CN110698179A - 一种高性能镁碳砖及其制备方法 - Google Patents
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- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 title claims abstract description 196
- 239000000395 magnesium oxide Substances 0.000 title claims abstract description 98
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title claims abstract description 86
- 239000011449 brick Substances 0.000 title claims abstract description 66
- 229910052799 carbon Inorganic materials 0.000 title claims abstract description 65
- 238000002360 preparation method Methods 0.000 title claims abstract description 23
- 239000000843 powder Substances 0.000 claims abstract description 36
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims abstract description 31
- 238000002156 mixing Methods 0.000 claims abstract description 28
- 229910052751 metal Inorganic materials 0.000 claims abstract description 24
- 239000002184 metal Substances 0.000 claims abstract description 24
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 23
- 239000010439 graphite Substances 0.000 claims abstract description 22
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 22
- 239000002245 particle Substances 0.000 claims abstract description 22
- 239000005011 phenolic resin Substances 0.000 claims abstract description 19
- 229920001568 phenolic resin Polymers 0.000 claims abstract description 19
- 229910052582 BN Inorganic materials 0.000 claims abstract description 17
- 239000000654 additive Substances 0.000 claims abstract description 16
- 239000000126 substance Substances 0.000 claims abstract description 16
- 230000000996 additive effect Effects 0.000 claims abstract description 14
- 238000000465 moulding Methods 0.000 claims abstract description 14
- 239000010426 asphalt Substances 0.000 claims abstract description 13
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims abstract description 12
- 239000011230 binding agent Substances 0.000 claims abstract description 12
- 239000002994 raw material Substances 0.000 claims abstract description 11
- 238000001035 drying Methods 0.000 claims abstract description 10
- 238000003825 pressing Methods 0.000 claims abstract description 10
- 239000003575 carbonaceous material Substances 0.000 claims abstract description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- 239000000203 mixture Substances 0.000 claims description 12
- 239000003963 antioxidant agent Substances 0.000 claims description 9
- 230000003078 antioxidant effect Effects 0.000 claims description 8
- 239000007767 bonding agent Substances 0.000 claims description 7
- 229910052681 coesite Inorganic materials 0.000 claims description 6
- 229910052906 cristobalite Inorganic materials 0.000 claims description 6
- 238000009826 distribution Methods 0.000 claims description 6
- 238000007580 dry-mixing Methods 0.000 claims description 6
- 239000001095 magnesium carbonate Substances 0.000 claims description 6
- 235000014380 magnesium carbonate Nutrition 0.000 claims description 6
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 claims description 6
- 229910000021 magnesium carbonate Inorganic materials 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 6
- 229910052682 stishovite Inorganic materials 0.000 claims description 6
- 229910052905 tridymite Inorganic materials 0.000 claims description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- -1 aluminum-magnesium-carbon Chemical compound 0.000 claims description 3
- 229910052593 corundum Inorganic materials 0.000 claims description 3
- 239000007787 solid Substances 0.000 claims description 3
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 3
- 239000011819 refractory material Substances 0.000 abstract description 6
- 239000000463 material Substances 0.000 abstract description 5
- 230000035939 shock Effects 0.000 abstract description 4
- 230000007797 corrosion Effects 0.000 abstract description 3
- 238000005260 corrosion Methods 0.000 abstract description 3
- 230000000694 effects Effects 0.000 abstract description 3
- 230000003647 oxidation Effects 0.000 description 9
- 238000007254 oxidation reaction Methods 0.000 description 9
- 230000003628 erosive effect Effects 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 230000032683 aging Effects 0.000 description 3
- 238000007599 discharging Methods 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 238000005303 weighing Methods 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- 239000013500 performance material Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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Abstract
本发明涉及到耐火材料技术领域,尤其为一种高性能镁碳砖及其制备方法,包括以下步骤:S1,选取原料:电熔镁砂颗粒,电熔镁砂细粉,金属铝粉,六方氮化硼,鳞片石墨,高温沥青粉,酚醛树脂结合剂,并根据配方按重量百分比取料;S2,混料;S3,成型:将混料压制成型制成半成品砖坯;S4,烘烤:将压制好的半成品砖坯放入干燥窑中烘烤固化,得到高性能镁碳砖成品。本发明使用六方氮化硼作为镁碳砖的添加剂,主要在于六方氮化硼大部分性能优于碳素材料,摩擦系数低,高温稳定性好,热震稳定性好,而且具有强度高,耐腐蚀性强等特点,是良好的耐火材料添加剂,生产出来的镁碳砖各项物化指标均比当前使用的镁碳砖效果好,大大提高了镁碳砖的使用寿命。
Description
技术领域
本发明涉及耐火材料技术领域,尤其是一种高性能镁碳砖及其制备方法。
背景技术
镁碳砖作为20世纪70年代兴起的新型耐火材料,它以镁砂为主要原料制作而成,具有耐火度高、抗热震性优良和抗侵蚀能力强等优良特性而被广泛用于钢铁企业,随着近年来我国钢铁行业的迅猛发展,镁碳砖作为钢铁行业必不可少的优良耐火材料,但是镁碳砖作为高温性能材料,在使用过程中面临苛刻的产工艺,其镁碳砖具有优良的抗渣侵蚀性、热稳定性和抗氧化性是必不可少的,但是镁碳砖作为含碳制品,碳具有易氧化的弱点,很容易引起镁碳砖制品各项物理和化学指标降低,抗侵蚀能力降低,使镁碳砖的使用效果大大降低,在镁碳砖中加入添加剂能够有效的防止碳的氧化,提高镁碳砖的高温使用性能,添加剂的作用主要在两个方面:一方面是从热力学角度考虑,在高温的工况条件下,添加剂与碳的生成物与氧的亲和力大,优先与氧反应,阻止了碳的氧化,从而起到了保护碳的作用;另一方面是从动力学角度考虑,添加剂与O2、CO、C反应的生成物堵塞镁碳砖制品内的气孔改善镁碳砖制品内部的显微结构,使镁碳砖制品更加致密,阻止了O2向镁碳砖制品内部的氧化,从而保护镁碳砖制品不被氧化,当前使用的抗氧化剂主要有金属或合金细粉和非金属细粉。
上述镁碳砖的添加剂,有些抗氧化性不太理想,有的虽提高了镁碳砖的抗氧化性,但其他的高温性能受到了影响,含硼的抗氧化剂防氧化效果优良,解决了其他抗氧化剂对镁碳砖高温性能的影响,因此需要一种高性能镁碳砖及其制备方法。
发明内容
本发明的目的是为了解决现有技术中存在的缺点,而提出的一种高性能镁碳砖及其制备方法。
为了实现上述目的,本发明采用了如下技术方案:
一种高性能镁碳砖及其制备方法,包括以下步骤:S1,选取原料:电熔镁砂颗粒,电熔镁砂细粉,金属铝粉,六方氮化硼,鳞片石墨,高温沥青粉,酚醛树脂结合剂,并根据配方按重量百分比取料;
S2,混料:首先按配方的一定比例把电熔镁砂颗粒加入到混料机中干混3~5分钟,然后再缓慢加入酚醛树脂结合剂混3~5分钟,之后再加入鳞片石墨混7~10分钟,最后加入电熔镁砂细粉、六方氮化硼粉及金属铝粉高速混炼20~40分钟出泥料;
S3,成型:将混料完成的泥料按一定的重量加入到模具中压制成型制成半成品砖坯;
S4,烘烤:将压制好的半成品砖坯放入干燥窑中烘烤固化,得到高性能镁碳砖成品。
优选的,所述S1,原料按重量百分比包括如下组分:65%~75%的5-1mm电熔镁砂颗粒,10%~20%的1~0.075mm电熔镁砂细粉,1%~3%的添加剂金属铝粉,1%~3%的六方氮化硼,8%~16%的鳞片石墨,1%~2%的高温沥青粉和2%~4%的酚醛树脂结合剂。
优选的,所述S1,电熔镁砂颗粒粒度级配为5~3mm、3~1mm、1~0.075mm,各粒度级配的质量比为(2~5):(3~5):(2~5),再生铝镁碳料的化学组成比例为MgO≧97.5%,Al2O3≤0.2%,CaO<1.2%,SiO2<1.0%,体积密度≧3.50g/cm3,电熔镁砂细粉粒度为120目~325目,所述电熔镁砂化学组成所占的质量百分比例为MgO≧97.5%,CaO<1.2%,SiO2<1.0%,体积密度≧3.50g/cm3。
优选的,所述S1,金属铝粉粒度为120目~325目,其纯度按质量百分比>99.9%,金属铝粉为抗氧化剂。
优选的,所述S1,六方氮化硼粉80目~200目,其纯度按质量百分比BN≥99%,B2O3≤0.5%,六方氮化硼粉为抗氧化剂。
优选的,所述S1,鳞片石墨粒度为200目~600目,鳞片石墨化学组成所占的质量百分比例为C≧94.50%,灰分<0.76%,水分<0.52%。
优选的,所述S1,酚醛树脂结合剂的粘度为13000~15000Pa.s(25℃),固含量≧78%,残碳量45%~50%,水分≤3%~6%,PH=6~8。
优选的,所述S3,模具中压制压力为6300KN。
优选的,所述S4,干燥窑中烘烤温度为150~220℃,烘烤时间为16h~24h。
与现有技术相比,本发明提出了一种高性能镁碳砖及其制备方法,具有以下有益效果:
1、本发明提供了一种高性能镁碳砖及其制备方法,使用六方氮化硼作为镁碳砖的添加剂,主要在于六方氮化硼大部分性能优于碳素材料,摩擦系数低,高温稳定性好,热震稳定性好,而且具有强度高,耐腐蚀性强等特点,是良好的耐火材料添加剂,生产出来的镁碳砖各项物化指标均比当前使用的镁碳砖效果好,既提高了镁碳砖的抗氧化性,又增强了其抗渗透性、抗高温侵蚀性,大大提高了镁碳砖的使用寿命。
本发明中,该装置中未涉及部分均与现有技术相同或可采用现有技术加以实现,本发明提供了一种高性能镁碳砖及其制备方法,使用六方氮化硼作为镁碳砖的添加剂,主要在于六方氮化硼大部分性能优于碳素材料,摩擦系数低,高温稳定性好,热震稳定性好,而且具有强度高,耐腐蚀性强等特点,是良好的耐火材料添加剂,生产出来的镁碳砖各项物化指标均比当前使用的镁碳砖效果好,既提高了镁碳砖的抗氧化性,又增强了其抗渗透性、抗高温侵蚀性,大大提高了镁碳砖的使用寿命。
具体实施方式
下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
一种高性能镁碳砖及其制备方法,包括以下步骤:S1,选取原料:电熔镁砂颗粒,电熔镁砂细粉,金属铝粉,六方氮化硼,鳞片石墨,高温沥青粉,酚醛树脂结合剂,并根据配方按重量百分比取料;
S2,混料:首先按配方的一定比例把电熔镁砂颗粒加入到混料机中干混3~5分钟,然后再缓慢加入酚醛树脂结合剂混3~5分钟,之后再加入鳞片石墨混7~10分钟,最后加入电熔镁砂细粉、六方氮化硼粉及金属铝粉高速混炼20~40分钟出泥料;
S3,成型:将混料完成的泥料按一定的重量加入到模具中压制成型制成半成品砖坯;
S4,烘烤:将压制好的半成品砖坯放入干燥窑中烘烤固化,得到高性能镁碳砖成品。
所述S1,原料按重量百分比包括如下组分:65%~75%的5-1mm电熔镁砂颗粒,10%~20%的1~0.075mm电熔镁砂细粉,1%~3%的添加剂金属铝粉,1%~3%的六方氮化硼,8%~16%的鳞片石墨,1%~2%的高温沥青粉和2%~4%的酚醛树脂结合剂。
所述S1,电熔镁砂颗粒粒度级配为5~3mm、3~1mm、1~0.075mm,各粒度级配的质量比为(2~5):(3~5):(2~5),再生铝镁碳料的化学组成比例为MgO≧97.5%,Al2O3≤0.2%,CaO<1.2%,SiO2<1.0%,体积密度≧3.50g/cm3,电熔镁砂细粉粒度为120目~325目,所述电熔镁砂化学组成所占的质量百分比例为MgO≧97.5%,CaO<1.2%,SiO2<1.0%,体积密度≧3.50g/cm3。
所述S1,金属铝粉粒度为120目~325目,其纯度按质量百分比>99.9%,金属铝粉为抗氧化剂。
所述S1,六方氮化硼粉80目~200目,其纯度按质量百分比BN≥99%,B2O3≤0.5%,六方氮化硼粉为抗氧化剂。
所述S1,鳞片石墨粒度为200目~600目,鳞片石墨化学组成所占的质量百分比例为C≧94.50%,灰分<0.76%,水分<0.52%。
所述S1,酚醛树脂结合剂的粘度为13000~15000Pa.s(25℃),固含量≧78%,残碳量45%~50%,水分≤3%~6%,PH=6~8。
所述S3,模具中压制压力为6300KN。
所述S4,干燥窑中烘烤温度为150~220℃,烘烤时间为16h~24h。
实施例1
1.选取根据配方按重量百分比原料:电熔镁砂5~1mm颗粒为65%,电熔镁砂细粉为15%,高温沥青粉1%、金属铝粉1%,六方氮化硼粉1%,鳞片石墨14%,酚醛树脂结合剂3%。
2.混料:首先按一定比例把电熔镁砂颗粒加入到混料机中干混5分钟,然后再缓慢加入酚醛树脂结合剂混3分钟,之后再加入鳞片石墨混10分钟,最后加入电熔镁砂细粉、高温沥青粉、金属铝粉、六方氮化硼粉复合混炼30分钟出料。
3.成型:将混练完成的泥料按放入泥料盆中困料10分钟,称量一定重量的泥料放入压机模框中,在压力为6300KN的压机上压制成型。
4.烘烤:将压制好的半成品砖坯放入干燥隧道窑中烘烤固化,烘烤温度为180℃,烘烤时间为22h,得到高性能镁碳砖成品。
实施例2
1.选取根据配方按重量百分比原料:电熔镁砂5~1mm颗粒为65%,电熔镁砂细粉为14%,高温沥青粉1%,金属铝粉1%,氮化硼粉1.5%,鳞片石墨14%,酚醛树脂结合剂3%。
2.混料:首先按一定比例把电熔镁砂颗粒加入到混料机中干混5分钟,然后再缓慢加入酚醛树脂结合剂混3分钟,之后再加入鳞片石墨混10分钟,最后加入电熔镁砂细粉、高温沥青粉、金属铝粉、六方氮化硼粉复合混炼30分钟出料。
3.成型:将混练完成的泥料按放入泥料盆中困料10分钟,称量一定重量的泥料放入压机模框中,在压力为6300KN的压机上压制成型。
4.烘烤:将压制好的半成品砖坯放入干燥隧道窑中烘烤固化,烘烤温度为200℃,烘烤时间为22h,得到高性能镁碳砖成品。
实施例3
1.选取根据配方按重量百分比原料:电熔镁砂5~1mm颗粒为65%,电熔镁砂细粉为14%,,高温沥青粉1%,金属铝粉1%,六方氮化硼细粉2%,鳞片石墨14%,酚醛树脂结合剂3%。
2.混料:首先按一定比例把电熔镁砂颗粒加入到混料机中干混5分钟,然后再缓慢加入酚醛树脂结合剂混3分钟,之后再加入鳞片石墨混10分钟,最后加入电熔镁砂细粉、高温沥青粉、金属铝粉、六方氮化硼粉复合混炼30分钟出料。
3.成型:将混练完成的泥料按放入泥料盆中困料10分钟,称量一定重量的泥料放入压机模框中,在压力为6300KN的压机上压制成型。
4.烘烤:将压制好的半成品砖坯放入干燥隧道窑中烘烤固化,烘烤温度为220℃,烘烤时间为22h,得到高性能镁碳砖成品。
实施例1、2、3检测数据如表1:
表1
主要理化指标 | 实施例1 | 实施例2 | 实施例3 |
体积密度,g/cm3 | 3.02 | 3.05 | 3.03 |
显气孔率,% | 2.8 | 2.76 | 2.72 |
耐压强度,Mpa | 38.2 | 40.5 | 38.7 |
高温抗折强度,Mpa | 11.2 | 11.7 | 12.2 |
MgO,% | 73.6 | 75.6 | 75.2 |
C,% | 14.5 | 14.6 | 14.7 |
以上实施例仅仅是对本发明的优选实施方式进行描述,并非对本发明的范围进行界定,在不脱离本发明设计精神的前提下,本领域普通工程技术人员对本发明的技术方案作出的各种改进和变型,均应落入本发明的权利要求书确定的保护范围内。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (9)
1.一种高性能镁碳砖及其制备方法,其特征在于,包括以下步骤:
S1,选取原料:电熔镁砂颗粒,电熔镁砂细粉,金属铝粉,六方氮化硼,鳞片石墨,高温沥青粉,酚醛树脂结合剂,并根据配方按重量百分比取料;
S2,混料:首先按配方的一定比例把电熔镁砂颗粒加入到混料机中干混3~5分钟,然后再缓慢加入酚醛树脂结合剂混3~5分钟,之后再加入鳞片石墨混7~10分钟,最后加入电熔镁砂细粉、六方氮化硼粉及金属铝粉高速混炼20~40分钟出泥料;
S3,成型:将混料完成的泥料按一定的重量加入到模具中压制成型制成半成品砖坯;
S4,烘烤:将压制好的半成品砖坯放入干燥窑中烘烤固化,得到高性能镁碳砖成品。
2.根据权利要求1所述的一种高性能镁碳砖及其制备方法,其特征在于,所述S1,原料按重量百分比包括如下组分:65%~75%的5-1mm电熔镁砂颗粒,10%~20%的1~0.075mm电熔镁砂细粉,1%~3%的添加剂金属铝粉,1%~3%的六方氮化硼,8%~16%的鳞片石墨,1%~2%的高温沥青粉和2%~4%的酚醛树脂结合剂。
3.根据权利要求1所述的一种高性能镁碳砖及其制备方法,其特征在于,所述S1,电熔镁砂颗粒粒度级配为5~3mm、3~1mm、1~0.075mm,各粒度级配的质量比为(2~5):(3~5):(2~5),再生铝镁碳料的化学组成比例为MgO≧97.5%,Al2O3≤0.2%,CaO<1.2%,SiO2<1.0%,体积密度≧3.50g/cm3,电熔镁砂细粉粒度为120目~325目,所述电熔镁砂化学组成所占的质量百分比例为MgO≧97.5%,CaO<1.2%,SiO2<1.0%,体积密度≧3.50g/cm3。
4.根据权利要求1所述的一种高性能镁碳砖及其制备方法,其特征在于,所述S1,金属铝粉粒度为120目~325目,其纯度按质量百分比>99.9%,金属铝粉为抗氧化剂。
5.根据权利要求1所述的一种高性能镁碳砖及其制备方法,其特征在于,所述S1,六方氮化硼粉80目~200目,其纯度按质量百分比BN≥99%,B2O3≤0.5%,六方氮化硼粉为抗氧化剂。
6.根据权利要求1所述的一种高性能镁碳砖及其制备方法,其特征在于,所述S1,鳞片石墨粒度为200目~600目,鳞片石墨化学组成所占的质量百分比例为C≧94.50%,灰分<0.76%,水分<0.52%。
7.根据权利要求1所述的一种高性能镁碳砖及其制备方法,其特征在于,所述S1,酚醛树脂结合剂的粘度为13000~15000Pa.s(25℃),固含量≧78%,残碳量45%~50%,水分≤3%~6%,PH=6~8。
8.根据权利要求1所述的一种高性能镁碳砖及其制备方法,其特征在于,所述S3,模具中压制压力为6300KN。
9.根据权利要求1所述的一种高性能镁碳砖及其制备方法,其特征在于,所述S4,干燥窑中烘烤温度为150~220℃,烘烤时间为16h~24h。
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