CN116283314A - 高炉出铁沟摆动流槽用浇注料及其制备方法 - Google Patents
高炉出铁沟摆动流槽用浇注料及其制备方法 Download PDFInfo
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Abstract
本发明提供一种高炉出铁沟摆动流槽用浇注料及其制备方法,其中的浇注料按重量份计组成包括:高铝材料45~68份、碳化硅10~18份、红柱石5~15份、纯铝酸钙水泥2‑4份、分散剂0.1~0.3份,以及复合添加剂10~20份。利用本发明,能够解决现有的常用摆动溜槽衬体抗冲击蚀损性能低、使用寿命短于主沟、修补更换频繁等问题。
Description
技术领域
本发明涉及钢铁冶金用不定形耐火材料技术领域,更为具体地,涉及一种高炉摆动流槽用浇注料及其制备方法。
背景技术
在目前大中型高炉出铁沟***中,摆动溜槽几乎是必不可少的铁水流转机构。由于摆动溜槽衬体的服役环境苛刻复杂多变,大多数情况下摆动流槽要短于主沟的使用寿命,损坏后进行热修补和更换的情况较为普遍,施工强度加大,不利于高炉出铁顺行。
在摆动流槽耐火材料使用环境中,间隙式出铁方式使得摆动流槽耐火衬体,始终存在着重力冲刷、剪切磨损、高温氧化、温度急剧变化等复杂因素的循环作用,因而此部位材料需要具有优良的冲击韧性、耐磨性、抗氧化性和抗热震性等。其整体所采用的材质应该是更适用于摆动流槽的专用耐火材料,因此,亟需提供一种新的摆动流槽用材料。
发明内容
鉴于上述问题,本发明的目的是提供一种高炉出铁沟摆动流槽用浇注料及其制备方法,以解决现有的常用摆动溜槽衬体抗冲击蚀损性能低、使用寿命短于主沟、修补更换频繁等问题。
本发明提供的高炉出铁沟摆动流槽用浇注料,按重量份计组成包括:高铝材料45~68份、碳化硅10~18份、红柱石5~15份、纯铝酸钙水泥2-4份、分散剂0.1~0.3份,以及复合添加剂10~20份。
此外,优选的方案是,所述高铝材料包括刚玉材料的一种、几种或刚玉材料与特级矾土熟料的复合;其中,
所述刚玉材料的骨料粒度为10~5mm、5~3mm、3~1mm或1~0.088mm;
所述刚玉材料的细粉粒度≤0.074mm,Al2O3的含量>94.5%;
所述特级矾土熟料的粒度为10~5mm,Al2O3的含量>88%。
此外,优选的方案是,所述碳化硅的粒度为8~5mm、5~3mm或3~1mm,SiC的含量>97.5%。
此外,优选的方案是,所述红柱石的粒度为5~3mm、3~1mm或1~0.088mm,矿相Al2O3·SiO2的含量>90%。
此外,优选的方案是,所述纯铝酸钙水泥为CA80水泥,其中,Al2O3的含量>78%。
此外,优选的方案是,所述分散剂包括聚磷酸盐类化合物、聚乙二醇基聚合物FS20中一种或者两种。
此外,优选的方案是,所述复合添加剂,按重量份计组成包括:氧化铝微粉5~10份、硅灰1~3份、纳米炭黑粉0.2~1份、含碳树脂粉0.5~1.5份、Si-SiC复合粉2~5份、氧化镁粉0.2~1份、高温无机纤维0.05~0.1份,其中,
所述氧化铝微粉的粒度<1μm,Al2O3的含量>99.9%;
所述硅灰的粒度<0.15μm,SiO2的含量为>95%;
所述纳米碳黑粉的粒度<30nm,纳米碳的含量>98%,挥发份<1.5%,灰分<0.5%;
所述含碳树脂粉的粒度<0.088mm,碳的含量>80%;
所述Si-SiC复合粉的粒度<20μm,SiC的含量为>60%;
所述氧化镁微粉的粒度<0.088mm,MgO的含量>90%;
所述高温无机纤维包括玄武岩纤维、短切碳纤维、莫来石纤维的一种或两种,长径比为75:1。
本发明还提供一种制备高炉出铁沟摆动流槽用浇注料的方法,包括:
将复合添加剂的各个组份按照预设比例进行混合形成复合添加剂粉料;
将所述复合添加剂粉料与分散剂、纯铝酸钙水泥、高铝材料、碳化硅、红柱石按照预设比例进行混合搅拌,形成混合散料;
将所述混合散料进行筛分、浆料进行处理,制备成高炉出铁沟摆动流槽用浇注料。
此外,优选的方案是,在制备成高炉出铁沟摆动流槽用浇注料之后,还包括:将制备的高炉出铁沟摆动流槽用浇注料进行易性检验;
检验合格后袋装备用。
此外,优选的方案是,采用强制搅拌机对所述复合添加剂粉料与分散剂、纯铝酸钙水泥、高铝材料、碳化硅、红柱石按照比例混合搅拌。
从上面的技术方案可知,本发明提供的高炉出铁沟摆动流槽用浇注料及其制备方法,与传统的摆动溜槽耐火材料相比,本发明的高炉摆动溜槽用浇注料流动性更好,可施工性更强,易于形成致密性良好的构筑体;沟槽衬体热态强度高、抗冲刷性好、抗冲击韧性和抗疲劳损伤强、抗氧化和抗热震性能优良,减轻铁水对摆动流槽衬体的冲击破坏、剪切磨损以及热冲击蚀损、氧化介质化学破坏作用;能够大幅度摆动流槽延长材料的使用寿命,利于高炉铁水生产的安全顺行。
为了实现上述以及相关目的,本发明的一个或多个方面包括后面将详细说明的特征。下面的说明以及附图详细说明了本发明的某些示例性方面。然而,这些方面指示的仅仅是可使用本发明的原理的各种方式中的一些方式。此外,本发明旨在包括所有这些方面以及它们的等同物。
附图说明
通过参考以下结合附图的说明的内容,并且随着对本发明的更全面理解,本发明的其它目的及结果将更加明白及易于理解。在附图中:
图1为根据本发明实施例的制备高炉出铁沟摆动流槽用浇注料的方法流程示意图。
在所有附图中相同的标号指示相似或相应的特征或功能。
具体实施方式
在下面的描述中,出于说明的目的,为了提供对一个或多个实施例的全面理解,阐述了许多具体细节。然而,很明显,也可以在没有这些具体细节的情况下实现这些实施例。在其它例子中,为了便于描述一个或多个实施例,公知的结构和设备以方框图的形式示出。
针对前述提出的现有的常用摆动溜槽衬体抗冲击蚀损性能低、使用寿命短于主沟、修补更换频繁等问题,本发明提供了一种高炉出铁沟摆动流槽用浇注料及其制备方法。
本发明提供的高炉出铁沟摆动流槽用浇注料,按重量份计组成包括:高铝材料45~68份、碳化硅10~18份、红柱石5~15份、纯铝酸钙水泥2-4份、分散剂0.1~0.3份,以及复合添加剂10~20份。
在本发明的实施例中,所述高铝材料包括刚玉材料的一种、几种或刚玉材料与特级矾土熟料的复合;其中,刚玉材料的骨料粒度为10~5mm、5~3mm、3~1mm或1~0.088mm;刚玉材料的细粉粒度≤0.074mm,Al2O3的含量>94.5%;特级矾土熟料的粒度为10~5mm,Al2O3的含量>88%。
其中,所述碳化硅的粒度为8~5mm、5~3mm或3~1mm,SiC的含量>97.5%。所述红柱石的粒度为5~3mm、3~1mm或1~0.088mm,矿相Al2O3·SiO2的含量>90%。所述纯铝酸钙水泥为CA80水泥,其中,Al2O3的含量>78%。所述分散剂包括聚磷酸盐类化合物、聚乙二醇基聚合物FS20中一种或者两种。
在本发明的实施例中,所述复合添加剂,按重量份计组成包括:氧化铝微粉5~10份、硅灰1~3份、纳米炭黑粉0.2~1份、含碳树脂粉0.5~1.5份、Si-SiC复合粉2~5份、氧化镁粉0.2~1份、高温无机纤维0.05~0.1份,其中,所述氧化铝微粉的粒度<1μm,Al2O3的含量>99.9%;所述硅灰的粒度为<0.15μm,SiO2的含量为>95%;所述纳米碳黑粉的粒度<30nm,纳米碳的含量>98%,挥发份<1.5%,灰分<0.5%;所述含碳树脂粉的粒度<0.088mm,碳的含量>80%;所述Si-SiC复合粉的粒度为<20μm,SiC的含量为>60%;所述氧化镁微粉的粒度为<0.088mm,MgO的含量>90%;所述高温无机纤维包括玄武岩纤维、短切碳纤维、莫来石纤维的一种或两种,长径比为75:1。
在本发明的实施例中,采用的大尺寸特级矾土熟料、以及刚玉、红柱石骨料,提高浇注料的抗冲刷磨损性能、化学侵蚀性能、材料间结合强度和抗热震损伤性能。这几种骨料中原有的刚玉相、莫来石相、红柱石相以及原位反应产生的新莫来石相,存在着热膨胀系数的差异,从而提高浇注料的抗热震损伤能力,减少衬体热裂纹扩展和热剥落的发生。
本发明的浇注料引入的氧化铝微粉、硅灰、红柱石等基质粉料原位反应烧结、二次莫来石化等过程生成新相莫来石;引入的氧化镁微粉,和氧化铝微粉在高温条件下反应生成新相镁铝尖晶石。热膨胀系数低的莫来石、尖晶石矿相的产生过程伴随着体积膨胀,不但强化基质-颗粒间及基质间结合强度,而且也增强材料致密性、提高材料的抗热冲击韧性、抗铁水冲刷能力和衬体整体结构稳定性。
本发明的浇注料中的含碳树脂粉是非均质石墨化结构,韧性很好,加热时树脂粉软化并转移到气孔中,与高度分散性的纳米炭黑粉共同作用,在材料中形成牢固结合的柔韧性碳网络结构,能够改善材料在受到热冲击时的应力结构,利于吸收产生的冲击力和提高碳化后强度、抗剥落性。
本发明中的C源材料与Si-SiC复合粉中的单质Si粉反应生成β-SiC微纤维,由于其桥接和钉扎效应,利于阻止微裂纹扩展;加上引入的高温无机纤维,提高了此底部、侧壁及流嘴部位的抗冲击断裂韧性,能够有效抵御高温铁水对这些区域的剪切磨蚀、裂纹扩展和结构剥落损伤等。
本发明的浇注料引入的抗氧化剂Si-SiC复合粉为超微粉,粒度小、活性高,在衬体表面受氧化作用利于形成密封性釉薄层,超微粉之间原位反应生成的新相填充了大量细小气孔缝隙;这些反应有效阻隔氧化性介质的侵渗,提高材料整体抗氧化能力。
本发明采用的分散剂包含聚磷酸盐类化合物、聚乙二醇基聚合物FS20,具备有效解絮凝、高效减水的效果,并与多峰粒度分布的超微粉料协同作用,降低总的加水量,施工性能优良,改善浇注料的施工和易性和施工效率,材料的组织性能和使用效果都得到了改善。
与传统的摆动溜槽耐火材料相比,本发明所述的高炉摆动溜槽用浇注料流动性更好,可施工性更强,出铁过程中摆动溜槽衬体抗冲刷性能好、抗冲击韧性和抗疲劳损伤强、抗氧化和抗热震性能优良,其使用寿命得到大幅度延长,施工强度和维修更换次数都得到了改善。
本发明还提供一种制备高炉出铁沟摆动流槽用浇注料的方法,图1示出了根据本发明实施例的制备高炉出铁沟摆动流槽用浇注料的方法流程,如图1所示,制备高炉出铁沟摆动流槽用浇注料的方法包括:
S110:将复合添加剂的各个组份按照预设比例进行混合形成复合添加剂粉料;
S120:将所述复合添加剂粉料与分散剂、纯铝酸钙水泥、高铝材料、碳化硅、红柱石按照预设比例进行混合搅拌,形成混合散料;
S130:将所述混合散料进行筛分、浆料进行处理,制备成高炉出铁沟摆动流槽用浇注料。
此外,在制备成高炉出铁沟摆动流槽用浇注料之后,还包括:将制备的高炉出铁沟摆动流槽用浇注料进行易性检验;检验合格后袋装备用。
在本发明的实施例中,采用强制搅拌机对所述复合添加剂粉料与分散剂、纯铝酸钙水泥、高铝材料、碳化硅、红柱石按照比例混合搅拌。现场施工时,加适量洁净水进行强制搅拌,形成和易性良好的均匀湿混料后投放浇注使用。
下面结合实施例来说明本发明的具体实施方式,但以下实施例只是用来详细说明本发明,并不以这些具体实施例来限制本发明的范围。
实施例一
按照重量份计,复合添加剂组成如下:氧化铝微粉5份,硅灰1份,纳米碳黑粉0.4份,含碳树脂粉1.2份,Si-SiC复合粉2.14份,氧化镁粉0.2份,玄武岩纤维0.06份。
高炉出铁沟摆动流槽用浇注料的配比,按重量份计,组成如下:特级矾土29分,棕刚玉12份,致密刚玉10份,碳化硅10份,红柱石15份,白刚玉细粉10份,纯铝酸钙CA80水泥3.9份,分散剂0.1份,以及复合添加剂10份。
高炉出铁沟摆动流槽用浇注料的制备方法,包括以下步骤:先将配比确定的细粉料进行称量、混均,得到复合添加剂;然后与其它粉剂进行预混和,再加入骨料,利用强制搅拌机混合5~8分钟后,进行检验,合格后装袋,构成散料产品,运输到现场加水搅拌浇注使用。
实施例二
按照重量份计,复合添加剂组成如下:氧化铝微粉5.5份,硅灰1.4份,纳米碳黑粉0.6份,含碳树脂粉0.7份,Si-SiC复合粉2.83份,氧化镁粉0.4份,玄武岩纤维0.04份、莫来石纤维0.03份。
高炉出铁沟摆动流槽用浇注料的配比,按重量份计,组成如下:棕刚玉骨料28份,特级矾土23份,碳化硅15份,红柱石13份,白刚玉细粉5.65份,纯铝酸钙CA80水泥3.7份,分散剂0.15份,以及复合添加剂11.5份。
高炉出铁沟摆动流槽用浇注料的制备方法,包括以下步骤:先将配比确定的细粉料进行称量、混均,得到复合添加剂;然后与其它粉剂进行预混和,再加入骨料,利用强制搅拌机混合5~8分钟后,进行检验,合格后装袋,构成散料产品,运输到现场加水搅拌浇注使用。
实施例三
按照重量份计,复合添加剂组成如下:氧化铝微粉6.5份,硅灰2份,纳米碳黑粉0.8份,含碳树脂粉0.9份,Si-SiC复合粉2.42份,氧化镁粉0.3份,短切碳纤维0.04份,莫来石纤维0.04份。
高炉出铁沟摆动流槽用浇注料的配比,按重量份计,组成如下:棕刚玉骨料35,特级矾土17份,碳化硅10份,红柱石15份,白刚玉细粉7.5份,纯铝酸钙CA80水泥2.35份,分散剂0.15份,以及复合添加剂13份。
高炉出铁沟摆动流槽用浇注料的制备方法,包括以下步骤:先将配比确定的细粉料进行称量、混均,得到复合添加剂;然后与其它粉剂进行预混和,再加入骨料,利用强制搅拌机混合5~8分钟后,进行检验,合格后装袋,构成散料产品,运输到现场加水搅拌浇注使用。
实施例四
按照重量份计,复合添加剂组成如下:氧化铝微粉7.5份,硅灰1.8份,纳米碳黑粉0.7份,含碳树脂粉1份,Si-SiC复合粉3.35份,氧化镁粉0.6份,短切碳纤维0.05份。
高炉出铁沟摆动流槽用浇注料的配比,按重量份计,组成如下:致密刚玉骨料10份,棕刚玉骨料38,碳化硅12份,红柱石14份,白刚玉细粉8份,纯铝酸钙CA80水泥2.8份,分散剂0.2份,以及复合添加剂15份。
高炉出铁沟摆动流槽用浇注料的制备方法,包括以下步骤:先将配比确定的细粉料进行称量、混均,得到复合添加剂;然后与其它粉剂进行预混和,再加入骨料,利用强制搅拌机混合5~8分钟后,进行检验,合格后装袋,构成散料产品,运输到现场加水搅拌浇注使用。
实施例五
按照重量份计,复合添加剂组成如下:氧化铝微粉8.5份,硅灰2.2份,纳米碳黑粉0.9份,含碳树脂粉1.3份,Si-SiC复合粉3.71份,氧化镁粉0.8份,玄武岩纤维0.06份、莫来石纤维0.03份。
高炉出铁沟摆动流槽用浇注料的配比,按重量份计,组成如下:棕刚玉25份,致密刚玉20份,碳化硅15份,红柱石11份,白刚玉细粉8.25份,纯铝酸钙CA80水泥3份,分散剂0.25份,以及复合添加剂17.5份。
高炉出铁沟摆动流槽用浇注料的制备方法,包括以下步骤:先将配比确定的细粉料进行称量、混均,得到复合添加剂;然后与其它粉剂进行预混和,再加入骨料,利用强制搅拌机混合5~8分钟后,进行检验,合格后装袋,构成散料产品,运输到现场加水搅拌浇注使用。
实施例六
按照重量份计,复合添加剂组成如下:氧化铝微粉9.5份,硅灰2.6份,纳米碳黑粉1份,含碳树脂粉1.4份,Si-SiC复合粉4.5份,氧化镁粉0.9份,玄武岩纤维0.05份、莫来石纤维0.05份。
高炉出铁沟摆动流槽用浇注料的配比,按重量份计,组成如下:棕刚玉21份,致密刚玉26份,碳化硅13份,红柱石8份,白刚玉细粉8.7份,纯铝酸钙CA80水泥3份,分散剂0.3份,以及复合添加剂20份。
高炉出铁沟摆动流槽用浇注料的制备方法,包括以下步骤:先将配比确定的细粉料进行称量、混均,得到复合添加剂;然后与其它粉剂进行预混和,再加入骨料,利用强制搅拌机混合5~8分钟后,进行检验,合格后装袋,构成散料产品,运输到现场加水搅拌浇注使用。
以普通的高炉出铁沟的摆动溜槽浇注料的性能指标为基本例,本发明的浇注料实施例1-6测试性能指标、使用效果与之进行了对比,其结果表1所示。
由表中可以看到,本发明的高炉出铁沟摆动溜槽浇注料结合强度高,抗冲刷性能好、抗热震损伤性能好,使用过程中没有出现宏观裂纹、体积稳定性保持良好,整个使用过程中维修次数少、劳动强度低,使用寿命得到了大幅增长,高效地保证了出铁安全顺行。
通过上述实施方式可以看出,本发明提供的高炉出铁沟摆动流槽用浇注料及其制备方法,与传统的摆动溜槽耐火材料相比,本发明的高炉摆动溜槽用浇注料流动性更好,可施工性更强,出铁过程中摆动溜槽衬体抗冲刷性能好、抗冲击韧性和抗疲劳损伤强、抗氧化和抗热震性能优良,以提高此材料抵抗环境作用而不损毁能力,进而延长摆动流槽的整体使用寿命;这种材料不仅可以降低整体耐材消耗,而且会减少现场的作业强度和难度,有益于高炉出铁安全顺行。
如上参照附图以示例的方式描述了根据本发明提出的高炉出铁沟摆动流槽用浇注料及其制备方法。但是,本领域技术人员应当理解,对于上述本发明所提出的高炉出铁沟摆动流槽用浇注料及其制备方法,还可以在不脱离本发明内容的基础上做出各种改进。因此,本发明的保护范围应当由所附的权利要求书的内容确定。
Claims (10)
1.一种高炉出铁沟摆动流槽用浇注料,其特征在于,按重量份计组成包括:高铝材料45~68份、碳化硅10~18份、红柱石5~15份、纯铝酸钙水泥2-4份、分散剂0.1~0.3份,以及复合添加剂10~20份。
2.如权利要求1所述的高炉出铁沟摆动流槽用浇注料,其特征在于,
所述高铝材料包括刚玉材料的一种、几种或刚玉材料与特级矾土熟料的复合;其中,
所述刚玉材料的骨料粒度为10~5mm、5~3mm、3~1mm或1~0.088mm;
所述刚玉材料的细粉粒度≤0.074mm,Al2O3的含量>94.5%;
所述特级矾土熟料的粒度为10~5mm,Al2O3的含量>88%。
3.如权利要求1所述的高炉出铁沟摆动流槽用浇注料,其特征在于,
所述碳化硅的粒度为8~5mm、5~3mm或3~1mm,SiC的含量>97.5%。
4.如权利要求1所述的高炉出铁沟摆动流槽用浇注料,其特征在于,
所述红柱石的粒度为5~3mm、3~1mm或1~0.088mm,矿相Al2O3·SiO2的含量>90%。
5.如权利要求1所述的高炉出铁沟摆动流槽用浇注料,其特征在于,
所述纯铝酸钙水泥为CA80水泥,其中,Al2O3的含量>78%。
6.如权利要求1所述的高炉出铁沟摆动流槽用浇注料,其特征在于,
所述分散剂包括聚磷酸盐类化合物、聚乙二醇基聚合物FS20中一种或者两种。
7.如权利要求1所述的高炉出铁沟摆动流槽用浇注料,其特征在于,
所述复合添加剂,按重量份计组成包括:氧化铝微粉5~10份、硅灰1~3份、纳米炭黑粉0.2~1份、含碳树脂粉0.5~1.5份、Si-SiC复合粉2~5份、氧化镁粉0.2~1份、高温无机纤维0.05~0.1份,其中,
所述氧化铝微粉的粒度<1μm,Al2O3的含量>99.9%;
所述硅灰的粒度<0.15μm,SiO2的含量为>95%;
所述纳米碳黑粉的粒度<30nm,纳米碳的含量>98%,挥发份<1.5%,灰分<0.5%;
所述含碳树脂粉的粒度<0.088mm,碳的含量>80%;
所述Si-SiC复合粉的粒度<20μm,SiC的含量为>60%;
所述氧化镁微粉的粒度<0.088mm,MgO的含量>90%;
所述高温无机纤维包括玄武岩纤维、短切碳纤维、莫来石纤维的一种或两种,长径比为75:1。
8.一种制备如权利要求1-7任一项所述的高炉出铁沟摆动流槽用浇注料的方法,其特征在于,包括:
将复合添加剂的各个组份按照预设比例进行混合形成复合添加剂粉料;
将所述复合添加剂粉料与分散剂、纯铝酸钙水泥、高铝材料、碳化硅、红柱石按照预设比例进行混合搅拌,形成混合散料;
将所述混合散料进行筛分、浆料进行处理,制备成高炉出铁沟摆动流槽用浇注料。
9.如权利要求8所述的高炉出铁沟摆动流槽用浇注料的方法,其特征在于,在制备成高炉出铁沟摆动流槽用浇注料之后,还包括:
将制备的高炉出铁沟摆动流槽用浇注料进行易性检验;
检验合格后袋装备用。
10.如权利要求8所述的高炉出铁沟摆动流槽用浇注料的方法,其特征在于,采用强制搅拌机对所述复合添加剂粉料与分散剂、纯铝酸钙水泥、高铝材料、碳化硅、红柱石按照比例混合搅拌。
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