CN112408964A - 一种铝电解槽用防渗砖 - Google Patents

一种铝电解槽用防渗砖 Download PDF

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CN112408964A
CN112408964A CN202011479102.8A CN202011479102A CN112408964A CN 112408964 A CN112408964 A CN 112408964A CN 202011479102 A CN202011479102 A CN 202011479102A CN 112408964 A CN112408964 A CN 112408964A
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fine powder
brick
electrolytic cell
aluminum silicate
impermeable
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王来稳
于建宾
马渭奎
王刚
章艺
王文武
张海霞
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Sinosteel Luoyang Institute of Refractories Research Co Ltd
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Sinosteel Nanjing Environmental Engineering Technology Research Institute Co ltd
Sinosteel Luoyang Institute of Refractories Research Co Ltd
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Abstract

本发明属于耐火材料领域，涉及一种铝电解槽用防渗砖，涉及的一种铝电解槽用防渗砖采用纯细粉作为原料；所述的纯细粉为硅酸铝，所述硅酸铝由叶蜡石、焦宝石、黏土、硅石、钠长石、钾长石中的至少三种组成；新型防渗砖还外加有细粉助烧剂，混合均匀，加入结合剂造粒，机压成型并高温烧成。本发明选取硅酸铝原料均为细粉，制备的产品成分一致性好，结构均匀，体积密度高，显气孔率低，与渗透的电解质反应均匀，能快速形成一层防渗层，所制备的防渗砖能有效改善和减缓铝电解槽电解质对防渗砖的侵蚀和渗透，从而能有效解决电解槽槽底寿命过低的问题。

Description

一种铝电解槽用防渗砖
技术领域
本发明属于耐火材料领域，具体涉及一种铝电解槽用防渗砖。
背景技术
铝电解槽一般由石墨质或碳化硅质工作层、硅酸铝阻碍层、保温层三层结构构成。硅酸铝阻碍层在阴极炭块下部，通常采用15~25 cm 厚的干式防渗料或5.0~6.5cm的防渗砖，用于防止电解质进一步渗透，保护下部的保温材料，维持铝电解槽的热平衡。因此铝电解槽槽底硅酸铝阻碍层抗电解质侵蚀性能的优劣对于电解槽的使用寿命有着至关重要的影响。
硅酸铝阻碍层的高致密性和低渗透性并不是阻止电解质渗透的最好方法，而是需要阻碍层成分和结构均匀一致，能快速与渗透的电解质生成一层致密的原位防渗层，从而阻止或延缓电解质的进一步渗透。
目前防渗砖或者干式防渗料的生产均需要一定的颗粒级配，通常骨料占50-70%、细粉占30-50%，再添加适当的助烧剂。虽然能在一定程度上与渗透的电解质反应生成防渗层，但是由于骨料与细粉在成分和结构上的不一致，导致骨料与细粉与渗透的电解质反应速度不一致。细粉结构疏松，与电解质反应速度快，骨料致密，反应速度慢，而且二者的成分也不同，导致骨料无法与细粉同步反应并生成防渗层，因而防渗效果不是最理想。
因此，非常有必要发明一种防渗效果好的成分一致、结构均匀的铝电解槽用防渗砖。
发明内容
本发明要解决的技术问题是提供一种铝电解槽用防渗砖及其制备方法，以克服现有技术的抗电解质侵蚀和渗透差的技术问题。
为解决上述技术问题，本发明采用如下技术方案：
一种铝电解槽用防渗砖，防渗砖采用纯细粉作为原料；所述的纯细粉为硅酸铝，所述硅酸铝由叶蜡石、焦宝石、黏土、硅石、钠长石、钾长石中的至少三种组成，新型防渗砖还外加有细粉助烧剂，混合均匀，加入结合剂造粒，机压成型并高温烧成。
所述硅酸铝中叶蜡石、焦宝石、黏土、硅石、钠长石、钾长石的重量百分比范围为：叶腊石0~65%，焦宝石0~46%，黏土0~30%，硅石0~16%，钠长石0~3%，钾长石0~4%。
所述细粉助烧剂为四硅酸钾和二硅酸钾按照摩尔比1：1预先熔融而成的硅酸钾共熔物，其熔点为742℃；助烧剂添加量为硅酸铝细粉重量的0.5%-1%，粒度≤500目。
所用硅酸铝的原料的粒度均≤100目。
所用硅酸铝原料细粉造粒用结合剂为PVA溶液，溶液浓度5%-8%，添加量为硅酸铝细粉重量的5.0%-7%。
一种铝电解槽用防渗砖的制备方法，包括以下步骤：
1) 按比例称取原料，并在混料机内混合均匀；
2) 将混均匀的原料倒入混练机内，加入结合剂，造粒、过筛；
3) 将造粒料在压砖机内成型，成型压力60-80吨；
4) 将压制成型的砖坯在200-400℃保温18-24小时；
5) 将烘干的砖坯在1000-1150℃保温6-8小时；
6) 成品检验入库。
本发明提出的一种铝电解槽用防渗砖及其制备方法，采用上述技术方案，与现有技术相比，本发明选取硅酸铝原料细粉，通过细粉混合、造粒、成型和烧成等工序，制备的产品成分一致性好，结构均匀，体积密度高，显气孔率低，与渗透的电解质反应均匀，能快速形成一层防渗层；参照ISO20292:2009标准，对得到的产品进行抗冰晶石侵蚀试验；试验结果：渗透层反应面积≤3.0cm2，渗透深度≤2.2mm，完全满足电解槽用防渗砖的性能指标；试验结果表明：采用纯细粉硅酸铝原料，所生产防渗砖能有效改善和减缓铝电解槽电解质对防渗砖的侵蚀和渗透，从而能有效解决电解槽槽底寿命过低的问题。 具体实施方式
结合具体实施例对本发明加以说明：
实施例1：一种铝电解槽用防渗砖，包括以下重量份的组分：
叶蜡石65%，焦宝石32%，钠长石3%，外加1.0%硅酸钾共熔物；上述原料叶蜡石中SiO2含量≥70%，Al2O3≤26%，粒度100目；焦宝石中SiO2含量≥55%，Al2O3≤45%，粒度100目；钠长石中SiO2含量≥65%，Al2O3≤20%，Na2O≤12%，粒度100目；四硅酸钾和二硅酸钾的共熔物粒度1000目。
上述铝电解槽用防渗砖的制备方法包括以下步骤：
1) 按比例称取原料，并在混料机内混合均匀4小时；
2) 将混均匀的原料倒入混练机内，加入结合剂浓度8%的PVA溶液，加入量为混合料重量的5.0%，混练20分钟后过15目筛；
3) 将过筛后造粒料在压砖机内成型，压砖机的压力80吨；
4) 将压制成型的砖坯在200℃保温24小时；
5) 将烘干的砖坯在1150℃保温8小时；
6) 成品检验入库。
本发明制得的防渗砖SiO2含量65.1%，Al2O3含量31.9%，Na2O
含量1.26%，显气孔率为9.6%，体积密度为2.25g.cm-3,常温耐压强度为65MPa,导热系数：300℃为1.22W(m.K),600℃为1.45W(m.K),900℃为1.47W(m.K)；反应侵蚀面积为3.0cm2，渗透深度≤2.2mm。
实施例2：一种铝电解槽用防渗砖，包括以下重量份的组分：
叶蜡石43%，焦宝石46%，硅石8%，钾长石3%，外加0.8%硅铝钾助烧剂。上述原料叶蜡石中SiO2含量≥70%，Al2O3≤26%，粒度150目；焦宝石中SiO2含量≥55%，Al2O3≤45%，粒度150目；钾长石中SiO2含量≥67%，Al2O3≤20%，K2O≤12%，粒度150目；四硅酸钾和二硅酸钾的共熔物粒度800目。
上述铝电解槽用防渗砖的制备方法包括以下步骤：
1) 按比例称取原料，并在混料机内混合均匀4小时；
2) 将混均匀的原料倒入混练机内，加入结合剂浓度7%的PVA溶液，加入量为混合料重量的6%，混练20分钟后过15目筛；
3) 将过筛后造粒料在压砖机内成型，压砖机的压力70吨；
4) 将压制成型的砖坯在300℃保温20小时；
5) 将烘干的砖坯在1100℃保温8小时；
6) 成品检验入库。
本发明制得的防渗砖SiO2含量65.4%，Al2O3含量32.5%，K2O
含量1.73%，显气孔率为8.3%，体积密度为2.29g.cm-3,常温耐压强度为67MPa,导热系数：300℃为1.28W(m.K),600℃为1.47W(m.K),900℃为1.48W(m.K)。反应侵蚀面积为2.7cm2，渗透深度≤1.8mm。
实施例3：一种铝电解槽用防渗砖，包括以下重量份的组分：
黏土60%，焦宝石20%，硅石16%，钾长石4%，外加0.6%硅酸钾共熔物。上述原料黏土中SiO2含量≥55%，Al2O3≤35%，Fe2O3≤3.0,粒度200目；焦宝石中SiO2含量≥55%，Al2O3≤45%，粒度200目；钾长石中SiO2含量≥67%，Al2O3≤20%，K2O≤12%，粒度200目；四硅酸钾和二硅酸钾的共熔物粒度600目。
上述铝电解槽用防渗砖的制备方法包括以下步骤：
1) 按比例称取原料，并在混料机内混合均匀4小时；
2) 将混均匀的原料倒入混练机内，加入结合剂浓度6%的PVA溶液，加入量为混合料重量的6.5%，混练20分钟后过15目筛；
3) 将过筛后造粒料在压砖机内成型，压砖机的压力60吨；
4) 将压制成型的砖坯在350℃保温18小时；
5) 将烘干的砖坯在1050℃保温6小时；
6) 成品检验入库。
本发明制得的防渗砖SiO2含量62.7%，Al2O3含量30.8%，K2O
含量1.98%，显气孔率为7.5%，体积密度为2.31g.cm-3,常温耐压强度为69MPa,导热系数：300℃为1.29W(m.K),600℃为1.49W(m.K),900℃为1.49W(m.K)。反应侵蚀面积为2.5cm2，渗透深度≤1.7mm。
实施例4：一种铝电解槽用防渗砖，包括以下重量份的组分：
叶蜡石40%，黏土30%，焦宝石15%，硅石12%，钠长石3%，外加0.5%硅酸钾共熔物。上述原料叶蜡石中SiO2含量≥70%，Al2O3≤26%，粒度300目；黏土中SiO2含量≥55%，Al2O3≤35%，Fe2O3≤3.0,粒度300目；焦宝石中SiO2含量≥55%，Al2O3≤45%，粒度300目；钠长石中SiO2含量≥67%，Al2O3≤20%，K2O≤12%，粒度300目；四硅酸钾和二硅酸钾的共熔物粒度500目。
上述铝电解槽用防渗砖的制备方法包括以下步骤：
1) 按比例称取原料，并在混料机内混合均匀4小时；
2) 将混均匀的原料倒入混练机内，加入结合剂浓度5%的PVA溶液，加入量为混合料重量的7%，混练20分钟后过15目筛；
3) 将过筛后造粒料在压砖机内成型，压砖机的压力60吨；
4) 将压制成型的砖坯在400℃保温18小时；
5) 将烘干的砖坯在1000℃保温6小时；
6) 成品检验入库。
本发明制得的防渗砖SiO2含量66.8%，Al2O3含量28.3%，Na2O
含量1.37%，显气孔率为6.4%，体积密度为2.35g.cm-3,常温耐压强度为72MPa,导热系数：300℃为1.31W(m.K),600℃为1.52W(m.K),900℃为1.53W(m.K)；反应侵蚀面积为2.2cm2，渗透深度≤1.3mm。

Claims (5)

1.一种铝电解槽用防渗砖，其特征在于：防渗砖采用纯细粉作为原料，外加细粉助烧剂；所述的纯细粉为硅酸铝，所述硅酸铝由叶蜡石、焦宝石、黏土、硅石、钠长石、钾长石中的至少三种组成。
2.如权利要求1所述的一种铝电解槽用防渗砖，其特征在于：所述细粉助烧剂为四硅酸钾和二硅酸钾按照摩尔比1：1预先熔融而成的共熔物，其熔点为742℃；助烧剂添加量为硅酸铝细粉重量的0.5%-1%，粒度≤500目。
3.如权利要求1所述的一种铝电解槽用防渗砖，其特征在于：所述硅酸铝中叶蜡石、焦宝石、黏土、硅石、钠长石、钾长石的重量百分比范围为：叶腊石0~65%，焦宝石0~46%，黏土0~30%，硅石0~16%，钠长石0~3%，钾长石0~4%。
4.如权利要求1所述的一种铝电解槽用防渗砖，其特征在于：所用硅酸铝的原料的粒度均≤100目。
5.如权利要求1所述的一种铝电解槽用防渗砖，其特征在于：所用硅酸铝原料细粉造粒用结合剂为PVA溶液，溶液浓度5%-8%，添加量为硅酸铝细粉重量的5.0%-7%。
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