CN107856166B - 一种锆刚玉电熔砖冒口保温结构及浇铸保温方法 - Google Patents
一种锆刚玉电熔砖冒口保温结构及浇铸保温方法 Download PDFInfo
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Abstract
本发明涉及一种锆刚玉电熔砖冒口保温结构及浇铸保温方法,技术方案是,包括保温箱和设置在保温箱内的砂型模具,保温箱的内壁与砂型模具的外壁之间填充有保温砂,所述砂型模具是由下部的砖体砂型和上部的冒口砂型构成的上部开口的中空一体结构,砖体砂型的内腔构成锆刚玉电熔砖的砖体成型空间,冒口砂型的内腔构成补缩空间,冒口砂型的上口部覆盖有膨胀式保温层,膨胀式保温层是由下部的玻璃棉层和上部的膨胀石墨层构成的双层复合结构,本发明浇铸后通过在冒口上口部覆盖膨胀式保温层,对冒口进行隔热保温,延长冒口内的液态时间,从而提高了无缩孔浇铸电熔砖的容重,同时在浇铸过程中省去了排气的过程,工艺得到了简化,使用方便,效果好。
Description
技术领域
本发明涉及玻璃窑炉用电熔锆刚玉耐火材料领域,特别是一种锆刚玉电熔砖冒口保温结构及浇铸保温方法。
背景技术
锆刚玉电熔砖是用于玻璃窑炉的窑池砌筑,其原料是有澳大利亚进口的优质锆砂、国产氧化铝粉以及微量纯碱为原料,混合后加入电弧炉经过2000℃以上高温熔化,最后经过吹氧、精炼浇铸砂型成型,后期需要保温退火,毛坯砖精加工、预组装,到包装发货完成整个生产流程,锆刚玉电熔砖根据锆含量的调配制成锆含量为33﹪、36%、41%的电熔砖,按照玻璃窑炉的需求设计在不同的部位。随着锆刚玉电熔砖生产技术的不断完善,从成型率到成分的稳定都能做出品质优良的电熔砖,我们国产电熔砖在玻璃窑炉使用性能方面与合资品牌“北京西普”“山东旭硝子”对比唯一的缺陷表现在使用寿命的差距。并且仅仅是在无缩孔砖差别,无缩孔砖顾名思义就是砖内居中部分无疏松、无缩孔、光滑致密度优良,合资品牌在这方面做的比较优秀,因此合资品牌的电熔砖占据国内高端玻璃行业的,原因就是无缩孔砖的内部致密度好,可以延长玻璃窑炉的使用寿命,并且为玻璃窑炉的稳定生产带来保证。
无缩孔电熔砖的容重标准是33#不小于3.75,41#不小于3.95,国产电熔砖都能做到这个标准,但合资品牌的无缩孔电熔砖容重要超出这个标0.05至0.1.
以池壁砖规格300mmx400mmx1500mm为例,电熔砖高温溶液浇铸型腔后,接触型腔的部分是常温状态,高温溶液会快速在表层凝固,形成一个硬壳,温度的急剧变化导致热胀冷缩过程在电熔砖表层快速完成,也就是电熔砖的体积在此期间已经定型;但是电熔砖中间部位还处于液态的高温状态,热胀冷缩过程远远没有结束,还在进行,那么砖体中心部位由于热胀冷缩形成的空隙需要冒口部位的溶液来补充,随着时间的延长,冒口内溶液从高温到低温不断下降,冒口内溶液温度下降到粘度增大时一定程度时不再补充缩孔。
33#池壁砖规格为300mmx400mmx1500mm重量约675kg,容重为3.75。砖重685时,容重为3.8,砖重693公斤时容重为3.85,即目前的33#池壁电熔砖要想达到合资品牌电熔砖的容重需要冒口持续给砖体补充溶液重量为:10kg至18kg。
浇铸后的电熔砖在保温箱内的保温材料大多是3mm至8mm颗粒度的硅砂,冒口处向上的规格为500mmx600mm,由于浇铸后有排气过程,排气过程约需要30分钟时间,目的是辅助冒口内溶液补缩砖体,通过多年观察以及砖的内部结构说明,此方法不能达到电熔砖内部致密的理想效果。并且导致大量热量从冒口上面流失,缩短从液体变为固体的时间。从而得出结论:延长冒口内溶液的液态时间,延长冒口内溶液对砖体疏松补缩的时间是最有效的提高电熔砖致密度的方法。
发明内容
针对上述情况,为克服现有技术之缺陷,本发明之目的就是提供一种锆刚玉电熔砖冒口保温结构及浇铸保温方法,可有效解决延长冒口内料液补缩时间,提高电熔砖容重的问题。
本发明解决的技术方案是,一种锆刚玉电熔砖冒口保温结构,包括保温箱和设置在保温箱内的砂型模具,保温箱的内壁与砂型模具的外壁之间填充有保温砂,所述砂型模具是由下部的砖体砂型和上部的冒口砂型构成的上部开口的中空一体结构,砖体砂型的内腔构成锆刚玉电熔砖的砖体成型空间,冒口砂型的内腔构成补缩空间,冒口砂型的上口部覆盖有膨胀式保温层,膨胀式保温层是由下部的玻璃棉层和上部的膨胀石墨层构成的双层复合结构。
一种锆刚玉电熔砖浇铸保温方法,包括以下步骤:
(1)、将砂型模具放置在保温箱内,保温箱的内壁与砂型模具的外壁之间填充保温砂,开始将融化好的锆刚玉电熔砖料液对砂型模具进行浇铸。
(2)、浇铸完成后,3min内将膨胀式保温层覆盖式放置在砂型模具的上口部,
所述的膨胀式保温层是由下部的玻璃棉层31和上部的膨胀石墨层32构成的双层复合结构;
所述的玻璃棉层是由玻璃棉制成;
所述膨胀石墨层是由膨胀石墨1000g、漂珠300g、铝热剂200g、高模水玻璃100g和水100g制成的;
将玻璃棉的双面喷洒低模水玻璃,使其达到湿润状态;
将膨胀石墨、漂珠、铝热剂在搅拌机内搅拌3分钟,再将水与高模水玻璃混合后加入搅拌机,再搅拌3分钟制成混合料;
将混合料均匀的铺在玻璃棉上刮平即得膨胀式保温层;
(3)、7-14天后出箱拆模即得锆刚玉电熔砖。
本发明模具结构新颖独特,简单合理,易操作,易生产,成本低,浇铸后通过在冒口上口部覆盖膨胀式保温层,对冒口进行隔热保温,延长冒口内的液态时间,从而提高了无缩孔浇铸电熔砖的容重,同时在浇铸过程中省去了排气的过程,工艺得到了简化,使用方便,效果好,是电熔砖生产上的创新。
附图说明
图1为本发明的剖面主视图。
图2为本发明膨胀式保温层的剖视图。
具体实施方式
以下结合附图对本发明的具体实施方式作进一步详细说明。
如图1-2所示,本发明包括保温箱4和设置在保温箱内的砂型模具,保温箱4的内壁与砂型模具的外壁之间填充有保温砂5,所述砂型模具是由下部的砖体砂型1和上部的冒口砂型2构成的上部开口的中空一体结构,砖体砂型1的内腔构成锆刚玉电熔砖的砖体成型空间,冒口砂型2的内腔构成补缩空间,冒口砂型2的上口部覆盖有膨胀式保温层3,膨胀式保温层3是由下部的玻璃棉层31和上部的膨胀石墨层32构成的双层复合结构。
为保证使用效果,所述的玻璃棉层31为玻璃棉,其厚度为5-8mm;所述的膨胀石墨层32的厚度为15mm。
所述砂型模具的下端面与保温箱4的底面之间的保温砂至少为200mm。
所述砖体成型空间和补缩空间内均填充有锆刚玉电熔砖料液6。
一种锆刚玉电熔砖浇铸保温方法,包括以下步骤:
(1)、将砂型模具放置在保温箱4内,保温箱4的内壁与砂型模具的外壁之间填充保温砂5,开始将融化好的锆刚玉电熔砖料液对砂型模具进行浇铸。
(2)、浇铸完成后,3min内将膨胀式保温层3覆盖式放置在砂型模具的上口部,
所述的膨胀式保温层3是由下部的玻璃棉层31和上部的膨胀石墨层32构成的双层复合结构;
所述的玻璃棉层31是由玻璃棉制成;
所述膨胀石墨层32是由膨胀石墨1000g、漂珠300g、铝热剂200g、高模水玻璃100g和水100g制成的;
将玻璃棉的双面喷洒低模水玻璃,使其达到湿润状态;
将膨胀石墨、漂珠、铝热剂在搅拌机内搅拌3分钟,再将水与高模水玻璃混合后加入搅拌机,再搅拌3分钟制成混合料;
将混合料均匀的铺在玻璃棉上刮平即得膨胀式保温层;
(3)、7-14天后出箱拆模即得锆刚玉电熔砖。
所述低模水玻璃的模数为2.2至2.6,所述高模水玻璃的模数为3.0至3.3。
所述玻璃棉层的厚度为15mm;所述的膨胀石墨层32的厚度为15mm。
所述铝热剂为铝和三氧化二铁组成。
由上述情况可以清楚的看出,本发明通过在冒口上口部覆盖膨胀式保温层,对冒口进行隔热保温,延长冒口内的液态时间,膨胀石墨层在升温过程中膨胀,在1000℃时膨胀完全,膨胀体积可以达到初始时的200倍以上,膨胀后称为石墨蠕虫,由原鳞片状变为密度很低的蠕虫状,形成了一个非常好的绝热层,从而延长冒口内的料液液态时间,玻璃棉层31为膨胀石墨层提供一个很好的支撑,同时防止膨胀石墨层与冒口内的料液接触时污染冒口内的溶液,经实际使用,取得了良好的技术效果:
以300mmx400mmx1500mm规格无缩孔池壁砖为例:
改善前冒口规格为:500mm宽x600mm长x700mm高、冒口重:672kg、冒口容重3.2;砖重:675kg、砖体容重3.75;
改善后冒口规格为:500mm宽x600mm长x700mm高、冒口重:654kg、冒口容重3.10;砖重:693kg、砖体容重3.85;
缩小冒口的改善结果:500mmx600mmx600mm,冒口重量是540kg、冒口容重是3.0,砖重685kg、砖容重是3.80.
由上述情况可以清楚的看出,本发明浇铸后通过在冒口上口部覆盖膨胀式保温层,对冒口进行隔热保温,延长冒口内的液态时间,从而提高了无缩孔浇铸电熔砖的容重,如果使用缩小冒口,使池壁砖冒口重量减少约132kg后仍然能够达到标准容重,冒口按成本价每公斤10元计算,一块池壁砖节约1320元,如果使用同规格冒口,池壁砖容重体改0.1,效果十分明显,而且更重要的是,在浇铸过程中省去了排气的过程,工艺得到了简化,有良好的社会和经济效益。
Claims (7)
1.一种锆刚玉电熔砖冒口保温结构,包括保温箱(4)和设置在保温箱内的砂型模具,保温箱(4)的内壁与砂型模具的外壁之间填充有保温砂(5),其特征在于,所述砂型模具是由下部的砖体砂型(1)和上部的冒口砂型(2)构成的上部开口的中空一体结构,砖体砂型(1)的内腔构成锆刚玉电熔砖的砖体成型空间,冒口砂型(2)的内腔构成补缩空间,冒口砂型(2)的上口部覆盖有膨胀式保温层(3),膨胀式保温层(3)是由下部的玻璃棉层(31)和上部的膨胀石墨层(32)构成的双层复合结构;
浇铸方法为:
(1)、将砂型模具放置在保温箱(4)内,保温箱(4)的内壁与砂型模具的外壁之间填充保温砂(5),开始将融化好的锆刚玉电熔砖料液对砂型模具进行浇铸;
(2)、浇铸完成后,3min内将膨胀式保温层(3)覆盖式放置在砂型模具的上口部,
所述的膨胀式保温层(3)是由下部的玻璃棉层(31)和上部的膨胀石墨层(32)构成的双层复合结构;
所述的玻璃棉层(31)是由玻璃棉制成;
所述膨胀石墨层(32)是由膨胀石墨1000g、漂珠300g、铝热剂200g、高模水玻璃100g和水100g制成的;
将玻璃棉的双面喷洒低模水玻璃,使其达到湿润状态;
将膨胀石墨、漂珠、铝热剂在搅拌机内搅拌3分钟,再将水与高模水玻璃混合后加入搅拌机,再搅拌3分钟制成混合料;
将混合料均匀的铺在玻璃棉上刮平即得膨胀式保温层;
(3)、7-14天后出箱拆模即得锆刚玉电熔砖。
2.根据权利要求1所述的锆刚玉电熔砖冒口保温结构,其特征在于,所述的玻璃棉层(31)厚度为5-8mm。
3.根据权利要求1所述的锆刚玉电熔砖冒口保温结构,其特征在于,所述的膨胀石墨层(32)的厚度为15mm。
4.根据权利要求1所述的锆刚玉电熔砖冒口保温结构,其特征在于,所述砂型模具的下端面与保温箱(4)的底面之间的保温砂至少为200mm。
5.根据权利要求1所述的锆刚玉电熔砖冒口保温结构,其特征在于,所述砖体成型空间和补缩空间内均填充有锆刚玉电熔砖料液(6)。
6.根据权利要求1所述的锆刚玉电熔砖冒口保温结构,其特征在于,所述低模水玻璃的模数为2.2至2.6,所述高模水玻璃的模数为3.0至3.3。
7.根据权利要求1所述的锆刚玉电熔砖冒口保温结构,其特征在于,所述铝热剂为铝和三氧化二铁组成。
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