Low-cost long-life aluminum-silicon refractory and method for preparing the same
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- ZHENGZHOU RUITAI REFRACTORY MATERIALS TECH CO LTD
- Filing Date
- 2026-04-01
- Publication Date
- 2026-06-09
Smart Images
Figure SMS_1 
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Abstract
Description
Technical Field
[0001] This invention relates to the technical field of refractory materials, and more specifically, to a low-cost, long-life aluminum-silicon refractory material and its preparation method. Background Technology
[0002] Refractory materials are the foundation of all high-temperature industries. The development of important pillar industries of the national economy, such as steel, non-ferrous metals, building materials, and petrochemicals, is closely related to the technological progress and development of refractory materials. In order to adapt to the sustainable development of high-temperature industries, it is necessary to realize the green development concept of improving the variety and quality of refractory materials used in high-temperature industries, making the production process energy-saving and environmentally friendly, and ensuring long service life and harmlessness. The refractory materials industry must provide important basic guarantees for the development of high-temperature industries.
[0003] In recent years, the high-temperature industry has developed towards large-scale, diversified raw material and energy sources, and high efficiency in energy conservation and emission reduction. As a result, the refractory materials used in the kiln lining of high-temperature kilns have been subjected to a significant increase in thermal stress, mechanical stress, and chemical erosion, which has seriously affected the service life and operating rate of high-temperature industrial kilns.
[0004] Traditional aluminosilicate refractories (such as high-alumina bricks) typically use large amounts of high-grade bauxite or industrial alumina as raw materials, resulting in high costs. Furthermore, their service life is often limited by two key factors: 1. Poor thermal shock resistance: It is prone to cracking and structural spalling when the temperature changes drastically.
[0005] 2. High temperature creep: It is prone to deformation under long-term high temperature and load. Summary of the Invention
[0006] In order to overcome the above-mentioned problems and shortcomings of traditional aluminosilicate refractory materials, the purpose of this invention is to provide a long-life aluminosilicate refractory material with low cost, low high-temperature creep and excellent thermal shock stability.
[0007] The low-cost, long-life aluminosilicate refractory material of the present invention is made from the following raw materials by weight percentage: 50%~70% low-grade bauxite clinker, 5%~15% recycled aluminosilicate refractory fine powder, 10%~20% natural quartz sand, 3%~8% α-Al2O3, 5%~10% Guangxi white clay, and 1.5%~5% composite additives; the firing temperature of the refractory material is 1350℃~1400℃; the composite additives are composed of lightly calcined magnesia, lithium mineral powder and rare earth oxide powder, and the lithium mineral powder is one of spodumene, lepidolite, and lithium aluminum phosphate.
[0008] The low-grade bauxite clinker contains 50% to 65% Al2O3.
[0009] Among them, the low-grade bauxite clinker contains: 10% to 20% of 5mm to 3mm particles, 20% to 40% of 3mm to 1mm particles, 5% to 20% of 1mm to 0.1mm particles, and 5% to 20% of 180-mesh powder.
[0010] The weight ratio of the lightly calcined magnesium oxide, lithium mineral powder, and rare earth oxide powder is 5~10: 1~7.5: 1~2.5.
[0011] The composite additive contains 1% to 3% light-burned magnesium oxide, 0.3% to 1.5% lithium minerals, and 0.2% to 0.5% rare earth oxides.
[0012] The lightly calcined magnesium oxide contains MgO ≥ 85% and Fe2O3 ≤ 1.3%.
[0013] The rare earth oxide powder is at least one of Y2O3, La2O3 and CeO2.
[0014] This invention also relates to a method for preparing the above-mentioned low-cost, long-life aluminum-silicon refractory material, which includes the following steps: (1) Grind the low-grade bauxite clinker, natural quartz sand and recycled alumina-silicon refractory material into fine powder, and take the low-grade bauxite clinker, recycled alumina-silicon refractory material, natural quartz sand, α-Al2O3, Guangxi white clay, lightly calcined magnesium oxide, lithium minerals and rare earth oxides according to the weight percentage for later use. (2) Mix the prepared raw materials with the organic binder to obtain mud; (3) The mud material is pressed into shape by a press to obtain a semi-finished product; (4) The semi-finished product is put into a drying kiln to dry, and a semi-finished product with a residual moisture content of less than 1% is obtained; (5) The dried semi-finished product is put into a high-temperature tunnel kiln and fired at 1350~1400℃, and the finished product is selected.
[0015] The organic binder is a calcium lignosulfonate solution with a specific gravity of 1.10-1.20, and the amount added is 3% to 5% of the weight of the raw material.
[0016] The drying temperature of the drying kiln is 100~120℃. Beneficial effects
[0017] Compared with existing technologies, the low-cost, long-life aluminum-silicon refractory material of the present invention has the following beneficial effects: 1. Low cost: Using low-grade bauxite (such as Al2O3 50-65%), natural quartz sand, and recycled refractory waste bricks as the main raw materials significantly reduces raw material costs; 2. Long lifespan: Through design, an interwoven network of mullite crystals is generated in situ inside the material, and specific additives are introduced to form a low-expansion second phase (such as cordierite), which significantly improves the material's thermal shock resistance and high-temperature volume stability, and extends the service life of high-temperature kilns. Detailed Implementation
[0018] The technical solution of the present invention will be further explained clearly and completely below with reference to specific embodiments.
[0019] This invention relates to a low-cost, long-life aluminosilicate refractory material, made from the following raw materials by weight percentage: 50%–70% low-grade bauxite clinker (Al2O3 content 50-65%), 10%–20% natural quartz sand (particle size 0.5mm–0.1mm), 3–8% α-Al2O3 (particle size 5–10μm), 5%–10% Guangxi white clay (200 mesh), 5%–15% recycled aluminosilicate refractory fine powder (180 mesh), and 2.5%–5% composite additives. The composite additives consist of lightly calcined magnesia, lithium mineral powder, and rare earth oxide powder. In the refractory material of this invention, the low-grade bauxite clinker comprises: 10%–20% 5mm–3mm particles, 20%–40% 3mm–1mm particles, 5%–20% 1mm–0.1mm particles, and 5%–20% 180-mesh powder. In the composite additive, the weight ratio of light-burned magnesium oxide, lithium mineral powder, and rare earth oxide powder is 5~10: 1~7.5: 1~2.5. The light-burned magnesium oxide contains MgO ≥ 85% and Fe2O3 ≤ 1.3%. The lithium mineral powder is one of spodumene, lepidolite, and lithium aluminum phosphate, preferably lithium aluminum phosphate. The rare earth oxide powder (200 mesh) is at least one of Y2O3, La2O3, and CeO2.
[0020] The preparation method of the above-mentioned low-cost, long-life aluminum-silicon refractory material of the present invention includes the following steps: a. Grind the low-grade bauxite clinker into four different particle sizes: 5mm-3mm, 3mm-1mm, 1mm-0.1mm, and 180 mesh, for later use; b. Grind the natural quartz sand into fine particles with a particle size of 0.5mm to 0.1mm, and set aside. c. Grind the recycled aluminum-silicon refractory material into fine powder with a particle size of 180 mesh, and set aside. d. By weight percentage: 50%-70% low-grade bauxite clinker (10%-20% low-grade bauxite clinker of 5mm-3mm, 20%-40% low-grade bauxite clinker of 3mm-1mm, 5%-20% low-grade bauxite clinker of 1mm-0.1mm, 5%-20% low-grade bauxite clinker of 180 mesh), 10%-20% natural quartz sand of 0.5mm-0.1mm, 3%-8% α-Al2O3 of 5-10μm, 5%-10% Guangxi white clay of 200 mesh, 5%-15% recycled alumina-silicon refractory material of 180 mesh, 1%-3% lightly calcined magnesia of 200 mesh, 0.3%-1.5% lithium mineral of 200 mesh, and 0.2%-0.5% rare earth oxides of 200 mesh, for later use; e. Add the 5mm-3mm low-grade bauxite clinker, 3mm-1mm low-grade bauxite clinker, 1mm-0.1mm low-grade bauxite clinker, and 0.5mm-0.1mm natural quartz sand from step d to a mixing mill and dry mix for 3-5 minutes. Then add an organic binder (calcium lignosulfonate solution, specific gravity 1.10-1.20, added at 3%-5% of the raw material weight) and continue mixing for 5-10 minutes. Finally, add 180-mesh low-grade bauxite clinker powder, 5-10μm α-Al2O3 micro powder, 200-mesh Guangxi white clay, 180-mesh recycled alumina-silicon refractory fine powder, and composite additives to the mixing mill and mix for 10-15 minutes to obtain the compacted mud. f. Press the crushed mud into shape using a press to obtain a semi-finished product; g. Dry the semi-finished product in a drying kiln at 100~120℃ until the residual moisture content is below 1%; h. Load the dried and qualified semi-finished products into the kiln car and fire them at 1350℃~1400℃. Select the finished products according to national standards.
[0021] The low-cost, long-life refractory material prepared by this invention has a low cost, high-temperature volume stability, excellent erosion resistance, and excellent thermal shock stability, which can significantly extend the service life of high-temperature industrial kilns and reduce energy consumption. Example
[0022] The preparation method of the low-cost, long-life aluminum-silicon refractory material in this embodiment is as follows: Prepare the following by weight percentage: 5~3mm low-grade bauxite clinker (Al2O3 content 58%), 3~1mm low-grade bauxite clinker (Al2O3 content 58%), 1~0.1mm low-grade bauxite clinker (Al2O3 content 58%), 180-mesh low-grade bauxite clinker (Al2O3 content 58%), 0.5~0.1mm natural quartz sand, 5~10μm α-Al2O3, 200-mesh Guangxi white clay, 180-mesh recycled alumina-silicon refractory fine powder, and composite additives (200-mesh light-burned magnesia, 200-mesh lithium minerals and 200-mesh rare earth oxides) for later use; The above-mentioned low-grade bauxite clinker of 5~3mm, 3~1mm and 1~0.1mm is added to the mixer and dry-mixed for 3~5 minutes. Then, an organic binder is added and the mixture is continued to be mixed for 5~10 minutes. Finally, 180-mesh low-grade bauxite clinker powder, 5~10μm α-Al2O3 micro powder, 200-mesh Guangxi white clay, 180-mesh recycled alumina-silicon refractory fine powder and 200-mesh composite additive are added to the mixer and mixed for 10~15 minutes to obtain the mixed mud material. The crushed mud is pressed into shape by a press to obtain a semi-finished product; The semi-finished product is dried in a drying chamber at 100~120℃ until the residual moisture content is less than 1%. After drying, qualified semi-finished products are loaded into kiln cars and placed into a high-temperature tunnel kiln. They are then fired at 1400°C for 2 hours. The finished products are then selected to obtain the aluminosilicate refractory material of this invention.
[0023] The weight percentage of raw materials used in each embodiment is shown in Table 1.
[0024] Table 1
[0025] Comparative Example 1 Compared with Example 2, the difference is that the composite additive was not added and the content of α-Al2O3 was 8%.
[0026] Comparative Example 2 The difference from Example 2 lies in the composite additive, which in this comparative example is a mixture of 1.0% lithium aluminum phosphate and 2.2% lanthanum cerium oxide.
[0027] Comparative Example 3 The difference from Example 2 lies in the composite additive, which in this comparative example is a mixture of 2.0% lightly calcined magnesium oxide and 1.2% lanthanum cerium oxide.
[0028] Performance testing
[0029] The physicochemical properties of the aluminosilicate refractory materials in the examples and comparative examples are shown in Table 2 below.
[0030] Table 2
[0031] The above description is merely a preferred embodiment of the present invention, and the present invention highlights its essential features through the above embodiments. Those skilled in the art should understand that any equivalent substitution of the raw materials used or substitution of known means, made without departing from the concept and essence of the present invention, falls within the protection scope of the present invention and is not limited to the specific embodiments described above.
Claims
1. A low-cost, long-life aluminum-silicon refractory material, characterized in that... It is made from the following raw materials by weight percentage: 50%~70% low-grade bauxite clinker, 5%~15% recycled aluminosilicate refractory fine powder, 10%~20% natural quartz sand, 3%~8% α-Al2O3, 5%~10% Guangxi white clay, and 1.5%~5% composite additives; the firing temperature of the refractory is 1350℃~1400℃; the composite additives are composed of light-burned magnesia, lithium mineral powder and rare earth oxide powder, and the lithium mineral powder is one of spodumene, lepidolite, and lithium aluminum phosphate.
2. The low-cost, long-life aluminosilicate refractory material according to claim 1, characterized in that: The low-grade bauxite clinker contains 50% to 65% Al2O3.
3. The low-cost, long-life aluminosilicate refractory material according to claim 1 or 2, characterized in that: In the low-grade bauxite clinker: 10% to 20% of the particles are 5mm to 3mm, 20% to 40% of the particles are 3mm to 1mm, 5% to 20% of the particles are 1mm to 0.1mm, and 5% to 20% of the 180-mesh powder is 180-mesh.
4. The low-cost, long-life aluminosilicate refractory material according to claim 1, characterized in that: The weight ratio of the lightly calcined magnesium oxide, lithium mineral powder, and rare earth oxide powder is 5~10: 1~7.5: 1~2.
5.
5. The low-cost, long-life aluminosilicate refractory material according to claim 1, characterized in that: The raw materials contain 1% to 3% lightly calcined magnesium oxide, 0.3% to 1.5% lithium minerals, and 0.2% to 0.5% rare earth oxides.
6. The low-cost, long-life aluminosilicate refractory material according to claim 1, characterized in that: The lightly calcined magnesium oxide contains MgO ≥ 85% and Fe2O3 ≤ 1.3%.
7. The low-cost, long-life aluminosilicate refractory material according to claim 1, characterized in that: The rare earth oxide powder is at least one of Y2O3, La2O3 and CeO2.
8. The method for preparing the low-cost, long-life aluminum-silicon refractory material according to any one of claims 1-7, characterized in that... Includes the following steps: (1) Grind the low-grade bauxite clinker, natural quartz sand and recycled aluminosilicate refractory material into fine powder, and take the following by weight percentage: low-grade bauxite clinker, recycled aluminosilicate refractory material, natural quartz sand, α-Al2O3, Guangxi white clay, lightly calcined magnesium oxide, lithium minerals and rare earth oxides for later use. (2) Mix the prepared raw materials with the organic binder to obtain mud; (3) The mud material is pressed into shape by a press to obtain a semi-finished product; (4) The semi-finished product is put into a drying kiln to dry, and a semi-finished product with a residual moisture content of less than 1% is obtained; (5) The dried semi-finished product is put into a high-temperature tunnel kiln and fired at 1350~1400℃, and the finished product is selected.
9. The method for preparing low-cost, long-life aluminum-silicon refractory material according to claim 8, characterized in that: The organic binder is a calcium lignosulfonate solution with a specific gravity of 1.10-1.20, and the amount added is 3% to 5% of the weight of the raw material.
10. The method for preparing low-cost, long-life aluminosilicate refractory material according to claim 8, characterized in that: The drying temperature of the drying kiln is 100~120℃.