CN106747489B - 一种贫铁矿磁化焙烧回转窑衬砖及其制备方法 - Google Patents

一种贫铁矿磁化焙烧回转窑衬砖及其制备方法 Download PDF

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CN106747489B
CN106747489B CN201611021632.1A CN201611021632A CN106747489B CN 106747489 B CN106747489 B CN 106747489B CN 201611021632 A CN201611021632 A CN 201611021632A CN 106747489 B CN106747489 B CN 106747489B
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张寒
赵惠忠
李静捷
余俊
赵鹏达
陈建威
易萍
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Leling City Rebounding Factory
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Abstract

本发明涉及一种贫铁矿磁化焙烧回转窑衬砖及其制备方法。其技术方案是:以60~65wt%的高纯镁砂颗粒为骨料,以10~15wt%的ρ‑Al2O3微粉、20~25wt%的轻烧镁砂细粉和1~4wt%的三氧化二镍微粉为基质料;按所述骨料的含量和所述基质料的成分及含量进行配料,先将所述基质料混匀,再将混匀后的基质料加入所述骨料中,混匀;然后外加占所述基质料与所述骨料之和5~8wt%的锆溶胶,混匀,振动成型,养护,干燥;最后置于马弗炉中,以3~5℃/min的升温速率升温至1500~1600℃,保温1~2小时,随炉冷却,制得贫铁矿磁化焙烧回转窑衬砖。本发明具有成本低廉和工艺流程简单的特点;所制备的贫铁矿磁化焙烧回转窑衬砖的抗渣侵蚀性强、导热系数小和冷态耐压强度大。

Description

一种贫铁矿磁化焙烧回转窑衬砖及其制备方法
技术领域
本发明属于磁化焙烧回转窑衬砖技术领域。具体涉及一种贫铁矿磁化焙烧回转窑衬砖及其制备方法。
背景技术
贫铁矿是指氧化铁含量较低的铁矿石,一般Fe2O3含量为30~40wt%,甚至更低。贫铁矿中含有大量脉石,在冶炼过程中易产生大量熔渣,且增加燃料消耗,降低设备的生产率。此外,贫铁矿中的脉石含有大量杂质元素,影响钢铁质量。因此,贫铁矿入炉前要进行磁化焙烧预处理(便于铁矿磁选),以提高铁含量、降低脉石含量和减少有害元素。
磁化焙烧回转窑是贫铁矿预处理的重要设备,广泛应用于赤铁矿、菱铁矿、褐铁矿和黄铁矿等弱磁性贫铁矿的焙烧预处理。在磁化焙烧过程中,回转窑内衬因遭受大量低熔相的侵蚀和渗透而容易形成“结圈”(薛生晖,等.“菱褐铁矿回转窑磁化焙烧技术研究现状”,《矿冶工程》,2012,32(z1):pp42~45),严重影响磁化焙烧回转窑的正常运转,这对贫铁矿磁化焙烧回转窑衬砖提出了严格的要求。
目前,贫铁矿磁化焙烧回转窑衬砖主要为“莫来石砖”和“莫来石-碳化硅浇注料/预制件”(付向辉,等.“大型工业磁化焙烧回转窑结圈研究及预防控制”,《有色金属(选矿部分)》,2013,(z1):pp236~239)。
采用莫来石砖作为贫铁矿磁化焙烧回转窑衬砖,不仅耐火度高,且具有良好的机械力学性能(耐磨损)和抗化学腐蚀性能,但莫来石砖在高温条件下易与熔渣中的CaO、SiO2等成分发生反应,被熔渣消耗,降低了莫来石砖的使用寿命。
采用莫来石-碳化硅浇注料/预制件作为贫铁矿磁化焙烧回转窑衬砖,虽其高温力学和热学性能优良,尤其SiC的引入增强了衬砖的抗熔渣侵蚀和抗冲刷性能,但莫来石-碳化硅浇注料/预制件的导热系数大,增大了贫铁矿磁化焙烧回转窑窑体的热散失,导致回转窑筒体温度偏高而变形,且SiC的氧化也影响了贫铁矿磁化焙烧回转窑衬砖的使用寿命。
此外,莫来石、碳化硅等耐火原料成本较高,莫来石-碳化硅质耐火材料的制备工艺复杂(尤其SiC的抗氧化工艺),这更加增大了贫铁矿磁化焙烧回转窑衬砖的开发成本。
发明内容
本发明旨在克服现有技术缺陷,目的是提供一种工艺简单和成本低廉的贫铁矿磁化焙烧回转窑衬砖的制备方法,用该方法制备的贫铁矿磁化焙烧回转窑衬砖的抗渣侵蚀性强、导热系数小和冷态耐压强度大。
为实现上述目的,本发明采用的技术方案是:以60~65wt%的高纯镁砂颗粒为骨料,以10~15wt%的ρ-Al2O3微粉、20~25wt%的轻烧镁砂细粉和1~4wt%的三氧化二镍微粉为基质料;按所述骨料的含量和所述基质料的成分及含量进行配料,先将所述基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;然后外加占所述基质料与所述骨料之和5~8wt%的锆溶胶,混合均匀,振动成型,25~30℃条件下养护12~24小时,在180~200℃条件下干燥12~18小时;最后置于马弗炉中,以3~5℃/min的升温速率升温至1500~1600℃,保温1~2小时,随炉冷却,制得贫铁矿磁化焙烧回转窑衬砖。
所述高纯镁砂颗粒的主要化学成分是:MgO含量≥97wt%,SiO2含量≤1wt%;高纯镁砂颗粒的粒度为0.1~5mm。
所述ρ-Al2O3微粉的Al2O3含量≥98wt%;ρ-Al2O3微粉的粒度为60~80μm。
所述轻烧镁砂细粉的MgO含量≥97wt%;轻烧镁砂细粉的粒度为60~80μm。
所述三氧化二镍微粉的Ni2O3含量≥99wt%;三氧化二镍微粉的粒度为60~80μm。
所述锆溶胶的ZrO2含量为15~20wt%。
由于采取上述技术方案,本发明与现有技术相比具有如下积极效果:
1、本发明所用原料成本低廉,无需特殊的制备设备和处理技术,节省劳动力资源,工艺流程简单。
2、本发明通过烧成过程中原位形成尖晶石固溶体,增强了贫铁矿磁化焙烧回转窑衬砖的致密度,进而提高了材料的抗渣侵蚀性和冷态耐压强度。
3、本发明利用原料组分的分解反应造孔,并结合溶胶胶粒的表面效应对材料内的气孔尺寸微细化,进而降低了贫铁矿磁化焙烧回转窑衬砖的导热系数。
本发明所制备的贫铁矿磁化焙烧回转窑衬砖经测定:1500℃×3h静态坩埚法抗渣实验侵蚀指数为1~6%;导热系数(500℃温度条件下测定)为7.2~7.7W/(m·K);冷态耐压强度为70~75MPa。
因此,本发明具有成本低廉和工艺流程简单的特点;所制备的贫铁矿磁化焙烧回转窑衬砖的抗渣侵蚀性强、导热系数小和冷态耐压强度大。
具体实施方式
下面结合具体实施方式对本发明作进一步的描述,并非对其保护范围的限制。
为避免重复,先将本具体实施方式中所涉及的骨料、基质料和硅溶胶统一描述如下,实施例中不再赘述:
所述高纯镁砂颗粒的主要化学成分是:MgO含量≥97wt%,SiO2含量≤1wt%;高纯镁砂颗粒的粒度为0.1~5mm。
所述ρ-Al2O3微粉的Al2O3含量≥98wt%;ρ-Al2O3微粉的粒度为60~80μm。
所述轻烧镁砂细粉的MgO含量≥97wt%,轻烧镁砂细粉的粒度为60~80μm。
所述三氧化二镍微粉的Ni2O3含量≥99wt%,三氧化二镍微粉的粒度为60~80μm。
所述锆溶胶的ZrO2含量为15~20wt%。
实施例1
一种贫铁矿磁化焙烧回转窑衬砖及其制备方法。以60~62wt%的高纯镁砂颗粒为骨料,以10~12wt%的ρ-Al2O3微粉、23~25wt%的轻烧镁砂细粉和1~3wt%的三氧化二镍微粉为基质料;按所述骨料的含量和所述基质料的成分及含量进行配料,先将所述基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;然后外加占所述基质料与所述骨料之和5~7wt%的锆溶胶,混合均匀,振动成型,25~30℃条件下养护12~24小时,在180~200℃条件下干燥12~18小时;最后置于马弗炉中,以3~5℃/min的升温速率升温至1500~1600℃,保温1~2小时,随炉冷却,制得贫铁矿磁化焙烧回转窑衬砖。
本实施例所制备的贫铁矿磁化焙烧回转窑衬砖经测定:1500℃×3h静态坩埚法抗渣实验侵蚀指数为1~3%;导热系数(500℃温度条件下测定)为7.2~7.4W/(m·K);冷态耐压强度为70~72MPa。
实施例2
一种贫铁矿磁化焙烧回转窑衬砖及其制备方法。以61~63wt%的高纯镁砂颗粒为骨料,以11~13wt%的ρ-Al2O3微粉、22~24wt%的轻烧镁砂细粉和1~3wt%的三氧化二镍微粉为基质料;按所述骨料的含量和所述基质料的成分及含量进行配料,先将所述基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;然后外加占所述基质料与所述骨料之和5~7wt%的锆溶胶,混合均匀,振动成型,25~30℃条件下养护12~24小时,在180~200℃条件下干燥12~18小时;最后置于马弗炉中,以3~5℃/min的升温速率升温至1500~1600℃,保温1~2小时,随炉冷却,制得贫铁矿磁化焙烧回转窑衬砖。
本实施例所制备的贫铁矿磁化焙烧回转窑衬砖经测定:1500℃×3h静态坩埚法抗渣实验侵蚀指数为2~4%;导热系数(500℃温度条件下测定)为7.3~7.5W/(m·K);冷态耐压强度为71~73MPa。
实施例3
一种贫铁矿磁化焙烧回转窑衬砖及其制备方法。以62~64wt%的高纯镁砂颗粒为骨料,以12~14wt%的ρ-Al2O3微粉、21~23wt%的轻烧镁砂细粉和2~4wt%的三氧化二镍微粉为基质料;按所述骨料的含量和所述基质料的成分及含量进行配料,先将所述基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;然后外加占所述基质料与所述骨料之和6~8wt%的锆溶胶,混合均匀,振动成型,25~30℃条件下养护12~24小时,在180~200℃条件下干燥12~18小时;最后置于马弗炉中,以3~5℃/min的升温速率升温至1500~1600℃,保温1~2小时,随炉冷却,制得贫铁矿磁化焙烧回转窑衬砖。
本实施例所制备的贫铁矿磁化焙烧回转窑衬砖经测定:1500℃×3h静态坩埚法抗渣实验侵蚀指数为3~5%;导热系数(500℃温度条件下测定)为7.4~7.6W/(m·K);冷态耐压强度为72~74MPa。
实施例4
一种贫铁矿磁化焙烧回转窑衬砖及其制备方法。以63~65wt%的高纯镁砂颗粒为骨料,以13~15wt%的ρ-Al2O3微粉、20~22wt%的轻烧镁砂细粉和2~4wt%的三氧化二镍微粉为基质料;按所述骨料的含量和所述基质料的成分及含量进行配料,先将所述基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;然后外加占所述基质料与所述骨料之和6~8wt%的锆溶胶,混合均匀,振动成型,25~30℃条件下养护12~24小时,在180~200℃条件下干燥12~18小时;最后置于马弗炉中,以3~5℃/min的升温速率升温至1500~1600℃,保温1~2小时,随炉冷却,制得贫铁矿磁化焙烧回转窑衬砖。
本实施例所制备的贫铁矿磁化焙烧回转窑衬砖经测定:1500℃×3h静态坩埚法抗渣实验侵蚀指数为4~6%;导热系数(500℃温度条件下测定)为7.5~7.7W/(m·K);冷态耐压强度为73~75MPa。
本具体实施方式与现有技术相比具有如下积极效果:
1、本具体实施方式所用原料成本低廉,无需特殊的制备设备和处理技术,节省劳动力资源,工艺流程简单。
2、本具体实施方式通过烧成过程中原位形成尖晶石固溶体,增强了贫铁矿磁化焙烧回转窑衬砖的致密度,进而提高了材料的抗渣侵蚀性和冷态耐压强度。
3、本具体实施方式利用原料组分的分解反应造孔,并结合溶胶胶粒的表面效应对材料内的气孔尺寸微细化,进而降低了贫铁矿磁化焙烧回转窑衬砖的导热系数。
本具体实施方式所制备的贫铁矿磁化焙烧回转窑衬砖经测定:1500℃×3h静态坩埚法抗渣实验侵蚀指数为1~6%;导热系数(500℃温度条件下测定)为7.2~7.7W/(m·K);冷态耐压强度为70~75MPa。
因此,本具体实施方式具有成本低廉和工艺流程简单的特点;所制备的贫铁矿磁化焙烧回转窑衬砖的抗渣侵蚀性强、导热系数小和冷态耐压强度大。

Claims (5)

1.一种贫铁矿磁化焙烧回转窑衬砖的制备方法,其特征在于以60~65wt%的高纯镁砂颗粒为骨料,以10~15wt%的ρ-Al2O3微粉、20~25wt%的轻烧镁砂细粉和1~4wt%的三氧化二镍微粉为基质料;按所述骨料的含量和所述基质料的成分及含量进行配料,先将所述基质料混匀,再将混匀后的基质料加入所述骨料中,混合均匀;然后外加占所述基质料与所述骨料之和5~8wt%的锆溶胶,混合均匀,振动成型,25~30℃条件下养护12~24小时,在180~200℃条件下干燥12~18小时;最后置于马弗炉中,以3~5℃/min的升温速率升温至1500~1600℃,保温1~2小时,随炉冷却,制得贫铁矿磁化焙烧回转窑衬砖;
所述ρ-Al2O3微粉的Al2O3含量≥98wt%;ρ-Al2O3微粉的粒度为60~80μm;
所述三氧化二镍微粉的Ni2O3含量≥99wt%;三氧化二镍微粉的粒度为60~80μm。
2.根据权利要求1所述的贫铁矿磁化焙烧回转窑衬砖的制备方法,其特征在于所述高纯镁砂颗粒的主要化学成分是:MgO含量≥97wt%,SiO2含量≤1wt%;高纯镁砂颗粒的粒度为0.1~5mm。
3.根据权利要求1所述的贫铁矿磁化焙烧回转窑衬砖的制备方法,其特征在于所述轻烧镁砂细粉的MgO含量≥97wt%;轻烧镁砂细粉的粒度为60~80μm。
4.根据权利要求1所述的贫铁矿磁化焙烧回转窑衬砖的制备方法,其特征在于所述锆溶胶的ZrO2含量为15~20wt%。
5.一种贫铁矿磁化焙烧回转窑衬砖,其特征在于所述贫铁矿磁化焙烧回转窑衬砖是根据权利要求1~4项中任一项所述的贫铁矿磁化焙烧回转窑衬砖的制备方法所制备的贫铁矿磁化焙烧回转窑衬砖。
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