CN107162613A - 一种环保型高炉铁沟料及其制备方法 - Google Patents

一种环保型高炉铁沟料及其制备方法 Download PDF

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CN107162613A
CN107162613A CN201710401766.4A CN201710401766A CN107162613A CN 107162613 A CN107162613 A CN 107162613A CN 201710401766 A CN201710401766 A CN 201710401766A CN 107162613 A CN107162613 A CN 107162613A
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blast furnace
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徐华
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Changxin Huayue Refractory Material Factory
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Abstract

本发明提供了一种环保型高炉铁沟料及其制备方法，所述环保型高炉铁沟料由以下重量份的原料制成：刚玉粉30～60份，二氧化硅15～30份，碳化硅40～55份，远红外陶瓷粉0.5～2份，生物质衍生炭材料3～9份和结合剂0.5～1.5份。本发明以生物质衍生炭材料替代沥青，实现了原料的可再生性以及资源的有效利用；加入远红外陶瓷粉作为活性材料，有效提高了高炉铁沟料的耐高温和热震稳定性；生产工序简单，原料价格低廉，大大降低了生产成本。

Description

一种环保型高炉铁沟料及其制备方法
技术领域
本发明涉及耐火材料技术领域，尤其涉及一种耐高温和高热震稳定性的环保型高炉铁沟料及其制备方法。
背景技术
在资源、环境日益成为制约我国耐火材料行业发展的“瓶颈”，经济和市场发展形势发生变化的情况下，耐火材料行业的发展之路面临着多重考验和挑战。出铁沟是高温铁水和熔渣流经的通道，对日常高炉炼铁的顺行起者至关重要的作用。高炉铁沟料作为出铁沟重要的耐火材料，直接受到铁水和熔渣的高温冲刷和化学腐蚀，同时还受到温度的急冷急热的变化，这就需要高炉铁沟料具有较强的耐高温和热震稳定性等性能。然而，高炉铁沟料的作业现场常产生烟尘和难闻的气味，环境及其恶劣，危害工人的健康，不利于环保。造成该结果的主要原因为：沥青原料比其它碳原料更富有亲水性，而且分散性也优越，大部分的高炉铁沟料使用沥青作为主要原料，但沥青原料通过煤干馏获得的煤系沥青含有苯并芘等致癌性的污染环境物质，在热态施工和干燥升温中，高炉铁沟料的沥青原料中的挥发分气化，并产生烟尘和难闻的气味。
中国专利文献上公开了一种“高炉铁钩浇注料及其制备方法”，其公告号为CN105000898A，该发明由刚玉粉、碳化硅粉、粘土、水泥、α-Al2O3、二氧化硅、三聚磷酸钠、铝粉、有机纤维、高铝粉煤灰制成，在保证浇注料满足要求的同时，降低了成本。但是该发明虽然成本较低，但是其各项指标性能并没有检测，同时也没有解决污染问题。因此，如何加大新技术、环保原料在高炉铁沟料设计和制造过程中的应用，在不降低铁沟料性能的前提下，实现无沥青化是本领域技术人员亟待解决的问题。
发明内容
本发明为了克服传统的高炉铁沟料成份对环境造成污染的问题，提供了一种耐高温和高热震稳定性的环保型高炉铁沟料。
本发明还提供了一种工艺简单的环保型高炉铁沟料的制备方法。
为了实现上述目的，本发明采用以下技术方案：
一种环保型高炉铁沟料，所述环保型高炉铁沟料由以下重量份的原料制成：刚玉粉30～60份，二氧化硅15～30份，碳化硅40～55份，远红外陶瓷粉0.5～2份，生物质衍生炭材料3～9份和结合剂0.5～1.5份。
本发明采用生物质衍生炭材料替代传统的不可再生的碳素材料作为原料，生物质衍生炭材料是以原始生物质(树叶、茎杆、果壳)，生物质衍生物(纤维素、木质素、半纤维素、蛋白质、二糖、单糖)为原料经过煅烧热解处理，经活化剂活化后得到的生物材料，利用生物质原料制备各种碳材料，可以降低碳材料生产成本，实现碳材料的可持续发展。
远红外陶瓷粉能够辐射出比正常物体更多的远红外线(红外辐射率更高)，具有活化功能。本发明在配方组分中加入少量的远红外陶瓷粉，通过分子间的协同作用，增加材料的活性，可以提高高炉铁沟料的耐高温和抗渗透性。
作为优选，所述远红外陶瓷粉由以下重量份的原料组成：0.1～0.8份的MgO，0.05～1份的Al2O3，0.2～0.5份的TiO2，0.06～0.2份的ZrO2和0.04～0.4份的Fe2O3。
作为优选，所述生物质衍生炭材料为生物质活性碳纤维、生物质碳分子筛和生物质基活性炭中的一种或几种。
作为优选，所述碳化硅的粒径小于0.088mm。
作为优选，所述结合剂为T60含碳树脂和酚醛树脂粉，所述T60含碳树脂和所述酚醛树脂粉质量比为1：(2～4)。
作为优选，所述酚醛树脂粉的粒径为0.088～0.1mm。
本发明使用了T60含碳树脂和酚醛树脂为结合剂，使用过程不产生有害烟气，具有环保特性。具体的，T60含碳树脂在200℃以下仍可以保持较好的流动性，而酚醛树脂在200℃以下时就开始发生固化，固化速率较快，二者在适当比例下使用可获得较好的挤压深度。此外，T60含碳树脂高温固化后，会在形成“蘑菇状”泥包，增大高炉铁沟料的附着面积，提高了高炉铁沟料的耐冲刷性能，从而延长使用寿命。
一种环保型高炉铁沟料的制备方法，包括以下步骤：
(1)按上述重量份分别称取刚玉粉，二氧化硅，碳化硅，远红外陶瓷粉和生物质衍生炭材料混合搅拌均匀，得到预制混合粉；
(2)称取上述重量份结合剂，先将1/2的结合剂加入到步骤(1)得到的预制混合粉中，混合均匀后，再加入剩余的结合剂，混合均匀得到混合粉；
(3)对步骤(2)中的混合粉进行出料、成型，在115～135MPa下压实，保压时间2～4min；
(4)将步骤(3)中成型后的耐火材料经110～120℃干燥10～18h后，埋于装有4～8mm粒度焦炭的匣钵中在1400～1600℃下保温3～5h，冷却后得到环保型高炉铁沟料。
结合剂分两次加入有利于充分混合，使得制备的高炉铁沟料的稳定性好。
本发明具有如下有益效果：
(1)以生物质衍生炭材料替代沥青，实现了原料的可再生性以及资源的有效利用；
(2)加入远红外陶瓷粉作为活性材料，有效提高了高炉铁沟料的耐高温和热震稳定性；
(2)该环保型高炉铁沟料的生产工序简单，原料价格低廉，大大降低了生产成本。
具体实施方式
下面通过具体实施例，对本发明的技术方案作进一步具体的说明。
在本发明中，若非特指，所有设备和原料均可从市场购得或是本行业常用的，下述实施例中的方法，如无特别说明，均为本领域常规方法。
实施例1
(1)分别称取刚玉粉30g，二氧化硅15g，碳化硅(粒径＜0.088mm)40g，远红外陶瓷粉0.5g(0.1g的MgO，0.1g的Al2O3，0.2g的TiO2，0.06g的ZrO2，0.04g的Fe2O3)，生物质活性碳纤维3g混合，搅拌均匀，得到预制混合粉；
(2)分别称取T60含碳树脂0.1g，酚醛树脂粉(粒径为0.088～0.1mm)0.4g配成结合剂，先将1/2的结合剂加入到步骤(1)得到的预制混合粉中，混合均匀后，再加入剩余的结合剂，混合均匀得到混合粉；
(3)对步骤(2)中的混合粉进行出料、成型，在115MPa下压实，保压时间2min；
(4)将步骤(3)中成型后的耐火材料经110℃干燥10h后，埋于装有4mm粒度焦炭的匣钵中在1400℃下保温3h，冷却后得到环保型高炉铁沟料。
实施例2
(1)分别称取刚玉粉60g，二氧化硅30g，碳化硅(粒径＜0.088mm)55g，远红外陶瓷粉2g(0.8g的MgO，0.1g的Al2O3，0.5g的TiO2，0.2g的ZrO2，0.4g的Fe2O3)，生物质碳分子筛3g，生物质基活性炭6g混合，搅拌均匀，得到预制混合粉；
(2)分别称取T60含碳树脂0.5g，酚醛树脂粉(粒径为0.088～0.1mm)1g配成结合剂，先将1/2的结合剂加入到步骤(1)得到的预制混合粉中，混合均匀后，再加入剩余的结合剂，混合均匀得到混合粉；
(3)对步骤(2)中的混合粉进行出料、成型，在135MPa下压实，保压时间4min；
(4)将步骤(3)中成型后的耐火材料经120℃干燥18h后，埋于装有8mm粒度焦炭的匣钵中在1600℃下保温5h，冷却后得到环保型高炉铁沟料。
实施例3
(1)分别称取刚玉粉45g，二氧化硅25g，碳化硅(粒径＜0.088mm)50g，远红外陶瓷粉1g(0.4g的MgO，0.05g的Al2O3，0.25g的TiO2，0.1g的ZrO2，0.2g的Fe2O3)，生物质基活性炭6g混合，搅拌均匀，得到预制混合粉；
(2)分别称取T60含碳树脂0.3g，酚醛树脂粉(粒径为0.088～0.1mm)0.9g配成结合剂，先将1/2的结合剂加入到步骤(1)得到的预制混合粉中，混合均匀后，再加入剩余的结合剂，混合均匀得到混合粉；
(3)对步骤(2)中的混合粉进行出料、成型，在125MPa下压实，保压时间3min；
(4)将步骤(3)中成型后的耐火材料经115℃干燥14h后，埋于装有6mm粒度焦炭的匣钵中在1500℃下保温4h，冷却后得到环保型高炉铁沟料。
对比例
对比例与实施例1的不同之处在于，对比例的配方中未加入远红外陶瓷粉，碳素材料为沥青，其余工艺与实施例1完全相同。
对实施例1-3和对比例制得的高炉铁沟料进行性能检测，结果如表1所示。
表1.性能检测结果
根据表1的结果可以看出，本发明提供环保型高炉铁沟料相对于传统的高炉铁沟料显孔隙率高，耐受温度高，具有良好的抗热震性能，可进出≥1250℃炉膛，不炸裂。
本发明以生物质衍生炭材料替代沥青，实现了原料的可再生性以及资源的有效利用；加入远红外陶瓷粉作为活性材料，有效提高了高炉铁沟料的耐高温和热震稳定性；生产工序简单，原料价格低廉，大大降低了生产成本。

Claims (7)

1.一种环保型高炉铁沟料，其特征在于，所述环保型高炉铁沟料由以下重量份的原料制成：刚玉粉30～60份，二氧化硅15～30份，碳化硅40～55份，远红外陶瓷粉0.5～2份，生物质衍生炭材料3～9份和结合剂0.5～1.5份。
2.根据权利要求1所述的一种环保型高炉铁沟料，其特征在于，所述远红外陶瓷粉由以下重量份的原料组成：0.1～0.8份的MgO，0.05～1份的Al2O3，0.2～0.5份的TiO2，0.06～0.2份的ZrO2和0.04～0.4份的Fe2O3。
3.根据权利要求1所述的一种环保型高炉铁沟料，其特征在于，所述生物质衍生炭材料为生物质活性碳纤维、生物质碳分子筛和生物质基活性炭中的一种或几种。
4.根据权利要求1所述的一种环保型高炉铁沟料，其特征在于，所述碳化硅的粒径小于0.088mm。
5.根据权利要求1所述的一种环保型高炉铁沟料，其特征在于，所述结合剂为T60含碳树脂和酚醛树脂粉，所述T60含碳树脂和所述酚醛树脂粉质量比为1：(2～4)。
6.根据权利要求5所述的一种环保型高炉铁沟料，其特征在于，所述酚醛树脂粉的粒径为0.088～0.1mm。
7.一种如权利要求1-6任一所述的环保型高炉铁沟料的制备方法，其特征在于，包括以下步骤：
(1)按上述重量份分别称取刚玉粉，二氧化硅，碳化硅，远红外陶瓷粉和生物质衍生炭材料混合搅拌均匀，得到预制混合粉；
(2)称取上述重量份结合剂，先将1/2的结合剂加入到步骤(1)得到的预制混合粉中，混合均匀后，再加入剩余的结合剂，混合均匀得到混合粉；
(3)对步骤(2)中的混合粉进行出料、成型，在115～135MPa下压实，保压时间2～4min；
(4)将步骤(3)中成型后的耐火材料经110～120℃干燥10～18h后，埋于装有4～8mm粒度焦炭的匣钵中在1400～1600℃下保温3～5h，冷却后得到环保型高炉铁沟料。
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