CN113416067A - 一种铁水包用防氧化抗冲击浇注料、制备方法及铁水包 - Google Patents

一种铁水包用防氧化抗冲击浇注料、制备方法及铁水包 Download PDF

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CN113416067A
CN113416067A CN202110658645.4A CN202110658645A CN113416067A CN 113416067 A CN113416067 A CN 113416067A CN 202110658645 A CN202110658645 A CN 202110658645A CN 113416067 A CN113416067 A CN 113416067A
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ladle
mullite
impact
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oxidation
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CN113416067B (zh
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周旺枝
徐国涛
赵元
张洪雷
刘黎
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Wuhan Iron and Steel Co Ltd
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Abstract

本发明公开了一种铁水包用防氧化抗冲击浇注料，由如下质量百分比的物质组成：烧结莫来石骨料：50～65%，红柱石：3～8%，碳化硅：3～14%，电熔莫来石细粉：10%～30%，锆莫来石细粉：0.01%～5%，氧化铝微粉：0.1～3%，铝粉：0.05～0.1%，纯铝酸钙水泥结合剂：3～6%，NaHCO3：0.01～0.1%，硼酸：0.02～0.12%，水玻璃：0.01～0.3%；减水剂FDN：0.03～0.13%。本发明还公开了铁水包用防氧化抗冲击浇注料的制备方法，以及铁水包。本发明增强了包底及包壁下侧工作层的强度、抗钢水及废钢块的冲击性和抗氧化性，有针对性地解决了包底及包壁下侧的损蚀难题。

Description

一种铁水包用防氧化抗冲击浇注料、制备方法及铁水包
技术领域
本发明涉及一种铁水包用浇注料，具体涉及一种铁水包用防氧化抗冲击浇注料，本发明还涉及浇注料的制备方法以及铁水包，属于炼钢用耐火材料领域。
背景技术
铁水包是承担铁水运输的重要载体，其运行的安全、稳定直接影响炼钢生产的顺行，也影响工序的能耗与成本。铁水包在使用过程中，包衬要经受1300-1400℃左右高温铁水的冲刷、浸泡、热冲击、机械磨损以及渣、铁的侵蚀，有些钢厂还要在铁水包进行脱硫作业。随着钢厂降低铁钢比的需要，国内不少钢厂在铁水包中加入废钢，提高了钢铁生产流程中的废钢比，但也加剧了对包衬的冲击和侵蚀，如某钢厂150t铁水包加废钢前考核炉龄800次，加废钢后降低到600次。
作为铁水包用耐火材料，其关键要具备抗热震冲击性、抗脱硫剂和渣侵蚀性和清理包底结渣的机械应力冲击性。目前，很多钢厂的铁水包采用铝碳化硅碳砖工作层，轻质粘土砖作为永久层的砌筑模式。铁水包工作层直接与高温铁水和废钢接触，其中的石墨等碳素材料被氧化铁氧化变疏松而强度变差，先受到侵蚀，抗冲刷能力急剧下降，同时含有碳的情况下，导热系数较高，导致铁水温降增加。向铁水包内投加废钢，铁水包加入废钢后温度降低，废钢不融化或凝固成坨，加大了铁水包底及下侧包衬的热冲击和机械应力冲击，造成铁水包包底及包衬损蚀，严重影响了铁水包的使用寿命。
公开号为CN108101556A的中国发明专利公开了用于铁水包的碳质不定形耐火材料，碳质不定形耐火材料的组成包括：耐火骨料、粉料、结合剂，耐火骨料为硅石，粉料包括石英砂、粉煤灰和冶金焦粉，结合剂包括煤质沥青，其中以质量份计各组分配比为，硅石：石英砂：粉煤灰：冶金焦粉：煤质沥青＝40～60份：5～10份：10～20份：10～20份：5份，该发明的碳质耐火材料和铝酸盐质耐火材料的优点，既可以耐受高温，采用硅石、粉煤灰配料生产的耐火材料成本较低。但是碳质材料直接与高温铁水和废钢接触容易氧化，造成材质疏松而损蚀，导致铁水包寿命下降。公开号为CN107344860A的中国发明专利公开了用于铁水罐的浇注材料，所述浇注材料按重量份计算配比如下：氧化铝：50～70份，二氧化硅：10～40份，莫来石：10～20份，耐热钢纤维：3～6份，加水量：5～7份。浇注方法包括：清洁铁水罐内部及模具，并在模具与浇注料接触面上涂润滑脂；在铁水罐内砌筑一层35mm厚度高铝砖做为永久层，安装调整内膜工；将浇注料各组分依次经干混和湿混；将湿混后的浇注料注入模具，浇注时用振动棒进行振动；浇注料成型后，自然养护24h，脱模处理；拆模后在空气中自然养护48h后进行烘烤处理。该铁水罐用浇注料虽然强度高，抗热震性好，但是耐渣和脱硫剂侵蚀性不够。
在冶金行业大废钢比的趋势下，开发出一种新型抗热震冲击保温铁水包迫在眉睫。为提高铁水包包衬寿命，必须根据铁水包目前使用工艺中存在的问题，针对性的改进结构和材质，开发新型的抗冲击抗侵蚀保温性好的铁水包。
发明内容
本发明所要解决的技术问题是针对上述现有技术存在的不足而提供一种铁水包用防氧化抗冲击浇注料，克服了现有铁水包在投加废钢的使用过程中，铁水包下侧工作层耐火材料易氧化，抗热震冲击能力差，保温性差等局限性，满足了大废钢比下铁水包加废钢的工艺要求。
本发明具体是这样实现的：
一种铁水包用防氧化抗冲击浇注料，由如下质量百分比的物质组成：烧结莫来石骨料：50～65％，红柱石：3～8％，碳化硅：3～10％，电熔莫来石细粉：10％～30％，锆莫来石细粉：0.01％～5％，氧化铝微粉：0.1～3％，铝粉：0.05～0.1％，纯铝酸钙水泥结合剂：3～6％，NaHCO3：0.01～0.1％，硼酸：0.02～0.12％，水玻璃：0.01～0.3％；减水剂FDN：0.03～0.13％。
采用莫来石是因为莫来石具有含量高，体积密度大，热震稳定性好，高温蠕变小和抗化学腐蚀性好等优点，适合铁水包加强层浇注料的使用环境。骨料使用烧结莫来石，而基质采用电熔莫来石细粉，相互配合使用，有利于保证浇注料的性能，又能节约成本。
锆莫来石是在莫来石中引入ZrO2，能进一步提高莫来石的抗化学侵蚀、抗热震并降低膨胀系数。
加入碳化硅和氧化铝微粉，可以部分替代结合剂铝酸钙水泥，形成低水泥结合，提高浇注料的中高温强度。同时加入碳化硅，可以有效提高浇注料的耐磨性，能更有效地提高铁水包内衬的抗冲刷性。但是碳化硅加入过多，会影响浇注料的中低温强度。
加入氧化铝微粉一方面可以起到基质的作用，可以填充大中小颗粒之间的气孔，以提高浇注料坯体的体积密度和降低气孔率。由于排挤出空气，可以达到降低加水量的目的。由于微粉具有较大的比表面积与反应活性，可以在较低的温度下烧结。
红柱石在高温下生成莫来石过程中的体积膨胀，能有效抵消高温下的烧结收缩，保证加强层浇注料的体积稳定，红柱石未完全莫来石化，形成多项复合材料结构，利于各矿物膨胀系数的失配而提高热震稳定性。红柱石高温莫来石化后，基质形成针织状莫来石相互交织的网络显微结构，能提高制品的荷重软化温度和抗蠕变性能。
加入金属铝粉，在试样的烧成过程中，金属铝粉熔融对骨料颗粒的填充，铝的氧化产生的体积膨胀效应，均使材料变得更加致密，金属铝在高温下熔融后结聚，形成的局部连续金属相填充于材料的颗粒之间，对吸收应力及阻止应力扩展起到积极作用。
NaHCO3、硼酸作为缓凝剂可以延迟浇注料硬化时间，有助于现场施工时间的保证。
水玻璃能有效提高浇注料的和易性、可塑性，可提高该浇注料的密实度、强度。减水剂FDN具有明显的减水分散效果，减水率为15％～30％，能有效减少加水量，提高加强层浇注料的强度。
更进一步的方案是：
锆莫来石细粉中ZrO2的质量百分含量为：5～25％；
更进一步的方案是：
所述莫来石骨料粒径为：1～5mm；
更进一步的方案是：
所述红柱石的粒径为：0.1～0.01mm；
更进一步的方案是：
所述碳化硅粒径为小于0.088mm；
更进一步的方案是：
所述铝粉粒径为：小于0.01mm；
更进一步的方案是：
所述锆莫来石细粉及电熔莫来石细粉粒径为：小于0.074mm；
更进一步的方案是：
氧化铝微粉粒径为：3μm～6μm；
本发明还公开了所述铁水包用防氧化抗冲击浇注料的制备方法，具体包括：
将按质量比例称量的红柱石、铝酸钙水泥装入混料机混合5～25min，得到预混料A备用；将按质量比例称量的碳化硅、电熔莫来石、锆莫来石细粉、铝粉和添加剂加入混料机搅拌15～35min，得到预混料B备用；将预混料A和预混料B在搅拌机中干混10～30min，即可得到铁水包用耐火浇注料。
本发明还提供了一种铁水包，其结构分为3层，由外到内分别是：最外层的轻质莫来石浇注料保温永久层，中间的错缝砌筑的莫来石红柱石碳化硅砖工作层，以及最内侧的加强层，加强层由铁水包用防氧化抗冲击浇注料浇注而成。
对于本领域技术人员来说，轻质莫来石浇注料保温永久层，莫来石红柱石碳化硅砖都是本领域常规的材料，此处不再赘述。
更进一步的方案是：
加强层浇注料浇注的高度为包底到铁水包内衬高度的1/4～1/3。
更进一步的方案是：
加强层浇注料浇注的厚度为30～120mm。
与现有技术相比，本发明的有益效果是：
(1)永久层采用轻质莫来石浇注料，提高了铁水包的保温性，减少了铁水包受铁后运输及等待时的温降。
(2)工作层砖采用莫来石碳化硅红柱石砖错缝砌筑，增强了工作层的抗热震抗冲击性和抗氧化性和严密性。
(3)现有技术中，包底及包壁下侧受铁水及废钢冲击力最大，是最易损毁的环节，加砌增强层，增强了包底及包壁下侧工作层的强度、抗钢水及废钢块的冲击性和抗氧化性，有针对性地解决了包底及包壁下侧的损蚀难题。
(4)加强层的浇注包括包底及铁水包内壁高度的1/4～1/3，并不是整个铁水包内壁，这种科学的选择性的浇注，既有利于节约成本，又能提高铁水包的使用寿命。
(5)整个铁水包内衬耐火材料体系中都选用莫来石，膨胀均匀、热震稳定性极好、荷重软化点高、高温蠕变值小、硬度大、抗化学腐蚀性好。
(6)用莫来石碳化硅红柱石砖及铁水包用防氧化抗冲击浇注料取代了现有技术的铝碳化硅碳砖，增强了耐火材料的抗氧化性，提高耐火材料的热稳定性。降低了工作层的导热性，有效地减少了铁水温降。
附图说明
图1为本发明铁水包的结构示意图。
具体实施方式
下面结合附图和具体实施例对本发明作进一步的说明。
实施例1
如附图1所示，本发明提供的铁水包，包括3层，由外到内分别是：最外层的轻质莫来石浇注料保温永久层1，中间的错缝砌筑的莫来石红柱石碳化硅砖工作层2，以及最内侧的加强层3，加强层由铁水包用防氧化抗冲击浇注料浇注而成。本发明的核心在于加强层的浇注料。
对于铁水包用防氧化抗冲击浇注料，通过如下实施例进行说明。
实施例2
采用的铁水包增强层的厚度为60mm，增强层包括包底及工作层高度的1/3。增强层浇注料的组成按质量百分比计为：电熔莫来石骨料：60％，红柱石：9％，碳化硅：10％，锆莫来石细粉：12％，氧化铝微粉：3％，铝粉：0.05～0.1％，纯铝酸钙水泥结合剂：5.75％，NaHCO3：0.05％，硼酸：0.03％，水玻璃：0.1％；减水剂FDN：0.07％。
将按质量比例称量的红柱石、铝酸钙水泥装入混料机混合20min，得到预混料A备用；将按质量比例称量的碳化硅、电熔莫来石、锆莫来石细粉、铝粉和添加剂加入混料机搅拌30min，得到预混料B备用；将预混料A和预混料B在搅拌机中干混23min，即可得到铁水包用耐火浇注料。
该浇注料常温耐压强度为37MPa，体积密度为2.68g/cm3，高温烧后耐压强度为65MPa。增强层浇注、烘烤后，铁水包投入使用，铁水温降减少17℃，包底及包壁下侧未出现损毁及损蚀，使用炉数923炉。
实施例3
采用的铁水包增强层的厚度为80mm，增强层包括包底及工作层高度的7/24。加强层浇注料的组成按质量百分比计为：电熔莫来石骨料：63％，红柱石：8％，碳化硅：11％，锆莫来石细粉：12％，氧化铝微粉：2％，铝粉：0.07％，纯铝酸钙水泥结合剂：3.65％，NaHCO3：0.02％，硼酸：0.05％，水玻璃：0.2％；减水剂FDN：0.01％。
将按质量比例称量的红柱石、铝酸钙水泥装入混料机混合20min，得到预混料A备用；将按质量比例称量的碳化硅、电熔莫来石、锆莫来石细粉、铝粉和添加剂加入混料机搅拌30min，得到预混料B备用；将预混料A和预混料B在搅拌机中干混23min，即可得到铁水包用耐火浇注料。
增强层浇注、烘烤后，该铁水包投入使用，铁水温降减少21℃，包底及包壁下侧未出现损毁及损蚀，使用炉数942炉。
尽管这里参照本发明的解释性实施例对本发明进行了描述，上述实施例仅为本发明较佳的实施方式，本发明的实施方式并不受上述实施例的限制，应该理解，本领域技术人员可以设计出很多其他的修改和实施方式，这些修改和实施方式将落在本申请公开的原则范围和精神之内。

Claims (7)

1.一种铁水包用防氧化抗冲击浇注料，其特征在于由如下质量百分比的物质组成：烧结莫来石骨料：50～65%，红柱石：3～8%，碳化硅：3～14%，电熔莫来石细粉：10%～30%，锆莫来石细粉：0.01%～5%，氧化铝微粉：0.1～3%，铝粉：0.05～0.1%，纯铝酸钙水泥结合剂：3～6%，NaHCO3：0.01～0.1%，硼酸：0.02～0.12%，水玻璃：0.01～0.3%；减水剂FDN：0.03～0.13%。
2.根据权利要求1所述铁水包用防氧化抗冲击浇注料，其特征在于：
锆莫来石细粉中ZrO2的质量百分含量为：5～25%。
3.根据权利要求1所述铁水包用防氧化抗冲击浇注料，其特征在于：
所述莫来石骨料粒径为：1～5mm；
所述红柱石的粒径为：0.1～0.01mm；
所述碳化硅粒径小于0.088mm；
所述铝粉粒径小于0.01mm；
所述锆莫来石细粉及电熔莫来石细粉粒径小于0.074mm；
氧化铝微粉粒径为：3μm～6μm。
4.权利要求1至3任一权利要求所述铁水包用防氧化抗冲击浇注料的制备方法，其特征在于包括：
将按质量比例称量的红柱石、铝酸钙水泥装入混料机混合5～25min，得到预混料A备用；将按质量比例称量的碳化硅、电熔莫来石、锆莫来石细粉、铝粉和添加剂加入混料机搅拌15～35min，得到预混料B备用；将预混料A和预混料B在搅拌机中干混10～30min，即可得到铁水包用耐火浇注料。
5.一种铁水包，结构分为3层，由外到内分别是：最外层的轻质莫来石浇注料保温永久层，中间的错缝砌筑的莫来石红柱石碳化硅砖工作层，以及最内侧的加强层，其特征在于：所述加强层由权利要求1至3任一权利要求所述铁水包用防氧化抗冲击浇注料浇注而成。
6.根据权利要求5所述铁水包，其特征在于：
加强层浇注料浇注的高度为包底到铁水包内衬高度的1/4～1/3。
7.根据权利要求5所述铁水包，其特征在于：
加强层浇注料浇注的厚度为30～120mm。
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