CN107043247B - 一种高温膏状密封垫子及其制备方法 - Google Patents
一种高温膏状密封垫子及其制备方法 Download PDFInfo
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- 238000007789 sealing Methods 0.000 title claims abstract description 26
- 238000002360 preparation method Methods 0.000 title abstract description 6
- 239000000843 powder Substances 0.000 claims abstract description 35
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 32
- 239000010431 corundum Substances 0.000 claims abstract description 22
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 19
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims abstract description 18
- 239000003292 glue Substances 0.000 claims abstract description 17
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 17
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- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 claims abstract description 15
- 239000006229 carbon black Substances 0.000 claims abstract description 15
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims abstract description 15
- 239000010443 kyanite Substances 0.000 claims abstract description 15
- 229910052850 kyanite Inorganic materials 0.000 claims abstract description 15
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- 229920005551 calcium lignosulfonate Polymers 0.000 claims abstract description 11
- RYAGRZNBULDMBW-UHFFFAOYSA-L calcium;3-(2-hydroxy-3-methoxyphenyl)-2-[2-methoxy-4-(3-sulfonatopropyl)phenoxy]propane-1-sulfonate Chemical compound [Ca+2].COC1=CC=CC(CC(CS([O-])(=O)=O)OC=2C(=CC(CCCS([O-])(=O)=O)=CC=2)OC)=C1O RYAGRZNBULDMBW-UHFFFAOYSA-L 0.000 claims abstract description 11
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- 238000000034 method Methods 0.000 claims description 11
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 16
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 15
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- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- RWDBMHZWXLUGIB-UHFFFAOYSA-N [C].[Mg] Chemical compound [C].[Mg] RWDBMHZWXLUGIB-UHFFFAOYSA-N 0.000 description 1
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- 229910052782 aluminium Inorganic materials 0.000 description 1
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
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- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 1
- 239000010421 standard material Substances 0.000 description 1
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Abstract
本发明公开一种高温膏状密封垫子及其制备方法,按重量百分含量计,包含以下组份:棕刚玉60%~65%、活性α‑Al2O3微粉5%~8%、苏州土5%~8%、烧结莫来石3%~5%、蓝晶石5%~8%、碳黑6%~10%、硅微粉2%~5%、木质磺酸钙3%~5%、甲基纤维素1%~2%;用高温胶水和硅溶胶将上述的各组份调制成膏状。该垫子抗侵蚀性好、粘结性强、塑性强、不易高温烧结,易清理、易保存,存放周期长、使用时无粉尘,对人体无害、易套补、耐高温、密封性能强、使用方便、性价比高、适应市场需求。
Description
技术领域:
本发明属于耐火材料领域,涉及一种以氧化铝(Al2O3、C、SiO2)为基料的耐火材料,尤其涉及一种高温膏状密封垫子及其制备方法。
技术背景:
目前,随着国内高效连铸技术的不断普及,滑动水口的使用寿命也在不断延长,钢包滑板的寿命已经由原来的1次~2次延长至3次~8次,较好地满足了连铸生产的需要。但是上水口的热修更换仍需要较长的时间,在钢厂操作环境恶劣的的情况下,操作工劳动强度较大。因此,延长上水口的使用寿命,减少上水口更换次数,缩短上水口的更换时间,可以有效提高钢包的周转效率,节省炼钢吨钢耐材成本,进而达到节省吨钢成本的目的。
根据现场上水口使用情况,上水口在清理过程中的损耗明显大于耐材自身的侵蚀情况。根据此种情况,尽量避免上水口在清理过程中的损耗,可以有效延长上水口的使用寿命。因此生产一种易于清理、用量均一、存放时间足够长的新型高温膏状密封垫子势在必行。
目前现有的上滑板和上水口的接缝火泥多以磷酸盐、水或水玻璃结合的刚玉-碳质、刚玉-铬质或高铝质火泥和卤水结合的纯镁质或镁碳质火泥。这些类型的火泥在使用过程中普遍存在着以下几种缺点:一是抗侵蚀性能差,使用过程中易发生夹钢情况。二是每批次的使用过程调整火泥塑性和黏稠度存在着不稳定性。
在加入结合剂环节,加入量的多少大多依赖于操作工的经验,并且随着存放时间的长短,火泥的状态也存在着较大差别,完全凭经验判断。同时,在火泥的使用量上,用量也没有一定的参照标准。然而,如果火泥使用量较少,可能会导致穿钢事故;用量过多,则会造成多余的火泥进入机构模腔,造成滑板面压失衡,进而出现滑板断裂或滑板面之间夹钢或穿钢事故。三是烧结性过强,造成用后黏接上水口不易清理,清理过程中导致上水口机械损坏严重;由于收缩较大,易造成滑板和上水口之间出现夹钢和穿钢事故。
目前国内许多钢厂在更换上水口和上滑板时,接缝料与水口座砖、透气砖、滑动水口砖本体发生烧结反应,接缝料不易剥落,操作工在高温下长时间用撬棍一点点的清除,或者用风镐打碎,一点一点的拆除,在用风镐拆打上水口砖和接缝料时,风镐头经常滑落到座砖一侧,伤击座砖,使座砖扩径,座砖与上水口砖之间缝隙增大,导致钢水渗入缝隙,而不得提前下包,影响钢包的使用寿命,处理不及时还会发生上水口周围漏钢事故。同时有的钢厂采用冷水浇在机构和上水口里面,用极冷极热的方式清除已发生烧结的接缝料,这种方式导致机构变形,上水口炸裂。因此需要提供一种新的高温膏状密封垫子,以解决现有的接缝料不环保,对人体有害,施工不方便,粘结性不强,易高温烧结,不易清理,不易套补等技术问题。
发明内容:
本发明的目的在于提供一种高温膏状密封垫子。
本发明的另一目的在于提供一种高温膏状密封垫子及其制备方法。
本发明的目的通过以下技术方案实现:
一种高温膏状密封垫子,按重量百分含量计,包含以下组份:棕刚玉60%~65%、活性α-Al2O3微粉5%~8%、苏州土5%~8%、烧结莫来石3%~5%、蓝晶石5%~8%、碳黑6%~10%、硅微粉2%~5%、木质磺酸钙3%~5%、甲基纤维素1%~2%,上述配方中,所有组分重量之和为100%;用高温胶水和硅溶胶将上述的各组份调制成膏状。
优选的:按重量计,所述高温胶水的用量占所述各组份总量的2%~4%;所述硅溶胶的用量占所述各组份总量的16%~18%。
上述各组份的颗粒级配为:棕刚玉为(70~120目、120~0目、200~0目、320~0目),活性α-Al2O3微粉的粒径≤2um,苏州土200~600目,烧结莫来石180~300目,蓝晶石35~120目,碳黑为N220型,硅微粉的粒径≤2um。进一步优选的:所述各组份的颗粒级配为:棕刚玉为(70~120目、120~0目、200~0目、320~0目),活性α-Al2O3微粉的粒径1um,苏州土200目,烧结莫来石200目,蓝晶石80目,碳黑为N220型,92硅微粉的粒径1um。
按重量百分含量计,所述棕刚玉的粒度级配为:
进一步优选的,所述棕刚玉的粒度级配为:
上述的硅微粉为95或92硅微粉。
上述的高温膏状密封垫子,所述的高温胶水、硅溶胶为液体做为粘结剂使用,2种粘结剂按不同比例配合使用。
上述的高温膏状密封垫子中各组分的质量标准优选为:
所述的棕刚玉:Al2O3≥92%、Fe2O3≤1.5%;
活性α-Al2O3微粉:Al2O3≥99%、Fe2O3≤0.2%;
苏州土:Al2O3 36%~38%、SiO2 45%~48%、Fe2O3≤1.0%;
烧结莫来石:Al2O3≥70%、Fe2O3≤1.0;
蓝晶石:Al2O3 50%~55%、Fe2O3≤1.0%;
碳黑为N220型:C≥95%;
92硅微粉:SiO2≥92%
木质磺酸钙:木质素50.0%~65.0%、pH值4~6;
甲基纤维素:甲氧基含量26%~33%,水不溶物≤2.0%
更进一步有选为:
所述的棕刚玉:Al2O3≥92%、Fe2O3≤1.5%、体密≥3.9克/立方厘米;
活性a-Al2O3微粉:Al2O3≥99%、Fe2O3≤0.2%、体密≥3.95克/立方厘米;
苏州土:Al2O3 36%~38%、SiO2 45%~48%、Fe2O3≤1.0%;
烧结莫来石:Al2O3≥70%、Fe2O3≤1.0;
蓝晶石:Al2O3 50%~55%、Fe2O3≤1.0%、线变化(1450℃×2H)>12%;
碳黑为N220型:C≥95%;
92硅微粉:SiO2≥92%;
木质磺酸钙:木质素50.0%~65.0%、pH值4~6;
甲基纤维素:甲氧基含量26%~33%,水不溶物≤2.0%
高温胶水:无机陶瓷材料和改性固化剂组成的双组分耐1730℃高温胶粘剂,固化后无收缩,具有优异的耐超高温、阻烧、耐磨、耐油、耐酸碱等性能。
硅溶胶:SiO2 25%~26%、Na2O≤0.30%、pH值8.5~10。
一般的原料也可以实现本发明的目的,但是高质量标准的原料有助于进一步提高高温膏状密封垫子的质量。
上述高温膏状密封垫子的制备方法,按比例将活性α-Al2O3微粉、苏州土、烧结莫来石、蓝晶石、碳黑、硅微粉、木质磺酸钙、甲基纤维素混合均匀,然后按比例加硅溶胶混合均匀,再按比例投入棕刚玉继续搅拌均匀,然后加入高温胶水搅拌后成膏状待加工成规定的外形尺寸。
具体制备方法为:按比例将活性α-Al2O3微粉、苏州土、烧结莫来石、蓝晶石、碳黑、硅微粉、木质磺酸钙、甲基纤维素的混合物用搅拌机搅拌混合10~30分钟,待粉料混合粉颜色呈黑色后,将硅溶胶倒入搅拌机混合5~20分钟,将按照颗粒级配配好的棕刚玉投入搅拌机内继续搅拌,5~20分钟后加入高温胶水,接着搅拌2~10分钟成膏状,,根据用户规定尺寸加工成垫子。
本发明高温膏状密封垫子由2种不同的结合剂共同完成,分别是高温胶水、硅溶胶。其结合原理:高温胶水属于无机陶瓷材料和改性固化剂组成的双组分耐1730℃高温胶粘剂,固化后无收缩,具有优异的耐超高温、阻烧、耐磨、耐油、耐酸碱等性能,主要用于高温工况下工作的设备、部件的粘接和灌封。硅溶胶:用着各种无机材料的粘结剂,具有粘结力强、耐高温(1500℃~1600℃)等特点,与其它物质混合时分散性和渗透性都非常好,当硅溶胶水份蒸发时,胶体粒子牢固地附着在物体表面,粒子间形成硅氧结合,是性能优良的粘结剂。
在高温膏状密封垫子的设计制作过程中,最主要的一个因素为结合剂的选择,它要求可以长期存放且不变硬不开裂,保存时间不能短于3个月。因此在结合剂的选择上,研究人员分别试验了沥青、水泥、水玻璃、磷酸铝,最终选择硅溶胶和高温胶水,不仅解决了搅拌问题,同时解决了存放时间短的问题,存放时间达到了4~6个月。
塑性的调节:为了使配方原料塑性达到最好,首先,发明人员对颗粒粒度级配进行了试验。为了较明显地对比出塑性的好坏,暂时使用硅溶胶作为结合剂进行试验,其中分别对比了180目、320目棕刚玉细粉以及两种复合结合剂加入的情况,最后通过颗粒级配公式计算和试验实际相结合,选出最佳的粒度级配。将粒度级配调整前生产的垫子放置2周后折叠,可见折叠后火泥垫表面粗糙空隙多且开裂现象严重。将粒度级配调整后生产的火泥垫存放时间2周后折叠,可见折叠后火泥垫表面光滑且没有裂纹现象出现。由此可见,粒度级配调整后,火泥垫的塑性得到明显改善,开裂的现象得到有效控制。
除特别说明外,本发明所涉及的原料均可以通过市场购买获得。
本发明的有益效果:
(1)抗侵蚀性好;(2)粘结性强;(3)塑性强;(4)不易高温烧结,易清理;(5)易保存,存放周期长;(6)环保,使用时无粉尘,对人体无害;(7)易套补;(8)使用方便,适应市场需求;(9)具有显著的经济效益;(10)耐高温;(11)密封性能强;(12)性价比高。
将按照上述工艺配方生产的垫子在江苏某钢厂100吨钢包(滑板使用6次)进行了大批量使用和河南某钢厂120吨钢包(滑板使用3次)进行了大批量应用。两个钢厂通过高温膏状密封垫子的应用,有效地减少了清理上水口和上滑板接缝处火泥造成的不必要的机械损毁,使得两钢厂上水口使用寿命分别由9次~13次延长至17次~22次和由17次~26次延长至20次~30次,同时大大降低了工人的劳动强度,在降低了火泥的消耗量同时,还提高了现场的安全操作系数。
具体实施方式:
原料规格如下:
棕刚玉:Al2O3≥92%、Fe2O3≤1.5%、体密≥3.9克/立方厘米;
活性a-Al2O3微粉:Al2O3≥99%、Fe2O3≤0.2%、体密≥3.95克/立方厘米;
苏州土:Al2O3 36%~38%、SiO2 45%~48%、Fe2O3≤1.0%;
烧结莫来石:Al2O3≥70%、Fe2O3≤1.0;
蓝晶石:Al2O3 50%~55%、Fe2O3≤1.0%、线变化(1450℃×2H)>12%;
碳黑为N220型:C≥95%;
92硅微粉:SiO2≥92%;
木质磺酸钙:木质素50.0%~65.0%、pH值4~6;
甲基纤维素:甲氧基含量26%~33%,水不溶物≤2.0%
高温胶水:无机陶瓷材料和改性固化剂组成的双组分耐1730℃高温胶粘剂,固化后无收缩,具有优异的耐超高温、阻烧、耐磨、耐油、耐酸碱等性能。
硅溶胶:SiO2 25%~26%、Na2O≤0.30%、pH值8.5~10。
以上原料均可以市场购买获得。
实施例1:
棕刚玉经破碎筛分后按表1中的配方进行配料,按表2的配料将活性α-Al2O3微粉、苏州土、烧结莫来石、蓝晶石、碳黑、92硅微粉、木质磺酸钙、甲基纤维素的混合物经行星式搅拌机混合15分钟,待粉料混合粉颜色呈黑色后,将硅溶胶倒入搅拌机混合10分钟,将按照颗粒级配配好的棕刚玉投入搅拌机内继续搅拌,10分钟后加入高温胶水,接着搅拌5分钟成膏状即可,对成品火泥做理化检测,然后根据用户规定尺寸加工成垫子,检测合格后包装发货。表2中有3个配方,其中配方1、配方2和配方3中棕刚玉的颗粒级配依次分别为表1中的颗粒级配1、颗粒级配2和颗粒级配3。
表1棕刚玉的颗粒级配
规格 | 颗粒级配1(%) | 颗粒级配2(%) | 颗粒级配3(%) |
70~120目 | 6 | 7 | 9 |
120~0目 | 9 | 10 | 9 |
200~0目 | 11 | 13 | 16 |
320~0目 | 74 | 70 | 66 |
表2:配方1、2、3中各组分的百分含量
表3按照表2中配方1、2、3所制得的产品的理化测试指标对照表
根据表3中的检验结果可知:以上3个配方都能正常使用,其中以配方2效果最为显著。使用结果显示:该垫子抗侵蚀性好、粘结性强、塑性强、不易高温烧结,易清理、易保存,存放周期长、使用时无粉尘,对人体无害、易套补、耐高温、密封性能强、使用方便、性价比高、适应市场需求。
Claims (6)
1.一种高温膏状密封垫子,其特征在于:按重量百分含量计,由以下组分组成:棕刚玉60%~65%、活性α-Al2O3微粉5%~8%、苏州土5%~8%、烧结莫来石3%~5%、蓝晶石5%~8%、碳黑6%~10%、硅微粉2%~5%、木质磺酸钙3%~5%、甲基纤维素1%~2%;用高温胶水和硅溶胶将上述的各组分调制成膏状;所述的高温胶水为由无机陶瓷材料和改性固化剂组成的双组分耐1730℃高温胶粘剂;
按重量计,所述高温胶水的用量占所述各组分总量的2%~4%;所述硅溶胶的用量占所述各组分总量的16%~18%;
所述各组分的颗粒级配为:棕刚玉为70~120目、120~0目、200~0目、320~0目,活性α-Al2O3微粉的粒径≤2um, 苏州土200~600目,烧结莫来石180~300目,蓝晶石35~120目,碳黑为N220型,硅微粉的粒径≤2um;
按重量百分含量计,所述棕刚玉的粒度级配为:
70~120目 5%~10%
120~0目 8%~14%
200~0目 10%~16%
320~0目 65%~75%。
2.根据权利要求1所述的高温膏状密封垫子,其特征在于:所述各组分的颗粒级配为:活性α-Al2O3微粉的粒径1um, 苏州土200目,烧结莫来石200目,蓝晶石80目,碳黑为N220型,92硅微粉的粒径1um。
3.根据权利要求1所述的高温膏状密封垫子,其特征在于:所述棕刚玉的粒度级配为:
70~120目 7%
120~0目 10%
200~0目 13%
320~0目 70%。
4.根据权利要求1所述的高温膏状密封垫子,其特征在于:所述的硅微粉为95或92硅微粉。
5.权利要求1~4中任一所述高温膏状密封垫子的制备方法,其特征在于:按比例将活性α-Al2O3微粉、苏州土、烧结莫来石、蓝晶石、碳黑、硅微粉、木质磺酸钙、甲基纤维素混合均匀,然后按比例加硅溶胶混合均匀,再按比例投入棕刚玉继续搅拌均匀,然后加入高温胶水搅拌后成膏状待加工成规定的外形尺寸。
6.根据权利要求5所述的方法,其特征在于:按比例将活性α-Al2O3微粉、苏州土、烧结莫来石、蓝晶石、碳黑、硅微粉、木质磺酸钙、甲基纤维素的混合物用搅拌机搅拌混合10~30分钟,待粉料混合粉颜色呈黑色后,将硅溶胶倒入搅拌机混合5~20分钟,将按照颗粒级配配好的棕刚玉投入搅拌机内继续搅拌,5~20分钟后加入高温胶水,接着搅拌2~10分钟成膏状,根据用户规定尺寸加工成垫子。
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