CN105645936A - 一种高铝空心球轻质浇注料及其制备方法 - Google Patents
一种高铝空心球轻质浇注料及其制备方法 Download PDFInfo
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- 238000002360 preparation method Methods 0.000 title claims abstract description 24
- 229910052782 aluminium Inorganic materials 0.000 title abstract 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 104
- 239000000843 powder Substances 0.000 claims abstract description 30
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 26
- 239000002994 raw material Substances 0.000 claims abstract description 26
- 239000004927 clay Substances 0.000 claims abstract description 23
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 16
- 239000004568 cement Substances 0.000 claims abstract description 12
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 claims abstract description 10
- 238000002156 mixing Methods 0.000 claims abstract description 7
- 235000019982 sodium hexametaphosphate Nutrition 0.000 claims abstract description 7
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 claims abstract description 7
- 235000019832 sodium triphosphate Nutrition 0.000 claims abstract description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000008187 granular material Substances 0.000 claims description 15
- 229910052593 corundum Inorganic materials 0.000 claims description 12
- 239000000203 mixture Substances 0.000 claims description 12
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 12
- 239000011734 sodium Substances 0.000 claims description 9
- 229910052681 coesite Inorganic materials 0.000 claims description 6
- 229910052906 cristobalite Inorganic materials 0.000 claims description 6
- 229910052682 stishovite Inorganic materials 0.000 claims description 6
- 239000000126 substance Substances 0.000 claims description 6
- 229910052905 tridymite Inorganic materials 0.000 claims description 6
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 3
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 3
- 229910052708 sodium Inorganic materials 0.000 claims description 3
- 238000000034 method Methods 0.000 abstract description 11
- 238000009413 insulation Methods 0.000 abstract description 9
- 238000003303 reheating Methods 0.000 abstract description 7
- 230000000694 effects Effects 0.000 abstract description 6
- 238000004519 manufacturing process Methods 0.000 abstract description 5
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 abstract description 3
- 230000002349 favourable effect Effects 0.000 abstract 2
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 abstract 1
- 238000007580 dry-mixing Methods 0.000 abstract 1
- 235000012239 silicon dioxide Nutrition 0.000 abstract 1
- 238000010438 heat treatment Methods 0.000 description 20
- 239000000463 material Substances 0.000 description 13
- 238000001514 detection method Methods 0.000 description 6
- 239000011449 brick Substances 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 5
- 238000004321 preservation Methods 0.000 description 5
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000005054 agglomeration Methods 0.000 description 2
- 230000002776 aggregation Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000009749 continuous casting Methods 0.000 description 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229910001051 Magnalium Inorganic materials 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 239000007767 bonding agent Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000009970 fire resistant effect Effects 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 238000009847 ladle furnace Methods 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
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Abstract
本发明涉及一种高铝空心球轻质浇注料及其制备方法。其技术方案是：以28~48wt%的高铝空心球、14~30wt%的焦宝石、6~30wt%的矾土细粉、6~10wt%的氧化铝微粉、1~5wt%的二氧化硅微粉、2~10wt%的铝酸钙水泥和1~5wt%的广西黏土为原料，外加所述原料0.04~0.2wt%的三聚磷酸钠和0.1~0.5wt%的六偏磷酸钠，干混1~3min，再外加所述原料的7~15wt%的水，混合2~5min，即得高铝空心球轻质浇注料。本发明具有工艺简单、生产成本低和对设备无特殊要求的特点；所制备的高铝空心球轻质浇注料体积密度低、热导率低、耐压强度高、重烧线变化率低、体积稳定性好和隔热保温效果好，适用于钢包永久层。
Description
技术领域
本发明属于轻质浇注料技术领域。具体涉及一种高铝空心球轻质浇注料及其制备方法。
背景技术
在传统能源日益枯竭和新能源发展缓慢的今天，为人类可持续发展，开发轻质、高强、热震稳定性好、使用温度高、能满足轻型结构超高温窑炉所需的内衬材料是当前最迫切的任务。钢包是炼钢厂重要的热工设备，随着炼钢技术的不断发展，冶炼温度提高和连铸比增加，钢水在钢包中停留时间延长，尤其是炉外精炼LF、RH工艺对钢包内衬要求越来越苛刻，钢包内衬材质、维护施工工艺也需不断改进，努力降低耐火材料消耗和成本，提高钢包热状态，符合精炼和连铸工艺要求是钢包用耐材的主要发展趋势。
大型钢包永久层由于从钢包安全角度考虑，一般采用高铝浇注料、高铝砖或者腊石砖。使用蜡石砖和高铝砖，砖缝较多，安全性难以保障；高铝浇注料保温性能较差，永久层的保温效果没有充分发挥，而且安全性较差，使得工作层用料在使用到一定残厚时不敢继续使用（国内铝镁预制砖下线残厚一般在60~80mm，而日本的残厚控制在40mm左右），工作层材料不能充分使用是造成钢包消耗耐材高的重要原因。因此为了保证安全，有必要开发具有高强度、低导热的新型浇注料来替代高铝浇注料。
目前，不少新型的隔热材料已被研究出来并应用于各种高温窑炉的永久层或者工作层中，利用这些新型隔热材料制备出的浇注料虽然具有优异的隔热性能，但其强度却往往达不到标准，限制了这种材料的应用范围。张国栋等人采用氧化铝空心球和α-Al2O3微粉为原料制备了低水泥结合氧化铝空心球轻质浇注料，荷重软化温度高达1600℃，抗折强度也达8.0MPa，但其热导率和强度仍有待提高（低水泥结合氧化铝空心球轻质浇注料的研究[J].耐火与石灰.2009,34(5)）。“一种制备轻质高强度氧化铝空心球陶瓷的制备方法”（CN1554616A)的专利技术，以α-Al2O3微粉和氧化铝空心球为原料，以磷酸溶液为结合剂，制备的轻质隔热砖体积密度较低，为1.2~1.4g/cm3，抗折强度和耐压强度较大，分别为5~12MPa和10~30MPa，但该法只以氧化铝空心球和α-Al2O3微粉为原料，在高温下难以烧结，需要更高温度烧成，成本较高，并且其导热率较高。“一种氧化铝空心球隔热耐火材料的制备方法”（CN102491761A）的专利技术，所制备的氧化铝空心球隔热耐火材料虽抗热震性能优良、体积密度低和热导率低，但耐压强度降低，仅有7~14MPa。
发明内容
本发明旨在克服现有技术缺陷，目的是提供一种工艺简单、生产成本低和对设备无特殊要求的高铝空心球轻质浇注料的制备方法；用该方法制备的高铝空心球轻质浇注料体积密度低、热导率低、耐压强度高、重烧线变化率低、体积稳定性好和隔热保温效果好，适用于钢包永久层。
为实现上述目的，本发明采用的技术方案是：以28~48wt%的高铝空心球、14~30wt%的焦宝石、6~30wt%的矾土细粉、6~10wt%的氧化铝微粉、1~5wt%的二氧化硅微粉、2~10wt%的铝酸钙水泥和1~5wt%的广西黏土为原料，外加所述原料0.04~0.2wt%的三聚磷酸钠和0.1~0.5wt%的六偏磷酸钠，干混1~3min，再外加所述原料的7~15wt%的水，混合2~5min，即得高铝空心球轻质浇注料。
所述高铝空心球的主要化学成分是：Al2O3为55~65wt%，SiO2为25~35wt%；高铝空心球的颗粒级配是：粒度小于8mm且大于或等于5mm的颗粒为10~20wt%，粒度小于5mm且大于或等于3mm的颗粒为30~50wt%，粒度小于3mm且大于或等于1mm的颗粒为30~60wt%。
所述焦宝石的主要化学成分是：Al2O3为40~50wt%，SiO2为40~60wt%，Fe2O3为1~3wt%；焦宝石的颗粒级配是：粒度小于1mm且大于或等于0.5mm的颗粒为50~60wt%，粒度小于0.5mm且大于或等于0.074mm的颗粒为40~50wt%。
所述矾土细粉的Al2O3含量≥88wt%，粒度≤0.088mm。
所述氧化铝微粉的Al2O3含量≥98wt%，粒度≤3μm。
所述二氧化硅微粉的SiO2含量≥95wt%，粒度≤3μm。
所述铝酸钙水泥的Al2O3含量≥71wt%，CaO含量≤30wt%，粒度≤3μm。
所述广西黏土的SiO2含量≥40wt%，Al2O3≤40wt%，粒度为≤3μm。
所述三聚磷酸钠的Na5P3O10含量≥98wt%，粒度≤1mm。
所述六偏磷酸钠的Na6P6O18含量≥98wt%，粒度≤1mm。
由于采用上述技术方案，本发明与现有技术相比具有如下积极效果：
本发明采用的高铝空心球具有中空结构，体积密度低、强度较高和经热处理后的体积变化小；经过高温处理的高铝空心球球壳中有大量的莫来石生成，进一步提高了材料的强度。使用高铝空心球作为骨料制备的轻质浇注料具有较低的体积密度和较高的显气孔率，保证了高铝空心球轻质浇注料具有优异的隔热保温性能；由于适当的骨料与细粉的配比和高温下的烧结作用，高铝空心球轻质浇注料也具有较高的常温抗折强度和常温耐压强度，永久线变化率小。
本发明所制备的高铝空心球轻质浇注料，在110℃×24h和1300℃×3h条件下热处理后经检测：体积密度为1.82~2.00g/cm3和1.81~1.98g/cm3；显气孔率为33~37%和35~39%；常温抗折强度为2~6MPa和9~12MPa；常温耐压强度为17~29MPa和36~51MPa。所制备的高铝空心球轻质浇注料，在1300℃×3h条件下热处理后的永久线变化率为-0.13~-0.18，1300℃×3h热处理后在500℃条件下的导热系数为0.51~0.60W·(m·K)-1。
因此，本发明有工艺简单、生产成本低和对设备无特殊要求的特点；所制备的高铝空心球轻质浇注料体积密度低、热导率低、耐压强度高、重烧线变化率低、体积稳定性好和隔热保温效果好，适用于钢包永久层。
具体实施方式
下面结合具体实施方式对本发明作进一步的描述，并非对其保护范围的限制。
为避免重复，先将本具体实施方式中所涉及的原料统一描述如下，实施例中不再赘述：
所述高铝空心球的主要化学成分是：Al2O3为55~65wt%，SiO2为25~35wt%；高铝空心球的颗粒级配是：粒度小于8mm且大于或等于5mm的颗粒为10~20wt%，粒度小于5mm且大于或等于3mm的颗粒为30~50wt%，粒度小于3mm且大于或等于1mm的颗粒为30~60wt%。
所述焦宝石的主要化学成分是：Al2O3为40~50wt%，SiO2为40~60wt%，Fe2O3为1~3wt%；焦宝石的颗粒级配是：粒度小于1mm且大于或等于0.5mm的颗粒为50~60wt%，粒度小于0.5mm且大于或等于0.074mm的颗粒为40~50wt%。
所述矾土细粉的Al2O3含量≥88wt%，粒度≤0.088mm。
所述氧化铝微粉的Al2O3含量≥98wt%，粒度≤3μm。
所述二氧化硅微粉的SiO2含量≥95wt%，粒度≤3μm。
所述铝酸钙水泥的Al2O3含量≥71wt%，CaO含量≤30wt%，粒度≤3μm。
所述广西黏土的SiO2含量≥40wt%，Al2O3≤40wt%，粒度为≤3μm。
所述三聚磷酸钠的Na5P3O10含量≥98wt%，粒度≤1mm。
所述六偏磷酸钠的Na6P6O18含量≥98wt%，粒度≤1mm。
实施例1
一种高铝空心球轻质浇注料及其制备方法。以28~33wt%的高铝空心球、18~22wt%的焦宝石、24~30wt%的矾土细粉、8~9wt%的氧化铝微粉、4~5wt%的二氧化硅微粉、2~4wt%的铝酸钙水泥和2~3wt%的广西黏土为原料，外加所述原料0.04~0.08wt%的三聚磷酸钠和0.1~0.2wt%的六偏磷酸钠，干混1~3min，再外加所述原料的7~9wt%的水，混合2~5min，即得高铝空心球轻质浇注料。
本实施例所制备的高铝空心球轻质浇注料，在110℃×24h和1300℃×3h条件下热处理后经检测：体积密度为1.90~2.00g/cm3和1.90~1.98g/cm3；显气孔率为33~34%和35~37%；常温抗折强度为3~5MPa和10~12MPa；常温耐压强度为17~19MPa和48~51MPa；所制备的高铝空心球轻质浇注料，在1300℃×3h条件下热处理后的永久线变化率为-0.14~-0.16；1300℃×3h热处理后在500℃条件下的导热系数为0.55~0.60W·(m·K)-1。
实施例2
一种高铝空心球轻质浇注料及其制备方法。以33~38wt%的高铝空心球、22~26wt%的焦宝石、18~24wt%的矾土细粉、9~10wt%的氧化铝微粉、1~2wt%的二氧化硅微粉、8~10wt%的铝酸钙水泥和3~4wt%的广西黏土为原料，外加所述原料0.08~0.12wt%的三聚磷酸钠和0.2~0.3wt%的六偏磷酸钠，干混1~3min，再外加所述原料的9~11wt%的水，混合2~5min，即得高铝空心球轻质浇注料。
本实施例所制备的高铝空心球轻质浇注料，在110℃×24h和1300℃×3h条件下热处理后经检测：体积密度为1.90~1.96g/cm3和1.89~1.93g/cm3；显气孔率为33~34%和36~38%；常温抗折强度为2~4MPa和10~11MPa；常温耐压强度为20~22MPa和46~48MPa；所制备的高铝空心球轻质浇注料，在1300℃×3h条件下热处理后的永久线变化率为-0.16~-0.18；1300℃×3h热处理后在500℃条件下的导热系数为0.54~0.58W·(m·K)-1。
实施例3
一种高铝空心球轻质浇注料及其制备方法。以38~43wt%的高铝空心球、26~30wt%的焦宝石、6~12wt%的矾土细粉、6~7wt%的氧化铝微粉、2~3wt%的二氧化硅微粉、4~6wt%的铝酸钙水泥和4~5wt%的广西黏土为原料，外加所述原料0.12~0.16wt%的三聚磷酸钠和0.3~0.4wt%的六偏磷酸钠，干混1~3min，再外加所述原料的11~13wt%的水，混合2~5min，即得高铝空心球轻质浇注料。
本实施例所制备的高铝空心球轻质浇注料，在110℃×24h和1300℃×3h条件下热处理后经检测：体积密度为1.89~1.94g/cm3和1.84~1.90g/cm3；显气孔率为34~35%和37~38%；常温抗折强度为5~6MPa和9~10MPa；常温耐压强度为27~29MPa和41~43MPa；所制备的高铝空心球轻质浇注料，在1300℃×3h条件下热处理后的永久线变化率为-0.14~-0.16；1300℃×3h热处理后在500℃条件下的导热系数为0.52~0.55W·(m·K)-1。
实施例4
一种高铝空心球轻质浇注料及其制备方法。以43~48wt%的高铝空心球、14~18wt%的焦宝石12~18wt%的矾土细粉、7~8wt%的氧化铝微粉、3~4wt%的二氧化硅微粉、6~8wt%的铝酸钙水泥和1~2wt%的广西黏土为原料，外加所述原料0.16~0.20wt%的三聚磷酸钠和0.4~0.5wt%的六偏磷酸钠，干混1~3min，再外加所述原料的13~15wt%的水，混合2~5min，即得高铝空心球轻质浇注料。
本实施例所制备的高铝空心球轻质浇注料，在110℃×24h和1300℃×3h条件下热处理后经检测：体积密度为1.82~1.87g/cm3和1.81~1.85g/cm3；显气孔率为35~37%和38~39%；常温抗折强度为4~5MPa和9~10MPa；常温耐压强度为22~24MPa和36~38MPa；所制备的高铝空心球轻质浇注料，在1300℃×3h条件下热处理后的永久线变化率为-0.13~-0.15；1300℃×3h热处理后在500℃条件下的导热系数为0.51~0.53W·(m·K)-1。
本具体实施方式采用的高铝空心球具有中空结构，体积密度低、强度较高和经热处理后的体积变化小；经过高温处理的高铝空心球球壳中有大量的莫来石生成，进一步提高了材料的强度。使用高铝空心球作为骨料制备的轻质浇注料具有较低的体积密度和较高的显气孔率，保证了高铝空心球轻质浇注料具有优异的隔热保温性能；由于适当的骨料与细粉的配比和高温下的烧结作用，高铝空心球轻质浇注料也具有较高的常温抗折强度和常温耐压强度，永久线变化率小。
本具体实施方式所制备的高铝空心球轻质浇注料，在110℃×24h和1300℃×3h条件下热处理后经检测：体积密度为1.82~2.00g/cm3和1.81~1.98g/cm3；显气孔率为33~37%和35~39%；常温抗折强度为2~6MPa和9~12MPa；常温耐压强度为17~29MPa和36~51MPa。所制备的高铝空心球轻质浇注料，在1300℃×3h条件下热处理后的永久线变化率为-0.13~-0.18，1300℃×3h热处理后在500℃条件下的导热系数为0.51~0.60W·(m·K)-1。
因此，本具体实施方式有工艺简单、生产成本低和对设备无特殊要求的特点；所制备的高铝空心球轻质浇注料体积密度低、热导率低、耐压强度高、重烧线变化率低、体积稳定性好和隔热保温效果好，适用于钢包永久层。
Claims (9)
1.一种高铝空心球轻质浇注料的制备方法，其特征在于所述制备方法是：以28~48wt%的高铝空心球、14~30wt%的焦宝石、6~30wt%的矾土细粉、6~10wt%的氧化铝微粉、1~5wt%的二氧化硅微粉、2~10wt%的铝酸钙水泥和1~5wt%的广西黏土为原料，外加所述原料0.04~0.2wt%的三聚磷酸钠和0.1~0.5wt%的六偏磷酸钠，干混1~3min，再外加所述原料的7~15wt%的水，混合2~5min，即得高铝空心球轻质浇注料；
所述高铝空心球的主要化学成分是：Al2O3为55~65wt%，SiO2为25~35wt%；高铝空心球的颗粒级配是：粒度小于8mm且大于或等于5mm的颗粒为10~20wt%，粒度小于5mm且大于或等于3mm的颗粒为30~50wt%，粒度小于3mm且大于或等于1mm的颗粒为30~60wt%；
所述焦宝石的主要化学成分是：Al2O3为40~50wt%，SiO2为40~60wt%，Fe2O3为1~3wt%；焦宝石的颗粒级配是：粒度小于1mm且大于或等于0.5mm的颗粒为50~60wt%，粒度小于0.5mm且大于或等于0.074mm的颗粒为40~50wt%。
2.根据权利要求1所述高铝空心球轻质浇注料的制备方法，其特征在于所述矾土细粉的Al2O3含量≥88wt%，粒度≤0.088mm。
3.根据权利要求1所述高铝空心球轻质浇注料的制备方法，其特征在于所述氧化铝微粉的Al2O3含量≥98wt%，粒度≤3μm。
4.根据权利要求1所述高铝空心球轻质浇注料的制备方法，其特征在于所述二氧化硅微粉的SiO2含量≥95wt%，粒度≤3μm。
5.根据权利要求1所述高铝空心球轻质浇注料的制备方法，其特征在于所述铝酸钙水泥的Al2O3含量≥71wt%，CaO含量≤30wt%，粒度≤3μm。
6.根据权利要求1所述高铝空心球轻质浇注料的制备方法，其特征在于所述广西黏土的SiO2含量≥40wt%，Al2O3≤40wt%，粒度为≤3μm。
7.根据权利要求1所述高铝空心球轻质浇注料的制备方法，其特征在于所述三聚磷酸钠的Na5P3O10含量≥98wt%，粒度≤1mm。
8.根据权利要求1所述高铝空心球轻质浇注料的制备方法，其特征在于所述六偏磷酸钠的Na6P6O18含量≥98wt%，粒度≤1mm。
9.一种高铝空心球轻质浇注料，其特征在于所述高铝空心球轻质浇注料是根据权利要求1~8项中任一项所述的高铝空心球轻质浇注料的制备方法所制备的高铝空心球轻质浇注料。
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