CN117486623B - 一种高耐磨砖及其制备方法 - Google Patents
一种高耐磨砖及其制备方法 Download PDFInfo
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- 239000011449 brick Substances 0.000 title claims abstract description 59
- 238000002360 preparation method Methods 0.000 title description 9
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 35
- 239000002245 particle Substances 0.000 claims abstract description 35
- 239000010431 corundum Substances 0.000 claims abstract description 32
- 239000002994 raw material Substances 0.000 claims abstract description 31
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims abstract description 30
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 30
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 22
- 239000000843 powder Substances 0.000 claims abstract description 15
- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 15
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 14
- 238000005245 sintering Methods 0.000 claims abstract description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract 8
- 229910052681 coesite Inorganic materials 0.000 claims abstract 4
- 229910052906 cristobalite Inorganic materials 0.000 claims abstract 4
- 239000000377 silicon dioxide Substances 0.000 claims abstract 4
- 229910052682 stishovite Inorganic materials 0.000 claims abstract 4
- 229910052905 tridymite Inorganic materials 0.000 claims abstract 4
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- NLZUEZXRPGMBCV-UHFFFAOYSA-N Butylhydroxytoluene Chemical group CC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 NLZUEZXRPGMBCV-UHFFFAOYSA-N 0.000 claims description 2
- 238000007664 blowing Methods 0.000 claims description 2
- 235000010354 butylated hydroxytoluene Nutrition 0.000 claims description 2
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- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 claims description 2
- 239000002912 waste gas Substances 0.000 claims description 2
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- 239000004568 cement Substances 0.000 abstract description 11
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- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 description 1
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- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
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Abstract
本申请涉及耐火材料技术领域，公开了一种高耐磨砖，所述高耐磨砖主要由以下质量百分比的原料制备而成：粒度5‑3mm的棕刚玉8‑12w％，粒度3‑1mm的棕刚玉20‑25wt％，粒度1‑0mm的棕刚玉18‑22wt％；粒度3‑1mm的莫来石10‑15wt％，粒度≤0.088mm的莫来石6‑10wt％；粒度≤0.088mm的碳化硅15‑20wt％；粒度≤0.088mm的广西白泥6‑10wt％以及占上述原料总重量3‑4％的木质素溶液作结合剂，所述棕刚玉颗粒中Al2O3≥95％；莫来石颗粒及细粉中Al2O3≥70％、S iO2≤30％；碳化硅粉中S i C≥97％，广西白泥细粉中Al2O3≥32％、S i O2≤48％。所述高耐磨中棕刚玉、碳化硅和莫来石均为高纯度、高耐磨原料，通过添加促烧结剂，在高温下形成致密而且结合牢固的复合矿物相，显著提高了制品的耐磨和抗剥落性能，应用于水泥窑窑口，可有效延长砌筑体的使用寿命。
Description
技术领域
本发明涉及耐火材料技术领域，具体为一种高耐磨砖及其制备方法。
背景技术
高耐磨砖是一种耐磨性能优良的耐火材料制品，特别适用于水泥窑窑口水泥熟料冲刷比较严重的部位。过去水泥窑窑口砌筑常用的耐火砖都是一些传统产品，如普通高铝砖、磷酸盐结合高铝砖，这些产品耐磨性能差，结合强度低，不耐冲刷，剥落损毁严重，从而缩短了使用周期，也影响了水泥熟料产量的提升。而高耐磨砖从优选原料入手，首先选定耐磨性能优良的棕刚玉做主原料，尖棱状莫来石作次原料，引入在烧结过程中能改善晶体结构的碳化硅细粉，并添加广西白泥作促烧结剂，通过调整颗粒级配，合理优化配比，通过高温烧结形成牢固的复合晶相，大大提高了制品的耐压强度和耐磨性能，替代传统产品普通高铝砖、磷酸盐结合高铝砖，寿命提高一倍以上。
发明内容
本发明的目的在于提供一种水泥窑窑口用高耐磨砖及其制备方法，改善了制品的耐磨性能和抗剥落性能，高温下结构致密，结合牢固，不易损毁，并且制作过程常规，易于施工等优点。
为实现以上目的，本发明通过以下技术方案予以实现：一种高耐磨砖，所述高耐磨砖主要由以下质量百分比的原料制备而成：粒度5-3mm的棕刚玉8-12w％，粒度3-1mm的棕刚玉20-25wt％，粒度1-0mm的棕刚玉18-22wt％；粒度3-1mm的莫来石10-15wt％，粒度≤0.088mm的莫来石6-10wt％；粒度≤0.088mm的碳化硅15-20wt％；粒度≤0.088mm的广西白泥6-10wt％以及占上述原料总重量3-4％的木质素溶液作结合剂。
优选的，所述棕刚玉颗粒中A l2O3≥95％；莫来石颗粒及细粉中A l2O3≥70％、S iO2≤30％；碳化硅粉中S i C≥97％，广西白泥细粉中A l2O3≥32％、S i O2≤48％。
优选的，所述促烧结剂为广西白泥，所述结合剂为木质素溶液。
优选的，所述高耐磨砖主要由以下质量百分比的原料制备而成：粒度5-3mm的棕刚玉8-12w％，粒度3-1mm的棕刚玉20-25wt％，粒度1-0mm的棕刚玉18-22wt％；粒度3-1mm的莫来石10-15wt％，粒度≤0.088mm的莫来石6-10wt％；粒度≤0.088mm的碳化硅15-20wt％；粒度≤0.088mm的广西白泥6-10wt％以及占上述原料总重量3-4％的木质素溶液作结合剂。所述高耐磨砖中Al2O3≥62％、S i C≥15％、S iO2≤13％。
一种高耐磨砖及其制备方法，包括以下步骤：
步骤一、原料预处理：首先对原料及粒度要求配料进行称重，随后将所述称重的主料进行筛分，同时按照筛分所获得的材料能够按照棕刚玉颗粒与莫来石颗粒所配对的比例进行匹配放置到混合机中进行干混2-3分钟，同时在干混的时候在内部加入抗氧化剂；
步骤二、辅料处理：将干混处理得到的混合颗粒料A内部加入结合剂，放置在搅拌碾磨机中进行混碾3-5分钟；
步骤三、物料收集：将得到的混合颗粒料A进行混碾出来后，在将混合颗粒料A放置进入到搅拌罐中，通过在搅拌的时候加入结合剂以及碳化硅细粉、广西白泥细粉混碾8-10分钟成为半干可塑状泥料即可进行出料；
步骤四、混合好的泥料A按照工艺卡片要求的重量称重后加入砖坯模具中使之成型，砖坯成型时需要采用630t电控螺旋压力机制坯并利用压力机自带的的出模系统出模，出模的砖坯放置在干燥车上,半成品体积密度控制在2.95-3.02g/cm3；
步骤五、将放有砖坯的干燥车送进入到干燥器中，通过110-120℃×24h干燥后，检测砖坯中所含有的残余水分，确保残余水分≤0.7％；
步骤六、干燥后的砖坯通过操作人员的输送将砖坯装入窑车，通过推入110米高温隧道，随后在窑内经1580℃的高温，同时需要通过10-12h的烧制才可得耐磨砖成品砖体。
优选的，所述步骤一中，混合粉末的细度条件为180～200目。
优选的，所述步骤六中还包括以下步骤：
S701、准备工作：操作人员需要将耐磨砖成品砖体放置在清扫箱中，对耐磨砖成品砖体进行10-60min清扫，确保砖体表面干净、平整且无油脂、尘埃或其他污染物；
S702、涂料准备：将硬质涂层所需要的氮化硅、钛氮化物、碳化硅与水安装比例进行配对，随后输送进入到搅拌罐中，进行搅打，形成大量涂抹的胶体；
S703、涂抹机进行制备涂抹：操作人员需要将耐磨砖成品砖体放置在刷涂机中，通过对耐磨砖成品砖体进行10-30min刷制。
优选的，所述抗氧剂为2,6-二叔丁基对甲酚。
优选的，所述筛分所述使用180目的分子筛进行筛分，筛上物由管道真空输送返回球磨机再次球磨，球磨和筛分全部密闭进行，物料采用真空输送，气料通过空气喷吹震打分离，气料分离后的含尘废气通过滤芯过滤器过滤。
本发明提供了一种高耐磨砖及其制备方法。具备以下有益效果：
本发明高耐磨中棕刚玉、碳化硅和莫来石均为高纯度、高耐磨原料，通过添加促烧结剂，在高温下形成致密而且结合牢固的复合矿物相，显著提高了制品的耐磨和抗剥落性能，应用于水泥窑窑口，可有效延长砌筑体的使用寿命。
具体实施方式
下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例一：
本发明实施例提供一种高耐磨砖，所述高耐磨砖主要由以下质量百分比的原料制备而成：粒度5-3mm的棕刚玉8-12w％，粒度3-1mm的棕刚玉20-25wt％，粒度1-0mm的棕刚玉18-22wt％；粒度3-1mm的莫来石10-15wt％，粒度≤0.088mm的莫来石6-10wt％；粒度≤0.088mm的碳化硅15-20wt％；粒度≤0.088mm的广西白泥6-10wt％以及占上述原料总重量3-4％的木质素溶液作结合剂。
所述棕刚玉颗粒中A l2O3≥95％；莫来石颗粒及细粉中Al2O3≥70％、S i O2≤30％；碳化硅粉中S i C≥97％，广西白泥细粉中Al2O3≥32％、S iO2≤48％。
所述促烧结剂为广西白泥，所述结合剂为木质素溶液。
所述高耐磨砖主要由以下质量百分比的原料制备而成：粒度5-3mm的棕刚玉8-12w％，粒度3-1mm的棕刚玉20-25wt％，粒度1-0mm的棕刚玉18-22wt％；粒度3-1mm的莫来石10-15wt％，粒度≤0.088mm的莫来石6-10wt％；粒度≤0.088mm的碳化硅15-20wt％；粒度≤0.088mm的广西白泥6-10wt％以及占上述原料总重量3-4％的木质素溶液作结合剂。所述高耐磨砖中Al2O3≥62％、S i C≥15％、S iO2≤13％。
以上原料经湿碾机混碾后，采用630t电控螺旋压力机成型制坯，砖坯经110-120℃×24h干燥后装车入窑，经1580℃的高温烧成可得耐磨砖成品砖体。其主要化学成分及性能指标见表1。
实施例二：
本实施例水泥窑窑口用高耐磨砖，采用粒度5-3mm的棕刚玉8w％，粒度3-1mm的棕刚玉25wt％，粒度1-0mm的棕刚玉20wt％，粒度3-1mm的莫来石11wt％，粒度≤0.088mm的莫来石10wt％，粒度≤0.088mm的碳化硅16wt％，粒度≤0.088mm的广西白泥10wt％以及占上述原料总重量3.5％的木质素溶液作结合剂。所述高耐磨砖中Al2O3≥62％、S i C≥15％、SiO2≤13％。
以上原料经湿碾机混碾后，采用630t电控螺旋压力机成型制坯，砖坯经110-120℃×24h干燥后装车入窑，经1580℃的高温烧成可得耐磨砖成品砖体。其主要化学成分及性能指标见表1。
实施例三：
本实施例水泥窑窑口用高耐磨砖，采用粒度5-3mm的棕刚玉9w％，粒度3-1mm的棕刚玉23wt％，粒度1-0mm的棕刚玉21wt％，粒度3-1mm的莫来石12wt％，粒度≤0.088mm的莫来石9wt％，粒度≤0.088mm的碳化硅17wt％，粒度≤0.088mm的广西白泥9wt％以及占上述原料总重量3.5％的木质素溶液作结合剂。所述高耐磨砖中Al2O3≥62％、S i C≥15％、SiO2≤13％。
以上原料经湿碾机混碾后，采用630t电控螺旋压力机成型制坯，砖坯经110-120℃×24h干燥后装车入窑，经1580℃的高温烧成可得耐磨砖成品砖体。其主要化学成分及性能指标见表1。
实施例四：
本实施例水泥窑窑口用高耐磨砖，采用粒度5-3mm的棕刚玉11w％，粒度3-1mm的棕刚玉24wt％，粒度1-0mm的棕刚玉18wt％，粒度3-1mm的莫来石14wt％，粒度≤0.088mm的莫来石7wt％，粒度≤0.088mm的碳化硅20wt％，粒度≤0.088mm的广西白泥6wt％以及占上述原料总重量3.5％的木质素溶液作结合剂。所述高耐磨砖中Al2O3≥62％、S i C≥15％、SiO2≤13％。
以上原料经湿碾机混碾后，采用630t电控螺旋压力机成型制坯，砖坯经110-120℃×24h干燥后装车入窑，经1580℃的高温烧成可得耐磨砖成品砖体。其主要化学成分及性能指标见表1。
比例1：
本对比例的制备方法与实施例一相同，区别在于在进行步骤一时，混合原料中不加入棕刚玉颗粒。
对比例2：
本对比例的制备方法与实施例一相同，区别在于在进行步骤一时，混合原料时不加入莫来石颗粒。
对比例3：
本对比例的制备方法与实施例一相同，区别在于在进行步骤二时，不用在内部加入抗氧化剂。
表1实施例一～4高耐磨砖性能指标
实施例一-四相关技术指标都能满足水泥窑窑口使用，相比较而言，实施例一颗粒级配更加合理，临界大颗粒5-3mm的用量适中，各种细粉的加入量也最佳。优选的实施例一有助于提高制品的体积密度和耐压强度，同等实验条件下耐磨性能最好，磨损率最低。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。
Claims (3)
1.一种高耐磨砖，其特征在于，所述高耐磨砖主要由以下质量百分比的原料制备而成：粒度5-3mm的棕刚玉颗粒8-12w%，粒度3-1mm的棕刚玉颗粒20-25wt%，粒度1-0mm的棕刚玉颗粒18-22wt%；粒度3-1mm的莫来石颗粒10-15wt%，粒度≤0.088mm的莫来石细粉6-10wt%；粒度≤0.088mm的碳化硅细粉15-20wt%；粒度≤0.088mm的广西白泥细粉6-10wt%以及占上述原料总重量3-4%的木质素溶液作结合剂，所述棕刚玉颗粒中Al2O3≥95%；莫来石颗粒及细粉中Al2O3≥70%、SiO2≤30%；碳化硅细粉中SiC≥97%，广西白泥细粉中Al2O3≥32%、SiO2≤48%，所述广西白泥细粉为促烧结剂，所述高耐磨砖中Al2O3≥62%、SiC≥15%、SiO2≤13%；
原料预处理包括：按照棕刚玉颗粒与莫来石颗粒所配对的比例进行匹配放置到混合机中进行干混2-3分钟，同时在干混的时候在内部加入抗氧化剂；
所述抗氧化剂为2,6-二叔丁基对甲酚。
2.根据权利要求1所述的一种高耐磨砖的制备方法，其特征在于，包括以下步骤：
步骤一、原料预处理：首先对原料及粒度要求配料进行称重，随后将所述称重的主料进行筛分，同时按照棕刚玉颗粒与莫来石颗粒所配对的比例进行匹配放置到混合机中进行干混2-3分钟，同时在干混的时候在内部加入抗氧化剂，得到混合颗粒料A；
步骤二、辅料处理：将干混处理得到的混合颗粒料A内部加入结合剂，放置在搅拌碾磨机中进行混碾3-5分钟；
步骤三、物料收集：将得到的混合颗粒料A进行混碾出来后，放置进入到搅拌罐中，通过在搅拌的时候加入碳化硅细粉、莫来石细粉与广西白泥细粉混碾8-10分钟成为半干可塑状泥料即可进行出料，得到泥料A；
步骤四、混合好的泥料A按照工艺卡片要求的重量称重后加入砖坯模具中加压使之成型，砖坯成型时需要采用630t电控螺旋压力机制坯并利用压力机自带的出模系统出模，出模的砖坯放置在干燥车上,半成品体积密度控制在2.95-3.02g/cm³；
步骤五、将放有砖坯的干燥车送进入到干燥器中，通过110-120℃×24h干燥后，检测砖坯中所含有的残余水分，确保残余水分≤0.7%；
步骤六、干燥后的砖坯通过操作人员的输送将砖坯装入窑车，通过推入110米高温隧道，随后在窑内经1580℃的高温，同时需要通过10-12h的烧制才可得耐磨砖成品砖体。
3.根据权利要求2所述的一种高耐磨砖的制备方法，其特征在于，所述筛分使用180目的分子筛进行筛分，筛上物由管道真空输送返回球磨机再次球磨，球磨和筛分全部密闭进行，物料采用真空输送，气料通过空气喷吹震打分离，气料分离后的含尘废气通过滤芯过滤器过滤。
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