Novel charge level indicator combined brick and preparation method thereof

Abstract

The invention discloses a novel charge level indicator combination brick and a preparation method thereof. The charge level indicator combination brick comprises the following components in percentage by mass: 20-30% of flint clay, 30-40% of alumina, 3-7% of silica fume, 20-30% of waste refractory bricks and 4-10% of aluminate cement. The preparation method comprises the following steps: calculating the required weight of each raw material according to the formula proportion requirement, and accurately weighing each raw material; adding the prepared raw materials into a stirrer, carrying out dry mixing, and then adding water for mixing; putting the mixed castable into a model, and carrying out vibration molding on a vibration table; curing the molded product with the mold in an environment with specified humidity and temperature; after the mold is dismounted, maintenance is carried out under the normal-temperature condition; drying the cured green bricks for specified time; and sintering the dried brick blank to obtain the charge level indicator combined brick. The product is produced by a slip casting process method, and the problems of complex structure, small required quantity, large volume, difficulty in production, serious deformation after firing, unstable use performance and the like of the combined brick of the charge level gauge of the dry quenching furnace are solved.

Description

Technical Field

[0001] The invention belongs to the field of coking, and in particular relates to a novel material level meter combined brick and a preparation method thereof. Background Art

[0002] During the quenching process of the coking industry, the detection of the coke level determines the operation of the dry quenching technician. The quality of the dry quenching brick has a direct impact on the masonry and the stable operation of the radar level meter. At present, the level meter bricks on the market are usually made of hand-formed clay products due to their complex structure, small demand and large size. Many hand-formed products need to be processed to the required shape during the blank process. Due to the strength of the blank, damage and deformation often occur. The forming effect of hand-made products is not as good as that of machine pressing and grouting, and they are very easy to deform during the firing process, resulting in irreversible changes in the brick structure, cracking of the brick, and falling of corners. As a result, the bricks do not match in the later construction, and the bricks need to be processed twice, which is time-consuming and labor-intensive. Summary of the invention

[0003] Purpose of the invention: To provide a new type of material level meter combination brick and its preparation method in view of the problems of complex structure, small required quantity, large volume, difficult production, serious deformation after firing, and unstable performance of the CDQ furnace material level meter combination brick.

[0004] Technical solution: To achieve the above purpose, the present invention provides a new type of material level meter combined brick, which includes the following components in terms of mass percentage:

[0005] Coke 20-30%, bauxite 30-40%, silica fume 3-7%, waste refractory bricks 20-30%, aluminate cement 4-10%.

[0006] Furthermore, the composition of the coke gemstone includes Al2O3, SiO2, and Fe2O3; the composition of the alumina includes Al2O3, SiO2, and Fe2O3; the composition of the silica fume includes SiO2 and Fe2O3; the composition of the waste refractory bricks includes Al2O3, SiO2, and Fe2O3; and the composition of the aluminate cement includes Al2O3. The specific composition ratio requirements are shown in the following table:

[0007]

[0008] Furthermore, the particle size of the coke gemstone includes 5-3mm, 3-1mm, and 1-0mm; the particle size of the alumina is 3-0mm and 200 mesh; the particle size of the silica fume is greater than 500 mesh; and the particle size of the waste refractory bricks is 3-0mm.

[0009] The present invention also provides a method for preparing a novel material level meter combined brick, comprising the following steps:

[0010] S1: Calculate the required weight of each raw material according to the formula ratio requirements and accurately weigh each raw material;

[0011] S2: Add the prepared raw materials into the mixer, dry mix them first and then add water to mix them, so that the raw materials are mixed evenly and most of the gas in the castable is discharged;

[0012] S3: Put the mixed castable into the mold and vibrate it on a vibration table;

[0013] S4: The molded product is cured under the specified humidity and temperature environment with the mold; after the mold is removed, it needs to be cured under normal temperature conditions;

[0014] S5: drying the cured bricks for a specified time;

[0015] S6: sintering the dried bricks to obtain level meter assembly bricks.

[0016] Furthermore, in step S2, the dry mixing time is 2 minutes, the mass of water added is 6-10% of the raw materials, and the mixing time of adding water is 3 minutes.

[0017] Furthermore, in step S3, a vibrating rod or a vibrating insert is used to perform auxiliary operation to remove gas from the castable.

[0018] Furthermore, the vibration time in step S3 is 3 to 5 minutes.

[0019] Furthermore, in step S4, the humidity and temperature environment are specified to be above 90% and below 30° C.; the curing time with the mold is 12 hours; and the curing time after the mold is removed is 4-7 days.

[0020] Furthermore, the drying temperature environment in step S5 is 60-100° C., and the drying time is 7-10 days.

[0021] Furthermore, the sintering temperature in step S6 is 1300°C.

[0022] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0023] 1. Improved process: The use of grouting molding to produce products can greatly improve the production efficiency of the products. At the same time, the shape of the products after production changes little. Compared with the original production process, it not only reduces the secondary processing procedures, but also reduces the breakage rate of the products in the secondary processing. The grouting molding process can quickly make the green body have a high strength and will not deform during transportation and drying.

[0024] 2. Raw material iteration. The materials used in the original process are mainly made of clay waste and part of clay mixed together. For the convenience of production, the moisture content is relatively high, which causes the product to deform and collapse due to factors such as gravity in the later stage. The present invention uses alumina, coke, waste refractory bricks, cement, etc. as the main raw materials. During the firing process, it can stably form a binding phase, and the product forms a bridge-like link (the liquid phase generated during the firing process flows into the gap between the materials. During cooling, due to the sudden drop in temperature (from 1300°C to 950°C), solidification occurs with a certain shrinkage, forming a stable crystal phase connected at both ends, and the middle part shrinks and becomes thinner, similar to a bridge structure), which improves the mechanical strength of the material; while the materials used in the existing production methods are all fired products, and it is difficult to form high-performance products during the later heat treatment process. Using waste refractory bricks as raw materials effectively improves the recycling rate of resources and reduces the accumulation of solid waste.

[0025] 3. Improvement of construction quality. A new type of CDQ level meter base brick is used. Due to the new technology, the product surface is smooth and flat, and the brick joints can fit perfectly, which reduces the secondary processing time of brick body mismatch, greatly saves construction time and ensures construction quality. DETAILED DESCRIPTION

[0026] The present invention is further explained below in conjunction with specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention. After reading the present invention, various equivalent forms of modifications to the present invention by those skilled in the art all fall within the scope defined by the claims attached to this application.

[0027] Embodiment 1:

[0028] This embodiment provides a new type of material level meter combined brick, which includes the following components in terms of mass percentage:

[0029] Coke 20%, bauxite 40%, silica fume 3%, waste refractory bricks 27%, aluminate cement 10%.

[0030] The main components of the components are shown in Table 1:

[0031] Table 1

[0032]

[0033] The particle sizes of coke stones include 5-3mm, 3-1mm, and 1-0mm; the particle sizes of alumina are 3-0mm and 200 meshes; the particle size of silica fume is greater than 500 meshes; and the particle size of waste refractory bricks is 3-0mm.

[0034] This embodiment provides a method for preparing a novel material level meter assembly brick, comprising the following steps:

[0035] S1: Calculate the required weight of each raw material according to the formula ratio requirements and accurately weigh each raw material;

[0036] S2: Add the prepared raw materials into a mixer, dry mix for 2 minutes, then add 6% water of the raw materials and mix for 3 minutes to mix the raw materials evenly and discharge most of the gas in the castable;

[0037] S3: Put the mixed castable into the mold and vibrate it on a vibration table;

[0038] At the same time, use a vibrating rod or vibrating insert for auxiliary operation to remove the gas in the castable; the vibration time is 3 minutes;

[0039] S4: The molded product is cured for 12 hours in an environment with a humidity of more than 90% and a temperature of 30°C; after the mold is removed, it needs to be cured at room temperature for another 4 days;

[0040] S5: drying the cured bricks at 60°C for 7 days;

[0041] S6: sinter the dried green bricks at 1300° C. to obtain level meter assembly bricks.

[0042] Embodiment 2:

[0043] This embodiment provides a new type of material level meter combined brick, which includes the following components in terms of mass percentage:

[0044] Coke 30%, bauxite 30%, silica fume 7%, waste refractory bricks 29%, aluminate cement 4%.

[0045] The main components of the components are shown in Table 2:

[0046] Table 2

[0047]

[0048] The particle sizes of coke stones include 5-3mm, 3-1mm, and 1-0mm; the particle sizes of alumina are 3-0mm and 200 meshes; the particle size of silica fume is greater than 500 meshes; and the particle size of waste refractory bricks is 3-0mm.

[0049] This embodiment provides a method for preparing a novel material level meter assembly brick, comprising the following steps:

[0050] S1: Calculate the required weight of each raw material according to the formula ratio requirements and accurately weigh each raw material;

[0051] S2: Add the prepared raw materials into a mixer, dry mix for 2 minutes, then add 10% of the water in the raw materials and mix for 3 minutes to mix the raw materials evenly and discharge most of the gas in the castable;

[0052] S3: Put the mixed castable into the mold and vibrate it on a vibration table;

[0053] At the same time, use a vibrating rod or vibrating insert for auxiliary operation to remove the gas in the castable; the vibration time is 5 minutes;

[0054] S4: The molded product is cured for 12 hours in an environment with a humidity of more than 90% and a temperature of 30°C; after the mold is removed, it needs to be cured for another 7 days at room temperature;

[0055] S5: drying the cured bricks at 100°C for 10 days;

[0056] S6: sinter the dried green bricks at 1300° C. to obtain level meter assembly bricks.

[0057] Embodiment 3:

[0058] This embodiment provides a new type of material level meter combined brick, which includes the following components in terms of mass percentage:

[0059] Coke 28%, bauxite 37%, silica fume 5%, waste refractory bricks 20%, aluminate cement 10%.

[0060] The main components of the components are shown in Table 3:

[0061] Table 3

[0062]

[0063] The particle sizes of coke stones include 5-3mm, 3-1mm, and 1-0mm; the particle sizes of alumina are 3-0mm and 200 meshes; the particle size of silica fume is greater than 500 meshes; and the particle size of waste refractory bricks is 3-0mm.

[0064] This embodiment provides a method for preparing a novel material level meter assembly brick, comprising the following steps:

[0065] S1: Calculate the required weight of each raw material according to the formula ratio requirements and accurately weigh each raw material;

[0066] S2: Add the prepared raw materials into the mixer, dry mix for 2 minutes, then add 8% water of the raw materials and mix for 3 minutes to mix the raw materials evenly and discharge most of the gas in the castable;

[0067] S3: Put the mixed castable into the mold and vibrate it on a vibration table;

[0068] At the same time, use a vibrating rod or vibrating insert for auxiliary operation to remove the gas in the castable; the vibration time is 4 minutes;

[0069] S4: The molded product is cured for 12 hours in an environment with a humidity of more than 90% and a temperature of 30°C; after the mold is removed, it needs to be cured for another 6 days at room temperature;

[0070] S5: drying the cured bricks at 80°C for 8 days;

[0071] S6: sinter the dried green bricks at 1300° C. to obtain level meter assembly bricks.

[0072] Comparative Example 1:

[0073] The performance indicators of the material level meter combination bricks obtained in Examples 1 to 3 and the material level meter bricks obtained by the existing manual forming process were tested and compared, as shown in Table 4 below:

[0074] Table 4

[0075]

[0076] It can be seen from Table 4 that the new composite brick products have been greatly improved in strength compared with the original manual molding, increasing the strength of the material. The increase in strength reduces the phenomenon of brick damage due to collision during transportation; in the dry quenching furnace, due to the large output and frequent heat exchange every day, the thermal shock stability of the material is required to be high. The improvement of thermal shock stability helps to extend the service life of the material; the increase in volume density reflects that the particles of the product obtained by casting molding are more densely stacked than those of manual molding, making the reaction during the product firing process easier and forming more bridge structures, ensuring the strength stability of the material.

Claims

1. A new type of material level meter combination brick, characterized in that: The components include the following in percentage by mass: Coke 20-30%, bauxite 30-40%, silica fume 3-7%, waste refractory bricks 20-30%, aluminate cement 4-10%.

2. The novel material level meter combination brick according to claim 1 is characterized in that: The components of the coke include Al2O3, SiO2, and Fe2O3; the components of the alumina include Al2O3, SiO2, and Fe2O3; the components of the silica ash include SiO2 and Fe2O3; the components of the waste refractory bricks include Al2O3, SiO2, and Fe2O3; and the components of the aluminate cement include Al2O3.

3. A new type of material level meter combination brick according to claim 1 or 2, characterized in that: The particle sizes of the coke stones include 5-3mm, 3-1mm, and 1-0mm; the particle sizes of the alumina are 3-0mm and 200 mesh; the particle size of the silica fume is greater than 500 mesh; and the particle size of the waste refractory bricks is 3-0mm.

4. The method for preparing a novel material level meter combination brick according to claim 1, characterized in that: The steps include: S1: Calculate the required weight of each raw material according to the formula ratio requirements and accurately weigh each raw material; S2: Add the prepared raw materials into the mixer, dry mix them first and then add water to mix them, so that the raw materials are mixed evenly and most of the gas in the castable is discharged; S3: Put the mixed castable into the mold and vibrate it on a vibration table; S4: The molded product is cured under the specified humidity and temperature environment with the mold; after the mold is removed, it needs to be cured under normal temperature conditions; S5: drying the cured bricks for a specified time; S6: sintering the dried green bricks to obtain level meter assembly bricks.

5. The method for preparing a novel material level meter combined brick according to claim 4, characterized in that: The dry mixing time in step S2 is 2 minutes, the mass of water added is 6-10% of the raw materials, and the mixing time of adding water is 3 minutes.

6. The method for preparing a novel material level meter combined brick according to claim 4, characterized in that: In step S3, a vibrating rod or a vibrating insert is used to perform auxiliary operation to remove gas from the castable.

7. The method for preparing a novel material level meter combined brick according to claim 6, characterized in that: The vibration time in step S3 is 3 to 5 minutes.

8. The method for preparing a novel material level meter combined brick according to claim 4, characterized in that: In step S4, the humidity and temperature environment are specified to be above 90% and below 30° C.; the curing time with the mold is 12 hours; and the curing time after the mold is removed is 4-7 days.

9. The method for preparing a novel material level meter combined brick according to claim 4, characterized in that: The drying temperature environment in step S5 is 60-100° C., and the drying time is 7-10 days.

10. The method for preparing a novel material level meter combined brick according to claim 4, characterized in that: The sintering temperature in step S6 is 1300°C.

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