CN109180165B - 一种滑板砖的制备方法 - Google Patents

一种滑板砖的制备方法 Download PDF

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CN109180165B
CN109180165B CN201811024068.8A CN201811024068A CN109180165B CN 109180165 B CN109180165 B CN 109180165B CN 201811024068 A CN201811024068 A CN 201811024068A CN 109180165 B CN109180165 B CN 109180165B
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CN109180165A (zh
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马军强
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Luoyang Kechuang New Material Co ltd
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Abstract

本发明公开了一种滑板砖的制备方法，包括以下步骤：混合、成型、养护、干燥、烧成、真空‑加压浸渍、再干燥、套箍、磨制、贴面和包装。本发明所制备的滑板砖摒弃昂贵的压力成型机，采用振动浇注成型，投资成本低。滑板砖经高温烧成后形成牢固的陶瓷结合，真空‑加压浸渍后，具有强度高，耐磨损，不拉毛，耐冲刷，扩孔速率小，氧化失碳后仍能保持组织结构致密等优点，可满足多炉连滑之需求，技术水平超过国内外本领域同类水平。

Description

一种滑板砖的制备方法
技术领域
本发明属于耐火材料技术领域，具体涉及一种滑板砖的制备方法。
背景技术
滑板砖是炼钢厂连铸机浇铸过程中钢水的控制装置，能够精确地调节从钢包到连铸中间包的钢水流量，使流入和流出的钢水达到平衡，从而使连铸操作更容易控制。
目前，市场上广泛使用的滑板砖按热处理温度分两类：免烧滑板砖和高温烧成滑板砖，热处理温度分别为500-600℃和1300-1500℃。免烧滑板砖和高温烧成滑板砖的共同点为：成型方式皆为机压成型，需要昂贵的大吨位压力成型机；结合形式皆为碳结合。这样，当浇注高氧钢、高锰钢、Ca处理钢、镇静钢等特种钢时，钢水中的氧与滑板砖中的碳反应，滑板砖就会因氧化失碳形成变质层，结构疏松，易被钢水冲刷而损毁，造成连滑次数较低，不能满足多炉连滑需求。
发明内容
本发明旨在克服现有技术缺陷，目的在于提供一种强度高，耐冲刷，抗热震性好，氧化失碳后仍能保持组织结构致密，连滑次数较高的陶瓷结合滑板砖的制备方法。
为实现上述目的，本发明采用如下技术方案：
一种滑板砖的制备方法，其特征在于包括下列步骤：
①混合：将35-45wt％的5-1mm刚玉，5-20wt％的3-1mm莫来石，10-25wt％的1-0mm刚玉，15-25wt％的325目刚玉，1-5wt％的2μm氧化铝微粉，2-5wt％的5μm硅石和0.05～0.2wt％的Castament FS65减水剂置入星式搅拌机，搅拌5-10分钟，制成均匀混合料；
②成型：向上述星式搅拌机中加入均匀混合料5～8wt％的硅溶胶改性水性丙烯酸树脂，强力搅拌5-10分钟，然后注入滑板砖模具，振动成型；
③养护、干燥：将上述浇注成型体连同模具一起置入养护窑，于60～80℃养护12～24小时，脱模得到坯体，然后将坯体置入干燥窑，于180～200℃干燥12～24小时；
④烧成：将干燥好的坯体置入高温梭式窑，于1350～1550℃煅烧3～5小时；
⑤真空-加压浸渍：首先将烧制好的滑板砖于常温下置入真空-加压浸渍机，抽真空至100Pa以下，然后注入水溶性环保树脂对滑板砖进行浸渍，最后加压，压力为1.0～1.4MPa，保压时间为1～4小时。
⑥再干燥：将浸渍水溶性环保树脂后的滑板砖置于干燥窑中，于150～180℃干燥5～8小时；
⑦套箍：将钢箍置于高频感应加热器中加热5～10秒，然后取出套在滑板砖外侧面；
⑧磨制：用平面磨床对滑板砖的滑动面进行磨平、抛光，平整度小于0.05mm；
⑨贴面及包装：磨制好的滑板经检验合格后，在背面粘贴矿棉垫和马口铁，然后包装入库。
所述刚玉为板状刚玉、白刚玉、棕刚玉中的至少一种，板状刚玉和白刚玉化学组分的质量百分比为：Al2O3≥99％、SiO2≤0.2％、Fe2O3≤0.1％、R2O≤0.4％，棕刚玉化学组分的质量百分比为：Al2O3≥94％、SiO2≤1.0％、Fe2O3≤0.5％。
所述莫来石为电熔莫来石、烧结莫来石中的至少一种，其化学组分的质量百分比为：Al2O3≥70％、SiO2≤30％、Fe2O3≤0.1％、R2O≤0.3％。
所述氧化铝微粉为α-氧化铝微粉，其化学组分的质量百分比为：Al2O3≥99.3％、SiO2≤0.1％、Fe2O3≤0.1％、R2O≤0.3％。
所述硅石为天然硅石，其化学组分的质量百分比为：SiO2≥99.0％，Al2O3≤0.5％、Fe2O3≤0.2％。
所述硅溶胶改性水性丙烯酸树脂，硅溶胶占比15％，固含量40±2％。
所述水溶性环保树脂为水性环氧树脂、水性丙烯酸树脂、水性聚氨酯树脂中的任意一种。
与现有技术相比，本发明带来的有益效果为：以振动浇注成型替代机压成型，摒弃了昂贵的压力成型机，投资成本低；结合剂由对环境有污染的酚醛树脂改为环保型的硅溶胶改性水性丙烯酸树脂；结合剂中的硅溶胶，使得滑板砖在烧成后形成牢固的陶瓷结合；真空-加压浸渍物由污染环境的沥青改为环境友好型的水性环保树脂；本发明的滑板砖在服役过程中具有强度高，耐磨损，不拉毛，耐冲刷，扩孔速率小，氧化失碳后仍能保持组织结构致密等优点，可满足多炉连滑之需求，技术水平超过国内外本领域同类水平。
具体实施方式
以下结合具体实施例对本发明作进一步详细说明，并非对其保护范围的限制。
实施例1
一种滑板砖的制备方法，包括以下步骤：
①混合：将40wt％的5-1mm板状刚玉，15wt％的3-1mm烧结莫来石，15wt％的1-0mm板状刚玉，19.9wt％的325目板状刚玉，5wt％的2μm氧化铝微粉，5wt％的5μm硅石和0.1wt％的Castament FS65减水剂置入星式搅拌机，搅拌6分钟，制成均匀混合料；
②成型：向上述星式搅拌机中加入均匀混合料6wt％的硅溶胶改性水性丙烯酸树脂，强力搅拌6分钟，然后注入滑板砖模具，振动成型；
③养护、干燥：将上述浇注成型体连同模具一起置入养护窑，于70℃养护16小时，脱模得到坯体，然后将坯体置入干燥窑，于190℃干燥13小时；
④烧成：将干燥好的坯体置入高温梭式窑，于1450℃煅烧5小时；
⑤真空-加压浸渍：首先将烧制好的滑板砖于常温下置入真空-加压浸渍机，抽真空至90Pa，然后注入水溶性环氧树脂对滑板砖进行浸渍，最后加压，压力为1.1MPa，保压时间为2小时。
⑥再干燥：将浸渍水溶性环氧树脂后的滑板砖置于干燥窑中，于160℃干燥6小时；
⑦套箍：将钢箍置于高频感应加热器中加热8秒，然后取出套在滑板砖外侧面；
⑧磨制：用平面磨床对滑板砖的滑动面进行磨平、抛光，平整度小于0.05mm；
⑨贴面及包装：磨制好的滑板经检验合格后，在背面粘贴矿棉垫和马口铁，然后包装入库。
本实施例所制备的陶瓷结合滑板砖，其主要物理性能是：显气孔率为5.1％，体积密度为3.21g/cm3，常温耐压强度213MPa，1450℃×0.5h条件下高温抗折强度12.6MPa，1100℃条件水冷热震28次。
该滑板经国内某钢厂100吨高氧钢包使用，连滑5次。
实施例2
一种滑板砖的制备方法，包括以下步骤：
①混合：将45wt％的5-1mm白刚玉，12wt％的3-1mm电熔莫来石，15wt％的1-0mm白刚玉，20.85wt％的325目板状刚玉，3wt％的2μm氧化铝微粉，4wt％的5μm硅石和0.15wt％的Castament FS65减水剂置入星式搅拌机，搅拌7分钟，制成均匀混合料；
②成型：向上述星式搅拌机中加入均匀混合料5.9wt％的硅溶胶改性水性丙烯酸树脂，强力搅拌7分钟，然后注入滑板砖模具，振动成型；
③养护、干燥：将上述浇注成型体连同模具一起置入养护窑，于75℃养护15小时，脱模得到坯体，然后将坯体置入干燥窑，于185℃干燥15小时；
④烧成：将干燥好的坯体置入高温梭式窑，于1500℃煅烧4小时；
⑤真空功压浸渍：首先将烧制好的滑板砖于常温下置入真空-加压浸渍机，抽真空至85Pa，然后注入水溶性丙烯酸树脂对滑板砖进行浸渍，最后加压，压力为1.2MPa，保压时间为3小时。
⑥再干燥：将浸渍水溶性环氧树脂后的滑板砖置于干燥窑中，于180℃干燥7小时；
⑦套箍：将钢箍置于高频感应加热器中加热7秒，然后取出套在滑板砖外侧面；
⑧磨制：用平面磨床对滑板砖的滑动面进行磨平、抛光，平整度小于0.05mm；
⑨贴面及包装：磨制好的滑板经检验合格后，在背面粘贴矿棉垫和马口铁，然后包装入库。
本实施例所制备的陶瓷结合滑板砖，其主要物理性能是：显气孔率为4.9％，体积密度为3.22g/cm3，常温耐压强度206MPa，1450℃×0.5h条件下高温抗折强度12.5MPa，1100℃条件水冷热震26次。
该滑板经国内某钢厂150吨Ca处理钢包使用，连滑6次。
从上述实施例可以看出，本发明提供一种采用振动浇注成型，高温烧成并真空-加压浸渍后，具有强度高，耐冲刷，抗热震性好，连滑次数较高的陶瓷结合滑板砖的制备方法。

Claims (7)

1.一种滑板砖的制备方法，其特征在于包括下列步骤：
①混合：将35-45wt％的5-1mm刚玉，5-20wt％的3-1mm莫来石，10-25wt％的1-0mm刚玉，15-25wt％的325目刚玉，1-5wt％的2μm氧化铝微粉，2-5wt％的5μm硅石和0.05～0.2wt％的Castament FS65减水剂置入星式搅拌机，搅拌5-10分钟，制成均匀混合料；
②成型：向上述星式搅拌机中加入均匀混合料5～8wt％的硅溶胶改性水性丙烯酸树脂，强力搅拌5-10分钟，然后注入滑板砖模具，振动成型；
③养护、干燥：将上述浇注成型体连同模具一起置入养护窑，于60～80℃养护12～24小时，脱模得到坯体，然后将坯体置入干燥窑，于180～200℃干燥12～24小时；
④烧成：将干燥好的坯体置入高温梭式窑，于1350～1550℃煅烧3～5小时；
⑤真空-加压浸渍：首先将烧制好的滑板砖于常温下置入真空-加压浸渍机，抽真空至100Pa以下，然后注入水溶性环保树脂对滑板砖进行浸渍，最后加压，压力为1.0～1.4MPa，保压时间为1～4小时；
⑥再干燥：将浸渍水溶性环保树脂后的滑板砖置于干燥窑中，于150～180℃干燥5～8小时；
⑦套箍：将钢箍置于高频感应加热器中加热5～10秒，然后取出套在滑板砖外侧面；
⑧磨制：用平面磨床对滑板砖的滑动面进行磨平、抛光，平整度小于0.05mm；
⑨贴面及包装：磨制好的滑板经检验合格后，在背面粘贴矿棉垫和马口铁，然后包装入库；
所述硅溶胶改性水性丙烯酸树脂，硅溶胶占比5-15％，固含量40+2％。
2.根据权利要求1所述的滑板砖的制备方法，其特征在于，所述刚玉为板状刚玉、白刚玉、棕刚玉中的至少一种，板状刚玉和白刚玉化学组分的质量百分比为：Al2O3≥99％、SiO2≤0.2％、Fe2O3≤0.1％、R2O≤0.4％，棕刚玉化学组分的质量百分比为：Al2O3≥94％、SiO2≤1.0％、Fe2O3≤0.5％。
3.根据权利要求1所述的滑板砖的制备方法，其特征在于，所述莫来石为电熔莫来石、烧结莫来石中的至少一种，其化学组分的质量百分比为：Al2O3≥70％、SiO2≤30、Fe2O3≤0.1％、R2O≤0.3％。
4.根据权利要求1所述的滑板砖的制备方法，其特征在于，所述氧化铝微粉为α-氧化铝微粉，其化学组分的质量百分比为：Al2O3≥99.3％、5iO2≤0.1％、Fe2O3≤0.1％、R2O≤0.3％。
5.根据权利要求1所述的滑板砖的制备方法，其特征在于，所述硅石为天然硅石，其化学组分的质量百分比为：SiO2≥99.0％，Al2O3≤0.5％、Fe2O3≤0.2％。
6.根据权利要求1所述的滑板砖的制备方法，其特征在于，所述水溶性环保树脂为水性环氧树脂、水性丙烯酸树脂、水性聚氨酯树脂中的任意一种。
7.根据权利要求1～6中任一项所述的滑板砖的制备方法所制备的滑板砖。
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