CN106747583A - 一种300kg级轻质莫来石砖及其制备工艺 - Google Patents
一种300kg级轻质莫来石砖及其制备工艺 Download PDFInfo
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Abstract
本发明公开了一种300kg级轻质莫来石砖及其制备工艺。该莫来石砖采用以下重量百分比组份:苏州泥5‑18%,α‑氧化铝微粉24‑35%,硅灰1‑3%,紫木节3‑8%,膨润土8‑15%,焦宝石3‑8%,沸石粉2‑9%,碳酸钙粉10‑20%和白水泥12‑18%;此外,还额外添加了以上组份重量总和为计算基准的以下组份:发泡剂2‑5%,水75‑100%,分散剂0.6‑1.4%。本发明的级轻质莫来石砖具有体积密度小、强度高、导热系数小、可成型大型砖等优点。
Description
技术领域
本发明涉及轻质保温耐火材料,具体涉及一种300kg级轻质莫来石砖及其制备工艺。
背景技术
轻质莫来石砖以其纯度高、耐高温、强度大、导热系数低等优越性能,广泛应用于石化、电力等行业高温热工设备的保温层衬里,甚至工作衬里。根据体积密度不同,通常可将轻质莫来石砖分为23级(500kg/m3)、26级、28级、30级等等,体积密度最小的轻质莫来石砖为23级轻质莫来石砖。目前轻质莫来石砖的成型方法采用挤压成型方式。
随着热工设备对耐火材料越来越严苛的要求,以及节能减排的需求,保温材料向体积密度更轻、导热系数更小、能耐高温、具有足够强度的方向发展成为必然。根据对国外市场的了解,他们对超轻保温材料的需求欲望远远大于国内,而且国内尚无体积密度小于500kg/m3的轻质莫来石砖,因此,研究开发超轻莫来石保温砖有利于抢先占领国际和国内市场。
传统的挤压成型不能满足超轻莫来石砖成型工艺要求,体积密度500kg/m3已经达到极限值,不可能再降低。而且挤压成型对超轻砖成型有致命缺陷:由于配方中加入了锯末、聚丙乙烯球等烧失剂,挤压成型后砖坯有较大体积反弹过程,这个过程会在砖体内部形成大量宏观物理缺陷,即使高温烧成后这些缺陷也不会消失,从而导致超轻砖强度降低,大量贯穿的裂纹也会使导热系数增大,从而降低保温节能的效果。
发明内容
发明目的:本发明所要解决的技术问题是针对现有技术的不足,提供一种体积密度小、强度高、导热系数小的轻质莫来石砖的制备工艺。
为了解决上述技术问题,本发明提供的一种300kg级轻质莫来石砖配方,具体制备工艺为:
以上组分重量百分比之和为100%;
此外,额外添加以下组份,计算基准为上述组分总重量:
发泡剂 2-5%;
洁净水 75-100%;
陶瓷分散剂 0.6-1.4%。
本发明中,苏州泥为200-500目,优选200目;α-氧化铝微粉为1000-1500目,优选1000目;硅灰为96硅灰;紫木节为500-700目,优选500目;膨润土为200-500目,优选200目;焦宝石为特级焦宝石,200-500目,优选200目;沸石粉为斜发沸石粉,500-700目,优选500目;碳酸钙粉为轻质碳酸钙粉,200-500目,优选200目;水泥为白水泥;外加组份发泡剂为铝粉发泡剂,1500-2000目,优选1500目;外加组份分散剂为陶瓷分散剂。
本发明中,陶瓷分散剂为淡黄色至黄色液体,pH值在6.0-8.5%,密度≥1.10g/cm3,能够吸附在各种微小颗粒表面并产生静电斥力使浆体分散,避免沉降、返粗,具有良好的悬浮稳定作用。
一种300kg级轻质莫来石砖的制备工艺,包括如下步骤:
(1)湿态球磨均化混合制浆:将除水泥、发泡剂以外的所有原材料加入到湿态球磨机中,球磨均化30-60分钟,优选30分钟,出浆备用,0.5-1小时内用完;
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入水泥搅拌3-5分钟,然后再加入发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化36-48小时,优选36小时后拆模;
(5)养护:恒温恒湿养护2-3天,优选3天;
(6)烘干:40-60℃,优选60℃烘烤24-48小时,优选24小时;
(7)烧成:隧道窑1200-1300℃高温烧成,保温36-48小时,优选36小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
本发明中,湿态球磨均化混合制浆过程湿磨球采用氧化铝材质球,大球规格为中球规格为小球规格为大球、中球、小球按重量比(0.5-1.5):(1.8-2.3):(3.0-4.0)组合,优选重量比1:2:3.5。
有益效果:
采用本发明制备的轻质莫来石砖单位重量轻,体积密度小,达到300±20kg/m3左右,有利于减少窑体自重,降低耐火材料负荷过重对窑体造成损坏的可能性,延长使用寿命;导热系数低,540℃下导热系数≤0.120w/m·k,有效减少窑体热量损失,可提高能源利用率20%以上,节能环保;最高使用温度可达1200℃,可用于环境温度要求较高的热工设备保温层;常温耐压强度可达1.1MPa,解决了保温材料强度低的问题,有利于提高砖体称重和剪切能力,减少窑体损坏的可能性。
具体实施方式
实施例1
工艺配方为:
具体步骤如下:
(1)湿态球磨均化混合制浆:将除白水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化40分钟,出浆备用,1小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入白水泥搅拌3分钟,然后再加入铝粉发泡剂,继续搅拌3分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化40小时后拆模;
(5)养护:恒温恒湿养护2天;
(6)烘干:50℃烘烤36小时;
(7)烧成:隧道窑1200-1300℃高温烧成,保温40小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例2
工艺配方为:
具体步骤如下:
(1)湿态球磨均化混合制浆:将除白水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化30分钟,出浆备用,1小时内用完。其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积的(1)中浆体,置于叶片搅拌机中,加入白水泥搅拌3分钟,然后再加入铝粉发泡剂,继续搅拌3分钟;
(3)浇注成型:将(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化36小时后拆模;
(5)养护:恒温恒湿养护3天;
(6)烘干:60℃烘烤24小时;
(7)烧成:隧道窑1200-1300℃高温烧成,保温36小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例3
工艺配方为:
具体步骤如下:
(1)湿态球磨均化混合制浆:将除白水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化50分钟,出浆备用,1小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入白水泥搅拌3分钟,然后再加入铝粉发泡剂,继续搅拌3分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化48小时后拆模;
(5)养护:恒温恒湿养护3天;
(6)烘干:60℃烘烤48小时;
(7)烧成:隧道窑1200-1300℃高温烧成,保温48小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例4
具体步骤如下:
(1)湿态球磨均化混合制浆:将除白水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化30分钟,出浆备用,0.5小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入白水泥搅拌3分钟,然后再加入铝粉发泡剂,继续搅拌3分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化36小时后拆模;
(5)养护:恒温恒湿养护2天;
(6)烘干:40℃烘烤24小时;
(7)烧成:隧道窑1200-1300℃高温烧成,保温36小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例5
具体步骤如下:
(1)湿态球磨均化混合制浆:将除白水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化60分钟,出浆备用,1小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入白水泥搅拌5分钟,然后再加入铝粉发泡剂,继续搅拌5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化48小时后拆模;
(5)养护:恒温恒湿养护3天;
(6)烘干:60℃烘烤48小时;
(7)烧成:隧道窑1200-1300℃高温烧成,保温48小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例6
具体步骤如下:
(1)湿态球磨均化混合制浆:将除白水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化50分钟,出浆备用,0.8小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入白水泥搅拌4分钟,然后再加入铝粉发泡剂,继续搅拌4分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化42小时后拆模;
(5)养护:恒温恒湿养护2天;
(6)烘干:50℃烘烤36小时;
(7)烧成:隧道窑1200-1300℃高温烧成,保温42小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例7
具体步骤如下:
(1)湿态球磨均化混合制浆:将除白水泥、铝粉以外的所有原材料加入到湿态球磨机中,球磨均化40分钟,出浆备用,1小时内用完;其中湿磨球采用氧化铝材质球,大球中球小球
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入白水泥搅拌4分钟,然后再加入铝粉发泡剂,继续搅拌4分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化45小时后拆模;
(5)养护:恒温恒湿养护2天;
(6)烘干:50℃烘烤40小时;
(7)烧成:隧道窑1200-1300℃高温烧成,保温40小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
实施例效果:
表1为实施例1-7所制备300kg级轻质莫来石砖的体积密度、耐压强度、导热系数值。
表1实施例1-7所制备的300kg级轻质莫来石砖性能参数
本发明提供了一种300kg级轻质莫来石砖及其制备工艺的思路及方法,具体实现该技术方案的方法和途径很多,以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。本实施例中未明确的各组成部分均可用现有技术加以实现。
Claims (5)
1.一种300kg级轻质莫来石砖,其特征在于,包括按以下重量百分比的组份:
以上组分重量百分比之和为100%;
此外,额外添加以下组份,计算基准为上述组分总重量:
发泡剂 2-5%;
水 75-100%;
分散剂 0.6-1.4%。
2.根据权利要求1所述的一种300kg级轻质莫来石砖,其特征在于,所述苏州泥为200-500目;所述α-氧化铝微粉为1000-1500目;所述硅灰为96硅灰;所述紫木节为500-700目;所述膨润土为200-500目;所述焦宝石为特级焦宝石,200-500目;所述沸石粉为斜发沸石粉,500-700目;所述碳酸钙粉为轻质碳酸钙粉,200-500目;所述水泥为白水泥;所述外加组份发泡剂为铝粉发泡剂,1500-2000目;所述外加组份分散剂为陶瓷分散剂。
3.根据权利要求2所述的一种300kg级轻质莫来石砖,其特征在于,所述陶瓷分散剂为淡黄色至黄色液体,pH值在6.0-8.5%,密度≥1.10g/cm3。
4.权利要求1所述一种300kg级轻质莫来石砖的制备工艺,其特征在于,包括如下步骤:
(1)湿态球磨均化混合制浆:将除水泥、发泡剂以外的所有原材料加入到湿态球磨机中,球磨均化30-60分钟,出浆备用,0.5-1小时内用完;
(2)叶片搅拌混合制浆:量取所需体积步骤(1)制备的浆体,置于叶片搅拌机中,加入水泥搅拌3-5分钟,然后再加入发泡剂,继续搅拌3-5分钟;
(3)浇注成型:将步骤(2)中制好的浆体倒入模具中成型;
(4)脱模:自然硬化36-48小时后拆模;
(5)养护:恒温恒湿养护2-3天;
(6)烘干:40-60℃烘烤24-48小时;
(7)烧成:隧道窑1200-1300℃高温烧成,保温36-48小时;
(8)附加工:将烧成的超轻莫来石砖加工成所需形状。
5.根据权利要求4所述的一种300kg级轻质莫来石砖的制备工艺,其特征在于,所述湿态球磨均化混合制浆过程湿磨球采用氧化铝材质球,大球规格为中球规格为小球规格为大球、中球、小球按重量比(0.5-1.5):(1.8-2.3):(3.0-4.0)组合。
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