辐射节能用纳米共晶陶瓷材料制备新技术及其红外辐射机制

This project is devoted to providing a novel process of plasma spheroidization for the preparation of high emissivity infrared radiation nano-ceramic powder with eutectic structure, and then developing a highly efficient radiation energy-saving coating material. By the application of the as prepared infrared ceramic coating, realize the purpose of radiation energy-saving in furnace operations. Relationships between plasma spheroidization process, microstructure characteristic, and infrared radiation performance of the high emissivity infrared radiation ceramic powder will be studied, The mechanism for improving 1-5 μm near-infrared emissivity will also be revealed. Nextly, by controlling the microstructure of the ceramic powder, as well as adjusting the formulation of the coating, achieve the coating material with high emissivity, high temperature resistantane and good thermal shock resistance. Then, through the application of the energy-saving coating material, make the energy-saving rate of the thermal furnace is greater than 10% in one year service period. Finally, establish a corresponding energy-saving effect evaluation model, and reveal the long-term energy-saving mechanisms of the as-prepared infrared radiation coating material. The research results of this project will provide theoretical and technical support for the design, preparation and application of highly efficient infrared radiation energy-saving ceramic materials, and make a substantive contribution to the energy-saving and sustainable development of the thermal furnaces industry.

本项目旨在研究"具有高发射率的纳米共晶红外辐射陶瓷粉体"的等离子球化制备新技术，进而研制出高效辐射节能涂层材料，利用其强化辐射传热作用，实现热工炉窑的辐射节能。研究并掌握高发射率红外辐射陶瓷粉体的"等离子球化工艺制度--稀土掺杂的纳米共晶结构--红外辐射性能"之间的对应关系规律，进而揭示1-5 μm 近红外波段发射率得以提高的物理机制。通过对陶瓷粉体中"红外辐射基元"的调控，以及对涂层材料配方组成和涂覆制度的调整，实现红外节能涂层材料的高发射率、耐高温和抗热震性能的集成，从而使其在一年服役期内的节能率达到10%以上，在此基础上，研究并建立相应的节能效果评价模型，揭示红外辐射节能涂层材料的长效节能机制。 项目研究成果，将为基于辐射节能的红外陶瓷涂层材料的设计、制备和应用提供理论和技术支撑，为我国热工炉窑及其相关产业的节能、降耗和可持续发展做出实质性贡献。

采用等离子球化、火焰喷淬和固相合成等工艺研制成功系列红外发射率≥0.93的RE2O3-Al2O3-ZrO2基（RE=Ce/La/Y）纳米共晶氧化物陶瓷材料，实现了晶粒尺寸在纳米/微米尺度的连续调控，使各物相晶粒尺寸<150nm，阐明了红外发射率显著提升的掺杂带隙调控机制。以高发射率陶瓷粉体为辐射基料研制成功存储稳定施工粘度<20s的红外辐射节能涂料，涂层冲击强度为3000g cm无裂纹剥落，应用于多种高温热工装备均实现了年节能率>10%的节能效果，对我国冶金、石化、建材等高温工业的节能减排具有重要意义。相关研究成果发表SCI论文12篇，申请发明专利3项。圆满完成项目考核指标。