CN111574233B - Ceramic wear-resistant hot gunning mix and preparation method thereof - Google Patents
Ceramic wear-resistant hot gunning mix and preparation method thereof Download PDFInfo
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- CN111574233B CN111574233B CN202010452271.6A CN202010452271A CN111574233B CN 111574233 B CN111574233 B CN 111574233B CN 202010452271 A CN202010452271 A CN 202010452271A CN 111574233 B CN111574233 B CN 111574233B
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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
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D1/00—Casings; Linings; Walls; Roofs
- F27D1/16—Making or repairing linings increasing the durability of linings or breaking away linings
- F27D1/1636—Repairing linings by projecting or spraying refractory materials on the lining
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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
- C04B2235/02—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
- C04B2235/3427—Silicates other than clay, e.g. water glass
- C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
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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
- C04B2235/40—Metallic constituents or additives not added as binding phase
- C04B2235/402—Aluminium
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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
- C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
- C04B2235/428—Silicon
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D1/00—Casings; Linings; Walls; Roofs
- F27D1/16—Making or repairing linings increasing the durability of linings or breaking away linings
- F27D2001/1605—Repairing linings
Abstract
The invention discloses a ceramic wear-resistant hot gunning mix and a preparation method thereof, which is prepared by refractory aggregate and a bonding agent, wherein the addition amount of the bonding agent is 25-30% of the total weight of the refractory aggregate; the refractory aggregate is composed of composite metal powder, silica particles with the particle size of 3-1mm, silica particles with the particle size of 1-0.088mm and silica fine powder with the particle size of less than 0.088; the ceramic wear-resistant hot-state gunning material has the excellent performances of high temperature resistance, erosion resistance, wear resistance, stripping resistance, stable high-temperature volume, good compatibility with residual brick masonry, strong bonding capability, convenient construction and the like, and is an ideal refractory material for hot repair when masonry such as a pot wall of a carbon calciner and a carbonization chamber of a coke oven is damaged.
Description
Technical Field
The invention relates to the technical field of unshaped refractory materials, in particular to a ceramic wear-resistant hot gunning mix and a preparation method thereof.
Background
The pot furnace is self-heating calcining equipment utilizing material volatile component combustion. Wherein, the material does not directly contact with the air, the carbon burning loss is less, and trace volatile matter deposition pyrolytic carbon can be formed on coke particles, the weight of the calcined coke is higher, so the pot furnace is widely adopted in the carbon industry.
The calcined petroleum coke produced by the pot calciner is a main raw material for producing an anode for electrolytic aluminum, the service life of the pot calciner is generally 8-10 years under the normal operation state of the pot calciner, but in recent years, due to various factors such as standard exceeding of sulfur content in the petroleum coke, relative backward process and the like, the service life of the pot calciner is greatly reduced, such as the weight problem of a pot body silica brick, the technical problem of furnace building, the temperature control problem, the abrasion problem of the raw material to a silica brick wall and the like, the phenomena of corrosion and delamination, pitted surface, depression and the like of the inner wall of the pot body silica brick wall with different degrees can occur when the operation time of the pot calciner is less than 1 year, the local part even has a string hole phenomenon, the depth reaches 60mm (the wall thickness of the pot body is 80mm), most of the depressions appear in 3 layers and 4 layers, even six to seven layers (the total layers of calciners are 8 layers), and after the phenomena occur, the service life of the pot calciner can be directly influenced, The capacity and the furnace temperature are also limited greatly, and the holes on the wall of the tank are expanded gradually, so that the furnace body loses the production capacity, and the whole tank type calcining furnace is scrapped in severe cases. If the means of blowing-out and overhaul is adopted, generally, the time from blowing-out, dismantling, building and baking of a pot-type calcining furnace to trial production is about one year, and the cost is quite high, so that the yield is influenced, and high maintenance cost is required. Therefore, the pot-type calcining furnace is subjected to thermal state maintenance at the normal operating temperature, and has great significance in the aspects of avoiding premature damage of the furnace body, minimizing the harm of high-temperature accidents, prolonging the service life of the furnace body and the like. The maintenance problem of the calcining furnace becomes a common problem in the domestic carbon industry at present.
When the calcining furnace is damaged, the pot wall bricks are corroded and peeled, and are difficult to find at first, and when the pot wall bricks with the thickness of 80mm are corroded to a certain degree, the phenomena of fire leaping and fire leakage gradually occur in the flame path. The conventional repair method is: 1. the defects that siliceous mud or clay mud is used for spray repair maintenance of small holes are as follows: the strength of the slurry is low, and frequent spray repair is needed; 2. for the cavity with larger damage, the furnace is shut down to observe the damage condition of the silica brick, the temperature in the furnace is reduced to the construction temperature, then the silica brick is dug and repaired, and the defects are that: the overlong repair time delays the production time and reduces the yield.
On the whole, the gunning mix is suitable for various furnace types, and the gunning mix is mainly made of high-alumina carbon, aluminum magnesium, magnesium dolomite and the like. The gunning materials with different compositions have different gunning effects on different refractory bricks, for example, high-alumina carbon gunning materials are mainly used for blast furnace gunning, aluminum-magnesium gunning materials are mainly used for heating furnace gunning, and magnesium dolomite gunning materials are mainly used for converters. Aiming at the defects of poor adhesion property, insufficient wear resistance, short service life and the like of the gunning material made of the materials in the calcining furnace in the carbon industry. The invention patent with the patent application number of 200810226952.X discloses a composite combined siliceous thermal repair material and a preparation method thereof, wherein the weight percentage of the components is 45-55% of siliceous clinker aggregate, 8-12% of siliceous clinker powder, 20-30% of natural silica powder, 8-12% of composite bonding agent, 3-5% of plasticizer and 1-1.5% of dispersing agent. Therefore, how to obtain the thermal-state gunning mix for the carbon calcining furnace, which has simple composition, good adhesion property, wear resistance and thermal shock stability, becomes a technical problem to be solved urgently.
Disclosure of Invention
The invention aims to provide a ceramic wear-resistant hot gunning material and a preparation method thereof, so that a kiln which is seriously damaged and faces production halt can be continuously used for a long time after being subjected to hot gunning under the condition of no production halt, and a user is prevented from huge economic loss caused by production halt.
The technical scheme adopted by the invention for realizing the purpose is as follows: a ceramic wear-resistant hot gunning mix is prepared from refractory aggregate and a binding agent, wherein the addition amount of the binding agent is 25-30% of the total weight of the refractory aggregate;
the refractory aggregate is composed of composite metal powder, silica particles with the particle size of 3-1mm, silica particles with the particle size of 1-0.088mm and silica fine powder with the particle size of less than 0.088;
the refractory aggregate comprises the following raw materials in percentage by weight: 3-6% of composite metal powder, 20-30% of silica particles with the particle size of 3-1mm, 30-40% of silica particles with the particle size of 1-0.088mm and 34-37% of silica fine powder with the particle size of less than 0.088 mm.
Wherein, the bonding agent is nanometer silica sol.
Wherein the composite metal powder is composed of metal silicon powder with the granularity of 325 meshes or less and metal aluminum powder with the granularity of 325 meshes or less.
Wherein the metal silicon powder and the metal aluminum powder in the composite metal powder comprise the following components in percentage by weight: 80-90% of metal silicon powder and 10-20% of metal aluminum powder.
The invention prepares the composite metal fine powder and the superfine powder by fully mixing the metal silicon powder below 325 meshes with the metal aluminum powder below 325 meshes, so that the metal silicon powder and the aluminum powder are further dispersed in the gunning mix, and more importantly, when in use, the high-temperature aluminum powder is at the high temperature of a carbon calcining furnace bodyAnd forming a new high temperature ceramic bonding mass under an oxidizing atmosphere: acicular mullite crystal phase 3Al2O3·2SiO2And quartz SiO2The formed new high-temperature ceramic bonding substances greatly improve the wear resistance and the thermal shock stability of the gunning material, and in addition, the superfine silicon micro powder and the aluminum micro powder which are partially unreacted in the subsequent process are interwoven with the acicular mullite crystal phase 3Al generated in the subsequent process2O3·2SiO2And quartz SiO2Around the whiskers of the amorphous phase, a firm skeleton effect is formed, thereby improving the final strength.
Because the raw material of the invention is silica which has similar performance to the common silica brick of the furnace body of the carbon calciner, the expansion or contraction degree of the gunning mix is closer to that of the silica brick at different temperatures, thereby reducing the internal stress, enhancing the adhesive property of the gunning mix, leading the gunning mix to be firmly adhered on the furnace body and prolonging the service life of the gunning mix.
The preparation method of the ceramic wear-resistant hot gunning mix comprises the following steps:
step one, preparing composite metal powder: fully mixing 80-90% of metal silicon powder with the granularity of less than 325 meshes by weight and 10-20% of metal aluminum powder with the granularity of less than 325 meshes by weight; obtaining composite metal powder;
and secondly, weighing 20-30% of silica particles with the particle size of 3mm-1mm, 30-40% of silica particles with the particle size of 1mm-0.088mm, 34-37% of silica fine powder with the particle size of less than or equal to 0.088mm and 3-6% of composite metal powder according to the weight percentage, adding the raw materials into a vertical forced stirrer for mixing for 6-8min, packaging the raw materials into woven bags with inner films to obtain the single weight of 25Kg or 50Kg, and placing the single weight and the prepared nano silica sol well to obtain the ceramic wear-resistant thermal spray repair material for the carbon calciner.
The invention also provides a construction method of the ceramic wear-resistant hot gunning mix, which comprises the following steps: pouring the refractory aggregate into a stirrer, adding the sol binder, wherein the adding amount is 25-30% of the total weight of the refractory aggregate, uniformly stirring, completely wrapping the nano silica sol on the surface of the refractory aggregate, and performing secondary spraying on the damaged part of the furnace wall of the carbon calciner by using a spraying machine without ageing.
Wherein the sol binder coats the refractory aggregate with sol material, the nano silica sol contains a large amount of water and hydroxyl, and the nano silica sol reacts with the original material under the action of the temperature of the carbon calcining furnace body to form SiO under the subsequent use2And the ceramic is combined, so that the high-temperature strength of the gunning material is further enhanced, and the wear resistance and the thermal shock stability are further enhanced.
Compared with the gunning mix for the carbon calcining furnace in the market, the gunning mix for the carbon calcining furnace in the market uses the acidic binder phosphoric acid or aluminum dihydrogen phosphate, is easy to react with the simple substance iron brought in the refractory raw material during processing to swell, so the gunning mix can be used only after being subjected to ageing (after reacting with the simple substance iron), the neutral sol binder is used, and the neutral sol binder can not react with the simple substance iron in the refractory material, so the ageing is not needed, and the operation is simple.
The gunning mix for the carbon calcining furnace in the current market is as follows: 1. the defects that siliceous mud or clay mud is used for spray repair maintenance of small holes are as follows: the strength of the slurry is low, and frequent spray repair is needed; 2. and for the cavity with larger damage, the furnace is shut down to observe the damage condition of the silica brick, and when the temperature in the furnace is reduced to the construction temperature, the silica brick is dug and repaired.
The invention adopts 3-1mm, 1-0.088mm refractory aggregate and-0.088 mm powder, can carry out spray repair on smaller cavities and can also carry out repair on larger cavities, and adopts multistage particle gradation of 3-1mm, 1-0.088mm refractory aggregate and-0.088 mm powder, can obviously improve the volume density, the strength and the wear resistance of the spray repair material, can avoid the small cavities from being frequently sprayed and repaired by siliceous mud or clay mud consisting of fine powder, and can also avoid the damage to the larger cavities and the shutdown for using silica bricks for repair, thereby realizing the repair of the larger cavities without stopping the furnace and influencing the production problem.
Because the air flow and material flow in the furnace damage the furnace body, the invention utilizes the opportunity of fixed repair or short-term air repair of the calcining furnace or carries out hot spray repair under the condition of no production stop, improves the operating rate of the calcining furnace, reduces the heat loss of major repair cooling, increases the production and reduces the consumption, and divides various raw materials into multi-grade granularity, fine powder and ultramicroThe powder is filled in the pore space of the particle stack, so that the mixing is more sufficient, the raw materials are uniformly dispersed, and a smaller intercrystalline gap can be reserved when the powder is used; the sol binder is nano silica sol, the sol binder coats the surface of the refractory aggregate with sol substances, the nano silica sol contains a large amount of water and hydroxyl, and the nano silica sol reacts with the original material under the action of the temperature of a carbon calcining furnace body to form SiO during subsequent use2And the ceramic is combined, so that the high-temperature strength of the gunning material is further enhanced, and the wear resistance and the thermal shock stability are further enhanced.
The ceramic wear-resistant thermal-state gunning material disclosed by the invention has the advantages that the bonding strength and the wear resistance of bricks and the gunning material are improved, the gunning times are reduced, the construction strength is reduced, and the labor and energy losses are reduced. When the method is applied to a carbon calcining furnace, the furnace which is seriously damaged and faces the production stop can be continuously used for a long time after being thermally sprayed under the condition of no production stop, so that a user is prevented from huge economic loss caused by the production stop. The material can also be used for filling the position which is not suitable for masonry during cold repair of the kiln, is an ideal material for reinforcing the masonry, and can prolong the service life of the kiln.
The ceramic wear-resistant hot-state gunning material has the excellent performances of high temperature resistance, erosion resistance, wear resistance, stripping resistance, stable high-temperature volume, good compatibility with residual brick masonry, strong bonding capability, convenient construction and the like, and is an ideal refractory material for hot repair when masonry such as a pot wall of a carbon calciner and a carbonization chamber of a coke oven is damaged.
Detailed Description
The invention is further described with reference to specific embodiments, without limiting its scope.
Example 1
The weight fractions of the components in this example are shown in table 1.
Example 2
The weight fractions of the components in this example are shown in Table 2.
Example 3
The weight fractions of the components in this example are shown in Table 3.
Example 4
The weight fractions of the components in this example are shown in Table 4.
The preparation method of the ceramic wear-resistant hot-state gunning mix of the embodiments 1, 2, 3 and 4 comprises the following steps:
step one, preparing composite metal powder: fully mixing 80-90% of metal silicon powder with the granularity of less than 325 meshes by weight and 10-20% of metal aluminum powder with the granularity of less than 325 meshes by weight; obtaining composite metal powder;
and secondly, weighing 20-30% of silica particles with the particle size of 3mm-1mm, 30-40% of silica particles with the particle size of 1mm-0.088mm, 34-37% of silica fine powder with the particle size of less than or equal to 0.088mm and 3-6% of composite metal powder according to the weight percentage, adding the raw materials into a vertical forced stirrer for mixing for 6-8min, packaging the raw materials into woven bags with inner films to obtain the single weight of 25Kg or 50Kg, and placing the single weight and the prepared nano silica sol well to obtain the ceramic wear-resistant thermal spray repair material for the carbon calciner.
The construction method of the ceramic wear-resistant hot gunning mix comprises the following steps: pouring the refractory aggregate into a stirrer, adding the sol binder, wherein the adding amount is 25-30% of the total weight of the refractory aggregate, uniformly stirring, completely wrapping the nano silica sol on the surface of the refractory aggregate, and performing secondary spraying on the damaged part of the furnace wall of the carbon calciner by using a spraying machine without ageing.
Claims (3)
1. Ceramic wear-resistant materialThe hot gunning mix is characterized in that: is prepared by refractory aggregate and a bonding agent, wherein the addition amount of the bonding agent is 25-30% of the total weight of the refractory aggregate; the refractory aggregate is composed of composite metal powder, silica particles with the particle size of 3-1mm, silica particles with the particle size of 1-0.088mm and silica fine powder with the particle size of less than 0.088; the refractory aggregate comprises the following raw materials in percentage by weight: 3-6% of composite metal powder, wherein the composite metal powder consists of metal silicon powder with the granularity of 325 meshes and metal aluminum powder with the granularity of 325 meshes, and the weight percentages are as follows: 80-90% of metal silicon powder and 10-20% of metal aluminum powder; 20-30% of silica particles with a particle size of 3-1mm, 30-40% of silica particles with a particle size of 1-0.088mm, and 34-37% of silica fine powder with a particle size of less than 0.088 mm; the bonding agent is nano silica sol, and the metal silicon powder and the aluminum powder form a new high-temperature ceramic bonding substance in the ceramic wear-resistant hot gunning mix at the high temperature of the carbon calcining furnace body: acicular mullite crystal phase 3Al2O3·2SiO2And quartz SiO2An amorphous crystalline phase.
2. The preparation method of the ceramic wear-resistant hot gunning mix as claimed in claim 1, wherein: step one, preparing composite metal powder: fully mixing 80-90% of metal silicon powder with the granularity of less than 325 meshes by weight and 10-20% of metal aluminum powder with the granularity of less than 325 meshes by weight; obtaining composite metal powder; and secondly, weighing 20-30% of silica particles with the particle size of 3mm-1mm, 30-40% of silica particles with the particle size of 1mm-0.088mm, 34-37% of silica fine powder with the particle size of less than or equal to 0.088mm and 3-6% of composite metal powder according to the weight percentage, adding the raw materials into a vertical forced stirrer for mixing for 6-8min, packaging the raw materials into woven bags with inner films to obtain the single weight of 25Kg or 50Kg, and placing the single weight and the prepared nano silica sol well to obtain the ceramic wear-resistant thermal spray repair material for the carbon calciner.
3. The construction method of the ceramic wear-resistant hot gunning mix as claimed in claim 1, wherein: pouring the refractory aggregate into a stirrer, adding the sol binder, wherein the adding amount is 25-30% of the total weight of the refractory aggregate, uniformly stirring, completely wrapping the nano silica sol on the surface of the refractory aggregate, and performing secondary spraying on the damaged part of the furnace wall of the carbon calciner by using a spraying machine without ageing.
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| CN107032810A (en) * | 2017-05-23 | 2017-08-11 | 武汉钢铁有限公司 | A kind of excellent sintering large flue gunning refractory of adhesive property and preparation method |
| CN110041058A (en) * | 2019-05-10 | 2019-07-23 | 武汉钢铁有限公司 | A kind of material for repairing for coke oven furnace lining |
| CN110981509A (en) * | 2019-12-16 | 2020-04-10 | 江苏诺明高温材料股份有限公司 | Preparation method of low-cost low-water-demand siliceous heat supplementing material |
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| CN111574233A (en) | 2020-08-25 |
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