CN110642631A - 一种铁水包内衬用捣打料及其制备方法 - Google Patents
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Abstract
本发明涉及一种铁水包内衬用捣打料及其制备方法,其原料组成质量百分比为:所述的硅石为52~57%,高铝矾土为20~23%,粘土为5~10%,石墨为5~15%,粉煤灰为0.1~5%,碳化硅粉为0.2~5%,铬渣粉为0.1~3%,硅酸钠为0.1~1%,聚磷酸铝为0.1~1%。本发明的优点:使用过程中结构强度较高,不会在使用过程中发生松动、剥落等损坏而导致漏包事故,保障了铁水包吊运过程中周边的人身和设备安全,同时不会发生铁水粘包现象,避免渣中包裹铁水,提高铁水的回收率,在安全性和经济性方面都有极大的提升。
Description
技术领域
本发明属于硅铁生产技术领域,具体涉及一种铁水包内衬用捣打料及其制备方法。
背景技术
在硅铁生产中,装盛铁水的铁水包属于主要设备,铁水包质量的好坏,尤其是内部耐火材料的好坏直接影响到铁水包使用过程中的安全性(尤其是发生穿包事故)、铁水回收率以及修包的工作量。传统硅铁生产用铁水包结构由钢壳和内衬耐火材料组成,内衬耐火材料常用粘土砖砌筑,在使用过程中存在较多缺点:例如安全系数低,时有发生穿包事故甚至漏包事故,每漏一次包损失至少在万元以上,对铁水包吊运过程周边的人身和设备安全带来极大的隐患,同时铁水粘包比较严重,大量铁水随渣而处理掉,带来了极大的浪费。
发明内容
本发明的目的在于克服现有技术的不足,提供一种铁水包内衬用捣打料及其制备方法。本发明制备的捣打料结构强度较高,同时不会发生铁水粘包现象,避免渣中包裹铁水,提高了铁水的回收率,在安全性和经济性方面都有极大的提升。
本发明的目的是通过以下技术方案来实现的:
一种铁水包内衬用捣打料,以质量百分比计,其原料组成为:骨料为72~80%,粉料为10.1~30%,抗侵蚀剂为0.3~8%,结合剂为0.2~2%;
所述的骨料包括硅石和高铝矾土,粉料包括粘土、石墨和粉煤灰,抗侵蚀剂包括碳化硅粉和铬渣粉,结合剂包括硅酸钠和聚磷酸铝。
优选地,以捣打料总量计,所述的硅石为52~57%,高铝矾土为20~23%,粘土为5~10%,石墨为5~15%,粉煤灰为0.1~5%,碳化硅粉为0.2~5%,铬渣粉为0.1~3%,硅酸钠为0.1~1%,聚磷酸铝为0.1~1%;
优选地,以捣打料总量计,所述的硅石为55%,高铝矾土为20%,粘土为8%,石墨为9.5%,粉煤灰为2.5%,碳化硅粉为1.5%,铬渣粉为2.3%,硅酸钠为0.4%,聚磷酸铝为0.8%。
优选地,以硅石总量计,所述的硅石粒度分布为:6~7mm占16%,5~6mm占17%,4~5mm占17%,3~4mm占24%,2~3mm占26%;
优选地,以高铝矾土总量计,所述的高铝矾土粒度分布为:4~5mm占12%,3~4mm占16%,2~3mm占17.5%,1~2mm占22.5%,0.38~1mm占32%;所述的粘土、石墨、粉煤灰、碳化硅粉、铬渣粉粒度均≧200目;所述的硅酸钠、聚磷酸铝为固态粉体。
所述的硅石爆裂率≧80%,SiO2含量≧98%;所述的高铝矾土中Al2O3含量≧80%,Fe2O3含量≦2%,TiO2含量≦4%,CaO+MgO含量≦0.6%,K2O+Na2O含量≦0.6%,体积密度≧2.75g/cm3;所述的粘土中SiO2含量≧44%,Al2O3含量≧37%,Fe2O3含量≦2%,TiO2含量≦2%,CaO+MgO含量≦0.8%,K2O+Na2O含量≦0.8%;所述的粉煤灰中SiO2含量≧50%,Al2O3含量≧31%,Fe2O3含量≦6%,CaO+MgO含量≦4.5%,失重≦5%;所述的铬渣粉中Cr2O3含量≧12%,SiO2+Al2O3含量≧38%,CaO+MgO含量≦40%,Fe2O3含量≦0.3%。
本发明的另一目的在于提供一种铁水包内衬用捣打料的制备方法,步骤为:
(1)依重量百分比称取硅酸钠、聚磷酸铝,按照重量比为1:3的比例添加3倍重量的水,并加热到50℃下搅拌,直到硅酸钠、聚磷酸铝全部溶于水中,形成外加剂溶液;
(2)依重量百分比称取粘土、石墨、粉煤灰、碳化硅粉、铬渣粉先进行预混合,再加入硅石、高铝矾土进行混合,形成配合料,在混合的过程中,雾化加入外加剂溶液;
(3)按照配合料:水的重量比为9:1的比例称取自来水,边搅拌边添加到配合料中,搅拌时间为6分钟,形成湿基捣打料;
(4)将湿基捣打料涂抹于铁水包内壁的模具间隙中,进行捣打操作。
本发明的硅石和高铝矾土作为骨料,在捣打料中起到骨架的作用,尤其是在高温条件下,具有良好的物理力学性能,具有较高的耐火度,能够承受高温铁水和浮渣的侵蚀与冲刷,同时低成本骨料的大量引入,降低了耐火捣打料的成本。本发明中当硅石和高铝矾土总的重量百分比小于72%时,在铁水从矿热炉流入铁水包的冲刷点易被冲刷侵蚀,该处捣打料层变薄而降低铁水包的使用寿命,此时由于粉体原料过多,在高温铁水冲刷过程中易于脱落,降低硅铁产品的品质;当硅石和高铝矾土总的重量百分比大于80%时,在捣打料烘烤过程中易于生成大量的微裂纹,使用过程中铁水易于沿缝隙向捣打料内部加速侵蚀,从而降低铁水包的使用寿命;当硅石和高铝矾土总的重量百分比在72~80%时,达到使用性能的最佳范围区间,烘烤过程中不易出现裂纹,提高了捣打料铁水包内的表面质量,从而形成致密的耐火层,同时骨料充足,抗铁水冲刷性能优异,铁水包使用次数较多。
本发明的粘土、石墨和粉煤灰作为粉料,起填充骨料空隙、改善加工操作性能、避免粘渣粘铁水性、增强料性等作用,同时还具有良好的结合性能,填充于骨料所造成的间隙,达到最佳的堆积密度,便于获得最佳的使用性能,此外,粉料可以排挤出气孔中的水从而降低捣打料的加水量;引入工业固废粉煤灰使得捣打层的保温效率高,耐火度高,热导率小,能减轻捣打层厚度、缩短烧成时间、降低燃料消耗、提高热效率、降低成本。本发明中当粘土、石墨和粉煤灰总的重量百分比小于10%时,在捣打料配比中粉料过少,粉料不能有效填充骨料的间隙,导致在骨料中有大量的微小空隙存在,同时降低了骨料之间的结合性,烘烤后的捣打料强度严重不足,易于脱落,在使用过程中存在极大的安全隐患,同时捣打层中大量的空隙存在,降低了铁水包的使用次数,且易发生穿包事故;当粘土、石墨和粉煤灰总的重量百分比大于30%时,捣打料中的粉料过多,导致烘烤后的强度降低,且烘烤过程中易于生成大量的微裂纹,使用过程中铁水易于沿缝隙向捣打料内部加速侵蚀,同时提高了原料的成本;当粘土、石墨和粉煤灰总的重量百分比在10.1~30%时,达到使用性能的最佳范围区间,粉料填充大、中、小颗粒之间的气孔以提高捣打料坯体的体积密度与降低气孔率,同时由于排挤出气孔中的水可以降低捣打料的加水量,提高了烘烤后捣打层的强度以及铁水包的使用次数。
本发明的碳化硅粉和铬渣粉作为抗侵蚀剂,极大的提升了捣打料抗铁水和渣的侵蚀、冲刷性能,降低了捣打层的粘渣、粘铁水性,提高了捣打层在使用过程中的耐火度、耐热震性,同时将难以处置的工业危废铬渣粉变废为宝,发挥其最大的经济性。本发明中当碳化硅粉和铬渣粉总的重量百分比小于0.3%时,上述优异效果不显著,使用效果不明显;当碳化硅粉和铬渣粉总的重量百分比大于8%时,会导致捣打料中粉体原料过多,导致烘烤后的强度降低,且烘烤过程中易于生成大量的微裂纹,使用过程中铁水易于沿缝隙向捣打料内部加速侵蚀,同时提高了原料的成本;当碳化硅粉和铬渣粉总的重量百分比在0.3~8%时,达到使用性能的最佳范围区间,且性价比较高,利用工业危废铬渣粉添加量较多。
本发明的硅酸钠和聚磷酸铝作为结合剂,在提升捣打料的耐高温、抗震动、抗剥落、耐高温气流、铁水冲刷性能方面优异,使得捣打料的物料之间固化结合能力强,同时配料方便、快捷,在改善捣打料的耐火可塑性、耐侵蚀性都很优异。本发明中当硅酸钠和聚磷酸铝总的重量百分比小于0.2%时,上述优异效果不显著,使用效果难以达到预期水平;当硅酸钠和聚磷酸铝总的重量百分比大于2%时,铁水包在使用过程中易于析出大量低熔点物质,导致粘渣现象比较严重,尤其是大大的增加了原料成本;当硅酸钠和聚磷酸铝总的重量百分比在0.2~2%时,达到使用性能的最佳范围区间,且性价比较高。
本发明的骨料组成中,硅石为52~57%,高铝矾土为20~23%,二者的比例组合有利于提高捣打料的耐火度及抗铁水的冲刷和侵蚀能力,捣打层在铁水包烤包过程中不易产生裂纹;该比例组合下配置的捣打料在铁水包使用的过程中效果显著,同时具有性价比较高的优势。
本发明的粉料组成中,粘土为5~10%,石墨为5~15%,粉煤灰为0.1~5%,三者的比例组合既满足了烧结后捣打料之间结合的作用,同时提高了捣打料烘烤后的强度、耐火度及抗铁水的冲刷和侵蚀性能,减少捣打层内部裂纹的生成,同时改善捣打料的加工操作性能、避免粘渣粘铁水性、增强料性等作用,填充于骨料所造成的间隙,达到最佳的堆积密度;该比例组合下配置的捣打料在铁水包使用的过程中效果显著,同时具有性价比较高的优势。
本发明的抗侵蚀剂组成中,碳化硅粉为0.2~5%,铬渣粉为0.1~3%,二者的比例组合极大的提升了捣打料抗铁水和渣的侵蚀、冲刷性能,降低了捣打层的粘渣、粘铁水性,提高了捣打层在使用过程中的耐火度、耐热震性;该比例组合下配置的捣打料在铁水包使用的过程中效果显著,同时具有性价比较高、将难以处置的工业危废铬渣粉变废为宝的优势。
本发明的结合剂组成中,硅酸钠为0.1~1%,聚磷酸铝为0.1~1%,二者的比例组合使得捣打料的物料之间固化结合能力大大提升,从而显著改善捣打料的耐高温、抗震动、抗剥落、耐高温气流、铁水冲刷性能,在加工过程中提高了捣打料的耐火可塑性;该比例组合下配置的捣打料在铁水包使用的过程中效果显著,同时具有性价比较高的优势。
本发明的骨料组成中,硅石粒度分布为:6~7mm占16%,5~6mm占17%,4~5mm占17%,3~4mm占24%,2~3mm占26%;高铝矾土粒度分布为:4~5mm占12%,3~4mm占16%,2~3mm占17.5%,1~2mm占22.5%,0.38~1mm占32%;二者的粒度分布及比例组合有利于颗粒之间的穿插、咬合和钉销作用、可提高结合强度,有利于改善泥料的流变性、提高触变性、从而有利于提高体积密度,使得捣打料达到最紧密堆积;该比例组合下配置的捣打料在铁水包使用的过程中效果显著,同时具有性价比较高的优势。
先称取粘土、石墨、粉煤灰、碳化硅粉、铬渣粉进行预混合,是为了促使粉体原料之间混合均匀,尤其是含量较少的粉体原料;再加入硅石、高铝矾土进行混合,使得骨料和粉体原料之间混合均匀,有利于填充骨料空隙,达到最佳的堆积密度,便于获得最佳的使用性能,此外,粉料可以排挤出气孔中的水从而降低捣打料的加水量。
在配合料的混合过程中,加入雾化的外加剂溶液,有利于结合剂硅酸钠、聚磷酸铝与其他粉体原料的充分混合,并使表面附着结合剂的粉体原料均匀的包裹在骨料的表面,可提高物料之间的结合强度,改善泥料的流变性、提高触变性、从而有利于提高体积密度,使得捣打料达到最紧密堆积。
与现有技术相比,本发明的积极效果是:
(1)采用捣打料作铁水包内衬,具有较高的热震稳定性、耐浸蚀性和抗穿透性,使用中捣打层粘铁粘渣少,无裂纹及剥落;
(2)使用寿命长,结构强度较高,不会在使用过程中发生松动、剥落等损坏而导致漏包事故,保障了铁水包吊运过程中周边的人身和设备安全;
(3)不会发生铁水粘包现象,避免渣中包裹铁水,提高铁水的回收率,在安全性和经济性方面都有极大的提升。
(4)本发明所指的铁水包内部耐火材料分为两层,外层属于永久层,不与铁水接触,内层直接与铁水接触,定期更换,属于内衬用捣打料。
(5)本发明属于内衬用捣打料,在使用过程中结构强度较高,不会在使用过程中发生松动、剥落等损坏而导致漏包事故,保障了铁水包吊运过程中周边的人身和设备安全,同时不会发生铁水粘包现象,避免渣中包裹铁水,提高铁水的回收率,在安全性和经济性方面都有极大的提升。
附图说明
图1:本发明铁水包结构俯视图;
附图中标记的具体含义如下:1为捣打料,2为永久层,3为外壳,4为出铁嘴,5为铁水包腔。
现结合附图和实施例对本发明作进一步说明:
具体实施方式
本发明实施例1-4中的原料组成见表1;
本发明实施例1-4中所述铁水包内衬用捣打料的制备方法,步骤为:
(1)依重量百分比称取硅酸钠、聚磷酸铝,按照重量比为1:3的比例添加3倍重量的水,并加热到50℃下搅拌,直到硅酸钠、聚磷酸铝全部溶于水中,形成外加剂溶液;
(2)依重量百分比称取粘土、石墨、粉煤灰、碳化硅粉、铬渣粉先进行预混合,再加入硅石、高铝矾土进行混合,形成配合料,在混合的过程中,雾化加入外加剂溶液;
(3)按照配合料:水的重量比为9:1的比例称取自来水,边搅拌边添加到配合料中,搅拌时间为6分钟,形成湿基捣打料;
(4)将湿基捣打料涂抹于铁水包内壁的模具间隙中,进行捣打操作。
并根据《GB/T 4513.6-2017不定性耐火材料第6部分:物理性能的测定》及《GB8932.3-1988致密耐火浇注料常温抗折强度和耐压强度试验方法》标准测试本发明实施例1-4中的性能参数,见表1;
表1原料组成及性能参数
由此说明,本发明提供的铁水包内衬用捣打料具有较好的性能参数。
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员,在不脱离本发明构思的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围内。
Claims (6)
1.一种铁水包内衬用捣打料,其特征在于,按照质量百分比计,其原料组成为:骨料为72~80%,粉料为10.1~30%,抗侵蚀剂为0.3~8%,结合剂为0.2~2%;所述的骨料包括硅石和高铝矾土,粉料包括粘土、石墨和粉煤灰,抗侵蚀剂包括碳化硅粉和铬渣粉,结合剂包括硅酸钠和聚磷酸铝。
2.如权利要求1所述的一种铁水包内衬用捣打料,其特征在于,以捣打料总量计,所述的硅石为52~57%,高铝矾土为20~23%,粘土为5~10%,石墨为5~15%,粉煤灰为0.1~5%,碳化硅粉为0.2~5%,铬渣粉为0.1~3%,硅酸钠为0.1~1%,聚磷酸铝为0.1~1%。
3.如权利要求1所述的一种铁水包内衬用捣打料,其特征在于,以捣打料总量计,所述的硅石为55%,高铝矾土为20%,粘土为8%,石墨为9.5%,粉煤灰为2.5%,碳化硅粉为1.5%,铬渣粉为2.3%,硅酸钠为0.4%,聚磷酸铝为0.8%。
4.如权利要求1所述的一种铁水包内衬用捣打料,其特征在于,以硅石总量计,所述的硅石粒度分布为:6~7mm占16%,5~6mm占17%,4~5mm占17%,3~4mm占24%,2~3mm占26%;
以高铝矾土总量计,所述的高铝矾土粒度分布为:4~5mm占12%,3~4mm占16%,2~3mm占17.5%,1~2mm占22.5%,0.38~1mm占32%;
所述的粘土、石墨、粉煤灰、碳化硅粉、铬渣粉粒度均≧200目;所述的硅酸钠、聚磷酸铝为固态粉体。
5.如权利要求1所述的一种铁水包内衬用捣打料,其特征在于,所述的硅石爆裂率≧80%,SiO2含量≧98%;所述的高铝矾土中Al2O3含量≧80%,Fe2O3含量≦2%,TiO2含量≦4%,CaO+MgO含量≦0.6%,K2O+Na2O含量≦0.6%,体积密度≧2.75g/cm3;所述的粘土中SiO2含量≧44%,Al2O3含量≧37%,Fe2O3含量≦2%,TiO2含量≦2%,CaO+MgO含量≦0.8%,K2O+Na2O含量≦0.8%;所述的粉煤灰中SiO2含量≧50%,Al2O3含量≧31%,Fe2O3含量≦6%,CaO+MgO含量≦4.5%,失重≦5%;所述的铬渣粉中Cr2O3含量≧12%,SiO2+Al2O3含量≧38%,CaO+MgO含量≦40%,Fe2O3含量≦0.3%。
6.如权利要求1所述的一种铁水包内衬用捣打料的制备方法,其具体步骤为:
(1)依重量百分比称取硅酸钠、聚磷酸铝,按照重量比为1:3的比例添加3倍重量的水,并加热到50℃下搅拌,直到硅酸钠、聚磷酸铝全部溶于水中,形成外加剂溶液;
(2)依重量百分比称取粘土、石墨、粉煤灰、碳化硅粉、铬渣粉先进行预混合,再加入硅石、高铝矾土进行混合,形成配合料,在混合的过程中,雾化加入外加剂溶液;
(3)按照配合料:水的重量比为9:1的比例称取自来水,边搅拌边添加到配合料中,搅拌时间为6分钟,形成湿基捣打料;
(4)将湿基捣打料涂抹于铁水包内壁的模具间隙中,进行捣打操作。
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