莫来石晶须前驱体定量原位制备莫来石-刚玉轻质耐火材料的性能及其机理研究

Lightweight refractory materials widely used in ceramics, metallurgy, building materials and other industrial fields, its performance improvement plays an important role in the comprehensive development of these industries. This project firstly puts forward the mullite precursor quantitative in-situ preparation of lightweight refractory materials, and creatively controls the pseudo particle size and amount of mullite whisker precursor, which make quantitative distribution in corundum matrix. The granulation particle size and the in-situ growth mechanism of mullite whisker precursor are investigated in order to optimize the microstructure morphology such as the ideal mullite whisker length diameter ratio, content and distribution after firing, the thermal and mechanical properties of materials can be effectively enhanced and improved. The effect of reasonable proportion between the waste gangue and natural bauxite on the application of mullite precursors and matrix preform body are studied, in order to bring in the waste and natural materials as much as possible, which conform to the sustainable development of the refractory materials, and the requirement of the national energy conservation and environmental protection. The relationship among the thermal and mechanical properties, the key control parameters of the precursor, and microstructure are studied. The project will master the mullite whisker precursor quantitative in situ formation of mullite whiskers and the interaction mechanism of mullite whisker combined very well with corundum matrix to improve materials properties, and make fundamental innovation for the benign development of high performance lightweight refractory.

轻质耐火材料广泛地应用于陶瓷、冶金、建材等工业领域，它的性能提高对这些工业领域的综合发展起着重要作用。本项目首次提出采用莫来石晶须前驱体定量原位制备莫来石-刚玉轻质耐火材料，创新地控制莫来石晶须前驱体假性颗粒尺寸和多少在刚玉质基体中的定量分布，研究莫来石晶须前驱体的造粒粒径控制及对莫来石晶须原位生长的作用机理，以实现烧成后理想的莫来石晶须长径比、含量与分布等的优化显微结构形态，使材料的热学、力学性能等得到有效提高和改善；研究废料煤矸石、铝矾土等天然矿物原料在莫来石晶须前驱体和基体坯料中的应用，使其最大资源化利用，符合耐火材料的可持续发展及国家节能环保要求；研究莫来石-刚玉轻质耐火材料的热学和力学性能、前驱体的关键控制参数和微观结构三者之间的关系，掌握莫来石晶须前驱体定量原位形成莫来石晶须并与刚玉基体很好结合提高性能的相互作用机理，为高性能的轻质耐火材料的良性发展做出基础性创新。

本课题主要从莫来石晶须前驱体的基础配方、影响莫来石晶须前驱体定量原位制备莫来石-刚玉轻质耐火材料结构与性能的因素、以及莫来石晶须前驱体定量原位制备莫来石-刚玉轻质耐火材料的结构和性能优化三个方面开展了较为深入的探究及作用机理分析。课题以实现废料煤矸石、铝矾土等天然矿物原料在陶瓷生产领域的最大资源化利用为目的，将废料和天然矿物原料作为主体原料引入到莫来石晶须前驱体坯料配方中，使废料利用率达到最大化，其中煤矸石等废料利用率可高达35%，为工业化生产提供理论基础保证。本项目创新地将莫来石前驱体造粒，控制莫来石晶须前驱体假性颗粒尺寸和多少在刚玉质基体中的定量分布以实现烧成后理想的莫来石晶须长径比、含量与分布等的显微结构形态，使材料的热学和力学性能得到有效提高和改善。当莫来石前驱体造粒粒径控制在60-80目筛范围内，样品的各项性能指标较优。探寻了有效提高轻质耐火材料性能的相关工艺手段。认识了莫来石晶须前驱体定量原位形成莫来石晶须并与刚玉基体很好结合提高性能的相互作用机理，为工业化生产提供理论基础保证。