CN109400127B - Air-permeable material for ladle and preparation method thereof - Google Patents
Air-permeable material for ladle and preparation method thereof Download PDFInfo
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- CN109400127B CN109400127B CN201811267733.6A CN201811267733A CN109400127B CN 109400127 B CN109400127 B CN 109400127B CN 201811267733 A CN201811267733 A CN 201811267733A CN 109400127 B CN109400127 B CN 109400127B
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- ladle
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- 239000000463 material Substances 0.000 title claims abstract description 85
- 238000002360 preparation method Methods 0.000 title claims abstract description 16
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 66
- 239000010431 corundum Substances 0.000 claims abstract description 63
- 239000002245 particle Substances 0.000 claims abstract description 57
- 239000000843 powder Substances 0.000 claims abstract description 52
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 24
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 23
- 239000000654 additive Substances 0.000 claims abstract description 22
- 239000008187 granular material Substances 0.000 claims abstract description 21
- 238000002156 mixing Methods 0.000 claims abstract description 21
- 238000003756 stirring Methods 0.000 claims abstract description 21
- 230000000996 additive effect Effects 0.000 claims abstract description 20
- 239000004088 foaming agent Substances 0.000 claims abstract description 20
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 16
- 238000010438 heat treatment Methods 0.000 claims abstract description 16
- 229920005989 resin Polymers 0.000 claims abstract description 16
- 239000011347 resin Substances 0.000 claims abstract description 16
- 239000006004 Quartz sand Substances 0.000 claims abstract description 15
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 15
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims abstract description 15
- 229910052594 sapphire Inorganic materials 0.000 claims abstract description 15
- 239000005011 phenolic resin Substances 0.000 claims abstract description 14
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 14
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229920001568 phenolic resin Polymers 0.000 claims abstract description 13
- 239000004094 surface-active agent Substances 0.000 claims abstract description 13
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 12
- 239000006260 foam Substances 0.000 claims abstract description 12
- 239000011863 silicon-based powder Substances 0.000 claims abstract description 12
- 239000003381 stabilizer Substances 0.000 claims abstract description 12
- KLZUFWVZNOTSEM-UHFFFAOYSA-K Aluminum fluoride Inorganic materials F[Al](F)F KLZUFWVZNOTSEM-UHFFFAOYSA-K 0.000 claims abstract description 10
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 10
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 10
- UNTBPXHCXVWYOI-UHFFFAOYSA-O azanium;oxido(dioxo)vanadium Chemical compound [NH4+].[O-][V](=O)=O UNTBPXHCXVWYOI-UHFFFAOYSA-O 0.000 claims abstract description 10
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims abstract description 10
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 10
- 239000010439 graphite Substances 0.000 claims abstract description 10
- 239000004568 cement Substances 0.000 claims abstract description 9
- 238000004519 manufacturing process Methods 0.000 claims abstract description 8
- IRPGOXJVTQTAAN-UHFFFAOYSA-N 2,2,3,3,3-pentafluoropropanal Chemical compound FC(F)(F)C(F)(F)C=O IRPGOXJVTQTAAN-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000001723 curing Methods 0.000 claims abstract description 7
- 238000001035 drying Methods 0.000 claims abstract description 7
- 238000012216 screening Methods 0.000 claims abstract description 7
- 239000000203 mixture Substances 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 11
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 8
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical group [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 8
- 238000005266 casting Methods 0.000 claims description 6
- 238000000748 compression moulding Methods 0.000 claims description 6
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 5
- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 claims description 4
- DBMJMQXJHONAFJ-UHFFFAOYSA-M Sodium laurylsulphate Chemical compound [Na+].CCCCCCCCCCCCOS([O-])(=O)=O DBMJMQXJHONAFJ-UHFFFAOYSA-M 0.000 claims description 4
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 claims description 4
- 239000001768 carboxy methyl cellulose Substances 0.000 claims description 4
- GVGUFUZHNYFZLC-UHFFFAOYSA-N dodecyl benzenesulfonate;sodium Chemical group [Na].CCCCCCCCCCCCOS(=O)(=O)C1=CC=CC=C1 GVGUFUZHNYFZLC-UHFFFAOYSA-N 0.000 claims description 4
- 235000019387 fatty acid methyl ester Nutrition 0.000 claims description 4
- 229940051841 polyoxyethylene ether Drugs 0.000 claims description 4
- 229920000056 polyoxyethylene ether Polymers 0.000 claims description 4
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 claims description 4
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 claims description 4
- 229940080264 sodium dodecylbenzenesulfonate Drugs 0.000 claims description 4
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical group [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 claims description 4
- 235000019982 sodium hexametaphosphate Nutrition 0.000 claims description 4
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 4
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 claims description 4
- 239000004408 titanium dioxide Substances 0.000 claims description 4
- 239000011787 zinc oxide Substances 0.000 claims description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical group C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 claims 1
- 239000011734 sodium Substances 0.000 claims 1
- 229910052708 sodium Inorganic materials 0.000 claims 1
- 229940083575 sodium dodecyl sulfate Drugs 0.000 claims 1
- 235000019333 sodium laurylsulphate Nutrition 0.000 claims 1
- 230000035699 permeability Effects 0.000 abstract description 6
- 238000009991 scouring Methods 0.000 abstract description 4
- 235000019580 granularity Nutrition 0.000 abstract 1
- 238000009740 moulding (composite fabrication) Methods 0.000 abstract 1
- 238000003825 pressing Methods 0.000 abstract 1
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 14
- 239000002994 raw material Substances 0.000 description 13
- 229910052742 iron Inorganic materials 0.000 description 7
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 239000002893 slag Substances 0.000 description 3
- 229910052938 sodium sulfate Inorganic materials 0.000 description 3
- 235000011152 sodium sulphate Nutrition 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000011449 brick Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000006477 desulfuration reaction Methods 0.000 description 2
- 230000023556 desulfurization Effects 0.000 description 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 230000008092 positive effect Effects 0.000 description 2
- 230000009257 reactivity Effects 0.000 description 2
- 239000011593 sulfur Substances 0.000 description 2
- 229910052717 sulfur Inorganic materials 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000004872 foam stabilizing agent Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000010310 metallurgical process Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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- 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
- C04B35/10—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 aluminium oxide
- C04B35/101—Refractories from grain sized mixtures
- C04B35/103—Refractories from grain sized mixtures containing non-oxide refractory materials, e.g. carbon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/02—Linings
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- 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
- C04B35/10—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 aluminium oxide
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- C04B35/62605—Treating the starting powders individually or as mixtures
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0038—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by superficial sintering or bonding of particulate matter
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- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/04—Removing impurities by adding a treating agent
- C21C7/064—Dephosphorising; Desulfurising
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- C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B2235/3222—Aluminates other than alumino-silicates, e.g. spinel (MgAl2O4)
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- 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
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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
- C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
- C04B2235/422—Carbon
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Abstract
The invention relates to a breathable material for a ladle and a preparation method thereof. The technical scheme is as follows: mixing fine corundum powder and alpha-Al2O3Mixing the micro powder, the fine quartz sand powder, the aluminum hydroxide, the aluminum fluoride, the additive, the foaming agent, the foam stabilizer, the water reducer and the calcium aluminate cement, adding water, stirring, forming, curing, drying, performing heat treatment at 1400-1600 ℃, crushing, and screening to obtain a granular material A and a granular material B with different granularities. And then mixing the thermosetting phenolic resin, the surfactant, the elemental silicon powder, the silicon carbide powder, the copper powder and the ammonium metavanadate, and uniformly stirring to obtain the modified resin. And then uniformly mixing the corundum particles, the particle material A, the particle material B, the crystalline flake graphite, the silicon carbide powder and the modified resin, pressing and forming, and carrying out heat treatment at 100-300 ℃ to obtain the breathable material for the ladle. The invention has low production cost, and the prepared air permeable material for the ladle has the characteristics of high-temperature rupture strength, stable air permeability, excellent anti-scouring performance and long service life.
Description
Technical Field
The invention belongs to the technical field of breathable materials. In particular to a breathable material for a ladle and a preparation method thereof.
Background
The molten iron pretreatment desulfurization process is an important metallurgical process flow for smelting low-sulfur or ultra-low-sulfur steel. Aiming at the problems of low slagging efficiency, large iron loss, more residual slag in molten iron and the like after molten iron desulfurization, the air brick is arranged on the side surface or the bottom surface of the molten iron ladle, gas is blown into the molten iron through the air brick to stir, a bare surface is formed on the liquid surface, and remarkable effects are achieved in the aspects of improving slag discharge and slag collection, improving the molten iron pretreatment process and the like.
The existing air permeable material comprises clay, corundum, spinel and the like, and the types of the air permeable material mainly comprise a dispersion type, a straight through hole type, a slit type and the like according to actual working conditions. In the actual use process, the breathable material mainly has the problems of unstable breathable performance, poor corrosion resistance, low high-temperature strength and the like.
In the prior art, the additive is introduced to promote the sintering of the breathable material and adjust the texture structure, so that the mechanical strength, the erosion resistance and the like of the breathable material are improved to a certain extent, but certain defects still exist in the aspects of the high-temperature strength, the breathable stability and the like of the breathable material.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and aims to provide the preparation method of the air permeable material for the ladle, which has low production cost, and the air permeable material for the ladle prepared by the method has the advantages of high-temperature rupture strength, stable air permeability, excellent anti-scouring performance and long service life.
In order to achieve the purpose, the technical scheme adopted by the invention comprises the following specific steps:
firstly, 40-60 wt% of corundum fine powder and 1-10 wt% of alpha-Al2O3Mixing micro powder, 30-50 wt% of quartz sand fine powder, 1-10 wt% of aluminum hydroxide, 1-10 wt% of aluminum fluoride, 1-5 wt% of additive, 1-5 wt% of foaming agent, 1-5 wt% of foam stabilizer, 0.1-1 wt% of water reducer and 1-5 wt% of calcium aluminate cement to obtain a mixture; and adding water accounting for 10-20 wt% of the mixture, uniformly stirring, casting, and curing for 10-20 hours to obtain a cured blank.
Secondly, drying the cured blank at 90-120 ℃ for 12-24 hours, and then carrying out heat treatment at 1400-1600 ℃ for 5-7 hours to obtain a pre-sintered material; and then crushing and screening the pre-sintered material to obtain a granular material A with the granularity of less than 0.25mm and a granular material B with the granularity of 0.25-1 mm.
And thirdly, mixing 40-60 wt% of thermosetting phenolic resin, 1-10 wt% of surfactant, 10-20 wt% of elemental silicon powder, 20-40 wt% of silicon carbide powder, 1-5 wt% of copper powder and 1-10 wt% of ammonium metavanadate, and uniformly stirring to obtain the modified resin.
And fourthly, mixing 50-70 wt% of corundum particles, 1-10 wt% of particle materials A, 10-30 wt% of particle materials B, 1-10 wt% of crystalline flake graphite, 1-5 wt% of silicon carbide powder and 1-10 wt% of modified resin, uniformly stirring, performing compression molding under the condition of 80-120 MPa, and performing heat treatment at 100-300 ℃ for 10-20 hours to obtain the breathable material for the ladle.
The corundum fine powder is plate-shaped corundum fine powder or Al of white corundum fine powder and corundum fine powder2O3The content is more than 99 wt%, and the granularity of the corundum fine powder is less than 0.088 mm.
The corundum particles are plate-shaped corundum particles or white corundum particles and Al of the corundum particles2O3The content is more than 99 wt%, and the granularity of the corundum particles is 1-3 mm.
The alpha-Al2O3Micronized Al2O3More than 99 wt% of alpha-Al2O3The granularity of the micro powder is less than 0.01 mm.
SiO of the quartz sand fine powder2The content is more than 99 wt%, and the granularity of the quartz sand fine powder is less than 0.088 mm.
Al (OH) of the aluminum hydroxide3The content is more than 99 wt%, and the granularity of the aluminum hydroxide is less than 0.045 mm.
The Si content of the elemental silicon powder is more than 99 wt%, and the granularity is less than 0.088 mm.
The SiC content of the silicon carbide powder is more than 97 wt%, and the granularity is less than 0.088 mm.
The Cu content of the copper powder is more than 99 wt%, and the particle size is less than 0.088 mm.
The content of C in the flake graphite is more than 97 wt%, and the granularity is less than 0.088 mm.
The additive is zinc oxide or titanium dioxide, the purity of the additive is more than 99 wt%, and the granularity of the additive is less than 0.088 mm.
AlF of said aluminum fluoride3The content is more than 99 wt%.
The foaming agent is sodium dodecyl benzene sulfonate or sodium dodecyl sulfate, and the purity of the foaming agent is more than 98 wt%.
The foam stabilizer is fatty alcohol-polyoxyethylene ether sodium sulfate or sodium carboxymethylcellulose.
The water reducing agent is sodium hexametaphosphate or sodium tripolyphosphate, and the purity of the water reducing agent is more than 98 wt%.
In the calcium aluminate cement: al (Al)2O3The content is more than 65 wt%; SiO 22The content is less than 0.5 wt%; fe2O3The content is less than 0.3 wt%.
The room temperature viscosity of the thermosetting phenolic resin is less than 10000 centipoises, and the moisture content is less than 15 wt%.
The surfactant is fatty acid methyl ester or propylene oxide.
The purity of the ammonium metavanadate is more than 99 wt%.
Due to the adoption of the technical scheme, compared with the prior art, the invention has the following positive effects:
(1) the invention utilizes additive, corundum, quartz sand, aluminum hydroxide and alpha-Al2O3The reactivity of different raw materials such as micro powder, foaming agent and the like under different temperature conditions, the prefabricated fine-grain structure granules mainly comprising corundum and mullite have the characteristics of multi-stage through hole structure and high strength. The invention utilizes the modified resin obtained after the thermosetting phenolic resin treatment to ensure that the simple substance silicon powder, the silicon carbide powder and the like are uniformly distributed among the corundum particles, the prefabricated particle material A and the prefabricated particle material B, and the organizational structure of the material is adjusted by combining with the heat treatment. Therefore, the prepared air permeable material for the ladle has higher normal-temperature rupture strength.
(2) The invention avoids the introduction of impurity phase due to the control of the high-temperature reaction process among the raw materials with different characteristics, and forms stable fine grain mosaic structures among the prefabricated granule A, the prefabricated granule B and the corundum granules, so that the prepared air-permeable material for the ladle has higher high-temperature rupture strength.
(3) According to the invention, through hole structures with different scales are formed among different raw material particles by utilizing the composite action of the raw materials such as the additive, the foaming agent, the thermosetting phenolic resin, the silicon carbide and the like at different stages and the particle size difference among different raw materials, so that the material is endowed with stable air permeability while the high mechanical strength is ensured.
(4) According to the structure and performance characteristics of the air-permeable material for the ladle, the preparation process is controlled step by step, so that the growth and occurrence states of crystal grains are regulated, the formation and communication states of pores are controlled, and the ingenious control on the structure and performance of the material is realized. In addition, the invention has wide raw material source and low production cost, and the prepared air permeable material for the ladle has stable performance.
The performance of the prepared air-permeable material for the ladle is detected as follows: the bulk density is 2.5-2.9 g/cm3The apparent porosity is 23-31%, the normal temperature flexural strength is more than 7MPa, and the high temperature (1400 ℃) flexural strength is more than 6 MPa.
Therefore, the invention has low production cost, and the prepared air permeable material for the ladle has the characteristics of high-temperature rupture strength, stable air permeability, excellent anti-scouring performance and long service life.
Detailed Description
The invention is further described with reference to specific embodiments, without limiting its scope.
In order to avoid repetition, the particle sizes of the raw materials related to the present embodiment are uniformly described as follows, and are not described in detail in the examples:
al of the corundum fine powder2O3The content is more than 99 wt%, and the granularity of the corundum fine powder is less than 0.088 mm.
Al of the corundum particles2O3The content is more than 99 wt%, and the granularity of the corundum particles is 1-3 mm.
The alpha-Al2O3Micronized Al2O3More than 99 wt% of alpha-Al2O3The granularity of the micro powder is less than 0.01 mm.
SiO of the quartz sand fine powder2The content is more than 99 wt%, and the granularity of the quartz sand fine powder is less than 0.088 mm.
Al (OH) of the aluminum hydroxide3The content is more than 99 wt%, and the granularity of the aluminum hydroxide is less than 0.045 mm.
The Si content of the elemental silicon powder is more than 99 wt%, and the granularity is less than 0.088 mm.
The SiC content of the silicon carbide powder is more than 97 wt%, and the granularity is less than 0.088 mm.
The Cu content of the copper powder is more than 99 wt%, and the particle size is less than 0.088 mm.
The content of C in the flake graphite is more than 97 wt%, and the granularity is less than 0.088 mm.
The purity of the additive is more than 99 wt%, and the particle size is less than 0.088 mm.
AlF of said aluminum fluoride3The content is more than 99 wt%.
The purity of the foaming agent is more than 98 wt%.
The purity of the water reducing agent is more than 98 wt%.
In the calcium aluminate cement: al (Al)2O3The content is more than 65 wt%; SiO 22The content is less than 0.5 wt%; fe2O3The content is less than 0.3 wt%.
The room temperature viscosity of the thermosetting phenolic resin is less than 10000 centipoises, and the moisture content is less than 15 wt%.
The purity of the ammonium metavanadate is more than 99 wt%.
Example 1
A permeable material for a ladle and a preparation method thereof. The preparation method in this example is:
firstly, 40-45 wt% of corundum fine powder and 1-10 wt% of alpha-Al2O3Mixing micro powder, 45-50 wt% of quartz sand fine powder, 1-10 wt% of aluminum hydroxide, 1-10 wt% of aluminum fluoride, 1-5 wt% of additive, 1-5 wt% of foaming agent, 1-5 wt% of foam stabilizer, 0.1-1 wt% of water reducer and 1-5 wt% of calcium aluminate cement to obtain a mixture; and adding water accounting for 10-15 wt% of the mixture, uniformly stirring, casting and molding, and curing for 15-20 hours to obtain a cured blank.
Secondly, drying the cured blank at the temperature of 90-110 ℃ for 12-16 hours, and then carrying out heat treatment at the temperature of 1500-1600 ℃ for 5-7 hours to obtain a pre-sintered material; and then crushing and screening the pre-sintered material to obtain a granular material A with the granularity of less than 0.25mm and a granular material B with the granularity of 0.25-1 mm.
And thirdly, mixing 40-45 wt% of thermosetting phenolic resin, 1-10 wt% of surfactant, 10-20 wt% of elemental silicon powder, 35-40 wt% of silicon carbide powder, 1-5 wt% of copper powder and 1-10 wt% of ammonium metavanadate, and uniformly stirring to obtain the modified resin.
And fourthly, mixing 50-55 wt% of corundum particles, 1-4 wt% of particle materials A, 25-30 wt% of particle materials B, 7-10 wt% of crystalline flake graphite, 3-5 wt% of silicon carbide powder and 1-4 wt% of modified resin, uniformly stirring, performing compression molding under the condition of 80-100 MPa, and performing heat treatment at 100-180 ℃ for 10-15 hours to obtain the breathable material for the ladle.
In this embodiment:
the corundum fine powder is plate-shaped corundum fine powder;
the corundum particles are plate-shaped corundum particles;
the additive is zinc oxide;
the foaming agent is sodium dodecyl benzene sulfonate;
the foam stabilizer is fatty alcohol-polyoxyethylene ether sodium sulfate;
the water reducing agent is sodium tripolyphosphate;
the surfactant is fatty acid methyl ester.
The performance of the permeable material for ladles prepared in this example was tested: the bulk density is 2.5-2.7g/cm3(ii) a The apparent porosity is 26-31%; the normal temperature rupture strength is more than 8 MPa; the high-temperature (1400 ℃) rupture strength is more than 7 MPa.
Example 2
A permeable material for a ladle and a preparation method thereof. The preparation method in this example is:
firstly, 45-50 wt% of corundum fine powder and 1-10 wt% of alpha-Al2O3The material comprises micro powder, 40-45 wt% of quartz sand fine powder, 1-10 wt% of aluminum hydroxide, 1-10 wt% of aluminum fluoride, 1-5 wt% of additives, 1-5 wt% of foaming agents, 1-5 wt% of foam stabilizers, 0.1-1 wt% of water reducing agents and 1-5 wt% of calcium aluminate cementMixing to obtain a mixture; and adding water accounting for 14-20 wt% of the mixture, uniformly stirring, casting, and curing for 10-16 hours to obtain a cured blank.
Secondly, drying the cured blank at 100-120 ℃ for 15-20 hours, and then carrying out heat treatment at 1400-1500 ℃ for 5-7 hours to obtain a pre-sintered material; and then crushing and screening the pre-sintered material to obtain a granular material A with the granularity of less than 0.25mm and a granular material B with the granularity of 0.25-1 mm.
And thirdly, mixing 45-50 wt% of thermosetting phenolic resin, 1-10 wt% of surfactant, 10-20 wt% of elemental silicon powder, 30-35 wt% of silicon carbide powder, 1-5 wt% of copper powder and 1-10 wt% of ammonium metavanadate, and uniformly stirring to obtain the modified resin.
And fourthly, mixing 55-60 wt% of corundum particles, 3-6 wt% of particle materials A, 20-25 wt% of particle materials B, 5-8 wt% of crystalline flake graphite, 1-3 wt% of silicon carbide powder and 7-10 wt% of modified resin, uniformly stirring, performing compression molding under the condition of 90-110 MPa, and performing heat treatment at the temperature of 200-300 ℃ for 14-20 hours to prepare the breathable material for the ladle.
In this embodiment:
the corundum fine powder is white corundum fine powder;
the corundum particles are white corundum particles;
the additive is titanium dioxide;
the foaming agent is sodium dodecyl sulfate;
the foam stabilizer is sodium carboxymethyl cellulose;
the water reducing agent is sodium hexametaphosphate;
the surfactant is propylene oxide.
The performance of the permeable material for ladles prepared in this example was tested: the bulk density is 2.5-2.8 g/cm3(ii) a The apparent porosity is 25-31%; the normal temperature rupture strength is more than 9 MPa; the high-temperature (1400 ℃) rupture strength is more than 7 MPa.
Example 3
A permeable material for a ladle and a preparation method thereof. The preparation method in this example is:
firstly, 50-55 wt% of corundum fine powder and 1-10 wt% of alpha-Al2O3Mixing micro powder, 35-40 wt% of quartz sand fine powder, 1-10 wt% of aluminum hydroxide, 1-10 wt% of aluminum fluoride, 1-5 wt% of additive, 1-5 wt% of foaming agent, 1-5 wt% of foam stabilizer, 0.1-1 wt% of water reducer and 1-5 wt% of calcium aluminate cement to obtain a mixture; and adding 15-18 wt% of water into the mixture, uniformly stirring, casting and molding, and curing for 12-17 hours to obtain a cured blank.
Secondly, drying the cured blank at the temperature of 90-110 ℃ for 18-24 hours, and then carrying out heat treatment at the temperature of 1450-1550 ℃ for 5-7 hours to obtain a pre-sintered material; and then crushing and screening the pre-sintered material to obtain a granular material A with the granularity of less than 0.25mm and a granular material B with the granularity of 0.25-1 mm.
And thirdly, mixing 50-55 wt% of thermosetting phenolic resin, 1-10 wt% of surfactant, 10-20 wt% of elemental silicon powder, 25-30 wt% of silicon carbide powder, 1-5 wt% of copper powder and 1-10 wt% of ammonium metavanadate, and uniformly stirring to obtain the modified resin.
And fourthly, mixing 60-65 wt% of corundum particles, 5-8 wt% of particle materials A, 15-20 wt% of particle materials B, 3-6 wt% of crystalline flake graphite, 2-4 wt% of silicon carbide powder and 5-8 wt% of modified resin, uniformly stirring, performing compression molding under the condition of 100-120 MPa, and performing heat treatment at the temperature of 150-250 ℃ for 10-15 hours to prepare the breathable material for the ladle.
In this embodiment:
the corundum fine powder is white corundum fine powder;
the corundum particles are white corundum particles;
the additive is zinc oxide;
the foaming agent is sodium dodecyl benzene sulfonate;
the foam stabilizer is fatty alcohol-polyoxyethylene ether sodium sulfate;
the water reducing agent is sodium tripolyphosphate;
the surfactant is fatty acid methyl ester.
The performance of the permeable material for ladles prepared in this example was tested: the bulk density is 2.7-2.9 g/cm3(ii) a The apparent porosity is 23-29%; the normal temperature rupture strength is more than 9 MPa; the high-temperature (1400 ℃) rupture strength is more than 10 MPa.
Example 4
A permeable material for a ladle and a preparation method thereof. The preparation method in this example is:
firstly, 55-60 wt% of corundum fine powder and 1-10 wt% of alpha-Al2O3Mixing micro powder, 30-35 wt% of quartz sand fine powder, 1-10 wt% of aluminum hydroxide, 1-10 wt% of aluminum fluoride, 1-5 wt% of additive, 1-5 wt% of foaming agent, 1-5 wt% of foam stabilizer, 0.1-1 wt% of water reducer and 1-5 wt% of calcium aluminate cement to obtain a mixture; and adding 15-18 wt% of water into the mixture, uniformly stirring, casting, and curing for 10-16 hours to obtain a cured blank.
Secondly, drying the cured blank at 100-120 ℃ for 15-20 hours, and then carrying out heat treatment at 1500-1600 ℃ for 5-7 hours to obtain a pre-sintered material; and then crushing and screening the pre-sintered material to obtain a granular material A with the granularity of less than 0.25mm and a granular material B with the granularity of 0.25-1 mm.
And thirdly, mixing 55-60 wt% of thermosetting phenolic resin, 1-10 wt% of surfactant, 10-20 wt% of elemental silicon powder, 20-25 wt% of silicon carbide powder, 1-5 wt% of copper powder and 1-10 wt% of ammonium metavanadate, and uniformly stirring to obtain the modified resin.
And fourthly, mixing 65-70 wt% of corundum particles, 7-10 wt% of particle materials A, 10-15 wt% of particle materials B, 1-4 wt% of crystalline flake graphite, 3-5 wt% of silicon carbide powder and 3-6 wt% of modified resin, uniformly stirring, performing compression molding under the condition of 90-110 MPa, and performing heat treatment at the temperature of 150-250 ℃ for 14-20 hours to obtain the breathable material for the ladle.
In this embodiment:
the corundum fine powder is plate-shaped corundum fine powder;
the corundum particles are plate-shaped corundum particles;
the additive is titanium dioxide;
the foaming agent is sodium dodecyl sulfate;
the foam stabilizer is sodium carboxymethyl cellulose;
the water reducing agent is sodium hexametaphosphate;
the surfactant is propylene oxide.
The performance of the permeable material for ladles prepared in this example was tested: the bulk density is 2.5-2.7g/cm3(ii) a The apparent porosity is 29-31%; the normal temperature rupture strength is more than 8 MPa; the high-temperature (1400 ℃) rupture strength is more than 7 MPa.
Compared with the prior art, the specific implementation mode has the following positive effects:
(1) the specific embodiment utilizes additives, corundum, quartz sand, aluminum hydroxide and alpha-Al2O3The reactivity of different raw materials such as micro powder, foaming agent and the like under different temperature conditions, the prefabricated fine-grain structure granules mainly comprising corundum and mullite have the characteristics of multi-stage through hole structure and high strength. In the embodiment, the modified resin obtained after the thermosetting phenolic resin is treated is used for ensuring that the elemental silicon powder, the silicon carbide powder and the like are uniformly distributed among the corundum particles, the prefabricated particle material A and the prefabricated particle material B, and the texture structure of the material is adjusted by combining heat treatment. Therefore, the prepared air permeable material for the ladle has higher normal-temperature rupture strength.
(2) According to the specific embodiment, the high-temperature reaction process among the raw materials with different characteristics is controlled, so that the introduction of an impurity phase is avoided, stable fine-grain mosaic structures are formed among the prefabricated granular material A, the prefabricated granular material B and the corundum particles, and the prepared breathable material for the ladle has high-temperature rupture strength.
(3) According to the specific embodiment, through hole structures with different scales are formed among different raw material particles by utilizing the composite action of the raw materials such as the additive, the foaming agent, the thermosetting phenolic resin, the silicon carbide and the like at different stages and the particle size difference among different raw materials, so that the high mechanical strength is ensured, and the material is endowed with stable air permeability.
(4) According to the structure and performance characteristics of the air-permeable material for the ladle, the preparation process is controlled step by step, so that the growth and occurrence states of crystal grains are adjusted, the formation and communication states of pores are controlled, and the ingenious control on the structure and performance of the material is realized. In addition, the specific embodiment has wide raw material sources and low production cost, and the prepared air permeable material for the ladle has stable performance.
The performance of the breathable material for the ladle prepared by the embodiment is detected as follows: the bulk density is 2.5-2.9 g/cm3The apparent porosity is 23-31%, the normal temperature flexural strength is more than 7MPa, and the high temperature (1400 ℃) flexural strength is more than 6 MPa.
Therefore, the production cost of the embodiment is low, and the prepared air permeable material for the ladle has the characteristics of high-temperature rupture strength, stable air permeability, excellent anti-scouring performance and long service life.
Claims (10)
1. A preparation method of the air permeable material for the ladle is characterized by comprising the following steps:
firstly, 40-60 wt% of corundum fine powder and 1-10 wt% of alpha-Al2O3Mixing micro powder, 30-50 wt% of quartz sand fine powder, 1-10 wt% of aluminum hydroxide, 1-10 wt% of aluminum fluoride, 1-5 wt% of additive, 1-5 wt% of foaming agent, 1-5 wt% of foam stabilizer, 0.1-1 wt% of water reducer and 1-5 wt% of calcium aluminate cement to obtain a mixture; adding water accounting for 10-20 wt% of the mixture, uniformly stirring, casting, and curing for 10-20 hours to obtain a cured blank;
secondly, drying the cured blank at 90-120 ℃ for 12-24 hours, and then carrying out heat treatment at 1400-1600 ℃ for 5-7 hours to obtain a pre-sintered material; then crushing and screening the pre-sintered material to obtain a granular material A with the granularity of less than 0.25mm and a granular material B with the granularity of 0.25-1 mm;
step three, mixing 40-60 wt% of thermosetting phenolic resin, 1-10 wt% of surfactant, 10-20 wt% of elemental silicon powder, 20-40 wt% of silicon carbide powder, 1-5 wt% of copper powder and 1-10 wt% of ammonium metavanadate, and uniformly stirring to obtain modified resin;
fourthly, mixing 50-70 wt% of corundum particles, 1-10 wt% of particle materials A, 10-30 wt% of particle materials B, 1-10 wt% of crystalline flake graphite, 1-5 wt% of silicon carbide powder and 1-10 wt% of modified resin, uniformly stirring, performing compression molding under the condition of 80-120 MPa, and performing heat treatment at the temperature of 100-300 ℃ for 10-20 hours to prepare the breathable material for the ladle;
the corundum fine powder is plate-shaped corundum fine powder or Al of white corundum fine powder and corundum fine powder2O3The content is more than 99 wt%, and the granularity of the corundum fine powder is less than 0.088 mm;
the corundum particles are plate-shaped corundum particles or white corundum particles and Al of the corundum particles2O3The content is more than 99 wt%, and the granularity of the corundum particles is 1-3 mm;
the alpha-Al2O3Micronized Al2O3More than 99 wt% of alpha-Al2O3The granularity of the micro powder is less than 0.01 mm;
SiO of the quartz sand fine powder2The content is more than 99 wt%, and the granularity of the quartz sand fine powder is less than 0.088 mm;
al (OH) of the aluminum hydroxide3The content is more than 99 wt%, and the granularity of the aluminum hydroxide is less than 0.045 mm;
the Si content of the elemental silicon powder is more than 99 wt%, and the granularity is less than 0.088 mm;
the SiC content of the silicon carbide powder is more than 97 wt%, and the granularity is less than 0.088 mm;
the Cu content of the copper powder is more than 99 wt%, and the granularity is less than 0.088 mm;
the content of C in the flake graphite is more than 97 wt%, and the granularity is less than 0.088 mm;
the additive is zinc oxide or titanium dioxide; the purity of the additive is more than 99 wt%, and the particle size is less than 0.088 mm.
2. The method for producing a permeable material for a ladle according to claim 1, characterized in thatCharacterised by AlF of the aluminium fluoride3The content is more than 99 wt%.
3. The method of claim 1, wherein the foaming agent is sodium dodecylbenzenesulfonate or sodium dodecylsulfate, and the purity of the foaming agent is greater than 98 wt%.
4. The method for preparing the air-permeable material for the foundry ladle according to claim 1, wherein the foam stabilizer is sodium fatty alcohol-polyoxyethylene ether sulfate or sodium carboxymethylcellulose.
5. The method for preparing the air-permeable material for the foundry ladle according to claim 1, characterized in that the water reducing agent is sodium hexametaphosphate or sodium tripolyphosphate, and the purity of the water reducing agent is more than 98 wt%.
6. The method for preparing the air-permeable material for the foundry ladle according to claim 1, wherein in the calcium aluminate cement: al (Al)2O3The content is more than 65 wt%; SiO 22The content is less than 0.5 wt%; fe2O3The content is less than 0.3 wt%.
7. The method of claim 1, wherein the thermosetting phenol resin has a room temperature viscosity of less than 10000 cps and a moisture content of less than 15 wt%.
8. The method according to claim 1, wherein the surfactant is fatty acid methyl ester or propylene oxide.
9. The method according to claim 1, wherein the purity of the ammonium metavanadate is greater than 99 wt%.
10. A ladle gas permeable material produced by the method for producing a ladle gas permeable material according to any one of claims 1 to 9.
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CN103242051A (en) * | 2013-05-30 | 2013-08-14 | 武汉科技大学 | Lightweight corundum-mullite castable and preparation method thereof |
CN105859309A (en) * | 2016-03-31 | 2016-08-17 | 武汉科技大学 | Dispersive air brick and preparation method thereof |
CN107311680A (en) * | 2017-07-28 | 2017-11-03 | 武汉科技大学 | A kind of lightweight corundum-mullite castable and preparation method thereof |
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CN105859309A (en) * | 2016-03-31 | 2016-08-17 | 武汉科技大学 | Dispersive air brick and preparation method thereof |
CN107311680A (en) * | 2017-07-28 | 2017-11-03 | 武汉科技大学 | A kind of lightweight corundum-mullite castable and preparation method thereof |
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