CN111004019B - 焚烧炉二次风口部位内衬的制备方法 - Google Patents

焚烧炉二次风口部位内衬的制备方法 Download PDF

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CN111004019B
CN111004019B CN201911214809.3A CN201911214809A CN111004019B CN 111004019 B CN111004019 B CN 111004019B CN 201911214809 A CN201911214809 A CN 201911214809A CN 111004019 B CN111004019 B CN 111004019B
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王永萍
潘宇峰
赵玲娣
高立
陆兆鑫
李剑锋
王捷
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Shanghai Baosteel Industry Technological Service Co Ltd
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Abstract

本发明公开了一种焚烧炉二次风口部位内衬的制备方法，本方法按焚烧炉二次风口截面径向四等分构成四块耐火砖，按耐火砖形状制作模具；选用板状刚玉、煅烧氧化铝粉、超细氧化铝粉、纯铝酸钙水泥以及复合高效外加剂制作耐火砖浇注料；将制作的耐火砖浇注料通过套模具制成四块耐火砖，四块耐火砖脱模后以常温至400℃的烘烤曲线进行烘烤；耐火砖烘烤后常温下冷却，制得焚烧炉二次风口部位内衬。本方法传统焚烧炉二次风口部位内衬制备的缺陷，减少模具费用，降低维修成本，提高内衬使用寿命及修复效率。

Description

焚烧炉二次风口部位内衬的制备方法
技术领域
本发明涉及工业炉窑修复技术领域，尤其涉及一种焚烧炉二次风口部位内衬的制备方法。
背景技术
本方法涉及的焚烧炉是处理沥青焦回转窑排出废气的一种设备，该焚烧炉运行附件较多，包括与管道相连的一次空气口、二次空气口、预热空气孔等，其连接处均采用浇注形式结构。如图1所示，炉壁1间隔设有二次空气口2，二次空气口2外覆盖有连通的二次空气通入管道3，因此,在二次风口部位内衬修复中，二次风口接口部位不能拆除，无法实现在线浇注修复。因此，传统的焚烧炉二次风口部位内衬制备中，一般采用耐火组合砖砌筑的方法，如图2和图3所示，二次风口沿水平方向截面呈梯形、沿垂直方向截面为矩形体4，矩形体4居中设有圆孔41，该圆孔41在梯形的小头端面设有球面42，该矩形体以截面径向等分划分为八块耐火砖，并在矩形体截面四角划分为四块耐火砖，共计十二块耐火砖构成二次风口部位内衬.该部位结构复杂，砖型多而复杂，涉及十二种砖型，且每种砖型数量少，导致高额的模具费用投入，极大提高了维修成本，降低修复效率。
发明内容
本发明所要解决的技术问题是提供一种焚烧炉二次风口部位内衬的制备方法，本方法传统焚烧炉二次风口部位内衬制备的缺陷，减少模具费用，降低维修成本，提高内衬使用寿命及修复效率。
为解决上述技术问题，本发明焚烧炉二次风口部位内衬的制备方法包括如下步骤：
步骤一、按焚烧炉二次风口截面径向四等分构成四块耐火砖，按四块耐火砖形状分别制作四套模具；
步骤二、选用以重量百分比计的70～80%板状刚玉、5～10%煅烧氧化铝粉、5～10%超细氧化铝粉和10～20%纯铝酸钙水泥，并添加复合高效外加剂制作耐火砖浇注料；
步骤三、将制作的耐火砖浇注料分别浇注于四套模具制成四块耐火砖，四块耐火砖脱模后进行烘烤；
步骤四、耐火砖烘烤在常温～60℃范围内保温2小时，在60～110℃范围内升温速度为5℃/h，保温10小时；在110～200℃范围内升温速度为10℃/h，保温10小时；在200℃时保温2小时；在200～300℃范围内升温速度为10℃/h，保温10小时；在300℃时保温2小时，在300～400℃范围内升温速度为20℃/h，保温5小时；在400℃时保温4小时；
步骤五、耐火砖烘烤后常温下冷却，制得焚烧炉二次风口部位内衬。
进一步，所述板状刚玉的粒度为8～0mm。
进一步，所述复合高效外加剂为牌号为T390S的高纯分散剂和硼酸，其中T390S的高纯分散剂添加量为耐火砖浇注料重量的0.06～0.15%，硼酸添加量为耐火砖浇注料重量的0.01～0.05%。
由于本发明焚烧炉二次风口部位内衬的制备方法采用了上述技术方案，即本方法按焚烧炉二次风口截面径向四等分构成四块耐火砖，按耐火砖形状制作模具；选用板状刚玉、煅烧氧化铝粉、超细氧化铝粉、纯铝酸钙水泥以及复合高效外加剂制作耐火砖浇注料；将制作的耐火砖浇注料通过套模具制成四块耐火砖，四块耐火砖脱模后以常温至400℃的烘烤曲线进行烘烤；耐火砖烘烤后常温下冷却，制得焚烧炉二次风口部位内衬。本方法传统焚烧炉二次风口部位内衬制备的缺陷，减少模具费用，降低维修成本，提高内衬使用寿命及修复效率。
附图说明
下面结合附图和实施方式对本发明作进一步的详细说明：
图1为焚烧炉二次风口示意图；
图2为焚烧炉二次风口截面示意图；
图3为图2的A-A向视图。
图4为本方法中二次风口截面等分示意图；
图5为本方法制得的耐火砖示意图。
具体实施方式
实施例如图4和图5所示，本发明焚烧炉二次风口部位内衬的制备方法包括如下步骤：
步骤一、按焚烧炉二次风口截面4径向四等分构成四块耐火砖43，按四块耐火砖43形状分别制作四套模具；
步骤二、选用以重量百分比计的70～80%板状刚玉、5～10%煅烧氧化铝粉、5～10%超细氧化铝粉和10～20%纯铝酸钙水泥，并添加复合高效外加剂制作耐火砖浇注料；
步骤三、将制作的耐火砖浇注料分别浇注于四套模具制成四块耐火砖43，四块耐火砖43脱模后进行烘烤；
步骤四、耐火砖43烘烤在常温～60℃范围内保温2小时，在60～110℃范围内升温速度为5℃/h，保温10小时；在110～200℃范围内升温速度为10℃/h，保温10小时；在200℃时保温2小时；在200～300℃范围内升温速度为10℃/h，保温10小时；在300℃时保温2小时，在300～400℃范围内升温速度为20℃/h，保温5小时；在400℃时保温4小时；
步骤五、耐火砖43烘烤后常温下冷却，制得焚烧炉二次风口部位内衬。
优选的，所述板状刚玉的粒度为8～0mm。
优选的，所述复合高效外加剂为牌号为T390S的高纯分散剂和硼酸，其中T390S的高纯分散剂添加量为耐火砖浇注料重量的0.06～0.15%，硼酸添加量为耐火砖浇注料重量的0.01～0.05%。T390S高纯分散剂为武汉善达化工有限公司专门针对耐火材料浇注料研发、设计的高纯分散剂，由最新技术研制的聚乙二醇合成技术，经过独特的分子链设计，使得该产品在浇注料使用中具有极佳的流动性和高减水率，特别是在含有金属铝的浇注料中进行完美匹配，解决了传统羧酸减水剂遇到金属铝出现鼓胀现象。
本方法制得的焚烧炉二次风口部位内衬可在二次空气通入管道不拆除的前提下，对二次风口部位内衬进行砌筑更换，降低维修成本，确保的炉衬使用寿命。
本方法将二次风口部位内衬划分为四块耐火砖，并相应的制作模具降低至4套，与原组合砖砌筑方法相比，极大减少了模具的数量，降低二次风口部位内衬的制作成本。同时，将制得的耐火砖按常温至400℃的烘烤曲线进行烘烤，比传统二次风口部位内衬烧成温度大大降低，节省能源，降低碳排放。采用本方法的浇注料以及烘烤曲线制得的耐火砖各项指标如下表所示，
指标项目 单 位 保证值 典型值
体积密度110℃ kg/m<sup>3</sup> <u>&gt;</u> 2600 2620
施工用量 kg/m<sup>3</sup> 2570
重烧线收缩（加热5小时）
815℃ % -0.1
1000℃ % <u>&lt;</u> 0.3 -0.1
1200℃ % -0.1
1400℃ % -0.2
常温耐压强度（加热5小时）
110℃ MPa <u>&gt;</u> 40 66.7
1000℃ MPa <u>&gt;</u> 40 60.8
1200℃ MPa 59.8
1400℃ MPa 58.3
平均温度下的导热系数
600℃ W / m K 1.6
800℃ W / m K 1.45
1000℃ W / m K 1.35
化学成分
Al<sub>2</sub>O<sub>3</sub> % <u>&gt;</u>92 94.1
S iO<sub>2</sub> % ≤0.1
Fe<sub>2</sub>O<sub>3</sub> % ≤0.3 0.1
TiO<sub>2</sub> % 微量
CaO % 4.9
MgO+K<sub>2</sub>O+Na<sub>2</sub>O % ≤0.4 ≤0.4
由上表可见，本方法制得的二次风口部位内衬具有良好的抗剥落性能，高温体积稳定性好，抗气流冲刷及抗气氛侵蚀能力强。采用本方法制得的二次风口部位内衬解决了二次风口内衬更换所需组合砖生产成本高的问题，降低了维修成本。通过预制耐火砖块砌筑的方法不仅降低了制砖的模具数量及费用，也降低了制作过程中的能源成本投入，在不拆除外部冷却风管的前提下，可靠、高效完成二次风口内衬的更换。

Claims (1)

1.一种焚烧炉二次风口部位内衬的制备方法，其特征在于本方法包括如下步骤：
步骤一、按焚烧炉二次风口截面径向四等分构成四块耐火砖，按四块耐火砖形状分别制作四套模具；
步骤二、选用以重量百分比计的70～80%板状刚玉、5～10%煅烧氧化铝粉、5～10%超细氧化铝粉和10～20%纯铝酸钙水泥，并添加复合高效外加剂制作耐火砖浇注料；
步骤三、将制作的耐火砖浇注料分别浇注于四套模具制成四块耐火砖，四块耐火砖脱模后进行烘烤；
步骤四、耐火砖烘烤在常温～60℃范围内保温2小时，在60～110℃范围内升温速度为5℃/h，保温10小时；在110～200℃范围内升温速度为10℃/h，保温10小时；在200℃时保温2小时；在200～300℃范围内升温速度为10℃/h，保温10小时；在300℃时保温2小时，在300～400℃范围内升温速度为20℃/h，保温5小时；在400℃时保温4小时；
步骤五、耐火砖烘烤后常温下冷却，制得焚烧炉二次风口部位内衬；
其中，所述板状刚玉的粒度为8mm；
所述复合高效外加剂为牌号为T390S的高纯分散剂和硼酸，其中T390S的高纯分散剂添加量为耐火砖浇注料重量的0.06～0.15%，硼酸添加量为耐火砖浇注料重量的0.01～0.05%。
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