High-temperature fire-resistant thermal insulation material and preparation method thereof

Abstract

The invention provides a high-temperature fire-resistant thermal insulation material and a preparation method thereof, and the high-temperature fire-resistant thermal insulation material comprises the following raw materials in percentage by mass: 23-27% of magnesian mud, 23-27% of waste rollers, 23-27% of refractory brick particles, 13-17% of calcined talc, 3-7% of coal water slurry ash and 3-7% of porcelain powder. According to the formula, the high-aluminum solid waste raw material is adopted as the high-temperature fire-resistant thermal insulation material, the high-temperature fire-resistant thermal insulation material which can be recycled infinitely can be prepared, crushing is avoided while the state of a kiln is stabilized, the problem that waste green bricks are directly used for stabilizing the sintering atmosphere of the kiln after the kiln is empty is solved, and the production cost is reduced. The problems that part of waste green bricks are broken after being fired and taken out of a kiln due to moisture absorption of air or insufficient strength, cleaning is difficult, potential safety hazards exist, cyclic utilization cannot be achieved, and heat preservation plates sold in the market are high in cost are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ceramic production, in particular to a high-temperature refractory insulating material and a preparation method thereof. BACKGROUND

[0002] In the ceramic production process, due to equipment failure, power failure, weather and other irresistible factors, the kiln may be empty. If the green brick is directly put into the kiln for trial firing after the kiln is empty, the color and shape of the product are unstable 8-15 minutes after the product is taken out of the kiln due to the influence of factors such as the temperature, atmosphere and airflow instability of the kiln, and the physical properties of the product are also unstable, resulting in a large number of low-grade products, which increases the production cost. Therefore, a part of the waiting brick is needed to be added before the normal green brick is put into the kiln, so that the state of the kiln tends to be stable, and then the normal decorated green brick is put into the kiln for firing.

[0003] At present, the abandoned green bricks (such as those with missing corners and flaws) collected before are used as waiting bricks for trial firing after the kiln is empty, so that the firing atmosphere of the kiln is gradually stabilized. However, these collected abandoned green bricks are naturally placed on the green brick rack for use, and the waiting time in the natural environment is different. When they are added into the kiln for trial firing, 40-50% of the green bricks will be cracked due to moisture absorption of air or insufficient strength. Therefore, the handling of the cracked green bricks needs a second cleaning of the site, is easy to cause injury, and the cracked green bodies cannot be used again. In addition, the Mohs hardness of the trial fired green bricks after high-temperature porcelainization is greater than 5, which is difficult to crush and recycle.

[0004] Of course, the waiting brick can also be an insulating board. Such an insulating board should have the properties of part of high-temperature refractory materials, and also needs to have the properties of not softening and deforming at high temperature, stable shrinkage, good thermal shock resistance, rapid cooling and heating performance, etc. However, such an insulating board is relatively expensive to purchase on the market.

[0005] Therefore, the prior art has defects and needs to be improved and developed. SUMMARY

[0006] The technical problem to be solved by the present application is to provide a high-temperature refractory insulating material and a preparation method thereof, aiming at solving the problem that the prior art directly uses abandoned green bricks to stabilize the firing atmosphere of the kiln after the kiln is empty, some abandoned green bricks are cracked due to moisture absorption of air or insufficient strength when they are taken out of the kiln, which is difficult to clean, has safety hazards, and cannot be recycled, and the problem that the insulating board sold on the market is expensive.

[0007] The technical solution adopted by the present application to solve the technical problem is as follows: The first aspect of the present application provides a high-temperature refractory insulation material, wherein the raw materials of the high-temperature refractory insulation material comprise, in percentage by mass: magnesia mud 23-27%, waste roller 23-27%, refractory brick particles 23-27%, calcined talc 13-17%, coal water slurry ash residue 3-7%, and porcelain powder 3-7%.

[0008] In an embodiment of the present application, the chemical composition of the high-temperature refractory insulation material comprises, in percentage by mass: SiO2 39-40%, Al2O3 41-42%, Fe2O3 1-1.5%, CaO 1-1.5%, MgO 11-12%, K2O 0.2-0.4%, Na2O 0.5-0.6%, and loss on ignition 3-4%.

[0009] In an embodiment of the present application, the chemical composition of the magnesia mud comprises, in percentage by mass: SiO2 58-62%, Al2O3 5-10%, Fe2O3 0-3%, CaO 0-3%, MgO 20-27%, K2O 0-3%, Na2O 0-3%, and loss on ignition 6-10%; The chemical composition of the waste roller comprises, in percentage by mass: SiO2 20-25%, Al2O3 68-76%, Fe2O3 0-3%, CaO 0-3%, MgO 0-5%, K2O 0-3%, Na2O 0-3%, and loss on ignition 0-5%; The chemical composition of the refractory brick particles comprises, in percentage by mass: SiO2 27-33%, Al2O3 55-65%, Fe2O3 0-3%, CaO 0-3%, MgO 0-5%, K2O 0-3%, Na2O 0-3%, and loss on ignition 0-5%; The chemical composition of the calcined talc comprises, in percentage by mass: SiO2 55-59%, Al2O3 0-5%, Fe2O3 0-3%, CaO 0-3%, MgO 25-35%, K2O 0-3%, Na2O 0-3%, and loss on ignition 8-12%; The chemical composition of the coal water slurry ash residue comprises, in percentage by mass: SiO2 48-52%, Al2O3 28-36%, Fe2O3 0-3%, CaO 8-13%, MgO 0-5%, K2O 0-3%, Na2O 0-3%, and loss on ignition 0-5%; The chemical composition of the porcelain powder comprises, in percentage by mass: SiO2 67~71 %, Al2O3 18~26 %, Fe2O3 0~3 %, CaO 0~3 %, MgO 0~5 %, K2O 0~3 %, Na2O 0~3 %, loss on ignition 0~5 %.

[0010] In one embodiment of the present application, the mineral composition of the refractory brick particles comprises, by mass percentage: mullite 10~15 %, corundum 30~45 %, glass phase 20~30 %, quartz and / or cristobalite 10~20 %, other impurities 5~10 %.

[0011] In one embodiment of the present application, the mineral composition of the waste roller comprises, by mass percentage: mullite 10~15 %, corundum 40~60 %, glass phase 5~10 %, quartz and / or cristobalite 5~10 %, other impurities 5~10 %.

[0012] In one embodiment of the present application, the crystal phase of the high-temperature refractory insulation material comprises: magnesium aluminate spinel, periclase, forsterite, mullite and corundum.

[0013] The second aspect embodiment of the present application provides a preparation method of a high-temperature refractory insulation material, wherein the method comprises: mixing, by mass percentage, magnesia clay 23~27 %, waste roller 23~27 %, refractory brick particles 23~27 %, calcined talc 13~17 %, coal water slurry ash 3~7 %, and porcelain powder 3~7 % to obtain a slurry; screening the slurry to remove iron and then grinding to obtain a powder; firing the powder after compression molding to obtain the high-temperature refractory insulation material.

[0014] In one embodiment of the present application, the moisture content of the slurry is 34~36 %, the flow rate is 55~90 s, the specific gravity is 1.70~1.75 g / ml, and the fineness is 325 mesh residue 3~5 % measured by a four-cup viscometer.

[0015] In one embodiment of the present application, the high-temperature refractory insulation material is obtained by firing the powder after compression molding, comprising: firing the powder after compression molding under the conditions of magnesium high-temperature flux and a kiln temperature of 1210~1230 ℃ to obtain the high-temperature refractory insulation material.

[0016] In one embodiment of the present application, the high-temperature refractory insulation material is a heat insulation plate for a ceramic roller kiln.

[0017] The application discloses a high-temperature refractory thermal insulation material and a preparation method thereof, and the raw material of the high-temperature refractory thermal insulation material comprises, in percentage by mass, 23-27% of magnesia mud, 23-27% of waste roller, 23-27% of refractory brick particles, 13-17% of calcined talc, 3-7% of coal water slurry ash, and 3-7% of porcelain powder. The high-temperature refractory thermal insulation material prepared by using the high-aluminum solid waste raw material as the formula of the high-temperature refractory thermal insulation material can be used infinitely, can not be broken in the stable kiln state, solves the problem of the sintering atmosphere of the kiln stabilized by directly using the waste brick blank after the kiln is empty, and solves the problems of the broken waste brick blank due to the moisture of the hygroscopic air or the insufficient strength, the difficulty in cleaning, the safety hazard, the impossibility of recycling, and the high cost of the thermal insulation board sold on the market. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 It is a flow chart of the preferable embodiment of the preparation method of the high-temperature refractory thermal insulation material in the application. DETAILED DESCRIPTION

[0019] In order to make the purpose, technical scheme and advantages of the application more clear and definite, the application is further described in detail below with reference to the drawings and examples. It should be understood that the specific examples described herein are only used to explain the application, and are not used to limit the application.

[0020] For the problem of the sintering atmosphere of the kiln stabilized by directly using the waste brick blank after the kiln is empty in the prior art, the waste brick blank is broken due to the moisture of the hygroscopic air or the insufficient strength, it is difficult to clean, there is a safety hazard, recycling is impossible, and the thermal insulation board sold on the market is high in cost. Some high-aluminum solid waste raw materials in ceramic production, such as waste roller, refractory brick, alumina fiber cotton, coal water slurry ash, broken porcelain powder and other difficult-to-treat and difficult-to-degrade raw materials, can be used to prepare the thermal insulation board which can be used infinitely, solve the problem of material waste in the process of adjusting the sintering atmosphere of the kiln to the stable state after the kiln is empty, and solve the problem of the original solid waste raw material which needs to be paid for external transportation and treatment. The example of the application can prepare the thermal insulation board which can be used infinitely through formula debugging and a reasonable process flow. The application example provides a high-temperature refractory thermal insulation material, and the raw material of the high-temperature refractory thermal insulation material comprises, in percentage by mass, 23-27% of magnesia mud, 23-27% of waste roller, 23-27% of refractory brick particles, 13-17% of calcined talc, 3-7% of coal water slurry ash, and 3-7% of porcelain powder.

[0021] The embodiment of the application uses low-price magnesium clay raw materials and high-alumina solid waste materials with high-temperature resistance as raw materials, such as kiln waste rods, waste refractory bricks after kiln wall maintenance, coal water slurry ash, broken ceramic powder, etc., to form ceramic conventional powder after processing of the raw materials. Exemplarily, the magnesium clay is also called magnesium cementing material or magnesium cement, mainly including magnesium oxychloride cement, magnesium oxysulfide cement, magnesium phosphate cement, etc., and its characteristics are light weight, high strength, excellent mechanical properties, good fire resistance and heat insulation. The waste roller rod refers to the waste formed in the production process of ceramic roller rods, and the waste ceramic roller rod contains a high amount of alumina and has high utilization value. The refractory brick particles are granular materials formed after breaking of the refractory bricks, and the refractory bricks are refractory materials with certain shape and size; the refractory brick particles can maintain stable performance at high temperature and have good corrosion resistance to chemical substances such as acids and bases and can withstand certain mechanical action. The calcined talc is a material formed after talc is calcined at high temperature, and after calcination, the whiteness is enhanced, the particle distribution is uniform, the surface is smooth and glossy, the color does not change at high temperature, and the chemical properties are stable. The coal water slurry ash is generated by a coal water slurry boiler and generally has three forms of dry ash, wet ash and slurry ash.

[0022] The embodiment of the application uses high-alumina solid waste raw materials as the formula of high-temperature refractory insulation materials, which can prepare high-temperature refractory insulation materials that can be used infinitely, and the high-temperature refractory insulation materials will not be broken while stabilizing the kiln state, solving the problem of directly using waste dry billets to stabilize the firing atmosphere of the kiln after the kiln is empty, and part of the waste brick billets will be broken after being fired out of the kiln due to the moisture of the absorbed air or insufficient strength, which is difficult to clean and has safety hazards, and cannot be recycled, and the problem of high cost of the insulation boards sold on the market.

[0023] In the embodiment of the application, the chemical composition of the high-temperature refractory insulation material includes, by mass percentage: SiO239~40%, Al2O341~42%, Fe2O31~1.5%, CaO 1~1.5%, MgO 11~12%, K2O 0.2~0.4%, Na2O 0.5~0.6%, and loss on ignition 3~4%.

[0024] In the chemical composition of the high-temperature refractory insulation material, the total content of potassium oxide (K2O), sodium oxide (Na2O), and iron oxide (Fe2O3) as low-temperature fluxing agents is ≤3.0±0.2%, the content of aluminum oxide (Al2O3) is >40%, and the content of magnesium oxide (MgO) is >10%. At a high temperature of 1220℃ in the kiln (173 Fukelu ring temperature 1145~1150℃), the new crystal phase can be fully formed, and when recycled later, the temperature should be higher than this temperature to participate in other reactions, and even if it participates in other reactions, it will still maintain the original crystal phase filled in the high-temperature refractory insulation material.

[0025] In one embodiment of this application, the chemical composition of the magnesia mud, by mass percentage, includes: SiO2 58~62%, Al2O3 5~10%, Fe2O3 0~3%, CaO 0~3%, MgO 20~27%, K2O 0~3%, Na2O 0~3%, Loss on ignition 6~10%; The chemical composition of the waste roller bar, by mass percentage, includes: SiO2 20~25%, Al2O3 68~76%, Fe2O3 0~3%, CaO 0~3%, MgO 0~5%, K2O 0~3%, Na2O 0~3%, Loss on ignition 0~5%; The chemical composition of the refractory brick particles, by mass percentage, includes: SiO2 27-33%, Al2O3 55-65%, Fe2O3 0-3%, CaO 0-3%, MgO 0-5%, K2O 0-3%, Na2O 0-3%, Loss on ignition 0-5%; The chemical composition of the calcined talc, by mass percentage, includes: SiO2 55~59%, Al2O3 0~5%, Fe2O3 0~3%, CaO 0~3%, MgO 25~35%, K2O 0~3%, Na2O 0~3%, Loss on ignition 8~12%; The chemical composition of the coal-water slurry ash residue, by mass percentage, includes: SiO2 48~52%, Al2O3 28~36%, Fe2O3 0~3%, CaO 8~13%, MgO 0~5%, K2O 0~3%, Na2O 0~3%, Loss on ignition 0~5%; The chemical composition of the ceramic powder, by mass percentage, includes: SiO2 67~71%, Al2O3 18~26%, Fe2O3 0~3%, CaO 0~3%, MgO 0~5%, K2O 0~3%, Na2O 0~3%, Loss on ignition 0~5%.

[0026] Based on the chemical composition of magnesia mud, waste rollers, refractory brick particles, calcined talc, coal-water slurry ash, and ceramic powder, the high-temperature refractory insulation material obtained in this application has certain flexural strength, high-temperature resistance without softening or deformation at high temperatures, low expansion coefficient and shrinkage stability, and good thermal shock resistance and rapid heating and cooling performance. It can be recycled and the number of times is unlimited.

[0027] In this embodiment of the application, the mineral composition of the refractory brick particles, by mass percentage, includes: Mullite 10-15%, corundum 30-45%, glass phase 20-30%, quartz and / or cristobalite 10-20%, other impurities 5-10%.

[0028] The mineral composition of the refractory brick particles in the embodiments of the present application includes 30-45% corundum, which has very high hardness and chemical stability, and serves as the main crystal phase of the refractory material, thereby providing excellent high-temperature strength, thermal shock resistance and chemical corrosion resistance; mullite has a low thermal expansion coefficient and good thermal shock resistance, can form an interlocking structure with corundum, relieve thermal stress, reduce the risk of cracking, and at the same time improve the high-temperature stability of the material.

[0029] In the embodiments of the present application, the mineral composition of the waste roller includes, by mass percentage: Mullite 10-15%, corundum 40-60%, glass phase 5-10%, quartz and / or cristobalite 5-10%, other impurities 5-10%.

[0030] The corundum content of the waste roller in the embodiments of the present application is very high, which can provide stronger high-temperature creep resistance and chemical corrosion resistance.

[0031] In the embodiments of the present application, the crystal phase of the high-temperature refractory insulation material includes magnesium aluminate spinel, periclase, forsterite, mullite and corundum.

[0032] Specifically, low-valence magnesia clay raw materials and high-alumina solid waste materials with high-temperature resistance are used as raw materials, and after molding by a press, magnesium aluminate spinel, periclase, forsterite, mullite, corundum and other high-temperature stable composite crystal phase high-temperature refractory insulation materials are formed under the conditions of magnesium high-temperature fluxing agent and kiln 1220±10℃ high-temperature conditions.

[0033] Among them, the crystal structure of magnesium aluminate spinel is isometric, the atomic arrangement is close, the bond energy is strong, the melting point is high, the thermal expansion coefficient is low, which can reduce the thermal stress at high temperature, avoid cracking, the crystal structure is stable, and can resist sudden temperature changes. The crystal structure of forsterite is orthorhombic, which is mostly short columnar or thick plate-like, the crystal structure of mullite is an aluminosilicate high-temperature solid solution, which is needle-like or radiating cluster-like, the chemical composition is stable, the AI2O3 content is high, the structure is stable at high temperature, and the deformation is reduced, and the resistance to acid and alkali corrosion is strong. Corundum has high chemical stability to acid and alkali, metal melt, high mechanical strength and good wear resistance.

[0034] The crystal phase of the embodiment of the present application includes magnesium aluminum spinel, periclase, forsterite, mullite and corundum, the melting point of all the crystal phases is more than 1800 DEG C, which improves the stability of the material at high temperature; the thermal conductivity of mullite and forsterite is low, which reduces heat transfer and improves the heat preservation effect; the crystal structure of spinel and mullite relieves thermal stress and avoids cracking; corundum and mullite have strong resistance to acid and alkali and molten slag, which prolongs the service life of the material; through composite addition (such as magnesium aluminum spinel + periclase), the thermal expansion coefficient and corrosion resistance are optimized.

[0035] The high-temperature refractory insulation material has certain flexural strength, high-temperature performance of not softening and not changing shape at high temperature, low expansion coefficient and shrinkage stability, and good thermal shock resistance, rapid cooling and heating performance, and can be recycled without limitation on the number of times.

[0036] Please refer to Figure 1 , Figure 1 is a flow chart of the preparation method of the high-temperature refractory insulation material in the present application. As shown in Figure 1 , the method comprises the following steps: Step S100, according to the mass percentage, 23-27% of magnesia mud, 23-27% of waste roller, 23-27% of refractory brick particles, 13-17% of calcined talc, 3-7% of coal water slurry ash, and 3-7% of porcelain powder are mixed to prepare a slurry.

[0037] Specifically, the present application uses a certain proportion of magnesia mud, and the ingredients are mixed according to the blank formula ratio, a certain amount of water reducing agent is added, and the processing process has a certain suspensibility to form a flowable ceramic slurry.

[0038] In the embodiment of the present application, the moisture content of the slurry is 34-36%, the flow rate measured by a four-cup viscometer is 55-90 s, the specific gravity is 1.70-1.75 g / ml, and the fineness is 3-5% on a 325 mesh screen.

[0039] Specifically, the fineness of the slurry can reflect the firing temperature and shrinkage rate of the body to a certain extent during the kiln firing stage. Within a certain range, the finer the fineness of the slurry, the lower the firing temperature of the body. There are two ways to reflect the fineness of the slurry, one is to detect the slurry with a 325 mesh standard screen, and the other is to detect the particle size by particle size analysis, which can observe the particle size distribution state of D50 and D90. The particle size analysis of the slurry is shown in Tables 1 and 2.

[0040] Table 1

[0041] Table 2

[0042] The application embodiment prepares high-temperature refractory insulation materials with good performance by controlling parameters of the slurry.

[0043] As shown in the method for preparing the high-temperature refractory insulation material, Figure 1 the method further comprises the following steps: In step S200, the slurry is screened and iron is removed, and then the slurry is ground to obtain a powder.

[0044] Specifically, when the slurry is screened and iron is removed, the slurry is screened through two layers of screens (30+60 mesh screens), which can screen out harmful coarse particles, mica sheets, impurities, wood chips, fibers and other substances in the raw materials, and prevent the screens from being damaged and the slurry from being incompletely screened, thereby blocking the spray tower nozzles. The function of iron removal is to remove as many fine iron-containing mineral particles in the slurry as possible, effectively preventing the melting temperature from being reduced, the local premature melting reaction from being caused, the blister and impurity and bulge defects from being caused, and the service life of the high-temperature refractory insulation material from being affected.

[0045] As shown in the method for preparing the high-temperature refractory insulation material, Figure 1 the method further comprises the following steps: In step S300, the powder is pressed and formed, and then is fired to obtain the high-temperature refractory insulation material.

[0046] In the application embodiment, the step S300 specifically comprises: the powder is pressed and formed, and then is fired in a kiln with a magnesium high-temperature fluxing agent and at a temperature of 1210-1230℃ to obtain the high-temperature refractory insulation material.

[0047] The magnesium high-temperature fluxing agent (magnesium-based fluxing agent) is a kind of material with magnesium oxide or magnesium-containing compounds as core components, which can optimize the high-temperature process by reducing the melting point of the material or promoting the melting reaction.

[0048] Specifically, the magnesium high-temperature fluxing agent is used in the application embodiment, and the magnesia slurry mainly contains magnesium silicates (such as talc and magnesite). After being mixed with alumina, the magnesium oxide (MgO) and the alumina (Al2O3) generate the magnesium aluminate spinel (MgAl2O4) through a solid-phase reaction at high temperature (usually >1000℃). When there is silicon dioxide (SiO2) in the system (such as talc containing SiO2), the MgSiO3 (enstatite) is generated at 1200-1300℃, and the cordierite (Mg2Al4Si5O 18 ), which enhances the thermal shock stability, and the low thermal expansion of the spinel and the cordierite (the thermal expansion coefficient of the spinel is 7×10 -6The K) can reduce thermal stress cracking and improve mechanical strength. In the magnesium-aluminum refractory material, the magnesium-aluminum spinel can improve the high-temperature strength, thermal shock resistance and slag corrosion resistance of the refractory material, and can inhibit the growth and recrystallization of periclase crystals at high temperature, and enhance the structural stability of the material. The total content of low-temperature fluxing agents such as potassium oxide, sodium oxide and iron oxide is also controlled. The low-temperature fluxing agents can melt to form a small amount of glass body during the firing process, which combines with high-temperature substances to have certain strength. If the total content of low-temperature fluxing agents such as potassium oxide, sodium oxide and iron oxide is too high, it is not conducive to the repeated use of the insulation board.

[0049] In an embodiment of the present application, the high-temperature refractory insulation material is an insulation board for a ceramic roller kiln.

[0050] In the embodiment of the present application, low-magnesium mud raw materials and high-alumina solid waste materials with high-temperature resistance are used as raw materials. After molding in a press, magnesium high-temperature fluxing agents and kiln 1220±10 degrees high-temperature conditions form a high-temperature stable composite crystal phase insulation board with magnesium-aluminum spinel, periclase, magnesium olivine, mullite, corundum, etc. The insulation board can maximize the solution in the empty kiln state without wasting products, and the kiln can transition from an unstable state to a stable state, thereby ensuring the color, brick shape, cutting performance and other physical properties of the product in a normal controlled stable state. At the same time, it can improve the product's superior rate and save production costs. Moreover, the insulation board provided by the embodiment of the present application has certain folding strength, high-temperature non-softening and non-shape-changing high-temperature resistance, low-expansion coefficient shrinkage stability, good thermal shock resistance, and rapid cooling and heating performance, and can be used repeatedly without limitation.

[0051] Moreover, the embodiment of the present application can realize automatic and intelligent loading and unloading of the insulation board. Specifically, the insulation board is controlled to a certain specification and thickness (according to the width of the kiln), and the inverted brick adding device can be used to add the insulation board to the conveying belt at the front of the kiln. The finished product kiln operates in a mass production mode without the need for separate control. After the finished product kiln is discharged, the insulation board is collected and arranged by the brick picking and stacking machine for next use.

[0052] The following specific embodiments are listed for illustration.

[0053] Embodiment one: Step S1, find suitable high-aluminum industrial waste slag and corresponding raw materials; Step S2, through the debugging of the formula, the corresponding experimental test is carried out on the sample after trial firing; Step S3, according to the test results, optimize to the best formula; Step S4, according to the finished product kiln firing system, set the corresponding parameters of slurry and powder Step S5, prepare samples through small batch pilot production; Step S6, the sample's bending strength, thermal shock resistance, quenching and tempering performance and other performance tests; Step S7, optimizing the formula according to the sample test; Step S8, orthogonal test and verification.

[0054] The formula includes, by mass percentage: Magnesia mud 25%, waste roller 25%, refractory brick particles 25%, calcined talc 15%, coal water slurry ash 5%, porcelain powder 5%.

[0055] The chemical composition of the magnesia mud includes, by mass percentage: SiO260.14%, Al2O35.90%, Fe2O31.22%, CaO 1.53%, MgO 23.25%, K2O 0.15%, Na2O 0.26%, loss on ignition 7.21%, and the balance is impurities; The chemical composition of the waste roller includes, by mass percentage: SiO222.46%, Al2O373.93%, Fe2O30.51%, CaO 0.71%, MgO 0.51%, K2O 0.29%, Na2O 0.65%, loss on ignition 0.78%, and the balance is impurities; The chemical composition of the refractory brick particles includes, by mass percentage: SiO230.12%, Al2O360.75%, Fe2O32.68%, CaO 1.59%, MgO 2.35%, K2O 0.58%, Na2O 0.84%, loss on ignition 0.25%, and the balance is impurities; The chemical composition of the calcined talc includes, by mass percentage: SiO257.27%, Al2O30.41%, Fe2O30.15%, CaO 1.36%, MgO 33.1%, Na2O 0.15%, loss on ignition 10.16%, and the balance is impurities; The chemical composition of the coal water slurry ash includes, by mass percentage: SiO250.40%, Al2O331.90%, Fe2O32.23%, CaO 11.38%, MgO 0.75%, K2O 0.30%, Na2O 0.55%, loss on ignition 1.17%, and the balance is impurities; The chemical composition of the porcelain powder includes, by mass percentage: SiO2 69.04%, Al2O3 21.82%, Fe2O3 0.76%, CaO 1.31%, MgO 1.36%, K2O 2.06%, Na2O 2.87%, loss on ignition 0.53%, and the balance is impurities.

[0056] High temperature deformation resistance, shrinkage, and water absorption rate test of the insulation board: A laboratory sample was prepared, with a size of 150 mm in length, 100 mm in width, and 9 mm in thickness. The sample was suspended 3 cm from both sides by refractory strips, and was lightly placed on the two ends to form a bridge. The sample was heated to 1300±10 degrees by a laboratory furnace and was kept at this temperature for 30 minutes, and then was automatically cooled to room temperature. The sample was repeatedly fired, and it was determined whether the sample was deformed. The results are shown in Table 3.

[0057] Table 3

[0058] Thermal shock resistance test of the insulation board: A specially designed device (such as a movable clamp) was used to hold the 6 mm and 20 mm thick insulation board samples, which were placed in a 1300±10 degree electric furnace and kept at this temperature for 60 minutes. Then the samples in the clamp were slowly withdrawn from the furnace chamber. Considering the rapid cooling and slow cooling zones of the kiln, the actual situation of the kiln was simulated, and the cooling speed was accelerated by using a fan to blow cold air. The samples were cooled in air to a surface temperature of 100-120°C, and it was observed whether cracks or chipping occurred. After 15 or more reciprocating experiments, no cracks or chipping occurred. As shown in Table 4, the thermal conductivity and cooling speed of the thick and thin samples were tested simultaneously, which reflected their applicable range.

[0059] Table 4

[0060] Bending strength test of the insulation board: The sample was cut into a 300×600 mm size, and a ceramic digital bending instrument was used for testing. The insulation board could maintain a certain bending strength, and was not easily broken when the insulation board was automatically collected and stacked in the kiln or mechanical equipment. The results are shown in Table 5.

[0061] Table 5

[0062] Benefit statistics: The use of the insulation board in the kiln large empty kiln (time≥30 minutes) and small empty kiln (5-10 minutes) under non-continuous production conditions stabilized the temperature, airflow, and atmosphere of the kiln, and stabilized the color and brick shape of the product. For manufacturing enterprises, the small process platform is currently arranged for orders, and the number of specification, thickness, and body color conversion is large. With the increase in the number of empty kilns and the longer time, the loss is greater, and the recyclable insulation board has a greater value. The present application reduces the cost and stabilizes the quality, and the product out of the kiln is a high-quality product with stable quality. The benefit statistics are shown in Table 6.

[0063] Table 6

[0064] The embodiment of the application is suitable for ceramic manufacturing, and is also suitable for high-temperature refractory firing production, and can be used for manufacturing high-temperature refractory insulation boards and bricks, or experimental equipment insulation materials, etc.

[0065] The application provides a high-temperature refractory insulation material and a preparation method thereof, raw materials of the high-temperature refractory insulation material comprise, in percentage by mass, 23-27% of magnesia mud, 23-27% of waste roller, 23-27% of refractory brick particles, 13-17% of calcined talc, 3-7% of coal water slurry ash, and 3-7% of porcelain powder. The application uses high-aluminum solid waste as a formula of the high-temperature refractory insulation material, can prepare the high-temperature refractory insulation material which can be used infinitely, and can not be broken while stabilizing the state of a kiln, solves the problem that the atmosphere of firing is stabilized by directly using waste bricks in an empty kiln, and part of the waste bricks is broken after being taken out of the kiln due to moisture of air or insufficient strength, is difficult to clean, has a safety hazard, and cannot be recycled, and the problem that the cost of the insulation boards sold on the market is high.

[0066] It should be understood that the application of the application is not limited to the above examples, and can be improved or changed according to the above description for ordinary skilled persons in the art, and all these improvements and changes should belong to the protection scope of the appended claims of the application.

Claims

1. A high temperature refractory insulating material, characterized in that, The raw material of the high-temperature refractory insulation material comprises, in percentage by mass: Magnesia mud 23-27%, waste roller 23-27%, refractory brick particles 23-27%, calcined talc 13-17%, coal water slurry ash residue 3-7%, and porcelain powder 3-7%.

2. A high temperature refractory insulating material according to claim 1, characterised in that, The chemical composition of the high-temperature refractory insulation material comprises, in percentage by mass: SiO2 39-40%, Al2O3 41-42%, Fe2O3 1-1.5%, CaO 1-1.5%, MgO 11-12%, K2O 0.2-0.4%, Na2O 0.5-0.6%, and loss on ignition 3-4%.

3. The high-temperature refractory insulating material of claim 1, wherein, The chemical composition of the magnesia mud comprises, in percentage by mass: SiO2 58-62%, Al2O3 5-10%, Fe2O3 0-3%, CaO 0-3%, MgO 20-27%, K2O 0-3%, Na2O 0-3%, and loss on ignition 6-10%. The chemical composition of the waste roller comprises, in percentage by mass: SiO2 20-25%, Al2O3 68-76%, Fe2O3 0-3%, CaO 0-3%, MgO 0-5%, K2O 0-3%, Na2O 0-3%, and loss on ignition 0-5%. The chemical composition of the refractory brick particles comprises, in percentage by mass: SiO2 27-33%, Al2O3 55-65%, Fe2O3 0-3%, CaO 0-3%, MgO 0-5%, K2O 0-3%, Na2O 0-3%, and loss on ignition 0-5%. The chemical composition of the calcined talc comprises, in percentage by mass: SiO2 55-59%, Al2O3 0-5%, Fe2O3 0-3%, CaO 0-3%, MgO 25-35%, K2O 0-3%, Na2O 0-3%, and loss on ignition 8-12%. The chemical composition of the coal water slurry ash residue comprises, in percentage by mass: SiO2 48-52%, Al2O3 28-36%, Fe2O3 0-3%, CaO 8-13%, MgO 0-5%, K2O 0-3%, Na2O 0-3%, and loss on ignition 0-5%. The chemical composition of the porcelain powder comprises, in percentage by mass: SiO2 67-71%, Al2O3 18-26%, Fe2O3 0-3%, CaO 0-3%, MgO 0-5%, K2O 0-3%, Na2O 0-3%, and loss on ignition 0-5%.

4. The high-temperature refractory insulating material of claim 1, wherein, The mineral composition of the refractory brick particles comprises, in percentage by mass: Mullite 10-15%, corundum 30-45%, glass phase 20-30%, quartz and / or cristobalite 10-20%, and other impurities 5-10%.

5. The high-temperature refractory insulating material of claim 1, wherein, The mineral composition of the waste roller comprises, in percentage by mass: Mullite 10-15%, corundum 40-60%, glass phase 5-10%, quartz and / or cristobalite 5-10%, and other impurities 5-10%.

6. The high-temperature refractory insulating material of claim 1, wherein, The crystal phase of the high-temperature refractory insulation material comprises magnesium-aluminum spinel, periclase, forsterite, mullite and corundum.

7. A method for producing a high-temperature refractory insulating material, characterized by, The high-temperature refractory insulation material comprises: The magnesium clay 23-27%, waste roller 23-27%, refractory brick particles 23-27%, calcined talc 13-17%, coal water slurry ash 3-7%, and porcelain powder 3-7% are mixed to obtain a slurry; The slurry is screened and iron is removed to obtain a powder; The powder is pressed and molded, and then fired to obtain the high-temperature refractory insulation material.

8. The method of producing a high-temperature refractory thermal insulating material according to claim 7, characterized in that, The moisture content of the slurry is 34-36%, the flow rate is 55-90s measured by a four-cup viscometer, the specific gravity is 1.70-1.75g / ml, and the fineness is 325 mesh with a residue of 3-5%.

9. The method of claim 7, wherein the high-temperature refractory insulating material is prepared by mixing the inorganic fiber, the inorganic binder, and the inorganic filler, and then sintering the mixture at a temperature of 1,000°C or higher. The powder is pressed and molded, and then fired to obtain the high-temperature refractory insulation material, which comprises: The powder is pressed and molded, and then fired in a kiln with a magnesium high-temperature flux and a temperature of 1210-1230℃ to obtain the high-temperature refractory insulation material.

10. The method of claim 7, wherein the high-temperature refractory insulating material is prepared by mixing the inorganic fiber, the inorganic binder, and the inorganic filler, and then sintering the mixture at a temperature of 1,000°C or higher. The high-temperature refractory insulation material is a heat insulation plate for a ceramic roller kiln.

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