CN113149620A - 轻质莫来石-尖晶石空心球匣钵加压成型工艺 - Google Patents

轻质莫来石-尖晶石空心球匣钵加压成型工艺 Download PDF

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CN113149620A
CN113149620A CN202110311806.2A CN202110311806A CN113149620A CN 113149620 A CN113149620 A CN 113149620A CN 202110311806 A CN202110311806 A CN 202110311806A CN 113149620 A CN113149620 A CN 113149620A
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王家邦
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Abstract

轻质莫来石‑尖晶石空心球匣钵加压成型工艺，涉及耐火材料领域，以重量份数计，将苏州二号泥8‑12份，α‑氧化铝粉8‑12份，α‑氧化铝微粉4‑6份，电熔刚玉粉6‑8份，电熔莫来石粉13‑21份，电熔尖晶石空心球0.2‑1mm15‑25份，电熔尖晶石空心球1‑2mm4~6份，轻质莫来石颗粒0‑1mm5‑15份，轻质莫来石颗粒1‑2mm10‑20份放入搅拌机中充分混合，加入结合剂纸浆废液，经充分搅拌后形成有一定粘结性的混合料，将混合料倒入模具，加压成型，入窑烧成，制得的匣钵具有重量轻、产品使用寿命长，性价比高的优点。

Description

轻质莫来石-尖晶石空心球匣钵加压成型工艺
技术领域
本发明涉及耐火材料领域，具体而言，涉及一种轻质莫来石-尖晶石空心球匣钵的加压成型工艺。
背景技术
目前，适用于1500℃以上温度的高温匣钵均是由电熔莫来石和刚玉制备，例如，中国专利申请CN201810903009.1公开了“一种高温烧制用匣钵“，以氧化铝粉、高岭土粉、粘土粉、白刚玉、石英和莫来石等为原料，经过混合成型后进行高温烧制而成。较市面上预先合成的石英，莫来石，再混合成型的匣钵，生成的成品相更均匀，颜色以及热震稳定性更好，生成的相热膨胀系数小，因而它具有极高的热震稳定性，而且加入了石英，可以提高热震性能，且批量生产时能保持产品的抗裂性、均匀性和质量的稳定性，适于在温差较大环境中。存在的不足是使用寿命短和不稳定的问题，以荧光粉烧结为例，目前寿命在10~30次之间。
发明内容
为进一步提高烧结温度高于1500℃产品烧结用匣钵的寿命，本发明克服上述不足，提供一种重量轻、性价比高和使用寿命长的轻质莫来石-尖晶石空心球匣钵的加压成型工艺。主要创新在于采用高纯轻质高强莫来石颗粒取代电熔莫来石，采用尖晶石空心球取代刚玉颗粒，通过压制工艺成型，经高温烧结后使用，可大幅度提高产品使用寿命。
具体是这样实施的：轻质莫来石-尖晶石空心球匣钵加压成型工艺，其特征在于，以重量份数计，将苏州二号泥8-12份，α-氧化铝粉8-12份，α-氧化铝微粉4-6份，电熔刚玉粉6-8份，电熔莫来石粉13-21份，电熔尖晶石空心球0.2-1mm15-25份，电熔尖晶石空心球1-2mm4~6份，轻质莫来石颗粒0-1mm5-15份，轻质莫来石颗粒1-2mm10-20份放入搅拌机中充分混合，加入结合剂纸浆废液，经充分搅拌后形成有一定粘结性的混合料，将混合料倒入模具，加压成型，入窑烧成。
所述苏州二号泥的Al2O3含量33-35%，Fe2O3≤0.80% ，K2O+ Na2O≤0.80%，细度320目筛余＜10％。
所述α-氧化铝粉的Al2O3含量大于95％，细度320目筛余＜10％。
所述α-氧化铝微粉的Al2O3含量大于95％，粒度中位直径D50＜2μm。
所述电熔刚玉粉的Al2O3含量大于98.5％，细度320目筛余＜10％。
所述电熔莫来石粉的Al2O3含量68-73%，细度320目筛余＜10％。
所述电熔尖晶石空心球采用牌号为晶邦的电熔尖晶石空心球。
所述轻质莫来石颗粒，体积密度≤2g/cm3，Al2O3%≥60，SiO2%≤37，Al2O3+SiO2%≥97，Fe2O3+TiO2%≤2。
作为结合剂的纸浆废液，其固形物质量百分比浓度为20～25%。
制备时,在各粉料和骨料中加入结合剂纸浆废液，形成纸浆废液重量含量为6-8%的混合料，经充分搅拌后备用，把混合料倒入模具，加压成型，脱模之后入干燥窑烘干，送入窑中烧成，烧成温度控制在1350℃-1550℃之间，保温时间为4-8小时。
轻质莫来石颗粒采用高纯黏土与氧化铝粉引入锯末作为造孔剂，经高温烧结后破碎制备，内含丰富的孔洞，在实际应用中，急冷急热产生的应力，能得到有效释放，产生的微裂纹及宏观裂纹，由于孔洞的存在，可以让其转向而消除裂纹扩展，从而表现出良好的抗热震性能，引入轻质莫来石能有效提高产品的抗热震性能，从而提高产品使用寿命。尖晶石空心球具有比氧化铝空心球更小的膨胀系数，产品熔点在2100℃，同时也具有良好的抗热震性能，其引入能有效提高产品的使用温度，从而为使用温度在1500℃以上的长寿命匣钵生产奠定基础。
本发明与传统产品相比，具有匣钵重量轻、产品使用寿命长，性价比高的优点。
具体实施方式
下面将结合实施例对本发明的实施方案进行详细描述，但是本领域技术人员将会理解，下列实施例仅用于说明本发明，而不应视为限制本发明的范围。实施例中涉及的各原料标准为：
苏州二号泥的Al2O3含量33-35%，Fe2O3≤0.80% ，K2O+ Na2O≤0.80%,细度320目筛余＜10％。
α-氧化铝粉的Al2O3含量大于95％，细度320目筛余＜10％。
α-氧化铝微粉的Al2O3含量大于95％，粒度中位直径D50＜2μm。
电熔刚玉粉的Al2O3含量大于98.5％, 细度320目筛余＜10％。
电熔莫来石粉的Al2O3含量68-73%，细度320目筛余＜10％。
电熔尖晶石空心球采用牌为晶邦的电熔尖晶石空心球，其指标如下：
Figure 774243DEST_PATH_IMAGE002
所述轻质莫来石颗粒，采用高纯黏土与氧化铝粉引入锯末作为造孔剂，经高温烧结后破碎制备，体积密度≤2g/cm3，Al2O3%≥60，SiO2%≤37，Al2O3+SiO2%≥97，Fe2O3+TiO2%≤2。
作为结合剂的纸张废液，其固形物质量百分比浓度为20～25%。
实施例1，轻质莫来石-尖晶石空心球匣钵加压成型工艺，以重量份数计，称取苏州二号泥12份，α-氧化铝粉8份，α-氧化铝微粉4份，电熔刚玉粉8份，电熔莫来石粉13份，电熔尖晶石空心球0.2-1mm25份，电熔尖晶石空心球1-2mm6份，轻质莫来石颗粒0-1mm5份，轻质莫来石颗粒1-2mm19份，放入搅拌机中充分混合，加入结合剂纸浆废液，形成纸浆废液重量含量为6%的混合料，经充分搅拌后备用，把混合料倒入模具，加压成型，脱模之后入干燥窑烘干，送入窑中烧成，所用的煅烧窑炉，可以是梭式窑、隧道窑、倒焰窑或滚道窑，烧成温度控制在1450℃，保温时间为6小时，所得成品的性能指标见表1。
实施例2-实施例7，参考实施例1，各实施例的原料配伍和成品性能指标见表1。
表1
Figure DEST_PATH_IMAGE004
实施例8-10,原料配伍和实施例3相同,烧成后保温时间6小时，烧成温度和成品性能指标见表2。
表2
Figure DEST_PATH_IMAGE006
由此可见，本制备方法中最佳的烧成温度为1450±50℃。
实施例11-13,原料配方和实施例3相同,烧成温度为1450℃，保温时间和成品性能指标见表3。
表3
Figure DEST_PATH_IMAGE008
上述实施例1-13制得的匣钵，使用30次后匣钵的表面状态均无裂纹、无脱落、无破损，从表1至表3中可以看出，使用寿命至少在40次以上，最高能达60次，远高于市场上目前高温匣钵10-30次的使用寿命，且匣钵重量轻，性价比更高。

Claims (7)

1.轻质莫来石-尖晶石空心球匣钵加压成型工艺，其特征在于，以重量份数计，将苏州二号泥8-12份，α-氧化铝粉8-12份，α-氧化铝微粉4-6份，电熔刚玉粉6-8份，电熔莫来石粉13-21份，电熔尖晶石空心球0.2-1mm15-25份，电熔尖晶石空心球1-2mm4~6份，轻质莫来石颗粒0-1mm5-15份，轻质莫来石颗粒1-2mm10-20份放入搅拌机中充分混合，加入结合剂纸浆废液，经充分搅拌后形成有一定粘结性的混合料，将混合料倒入模具，加压成型，入窑烧成。
2.根据权利要求1所述的轻质莫来石-尖晶石空心球匣钵加压成型工艺，其特征在于所述苏州二号泥的Al2O3含量33-35%，Fe2O3≤0.80% ，K2O+ Na2O≤0.80%，细度320目筛余＜10％；所述α-氧化铝粉的Al2O3含量大于95％，细度320目筛余＜10％；所述α-氧化铝微粉的Al2O3含量大于95％，粒度中位直径D50＜2μm；所述电熔刚玉粉的Al2O3含量大于98.5％，细度320目筛余＜10％；所述电熔莫来石粉的Al2O3含量68-73%，细度320目筛余＜10％；所述电熔尖晶石空心球采用牌号为晶邦的电熔尖晶石空心球；所述轻质莫来石颗粒，体积密度≤2g/cm3，Al2O3%≥60，SiO2%≤37，Al2O3+SiO2%≥97，Fe2O3+TiO2%≤2；所述纸浆废液，其固形物质量百分比浓度为20～25%。
3.根据权利要求1或2所述的轻质莫来石-尖晶石空心球匣钵加压成型工艺，其特征在于轻质莫来石颗粒采用高纯黏土与氧化铝粉引入锯末作为造孔剂，经高温烧结后破碎制备。
4.根据权利要求1所述的轻质莫来石-尖晶石空心球匣钵加压成型工艺，其特征在于在各粉料和骨料中加入结合剂纸浆废液，形成纸浆废液重量含量为6-8%的混合料，经充分搅拌后备用，把混合料倒入模具，加压成型，脱模之后入干燥窑烘干，送入窑中烧成。
5.根据权利要求1或4所述的轻质莫来石-尖晶石空心球匣钵加压成型工艺，其特征在于烧成温度控制在1350℃-1550℃之间，保温时间为4-8小时。
6.根据权利要求5所述的轻质莫来石-尖晶石空心球匣钵加压成型工艺，其特征在于烧成温度为1450±50℃。
7.根据权利要求1所述的轻质莫来石-尖晶石空心球匣钵加压成型工艺，其特征在于，以重量份数计，原料配伍为：苏州二号泥10份，α-氧化铝粉10份，α-氧化铝微粉5份，电熔刚玉粉7份，电熔莫来石粉18份，电熔尖晶石空心球0.2-1mm20份，电熔尖晶石空心球1-2mm5份，轻质莫来石颗粒0-1mm10份，轻质莫来石颗粒1-2mm15份。
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