CN108585807B - 一种用于高炉水渣冲制槽中后段的高强耐磨浇注料 - Google Patents
一种用于高炉水渣冲制槽中后段的高强耐磨浇注料 Download PDFInfo
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Abstract
本发明公开了一种用于高炉水渣冲制槽中后段的高强耐磨浇注料。所述原料组分按质量份数计分别为：废旧陶瓷骨料40～70份、棕刚玉3～25份、碳化硅细粉1～5份、铝酸钙水泥10～25份、三氧化二铬细粉0.5～5份、耐热钢纤维1～4份、二氧化硅微粉1～8份；所述外加组分占原料组分的质量百分数分别为：有机防爆纤维0.05～0.5wt％、碳化硼0.5～1.5wt％、减水剂0.05～0.5wt％，缓凝剂0.02～0.2wt％。本发明利用废旧陶瓷材料结构致密、硬度高，耐冲刷的特点，将废旧陶瓷作为主要原料来生产高炉冲渣沟中后段的耐磨浇注料，具有成本低，强度高、耐磨损性能好、使用寿命长等特点，同时实现了节能减排。
Description
技术领域
本发明属于复合材料技术领域，具体涉及一种用于高炉水渣冲制槽中后段的高强耐磨浇注料。
背景技术
水渣冲制槽是高炉炉渣冲制的关键设备之一，它的主要工作原理是：液态高炉熔渣从渣沟流入水渣冲制槽(冲渣沟)，高速水流从熔渣落入点下部喷出，将熔渣瞬间淬化成颗粒状的水渣，并将其冲入冷凝塔或者水渣池。冲渣沟中后段内衬损毁的原因主要有以下几个方面：
1.渣水混合物高速流动时(约20m/s)的强力冲刷。
2.冲渣沟在红渣和喷水的交替作用，使内衬受到热冲击的磨损破坏。
3.冲渣水循环使用，弱酸性介质积淀，对内衬材料的侵蚀。
目前冲渣沟常用的内衬材料为U形锰钢或铸铁板、也有部分厂家采用铸石板或陶瓷衬板。普遍存在着抗热振性差、不耐冲刷、内衬材料使用寿命较短、成本高等问题。U形锰钢板或铸铁件易更换，但耐磨性、耐热冲击性、耐酸侵蚀性均较差，且易锈蚀，使用周期短，一般约3～5个月。铸石板或陶瓷衬板虽然耐磨性好，使用寿命长，但整体性能差，砌筑缝为薄弱环节，易整块脱落，砌筑施工周期长，施工成本高。
许多陶瓷材料一旦在生产或使用过程中产生裂纹或性能不达标，则会被淘汰成为陶瓷废料。目前，陶瓷废料仍是以随意堆积存放或作为垃圾丢弃填埋，并未很好的循环利用，造成资源的浪费。大量可再生利用的陶瓷废料都被堆放在野外。因结构致密、硬度高、难以被分解，导致陶瓷废料堆积如山，给当地环境带来了巨大的压力。
发明内容
本发明目的在于利用废旧高压电瓷制造一种成本低、性能优良的高炉水渣冲制槽中后段的高强耐磨浇注料。
为达到上述目的，采用技术方案如下：
用于高炉水渣冲制槽中后段的高强耐磨浇注料，包括原料组分和外加组分；
所述原料组分按质量份数计分别为：废旧陶瓷骨料40～70份、棕刚玉3～25份、碳化硅细粉1～5份、铝酸钙水泥10～25份、三氧化二铬细粉0.5～5份、耐热钢纤维1～4份、二氧化硅微粉1～8份；
所述外加组分占原料组分的质量百分数分别为：有机防爆纤维0.05～0.5wt％、碳化硼0.5～1.5wt％、减水剂0.05～0.5wt％，缓凝剂0.02～0.2wt％。
按上述方案，所述的废旧陶瓷中包含35～90wt％的Al2O3、5～55wt％的SiO2，0～2wt％的Fe2O3；颗粒级配是8～5mm为9～25wt％、5～3mm为10～30wt％、3～1mm为5～25wt％、1～0mm为0～20wt％。
按上述方案，所述棕刚玉中包含95～97wt％的Al2O3，体积密度为3.85～3.95g/cm3，颗粒级配1～0mm为0～25wt％、0.088～0mm为1～15wt％。
按上述方案，所述的耐热钢纤维中C≤0.2wt％，Si≤1.5wt％，Mn≤1.5wt％，Cr含量为24～27wt％。
按上述方案，所述有机防爆纤维选用聚丙烯高分子化合物，长度3-5mm，熔点50-70℃。
按上述方案，所述减水剂是聚羧酸减水剂FS65和六偏磷酸钠中一种或者两者混合。
按上述方案，所述的缓凝剂是草酸和柠檬酸中一种或者两者混合。
本发明采用废旧陶瓷材料在1280-1350℃烧成过程中经过一系列的物理、化学反应，具有杂质低，硬度大，耐磨性好，作为骨料加入浇注料中，可以有效降低成本，达到高强、耐磨、抗侵蚀的效果。同时通过对废旧资源的二次利用，达到节能减排效果。同时本方案加入硬度大、耐磨性好的棕刚玉，碳化硅原料，进一步提升了浇注料的耐磨性和抗侵蚀性能。通过添加高效分散剂及缓凝剂来调整浇注料的施工性能，从而使浇注料在水渣冲制槽中后段易于整体浇筑。
本发明的有益效果是：
本发明利用废旧陶瓷材料结构致密、硬度高，耐冲刷的特点，将废旧陶瓷作为主要原料来生产高炉冲渣沟中后段的耐磨浇注料，具有成本低，强度高、耐磨损性能好、使用寿命长等特点，同时实现了节能减排。
本发明浇注料具有流动性好、成本低、耐冲刷、热震稳定性好、抗水渣侵蚀性好、强度高、寿命长等特点，社会经济效益显著。
本发明特别适用于水渣冲制槽中后段浇筑。
具体实施方式
以下实施例进一步阐释本发明的技术方案，但不作为对本发明保护范围的限制。
实施例1
一种用于高炉水渣冲制槽中后段的高强耐磨浇注料，由主原料组份和外加组份组成；主原料及质量百分数为：废旧陶瓷骨料45％、棕刚玉25％、碳化硅细粉4.5％、铝酸钙水泥16％、三氧化二铬细粉2％、耐热钢纤维3％、二氧化硅微粉4％。外加组分及其所占上述主原料总质量的质量百分数为：有机防爆纤维0.1％、碳化硼0.5％、减水剂0.2％(聚羧酸减水剂FS65加入量0.05％，六偏磷酸钠加入量0.15％)，缓凝剂0.03％(柠檬酸加入量0，草酸加入量0.03％)。
然后外加上述混合料的5.5wt％的水，搅拌均匀后振动成型，最后在室温条件下养护12～48h脱模。
采用的废旧陶瓷Al2O3含量为60.3wt％，SiO2含量为33.9wt％，Fe2O3含量为1.2wt％，颗粒级配是：8～5mm为15wt％、5～3mm为15wt％、3～1mm为15wt％、1～0为0。
采用的棕刚玉是：Al2O3含量为95.2wt％，体积密度为3.90g/cm3，颗粒级配是：1～0mm为20wt％、0.088～0mm为5wt％。
上述各组分按照质量比称量后加入强制式搅拌机混合均匀，吨包袋包装运输，在施工现场使用时将混合料投入强制式搅拌机并按规定加水量加水搅拌2～3min，出料后装填到事前支好的模具中，用振动棒振动密实。带模自然养护超过12h以上拆模，拆模后即可投入正常使用。本实施例性能检测结果见表1所示。
表1
本实施例在南京某钢厂1#高炉高炉水渣冲制槽内衬中后段(总长30米)应用时间已达4年6个月，效果良好。
实施例2
一种用于高炉水渣冲制槽中后段的高强耐磨浇注料，由主原料组份和外加组份组成；主原料及质量百分数为：废旧陶瓷骨料55％、棕刚玉13％、碳化硅细粉2％、铝酸钙水泥20％、三氧化二铬细粉1.5％、耐热钢纤维2％、二氧化硅微粉5％。外加组分及其所占上述主原料总质量的质量百分数为：有机防爆纤维0.08％、碳化硼1.5％、减水剂0.2％(聚羧酸减水剂FS65加入量0.1％，六偏磷酸钠加入量0.1％)，缓凝剂0.06％(柠檬酸加入量0。05％，草酸加入量0.01％)。
然后外加上述混合料的6.5wt％的水，搅拌均匀后振动成型，最后在室温条件下养护12～48h脱模。
采用的废旧陶瓷中Al2O3含量为58.5wt％，SiO2含量为43.2wt％，Fe2O3含量为0.8wt％，颗粒级配是：8～5mm为18wt％、5～3mm为18wt％、3～1mm为15wt％、1～0mm为4wt％
采用的棕刚玉中Al2O3含量为95.0wt％，体积密度为3.89g/cm3，颗粒级配是：1～0mm为8wt％，0.088～0mm为5wt％。
上述各组分按照质量比称量后加入强制式搅拌机混合均匀，吨包袋包装运输，在施工现场使用时将混合料投入强制式搅拌机并按规定加水量加水搅拌2～3min，出料后装填到事前支好的模具中，用振动棒振动密实。带模自然养护超过12h以上拆模，拆模后即可投入正常使用。性能检测结果见表2所示。
表2
本实施例在南京某钢厂2#高炉高炉水渣冲制槽内衬中后段(总长40米)应用时间已达3年6个月，效果良好。
实施例3
一种用于高炉水渣冲制槽中后段的高强耐磨浇注料，由主原料组份和外加组份组成；主原料及质量百分数为：废旧陶瓷骨料65％、棕刚玉3％、碳化硅细粉5％、铝酸钙水泥18％、三氧化二铬细粉1％、耐热钢纤维1％、二氧化硅微粉6％。外加组分及其所占上述主原料总质量的质量百分数为：有机防爆纤维0.05％、碳化硼1％、减水剂0.15％(聚羧酸减水剂FS65加入量0.15％，六偏磷酸钠加入量0)，缓凝剂0.04％(柠檬酸加入量0.04％，草酸加入量0)。
然后外加上述混合料的7.5wt％的水，搅拌均匀后振动成型，最后在室温条件下养护12～48h脱模。
采用的废旧陶瓷中Al2O3含量为50.1wt％，SiO2含量为40.2wt％，Fe2O3含量为1.6wt％，颗粒级配是：8～5mm为20wt％、5～3mm为15wt％、3～1mm为15wt％、1～0mm为15wt％
采用的棕刚玉中Al2O3含量为95.6wt％，体积密度为3.92g/cm3，颗粒级配是0.088～0mm为3wt％。
上述各组分按照质量比称量后加入强制式搅拌机混合均匀，吨包袋包装运输，在施工现场使用时将混合料投入强制式搅拌机并按规定加水量加水搅拌2～3min，出料后装填到事前支好的模具中，用振动棒振动密实。带模自然养护超过12h以上拆模，拆模后即可投入正常使用。性能检测结果见表3所示。
表3
该实例在唐山迁安某钢厂1#高炉水渣冲制槽内衬中后段(长度50米)上应用时间已达3年，效果良好。
按上述配比生产的高强耐磨浇注料在南京某钢厂、唐山迁安某钢厂高炉水渣冲制槽中后段依次投入使用，目前寿命均达到3年以上，现场观察后可以看到冲渣沟中后段的沟底以及侧壁没有明显的侵蚀和磨损，使用效果良好，业主非常满意。据此推断，本发明的使用寿命在3～5年以上。该产品具有成本低，强度高，耐冲刷等特点，较以往其它高炉冲渣沟内衬半年到一年半的使用寿命，本发明使用寿命大幅提高，通过采用大量的陶瓷废旧材料，节能减排及环境保护效果明显，社会经济效益显著。
上述实施例仅仅是为清楚地说明所作地实例，而并非对实施方式的限制，对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其他不同形式的变化或者变动。这里无需也无法对所有实施方式予以穷举。而因此所引申的显而易见的变化或变动仍处于本发明创造的保护范围。
Claims (5)
1.用于高炉水渣冲制槽中后段的高强耐磨浇注料，其特征在于包括原料组分和外加组分；
所述原料组分按质量份数计分别为：废旧陶瓷骨料40～70份、棕刚玉3～25份、碳化硅细粉1～5份、铝酸钙水泥10～25份、三氧化二铬细粉0.5～5份、耐热钢纤维1～4份、二氧化硅微粉1～8份；
所述外加组分占原料组分的质量百分数分别为：有机防爆纤维0.05～0.5wt％、碳化硼0.5～1.5wt％、减水剂0.05～0.5wt％，缓凝剂0.02～0.2wt％；
所述的废旧陶瓷中包含50.1～60.3wt％的Al2O3、33.9～43.2wt％的SiO2，0.8～1.6wt％的Fe2O3；颗粒级配是8～5mm为9～25wt％、5～3mm为10～30wt％、3～1mm为5～25wt％、1～0mm为0～20wt％；
所述棕刚玉中包含95～97wt％的Al2O3，体积密度为3.85～3.95g/cm3，颗粒级配1～0mm为0～25wt％、0.088～0mm为1～15wt％。
2.如权利要求1所述用于高炉水渣冲制槽中后段的高强耐磨浇注料，其特征在于所述的耐热钢纤维中C≤0.2wt％，Si≤1.5wt％，Mn≤1.5wt％，Cr含量为24～27wt％。
3.如权利要求1所述用于高炉水渣冲制槽中后段的高强耐磨浇注料，其特征在于所述有机防爆纤维为聚丙烯高分子化合物，长度3-5mm，熔点50-70℃。
4.如权利要求1所述用于高炉水渣冲制槽中后段的高强耐磨浇注料，其特征在于所述减水剂是聚羧酸减水剂FS65和六偏磷酸钠中一种或者两者混合。
5.如权利要求1所述用于高炉水渣冲制槽中后段的高强耐磨浇注料，其特征在于所述的缓凝剂是草酸和柠檬酸中一种或者两者混合。
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