CN110372342A - 一种撇渣器预制件用无水泥铁沟浇注料 - Google Patents

一种撇渣器预制件用无水泥铁沟浇注料 Download PDF

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CN110372342A
CN110372342A CN201910753899.7A CN201910753899A CN110372342A CN 110372342 A CN110372342 A CN 110372342A CN 201910753899 A CN201910753899 A CN 201910753899A CN 110372342 A CN110372342 A CN 110372342A
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iron runner
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魏建修
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MCC WUHAN METALLURGICAL BUILDING RESEARCH INSTITUTE Co Ltd
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Abstract

本发明公开了一种无水泥铁沟浇注料，其组成致密刚玉骨料58～62％；碳化硅6～10％；球沥青2～3％；氮化硅粉1.5～6％；氧化铝微粉6～10％；二氧化硅微粉3～6％；纳米炭黑0.2～0.4％碳化硅粉3～8％；碳化硼粉0.2～0.4％；金属铝粉0.5‑1％；金属硅粉0.5‑1％；防爆纤维0.08～0.12％；分散剂0.1～0.3％；致密刚玉粉2‑8％。本发明以高纯二氧化硅微粉和氧化铝微粉组合的纯微粉结合的铁沟浇注料体系，使纯度、耐火度、及浇注料的致密程度达到了一个新的高度。得益于本发明体系的高纯度、高致密性等，本发明将铁沟浇注料中最具高温代表性的指标1400度保温1小时热态抗折强度最高做到了10MPa以上。

Description

一种撇渣器预制件用无水泥铁沟浇注料
技术领域
本发明属于材料技术领域，具体涉及一种撇渣器预制件用无水泥铁沟浇注料。
背景技术
高炉出铁场铁沟是炼铁工艺的重要一环，铁沟的定修周期长短对钢铁公司在环保及经济效益上有重要的意义。如何在保证安全使用的前提下，保证铁沟材料的使用寿命、延长高炉的定修周期、是一个重要课题。铁沟撇渣器的使用寿命直接决定着主铁沟的定修周期，所以该部位的材料需要最佳的使用效果，目前国内外几乎都是采用的水泥结合的铝碳化硅碳质的铁沟浇注料，然而该体系即使采用最高档次的原材料，也无法避免因水泥引入，生成钙长石等低熔点物质带来的高温性能劣化，因此水泥结合体系铁沟浇注为在1400℃保温1小时的热态抗折强度一般只能达到1-4MPa，很难达到5MPa以上。
国内学者为达到铁沟浇注料无水泥化的目的进行了大量的研究，一般方法是采用硅溶胶或者采用水硬性氧化铝来替代水泥，提供铁沟浇注料的早期强度。然而，硅溶胶因其自身无法克服的缺点(施工麻烦、冬季结冰失效、现场受高温影响大、加液量大等)，使用效果相比水泥结合铁沟浇注料没有优势。水硬性氧化铝完全替代水泥结合不但强度低，而且这种氧化铝稳定性不好，尤其水化速度受温度影响极其敏感，同时中温失去结晶水的过程常常会产生微裂纹，使材料的结构致密程度受到影响。因此在无水泥铁沟浇注料一直没有比较可行的新的优化方案。
CN201611150300.3一种高炉出铁用无水泥铁沟浇注料及其制备方法，采用ρ-氧化铝替代水泥产生早期强度，减少因水泥带来的低熔物。但其加水量大、ρ-氧化铝本身不稳定，ρ-氧化铝在浇注料中受环境温度影响，反应活性差别很大，凝固时间不易控制。
山东理工大学学报，2012第26卷第4期公开了无水泥铁沟浇注料的研制，采用ρ-氧化替代水泥产生早期强度，减少因水泥带来的低熔物。但其加水量大、ρ-氧化铝本身及应用不稳定、中温失去结晶水导致结构疏松。
CN201410055772.5一种致密型高强度SiAlON结合铁沟浇注料及其制作方法，采用硅溶胶，实现基质增强及无水泥化。但其施工麻烦、硅溶胶冬季结冰失效、现场受高温影响大、加液量大。
发明内容
本发明目的在于针对现有技术的不足，提供一种撇渣器预制件用无水泥铁沟浇注料的制备方法，所得铁沟浇注料1400度保温1小时热态抗折强度最高达到10MPa以上。
为达到上述目的，采用技术方案如下：
一种无水泥铁沟浇注料，其组成按质量百分比计为：
上述方案中，所述致密刚玉骨料粒径为0-8mm；其中不同粒径颗粒所占质量百分比为：5-8mm 25％，3-5mm 14％，1-3mm 14％，0-1mm 5-9％；所含Al2O3＞98.5wt％，Fe2O3＜0.2wt％。
上述方案中，所述致密刚玉粉细度≤74um；所含Al2O3＞98.5wt％，Fe2O3＜0.2wt％。
上述方案中，所述碳化硅粒径为0-1mm；其中SiC＞98.5wt％，Fe2O3＜0.3wt％。
上述方案中，所述球沥青的粒度不大于1.5mm。本发明选用高温球沥青，该高残炭含量的沥青有利于提升铁沟浇注料的抗渣性能。
上述方案中，所述氧化铝微粉细度为d50＜1.2微米，原晶的晶体直径控制在0.5um左右，晶体直径波动范围为0.05um以内，α相转化率达到95％以上；其中Al2O3＞99.5wt％、Na2O＜0.1wt％。活性非常稳定，具有更好的减水性能，流动性好，强度发展好。
上述方案中，所述二氧化硅微粉SiO2＞99wt％，pH值小于4，体积平均粒径小于0.3微米。
上述方案中，所述碳化硼粉含量B4C>95wt％,细度为≤45um。
上述方案中，所述金属硅粉的粒度≤45μm，Si含量＞98.5wt％。
上述方案中，所述金属铝粉为氮气雾化工艺生产的，Al≥99wt％，细度为≤74um。
上述方案中，所述碳化硅粉中SiC含量≥98％，细度为≤74um。
上述方案中，所述分散剂为聚丙烯酸盐、聚羧酸、氧化铝粉等的混合物，是一种高效的复合减水剂，有极佳的减水性能，同时不宜泌水，有良好的稳定性，避免铁沟浇注料鼓胀开裂。
上述方案中，所述氮化硅粉Si3N4≥94％，细度为≤45um
上述方案中，所述防爆纤维为聚丙防爆纤维，熔点为170±10℃、长度为5～3mm。
上述方案中，所述纳米炭黑为德国产N990R型。
高纯二氧化硅微粉组成中玻璃相明显高于普通二氧化硅微粉，且杂质含量极低，发明人尝试性地在铁沟浇注料中使用最新高纯硅微粉做为结合剂，首次发现这种高纯二氧化硅微粉具有独特的自结合性，当在铁沟浇注料中加入量达到3％以上时，可以完全替代水泥产生足够的早期强度。所述高纯二氧化硅微粉相对于普通微分有以下区别：
高纯二氧化硅微粉体积平均粒径仅为普通二氧化硅微粉的10％，比表面积比普通二氧化硅微粉高近50％，因此其活性更高。
高纯二氧化硅微粉比普通二氧化硅微粉可以降低铁沟浇注料的加水量，提高铁沟浇注料的体积密度、冷态强度和热态抗折强度，减少了浇注料的气孔率和低熔相的产生，降低了渣对浇注料的侵蚀。
本发明创造性地采用以高纯二氧化硅微粉和氧化铝微粉组合的纯微粉结合的铁沟浇注料体系，该体系使铁沟浇注料基质的纯度、耐火度、及浇注料的致密程度达到了一个新的高度。由于这种纯微粉结合体系完全不同于水泥结合浇注料体系，所以传统铁沟浇注料中的一些粉体产生了不同的作用及影响。得益于本发明体系的高纯度、高致密性等，本发明将铁沟浇注料中最具高温代表性的指标1400度保温1小时热态抗折强度最高做到了10MPa以上，这对水泥结合铁沟浇注料是不可想象的，水泥结合铁沟浇注料该指标只能做到4MPa左右。
本发明创新的将德国产N990R型纳米炭黑做为一种改良浆体施工性能的改良剂及微粉结合的铁沟浇注料的促凝剂。普通炭黑使铁沟浇注料失去流动性或者增大浇注料的加水量，使用铁沟浇注料性能劣化，而该纳米炭黑不但可以增强浇注料的抗渣性，而且使本浇注料在高致密状态下较好的泛浆，振动时产生的气泡更均匀化。同时，这种纳米炭黑对微粉结合的铁沟浇注料具有促凝作用。
本发明将传统水泥结合铁沟浇注料中起防爆作用的金属铝粉的加入量大幅度提高，用来与金属硅粉配合做防氧化剂，达到更好的抗氧化作用；并且高温下与氮化硅粉生成塞隆结合相，从而大幅度提高材料高温下的热态强度及耐铁水冲刷的能力，这在传统水泥结合铁沟浇注料中是无法实现的，因为金属铝粉在水泥结合的铁沟浇注料中产生大量氢气，限制了金属铝粉的加入量，而实验证明，本发明中金属铝粉不但在抗氧化方面明显优于金属硅粉，而且可以明显提高铁沟浇注料的抗渣性能。
具体实施方式
以下实施例进一步阐释本发明的技术方案，但不作为对本发明保护范围的限制。
实施例1
一种撇渣器预制件用无水泥铁沟浇注料，各组分及其所占质量百分比为：将致密刚玉骨料56％；碳化硅0-1mm:10％；球沥青2％；氧化铝微粉6％；高纯二氧化硅微粉6％；碳化硅粉8％；氮化硅粉1.5％；纳米炭黑0.3％；金属铝粉0.5％，防爆纤维0.08％；分散剂0.1％；金属硅粉1％；碳化硼粉0.2％；致密刚玉粉6.32％。将各原料按上述配比称取并充分混合；再加入水(水的质量为各原料总质量的3.2％)搅拌均匀后振动成型；成型后所得试样经自然干燥24h后在110℃下再进行热处理24h，制得撇渣器预制件用无水泥铁沟浇注料试样。
将本实施例所制得的撇渣器预制件用无水泥铁沟浇注料试样进行性能检测，结果如表1所示。采用的性能检测方法按照现行国家标准或行业标准进行(GB/T3001—2017)，所得检测结果为3次平均检测结果见表1所示。
表1
实施例2
一种撇渣器预制件用无水泥铁沟浇注料，各组分及其所占质量百分比为：将致密刚玉骨料62％；碳化硅0-1mm:6％；球沥青2％；氧化铝微粉6％；高纯二氧化硅微粉5％；碳化硅粉3％；氮化硅粉6％；纳米炭黑0.2％；金属铝粉0.6％，防爆纤维0.1％；分散剂0.2％；金属硅粉0.6％；碳化硼粉0.3％；致密刚玉粉8％。将各原料按上述配比称取并充分混合；再加入水(水的质量为各原料总质量的3.2％)搅拌均匀后振动成型；成型后所得试样经自然干燥24h后在110℃下再进行热处理24h，制得撇渣器预制件用无水泥铁沟浇注料试样。
将本实施例所制得的撇渣器预制件用无水泥铁沟浇注料试样进行性能检测，所得检测结果为3次平均检测结果见表2所示。
表2
实施例3
一种撇渣器预制件用无水泥铁沟浇注料，各组分及其所占质量百分比为：将致密刚玉骨料58.93％；碳化硅0-1mm:10％；球沥青2.5％；氧化铝微粉10％；高纯二氧化硅微粉3％；碳化硅粉8％；氮化硅粉3％；纳米炭黑0.4％；金属铝粉1％，防爆纤维0.08％；分散剂0.1％；金属硅粉0.5％；碳化硼粉0.4％；致密刚玉粉2％。将各原料按上述配比称取并充分混合；再加入水(水的质量为各原料总质量的3.2％)搅拌均匀后振动成型；成型后所得试样经自然干燥24h后在110℃下再进行热处理24h，制得撇渣器预制件用无水泥铁沟浇注料试样。
将本实施例所制得的撇渣器预制件用无水泥铁沟浇注料试样进行性能检测，所得检测结果为3次平均检测结果见表3所示。
表3
实施例4
一种撇渣器预制件用无水泥铁沟浇注料，各组分及其所占质量百分比为：将致密刚玉骨料60％；碳化硅0-1mm:8％；球沥青3％；氧化铝微粉8％；高纯二氧化硅微粉4.5％；碳化硅粉5.5％；氮化硅粉3.75％；纳米炭黑0.2％；金属铝粉0.75％，防爆纤维0.1％；分散剂0.1％；金属硅粉0.75％；碳化硼粉0.35％；致密刚玉粉5％。将各原料按上述配比称取并充分混合；再加入水(水的质量为各原料总质量的3.2％)搅拌均匀后振动成型；成型后所得试样经自然干燥24h后在110℃下再进行热处理24h，制得撇渣器预制件用无水泥铁沟浇注料试样。
将本实施例所制得的撇渣器预制件用无水泥铁沟浇注料试样进行性能检测，所得检测结果为3次平均检测结果见表4所示。
表4
上述结果表明，本发明所述一种撇渣器预制件用无水泥铁沟浇注料，具有加水量低、致密性好、无水泥、热态强度高、抗渣性好等特点。需要说明的是：以上所有实例中，如将高纯二氧化硅微粉改为传统二氧化硅微粉，其余保持不变，浇注料均会因为无法固化并产生足够的脱模强度而变得完全不成立。

Claims (10)

1.一种无水泥铁沟浇注料，其特征在于组成按质量百分比计为：
2.如权利要求1所述无水泥铁沟浇注料，其特征在于所述致密刚玉骨料粒径为0-8mm；其中不同粒径颗粒所占质量百分比为：5-8mm 25％，3-5mm 14％，1-3mm 14％，0-1mm 5-9％；所含Al2O3＞98.5wt％，Fe2O3＜0.2wt％；所述致密刚玉粉细度≤74um；所含Al2O3＞98.5wt％，Fe2O3＜0.2wt％。
3.如权利要求1所述无水泥铁沟浇注料，其特征在于所述碳化硅粒径为0-1mm；其中SiC＞98.5wt％，Fe2O3＜0.3wt％；所述球沥青的粒度不大于1.5mm。
4.如权利要求1所述无水泥铁沟浇注料，其特征在于所述氧化铝微粉细度为d50＜1.2微米，原晶的晶体直径控制在0.5um左右，晶体直径波动范围为0.05um以内，α相转化率达到95％以上；其中Al2O3＞99.5wt％、Na2O＜0.1wt％。
5.如权利要求1所述无水泥铁沟浇注料，其特征在于所述二氧化硅微粉SiO2＞99wt％，pH值小于4，体积平均粒径小于0.3微米。
6.如权利要求1所述无水泥铁沟浇注料，其特征在于所述碳化硼粉含量B4C>95wt％,细度为≤45um；所述金属硅粉的粒度≤45μm，Si含量＞98.5wt％。
7.如权利要求1所述无水泥铁沟浇注料，其特征在于所述金属铝粉为氮气雾化工艺生产的，Al≥99wt％，细度为≤74um；所述碳化硅粉中SiC含量≥98％，细度为≤74um。
8.如权利要求1所述无水泥铁沟浇注料，其特征在于所述分散剂为聚丙烯酸盐、聚羧酸、氧化铝粉的混合物。
9.如权利要求1所述无水泥铁沟浇注料，其特征在于所述氮化硅粉Si3N4≥94％，细度为≤45um。
10.如权利要求1所述无水泥铁沟浇注料，其特征在于所述防爆纤维为聚丙防爆纤维，熔点为170±10℃、长度为5～3mm；所述纳米炭黑为德国产N990R型。
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