CN111995427A - 一种抗热震异形大块硅砖及其制备方法 - Google Patents
一种抗热震异形大块硅砖及其制备方法 Download PDFInfo
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 title claims abstract description 232
- 239000011449 brick Substances 0.000 title claims abstract description 97
- 239000000377 silicon dioxide Substances 0.000 title claims abstract description 71
- 230000035939 shock Effects 0.000 title claims abstract description 23
- 238000002360 preparation method Methods 0.000 title claims abstract description 11
- 239000005350 fused silica glass Substances 0.000 claims abstract description 32
- 238000001816 cooling Methods 0.000 claims abstract description 24
- 239000002994 raw material Substances 0.000 claims abstract description 14
- 238000004519 manufacturing process Methods 0.000 claims abstract description 9
- 239000000843 powder Substances 0.000 claims description 73
- 239000002245 particle Substances 0.000 claims description 43
- 239000004576 sand Substances 0.000 claims description 36
- 239000002699 waste material Substances 0.000 claims description 21
- 238000001354 calcination Methods 0.000 claims description 17
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 16
- 238000001035 drying Methods 0.000 claims description 15
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 13
- 229910052791 calcium Inorganic materials 0.000 claims description 13
- 239000011575 calcium Substances 0.000 claims description 13
- 238000002156 mixing Methods 0.000 claims description 11
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 claims description 10
- 239000004927 clay Substances 0.000 claims description 10
- 239000010436 fluorite Substances 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 8
- 229910052742 iron Inorganic materials 0.000 claims description 8
- 229920005610 lignin Polymers 0.000 claims description 8
- 238000004321 preservation Methods 0.000 claims description 8
- 238000005245 sintering Methods 0.000 claims description 6
- 238000000465 moulding Methods 0.000 claims description 5
- 238000003825 pressing Methods 0.000 claims description 5
- 238000005303 weighing Methods 0.000 claims description 5
- 230000002378 acidificating effect Effects 0.000 claims description 4
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 4
- 239000011230 binding agent Substances 0.000 claims description 2
- 239000007767 bonding agent Substances 0.000 claims description 2
- 230000005484 gravity Effects 0.000 claims description 2
- 235000013312 flour Nutrition 0.000 claims 1
- 239000010453 quartz Substances 0.000 abstract description 12
- 238000000034 method Methods 0.000 abstract description 10
- 238000006243 chemical reaction Methods 0.000 abstract description 6
- 229910052906 cristobalite Inorganic materials 0.000 abstract description 6
- 229910052905 tridymite Inorganic materials 0.000 abstract description 6
- 230000000694 effects Effects 0.000 abstract description 3
- 235000012239 silicon dioxide Nutrition 0.000 description 11
- 239000000203 mixture Substances 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 230000035772 mutation Effects 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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Abstract
本发明涉及一种抗热震异形大块硅砖及其制备方法,通过在结晶石英原料中添加部分熔融石英,利用熔融石英本身纯度高、高温状态下成玻璃态结构、热膨胀系数非常小、不发生各相的转化的优点,降低了烧结后硅砖内鳞石英和方石英的含量,总体上降低了结晶石英相转化过程中产生的体积效应,进一步降低了硅砖冷却过程中产生的裂纹。由于仅替代部分结晶石英原料,因此比用纯熔融石英做的产品性价比要高很多;同时产品可以和大宗小型产品同步烧成,大幅提高生产效率。
Description
技术领域
本发明涉及硅砖制备技术领域,尤其涉及一种抗热震异形大块硅砖及其制备方法。
背景技术
目前现有的硅砖生产工艺为采用天然的结晶石英为原料,添加矿化剂,在烧结过程中,促使全部结晶石英转化成60%左右的鳞石英,30%左右的方石英,9%左右的玻璃相及1%的残余石英。结晶石英向鳞石英和方石英的转化过程中体积会分别增加14.4%和16.7%,产生体积膨胀,这种体积膨胀会在硅砖内产生较大应力。且在硅砖冷却降温过程中,鳞石英、方石英及残余石英分别在600℃、220℃、120℃左右会产生体积突变,会大幅降低硅砖的抗热震性能。
基于上述问题,在制备砖型复杂、体积较大的异形大块硅砖的过程中,合格率普遍很低,因为这些产品数量少,不能单独烧成,只好随着大批大量小型硅砖烧成,即便延长保温时间,由于烧成和冷却都是由表及里的过程,就造成硅砖内外温度变化不一致,导致内外的膨胀和冷缩不一致而产生裂纹,造成废品,不得不一次次的重复生产,降低了生产效率和供货效率。即使用梭式窑超长时间的保温能够保障生产的成功,但也受制于生产装备的限制,导致生产能耗高、效率低。
发明内容
为解决现有技术的不足,本发明提出一种抗热震异形大块硅砖及其制备方法,通过在硅砖中添加部分熔融石英的方式,利用熔融石英本身纯度高、高温状态下成玻璃态结构、热膨胀系数非常小、不发生各相的转化的优点,总体上降低石英转化的体积效应,进而减少硅砖裂纹的产生。
为实现以上目的,本发明所采用的技术方案包括:
一种抗热震异形大块硅砖,其特征在于,可选自包括以质量分数计的如下组分:20%~50%的熔融石英、25%~65%的硅砂、10%~20%的废砖砂、10%~15%的熔融石英细粉、18%~25%的硅砂细粉、10%~15%的废砖砂细粉、+0.4%~1.4%的萤石细粉、+0.2%~0.8%的铁鳞细粉、+0.4%~1.4%的粘土粉、+0.7%~2%的钙粉、+1.5%~2.5%的结合剂。
进一步地,所述熔融石英粒度优选为小于等于3mm,且二氧化硅含量优选为不低于99%。
进一步地,所述熔融石英细粉粒度小于等于0.088mm,且二氧化硅含量不低于99%。
进一步地,所述硅砂粒度优选为小于等于2.2mm,所述废砖砂粒度优选为小于等于2.5mm,所述硅砂细粉粒度优选为小于等于0.088mm,所述废砖砂粒度小于等于0.088mm,所述萤石细粉粒度优选为小于等于0.088mm,所述铁鳞细粉粒度优选为小于等于0.088mm,所述粘土粉粒度优选为小于等于0.044mm,所述钙粉粒度优选为小于等于0.038mm。
进一步地,所述硅砂细粉优选为新密硅石粉。
进一步地,所述结合剂优选为木质素溶液、酸性硅溶胶,所述木质素溶液的比重区间优选为1.15~1.17g/cm3。
进一步地,一种抗热震异形大块硅砖的制备方法,包括以下步骤:
S1、原料混合:将所述原料称重、混合后加入适量水,放入搅拌机中混合均匀形成泥料;
S2、压制成型:将所述混合后的泥料放入模具中,进行机压或震动成型,制成砖坯;
S3、干燥:将所述成型后的砖坯放入干燥器中干燥,得到干燥砖坯;
S4、烧结:将所述干燥砖坯放入煅烧炉中升温煅烧,然后放入隧道窑或梭式窑中保温煅烧至砖坯烧结;
S5、降温冷却:将所述烧结后的砖坯进行降温冷却,得到抗热震异形大块硅砖。
进一步地,所述步骤S3中干燥温度区间优选为80~110℃,所述干燥砖坯的水分质量含量优选为小于0.5%。
进一步地,所述步骤S4中升温煅烧的升温速率优选为20~80℃/h,升温终点1420℃,所述保温煅烧的温度区间优选为1050~1450℃,保温时间优选为6~20小时。
进一步地,所述步骤S5中降温终点温度为100℃。
本发明的有益效果为:
采用本发明所述抗热震异形大块硅砖及其制备方法,通过在结晶石英原料中添加部分熔融石英,降低了烧结后硅砖内鳞石英和方石英的含量,总体上降低了结晶石英相转化过程中产生的体积效应,进一步降低了硅砖冷却过程中产生的裂纹。由于仅替代部分结晶石英原料,因此比用纯熔融石英做的产品性价比要高很多;同时产品可以和大宗小型产品同步烧成,大幅提高生产效率。
具体实施方式
实施例1
一种抗热震异形大块硅砖,选自以质量分数计的如下组分:20%的熔融石英、35%的硅砂、15%的废砖砂、10%的熔融石英细粉、20%的新密硅石粉、+0.8%(均为占起始料总重量的百分比)的萤石细粉、+0.3%的铁鳞细粉、+0.3%的粘土粉、+1.6%的钙粉、+1.8%的木质素溶液。进一步地,所述熔融石英粒度优选为小于等于3mm,所述硅砂粒度优选为小于等于2.2mm,所述废砖砂粒度优选为小于等于2.5mm,所述熔融石英细粉粒度优选为小于等于0.088mm,所述新密硅石粉粒度优选为小于等于0.088mm,所述萤石细粉粒度优选为小于等于0.088mm,所述铁鳞细粉粒度优选为小于等于0.088mm,所述粘土粉粒度优选为小于等于0.044mm,所述钙粉粒度优选为小于等于0.038mm。
优选的,上述抗热震异形大块硅砖通过如下方法制备,包括以下步骤:
S1、将熔融石英、硅砂、废砖砂、熔融石英细粉、新密硅石粉、萤石细粉、铁鳞细粉、粘土粉、钙粉、木质素溶液等原料称重、混合后加入+6%的水,放入搅拌机中搅拌20~30min,混合均匀形成泥料;
S2、压制成型:将所述混合后的泥料放入模具中,进行机压或震动成型,制成砖坯;
S3、干燥:将所述成型后的砖坯放入干燥器中干燥,干燥温度区间为80~110℃,得到水分质量含量小于0.5%干燥砖坯;
S4、烧结:将所述干燥砖坯放入煅烧炉中以20~25℃/h的速率升温煅烧,升温终点1420℃,然后放入1430℃的隧道窑或梭式窑中保温煅烧20h;
S5、降温冷却:将所述烧结后的砖坯进行降温冷却,先以40~50℃/h的降温速率降温至700℃,然后以20~25℃/h的降温速率降温至100℃,得到低膨胀抗热震异形大块硅砖。
实施例2
一种抗热震异形大块硅砖,选自以质量分数计的如下组分:35%的熔融石英、20%的硅砂、15%的废砖砂、10%的熔融石英细粉、20%的新密硅石粉、+0.6%的萤石细粉、+0.3%的铁鳞细粉、+0.3%的粘土粉、+1.4%的钙粉、+1.8%的木质素溶液。进一步地,所述熔融石英粒度优选为小于等于3mm,所述硅砂粒度优选为小于等于2.2mm,所述废砖砂粒度优选为小于等于2.5mm,所述熔融石英细粉粒度优选为小于等于0.088mm,所述新密硅石粉粒度优选为小于等于0.088mm,所述萤石细粉粒度优选为小于等于0.088mm,所述铁鳞细粉粒度优选为小于等于0.088mm,所述粘土粉粒度优选为小于等于0.044mm,所述钙粉粒度优选为小于等于0.038mm。
优选的,上述抗热震异形大块硅砖通过如下方法制备,包括以下步骤:
S1、将熔融石英、硅砂、废砖砂、熔融石英细粉、新密硅石粉、萤石细粉、铁鳞细粉、粘土粉、钙粉、木质素溶液等原料称重、混合后加入+6%的水,放入搅拌机中搅拌20~30min,混合均匀形成泥料;
S2、压制成型:将所述混合后的泥料放入模具中,进行机压或震动成型,制成砖坯;
S3、干燥:将所述成型后的砖坯放入干燥器中干燥,干燥温度区间为80~110℃,得到水分质量含量小于0.5%干燥砖坯;
S4、烧结:将所述干燥砖坯放入煅烧炉中以20~25℃/h的速率升温煅烧,升温终点1420℃,然后放入1440℃的隧道窑或梭式窑中保温煅烧15h;
S5、降温冷却:将所述烧结后的砖坯进行降温冷却,先以40~50℃/h的降温速率降温至700℃,然后以20~25℃/h的降温速率降温至100℃,得到低膨胀抗热震异形大块硅砖。
实施例3
一种抗热震异形大块硅砖,选自以质量分数计的如下组分:50%的熔融石英、20%的废砖砂、15%的熔融石英细粉、15%的废砖砂细粉、+1%的钙粉、+1.8%的酸性硅溶胶。进一步地,所述熔融石英粒度优选为小于等于3mm,所述废砖砂粒度优选为小于等于2.5mm,所述熔融石英细粉粒度优选为小于等于0.088mm,所述废砖砂细粉粒度优选为小于等于0.088mm,所述钙粉粒度优选为小于等于0.038mm。
优选的,上述抗热震异形大块硅砖通过如下方法制备,包括以下步骤:
S1、熔融石英、废砖砂、熔融石英细粉、废砖砂细粉、钙粉、酸性硅溶胶等原料称重、混合后加入+6%的溶胶,放入搅拌机中搅拌20~30min,混合均匀形成泥料;
S2、压制成型:将所述混合后的泥料放入模具中,进行机压或震动成型,制成砖坯;
S3、干燥:将所述成型后的砖坯放入干燥器中干燥,干燥温度区间为80~110℃,得到水分质量含量小于0.5%干燥砖坯;
S4、烧结:将所述干燥砖坯放入煅烧炉中以50~80℃/h的速率升温煅烧,升温终点1420℃,然后放入1050℃的隧道窑或梭式窑中保温煅烧6h;
S5、降温冷却:将所述烧结后的砖坯进行降温冷却,以80~100℃/h的降温速率降温至100℃,得到低膨胀抗热震异形大块硅砖。
表1抗热震异形大块硅砖的性能指标
项目 | 单位 | 实施例1 | 实施例2 | 实施例3 | 普通硅砖 |
SiO2 | % | 94.5 | 95 | 96.5 | 94 |
显气孔率 | % | 21 | 20.5 | 19 | 22 |
耐压 | MPa | 35 | 38 | 40 | 30 |
荷重温度 | ℃ | 1655 | 1655 | 1660 | 1650 |
以上所述仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到的变化或替换等都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应该以权利要求书的保护范围为准。
Claims (10)
1.一种抗热震异形大块硅砖,其特征在于,可选自包括以质量分数计的如下组分:20%~50%的熔融石英、25%~65%的硅砂、10%~20%的废砖砂、10%~15%的熔融石英细粉、18%~25%的硅砂细粉、10%~15%的废砖砂细粉、外加0.4%~1.4%的萤石细粉、0.2%~0.8%的铁鳞细粉、0.4%~1.4%的粘土粉、0.7%~2%的钙粉、1.5%~2.5%的结合剂。
2.如权利要求1所述的硅砖,其特征在于,所述熔融石英粒度小于等于3mm,且二氧化硅含量不低于99%。
3.如权利要求1所述的硅砖,其特征在于,所述熔融石英细粉粒度小于等于0.088mm,且二氧化硅含量不低于99%。
4.如权利要求1至3任一项所述的硅砖,其特征在于,所述硅砂粒度小于等于2.2mm,所述废砖砂粒度小于等于2.5mm,所述硅砂细粉粒度小于等于0.088mm,所述废砖砂粒度小于等于0.088mm,所述萤石细粉粒度小于等于0.088mm,所述铁鳞细粉粒度小于等于0.088mm,所述粘土粉粒度小于等于0.044mm,所述钙粉粒度小于等于0.038mm。
5.如权利要求4所述的硅砖,其特征在于,所述硅砂细粉为新密硅石粉。
6.如权利要求4所述的硅砖,其特征在于,所述结合剂为木质素溶液和/或酸性硅溶胶;所述木质素溶液的比重区间为1.15~1.17g/cm3。
7.一种抗热震异形大块硅砖的制备方法,其特征在于,包括以下步骤:
S1、原料混合:将所述原料称重、混合后加入5%~10%的水,放入搅拌机中混合均匀形成泥料;
S2、压制成型:将所述混合后的泥料放入模具中,进行机压或震动成型,制成砖坯;
S3、干燥:将所述成型后的砖坯放入干燥器中干燥,得到干燥砖坯;
S4、烧结:将所述干燥砖坯放入煅烧炉中升温煅烧,然后放入隧道窑或梭式窑中保温煅烧直至砖坯烧结;
S5、降温冷却:将所述烧结后的砖坯进行降温冷却,得到抗热震异形大块硅砖。
8.如权利要求7所述的制备方法,其特征在于,所述步骤S3中干燥温度区间为80~110℃,所述干燥砖坯的水分质量含量小于0.5%。
9.如权利要求7所述的制备方法,其特征在于,所述步骤S4中升温煅烧的升温速率为20~80℃/h,升温终点1420℃,所述保温煅烧的温度区间为1050~1450℃,保温时间为6~20小时。
10.如权利要求7至9任一项所述的制备方法,其特征在于,所述步骤S5中降温终点温度为100℃。
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