CN111875395A - 一种节能型轻质发泡陶瓷通体耐火材料、节能型轻质发泡陶瓷通体耐火板及其应用 - Google Patents
一种节能型轻质发泡陶瓷通体耐火材料、节能型轻质发泡陶瓷通体耐火板及其应用 Download PDFInfo
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Abstract
本发明属于发泡陶瓷耐火材料技术领域,公开了一种节能型轻质发泡陶瓷通体耐火材料,包括硅砂、钾长石、透辉石、高温砂、滑石粉、发泡剂。同时还提供了利用该材料配方制备的节能型轻质发泡陶瓷通体耐火板,其中,硅砂为高硅含量的砂石,提高了板材的硬度,高温砂中也含有大量的硅元素,硅比例的增加,提高了烧成温度;含透辉石的原料中含有较多的铝、钙、镁等元素,其中镁和铝起到耐火作用,铝元素还有效提高了板材的强度和韧性,此外,硅、铝元素的增加,共同提高了始熔温度和烧结温度,使板材在保持原有硬度、强度、韧性的前提下的始熔温度提高至1200℃或以上,裸板状态下已经具有良好的耐火性能,无需添加任何外层防火涂料即可通过耐火极限检测。
Description
技术领域
本发明属于耐火材料技术领域,具体涉及一种节能型轻质发泡陶瓷通体耐火材料、节能型轻质发泡陶瓷通体耐火板及其应用。
背景技术
目前为止,尽管技术上发泡陶瓷密度0.10~0.99g/cm3都可实现,但由于较低的密度可以有效降低板体的导热系数,因此市场接受的发泡陶瓷保温板的密度尽可能控制在小于0.2g/cm3;即便是需要负担一些抗撞击功能的发泡陶瓷隔墙板,其密度也集中控制在0.36~0.45g/cm3。然而前述两者在裸板状态下的闭气孔太多,遇明火容易炸裂,导致其裸板无法满足在1000℃下的耐火极限能达到3h,因此无法通过耐火极限的检测,只能额外添加外层防火涂料才能通过检测。
发明内容
本发明的目的是提供一种节能型轻质发泡陶瓷通体耐火材料、节能型轻质发泡陶瓷通体耐火板及其应用,以解决现有技术中存在的一个或多个技术问题,至少提供一种有益的选择或创造条件。
为了克服上述技术问题,本发明采用的技术方案如下:
一种节能型轻质发泡陶瓷通体耐火材料,主要由以下原料制得:硅砂、钾长石、透辉石、高温砂、滑石粉、发泡剂。
其中,所述高温砂的原料组成及质量百分占比为(28℃,58%RH):Al2O3 18.61%、SiO272.63%、Fe2O3 0.81%、CaO 0.02%、MgO 0.15%、K2O 0.69%、Na2O 0.06%、TiO20.16%,灼烧减量(1025℃)为6.72%。所述钾长石的原料组成及质量百分占比为(25℃,65%RH):Al2O3 14.37%、SiO2 71.92%、Fe2O3 0.32%、CaO 1.84%、MgO 0.34%、K2O5.05%、Na2O 3.78%、TiO2 0.07%,灼烧减量(1025℃)为2.15%。
作为上述方案的进一步改进,按重量份计,主要由以下原料制得:硅砂30~40份,钾长石30~35份、透辉石15~20份、高温砂5~10份、滑石粉3~5份、发泡剂0.5-3份。该配方保证了共融体的产生,从而保证坯体按照设计的要求进行发泡。
作为上述方案的进一步改进,所述硅砂为高硅含量的砂石(硅含量高于92%),选自石英砂、河砂、海砂或硅石中的至少一种。硅元素的比例增加,使得烧成温度适当提高,孔壁增厚,减少或避免因气体膨胀的增加而导致孔壁破裂。
作为上述方案的进一步改进,所述透辉石可用长石与高岭石所得的共生物替代。
作为上述方案的进一步改进,所述发泡剂为煤粉。煤粉在燃烧时产生更多的气体,因而能打通闭气孔,使得闭气孔减少,通气孔增多。
一种节能型轻质发泡陶瓷通体耐火板,其原料包括如上一项所述的节能型轻质发泡陶瓷通体耐火材料。
如上所述的节能型轻质发泡陶瓷通体耐火板在防火墙中的应用。
如上所述节能型轻质发泡陶瓷通体耐火板的配制方法,包括如下步骤:按如上任一项所述的节能型轻质发泡陶瓷通体耐火材料的原料配方备料,混合、球磨、造粒、过筛,经过散装匣钵装料后烧成、切割加工,得所述节能型轻质发泡陶瓷通体耐火板。所述球磨为干法球磨或湿法球磨。所述节能型轻质发泡陶瓷通体耐火板的密度为密度0.60~1.00g/cm3。所述烧成的温度为1200~1250℃,所述烧成的时长为18~30h。
其中,发泡孔径的分布为:直径1~2mm的孔径占比为10~20%,直径2~4mm的孔径占比70~80%;同时,常规发泡陶瓷的闭气孔率在80%以上,而本发明的闭气孔率为50~60%,通孔率约为40~50%,通过增加通孔率以减少闭气孔率,目的就是为了增加气体在气泡内的空间,从而延长膨胀时间,并降低炸裂概率。
本发明的有益效果是:本发明提供一种节能型轻质发泡陶瓷通体耐火材料,其主要原料包括硅砂、钾长石、透辉石、高温砂、滑石粉、发泡剂。同时还提供了利用该材料配方制备的节能型轻质发泡陶瓷通体耐火板,其中,所述硅砂为高硅含量的砂石,硅元素起到骨架作用,提高了板材的硬度,高温砂中也含有大量的硅元素,硅比例的增加,提高了烧成温度;含透辉石的原料中含有较多的铝、钙、镁等元素,其中镁和铝起到耐火作用,铝元素还有效提高了板材的强度和韧性,此外,硅、铝元素的增加,共同提高了始熔温度和烧结温度,使得板材在保持原有硬度、强度、韧性的前提下将始熔温度提高至1200℃或以上,裸板状态下的节能型轻质发泡陶瓷通体耐火板已经具有良好的耐火性能,无需添加任何外层防火涂料即可通过耐火极限检测,同时还具有良好的保温隔热、隔音降噪、防水防潮等性能和强度大、硬度高、耐火性能好的特点,是一种高效的节能型轻质发泡陶瓷通体耐火板,应用前景广泛。
具体实施方式
下面结合实施例对本发明进行具体描述,以便于所属技术领域的人员对本发明的理解。有必要在此特别指出的是,实施例只是用于对本发明做进一步说明,不能理解为对本发明保护范围的限制,所属领域技术熟练人员,根据上述发明内容对本发明所作出的非本质性的改进和调整,应仍属于本发明的保护范围。同时,下述所提及的原料未详细说明的,均为市售产品;未详细提及的工艺步骤或提取方法为均为本领域技术人员所知晓的工艺步骤或提取方法。
实施例1
将石英砂30Kg,钾长石30Kg、透辉石15Kg、高温砂5Kg、滑石粉3Kg、煤粉0.5Kg均匀混合,进行球磨、造粒、过筛,再经过散装匣钵装料后在1200℃下烧成25h、切割加工,得所述节能型轻质发泡陶瓷通体耐火板1。
实施例2
将河砂40Kg,钾长石35Kg、透辉石20Kg、高温砂10Kg、滑石粉5Kg、煤粉1.0Kg均匀混合,进行球磨、造粒、过筛,再经过散装匣钵装料后在1220℃下烧成18h、切割加工,得所述节能型轻质发泡陶瓷通体耐火板2。
实施例3
将海砂35Kg,钾长石32Kg、透辉石18Kg、高温砂7.5Kg、滑石粉4Kg、煤粉1.8Kg均匀混合,进行球磨、造粒、过筛,再经过散装匣钵装料后在1210℃下烧成21h、切割加工,得所述节能型轻质发泡陶瓷通体耐火板3。
烧成证明,本发明配方坯体在1200℃以下基本不发泡或者仅仅处于刚刚发泡的状态,不能达到均匀发泡的要求;而在1200℃以上,根据配比不同,发泡孔径大小不同,并达到成形裸板能实现1000℃耐火三小时的要求。迄今为止,没有公开报道其他裸板能实现1000℃耐火三小时的记录。
对于本发明所属技术领域的普通技术人员来说,在不脱离本发明构思的前提下还可以做出若干简单推演或替换,而不必经过创造性的劳动。因此,本领域技术人员根据本发明的揭示,对本发明做出的简单改进都应该在本发明的保护范围之内。上述实施例为本发明的优选实施例,凡与本发明类似的工艺及所作的等效变化,均应属于本发明的保护范畴。
Claims (7)
1.一种节能型轻质发泡陶瓷通体耐火材料,其特征在于,主要由以下原料制得:硅砂、钾长石、透辉石、高温砂、滑石粉、发泡剂。
2.根据权利要求1所述的节能型轻质发泡陶瓷通体耐火材料,其特征在于,按重量份计,主要由以下原料制得:硅砂30~40份,钾长石30~35份、透辉石15~20份、高温砂5~10份、滑石粉3~5份、发泡剂0.5-3份。
3.根据权利要求1所述的节能型轻质发泡陶瓷通体耐火材料,其特征在于,所述硅砂自石英砂、河砂、海砂或硅石中的至少一种。
4.根据权利要求1所述的节能型轻质发泡陶瓷通体耐火材料,其特征在于,所述透辉石可采用长石与高岭石所得的共生物替代。
5.根据权利要求1所述的节能型轻质发泡陶瓷通体耐火材料,其特征在于,所述发泡剂为煤粉。
6.一种节能型轻质发泡陶瓷通体耐火板,其特征在于,所述节能型轻质发泡陶瓷通体耐火板的原料包括权利要求1-5中任一项所述的节能型轻质发泡陶瓷通体耐火材料。
7.权利要求6所述的节能型轻质发泡陶瓷通体耐火板在防火墙中的应用。
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