炉使用寿命。且该方法采用的原料易得、成分搭配合理,制备步骤简单。
具体实施方式
下面通过具体实施方式,对本发明的技术方案做进一步的详细描述。
实施例1
本实施例提供一种红柱石复合耐火砖,它包括骨料、细料和纸浆水,其中,所述纸浆水的质量为所述骨料和所述细料总质量的4.5%。所述骨料和所述细料由下述质量百分数的原料组成:铝矾土熟料大颗粒5%、红柱石大颗粒10%、莫来石大颗粒17%、红柱石小颗粒27%、红柱石细粉34%、高岭土微粉5%、硅微粉2%。
其中,所述铝矾土熟料大颗粒的粒度为1 mm~3 mm、所述莫来石大颗粒的粒度为1mm~3 mm、所述红柱石大颗粒的粒度为1 mm~3 mm、所述红柱石小颗粒的粒度小于1 mm、所述红柱石细粉的粒度小于0.074 mm、所述高岭土微粉的粒度小于0.043mm、所述硅微粉的粒度小于2微米。各原料中的化学成分如表1所示。
表1、各原料主要化学成分
本实施例还提供一种所述红柱石复合耐火砖的制备方法,具体制备步骤包括:
分别将红柱石、铝矾土熟料、焦宝石、高岭土、莫来石进行粉碎,制得上述粒度的原料。
将上述质量百分数的所述铝矾土熟料大颗粒、所述红柱石大颗粒、所述莫来石大颗粒、所述红柱石小颗粒及所述纸浆水进行混碾5分钟制得预制泥料;然后向所述预制泥料中加入上述质量百分数的所述红柱石细粉、所述高岭土微粉和所述硅微粉并进行混碾20分钟,制得混碾泥料。
采用压力吨位大于315吨的制砖机将所述混碾泥料压制成砖坯,然后将所述砖坯放入隧道式干燥洞中进行干燥24小时,其中控制所述隧道式干燥洞的进口温度为60℃、出口温度为130℃;将干燥后的所述砖坯装入燃气隧道窑中在1480℃的温度下进行煅烧12小时,从而制得所述红柱石复合耐火砖。经检测,本实施例制得的所述红柱石复合耐火砖密度为2.46 g/cm3。
由本实施例提供的制备方法制备的红柱石复合耐火砖,可应用于砌筑碳素焙烧炉火道墙。
实施例2
本实施例提供一种红柱石复合耐火砖,具体原料成分与实施例1大致相同,不同之处在于,本实施例中,所述纸浆水的质量为所述骨料和所述细料总质量的5.5%,所述骨料和所述细料包括下述质量百分数的原料:铝矾土熟料大颗粒5%、红柱石大颗粒10%、莫来石大颗粒17%、红柱石小颗粒29%、红柱石细粉32%、高岭土微粉5%、硅微粉2%。
本实施例所述的红柱石复合耐火砖的制备方法与实施例1中的制备方法大致相同,不同之处在于:将所述混碾泥料压制成砖坯,然后将所述砖坯放入隧道式干燥洞中进行干燥36小时,其中控制所述隧道式干燥洞的进口温度为60℃、出口温度为130℃;将干燥后的所述砖坯装入燃气隧道窑中在1470℃的温度下进行煅烧10小时;从而制得所述红柱石复合耐火砖。经检测,本实施例制得的所述红柱石复合耐火砖密度为2.49 g/cm3。
由本实施例提供的制备方法制备的红柱石复合耐火砖,可应用于砌筑碳素焙烧炉火道墙。
实施例3
本实施例提供一种红柱石复合耐火砖,具体原料成分与实施例1大致相同,不同之处在于,本实施例中,所述纸浆水的质量为所述骨料和所述细料总质量的5.5%,所述骨料和所述细料包括下述质量百分数的原料:铝矾土熟料大颗粒8%、红柱石大颗粒10%、莫来石大颗粒14%、红柱石小颗粒28%、红柱石细粉30%、高岭土微粉6%、硅微粉4%。
本实施例所述的红柱石复合耐火砖的制备方法与实施例1中的制备方法大致相同,不同之处在于:将所述混碾泥料压制成砖坯,然后将所述砖坯放入隧道式干燥洞中进行干燥26小时,其中控制所述隧道式干燥洞的进口温度为60℃、出口温度为130℃;然后将干燥后的砖坯在1450℃的温度下进行煅烧20小时从而制得所述红柱石复合耐火砖。经检测,本实施例制得的所述红柱石复合耐火砖密度为2.47 g/cm3。
由本实施例提供的制备方法制备的红柱石复合耐火砖,可应用于砌筑碳素焙烧炉火道墙。
红柱石复合耐火砖性能检测:分别对实施例1~3制备的红柱石复合耐火砖中Al2O3、Fe2O3含量、显气孔率、常温耐压强度和1350℃高温抗折强度性能进行检测,并在0.2MPa压力、1280℃煅烧25小时和50小时的蠕变率进行检测,检测结果如表2所示。
表2、红柱石复合耐火砖性能检测
从上表中可以看出:实施例1~3提供的红柱石复合耐火砖的软化点大于1600℃、常温耐压强度大于75MPa、蠕变率绝对值小于0.4%、显气孔率介于15%~16.2%之间、热膨胀率小于0.7%,因此所述红柱石复合耐火砖各项性能指标符合GB/T3994-2013规定的指标,所述红柱石复合耐火砖具有载荷软化温度高、低蠕变、高抗热震的性能,能应用于砌筑碳素焙烧炉火道墙来焙烧生产阳极碳块。
最后应当说明的是:以上实施例仅用以说明本发明的技术方案而非对其限制;尽管参照较佳实施例对本发明进行了详细的说明,所属领域的普通技术人员应当理解:依然可以对本发明的具体实施方式进行修改或者对部分技术特征进行等同替换;而不脱离本发明技术方案的精神,其均应涵盖在本发明请求保护的技术方案范围当中。
Claims (9)
1.一种红柱石复合耐火砖,包括主料和添加剂,其特征在于,所述主料包括下述质量百分数的原料:铝矾土熟料大颗粒5%~10%、红柱石大颗粒10%~20%、莫来石大颗粒14%~20%、红柱石小颗粒14%~30%、红柱石细粉15%~35%、高岭土微粉5%~10%、硅微粉2%~5%;所述添加剂的质量为所述主料质量的4.5%~5.5%。
2.根据权利要求1所述的红柱石复合耐火砖,其特征在于,所述主料包括下述质量百分数的原料:铝矾土熟料大颗粒5%、红柱石大颗粒10%、莫来石大颗粒17%、红柱石小颗粒27%、红柱石细粉34%、高岭土微粉5%、硅微粉2%。
3.根据权利要求1或2所述的红柱石复合耐火砖,其特征在于,所述铝矾土熟料大颗粒的粒度为1 mm~3 mm;所述莫来石大颗粒的粒度为1 mm~3 mm,所述红柱石大颗粒的粒度为1 mm~3 mm。
4.根据权利要求3所述的红柱石复合耐火砖,其特征在于,所述红柱石小颗粒的粒度小于1 mm。
5.根据权利要求4所述的红柱石复合耐火砖,其特征在于,所述红柱石细粉的粒度小于0.074 mm、所述高岭土微粉的粒度小于0.043mm、所述硅微粉的粒度小于2微米。
6.根据权利要求5所述的红柱石复合耐火砖,其特征在于,所述添加剂为纸浆水。
7.一种所述的红柱石复合耐火砖的制备方法,包括以下步骤:
(1)按照权利要求1~6任一项所述的红柱石复合耐火砖原料质量百分数计算,将铝矾土熟料大颗粒、红柱石大颗粒、莫来石大颗粒、红柱石小颗粒及添加剂进行混碾制得预制泥料;然后向所述预制泥料中加入红柱石细粉、高岭土微粉、硅微粉并进行混碾制得混碾泥料;
(2)将所述混碾泥料压制成砖坯,所述砖坯经干燥煅烧后制得所述红柱石复合耐火砖。
8.根据权利要求9所述的红柱石复合耐火砖的制备方法,其特征在于,所述步骤(2)包括:将所述混碾泥料压制成砖坯,将所述砖坯在温度为60℃~130℃条件下进行干燥时间24小时~36小时;然后将干燥后的所述砖坯在1420℃~1450℃的温度下进行煅烧10小时~24小时,从而制得所述红柱石复合耐火砖。
9.一种权利要求1~6任一项所述的红柱石复合耐火砖的应用,其特征在于,所述红柱石复合耐火砖应用于碳素焙烧炉中。
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