陶瓷纖維耐火材料的節能和效果

• 近年來(lai)陶瓷纖維在高(gao)溫(wen)(wen)燒成(cheng)窯爐(lu)方面的應用(yong)前景日(ri)益擴大(da)，以陶瓷纖維制(zhi)(zhi)成(cheng)的耐火氈、毯類制(zhi)(zhi)品(pin)，使(shi)用(yong)溫(wen)(wen)度可(ke)達到1649℃。它以隔熱效果好，使(shi)用(yong)簡便，特別是蓄熱小等特征(zheng)，普遍采用(yong)于(yu)各式窯爐(lu)中(zhong)，大(da)大(da)顯示(shi)出很高(gao)的節能效率。

• （１）品(pin)種(zhong)與性能：陶瓷(ci)耐(nai)火纖(xian)(xian)維(wei)(wei)(wei)重(zhong)要(yao)的(de)(de)(de)指標是纖(xian)(xian)維(wei)(wei)(wei)的(de)(de)(de)直徑與熱穩(wen)定(ding)性。陶瓷(ci)工業中常用(yong)的(de)(de)(de)是al2o3sio2纖(xian)(xian)維(wei)(wei)(wei)，根據al2o3的(de)(de)(de)含量(liang)(liang)高(gao)低(di)分為不(bu)同的(de)(de)(de)使用(yong)范圍，也在其中引入cr2o3材料(liao)以提高(gao)其耐(nai)火與抗氧(yang)化(hua)(hua)(hua)(hua)特性。一般氧(yang)化(hua)(hua)(hua)(hua)鋁含量(liang)(liang)高(gao)、氧(yang)化(hua)(hua)(hua)(hua)鐵等(deng)雜質含量(liang)(liang)低(di)的(de)(de)(de)纖(xian)(xian)維(wei)(wei)(wei)制品(pin)呈純(chun)白色(se)、引入氧(yang)化(hua)(hua)(hua)(hua)鉻的(de)(de)(de)纖(xian)(xian)維(wei)(wei)(wei)呈銷帶奶(nai)黃調的(de)(de)(de)顏色(se)。陶瓷(ci)纖(xian)(xian)維(wei)(wei)(wei)的(de)(de)(de)平(ping)均直徑為22—33微米。纖(xian)(xian)維(wei)(wei)(wei)細、密度小、導熱率低(di)者使用(yong)溫(wen)度高(gao)。若纖(xian)(xian)維(wei)(wei)(wei)粗、密度大時使用(yong)效(xiao)果不(bu)理想。纖(xian)(xian)維(wei)(wei)(wei)的(de)(de)(de)熱穩(wen)定(ding)性指標更為重(zhong)要(yao)。al2o3－sio2纖(xian)(xian)維(wei)(wei)(wei)各種(zhong)產(chan)品(pin)在1260℃的(de)(de)(de)線收(shou)縮范圍為35—88％之間。收(shou)縮量(liang)(liang)也直接影響到熱穩(wen)定(ding)性。由于纖(xian)(xian)維(wei)(wei)(wei)導熱率低(di)、密度小、重(zhong)量(liang)(liang)輕(qing)，在設計建造窯(yao)爐時均采(cai)用(yong)較輕(qing)的(de)(de)(de)鋼架支撐結構，從而使陶瓷(ci)窯(yao)爐的(de)(de)(de)發(fa)展(zhan)進(jin)入“窯(yao)爐輕(qing)量(liang)(liang)化(hua)(hua)(hua)(hua)”時代。纖(xian)(xian)維(wei)(wei)(wei)蓄熱小、適(shi)應快速升溫(wen)、冷卻燒成(cheng)方(fang)式。纖(xian)(xian)維(wei)(wei)(wei)有(you)柔性可加工成(cheng)帶凹槽或開口的(de)(de)(de)制品(pin)，且具有(you)良(liang)好(hao)的(de)(de)(de)抗機械震(zhen)動與沖擊的(de)(de)(de)能力，化(hua)(hua)(hua)(hua)學穩(wen)定(ding)性也較好(hao)，這些優點(dian)為新型窯(yao)爐的(de)(de)(de)發(fa)展(zhan)，并波及到陶瓷(ci)工藝(yi)、行業的(de)(de)(de)發(fa)展(zhan)產(chan)生重(zhong)要(yao)的(de)(de)(de)推動作用(yong)。

• 目(mu)前陶(tao)瓷纖(xian)(xian)維制(zhi)品有(you)：氈(zhan)、毯、砌塊、散(san)狀纖(xian)(xian)維、纖(xian)(xian)維紙(zhi)及真空成型(xing)的各種(zhong)制(zhi)品，工(gong)作(zuo)范圍一(yi)般在(zai)(zai)871—1427℃，特殊情況(kuang)下可短期在(zai)(zai)極限溫(wen)度以(yi)上的高溫(wen)下使用。 散(san)狀纖(xian)(xian)維分清過渣或(huo)未清過渣兩種(zhong)：加(jia)(jia)潤滑(hua)劑(ji)或(huo)未加(jia)(jia)潤滑(hua)劑(ji)者(zhe)；長、短纖(xian)(xian)維摻(chan)合一(yi)起者(zhe)等。幾種(zhong)纖(xian)(xian)維亦可摻(chan)合使用。未經清渣纖(xian)(xian)維便(bian)宜，可用于填充接縫處的填料。加(jia)(jia)入潤滑(hua)劑(ji)的纖(xian)(xian)維制(zhi)品便(bian)于操(cao)作(zuo)施工(gong)，粉塵(chen)小。安(an)裝纖(xian)(xian)維時散(san)入空氣中的粉塵(chen)雖(sui)無很大毒害，但會導致皮膚發癢(yang)或(huo)刺痛(tong)咽喉(hou)，故(gu)在(zai)(zai)施工(gong)時要(yao)注意防護(hu)。

• （２）砌筑方(fang)(fang)法(fa)與(yu)注(zhu)意事項：耐(nai)(nai)火(huo)纖(xian)(xian)(xian)(xian)維(wei)(wei)氈(zhan)、適用(yong)(yong)(yong)于窯爐(lu)內襯(chen)(chen)可大(da)大(da)提高(gao)(gao)(gao)節(jie)能(neng)效率。一(yi)般使(shi)用(yong)(yong)(yong)有機粘合劑(ji)使(shi)纖(xian)(xian)(xian)(xian)維(wei)(wei)卷合成(cheng)(cheng)筒(tong)形或(huo)薄板形織物。窯爐(lu)內壁采(cai)(cai)用(yong)(yong)(yong)高(gao)(gao)(gao)溫(wen)(wen)輕質(zhi)耐(nai)(nai)火(huo)磚砌筑后(hou)，可用(yong)(yong)(yong)陶(tao)瓷(ci)纖(xian)(xian)(xian)(xian)維(wei)(wei)耐(nai)(nai)火(huo)氈(zhan)粘貼成(cheng)(cheng)內襯(chen)(chen)，經燒(shao)成(cheng)(cheng)后(hou)，纖(xian)(xian)(xian)(xian)維(wei)(wei)氈(zhan)或(huo)板形成(cheng)(cheng)一(yi)定的(de)(de)剛性(xing)并具有令(ling)人滿意的(de)(de)回復能(neng)力，冷卻時能(neng)彈回使(shi)接(jie)縫繃緊。 砌筑纖(xian)(xian)(xian)(xian)維(wei)(wei)通常(chang)有兩(liang)種方(fang)(fang)法(fa)：一(yi)是將(jiang)氈(zhan)毯(tan)(tan)一(yi)層一(yi)層敷貼，再用(yong)(yong)(yong)栓桿鉚(liu)接(jie)起來，一(yi)般在1222℃以下采(cai)(cai)用(yong)(yong)(yong)耐(nai)(nai)溫(wen)(wen)金屬(shu)栓桿，1223℃以上采(cai)(cai)用(yong)(yong)(yong)陶(tao)瓷(ci)質(zhi)鉚(liu)接(jie)件(jian)(jian)(jian)(jian)。靠(kao)熱(re)(re)面(mian)一(yi)端(duan)用(yong)(yong)(yong)散(san)狀纖(xian)(xian)(xian)(xian)維(wei)(wei)和耐(nai)(nai)熱(re)(re)水泥填(tian)充。采(cai)(cai)用(yong)(yong)(yong)陶(tao)瓷(ci)質(zhi)鉚(liu)接(jie)件(jian)(jian)(jian)(jian)還可防止因碳素(su)沉(chen)積引起的(de)(de)纖(xian)(xian)(xian)(xian)維(wei)(wei)變質(zhi)。第二(er)種方(fang)(fang)法(fa)是采(cai)(cai)用(yong)(yong)(yong)預(yu)制(zhi)組合件(jian)(jian)(jian)(jian)、即用(yong)(yong)(yong)氈(zhan)毯(tan)(tan)堆(dui)疊而成(cheng)(cheng)的(de)(de)預(yu)制(zhi)件(jian)(jian)(jian)(jian)或(huo)用(yong)(yong)(yong)寬305mm的(de)(de)氈(zhan)毯(tan)(tan)折疊成(cheng)(cheng)手風琴(qin)式的(de)(de)預(yu)制(zhi)件(jian)(jian)(jian)(jian)。兩(liang)者相比，后(hou)者因緊挨爐(lu)殼到熱(re)(re)面(mian)均為同樣材(cai)料，節(jie)能(neng)效率更高(gao)(gao)(gao)、但成(cheng)(cheng)本較高(gao)(gao)(gao)。 溫(wen)(wen)度升(sheng)高(gao)(gao)(gao)時，纖(xian)(xian)(xian)(xian)維(wei)(wei)預(yu)制(zhi)件(jian)(jian)(jian)(jian)砌筑形成(cheng)(cheng)的(de)(de)接(jie)縫需用(yong)(yong)(yong)有伸(shen)縮性(xing)的(de)(de)纖(xian)(xian)(xian)(xian)維(wei)(wei)鑲嵌。用(yong)(yong)(yong)預(yu)制(zhi)組合件(jian)(jian)(jian)(jian)安裝方(fang)(fang)便(bian)、迅速且維(wei)(wei)修方(fang)(fang)便(bian)，只需將(jiang)損壞(huai)部分替換下來。

• 就熱效率來說，層層敷貼(tie)方式(shi)明顯優于(yu)預制(zhi)組(zu)合件(jian)(jian)。因為前者(zhe)的(de)纖(xian)維(wei)方向垂直(zhi)于(yu)熱流，堆(dui)疊形的(de)預制(zhi)組(zu)合件(jian)(jian)纖(xian)維(wei)方向平(ping)行(xing)于(yu)熱流，兩者(zhe)的(de)導熱量差值約為20—40％，如手風琴狀折疊的(de)預制(zhi)組(zu)合件(jian)(jian)則介(jie)于(yu)兩者(zhe)之(zhi)間，它的(de)纖(xian)維(wei)方向對于(yu)熱流既(ji)平(ping)行(xing)又(you)垂直(zhi)。

• （３）發展(zhan)前景展(zhan)望(wang)：由(you)于(yu)(yu)(yu)能(neng)(neng)(neng)源價格不斷上漲，燃料成(cheng)本將會成(cheng)為扼制陶(tao)瓷(ci)業發展(zhan)的(de)瓶頸，節(jie)能(neng)(neng)(neng)愈(yu)加重要。人們(men)對(dui)窯爐(lu)熱損失愈(yu)來愈(yu)關心(xin)，有的(de)直接在(zai)(zai)原有耐(nai)(nai)(nai)火(huo)內襯表面加貼(tie)一層耐(nai)(nai)(nai)火(huo)陶(tao)瓷(ci)纖(xian)維(wei)以提高熱效率。在(zai)(zai)加貼(tie)前必須將窯壁上明顯的(de)裂(lie)紋或剝落部(bu)位修復好。不過隔熱耐(nai)(nai)(nai)火(huo)磚與(yu)(yu)耐(nai)(nai)(nai)火(huo)纖(xian)維(wei)也不能(neng)(neng)(neng)任意濫用。迄今為止如堿(jian)性吹(chui)氧煉(lian)鋼爐(lu)、水泥回轉窯等(deng)內襯，由(you)于(yu)(yu)(yu)高溫(wen)化學侵蝕(shi)嚴(yan)重，都暫時不能(neng)(neng)(neng)用纖(xian)維(wei)作內襯。 對(dui)于(yu)(yu)(yu)連(lian)(lian)續加熱設備(bei)如陶(tao)瓷(ci)隧(sui)道窯，早已實現了采(cai)用耐(nai)(nai)(nai)火(huo)陶(tao)瓷(ci)纖(xian)維(wei)用作連(lian)(lian)續加熱設備(bei)的(de)內襯，據有關資料報道，快速推板窯與(yu)(yu)隧(sui)道窯中(zhong)采(cai)用耐(nai)(nai)(nai)火(huo)陶(tao)瓷(ci)纖(xian)維(wei)節(jie)能(neng)(neng)(neng)效果(guo)(guo)都很顯著。尤其是超高溫(wen)加熱，如燒成(cheng)溫(wen)度在(zai)(zai)1538℃—1649℃的(de)窯爐(lu)中(zhong)，采(cai)用耐(nai)(nai)(nai)火(huo)纖(xian)維(wei)的(de)節(jie)能(neng)(neng)(neng)效果(guo)(guo)。

• 目前，歐美及日(ri)本(ben)的(de)陶(tao)瓷(ci)(ci)(ci)窯(yao)爐設(she)備全部(bu)采(cai)用陶(tao)瓷(ci)(ci)(ci)纖(xian)維(wei)(wei)內襯(chen)。不久前日(ri)本(ben)將(jiang)燃氣隧道(dao)窯(yao)分(fen)(fen)解為諸(zhu)如車廂(xiang)結構進(jin)行分(fen)(fen)節制造、然后再運抵瓷(ci)(ci)(ci)廠施工現(xian)場組裝，這一(yi)切都(dou)是由于采(cai)用陶(tao)瓷(ci)(ci)(ci)纖(xian)維(wei)(wei)材料，大大節省(sheng)了窯(yao)爐造價(jia)，更簡(jian)便的(de)緣故。從材質改型(xing)方(fang)面推進(jin)陶(tao)瓷(ci)(ci)(ci)纖(xian)維(wei)(wei)制品節能效果的(de)研(yan)究也(ye)正(zheng)在進(jin)行中(zhong)。