耐火材料结合和黏合剂.ppt

1、Unit 23 Refractory Bonds and Binders,耐火材料结合和黏合剂,1、The importance of bond phase in refractories, in holding the aggregate/grain phases together and enabling large components to be fabricated, is indicated by use of the type of bond in the refractory name. 耐火材料中结合相在维持骨料/晶粒相的结合及使大元件能够焊接在一起的重要作用通过以耐火材料的

2、名义使用的黏合类型得以表明。,The fired integrity of refractories relied on natural bonding or the silicate or aluminosilicate bonds derived from vitrification reactions. 耐火材料煅烧的完整性依赖于自然粘结或硅酸盐或源自玻璃化反应的铝砂酸盐结合。,Bonds initially were synthesized through the use of fine additions, termed mineralizers, later followed by

3、 the introduction of separate cementitious and glassy bond systems. 结合剂最初是由精制添加剂来合成的，命名为矿化剂。后来紧接着引入了分开的似水泥的和玻璃的粘结体系。,2、One of the most significant developments in bond systems has been of those used for monolithic or unshaped refractories that can be formed and shaped in situ. 粘结剂体系的最重要发展之一是用于整块或未加工

4、的耐火材料，这些不定型的耐火材料可以原位成型加工,Monolithic refractory materials are mixtures that contain aggregates and binders prepared ready-for-use either directly in the condition in which they are supplied or after the addition of suitable liquids. 块体耐火材料是一种混合物，包含骨料和黏合剂，事先准备好以备用。这些备料要么是在供应的条件下要么是在适当的液体添加之后。,Monolith

5、ic refractories have been known for many years, but it is only since the 1960s that their use has gained general acceptance in the refractory community. 块体耐火材料已经为人所知多年，但是直到1960s以后它们的应用才引起耐火材料协会的广泛关注。,The types of monolithics now commonplace, such as castables (a dry mix, which, when mixed with water

6、, can be shaped by casting or vibrating) , gunning mixes (free-flowing mixtures specially made for placing by pneumatic or mechanical projection), and moldables or plastics (a plastic clay form, which can be rammed into position), all have evolved from bond systems largely different from those used

7、in brick .,目前普及的块体的类型，如铸块（一种干式混合，当与水混合时可以通过铸造和振荡成型）、喷补料（自由流动的混合物，特别为利用空气或机械力喷射的浇铸而成）、可模压或可塑料（一种可塑粘土的类型，可以捣打成型），都是从黏合剂体系中演变而来的，这和在砖体中使用的那些有很大的不同。,Unshaped refractories, in general, use similar aggregate materials as shaped brick. 未成形的耐火材料，一般来说，都是使用相似的骨料作为成型砖体。,However, the binders used to form the bo

8、nding phase are very different, and it has been developments in aluminate-, silicate-, and phosphate-bond systems or combinations of these systems that has led to the widespread use of monolithics. 但是，用于形成结合相的黏合剂却大不相同，并且在铝酸盐、硅酸盐和磷酸键体系或这些体系的联合中得到发展，这导致块料的广泛使用。,Initially, monolithics were used for rep

9、air or in less-severe positions, but they now account for 60% of refractory production and are used in almost all areas of furnace linings. 最初，块料用于修复或者不重要的位置，但是现在他们占了耐火材料生产量的60%，几乎应用在炉内衬的所有方面。,3、The bonds formed in monolithics during processing or service may be of several types. 在加工或服役过程中块料结合的形成类型可

10、能有几种。,4、A ceramic (physical) bond, which is present at room temperature but develops on firing and may be a glass and/or ceramic bond. These typically are formed from clays on firing. 一种陶瓷结合（物理结合）在室温下存在但是煅烧阶段会长大，这可能是玻璃或陶瓷结合。他们主要是由煅烧粘土而成。,5、A hydraulic (chemical) cementlike, silicate, or aluminate bo

11、nd, which involves setting and hardening at room temperature when water is added to the system. 一种液压（化学）黏合剂、硅酸盐或铝酸盐结合，当水加入体系时，需要在室温下调节和淬火。,When it is heated, the bond strength may decrease as the hydraulic bond is destroyed but increase again as a high-temperature ceramic bond forms. 当加热时，键能可能会降低，因为

12、液压结合被破坏，但是作为高温陶瓷结合剂形式时又会增加。,These are the most common bonds in modern castables, and they usually are based on calcium aluminate (CA) cements. 在现代铸块中这些是最普遍的结合剂，他们经常是建立在铝酸钙水泥基础之上的。,6、A mineral (chemical) bond which involves hardening at room temperature or above but below the sintering temperature. 一

13、种矿物质（化学）结合需在在室温或者高于室温但是低于烧结温度下淬火。,The most common of these utilize phosphoric acid or sodium silicate. 这些运用最普遍的是磷酸或者硅酸钠。,This bonding produces high strengths when heated to temperatures of 150 . 当加热到150时结合产生很高的强度。,Phosphate bonds can be developed by simply adding phosphoric acid or less-acidic media

14、, such as Al(H2P04)3 or NH4H2PO4, to a mixture containing Al2O3, or MgO fines. AlPO4 is formed on reaction with Al2O3, and it is a highly refractory bond phase.,磷酸键可以通过只加入磷酸或者弱酸介质到包含氧化铝或氧化镁的混合物中形成的，如Al(H2P04)3或NH4H2PO4 。AlPO4是和氧化铝反应之后形成，是一个高耐火结合相。,There are serious problems of aging of stored produc

15、ts, and reactions during storage must be inhibited. 储存产品的老化是很严重的问题，储存期间的反应结合必须得加以控制。,The bonding mechanism was first reviewed by Kingery, and Gonzalez and Halloran thoroughly studied the basic chemistry of the aluminum phosphate bond and correlated high-temperature mechanical behavior to the texture

16、 and chemistry of various phosphate-bonded refractories. 结合机理首先被Kingery发表，Gonzalez及 Halloran认真仔细的研究了正磷酸铝结合的碱性化学，并将不同磷酸结合耐火材料的高温机械性能和其结构和化学性质联系起来。,7、The first plastic monolithics were made as semibaked, puttylike, firebrick that were installed in chunks with a hammer. 第一个塑性块料是作为半烘烤、油灰似的、耐火砖而制成的，用锤子固定

17、在厚块中。,Initially, these plastic refractories were used in boilers, but, by 1930, they were being used successfully in forge furnaces, gas generators, coke ovens, and heat-treatment furnaces. 最初，这些塑性耐火材料用在锅炉上，但是直到1930年，开始成功用于锻造炉、气体发生器、焦炉和热处理炉。,Plastics and ramming mixes are now available as heat-or ai

18、r-setting versions with phosphate or organic resin as well as clay-based bonds. 塑性材料和搪炉料目前可通过和磷酸盐或有机树脂及黏土基结合，以热硬性或气硬性形式获得。,Installation can be via ramming, vibration, or gunning, the latter techniques being developed in the 1970s and 1980s. 安装可以通过打捣打、振动或喷射，后一个技术是在1970s和1980s期间发展起来的。,8、The hydraulic

19、properties of calcium aluminate castable cements (CACs) were discovered in France before 1856. 铝酸钙浇铸水泥的水硬性在1856年之前在法国发现。,CACs first were manufactured by sintering or fusing bauxite and/or alumina plus limestone in rotary or shaft kilns. 铝酸钙浇铸水泥首先是由烧结或熔融铝土矿或/和氧化铝加入一些石灰岩在旋转或竖窑中制得的。,In 1902, however, C

20、ACs had been produced by heating low-grade aluminous materials with limestone, but this material was marketed as a rapid-hardening additive to Portland cement and plaster, not as a refractory cement by itself . 不过在1902年，铝酸钙浇铸水泥通过加热低等矾土材料和石灰岩生产出来，但是这种材料是作为硅酸盐水泥和灰泥的一种快硬添加剂问世市场的，本身不是作为耐火水泥。,By WWII, re

21、fractory concrete was well established in many industries for furnaces or ovens and as linings in boilers and stacks, although early cements were impure, so that use temperatures were limited to 1500 up. 到了第二次世界大战期间，耐火混凝土在许多工业中完善成长，主要用于熔炉和烤箱及作为锅炉和烟囱的内衬，不过由于早期的水泥都不纯，所以使用温度限定在1500以下。,Development of dr

22、y cement-aggregate mixes from improvements in binders, in particular, the use of submicrometer particles, led to better slip rheology and product sinterability (because of greater surface area). 通过改进粘结剂，干式水泥和骨料混合料得到发展，特别是亚微米颗粒的使用导致了泥浆流变学和产品烧结性能的改善提高，这是因为比表面积增大了。,The dry mix for the castable contains

23、 a carefully graded range of aggregates, the required amount of cement, and additives to improve workability, flow, and setting behavior. 铸料的干式混合料包含一系列严格分级的骨料，需要量的水泥、改善使用性能、流量和硬化性能的添加剂。,The water content in a typical dry-pressed refractory brick is 0.5% 3% , but it is 8% 15% in a castable mix to all

24、ow the hydration products to form and give suitable rheology for casting. 在典型的干压耐火砖中水的含量是0.5%-3%，但是在铸料粉料中含量是8%-15%，以使得水合物产品形成及给予铸造所需的适合的流变性。,9、Conventional concretes contain 15% -20% calcium aluminate cement. 普通混凝土包含15%-20%的铝酸钙水泥。,Reduction of cement content to 5% 8% without loss in strength was ach

25、ieved by addition of fine particulate refractory bond material, which promoted homogeneous distribution of cement; therefore, made the hydraulic bond fully utilized. 可以通过加入细颗粒的耐火结合材料来减少水泥的含量到5%-8%，并且强度不降低，这些材料可以提高水泥的均匀分布，使得液压结合充分利用。,More careful control of the size of grain fractions and bond-matrix

26、 components led to the improved particle-packing efficiency. 更仔细的控制晶粒部分的尺寸大小和基质结合元件可以使晶粒包裹效率提高。,Cement contents were reduced to 1 % by adding deflocculant and two very fine particle sizes consisting of l100m powder that was nonhydrating and 0.01O.lm powder that did not form gels with water. 通过加入抗絮凝剂

27、和两种粒度分别是1-100微米和0.01-0.1微米的颗粒粉末可以使水泥的含量降低至小于1% 。这是粒径为0.01O.lm非水溶性的颗粒，与水不会胶凝。,Mixing these in a 1 ：100 ratio, respectively, so that the finer can fill the space between the coarser particles reduces water consumption and porosity of the concrete, giving greater strength. 以1:100的比例混合，这样细微粒可以填充粗微粒的间隙减少混凝土中耗水量和气孔率，使强度更大。,Some low-cement monolithics cannot be cast because of the low water content, and, therefore, are vibration compacted; others flow without vibration (self-flowing castables, SFCs). 由于水含量不足一些粗劣水泥的块料不能铸造，因此一些通过振动压实，其余的塑变的不用振动压实即浇铸。,These are self-leveling, with h