CN110372343A - 蓄热式加热炉用蜂窝体及其制备方法 - Google Patents
蓄热式加热炉用蜂窝体及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种蓄热式加热炉用蜂窝体及其制备方法。所述蜂窝体采用高铝矾土、铬刚玉为主成分,粘土作结合剂,添加碳化硅、硅微粉、α‑Al2O3微粉,同时加入助烧剂、增韧剂、润滑剂、增塑剂、高温粘结剂,通过混料、真空练泥、挤出、定形干燥及烧成等工艺步骤制成。本发明蜂窝体符合蓄热式燃烧技术的工艺要求,具有蓄热量大、高温性能稳定,换热效率高、寿命长的性能,可降低钢铁厂由于更换蜂窝体而停炉的次数,提高加热炉的生产作业率,减少设备维修费用,真正起到增产节约的作用,具有明显的经济效益,使用前景非常广阔。
Description
技术领域
本发明属于冶金耐火材料技术领域,涉及钢铁行业加热炉用的蓄热体及其制备方法,更具体而言,提供一种蓄热式加热炉用蜂窝体及其制备方法。
背景技术
蓄热式加热炉在冶金行业发展非常迅速,受到诸多钢铁企业的欢迎,节能效果十分显著,满足了我国工业发展要求。蓄热体是蓄热式加热炉的关键部分,蜂窝体是目前所用蓄热体中结构较为合理,换热效率高的一种耐火制品,由于其单位面积大、蓄热量大、换热速度快、节能效果好、配套设备简单等特点,越来越多地使用于蓄热式加热炉中。
蓄热式加热炉用蜂窝体使用环境恶劣,必须具备以下性能:一是蜂窝体必须满足长期在高温下工作的要求,高温性能稳定;二是在频繁的蓄/放热使用条件下,蜂窝体始终处于加热和冷却交替循环的工作状态,经常承受着因内外温差变化而引起的应力作用,因此蜂窝体的抗热震性能要好;三是蜂窝体需要及时吸热、放热,必须具有良好的导热性能;四是蜂窝体作为蓄热体,要求其具有尽可能高的贮热能力;五是蜂窝体抗烟气侵蚀性好。目前在用的蜂窝体,很多因材质选择或配方不合理,在冶金加热炉中使用效果不好,产品性能达不到使用要求,蜂窝体会因为变形导致孔道堵塞,因不能承受温度波动而破裂甚至粉碎,因抗烟气侵蚀能力差而导致蜂窝体烧损等,这些问题导致蜂窝体寿命短,严重制约了其蓄热性能的发挥,也会影响蓄热式炉的质量和设备的正常运行。
本发明针对蓄热式加热炉用蜂窝体配方进行改进,使得本发明蜂窝体符合蓄热式燃烧技术的工艺要求,具有蓄热量大、高温性能稳定,换热效率高、寿命长的优良性能,可以满足日益苛刻的加热炉生产和维修需要。
发明内容
基于上述问题,本发明提供一种蓄热式加热炉用蜂窝体及其制备方法。
本发明所采用的技术方案如下:
根据本发明的一个方面,本发明提供的一种蓄热式加热炉用蜂窝体,所述蜂窝体采用高铝矾土、铬刚玉为主成分,粘土作结合剂,添加碳化硅、硅微粉、α-Al2O3微粉,同时加入助烧剂、增韧剂、润滑剂、增塑剂、高温粘结剂。所述蜂窝体是通过混料、真空练泥、挤出、定形干燥及烧成等工艺步骤制成。
其中,按照重量百分比计,所述蜂窝体的原料包括:高铝矾土45%~55%;铬刚玉15%~25%;粘土5%~10%;碳化硅5%~8%;硅微粉0%~5%;α-Al2O3微粉3%~6%;助烧剂0.5%~1.5%;增韧剂1%~3%;润滑剂2%~4%;增塑剂1%~3%;以及高温粘结剂2%~4%。
蜂窝体是加热炉蓄热式燃烧技术的关键,要求其高温性能稳定。如果蜂窝体不耐高温,在重力作用下,蓄热箱高温段蓄热体将出现高温变形与塌陷,一方面使蜂窝体通孔变形缩小,增大了蓄热体的流动阻力,同时还导致蓄热体高度缩小,在蓄热箱上部会出现较大空隙,气流在流动过程中,优先从无阻隔的地方流动,引起高温烟气和冷却气体短路,这时高温烟气会直接进入排烟管道,造成排出的烟温过高,最终蓄热式蜂窝体会损坏,使蓄热箱失去蓄热作用。
本发明的蜂窝体,主成分之一高铝矾土,其Al2O3含量≥85%,粒度≤0.088mm,重量占比为45%~55%。高铝矾土耐火度高达1790℃以上,可以满足加热炉的使用温度要求。高铝矾土还具备荷重软化温度高的特性,可以显著改善和提高蜂窝体的耐高温性能,使其在高温使用时不易发生变形或塌陷等问题。
本发明的蜂窝体,主成分之一铬刚玉,其Cr2O3含量为12%~15%,粒度≤0.088mm,重量占比为15%~25%。铬刚玉熔点高,热膨胀性小,高温下体积稳定,不发生膨胀和收缩,也不与任何炉渣起反应,抗渣性优良,能显著改善和提高蜂窝体的高温体积稳定性和抗烟气侵蚀性能。
蜂窝体主要功能是蓄热,较轻的蜂窝体会降低其蓄热能力。随着体积密度增加,蓄热量也会增加。高铝矾土和铬刚玉密度大,蓄热性能好,所以本发明的蜂窝体比热容较高,蓄热量大,有利于减小蓄热室的体积。
本发明中,所述的蜂窝体选用的结合剂为软质粘土,其Al2O3含量为28%~33%,粒度≤5μm,重量占比为5%~10%。软质粘土具有良好的分散性、可塑性,干燥性和和烧结性等,用于制造蜂窝体来说优选于其他类的结合剂。
所述的蜂窝体添加的碳化硅为碳化硅细粉,其SiC含量≥90%,粒度≤0.088mm,重量占比为5%~8%。加入碳化硅可以提高材料的耐磨性和导热性,改善材料的抗剥落性和抗侵蚀性,可以满足加热炉用蜂窝体的抗热震性使用要求,保证蜂窝体在服役期内不产生脱落和脆裂。
所述的蜂窝体添加的硅微粉和α-Al2O3微粉,可以增加蜂窝体的比表面积,提高蜂窝体的蓄热能力。其中,硅微粉,其SiO2含量≥95%,粒度≤2μm,重量占比为0%~5%;α-Al2O3微粉,其Al2O3含量≥99%,粒度≤2μm,重量占比为3%~6%。
所述的蜂窝体的助烧剂可选用MgO、CaO、TiO2中的任一种或任几种,重量占比为0.5%~1.5%,可促进蜂窝体的高温陶瓷烧结。
所述的蜂窝体的增韧剂可选用ZrO2,加量在1%~3%。ZrO2的相变特性可以提高蜂窝体的断裂韧性和抗弯强度,使蜂窝体具有良好的抗热震性。
所述的蜂窝体的润滑剂可选用桐油和/或硬脂酸,重量占比为2%~4%。
所述的蜂窝体的增塑剂可选用甘油等有机醇,重量占比为1%~3%。
所述的蜂窝体的高温粘结剂可选用糊精和有机纤维素,重量占比为2%~4%。
根据本发明的另一方面,本发明提供的上述蜂窝体的制备方法如下:
第一步,先将上述原料按比例备料,在搅拌机中加水充分混合,搅拌成泥状料;第二步,反复真空练泥至少三次;第三步,将混练好的泥料装入模具;第四步,挤压成型;第五步,将挤制好的蜂窝体放入窑内快速烘干;第六步,将已烘干的蜂窝体进行打磨处理;第七步,将打磨好的蜂窝体再次烘干;第八步,将蜂窝体放到1400℃±50℃的高温窑中焙烧,得到所述蜂窝体。
与现有蜂窝体技术相比较,本发明的蓄热式加热炉用蜂窝体及其制备方法具有以下优势:
1.耐火度高,可以满足蓄热式加热炉一般不高于1450℃的使用温度要求。
2.密度高,比热大,具有较高的贮热能力,可以减小蓄热室体积,有利于设备的微型化。
3.热膨胀小,高温体积稳定性好。
4.荷重软化温度高,能够抵抗高温时重力对蜂窝体的作用,以及烟气对蜂窝体的不断冲刷。
5.导热性好,传热快,有利于换向时间缩短,热效率高。
6.热震稳定性好,能够长期处于急冷急热的蓄热体工作环境下不被损坏。
7.抗渣性好,不与加热炉烟尘中的氧化铁或氧化亚铁反应形成低共熔物,不会降低蜂窝体的软化或熔化温度。
8.性价比高。
本发明的蓄热式加热炉用蜂窝体由于具有以上优势,使用寿命得到延长,降低了钢铁厂由于更换蜂窝体而停炉的次数,提高了加热炉的生产作业率,减少了设备维修费用,真正起到了增产节约的作用,具有明显的经济效益,其使用前景非常广阔。
具体实施方式
下面将结合本发明实施例对本发明实施例中的技术方案进行清楚、完整地描述:
实施例1~4
本发明各实施例的蓄热式加热炉用蜂窝体原料及其按重量份计量的含量如表1所列,实施例1~4的制备方法相同。将上述各种原料按照表1中所示的配比称量备料,在搅拌机中加水充分混合,搅拌成泥状料,经过三次真空练泥,装模挤压成型,将挤制好的蜂窝体放入窑内快速烘干后打磨处理,再次烘干,最后放入1400℃的高温窑中焙烧,制得实施例1~4的蓄热式加热炉用蜂窝体。
表1各实施例配比
项目 | 实施例1 | 实施例2 | 实施例3 | 实施例4 |
高铝矾土粉 | 45 | 47 | 50 | 55 |
铬刚玉粉 | 20 | 25 | 18 | 15 |
粘土粉 | 10 | 6 | 8 | 5 |
碳化硅粉 | 8 | 5 | 6 | 5 |
硅微粉 | 0 | 3 | 4 | 5 |
α-Al<sub>2</sub>O<sub>3</sub>微粉 | 6 | 4 | 4 | 3 |
MgO | 0.5 | 1 | 0.5 | 0 |
CaO | 0 | 0 | 0 | 0.5 |
TiO<sub>2</sub> | 0.5 | 0.5 | 0 | 0.5 |
ZrO<sub>2</sub> | 3 | 1.5 | 2 | 1 |
桐油 | 3 | 0 | 2 | 1 |
硬脂酸 | 1 | 2 | 1 | 2 |
甘油 | 1 | 2 | 2 | 3 |
糊精 | 1 | 1.5 | 1.5 | 2 |
有机纤维素 | 1 | 1.5 | 1 | 2 |
本发明实施例1~4的蓄热式加热炉用蜂窝体的主要技术指标如表2所列,各性能指标依据国家标准、行业标准或团体标准中的相关规定进行检测。
表2各实施例的性能
本发明的蓄热式加热炉用蜂窝体是针对我国钢铁行业加热炉实际工作条件研制的,其制造工艺简单,蜂窝体的生产成本不高。但其通过优化原料并合理配比具有了优良的蓄热性能,且抗热震性好、高温体积稳定、抗渣性好,使用寿命较高,满足了加热炉维修周期的要求,为加热炉的增产节约奠定了基础,拥有巨大的社会价值和经济效益。
Claims (10)
1.一种蓄热式加热炉用蜂窝体,其特征在于,所述蜂窝体采用高铝矾土、铬刚玉为主成分,粘土作结合剂,添加碳化硅、硅微粉、α-Al2O3微粉,以及助烧剂、增韧剂、润滑剂、增塑剂、和高温粘结剂;
按照重量百分比计,所述蜂窝体的原料包括:
2.根据权利要求1所述的蓄热式加热炉用蜂窝体,其特征在于,所述高铝矾土,其Al2O3含量≥85%,粒度≤0.088mm。
3.根据权利要求1所述的蓄热式加热炉用蜂窝体,其特征在于,所述铬刚玉,其Cr2O3含量为12%~15%,粒度≤0.088mm。
4.根据权利要求1所述的蓄热式加热炉用蜂窝体,其特征在于,所述粘土为软质粘土,其Al2O3含量为28%~33%,粒度≤5μm。
5.根据权利要求1所述的蓄热式加热炉用蜂窝体,其特征在于,所述碳化硅为细粉,其SiC含量≥90%,粒度≤0.088mm。
6.根据权利要求1所述的蓄热式加热炉用蜂窝体,其特征在于,所述硅微粉,其SiO2含量≥95%,粒度≤2μm;所述α-Al2O3微粉,其Al2O3含量≥99%,粒度≤2μm。
7.根据权利要求1所述的蓄热式加热炉用蜂窝体,其特征在于,所述助烧剂为MgO、CaO、TiO2中的任一种或几种。
8.根据权利要求1所述的蓄热式加热炉用蜂窝体,其特征在于,所述增韧剂为ZrO2。
9.根据权利要求1所述的蓄热式加热炉用蜂窝体,其特征在于,所述润滑剂为桐油和/或硬脂酸;所述增塑剂为甘油;所述高温粘结剂为糊精和有机纤维素。
10.一种权利要求1~9任一项所述的蓄热式加热炉用蜂窝体的制备方法,其特征在于,所述制备方法包括以下步骤:
第一步,将所述原料按比例备料,在搅拌机中加水充分混合,搅拌成泥状料;
第二步,反复真空练泥至少三次;
第三步,将混练好的泥料装入模具;
第四步,挤压成型;
第五步,将挤压成型的蜂窝体放入窑内快速烘干;
第六步,将已烘干的蜂窝体进行打磨处理;
第七步,将打磨好的蜂窝体再次烘干;
第八步,将再次烘干后的蜂窝体放到1400℃±50℃的高温窑中焙烧,得到所述蜂窝体。
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