The objective of the invention is to seek a kind of method, to produce a kind of novel fire resistant fire-resistant plastic material, should have the physical and chemical index that is better than existing refractory materials, energy consumption is low again, production cost is low, moulding arbitrarily, construction speed soon, long service life.
The present invention is by the alumine aggregate that adopts suitable granularity and powder, clay matter refractory mortar, make it organically to be combined into the plastic material of stiff mud paste as chemical bond with Tai-Ace S 150, with the mechanical or manual liner of making into various special-shaped prefabricated components firm by ramming or building up the whole type of furnace, be the moulding of nature volatile dry, also can toast drying.
The content of high alumina rock soil aggregate and powder is pressed the YB2215-78 standard and is adopted, and clay matter refractory mortar is pressed the YB396-63 standard and adopted, and Tai-Ace S 150 is pressed the HG1-32-77 standard and adopted.Above-mentioned raw materials forbids to sneak into Wingdale, impurity such as magnesia, siliceous, by high alumina rock soil and the resultant total AL of clay matter refractory mortar2O3Content should 〉=65%, the foreign matter content scope that can not be above standard, like this, the refractoriness of made plastic material and hot strength just can with AL2O3Content be directly proportional.
Because clay matter refractory mortar is mainly by AL2O3And SIO2Form, both fusing points are respectively 2045 ℃, 1670～1710 ℃, thereby the refractoriness and the hot strength of plastic material have been improved, strengthen the adhesive effect between each raw material in addition in addition, particularly after being heated to more than 900 ℃, can generate secondary mullite, so obtain excellent high.
With high alumina rock soil aggregate, powder and clay matter refractory mortar total amount is 100% calculating, add 10～13% chemical bond Tai-Ace S 150, not only plasticity-is good, especially can obtain effects such as normal temperature or high-temperature pressure-proof height, anti-folding, good thermal shock stability, for making solid sulphuric acid aluminium be dissolved as solution in regulation proportion 1.2～1.4 scopes very soon, can adopt heating method, often the proportion of solution is measured in stirring simultaneously, in the regulation specific gravity range, alum liquor is colloidal.
Technological process of the present invention is as follows:
1. at first check and accept starting material, and detect each raw-material Chemical Composition, granularity, refractoriness and water-intake rate by aforesaid standards; The Chemical Composition of high alumina rock soil aggregate and powder is pressed YB365-75 and is detected, and granularity is pressed GB1345-75 and detected, and impurity level is pressed YB2215-78 and detected, and the Chemical Composition of clay matter refractory mortar and granularity are pressed YB396-63 and detected.Refractoriness is all pressed YB368-75 and is detected, and water-intake rate is pressed YB842-75 and detected.Tai-Ace S 150 AL2(SO4)3.18H2The check of O is as the criterion with the HG1-32-77 standard and carries out.
With above-mentioned three kinds of starting material in following ratio weigh batching, high alumina rock soil aggregate 45～50%, powder 35～45%, clay matter refractory mortar 10～15%.
The material that will prepare carry out dried be mixed even, artificial or machinery all can, generally turn over and mix more than 3～4 times.
4. driedly be mixed that to pour proportion after even into be that 1.2～1.4 sulfuric acid bores solution, add-on is 8～15% of an above-mentioned batching total amount, also turns over and mixes more than 3～4 times.
5. the fire-resistant plastic material that mixes is poured into obturage in the container that can seal and carried out ageing mixture, temperature ageing mixture 24 hours more than 20 ℃ time the, temperature ageing mixture 48 hours below 15 ℃ the time.
But the ageing mixture time arrive after inspection by sampling, see whether mix, generally by rule of thumb with holding this plastic material, about 4 kilograms of grip, pinch agglomerating overhead 1 meter highly loose one's grip and allow it freely land, still agglomerating substantially then qualify then proves defective if be loose shape.If defective then need to mix again and ageing mixture till qualified.
7. the ageing mixture brickwork that can break a seal after qualified is about to bulk cargo and makes firm by ramming or vibrate into various special shaped bricks or build up the liner of the whole type of furnace; (25～50kg) sealing bags of packing into are obturaged immediately, reinstall outer bags such as woven bag, indicate indexs such as protection against the tide and effective service life with the bulk cargo weighing as do not use then at once.
The bulk cargo shelf lives was generally 3 months, open bag agglomerating with holding (about 4 kilograms of grip) if surpass the storage phase, liftoff 1 meter still agglomerating substantially after falling, prove that this material still can use, if being loose shape then can not use, an amount of alum liquor of palpus adding mixes ageing mixture and can recover its plasticity-more than 24 hours.No longer have plasticity-after this material baking (sintering), the physical and chemical index before and after the sintering is also variant.
With material brickwork of the present invention, in the production use as produce break, wearing and tearing or damaged in collision etc., no matter cold and hot all can be repaired rhegma, but cold-patch is different with the Chemical bond agent content of vulcanizing, and must will wait to repair part and shave except that melting knurl and blow off the surface with the compression airduct in the furnace lining surface.
The main physical and chemical index of plastic material of the present invention all meets or exceeds existing refractory materials of the same type, and does not need sintering to use, and it is 11.8～16.1MPa that very high intensity is promptly arranged behind this material drying and moulding, and intensity is higher behind the sintering.Its leading indicator is as follows:
1. refractoriness:＞1790 ℃
2. cold crushing strength (1350 ℃ * 2Burn the back): 32.6～36.8MPa
Crushing strength under high temperature (1350 ℃ * 1h): 2.02～3.09MPa
High temperature break resistant intensity (1400 ℃ * 1h): 0.83～6.99MPa
5. thermal shock (1100 ℃ of water-cooleds):＞50 times
6. volume density: 2.22t/m3
7. coefficient of thermal expansion (100～1300 ℃) :-0.46～+ 0.17%
Compare with refractory brick at present commonly used, improve work-ing life more than 4 times.Can make various quarls and burner block etc., not need heated baking to be shaped, only get final product, save heat energy greatly than corresponding high alumina brick, because this material contains AL by the normal temperature seasoning2O3Amount 〉=65% is with high alumina brick AL2O3Content (70～90%) is close, thus have the performance index close with high alumina brick, and production cost is lower than high alumina brick.In addition, this material and magnesia brick relatively have close or are better than the performance index of magnesia brick, and production cost also is lower than magnesia brick.
Technology with various quarls of this materials processing or making monolithic lining is simple, make prefabricated component or take the product module formula to build furnace lining by laying bricks or stones, yield rate absolutely, construction speed is fast, in conjunction with solid and reliable, it is good to have slag resistance, characteristics such as good and hot withstand voltage, the folding strength height of anti-oxidant atmosphere, it is convenient to repair, and labour intensity is low.
Most preferred embodiment of the present invention is as follows:
The alumine aggregate (granularity≤5mm): 48kg
Alumine powder (granularity 0.074～0.297mm): 40kg
Clay matter refractory mortar (granularity 0.074～0.297mm): 12kg
Above-mentioned three kinds of raw materials are prepared in 23 ± 15 ℃ of weighings, are turned over and be mixed evenly, drop into stirrer and stirred 10 minutes, dried be mixed even till.
Add 12kg alum liquor (proportion 1.31), stirred again 10 minutes, poured the container sealing ageing mixture then into 30 hours, after ageing mixture was finished, Kaifeng was inspected, qualified promptly pouring in the preprepared latex rubber bag, obturage immediately, be the thermophilic and refractory plastic material bulk cargo in the woven bag of packing into.
Plastic material of the present invention can be used for the liner of forging furnace, steel melting furnace High Temperature Furnaces Heating Apparatuss such as (1700 ℃ of liquid steel temperatures), refractory brick commonly used was with one month or just gone bad the first quarter, and material of the present invention used 1 year not bad yet, improve 4～10 times than refractory brick commonly used such as silica brick equal life.In addition, plastic material brickwork of the present invention and to repair the stove time all short, but make into bit brick firm by ramming immediately with regard to the demoulding with this material, but one day be the drying brickwork, about two days of brickwork time; Refractory materials prefabricated component commonly used needs more than four days.Repair the stove time with this material and only need 1～2 hour, but be made into the stove demoulding in three days, furnace drying time four to six days is roughly suitable with refractory materials commonly used.
Its starting material source of plastic material of the present invention is wide, inexpensive, production cost is about 500 yuan/ton, the market price can reach 1000～1200 yuan/ton, its cost is equivalent to the cost of refractory materials commonly used such as silica brick, and price is higher than refractory materials commonly used, with 500 yuan of calculating of profit per ton, produce 5000 tons per year, can make a profit 2,500,000 yuan, calculate, import Japan 1500～2000 dollars per ton of H-24 of hotblast stove with the import substitution brick, amount to about 7500～10000 yuan/ton of Renminbi, replace with this material, saving Renminbi per ton has been saved foreign exchange more than 9,000 yuan simultaneously.
In sum, the novel refractory that thermophilic and refractory plastic material of the present invention is a kind of less energy-consumption, r is good has excellent physical and chemical index, it is promptly plastic need not dry by the fire burning (sintering), plasticity-is good, can make into various special shaped bricks or monolithic lining firm by ramming, makes simple and easy, labour intensity is low, construction speed is fast, and long service life does not need great amount of investment, both can be mass-produced, also be suitable for medium-sized and small enterprises production.