CN111269008B - Zirconium-containing ceramic welding material for hot repair and sealing of coke oven wall and repair method - Google Patents
Zirconium-containing ceramic welding material for hot repair and sealing of coke oven wall and repair method Download PDFInfo
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Abstract
The invention provides a zirconium-containing ceramic welding material for hot repair of the surface of the wall of a coke oven; the composition is prepared by uniformly mixing the following components in percentage by mass: 45-58% of 0.1-5 mm fused quartz, 16-22% of 0.04-0.1 mm fused white corundum, 20-32% of calcium-stabilized zirconia with the particle size of less than 1mm, 3-5% of 300-500 mesh metal silicon powder and 3-5% of 300-500 mesh metal aluminum powder. The repair construction process has higher combustion efficiency and sintering effect, the zirconium-containing ceramic repair welding material can reach the optimal fluidity and viscosity, and the construction body can effectively and fully cover the surface of the coke oven wall, thereby achieving the ideal sealing effect. The ceramic welding material has good combustion in the construction process, the flame is not easily cut off when a welding gun is moved, the combustion temperature of a core area reaches 1600 ℃ during combustion, the welding material is fully combusted, the liquid phase is more during welding, the surface of the welding material is compact and flat, the wall-mounting rate of the welding material is high, the rebound is less, and the rebound is about 5%.
Description
Technical Field
The invention relates to the technical field of coke oven wall repair, in particular to a zirconium-containing ceramic welding material for hot repair and sealing of the surface of a coke oven wall; the invention also relates to a method for repairing the wall of the coke oven by applying the zirconium-containing ceramic welding material.
Background
In the normal production operation process of the coke oven, along with the increase of the furnace age, the problems of furnace wall denudation, pitted surface, cracks, leakage, perforation and the like often occur, and the problems are mainly caused by the following reasons after analysis:
firstly, the temperature change of the furnace wall of the carbonization chamber of the coke furnace at the furnace head position caused by the repeated coal charging and coke pushing operations;
secondly, mechanical stress is generated when the furnace door is removed, the furnace door is put on and coke is pushed in the production process;
thirdly, the physical and chemical actions lead the wall of the coke oven to generate denudation and pitted surface;
fourthly, the graphite accumulated on the surface of the damaged furnace wall generates a carburizing effect on the furnace wall bricks of the carbonization chamber, so that the surface of the furnace wall is further peeled off, and a larger area is further generated to be peeled off to arrange and generate perforation.
For the damage of the oven wall of the coke oven carbonization chamber caused by the reasons, if the maintenance is timely and the measures are properly taken, the damage speed of the oven carbonization chamber wall of the coke oven can be delayed, and the purpose of prolonging the service life of the coke oven is achieved.
According to the special production operation conditions of the coke oven, the following conditions are required for the repair and maintenance of the coke oven:
firstly, the coke oven repair is carried out under the thermal state condition as far as possible without cooling the oven randomly;
secondly, the coke oven repair operation is simple, the working efficiency is high, and the repair time is short;
thirdly, the repair efficiency and the repair quality are ensured due to proper repair capability;
fourthly, the effectiveness of the repair operation must be ensured while the repair quality is ensured.
The only existing technologies for meeting the repair conditions are high-temperature ceramic repair welding technologies, which have been the subject of main scientific research and development for industrial kiln maintenance for 20 years, and the research and development aims to ensure that the formed refractory material coating has higher stability and is adaptive to parameter changes under working conditions. The discussion of ceramic weldments in this respect is found in British patent Specifications GB 2257136-A and GB 1330894.
But two basic conditions are provided for ensuring the normal production of furnaces such as coke ovens and the like: firstly, the furnace wall has enough strength; secondly, the furnace wall has good tightness. In the research and application of the existing ceramic welding repair material and method, the research direction focuses on the aspects of increasing the refractoriness under load, refractoriness and other physical properties of the welding repair material, and the method has no problem on ensuring the strength of the repaired furnace body, but neglects the requirement on ensuring the tightness of the furnace body.
In the initial stage and the middle stage of the coke oven, main problems are concentrated on the denudation pitted surface, cracks and the like of the oven wall, the damage area is generally large, and the damage parts are quite dispersed, which are main reasons for causing the blowby of a coke oven carbonization chamber and increasing the emission of pollutants. Based on the technical requirements of furnace wall repair, the damaged furnace wall needs to move in a large range during repair welding and often moves in a jumping mode, a ceramic repair welding construction body is a thin layer, and some of the ceramic repair welding construction bodies need to be 3-5 mm, and the ceramic repair welding construction bodies mainly play a strict role. The existing common ceramic welding repair materials and welding repair methods of magnesium, silicon, high-alumina, mullite and the like can not meet the requirement when the furnace wall is subjected to ceramic welding repair, and the method has great limitations.
Disclosure of Invention
The invention aims to provide a zirconium-containing ceramic welding material for hot repair and sealing of the surface of the wall of a coke oven; it is a zirconium-containing ceramic welding material suitable for hot repair and sealing of the surface of the wall of the coke oven. The invention also aims to provide a method for repairing the wall of the coke oven by using the zirconium-containing ceramic soldering material. A method for repairing the furnace wall by applying a zirconium-containing ceramic welding material for hot repair and sealing of the surface of the furnace wall of a coke furnace,
in order to achieve the purpose, the invention adopts the technical scheme that: a zirconium-containing ceramic welding material for hot repair of the surface of the wall of a coke oven; the formula is characterized by being prepared by uniformly mixing the following components in percentage by mass: 45-58% of 0.1-5 mm fused quartz, 16-22% of 0.04-0.1 mm fused white corundum, 20-32% of calcium-stabilized zirconia with the particle size of less than 1mm, 3-5% of 300-500 mesh metal silicon powder and 3-5% of 300-500 mesh metal aluminum powder.
Wherein: the content of silicon oxide in fused quartz is not less than 99.7%, the content of aluminum oxide in electric fused white corundum is not less than 99.5%, the content of zirconium oxide in calcium-stabilized zirconia is not less than 94.5%, the purity of metal silicon powder is not less than 98.5%, and the purity of metal aluminum powder is not less than 99.7%.
The invention provides a zirconium-containing ceramic welding material for hot repair of the surface of the wall of a coke oven; the chemical composition is characterized by comprising the following chemical components in percentage by mass: silicon dioxide SiO 248-60%, aluminum oxide Al2O 316-22%, zirconium oxide ZrO 220-30%, silicon Si 1-4%, calcium oxide CaO 1-2%, and ferrous oxide FeO 1-2%.
Wherein: the silicon dioxide is mainly from fused quartz and metal silicon powder, the aluminum oxide is mainly from electric melting white corundum and metal aluminum powder, the zirconium oxide and the calcium oxide are mainly from calcium-stabilized zirconium oxide, and the ferrous oxide is mainly from trace impurities in the raw materials.
A method for repairing a furnace wall by applying a zirconium-containing ceramic welding material for hot repair and sealing of the surface of the furnace wall of a coke oven is characterized by comprising the following steps:
(1) pouring the zirconium-containing ceramic welding repair material into a hopper of the ceramic welding repair machine, and adjusting the feeding speed of a turntable of the hopper of the welding repair machine to be 10-30 r/min.
(2) Adjusting the oxygen pressure value to be 0.3MP, adjusting the oxygen flow to be 30 Nm/h, and adjusting the adjusting valve to ensure that the material spraying amount is 100-160 kg/h.
(3) The ceramic welding material firstly enters a mixer of the ceramic welding machine to be mixed with oxygen for the first time, then enters a material conveying pipe under the conveying of the oxygen, is added with the oxygen for the second time and is mixed, and finally is conveyed to an area to be repaired through a welding gun.
In the step (1), if the feeding speed of a hopper turntable is less than 10 revolutions per minute, if the speed of the turntable is less than 10 revolutions per minute, the feeding amount is too small, the discharging amount at the welding gun head is less, the gas is more, the combustible substance is less and is not easy to burn, enough molten pool adsorbing material is not available, the material is blown away by the gas to cause the wall-mounting rate to be low, and the welding repair effect cannot be achieved; if the speed of the turntable is more than 30 revolutions per minute, the feeding amount is too large, the problems of blockage of a mixer and a welding gun head, uneven discharging, incomplete combustion and the like are easily caused, the welding repair quality is seriously influenced, and equipment can be damaged
In the step (2), the oxygen pressure is 0.3MP, the oxygen flow is 30 Nm/h, the material conveying capacity is best, and the zirconium-containing ceramic welding material can be driven to output most effectively; the amount of the sprayed material is 100-160 kg/h, so that the welding repair material can be guaranteed to have a good combustion effect on the surface of a furnace wall on the basis of the feeding speed, the oxygen pressure and the oxygen flow parameters, the optimal output range of the welding repair efficiency is considered, the problems of low wall-loading rate, insufficient combustion, gun blockage and the like can be caused when the output range is lower than or higher than the optimal output range, and adverse effects are caused on the welding repair quality.
The invention provides a method for repairing a furnace wall, wherein a ceramic welding repair machine is a utility model patent product of my department, and the patent numbers are as follows: 201220459485.7, name: the improved pneumatic ceramic welding machine; the welder that uses also is my department utility model patent product, patent number: 201821592428. X, name: a welding gun for a coke oven ceramic welding machine.
The zirconium-containing ceramic welding repair material provided by the invention is fully mixed by a ceramic welding repair machine and related technologies, is finally sprayed to the surface of the furnace wall of a coke oven by a ceramic welding repair welding gun, is combusted and melted under the action of high temperature and combustion-supporting gas on the surface of the furnace wall, and is finally sintered on the surface of the furnace wall to form a compact construction body. The construction process has higher combustion efficiency and sintering effect, the zirconium-containing ceramic welding repair material can reach the optimal fluidity and viscosity, and the construction body can effectively and fully cover the surface of the coke oven wall, thereby achieving the ideal sealing effect. The ceramic welding material has good combustion in the construction process, the flame is not easily cut off when a welding gun is moved, the combustion temperature of a core area reaches 1600 ℃ during combustion, the welding material is fully combusted, the liquid phase is more during welding, the surface of the welding material is compact and flat, the wall-mounting rate of the welding material is high, the rebound is less, and the rebound is about 5%.
Meanwhile, the construction body has better thermal shock stability, chemical erosion resistance and wear resistance and has optimal high-temperature compressive strength. The problems that the sealing construction of the surface of the furnace wall of the coke furnace is difficult, the efficiency is low, the welding material is low in the wall-mounting rate and is wasted seriously, the material hanging time is short, the material cannot meet the requirements of the construction process and the construction quality and the like are effectively solved, the problems that the emission of pollutants is increased, the coke quality is influenced, the thermal repair maintenance of the surface of the furnace wall is not in place, the perforation is further deteriorated, the service life of the coke furnace is influenced and the like caused by the problems of the corrosion, the cracks, the channeling and the like of the surface of the furnace wall are solved, and the application prospect is great.
Drawings
FIG. 1 is a schematic diagram of the implementation and application of the method of the present invention.
In the figure: 1-hopper, 2-blender, 3-secondary oxygenation pipe, 4-welding gun, 5-carbonization chamber furnace wall, and 6-damaged part.
Detailed Description
Under the normal production condition of the coke oven, deep pits, fusion holes, cracks and perforations appear on the oven wall of the carbonization chamber of the coke oven, the coking chamber has serious blowby after coal is loaded, a chimney emits black smoke, a combustion chamber sets up a flame path to blow by, and the gas resource is wasted. The damaged area is large and dispersed, and needs to be repaired; the furnace wall of the coke oven carbonization chamber has the defects of denudation, cracking, pitted surface and cracks, and needs to be repaired. The zirconium-containing ceramic welding material for hot repair and sealing of the coke oven wall and the repair method provided by the invention are adopted for hot repair, so that an ideal technical effect can be obtained.
Five kinds of zirconium-containing ceramic welding materials with different proportions are prepared and applied to engineering examples.
Example 1; taking 52kg of fused quartz with the particle size of 0.1-5 mm, 21kg of fused white corundum with the particle size of 0.04-0.1 mm, 21kg of calcium-stabilized zirconia with the particle size of less than 1mm, 3kg of metal silicon powder with the particle size of 300-500 meshes and 3kg of metal aluminum powder with the particle size of 300-500 meshes; the materials are stirred and mixed evenly to obtain the zirconium-containing ceramic welding material.
The zirconium-containing ceramic welding material prepared in the embodiment is used for welding and repairing damaged parts 6 such as pits, fusion holes, cracks, perforations, denudation, cracks, pitted surfaces and the like on a furnace wall 5 of a carbonization chamber of a coke furnace, and the specific implementation method is as follows:
see fig. 1; and (1) connecting the ceramic soldering machine and auxiliary equipment thereof, and communicating oxygen, air and auxiliary oxygen. The zirconium-containing ceramic soldering material obtained in the embodiment is poured into a hopper 1 of the ceramic soldering machine, the damage condition of the surface of the furnace wall and the proportioning condition of the ceramic soldering material are repaired as required, and the feeding speed of a turntable of the hopper of the soldering machine is adjusted to 15 revolutions per minute.
Step (2), adjusting the oxygen pressure value to be 0.3MP, and adjusting the oxygen flow to be 30 Nm/h; the regulating valve was adjusted to give a shot size of 110 kg/h.
And (3) under the conditions of the steps (1) and (2), firstly, enabling the zirconium-containing ceramic welding material in the hopper 1 to enter a mixer 2 of a ceramic welding machine to be mixed with oxygen for the first time, then, under the condition of oxygen conveying, enabling the zirconium-containing ceramic welding material to enter a material conveying pipe and to be mixed with the oxygen input by the secondary oxygen adding pipe 3 again, enabling the oxygen content of the mixed material conveying gas to reach 50-60%, and finally, spraying the mixed material conveying gas to a to-be-repaired area, namely a damaged part 6 through a welding gun 4. The zirconium-containing ceramic welding material is combusted under the assistance of oxygen and is fused and sintered on the surface of the high-temperature furnace wall, and finally the purpose of repairing the damaged wall surface and the sealed furnace wall is achieved.
Example 2; 53kg of fused quartz with the particle size of 0.1-5 mm, 17kg of fused white corundum with the particle size of 0.04-0.1 mm, 24kg of calcium-stabilized zirconia with the particle size of less than 1mm, 3kg of metal silicon powder with the particle size of 300-500 meshes and 3kg of metal aluminum powder with the particle size of 300-500 meshes are taken; the materials are stirred and mixed evenly to obtain the zirconium-containing ceramic welding material.
The zirconium-containing ceramic welding material prepared in the embodiment is used for welding and repairing damaged parts 6 such as pits, fusion holes, cracks, perforations, denudation, cracks, pitted surfaces and the like on a furnace wall 5 of a carbonization chamber of a coke furnace, and the specific implementation method is as follows:
and (1) adjusting the feeding speed of a hopper turntable of the welding repair machine to be 20 revolutions per minute, and the rest is the same as the embodiment 1.
Step (2), adjusting the oxygen pressure value to be 0.3MP, and adjusting the oxygen flow to be 30 Nm/h; the regulating valve was adjusted to give a spray quantity of 130 kg/h.
Step (3), same as example 1.
Example 3; taking 50kg of fused quartz with the particle size of 0.1-5 mm, 17kg of fused white corundum with the particle size of 0.04-0.1 mm, 27kg of calcium-stabilized zirconia with the particle size of less than 1mm, 3kg of metal silicon powder with the particle size of 300-500 meshes and 3kg of metal aluminum powder with the particle size of 300-500 meshes; the materials are stirred and mixed evenly to obtain the zirconium-containing ceramic welding material.
The zirconium-containing ceramic welding material prepared in the embodiment is used for welding and repairing damaged parts 6 such as pits, fusion holes, cracks, perforations, denudation, cracks, pitted surfaces and the like on a furnace wall 5 of a carbonization chamber of a coke furnace, and the specific implementation method is as follows:
and (1) adjusting the feeding speed of a hopper turntable of the welding repair machine to be 30 revolutions per minute, and the rest is the same as the embodiment 1.
Step (2), adjusting the oxygen pressure value to be 0.3MP, and adjusting the oxygen flow to be 30 Nm/h; the regulating valve was adjusted to achieve a shot size of 155 kg/h.
Step (3), same as example 1.
Example 4; 48kg of fused quartz with the particle size of 0.1-5 mm, 16kg of fused white corundum with the particle size of 0.04-0.1 mm, 30kg of calcium-stabilized zirconia with the particle size of less than 1mm, 3kg of metal silicon powder with the particle size of 300-500 meshes and 3kg of metal aluminum powder with the particle size of 300-500 meshes are taken and stirred and mixed uniformly to obtain the zirconium-containing ceramic welding material.
The zirconium-containing ceramic welding material prepared in the embodiment is used for welding and repairing damaged parts 6 such as pits, fusion holes, cracks, perforations, denudation, cracks, pitted surfaces and the like on a furnace wall 5 of a carbonization chamber of a coke furnace, and the specific implementation method is as follows:
and (1) adjusting the feeding speed of a hopper turntable of the welding repair machine to 25 revolutions per minute, and the rest is the same as the embodiment 1.
Step (2), adjusting the oxygen pressure value to be 0.3MP, and adjusting the oxygen flow to be 30 Nm/h; the regulating valve was adjusted to give a spray quantity of 145 kg/h.
Step (3), same as example 1.
Example 5; 55kg of fused quartz with the particle size of 0.1-5 mm, 16kg of fused white corundum with the particle size of 0.04-0.1 mm, 23kg of calcium-stabilized zirconia with the particle size of less than 1mm, 3kg of metal silicon powder with the particle size of 300-500 meshes and 3kg of metal aluminum powder with the particle size of 300-500 meshes are taken; the materials are stirred and mixed evenly to obtain the zirconium-containing ceramic soldering material
The zirconium-containing ceramic welding material prepared in the embodiment is used for welding and repairing damaged parts 6 such as pits, fusion holes, cracks, perforations, denudation, cracks, pitted surfaces and the like on a furnace wall 5 of a carbonization chamber of a coke furnace, and the specific implementation method is as follows:
and (1) adjusting the feeding speed of a hopper turntable of the welding repair machine to be 30 revolutions per minute, and the rest is the same as the embodiment 1.
Step (2), adjusting the oxygen pressure value to be 0.3MP, and adjusting the oxygen flow to be 30 Nm/h; the regulating valve was adjusted to give a spray quantity of 160 kg/h.
Step (3), same as example 1.
By using the 5 kinds of zirconium-containing ceramic welding materials and the welding method configured in the embodiments 1 to 5, and by observation and test of engineering implementation, the five kinds of ceramic welding materials provided by the embodiments all burn well, and are not easy to break fire when a welding gun is moved, the combustion temperature of a core region reaches 1600 ℃ during combustion, the welding materials burn sufficiently, more liquid phase is generated during welding, the surface of the welding materials is compact and flat, the wall-mounting rate of the welding materials is high, the rebound is less, and the rebound is about 5%. The performance indexes of the furnace wall repairing position are as follows through measurement:
(1) refractoriness under load of 0.2MPa T0.61429 deg.C
0.2MPa T2.0 1441℃
0.2MPa T4.0 1447℃
(2) Refractoriness of 1520 DEG C
(3) Normal temperature compression strength of 110 ℃ x 24h 35-40 MPa
(4) Thermal shock stability 1100 deg.C, water cooling more than or equal to 15 times
(5) 3 percent of residual silicon
According to the construction process and the results of the embodiment, the zirconium-containing ceramic welding material for the thermal state repairing and sealing of the surface of the coke oven wall and the method for repairing the oven wall are very suitable for repairing the coke oven wall. The zirconium-containing ceramic welding material is more fully combusted in the construction process, more liquid phase substances are formed, and the construction performance is greatly improved. The surface of a welding area after construction is compact and flat, and the zirconium-containing ceramic welding material can weld and repair a deep pit, a molten tunnel and a perforated furnace wall; the method can effectively weld and repair the furnace wall with denudation, cracking, pitted surface and crack, and the ceramic welds and repairs a thin layer of sealing material, thereby achieving the effects of repairing and sealing the furnace wall, not influencing the normal production of the coke furnace, prolonging the service life of the coke furnace and reducing the environmental pollution. In addition, in terms of physical properties, the loaded softening point of the zirconium-containing ceramic welding material is slightly reduced, but the construction and repair parts of the ceramic welding material are non-bearing structural parts, the requirement on the loaded softening point of the welding material is not high, the requirement on the T0.6=1429 ℃ can completely meet the normal production and use requirements of a coke oven, and meanwhile, the zirconium-containing ceramic welding material has better toughness and thermal shock stability for more than 15 times and is not easy to crack and fall off. The repaired furnace wall is flat and smooth, and the normal production of the coke oven is not influenced; meanwhile, the sealing effect is good, the wall of the coke oven does not have leakage, and the zirconium-containing ceramic welding material has high combustion temperature, the zirconium-containing ceramic welding material is fully combusted, and almost no rebound materials exist, so that particularly when the furnace bottom of the carbonization chamber is vertically welded downwards, the ceramic welding material cannot be accumulated on the surface of the furnace bottom, the quality problems of entrainment and the like cannot exist, the ceramic welding quality is influenced, and the aim of repairing the furnace bottom of the carbonization chamber can be fulfilled. In a word, the zirconium-containing ceramic welding material has very good construction operation performance and enough physical strength, can achieve a very good furnace wall sealing effect, can weld and repair a pit, a molten tunnel and a perforated furnace wall, can weld and repair a furnace wall and a furnace bottom brick with corrosion, pitted surface and crack, and has very wide popularization value.
Claims (4)
1. A zirconium-containing ceramic welding material for hot repair of the surface of the wall of a coke oven; the formula is characterized by being prepared by uniformly mixing the following components in percentage by mass: 45-58% of 0.1-5 mm fused quartz, 16-22% of 0.04-0.1 mm fused white corundum, 20-32% of calcium-stabilized zirconia with the particle size of less than 1mm, 3-5% of 300-500 mesh metal silicon powder and 3-5% of 300-500 mesh metal aluminum powder;
the zirconium-containing ceramic welding material comprises the following chemical components in percentage by mass: silicon dioxide SiO248-60% of aluminum oxide Al2O316-22% of zirconium oxide ZrO220-30%, silicon Si 1-4%, calcium oxide CaO 1-2%, and ferrous oxide FeO 1-2%.
2. The zirconium-containing ceramic welding material for the thermal repair of the surface of the wall of the coke oven of claim 1; the method is characterized in that: the content of silicon oxide in fused quartz is not less than 99.7%, the content of aluminum oxide in electric fused white corundum is not less than 99.5%, the content of zirconium oxide in calcium-stabilized zirconia is not less than 94.5%, the purity of metal silicon powder is not less than 98.5%, and the purity of metal aluminum powder is not less than 99.7%.
3. The zirconium-containing ceramic welding material for the thermal repair of the surface of the wall of the coke oven of claim 1; the method is characterized in that: the silicon dioxide is from fused quartz and metal silicon powder, the aluminum oxide is from electric melting white corundum and metal aluminum powder, the zirconium oxide and the calcium oxide are from calcium-stabilized zirconium oxide, and the ferrous oxide is from trace impurities in the raw materials.
4. A method for repairing a furnace wall by applying a zirconium-containing ceramic welding material for hot repair and sealing of the surface of the furnace wall of a coke oven is characterized by comprising the following steps:
(1) pouring the zirconium-containing ceramic soldering material of claim 1 into a hopper of a ceramic soldering machine, and adjusting the feeding speed of a turntable of the hopper of the soldering machine to 10-30 r/min;
(2) adjusting the oxygen pressure value to 0.3MP and the oxygen flow to 30Nm3Adjusting the adjusting valve to ensure that the spraying amount is 100-160 kg/h;
(3) the ceramic welding material firstly enters a mixer of the ceramic welding machine to be mixed with oxygen for the first time, then enters a material conveying pipe under the conveying of the oxygen, is added with the oxygen for the second time and is mixed, and finally is conveyed to an area to be repaired through a welding gun.
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