CN109020579A - 钢包保温用铝镁轻质浇注料 - Google Patents
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- 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 31
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- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 12
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 12
- 239000011863 silicon-based powder Substances 0.000 claims abstract description 12
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 11
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 11
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Abstract
本发明公开了一种钢包保温用铝镁轻质浇注料,包括浇注料主料,所述浇注料主料按重量百分比包括如下组分:电熔白刚玉和板状刚玉中的一种或两种占10~55%,氧化铝空心球占10~55%,电熔镁砂粉占1~8%,烧结尖晶石颗粒1~5%,超细尖晶石微粉占1~8%,活性氧化铝粉占2~8%,铝酸钙水泥占3~7%,硅微粉占0~2%;本发明通过严格控制浇注料主料各组分的重量百分比,形成连续颗粒紧密堆积,实现浇注料的致密化,使浇注料具备较高的常温强度、热态高温强度以及较低的热导率,能适用于钢厂较恶劣的环境。
Description
技术领域
本发明涉及一种浇注料,特别是指一种钢包保温用铝镁轻质浇注料。
背景技术
随着对节能减排要求的提高,人们越来越重视能直接用于工作面的高强、耐高温、抗侵蚀的轻质隔热耐火材料。耐火材料微孔轻量化,在保持强度和抗渣侵蚀性不降低的条件下,可降低结构热应力,提高抗热震性,降低材料热导率,特别是用于工作衬可显著减少热损失,降低能源消耗,一定程度上还可减少耐火材料的资源消耗,从而可实现高效长寿和节能降耗一体化。
目前,钢包永久层大多使用常规刚玉浇注料,导热系数为1.8~2.0W/(m·K),部分钢厂采用在永久层与钢壳之间加装隔热纤维板,但有两点弊端,一是减薄了工作层的厚度;二是纤维板破碎后降低了钢包的平衡性。
徐超等在《高铝空心球轻质浇注料的硏制试验》(耐火材料,2016,50(8):291-293)一文中研究了经热处理后高铝空心球的致密度、强度和物相组成,然后分别以质量分数为30%、35%、40%、45%的高铝空心球为骨料制备了轻质浇注料,研究了空心球加入量对轻质浇注料性能的影响。结果表明高铝空心球加入量为40%时,烘干及热处理后轻质浇注料试样的致密度和强度相对最佳。该文献主要研究了空心球加入量对浇注料强度的影响,未涉及如何提高浇注料的保温性能。
发明内容
本发明的目的在于提供一种热态高温性能和保温性能良好的钢包保温用铝镁轻质浇注料。
为实现上述目的,本发明所提供的钢包保温用铝镁轻质浇注料包括浇注料主料,所述浇注料主料按重量百分比包括如下组分:电熔白刚玉和板状刚玉中的一种或两种占10~55%,氧化铝空心球占10~55%,电熔镁砂粉占1~8%,烧结尖晶石颗粒1~5%,超细尖晶石微粉占1~8%,活性氧化铝粉占2~8%,铝酸钙水泥占3~7%,硅微粉占0~2%;所述电熔白刚玉或板状刚玉中不同粒度颗粒占刚玉总重量的百分比为:8<粒度≤15mm占10~30%,5<粒度≤8mm占5~30%,3<粒度≤5mm占5~30%,1<粒度≤3mm占10~20%,0.1<粒度≤1mm占5~20%,粒度≤0.01mm占5~30%;所述氧化铝空心球中不同粒度颗粒占氧化铝空心球总重量的百分比为:3<粒度≤5mm占10~40%,2<粒度≤3mm占10~40%,1<粒度≤2mm占10~40%,0.2<粒度≤1mm占10~30%;所述电熔镁砂的粒度≤0.1mm,所述烧结尖晶石颗粒的粒度为0.1~1mm,所述超细尖晶石微粉的粒度≤25μm,所述活性氧化铝粉的粒度≤0.1mm。
本发明所提供的浇注料,其组分的选择和含量控制的原理在于:
1)本发明铝镁轻质浇注料,由电熔白刚玉和板状刚玉中的一种或两种与氧化铝复合组成骨料,再加入一定含量与粒度的氧化铝空心球,能有效降低浇注料的自重,降低结构热应力,提高抗热震性,降低材料热导率。
2)本发明骨料中大颗粒成分较多,引入了粒度为8~15mm、5~8mm的刚玉颗粒,与加入的细粉形成紧密堆积,使试样的强度大大增加。采用电熔镁砂粉、超细的尖晶石微粉、活性氧化铝粉、硅微粉及铝酸钙水泥组成浇注料基质,其中,加入的电熔镁砂细粉能与原料中的氧化铝反应原位生成镁铝尖晶石,在浇注料内部形成微裂纹从而提高浇注料的抗热震性,但原位生成的尖晶石过多会导致微裂纹数量过多从而导致浇注料的强度下降,因此,本发明通过控制电熔镁砂细粉的加入量来控制浇注料中原位生成的尖晶石的含量从而控制浇注料中微裂纹的数量。
3)本发明还通过控制加入的烧结尖晶石颗粒与超细尖晶石微粉的含量来控制浇注料中尖晶石的总含量,在浇注料中间形成一定粒度梯度的尖晶石,增强浇注料的致密性和高温热态强度。浇注料中加入硅微粉是为了增加试样的中温强度,防止浇注料在烘烤、搬运过程中形成裂纹破碎,但硅微粉加入不能过多,因为硅微粉加入后会导致试样在高温状态下液相变多,从而导致热态高温强度降低。
4)实践证明,浇注料中对骨料进行粒度配级对浇注料性能有重要影响,本发明通过严格控制浇注料主料中电熔白刚玉、板状刚玉、氧化铝空心球及各种细粉的重量百分比,形成连续颗粒紧密堆积,最大实现浇注料的致密化,使浇注料具备较高的常温强度、热态高温强度以及较低的热导率,能适用于钢厂较恶劣的环境。
优选地,该浇注料还包括外加剂(可以作为配料在浇注混料时另配),所述外加剂为FDN减水剂和防爆有机纤维,所述外加剂的重量为浇注料主料重量的0.5~1.5%。FDN减水剂具有优异减水有助提高材料整体强度作用,防爆有机纤维具有利于水分排出预防材料局部爆裂作用。
进一步地,所述FDN减水剂的重量为浇注料主料重量的0.5~1%、所述防爆有机纤维的重量为浇注料主料重量的0.01~0.15%。
进一步地,所述防爆有机纤维为聚丙烯纤维或聚乙烯纤维中的一种或两种。
优选地,所述电熔白刚玉或板状刚玉中不同粒度颗粒占刚玉总重量的百分比为:8<粒度≤15mm占20~30%;5<粒度≤8mm占10~20%;3<粒度≤5mm占10~15%;1<粒度≤3mm占10~20%;0.1<粒度≤1mm占10~20%;粒度≤0.01mm占20~30%。
优选地,所述氧化铝空心球中不同粒度颗粒占氧化铝空心球总重量的百分比为:3<粒度≤5mm占20~35%;2<粒度≤3mm占20~30%;1<粒度≤2mm占15~30%;0.2<粒度≤1mm占10~30%。
优选地,所述电熔白刚玉和板状刚玉中的一种或两种合计占浇注料主料重量的25~55%,所述氧化铝空心球占浇注料主料重量的15~50%。
优选地,所述硅微粉的粒度≤1μm。
与现有技术相比,本发明的有益效果在于:
1)本发明通过严格控制浇注料主料各组分的重量百分比,形成连续颗粒紧密堆积,实现浇注料的致密化,使浇注料具备较高的常温强度、热态高温强度以及较低的热导率,能适用于钢厂较恶劣的环境;
2)本发明通过成分控制,在浇注料内形成一定粒度梯度的尖晶石,提高了浇注料的热态高温性能与抗渣性能,而通过加入轻质骨料,降低了浇注料的导热系数,使得本发明综合性能较高。
3)本发明具有高强度、低热导率的特性,用于钢包永久层能起到良好的保温作用,降低钢包壳的温度,钢包永久层浇注料导热系数从约1.8~2W/(m·K)降低至0.9~1.3W/(m·K),在其他条件不变的情况下,能降低钢包壳温度50度左右;
4)由于保温性能的提高,钢水在钢包中温降得到降低,配合钢包全程加盖技术,可降低转炉出钢钢水温度10~15度,从而降低吨钢成本。
具体实施方式
下面通过具体实施例对本发明作进一步的详细说明。
实施例1~6
本发明所提供的钢包保温用铝镁轻质浇注料,由浇注料主料和外加剂组成,其中:
浇注料主料按重量百分比包括如下组分:电熔白刚玉和板状刚玉中的一种或两种占10~55%,氧化铝空心球占10~55%,电熔镁砂粉占1~8%,烧结尖晶石颗粒1~5%,超细尖晶石微粉占1~8%,活性氧化铝粉占2~8%,铝酸钙水泥占3~7%,硅微粉占0~2%。
外加剂为FDN减水剂和防爆有机纤维,所述防爆有机纤维为聚丙烯纤维和/或聚乙烯纤维,其中FDN减水剂的重量为浇注料主料重量的0.5~1%、防爆有机纤维的重量为浇注料主料重量的0.01~0.15%。
各实施例中浇注料主料和外加剂的具体物料配比如下表1所示:
表1 各实施例配料表
组分 | 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 | 实施例6 |
电熔白刚玉 | 0 | 50% | 15% | 35% | 40% | 10% |
板状刚玉 | 30% | 0 | 15% | 20% | 0 | 35% |
两种刚玉合计 | 30% | 50% | 30% | 55% | 40% | 45% |
氧化铝空心球 | 50% | 25% | 50% | 15% | 40% | 35% |
电熔镁砂粉 | 5% | 2% | 4% | 8% | 5% | 3% |
烧结尖晶石颗粒 | 3% | 5% | 1% | 4% | 1% | 3% |
超细尖晶石微粉 | 5% | 8% | 6% | 6% | 5% | 5% |
活性氧化铝粉 | 2% | 5% | 4% | 4% | 4% | 4% |
铝酸钙水泥 | 4% | 4% | 4% | 6% | 4% | 4% |
硅微粉 | 1% | 1% | 1% | 2% | 1% | 1% |
FDN减水剂 | 0.6% | 0.5% | 0.6% | 0.8% | 0.5% | 0.5% |
防爆有机纤维 | 0.15% | 0.1% | 0.15% | 0.10% | 0.15% | 0.15% |
注:外加剂的两种组分FDN减水剂和防爆有机纤维的含量是相对于浇注料主料总重量的百分比,不算在浇注料主料范围内。
电熔白刚玉或板状刚玉中不同粒度颗粒占刚玉总重量的百分比为:8<粒度≤15mm占10~30%,5<粒度≤8mm占5~30%,3<粒度≤5mm占5~30%,1<粒度≤3mm占10~20%,0.1<粒度≤1mm占5~20%,粒度≤0.01mm占5~30%。各实施例中,刚玉的具体粒度分布见下表2:
表2 刚玉粒度分布表
粒径范围 | 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 | 实施例6 |
8~15mm | 30% | 15% | 30% | 10% | 20% | 30% |
5~8mm | 10% | 10% | 10% | 20% | 20% | 10% |
3~5mm | 10% | 18% | 15% | 20% | 10% | 10% |
1~3mm | 20% | 18% | 10% | 10% | 10% | 10% |
0~1mm | 10% | 12% | 10% | 10% | 10% | 20% |
≤0.01mm | 20% | 27% | 30% | 30% | 30% | 20% |
氧化铝空心球中不同粒度颗粒占氧化铝空心球总重量的百分比为:3<粒度≤5mm占10~40%,2<粒度≤3mm占10~40%,1<粒度≤2mm占10~40%,0.2<粒度≤1mm占10~30%。各实施例中,氧化铝空心球的具体粒度分布见下表2:
表3 氧化铝空心球粒度分布表
粒径范围 | 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 | 实施例6 |
3~5mm | 30% | 40% | 35% | 35% | 20% | 35% |
2~3mm | 30% | 20% | 20% | 10% | 30% | 20% |
1~2mm | 30% | 10% | 25% | 25% | 25% | 15% |
0.2~1mm | 10% | 30% | 20% | 30% | 25% | 30% |
其他成分的粒度分布:电熔镁砂的粒度≤0.1mm,烧结尖晶石颗粒的粒度为0.1~1mm,超细尖晶石微粉的粒度≤25μm,活性氧化铝粉的粒度≤0.1mm,硅微粉的粒度≤1μm。
试验例
按照上述各实施例的组分选择原材料,将浇注料混匀,然后加入FDN减水剂和防爆有机纤维混匀,混匀后加入混合料总量重量百分比的3~5%的水搅拌,搅拌过程中***振动棒振动以利于排气,将浇注料制成40×40×160mm的条状试样,经混料、搅拌、成型、养护后,于110℃下保温24小时进行热处理,制备得到铝镁轻质浇注料。
测试项目和所采用的方法如下:采用YB/T 5200-1993测试材料的显气孔率和体积密度;采用YB/T 5201-1993测试材料的常温抗折强度和耐压强度;采用YB/T 5203-1993测试材料的线变化率;采用GB/T 3002-2007测试材料的高温抗折强度;采用YB/T 4130-2005测试材料的导热系数。采用YB/T376.1-1995测试材料的抗热震性,水冷5次后测试试样抗折强度,从而计算出试样的强度保持率。采用GB/T 8931-2007测试材料的抗渣侵蚀性,得到渣碱度=3.4时的渣侵蚀指数,方法为:采用回转抗渣法将浇注料试样于1550℃回转炉中保温2小时,切开试样横向断面,检测试样的渣侵蚀指数,各配方均取3条试样进行实验并取平均值。
表4 试样物理性能
项目 | 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 | 实施例6 |
渣侵蚀指数(碱度=3.4) | 11.8 | 12.6 | 11.7 | 12.2 | 12.3 | 11.9 |
体积密度/g·cm-3 | 1.93 | 2.75 | 1.96 | 2.68 | 2.02 | 2.17 |
显气孔率/% | 29.3 | 19.2 | 29.7 | 19.6 | 28.8 | 29.1 |
线变化率/% | 0.37 | 0.28 | 0.24 | 0.31 | 0.29 | 0.27 |
常温抗折强度/MPa | 8.9 | 9.5 | 9.7 | 9.2 | 10.1 | 9.2 |
常温抗压强度/Mpa | 65.3 | 61.8 | 63.2 | 65.5 | 73.1 | 66.8 |
高温抗折强度/Mpa | 6.9 | 7.6 | 6.5 | 7.1 | 7.2 | 6.4 |
1000℃导热系数W/(m·K) | 0.83 | 1.26 | 0.91 | 1.34 | 0.86 | 0.92 |
水冷5次后强度保持率/% | 78 | 71 | 76 | 73 | 82 | 72 |
表4结果显示,按本发明各实施例制备得到的铝镁轻质浇注料,其渣侵蚀指数(碱度=3.4)均小于14%(常规刚玉浇注料为14~17%),显示出其具有很好的抗渣侵蚀性能。其线变化率均小于0.5%,说明其膨胀收缩性不大,利于施工。其常温强度和高温强度较高,更能适应恶劣的环境。导热系数较普通刚玉浇注料有了显著的下降(常规刚玉浇注料为1.8-2.0W/(m·K)),水冷5次后的强度保持率也较高,在75%左右,说明本发明具热震稳定性较好。
Claims (8)
1.一种钢包保温用铝镁轻质浇注料,包括浇注料主料,其特征在于:所述浇注料主料按重量百分比包括如下组分:电熔白刚玉和板状刚玉中的一种或两种占10~55%,氧化铝空心球占10~55%,电熔镁砂粉占1~8%,烧结尖晶石颗粒1~5%,超细尖晶石微粉占1~8%,活性氧化铝粉占2~8%,铝酸钙水泥占3~7%,硅微粉占0~2%;
所述电熔白刚玉或板状刚玉中不同粒度颗粒占刚玉总重量的百分比为:8<粒度≤15mm占10~30%,5<粒度≤8mm占5~30%,3<粒度≤5mm占5~30%,1<粒度≤3mm占10~20%,0.1<粒度≤1mm占5~20%,粒度≤0.01mm占5~30%;
所述氧化铝空心球中不同粒度颗粒占氧化铝空心球总重量的百分比为:3<粒度≤5mm占10~40%,2<粒度≤3mm占10~40%,1<粒度≤2mm占10~40%,0.2<粒度≤1mm占10~30%;
所述电熔镁砂的粒度≤0.1mm,所述烧结尖晶石颗粒的粒度为0.1~1mm,所述超细尖晶石微粉的粒度≤25μm,所述活性氧化铝粉的粒度≤0.1mm。
2.根据权利要求1所述的钢包保温用铝镁轻质浇注料,其特征在于:还包括外加剂,所述外加剂为FDN减水剂和防爆有机纤维,所述外加剂的重量为浇注料主料重量的0.5~1.5%。
3.根据权利要求2所述的钢包保温用铝镁轻质浇注料,其特征在于:所述FDN减水剂的重量为浇注料主料重量的0.5~1%、所述防爆有机纤维的重量为浇注料主料重量的0.01~0.15%。
4.根据权利要求2所述的钢包保温用铝镁轻质浇注料,其特征在于:所述防爆有机纤维为聚丙烯纤维或聚乙烯纤维中的一种或两种。
5.根据权利要求1~4中任一项所述的钢包保温用铝镁轻质浇注料,其特征在于:所述电熔白刚玉或板状刚玉中不同粒度颗粒占刚玉总重量的百分比为:8<粒度≤15mm占20~30%,5<粒度≤8mm占10~20%,3<粒度≤5mm占10~15%,1<粒度≤3mm占10~20%,0.1<粒度≤1mm占10~20%,粒度≤0.01mm占20~30%。
6.根据权利要求1~4中任一项所述的钢包保温用铝镁轻质浇注料,其特征在于:所述氧化铝空心球中不同粒度颗粒占氧化铝空心球总重量的百分比为:3<粒度≤5mm占20~35%,2<粒度≤3mm占20~30%,1<粒度≤2mm占15~30%,0.2<粒度≤1mm占10~30%。
7.根据权利要求1~4中任一项所述的钢包保温用铝镁轻质浇注料,其特征在于:所述电熔白刚玉和板状刚玉中的一种或两种合计占浇注料主料重量的25~55%,所述氧化铝空心球占浇注料主料重量的15~50%。
8.根据权利要求1~4中任一项所述的钢包保温用铝镁轻质浇注料,其特征在于:所述硅微粉的粒度≤1μm。
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Application publication date: 20181218 |