CN114669733B - 一种高寿命铁水罐罐嘴的修砌方法 - Google Patents
一种高寿命铁水罐罐嘴的修砌方法 Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 39
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- 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 claims abstract description 26
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- 239000010703 silicon Substances 0.000 claims abstract description 11
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Abstract
本发明公开了一种高寿命铁水罐罐嘴的修砌方法,属于铁水罐罐嘴技术领域。本发明包括以下步骤:使用浇注料对铁水罐100的罐嘴110进行浇注成型,并在浇注料中内置钢芯加固件,所述浇注料材料按重量份计算配比如下:铝矾土:30~40份,莫来石:30~50份,硅微粉:5~10份,红柱石:10~20份,防爆纤维:2~4份;自然干燥24h~30h后进行烘烤;小火烘烤12h~24h后,然用中火烘烤12h,再用大火烘烤6h。为解决现有技术存在的问题,本发明拟提供一种高寿命铁水罐罐嘴修砌方法,能够显著提高烧嘴抗热震性能,且在使用过程中无渗铁情况发生,大幅度降低铁水罐罐嘴维修次数及工人劳动强度,有效提高了铁水罐的周转率和安全可靠性。
Description
技术领域
本发明涉及铁水罐罐嘴技术领域,更具体地说,涉及一种高寿命铁水罐罐嘴的修砌方法。
背景技术
铁水罐放置于铁水车上,适用于高炉和转炉之间承接及运输铁水的容器。其中铁水罐罐嘴作为铁水罐重要的组成部分决定了其使用性能的优劣。传统铁水罐罐嘴采用耐火砖砌,在使用过程中罐嘴黏渣严重,并且KR脱硫工艺扒渣过程容易将耐火砖松动,铁水容易在耐火砖的间隙处蚀,造成铁水罐嘴整体损坏,对流嘴砖和渣线砖伤害较大。既不利于周转率的提高,也造成了维修成本增大和运行安全性风险。基本上线运行20罐左右就需要下线将罐嘴黏渣清理。
针对罐嘴主要是耐火砖间缝隙浸蚀和扒渣过程会松动耐火砖这个情况,科研工作者及企业采用整体铁水罐罐嘴浇注料方法,首先使用矾土质浇注料,罐嘴寿命得到了显著的提升,随着材料进一步的优化,采用刚玉质浇注料所浇注的罐嘴其使用寿命高达150—200次左右,但是依旧存在不足,由于刚玉质耐火浇注料抗热震性能较差导致出现耐火浇注料出现整体掉块的现象严重影响了生产的安全和稳定性。
经检索,有关铁水脱硫方法的技术已有专利文献公开,如中国专利公开号为:CN101020610A,公开了一种铁水罐浇注料与浇注工艺及专用模具,一种以特级矾土熟料、亚白刚玉、Al2O3组成的浇注料对铁水罐罐底浇注成型。该方法在一定程度上提升了铁水罐浇注料的高温性能。但依旧存在不足,浇注料的热震稳定性较差导致铁水罐服役时间大大缩减。
又如文献《Al2O3-SiC-C质铁水罐整体浇注技术》张禹,魏继刚,鞍钢技术2004年第1期38-40页,介绍一种采用轻质高铝砖砌筑铁水罐永久层,并且对铁水罐进行浇注。该方法在一定程度提升铁水罐的使用寿命。但是依旧存在不足:Al2O3-SiC-C浇注料成本较高且长时间使用后,并且原材料电熔棕刚玉在生产过程中会产生严重的污染。。
发明内容
1.发明要解决的技术问题
为解决现有技术存在的问题,本发明拟提供一种高寿命铁水罐罐嘴修砌方法,能够显著提高烧嘴抗热震性能,且在使用过程中无渗铁情况发生,大幅度降低铁水罐罐嘴维修次数及工人劳动强度,有效提高了铁水罐的周转率和安全可靠性。
2.技术方案
为达到上述目的,本发明提供的技术方案为:
本发明的一种高寿命铁水罐罐嘴的修砌方法,包括以下步骤:
(1)使用浇注料对铁水罐100的罐嘴110进行浇注成型,并在浇注料中内置钢芯加固件,所述浇注料材料按重量份计算配比如下:铝矾土:30~40份,莫来石:30~50份,硅微粉:5~10份,红柱石:10~20份,防爆纤维:2~4份;
(2)自然干燥24h~30h;
(3)烘烤:小火烘烤12h~24h后,然用中火烘烤12h,再用大火烘烤6h。
优选的,浇注料材料的粒度由5mm~8mm、5mm~3mm、3mm~1mm、1mm~0.074mm以及小于0.074mm的5种粒径组成,且粒径5mm~8mm、5mm~3mm、3mm~1mm、1~0.074mm以及小于0.074mm所对应的重量份数依次为20~27份、15~20份、20~23份、15~20份以及10~17份。
优选的,莫来石和铝矾土的粒径由5mm~8mm、5mm~3mm、3mm~1mm和1mm~0.074mm的四种种粒径组成,所述红柱石的粒径由1mm~0.074mm和小于0.074mm的两种粒径组成,所述硅微粉的粒径小于0.074mm。
优选的,防爆纤维的长度为2mm~8mm,直径为0.01mm~0.03mm。
优选的,步骤(3)中先由室温升至130℃烘烤12h~24h,然后由130℃升至320℃烘烤12h,再由320℃升至800℃烘烤6h。
优选的,钢芯加固件为螺纹钢筋。
3.有益效果
采用本发明提供的技术方案,与现有技术相比,具有如下有益效果:
(1)本发明的一种高寿命铁水罐罐嘴的修砌方法,采用莫来石浇注料,较刚玉质以及矾土质浇注料的抗热震性能得到了显著的提升,在长时间的服役过程中不会极难产生开裂等有效抑制渗铁的现象进而显著的提高的铁水罐罐嘴的服役时间,大幅度降低铁水罐罐嘴维修次数及工人劳动强度,有效提高了铁水罐的周转率和安全可靠性。另外,莫来石原料制造工艺简单、价格低廉并且在制备的过程中不会产生环境污染。
(2)本发明的一种高寿命铁水罐罐嘴的修砌方法,莫来石和铝矾土作为骨料和基质材料应用于浇注料中,其主要作用是作为骨料搭建结构和材料的基本强度。硅微粉可有效的填充基体中微小孔隙进而提升基体的致密度,另外高温条件下,硅微粉可与基质中氧化铝反应生产莫来石进而提升材料强度和热震稳定性。红柱石高温条件下分解生成莫来石和石英相降低基体孔隙率的同时提升了浇注料的强度。防爆纤维与其它耐火材料混合均匀,成形后,进行烘烤,随着烘烤温度不断升高,并达到一定温度时这种纤维即开始软化、收缩、熔化,最后形成气孔并碳化,它们在施工体内分布形成微小网络气孔,它能打开水气通道,减轻内部应力,防止爆裂,提高整体使用寿命。
(3)本发明的一种高寿命铁水罐罐嘴的修砌方法,钢芯加固件主要是在浇注料材料基体中起到加固以及改善材料的常温和高温机械强度。将铁水罐的罐嘴上所受荷载分散到受力螺纹钢筋上,提高材料的机械强度,同时也能防止因浇注料的收缩和温度变化等原因产生的裂缝。
(4)本发明的一种高寿命铁水罐罐嘴的修砌方法,先由室温升至130℃烘烤12h~24h,然后由130℃升至320℃烘烤12h,再由320℃升至800℃烘烤6h。采用分段式烘烤工艺有效的抑制裂纹在基体的产生和扩展,烘烤制度对材料的使用性具有显著的影响,能够显著提高烧嘴抗热震性能,且在使用过程中无渗铁情况发生,大幅度降低铁水罐罐嘴维修次数及工人劳动强度,有效提高了铁水罐的周转率和安全可靠性。
附图说明
图1为本发明的一种高寿命铁水罐罐嘴的结构示意图。
图中:
100、铁水罐;110、罐嘴;111、浇注料;112、钢芯加固件。
具体实施方式
为进一步了解本发明的内容,结合附图对本发明作详细描述。
在本发明的描述中,需要说明的是,术语“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系,仅是为了便于描述本发明和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本发明的限制。此外,术语“第一”、“第二”、“第三”仅用于描述目的,而不能理解为指示或暗示相对重要性。
下面结合实施例对本发明作进一步的描述。
实施例1
本实施例的一种高寿命铁水罐罐嘴的修砌方法,包括以下步骤:
(1)使用浇注料111对铁水罐100的罐嘴110进行浇注成型,并在浇注料中内置钢芯加固件112,所述浇注料111材料按重量份计算配比如下:铝矾土:30~40份,莫来石:30~50份,硅微粉:5~10份,红柱石:10~20份,防爆纤维:2~4份,具体地,本实施例中铝矾土:30份,莫来石:35份,硅微粉:10份,红柱石:20份,防爆纤维:2份,首先将上述原料按重要份进行称重,并混合均匀,然后添加1~3份质量的水搅拌均匀后进行浇注成型,所制备的浇注料111的水冷热震次数提升至30次。
本实施例的铁水罐罐嘴的修砌方法采用莫来石浇注料111较刚玉质以及矾土质浇注料111的抗热震性能得到了显著的提升,在长时间的服役过程中不会极难产生开裂等有效抑制渗铁的现象进而显著的提高的铁水罐罐嘴的服役时间,大幅度降低铁水罐罐嘴维修次数及工人劳动强度,有效提高了铁水罐的周转率和安全可靠性。另外,莫来石原料制造工艺简单、价格低廉并且在制备的过程中不会产生环境污染。莫来石和铝矾土作为骨料和基质材料应用于浇注料111中,其主要作用是作为骨料搭建结构和材料的基本强度。硅微粉可有效的填充基体中微小孔隙进而提升基体的致密度,另外高温条件下,硅微粉可与基质中氧化铝反应生产莫来石进而提升材料强度和热震稳定性。红柱石高温条件下分解生成莫来石和石英相降低基体孔隙率的同时提升了浇注料的强度。防爆纤维与其它耐火材料混合均匀,成形后,进行烘烤,随着烘烤温度不断升高,并达到一定温度时这种纤维即开始软化、收缩、熔化,最后形成气孔并碳化,它们在施工体内分布形成微小网络气孔,它能打开水气通道,减轻内部应力,防止爆裂,提高整体使用寿命。
目前大部分的采用刚玉质材料制备铁水罐罐嘴,但在存在莫来石材质。本实施例的铁水罐罐嘴的修砌方法在莫来石浇注料111的基础上进行改进提高了材料的机械强度、热震稳定性进而改善了其使用性能。本实施例所采用的配比是通过优化高温条件下,莫来石以及熔融液相在基体中的生成量,提高材料的常温、高温机械强度以及降低式样孔隙率进而改善材料的抗侵蚀作用。本实施例浇注料111中的硅微粉通过自身作用首先提高浆料的在浇注过程中的流动性,其次在高温条件下生成熔融液相填充基体内部气孔;红柱石高温条件下分解生成莫来石和熔融石英相,且熔融石英相也可通过自身流动作用填充基体内部孔隙,莫来石的生成提高了材料的常温、高温的机械强度和热震稳定性。
本实施例中钢芯加固件112为螺纹钢筋,且沿铁水罐100高度方向均匀分布有多个钢芯加固件112。钢芯加固件112主要是在浇注料111材料基体中起到加固以及改善材料的常温和高温机械强度。将铁水罐100的罐嘴110上所受荷载分散到受力螺纹钢筋上,提高材料的机械强度,同时也能防止因浇注料111的收缩和温度变化等原因产生的裂缝。其作用机制主要包括:
①螺纹钢筋与浇注料111接触面上化学吸附作用力,也称胶结力。
②浇注料111收缩,将螺纹钢筋紧紧握固而产生摩擦力。
③螺纹钢筋表面凹凸不平与浇注料之间产生的机械咬合作用,也称咬合力。
本发明在莫来石浇注料111中内置钢芯加固件112,能够显著提高浇注料111的整体的强度和断裂韧性,同时由于螺纹钢筋的膨胀系数大于浇注料111的膨胀系数所产生的残余应力,能够有效抑制浇注料111内部裂纹的扩散,进一步提高浇注料111材料整体的强度和韧性。
本实施例中浇注料111材料的粒度由5mm~8mm、5mm~3mm、3mm~1mm、1mm~0.074mm以及小于0.074mm的5种粒径组成,且粒径5mm~8mm、5mm~3mm、3mm~1mm、1~0.074mm以及小于0.074mm所对应的重量份数依次为20~27份、15~20份、20~23份、15~20份以及10~17份。具体地,本实施例中粒径5mm~8mm、5mm~3mm、3mm~1mm、1~0.074mm以及小于0.074mm所对应的重量份数依次为27份、18份、23份、15份以及17份。
本实施例中莫来石和铝矾土的粒径由5mm~8mm、5mm~3mm、3mm~1mm和1mm~0.074mm的四种种粒径组成,所述红柱石的粒径由1mm~0.074mm和小于0.074mm的两种粒径组成,所述硅微粉的粒径小于0.074mm。所述防爆纤维的长度为2mm~8mm,直径为0.01mm~0.03mm。具体地,本实施例中防爆纤维的长度为2mm,直径为0.02mm。
(2)自然干燥24h~30h;
(3)烘烤:小火烘烤12h~24h后,然用中火烘烤12h,再用大火烘烤6h,具体地,本实施例中,先由室温升至130℃烘烤12h~24h,然后由130℃升至320℃烘烤12h,再由320℃升至800℃烘烤6h。采用分段式烘烤工艺有效的抑制裂纹在基体的产生和扩展,烘烤制度对材料的使用性具有显著的影响,能够显著提高烧嘴抗热震性能,且在使用过程中无渗铁情况发生,大幅度降低铁水罐罐嘴维修次数及工人劳动强度,有效提高了铁水罐的周转率和安全可靠性。
实施例2
本实施例的一种高寿命铁水罐罐嘴的修砌方法,基本步骤同实施例1中所述,其不同之处在于,本实施例本实施例中铝矾土:40份,莫来石:30份,硅微粉:5份,红柱石:18份,防爆纤维:3份,首先将上述原料按重要份进行称重,并混合均匀,然后添加1~3份质量的水搅拌均匀后进行浇注成型,所制备的浇注料111的水冷热震次数提升至38次。
本实施例中粒径5mm~8mm、5mm~3mm、3mm~1mm、1~0.074mm以及小于0.074mm所对应的重量份数依次为25份、20份、21份、16份以及13份。
本实施例中防爆纤维的长度为6mm,直径为0.01mm。
实施例3
本实施例的一种高寿命铁水罐罐嘴的修砌方法,基本步骤同实施例1中所述,其不同之处在于,本实施例本实施例中铝矾土:30份,莫来石:35份,硅微粉:10份,红柱石:20份,防爆纤维:2份,首先将上述原料按重要份进行称重,并混合均匀,然后添加1~3份质量的水搅拌均匀后进行浇注成型,所制备的浇注料111的水冷热震次数提升至35次。
本实施例中粒径5mm~8mm、5mm~3mm、3mm~1mm、1~0.074mm以及小于0.074mm所对应的重量份数依次为20份、15份、20份、20份以及10份。
本实施例中防爆纤维的长度为8mm,直径为0.03mm。
以上示意性的对本发明及其实施方式进行了描述,该描述没有限制性,附图中所示的也只是本发明的实施方式之一,实际的结构并不局限于此。所以,如果本领域的普通技术人员受其启示,在不脱离本发明创造宗旨的情况下,不经创造性的设计出与该技术方案相似的结构方式及实施例,均应属于本发明的保护范围。
Claims (3)
1.一种高寿命铁水罐罐嘴的修砌方法,其特征在于:包括以下步骤:
(1)使用浇注料(111)对铁水罐(100)的罐嘴(110)进行浇注成型,并在浇注料(111)中内置钢芯加固件(112),所述浇注料(111)材料按重量份计算配比如下:铝矾土:30~40份,莫来石:30~50份,硅微粉:5~10份,红柱石:10~20份,防爆纤维:2~4份;
(2)自然干燥24h~30h;
(3)烘烤:先由室温升至130℃烘烤12h~24h,然后由130℃升至320℃烘烤12h,再由320℃升至800℃烘烤6h;
所述防爆纤维的长度为2mm~8mm,直径为0.01mm~0.03mm;
所述内置钢芯加固件(112)为螺纹钢筋。
2.根据权利要求1所述的一种高寿命铁水罐罐嘴的修砌方法,其特征在于:所述浇注料(111)材料的粒度由5mm~8mm、5mm~3mm、3mm~1mm、1mm~0.074mm以及小于0.074mm的5种粒径组成,且粒径5mm~8mm、5mm~3mm、3mm~1mm、1~0.074mm以及小于0.074mm所对应的重量份数依次为20~27份、15~20份、20~23份、15~20份以及10~17份。
3.根据权利要求2所述的一种高寿命铁水罐罐嘴的修砌方法,其特征在于:所述莫来石和铝矾土的粒径由5mm~8mm、5mm~3mm、3mm~1mm和1mm~0.074mm的四种种粒径组成,所述红柱石的粒径由1mm~0.074mm和小于0.074mm的两种粒径组成,所述硅微粉的粒径小于0.074mm。
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