High-temperature-resistant quartz sand dry vibration material and preparation method thereof

Abstract

The invention discloses a high-temperature-resistant quartz sand dry vibration material and a preparation method thereof, and relates to the technical field of refractory materials. The dry vibration material comprises quartz sand, fused quartz sand and a binder in parts by weight, fused quartz is added in the production process of the dry vibration material, the refractoriness of the produced dry vibration material is improved, more importantly, the dry vibration material shows stable thermal expansion performance within the full temperature range of 1500-1590 DEG C, and the thermal expansion performance of the dry vibration material is improved. The thermal expansion coefficient and the temperature response linearity are optimally balanced, structural deformation caused by too large expansion amount is avoided, interface separation caused by shrinkage is avoided, use requirements of different high-temperature casting working conditions can be widely met, and the material type selection cost and replacement frequency of a user are reduced; the blanking speed and the stacking compactness of the prepared dry vibration material are accurately considered, the stacking speed is high, the final compactness reaches the standard, the construction difficulty is effectively reduced, the construction efficiency is improved, and the construction contradiction caused by unbalanced grain composition of a traditional material is solved.

Description

Technical Field

[0001] This invention relates to the field of refractory materials technology, specifically to a high-temperature resistant quartz sand dry vibratory material and its preparation method. Background Technology

[0002] As modern casting processes continue to evolve towards higher temperatures, with melting temperatures frequently exceeding 1600℃, traditional natural quartz sand dry vibratory refractory materials can no longer meet the stringent demands of industrial production. This has gradually exposed three core technological defects, becoming key bottlenecks restricting the service life of refractory materials and production safety: Insufficient refractoriness: Natural quartz sand is prone to phase transformation expansion at high temperatures above 1600℃, which leads to a decrease in the stability of the material structure and makes it unable to withstand the continuous effects of high-temperature smelting conditions for a long time. Construction performance contradiction: The particle size distribution design of traditional formulas is unreasonable, making it difficult to balance the feeding speed and the packing density of dry vibratory materials. Either the feeding is slow, affecting construction efficiency, or the density is insufficient, which makes it easy to break during subsequent use. Significant safety hazards: Natural quartz sand has a high coefficient of thermal expansion, which can easily cause abnormal expansion of the furnace lining under high-temperature conditions, and even lead to serious safety risks such as the furnace cover lifting, threatening the safety of personnel and equipment on the production site.

[0003] The above problems are common industry challenges faced by refractory material manufacturers, and there is an urgent need to develop new dry-vibration materials with better performance. Summary of the Invention

[0004] The purpose of this invention is to provide a high-temperature resistant quartz sand dry vibratory material and its preparation method, so as to solve the problems raised in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a high-temperature resistant quartz sand dry vibratory material, comprising the following components by weight: 70-80 parts of quartz sand 20-30 parts of fused silica sand 0.5-1.0 parts of adhesive The method for preparing the fused silica sand includes the following steps: S1. High-purity natural quartz sand is selected, which is washed to remove impurities and dried at 120-150℃. S2. The high-purity natural quartz sand dried and dehydrated in step S1 is sent into an electric arc furnace and heated to 1750-1900℃ for high-temperature melting. After being kept at the temperature and homogenized, it is shaped by rapid or slow cooling. S3. Then, the quartz sand that has been melted and formed at high temperature in step S2 is subjected to coarse crushing and fine crushing in sequence. After completion, the target particle size is screened out by a vibrating screen or an air classifier. S4. Subsequently, a second acid washing and purification process is carried out. The mixture is then rinsed with clean water until neutral and dried to obtain fused silica sand with qualified purity and particle size distribution.

[0006] In this invention, quartz sand is used as the matrix material to provide the main high-temperature resistant skeleton. In addition, its raw material cost has a significant advantage compared with other raw materials, making it suitable as the main component of dry vibratory material. Fused quartz plays a core role in skeleton filling and performance optimization in dry vibratory material. With its extremely low coefficient of thermal expansion, it can significantly improve the thermal shock resistance of dry vibratory material and prevent cracking and spalling of the material under rapid cooling and heating conditions. Its excellent high-temperature resistance and chemical inertness can enhance the structural stability of dry vibratory material in high-temperature environments and resist the corrosion of molten slag and molten metal. At the same time, its high purity can reduce the interference of impurities on the performance of dry vibratory material. Combined with the construction characteristics of dry vibratory material, it can further ensure the density and durability of the lining after molding. Therefore, it is often used in the formulation of furnace lining dry vibratory material in metallurgy, casting and other fields.

[0007] As a preferred technical solution, the quartz sand is composed of large-particle quartz sand, small-particle quartz sand, and micro-particle quartz sand; The particle size distribution of the large-particle quartz sand, small-particle quartz sand, and micro-particle quartz sand is as follows: large-particle quartz sand has a particle size of 2-10 mm, small-particle quartz sand has a particle size of 0.25 mm-2 mm, and micro-particle quartz sand has a particle size of <0.25 mm.

[0008] As a preferred technical solution, the proportions of large-particle quartz sand, small-particle quartz sand, and micro-particle quartz sand in the quartz sand are as follows: large-particle quartz sand accounts for 30-50%, small-particle quartz sand accounts for 20-40%, and micro-particle quartz sand accounts for 20-40%.

[0009] As a preferred technical solution, the density of the quartz sand is 2.04-2.12 / cm3.

[0010] As a preferred technical solution, the fused silica sand is composed of large-particle fused silica sand, small-particle fused silica sand, and micro-particle fused silica sand; The particle size distribution and proportion of large-particle fused silica sand, small-particle fused silica sand, and micro-particle fused silica sand in the fused silica sand are as follows: Large-particle fused silica sand has a particle size of 2-10mm and accounts for 25-75% of the total fused silica sand. Small-particle fused silica sand has a particle size of 0.25mm-2mm and accounts for 25-75% of the total fused silica sand. The micro-particle fused silica sand has a particle size of <0.25mm and accounts for 0-50% of the fused silica sand. As a preferred technical solution, the adhesive is a boron-based compound.

[0011] In the technical solution of this invention, the application of boron compounds as binders in dry vibratory refractory materials has several significant advantages: it can form a low-melting-point glass phase at lower temperatures, quickly achieving bonding between dry vibratory refractory particles, improving the room temperature strength and molding stability of the lining, and helping the dry vibratory refractory material to quickly obtain a certain structural strength after construction; at high temperatures, the glass phase it forms can be evenly distributed in the gaps between aggregates, filling pores and optimizing material density, while the low expansion characteristics of aggregates such as fused silica alleviate thermal stress at high temperatures, enhancing the thermal shock resistance and high-temperature structural stability of the dry vibratory refractory material; in addition, boron oxide has relatively stable chemical properties, good compatibility with most refractory aggregates, and will not introduce too many impurities that affect the high temperature resistance and erosion resistance of the dry vibratory refractory material, and can also reduce the sintering temperature of the dry vibratory refractory material to a certain extent, optimizing its high-temperature performance.

[0012] As a preferred technical solution, the particle size of the adhesive is 200 mesh.

[0013] The present invention also provides a method for preparing high-temperature resistant quartz sand dry vibratory material, comprising the following steps: adding quartz sand, fused quartz sand and binder into a mixer and stirring evenly to obtain high-temperature resistant quartz sand dry vibratory material.

[0014] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention improves the refractoriness of dry vibratory materials by adding fused silica during the production process. More importantly, this dry vibratory material exhibits stable thermal expansion performance across the entire temperature range of 1500-1590℃, achieving an optimal balance between the coefficient of thermal expansion and the linearity of temperature response. It avoids structural deformation due to excessive expansion and interface separation due to shrinkage, making it widely adaptable to the application requirements of different high-temperature casting conditions and reducing the material selection cost and replacement frequency for users. 2. By optimizing the particle size distribution of quartz sand, fused silica, and binder, this invention achieves a precise balance between the feeding speed and the packing density of the dry vibratory material prepared by this invention. The packing rate is fast and the final density meets the standard, which effectively reduces the construction difficulty, improves the construction efficiency, and solves the construction contradiction caused by the imbalance of particle size distribution of traditional materials. 3. By selecting a binder with a suitable particle size and optimizing the amount added, the binder can be evenly dispersed and fill the gaps between quartz sand particles. This not only improves the bulk density and mechanical strength of the material, but also reduces local stress concentration, significantly improves the thermal shock stability of the material, and extends the service life of the material. Attached Figure Description

[0015] Figure 1 This is a test diagram of the accumulation velocity of the dry vibratory material prepared in Examples 1, 2 and 3 of this invention; Figure 2 This is a comparative test diagram of the high-temperature expansion performance of the dry vibratory materials prepared in Examples 1 and 2 of this invention at 1500°C. Figure 3 This is a comparative graph showing the high-temperature expansion properties of the dry vibratory materials prepared in Examples 1, 2, and 3 of this invention at 1550°C. Figure 4 This is a comparative graph showing the high-temperature expansion performance of the dry vibratory materials prepared in Examples 1, 2, and 3 of this invention at 1590°C. Figure 5 This is a comparison chart of the dry vibratory material accumulation velocity tests prepared in Example 1 and Comparative Example 1 in this invention; Figure 6 This is a comparative graph showing the high-temperature expansion performance of the dry vibratory materials prepared in Example 1 and Comparative Example 1 at 1500°C. Figure 7 This is a comparative graph showing the high-temperature expansion performance of the dry vibratory materials prepared in Example 1 and Comparative Example 1 at 1550°C. Figure 8 This is a comparative graph showing the high-temperature expansion performance of the dry vibratory materials prepared in Example 1 and Comparative Example 1 at 1590°C. Figure 9 This is a comparison chart of the high-temperature thermal expansion tests of the dry vibratory materials prepared in Example 1 and Comparative Example 1 at 1550℃ and 1590℃, respectively, in this invention. Figure 10 This is a comparison chart of the high-temperature thermal expansion tests of the dry vibratory materials prepared in Example 2 and Comparative Example 2 at 1550℃ and 1590℃, respectively, in this invention. Figure 11 This is a comparison chart of the high-temperature thermal expansion tests of the dry vibratory materials prepared in Example 3 and Comparative Example 3 at 1550℃ and 1590℃, respectively. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Example 1 This embodiment provides a high-temperature resistant quartz sand dry vibratory material, comprising the following components by weight: The composition consists of 75 parts silica sand, 25 parts fused silica sand, and 0.8 parts binder (α). The proportion of large-particle fused silica sand in the fused silica sand is 38.0%, the proportion of small-particle fused silica sand is 30.6%, and the proportion of micro-particle fused silica sand is 31.4%. The method for preparing the fused silica sand includes the following steps: S1. High-purity natural quartz sand is selected, which is washed to remove impurities and dried at 120-150℃. S2. The high-purity natural quartz sand dried and dehydrated in step S1 is sent into an electric arc furnace and heated to 1750-1900℃ for high-temperature melting. After being kept at the temperature and homogenized, it is shaped by rapid or slow cooling. S3. Then, the quartz sand that has been melted and formed at high temperature in step S2 is subjected to coarse crushing and fine crushing in sequence. After completion, the target particle size is screened out by a vibrating screen or an air classifier. S4. Subsequently, a second acid washing and purification process is carried out. The mixture is then rinsed with clean water until neutral and dried to obtain fused silica sand with qualified purity and particle size distribution.

[0018] This embodiment also provides a method for preparing high-temperature resistant quartz sand dry vibratory material. The specific steps are as follows: 75 parts of quartz sand, 25 parts of fused quartz sand, and 0.8 parts of binder are added to a mixer (the mixer speed is 50 r / min, and the stirring time is 3 min) to obtain high-temperature resistant quartz sand dry vibratory material.

[0019] Example 2 The difference between this embodiment and Embodiment 1 is that only the amount of fused silica sand added is changed. The amount of fused silica sand added is 20 parts, while the other raw materials and production steps are the same.

[0020] Example 3 The difference between this embodiment and Embodiment 1 is that this comparative example only changes the amount of fused silica sand added, which is 30 parts; the other raw materials and production steps are the same.

[0021] Comparative Example 1 The difference between this comparative example and Example 1 is that only the particle size of the fused silica sand is changed. The particle size distribution of the fused silica sand is as follows: medium and large particles account for 38.6%, small particles account for 28.8%, and micro particles account for 31.6%. All other raw materials and production steps are the same.

[0022] Comparative Example 2 The difference between this comparative example and Example 1 is that only the amount of adhesive added was changed from α0.8 parts to β0.6 parts, while the other raw materials and production steps are the same.

[0023] Comparative Example 3 The difference between this comparative example and Example 2 is that only the amount of adhesive added was changed from α0.8 parts to β0.6 parts, while the other raw materials and production steps are the same.

[0024] Comparative Example 4 The difference between this comparative example and Example 3 is that only the amount of adhesive added was changed from α0.8 parts to β0.6 parts, while the other raw materials and production steps are the same.

[0025] like Figure 1 , Figure 2 , Figure 3 The figure shown is a test graph of the stacking velocity and high-temperature expansion performance of the dry vibratory materials prepared in Examples 1, 2 and 3. Figure 1 The graph shows the accumulation rate test results of the dry vibratory materials prepared in Examples 1, 2, and 3. In the graph, Example 1 is marked as 25%, Example 2 as 20%, and Example 3 as 30%. Figure 2 The graph shows the high-temperature expansion performance of the dry vibratory materials prepared in Examples 1 and 2 at 1500°C. In the graph, Example 1 is marked as 25% and Example 2 is marked as 20%. Figure 3 The graph shows the high-temperature expansion performance of the dry vibratory materials prepared in Examples 1, 2, and 3 at 1550°C. In the graph, Example 1 is marked as 25%, Example 2 as 20%, and Example 3 as 30%. Figure 4 The graph shows the high-temperature expansion performance test results of the dry vibratory materials prepared in Examples 1, 2, and 3 at 1590°C. In the graph, Example 1 is marked as 25%, Example 2 as 20%, and Example 3 as 30%.

[0026] Test results revealed significant differences in the high-temperature thermal expansion performance of the dry vibratory mix with varying fused silica sand ratios. The 20% fused silica sand ratio exhibited abnormally high expansion at 1550℃ and 1590℃, reaching approximately 2.4%, far exceeding the range of thermal expansion coefficients for conventional materials. The 25% fused silica sand ratio showed superior thermal stability at 1500℃, 1550℃, and 1590℃, with relatively small and gradual thermal expansion. While the 30% fused silica sand ratio showed expansion within acceptable limits, it exhibited significant shrinkage at 1590℃, which may be related to changes in its microstructure. Considering the thermal expansion performance of the three fused silica sand ratios, the 25% fused silica sand ratio dry vibratory mix demonstrated the best high-temperature suitability, with significantly lower thermal expansion than the 20% fused silica sand ratio, and remained stable within the test temperature range, avoiding material stress problems caused by extreme expansion. Compared to dry vibratory mixes with a 30% fused silica sand content, dry vibratory mixes with a 25% fused silica sand content did not exhibit abnormal shrinkage at 1590℃. This stability is particularly important for high-temperature applications. The 25% fused silica sand content achieves an optimal balance in both the coefficient of thermal expansion and the linearity of temperature response, preventing structural deformation due to excessive expansion and interface separation due to shrinkage. This superior overall performance makes it the most reliable fused silica sand content choice for high-temperature environments.

[0027] like Figure 5 , Figure 6 , Figure 7 , Figure 8 The figure shows the test graphs of the stacking velocity of the dry vibratory material prepared in Example 1 and Comparative Example 1, as well as the test graphs of the high temperature expansion performance at 1500℃, 1550℃ and 1590℃. In the figure, Example 1 is marked as 25%-① and Comparative Example is marked as 25%-②. As can be seen from the figure, although the feeding speed of the dry vibratory material prepared in Comparative Example 1 is slightly faster, and the thermal expansion at 1550℃ and 1590℃ is relatively high, the formulation used in Example 1 is the optimal choice based on the comprehensive test results.

[0028] The role of binders in dry vibratory quartz sand is mainly reflected in reducing the coefficient of thermal expansion, promoting sintering, and improving high-temperature stability. Appropriate addition can optimize the sintering network between quartz sand particles, improve densification and mechanical strength, while avoiding a decrease in high-temperature viscosity due to excessive glass phase, which reduces thermal shock resistance and leads to cracking. Therefore, we changed the amount of binder α in Examples 1, 2, and 3, changing it from α to β. Example 1 with the changed binder amount is Comparative Example 2, Example 2 with the changed binder amount is Comparative Example 3, and Example 3 with the changed binder amount is Comparative Example 4. Figure 9 This is a comparison chart showing the high-temperature thermal expansion tests of the dry vibratory materials prepared in Example 1 and Comparative Example 2 at 1500℃, 1550℃, and 1590℃. Figure 10 This is a comparison chart showing the high-temperature thermal expansion tests of the dry vibratory materials prepared in Example 2 and Comparative Example 3 at 1500℃, 1550℃, and 1590℃. Figure 11 Comparison of high-temperature thermal expansion tests of the dry vibratory materials prepared in Example 3 and Comparative Example 4 at 1500℃, 1550℃ and 1590℃. Figure 9 Example 1 is labeled as 25% (α), and Comparative Example 2 is labeled as 25% (β); Figure 10 Example 2 is labeled as 20% (α), and Comparative Example 3 is labeled as 20% (β); Figure 11 Example 3 is labeled as 30% (α), and Comparative Example 4 is labeled as 30% (β).

[0029] The test results showed that Comparative Examples 1, 2, and 3 exhibited significantly increased expansion at 1550°C and 1590°C compared to Examples 1, 2, and 3, which did not meet our requirements. Therefore, the amount of binder added α in Examples 1, 2, and 3 was the optimal solution.

[0030] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A high-temperature resistant quartz sand dry vibratory material, characterized in that, Includes the following components in parts by weight: 70-80 parts of quartz sand 20-30 parts of fused silica sand 0.5-1.0 parts of adhesive The method for preparing the fused silica sand includes the following steps: S1. High-purity natural quartz sand is selected, which is washed to remove impurities and dried at 120-150℃. S2. The high-purity natural quartz sand dried and dehydrated in step S1 is sent into an electric arc furnace and heated to 1750-1900℃ for high-temperature melting. After being kept at the temperature and homogenized, it is shaped by rapid or slow cooling. S3. Then, the quartz sand that has been melted and formed at high temperature in step S2 is subjected to coarse crushing and fine crushing in sequence. After completion, the target particle size is screened out by a vibrating screen or an air classifier. S4. Subsequently, a second acid washing and purification process is carried out. The mixture is then rinsed with clean water until neutral and dried to obtain fused silica sand with qualified purity and particle size distribution.

2. The high-temperature resistant quartz sand dry vibratory material according to claim 1, characterized in that, The quartz sand is composed of large-particle quartz sand, small-particle quartz sand, and micro-particle quartz sand. The particle size distribution of the large-particle quartz sand, small-particle quartz sand, and micro-particle quartz sand is as follows: large-particle quartz sand has a particle size of 2-10 mm, small-particle quartz sand has a particle size of 0.25 mm-2 mm, and micro-particle quartz sand has a particle size of <0.25 mm.

3. The high-temperature resistant quartz sand dry vibratory material according to claim 2, characterized in that, The proportions of large-particle quartz sand, small-particle quartz sand, and micro-particle quartz sand in the quartz sand are as follows: large-particle quartz sand accounts for 30-50%, small-particle quartz sand accounts for 20-40%, and micro-particle quartz sand accounts for 20-40%.

4. The high-temperature resistant quartz sand dry vibratory material according to claim 2, characterized in that, The density of the quartz sand is 2.04-2.12 g / cm³. 3 .

5. The high-temperature resistant quartz sand dry vibratory material according to claim 1, characterized in that, The fused silica sand is composed of large-particle fused silica sand, small-particle fused silica sand, and micro-particle fused silica sand. The particle size distribution and proportion of large-particle fused silica sand, small-particle fused silica sand, and micro-particle fused silica sand in the fused silica sand are as follows: Large-particle fused silica sand has a particle size of 2-10mm and accounts for 25-75% of the total fused silica sand. Small-particle fused silica sand has a particle size of 0.25mm-2mm and accounts for 25-75% of the total fused silica sand. The micro-particle fused silica sand has a particle size of <0.25mm and accounts for 0-50% of the fused silica sand.

6. The high-temperature resistant quartz sand dry vibratory material according to claim 1, characterized in that, The adhesive is a boron-based compound.

7. The high-temperature resistant quartz sand dry vibratory material according to claim 6, characterized in that, The adhesive has a particle size of 200 mesh.

8. A method for preparing a high-temperature resistant quartz sand dry vibratory material as described in any one of claims 1-7, characterized in that, Includes the following steps: Quartz sand, fused quartz sand, and binder are added to a mixer and stirred evenly to obtain high-temperature resistant quartz sand dry vibrating material.

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