CN109232006A - 一种低气孔率耐侵蚀酸性干振料及其制备方法 - Google Patents
一种低气孔率耐侵蚀酸性干振料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种低气孔率耐侵蚀酸性干振料及其制备方法。其原料组分及各组分的配比为:具有3‑5mm、1‑2mm、0‑1mm三种粒径的石英砂颗粒共50‑60份，氧化铬细粉15‑20份，电熔石英细粉20‑25份，磷酸盐+硼酐1.5‑3份。本发明的优点在于：大大改善了材料的耐侵蚀能力，大大降低了气孔率，提高了干振料真实密度，进一步提高了炉衬的抗侵蚀效果，在此基础上添加ZrO2，改善了基质部分的化学稳定性，还提高了抗渣侵蚀能力，尤其是添加电熔石英与上述成分匹配，提高了热震稳定性，避免频繁停炉带来的冷热冲击导致的裂纹，结合着磷酸盐+硼酐复合作烧结助剂，提高了烧结效率，降低了烧结能耗，从而大大提高了炉衬的使用寿命。
Description
技术领域
本发明涉及一种熔炼生产用炉料，具体地说是一种低气孔率耐侵蚀酸性干振料及其制备方法。
背景技术
在铸铁行业中，生产者从熔炼合金及生产成本考虑会选择品质不同的炉料，通常包括有生铁、废钢、回炉料等，当采用的废料比重较大时，会给耐火炉衬带来较大侵蚀，后来申请人虽然提出过一种能够提高化学稳定性以及抗侵蚀能力的干振料，然而其主要是通过氧化锆粉的添加来改善化学性能，其最终结果是虽然提高了材料抗侵蚀能力和基质的化学稳定性，但是其气孔率增大，降低了使用寿命，由此使得生产成本并没有降低。
发明内容
本发明要解决的技术问题是提供一种气孔率低、抗侵蚀能力强、化学稳定性好且使用寿命长的低气孔率耐侵蚀酸性干振料及其制备方法。
为了解决上述技术问题，本发明的低气孔率耐侵蚀酸性干振料，其原料组分及各组分的配比为: 具有3-5mm、1-2mm、0-1mm三种粒径的石英砂颗粒共50-60份，氧化铬细粉15-20份，电熔石英细粉20-25份，磷酸盐+硼酐1.5-3份。
所述石英砂的成分包含有98-99%的SiO2、0.4-0.5%的Al2O3、0.1-0.2%的Fe、0.1-0.2%的K2O以及剩余杂质。
所述3-5mm粒径的石英砂颗粒占30-45份，所述1-2mm粒径的石英砂颗粒占15-30份，所述0-1mm粒径的石英砂颗粒占10-25份。
按照上述原料配比进行取样，料斗放料至皮带秤进行记重，然后将称取的原料传输至搅拌机，在搅拌机内进行混合搅拌均匀，传输至包装料斗进行包装即可。
所述搅拌速度为55-65转/分钟。
所述搅拌时间为5-10分钟。
本发明的优点在于：
采用高纯石英砂添加氧化硅微粉的方式，大大改善了材料的耐侵蚀能力，同时采用石英砂以及上述各种成分的最优颗粒继配，大大降低了气孔率，提高了干振料真实密度，进一步提高了炉衬的抗侵蚀效果，在此基础上添加ZrO2，改善了基质部分的化学稳定性，还提高了抗渣侵蚀能力，尤其是添加电熔石英与上述成分匹配，提高了热震稳定性，避免频繁停炉带来的冷热冲击导致的裂纹，结合着磷酸盐+硼酐复合作烧结助剂，提高了烧结效率，降低了烧结能耗，从而大大提高了炉衬的使用寿命。
具体实施方式
下面结合具体实施方式，对本发明的低气孔率耐侵蚀酸性干振料及其制备方法作进一步详细说明。
实施例一：
本实施例的低气孔率耐侵蚀酸性干振料，其原料组分及各组分的配比为: 其原料组分及各组分的配比为: 具有3mm、1mm、0.1mm三种粒径的石英砂颗粒共50份，氧化铬细粉15份，电熔石英细粉20份，磷酸盐+硼酐1.5份；其中，所说的石英砂颗粒中，3mm粒径的石英砂颗粒占40份，1mm粒径的石英砂颗粒占20份，所述0.1mm粒径的石英砂颗粒占20份；将上述原料配比进行取样，料斗放料至皮带秤进行记重，然后将称取的原料传输至搅拌机，在搅拌机内进行混合搅拌均匀，搅拌时间为55转/分钟，搅拌时间为5分钟，传输至包装料斗进行包装即可，本实施例中，石英砂的成分包含有98%的SiO2、0.4%的Al2O3、0.1%的Fe、0.1%的K2O以及剩余杂质。
实施例二：
本实施例的低气孔率耐侵蚀酸性干振料，其原料组分及各组分的配比为: 其原料组分及各组分的配比为: 具有4mm、1.5mm、0.5mm三种粒径的石英砂颗粒共60份，氧化铬细粉18份，电熔石英细粉20份，磷酸盐+硼酐2份,其中，4mm粒径的石英砂颗粒占42份，1.5mm粒径的石英砂颗粒占25份，0.5mm粒径的石英砂颗粒占22份，将上述原料配比进行取样，料斗放料至皮带秤进行记重，然后将称取的原料传输至搅拌机，在搅拌机内进行混合搅拌均匀，搅拌时间为60转/分钟，搅拌时间为7分钟，传输至包装料斗进行包装即可，本实施例中，石英砂的成分包含有98%的SiO2、0.4%的Al2O3、0.2%的Fe、0.2%的K2O以及剩余杂质。
实施例三：
本实施例的低气孔率耐侵蚀酸性干振料，其原料组分及各组分的配比为: 具有4.5mm、1.8mm、0.8mm三种粒径的石英砂颗粒共60份，氧化铬细粉18份，电熔石英细粉20份，磷酸盐+硼酐2份，氧化铬细粉采用200目细粉，电熔石英细粉的粒径为1mm，磷酸盐+硼酐的粒径为100目，其中，4.5mm粒径的石英砂颗粒占33份，1.8mm粒径的石英砂颗粒占15份，0.8mm粒径的石英砂颗粒占12份，将上述原料配比进行取样，料斗放料至皮带秤进行记重，然后将称取的原料传输至搅拌机，在搅拌机内进行混合搅拌均匀，搅拌时间为63转/分钟，搅拌时间为8分钟，传输至包装料斗进行包装即可，本实施例中， 石英砂的成分包含有99%的SiO2、0.5%的Al2O3、0.1%的Fe、0.1%的K2O以及剩余杂质。
实施例四：
本实施例的低气孔率耐侵蚀酸性干振料，其原料组分及各组分的配比为:具有5mm、2mm、1mm三种粒径的石英砂颗粒共60份，氧化铬细粉20份，电熔石英细粉25份，磷酸盐+硼酐3份，氧化铬细粉采用200目细粉，电熔石英细粉的粒径为2mm，磷酸盐+硼酐的粒径为100目，其中，5mm粒径的石英砂颗粒占45份，2mm粒径的石英砂颗粒占30份，1mm粒径的石英砂颗粒占25份，将上述原料配比进行取样，料斗放料至皮带秤进行记重，然后将称取的原料传输至搅拌机，在搅拌机内进行混合搅拌均匀，搅拌时间为65转/分钟，搅拌时间为10分钟，传输至包装料斗进行包装即可，本实施例中，石英砂的成分包含有99%的SiO2、0.5%的Al2O3、0.2%的Fe、0.2%的K2O以及剩余杂质。
本产品在传统酸性干振料上进行物理改良和化学改良，双管齐下，极大地提升了产品使用寿命，物理方面以提高堆积密度为目标，降低了气孔率，通过实施例三和实施例四的记载也可以看出，氧化铬细粉、电熔石英细粉以及磷酸盐+硼酐的粒径均具有一定的规格，通过明确了各种成分的规格与石英砂颗粒进行复配，起到了相互填充的效果，融合度非常高，也就验证了具有非常高的堆积密度，另外，化学改进以多种添加剂复合的方式，包含抗侵蚀成分（ZrO2），抗热震成份电熔石英（SiO2），抗侵蚀成分（ZrO2），烧结助剂磷酸盐+硼酐（P2O5+B2O3 ），各种成分相互匹配，大大提高了炉衬的使用寿命。
为了验证本发明的实际效果，下面给了实验室堆积密度测试对比数据以及常规堆积密度测试的试验数据：
从上面表格可以看出，改进2配方得到的堆积密度最大，孔隙率最低，通过曲线表表现出的突变数值，也就验证了通过该方法制备的低气孔率耐侵蚀酸性干振料，具有低气孔率、耐侵蚀性能优异、化学稳定性好、裂纹倾向性低等特点，用于铸铁行业无芯感应电炉，经过与常规酸性干振料相比，也可以明显看出此材料比常规酸性干振料有更好的抗侵蚀、抗热震性能。
Claims (6)
1.一种低气孔率耐侵蚀酸性干振料，其原料组分及各组分的配比为: 具有3-5mm、1-2mm、0-1mm三种粒径的石英砂颗粒共50-60份，氧化铬细粉15-20份，电熔石英细粉20-25份，磷酸盐+硼酐1.5-3份。
2.按照权利要求1所述的低气孔率耐侵蚀酸性干振料，其特征在于：所述石英砂的成分包含有98-99%的SiO2、0.4-0.5%的Al2O3、0.1-0.2%的Fe、0.1-0.2%的K2O以及剩余杂质。
3.按照权利要求1或2所述的低气孔率耐侵蚀酸性干振料，其特征在于：所述3-5mm粒径的石英砂颗粒占30-45份，所述1-2mm粒径的石英砂颗粒占15-30份，所述0-1mm粒径的石英砂颗粒占10-25份。
4.一种低气孔率耐侵蚀酸性干振料的制备方法，其特征在于：按照权利要求1的原料配比进行取样，料斗放料至皮带秤进行记重，然后将称取的原料传输至搅拌机，在搅拌机内进行混合搅拌均匀，传输至包装料斗进行包装即可。
5.按照权利要求4所述的低气孔率耐侵蚀酸性干振料的制备方法，其特征在于：所述搅拌时间为55-65转/分钟。
6.按照权利要求5所述的低气孔率耐侵蚀酸性干振料的制备方法，其特征在于：所述搅拌时间为5-10分钟。
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