CN107140997A - 一种窑口浇注料及其生产工艺 - Google Patents
一种窑口浇注料及其生产工艺 Download PDFInfo
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Abstract
本发明公开了一种窑口浇注料,属于耐火材料领域,本发明按照下列质量百分比进行配置:粒度为1~8mm的均化矾土8~15%,粒度为1~8mm的焦宝石5~10%,粒度为1~3mm的碳化硅20~25%,粒度为1~3mm的红柱石10~15%,粒度为0.001~0.088mm的高铝矾土粉4~10%,0~2.5μm煅烧α氧化铝3~5%,0~0.15μm硅微粉5~8%,粒度为1~4mm的白刚玉粉20~25%,铝酸钙水泥5~10%,防爆纤维0.1~0.5%,粒度为1~8mm的氧化铝空心球5~8%,复合减水剂0.2~0.3%。本发明可以显著提高窑口的热抗震性能、抗侵蚀性能以及耐磨性能,可以进一步降低窑口的重量,延长窑口的使用寿命。
Description
技术领域
本发明涉及耐火材料领域,具体涉及一种窑口浇注料及其生产工艺。
背景技术
进入 21 世纪,随着新型干法水泥生产工艺和技术的成熟,我国大规格回转窑的新型干法水泥生产线数量得到了迅猛发展,这得益于新型干法水泥回转窑直径∮4.5~6m,窑长 70~84m,具有窑温高、窑速快、产量大,经济效益好的优势,但也带来了窑内衬受碱侵蚀加重、结构更复杂等问题。
由于前窑口与冷却机相连,前窑口处的温度在 1100℃~1450℃范围内波动,所以窑口处的耐火材料要求具有良好的热震稳定性。持续的温度变化带来热应力不断的变化而使耐火材料产生破坏效果。转体窑在长期的转动下,窑体会发生变形,从而对耐火内衬形成挤压,窑口浇注料会受到挤压而脱落,虽然采用了很多措施,不断提高窑口耐火材料的综合性能,但窑口损坏现象依然存在,严重影响水泥企业的安全生产和正常运行。
目前,窑口所用的耐火材料主要为刚玉质或高铝质浇注料,例如专利号CN102584296B所提供的刚玉-碳化硅浇注料、CN104355646B所提供的刚玉质浇注料,解决了浇注料内部气孔多且不均匀以及不耐磨的问题,在一定程度上提高了使用寿命,但是,对于热震稳定性这方便的硬性需求还是难以满足,使用过程中的热应力使得耐火材料制品产生裂纹,并逐步导致裂纹扩展和制品部分剥落,最终使制品损坏,难以满足现有需要。
发明内容
在上述背景的基础下,本发明旨在提供一种窑口浇注料及其生产工艺,利用合理的粒度组成、气孔率,以及利用不同原料之间的热膨胀系数的差异,以此来提高该耐火浇注料的热震性能、抗侵蚀性能以及耐磨性能,大大延长使用寿命。
本发明的目的是通过以下技术方案实现的:一种窑口浇注料,所述窑口浇注料的原料按照下列质量百分比进行配置:
粒度为1~8mm的均化矾土 8~15%
粒度为1~8mm的焦宝石 5~10%
粒度为1~3mm的碳化硅 20~25%
粒度为1~3mm的红柱石 10~15%
粒度为0.001~0.088mm的高铝矾土粉 4~10%
0~2.5μm煅烧α氧化铝 3~5%
0~0.15μm硅微粉 5~8%
粒度为1~4mm的白刚玉粉 20~25%
铝酸钙水泥 5~10%
防爆纤维 0.1~0.5%
粒度为1~8mm的氧化铝空心球 5~8%
复合减水剂 0.2~0.3%
上述各项组分含量之和为100%。
优选地,所述复合减水剂为氨基酸磺酸盐系高效减水剂与FDN高效减水剂以及三聚磷酸钠的混合物,所述复合减水剂中各组分的质量比为:
氨基酸磺酸盐系高效减水剂:FDN高效减水剂:三聚磷酸钠 = 1:1.2:1.5
本发明还提供了该窑口浇注料的生产工艺,包括以下步骤:
a、将称量好的的均化钒土、焦宝石、碳化硅、红柱石以及铝酸钙水泥放入搅拌机中进行搅拌,搅拌时间控制在5~10分钟,形成骨基料;
b、将称量好的高铝矾土粉、煅烧α氧化铝、硅微粉、白刚玉粉搅拌混合,形成粉基料;
c、将上述骨基料以及粉基料进行混合,然后加入氧化铝空心球搅拌均匀,形成基料;
d、将基料与复合减水剂分开包装,再一起进行包装,形成最终的浇注料。
进一步的,所述窑口浇注料的使用方法包括以下步骤:
1)将基料倒入搅拌机中搅拌,等待加水搅拌;
2)将复合减水剂倒入称量好的水中混合均匀,再将该混合水倒入搅拌机中,将基料进行搅拌,边倒水,边搅拌,搅拌时间在 10~15分钟;
3)将搅拌好的浇注料利用模具进行成型,在常温下养护24~48h,然后放入干燥箱内进行烘干,烘干时间在24h~48h;
4)将干燥好的成品进行加热处理,以5℃/min的速度从110℃加热到1200℃,保温3h。
本发明的有益效果是:本发明提供的窑口浇注料,由均化矾土、焦宝石、碳化硅、红柱石、高铝矾土粉、煅烧α氧化铝、硅微粉、白刚玉粉、铝酸钙水泥、防爆纤维、氧化铝空心球以及复合减水剂构成,首先利用不同原料之间的热膨胀系数的差异,使得窑口制品内部产生一定量的细微裂纹,从而提高窑口的热震稳定性,且通过氧化铝空心球,一方面可以降低制品的重量,另一方面,替代闭气孔,阻碍热应力的“尖端效应”,以此来再次提高耐火材料的热震稳定性,通过减少显气孔来提高抗侵蚀性能,利用各项原料选定的粒度来提高制品的结合强度,提高耐磨性能。利用此复合减水剂,可以提高减水效果且不离析,流动性良好,配合浇注料的其他性能也很理想。其中的高温反应原料在加热过程中反应产出一定量的莫来石以及钙长石,与均化钒土中均匀分布的杂质形成高粘度的硅酸盐,以此来提高高温抗折强度。其中生成的氧化硅与氧化铝在制品表面形成釉层,在一定程度上封闭浇注料表面的气孔同时降低显气孔率,显著阻隔碱蒸汽向制品内部渗入以及侵蚀的过程,延长了使用寿命。
具体实施方式
下面结合实施例对本发明作进一步详细说明。本具体实施例仅仅是对本发明的解释,其并不是对发明的限制,本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出任何修改,但只要在本发明的权利要求范围内都受到专利法的保护。
实施例1:
一种窑口浇注料,所述窑口浇注料的原料按照下列质量百分比进行配置:
粒度为5mm的均化矾土 15%
粒度为3mm的焦宝石 10%
粒度为3mm的碳化硅 20%
粒度为3mm的红柱石 10%
粒度为0.08mm的高铝矾土粉 5%
2.5μm煅烧α氧化铝 5%
0.15μm硅微粉 5%
粒度为3mm的白刚玉粉 20%
铝酸钙水泥 5%
防爆纤维 0.2%
粒度为5mm的氧化铝空心球 5%
复合减水剂 0.2%
其中,所述复合减水剂为氨基酸磺酸盐系高效减水剂与FDN高效减水剂以及三聚磷酸钠的混合物,所述复合减水剂中各组分的质量比为:
氨基酸磺酸盐系高效减水剂:FDN高效减水剂:三聚磷酸钠 = 1:1.2:1.5
本发明还提供该窑口浇注料的生成工艺,包括,a、将称量好的的均化钒土、焦宝石、碳化硅、红柱石以及铝酸钙水泥放入搅拌机中进行搅拌,搅拌时间控制在10分钟,形成骨基料;
b、将称量好的高铝矾土粉、煅烧α氧化铝、硅微粉、白刚玉粉搅拌混合,形成粉基料;
c、将上述骨基料以及粉基料进行混合,然后加入氧化铝空心球搅拌均匀,形成基料;
d、将基料与复合减水剂分开包装,再一起进行包装,形成最终的浇注料。
本窑口浇注料的使用方法如下:
1)将基料倒入搅拌机中搅拌,等待加水搅拌;
2)将复合减水剂倒入称量好的水中混合均匀,再将该混合水倒入搅拌机中,将基料进行搅拌,边倒水,边搅拌,搅拌时间在 15分钟;
3)将搅拌好的浇注料利用模具进行成型,在常温下养护48h,然后放入干燥箱内进行烘干,烘干时间在48h;
4)将干燥好的成品进行加热处理,以5℃/min的速度从110℃加热到1200℃,保温3h。
实施例2:
一种窑口浇注料,所述窑口浇注料的原料按照下列质量百分比进行配置:
粒度为5mm的均化矾土 10%
粒度为3mm的焦宝石 10%
粒度为3mm的碳化硅 25%
粒度为3mm的红柱石 10%
粒度为0.08mm的高铝矾土粉 5%
2.5μm煅烧α氧化铝 2%
0.15μm硅微粉 8%
粒度为3mm的白刚玉粉 20%
铝酸钙水泥 5%
防爆纤维 0.2%
粒度为5mm的氧化铝空心球 5%
复合减水剂 0.2%
其中,所述复合减水剂为氨基酸磺酸盐系高效减水剂与FDN高效减水剂以及三聚磷酸钠的混合物,所述复合减水剂中各组分的质量比为:
氨基酸磺酸盐系高效减水剂:FDN高效减水剂:三聚磷酸钠 = 1:1.2:1.5
本发明还提供该窑口浇注料的生成工艺,包括,a、将称量好的的均化钒土、焦宝石、碳化硅、红柱石以及铝酸钙水泥放入搅拌机中进行搅拌,搅拌时间控制在10分钟,形成骨基料;
b、将称量好的高铝矾土粉、煅烧α氧化铝、硅微粉、白刚玉粉搅拌混合,形成粉基料;
c、将上述骨基料以及粉基料进行混合,然后加入氧化铝空心球搅拌均匀,形成基料;
d、将基料与复合减水剂分开包装,再一起进行包装,形成最终的浇注料。
本窑口浇注料的使用方法如下:
1)将基料倒入搅拌机中搅拌,等待加水搅拌;
2)将复合减水剂倒入称量好的水中混合均匀,再将该混合水倒入搅拌机中,将基料进行搅拌,边倒水,边搅拌,搅拌时间在 15分钟;
3)将搅拌好的浇注料利用模具进行成型,在常温下养护48h,然后放入干燥箱内进行烘干,烘干时间在48h;
4)将干燥好的成品进行加热处理,以5℃/min的速度从110℃加热到1200℃,保温3h。
实施例1:
一种窑口浇注料,所述窑口浇注料的原料按照下列质量百分比进行配置:
粒度为5mm的均化矾土 8%
粒度为3mm的焦宝石 5%
粒度为3mm的碳化硅 25%
粒度为3mm的红柱石 10%
粒度为0.08mm的高铝矾土粉 10%
2.5μm煅烧α氧化铝 5%
0.15μm硅微粉 7%
粒度为3mm的白刚玉粉 20%
铝酸钙水泥 5%
防爆纤维 0.2%
粒度为5mm的氧化铝空心球 5%
复合减水剂 0.2%
其中,所述复合减水剂为氨基酸磺酸盐系高效减水剂与FDN高效减水剂以及三聚磷酸钠的混合物,所述复合减水剂中各组分的质量比为:
氨基酸磺酸盐系高效减水剂:FDN高效减水剂:三聚磷酸钠 = 1:1.2:1.5
本发明还提供该窑口浇注料的生成工艺,包括,a、将称量好的的均化钒土、焦宝石、碳化硅、红柱石以及铝酸钙水泥放入搅拌机中进行搅拌,搅拌时间控制在10分钟,形成骨基料;
b、将称量好的高铝矾土粉、煅烧α氧化铝、硅微粉、白刚玉粉搅拌混合,形成粉基料;
c、将上述骨基料以及粉基料进行混合,然后加入氧化铝空心球搅拌均匀,形成基料;
d、将基料与复合减水剂分开包装,再一起进行包装,形成最终的浇注料。
本窑口浇注料的使用方法如下:
1)将基料倒入搅拌机中搅拌,等待加水搅拌;
2)将复合减水剂倒入称量好的水中混合均匀,再将该混合水倒入搅拌机中,将基料进行搅拌,边倒水,边搅拌,搅拌时间在 15分钟;
3)将搅拌好的浇注料利用模具进行成型,在常温下养护48h,然后放入干燥箱内进行烘干,烘干时间在48h;
4)将干燥好的成品进行加热处理,以5℃/min的速度从110℃加热到1200℃,保温3h。
上述实施例中所用的各组分是本领域技术人员公知的产品,在市场上均可购买到,利用各组分原料之间热膨胀系数的差异,可以使得浇注料内部产生一定量的微小裂纹,提高浇注料的热震稳定性,添加的氧化铝空心球,可以降低浇注料的质量,降低运输成本,还可以阻碍热应力的作用,以及添加的防爆纤维,都可以提高热震稳定性,碳化硅、矾土粉、煅烧α氧化铝以及硅微粉等细粉相作用,可以提高抗碱侵蚀性能,利用不同粒度的原料可以提高浇注料的耐磨性能,利用复合减水剂,可以提高减水效果,同时配合整体浇注料的性能良好,延长浇注料的使用寿命在20~24个月之间。
上述实施例1-3的物理指标比较见下表
Claims (3)
1.一种窑口浇注料,其特征在于,所述窑口浇注料的原料按照下列质量百分比进行配置:
粒度为1~8mm的均化矾土 8~15%
粒度为1~8mm的焦宝石 5~10%
粒度为1~3mm的碳化硅 20~25%
粒度为1~3mm的红柱石 10~15%
粒度为0.001~0.088mm的高铝矾土粉 4~10%
0~2.5μm煅烧α氧化铝 3~5%
0~0.15μm硅微粉 5~8%
粒度为1~4mm的白刚玉粉 20~25%
铝酸钙水泥 5~10%
防爆纤维 0.1~0.5%
粒度为1~8mm的氧化铝空心球 5~8%
复合减水剂 0.2~0.3%
上述各项组分含量之和为100%。
2.根据权利要求1所述窑口浇注料,其特征在于,所述复合减水剂为氨基酸磺酸盐系高效减水剂与FDN高效减水剂以及三聚磷酸钠的混合物,所述复合减水剂中各组分的质量比为:
氨基酸磺酸盐系高效减水剂:FDN高效减水剂:三聚磷酸钠 = 1:1.2:1.5
一种生产权利要求1所述窑口浇注料的工艺,其特征在于,包括以下步骤:
a、将称量好的的均化钒土、焦宝石、碳化硅、红柱石以及铝酸钙水泥放入搅拌机中进行搅拌,搅拌时间控制在5~10分钟,形成骨基料;
b、将称量好的高铝矾土粉、煅烧α氧化铝、硅微粉、白刚玉粉搅拌混合,形成粉基料;
c、将上述骨基料以及粉基料进行混合,然后加入氧化铝空心球搅拌均匀,形成基料;
d、将基料与复合减水剂分开包装,再一起进行包装,形成最终的浇注料。
3.根据权利要求1或2所述窑口浇注料,其特征在于,所述窑口浇注料的使用方法包括以下步骤:
1)将基料倒入搅拌机中搅拌,等待加水搅拌;
2)将复合减水剂倒入称量好的水中混合均匀,再将该混合水倒入搅拌机中,将基料进行搅拌,边倒水,边搅拌,搅拌时间在 10~15分钟;
3)将搅拌好的浇注料利用模具进行成型,在常温下养护24~48h,然后放入干燥箱内进行烘干,烘干时间在24h~48h;
4)将干燥好的成品进行加热处理,以5℃/min的速度从110℃加热到1200℃,保温3h。
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