Summary of the invention
The shortcoming existing in order to overcome above-mentioned prior art, the object of the present invention is to provide the method for the online pressure sealing of a kind of blast-furnace tuyere coal gas, do not affecting under the prerequisite of blast-furnace tuyere function, under the condition stopping production without blast furnace staying, realizing tuyere gas is leaked and carries out online pressure sealing;
The method of the online pressure sealing of this blast-furnace tuyere gas leak, comprises the steps:
A). the surface preparation of blast-furnace tuyere leakage point, remove near the dirt settling on the surface of air port leakage point, make surface cleaning and surface coarsening activation;
B). on blast-furnace tuyere leakage point surface, utilize electric arc spraying equipment to spray the first alloy layer; The alloying element of described the first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:5-10%, Fe:2-3%, Ni:80-90%, rare earth element: 2-5%; The arc voltage of electric arc spraying equipment is 30-40V, and working current is 160-260A; In this spraying process, the continual spray-coating surface that blows to of the pressurized air of 0.6-0.8MPa, and the direction that pressurized air blows is vertical with spray-coating surface; The thickness of the first alloy layer forming is 0.1-0.3mm;
C). on the first alloy layer surface, utilize electric arc spraying equipment to spray the second alloy layer, the alloying element of described the second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co-:5-10%, and Cr:2-5%, Mo:3-10%, W:2-4%, rare earth element: 2-5%, all the other are Ni; The arc voltage of electric arc spraying equipment is 26-32V, working current: 200-240A; In this spraying process, the pressurized air of 0.6-0.8MPa is the continual spray-coating surface that blows to still: and the direction that pressurized air blows is vertical with spray-coating surface; The thickness of the second alloy layer forming is 0.5-2.0mm;
D). at the second alloy layer surface brush coating layer hole sealing agent.
Further technical scheme as aforesaid method: in step a, the surface preparation of blast-furnace tuyere leakage point adopts spray 6-10 order SiC sand to carry out Cress and surface active.
Further technical scheme as aforesaid method: the thickness of described the second alloy layer is 0.8-1.5mm.
The leak stopping layer forming based on aforesaid method provided by the invention, comprises the first alloy layer, the second alloy layer; Described the first alloy layer is sprayed on blast-furnace tuyere leakage point surface, and described the second alloy layer is sprayed on the surface of described the first alloy layer;
The alloying element of described the first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:5-10%, Fe:2-3%, Ni:80-90%, rare earth element: 2-5%; The thickness of described the first alloy layer is 0.1-0.3mm;
The alloying element of described the second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co:5-10%, and Cr:2-5%, Mo:3-10%, W:2-4%, rare earth element: 2-5%, all the other are Ni; The thickness of described the second alloy layer is 0.5-2.0mm.
Further technical scheme as leak stopping layer: the thickness of described the second alloy layer is 0.8-1.5mm.
The invention has the beneficial effects as follows: on blast-furnace tuyere gas leak point, electric arc spraying forms leak stopping layer, solve the gas leak problem in blast-furnace tuyere region, and the leak stopping coating forming has the features such as high temperature oxidation resisting, high ductibility, thermal shock resistance are good, in blast furnace working process, can not ftracture by internal stress, make air port more traditional blocking method in work-ing life improve 2-3 doubly; Greatly reduce the risk of carbon monoxide poisoning, ensured flushing and casting personnel's personnel safety, significant to keeping the safety in production; Simultaneously due to the prolongation in work-ing life, thereby reduce the repair time, increase economic efficiency, be conducive to reduce costs, improve output and energy-saving and emission-reduction;
When this sprays leak stopping layer in addition, blast furnace needn't stop production by damping down, has overcome the defect that the necessary blast furnace staying of traditional blocking method stops production; And safe operation process is reliable, can there is not the detonation accident such as even explode; Site operation safe ready and leak stopping efficiency are high, and cost is low.
Embodiment
The method of the online pressure sealing of this blast-furnace tuyere coal gas, is not affecting under the prerequisite of blast-furnace tuyere function, under the condition stopping production without blast furnace staying, realizes tuyere gas is leaked and carries out online pressure sealing.
Embodiment mono-: the method for the online pressure sealing of this blast-furnace tuyere coal gas, comprises step:
A). the surface preparation of blast-furnace tuyere leakage point, remove near the dirt settling on the surface of air port leakage point, make surface cleaning and surface coarsening activation; In this step a, the surface preparation of blast-furnace tuyere leakage point adopts spray 6 order SiC sand to carry out cleaning and roughening and surface active.
B). blast-furnace tuyere leakage point surface, utilizes electric arc spraying equipment to spray the first alloy layer; The alloying element of described the first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:5%, Fe:2%, Ni:88%, rare earth element: 5%.In step b, during spraying the first alloy layer, what take is Ultrasonic Arc Sprayed, and processing condition are: arc voltage 30, working current: 160.In the spraying process of this step b, the continual spray-coating surface that blows to of the pressurized air of 0.8MPa, and the direction that pressurized air blows is vertical with spray-coating surface.This pressurized air preferably adopts the constant pressure of 0.8MPa to blow out.The thickness of described the first alloy layer that in addition, step b forms is 0.1mm.
Spraying the first alloy layer can adopt metal wire material to pass through Ultrasonic Arc Sprayed, the forming process of the first alloy layer is as shown in the 1a of Fig. 1,1b, 1c, during thermospray, silk material is heated to molten state or high-ductility state by thermal source, under the thrust of adscititious gases or flame stream itself (being to have adopted pressurized air in this embodiment), atomization high-velocity jet are to matrix 2 surfaces, after melting there is fierce collision with matrix and be out of shape, flatten and be deposited on matrix 2 surfaces in the particle 1 of coated material, simultaneously chilling and rapid solidification, particle is layer deposition and be piled into coating 3 so then.Coating for by the interlaced in layer stacking laminate structure forming of wave that is of countless particle and distortion particle, forms the first alloy layer.
C). on the first alloy layer surface, utilize electric arc spraying equipment to spray the second alloy layer, the alloying element of described the second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co-:5%, Cr:5%, Mo:10%, W:4%, rare earth element: 5%, Ni:71%.In step c, during spraying the second alloy layer, adopt silk material to form by Ultrasonic Arc Sprayed.Processing condition are: arc voltage is 26V, working current: 200A.In the spraying process of step c, the continual spray-coating surface that blows to of the pressurized air of 0.6MPa: and the direction that pressurized air blows is vertical with spray-coating surface; The thickness of the second alloy layer forming is 0.5mm.
D). described the second alloy layer, the first alloy layer are carried out to follow-up sealing of hole processing.Further: described in steps d, later stage sealing of hole is processed and adopted high temperature organosilicon paint that the space of coating is sealed, and prevents high-temperature gas etched the matrix.
Embodiment bis-: the method for the online pressure sealing of this blast-furnace tuyere coal gas, comprises step:
A). the surface preparation of blast-furnace tuyere leakage point, remove near the dirt settling on the surface of air port leakage point, make surface cleaning and surface coarsening activation; In this step a, the surface preparation of blast-furnace tuyere leakage point adopts spray 10 order SiC sand to carry out cleaning and roughening and surface active;
B). blast-furnace tuyere leakage point surface, utilizes electric arc spraying equipment to spray the first alloy layer; The alloying element of described the first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:10%, Fe:3%, Ni:83%, rare earth element: 4%.In step b, during spraying the first alloy layer, what take is Ultrasonic Arc Sprayed, and processing condition are: arc voltage 40V, working current: 260A.In the spraying process of this step b, the continual spray-coating surface that blows to of the pressurized air of 0.8MPa, and the direction that pressurized air blows is vertical with spray-coating surface.The thickness of described the first alloy layer that in addition, step b forms is 0.3mm.
C). on the first alloy layer surface, utilize electric arc spraying equipment to spray the second alloy layer, the alloying element of described the second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co-:6%, Cr:4%, Mo:8%, W:2%, rare earth element: 5%, Ni:75%.In step c, during spraying the second alloy layer, what take is also that a material passes through Ultrasonic Arc Sprayed, and processing condition are: arc voltage is 32V, working current: 240A.In step c process, the continual spray-coating surface that blows to of the pressurized air of 0.6MPa: and the direction that pressurized air blows is vertical with spray-coating surface; The thickness of the second alloy layer forming is 2.0mm.
D). described the second alloy layer, the first alloy layer are carried out to follow-up sealing of hole processing.Further: described in steps d, later stage sealing of hole is processed and adopted high temperature organosilicon paint that the space of coating is sealed.
Embodiment tri-: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment mono-difference is:
Step a) the surface preparation of middle blast-furnace tuyere leakage point adopts spray 7 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:10%, Fe:2%, Ni:86%, rare earth element: 2%; In step b, during spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 35V, working current: 210A; The thickness of described the first alloy layer that step b forms is 0.15mm;
C). alloying element Co, the Cr of described the second alloy layer, Mo, W, Ni, rare earth element; Mass percent is: Co:8%, Cr:5%, Mo:10%, W:3%, rare earth element: 4%, Ni:70%; In step c, during spraying the second alloy layer, Ultrasonic Arc Sprayed processing condition are: arc voltage 28V, working current: 220A; In step c process, the continual spray-coating surface that blows to of the pressurized air of 0.6MPa; The thickness of the second alloy layer forming is 0.8mm.
All the other do not state technology with embodiment mono-.
Embodiment tetra-: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment mono-difference is:
Step a) the surface preparation of middle blast-furnace tuyere leakage point adopts spray 8 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:8%, Fe:3%, Ni:84%, rare earth element: 5%;
In step b, during spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 32V, working current: 180A; The thickness of described the first alloy layer that step b forms is 0.2mm;
C). alloying element Co, the Cr of described the second alloy layer, Mo, W, Ni, rare earth element; Mass percent is: Co:6%, Cr:5%, Mo:6%, W:2%, rare earth element: 5%, Ni:76%;
In step c, during spraying the second alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage is 29V, working current: 225A; The thickness of the second alloy layer forming is 1.0mm;
All the other do not state technology with embodiment mono-.
Embodiment five: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment mono-difference is:
Step a) the surface preparation of middle blast-furnace tuyere leakage point adopts spray 8 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:6%, Fe:2%, Ni:90%, rare earth element: 2%;
In step b, during spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 37V, working current: 230A; The thickness of described the first alloy layer that step b forms is 0.2mm;
C). alloying element Co, the Cr of described the second alloy layer, Mo, W, Ni, rare earth element; Mass percent is: Co:9%, Cr:5%, Mo:8%, W:4%, rare earth element: 2%, Ni:72%;
In step c, during spraying the second alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage is 30V, working current: 230A; The thickness of the second alloy layer forming is 1.2mm;
All the other do not state technology with embodiment mono-.
Embodiment six: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment mono-difference is:
Step a) the surface preparation of middle blast-furnace tuyere leakage point adopts spray 9 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:3%, Fe:2%, Ni:90%, rare earth element: 5%;
In step b, during spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 38V, working current: 240A; The thickness of described the first alloy layer that step b forms is 0.25mm;
C). alloying element Co, the Cr of described the second alloy layer, Mo, W, Ni, rare earth element; Mass percent is: Co:7%, Cr:3%, Mo:6%, W:4%, rare earth element: 3%, Ni:77%;
In step c, during spraying the second alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage is 31V, working current: 235A; The thickness of the second alloy layer forming is 1.5mm;
All the other do not state technology with embodiment mono-.
Embodiment seven: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment mono-difference is:
Step a) the surface preparation of middle blast-furnace tuyere leakage point adopts spray 9 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:7%, Fe:2%, Ni:89%, rare earth element: 2%;
In step b, during spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 39V, working current: 250A; The thickness of described the first alloy layer that step b forms is 0.28mm;
C). alloying element Co, the Cr of described the second alloy layer, Mo, W, Ni, rare earth element; Mass percent is: Co:5%, Cr:5%, Mo:4%, W:3%, rare earth element: 3%, Ni:80%;
In step c, during spraying the second alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage is 27V, working current: 210A; The thickness of the second alloy layer forming is 0.7mm;
All the other do not state technology with embodiment mono-.
The blast-furnace tuyere coal gas leak stopping layer being formed by above-described embodiment, comprises the first alloy layer, the second alloy layer; Described the first alloy layer is sprayed on blast-furnace tuyere leakage point surface, and described the second alloy layer is sprayed on the surface of described the first alloy layer; The alloying element of described the first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:5-10%, Fe:2-3%, Ni:80-90%, rare earth element: 2-5%; The thickness of described the first alloy layer is 0.1-0.3mm;
The alloying element of described the second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co:5-10%, and Cr:2-5%, Mo:3-10%, W:2-4%, rare earth element: 2-5%, all the other are Ni; The thickness of described the second alloy layer is 0.5-2.0mm.
While spraying the first alloy layer, liquid metal particle is invaded in these tiny flaws and is formed the combination of mechanical rivet type.On matrix and the first alloy layer interface, the first alloy layer and the second alloy layer interface, interlayer is fine in conjunction with obtaining.Uneven on interface, is conducive to improve the bonding strength of coating.
To the first alloy layer that utilizes processing method of the present invention to form, the many kinds of parameters of the second alloy layer, do following simultaneous test below, to prove the effect of the plugged zone that processing method of the present invention forms:
(1) bonding strength of plugged zone:
The bonding strength of table 1 alloy layer
As can be seen from Table 1, although the main combination of sample alloy layer is mechanical bond, but form owing to having sprayed the NiAl alloy layer (i.e. the first alloy layer) of one deck bottoming the micro metallurgic bonding point that some disperses distribute, can significantly improve the bonding strength that improves coating and matrix, and the size of itself and substrate combinating strength mainly depends on the bonding strength with prime coat and matrix, thus the selection of prime coat material and the quality of coating quality very important to the performance of plugged zone.
(2) coating microhardness
The sample adopting is the metallographic specimen through polishing, polishing, and matrix is No. 45 steel, and plugged zone thickness is about 1.0mm.During test, adding load is 300g, and the loading time is 10 seconds, and the microhardness result of matrix and alloy layer is respectively in Table 2 and table 3.
The microhardness of table 2 matrix
The microhardness of table 3 alloy layer
As can be seen from the above table, the character of coating hardness and spray material is undivided, but alloy layer hardness and spray material hardness has any different, even same spray material, alloy layer hardness is also different conventionally.Alloy layer contains pore and hole, and the weave construction of alloy layer has heterogencity, thereby causes the heterogencity of alloy layer hardness.And the combined alloy layer of the first alloy layer, the second alloy layer formation is that plugged zone microhardness is higher.
(3) alloy layer thermal shock performance
Thermal shock resistance test:
1) sample is placed in cabinet-type electric furnace and is heated,, be incubated 10 minutes, after taking-up, immerse immediately in cold water;
2) be again put in electric furnace heating;
3) repeated execution of steps 1,2, until alloy layer peels off area, account for 10% of the alloy layer total area;
4) record the number of times that starts to be heated to the water-cooled of taking while peeling off from alloy layer.
Sample is the single alloy layer that utilizes the material of the second alloy layer to make, the combined alloy layer that utilizes the first alloy layer and the second alloy layer to form, and carries out thermal shock resistance test respectively under 500 ℃ and 700 ℃ of conditions, and test-results is as shown in table 4:
Table 4 alloy layer thermal shock test data
Evidence: combined alloy layer thermal shock resistance is slightly better than single alloy layer thermal shock resistance, this is mainly due to the transition layer that forms afterwards of spraying end silk (first), has reduced cold cycling alternating stress, has improved its thermal shock performance.
Above-described embodiment is only preferred embodiment of the present invention, does not represent that the present invention is only confined to above-described embodiment.