Fireproof heat-insulating brick based on industrial kiln shell

Abstract

The invention relates to the technical field of fire-resistant heat-insulating bricks, and discloses a fire-resistant heat-insulating brick based on an industrial kiln shell, the fire-resistant heat-insulating brick comprises a brick body, the front of the brick body is provided with a tenon edge, the rear of the brick body is provided with a mortise edge, the brick body is internally provided with a mounting groove, and the brick body is internally provided with a filler and a supporting ball. Mounting grooves are formed in the brick body, the filler and the supporting balls are located in the mounting grooves, the mounting grooves are hexagonal, the mounting grooves penetrate through the interior of the brick body, and the brick body is prepared from, by weight, 30-50 parts of aluminum oxide hollow balls, 20-30 parts of mullite powder, 10-20 parts of cordierite particles, 5-15 parts of ceramic fibers, 5-10 parts of binding agents and 1-5 parts of additives. According to the refractory heat-insulating brick, the mounting groove is formed in the brick body, so that the weight of the brick body is reduced, and the problems that according to a traditional refractory heat-insulating brick for the industrial kiln shell, the compressive strength of a light brick is generally low, the density of a high-strength brick is generally large, and the building material cost and energy consumption of a kiln are increased are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of refractory and heat-insulating bricks, specifically to refractory and heat-insulating bricks for industrial furnace shells. Background Art

[0002] Refractory and heat-insulating bricks are building materials with excellent refractory and heat-insulating properties, and are widely used in high-temperature environments such as industrial furnaces and high-temperature pipelines. The refractoriness of refractory and heat-insulating bricks generally reaches above 1580°C, and they can withstand high temperatures without softening or melting. At the same time, its thermal conductivity is relatively low, generally between 0.2 - 0.5 W / (m·K), and the heat-insulating performance is greatly improved compared with ordinary red bricks. In terms of application, in blast furnaces and converters in the metallurgical industry, cement kilns in the building materials industry, and reaction furnaces in the chemical industry, refractory and heat-insulating bricks can all play an important role. They can not only reduce heat loss, improve energy utilization efficiency, protect the equipment shell, extend the service life of the equipment, but also create a safer and more comfortable working environment for workers.

[0003] For traditional refractory and heat-insulating bricks for industrial furnace shells, since the compressive strength of lightweight bricks is generally low and it is difficult to withstand the pressure inside the furnace, while the density of high-strength bricks is generally large, when meeting the requirements of the furnace structure strength, it is necessary to use high-density high-strength bricks, which in turn increases the load-bearing of the furnace, thus causing problems that are not conducive to thin-wall design and increasing the material cost and energy consumption of furnace construction. Summary of the Invention

[0004] In view of the deficiencies of the prior art, the present invention provides refractory and heat-insulating bricks for industrial furnace shells, and solves the problems that for traditional refractory and heat-insulating bricks for industrial furnace shells, since the compressive strength of lightweight bricks is generally low and it is difficult to withstand the pressure inside the furnace, while the density of high-strength bricks is generally large, when meeting the requirements of the furnace structure strength, it is necessary to use high-density high-strength bricks, which in turn increases the load-bearing of the furnace, thus causing problems that are not conducive to thin-wall design and increasing the material cost and energy consumption of furnace construction.

[0005] To achieve the above objectives, the present invention is realized through the following technical solutions: Refractory and heat-insulating bricks for industrial furnace shells, including a brick body, a tenon edge is provided in front of the brick body, a mortise edge is provided behind the brick body, an installation groove is opened inside the brick body, and a filler and a support ball are provided inside the brick body, and the filler and the support ball are located inside the installation groove.

[0006] By adopting the above technical solution, installation grooves are formed inside the brick body to reduce the weight of the brick body, and at the same time, support balls are arranged inside the installation grooves to improve the strength of the brick body, thereby improving the problems of traditional refractory insulation bricks for industrial furnace shells. Due to the generally low compressive strength of lightweight bricks, it is difficult to withstand the pressure inside the furnace, while the density of high-strength bricks is generally large. When meeting the requirements of the furnace structure strength, it is necessary to use high-density high-strength bricks, which increases the load-bearing of the furnace, is not conducive to the thin-walled design, and increases the cost of furnace construction materials and energy consumption.

[0007] Preferably, the installation groove is hexagonal and penetrates through the inside of the brick body.

[0008] Preferably, the raw materials of the brick body include, by weight: 30-50 parts of alumina hollow balls, 20-30 parts of mullite powder, 10-20 parts of cordierite particles, 5-15 parts of ceramic fiber, 5-10 parts of binder, and 1-5 parts of additive.

[0009] Preferably, the support ball is an alumina hollow ball, the particle size of the alumina hollow ball is 5-10 mm, and the wall thickness is 0.3-0.5 mm.

[0010] Preferably, the filler includes mullite particles and cordierite fibers, the particle size of the mullite particles is 2-5 mm, and the length of the cordierite fibers is 10-30 mm.

[0011] Preferably, the width of the tenon edge is 8-12 mm, the depth of the mortise edge is 10-15 mm, and the fitting clearance between the tenon edge and the mortise edge is ≤0.5 mm.

[0012] Preferably, the side length of the installation groove is 15-25 mm, and the center distance between adjacent installation grooves is 30-40 mm.

[0013] Preferably, the ceramic fiber is alumina fiber with a diameter of 5-10 μm, the binder is aluminum sol or silica sol, and the additive is nano-zirconia or silicon carbide particles.

[0014] The preparation process of the refractory insulation brick for industrial furnace shells includes the following steps:

[0015] S1. Batching: Weigh the raw materials for making the brick body by weight, and put the raw materials for the brick body into a double-shaft mixer and mix for 30-60 min;

[0016] S2. Forming: Fill the mixed material into a press with a hexagonal installation groove mold, and press at a pressure of 100-200 MPa to form a brick blank with an installation groove;

[0017] S3. Drying: Move the brick blank with the installation groove into the tunnel kiln and dry it at 100 - 200 °C for 12 - 24 h;

[0018] S4. Sintering: Transfer the dried brick blank into a shuttle kiln, heat it at a heating rate of 5 - 10 °C / min to 1500 - 1600 °C, keep it warm for 3 - 5 h, and then cool it with the furnace;

[0019] S5. Preparation of support balls and fillers: Screen out alumina hollow balls meeting the requirements of a particle size of 5 - 10 mm and a wall thickness of 0.3 - 0.5 mm; Weigh mullite particles and cordierite fibers by weight parts;

[0020] S6. Installation of support balls and fillers: In the installation groove of the sintered brick body, first evenly place the support balls, and then fill the gaps between the support balls with the fillers;

[0021] S7. Processing: Perform milling processing on the brick body with the support balls and fillers installed for the tenon edge and mortise edge, and control the precision within ±0.2 mm;

[0022] S8. Detection: Detect the compressive strength, thermal conductivity and thermal shock stability of the finished brick body.

[0023] The present invention provides a refractory and heat-insulating brick for the shell of an industrial kiln. It has the following beneficial effects:

[0024] 1. In the present invention, by opening an installation groove inside the brick body, the weight of the brick body is reduced, and at the same time, support balls are arranged inside the installation groove to improve the strength of the brick body, thus improving the problem that in traditional refractory and heat-insulating bricks for the shell of an industrial kiln, due to the generally low compressive strength of lightweight bricks, it is difficult to withstand the pressure inside the kiln, while the density of high-strength bricks is generally large, so when meeting the requirements of the kiln structure strength, it is necessary to use high-density high-strength bricks, which increases the load-bearing of the kiln, is not conducive to the thin-wall design, and increases the material cost and energy consumption of the kiln construction.

[0025] 2. In the present invention, through the design of the tenon edge in the front and the mortise edge in the back of the brick body, with its specific size and extremely small fitting gap, adjacent brick bodies can be accurately spliced and tightly connected during the masonry of the kiln. This connection method increases the contact area, effectively disperses the pressure, restricts the relative displacement between the brick bodies, can resist external forces such as vibration, thermal expansion and contraction, and material gravity during the operation of the kiln, prevents the brick bodies from displacement and falling off, ensures the integrity of the kiln structure, and extends the service life of the kiln.

[0026] 3. In the present invention, through the close cooperation of each step of the preparation process, from ensuring the uniform mixing of raw materials during batching, to optimizing the performance of the brick body during forming, drying, and sintering, to the preparation and installation of support balls and fillers, and finally to machining and testing, the parameters are strictly controlled at each step. This ensures the stable and reliable quality of the brick body, meets the usage standards of industrial kilns, screens out unqualified products, and ensures that the products entering the market can effectively perform their functions. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a front three-dimensional structural schematic diagram of the present invention;

[0028] Figure 2 is a top-view structural schematic diagram of the present invention;

[0029] Figure 3 is a cross-sectional structural schematic diagram of the present invention;

[0030] Figure 4 is the present invention Figure 3 a magnified schematic diagram of the structure at A in;

[0031] Figure 5 is a process flow chart of the preparation process of the present invention.

[0032] Among them, 1, mortise edge; 2, brick body; 3, tenon edge; 4, installation groove; 5, filler; 6, support ball. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0033] Next, the technical solutions of the present invention will be clearly and completely described in conjunction with the drawings of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0034] Please refer to the attached Figure 1 - attached Figure 4 , the embodiment of the present invention provides a refractory and heat-insulating brick for an industrial kiln shell, including a brick body 2. A tenon edge 3 is arranged in front of the brick body 2, a mortise edge 1 is arranged behind the brick body 2, an installation groove 4 is opened inside the brick body 2, a filler 5 and a support ball 6 are arranged inside the brick body 2, and the filler 5 and the support ball 6 are located inside the installation groove 4.

[0035] Specifically, the brick body 2 can function to set the tenon edge 3 at the front and the mortise edge 1 at the rear, and at the same time, it also functions to open the installation groove 4 to accommodate the filler 5 and the support ball 6. Through the tenon edge 3 at the front and the mortise edge 1 at the rear of the brick body 2, the brick body 2 can achieve precise splicing during the kiln lining process. The design of tenon and mortise cooperation can ensure the tight connection of adjacent brick bodies 2, enhance the overall structural stability, prevent the displacement and shedding of the brick body 2 caused by factors such as vibration, thermal expansion and contraction, and ensure the integrity of the kiln structure. The filler 5 and the support ball 6 can function to improve the heat insulation performance, thereby reducing the heat transfer from the inside of the kiln to the shell, enhancing the heat insulation performance of the kiln and reducing energy consumption.

[0036] Please refer to the attached Figure 1 - attached Figure 4 , the installation groove 4 is hexagonal and penetrates through the inside of the brick body 2.

[0037] Specifically, the hexagonal structure has strong geometric stability, with an interior angle of 120°. Compared with other shapes, it can disperse stress more evenly when subjected to external forces. The penetrating design enables the support ball 6 and the filler 5 to be evenly distributed inside the brick body 2, enhancing the overall compressive capacity of the brick body 2, reducing deformation or damage caused by local stress concentration, and ensuring the structural stability of the kiln under complex working conditions such as high temperature and high pressure. The penetrating hexagonal installation groove 4 facilitates the filling and installation of the filler 5 and the support ball 6, and can make their distribution more uniform. The regular hexagonal shape is conducive to the close arrangement of the support balls 6, improving the space utilization rate and enhancing the support effect. At the same time, the filler 5 can better fill the gaps, further enhancing the heat insulation performance of the brick body 2 and reducing heat transfer.

[0038] The raw materials of the brick body 2 by weight include: 30 - 50 parts of alumina hollow balls, 20 - 30 parts of mullite powder, 10 - 20 parts of cordierite particles, 5 - 15 parts of ceramic fiber, 5 - 10 parts of binder, and 1 - 5 parts of additive.

[0039] Specifically, 30-50 parts of hollow alumina balls are used as the main raw materials. They have excellent high temperature resistance and high softening point, and can withstand the high temperature environment in the kiln. The hollow structure reduces the weight of the brick body 2 while ensuring strength, and provides a certain insulation space for the brick body 2. 20-30 parts of mullite powder have good high temperature stability and mechanical strength, can maintain the structure of the brick body 2 at high temperature, and enhance the compression and wear resistance of the brick body 2. The two work together to improve the high temperature resistance and high strength performance of the brick body 2; 10-20 parts of cordierite particles have a low thermal expansion coefficient and good thermal insulation performance, which can effectively prevent heat transfer and cooperate with the hollow alumina balls. , further reduce the thermal conductivity of the brick body 2, reduce the heat loss of the kiln, and improve the energy utilization efficiency. 5-15 parts of ceramic fiber also have excellent thermal insulation properties. Its fibrous structure can form an air insulation layer, and can enhance the toughness of the brick body 2, prevent cracks caused by thermal stress, and play a key role in thermal insulation and thermal shock resistance; 5-10 parts of binder are used to bond other raw materials so that the various components are tightly combined into a whole to ensure the structural stability of the brick body 2 during molding and use. It can fill the gaps between the raw materials, improve the density of the brick body 2, and enhance the mechanical properties and corrosion resistance of the brick body 2; 1-5 parts of additives can significantly improve the performance of the brick body 2.

[0040] The supporting balls 6 are hollow alumina balls with a particle size of 5-10 mm and a wall thickness of 0.3-0.5 mm.

[0041] Specifically, the hollow alumina ball itself has high strength, and the particle size of 5-10mm enables it to effectively support the inside of the brick body 2 and disperse the external pressure. The wall thickness of 0.3-0.5mm ensures that the ball is not easily crushed when under pressure. It cooperates with the installation groove 4 and the filler 5 to enhance the overall pressure resistance and ensure that the kiln is stable under the heavy pressure of materials and mechanical vibration. The risk of deformation and damage is reduced; the hollow structure greatly reduces the density of the support ball 6, and the internal air forms a good insulation layer. The particle size and wall thickness parameter control ensure that the ball has enough space to store air for insulation , while maintaining the strength of the sphere, and working together with the filler 5 in the brick body 2, it can effectively prevent heat conduction, reduce the thermal conductivity of the brick body 2, reduce heat loss in the kiln, and improve energy utilization efficiency; alumina has good thermal stability, and the hollow ball structure can relieve thermal stress. When the kiln temperature changes drastically, the hollow ball with a particle size of 5-10mm and a wall thickness of 0.3-0.5mm can buffer the temperature shock and reduce the cracking of the brick body 2 caused by thermal expansion and contraction. Even if part of the sphere is affected, the independent structure limits the expansion of the crack in the brick body 2, thereby maintaining the overall thermal shock stability of the brick body 2.

[0042] The filler 5 includes mullite particles and cordierite fibers. The particle size of the mullite particles is 2-5 mm, and the length of the cordierite fibers is 10-30 mm.

[0043] Specifically, mullite particles with a particle size of 2 - 5 mm have good heat insulation properties themselves. They are stacked with each other inside the brick body 2 to form a heat insulation layer, hindering heat conduction. The length of cordierite fibers is 10 - 30 mm, and the fibrous structure can further disperse the heat transfer path. The two work together to effectively reduce the thermal conductivity of the brick body 2, reduce the heat transfer from the inside of the kiln to the outside, improve the heat insulation effect, and reduce energy loss. The mullite particles have a relatively high hardness and are filled inside the brick body 2, which can enhance the compressive strength of the brick body 2. The cordierite fibers have good flexibility and are interspersed between the mullite particles. Just like "steel bars", they connect the particles together, enhancing the overall structural strength of the filler 5 and endowing the brick body 2 with a certain toughness, so that it is not easy to crack and loosen when subjected to external impact or thermal stress, ensuring the integrity and stability of the brick body 2. The 2 - 5 mm mullite particles and 10 - 30 mm cordierite fibers cooperate with each other in size. The mullite particles fill large voids, and the cordierite fibers fill small gaps, and they can be evenly distributed in the installation groove 4 of the brick body 2, avoiding local vacancies or accumulations, and ensuring the consistency and stability of the performance of the brick body 2.

[0044] The width of the tenon edge 3 is 8 - 12 mm, the depth of the mortise edge 1 is 10 - 15 mm, and the fitting clearance between the tenon edge 3 and the mortise edge 1 ≤ 0.5 mm.

[0045] Specifically, through the width of the tenon edge 3 of 8 - 12 mm and the depth of the mortise edge 1 of 10 - 15 mm, such a size combination enables adjacent brick bodies 2 to be fully inserted during splicing, increasing the contact area between the tenon and mortise. The larger contact area can effectively disperse the pressure and enhance the stability of the connection part. The fitting clearance between the tenon edge 3 and the mortise edge 1 ≤ 0.5 mm, ensuring a tight fit between the two, reducing the existence of gaps, preventing heat from dissipating through the gaps, and improving the overall heat insulation performance of the kiln. The tight tenon - mortise fit effectively restricts the relative displacement between the brick bodies 2. During the operation of the kiln, it will be affected by various factors such as thermal expansion and contraction caused by high temperature, the gravity of the material, and mechanical vibration. The precise dimensions and extremely small fitting clearance of the tenon edge 3 and the mortise edge 1 make the brick bodies 2 form a stable overall structure after splicing, resist these external forces, prevent the brick bodies 2 from loosening and misaligning, ensure the integrity and reliability of the kiln structure, and extend the service life of the kiln. The clear dimensions of the tenon edge 3 and the mortise edge 1 provide precise installation standards for construction workers, making the operation more standardized and convenient during the masonry of the kiln. Construction workers can quickly and accurately perform splicing, improve construction efficiency, and at the same time ensure the installation quality and reduce problems caused by improper installation.

[0046] The side length of the installation groove 4 is 15 - 25 mm, and the center - to - center distance between adjacent installation grooves 4 is 30 - 40 mm.

[0047] Specifically, by setting the side length of the installation groove 4 to be 15 - 25 mm, a suitable accommodation space for the internal support balls 6 and the filler 5 is ensured. If the side length is too small, it is difficult to place the support balls 6 and the filler 5 reasonably, which will affect the heat insulation and support effects. If the side length is too large, the structural strength of the brick body 2 will be weakened. The center - to - center distance between adjacent installation grooves 4 is 30 - 40 mm, which ensures that the brick body 2 still has enough solid parts to withstand pressure and maintain structural stability when multiple installation grooves 4 are provided. At the same time, it also provides sufficient distribution space for the heat - insulating material, effectively reducing the thermal conductivity coefficient and achieving the balance between structure and heat - insulating performance. The appropriate side length and spacing facilitate the uniform distribution of the support balls 6 and the filler 5. The side length of the installation groove 4 enables the support balls 6 to be closely arranged without mutual extrusion and deformation, giving full play to their support role. The center - to - center distance between adjacent installation grooves 4 allows the filler 5 to be evenly filled in the area between the installation grooves 4, enhancing the overall heat - insulating effect and avoiding local heat - insulating weak points. The unified side length and center - to - center distance of the installation grooves 4 make the structure of each part of the brick body 2 uniform. When bearing external forces and thermal stresses, the stress and deformation conditions of each part are similar, ensuring the consistency of the overall mechanical properties of the brick body 2, reducing the risk of damage to the brick body 2 caused by local differences, and improving the reliability of the brick body 2 under the complex working conditions of the kiln furnace.

[0048] The ceramic fiber is alumina fiber with a diameter of 5 - 10 μm, the binder is aluminosilicate sol or silica sol, and the additive is nano - zirconia or silicon carbide particles.

[0049] Specifically, the alumina fiber with a diameter of 5 - 10 μm as the ceramic fiber has excellent flexibility and heat insulation. Its small diameter enables it to form a dense fiber network inside the brick body 2, enhancing the toughness of the brick body 2 and effectively preventing crack propagation. At the same time, the air layer between the fibers further reduces the thermal conductivity coefficient of the brick body 2, improves the heat - insulating effect, and reduces the heat loss of the kiln furnace. The binder is selected as aluminosilicate sol or silica sol, which play a bonding role in the raw materials of the brick body 2. During the high - temperature sintering process, the aluminosilicate sol or silica sol is tightly combined with other raw materials, filling the voids between the particles, improving the density of the brick body 2, ensuring the structural stability of the brick body 2 during the forming and using processes, enhancing the compressive strength and erosion - resistance ability of the brick body 2, and maintaining the integrity of the overall structure of the brick body 2. The additive is nano - zirconia or silicon carbide particles, which can significantly optimize the performance of the brick body 2. Nano - zirconia improves the thermal shock resistance of the brick body 2 through the phase - transformation toughening mechanism, making it not easy to crack under sudden temperature changes. Silicon carbide particles can improve the oxidation resistance and wear resistance of the brick body 2, resist high temperature, chemical erosion, and material scouring in the kiln furnace, extend the service life of the brick body 2, and improve the comprehensive performance of the brick body 2.

[0050] Please refer to the attached Figure 1 - attached Figure 5 , and the preparation process of the refractory heat - insulating brick for the industrial kiln furnace shell includes the following steps:

[0051] S1. Batching: Weigh the raw materials for making the brick body 2 by weight parts, and put the raw materials for the brick body 2 into a double-shaft mixer and mix for 30 - 60 min;

[0052] S2. Molding: Fill the mixed materials into a press with a mold having a hexagonal mounting groove 4, and press at a pressure of 100 - 200 MPa to form a brick blank with a mounting groove 4;

[0053] S3. Drying: Move the brick blank with a mounting groove 4 into a tunnel kiln and dry at 100 - 200 °C for 12 - 24 h;

[0054] S4. Sintering: Transfer the dried brick blank to a shuttle kiln, heat it at a heating rate of 5 - 10 °C / min to 1500 - 1600 °C, hold for 3 - 5 h, and then cool with the furnace;

[0055] S5. Preparation of support balls 6 and filler 5: Screen out alumina hollow balls meeting the requirements of a particle size of 5 - 10 mm and a wall thickness of 0.3 - 0.5 mm; Weigh the mullite particles and cordierite fibers by weight parts;

[0056] S6. Installing support balls 6 and filler 5: In the mounting groove 4 of the sintered brick body 2, first evenly place the support balls 6, and then fill the filler 5 in the gaps between the support balls 6;

[0057] S7. Processing: Perform milling on the tenon edge 3 and mortise edge 1 of the brick body 2 installed with support balls 6 and filler 5, and control the precision within ±0.2 mm;

[0058] S8. Detection: Detect the compressive strength, thermal conductivity and thermal shock stability of the finished brick body 2.

[0059] Specifically, when preparing the ingredients, accurately weigh the raw materials for making the brick body 2 and mix them in a double-shaft mixer for 30 - 60 minutes. This can fully blend the raw materials such as alumina hollow spheres and mullite powder, ensuring that the components of each part of the brick body 2 are consistent. This avoids performance differences caused by uneven distribution of raw materials and lays a foundation for the subsequent stable and reliable performance of the brick body 2. In the forming step, the mixed material is pressed into a brick blank under a pressure of 100 - 200 MPa through a mold with a hexagonal mounting groove 4. The use of pressure and the mold enables the brick blank to accurately obtain the designed shape and size. In particular, the formation of the hexagonal mounting groove 4 creates a suitable space for the subsequent installation of the support balls 6 and the filler 5, ensuring the structural integrity and functionality of the brick body 2. In the drying process, the brick blank with the mounting groove 4 is dried at 100 - 200 °C for 12 - 24 hours to remove moisture. This can prevent the moisture from rapidly vaporizing during the subsequent sintering process, generating pores or cracks and affecting the quality of the brick body 2. At the same time, the drying process helps the binder to initially play a binding role, enhancing the bonding force between the raw materials and optimizing the performance of the brick body 2. During the sintering process, the brick blank is heated in a shuttle kiln at a rate of 5 - 10 °C / min to 1500 - 1600 °C and held for 3 - 5 hours, and then cooled with the furnace. The high temperature promotes physical and chemical reactions of the raw materials, forming a stable crystal structure, significantly improving the physical properties such as the compressive strength and thermal shock stability of the brick body 2, enabling it to withstand the high-temperature environment of industrial kilns. In the preparation step of the support balls 6 and the filler 5, alumina hollow spheres with specific particle sizes and wall thicknesses are selected as the support balls 6, and mullite particles and cordierite fibers are weighed by weight parts as the filler 5, ensuring that the quality and specifications of the support balls 6 and the filler 5 meet the design requirements, providing a guarantee for the subsequent improvement of the heat insulation and support performance of the brick body 2. When installing the support balls 6 and the filler 5, the support balls 6 are evenly placed in the mounting groove 4 of the brick body 2, and then the filler 5 is filled in the gaps, enabling the support balls 6 and the filler 5 to be reasonably distributed inside the brick body 2. The support balls 6 provide a supporting role, enhancing the compressive capacity; the filler 5 fills the gaps, improving the heat insulation performance, and jointly perfecting the internal structure of the brick body 2. In the processing step, the brick body 2 with the support balls 6 and the filler 5 installed is subjected to milling processing of the tenon edge 3 and the mortise edge 1, and the precision is controlled within ±0.2 mm. The precise processing ensures the dimensional accuracy of the tenon edge 3 and the mortise edge 1, realizes a tight fit, facilitates the installation of the brick body 2 in the kiln, and enhances the overall structural stability. In the inspection step, the finished brick body 2 is inspected for compressive strength, thermal conductivity, and thermal shock stability. Unqualified products can be screened out. Through the inspection, it is ensured that the quality of the products entering the market meets the usage standards of industrial kilns, ensuring that the products can effectively play the functions of heat insulation, compression resistance, and thermal shock resistance in actual applications.

[0060] Although the embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A refractory heat-insulating brick for an industrial furnace shell, comprising a brick body (2), characterized in that: A tenon edge (3) is provided in front of the brick body (2), a mortise edge (1) is provided behind the brick body (2), an installation groove (4) is formed inside the brick body (2), and a filler (5) and a support ball (6) are arranged inside the brick body (2). The filler (5) and the support ball (6) are located inside the installation groove (4).

2. The refractory heat-insulating brick for an industrial furnace shell according to claim 1, wherein: The installation groove (4) is hexagonal and penetrates through the inside of the brick body (2).

3. The refractory and heat-insulating brick for an industrial furnace shell according to claim 1, characterized in that: The raw materials of the brick body (2) include, by weight: 30-50 parts of alumina hollow balls, 20-30 parts of mullite powder, 10-20 parts of cordierite particles, 5-15 parts of ceramic fibers, 5-10 parts of binder, and 1-5 parts of additive.

4. The refractory insulation brick for the industrial furnace shell according to claim 1, characterized in that: The support ball (6) is an alumina hollow ball, and the alumina hollow ball has a particle size of 5-10 mm and a wall thickness of 0.3-0.5 mm.

5. The refractory heat-insulating brick for an industrial furnace shell according to claim 1, characterized in that: The filler (5) includes mullite particles and cordierite fibers. The mullite particles have a particle size of 2-5 mm, and the cordierite fibers have a length of 10-30 mm.

6. The refractory heat-insulating brick for an industrial furnace shell according to claim 1, wherein: The width of the tenon edge (3) is 8-12 mm, the depth of the mortise edge (1) is 10-15 mm, and the clearance between the tenon edge (3) and the mortise edge (1) is ≤0.5 mm.

7. The refractory heat-insulating brick for an industrial furnace shell according to claim 1, wherein: The side length of the installation groove (4) is 15-25 mm, and the center distance between adjacent installation grooves (4) is 30-40 mm.

8. The refractory and heat-insulating brick for an industrial furnace shell according to claim 3, wherein: The ceramic fiber is alumina fiber with a diameter of 5-10 μm, the binder is aluminum sol or silicon sol, and the additive is nano-zirconia or silicon carbide particles.

9. The preparation process of refractory heat-insulating bricks for industrial furnace shells is characterized in that It includes the following steps: S1. Batching: Weigh the raw materials for making the brick body (2) by weight, and put the raw materials for the brick body (2) into a double-shaft mixer and mix for 30-60 min; S2. Forming: Fill the mixed material into a press with a mold having a hexagonal installation groove (4), and press at a pressure of 100-200 MPa to form a brick blank with an installation groove (4); S3. Drying: Move the brick blank with an installation groove (4) into a tunnel kiln and dry at 100-200 °C for 12-24 h; S4. Sintering: Transfer the dried brick blank to a shuttle kiln, heat it at a heating rate of 5-10 °C / min to 1500-1600 °C, keep it warm for 3-5 h, and then cool it with the furnace; S5. Preparation of the support ball (6) and the filler (5): Screen out alumina hollow balls that meet the requirements of a particle size of 5-10 mm and a wall thickness of 0.3-0.5 mm; weigh mullite particles and cordierite fibers by weight; S6. Installing the support ball (6) and the filler (5): In the installation groove (4) of the sintered brick body (2), first evenly place the support ball (6), and then fill the filler (5) in the gaps between the support balls (6); S7. Processing: Perform milling processing on the brick body (2) installed with the support ball (6) and the filler (5), and control the accuracy within ±0.2 mm; S8. Detection: Detect the compressive strength, thermal conductivity and thermal shock stability of the finished brick body (2).

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