A method for processing damage-resistant refractory bricks

Abstract

The invention discloses a method for processing anti-breakage refractory bricks, which comprises the following steps: S1, preparation of raw materials: preparation of solid raw materials: 40-55 parts by weight of bauxite, 10-15 parts by weight of magnesia sand fine particles, 5-10 parts by weight of semi-siliceous clay, 2-4 parts by weight of diatomaceous earth, 5-7 parts by weight of corundum powder and 3-5 parts by weight of ceramic particles; preparation of liquid raw materials: 10-20 parts by weight of clean water, 2-4 parts by weight of white latex, 3-5 parts by weight of phenolic resin, 1-2 parts by weight of silica sol and 2-4 parts by weight of sodium silicate. The method adopts a certain proportion of bauxite and magnesia sand fine particles to mix, and adds components such as ceramics, corundum powder and diatomaceous earth, so as to effectively improve the refractory capacity of the refractory bricks. At the same time, when the refractory bricks are made into brick blanks, the emulsion used for mixing is better than that of traditional brick blanks, so that the brick blanks are not easy to break during production, and the brick blank yield rate is high.

Description

Technical Field

[0001] The invention discloses a method for processing damage-resistant refractory bricks, and belongs to the technical field of refractory brick processing. Background Art

[0002] Refractory bricks are called fire bricks for short. Refractory materials made by burning refractory clay or other refractory raw materials. They are light yellow or brownish in color. They are mainly used for building smelting furnaces and can withstand high temperatures of 1580℃-1770℃. They are also called fire bricks. Refractory materials with certain shapes and sizes. According to the preparation process, they can be divided into fired bricks, unfired bricks, fused bricks, and refractory insulation bricks; according to the shape and size, they can be divided into standard bricks, ordinary bricks, special bricks, etc.

[0003] Refractory materials are generally divided into two types, namely, unshaped refractory materials and shaped refractory materials. Unshaped refractory materials, also called castables, are mixed powder particles composed of multiple aggregates or aggregates and one or more binders. When used, they must be mixed with one or more liquids to be evenly mixed and have strong fluidity. Shaped refractory materials generally refer to refractory bricks, which have standard shapes and can also be temporarily processed when building and cutting according to needs.

[0004] In the existing refractory brick manufacturing method, water and refractory brick materials are usually mixed during the manufacturing process, which makes the refractory bricks have poor hardness and are easily damaged after firing. In addition, during the manufacturing process, pores are easily formed inside the brick blank, which affects the quality of the refractory bricks. Summary of the invention

[0005] The purpose of the present invention is to provide a method for processing anti-breakage refractory bricks in order to solve the above-mentioned shortcomings.

[0006] A method for processing anti-breakage refractory bricks, the method comprising the following steps:

[0007] S1. Preparation of raw materials:

[0008] (1) Preparation of solid raw materials: 40-55 parts by weight of bauxite, 10-15 parts by weight of fine magnesia particles, 5-10 parts by weight of semi-siliceous clay, 2-4 parts by weight of diatomaceous earth, 5-7 parts by weight of corundum powder and 3-5 parts by weight of ceramic particles;

[0009] (2) Preparation of liquid raw materials: 10-20 parts by weight of clean water, 2-4 parts by weight of white latex, 3-5 parts by weight of phenolic resin, 1-2 parts by weight of silica sol and 2-4 parts by weight of sodium silicate;

[0010] S2. Solid raw material processing:

[0011] (1) Crushing: crushing the bauxite, diatomite and ceramic particles respectively by a crusher, and screening the crushed bauxite, diatomite and ceramic particles by a material screen;

[0012] (2) Mixing solid raw materials: Pour the solid raw materials into a mixer according to the formula ratio of S1, and mix the filtered and screened raw materials through the mixer. The mixing time is 30-45 minutes, and the internal temperature of the mixer is less than 35° C.;

[0013] S3. Liquid raw material processing:

[0014] (1) Mixing liquid raw materials: Pour the liquid raw materials into a mixer according to the formula ratio of S1, and use the mixer to mix the liquid raw materials. The temperature inside the mixer is 35-45 degrees Celsius;

[0015] (2) Observation of liquid mixed raw materials: After mixing the liquid raw materials, the mixing time is 60-80 minutes. When the liquid in the mixer becomes viscous, stop mixing.

[0016] S4. Production of bricks:

[0017] (1) Mixing solid and liquid raw materials: Pour the mixed solid raw materials and liquid raw materials into a mixer for mixing. After mixing evenly, send them into a mixer for mixing. The mixing time is 60-75 minutes. After the mixing is completed, the raw materials for bricks are obtained;

[0018] (2) Material loading: Load the kneaded brick raw materials into the brick mold. When loading the mold, first load half of the brick raw materials into the brick mold, then apply a layer of liquid mixed raw materials on the surface of the mold raw materials, the thickness of the coating is less than 3mm, and finally load the other half of the brick raw materials;

[0019] (3) Pressing and forming: using extrusion equipment to squeeze the raw materials in the brick blank to form the brick blank and prevent the formation of pores after the brick blank is formed;

[0020] S5, brick blank drying: take the formed brick blank out of the brick mold, wrap a layer of tissue paper on the outside of the brick blank, and then place the brick blank on a rack to dry for 2-3 days, and then spray water mist on the brick blank. After spraying water mist, dry it for 4-5 days, remove the cotton cloth on the brick blank, and obtain the finished brick blank;

[0021] S6. Brick firing: Check the finished bricks, and place the bricks without defects in a drying kiln for drying at a temperature of 60-75°C for 3 hours. The dried bricks are then sent to the kiln for firing via a kiln car.

[0022] S7. Finished product inspection: inspect the fired refractory bricks.

[0023] Preferably, the content of magnesium oxide in the magnesia fine particles of the S1 step is greater than 98.5%, and the content of aluminum oxide in bauxite is greater than 80%.

[0024] Preferably, the water content of the white latex in step S1 is less than 70%, the water content of the silica sol is less than 50%, and the sodium silicate is in powder form.

[0025] Preferably, in the S2 sub-step, the solid raw material is screened after being crushed, and the mesh size of the material screen used is less than 2.5 mm.

[0026] Preferably, when the bricks are extruded by the extrusion equipment in the step S4, the pressure of each extrusion is ensured to be the same, and the number of extrusions is 6-8 times.

[0027] Preferably, in said S4, the solid and liquid raw materials are mixed in steps, and the mixing temperature is maintained between 60-75° C. When the materials are filled into a mold, the mold should be filled after the mixed raw materials are cooled.

[0028] Preferably, the finished product inspection in step S7 adopts sampling inspection, and the inspection items include the hardness of the finished product, whether there are defects on the surface, and the thermal insulation performance.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] The method can effectively improve the refractory capacity of refractory bricks by mixing a certain proportion of bauxite and magnesia sand fine particles, adding ceramics, corundum powder, diatomaceous earth and other ingredients when manufacturing refractory bricks. At the same time, the refractory bricks use emulsions for mixing when making brick blanks. Compared with traditional brick blanks, the refractory bricks have better viscosity, making it difficult for the brick blanks to break during production, and the brick blank yield is high. The emulsion is mixed with heat-resistant and high-temperature resistant silica sol and sodium silicate, which can improve the thermal insulation capacity of the refractory bricks. In addition, when making brick blanks, the brick blanks are extruded using extrusion equipment, which can effectively prevent the use of mixed emulsions, prevent the appearance of pores in the brick blanks, and improve the yield of refractory bricks. DETAILED DESCRIPTION

[0031] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] Embodiment 1

[0033] A method for processing anti-breakage refractory bricks, the method comprising the following steps:

[0034] S1. Preparation of raw materials:

[0035] (1) Preparation of solid raw materials: 40 parts by weight of bauxite, 10 parts by weight of fine magnesia particles, 5 parts by weight of semi-siliceous clay, 2 parts by weight of diatomaceous earth, 5 parts by weight of corundum powder and 3 parts by weight of ceramic particles;

[0036] (2) Preparation of liquid raw materials: 10 parts by weight of clean water, 2 parts by weight of white latex, 3 parts by weight of phenolic resin, 1 part by weight of silica sol and 2 parts by weight of sodium silicate;

[0037] S2. Solid raw material processing:

[0038] (1) Crushing: crushing the bauxite, diatomite and ceramic particles respectively by a crusher, and screening the crushed bauxite, diatomite and ceramic particles by a material screen;

[0039] (2) Mixing solid raw materials: Pour the solid raw materials into a mixer according to the formula ratio of S1, and mix the filtered and screened raw materials through the mixer. The mixing time is 30 minutes, and the internal temperature of the mixer is less than 35° C.;

[0040] S3. Liquid raw material processing:

[0041] (1) Mixing liquid raw materials: Pour the liquid raw materials into a mixer according to the formula ratio of S1, and use the mixer to mix the liquid raw materials. The temperature inside the mixer is 35 degrees Celsius;

[0042] (2) Observation of liquid mixed raw materials: After mixing the liquid raw materials, the mixing time is 60-80 minutes. When the liquid in the mixer becomes viscous, stop mixing.

[0043] S4. Production of bricks:

[0044] (1) Mixing solid and liquid raw materials: Pour the mixed solid raw materials and liquid raw materials into a mixer for mixing. After mixing evenly, send them into a mixer for mixing. The mixing time is 60 minutes. After the mixing is completed, the raw materials for bricks are obtained.

[0045] (2) Material loading: Load the kneaded brick raw materials into the brick mold. When loading the mold, first load half of the brick raw materials into the brick mold, then apply a layer of liquid mixed raw materials on the surface of the mold raw materials, the thickness of the coating is less than 3mm, and finally load the other half of the brick raw materials;

[0046] (3) Pressing and forming: using extrusion equipment to squeeze the raw materials in the brick blank to form the brick blank and prevent the formation of pores after the brick blank is formed;

[0047] S5, brick blank drying: take the formed brick blank out of the brick mold, wrap the outer side of the brick blank with a layer of tissue paper, then place the brick blank on a rack to dry for 2 days, then spray water mist on the brick blank, after spraying water mist, dry it for 4 days, remove the cotton cloth on the brick blank, and obtain the finished brick blank;

[0048] S6. Brick firing: Check the finished bricks, place the bricks without defects in a drying kiln for drying at a temperature of 60°C for 3 hours, and send the dried bricks to the kiln through a kiln car for firing;

[0049] S7. Finished product inspection: inspect the fired refractory bricks.

[0050] Furthermore, the content of magnesium oxide in the fine particles of magnesia in step S1 is greater than 98.5%, and the content of aluminum oxide in bauxite is greater than 80%.

[0051] Furthermore, the water content of the white latex in step S1 is less than 70%, the water content of the silica sol is less than 50%, and the sodium silicate is in powder form.

[0052] Furthermore, in step S2, after the solid raw material is crushed and screened, the mesh size of the material screen used is less than 2.5 mm.

[0053] Furthermore, when the bricks are extruded by the extrusion equipment in step S4, the pressure of each extrusion is ensured to be the same, and the number of extrusions is 7 times.

[0054] Furthermore, S4 performs internal kneading of solid and liquid raw materials in steps, and the internal kneading temperature is maintained between 65° C. When the materials are loaded into the mold, the mold should be loaded after the internal kneaded raw materials are cooled.

[0055] Furthermore, the finished product inspection in step S7 adopts sampling inspection, and the inspection items include the hardness of the finished product, whether there are defects on the surface, and the thermal insulation performance.

[0056] Embodiment 2

[0057] A method for processing anti-breakage refractory bricks, the method comprising the following steps:

[0058] S1. Preparation of raw materials:

[0059] (1) Preparation of solid raw materials: 50 parts by weight of bauxite, 12 parts by weight of fine magnesia particles, 8 parts by weight of semi-siliceous clay, 3 parts by weight of diatomaceous earth, 6 parts by weight of corundum powder and 4 parts by weight of ceramic particles;

[0060] (2) Preparation of liquid raw materials: 15 parts by weight of clean water, 3 parts by weight of white latex, 4 parts by weight of phenolic resin, 1 part by weight of silica sol and 3 parts by weight of sodium silicate;

[0061] S2. Solid raw material processing:

[0062] (1) Crushing: crushing the bauxite, diatomite and ceramic particles respectively by a crusher, and screening the crushed bauxite, diatomite and ceramic particles by a material screen;

[0063] (2) Mixing solid raw materials: Pour the solid raw materials into a mixer according to the formula ratio of S1, and mix the filtered and screened raw materials through the mixer. The mixing time is 30 minutes, and the internal temperature of the mixer is less than 35° C.;

[0064] S3. Liquid raw material processing:

[0065] (1) Mixing liquid raw materials: Pour the liquid raw materials into a mixer according to the formula ratio of S1, and use the mixer to mix the liquid raw materials. The temperature inside the mixer is 35 degrees Celsius;

[0066] (2) Observation of liquid mixed raw materials: After mixing the liquid raw materials, the mixing time is 60-80 minutes. When the liquid in the mixer becomes viscous, stop mixing.

[0067] S4. Production of bricks:

[0068] (1) Mixing solid and liquid raw materials: Pour the mixed solid raw materials and liquid raw materials into a mixer for mixing. After mixing evenly, send them into a mixer for mixing. The mixing time is 70 minutes. After the mixing is completed, the raw materials for bricks are obtained.

[0069] (2) Material loading: Load the kneaded brick raw materials into the brick mold. When loading the mold, first load half of the brick raw materials into the brick mold, then apply a layer of liquid mixed raw materials on the surface of the mold raw materials, the thickness of the coating is less than 3mm, and finally load the other half of the brick raw materials;

[0070] (3) Pressing and forming: using extrusion equipment to squeeze the raw materials in the brick blank to form the brick blank and prevent the formation of pores after the brick blank is formed;

[0071] S5, brick blank drying: take the formed brick blank out of the brick mold, wrap the outer side of the brick blank with a layer of tissue paper, then place the brick blank on a rack to dry for 2 days, then spray water mist on the brick blank, after spraying water mist, dry it for 4 days, remove the cotton cloth on the brick blank, and obtain the finished brick blank;

[0072] S6. Brick firing: Check the finished bricks, place the bricks without defects in a drying kiln for drying at a temperature of 60°C for 3 hours, and send the dried bricks to the kiln through a kiln car for firing;

[0073] S7. Finished product inspection: inspect the fired refractory bricks.

[0074] Furthermore, the content of magnesium oxide in the fine particles of magnesia in step S1 is greater than 98.5%, and the content of aluminum oxide in bauxite is greater than 80%.

[0075] Furthermore, the water content of the white latex in step S1 is less than 70%, the water content of the silica sol is less than 50%, and the sodium silicate is in powder form.

[0076] Furthermore, in step S2, after the solid raw material is crushed and screened, the mesh size of the material screen used is less than 2.5 mm.

[0077] Furthermore, when the bricks are extruded by the extrusion equipment in step S4, the pressure of each extrusion is ensured to be the same, and the number of extrusions is 7 times.

[0078] Furthermore, S4 performs internal kneading of solid and liquid raw materials in steps, and the internal kneading temperature is maintained between 65° C. When the materials are loaded into the mold, the mold should be loaded after the internal kneaded raw materials are cooled.

[0079] Furthermore, the finished product inspection in step S7 adopts sampling inspection, and the inspection items include the hardness of the finished product, whether there are defects on the surface, and the thermal insulation performance.

[0080] According to the experiments, the second embodiment is the best embodiment of this scheme.

[0081] The method can effectively improve the refractory capacity of refractory bricks by mixing a certain proportion of bauxite and magnesia sand fine particles, adding ceramics, corundum powder, diatomaceous earth and other ingredients when manufacturing refractory bricks. At the same time, the refractory bricks use emulsions for mixing when making brick blanks. Compared with traditional brick blanks, the refractory bricks have better viscosity, making it difficult for the brick blanks to break during production, and the brick blank yield is high. The emulsion is mixed with heat-resistant and high-temperature resistant silica sol and sodium silicate, which can improve the thermal insulation capacity of the refractory bricks. In addition, when making brick blanks, the brick blanks are extruded using extrusion equipment, which can effectively prevent the use of mixed emulsions, prevent the appearance of pores in the brick blanks, and improve the yield of refractory bricks.

[0082] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for processing anti-breakage refractory bricks, characterized in that: The method comprises the following steps: S1. Preparation of raw materials: (1) Preparation of solid raw materials: 40-55 parts by weight of bauxite, 10-15 parts by weight of fine magnesia particles, 5-10 parts by weight of semi-siliceous clay, 2-4 parts by weight of diatomaceous earth, 5-7 parts by weight of corundum powder and 3-5 parts by weight of ceramic particles; (2) Preparation of liquid raw materials: 10-20 parts by weight of clean water, 2-4 parts by weight of white latex, 3-5 parts by weight of phenolic resin, 1-2 parts by weight of silica sol and 2-4 parts by weight of sodium silicate; S2. Solid raw material processing: (1) Crushing: crushing the bauxite, diatomite and ceramic particles respectively by a crusher, and screening the crushed bauxite, diatomite and ceramic particles by a material screen; (2) Mixing solid raw materials: Pour the solid raw materials into a mixer according to the formula ratio of S1, and mix the filtered and screened raw materials through the mixer. The mixing time is 30-45 minutes, and the internal temperature of the mixer is less than 35° C.; S3. Liquid raw material processing: (1) Mixing liquid raw materials: Pour the liquid raw materials into a mixer according to the formula ratio of S1, and use the mixer to mix the liquid raw materials. The temperature inside the mixer is 35-45 degrees Celsius; (2) Observation of liquid mixed raw materials: After mixing the liquid raw materials, the mixing time is 60-80 minutes. When the liquid in the mixer becomes viscous, stop mixing. S4. Production of bricks: (1) Mixing solid and liquid raw materials: Pour the mixed solid raw materials and liquid raw materials into a mixer for mixing. After mixing evenly, send them into a mixer for mixing. The mixing time is 60-75 minutes. After the mixing is completed, the raw materials for bricks are obtained; (2) Material loading: Load the kneaded brick raw materials into the brick mold. When loading the mold, first load half of the brick raw materials into the brick mold, then apply a layer of liquid mixed raw materials on the surface of the mold raw materials, the thickness of the coating is less than 3mm, and finally load the other half of the brick raw materials; (3) Pressing and forming: using extrusion equipment to squeeze the raw materials in the brick blank to form the brick blank and prevent the formation of pores after the brick blank is formed; S5, brick blank drying: take the formed brick blank out of the brick mold, wrap a layer of tissue paper on the outside of the brick blank, and then place the brick blank on a rack to dry for 2-3 days, and then spray water mist on the brick blank. After spraying water mist, dry it for 4-5 days, remove the cotton cloth on the brick blank, and obtain the finished brick blank; S6. Brick firing: Check the finished bricks, and place the bricks without defects in a drying kiln for drying at a temperature of 60-75°C for 3 hours. The dried bricks are then sent to the kiln for firing via a kiln car. S7. Finished product inspection: inspect the fired refractory bricks.

2. A method for processing anti-breakage refractory bricks according to claim 1, characterized in that: The content of magnesium oxide in the fine particles of magnesia sand in step S1 is greater than 98.5%, and the content of aluminum oxide in bauxite is greater than 80%.

3. A method for processing anti-breakage refractory bricks according to claim 1, characterized in that: The water content of the white latex in step S1 is less than 70%, the water content of the silica sol is less than 50%, and the sodium silicate is in powder form.

4. A method for processing anti-breakage refractory bricks according to claim 1, characterized in that: In the S2 step, the solid raw material is screened after being crushed, and the mesh size of the material screen used is less than 2.5 mm.

5. The method for processing anti-breakage refractory bricks according to claim 1, characterized in that: When the bricks are squeezed by the squeezing equipment in the step S4, the pressure of each squeezing is ensured to be the same, and the number of squeezing times is 6-8 times.

6. A method for processing anti-breakage refractory bricks according to claim 1, characterized in that: In the step S4, the solid and liquid raw materials are mixed in steps, and the mixing temperature is maintained between 60-75° C. When the materials are filled into the mold, the mold should be filled after the mixed raw materials are cooled.

7. A method for processing anti-breakage refractory bricks according to claim 1, characterized in that: The finished product inspection in step S7 adopts sampling inspection, and the inspection items include the hardness of the finished product, whether there are defects on the surface, and the thermal insulation performance.