Preparation And Performance Characterization Of Mullite Lightweight Thermal-insulation Materials By Foaming

The foaming method was considered to be the most potential preparation method, with asimple process, uniform pore and high closed porosity, however it was limited used for the poorstability. In this paper, Based on the overview of preparation method and the status quo oflightweight refractories, for the bottlenecks of prepared of the foaming method, proposed to usethe compound and simple process to prepare the efficient and stable foaming agent, and thenprepared mullite lightweight insulation materials with the foaming agent. Studied the complexproject of the foaming agent and its performance, and the process of mullite lightweightinsulation materials with foaming method, analyzed its microstructure, properties and theirrelations, for finding the effective way to prepare the lightweight insulation materials withfoaming method, optimizing the performance of materials. The specific studies include:(1) With the anionic SDS as the main raw materials, with water-soluble natural polymer(F1, F2)as the foaming stabilizing agent, with long-chain alcohols as additives, prepared two kindsfoaming agent G1&G2. And the structure and properties were characterized. Results showedthat the properties of G1were better than G2s. The foaming expansion of G1reached26inthe amount of water for50mL, and the foam had uniform bubble size, about0.4mm, and wellstability.(2) With G1as a foaming agent, with Al2O3and SiO2as the main raw materials, different unitweights materials can be prepared by foaming method. Results showed that process as thefoaming to the slurry to form a foaming slurry, and then by drying and firing could meet therequirements; and the unit weights could be controlled by changing the foaming addition; thesample had well pore structure, a lower thermal conductivity and well mechanical propertiesto achieve the goal of performance optimization.(3) With the solid waste-roller waste as the main raw materials, different unit weights materialscan be prepared by foaming method. The preparation process was simple, and sample hadwell pore structure, a lower thermal conductivity and well mechanical properties, utilized thelow-cost and high value-added of solid waste.Using the highly efficient and stable foaming agent, the foaming method can be used toprepared the lightweight insulation materials, it had a simple preparation process, we can controlits performance by changed the distribution of the pore size of foaming, and the foamingaddition, and the preparation process. But the stability of the foaming slurry and the dryingprocess with foaming method should be further studied.