CN107324783A - 一种撇渣器横梁快换预制件及其制备方法 - Google Patents
一种撇渣器横梁快换预制件及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种撇渣器横梁快换预制件,成分包括15~8mm高铝矾土10~15份,8~5mm板状刚玉18~25份,5~3mm板状刚玉5~10份,3~1mm白刚玉10~15份,1~0mm白刚玉5~10份,不大于200目白刚玉粉6~10份,1~0mm碳化硅10~15份,不大于200目碳化硅4~8份,碳化硼粉1~3份,氮化硅粉3~5份,活性氧化铝粉10~15份,高温沥青粉1~3份,添加剂2~3份,铝酸钙水泥0.3~0.5份,金属铝粉0.05~0.15份,防爆纤维0.01~0.03份。还公开了制备该撇渣器横梁快换预制件的方法。本发明的优点在于,通过对材质的改进以及结构的更新,实现对蔽渣器进行快速更换,并能减少或防止现有撇渣器开裂漏渣的现象发生,有效解决了高炉出铁沟配套用浇注撇渣器使用寿命较短的问题。
Description
技术领域
本发明涉及一种撇渣器横梁快换预制件及其制备方法,属于高炉炉前用耐火材料技术领域。
背景技术
撇渣器是出铁过程中熔渣和铁水分离的地方。撇渣器上接主铁沟,下连支铁沟,旁连下渣沟,在出铁场上处于中间位置。撇渣器由前沟槽、渣坝、档板、过道、小井(铁水出口,接流向铁水罐的支沟)和放残铁孔道组成。在结构方面,撇渣器的过道必须保证在铁口发生跑大流时也不憋流,因此,应根据炉容的大小和出铁次数的多少,确定适宜的过道尺寸。撇渣器作为高炉炉前渣铁分离的主要没备,其使用效果的优劣和使用寿命的长短,对高炉炉况的稳定和顺行以及炼铁成本的影响至关重要。目前各钢铁厂使用的撇渣器有整体浇注形式和用散状料捣打制作成型形式,大部分采用正副两组,以便出现问题时快速更换。修补方法采用在线现场热态修补方式来维护,一次性不修补的使用时间都较短,使用寿命为l~3个月(大部分是1个月),维护工作量和劳动强度大,环境恶劣,安全隐患也较大。也有采用一组炭质捣打料加水管冷却的撇渣器,使用寿命能够达到半年左右,但炭质捣打料加水冷的撇渣器,虽然使用寿命较长,但使用时长时间暴露本体造成其抗氧化性能差,耗水量大、能耗高,而且一旦出现漏水问题,则会出现重大事故。影响撇渣器使用效果的因素不但包括结构设计方面的原因,更为关键的是材质方面的原因,专利201210281607.2、201620484072.2、201320790835.2等主要都是从结构设计方面对撇渣器进行了改进,发明专利200610053908.4虽然从材料配比上面提出了一些技术方案,但总体上还是采用与铁沟浇注料相同的材料配比,采用的是低水泥结合,因CaO的存在在使用过程中撇渣器内会生成大量的钙铝黄长石等低熔点液相,造成撇渣器的使用寿命大大降低,对高炉生产的连续性和稳定性、对炼铁生产成本、对下工序的后续处理都有较大的影响。
发明内容
本发明要解决的技术问题是提供一种撇渣器横梁快换预制件以及制备其的方法,所采用的技术原理是采用超微粉结合方式制备撇渣器横梁快换预制件,避免了采用水泥结合造成的低熔点相过多引起抗冲刷性和抗侵蚀性降低的现象,在材质配比方面引入部分碳化硼和氮化硅,碳化硼有助于提高预制件的抗氧化性能,氮化硅具有抗热震性好、高温蠕变小,与渣、铁难润湿等特性,使撇渣器能够承受铁水、炉渣的侵蚀和磨损,增强了撇渣器抗铁水侵蚀和冲刷能力。
本发明是通过以下技术方案来实现的。
一种撇渣器横梁快换预制件,成分包括15~8mm高铝矾土10~15份,8~5mm板状刚玉18~25份,5~3mm板状刚玉5~10份,3~1mm白刚玉10~15份,1~0mm白刚玉5~10份,不大于200目白刚玉粉6~10份,1~0mm碳化硅10~15份,不大于200目碳化硅4~8份,碳化硼粉1~3份,氮化硅粉3~5份,活性氧化铝粉10~15份,高温沥青粉1~3份,添加剂2~3份,铝酸钙水泥0.3~0.5份,金属铝粉0.05~0.15份,防爆纤维0.01~0.03份。
进一步地,所采用的高铝矾土中Al2O3的质量百分含量不小于88%。
进一步地,所采用的碳化硅中SiC的质量百分含量不小于97%。
制备以上撇渣器横梁快换预制件的方法,步骤包括:
(1)将各种规格种类的原料按比例配好混合后外加质量百分比3%~3.3%的水搅拌均匀;
(2)在模具中振动浇注成型;
(3)成型8小时后脱模;
(4)养护24小时;
(5)产品养护后以10℃/h的升温速度升温到120℃,保温12小时;再以15℃/h的升温速度升温到330℃,保温12小时;再以20℃/h的升温速度升温到600℃,保温12小时;再以25℃/h的升温速度升温到800℃,保温12小时;自然冷却降温,制得撇渣器横梁快换预制件。
在主体材质方面,撇渣器横梁快换预制件采用三氧化二铝-碳化硅-碳体系,使用过程中会氧化产生一部分二氧化硅,以此为基础,对各主要组分的加入量和加入形式作进一步的确定。撇渣器横梁上损毁严重的部位,往往也是使用环境最恶劣的部位,根据撇渣器主要受冲刷和侵蚀作用,只有选用在使用条件下低熔物含量低的材料才能符合使用要求,而且使用过程尽量避免碳化硅的氧化,同时注意提高撇渣器横梁预制件的体积密度,降低气孔率。其他分散剂和减水剂含量为5~15%,撇渣器横梁快换预制件中靠复合添加剂起到结合作用。撇渣器横梁中加入碳化硅可以提高材料的抗熔渣侵蚀、耐冲刷、抗热震性能。撇渣器横梁的抗渣性能和使月寿命很大程度上取决于碳化硅的纯度和粒度分布,并直接影响衬体的抗渣性和抗渗透性。另外碳化硅可起到防止碳氧化的作用,使碳的抗剥落性和耐侵蚀性得到提高。还因其硬度高而能提高铁沟料的抗冲刷能力,而碳素对提高配渣器抗热震稳定性有较大的作用。增加碳化硅含量有利于提高撇渣器抗高炉渣的侵蚀,碳化硅主要以细粉形式加入,但也可能部分以颗粒形式加入。
由于三氧化二铝-碳化硅-碳体系中的含碳材料和氧化气氛下容易发生炭氧化,虽然碳化硅可减少碳氧化,但本发明中抗氧化剂是必不可少的,本发明在铝粉、硅粉二者复合的基础上添加碳化硼作为抗氧化剂,其机理为能够比碳优先氧化,在一定温度下形成稳定的金属碳化物,比如硅在内部与碳以及其氧化物形成碳化物或氧化物,即首先形成金属碳化物,再逐渐被氧化起到作用。
本发明的有益效果:
本发明通过对材质的改进以及结构的更新,实现对蔽渣器进行快速更换,并能减少或防止现有撇渣器开裂漏渣的现象发生,有效解决了高炉出铁沟配套用浇注撇渣器使用寿命较短的问题,既节约了重新制作撇渣器浇注料的使用量,同时也节省了撇渣器的烘烤时间,降低了工人的劳动强度,大大提高了生产效率和经济效益。本发明将撇渣器横梁设计成方便更换的预制件方式,有效解决了撇渣器使用寿命短对高炉生产的影响问题。本发明所制备的撇渣器横梁具有使用寿命长、高温强度高、不粘渣铁、抗渣铁冲刷磨损、抗渣铁化学侵蚀等优点,可降低炉前工人的劳动强度,同时也有利于延长撇渣器的使用寿命和防止撇渣器“冻结”事故的发生,能够有效促进高炉炉况的稳定和顺利运行,显著降低炼铁厂吨铁辅料消耗成本。
具体实施方式
下面根据实施例对本发明作进一步详细说明。
实例1
本实施例中所采用的原料规格种类及质量份数为:15~8mm高铝矾土10份,8~5mm板状刚玉25份,5~3mm板状刚玉5份,3~1mm白刚玉10份,1~0mm白刚玉5份,不大于200目白刚玉粉6份,1~0mm碳化硅15份,不大于200目碳化硅4份,碳化硼粉1份,氮化硅粉5份,活性氧化铝粉10份,高温沥青粉1份,添加剂3份,铝酸钙水泥0.3份,金属铝粉0.15份,防爆纤维0.01份。制备工艺过程包括:(1)将各种规格种类的原料按比例配好混合后外加质量百分比3%的水搅拌均匀;(2)在模具中振动浇注成型;(3)成型8小时后脱模;(4)养护24小时;(5)产品养护后以10℃/h的升温速度升温到120℃,保温12小时;再以15℃/h的升温速度升温到330℃,保温12小时;再以20℃/h的升温速度升温到600℃,保温12小时;再以25℃/h的升温速度升温到800℃,保温12小时;自然冷却降温,制得撇渣器横梁快换预制件。
实例2
本实施例中所采用的原料规格种类及质量份数为:15~8mm高铝矾土15份,8~5mm板状刚玉18份,5~3mm板状刚玉10份,3~1mm白刚玉15份,1~0mm白刚玉10份,不大于200目白刚玉粉10份,1~0mm碳化硅10份,不大于200目碳化硅8份,碳化硼粉3份,氮化硅粉3份,活性氧化铝粉15份,高温沥青粉3份,添加剂2份,铝酸钙水泥0.5份,金属铝粉0.05份,防爆纤维0.03份。制备工艺过程包括:(1)将各种规格种类的原料按比例配好混合后外加质量百分比3.3%的水搅拌均匀;(2)在模具中振动浇注成型;(3)成型8小时后脱模;(4)养护24小时;(5)产品养护后以10℃/h的升温速度升温到120℃,保温12小时;再以15℃/h的升温速度升温到330℃,保温12小时;再以20℃/h的升温速度升温到600℃,保温12小时;再以25℃/h的升温速度升温到800℃,保温12小时;自然冷却降温,制得撇渣器横梁快换预制件。
实例3
本实施例中所采用的原料规格种类及质量份数为:15~8mm高铝矾土12份,8~5mm板状刚玉18份,5~3mm板状刚玉8份,3~1mm白刚玉12份,1~0mm白刚玉10份,不大于200目白刚玉粉8份,1~0mm碳化硅12份,不大于200目碳化硅6份,碳化硼粉2份,氮化硅粉4份,活性氧化铝粉12份,高温沥青粉2份,添加剂2份,铝酸钙水泥0.4份,金属铝粉0.01份,防爆纤维0.02份。制备工艺过程包括:(1)将各种规格种类的原料按比例配好混合后外加质量百分比3.1%的水搅拌均匀;(2)在模具中振动浇注成型;(3)成型8小时后脱模;(4)养护24小时;(5)产品养护后以10℃/h的升温速度升温到120℃,保温12小时;再以15℃/h的升温速度升温到330℃,保温12小时;再以20℃/h的升温速度升温到600℃,保温12小时;再以25℃/h的升温速度升温到800℃,保温12小时;自然冷却降温,制得撇渣器横梁快换预制件。
实例4
本实施例中所采用的原料规格种类及质量份数为:15~8mm高铝矾土14份,8~5mm板状刚玉20份,5~3mm板状刚玉10份,3~1mm白刚玉12份,1~0mm白刚玉9份,不大于200目白刚玉粉10份,1~0mm碳化硅15份,不大于200目碳化硅4份,碳化硼粉2份,氮化硅粉3份,活性氧化铝粉13份,高温沥青粉3份,添加剂2份,铝酸钙水泥0.3份,金属铝粉0.12份,防爆纤维0.03份。制备工艺过程包括:(1)将各种规格种类的原料按比例配好混合后外加质量百分比3.2%的水搅拌均匀;(2)在模具中振动浇注成型;(3)成型8小时后脱模;(4)养护24小时;(5)产品养护后以10℃/h的升温速度升温到120℃,保温12小时;再以15℃/h的升温速度升温到330℃,保温12小时;再以20℃/h的升温速度升温到600℃,保温12小时;再以25℃/h的升温速度升温到800℃,保温12小时;自然冷却降温,制得撇渣器横梁快换预制件。
上述实施例只为说明本发明的技术构思及特点,其目的在于让熟悉此领域技术的人士能够了解本发明内容并加以实施,并不能以此限制本发明的保护范围。凡根据本发明精神实质所作的等效变化或修饰,都应涵盖在本发明的保护范围内。
Claims (4)
1.一种撇渣器横梁快换预制件,其特征在于,成分包括15~8mm高铝矾土10~15份,8~5mm板状刚玉18~25份,5~3mm板状刚玉5~10份,3~1mm白刚玉10~15份,1~0mm白刚玉5~10份,不大于200目白刚玉粉6~10份,1~0mm碳化硅10~15份,不大于200目碳化硅4~8份,碳化硼粉1~3份,氮化硅粉3~5份,活性氧化铝粉10~15份,高温沥青粉1~3份,添加剂2~3份,铝酸钙水泥0.3~0.5份,金属铝粉0.05~0.15份,防爆纤维0.01~0.03份。
2.根据权利要求1所述的撇渣器横梁快换预制件,其特征在于,所采用的高铝矾土中Al2O3的质量百分含量不小于88%。
3.根据权利要求1所述的撇渣器横梁快换预制件,其特征在于,所采用的碳化硅中SiC的质量百分含量不小于97%。
4.制备权利要求1-4任一项撇渣器横梁快换预制件的方法,其特征在于,步骤包括:
(1)将各种规格种类的原料按比例配好混合后外加质量百分比3%~3.3%的水搅拌均匀;
(2)在模具中振动浇注成型;
(3)成型8小时后脱模;
(4)养护24小时;
(5)产品养护后以10℃/h的升温速度升温到120℃,保温12小时;再以15℃/h的升温速度升温到330℃,保温12小时;再以20℃/h的升温速度升温到600℃,保温12小时;再以25℃/h的升温速度升温到800℃,保温12小时;自然冷却降温,制得撇渣器横梁快换预制件。
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