CN114671692B - Double-layer high-strength heat-preservation refractory castable and preparation method thereof - Google Patents

Double-layer high-strength heat-preservation refractory castable and preparation method thereof Download PDF

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CN114671692B
CN114671692B CN202210450294.2A CN202210450294A CN114671692B CN 114671692 B CN114671692 B CN 114671692B CN 202210450294 A CN202210450294 A CN 202210450294A CN 114671692 B CN114671692 B CN 114671692B
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castable
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silicon
parts
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CN114671692A (en
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王娇
吴磊
曹洁
张志成
佘亚锋
佘凤娅
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Changxing Mingtian Furnace Material Co ltd
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Changxing Mingtian Furnace Material Co ltd
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Abstract

The invention relates to a double-layer high-strength heat-preservation refractory castable and a preparation method thereof, wherein the refractory castable comprises an inner-layer castable and an outer-layer castable, the preparation raw materials of the inner-layer castable comprise a first aggregate and a blending material, and the first aggregate comprises a silicon-aluminum aggregate and ceramic reinforcing particles; the preparation raw materials of the outer-layer castable comprise a second aggregate and a blending material, wherein the second aggregate comprises a silicon-aluminum aggregate and composite microcapsule particles; the silicon-aluminum aggregate comprises high-aluminum aggregate, silicon carbide, fine alumina powder, silicon micro powder and white corundum powder; the admixture comprises metal silicon powder, spherical asphalt, cement, an explosion-proof agent and a dispersing agent.

Description

Double-layer high-strength heat-preservation refractory castable and preparation method thereof
Technical Field
The invention belongs to the technical field of refractory furnace burden, and particularly relates to a double-layer high-strength heat-preservation refractory castable and a preparation method thereof.
Background
The blast furnace is the main equipment for smelting pig iron, the tapping runner is the necessary path for molten iron to flow from the furnace to the molten iron tank, and the quality and performance of the tapping runner are related to the quality of the molten iron and the normal production of the blast furnace. The working environment of the iron runner is severe, the iron runner can be repeatedly washed by high-temperature molten iron, the temperature change is severe, the material requirement of the iron runner is very stable, and the corrosion can be slowed down in the long-term use process.
At present, most of the workers in the field study the iron runner, and study the stability, the scouring resistance and the corrosion resistance of the material of the iron runner, however, the requirement of the iron runner on the strength of the iron runner is higher in the working environment, and the inventor finds that the damage of the iron runner caused by severe temperature change can be effectively relieved by improving the heat insulation performance of the iron runner.
Disclosure of Invention
Aiming at the problems, the invention provides a double-layer high-strength heat-preservation refractory castable and a preparation method thereof, wherein the refractory castable comprises an inner-layer castable and an outer-layer castable, the preparation raw materials of the inner-layer castable comprise a first aggregate and a blending material, and the first aggregate comprises a silicon-aluminum aggregate and ceramic reinforcing particles;
the preparation raw materials of the outer-layer castable comprise a second aggregate and a blending material, wherein the second aggregate comprises a silicon-aluminum aggregate and composite microcapsule particles;
the silicon-aluminum aggregate comprises high-aluminum aggregate, silicon carbide, fine alumina powder, silicon micro powder and white corundum powder; the admixture comprises metal silicon powder, spherical asphalt, cement, an explosion-proof agent and a dispersing agent.
Aiming at the defects of the existing light heat-insulating castable, the invention designs the double-layer refractory castable, the inner-layer castable is directly contacted with furnace charge in an industrial kiln, and the castable has higher strength and better corrosion resistance under the holding of ceramic reinforced particles; the outer layer casting material is porous light casting material, and has good heat preservation performance. And the silicon-aluminum aggregate and the admixture of the inner-layer castable and the outer-layer castable are the same, namely most components are the same, so that the two layers are ensured to have better binding property and are firmly combined with each other to form a pouring protective layer of the industrial kiln together.
Optionally, the ceramic reinforcing particles are prepared from silicon-aluminum sol and clay, and the particle size of the ceramic reinforcing particles is 1-3mm; the mass ratio of the silicon-aluminum sol to the clay is (0.05-0.2): 1.
According to the invention, the ceramic reinforcing particles are added into the first aggregate of the inner-layer castable, the ceramic reinforcing particles can be uniformly dispersed in the first aggregate, and the particles have high strength and good high-temperature and corrosion resistance, so that the strength, the high-temperature and the corrosion resistance of the inner-layer castable are improved. The inventor has also discovered unexpectedly that the surface substance of the ceramic reinforcing particles in the high-temperature environment can act or react with certain components of the inner-layer castable to strengthen the connection between the ceramic reinforcing particles and other components, and although the inventor has not explored a specific reaction principle, the inventor supposes that Al-Si-C and oxide thereof in the silicon-aluminum aggregate and cement thereof react with the components of the ceramic reinforcing particles at high temperature to generate crystals or whiskers with higher strength, so that the strength and stability of the inner-layer castable are improved.
Optionally, the composite microcapsule particles are spherical, and sequentially include an organic layer, an inorganic layer and an internal filler from outside to inside, the organic layer includes phenolic resin, a carbon forming agent and aluminum ethoxide, the inorganic layer includes silica-alumina sol, and the internal filler includes aluminum powder and/or calcium hydroxide. The particle size of the composite microcapsule particles is 1-5mm.
Optionally, the carbon forming agent is pentaerythritol, and the mass ratio of the phenolic resin to the carbon forming agent to the aluminum ethoxide is 1 (1.1-1.5) to 0.02-0.12. Preferably, the phenolic resin has a molecular weight of 100 to 200.
Optionally, the outer layer casting material further comprises a curing agent, the curing agent comprises hydroxymethyl urea and sodium carbonate and is used for curing phenolic resin, and the mass ratio of the phenolic resin to the hydroxymethyl urea to the sodium carbonate is 1 (0.9-2) to 0.6-1.
According to the invention, the composite microcapsule particles are added into the outer-layer castable, and the organic layer of the composite microcapsule particles can play a role of an adhesive during mixing and pouring of the second aggregate and the admixture, so that the composite microcapsule particles, the second aggregate and the admixture are combined more firmly, and when the composite microcapsule particles are used, the organic layer is carbonized to form holes under the high-temperature action of an industrial kiln, and a uniform pore structure is formed inside the outer-layer castable and on the outer layer of the composite microcapsule particles, so that the heat insulation performance is improved. In addition, the aluminum ethoxide added into the organic layer plays a role of a surfactant, so that the uniform dispersion of the composite microcapsule particles in the second aggregate is promoted when the outer-layer castable is prepared, and meanwhile, the aluminum ethoxide is beneficial to uniformly mixing all components of the organic layer per se and promoting the combination of the organic layer and the inorganic layer.
Calcium hydroxide in the internal filler can absorb part of carbon dioxide released during carbonization of the organic layer through pores of the inorganic layer, so that cracking caused by excessive release of carbon dioxide in a short time in the use process of the outer-layer castable is prevented; when the temperature is higher, the inorganic layer is cracked, internal fillers, namely aluminum powder, calcium carbonate and part of unreacted calcium hydroxide are released, wherein the calcium carbonate is decomposed into calcium oxide and carbon dioxide by high heat, which is equivalent to secondary release of carbon dioxide, the calcium hydroxide is decomposed into calcium oxide and water by high heat, the calcium oxide is matched with the components of the outer-layer castable to improve the strength of the outer-layer castable, and the aluminum powder is oxidized to generate aluminum oxide, so that the strength of the outer-layer castable can be further improved.
Optionally, the grain size of the high-alumina aggregate of the inner-layer castable is 5-8mm, the grain size of the silicon carbide is 0.5-1mm, the SiC content in the silicon carbide is not less than 98%, the grain size of the fine alumina powder is 5-8 μm, and Al in the fine alumina powder 2 O 3 The content of the silicon dioxide is not less than 87 percent, the grain diameter of the silicon micro powder is 0.1-0.5 mu m, and SiO in the silicon micro powder 2 The content is not less than 95 percent, and the grain diameter of the white corundum powder is 5-10mm.
Optionally, the grain size of the high-alumina aggregate of the outer-layer castable is 8-10mm, the grain size of the silicon carbide is 1-2mm, the SiC content in the silicon carbide is not less than 98%, the grain size of the fine alumina powder is 8-15 μm, and Al in the fine alumina powder is Al 2 O 3 The content of the silicon dioxide is not less than 87 percent, the grain diameter of the silicon micro powder is 0.5-1.5 mu m, and SiO in the silicon micro powder 2 The content is not less than 95%, and the grain diameter of the white alundum powder is 5-15mm.
Optionally, the grain size of the metal silicon powder of the inner-layer castable and the outer-layer castable is 0.1-0.3 μm, the grain size of the spherical asphalt is 0.5-0.9mm, and the cement is high-alumina 80 cement.
Optionally, the explosion-proof agent is metal aluminum powder and polypropylene fiber, the particle size of the metal aluminum powder is 45-55 μm, and the length of the polypropylene fiber is 5-10mm.
Optionally, the dispersing agent is selected from one or two of sodium hexametaphosphate and sodium tripolyphosphate.
Optionally, the inner layer castable comprises the following raw materials in parts by weight: 50-60 parts of high-aluminum aggregate, 15-25 parts of silicon carbide, 5-7 parts of fine aluminum oxide powder, 3-5 parts of silicon micropowder, 3-5 parts of white corundum powder, 10-18 parts of ceramic reinforced particles, 2-3 parts of metal silicon powder, 2-3 parts of spherical asphalt, 2-3 parts of cement, 0.1-0.2 part of explosion-proof agent and 0.1-0.2 part of dispersing agent.
Optionally, the outer-layer castable comprises the following raw materials in parts by weight: 55-66 parts of high-aluminum aggregate, 10-20 parts of silicon carbide, 5-7 parts of fine aluminum oxide powder, 3-5 parts of silicon micropowder, 3-5 parts of white corundum powder, 10-15 parts of composite microcapsule particles, 2-3 parts of metal silicon powder, 2-3 parts of spherical asphalt, 2-3 parts of cement, 0.1-0.2 part of explosion-proof agent and 0.1-0.2 part of dispersing agent.
The preparation method of the refractory castable comprises a preparation method of the ceramic reinforced particles, a preparation method of the composite microcapsule particles, a preparation method of an inner-layer castable and a preparation method of an outer-layer castable.
Optionally, the preparation method of the ceramic reinforced particle comprises the following steps:
(1) Mixing the silicon-aluminum sol and the clay according to the mass ratio (0.05-0.2) to 1 to obtain first mixed slurry;
(2) Filtering the first mixed slurry, and drying at 100-120 ℃ to obtain first powder;
(3) And roasting the first powder at 900-1200 ℃ for 6-8h to obtain the ceramic reinforced particles.
Optionally, the preparation method of the inner layer castable comprises the following steps:
(4) Uniformly mixing the silicon-aluminum aggregate of the inner-layer castable and the ceramic reinforcing particles according to the mass parts to obtain an inner-layer premix;
(5) And mixing the inner-layer premix and the blended material according to the mass parts, and uniformly stirring to obtain the inner-layer castable.
Optionally, the preparation method of the composite microcapsule particle includes the following steps:
(6) Mixing aluminum powder and calcium hydroxide powder with equal mass with the silicon-aluminum sol, and performing ultrasonic treatment to uniformly disperse the mixture to obtain second mixed slurry;
(7) Filtering the second mixed slurry, and drying at 100-120 ℃ to obtain second powder;
(8) Roasting the second powder at 500-700 ℃ for 5-6h to obtain a prefabricated blank, soaking the prefabricated blank in water for 0.5-1h, and then drying at 30-50 ℃ to obtain a blank;
(9) Dissolving phenolic resin and aluminum ethoxide in the mass ratio of 1 (0.02-0.12) in ethanol, and uniformly mixing to obtain a coating solution;
(10) And (5) immersing the embryo body obtained in the step (8) into the coating liquid, carrying out ultrasonic treatment for 10-20min, taking out the embryo body with the coating liquid on the surface, and drying at room temperature to remove ethanol to obtain the composite microcapsule particles with wet surfaces.
Optionally, the preparation method of the outer castable comprises the following steps:
(11) Uniformly mixing silicon-aluminum aggregate of the outer-layer castable, adding the composite microcapsule particles, uniformly mixing, and uniformly mixing a curing agent to obtain an outer-layer premix;
(12) And mixing the outer-layer premix and the blending material according to the mass parts, and uniformly stirring to obtain the outer-layer castable.
In the step (8), calcium hydroxide inside the second powder after being roasted is decomposed, so that the prefabricated blank is immersed in water, water enters the prefabricated blank through the pores of the inorganic layer and reacts with calcium oxide to generate calcium hydroxide, and carbon dioxide can be absorbed conveniently in the subsequent use process.
Preferably, in the step (6), aluminum powder and the silicon-aluminum sol are mixed, and are subjected to ultrasonic treatment and uniform dispersion to obtain a third mixed slurry, and calcium hydroxide powder and the silicon-aluminum sol are mixed, and are subjected to ultrasonic treatment and uniform dispersion to obtain a fourth mixed slurry; wherein the aluminum powder and the calcium hydroxide powder have the same mass;
in the step (7), the third mixed slurry is filtered and dried at the temperature of 100-120 ℃ to obtain third powder, and the fourth mixed slurry is filtered and dried at the temperature of 100-120 ℃ to obtain fourth powder;
in the step (8), the third powder and the fourth powder are respectively roasted at 500 ℃ for 6 hours to respectively obtain a first blank body and a second prefabricated blank body, then the second prefabricated blank body is soaked in water for 0.5 hour and then dried at 30 ℃ to obtain a second blank body;
and (10) immersing the first embryo body and the second embryo body with equal mass into the coating liquid, performing ultrasonic treatment for 20min, taking out the embryo body with the coating liquid on the surface, and drying at room temperature to remove ethanol to obtain the composite microcapsule particles with wet surfaces.
Because the aluminum powder is hydrated in water, the aluminum powder and the calcium hydroxide powder can be respectively filled in the inorganic layer, and only the composite microcapsule particles filled with the calcium hydroxide powder are soaked in water, so that the composite microcapsule particles filled with the aluminum powder are protected.
Detailed Description
Example 1
The double-layer high-strength heat-preservation refractory castable disclosed by the embodiment comprises an inner-layer castable and an outer-layer castable, wherein the inner-layer castable comprises a first aggregate and a blending material, and the first aggregate comprises a silicon-aluminum aggregate and ceramic reinforcing particles;
the preparation raw materials of the outer-layer castable comprise a second aggregate and a blending material, wherein the second aggregate comprises silicon-aluminum aggregate and composite microcapsule particles;
the silicon-aluminum aggregate comprises high-aluminum aggregate, silicon carbide, fine alumina powder, silicon micro powder and white corundum powder; the admixture comprises metal silicon powder, spherical asphalt, cement, an explosion-proof agent and a dispersing agent.
The preparation raw materials of the ceramic reinforced particles comprise silicon-aluminum sol and clay, and the particle size of the ceramic reinforced particles is 1-3mm; the mass ratio of the silica-alumina sol to the clay is 0.05.
The composite microcapsule particles are spherical and sequentially comprise an organic layer, an inorganic layer and an internal filler from outside to inside, wherein the organic layer comprises phenolic resin (CAS number 9003-35-4), pentaerythritol and aluminum ethoxide, the inorganic layer comprises silicon-aluminum sol, and the internal filler comprises aluminum powder and/or calcium hydroxide. The particle size of the composite microcapsule particles is 1mm.
The outer-layer castable also comprises a curing agent, wherein the curing agent comprises hydroxymethyl urea and sodium carbonate, and the mass ratio of the phenolic resin to the hydroxymethyl urea to the sodium carbonate is 1.
The grain diameter of the high-alumina aggregate of the inner-layer castable is 5-8mm, the grain diameter of the silicon carbide is 0.5-1mm, and the silicon carbide is carbonizedThe SiC content in silicon is not less than 98%, the grain size of the alumina fine powder is 5-8 μm, and the Al content in the alumina fine powder 2 O 3 The content of the silicon dioxide is not less than 87 percent, the grain diameter of the silicon micro powder is 0.1-0.5 mu m, and SiO in the silicon micro powder 2 The content is not less than 95 percent, and the grain diameter of the white corundum powder is 5-10mm.
The grain size of the high-alumina aggregate of the outer-layer castable is 8-10mm, the grain size of the silicon carbide is 1-2mm, the SiC content in the silicon carbide is not lower than 98%, the grain size of the fine alumina powder is 8-15 mu m, and Al in the fine alumina powder 2 O 3 The content of the silicon dioxide is not less than 87 percent, the grain diameter of the silicon micro powder is 0.5-1.5 mu m, and SiO in the silicon micro powder 2 The content is not less than 95%, and the grain diameter of the white alundum powder is 5-15mm.
The grain diameter of the metal silicon powder of the inner layer casting material and the outer layer casting material is 0.1-0.3 mu m, the grain diameter of the spherical asphalt is 0.5-0.9mm, and the cement is high-alumina 80 cement.
The explosion-proof agent is metal aluminum powder and polypropylene fiber with the same mass, the particle size of the metal aluminum powder is 45-55 mu m, and the length of the polypropylene fiber is 5-10mm.
The dispersing agent is sodium hexametaphosphate and sodium tripolyphosphate with the same mass.
The inner layer castable comprises the following raw materials in parts by weight: 50 parts of high-alumina aggregate, 15 parts of silicon carbide, 5 parts of alumina fine powder, 3 parts of silicon micropowder, 3 parts of white corundum powder, 10 parts of ceramic reinforcing particles, 2 parts of metal silicon powder, 2 parts of spherical asphalt, 2 parts of cement, 0.1 part of explosion-proof agent and 0.1 part of dispersing agent.
The outer-layer castable comprises the following raw materials in parts by weight: 55 parts of high-aluminum aggregate, 10 parts of silicon carbide, 5 parts of fine alumina powder, 3 parts of silicon micropowder, 3 parts of white corundum powder, 10 parts of composite microcapsule particles, 2 parts of metal silicon powder, 2 parts of spherical asphalt, 2 parts of cement, 0.1 part of explosion-proof agent and 0.1 part of dispersing agent.
The preparation method of the refractory castable material in this embodiment includes a preparation method of the ceramic reinforcing particles, a preparation method of the composite microcapsule particles, a preparation method of the inner castable material, and a preparation method of the outer castable material.
The preparation method of the ceramic reinforced particle comprises the following steps:
(1) Mixing the silicon-aluminum sol and the clay according to a mass ratio of 0.05;
(2) Filtering the first mixed slurry, and drying at 100 ℃ to obtain first powder;
(3) And roasting the first powder at 900 ℃ for 8h to obtain the ceramic reinforced particles.
The preparation method of the inner layer casting material comprises the following steps:
(4) Uniformly mixing the silicon-aluminum aggregate of the inner-layer castable and the ceramic reinforcing particles according to the mass parts to obtain inner-layer premix;
(5) And mixing the inner-layer premix and the blended material according to the mass parts, and uniformly stirring to obtain the inner-layer castable.
The preparation method of the composite microcapsule particles comprises the following steps:
(6) Mixing aluminum powder and calcium hydroxide powder with equal mass with the silicon-aluminum sol, and performing ultrasonic treatment to uniformly disperse the mixture to obtain second mixed slurry;
(7) Filtering the second mixed slurry, and drying at 100 ℃ to obtain second powder;
(8) Roasting the second powder at 500 ℃ for 6h to obtain a prefabricated blank, soaking the prefabricated blank in water for 0.5h, and then drying at 30 ℃ to obtain a blank;
(9) Dissolving phenolic resin, pentaerythritol and aluminum ethoxide in ethanol according to the mass ratio of 1;
(10) And (4) immersing the embryo body obtained in the step (8) into the coating liquid, carrying out ultrasonic treatment for 20min, taking out the embryo body with the coating liquid on the surface, and drying at room temperature to remove ethanol to obtain the composite microcapsule particles with wet surfaces.
The preparation method of the outer-layer castable comprises the following steps:
(11) Uniformly mixing silicon-aluminum aggregate of the outer-layer castable, adding the composite microcapsule particles, uniformly mixing, adding the curing agent, and uniformly mixing to obtain an outer-layer premix;
(12) And mixing the outer-layer premix and the blending material according to the mass parts, and uniformly stirring to obtain the outer-layer castable.
Comparative example 1
The double-layer high-strength heat-preservation refractory castable in the comparative example is the same as that in example 1, except that the inner-layer castable does not contain ceramic reinforcing particles, and the outer-layer castable does not contain composite microcapsule particles and a curing agent.
The preparation method of the inner layer castable comprises the following steps: (1) Uniformly mixing the silicon-aluminum aggregate of the inner-layer castable according to the mass part in the embodiment 1 to obtain inner-layer premix; (2) And (3) mixing the inner-layer premix and the blended material according to the mass parts in the embodiment 1, and uniformly stirring to obtain an inner-layer castable.
The preparation method of the outer-layer castable comprises the following steps: (1) Uniformly mixing the silicon-aluminum aggregate of the outer-layer castable according to the mass part of the embodiment 1 to obtain an outer-layer premix; (2) And (2) mixing the outer-layer premix and the blending material according to the mass part of the embodiment 1, and uniformly stirring to obtain an outer-layer castable.
Example 2
The double-layer high-strength heat-preservation refractory castable and the preparation method thereof in the embodiment are the same as those in the embodiment 1, and the difference is that the preparation raw materials of the ceramic reinforcing particles are silica-alumina sol and common sandy soil.
The preparation method of the ceramic reinforced particles of the embodiment comprises the following steps:
(1) Mixing the silicon-aluminum sol and common sandy soil according to a mass ratio of 0.05;
(2) Filtering the first mixed slurry, and drying at 100 ℃ to obtain first powder;
(3) The first powder was calcined at 900 ℃ for 8 hours to obtain ceramic reinforcing particles of the present example.
Example 3
The double-layer high-strength heat-preservation refractory castable and the preparation method thereof in this embodiment are the same as those in embodiment 1, except that the raw material for preparing the ceramic reinforcing particles is clay.
The preparation method of the ceramic reinforced particle of the embodiment comprises the following steps: the clay was made into a spherical shape having a particle size of 1 to 3mm and calcined at 900 ℃ for 8 hours to obtain ceramic reinforcing granules of this example.
Example 4
The double-layer high-strength heat-preservation refractory castable and the preparation method thereof are the same as those in example 1, and are different from the refractory castable in that the mass ratio of the silica-alumina sol to the clay is 0.2.
Example 5
The double-layer high-strength heat-preservation refractory castable and the preparation method thereof are the same as those in example 1, and are different from the refractory castable in that the mass ratio of the silica-alumina sol to the clay is 0.04.
Example 6
The dual-layer high-strength heat-preservation refractory castable and the preparation method thereof in this embodiment are the same as those in embodiment 4, except that the composite microcapsule particles sequentially comprise an inorganic layer and an internal filler from outside to inside, and a curing agent is not added to the outer-layer castable.
The preparation method of the composite microcapsule particle of the present embodiment includes the following steps:
(1) Mixing aluminum powder and calcium hydroxide powder with equal mass with the silicon-aluminum sol, and performing ultrasonic treatment to uniformly disperse the mixture to obtain second mixed slurry;
(2) Filtering the second mixed slurry, and drying at 100 ℃ to obtain second powder;
(3) And roasting the second powder at 500 ℃ for 6h to obtain a prefabricated blank, soaking the prefabricated blank in water for 0.5h, and drying at 30 ℃ to obtain the composite microcapsule particles.
Example 7
The double-layer high-strength heat-preservation refractory castable and the preparation method thereof in the embodiment are the same as those in embodiment 4, and the difference is that the composite microcapsule particles sequentially comprise an organic layer and an internal filler from outside to inside.
The preparation method of the composite microcapsule particle of the present embodiment includes the following steps:
(1) Dissolving phenolic resin and aluminum ethoxide in ethanol according to the mass ratio of 1.02, and uniformly mixing to obtain a coating solution;
(2) Mixing aluminum powder and calcium hydroxide powder with equal mass with the coating liquid, carrying out ultrasonic treatment for 20min, taking out the solid with the coating liquid on the surface, and drying at room temperature to remove ethanol to obtain the composite micro-capsule particles with wet surfaces.
Example 8
The dual-layer high-strength heat-preservation refractory castable and the preparation method thereof in the embodiment are the same as those in the embodiment 4, and the difference is that the internal filler of the composite microcapsule particles is common sandy soil.
In the preparation method of the composite microcapsule particles of this example, ordinary sandy soil was used instead of the aluminum powder and the calcium hydroxide powder.
Example 9
The dual-layer high-strength heat-preservation refractory castable and the preparation method thereof in the embodiment are the same as those in the embodiment 4, and are different in that only aluminum powder is used as an internal filler of the composite microcapsule particles, only aluminum powder is used in the corresponding preparation method of the composite microcapsule particles, and the prefabricated blank can be directly added into the coating liquid without water immersion treatment.
Example 10
The dual-layer high-strength heat-preservation refractory castable and the preparation method thereof in this embodiment are the same as those in embodiment 4, except that the internal filler of the composite microcapsule particles is only calcium hydroxide, and only calcium hydroxide is used in the corresponding preparation method of the composite microcapsule particles.
Example 11
The dual-layer high-strength heat-preservation refractory castable and the preparation method thereof in the embodiment are the same as those in the embodiment 4, and the difference is that the aluminum powder and the calcium hydroxide are separately prepared into composite microcapsule particles, namely, some composite microcapsule particles only contain the aluminum powder, and some composite microcapsule particles only contain the calcium hydroxide.
The preparation method of the composite microcapsule particles comprises the following steps: (1) Mixing aluminum powder and the silicon-aluminum sol, performing ultrasonic treatment to disperse uniformly to obtain a third mixed slurry, mixing calcium hydroxide powder and the silicon-aluminum sol, and performing ultrasonic treatment to disperse uniformly to obtain a fourth mixed slurry; wherein the aluminum powder and the calcium hydroxide powder have the same mass;
(2) Filtering the third mixed slurry, drying at 100-120 ℃ to obtain third powder, filtering the fourth mixed slurry, and drying at 100-120 ℃ to obtain fourth powder;
(3) Roasting the third powder and the fourth powder at 500 ℃ for 6 hours respectively to obtain a first preform body and a second preform body respectively, soaking the second preform body in water for 0.5 hour, and drying at 30 ℃ to obtain a second preform body;
(4) Dissolving phenolic resin and aluminum ethoxide in ethanol according to the mass ratio of 1.02, and uniformly mixing to obtain a coating solution;
(5) And immersing the first embryo body and the second embryo body with equal mass into the coating liquid, performing ultrasonic treatment for 20min, taking out the embryo body with the coating liquid on the surface, and drying at room temperature to remove ethanol to obtain the composite microcapsule particles with wet surfaces.
Example 12
The double-layer high-strength heat-preservation refractory castable and the preparation method thereof are the same as those in the embodiment 11, and are different from the embodiment in that the mass ratio of phenolic resin to aluminum ethoxide is 1.
Example 13
The double-layer high-strength heat-preservation refractory castable and the preparation method thereof in the embodiment are the same as those in the embodiment 11, and are different from the embodiment in that the mass ratio of the phenolic resin to the aluminum ethoxide is 1.
Example 14
The double-layer high-strength heat-preservation refractory castable and the preparation method thereof in the embodiment are the same as those in the embodiment 12, and the difference is that the inner-layer castable comprises the following raw materials in parts by weight: 60 parts of high-aluminum aggregate, 25 parts of silicon carbide, 7 parts of fine alumina powder, 5 parts of silicon micropowder, 5 parts of white corundum powder, 18 parts of ceramic reinforcing particles, 3 parts of metal silicon powder, 3 parts of spherical asphalt, 3 parts of cement, 0.2 part of explosion-proof agent and 0.2 part of dispersing agent.
Example 15
The double-layer high-strength heat-preservation refractory castable and the preparation method thereof in the embodiment are the same as those in the embodiment 12, and have the difference that the outer-layer castable comprises the following raw materials in parts by weight: 66 parts of high-aluminum aggregate, 20 parts of silicon carbide, 7 parts of fine alumina powder, 5 parts of silicon micropowder, 5 parts of white corundum powder, 15 parts of composite micro-capsule particles, 3 parts of metal silicon powder, 3 parts of spherical asphalt, 3 parts of cement, 0.2 part of explosion-proof agent and 0.2 part of dispersing agent.
The inner layer castable and the outer layer castable of the above examples and comparative examples were poured outside a blast furnace, cured by baking, and measured for the room-temperature flexural strength at 1450 ℃ for 3 hours, and the room-temperature compressive strength and the apparent porosity at 1450 ℃ for 3 hours, with the results shown in tables 1 and 2 below.
Table 1 comparison of strength of inner layer castable of example and comparative example 1
Normal temperature bending strength/Mpa Normal temperature compressive strength/Mpa
Example 1 12.38 110
Example 2 11.66 103
Example 3 11.85 105
Example 4 12.41 113
Example 5 12.02 107
Example 14 12.39 112
Comparative example 1 9.61 77
TABLE 2 comparison of the apparent porosity of the outer layer casting materials of the examples and comparative example 1
Apparent porosity/% Apparent porosity/%
Example 1 14.9 Example 12 15.0
Example 6 10.8 Example 13 15.3
Example 7 12.5 Example 15 15.1
Example 8 16.2 Comparative example 1 10.7
Example 9 16.1
TABLE 3 comparison of the room-temperature rupture strength of the outer castable of examples and comparative examples
Figure BDA0003618303070000101
Figure BDA0003618303070000111
As can be seen from Table 1, the inner layer castable prepared by the invention has higher compressive strength and rupture strength, and can effectively cope with the high-temperature use environment of the blast furnace tapping channel.
As shown in Table 2, the composite microcapsule particles of example 8 had no internal filler, and example 9 had no calcium hydroxide, but had a large apparent porosity, and could not absorb excessive CO released by carbonization of the organic layer 2 And a small amount of fine cracks appear on the surface of the outer-layer castable. The apparent porosity of example 12 was comparable to that of example 4, but the apparent pore distribution was more uniform. Although the apparent porosity of example 13 was slightly increased, the apparent pore distribution was not uniform. As can be seen from tables 2 and 3, the inventive compositionsThe layer casting material has higher compressive strength and apparent porosity and good heat preservation performance.

Claims (8)

1. The double-layer high-strength heat-preservation refractory castable is characterized by comprising an inner-layer castable and an outer-layer castable, wherein the inner-layer castable is prepared from raw materials including a first aggregate and a blending material, and the first aggregate comprises a silicon-aluminum aggregate and ceramic reinforcing particles;
the preparation raw materials of the outer-layer castable comprise a second aggregate and a blending material, wherein the second aggregate comprises a silicon-aluminum aggregate and composite microcapsule particles;
the composite microcapsule particles sequentially comprise an organic layer, an inorganic layer and an internal filler from outside to inside, wherein the organic layer comprises phenolic resin, a carbon forming agent and aluminum ethoxide, the inorganic layer comprises silicon-aluminum sol, and the internal filler comprises aluminum powder and/or calcium hydroxide;
the silicon-aluminum aggregate comprises high-aluminum aggregate, silicon carbide, fine alumina powder, silicon micro powder and white corundum powder; the admixture comprises metal silicon powder, spherical asphalt, cement, an explosion-proof agent and a dispersing agent;
the inner layer castable comprises the following raw materials in parts by weight: 50-60 parts of high-aluminum aggregate, 15-25 parts of silicon carbide, 5-7 parts of fine alumina powder, 3-5 parts of silicon micropowder, 3-5 parts of white corundum powder, 10-18 parts of ceramic reinforced particles, 2-3 parts of metal silicon powder, 2-3 parts of spherical asphalt, 2-3 parts of cement, 0.1-0.2 part of explosion-proof agent and 0.1-0.2 part of dispersing agent;
the outer-layer castable comprises the following raw materials in parts by weight: 55-66 parts of high-aluminum aggregate, 10-20 parts of silicon carbide, 5-7 parts of fine aluminum oxide powder, 3-5 parts of silicon micropowder, 3-5 parts of white corundum powder, 10-15 parts of composite microcapsule particles, 2-3 parts of metal silicon powder, 2-3 parts of spherical asphalt, 2-3 parts of cement, 0.1-0.2 part of explosion-proof agent and 0.1-0.2 part of dispersing agent.
2. The castable refractory according to claim 1, wherein the ceramic reinforcing particles are prepared from raw materials including silica-alumina sol and clay, and have a particle size of 1-3mm.
3. The castable refractory of claim 2, wherein the ceramic reinforcing particles have a silica-alumina sol to clay mass ratio of (0.05-0.2): 1.
4. The castable refractory according to claim 2, wherein the composite microcapsule particles are spherical, and the particle size of the composite microcapsule particles is 1-5mm.
5. The castable refractory of claim 1, wherein the outer castable further comprises a curing agent comprising methylol urea and sodium carbonate for curing phenolic resin;
the carbon forming agent is pentaerythritol.
6. The castable refractory according to claim 1, wherein the high alumina aggregate of the inner castable has a particle size of 5-8mm, the silicon carbide has a particle size of 0.5-1mm, the SiC content in the silicon carbide is not less than 98%, the alumina fine powder has a particle size of 5-8 μm, and Al in the alumina fine powder 2 O 3 The content of the silicon dioxide is not less than 87 percent, the grain diameter of the silicon micro powder is 0.1-0.5 mu m, and SiO in the silicon micro powder 2 The content is not less than 95%, and the grain diameter of the white alundum powder is 5-10mm.
7. The refractory castable according to claim 1, wherein the high-alumina aggregate of the outer castable has a particle size of 8-10mm, the silicon carbide has a particle size of 1-2mm, the content of SiC in the silicon carbide is not less than 98%, the alumina fine powder has a particle size of 8-15 μm, and Al in the alumina fine powder 2 O 3 The content of the silicon dioxide is not less than 87 percent, the grain diameter of the silicon micro powder is 0.5 to 1.5 mu m, and SiO in the silicon micro powder 2 The content is not less than 95 percent, and the grain diameter of the white corundum powder is 5-15mm.
8. The method for preparing a castable refractory according to claim 6 or 7, including a method for preparing the ceramic reinforcing particles, a method for preparing composite microcapsule particles, a method for preparing an inner castable and a method for preparing an outer castable;
the preparation method of the ceramic reinforced particle comprises the following steps:
(1) Mixing the silicon-aluminum sol and the clay according to the mass ratio (0.05-0.2) to 1 to obtain first mixed slurry;
(2) Filtering the first mixed slurry, and drying at 100-120 ℃ to obtain first powder;
(3) Roasting the first powder at 900-1200 ℃ for 6-8h to obtain the ceramic reinforced particles;
the preparation method of the inner layer casting material comprises the following steps:
(4) Uniformly mixing the silicon-aluminum aggregate of the inner-layer castable and the ceramic reinforcing particles according to the mass parts to obtain inner-layer premix;
(5) Mixing the inner-layer premix and the blending material according to the mass parts, and uniformly stirring to obtain an inner-layer castable;
the preparation method of the composite microcapsule particles comprises the following steps:
(6) Mixing aluminum powder and calcium hydroxide powder with the silicon-aluminum sol, and performing ultrasonic treatment to disperse uniformly to obtain second mixed slurry;
(7) Filtering the second mixed slurry, and drying at 100-120 ℃ to obtain second powder;
(8) Roasting the second powder at 500-700 ℃ for 5-6h to obtain a prefabricated blank, soaking the prefabricated blank in water for 0.5-1h, and then drying at 30-50 ℃ to obtain a blank;
(9) Dissolving phenolic resin and aluminum ethoxide in the mass ratio of 1 (0.02-0.12) in ethanol, and uniformly mixing to obtain a coating solution;
(10) Immersing the embryo body obtained in the step (8) into the coating liquid, carrying out ultrasonic treatment for 10-20min, taking out the embryo body with the coating liquid on the surface, and drying at room temperature to remove ethanol to obtain the composite microcapsule particles with wet surfaces;
the preparation method of the outer-layer castable comprises the following steps:
(11) Uniformly mixing the silicon-aluminum aggregate of the outer-layer castable, adding the composite microcapsule particles, uniformly mixing, adding the curing agent, and uniformly mixing to obtain an outer-layer premix;
(12) And mixing the outer-layer premix and the blended material according to the mass parts, and uniformly stirring to obtain the outer-layer castable.
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