Lightweight refractory castable reinforcing agent and preparation method thereof

Abstract

The invention relates to a light refractory castable reinforcing agent and a preparation method thereof. The light refractory castable reinforcing agent comprises 28-60 parts by weight of bauxite, 13-30 parts by weight of a plasticizer, 25-35 parts by weight of a composite binder, 0.5-2 parts by weight of a composite dispersant and 1.5-5 parts by weight of rare earth. The particle size of the bauxite is less than 0.075 mm, and the content of Al2O3 is more than 70%. According to the reinforcing agent, the composite dispersing agent and the rare earth component are added, so that the physical and chemical properties of the castable are improved, and the normal-temperature pressure resistance, fracture resistance, high-temperature pressure resistance and fracture resistance of the light refractory castable are enhanced. Besides, the silicon dioxide can be uniformly dispersed into the castable to be subjected to secondary reaction with cement hydration by-products in the castable to generate a large amount of silicon dioxide gel, and the generated gel can block capillary micropores in the castable, so that the internal compactness of the castable is improved, and the compression strength, the breaking strength and the wear resistance are remarkably enhanced.

Description

Technical Field

[0001] The invention relates to the technical field of refractory material research and development, and in particular to a lightweight refractory castable reinforcing agent and a preparation method thereof. Background Art

[0002] Insulating refractory castables, also known as lightweight refractory castables or lightweight insulating refractory castables, refer to a mixture of refractory lightweight aggregates, fine powders, binders and additives, with a general bulk density of less than 1.8g / cm 3 , or the total porosity is greater than 45%, the linear shrinkage after burning is less than 1.5% after being kept warm for 5 hours at the specified temperature. At present, the binder or the mixture of binder and additives is generally packaged separately in China. After the materials arrive at the site, the separately packaged binder or the mixture of binder and additives is mixed with other pre-mixed ingredients on site for use. The more advanced technology abroad generally pre-mixes cement and additives in aggregates and fine powders, and uses them directly at the time of delivery.

[0003] Lightweight castables have the advantages of good thermal insulation, light weight, short production process, low energy consumption, high recyclability and easy mechanized construction. They have been widely used in high-temperature industrial kilns in the metallurgical, building materials, nonferrous metals, chemical and electric power industries, and have achieved remarkable energy-saving and consumption-reducing effects.

[0004] However, existing lightweight castables also have problems with difficult-to-control on-site construction and baking conditions, as well as the problem of easy alkali reversion. Therefore, modular construction (prefabrication) and baking are carried out in advance in the production plant, and then transported to the construction site for overall assembly, or even transported to the site in an assembled overall form, which has become the mainstream technical route for the application of lightweight castables.

[0005] However, the smooth implementation of this technical route puts forward higher requirements on the early strength of lightweight castables. Generally speaking, the smaller the bulk density of lightweight castables, the lower its strength after drying. For example, the bulk density is less than 1.0g / cm 3 The room temperature compressive strength of 110℃×24h is about 2-5MPa; the volume density is 1.4-1.7g / cm 3 The room temperature compressive strength of lightweight castables at 110℃×24h is only about 20MPa. With the advancement of technology, the strength of high-strength lightweight castables after drying can only reach about 40MPa, which is still difficult to meet the early strength requirements of prefabricated lightweight castable modules, especially the continuous increase in module size and the increase in structural complexity require higher strength as a prerequisite. Summary of the invention

[0006] Based on this, it is necessary to provide a lightweight refractory castable reinforcing agent and a preparation method thereof, which can improve the strength of the lightweight castable after drying and firing, in order to solve the above technical problems.

[0007] In a first aspect, the present invention provides a lightweight refractory castable reinforcing agent, comprising 28 to 60 parts by weight of bauxite, 13 to 30 parts by weight of a plasticizer, 25 to 35 parts by weight of a composite binder, 0.5 to 2 parts by weight of a composite dispersant, and 1.5 to 5 parts by weight of a rare earth;

[0008] The particle size of the bauxite is less than 0.075 mm, and the content of Al2O3 exceeds 70%.

[0009] In one embodiment, the particle size of the plasticizer is less than 0.075 mm, and the plasticizer comprises at least one or more combinations of plastic clay, bentonite, talcum powder, and ultrafine oxide powder.

[0010] In one embodiment, the plasticity index of the plasticizer exceeds 17, and when the plasticizer contains particles with a particle size exceeding 0.075 mm, the content of the particles with a particle size exceeding 0.075 mm does not exceed 50% of the total mass of the plasticizer.

[0011] In one embodiment, the composite binder has a particle size of less than 0.025 mm and includes at least one or more combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, and carboxymethyl ether cellulose.

[0012] In one embodiment, the composite dispersant includes at least one or more combinations of polycarboxylates, lignin sulfonates, citric acid, naphthalene sulfonate formaldehyde copolymers, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymers, and ether-based polycarboxylate amphoteric dispersants.

[0013] In one embodiment, the composite dispersant is a multifunctional small molecule or polymer compound containing active groups, and the active groups at least include hydroxyl, quinone and carboxyl groups.

[0014] In one embodiment, the composite dispersant is composed of a non-ionic surfactant and an ionic dispersant, the non-ionic surfactant has a volume restriction effect and a permeation effect, and the adsorption model of the ionic dispersant includes a tail adsorption model, a ring adsorption model, a horizontal adsorption model and a bridging adsorption model.

[0015] In one embodiment, the rare earth includes at least one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium.

[0016] In a second aspect, the present invention provides a method for preparing a lightweight refractory castable reinforcing agent, which is used to prepare the lightweight refractory castable reinforcing agent described in the first aspect, and the method comprises:

[0017] 28 to 60 parts by weight of bauxite, 13 to 30 parts by weight of a plasticizer, and 25 to 35 parts by weight of a composite binder are added into a sealed mixer and mixed to obtain a first mixture;

[0018] Adding 0.5 to 2 parts by weight of a composite dispersant to the first mixture and kneading the mixture so that the composite dispersant and the components in the first mixture are fully dispersed and fused to obtain a second mixture;

[0019] Adding 1.5 to 5 parts by weight of rare earth to the second mixture and continuously mixing, and after mixing evenly, obtaining the lightweight refractory castable reinforcing agent;

[0020] The particle size of the bauxite is less than 0.075 mm, and the content of Al2O3 exceeds 70%.

[0021] In one embodiment, the plasticizer has a particle size of less than 0.075 mm and comprises at least one or more combinations of plastic clay, bentonite, talc, and ultrafine oxide powder;

[0022] The composite binder has a particle size of less than 0.025 mm and comprises at least one or more combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, and carboxymethyl ether cellulose;

[0023] The composite dispersant at least includes one or more combinations of polycarboxylates, lignin sulfonates, citric acid, naphthalene sulfonate formaldehyde copolymers, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymers, and ether-based polycarboxylate amphoteric dispersants;

[0024] The rare earths include at least one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium.

[0025] The above-mentioned lightweight refractory castable reinforcing agent and preparation method thereof have the following advantages:

[0026] (1) By adding composite dispersants and rare earth components, the physical and chemical properties of the castable are improved, and the room temperature pressure resistance, flexural strength, high temperature pressure resistance and flexural strength of the lightweight refractory castable are enhanced.

[0027] (2) It can be evenly dispersed inside the castable and undergo a secondary reaction with the byproducts of cement hydration in the castable to generate a large amount of silica gel. The generated gel can block the capillary pores inside the castable, thereby increasing the density of the castable, and significantly enhancing the compressive strength, flexural strength and wear resistance.

[0028] (3) It can significantly enhance the room temperature flexural and compressive strength of lightweight refractory castables. Under the same test conditions, the addition of this enhancer can increase the flexural strength at 110℃×24h by more than 3-5 MPa, and the compressive strength at 110℃×24h by more than 10 MPa.

[0029] (4) It can significantly enhance the high-temperature flexural and compressive strength of lightweight refractory castables. Under the same test conditions, the addition of this enhancer can increase the flexural strength (above 1400°C) × 3h by 8-10 MPa, and the compressive strength (above 1400°C) × 3h by more than 15-20 MPa.

[0030] (5) The method of use is simple. Just add it into the castable and stir evenly. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0032] Figure 1 The present invention provides a schematic flow chart of a method for preparing a lightweight refractory castable reinforcing agent. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] It should be noted that when a component is referred to as being "fixed to" or "disposed on" another component, it may be directly on the other component or there may be a central component. When a component is considered to be "connected to" another component, it may be directly connected to the other component or there may be a central component at the same time. The terms "vertical", "horizontal", "upper", "lower", "left", "right" and similar expressions used in the specification of the present invention are for illustrative purposes only and do not represent the only implementation method.

[0035] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0036] In the present invention, unless otherwise clearly specified and limited, a first feature being “above” or “below” a second feature may mean that the first feature is directly in contact with the second feature, or the first feature and the second feature are indirectly in contact through an intermediate medium. Moreover, a first feature being “above”, “above” or “above” a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being “below”, “below” or “below” a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0037] Unless otherwise defined, all technical and scientific terms used in the specification of the present invention have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used in the specification of the present invention includes any and all combinations of one or more related listed items.

[0038] Combine the following Figure 1 The invention discloses a lightweight refractory castable reinforcing agent and a preparation method thereof.

[0039] In one embodiment, a lightweight refractory castable reinforcing agent includes 28 to 60 parts by weight of bauxite, 13 to 30 parts by weight of a plasticizer, 25 to 35 parts by weight of a composite binder, 0.5 to 2 parts by weight of a composite dispersant, and 1.5 to 5 parts by weight of a rare earth.

[0040] Wherein, the particle size of bauxite is less than 0.075mm, and the content of Al2O3 exceeds 70%. The particle size of the plasticizer is less than 0.075mm, and at least includes one or more combinations of plastic clay, bentonite, talcum powder, and oxide ultrafine powder. The plasticity index of the plasticizer exceeds 17, and when the plasticizer has particles with a particle size exceeding 0.075mm, the content of particles with a particle size exceeding 0.075mm does not exceed 50% of the total mass of the plasticizer. The particle size of the composite binder is less than 0.025mm, and at least includes one or more combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, and carboxymethyl ether cellulose. The composite dispersant includes at least one or more combinations of polycarboxylates, lignin sulfonates, citric acid, naphthalene sulfonate formaldehyde copolymers, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymers, and ether-based polycarboxylate amphoteric dispersants. The rare earths include at least one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium.

[0041] In this embodiment, the composite dispersant is a multifunctional small molecule or polymer compound containing active groups, and the active groups include at least hydroxyl, quinone and carboxyl groups. The composite dispersant is composed of a non-ionic surfactant and an ionic dispersant. The non-ionic surfactant has a volume restriction effect and a permeation effect. The adsorption model of the ionic dispersant includes a tail adsorption model, a ring adsorption model, a horizontal adsorption model and a bridging adsorption model.

[0042] The above-mentioned lightweight refractory castable reinforcing agent has the following advantages:

[0043] (1) By adding composite dispersants and rare earth components, the physical and chemical properties of the castable are improved, and the room temperature pressure resistance, flexural strength, high temperature pressure resistance and flexural strength of the lightweight refractory castable are enhanced.

[0044] (2) It can be evenly dispersed inside the castable and undergo a secondary reaction with the byproducts of cement hydration in the castable to generate a large amount of silica gel. The generated gel can block the capillary pores inside the castable, thereby increasing the density of the castable, and significantly enhancing the compressive strength, flexural strength and wear resistance.

[0045] (3) It can significantly enhance the room temperature flexural and compressive strength of lightweight refractory castables. Under the same test conditions, the addition of this enhancer can increase the flexural strength at 110℃×24h by more than 3-5 MPa, and the compressive strength at 110℃×24h by more than 10 MPa.

[0046] (4) It can significantly enhance the high-temperature flexural and compressive strength of lightweight refractory castables. Under the same test conditions, the addition of this enhancer can increase the flexural strength (above 1400°C) × 3h by 8-10 MPa, and the compressive strength (above 1400°C) × 3h by more than 15-20 MPa.

[0047] (5) The method of use is simple. Just add it into the castable and stir evenly.

[0048] like Figure 1 As shown, in one embodiment, a method for preparing a lightweight refractory castable reinforcing agent, used to prepare the lightweight refractory castable reinforcing agent, comprises the following steps:

[0049] Step S110, adding 28 to 60 parts by weight of bauxite, 13 to 30 parts by weight of a plasticizer, and 25 to 35 parts by weight of a composite binder into a sealed mixer and mixing them to obtain a first mixture.

[0050] Step S120, adding 0.5 to 2 parts by weight of a composite dispersant to the first mixture and kneading the mixture so that the composite dispersant and the components in the first mixture are fully dispersed and fused to obtain a second mixture.

[0051] Step S130, adding 1.5 to 5 parts by weight of rare earth to the second mixture and continuing to mix, and after mixing evenly, obtaining a lightweight refractory castable reinforcing agent.

[0052] Among them, the particle size of bauxite is less than 0.075mm, and the content of Al2O3 exceeds 70%. The particle size of the plasticizer is less than 0.075mm, and at least includes one or more combinations of plastic clay, bentonite, talcum powder, and oxide ultrafine powder. The particle size of the composite binder is less than 0.025mm, and at least includes one or more combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, and carboxyl methyl ether cellulose. The composite dispersant includes at least one or more combinations of polycarboxylates, lignin sulfonates, citric acid, naphthalene sulfonate formaldehyde copolymers, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymers, and ether-based polycarboxylate amphoteric dispersants. Rare earths include at least one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium, and dysprosium.

[0053] In a specific embodiment, the lightweight refractory castable reinforcing agent provided by the present invention, also known as GM-169 lightweight refractory castable reinforcing agent, is mainly composed of the following components in parts by weight:

[0054] 28-60 parts of bauxite material with particle size <0.075mm and Al2O3>70%, 13-30 parts of plasticizer with particle size <0.075mm (including but not limited to one or several combinations of plastic clay, bentonite, talcum powder, oxide ultrafine powder, etc.), 25-35 parts of composite binder with particle size <0.025mm (including but not limited to one or several combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, carboxymethyl ether cellulose, etc.), 0.5-2 parts of composite dispersant (including but not limited to one or several combinations of polycarboxylates, lignin sulfonates, citric acid, naphthalene sulfonate formaldehyde copolymers, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymers, ether polycarboxylate amphoteric dispersants, etc.), and 1.5-5 parts of rare earth (including but not limited to one or several combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium, etc.).

[0055] In this embodiment, the plasticizer refers to clay or compound material with a certain fineness and dispersion. When mixed evenly with an appropriate amount of water, it can become a plastic clay material with a certain moisture content. It can be molded into various shapes without cracking under the action of external force, and maintain its original shape after the external force is removed. This property is called plasticity. Plasticity is judged by the plasticity index, which refers to the difference between the liquid limit and the plastic limit, generally expressed by IP (Plasticity Index) = WL (Liquid Limit) - WP (Plastic Limit). For example, when the natural water content is greater than the liquid limit, the clay or compound material is in a flowing state; when the natural water content is less than the shrinkage limit, the clay or compound material is in a solid state; when the natural water content is greater than the shrinkage limit and less than the plastic limit, the clay or compound material is in a semi-solid state; when the natural water content is greater than the plastic limit and less than the liquid limit, the clay or compound material is in a plastic state.

[0056] In this embodiment, the clay or batch material has no plasticity, which means that the content of particles with a plasticity index less than or equal to 10 and a particle size greater than 0.075 mm does not exceed 50% of the total mass, and the clay or batch material has plasticity, which means that the content of particles with a plasticity index greater than 10 and a particle size greater than 0.075 mm does not exceed 50% of the total mass. Among them, IP>17 indicates that the clay or batch material has strong plasticity. IP>10 indicates that the clay or batch material has strong plasticity; IP≦10 indicates that the clay or batch material has poor plasticity or no plasticity.

[0057] Therefore, when selecting plasticizers, the first thing to do is to test whether the plasticity index and particle size of the plasticizer meet the requirements. That is, the content of particles with IP>10 and a particle size greater than 0.075 mm does not exceed 50% of the total mass, especially the content of particles with IP>17 and a particle size greater than 0.075 mm does not exceed 50% of the total mass.

[0058] It should be noted that the action mechanism of plasticizers is divided into the action mechanism of non-polar plasticizers and the action mechanism of polar plasticizers. Non-polar plasticizers enter between molecular chains, expand the distance between molecules, reduce the forces between molecules, and thus improve processing performance. Polar plasticizers interact with polar groups of polar macromolecules, which is equivalent to a shielding and coating effect on polar groups, reducing the interaction between polar groups in molecules, weakening the forces between molecules, and improving processing performance.

[0059] In this embodiment, the binder plays a particularly important role in the castable, which is combined into a whole by the action of the binder, and the properties of the binder also determine the physical properties and mechanical strength of the monolithic refractory at room temperature, medium temperature and high temperature to a large extent. According to the different bonding mechanisms of the binder, it can be divided into hydration bonding (such as calcium aluminate cement and hydrated alumina bonding), chemical bonding (such as phosphate bonding), cohesion bonding (such as silica, ultrafine alumina and other micro powder bonding), silica-alumina sol bonding, etc.

[0060] However, each binder has its advantages and disadvantages. For example, calcium aluminate cement has a short setting time, high demoulding strength, and good mechanical properties in high temperature environments, but it is not suitable for medium temperature environments. Phosphates and silica sols are suitable for medium temperature environments. Hydrated alumina, silica sol, and non-siliceous sols have the advantages of low impurity content, which is conducive to improving the purity of the castable and thus enhancing its mechanical properties. In addition, calcium aluminate cement, silica sol, water, and alumina all require a large amount of water, resulting in low apparent porosity and poor anti-burst performance.

[0061] Therefore, considering the advantages and disadvantages of various binders, the present invention adopts a composite binder, which has the advantages of various binders to avoid the disadvantages of various binders, thereby greatly improving various properties of the castable.

[0062] In the present embodiment, the composite dispersant is a multifunctional small molecule or polymer compound, containing a large number of active groups such as hydroxyl, quinone, carboxyl, etc., with a large internal surface area, strong adsorption, exchange, complexation, and chelation capabilities, and can well improve the fluidity and bonding strength of the castable. It hinders the mutual attraction and flocculation between particles through electrostatic action and steric hindrance, thereby obtaining a well-dispersed slurry. It is adsorbed on the surface of the particles through electrostatic action, enhancing the electrostatic repulsion between the colloid particles, and at the same time has an adsorption layer of a certain thickness, forming a steric effect. For non-ionic surfactants, when they are adsorbed on the dispersed phase particles, the dispersed phase particles will be surrounded by the surfactant, forming a spatial barrier, which hinders the collision between ultrafine particles, so that the dispersed phase particles can stably exist in the liquid phase, thereby changing the fluidity of the castable.

[0063] For example, citric acid, molecular formula: C6H8O7, molecular weight: 192.12, is an organic small molecule anionic dispersant, which mainly relies on electrostatic repulsion to achieve dispersion. Its longest dimension in water is about 1.098nm. It is a tribasic acid with three-level ionization, that is, it can ionize different ion types at different pH stages, and the proportion of ion types is also different. Another example is FDN, also called sodium naphthalenesulfonate formaldehyde condensate, which belongs to the naphthalene series water reducer. It is composed of hydrophobic methylene connecting naphthalene ring and hydrophilic sulfonic acid group. Molecular formula: (C 10 H6CH2NaSO3)n, where n=9-13, molecular weight: 2187-3159. FDN main chain length: 5.0nm-7.0nm, side chain length: less than 0.5nm. Another example is amphoteric surfactants, such as ether-based polycarboxylate amphoteric surfactants FS10 and FS20. When such molecules approach cations, they will adsorb their negatively charged anionic spherical shells covered with nonionic side chains with surface activity onto the surface of the cations through electrostatic action, which is usually called the "hedgehog mechanism". When such dispersant molecules approach anions or uncharged nonionic molecules, such as the surface of polyethers, they will leave their nonionic spherical shells with activation on the polyether side chains by means of hydrogen bridges (hydrogen bonds), which is called the "octopus mechanism".

[0064] In this embodiment, the composite dispersant is composed of a nonionic surfactant and an ionic dispersant. The nonionic surfactant is mainly explained by the steric hindrance theory (HVO theory). There are many explanations about this theory, but it mainly refers to two effects: volume restriction effect. When two particles with a polymer adsorption layer on the surface are close to each other, the adsorption between them is just close or squeezed, and the volume is reduced but not mutually permeable; and the polymer chain reduces its own possible configuration number due to space restriction, and the configuration entropy is reduced, which increases the free energy of the system and produces a repulsive effect. The permeation effect, when the particles adsorbed with the polymer surfactant are close to each other, the molecular chains on the surface will intersperse with each other, and the repulsive potential energy between them comes from the increase of local concentration. This is a non-thermodynamic spontaneous process, so the system is in a stable dispersed state.

[0065] The mechanism of action of ionic dispersants is mainly explained by DLVO theory, and sometimes involves steric hindrance theory. Common adsorption models of polymer admixtures include "tail adsorption model", "ring adsorption model" and "horizontal adsorption model", and sometimes "bridge adsorption". According to the mechanism of action of various dispersants, through many experiments, it was finally determined that the composite dispersant was added to the castable enhancer, and finally achieved a more ideal effect of the enhancer.

[0066] In this embodiment, the selection of rare earth After adding rare earth ore to refractory products of different materials, the performance of the refractory has changed, especially the strength of the product has increased greatly, and the crystal phase micro-area analysis shows that rare earth has participated in the growth and development process of the main crystal phase, which provides an effective way to improve certain properties of refractory. Therefore, the use of rare earth can significantly improve the performance of various aspects of refractory such as physical properties, chemical properties and thermal properties. Rare earth elements can promote the formation of compounds in refractory materials and the stability of crystal structure, so that the material has better high temperature resistance and corrosion resistance. In addition, the addition of rare earth elements in refractory materials can also increase the wear resistance of the material and improve its service life.

[0067] Next, the lightweight refractory castable reinforcing agent provided by the present invention is described through Examples 1 to 5:

[0068] Embodiment 1:

[0069] According to the formula: 50 parts of bauxite material with particle size <0.075mm and Al2O3>70%, 20 parts of plasticizer with particle size <0.075mm (including but not limited to one or several combinations of plastic clay, bentonite, talcum powder, oxide ultrafine powder, etc.), 25 parts of composite binder with particle size <0.025mm (including but not limited to one or several combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, carboxymethyl ether cellulose, etc.), composite dispersant (including but not limited to polycarboxylate, lignin sulfonate , naphthalenesulfonate formaldehyde copolymer, polyethylene glycol, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymer, etc.) 1 part and rare earth (including but not limited to one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium, etc.) 4 parts of the formula, preferably the alumina material, plasticizer and binder raw materials are added into a sealed mixer and mixed for 15 minutes, and then the dispersant is added and mixed for 10 minutes to make the various raw materials fully dispersed and fused, and finally the rare earth raw materials are added, mixed for 5 minutes, and stored in a sealed package to obtain a lightweight refractory castable reinforcer.

[0070] The overall proportion of the reinforcing agent prepared in Example 1 after being added to the lightweight refractory castable is shown in Table 1:

[0071] Table 1

[0072] Component name Specification Ratio (without enhancer) Ratio (adding enhancer) Lightweight Aggregate 61 61 80 Alumina 200 mesh 20 20 CA70 cement 5 5 Silica powder 5 5 Kyanite 5 5 Enhancer / 6 Clay 4 4 Six deviations 0.15 0.15

[0073] According to the ratio in Table 1, the test results of various physical and chemical properties of the lightweight refractory castables with and without the reinforcing agent prepared in Example 1 are shown in Table 2:

[0074] Table 2

[0075]

[0076]

[0077] Embodiment 2:

[0078] According to the formula: 55 parts of bauxite material with particle size <0.075mm and Al2O3>70%, 15 parts of plasticizer with particle size <0.075mm (including but not limited to one or several combinations of plastic clay, bentonite, talcum powder, oxide ultrafine powder, etc.), 27 parts of composite binder with particle size <0.025mm (including but not limited to one or several combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, carboxymethyl ether cellulose, etc.), composite dispersant (including but not limited to polycarboxylate, lignin sulfonate, naphthalene The invention discloses a formula of 0.5 parts of sulfonate formaldehyde copolymer, polyethylene glycol, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymer, etc.) and 2.5 parts of rare earth (including but not limited to one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium, etc.), preferably adding alumina, plasticizer and binder into a sealed mixer and mixing for 15 minutes, then adding dispersant and mixing for 10 minutes to make various raw materials fully dispersed and fused, finally adding rare earth raw material, mixing for 5 minutes, sealing and packaging for storage, to obtain a lightweight refractory castable reinforcer.

[0079] The overall proportion of the reinforcing agent prepared in Example 2 after being added to the lightweight refractory castable is shown in Table 3:

[0080] Table 3

[0081]

[0082]

[0083] According to the ratio in Table 3, the test results of various physical and chemical properties of the lightweight refractory castables with and without the reinforcing agent prepared in Example 2 are shown in Table 4:

[0084] Table 4

[0085]

[0086] Embodiment 3:

[0087] According to the formula: 48 parts of bauxite material with particle size <0.075mm and Al2O3>70%, 18 parts of plasticizer with particle size <0.075mm (including but not limited to one or several combinations of plastic clay, bentonite, talcum powder, oxide ultrafine powder, etc.), 30 parts of composite binder with particle size <0.025mm (including but not limited to one or several combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, carboxymethyl ether cellulose, etc.), composite dispersant (including but not limited to polycarboxylate, lignin sulfonate, naphthalene The invention discloses a lightweight refractory castable reinforcer comprising: a sulfonate formaldehyde copolymer, a sulfonate formaldehyde copolymer, a polyethylene glycol, a melamine formaldehyde, a sulfonic acid olefin hydroxyl copolymer, etc., and a rare earth (including but not limited to one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium, etc.) 1.8 parts and a rare earth (including but not limited to one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium, etc.) 2.2 parts. The alumina material, the plasticizer and the binder are preferably added into a sealed mixer and mixed for 15 minutes. The dispersant is then added and mixed for 10 minutes to fully disperse and fuse the various raw materials. Finally, the rare earth raw material is added and mixed for another 5 minutes. The mixture is sealed and packaged for storage to obtain a lightweight refractory castable reinforcer.

[0088] The overall proportion of the reinforcing agent prepared in Example 3 after being added to the lightweight refractory castable is shown in Table 5:

[0089] Table 5

[0090] name Specification Ratio (without enhancer) Ratio (adding enhancer) Lightweight Aggregate 61 61 Floating beads 4 4 80 Alumina 200 mesh 16 16 CA70 cement 5 5 Silica powder 5 5 Kyanite 5 5 Enhancer / 6 Clay 4 4 Six deviations 0.15 0.15

[0091] According to the ratio in Table 5, the test results of various physical and chemical properties of the lightweight refractory castables with and without the reinforcing agent prepared in Example 3 are shown in Table 6:

[0092] Table 6

[0093]

[0094] Embodiment 4:

[0095] According to the formula: 28 parts of bauxite material with particle size <0.075mm and Al2O3>70%, 30 parts of plasticizer with particle size <0.075mm (including but not limited to one or several combinations of plastic clay, bentonite, talcum powder, oxide ultrafine powder, etc.), 35 parts of composite binder with particle size <0.025mm (including but not limited to one or several combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, carboxymethyl ether cellulose, etc.), composite dispersant (including but not limited to polycarboxylate, lignin sulfonate , naphthalenesulfonate formaldehyde copolymer, polyethylene glycol, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymer, etc.) 2 parts and rare earth (including but not limited to one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium, etc.) 5 parts of the formula, preferably the alumina material, plasticizer and binder raw materials are added into a sealed mixer and mixed for 15 minutes, and then the dispersant is added and mixed for 10 minutes to make the various raw materials fully dispersed and fused, and finally the rare earth raw material is added, mixed for 5 minutes, and stored in a sealed package to obtain a lightweight refractory castable reinforcer.

[0096] The overall proportion of the reinforcing agent prepared in Example 4 after being added to the lightweight refractory castable is shown in Table 7:

[0097] Table 7

[0098] name Specification Ratio (without enhancer) Ratio (adding enhancer) Lightweight Aggregate 61 61 Perlite 5 5 80 homogenized material 200 mesh 15 15 CA70 cement 5 5 Silica powder 5 5 Kyanite 6 6 Enhancer / 6 Clay 3 3 Six deviations 0.15 0.15

[0099] According to the ratio in Table 7, the test results of various physical and chemical properties of the lightweight refractory castables with and without the reinforcing agent prepared in Example 4 are shown in Table 8:

[0100] Table 8

[0101]

[0102]

[0103] Embodiment 5:

[0104] According to the formula: 60 parts of bauxite with particle size <0.075mm and Al2O3>70%, 13 parts of plasticizer with particle size <0.075mm (including but not limited to one or several combinations of plastic clay, bentonite, talcum powder, oxide ultrafine powder, etc.), 25 parts of composite binder with particle size <0.025mm (including but not limited to one or several combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, carboxymethyl ether cellulose, etc.), composite dispersant (including but not limited to polycarboxylate, lignin sulfonate, naphthalene The invention discloses a formula of 0.5 parts of sulfonate formaldehyde copolymer, polyethylene glycol, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymer, etc.) and 1.5 parts of rare earth (including but not limited to one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium, etc.), preferably adding alumina, plasticizer and binder into a sealed mixer and mixing for 15 minutes, then adding dispersant and mixing for 10 minutes to make various raw materials fully dispersed and fused, finally adding rare earth raw material, mixing for 5 minutes, sealing and packaging for storage, to obtain a lightweight refractory castable reinforcer.

[0105] The overall proportion of the reinforcing agent prepared in Example 5 after being added to the lightweight refractory castable is shown in Table 9:

[0106] Table 9

[0107]

[0108]

[0109] According to the ratio in Table 9, the test results of various physical and chemical properties of the lightweight refractory castables with and without the reinforcing agent prepared in Example 5 are shown in Table 10:

[0110] Table 10

[0111]

[0112] In summary, the lightweight refractory castable reinforcing agent provided by the present invention, i.e., GM-169 lightweight refractory castable reinforcing agent, has the following advantages:

[0113] (1) It can be evenly dispersed inside the castable and react with the byproducts of cement hydration in the castable to generate a large amount of silica gel. The generated gel can block the capillary pores inside the castable, thereby increasing the density of the castable, and significantly enhancing the compressive strength, flexural strength and wear resistance.

[0114] (2) It can significantly enhance the room temperature flexural and compressive strength of lightweight refractory castables. Under the same test conditions, adding a reinforcing agent can increase the flexural strength at 110℃×24h by more than 3-5 MPa, and the compressive strength at 110℃×24h by more than 10 MPa.

[0115] (3) It can significantly enhance the high-temperature flexural and compressive strength of lightweight refractory castables. Under the same test conditions, by adding a reinforcing agent, the flexural strength (above 1400°C) × 3h increases by 8-10 MPa, and the compressive strength (above 1400°C) × 3h increases by more than 15-20 MPa.

[0116] (4) The method of use is simple. Just add it into the castable and stir evenly before use.

[0117] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0118] The above-mentioned embodiments only express several implementation methods of the present invention, and the description thereof is relatively specific and detailed, but it cannot be understood as limiting the scope of the patent of the present invention. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A lightweight refractory castable enhancer, characterized in that: The invention comprises 28 to 60 parts by weight of bauxite, 13 to 30 parts by weight of a plasticizer, 25 to 35 parts by weight of a composite binder, 0.5 to 2 parts by weight of a composite dispersant and 1.5 to 5 parts by weight of a rare earth; The particle size of the bauxite is less than 0.075 mm, and the content of Al2O3 exceeds 70%.

2. The lightweight refractory castable reinforcing agent according to claim 1, characterized in that: The particle size of the plasticizer is less than 0.075 mm, and at least includes one or more combinations of plastic clay, bentonite, talcum powder, and ultrafine oxide powder.

3. The lightweight refractory castable reinforcing agent according to claim 2, characterized in that: The plasticity index of the plasticizer exceeds 17, and when the plasticizer contains particles with a particle size exceeding 0.075 mm, the content of the particles with a particle size exceeding 0.075 mm does not exceed 50% of the total mass of the plasticizer.

4. The lightweight refractory castable reinforcing agent according to claim 2, characterized in that: The particle size of the composite binder is less than 0.025 mm, and at least includes one or more combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, and carboxymethyl ether cellulose.

5. The lightweight refractory castable reinforcing agent according to claim 4, characterized in that: The composite dispersant at least includes one or more combinations of polycarboxylates, lignin sulfonates, citric acid, naphthalene sulfonate formaldehyde copolymers, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymers, and ether-based polycarboxylate amphoteric dispersants.

6. The lightweight refractory castable reinforcing agent according to claim 5, characterized in that: The composite dispersant is a multifunctional small molecule or high molecular compound containing active groups, and the active groups at least include hydroxyl groups, quinone groups and carboxyl groups.

7. The lightweight refractory castable reinforcing agent according to claim 6, characterized in that: The composite dispersant is composed of a nonionic surfactant and an ionic dispersant. The nonionic surfactant has a volume restriction effect and a permeation effect. The adsorption model of the ionic dispersant includes a tail adsorption model, a ring adsorption model, a horizontal adsorption model and a bridging adsorption model.

8. The lightweight refractory castable reinforcing agent according to claim 6, characterized in that: The rare earths include at least one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium.

9. A method for preparing a lightweight refractory castable reinforcing agent, for preparing the lightweight refractory castable reinforcing agent according to any one of claims 1 to 8, characterized in that: The method comprises: 28 to 60 parts by weight of bauxite, 13 to 30 parts by weight of a plasticizer, and 25 to 35 parts by weight of a composite binder are added into a sealed mixer and mixed to obtain a first mixture; Adding 0.5 to 2 parts by weight of a composite dispersant to the first mixture and kneading the mixture so that the composite dispersant and the components in the first mixture are fully dispersed and fused to obtain a second mixture; Adding 1.5 to 5 parts by weight of rare earth to the second mixture and continuously mixing, and after mixing evenly, obtaining the lightweight refractory castable reinforcing agent; The particle size of the bauxite is less than 0.075 mm, and the content of Al2O3 exceeds 70%.

10. The method for preparing a lightweight refractory castable reinforcing agent according to claim 9, characterized in that: The plasticizer has a particle size of less than 0.075 mm and comprises at least one or more combinations of plastic clay, bentonite, talcum powder, and ultrafine oxide powder; The composite binder has a particle size of less than 0.025 mm and comprises at least one or more combinations of ρ-Al2O3, aluminum dihydrogen phosphate, aluminum sulfate, refractory clay, silicate, dextrin, and carboxymethyl ether cellulose; The composite dispersant at least includes one or more combinations of polycarboxylates, lignin sulfonates, citric acid, naphthalene sulfonate formaldehyde copolymers, melamine formaldehyde, sulfonic acid olefin hydroxyl copolymers, and ether-based polycarboxylate amphoteric dispersants; The rare earths include at least one or more combinations of lanthanum, cerium, neodymium, samarium, europium, gadolinium, terbium and dysprosium.

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