CN107385153B - Method for manufacturing air brick capable of stirring motion state of metal melt in metallurgical furnace into spiral flow - Google Patents
Method for manufacturing air brick capable of stirring motion state of metal melt in metallurgical furnace into spiral flow Download PDFInfo
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- CN107385153B CN107385153B CN201710788923.1A CN201710788923A CN107385153B CN 107385153 B CN107385153 B CN 107385153B CN 201710788923 A CN201710788923 A CN 201710788923A CN 107385153 B CN107385153 B CN 107385153B
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/04—Removing impurities by adding a treating agent
- C21C7/072—Treatment with gases
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
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Abstract
A can stir the movement state of the metal melt in the metallurgical furnace to take the form of the air brick of the spiral flow and make the method, is suitable for smelting the air brick needed by any metal melt, the refractory material part of the air brick is formed by ceramic rod, ceramic cylinder, embedding castables several parts, and set up the air channel with spiral characteristic in the relevant position, the special structural composition of the invention can design the quantity, specification, shape and arrangement of the air channel flexibly, can control the distribution regularity of the air channel effectively, and improve the stirring way by controlling every parameter of the air channel, to different smelting characteristics and smelting environment, on the one hand, can confirm the optimal arrangement parameter of the air channel through the numerical simulation of software and simulation experiment, thus can stir the metal melt more fully, in order to meet and smelt the high-quality products, will shorten the smelting time at the same time, has the significance of energy conservation and consumption reduction; on the other hand, the relative service life of the air brick can be prolonged by changing the material and the forming process of each component.
Description
Technical Field
The invention relates to a metal liquid stirring device in a metallurgical furnace, in particular to an air brick which can stir the motion state of metal melt in the metallurgical furnace into spiral flow, belonging to the field of refractory materials.
Background
In the field of ferrous metallurgy, external refining is the subversive development of steel-making process, and the task of adjusting molten steel components and removing inclusions by temperature is transferred to a secondary refining process for smelting in a steel ladle. The appearance of external refining greatly improves the chemical property and mechanical property of steel, and more steel smelting units can smelt high-alloy steel such as stainless steel in steel ladles at present. The basic principle of external refining is that at a certain temperature, molten steel and steel slag are fully contacted and reacted through strong stirring, and the purpose of refining the molten steel is achieved by matching methods such as vacuumizing and the like. The stirring of molten steel also has the concept of electromagnetic stirring at present, but the actual application still adopts the traditional method, namely a gas brick bottom blowing technology.
The gas channels of the gas permeable bricks are currently formed by the following methods: the slit type gas channel has a flat cross section and is distributed in a conical or cylindrical shape; the gas channel is similar to a slit type, and the cross section of the gas channel is circular or nearly circular; the dispersion type realizes ventilation by means of gaps among particles, compared with the invention, the gas channels of the gas permeable bricks belong to the same category at present, the stirring effect is that molten steel circulates from bottom to top, and the flowing state of spiral flow does not appear.
Similarly, the smelting of metallic aluminum also uses air bricks for stirring and temperature adjustment, and the form of the air bricks is mostly dispersed type air bricks.
The anode furnace for smelting the metal copper also uses the air brick, and the ventilation form is similar to the air brick of the refining ladle.
The air brick is also used in the intermediate ladle in the ferrous metallurgy, and the ventilation mode is similar to that of the refining ladle air brick.
The air brick is also used in the iron and steel metallurgical ladle, and the ventilation mode is similar to that of the refining ladle air brick.
No document is reported on the change of the flowing state of the metal liquid in the furnace by designing the ventilating channel of the air brick.
Disclosure of Invention
In order to realize that the movement of the metal melt in the furnace is in a spiral flow state so as to obtain a more sufficient stirring effect, the invention adopts the technical scheme that:
the refractory material part of the air brick consists of a columnar ceramic rod and embedded casting material, or consists of a columnar ceramic rod, one or more ceramic cylinders and embedded casting material, or consists of one or more ceramic cylinders and embedded casting material, at least one spiral ventilation channel is arranged on at least one surface of the side surface of the columnar ceramic rod and the inner side surface or the outer side surface of the ceramic cylinder, and the rest surfaces can be arranged into non-spiral ventilation channels or no ventilation channels.
2, if a plurality of spiral ventilation channels are arranged on the same surface, the spiral directions of the spiral ventilation channels are required to be the same, and if the spiral ventilation channels are arranged on a plurality of surfaces, the spiral directions of the spiral ventilation channels on different surfaces can be the same or opposite.
3, non-spiral ventilation channels can be arranged in the columnar ceramic rods and the ceramic cylinder, the number of each part of the non-spiral ventilation channels is 1 to 60, the columnar ceramic rods can also be dispersed ventilation blocks, and the non-spiral ventilation channels can also be arranged in the embedding casting material.
4, the geometrical characteristic of the spiral vent channel is that after the surface is cut along the generatrix and unfolded, the included angle between the vent channel and the intersected generatrix is more than 0 degree and less than 90 degrees.
And 5, the shortest distance between the same spiral channels and the shortest distance between two nearest spiral channels are more than or equal to 1 mm.
And 6, all the ventilation channels can be arranged to penetrate through the upper end surface of the air brick, and part or all of the ventilation channels can not penetrate through the upper end surface of the air brick.
The design can increase the number of the ventilation channels after the ventilation bricks are used to a certain degree, and improve the air supply quantity, for example, partial ventilation channels are 100mm away from the upper working surface, and when the ventilation bricks are worn by 100mm, the ventilation channels are opened, so that the air supply quantity is improved. The design also aims at the condition that the air bricks are used in turn, for example, two air bricks are arranged in one ladle, one air brick is used firstly, after the first air brick is used to the safe height, the second air brick is used, the air channel of the second air brick is designed to be non-through, and when the air brick is used, the air brick is just worn to the air channel position.
And 7, the cross section of all the air channels can be set to be a circle with the diameter of 0.01mm-3mm, a semicircle or a square with the cross section with the effective thickness of 0.01mm-0.5mm and the effective length of 1mm-80mm, and all the air channels can be in any one or the combination of the two forms.
8, the material for manufacturing the ventilation channel is a strip-shaped or linear organic matter which can be burnt and lost within the maximum temperature of 500 ℃, and is attached to the corresponding curved surface by means of pasting, electrostatic adsorption and clamping by a clamp.
The technical scheme is mainly explained for the vent channels arranged on the surfaces of the columnar ceramic rods or the ceramic cylinders, and the vent channels at other positions are not limited.
9, the material of the vent channel can be directly manufactured on the curved surface by brushing or 3D printing, the material for manufacturing the vent channel by 3D printing needs to be lost by burning within the range of 500 ℃ at most, and can be any one of photosensitive resin, hard PLA plastic, ABS plastic and 3D printing wax.
10, setting an anchoring groove with the depth of 1mm-10mm in the safe height range of the outer surface of the columnar ceramic rod and the inner surface or the outer surface of the ceramic cylinder, if the anchoring groove is arranged on the surface with the ventilation channel, the anchoring groove can be a plurality of isolated anchoring grooves with a circular or polygonal shape, if the anchoring groove is arranged on the surface without the ventilation channel, the anchoring groove can be the anchoring groove with the characteristics, the anchoring groove can also be one or a plurality of annular anchoring grooves with the cross section of any shape, or any combination of the anchoring grooves, and all the anchoring grooves can not intersect with the ventilation channel.
11, the diameter of any part of the columnar ceramic rod can be equal or unequal, and the diameter range is as follows: 10mm-100mm, the thickness of any part of the ceramic cylinder can be equal or unequal, and the thickness range is as follows: 5mm-100mm, the inner diameters of any parts of the ceramic cylinders can be equal or unequal, the range of the inner diameters is 12mm-300mm, and the minimum distance between the adjacent ceramic cylinders and the minimum distance between the ceramic cylinders and the columnar ceramic rod are 0.5mm-60 mm.
12, the normal temperature compressive strength of the columnar ceramic rod and the ceramic cylinder material is more than or equal to 80MPa, the normal temperature flexural strength is more than or equal to 12MPa, and the change rate of a re-burning line after the temperature is kept at 1550 ℃ for 3 hours is-0.1 to +0.1 percent.
13, the columnar ceramic rod and the ceramic cylinder can be formed by isostatic pressing, wet gel injection molding or vibration casting and are treated at the temperature of 500-1800 ℃ at most.
14, the material of the columnar ceramic rod or the ceramic cylinder can be any one of corundum, magnesium, corundum-spinel and corundum-mullite which are combined by calcium aluminate cement or are not combined by cement, and can also be added with 0 to 30 percent of chromic oxide or a refractory raw material containing chromic oxide and 0 to 10 percent of zirconium oxide or a refractory raw material containing zirconium oxide.
15, the refractory raw material of the columnar ceramic rod or the ceramic cylinder can be sintered corundum, fused corundum, alumina micropowder, alumina, mullite, magnesia, spinel, silica micropowder, quartz, chromium oxide, zirconia, chromium corundum, zirconia corundum and zirconite, and the bonding agent can be any one of calcium aluminate cement, aluminum sulfate, silica sol, alumina sol and rho alumina.
16, the embedded castable can be any one of corundum castable, magnesium castable, corundum spinel castable and corundum mullite castable which are combined by calcium aluminate cement or cement-free and contain chromium or do not contain chromium, and also can be the castable formed by adding 0.001 to 10 percent of zirconia or refractory raw materials containing zirconia into the castable.
17, the manufacturing process flow of the invention is as follows:
17.1, designing the size of the air brick according to the size of the metallurgical furnace and the thickness of the furnace bottom;
17.2, designing the composition structure of the air brick and the specification, shape and number of the ventilation channels;
17.3, determining the manufacturing process of the columnar ceramic rod and the ceramic cylinder according to a design drawing;
17.4, processing and manufacturing a columnar ceramic rod and a columnar ceramic cylinder;
17.5, attaching ignition loss substances capable of forming a ventilation channel on the outer side surface of the columnar ceramic rod and the inner and outer side surfaces of the ceramic cylinder, wherein the distribution of the ignition loss substances is one of the cores for embodying the technical characteristics of the invention;
17.6, fixing the columnar ceramic rod and the ceramic cylinder in the air brick die;
17.7, vibration molding and embedding the casting material;
17.8, curing the belt mold for 1 to 12 hours in an environment with the humidity of 60 to 95 percent and the temperature of 30 to 70 ℃, and drying the belt mold at the highest temperature of 300 ℃ after the mold is removed;
17.9, treating the dried green body at the temperature of 500-1650 ℃;
17.10, wrapping a stainless steel outer cylinder, welding a rear cover and a tail pipe to complete manufacturing;
17.11, in the step 17.6, the steel can also be fixed in a stainless steel outer cylinder, and the steel is maintained for 1 to 12 hours under the environment with the humidity of 60 to 95 percent and the temperature of 30 to 70 ℃, then is treated at the low temperature of 500 to 800 ℃, and then is welded with a rear cover and a tail pipe to complete the manufacture.
The invention has the beneficial effects that: the special structural components can flexibly design the number, specification, shape and arrangement of the ventilation channels, the material of each component can be flexibly selected, compared with the conventional slit type ventilation brick or the conventional ventilation brick, the distribution regularity of the ventilation channels can be effectively controlled, the stirring mode is improved by controlling various parameters of the ventilation channels, and aiming at different smelting characteristics and smelting environments, on one hand, the optimal arrangement parameters of the ventilation channels can be determined through software numerical simulation and simulation experiments, so that the metal melt can be stirred more fully, the stirring efficiency and the stirring effect are improved, high-quality products can be smelted, meanwhile, the smelting time can be shortened, and the significance of energy conservation and consumption reduction is realized; on the other hand, the relative service life of the air brick can be prolonged by changing the material and the forming process of each component.
Description of the drawings:
FIG. 1: a sectional view of a refractory part of the air brick;
FIG. 2: the cross section structure of the air brick;
FIG. 3: the columnar ceramic rod is in a cross section structure of a diffusion brick;
FIG. 4 is a schematic view of: all the ventilation channels do not penetrate through and are in a spiral shape, and the curved surface where the ventilation channels are located is expanded into a structure diagram along a bus;
FIG. 5: the curved surface where part of the ventilation channel does not penetrate develops the structure chart;
FIG. 6: the curved surface without the ventilation channel is developed into a structural diagram;
FIG. 7 is a schematic view of: the structural drawing of the curved surface where the non-spiral single ventilation channel is located is developed;
FIG. 8: the curved surface where the spiral and composite ventilation channels are located is unfolded into a structural diagram;
FIG. 9: the structural drawing of the curved surface where the non-spiral and composite ventilation channel is located is developed;
FIG. 10: the structure chart is developed in a conical curved surface;
in the figure, 1: columnar ceramic rod, 2: ceramic cylinder, 3: embedding castable, 4: strip-shaped ventilation channel, 5: linear vent channel, 6: anchor groove, 7: metal housing, 8 rear cover, 9 tail tube, α: the included angle between the midline of the spiral vent channel and the generatrix where it intersects.
Detailed Description
1, air brick structure example:
1.1, a cylindrical ceramic rod and a plurality of ceramic cylinders:
the diameter of the columnar ceramic rod 1 is 30mm, 56 linear ventilation channels with the diameter of 0.5mm are arranged in the middle, the outer surface is provided with strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20mm, the number of the strip-shaped ventilation channels is 6, the angle alpha is 20 degrees, the strip-shaped ventilation channels are uniformly distributed, the linear ventilation channels 5 with the same interval are arranged among the strip-shaped ventilation channels 4, and the diameter of the linear ventilation channels is 0.5 mm;
the thickness of the first ceramic cylinder 2 is 12mm, the inner diameter of the upper end and the lower end is 40mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall is provided with 8 strip-shaped ventilation channels with the specification of 0.2 multiplied by 20mm, the angle alpha is 25 degrees, the two ventilation channels rotate rightwards and are uniformly distributed, linear ventilation channels 5 with the same interval are arranged among the strip-shaped ventilation channels 4, and the diameter is 0.5 mm;
the thickness of the second ceramic cylinder 2 is 15mm, the inner diameter of the upper end and the lower end is 70mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall is provided with strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20mm, the number of the ventilation channels is 13, the angle alpha is 28 degrees, the ventilation channels rotate rightwards and are uniformly distributed, linear ventilation channels 5 with the same interval are arranged among the ventilation channels 4, and the diameter of the ventilation channels is 0.5 mm;
the thickness of the third ceramic cylinder 2 is 5mm, the inner diameter of the upper end and the lower end is 110mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall is provided with 45 strip-shaped ventilation channels with the specification of 0.15 multiplied by 60mm, the angle alpha is 28 degrees, and the ventilation channels rotate rightwards and are uniformly distributed;
the rest part is the embedding castable 3, the outermost layer is the embedding castable 3, the diameter of the upper part is 122mm, and the diameter of the lower part is 130 mm.
1.2, there is not column ceramic rod 1, a plurality of ceramic section of thick bamboo 2, ceramic section of thick bamboo 2 is fan-shaped after expanding:
the thickness of the first ceramic cylinder 2 is 12mm, the inner diameter of an upper opening is 52mm, the inner diameter of a lower opening is 60mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall of the ceramic cylinder is provided with strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20mm, the number of the ventilation channels is 9, the angle alpha is 15 degrees, and the ventilation channels rotate rightwards and are uniformly distributed;
the thickness of the second ceramic cylinder 2 is 5mm, the inner diameter of the upper end is 80mm, the inner diameter of the lower end is 90mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall is provided with strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20mm, the number of the ventilation channels is 13, the angle alpha is 15 degrees, the ventilation channels are uniformly distributed and rotated rightwards, linear ventilation channels 5 with the same interval are arranged among the strip-shaped ventilation channels 4, and the diameter of the ventilation channels is 0.5 mm;
the thickness of the third ceramic cylinder 2 is 5mm, the inner diameters of the upper end and the lower end are 100mm, the inner diameter of the lower end is 110mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall is provided with strip-shaped ventilation channels 4 with the specification of 0.15 multiplied by 20mm, the number of the ventilation channels is 16, the angle alpha is 15 degrees, and the ventilation channels rotate rightwards and are uniformly distributed;
the rest part is embedded casting material 3, the diameter of the upper part of the outermost layer, which is embedded casting material 3, is 122mm, and the diameter of the lower part is 130 mm.
1.3, do not set up column ceramic rod 1, a plurality of ceramic cylinder 2, and ceramic cylinder 2 is the rectangle after expanding:
the thickness of the first ceramic cylinder 2 is 12mm, the inner diameter of the upper opening is 52mm, the inner diameter of the lower opening is 52mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall of the ceramic cylinder is provided with strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20mm, the number of the ventilation channels is 9, the angle alpha is 15 degrees, and the ventilation channels rotate rightwards and are uniformly distributed;
the thickness of the second ceramic cylinder 2 is 5mm, the inner diameter of the upper end and the lower end of the second ceramic cylinder is 90mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall of the second ceramic cylinder is provided with strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20mm, the number of the ventilation channels is 13, the angle alpha is 15 degrees, the ventilation channels rotate rightwards and are uniformly distributed, linear ventilation channels 5 with the same interval are arranged among the strip-shaped ventilation channels 4, and the diameter of the linear ventilation channels is 0.5 mm;
the thickness of the third ceramic cylinder 2 is 5mm, the inner diameter of the upper end and the lower end is 110mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall is provided with strip-shaped ventilation channels 4 with the specification of 0.15 multiplied by 20mm, the number of the ventilation channels is 16, the angle alpha is 15 degrees, and the ventilation channels are rotated left and uniformly distributed;
the rest part is the embedding castable 3, the outermost layer is the embedding castable 3, the diameter of the upper part is 122mm, and the diameter of the lower part is 130 mm.
1,4, manufacturing a dispersion type columnar ceramic rod 1, and manufacturing a plurality of ceramic cylinders 2:
the diameter of the columnar ceramic rod 1 is 60mm, the columnar ceramic rod is pressed into a dispersion type ventilation block, strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20mm are arranged on the outer surface, the number of the ventilation channels is 3, and the value of alpha is 10 degrees;
the thickness of a first ceramic cylinder 2 is 5mm, the inner diameter of the upper end and the lower end of the first ceramic cylinder is 90mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall of the first ceramic cylinder is provided with strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20mm, the number of the ventilation channels is 13, the angle alpha is 15 degrees, the ventilation channels rotate rightwards and are uniformly distributed, linear ventilation channels 5 with the same interval are arranged among the strip-shaped ventilation channels 4, and the diameter of the linear ventilation channels is 0.5 mm;
the diameter of the upper part of the embedding casting material 3 outside the second ceramic cylinder 2 is 122mm, and the diameter of the lower part is 130 mm. Strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20cm are arranged at the part, and the number of the ventilation channels is 12.
1.5, a columnar ceramic rod 1 and a ceramic cylinder 2 are arranged, and a straight-through type ventilation channel is arranged in an embedding casting material 3:
the diameter of the columnar ceramic rod 1 is 30mm, linear ventilation channels 5 with the diameter of 0.5mm are arranged in the middle, the number of the linear ventilation channels is 6, the specification of strip ventilation channels 4 arranged on the outer surface is 0.2 multiplied by 20mm, the right rotation and the number of the strip ventilation channels are 6, the angle alpha is 20 degrees, the linear ventilation channels 5 with the same interval are uniformly distributed, and the diameter of the linear ventilation channels 5 is 0.5 mm;
the thickness of the ceramic cylinder 2 is 12mm, the inner diameter of an upper opening is 52mm, the inner diameter of a lower opening is 60mm, the inner wall of the ceramic cylinder 2 is provided with an anchoring groove 6, the outer wall of the ceramic cylinder is provided with strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20mm, the number of the ventilation channels is 9, the angle alpha is 15 degrees, the ventilation channels rotate rightwards and are uniformly distributed;
the rest is embedded casting material 3, the diameter of the upper part of the outer side embedded casting material 3 is 122mm, the diameter of the lower part is 130mm, strip-shaped ventilation channels 4 with the specification of 0.2 multiplied by 20cm are arranged at the part, the number is 12, and the channels are uniformly distributed in a ring.
2, making examples of the columnar ceramic rod 1 and the ceramic cylinder 2:
2.1 casting moulding, suitable for objects with a wall thickness greater than 10mm
Corundum castable: 30 percent of plate-shaped corundum with the specification of 3-8mm, 22 percent of plate-shaped corundum with the specification of 1-3mm, 18 percent of plate-shaped corundum with the specification of 0-1mm, 20 percent of plate-shaped corundum with 325 meshes or 180 meshes, 6 percent of 70 pure calcium aluminate cement, 4 percent of alumina micropowder, 0.15 percent of water reducing agent FS10, 4.1 percent of water, vibration molding, curing at 60 ℃ for 8 hours, drying at 300 ℃ and firing at 1600 ℃.
The plate-shaped corundum and the white corundum in the formula can be randomly exchanged according to the same specification.
The corundum-mullite castable can be prepared by replacing the same raw material with 5-80% of mullite or alumina with more than 85% of aluminum content in mass ratio in the corundum castable.
Magnesium castable: 32 percent of fused magnesia with the granularity of 3-8mm, 25 percent of fused magnesia with the granularity of 1-3mm, 18 percent of fused magnesia with the granularity of 0-1mm, 22 percent of fused magnesia with the specification of 320 meshes or 180 meshes, 3 percent of silicon micropowder with the granularity of more than 92, 0.2 percent of sodium tripolyphosphate and 0.06 percent of sodium hexametaphosphate, and the preparation is finished after adding water, stirring, directly entering a mold at the temperature of 150 ℃ and drying at the temperature of 300 ℃ at most.
The corundum castable or the corundum mullite castable can be prepared by replacing raw materials with the same mass with 0.5-4% of chromium oxide fine powder or chromium corundum in mass ratio, and the magnesium castable can be prepared by replacing raw materials with the same mass and granularity with 0.5-20% of chromium oxide or chromium corundum in mass ratio.
The corundum spinel castable can be prepared by replacing the corundum with the spinel with the same specification by 0.5-30% of any specification in mass ratio.
The chrome corundum spinel castable can be prepared by replacing raw materials with the same quality and specification with 0.5-4% of chrome oxide fine powder or chrome corundum by mass ratio.
The zirconium-containing castable can be prepared by replacing raw materials with the same mass and specification with 0.1-10% of zirconia fine powder or zirconia corundum fine powder or zirconite fine powder in corundum castable, corundum-mullite castable, corundum-spinel castable, chrome-corundum castable and chrome-corundum-spinel castable.
In the cement-bonded castable example, rho alumina with the same mass can be used for replacing cement to prepare cement-free castable, and silica sol or alumina sol with the mass ratio of 6-10% can be used for replacing cement to prepare sol-bonded castable.
2.2, Wet injection Molding
Sol-gel injection molding: adding 30% silica sol by weight of 15% of alumina micro powder into alumina micro powder, stirring or ball-milling, adding 5% dilute hydrochloric acid by weight of 4% of silica sol, quickly stirring uniformly, injection-molding, standing at 50 ℃ for 6h, curing, drying, and sintering at 1600 ℃ to obtain the final product.
The corundum fine powder, the mullite fine powder, the chromium oxide, the zirconium oxide, the zirconia corundum, the zirconite and the quartz are added in any proportion in the preparation method, so that products with different corresponding compositions can be prepared.
Gel casting of organic monomers: mixing acrylamide and methylene bisacrylamide in a weight ratio of 12:1 to prepare a solution with the concentration of 4%, adding alumina micropowder to prepare slurry with the solid phase content of 75%, stirring or ball-milling, adding 1% by mass of acrylamide and 10% by mass of ammonium persulfate solution, uniformly stirring, adding tetramethylethylenediamine with the mass of 0.01% by mass of the acrylamide, curing at 30 ℃ for 50min, demolding, drying, and firing at 1650 ℃ to finish the preparation.
The chromium oxide, the zirconium oxide, the corundum-zirconia and the mullite in any proportion can be added in the preparation method to prepare products with different corresponding compositions. In addition, the method is prepared by a typical gel injection molding method, has certain toxicity, and can also be prepared by a diatomite, gelatin, vegetable protein and polyvinyl alcohol type gel injection molding system.
2.3 isostatic pressing
Adding 0.5% of condensation type polyvinyl alcohol powder into the alumina micro powder, adding 3% of water, uniformly mixing, carrying out isostatic pressing under the pressure of 120MPa, demoulding, drying, and sintering at 1700 ℃ to obtain the product.
In the above-mentioned technological process, the addition of chromium oxide, mullite, zirconium oxide or zirconium corundum also can be used for making the product with different compositions.
2.4 isostatic pressing Dispersion type columnar ceramic rod 1
50 percent of tabular corundum particles with the specification of 0.5-1mm, 4 percent of chromium oxide micro powder, 5 percent of zirconia powder, 5 percent of alumina micro powder, 3 percent of quartz powder and 3 percent of condensed polyvinyl alcohol saturated solution are added, and the mixture is formed under the isostatic pressure of 80MPa, dried and sintered at 1700 ℃ to finish the manufacturing.
Example of the method of setting the vent passage
And (3) applying an adhesive on one surface of a PE film with the thickness of 0.2mm and the width of 20mm, and then attaching the PE film to the prepared surface to finish the preparation.
The adhesive tape is adopted to arrange the strip-shaped ventilation channels 4, and paper base, cloth base and PVC base adhesive tapes which are not corroded or penetrated by water in a short time after surface treatment can be directly pasted on the required surface to finish the manufacturing.
And (3) winding a PE monofilament round wire with the diameter of 0.5mm on a required surface, and fixing two ends of the PE monofilament round wire by using a clamp or an adhesive to finish the manufacturing.
The ventilation channel is manufactured by a 3D printing method, the required materials are photosensitive resin, hard PLA plastic, ABS plastic and 3D printing wax, and the ventilation channel with a square or semicircular section can be manufactured.
4 embedding castable 3 example
Similar to example 2.1.
5, manufacturing process of air brick
5.1 methods one
Designing the air brick according to the procedure 1;
manufacturing a columnar ceramic rod 1 and a ceramic cylinder 2 by selecting one method according to the procedure 2;
arranging a ventilation channel according to the procedure '3';
fixing each prefabricated assembly in a gas permeable brick mold;
adding embedding castable 3 into the mixture after vibration forming;
maintaining for 12h in an environment with relative humidity of 60-95% and temperature of 50 ℃, removing the mold, drying, and processing at the maximum temperature of 500 ℃ to complete the manufacture, or firing at the maximum temperature of 1650 ℃;
and assembling the air brick metal shell 7, welding the rear cover 8 and the tail pipe 9 to finish the manufacture.
5.2 method two
Designing the air brick according to the procedure 1;
manufacturing a columnar ceramic rod 1 and a ceramic cylinder 2 by selecting one method according to the procedure 2;
arranging a ventilation channel according to the procedure '3';
fixing each component of the prefabricated number in the air brick metal shell 7;
adding embedding castable 3 into the mixture after vibration forming;
curing for 12h in an environment with relative humidity of 60-95% and temperature of 50 ℃, removing the mold, drying, and processing at the maximum temperature of 500 ℃ to complete the manufacture, or firing at the maximum temperature of 800 ℃;
and welding the rear cover 8 and the tail pipe 9 to finish the manufacture.
Claims (11)
1. A method for manufacturing an air brick capable of stirring a metal melt in a metallurgical furnace in a motion state to form a spiral flow comprises the following steps: the method is characterized in that:
1) the manufacturing method of the ceramic rod comprises the following steps: manufacturing a columnar ceramic rod with the diameter of 30mm by using an isostatic pressing, wet gel injection molding or vibration casting molding method; the middle of the ceramic rod is provided with 6 linear ventilation channels (5) with the diameter of 0.5mm, the outer surface is provided with strip ventilation channels (4), the specification is 0.2mm multiplied by 20mm, the number of the strip ventilation channels is 6, the angle alpha is 20 degrees, the strip ventilation channels are uniformly distributed, the linear ventilation channels (5) with the same interval are arranged among the strip ventilation channels (4), and the diameter is 0.5 mm; the outer surface ventilation channel of the ceramic rod adopts a PE film with the specification of 0.2mm in thickness and 20mm in width, and the outer surface ventilation channel is pasted on the surface of the ceramic rod after an adhesive is coated on one surface of the PE film, so that the manufacturing is completed;
2) the manufacturing method of the ceramic cylinder comprises the following steps: the method comprises the following steps of manufacturing three ceramic cylinders by using an isostatic pressing forming, wet gel injection molding or vibration casting forming method, wherein the thickness of the first ceramic cylinder (2) is 12mm, the inner diameters of the upper end and the lower end are 40mm, the inner wall of the ceramic cylinder (2) is provided with an anchoring groove (6), the outer wall is provided with 8 strip-shaped ventilation channels with the specification of 0.2 multiplied by 20mm, the angle alpha is 25 degrees, the right rotation and the uniform distribution are realized, linear ventilation channels (5) with the same interval are arranged among the strip-shaped ventilation channels (4), and the diameter is 0.5 mm; the thickness of the second ceramic cylinder (2) is 15mm, the inner diameter of the upper end and the lower end is 70mm, the inner wall of the ceramic cylinder (2) is provided with an anchoring groove (6), the outer wall is provided with 13 strip-shaped ventilation channels (4) with the specification of 0.2 multiplied by 20mm, the angle alpha is 28 degrees, the strip-shaped ventilation channels are rotated rightwards and uniformly distributed, linear ventilation channels (5) with the same interval are arranged among the strip-shaped ventilation channels (4), and the diameter is 0.5 mm; the thickness of the third ceramic cylinder (2) is 5mm, the inner diameter of the upper end and the lower end is 110mm, the inner wall of the ceramic cylinder (2) is provided with an anchoring groove (6), the outer wall is provided with 5 strip-shaped ventilation channels (4) with the specification of 0.15 multiplied by 60mm, the angle alpha is 28 degrees, the ventilation channels are rotated rightwards and uniformly distributed, and the arrangement method of the ventilation channels is the same as that of the ceramic rods;
3) fixing the manufactured ceramic rod and the ceramic cylinder in a breathable brick mold, performing vibration molding, adding an embedding material, maintaining the mold for 12 hours in an environment with the humidity of 60-95% and the temperature of 30-70 ℃, removing the mold, drying at the highest temperature of 300 ℃ and firing at the temperature of 1650 ℃;
4) and assembling the metal shell (7) of the air brick, welding the rear cover (8) and the tail pipe (9) to finish the manufacture.
2. The method of claim 1, further comprising: when a plurality of spiral ventilation channels are arranged on the same surface, the spiral directions of the spiral ventilation channels are required to be the same, and when the spiral ventilation channels are arranged on a plurality of surfaces, the spiral directions of the spiral ventilation channels on different surfaces can be the same or opposite.
3. The method of claim 1, further comprising: non-spiral ventilation channels can be arranged in the columnar ceramic rods and the ceramic cylinder, the number of each part of non-spiral ventilation channels is 1 to 60, the columnar ceramic rods can also be dispersed ventilation blocks, and the non-spiral ventilation channels can also be arranged in the embedding casting material.
4. The method of claim 1, further comprising: the shortest distance between the same spiral channels and the shortest distance between two nearest spiral channels are more than or equal to 1 mm.
5. The method of claim 1, further comprising: all the ventilation channels can be arranged to penetrate through the upper end face of the air brick, and can also be partially or completely not penetrated through the upper end face of the air brick.
6. The method of claim 1, further comprising: the ventilation channel on the outer surface of the ceramic rod can be manufactured by 3D printing instead of a PE film, and the 3D printing material is any one of photosensitive resin, hard PLA plastic, ABS plastic and 3D printing wax.
7. The method of claim 1, further comprising: the normal temperature compressive strength of the columnar ceramic rod and the ceramic cylinder material is more than or equal to 80MPa, the normal temperature rupture strength is more than or equal to 12MPa, and the change rate of a re-burning line after the temperature is kept at 1550 ℃ for 3 hours is-0.1 to +0.1 percent.
8. The method of claim 1, further comprising: the material of the columnar ceramic rod or the ceramic cylinder is any one of corundum, magnesium, corundum-spinel and corundum-mullite which are combined by calcium aluminate cement or cement-free.
9. The method of claim 1, further comprising: the refractory raw material of the columnar ceramic rod or ceramic cylinder is sintered corundum, fused corundum, alumina micropowder, alumina, mullite, magnesia, spinel, silica micropowder, quartz, chromium oxide, zirconia, chromium corundum, zirconia corundum and zirconite, and the bonding agent can be any one of calcium aluminate cement, silica sol, alumina sol and rho alumina.
10. The method of claim 1, further comprising: the embedded castable is any one of corundum castable, magnesium castable, corundum spinel castable and corundum mullite castable, which are combined with calcium aluminate cement or are combined without cement and contain chromium or do not contain chromium.
11. The method of claim 1, further comprising: steps 3), 4) may be replaced by: fixing the ceramic rod and the ceramic cylinder in a stainless steel outer cylinder, curing for 1-12 h under the environment with the humidity of 60-95% and the temperature of 30-70 ℃, then performing low-temperature treatment at 500-800 ℃, and then welding a rear cover and a tail pipe to finish the manufacture.
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| CN201710788923.1A CN107385153B (en) | 2017-09-05 | 2017-09-05 | Method for manufacturing air brick capable of stirring motion state of metal melt in metallurgical furnace into spiral flow |
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| CN108097942B (en) * | 2017-12-29 | 2023-10-20 | 武汉科技大学 | Composite electromagnetic field monitoring type steel ladle air brick |
| CN108997001B (en) * | 2018-08-05 | 2023-06-06 | 洛阳科创新材料股份有限公司 | Preparation method of microporous ceramic rod for air brick |
| CN111793734B (en) * | 2020-06-29 | 2023-11-17 | 洛阳利尔功能材料有限公司 | 3D printing air brick and preparation method thereof |
| CN111893244B (en) * | 2020-07-30 | 2021-12-24 | 武汉科技大学 | Air brick for bottom blowing of fine argon bubbles for ladle refining |
| CN113999028A (en) * | 2021-11-12 | 2022-02-01 | 瑞泰马钢新材料科技有限公司 | Aluminum back seam material for steel ladle and preparation method thereof |
| CN114277216A (en) * | 2021-12-27 | 2022-04-05 | 辽宁丰德耐磨新材料制品有限公司 | In-ladle argon blowing stirring method for production of wear-resistant steel balls |
| CN114367653B (en) * | 2022-01-07 | 2024-03-29 | 濮阳濮耐高温材料（集团）股份有限公司 | Fluid stirring purifying element with scroll structure |
| CN114309565B (en) * | 2022-01-08 | 2024-04-05 | 濮阳濮耐高温材料（集团）股份有限公司 | Fluid stirring purifying element with circular arc air flue |
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