CN110527790B - Manufacturing method of anti-breaking combined tapered dispersion air brick - Google Patents
Manufacturing method of anti-breaking combined tapered dispersion air brick Download PDFInfo
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- CN110527790B CN110527790B CN201810498874.2A CN201810498874A CN110527790B CN 110527790 B CN110527790 B CN 110527790B CN 201810498874 A CN201810498874 A CN 201810498874A CN 110527790 B CN110527790 B CN 110527790B
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- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
- B28B3/021—Ram heads of special form
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
- B28B3/04—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form with one ram per mould
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
- C04B35/105—Refractories from grain sized mixtures containing chromium oxide or chrome ore
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- 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
- C21C7/072—Treatment with gases
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
- C04B2235/34—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
- C04B2235/3418—Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
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- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
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Abstract
The invention provides a method for manufacturing a break-proof combined tapered dispersion air brick, provides a method for manufacturing an air brick containing a break-proof core dispersion block, and provides a method for manufacturing an air brick by taking the dispersion block as an important component.
Description
Technical Field
The invention relates to an external refining bottom argon blowing system of a ferrous metallurgy furnace, in particular to a ladle air brick in the aspect of refractory materials in structural ceramics, and more particularly relates to a structure, a manufacturing method and a formula of a dispersion type air brick in the air brick.
Background
In the field of ferrous metallurgy, external refining appears as the subversive development of a steelmaking process, and the tasks of adjusting molten steel components and removing inclusions by temperature are transferred to a secondary refining process for smelting in a ladle, so that the ladle air brick is a core functional element of high-quality steel.
The development process of the ladle air brick is probably as follows: at first, high-aluminum clay dispersive air brick is appeared, the first generation air brick is defined as the first generation air brick, although the service life of the first generation air brick is only a plurality of times, the first generation air brick belongs to bottom blowing in the mode, the method has the improvement significance compared with the original top blowing stirring, along with the development of metallurgical materials, the air brick appears in a slit type, the service life of the air brick is greatly prolonged, the development of ferrous metallurgy is fully promoted, at present, most of ladle air bricks also adopt slit type air bricks, the service life of the air brick is different according to the difference of refining conditions and is different from 7 times to 8 times to about 100 times, in recent years, a dispersive air brick is also appeared in the market, the second generation air brick is defined as the second generation air brick, and under certain refining conditions, the dispersive air brick has the advantages or performance characteristics which cannot be possessed by the slit type air brick, such as difficult fracture, no need of oxygen lance cleaning and the like.
The air brick is conical in appearance, circular in cross section, provided with a refractory material body, a metal shell, a tail pipe and the like, and has the function of conveying argon into a ladle to stir molten steel to achieve the purposes of refining and the like.
The slit-type air brick is an air brick with an argon channel having a specific physical shape, and the slit can be generated by splicing ceramic plates, embedding strip-shaped or linear lost-burning objects in the air brick casting material and performing high-temperature lost-burning.
The dispersive air brick comprises a first generation, a second generation and a novel dispersive air brick related to the invention, a large number of mutually communicated gaps or air holes are reserved on a refractory material body in a particle grading mode to achieve the purpose of passing through argon, and the manufacturing method is generally formed by pressing.
The first generation of dispersive air brick has a completely conical dispersive air brick, that is, the refractory material body is completely the dispersive air brick, the manufacturing method is from the big head of the air brick to manual tamping, then single-side machine pressing is developed, the pressed surface is the big head part of the air brick, but the refractory material body is conical, and the height-diameter ratio of the air brick is too large, so the pressing method has the defects of uneven inside of a blank and the like, and the dispersive air brick with good performance cannot be manufactured.
The structure of the second generation dispersion type air brick appearing in recent years is different from that of the first generation dispersion air brick, the refractory material body comprises square dispersion blocks, the periphery of the square dispersion blocks is wrapped with a casting material and a base (shown in figure 1), the dispersion blocks are made into square shapes, so that the lateral surfaces of the square dispersion blocks are conveniently pressed by single surface stress, the uniformity of the dispersion blocks is high, and the service performance is ideal.
In the second generation of dispersive air brick, the structural form of the square dispersion block inevitably causes the restriction of the ventilation sectional area, for example, the diameter of the small end of the general air brick is 120mm, the square dispersion block can only be manufactured into a circle with the inscribed diameter and the diameter of 120mm, and the area of the square dispersion block is about 63.7 percent of the area of the circle.
As described above, the gas passage of the dispersive air brick intentionally creates void defects through the grain composition of the dispersive block to realize ventilation, because a large number of defects are in the inside, various mechanical properties of the dispersive block are inevitably reduced, if the internal defects of the dispersive block are reduced to improve the mechanical properties, the ventilation amount is affected on the premise of a limited sectional area, and therefore, if a method is provided, the defects of the gas passage in the inner part of the dispersive block can be reduced to improve the mechanical properties of the dispersive block, and the ventilation amount and the manufacturing uniformity of the dispersive block can be ensured, so that the dispersive air brick with a long service life can be provided. It is known that the reduction of the defects of the air voids inside the dispersion block can be achieved by means of formulations and processes; the manufacturing uniformity of the dispersion block can be realized by a process means; the air permeability can be ensured only by increasing the sectional area of the dispersion block, the dispersion block is made into a cone shape consistent with the air brick, namely, the dispersion block is made into a shape consistent with a first generation dispersion air brick from the aspect of appearance, and the defects of the first generation dispersion air brick can be overcome, namely the subject of the invention is that: the combined conical dispersion air brick comprises the structure, the manufacturing method, the formula and the like.
In addition, the conical air brick with the characteristics is consistent with the first generation dispersive air brick in appearance, and can be realized by an isostatic pressing method in terms of manufacturing process, but when materials with ventilation gap defects are pressed by the method, the materials are easy to break and crack, the yield is too low, and the production efficiency is very low.
In the prior related art, the core of the patent 201020104628.3 is 'a slit ventilation part (4) positioned in a core part and a dispersion ventilation part (5) arranged outside the slit ventilation part (4)', which means 'good stirring effect, good purification effect and high working efficiency'; the effect of patent 201120352995.X is similar to 201020104628.3; patent 201520819368.0 puts a column inner core in the center of the dispersion part, and the beneficial effect is: the method is not only beneficial to molding, but also can eliminate the thermal stress on the air brick when in use, and correspondingly improves the safety factor of the air brick; the 201520821852.7 air brick is completely an integral dispersion shape, and the meaning is 'large ventilation volume'; patents 201610199792.9 and 201610202807.2 disclose a dispersion brick prepared by casting; patent 201610794506.3 discloses a dispersion air brick prepared by extrusion; patent 201710013255.5 discloses a method of casting a dispersion air brick with a sponge.
Disclosure of Invention
In order to realize the idea and achieve corresponding beneficial effects, the technical scheme adopted by the invention is as follows:
1, structure of
1.1 the refractory part of the air brick comprises: the conical dispersion block is characterized in that the conical dispersion block is divided into two symmetrical parts along the axial line in the longitudinal direction and is directly and physically combined to form the conical dispersion block, the combined dispersion block is in physical contact with the base, an air chamber is arranged between the conical dispersion block and the base, the dispersion block is tightly attached to a metal shell of the air brick through fire clay, and the base and the metal shell of the air brick are filled with the seam casting material, so that the conical dispersion air brick is of a basic structure of a combined conical dispersion air brick as shown in a figure 2.
The gas channel of the base is slit type, the height of the base is 80mm-250mm, one or two anchoring grooves are arranged on the base, the outline of the base can be conical or cylindrical, and the thickness of the fire clay is 0.1mm-3 mm.
The core of the scheme is that the dispersion block is conical and is divided into two symmetrical parts, the conical meaning is that the air permeability is large from the volume, and the dividing meaning is that the dispersion block can be formed by single-sided machine pressing, so that the pressing uniformity is ensured.
1.2, the refractory material part of the air brick comprises: the cone-shaped diffusion block is characterized in that the cone-shaped diffusion block is divided into two symmetrical parts along the axial line in the longitudinal direction and is directly and physically combined, the combined diffusion block is in physical contact with the base, an air chamber is arranged between the diffusion block and the base, the diffusion block is tightly attached to a metal shell of an air brick through fire clay, and the base and the metal shell of the air brick are filled with seam casting materials, so that the cone-shaped diffusion air brick is of a structure shown in figure 3 and is a combined cone-shaped diffusion air brick with a breakage prevention type.
The gas channel of the base is slit type, the height of the base is 80mm-250mm, one or two anchoring grooves are arranged on the base, the outline of the base can be conical or cylindrical, the thickness of the fire clay is 0.1mm-3mm, the diameter of the anti-breaking core is 20mm-80mm, the critical granularity of the anti-breaking core casting material is required to be not more than 6mm, the cold-state breaking strength at 1620 ℃ is more than or equal to 36MPa, the corresponding linear change rate is + 0.08% to + 0.25%, and the refractoriness is more than or equal to 1810 ℃.
On the basis of the scheme 1, the anti-breaking core made of high-performance castable is designed in the center of the conical dispersion block, and the anti-breaking core is significant in preventing the dispersion block from breaking.
1.3, the structure of the air brick comprises: the anti-permeability combined tapered dispersive air brick comprises a tapered dispersive block, a base and a joint pouring material, wherein the cross section of the tapered dispersive block is a circle, the tapered dispersive block is characterized in that the tapered dispersive block is longitudinally divided into two symmetrical parts along an axis and is directly and physically combined, the combined dispersive block is in physical contact with the base, an air chamber is arranged between the tapered dispersive block and the base, the gap between the tapered dispersive block and the metal shell of the air brick and the gap between the base and the metal shell of the air brick are filled with the joint pouring material, and the structure is as shown in figure 4, so that the anti-permeability combined tapered dispersive air brick is formed.
The thickness of the thinnest part of the seam casting material is 8mm-30mm, the gas channel of the base is in a slit type, the height of the base is 80mm-250mm, one or two anchoring grooves are formed in the base, and the contour of the base can be conical or cylindrical.
According to the scheme, seam fire clay is removed on the basis of the scheme 1 and is replaced by seam castable, and the fire clay is always a weak point compared with refractory castable, so that the significance of the scheme 3 can avoid the possibility that the air brick described in the scheme 1 is infiltrated from the fire clay part in the later period, meanwhile, the cross section of a diffusion block formed by combining two sections can be theoretically circular, the manufacturing precision of the diffusion block is required to be higher, the defect that the diffusion block and a metal shell are connected by the fire clay is certain, the defect can be avoided by replacing the diffusion block by the refractory castable, but on the other hand, the defect of the scheme and the scheme 1 is that the seam castable is arranged around the diffusion block, so that the ventilation area is slightly reduced, and the ventilation area and the refractory castable are advanced.
1.4, two parts are combined into a conical dispersion block with a round cross section, an anti-breaking core at the center of the dispersion block, a base and a joint pouring material, when the two parts are combined into the symmetrical dispersion block, a complete cylindrical vacancy is formed at the center of the dispersion block, wherein the anti-breaking core is formed by pouring high-performance refractory pouring material in a vibration mode, the conical dispersion block is characterized in that the conical dispersion block is longitudinally divided into two symmetrical parts along an axis and is directly and physically combined, the combined dispersion block is in physical contact with the base, an air chamber is arranged between the dispersion block and the base, the gap between the dispersion block and a metal shell of an air brick and the gap between the base and the metal shell of the air brick are filled with the joint pouring material, and the structure is shown in figure 5 and is the anti-breaking and anti-permeability combined type conical dispersion air brick.
The thickness of the thinnest part of the joint castable is 8mm-30mm, the gas channel of the base is in a slit type, the height of the base is 80mm-250mm, one or two anchoring grooves are arranged on the base, the outline of the base can be in a conical or cylindrical shape, the critical granularity of the core breaking-proof castable is required to be not more than 6mm, the cold-state breaking strength at 1620 ℃ is not more than 36MPa, the corresponding linear change rate is between + 0.08% and + 0.25%, and the refractoriness is not less than 1810 ℃.
The scheme is that seam fire clay is removed on the basis of the scheme 2, the seam fire clay is used for replacing the seam fire clay, and similarly, the fire clay is a weak point for ever comparing with a refractory castable, so that the significance of the scheme 4 can avoid that an air brick described in the scheme 2 is possibly infiltrated with steel from the fire clay part in the later period, meanwhile, the cross section of a dispersion block formed by combining two sections can be theoretically circular, the preparation precision of the dispersion block is required to be higher, the fire clay is used for connecting the dispersion block with a metal shell to have certain defects, the refractory castable is used for replacing the dispersion block, the defects can be avoided, but on the other hand, the defects of the scheme and the scheme 2 are that the seam fire clay is arranged around the dispersion block, so the ventilation area is slightly reduced, and the two have respective advancement.
2, the manufacturing method of the conical dispersion block comprises the following steps:
2.1 case of a dispersion without a break-proof core, as in the form of FIG. 8:
preparing materials according to a formula, respectively and uniformly mixing all the granular materials and the fine powder materials, adding all the granular materials into a stirrer, adding a polyvinyl alcohol solution, uniformly mixing, adding the rest fine powder materials, mixing for 3min, and forming the materials for later use;
designing a dispersion block into two symmetrical parts, wherein the forming mode is single-side compression forming, the compression surface is a surface of the dispersion block cut along the axis, a mould is manufactured according to a brick shape, the compression surface of an upper pressure head is a plane (shown in figures 12 and 13), then a mixed material is added to compress each part of the dispersion block, the forming pressure is 70MPa-150MPa, and a straight section of 1mm-10mm is reserved in the compressed dispersion block;
drying the pressed two-petal dispersion block at the maximum temperature of 150 ℃ and firing the two-petal dispersion block at the maximum temperature of 1500-1700 ℃ to obtain the two-petal dispersion block;
and (3) grinding the straight section of the two-petal dispersion block, wherein the precision is required to be ensured, and the two polished dispersion blocks are directly and physically combined to complete the manufacturing of the dispersion core.
2.2 case of a center of the dispersion block with an anti-breaking core, as in the form of fig. 11:
preparing materials according to a formula, respectively and uniformly mixing all the granular materials and the fine powder materials, adding all the granular materials into a stirrer, adding a polyvinyl alcohol solution, uniformly mixing, adding the rest fine powder materials, mixing for 3min, and forming the materials for later use;
designing a dispersion block into two symmetrical parts, wherein the forming mode is single-side compression forming, the compression surface is a surface of the dispersion block cut along the axis, manufacturing a mould according to a brick shape, designing a semi-cylindrical bulge with the diameter of 20mm-80mm along the length direction on the central line of the compression surface of an upper pressure head, and containing a straight section with the diameter of 1mm-10mm (shown in figures 15 and 16), adding a mixed material to press each part of the dispersion block, the forming pressure is 70MPa-150MPa, and the pressed dispersion block is reserved with a straight section with the diameter of 1mm-10 mm;
drying the pressed two-petal dispersion block at the maximum temperature of 150 ℃ and firing the two-petal dispersion block at the maximum temperature of 1500-1700 ℃ to obtain the two-petal dispersion block;
grinding off the straight section of the two-petal dispersion block, wherein the precision is required to be ensured, and directly and physically combining the two-petal dispersion block after grinding to finish the manufacturing of the dispersion core, wherein the center of the dispersion core naturally forms a cylindrical hollow core with the diameter of 20-80 mm.
The manufacturing method of the diffusion block is one of the cores of the invention, namely two petals are separately pressed, the stress height is lower, so the uniformity of the product can be ensured, then the conical diffusion block is polished and combined, the uniformity degree of the internal structure of the pressed conical diffusion block cannot be realized by pressing single surfaces at two ends, and the production and manufacturing efficiency cannot be realized by isostatic pressing one-step forming.
3, structure for manufacturing dispersive block die and using method
3.1 the mould includes the steel bottom plate comprising straight section, four pieces of detachable steel side plates and steel die frame, in addition there is steel pressure head, the bottom plate cavity is identical to arc appearance of the scattered piece pressed, the bottom plate straight section height is 1mm-10mm, the thickness of the side plate is 20mm-50mm, the effective thickness of the die frame is 50mm-100mm, take the form of oblique angle combination between the adjacent side plates, the oblique angle is 40-50 ° overlook, four side plates, match with die frame cavity after the bottom plate is combined, the contact surface of the die frame and side plate after combining has 1-15 ° demold slightly, side plate after combining and bottom plate can be pushed out of the die frame by the ejector pin in the press under the bottom plate, the size of the pressure head is smaller than the corresponding minimum size of the inner mould matched with it by 0.2mm-10 mm.
The scheme is designed based on the shape characteristics of a pressed product, and the detachable side plate and the product are ejected out simultaneously when the side plate is taken off, so that the product is not damaged, and the scheme has certain advancement.
3.2 using method of the mould: the mold is designed and assembled on the top of the hydraulic press as shown in fig. 12 and 13, and then the pre-mixed material is added.
Slowly pressurizing, setting specific pressure, wherein the pressing position of the pressure head is required to be the upper dotted line shown in figure 12 and figure 13, the pressing position can be controlled by the volume of the fed materials, the height shown by the dotted line is the height of the straight section, and the pressure head is lifted after the pressure is maintained for 20 seconds.
The bottom plate of the mold is pushed up by a press ram, and the bottom plate, the side plates, and the pressed sample block are simultaneously pushed out, as shown in fig. 17.
And after the four side plates are removed, the sample block is moved to a kiln car and is dried after being filled with the sample block.
Cleaning the bottom plate and the side plate, reassembling, and pressing the next scattered block according to the same method.
If the dispersion block with the cylindrical hole needs to be pressed, only a semi-cylindrical core is processed along the length direction of a pressure head when a die is manufactured, and the cylindrical core also comprises a straight section, the height of the straight section is the same as the height of the reserved straight section of the dispersion block and the height of the straight section of a die bottom plate, and other pressing methods are the same as the above.
4, formula of dispersible block
4.1, one or more of plate-shaped corundum with the granularity of 1mm-2mm, white corundum and chromium corundum with the chromium oxide content of 1 wt% -5 wt% are combined according to any proportion, the total amount is 32 wt% -40 wt%, one or more of plate-shaped corundum with the granularity of 0.2mm-0.8mm, white corundum and chromium corundum with the chromium oxide content of 1 wt% -5 wt% are combined according to any proportion, the total amount is 45 wt% -57 wt%, one or more of plate-shaped corundum with the granularity of less than or equal to 325 meshes, white corundum and chromium corundum with the chromium oxide content of 1 wt% -5 wt% are combined according to any proportion, the total amount is 0.5 wt% -11 wt%, alpha alumina micropowder is 1.5 wt% -10 wt%, chromium oxide micropowder is 1 wt% -8 wt%, purity is more than or equal to 99.9%, quartz powder with the granularity of less than or equal to 325 meshes is 2 wt% -5 wt%, 97 percent of silicon dioxide micro powder is 0.02 to 2 percent by weight, and 2 to 5 percent of condensation type polyvinyl alcohol saturated solution is added during forming.
4.2, the total amount of one or more of plate-shaped corundum with the granularity of 0.6-1.4 mm, white corundum and chromium corundum with the chromium oxide content of 1-5 wt% combined according to any proportion is 76-89 wt%, the total amount of one or more of plate-shaped corundum with the granularity of less than or equal to 325 meshes, white corundum and chromium corundum with the chromium oxide content of 1-5 wt% combined according to any proportion is 1-13 wt%, alpha alumina micropowder is 1-12 wt%, chromium oxide micropowder is 1-7 wt%, purity is more than or equal to 99.9%, quartz powder with the granularity of less than or equal to 325 meshes is 1-6 wt%, 97 silica micropowder is 0.1-2 wt%, and a condensation type polyvinyl alcohol saturated solution is added during molding is 2-5 wt%.
4.3 equal-diameter particles with any size and with the particle size range of 1.2mm-1.8mm, can be one or any combination of more of plate-shaped corundum, white corundum and chromium corundum with the chromium oxide content of 1 wt% -5 wt% according to any proportion, the total amount is 37 wt% -42 wt%, any equal-diameter particles with the particle size range of 0.2mm-0.8mm, can be one or any combination of more of plate-shaped corundum, white corundum and chromium corundum with the chromium oxide content of 1 wt% -5 wt% according to any proportion, the total amount is 36 wt% -41 wt%, the total amount of one or any combination of plate-shaped corundum, white corundum and chromium corundum with the particle size of less than or equal to 325 meshes is 2 wt% -14 wt%, the alpha alumina micro powder is 2 wt% -13 wt%, and the chromium oxide micro powder is 2 wt% -11 wt%, the purity is more than or equal to 99.9 percent, the granularity is less than or equal to 325 meshes, the quartz powder accounts for 1.5 to 2.5 weight percent, the 97 silicon dioxide micro powder accounts for 0.3 to 3.5 weight percent, and the condensed polyvinyl alcohol saturated solution accounts for 2 to 5 weight percent when the silica powder is formed.
4.4 formula of the air brick dispersed block is: the equal-diameter particles with any size and the particle size range of 0.8mm-1.2mm can be one or any combination of plate-shaped corundum, white corundum and chrome corundum with the chrome oxide content of 1 wt% -5 wt% according to any proportion, the total amount is 77 wt% -88 wt%, the plate-shaped corundum with the particle size less than or equal to 325 meshes, the total amount of one or more of white corundum and chrome corundum with chrome oxide content of 1 wt% -5 wt% combined according to any proportion is 2 wt% -14 wt%, the alpha alumina micro powder is 3.5 wt% -8 wt%, the chrome oxide micro powder is 1.5 wt% -6 wt%, the purity is more than or equal to 99.9%, the quartz powder with the granularity less than or equal to 325 meshes is 0.5 wt% -4 wt%, the 97 silicon dioxide micro powder is 0.05 wt% -1.8 wt%, and a condensation type polyvinyl alcohol saturated solution is added during forming for 2 wt% -5 wt%.
5, physical indexes of the dispersion block: the cold-state rupture strength after heat preservation for 4 hours at 1685 ℃ is 6MPa to 10MPa, the corresponding compressive strength is 25MPa to 90MPa, the corresponding porosity is 23 percent to 32 percent, and the refractoriness is more than or equal to 1810 ℃.
The invention has the beneficial effects that: each technical scheme has different characteristics and beneficial effects, and is attached to the subsequent technical scheme, in general, the invention aims to make all the refractory material parts of the consumption sections of the air bricks into the dispersion blocks, and because the cross section area of ventilation is enlarged, the ventilation channels in the dispersion blocks can be designed to be smaller, namely the gaps or defects of the dispersion blocks are fewer, the mechanical properties of the dispersion blocks can be naturally improved, and the service life is prolonged, and the invention also has the beneficial effects. The principle of the technical measures adopted by the specification is to avoid the internal unevenness accompanying with the compression molding of the big end and the small end of the dispersion block, so that the dispersion block is divided into two sections which are respectively subjected to single-side compression molding, the uniformity of the dispersion block is ensured, the manufacturing is realized by some necessary technological means such as polishing, and then the measures of reserving a cylindrical core, designing seam castable on the periphery of the dispersion block and the like are all adopted to gradually optimize the technical scheme; the scheme does not adopt an isostatic pressing or casting molding mode to manufacture the conical dispersion block, because the technical means have serious defects or are not mature enough, and an effective and reliable product cannot be provided.
The technical scheme also provides a series of disperse block manufacturing formulas based on other technical schemes, which are greatly different from the traditional disperse block formula, and the design concept of the formula is to properly reduce the ventilation gaps in the disperse block, ensure higher penetration of the gaps and improve the performance index of the disperse block as much as possible, so that the long service life is realized, if larger closed gaps exist, the air permeability is not contributed, and the performance of the material is possibly reduced.
Therefore, it is the ultimate object and benefit of the present invention to produce a long life and functional tapered dispersion air brick for use in large ladles, such as 300 ton refined ladles.
Description of the drawings:
FIG. 1: a section view of a traditional air brick;
FIG. 2: the scattered blocks are not provided with anti-breaking cores, and the fire clay is used for jointing the section view of the air brick;
FIG. 3: the scattered blocks are provided with anti-breaking cores, and the fire clay is used for jointing the section view of the air brick;
FIG. 4: the scattered blocks are not provided with anti-breaking cores, and the section of the air brick is jointed by castable;
FIG. 5: the scattered blocks are provided with anti-breaking cores, and the section view of the air brick is jointed by castable;
FIG. 6: cross-sectional view of the dispersion block without the cylindrical hole after pressing;
FIG. 7: a section view of a dispersion block without a cylindrical hole after polishing;
FIG. 8: a combined rear section view of the dispersion block without the cylindrical hole;
FIG. 9: a cross-sectional view of the pressed dispersed blocks with cylindrical holes;
FIG. 10: a section view of the dispersion block with the cylindrical hole after polishing;
FIG. 11: a combined rear section view of the dispersion block with the cylindrical hole;
FIG. 12: a cross-sectional view of the assembled mold;
FIG. 13: a cross-sectional view of the assembled mold;
FIG. 14: a top view of the assembled mold;
FIG. 15: a cross section schematic diagram of a mold used for the dispersion block with the breakage-proof core after assembly;
FIG. 16: a cross section schematic diagram of a mold used for the dispersion block with the breakage-proof core after assembly;
FIG. 17: and (5) demolding after the mold is ejected out.
In the figure: the method comprises the following steps: dispersing blocks, namely: joint castable, III: base, the four: prevent disconnected core, fifthly: slit, and (c): an anchoring groove, and c: air chamber, (: a cylindrical groove, ninthly: bottom plate, r: the side plate of the mould is provided with a side plate,
the mould frame is provided with a mould frame,
the pressure head is arranged on the upper portion of the pressure head,
the cylindrical core is provided with a cylindrical hole,
block-shaped dispersion block, H: straight section height, D: core breakage prevention, diameter of cylindrical groove, α: die side plate combination angle, β: and (4) demolding angle of the mold.
Detailed Description
1, diffusion Block (r) formula example
Based on the technical scheme, the method is shown in tables 1 to 4:
TABLE 1 diffusion Block (formula example)
TABLE 2 diffusion Block (r) formula example
TABLE 3 Substruction of Substruction (r) formula
TABLE 4 diffusion Block (r) formula example
The formulations listed in tables 1-4 all produced dispersions described in this scheme, with 1# in each table being the optimum formulation.
Example of mold use
Pressing dispersion blocks (I) with the diameters of phi 120 and phi 170 and the height of 380mm respectively.
2.1, designing four side plates of die to have thickness of 50mm in the R, taking height H1 of two side plates in the R as 96mm, taking height H2 of end side plate with big head as 200mm, taking height H3 of end side plate with small head as 176mm, die frame
The effective thickness is 80mm, the top view of the inner cavity is trapezoidal, the size of the lower part is 215mm multiplied by 275mm multiplied by 480mm, the size of the upper part is 223mm multiplied by 283mm multiplied by 488mm, and the demoulding is naturally formedAngle, pressure head
The top view is trapezoidal, with dimensions of 119mm × 169mm × 379 mm.
2.2, the die parts are assembled and fixed on the table top of a hydraulic press with 600 tons as shown in figures 12 and 13, and then the premixed materials are added.
2.3, slowly pressurizing, setting the pressure to 415 tons, requiring the pressing position of the pressure head to be figure 12, controlling the upper broken line shown in figure 13 through the weight of the fed materials, taking the height of the straight section as shown by the broken line, taking 10mm in the example, lifting the pressure head after keeping the pressure for 20 seconds
And 2.4, pushing the bottom plate of the mold by a pressure machine, wherein the bottom plate ninthly, the side plate ninthly and the pressed sample block are simultaneously ejected, as shown in fig. 17.
And 2.5, after removing the four side plates, moving the sample block to a kiln car, and after filling, drying the sample block for baking.
2.6 the bottom plate, the side plates and the holes in the bottom plate are cleaned and then reassembled, and then the next scattered block is pressed according to the same method.
If the dispersion block with the cylindrical hole needs to be pressed, the pressure head is used for pressing the dispersion block with the cylindrical hole only when the die is manufactured
Processing a semi-cylindrical core along the length direction
It should be noted that this cylindrical core also comprises straight sections, the height of which is the same as the height of the straight sections reserved for the diffusion (r), the other pressing methods being the same as those described.
3, air brick manufacturing method example
3.1 preparation method of Dispersion block I
3.1.1 As shown in FIG. 8, the preparation of the diffusion block (r) without cylindrical holes:
preparing materials according to the formula, selecting any formula in the examples, respectively and uniformly mixing all the granular materials and the fine powder materials, adding all the granular materials into a stirrer, then adding a polyvinyl alcohol solution, uniformly mixing, adding the rest fine powder materials, mixing for 3min, and then standby forming the materials;
designing a disperse block I into two symmetrical parts, wherein the forming mode is single-side compression forming, the compression surface is a surface of the disperse block I cut along the axis, a mould is manufactured according to a brick shape, the compression surface of an upper pressure head is a plane, then a mixed material is added to press each part of the disperse block I, the forming pressure is 70MPa-150MPa, such as 80MPa, and a straight section of 1mm-10mm is reserved for the pressed disperse block I, such as 10 mm;
drying the pressed two-petal dispersion block at the maximum of 150 ℃ and firing at the maximum of 1500-1700 ℃, for example firing at 1700 ℃;
grinding off the straight section of the first two-petal dispersion block, wherein the precision is required to be ensured, and the first two-petal dispersion block after grinding is directly and physically combined to finish the first preparation of the dispersion block.
3.1.2 preparation of Dispersion blocks with cylindrical holes (see FIG. 11)
Preparing materials according to the formula, selecting any formula in the examples, respectively and uniformly mixing all the granular materials and the fine powder materials, adding all the granular materials into a stirrer, then adding a polyvinyl alcohol solution, uniformly mixing, adding the rest fine powder materials, mixing for 3min, and then standby forming the materials;
designing a dispersion block into two symmetrical parts, wherein the molding mode is single-side compression molding, the compression surface is a surface of the dispersion block cut along the axis, manufacturing a mold according to a brick shape, designing a semi-cylindrical bulge with the diameter of 20mm-80mm, such as a semi-cylinder with the diameter of 50mm, on the central line of the compression surface of an upper pressure head along the length direction, and containing a straight section with the diameter of 1mm-10mm, such as the straight section with the height of 8mm, then adding a mixed material to press each part of the dispersion block I, wherein the molding pressure is 70MPa-150MPa, reserving a straight section with the diameter of 1mm-10mm for the pressed dispersion block I, and only if the reserved straight section of the dispersion block I is the same as the height of the convex straight section of the semi-cylindrical bulge of the upper pressure head, manufacturing an anti-breaking core with a standard circular cross section;
drying the pressed two-petal dispersion block at the maximum of 150 ℃ and firing at the maximum of 1500-1700 ℃, wherein the firing temperature is 1520 ℃;
grinding the straight section of the first two-petal dispersion block, wherein the precision is required to be ensured, and directly and physically combining the ground first two-petal dispersion block to finish the manufacture of the first dispersion block, wherein a cylindrical hole with the diameter of 20-80mm is naturally formed in the center of the first dispersion block.
3.2 method for manufacturing air brick
3.2.1 making blocks without breaking core and air brick with fire clay seam as shown in FIG. 2
Firstly, manufacturing a base seat, reserving an air chamber up and down, selecting a slit type gas channel, casting, and firing at 1500-1700 ℃, wherein the material is selected from the traditional air brick casting material;
coating fire clay on the outer surface of the combined dispersion block I, pressing the fire clay into a metal shell of the air brick, wherein the thickness of the fire clay is required to be 0.1mm-3mm, and then drying at the maximum temperature of 150 ℃;
after a base is fixed at the corresponding position of the air brick through a clamp and is fixed on a vibration table, seam casting materials are poured around the base, the seam casting materials are traditional air brick casting materials, and the critical granularity of the used raw materials does not exceed one half of the minimum thickness of the seam casting materials and does not exceed 6 mm;
curing at 50-70 deg.C, and baking at 150 deg.C;
and welding the rear cover and the tail pipe of the air brick to complete the manufacture.
3.2.2 making dispersed blocks (without breaking core) and jointing air brick with casting material
Firstly, manufacturing a base seat, reserving an air chamber up and down, selecting a slit type gas channel, casting, and firing at 1500-1700 ℃, wherein the material is selected from the traditional air brick casting material;
physically combining two disperse blocks I, bundling the two disperse blocks I by using a high-strength nylon wire with the diameter of less than 0.5mm, and then fixing a base III and the combined disperse blocks I in a metal shell of an air brick and fixing the base III and the combined disperse blocks I on a vibration table;
pouring joint castable around the base and the dispersion block, wherein the joint castable is traditional air brick castable, and the critical granularity of the used raw materials is not more than one half of the minimum thickness of the joint castable and is not more than 6 mm;
curing at 50-70 deg.C, and baking at 220 deg.C maximum;
and welding the rear cover and the tail pipe of the air brick to complete the manufacture.
3.2.3 making blocks with anti-breaking core (R) as shown in FIG. 3, air brick with fire clay seam
Firstly, manufacturing a base seat, reserving an air chamber up and down, selecting a slit type gas channel, casting, and firing at 1500-1700 ℃, wherein the material is selected from the traditional air brick casting material;
coating fire clay on the outer surface of the combined diffusion block I with the cylindrical hole, pressing the fire clay into a metal shell of the air brick, wherein the thickness of the fire clay is required to be 0.1-3 mm, and then drying at the maximum temperature of 150 ℃;
fixing the baked semi-finished product on a vibrating table, pouring a high-performance pouring material into cylindrical holes of a dispersed block I, wherein the critical granularity of the pouring material is required to be not more than 6mm, the cold-state breaking strength at 1620 ℃ is more than or equal to 36MPa, the corresponding linear change rate is between + 0.08% and + 0.25%, the refractoriness is more than or equal to 1810 ℃, after the high-performance pouring material is poured, naturally solidifying the high-performance pouring material at the temperature of between 20 and 35 ℃, and then baking the high-performance pouring material at the maximum temperature of 150 ℃;
after a base is fixed at the corresponding position of the air brick through a clamp and is fixed on a vibration table, seam casting materials are poured around the base, the seam casting materials are traditional air brick casting materials, the critical granularity of the used raw materials does not exceed one half of the minimum thickness of the seam casting materials and does not exceed 6 mm;
curing at 50-70 deg.C, and baking at 150 deg.C;
and welding the rear cover and the tail pipe of the air brick to complete the manufacture.
3.2.4 making blocks with anti-breaking core and air brick with pouring material seam as shown in FIG. 5
Firstly, manufacturing a base seat, reserving an air chamber up and down, selecting a slit type gas channel, casting, and firing at 1500-1700 ℃, wherein the material is selected from the traditional air brick casting material;
physically combining two disperse blocks I, bundling the two disperse blocks I by using a high-strength nylon wire with the diameter of less than 0.5mm, and fixing the combined disperse blocks I together in a metal shell of an air brick and on a vibration table;
pouring a seam pouring material around the dispersion block, wherein the seam pouring material is a traditional air brick pouring material, and the critical granularity of the raw materials is not more than one half of the minimum thickness of the seam pouring material and is not more than 6 mm;
after the casting material is poured, curing at 50-70 ℃ and baking at the maximum temperature of 150 ℃;
fixing the finished product on a vibrating table, pouring a high-performance pouring material into cylindrical holes of the dispersed blocks I, wherein the critical granularity of the pouring material is required to be not more than 6mm, the cold-state breaking strength at 1620 ℃ is more than or equal to 36MPa, the corresponding linear change rate is between + 0.08% and + 0.25%, the refractoriness is more than or equal to 1810 ℃, naturally solidifying at 20-35 ℃ after the high-performance pouring material is poured, and then baking at the maximum temperature of 150 ℃;
after a base is fixed at the corresponding position of the semi-finished product through a clamp and is fixed on a vibration table, seam casting materials are poured around the base, the seam casting materials are traditional air brick casting materials, the critical granularity of the used raw materials does not exceed one half of the minimum thickness of the seam casting materials and does not exceed 6 mm;
curing at 50-70 deg.C, and baking at 150 deg.C;
and welding the rear cover and the tail pipe of the air brick to complete the manufacture.
Claims (1)
1. The manufacturing method of the anti-breaking combined tapered dispersion air brick is characterized by comprising the following steps:
1.1 preparation of the dispersion block with the anti-breaking core:
preparing materials according to a formula, respectively and uniformly mixing all the granular materials and the fine powder materials, adding all the granular materials into a stirrer, adding a polyvinyl alcohol solution, uniformly mixing, adding the rest fine powder materials, mixing for 3min, and forming the materials for later use;
designing a dispersion block into two symmetrical parts, wherein the forming mode is single-side compression forming, the compression surface is a surface of the dispersion block cut along the axis, manufacturing a mould according to a brick shape, designing a semi-cylindrical bulge with the diameter of 20mm-80mm along the length direction on the central line of the compression surface of an upper pressure head, and containing a straight section with the diameter of 1mm-10mm, then adding mixed materials to press each part of the dispersion block, the forming pressure is 70MPa-150MPa, and the pressed dispersion block is reserved with the straight section with the diameter of 1mm-10 mm;
drying the pressed two-petal dispersion block at the maximum temperature of 150 ℃ and firing the two-petal dispersion block at the maximum temperature of 1500-1700 ℃ to obtain the two-petal dispersion block;
grinding off the straight section of the two-petal dispersion block, wherein the precision is required to be ensured, and the two-petal dispersion block after grinding is directly and physically combined to finish the manufacturing of the dispersion core, wherein the center of the dispersion core naturally forms a cylindrical hollow with the diameter of 20-80 mm;
1.2 disperse block belt anti-breaking core, with the preparation of fire clay seam air brick:
firstly, a base (3) is manufactured, an air chamber (7) is reserved above and below the base (3), a slit type (5) is selected for an air channel, the base is formed by casting and is fired at 1500-1700 ℃, and the material is selected from the traditional air brick casting material;
coating fire clay on the outer surface of the combined dispersion block with the cylindrical hollow structure and pressing the dispersion block into a metal shell of the air brick, wherein the thickness of the fire clay is required to be 0.1-3 mm, and then drying the dispersion block at the maximum temperature of 150 ℃;
fixing the baked semi-finished product on a vibrating table, pouring a high-performance pouring material into the cylindrical hollow of the dispersed block, wherein the critical granularity of the pouring material is required to be not more than 6mm, the cold-state breaking strength at 1620 ℃ is more than or equal to 36MPa, the corresponding linear change rate is between + 0.08% and + 0.25%, the refractoriness is more than or equal to 1810 ℃, after the high-performance pouring material is poured, naturally solidifying the high-performance pouring material at the temperature of between 20 and 35 ℃, and then baking the high-performance pouring material at the maximum temperature of 150 ℃;
after the base is fixed at the corresponding position of the air brick through a clamp and is fixed on a vibration table, pouring joint castable (2) around the base (3), wherein the joint castable (2) is the traditional air brick castable, and the critical granularity of raw materials used by the joint castable (2) is not more than one half of the minimum thickness of the joint castable (2) and is not more than 6 mm;
curing at 50-70 deg.C, and baking at 150 deg.C;
welding the rear cover and the tail pipe of the air brick to complete the manufacture;
1.3 the dispersed block with anti-breaking core, and the making of the air brick with casting material joint:
firstly, a base (3) is manufactured, an air chamber (7) is reserved above and below the base (3), a slit type (5) is selected for an air channel, the base is formed by casting and is fired at 1500-1700 ℃, and the material is selected from the traditional air brick casting material;
physically combining the two sections of dispersion blocks, bundling the dispersion blocks by using a high-strength nylon wire with the diameter of less than 0.5mm, and fixing the combined dispersion blocks in a metal shell of the air brick and on a vibration table;
pouring a seam pouring material (2) around the dispersion block, wherein the seam pouring material (2) is a traditional air brick pouring material, and the critical granularity of raw materials used by the seam pouring material (2) is not more than one half of the minimum thickness of the seam pouring material (2) and is not more than 6 mm;
after the casting material is poured, curing at 50-70 ℃ and baking at the maximum temperature of 150 ℃;
fixing the finished product on a vibrating table, pouring a high-performance pouring material into the cylindrical hollow part of the dispersed block, wherein the critical granularity of the pouring material is required to be not more than 6mm, the cold-state breaking strength at 1620 ℃ is more than or equal to 36MPa, the corresponding linear change rate is between + 0.08% and + 0.25%, the refractoriness is more than or equal to 1810 ℃, after the high-performance pouring material is poured, naturally solidifying the high-performance pouring material in the environment of 20-35 ℃, and then baking the high-performance pouring material at the maximum temperature of 150 ℃;
after the base is fixed at the corresponding position of the semi-finished product through a clamp and is fixed on a vibration table, pouring joint castable (2) around the base (3), wherein the joint castable (2) is a traditional air brick castable, and the critical granularity of raw materials used by the joint castable (2) is not more than one half of the minimum thickness of the joint castable (2) and is not more than 6 mm;
curing at 50-70 deg.C, and baking at 150 deg.C;
and welding the rear cover and the tail pipe of the air brick to complete the manufacture.
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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 |
| CN106380214A (en) * | 2016-08-31 | 2017-02-08 | 长兴科特碳化硅有限公司 | Composite diffusion air-permeable brick for ladles, and production method thereof |
| CN106588098A (en) * | 2017-01-09 | 2017-04-26 | 武汉科技大学 | Dispersion corundum-spinel air brick and preparation method thereof |
| CN107117951A (en) * | 2017-05-27 | 2017-09-01 | 武汉科技大学 | A kind of high-strength dispersive air brick and preparation method thereof |
| CN107199330A (en) * | 2017-04-06 | 2017-09-26 | 洛阳利尔耐火材料有限公司 | A kind of ladle complex air-permeable brick and preparation method thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105859309A (en) * | 2016-03-31 | 2016-08-17 | 武汉科技大学 | Dispersive air brick and preparation method thereof |
| CN106380214A (en) * | 2016-08-31 | 2017-02-08 | 长兴科特碳化硅有限公司 | Composite diffusion air-permeable brick for ladles, and production method thereof |
| CN106588098A (en) * | 2017-01-09 | 2017-04-26 | 武汉科技大学 | Dispersion corundum-spinel air brick and preparation method thereof |
| CN107199330A (en) * | 2017-04-06 | 2017-09-26 | 洛阳利尔耐火材料有限公司 | A kind of ladle complex air-permeable brick and preparation method thereof |
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