CN109265181A - 锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料 - Google Patents
锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料 Download PDFInfo
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Abstract
本发明提供了一种锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料及其制备方法和应用,属于特殊涂料技术领域。该陶瓷涂料包括按质量百分含量计的组分:填料45~51.2%,粘结剂35%,添加剂5.22%,助剂1.22%和余量的水;其中填料包括合成莫来石27.5%、刚玉粉9.9%、纯铝酸钙微粉1.5‑2.7%、活性氧化铝微粉1.9‑4.5%、硅微粉1.8‑3.6%、稀土氧化物3%。其制备方法是将粘结剂加水混合得粘结剂液体,然后将研磨细化处理至粒度≤5μm的填料加入到粘结剂液体中,再加入助剂搅拌均匀,过滤封装。该涂料可以涂覆于锅炉水冷壁炉管及加热炉炉管外表面形成陶瓷涂层。
Description
技术领域
本发明属于涂料技术领域,提供一种锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料及制备方法。
背景技术
电站锅炉、石油石化加热炉及中小工业锅炉等的生产运行中,煤粉锅炉(包括燃油气加热炉)沾污结渣给锅炉的安全运行造成极大隐患,同时影响锅炉以及加热炉效率。高温烟气作用下,粘结在水冷壁或高温过热器上以及加热炉炉管的灰渣会与管壁发生复杂的化学反应,形成高温腐蚀、沾污、结渣一般被认为是高温腐蚀的前奏。高温换热器表面沾污结渣直接导致锅炉以及加热炉换热能力下降,炉效和出力降低,进而换热表面受热不匀导致炉管热应力不均和被加热工质受热不匀,同时炉膛温度升高导致炉管超温运行、氮氧化物生成及排放加剧和排烟温度过高,沾污结渣加剧换热表面腐蚀,这些问题直接影响安全生产、节能减排、产品质量与产能,降低设备使用寿命,给企业带来重大损失。据相关统计数据表明,火电锅炉受热面爆管泄漏所导致的非计划停用时间占总非计划停用时间的40%,约占锅炉停用次数的70%,其中,受热面的高温腐蚀是造成管道爆管泄漏的主要原因。在减轻受热面高温腐蚀措施中,对管壁进行喷涂防腐蚀材料具有广阔的应用前景。
在众多防腐材料中,复合陶瓷涂层显现出独特的优势,喷涂之后的受热面管壁兼具金属与陶瓷的双重优点,既有陶瓷材料的抗热、抗磨、抗腐蚀特性,又具备金属材料的韧性。在金属表面制备陶瓷涂层的方法很多,其中热化学反应法是近年来表面工程技术的一个热门领域,该方法采用粘结剂将细微陶瓷粒子制成陶瓷浆料,涂刷在经过活化的基材表面上,室温自然干燥后,在一定温度下进行高温固化,在热固化过程中产生新的陶瓷相。采用热化学反应法在锅炉受热面管壁制备复合陶瓷涂层,可以利用锅炉自身热量进行热固化,因而不需要额外能量消耗。该工艺基本思路是金属基体与涂层在界面处发生化学反应,使二者通过化学键而牢固结合在一起。热化学反应法具有工艺简单、成本低廉、维护简便且适用范围广等优点。陶瓷涂料作为一种新型功能材料,还可起到耐高温腐蚀和提高发射率的作用,但现有技术的陶瓷涂料无法解决高沾污和高温腐蚀特别是还原性腐蚀问题,因此不能综合实现上述功能,且使用过程中不同程度存在涂层龟裂、脱落、粉化的情况,严重影响涂层的使用寿命,目前这些问题仍无法有效解决。
发明内容
针对现有技术中存在的上述不足,本发明提供了一种锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料。
本发明的另一目的是提供上述高温防腐抗沾污防结渣陶瓷涂料的制备方法。
本发明的又一目的是提供上述高温防腐抗沾污防结渣陶瓷涂料的应用。
本发明通过以下技术方案实现上述目的:
一种锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,按质量百分含量计的组分:
合成莫来石:27.5%、刚玉粉:9.9%、纯铝酸钙微粉:1.5-4%、活性氧化铝微粉:1.9-4.5%、硅微粉:1.8-3.6%、锂辉石:2.0%、红柱石:3.0%、稀土氧化物(氧化钇和氧化铈)3.0%、减水剂:0.10%、防爆剂:0.12%、粘结剂磷酸二氢铝:35%、助剂:1.22%、水:余量;其中助剂包括:分散剂0.7%、润湿剂:0.2%、消泡剂:0.5%、流变剂:1.0%。
按上述配比,除粘结剂、助剂外,涂料填料的化学成分为:
无机涂层在高温下有良好导热性、耐磨损、耐酸碱腐蚀等特性。锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料涂层应具有高温耐磨性和抗高温酸性气体侵蚀性。涂料从施工到投产需要具有高附着力、较大黏附强度和较低的含水量,以保证在喷涂及烘烤过程中不产生裂纹及剥落,在低温、中温、高温等加热过程中始终保持足够的强度,始终保持体积稳定。依据涂料的使用要求,选择热态体积稳定,耐火、耐磨、抗侵蚀性良好,化学纯度高,吸水率较低的耐火材料,如:合成莫来石、白刚玉、亚白刚玉做主要填料。添加主要起结合作用的纯铝酸钙微粉和活性氧化铝微粉及低气孔硅微粉,用以获得低温强度,添加含锂矿物获得中温强度。当温度达到1000℃时,Li+以置换方式和Al2O3形成锂铝尖晶石。添加红柱石可使涂层在高温条件下的体积维持不变或变化极其微小。添加复合磷酸盐减水剂使加水量减少。添加有机纤维可增加涂层的湿态强度,预防局部烘烤过热产生剥落,并在烘烤过程中疏导排出水分,实现快速烘炉。
在本发明中,纯铝酸钙微粉是一种Al2O3含量约为70%的水硬性结合剂,其矿物组成为:主晶相CA、CA2、次晶相Cl2A7、α-Al2O3,用于温度1400℃以上的高温环境,因其具有良好的流变性,适合于做耐高温涂料。其化学成分见表1,物理性能见表2.
表1纯铝酸钙的化学成分%
表2纯铝酸钙的物理性能
在本发明中,活性氧化铝粉为是一种无晶体团聚、单峰活性氧化铝,适用于与硅微粉配伍的耐高温涂料,有利于提高制品的烧结活性。其化学成分见表3,物理性能见表4。
表3活性氧化铝化学成分%
表4活性氧化铝物理性能
在本发明中,硅微粉以其高流动性和低加水量,成为锅炉水冷壁抗沾污结渣涂料的添加料,硅微粉遇水后形成的-Si-OH胶团(硅醇基)在低温状态起粘结作用。在高温条件下易与α-Al2O3结为柱状、针状莫来石晶体,从而使材料获得更好的高温性能。其化学成分见表5.
表5硅微粉化学成分%
在本发明中,红柱石(Al2O3·SiO2)在高温条件下不可逆转地转化为莫来石,对调整Al2O3-SiO2系统耐火制品的高温性能(高温体积稳定性、抗热震性)起着重要作用。由于耐高温涂料比定形耐火制品高温收缩率一般要大一些,在耐高温涂料中添加适合的膨胀剂(蓝晶石、红柱石)而尤为必要。红柱石因其品质不同,高温膨胀率在3%-6%,1400℃莫来石转化率>70%,更适合于做耐高温涂料的添加材料,其化学成分见表6.
表6红柱石化学成分
在本发明中,锂辉石(Li2O·Al2O3·4SiO2)在加热条件下性质非常活泼,由于Li+离子的活泼迁移,在Al2O3-SiO2系统耐高温涂料中从低温到中温都起到增强作用。Li2O从1000℃开始发生向Li2O·5Al2O3的固相离子交换,形成了锂铝尖晶石(Li2O·5Al2O3),从而使物料获得强度,因而称其为矿化剂、烧结剂。
上述高温防腐抗沾污防结渣陶瓷涂料中,所述稀土氧化物为氧化钇和氧化铈。通过添加稀土氧化物可以提高机械强度,特别是与高岭土以及磷酸二氢铝共用烧结时形成稀土铝酸盐抑制晶粒长大,提高致密性,进而增加强度和抗污能力。而两种稀土氧化物共用时,其相互促进作用,能进一步改善产品性能。作为优选方案,上述耐高温防腐蚀抗沾污防结渣陶瓷涂料中,所述氧化钇的质量百分含量为1.5%,氧化铈的质量百分含量为1.5%。
作为优选方案,上述高温防腐抗沾污防结渣陶瓷涂料中,还包括分散剂、润湿剂和消泡剂中的一种以上的助剂,助剂质量百分含量不超过3%。助剂主要用来提高分散性、润湿性和避免涂膜时产生气泡造成的局部缺陷。分散剂、消泡剂和润湿剂均可以选用本领域常规市售商品,例如分散剂可选择CF-10,Hensic H-4200等,消泡剂可以选择DF104,HensicH-210.Hensic H-231等。上述高温防腐抗沾污防结渣陶瓷涂料中,包括按质量百分含量计的分散剂0.7%,润湿剂0.2%和消泡剂0.5%。
作为优选方案,上述高温防腐抗沾污防结渣陶瓷涂料中,所述粘结剂为磷酸二氢铝,其自身熔点较高,高温下键合能较高,不易熔化,提高了粘结剂的耐热性。采用无机粘结剂不仅耐高温,而且在高温下干燥后与基体粘结力强,还可提高强度和光洁度,以增强抗污能力。这两种粘结剂共用产生的效果明显优于采用单一粘结剂,在高温下具有良好的粘结性能,涂层膨胀率小,与基体间结合能力强,磷酸二氢铝的质量百分含量为35%。
上述高温防腐抗沾污防结渣陶瓷涂料的制备方法,包括如下步骤:
(1):按物料的百分含量比备料;
(2):将填料和添加剂混合,得填料混合物;
(3):将粘结剂、水、助剂混合搅拌均匀,得粘结剂混合物;
(4):将第二、三步制得的混合物再混合,经研磨使细度达到≤5μm过滤后封装。
试样为20G钢基材加工成20x20x2mm的平板试样,试样表面采用喷砂处理,使用40-100目的石英砂,对加工完成的平板试样表面进行喷砂处理,使其表面除锈等级达到Sa2.5-3,以便涂料的附着和烧结。将复合陶瓷悬浮浆料液搅拌均匀,过滤至涂料喷枪中,对喷砂处理达到要求的试样片进行涂料喷涂,喷涂完毕后将试样片放入箱式电阻炉中进行加热固化。热固化过程为:以3-5℃/min从室温升至85℃,保温2h,再以3-5℃/min升至450℃,保温6h后随炉自然冷却。
本发明有益效果:
①以合成莫来石、刚玉为主料,添加纯铝酸钙微粉、活性氧化铝微粉、稀土氧化物、硅微粉和膨胀剂、促烧剂、减水剂、防爆剂等,研发的涂料满足了从喷涂施工、热风烘炉到锅炉投产等整个过程的需要,适合锅炉水冷壁涂料的要求。已在10余座锅炉上使用,均取得令人满意的效果。
②锅炉水冷壁抗沾污涂料在加热过程中经过3个阶段:(室温下)加水后的硬化阶段;(100-700℃)加热排出吸附水和结晶水阶段;(700-1100℃)进入陶瓷相结合阶段。温度大于1100℃升温过程的固相反应已基本结束,物料形成多元化高熔点稳定相:3Al2O3·2SiO2、α-Al2O3、Al2O3·SiO2、α-SiO2。具有抗沾污结渣功能。
③本发明高温防腐抗沾污防结渣陶瓷涂料可耐1790℃高温,且高温下仍保持较高发射率,强化换热;表面能低,抗沾污结渣;涂层集化学惰性和钝化保护于一身,具有自清洁作用,有效防止沾污结渣,保护基体,特别是金属材质的基体,提高锅炉的换热效率,使受热面更加均匀;耐高温腐蚀,使用寿命长,施用简便,实际应用效果明显,广泛适用于石油石化加热炉及电站锅炉炉管等。
具体实施方式
下面结合具体实施例对本发明作进一步说明,以助于理解本发明的内容。
实施例一:
1)粘结剂液体的制得:在15.88质量份的水中,缓慢加入磷酸二氢铝35份,搅拌10-20min。
2)填料混合物的制得:将27.5质量份的合成莫来石、9.9质量份的刚玉粉、1.5质量份的纯铝酸钙微粉、3.2质量份的活性氧化铝微粉、1.8质量份的硅微粉、3.0质量份膨胀剂(红柱石)、2.0质量份的烧结剂(锂辉石)、0.10质量份的减水剂(复合磷酸盐)、0.12质量份的防爆剂(有机纤维)混合加入球磨机中研磨,直至细度达到≤5μm。
3)在粘结剂液体中加入填料混合物,再加入分散剂0.7份、润湿剂0.2份、消泡剂0.5份,1000rpm搅拌40min,混合均匀过滤后封装。
实施例二至九,配比见表7,制备工艺依照实施例一。
表7原料配比
①添加剂为:
②所有粉料细度均<5μm
③粘结剂为磷酸二氢铝,含固量40%。
④助剂为:分散剂0.7%、润湿剂0.02%、消泡剂0.5%。
Claims (10)
1.一种锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,其特征在于,按质量百分含量计的组分:填料45.6-51.2%,粘结剂35%,添加剂5.22%,助剂1.22%和余量的水;其中填料包括合成莫来石27.5%、刚玉粉9.9%、纯铝酸钙微粉1.5-2.7%、活性氧化铝微粉1.9-4.5%、硅微粉1.8-3.6%、稀土氧化物3%。
2.根据权利要求1所述的锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,其特征在于,所述粘结剂为磷酸二氢铝。
3.根据权利要求2所述的锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,其特征在于,所述磷酸二氢铝的质量百分含量为35%。
4.根据权利要求1所述的锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,其特征在于,所述的添加剂为膨胀剂、烧结剂、减水剂、防爆剂。
5.根据权利要求4所述的锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,其特征在于,所述的膨胀剂为红柱石,烧结剂为锂辉石,减水剂为复合磷酸盐,防爆剂为有机纤维。
6.根据权利要求5所述的锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,其特征在于,所述红柱石的质量百分含量为3.0%,锂辉石的质量百分含量为2.0%,复合磷酸盐的质量百分含量为0.10%,有机纤维的质量百分含量为0.12%。
7.根据权利要求1所述的锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,其特征在于,所述的助剂为分散剂、润湿剂、消泡剂,质量百分含量为3%。
8.根据权利要求1所述的锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,其特征在于,所述稀土氧化物为氧化钇和氧化铈。
9.根据权利要求8所述的锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料,其特征在于,所述氧化钇和氧化铈的质量百分含量为3%。
10.根据权利要求1~9任一所述的锅炉水冷壁高温防腐抗沾污防结渣陶瓷涂料的制备方法,其特征在于,将粘结剂加水混合得粘结剂液体,然后将填料研磨细化处理至细度≤5μm后加入到粘结剂液体中,再加入助剂搅拌均匀,过滤封装。
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