发泡/催化法制备晶须自增强莫来石轻质保温耐火材料及其高温力学/热学性能

Energy efficiency of industrial furnace in China is about 20% lower than that in developed countries. Lightweight insulation refractories with high mechanical properties are very important for energy-saving of high-temperature industry. Mullite lightweight insulation refractories, possessing many unique properties, are suitable candidates for energy-saving in high-temperature industrial furnace. However, mullite lightweight insulation refractories prepared by conventional method suffer from low mechanical properties and poor thermal insulation properties. To address these problems, based on the knowledge of catalysis chemistry and surface chemistry, the present research project aims to in-situ synthesize whiskers self-reinforced mullite lightweight insulation refractories by using foam-gelcasting/catalytic method with the addition of catalysts and high-temperature inorganic nano-foaming agents. The following investigations will be carried out in the project: 1) The synthesis of mullite whiskers by in-situ catalytic reaction method; 2) Optimizing of foaming agent and rheological behavior and gelling behavior of mullite slurries; 3) The preparation of whiskers self-reinforced mullite lightweight insulation refractories with hierarchical porous structure using foam-gelcasting/catalytic method; 4) The high-temperature mechanical properties and thermal insulation properties of prepared whiskers self-reinforced mullite lightweight insulation refractories. The basic theory on the preparation of whiskers self-reinforced mullite lightweight insulation refractories will be elucidated on the basis of the experimental results and new kinds of lightweight insulation refractories with good mechanical properties and thermal insulation properties, and long service life for energy-saving in high-temperature industry will be prepared.

我国工业窑炉的平均热效率比发达国家低约20%，能耗高。莫来石轻质保温耐火材料在高温窑炉的节能降耗方面具有很好的应用前景，但传统的莫来石轻质耐火材料存在着机械性能差、保温效果不佳等不足。为解决该问题，在催化化学和表面化学的相关理论指导下，本项目拟在常规的发泡工艺中引入催化剂和高温无机纳米造孔剂，在优化泡沫剂(包括分散剂、粘结剂、稳泡剂和发泡剂)的基础上，采用发泡/催化法制备高性能的晶须自增强莫来石轻质保温耐火材料。重点研究：1) 原位催化反应制备莫来石晶须及柱晶粉体；2) 泡沫剂的优选和浆料流变性、稳定性研究；3) 发泡/催化法制备晶须原位自增强莫来石轻质耐火材料；4) 晶须自增强莫来石轻质耐火材料的高温机械性能及热学性能研究等。通过研究为晶须自增强莫来石轻质保温耐火材料的制备奠定理论基础，为我国高温工业提供性能优良的新型高效、长寿命轻质保温耐火制品，大幅度降低工业窑炉的能耗。

我国工业窑炉的平均热效率比发达国家低约20%，能耗高。莫来石轻质保温耐火材料在高温窑炉的节能降耗方面具有很好的应用前景，但传统的莫来石轻质耐火材料存在着机械性能差、保温效果不佳等不足。为解决该问题，在催化化学和表面化学的相关理论指导下，本项目在常规的发泡工艺中引入催化剂和高温无机纳米发泡剂，采用发泡/催化法制备了高性能的晶须自增强莫来石轻质保温耐火材料。重点研究了如下内容：1) 发泡-注凝成型法制备莫来石柱晶自增强多孔陶瓷及其高温力学和热学性能；2) 锆英石(ZrSiO4)、碳酸钙(CaCO3)及碳化硅(SiC)对发泡-注凝成型制备莫来石多级孔陶瓷的影响；3) 发泡-注凝/催化氮化制备Si3N4及Si3N4/SiC多孔陶瓷多孔陶瓷研究；4) 原位氮化反应制备氮化钛(TiN)、TiN-碳掺杂氮化硼(BCN)和TiN-Si3N4-BCN复合多孔陶瓷及其隔热性能；5) 发泡-注凝成型法制备MgAl2O4多孔陶瓷及其力学和热学性能。通过研究为晶须自增强轻质保温耐火材料的制备奠定理论基础，为我国高温工业提供性能优良的新型高效、长寿命保温隔热轻质保温耐火制品，大幅度降低工业窑炉的能耗。