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CN111116172A - Low-density mullite heat-insulating brick and preparation method thereof - Google Patents

Low-density mullite heat-insulating brick and preparation method thereof Download PDF

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Publication number
CN111116172A
CN111116172A CN201911421962.3A CN201911421962A CN111116172A CN 111116172 A CN111116172 A CN 111116172A CN 201911421962 A CN201911421962 A CN 201911421962A CN 111116172 A CN111116172 A CN 111116172A
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parts
content
alumina
temperature
heat
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CN201911421962.3A
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Inventor
刘程
冯斌
杨华亮
张苏轼
孔令锋
周忠
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Foshan Ceramic Research Institute Co ltd
Guangdong Jingang New Material Co ltd
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Foshan Ceramic Research Institute Co ltd
Guangdong Jingang New Material Co ltd
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Priority to CN201911421962.3A priority Critical patent/CN111116172A/en
Publication of CN111116172A publication Critical patent/CN111116172A/en
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    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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Abstract

The invention discloses a low-density mullite heat-insulating brick which is mainly prepared from the following raw materials in parts by volume: 30-50 parts of sedimentation tank mud, 5-30 parts of alumina, 10-30 parts of an expanding agent, 20-35 parts of kaolin, and 150-250 parts of polystyrene balls. The volume density of the low-density mullite heat-insulating brick is 0.55-0.65g/cm3The compression strength is 1.0-2.5MPa, and the rate of change of a re-burning line is +/-0.5% at 1510 ℃ for 24 h; the heat conductivity coefficient is 0.21-0.3W/(m.K) when the average temperature is 1000 ℃. The invention also discloses a preparation method of the heat insulation brick, which adopts extrusion molding and has high production efficiency.

Description

Low-density mullite heat-insulating brick and preparation method thereof
Technical Field
The invention belongs to the field of new material preparation, and particularly relates to a low-density mullite heat-insulating brick and a preparation method thereof.
Background
The kiln is the most critical equipment for firing ceramic products, and the low-density mullite heat-insulating brick is the key material for forming the kiln equipment. With the increasing attention of human beings on greenhouse gas emission, the reduction of the energy consumption of the high-temperature kiln is very important. The light low-density mullite heat-insulating brick is used for building the high-temperature kiln, so that the heat storage of the high-temperature kiln can be reduced, and the energy consumption of the kiln can be reduced.
On the other hand, the ceramic roller is a key material used on roller kilns fired by building ceramics and daily ceramics. When the ceramic roller is produced, a large amount of waste water is generated in the raw material ball milling process, the waste water contains a small part of refractory silt, and the silt is precipitated at the bottom of a sedimentation tank. The method is characterized in that the method comprises the following steps of cleaning a sedimentation tank every time, digging out refractory slurry (sedimentation tank sludge for short) which is complex in components, and can not be used for roller rod production and can only be poured out as garbage. In order to reduce the environmental damage caused by the industrial wastes, it is of practical significance to use the industrial wastes to make useful products.
Disclosure of Invention
The invention aims to solve the technical problem of providing a low-density mullite heat-insulating brick which has low volume density and small heat conductivity coefficient and can effectively reduce the heat consumption of kiln firing; and can realize the resource utilization of the sedimentation tank mud.
The invention also aims to solve the technical problem of providing a preparation method of the low-density mullite heat-insulating brick, which has high production efficiency.
In order to solve the technical problems, the invention provides a low-density mullite heat-insulating brick which is mainly prepared from the following raw materials in parts by volume: 30-50 parts of sedimentation tank mud, 5-30 parts of alumina, 10-30 parts of an expanding agent, 20-35 parts of kaolin, and 150-250 parts of polystyrene balls.
As an improvement of the technical scheme, the sedimentation tank mud is generated in the production process of the ceramic roller rod; al in the sedimentation tank mud2O3The content of (B) is 60-65 wt%, SiO2Is 25 to 30 wt%, ZrO2The content of (B) is 0.1-3 wt%;
the maximum particle size of the sedimentation tank mud is less than 44 mu m.
As an improvement of the technical scheme, the polystyrene ball is less than 1.5 mm.
As an improvement of the technical scheme, the expanding agent is one or a combination of kyanite, andalusite and sillimanite; al in the expanding agent2O3Content is more than or equal to 50 wt%, Fe2O3The content is less than or equal to 1.0 wt%, and the maximum particle size is less than 100 mu m.
As an improvement of the technical scheme, the expanding agent is kyanite or andalusite.
As an improvement of the technical scheme, the alumina is gamma-alumina and/or α -alumina;
in the α -alumina, Al2O3The content is more than or equal to 99 wt%, and the maximum granularity is less than 44 mu m;
in the gamma-alumina, Al is2O3The content is more than or equal to 97wt percent, and the maximum granularity is less than 88 mu m.
As an improvement of the technical scheme, Al in the kaolin is2O3Content not less than 30 wt%, Fe2O3The content is less than or equal to 1.2 wt%, and the maximum particle size is less than 90 mu m.
As an improvement of the technical proposal, the volume density of the heat insulation brick is 0.55-0.65g/cm3The compression strength is 1.0-2.5MPa, and the rate of change of a re-burning line is +/-0.5% at 1510 ℃ for 24 h;
the heat conductivity coefficient is 0.21-0.3W/(m.K) when the average temperature is 1000 ℃;
al in the low-density mullite heat-insulating brick2O365-68 wt.% of Fe2O3The content is less than or equal to 1.0wt percent.
Correspondingly, the invention provides a preparation method of the low-density mullite heat-insulating brick, which comprises the following steps:
(1) uniformly mixing 20-50 parts of sedimentation tank mud, 5-20 parts of gamma-alumina, 5-20 parts of α -alumina, 10-30 parts of an expanding agent and 20-35 parts of kaolin;
(2) adding 150 portions of polystyrene balls and 250 portions of polystyrene balls, and adding a preset amount of water. Uniformly mixing to obtain pug;
(3) extruding and molding the pug to obtain a green body of the heat-insulating brick;
(4) and drying, sintering and processing the heat-insulating brick blank to obtain a low-density mullite heat-insulating brick finished product.
As an improvement of the technical scheme, the firing curve of the heat-insulating brick blank is as follows:
the temperature is raised for 4 to 6 hours from the room temperature to 200 ℃;
the temperature is raised for 2 to 5 hours from 200 to 600 ℃;
keeping the temperature at 600 ℃ for 1.5-2.5 h;
the temperature is raised for 4.5 to 5.5 hours from 600 ℃ to 1100 ℃;
heating for 5-7h from 1100 ℃ to the highest firing temperature;
preserving the heat for 10-12h at the highest sintering temperature;
the maximum firing temperature is 1450-.
The implementation of the invention has the following beneficial effects:
1. the method applies the sedimentation tank mud generated in the production process of the ceramic roller rod to the production of the low-density mullite heat-insulating brick, realizes the resource utilization of the sedimentation tank mud, and is energy-saving and environment-friendly.
2. The volume density of the heat-insulating brick is effectively reduced by controlling the addition amount of the polystyrene balls; furthermore, the heat conductivity coefficient of the heat insulation brick is effectively reduced by controlling the granularity of the polystyrene balls. The volume density of the heat insulation brick is 0.55-0.65g/cm3And when the average temperature is 1000 ℃, the thermal conductivity is 0.21-0.3W/(m.K).
3. The invention ensures that the mullite phase and the corundum phase in the fired heat-insulating brick are reasonable by a reasonable formula structure and sintering under a specific firing system, thereby ensuring that the compressive strength and the re-firing line change rate of the heat-insulating brick are kept in a reasonable range.
4. The invention adopts the extrusion molding process, and has high production efficiency.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail below.
The invention discloses a low-density mullite heat-insulating brick which is mainly prepared from the following raw materials in parts by volume: 30-50 parts of sedimentation tank mud, 5-30 parts of alumina, 10-30 parts of an expanding agent, 20-35 parts of kaolin, and 150-250 parts of polystyrene balls.
Wherein the sedimentation tank mud is generated in the production process of the ceramic roller; al in mud of sedimentation tank adopted by the invention2O3The content of (B) is 60-65 wt%, SiO2Is 25 to 30 wt%, ZrO2The content of (B) is 0.1-3 wt%; the adding volume portion of the sedimentation tank mud is 30-50 portions, preferably 40-50 portions.
The polystyrene balls are main pore-forming agents, are decomposed within the temperature range of 150-400 ℃, form holes in the low-density mullite heat-insulating brick blank, and have thicker hole walls and higher strength. When the added volume part of the polystyrene ball is less than 150 parts, the hole structure is too few, and the volume density and the heat conductivity coefficient are high; when the polystyrene spheres are added in an amount of more than 250 parts by volume, an excessive pore structure is generated and the compressive strength is low. Furthermore, in order to control the thermal conductivity, the granularity of the polystyrene spheres is controlled to be less than 1.5mm, and specifically, the granularity of the polystyrene spheres is controlled to be 0.1-1.4 mm.
Decomposing the polystyrene ball at the temperature of 150-; however, in the post-firing process, due to the decomposition of other materials, gas is released and shrinkage is generated at the same time, the pore structures are damaged, and the volume density and the heat conductivity coefficient of the insulating brick are improved. In order to overcome the problem, the invention adjusts the formula structure, and the concrete steps are as follows:
in the formulation of the present invention, the kaolin functions asProviding plasticity and a part of mullite crystal phase, but decomposing the kaolin at the temperature of 600-800 ℃ to release crystal water, and damaging the existing pore structure by generated gas; and it will produce large shrinkage after releasing crystal water and also destroy the pore structure. Therefore, the invention introduces sedimentation tank mud into the formula, which can provide part of plasticity and reduce the addition amount of kaolin; on the other hand, the alumina and the expanding agent are introduced into the formula, the alumina does not shrink in the firing process, the expanding agent can generate certain expansion in the firing process, and the hole structure of the heat-insulating brick can be effectively maintained through the combination of the alumina and the expanding agent. After the above-mentioned means are adopted, the volume portion of kaolin in the formula of the invention is 20-35 portions, preferably 30-35 portions. Further, controlling Al in the kaolin2O3Content not less than 30 wt%, Fe2O3The content is less than or equal to 1.2wt percent. The kaolin generates more mullite phases in the firing process, and the thermal shock stability of the heat-insulating brick can be improved; meanwhile, the content of organic matters is low, and the shrinkage is small.
Specifically, the alumina in the invention is added in an amount of 5-30 parts by volume, preferably 10-20 parts by volume, the alumina in the invention can be gamma-alumina and/or α -alumina, preferably gamma-alumina and α -alumina, wherein the α -alumina is calcined α -alumina micropowder, and Al in the alumina micropowder is added2O3The content is more than or equal to 99 wt%; the gamma-alumina is industrial alumina and Al thereof2O3The content is more than or equal to 97wt percent. The two kinds of alumina have high reaction activity, can partially react with silicon dioxide in other raw materials at high temperature to form a mullite crystal phase, reduce shrinkage in the firing process and simultaneously improve the thermal shock stability of the low-density mullite heat-insulating brick.
Specifically, in the invention, the expanding agent is selected from one or a combination of sillimanite, kyanite and andalusite; al in the expanding agent2O3Content is more than or equal to 50 wt%, Fe2O3The content of (B) is less than or equal to 1.0 wt%. Preferably, the expanding agent is kyanite or andalusite. The expanding agent can expand at high temperature, so that the sintering shrinkage is effectively reduced, and the hole structure of the insulating brick is reserved; all in oneWhen the thermal expansion agent is used, the expansion agent reacts at high temperature to form mullite, the proportion of corundum phase and mullite phase is optimized, the thermal expansion coefficient is reduced, and the thermal shock stability is improved.
Further, in order to form a reasonable pore structure, the particle sizes of various raw materials are controlled, wherein the maximum particle size of sedimentation tank mud is controlled to be less than 44 microns, the maximum particle size of a swelling agent is controlled to be less than 100 microns, the maximum particle size of α -alumina is controlled to be less than 44 microns, the maximum particle size of gamma-alumina is controlled to be less than 88 microns, and the maximum particle size of kaolin is controlled to be less than 90 microns, specifically, the particle size range of sedimentation tank mud is 2-40 microns, the particle size range of a swelling agent is 40-90 microns, the particle size range of α -alumina is 1-40 microns, the particle size range of gamma-alumina is 20-80 microns, and the particle size of kaolin is 0.1-50 microns, and the particle sizes of various raw materials are controlled to enable the various raw materials to be tightly stacked, so that the porosity of a blank body is reduced, a good foundation is provided for forming a reasonable pore structure for a polystyrene sphere in a later period.
Correspondingly, the invention also discloses a preparation method of the low-density mullite heat-insulating brick, which comprises the following steps:
(1) uniformly mixing 30-50 parts of sedimentation tank mud, 5-30 parts of alumina, 10-30 parts of an expanding agent and 20-35 parts of kaolin;
the raw materials have similar densities and are easy to mix uniformly.
(2) Adding 150 portions of polystyrene balls and 250 portions of polystyrene balls, and adding a preset amount of water. Uniformly mixing to obtain pug;
wherein the water content of the pug is 15-40%; the pug with the water content range has good plasticity and is suitable for subsequent extrusion molding.
Preferably, the mixing process is performed in an edge runner mill, in which the mixing of the polystyrene balls having a large difference in density with other raw materials can be efficiently achieved.
(3) Extruding and molding the pug to obtain a green body of the heat-insulating brick;
the invention optimizes the formula structure, so that the heat insulation brick can be molded by adopting an extrusion molding process, and the production efficiency is greatly improved.
(4) And drying, sintering and processing the heat-insulating brick blank to obtain a low-density mullite heat-insulating brick finished product.
Preferably, the moisture content of the heat insulation brick blank body after drying is less than 1 wt%; can effectively prevent the defect that the insulating brick cracks in the firing process.
Firing the heat insulation brick blank in a tunnel kiln or a tunnel kiln;
preferably, the firing profile is:
the temperature is raised for 4 to 6 hours from the room temperature to 200 ℃;
the temperature is slowly increased within the temperature range, which is beneficial to fully decomposing the polystyrene balls and forming a good hole structure in the green brick. If the temperature rises too fast within the temperature range, the polystyrene spheres expand rapidly, and the expansion speed exceeds the thermal decomposition speed, so that green bricks are cracked. Meanwhile, in the temperature range, other organic matters in the green brick are not decomposed, and oxygen in the green brick is sufficient, so that the complete decomposition of the polystyrene balls is facilitated. In addition, the temperature rise speed is reduced at the temperature, so that the water in the green bricks can be fully discharged, and the green bricks can be prevented from cracking.
The temperature is raised for 2 to 5 hours from 200 to 600 ℃;
keeping the temperature at 600 ℃ for 1.5-2.5 h;
the temperature is raised for 4.5 to 5.5 hours from 600 ℃ to 1100 ℃;
heating for 5-7h from 1100 ℃ to the highest firing temperature;
preserving the heat for 10-12h at the highest sintering temperature;
the maximum firing temperature is 1450-.
The invention effectively reduces the volume density and the heat conductivity coefficient through the compound adjustment of the formula and the preparation process. Preferably, the low-density mullite heat-insulating brick has the volume density of 0.55-0.65g/cm3The compression strength is 1.0-2.5MPa, and the rate of change of a re-burning line is +/-0.5% at 1510 ℃ for 24 h; the heat conductivity coefficient is 0.21-0.3W/(m.K) when the average temperature is 1000 ℃;
the invention is further illustrated by the following specific examples:
example 1:
the formula is as follows:
50 parts of sedimentation tank mud, 10 parts of calcined α alumina micro powder, 20 parts of kyanite, 35 parts of kaolin and 180 parts of polystyrene spheres.
Wherein, Al is contained in the mud in the sedimentation tank2O3The content of SiO is 63 percent2Content of 30% ZrO22.5% of aluminum oxide, a maximum particle size of 41 μm, and Al in calcined α2O3The content is 99.5 percent, and the maximum particle size is 40 mu m; al in kyanite2O3The content is 54 percent, and the maximum particle size is 95 mu m; al in kaolin2O332% of Fe2O3The content is 0.4 percent, and the maximum granularity is 88 mu m; the particle size range of the polystyrene spheres is 1-1.4 mm.
The preparation method comprises the following steps:
(1) uniformly mixing the sedimentation tank mud, calcined α alumina micro powder, kyanite and kaolin according to the volume part ratio;
(2) adding polystyrene balls according to the volume ratio, mixing, adding water, and continuously and uniformly mixing;
(3) extruding and molding the mixed pug in an extruder;
(4) drying the green body until the moisture content is less than 1%, and firing in a kiln at 1500 ℃;
the firing system is as follows:
heating for 5h from room temperature to 200 ℃;
the temperature is raised for 4 hours from 200 ℃ to 600 ℃;
keeping the temperature at 600 ℃ for 2 h;
the temperature is raised for 5 hours from 600 ℃ to 1100 ℃;
keeping the temperature at 1100 ℃ for 2 h;
the temperature is raised for 6 hours from 1100 ℃ to 1500 ℃;
keeping the temperature at 1500 ℃ for 10 h.
Example 2:
the formula is as follows:
40 parts of sedimentation tank mud, 10 parts of industrial alumina, 5 parts of calcined α alumina micro powder, 15 parts of kyanite, 30 parts of kaolin and 200 parts of polystyrene balls.
Wherein Al in the mud of the sedimentation tank2O3Content 65% SiO2ZrO content of 28%2The content is as follows: 0.5 percent, and the particle size range is 20-40 mu m; al in industrial alumina2O3The content of (A) is 98.2%, the particle size range is 20-60 mu m, and Al in calcined α aluminum oxide2O3The content is 99.3 percent, and the particle size range is 10-40 mu m; al in kyanite2O3The content is 55 percent, and the particle size range is 50-90 mu m; al in kaolin2O3Content of (3%) 35% Fe2O3The content is 0.5 percent, and the particle size range is 1-80 mu m; the particle size range of the polystyrene spheres is 0.5-1.2 mm.
The preparation method comprises the following steps:
(1) uniformly mixing the sedimentation tank mud, industrial alumina, calcined α alumina micro powder, kyanite and kaolin according to the volume ratio;
(2) adding polystyrene balls according to the volume ratio, mixing, adding water, and continuously and uniformly mixing to obtain pug;
(3) extruding and molding the mixed pug in an extruder;
(4) drying the green body until the moisture content is less than 1%, and firing in a kiln at 1500 ℃;
the firing system is as follows:
heating for 5h from room temperature to 200 ℃;
the temperature is raised for 4 hours from 200 ℃ to 600 ℃;
keeping the temperature at 600 ℃ for 2 h;
the temperature is raised for 5 hours from 600 ℃ to 1100 ℃;
preserving heat for 3h at 1100 ℃;
the temperature is raised for 6 hours from 1100 ℃ to 1500 ℃;
keeping the temperature at 1500 ℃ for 10 h.
Example 3:
the formula is as follows:
40 parts of sedimentation tank mud, 10 parts of industrial alumina, 10 parts of calcined α alumina micro powder, 30 parts of andalusite, 35 parts of kaolin and 240 parts of polystyrene balls.
Wherein Al in the mud of the sedimentation tank2O3The content of SiO is 61%2Content (wt.)Is 25% ZrO2The content is 1.2 percent, and the particle size range is 10-30 mu m; al in industrial alumina2O398% content, grain size range of 50-74 μm, Al in calcined α alumina2O3The content is 99.8 percent, and the maximum granularity is 10-40 mu m; al in andalusite2O3The content is 58 percent, and the particle size range is 60-90 mu m; al in kaolin2O337% of Fe2O3The content is 0.2 percent, and the particle size range is 0.1-20 mu m; the particle size range of the polystyrene spheres is 0.8-1.4 mm.
The preparation method comprises the following steps:
(1) uniformly mixing the sedimentation tank mud, the industrial alumina, calcined α alumina micro powder, andalusite and kaolin according to the volume ratio;
(2) pouring the premixed mixture into an edge runner mill, mixing the premixed mixture with polystyrene balls added according to the volume proportion, adding water, and continuously and uniformly mixing to obtain pug;
(3) extruding and molding the mixed pug in an extruder;
(4) drying the green body until the moisture content is less than 1%, and firing in a kiln at 1450 ℃;
the firing system is as follows:
heating for 5h from room temperature to 200 ℃;
the temperature is raised for 4 hours from 200 ℃ to 600 ℃;
keeping the temperature at 600 ℃ for 2 h;
the temperature is raised for 5 hours from 600 ℃ to 1100 ℃;
preserving the heat for 2.2 hours at 1100 ℃;
the temperature is raised for 6 hours from 1100 ℃ to 1450 ℃;
the temperature is kept at 1450 ℃ for 10 h.
Example 4:
the formula is as follows:
45 parts of sedimentation tank mud, 20 parts of industrial alumina, 30 parts of andalusite, 30 parts of kaolin and 200 parts of polystyrene balls.
Wherein Al in the mud of the sedimentation tank2O3SiO in an amount of 61%2ZrO in an amount of 21%2The content is 0.2 percent, and the particle size range is 2-25 mu m; industrial processAl in alumina2O3The content is 97.5 percent, and the particle size range is 30-70 mu m; al in andalusite2O3The content is 60 percent, and the particle size range is 50-90 mu m; al in kaolin2O337 percent of Fe2O3The content is 0.5 percent, and the particle size range is 0.1-20 mu m; the particle size range of the polystyrene spheres is 0.3-1 mm.
The preparation method comprises the following steps:
(1) adding the sedimentation tank mud, the industrial alumina, the andalusite and the kaolin into a stirrer according to the volume ratio for premixing;
(2) pouring the premixed mixture into an edge runner mill, mixing the premixed mixture with polystyrene balls added according to the volume proportion, and adding water to continuously and uniformly mix;
(3) extruding and molding the mixed pug in an extruder;
(4) drying the green body until the moisture content is less than 1%, and firing in a kiln at 1500 ℃;
the firing system is as follows:
heating for 5h from room temperature to 200 ℃;
the temperature is raised for 4 hours from 200 ℃ to 600 ℃;
keeping the temperature at 600 ℃ for 2 h;
the temperature is raised for 5 hours from 600 ℃ to 1100 ℃;
preserving heat for 3h at 1100 ℃;
the temperature is raised for 6 hours from 1100 ℃ to 1500 ℃;
the highest firing temperature is 1500 ℃;
keeping the temperature at 1500 ℃ for 10 h.
The low bulk density mullite blocks of examples 1-4 were tested and the results are shown in the following table:
Figure BDA0002352617040000091
in conclusion, the low-density mullite heat-insulating brick prepared by the invention has Al2O3The content is 65-68 wt%, and the volume density is 0.55-0.65/cm3(ii) a The normal temperature compressive strength is 1-2.5MPa, and the heat conductivity coefficient is 0.21-0 at 1000 ℃.3W/(m.K); the rate of change of the line of re-burning at 1510 ℃ for 24h is +/-0.5%.
The above disclosure is only for the purpose of illustrating the preferred embodiments of the present invention, and it is therefore to be understood that the invention is not limited by the scope of the appended claims.

Claims (10)

1. The low-density mullite heat-insulating brick is characterized by being mainly prepared from the following raw materials in parts by volume: 30-50 parts of sedimentation tank mud, 5-30 parts of alumina, 10-30 parts of an expanding agent, 20-35 parts of kaolin, and 150-250 parts of polystyrene balls.
2. The low bulk density mullite thermal insulating brick of claim 1 wherein said settling pond sludge is produced during the production of ceramic rods; al in the sedimentation tank mud2O3The content of (B) is 60-65 wt%, SiO2Is 25 to 30 wt%, ZrO2The content of (B) is 0.1-3 wt%;
the maximum particle size of the sedimentation tank mud is less than 44 mu m.
3. The low bulk density mullite thermal block of claim 1 or 2 wherein the polystyrene spheres are < 1.5 mm.
4. The low-density mullite thermal insulating brick as claimed in claim 1, wherein said expanding agent is selected from one or a combination of kyanite, andalusite and sillimanite; al in the expanding agent2O3Content is more than or equal to 50 wt%, Fe2O3The content is less than or equal to 1.0 wt%, and the maximum particle size is less than 100 mu m.
5. The low bulk density mullite thermal insulating brick of claim 4 wherein said expansion agent is selected from kyanite or andalusite.
6. The low bulk density mullite thermal insulating brick of claim 1 wherein said alumina is selected from the group consisting of gamma alumina and or α alumina;
in the α -alumina, Al2O3The content is more than or equal to 99 wt%, and the maximum granularity is less than 44 mu m;
in the gamma-alumina, Al is2O3The content is more than or equal to 97wt percent, and the maximum granularity is less than 88 mu m.
7. The low bulk density mullite thermal insulation brick of claim 1 wherein said kaolin has Al therein2O3Content not less than 30 wt%, Fe2O3The content is less than or equal to 1.2 wt%, and the maximum particle size is less than 90 mu m.
8. The low bulk density mullite thermal block of claim 1 wherein the low bulk density mullite thermal block has a bulk density of from 0.55 to 0.65g/cm3The compressive strength is 1.0-2.5MPa,
the rate of change of a re-burning line is +/-0.5 percent at 1510 ℃ for 24 h;
the heat conductivity coefficient is 0.21-0.3W/(m.K) when the average temperature is 1000 ℃;
al in the low-density mullite heat-insulating brick2O365-68 wt.% of Fe2O3The content is less than or equal to 1.0wt percent.
9. A method of making a low bulk density mullite thermal insulation brick of any one of claims 1-8 comprising:
(1) uniformly mixing 20-50 parts of sedimentation tank mud, 5-20 parts of gamma-alumina, 5-20 parts of α -alumina, 10-30 parts of an expanding agent and 20-35 parts of kaolin;
(2) adding 150 portions of polystyrene balls and 250 portions of polystyrene balls, and adding a preset amount of water. Uniformly mixing to obtain pug;
(3) extruding and molding the pug to obtain a green body of the heat-insulating brick;
(4) and drying, sintering and processing the heat-insulating brick blank to obtain a low-density mullite heat-insulating brick finished product.
10. The method of claim 9, wherein the green body of the mullite thermal insulation brick has a firing profile of:
the temperature is raised for 4 to 6 hours from the room temperature to 200 ℃;
the temperature is raised for 2 to 5 hours from 200 to 600 ℃;
keeping the temperature at 600 ℃ for 1.5-2.5 h;
the temperature is raised for 4.5 to 5.5 hours from 600 ℃ to 1100 ℃;
heating for 5-7h from 1100 ℃ to the highest firing temperature;
preserving the heat for 10-12h at the highest sintering temperature;
the maximum firing temperature is 1450-.
CN201911421962.3A 2019-12-31 2019-12-31 Low-density mullite heat-insulating brick and preparation method thereof Pending CN111116172A (en)

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