High-fiber-content prefabricated part and preparation method thereof

Abstract

The invention discloses a high-fiber-content prefabricated part and a preparation method thereof, and belongs to the technical field of kiln lining materials, the high-fiber-content prefabricated part comprises the following raw materials by weight: 30-74 parts of a ceramic base material, 5-40 parts of metal fibers, 15-20 parts of sodium borosilicate composite microwave irradiation modified hollow carbon nanofibers, and 6-10 parts of coated vacuum plasma treated basalt fibers; the sodium borosilicate composite microwave irradiation modified hollow carbon nanofibers are prepared by modifying hollow carbon nanofibers with sodium borosilicate and then performing microwave irradiation modification; the coated type vacuum plasma treatment basalt fiber is obtained by mixing zinc nitrate and strontium nitrate according to the molar ratio of 1: (0.1-0.2) and coating the surface of the basalt fiber subjected to vacuum plasma treatment with the mixture. The fiber content of the prepared high-fiber-content prefabricated part is remarkably increased, and the prefabricated part is high in strength, good in thermal shock resistance and capable of being well applied to the field of kiln linings.

Description

Technical Field

[0001] The present invention relates to the technical field of kiln lining materials, and particularly relates to a prefabricated part with a high fiber content and a preparation method thereof. In particular, it relates to a prefabricated part with a high fiber content suitable for the kiln lining. Background Art

[0002] In high-temperature industrial equipment such as kilns, the performance of the lining material is crucial. Traditional kiln lining materials include types such as fireclay bricks, high-alumina bricks, silica bricks, magnesia bricks, and silicon carbide bricks. These materials all have more or less problems such as easy wear or severe erosion in high-temperature environments.

[0003] Currently, the fiber content of prefabricated parts for kiln linings is generally low, usually less than 5%. How to increase the fiber content and prepare prefabricated parts with a high fiber content, high strength, and good thermal shock stability has become a technical problem in this field.

[0004] Based on this, the present invention designs a prefabricated part with a high fiber content and a preparation method thereof to solve the above problems. Summary of the Invention

[0005] In view of the above-mentioned drawbacks of the prior art, the present invention provides a prefabricated part with a high fiber content and a preparation method thereof.

[0006] To achieve the above object, the present invention is realized through the following technical solutions:

[0007] A prefabricated part with a high fiber content is composed of the following raw materials in parts by weight: 30 - 74 parts of ceramic base material, 5 - 40 parts of metal fiber, 15 - 20 parts of borosilicate composite microwave-irradiated modified hollow carbon nanofibers, and 6 - 10 parts of coated vacuum plasma-treated basalt fibers; wherein, the borosilicate composite microwave-irradiated modified hollow carbon nanofibers are prepared by modifying hollow carbon nanofibers with borosilicate and then subjecting them to microwave irradiation modification; the coated vacuum plasma-treated basalt fibers are obtained by coating the surface of vacuum plasma-treated basalt fibers with a mixture of zinc nitrate and strontium nitrate in a molar ratio of 1:0.1 - 0.2.

[0008] Furthermore, the preparation steps of the borosilicate composite microwave-irradiated modified hollow carbon nanofibers are as follows:

[0009] (1): Take 20 ml of deionized water in a 50 ml glass bottle, add 5 - 7 g of borosilicate, and prepare a 20 - 25.93 wt% borosilicate solution for standby;

[0010] (2): Take 10 - 20 g of hollow carbon nanofibers and soak them in a sodium borosilicate solution so that the sodium borosilicate is adsorbed on the surface of the hollow carbon nanofibers. Then take out the hollow carbon nanofibers and place them in a freeze dryer at -40 to -20 °C to obtain hollow carbon nanofibers with sodium borosilicate loaded on the surface;

[0011] (3): Then put the hollow carbon nanofibers with sodium borosilicate loaded on the surface into a microwave materials chemistry workstation and perform microwave irradiation treatment at 82 - 85 °C for 0.2 - 0.5 h.

[0012] Furthermore, the preparation steps of the coated vacuum plasma-treated basalt fiber are as follows:

[0013] (1): Take zinc nitrate and strontium nitrate according to a molar ratio of 1:0.1 - 0.2, add 3 - 5 times the total volume of the reactants of water, stir evenly to obtain a coating solution for standby;

[0014] (2): Place the basalt fiber in a vacuum plasma treatment device, evacuate to 10 -3 ~10 -5 Pa and then introduce nitrogen. Turn on the plasma generator to generate plasma. High-energy particles interact with the surface of the basalt fiber to modify the surface of the basalt fiber;

[0015] (3): Put the vacuum plasma-treated basalt fiber into the coating solution, after coating by the impregnation method, carry out centrifugation, drying, and calcination at 500 - 550 °C for 1 - 2 h to obtain the coated vacuum plasma-treated basalt fiber.

[0016] Furthermore, the ceramic base material is a composition of one or more of corundum, alumina, silicon carbide, and mullite.

[0017] Furthermore, the processing power of the plasma generator is 200 - 350 W, and the processing time is 2 - 5 min.

[0018] Furthermore, the thermal shock stability of the high fiber content preform is ≥18 times for water cooling at 1100 °C, and the compressive strength is 138.4 - 144.3 MPa.

[0019] To better achieve the purpose of the present invention, the present invention also provides a preparation method of a high fiber content preform, including the following steps:

[0020] Step (1), batching: Weigh the ceramic base material, metal fiber, boron-silicate-sodium-compound microwave irradiation modified hollow carbon nanofibers, and coated vacuum plasma-treated basalt fiber according to the raw material ratio;

[0021] Step (2), pulping: Add the raw materials into a stirring tank and add 19 - 22% of the total mass of the raw materials of water for pulping;

[0022] Step (3), forming: Use a forming machine to prepare a preform with a high fiber content.

[0023] To better achieve the object of the present invention, the present invention also provides a preform with a high fiber content prepared according to the described preparation method.

[0024] To better achieve the object of the present invention, the present invention also provides the application of the preform with a high fiber content in the preparation of the inner lining material of a kiln furnace.

[0025] Compared with the prior art, the beneficial effects of the present invention are as follows: The fiber content of the preform with a high fiber content prepared by the present invention is significantly increased, and the preform has high strength and good thermal shock stability (the number of water-cooling times at 1100°C ≥ 18 times), and can be preferably used in the field of the inner lining of a kiln furnace. Description of the Drawings

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention, and those of ordinary skill in the art can also obtain other drawings based on these drawings without creative efforts.

[0027] Figure 1 It is a flowchart of the preparation method of a preform with a high fiber content of the present invention. Detailed Embodiments

[0028] To make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are some but not all of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art without creative efforts based on the embodiments of the present invention belong to the scope of protection of the present invention.

[0029] Example 1: The borosilicate composite microwave irradiation modified hollow carbon nanofibers are prepared by microwave irradiation modification after modifying the hollow carbon nanofibers with borosilicate. The specific steps are as follows:

[0030] (1): Take 20 ml of deionized water in a 50 ml glass bottle, add 5 g of borosilicate, and prepare a 20 wt% borosilicate solution for standby;

[0031] (2): Take 10 g of hollow carbon nanofibers and soak them in a sodium borosilicate solution so that the sodium borosilicate is adsorbed on the surface of the hollow carbon nanofibers. Then take out the hollow carbon nanofibers and place them in a freeze dryer at -40 °C to obtain hollow carbon nanofibers with sodium borosilicate loaded on their surface;

[0032] (3): Then put the hollow carbon nanofibers with sodium borosilicate loaded on their surface into a microwave materials chemistry workstation and perform microwave irradiation treatment at 85 °C for 0.2 h; Microwave irradiation can intensify the molecular motion of sodium borosilicate and hollow carbon nanofibers, promote the interaction between the two, make the sodium borosilicate more firmly loaded on the surface of the hollow carbon nanofibers, and improve the stability and uniformity of the loading.

[0033] When applied to high-temperature oxidation environments such as kiln lining materials, sodium borosilicate can be rapidly oxidized to form a B2O3 glass phase. The B2O3 glass phase has good fluidity at high temperatures and can fill defects such as cracks and voids between hollow carbon nanofibers and between hollow carbon nanofibers and other materials, which is beneficial to reducing problems such as wear and erosion of materials in high-temperature environments, realizing self-healing of materials, and enhancing the strength of materials. At the same time, a barrier structure can be formed, which is beneficial to improving thermal shock stability.

[0034] The coated vacuum plasma-treated basalt fiber is obtained by coating a mixture of zinc nitrate and strontium nitrate on the surface of the vacuum plasma-treated basalt fiber. The specific steps are as follows:

[0035] (1): Take zinc nitrate and strontium nitrate according to a molar ratio of 1:0.1, add 3 times the total volume of the reactants of water, stir evenly to obtain a coating solution for standby;

[0036] (2): Place the basalt fiber in a vacuum plasma treatment device, evacuate to 10 -3 Pa and then introduce nitrogen, turn on the plasma generator to generate plasma, and the high-energy particles interact with the surface of the basalt fiber to modify the surface of the basalt fiber. The processing power of the plasma generator is 200 W and the processing time is 5 min;

[0037] (3): Put the vacuum plasma-treated basalt fiber into the coating solution, perform coating by the impregnation method, and then centrifuge, dry, and calcine at 500 °C for 2 h to obtain the coated vacuum plasma-treated basalt fiber.

[0038] Coating the vacuum plasma-treated basalt fiber with a mixture of zinc nitrate and strontium nitrate is beneficial to the diffusion of zinc and strontium ions into the fiber interior and into the lattice structure of the fiber. At the same time, during the calcination process, the chemical composition and crystal structure of the basalt fiber are changed, and a modified layer is formed on the surface of the basalt fiber, which is beneficial to improving thermal shock stability and enhancing the strength of the material.

[0039] Example 2: The borosilicate composite microwave-irradiated modified hollow carbon nanofibers are prepared by modifying the hollow carbon nanofibers with borosilicate and then performing microwave irradiation modification. The specific steps are as follows:

[0040] (1): Take 20 ml of deionized water in a 50 ml glass bottle, add 7 g of borosilicate, and prepare a 25.93 wt% borosilicate solution for standby.

[0041] (2): Take 20 g of hollow carbon nanofibers, immerse them in the borosilicate solution to allow the borosilicate to adsorb on the surface of the hollow carbon nanofibers, and then take out the hollow carbon nanofibers and freeze-dry them at -20 °C to obtain hollow carbon nanofibers with borosilicate loaded on the surface.

[0042] (3): Then put the hollow carbon nanofibers with borosilicate loaded on the surface into a microwave materials chemistry workstation and perform microwave irradiation treatment at 82 °C for 0.5 h; microwave irradiation can intensify the molecular motion of borosilicate and hollow carbon nanofibers, promote the interaction between the two, make the borosilicate more firmly loaded on the surface of the hollow carbon nanofibers, and improve the stability and uniformity of the loading.

[0043] When applied to high-temperature oxidation environments such as kiln lining materials, borosilicate can be quickly oxidized to form a B2O3 glass phase. The B2O3 glass phase has good fluidity at high temperatures and can fill the cracks, voids and other defects between the hollow carbon nanofibers, between the hollow carbon nanofibers and other materials, which is beneficial to reducing problems such as wear and erosion of the material in a high-temperature environment, realizing self-healing of the material, and enhancing the strength of the material. At the same time, a barrier structure can be formed, which is beneficial to improving the thermal shock stability.

[0044] The coated vacuum plasma-treated basalt fibers are obtained by coating a mixture of zinc nitrate and strontium nitrate on the surface of the vacuum plasma-treated basalt fibers. The specific steps are as follows:

[0045] (1): Take zinc nitrate and strontium nitrate according to a molar ratio of 1:0.2, add 5 times the total volume of the reactants of water, stir evenly to obtain a coating solution for standby.

[0046] (2): Place the basalt fibers in a vacuum plasma treatment device, evacuate to 10 -5 Pa and then introduce nitrogen, turn on the plasma generator to generate plasma, and the high-energy particles interact with the surface of the basalt fibers to modify the surface of the basalt fibers. The processing power of the plasma generator is 350 W and the processing time is 2 min.

[0047] (3): Put the vacuum plasma-treated basalt fibers into the coating solution, coat them by the impregnation method, and then centrifuge, dry, and calcine at 550 °C for 1 h to obtain the coated vacuum plasma-treated basalt fibers.

[0048] Coating basalt fibers treated by vacuum plasma with a mixture of zinc nitrate and strontium nitrate is beneficial to the diffusion of zinc and strontium ions into the interior of the fibers and their entry into the lattice structure of the fibers. At the same time, during the calcination process, the chemical composition and crystal structure of the basalt fibers are changed, and a modified layer is formed on the surface of the basalt fibers, which is beneficial to improving the thermal shock stability and enhancing the strength of the material.

[0049] Example 3: Borosilicate composite microwave-irradiated modified hollow carbon nanofibers are prepared by microwave irradiation modification after modifying hollow carbon nanofibers with borosilicate. The specific steps are as follows:

[0050] (1): Take 20 ml of deionized water in a 50 ml glass bottle, add 6 g of borosilicate, and prepare a 23.08 wt% borosilicate solution for standby.

[0051] (2): Take 15 g of hollow carbon nanofibers, immerse them in the borosilicate solution to adsorb borosilicate on the surface of the hollow carbon nanofibers, and then take out the hollow carbon nanofibers and freeze-dry them at -30 °C to obtain hollow carbon nanofibers with borosilicate loaded on the surface.

[0052] (3): Then put the hollow carbon nanofibers with borosilicate loaded on the surface into a microwave materials chemistry workstation and perform microwave irradiation treatment at 84 °C for 0.3 h; microwave irradiation can intensify the molecular motion of borosilicate and hollow carbon nanofibers, promote the interaction between the two, make borosilicate more firmly loaded on the surface of the hollow carbon nanofibers, and improve the stability and uniformity of the loading.

[0053] When applied to high-temperature oxidation environments such as kiln lining materials, borosilicate can be quickly oxidized to form a B2O3 glass phase. The B2O3 glass phase has good fluidity at high temperatures and can fill defects such as cracks and voids between hollow carbon nanofibers and between hollow carbon nanofibers and other materials, which is beneficial to reducing problems such as wear and erosion of the material in a high-temperature environment, realizing self-healing of the material, and enhancing the strength of the material. At the same time, a barrier structure can be formed, which is beneficial to improving the thermal shock stability.

[0054] Coated vacuum plasma-treated basalt fibers are obtained by coating the surface of basalt fibers treated by vacuum plasma with a mixture of zinc nitrate and strontium nitrate. The specific steps are as follows:

[0055] (1): Take zinc nitrate and strontium nitrate according to a molar ratio of 1:0.15, add 4 times the total volume of the reactants of water, stir evenly to obtain a coating solution for standby.

[0056] (2): Place the basalt fibers in a vacuum plasma treatment device, evacuate to 10 -4After introducing nitrogen at Pa, turn on the plasma generator to generate plasma. High-energy particles interact with the surface of basalt fibers to modify the surface of basalt fibers. The processing power of the plasma generator is 250 W, and the processing time is 3 min;

[0057] (3): Put the basalt fibers treated by vacuum plasma into the coating solution, coat them by the impregnation method, and then centrifuge, dry, and calcine at 540 °C for 1.6 h to obtain coated vacuum plasma-treated basalt fibers.

[0058] Coating the vacuum plasma-treated basalt fibers with a mixture of zinc nitrate and strontium nitrate is beneficial for the diffusion of zinc and strontium ions into the interior of the fibers and into the lattice structure of the fibers. At the same time, during the calcination process, the chemical composition and crystal structure of the basalt fibers are changed, and a modified layer is formed on the surface of the basalt fibers, which is beneficial for improving the thermal shock stability and enhancing the strength of the material.

[0059] Example 4: Please refer to the Figure 1 of the accompanying drawings of the specification. A method for preparing a preform with a high fiber content includes the following steps:

[0060] Step (1), batching: Weigh 74 parts (corundum) of ceramic base material, 5 parts (446) of metal fiber, 15 parts of the sodium borosilicate composite microwave irradiation modified hollow carbon nanofibers prepared in Example 1, and 6 parts of the coated vacuum plasma-treated basalt fibers prepared in Example 1 according to the raw material ratio.

[0061] Step (2), pulping: Add the raw materials into a stirring tank and add 19% of the total mass of the raw materials of water to make pulp;

[0062] Step (3), forming: Use a forming machine to prepare a preform with a high fiber content.

[0063] Example 5: A method for preparing a preform with a high fiber content includes the following steps:

[0064] Step (1), batching: Weigh 30 parts of ceramic base material (10 parts of corundum, 5 parts of alumina, 5 parts of silicon carbide, 10 parts of mullite), 40 parts (304) of metal fiber, 20 parts of the sodium borosilicate composite microwave irradiation modified hollow carbon nanofibers prepared in Example 2, and 10 parts of the coated vacuum plasma-treated basalt fibers prepared in Example 2 according to the raw material ratio.

[0065] Step (2), pulping: Add the raw materials into a stirring tank and add 22% of the total mass of the raw materials of water to make pulp;

[0066] Step (3), forming: Use a forming machine to prepare a preform with a high fiber content.

[0067] Example 6: A method for preparing a preform with a high fiber content includes the following steps:

[0068] Step (1), batching: Weigh 64 parts of ceramic base material (24 parts of corundum, 20 parts of alumina, 20 parts of silicon carbide), 10 parts of metal fiber (310s), 18 parts of sodium borosilicate composite microwave irradiation modified hollow carbon nanofibers prepared in Example 3, and 8 parts of coated vacuum plasma treated basalt fibers prepared in Example 3 according to the raw material ratio.

[0069] Step (2), pulping: Add the raw materials into a stirring tank and add 20% of the total mass of the raw materials of water for pulping;

[0070] Step (3), forming: Use a forming machine to prepare a preform with a high fiber content.

[0071] Example 7: Different from Example 6, the metal fiber is two of 446, 304, and 310s and is mixed in any proportion.

[0072] Example 8: Different from Example 6, the metal fiber is three of 446, 304, and 310s and is mixed in any proportion.

[0073] Comparative Example 1: Different from Example 3: The sodium borosilicate composite microwave irradiation modified hollow carbon nanofibers are replaced with sodium borosilicate modified hollow carbon nanofibers. The specific steps are as follows:

[0074] (1): Take 20 ml of deionized water in a 50 ml glass bottle, add 6 g of sodium borosilicate, and prepare a 23.08 wt% sodium borosilicate solution for standby;

[0075] (2): Take 15 g of hollow carbon nanofibers, soak them in the sodium borosilicate solution to adsorb sodium borosilicate on the surface of the hollow carbon nanofibers, and then take out the hollow carbon nanofibers and place them in freeze-drying at -30 °C.

[0076] After that, prepare a preform with a high fiber content, including the following steps:

[0077] Step (1), batching: Weigh 64 parts of ceramic base material (24 parts of corundum, 20 parts of alumina, 20 parts of silicon carbide), 10 parts of metal fiber (310s), 18 parts of sodium borosilicate modified hollow carbon nanofibers prepared in Comparative Example 1, and 8 parts of coated vacuum plasma treated basalt fibers prepared in Example 3 according to the raw material ratio.

[0078] Step (2), pulping: Add the raw materials into a stirring tank and add 20% of the total mass of the raw materials of water for pulping;

[0079] Step (3), forming: Use a forming machine to prepare a preform with a high fiber content.

[0080] Comparative Example 2: The difference from Example 6 is that it does not contain coated vacuum plasma-treated basalt fibers.

[0081] To prepare a preform with a high fiber content, the following steps are included:

[0082] Step (1), batching: Weigh 64 parts of ceramic base material (24 parts of corundum, 20 parts of alumina, 20 parts of silicon carbide), 10 parts of metal fiber (310s), and 26 parts of the sodium borosilicate composite microwave-irradiated modified hollow carbon nanofibers prepared in Example 3 according to the raw material ratio.

[0083] Step (2), pulping: Add the raw materials into a stirring tank and add 20% of the total mass of the raw materials of water for pulping;

[0084] Step (3), forming: Use a forming machine to prepare a preform with a high fiber content.

[0085] Comparative Example 3: The difference from Example 6 is that it does not contain sodium borosilicate composite microwave-irradiated modified hollow carbon nanofibers.

[0086] To prepare a preform with a high fiber content, the following steps are included:

[0087] Step (1), batching: Weigh 64 parts of ceramic base material (24 parts of corundum, 20 parts of alumina, 20 parts of silicon carbide), 10 parts of metal fiber (310s), and 26 parts of the coated vacuum plasma-treated basalt fibers prepared in Example 3 according to the raw material ratio.

[0088] Step (2), pulping: Add the raw materials into a stirring tank and add 20% of the total mass of the raw materials of water for pulping;

[0089] Step (3), forming: Use a forming machine to prepare a preform with a high fiber content.

[0090] Comparative Example 4: The difference from Example 3 is that the coated vacuum plasma-treated basalt fibers are replaced with coated basalt fibers. The specific steps are as follows:

[0091] (1): Take zinc nitrate and strontium nitrate according to a molar ratio of 1:0.15, add 4 times the total volume of the reactants of water, stir evenly to obtain a coating solution for standby;

[0092] (2): Put the basalt fibers into the coating solution, after coating by the impregnation method, carry out centrifugation, drying, and calcination at 540 °C for 1.6 h.

[0093] After that, to prepare a preform with a high fiber content, the following steps are included:

[0094] Step (1), batching: Weigh 64 parts of ceramic base material (24 parts of corundum, 20 parts of alumina, 20 parts of silicon carbide), 10 parts of metal fiber (310s), 18 parts of sodium borosilicate composite microwave irradiation modified hollow carbon nanofibers prepared in Example 3, and 8 parts of coated basalt fibers prepared in Comparative Example 4.

[0095] Step (2), pulping: Add the raw materials into a stirring tank and add 20% of the total mass of the raw materials of water for pulping;

[0096] Step (3), forming: Use a forming machine to prepare a preform with a high fiber content.

[0097] Comparative Example 5: The difference from Example 3 is that the coated vacuum plasma treated basalt fibers are replaced with vacuum plasma treated basalt fibers. The specific steps are as follows: Place the basalt fibers in a vacuum plasma treatment device, evacuate to 10 -4 Pa and then introduce nitrogen, turn on the plasma generator to generate plasma, and high-energy particles interact with the surface of the basalt fibers to modify the surface of the basalt fibers. The treatment power of the plasma generator is 250W and the treatment time is 3min.

[0098] Then prepare a preform with a high fiber content, including the following steps:

[0099] Step (1), batching: Weigh 64 parts of ceramic base material (24 parts of corundum, 20 parts of alumina, 20 parts of silicon carbide), 10 parts of metal fiber (310s), 18 parts of sodium borosilicate composite microwave irradiation modified hollow carbon nanofibers prepared in Example 3, and 8 parts of vacuum plasma treated basalt fibers prepared in Comparative Example 5.

[0100] Step (2), pulping: Add the raw materials into a stirring tank and add 20% of the total mass of the raw materials of water for pulping;

[0101] Step (3), forming: Use a forming machine to prepare a preform with a high fiber content.

[0102] Comparative Example 6: The difference from Example 3 is that the coated vacuum plasma treated basalt fibers are replaced with basalt fibers.

[0103] Then prepare a preform with a high fiber content, including the following steps:

[0104] Step (1), batching: Weigh 64 parts of ceramic base material (24 parts of corundum, 20 parts of alumina, 20 parts of silicon carbide), 10 parts of metal fiber (310s), 18 parts of sodium borosilicate composite microwave irradiation modified hollow carbon nanofibers prepared in Example 3, and 8 parts of basalt fibers.

[0105] Step (2), Pulping: Add the raw materials into a stirring tank, and add water accounting for 20% of the total mass of the raw materials for pulping;

[0106] Step (3), Shaping: Use a shaping machine to prepare prefabricated parts with a high fiber content.

[0107] Experimental Examples: Detect the properties (thermal shock stability and compressive strength) of the prefabricated parts with a high fiber content prepared in Examples IV - VI and Comparative Examples I - V. The results are shown in Table 1.

[0108] Table 1 Performance Test Results

[0109] Project Thermal shock stability, water cooling times at 1100°C, times Compressive strength, MPa Example 4 20 141.5 Example 5 18 138.4 Example 6 22 144.3 Comparative Example 1 14 108.6 Comparative Example 2 6 86.6 Comparative Example 3 11 104.5 Comparative Example 4 12 113.6 Comparative Example 5 9 103.2 Comparative Example 6 8 98.7

[0110] As can be seen from Table 1, the compressive strength of Examples IV - VI is between 138.4 - 144.3 MPa, showing good mechanical properties. The compressive strength of Comparative Example I decreases. Microwave irradiation can intensify the molecular movement of sodium borosilicate and hollow carbon nanofibers, promote the interaction between the two, make sodium borosilicate more firmly loaded on the surface of hollow carbon nanofibers, improve the stability and uniformity of the loading, and is conducive to the rapid oxidation of sodium borosilicate to generate B2O3 glass phase in a high-temperature oxidation environment. Since sodium borosilicate is evenly dispersed, it can evenly fill the cracks between hollow carbon nanofibers and between hollow carbon nanofibers and other materials, realizing the self-healing of the material and further enhancing the strength of the material. When Comparative Example II does not contain coated vacuum plasma-treated basalt fibers, the compressive strength drops significantly. This indicates that this fiber plays an important role in enhancing the mechanical properties of the material. After Comparative Example III does not contain sodium borosilicate composite microwave-irradiated modified hollow carbon nanofibers, the compressive strength decreases, indicating that this fiber also plays a role in enhancing the mechanical properties of the material. After replacing the coated vacuum plasma-treated basalt fibers in Comparative Examples IV, V, and VI with coated basalt fibers, vacuum plasma-treated basalt fibers, and basalt fibers respectively, the compressive strength all decreases to a certain extent. It shows that the treatment process has an important influence on the mechanical properties of basalt fibers, and through the combination of coating treatment and vacuum plasma treatment, a synergistic effect is exerted.

[0111] The prefabricated parts with a high fiber content prepared by the present invention have a significantly increased fiber content, and the prefabricated parts have high strength and good thermal shock stability (the number of water cooling times at 1100 °C for thermal shock stability ≥ 18 times), and can be preferably used in the field of furnace linings.

[0112] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements will not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A preform with a high fiber content, characterized in that, It consists of the following raw materials in parts by weight: 30 - 74 parts of ceramic base material, 5 - 40 parts of metal fiber, 15 - 20 parts of sodium borosilicate composite microwave-irradiated modified hollow carbon nanofibers, and 6 - 10 parts of coated vacuum plasma-treated basalt fibers; among them, the sodium borosilicate composite microwave-irradiated modified hollow carbon nanofibers are prepared by microwave irradiation modification after modifying hollow carbon nanofibers with sodium borosilicate; the coated vacuum plasma-treated basalt fibers are obtained by coating the surface of vacuum plasma-treated basalt fibers with a mixture of zinc nitrate and strontium nitrate in a molar ratio of 1:0.1 - 0.

2.

2. The high-fiber-content preform according to claim 1, wherein The preparation steps of the sodium borosilicate composite microwave-irradiated modified hollow carbon nanofibers are as follows: (1): Take 20 ml of deionized water in a 50 ml glass bottle, add 5 - 7 g of sodium borosilicate, and prepare a 20 - 25.93 wt% sodium borosilicate solution for standby. (2): Take 10 - 20 g of hollow carbon nanofibers, soak them in the sodium borosilicate solution to adsorb sodium borosilicate on the surface of the hollow carbon nanofibers, and then take out the hollow carbon nanofibers and freeze-dry them at -40 to -20 °C to obtain hollow carbon nanofibers with sodium borosilicate loaded on the surface. (3): Then put the hollow carbon nanofibers with sodium borosilicate loaded on the surface into a microwave materials chemistry workstation and perform microwave irradiation treatment at 82 - 85 °C for 0.2 - 0.5 h.

3. The high-fiber-content preform according to claim 1, wherein, The preparation steps of the coated vacuum plasma-treated basalt fibers are as follows: (1): Take zinc nitrate and strontium nitrate according to a molar ratio of 1:0.1 - 0.2, add water 3 - 5 times the total volume of the reactants, stir evenly to obtain a coating solution for standby. (2): Place the basalt fiber in a vacuum plasma treatment device, evacuate to 10 -3 ~10 -5 Pa, then introduce nitrogen gas, turn on the plasma generator to generate plasma, and the high-energy particles interact with the surface of the basalt fiber to modify the surface of the basalt fiber; (3): Put the vacuum plasma-treated basalt fibers into the coating solution, coat them by the impregnation method, and then perform centrifugation, drying, and calcination at 500 - 550 °C for 1 - 2 h to obtain the coated vacuum plasma-treated basalt fibers.

4. The high-fiber-content preform according to claim 1, wherein, The ceramic base material is a composition of one or more of corundum, alumina, silicon carbide, and mullite.

5. The high-fiber-content preform according to claim 1, wherein The processing power of the plasma generator is 200 - 350 W, and the processing time is 2 - 5 min.

6. The preform with a high fiber content according to any one of claims 1 to 5, characterized in that, The thermal shock stability of the high-fiber-content preform is ≥18 times of water cooling at 1100 °C, and the compressive strength is 138.4 - 144.3 MPa.

7. A method for preparing a preform with a high fiber content according to claim 6, characterized in that, It includes the following steps: Step (1), batching: Weigh the ceramic base material, metal fiber, sodium borosilicate composite microwave-irradiated modified hollow carbon nanofibers, and coated vacuum plasma-treated basalt fibers according to the raw material ratio. Step (2), pulping: Add the raw materials into a stirring tank and add 19 - 22% of the total mass of the raw materials of water for pulping. Step (3), forming: Use a forming machine to prepare a high-fiber-content preform.

8. A high-fiber-content preform prepared by the preparation method according to claim 7.

9. The application of the high-fiber-content preform according to claim 1, 2, 3, 4, 5, 6 or 8 in the preparation of furnace lining materials.

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