CN110028316B - 一种堇青石窑具匣钵及其制备方法 - Google Patents
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Abstract
一种堇青石窑具匣钵及其制备方法,属于耐火材料技术领域。其特征在于,原料重量份组成为:3‑1mm莫来石M47 10~15份,1‑0mm莫来石M47 10~15份,2‑1mm堇青石16~20份,粒径<150目堇青石7~12份,0.5‑0mm硅线石8~13份,粒径<200目红柱石7~13份,粒径<240目碳化硅4~7份,粒径<240目亚白刚玉5~10份,氧化铝CA 370C微粉3~6份,0.045mm苏州土4~6份,纸浆3.5~5.5份,磷酸0.3~0.6份,糊精0.3~0.6份。本发明具有足够的高温荷重软化温度、较高的耐火度、良好的耐急冷急热性。匣钵在反复加热、冷却后,仍能维持一定的机械强度,不致破裂。
Description
技术领域
一种堇青石窑具匣钵及其制备方法,属于耐火材料技术领域。
背景技术
匣钵是一种窑炉上长期使用的窑具,是消耗性用材。在陶瓷,建材,化工,冶金,玻璃等行业应用广泛。目前所应用的匣钵大都因自身质量较重而使承载能力收到限制,且能耗大,透热性能较差,使用过程中易开裂,破损率高,使用寿命短。如何提高匣钵的机械强度、高温荷重软化温度、耐急冷急热性、耐火度、导热性,是现在亟待解决的问题。
发明内容
本发明要解决的技术问题是:克服现有技术的不足,提供一种使用温度高、寿命长的堇青石窑具匣钵及其制备方法。
本发明解决其技术问题所采用的技术方案是:该堇青石窑具匣钵,其特征在于,原料重量份组成为:3-1mm莫来石M47 10~15份,1-0mm莫来石M47 10~15份,2-1mm堇青石16~20份,粒径<150目堇青石7~12份,0.5-0mm硅线石8~13份,粒径<200目红柱石7~13份,粒径<240目碳化硅4~7份,粒径<240目亚白刚玉5~10份,氧化铝CA 370C微粉3~6份,0.045mm苏州土4~6份,纸浆3.5~5.5份,磷酸0.3~0.6份,糊精0.3~0.6份。
堇青石具有热膨胀系数小、抗热震稳定胜好等优点,主要用于陶瓷窑具的生产。(20~1000℃)堇青石线膨胀系数(1.1-2.0)×10-6/℃,碳化硅4.7×10-6/℃ ,莫来石5.3×10-6/℃,三者在同温度下膨胀系数不同,形成热膨胀系数梯度。堇青石高温性能较差,不稳定,烧成范围窄,而莫来石耐火度高,高温抗蠕变性好,耐剥落耐侵蚀性好,高温稳定。堇青石与莫来石两者热膨胀系数的失匹配,在两相界面形成微裂纹,虽能使材料具有较好的的抗热震性及高温性能,但是使用寿命仍显不足;本发明加入适量的高导热系数的SiC,提高窑具的导热性,减小在急冷急热过程中窑具各部位的温差,减小热应力,提高窑具抗热震性及使用寿命。
加入堇青石形成莫来石-堇青石-碳化硅的组织结构,该结构膨胀系数小于莫来石-碳化硅的膨胀系数,抗热震性优于莫来石-碳化硅材料。
M47是1580℃高温煅烧的人工合成莫来石骨料,主晶相为柱状莫来石,有少量玻璃相和钛酸铝填充于莫来石晶间,构成了连续的骨架结构。该骨料铁含量低,气孔率低,致密度高,抗侵蚀性能好。
利用红柱石、硅线石在高温下的莫来石化,形成针状网络结构,提高制品的高温稳定性,热震性能,抗蠕变性能,提高窑具的中高温强度。
基质中红柱石、硅线石分解形成的SiO2及SiC氧化生成的SiO2与刚玉砂细粉、氧化铝微粉反应,形成二次莫来石化网络穿插于莫来石骨料之间,进一步提高了制品的高温稳定性,抗蠕变性能,抗热震性能。
基于前述的理化性能,本产品在使用过程中表现为耐腐蚀、不落渣,使用寿命长,是传统的刚玉-莫来石、莫来石-堇青石等无法比拟的,是使用温度1400℃以下的理想窑具。
优选的,原料重量份组成为:3-1mm莫来石M47 12~14份,1-0mm莫来石M47 12~14份,2-1mm堇青石17~19份,粒径<150目堇青石9~10份,0.5-0mm硅线石9~11份,粒径<200目红柱石9~10份,粒径<240目碳化硅5.5~6.5份,粒径<240目亚白刚玉7~8份,氧化铝CA370C微粉4~5份,0.045mm苏州土4.5~5.6份,纸浆4.2~5.1份,磷酸0.4~0.5份,糊精0.4~0.5份。优选的原料配比下能够达到更好的热震性和强度。
优选的,所述的3-1mm莫来石M47和1-0mm莫来石M47的化学质量百分比组成为Al2O350%~50.3%,Fe2O30.82%~0.92%,SiO246.8%~47.05%,TiO20.91%~0.94%,MgO0.05%~0.07%,CaO0.65%~0.72%,Na2O0.09%~0.11%和余量杂质。
优选的,所述的2-1mm堇青石和粒径<150目堇青石的化学质量百分比组成为Al 2O334.12%~34.56%,Fe2O30.75%~0.94%,SiO248.56%~49.12%,TiO20.75%~1.13%,MgO13.11%~13.35%和余量杂质。
优选的莫来石和堇青石组成能够更好的配合达到更好的抗热震性及高温性能。
更优选的,所述的3-1mm莫来石M47和1-0mm莫来石M47的化学质量百分比组成为Al2O350.20%,Fe2O30.86%,SiO247.01%,TiO20.93%,MgO 0.06%,CaO 0.69%,Na2O0.11%和余量杂质;耐火度为1770℃。
更优选的,所述的2-1mm堇青石和粒径<150目堇青石的化学质量百分比组成为Al2O334.39%,Fe2O30.88%,SiO248.83%,TiO20.95%,MgO13.23%和余量杂质;耐火度为1380℃。
更优选的莫来石和堇青石组成能够更好的配合达到本发明最好的抗热震性及高温性能。
一种堇青石窑具匣钵的制备方法,其特征在于,制备工艺为:
1)按配比将原料加入行星式湿碾机搅拌20分钟,混练均匀后出料,困料12h~15h;
2)液压机成型,控制湿坯气孔率为18.5%~20.0%,湿坯体积密度为2.48 g/cm3~2.68g/cm3;
3)干燥洞干燥,干燥温度为40℃~110℃,装前打音良好无裂纹,残余水分为0.45%~0.52%;
4)隧道窑烧成,烧成温度为1340℃~1360℃,烧成时间为6h~8h。
优选的,步骤2)中所述的湿坯气孔率为19%~19.5%,湿坯体积密度为2.53 g/cm3~2.60g/cm3。
优选的,步骤3)中所述的干燥温度为50℃~60℃,残余水分为0.48%~0.50%。
优选的,步骤4)中所述的烧成温度为1350℃,烧成时间为7h。
现有技术相比,本发明的所具有的有益效果是:
(1)足够的常温机械强度。使匣钵在搬运和装车承受重量时,不致破损。
(2)足够的高温荷重软化温度。比所装制品的烧成温度高50~100℃以上,从而保证在制品的烧成温度下,匣钵不会软化变形。
(3)较高的耐火度。比所装填的制品的烧成温度高300℃以上。
(4)良好的耐急冷急热性。使匣钵在反复加热、冷却后,仍能维持一定的机械强度,不致破裂。堇青石匣钵拥有具有良好的热稳定性,使用寿命长。特别适用在陶瓷、玻璃、冶金、化工等快速烧成的辊道窑上使用。
(5)良好的导热性能低蓄热性。
具体实施方式
下面结合具体实施例对本发明做进一步说明,其中实施例1为最佳实施。
实施例1
1)按配比将原料加入行星式湿碾机搅拌20分钟;原料重量份组成为:3-1mm莫来石M47 13份,1-0mm莫来石M47 13份,2-1mm堇青石18份,粒径<150目堇青石9.5份,0.5-0mm硅线石10份,粒径<200目红柱石9.5份,粒径<240目碳化硅6份,粒径<240目亚白刚玉7.5份,氧化铝CA370C微粉4.5份,0.045mm苏州土5份,纸浆4.5份,磷酸0.45份,糊精0.45份;3-1mm莫来石M47和1-0mm莫来石M47的化学质量百分比组成为Al2O350.20%,Fe2O30.86%,SiO247.01%,TiO20.93%,MgO 0.06%,CaO 0.69%,Na2O0.11%和余量杂质;耐火度为1770℃;2-1mm堇青石和粒径<150目堇青石的化学质量百分比组成为Al2O334.39%,Fe2O30.88%,SiO248.83%,TiO20.95%,MgO13.23%和余量杂质;耐火度为1380℃;混练均匀后出料陈放困料13h;
2)液压机成型,控制湿坯气孔率为19%%,湿坯体积密度2.56g/cm3;
3)干燥洞干燥,干燥温度为55℃,装前打音良好无裂纹,残余水分为0.49%;
4)隧道窑烧成,烧成温度为1350℃,烧成时间为7h。
实施例2
1按配比将原料加入行星式湿碾机搅拌20分钟;原料重量份组成为:3-1mm莫来石M47 14份,1-0mm莫来石M47 12份,2-1mm堇青石19份,粒径<150目堇青石9份,0.5-0mm硅线石11份,粒径<200目红柱石9份,粒径<240目碳化硅6.5份,粒径<240目亚白刚玉7份,氧化铝CA370C微粉5份,0.045mm苏州土4.5份,纸浆5.1份,磷酸0.4份,糊精0.5份;3-1mm莫来石M47和1-0mm莫来石M47的化学质量百分比组成为Al2O350.20%,Fe2O30.86%,SiO247.01%,TiO20.93%,MgO 0.06%,CaO 0.69%,Na2O0.11%和余量杂质;耐火度为1770℃;2-1mm堇青石和粒径<150目堇青石的化学质量百分比组成为Al2O334.39%,Fe2O30.88%,SiO248.83%,TiO20.95%,MgO13.23%和余量杂质;耐火度为1380℃;混练均匀后出料陈放困料14h;
2)液压机成型,控制湿坯气孔率为19.5%,湿坯体积密度为2.60g/cm3;
3)干燥洞干燥,干燥温度为60℃,装前打音良好无裂纹,残余水分为0.50%;
4)隧道窑烧成,烧成温度为1350℃,烧成时间为7h。
实施例3
1)按配比将原料加入行星式湿碾机搅拌20分钟;原料重量份组成为:3-1mm莫来石M47 12份,1-0mm莫来石M47 14份,2-1mm堇青石17份,粒径<150目堇青石10份,0.5-0mm硅线石9份,粒径<200目红柱石10份,粒径<240目碳化硅5.5份,粒径<240目亚白刚玉8份,氧化铝CA370C微粉4份,0.045mm苏州土5.6份,纸浆4.2份,磷酸0.5份,糊精0.4份;3-1mm莫来石M47和1-0mm莫来石M47的化学质量百分比组成为Al2O350.20%,Fe2O30.86%,SiO247.01%,TiO20.93%,MgO 0.06%,CaO 0.69%,Na2O0.11%和余量杂质;耐火度为1770℃;2-1mm堇青石和粒径<150目堇青石的化学质量百分比组成为Al2O334.39%,Fe2O30.88%,SiO248.83%,TiO20.95%,MgO13.23%和余量杂质;耐火度为1380℃;混练均匀后出料陈放困料13h;
2)液压机成型,控制湿坯气孔率为19%,湿坯体积密度为2.53 g/cm3;
3)干燥洞干燥,干燥温度为50℃,装前打音良好无裂纹,残余水分为0.48%;
4)隧道窑烧成,烧成温度为1350℃,烧成时间为7h。
实施例4
1)按配比将原料加入行星式湿碾机搅拌20分钟;原料重量份组成为:3-1mm莫来石M47 15份,1-0mm莫来石M47 10份,2-1mm堇青石20份,粒径<150目堇青石7份,0.5-0mm硅线石13份,粒径<200目红柱石7份,粒径<240目碳化硅7份,粒径<240目亚白刚玉5份,氧化铝CA 370C微粉6份,0.045mm苏州土4份,纸浆5.5份,磷酸0.3份,糊精0.6份。3-1mm莫来石M47和1-0mm莫来石M47的化学质量百分比组成为Al2O350.3%,Fe2O30.82%,SiO247.05%,TiO20.91%,MgO0.07%,CaO0.65%,Na2O0.11%和余量杂质。2-1mm堇青石和粒径<150目堇青石的化学质量百分比组成为Al2O334.56%,Fe2O30.75%,SiO249.12%,TiO20.75%,MgO13.35%和余量杂质。混练均匀后出料陈放困料12h;
2)液压机成型,控制湿坯气孔率为18.5%,湿坯体积密度为2.48 g/cm3;
3)干燥洞干燥,干燥温度为40℃,装前打音良好无裂纹,残余水分为0.45%;
4)烧成,烧成温度为1340℃,烧成时间为6h。
实施例5
1)按配比将原料加入行星式湿碾机搅拌20分钟;原料重量份组成为:3-1mm莫来石M47 10份,1-0mm莫来石M47 15份,2-1mm堇青石16份,粒径<150目堇青石12份,0.5-0mm硅线石8份,粒径<200目红柱石13份,粒径<240目碳化硅4份,粒径<240目亚白刚玉10份,氧化铝CA 370C微粉3份,0.045mm苏州土6份,纸浆3.5份,磷酸0.6份,糊精0.3份。3-1mm莫来石M47和1-0mm莫来石M47的化学质量百分比组成为Al2O350%,Fe2O30.92%,SiO246.8%,TiO20.94%,MgO0.05%,CaO0.72%,Na2O0.09%和余量杂质。2-1mm堇青石和粒径<150目堇青石的化学质量百分比组成为Al2O334.12%,Fe2O30.94%,SiO248.56%,TiO21.13%,MgO13.11%和余量杂质。混练均匀后出料陈放困料15h;;
2)液压机成型,控制湿坯气孔率为20.0%,湿坯体积密度为2.68g/cm3;
3)干燥洞干燥,干燥温度为110℃,装前打音良好无裂纹,残余水分为0.52%;
4)烧成,烧成温度为1360℃,烧成时间为7 h。
对比例1
工艺和原料配比同实施例1,不同的是原料中莫来石M473-1mm莫来石M47的用量为26份,粒径为1-0mm。
对比例2
工艺和原料配比同实施例1,不同的是原料中堇青石的用量为40份。
对比例3
工艺和原料配比同实施例1,不同的是原料中堇青石的用量为27份,粒径为<150目。
对比例4
工艺和原料配比同实施例1,不同的是原料中硅线石用量为4份,红柱石用量为20份。
对比例5
工艺和原料配比同实施例1,不同的是原料中不使用碳化硅。
对比例6
工艺和原料配比同实施例1,不同的是原料中纸浆0.5份,磷酸5份,糊精0.3份。
实施例1~5的成品外观:烧后成品外观稍显淡黄色。打音:打音清脆钢音。
实施例和对比的性能测试结果见表1~表4。
表1
表2
表3
表4
以上所述,仅是本发明的较佳实施例而已,并非是对本发明作其它形式的限制,任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以变更或改型为等同变化的等效实施例。但是凡是未脱离本发明技术方案内容,依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与改型,仍属于本发明技术方案的保护范围。
Claims (1)
1.一种堇青石窑具匣钵,其特征在于,原料重量份组成为:3-1mm莫来石M47 13份,1-0mm莫来石M47 13份,2-1mm堇青石18份,粒径<150目堇青石9.5份,0.5-0mm硅线石10份,粒径<200目红柱石9.5份,粒径<240目碳化硅6份,粒径<240目亚白刚玉7.5份,氧化铝CA370C微粉4.5份,0.045mm苏州土5份,纸浆4.5份,磷酸0.45份,糊精0.45份;3-1mm莫来石M47和1-0mm莫来石M47的化学质量百分比组成为Al2O350.20%,Fe2O30.86%,SiO247.01%,TiO20.93%,MgO 0.06%,CaO 0.69%,Na2O0.11%和余量杂质;耐火度为1770℃;2-1mm堇青石和粒径<150目堇青石的化学质量百分比组成为Al2O334.39%,Fe2O30.88%,SiO248.83%,TiO20.95%,MgO13.23%和余量杂质;耐火度为1380℃;
所述堇青石窑具匣钵的制备方法为:
1)按配比将原料加入行星式湿碾机搅拌20分钟;混练均匀后出料陈放困料13h;
2)液压机成型,控制湿坯气孔率为19%,湿坯体积密度2.56g/cm3;
3)干燥洞干燥,干燥温度为55℃,装前打音良好无裂纹,残余水分为0.49%;
4)隧道窑烧成,烧成温度为1350℃,烧成时间为7h。
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