CN109231968A - 连铸中间包工作衬用干式料及其制备方法 - Google Patents
连铸中间包工作衬用干式料及其制备方法 Download PDFInfo
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- CN109231968A CN109231968A CN201811079762.XA CN201811079762A CN109231968A CN 109231968 A CN109231968 A CN 109231968A CN 201811079762 A CN201811079762 A CN 201811079762A CN 109231968 A CN109231968 A CN 109231968A
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Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/03—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on magnesium oxide, calcium oxide or oxide mixtures derived from dolomite
- C04B35/04—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on magnesium oxide, calcium oxide or oxide mixtures derived from dolomite based on magnesium oxide
- C04B35/043—Refractories from grain sized mixtures
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62204—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse
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- C04B35/803—
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
- C04B35/82—Asbestos; Glass; Fused silica
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3201—Alkali metal oxides or oxide-forming salts thereof
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
- C04B2235/3208—Calcium oxide or oxide-forming salts thereof, e.g. lime
- C04B2235/321—Dolomites, i.e. mixed calcium magnesium carbonates
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3409—Boron oxide, borates, boric acids, or oxide forming salts thereof, e.g. borax
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Abstract
本发明涉及一种连铸中间包工作衬用干式料及其制备方法,所述干式料原料组分为:镁砂40‑70%,煅烧白云石10‑25%,镁白云石砂10‑30%,镁碳砖回收料5‑15%,低温粘结剂1.0‑5.0%,粘土0‑5%,中温粘结剂0.5‑8%,抗氧化剂0.5‑5%,助烧剂0.5‑5%,粉尘抑制剂0.1‑5%。所制备的中间包工作衬体积密度1.8‑2.5g/cm3,110℃×24h耐压强度2.5‑4MPa,1550℃×3h耐压强度6‑12MPa,耐火度>1750℃,线变化率‑4%‑+4%,1100℃水冷50次不开裂,使用寿命>30h,具有强度高、抗热震性好、抗渣侵蚀性能好、钢水净化能力强、寿命长以及环保的特点。
Description
技术领域
本发明属于炼钢连铸用耐火材料技术领域,涉及一种连铸中间包工作衬用干式料及其制备方法。
背景技术
中间包是连铸工艺流程中位于钢包和结晶器之间的过渡容器。随着技术的进步,目前中间包钢水已开始应用钢水再加热技术、中间包保温技术、氩气密封、氩气搅拌技术。这些技术应用的共同目标即是清除钢液中非金属夹杂物、防止二次氧化、减轻耐火材料对钢液的侵蚀及中包渣的卷入。中间包干式料是近些年发展起来的新一代工作衬用耐火材料,具有施工方便、升温速度快、使用寿命长和脱包容易等优点,并且中间包干式料对钢水中非金属夹杂物有很强的吸附作用,从而具有净化钢水作用,因而引起广泛关注。
CN200810121599.9公开了一种环保型连铸中间包干式料及其制备方法,以电熔镁砂为主要原料,外加α-Al2O3、SiO2、CaO和树脂添加剂,该专利技术制得的中间包虽然具有强度高、寿命长以及耐侵蚀的特点,但是产品含有十二烷、无水树脂和六亚甲基四胺等组分,在烘烤过程中易产生刺激性气味,对环境仍有一定的污染。CN200910095277.6公开了一种环保型干式料配方,以镁砂为主要原料,外加废镁碳砖颗粒、糖类复合结合剂、助烧剂、抗氧化剂。该专利技术制得的中间包具有抗侵蚀性能好、易解体、使用寿命长、无有毒有害气体产生、对环境无污染的特点,但是其在烘烤过程中易开裂垮塌。CN105418082A公开了一种长寿命环保中间包干式料,该发明以电熔镁砂为主要原料,选择松香和含水硅酸盐作为复合结合剂,虽然解决了因树脂结合剂烘烤产生的有害刺激性气体以及不利于洁净炼钢和环保要求等问题,但该干式料使用过程中结构致密和保温性能较差。
综合而言,目前已知的各种干式料主要存在以下技术问题:第一结合剂不环保,烘烤过程中对环境易产生污染;第二,干式料工作衬在制作过程中,烘干脱模强度低,容易出现开裂;第三,干式料工作衬在使用过程中保温性能差,不能长时间满足使用要求等缺点,这些缺点制约了干式料中间包的大规模使用。因此,研究和开发性能更好的中间包用干式料组成对于生产高品质钢具有重要意义。
发明内容
本发明所要解决的技术问题是针对现有技术中存在的上述不足,提供一种连铸中间包工作衬用干式料及其制备方法,该工作衬同时具有强度高、抗热震性好、抗渣侵蚀性能好、钢水净化能力强、寿命长以及环保的特点,有望推广进行大规模生产。
为解决上述技术问题,本发明提供的技术方案是:
提供一种连铸中间包工作衬用干式料,其原料组分及其质量百分比如下:
按上述方案,所述镁白云石砂中MgO含量为50-70%。
按上述方案,所述低温粘结剂为聚多糖,或酚醛聚合物,或聚多糖和酚醛聚合物按质量比1~5:1的混合物,所述酚醛聚合物组分及质量百分含量为:英国939P酚醛树脂粉70%,丙烯酸树脂20~25%,纤维素2.5~5%,聚乙烯醇2.5~5%;所述聚多糖为葡萄糖、木糖、半乳糖、果糖、甘露糖、山梨糖、蔗糖、麦芽糖、蜜糖、普通糖醛酸中的一种或几种的混合物。
按上述方案,所述粘土为白泥,高岭土,膨润土中的一种或者其混合物。加入粘土的作用是增强成型后干式料工作衬的表面质量,在中间包温度升高过程中作为助熔剂辅助工作面的烧结,从而提高工作衬的结合强度。当中温粘结剂添加量较大时,粘土可不加。
按上述方案,所述中温粘结剂为磷酸盐、碱金属硅酸盐中的一种或者二者的混合物,其中磷酸盐为磷酸钠、磷酸二氢钠、六偏磷酸钠中的一种,碱金属硅酸盐为无水硅酸钠或水合硅酸钠。
按上述方案,所述抗氧化剂为硅铁合金粉末(Fe粉、Si粉质量比为3:7~12)、铝硅合金粉末(Al粉、Si粉质量比为7~27:3)、镁铝合金粉末(Mg粉、Al粉质量比为=3:2~4.5)中的一种;所述Fe粉、Al粉、Mg粉的平均粒径为1-500μm,Si粉的平均粒径为1-50μm。
按上述方案,所述助烧剂为硼氧化物、硼酸中的一种或两者的混合物,或多晶氧化铝纤维,或石英纤维,其中,所述硼氧化物为B2O3或BxO,x=2-7,所述多晶氧化铝纤维及石英纤维的长度为0.5-5μm。
按上述方案,所述粉尘抑制剂为矿物油、煤油、乙二醇、硅溶胶、铝溶胶或铝溶胶与硅铝溶胶的混合物。
本发明还包括上述连铸中间包工作衬用干式料的制备方法,具体步骤如下:
1)称取原料,备用;
2)球磨:先将镁砂、煅烧白云石、镁白云石砂、镁碳砖回收料放入球磨机中混合0.5-10h,待混匀后,根据需要依次加入低温粘结剂、粘土、中温粘结剂、抗氧化剂、助烧剂以及粉尘抑制剂,再次进行球磨混合,混合时间为0.5-5h,球磨结束后得到配合料,利用抽气法或压缩法对所得配合料进行排气保存,得到连铸中间包工作衬用干式料。
按上述方案,步骤2)所述球磨机为行星式球磨机、卧式球磨机或立式球磨机。
本发明还进一步包括根据上述连铸中间包工作衬用干式料制备得到的中间包工作衬。
以及包括上述工作衬的中间包,中间包从外层到里层依次包括钢壳、保温层、永久层以及工作衬。
上述中间包工作衬的制备方法,具体步骤如下:先将胎膜和中间包内永久层表面清理干净,在永久层和胎膜表面刷一层机油,然后将胎膜放置于中间包里面,永久层和胎膜之间形成间隙,待中间包温度降低至100℃以下,向间隙内倒入所述的干式料,捣打成型得到工作衬。
制备工作衬时,先进行包底施工,再将胎膜放入中间包,然后向中间包间隙倒入干式料,并进行捣实,使间隙填充密实,然后开动胎膜内部的振动电机,振动0.5-5h,再对振动后的胎膜进行加热,加热温度为200-450℃,时间为0.5-6h,待胎膜冷却后拔出胎膜,利用烤包器对中间包内部进行烘烤(烘烤的温度为700-1200℃,烘烤时间为1-5h)后得到连铸中间包工作衬。
本发明采用中、低、高温结合剂(粘土)搭配使用,室温-800℃时,中低温粘结剂起作用,当温度超过700℃时,工作衬颗粒之间会形成陶瓷结合,强度和耐侵蚀性能大大提高。不论是成型后的低温脱模强度,还是高温强度均良好,因而产品在现实使用过程中易成型、方面使用。另外,本发明利用镁砂、煅烧白云石、镁白云石砂以及镁碳砖回收料为主要原料,可以大量利用废弃镁碳砖,减少其对环境的污染,所用结合剂均比较环保,无污染,具有良好的环境匹配性。本发明采用大量的钙质基体材料如煅烧白云石和镁白云石砂,可有效提高工作衬在使用过程对钢水中夹杂物的吸附,还可以提高工作衬的耐侵蚀性,适用于生产高品质洁净钢。同时,基体中镁砂和镁碳砖回收料不仅可提高产品的高温强度,也可获得优良的抗熔钢和熔渣侵蚀性能,使得干式料工作衬的使用寿命大大提高。
本发明的有益效果在于:1、本发明提供的干式料所制备的中间包工作衬体积密度为1.8-2.5g/cm3,110℃×24h耐压强度为2.5-4MPa,1550℃×3h耐压强度为6-12MPa,耐火度大于1750℃,线变化率为-4%-+4%,1100℃水冷50次不开裂,实际使用寿命大于30h,具有强度高、抗热震性好、抗渣侵蚀性能好、钢水净化能力强、寿命长以及环保的特点;2、本发明制备方法简单,成本低,有工业推广价值。
具体实施方式
为使本领域技术人员更好地理解本发明的技术方案,下面结合实施例对本发明作进一步详细描述。
实施例1
一种连铸中间包工作衬用干式料,其制备方法包括如下步骤:
1)按以下质量百分比选取原料:
(1)主要原料:镁砂55%,煅烧白云石20%,镁白云石砂10%(其中MgO含量为65%),镁碳砖回收料5%;
所用镁砂粒径配比为:8-5mm占10%,5-3mm占10%,3-1mm占25%,1-0.5mm占10%,0.5-0.088mm占20%,小于0.088mm占25%;所用煅烧白云石粒径配比为:3-1mm占20%,1-0.5mm占30%,0.5-0.088mm占25%,小于0.088mm占25%;所用镁白云石砂粒径配比为:3-1mm占20%,1-0.5mm占25%,0.5-0.088mm占25%,小于0.088mm占30%;所用镁碳砖回收料粒径配比为:3-1mm占35%,1-0.5mm占35%,小于0.5mm占30%。
(2)低温粘结剂(2.0%):采用葡萄糖和麦芽糖混合物,其中,葡萄糖占质量比为60%,麦芽糖占质量比为40%;
(3)粘土(1%):采用高岭土为粘土。
(4)中温粘结剂2%:磷酸二氢钠(30wt%),无水硅酸钠(70wt%)。
(5)抗氧化剂(2%):Fe粉(20wt%,100μm),Si粉(80wt%,5μm)。
(6)助烧剂(1%):硼酸。
(7)粉尘抑制剂(2%):矿物油。
2)配合料的制备:按照原料配比进行配料。配料过程中,先选取主要原料,然后放入球磨机中进行混合5h;待混匀后,再依次加入低温粘结剂、粘土、中温粘结剂、抗氧化剂、助烧剂以及粉尘抑制剂,再进行球磨混合,混合时间为2h,球磨结束后得到配合料。混合过程中球磨机为行星式球磨机。
3)排气保存:利用抽气法对配合料进行排气保存,得到连铸中间包工作衬用干式料。
工作衬的制备:先将中间包胎膜清理干净,并在其表面刷一层机油。待中间包温度降低至50℃时,将永久层表面清理干净。制备工作衬时,先进行包底施工,再将胎膜放入中间包,再向中间包间隙倒入上述制备的干式料,并进行捣实,使间隙填充密实。然后开动胎膜内部的振动电机,振动3h,再对振动后的胎膜进行加热,加热温度为250℃,时间为1.5h,待胎膜冷却后拔出胎膜,待用。上线使用前再利用烤包器对中间包内部进行烘烤2.5h后投入使用,烘烤温度为1100℃。
经测试,利用本实施例的干式料所制备的中间包工作衬体积密度为2.1g/cm3,110℃×24h耐压强度为3.2MPa,1550℃×3h耐压强度为7.5MPa,耐火度为1760℃,线变化率为-3%,1100℃水冷50次不开裂,实际使用寿命为35h,具有强度高、抗热震性好、抗渣侵蚀性能好、钢水净化能力强、寿命长以及环保的特点。
实施例2
一种连铸中间包工作衬用干式料,其制备方法包括如下步骤:
1)按以下质量百分比选取原料:
(1)主要原料:镁砂70%,煅烧白云石10%,镁白云石砂10%(其中MgO含量为50%),镁碳砖回收料5%;
所用镁砂粒径配比为:8-5mm占5%,5-3mm占10%,3-1mm占20%,1-0.5mm占10%,0.5-0.088mm占25%,小于0.088mm占30%;所用煅烧白云石粒径配比为:3-1mm占35%,1-0.5mm占20%,0.5-0.088mm占15%,小于0.088mm占30%;所用镁白云石砂粒径配比为:3-1mm占25%,1-0.5mm占35%,0.5-0.088mm占25%,小于0.088mm占15%;所用镁碳砖回收料粒径配比为:3-1mm占40%,1-0.5mm占40%,小于0.5mm占20%。
(2)低温粘结剂1.0%:低温粘结剂采用酚醛聚合物(由英国939P酚醛树脂粉70wt%、丙烯酸树脂20wt%、纤维素5wt%以及聚乙烯醇5wt%组成。
(3)粘土0.5%:采用膨润土作为粘土。
(4)中温粘结剂0.5%:六偏磷酸钠。
(5)抗氧化剂1%:铝硅合金粉末(Al粉占70%,Si粉占30%,Al粉粒径为50μm,Si粉粒径为5μm)。
(6)助烧剂1%:多晶氧化铝纤维,纤维长度为4μm。
(7)粉尘抑制剂1%:粉尘抑制剂为煤油。
室温-700℃时,中低温粘结剂起作用,当温度超过700℃时,工作衬颗粒之间会形成陶瓷结合,强度和耐侵蚀性能大大提高。
2)配合料的制备:按照原料配比进行配料。配料过程中,先选取主要原料,然后放入球磨机中进行混合8h;待混匀后,再依次加入低温粘结剂、粘土、中温粘结剂、抗氧化剂、助烧剂以及粉尘抑制剂,再进行球磨混合,混合时间为1h,球磨结束后得到配合料。混合过程中球磨机为卧式球磨机。
3)排气保存:利用抽气法对配合料进行排气保存,得到连铸中间包工作衬用干式料。
工作衬的制备:先将中间包胎膜清理干净,并在其表面刷一层机油。待中间包温度降低至80℃后,将永久层表面清理干净。制备工作衬时,先进行包底施工,再将胎膜放入中间包,再向中间包间隙倒入上述制备的干式料,并进行捣实,使间隙填充密实。然后开动胎膜内部的振动电机,振动1.5h。再对振动后的胎膜进行加热,温度为300℃,时间为3h。最后,待胎膜冷却后拔出胎膜,待用。上线使用前再利用烤包器进行烘烤4h左右后投入使用,烘烤温度为1000℃左右。
经测试,利用本实施例的干式料所制备的中间包工作衬体积密度为2.3g/cm3,110℃×24h耐压强度为3.5MPa,1550℃×3h耐压强度为8.1MPa,耐火度为1770℃,线变化率为-3.1%-+2.8%,1100℃水冷50次不开裂,实际使用寿命为40h,具有强度高、抗热震性好、抗渣侵蚀性能好、钢水净化能力强、寿命长以及环保的特点。
实施例3
一种连铸中间包工作衬用干式料,其制备方法包括如下步骤:
1)按以下质量百分比选取原料:
(1)主要原料:镁砂40%,煅烧白云石25%,镁白云石砂10%(其中MgO含量为70%),镁碳砖回收料15%;
所用镁砂粒径配比为:8-5mm占10%,5-3mm占15%,3-1mm占20%,1-0.5mm占12%,0.5-0.088mm占20%,小于0.088mm占23%;所用煅烧白云石粒径配比为:3-1mm占30%,1-0.5mm占25%,0.5-0.088mm占20%,小于0.088mm占25%;所用镁白云石砂粒径配比为:3-1mm占20%,1-0.5mm占30%,0.5-0.088mm占20%,小于0.088mm占30%;所用镁碳砖回收料粒径配比为:3-1mm占40%,1-0.5mm占45%,小于0.5mm占15%。
(2)低温粘结剂3.0%:采用蔗糖和麦芽糖按质量比1:1混合得到。
(3)粘土1.5%:采用白泥和高岭土按质量比1:1混合得到的。
(4)中温粘结剂2.5%:采用水合硅酸钠作为中温粘结剂。
(5)抗氧化剂0.5%:采用镁铝合金粉末(Mg粉60%,Al粉40%,Mg粉和Al粉的平均粒径均为200μm)。
(6)助烧剂0.5%:石英纤维,石英纤维的长度为2μm。
(7)粉尘抑制剂2%:粉尘抑制剂为乙二醇。
室温-700℃时,中低温粘结剂起作用,当温度超过700℃时,工作衬颗粒之间会形成陶瓷结合,强度和耐侵蚀性能大大提高。
2)配合料的制备:按照原料配比进行配料。配料过程中,先选取主要原料,然后放入球磨机中进行混合8h;待混匀后,再依次加入低温粘结剂、粘土、中温粘结剂、抗氧化剂、助烧剂以及粉尘抑制剂,再进行球磨混合,混合时间为4h,球磨结束后得到配合料。混合过程中球磨机为立式球磨机。
3)排气保存:利用抽气法对配合料进行排气保存,得到连铸中间包工作衬用干式料。
工作衬的制备:先将中间包胎膜清理干净,并在其表面刷一层机油。待中间包温度降低至30℃左右,将永久层表面清理干净。制备工作衬时,先进行包底施工,再将胎膜放入中间包,再向中间包间隙倒入上述制备的干式料,并进行捣实,使间隙填充密实。然后开动胎膜内部的振动电机,振动4h。再对振动后的胎膜进行加热,温度为400℃之间,时间为5h左右。最后,待胎膜冷却后拔出胎膜,待用。上线使用前再利用烤包器进行烘烤4h左右后投入使用,烘烤温度为800℃左右。
经测试,利用本实施例的干式料所制备的中间包工作衬体积密度为2.5g/cm3,110℃×24h耐压强度为2.9MPa,1550℃×3h耐压强度为10MPa,耐火度大于1780℃,线变化率为-2%-+2%,1100℃水冷50次不开裂,实际使用寿命为40h,具有强度高、抗热震性好、抗渣侵蚀性能好、钢水净化能力强、寿命长以及环保的特点。
实施例4
一种连铸中间包工作衬用干式料,其制备方法包括如下步骤:
1)按以下质量百分比选取原料:
(1)主要原料:镁砂40%,煅烧白云石25%,镁白云石砂10%(其中MgO含量为70%),镁碳砖回收料15%;
所用镁砂粒径配比为:8-5mm占10%,5-3mm占10%,3-1mm占30%,1-0.5mm占10%,0.5-0.088mm占20%,小于0.088mm占20%;所用煅烧白云石粒径配比为:3-1mm占35%,1-0.5mm占20%,0.5-0.088mm占15%,小于0.088mm占30%;所用镁白云石砂粒径配比为:3-1mm占20%,1-0.5mm占30%,0.5-0.088mm占20%,小于0.088mm占30%;所用镁碳砖回收料粒径配比为:3-1mm占25%,1-0.5mm占45%,小于0.5mm占30%。
(2)低温粘结剂(2.5%):采用果糖和蔗糖按质量比1:1混合得到。
(3)粘土(0.5%):高岭土。
(4)中温粘结剂3%:磷酸钠和磷酸二氢钠按质量比1:1混合得到。
(5)抗氧化剂(1%):采用镁铝合金粉末(Mg粉60%,Al粉40%,Mg粉和Al粉的平均粒径均为250μm)。
(6)助烧剂(2%):多晶氧化铝纤维,多晶氧化铝纤维长度为5μm。
(7)粉尘抑制剂(1%):粉尘抑制剂为乙二醇。
室温-700℃时,中低温粘结剂起作用,当温度超过700℃时,工作衬颗粒之间会形成陶瓷结合,强度和耐侵蚀性能大大提高。
2)配合料的制备:按照原料配比进行配料。配料过程中,先选取主要原料,然后放入球磨机中进行混合8h;待混匀后,再依次加入低温粘结剂、粘土、中温粘结剂、抗氧化剂、助烧剂以及粉尘抑制剂,再进行球磨混合,混合时间为5h,球磨结束后得到配合料。混合过程中球磨机可为行星式球磨机。
3)排气保存:利用压缩法对配合料进行排气保存,得到连铸中间包工作衬用干式料。
工作衬的制备:先将中间包胎膜清理干净,并在其表面刷一层机油。待中间包温度降低至30℃左右,将永久层表面清理干净。制备工作衬时,先进行包底施工,再将胎膜放入中间包,再向中间包间隙倒入上述制备的干式料,并进行捣实,使间隙填充密实。然后开动胎膜内部的振动电机,振动4.5h。再对振动后的胎膜进行加热,温度为300℃,时间为5h左右。最后,待胎膜冷却后拔出胎膜,待用。上线使用前再利用烤包器进行烘烤4.5h左右后投入使用,烘烤温度为1150℃左右。
经测试,利用本实施例的干式料所制备的中间包工作衬体积密度为2.0g/cm3,110℃×24h耐压强度为3.0MPa,1550℃×3h耐压强度为7.5MPa,耐火度1755℃,线变化率为-3.5%-+3.5%,1100℃水冷50次不开裂,实际使用寿命为35h,具有强度高、抗热震性好、抗渣侵蚀性能好、钢水净化能力强、寿命长以及环保的特点。
Claims (10)
1.一种连铸中间包工作衬用干式料,其特征在于,其原料组分及其质量百分比如下:
2.根据权利要求1所述的连铸中间包工作衬用干式料,其特征在于,所述低温粘结剂为聚多糖,或酚醛聚合物,或聚多糖和酚醛聚合物按质量比1~5:1的混合物,所述酚醛聚合物组分及质量百分含量为:英国939P酚醛树脂粉70%,丙烯酸树脂20~25%,纤维素2.5~5%,聚乙烯醇2.5~5%;所述聚多糖为葡萄糖、木糖、半乳糖、果糖、甘露糖、山梨糖、蔗糖、麦芽糖、蜜糖、普通糖醛酸中的一种或几种的混合物。
3.根据权利要求1所述的连铸中间包工作衬用干式料,其特征在于,所述粘土为白泥,高岭土,膨润土中的一种或者其混合物。
4.根据权利要求1所述的连铸中间包工作衬用干式料,其特征在于,所述中温粘结剂为磷酸盐、碱金属硅酸盐中的一种或者二者的混合物,其中磷酸盐为磷酸钠、磷酸二氢钠、六偏磷酸钠中的一种,碱金属硅酸盐为无水硅酸钠或水合硅酸钠。
5.根据权利要求1所述的连铸中间包工作衬用干式料,其特征在于,所述抗氧化剂为硅铁合金粉末、铝硅合金粉末、镁铝合金粉末中的一种。
6.根据权利要求1所述的连铸中间包工作衬用干式料,其特征在于,所述助烧剂为硼氧化物、硼酸中的一种或两者的混合物,或多晶氧化铝纤维,或石英纤维,其中,所述硼氧化物为B2O3或BxO,x=2-7,所述多晶氧化铝纤维及石英纤维的长度为0.5-5μm。
7.根据权利要求1所述的连铸中间包工作衬用干式料,其特征在于,所述粉尘抑制剂为矿物油、煤油、乙二醇、硅溶胶、铝溶胶或铝溶胶与硅铝溶胶的混合物。
8.一种权利要求1-7任一所述的连铸中间包工作衬用干式料的制备方法,其特征在于,具体步骤如下:
1)称取原料,备用;
2)球磨:先将镁砂、煅烧白云石、镁白云石砂、镁碳砖回收料放入球磨机中混合0.5-10h,待混匀后,根据需要依次加入低温粘结剂、粘土、中温粘结剂、抗氧化剂、助烧剂以及粉尘抑制剂,再次进行球磨混合,混合时间为0.5-5h,球磨结束后得到配合料,利用抽气法或压缩法对所得配合料进行排气保存,得到连铸中间包工作衬用干式料。
9.一种根据权利要求1-7任一所述的连铸中间包工作衬用干式料制备得到的中间包工作衬。
10.一种含有权利要求9所述中间包工作衬的中间包。
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