CN107270035A - 一种防腐保温管道及其加工工艺 - Google Patents
一种防腐保温管道及其加工工艺 Download PDFInfo
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Abstract
本发明提供了一种防腐保温管道及其加工工艺,防腐保温管道包括钢管、耐高温层、保温层和防腐层,所述耐高温层涂覆在钢管外表面,厚度为100‑220微米;所述保温层涂覆在耐高温层的外表面,厚度为100‑200微米;所述防腐层涂覆在保温层的外表面,厚度为200‑300微米;所述耐高温层由耐高温底漆涂覆而成;所述保温层采用保温涂料涂覆而成,所述防腐层采用防腐涂料涂覆而成。本发明既能保证钢管的耐高温效果,又能成倍提升钢管的保温和防腐性能,同时又不增加成本。
Description
技术领域
本发明涉及管道技术领域,具体涉及一种防腐保温管道及其加工工艺。
背景技术
利用金属管道进行资源的长途输送是现阶段工业上采用的常见手段,如石油开采、天然气输送、供热输送及供水输送等等。在管道的长途输送中,对金属管道的保护是尤为重要的,因为,有较长的金属管道是埋在远离人们的生活居住点的,有的地段甚至环境状况非常恶劣。例如低洼、沼泽等强腐蚀区,土壤环境条件恶劣、地下水位高,当管道防腐层出现局部破损或老化后,形成大阴极(非破坏区)、小阳级(破损点),作为阳极的金属管道部位因这种电化学腐蚀,导致穿孔腐蚀,保温管道使用寿命下降。
为了延长保温管道在低洼和沼泽地区使用寿命,以往通常采用外加电流或牺牲阳极的阴极保护技术,外加电流法需要持续外部电源,维护电源费用较高,并且因低洼沼泽地杂散电流作用导致过保护,引发防腐层的破坏及管材氢脆,牺牲阳极虽然免维护,但依然存在着远离阳极点保护作用降低问题,近几年国内也出现了一种电化学保温管,通过以单纯锌铝为主形成合金镀层,实现了旧油管基材的全覆盖,仅适用在普通土壤二级腐蚀环境下使用,在沼泽和低洼含盐碱量高的一级土壤强腐蚀区域使用,锌铝原子作为阳极材料加快了消耗,存在涂层提前粉化和老化问题,缩短了使用寿命。
发明内容
本发明的目的是针对现有技术的问题,提供一种防腐保温管道及其加工工艺。
为了达到上述目的,本发明通过以下技术方案来实现:
一种防腐保温管道,包括钢管、耐高温层、保温层和防腐层,其特征在于,所述耐高温层涂覆在钢管外表面,厚度为100-220微米;所述保温层涂覆在耐高温层的外表面,厚度为100-200微米;所述防腐层涂覆在保温层的外表面,厚度为200-300微米;
所述耐高温层由耐高温底漆涂覆而成;所述保温层采用保温涂料涂覆而成,所述防腐层采用防腐涂料涂覆而成。
进一步地,所述耐高温层包括耐高温粉料和浆料;
所述耐高温粉料包含以下按重量份计的原料:碳化硅10-30份,硅树脂2-8份,膨润土1-3份,纳米氧化铝15-20份,镍粉1-3份,纳米氧化镁5-10份,氧化钛4-7份,纳米二氧化锆4-10份和纳米二氧化硅20-40份;
所述浆料包含以下按重量份计的原料:丙二醇甲醚5-30份,无水乙醇1-12份,工业乙醇2-15份和丙二醇甲醚醋酸酯3-15份。
进一步地,所述保温涂料包含以下按重量份计的原料:
环氧树脂80-100份,水泥15-20份,甲基丙烯酸甲酯10-15份,闭孔珍珠岩30-45份,重质碳酸钙5-8份,轻质碳酸钙4-6份,乙二醇40-45份,硅油1-5份和水60-75份。
进一步地,所述重质碳酸钙的粒度为50-65微米,所述轻质碳酸钙的粒度为50-65微米。
进一步地,所述防腐涂料包含以下按重量份计的原料:环氧树脂40-50份,云母氧化铁20-30份,云母10-20份,滑石粉20-25份,分散剂1-2份,固化剂1-2份,乙醇15-30份。
进一步地,所述环氧树脂的分子量为500-800,所述分散剂包括质量为比1:1的双十八烷基酯基季铵盐和脂肪醇聚氧乙烯基醚。
进一步地,所述防腐涂料的制备方法包括如下步骤:
(1)按所需重量份准备好各项原料,将环氧树脂、云母氧化铁、云母、滑石粉和分散剂混合均匀,在100-120℃下研磨2-3小时,得到改性研磨浆;
(2)将所述改性研磨浆冷却至40-50℃后,加入乙醇并混合均匀,得到混合料;
(3)将所述混合料于50-60℃下保温熟化1-2小时,得到所述防腐涂料。
一种防腐保温管道的加工工艺,包括以下步骤:
(1)清除钢管外表面盐分、油污及氧化皮,对钢管外表面实施抛丸除锈处理,表面处理质量达到Sa2.5近白清理级,锚纹深度达到80-150微米;
(2)在密闭熔池中将低熔点的Zn、Al活泼金属加热到430-700℃,相继熔融;
(3)表面进行过抛丸除锈处理的钢管浸入熔池中2-3min,钢管表面形成Zn-Al合金内层;
(4)将经过步骤(3)处理的钢管取出熔池悬吊冷却,利用远红外测温仪测试表面温度,待钢管表面温度冷却至200-300℃,悬吊钢管转入热喷涂工位;
(5)采用等离子喷涂法依次在所述钢管的表面喷涂耐高温层、保温层和防腐层;冷却后得到所述防腐保温管道。
进一步地,所述喷涂的喷枪与基体表面应呈直角,无法垂直的部位斜度不宜小于60-80°,喷口与基体表面的距离为200-300mm,所述耐高温层和保温层的涂层干燥时间不少于6-8小时,所述防腐层的涂层干燥时间不少于12小时。
本发明与现有技术相比,具有如下的有益效果:
本发明在预先经过抛丸除锈处理的钢管表面,利用热浸镀和热喷涂联合工艺,在钢管基材外表面形成一种嵌入到基材中的多元合金镀层,形成致密的金相组织,确保了镀层对钢管的结合力,镀层具有抗冲击特性。在钢管表面依次设置的耐高温层、保温层和防腐层,既能保证钢管的耐高温效果,又能成倍提升钢管的保温和防腐性能,同时又不增加成本。
本发明所采用的耐高温涂层采种多种纳米级颗粒,使晶粒、晶界以及他们之间的结合都达到纳米水平,使涂层的强度、韧性和超塑性大幅度提高,镍粉、纳米氧化镁、氧化钛、纳米二氧化锆和纳米二氧化硅的加入,不仅能提高涂层的强度,且能显著提高涂层的高温耐受性,同时具有一定的耐腐蚀性。采用的保温涂层,成本低,具有优异的保温性能,能显著提高涂层的保温隔热性能。采用的防腐层选择环氧树脂为主要的原料,同时添加云母氧化铁、云母和滑石粉,起到阴极保护的作用,大大提高涂层的耐腐蚀性能,且制备方法简单,适合工业化生产。
具体实施方式
下面结合实施例对本发明作进一步说明。
实施例1
一种防腐保温管道,包括钢管、耐高温层、保温层和防腐层,其特征在于,所述耐高温层涂覆在钢管外表面,厚度为100微米;所述保温层涂覆在耐高温层的外表面,厚度为200微米;所述防腐层涂覆在保温层的外表面,厚度为200微米;
所述耐高温层由耐高温底漆涂覆而成;所述保温层采用保温涂料涂覆而成,所述防腐层采用防腐涂料涂覆而成。
所述耐高温层包括耐高温粉料和浆料;
所述耐高温粉料包含以下按重量份计的原料:碳化硅30份,硅树脂2份,膨润土3份,纳米氧化铝15份,镍粉3份,纳米氧化镁5份,氧化钛7份,纳米二氧化锆4份和纳米二氧化硅40份;
所述浆料包含以下按重量份计的原料:丙二醇甲醚5份,无水乙醇12份,工业乙醇2份和丙二醇甲醚醋酸酯15份。
所述保温涂料包含以下按重量份计的原料:
环氧树脂80份,水泥20份,甲基丙烯酸甲酯10份,闭孔珍珠岩45份,重质碳酸钙5份,轻质碳酸钙6份,乙二醇40份,硅油5份和水60份。
所述重质碳酸钙的粒度为65微米,所述轻质碳酸钙的粒度为50微米。
所述防腐涂料包含以下按重量份计的原料:环氧树脂50份,云母氧化铁20份,云母20份,滑石粉20份,分散剂2份,固化剂1份,乙醇30份。
进一步地,所述环氧树脂的分子量为500,所述分散剂包括质量为比1:1的双十八烷基酯基季铵盐和脂肪醇聚氧乙烯基醚。
所述防腐涂料的制备方法包括如下步骤:
(1)按所需重量份准备好各项原料,将环氧树脂、云母氧化铁、云母、滑石粉和分散剂混合均匀,在120℃下研磨2小时,得到改性研磨浆;
(2)将所述改性研磨浆冷却至50℃后,加入乙醇并混合均匀,得到混合料;
(3)将所述混合料于50℃下保温熟化2小时,得到所述防腐涂料。
所述防腐保温管道的加工工艺,包括以下步骤:
(1)清除钢管外表面盐分、油污及氧化皮,对钢管外表面实施抛丸除锈处理,表面处理质量达到Sa2.5近白清理级,锚纹深度达到80微米;
(2)在密闭熔池中将低熔点的Zn、Al活泼金属加热到700℃,相继熔融;
(3)表面进行过抛丸除锈处理的钢管浸入熔池中2min,钢管表面形成Zn-Al合金内层;
(4)将经过步骤(3)处理的钢管取出熔池悬吊冷却,利用远红外测温仪测试表面温度,待钢管表面温度冷却至300℃,悬吊钢管转入热喷涂工位;
(5)采用等离子喷涂法依次在所述钢管的表面喷涂耐高温层、保温层和防腐层;冷却后得到所述防腐保温管道。
所述喷涂的喷枪与基体表面应呈直角,无法垂直的部位斜度不宜小于60°,喷口与基体表面的距离为300mm,所述耐高温层和保温层的涂层干燥时间不少于6小时,所述防腐层的涂层干燥时间不少于12小时。
对本实施例提供的防腐保温管道进行性能检测,结果如表1所示:
表1
实施例2
一种防腐保温管道,包括钢管、耐高温层、保温层和防腐层,其特征在于,所述耐高温层涂覆在钢管外表面,厚度为220微米;所述保温层涂覆在耐高温层的外表面,厚度为100微米;所述防腐层涂覆在保温层的外表面,厚度为300微米;
所述耐高温层由耐高温底漆涂覆而成;所述保温层采用保温涂料涂覆而成,所述防腐层采用防腐涂料涂覆而成。
所述耐高温层包括耐高温粉料和浆料;
所述耐高温粉料包含以下按重量份计的原料:碳化硅10份,硅树脂8份,膨润土1份,纳米氧化铝20份,镍粉1份,纳米氧化镁10份,氧化钛4份,纳米二氧化锆10份和纳米二氧化硅20份;
所述浆料包含以下按重量份计的原料:丙二醇甲醚30份,无水乙醇1份,工业乙醇15份和丙二醇甲醚醋酸酯3份。
所述保温涂料包含以下按重量份计的原料:
环氧树脂100份,水泥15份,甲基丙烯酸甲酯15份,闭孔珍珠岩30份,重质碳酸钙8份,轻质碳酸钙4份,乙二醇45份,硅油1份和水75份。
所述重质碳酸钙的粒度为50微米,所述轻质碳酸钙的粒度为65微米。
所述防腐涂料包含以下按重量份计的原料:环氧树脂40份,云母氧化铁30份,云母10份,滑石粉25份,分散剂1份,固化剂2份,乙醇15份。
进一步地,所述环氧树脂的分子量为800,所述分散剂包括质量为比1:1的双十八烷基酯基季铵盐和脂肪醇聚氧乙烯基醚。
所述防腐涂料的制备方法包括如下步骤:
(1)按所需重量份准备好各项原料,将环氧树脂、云母氧化铁、云母、滑石粉和分散剂混合均匀,在100℃下研磨3小时,得到改性研磨浆;
(2)将所述改性研磨浆冷却至40℃后,加入乙醇并混合均匀,得到混合料;
(3)将所述混合料于60℃下保温熟化1小时,得到所述防腐涂料。
所述防腐保温管道的加工工艺,包括以下步骤:
(1)清除钢管外表面盐分、油污及氧化皮,对钢管外表面实施抛丸除锈处理,表面处理质量达到Sa2.5近白清理级,锚纹深度达到150微米;
(2)在密闭熔池中将低熔点的Zn、Al活泼金属加热到430℃,相继熔融;
(3)表面进行过抛丸除锈处理的钢管浸入熔池中3min,钢管表面形成Zn-Al合金内层;
(4)将经过步骤(3)处理的钢管取出熔池悬吊冷却,利用远红外测温仪测试表面温度,待钢管表面温度冷却至200℃,悬吊钢管转入热喷涂工位;
(5)采用等离子喷涂法依次在所述钢管的表面喷涂耐高温层、保温层和防腐层;冷却后得到所述防腐保温管道。
所述喷涂的喷枪与基体表面应呈直角,无法垂直的部位斜度不宜小于80°,喷口与基体表面的距离为200mm,所述耐高温层和保温层的涂层干燥时间不少于8小时,所述防腐层的涂层干燥时间不少于12小时。
对本实施例提供的防腐保温管道进行性能检测,结果如表2所示:
表2
实施例3
一种防腐保温管道,包括钢管、耐高温层、保温层和防腐层,其特征在于,所述耐高温层涂覆在钢管外表面,厚度为160微米;所述保温层涂覆在耐高温层的外表面,厚度为150微米;所述防腐层涂覆在保温层的外表面,厚度为250微米;
所述耐高温层由耐高温底漆涂覆而成;所述保温层采用保温涂料涂覆而成,所述防腐层采用防腐涂料涂覆而成。
所述耐高温层包括耐高温粉料和浆料;
所述耐高温粉料包含以下按重量份计的原料:碳化硅20份,硅树脂5份,膨润土2份,纳米氧化铝18份,镍粉2份,纳米氧化镁8份,氧化钛6份,纳米二氧化锆7份和纳米二氧化硅30份;
所述浆料包含以下按重量份计的原料:丙二醇甲醚20份,无水乙醇7份,工业乙醇8份和丙二醇甲醚醋酸酯9份。
所述保温涂料包含以下按重量份计的原料:
环氧树脂90份,水泥18份,甲基丙烯酸甲酯13份,闭孔珍珠岩38份,重质碳酸钙5份,轻质碳酸钙5份,乙二醇43份,硅油3份和水68份。
所述重质碳酸钙的粒度为58微米,所述轻质碳酸钙的粒度为58微米。
所述防腐涂料包含以下按重量份计的原料:环氧树脂46份,云母氧化铁25份,云母15份,滑石粉23份,分散剂1.5份,固化剂1份,乙醇27份。
进一步地,所述环氧树脂的分子量为600,所述分散剂包括质量为比1:1的双十八烷基酯基季铵盐和脂肪醇聚氧乙烯基醚。
所述防腐涂料的制备方法包括如下步骤:
(1)按所需重量份准备好各项原料,将环氧树脂、云母氧化铁、云母、滑石粉和分散剂混合均匀,在110℃下研磨2.5小时,得到改性研磨浆;
(2)将所述改性研磨浆冷却至45℃后,加入乙醇并混合均匀,得到混合料;
(3)将所述混合料于55℃下保温熟化1.5小时,得到所述防腐涂料。
所述防腐保温管道的加工工艺,包括以下步骤:
(1)清除钢管外表面盐分、油污及氧化皮,对钢管外表面实施抛丸除锈处理,表面处理质量达到Sa2.5近白清理级,锚纹深度达到115微米;
(2)在密闭熔池中将低熔点的Zn、Al活泼金属加热到550℃,相继熔融;
(3)表面进行过抛丸除锈处理的钢管浸入熔池中2min,钢管表面形成Zn-Al合金内层;
(4)将经过步骤(3)处理的钢管取出熔池悬吊冷却,利用远红外测温仪测试表面温度,待钢管表面温度冷却至250℃,悬吊钢管转入热喷涂工位;
(5)采用等离子喷涂法依次在所述钢管的表面喷涂耐高温层、保温层和防腐层;冷却后得到所述防腐保温管道。
所述喷涂的喷枪与基体表面应呈直角,无法垂直的部位斜度不宜小于70°,喷口与基体表面的距离为250mm,所述耐高温层和保温层的涂层干燥时间不少于7小时,所述防腐层的涂层干燥时间不少于12小时。
对本实施例提供的防腐保温管道进行性能检测,结果如表3所示:
表3
以上仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (9)
1.一种防腐保温管道,包括钢管、耐高温层、保温层和防腐层,其特征在于,所述耐高温层涂覆在钢管外表面,厚度为100-220微米;所述保温层涂覆在耐高温层的外表面,厚度为100-200微米;所述防腐层涂覆在保温层的外表面,厚度为200-300微米;
所述耐高温层由耐高温底漆涂覆而成;所述保温层采用保温涂料涂覆而成,所述防腐层采用防腐涂料涂覆而成。
2.根据权利要求1所述的一种防腐保温管道,其特征在于,所述耐高温层包括耐高温粉料和浆料;
所述耐高温粉料包含以下按重量份计的原料:碳化硅10-30份,硅树脂2-8份,膨润土1-3份,纳米氧化铝15-20份,镍粉1-3份,纳米氧化镁5-10份,氧化钛4-7份,纳米二氧化锆4-10份和纳米二氧化硅20-40份;
所述浆料包含以下按重量份计的原料:丙二醇甲醚5-30份,无水乙醇1-12份,工业乙醇2-15份和丙二醇甲醚醋酸酯3-15份。
3.根据权利要求1所述的一种防腐保温管道,其特征在于,所述保温涂料包含以下按重量份计的原料:
环氧树脂80-100份,水泥15-20份,甲基丙烯酸甲酯10-15份,闭孔珍珠岩30-45份,重质碳酸钙5-8份,轻质碳酸钙4-6份,乙二醇40-45份,硅油1-5份和水60-75份。
4.根据权利要求3所述的一种防腐保温管道,其特征在于,所述重质碳酸钙的粒度为50-65微米,所述轻质碳酸钙的粒度为50-65微米。
5.根据权利要求1所述的一种防腐保温管道,其特征在于,所述防腐涂料包含以下按重量份计的原料:环氧树脂40-50份,云母氧化铁20-30份,云母10-20份,滑石粉20-25份,分散剂1-2份,固化剂1-2份,乙醇15-30份。
6.根据权利要求5所述的一种防腐保温管道,其特征在于,所述环氧树脂的分子量为500-800,所述分散剂包括质量为比1:1的双十八烷基酯基季铵盐和脂肪醇聚氧乙烯基醚。
7.根据权利要求5所述的一种防腐保温管道,其特征在于,所述防腐涂料的制备方法包括如下步骤:
(1)按所需重量份准备好各项原料,将环氧树脂、云母氧化铁、云母、滑石粉和分散剂混合均匀,在100-120℃下研磨2-3小时,得到改性研磨浆;
(2)将所述改性研磨浆冷却至40-50℃后,加入乙醇并混合均匀,得到混合料;
(3)将所述混合料于50-60℃下保温熟化1-2小时,得到所述防腐涂料。
8.一种如权利要求1-7任意一项所述的防腐保温管道的加工工艺,其特征在于,包括以下步骤:
(1)清除钢管外表面盐分、油污及氧化皮,对钢管外表面实施抛丸除锈处理,表面处理质量达到Sa2.5近白清理级,锚纹深度达到80-150微米;
(2)在密闭熔池中将低熔点的Zn、Al活泼金属加热到430-700℃,相继熔融;
(3)表面进行过抛丸除锈处理的钢管浸入熔池中2-3min,钢管表面形成Zn-Al合金内层;
(4)将经过步骤(3)处理的钢管取出熔池悬吊冷却,利用远红外测温仪测试表面温度,待钢管表面温度冷却至200-300℃,悬吊钢管转入热喷涂工位;
(5)采用等离子喷涂法依次在所述钢管的表面喷涂耐高温层、保温层和防腐层;冷却后得到所述防腐保温管道。
9.根据权利要求8所述的防腐保温管道的加工工艺,其特征在于,所述喷涂的喷枪与基体表面应呈直角,无法垂直的部位斜度不宜小于60-80°,喷口与基体表面的距离为200-300mm,所述耐高温层和保温层的涂层干燥时间不少于6-8小时,所述防腐层的涂层干燥时间不少于12小时。
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