CN115353397A - 一种高强度轻质耐酸浇注料及其制备方法 - Google Patents
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Abstract
本发明公开了一种高强度轻质耐酸浇注料及及其制备方法,利用以下配方组分的原料:粒度为5~3mm的煅烧后废瓷/废砖20~30%、粒度为5~3mm的熔炼铝灰渣15~20%、粒度为5~3mm的微孔刚玉10~15%、粒度为3~1mm的微孔刚玉10~15%、粒度为3~1mm的莫来石轻骨料10~15%、粒度为3~1mm的蛭石粉10~15%、粒度为3~1mm的硅微粉5~10%、粒度为≤5mm氧化铝粉4~8%、普硅水泥2~5%、长度为5‑10mm的防爆纤维2~5%、外加剂0.5~1%,并且对废砖、废瓷、熔炼铝灰渣和防爆纤维进行处理加工,减少原料制备或者购买的成本投入,且有效降低产品的密度,以及增强浇注料的强度。
Description
技术领域
本发明涉及不定型耐火材料技术领域,特别是一种高强度轻质耐酸浇注料及其制备方法。
背景技术
耐火材料分为定型耐火材料和不定型耐火材料。不定型耐火材料通常指浇注料,可解释为:浇注料是由多种骨料或集料和一种或多种粘和剂组成的混合粉状颗料,使用时必须和一种或多种液体配合搅拌均匀,具有较强的流动性和可塑性。或者解释为:浇注料是一种由耐火物质制成的粒状和粉状材料,并加入一定量结合剂和水分共同组成。它具有较高的流动性,适宜用浇注方法施工,并无需加热即可硬化的不定形耐火材料。由耐火骨料、粉料、结合剂、外加剂、水或其他液体材料组成。一般在使用现场以浇注、震动或捣固的方法浇筑成型,也可以制成预制件使用。
一般浇注料都是使用刚玉质、莫来石质、复合的刚玉莫来石质、尖晶石质等晶相的原料进行粉碎后按照一定的颗粒大小和配比加入粘和剂和外加剂混合而成,耐火原料原料昂贵,这样生产下来成本较高,而且这些耐火原料需要预先烧结或者电熔的方式进行预加工,能源消耗较大,亟需一种可以利用一些工业或者建筑的废弃料进行制备的高强度轻质耐酸浇注料,以求降低原料的成本以及实现节能降耗的需求。
发明内容
本发明的目的在于提供一种高强度轻质耐酸浇注料及其制备方法,以解决传统浇注料因为原料昂贵导致生产成本高,而且耐火原料需要预先烧结或者电熔的方式进行预加工,能源消耗较大的问题。
为解决上述的技术问题,本发明采用以下技术方案:
一种高强度轻质耐酸浇注料,包括以下按照重量百分比表示的配方组分:粒度为5~3mm的煅烧后废瓷/废砖20~30%、粒度为5~3mm的熔炼铝灰渣15~20%、粒度为5~3mm的微孔刚玉10~15%、粒度为3~1mm的微孔刚玉10~15%、粒度为3~1mm的莫来石轻骨料10~15%、粒度为3~1mm的蛭石粉10~15%、粒度为3~1mm的硅微粉5~10%、粒度为≤5mm氧化铝粉4~8%、普硅水泥2~5%、长度为5-10mm的防爆纤维2~5%、外加剂0.5~1%。
进一步的技术方案是:所述废瓷/废砖中的废瓷和废砖的比例为1∶1~1.5。
进一步的技术方案是:所述废砖中二氧化硅的含量至少为93%及以上。
进一步的技术方案是:所述熔炼铝灰渣中铝、氧化铝和偏铝酸盐的总含量至少为60%及以上。
进一步的技术方案是:所述氧化铝粉为空心氧化铝空心微球。
进一步的技术方案是:所述外加剂包括1∶1∶1的消泡剂、有机硅偶联剂和有机减水剂。
一种高强度轻质耐酸浇注料的制备方法,包括以下步骤:
S1、将废砖投入破碎机粉碎后,再利用球磨机进行粉磨,最后筛分后保留粒度为5~3mm和3mm以下的两种粉料;
S2、将废瓷投入破碎机粉碎后,再利用球磨机进行粉磨,最后筛分后保留粒度为5~3mm和3mm以下的两种粉料;
S3、选用铝熔炼炉内的熔炼铝灰渣投入破碎机粉碎后,再进入球磨机,然后高温煅烧,最后筛分后保留粒度为5~3mm和3mm以下的两种粉料;
S4、将防爆纤维浸入熔融的焦油沥青中,并搅拌10-15分钟,捞出沥干后自然降温;
S5、按照配方组分,将S1-S4中的各种物料加入混合机进行混合;
S6、将S5中的混合料进行灌装储存。
进一步的技术方案是:S1、S2和S3中物料在煅烧前经过除铁处理。
进一步的技术方案是:将S1中3mm以下的粉料添入硅微粉内,将S2中的3mm以下的粉料添入普硅水泥中,将S3中3mm以下的粉料添入氧化铝空心微球内。
与现有技术相比,本发明的有益效果是:
1、本发明利用废弃的粘土瓷砖、高硅砖以及熔炼铝灰渣,为硅铝系抗酸耐火浇注料大量提供所需的氧化硅、氧化铝以及结合所需的粘土质,减少耐火原料的购买或者制备,降低生产成本和能源消耗;
2、而且粘土瓷砖、高硅砖以及熔炼铝灰渣均为高温烧制后的产物,其内部基本上都是不同程度的微孔或者多孔结构,有效降低浇注料的整体密度,减轻重量,其中的微孔结构更有利于阻热保温。
3、本发明的产品在制备时,将粘土瓷砖、高硅砖以及熔炼铝灰渣分选为大粒度的骨料和细粒度的补充料,粘土瓷砖的补充料可以与普硅水泥作为结合材料一起使用,高硅砖的补充料可以与硅微粉一起使用,熔炼铝灰渣的补充料可以与氧化铝一起使用,在实现浇注料基本性能的同时,均有效降低其余原料的使用。
4、本发明的产品在制备时,对防爆纤维进行润焦油沥青,进一步对浇注料进行增韧,提高抗热震性能。
具体实施方式
为使本发明实施方式的目的、技术方案和优点更加清楚,下面将结合本发明的实施方式,对本发明实施方式中的技术方案进行清楚、完整地描述,显然,所描述的实施方式是本发明一部分实施方式,而不是全部的实施方式。通常在示出的本发明实施方式的配方组份可以以各种不同的配置来布置和设计。
需要说明的是,在不冲突的情况下,本发明中的实施方式及实施方式中的特征可以相互组合。
实施例一:
本实施例示出了一种高强度轻质耐酸浇注料,包括以下按照重量百分比表示的配方组分:粒度为5~3mm的煅烧后废瓷/废砖20~30%、粒度为5~3mm的熔炼铝灰渣15~20%、粒度为5~3mm的微孔刚玉10~15%、粒度为3~1mm的微孔刚玉10~15%、粒度为3~1mm的莫来石轻骨料10~15%、粒度为3~1mm的蛭石粉10~15%、粒度为3~1mm的硅微粉5~10%、粒度为≤5mm氧化铝粉4~8%、普硅水泥2~5%、长度为5-10mm的防爆纤维2~5%、外加剂0.5~1%。
配方1:粒度为5~3mm的煅烧后废瓷/废砖24%、粒度为5~3mm的熔炼铝灰渣17%、粒度为5~3mm的微孔刚玉10%、粒度为3~1mm的微孔刚玉10%、粒度为3~1mm的莫来石轻骨料10%、粒度为3~1mm的蛭石粉10%、粒度为3~1mm的硅微粉7%、粒度为≤5mm氧化铝粉5%、普硅水泥3%、长度为5-10mm的防爆纤维3%、外加剂1%。
选用配方1进行生产,可以利用土瓷砖、高硅砖以及熔炼铝灰渣,为硅铝系抗酸耐火浇注料大量提供所需的氧化硅、氧化铝以及结合所需的粘土质,减少耐火原料的购买或者制备,降低生产成本和能源消耗,适当补充硅微粉、氧化铝粉和普硅水泥即可;引入质低最轻矿石之一的蛭石粉,保证耐火性能的同时,更进一步降低浇注料密度;而且粘土瓷砖、高硅砖以及熔炼铝灰渣均为高温烧制后的产物,其内部基本上都是不同程度的微孔或者多孔结构,有效降低浇注料的整体密度,减轻重量,其中的微孔结构更有利于阻热保温。配方1得到的产品,在用于钢包浇筑时,基本能达到所需的耐火温度。
配方2:粒度为5~3mm的煅烧后废瓷/废砖30%、粒度为5~3mm的熔炼铝灰渣15%、粒度为5~3mm的微孔刚玉10%、粒度为3~1mm的微孔刚玉10%、粒度为3~1mm的莫来石轻骨料10%、粒度为3~1mm的蛭石粉10%、粒度为3~1mm的硅微粉5%、粒度为≤5mm氧化铝粉4%、普硅水泥2%、长度为5-10mm的防爆纤维3%、外加剂1%。
在配方1的基础上,配方2的产品引入了更多的氧化硅和粘土质,适当减少普硅水泥的使用,节约成本。
配方3:粒度为5~3mm的煅烧后废瓷/废砖20%、粒度为5~3mm的熔炼铝灰渣20%、粒度为5~3mm的微孔刚玉10%、粒度为3~1mm的微孔刚玉10%、粒度为3~1mm的莫来石轻骨料10%、粒度为3~1mm的蛭石粉10%、粒度为3~1mm的硅微粉7%、粒度为≤5mm氧化铝粉4%、普硅水泥5%、长度为5-10mm的防爆纤维3%、外加剂1%。
在配方1的基础上,配方3的产品引入了更多的氧化铝,减少了氧化铝粉的使用,节约成本。
表1:配方1-3产品与普通硅铝系浇注料的试验性能对照参数
上述试验结果均为五个实验组中的求平均值。
在上表可以看出,配方1-3的产品基本性能与普通硅铝系浇注料相比均有提升,其中,体积密度和显气孔率的数值差距最大,可以知晓受煅烧后废瓷/废砖和熔炼铝灰渣的掺比的影响,煅烧后废瓷/废砖的占比越多,密度越小,强度降低,反之,当熔炼铝灰渣的占比越多,密度越大,强度增加。
优选的所述废瓷/废砖中的废瓷和废砖的比例为1∶1~1.5。
废砖占比多,提供的二氧化硅多。
优选的,所述废砖中二氧化硅的含量至少为93%及以上。
选择二氧化硅的含量至少为93%及以上的高硅废砖。
优选的,所述熔炼铝灰渣中铝、氧化铝和偏铝酸盐的总含量至少为60%及以上。
便于熔炼铝灰渣煅烧后产出的氧化铝粉越多。
优选的,所述氧化铝粉为空心氧化铝空心微球。
降低浇注料的密度,且提升保温性能。
优选的,所述外加剂包括1∶1∶1的消泡剂、有机硅偶联剂和有机减水剂。
一种高强度轻质耐酸浇注料的制备方法,包括以下步骤:
S1、将废砖投入破碎机粉碎后,再利用球磨机进行粉磨,最后筛分后保留粒度为5~3mm和3mm以下的两种粉料;
S2、将废瓷投入破碎机粉碎后,再利用球磨机进行粉磨,最后筛分后保留粒度为5~3mm和3mm以下的两种粉料;
S3、选用铝熔炼炉内的熔炼铝灰渣投入破碎机粉碎后,再进入球磨机,然后高温煅烧,最后筛分后保留粒度为5~3mm和3mm以下的两种粉料;
S4、将防爆纤维浸入熔融的焦油沥青中,并搅拌10-15分钟,捞出沥干后自然降温;
S5、按照配方组分,将S1-S4中的各种物料加入混合机进行混合;
S6、将S5中的混合料进行灌装储存。
本发明的产品在制备时,将粘土瓷砖、高硅砖以及熔炼铝灰渣分选为大粒度的骨料和细粒度的补充料,粘土瓷砖的补充料可以与普硅水泥作为结合材料一起使用,高硅砖的补充料可以与硅微粉一起使用,熔炼铝灰渣的补充料可以与氧化铝一起使用,在实现浇注料基本性能的同时,均有效降低其余原料的使用。
而且对防爆纤维进行润焦油沥青,进一步对浇注料进行增韧,提高抗热震性能
优选的,S1、S2和S3中物料在煅烧前经过除铁处理。
去除铁杂质,提高耐火性。
优选的,将S1中3mm以下的粉料添入硅微粉内,将S2中的3mm以下的粉料添入普硅水泥中,将S3中3mm以下的粉料添入氧化铝空心微球内。
将相同物质或者相同作用的物料进行混合使用,有利于减少硅微粉、氧化铝空心微球、普硅水泥的使用,降低成本。
尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (9)
1.一种高强度轻质耐酸浇注料,其特征在于,包括以下按照重量百分比表示的配方组分:粒度为5~3mm的煅烧后废瓷/废砖20~30%、粒度为5~3mm的熔炼铝灰渣15~20%、粒度为5~3mm的微孔刚玉10~15%、粒度为3~1mm的微孔刚玉10~15%、粒度为3~1mm的莫来石轻骨料10~15%、粒度为3~1mm的蛭石粉10~15%、粒度为3~1mm的硅微粉5~10%、粒度为≤5mm氧化铝粉4~8%、普硅水泥2~5%、长度为5-10mm的防爆纤维2~5%、外加剂0.5~1%。
2.根据权利要求1所述的一种高强度轻质耐酸浇注料,其特征在于:所述废瓷/废砖中的废瓷和废砖的比例为1∶1~1.5。
3.根据权利要求2所述的一种高强度轻质耐酸浇注料,其特征在于:所述废砖中二氧化硅的含量至少为93%及以上。
4.根据权利要求1所述的一种高强度轻质耐酸浇注料,其特征在于:所述熔炼铝灰渣中铝、氧化铝和偏铝酸盐的总含量至少为60%及以上。
5.根据权利要求1所述的一种高强度轻质耐酸浇注料,其特征在于:所述氧化铝粉为空心氧化铝空心微球。
6.根据权利要求1所述的一种高强度轻质耐酸浇注料,其特征在于:所述外加剂包括1∶1∶1的消泡剂、有机硅偶联剂和有机减水剂。
7.根据权利要求1-6任一项所述一种高强度轻质耐酸浇注料的制备方法,其特征在于:包括以下步骤:
S1、将废砖投入破碎机粉碎后,再利用球磨机进行粉磨,最后筛分后保留粒度为5~3mm和3mm以下的两种粉料;
S2、将废瓷投入破碎机粉碎后,再利用球磨机进行粉磨,最后筛分后保留粒度为5~3mm和3mm以下的两种粉料;
S3、选用铝熔炼炉内的熔炼铝灰渣投入破碎机粉碎后,再进入球磨机,然后高温煅烧,最后筛分后保留粒度为5~3mm和3mm以下的两种粉料;
S4、将防爆纤维浸入熔融的焦油沥青中,并搅拌10-15分钟,捞出沥干后自然降温;
S5、按照配方组分,将S1-S4中的各种物料加入混合机进行混合;
S6、将S5中的混合料进行灌装储存。
8.根据权利要求1所述的一种高强度轻质浇注料的制备方法,其特征在于:S1、S2和S3中物料在煅烧前经过除铁处理。
9.根据权利要求1所述的一种高强度轻质浇注料的制备方法,其特征在于:将S1中3mm以下的粉料添入硅微粉内,将S2中的3mm以下的粉料添入普硅水泥中,将S3中3mm以下的粉料添入氧化铝空心微球内。
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