CN113248274A - 一种纳米碳化硅晶须增强耐温抗磨喷口及其制造方法 - Google Patents
一种纳米碳化硅晶须增强耐温抗磨喷口及其制造方法 Download PDFInfo
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- 229910052681 coesite Inorganic materials 0.000 claims abstract description 17
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- 229910052594 sapphire Inorganic materials 0.000 claims abstract description 17
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 17
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- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 claims description 18
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- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims description 6
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- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明公开了一种纳米碳化硅晶须增强耐温抗磨喷口的制造方法，包括如下步骤：基质粉料的预混合：纳米SiCw晶须、板状刚玉细粉、活性α‑Al2O3微粉、SiO2微粉、铝酸盐水泥、外加剂按照设定的比例，放入搅拌机中混合，混好的基质料密封保存待用；并将按配比称量好的SiC颗粒与预混好的基质粉料混合，再分散添加适量的HCA耐高温纤维，继续搅拌，最后外加占物料总重量5～8％的水混合搅拌，搅拌完全充分均匀后，注入喷涂硅油成膜的清洁干净模具中，然后震动成型，待表面泛浆后，静置48h以上脱模，再置入110℃的热处理炉干燥处理，然后炉内按升温、保温曲线进行不少于127h的烘焙，直至升到预设温度，再缓慢降温直至室温。本发明有效提升喷口的韧性和抗热震性。
Description
技术领域
本发明涉及燃煤发电燃烧系统技术领域，具体涉及一种纳米碳化硅晶须增强耐温抗磨喷口的制造方法。
背景技术
燃煤发电燃烧系统的锅炉燃烧器，作用是将燃料（煤粉）与燃烧所需空气，按一定的比例、速度和混合方式，经喷口送入炉膛，保证燃烧迅速、充分，能很好的适应运行过程中负荷变化和煤种的变化，减少NOx的生成，满足超低排放的环保要求；因此，如何更好地实现燃料与空气混合均匀、燃烧充分、防止燃料的浪费至关重要。
传统的燃烧器喷口采用耐热铸钢件材料，易磨损、耐温低（1000℃以下），易在高温下发生氧化腐蚀、变形翘曲，引起喷口尺寸与原始设计尺寸的偏差，造成喷口附近火焰射程变短，温升过高，易产生结渣，并加速了喷口的烧损，导致喷口的工作效率降低，影响设备正常运行，缩短使用寿命。
鉴于上述喷口的缺陷，本发明通过纳米碳化硅晶须增强等措施，克服普通碳化硅脆性大易断裂、高温易氧化的缺陷，并采用使用过程中炉内自烧结节能工艺，制备一种纳米碳化硅晶须增强耐温抗磨喷口，它具有耐高温、抗冲刷、结构强度高、整体性好、热震稳定性好、使用寿命长、成型方便等特点，使其在该领域具有独特的利用价值。
发明内容
本发明要解决的技术问题是提供一种纳米碳化硅晶须增强耐温抗磨喷口，有效提升喷口的韧性和抗热震性。
为解决上述技术问题，本发明采取如下技术方案：一种纳米碳化硅晶须增强耐温抗磨喷口，由增强碳化硅基浇注材料，利用模具浇注成型，通过升温干燥和焙烧制造而成；喷口结构外形和尺寸均按照锅炉原始喷口设计尺寸。
作为优选：所述的纳米碳化硅晶须增强碳化硅基浇注料按照质量比由以下成分组成：2-7%的纳米SiCw晶须、62-75%的SiC颗粒、1-3%的板状刚玉细粉、5-9%的活性α-Al2O3微粉、5.5-9.5%的SiO2微粉、3-7%的铝酸盐水泥、3-5%的HCA耐高温纤维以及占上述组分总量0.1-0.3%的外加剂。
作为优选：所述的纳米SiCw晶须直径0.1-0.2μm，长度10-100μm，化学成分要求为：SiCw含量≥98%； 所述的SiC颗粒包含29%的粒度为5-3mm颗粒；18%的粒度为3-1mm颗粒；22%的粒度为1-0mm颗粒，化学成分要求为：SiC含量≥98%；所述的板状刚玉细粉的粒度小于325目，化学成分要求为：Al2O3含量≥99.1%；所述的活性α-Al2O3微粉，中位粒径2μm ，化学成分要求为：Al2O3含量≥99.5%，其中活性成份≥95%；所述的SiO2微粉的粒度小于1μm，化学成分要求为：SiO2≥97.5％； 所述的铝酸盐水泥为纯铝酸钙水泥，化学成分要求为：Al2O3含量大于68.5%；所述的耐高温纤维，直径0.5mm，长度25mm，熔点≥1460℃；所述的外加剂，由柠檬酸水溶液、化学纯磷酸三钠溶液以及木质素磺酸钙溶液按照2-3.5：1.25-1.5：1-2比例混合而成。
本发明还提供一种纳米碳化硅晶须增强碳化硅基浇注料制备方法，包括如下步骤：
1）基质粉料的预混合：将纳米SiCw晶须、板状刚玉细粉、活性α-Al2O3微粉、SiO2微粉、纯铝酸钙水泥、外加剂按照设定的比例，放入混料搅拌机中混合20-30分钟，以使纳米SiCw晶须、板状刚玉细粉、SiO2微粉和活性α-Al2O3微粉充分混合均匀，混好的基质粉料密封待用。
2）浇注料的搅拌：将按配比称量好的SiC颗粒与预先混合好的基质粉料，置入强制式搅拌机中混合5～10分钟，再缓慢分散添加适量的HCA耐高温纤维，继续搅拌5分钟，最后外加占物料总重量5～8％的水混合搅拌不少于5分钟，搅拌完全充分均匀后，应在20分钟内使用完毕。
3）燃烧器喷口的浇注成型：浇注料制备完成，立即注入喷涂硅油成膜的清洁干净模具中，在振动台上震动成型或使用附着式振动器分层震动成型，待表面泛浆无气泡后，剔除表面余浆并抹压平整；静置养护48-72h脱模。
4）燃烧器喷口的干燥和焙烧：浇注成型脱模后，置入110℃的热处理炉干燥处理不少于24h，保温24h，使自由水水分充分排出；然后转入焙烧阶段，按15℃/h预设温度升温至350℃，保温30h，继续按15℃/h升温至600℃，保温16h；按上述升温曲线进行不少于127h的烘焙，最后缓慢降温直至室温即可安装使用。
作为优选，所述喷口置入110℃的热处理炉干燥处理不少于24h，保温24h,待自由水水分充分排出后；转入焙烧阶段，按15℃/h预设温度升温至350℃，保温30h，再按15℃/h升温至600℃，保温16h；按上述要求进行不少于127h的烘焙，最后缓慢炉内降温，降至室温即完成喷口制造的升温曲线。
作为优选，所述的62-75%SiC颗粒由不同粒径的SiC颗粒组成。
作为优选，69%的SiC颗粒包含29%的粒度为5-3mm颗粒，18%的粒度为3-1mm颗粒和22%的粒度为1-0mm颗粒。
本发明的有益效果为：
（1）本发明的喷口主要材质为碳化硅，能耐高温、耐腐蚀、抗冲刷，通过添加纳米碳化硅晶须可以有效提升喷口的韧性和抗热震性；
（2）本发明的喷口采用浇注一体成型，喷口框体和钝体不需要单独制造，整体性好；
（3）本发明采用炉内自烧结工艺，制造过程中只需要进行低温干燥焙烧，喷口在使用过程中的高温环境下，强度可以得到进一步提升。
附图说明
下面结合附图和实施例对本发明作进一步说明。
图1为本发明陶瓷喷口的结构示意图；
图2为本发明陶瓷喷口框体的结构示意图；
图3为本发明陶瓷喷口钝体的结构示意图。
具体实施方式
下面将结合具体实施例对本发明作详细的介绍：如图1所示的本发明的锅炉燃烧器喷口（图中1为框体，2为钝体），由增强碳化硅基浇注材料，利用模具浇注成型，通过升温干燥和焙烧制造而成；喷口结构外形和尺寸均按照锅炉原始喷口设计尺寸。
实施例1
本发明所述的一种纳米碳化硅晶须增强碳化硅基浇注料，由以下组分组成：
3%的纳米SiCw晶须、69%的SiC颗粒（包含29%的粒度为5-3mm颗粒；18%的粒度为3-1mm颗粒；22%的粒度为1-0mm颗粒）、2.5%的板状刚玉细粉、9%的活性α-Al2O3微粉、7%的SiO2微粉、5%的铝酸盐水泥、4.5%的HCA耐高温纤维以及占上述组分总量0.2%的外加剂（由0.1%的柠檬酸水溶液、0.046%的化学纯磷酸三钠以及0.054%的木质素磷酸钙组成）。
本发明的一种如上所述纳米碳化硅晶须增强碳化硅基浇注料制备方法，包括如下步骤 ：
1）基质粉料的预混合：将纳米SiCw晶须、板状刚玉细粉、活性α-Al2O3微粉、SiO2微粉、纯铝酸钙水泥、外加剂按照设定的比例，放入搅拌机中混合20-30分钟，以使纳米SiCw晶须、板状刚玉细粉、SiO2微粉和活性α-Al2O3微粉充分混合均匀，混好的基质粉料密封待用。
2）浇注料的搅拌：将按配比称量好的SiC颗粒与预先混合好的基质粉料置入强制式搅拌机中混合5～10分钟，再缓慢均匀分散添加HCA耐高温纤维，继续搅拌5分钟，最后外加占物料总重量6％的水混合搅拌不少于5分钟，搅拌完全充分均匀后，应在20分钟内使用完毕。
3）燃烧器喷口的浇注成型
浇注料制备完成，立即注入喷涂硅油成膜的清洁干净模具中，在振动台上震动成型或使用附着式振动器分层震动成型，待表面泛浆无气泡后，剔除表面余浆并抹压平整；静置养护48-72h脱模。
4）燃烧器喷口的干燥和焙烧
浇注成型脱模后，置入110℃的热处理炉干燥处理不少于24h，保温24h,使自由水水分充分排出；然后转入焙烧阶段，按20℃/h预设温度升温至400℃，保温24h，继续按20℃/h升温至600℃，保温12h；按上述升温曲线进行不少于108.5h的烘焙，最后缓慢降温直至室温即可。
5）测试值
实施例2
本发明的一种纳米碳化硅晶须增强碳化硅基浇注料，由以下组分组成：
5%的纳米SiCw晶须、69%的SiC颗粒（包含29%的粒度为5-3mm颗粒；18%的粒度为3-1mm颗粒；22%的粒度为1-0mm颗粒）、2.5%的板状刚玉细粉、8%的活性α-Al2O3微粉、6%的SiO2微粉、5%的铝酸盐水泥、4.5%的HCA耐高温纤维以及占上述组分总量0.2%的外加剂（由0.1%的柠檬酸水溶液、0.046%的化学纯磷酸三钠以及0.054%的木质素磷酸钙组成）。
本发明的一种如上所述纳米碳化硅晶须增强碳化硅基浇注料制备方法，包括如下步骤 ：
1）基质粉料的预混合：将纳米SiCw晶须、板状刚玉细粉、活性α-Al2O3微粉、SiO2微粉、纯铝酸钙水泥、外加剂按照设定的比例，放入搅拌机中混合20-30分钟，以使纳米SiCw晶须、板状刚玉细粉、SiO2微粉和活性α-Al2O3微粉充分混合均匀，混好的基质粉料密封待用。
2）浇注料的搅拌：将按配比称量好的SiC颗粒与预先混合好的基质粉料置入强制式搅拌机中混合5～10分钟，再缓慢均匀分散添加HCA耐高温纤维，继续搅拌5分钟，最后外加占物料总重量6％的水混合搅拌不少于5分钟，搅拌完全充分均匀后，应在20分钟内使用完毕。
3）燃烧器喷口的浇注成型
浇注料制备完成，立即注入喷涂硅油成膜的清洁干净模具中，在振动台上震动成型或使用附着式振动器分层震动成型，待表面泛浆无气泡后，剔除表面余浆并抹压平整，静置养护48-72h脱模。
4）燃烧器喷口的干燥和焙烧
浇注成型脱模后，置入110℃的热处理炉干燥处理不少于24h，保温24h,使自由水水分充分排出；然后转入焙烧阶段，按15℃/h预设温度升温至350℃，保温24h，继续按15℃/h升温至600℃，保温24h；按上述升温曲线进行不少于128.5h的烘焙，最后缓慢降温直至室温即可。
5）测试值
实施例3
本发明一种纳米碳化硅晶须增强碳化硅基浇注料，由以下组分组成：
6.5%的纳米SiCw晶须、69%的SiC颗粒（包含29%的粒度为5-3mm颗粒；18%的粒度为3-1mm颗粒；22%的粒度为1-0mm颗粒）、2%的板状刚玉细粉、8%的活性α-Al2O3微粉、5%的SiO2微粉、5%的铝酸盐水泥、4.5%的HCA耐高温纤维以及上述总量0.2%的外加剂（由0.1%柠檬酸水溶液、0.046%化学纯磷酸三钠以及0.054%木质素磷酸钙组成）。
本发明的一种如上所述纳米碳化硅晶须增强碳化硅基浇注料制备方法，包括如下步骤 ：
1）基质粉料的预混合：将纳米SiCw晶须、板状刚玉细粉、活性α-Al2O3微粉、SiO2微粉、纯铝酸钙水泥、外加剂按照设定的比例，放入搅拌机中混合20-30分钟，以使纳米SiCw晶须、板状刚玉细粉、SiO2微粉和活性α-Al2O3微粉充分混合均匀，混好的基质粉料密封待用。
2）浇注料的搅拌：将按配比称量好的SiC颗粒与预先混合好的基质粉料置入强制式搅拌机中混合5～10分钟，再缓慢均匀分散添加HCA耐高温纤维，继续搅拌5分钟，最后外加占物料总重量6％的水混合搅拌不少于5分钟，搅拌完全充分均匀后，应在20分钟内使用完毕。
3）燃烧器喷口的浇注成型
浇注料制备完成，立即注入喷涂硅油成膜的清洁干净模具中，在振动台上震动成型或使用附着式振动器分层震动成型，待表面泛浆无气泡后，剔除表面余浆并抹压平整；静置养护48-72h脱模。
4）燃烧器喷口的干燥和焙烧
浇注成型脱模后，置入110℃的热处理炉干燥处理不少于24h，保温24h，使自由水水分充分排出后；然后转入焙烧阶段，按15℃/h预设温度升温至350℃，保温30h，继续按15℃/h升温至600℃，保温16h；按上述升温曲线进行不少于126.5h的烘焙，最后缓慢降温直至室温即可。
5）测试值
以上所述实施例可以在上述实施例的基础上，根据产品的实际需求，通过数值的简单替换即可获得更多个实施例，且这种替换是本领域技术人员能够简单实现并实施的；所述实施例仅是对本发明的解释，并不是对本发明的限制，本领域技术人员根据本发明作出的等效变换与修改，均属本发明保护范围。
Claims (7)
1.一种纳米碳化硅晶须增强耐温抗磨喷口制造方法，其特征在于：包括如下步骤：
1）将2-7%的纳米SiCw晶须、1-3%的板状刚玉细粉、5-9%的活性α-Al2O3微粉、5.5-9.5%的SiO2微粉、3-7%的铝酸盐水泥以及0.1-0.3%外加剂的基质粉料，放入混料搅拌机中预混合20-30分钟，充分混合均匀，密封待用，其中外加剂由柠檬酸水溶液、化学纯磷酸三钠溶液以及木质素磺酸钙溶液按照2-3.5：1.25-1.5：1-2比例混合而成；
2）将称量好的62-75%SiC颗粒与预先混合好的上述基质粉料，置入强制式搅拌机中混合5～10分钟，再缓慢分散添加3-5%的HCA耐高温纤维，继续搅拌5分钟，最后外加占物料总重量5～8％的水，混合搅拌不少于5分钟，搅拌完全充分均匀后，制备成喷口浇注料，制成的浇注料须在20分钟内使用完毕；
3）将制备完成的浇注料注入喷涂硅油已成膜的清洁干净模具中，在振动台上震动成型或使用附着式振动器分层震动成型，待表面泛浆无气泡后，剔除表面余浆并抹压平整，完成燃烧器喷口的浇注成型，静置养护48-72h脱模；
4）将上述浇注成型脱模的喷口，置入110℃的热处理炉干燥处理不少于24h，保温24h，待自由水水分充分排出后转入焙烧阶段，按15℃/h预设温度升温至350℃，保温30h，再按15℃/h升温至600℃，保温16h；按上述升温曲线进行不少于127h的烘焙，最后缓慢炉内降温，降至室温即完成喷口制造。
2.根据权利要求1所述的一种纳米碳化硅晶须增强耐温抗磨喷口制造方法，其特征在于：所述的62-75%SiC颗粒由不同粒径的SiC颗粒组成。
3.根据权利要求2所述的一种纳米碳化硅晶须增强耐温抗磨喷口制造方法，其特征在于：69%的SiC颗粒包含29%的粒度为5-3mm颗粒，18%的粒度为3-1mm颗粒和22%的粒度为1-0mm颗粒。
4.根据权利要求1所述的一种纳米碳化硅晶须增强耐温抗磨喷口制造方法，其特征在于：所述喷口置入110℃的热处理炉干燥处理不少于24h，保温24h,待自由水水分充分排出后；转入焙烧阶段，按15℃/h预设温度升温至350℃，保温30h，再按15℃/h升温至600℃，保温16h；按上述要求进行不少于127h的烘焙，最后缓慢炉内降温，降至室温即完成喷口制造的升温曲线。
5.权利要求1-4中任意一项所述的纳米碳化硅晶须增强耐温抗磨喷口制造方法生产的纳米碳化硅晶须增强耐温抗磨喷口，其特征在于：由纳米碳化硅晶须增强碳化硅基浇注料利用模具浇注成型，通过升温干燥和焙烧制造而成。
6.权利要求5所述的纳米碳化硅晶须增强耐温抗磨喷口，其特征在于：所述的纳米碳化硅晶须增强碳化硅基浇注料按照质量比由以下成分组成：2-7%的纳米SiCw晶须、62-75%的SiC颗粒、1-3%的板状刚玉细粉、5-9%的活性α-Al2O3微粉、5.5-9.5%的SiO2微粉、3-7%的铝酸盐水泥、3-5%的HCA耐高温纤维以及占上述组分总量0.1-0.3%的外加剂。
7.根据权利要求6所述的纳米碳化硅晶须增强碳化硅基浇注料，其特征在于：所述的纳米SiCw晶须直径0.1-0.2μm，长度10-100μm，化学成分要求为：SiCw含量≥98%； 所述的SiC颗粒包含29%的粒度为5-3mm颗粒；18%的粒度为3-1mm颗粒；22%的粒度为1-0mm颗粒，化学成分要求为：SiC含量≥98%；所述的板状刚玉细粉的粒度小于325目，化学成分要求为：Al2O3含量≥99.1%；所述的活性α-Al2O3微粉，中位粒径2μm ，化学成分要求为：Al2O3含量≥99.5%，其中活性成份≥95%；所述的SiO2微粉的粒度小于1μm，化学成分要求为：SiO2≥97.5％； 所述的铝酸盐水泥为纯铝酸钙水泥，化学成分要求为：Al2O3含量大于68.5%；所述的耐高温纤维，直径0.5mm，长度25mm，熔点≥1460℃；所述的外加剂，由柠檬酸水溶液、化学纯磷酸三钠溶液以及木质素磺酸钙溶液按照2-3.5：1.25-1.5：1-2比例混合而成。
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