A bionic structure lightweight energy-saving sagger and its preparation method

Abstract

The present invention discloses a bionic structure lightweight energy-saving sagger and a preparation method thereof. The preparation method is as follows: S1, a mixed granular material and a mixed fine powder material of a certain mass ratio are mixed to obtain a mixture; S2, the mixture and a colloidal solution are mixed according to a certain mass ratio to obtain a castable; S3, the castable is cast and molded, and a sagger green body is obtained after drying and demoulding; S4, the sagger green body is dried and then heat-treated to obtain a bionic structure lightweight energy-saving sagger; the mixed granular material includes cordierite particles and mullite particles; the mixed fine powder material includes pyrope stone fine powder, serpentine fine powder, calcium magnesium feldspar fine powder, zircon fine powder and calcium aluminate cement; the colloidal solution is formed by mixing and stirring ρ-alumina fine powder, potassium fluorozirconate and water. The present invention has a simple process, a low sintering temperature, and does not require the introduction of other admixtures. The prepared bionic structure lightweight energy-saving sagger has good sintering performance, low bulk density, low apparent porosity, high closed porosity, high strength and high thermal shock stability.

Description

Technical Field

[0001] The present invention relates to the technical field of saggers, and in particular to a lightweight energy-saving sagger with a bionic structure and a preparation method thereof. Background Art

[0002] Sagger is a container that holds objects to be burned at high temperatures, and is separated and refilled after burning, and the cycle repeats. Zhang Jian, Zhou Shixin, Hu Shanzhou. Research and development of mullite-corundum sagger[J]. Ceramic Engineering, 2001，(4):10-12+18 ). In terms of the service conditions of the sagger, it needs to have the following main functions:

[0003] (1) Good thermal shock stability. The sagger cycle faces the operating conditions of "room temperature-high temperature-room temperature". It is not a one-time use, and the longer the cycle life, the lower the single cost of the sagger service. Therefore, the essence of requiring the sagger to be durable is that the sagger has good thermal shock stability.

[0004] (2) No contamination of the carrier. The sagger does not undergo significant chemical reactions or structural peeling with the carrier during high-temperature service, ensuring good structure and stable performance.

[0005] (3) Small specific gravity and low volume density. When the sagger is in service, it is placed on the roller or push plate. If the specific gravity of the sagger is too large, it will directly affect the deformation of the roller or push plate and cause damage. Therefore, under the same effective holding volume, the volume density of the sagger is required to be small to reduce the damage and consumption of the high-temperature kiln accessories.

[0006] (4) Energy saving and environmental protection. Saggers are shaped products that are fired. The higher the firing temperature and the greater the energy consumption, the higher the cost of the saggers, which significantly reduces the competitiveness of the saggers. At present, the firing of saggers usually adopts high-temperature sintering to achieve densification, and the general firing temperature is about 1400℃. Therefore, reducing the firing temperature of saggers, saving energy and protecting the environment while reducing the preparation cost of saggers is also a focus of common concern for manufacturers and users.

[0007] At present, it is difficult to achieve lightweight and energy-saving saggers in the field of sintering positive electrode materials for new energy batteries. This is because the lightweighting of the saggers must first face the problem of increased porosity, and the increase in porosity leads to a series of problems such as reduced corrosion resistance, cracking, and peeling of the saggers ( Shan Zhilin, Zhao Huizhong, Jiang Wentao, et al. Properties of sagger materials for sintering positive electrode materials for lithium batteries [J]. Refractory Materials, 2020, 54(4): 305-309 However, in areas where the sagger is hardly corroded during service (such as rare earth burning, ceramic product dehydration, kiln tools, etc.), or when the filler and the sagger body have poor wettability, the lightweight and energy-saving and environmental protection of the sagger ( Chen Han, Guo Lucun. Key material technology for energy saving in special ceramic high temperature engineering[J]. Vacuum Electronic Technology Art, 2018, (4): 29-33 ) has broad application prospects.

[0008] The main means of lightweighting commonly used saggers include the following:

[0009] (1) Reduce the thickness of the side walls and bottom of the sagger. Reducing the thickness of the side walls and bottom of the sagger can significantly reduce the weight of the sagger, but its essence is to reduce weight and does not achieve changes in the microstructure. In addition, the reduction in the size of the sagger can easily lead to a decrease in the strength of the sagger green body, significantly increasing the scrap rate of the sagger.

[0010] (2) Introducing burnt materials to increase the porosity of the material. By introducing burnt materials to volatilize and escape at high temperatures, and forming primary pores inside the sagger, the volume density of the sagger can be reduced, and the lightweight of the sagger can be achieved ( Yin Hongfeng, Dang Juanling, Xin Yalou, et al. Research status and development trend of lightweight refractory materials[J]. Materials Review, 2018, 32(15): 2618-2625+2639 This type of technical means is similar to the mechanism of preparing lightweight / lightweight refractory materials, but the size and distribution of the primary pores produced by the burn-out method depend on the morphology and dispersion of the burn-out material, and it weakens the mechanical strength of the material, affecting the service performance of the sagger. In addition, the introduction of the burn-out material (pore-forming agent) not only increases the cost of the sagger, but is also not conducive to energy conservation and environmental protection.

[0011] (3) Forming pores through particle accumulation. Without introducing other burnt materials, forming pores by loose accumulation of particles is also an effective method ( Yi Ping, Zhao Huizhong, Zhao Pengda. Effect of silica sol on mullite microsphere thermal insulation refractory materials Effect of different materials on performance[J]. Bulletin of Silicate, 2018, 37(12): 3930-3934 ), such as the use of spherical particles to self-accumulate, a larger porous structure can be obtained, but the particle stacking method reduces the contact area of the material, thereby reducing the sintering performance of the material and also damaging the mechanical strength of the sagger. In addition, the preparation process of raw materials with special morphology (sphericity) and structure (micro-nanopores, etc.) is complex and costly, which undoubtedly increases the cost of material development.

[0012] (4) In-situ formation of low-dimensional structures such as whiskers / fibers to achieve lightweighting ( Xiong Xun, Liu Hao, Ma Yan, et al. Porous mullite Research on preparation and properties of ceramics[J]. Refractories, 2019, 53(5): 336-341+347 Whiskers are formed in situ during high-temperature firing in the sagger, enhancing the mechanical strength of the sagger. The interlacing of the whiskers also helps improve the material's thermal shock resistance. The formation of low-dimensional whiskers / fibers also effectively reduces the material's specific gravity. However, the in-situ formation of whiskers / fibers and their growth are difficult to control, the process is complex, and the selection and introduction of liquid or gaseous media increases the development cost of the sagger. Summary of the Invention

[0013] The purpose of the present invention is to address the above-mentioned shortcomings of the prior art and propose a bionic structure lightweight energy-saving sagger and a preparation method thereof. The method has a simple process, a low sintering temperature, and does not require the introduction of other additives. The prepared bionic structure lightweight energy-saving sagger has good sintering performance, low bulk density, low apparent porosity, high closed porosity, high strength, and high thermal shock stability.

[0014] The method for preparing a bionic structure lightweight energy-saving sagger of the present invention comprises the following specific steps:

[0015] S1. Mixing a mixed granular material and a mixed fine powder material in a certain mass ratio to obtain a mixed material;

[0016] S2, mixing the mixed material and the colloidal solution in a certain mass ratio to obtain a casting material;

[0017] S3, casting the castable into shape, drying and demoulding to obtain a sagger green body;

[0018] S4, drying the sagger green body and then heat-treating it to obtain a bionic structure lightweight energy-saving sagger;

[0019] The mixed granular material includes cordierite particles and mullite particles; the mixed fine powder material includes pyroxene fine powder, serpentine fine powder, calcite fine powder, zircon fine powder and calcium aluminate cement;

[0020] The colloidal solution is prepared by mixing and stirring ρ-alumina fine powder, potassium fluorozirconate and water.

[0021] Furthermore, the mass ratio of the cordierite particles to the mullite particles is 100:(25-30).

[0022] Furthermore, the mass ratio of the pyroxene fine powder, serpentine fine powder, calcite fine powder, zircon fine powder and calcium aluminate cement is 100:(12-15):(3-5):(5-8):(6-9).

[0023] Furthermore, the mass ratio of the mixed granular material to the mixed fine powder material is 100:(75-80); and\or,

[0024] The mass ratio of mixture: colloidal solution is 100:(5.5~6.5).

[0025] Furthermore, in the colloidal solution, the mass ratio of ρ-alumina fine powder: potassium fluorozirconate: water is (7-12): (2.2-2.8):100.

[0026] Furthermore, the particle size of the ρ-alumina fine powder is 10 to 15 μm.

[0027] Furthermore, in step S3, the mold is removed after drying at a temperature of 25 to 35° C. for 4 to 5 hours; and\or,

[0028] In step S4, the sagger green body is placed at 100-110° C. and dried for 4-6 hours.

[0029] Furthermore, in step S4, the heat treatment is carried out at 1200-1250° C. for 3-5 hours.

[0030] Furthermore, the cordierite particles have a particle size of 0.1 to 2 mm; and\or,

[0031] The mullite particles have a particle size of 0.1 to 1.5 mm, and the composition of the mullite particles is: Al2O3 content of 35 to 40 wt%, SiO2 content ≥ 60 wt%; and\or,

[0032] The particle size of the calcite fine powder is 55 to 60 μm, and the composition of the calcite fine powder is Ca2MgSi2O7 content ≥ 90 wt%, Fe2O3 content ≤ 0.6 wt%, and TiO2 content ≤ 0.5 wt%; and\or,

[0033] The potassium fluorozirconate is chemically pure.

[0034] A lightweight energy-saving sagger with a bionic structure prepared by the above-mentioned preparation method.

[0035] The beneficial effects of the present invention are:

[0036] (1) The present invention prepares a lightweight energy-saving sagger by premixing and mixing granular materials and fine powder materials, and combines the casting molding process, without the need for large-scale machine pressing equipment or special raw materials, and the process is simple.

[0037] (2) The present invention regulates the decomposition of cordierite and forms a liquid medium environment by introducing calcium-containing components (calcium magnesium feldspar and calcium aluminate cement), promotes the solid solution diffusion of the components, is beneficial to improving the sintering activity of the material system, reduces the sintering temperature of the sagger, and enhances the sintering bond between the aggregate and the matrix while saving energy and protecting the environment, thereby ensuring the mechanical strength of the sagger.

[0038] (3) The present invention utilizes the hydrolysis of ρ-alumina and the ionization of potassium fluorozirconate to form [-Al-OH-] 2+ 、[-Al-O-] + and [ZrF6] 2- The electrostatic adsorption type long chain bonding improves the bonding performance of castable particles and fine powder, increases the bonding strength of the sagger, and thus improves its sintering performance.

[0039] (4) The present invention utilizes potassium source to promote the in-situ decomposition of cordierite and form a honeycomb bionic structure. Under the premise of not increasing the primary porosity and apparent porosity of the sagger, the secondary pore structure morphology is adjusted by low-melting phase enrichment and shrinkage to form closed pores, which significantly reduces the volume density of the sagger and realizes lightweighting of the sagger.

[0040] The bionic structure lightweight energy-saving sagger prepared by the present invention has been tested:

[0041] (GB / T 2997-2015) Bulk density: 1.6-1.9 g / cm 3

[0042] (GB / T 2997-2015) apparent porosity: 22.6-25.8%

[0043] (GB / T 2997-2015) Closed porosity: 17.4-18.3%

[0044] (GB / T 2072-2008) compressive strength: 37~42MPa

[0045] (GB / T 30873-2014) 1100℃ thermal shock resistance test: water rapid cooling method, cycle number 52 to 54 times. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 This is a photo of the appearance of the bionic structure lightweight energy-saving sagger sample prepared in Example 1.

[0047] Figure 2 This is an SEM photo of the bionic structure lightweight energy-saving sagger sample prepared in Example 1. DETAILED DESCRIPTION

[0048] The following are specific embodiments of the present invention and the accompanying drawings to further describe the technical solutions of the present invention, but the present invention is not limited to these embodiments.

[0049] Example 1

[0050] A method for preparing a bionic structure lightweight energy-saving sagger, the specific steps are as follows:

[0051] 1) cordierite particles: mullite particles were prepared in a mass ratio of 100:26, added to a roller mixer, and mixed for 28 minutes to obtain a mixed granular material;

[0052] 2) Add the following ingredients: pyroxene fine powder: serpentine fine powder: calcite fine powder: zircon fine powder: calcium aluminate cement in a mass ratio of 100:13:4:6:7 to a roller mixer and mix for 50 minutes to obtain a mixed fine powder;

[0053] 3) Add the mixed granular material to the mixed fine powder at a mass ratio of 100:78, add the mixed granular material to the blender and mix for 15 minutes to obtain a mixture;

[0054] 4) preparing a colloidal solution of ρ-alumina fine powder, potassium fluorozirconate, and water in a mass ratio of 8:2.4:100 and stirring at 58° C. for 16 minutes;

[0055] 5) The mixture was prepared in a mass ratio of 100:6.2 of the mixed material and colloidal solution, and mixed in a blender for 6 minutes. The mixture was then poured into a mold for molding. The mixture was dried at 30° C. for 5 hours and then demolded to obtain a sagger green body.

[0056] 6) Dry the sagger green body at 105° C. for 5 hours, then keep it at 1230° C. for 3 hours, and cool it to room temperature in the furnace to obtain a bionic structure lightweight energy-saving sagger.

[0057] The particle size of the cordierite particles is 0.1 to 2 mm.

[0058] The particle size of the mullite particles is 0.1-1.5 mm, and the composition of the mullite particles is: Al2O3 content is 35-40wt%, and SiO2 content is ≥60wt%.

[0059] The particle size of the calcite fine powder is 55-60 μm, and the composition of the calcite fine powder is Ca2MgSi2O7 content ≥90wt%, Fe2O3 content ≤0.6wt%, and TiO2 content ≤0.5wt%.

[0060] The particle size of the ρ-alumina fine powder is 10 to 15 μm.

[0061] Potassium fluorozirconate was chemically pure.

[0062] The bionic structure lightweight energy-saving sagger prepared in this embodiment was tested:

[0063] (GB / T 2997-2015) Bulk density: 1.8g / cm 3

[0064] (GB / T 2997-2015) Apparent porosity: 23.7%

[0065] (GB / T 2997-2015) Closed porosity: 17.4%

[0066] (GB / T 2072-2008) compressive strength: 40MPa

[0067] (GB / T 30873-2014) 1100℃ thermal shock test: water rapid cooling method, 54 cycles.

[0068] Figure 1 This is a photo of the appearance of the bionic structure lightweight energy-saving sagger sample prepared in this example; it can be seen that the sample has a smooth and flat appearance, no damaged corners, and a good overall structure, indicating that the sample is tightly bonded and sintered densely.

[0069] Figure 2 This is an SEM photo of the bionic structure lightweight energy-saving sagger sample prepared in this example; it can be seen that the components in the sample are evenly dispersed, the low-melting phase is enriched and shrunk to form a large number of honeycomb closed pores, and the matrix area is well sintered and bonded.

[0070] Example 2

[0071] A method for preparing a bionic structure lightweight energy-saving sagger, the specific steps are as follows:

[0072] 1) preparing cordierite particles and mullite particles in a mass ratio of 100:25, adding the particles to a roller mixer, and mixing for 30 minutes to obtain a mixed granular material;

[0073] 2) Add the following ingredients: pyroxene fine powder: serpentine fine powder: calcite fine powder: zircon fine powder: calcium aluminate cement in a mass ratio of 100:12:5:5:9 to a roller mixer and mix for 45 minutes to obtain a mixed fine powder;

[0074] 3) The mixed granular material and the mixed fine powder were prepared in a mass ratio of 100:80, added to a blender and mixed for 12 minutes to obtain a mixture;

[0075] 4) preparing a mixture of ρ-alumina fine powder: potassium fluorozirconate: water in a mass ratio of 12:2.2:100, stirring at 60°C for 20 minutes to obtain a colloidal solution;

[0076] 5) The mixture was prepared in a mass ratio of 100:6.5 of the mixture and the colloidal solution, and the mixture was added to a blender and mixed for 8 minutes. The mixture was then poured into a mold and cast into shape. The mixture was dried at 25° C. for 5 hours and then demolded to obtain a sagger green body.

[0077] 6) The sagger green body was placed at 110° C. for 4 hours and then kept at 1200° C. for 4 hours, and then cooled to room temperature in the furnace to obtain a bionic structure lightweight energy-saving sagger.

[0078] The particle size of the cordierite particles is 0.1 to 2 mm.

[0079] The particle size of the mullite particles is 0.1-1.5 mm, and the composition of the mullite particles is: Al2O3 content is 35-40wt%, and SiO2 content is ≥60wt%.

[0080] The particle size of the calcite fine powder is 55-60 μm, and the composition of the calcite fine powder is Ca2MgSi2O7 content ≥90wt%, Fe2O3 content ≤0.6wt%, and TiO2 content ≤0.5wt%.

[0081] The particle size of the ρ-alumina fine powder is 10 to 15 μm.

[0082] Potassium fluorozirconate was chemically pure.

[0083] The bionic structure lightweight energy-saving sagger prepared in this embodiment was tested:

[0084] (GB / T 2997-2015) Bulk density: 1.9g / cm 3

[0085] (GB / T 2997-2015) Apparent porosity: 22.6%

[0086] (GB / T 2997-2015) Closed porosity: 17.5%

[0087] (GB / T 2072-2008) compressive strength: 42MPa

[0088] (GB / T 30873-2014) 1100℃ thermal shock test: water rapid cooling method, 53 cycles.

[0089] Example 3

[0090] A method for preparing a bionic structure lightweight energy-saving sagger, the specific steps are as follows:

[0091] 1) Add cordierite particles to mullite particles in a mass ratio of 100:30, add the particles to a roller mixer, and mix for 25 minutes to obtain a mixed granular material;

[0092] 2) Add the following ingredients: pyroxene fine powder: serpentine fine powder: calcite fine powder: zircon fine powder: calcium aluminate cement in a mass ratio of 100:15:3:8:6 to a roller mixer and mix for 40 minutes to obtain a mixed fine powder;

[0093] 3) The mixed granular material and the mixed fine powder were prepared in a mass ratio of 100:75, and the mixture was added into a blender and mixed for 10 minutes to obtain a mixture;

[0094] 4) Prepare a colloidal solution by mixing ρ-alumina fine powder: potassium fluorozirconate: water in a mass ratio of 7:2.8:100 and stirring at 55°C for 15 minutes;

[0095] 5) The mixture was prepared in a mass ratio of 100:5.5 of the mixture and the colloidal solution, and the mixture was added to a blender and mixed for 5 minutes. The mixture was then poured into a mold and cast into shape. The mixture was dried at 35° C. for 4 hours and then demolded to obtain a sagger green body.

[0096] 6) The sagger green body was placed at 100° C. for 6 hours and then kept at 1250° C. for 5 hours, and then cooled to room temperature in the furnace to obtain a bionic structure lightweight energy-saving sagger.

[0097] The particle size of the cordierite particles is 0.1 to 2 mm.

[0098] The particle size of the mullite particles is 0.1-1.5 mm, and the composition of the mullite particles is: Al2O3 content is 35-40wt%, and SiO2 content is ≥60wt%.

[0099] The particle size of the calcite fine powder is 55-60 μm, and the composition of the calcite fine powder is Ca2MgSi2O7 content ≥90wt%, Fe2O3 content ≤0.6wt%, and TiO2 content ≤0.5wt%.

[0100] The particle size of the ρ-alumina fine powder is 10 to 15 μm.

[0101] Potassium fluorozirconate was chemically pure.

[0102] The bionic structure lightweight energy-saving sagger prepared in this embodiment was tested:

[0103] (GB / T 2997-2015) Bulk density: 1.6g / cm 3

[0104] (GB / T 2997-2015) apparent porosity: 25.8%

[0105] (GB / T 2997-2015) Closed porosity: 18.3%

[0106] (GB / T 2072-2008) compressive strength: 37MPa

[0107] (GB / T 30873-2014) 1100℃ thermal shock test: water rapid cooling method, 52 cycles.

[0108] Comparative Example 1

[0109] A method for preparing a lightweight sagger, the specific steps are as follows:

[0110] 1) preparing cordierite particles and mullite particles in a mass ratio of 100:25, adding the particles to a roller mixer, and mixing for 30 minutes to obtain a mixed granular material;

[0111] 2) Add the following ingredients: pyroxene fine powder: serpentine fine powder: calcite fine powder: zircon fine powder: calcium aluminate cement in a mass ratio of 100:12:5:5:9 to a roller mixer and mix for 45 minutes to obtain a mixed fine powder;

[0112] 3) Add the mixed granular material to the mixed fine powder in a mass ratio of 100:45, add the mixed granular material to the mixed fine powder in a blender and mix for 12 minutes to obtain a mixture;

[0113] 4) preparing a mixture of ρ-alumina fine powder: potassium fluorozirconate: water in a mass ratio of 12:2.2:100, stirring at 60°C for 20 minutes to obtain a colloidal solution;

[0114] 5) The mixture was prepared in a mass ratio of 100:6.5 of the mixture and the colloidal solution, and the mixture was added to a blender and mixed for 8 minutes. The mixture was then poured into a mold and cast into shape. The mixture was dried at 25° C. for 5 hours and then demolded to obtain a sagger green body.

[0115] 6) The sagger green body was placed at 110° C. for 4 hours and then kept at 1200° C. for 4 hours, and then cooled to room temperature in the furnace to obtain a bionic structure lightweight energy-saving sagger.

[0116] The particle size of the cordierite particles is 0.1 to 2 mm.

[0117] The particle size of the mullite particles is 0.1-1.5 mm, and the composition of the mullite particles is: Al2O3 content is 35-40wt%, and SiO2 content is ≥60wt%.

[0118] The particle size of the calcite fine powder is 55-60 μm, and the composition of the calcite fine powder is Ca2MgSi2O7 content ≥90wt%, Fe2O3 content ≤0.6wt%, and TiO2 content ≤0.5wt%.

[0119] The particle size of the ρ-alumina fine powder is 10 to 15 μm.

[0120] Potassium fluorozirconate was chemically pure.

[0121] The lightweight sagger prepared in this comparative example was tested:

[0122] (GB / T 2997-2015) Bulk density: 1.4g / cm 3

[0123] (GB / T 2997-2015) apparent porosity: 29.3%

[0124] (GB / T 2997-2015) Closed porosity: 6.5%

[0125] (GB / T 2072-2008) compressive strength: 29MPa

[0126] (GB / T 30873-2014) 1100℃ thermal shock test: water rapid cooling method, number of cycles: 22 times.

[0127] It can be seen that reducing the amount of mixed fine powder added increases the porosity between particles and reduces the sintering performance of the material. Although the volume density of the sagger is low, the closed porosity is also greatly reduced, and the pores in the sagger are mainly open pores, which significantly reduces the mechanical strength of the sagger. At the same time, due to the change of the pore characteristics from closed to open, the number of water quenching cycles is significantly reduced, and the thermal shock stability of the sagger is weakened.

[0128] Comparative Example 2

[0129] A method for preparing a lightweight sagger, the specific steps are as follows:

[0130] 1) Add cordierite particles to mullite particles in a mass ratio of 100:30, add the particles to a roller mixer, and mix for 25 minutes to obtain a mixed granular material;

[0131] 2) Add the following ingredients: pyroxene fine powder: serpentine fine powder: calcite fine powder: zircon fine powder: calcium aluminate cement in a mass ratio of 100:15:3:8:6 to a roller mixer and mix for 40 minutes to obtain a mixed fine powder;

[0132] 3) The mixed granular material and the mixed fine powder were prepared in a mass ratio of 100:75, and the mixture was added into a blender and mixed for 10 minutes to obtain a mixture;

[0133] 4) Prepare a colloidal solution by mixing ρ-alumina fine powder: potassium fluorozirconate: water in a mass ratio of 7:2.8:100 and stirring at 55°C for 15 minutes;

[0134] 5) The mixture was prepared in a mass ratio of 100:5.5 of the mixture and the colloidal solution, and the mixture was added to a blender and mixed for 5 minutes. The mixture was then poured into a mold and cast into shape. The mixture was dried at 35° C. for 4 hours and then demolded to obtain a sagger green body.

[0135] 6) The sagger green body was placed at 100° C. and dried for 6 hours, then kept at 1300° C. for 5 hours, and then cooled to room temperature in the furnace to obtain a bionic structure lightweight energy-saving sagger.

[0136] The particle size of the cordierite particles is 0.1 to 2 mm.

[0137] The particle size of the mullite particles is 0.1-1.5 mm, and the composition of the mullite particles is: Al2O3 content is 35-40wt%, and SiO2 content is ≥60wt%.

[0138] The particle size of the calcite fine powder is 55-60 μm, and the composition of the calcite fine powder is Ca2MgSi2O7 content ≥90wt%, Fe2O3 content ≤0.6wt%, and TiO2 content ≤0.5wt%.

[0139] The particle size of the ρ-alumina fine powder is 10 to 15 μm.

[0140] Potassium fluorozirconate was chemically pure.

[0141] The lightweight sagger prepared in this comparative example was tested:

[0142] (GB / T 2997-2015) Bulk density: 2.3g / cm 3

[0143] (GB / T 2997-2015) Apparent porosity: 18.5%

[0144] (GB / T 2997-2015) Closed porosity: 3.8%

[0145] (GB / T 2072-2008) compressive strength: 55MPa

[0146] (GB / T 30873-2014) 1100℃ thermal shock test: water rapid cooling method, number of cycles: 25 times.

[0147] It can be seen that increasing the sintering temperature leads to changes in the sintering properties of the components, the density of the sagger increases, the bulk density increases, and the apparent porosity decreases; at the same time, due to changes in the low-melting phase enrichment characteristics, the number of closed pores is affected. Although the mechanical strength of the sagger is improved, the number of water quenching cycles is reduced, and the thermal shock stability of the sagger is significantly reduced.

[0148] Any matters not mentioned above shall be subject to the existing technology.

[0149] Although some specific embodiments of the present invention have been described in detail through examples, those skilled in the art should understand that the above examples are for illustration only and are not intended to limit the scope of the present invention. Those skilled in the art of the present invention may make various modifications or additions to the described specific embodiments or replace them in similar ways, but they will not deviate from the direction of the present invention or exceed the scope defined by the appended claims. Those skilled in the art should understand that any modifications, equivalent replacements, improvements, etc. made to the above embodiments based on the technical essence of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for preparing a bionic structure lightweight energy-saving sagger, characterized in that: The specific steps are as follows: S1. Mixing a mixed granular material and a mixed fine powder material in a certain mass ratio to obtain a mixed material; S2, mixing the mixed material and the colloidal solution in a certain mass ratio to obtain a casting material; S3, casting the castable into shape, drying and demoulding to obtain a sagger green body; S4, drying the sagger green body and then heat-treating it to obtain a bionic structure lightweight energy-saving sagger; The mixed granular material includes cordierite particles and mullite particles; the mixed fine powder material includes pyroxene fine powder, serpentine fine powder, calcite fine powder, zircon fine powder and calcium aluminate cement; The colloidal solution is prepared by mixing and stirring ρ-alumina fine powder, potassium fluorozirconate and water; The mass ratio of the mixed granular material to the mixed fine powder material is 100:(75-80); In step S4, the heat treatment is carried out at 1200-1250° C. for 3-5 hours.

2. The method for preparing a bionic structure lightweight energy-saving sagger according to claim 1, characterized in that: The mass ratio of the cordierite particles to the mullite particles is 100:(25-30).

3. The method for preparing a bionic structure lightweight energy-saving sagger according to claim 1, characterized in that: The mass ratio of the pyroxene fine powder, serpentine fine powder, calcite fine powder, zircon fine powder and calcium aluminate cement is 100:(12-15):(3-5):(5-8):(6-9).

4. The method for preparing a bionic structure lightweight energy-saving sagger according to claim 1, characterized in that: The mass ratio of mixture: colloidal solution is 100:(5.5~6.5).

5. The method for preparing a bionic structure lightweight energy-saving sagger according to any one of claims 1 to 4, characterized in that: In the colloidal solution, the mass ratio of ρ-alumina fine powder: potassium fluorozirconate: water is (7-12): (2.2-2.8):

100.

6. The method for preparing a bionic structure lightweight energy-saving sagger according to claim 5, characterized in that: The particle size of the ρ-alumina fine powder is 10-15 μm.

7. A method for preparing a bionic structure lightweight energy-saving sagger according to any one of claims 1 to 4, characterized in that: In step S3, the mold is removed after drying at a temperature of 25-35° C. for 4-5 hours; and\or, In step S4, the sagger green body is dried at 100-110° C. for 4-6 hours.

8. The method for preparing a bionic structure lightweight energy-saving sagger according to any one of claims 1 to 4, characterized in that: The cordierite particles have a particle size of 0.1 to 2 mm; and\or, The mullite particles have a particle size of 0.1-1.5 mm, and the composition of the mullite particles is: Al2O3 content of 35-40wt%, SiO2 content ≥60wt%; and\or, The particle size of the calcite fine powder is 55-60 μm, and the composition of the calcite fine powder is Ca2MgSi2O7 content ≥ 90wt%, Fe2O3 content ≤ 0.6wt%, and TiO2 content ≤ 0.5wt%; and\or, The potassium fluorozirconate is chemically pure.

9. A bionic structure lightweight energy-saving sagger prepared by the preparation method according to any one of claims 1 to 8.

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