CN104736730A - 耐熔融铝侵蚀的改良气泡泵 - Google Patents

耐熔融铝侵蚀的改良气泡泵 Download PDF

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CN104736730A
CN104736730A CN201380025473.0A CN201380025473A CN104736730A CN 104736730 A CN104736730 A CN 104736730A CN 201380025473 A CN201380025473 A CN 201380025473A CN 104736730 A CN104736730 A CN 104736730A
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pump
airlift pump
airlift
molten aluminum
pottery
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CN104736730B (zh
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容·M·李
詹姆斯·M·科斯蒂诺
伊戈尔·科马罗夫斯基
杰罗姆·S·卡普
C·拉马德瓦·沙斯特里
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ArcelorMittal Investigacion y Desarrollo SL
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04F—PUMPING OF FLUID BY DIRECT CONTACT OF ANOTHER FLUID OR BY USING INERTIA OF FLUID TO BE PUMPED; SIPHONS
    • F04F1/00—Pumps using positively or negatively pressurised fluid medium acting directly on the liquid to be pumped
    • F04F1/18—Pumps using positively or negatively pressurised fluid medium acting directly on the liquid to be pumped the fluid medium being mixed with, or generated from the liquid to be pumped
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/003—Apparatus
    • C23C2/0034—Details related to elements immersed in bath
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
    • C22B9/05—Refining by treating with gases, e.g. gas flushing also refining by means of a material generating gas in situ
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/003—Apparatus
    • C23C2/0034—Details related to elements immersed in bath
    • C23C2/00342—Moving elements, e.g. pumps or mixers
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/325—Processes or devices for cleaning the bath
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/50—Controlling or regulating the coating processes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • 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
    • F27D27/00—Stirring devices for molten material
    • F27D27/005—Pumps
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/12—Aluminium or alloys based thereon
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • 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
    • F27D3/00—Charging; Discharging; Manipulation of charge
    • F27D2003/0034—Means for moving, conveying, transporting the charge in the furnace or in the charging facilities
    • F27D2003/0054—Means to move molten metal, e.g. electromagnetic pump

Abstract

一种具有由耐熔融铝侵蚀的材料形成的内部的气泡泵。内部的表面可由陶瓷形成。所述陶瓷可选自氧化铝、氧化镁、硅酸盐、碳化硅或石墨及其混合物。陶瓷可以是不含碳的85％Al2O3磷酸盐结合可浇注耐火材料。

Description

耐熔融铝侵蚀的改良气泡泵
技术领域
本发明涉及用于将熔融金属涂布到钢上的设备。更特别地，其涉及用于熔融金属浴以从待涂布钢带附近的熔融金属中移除表面浮渣的气泡泵。最特别地，其涉及保护这种气泡泵内部免受由熔融金属附加的侵蚀和破坏。
背景技术
多年来都使用熔融铝和熔融锌来涂布钢的表面。涂布工艺步骤之一是将钢片浸入熔融铝或熔融锌中。涂层的表面质量对于生产高质量涂布产品是非常重要的。然而，在2007年镀铝钢向美国市场的引入对于镀铝作业线是相当大的挑战。早期试验由于涂层缺陷而导致了大于50％的不良品。
缺陷的主要来源之一是在漂浮在管嘴(snout)内铝浴上和粘到带上的浮渣。为了实现高质量的表面抛光，需要从待涂布表面移走熔融金属浴中(尤其是管嘴内侧的限制区域中)的漂浮浮渣和氧化物。碳钢气动浮渣泵(也被称为气泡泵)已被用于从涂布区移除浮渣。实施推拉式管嘴泵以确保管嘴内的无浮渣熔融表面使得高质量涂层成为可能。气泡泵(亦称为浮渣泵)使用通过将压缩气体、空气、水蒸气的气泡或其他蒸气气泡引入出口管而使流体例如水或油(或在该情况下为熔融金属)升高的人工提升技术。这具有相对于管入口侧的流体静压降低出口管中的流体静压的作用。将气泡泵用于金属涂层作业线的熔融金属浴以从管嘴内的镀铝浴表面移除漂浮浮渣，从而防止涂布带上与浮渣相关的缺陷。因此，气泡泵在高质量汽车镀铝薄板生产中是关键的硬件部件。
影响生产成本的主要因素之一是镀铝锅硬件故障。硬件故障中主要是气泡泵(拉力泵)的故障。由碳钢制成的气泡泵的平均使用寿命为8小时至12小时，其导致每月使用35至40个泵(对于2周生产而言)。在生产期间更换碳钢气泡泵导致了生产中断以及熔融金属浴的污染。此外，在碳钢泵更换期间必然使经涂布钢片的“品质”降级(导致了价值较小的产品)。此外，泵更换需要线路停止并重新启动，导致了启动线圈的过度消耗。归因于气泡泵的平均损失大约接近一百万美元/年。气泡泵寿命的增加将显著地减少降级片的量，并且将减少停工期和成本。
因此，本领域需要可以比裸碳钢管泵持续显著更久的用于熔融铝浴的气泡泵。
发明内容
本发明是具有由耐熔融铝侵蚀的材料形成的内部的气泡泵。内部的表面可以由陶瓷形成。陶瓷可选自氧化铝、氧化镁、硅酸盐、碳化硅或石墨及混合物。陶瓷可以是不含碳的85％Al2O3磷酸盐结合可浇注耐火材料。
气泡泵的外部可由碳钢管材形成。气泡泵可由接合到一起的多个管材区段形成。气泡泵可包括3个直管材件和3个弯管材件。多个管材区段可通过受压法兰接头(compression flange joints)接合在一起。受压法兰接头可压紧内部陶瓷材料以使得熔融铝不能渗入接头。耐熔融铝侵蚀的内部的材料的受压法兰接头可在气泡泵的区段之间形成45度角的凸/凹接头(male/female joint)。
附图说明
图1是气泡泵的示意图(未按比例)；以及
图2是气泡泵的件之间的接头的横截面的示意性描绘。
具体实施方式
本发明人试图开发改进泵性能并且显著提高泵的使用寿命(优选至少五天)的方法。对碳钢气泡泵的故障模式进行了广泛的研究。基于结果，本发明人开发了具有浇注陶瓷保护衬里的改良气泡泵。所述改良泵的一个实施方案连续地持续长达167小时(约7天)而没有故障，表明了相对于碳钢泵在熔融铝中通常经验所得的8至12小时的使用寿命具有很大的性能优势。泵设计的改变和浇注耐火衬里的引入是改良的关键因素。
图1是气泡泵未按比例的示意图。所述气泡泵包括：垂直入口部1，使垂直入口1连接到水平件3的弯头2，使水平件3连接到垂直出口件5的另一个弯头4，用于引导包含不想要浮渣的流出金属离开金属浴涂布区的出口弯头。与垂直出口件5相连接的是气体输入管线6。管线6用于将气体注入熔融金属，造成垂直出口支管上的较低压力，导致金属向下流入垂直入口1并且向上/流出垂直出口5。
故障模式分析
U形气泡泵在668℃(1235°F)的温度下在熔化锅中运行。熔体的化学成分通常为Al-9.5％Si-2.4％Fe。泵的入口定位在管嘴内的熔融铝浴中，并且出口定位在管嘴外侧。泵送作用通过氮气鼓泡进入出口侧上泵的垂直支管中产生。环境温度下的氮气以40psi和约120标准立方英尺/小时(scfh，90-150scfh)的流速引入。氮气膨胀产生气泡，其通过出口逸出，同时将液态金属排出。所述排出造成泵两侧之间的压差，产生了允许熔体和漂浮浮渣被吸入入口中的吸力。所述工艺是连续的，从而能够连续地从管嘴内部移除浮渣并排到外面。
在气泡泵中存在三个主要的故障区域，按严重程度的顺序为：1)出口压头(弯头6)内部；2)出口侧上的垂直区段(垂直件5)的氮气入口喷嘴周围；以及3)入口侧上的垂直区段(垂直件1)中部。为了更好地理解故障模式，将工作约12小时后发生故障的常规碳钢泵拆成两半并进行分析。分析示出泵的水平底部是几乎完整的，而入口和出口区段被严重破坏。同样，材料损耗主要发生在气泡泵内部，而外径保持不变。侵蚀程度在泵的不同位置是不同的。
气泡泵的水模型化
本发明人认为泵内的流体动力学影响故障模式。然而，尚未很好地了解影响流体流动的设计因素。为了研究熔体湍流的影响，建立了小的Plexiglas玻璃气泡泵模型(1∶2比例)并使其在水中运行。所述模型允许研究气体压力、入口位置、弯头半径、出口的取向和形状对泵运行和性能的影响。确定了正常运行期间泵中的水流动特征，并且确定了故障泵中观察到的腐蚀和金属损失的位置对应于水模型内湍流的位置。
铝侵蚀的机制
通过金相技术研究碳钢泵中材料损失的机理。铝侵蚀存在几个阶段。在铝与泵接触的第一时刻中，由于液态铝与钢表面之间的反应而导致在内壁上形成了硬且脆性的金属间化合物层。该层基本上限制了铝和铁扩散通过它并且限制了对钢的进一步侵蚀。因此金属间化合物层充当了金属体上的类保护涂层。然而，每当在表面上出现机械应力，该脆性层就产生微裂纹并从钢表面脱落，造成深坑。因为坑的底部不再受金属间化合物层保护，其被熔体侵蚀直至形成新层。当应力继续存在于钢表面上时该过程自身反复发生，因此金属损失将继续增加。侵蚀所涉及的应力可能是在易受影响位置处的熔体湍流和/或外来粒子碰撞的结果。因此侵蚀过程的特征可在于通过液态铝发生动态冲蚀。
因此，运行中的碳钢气泡泵的故障由动态凹陷和磨损(动态冲蚀)产生。侵蚀程度在不同位置是不同的。未暴露于熔体湍流的泵的外表面具有较小损坏，并因此在最少保护的情况下在熔体中存在。熔体侵蚀和金属损失主要从内向外发展。
本发明人确定，可经受住停滞熔体中熔融铝侵蚀的涂层可能在泵中经历的湍流条件下发生故障。在这样的动态条件下，对泵体的较强涂层粘附性对于保护是至关重要的。本发明人还确定，为了改进泵性能，必须将泵的内表面与熔融铝隔离开。所述隔离层必须是粘着的、厚的且连续的。保护层中的任何开口都可导致泵故障。
用于保护性衬里的耐火材料的选择
基于故障研究和水模型化的知识，本发明人开发了新的气泡泵。对于保护性衬里材料的要求为：1)抗液体铝渗透的非润湿材料；2)避免预热的耐热冲击材料；3)耐蚀材料；4)低成本和5)设计灵活性。为了满足所述要求，进行了文献检索和实验室测试。选择不含碳的85％Al2O3磷酸盐结合可浇注耐火材料。
本发明泵的设计
标准碳钢气泡泵的形状包括三个90度弯头区段。复杂的形状使得很难在整个壳体内浇注陶瓷衬里而没有接头。因此，必须将壳体切割为几个区段，分别对各区段进行浇注，随后组装泵。对于每个组装的部分的接头，还必须保持使用期间的完整性。为了解决这些严格的要求，组装泵时使用了下述手段：1)耐火衬里的区段之间独特的45度角凸/凹接头；2)两个法兰接头，以组装泵的三个件，使得陶瓷保护性衬里的接头能够处于受压状态；3)弯头中的连续陶瓷衬里，以减少通过接头的铝侵蚀；以及4)出口区域中的法兰修饰，以使陶瓷衬里处于受压状态。
图2是气泡泵的件之间的接头的横截面的示意性描绘。接头由现有技术气泡泵的碳钢壳体8组成，其各个件衬有耐熔融金属的陶瓷9。彼此相邻接的陶瓷9的末端呈约45度角以允许良好的压紧配合。气泡泵的各部分利用紧固装置11通过法兰接头10受压连接在一起。
使用受压接头以维持保护性衬里接头处于受压状态，从而密封保护性衬里接头以对抗熔融金属渗透。保护性衬里可由耐熔融铝侵蚀的任何材料形成，例如抗熔融金属的非润湿材料。非润湿材料的实例是氧化铝、氧化镁、硅酸盐、碳化硅或石墨以及这些陶瓷材料的混合物。

Claims (10)

1.一种气泡泵，其具有由耐熔融铝侵蚀的材料形成的内部。
2.如权利要求1所述的气泡泵，其中所述内部的表面由陶瓷形成。
3.如权利要求2所述的气泡泵，其中所述内部的表面由选自以下的陶瓷形成：氧化铝、氧化镁、硅酸盐、碳化硅或石墨及混合物。
4.如权利要求2所述的气泡泵，其中所述陶瓷是不含碳的85％Al2O3磷酸盐结合可浇注耐火材料。
5.如权利要求1所述的气泡泵，其中外部由碳钢管材形成。
6.如权利要求1所述的气泡泵，其中所述泵由接合在一起的多个管材区段形成。
7.如权利要求6所述的气泡泵，其中所述多个管材区段包括3个直件和3个弯头件。
8.如权利要求6所述的气泡泵，其中所述多个管材区段通过受压法兰接头接合在一起。
9.如权利要求8所述的气泡泵，其中所述受压法兰接头压紧所述内部的陶瓷材料以使得熔融铝不能渗过所述接头。
10.如权利要求9所述的气泡泵，其中所述耐熔融铝侵蚀的内部的材料的所述受压法兰接头在气泡泵的区段之间形成45度角凸/凹接头。
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