CN112408957B - 一种铁沟浇注料及其制备方法 - Google Patents
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims abstract description 84
- 229910052742 iron Inorganic materials 0.000 title claims abstract description 42
- 238000002360 preparation method Methods 0.000 title 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 53
- 239000010431 corundum Substances 0.000 claims abstract description 39
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 36
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 35
- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 35
- 239000000203 mixture Substances 0.000 claims abstract description 26
- 239000000843 powder Substances 0.000 claims abstract description 23
- 239000003963 antioxidant agent Substances 0.000 claims abstract description 20
- 230000003078 antioxidant effect Effects 0.000 claims abstract description 18
- 239000003575 carbonaceous material Substances 0.000 claims abstract description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 18
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 10
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 10
- 229910052751 metal Inorganic materials 0.000 claims description 48
- 239000002184 metal Substances 0.000 claims description 48
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 47
- 239000011863 silicon-based powder Substances 0.000 claims description 38
- 239000002245 particle Substances 0.000 claims description 19
- 238000003756 stirring Methods 0.000 claims description 18
- 239000000835 fiber Substances 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 10
- 229910052594 sapphire Inorganic materials 0.000 claims description 10
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 239000011230 binding agent Substances 0.000 claims description 7
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims description 7
- 239000004568 cement Substances 0.000 claims description 7
- 238000007580 dry-mixing Methods 0.000 claims description 7
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 7
- 239000010426 asphalt Substances 0.000 claims description 6
- 229910052710 silicon Inorganic materials 0.000 claims description 6
- 239000010703 silicon Substances 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 4
- 238000005303 weighing Methods 0.000 claims description 3
- 239000007767 bonding agent Substances 0.000 claims description 2
- 239000011819 refractory material Substances 0.000 abstract description 5
- 238000013461 design Methods 0.000 abstract description 2
- 239000000523 sample Substances 0.000 description 23
- 238000002844 melting Methods 0.000 description 5
- 230000008018 melting Effects 0.000 description 5
- 239000013068 control sample Substances 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 238000005266 casting Methods 0.000 description 3
- 238000010079 rubber tapping Methods 0.000 description 3
- 230000003628 erosive effect Effects 0.000 description 2
- 239000013074 reference sample Substances 0.000 description 2
- 238000009991 scouring Methods 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
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Abstract
本发明涉及耐火材料技术领域,尤其是涉及一种铁沟浇注料及其制备方法;按照重量份数计,包括:均化矾土33‑36份、棕刚玉22‑24份、碳化硅24‑27份、碳素材料2.35‑2.60份、结合剂2.30‑2.60份、超微粉8.0‑8.8份、防爆剂0.05‑0.08份、抗氧化剂3.24‑3.58份和减水剂0.18‑0.23份;本发明的目的在于提供一种铁沟浇注料及其制备方法,通过铁沟浇注料的设计可以解决现有技术中存在的我国大中型高炉出铁场大多使用以棕钢玉为骨料的Al2O3‑SiC‑C铁沟浇注料,其价格较高的技术问题。
Description
技术领域
本发明涉及耐火材料技术领域,尤其是涉及一种铁沟浇注料及其制备方法。
背景技术
高炉出铁沟是高温铁水和熔渣的通道,铁沟浇注料是使用在此通道的一种不定型耐火材料,是高炉炉前用主要耐材之一,占70%以上。铁沟浇注料周期性地受到铁水冲刷、熔渣侵蚀、高温热应力作用,因此对其要求是:耐高温、耐侵蚀、耐冲刷、抗渗透、高导热性。铁沟浇注料性能的好坏、使用寿命高低、通铁量大小直接影响到生产成本、劳动强度和工作环境。
目前,我国大中型高炉出铁场大多使用Al2O3-SiC-C铁沟浇注料,其骨料以棕钢玉为主,价格较高。随着钢铁行业步入不景气周期,耐火材料已经成为其降本增效的重要环节。同时,当今市场经济条件下,竞争日益激烈,出铁厂耐材整体承包价格不断压低,在保证铁沟安全、高效、长寿命运行的前提下,降低铁沟浇注料的原料成本已经迫在眉睫,研究和生产低成本高性能的高炉出铁沟耐火材料已经成为企业发展的目标。
因此,针对上述问题本发明急需提供一种铁沟浇注料及其制备方法。
发明内容
本发明的目的在于提供一种铁沟浇注料及其制备方法,通过铁沟浇注料的设计以解决现有技术中存在的我国大中型高炉出铁场大多使用Al2O3-SiC-C铁沟浇注料,其骨料以棕钢玉为主,价格较高的技术问题。
本发明提供的一种铁沟浇注料,按重量份数计,包括均化矾土33-36份、棕刚玉22-24份、碳化硅24-27份、碳素材料2.35-2.60份、结合剂2.30-2.60份、超微粉8.0-8.8份、防爆剂0.05-0.08份、抗氧化剂3.24-3.58份和减水剂0.18-0.23份。
优选地,均化矾土包括粒径为3-5mm的均化矾土10-12份、粒径为5-8mm的均化矾土11-13份和粒径为8-15mm的均化矾土10-13份。
优选地,棕刚玉包括粒径为0-1mm的棕刚玉2份和粒径为1-3mm的棕刚玉20份。
优选地,抗氧化剂为第一金属硅粉、第二金属硅粉和金属铝粉的混合物,第一金属硅粉、第二金属硅粉和金属Al粉的质量比为1:1:1;第一金属硅粉的平均粒径为45.22μm,第二金属硅粉的平均粒径为2.82μm。
优选地,均化矾土中Al2O3含量≥88%;棕刚玉中的Al2O3含量≥95%;碳化硅的纯度≥97%。
优选地,超微粉为硅微粉和ɑ-Al2O3微粉混合物;硅微粉和ɑ-Al2O3微粉的质量比为1:2。
优选地,碳化硅包括粒径为200目碳化硅12份和粒径为0-1mm的碳化硅12份。
优选地,碳素材料为球状沥青;结合剂为纯铝酸钙水泥。
优选地,防爆剂为普通有机纤维;减水剂为三聚磷酸钠。
本发明还提供了一种基于如上述中任一项所述的铁沟浇注料的制备方法,包括如下步骤:
按照重量计,分别称量均化矾土、棕刚玉、碳化硅、碳素材料、结合剂、超微粉、防爆剂、抗氧化剂和减水剂,获得混合料;
混合料加入搅拌机中干混搅拌1-2min,然后加入水,混合料与水的质量比为100:4.2-4.5,搅拌3-5min,倒入模具中,依次进行振动、养护、烘烤,获得Al2O3-SiC-C铁沟浇注料。
本发明提供的一种铁沟浇注料与现有技术相比至少具有以下进步:
本发明采用均化矾土替换棕刚玉,采用超细金属硅粉部分替换普通金属硅粉,获得以均化矾土为骨料的铁沟浇注料,以均化矾土为骨料的铁沟浇注料与以棕刚玉为骨料的铁沟浇注料相比,性能接近,但是产品价格大幅度下降,有利于降低生产成本。
具体实施方式
下面对本发明的技术方案进行清楚、完整地描述,显然,所描述的实施例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。
本发明提供了一种铁沟浇注料,按重量份数计,包括均化矾土33-36份、棕刚玉22-24份、碳化硅24-27份、碳素材料2.35-2.60份、结合剂2.30-2.60份、超微粉8.0-8.8份、防爆剂0.05-0.08份、抗氧化剂3.24-3.58份和减水剂0.18-0.23份。
具体地,均化矾土包括粒径为3-5mm的均化矾土10-12份、粒径为5-8mm的均化矾土11-13份和粒径为8-15mm的均化矾土10-13份。
具体地,棕刚玉包括粒径为0-1mm的棕刚玉2份和粒径为1-3mm的棕刚玉20份。
具体地,抗氧化剂为第一金属硅粉、第二金属硅粉和金属铝粉的混合物,第一金属硅粉、第二金属硅粉和金属Al粉的质量比为1:1:1;第一金属硅粉的平均粒径为45.22μm,第二金属硅粉的平均粒径为2.82μm。
具体地,均化矾土中Al2O3含量≥88%;棕刚玉中的Al2O3含量≥95%;碳化硅的纯度≥97%。
具体地,超微粉为硅微粉和ɑ-Al2O3微粉混合物;硅微粉和ɑ-Al2O3微粉的质量比为1:2。
具体地,碳化硅包括粒径为200目碳化硅12份和粒径为0-1mm的碳化硅12份。
具体地,碳素材料为球状沥青;结合剂为纯铝酸钙水泥。
具体地,防爆剂为普通有机纤维;减水剂为三聚磷酸钠。
本发明还提供了一种基于如上述中任一项所述的铁沟浇注料的制备方法,包括如下步骤:
S1)按照重量计,分别称量均化矾土、棕刚玉、碳化硅、碳素材料、结合剂、超微粉、防爆剂、抗氧化剂和减水剂,获得混合料;
S2)混合料加入搅拌机中干混搅拌1-2min,然后加入水,混合料与水的质量比为100:4.2-4.5,搅拌3-5min,倒入模具中,依次进行振动、养护、烘烤,获得Al2O3-SiC-C铁沟浇注料。
本发明采用均化矾土替换棕刚玉,采用超细金属硅粉部分替换普通金属硅粉,获得以均化矾土为骨料的铁沟浇注料,以均化矾土为骨料的铁沟浇注料与以棕刚玉为骨料的铁沟浇注料相比,性能接近,但是产品价格大幅度下降,有利于降低生产成本。
实施例一
样品1制备
将33份的均化矾土、22份的棕刚玉、24份碳化硅,2.35份的碳素材料、2.3份的铝酸钙水泥、2.6份的硅微粉,5.4份的ɑ-Al2O3微粉、0.05份的普通有机纤维、3.24份的抗氧化剂和0.18份的三聚磷酸钠混合,获得混合料;
混合料加入搅拌机中干混搅拌1-2min,然后加入占混合料总质量4.2-4.5%的水,搅拌3-5min;搅拌均匀后放入模具,制备成40×40×160mm的试样,依次进行振动、自然养护24h、经110℃/24h烘干后,获得样品1。
其中,均化矾土包括粒径为3-5mm的均化矾土12份,粒径为5-8mm的均化矾土11份,粒径为8-15份的均化矾土10份;
其中,棕刚玉包括粒径为1-3mm的棕刚玉20份,粒径为0-1mm的棕刚玉2份;
其中,碳化硅包括粒径为200目的碳化硅12份,粒径为0-1mm的碳化硅12份;
其中,抗氧化剂包括第一金属硅粉1.08份,第二金属硅粉1.08份和200目金属铝粉1.08份;第一金属硅粉的平均粒径为45.22μm,第二金属硅粉的平均粒径为2.82μm。
碳素材料为球状沥青。
普通有机纤维的熔点110℃,为本领域常规使用的有机纤维。
样品1性能见表1。
对照样品1制备
将55份的棕刚玉、24份碳化硅,2.35份的碳素材料、2.3份的铝酸钙水泥、2.6份的硅微粉,5.4份的ɑ-Al2O3微粉、0.05份的普通有机纤维、3.24份的抗氧化剂和0.18份的三聚磷酸钠混合,获得混合料;
混合料加入搅拌机中干混搅拌1-2min,然后加入占混合料总质量4.2-4.5%的水,搅拌3-5min;搅拌均匀后放入模具,制备成40×40×160mm的试样,依次进行振动、自然养护24h、经110℃/24h烘干后,获得对照样品1。
其中,棕刚玉包括粒径为1-3mm的棕刚玉20份,粒径为0-1mm的棕刚玉2份;粒径为3-5mm的棕刚玉12份,粒径为5-8mm的棕刚玉11份和粒径为8-15mm的棕刚玉10份;
其中,碳化硅包括粒径为200目的碳化硅12份,粒径为0-1的碳化硅12份;
其中,抗氧化剂包括第一金属硅粉2.16份和200目金属铝粉1.08份;第一金属硅粉的平均粒径为45.22μm。
碳素材料为球状沥青。
普通有机纤维的熔点110℃,为本领域常规使用的有机纤维。
对照样品1的性能见表1。
样品1与对照样品1的区别特征在于采用均化矾土代替粗骨料部分的棕刚玉,在3.24份的抗氧化剂中采用第二金属硅粉部分替换第一金属硅粉,获得的样品1的性能接近对照样品1,110℃烘烤24小时后,耐压强度、抗折强度还优于对照样品1,同时由于均化矾土替换了骨料部分的棕刚玉,使得样品1的价格远远低于对照样品1。均化矾土平均吨价3200元,棕刚玉平均吨价4250元,由此,大大降低了浇注料的生产成本。
实施例二
样品2制备
将36份的均化矾土、26份的棕刚玉、27份碳化硅,2.6份的碳素材料、2.6份的铝酸钙水泥、3.0份的硅微粉,5.5份的ɑ-Al2O3微粉、0.08份的普通有机纤维、3.6份的抗氧化剂和0.23份的三聚磷酸钠混合,获得混合料;
混合料加入搅拌机中干混搅拌1-2min,然后加入占混合料总质量4.2-4.5%的水,搅拌3-5min;搅拌均匀后放入模具,制备成40×40×160mm的试样,依次进行振动、自然养护24h、经110℃/24h烘干后,获得样品2。
其中,均化矾土包括粒径为3-5mm的均化矾土13份,粒径为5-8mm的均化矾土13份,粒径为8-15mm的均化矾土10份;
其中,棕刚玉包括粒径为1-3mm的棕刚玉22份,粒径为0-1mm的棕刚玉4份;
其中,碳化硅包括粒径为200目的碳化硅13份,粒径为0-1的碳化硅14份;
其中,抗氧化剂包括第一金属硅粉1.2份,第二金属硅粉1.2份和200目金属铝粉1.2份;第一金属硅粉的平均粒径为45.22μm,第二金属硅粉的平均粒径为2.82μm。
碳素材料为球状沥青。
普通有机纤维的熔点110℃,为本领域常规使用的有机纤维。
样品2性能见表1。
对照样品2制备
将62份的棕刚玉、27份碳化硅,6份的碳素材料、2.6份的铝酸钙水泥、3.0份的硅微粉,5.5份的ɑ-Al2O3微粉、0.08份的普通有机纤维(熔点110℃)、3.6份的抗氧化剂和0.23份的三聚磷酸钠混合,获得混合料;
混合料加入搅拌机中干混搅拌1-2min,然后加入占混合料总质量4.2-4.5%的水,搅拌3-5min;搅拌均匀后放入模具,制备成40×40×160mm的试样,依次进行振动、自然养护24h、经110℃/24h烘干后,获得对照样品2。
其中,棕刚玉包括粒径为1-3mm的棕刚玉22份,粒径为0-1mm的棕刚玉4份;粒径为3-5mm的棕刚玉13份,粒径为5-8mm的棕刚玉13份和粒径为8-15mm的棕刚玉10份;
其中,碳化硅包括粒径为200目的碳化硅13份,粒径为0-1的碳化硅14份;
其中,抗氧化剂包括第一金属硅粉2.4份和金属铝粉200目1.2份;第一金属硅粉的平均粒径为45.22μm。
碳素材料为球状沥青。
普通有机纤维的熔点110℃,为本领域常规使用的有机纤维。
对照样品2的性能见表1。
样品2与对照样品2的区别特征在于采用均化矾土代替粗骨料部分的棕刚玉,在3.6份的抗氧化剂中采用第二金属硅粉部分替换第一金属硅粉,获得的样品2的性能接近对照样品2,1450℃热处理3h后的抗折强度还优于对照样品2;同时由于均化矾土替换了棕刚玉,均化矾土平均吨价3200元,棕刚玉平均吨价4250元,由此,大大降低了浇注料的生产成本。
表1获得的铁沟料性能检测结果
最后应说明的是:以上各实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述各实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分或者全部技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的范围。
Claims (9)
1.一种铁沟浇注料,其特征在于:按重量份数计,包括:均化矾土33-36份、棕刚玉22-24份、碳化硅24-27份、碳素材料2.35-2.60份、结合剂2.30-2.60份、超微粉8.0-8.8份、防爆剂0.05-0.08份、抗氧化剂3.24-3.58份和减水剂0.18-0.23份;抗氧化剂为第一金属硅粉、第二金属硅粉和金属铝粉的混合物,第一金属硅粉、第二金属硅粉和金属Al粉的质量比为1:1:1;第一金属硅粉的平均粒径为45.22μm,第二金属硅粉的平均粒径为2.82μm。
2.根据权利要求1所述的铁沟浇注料,其特征在于:均化矾土包括粒径为3-5mm的均化矾土10-12份、粒径为5-8mm的均化矾土11-13份和粒径为8-15mm的均化矾土10-13份。
3.根据权利要求1所述的铁沟浇注料,其特征在于:棕刚玉包括粒径为0-1mm的棕刚玉2份和粒径为1-3mm的棕刚玉20份。
4.根据权利要求1所述的铁沟浇注料,其特征在于:均化矾土中Al2O3含量≥88%;棕刚玉中的Al2O3含量≥95%;碳化硅的纯度≥97%。
5.根据权利要求1所述的铁沟浇注料,其特征在于:超微粉为硅微粉和ɑ-Al2O3微粉混合物;硅微粉和ɑ-Al2O3微粉的质量比为1:2。
6.根据权利要求1所述的铁沟浇注料,其特征在于:碳化硅包括粒径为200目碳化硅12份和粒径为0-1mm的碳化硅12份。
7.根据权利要求1所述的铁沟浇注料,其特征在于:碳素材料为球状沥青;结合剂为纯铝酸钙水泥。
8.根据权利要求1所述的铁沟浇注料,其特征在于:防爆剂为普通有机纤维;减水剂为三聚磷酸钠。
9.一种基于如权利要求1-8中任一项所述的铁沟浇注料的制备方法,其特征在于,包括如下步骤:
按照重量计,分别称量均化矾土、棕刚玉、碳化硅、碳素材料、结合剂、超微粉、防爆剂、抗氧化剂和减水剂,获得混合料;
混合料加入搅拌机中干混搅拌1-2min,然后加入水,混合料与水的质量比为100:4.2-4.5,搅拌3-5min,倒入模具中,依次进行振动、养护、烘烤,获得Al2O3-SiC-C铁沟浇注料。
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