Air hardening refractory mortar, its preparation method and application

Abstract

The application relates to the technical field of refractory materials, in particular to an air hardening refractory mortar, a preparation method and application thereof. The application provides an air hardening refractory mortar, which comprises the following components in percentage by weight: 28-32% of mullite brick back material; 10-15% of kaolin; 27-35% of high alumina material; and 23-34% of soap flower alkali; and the sum of the usage of the components is 100%. In the air hardening refractory mortar, the components can be well matched and acted, the viscosity and strength of the mortar are improved, the air hardening refractory mortar obtained finally has high bonding strength, can be quickly combined with a masonry in a construction process, has short curing time at normal temperature, and has high hardness after curing.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of refractory materials, and particularly relates to an air hardening refractory mortar, a preparation method and application thereof. BACKGROUND

[0002] The air hardening refractory mortar is a joint material which is hardened by chemical combination or hydration combination at normal temperature. The existing air hardening refractory mortar has the following technical defects:

[0003] 1) poor construction performance and low bonding strength;

[0004] 2) after the mortar is applied on the bricks, the mortar may lose the kneadability due to water loss before the bricks are laid, resulting in construction quality defects such as uneven and unsaturated brick joints; the mortar may also flow out of the brick joints;

[0005] 3) due to the water loss of the mortar, the mortar only exists loosely in the brick joints after the laying, and cannot bond the laying into a solid and dense whole;

[0006] 4) the mortar needs to be dried at 110 DEG C to have strength, and if the sintering is not good, the mortar cannot well bond the bricks together. Therefore, some countries (such as the United States, Japan, etc.) have developed air hardening refractory mortar which is hardened at room temperature after construction, produces certain hardness, and forms firm bonding with the laying by sintering at high temperature in use. SUMMARY

[0007] In view of this, the present application aims to provide an air hardening refractory mortar, a preparation method and application thereof, the air hardening refractory mortar provided by the present application has high bonding strength, short curing time at normal temperature, and high hardness after curing.

[0008] The present application provides an air hardening refractory mortar, which comprises:

[0009]

[0010]

[0011] The sum of the amounts of the components is 100%.

[0012] Preferably, the mass content of aluminum element in the mullite brick back material is 54% to 60%.

[0013] Preferably, the mass content of aluminum element in the kaolin is 32% to 38%, and the mass content of silicon element is 46% to 52%.

[0014] Preferably, the mass content of aluminum element in the high-alumina material is 45% to 60%.

[0015] Preferably, the high alumina material comprises at least one of kyanite powder, bauxite and mullite powder.

[0016] The application further provides a preparation method of the air hardening refractory mortar, comprising the following steps:

[0017] The mullite brick back material, kaolin, high alumina material and sodium silicate are mixed to obtain the air hardening refractory mortar.

[0018] The application further provides an application of the air hardening refractory mortar or the air hardening refractory mortar prepared by the preparation method as a lining material and a repairing material of industrial kiln, hot blast furnace and blast furnace.

[0019] The application further provides a use method of the air hardening refractory mortar, comprising the following steps:

[0020] After the air hardening refractory mortar is used, it is hardened at room temperature and sintered by use.

[0021] The air hardening refractory mortar is the air hardening refractory mortar or the air hardening refractory mortar prepared by the preparation method.

[0022] Preferably, the time of hardening at room temperature is 1.5-2.5 min.

[0023] Preferably, the temperature of use is not more than 1500 DEG C.

[0024] The application provides an air hardening refractory mortar, comprising: mullite brick back material 28wt%-32wt%; kaolin 10wt%-15wt%; high alumina material 27wt%-35wt%; sodium silicate 23wt%-34wt%; and the sum of the amounts of the components is 100%. In the air hardening refractory mortar provided by the application, the components can be well matched and interacted, the viscosity and strength of the mortar are improved, the air hardening refractory mortar obtained finally has high bonding strength, can be quickly combined with the lining in the construction process, has short normal temperature curing time and high hardness after curing. DETAILED DESCRIPTION

[0025] The technical solutions of the application will be described clearly and completely below with reference to the embodiments of the application. Obviously, the described embodiments are only some of the embodiments of the application, but not all the embodiments of the application. Based on the embodiments in the application, all the other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the application.

[0026] The application provides an air hardening refractory mortar, comprising:

[0027]

[0028] The sum of the amounts of the components is 100%.

[0029] In some embodiments of the present application, the mass content of aluminum element in the mullite brick return material is 54% to 60%, such as 56%, 60%, or 54%. The mullite brick return material is obtained by crushing the mullite brick edge and corner material by a crusher.

[0030] In some embodiments of the present application, the mass content of aluminum element in the kaolin is 32% to 38%, such as 35% or 36%; and the mass content of silicon element is 46% to 52%, such as 46% or 51%.

[0031] In some embodiments of the present application, the mass content of aluminum element in the high-alumina material is 45% to 60%, such as 51%, 45%, or 60%. The particle size of the high-alumina material is 0.1 to 1 mm.

[0032] In some embodiments of the present application, the high-alumina material includes at least one of kyanite powder, bauxite, and mullite powder.

[0033] The present application also provides a preparation method of the air hardening refractory mortar described above, including the following steps:

[0034] The mullite brick return material, the kaolin, the high-alumina material, and the sodium carbonate are uniformly mixed to obtain the air hardening refractory mortar.

[0035] In some embodiments of the present application, the mixing is performed at room temperature. The mixing is stirring and mixing.

[0036] In some embodiments of the present application, after the mixing, the method further includes: sealing and storing.

[0037] The present application also provides an application of the air hardening refractory mortar described above as a lining material and a repairing material of industrial kiln, hot blast furnace, and blast furnace.

[0038] Specifically, the application includes the application as a lining material and a repairing material of a hot blast furnace top, a regenerator, and a combustion chamber; a blast furnace bottom, a hearth, a bosh, and a belly; and a top and a wall of an industrial kiln.

[0039] The present application also provides a use method of the air hardening refractory mortar described above, including the following steps:

[0040] After the air hardening refractory mortar is constructed, it is hardened at room temperature, and sintering is achieved by use.

[0041] In some embodiments of the present application, the time for hardening at room temperature is 1.5 to 2.5 minutes, such as 2 minutes or 2.5 minutes.

[0042] In some embodiments of the present application, the temperature used is not more than 1500 DEG C, such as 1500 DEG C, 1450 DEG C. The present application does not have special restrictions on the use time, and the specific time can be 3h, 2.5h.

[0043] The present application does not have special restrictions on the source of the raw materials used above, and can be generally commercially available.

[0044] The present application uses sodium sulfate to replace water, which has binding properties. It solves the problem of loss of workability of refractory mortar due to water loss during construction, resulting in uneven and unsatisfactory construction quality defects such as brick joints. The air hardening refractory mortar obtained is not easy to lose water, and can bond the masonry into a solid and dense whole after masonry.

[0045] The air hardening refractory mortar provided by the present application does not need to be dried and can harden at room temperature to produce a certain hardness, reducing the construction period and cost.

[0046] The air hardening refractory mortar provided by the present application has high hardness after solidification.

[0047] The air hardening refractory mortar provided by the present application has a use temperature of not more than 1500 DEG C.

[0048] In order to further illustrate the present application, the air hardening refractory mortar, its preparation method and application provided by the present application are described in detail below in combination with examples, but it should not be understood as limiting the scope of protection of the present application.

[0049] Example 1

[0050] The air hardening refractory mortar comprises:

[0051]

[0052] The mass content of aluminum element in the mullite brick return material is 56%;

[0053] The mass content of aluminum element in the kaolin is 35%, and the mass content of silicon element is 46%;

[0054] The high alumina material is lanxide powder (particle size is 0.1-1mm); the mass content of aluminum element in the high alumina material is 51%.

[0055] Preparation of air hardening refractory mortar:

[0056] After the mullite brick return material, kaolin, high alumina material and sodium sulfate are stirred and uniformly mixed in a stirrer at room temperature, the air hardening refractory mortar is obtained and stored in a barrel.

[0057] According to GB / T 22459.4-2022, the obtained air hardening refractory mortar is detected, and the cold bending strength is 3.1 MPa; a certain strength is generated at room temperature after construction, and the sintering in use and the masonry form a firm bonding.

[0058] The use of the air hardening refractory mortar:

[0059] The air hardening refractory mortar is applied to the gap between the masonry, hardened at room temperature for 2 min, sintered at 1000 DEG C for 3 h, and the obtained air hardening refractory mortar is detected according to GB / T 22459.4-2022, and the bending strength is 8.6 MPa after sintering at 1000 DEG C for 3 h.

[0060] The test shows that the time with strength at room temperature is 2 min; the material strength detection after hardened at room temperature for 2 min is according to GB / T 22459.4-2022, and the detection result is that the cold bending strength is 2.9 MPa.

[0061] Example 2

[0062] The air hardening refractory mortar comprises:

[0063]

[0064]

[0065] The mass content of aluminum element in the mullite brick return material is 60%;

[0066] The mass content of aluminum element in the kaolin is 35%, and the mass content of silicon element is 46%;

[0067] The high alumina material is lanxide powder (particle size is 0.1-1 mm), and the mass content of aluminum element in the high alumina material is 45%.

[0068] Preparation of the air hardening refractory mortar:

[0069] The mullite brick return material, kaolin, high alumina material and sodium carbonate are stirred and mixed uniformly in a stirrer at room temperature, and the air hardening refractory mortar is obtained and stored in a barrel.

[0070] According to GB / T 22459.4-2022, the obtained air hardening refractory mortar is detected, and the cold bending strength is 3.6 MPa; according to GB / T 5988, the heating line changes 1500 DEG C x 3h, and the detection value is-2.39%. The temperature for long-term use is not more than 1500 DEG C, the effective life can be used for a long time, and there is no damage.

[0071] The use of the air hardening refractory mortar:

[0072] The air hardening refractory mortar is applied to the gap between the masonry, hardened at room temperature for 2 min, and sintered at 1500 DEG C for 3 h.

[0073] The test shows that the time with strength at room temperature is 2 min; the strength detection of the material hardened at room temperature for 2 min is according to GB / T 22459.4-2022, and the detection result is that the cold bending adhesive strength is 3.25 MPa.

[0074] Example 3

[0075] The air hardening refractory mortar comprises:

[0076]

[0077] The mass content of aluminum element in the mullite brick return material is 54%;

[0078] The mass content of aluminum element in the kaolin is 36%, and the mass content of silicon element is 51%;

[0079] The high alumina material is lanxide powder (particle size is 0.1-1 mm); the mass content of aluminum element in the high alumina material is 60%.

[0080] Preparation of the air hardening refractory mortar:

[0081] After the mullite brick return material, the kaolin, the high alumina material and the sodium carbonate are stirred and mixed uniformly in the stirrer at room temperature, the air hardening refractory mortar is obtained, and is put into a barrel for sealing and storage.

[0082] According to GB / T 22459.4-2022, the air hardening refractory mortar obtained is detected, and the cold bending adhesive strength is 4.1 MPa; according to GB / T 5988, the detection value of heating line change at 1500 DEG C x 3 h is-3.2%. The temperature for long-term use is not more than 1450 DEG C, the effective life can be used for a long time, and there is no damage.

[0083] Use of the air hardening refractory mortar:

[0084] The air hardening refractory mortar is applied to the gap between the masonry, hardened at room temperature for 2.5 min, and sintered at 1450 DEG C for 2.5 h.

[0085] The test shows that the time with strength at room temperature is 2.5 min; the strength detection of the material hardened at room temperature for 2.5 min is according to GB / T 22459.4-2022, and the detection result is that the cold bending adhesive strength is 3.9 MPa.

[0086] Comparative Example 1

[0087] The difference from Example 1 is that:

[0088] The mullite brick back material in Example 1 is replaced by coal gangue (wherein the mass content of aluminum element is 45%).

[0089] According to GB / T 22459.4-2022, the obtained air hardening refractory mortar is detected, and the cold bending adhesive strength is 1.2 MPa; according to GB / T 5988, the heating line change 1500℃×3h detection value is-5.6%. The long-term use temperature is not more than 1300℃, and the effective life can be used for a long time.

[0090] The use of the air hardening refractory mortar:

[0091] The air hardening refractory mortar is applied to the gap between the masonry, hardened at room temperature for 4min, and sintered by using at 1000℃ for 5h.

[0092] It is tested that the time with strength at room temperature is 4min; the material strength detection after hardened at room temperature for 4min is according to GB / T 22459.4-2022, and the detection result is that the cold bending adhesive strength is 0.9MPa.

[0093] Comparative Example 2

[0094] The difference from Example 1 is that:

[0095] The kaolin in Example 1 is replaced by Guangxi white mud (wherein the mass content of aluminum element is 35%, and the mass content of silicon element is 50%).

[0096] According to GB / T 22459.4-2022, the obtained air hardening refractory mortar is detected, and the cold bending adhesive strength is 0.9 MPa; according to GB / T 5988, the heating line change 1500℃×3h detection value is-7.5%. The long-term use temperature is not more than 1300℃.

[0097] The use of the air hardening refractory mortar:

[0098] The air hardening refractory mortar is applied to the gap between the masonry, hardened at room temperature for 3min, and sintered by using at 1000℃ for 4h.

[0099] It is tested that the time with strength at room temperature is 3min; the material strength detection after hardened at room temperature for 3min is according to GB / T 22459.4-2022, and the detection result is that the cold bending adhesive strength is 1.23MPa.

[0100] Comparative Example 3

[0101] The difference from example 1 is that:

[0102] The high alumina material in example 1 is replaced by sillimanite (particle size 0.1-1mm, in which the mass content of aluminum element is 49%).

[0103] According to GB / T 22459.4-2022, the obtained air hardening refractory mortar is detected, and the cold bending strength is 0.45MPa; according to GB / T 5988, the detection value of heating line change 1500℃x3h is-4.61%. The long-term use temperature is not more than 1400℃.

[0104] The use of the air hardening refractory mortar:

[0105] The air hardening refractory mortar is applied to the gap between the masonry, hardened at room temperature for 5min, and sintered by using at 1000℃ for 6h.

[0106] It is tested that the time of having strength at room temperature is 5min; the material strength detection after hardened at room temperature for 5min is according to GB / T 22459.4-2022, and the detection result is that the cold bending strength is 0.96MPa.

[0107] The above description of the disclosed embodiments enables those skilled in the art to carry out or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to these embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An air-hardening refractory mortar, comprising: Mullite bricks contain 28 wt%~32 wt% recycled material; Kaolin 10 wt%~15 wt%; High-alumina materials: 27 wt%~35 wt%; Sodium silicate 23 wt%~34 wt%; The sum of the amounts of all components is 100%; The aluminum content in the recycled mullite brick material is 54%~60% by mass. The kaolin contains 32% to 38% aluminum and 46% to 52% silicon by mass. The high-alumina material is kylanite powder; The high-alumina material contains 45% to 60% aluminum by mass.

2. A method for preparing the air-hardening refractory mortar according to claim 1, comprising the following steps: After mixing mullite brick reclaimed material, kaolin, high-alumina materials and sodium silicate, an air-hardening refractory slurry is obtained.

3. The application of the air-hardening refractory mortar of claim 1 or the air-hardening refractory mortar prepared by the preparation method of claim 2 as a masonry material and repair material for industrial kilns, hot blast stoves and blast furnaces.

4. A method for using an air-hardening refractory mortar, comprising the following steps: After being applied using air-hardening refractory mortar, it hardens at room temperature and is then sintered through use. The air-hardening refractory slurry is the air-hardening refractory slurry of claim 1 or the air-hardening refractory slurry prepared by the preparation method of claim 2.

5. The method of use according to claim 4, characterized in that, The curing time at room temperature is 1.5 to 2.5 minutes.

6. The method of use according to claim 4, characterized in that, The temperature used shall not exceed 1500℃.

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