CN108947547B - 一种耐高温钢包安全衬浇注料 - Google Patents
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Abstract
本发明公开了一种耐高温钢包安全衬浇注料,原料重量份组成如下:六铝酸钙65~75;刚玉粉15~30;氧化铝粉10~15;胶凝剂5~8;膨胀剂0~5;分散剂0.5~0.8;气孔弥散剂0.01~0.05。所述六铝酸钙中,CaO含量为7~9wt%、SiO2含量为0.1~0.3wt%。所述六铝酸钙的显气孔率为20~30%、体积密度为2.7~2.9g/cm3。本发明提供的耐高温钢包安全衬浇注料,能够满足钢包安全节能降耗的需求,且施工性优良,安全可靠,有效降低钢包钢壳温度。
Description
技术领域
本发明涉及耐火材料技术领域,具体涉及一种耐高温钢包安全衬浇注料。
背景技术
钢铁冶炼过程中,钢包作为高温冶炼搬运容器,其安全性尤其重要,因此,钢包工作层后的永久层是安全保障的坚实防线。目前国内外钢包安全衬材料基本都采用铝硅或铝镁体系材料,为保障使用的安全性,一般都采用整体浇注衬结构。但随着节能降耗需求的提出,对于钢包永久层隔热保温,降低材料消耗也逐步得到耐火材料工作者的重视,在钢包永久层材料轻量化及降低材料热导率上进行诸多研究探讨。
浇注料材料体系中,轻量化、提高隔热性能的基本思路,一方面是采用轻质骨料(多孔、微孔、空心)代替致密骨料;另一方面,在材料中添加适量的发泡剂,形成多孔、微孔浇注体。通过以上方式,可以得到一定的效果,降低浇注料的体密,提高了材料的隔热性。但钢包作为高危险的容器,其安全材料的耐高温性和抗渣、铁能力要求很高,随着原常规铝硅、铝镁体系材料的轻量化,其使用安全风险性也随之提高,因此轻量化程度有限,在能够满足钢包安全性的前提下,目前材料体密水准处于2.6-2.8g/cm3,材料的热导率(1000℃下)处于0.8-1.0W·(m·K)-1。
发明内容
本发明提供了一种耐高温钢包安全衬浇注料,能够满足钢包安全节能降耗的需求,且施工性优良,安全可靠,有效降低钢包钢壳温度。
一种耐高温钢包安全衬浇注料,原料重量份组成如下:
本发明提供的钢包安全衬浇注料采用高纯六铝酸钙为主体原料,通过加入气孔弥散剂,优化浇注料的胶凝体系,得到适合钢包整体浇注的耐高温安全节能浇注料。现场正常施工运转时,能够在1650℃稳定使用,作为临时工作衬,抵御钢水和钢渣的侵蚀,浇注料的体积密度为2.1~2.6g/cm3,1000℃下的热导率为0.4~0.7W·(m·K)-1。
制备浇注料时,将各组分混合搅拌均匀即可。
本发明采用六铝酸钙为原料,六铝酸钙采用大颗粒作为浇注料的骨料。优选地,所述六铝酸钙的粒度级配如下:
本发明中,粒度级配中的粒径均为数均粒径,配比为重量份配比。
六铝酸钙(CaAl12O19,缩写为CA6)是CaO-Al2O3二元系统中重要的化合物。CA6晶粒的生长存在各向异性,形成片状结晶形貌,可以作为增韧相提高材料力学性能,与氧化铝有很好的化学相容性及相近的热膨胀性,可以与板状刚玉以任意比例复合使用,同时,CA6熔点较高,在高温还原气氛下有很好的稳定性,在碱性环境中有足够的抗侵蚀能力,在含氧化铁渣中的溶解度低。
作为优选,所述六铝酸钙中,CaO含量为7~9wt%、SiO2含量为0.1~0.3wt%。所述六铝酸钙的显气孔率为20~30%、体积密度为2.7~2.9g/cm3。
六铝酸钙在1000℃下的热导率很低,仅有1.7W·(m·K)-1。为了使材料尽可能轻量化,在主体原料六铝酸钙的选择上,并没有选择高体密的原料,而是选择了气孔较多的低体密原料,所选密度原料其抗渣抗铁性能仍然比较优异,能满足要求。
由于采用六铝酸钙作为浇注料的骨料,气孔率较高,具有较大的吸水性,因此容易导致浇注料加水后,流动性衰减很快,加水混合好的浆料,由于骨料的吸水,导致料浆中的水分迅速减少,而使得料浆出现凝滞现象,流动性恶化,不能维持现场施工时间的需求。
因此,通过添加气孔弥散剂来解决,优选地,所述气孔弥散剂为Gaproment NG10。
气孔弥散剂可以在浇注料加水搅拌过程中,形成大量的微气泡,这些微气泡的存在,一方面进一步降低了料浆的密度,同时微气泡吸附在骨料表面,形成气膜阻碍了骨料对料浆中水的吸收,有效的延长了浇注料的可施工时间。但微气泡的存在,也会导致浇注料的硬化时间大大延长,在通常的16-24小时内完成浇注脱模难以满足。
因此,需要选择合适的胶凝剂,优选地,所述胶凝剂为铝酸钙水泥,胶凝剂中CaO含量为32~35wt%、Al2O3含量为65~68wt%。
所述铝酸钙水泥为快凝型铝酸钙水泥,缩短浇注料的硬化时间,在预期时间内完成浇注脱模。
作为优选,所述快凝型铝酸钙水泥的物相重量份组成为:
CaO·Al2O3 80~85;
CaO·2Al2O3 15~20;
12CaO·7Al2O3 0.4~0.5。
所优选的快凝型铝酸钙水泥,由于具有更高的CA(即CaO·Al2O3)相,因此,可以提供更高的体系强度;此外具有一定量的C12A7(12CaO·7Al2O3)相,可以达到较短时间内凝结的效果,与所选的气孔弥散剂之间相互配合,可以达到理想的施工效果。
作为优选,所述氧化铝粉的粒径D50≤2μm。所述刚玉粉采用板状刚玉,所述刚玉粉的粒径(数均粒径)≤88μm。
钢包大小不同,对材料的膨胀性要求也不一样,通过添加合适量的膨胀剂加以调整。
作为优选,所述膨胀剂为镁砂和硅微粉的混合物,镁砂与硅微粉的质量比为5~9。进一步优选,镁砂中MgO含量≥96wt%,粒度≤0.088mm;硅微粉中SiO2含量≥94wt%,D50≤1μm。
作为优选,所述安全衬浇注料的原料重量份组成如下:
作为优选,分散剂为Monaladd M10。
分散剂MonaladdM10,可以有效的快速分散细粉和微粉,形成流动体,加速Gaproment NG10在料浆中形成微气泡并分散,形成稳定的料浆,防止过多的水加入而导致泌水现象。
通过调节分散剂Monaladd M10、气孔弥散剂Gaproment NG10以及胶凝剂的加入比例,可以充分有效的调整材料的施工性能、体积密度、强度以及隔热性能。
通过调整膨胀剂的种类以及用量能够有效地调整控制材料1500℃×3h残余膨胀在0~2%范围内。
本发明提供的钢包安全衬浇注料按照国家标准检测得到的各项技术指标为:浇注料体积密度2.1~2.6g/cm3,常温耐压强度在30MPa以上,1100℃水冷条件下材料的热震稳定次数可以达到40次以上,1000℃下热导率为0.4~0.7W·(m·K)-1。
从检测结果看,本发明提供的安全节能钢包安全衬浇注料强度高、热震稳定性好,且重量比目前在用的耐火材料降低15~25%,热导率降低了25~40%。
具体实施方式
实施例1~6
实施例1~6中各组分的重量份配比如表1所示。
表1
表1中的分散剂均采用分散剂为Monaladd M10(武汉善达化工有限公司),气孔弥散剂均采用Gaproment NG10(武汉善达化工有限公司)。
表1中,胶凝剂采用铝酸钙水泥,六铝酸钙、膨胀剂、胶凝剂的具体参数如下:
六铝酸钙:显气孔率20~30%、体积密度2.7~2.9g/cm3、CaO含量7~9wt%、SiO2含量0.1~0.3wt%;
刚玉粉:Al2O3含量≥99wt%,粒度≤88μm;
氧化铝粉:Al2O3含量≥99wt%,D50≤2μm;
膨胀剂:MgO含量85~90wt%,SiO2含量8~14wt%;
胶凝剂:CaO含量32~34wt%、Al2O3含量65~68wt%;
镁砂中MgO含量≥96wt%,粒度≤0.088mm;
硅微粉中SiO2含量≥94wt%,D50≤1μm。
表2
根据上述说明书的揭示和教导,本发明所属领域的技术人员还可以对上述实施方式进行适当的变更和修改。因此,本发明并不局限于上面揭示和描述的具体实施方式,对本发明的一些修改和变更也应当落入本发明的权利要求的保护范围内。此外,尽管本说明书中使用了一些特定的术语,但这些术语只是为了方便说明,并不对本发明构成任何限制。
Claims (6)
2.如权利要求1所述的耐高温钢包安全衬浇注料,其特征在于,所述六铝酸钙中,CaO含量为7~9wt%、SiO2含量为0.1~0.3wt%。
3.如权利要求1所述的耐高温钢包安全衬浇注料,其特征在于,所述铝酸钙水泥的物相重量份组成为:
CaO·Al2O3 80~85;
CaO·2Al2O3 15~20;
12CaO·7Al2O3 0.4~0.5。
4.如权利要求1所述的耐高温钢包安全衬浇注料,其特征在于,所述膨胀剂为镁砂和硅微粉的混合物,镁砂与硅微粉的质量比为5~9。
5.如权利要求4所述的耐高温钢包安全衬浇注料,其特征在于,镁砂中MgO含量≥96wt%,粒度≤0.088mm;硅微粉中SiO2含量≥94wt%,D50≤1μm。
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