阅读说明：本技术 一种保温耐火浇注料及其制备方法、浇筑方法、应用 (Heat-preservation refractory castable and preparation method, pouring method and application thereof ) 是由 刘智 王文建 马国勇 王勇 庞继勇 于 2020-06-28 设计创作，主要内容包括：本发明涉及保温耐火浇注料技术领域,具体涉及一种保温耐火浇注料及其制备方法、浇筑方法、应用。按质量百分数计,所述浇注料的原料包括1.7～2.6％的第一组分和97.4～98.3％的第二组分；其中,所述第一组分包括胶结剂35～40％、黏土粉13～20％、轻质骨料40～50％,所述第二组分为水。本发明的这种耐火浇筑料虽然容重较轻,但体积稳定、强度高、结构气密较好,结构重量较其他浇注料减轻40～60％。同时,本发明的这种耐火浇筑料具有很好的保温隔热效果,使用温度高,可直接接触火焰作工作衬使用,实现高温节能,可快速烘炉,高空隙率排气顺畅,缩短烘炉工期,经济效益显著。(The invention relates to the technical field of heat-insulating refractory castable, in particular to a heat-insulating refractory castable and a preparation method, a pouring method and application thereof. The castable comprises the following raw materials, by mass, 1.7-2.6% of a first component and 97.4-98.3% of a second component; the first component comprises 35-40% of cementing agent, 13-20% of clay powder and 40-50% of lightweight aggregate, and the second component is water. The refractory pouring material disclosed by the invention is light in volume weight, but is stable in volume, high in strength and good in structural air tightness, and the structural weight is reduced by 40-60% compared with other pouring materials. Meanwhile, the refractory casting material has good heat preservation and insulation effects, high use temperature, can be directly contacted with flame to be used as a working lining, realizes high temperature energy conservation, can be used for quickly baking a furnace, has high porosity and smooth exhaust, shortens the baking period and has remarkable economic benefit.)

1. The heat-insulating refractory castable is characterized by comprising the following raw materials, by mass, 1.7-2.6% of a first component and 97.4-98.3% of a second component; the first component comprises 35-40% of cementing agent, 13-20% of clay powder and 40-50% of lightweight aggregate, and the second component is water.

2. The insulating refractory castable material according to claim 1, wherein the raw materials of the insulating refractory castable material comprise, in mass percent, 2% of the first component and 98% of the second component; the first component comprises 38% of cementing agent, 16% of clay powder and 46% of lightweight aggregate, and the second component is water.

3. The insulating refractory castable according to claim 1 or 2, wherein the lightweight aggregate comprises any one of expanded perlite, expanded vermiculite, ceramsite, clayey or high alumina porous clinker;

alternatively, the cementing agent comprises at least one of ordinary portland cement, alumina cement, water glass, phosphate, and the like.

4. The insulating refractory castable material according to claim 1 or 2, further comprising an additive, preferably the additive comprises at least one of a water reducing agent, a plasticizer and a defoaming agent.

5. The preparation method of the heat-preservation refractory castable material according to any one of claims 1 to 4, characterized by comprising the steps of wetting the aggregate with water, adding the cementing agent, the clay powder and the rest water, and stirring until the color of the aggregate is uniform.

6. The preparation method of the heat-preservation refractory castable according to claim 5, wherein the refractory castable is obtained by stirring until the color is uniform and the castable can be kneaded into a mass by hand;

or in the preparation method, the water is divided into two parts, one part of the water is used for wetting the aggregate, and the other part of the water, the cementing agent and the clay powder are added into the wetted aggregate;

alternatively, the preparation method further comprises a step of adding an additive to the wetted aggregate.

7. The method for preparing the heat-preservation refractory castable according to claim 5 or 6, wherein when the cementing agent is ordinary portland cement, the prepared heat-preservation refractory castable should not be allowed to stand for more than 60min, or when the cementing agent is alumina cement, water glass or phosphate, the prepared heat-preservation refractory castable should not be allowed to stand for more than 30 min.

8. The pouring method of the heat-preservation refractory castable obtained by the preparation method according to any one of claims 5-7, characterized by comprising the following steps:

(1) cleaning a pouring base surface, and fixing a pouring model for later use;

(2) and pouring the prepared heat-preservation refractory castable in layers and vibrating the prepared heat-preservation refractory castable in the model in layers to obtain the heat-preservation refractory castable.

9. The pouring method according to claim 8, wherein in the pouring method, when the heat-preservation refractory castable is poured on the surface of a castable which is just poured, pouring is carried out after the castable is maintained for 24 hours; preferably, when the cementing agent in the casting material is water glass or phosphate, the next layer of casting material is cast after the water glass or phosphate is isolated by waterproof paper and a plastic film;

or in the pouring method, when the joint is poured, the loose part on the surface of the joint is cleaned, and pouring is carried out after watering and wetting;

or in the pouring method, the surface of the poured material after pouring is vibrated, leveled and dense, and cracks which can not be seen by naked eyes are avoided;

or in the pouring method, the maintenance system of the lightweight castable adopts dry maintenance or does not need maintenance.

10. Use of a heat insulating refractory castable material prepared by a method according to any one of claims 5 to 7 or obtained by a casting method according to claim 8 or 9 in boiler hearth construction.

Technical Field

The invention relates to the technical field of heat-insulating refractory castable, in particular to a heat-insulating refractory castable and a preparation method, a pouring method and application thereof.

Background

The information in this background section is only for enhancement of understanding of the general background of the invention and is not necessarily to be construed as an admission or any form of suggestion that this information forms the prior art that is already known to a person of ordinary skill in the art.

At present, the following heat preservation refractory castable is generally adopted for construction in China:

(1) the heavy castable is formed by mixing granular and powdery raw materials made of refractory substances, a quantitative bonding agent and water, has high fluidity, is suitable for construction in a pouring mode, and is an unshaped refractory raw material which can be hardened without heating. The heavy castable is usually cast and formed in a casting, bombing or tamping mode on the application site, has the advantages of heat insulation, heat preservation, low water absorption and the like, is convenient to construct, and is a product for constructing alkali-resistant erosion parts at high temperature. Meanwhile, the heavy castable has the advantages of good workability, strong cohesive force, long initial setting time and controllable construction time, high strength increase speed, strong impermeability, no need of acidification treatment and easy dense filling of mortar joints of the pipe-wrapping masonry.

(2) The clay refractory castable is a castable refractory castable prepared by using soft clay as a bonding agent, and refractory aggregate, powder and an additive such as aluminum silicate or corundum-mullite, and has the characteristics of high medium-temperature strength, high thermal-state strength, good volume stability at high temperature and strong spalling resistance.

(3) The low-cement SiC refractory castable uses SiC with SiC more than 97 percent as refractory aggregate and powder, and SiO is added₂Superfine powder and silicon metal antioxidant, refractory cement as binder and polyphosphate water reducing agent, and low-cement SiC refractory casting material features low linear expansion coefficient, high heat conductivity, high strength and high antiwear performance.

At present, the commonly used heat-insulating refractory castable material has the following construction defects:

(i) since the refractory castable of silicon carbide has poor water solubility, in a water-based unshaped refractory such as a castable, the refractory castable of silicon carbide sometimes has poor compactness due to poor fluidity, and further, is poor in sintering and difficult to obtain high strength, and has the greatest disadvantage that the refractory castable of silicon carbide is chemically unstable in a certain atmosphere, and for example, is easily corroded in an oxidizing gas (such as oxygen, steam, carbon monoxide, carbon dioxide), iron oxide, etc., and is easily decomposed by oxidation in molten iron and vacuum.

(ii) The clay refractory castable has the advantages of acid slag and acid gas corrosion resistance, poor resistance to alkaline substances, good thermal property, and rapid cooling and heating resistance, and after the temperature of the clay refractory castable exceeds 1200 ℃, low-melting-point substances in the clay refractory castable melt gradually, and the particles are very tightly close to each other due to the surface tension effect, so that the volume shrinkage occurs.

Disclosure of Invention

The invention discloses a heat-insulating refractory castable and a preparation method, a pouring method and application thereof, and the heat-insulating refractory castable has the characteristics of small volume density, small heat conductivity, good pouring integrity, good drying strength, high use temperature, energy conservation, environmental protection, certain compressive strength, convenience in construction and the like. Meanwhile, the castable is suitable for an unshaped refractory material formed in a pouring mode and has the advantages of fire resistance, high temperature resistance and corrosion resistance.

Specifically, to achieve the above object, the technical solution of the present invention is as follows:

the invention discloses a heat-insulating refractory castable, which comprises the following raw materials, by mass, 1.7-2.6% of a first component and 97.4-98.3% of a second component; the first component comprises 35-40% of cementing agent, 13-20% of clay powder and 40-50% of lightweight aggregate; the second component is water.

Further, the raw materials of the heat-preservation refractory castable comprise 2% of a first component and 98% of a second component in percentage by mass; wherein, the first component comprises 38% of cementing agent, 16% of clay powder and 46% of lightweight aggregate; the second component is water.

Furthermore, the lightweight aggregate comprises any one of expanded perlite, expanded vermiculite, ceramsite, clayey or high-alumina porous clinker and the like, and the obtained heat-insulating refractory castable has light volume weight, stable volume, high strength, good structure air tightness and obviously reduced structure weight compared with other castables by taking the lightweight materials as the aggregate.

Further, the cementing agent includes at least one of ordinary portland cement, alumina cement, water glass, phosphate, and the like.

Further, the heat-preservation refractory castable also comprises an additive, such as at least one of a water reducing agent, a plasticizer, a defoaming agent and the like.

The second aspect of the invention discloses a preparation method of the heat-preservation refractory castable, which comprises the steps of wetting the aggregate with water, then adding the cementing agent, clay powder and the rest water, and stirring until the color of the material is uniform.

Further, in the preparation method, the mixture is stirred until the color is uniform and the mixture is kneaded into a dough by hand, so that the health food is obtained.

Further, in the preparation method, the water is divided into two parts, namely, one part of the water is used for wetting the aggregate, and the other part of the water, the cementing agent and the clay powder are added into the wetted aggregate.

Further, the preparation method also comprises a step of adding an additive into the wetted aggregate.

Further, when the cementing agent is ordinary portland cement, the standing time of the prepared heat-preservation refractory castable should not exceed 60 min.

Furthermore, when the cementing agent is alumina cement, water glass or phosphate, the standing time of the prepared heat-preservation refractory castable should not exceed 30 min.

The third aspect of the invention discloses a pouring method of the heat-preservation refractory castable obtained by the preparation method of the second aspect, which comprises the following steps:

(1) and cleaning the pouring base surface, and fixing the pouring model for later use.

(2) And pouring the prepared heat-preservation refractory castable in layers and vibrating the prepared heat-preservation refractory castable in the model in layers to obtain the heat-preservation refractory castable.

Further, in the pouring method, when the heat-preservation refractory castable is poured on the surface of the castable which is just poured and formed, pouring is carried out after the castable is maintained for 24 hours. And, preferably, when the cementing agent in the casting material is water glass or phosphate, the next layer of casting material is cast after the water glass or phosphate is isolated by waterproof paper and a plastic film.

Furthermore, in the pouring method, when the joint is poured, loose parts on the surface of the joint are cleaned, and pouring is carried out after watering and wetting.

Furthermore, in the pouring method, the surface of the poured material after pouring is vibrated to be flat and dense, and cracks which can not be seen by naked eyes are avoided.

Furthermore, in the pouring method, the curing system of the lightweight castable is determined according to the cementing agent, and dry curing or no curing is adopted.

In a fourth aspect of the invention, the application of the heat-preservation refractory castable in boiler hearth construction is disclosed.

Compared with the prior art, the invention has the following beneficial effects:

(1) the heat-insulating refractory pouring material disclosed by the invention is light in volume weight, but is stable in volume, high in strength, good in structural air tightness and remarkably reduced in structural weight compared with other pouring materials.

(2) The heat-preservation fireproof casting material has good heat-preservation and heat-insulation effects and high use temperature, can be directly contacted with flame to be used as a working lining, realizes high-temperature energy conservation, can be used for quickly baking a furnace, has high porosity and smooth exhaust, shortens the baking period, and has remarkable economic benefit.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description serve to explain the invention and not to limit the invention. Embodiments of the invention are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is a diagram showing the effect of the insulating refractory castable prepared according to the first embodiment of the invention.

Fig. 2 is an effect diagram of pouring and molding of the heat-preservation refractory castable prepared according to the first embodiment of the invention.

Detailed Description

The invention will be further illustrated with reference to the following specific examples. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. The experimental procedures, in which specific conditions are not noted in the following examples, are generally carried out according to conventional conditions or according to conditions recommended by the manufacturers.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The reagents or starting materials used in the present invention can be purchased from conventional sources, and unless otherwise specified, the reagents or starting materials used in the present invention can be used in a conventional manner in the art or in accordance with the product specifications. In addition, any methods and materials similar or equivalent to those described herein can be used in the methods of the present invention. The preferred methods and materials described in this invention are exemplary only. The invention will now be further illustrated with reference to specific examples.

First embodiment

The preparation method of the heat-preservation refractory castable comprises the following raw materials by mass percent: 2% of a first component and 98% of a second component; the first component comprises 38% of 42.5 portland cement, 16% of clay powder and 46% of expanded perlite, and the second component is water. The preparation method comprises the following steps:

(1) the first component and the second component are respectively weighed according to the proportion of the raw materials in the embodiment.

(2) Dividing the water into two parts, namely wetting the expanded perlite by one part, adding the cementing agent, the clay powder and the other part of water into the wetted expanded perlite, stirring until the color is uniform, and kneading into a mass by hand to obtain the heat-insulating refractory castable, wherein an effect diagram of the castable is shown in fig. 1.

(3) Pouring the heat-preservation refractory castable obtained in the step (2) into a clean cuboid mold for vibration molding, wherein the vibration time is 15 minutes, the compression ratio of a mixture is 1.8, the volume density of the castable is ensured, after molding, natural curing is carried out for 3 days, the environmental temperature is controlled below 25 ℃, when the environmental temperature is higher than 25 ℃, wet curing is carried out after initial setting, and after curing, the obtained heat-preservation refractory castable is shown in figure 2, and after testing, the castable has the volume density of 0.621g/cm³The compression strength is 1.84MPa, the fire-resistant temperature is above 900 ℃, and the thermal conductivity is 0.166W/(m.k).

Second embodiment

The preparation method of the heat-preservation refractory castable comprises the following raw materials by mass percent: 1.7% of the first component and 98.3% of the second component; the first component comprises 40% of 42.5 portland cement, 20% of clay powder and 40% of expanded vermiculite, and the second component is water. The preparation method comprises the following steps:

(1) the first component and the second component are respectively weighed according to the proportion of the raw materials in the embodiment.

(2) And (2) dividing the water into two parts, namely wetting the expanded vermiculite by using one part, adding the cementing agent, the clay powder and the other part of water into the wetted expanded vermiculite, stirring until the color is uniform, and kneading the mixture into a mass by hand to obtain the heat-insulating refractory castable.

(3) Pouring the heat-preservation refractory castable obtained in the step (2) into a clean cuboid mold for vibration molding, wherein the vibration time is 12 minutes, the compression ratio of the mixture is 1.8, so as to ensure the volume density of the castable, after molding, performing natural curing for 3 days, controlling the ambient temperature below 25 ℃, and when the ambient temperature is higher than 25 ℃, performing wet curing after initial setting, and after curing is completed. Through testing, the volume density of the obtained heat-preservation refractory castable is 0.633g/cm³The compression strength is 1.72MPa, the fire-resistant temperature is above 900 ℃, and the thermal conductivity is 0.177W/(m.k).

Third embodiment

The preparation method of the heat-preservation refractory castable comprises the following raw materials by mass percent: 2.4% of the first component and 97.6% of the second component; the first component comprises 37% of 42.5 portland cement, 13% of clay powder and 50% of expanded perlite, and the second component is water. The preparation method comprises the following steps:

(1) the first component and the second component are respectively weighed according to the proportion of the raw materials in the embodiment.

(2) And (2) uniformly dividing the water into two parts, namely wetting the expanded perlite by one part, adding the cementing agent, the clay powder and the other part of water into the wetted expanded perlite, stirring until the color is uniform, and kneading into a mass by hand to obtain the heat-insulating refractory castable.

(3) Pouring the heat-preservation refractory castable obtained in the step (2) into a clean cuboid mould for vibration molding for 14 minutes to enable the mixture to be stirredThe compression ratio of the casting material is 1.6 to ensure the volume density of the casting material, after molding, natural curing is carried out for 3 days, the environmental temperature is controlled below 25 ℃, when the environmental temperature is higher than 25 ℃, wet curing is carried out after initial setting, and after curing is finished. Through testing, the volume density of the obtained heat-preservation refractory castable is 0.627g/cm³The compression strength is 1.66MPa, the fire-resistant temperature is above 900 ℃, and the thermal conductivity is 0.189W/(m.k).

Fourth embodiment

The preparation method of the heat-preservation refractory castable comprises the following raw materials by mass percent: 2.6% of the first component and 97.4% of the second component; the first component comprises 35% of 42.5 portland cement, 18% of clay powder and 47% of ceramsite, and the second component is water. The preparation method comprises the following steps:

(1) the first component and the second component are respectively weighed according to the proportion of the raw materials in the embodiment.

(2) And (2) dividing the water into two parts, namely wetting the ceramsite by one part, adding the cementing agent, the clay powder and the other part of water into the wetted ceramsite, adding a defoaming agent accounting for 3.5% of the total mass of the first component, stirring until the color is uniform, and kneading into a mass by hand to obtain the heat-insulating refractory castable.

(3) Pouring the heat-preservation refractory castable obtained in the step (2) into a clean cuboid mold for vibration molding, wherein the vibration time is 12 minutes, the compression ratio of the mixture is 1.6, so as to ensure the volume density of the castable, after molding, performing natural curing for 3 days, controlling the ambient temperature below 25 ℃, and when the ambient temperature is higher than 25 ℃, performing wet curing after initial setting, and after curing is completed. Through testing, the volume density of the obtained heat-insulating refractory castable is 0.613g/cm³The compression strength is 1.79MPa, the fire-resistant temperature is above 900 ℃, and the thermal conductivity is 0.184W/(m.k).

Fifth embodiment

The preparation method of the heat-preservation refractory castable comprises the following raw materials by mass percent: 2% of a first component and 98% of a second component; the first component comprises 38% of 42.5 portland cement, 16% of clay powder and 46% of corundum-mullite aggregate, and the second component is water. The preparation method comprises the following steps:

(1) the first component and the second component are respectively weighed according to the proportion of the raw materials in the embodiment.

(2) And (2) dividing the water into two parts, namely wetting the corundum mullite by using one part of the water, adding the cementing agent, the clay powder and the other part of the water into the wetted corundum mullite, stirring until the color is uniform, kneading into a mass by hand and easily forming, thus obtaining the heat-insulating refractory castable.

(3) Pouring the heat-preservation refractory castable obtained in the step (2) into a clean cuboid mold for vibration molding, wherein the vibration time is 15 minutes, the compression ratio of a mixture is 1.8, the volume density of the castable is ensured, after molding, natural curing is carried out for 3 days, the environmental temperature is controlled below 25 ℃, when the environmental temperature is higher than 25 ℃, wet curing is carried out after initial setting, and after curing, tests show that the castable has the volume density of 3.387g/cm³The compression strength is 1.73MPa, the fire-resistant temperature is above 700 ℃, and the thermal conductivity is 0.294W/(m.k).

Although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.