Anti-thermal shock wear-resistant castable for household garbage incinerator and preparation method and device thereof

Abstract

The application discloses a heat-shock-resistant wear-resistant castable for household garbage incinerator and a preparation method and device thereof. The castable comprises, in terms of weight fractions, 130-160 parts of fused corundum powder, 80-100 parts of zirconium powder, 50-65 parts of silicon dioxide, 30-40 parts of bauxite clinker, 25-35 parts of pure calcium aluminate cement, 15-20 parts of red column stone particles, 10-15 parts of silicon carbide powder, 8-12 parts of zinc oxide powder, 6-10 parts of carbon black, 5-8 parts of wood ash, 5-8 parts of water reducing agent, 3-6 parts of dispersing agent, and 4-11 parts of toughening additive. The castable has better high-temperature resistance and heat-shock resistance. The castable can withstand extreme heat in a high-temperature environment without softening, melting or cracking. The heat conduction and heat insulation of the castable are balanced, so that the castable has little damage to the inside when facing severe heat changes, and has excellent heat-shock resistance.

Description

Technical Field

[0001] This invention relates to the field of refractory materials technology, specifically to thermal shock resistant and wear-resistant castables for municipal solid waste incinerators, as well as their preparation methods and apparatus. Background Technology

[0002] Utilizing new dry-process kilns to treat municipal solid waste is one of the most effective methods for processing household waste. In addition to inheriting the advantages of rotary incinerators, new dry-process kilns offer distinct advantages: the kiln is long enough to ensure complete combustion of waste and thorough decomposition of toxic gases, reducing pressure on the flue gas treatment system and protecting the environment; the kiln has a high heat load, with flue gas temperatures reaching up to 1700 degrees Celsius during production, ensuring complete combustion and thorough decomposition of toxic gases; waste does not require careful crushing before entering the kiln, making it highly adaptable; the waste tumbles, collapses, and mixes within the kiln, ensuring good contact with air, resulting in a large daily processing capacity, no secondary pollution from furnace ash, and heavy metals are fixed in the crystalline structure of the clinker. Municipal solid waste is complex, including glass, ceramics, ash, metals, rubber, and plastics. During calcination in the decomposition furnace of a new dry-process cement production line, an acidic and alkaline atmosphere is generated, posing a significant challenge to the wear-resistant and heat-resistant castables used in the kiln. Currently used castables have poor chemical corrosion resistance, poor thermal shock stability, and a short service life, generally around six months, which no longer meets the requirements under these conditions. Summary of the Invention

[0003] The purpose of this invention is to provide a thermal shock resistant and wear-resistant castable for municipal solid waste incinerators, as well as a preparation method and apparatus. This castable has superior thermal shock resistance and significantly improves its service life.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A thermal shock resistant and wear-resistant castable for municipal solid waste incinerators, and its preparation method and apparatus. The castable, by weight, comprises: 130-160 parts fused alumina powder, 80-100 parts zircon powder, 50-65 parts silica, 30-40 parts high-alumina bauxite clinker, 25-35 parts pure calcium aluminate cement, 15-20 parts andalusite particles, 10-15 parts silicon carbide powder, 8-12 parts zinc oxide micro powder, 6-10 parts carbon black, 5-8 parts wood ash, 5-8 parts water-reducing agent, 3-6 parts dispersant, and 4-11 parts toughening additive.

[0006] Preferably, the toughening additive comprises, by weight, 2 to 5 parts of polypropylene plastic microparticles with a particle size of 35 to 60 μm, 1 to 3 parts of spherical asphalt particles with a particle size of 6 to 100 μm, and 1 to 3 parts of carbon fiber.

[0007] Carbon fiber is carbon fiber with a diameter of 2 to 5 μm and a length of 1 to 5 mm.

[0008] Preferably, the fused alumina powder contains 55%–65% particles with a diameter of 25–35 μm, 20%–30% particles with a diameter of 15–22 μm, and the remainder particles with a diameter of 9–14 μm.

[0009] The particle size of zircon powder is 15–25 μm;

[0010] The particle size of silica is 10–20 μm;

[0011] The particle size of andalusite is 100–200 μm;

[0012] The particle size of silicon carbide powder is 5–15 μm;

[0013] The particle size of zinc oxide micro powder is 1–3 μm.

[0014] Preferably, the preparation method of the above-mentioned thermal shock resistant and wear-resistant castable for municipal solid waste incinerators includes the following steps:

[0015] S1. Preparation of mixed raw material A:

[0016] First, place the fused alumina into the mixing tank. Then, add zircon powder, silica, high-alumina bauxite clinker, and pure calcium aluminate cement into the mixing tank in multiple batches and mix them thoroughly with the fused alumina to form mixed raw material A.

[0017] S2. Preparation of mixed raw material B:

[0018] Andalusite granules, silicon carbide powder, zinc oxide micro powder, carbon black, wood ash, water-reducing agent, dispersant, and toughening additive are added to the mixing tank in multiple batches and thoroughly mixed to form mixed raw material B.

[0019] S3. Preparation of castable refractory:

[0020] First, put the mixed raw material A into the mixing tank. Then, add the mixed raw material B into the mixing tank in multiple batches and mix it thoroughly with the mixed raw material A. The amount of mixed raw material B added at one time is 10% to 15% of the total amount. Add water at one time along with mixed raw material B. The amount of water added at one time is 0.6% to 1.2% of the total mass of mixed raw material A. After each addition, stir and mix thoroughly for 10 to 15 minutes before adding the next batch, until all the mixture is completely mixed.

[0021] S4. Thermal insulation treatment:

[0022] The casting material prepared in step S3 is placed in a sealed container and kept at 90-150°C for 8-16 hours. During the heat preservation process, the casting material is subjected to high-frequency vibration and stirring for 5-10 minutes every 30 minutes.

[0023] The high-frequency vibration frequency is 15-20 kHz;

[0024] This yields a thermal shock resistant and wear-resistant castable.

[0025] Preferably, in step S1, the amount added at one time is 15% to 25% of the total amount. After each addition, the mixture is stirred thoroughly for 10 to 15 minutes before adding the next batch, until all the mixture is completely mixed.

[0026] Ultrasonic vibration is applied to the mixing tank to ensure that the raw materials are thoroughly mixed under ultrasonic vibration conditions. The ultrasonic vibration frequency is 25-30KHz and the power is 2-4kw.

[0027] Preferably, in step S2, the amount added at one time is 15% to 25% of the total amount. After each addition, the mixture is stirred thoroughly for 10 to 15 minutes before adding the next batch, until all the mixture is completely mixed.

[0028] Ultrasonic vibration is applied to the mixing tank to ensure that the raw materials are thoroughly mixed under ultrasonic vibration conditions. The ultrasonic vibration frequency is 30-35KHz and the power is 3-5kw.

[0029] Preferably, the device for preparing thermal shock resistant and wear-resistant castable for municipal solid waste incinerators is used to realize the preparation method of thermal shock resistant and wear-resistant castable for municipal solid waste incinerators as described above. It includes a mixing mechanism and a heat preservation mechanism. The mixing mechanism includes a mixing container cylinder with its opening facing upward. A vertically extending mixing and stirring main shaft is rotatably connected to the bottom of the mixing container cylinder. Multiple main stirring rods extending radially are fixed on the mixing and stirring main shaft. A stirring short rod is fixed to the outer end of the main stirring rod.

[0030] A drive housing is fixed at the bottom of the mixing container cylinder. The lower end of the mixing and stirring main shaft extends into the drive housing. A stirring drive motor for driving the mixing and stirring main shaft to rotate is fixed inside the drive housing.

[0031] Preferably, a plurality of vibrating rod connecting rings are fixed on the outer wall of the mixing container, and an ultrasonic vibrating rod is fixedly connected in the vibrating rod connecting ring.

[0032] Preferably, the top of the mixing container is connected to a mixing cylinder end cap with the opening facing downwards, and a vertically extending first conveying pipe and multiple vertically extending second conveying pipes are fixed on the mixing cylinder end cap.

[0033] Compared with the prior art, the beneficial effects of the present invention are reflected in the following aspects:

[0034] 1. The castable of the present invention has better high temperature resistance and thermal shock resistance. The castable combines multiple high temperature and wear-resistant materials such as fused alumina powder, zircon powder, silica and high alumina bauxite clinker. Under appropriate ratio, the final product can not only withstand the extreme heat in high temperature environment without softening, melting or cracking, but also has a perfect balance between thermal conductivity and thermal insulation performance. When toughening additives are added to the formula, they act as a buffer layer in the microstructure. When the prepared refractory lining layer expands and contracts rapidly, it buffers and absorbs most of the internal stress to protect the overall structure from collapse. This makes the castable very resistant to internal damage when facing drastic thermal changes and has excellent thermal shock resistance.

[0035] 2. The castable of the present invention has excellent wear resistance. Since the waste is relatively complex, including glass, ceramics, ash, metal, rubber, plastics, etc., it will cause a lot of wear inside the waste incinerator. The castable formula adds an appropriate amount of pure calcium aluminate cement, which can greatly increase the wear resistance of the prepared refractory lining layer, and resist these wears for a long time, so as to extend the service life and reduce maintenance costs.

[0036] 3. The castable of the present invention has excellent compaction properties to prevent corrosion by high-temperature gases or chemicals, thereby extending its service life;

[0037] 5. The castable of the present invention has excellent resistance to chemical erosion. The interior of a waste incinerator is exposed to various chemical gases and chemicals. The refractory lining prepared by this castable has a better airtight microstructure, which can resist various chemical erosions and ensure stable performance and structure. Attached Figure Description

[0038] Figure 1 This is a flow chart of the preparation process of the castable refractory of the present invention;

[0039] Figure 2 This is a front view of the mixing device of the present invention;

[0040] Figure 3 This is a top view of the mixing container of the present invention;

[0041] Figure 4 This is a top view of the mixing cylinder end cap of the present invention.

[0042] In the figure, 10-mixing container, 11-mixing and stirring main shaft, 111-main stirring rod, 112-stirring short rod, 12-drive container shell, 121-stirring drive motor, 13-vibration rod connecting ring, 131-ultrasonic vibration rod, 14-mixing container end cover, 141-first conveying pipe, 142-second conveying pipe. Detailed Implementation

[0043] The following is combined Figures 1-4 The present invention will be described in detail. For ease of description, the orientations mentioned below are defined as follows: The directions of up, down, left, right, front, and back mentioned below are consistent with the directions of up, down, left, right, front, and back in the projection relationship of the respective main view or structural schematic diagram.

[0044] Example 1:

[0045] The thermal shock resistant and wear-resistant castable for municipal solid waste incinerators comprises, by weight, 130 parts fused alumina powder, 80 parts zircon powder, 50 parts silica, 30 parts high-alumina bauxite clinker, 25 parts pure calcium aluminate cement, 15-20 parts andalusite granules, 10-15 parts silicon carbide powder, 8-12 parts zinc oxide micro powder, 6-10 parts carbon black, 5-8 parts wood ash, 5-8 parts water-reducing agent, 3-6 parts dispersant, and 4 parts toughening additive.

[0046] The toughening additive comprises, by weight, 2 parts polypropylene plastic microparticles with a particle size of 35-60 μm, 1 part spherical asphalt particles with a particle size of 6-100 μm, and 1 part carbon fiber.

[0047] Carbon fiber is carbon fiber with a diameter of 2 to 5 μm and a length of 1 to 5 mm.

[0048] The fused alumina powder has 55% particle size of 25-35 μm, 20% particle size of 15-22 μm, and the remainder particle size of 9-14 μm.

[0049] The particle size of zircon powder is 15–17 μm;

[0050] The particle size of silica is 10–12 μm;

[0051] The particle size of andalusite is 100–120 μm;

[0052] The particle size of silicon carbide powder is 5–7 μm;

[0053] The particle size of zinc oxide micro powder is 1-2 μm.

[0054] Example 2:

[0055] Based on Example 1, the amount of fused alumina powder was 134 parts and the amount of zircon powder was 83 parts.

[0056] Example 3:

[0057] Based on Example 1, the amount of fused alumina powder was 138 parts and the amount of zircon powder was 86 parts.

[0058] Example 4:

[0059] Based on Example 1, the amount of fused alumina powder was 142 parts and the amount of zircon powder was 89 parts.

[0060] Example 5:

[0061] Based on Example 1, the amount of fused alumina powder was 146 parts and the amount of zircon powder was 92 parts.

[0062] Example 6:

[0063] Based on Example 1, the fused alumina powder is 150 parts and the zircon powder is 95 parts.

[0064] Example 7:

[0065] Based on Example 1, the amount of fused alumina powder is 155 parts and the amount of zircon powder is 98 parts.

[0066] Example 8:

[0067] Based on Example 1, the amount of fused alumina powder is 160 parts and the amount of zircon powder is 100 parts.

[0068] Experimental Example 1:

[0069] The castable formulations of Examples 1-8 were respectively made into refractory linings. The refractory linings were continuously heated using an acetylene torch until the temperature reached 1500°C. The heating was continued until the refractory linings were held at 1500°C for 10 minutes. Then the heating was stopped and the refractory linings were cooled using air at 0°C to allow them to return to room temperature within 30 seconds. The refractory linings were then held at room temperature for 5 minutes. The above heating and cooling process was repeated to test the service life of the refractory linings. The higher the service life of the refractory linings, the better the corresponding castable formulation is compared with the prior art.

[0070] The failure of the refractory layer is determined when the surface of the refractory layer shows cracking and peeling.

[0071] Table 1. Life test data of refractory lining layer

[0072]

[0073]

[0074] Analysis of Table 1 shows that as the amount of fused alumina powder and zircon powder increases, the service life of the refractory lining generally shows an increasing trend, and the best performance is shown in the data of Example 6. However, the amount is relative, and the ratio of fused alumina powder and zircon powder should not be too high.

[0075] Example 9:

[0076] Based on Example 6, the amount of silica is 52 parts, the amount of high-alumina bauxite clinker is 31.5 parts, and the amount of pure calcium aluminate cement is 26.5 parts.

[0077] Example 10:

[0078] Based on Example 6, the amount of silica is 54 parts, the amount of high-alumina bauxite clinker is 33 parts, and the amount of pure calcium aluminate cement is 28 parts.

[0079] Example 11:

[0080] Based on Example 6, the amount of silica is 56 parts, the amount of high-alumina bauxite clinker is 34.5 parts, and the amount of pure calcium aluminate cement is 29.5 parts.

[0081] Example 12:

[0082] Based on Example 6, the amount of silica is 58 parts, the amount of high-alumina bauxite clinker is 36 parts, and the amount of pure calcium aluminate cement is 31 parts.

[0083] Example 13:

[0084] Based on Example 6, the amount of silica is 60 parts, the amount of high-alumina bauxite clinker is 37.5 parts, and the amount of pure calcium aluminate cement is 32.5 parts.

[0085] Example 14:

[0086] Based on Example 6, the amount of silica is 62 parts, high-alumina bauxite clinker is 39 parts, and pure calcium aluminate cement is 34 parts.

[0087] Example 15:

[0088] Based on Example 6, the amount of silica is 65 parts, the amount of high-alumina bauxite clinker is 40 parts, and the amount of pure calcium aluminate cement is 35 parts.

[0089] Experimental Example 2:

[0090] The castable formulations of Examples 6 and 9-15 were respectively used to prepare refractory linings. The refractory linings were continuously heated using an acetylene torch until the temperature reached 1500°C. The heating was continued until the refractory linings were held at 1500°C for 10 minutes. Then the heating was stopped and the refractory linings were cooled using air at 0°C to allow them to return to room temperature within 30 seconds. The refractory linings were then held at room temperature for 5 minutes. The above heating and cooling process was repeated to test the service life of the refractory linings. The higher the service life of the refractory linings, the better the corresponding castable formulation is compared with the prior art.

[0091] The failure of the refractory layer is determined when the surface of the refractory layer shows cracking and peeling.

[0092] Table 2. Life test data of refractory lining layer

[0093]

[0094]

[0095] Analysis of Table 2 shows that as the amount of silica, high-alumina bauxite clinker and pure calcium aluminate cement increases, the service life of the refractory lining generally shows an increasing trend, and the best performance is shown in the data of Example 11. However, the amount is relative, and the proportion of fused alumina powder and zircon powder should not be too high.

[0096] Example 16:

[0097] Based on Example 11, wherein the toughening additive is 5 parts;

[0098] The toughening additive comprises, by weight, 3 parts polypropylene plastic microparticles with a particle size of 35-60 μm, 1 part spherical asphalt particles with a particle size of 6-100 μm, and 1 part carbon fiber.

[0099] Example 17:

[0100] Based on Example 11, wherein the toughening additive is 8 parts;

[0101] The toughening additive comprises, by weight, 4 parts polypropylene plastic microparticles with a particle size of 35-60 μm, 2 parts spherical asphalt particles with a particle size of 6-100 μm, and 2 parts carbon fiber.

[0102] Example 18:

[0103] Based on Example 11, wherein the toughening additive is 11 parts;

[0104] The toughening additive comprises, by weight, 5 parts polypropylene plastic microparticles with a particle size of 35-60 μm, 3 parts spherical asphalt particles with a particle size of 6-100 μm, and 3 parts carbon fiber.

[0105] Example 19:

[0106] Based on Example 17, the zircon powder has a particle size of 19-21 μm, the silica has a particle size of 14-16 μm, the andalusite has a particle size of 140-160 μm, the silicon carbide powder has a particle size of 9-11 μm, and the zinc oxide powder has a particle size of 2-3 μm.

[0107] Example 20:

[0108] Based on Example 17, the zircon powder has a particle size of 23-25 ​​μm, the silica has a particle size of 18-20 μm, the andalusite has a particle size of 180-200 μm, the silicon carbide powder has a particle size of 13-15 μm, and the zinc oxide powder has a particle size of 2-3 μm.

[0109] Example 21:

[0110] Based on Example 19, the fused alumina powder has 56% particle size of 25-35 μm, 21% particle size of 15-22 μm, and the remaining particle size of 9-14 μm.

[0111] Example 22:

[0112] Based on Example 19, the fused alumina powder has 57% particle size of 25-35 μm, 22% particle size of 15-22 μm, and the remaining particle size of 9-14 μm.

[0113] Example 23:

[0114] Based on Example 19, the fused alumina powder has 58% particle size of 25-35 μm, 23% particle size of 15-22 μm, and the remaining particle size of 9-14 μm.

[0115] Example 24:

[0116] Based on Example 19, the fused alumina powder has 59% particle size of 25-35 μm, 24% particle size of 15-22 μm, and the remaining particle size of 9-14 μm.

[0117] Example 25:

[0118] Based on Example 19, the fused alumina powder has 60% particle size of 25-35 μm, 25% particle size of 15-22 μm, and the remaining particle size of 9-14 μm.

[0119] Example 26:

[0120] Based on Example 19, the fused alumina powder has 61% particle size of 25-35 μm, 26% particle size of 15-22 μm, and the remaining particle size of 9-14 μm.

[0121] Example 27:

[0122] Based on Example 19, the fused alumina powder has 63% particle size of 25-35 μm, 28% particle size of 15-22 μm, and the remaining particle size of 9-14 μm.

[0123] Example 28:

[0124] Based on Example 19, the fused alumina powder has 65% particle size of 25-35 μm, 30% particle size of 15-22 μm, and the remaining particle size of 9-14 μm.

[0125] Experimental Example 3:

[0126] The castable formulations of Examples 21-28 were respectively made into refractory linings. The refractory linings were continuously heated using an acetylene torch until the temperature reached 1500°C. The heating was continued until the refractory linings were held at 1500°C for 10 minutes. Then the heating was stopped and the refractory linings were cooled using air at 0°C to allow them to return to room temperature within 30 seconds. The refractory linings were then held at room temperature for 5 minutes. The above heating and cooling process was repeated to test the service life of the refractory linings. The higher the service life of the refractory linings, the better the corresponding castable formulation is compared with the prior art.

[0127] The failure of the refractory layer is determined when the surface of the refractory layer shows cracking and peeling.

[0128] Table 3. Life test data of refractory lining layer

[0129]

[0130]

[0131]

[0132] Analysis of Table 3 shows that as the particle size of zircon powder, silicon dioxide, andalusite particles, silicon carbide powder, and zinc oxide micro powder are adjusted, and the particle size ratio of fused alumina powder is improved, the service life of the refractory lining shows significant differences, and the best performance is shown in the data of Example 25.

[0133] Example 29:

[0134] This embodiment describes a method for preparing a thermal shock resistant and wear-resistant castable, based on the thermal shock resistant and wear-resistant castable for a municipal solid waste incinerator described in Embodiment 25 above, including the following steps:

[0135] S1. Preparation of mixed raw material A:

[0136] First, place the fused alumina into the mixing tank. Then, add zircon powder, silica, high-alumina bauxite clinker, and pure calcium aluminate cement into the mixing tank in multiple batches and mix them thoroughly with the fused alumina to form mixed raw material A.

[0137] Each ingredient is added at a time in amounts of 15% of the total amount. After each addition, the mixture should be stirred thoroughly for 10 minutes before adding the next batch, until all ingredients are completely mixed.

[0138] Furthermore, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are fully stirred and mixed. The ultrasonic vibration frequency is 25KHz and the power is 2kw.

[0139] S2. Preparation of mixed raw material B:

[0140] Andalusite granules, silicon carbide powder, zinc oxide micro powder, carbon black, wood ash, water-reducing agent, dispersant, and toughening additive are added to the mixing tank in multiple batches and thoroughly mixed to form mixed raw material B.

[0141] Each ingredient is added at a time in amounts of 15% of the total amount. After each addition, the mixture should be stirred thoroughly for 10 minutes before adding the next batch, until all ingredients are completely mixed.

[0142] Furthermore, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are fully stirred and mixed. The ultrasonic vibration frequency is 30KHz and the power is 3kw.

[0143] S3. Preparation of castable refractory:

[0144] First, put the mixed raw material A into the mixing tank. Then, add the mixed raw material B into the mixing tank in multiple batches and mix it thoroughly with the mixed raw material A. The amount of mixed raw material B added at one time is 10% of the total amount. Water is added at one time along with mixed raw material B. The amount of water added at one time is 0.6% of the total mass of mixed raw material A. After each addition, stir and mix thoroughly for 10 minutes before adding the next batch, until all the mixture is completely mixed.

[0145] This yields a thermal shock resistant and wear-resistant castable.

[0146] Example 30:

[0147] Based on Example 29, in step S1, the amount of each raw material added at one time is 17.5% of the total amount. After each addition, the mixture is stirred and mixed thoroughly for 11 minutes before adding the next batch, until all the raw materials are mixed.

[0148] In step S1, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are thoroughly stirred and mixed. The ultrasonic vibration frequency is 26KHz and the power is 3kw.

[0149] In step S2, each raw material is added at a time in an amount of 17.5% of the total amount. After each addition, the mixture is stirred thoroughly for 11 minutes before adding the next batch, until all the raw materials are mixed.

[0150] In step S2, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are thoroughly stirred and mixed. The ultrasonic vibration frequency is 31KHz and the power is 4kw.

[0151] In step S3, the amount of mixed raw material B added at one time is 11% of the total amount, and water is added at one time along with mixed raw material B. The amount of water added at one time is 0.7% of the total mass of mixed raw material A. After each addition, the mixture is stirred thoroughly for 11 minutes before adding the next batch, until all the mixture is completely mixed.

[0152] Example 31:

[0153] Based on Example 29, in step S1, the amount of each raw material added at one time is 20% of the total amount. After each addition, the mixture is stirred thoroughly for 12 minutes before the next batch is added, until all the raw materials are mixed.

[0154] In step S1, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are fully stirred and mixed. The ultrasonic vibration frequency is 27KHz and the power is 3kw.

[0155] In step S2, each ingredient is added at a time in an amount of 20% of the total amount. After each addition, the mixture is stirred thoroughly for 12 minutes before adding the next batch, until all ingredients are mixed.

[0156] In step S2, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are fully stirred and mixed. The ultrasonic vibration frequency is 32KHz and the power is 4kw.

[0157] In step S3, the amount of mixed raw material B added at one time is 12% of the total amount, and water is added at one time along with mixed raw material B. The amount of water added at one time is 0.9% of the total mass of mixed raw material A. After each addition, the mixture is stirred and mixed for 12 minutes before adding the next batch, until all the mixture is completely mixed.

[0158] Example 32:

[0159] Based on Example 29, in step S1, the amount of each raw material added at one time is 22.5% of the total amount. After each addition, the mixture is stirred and mixed thoroughly for 13 minutes before adding the next batch, until all the raw materials are mixed.

[0160] In step S1, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are thoroughly stirred and mixed. The ultrasonic vibration frequency is 28KHz and the power is 3kw.

[0161] In step S2, each raw material is added at a time in an amount of 22.5% of the total amount. After each addition, the mixture is stirred thoroughly for 13 minutes before adding the next batch, until all the raw materials are mixed.

[0162] In step S2, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are fully stirred and mixed. The ultrasonic vibration frequency is 33KHz and the power is 4kw.

[0163] In step S3, the amount of mixed raw material B added at one time is 13% of the total amount, and water is added at one time along with mixed raw material B. The amount of water added at one time is 1.1% of the total mass of mixed raw material A. After each addition, the mixture is stirred thoroughly for 13 minutes before adding the next batch, until all the mixture is completely mixed.

[0164] Example 33:

[0165] Based on Example 29, in step S1, the amount of each raw material added at one time is 25% of the total amount. After each addition, the mixture is stirred thoroughly for 15 minutes before the next batch is added, until all the raw materials are mixed.

[0166] In step S1, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are fully stirred and mixed. The ultrasonic vibration frequency is 30KHz and the power is 4kw.

[0167] In step S2, each ingredient is added at a time in an amount of 25% of the total amount. After each addition, the mixture is stirred thoroughly for 15 minutes before adding the next batch, until all ingredients are mixed.

[0168] In step S2, ultrasonic vibration is applied to the mixing tank during the mixing process. Under the ultrasonic vibration environment, the raw materials are fully stirred and mixed. The ultrasonic vibration frequency is 35KHz and the power is 5kw.

[0169] In step S3, the amount of mixed raw material B added at one time is 15% of the total amount, and water is added at one time along with mixed raw material B. The amount of water added at one time is 1.2% of the total mass of mixed raw material A. After each addition, the mixture is stirred thoroughly for 15 minutes before adding the next batch, until all the mixture is completely mixed.

[0170] Experimental Example 4:

[0171] Based on the castable formulation of Example 25, castable finished products were prepared according to the preparation methods of Examples 29 to 33. These castable finished products were then used to form refractory linings. The refractory linings were continuously heated using an acetylene torch until the temperature reached 1500°C. The heating was continued until the refractory linings were held at 1500°C for 10 minutes. Then the heating was stopped, and the refractory linings were cooled using air at 0°C to allow them to return to room temperature within 30 seconds. The refractory linings were then held at room temperature for 5 minutes. The above heating and cooling process was repeated to test the service life of the refractory linings. The higher the service life of the refractory linings, the better the corresponding castable preparation method is compared with the prior art.

[0172] The failure of the refractory layer is determined when the surface of the refractory layer shows cracking and peeling.

[0173] Table 4. Life test data of refractory lining layer

[0174]

[0175]

[0176] As can be seen from the analysis of Table 4, when the castable is prepared using the process of the present invention, and as the mixing preparation parameters are adjusted, the service life of the refractory lining generally shows an upward trend, and the best performance is shown in the data of Example 31.

[0177] Example 34:

[0178] Based on Example 31, a heat preservation treatment was also performed after step S3, as detailed below;

[0179] S4. Thermal insulation treatment:

[0180] The casting material prepared in step S3 is placed in a sealed container and kept at 90°C for 8 hours. During the heat preservation process, the casting material is subjected to high-frequency vibration and stirring for 5 minutes every 30 minutes.

[0181] The high-frequency vibration frequency is 15KHz.

[0182] Example 35:

[0183] Based on Example 31, a heat preservation treatment was also performed after step S3, as detailed below;

[0184] S4. Thermal insulation treatment:

[0185] The casting material prepared in step S3 is placed in a sealed container and kept at 110°C for 10 hours. During the heat preservation process, the casting material is subjected to high-frequency vibration and stirring for 10 minutes every 30 minutes.

[0186] The high-frequency vibration frequency is 17KHz.

[0187] Example 36:

[0188] Based on Example 31, a heat preservation treatment was also performed after step S3, as detailed below;

[0189] S4. Thermal insulation treatment:

[0190] The casting material prepared in step S3 is placed in a sealed container and kept at 150°C for 16 hours. During the heat preservation process, the casting material is subjected to high-frequency vibration and stirring for 10 minutes every 30 minutes.

[0191] The high-frequency vibration frequency is 20KHz.

[0192] Experimental Example 5:

[0193] Based on the castable formulation of Example 25, castable finished products were prepared according to the preparation methods of Examples 34-36. These castable finished products were then used to form refractory linings. The refractory linings were continuously heated using an acetylene torch until the temperature reached 1500°C. The heating was continued until the refractory linings were held at 1500°C for 10 minutes. Then the heating was stopped, and the refractory linings were cooled using air at 0°C to allow them to return to room temperature within 30 seconds. The refractory linings were then held at room temperature for 5 minutes. The above heating and cooling process was repeated to test the service life of the refractory linings. The higher the service life of the refractory linings, the better the corresponding castable preparation method is compared with the prior art.

[0194] The failure of the refractory layer is determined when the surface of the refractory layer shows cracking and peeling.

[0195] Table 5. Life test data of refractory lining layer

[0196]

[0197]

[0198] As can be seen from the analysis of Table 5, when the castable is prepared using the process of the present invention and heat preservation treatment is performed at the end of the process, the service life of the refractory lining layer generally shows an upward trend, and the data of Example 35 shows the best performance.

[0199] Comparative Experiment Example 1:

[0200] In the castable formulation of Example 25, the toughening additives were removed, and then the castable finished product was prepared according to the preparation methods of Examples 34-36. These castable finished products were then made into refractory linings. The refractory linings were continuously heated using an acetylene torch until the temperature reached 1500°C, and the heating was continued to maintain the refractory linings at 1500°C for 10 minutes. Then the heating was stopped, and the refractory linings were cooled using air at 0°C to restore them to room temperature within 30 seconds. The refractory linings were then maintained at room temperature for 5 minutes. The above heating and cooling process was repeated to test the service life of the refractory linings.

[0201] Table 6. Life test data of refractory lining layer

[0202]

[0203]

[0204] By comparing the experimental data in Example 1, it can be seen that when the toughening additive is missing in the castable formula, even if the same preparation process is used, the actual service life of the final refractory lining will be greatly reduced, to only about 70% of the original.

[0205] In terms of thermal shock resistance, the material needs to have sufficient toughness to resist the huge internal stress generated by thermal expansion and contraction. Otherwise, this internal stress will "crush" its own structure, causing the refractory lining to fail. Adding toughening additives, such as polypropylene plastic microparticles, spherical asphalt particles, and carbon fibers, can fill the microstructure of the refractory lining and act as a buffer layer. During rapid thermal expansion and contraction, they can buffer and absorb most of the internal stress to protect the overall structure from collapse.

[0206] Comparative Experiment Example 2:

[0207] In the castable formulation of Example 25, carbon black and wood ash were removed, and then the castable was prepared according to the preparation methods of Examples 34-36. These castables were then used to make refractory linings. The refractory linings were continuously heated using an acetylene torch until the temperature reached 1500°C. The heating was continued until the refractory lining was held at 1500°C for 10 minutes. Then the heating was stopped, and the refractory lining was cooled using air at 0°C to allow it to return to room temperature within 30 seconds. The refractory lining was then held at room temperature for 5 minutes. The above heating and cooling process was repeated to test the service life of the refractory linings.

[0208] Table 7. Life test data of refractory lining layer

[0209]

[0210]

[0211] By comparing the experimental data in Example 2, it can be seen that when carbon black and wood ash are missing from the castable formula, even if the same preparation process is used, the actual service life of the final refractory lining is reduced to only about 85% of the original.

[0212] Because carbon black and wood ash can fill the microscopic voids in the material during the preparation process, they provide a certain degree of support to the material as a whole. This helps the finished refractory lining maintain a large number of microscopic voids while preventing these microscopic voids and cracks from spreading further. This helps maintain the structural stability of the finished refractory lining and thus improves its service life.

[0213] Example 37:

[0214] This embodiment describes a device for preparing thermal shock resistant and wear-resistant castable for municipal solid waste incinerators, used to implement the method for preparing thermal shock resistant and wear-resistant castable for municipal solid waste incinerators in Embodiment 35 above. It includes a mixing mechanism and a heat preservation mechanism. The heat preservation mechanism is an existing heat preservation device used to keep the castable prepared by the mixing mechanism warm. The mixing mechanism includes a mixing container 10 with the opening facing upward. A vertically extending mixing and stirring main shaft 11 is rotatably connected to the bottom of the mixing container 10. Multiple main stirring rods 111 extending radially are fixed on the mixing and stirring main shaft 11. A stirring short rod 112 is fixed to the outer end of the main stirring rod 111.

[0215] A drive housing 12 is fixed at the bottom of the mixing container 10. The lower end of the mixing and stirring main shaft 11 extends into the drive housing 12. A stirring drive motor 121 for driving the mixing and stirring main shaft 11 to rotate is fixed inside the drive housing 12.

[0216] Multiple vibrating rod connecting rings 13 are fixed to the outer wall of the mixing container 10, and an ultrasonic vibrating rod 131 is fixedly connected in the vibrating rod connecting ring 13.

[0217] The top of the mixing container 10 is connected to a mixing cylinder end cap 14 with the opening facing downward. A vertically extending first conveying pipe 141 and multiple vertically extending second conveying pipes 142 are fixed on the mixing cylinder end cap 14.

[0218] In practical applications, researchers have discovered that certain raw materials, when mixed in a golden ratio, can cause fluctuations in the overall performance of the finished product, or more or less cause a decrease in the overall performance of the finished product. The same applies to the particle size ratio of some raw materials.

Claims

1. A thermal shock resistant and wear-resistant castable for municipal solid waste incinerators, characterized in that, The castable refractory comprises, by weight, 130-160 parts fused alumina powder, 80-100 parts zircon powder, 50-65 parts silica, 30-40 parts high-alumina bauxite clinker, 25-35 parts pure calcium aluminate cement, 15-20 parts andalusite particles, 10-15 parts silicon carbide powder, 8-12 parts zinc oxide micro powder, 6-10 parts carbon black, 5-8 parts wood ash, 5-8 parts water-reducing agent, 3-6 parts dispersant, and 4-11 parts toughening additive. The toughening additive comprises, by weight, 2-5 parts of polypropylene plastic microparticles with a particle size of 35-60 μm, 1-3 parts of spherical asphalt particles with a particle size of 6-100 μm, and 1-3 parts of carbon fiber. The carbon fiber is a carbon fiber with a diameter of 2~5μm and a length of 1~5mm; The fused alumina powder contains 55% to 65% particles with a diameter of 25 to 35 μm, 20% to 30% particles with a diameter of 15 to 22 μm, and the remainder particles with a diameter of 9 to 14 μm. The zircon powder has a particle size of 15~25μm; The particle size of the silica is 10~20μm; The andalusite particles have a particle size of 100~200μm; The particle size of the silicon carbide powder is 5~15μm; The zinc oxide micro powder has a particle size of 1~3μm; The preparation method of the thermal shock resistant and wear-resistant castable for municipal solid waste incinerators includes the following steps: S1. Preparation of mixed raw material A: First, put the fused alumina powder into the mixing tank. Then, add zircon powder, silica, high-alumina bauxite clinker, and pure calcium aluminate cement into the mixing tank in multiple batches and mix them thoroughly with the fused alumina powder to form mixed raw material A. S2. Preparation of mixed raw material B: Andalusite granules, silicon carbide powder, zinc oxide micro powder, carbon black, wood ash, water-reducing agent, dispersant, and toughening additive are added to the mixing tank in multiple batches and thoroughly mixed to form mixed raw material B. S3. Preparation of castable refractory: First, put the mixed raw material A into the mixing tank. Then, add the mixed raw material B into the mixing tank in multiple batches and mix it thoroughly with the mixed raw material A. The amount of mixed raw material B added at one time is 10% to 15% of the total amount. Add water at one time along with mixed raw material B. The amount of water added at one time is 0.6% to 1.2% of the total mass of mixed raw material A. After each addition, stir and mix thoroughly for 10 to 15 minutes before adding the next batch, until all the mixture is completely mixed. S4. Thermal insulation treatment: The casting material prepared in step S3 is placed in a sealed container and kept at 90~150℃ for 8~16 hours. During the heat preservation process, the casting material is subjected to high-frequency vibration and stirring for 5~10 minutes every 30 minutes. The high-frequency vibration frequency is 15~20kHz; This yields a thermal shock resistant and wear-resistant castable.

2. The thermal shock resistant and wear-resistant castable for municipal solid waste incinerators according to claim 1, characterized in that, In step S1, the amount added at one time is 15% to 25% of the total amount. After each addition, stir and mix thoroughly for 10 to 15 minutes before adding the next batch, until all the mixture is completely mixed. Ultrasonic vibration is applied to the mixing tank to ensure that the raw materials are thoroughly mixed under ultrasonic vibration conditions. The ultrasonic vibration frequency is 25~30kHz and the power is 2~4kW.

3. The thermal shock resistant and wear-resistant castable for municipal solid waste incinerators according to claim 1, characterized in that, In step S2, the amount added at one time is 15% to 25% of the total amount. After each addition, stir and mix thoroughly for 10 to 15 minutes before adding the next batch, until all the mixture is completely mixed. Ultrasonic vibration is applied to the mixing tank to ensure that the raw materials are thoroughly mixed under ultrasonic vibration conditions. The ultrasonic vibration frequency is 30~35kHz and the power is 3~5kW.

4. A device for preparing thermal shock resistant and wear-resistant castable for municipal solid waste incinerators, used to prepare the thermal shock resistant and wear-resistant castable for municipal solid waste incinerators as described in claim 1, characterized in that, It includes a mixing mechanism and a heat preservation mechanism. The mixing mechanism includes a mixing container (10) with the opening facing upward. A vertically extending mixing and stirring main shaft (11) is rotatably connected to the bottom of the mixing container (10). Multiple main stirring rods (111) extending radially are fixed on the mixing and stirring main shaft (11). A stirring short rod (112) is fixed to the outer end of the main stirring rod (111). The bottom of the mixing container (10) is fixed with a drive housing (12), the lower end of the mixing and stirring main shaft (11) extends into the drive housing (12), and a stirring drive motor (121) for driving the mixing and stirring main shaft (11) to rotate is fixed inside the drive housing (12).

5. The preparation apparatus according to claim 4, characterized in that, Multiple vibration rod connecting rings (13) are fixed on the outer wall of the mixing container (10), and an ultrasonic vibration rod (131) is fixedly connected in the vibration rod connecting ring (13).

6. The preparation apparatus according to claim 4, characterized in that, The mixing container (10) is connected to a mixing container end cap (14) with the opening facing downward. The mixing container end cap (14) is fixed with a vertically extending first conveying pipe (141) and multiple vertically extending second conveying pipes (142).

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