Novel efficient fire-resistant heat-insulating brick and preparation method thereof

Abstract

The invention relates to the technical field of preparation of refractory materials, and discloses a novel efficient refractory heat-insulating brick and a preparation method thereof.The novel efficient refractory heat-insulating brick is prepared from, by weight, 20-30 parts of refractory clay, 45-65 parts of composite mineral filler, 8-15 parts of composite fibers and 1-5 parts of aluminum powder; the composite mineral filler comprises the following raw materials in parts by weight: 10-20 parts of diatomite, 10-15 parts of perlite, 5-15 parts of vermiculite, 10-15 parts of aluminum oxide foam, 5-10 parts of zirconium oxide and 1-5 parts of silicon carbide, and the composite fiber comprises the following raw materials in parts by weight: 5-10 parts of ceramic fiber and 3-5 parts of glass fiber. The composite fibers and the aluminum powder are added into the raw materials, so that the mechanical strength of the fire-resistant and heat-insulating brick is improved, and the situation that the fire-resistant and heat-insulating brick is damaged due to bearing various stresses in the actual use process is effectively avoided. Therefore, the service life of the fireproof heat-insulating brick is further prolonged, and the fireproof heat-insulating brick can stably work for a long time in a severe high-temperature environment.

Description

Technical Field

[0001] The invention relates to the technical field of refractory material preparation, in particular to a novel high-efficiency refractory heat-insulating brick and a preparation method thereof. Background Art

[0002] In industrial production, especially in high-temperature industrial environments, refractory insulation materials play a vital role. Refractory materials mainly focus on fire resistance to withstand chemical erosion and mechanical impact in high-temperature environments. However, with the continuous advancement of industrial technology and the increase in energy costs, higher requirements are placed on the thermal insulation performance of refractory materials. Early refractory insulation bricks usually used a single material component and a simple manufacturing process, resulting in limited insulation effects and difficulty in meeting increasingly stringent energy-saving and environmental protection standards.

[0003] Although the existing refractory insulation bricks have excellent high temperature resistance, they have obvious shortcomings in mechanical strength. They are prone to breakage when subjected to greater pressure or impact, thus affecting their service life and safety performance. Due to insufficient mechanical strength, they are prone to cracking, falling off or even collapse, leading to equipment failure or even safety accidents. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a new type of high-efficiency refractory insulation brick and a preparation method thereof, which solves the problems of low mechanical strength and low reliability and inability to ensure stability.

[0005] To achieve the above objectives, the present invention is implemented through the following technical scheme: the new high-efficiency refractory insulation brick comprises the following raw materials in parts by weight: 20 to 30 parts of refractory clay, 45 to 65 parts of composite mineral filler, 8 to 15 parts of composite fiber, and 1 to 5 parts of aluminum powder.

[0006] Preferably, the composite mineral filler comprises the following raw materials in parts by weight: 10-20 parts of diatomaceous earth, 10-15 parts of perlite, 5-15 parts of vermiculite, 10-15 parts of alumina foam, 5-10 parts of zirconium oxide, and 1-5 parts of silicon carbide.

[0007] Preferably, the composite fiber comprises the following raw materials in parts by weight: 5 to 10 parts of ceramic fiber and 3 to 5 parts of glass fiber.

[0008] Preferably, the preparation method of the novel high-efficiency refractory insulation brick comprises the following steps:

[0009] Step 1: First, pre-treat the raw materials, crush, dry and screen the raw materials, and then mix the screened raw materials with water to prepare slurry;

[0010] Step 2: The mud is in a plastic state after being in a fluid, semi-fluid, and paste state. In this state, it is squeezed into a brick-forming mold and compacted into the basic shape of the brick using a pressing or vibration molding technique. After the mud is slightly hardened, it is demolded to obtain a preliminarily formed brick.

[0011] Step 3: Place the formed bricks in a drying area or drying room and dry them naturally or use drying equipment that controls humidity and temperature to remove moisture from the mud. Place the formed bricks in a drying area or drying room and dry them naturally or use drying equipment that controls humidity and temperature to remove moisture from the mud bricks.

[0012] Step 4: Place the dried bricks into the kiln for preheating to remove residual moisture and stabilize the bricks. They are fired at high temperatures in the kiln. During the firing process, the main components of the bricks undergo chemical and physical changes. After firing, the bricks need to be slowly cooled.

[0013] Step 5: Inspect the quality of fired bricks, pack qualified refractory and thermal insulation bricks, prepare for shipment or storage, store bricks in a dry and ventilated environment, avoid high humidity and direct sunlight, handle and trim unqualified bricks, and ensure that all bricks meet the requirements for use.

[0014] Preferably, in step 1, the raw materials are crushed, dried, screened and mixed, including the following specific steps:

[0015] Step 1: The raw materials to be crushed include the following

[0016] Refractory clay, diatomaceous earth, perlite, vermiculite, alumina foam, zirconium oxide and silicon carbide are crushed to a suitable particle size, and ceramic fiber and glass fiber are crushed to a suitable length;

[0017] Step 2: Then use an oven or hot air circulation dryer to dry the crushed raw materials to reduce the moisture content of the materials and prevent the materials from sticking and solidifying during the mixing and molding process;

[0018] Step 3: Use a vibrating screen or cyclone separator to screen the dried raw materials. Aluminum powder is usually crushed, dried and screened and can be used directly;

[0019] Step 4: Pour the processed raw materials into the blender one by one and stir and mix them. Add water into the blender as the blender is working and continue stirring until the raw materials and water are fully mixed into slurry.

[0020] Preferably, in the step 2, the slurry is in a plastic state after being in a fluid state, a semi-fluid state, and a paste state:

[0021] When the raw materials are mixed to form mud, it contains a large amount of water. At this time, the mud is in a fluid state, the particles are evenly dispersed in the water, and the whole presents low viscosity and high fluidity, and can flow and pour freely;

[0022] After that, the mud is left to settle so that the liquid will float up and the excess liquid will be removed. At this time, the mud becomes semi-fluid, a bit like a thick paste. Continue to dry it to further reduce the water content in the mud, speed up the loss of water, increase the intensity and frequency of stirring, make the particles more tightly bonded, and the mud will become a paste, similar to the texture of toothpaste.

[0023] Allow the paste mud to stand in a relatively stable environment for a period of time so that the internal structure can gradually stabilize and mature to form a plastic state. Moderately knead or squeeze the paste mud manually or mechanically to promote the arrangement and bonding of particles, so that it forms a structure with a certain plasticity.

[0024] Preferably, in step 5, the quality inspection includes inspection of size, appearance, density, compressive strength and refractoriness:

[0025] Dimension inspection: Use calipers, vernier calipers, thickness gauges or measuring tools to measure the length, width and height of bricks. Ensure that each brick meets the design size requirements and check whether the geometric shape of the bricks is uniform;

[0026] Appearance inspection: Use the naked eye and a magnifying glass to check the appearance quality of the bricks to see if there are cracks, bubbles, surface defects or uneven areas. You can use a magnifying glass or microscope to conduct a detailed inspection of the surface to find tiny flaws;

[0027] Density test: Density test is carried out using dry density or drainage method:

[0028] Dry density: Measure the mass and volume of a brick using the formula Calculate the density, where ρ represents density, m represents mass, V represents volume, and the unit of density is kg / m3;

[0029] Displacement method: Place the brick in a known volume of water and measure the change in water level to calculate the volume and density;

[0030] Compressive strength test: Use a compression tester on which pressure is gradually applied until the brick breaks, using the formula Calculate the compressive strength, where f is the compressive strength of the brick, P is the failure pressure, and S is the area of ​​the stacking surface;

[0031] Refractoriness test: Use a refractoriness test furnace, gradually increase the temperature in the test furnace, and record the stability and softening point of the bricks at a specific temperature.

[0032] Preferably, in step 4, high temperature firing includes the following specific steps:

[0033] Heating stage: heating to 1000°C at a heating rate of 5-10°C / min;

[0034] Insulation stage: Insulation at 1000℃ for 2 to 3 hours;

[0035] Continue heating stage: heating to 1400-1500℃ at a heating rate of 3-5℃ / min;

[0036] Second insulation stage: keep warm at 1400-1500℃ for 4-6 hours;

[0037] Cooling stage: Natural cooling to room temperature.

[0038] The present invention provides a novel high-efficiency refractory heat-insulating brick and a preparation method thereof, which has the following beneficial effects:

[0039] 1. The present invention increases the mechanical strength of the refractory insulation bricks by adding composite fiber and aluminum powder to the raw materials, effectively avoiding the refractory insulation bricks from being damaged due to various stresses during actual use. This further increases the service life of the refractory insulation bricks, allowing them to work stably for a long time in harsh high-temperature environments.

[0040] 2. In the present invention, the reliability of refractory insulation bricks is greatly improved, and the failure rate of equipment caused by damage to refractory insulation bricks is significantly reduced, which greatly ensures the continuity and stability of the production process. The reduction in the failure rate also effectively reduces the possibility of safety accidents caused by equipment failure, providing a strong guarantee for the life safety of the staff and the normal production and operation of the enterprise.

[0041] 3. The present invention subjects the mud to a more in-depth and sophisticated processing, so that the mud successively undergoes fluid, semi-fluid and paste stages, and finally forms a plastic state. Through such gradual transformation and processing, a finer mud texture can be obtained. Due to the refinement and uniform distribution of the mud particles, the internal structure of the manufactured refractory insulation bricks is tighter and more uniform, and the bonding between the various parts is more firm and reliable. This tight and firm bonding feature greatly improves the quality and stability of the refractory insulation bricks, effectively avoids cracks and looseness problems that may occur during use, thereby significantly reducing the need for rework due to substandard product quality, which not only saves time and labor costs, but also ensures the high efficiency of production and the high quality of products. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 The present invention is a flow chart of a method for preparing a novel high-efficiency refractory heat-insulating brick. DETAILED DESCRIPTION

[0043] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only 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.

[0044] Example:

[0045] Please refer to the attached Figure 1 The embodiment of the present invention provides a new type of high-efficiency refractory insulation brick, which includes the following raw materials in parts by weight: 20 to 30 parts of refractory clay, 45 to 65 parts of composite mineral filler, 8 to 15 parts of composite fiber, and 1 to 5 parts of aluminum powder.

[0046] The composite mineral filler comprises the following raw materials in parts by weight: 10-20 parts of diatomaceous earth, 10-15 parts of perlite, 5-15 parts of vermiculite, 10-15 parts of alumina foam, 5-10 parts of zirconium oxide and 1-5 parts of silicon carbide.

[0047] The composite fiber comprises the following raw materials in parts by weight: 5 to 10 parts of ceramic fiber and 3 to 5 parts of glass fiber.

[0048] The preparation method of the novel high-efficiency refractory insulation brick comprises the following steps:

[0049] Step 1: First, pre-treat the raw materials, crush, dry and screen the raw materials, and then mix the screened raw materials with water to prepare slurry;

[0050] Step 2: The mud is in a plastic state after being in a fluid, semi-fluid, and paste state. In this state, it is squeezed into a brick-forming mold and compacted into the basic shape of the brick using a pressing or vibration molding technique. After the mud is slightly hardened, it is demolded to obtain a preliminarily formed brick.

[0051] Step 3: Place the formed bricks in a drying area or drying room and dry them naturally or use drying equipment that controls humidity and temperature to remove moisture from the mud. Place the formed bricks in a drying area or drying room and dry them naturally or use drying equipment that controls humidity and temperature to remove moisture from the mud bricks.

[0052] Step 4: Place the dried bricks into the kiln for preheating to remove residual moisture and stabilize the bricks. They are fired at high temperatures in the kiln. During the firing process, the main components of the bricks undergo chemical and physical changes. After firing, the bricks need to be slowly cooled.

[0053] Step 5: Inspect the quality of fired bricks, pack qualified refractory and thermal insulation bricks, prepare for shipment or storage, store bricks in a dry and ventilated environment, avoid high humidity and direct sunlight, handle and trim unqualified bricks, and ensure that all bricks meet the requirements for use.

[0054] In step 1, the raw materials are crushed, dried, screened and mixed, including the following specific steps:

[0055] Step 1: The raw materials to be crushed include the following

[0056] Refractory clay, diatomaceous earth, perlite, vermiculite, alumina foam, zirconium oxide and silicon carbide are crushed to a suitable particle size, and ceramic fiber and glass fiber are crushed to a suitable length;

[0057] Step 2: Then use an oven or hot air circulation dryer to dry the crushed raw materials to reduce the moisture content of the materials and prevent the materials from sticking and solidifying during the mixing and molding process;

[0058] Step 3: Use a vibrating screen or cyclone separator to screen the dried raw materials. Aluminum powder is usually crushed, dried and screened and can be used directly;

[0059] Step 4: Pour the processed raw materials into the blender one by one and stir and mix them. Add water into the blender as the blender is working and continue stirring until the raw materials and water are fully mixed into slurry.

[0060] In step 2, the mud is transformed into a plastic state after passing through the fluid, semi-fluid and paste states:

[0061] When the raw materials are mixed to form mud, it contains a large amount of water. At this time, the mud is in a fluid state, the particles are evenly dispersed in the water, and the whole presents low viscosity and high fluidity, and can flow and pour freely;

[0062] After that, the mud is left to settle so that the liquid will float up and the excess liquid will be removed. At this time, the mud becomes semi-fluid, a bit like a thick paste. Continue to dry it to further reduce the water content in the mud, speed up the loss of water, increase the intensity and frequency of stirring, make the particles more tightly bonded, and the mud will become a paste, similar to the texture of toothpaste.

[0063] Allow the paste mud to stand in a relatively stable environment for a period of time so that the internal structure can gradually stabilize and mature to form a plastic state. Moderately knead or squeeze the paste mud manually or mechanically to promote the arrangement and bonding of particles, so that it forms a structure with a certain plasticity.

[0064] In step 5, quality inspection includes inspection of size, appearance, density, compressive strength and refractoriness:

[0065] Dimension inspection: Use calipers, vernier calipers, thickness gauges or measuring tools to measure the length, width and height of bricks to ensure that each brick meets the design size requirements and check whether the geometric shape of the bricks is uniform;

[0066] Appearance inspection: Use the naked eye and a magnifying glass to check the appearance quality of the bricks to see if there are cracks, bubbles, surface defects or uneven areas. You can use a magnifying glass or microscope to conduct a detailed inspection of the surface to find tiny flaws;

[0067] Density test: Density test is carried out using dry density or drainage method:

[0068] Dry density: Measure the mass and volume of a brick using the formula Calculate the density, where ρ represents density, m represents mass, V represents volume, and the unit of density is kg / m3;

[0069] Displacement method: Place the brick in a known volume of water and measure the change in water level to calculate the volume and density;

[0070] Compressive strength test: Use a compression tester on which pressure is gradually applied until the brick breaks, using the formula Calculate the compressive strength, where f is the compressive strength of the brick, P is the failure pressure, and S is the area of ​​the stacking surface;

[0071] Refractoriness test: Use a refractoriness test furnace, gradually increase the temperature in the test furnace, and record the stability and softening point of the bricks at a specific temperature.

[0072] In step 4, high temperature firing includes the following specific steps:

[0073] Heating stage: heating to 1000°C at a heating rate of 5-10°C / min;

[0074] Insulation stage: Insulation at 1000℃ for 2 to 3 hours;

[0075] Continue heating stage: heating to 1400-1500℃ at a heating rate of 3-5℃ / min;

[0076] Second insulation stage: keep warm at 1400-1500℃ for 4-6 hours;

[0077] Cooling stage: Natural cooling to room temperature.

[0078] Embodiment 1:

[0079] Select 20 parts of refractory clay, 10 parts of diatomaceous earth, 10 parts of perlite, 5 parts of vermiculite, 10 parts of alumina foam, 5 parts of zirconium oxide, 1 part of silicon carbide, 2 parts of aluminum powder, 5 parts of ceramic fiber and 3 parts of glass fiber.

[0080] Refractory clay, diatomaceous earth, perlite, vermiculite, alumina foam and zirconium oxide are crushed to a particle size of less than 1 mm; aluminum powder and silicon carbide powder are sieved to retain particles with a particle size of 0.1 mm;

[0081] Refractory clay, diatomaceous earth, perlite, vermiculite, alumina foam, zirconium oxide, aluminum powder and silicon carbide were mixed in a blender for 30 minutes, ceramic fiber and glass fiber were added, and stirring was continued for 15 minutes;

[0082] The material is pressed into shape at a pressure of 20 MPa;

[0083] Dry in a drying equipment at 120°C for 12 hours;

[0084] Heating stage: put the bricks into the kiln and heat them to 1000℃ at a heating rate of 5℃ / min;

[0085] Insulation stage: 1000℃ for 2 hours;

[0086] Continue heating stage: heating to 1400℃ at a heating rate of 3℃ / min;

[0087] Second insulation stage: insulation at 1400℃ for 4 hours.

[0088] Embodiment 2:

[0089] Select 30 parts of refractory clay, 20 parts of diatomaceous earth, 15 parts of perlite, 15 parts of vermiculite, 15 parts of alumina foam, 10 parts of zirconium oxide, 5 parts of silicon carbide, 5 parts of aluminum powder, 10 parts of ceramic fiber and 5 parts of glass fiber.

[0090] Refractory clay, diatomaceous earth, perlite, vermiculite, alumina foam and zirconium oxide are crushed to a particle size of less than 0.8 mm; aluminum powder and silicon carbide powder are sieved to retain particles with a particle size of 0.1 mm;

[0091] Refractory clay, diatomaceous earth, perlite, vermiculite, alumina foam, zirconium oxide, aluminum powder and silicon carbide were mixed in a blender for 40 minutes, ceramic fiber and glass fiber were added, and stirring was continued for 30 minutes;

[0092] The material is pressed into shape at a pressure of 160 MPa;

[0093] Dry in a drying equipment at 130°C for 18 hours;

[0094] Heating stage: put the bricks into the kiln and heat them to 1500℃ at a heating rate of 10℃ / min;

[0095] Insulation stage: 1000℃ for 3 hours;

[0096] Continue heating stage: heating to 1500℃ at a heating rate of 5℃ / min;

[0097] Second insulation stage: insulation at 1500℃ for 6 hours.

[0098] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. New high-efficiency refractory insulation bricks, characterized by: The invention comprises the following raw materials in parts by weight: 20 to 30 parts of refractory clay, 45 to 65 parts of composite mineral filler, 8 to 15 parts of composite fiber and 1 to 5 parts of aluminum powder.

2. The new high-efficiency refractory insulation brick according to claim 1 is characterized in that: The composite mineral filler comprises the following raw materials in parts by weight: 10-20 parts of diatomaceous earth, 10-15 parts of perlite, 5-15 parts of vermiculite, 10-15 parts of alumina foam, 5-10 parts of zirconium oxide and 1-5 parts of silicon carbide.

3. The new high-efficiency refractory insulation brick according to claim 1 is characterized in that: The composite fiber comprises the following raw materials in parts by weight: 5 to 10 parts of ceramic fiber and 3 to 5 parts of glass fiber.

4. A method for preparing a novel high-efficiency refractory insulation brick, characterized in that: The novel high-efficiency refractory insulation brick used in any one of claims 1 to 3 comprises the following method steps: Step 1: First, pre-treat the raw materials, crush, dry and screen the raw materials, and then mix the screened raw materials with water to prepare slurry; Step 2: The mud is in a plastic state after being in a fluid, semi-fluid and paste state. In this state, it is squeezed into a brick-forming mold. The mud is compacted and formed into the basic shape of the brick using pressing or vibration molding technology. After the mud is slightly hardened, it is demolded to obtain a preliminarily formed brick. Step 3: Place the formed bricks in a drying area or drying room and dry them naturally or use drying equipment that controls humidity and temperature to remove moisture from the mud. Place the formed bricks in a drying area or drying room and dry them naturally or use drying equipment that controls humidity and temperature to remove moisture from the mud bricks. Step 4: Place the dried bricks into the kiln for preheating to remove residual moisture and stabilize the bricks. They are fired at high temperatures in the kiln. During the firing process, the main components of the bricks undergo chemical and physical changes. After firing, the bricks need to be slowly cooled. Step 5: Inspect the quality of fired bricks, pack qualified refractory and thermal insulation bricks, prepare for shipment or storage, store bricks in a dry and ventilated environment, avoid high humidity and direct sunlight, handle and trim unqualified bricks, and ensure that all bricks meet the requirements for use.

5. The method for preparing the novel high-efficiency refractory insulation brick according to claim 4 is characterized in that: In the step 1, the raw materials are crushed, dried, screened and mixed, including the following specific steps: Step 1: The raw materials to be crushed include the following Refractory clay, diatomaceous earth, perlite, vermiculite, alumina foam, zirconium oxide and silicon carbide are crushed to a suitable particle size, and ceramic fiber and glass fiber are crushed to a suitable length; Step 2: Then use an oven or hot air circulation dryer to dry the crushed raw materials to reduce the moisture content of the materials and prevent the materials from sticking and solidifying during the mixing and molding process; Step 3: Use a vibrating screen or cyclone separator to screen the dried raw materials. Aluminum powder is usually crushed, dried and screened and can be used directly; Step 4: Pour the processed raw materials into the blender one by one and stir and mix them. Add water into the blender as the blender is working and continue stirring until the raw materials and water are fully mixed into slurry.

6. The method for preparing the novel high-efficiency refractory insulation brick according to claim 4 is characterized in that: In the step 2, the slurry is transformed into a plastic state after being in a fluid state, a semi-fluid state, and a paste state: When the raw materials are mixed to form mud, it contains a large amount of water. At this time, the mud is in a fluid state, the particles are evenly dispersed in the water, and the whole presents low viscosity and high fluidity, and can flow and pour freely; After that, the mud is left to settle so that the liquid will float up and the excess liquid will be removed. At this time, the mud becomes semi-fluid, a bit like a thick paste. Continue to dry it to further reduce the water content in the mud, speed up the loss of water, increase the intensity and frequency of stirring, make the particles more tightly bonded, and the mud will become a paste, similar to the texture of toothpaste. Allow the paste mud to stand in a relatively stable environment for a period of time so that the internal structure can gradually stabilize and mature to form a plastic state. Moderately knead or squeeze the paste mud manually or mechanically to promote the arrangement and bonding of particles, so that it forms a structure with a certain plasticity.

7. The method for preparing the novel high-efficiency refractory insulation brick according to claim 4 is characterized in that: In step 5, the quality inspection includes inspection of size, appearance, density, compressive strength and refractoriness: Dimensional inspection: Use calipers, vernier calipers, thickness gauges or measuring tools to measure the length, width and height of bricks; Appearance inspection: Use the naked eye and a magnifying glass to check the appearance quality of the bricks to see if there are cracks, bubbles, surface defects or uneven areas; Density test: Density test is carried out using dry density or drainage method: Dry density: Measure the mass and volume of a brick using the formula Calculate the density, where ρ represents density, m represents mass, V represents volume, and the unit of density is kg / m3; Displacement method: Place the brick in a known volume of water and measure the change in water level to calculate the volume and density; Compressive strength test: Use a compression tester on which pressure is gradually applied until the brick breaks, using the formula Calculate the compressive strength, where f is the compressive strength of the brick, P is the failure pressure, and S is the area of ​​the stacking surface; Refractoriness test: Use a refractoriness test furnace, gradually increase the temperature in the test furnace, and record the stability and softening point of the bricks at a specific temperature.

8. The method for preparing the novel high-efficiency refractory insulation brick according to claim 4 is characterized in that: In the step 4, high temperature firing includes the following specific steps: Heating stage: heating to 1000-1500°C at a heating rate of 5-10°C / min; Insulation stage: Insulation at 1000℃ for 2 to 3 hours; Continue heating stage: heating to 1400-1500℃ at a heating rate of 3-5℃ / min; Second insulation stage: keep warm at 1400-1500℃ for 4-6 hours; Cooling stage: Cool naturally to room temperature.

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