Environment-friendly corundum quality mud and its using method

Abstract

The application discloses an environment-friendly corundum quality mud and a use method thereof, and belongs to the field of unshaped refractory materials. The mud comprises the following components in percentage by mass: fine aggregate of aluminum-rich natural mineral 46-50%; self-binding silicon micro powder 5-6%; aluminum-rich natural mineral 2000-mesh micro powder 16-20%; aluminum-rich natural mineral 200-mesh fine powder 26-30%; dispersing agent 0.3-0.5%; and high-efficiency plasticizing and reinforcing agent 0.1-0.2%. The main material of the mud has zero energy consumption, the proportion of natural minerals is more than 90%, the cost is reduced, and the mud has the characteristics of low water addition amount, good compactness, high purity and the like, can make the brick and the mud be damaged synchronously, and has important application prospect.

Description

Technical Field

[0001] This invention belongs to the field of unshaped refractory materials, specifically relating to an environmentally friendly corundum slurry and its application method. Background Technology

[0002] Refractory mortar is a type of monolithic refractory material mainly used for laying refractory bricks. Corundum mortar is one of the refractory mortars with relatively high high-temperature resistance. Traditional corundum mortar is primarily composed of corundum powder, generally bonded with aluminum dihydrogen phosphate. Traditional corundum mortar has the following drawbacks: 1. Large liquid addition volume, high porosity, high content of low-melting-point substances, and poor long-term high-temperature resistance; the addition of large amounts of low-melting-point clay to improve the mortar's viscosity and large amounts of organic binders to ensure a certain early bonding strength, however, results in these organic substances burning away at high temperatures, leaving numerous pores that severely affect the mortar's density. 2. Due to the low activity and poor sintering properties of corundum powder itself, the mortar exhibits poor low-temperature sintering properties, resulting in low bonding strength with bricks under medium and low temperature conditions and large fluctuations in softening under load. 3. Corundum powder is a high-energy-consuming and high-polluting product, with each ton of corundum consuming nearly 2500 kWh of electricity.

[0003] Therefore, in order to improve the performance of traditional corundum mortar and achieve synchronous damage with brick linings of the same grade, it is of great significance to study a low-energy-consumption, environmentally friendly corundum mortar with small liquid addition, less low-melting-point substances, and better long-term high-temperature resistance. This is a technical problem that urgently needs to be solved in the field of unshaped refractory materials in the new era. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by providing an environmentally friendly corundum slurry and its application method. This slurry has zero energy consumption as its main material, reducing costs, and features low water consumption, good density, and high purity, allowing for simultaneous damage to bricks and slurry.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0006] An environmentally friendly corundum-based mud is provided, with the following powder composition by weight percentage:

[0007]

[0008] in:

[0009] The aluminum-rich natural mineral fine aggregate, aluminum-rich natural mineral micro powder, and aluminum-rich natural mineral fine powder are all derived from a natural mineral with extremely high alumina content and extremely low crystal water. The natural mineral contains Al2O3 ≥ 94wt%, SiO2 ≤ 3.5wt%, H2O ≤ 1wt%, and has a water absorption rate ≤ 1.6%.

[0010] Natural mineral is a natural mineral with extremely high alumina content and extremely low crystal water content. Due to its extremely low crystal water content, it can be used directly without calcination or electrofusion processes. Its core indicators such as water absorption rate and aluminum content have reached the level of electrofused brown fused alumina.

[0011] According to the above scheme, the aluminum-rich natural mineral fine aggregate has a particle size of 0.1-0.5 mm, contains Al2O3 ≥ 94 wt%, SiO2 ≤ 3.5 wt%, H2O ≤ 1%, and has a water absorption rate ≤ 1.6%.

[0012] According to the above scheme, the 2000-mesh aluminum-rich natural mineral powder has a fineness ≤6.5µm; it contains Al2O3 ≥94wt%, SiO2 ≤3.5wt%, and H2O ≤1%. This fineness of raw mineral powder not only has good filling properties but also certain binding properties.

[0013] According to the above scheme, the aluminum-rich natural mineral 200-mesh fine powder has a fineness ≤74um; and contains Al2O3 ≥94wt%, SiO2 ≤3.5wt%, and H2O ≤1%.

[0014] According to the above scheme, the self-bonded silicon micropowder SiO2 ≥ 99wt%, pH value ≤ 4, D 90 With a size of ≤0.4 micrometers, it can generate strong independent self-binding properties without the addition of cations such as magnesium oxide.

[0015] According to the above scheme, the dispersant is a mixture of polyacrylic acid liquid and alumina powder by spraying at a mass ratio of 1:3 to 1:4, wherein the molecular weight of polyacrylic acid is 5000-12000.

[0016] According to the above scheme, the high-efficiency plasticizing reinforcing agent is a powdered hyperbranched network polyethylene glycol ether with excellent binding plasticity, which can instantly transform self-flowing slurry into a non-flowing plastic body.

[0017] A method for using the above-mentioned environmentally friendly corundum mud is provided, the specific steps of which are as follows:

[0018] First, mix 45-55 wt% of mud powder with a certain amount of water (9-10% of the total mass of mud powder) until it is very thin. Then, gradually add the remaining mud powder to the mixture and stir until it reaches a better consistency, so that the mud reaches the best construction state.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] 1. This invention provides an environmentally friendly corundum mud, which uses a newly discovered aluminum-rich natural mineral with extremely high aluminum content, extremely low crystal water content, and extremely low water absorption rate as the main material. It can directly replace the energy-intensive fused corundum as the main material of corundum mud without sintering and electrofusion. The proportion of natural mineral in mud powder exceeds 90%, which reduces costs.

[0021] 2. This invention uses a synergistic combination of aluminum-rich natural minerals of different particle sizes. The fine aggregates and powders of aluminum-rich natural minerals replace brown corundum to ensure the basic properties of the mud. The aluminum-rich natural mineral micro-powder not only has good filling properties but also certain binding properties. Together with a small amount of self-bonded silica micro-powder and a high-efficiency plasticizer, it provides the binding strength of the mud, replacing traditional binders. This significantly reduces the amount of water added to the mud, reduces the porosity and low-melting-phase formation of the mud, and improves the density and purity of the mud. At the same time, because the filling and binding effects of the aluminum-rich natural mineral micro-powder replace some of the strength and filling properties provided by the self-bonded silica micro-powder, the amount of self-bonded silica micro-powder used is reduced, avoiding the situation where the mud solidifies too quickly and the construction time is insufficient due to excessive self-bonded silica micro-powder addition.

[0022] 3. The aluminum-rich natural minerals produce active alumina during medium-temperature dehydration, which, together with the self-bonded silica powder, forms a mullite phase at an even lower temperature. This volume expansion compensates for the shrinkage caused by the dehydration of the natural mineral powder, ensuring the medium-temperature strength of the mud. Attached Figure Description

[0023] Figure 1 The macroscopic morphology of natural mineral particles is shown in the examples.

[0024] Figure 2 The XRD pattern of the natural minerals shown in the examples is shown.

[0025] Figure 3 The example shows the TG-DSC of natural minerals. Detailed Implementation

[0026] To better understand the present invention, the following embodiments further illustrate the content of the present invention, but the content of the present invention is not limited to the following embodiments.

[0027] In the following embodiments:

[0028] In this embodiment of the invention, the alumina-rich raw ore fine aggregate, the 2000-mesh alumina-rich raw ore powder, and the 200-mesh alumina-rich raw ore fine powder all originate from a natural mineral with extremely high alumina content and extremely low water of crystallization. This natural mineral contains Al2O3 ≥ 94wt%, SiO2 ≤ 3.5wt%, H2O ≤ 1wt%, and has a water absorption rate ≤ 1.6%. Wherein:

[0029] The fine aggregate of the rich aluminum raw ore has a particle size of 0.1-0.5 mm, contains Al2O3 ≥ 94 wt%, SiO2 ≤ 3.5 wt%, H2O ≤ 1%, and has a water absorption rate ≤ 1.6%.

[0030] The fineness of the 200-mesh aluminum-rich raw ore powder is ≤74um; Al2O3≥94wt%, SiO2≤3.5wt%, H2O≤1%.

[0031] The fineness of the 2000-mesh aluminum-rich raw ore powder is ≤6.5um; it contains ≥94wt% Al2O3, ≤3.5wt% SiO2, and ≤1% H2O.

[0032] Relevant tests were conducted on natural minerals, and the results were as follows: Figure 1-3 As shown, where:

[0033] Figure 1 The image shows the macroscopic morphology of natural mineral particles. It can be seen that the surface of natural mineral particles is smooth and flat, and they exhibit obvious cleavage.

[0034] Figure 2 The XRD results of the natural mineral show that its main crystalline phase is Al2O3, with small amounts of SiO2 and Al4O8H2 present. Al4O8H2 should be diaspore with -OH. The semi-quantitative results of the three are 92%, 3% and 5%, respectively.

[0035] Figure 3 The results of the TG-DSC experiment on the natural mineral show that there is obvious endothermic phenomenon and weight loss at 500-600℃. Combined with the XRD results, it can be seen that this is caused by the precipitation of -OH in diaspore Al4O8H2 upon heating, with the maximum weight loss ratio being 0.71%.

[0036] The self-bonded silicon micropowder has SiO2 ≥ 99wt%, pH value ≤ 4, and volume average particle size ≤ 0.3 micrometers.

[0037] The dispersant is a spray mixture of liquid polyacrylic acid and alumina powder at a mass ratio of 1:3, wherein the molecular weight of polyacrylic acid is 5000-12000 and it has excellent water-reducing properties.

[0038] The high-efficiency plasticizing and reinforcing agent is a powdered hyperbranched network polyethylene glycol ether, specifically PT1088 from BASF, Germany.

[0039] Example 1

[0040] An environmentally friendly corundum-based mud is provided, the powder components and their mass percentages are as follows:

[0041]

[0042] Weigh and thoroughly mix all raw materials according to the above proportions. Then, mix half of the mud powder with 9.4% (by weight of the total mud powder) of water until it reaches an extremely thin consistency. Slowly add the remaining mud powder to the mixture and stir until it reaches a suitable consistency, ensuring the mud reaches its optimal construction condition. After molding, allow the sample to air dry for 24 hours, then heat-treat it at 110℃ for 24 hours to obtain an environmentally friendly corundum mud sample.

[0043] The environmentally friendly corundum slurry samples prepared in this embodiment were subjected to performance testing, and the results are shown in Table 1. The performance testing methods used were in accordance with current national or industry standards, and the test results are the average of three test results (the same applies below).

[0044] Table 1. Performance test results of the environmentally friendly corundum slurry samples prepared in Example 1

[0045]

[0046] Example 2

[0047] An environmentally friendly corundum-based mud is provided, the powder components and their mass percentages are as follows:

[0048]

[0049]

[0050] Weigh and thoroughly mix all raw materials according to the above proportions. Then, mix half of the mud powder with 9.4% (by weight of the total mud powder) of water until it reaches an extremely thin consistency. Slowly add the remaining mud powder to the mixture and stir until it reaches a suitable consistency, ensuring the mud reaches its optimal construction condition. After molding, allow the sample to air dry for 24 hours, then heat-treat it at 110℃ for 24 hours to obtain an environmentally friendly corundum mud sample.

[0051] The environmentally friendly corundum slurry samples prepared in this embodiment were subjected to performance testing, and the results are shown in Table 2. The performance testing methods used were in accordance with current national or industry standards, and the test results are the average of three test results (the same applies below).

[0052] Table 2. Performance test results of the environmentally friendly corundum slurry samples prepared in Example 2

[0053]

[0054] Example 3

[0055] An environmentally friendly corundum-based mud is provided, the powder components and their mass percentages are as follows:

[0056]

[0057] Weigh and thoroughly mix all raw materials according to the above proportions. Then, mix half of the mud powder with 9.8% of the total mass of water until it reaches an extremely thin consistency. Slowly add the remaining mud powder to the mixture and stir until it reaches a suitable consistency, ensuring the mud reaches its optimal construction condition. After molding, allow the sample to air dry for 24 hours, then heat-treat it at 110℃ for 24 hours to obtain an environmentally friendly corundum mud sample.

[0058] The environmentally friendly corundum slurry samples prepared in this embodiment were subjected to performance testing, and the results are shown in Table 1. The performance testing methods used were in accordance with current national or industry standards, and the test results are the average of three test results (the same applies below).

[0059] Table 3. Performance test results of the environmentally friendly corundum slurry samples prepared in Example 3

[0060]

[0061]

[0062] Example 4

[0063] An environmentally friendly corundum-based mud is provided, the powder components and their mass percentages are as follows:

[0064]

[0065] Weigh and thoroughly mix all raw materials according to the above proportions. Then, mix half of the mud powder with 9.5% of the total mass of water until it reaches an extremely thin consistency. Slowly add the remaining mud powder to the mixture and stir until it reaches the optimal consistency, ensuring the mud reaches the best construction condition. After molding, allow the sample to air dry for 24 hours, then heat-treat it at 110℃ for 24 hours to obtain an environmentally friendly corundum mud sample.

[0066] The environmentally friendly corundum slurry samples prepared in this embodiment were subjected to performance testing, and the results are shown in Table 4. The performance testing methods used were in accordance with current national or industry standards, and the test results are the average of three test results (the same applies below).

[0067] Table 4. Performance test results of the environmentally friendly corundum slurry samples prepared in Example 4

[0068]

[0069] The above results indicate that the environmentally friendly corundum slurry of the present invention has the characteristics of low water addition, good density, and high purity, and can cause bricks and slurry to be damaged simultaneously.

[0070] Obviously, the above embodiments are merely examples for clear illustration and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. An environmentally friendly corundum-based mud, characterized by, The powder composition is as follows in mass percentage: Aluminum-rich natural mineral fine aggregate 46-50%; Aluminum-rich natural mineral 2000-mesh powder 16-20%; Aluminum-rich natural mineral 200-mesh powder 26-30%; Self-binding silicon powder 5-6%; Dispersant 0.3-0.5%; High-efficiency plasticizing enhancer 0.1-0.2%; wherein: The aluminum-rich natural mineral fine aggregate, the aluminum-rich natural mineral powder and the aluminum-rich natural mineral powder are all derived from a natural mineral with very high alumina content and very low crystal water, the natural mineral contains Al2O3≥94wt%, SiO2≤3.5wt%, H2O≤1wt%, and water absorption rate ≤1.6%; the main crystal phase of the natural mineral is Al2O3, and a small amount of SiO2 and Al4O8H2 exist in the natural mineral, Al4O8H2 is hard bauxite with -OH, and the semi-quantitative results of the three are 92%, 3% and 5%, respectively; The particle size of the aluminum-rich natural mineral fine aggregate is 0.1-0.5mm.

2. The environmentally friendly corundum-based mud according to claim 1, characterized in that, The self-bound silicon powder has SiO2≥99wt%, pH≤4, D 90 ≤0.4 microns.

3. The environmentally friendly corundum-based mud according to claim 1, characterized in that, The dispersant is a spray mixture of polyacrylic acid liquid and aluminum oxide powder with a mass ratio of 1:3-1:4, wherein the molecular weight of the polyacrylic acid is 5000-12000.

4. The environmentally friendly corundum-based mud according to claim 1, characterized in that, The high-efficiency plasticizing enhancer is a powdered hyperbranched network polyethylene glycol ester ether.

5. A method for using the environmentally friendly corundum-based mud according to any one of claims 1 to 4, characterized in that, The specific steps are as follows: First, 45-55% of the mud powder is fully mixed with 9-10% of the total mass of the mud powder to obtain a dilute mixture, and then the remaining mud powder is gradually added to the obtained dilute mixture to obtain a mud with appropriate consistency.

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