CN113443896A - 一种高硬度耐腐蚀的镁碳砖及其加工方法 - Google Patents

一种高硬度耐腐蚀的镁碳砖及其加工方法 Download PDF

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CN113443896A
CN113443896A CN202110506458.4A CN202110506458A CN113443896A CN 113443896 A CN113443896 A CN 113443896A CN 202110506458 A CN202110506458 A CN 202110506458A CN 113443896 A CN113443896 A CN 113443896A
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carbon
magnesia
material component
brick
carbon brick
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龚育才
彭仁
张雪松
俞晓东
曹丽云
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Jiangsu Sujia Group New Materials Co ltd
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Abstract

本发明公开了一种高硬度耐腐蚀的镁碳砖及其加工方法，涉及镁碳砖技术领域，其配料含有镁料组分、碳料组分、结合剂组分、加强料组分和耐蚀料组分，其中镁料组分、碳料组分、结合剂组分、加强料组分和耐蚀料组分之间的含量比为3:1:4：0.5:0.5。该高硬度耐腐蚀的镁碳砖及其加工方法，既能够有效保证镁碳砖中的低碳需求，又能在低碳的前提下，使镁碳砖仍具有良好的性能，氧化铝粉和铝粉的加入，在烧结时，氧化镁和氧化铝形成铝镁尖晶石，能提高镁碳砖的强度和硬度，钢铁微粒的加入，直接增强了镁碳砖的强度和硬度，最后，提高氧化镁含量，使炉渣中氧化镁达到饱和状态而减少氧化镁的溶解，减少炉渣与氧化镁的化学反应，从而减少镁碳砖的化学侵蚀。

Description

一种高硬度耐腐蚀的镁碳砖及其加工方法
技术领域
本发明涉及镁碳砖技术领域，具体为一种高硬度耐腐蚀的镁碳砖及其加工方法。
背景技术
镁碳砖相较于普通砖，具有显著优点，它作为一种复合耐火材料，有效地利用了镁砂的抗渣侵蚀能力强和碳的高导热性及低膨胀性，补偿了镁砂耐剥落性差的最大缺点，镁碳砖具有良好的耐高温性能，抗渣能力强，抗热震性好，高温蠕变低。
结合剂是生产镁碳砖的关键材料，现在生产镁碳砖多数选用合成酚醛树脂作为结合剂。
现有的镁碳砖通过提高碳含量来提高镁碳砖的硬度，但碳含量提高，无异于会加大镁碳砖的热损耗，镁碳砖的体积密度也随含碳量的增大而增大，常温耐压强度降低，且含碳量过高也使得镁碳砖环保性能下降，因此需要寻找另一种既可提高硬度，又不会引入过多碳质的改进办法。
发明内容
针对现有技术的不足，本发明提供了一种高硬度耐腐蚀的镁碳砖及其加工方法，解决了上述背景技术中提出的问题。
为实现以上目的，本发明通过以下技术方案予以实现：一种高硬度耐腐蚀的镁碳砖，其配料含有镁料组分、碳料组分、结合剂组分、加强料组分和耐蚀料组分，其中镁料组分、碳料组分、结合剂组分、加强料组分和耐蚀料组分之间的含量比为3:1:4：0.5:0.5。
可选的，所述镁料组分具体组成为废镁碳砖、镁橄榄石、镁砂细粉、电熔镁砂和煤油，其中按含量比计，废镁碳砖：镁橄榄石：镁砂细粉：电熔镁砂：沥青＝2:1：1:1：3。
可选的，所述镁料组分中，废镁碳砖、镁橄榄石、镁砂细粉和电熔镁砂均研磨成可过100目筛的细粉，并以沥青混合成流状体。
可选的，所述碳料组分具体由鳞片石墨、纳米碳黑和纳米尺寸碳组成，按含量比计，鳞片石墨：纳米碳黑：纳米尺寸碳＝5:1:1。
可选的，所述鳞片石墨选用100目+1000目型鳞片石墨。
可选的，所述结合剂组分具体选材为纳米炭黑及酚醛树脂，该结合剂组分制备方法为：将纳米炭黑加入酚醛树脂中，并高速搅拌。
可选的，所述加强料组分具体由抗氧化剂、氧化铝粉、铝粉和钢铁微粒组成，按含量比计，抗氧化剂：氧化铝粉：铝粉：钢铁微粒＝1:4:4:3。
可选的，所述抗氧化剂具体为碳纳米管和α-Al2O3的铝碳耐火材料，且碳纳米管和α-Al2O3的铝碳耐火材料为等比添加。
可选的，所述耐蚀料组分具体由氧化钙晶粒、氧化镁粉末和无水树脂，按含量比计，氧化钙晶粒：氧化镁粉末：无水树脂＝1:2:0.3。
基于上述原料，本发明还公开了一种高硬度耐腐蚀的镁碳砖的加工方法。
可选的，该加工方法具体步骤如下：
①将镁料组分和碳料组分先后加入到结合剂组分中，充分且高速搅拌，至完全混合均匀；
②将氧化铝粉、铝粉和钢铁微粒依次加入上述混合物中，充分搅拌混合；
③加入碳纳米管和α-Al2O3的铝碳耐火材料，搅拌至均匀状态；
④加入氧化钙晶粒和氧化镁粉末，搅拌均匀；
⑤上模，入炉，进行砖块烧结；
⑥烧制好的砖块外壁面均匀涂覆无水树脂，涂覆厚度为0.2mm。
本发明提供了一种高硬度耐腐蚀的镁碳砖及其加工方法，具备以下有益效果：
1.该高硬度耐腐蚀的镁碳砖及其加工方法，废镁碳砖的取用，能够有效提高镁碳砖的可回收性能，取废镁碳砖作为镁料组分的一部分，可以降低镁材耗费成本，做法也更为环保，沥青的添入，用以延缓镁材的氧化，使得在投入生产前，镁料能够保持良好的纯度，且沥青的存在，可以在镁料颗粒表面形成一个薄薄的涂层，以降低镁料颗粒在使用过程中的热膨胀，以此来达到提高低碳镁碳砖的热震稳定性。
2.该高硬度耐腐蚀的镁碳砖及其加工方法中，含100目+1000目型鳞片石墨的镁碳砖的抗氧化性能最好且热导率最大，而通过添加少量的纳米碳黑，镁碳砖的弹性模量得到明显降低，不同微粒之间的热应力也得到缓和，镁碳砖的热震稳定性及抗侵蚀性均有所提高，纳米尺寸碳能在基质中更好的分布，填充气孔，增大体积密度，使得镁碳砖的强度增加，抗侵蚀性增强，此外，纳米尺寸碳能吸收和缓解由于热膨胀和耐火材料微粒的收缩所引起的热应力，减少了材料内部不同部分之间的热应力，改善了材料的热震稳定性。
3.该高硬度耐腐蚀的镁碳砖及其加工方法中，以纳米炭黑及酚醛树脂相结合的复合结合剂，使得结合剂炭化后的石墨化程度提高，基质内形成微气孔，提高了镁碳砖的常温抗折强度、高温抗折强度等力学性能，而以碳纳米管和α-Al2O3的铝碳耐火材料为抗氧化剂，使得镁碳砖具有更好的热震稳定性，且能使材料在降低碳含量的同时具有与普通铝碳耐火材料相当的性能。
4.该高硬度耐腐蚀的镁碳砖及其加工方法中，氧化铝粉和铝粉的加入，在烧结时，氧化镁和氧化铝形成铝镁尖晶石，能提高镁碳砖的强度和硬度，也能有效延长镁碳砖的使用寿命，钢铁微粒的加入，直接增强了镁碳砖的强度和硬度。
5.该高硬度耐腐蚀的镁碳砖及其加工方法中，提高氧化镁含量，使炉渣中氧化镁达到饱和状态而减少氧化镁的溶解，由于氧化镁为碱性氧化物，增大炉渣碱度可以减少炉渣与氧化镁的化学反应，从而减少镁碳砖的化学侵蚀，氧化钙晶粒稳定，表面活性低，发生水化的难度大，对外界水分向颗粒内部渗入的阻力也大，借此能够提高镁碳砖的抗水化性能，无水树脂作为镁碳砖的外部涂层，将镁碳砖密封，使其与外界隔绝，从而提高镁碳砖的耐腐蚀性能。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。
实施例1
一种高硬度耐腐蚀的镁碳砖，其配料含有镁料组分、碳料组分、结合剂组分、加强料组分和耐蚀料组分，其中镁料组分、碳料组分、结合剂组分、加强料组分和耐蚀料组分之间的含量比为3:1:4：0.5:0.5；
镁料组分具体组成为废镁碳砖、镁橄榄石、镁砂细粉、电熔镁砂和煤油，其中按含量比计，废镁碳砖：镁橄榄石：镁砂细粉：电熔镁砂：沥青＝2:1：1:1：3；
进一步地，镁料组分中，废镁碳砖、镁橄榄石、镁砂细粉和电熔镁砂均研磨成可过100目筛的细粉，并以沥青混合成流状体；
废镁碳砖的取用，能够有效提高镁碳砖的可回收性能，取废镁碳砖作为镁料组分的一部分，可以降低镁材耗费成本，做法也更为环保，沥青的添入，用以延缓镁材的氧化，使得在投入生产前，镁料能够保持良好的纯度，且沥青的存在，可以在镁料颗粒表面形成一个薄薄的涂层，以降低镁料颗粒在使用过程中的热膨胀，以此来达到提高低碳镁碳砖的热震稳定性；
碳料组分具体由鳞片石墨、纳米碳黑和纳米尺寸碳组成，按含量比计，鳞片石墨：纳米碳黑：纳米尺寸碳＝5:1:1；
进一步地，鳞片石墨选用100目+1000目型鳞片石墨；
含100目+1000目型鳞片石墨的镁碳砖的抗氧化性能最好且热导率最大，而通过添加少量的纳米碳黑，镁碳砖的弹性模量得到明显降低，不同微粒之间的热应力也得到缓和，镁碳砖的热震稳定性及抗侵蚀性均有所提高，纳米尺寸碳能在基质中更好的分布，填充气孔，增大体积密度，使得镁碳砖的强度增加，抗侵蚀性增强，此外，纳米尺寸碳能吸收和缓解由于热膨胀和耐火材料微粒的收缩所引起的热应力，减少了材料内部不同部分之间的热应力，改善了材料的热震稳定性，该三种碳材料能够有效保证镁碳砖中低碳需求，且在低碳的前提下，镁碳砖仍具有良好的性能；
结合剂组分具体选材为纳米炭黑及酚醛树脂，该结合剂组分制备方法为：将纳米炭黑加入酚醛树脂中，并高速搅拌；
该复合结合剂使得结合剂炭化后的石墨化程度提高，基质内形成微气孔，提高了镁碳砖的常温抗折强度、高温抗折强度等力学性能；
加强料组分具体由抗氧化剂、氧化铝粉、铝粉和钢铁微粒组成，按含量比计，抗氧化剂：氧化铝粉：铝粉：钢铁微粒＝1:4:4:3；
氧化铝粉和铝粉的加入，在烧结时，氧化镁和氧化铝形成铝镁尖晶石，能提高镁碳砖的强度和硬度，也能有效延长镁碳砖的使用寿命，钢铁微粒的加入，直接增强了镁碳砖的强度和硬度；
抗氧化剂具体为碳纳米管和α-Al2O3的铝碳耐火材料，且碳纳米管和α-Al2O3的铝碳耐火材料为等比添加；
同时添加碳纳米管和α-Al2O3的铝碳耐火材料具有更好的热震稳定性，且能使材料在降低碳含量的同时具有与普通铝碳耐火材料相当的性能；
耐蚀料组分具体由氧化钙晶粒、氧化镁粉末和无水树脂，按含量比计，氧化钙晶粒：氧化镁粉末：无水树脂＝1:2:0.3；
提高氧化镁含量，使炉渣中氧化镁达到饱和状态而减少氧化镁的溶解，由于氧化镁为碱性氧化物，增大炉渣碱度可以减少炉渣与氧化镁的化学反应，从而减少镁碳砖的化学侵蚀，氧化钙晶粒稳定，表面活性低，发生水化的难度大，对外界水分向颗粒内部渗入的阻力也大，借此能够提高镁碳砖的抗水化性能，无水树脂作为镁碳砖的外部涂层，将镁碳砖密封，使其与外界隔绝，从而提高镁碳砖的耐腐蚀性能。
实施例2
一种高硬度耐腐蚀的镁碳砖的加工方法，该加工方法具体步骤如下：
①将镁料组分和碳料组分先后加入到结合剂组分中，充分且高速搅拌，至完全混合均匀；
②将氧化铝粉、铝粉和钢铁微粒依次加入上述混合物中，充分搅拌混合；
③加入碳纳米管和α-Al2O3的铝碳耐火材料，搅拌至均匀状态；
④加入氧化钙晶粒和氧化镁粉末，搅拌均匀；
⑤上模，入炉，进行砖块烧结；
⑥烧制好的砖块外壁面均匀涂覆无水树脂，涂覆厚度为0.2mm。
综上，该高硬度耐腐蚀的镁碳砖及其加工方法，采用鳞片石墨、纳米碳黑和纳米尺寸碳三种碳材料，既能够有效保证镁碳砖中的低碳需求，又能在低碳的前提下，使镁碳砖仍具有良好的性能，氧化铝粉和铝粉的加入，在烧结时，氧化镁和氧化铝形成铝镁尖晶石，能提高镁碳砖的强度和硬度，也能有效延长镁碳砖的使用寿命，钢铁微粒的加入，直接增强了镁碳砖的强度和硬度，最后，提高氧化镁含量，使炉渣中氧化镁达到饱和状态而减少氧化镁的溶解，减少炉渣与氧化镁的化学反应，从而减少镁碳砖的化学侵蚀，氧化钙晶粒稳定，表面活性低，发生水化的难度大，对外界水分向颗粒内部渗入的阻力也大，借此能够提高镁碳砖的抗水化性能，无水树脂作为镁碳砖的外部涂层，将镁碳砖密封，使其与外界隔绝，从而提高镁碳砖的耐腐蚀性能。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，根据本发明的技术方案及其发明构思加以等同替换或改变，都应涵盖在本发明的保护范围之内。

Claims (10)

1.一种高硬度耐腐蚀的镁碳砖，其特征在于：镁碳砖配料含有镁料组分、碳料组分、结合剂组分、加强料组分和耐蚀料组分，其中镁料组分、碳料组分、结合剂组分、加强料组分和耐蚀料组分之间的含量比为3:1:4：0.5:0.5。
2.根据权利要求1所述的一种高硬度耐腐蚀的镁碳砖，其特征在于：所述镁料组分具体组成为废镁碳砖、镁橄榄石、镁砂细粉、电熔镁砂和煤油，其中按含量比计，废镁碳砖：镁橄榄石：镁砂细粉：电熔镁砂：沥青＝2:1：1:1：3。
3.根据权利要求2所述的一种高硬度耐腐蚀的镁碳砖，其特征在于：所述镁料组分中，废镁碳砖、镁橄榄石、镁砂细粉和电熔镁砂均研磨成可过100目筛的细粉，并以沥青混合成流状体。
4.根据权利要求1所述的一种高硬度耐腐蚀的镁碳砖，其特征在于：所述碳料组分具体由鳞片石墨、纳米碳黑和纳米尺寸碳组成，按含量比计，鳞片石墨：纳米碳黑：纳米尺寸碳＝5:1:1。
5.根据权利要求4所述的一种高硬度耐腐蚀的镁碳砖，其特征在于：所述鳞片石墨选用100目+1000目型鳞片石墨。
6.根据权利要求1所述的一种高硬度耐腐蚀的镁碳砖，其特征在于：所述结合剂组分具体选材为纳米炭黑及酚醛树脂，该结合剂组分制备方法为：将纳米炭黑加入酚醛树脂中，并高速搅拌。
7.根据权利要求1所述的一种高硬度耐腐蚀的镁碳砖，其特征在于：所述加强料组分具体由抗氧化剂、氧化铝粉、铝粉和钢铁微粒组成，按含量比计，抗氧化剂：氧化铝粉：铝粉：钢铁微粒＝1:4:4:3。
8.根据权利要求7所述的一种高硬度耐腐蚀的镁碳砖，其特征在于：所述抗氧化剂具体为碳纳米管和α-Al2O3的铝碳耐火材料，且碳纳米管和α-Al2O3的铝碳耐火材料为等比添加。
9.根据权利要求1所述的一种高硬度耐腐蚀的镁碳砖，其特征在于：所述耐蚀料组分具体由氧化钙晶粒、氧化镁粉末和无水树脂，按含量比计，氧化钙晶粒：氧化镁粉末：无水树脂＝1:2:0.3。
10.一种高硬度耐腐蚀的镁碳砖的加工方法，其特征在于：该加工方法包含权利要求1-9所述的任意一项高硬度耐腐蚀的镁碳砖，该加工方法具体步骤如下：
①将镁料组分和碳料组分先后加入到结合剂组分中，充分且高速搅拌，至完全混合均匀；
②将氧化铝粉、铝粉和钢铁微粒依次加入上述混合物中，充分搅拌混合；
③加入碳纳米管和α-Al2O3的铝碳耐火材料，搅拌至均匀状态；
④加入氧化钙晶粒和氧化镁粉末，搅拌均匀；
⑤上模，入炉，进行砖块烧结；
⑥烧制好的砖块外壁面均匀涂覆无水树脂，涂覆厚度为0.2mm。
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