CN109437935A - 磷酸盐高铝砖的生产方法 - Google Patents

磷酸盐高铝砖的生产方法 Download PDF

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CN109437935A
CN109437935A CN201811569526.6A CN201811569526A CN109437935A CN 109437935 A CN109437935 A CN 109437935A CN 201811569526 A CN201811569526 A CN 201811569526A CN 109437935 A CN109437935 A CN 109437935A
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牛伟海
张顺卿
张晓强
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Zhengzhou Shuntong New Refractory Materials Co Ltd
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Abstract

本发明公开了一种磷酸盐高铝砖的生产方法，是由Al2O3＞85%的高铝矾土熟料93%；硅质旧砖细粉6%；硅微粉1%为原料，以浓度55%的磷酸二氢铝溶液为结合剂制备而成：首先将高铝矾土熟料、硅质旧砖细粉和硅微粉以及适量结合剂磷酸二氢铝溶液一起加入强制式混料机内搅拌均匀，困料4小时后再重新混炼15min，用400吨压力机压制成砖坯，然后入600℃低温窑炉中烘焙72小时得到成品磷酸盐高铝砖。本发明利用废旧遗弃的硅质作为产品的次要原料，不仅解决了部分废旧材料的处理问题，减轻了废旧材料对环境造成的危害；关键是提高了磷酸盐高铝质产品的使用寿命，节约了使用单位的生产成本，对开发潜在客户提供了有力的技术支撑。

Description

磷酸盐高铝砖的生产方法
技术领域
本发明涉及耐火材料的生产方法，尤其是涉及一种用于电炉炉顶、水泥窑烧成段、电站锅炉燃烧室等用的磷酸盐高铝砖的生产方法。
背景技术
上世纪九十年代初，磷酸盐制品（磷酸盐砖）在我国发展非常迅速，特别是在电炉炉顶、水泥窑及电站锅炉燃烧室等方面的应用较多。
目前我国使用的磷酸盐高铝制品，基本都是采用高铝材料+磷酸溶液制备的，存在荷重软化温度低、耐磨性能一般、极冷极热次数低并且蠕变偏高，且生产成本偏高。其主要材料来源是我国河南、山西地区。同时焦化厂的硅砖则是采取将使用后的废旧材料就地掩埋，进行处理，这不仅造成大量的资源浪费，同时由于采用掩埋的方式处理大量的废旧材料，还会造成土地浪费和地下水污染等不良后果，对环境危害很大。
发明内容
本发明的目的在于提供一种磷酸盐高铝砖的生产方法，以废旧的硅质旧砖作为主要添加料，大大降低了生产成本。
为实现上述目的，本发明可采取下述技术方案：
本发明所述的磷酸盐高铝砖的生产方法，是由Al2O3＞85%的高铝矾土熟料，硅质旧砖、硅微粉为原料，以浓度55%的磷酸二氢铝溶液为结合剂按照下述重量百分配比和方法制备而成：
原料配比：
Al2O3＞85%的高铝矾土熟料93%，其中：5-8mm颗粒料35%；3-5mm颗粒料20%；0-3mm颗粒料15%，粒径≤0.074mm细粉23%；
粒径≤0.074mm的硅质旧砖细粉6%；
硅微粉1%；
制备方法：将上述按比例称量的高铝矾土熟料、硅质旧砖细粉和硅微粉以及适量结合剂磷酸二氢铝溶液一起加入强制式混料机内搅拌均匀，困料4小时后再重新混炼15min，用400吨压力机压制成砖坯，然后入600℃低温窑炉中烘焙72小时得到成品磷酸盐高铝砖。
所述硅质旧砖为经过重复使用后拆除的废弃旧硅质砖，其主要晶相为磷石英。硅质旧砖的理化指标要满足SiO2≥96%；Al2O3≤0.5%；Fe2O3≤0.7%；CaO≥2.1%；R2O≤0.1%。
成品磷酸盐高铝砖的理化指标如下（与国标JC/T350-2013磷酸盐高铝制品比较）：
虽然化学指标略微偏低，但物理指标则有很大的提高；与常规砖体相比，将其应用在窑炉炉顶、水泥窑烧成段、电站锅炉燃烧室等部位中，可大大其提高使用寿命。具体来说，用在电炉炉顶上，可使用300次（原130次）；用在水泥窑烧成段上，可使用九个月（原来的磷酸盐高铝砖的使用寿命为六个月）；用在电站锅炉燃烧室等部位可使用五年（原来电站锅炉燃烧室耐材仅使用三年）。
本发明利用废旧硅砖作为次要原料，因为废旧硅砖在生产和使用后的主要晶相为磷石英，并含有一定量的石灰乳CaO,以硅微粉作为诱导剂，有效利用砖体在高温使用时的热能，促使砖体组织结构中的Al2O3与废旧硅砖中的SiO2反应，形成针状结构的莫来石晶相，由犬牙交错的针状晶相结构提高制品的耐磨性、高荷软、高极冷极热性及低蠕变性能，令废旧硅砖料换发出强有力的新生。
本发明采用精准的原料配比和级配，使砖体基质中Al2O3和SiO2在高温下达到理想的相平衡，即制备的成品磷酸盐高铝砖在高温使用条件下能促使组织结构中完全形成莫来石，由于莫来石3AI2O3•2SiO2在二元系中常压下稳定的二元固溶体，属斜方晶系，形成柱状或针状晶体结构，熔融温度约达1910℃，熔点为1850℃，所以成品砖体才具备了较高的荷重软化温度、较高的高温抗压及抗折强度、较强的耐磨性能和急冷急热性能、较低的蠕变性能。
本发明利用废旧遗弃的硅质作为产品的次要原料，不仅解决了部分废旧材料的处理问题，减轻了废旧材料对环境造成的危害；关键是提高了磷酸盐高铝质产品的使用寿命，节约了使用单位的生产成本，对开发潜在客户提供了有力的技术支撑。
具体实施方式
下面通过具体实施例对本发明做更加详细的说明，以便于本领域技术人员的理解。
实施例1
一种磷酸盐高铝砖的生产方法，是由Al2O3＞85%的高铝矾土熟料，重复使用后拆除的废弃旧硅质砖、硅微粉为原料，以浓度55%的磷酸二氢铝溶液为结合剂按照下述重量百分配比和方法制备而成：
原料配比：
Al2O3＞85%的高铝矾土熟料93%，其中：5-8mm颗粒料35%；3-5mm颗粒料20%；0-3mm颗粒料15%，粒径≤0.074mm细粉23%；
粒径≤0.074mm的硅质旧砖细粉6%；
硅微粉1%；
制备方法：将上述按比例称量的高铝矾土熟料、硅质旧砖细粉和硅微粉以及适量的结合剂磷酸二氢铝溶液（浓度55%，添加量为物料总量的8%）一起加入强制式混料机内搅拌成泥料，困料4小时后再重新混炼15min，用400吨压力机压制成砖坯，然后入600℃低温窑炉中烘焙72小时得到成品磷酸盐高铝砖。
本发明所用的硅质旧砖要采用经过重复使用的砖体，经过反复使用后的硅质砖体其晶相组织稳定，可逆晶相转换基本为零。

Claims (3)

1.一种磷酸盐高铝砖的生产方法，其特征在于：是由Al2O3＞85%的高铝矾土熟料，硅质旧砖、硅微粉为原料，以浓度55%的磷酸二氢铝溶液为结合剂按照下述重量百分配比和方法制备而成：
原料配比：
Al2O3＞85%的高铝矾土熟料93%，其中：5-8mm颗粒料35%；3-5mm颗粒料20%；0-3mm颗粒料15%，粒径≤0.074mm细粉23%；
粒径≤0.074mm的硅质旧砖细粉6%；
硅微粉1%；
制备方法：将上述按比例称量的高铝矾土熟料、硅质旧砖细粉和硅微粉以及适量结合剂磷酸二氢铝溶液一起加入强制式混料机内搅拌均匀，困料4小时后再重新混炼15min，用400吨压力机压制成砖坯，然后入600℃低温窑炉中烘焙72小时得到成品磷酸盐高铝砖。
2.根据权利要求1所述的磷酸盐高铝砖的生产方法，其特征在于：所述硅质旧砖为经过重复使用后拆除的废弃旧硅质砖，其主要晶相为磷石英。
3.根据权利要求1所述的磷酸盐高铝砖的生产方法，其特征在于：所述硅质旧砖的理化指标为SiO2≥96%；Al2O3≤0.5%；Fe2O3≤0.7%；CaO≥2.1%；R2O≤0.1%。
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Publication number Priority date Publication date Assignee Title
CN110407592A (zh) * 2019-08-09 2019-11-05 洛阳特耐窑炉工程有限公司 一种铝质不定型耐火材料的配方及其制备方法
CN113754456A (zh) * 2021-11-09 2021-12-07 长沙中瓷新材料科技有限公司 一种莫来石基陶瓷材料及其制备方法
CN113754456B (zh) * 2021-11-09 2022-03-08 长沙中瓷新材料科技有限公司 一种莫来石基陶瓷材料及其制备方法

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