CN112851307B - 一种高炉风口表面耐高温陶瓷材料及其制备方法和应用 - Google Patents

一种高炉风口表面耐高温陶瓷材料及其制备方法和应用 Download PDF

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CN112851307B
CN112851307B CN202110074005.9A CN202110074005A CN112851307B CN 112851307 B CN112851307 B CN 112851307B CN 202110074005 A CN202110074005 A CN 202110074005A CN 112851307 B CN112851307 B CN 112851307B
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王长宝
邹仲平
苏荣茂
亓福川
陈相成
王延平
张英
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Shandong Iron and Steel Co Ltd
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Abstract

本发明公开了一种用于高炉风口表面的耐高温陶瓷材料及其制备方法和应用，所述耐高温陶瓷材料含有粒度为0.1～0.3mm的CaO20～25％，粒度为0.1～0.5mm的CuO15～20％，粒度≤0.088mm的Pr6O118～18％，粒度＜60μm的MnO13～20％，粒度为90～120目的SnO210～18％，粒度＜0.088mm的ZnO8％～15％，粒度为180～200目的活性α‑Al2O33～8％。该耐高温陶瓷材料具有耐高温、强度高、耐摩擦，抗侵蚀能力强等优点，加上先进的处理工艺，可满足高炉内部使用条件，与未处理的铜质风口小套相比，增强风口小套承受的临界热流强度和抗冲刷能力，从而大大提高了其使用寿命。同时，还可以提高铁水产量，降低风口小套漏水风险，改善高炉炉况，满足高炉稳定顺产作业要求。

Description

一种高炉风口表面耐高温陶瓷材料及其制备方法和应用
技术领域
本发明属于钢铁行业高炉风口用耐高温陶瓷领域，具体的说涉及一种用于高炉风口表面耐高温陶瓷材料及其制备方法和使用方法。
背景技术
高炉冶炼生铁生产中一个关键备件就是送风风口，高炉风口工作环境严峻，它处在2000℃以上的高温炉缸内，承受高温区的辐射和对流热冲击，风口前端受到1500℃左右的液态渣铁和高速循环运动的炽热物料的冲刷，风口内通过900℃～13000℃的热风，同时在燃烧循环区又受到强烈的氧化作用和微量元素对风口的浸润，此外在喷吹煤粉和兰炭条件下还受到材料的高速磨损，这些不利因素都加剧了风口破损。而高炉风口属连续工作而且无法在使用中检修更换的设备，一旦破损，通常需临时休风更换，从而给生铁产量、质量和焦比等带来不利的影响。风口寿命低，不仅备件费用增加，焦耗增加，而且高炉休风率增加，经济损失很大。
目前，我国高炉风口小套分为铜质和耐火材料质两种，但由于耐火材料质风口小套需要改变喷吹工艺，因此，绝大多数仍为铜套，采用空腔水冷却和螺旋水冷却两种形式。在使用过程中，由于风口头部伸入到高炉中，液态渣铁与风口前端接触，造成风口局部热流强度超过风口材质所能承受的临界热流强度，导致铜壁温度上升超过铜的熔点，风口被烧穿。或炉况不顺行，高炉悬塌料频繁，渣、铁出不净，造成铁液频繁冲刷风口小套而损坏。目前，风口小套的平均使用寿命只有6个月左右，已成为高炉进一步提高产量，优化各项经济技术指标的制约性因素之一。
发明内容
针对目前存在的问题，本发明的目的是对铜质高炉风口小套进行表面处理，提供一种优质的耐高温陶瓷材料和先进的处理工艺，对铜质小套表面保护处理，增强风口小套承受的临界热流强度和抗冲刷能力，从而提高其使用寿命。同时，还可以提高铁水产量，降低风口小套漏水风险，改善高炉炉况，满足高炉稳定顺产作业要求。
为解决上述技术问题，本发明采用的技术方案是：
以CaO、CuO、Pr6O11、MnO、SnO2、ZnO为主料，活性α-Al2O3为结合剂，以此料为风口小套表面材料。
一种高炉风口表面耐高温陶瓷材料包括如下原料组分：
Figure BDA0002906887780000021
作为一种优选，所述耐高温陶瓷材料包括如下原料组分：
Figure BDA0002906887780000022
进一步优选的，所述耐高温陶瓷材料包含如下原料组分：
Figure BDA0002906887780000023
再一步优选的，所述耐高温陶瓷材料包括如下原料组分：
Figure BDA0002906887780000024
Figure BDA0002906887780000031
本发明提供的优质的耐高温陶瓷材料，具有耐高温、强度高、耐摩擦，抗侵蚀能力强等优点，与未处理的铜质风口小套相比，使用寿命大大提高。
本发明中，CuO作为基体过度层，调节了涂层-铜基体及涂层结构与热应力分布，CaO熔点高达2572℃，离子晶体富有弹性，可提高了涂层耐火度和高温热稳定性。ZnO会与Al2O3生成锌尖晶石，化学式为ZnAl2O4，而Pr6O11以镨钕富集物的形式加入八面体型的锌尖晶石中，可提高等轴晶系的活性和稳定性。MnO作为立方晶系粉末，可与八面体晶体相互交叉，提高材料耐磨性。SnO2六方或斜方晶系粉末，提高材料的强度和抗侵蚀性能。同时，多种材料还可以相互交融，形式固溶体，对于提高材料的各项性能有重要意义。
本发明还提供了上述任一高炉风口表面耐高温陶瓷材料的制备方法，包括以下步骤：
按所述比例称取各种物料，放入搅拌机中混合搅拌5～8分钟获得混合物料，对混合物料加水后再混合搅拌5～8分钟，制得高炉风口表面耐高温陶瓷材料。
作为一种优选，按混合物料总重量的5％～10％加水。
本发明还提供了上述任一高炉风口表面耐高温陶瓷材料在对铜质高炉风口小套保护中的应用。
本发明还提供了一种高炉风口小套表面保护处理方法，具体包括以下步骤：
1)先对风口小套表面进行预处理，将风口小套放入干燥箱中，加热至450～600℃，保温8～10小时，让风口小套表面的金属铜氧化生成氧化铜，然后冷却至室温；
2)将上述任一高炉风口表面耐高温陶瓷材料均匀涂刷到预先处理的铜套表面2～3mm，再将风口小套放入干燥箱中，加热至110～150℃，保温24～26小时，然后再在高温炉中2200～2400℃温度下保温24～26小时，自然冷却后完成处理。
作为一种优选，步骤2)在高温炉保温以及自然冷却过程中，对铜套采用水冷却降温，以防止铜套熔化。
本发明具有积极有效的效果
1、同未处理铜套相比，表面处理后的风口小套，增强了其临界热流强度和抗冲刷能力，从而将风口小套的平均使用寿命由6个月左右提高到18个月左右。
2、同未处理铜套相比，表面处理后的风口小套，可减少高炉休风次数，提高铁水产量。
3、同未处理铜套相比，表面处理后的风口小套，可降低风口小套漏水风险，改善高炉炉况，满足高炉稳定顺产作业要求。
4、该耐高温陶瓷材料满足高炉内部工作条件，其主要理化指标如下：
Figure BDA0002906887780000041
具体实施方式
实施例1
一种高炉风口表面耐高温陶瓷材料，其原料配方见表1：
先对风口小套表面进行预处理，将风口小套放入干燥箱中，加热至450℃，保温8个小时，让风口小套表面的金属铜氧化生成氧化铜，然后冷却至室温。按表1中所述比例称取各种物料，放入搅拌机中混合搅拌5～8分钟，再加水(加水量为物料总重量的5％～10％)混合搅拌5～8分钟。将混好的材料均匀涂刷到预先处理的铜套表面2～3mm，再将风口小套放入干燥箱中，加热至110℃，保温24个小时，然后再在高温炉中2200℃温度下保温24小时(铜套采用水冷却降温)，自然冷却后即可投入使用。其主要理化指标如下：
Figure BDA0002906887780000042
实施例2
一种高炉风口表面耐高温陶瓷材料，其原料配方见表1：
该高温陶瓷材料制备及处理工艺同实施例1，其主要理化指标如下：
Figure BDA0002906887780000051
实施例3
一种高炉风口表面耐高温陶瓷材料，其原料配方见表1：
该高温陶瓷材料制备及处理工艺同实施例1，其主要理化指标如下：
Figure BDA0002906887780000052
实施例4
一种高炉风口表面耐高温陶瓷材料，其原料配方见表1：
该高温陶瓷材料制备及处理工艺同实施例1，其主要理化指标如下：
Figure BDA0002906887780000053
实施例5
一种高炉风口表面耐高温陶瓷材料，其原料配方见表1：
该高温陶瓷材料制备及处理工艺同实施例1，其主要理化指标如下：
Figure BDA0002906887780000054
Figure BDA0002906887780000061
实施例6
一种高炉风口表面耐高温陶瓷材料，其原料配方见表1：
该高温陶瓷材料制备及处理工艺同实施例1，其主要理化指标如下：
Figure BDA0002906887780000062
实施例7
一种高炉风口表面耐高温陶瓷材料，其原料配方见表1：
该高温陶瓷材料制备及处理工艺同实施例1，其主要理化指标如下：
Figure BDA0002906887780000063
表1实施例1～7原料配方表
单位：重量百分比(％)
原料 粒度分布 实施例1 实施例2 实施例3 实施例4 实施例5 实施例6 实施例7
CaO 0.1～0.3mm 25 22 22 20 21 23 24
CuO 0.1～0.5mm 17 19 17 15 18 16 20
Pr<sub>6</sub>O<sub>11</sub> ≤0.088mm 12 10 14 18 13 16 12
MnO ＜60μm 16 15 16 20 17 18 15
SnO<sub>2</sub> 90～120目 15 12 13 16 14 11 10
ZnO ＜0.088mm 10 14 12 8 13 9 14
α-Al<sub>2</sub>O<sub>3</sub> 180～200目 5 8 6 3 4 7 5
由实施例可以看出，本发明的高温陶瓷材料耐火度大于2600℃，满足高炉内部高温条件，耐压强度大于、等于53MPa，能有效抵御炉料的撞击，莫氏硬度大于或等于6.2，耐磨性能强，抗液体渣、铁接触次数达到16次或16次以上，大大降低了风口小套熔损率。且高温陶瓷材料与铜套结合强度高(≥40MPa)，结合牢固，能大大提高风口小套使用寿命。
最后所应说明的是，以上实施例仅用以说明本发明的技术方案而非限制。尽管参照实施例对本发明进行了详细说明，本领域的普通技术人员应该理解，对本发明的技术方案进行修改或者等同替换，都不脱离本发明技术方案的精神和范围，其均应涵盖在本发明的权利要求范围当中。

Claims (9)

1.一种高炉风口表面耐高温陶瓷材料，其特征在于，所述耐高温陶瓷材料包括如下原料组分：
Figure FDA0003610013780000011
2.根据权利要求1所述高炉风口表面耐高温陶瓷材料，其特征在于，所述材料含有如下原料组分：
Figure FDA0003610013780000012
3.根据权利要求1所述高炉风口表面耐高温陶瓷材料，其特征在于，所述耐高温陶瓷材料包括如下原料组分：
Figure FDA0003610013780000013
4.根据权利要求1所述高炉风口表面耐高温陶瓷材料，其特征在于，所述耐高温陶瓷材料包括如下原料组分：
Figure FDA0003610013780000021
5.一种权利要求1～4任一所述高炉风口表面耐高温陶瓷材料的制备方法，包括以下步骤：
按所述比例称取各种物料，放入搅拌机中混合搅拌5～8分钟获得混合物料，对混合物料加水后再混合搅拌5～8分钟，制得高炉风口表面耐高温陶瓷材料。
6.根据权利要求5所述的制备方法，其特征在于，按混合物料总重量的5％～10％加水。
7.权利要求1～4任一高炉风口表面耐高温陶瓷材料在对铜质高炉风口小套保护中的应用。
8.一种高炉风口小套表面保护处理方法，包括以下步骤：
1)先对风口小套表面进行预处理，将风口小套放入干燥箱中，加热至450～600℃，保温8～10小时，让风口小套表面的金属铜氧化生成氧化铜，然后冷却至室温；
2)将通过权利要求5所述制备方法制备好的高炉风口表面耐高温陶瓷材料均匀涂刷到预先处理的铜套表面2～3mm，再将风口小套放入干燥箱中，加热至110～150℃，保温24～26小时，然后再在高温炉中2200～2400℃温度下保温24～26小时，自然冷却后完成处理。
9.根据权利要求8所述的高炉风口小套表面保护处理方法，其特征在于，步骤2)在高温炉保温以及自然冷却过程中，对铜套采用水冷却降温。
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