CN116253561B - 用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺 - Google Patents

用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺 Download PDF

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CN116253561B
CN116253561B CN202211692662.0A CN202211692662A CN116253561B CN 116253561 B CN116253561 B CN 116253561B CN 202211692662 A CN202211692662 A CN 202211692662A CN 116253561 B CN116253561 B CN 116253561B
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parts
temperature
powder
refractory bricks
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CN116253561A (zh
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顾建中
沃巨鹏
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Yixing Longchang Refractory Co ltd
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Yixing Longchang Refractory Co ltd
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  • Compositions Of Oxide Ceramics (AREA)

Abstract

本发明公开了用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，所述耐火砖的制备原料按重量份数计包括90～150份莫来石、70～110份刚玉粉、6～11份黏土、10～15份高岭土、2～5份膨润土、5～12份球粘土、5～9份氧化铝粉末、3～7份黑曜石、4～8份火岩泥、2～6份方解石、3～6份玻璃粉末、1～3份纳米碳管、2～5份纳米二氧化钛、10～20份复合补充剂以及15～30份复合添加剂；所述耐火砖的生产工艺包括S1、配料，称取原料，备用；S2、混料，将原料进行混料；S3、预压制，将混料的原料压制成砖坯；S4、烘干，将砖坯进行烘干；S5、高温烧制，对烘干的进行烧制；S6、降温保型，将烧制的耐火砖在炉内保温一段时间；S7、冷却，将烧制的耐火砖冷却至室温即可。

Description

用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺
技术领域
本发明涉及耐火砖技术领域，具体为用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺。
背景技术
热导率是指单位时间内在单位温度梯度下沿热流方向通过材料单位面积传递的热量，是耐火砖的重要热物理性能性能之一，高温窑炉设备不同使用部位为了达到降低能耗的目的，采用耐火砖是不同的，主要是因为耐火砖的材料及生产工艺不同，热导率存在很大差别，采用热导率小的耐火砖砌筑热工窑炉的内衬可以减少厚度和热损失，节约能源；采用热导率大的耐火砖作为隔焰板和换热器，可以提高炉膛温度和传热效率；
目前使用的耐火砖在热振稳定性、抗化学侵蚀性以及耐磨性方面还有所欠缺。
发明内容
本发明的目的在于提供用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，该工艺制备的耐火砖具有良好的热稳定性。
为实现上述目的，本发明提供如下技术方案：
用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，耐火砖的制备原料按重量份数计包括90～150份莫来石、70～110份刚玉粉、6～11份黏土、10～15份高岭土、2～5份膨润土、5～12份球粘土、5～9份氧化铝粉末、3～7份黑曜石、4～8份火岩泥、2～6份方解石、3～6份玻璃粉末、1～3份纳米碳管、2～5份纳米二氧化钛、10～20份复合补充剂以及15～30份复合添加剂；
耐火砖的生产工艺包括以下步骤：
S1、配料，按重量份数计称取90～150份莫来石、70～110份刚玉粉、6～11份黏土、10～15份高岭土、2～5份膨润土、5～12份球粘土、5～9份氧化铝粉末、3～7份黑曜石、4～8份火岩泥、2～6份方解石、3～6份玻璃粉末、1～3份纳米碳管、2～5份纳米二氧化钛，备用；
并按重量份数计称取10～20份复合补充剂和15～30份复合添加剂，备用；
S2、混料，将步骤S1称取的原料在混料机中进行充分混料，并加入原料总质量2～10％的蒸馏水，混料时间为40～90min；
S3、预压制，将步骤S2混料完毕的原料在模具中进行压制，成型压力为2.5MPa～3.5MPa；
S4、烘干，将步骤S3压制成型的耐火砖砖坯在70～150℃的条件下烘干3～8h；
S5、高温烧制，将步骤S4烘干后的耐火砖砖坯进行烧制，烧成温度为1550℃～1750℃；
S6、降温保型，将步骤S5烧制完毕的耐火砖在炉内以2～4℃/min的降温速率降至750℃～850℃，保温50～90min；
S7、冷却，关闭炉火，使得耐火砖自然冷却至室温即可。
优选地，复合补充剂按重量份数计包括5～10份碳化硅纳米线、10～20份碳化硼、1～3份硅烷偶联剂、2～5份苯酚、2～6份甲醛水溶液、1～2份草酸，2～6份硅溶胶。
优选地，复合添加剂按重量份数计包括10～20份电熔镁砂粒、1～5份电熔镁砂粉、2～6份电熔尖晶石颗粒、2～7份电熔尖晶石粉、1～3份电熔尖晶石微粉、0.1～1份氮化硅粉、0.5～2份碳氮化钛粉、0.4～1份碳化钛粉、0.2～0.6份硼酸钠粉。
优选地，步骤S2中的混料机为超声混料机，混料时的超声频率为28KHz～48KHz。
优选地，步骤S2混料时，使混料环境压强处于0.3～0.6个标准大气压。
优选地，将步骤S3压制成型的耐火砖砖坯在50～85℃且通风的条件下进行烘干6～12h。
优选地，步骤S5中的温度控制过程为如下，先以1～3℃/min的升温速率将温度升至700℃，保温40～120min；
以1～3℃/min的降温速率将温度降至600～650℃，再以2～5℃/min的升温速率将温度升至1250℃，保温100～180min，
以2～5℃/min的降温速率将温度降至1150～1200℃，最后以2～4℃/min的升温速率将温度升至1550℃～1750℃，保温120～500min；
以2～4℃/min的降温速率将温度降至1450℃，在此温度下持续烧制120～500min。
优选地，莫来石的粒径为10μm～80μm。
优选地，刚玉粉的粒径为20μm～60μm。
优选地，如上述的用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，该工艺制备的耐火砖包括A型耐火砖和B型耐火砖，A型耐火砖和B型耐火砖组合固定在回转窑的内侧壁上，回转窑的内侧壁上先铺设固定一层A型耐火砖，再在A型耐火砖上铺设固定一层B型耐火砖；
A型耐火砖远离回转窑内侧壁的一侧具有第一中空槽，B型耐火砖靠近回转窑内侧壁的一侧具有第二中空槽；
第一中空槽内具有第一横向肋板和第一纵向肋板，第一横向肋板和第一纵向肋板将第一中空槽分隔为四个独立的第一空间，第二中空槽内具有第二横向肋板和第二纵向肋板，第二横向肋板和第二纵向肋板将第二中空槽分隔为四个独立的第二空间；
第一空间内放置有蜂窝机构的辅助支撑板，辅助支撑板由耐火砖同种材料烧制而成；
A型耐火砖具有第一中空槽的一侧四边处具有拼接配合凹槽；
第一空间和第二空间内填充有气凝胶颗粒，气凝胶颗粒的粒径在10～20mm，气凝胶颗粒为球形或者菱形十二面体。
与现有技术相比，本发明的有益效果是：
1、本发明的耐火砖具有更好的耐高温性，在高温下具有更好地抗侵蚀性能；
2、本发明的耐火砖具有更好的热振稳定性，在停窑、开窑以及旋窑运转状况等不稳定的情况下，窑内的温度变化比较大，本发明的耐火砖在温度剧烈变化下，不会出现龟裂或者是剥落的情况，在使用性能上具有巨大提升；
3、本发明的耐火砖具有更好的抗化学侵蚀性，能够有效抵挡灰份、熔渣、蒸汽对耐火砖产生较强的化学侵蚀；
4、本发明的耐火砖具有更好的耐磨性及机械强度，窑炉内材料的滑动及气流中粉尘的磨擦，均会对窑砖造成很大的冲刷或冲击磨损，本发明的耐火砖能够有效承受各种冲刷或冲击磨损；
4、本发明的耐火砖导热系数很小，有利于保持炉内的高温稳定，使得炉内热量不易流失，避免造成能源的浪费。
附图说明
图1是本发明的耐火砖在回转窑中的布局示意图；
图2是本发明中耐火砖的结构示意图。
图中，10-A型耐火砖、101-拼接配合凹槽、11-第一中空槽、111-第一横向肋板、112-第一纵向肋板、113-第一空间、20-B型耐火砖、21-第二中空槽、211-第二横向肋板、212-第二纵向肋板、213-第二空间。
具体实施方式
下面结合图1-图2对本发明进行详细说明，为叙述方便，现对下文所说的方位规定如下：下文所说的上下左右前后方向与各自主视图或结构示意图本身投影关系的上下左右前后方向一致。
实施例1：
用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，耐火砖的制备原料按重量份数计包括150份莫来石、110份刚玉粉、11份黏土、15份高岭土、5份膨润土、12份球粘土、9份氧化铝粉末、7份黑曜石、8份火岩泥、6份方解石、6份玻璃粉末、3份纳米碳管、5份纳米二氧化钛、20份复合补充剂以及30份复合添加剂；
莫来石的粒径为80μm，刚玉粉的粒径为60μm。
复合补充剂按重量份数计包括3.8份碳化硅纳米线、7.7份碳化硼、1.2份硅烷偶联剂、1.9份苯酚、2.3份甲醛水溶液、0.8份草酸，2.3份硅溶胶。
复合添加剂按重量份数计包括13.2份电熔镁砂粒、3.3份电熔镁砂粉、3.9份电熔尖晶石颗粒、4.6份电熔尖晶石粉、2份电熔尖晶石微粉、0.6份氮化硅粉、1.3份碳氮化钛粉、0.7份碳化钛粉、0.4份硼酸钠粉。
耐火砖的生产工艺包括以下步骤：
S1、配料，按重量份数计称取150份莫来石、110份刚玉粉、11份黏土、15份高岭土、5份膨润土、12份球粘土、9份氧化铝粉末、7份黑曜石、8份火岩泥、6份方解石、6份玻璃粉末、3份纳米碳管、5份纳米二氧化钛，备用；
并按重量份数计称取20份复合补充剂和30份复合添加剂，备用；
S2、混料，将步骤S1称取的原料在混料机中进行充分混料，并加入原料总质量10％的蒸馏水，混料时间为90min；
S3、预压制，将步骤S2混料完毕的原料在模具中进行压制，成型压力为3.5MPa；
S4、烘干，将步骤S3压制成型的耐火砖砖坯在150℃的条件下烘干8h；
S5、高温烧制，将步骤S4烘干后的耐火砖砖坯进行烧制，烧成温度为1750℃；
S6、降温保型，将步骤S5烧制完毕的耐火砖在炉内以4℃/min的降温速率降至850℃，保温90min；
S7、冷却，关闭炉火，使得耐火砖自然冷却至室温即可。
步骤S2中的混料机为超声混料机，混料时的超声频率为48KHz。
步骤S2混料时，使混料环境压强处于0.6个标准大气压。
步骤S5中的温度控制过程为如下，先以3℃/min的升温速率将温度升至700℃，保温120min；
以3℃/min的降温速率将温度降至650℃，再以5℃/min的升温速率将温度升至1250℃，保温180min，
以5℃/min的降温速率将温度降至1200℃，最后以4℃/min的升温速率将温度升至1750℃，保温500min；
以4℃/min的降温速率将温度降至1450℃，在此温度下持续烧制500min。
实施例2：
用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，耐火砖的制备原料按重量份数计包括90份莫来石、70份刚玉粉、6份黏土、10份高岭土、2份膨润土、5份球粘土、5份氧化铝粉末、3份黑曜石、4份火岩泥、2份方解石、3份玻璃粉末、1份纳米碳管、2份纳米二氧化钛、10份复合补充剂以及15份复合添加剂；
莫来石的粒径为10μm，刚玉粉的粒径为20μm。
复合补充剂按重量份数计包括2.2份碳化硅纳米线、4.4份碳化硼、0.4份硅烷偶联剂、0.9份苯酚、0.9份甲醛水溶液、0.4份草酸，0.8份硅溶胶。
复合添加剂按重量份数计包括8.7份电熔镁砂粒、0.9份电熔镁砂粉、1.7份电熔尖晶石颗粒、1.8份电熔尖晶石粉、0.9份电熔尖晶石微粉、0.1份氮化硅粉、0.4份碳氮化钛粉、0.3份碳化钛粉、0.2份硼酸钠粉。
耐火砖的生产工艺包括以下步骤：
S1、配料，按重量份数计称取90份莫来石、70份刚玉粉、6份黏土、10份高岭土、2份膨润土、5份球粘土、5份氧化铝粉末、3份黑曜石、4份火岩泥、2份方解石、3份玻璃粉末、1份纳米碳管、2份纳米二氧化钛，备用；
并按重量份数计称取10份复合补充剂和15份复合添加剂，备用；
S2、混料，将步骤S1称取的原料在混料机中进行充分混料，并加入原料总质量2％的蒸馏水，混料时间为40min；
S3、预压制，将步骤S2混料完毕的原料在模具中进行压制，成型压力为2.5MPa；
S4、烘干，将步骤S3压制成型的耐火砖砖坯在70℃的条件下烘干3h；
S5、高温烧制，将步骤S4烘干后的耐火砖砖坯进行烧制，烧成温度为1550℃；
S6、降温保型，将步骤S5烧制完毕的耐火砖在炉内以2℃/min的降温速率降至750℃，保温50min；
S7、冷却，关闭炉火，使得耐火砖自然冷却至室温即可。
步骤S2中的混料机为超声混料机，混料时的超声频率为28KHz。
步骤S2混料时，使混料环境压强处于0.3个标准大气压。
步骤S5中的温度控制过程为如下，先以1℃/min的升温速率将温度升至700℃，保温40min；
以1℃/min的降温速率将温度降至600，再以2℃/min的升温速率将温度升至1250℃，保温100min，
以2℃/min的降温速率将温度降至1150℃，最后以2℃/min的升温速率将温度升至1550℃，保温120min；
以2℃/min的降温速率将温度降至1450℃，在此温度下持续烧制120min。
实施例3：
用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，耐火砖的制备原料按重量份数计包括120份莫来石、90份刚玉粉、8份黏土、13份高岭土、3.5份膨润土、8份球粘土、7份氧化铝粉末、5份黑曜石、6份火岩泥、4份方解石、5份玻璃粉末、2份纳米碳管、4份纳米二氧化钛、15份复合补充剂以及22份复合添加剂；
莫来石的粒径为20μm，刚玉粉的粒径为30μm。
复合补充剂按重量份数计包括2.8份碳化硅纳米线、6.2份碳化硼、0.8份硅烷偶联剂、1.2份苯酚、1.7份甲醛水溶液、0.7份草酸，1.6份硅溶胶。
复合添加剂按重量份数计包括10.8份电熔镁砂粒、2.2份电熔镁砂粉、2.9份电熔尖晶石颗粒、2.8份电熔尖晶石粉、1.5份电熔尖晶石微粉、0.3份氮化硅粉、0.7份碳氮化钛粉、0.5份碳化钛粉、0.3份硼酸钠粉。
耐火砖的生产工艺包括以下步骤：
S1、配料，按重量份数计称取120份莫来石、90份刚玉粉、8份黏土、13份高岭土、3.5份膨润土、8份球粘土、7份氧化铝粉末、5份黑曜石、6份火岩泥、4份方解石、5份玻璃粉末、2份纳米碳管、4份纳米二氧化钛，备用；
并按重量份数计称取15份复合补充剂和22份复合添加剂，备用；
S2、混料，将步骤S1称取的原料在混料机中进行充分混料，并加入原料总质量5％的蒸馏水，混料时间为80min；
S3、预压制，将步骤S2混料完毕的原料在模具中进行压制，成型压力为3MPa；
S4、烘干，将步骤S3压制成型的耐火砖砖坯在110℃的条件下烘干6h；
S5、高温烧制，将步骤S4烘干后的耐火砖砖坯进行烧制，烧成温度为1650℃；
S6、降温保型，将步骤S5烧制完毕的耐火砖在炉内以3℃/min的降温速率降至800℃，保温70min；
S7、冷却，关闭炉火，使得耐火砖自然冷却至室温即可。
步骤S2中的混料机为超声混料机，混料时的超声频率为36KHz。
步骤S2混料时，使混料环境压强处于0.5个标准大气压。
步骤S5中的温度控制过程为如下，先以2℃/min的升温速率将温度升至700℃，保温80min；
以2℃/min的降温速率将温度降至650℃，再以4℃/min的升温速率将温度升至1250℃，保温120min，
以3℃/min的降温速率将温度降至1200℃，最后以3℃/min的升温速率将温度升至1650℃，保温180min；
以3℃/min的降温速率将温度降至1450℃，在此温度下持续烧制480min。
实施例4：
与实施例3不同之处在于，将步骤S3压制成型的耐火砖砖坯在85℃且通风的条件下进行烘干12h。
实施例5：
与实施例4不同之处在于，将步骤S3压制成型的耐火砖砖坯在50℃且通风的条件下进行烘干6h。
实施例6：
与实施例4不同之处在于，将步骤S3压制成型的耐火砖砖坯在65℃且通风的条件下进行烘干9h。
实施例7：
如上述实施例1～6的用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，该工艺制备的耐火砖包括A型耐火砖10和B型耐火砖20，A型耐火砖10和B型耐火砖20组合固定在回转窑的内侧壁上，回转窑的内侧壁上先铺设固定一层A型耐火砖10，再在A型耐火砖10上铺设固定一层B型耐火砖20；
A型耐火砖10远离回转窑内侧壁的一侧具有第一中空槽11，B型耐火砖20靠近回转窑内侧壁的一侧具有第二中空槽21；
第一中空槽11内具有第一横向肋板111和第一纵向肋板112，第一横向肋板111和第一纵向肋板112将第一中空槽11分隔为四个独立的第一空间113，第二中空槽21内具有第二横向肋板211和第二纵向肋板212，第二横向肋板211和第二纵向肋板212将第二中空槽21分隔为四个独立的第二空间213；
第一空间113内放置有蜂窝机构的辅助支撑板31，辅助支撑板31由耐火砖同种材料烧制而成；
A型耐火砖10具有第一中空槽11的一侧四边处具有拼接配合凹槽101；
第一空间113和第二空间213内填充有气凝胶颗粒，气凝胶颗粒的粒径在20mm，气凝胶颗粒为球形。
实施例8：
与实施例7不同之处在于，气凝胶颗粒的粒径在10mm，气凝胶颗粒为菱形十二面体。
实施例9：
与实施例7不同之处在于，气凝胶颗粒的粒径在15mm，气凝胶颗粒为菱形十二面体。

Claims (4)

1.用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，其特征在于，所述耐火砖的制备原料按重量份数计包括90～150份莫来石、70～110份刚玉粉、6～11份黏土、10～15份高岭土、2～5份膨润土、5～12份球粘土、5～9份氧化铝粉末、3～7份黑曜石、4～8份火岩泥、2～6份方解石、3～6份玻璃粉末、1～3份纳米碳管、2～5份纳米二氧化钛、10～20份复合补充剂以及15～30份复合添加剂；
所述耐火砖的生产工艺包括以下步骤：
S1、配料，按重量份数计称取90～150份莫来石、70～110份刚玉粉、6～11份黏土、10～15份高岭土、2～5份膨润土、5～12份球粘土、5～9份氧化铝粉末、3～7份黑曜石、4～8份火岩泥、2～6份方解石、3～6份玻璃粉末、1～3份纳米碳管、2～5份纳米二氧化钛，备用；
并按重量份数计称取10～20份复合补充剂和15～30份复合添加剂，备用；
S2、混料，将步骤S1称取的原料在混料机中进行充分混料，并加入原料总质量2～10％的蒸馏水，混料时间为40～90min；
S3、预压制，将步骤S2混料完毕的原料在模具中进行压制，成型压力为2.5MPa～3.5MPa；
S4、烘干，将步骤S3压制成型的耐火砖砖坯在70～150℃的条件下烘干3～8h；
S5、高温烧制，将步骤S4烘干后的耐火砖砖坯进行烧制，烧成温度为1550℃～1750℃；
S6、降温保型，将步骤S5烧制完毕的耐火砖在炉内以2～4℃/min的降温速率降至750℃～850℃，保温50～90min；
S7、冷却，关闭炉火，使得耐火砖自然冷却至室温即可；
所述复合补充剂按重量份数计包括5～10份碳化硅纳米线、10～20份碳化硼、1～3份硅烷偶联剂、2～5份苯酚、2～6份甲醛水溶液、1～2份草酸，2～6份硅溶胶；
所述复合添加剂按重量份数计包括10～20份电熔镁砂粒、1～5份电熔镁砂粉、2～6份电熔尖晶石颗粒、2～7份电熔尖晶石粉、1～3份电熔尖晶石微粉、0.1～1份氮化硅粉、0.5～2份碳氮化钛粉、0.4～1份碳化钛粉、0.2～0.6份硼酸钠粉；
步骤S2中的混料机为超声混料机，混料时的超声频率为28KHz～48KHz；
步骤S2混料时，使混料环境压强处于0.3～0.6个标准大气压；
将步骤S3压制成型的耐火砖砖坯在50～85℃且通风的条件下进行烘干6～12h；
步骤S5中的温度控制过程为如下，先以1～3℃/min的升温速率将温度升至700℃，保温40～120min；
以1～3℃/min的降温速率将温度降至600～650℃，再以2～5℃/min的升温速率将温度升至1250℃，保温100～180min，
以2～5℃/min的降温速率将温度降至1150～1200℃，最后以2～4℃/min的升温速率将温度升至1550℃～1750℃，保温120～500min；
以2～4℃/min的降温速率将温度降至1450℃，在此温度下持续烧制120～500min。
2.根据权利要求1所述的用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，其特征在于：所述莫来石的粒径为10μm～80μm。
3.根据权利要求1所述的用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，其特征在于：所述刚玉粉的粒径为20μm～60μm。
4.根据权利要求1～3任意一项所述的用于石膏制硫酸回转窑的环保型复合耐火砖的生产工艺，其特征在于：该工艺制备的耐火砖包括A型耐火砖(10)和B型耐火砖(20)，所述A型耐火砖(10)和所述B型耐火砖(20)组合固定在回转窑的内侧壁上，回转窑的内侧壁上先铺设固定一层所述A型耐火砖(10)，再在所述A型耐火砖(10)上铺设固定一层所述B型耐火砖(20)；
所述A型耐火砖(10)远离回转窑内侧壁的一侧具有第一中空槽(11)，所述B型耐火砖(20)靠近回转窑内侧壁的一侧具有第二中空槽(21)；
所述第一中空槽(11)内具有第一横向肋板(111)和第一纵向肋板(112)，所述第一横向肋板(111)和所述第一纵向肋板(112)将第一中空槽(11)分隔为四个独立的第一空间(113)，所述第二中空槽(21)内具有第二横向肋板(211)和第二纵向肋板(212)，所述第二横向肋板(211)和所述第二纵向肋板(212)将第二中空槽(21)分隔为四个独立的第二空间(213)；
所述第一空间(113)内放置有蜂窝机构的辅助支撑板(31)，所述辅助支撑板(31)由耐火砖同种材料烧制而成；
所述A型耐火砖(10)具有第一中空槽(11)的一侧四边处具有拼接配合凹槽(101)；
所述第一空间(113)和所述第二空间(213)内填充有气凝胶颗粒，所述气凝胶颗粒的粒径在10～20mm，所述气凝胶颗粒为球形或者菱形十二面体。
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