CN111825469B - 一种单铁口高炉用环保无水炮泥及其制备方法 - Google Patents
一种单铁口高炉用环保无水炮泥及其制备方法 Download PDFInfo
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Abstract
本发明属于高炉用耐火材料技术领域，公开了一种单铁口高炉用环保无水炮泥及其制备方法。所述炮泥由包括以下质量百分含量的原料配制而成：蓝晶石尾矿10％～25％；回收硅莫砖颗粒10％～35％；干熄焦焦末10％～15％；石墨化炉保温料5％～15％；粘土9％～15％；硅微粉1％～5％；绢云母3％～10％；碳化硅抽尘粉5％～15％；回收铝矾土粉15％～25％；环保沥青2％～5％；环保煤焦油15％～18％。本发明原料中大比例使用尾矿或工业固废，不仅大大降低了炮泥生产成本，而且有利于节能环保，促进资源再利用，同时制得的炮泥使用时操作方便、铁口深度稳定、易打泥、好开口、抗冲刷，出铁时无喷溅无浓烟黄烟，苯并a芘含量小于50㎎/kg，不仅更有利于改善高炉生产区域环境，而且保证了作业人员的身体健康。
Description
技术领域
本发明属于高炉用耐火材料技术领域，具体涉及一种单铁口高炉用环保无水炮泥及其制备方法。
背景技术
钢铁工业是中国的基础性工业，在国民经济中起着重要作用，截至2019年，我国钢铁年产能已超过9.9亿吨。高炉炼铁作为目前最主要的冶炼方式，运行过程中，需用炮泥来堵塞出铁口，因此炮泥质量和性能的优劣直接影响到高炉的安全稳定运行。
目前我国仍存在一大批单铁口高炉继续生产。由于单铁口连续出铁时，出铁间隔时间明显缩短，通常不超过30分钟，炮泥的烧结时间当也大大缩短，使得单铁口出铁所需要的炮泥性能要求更高。而现在市面上使用的炮泥多数照搬多出铁口高炉炮泥配方，往往存在成本较高、炮泥烧结不好、强度偏低、抗渣侵蚀性差、不耐熔渣和铁水的冲蚀，经常出现潮铁口和漏铁口现象，难以满足单铁口高炉使用的需求；虽然也有少量公开报道的单铁口高炉用炮泥，但通常采用普通煤焦油或蒽油为结合剂，且结合剂加入量往往偏高，导致炮泥在使用过程中会冒出大量的有毒黄烟，烟尘中苯并a芘含量远超1000㎎/kg。不仅使得工作条件更加恶劣，而且严重污染环境，同时苯并芘是世界公认的致癌物质之一，还会严重威胁到工人健康。
基于此，开发一种成本低廉、性能优良、安全环保的单铁口高炉用无水炮泥具有十分重要的现实意义。
发明内容
针对现有技术中存在的问题，本发明的目的是要提供一种成本低廉、铁口深度稳定、易打泥、好开口、抗冲刷、苯并芘含量低的单铁口高炉用环保无水炮泥及其制备方法。
本发明提供了一种单铁口高炉用环保无水炮泥，由包括以下质量百分含量的原料配制而成：
具体的，所述的蓝晶石尾矿粒度大于0mm且小于2mm，其中Al2O3含量≥10.00wt％，SiO2含量≥80.00wt％。
具体的，所述的回收硅莫砖颗粒为水泥回转窑用后拆除的硅莫砖残衬，经拣选、加工、破碎而成的颗粒，其粒度大于0mm且小于或等于1mm以及大于1mm且小于或等于3mm的两种颗粒级配组成，二者比例为3:7，其中Al2O3+SiC含量≥65.00wt％。
具体的，所述的干熄焦焦末粒度大于0mm且小于3mm，其中固定碳含量≥82.00wt％。
具体的，所述的石墨化炉保温料粒度大于0mm且小于3mm，其中SiC+C含量≥75.00wt％。
具体的，所述的粘土可选择焦作粘土，所述粘土粒度小于或等于200目。
具体的，所述的硅微粉为92硅微粉，其粒度小于或等于325目，SiO2含量≥92.00wt％，所述的绢云母可选择滁州绢云母，粒度小于或等于200目。
具体的，所述的碳化硅抽尘粉为碳化硅加工中产生的90碳化硅抽尘粉，其粒度小于或等于325目，SiC含量≥90.00wt％。
具体的，所述的回收铝矾土粉为研磨材料加工中产生的83铝矾土筛下粉，其粒度小于或等于200目，其中Al2O3含量≥83.00wt％。
具体的，环保沥青为高温煤焦油经脱水和除盐工艺处理后，将其加热至300～400℃，经过含有活性炭、钛白粉及钼酸锰等成份的滤网，处理后的原料经高压反应釜制得。所述环保沥青粒度大于0mm且小于或等于1mm，软化点温度为110±5℃，其中固定碳含量≥50.00wt％，且其苯并a芘含量小于400㎎/kg。
具体的，所述的环保煤焦油为200至380℃的高温煤焦油某一窄温度段的馏出物，其水分小于1％，其在55℃的运动粘度为100～200厘泊，800℃×7min检测残炭大于30wt％，且其苯并a芘含量小于200㎎/kg。
本发明还提供了如前文所述的单铁口高炉用环保无水炮泥的制备方法，包括以下步骤：
(1)按重量百分含量称取各原料，首先将环保沥青加入到环保煤焦油中在120℃保温12小时混合搅拌制得环保结合剂，环保结合剂中水分小于1％；
(2)将其余原料加入混碾机内干混5min，然后加入上述制得的温度保持在50±5℃的液体结合剂，混碾35～40min制得混合泥料，待混合泥料温度达到55±5℃后，取样检测马夏值；
(3)马夏值测量合格后进行出料，然后采用挤泥机挤出成型，切割包装得炮泥。
与现有技术相比，本发明的优点是:
1.本发明原料中大比例使用尾矿或工业固废，变废为宝，资源得到高效利用，不仅大大降低了生产成本，提高了产品性价比，而且有利于节能环保，形成绿色低碳循环经济。
2.本发明以环保沥青和环保煤焦油为结合剂，其中环保沥青为高温煤焦油经脱水和除盐工艺处理后，将其加热至300～400℃，经过含有活性炭、钛白粉及钼酸锰等成份的滤网，处理后的原料经高压反应釜制得；环保煤焦油可以由煤焦油蒸馏然后脱除苯并芘后加工而得；环保煤焦油为200至380℃的高温煤焦油某一窄温度段的馏出物。不仅原料易得，成本低廉，而且制得的炮泥产品中苯并a芘含量小于50㎎/kg，远低于行业标准《高炉用无水炮泥》YB/T4196-2018规定的100mg/kg，从而使得生产加工过程中不产生挥发性气体，无刺激性气味，开口出铁时无喷溅无浓烟黄烟，不仅有利于改善高炉生产区域环境，而且保证了作业人员的身体健康。
3.实验证明，本发明提供的环保无水炮泥在多座以上单铁口高炉上使用时，操作方便，易开易堵，铁口深度稳定，能够较好维护铁口区域炉墙；同时抗冲刷、抗渣性能稳定，不会出现夹铁、断铁口等现象，更能满足快速烧结强化的单铁口高炉应用需求，此外，其每次开口时所需钢钎较少，无需耗费氧管，既节省了炉前耗材，也降低了炉前职工的劳动强度。
具体实施方式
下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述。显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
以下实施例中，所述的蓝晶石尾矿粒度大于0mm且小于2mm，其中Al2O3含量≥10.00wt％，SiO2含量≥80.00wt％；所述的回收硅莫砖颗粒为水泥回转窑用后回收的硅莫砖颗粒，其由粒度大于0mm且小于或等于1mm以及大于1mm且小于或等于3mm的两种颗粒级配组成，其中Al2O3+SiC含量≥65.00wt％；所述的干熄焦焦末粒度大于0mm且小于3mm，其中固定碳含量≥82.00wt％；所述的石墨化炉保温料粒度大于0mm且小于3mm，其中SiC+C含量≥75.00wt％；所述的粘土可选择焦作粘土，所述粘土粒度小于或等于200目；所述的硅微粉为92硅微粉，其粒度小于或等于325目，SiO2含量≥92.00wt％，所述的绢云母粒度小于或等于200目；所述的碳化硅抽尘粉为碳化硅加工中产生的90碳化硅抽尘粉，其粒度小于或等于325目，SiC含量≥90.00wt％；所述的回收铝矾土粉为研磨材料加工中产生的83铝矾土筛下粉，其粒度小于或等于200目，其中Al2O3含量≥83.00wt％；所述的环保沥青粒度大于0mm且小于或等于1mm，软化点温度为110±5℃，其中固定碳含量≥50.00wt％，且其苯并a芘含量小于400㎎/kg；所述的环保煤焦油中水分小于1％，其在55℃的运动粘度为100～200厘泊，800℃×7min检测残炭大于30.00wt％，且其苯并a芘含量小于200㎎/kg。
实施例1
一种单铁口高炉用环保无水炮泥，由包括以下质量百分含量的原料配制而成：
一种单铁口高炉用环保无水炮泥的制备方法，包括以下步骤：
(1)按重量百分含量称取各原料，首先将环保沥青加入到环保煤焦油中混合搅拌制得液体结合剂，控制液体结合剂中水分小于1％；
(2)将其余原料加入混碾机内干混5min，然后加入上述制得的温度保持在50±5℃的液体结合剂，混碾35～40min制得混合泥料，待混合泥料温度达到55±5℃后，取样检测马夏值；
(3)马夏值测量合格后进行出料，然后采用挤泥机挤出成型，切割包装得炮泥。
(4)检测上述制得的泡泥产品的理化性质见表1。
将本实施例1制得的炮泥产品在国内某铸造企业180m3高炉上使用，日产铁水450吨，要求炮泥使用后无潮泥喷溅，铁口深度大于1.3米，出铁时间大于30min，不烧氧，开口时间小于15min。本实施例炮泥使用3天统计结果为：无潮泥无喷溅无黄烟，平均铁口深度1.35米，平均出铁时间35min，每炉打泥量65±10kg，无漏铁口断铁口，每炉使用钢钎1～3根，无烧氧，开口平均耗时7min。
实施例2
本实施例与实施例1基本相同，不同之处在于，一种单铁口高炉用环保无水炮泥，由包括以下质量百分含量的原料配制而成：
将本实施实例2制得的炮泥产品在国内某钢铁集团350m3高炉上使用，日产铁水1200吨。本实施例炮泥跟之前炮泥相比：铁口深度由1.2米稳定至1.5米，平均出铁时间由37min提高至48min，打泥量由120kg降至100kg，开口平均耗时由15min降至10min，本实施例炮泥使用无黄烟或喷溅。
实施例3
本实施例与实施例1基本相同，不同之处在于，一种单铁口高炉用环保无水炮泥，由包括以下质量百分含量的原料配制而成：
将本实施实例3制得的炮泥产品在国内某企业618m3高炉上使用，日产铁水量2300吨。本实施例30天514炉统计结果为：平均铁口深度1.9米，平均出铁时间53min，平均打泥量120kg，开口方式为直径45mm钻头钻至1米更换直径32mm钢钎，漏铁口5次，烧氧0炉，出铁现场无浓烟，开口平均耗时9min。
对比例
设置对比例1～3分别与上述实施例1～3的原料组分配比及制备方法相对应，不同之处在于，对比例1～3中采用普通煤沥青和煤焦油作为结合剂原料，本发明实施例1～3炮泥产品与对比例实施例1～3制得的炮泥产品的性能对比结果见表2。
表1为本发明实施例1～3炮泥产品理化性质
表2为本发明实施例1～3炮泥产品与对比例实施例1～3炮泥产品性能对比
由表1和表2可知，本发明制得的炮泥产品理化性能优良，苯并a芘含量均小于50㎎/kg，满足行业标准《高炉用无水炮泥》YB/T4196-2018规定的100mg/kg的规定，使用起来更加安全环保无污染，而且本发明制得的炮泥产品使用时干燥速度更快，且开口出铁时无喷溅无浓烟黄烟，更有利于改善高炉生产区域得环境以及保证作业人员的身体健康。
对所公开的实施例的上述说明，使本领域技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实+施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (2)
1.一种单铁口高炉用环保无水炮泥，其特征在于，由包括以下质量百分含量的原料配制而成：
蓝晶石尾矿 10%～25%；
回收硅莫砖颗粒 10%～35%；
干熄焦焦末 10%～15%；
石墨化炉保温料 5%～15%；
粘土 9%～15%；
硅微粉 1%～5%；
绢云母 3%～10%；
碳化硅抽尘粉 5%～15%；
回收铝矾土粉 15%～25%；
环保沥青 1%～5%；
环保煤焦油 15%～18%；
上述各成分质量百分含量之和为100%；
其中，所述的蓝晶石尾矿粒度大于0mm且小于2mm，其中Al2O3含量≥10.00wt%，SiO2含量≥80.00wt%；
所述的回收硅莫砖颗粒为水泥回转窑用后拆除的硅莫砖残衬，经拣选、加工、破碎而成的颗粒，其粒度大于0mm且小于或等于1mm以及大于1mm且小于或等于3mm的两种颗粒级配组成，二者比例为3：7，其中Al2O3+SiC含量≥65.00wt%；
所述的干熄焦焦末粒度大于0mm且小于3mm，其中固定碳含量≥82.00wt%；所述粘土粒度小于或等于200目；所述的硅微粉为92硅微粉，其粒度小于或等于325目，SiO2含量≥92.00wt%；所述的绢云母粒度小于或等于200目；
所述的碳化硅抽尘粉为碳化硅加工中产生的90碳化硅抽尘粉，其粒度小于或等于325目，SiC含量≥90.00wt%；
所述的回收铝矾土粉为研磨材料加工中产生的83铝矾土筛下粉，其粒度小于或等于200目，其中Al2O3含量≥83.00wt%；
所述环保沥青的制备过程为：高温煤焦油经脱水和除盐工艺处理后，将其加热至300～400℃，然后经过含有活性炭、钛白粉及钼酸锰成份的滤芯进行处理，处理后所得原料经高压反应釜制得环保沥青；所述环保沥青粒度大于0mm且小于或等于1mm，软化点温度为110±5℃，其中固定碳含量≥50.00wt%，且其苯并a芘含量小于400mg/kg；
所述环保煤焦油为高温煤焦油在200～380℃温度段的馏出物，所述的环保煤焦油中水分小于1%，其在55℃的运动粘度为100～200厘泊，800℃×7min检测残炭大于30wt%，且其苯并a芘含量小于200㎎/kg；
所述单铁口高炉用环保无水炮泥是通过以下制备方法所得：
（1）按重量百分含量称取各原料，首先将环保沥青加入到环保煤焦油中，在120℃保温12小时混合搅拌制得环保结合剂，环保结合剂中水分小于1%；
（2）将其余原料加入混碾机内干混5min，然后加入上述制得的温度保持在50±5℃的环保结合剂，混碾35～40min制得混合泥料，待混合泥料温度达到55±5℃后，取样检测马夏值；
（3）马夏值测量合格后进行出料，然后采用挤泥机挤出成型，切割包装得炮泥。
2.如权利要求1所述的单铁口高炉用环保无水炮泥，其特征在于：所述的石墨化炉保温料为石墨化炉石墨化处理工艺中经高温性能结构发生变化用后的保温料，其粒度大于0mm且小于3mm，其中SiC+C含量≥75.00wt%。
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