CN107324784A - 一种转炉挡渣用铝镁碳滑板砖及其制备方法 - Google Patents

一种转炉挡渣用铝镁碳滑板砖及其制备方法 Download PDF

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CN107324784A
CN107324784A CN201710575179.7A CN201710575179A CN107324784A CN 107324784 A CN107324784 A CN 107324784A CN 201710575179 A CN201710575179 A CN 201710575179A CN 107324784 A CN107324784 A CN 107324784A
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resisting
converter slag
corundum
slide brick
magnalium
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王建华
陆启海
涂方兵
吕忠华
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Anhui Xinhai Environmental Protection New Material Co Ltd
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Abstract

本发明公开了一种转炉挡渣用铝镁碳滑板砖及其制备方法，由以下重量比的组份制成：刚玉60‑70％、镁砂粉20‑28％、炭素材料2‑7％、抗氧化剂2‑5％、有机结合剂3‑5％；经过预混；投料混炼；压制成型；烘烤固化；坯体工作面磨平、金属打箍和工作面涂固体润滑剂；保温干燥处理。本发明的优点是：采用高硬度的刚玉质，保证滑板板面耐磨强度，避免板面强度低导致的板面拉毛钻钢问题；采用刚玉骨料降低了材料的热膨胀率，热震稳定性也明显好于镁碳质滑板，基本与铝碳质相当；细粉部分采用镁碳材质，使材料相比铝碳质或铝锆碳质具有更加优异抗渣侵蚀性，用后扩孔小，寿命更高。

Description

一种转炉挡渣用铝镁碳滑板砖及其制备方法
技术领域
本发明属于耐火材料技术领域，尤其涉及一种转炉挡渣用铝镁碳质滑板及其制备方法。
背景技术
转炉滑板法挡渣具有挡渣成功率高、下渣率小、挡渣效果优良、自动化率高等优势，已经成为国内外转炉出钢挡渣工艺的发展趋势。滑板转作为挡渣的重要功能部件，其所处使环境恶劣，更换最为频繁，是整个挡渣系统使用稳定性、安全性以及成本控制的关键。滑板砖应具有优良的耐高温强度、热震稳定性、抗侵蚀性及抗氧化性，以获得更高的使用寿命和稳定的操作状态。现有技术中，钢包滑板、转炉挡渣滑板使用的材质大多为铝碳质或铝锆碳质；铝锆碳质滑板具有耐磨性好、热震稳定性和耐高温性能优良等优点；在转炉挡渣滑板领域，烧成铝锆碳质滑板使用寿命可以达到12-18炉之间。缺点是，由于铝锆碳质材料的抗渣能力限制，滑板后期扩孔严重，滑板寿命很难再有大的提高，且铝锆碳的材料成本相对偏高，无形中增加了企业生产成本。
目前行业内镁碳砖在转炉内衬、转炉出钢口、钢包渣线等部位使用已成为绝对的主流，因为镁碳质滑板砖具有优良的抗渣能力、良好的耐高温性能、抗热震性以及高温抗蠕变性。缺点是，由于主原料镁砂硬度偏低(莫氏硬度5.5)，镁碳砖无法满足机构滑板高温下反复高强度磨擦要求。
发明内容
为克服现有技术的不足，本发明的目的是提供一种转炉挡渣用铝镁碳滑板砖及其制备方法，板面耐磨强度高、材料的热膨胀率低、热震稳定性好，具有优异的抗渣侵蚀性，用后扩孔小，寿命高。
为实现上述目的，本发明采用如下技术方案：
一种转炉挡渣用铝镁碳滑板砖，其特点是由以下重量比的组份制成：刚玉60-70％、镁砂粉20-28％、炭素材料2-7％、抗氧化剂2-5％、有机结合剂3-5％。
进一步地，所述的刚玉中氧化铝含量大于97.0％，刚玉粒度为0.28-3mm。
进一步地，所述的刚玉的粒度级配为3-1mm重量占比25-30％、1-0.5mm重量占比20-30％、0.5-0.28mm重量占比10-18％。
进一步地，所述的镁砂粉中氧化镁含量大于96.0％，镁砂粒度组成为0-0.088mm。
进一步地，所述的炭素材料为石墨、碳黑中的一种或组合，粒度小于0.154mm。
进一步地，所述的碳素材料优选的使用石墨，重量比为2-7％，粒度小于0.154mm。
进一步地，所述的抗氧化剂为金属铝粉、硅粉、碳化硼中的一种或数种，粒度小于0.088mm。
进一步地，所述的有机结合剂为酚醛树脂、沥青粉中的一种或组合。
一种转炉挡渣用铝镁碳滑板砖的制备方法，其特点是按照如下步骤进行：
步骤1 预混：投料混炼：先将镁砂粉、抗氧化剂、沥青粉、碳素材料预混5-10min；
步骤2 投料混炼：先将刚玉颗粒倒入混炼机中干混1-3min，然后加入酚醛树脂继续混合3-8min，最后加入预混合粉，继续混合15-30min形成泥料；
步骤3 压制成型：将混炼好的泥料加入模具中采用1000吨摩擦压砖机压制成砖坯；
步骤4 烘烤固化：将砖坯置于干燥窑中烘烤固化，烘烤温度为250-300℃，保温时间为10-20h；
步骤5将干燥后坯体工作面磨平到平整度0.06mm以内，然后金属打箍和工作面涂固体润滑剂；
步骤6 110℃保温1-3h干燥处理。
本发明的特点在于配方中0.28mm以上全部为刚玉，0.154mm以下全部为镁碳质细粉：镁砂粉、炭素材料、抗氧化剂。与现有铝碳质、铝锆碳质滑板砖及镁碳质滑板技术相比，本发明的优点是：
1、细粉部分是耐火材料在被侵蚀时最薄弱部位，本发明细粉部分采用抗渣侵蚀性优异的镁碳材质，使材料相比铝碳质、铝锆碳质滑板砖具有更加优异抗渣侵蚀性，用后侵蚀小，扩孔小，寿命更高；
2、采用高硬度的刚玉(莫氏硬度9)作骨料，保证了滑板板面耐磨性能，避免了镁砂骨料硬度低导致的滑板板面严重拉毛和钻钢问题；另外，刚玉相比镁砂热膨长率低，骨料尺寸大，绝对热膨胀值大，采用刚玉骨料降低了材料的热膨胀率，热震稳定性明显好于镁碳质滑板，基本与铝碳质滑板相当；
3、刚玉镁砂0.088-0.28mm粒度带断层，0.28mm以下无氧化铝成份，大幅地减少了高温铝镁尖晶石化反应，避免了反应体积膨胀导致的材料性能恶化；另外，0.088mm以上无镁砂成分，保证了材料骨架的耐磨性；
4、使用本技术方案生产出的滑板砖为不烧制品，只需进行低温干燥，省去了高能耗烧成过程，大大降低了能耗，节约成本。
具体实施方式
下面结合实施例对本发明做进一步说明。
一种转炉挡渣用铝镁碳滑板砖的制备方法，其特点是按照如下步骤进行：
步骤1 预混：投料混炼：先将镁砂粉、抗氧化剂、沥青粉、碳素材料预混5-10min；
步骤2 投料混炼：先将刚玉颗粒倒入混炼机中干混1-3min，然后加入酚醛树脂继续混合3-8min，最后加入预混合粉，继续混合15-30min形成泥料；
步骤3 压制成型：将混炼好的泥料加入模具中采用1000吨摩擦压砖机压制成砖坯；
步骤4 烘烤固化：将砖坯置于干燥窑中烘烤固化，烘烤温度为250-300℃，保温时间为10-20h；
步骤5 将干燥后坯体工作面磨平到平整度0.06mm以内，然后金属打箍和工作面涂固体润滑剂；
步骤6 110℃保温1-3h干燥处理。
需要说明的是上述转炉挡渣用铝镁碳滑板砖的制备方法是通用方法，原料组成选用根据具体实施例不同在相应步骤进行调整，不做限定性要求。
实施例1-3为本技术方案材料重量比、对比实施例4-5，并对其性能进行测试，结果如表1所示。
表1实施例及性能结果
从表1可以看出：骨料采用高硬度的刚玉，保证了滑板在使用时的板面耐磨强度，避免了镁碳质滑板板面强度低导致的使用中板面拉毛钻钢问题；刚玉相比镁砂热膨长率低，骨料尺寸大，绝对热膨胀值大，采用刚玉骨料降低了材料的热膨胀率，热震稳定性也明显好于镁碳质滑板，基本与铝碳质相当；细粉部分采用镁碳材质，由于镁碳材质优异的抗渣侵蚀性，使材料相比铝碳质或铝锆碳质具有更加优异抗渣侵蚀性，用后扩孔小，寿命更高。
在原料重量配比中，刚玉中氧化铝含量低于下降值97.0％时，杂质含量偏高，热态强度和抗侵蚀性差；刚玉骨料重量比为60-70％，高于上限值70％时，成型困难；低于下限值60％时，细粉量偏多，成型时易层裂。
镁砂粉重量比高于上限值28％时，细粉量偏多，成型时易层裂；低于下限值20％时，细粉中镁砂粉少，抗渣侵蚀性不好；镁砂中氧化镁含量低于下限值96.0％时，杂质含量偏高，热态强度和抗侵蚀性差。
炭素材料为石墨和炭黑中的一种或两种组合，粒度小于0.154mm；炭素材料有利于抗侵蚀性和热震稳定性，当重量比高于上限值7％时，炭素材料氧化后会引起滑板砖整体组织破坏；当重量比低于下限值2％时，热震稳定性、抗侵蚀性的改善作用不大。
抗氧化剂为金属铝粉、硅粉、碳化硼中的一种或数种，在材料中起到抗氧化和低中温增强的作用；当用量大于上限值5％时，在使用中会引起材料体积膨胀，体积稳定性差；当用量小于下限值2％时，材料结合强度低、高温抗折强度低，不能有效抑制和改善滑板热裂纹的发生。
有机结合剂为酚醛树脂、沥青粉中的一种或组合，酚醛树脂耐高温性能好，残碳率较高，能保持滑板结构的整体性和尺寸的稳定性，在交联后可以为耐火材料提供所需要的机械强度和耐热性能；沥青粉残碳率高，固化后形成的碳抗氧化性好，有利于材料的抗氧化性和抗侵蚀性。

Claims (9)

1.一种转炉挡渣用铝镁碳滑板砖，其特征在于，由以下重量比的组份制成：刚玉60-70％、镁砂粉20-28％、炭素材料2-7％、抗氧化剂2-5％、有机结合剂3-5％。
2.根据权利要求1所述的一种转炉挡渣用铝镁碳滑板砖，其特征在于，所述的刚玉中氧化铝含量大于97.0％，刚玉粒度为0.28-3mm。
3.根据权利要求1和2任一项所述的一种转炉挡渣用铝镁碳滑板砖，其特征在于，所述的刚玉的粒度级配为3-1mm重量占比25-30％、1-0.5mm重量占比20-30％、0.5-0.28mm重量占比10-18％。
4.根据权利要求1所述的一种转炉挡渣用铝镁碳滑板砖，其特征在于，所述的镁砂粉中氧化镁含量大于96.0％，镁砂粒度组成为0-0.088mm。
5.根据权利要求1所述的一种转炉挡渣用铝镁碳滑板砖，其特征在于，所述的炭素材料为石墨、碳黑中的一种或组合，粒度小于0.154mm。
6.根据权利要求1和5任一项所述的一种转炉挡渣用铝镁碳滑板砖，其特征在于，所述的碳素材料优选的使用石墨，重量比为2-7％，粒度小于0.154mm。
7.根据权利要求1所述的一种转炉挡渣用铝镁碳滑板砖，其特征在于，所述的抗氧化剂为金属铝粉、硅粉、碳化硼中的一种或数种，粒度小于0.088mm。
8.根据权利要求1所述的一种转炉挡渣用铝镁碳滑板砖，其特征在于，所述的有机结合剂为酚醛树脂、沥青粉中的一种或组合。
9.一种转炉挡渣用铝镁碳滑板砖的制备方法，其特征在于，按照如下步骤进行：
步骤1 预混：投料混炼：先将镁砂粉、抗氧化剂、沥青粉、碳素材料预混5-10min；
步骤2 投料混炼：先将刚玉颗粒倒入混炼机中干混1-3min，然后加入酚醛树脂继续混合3-8min，最后加入预混合粉，继续混合15-30min形成泥料；
步骤3 压制成型：将混炼好的泥料加入模具中采用1000吨摩擦压砖机压制成砖坯；
步骤4 烘烤固化：将砖坯置于干燥窑中烘烤固化，烘烤温度为250-300℃，保温时间为10-20h；
步骤5 将干燥后坯体工作面磨平到平整度0.06mm以内，然后金属打箍和工作面涂固体润滑剂；
步骤6 110℃保温1-3h干燥处理。
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