CN117430437A - 用于熔分炉蓄热室格子体的复合耐火材料及其制法和应用 - Google Patents
用于熔分炉蓄热室格子体的复合耐火材料及其制法和应用 Download PDFInfo
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- CN117430437A CN117430437A CN202311757136.2A CN202311757136A CN117430437A CN 117430437 A CN117430437 A CN 117430437A CN 202311757136 A CN202311757136 A CN 202311757136A CN 117430437 A CN117430437 A CN 117430437A
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- 239000002131 composite material Substances 0.000 title claims abstract description 63
- 239000011819 refractory material Substances 0.000 title claims abstract description 59
- 238000002844 melting Methods 0.000 title claims abstract description 30
- 230000008018 melting Effects 0.000 title claims abstract description 29
- 238000002360 preparation method Methods 0.000 title claims abstract description 14
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 116
- 239000000843 powder Substances 0.000 claims abstract description 101
- 229910052596 spinel Inorganic materials 0.000 claims abstract description 78
- 239000011029 spinel Substances 0.000 claims abstract description 78
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 76
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 59
- 239000011230 binding agent Substances 0.000 claims abstract description 58
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 48
- 239000011777 magnesium Substances 0.000 claims abstract description 48
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 48
- 229910052742 iron Inorganic materials 0.000 claims abstract description 39
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 27
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 27
- 239000011651 chromium Substances 0.000 claims abstract description 27
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 claims abstract description 25
- 229910000423 chromium oxide Inorganic materials 0.000 claims abstract description 25
- 229920001353 Dextrin Polymers 0.000 claims abstract description 23
- 239000004375 Dextrin Substances 0.000 claims abstract description 23
- 235000019425 dextrin Nutrition 0.000 claims abstract description 23
- 210000005056 cell body Anatomy 0.000 claims abstract description 15
- 229910052500 inorganic mineral Inorganic materials 0.000 claims abstract description 15
- 239000011707 mineral Substances 0.000 claims abstract description 15
- 238000003723 Smelting Methods 0.000 claims abstract description 13
- 238000002156 mixing Methods 0.000 claims description 54
- 239000007787 solid Substances 0.000 claims description 19
- RGPUVZXXZFNFBF-UHFFFAOYSA-K diphosphonooxyalumanyl dihydrogen phosphate Chemical compound [Al+3].OP(O)([O-])=O.OP(O)([O-])=O.OP(O)([O-])=O RGPUVZXXZFNFBF-UHFFFAOYSA-K 0.000 claims description 18
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 claims description 18
- 239000000347 magnesium hydroxide Substances 0.000 claims description 18
- 229910001862 magnesium hydroxide Inorganic materials 0.000 claims description 18
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 claims description 18
- 235000019982 sodium hexametaphosphate Nutrition 0.000 claims description 18
- 238000003756 stirring Methods 0.000 claims description 18
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 claims description 18
- 239000007767 bonding agent Substances 0.000 claims description 17
- 238000000034 method Methods 0.000 claims description 17
- 239000002994 raw material Substances 0.000 claims description 16
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
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- 239000000463 material Substances 0.000 abstract description 22
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 6
- 230000008569 process Effects 0.000 description 6
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- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 5
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- 239000002253 acid Substances 0.000 description 3
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- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 2
- MHKWSJBPFXBFMX-UHFFFAOYSA-N iron magnesium Chemical compound [Mg].[Fe] MHKWSJBPFXBFMX-UHFFFAOYSA-N 0.000 description 2
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- NDLPOXTZKUMGOV-UHFFFAOYSA-N oxo(oxoferriooxy)iron hydrate Chemical compound O.O=[Fe]O[Fe]=O NDLPOXTZKUMGOV-UHFFFAOYSA-N 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 235000012239 silicon dioxide Nutrition 0.000 description 2
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- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 229920001732 Lignosulfonate Polymers 0.000 description 1
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- 235000011941 Tilia x europaea Nutrition 0.000 description 1
- KMWBBMXGHHLDKL-UHFFFAOYSA-N [AlH3].[Si] Chemical class [AlH3].[Si] KMWBBMXGHHLDKL-UHFFFAOYSA-N 0.000 description 1
- VNYSVKIBBZAPBN-UHFFFAOYSA-N [Mg].[Cr].[Fe] Chemical compound [Mg].[Cr].[Fe] VNYSVKIBBZAPBN-UHFFFAOYSA-N 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
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- 230000008859 change Effects 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000003500 flue dust Substances 0.000 description 1
- 239000003546 flue gas Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
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- 230000005484 gravity Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
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- 239000012768 molten material Substances 0.000 description 1
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- 230000035699 permeability Effects 0.000 description 1
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 description 1
- 229910001950 potassium oxide Inorganic materials 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
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- 230000035939 shock Effects 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 1
- 229910001948 sodium oxide Inorganic materials 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
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- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/44—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminates
- C04B35/443—Magnesium aluminate spinel
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- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
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Abstract
本发明公开了用于熔分炉蓄热室格子体的复合耐火材料及其制法和应用,属于耐火材料领域。该复合耐火材料由镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉和结合剂制成,具体重量配比为:粒度为3‑1mm的镁铁尖晶石15‑30份;粒度为1‑0.088mm的镁铁尖晶石12‑25份;粒度<0.088mm的镁铁尖晶石15‑25份;粒度<1μm的铁鳞粉2‑3份;电熔氧化铬粉15‑30份;铬矿粉3‑5份;白糊精结合剂1.5份;镁凝胶结合剂2.5‑3.5份。该材料蓄热能力加强,能够解决现有耐火材料用于熔分炉蓄热室格子体容易炸裂剥落以及遭到化学侵蚀损毁的问题。
Description
技术领域
本发明是属于耐火材料领域,特别是关于一种用于熔分炉蓄热室格子体的复合耐火材料及其制法和应用。
背景技术
赤泥是氧化铝生产过程中排出的废渣,因技术、成本等原因,利用率极低,巨量的赤泥堆放问题成为世界性难题。目前,我国通过煤基直接还原烧成-渣铁磁选分离-母液溶出的新工艺流程,可以实现赤泥的完全利用。该工艺流程具体为:将拜耳法溶出后的高铁赤泥添加褐煤(含碳、二氧化硅、氧化铝、氧化镁等成分),作为还原剂,加入膨润土,高压压制成球,经过转底炉矿化,催化还原成单质铁或者是一氧化铁,形成球团,再加入少量的石灰、焦炭粉,在熔分炉里进行熔融化,强熔融化后,通过控制液固比等参数对熟料进行碱液溶出。铁的比重比较大,铁水就沉到下层炉底,富含大量二氧化硅的熔渣浮到这个铁水的上层,出现熔渣和铁水分离,得到高铝碱液和富铁残渣。上层含有氧化铁、氧化铝、氧化钙、氧化镁、氧化钾、氧化钠等成分,是生产矿棉的主要原料。下层炉底的铁水,经过出铁口排出生产出优质的铁水,该产品可作电炉炼钢的半钢原料。这种技术可实现拜耳法赤泥的全面综合利用。
在熔分炉熔融过程中,因为碱性成分非常高,碱性熔渣侵蚀非常严重。下层非铁非钢工况环境,若是按照炼铁的工况,那么炉衬材料用铝硅系材料加含碳材料最佳,若是炼钢的工况,是碱性的含碳材料最优。而赤泥冶炼工况为酸、碱熔渣侵蚀,又超高温(1600-1800℃),且冶炼过程中温度变化非常剧烈,整个熔池的上下部工况差异很大:熔融液上部是纯酸的熔融液,熔融液下部又是碱性的熔融液。而且在使用过程中,熔池内的环境变化也非常大,温度剧烈波动,气氛既酸又碱。在熔分炉内使用高铝质、镁系(镁铬、镁尖晶石、镁铝尖晶石)、铝尖晶石、镁碳砖、铝镁碳砖、铬刚玉等作为耐火材料,分别出现炉衬材料全部熔化堵塞出铁口、高温熔炼中炉体变红炉体烧穿、炉膛使用1-3炉全部熔化损毁等问题。因此,熔分炉用耐火材料成为制约熔分技术发展的问题。
蓄热室是一种回收和交换热量的重要装备,蓄热室格子体是载热蓄热体,因此,该部位要求有较好蓄热性能的材料。熔分炉蓄热室格子体面临的主要问题是:在生产过程易受到高温烟气、粉尘、熔渣渗透,遭到化学侵蚀,同时由于气流分布不均受到的冷热气体交替冲击,会出现剥落、炸裂等现象,尤其是炸裂后堵塞格孔而难以疏通,从而导致蓄热室作用降低,能耗增加,熔窑寿命大幅度降低。
公开于该背景技术部分的信息仅仅旨在增加对本发明的总体背景的理解,而不应当被视为承认或以任何形式暗示该信息构成已为本领域一般技术人员所公知的现有技术。
发明内容
本发明的目的在于解决现有耐火材料用于熔分炉蓄热室格子体容易炸裂剥落以及遭到化学侵蚀损毁的问题,提供用于熔分炉蓄热室格子体的复合耐火材料及其制法和应用。
本发明第一方面提供一种用于熔分炉蓄热室格子体的复合耐火材料,所述复合耐火材料由镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉和结合剂制成,其中,所述复合耐火材料原料的具体重量配比为:
粒度为3-1mm的镁铁尖晶石15-30份;
粒度为1-0.088mm的镁铁尖晶石12-25份;
粒度<0.088mm的镁铁尖晶石15-25份;
粒度<1μm的铁鳞粉2-3份;
电熔氧化铬粉15-30份;
铬矿粉3-5份;
白糊精结合剂1.5份;
镁凝胶结合剂2.5-3.5份。
本申请所采用的铬矿粉的化学组成为:55wt%的Cr2O3,15wt%的MgO,14wt%的Fe2O3,12wt%的Al2O3,杂质余量。
在本发明的一实施方式中,所述复合耐火材料原料的具体重量配比为:
粒度为3-1mm的镁铁尖晶石27份;
粒度为1-0.088mm的镁铁尖晶石20份;
粒度<0.088mm的镁铁尖晶石18份;
粒度<1μm的铁鳞粉3份;
电熔氧化铬粉22份;
铬矿粉4份;
白糊精结合剂1.5份;
镁凝胶结合剂3.5份。
在本发明的一实施方式中,所述镁铁尖晶石包括:75-85wt%的MgO和15-25wt%的Fe2O3。
在本发明的一实施方式中,所述镁凝胶结合剂由1重量份的固体磷酸二氢铝、1重量份的氢氧化镁微粉和0.6-0.7重量份的六偏磷酸钠组成。
在本发明的一实施方式中,所述镁凝胶结合剂通过以下步骤制备:
将固体磷酸二氢铝、氢氧化镁微粉在球磨机内混合共磨12-16小时;
加入六偏磷酸钠混合搅拌10-20分钟;
用温水调和成胶状体凝胶。
在本发明的一实施方式中,所述镁凝胶结合剂的波美度为50-52°Bé。
本发明第二方面提供上述复合耐火材料的制备方法,所述制备方法包括:
A.将粒度为3-1mm的镁铁尖晶石、粒度为1-0.088mm的镁铁尖晶石预混合3-5分钟,得到预混骨料;
B.将粒度<0.088mm的镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉搅拌预混合10-15分钟,得到预混粉料;
C. 将白糊精结合剂、镁凝胶结合剂加入所述预混骨料中,混合10-15分钟,再加入所述预混粉料,混炼8-12分钟,困料20-28小时;
D. 压制成型、80-150℃干燥、1650℃烧成8-12小时,即得所述复合耐火材料。
在本发明的一实施方式中,所述镁凝胶结合剂由1重量份的固体磷酸二氢铝、1重量份的氢氧化镁微粉和0.6-0.7重量份的六偏磷酸钠组成。
在本发明的一实施方式中,所述镁凝胶结合剂通过以下步骤制备:
将固体磷酸二氢铝、氢氧化镁微粉在球磨机内混合共磨12-16小时;
加入六偏磷酸钠混合搅拌10-20分钟;
用温水调和成胶状体凝胶。
本发明第三方面提供上述复合耐火材料或根据上述制备方法制备得到的复合耐火材料在熔分炉蓄热室格子体中的应用。
与现有技术相比,本发明达到的技术效果如下:
(1)本发明的复合耐火材料中氧化铁含量4-5wt%,使材料的蓄热能力加强,适合用作熔分炉蓄热室格子体。
(2)本发明的复合耐火材料中氧化铬含量30wt%以上,既能够抵抗高温碱性气流对耐火材料的损毁,又能够抵抗熔化物料带来的酸性气氛对镁系材料的侵蚀。
(3)本发明的复合耐火材料原料中包含镁铁尖晶石、铁鳞粉、铬矿粉等成分,烧结过程中能够形成镁铬铁尖晶石相、镁铁尖晶石相、镁铬尖晶石相、镁铝铁尖晶石相等多种尖晶石复合相,从而显著提高材料的热震稳定性,避免材料炸裂剥落,提高炉子使用寿命。
(4)通过白糊精和镁凝胶复合使用提高结合剂的胶结性能,增加原料的塑性及和易性,提高材料成型性能,解决格子砖成型难度大的问题;同时两种结合剂在制砖过程中形成作用梯度,常温和低温时白糊精发挥主要胶结作用,保证材料成型性能,中高温阶段则主要由镁凝胶与原料中的铬、铁、铝生成复合尖晶石相,进一步提高材料的高温性能。
具体实施方式
除非另有其它明确表示,否则在整个说明书和权利要求书中,术语“包括”或其变换如“包含”或“包括有”等等将被理解为包括所陈述的元件或组成部分,而并未排除其它元件或其它组成部分。
以下通过具体实施例说明本发明的技术方案。应该理解,本发明提到的一个或者多个步骤不排斥在组合步骤前后还存在其他方法和步骤,或者这些明确提及的步骤间还可以***其他方法和步骤。还应理解,这些实例仅用于说明本发明而不用于限制本发明的范围。除非另有说明,各方法步骤的编号仅为鉴别各方法步骤的目的,而非限制每个方法的排列次序或限定本发明的实施范围,其相对关系的改变或调整,在无实质技术内容变更的条件下,亦可视为本发明可实施的范畴。
实施例中所采用的原料和仪器,对其来源没有特定限制,在市场购买或者按照本领域内技术人员熟知的常规方法制备即可。
实施例1
一种用于熔分炉蓄热室格子体的复合耐火材料,其原料的具体重量配比为:粒度为3-1mm的镁铁尖晶石27份;粒度为1-0.088mm的镁铁尖晶石20份;粒度<0.088mm的镁铁尖晶石18份;粒度<1μm的铁鳞粉3份;电熔氧化铬粉22份;铬矿粉4份;白糊精结合剂1.5份;镁凝胶结合剂3.5份。其中,镁凝胶结合剂由1重量份的固体磷酸二氢铝、1重量份的氢氧化镁微粉和0.65重量份的六偏磷酸钠组成。镁铁尖晶石包括:75-85wt%的MgO和15-25wt%的Fe2O3。
所述复合耐火材料的制备方法,包括:
A.将粒度为3-1mm的镁铁尖晶石、粒度为1-0.088mm的镁铁尖晶石预混合5分钟,得到预混骨料;
B.将粒度<0.088mm的镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉搅拌预混合15分钟,得到预混粉料;
C. 将白糊精结合剂、镁凝胶结合剂加入所述预混骨料中,混合15分钟,再加入所述预混粉料,混炼12分钟,困料24小时;
D. 1000T压砖机压制成型、120℃干燥、1650℃烧成10小时,即得复合耐火材料。
其中,上述镁凝胶结合剂通过以下步骤制备:将固体磷酸二氢铝、氢氧化镁微粉在球磨机内混合共磨16小时;加入六偏磷酸钠混合搅拌20分钟;用温水调和成胶状体凝胶。得到的镁凝胶结合剂的波美度为52°Bé。
经测试,上述复合耐火材料达到如下技术指标:
实施例2
一种用于熔分炉蓄热室格子体的复合耐火材料,其原料的具体重量配比为:粒度为3-1mm的镁铁尖晶石30份;粒度为1-0.088mm的镁铁尖晶石25份;粒度<0.088mm的镁铁尖晶石15份;粒度<1μm的铁鳞粉2份;电熔氧化铬粉15份;铬矿粉5份;白糊精结合剂1.5份;镁凝胶结合剂2.5份。其中,镁凝胶结合剂由1重量份的固体磷酸二氢铝、1重量份的氢氧化镁微粉和0.7重量份的六偏磷酸钠组成。
所述复合耐火材料的制备方法,包括:
A.将粒度为3-1mm的镁铁尖晶石、粒度为1-0.088mm的镁铁尖晶石预混合3分钟,得到预混骨料;
B.将粒度<0.088mm的镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉搅拌预混合10分钟,得到预混粉料;
C. 将白糊精结合剂、镁凝胶结合剂加入所述预混骨料中,混合15分钟,再加入所述预混粉料,混炼10分钟,困料20小时;
D. 1000T压砖机压制成型、80℃干燥、1650℃烧成8小时,即得复合耐火材料。
其中,上述镁凝胶结合剂通过以下步骤制备:将固体磷酸二氢铝、氢氧化镁微粉在球磨机内混合共磨16小时;加入六偏磷酸钠混合搅拌20分钟;用温水调和成胶状体凝胶。得到的镁凝胶结合剂的波美度为52°Bé。
经测试,上述复合耐火材料达到如下技术指标:
实施例3
一种用于熔分炉蓄热室格子体的复合耐火材料,其原料的具体重量配比为:粒度为3-1mm的镁铁尖晶石15份;粒度为1-0.088mm的镁铁尖晶石12份;粒度<0.088mm的镁铁尖晶石25份;粒度<1μm的铁鳞粉3份;电熔氧化铬粉30份;铬矿粉3份;白糊精结合剂1.5份;镁凝胶结合剂2.5份。其中,镁凝胶结合剂由1重量份的固体磷酸二氢铝、1重量份的氢氧化镁微粉和0.65重量份的六偏磷酸钠组成。
所述复合耐火材料的制备方法,包括:
A.将粒度为3-1mm的镁铁尖晶石、粒度为1-0.088mm的镁铁尖晶石预混合5分钟,得到预混骨料;
B.将粒度<0.088mm的镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉搅拌预混合15分钟,得到预混粉料;
C. 将白糊精结合剂、镁凝胶结合剂加入所述预混骨料中,混合15分钟,再加入所述预混粉料,混炼12分钟,困料28小时;
D. 1000T压砖机压制成型、150℃干燥、1650℃烧成12小时,即得复合耐火材料。
其中,上述镁凝胶结合剂通过以下步骤制备:将固体磷酸二氢铝、氢氧化镁微粉在球磨机内混合共磨16小时;加入六偏磷酸钠混合搅拌20分钟;用温水调和成胶状体凝胶。得到的镁凝胶结合剂的波美度为52°Bé。
经测试,上述复合耐火材料达到如下技术指标:
对比例1
一种用于熔分炉蓄热室格子体的复合耐火材料,其原料的具体重量配比为:粒度为3-1mm的镁铁尖晶石27份;粒度为1-0.088mm的镁铁尖晶石20份;粒度<0.088mm的镁铁尖晶石18份;粒度<1μm的铁鳞粉3份;电熔氧化铬粉22份;白糊精结合剂1.5份;镁凝胶结合剂3.5份。其中,镁凝胶结合剂由1重量份的固体磷酸二氢铝、1重量份的氢氧化镁微粉和0.65重量份的六偏磷酸钠组成。
所述复合耐火材料的制备方法,包括:
A.将粒度为3-1mm的镁铁尖晶石、粒度为1-0.088mm的镁铁尖晶石预混合5分钟,得到预混骨料;
B.将粒度<0.088mm的镁铁尖晶石、铁鳞粉、电熔氧化铬粉搅拌预混合15分钟,得到预混粉料;
C. 将白糊精结合剂、镁凝胶结合剂加入所述预混骨料中,混合15分钟,再加入所述预混粉料,混炼12分钟,困料24小时;
D. 1000T压砖机压制成型、120℃干燥、1650℃烧成10小时,即得复合耐火材料。
其中,上述镁凝胶结合剂通过以下步骤制备:将固体磷酸二氢铝、氢氧化镁微粉在球磨机内混合共磨16小时;加入六偏磷酸钠混合搅拌20分钟;用温水调和成胶状体凝胶。得到的镁凝胶结合剂的波美度为52°Bé。
经测试,上述复合耐火材料达到如下技术指标:
本对比例中不含铬矿粉,无法与镁铁尖晶石能形成镁铁铬复合相,导致复合耐火材料气孔率提升,强度下降,从而导致复合耐火材料抗侵蚀性能下降。
对比例2
一种用于熔分炉蓄热室格子体的复合耐火材料,其原料的具体重量配比为:粒度为3-1mm的镁铁尖晶石27份;粒度为1-0.088mm的镁铁尖晶石20份;粒度<0.088mm的镁铁尖晶石18份;粒度<1μm的铁鳞粉3份;电熔氧化铬粉22份;铬矿粉4份;白糊精结合剂5份。
所述复合耐火材料的制备方法,包括:
A.将粒度为3-1mm的镁铁尖晶石、粒度为1-0.088mm的镁铁尖晶石预混合5分钟,得到预混骨料;
B.将粒度<0.088mm的镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉搅拌预混合15分钟,得到预混粉料;
C. 将白糊精结合剂加入所述预混骨料中,混合15分钟,再加入所述预混粉料,混炼12分钟,困料24小时;
D. 1000T压砖机压制成型、120℃干燥、1650℃烧成10小时,即得复合耐火材料。
经测试,上述复合耐火材料达到如下技术指标:
本对比例中镁凝胶结合剂由白糊精结合剂代替,白糊精的作用一般是提高材料的塑性和可加工性,防止使用环境中发生腐蚀和退化,属于有机结合剂,但会在低温下烧失失去结合性能,同时由于烧失会带来复合耐火材料气孔率上升、体密下降、强度下降等,从而导致材料的抗侵蚀和渗透能力下降,使用寿命缩短。
对比例3
一种用于熔分炉蓄热室格子体的复合耐火材料,其原料的具体重量配比为:粒度为3-1mm的镁铁尖晶石27份;粒度为1-0.088mm的镁铁尖晶石20份;粒度<0.088mm的镁铁尖晶石18份;粒度<1μm的铁鳞粉3份;电熔氧化铬粉22份;铬矿粉4份;镁凝胶结合剂5份。其中,镁凝胶结合剂由1重量份的固体磷酸二氢铝、1重量份的氢氧化镁微粉和0.65重量份的六偏磷酸钠组成。
所述复合耐火材料的制备方法,包括:
A.将粒度为3-1mm的镁铁尖晶石、粒度为1-0.088mm的镁铁尖晶石预混合5分钟,得到预混骨料;
B.将粒度<0.088mm的镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉搅拌预混合15分钟,得到预混粉料;
C. 将镁凝胶结合剂加入所述预混骨料中,混合15分钟,再加入所述预混粉料,混炼12分钟,困料24小时;
D. 1000T压砖机压制成型、120℃干燥、1650℃烧成10小时,即得复合耐火材料。
其中,上述镁凝胶结合剂通过以下步骤制备:将固体磷酸二氢铝、氢氧化镁微粉在球磨机内混合共磨16小时;加入六偏磷酸钠混合搅拌20分钟;用温水调和成胶状体凝胶。得到的镁凝胶结合剂的波美度为52°Bé。
经测试,上述复合耐火材料达到如下技术指标:
本对比例中白糊精结合剂由镁凝胶结合剂代替,材料的可塑性和可加工性下降,导致气孔升高,体密下降耐压强度下降,从而降低材料的抗侵蚀和抗渣性能。
对比例4
一种用于熔分炉蓄热室格子体的复合耐火材料,其原料的具体重量配比为:粒度为3-1mm的镁铁尖晶石27份;粒度为1-0.088mm的镁铁尖晶石20份;粒度<0.088mm的镁铁尖晶石18份;粒度<1μm的铁鳞粉3份;电熔氧化铬粉22份;铬矿粉4份;纸浆粉结合剂5份。
所述复合耐火材料的制备方法,包括:
A.将粒度为3-1mm的镁铁尖晶石、粒度为1-0.088mm的镁铁尖晶石预混合5分钟,得到预混骨料;
B.将粒度<0.088mm的镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉搅拌预混合15分钟,得到预混粉料;
C. 将纸浆粉结合剂加入所述预混骨料中,混合15分钟,再加入所述预混粉料,混炼12分钟,困料24小时;
D. 1000T压砖机压制成型、120℃干燥、1650℃烧成10小时,即得复合耐火材料。
经测试,上述复合耐火材料达到如下技术指标:
本对比例中白糊精结合剂和镁凝胶结合剂由纸浆粉结合剂代替,纸浆粉在耐火材料工业中属于暂时性结合剂,在常温下烘干后具有较强的结合强度,但加热到300℃以上,木质素磺酸盐会分解和燃烧掉,最后剩下少量的CaO或Na2O等容易形成低熔物的成分,导致耐火材料的使用性能下降。
前述对本发明的具体示例性实施方案的描述是为了说明和例证的目的。这些描述并非想将本发明限定为所公开的精确形式,并且很显然,根据上述教导,可以进行很多改变和变化。对示例性实施例进行选择和描述的目的在于解释本发明的特定原理及其实际应用,从而使得本领域的技术人员能够实现并利用本发明的各种不同的示例性实施方案以及各种不同的选择和改变。本发明的范围意在由权利要求书及其等同形式所限定。
Claims (10)
1.一种用于熔分炉蓄热室格子体的复合耐火材料,其特征在于,所述复合耐火材料由镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉和结合剂制成,其中,所述复合耐火材料原料的具体重量配比为:
粒度为3-1mm的镁铁尖晶石15-30份;
粒度为1-0.088mm的镁铁尖晶石12-25份;
粒度<0.088mm的镁铁尖晶石15-25份;
粒度<1μm的铁鳞粉2-3份;
电熔氧化铬粉15-30份;
铬矿粉3-5份;
白糊精结合剂1.5份;
镁凝胶结合剂2.5-3.5份。
2.根据权利要求1所述的复合耐火材料,其特征在于,所述复合耐火材料原料的具体重量配比为:
粒度为3-1mm的镁铁尖晶石27份;
粒度为1-0.088mm的镁铁尖晶石20份;
粒度<0.088mm的镁铁尖晶石18份;
粒度<1μm的铁鳞粉3份;
电熔氧化铬粉22份;
铬矿粉4份;
白糊精结合剂1.5份;
镁凝胶结合剂3.5份。
3.根据权利要求1所述的复合耐火材料,其特征在于,所述镁铁尖晶石包括:75-85wt%的MgO和15-25wt%的Fe2O3。
4.根据权利要求1所述的复合耐火材料,其特征在于,所述镁凝胶结合剂由1重量份的固体磷酸二氢铝、1重量份的氢氧化镁微粉和0.6-0.7重量份的六偏磷酸钠组成。
5.根据权利要求4所述的复合耐火材料,其特征在于,所述镁凝胶结合剂通过以下步骤制备:
将固体磷酸二氢铝、氢氧化镁微粉在球磨机内混合共磨12-16小时;
加入六偏磷酸钠混合搅拌10-20分钟;
用温水调和成胶状体凝胶。
6.根据权利要求4所述的复合耐火材料,其特征在于,所述镁凝胶结合剂的波美度为50-52°Bé。
7.根据权利要求1所述的复合耐火材料的制备方法,其特征在于,所述制备方法包括:
A.将粒度为3-1mm的镁铁尖晶石、粒度为1-0.088mm的镁铁尖晶石预混合3-5分钟,得到预混骨料;
B.将粒度<0.088mm的镁铁尖晶石、铁鳞粉、电熔氧化铬粉、铬矿粉搅拌预混合10-15分钟,得到预混粉料;
C. 将白糊精结合剂、镁凝胶结合剂加入所述预混骨料中,混合10-15分钟,再加入所述预混粉料,混炼8-12分钟,困料20-28小时;
D. 压制成型、80-150℃干燥、1650℃烧成8-12小时,即得所述复合耐火材料。
8.根据权利要求7所述的制备方法,其特征在于,所述镁凝胶结合剂由1重量份的固体磷酸二氢铝、1重量份的氢氧化镁微粉和0.6-0.7重量份的六偏磷酸钠组成。
9.根据权利要求8所述的制备方法,其特征在于,所述镁凝胶结合剂通过以下步骤制备:
将固体磷酸二氢铝、氢氧化镁微粉在球磨机内混合共磨12-16小时;
加入六偏磷酸钠混合搅拌10-20分钟;
用温水调和成胶状体凝胶。
10.根据权利要求1-6任一项所述的复合耐火材料或根据权利要求7-9任一项所述制备方法制备得到的复合耐火材料在熔分炉蓄热室格子体中的应用。
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