Efficient refractory material as well as preparation method and application thereof
By using high-melting point oxides and refractory fibers in refractory materials and controlling the mixing process, the problems of insufficient refractory resistance and poor thermal shock resistance in high-temperature environments are solved, and the high performance and long life of high-efficiency refractory materials are achieved.
Patent Information
- Application Number
- CN202411784050.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-06
- Publication Date
- 2025-03-18
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
Traditional refractory materials exhibit insufficient refractory resistance, poor thermal shock resistance, unsatisfactory resistance and corrosion resistance in high-temperature environments, resulting in a shortened service life and an increase in production costs in high-temperature equipment such as steel metallurgy furnaces, glass furnaces and cement rotary kilns.
By controlling the mixing speed and reaction temperature, high melting point oxides (such as alumina and magnesium oxide), refractory fibers (such as alumina and mullite fibers), binders and additives are used to form a dense structure to reduce pores and defects, thereby improving refractory and thermal shock resistance.
It realizes high refractory resistance, good thermal shock resistance, oxidation resistance and corrosion resistance of high-efficiency refractory materials, extends the service life of high-temperature equipment and reduces production costs.
Smart Images
Figure CN119638451A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of refractory materials, and in particular to a high-efficiency refractory material and a preparation method and application thereof. Background Art
[0002] Refractory materials play a vital role in high-temperature industrial fields such as metallurgy, chemical industry, electric power, and building materials. With the continuous development of industrial technology, the performance requirements for refractory materials are getting higher and higher. When facing higher temperatures, more complex chemical environments, and more severe thermal shocks, traditional refractory materials often show problems such as insufficient refractoriness, poor thermal shock resistance, and unsatisfactory oxidation resistance and corrosion resistance.
[0003] For example, in steel metallurgical furnaces, high temperature environments and complex chemical reactions pose severe challenges to the performance of refractory materials. Traditional refractory materials are prone to softening and cracking at high temperatures, which shortens the life of the furnace, increases production costs and maintenance frequency. In glass kilns, the erosion and thermal shock of high-temperature glass liquid also place high demands on the performance of refractory materials. Traditional refractory materials may not be able to withstand such extreme conditions, affecting the quality and efficiency of glass production. In cement rotary kilns, the wear and chemical erosion of high-temperature clinker also cause serious damage to refractory materials.
[0004] Therefore, the development of an efficient refractory material with high refractoriness, good thermal shock resistance, oxidation resistance and erosion resistance has become an urgent need in the current high-temperature industrial field. Summary of the invention
[0005] In view of this, the purpose of the present invention is to provide a high-efficiency refractory material and its preparation method and application, by controlling the mixing speed and reaction temperature, a dense structure is formed inside the material, pores and defects are reduced, and the refractory performance is improved.
[0006] To achieve the above technical objectives, the present invention provides a high-efficiency refractory material, comprising: high-melting-point oxides, refractory fibers, a binder and additives, wherein the high-melting-point oxides are aluminum oxide and magnesium oxide; and the refractory fibers are aluminum silicate fibers and mullite fibers.
[0007] Preferably, the aluminum oxide accounts for 40%-50% of the material, the magnesium oxide accounts for 20%-30% of the material, the aluminum silicate fiber accounts for 15%-20% of the material, the mullite fiber accounts for 10%-15% of the material, the binder accounts for 5%-10% of the material, the antioxidant accounts for 1%-2% of the material, and the anti-corrosion agent accounts for 2%-3% of the material.
[0008] A method for preparing a high-efficiency refractory material, applied to the above-mentioned high-efficiency refractory material, comprises the following steps: Prepare materials, including high melting point oxides, refractory fibers, binders and additives in certain proportions; Mixing: Mix the raw materials evenly through the reactor to ensure uniform distribution of ingredients; Preliminary granulation, making the mixed material into granules for subsequent molding; Granulate again to add toughness to the initially granulated material; Dry pressing, the toughened and modified material is dry pressed in a mold to form a green body of the desired shape; Sintering: sintering the green body at high temperature to form a dense structure and stable performance; Quality inspection, quality inspection of finished products, including testing of refractoriness, thermal shock resistance and strength performance indicators.
[0009] Preferably, in the mixing step, the pressure value, temperature value and stirring speed inside the reactor are obtained; Collecting mixture training data and reaction training data, training a speed recognition model for identifying the stirring speed based on the mixture training data, and training a temperature recognition model for identifying the target temperature value based on the reaction training data; The pressure value and the temperature value are input as the first characteristic data into the trained speed recognition model, and the stirring speed is output. The stirring speed is used as the parameter of the mixing step.
[0010] The pressure value is input as the second characteristic data into the trained temperature recognition model, and the target temperature value is output. The target temperature value is used as the parameter of the mixing step.
[0011] Preferably, the training method of the speed recognition model includes: i groups of mixture training data are collected, where i is an integer greater than 1, and the mixture training data includes historical mixture data and the stirring speed corresponding to the historical mixture data; the historical mixture data and the stirring speed corresponding to the historical mixture data are used as a sample set, and the sample set is divided into a training set and a test set, the historical mixture data in the training set is used as the input of the speed recognition model, and the stirring speed in the training set is used as the output of the speed recognition model, the speed recognition model is trained, and a speed recognition model that meets a preset accuracy is output.
[0012] Preferably, the training method of the temperature recognition model includes: Collect k groups of reaction training data, where k is an integer greater than 1, and the reaction training data includes historical reaction data and target temperature values corresponding to the historical reaction data; use the historical reaction data and the target temperature values corresponding to the historical reaction data as a sample set, and divide the sample set into a training set and a test set. Use the historical reaction data in the training set as the input of a temperature recognition model, use the target temperature values in the training set as the output of the temperature recognition model, train the temperature recognition model, and output a temperature recognition model that meets a preset accuracy.
[0013] Preferably, the speed recognition model and the temperature recognition model are naive Bayes models or support vector machine models.
[0014] The above-mentioned high-efficiency refractory materials can be used for the lining of high-temperature equipment such as steel-making furnaces and iron-making furnaces.
[0015] The above-mentioned high-efficiency refractory material can be used as refractory material of glass furnace to withstand the erosion and thermal shock of high-temperature molten glass.
[0016] The above-mentioned high-efficiency refractory material can be used as the refractory material of cement rotary kiln to resist the wear and chemical erosion of high-temperature clinker.
[0017] It can be seen from the above technical solutions that the present application has the following beneficial effects: 1: By using raw materials such as high melting point oxides and refractory fibers and a specific preparation process, it has a dense microstructure and fiber-reinforced structure, thereby improving the fire resistance and thermal shock resistance.
[0018] 2: Through the speed identification model and temperature identification model, the preparation process is accurately controlled and optimized, and the quality and performance of the product are improved.
[0019] 3: High-efficiency refractory materials have broad application prospects in high-temperature equipment such as steel metallurgical furnaces, glass kilns, cement rotary kilns, etc. They can improve the service life and safety of the furnace body and reduce production costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.
[0021] Figure 1 A preparation flow chart provided by the present invention; Figure 2 The mixing flow chart provided by the present invention. DETAILED DESCRIPTION
[0022] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, and use. It should be understood that in all of these figures, the same or similar reference numerals indicate the same or similar parts and features. The various drawings only schematically represent the concepts and principles of the embodiments of the present disclosure, and do not necessarily show the specific dimensions and proportions of the various embodiments of the present disclosure. Specific parts in specific drawings may be exaggerated to illustrate the relevant details or structures of the embodiments of the present disclosure. Example
[0023] A high-efficiency refractory material comprises: high-melting-point oxides, refractory fibers, a binder and an additive, wherein the high-melting-point oxides are aluminum oxide and magnesium oxide, providing high refractoriness; the refractory fibers are aluminum silicate fibers and mullite fibers, enhancing the toughness and thermal shock resistance of the material; the binder ensures the integrity and bonding strength of the material; and the additive improves the performance of the material, such as oxidation resistance, corrosion resistance, etc.
[0024] Specifically, the proportion of aluminum oxide in the material is 40%-50%. Specifically, when the proportion of aluminum oxide is within this range, it can provide the material with sufficient high refractoriness and ensure the stability and reliability of the material in a high temperature environment. The proportion of magnesium oxide in the material is 20%-30%. By controlling the proportion of magnesium oxide, the refractoriness and chemical stability of the material can be adjusted. The proportion of aluminum silicate fiber in the material is 15%-20%. The presence of this fiber helps to enhance the toughness and thermal shock resistance of the material and improve the adaptability of the material when the temperature changes. The proportion of mullite fiber in the material is 10%-15%, which can further improve the strength and thermal shock resistance of the material and reduce the cracking and damage of the material at high temperatures. The proportion of binder in the material is 5%-10%, and its function is to ensure the integrity and bonding strength of the material so that the components can be closely combined together. The proportion of antioxidant in the material is 1%-2%, which can prevent the material from being oxidized at high temperatures and extend the service life of the material. The proportion of anti-corrosion agent in the material is 2%-3%, which helps to improve the material's resistance to chemical corrosion, so that it can still maintain good performance in harsh environments.
[0025] A method for preparing a high-efficiency refractory material, applied to the above-mentioned high-efficiency refractory material, comprises the following steps: Prepare materials, prepare high melting point oxides, refractory fibers, binders and additives in a certain proportion, and prepare raw materials such as high melting point oxides, refractory fibers, binders and additives in proportion. Among them, high melting point oxides include aluminum oxide and magnesium oxide. Aluminum oxide accounts for 40%-50% of the material. It can provide high refractoriness for the material and ensure the stability and reliability of the material under high temperature environment. Magnesium oxide accounts for 20%-30% of the material, which helps to adjust the refractory properties and chemical stability of the material. Refractory fibers include aluminum silicate fibers and mullite fibers. Aluminum silicate fibers account for 15%-20% of the material, which can enhance the toughness and thermal shock resistance of the material and improve the adaptability of the material when the temperature changes. Mullite fibers account for 10%-15% of the material, which can further improve the strength and thermal shock resistance of the material and reduce the cracking and damage of the material at high temperature. The binder accounts for 5%-10% of the material. Its function is to ensure the integrity and bonding strength of the material so that the components can be closely combined. Additives include antioxidants and anti-corrosion agents. Antioxidants account for 1%-2% of the material, which can prevent the material from being oxidized at high temperatures and extend the service life of the material. Anti-corrosion agents account for 2%-3% of the material, which helps to improve the material's resistance to chemical corrosion, allowing it to maintain good performance in harsh environments. Mixing: Mix the raw materials evenly through the reactor to ensure that the components are evenly distributed. During the mixing process, specific stirring equipment and stirring technology are used to ensure that the raw materials are fully mixed and evenly distributed, so as to lay a good foundation for the subsequent preparation steps; Preliminary granulation is to make the mixed material into granules, which is convenient for subsequent molding operations and makes the material easier to handle and control in the subsequent processing. Preliminary granulation can make the material shape more regular, improve the fluidity and filling properties of the material, and facilitate the subsequent processing steps; Re-granulation can improve the toughness of the material, so that it can better withstand the influence of external forces and temperature changes during use. Through re-granulation, the performance of the material can be further improved, the strength and thermal shock resistance of the material can be increased, and the damage and failure of the material during use can be reduced; Dry pressing is to dry press the toughened and modified material in a mold to form a green body of the desired shape. During the dry pressing process, the pressure and time must be controlled to ensure that the density and shape of the green body meet the requirements. Dry pressing can form the material into a specific shape and size, preparing for the subsequent sintering step; Sintering: sintering the green body at high temperature to form a dense structure and stable performance; Quality inspection, sintering the green body at high temperature. During the sintering process, the sintering temperature, holding time and heating rate must be strictly controlled to ensure that the material forms a dense structure and stable performance. Through sintering, the various components in the material can react with each other to form a strong bond, improving the refractory properties and mechanical strength of the material. At the same time, sintering can also remove pores and defects in the material, improve the density and uniformity of the material, and make it more reliable and durable during use.
[0026] Furthermore, in the mixing step, the pressure value, temperature value and stirring speed inside the reactor are obtained; Collecting mixture training data and reaction training data, training a speed recognition model for identifying the stirring speed based on the mixture training data, and training a temperature recognition model for identifying the target temperature value based on the reaction training data; The pressure value and the temperature value are input as the first characteristic data into the trained speed recognition model, and the stirring speed is output. The stirring speed is used as the parameter of the mixing step.
[0027] The pressure value is input as the second characteristic data into the trained temperature recognition model, and the target temperature value is output, and the target temperature value is used as a parameter of the mixing step; The purpose is to accurately determine the stirring speed and target temperature value based on the real-time data such as the pressure value and temperature value inside the reactor through the trained speed recognition model and temperature recognition model, so as to realize intelligent control of the mixing step, ensure that the raw materials can be fully and evenly mixed during the mixing process, improve the quality and efficiency of the mixing, and provide more stable and reliable basic materials for subsequent preparation steps.
[0028] Specifically, the training method of the speed recognition model includes: Collect i groups of mixture training data, where i is an integer greater than 1. The mixture training data includes historical mixture data and the stirring speed corresponding to the historical mixture data. That is, experiments are conducted on the same historical mixture data using multiple stirring speeds, and the stirring speed with the best stirring speed is selected as the corresponding label of the corresponding historical mixture data. The historical mixing data and the stirring speed corresponding to the historical mixing data are taken as a sample set, and the sample set is divided into a training set and a test set. The historical mixing data in the training set is taken as the input of the speed recognition model, and the stirring speed in the training set is taken as the output of the speed recognition model. The speed recognition model is trained, and a speed recognition model that meets a preset accuracy is output. It should be noted that the standard of the preset accuracy is determined by technical personnel in this field according to actual conditions and is not specifically limited here.
[0029] The training method of the temperature recognition model includes: Collect k groups of reaction training data, where k is an integer greater than 1, and the reaction training data includes historical reaction data and target temperature values corresponding to the historical reaction data, that is, experiments are conducted on the same historical reaction data using multiple target temperature values, and the one with the best target temperature value is selected as the corresponding label of the corresponding historical reaction data; The historical reaction data and the target temperature values corresponding to the historical reaction data are taken as a sample set, and the sample set is divided into a training set and a test set. The historical reaction data in the training set is taken as the input of the temperature recognition model, and the target temperature value in the training set is taken as the output of the temperature recognition model. The temperature recognition model is trained to output a temperature recognition model that meets the preset accuracy. It should be noted that the standard of the preset accuracy is determined by technical personnel in this field according to actual conditions and is not specifically limited here.
[0030] It is worth mentioning that the speed recognition model and the temperature recognition model are naive Bayes models or support vector machine models.
[0031] The above-mentioned high-efficiency refractory materials can be used for the lining of high-temperature equipment such as steelmaking furnaces and ironmaking furnaces; for example, in steelmaking furnaces, due to the extremely high temperature during the steelmaking process and the strong fluidity and corrosiveness of molten steel, the requirements for refractory materials are very high. This high-efficiency refractory material can withstand the high temperature environment in the steelmaking furnace, effectively resist the erosion and scouring of molten steel, and ensure the safe operation of the steelmaking furnace. In ironmaking furnaces, which are also faced with high temperature, high pressure, and chemical erosion of raw materials such as iron ore and coke, this high-efficiency refractory material can be used as a lining to provide reliable protection for the ironmaking furnace.
[0032] The above-mentioned high-efficiency refractory material can be used as a refractory material for glass kilns to withstand the erosion and thermal shock of high-temperature molten glass. For example, in glass kilns, the temperature of molten glass is usually above 1500°C, and the erosion resistance and thermal shock resistance of refractory materials are extremely high. This high-efficiency refractory material can be used as a refractory material for glass kilns to withstand the erosion and thermal shock of high-temperature molten glass. For example, in the production of float glass, the refractory material in the glass kiln needs to withstand the immersion and flow of high-temperature molten glass for a long time. The excellent performance of this high-efficiency refractory material can ensure the stable operation of the glass kiln and extend the service life of the kiln.
[0033] The above-mentioned high-efficiency refractory material can be used as the refractory material of cement rotary kiln to resist the wear and chemical erosion of high-temperature clinker; for example, the high-temperature clinker constantly rolls and rubs in the rotary kiln, causing serious wear and chemical erosion to the refractory material. The above-mentioned high-efficiency refractory material can be used as the refractory material of cement rotary kiln to resist the wear and chemical erosion of high-temperature clinker. For example, in the production of new dry cement, the operating temperature of the cement rotary kiln is as high as about 1450°C. The high-efficiency refractory material can effectively protect the rotary kiln cylinder, reduce heat loss, and improve the efficiency and quality of cement production. Example
[0034] Based on the above embodiment, material preparation: High melting point oxides: Select high-quality aluminum oxide and magnesium oxide. The purity of aluminum oxide reaches more than 99%, and the particle size distribution is between 1-5 microns. The purity of magnesium oxide is 98%, and the particle size is 2-6 microns.
[0035] Refractory fiber: Aluminum silicate fiber and mullite fiber. The diameter of aluminum silicate fiber is 3-5 microns and the length is 10-20 mm. The diameter of mullite fiber is 4-6 microns and the length is 15-25 mm.
[0036] Binder: Choose a high temperature resistant inorganic binder, the main component of which is aluminum dihydrogen phosphate.
[0037] Additives: Add appropriate amount of antioxidant and anti-corrosion agent. The antioxidant is metal silicon powder, and the anti-corrosion agent is zirconium oxide powder.
[0038] Preparation process: Material preparation: Prepare the raw materials according to the following proportions: 45% alumina, 25% magnesium oxide, 18% aluminum silicate fiber, 12% mullite fiber, 7% binder, 1.5% antioxidant, and 2.5% anti-corrosion agent.
[0039] Mixing: Place the raw materials in a high-speed blender and mix at 1500 rpm for 30 minutes to ensure that all ingredients are mixed evenly.
[0040] Preliminary granulation: The mixed materials are preliminarily granulated by a spray granulator to form particles with a diameter of 0.5-1 mm.
[0041] Second granulation: The primary granulated particles are subjected to secondary granulation, using a rotary granulator to improve the uniformity and density of the particles.
[0042] Toughening modification: Add a certain amount of nano-silicon dioxide to the material and disperse it evenly through mechanical stirring to improve the toughness of the material.
[0043] Dry pressing: Place the toughened and modified particles into a mold and perform dry pressing at a pressure of 50MPa to form the required shape of the converter lining.
[0044] Sintering: The formed green body is placed in a high-temperature sintering furnace and sintered according to the following sintering process: the heating rate is 5°C / min, the temperature is raised to 1500°C and then kept at this temperature for 4 hours, and then naturally cooled to room temperature.
[0045] Quality inspection: The quality of the sintered refractory materials is inspected, including the testing of performance indicators such as refractoriness, thermal shock resistance, and strength. After testing, the refractoriness of the high-efficiency refractory material reaches above 1800℃, the number of thermal shock resistance is greater than 50 times, and the compressive strength is greater than 100MPa.
[0046] The exemplary implementation scheme of the present disclosure is described in detail above with reference to the preferred embodiments. However, it can be understood by those skilled in the art that, without departing from the concept of the present disclosure, various modifications and variations can be made to the above-mentioned specific embodiments, and various technical features and structures proposed in the present disclosure can be combined in various ways without exceeding the protection scope of the present disclosure, which is determined by the attached claims.
Claims
1. A high-efficiency refractory material, characterized in that: include: High melting point oxides, refractory fibers, binders and additives, wherein the high melting point oxides are aluminum oxide and magnesium oxide, providing high refractoriness; The refractory fibers are aluminum silicate fibers and mullite fibers, which enhance the toughness and thermal shock resistance of the material; the binder ensures the integrity and bonding strength of the material; and the additives improve the performance of the material, such as oxidation resistance and corrosion resistance.
2. A high efficiency refractory material according to claim 1, characterized in that: The aluminum oxide accounts for 40%-50% of the material, the magnesium oxide accounts for 20%-30% of the material, the aluminum silicate fiber accounts for 15%-20% of the material, the mullite fiber accounts for 10%-15% of the material, the binder accounts for 5%-10% of the material, the antioxidant accounts for 1%-2% of the material, and the anti-corrosion agent accounts for 2%-3% of the material.
3. A method for preparing a high-efficiency refractory material, applied to the high-efficiency refractory material according to any one of claims 1 to 2, characterized in that: The following steps are involved: Prepare materials, including high melting point oxides, refractory fibers, binders and additives in certain proportions; Mixing: mixing the raw materials evenly through the reactor; Preliminary granulation, making the mixed materials into granules; Granulate again to add toughness to the initially granulated material; Dry pressing, the toughened and modified material is dry pressed in a mold to form a green body of the desired shape; Sintering, sintering the green body at high temperature; Quality inspection, quality inspection of finished products, including testing of refractoriness, thermal shock resistance and strength performance indicators.
4. The method for preparing a high-efficiency refractory material according to claim 3, characterized in that: In the mixing step, the pressure value, temperature value and stirring speed inside the reactor are obtained; Collecting mixture training data and reaction training data, training a speed recognition model for identifying the stirring speed based on the mixture training data, and training a temperature recognition model for identifying the target temperature value based on the reaction training data; The pressure value and the temperature value are input into the trained speed recognition model as the first feature data, and the stirring speed is output, and the stirring speed is used as a parameter of the mixing step; The pressure value is input as the second characteristic data into the trained temperature recognition model, and the target temperature value is output. The target temperature value is used as the parameter of the mixing step.
5. The method for preparing a high-efficiency refractory material according to claim 4, characterized in that: The training method of the speed recognition model includes: i groups of mixture training data are collected, where i is an integer greater than 1, and the mixture training data includes historical mixture data and the stirring speed corresponding to the historical mixture data; the historical mixture data and the stirring speed corresponding to the historical mixture data are used as a sample set, and the sample set is divided into a training set and a test set, the historical mixture data in the training set is used as the input of the speed recognition model, and the stirring speed in the training set is used as the output of the speed recognition model, the speed recognition model is trained, and a speed recognition model that meets a preset accuracy is output.
6. The method for preparing a high-efficiency refractory material according to claim 5, characterized in that: The training method of the temperature recognition model includes: Collect k groups of reaction training data, where k is an integer greater than 1, and the reaction training data includes historical reaction data and target temperature values corresponding to the historical reaction data; use the historical reaction data and the target temperature values corresponding to the historical reaction data as a sample set, and divide the sample set into a training set and a test set. Use the historical reaction data in the training set as the input of a temperature recognition model, use the target temperature values in the training set as the output of the temperature recognition model, train the temperature recognition model, and output a temperature recognition model that meets a preset accuracy.
7. The method for preparing a high-efficiency refractory material according to claim 6, characterized in that: The speed recognition model and the temperature recognition model are naive Bayes models or support vector machine models.
8. The high-efficiency refractory material according to any one of claims 1 to 4 can be used for the lining of high-temperature equipment such as steel-making furnaces and iron-making furnaces.
9. The high-efficiency refractory material according to any one of claims 1 to 4 can be used as a refractory material for a glass furnace to withstand the erosion and thermal shock of high-temperature molten glass.
10. The high-efficiency refractory material according to any one of claims 1 to 4 can be used as a refractory material for a cement rotary kiln to resist the wear and chemical erosion of high-temperature clinker.