CN110105059B - 一种高抗热震、低蠕变热风炉用砖及其制造方法 - Google Patents
一种高抗热震、低蠕变热风炉用砖及其制造方法 Download PDFInfo
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Abstract
一种高抗热震、低蠕变热风炉用砖及其制造方法,属于耐火材料技术领域。其特征在于,重量份组成为:3‑1mm矾土19~27份、1‑0.5mm棕刚玉11~14份、粒径<320目棕刚玉8~12份、3‑1mm红柱石10~20份、0.5‑0.1mm红柱石9~16份、粒径<200目红柱石14~23份、粒径<5μm氧化铝微粉4.5~7.5份、粒径<0.045mm的苏州土5~8份、粒径<240目碳化硅4.5~5.5份、纸浆3.5~4.5份、磷酸0.2~0.5份、糊精0.3~0.7份、三聚磷酸钠0.1~0.2份。本发明中引入了碳化硅和特定粒度的红柱石和棕刚玉,在提高火砖荷重软化温度、高温蠕变性能的基础上,提高了产品的抗热震稳定性,作为热风炉用耐火材料能够显著地延长其使用寿命。
Description
技术领域
一种高抗热震、低蠕变热风炉用砖及其制造方法,属于耐火材料技术领域。
背景技术
炼铁高炉热风炉作用是把鼓风加热到要求的温度,用以提高高炉的效益和效率,它是按“蓄热”原理工作的。在燃烧室里燃烧煤气,高温废气通过格子砖并使之蓄热,当格子砖充分加热后,热风炉就可改为送风,此时有关燃烧各阀关闭,送风各阀打开,冷风经格子砖而被加热并送出。高炉装有3-4座热风炉/“单炉送风”时,两或三座加热,一座送风;轮流更换/“并联送风”时,两座加热。热风炉用耐火材料长期受重负荷和热负荷的作用,还受温度激变的影响。热应力作用,化学侵蚀作用,机械荷载作用是热风炉损毁的主要原因。此外热风炉还受炽热含尘气体的冲刷与腐蚀。平均风温1100-1200℃,个别热风炉的平均风温达1350℃左右。由于风温的提高,热风炉用耐火材料应具备更好的抗高温蠕变抗热震性。
但是目前热风炉用的材料在高炉高风温的情况下寿命偏短,无法满足大容积高炉生产的长寿命要求。
发明内容
本发明要解决的技术问题是:克服现有技术的不足,提供一种高抗热震、低蠕变热风炉用砖及其制造方法。
本发明解决其技术问题所采用的技术方案是:该一种高抗热震、低蠕变热风炉用砖,其特征在于,重量份组成为:3-1mm矾土19~27份、1-0.5mm棕刚玉11~14份、粒径<320目棕刚玉8~12份、3-1mm红柱石10~20份、0.5-0.1mm红柱石9~16份、粒径<200目红柱石14~23份、粒径<5μm氧化铝微粉4.5~7.5份、粒径<0.045mm的苏州土5~8份、碳化硅4.5~5.5份、纸浆3.5~4.5份、磷酸0.2~0.5份、糊精0.3~0.7份、三聚磷酸钠0.1~0.2份。
本发明根据高炉高风温长寿命要求选用高温体积稳定性更高的莫来石基低蠕变体系,根据使用部位复合使用红柱石、矾土、棕刚玉等原料生产高铝低蠕变制品,改善材料的矿物组成,提高其高温体积稳定性和抗侵蚀能力。本发明在烧结合成莫来石基(矾土在烧成过程中反应转化而成)低蠕变工艺基础上,引入不同粒度、不同数量的红柱石原料,通过烧成制度控制制品的莫来石化行为,对系列热风炉低蠕变砖进行了工艺优化和研究开发,逐步完善了天然原料为主的生产工艺技术,实现了制品从仅满足低蠕变到高热震低蠕变的优化。
本发明的组成中加入高导热系数的SiC,提高窑具的导热性,减小在急冷急热过程中窑具各部位的温差,减小热应力,提高窑具抗热震性。本发明中加入SiC形成莫来石-红柱石-碳化硅的组织结构,该结构膨胀系数小于莫来石-碳化硅的膨胀系数,抗热震性优于莫来石-碳化硅材料。本发明的原料中同时引入红柱石、矾土及碳化硅。红柱石分解形成的SiO2及SiC氧化生成的SiO 2 与矾土、刚玉、氧化铝微粉中的 Al2O 3 通过反应烧结形成莫来石网络穿插于莫来石骨料之间,提高了制品热震性和强度。
所述的重量份组成为:3-1mm矾土22~24份、1-0.5mm棕刚玉12~13份、粒径<320目棕刚玉9~10份、3-1mm红柱石13~16份、0.5-0.1mm红柱石12~14份、粒径<200目红柱石17~20份、粒径<5μm氧化铝微粉5.7~6份、粒径<0.045mm的苏州土6~7份、纸浆3.8~4.2份、磷酸0.45~0.55份、糊精0.4~0.5份、三聚磷酸钠0.13~0.17份。优选的原料配比能够达到更好的高热震低蠕变效果。
所述的3-1mm矾土与1-0.5mm棕刚玉的质量比为1.7~2:1。
所述的粒径<5μm氧化铝微粉与粒径<0.045mm的苏州土的质量比为0.8~1:1份。
所述的纸浆与磷酸的质量比为8:1。
所述的3-1mm红柱石、0.5-0.1mm红柱石、粒径<200目红柱石的质量百分比组成包括:Al2O3 56.58%、Fe2O3 0.74%、TiO2 0.26%、灼减0.83%;耐火度1790℃。
所述的苏州土的质量百分比组成包括Al2O336.79%、Fe2O30.69%、SiO247.39%、灼减14.10%。
一种上述的高抗热震、低蠕变热风炉用砖的制造方法,其特征在于,制备步骤为:
1)在湿碾机中按原料配比混练均匀后出碾:
2)在摩擦压砖机上进行成型;
3)将成型好的生坯装干燥窑车,推进隧道式干燥器干燥:
4)将干燥后的坯体按装窑图装窑车,烧成温度为1490℃~1530℃之间,推入隧道式烧成窑烧成。
所述的烧成温度为1490℃~1510℃。保温8 h ~10h。本发明的原料搭配,配合高达1500℃左右的烧成过程,在烧成过程中反应转化成的莫来石和刚玉,与砖坯中的特定粒度的红柱石和棕刚玉混合,能够大大提高材料的强度,适用温度更高。
与现有技术相比,本发明所具有的有益效果是:矾土在烧成过程中反应转化成的莫来石和刚玉,与砖坯中的特定粒度的红柱石和棕刚玉混合,能够大大提高材料的强度,适用温度更高;该方法制得的热风炉材料,综合了热风炉用低蠕变砖、红柱石砖、莫来石砖等的优良性能,刚玉与莫来石相较多,铝含量更高,低熔较少,具有良好的抗侵蚀能力,以及热震稳定性。在提高了耐火砖荷重软化温度、高温蠕变性能的基础上,提高了产品的抗热震稳定性,作为耐高温热风炉用耐火砖材料能够显著地延长使用寿命,满足大中型高炉热风炉高温长寿的要求。
具体实施方式
下面结合具体实施例对本发明做进一步说明,其中实施例1为最佳实施。
实施例1
1)在湿碾机中按原料配比:重量份组成为:3-1mm矾土23份、1-0.5mm棕刚玉12.5份、粒径<320目棕刚玉10份、3-1mm红柱石14.5份、0.5-0.1mm红柱石13份、粒径<200目红柱石18.5份、粒径<5μm氧化铝微粉5.8份、粒径<0.045mm的苏州土6.5份、粒径<240目碳化硅5份、纸浆4份、磷酸0.3份、糊精0.45份、三聚磷酸钠0.15份。苏州土的质量百分比组成包括Al2O336.79%、Fe2O30.69%、SiO247.39%、TiO20.45%、MgO0.10%、CaO0.24%、Na2O0.03%、灼减14.10%;所述的3-1mm红柱石、0.5-0.1mm红柱石、粒径<200目红柱石的质量百分比组成包括:Al2O3 56.58%、Fe2O3 0.74%、TiO2 0.26%、灼减 0.83%;耐火度1790℃。混练均匀后出碾:
1)在湿碾机中按原料配比:重量份组成为:3-1mm矾土25份、1-0.5mm棕刚玉15份、3-1mm红柱石10份、0.5-0.1mm红柱石10份、粒径<200目红柱石16份、粒径<5μm氧化铝微粉5份、粒径<0.045mm的苏州土6份、粒径<240目碳化硅5份、<320目棕刚玉8%,纸浆4份、磷酸0.3份、糊精0.45份、三聚磷酸钠0.15份。苏州土的质量百分比组成为Al2O336.79%、Fe2O30.69%、SiO247.39%、TiO20.45%、MgO0.10%、CaO0.24%、Na2O0.03%、灼减14.10%;混练均匀后出碾:
2)在摩擦压砖机上进行成型;
3)将成型好的生坯装干燥窑车,推进隧道式干燥器干燥:
4)将干燥后的坯体按装窑图装窑车,烧成温度为1500℃×9h,隧道窑烧成。
实施例2
1)在湿碾机中按原料配比:重量份组成为:3-1mm矾土22份、1-0.5mm棕刚玉13份、粒径<320目棕刚玉9份、3-1mm红柱石13份、0.5-0.1mm红柱石14份、粒径<200目红柱石17份、粒径<5μm氧化铝微粉6份、粒径<0.045mm的苏州土6份、粒径<240目碳化硅5.2份、纸浆4.2份、磷酸0.4份、糊精0.5份、三聚磷酸钠0.13份。苏州土的质量百分比组成包括Al2O337.69%、Fe2O30.67%、SiO246.39%、TiO20.47%、MgO0.11%、CaO0.22%、Na2O0.02%、灼减14.16%;所述的3-1mm红柱石、0.5-0.1mm红柱石、粒径<200目红柱石的质量百分比组成包括:Al2O3 56.58%、Fe2O3 0.74%、TiO2 0.26%、灼减 0.83%;耐火度1790℃。混练均匀后出碾:
2)在摩擦压砖机上进行成型;
3)将成型好的生坯装干燥窑车,推进隧道式干燥器干燥:
4)将干燥后的坯体按装窑图装窑车,烧成温度为1490℃×9h,推入隧道式烧成窑烧成。
实施例3
1)在湿碾机中按原料配比:重量份组成为:3-1mm矾土24份、1-0.5mm棕刚玉12份、粒径<320目棕刚玉11份、3-1mm红柱石16份、0.5-0.1mm红柱石12份、粒径<200目红柱石20份、粒径<5μm氧化铝微粉5.7份、粒径<0.045mm的苏州土7份、粒径<240目碳化硅4.8份、纸浆3.8份、磷酸0.25份、糊精0.4份、三聚磷酸钠0.17份。苏州土的质量百分比组成包括Al2O336.72%、Fe2O30.68%、SiO247.42%、TiO20.43%、MgO0.14%、CaO0.26%、Na2O0.04%、灼减14.08%;所述的3-1mm红柱石、0.5-0.1mm红柱石、粒径<200目红柱石的质量百分比组成包括:Al2O3 56.58%、Fe2O3 0.74%、TiO2 0.26%、灼减 0.83%;耐火度1790℃。混练均匀后出碾:
2)在摩擦压砖机上进行成型;
3)将成型好的生坯装干燥窑车,推进隧道式干燥器干燥:
4)将干燥后的坯体按装窑图装窑车,烧成温度为1510℃×9h,推入隧道式烧成窑烧成。
实施例4
1)在湿碾机中按原料配比:重量份组成为:3-1mm矾土19份、1-0.5mm棕刚玉14份、粒径<320目棕刚玉8份、3-1mm红柱石10份、0.5-0.1mm红柱石16份、粒径<200目红柱石14份、粒径<5μm氧化铝微粉7.5份、粒径<0.045mm的苏州土5份、粒径<240目碳化硅5.5份、纸浆3.5份、磷酸0.5份、糊精0.3份、三聚磷酸钠0.2份。苏州土的质量百分比组成包括Al2O336.74%、Fe2O30.68%、SiO247.41%、TiO20.46%、MgO0.09%、CaO0.21%、Na2O0.03%、灼减14.11%;所述的3-1mm红柱石、0.5-0.1mm红柱石、粒径<200目红柱石的质量百分比组成包括:Al2O3 56.58%、Fe2O3 0.74%、TiO2 0.26%、灼减 0.83%;耐火度1790℃。混练均匀后出碾:
2)在摩擦压砖机上进行成型;
3)将成型好的生坯装干燥窑车,推进隧道式干燥器干燥:
4)将干燥后的坯体按装窑图装窑车,烧成温度为1520℃×8h,推入隧道式烧成窑烧成。
实施例5
1)在湿碾机中按原料配比:重量份组成为:3-1mm矾土27份、1-0.5mm棕刚玉11份、粒径<320目棕刚玉12份、3-1mm红柱石20份、0.5-0.1mm红柱石9份、粒径<200目红柱石23份、粒径<5μm氧化铝微粉4.5份、粒径<0.045mm的苏州土8份、粒径<240目碳化硅4.5份、纸浆4.5份、磷酸0.2份、糊精0.7份、三聚磷酸钠0.1份。混练均匀后出碾:
2)在摩擦压砖机上进行成型;
3)将成型好的生坯装干燥窑车,推进隧道式干燥器干燥:
4)将干燥后的坯体按装窑图装窑车,烧成温度为1530℃×10h,推入隧道式烧成窑烧成。
对比例1
实施工艺和原料配比同实施例1,不同的是1-0.5mm棕刚玉的用量为22份、3-1mm矾土的用量为12.5份。
对比例2
实施工艺和原料配比同实施例1,不同的是红柱石的粒径均为0.5-0.1mm。
对比例3
实施工艺和原料配比同实施例1,不同的是纸浆的用量为0.15份、磷酸的用量为0.4份、糊精的用量为0.5份、三聚磷酸钠的用量为0.45份。
对比例4
1)在湿碾机中按原料配比:重量份组成为:3-1mm矾土23份、1-0.5mm棕刚玉12.5份、粒径<320目棕刚玉10份、3-1mm红柱石14.5份、0.5-0.1mm红柱石13份、粒径<200目红柱石18.5份、粒径<5μm氧化铝微粉5.8份、粒径<0.045mm的苏州土6.5份、纸浆4份、磷酸0.3份、糊精0.3份、三聚磷酸钠0.15份。苏州土的质量百分比组成为Al2O336.79%、Fe2O30.69%、SiO247.39%、TiO20.45%、MgO0.10%、CaO0.24%、Na2O0.03%、灼减14.10%,余量为杂质;混练均匀后出碾:
2)在摩擦压砖机上进行成型;
3)将成型好的生坯装干燥窑车,推进隧道式干燥器干燥:
4)将干燥后的坯体按装窑图装窑车,烧成温度为1500℃,推入隧道式烧成窑烧成。实施例和对比例的性能测试结果见表1。
表1
以上所述,仅是本发明的较佳实施例而已,并非是对本发明作其它形式的限制,任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以变更或改型为等同变化的等效实施例。但是凡是未脱离本发明技术方案内容,依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与改型,仍属于本发明技术方案的保护范围。
Claims (6)
1.一种高抗热震、低蠕变热风炉用砖,其特征在于,重量份组成为:3-1mm矾土19~27份、1-0.5mm棕刚玉11~14份、粒径<320目棕刚玉8~12份、3-1mm红柱石10~20份、0.5-0.1mm红柱石9~16份、粒径<200目红柱石14~23份、粒径<5μm氧化铝微粉4.5~7.5份、粒径<0.045mm的苏州土5~8份、粒径<240目碳化硅4.5~5.5份、纸浆3.5~4.5份、磷酸0.2~0.5份、糊精0.3~0.7份、三聚磷酸钠0.1~0.2份;
所述的3-1mm矾土与1-0.5mm棕刚玉的质量比为1.7~2:1;
所述的高抗热震、低蠕变热风炉用砖制备步骤为:
1)在湿碾机中按原料配比混练均匀后出碾:
2)在摩擦压砖机上进行成型;
3)将成型好的生坯装干燥窑车,推进隧道式干燥器干燥;
4)将干燥后的坯体按装窑图装窑车,烧成温度为1490℃~1530℃,推入隧道式烧成窑烧成。
2.根据权利要求1所述的一种高抗热震、低蠕变热风炉用砖,其特征在于:所述的重量份组成为:3-1mm矾土22~24份、1-0.5mm棕刚玉12~13份、粒径<320目棕刚玉9~10份、3-1mm红柱石13~16份、0.5-0.1mm红柱石12~14份、粒径<200目红柱石17~20份、粒径<5μm氧化铝微粉5.7~6份、粒径<0.045mm的苏州土6~7份、粒径<240目碳化硅4.7~5.3份、纸浆3.8~4.2份、磷酸0.45~0.5份、糊精0.4~0.5份、三聚磷酸钠0.13~0.17份。
3.根据权利要求1所述的一种高抗热震、低蠕变热风炉用砖,其特征在于:所述的粒径<5μm氧化铝微粉与粒径<0.045mm的苏州土的质量比为0.8~1:1份。
4.根据权利要求1所述的一种高抗热震、低蠕变热风炉用砖,其特征在于:所述的纸浆与磷酸的质量比为8:1。
5.根据权利要求1所述的一种高抗热震、低蠕变热风炉用砖,其特征在于:所述的3-1mm红柱石、0.5-0.1mm红柱石、粒径<200目红柱石的质量百分比组成包括:Al2O3 56.58%、Fe2O3 0.74%、TiO2 0.26%、灼减 0.83%;耐火度1790℃。
6.根据权利要求1所述的一种高抗热震、低蠕变热风炉用砖的制造方法,其特征在于:所述的烧成温度为1490℃~1510℃。
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