CN108083776A - 一种镁碳砖及其制备方法 - Google Patents

一种镁碳砖及其制备方法 Download PDF

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CN108083776A
CN108083776A CN201711466848.3A CN201711466848A CN108083776A CN 108083776 A CN108083776 A CN 108083776A CN 201711466848 A CN201711466848 A CN 201711466848A CN 108083776 A CN108083776 A CN 108083776A
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曹丽云
龚育才
张雪松
俞晓东
茹红强
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JIANGSU SUJIA GROUP NEW MATERIAL CO Ltd
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Abstract

本发明涉及一种镁碳砖及其制备方法，属于耐火材料制备技术领域。其组分按重量份计如下：电熔镁砂颗粒75～90份，碳素5～10份，添加剂1～5份和结合剂1～3份；将上述组分放入混练机中进行混炼，再经过压制成型和烘烤固化后得到最终的产品镁碳砖。本发明制备方法简单，步骤易于操作，改变了传统镁碳砖的思路，不配入镁砂细粉，基质中以碳素和少量添加剂为主，提高了镁碳砖对高温、真空、酸性渣的更好抵抗力，使得冶炼高级特殊钢时耐火材料炉衬的使用寿命得到提高，吨钢耐材消耗显著下降。

Description

一种镁碳砖及其制备方法
技术领域
本发明涉及一种镁碳砖及其制备方法，属于耐火材料制备技术领域。
背景技术
镁碳砖之所以有十分突出的使用效果，得益于其两种主要组成：镁砂和石墨。镁砂的主要成分是氧化镁。氧化镁的熔点高达2800℃，远高于炼钢温度。石墨的熔点高达3500℃，热膨胀率很低，韧性好，不容易被炉渣和钢水润湿。而且镁砂和石墨不共熔。兼有两者之长的复合物镁碳砖具有很高的耐高温能力，也不容易被钢渣渗透。
镁碳砖也有弱点。由于镁砂是碱性氧化物，通常炼钢时的炉渣的碱度为2～6，此时镁砂不容易被侵蚀，但是冶炼特殊钢种时碱度低的炉渣，特别是酸性炉渣很容易侵蚀镁砂；虽然镁砂和石墨不共熔，但是在高温真空条件下两者会发生氧化还原反应，方程式为MgO+C→Mg↑+CO↑。所以镁碳砖在超高温冶金，尤其是真空条件下损毁速度成倍提高。
随着经济的发展，不锈钢、硅钢、管线钢、汽车、电器用薄板钢、深冲钢、高等级轴承钢等高级钢种的需求越来越大。为了提高性能，这些高级钢种只有很少的夹杂物和不希望有的污染物质，冶炼些高级钢种需要的精炼条件和精炼手段也不同寻常。比如渣系的碱度从酸性到碱性的变换，精炼温度超过1700℃，精炼时间超过2小时，真空度也很高，所有这些都对耐火材料有了更严格的挑战。比如冶炼高级帘线钢时炉渣碱度从0.8到4变化，精炼时间很长，渣线镁碳砖的寿命只有几次。RH下部槽用镁碳砖在高温真空条件下使用，寿命也大为缩短。
镁碳砖是最主要的钢材精炼用耐火材料。虽然镁碳砖在上述条件下适应性不够，但是依然具有不可替代性。镁碳砖技术必须进一步发展以满足时代的需要。
发明内容
本发明的目的在于克服上述不足之处，提供一种对高温、真空、酸性渣具有更好抵抗力的无基质镁碳砖及其制备方法，使得产品在上述恶劣条件下的使用寿命大幅提高。
按照本发明提供的技术方案，一种镁碳砖，组分按重量份计如下：电熔镁砂颗粒75～90份，碳素5～10份，添加剂1～5份和结合剂1～3份；将上述组分放入混练机中进行混炼，再经过压制成型和烘烤固化后得到最终的产品镁碳砖；
所述碳素为石墨，石墨的粒度为350～400目，石墨中碳含量大于94％；所述电熔镁砂颗粒大小为1～5mm；所述添加剂为金属铁粉；所述结合剂为硼改性酚醛树脂。
所述的镁碳砖的制备方法，按重量份计包括如下步骤：
(1)混炼：按原料配比分别称取电熔镁砂颗粒75～90份、碳素5～10份、添加剂1～5份和结合剂1～3份；首先将电熔镁砂颗粒放入混炼机中干混2～15min，然后加入结合剂继续混合5～15min，接着向其中加入碳素，混合8～15min，最后加入添加剂继续混合5～15min形成泥料；混炼机转速为950～1000r/min，混炼时间为20～60min；
(2)压制成型：将步骤(1)混炼完成所得泥料加入模具中采用复合式摩擦压砖机进行压制成型制得砖坯，压力为2500～6300KN；
(3)烘烤固化：将步骤(2)所得砖坯置于隧道式干燥窑中烘烤固化，烘烤温度为180～300℃，烘烤时间为10～20h。
采用的混练机为旋移循环式混炼机。
传统的镁碳砖是由镁砂颗粒、镁砂细粉、碳粉、添加剂和结合剂构成。本发明突破传统的思维，镁碳砖中不配入镁砂细粉，基质中以碳素和少量添加剂为主。无基质镁碳砖细粉部分中镁砂含量不足。高温下镁砂细粉和碳粉的氧化还原反应难以进行。无基质镁碳砖细粉部分中碳含量极高，不易被各种碱度的高温熔渣侵润，所以应对低碱度熔渣时，侵蚀速度降低。
通过金属铁粉添加剂的使用来填充细粉，使无基质镁碳砖更为致密。
通过硼改性酚醛树脂结合剂的使用，硼改性酚醛树脂结合剂高温下石墨化，化学性质比传统的树脂碳稳定，不容易被镁砂细粉和其它物质氧化，提高了镁碳砖的抗氧化性，降低镁碳砖的热应力，减少剥落。
本发明的有益效果：本发明制备方法简单，步骤易于操作，改变了传统镁碳砖的思路，不配入镁砂细粉，基质中以碳素和少量添加剂为主，提高了镁碳砖对高温、真空、酸性渣的更好抵抗力，使得冶炼高级特殊钢时耐火材料炉衬的使用寿命得到提高，吨钢耐材消耗显著下降。
具体实施方式
下面将结合具体实施例对本发明作进一步的说明。
实施例1
一种镁碳砖，包括组分按重量百分数计为：电熔镁砂颗粒85％，碳素8％，添加剂5％，结合剂2％。
(1)混炼：采用旋移循环式混炼机进行混炼，按原料配比分别称取电熔镁砂颗粒、碳素、添加剂、结合剂，首先将电熔镁砂颗粒放入混炼机中干混5min，然后加入结合剂继续混合5min，接着向其中加入碳素，混合8min，最后加入添加剂继续混合10min形成泥料，混炼机转速定为970r/min；
(2)压制成型：将混炼完成的泥料加入模具中采用复合式摩擦压砖机进行压制成型制成砖坯，压力为3000KN；
(3)烘烤固化：将砖坯置于隧道式干燥窑中烘烤固化，烘烤温度为200℃，烘烤时间为15h。
实施例2
一种镁碳砖，包括组分按重量百分数计为：电熔镁砂颗粒90％，碳素5％，添加剂2％，结合剂3％。
(1)混炼：采用旋移循环式混炼机进行混炼，按原料配比分别称取电熔镁砂颗粒、碳素、添加剂、结合剂，首先将电熔镁砂颗粒放入混炼机中干混8min，然后加入结合剂继续混合10min，接着向其中加入碳素，混合10min，最后加入添加剂继续混合8min形成泥料，混炼机转速定为980r/min；
(2)压制成型：将混炼完成的泥料加入模具中采用复合式摩擦压砖机进行压制成型制成砖坯，压力为3500KN；
(3)烘烤固化：将砖坯置于隧道式干燥窑中烘烤固化，烘烤温度为200℃，烘烤时间为20h。
实施例3
一种镁碳砖，包括组分按重量百分数计为：电熔镁砂颗粒84％，碳素10％，添加剂4％，结合剂2％。
(1)混炼：采用旋移循环式混炼机进行混炼，按原料配比分别称取电熔镁砂颗粒、碳素、添加剂、结合剂，首先将电熔镁砂颗粒放入混炼机中干混10min，然后加入结合剂继续混合8min，接着向其中加入碳素，混合12min，最后加入添加剂继续混合12min形成泥料，混炼机转速定为970r/min；
(2)压制成型：将混炼完成的泥料加入模具中采用复合式摩擦压砖机进行压制成型制成砖坯，压力为4000KN；
(3)烘烤固化：将砖坯置于隧道式干燥窑中烘烤固化，烘烤温度为250℃，烘烤时间为15h。
对比实施例
取实施例1的原料组分配比，按上述的制备方法制成无基质的镁碳砖砖坯；另取实施例1的原料组分配比，其中用20％的镁砂细粉替换镁砂颗粒，按同样的制备方法制成普通的镁碳砖砖坯，进行性能检测对比。
按照GB/T2997、GB/T5072.2、GB/T3001、GB/T3002、GB/T 7320.1检测试样的显气孔率和体积密度、常温耐压强度、常温抗折强度、高温抗折强度和线膨胀率。
抗热震性试验：制成40mm×40mm×160mm的试样，加热到1100℃保温30min后，取出试样迅速放入室温水中急冷。重复以上过程至试样断裂，记录重复次数，以次数评价试样的抗热震性。
抗侵蚀性试验：制成坩埚试样尺寸、内孔尺寸为，采用静态抗侵蚀试验法，在坩埚试样内装填20g钢包渣，置于埋炭气氛下，于1500℃下保温3h。随炉冷却后将坩埚沿高度方向切开，测量坩埚中心截面的侵(渗透)面积S，计算其侵蚀指数S/S0×100％(S0为原坩埚中心孔的截面积)，以评价试样的抗侵蚀性。
检测数据如下表1所示。
表1
根据表中数据显示，同样条件下无基质的镁碳砖和普通的镁碳砖各项性能均相近，但无基质的镁碳砖的抗侵蚀性大大优于普通的镁碳砖，所以无基质的镁碳砖改变了传统镁碳砖的思路，提高了镁碳砖对高温、真空、酸性渣的更好抵抗力，使得冶炼高级特殊钢时耐火材料炉衬的使用寿命得到提高，吨钢耐材消耗显著下降。

Claims (3)

1.一种镁碳砖，其特征在于组分按重量份计如下：电熔镁砂颗粒75～90份，碳素5～10份，添加剂1～5份和结合剂1～3份；将上述组分放入混练机中进行混炼，再经过压制成型和烘烤固化后得到最终的产品镁碳砖；
所述碳素为石墨，石墨的粒度为350～400目，石墨中碳含量大于94%；所述电熔镁砂颗粒大小为1～5mm；所述添加剂为金属铁粉；所述结合剂为硼改性酚醛树脂。
2.权利要求1所述的镁碳砖的制备方法，其特征在于按重量份计包括如下步骤：
（1）混炼：按原料配比分别称取电熔镁砂颗粒75～90份、碳素5～10份、添加剂1～5份和结合剂1～3份；首先将电熔镁砂颗粒放入混炼机中干混2～15min，然后加入结合剂继续混合5～15min，接着向其中加入碳素，混合8～15min，最后加入添加剂继续混合5～15min形成泥料；混炼机转速为950～1000r/min，混炼时间为20～60min；
（2）压制成型：将步骤（1）混炼完成所得泥料加入模具中采用复合式摩擦压砖机进行压制成型制得砖坯，压力为2500～6300KN；
（3）烘烤固化：将步骤（2）所得砖坯置于隧道式干燥窑中烘烤固化，烘烤温度为180～300℃，烘烤时间为10～20h。
3.权利要求1所述的镁碳砖的制备方法，其特征在于：采用的混练机为旋移循环式混炼机。
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