CN112358302A - 一种自修复无水炮泥 - Google Patents
一种自修复无水炮泥 Download PDFInfo
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Abstract
本发明涉及硅铁生产技术领域,具体涉及一种自修复无水炮泥,包括以粉料41‑45%、骨料39‑45%、结合剂11‑14.5%、抗氧化剂1.5‑1.9%以及增塑剂0.9‑1.4%。所述粉料包括硅灰、粉煤灰以及粘土,所述骨料包括无烟煤、焦粉、石墨以及废旧碳砖,所述结合剂包括煤焦油、酚醛树脂、磷酸铝以及沥青粉,所述抗氧化剂包括Al粉、Fe粉以及Si粉,所述增塑剂包括羧甲基纤维素钠和聚乙烯醇。本发明通过调整组分和配比得到一种自修复无水炮泥,在高温条件下能够与炉眼砖牢固的结合为一体,自行修复逐渐扩大的炉眼尺寸,在满足堵铁口功能的同时,延长了修复周期,增加炉眼砖的使用寿命。
Description
技术领域
本发明涉及硅铁生产技术领域,具体涉及一种自修复无水炮泥。
背景技术
冶炼硅铁的矿热炉一般设置2-4个出铁口,硅铁合金和少量渣液从出铁口排出,因此,出铁口是矿热炉非常重要的部位。随着硅铁生产用矿热炉的大型化和强化冶炼技术的进步,出铁次数的增多,该部位的工艺条件变得更加苛刻。矿热炉在出铁水完成后,出铁口用炮泥堵塞,在矿热炉运行过程中,高温铁水及高压煤气射流频繁冲刷、侵蚀出铁口,并且在开、堵出铁口操作时,机械的震动和撞击,导致炉眼砖损坏速度快、使用周期较短、维护频率高,修眼的周期为2周左右;炉眼砖重新砌筑频率高,炉眼砖的使用寿命为2-3年,更换炉眼砖的直接及间接成本均较高,经济技术指标差。
利用回收粉煤灰、废旧碳砖等生产废弃物,可以减小了环境污染,降低生产成本。粉煤灰是由燃料(主要是煤)燃烧过程中排出的微小灰粒,燃料燃烧所产生烟气灰分中的细微固体颗粒物。废耐火砖为钢厂、水泥厂、玻璃窑、耐火材料厂等炉窑使用过废弃的耐火砖。通常被作为垃圾遗弃,不能作为高炉的耐火材料如高炉出铁口的炮泥的原料利用,既污染环境,又需要大量的处置场地,且处理费用高。
专利文献CN201611218948.X公开一种矿热炉用环保无水炮泥及其制备方法,无水炮泥按重量份计,镁橄榄石:10-20重量份,镁砂:10-45重量份,碳化硅:10-20重量份,焦炭:10-25重量份,沥青:5-15重量份,黏土:10-20重量份,氮化物:5-15重量份,蓝晶石:3-10重量份,石英粉:0-15重量份,炭黑油:12-20重量份,蒽油:2-8重量份,以及增塑剂:0.5-2重量份,其中,氮化物为氮化硅铁、氮化硅、氮化铝和氮化钛中的一种或几种混合,预混炭黑油和蒽油形成复合环保结合剂备用;原材料称好,加入混碾机干混;加入结合剂,混碾;加入增塑剂,搅拌;挤压成型。该发明对人体和环境安全,且高性能、低消耗、有良好的抗熔渣侵蚀、耐冲刷性能,但是自修复性能较差,堵眼效果有待提升。
专利文献CN201810042644.5公开了一种矿热炉用炮泥及其制备方法。炮泥的特征是具有回收铝碳化硅、碳砖破碎料。制备方法是:取按重量份比例的散料;粘土、绢云母粉、高温沥青、三氧化二铝微粉、蓝晶石、氮化硅铁;把改性煤焦油加热到70-90℃;把回收铝碳化硅、碳砖破碎料与焦粒混匀,加热至30-40℃;在颗粒料中加入3/4左右的改性煤焦油,混料3-5分钟,加入预混好的细粉部分,碾制25分钟以上,加入剩余的改性煤焦油碾8分钟以上;在上述步骤中混匀热好的散料中加入大部分的改性煤焦油,混料3-5分钟,加入最先步骤预混好的散料,碾制25分钟以上,加入剩余的改性煤焦油,碾8分钟以上。该矿热炉用炮泥及其制备方法的炮泥利用废耐火材料,生产成本低,但是制备分拣手续繁杂。
专利文献CN201711080223.3公开了一种矿热炉用无水炮泥及其制备方法。该矿热炉用无水炮泥包括以下重量份的各组分:耐火胶介质粉末20-30份,骨料15-25份,氮化硅8-16份,塑结剂15-20份,附着剂2-5份,粉煤灰2-5份,冶金固体废弃物40-50份。该发明所提供的矿热炉用无水炮泥,可大幅度提高单个炉眼使用周期,提高单个炉眼使用寿命。同时,可保证炉况长时间顺行,排渣、炭正常,可间接提高生产指标,但是同样存在自修复性能较差的问题。
综上,目前国内硅铁矿热炉用无水炮泥功能上仅仅满足堵铁口的需求,存在的问题也比较明显,即炉眼砖寿命较短,通常矿热炉的大修周期较短,增加了矿热炉的运行成本。同时,粉煤灰、废旧碳砖等废物的处理也系带解决,因此,能有效利用粉煤灰与废旧碳砖等生产废物,且堵铁口后与炉眼砖结合能力较强的无水炮泥材料就显得尤为重要。
发明内容
本发明的目的在于克服现有技术的不足,提供一种在高温条件下能够与炉眼砖牢固的结合为一体,自行修复逐渐扩大的炉眼尺寸的自修复无水炮泥,在满足堵铁口功能的同时,延长修复周期,增加炉眼砖的使用寿命。
本发明的目的通过以下技术方案来实现:
一种自修复无水炮泥,其特征在于,包括以下质量百分比的原料:粉料41-45%、骨料39-45%、结合剂11-14.5%、抗氧化剂1.5-1.9%以及增塑剂0.9-1.4%;
所述粉料为选自硅灰、粉煤灰以及粘土中的一种或几种,所述骨料为选自无烟煤、焦粉、石墨以及废旧碳砖中的一种或几种,所述结合剂为选自煤焦油、酚醛树脂、磷酸铝以及沥青粉中的一种或几种,所述抗氧化剂为选自Al粉、Fe粉以及Si粉中的一种或几种,所述增塑剂为羧甲基纤维素钠和/或聚乙烯醇。
本发明优选地技术方案中,包括以下质量百分比的原料:硅灰15-20%、粉煤灰15-25%、粘土3-7%、无烟煤5-10%、焦粉5-10%、石墨2-5%、废旧碳砖21-26%、煤焦油7-11%、酚醛树脂0.3-0.7%、磷酸铝0.3-0.8%、沥青粉1.4-5%、Al粉0.2-0.5%、Fe粉0.3-0.6%、Si粉0.8-1.2%、羧甲基纤维素钠0.5-1%以及聚乙烯醇为0.3-0.5%。
本发明优选地技术方案中,包括以下质量百分比的原料:硅灰15%、粉煤灰25%、粘土5%、无烟煤5%、焦粉10%、石墨2%、废旧碳砖22.2%、煤焦油8.3%、酚醛树脂0.5%、磷酸铝0.5%、沥青粉4.5%、Al粉0.3%、Fe粉0.4%、Si粉0.8%、羧甲基纤维素钠0.5%以及聚乙烯醇0.5%。
本发明优选地技术方案中,所述硅灰、粉煤灰与粘土粒度均≥60目;所述焦粉与石墨粒度范围为16-60目;所述无烟煤与废旧碳砖粒度范围为4-16目;所述沥青粉、Al粉、Fe粉与Si粉粒度均≥400目。
本发明优选地技术方案中,所述的硅灰中SiO2含量≥85%,CaO+MgO含量≤4.5%,Fe2O3+C含量≤3.5%。
本发明优选地技术方案中,所述的粉煤灰中SiO2+Al2O3含量≥85%,Fe2O3含量≤6%,CaO+MgO含量≤4.5%。
本发明优选地技术方案中,所述的粘土中SiO2含量≥44%,Al2O3含量≥37%,Fe2O3含量≤2%,TiO2含量≤2%,CaO+MgO含量≤0.8%,K2O+Na2O含量≤0.8%。
本发明优选地技术方案中,所述的焦粉C含量≥85%。
本发明优选地技术方案中,所述的石墨C含量≥90%。
本发明优选地技术方案中,所述的废旧碳砖C含量≥85%。
本发明优选地技术方案中,所述的废旧碳砖为硅铁矿热炉和/或硅锰矿热炉大修时更换的炉墙和/或炉底碳砖。
本发明的硅灰、粉煤灰和粘土作为粉料,起填充骨料空隙、改善泥球制作加工性能、提高无水炮泥高温下的强度以及增强料性等作用,同时还具有良好的结合性能,填充于骨料所形成的间隙,达到最佳的堆积密度,便于获得堵眼结实、不易跑眼等最佳的使用性能。选用硅灰、粉煤灰和粘土作为粉料是充分利用其粒度较小以及主要成分为SiO2、Al2O3且具有耐火度高、热导率小的特性,能够缩短无水炮泥堵眼后的烧成时间,提高堵眼的牢固程度,减少跑眼等安全事故的发生,尤其是硅灰、粉煤灰属于工业固废,在减少资源消耗的同时,变废为宝,大大的降低了无水炮泥的原料成本。本发明中粉料总的重量百分比为41-45%时,具有最佳的使用性能,能显著减少骨料中大量微小空隙的存在,同时提高了骨料之间的结合性,堵眼烧结后的无水炮泥强度较高,不易发生脱落现象,大大的提高了堵眼的安全系数。同时大量微小粉体小颗粒的存在,有利于硅铁炉的开眼,有利于顺畅生产,减少炉前工人开眼过程中的劳动强度。
本发明的无烟煤、焦粉、石墨和废旧碳砖作为骨料,在无水炮泥成型过程中起到骨架的作用,尤其是在高温条件下,具有良好的物理力学性能,具有较高的耐火度,堵眼结实。同时,低成本骨料的大量引入,特别是废旧碳砖的添加,在满足使用性能的同时,大大的降低了无水炮泥的成本,且实现了废旧碳砖的循环再利用。本发明中骨料总的重量百分比为39-45%时,具有最佳的使用性能,此时烧结后的无水炮泥对炉眼的修复效果恰好,且在高温情况下强度较高,不易于脱落。骨料总的重量百分比大于45%时,则对炉眼的修复效果过强,正常生产过程中,不到两天时间炉眼直径就小于80mm,难以满足正常的出铁要求;骨料总的重量百分比小于39%时,则对炉眼的修复效果过弱,正常生产过程中,十天左右时间炉眼直径就扩大到150mm,需要对炉眼进行修复,增加了维修成本。
本发明的煤焦油、酚醛树脂、磷酸铝和沥青粉作为结合剂,是无水炮泥的重要组分,在混料过程中,结合剂可以促使各类原料的混合均匀,填充空隙,提高无水炮泥的粘结强度,使用过程中,煤焦油和沥青炭化,提高了残炭量,对炮泥的高温性能有利,同时煤焦油中的非碳元素挥发排出,剩余的碳原子形成类石墨微晶,这些微晶的层状晶格呈不规则排列,高度分散,填充和封闭无水泥球与炉眼砖之间的空隙,提高了堵眼的牢固程度。本发明中结合剂总的重量百分比为11-14.5%时,具有最佳的使用性能,此时无水炮泥的体积密度、耐压强度比较高,内部的气孔率较小。在炮泥制作过程中不添加水,因此添加酚醛树脂、磷酸铝,提高常温下的成型能力。
本发明的Al粉、Fe粉、Si粉作为抗氧化剂,主要作用是提高无水炮泥的耐高温、耐磨性、常温强度和高温使用性能。Al粉在高温条件下与碳反应生成碳化铝和部分的氧化铝,具有耐高温、强度高的特性,可增强材料的强度,生成的新晶相可堵塞气孔,降低气孔率,提高材料的致密度,有利于材料的常温强度和中高温强度、烧结性能和高温使用性能。同时Al粉的熔点为660℃左右,堵眼后无水炮泥的温度可达900℃以上,Al粉变为液相,有效促进无水炮泥的烧结效果。Fe粉的作用是提高无水炮泥的高温强度,促进其烧结效果,减少炮泥内部的气孔率,提高堵眼牢固程度。Si粉在超过800℃时会与C反应生成β-SiC,沉积在无水泡泥的空隙中,堵塞气孔,提高无水炮泥的抗氧化性和强度。本发明中抗氧化剂总的重量百分比为1.5-1.9%时,具有最佳的使用性能,添加量过少时,其作用难以有效体现,添加量过多时,无水炮泥堵眼高温情况下容易产生较大裂纹和气孔,不利于材料的致密化,并降低无水炮泥的高温使用性能。
本发明的羧甲基纤维素钠、聚乙烯醇作为增塑剂,其作用是增强无水炮泥混合料的可塑性,降低混料过程中物料颗粒之间的摩擦力,并提高无水炮泥的成型质量,在颗粒之间起着柔性桥联作用,避免产生较大的应变而发生破裂及裂纹,脱模后仍然可保持所需的形状。本发明中增塑剂总的重量百分比为0.9-1.4%时,具有最佳的使用性能,添加量过少时,其作用难以有效体现,添加量过多时,会增加不必要的成本,且对炮泥的高温性能不利。
本发明的粉料组成中,硅灰为15-20%,粉煤灰为15-25%,粘土为3-7%,三者的比例组合能够实现粉料在无水炮泥中的最佳使用效果,在此比例范围之外,则不能够达到本发明达到的使用效果。
本发明的骨料组成中,无烟煤为5-10%,焦粉为5-10%,石墨为2-5%,废旧碳砖为21-26%,四者的比例组合能够实现骨料在无水炮泥中的最佳使用效果,在此比例范围之外,则不能够达到本发明达到的使用效果。
本发明的结合剂组成中,煤焦油为7-11%,酚醛树脂为0.3-0.7%,磷酸铝为0.3-0.8%,沥青粉为1.4-5%,四者的比例组合能够实现结合剂在无水炮泥中的最佳使用效果,在此比例范围之外,则不能够达到本发明达到的使用效果。
本发明的抗氧化剂组成中,Al粉为0.2-0.5%,Fe粉为0.3-0.6%,Si粉为0.8-1.2%,三者的比例组合能够实现抗氧化剂在无水炮泥中的最佳使用效果,在此比例范围之外,则不能够达到本发明达到的使用效果。
本发明的增塑剂组成中,羧甲基纤维素钠为0.5-1%,聚乙烯醇为0.3-0.5%,二者的比例组合能够实现增塑剂在无水炮泥中的最佳使用效果,在此比例范围之外,则不能够达到本发明达到的使用效果。
与现有技术相比,本发明具有以下有益效果:
(1)对炉眼的修复效果显著,使用无水炮泥后,炉眼不需要修复,大大的降低了炉眼修复的费用,以及修炉作业员工的劳动强度。
(2)堵眼效果好,堵眼后经过高温的烧结,煤焦油中的非碳元素挥发排出,剩余的碳原子形成类石墨微晶,这些微晶的层状晶格呈不规则排列,高度分散,填充和封闭无水泥球与炉眼砖之间的空隙,无水炮泥和炉眼砖结合成为一体,避免生产中堵不牢,铁水从炮泥与炉眼砖之间的缝隙中穿出,发生跑眼事故,大大的提高了炉前作业的安全系数,防止人员和设备的意外损失。
(3)改变了传统硅铁生产炉前人工配置含水泥球的作业方式,降低炉前作业人员劳动强度,改善炉前作业环境。无水炮泥采用工厂化生产方式,制作加工后直接运输到硅铁炉前使用,炮泥质量稳定性好,且混料均匀。
(4)有效利用硅灰、粉煤灰、废旧碳砖等生产废弃物,降低了无水炮泥的原料成本。
具体实施方式
以下提供本发明一种自修复无水炮泥的具体实施方式,但本发明不限于所提供的实施例。
本发明实施例和对比例中的炮泥采用如下制备方法得到:
将相应的各原料按照配比放入搅拌机中,搅拌均匀后进入成型机压制成型,成型后放置1h即为成品。
在对比例1中,煤焦油为2.3%,小于本发明限定的7-11%的范围,酚醛树脂为3.5%,大于本发明限定的0.3-0.7%的范围,沥青粉为7.5%,大于本发明限定的1.4-5%的范围,此时无水炮泥的常温耐压强度≤7MPa,不在本发明使用性能的最佳范围内。在对比例2中,硅灰为25%,大于本发明限定的15-20%的范围,粘土为2%,小于本发明限定的3-7%的范围,此时无水炮泥的常温耐压强度≤7MPa,不在本发明使用性能的最佳范围内。
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员,在不脱离本发明构思的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围内。
Claims (10)
1.一种自修复无水炮泥,其特征在于,包括以下质量百分比的原料:粉料41-45%、骨料39-45%、结合剂11-14.5%、抗氧化剂1.5-1.9%以及增塑剂0.9-1.4%。
2.根据权利要求1所述的自修复无水炮泥,其特征在于,所述粉料为选自硅灰、粉煤灰以及粘土中的一种或几种,所述骨料为选自无烟煤、焦粉、石墨以及废旧碳砖中的一种或几种,所述结合剂为选自煤焦油、酚醛树脂、磷酸铝以及沥青粉中的一种或几种,所述抗氧化剂为选自Al粉、Fe粉以及Si粉中的一种或几种,所述增塑剂为羧甲基纤维素钠和/或聚乙烯醇。
3.根据权利要求2所述的自修复无水炮泥,其特征在于,包括以下质量百分比的原料:硅灰15-20%、粉煤灰15-25%、粘土3-7%、无烟煤5-10%、焦粉5-10%、石墨2-5%、废旧碳砖21-26%、煤焦油7-11%、酚醛树脂0.3-0.7%、磷酸铝0.3-0.8%、沥青粉1.4-5%、Al粉0.2-0.5%、Fe粉0.3-0.6%、Si粉0.8-1.2%、羧甲基纤维素钠0.5-1%以及聚乙烯醇为0.3-0.5%。
4.根据权利要求1所述的自修复无水炮泥,其特征在于,包括以下质量百分比的原料:硅灰15%、粉煤灰24.5%、粘土5%、无烟煤5%、焦粉10%、石墨2%、废旧碳砖22.2%、煤焦油8.3%、酚醛树脂0.5%、磷酸铝0.5%、沥青粉4.5%、Al粉0.3%、Fe粉0.4%、Si粉0.8%、羧甲基纤维素钠0.5%以及聚乙烯醇0.5%。
5.根据权利要求2-4任一项所述的自修复无水炮泥,其特征在于,所述硅灰、粉煤灰与粘土粒度均≥60目;所述焦粉与石墨粒度范围为16-60目;所述无烟煤与废旧碳砖粒度范围为4-16目;所述沥青粉、Al粉、Fe粉与Si粉粒度均≥400目。
6.根据权利要求2-4任一项所述的自修复无水炮泥,其特征在于,所述硅灰中SiO2含量≥85%,CaO+MgO含量≤4.5%,Fe2O3+C含量≤3.5%。
7.根据权利要求2-4任一项所述的自修复无水炮泥,其特征在于,所述粉煤灰中SiO2+Al2O3含量≥85%,Fe2O3含量≤6%,CaO+MgO含量≤4.5%。
8.根据权利要求2-4任一项所述的所述的自修复无水炮泥,其特征在于,所述粘土中SiO2含量≥44%,Al2O3含量≥37%,Fe2O3含量≤2%,TiO2含量≤2%,CaO+MgO含量≤0.8%,K2O+Na2O含量≤0.8%。
9.根据权利要求2-4任一项所述的自修复无水炮泥,其特征在于,所述焦粉C含量≥85%,所述石墨C含量≥90%,所述废旧碳砖C含量≥85%。
10.根据权利要求2-4任一项所述的自修复无水炮泥,其特征在于,所述废旧碳砖为硅铁矿热炉和/或硅锰矿热炉大修时更换的炉墙和/或炉底碳砖。
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