CN108975926A - 一种电炉内衬耐火材料及其制备方法 - Google Patents
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Abstract
本发明提供一种电炉内衬耐火材料及其制备方法,涉及耐火材料技术领域。本发明电炉内衬耐火材料由以下原料制成:改性黏土、白云石、刚玉渣、石墨烯、氧化锆、结合剂、分散剂。本发明电炉内衬耐火材料内部致密、体积密度高,体积稳定性好,热膨胀小,耐火性能好,在高温环境下内衬结构稳定,降低内衬使用过程中产生的体积膨胀,内衬不容易形成裂纹,从而提高内衬使用寿命。
Description
技术领域
本发明涉及耐火材料技术领域,涉及一种电炉内衬耐火材料及其制备方法。
背景技术
电炉是把炉内的电能转化为热量对工件加热的加热炉,电炉可分为电阻炉、感应炉、电弧炉、等离子炉、电子束炉等。同燃料炉比较,电炉的优点有:炉内气氛容易控制;物料加热快;加热温度高;温度容易控制;生产过程较易实现机械化和自动化;劳动卫生条件好;热效率高;产品质量好,且更加环保,有利于缓解日趋严重的环境问题。
电炉是目前发展迅速、用途广泛的一种熔化设备,广泛用于钢、铁及有色合金的铸造生产。如何提高感应电炉内衬的使用寿命是目前铸造行业共同关心的课题。而影响电炉寿命的因素是一个系统工程。它包括内衬材料性能、操作者的技术素质、筑炉工具、烘炉工艺、炉料的清洁以等,但内衬材料性能才是影响炉衬寿命的首要因素。
合格的内衬材料须具备以下性能:1)具有良好的耐高温性,耐火度好,因为内外壁温差较大,要求内衬在热应力下有好的强度;2)具有足够的机械强度:因为内衬壁较薄,却要承受很重的金属液,同时还要承受装料时的冲击载荷,并要考虑到炉料搭桥时,捅料时承受的机械冲击;3)内衬需对液态金属及熔剂、溶渣等物具有稳定的物理化学性能,不应使与炉渣相反应剧烈,而加速对炉衬的浸蚀;4)导电和导热系数小,以保证在高温下有良好的电气绝缘性.保证安全生产;5)内衬的热膨胀系数宜尽量小,热稳定性好,能抗急冷急热,以免产生龟裂和剥落。
因此,研制一种合格的电炉内衬耐火材料尤为重要。
发明内容
针对现有技术不足,本发明提供一种电炉内衬耐火材料及其制备方法。
为实现以上目的,本发明通过以下技术方案予以实现:
一种电炉内衬耐火材料,所述电炉内衬耐火材料由以下重量份的原料制成:改性黏土20-30份、白云石18-25份、刚玉渣15-25份、石墨烯5-16份、氧化锆5-12份、结合剂2-5份、分散剂1-3份。
优选的,所述电炉内衬耐火材料由以下重量份的原料制成:改性黏土22-27份、白云石20-23份、刚玉渣17-23份、石墨烯7-14份、氧化锆7-10份、结合剂3-4份、分散剂1.5-2.6份。
优选的,所述改性黏土的改性方法为:称取8-10重量份干燥后的黏土研磨过200目筛,加入乙醇和水的混合液,用冰醋酸调节PH=4-5,超声波处理15-20min,再加入0.1-0.5重量份改性剂KH570,继续超声波处理7-10min,在装有回流冷凝管的圆底三口烧瓶中,油浴65℃恒温搅拌反应10-15min,反应后经清洗、干燥、研磨,得到黏土粉,将黏土粉进行300-350℃焙烧1-2h,冷却至室温,得到改性黏土。
优选的,所述乙醇和水按照质量比3:1混合。
优选的,所述黏土为高岭石、硬质黏土、高铝黏土、石英中的一种。
优选的,所述结合剂为硅铝凝胶粉、硅酸钠、硅酸钾、磷酸盐中的至少一种的水溶液。
优选的,所述磷酸盐为磷酸氢二钠、磷酸铝、磷酸氢二钾、磷酸二氢钠、磷酸二氢钾中的一种。
优选的,所述分散剂为三聚磷酸钠、六偏磷酸钠中的一种。
一种电炉内衬耐火材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将改性黏土、白云石、刚玉渣、石墨烯、氧化锆混合置于球磨机中,以无水酒精为介质球磨3-5h,然后再真空干燥得到混合粉料;
S3、将步骤S2制备的混合粉料放入混炼机中,加入结合剂、分散剂,混炼15-30min出料,然后在26-30Mpa压力下干压成型,制得耐火材料生坯;
S4、将成型后的耐火材料生坯在1750-1850℃烧结3-6h,之后自然冷却至室温,即可。
优选的,步骤S2所述真空干燥的真空度为0.01-0.015MPa,干燥温度为150-170℃,干燥时间为6-9h。
本发明提供一种电炉内衬耐火材料及其制备方法,与现有技术相比优点在于:
本发明电炉内衬耐火材料内部致密、体积密度高,体积稳定性好,热膨胀小,耐火性能好,在高温环境下内衬结构稳定,降低内衬使用过程中产生的体积膨胀,内衬不容易形成裂纹,从而提高内衬使用寿命;
本发明电炉内衬耐火材料采用的原料为改性黏土、白云石、刚玉渣、石墨烯、氧化锆配合结合剂、分散剂,科学合理,氧化锆的加入不不仅能够增强材料的耐火性能,还能提高材料的韧性;石墨烯使得材料内部接触更加紧密,从而减小烧成时因膨胀产生的应力,防止材料疏松或开裂;石墨烯的高强度保证了材料的优良的力学性能,同时可以提升材料的抗酸碱腐蚀性能与抗氧化性;白云石原料易得,刚玉渣的使用使得废物合理利用,减少了资源浪费,降低了成本;改性后的黏土与其他原料均匀分散,而且改性后的黏土性能稳定,配合结合剂,在高温时能形成固熔体结构,由此大大降低内衬使用过程中产生的体积膨胀,内衬不容易形成裂纹,从而提高内衬使用寿命。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚,下面结合实施例对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1:
本实施例中,电炉内衬耐火材料由以下重量份的原料制成:改性黏土20份、白云石18份、刚玉渣15份、石墨烯5份、氧化锆5份、结合剂2份、分散剂1份;
其中,改性黏土的改性方法为:称取8重量份干燥后的黏土研磨过200目筛,加入乙醇和水的混合液,用冰醋酸调节PH=4-5,超声波处理15min,再加入0.1重量份改性剂KH570,继续超声波处理7min,在装有回流冷凝管的圆底三口烧瓶中,油浴65℃恒温搅拌反应10min,反应后经清洗、干燥、研磨,得到黏土粉,将黏土粉进行300℃焙烧1h,冷却至室温,得到改性黏土,且,乙醇和水按照质量比3:1混合,黏土为高岭石;
结合剂为硅铝凝胶粉的水溶液;分散剂为三聚磷酸钠。
本实施例电炉内衬耐火材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将改性黏土、白云石、刚玉渣、石墨烯、氧化锆混合置于球磨机中,以无水酒精为介质球磨3h,然后在真空度为0.01MPa,温度为150℃,真空干燥6h,得到混合粉料;
S3、将步骤S2制备的混合粉料放入混炼机中,加入结合剂、分散剂,混炼15min出料,然后在26Mpa压力下干压成型,制得耐火材料生坯;
S4、将成型后的耐火材料生坯在1750℃烧结3h,之后自然冷却至室温,即可。
实施例2:
本实施例中,电炉内衬耐火材料由以下重量份的原料制成:改性黏土30份、白云石25份、刚玉渣25份、石墨烯16份、氧化锆12份、结合剂5份、分散剂3份;
其中,改性黏土的改性方法为:称取10重量份干燥后的黏土研磨过200目筛,加入乙醇和水的混合液,用冰醋酸调节PH=4-5,超声波处理20min,再加入0.5重量份改性剂KH570,继续超声波处理10min,在装有回流冷凝管的圆底三口烧瓶中,油浴65℃恒温搅拌反应15min,反应后经清洗、干燥、研磨,得到黏土粉,将黏土粉进行350℃焙烧2h,冷却至室温,得到改性黏土,且,乙醇和水按照质量比3:1混合,黏土为硬质黏土;
结合剂为硅铝凝胶粉、硅酸钠、硅酸钾按照质量比1:1:1混合后的水溶液;分散剂为六偏磷酸钠。
本实施例电炉内衬耐火材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将改性黏土、白云石、刚玉渣、石墨烯、氧化锆混合置于球磨机中,以无水酒精为介质球磨5h,然后在真空度为0.015MPa,温度为170℃,真空干燥9h,得到混合粉料;
S3、将步骤S2制备的混合粉料放入混炼机中,加入结合剂、分散剂,混炼30min出料,然后在30Mpa压力下干压成型,制得耐火材料生坯;
S4、将成型后的耐火材料生坯在1850℃烧结6h,之后自然冷却至室温,即可。
实施例3:
本实施例中,电炉内衬耐火材料由以下重量份的原料制成:改性黏土25份、白云石21份、刚玉渣20份、石墨烯10份、氧化锆8份、结合剂3.5份、分散剂2份;
其中,改性黏土的改性方法为:称取9重量份干燥后的黏土研磨过200目筛,加入乙醇和水的混合液,用冰醋酸调节PH=4-5,超声波处理18min,再加入0.3重量份改性剂KH570,继续超声波处理8.5min,在装有回流冷凝管的圆底三口烧瓶中,油浴65℃恒温搅拌反应13min,反应后经清洗、干燥、研磨,得到黏土粉,将黏土粉进行330℃焙烧1.5h,冷却至室温,得到改性黏土,且,乙醇和水按照质量比3:1混合,黏土为高铝黏土;
结合剂为硅铝凝胶粉、硅酸钠、磷酸盐按照质量比1:1:1混合后的水溶液;磷酸盐为磷酸氢二钠;分散剂为三聚磷酸钠。
本实施例电炉内衬耐火材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将改性黏土、白云石、刚玉渣、石墨烯、氧化锆混合置于球磨机中,以无水酒精为介质球磨4h,然后在真空度为0.012MPa,温度为160℃,真空干燥7.5h,得到混合粉料;
S3、将步骤S2制备的混合粉料放入混炼机中,加入结合剂、分散剂,混炼22min出料,然后在28Mpa压力下干压成型,制得耐火材料生坯;
S4、将成型后的耐火材料生坯在1800℃烧结4.5h,之后自然冷却至室温,即可。
实施例4:
本实施例中,电炉内衬耐火材料由以下重量份的原料制成:改性黏土22份、白云石20份、刚玉渣17份、石墨烯7份、氧化锆7份、结合剂3份、分散剂1.5份;
其中,改性黏土的改性方法为:称取8重量份干燥后的黏土研磨过200目筛,加入乙醇和水的混合液,用冰醋酸调节PH=4-5,超声波处理16min,再加入0.2重量份改性剂KH570,继续超声波处理8min,在装有回流冷凝管的圆底三口烧瓶中,油浴65℃恒温搅拌反应12min,反应后经清洗、干燥、研磨,得到黏土粉,将黏土粉进行340℃焙烧1.3h,冷却至室温,得到改性黏土,且,乙醇和水按照质量比3:1混合,黏土为石英;
结合剂为硅铝凝胶粉、硅酸钾、磷酸盐按照质量比1:1:1混合后的水溶液;磷酸盐为磷酸铝;分散剂为六偏磷酸钠。
本实施例电炉内衬耐火材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将改性黏土、白云石、刚玉渣、石墨烯、氧化锆混合置于球磨机中,以无水酒精为介质球磨4h,然后在真空度为0.03MPa,温度为155℃,真空干燥8h,得到混合粉料;
S3、将步骤S2制备的混合粉料放入混炼机中,加入结合剂、分散剂,混炼19min出料,然后在29Mpa压力下干压成型,制得耐火材料生坯;
S4、将成型后的耐火材料生坯在1780℃烧结5h,之后自然冷却至室温,即可。
实施例5:
本实施例中,电炉内衬耐火材料由以下重量份的原料制成:改性黏土27份、白云石23份、刚玉渣23份、石墨烯14份、氧化锆10份、结合剂4份、分散剂2.6份;
其中,改性黏土的改性方法为:称取10重量份干燥后的黏土研磨过200目筛,加入乙醇和水的混合液,用冰醋酸调节PH=4-5,超声波处理19min,再加入0.4重量份改性剂KH570,继续超声波处理9min,在装有回流冷凝管的圆底三口烧瓶中,油浴65℃恒温搅拌反应14min,反应后经清洗、干燥、研磨,得到黏土粉,将黏土粉进行310℃焙烧1.8h,冷却至室温,得到改性黏土,且,乙醇和水按照质量比3:1混合,黏土为高岭石;
结合剂为硅酸钠、硅酸钾、磷酸盐按照质量比1:1:1混合后的水溶液;磷酸盐为磷酸氢二钾;分散剂为六偏磷酸钠。
本实施例电炉内衬耐火材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将改性黏土、白云石、刚玉渣、石墨烯、氧化锆混合置于球磨机中,以无水酒精为介质球磨4h,然后在真空度为0.011MPa,温度为165℃,真空干燥7h,得到混合粉料;
S3、将步骤S2制备的混合粉料放入混炼机中,加入结合剂、分散剂,混炼28min出料,然后在27Mpa压力下干压成型,制得耐火材料生坯;
S4、将成型后的耐火材料生坯在1830℃烧结4h,之后自然冷却至室温,即可。
以上实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
Claims (10)
1.一种电炉内衬耐火材料,其特征在于,所述电炉内衬耐火材料由以下重量份的原料制成:改性黏土20-30份、白云石18-25份、刚玉渣15-25份、石墨烯5-16份、氧化锆5-12份、结合剂2-5份、分散剂1-3份。
2.根据权利要求1所述的电炉内衬耐火材料,其特征在于,所述电炉内衬耐火材料由以下重量份的原料制成:改性黏土22-27份、白云石20-23份、刚玉渣17-23份、石墨烯7-14份、氧化锆7-10份、结合剂3-4份、分散剂1.5-2.6份。
3.根据权利要求1或2所述的电炉内衬耐火材料,其特征在于,所述改性黏土的改性方法为:称取8-10重量份干燥后的黏土研磨过200目筛,加入乙醇和水的混合液,用冰醋酸调节PH=4-5,超声波处理15-20min,再加入0.1-0.5重量份改性剂KH570,继续超声波处理7-10min,在装有回流冷凝管的圆底三口烧瓶中,油浴65℃恒温搅拌反应10-15min,反应后经清洗、干燥、研磨,得到黏土粉,将黏土粉进行300-350℃焙烧1-2h,冷却至室温,得到改性黏土。
4.根据权利要求3所述的电炉内衬耐火材料,其特征在于:所述乙醇和水按照质量比3:1混合。
5.根据权利要求3所述的电炉内衬耐火材料,其特征在于:所述黏土为高岭石、硬质黏土、高铝黏土、石英中的一种。
6.根据权利要求1或2所述的电炉内衬耐火材料,其特征在于:所述结合剂为硅铝凝胶粉、硅酸钠、硅酸钾、磷酸盐中的至少一种的水溶液。
7.根据权利要求1或2所述的电炉内衬耐火材料,其特征在于:所述磷酸盐为磷酸氢二钠、磷酸铝、磷酸氢二钾、磷酸二氢钠、磷酸二氢钾中的一种。
8.根据权利要求1或2所述的电炉内衬耐火材料,其特征在于:所述分散剂为三聚磷酸钠、六偏磷酸钠中的一种。
9.一种如权利要求1-8任一所述电炉内衬耐火材料的制备方法,其特征在于,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将改性黏土、白云石、刚玉渣、石墨烯、氧化锆混合置于球磨机中,以无水酒精为介质球磨3-5h,然后再真空干燥得到混合粉料;
S3、将步骤S2制备的混合粉料放入混炼机中,加入结合剂、分散剂,混炼15-30min出料,然后在26-30Mpa压力下干压成型,制得耐火材料生坯;
S4、将成型后的耐火材料生坯在1750-1850℃烧结3-6h,之后自然冷却至室温,即可。
10.根据权利要求9所述的制备方法,其特征在于:步骤S2所述真空干燥的真空度为0.01-0.015MPa,干燥温度为150-170℃,干燥时间为6-9h。
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