阅读说明：本技术 耐火材料组合物、耐火材料及其制备方法 (Refractory composition, refractory and preparation method thereof ) 是由 任靖 杜钰 于金海 吕岩 张南 于 2018-07-19 设计创作，主要内容包括：本发明涉及耐火材料领域,公开了一种新的耐火材料组合物,由该耐火材料组合物制备得到的耐火材料,该耐火材料组合物含有FCC废催化剂、粘土、羧烷基纤维素、硅酸盐和硅溶胶,其中,相对于100重量份的所述FCC废催化剂,所述粘土的含量为3-20重量份,所述羧烷基纤维素的含量为5-20重量份,所述硅酸盐的含量为2-10重量份,所述硅溶胶的含量为2-15重量份。该耐火材料组合物通过FCC废催化剂代替粘土作为原料制备耐火材料,既解决了FCC废催化剂的环保处理问题,又可以得到性能较好的耐火材料,变废为宝,具有较好的经济效益和社会效益。(The invention relates to the field of refractory materials, and discloses novel refractory material compositions, a refractory material prepared from the refractory material composition, and the refractory material composition contains FCC waste catalyst, clay, carboxyalkyl cellulose, silicate and silica sol, wherein, relative to 100 parts by weight of the FCC waste catalyst, the clay content is 3-20 parts by weight, the carboxyalkyl cellulose content is 5-20 parts by weight, the silicate content is 2-10 parts by weight, and the silica sol content is 2-15 parts by weight.)

The refractory composition of claim , wherein the refractory composition comprises FCC spent catalyst, clay, carboxyalkyl cellulose, silicate and silica sol, wherein the clay is contained in an amount of 3 to 20 parts by weight, the carboxyalkyl cellulose is contained in an amount of 5 to 20 parts by weight, the silicate is contained in an amount of 2 to 10 parts by weight, and the silica sol is contained in an amount of 2 to 15 parts by weight, based on 100 parts by weight of the FCC spent catalyst.

2. The refractory composition according to claim 1, wherein the clay is contained in an amount of 5 to 15 parts by weight, the carboxyalkyl cellulose is contained in an amount of 5 to 10 parts by weight, the silicate is contained in an amount of 3 to 5 parts by weight, and the silica sol is contained in an amount of 3 to 5 parts by weight, relative to 100 parts by weight of the FCC spent catalyst.

3. The refractory composition of claim 1, wherein the carboxyalkyl cellulose is carboxymethyl cellulose and/or carboxyethyl cellulose, preferably carboxymethyl cellulose;

the silicate is sodium silicate and/or potassium silicate, preferably sodium silicate;

the silica sol has a silica content of 30 to 50 wt%.

A method for preparing kinds of refractory material, which is characterized in that the method comprises the following steps,

1) a step of mixing the refractory composition of any of claims 1-3 with water;

2) and drying and roasting the mixture mixed with water.

5. The method of claim 4, further comprising the step of allowing the resulting mixture to stand after mixing with water.

6. The method of claim 5, wherein the conditions of placement comprise: the temperature for standing is 5-40 deg.C, and the standing time is 12-72 hr.

7. The process of any of claims 4-6, wherein the water is used in an amount of 5-30 parts by weight per 100 parts by weight of the FCC spent catalyst in step 1).

8. The method of any of claims 4-6, wherein the drying in step 2) is at a temperature of 70-100 ℃ for a period of 5-20 hours.

9. The method as claimed in any of claims 4-6, wherein the calcination condition in step 2) includes calcination temperature of 1100-1150 ℃ for 0.5-4 hours.

10. A refractory obtained by the method of producing a refractory according to any of claims 4 to 9.

Technical Field

The invention relates to the field of refractory materials, in particular to refractory material compositions and a refractory material prepared from the refractory material compositions.

Background

The refractory brick is a refractory material fired by refractory clay or other refractory raw materials and is mainly used for bricking and smelting furnaces. The smelting furnace made of refractory bricks not only bears the action of high temperature, but also bears the tolerance of adjusting the appearance size of the bricks and balances the expansion stress among the bricks. Therefore, only by using refractory bricks with high compressive strength, a smelting furnace with high efficiency and long service life can be obtained.

The existing firebricks are mostly produced by adopting the traditional production process of clay solid bricks, and a large amount of soil is required in the production process, so that the ecological environment is damaged; the existing refractory brick has low strength, high brittleness and poor fire resistance and heat insulation performance, and can not meet the requirements of special buildings on high-performance refractory bricks.

Disclosure of Invention

The invention aims to overcome the problems that the preparation process of the refractory brick damages the ecological environment and the obtained refractory brick has poor fire resistance and heat insulation performance in the prior art, and provides novel refractory material compositions, refractory materials and a preparation method thereof.

In order to achieve the above objects, the aspect of the present invention provides refractory compositions, wherein the refractory compositions comprise FCC spent catalyst, clay, carboxyalkyl cellulose, silicate and silica sol, wherein the clay is contained in an amount of 3 to 20 parts by weight, the carboxyalkyl cellulose is contained in an amount of 5 to 20 parts by weight, the silicate is contained in an amount of 2 to 10 parts by weight, and the silica sol is contained in an amount of 2 to 15 parts by weight, relative to 100 parts by weight of the FCC spent catalyst.

Preferably, the clay is contained in an amount of 5 to 15 parts by weight, the carboxyalkyl cellulose is contained in an amount of 5 to 10 parts by weight, the silicate is contained in an amount of 3 to 5 parts by weight, and the silica sol is contained in an amount of 3 to 5 parts by weight, relative to 100 parts by weight of the FCC dead catalyst.

Preferably, the carboxyalkyl cellulose is carboxymethyl cellulose and/or carboxyethyl cellulose;

more preferably, the carboxyalkyl cellulose is carboxymethyl cellulose.

Preferably, the silicate is sodium silicate and/or potassium silicate;

more preferably, the silicate is sodium silicate.

Preferably, the silica sol has a silica content of 30 to 50 wt.%.

The invention also provides a preparation method of refractory materials, wherein the method comprises the following steps,

1) a step of mixing the refractory composition of the present invention with water;

2) and drying and roasting the mixture mixed with water.

Preferably, the method further comprises the step of placing the resulting mixture after mixing with water.

Preferably, the conditions of the placing include: the temperature for standing is 5-40 deg.C, and the standing time is 12-72 hr.

Preferably, in step 1), the water is used in an amount of 5 to 30 parts by weight with respect to 100 parts by weight of the FCC dead catalyst.

Preferably, in the step 2), the drying temperature is 70-100 ℃, and the drying time is 5-20 hours.

Preferably, the conditions of the calcination include: the roasting temperature is 1100-1150 ℃, and the roasting time is 0.5-4 hours.

The invention also provides the refractory material prepared by the preparation method of the refractory material.

According to the technical scheme, the invention provides novel refractory material compositions, a refractory material and a preparation method thereof, the refractory material composition is prepared by using the FCC waste catalyst to replace clay as a raw material, the problem of environmental protection treatment of the FCC waste catalyst is solved, the refractory material with better performance can be obtained, waste is changed into valuable, and the refractory material has better economic benefit and social benefit.

Detailed Description

For numerical ranges, between the endpoints of each range and the individual points, and between the individual points may be combined with each other to yield new numerical ranges or ranges, which should be considered as specifically disclosed herein.

In the present invention, the "FCC waste catalyst" means a fluid catalytic cracking waste catalyst after the use of a fluid catalytic cracking unit.

The aspect of the present invention provides refractory compositions, wherein the refractory compositions comprise FCC spent catalyst, clay, carboxyalkyl cellulose, silicate and silica sol, wherein the clay is contained in an amount of 3 to 20 parts by weight, the carboxyalkyl cellulose is contained in an amount of 5 to 20 parts by weight, the silicate is contained in an amount of 2 to 10 parts by weight, and the silica sol is contained in an amount of 2 to 15 parts by weight, relative to 100 parts by weight of the FCC spent catalyst.

From the viewpoint of further improving the fire resistance and thermal insulation properties of the resulting refractory material in step , it is preferable that the clay content is 4 to 20 parts by weight, the carboxyalkyl cellulose content is 4 to 15 parts by weight, the silicate content is 2 to 7 parts by weight, and the silica sol content is 2 to 10 parts by weight, with respect to 100 parts by weight of the FCC spent catalyst, and it is more preferable that the clay content is 5 to 15 parts by weight, the carboxyalkyl cellulose content is 5 to 10 parts by weight, the silicate content is 3 to 5 parts by weight, and the silica sol content is 3 to 5 parts by weight, with respect to 100 parts by weight of the FCC spent catalyst.

Specific examples of the content of the clay with respect to 100 parts by weight of the FCC spent catalyst may be, for example: 3 parts by weight, 4 parts by weight, 5 parts by weight, 6 parts by weight, 7 parts by weight, 8 parts by weight, 9 parts by weight, 10 parts by weight, 11 parts by weight, 12 parts by weight, 13 parts by weight, 14 parts by weight, 15 parts by weight, 16 parts by weight, 17 parts by weight, 18 parts by weight, 19 parts by weight, 20 parts by weight, and any two of these points.

Specific examples of the content of the carboxyalkyl cellulose with respect to 100 parts by weight of the FCC spent catalyst may be, for example: 5 parts by weight, 6 parts by weight, 7 parts by weight, 8 parts by weight, 9 parts by weight, 10 parts by weight, 11 parts by weight, 12 parts by weight, 13 parts by weight, 14 parts by weight, 15 parts by weight, 16 parts by weight, 17 parts by weight, 18 parts by weight, 19 parts by weight, 20 parts by weight, and any two of these points.

Specific examples of the content of the silicate may be, for example, with respect to 100 parts by weight of the FCC spent catalyst: 2 parts by weight, 3 parts by weight, 4 parts by weight, 5 parts by weight, 6 parts by weight, 7 parts by weight, 8 parts by weight, 9 parts by weight, 10 parts by weight, and any two of these points constitute any point value in the range.

Specific examples of the content of the silica sol with respect to 100 parts by weight of the FCC spent catalyst may be, for example: 2 parts by weight, 3 parts by weight, 4 parts by weight, 5 parts by weight, 6 parts by weight, 7 parts by weight, 8 parts by weight, 9 parts by weight, 10 parts by weight, 11 parts by weight, 12 parts by weight, 13 parts by weight, 14 parts by weight, 15 parts by weight, and any two of these points constitute any point value in the range.

According to the present invention, preferably, the carboxyalkyl cellulose is carboxymethyl cellulose and/or carboxyethyl cellulose; more preferably, the carboxyalkyl cellulose is carboxymethyl cellulose.

According to the invention, preferably, the silicate is sodium silicate and/or potassium silicate; more preferably, the silicate is sodium silicate.

According to the invention, the silica sol preferably has a silica content of 30 to 50% by weight.

Specific contents of silica in the silica sol include: 30 wt%, 31 wt%, 32 wt%, 33 wt%, 34 wt%, 35 wt%, 38 wt%, 40 wt%, 41 wt%, 42 wt%, 43 wt%, 44 wt%, 45 wt%, 48 wt%, 50 wt%, and any two of these points.

The invention also provides a preparation method of refractory materials, wherein the method comprises the following steps,

1) a step of mixing the refractory composition of the present invention with water;

2) and drying and roasting the mixture mixed with water.

According to the method of the present invention, it is preferable that the FCC spent catalyst is calcined and the calcined product is pulverized before mixing the refractory composition of the present invention with water, whereby the refractory and insulating properties of the resulting refractory can be further improved in step .

Preferably, the conditions of the above calcination include: the roasting temperature is 600-900 ℃, and the roasting time is 30-90 minutes. The firing may be performed, for example, in a microwave muffle furnace. The above pulverization may be carried out, for example, by cooling the calcined product to room temperature and then grinding and pulverizing the same with a 300-mesh grinder.

According to the method of the present invention, preferably, the clay is sieved through a 300 mesh screen before mixing the refractory composition of the present invention with water.

According to the method of the present invention, preferably, the method further comprises a step of leaving the resultant mixture after mixing with water.

The conditions for the above-mentioned placing may include, for example: the standing temperature is 5-40 ℃, and the standing time is 12-72 hours; preferably, the conditions of the above-mentioned placing include: the temperature for placing is 10-30 ℃, and the time for placing is 24-48 hours.

According to the method of the present invention, the amount of the water used may be selected according to the amount of the FCC waste catalyst, and preferably, the amount of the water used in step 1) is 5 to 30 parts by weight with respect to 100 parts by weight of the FCC waste catalyst; more preferably, the water is used in an amount of 10 to 25 parts by weight with respect to 100 parts by weight of the FCC spent catalyst in step 1).

In step 1), specific amounts of water used for 100 parts by weight of the FCC spent catalyst include, for example: 5 parts by weight, 6 parts by weight, 7 parts by weight, 8 parts by weight, 9 parts by weight, 10 parts by weight, 11 parts by weight, 12 parts by weight, 13 parts by weight, 14 parts by weight, 15 parts by weight, 16 parts by weight, 17 parts by weight, 18 parts by weight, 19 parts by weight, 20 parts by weight, 21 parts by weight, 22 parts by weight, 23 parts by weight, 24 parts by weight, 25 parts by weight, 26 parts by weight, 27 parts by weight, 28 parts by weight, 29 parts by weight, 30 parts by weight, and any point value in the range of any two of these point values.

According to the method of the present invention, in step 2), the drying may be performed by various methods generally used in the art, for example, in step 2), the drying temperature may be 70 to 100 ℃, and the drying time may be 5 to 20 hours.

Preferably, in step 2), the roasting conditions include: the roasting temperature is 1100-1150 ℃, and the roasting time is 0.5-4 hours.

The invention also provides the refractory material prepared by the preparation method of the refractory material.

The present invention will be described in detail below by way of examples.

In the following examples and comparative examples, the FCC waste catalyst was obtained from the chinese petrochemical yanshan petrochemical company, and before use, the FCC waste catalyst was calcined and then the calcined product was pulverized, specifically, after the calcined product was calcined in a microwave muffle furnace at 800 ℃ for 60 minutes, cooled to room temperature, and then pulverized by grinding using an industrial grinder with a 300 mesh screen.

Carboxymethyl cellulose was purchased from Weifang Ciliao cellulose Ltd; sodium silicate was purchased from west ampere, huachang water glass ltd. The silica sol was purchased from Shandong Baite New Material Co., Ltd, and the silica content was 30% by weight. The clay was additionally sieved through a 300 mesh screen prior to use.