CN111333409A - 一种再生镁碳质中间包干式料及其制备方法 - Google Patents

一种再生镁碳质中间包干式料及其制备方法 Download PDF

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CN111333409A
CN111333409A CN202010166784.0A CN202010166784A CN111333409A CN 111333409 A CN111333409 A CN 111333409A CN 202010166784 A CN202010166784 A CN 202010166784A CN 111333409 A CN111333409 A CN 111333409A
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于九利
胡玲军
赵现华
任林
刘丽
颜浩
赵伟
高梅
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Tianjin Ruilixin Environmental Protection Technology Co ltd
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Abstract

本发明属于耐火材料领域。本发明提供了一种再生镁碳质中间包干式振动料，所述中间包干式振动料由包括如下重量份的成分制成：再生镁碳砖颗粒30~70份，电熔镁砂颗粒或重烧镁砂颗粒0~40份，电熔镁砂细粉或重烧镁砂细粉10~30份，结合剂4~6份，抗氧化剂2~4份和促烧剂1~2份。本发明进一步提供了所述干式振动料的制备方法。本发明提供的干式料烧结程度低，使用后易于翻包解体，引入钢渣不润湿的再生镁碳砖中的石墨能够提高材料的抗熔渣侵蚀性能；采用废弃镁碳砖为原料，不仅减少了环境污染，还降低了耐火材料的成本和炼钢成本，为废弃镁碳砖的再利用提出了一种新的途径，对于节能降耗、环境保护具有重要的意义。

Description

一种再生镁碳质中间包干式料及其制备方法
技术领域
本发明涉及耐火材料技术领域，尤其涉及一种再生镁碳砖颗粒为原料的中间包干式振动料及其制备方法。
背景技术
钢铁市场竞争日趋激烈。在钢铁产品过剩的情况下，钢铁企业要在市场竞争中赢得主动，除了具有性能好的产品外，还要具有较低的成本优势。因此，为了生存，钢铁企业比以往任何时候更加重视企业内部挖潜和降低成本。
当前，在我国的耐火材料中，年产废弃物的数量非常大。这些废弃材料的存在，既占用了耕地空间，也对环境造成了污染，不利于当前节能环保理念的实现。近年来，随着企业发展的需要，大多数公司已经开始注重废弃耐材的回收利用。用这些加工处理后的可再利用耐火材料，不但可以用来制备新的耐火材料，而且有的还可以制备出较高性能的耐火材料成品。对这些用后废弃耐火材料的再生利用，不仅节约了国家的能源和资源，减轻了因堆积或掩埋这些废料对于周围环境的污染，同时也降低了处理这些废料的成本。所以，从我国长远的发展考虑，应该抓紧研究对于这些废弃耐火材料的回收利用，这是一项有着重大研究意义的课题。
镁质中间包干式振动料的主要原料是电熔镁砂，近年来随着市场需求变化，其价格已远远的超出了成本，使得镁质中间包干式振动料的生产基本没有经济效益。再生镁碳砖是对废弃钢包砖进行加工后的一种二次资源，属于废物再利用。但由于对废料的回收利用缺乏相应的鼓励措施及技术支持，再生镁碳砖典型的处理方式就是掩埋。既增加了产品生产成本，又造成了材料的浪费。近年来随着对环保的重视，废弃耐火材料的利用取得了一定的进展，但是在研究的深度与广度方面依然存在着一些不足，在整体的利用率方面还比较低。
发明内容
本发明的目的在于提供一种成本低、节约资源和使用寿命长的以再生镁碳砖为主要原料的中间包的干式振动料及其制备方法。本发明用再生镁碳砖颗粒代替大部分电熔镁砂制备镁碳质中间包干式振动料，提高了材料的利用率，同时提高了经济效益，达到了保护环境、节约资源的目的。
为了实现上述发明目的，本发明提供以下技术方案：
本发明提供了一种再生镁碳质中间包干式振动料，由包含以下重量份的成分制成：
Figure BDA0002407729620000021
作为优选，所述再生镁碳砖颗粒中，粒径3～5mm的组分、粒径1～3mm的组分与粒径≤1mm的组分的重量比为15～20：25～30：20～30。
作为优选，所述电熔镁砂细粉或重烧镁砂细粉的粒径小于等于0.1mm。
作为优选，所述结合剂为酚醛树脂和/或葡萄糖。
作为优选，所述抗氧化剂为金属硅粉、金属铝粉和碳化硅的一种或几种。
作为优选，所述促烧剂为红粘土、水玻璃和钛白粉的一种或几种。
本发明还提供了一种再生镁碳质中间包干式振动料的制备方法，包括如下步骤：
将各原料混合后进行振动成型、烘烤，得到再生镁碳质中间包干式振动料。
作为优选，所述振动成型的时间为8～10min。
作为优选，所述烘烤的温度为250～400℃，烘烤的时间为1.5～2h。
本发明的有益效果包括以下几点：
1)所述干式振动料抗熔渣侵蚀性能较好，应用过程中烧结程度低，使用后易于翻包解体。
2)在镁质耐火材料中引入低膨胀性及对钢渣不润湿的再生镁碳砖颗粒中的石墨，克服了镁质材料高温热膨胀大、抗熔渣渗透性差、抗热震稳定性差的缺点，对钢渣碱度波动适应性强。
3)在镁质耐火材料中引入抗氧化剂，可促进在耐火材料内部形成保护层以提高材料的抗氧化与抗侵蚀能力。
4)本发明以再生镁碳砖为主要原料，不仅节约了国家的矿物资源和能源，也减少了环境污染，降低了耐火材料的成本和炼钢成本，使废弃耐火材料的无害化、再生处理成为重要的发展方向。本发明为废弃镁碳砖的再利用提出了一种新的途径，对于节能降耗、保护环境具有重要的意义。
具体实施方式
本发明提供了一种再生镁碳质中间包干式振动料，由包含以下重量份的成分制成：
Figure BDA0002407729620000031
本发明制备再生镁碳质中间包干式振动料的原料包含30～70份的再生镁碳砖颗粒，优选为40～60份，进一步优选为45～55份。
本发明所述的再生镁碳砖颗粒中MgO含量优选≥70％，更优选≥80％；Al2O3含量优选≤5％，更优选≤3％。
本发明所述的再生镁碳砖颗粒中粒径3～5mm的组分、粒径1～3mm的组分与粒径≤1mm的组分的重量比优选为15～20：25～30：20～30，进一步优选为16～18：26～28：22～28。
本发明所述的再生镁碳砖颗粒中粒径3～5mm的组分包含粒径等于5mm的成分，不包含粒径等于3mm的成分；所述粒径1～3mm的组分包含粒径等于3mm的成分，不包含粒径等于1mm的成分。
本发明所述的再生镁碳砖颗粒优选为自制产品，所述再生镁碳砖颗粒的制备方法优选包含如下步骤：
(1)在炼铁和炼钢现场拆罐后，回收镁碳砖；
(2)拣选除杂：用铁锤剔除废砖表面的泥土、渣、铁块，敲掉变质层，按要求整齐堆放在预处理区域；
(3)水化处理：室温下采用水洗法水浸时间≥24h；
(4)干燥：将水化处理后的废弃镁碳砖装窑车，进隧道干燥窑，在110～130℃下干燥24h；
(5)去除假颗粒：通过混料机和轮碾机对干燥后的废弃镁碳砖进行研磨至颗粒料，再将颗粒料表面的细粉基质剥离，实现镁碳砖颗粒骨料和细粉基质的分离；
(6)筛分：混碾机放出骨料进振动筛，筛分得到5～3mm、3～1mm，1～0mm再生颗粒，其中大于5mm的颗粒返回步骤(5)再次研磨直至所有颗粒粒径≤5mm。
本发明制备再生镁碳质中间包干式振动料的原料包含0～40份的电熔镁砂颗粒或重烧镁砂颗粒，优选为10～40份，进一步优选为20～40份。
在本发明中，所述电熔镁砂颗粒中MgO优选≥94.5％，更优选≥96％；SiO2优选≤3.0％，更优选≤2.0％；体积密度优选≥3.35g/cm3，更优选≥4.35g/cm3；所述重烧镁砂颗粒中MgO优选≥91％，更优选≥95％；SiO2优选≤3.0％，更优选≤2.0％；体积密度优选≥3.1g/cm3，更优选≥4.1g/cm3。
本发明制备再生镁碳质中间包干式振动料的原料包含10～30份的电熔镁砂细粉或重烧镁砂细粉，优选为10～20份，进一步优选为15～20份。
本发明所述电熔镁砂细粉或重烧镁砂细粉的粒径优选≤0.1mm，还优选≤0.09mm，进一步优选≤0.088mm。
本发明制备再生镁碳质中间包干式振动料的原料包含4～6份的结合剂，优选为4.5～5.5份，进一步优选为5份。
本发明所述的结合剂优选为酚醛树脂和/或葡萄糖。
本发明制备再生镁碳质中间包干式振动料的原料包含2～4份的抗氧化剂，优选为2.5～3.5份，进一步优选为3份。
本发明所述的抗氧化剂优选为金属硅粉、金属铝粉和碳化硅的一种或几种。
本发明制备再生镁碳质中间包干式振动料的原料包含1～2份的促烧剂，优选为1.5份。
本发明所述的促烧剂优选为红粘土、水玻璃和钛白粉的一种或几种。
本发明还提供了一种再生镁碳质中间包干式振动料的制备方法，包括如下步骤：
将各原料混合后进行振动成型、烘烤，得到再生镁碳质中间包干式振动料。
本发明所述混合优选为将重烧镁砂细粉或电熔镁砂细粉、结合剂、抗氧化剂和促烧剂放进强制混料机中预混合8～12min，然后再和剩余原料放入搅拌机中搅拌均匀。
本发明所述振动成型的时间优选为8～10min，更优选为8.5～10min，进一步优选为8.5～9.5min。
本发明所述振动成型优选为采用功率为2～2.5kw的三相异步电动机振动成型。
本发明所述的烘烤中，烘烤温度优选为250～400℃，更优选为250～350℃，进一步优选为250～300℃。
本发明所述的烘烤中，烘烤时间优选为1.5～2h，更优选为2h。
本发明优选在所述烘烤结束后，强制风冷1～2h后脱模；进一步优选为强制风冷1h。
下面结合实施例对本发明提供的再生镁碳质中间包干式振动料及其制备方法进行详细的说明，但是不能把它们理解为对本发明保护范围的限定。
实施例1
将20kg电熔镁砂细粉(粒径≤0.1mm)、4kg酚醛树脂、4kg碳化硅和2kg水玻璃放入强制搅拌机预混合8min，得混匀的细粉；再将所述混匀的细粉和30kg再生镁碳砖颗粒(粒径3～5mm的组分、1～3mm的组分与≤1mm的组分的重量比为18：28：28)、40kg电熔镁砂颗粒放入搅拌机中，搅拌均匀，采用功率为2.2kw的三相异步电动机振动9min成型，在250℃条件下烘烤2h，强制风冷1h后脱模，即得。
实施例2
将20kg重烧镁砂细粉(粒径≤0.09mm)、6kg葡萄糖、2kg金属铝粉和2kg红粘土放入强制搅拌机中预混合10min，得混匀的细粉；再将所述混匀的细粉和20kg重烧镁砂颗粒、50kg再生镁碳砖颗粒(粒径3～5mm的组分、1～3mm的组分与≤1mm的组分的重量比为17：27：27)放入搅拌机中，搅拌均匀，采用功率为2.2kw的三相异步电动机振动10min成型，在300℃条件下烘烤1.5h，强制风冷1h后脱模，即得。
实施例3
将20kg电熔镁砂细粉(粒径≤0.088mm)、6kg酚醛树脂、3kg金属硅粉和1kg钛白粉放入强制搅拌机中预混合12min，得混匀的细粉；再将所述混匀的细粉和70kg再生镁碳砖颗粒(粒径3～5mm的组分、1～3mm的组分与≤1mm的组分的重量比为20：30：30)放入搅拌机中，搅拌均匀，采用功率为2.2kw的三相异步电动机振动8min成型，在400℃条件下烘烤2h，强制风冷1h后脱模，即得。
对比例
本对比例提供了一种干式振动料，与实施例1相比，区别仅在于，用电熔镁砂颗粒代替再生镁碳砖颗粒，所述电熔镁砂颗粒的MgO≥94.5％，SiO2≤3.0％，体积密度≥3.35g/cm3，所述电熔镁砂颗粒的粒径分布与实施例1所述再生镁碳砖颗粒的粒径分布相同。
对各实施例及对比例所得干式振动料的性能进行检测，结果如表1所示。
表1：干式振动料的性能检测结果
Figure BDA0002407729620000061
Figure BDA0002407729620000071
从表1的检测结果可以看出，再生镁碳砖颗粒加入量为30～70kg时，生产的干式振动料各项性能指标均能满足现场使用。加入再生镁碳砖颗粒的实施例1～3在1500℃下保温3h后的线性变化率和常温耐压强度明显低于对比例，这说明加入再生镁碳砖颗粒的干式振动料使用过程中的烧结程度低，易于翻包解体。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (9)

1.一种再生镁碳质中间包干式振动料，其特征在于，由包含以下重量份的成分制成：
Figure FDA0002407729610000011
2.根据权利要求1所述的干式振动料，其特征在于，所述再生镁碳砖颗粒中，粒径3～5mm的组分、粒径1～3mm的组分与粒径≤1mm的组分的重量比为15～20：25～30：20～30。
3.根据权利要求1或2所述的干式振动料，其特征在于，所述电熔镁砂细粉或重烧镁砂细粉的粒径≤0.1mm。
4.根据权利要求3所述的干式振动料，其特征在于，所述结合剂为酚醛树脂和/或葡萄糖。
5.根据权利要求3所述的干式振动料，其特征在于，所述抗氧化剂为金属硅粉、金属铝粉和碳化硅的一种或几种。
6.根据权利要求3所述的干式振动料，其特征在于，所述促烧剂为红粘土、水玻璃和钛白粉的一种或几种。
7.权利要求1～6任意一项所述再生镁碳质中间包干式振动料的制备方法，其特征在于，包括如下步骤：
将各原料混合后进行振动成型、烘烤，得到再生镁碳质中间包干式振动料。
8.根据权利要求7所述的制备方法，其特征在于，所述振动成型的时间为8～10min。
9.根据权利要求7或8所述的制备方法，其特征在于，所述烘烤的温度为250～400℃，烘烤的时间为1.5～2h。
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