CN107226687A - 用于高炉内衬喷补的浇注料及其制备方法 - Google Patents
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Abstract
本发明公开了一种用于高炉内衬喷补的浇注料及其制备方法,本浇注料以10~15wt%的矾土颗粒、40~50wt%的棕刚玉颗粒、10~20wt%的碳化硅细粉、15~25wt%的刚玉细粉、0.5~2wt%的金属硅粉、0.5~2%的球状沥青、2~7wt%的α‑Al2O3微粉和0.2~2wt%的氧化硅微粉为原料,外加所述原料8~15%的硅溶胶为结合剂。本方法按比例配制所述原料,加入搅拌机搅拌混合均匀,随后加入所述硅溶胶作为喷补润湿介质和结合剂,得到用于高炉内衬喷补的浇注料。本浇注料抗渣性能优越、强度高、粘附性能好、施工快捷,确保与高炉内衬受补面粘结为一体,本制备方法操作简单,可在高炉降低料线的情况下对露出的炉墙内衬进行喷补造衬,大面积快速修补高炉内衬。
Description
技术领域
本发明涉及耐火材料,尤其涉及一种用于高炉内衬喷补的浇注料及其制备方法。
背景技术
高炉内衬在保证高炉正常生产以及使用寿命方面起着重要的作用,高炉在使用一段时间后,由于炉内热冲击、侵蚀、磨损和氧化剥落等原因,会造成高炉内衬耐火材料层减薄,出现炉壳发红现象,影响高炉的正常生产。为了维持高炉的正常生产和长寿命,降低高炉的运行成本,对高炉内衬蚀损严重部位及时进行修补是延长高炉寿命的有效手段。
目前,高炉内衬喷补普遍采用湿法喷注工艺来进行施工,所采用的设备基本上是自动化程度较高的遥控喷补装置,其技术特点是预先将耐火混合料,包括所有的粗、中、细颗粒和结合剂与水混合成浇注料,由压送泵通过输送管道将浇注料输送到喷补机的喷嘴,然后在喷嘴处加入促凝剂,再借助高压空气通过喷嘴把浇注料喷注到需要喷补的高炉内衬蚀损区域表面。此工艺可实现在不停炉的前提下利用高炉休风对内衬进行喷补。与原来传统的停炉维修相比,高炉喷补使高炉损毁部位内衬得到了修复,喷补后利用高炉残剩余热实现喷补料的快速烘烤,无需另外进行烘炉,因此可以实现高炉快速送风,迅速恢复炉况。所以喷补修复工艺减少了高炉的大中修次数,降低了工程费用,减少了高炉停炉造成的产量损失,而且明显延长了高炉的使用寿命。
决定高炉内衬喷补维修效果的主要因素是两个方面的,一是施工装备及工艺;二是所用浇注料本身的性能。对于高炉内衬修复所用浇注料的性能要求如下:
1、与基体的粘结性能好,能使其与修补面粘结成为一体;
2、重烧线变化率小,从而保证具有良好的体积稳定性;
3、施工过程中的反弹率小,节约用料;
4、较高的耐火度和强度;
5、低气孔率和高致密度;
6、耐磨性好;
7、瞬间凝固、快强,以增加造衬厚度;
8、抗CO侵蚀性好。
其中最基本的要求是粘结强度,因为如果浇注料不能牢固地与受补面粘结为一体,其它的性能也就毫无意义。
目前,高炉内衬修补技术发展至今仍不够完善,浇注料的研制还有很大的研发空间,目前存在的主要问题为浇注料施工性能不稳定,材料性能如低加水量、高体密、高强度及耐用性等尚不突出。
发明内容
本发明所要解决的技术问题是提供一种用于高炉内衬喷补的浇注料及其制备方法,本浇注料抗渣性能优越、强度高、粘附性能好、施工快捷,确保与高炉内衬受补面粘结为一体,本制备方法操作简单,可在高炉降低料线的情况下对露出的炉墙内衬进行喷补造衬,大面积快速修补高炉内衬。
为解决上述技术问题,本发明用于高炉内衬喷补的浇注料以10~15wt%的矾土颗粒、40~50wt%的棕刚玉颗粒、10~20wt%的碳化硅细粉、15~25wt%的刚玉细粉、0.5~2wt%的金属硅粉、0.5~2%的球状沥青、2~7wt%的α-Al2O3微粉和0.2~2wt%的氧化硅微粉为原料,外加所述原料8~15 wt %的硅溶胶为结合剂。
进一步,所述矾土颗粒的粒径为3~8mm,其Al2O3含量不小于88%;所述棕刚玉颗粒的粒径为88µm~3mm,其Al2O3含量不小于94%。
进一步,所述碳化硅细粉的粒径为88µm~1mm,其SiC含量不低于96%。
进一步,所述刚玉细粉的粒度不大于0.074mm,其Al2O3含量不小于98.5%。
进一步,所述金属硅粉的粒度不大于0.074mm,其Si含量不小于97%。
进一步,所述球状沥青的粒度为0.5~1mm,其残炭量不小于50%。
进一步,所述α-Al2O3微粉的粒径小于5µm,其Al2O3 含量大于99%。
进一步,所述氧化硅微粉的粒径小于3µm,其SiO2含量大于95%。
进一步,所述硅溶胶的固含量为28~42%。
上述用于高炉内衬喷补的浇注料制备方法,按比例配制所述原料,加入搅拌机搅拌混合均匀,随后加入所述硅溶胶作为喷补润湿介质和结合剂,得到用于高炉内衬喷补的浇注料。
由于本发明用于高炉内衬喷补的浇注料及其制备方法采用了上述技术方案,即本浇注料以10~15wt%的矾土颗粒、40~50wt%的棕刚玉颗粒、10~20wt%的碳化硅细粉、15~25wt%的刚玉细粉、0.5~2wt%的金属硅粉、0.5~2%的球状沥青、2~7wt%的α-Al2O3微粉和0.2~2wt%的氧化硅微粉为原料,外加所述原料8~15 wt %的硅溶胶为结合剂。本方法按比例配制所述原料,加入搅拌机搅拌混合均匀,随后加入所述硅溶胶作为喷补润湿介质和结合剂,得到用于高炉内衬喷补的浇注料。本浇注料抗渣性能优越、强度高、粘附性能好、施工快捷,确保与高炉内衬受补面粘结为一体,本制备方法操作简单,可在高炉降低料线的情况下对露出的炉墙内衬进行喷补造衬,大面积快速修补高炉内衬。
具体实施方式
本发明用于高炉内衬喷补的浇注料以10~15wt%的矾土颗粒、40~50wt%的棕刚玉颗粒、10~20wt%的碳化硅细粉、15~25wt%的刚玉细粉、0.5~2wt%的金属硅粉、0.5~2%的球状沥青、2~7wt%的α-Al2O3微粉和0.2~2wt%的氧化硅微粉为原料,外加所述原料8~15wt %的硅溶胶为结合剂。
优选的,所述矾土颗粒的粒径为3~8mm,其Al2O3含量不小于88%;所述棕刚玉颗粒的粒径为88µm~3mm,其Al2O3含量不小于94%。
优选的,所述碳化硅细粉的粒径为88µm~1mm,其SiC含量不低于96%。
优选的,所述刚玉细粉的粒度不大于0.074mm,其Al2O3含量不小于98.5%。
优选的,所述金属硅粉的粒度不大于0.074mm,其Si含量不小于97%。
优选的,所述球状沥青的粒度为0.5~1mm,其残炭量不小于50%。
优选的,所述α-Al2O3微粉的粒径小于5µm,其Al2O3 含量大于99%。
优选的,所述氧化硅微粉的粒径小于3µm,其SiO2含量大于95%。
优选的,所述硅溶胶的固含量为28~42%。
上述用于高炉内衬喷补的浇注料制备方法,按比例配制所述原料,加入搅拌机搅拌混合均匀,随后加入所述硅溶胶作为喷补润湿介质和结合剂,得到用于高炉内衬喷补的浇注料。
本浇注料采用矾土和棕刚玉为复合骨料,引入SiC提高材料的热震稳定性,以硅溶胶作为结合剂,使其具备良好的常温力学强度和粘附强度,减少材料剥落,并可缩短施工体烘干过程的时间。其主要物理性能是:110℃烘干后的显气孔率为16~20%、体积密度为2.70~2.80g/cm3、抗折强度为5.0~10.0MPa、耐压强度>30MPa、粘结强度1~2MPa;815℃保温3小时后的显气孔率为18~22%、体积密度为2.65~2.75g/cm3、抗折强度为8.0~12.0MPa、耐压强度>50MPa、粘结强度>4.0MPa、加热永久线变化率为±0.1%;1400℃保温3小时后的显气孔率为17~21%、体积密度为2.70~2.80g/cm3、抗折强度为10.0~16.0MPa、耐压强度>100MPa、加热永久线变化率为0~+0.3%。本浇注料采用的硅溶胶,由于其SiO2的粒径范围一般在5nm~100nm,且粘度较低,具有很好的分散性和渗透性,因此浇注料在施工中,硅溶胶中的纳米SiO2和水都能渗透进入微孔中,加快胶凝并增强材料与高炉内衬的粘结性。同时浇注料基质中莫来石的原位生成伴随一定的体积膨胀,可以弥补浇注料加热过程中的收缩,保证制品的体积稳定性,进而提高其荷重软化温度与抗蠕变性。本浇注使用时可采用湿法喷补工艺进行热态喷补。
实施例1
本浇注料以10wt%的矾土颗粒、50wt%的棕刚玉颗粒、15wt%的碳化硅细粉、15wt%的刚玉细粉、0.5wt%的金属硅粉、0.5%的球状沥青、7wt%的α-Al2O3微粉和2wt%的氧化硅微粉为原料,外加所述原料8 wt %的硅溶胶为结合剂。
实施例2
本浇注料以15wt%的矾土颗粒、40wt%的棕刚玉颗粒、10wt%的碳化硅细粉、25wt%的刚玉细粉、2wt%的金属硅粉、2%的球状沥青、4wt%的α-Al2O3微粉和2wt%的氧化硅微粉为原料,外加所述原料10 wt %的硅溶胶为结合剂。
实施例3
本浇注料以12wt%的矾土颗粒、45wt%的棕刚玉颗粒、15wt%的碳化硅细粉、25wt%的刚玉细粉、2wt%的金属硅粉、2%的球状沥青、7wt%的α-Al2O3微粉和2wt%的氧化硅微粉为原料,外加所述原料15 wt %的硅溶胶为结合剂。
实例1、实例2和实例3浇注料的主要性能见下表:
由上表可见,本浇注料具有良好的高温体积稳定性、力学性能和抗渣性能,可以很好地与高炉内衬进行结合而不会产生剥落,且SiC的引入可以提高材料的热震稳定性,硅溶胶的使用使得材料不仅获得良好的结合强度,也可实现喷涂后的快速干燥,并提高喷补造衬的使用寿命,保障高炉炉役寿命。
Claims (10)
1.一种用于高炉内衬喷补的浇注料,其特征在于:所述浇注料以10~15wt%的矾土颗粒、40~50wt%的棕刚玉颗粒、10~20wt%的碳化硅细粉、15~25wt%的刚玉细粉、0.5~2wt%的金属硅粉、0.5~2%的球状沥青、2~7wt%的α-Al2O3微粉和0.2~2wt%的氧化硅微粉为原料,外加所述原料8~15 wt %的硅溶胶为结合剂。
2.根据权利要求1所述的用于高炉内衬喷补的浇注料,其特征在于:所述矾土颗粒的粒径为3~8mm,其Al2O3含量不小于88%;所述棕刚玉颗粒的粒径为88µm~3mm,其Al2O3含量不小于94%。
3.根据权利要求1所述的用于高炉内衬喷补的浇注料,其特征在于:所述碳化硅细粉的粒径为88µm~1mm,其SiC含量不低于96%。
4.根据权利要求1所述的用于高炉内衬喷补的浇注料,其特征在于:所述刚玉细粉的粒度不大于0.074mm,其Al2O3含量不小于98.5%。
5.根据权利要求1所述的用于高炉内衬喷补的浇注料,其特征在于:所述金属硅粉的粒度不大于0.074mm,其Si含量不小于97%。
6.根据权利要求1所述的用于高炉内衬喷补的浇注料,其特征在于:所述球状沥青的粒度为0.5~1mm,其残炭量不小于50%。
7.根据权利要求1所述的用于高炉内衬喷补的浇注料,其特征在于:所述α-Al2O3微粉的粒径小于5µm,其Al2O3 含量大于99%。
8.根据权利要求1所述的用于高炉内衬喷补的浇注料,其特征在于:所述氧化硅微粉的粒径小于3µm,其SiO2含量大于95%。
9.根据权利要求1所述的用于高炉内衬喷补的浇注料,其特征在于:所述硅溶胶的固含量为28~42%。
10.一种权利要求1至9任一项所述用于高炉内衬喷补的浇注料制备方法,其特征在于:按比例配制所述原料,加入搅拌机搅拌混合均匀,随后加入所述硅溶胶作为喷补润湿介质和结合剂,得到用于高炉内衬喷补的浇注料。
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