CN112830772A - 一种亚微米二氧化硅微粉结合铁沟浇注料及其制备方法 - Google Patents
一种亚微米二氧化硅微粉结合铁沟浇注料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种亚微米SiO2微粉结合铁沟浇注料及其制备方法,其组成按质量百分数计如下:致密刚玉骨料58~62wt%;碳化硅骨料6~10wt%;球沥青2~3wt%;氧化铝微粉4~10wt%;亚微米SiO2微粉4~5wt%;碳化硅粉7~10wt%;金属硅粉1~1.5wt%;分散剂0.1~0.15wt%;致密刚玉粉6~9wt%;防爆纤维0.06‑0.1wt%;轻烧镁粉0‑0.2wt%。本发明创新的在铁沟浇注料中采用亚微米SiO2微粉做为结合剂,完全替代水泥使浇注料产生足够的早期强度,突破了传统铁沟浇注料的研究瓶颈。降低了铁沟浇注料的加水量,提高了铁沟浇注料热态抗折强度,减少了浇注料低熔相的产生。同时解决了亚微米SiO2微粉结合铁沟浇注料的促凝问题及抗爆问题。
Description
技术领域
本发明属于耐火材料技术领域,具体涉及一种亚微米SiO2微粉结合铁沟浇注料及其制备方法。
背景技术
高炉出铁场铁沟在使用过程中,长期受到1450℃以上铁水和炉渣的强烈冲刷作用,使用环境极其恶劣,国内外几乎都是采用的水泥结合的铝碳化硅炭质的浇注料,然而该体系即使采用最高档次的原材料,也无法避免因水泥引入,生成钙长石等低熔点物质带来的高温性能劣化,从而严重制约了铁沟浇注料性能的进一步提高。因此,无水泥结合铁沟浇注料是一直是业界希望达到的理想状态。
国内学者为达到铁沟浇注料无水泥化的目的,进行了大量的研究。一般方法是采用硅溶胶或者采用水硬性氧化铝来替代水泥,提供铁沟浇注料的早期强度。然而,硅溶胶因其自身无法克服的缺点(施工麻烦、冬季结冰失效、现场受高温影响大、加液量大等),使用效果相比水泥结合铁沟浇注料没有优势,施工性能不能满足现场要求且使用效果波动较大。水硬性氧化铝在浇注料中完全替代水泥结合不但强度低,而且这种氧化铝稳定性不好,尤其水化速度受温度影响极其敏感,同时中温失去结晶水的过程常常会产生微裂纹,使材料的结构致密程度受到影响。
CN201611150300.3公开了一种高炉出铁用无水泥铁沟浇注料及其制备方法,采用ρ-氧化铝(水硬性氧化铝)替代水泥产生早期强度,减少因水泥带来的低熔物,但是加水量大、ρ-氧化铝本身不稳定,ρ-氧化铝在浇注料中受环境温度影响,反应活性差别很大,凝固时间不易控制。
CN201410055772.5公开了一种致密型高强度SiAlON结合铁沟浇注料及其制作方法,采用采用硅溶胶实现了基质增强及无水泥化,但是仍存在施工麻烦、硅溶胶冬季结冰失效、现场受高温影响大、加液量大等问题。
由于在结合方式上一直没有新的突破,因此在无水泥铁沟浇注料系统一直没有比较可行的新的优化方案。
发明内容
本发明目的在于提供一种亚微米SiO2微粉结合铁沟浇注料及其制备方法,突破了传统铁沟浇注料的研究瓶颈,产生足够的早期强度同时降低了铁沟浇注料的加水量,提高铁沟浇注料热态抗折强度,减少了浇注料低熔相的产生。
为达到上述目的,采用技术方案如下:
一种亚微米SiO2微粉结合铁沟浇注料,其组成按质量百分数计如下:
按上述方案,所述致密刚玉骨料的粒径0.1-8mm;其中Al2O3>98.5wt%,Fe2O3<0.2wt%。
按上述方案,所述碳化硅骨料粒度0.1-1mm;其中SiC含量≥98.5%,Fe2O3<0.3wt%。
按上述方案,所述球沥青的粒度≤1.5mm。
按上述方案,所述氧化铝微粉的粒度分布为:d10≤0.9μm;d50≤2μm;d90≤5μm,其Al2O3>99.5wt%、Na2O≤0.1wt%。
按上述方案,所述亚微米SiO2微粉d90≤0.5微米;其中SiO2>99.8wt%,pH值<4。
按上述方案,所述碳化硅粉的粒度≤74μm,其中SiC含量≥98wt%。
按上述方案,所述金属硅粉的粒度≤45μm;其中Si含量>98.5wt%。
按上述方案,所述分散剂为聚丙烯酸类减水剂。
按上述方案,所述致密刚玉粉粒度≤74μm;其中Al2O3>98.5wt%,Fe2O3<0.2wt%。
按上述方案,所述轻烧镁粉粒度≤74μm;其中MgO含量+烧失≥85wt%,烧失≥18wt%。
按上述方案,所述防爆纤维为聚乙烯醇类水溶性纤维;长度6毫米,直径18微米,熔点≤80℃。
上述亚微米SiO2微粉结合铁沟浇注料的制备方法,包括以下步骤:
将上述原料混合搅拌均匀,然后加入浇注料质量3.5-3.8%左右的水,充分搅拌后振动成型即得亚微米SiO2微粉结合铁沟浇注料。
与现有技术相比,本发明的有益效果为:
1)本发明创新的在铁沟浇注料中采用亚微米SiO2微粉做为结合剂,完全替代水泥使浇注料产生足够的早期强度,突破了传统铁沟浇注料的研究瓶颈。降低了铁沟浇注料的加水量,提高铁沟浇注料热态抗折强度,减少了浇注料低熔相的产生。
2)本发明创新的采用高活性轻烧镁粉,解决了亚微米SiO2微粉结合铁沟浇注料凝固时间长的问题。
3)本发明创新的采用特别型号的水溶性防爆纤维,解决了亚微米SiO2微粉结合铁沟浇注料这种超致密体系的防爆裂问题,在没有金属铝粉产生气体通道的前提下(由于该体系下,金属铝粉在没有水泥的条件下不能与水反应生成氢气),使亚微米SiO2微粉结合的铁沟浇注料具备优良的防爆性能,满足这种新结合体系浇注料现场快速烘烤的施工要求。
具体实施方式
为了更好地理解本发明,下面结合实施例进一步阐明本发明的内容,但本发明的内容不仅仅局限于下面的实施例。
以下实施例中,所述致密刚玉骨料粒径为0.1-8mm;致密刚玉骨料中不同粒径颗粒所占质量百分比为:5-8mm 25%,3-5mm 14%,1-3mm 14%,0.1-1mm 5-9%,所含Al2O3>98.5wt%,Fe2O3<0.2wt%。致密刚玉粉细度为≤74μm;所含Al2O3>98.5wt%,Fe2O3<0.2wt%。
所述碳化硅骨料粒度0.1-1mm:SiC>98.5wt%,Fe2O3<0.3wt%。所述碳化硅粉中SiC含量≥98%,细度为≤74μm。
所述球沥青的粒度不大于1.5mm;本发明选用高温球沥青,该高残炭含量的沥青有利于提升Al2O3-SiC-C质浇注料的抗渣性能。
所述氧化铝微粉的粒度分布为:d10≤0.9μm;d50≤2μm;d90≤5μm,其Al2O3>99.5wt%、Na2O≤0.1wt%。这种精选的氧化铝微粉具有较宽的粒度分布,与亚微米SiO2微粉形成良好的粒度紧密堆积,从而使浇注料呈现良好的减水性能及较低的料浆粘性。
所述亚微米SiO2微粉:d90≤0.5微米,SiO2>99.8wt%,pH值<4。
所述金属硅粉的粒度≤45μm,Si含量>98.5%。
所述分散剂为聚丙烯酸类高效减水剂,有极佳的减水性能。
所述轻烧镁粉粒度≤74μm,其MgO含量+烧失≥85wt%,烧失≥18wt%。
所述防爆纤维为聚乙烯醇类水溶性纤维;长度6毫米,直径18微米,熔点≤80℃。
实施例1
一种亚微米SiO2微粉结合铁沟浇注料,各组分及其所占质量百分比为:将致密刚玉骨料60%;碳化硅骨料8%;球沥青2.5%;氧化铝微粉8%;亚微米SiO2微粉5%;碳化硅粉8%;分散剂0.15%;金属硅粉1.25%;致密刚玉粉6.9%;轻烧镁粉0.1%;防爆纤维0.1%。将各原料按上述配比称取并充分混合;再加入水(水的质量为各原料总质量的3.5%)搅拌均匀后振动成型;成型后所得试样经自然干燥24h后在110℃下再进行热处理24h,制得亚微米SiO2微粉结合铁沟浇注料试样。
将本实施例所制得的亚微米SiO2微粉结合铁沟浇注料试样进行性能检测,结果如表1所示。采用的性能检测方法按照现行国家标准或行业标准进行,所得检测结果为3次平均检测结果(以下同)。
表1
实施例2
一种亚微米SiO2微粉结合铁沟浇注料,各组分及其所占质量百分比为:将致密刚玉骨料62%;碳化硅骨料:6%;球沥青3%;氧化铝微粉5.14%;亚微米SiO2微粉4.5%;碳化硅粉8.5%;分散剂0.1%;金属硅粉1.5%;致密刚玉粉9%;轻烧镁粉0.2%;防爆纤维0.06%。将各原料按上述配比称取并充分混合;再加入水(水的质量为各原料总质量的3.7%)搅拌均匀后振动成型;成型后所得试样经自然干燥24h后在110℃下再进行热处理24h,制得亚微米SiO2微粉结合铁沟浇注料试样。
将本实施例所制得的亚微米SiO2微粉结合铁沟浇注料试样进行性能检测,结果如表2所示。采用的性能检测方法按照现行国家标准或行业标准进行,所得检测结果为3次平均检测结果(以下同)。
表2
实施例3
一种亚微米SiO2微粉结合铁沟浇注料,各组分及其所占质量百分比为:将致密刚玉骨料58%;碳化硅骨料:10%;球沥青2%;氧化铝微粉10%;亚微米SiO2微粉4%;碳化硅粉7%;分散剂0.1%;金属硅粉1.17%;致密刚玉粉7.5%;轻烧镁粉0.15%;防爆纤维0.08%。将各原料按上述配比称取并充分混合;再加入水(水的质量为各原料总质量的3.6%)搅拌均匀后振动成型;成型后所得试样经自然干燥24h后在110℃下再进行热处理24h,制得亚微米SiO2微粉结合铁沟浇注料试样。
将本实施例所制得的亚微米SiO2微粉结合铁沟浇注料试样进行性能检测,结果如表3所示。采用的性能检测方法按照现行国家标准或行业标准进行,所得检测结果为3次平均检测结果(以下同)。
表3
实施例4
一种亚微米SiO2微粉结合铁沟浇注料,各组分及其所占质量百分比为:将致密刚玉骨料61%;碳化硅骨料:10%;球沥青2.715%;氧化铝微粉4%;亚微米SiO2微粉5%;碳化硅粉10%;分散剂0.125%;金属硅粉1%;致密刚玉粉6%;轻烧镁粉0.1%;防爆纤维0.06%。将各原料按上述配比称取并充分混合;再加入水(水的质量为各原料总质量的3.7%)搅拌均匀后振动成型;成型后所得试样经自然干燥24h后在110℃下再进行热处理24h,制得亚微米SiO2微粉结合铁沟浇注料试样。
将本实施例所制得的亚微米SiO2微粉结合铁沟浇注料试样进行性能检测,结果如表4所示。采用的性能检测方法按照现行国家标准或行业标准进行,所得检测结果为3次平均检测结果(以下同)。
表4
实施例5
一种亚微米SiO2微粉结合铁沟浇注料,各组分及其所占质量百分比为:将致密刚玉骨料60%;碳化硅骨料8%;球沥青2.5%;氧化铝微粉8%;亚微米SiO2微粉5%;碳化硅粉8%;分散剂0.15%;金属硅粉1.35%;致密刚玉粉6.9%;;防爆纤维0.1%。将各原料按上述配比称取并充分混合;再加入水(水的质量为各原料总质量的3.5%)搅拌均匀后振动成型;成型后所得试样经自然干燥24h后在110℃下再进行热处理24h,制得亚微米SiO2微粉结合铁沟浇注料试样。
将本实施例所制得的亚微米SiO2微粉结合铁沟浇注料试样进行性能检测,结果如表5所示。采用的性能检测方法按照现行国家标准或行业标准进行,所得检测结果为3次平均检测结果(以下同)。
表5
上述结果表明,本发明所述一种亚微米SiO2微粉结合铁沟浇注料,具有加水量低、致密性好、无水泥、热态强度高等特点。
显然,上述实施例仅仅是为清楚地说明所作的实例,而并非对实施方式的限制。对于所属领域的普通技术人员来说,在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而因此所引申的显而易见的变化或变动仍处于本发明创造的保护范围之内。
Claims (10)
2.如权利要求1所述亚微米SiO2微粉结合铁沟浇注料,其特征在于所述轻烧镁粉粒度≤74μm;其中MgO含量+烧失≥85wt%,烧失≥18wt%。
3.如权利要求1所述亚微米SiO2微粉结合铁沟浇注料,其特征在于所述致密刚玉骨料的粒径0.1-8mm;其中Al2O3>98.5wt%,Fe2O3<0.2wt%;所述致密刚玉粉粒度≤74μm;其中Al2O3>98.5wt%,Fe2O3<0.2wt%。
4.如权利要求1所述亚微米SiO2微粉结合铁沟浇注料,其特征在于所述碳化硅骨料粒度0.1-1mm;其中SiC含量≥98.5%,Fe2O3<0.3wt%;所述碳化硅粉的粒度≤74μm,其中SiC含量≥98wt%。
5.如权利要求1所述亚微米SiO2微粉结合铁沟浇注料,其特征在于所述球沥青为高温沥青,粒度≤1.5mm;所述分散剂为聚丙烯酸类减水剂。
6.如权利要求1所述亚微米SiO2微粉结合铁沟浇注料,其特征在于所述氧化铝微粉的粒度分布为:d10≤0.9μm;d50≤2μm;d90≤5μm,其Al2O3>99.5wt%、Na2O≤0.1wt%。
7.如权利要求1所述亚微米SiO2微粉结合铁沟浇注料,其特征在于所述亚微米SiO2微粉d90≤0.5微米;其中SiO2>99.8wt%,pH值<4。
8.如权利要求1所述亚微米SiO2微粉结合铁沟浇注料,其特征在于所述金属硅粉的粒度≤45μm;其中Si含量>98.5wt%。
9.如权利要求1所述亚微米SiO2微粉结合铁沟浇注料,其特征在于所述防爆纤维为聚乙烯醇类水溶性纤维;长度6毫米,直径18微米,熔点≤80℃。
10.权利要求1-9任一项所述亚微米SiO2微粉结合铁沟浇注料的制备方法,包括以下步骤:
将上述原料混合搅拌均匀,然后加入浇注料质量3.5-3.8%左右的水,充分搅拌后振动成型即得亚微米SiO2微粉结合铁沟浇注料。
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