CN107759208A - 熔铸β‑Al2O3砖的制造工艺 - Google Patents

熔铸β‑Al2O3砖的制造工艺 Download PDF

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CN107759208A
CN107759208A CN201610690947.9A CN201610690947A CN107759208A CN 107759208 A CN107759208 A CN 107759208A CN 201610690947 A CN201610690947 A CN 201610690947A CN 107759208 A CN107759208 A CN 107759208A
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魏晓敏
董运昆
朱卫科
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ZHENGZHOU DONGFANG ANCAI REFRACTORY CO Ltd
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Abstract

本发明公开了熔铸β‑Al2O3砖的制造工艺,包括以下步骤:利用优质进口煅烧氧化铝粉,添加优质助熔剂和辅助材料,在电脑全自动控制的三相电弧炉中经2500℃高温熔融,使配合料变成成分均匀的液态,然后澄清,澄清后再将2200℃左右的高温熔液以一定的铸速注入用优质氧化铝制品按一定级配制成的砖材模型中,砖材模型提前埋入保温介质,留出铸口,待浇铸完成后用保温介质覆盖上部进行自然退火保温,待砖材温度降至60℃以下时,将砖材连同模型从保温介质中吊出,清除模型,然后用专用的金刚石刀具进行精加工。本发明完全解决了熔铸β‑Al2O3砖出现缩松、缩孔的问题,充分提高了熔铸β‑Al2O3砖的产品质量。

Description

熔铸β-Al2O3砖的制造工艺
技术领域
本发明属于耐火材料生产技术领域,尤其涉及熔铸β-Al2O3砖的制造工艺。
背景技术
熔铸β-Al2O3砖是采用高纯度的煅烧氧化铝为原料,在电弧炉中2500℃以上的高温熔融、铸造而制成的。β-刚玉砖是由99%的β-Al2O3相构成,抗剥落性强,尤其对强碱蒸气显示出极高的耐侵蚀性,且几乎不含有玻璃相,对熔融玻璃不污染。用于玻璃熔窑中玻璃原料飞散现象少工作池的上部结构、燃烧口附近的胸墙、小炉嘴及吊墙等。
β-Al2O3是氧化铝的另一种变态,分子式为Na2O.11Al2O3,真密度为3.3-3.4g/㎝3,莫氏硬度6,融入Na2O的含量可达5-7%,熔铸β-Al2O3砖,主要是由β-Al2O3粗大光亮的板状晶体构成的白色(略微发绿)制品,含Al2O3 92%-95%,只有1%以下的玻璃相,其显气孔率小于15%,容重2.8-3.0g/㎝3。由于熔铸时,β-Al2O3与熔液之间的密度差很小,所以它实际上没有缩孔,由于Al2O3本身在2000℃以上被钠饱和,所以在高温下对碱蒸汽作用非常稳定。此外,其热稳定性在熔铸砖中也是最好的。
在制造熔铸β-Al2O3砖的过程中,由于β-Al2O3的特性,产品极易出现缩松、缩孔等缺陷。因此,解决缩松、缩孔等缺陷必须从原料选材及浇铸工艺上寻找出路。
发明内容
本发明为了解决现有技术中的不足之处,提供一种充分降低甚至杜绝缩松、缩孔等缺陷的熔铸β-Al2O3砖的制造工艺。
为解决上述技术问题,本发明采用如下技术方案:熔铸β- Al2O3砖的制造工艺,包括以下步骤:
(1)、砖材模型的制作以及原材料选择配制:采用进口的氧化铝粉α-Al2O3,其中Al2O3的纯度≧99.5%,对氧化铝粉进行煅烧,煅烧后的氧化铝粉加入助熔剂Na2O及其他辅助原料的混合物,加入到双螺旋混料机中搅拌均匀;同时采用进口的氧化铝粉按一定级配打制砖材模型;
(2)、熔化和澄清:将搅拌均匀的原材料加入全自动控制的三相电弧炉,高温熔化120分钟后,然后在2500℃保温澄清5分钟;
(3)、将砖材模型放入到保温箱中,并在保温箱内充填位于砖材模型底部及外壁四周的保温介质,然后在震动平台上震实,最后在砖材模型的顶部设置浇注冒口;
(4)、将熔化好2200℃的高温熔液以50㎏/s的铸速,通过浇注冒口注入砖材模型中,然后在砖材模型顶部覆盖不低于250㎜厚的保温介质;
(5)、将保温箱吊至保温区,采取有序保温退火的方法进行退火处理,待砖材温度降至60℃以下时,将砖材模型从保温箱内吊出,对砖材脱模,并对砖材外表面清理砂皮,同时对保温箱和砖材模型也进行清理;
(6)、采用专用的机床、特制的金刚石刀具对清理后的砖材进行精加工,以此达到设计要求。
所述步骤(1)中的的混合物中各原材料化学成分的重量百分比分别为:Al2O3≥91.3%;SiO2<1.42%;Fe2O3<0.22%;Na2O:5-8%;MgO<0.1%;CaO<0.5%;TiO2<0.04%。
所述步骤(2)中三相电弧炉配备3400KVA变压器。
采用上述技术方案,本发明是经多次试验从而总结出了行之有效的生产工艺,选择优质的原材料,调整混合原料的配比,采用先进的三相电弧炉进行科学的高温熔融,并有针对性的选取优质的高频电极,采用合理级配的氧化铝制品模型,并采用先进的保温退火办法,经过一系列的工艺攻关,完全解决了熔铸β-Al2O3砖出现缩松、缩孔的问题,充分提高了熔铸β-Al2O3砖的产品质量。
具体实施方式
本发明的熔铸β-Al2O3砖砖的制造工艺,包括以下步骤:
(1)、砖材模型的制作以及原材料选择配制:采用进口的氧化铝粉α-Al2O3,其中Al2O3的纯度≧99.5%,对氧化铝粉进行煅烧,煅烧后的氧化铝粉加入助熔剂Na2O及其他辅助原料的混合物,加入到双螺旋混料机中搅拌均匀;同时采用进口的氧化铝粉按一定级配打制砖材模型;
(2)、熔化和澄清:将搅拌均匀的原材料加入全自动控制的三相电弧炉,高温熔化120分钟后,然后在2500℃保温澄清5分钟;
(3)、将砖材模型放入到保温箱中,并在保温箱内充填位于砖材模型底部及外壁四周的保温介质,然后在震动平台上震实,最后在砖材模型的顶部设置浇注冒口;
(4)、将熔化好2200℃的高温熔液以50㎏/s的铸速,通过浇注冒口注入砖材模型中,然后在砖材模型顶部覆盖不低于250㎜厚的保温介质;
(5)、将保温箱吊至保温区,采取有序保温退火的方法进行退火处理,待砖材温度降至60℃以下时,将砖材模型从保温箱内吊出,对砖材脱模,并对砖材外表面清理砂皮,同时对保温箱和砖材模型也进行清理;
(6)、采用专用的机床、特制的金刚石刀具对清理后的砖材进行精加工,以此达到设计要求。
所述步骤(1)中的的混合物中各原材料化学成分的重量百分比分别为:Al2O3≥91.3%;SiO2<1.42%;Fe2O3<0.22%;Na2O:5-8%;MgO<0.1%;CaO<0.5%;TiO2<0.04%。
所述步骤(2)中三相电弧炉配备3400KVA变压器。

Claims (3)

1.熔铸β-Al2O3砖的制造工艺,其特征在于:包括以下步骤,
(1)、砖材模型的制作以及原材料选择配制:采用进口的氧化铝粉α-Al2O3,其中Al2O3的纯度≧99.5%,对氧化铝粉进行煅烧,煅烧后的氧化铝粉加入助熔剂Na2O及其他辅助原料的混合物,加入到双螺旋混料机中搅拌均匀;同时采用进口的氧化铝粉按一定级配打制砖材模型;
(2)、熔化和澄清:将搅拌均匀的原材料加入全自动控制的三相电弧炉,高温熔化120分钟后,然后在2500℃保温澄清5分钟;
(3)、将砖材模型放入到保温箱中,并在保温箱内充填位于砖材模型底部及外壁四周的保温介质,然后在震动平台上震实,最后在砖材模型的顶部设置浇注冒口;
(4)、将熔化好2200℃的高温熔液以50㎏/s的铸速,通过浇注冒口注入砖材模型中,然后在砖材模型顶部覆盖不低于250㎜厚的保温介质;
(5)、将保温箱吊至保温区,采取有序保温退火的方法进行退火处理,待砖材温度降至60℃以下时,将砖材模型从保温箱内吊出,对砖材脱模,并对砖材外表面清理砂皮,同时对保温箱和砖材模型也进行清理;
(6)、采用专用的机床、特制的金刚石刀具对清理后的砖材进行精加工,以此达到设计要求。
2.根据权利要求1所述的熔铸β- Al2O3砖的制造工艺,其特征在于:所述步骤(1)中的的混合物中各原材料化学成分的重量百分比分别为:Al2O3≥91.3%;SiO2<1.42%;Fe2O3<0.22%;Na2O:5-8%;MgO<0.1%;CaO<0.5%;TiO2<0.04%。
3.根据权利要求2所述的熔铸β- Al2O3砖的制造工艺,其特征在于:所述步骤(2)中三相电弧炉配备3400KVA变压器。
CN201610690947.9A 2016-08-20 2016-08-20 熔铸β‑Al2O3砖的制造工艺 Pending CN107759208A (zh)

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CN112225543A (zh) * 2020-10-12 2021-01-15 郑州方铭高温陶瓷新材料有限公司 一种应用于玻璃窑炉蓄热室的熔铸成型筒型陶瓷砖及其制备方法
CN113510823A (zh) * 2021-06-23 2021-10-19 河南省瑞泰科实业集团有限公司 一种熔铸高纯氧化铝耐火制品的保温成型的方法及保温箱及得到的耐火制品
CN117923886A (zh) * 2024-03-21 2024-04-26 淄博艾杰旭刚玉材料有限公司 耐侵蚀的α-β氧化铝熔铸砖及其制备方法

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CN112225543A (zh) * 2020-10-12 2021-01-15 郑州方铭高温陶瓷新材料有限公司 一种应用于玻璃窑炉蓄热室的熔铸成型筒型陶瓷砖及其制备方法
CN113510823A (zh) * 2021-06-23 2021-10-19 河南省瑞泰科实业集团有限公司 一种熔铸高纯氧化铝耐火制品的保温成型的方法及保温箱及得到的耐火制品
CN117923886A (zh) * 2024-03-21 2024-04-26 淄博艾杰旭刚玉材料有限公司 耐侵蚀的α-β氧化铝熔铸砖及其制备方法
CN117923886B (zh) * 2024-03-21 2024-07-02 淄博艾杰旭刚玉材料有限公司 耐侵蚀的α-β氧化铝熔铸砖及其制备方法

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