CN111285696B - 一种铝液耐火材料流道修补剂及其制备方法 - Google Patents
一种铝液耐火材料流道修补剂及其制备方法 Download PDFInfo
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 45
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 45
- 239000003795 chemical substances by application Substances 0.000 title claims abstract description 40
- 239000011819 refractory material Substances 0.000 title claims abstract description 25
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- 239000000654 additive Substances 0.000 claims abstract description 54
- 230000000996 additive effect Effects 0.000 claims abstract description 54
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims abstract description 41
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims abstract description 34
- 239000002131 composite material Substances 0.000 claims abstract description 22
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 claims abstract description 21
- 239000008098 formaldehyde solution Substances 0.000 claims abstract description 18
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 17
- 239000010431 corundum Substances 0.000 claims abstract description 17
- 239000005995 Aluminium silicate Substances 0.000 claims abstract description 16
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 claims abstract description 16
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 16
- 239000000835 fiber Substances 0.000 claims abstract description 16
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 16
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 15
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 claims abstract description 15
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 15
- 239000010703 silicon Substances 0.000 claims abstract description 15
- 239000006188 syrup Substances 0.000 claims abstract description 15
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 14
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims abstract description 5
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 9
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 9
- 229920002472 Starch Polymers 0.000 claims description 8
- 125000002091 cationic group Chemical group 0.000 claims description 8
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims 2
- 239000000377 silicon dioxide Substances 0.000 claims 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 abstract description 4
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Abstract
本发明公开了一种铝液耐火材料流道修补剂及其制备方法，修补剂包括干式混合料和液体混合外加剂；所述干式混合料由白刚玉粉、硅酸铝纤维粉、生高岭土粉、氧化铝微粉、硅微粉、硫酸钡、复合添加剂组成；所述液体混合外加剂由硫酸铝、水、糖浆、甲醛溶液、乙二醇组成。本发明的工艺简单，制备方便；本发明制备获得的耐火材料流道修补剂，抗铝液侵蚀及抗渣性好，不沾铝性能优异，与耐火材料热结合性优良，黏结强度不低于2Mpa，使用寿命长。
Description
技术领域
本发明涉及耐火材料技术领域，特别是涉及一种铝液耐火材料流道修补剂及其制备方法。
背景技术
熔铸是铝加工的第一道工序，为轧制、锻造、挤压等生产提供合格的锭坯，铸锭质量的高低直接与各种铝材的最终质量密切相关。铝熔铸的过程中需要用到熔铸炉，将铝融为铝液，铝液则经由铝液流道（流槽）流出。
目前铝熔铸行业，铝液流道由多个耐火材料预制件首尾连接组成，流道长度在几米到几十米之间。这就使得耐火材料预制件之间有接缝，越长的流道则接缝越多。由于铝液温度的原因，以及铝业流道本身对铝液起到承载并导向的作用，这就使得耐火材料预制之间的接缝材料满足耐铝液侵蚀，不开裂，不脱落，不沾铝，长期工作温度在600℃到800℃之间，使用寿命长的特点；且该接缝材料的施工也应该简单。
现有技术中的接缝材料使用寿命较短，一个铸次就需要接缝修补。频繁的修补，大大影响了生产的效率，因此急需一种能够解决现有接缝材料寿命短，延长接缝材料寿命的修补剂。
发明内容
本发明的目的就在于克服上述不足，提供一种铝液耐火材料流道修补剂及其制备方法。
为达到上述目的，本发明是按照以下技术方案实施的：
一种铝液耐火材料流道修补剂，所述修补剂包括干式混合料和液体混合外加剂；
所述干式混合料由白刚玉粉、硅酸铝纤维粉、生高岭土粉、氧化铝微粉、硅微粉、硫酸钡、复合添加剂组成；所述液体混合外加剂由硫酸铝、水、糖浆、甲醛溶液、乙二醇组成。
优选的，所述干式混合料按重量百分比计，配比如下：白刚玉粉22～52%；硅酸铝纤维粉25～45%；生高岭土粉3%、氧化铝微粉5～10%、硅微粉4～10%、硫酸钡4～10%、复合添加剂2 %。
优选的，所述干式混合料按重量百分比计，配比如下：320目的白刚玉粉42%、0~3mm的硅酸铝纤维粉35%、500目的生高岭土粉3%、3000目的氧化铝微粉5%、5000目的硅微粉8%、6000目的工业级硫酸钡5%、复合添加剂2 %。
优选的，所述复合添加剂按重量百分比计，配比如下：三聚磷酸钠50%、阳离子淀粉50%。
优选的，以干式混合料的重量为基准，所述液体混合外加剂为干式混合料重量的30～50%。
优选的，所述液体混合外加剂按重量百分比计，配比如下：硫酸铝28%、水61%、糖浆8.5%、甲醛溶液1.0%、乙二醇1.5%；所述甲醛溶液为规格37%级的工业甲醛溶液。
本发明还提供了一种铝液耐火材料流道修补剂的制备方法，包括以下步骤：
S1，干式混合料配制：
按照配比称量白刚玉粉、硅酸铝纤维粉、生高岭土粉、氧化铝微粉、硅微粉、硫酸钡、复合添加剂，送入粉体搅拌机中搅拌30分钟以上，得到干式混合料；
S2，液体混合外加剂配制：
按照配比称量硫酸铝、水、糖浆、甲醛溶液、乙二醇，送入高速分散机中搅拌均匀，得到液体混合外加剂；
S3，修补剂配制：
按照配比称量干式混合料、液体混合外加剂，送入搅拌机内搅拌8~10分钟后出料，使用塑料自封袋密封包装，得到修补剂成品。
本发明制备获得的修补剂用于铝液流道接缝使用，或者流道接缝修补使用；还可用于耐火材料的工作衬修补。
本发明的作用原理：
本发明的修补剂包括干式混合料和液体混合外加剂；干式混合料由白刚玉粉、硅酸铝纤维粉、生高岭土粉、氧化铝微粉、硅微粉、硫酸钡、复合添加剂组成；液体混合外加剂由硫酸铝、水、糖浆、甲醛溶液、乙二醇组成。
本发明采用白刚玉粉作为主要材料，生高岭土粉、三聚磷酸钠作为烧结剂使用；塑化剂为糖浆，增韧剂为硅酸铝纤维粉，结合剂硫酸铝，甲醛作为防腐剂，乙二醇润湿剂，硅微粉和氧化铝微粉为活性增强剂，硫酸钡作为铝液反润湿剂。
白刚玉粉抗铝液侵蚀及抗渣性好；添加硫酸钡作为铝液反润湿剂，反湿润剂与金属铝液润湿角小，不沾铝性能优异；本发明添加塑性剂，制作出一种塑性材料的修补剂。本发明制备获得的修补剂与耐火材料热结合性优良，黏结强度不低于2MPa；寿命长，寿命为流槽接缝为传统耐火泥的5倍以上，为箱体工作衬修补寿命可实现半年以上。pH值为7，且修补剂本身无污染、无毒、无侵蚀性。
本发明制备得到的修补剂可用于耐火材料流道的接缝处理，或者耐火材料工作衬上裂纹的修补。
与现有技术相比，本发明的有益效果为：
本发明的工艺简单，制备方便；本发明制备获得的耐火材料流道修补剂抗铝液侵蚀及抗渣性好，不沾铝性能优异，与耐火材料热结合性优良，黏结强度不低于2Mpa，使用寿命长。
具体实施方式
下面以具体实施例对本发明作进一步描述，在此发明的示意性实施例以及说明用来解释本发明，但并不作为对本发明的限定。
实施例1
一种铝液耐火材料流道修补剂，包括干式混合料、液体混合外加剂；液体混合外加剂的重量为干湿混合料重量的50%。
复合添加剂按重量百分比计，配比如下：工业级三聚磷酸钠50%、工业级阳离子淀粉50%；
液体混合外加剂按重量百分比计，配比如下：硫酸铝28%、水61%、食品级糖浆8.5%、规格37%级的工业甲醛溶液1.0%、工业级乙二醇1.5%。
干式混合料按重量百分比计，配比如下：320目的白刚玉粉32%、0~3mm的硅酸铝纤维粉45%、500目的生高岭土粉3%、3000目的氧化铝微粉5%、5000目的硅微粉4%、6000目的工业级硫酸钡9%、复合添加剂2 %。
一种铝液耐火材料流道修补剂的制备方法，包括以下步骤：
S1，干式混合料配制：
按照配比称量工业级三聚磷酸钠、工业级阳离子淀粉，在粉体搅拌机中预混合，装袋备用，获得复合添加剂；
按照配比称量320目的白刚玉粉、0~3mm的硅酸铝纤维粉、500目的生高岭土粉、3000目的氧化铝微粉、5000目的硅微粉、6000目的工业级硫酸钡、复合添加剂，送入粉体搅拌机中搅拌30分钟以上，得到干式混合料；
S2，液体混合外加剂配制：
按照配比称量硫酸铝、水、食品级糖浆、工业甲醛溶液、工业级乙二醇，送入高速分散机中搅拌均匀，倒入塑料筒中加盖密封备用，得到液体混合外加剂；
S3，修补剂配制：
按照配比称量干式混合料、液体混合外加剂，送入面粉搅拌机内搅拌8分钟后出料，使用塑料自封袋密封包装，得到修补剂成品。
实施例2
一种铝液耐火材料流道修补剂，包括干式混合料、液体混合外加剂；液体混合外加剂的重量为干湿混合料重量的37%。
复合添加剂按重量百分比计，配比如下：工业级三聚磷酸钠50%、工业级阳离子淀粉50%；
液体混合外加剂按重量百分比计，配比如下：硫酸铝28%、水61%、食品级糖浆8.5%、规格为37%级的工业甲醛溶液1.0%、工业级乙二醇1.5%。
干式混合料按重量百分比计，配比如下：320目的白刚玉粉42%、0~3mm的硅酸铝纤维粉35%、500目的生高岭土粉3%、3000目的氧化铝微粉5%、5000目的硅微粉8%、6000目的工业级硫酸钡5%、复合添加剂2 %。
一种铝液耐火材料流道修补剂的制备方法，包括以下步骤：
S1，干式混合料配制：
按照配比称量工业级三聚磷酸钠、工业级阳离子淀粉，在粉体搅拌机中预混合，装袋备用，获得复合添加剂；
按照配比称量320目的白刚玉粉、0~3mm的硅酸铝纤维粉、500目的生高岭土粉、3000目的氧化铝微粉、5000目的硅微粉、6000目的工业级硫酸钡、复合添加剂，送入粉体搅拌机中搅拌30分钟以上，得到干式混合料；
S2，液体混合外加剂配制：
按照配比称量硫酸铝、水、食品级糖浆、工业甲醛溶液、工业级乙二醇，送入高速分散机中搅拌均匀，倒入塑料筒中加盖密封备用，得到液体混合外加剂；
S3，修补剂配制：
按照配比称量干式混合料、液体混合外加剂，送入面粉搅拌机内搅拌9分钟后出料，使用塑料自封袋密封包装，得到修补剂成品。
实施例3
一种铝液耐火材料流道修补剂，包括干式混合料、液体混合外加剂；液体混合外加剂的重量为干湿混合料重量的30%。
复合添加剂按重量百分比计，配比如下：工业级三聚磷酸钠50%、工业级阳离子淀粉50%；
液体混合外加剂按重量百分比计，配比如下：硫酸铝28%、水61%、食品级糖浆8.5%、规格为37%级的工业甲醛溶液1.0%、工业级乙二醇1.5%。
干式混合料按重量百分比计，配比如下：320目的白刚玉粉52%、0~3mm的硅酸铝纤维粉25%、500目的生高岭土粉3%、3000目的氧化铝微粉5%、5000目的硅微粉9%、6000目的工业级硫酸钡4%、复合添加剂2 %。
一种铝液耐火材料流道修补剂的制备方法，包括以下步骤：
S1，干式混合料配制：
按照配比称量工业级三聚磷酸钠、工业级阳离子淀粉，在粉体搅拌机中预混合，装袋备用，获得复合添加剂；
按照配比称量320目的白刚玉粉、0~3mm的硅酸铝纤维粉、500目的生高岭土粉、3000目的氧化铝微粉、5000目的硅微粉、6000目的工业级硫酸钡、复合添加剂，送入粉体搅拌机中搅拌30分钟以上，得到干式混合料；
S2，液体混合外加剂配制：
按照配比称量硫酸铝、水、食品级糖浆、工业甲醛溶液、工业级乙二醇，送入高速分散机中搅拌均匀，倒入塑料筒中加盖密封备用，得到液体混合外加剂；
S3，修补剂配制：
按照配比称量干式混合料、液体混合外加剂，送入面粉搅拌机内搅拌10分钟后出料，使用塑料自封袋密封包装，得到修补剂成品。
将实施例1、实施例2、实施例3获得修补剂样品以及传统修补剂，进行物理性能测试，测试结果见下表：
根据测试结果对比，本发明获得的修补剂抗折强度，黏结强度均高于传统修补剂，因此耐铝液冲刷，不易脱落，使用寿命长。
本发明获得样品在东方希望铝业公司、皱平宏发铝业公司，进行了铝液流道施工应用，其使用寿命是传统修补剂的5倍以上。
本发明的技术方案不限于上述具体实施例的限制，凡是根据本发明的技术方案做出的技术变形，均落入本发明的保护范围之内。
Claims (4)
1.一种铝液耐火材料流道修补剂，其特征在于：所述修补剂包括干式混合料和液体混合外加剂；
所述干式混合料按重量百分比计，配比如下：白刚玉粉22～52％；硅酸铝纤维粉25～45％；生高岭土粉3％、氧化铝微粉5～10％、硅微粉4～10％、硫酸钡4～10％、复合添加剂2％；
所述液体混合外加剂由硫酸铝、水、糖浆、甲醛溶液、乙二醇组成；
所述复合添加剂按重量百分比计，配比如下：三聚磷酸钠50％、阳离子淀粉50％；
以干式混合料的重量为基准，所述液体混合外加剂为干式混合料重量的30～50％。
2.根据权利要求1所述的一种铝液耐火材料流道修补剂，其特征在于：所述干式混合料按重量百分比计，配比如下：320目的白刚玉粉42％、0～3mm的硅酸铝纤维粉35％、500目的生高岭土粉3％、3000目的氧化铝微粉5％、5000目的硅微粉8％、6000目的工业级硫酸钡5％、复合添加剂2％。
3.根据权利要求1所述的一种铝液耐火材料流道修补剂，其特征在于：所述液体混合外加剂按重量百分比计，配比如下：硫酸铝28％、水61％、糖浆8.5％、甲醛溶液1.0％、乙二醇1.5％；所述甲醛溶液为规格37％级的工业甲醛溶液。
4.根据权利要求1-3任一项所述的一种铝液耐火材料流道修补剂的制备方法，其特征在于：包括以下步骤：
S1，干式混合料配制：
按照配比称量白刚玉粉、硅酸铝纤维粉、生高岭土粉、氧化铝微粉、硅微粉、硫酸钡、复合添加剂，送入粉体搅拌机中搅拌30分钟以上，得到干式混合料；
S2，液体混合外加剂配制：
按照配比称量硫酸铝、水、糖浆、甲醛溶液、乙二醇，送入高速分散机中搅拌均匀，得到液体混合外加剂；
S3，修补剂配制：
按照配比称量干式混合料、液体混合外加剂，送入搅拌机内搅拌8～10分钟后出料，使用塑料自封袋密封包装，得到修补剂成品。
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