CN109020524A - 一种中频感应电炉用炉衬材料及其制备方法 - Google Patents
一种中频感应电炉用炉衬材料及其制备方法 Download PDFInfo
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Abstract
本发明提供一种中频感应电炉用炉衬材料及其制备方法,涉及电炉炉衬材料技术领域。本发明中频感应电炉用炉衬材料由以下原料制成:纳米二氧化硅、氧化锆微粉、镁铝尖晶石颗粒、刚玉细粉、微片石墨、稀土氧化物、固体水玻璃、结合剂、分散剂。本发明中频感应电炉用炉衬材料具有良好的致密性,炉衬气孔率小,体积密度大,均匀性高,烧结性好和耐激冷激热性好,有效防止温度的骤变炉衬开裂,减少裂纹修补,从延长使用寿命。
Description
技术领域
本发明涉及电炉炉衬材料技术领域,涉及一种中频感应电炉用炉衬材料及其制备方法。
背景技术
随着我国钢铁企业规模的扩大、炼钢技术不断更新、钢种不断增加,一系列冶金新技术、新工艺得到广泛地推广和应用,特别是中频炉技术。高效率、快速熔化、大型化已成为目前中频感应炉发展的新趋势,由此,对配套炉衬材料的成本和性能提出了更高的要求。
目前铸造行业中频感应电炉炉衬,主要采用的是石英砂炉衬和镁砂炉衬。对于石英砂炉衬材料,在1600℃温度下耐火材料颗粒之间就会出现液相,因此理论上它只能用于熔化铸铁和低熔点有色金属。同时,从相图上也可以看到,当熔体中含有锰和镍时,要避免使用石英砂炉衬,否则,一旦出现过热现象,会产生粘稠的氧化渣,并黏挂在炉衬上,导致频繁更换炉衬。此外,从安全和健康角度来讲,石英砂会严重影响人的健康;对于镁砂炉衬,由于矿源的因素,其物理性能和化学性能存在很大的差异,而这些物理性能和化学性能能将会严重影响到炉衬寿命的稳定性。对于镁砂炉衬,多使用镁砂为主要原材料、并外加3-5wt%硼酸为烧结剂混合而成。镁砂具有很高的烧结温度,极难烧结,添加一定量的硼酸,可以降低烧结温度,促进烧结,使炉衬获得较高的强度,以承受钢块的撞击以及钢水的冲刷。但由于镁质耐火材料的抗热震稳定性较差,在连续熔炼过程中还能保持良好的使用效果,但间歇式生产时,温度的骤变会导致炉衬材料极易开裂。裂纹若不修补,钢水钢渣可通过裂缝钻入炉衬,加快对炉衬的侵蚀,从而降低其使用寿命;若修补裂纹,不仅施工麻烦、提高劳动强度、加大生产成本,而且延误生产、降低生产效率。
因此,研制一种中频感应电炉用炉衬材料尤为重要。
发明内容
针对现有技术不足,本发明提供一种中频感应电炉用炉衬材料及其制备方法。
为实现以上目的,本发明通过以下技术方案予以实现:
一种中频感应电炉用炉衬材料,所述中频感应电炉用炉衬材料由以下重量份的原料制成:纳米二氧化硅15-30份、氧化锆微粉10-18份、镁铝尖晶石颗粒15-25份、刚玉细粉15-25份、微片石墨8-16份、稀土氧化物5-9份、固体水玻璃3-8份、结合剂1-3份、分散剂1-3份。
优选的,所述中频感应电炉用炉衬材料由以下重量份的原料制成:纳米二氧化硅22-25份、氧化锆微粉13-15份、镁铝尖晶石颗粒19-21份、刚玉细粉18-22份、微片石墨10-14份、稀土氧化物6-8份、固体水玻璃4-7份、结合剂1.4-2.6份、分散剂1.5-2.5份。
优选的,纳米二氧化硅23份、氧化锆微粉14份、镁铝尖晶石颗粒20份、刚玉细粉20份、微片石墨12份、稀土氧化物7份、固体水玻璃5.5份、结合剂2份、分散剂2份。
优选的,所述纳米二氧化硅的粒径为20-50nm。
优选的,所述稀土氧化物为氧化铈、氧化镨、氧化镧、氧化铷中的一种。
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,所述分散剂为三聚磷酸钠、六偏磷酸钠中的一种。
一种中频感应电炉用炉衬材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将纳米二氧化硅、氧化锆微粉、镁铝尖晶石颗粒、刚玉细粉、微片石墨、稀土氧化物球磨干混混合均匀,得到混合物;
S3、将步骤S2制备的混合物与固体水玻璃、结合剂、分散剂料混合置于搅拌机中,在转速400-600r/min下搅拌30-40min得到浆料,将浆料送入湿式球磨机中球磨4-5h后进行榨泥,得到泥饼;
S4、将步骤S2制备的泥饼送到成型机在80-100MPa下压制成型成生坯,将成型生坯送入温度为120-150℃的饱和蒸汽养护窑中继续养护17-20h,然后自然冷却,阴干,上釉,再烧结,即可。
优选的,步骤S4所述烧结在惰性气氛下烧结。
优选的,步骤S4所述烧结的升温程序为:先由室温以2-5℃/min的升温速率升温到700-800℃并保温1h,之后再以3-7℃/min的升温速率升温到1750-1850℃进行烧结。
本发明提供一种中频感应电炉用炉衬材料及其制备方法,与现有技术相比优点在于:
本发明中频感应电炉用炉衬材料具有良好的致密性,炉衬气孔率小,体积密度大,均匀性高,烧结性好和耐激冷激热性好,有效防止温度的骤变炉衬开裂,减少裂纹修补,从延长使用寿命;
本发明中频感应电炉用炉衬材料原料采用纳米二氧化硅、氧化锆微粉、镁铝尖晶石颗粒、刚玉细粉、微片石墨、稀土氧化物、固体水玻璃、结合剂、分散剂,镁铝尖晶石属中性,具有很好的抗酸、抗碱性;氧化锆微粉是优良的耐火材料,制备的炉衬材料热膨胀系数低、导热性好、抗热震稳定性好、抗剥落性好、抗碱侵蚀能力强,而且耐火度高于1750℃,软化温度高于1700℃,具有良好的耐腐蚀性、热态稳定性、化学稳定性和机械性能。
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,中频感应电炉用炉衬材料由以下重量份的原料制成:纳米二氧化硅15份、氧化锆微粉10份、镁铝尖晶石颗粒15份、刚玉细粉15份、微片石墨8份、稀土氧化物5份、固体水玻璃3份、结合剂1份、分散剂1份;
其中,纳米二氧化硅的粒径为20nm;稀土氧化物为氧化铈;结合剂为硅铝凝胶粉的水溶液;分散剂为三聚磷酸钠。
本实施例中频感应电炉用炉衬材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将纳米二氧化硅、氧化锆微粉、镁铝尖晶石颗粒、刚玉细粉、微片石墨、稀土氧化物球磨干混混合均匀,得到混合物;
S3、将步骤S2制备的混合物与固体水玻璃、结合剂、分散剂料混合置于搅拌机中,在转速400r/min下搅拌30min得到浆料,将浆料送入湿式球磨机中球磨4h后进行榨泥,得到泥饼;
S4、将步骤S2制备的泥饼送到成型机在80MPa下压制成型成生坯,将成型生坯送入温度为120℃的饱和蒸汽养护窑中继续养护17h,然后自然冷却,阴干,上釉,再烧结,即可。
实施例2:
本实施例中,中频感应电炉用炉衬材料由以下重量份的原料制成:纳米二氧化硅30份、氧化锆微粉18份、镁铝尖晶石颗粒25份、刚玉细粉25份、微片石墨16份、稀土氧化物9份、固体水玻璃8份、结合剂3份、分散剂3份;
其中,纳米二氧化硅的粒径为50nm;稀土氧化物为氧化镨;结合剂为硅酸钠的水溶液;分散剂为六偏磷酸钠。
本实施例中频感应电炉用炉衬材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将纳米二氧化硅、氧化锆微粉、镁铝尖晶石颗粒、刚玉细粉、微片石墨、稀土氧化物球磨干混混合均匀,得到混合物;
S3、将步骤S2制备的混合物与固体水玻璃、结合剂、分散剂料混合置于搅拌机中,在转速600r/min下搅拌40min得到浆料,将浆料送入湿式球磨机中球磨5h后进行榨泥,得到泥饼;
S4、将步骤S2制备的泥饼送到成型机在100MPa下压制成型成生坯,将成型生坯送入温度为150℃的饱和蒸汽养护窑中继续养护20h,然后自然冷却,阴干,上釉,再烧结,即可。
实施例3:
本实施例中,中频感应电炉用炉衬材料由以下重量份的原料制成:纳米二氧化硅23份、氧化锆微粉14份、镁铝尖晶石颗粒20份、刚玉细粉20份、微片石墨12份、稀土氧化物7份、固体水玻璃5.5份、结合剂2份、分散剂2份;
其中,纳米二氧化硅的粒径为35nm;稀土氧化物为氧化镧;结合剂为硅铝凝胶粉、硅酸钠、硅酸钾按照质量比1:1:1混合的水溶液;分散剂为六偏磷酸钠。
本实施例中频感应电炉用炉衬材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将纳米二氧化硅、氧化锆微粉、镁铝尖晶石颗粒、刚玉细粉、微片石墨、稀土氧化物球磨干混混合均匀,得到混合物;
S3、将步骤S2制备的混合物与固体水玻璃、结合剂、分散剂料混合置于搅拌机中,在转速500r/min下搅拌35min得到浆料,将浆料送入湿式球磨机中球磨4.5h后进行榨泥,得到泥饼;
S4、将步骤S2制备的泥饼送到成型机在90MPa下压制成型成生坯,将成型生坯送入温度为135℃的饱和蒸汽养护窑中继续养护18h,然后自然冷却,阴干,上釉,再烧结,即可。
实施例4:
本实施例中,中频感应电炉用炉衬材料由以下重量份的原料制成:纳米二氧化硅22份、氧化锆微粉13份、镁铝尖晶石颗粒19份、刚玉细粉18份、微片石墨10份、稀土氧化物6份、固体水玻璃4份、结合剂1.4份、分散剂1.5份;
其中,纳米二氧化硅的粒径为25nm;稀土氧化物为氧化铷;结合剂为硅铝凝胶粉、硅酸钾、磷酸盐按照质量比1:0.7:0.7混合的水溶液;分散剂为三聚磷酸钠。
本实施例中频感应电炉用炉衬材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将纳米二氧化硅、氧化锆微粉、镁铝尖晶石颗粒、刚玉细粉、微片石墨、稀土氧化物球磨干混混合均匀,得到混合物;
S3、将步骤S2制备的混合物与固体水玻璃、结合剂、分散剂料混合置于搅拌机中,在转速450r/min下搅拌32min得到浆料,将浆料送入湿式球磨机中球磨4.3h后进行榨泥,得到泥饼;
S4、将步骤S2制备的泥饼送到成型机在85MPa下压制成型成生坯,将成型生坯送入温度为125℃的饱和蒸汽养护窑中继续养护18h,然后自然冷却,阴干,上釉,再烧结,即可。
实施例5:
本实施例中,中频感应电炉用炉衬材料由以下重量份的原料制成:纳米二氧化硅25份、氧化锆微粉15份、镁铝尖晶石颗粒21份、刚玉细粉22份、微片石墨14份、稀土氧化物8份、固体水玻璃7份、结合剂2.6份、分散剂2.5份;
其中,纳米二氧化硅的粒径为40nm;稀土氧化物为氧化铈;结合剂为硅铝凝胶粉、硅酸钠、磷酸盐按照质量比1:0.6:0.3混合的水溶液;分散剂为六偏磷酸钠。
本实施例中频感应电炉用炉衬材料的制备方法,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将纳米二氧化硅、氧化锆微粉、镁铝尖晶石颗粒、刚玉细粉、微片石墨、稀土氧化物球磨干混混合均匀,得到混合物;
S3、将步骤S2制备的混合物与固体水玻璃、结合剂、分散剂料混合置于搅拌机中,在转速550r/min下搅拌38min得到浆料,将浆料送入湿式球磨机中球磨4-5h后进行榨泥,得到泥饼;
S4、将步骤S2制备的泥饼送到成型机在95MPa下压制成型成生坯,将成型生坯送入温度为140℃的饱和蒸汽养护窑中继续养护19h,然后自然冷却,阴干,上釉,再烧结,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)
1.一种中频感应电炉用炉衬材料,其特征在于,所述中频感应电炉用炉衬材料由以下重量份的原料制成:纳米二氧化硅15-30份、氧化锆微粉10-18份、镁铝尖晶石颗粒15-25份、刚玉细粉15-25份、微片石墨8-16份、稀土氧化物5-9份、固体水玻璃3-8份、结合剂1-3份、分散剂1-3份。
2.根据权利要求1所述的中频感应电炉用炉衬材料,其特征在于,所述中频感应电炉用炉衬材料由以下重量份的原料制成:纳米二氧化硅22-25份、氧化锆微粉13-15份、镁铝尖晶石颗粒19-21份、刚玉细粉18-22份、微片石墨10-14份、稀土氧化物6-8份、固体水玻璃4-7份、结合剂1.4-2.6份、分散剂1.5-2.5份。
3.根据权利要求1所述的中频感应电炉用炉衬材料,其特征在于,纳米二氧化硅23份、氧化锆微粉14份、镁铝尖晶石颗粒20份、刚玉细粉20份、微片石墨12份、稀土氧化物7份、固体水玻璃5.5份、结合剂2份、分散剂2份。
4.根据权利要求1或2或3所述的中频感应电炉用炉衬材料,其特征在于:所述纳米二氧化硅的粒径为20-50nm。
5.根据权利要求1或2或3所述的中频感应电炉用炉衬材料,其特征在于:所述稀土氧化物为氧化铈、氧化镨、氧化镧、氧化铷中的一种。
6.根据权利要求1或2或3所述的中频感应电炉用炉衬材料,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或3所述的中频感应电炉用炉衬材料,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。
8.一种如权利要求1-7任一所述中频感应电炉用炉衬材料的制备方法,其特征在于,包括以下步骤:
S1、按照重量份称取各个原料;
S2、将纳米二氧化硅、氧化锆微粉、镁铝尖晶石颗粒、刚玉细粉、微片石墨、稀土氧化物球磨干混混合均匀,得到混合物;
S3、将步骤S2制备的混合物与固体水玻璃、结合剂、分散剂料混合置于搅拌机中,在转速400-600r/min下搅拌30-40min得到浆料,将浆料送入湿式球磨机中球磨4-5h后进行榨泥,得到泥饼;
S4、将步骤S2制备的泥饼送到成型机在80-100MPa下压制成型成生坯,将成型生坯送入温度为120-150℃的饱和蒸汽养护窑中继续养护17-20h,然后自然冷却,阴干,上釉,再烧结,即可。
9.根据权利要求8所述的制备方法,其特征在于:步骤S4所述烧结在惰性气氛下烧结。
10.根据权利要求8所述的制备方法,其特征在于:步骤S4所述烧结的升温程序为:先由室温以2-5℃/min的升温速率升温到700-800℃并保温1h,之后再以3-7℃/min的升温速率升温到1750-1850℃进行烧结。
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Application publication date: 20181218 |