CN107244930A - 一种耐铁水侵蚀高炉炭砖及其制备方法 - Google Patents

一种耐铁水侵蚀高炉炭砖及其制备方法 Download PDF

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CN107244930A
CN107244930A CN201710372071.8A CN201710372071A CN107244930A CN 107244930 A CN107244930 A CN 107244930A CN 201710372071 A CN201710372071 A CN 201710372071A CN 107244930 A CN107244930 A CN 107244930A
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blast furnace
molten iron
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corrodes
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党锡江
张桂兰
杨勇
武爱云
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Fangda Carbon New Materials Technology Co Ltd
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Abstract

一种耐铁水侵蚀高炉炭砖及其制备方法，属于高炉长寿炉衬用耐火材料制备技术领域。本发明以不同粒级的高温电煅煤为基料，加入一定比例硅粉、白刚玉微粉、二氧化钛微粉和碳化硅共混，采用中温煤沥青做粘结剂，经过混捏、压型、焙烧、精加工制备而成。本发明采用振动成型方式，使用了新的工艺配方和技术、利用成熟的生产设备，生产出铁水溶蚀指数在12%以下，氧化率小于5%，耐压强度大于45MPa，其他指标达到超微孔炭砖理化指标的耐铁水侵蚀高炉炭砖。生产的产品质量满足高炉炉缸、炉腹、出铁口及铁口溜槽的技术设计和使用要求。

Description

一种耐铁水侵蚀高炉炭砖及其制备方法
技术领域
本发明属于高炉长寿炉衬用耐火材料制备技术领域，具体涉及一种耐铁水侵蚀高炉炭砖及其制备方法。
背景技术
随着钢铁工业的快速发展，炼铁技术的不断进步，炼铁高炉日趋大型化、长寿化，而且更加高效节能。高炉炉龄长寿成为世界炼铁行业不断追求的重要目标，也是衡量一个国家炼铁水平的重要标志之一。炼铁高炉炉缸用耐火材料工况条件恶劣，缸炉以及铁口区、铁口以下的异常侵蚀区炭砖的寿命长短是影响高炉整体长寿的关键环节之一。目前都使用的微孔炭砖、超微孔炭砖，为了提高导热性能在产品制备过程中添加了石墨化无烟煤，由于石墨化无烟煤是通过普煅煤在艾奇逊石墨化炉中高温处理得到的，石墨化炉不同区域温度差别较大，导致石墨化无烟煤性能差异也较大，生产的微孔炭砖、超微孔炭砖，其均质化程度不高，同时铁水侵蚀指数、氧化率等没有得以提升。耐铁水侵蚀高炉炭砖通过采用高温电煅煤，替代了电煅煤与石墨化无烟煤具有良好的导热性、抗热振性、抗碱性、抗剥落性、抗铁水和熔渣冲刷性为一体的炭砖，对发展现代化长寿、节能、环保大型高炉具有重要的意义。
发明内容
本发明所要解决的技术问题是针对现有技术中的缺点而提供一种具有优异的抗铁水溶蚀性、氧化性及较高的导热性、较高抗压强度的耐铁水侵蚀高炉炭砖。
本发明的另一目的为提供上述耐铁水侵蚀高炉炭砖的制备方法。
本发明解决其技术问题所采用的技术方案是：
一种耐铁水侵蚀高炉炭砖，其特征在于由以下重量份的物质组成：干料5份，粘结剂煤沥青为1.05-1.10份，其中干料由以下重量份的物质组成：4-2mm高温电煅煤21-28份,2-0.5mm高温电煅煤12-16份，0.075-0.002mm高温电煅煤39-45份，2-0.02mm碳化硅2-3份，-0.075mm工业硅粉7-10份，-0.075mm白刚玉8-10份。
一种耐铁水侵蚀高炉炭砖，其特征在于由以下重量份的物质组成：干料5份，粘结剂煤沥青为1.05-1.1份，其中干料由以下重量份的物质组成：4-2mm高温电煅煤20-28份,2-0.5mm高温电煅煤13-16份，0.075-0.002mm高温电煅煤40-45份2-0.02mm碳化硅2-3份,-0.075mm工业硅粉7-8份，-0.075mm白刚玉4-5份、二氧化钛粉3-5份。
其中碳化硅纯度≥80%，高温电煅煤的电阻率在250-320μΩm之间，硅粉中单质Si含量≥96%，白刚玉为电熔白刚玉，Al2O3含量≥98%，二氧化钛为耐火材料级，TiO2含量≥99.0%。
上述的耐铁水侵蚀高炉炭砖的制备方法，具体步骤如下：
a、物料：按照上述重量份取各种物料，将干料加入混捏锅共混，再加入粘结剂中温煤沥青进行混捏制得糊料；
b、成型冷却：将混捏制得糊料由振动成型机压制生制品,预振时间1-3分钟、大振时间1-3分钟，压型生制品经水冷48小时，水温控制20℃±5℃，然后自然冷却；
c、焙烧：将压型生制品装入环式焙烧炉内，按照升温曲线升温，焙烧最高温度1420℃条件下保持24小时，冷却至100小时后出炉，制得焙烧品。
所述的步骤c中的升温曲线为：
所述的步骤c中将压型生制品装入环式焙烧炉上层，大面平行于大墙方向，填充料粒度2-6mm。
本发明生产的耐铁水侵蚀高炉炭砖，在产品非无烟煤颗粒组织外的其他区域形成均匀稳定的碳化硅晶须，使得产品的氧化率由原来的7%左右降低到5%以下，提高了超微孔炭砖的抗氧化性能。
本发明生产的耐铁水侵蚀高炉炭砖，通过增加部分陶瓷相成分，控制反应温度的均匀性，使得炭和硅充分反应并填充在微孔中细化微孔孔径，降低了产品中大孔的比例，小于0.1μm孔径的气孔占总孔的比例增加，小于1μm孔径的气孔比例达到85%以上，从而提高了产品的抗铁水侵蚀性能，抗铁水溶蚀指数由原来的26%左右，降低到12%左右。
另外，随着陶瓷相成分的增加，产品的体积密度增大，抗压强度提高，达到45MPa以上。
与德国SGL生产的7RND超微孔炭砖、日本BC-8SR相比，各项性能优于或等同于国外产品。对比如下：
表4 国内外超微孔炭砖性能对比
其优异的抗铁水溶蚀性、氧化性及较高的导热性、较高抗压强度，可替代炉缸及铁口微孔及超微孔炭砖。
具体实施方式
以下结合具体的具体实施例，对本发明的技术方案作进一步的描述，但本发明并不限于这些实施例。
实施例1
一种耐铁水侵蚀高炉炭砖，由干料和粘结剂煤沥青组成，所述干料和粘结剂煤沥青质量比为5:1.05，由4-2mm高温电煅煤28份，2-0.5mm高温电煅煤12份，0.075-0.002mm高温电煅煤39份做基料，添加2-0.02mm碳化硅3份，-0.075mm工业硅粉7份，-0.075mm白刚玉10份组成。
一种耐铁水侵蚀高炉炭砖的制备方法，具体步骤如下：
a、物料：按照上述重量份取各种物料，将干料加入混捏锅共混，再加入粘结剂中温煤沥青进行混捏制得糊料；
b、成型冷却：由振动成型机压制生制品，预振时间3分钟、大振时间3分钟，压型生制品经水冷48小时，水温控制15℃，然后自然冷却；
c、焙烧：将压型生制品装入环式焙烧炉上层，大面平行于大墙方向，填充料粒度6mm，焙烧最高温度1420℃条件下保持24小时，冷却至100小时后出炉，制得焙烧品。
采用的焙烧升温曲线如下：
制备的耐铁水侵蚀高炉炭砖，产品理化指标如下：
实施例2
一种耐铁水侵蚀高炉炭砖，由干料和粘结剂煤沥青组成，所述干料和粘结剂煤沥青质量比为5:1.1，由4-2mm高温电煅煤21份，2-0.5mm高温电煅煤 16份，0.075-0.002mm高温电煅煤45份做基料，添加2-0.02mm碳化硅2份，-0.075mm工业硅粉10份，-0.075mm白刚玉8份组成。
一种耐铁水侵蚀高炉炭砖的制备方法，具体步骤如下：
a、物料：按照上述重量份取各种物料，将干料加入混捏锅共混，再加入粘结剂中温煤沥青进行混捏制得糊料；
b、成型冷却：由振动成型机压制生制品,预振时间2分钟、大振时间2分钟，压型生制品经水冷48小时，水温控制25℃，然后自然冷却；
c、焙烧：将压型生制品装入环式焙烧炉上层，大面平行于大墙方向，填充料粒度2mm，焙烧最高温度1420℃条件下保持24小时，冷却至100小时后出炉，制得焙烧品。
采用的焙烧升温曲线如下：
制备的耐铁水侵蚀高炉炭砖，产品理化指标如下：
实施例3
一种耐铁水侵蚀高炉炭砖，由干料和粘结剂煤沥青组成，所述干料和粘结剂煤沥青质量比为5:1.1；所述干料由4-2mm高温电煅煤21份，2-0.5mm高温电煅煤 16份，0.075-0.002mm高温电煅煤45份做基料，添加2-0.02mm碳化硅3份，-0.075mm工业硅粉7份，-0.075mm白刚玉4份、二氧化钛粉5份组成。
一种耐铁水侵蚀高炉炭砖的制备方法，具体步骤如下：
a、物料：按照上述重量份取各种物料，将干料加入混捏锅共混，再加入粘结剂中温煤沥青进行混捏制得糊料；
b、成型冷却：由振动成型机压制生制品,预振时间2分钟、大振时间3分钟，压型生制品经水冷48小时，水温控制20℃，然后自然冷却；
c、焙烧：将压型生制品装入环式焙烧炉上层，大面平行于大墙方向，填充料粒度4mm，焙烧最高温度1420℃条件下保持24小时，冷却至100小时后出炉，制得焙烧品。
采用的焙烧升温曲线如下：
制备的耐铁水侵蚀高炉炭砖，产品理化指标如下：
实施例4
一种耐铁水侵蚀高炉炭砖，由干料和粘结剂煤沥青组成，所述干料和粘结剂煤沥青质量比为5:1.05;所述干料由4-2mm高温电煅煤28份，2-0.5mm高温电煅煤 13份，0.075-0.002mm高温电煅煤40份做基料，添加2-0.02mm碳化硅2份，-0.075mm工业硅粉8份，-0.075mm白刚玉5份、二氧化钛粉3份组成。
一种耐铁水侵蚀高炉炭砖的制备方法，具体步骤如下：
a、物料：按照上述重量份取各种物料，将干料加入混捏锅共混，再加入粘结剂中温煤沥青进行混捏制得糊料；
b、成型冷却：由振动成型机压制生制品,预振时间3分钟、大振时间2分钟，压型生制品经水冷48小时，水温控制20℃，然后自然冷却；
c、焙烧：将压型生制品装入环式焙烧炉上层，大面平行于大墙方向，填充料粒度6mm，焙烧最高温度1420℃条件下保持24小时，冷却至100小时后出炉，制得焙烧品。
采用的焙烧升温曲线如下：
制备的耐铁水侵蚀高炉炭砖，产品理化指标如下：

Claims (6)

1.一种耐铁水侵蚀高炉炭砖，其特征在于由以下重量份的物质组成：干料5份，粘结剂煤沥青为1.05-1.10份，其中干料由以下重量份的物质组成：4-2mm高温电煅煤21-28份,2-0.5mm高温电煅煤12-16份，0.075-0.002mm高温电煅煤39-45份，2-0.02mm碳化硅2-3份，-0.075mm工业硅粉7-10份，-0.075mm白刚玉8-10份。
2.一种耐铁水侵蚀高炉炭砖，其特征在于由以下重量份的物质组成：干料5份，粘结剂煤沥青为1.05-1.1份，其中干料由以下重量份的物质组成：4-2mm高温电煅煤20-28份,2-0.5mm高温电煅煤13-16份，0.075-0.002mm高温电煅煤40-45份2-0.02mm碳化硅2-3份,-0.075mm工业硅粉7-8份，-0.075mm白刚玉4-5份、二氧化钛粉3-5份。
3.根据权利要求2所述的一种耐铁水侵蚀高炉炭砖，其特征在于：所述干料的特性为：
碳化硅纯度≥80%，高温电煅煤的电阻率在250-320μΩm之间，硅粉中单质Si含量≥96%，白刚玉为电熔白刚玉，Al2O3含量≥98%，二氧化钛为耐火材料级，TiO2含量≥99.0%。
4.根据上述任一权利要求所述的一种耐铁水侵蚀高炉炭砖的制备方法，其特征在于具体步骤如下：
a、物料：按照上述重量份取各种物料，将干料加入混捏锅共混，再加入粘结剂中温煤沥青进行混捏制得糊料；干混温度110-120℃，干混时间30-40min；湿混温度140-150℃，湿混时间40-50min；
b、成型冷却：将混捏制得糊料由振动成型机压制生制品，预振时间1-3分钟、大振时间1-3分钟，压型生制品经水冷48-60小时，水温控制15-25℃，然后自然冷却；
c、焙烧：将压型生制品装入环式焙烧炉内，按照升温曲线升温，焙烧最高温度1420℃条件下保持24小时，冷却至100小时后出炉，制得焙烧品。
5.根据权利要求4述的一种耐铁水侵蚀高炉炭砖的制备方法，其特征在于：所述的步骤c中的升温曲线为：
。
6.据权利要求4述的一种耐铁水侵蚀高炉炭砖的制备方法，其特征在于：所述的步骤c中将压型生制品装入环式焙烧炉上层，大面平行于大墙方向，填充料粒度2-6mm。
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