CN112479685B - 一种大量添加铸铁粉的优质rh喷补料及其生产方法 - Google Patents
一种大量添加铸铁粉的优质rh喷补料及其生产方法 Download PDFInfo
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- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 1
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Abstract
一种大量添加铸铁粉的优质RH喷补料及其生产方法,是由下列重量份数的原料制备而成:烧结镁砂35‑60份、镁尖晶石废砖10‑30份、复合结合剂12‑22份、复合烧结剂5‑20份、复合助结合剂3‑10份、复合纤维0.1‑2.0份。与现有技术相比,本发明的有益效果是:通过对现有RH喷补料配比进行优化设计和改进,在国内范围内首次添加大量铸铁粉,改善喷补料烧结性能,使之适合RH浸渍管的现场快速喷补维护的要求,烧结速度迅速、烧结强度高、附着性好、不回弹、抗侵蚀性好,同时生产方法简单、原材料成本降低。
Description
技术领域
本发明涉及炼钢厂RH真空精炼设备用耐火材料,尤其涉及一种大量添加铸铁粉的优质RH喷补料及其生产方法。
背景技术
近几十年,RH真空精炼技术取得了巨大进展,由原来单一的脱气功能发展到现在的真空脱气、脱碳、吹氧脱碳、喷粉脱硫、温度补偿、去夹杂、均匀温度和成分等多种功能,成为目前国内各大钢厂冶炼精品钢最常用的二次精炼冶金方法。
RH浸渍管是RH真空处理精炼工序最为关键冶炼装备,RH浸渍管由内衬耐火砖、自流料层、埋在中间部位的金属钢桶结构件和外层浇注料等四部分组成。浸渍管外层浇注料与内部大量钢桶金属结构件热膨胀系数相差很大,在烘烤及高温使用时,埋藏在浇注料内部的金属结构件膨胀尺寸远远大于外层浇注料的膨胀尺寸,当浇注料的整体强度无法抵抗这个膨胀力时,浇注料结构损坏,出现裂纹。同时,外层浇注料在使用过程中,受钢水的冲刷、钢水与钢渣的浸泡,还会不断被侵蚀。因此在浸渍管使用过程中,日常的喷补维护是极为关键和必要的作业。
目前国内外RH精炼的RH浸渍管为达到理想的使用寿命,普遍采用离线喷补维护,靠喷补料缓解钢水对浸渍管内层无铬环砖(或镁铬环砖)及外层浇注料的一部分侵蚀。常用方法为半干法喷补,也就是热态离线喷补,设备为半干法喷补机,喷补料一般为镁质、镁钙质等。
RH喷补料主体材料是烧结及电熔镁砂,抗侵蚀性能应付几炉一喷的节奏,基本不成问题,但结合系统及烧结性能千差万别。目前普通RH喷补料多数情况是烧结性能不好,即便喷补附着效果良好,但烧结效果不好,在RH精炼作业过程中,钢水高速流动,附着上的喷补料很快被冲刷下来,没有达到喷补维护效果,导致RH浸渍管因侵蚀、剥落、裂纹而停用下线。
发明内容
本发明的目的在于提供一种大量添加铸铁粉的优质RH喷补料及其生产方法,通过对现有RH喷补料配比进行优化设计和改进,在国内范围内首次添加大量铸铁粉,改善喷补料烧结性能,使之适合RH浸渍管的现场快速喷补维护的要求,烧结速度迅速、烧结强度高、附着性好、不回弹、抗侵蚀性好,同时生产方法简单、原材料成本降低。
为了达到上述目的,本发明采用以下技术方案实现:
一种大量添加铸铁粉的优质RH喷补料,是由下列重量份数的原料制备而成:烧结镁砂35-60份、镁尖晶石废砖10-30份、复合结合剂12-22份、复合烧结剂5-20份、复合助结合剂3-10份、复合纤维0.1-2.0份。
所述复合烧结剂是由铸铁粉、铬精矿、高钛渣按照下述添加比例制备而成:铸铁粉:铬精矿:高钛渣=1:(0-1.0):(0-0.5),铸铁粉粒度为80-150目,铬精矿粒度为40-70目,高钛渣粒度为120-180目。
所述复合结合剂是由金属铝粉、磷酸盐结合剂、硅酸盐结合剂、高温沥青粉、固体树脂粉按照下述添加比例制备而成:金属铝粉:磷酸盐结合剂:硅酸盐结合剂:高温沥青粉:固体树脂粉=1:(0-1.5):(0-1.5):(0-1.5):(0-1.0)。
所述复合助结合剂是由磷酸钠、磷酸二氢钙、膨润土、硅灰、活性氧化铝微粉、铬绿、抗反弹剂(武汉善达化工有限公司生产的STABEN-2013)按照下述添加比例制备而成:磷酸钠:磷酸二氢钙:膨润土:硅灰:活性氧化铝微粉:铬绿:抗反弹剂STABEN-2013=1:(0-1.5):(0.5-2.0):(0-4.0):(0-4.0):(0-1.0):(0.02-0.1)。
所述复合纤维是由纸纤维、麻纤维、聚丙烯纤维按照下述添加比例制备而成:纸纤维:麻纤维:聚丙烯纤维=1:(0-1.5):(0.05-0.1)。
烧结镁砂是重烧镁砂、中档镁砂或高纯镁砂中的一种或两种。
所述烧结镁砂中:小于等于3mm大于等于1mm的粗颗粒占15-25份、小于1mm大于等于0.074mm的细颗粒占10-20份、小于0.074mm细粉占10-20份。
所述镁尖晶石废砖:小于等于3mm大于等于1mm的粗颗粒占5-15份、小于1mm大于等于0.074mm的细颗粒占5-10份、小于0.074mm细粉占0-15份。
一种大量添加铸铁粉的优质RH喷补料的生产方法,包括如下步骤:
1)生产复合结合剂,将复合结合剂材料按照比例进行配料,每种料的配料精度小于20克,配好后统一加入到双锥混合机中预混,时间一般大于10分钟;预混合格的复合结合剂装袋,密封包装,待用。
2)生产复合烧结剂,将烧结剂材料按照比例进行配料,每种料的配料精度小于20克,配好后统一加入到双锥混合机中预混,时间一般大于10分钟;预混合格的复合烧结剂装袋包装,待用。
3)生产复合助结合剂,将复合助结合剂剂材料按照比例进行配料,每种料的配料精度小于20克,配好后统一加入到双锥混合机中预混,时间一般大于10分钟;预混合格的复合助结合剂装袋,密封包装,待用。
4)生产复合纤维,将复合纤维材料按照比例进行配料;每种料的配料精度小于10克,配好后统一装袋包装,无需混合,待用。
5)将按比例配好的烧结镁砂及镁尖晶石废砖,其中的小于3mm大于等于1mm粗颗粒颗粒、小于1mm大于等于0.074mm的细颗粒部分,以及复合纤维一次性加入到双轴式搅拌机中,混合5-8分钟,然后,再将按比例配好的烧结镁砂及镁尖晶石废砖,其中的小于0.074mm细粉部分,以及上述步骤1)、2)、3)中预先制备的复合结合剂、复合烧结剂、复合助结合剂一同加入到双轴式搅拌机中,再次混合3-8分钟,搅拌均匀,颜色一致,尤其是纤维分布均匀,即可出料,装袋包装,取样检验,入库待发。
与现有技术相比,本发明的有益效果是:
1)本发明首次在RH喷补料中大量引入铸铁粉等多种金属产品和矿产品,直接作为烧结剂,资源丰富、价格低廉,利用其在还原气氛下生成铁酸镁、氧化钛、碳化钛、氮化钛等高温矿相,促进新的RH喷补料在高温时能够充分烧结,氧化镁与沥青等材料形成的骨架结构组织均匀,RH喷补料烧结迅速、强度大,耐剥落性好,能够很好地满足RH精炼炉高频次连续作业、喷补时间极短的苛刻条件。另外,铸铁粉、高钛渣等物质本身就是铁的重要来源,没有杂质,不污染钢水,利于冶炼超纯净钢,而且高钛渣的原料是钛铁矿,其伴生的钒、钛、铬、钴、镍、铂族和钪等多种组份,都是对钢材有益的元素,具有很高的综合利用价值。
2)本发明引入金属铝粉,强化RH喷补料的中温结合,引入硅灰、活性氧化铝微粉、铬绿等超微粉材料,强化RH喷补料的高温结合,从而保证RH喷补料在喷补时、使用时的高温性能优良,其热震稳定性、抗侵蚀性、抗折强度得到大大改善,满足用户的使用要求。
3)本发明的RH喷补料,为了改善烧结性能,除引入高效的复合烧结剂之外,对喷补料的粒度组成也做了相应优化,在保证材料附着性和透气性的同时,将细粉的比例适当加大,强化基质部分对颗粒的包裹,有利于提高烧结的速度。
4)另外引入镁尖晶石废砖,替代一部分烧结镁砂,质优价低,抗侵蚀效果优良。
本发明RH喷补料与传统的喷补料相关指标对比如表1所示。
表1:本发明RH喷补料与传统的喷补料相关指标对比
注:因采用的烧结镁砂及镁尖晶石废砖的牌号、档次有较大差异,因此典型值范围较宽。
附图说明
图1是本发明一种大量添加铸铁粉的优质RH喷补料生产方法的工艺流程图。
具体实施方式
下面对本发明的具体实施方式作进一步说明:
实施例1:
某钢厂,130吨电炉2座,有2座130t“三车五位”RH真空处理槽,钢种有优质碳素结构钢、合金结构钢、齿轮钢、轴承钢、易切削非调质钢、弹簧钢、高压锅炉及管坯钢、锚链及系泊链钢、冷墩钢、预应力钢丝、钢绞线及工模具钢等。
炼钢厂钢种真空比~90%,除200×200mm连铸机部分钢种不真空处理外,其他连铸坯断面的钢种,100%进行真空处理。
每次喷补用料0.1-0.35吨,要求烧结时间小于10分钟,使用寿命大于2炉。其生产条件如表2所示。
表2:实施例1生产条件
项目 | 内容 |
电炉公称容量 | 130吨 |
电炉座数 | 2 |
连铸机座数 | 4 |
连铸机平均连浇周期 | ~50min |
RH装置数量 | 2座(三车五位) |
RH装置日处理能力(2座RH) | ~60炉 |
RH装置结构形式 | 钢包升降、双工位 |
热弯管形式 | U形 |
真空槽形式 | 分体式 |
浸渍管位置 | 焊接在真空槽底部 |
真空泵形式 | 干式机械真空泵 |
工作真空度,Pa | ≤67 |
高真空处理时间,min | 8~15(轴承钢20~35) |
真空处理温度,℃ | 1580-1650 |
热弯管数量(1座RH) | 3套 |
上部槽数量(1座RH) | 6套 |
下部槽数量(1座RH) | 8套 |
一种大量添加铸铁粉的优质RH喷补料,根据现场实际冶炼要求,优化方案,喷补料具体是由下列重量份数的原料配制而成:91重烧镁砂:45-55份、镁尖晶石废砖:15-25份、复合结合剂:16-22份,复合烧结剂:6-12份,复合助结合剂:7-10份,复合纤维1.0-1.2份。
91重烧镁砂中:小于等于3mm大于等于1mm的粗颗粒占20-25份、小于1mm大于等于0.074mm的细颗粒占10-15份、小于0.074mm细粉占10-20份。
镁尖晶石废砖:小于等于3mm大于等于1mm的粗颗粒占5-10份、小于1mm大于等于0.074mm的细颗粒占5-10份、小于0.074mm细粉占0-10份。
复合结合剂中:金属铝粉:磷酸盐结合剂:高温沥青粉:=1:(1-1.5):(0.5-1.0)。
复合烧结剂中:铸铁粉:高钛渣=1:(0.2-0.5),上述物料粒度为规定粒度标准的细粉。
复合助结合剂中:磷酸钠:膨润土:活性氧化铝微粉:抗反弹剂=1:(0.8-1.5):(0.5-2.0):(0.02-0.03)。
所述复合纤维中:纸纤维:聚丙烯纤维=1:(0.05-0.06)。
上述原料的性能指标见表3。
表3:实施例1原料性能指标
一种大量添加铸铁粉的优质RH喷补料的生产方法,具体方法步骤如下:
1)生产复合结合剂,将金属铝粉、磷酸盐结合剂、高温沥青粉按照比例进行配料,每种料的配料精度小于20克,配好后统一加入到双锥混合机中预混,时间一般大于10分钟。预混合格的复合结合剂装袋,密封包装,待用。
2)生产复合烧结剂,将铸铁粉、高钛渣按照比例进行配料,每种料的配料精度小于20克,配好后统一加入到双锥混合机中预混,时间一般大于10分钟。预混合格的复合烧结剂装袋包装,待用。
3)生产复合助结合剂,将磷酸钠、膨润土、活性氧化铝微粉、抗反弹剂STABEN-2013按照比例进行配料,每种料的配料精度小于20克,配好后统一加入到双锥混合机中预混,时间一般大于10分钟。预混合格的复合助结合剂装袋,密封包装,待用。
4)生产复合纤维,将纸纤维、聚丙烯纤维按照比例进行配料,每种料的配料精度小于10克,配好后统一装袋包装,无需混合,待用。
5)将按比例配好的91重烧镁砂及镁尖晶石废砖,其中的小于3mm大于等于1mm粗颗粒颗粒、小于1mm大于等于0.074mm的细颗粒部分,以及复合纤维一次性加入到双轴式搅拌机中,混合5-6分钟,然后,再将按比例配好的91重烧镁砂及镁尖晶石废砖,其中的小于0.074mm细粉部分,以及按比例配好,并预先混好的复合结合剂、复合烧结剂、复合助结合剂一同加入到双轴式搅拌机中,再次混合3-6分钟,搅拌均匀,颜色一致,尤其是纤维分布均匀,即可出料,装袋包装,取样检验,入库待发。
在钢厂2020.6.10-6.15期间,总计喷补122炉,每炉平均用料0.155吨,对比效果见表4。
表4:实施例1与普通RH喷补料效果对比
实施例2:
某钢厂,真空槽数量:10个(1#RH和2#RH各5个);工艺流程:转炉→LF→RH→铸机,转炉→RH→铸机;RH处理钢水温度1600-1650℃,处理周期为35-55min。其它主要工艺参数见表5。
表5:实施例2生产条件
每次喷补用料0.15-0.35吨,要求烧结时间小于12分钟,使用寿命大于3炉。
本发明的一种大量添加铸铁粉的优质RH喷补料,根据现场实际冶炼要求,优化方案,喷补料具体是由下列重量份数的原料配制而成:95中档镁砂:45-55份、镁尖晶石废砖:15-25份、复合结合剂:12-16份,复合烧结剂:6-12份,复合助结合剂:3-7份,复合纤维1.0-1.2份。
95中档镁砂:小于等于3mm大于等于1mm的粗颗粒占20-25份、小于1mm大于等于0.074mm的细颗粒占10-15份、小于0.074mm细粉占10-20份。
镁尖晶石废砖:小于等于3mm大于等于1mm的粗颗粒占15-20份、小于1mm大于等于0.074mm的细颗粒占10-15份、小于0.074mm细粉占10-15份。
复合结合剂中:金属铝粉:磷酸盐结合剂:固体树脂粉=1:(1-1.5):(0.3-0.8)。
复合烧结剂中:铸铁粉:铬精矿=1:(0.2-0.8),上述物料粒度为规定粒度标准的细粉。
复合助结合剂中:磷酸钠:膨润土:硅灰:抗反弹剂=1:(0.5-1.5):(0.3-1.5):(0.02-0.03)。
复合纤维中:纸纤维:聚丙烯纤维=1:(0.05-0.06)。
上述原料的性能指标见表6:
表6:实施例2原料性能指标
一种大量添加铸铁粉的优质RH喷补料的生产方法,具体方法步骤如下:
1)生产复合结合剂,将金属铝粉、磷酸盐结合剂、固体树脂粉按照比例进行配料,每种料的配料精度小于20克,配好后统一加入到双锥混合机中预混,时间一般大于10分钟。预混合格的复合结合剂装袋,密封包装,待用。
2)生产复合烧结剂,将铸铁粉、铬精矿按照比例进行配料,每种料的配料精度小于20克,配好后统一加入到双锥混合机中预混,时间一般大于10分钟。预混合格的复合烧结剂装袋包装,待用。
3)生产复合助结合剂,将磷酸钠、膨润土、硅灰、抗反弹剂STABEN-2013按照比例进行配料,每种料的配料精度小于20克,配好后统一加入到双锥混合机中预混,时间一般大于10分钟。预混合格的复合助结合剂装袋,密封包装,待用。
4)生产复合纤维,将纸纤维、聚丙烯纤维按照比例进行配料,每种料的配料精度小于10克,配好后统一装袋包装,无需混合,待用。
5)将按比例配好的95中档镁砂及镁尖晶石废砖,其中的小于3mm大于等于1mm粗颗粒颗粒、小于1mm大于等于0.074mm的细颗粒部分,以及复合纤维一次性加入到双轴式搅拌机中,混合5-6分钟,然后,再将按比例配好的95中档镁砂及镁尖晶石废砖,其中的小于0.074mm细粉部分,以及按比例配好,并预先混好的复合结合剂、复合烧结剂、复合助结合剂一同加入到双轴式搅拌机中,再次混合3-6分钟,搅拌均匀,颜色一致,尤其是纤维分布均匀,即可出料,装袋包装,取样检验,入库待发。
在钢厂2020.3.5-3.12期间,总计喷补78炉,每炉平均用料0.195吨,对比效果如表7所示。
表7:实施例2与普通RH喷补料的效果对比
Claims (3)
1.一种大量添加铸铁粉的优质RH喷补料,是由下列重量份数的原料配制而成:91重烧镁砂:45-55份、镁尖晶石废砖:15-25份、复合结合剂:16-22份,复合烧结剂:6-12份,复合助结合剂:7-10份,复合纤维1.0-1.2份;
91重烧镁砂中:小于等于3mm大于等于1mm的粗颗粒占20-25份、小于1mm大于等于0.074mm的细颗粒占10-15份、小于0.074mm细粉占10-20份;
镁尖晶石废砖:小于等于3mm大于等于1mm的粗颗粒占5-10份、小于1mm大于等于0.074mm的细颗粒占5-10份、小于0.074mm细粉占0-10份;
复合结合剂中:金属铝粉:磷酸盐结合剂:高温沥青粉:=1:(1-1.5):(0.5-1.0);
复合烧结剂中:铸铁粉:高钛渣=1:(0.2-0.5);
复合助结合剂中:磷酸钠:膨润土:活性氧化铝微粉:抗反弹剂=1:(0.8-1.5):(0.5-2.0):(0.02-0.03);
所述复合纤维中:纸纤维:聚丙烯纤维=1:(0.05-0.06)。
2.一种大量添加铸铁粉的优质RH喷补料,是由下列重量份数的原料配制而成:95中档镁砂:45-55份、镁尖晶石废砖:15-25份、复合结合剂:12-16份,复合烧结剂:6-12份,复合助结合剂:3-7份,复合纤维1.0-1.2份;
95中档镁砂:小于等于3mm大于等于1mm的粗颗粒占20-25份、小于1mm大于等于0.074mm的细颗粒占10-15份、小于0.074mm细粉占10-20份;
镁尖晶石废砖:小于等于3mm大于等于1mm的粗颗粒占15-20份、小于1mm大于等于0.074mm的细颗粒占10-15份、小于0.074mm细粉占10-15份;
复合结合剂中:金属铝粉:磷酸盐结合剂:固体树脂粉=1:(1-1.5):(0.3-0.8);
复合烧结剂中:铸铁粉:铬精矿=1:(0.2-0.8),上述物料粒度为规定粒度标准的细粉;
复合助结合剂中:磷酸钠:膨润土:硅灰:抗反弹剂=1:(0.5-1.5):(0.3-1.5):(0.02-0.03);
复合纤维中:纸纤维:聚丙烯纤维=1:(0.05-0.06)。
3.一种如权利要求1或2所述的大量添加铸铁粉的优质RH喷补料的生产方法,其特征在于,包括如下步骤:
1)生产复合结合剂,将复合结合剂材料按照比例进行配料,配好后统一加入到双锥混合机中预混,时间大于10分钟;
2)生产复合烧结剂,将烧结剂材料按照比例进行配料,配好后统一加入到双锥混合机中预混,时间大于10分钟;
3)生产复合助结合剂,将复合助结合剂剂材料按照比例进行配料,配好后统一加入到双锥混合机中预混,时间大于10分钟;
4)生产复合纤维,将复合纤维材料按照比例进行配料;
5)将按比例配好的烧结镁砂及镁尖晶石废砖,其中的小于3mm大于等于1mm粗颗粒颗粒、小于1mm大于等于0.074mm的细颗粒部分,以及复合纤维一次性加入到双轴式搅拌机中,混合5-8分钟,然后,再将按比例配好的烧结镁砂及镁尖晶石废砖,其中的小于0.074mm细粉部分,以及上述步骤1)、2)、3)中预先制备的复合结合剂、复合烧结剂、复合助结合剂一同加入到双轴式搅拌机中,再次混合3-8分钟。
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