Low-cost environment-friendly fire-resistant thermal insulation coating and preparation method thereof

Abstract

The invention relates to the field of fireproof materials, in particular to a low-cost environment-friendly fireproof thermal insulation coating which comprises the following components in parts by weight: 1-10 parts of sepiolite fabric, 10-20 parts of asbestos, 1-10 parts of aluminum silicate wool, 45-55 parts of wollastonite fiber, 5-15 parts of bentonite, 5-15 parts of perlite, 1-10 parts of an anti-cracking agent, 1-10 parts of a binding agent and 28-35 parts of water. The low-cost environment-friendly fire-resistant heat-preservation coating effectively overcomes the defect that a fire-resistant heat-preservation coating is prone to falling off and cracking in the using process of a glass melting cellar, the service life of the glass melting cellar is greatly prolonged, due to the fact that heat insulation performance and refractoriness are improved, the forming time of glass can be effectively shortened, then production efficiency is improved, and the production cost is reduced within the same time. And the production capacity is increased, and the purposes of energy conservation and environmental protection are achieved.

Description

Technical Field

[0001] The present invention belongs to the field of refractory materials, and in particular relates to a low-cost, environment-friendly, refractory and thermal insulation coating and a preparation method thereof. Background Art

[0002] With the increasing global focus on energy efficiency and environmental protection, the demand for efficient and environmentally friendly insulation materials in the construction and industrial sectors is growing. In particular, in rapidly developing economies such as China, a large number of new buildings and energy-saving renovation projects for existing buildings have emerged, driving the demand for high-performance insulation materials.

[0003] Refractory materials refer to inorganic, non-metallic materials with a refractoriness of 1580°C or higher. Low-cost, environmentally friendly, refractory thermal insulation coatings are becoming increasingly important as a key material for reducing energy loss. Refractory thermal insulation coatings are high-temperature resistant materials widely used in metallurgy, construction, chemical engineering, and other fields.

[0004] With the continuous improvement of scientific and technological levels, the research on the outer lining refractory materials of glass furnaces has become more and more in-depth. It has gradually been discovered that glass furnaces have the following problems: during the use of existing glass furnaces, the working environment of the glass furnace is harsh. Under the action of gas and liquid phases, due to the poor corrosion resistance of existing refractory materials, the outer lining refractory materials often crack and peel, which in turn shortens the service life of the glass furnace. In addition, during the use of glass furnaces, the thermal shock stability of existing outer lining refractory materials is weak. Due to the rapid rise and fall of temperature, the outer lining refractory materials of the furnace are prone to cracks and scratches. Therefore, how to overcome the above-mentioned technical problems and defects has become a key issue that needs to be solved. Summary of the Invention

[0005] The purpose of the present invention is to overcome the defects described in the background technology, thereby realizing a low-cost, environmentally friendly refractory thermal insulation coating to solve the problems of poor erosion resistance, weak thermal shock stability, and easy cracking, peeling, cracks, scratches and other problems of the outer lining refractory materials in the prior art.

[0006] In order to achieve the above-mentioned object of the invention, the technical solution of the present invention is: A low-cost, environmentally friendly, fire-resistant, and thermal-insulating coating comprises the following components in parts by weight: 1-10 parts of sepiolite wool, 10-20 parts of asbestos, 1-10 parts of aluminum silicate wool, 45-55 parts of wollastonite fiber, 5-15 parts of bentonite, 5-15 parts of perlite, 1-10 parts of an anti-cracking agent, 1-10 parts of a binder, and 28-35 parts of water.

[0007] In the above-mentioned low-cost environmentally friendly fire-resistant thermal insulation coating, the anti-cracking agent is a mixture of glass fiber and carbon fiber, and the binder is aluminum sulfate.

[0008] In the above-mentioned low-cost environmentally friendly fire-resistant thermal insulation coating, preferably, the low-cost environmentally friendly fire-resistant thermal insulation coating includes the following components in parts by weight: 5 parts of sepiolite wool, 15 parts of asbestos, 5 parts of aluminum silicate wool, 45 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 3 parts of anti-cracking agent, 7 parts of binder, and 29 parts of water.

[0009] In the above-mentioned low-cost environmentally friendly fire-resistant thermal insulation coating, preferably, the low-cost environmentally friendly fire-resistant thermal insulation coating includes the following components in parts by weight: 3 parts of sepiolite wool, 15 parts of asbestos, 2 parts of aluminum silicate wool, 45 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 5 parts of anti-cracking agent, 10 parts of binder, and 30 parts of water.

[0010] In the above-mentioned low-cost environmentally friendly fire-resistant thermal insulation coating, preferably, the low-cost environmentally friendly fire-resistant thermal insulation coating includes the following components in parts by weight: 5 parts of sepiolite wool, 13 parts of asbestos, 5 parts of aluminum silicate wool, 45 parts of wollastonite fiber, 10 parts of bentonite, 7 parts of perlite, 5 parts of anti-cracking agent, 10 parts of binder, and 30 parts of water.

[0011] In the above-mentioned low-cost environmentally friendly fire-resistant thermal insulation coating, preferably, the low-cost environmentally friendly fire-resistant thermal insulation coating includes the following components in parts by weight: 5 parts of sepiolite wool, 15 parts of asbestos, 5 parts of aluminum silicate wool, 50 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 1 part of anti-cracking agent, 4 parts of binder, and 28 parts of water.

[0012] In the above-mentioned low-cost environmentally friendly fire-resistant thermal insulation coating, preferably, the low-cost environmentally friendly fire-resistant thermal insulation coating includes the following components in parts by weight: 5 parts of sepiolite wool, 15 parts of asbestos, 5 parts of aluminum silicate wool, 50 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 4 parts of anti-cracking agent, 1 part of binder, and 29 parts of water.

[0013] The present invention also discloses a method for preparing the above-mentioned low-cost environmentally friendly fire-resistant thermal insulation coating, the preparation method comprising the following steps: Step 1: crush the raw materials, select sepiolite wool, wollastonite fiber, asbestos, aluminum silicate wool, and perlite, and introduce the raw materials into a grinder for crushing and stirring. The crushing and stirring time is 1-1.5h, and the crushing and stirring temperature is room temperature. After crushing and stirring, a uniform stirring material is obtained; Step 2: Add bentonite, anti-cracking agent, binder and water and the above stirring material to the grinder, control the grinding temperature to between 70-80 ° C, the grinding time is 45min, and after the grinding is completed, let it stand for 1-2h to obtain a coating raw material; Step 3: Secondary stirring: introduce the coating raw materials obtained in the above steps into the mixer and stir evenly for 30 minutes at a stirring temperature of 50-60°C; Step 4: Cooling: Cool the uniformly stirred coating to room temperature to obtain the coating.

[0014] Compared with the prior art, the low-cost, environmentally friendly, fire-resistant and thermal insulation coating of the present invention has at least the following beneficial effects: 1. The low-cost, environmentally friendly, fire-resistant and thermal-insulating coating of the present invention effectively solves the problem of easy peeling and cracking of fire-resistant and thermal-insulating coatings during use in glass melting furnaces, significantly extending the service life of glass melting furnaces. Moreover, due to the improved thermal insulation and refractoriness, it can effectively shorten the glass forming time, thereby improving production efficiency. Within the same time, it increases production volume, achieving the goal of energy conservation and environmental protection.

[0015] 2. The above steps prepare a low-cost, environmentally friendly, fire-resistant, and thermally insulating coating with the aforementioned weight percentages. Specific proportions of sepiolite, wollastonite fiber, asbestos, aluminum silicate wool, and perlite are selected and meticulously ground and stirred, resulting in a final product capable of maintaining effective thermal insulation even under extreme temperatures. This superior thermal insulation not only reduces heat conduction and energy consumption, but also extends equipment life, significantly contributing to energy conservation and consumption reduction in industrial applications. Furthermore, thanks to a rational formulation, the coating achieves high performance at a low cost.

[0016] 3. Furthermore, the low-cost, environmentally friendly, fire-resistant, thermal-insulating coating prepared through the aforementioned steps and containing the aforementioned weight percentages exhibits excellent crack resistance and mechanical strength. These properties make the coating particularly suitable for environments subject to large temperature fluctuations or mechanical stress variations, such as various locations within a glass furnace. DETAILED DESCRIPTION

[0017] The low-cost, environmentally friendly, fire-resistant and thermal insulation coating of the present invention is described in more detail below through specific implementation methods. Example 1

[0018] This embodiment discloses a low-cost, environmentally friendly refractory thermal insulation coating, which is used to solve the problems of poor erosion resistance, weak thermal shock resistance, and susceptibility to cracking, flaking, cracks, and scratches of the outer lining refractory materials in the prior art.

[0019] In this embodiment, the low-cost, environmentally friendly, fire-resistant and thermal insulation coating includes the following components in parts by weight: 1 to 10 parts of sepiolite wool, 10 to 20 parts of asbestos, 1 to 10 parts of aluminum silicate wool, 45 to 55 parts of wollastonite fiber, 5 to 15 parts of bentonite, 5 to 15 parts of perlite, 1 to 10 parts of anti-cracking agent, 1 to 10 parts of binder, and 28 to 35 parts of water.

[0020] In this embodiment, sepiolite wool has good heat resistance and chemical stability, can enhance the structural strength and durability of the coating, and improve the corrosion resistance of the coating. Asbestos is a mineral fiber traditionally used in refractory materials, which provides excellent fire resistance and thermal insulation properties, and improves the refractoriness of the coating. Aluminum silicate wool is a high-performance refractory fiber material with low thermal conductivity, good thermal insulation effect and excellent high temperature resistance, which is used to improve the thermal shock resistance of the coating. Wollastonite fiber, as an inorganic non-metallic material, has high heat resistance and mechanical strength, and can significantly improve the fire resistance and physical strength of the coating. Perlite has good thermal insulation and high physical and chemical stability. Bentonite is used to prevent production defects and improve production quality.

[0021] In this embodiment, the anti-cracking agent is a mixture of glass fiber and carbon fiber, and the binder is aluminum sulfate. Using a mixture of glass fiber and carbon fiber as an anti-cracking agent can effectively reduce the formation of cracks in the coating during the curing process and long-term use, ensuring the durability and reliability of the coating and preventing cracking during the casting process. Aluminum sulfate can form a stable aluminum oxide layer at high temperatures, increasing the heat resistance and chemical stability of the coating. Use as a binder can provide good fire resistance. At the same time, aluminum sulfate is not easy to burn and does not produce harmful gases, making it safer and more environmentally friendly.

[0022] Specifically, the low-cost, environmentally friendly, fire-resistant and thermal insulation coating described in this embodiment specifically includes the following components, in parts by mass: 5 parts of sepiolite wool, 15 parts of asbestos, 5 parts of aluminum silicate wool, 45 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 3 parts of anti-cracking agent, 7 parts of binder, and 29 parts of water.

[0023] The addition of a relatively high amount of binder helps enhance the coating's adhesion and structural stability. Meanwhile, an appropriate amount of anti-cracking agent effectively reduces the risk of cracking. The combination of asbestos and aluminum silicate wool provides excellent thermal insulation, making it suitable for areas requiring both good bonding and crack resistance, such as the sidewalls or roof of glass furnaces, which may experience significant temperature fluctuations and require high crack resistance. Furthermore, this formulation is suitable for use in critical areas to prevent heat loss.

[0024] This embodiment also discloses a method for preparing a low-cost, environmentally friendly, fire-resistant, and thermal-insulating coating having the above-mentioned weight percentage components, comprising the following steps: Step 1: crush the raw materials, select sepiolite wool, wollastonite fiber, asbestos, aluminum silicate wool, and perlite, and introduce the raw materials into a grinder for crushing and stirring. The crushing and stirring time is 1-1.5h, and the crushing and stirring temperature is room temperature. After crushing and stirring, a uniform stirring material is obtained; Step 2: Add bentonite, anti-cracking agent, binder and water and the above stirring material to the grinder, control the grinding temperature to between 70-80 ° C, the grinding time is 45min, and after the grinding is completed, let it stand for 1-2h to obtain a coating raw material; Step 3: Secondary stirring: introduce the coating raw materials obtained in the above steps into the mixer and stir evenly for 30 minutes at a stirring temperature of 50-60°C; Step 4: Cooling: Cool the uniformly stirred coating to room temperature to obtain the coating.

[0025] The low-cost, environmentally friendly fire-resistant and thermal insulation coating prepared through the above steps, with the aforementioned weight percentage composition, achieves multiple advantages, including high strength, high-temperature resistance, thermal insulation, strong crack resistance, and environmental friendliness in high-temperature environments. Not only does it exhibit excellent high-temperature resistance and thermal insulation properties, but it also possesses excellent construction adaptability and environmental friendliness, making it suitable for protective needs in a variety of industrial scenarios, particularly those with strict fire-resistant and thermal insulation requirements, such as glass furnaces. It meets the modern industrial requirements for high efficiency, environmental protection, and cost-effectiveness.

[0026] In addition, it should be noted that when preparing low-cost, environmentally friendly refractory and thermal insulation coatings through the above steps, first select a refractory material or a kiln lining as the base material and treat the surface of the base material to ensure that the base material surface is clean, flat, and free of oil stains and impurities. Then, use spraying, brushing, or rolling to evenly apply the coating to the surface of the base material, paying attention to controlling the thickness and uniformity of the coating. Finally, dry the coating according to the curing requirements to ensure that the coating is completely cured and forms a stable insulation layer. After completing the above basic work, the thermal insulation performance, thermal shock resistance, and oxidation resistance of the coating can be tested and evaluated. Example 2

[0027] The same points as the above embodiment are not repeated here, but the differences are as follows: In this embodiment, the low-cost, environmentally friendly, fire-resistant and thermal insulation coating includes the following components in parts by weight: 3 parts of sepiolite wool, 15 parts of asbestos, 2 parts of aluminum silicate wool, 45 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 5 parts of anti-cracking agent, 10 parts of binder, and 30 parts of water.

[0028] Compared with Example 1, in this embodiment, the amount of sepiolite wool and aluminum silicate wool is reduced, and the ratio of the anti-cracking agent to the binder is increased. More binder can further improve the mechanical strength of the coating, and more anti-cracking agent can enhance the coating's ability to resist cracks.

[0029] The low-cost, environmentally friendly, fire-resistant and thermal insulation coating made from the above-mentioned weight percentage components is particularly suitable for places where high coating strength requirements are required and cracks are easily generated, such as the bottom or supporting structure of a glass furnace. Example 3

[0030] The same points as the above embodiment will not be repeated here, but the differences are as follows: In this embodiment, the low-cost, environmentally friendly, fire-resistant and thermal insulation coating includes the following components in parts by weight: 5 parts of sepiolite wool, 13 parts of asbestos, 5 parts of aluminum silicate wool, 45 parts of wollastonite fiber, 10 parts of bentonite, 7 parts of perlite, 5 parts of anti-cracking agent, 10 parts of binder, and 30 parts of water.

[0031] Compared to Example 2, in this example, the asbestos content is slightly reduced, and the amount of perlite is reduced, but the ratio of the anti-cracking agent to the binder is maintained. Such adjustments can reduce costs without affecting the strength of the coating.

[0032] The coating created with these weight percentages offers a relatively balanced composition, making it suitable for low-cost projects, particularly those seeking to reduce material costs without sacrificing overall coating performance. It can be applied to non-critical stress-bearing areas of glass furnaces, such as sidewalls, where cost control is more important. Example 4

[0033] The same points as the above embodiment will not be repeated here, but the differences are as follows: The low-cost, environmentally friendly, fire-resistant and thermal insulation coating comprises the following components in parts by weight: 5 parts of sepiolite wool, 15 parts of asbestos, 5 parts of aluminum silicate wool, 50 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 1 part of anti-cracking agent, 4 parts of binder, and 28 parts of water.

[0034] In this embodiment, the amount of wollastonite fiber is increased, and the coating has better heat resistance and lower thermal conductivity, thereby providing better thermal insulation effect.

[0035] Although the ratio of the anti-cracking agent and the binder is reduced, the refractory thermal insulation coating prepared according to the ingredients of this embodiment is very suitable for use as a high-temperature insulation layer when no additional mechanical strength support is required, such as certain specific heating areas of a glass furnace, where the main focus is on minimizing heat loss rather than mechanical strength. Example 5

[0036] The same points as the above embodiment will not be repeated here, but the differences are as follows: The low-cost, environmentally friendly, fire-resistant and thermal insulation coating comprises the following components in parts by weight: 5 parts of sepiolite wool, 15 parts of asbestos, 5 parts of aluminum silicate wool, 50 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 4 parts of anti-cracking agent, 1 part of binder, and 29 parts of water.

[0037] This embodiment also uses a high proportion of wollastonite fiber, but slightly increases the amount of anti-cracking agent to 4 parts, which makes the coating have excellent thermal insulation performance and can prevent cracking to a certain extent.

[0038] It is suitable for situations where a balance between thermal insulation effect and a certain degree of crack resistance is required, such as the location of a glass kiln close to the combustion chamber, which can ensure efficient thermal insulation while avoiding cracks caused by temperature fluctuations.

[0039] In summary, the following Table 1 is obtained: Element Example 1 Example 2 Example 3 Example 4 Example 5 Sepiolite (parts) 5 3 5 5 5 Asbestos (parts) 15 15 13 15 15 Aluminum silicate wool (parts) 5 2 5 5 5 Wollastonite fiber (parts) 45 45 45 50 50 Bentonite (parts) 10 10 10 10 10 Perlite (parts) 10 10 7 10 10 Anti-cracking agent (parts) 3 5 5 1 4 Binder (parts) 7 10 10 4 1 Water (parts) 29 30 30 28 29 The performance of the low-cost, environmentally friendly, fire-resistant and thermal insulation coatings prepared from the multiple groups of examples in Table 1 above was tested. The thermal conductivity was tested in accordance with the "Test Method for Thermal Conductivity of Refractory Materials (Water Flow Plate Method) YB / T 4130-2005"; the thermal shock resistance was tested in accordance with the "Test Method for Thermal Shock Resistance of Refractory Materials GB / T 30873-2014". After testing, the following Table 2 was obtained: From Table 1 and Table 2 above, we can conclude that: The low-cost, environmentally friendly, fire-resistant and thermal insulation coating made from the components of Examples 1, 2, 3, 4, and 5 can effectively improve thermal shock resistance, crack resistance, and oxidation resistance compared to the existing technology. It can be seen that the component contents of Examples 1, 2, 3, 4, and 5 are reasonable, and Example 3 is the best example.

[0040] In addition, it should be noted that the preparation ingredients of Examples 1, 2, 3, 4, and 5 of this specification are not unique and unchanging data. This specification only lists the mass percentage data of the preparation raw materials of the most representative, better-performing coatings suitable for five different scenarios.

[0041] Unless otherwise defined, technical or scientific terms used herein shall have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0042] The exemplary embodiments of the present invention are described in detail above with reference to preferred embodiments. The scope of protection of the present invention is not limited thereto. Those skilled in the art will understand that, without departing from the concept of the present invention, various modifications and variations can be made to the above-mentioned specific embodiments, and various combinations of the various technical features proposed in the present invention can be made without exceeding the scope of protection of the present invention.

Claims

1. A low-cost, environmentally friendly, fire-resistant and thermal insulation coating, characterized in that: The low-cost, environmentally friendly, fire-resistant and thermal insulation coating includes the following components in parts by weight: 1-10 parts of sepiolite wool, 10-20 parts of asbestos, 1-10 parts of aluminum silicate wool, 45-55 parts of wollastonite fiber, 5-15 parts of bentonite, 5-15 parts of perlite, 1-10 parts of an anti-cracking agent, 1-10 parts of a binder, and 28-35 parts of water.

2. The low-cost, environmentally friendly, fire-resistant and thermal insulation coating according to claim 1, characterized in that: The anti-cracking agent is a mixture of glass fiber and carbon fiber, and the binder is aluminum sulfate.

3. The low-cost, environmentally friendly, fire-resistant and thermal insulation coating according to claim 2, characterized in that: The low-cost, environmentally friendly, fire-resistant and thermal insulation coating comprises the following components in parts by weight: 5 parts of sepiolite wool, 15 parts of asbestos, 5 parts of aluminum silicate wool, 45 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 3 parts of an anti-cracking agent, 7 parts of a binder, and 29 parts of water.

4. The low-cost, environmentally friendly, fire-resistant and thermal insulation coating according to claim 2, characterized in that: The low-cost, environmentally friendly, fire-resistant and thermal insulation coating includes the following components in parts by weight: 3 parts of sepiolite wool, 15 parts of asbestos, 2 parts of aluminum silicate wool, 45 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 5 parts of an anti-cracking agent, 10 parts of a binder, and 30 parts of water.

5. The low-cost, environmentally friendly, fire-resistant and thermal insulation coating according to claim 2, characterized in that: The low-cost, environmentally friendly, fire-resistant and thermal insulation coating includes the following components in parts by weight: 5 parts of sepiolite wool, 13 parts of asbestos, 5 parts of aluminum silicate wool, 45 parts of wollastonite fiber, 10 parts of bentonite, 7 parts of perlite, 5 parts of anti-cracking agent, 10 parts of binder, and 30 parts of water.

6. The low-cost, environmentally friendly, fire-resistant and thermal insulation coating according to claim 2, characterized in that: The low-cost, environmentally friendly, fire-resistant and thermal insulation coating comprises the following components in parts by weight: 5 parts of sepiolite wool, 15 parts of asbestos, 5 parts of aluminum silicate wool, 50 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 1 part of anti-cracking agent, 4 parts of binder, and 28 parts of water.

7. The low-cost, environmentally friendly, fire-resistant and thermal insulation coating according to claim 2, characterized in that: The low-cost, environmentally friendly, fire-resistant and thermal insulation coating comprises the following components in parts by weight: 5 parts of sepiolite wool, 15 parts of asbestos, 5 parts of aluminum silicate wool, 50 parts of wollastonite fiber, 10 parts of bentonite, 10 parts of perlite, 4 parts of anti-cracking agent, 1 part of binder, and 29 parts of water.

8. A method for preparing a low-cost, environmentally friendly, fire-resistant and thermal insulation coating, characterized in that: The steps include: Step 1: crush the raw materials, select sepiolite wool, wollastonite fiber, asbestos, aluminum silicate wool, and perlite, and introduce the raw materials into a grinder for crushing and stirring. The crushing and stirring time is 1-1.5h, and the crushing and stirring temperature is room temperature. After crushing and stirring, a uniform stirring material is obtained; Step 2: Add bentonite, anti-cracking agent, binder and water and the above stirring material to the grinder, control the grinding temperature to between 70-80 ° C, the grinding time is 45min, and after the grinding is completed, let it stand for 1-2h to obtain a coating raw material; Step 3: Secondary stirring: introduce the coating raw materials obtained in the above steps into the mixer and stir evenly for 30 minutes at a stirring temperature of 50-60°C; Step 4: Cooling: Cool the uniformly stirred coating to room temperature to obtain the coating.

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