CN113461410A - 一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖及其生产方法 - Google Patents
一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖及其生产方法 Download PDFInfo
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Abstract
本发明提供一种添加氮化钛包裹莫来石的Al‑Al2O3滑板砖及其生产方法。按重量百分比计,原料组成为:54‑74%的刚玉、6‑12%活性氧化铝微粉、10‑30%的电熔莫来石、5‑10%的金属铝粉,外加上述原料总量3‑4%的热固性酚醛树脂。通过引入氮化钛包裹的电熔莫来石原料,并利用金属结合技术,克服了传统滑板砖对碳的依赖,解决了含碳耐火材料碳含量降低对其抗侵蚀性、热震稳定性的不利影响,采用免烧免浸生产工艺,降低了生产成本,缩短了生产周期,同时又使滑板砖具有强度、抗氧化性、热震稳定性、抗侵蚀性优越,使用寿命长、安全系数高等特点。
Description
技术领域
本发明涉及一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖及其生产方法,属于功能耐火材料技术领域。
背景技术
我国中低品位矾土储量巨大,约占矾土资源的60%,实现中低品位矾土资源的高效、综合利用是实现耐火行业持续绿色发展的重要途径。利用中低品位矾土通过电熔法制备莫来石,形成的电熔莫来石形成其固有的针状结构,莫来石是常压下Al2O3-SiO2系统中唯一稳定的二元化合物,其熔点为1890±90℃。具有耐火度高、抗热震性能好、荷重软化温度高、抗蠕变、高温体积稳定性好、抗化学侵蚀、电绝缘性强等性质,属高级耐火材料,有利于提高耐火材料的综合性能。中低品位矾土制备的莫来石中TiO2含量较高。TiO2会反应生成碳氮化钛固溶体固溶在莫来石中。碳氮化钛固溶体是一种性能优良的非氧化物陶瓷材料,具有高熔点、高硬度、耐侵蚀和优异的抗氧化性等特性,在一些研究中表明,碳氮化钛固溶体的存在能显著增强莫来石陶瓷材料的强度和硬度,并且有利于莫来石的致密化。
非氧化物具有高温性能优异、热膨胀系数小、抗侵蚀性好的特点,使其成为碳的理想替代材料,非氧化物耐火材料的应用,使得耐火材料的转向新型非氧化物-氧化物复合耐火材料的方向发展,氧化物-非氧化物耐火材料与含碳耐火材料相比具有较好的抗氧化性。滑板砖通常采用含碳耐火材料,使其具有优异的抗侵蚀性和热震稳定性,然而含碳耐火材料在高温下易发生碳氧化,破坏产品结构,影响制品寿命,并且在使用过程中容易污染钢水,不符合洁净钢的冶炼要求,限制了其应用。研发既能适应普通钢的连铸又能适应特殊钢的连铸,同时满足生产洁净钢和品种钢冶炼要求的无碳滑板,势在必行。
发明内容
针对现有技术的不足,本发明的目的是提供一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖及其生产方法。通过引入氮化钛包裹的电熔莫来石原料,并利用金属结合技术,克服了传统滑板砖对碳的依赖,解决了含碳耐火材料碳含量降低对其抗侵蚀性、热震稳定性的不利影响,采用免烧免浸生产工艺,降低了生产成本,缩短了生产周期,同时又使滑板砖具有强度、抗氧化性、热震稳定性、抗侵蚀性优越,使用寿命长、安全系数高等特点。
为了实现上述目的,本发明所采用的技术方案是:
一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖,按重量百分比计,原料组成为:54-74%的刚玉、6-12%活性氧化铝微粉、10-30%的电熔莫来石、5-10%的金属铝粉,外加上述原料总量3-4%的热固性酚醛树脂。
所述刚玉为板状刚玉,其粒度范围为:1mm<粒度1≤2mm、0.5mm<粒度2≤1mm、0.044mm<粒度3≤0.5mm、0<粒度4≤0.044mm,不同粒度的重量比为:粒度1:粒度2:粒度3:粒度4=0-20:18-22:20-24:11-14。
所述活性氧化铝微粉的型号为RG4000和CL370,RG4000和CL370的重量比为1:1。
所述电熔莫来石的粒度范围为:1mm≤粒度≤2mm。
所述电熔莫来石是利用中低品位或废弃矾土,经过2000℃高温电熔制备得到的,按重量百分比计,电熔莫来石的主要组分重量含量为Al2O3:70-75%,SiO2:10-15%,TiO2:5-8%。
所述滑板砖的生产方法,包括以下步骤:
(1)将电熔莫来石在氮气气氛下,于1300℃热处理5-8h,得到氮化钛包裹的电熔莫来石原料,备用;
(2)按配比称取各原料,先将除酚醛树脂外的所有原料投入高速混练机中,以200-300转/分钟的转速混合2-5min,然后向高速混练机中加入酚醛树脂,继续以200-300转/分钟的转速混练30-40min后,得到成型用泥料,在温度20-35℃,湿度40-50%的恒温恒湿条件下困料8-12h后进行压制成型,得到滑板砖坯体;
(3)将坯体自然干燥24h后,送入干燥器烘干,干燥温度为200-230℃,在此温度下干燥8-10h;
(4)干燥后产品再经加箍、磨制、涂布,即制成本发明产品。
干燥器升温时在100℃之前的升温速率为5-10℃/h,100℃之后的升温速率为10-15℃/h。
本发明有益效果:
本发明利用中低品位或废弃矾土制备的含Ti2O3电熔莫来石,制备了添加氮化钛包裹的莫来石的Al-Al2O3滑板砖,该产品制备原料中不含碳,产品无需沥青浸渍,具有节能和环保优势,降低了生产成本,提高经济效益,为大力发展国家产业政策鼓励的节能型、利废型、保健型、生态型的耐火材料技术和产品提供了参考。
1、本发明产品的混料过程使用高速混练机,采用所有原料一次性投入混料的工艺路线,打破了传统先加颗粒料,再加树脂,最后加入预混合粉料的原料分次加入的混料方式,提高了泥料的稳定性。
2、本发明产品中加入电熔莫来石原料,该原料采用中低品位或废弃矾土制备而成,使用前经过1300℃氮气气氛下热处理,在莫来石外层形成氮化钛非氧化物层,经过热处理后的莫来石含有莫来石、氧化铝、碳氮化钛、氮化钛等物相,该莫来石具有传统莫来石低热膨胀系数的特点,同时还具有碳氮化钛和氮化钛熔点高、耐磨性好、抗氧化性强、抗侵蚀性好的特点,并具有良好的导热性和化学稳定性的优异性能,能改善滑板砖的热震稳定性。
3、本发明产品在使用过程中原位生成Ti(C,N)和Al2OC-AlN等非氧化物增强相,提升了滑板的高温使用性能。其中,电熔莫来石中的Ti2O3与酚醛树脂残碳或者N2反应分别形成TiC、TiN,TiC与TiN固溶形成Ti(C,N);金属铝在高温熔融状态下与氮气或Al2O3反应分别生成AlN、Al2O,AlN、Al2O与酚醛树脂的残碳反应生成Al2OC-AlN固溶体。与采用传统滑板相比,在滑板材料组成设计、提高富钛耐火原料利用价值方面有创新,实现了含高钛的低品位或废弃矾土的高效利用,又降低了滑板制备过程中对烧结刚玉的依赖。
4、本发明所得产品为金属和非金属结合滑板,非氧化物结合相一方面通过电熔莫来石原料预处理,在莫来石原料外层形成氮化钛非氧化物包裹层,将该非氧化物直接引入到滑板砖中改善滑板砖的性能,另一方面莫来石中的Ti在高温下原位生成碳氮化钛非氧化物增强相,改善滑板砖的性能。
5、本发明产品的无碳滑板砖,只有少量的树脂残碳,在很大程度上减小了滑动机构对钢液的增碳污染,为洁净钢的发展提供基础和保证;
6、本发明产品无需高温烧成,无需沥青浸渍和干馏工序,简化了生产工序,大大降低了生产成本;
7、经测试,本发明产品的性能指标为:显气孔率3-8%、体积密度3.00-3.15g/cm3、常温耐压强度140-210MPa、常温抗折强度13-18MPa,高温抗折强度30-55MPa。根据YB/T5049-2019《滑板砖》行业标准中HBLT-80牌号(不浸渍)指标要求:显气孔率≤13%、体积密度≥2.90g/cm3、常温耐压强度≥80MPa。本发明各项理化性能均达到行业标准,说明本发明产品具有较好的物理性能。
附图说明
图1热处理前电熔莫来石原料的XRD图;
图2热处理后电熔莫来石原料的XRD图;
图3所得滑板砖产品使用后的XRD图;
其中,X1、X2、X3分别对应实施例1、实施例2、实施例3所得滑板砖产品;
图4所得滑板砖产品使用后,产品中Ti(C,N)的SEM图。
具体实施方式
以下结合实施例对本发明的具体实施方式作进一步详细说明。
实施例1:
一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖,按重量百分比计,原料组成为:74%的板状刚玉、3%的CL370、3%的RG4000、10%的电熔莫来石、10%的金属铝粉,外加上述原料总量3%的热固性酚醛树脂。
板状刚玉的粒度范围为:1mm<粒度1≤2mm、0.5mm<粒度2≤1mm、0.044mm<粒度3≤0.5mm、0<粒度4≤0.044mm,不同粒度的重量比为:粒度1:粒度2:粒度3:粒度4=20:22:20:12。
电熔莫来石的粒度范围为:1≤粒度≤2mm;电熔莫来石是利用中低品位或废弃矾土经过2000℃高温电熔制备的含Ti2O3电熔莫来石,按重量百分比计,电熔莫来石的主要组分重量含量为Al2O3:70-75%,SiO2:10-15%,TiO2:5-8%。
该滑板砖的生产方法,包括以下步骤:
(1)将电熔莫来石在氮气气氛下,于1300℃热处理5-8h,得到氮化钛包裹的电熔莫来石原料,备用;
其中,热处理前后电熔莫来石原料的X射线衍射(XRD)图,如图1(热处理前)、图2(热处理后)所示。
(2)按配比称取各原料,先将除酚醛树脂外的所有原料投入高速混练机中,以200-300转/分钟的转速混合2-5min,然后向高速混练机中加入酚醛树脂,继续以200-300转/分钟的转速混练30-40分钟后,得到成型用泥料,在温度20-35℃,湿度40%-50%的恒温恒湿条件下困料8-12小时后进行压制成型,得到滑板砖坯体;
(3)将坯体自然干燥24小时后,送入干燥器烘干,干燥温度为200-230℃,100℃之前的升温速率为5-10℃/h,100℃之后的升温速率为10-15℃/h,干燥温度达到目标温度后保温8-10h;
其中,由于热固性酚醛树脂的特性,100℃之前树脂聚合反应进行,此时为树脂分子链结构形成的关键,升温不宜过快,升温过快会导致固化的结构破坏,使固化后的结构强度降低。
(4)干燥后产品再经加箍、磨制、涂布,即制成本发明产品。
其中,所得产品使用后的XRD图谱如图3(X1)所示,扫描电子显微镜(SEM)图如图4(右图为左图的局部放大图)所示,并对图4中点2处进行EDS能谱分析,结果如下表1(点2位置上各原子的百分比at%)所示。结合图3、图4和表1可知,所的产品在高温使用过程中原位生成Ti(C,N)和Al2OC-AlN等非氧化物增强相。
表1图4中点2的EDS能谱分析结果(at%)
项目 | Si | Al | O | N | C | Ti |
点2 | 6.23 | 11.38 | 45.66 | 6.03 | 9.92 | 20.78 |
所得产品的性能指标为:显气孔率3%、体积密度3.15g/cm3、常温耐压强度210MPa、常温抗折强度18MPa,高温抗折强度(1400℃×0.5h埋碳)55MPa。残余抗折强度保持率72.8%(1100℃风冷3次),产品的热震稳定性和强度较好。
实施例2:
一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖,按重量百分比计,原料组成为:64%的板状刚玉、3%的CL370、3%的RG4000、20%的电熔莫来石、10%的金属铝粉,外加上述原料总量3.5%的热固性酚醛树脂。
板状刚玉的粒度范围为:1mm<粒度1≤2mm、0.5mm<粒度2≤1mm、0.044mm<粒度3≤0.5mm、0<粒度4≤0.044mm,不同粒度的重量比为:粒度1:粒度2:粒度3:粒度4=10:22:20:12。
电熔莫来石的粒度范围为:1≤粒度≤2mm;电熔莫来石是利用中低品位或废弃矾土经过2000℃高温电熔制备的含Ti2O3电熔莫来石,按重量百分比计,电熔莫来石的主要组分重量含量为Al2O3:70-75%,SiO2:10-15%,TiO2:5-8%。
该滑板砖的生产方法与实施例1相同,所得产品的性能指标为:显气孔率5.7%、体积密度3.08g/cm3、常温耐压强度184MPa、常温抗折强度16MPa,高温抗折强度(1400℃×0.5h埋碳)53MPa。残余抗折强度保持率75.9%(1100℃风冷3次),产品的热震稳定性和强度较好。
实施例3:
一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖,按重量百分比计,原料组成为:54%的板状刚玉、3%的CL370、3%的RG4000、30%的电熔莫来石、10%的金属铝粉,外加上述原料总量4%的热固性酚醛树脂。
板状刚玉的粒度范围为:1mm<粒度1≤2mm、0.5mm<粒度2≤1mm、0.044mm<粒度3≤0.5mm、0<粒度4≤0.044mm,不同粒度的重量比为:粒度1:粒度2:粒度3:粒度4=0:22:20:12。
电熔莫来石的粒度范围为:1≤粒度≤2mm;电熔莫来石是利用中低品位或废弃矾土经过2000℃高温电熔制备的含Ti2O3电熔莫来石,按重量百分比计,电熔莫来石的主要组分重量含量为Al2O3:70-75%,SiO2:10-15%,TiO2:5-8%。
该滑板砖的生产方法与实施例1相同,所得产品的性能指标为:显气孔率8%、体积密度3.00g/cm3、常温耐压强度175MPa、常温抗折强度14MPa,高温抗折强度50MPa。残余抗折强度保持率83.4%(1100℃风冷3次),产品的热震稳定性和强度较好。
实施例4:
一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖,按重量百分比计,原料组成为:64%的板状刚玉、4%的CL370、4%的RG4000、20%的电熔莫来石、8%的金属铝粉,外加上述原料总量3.5%的热固性酚醛树脂。
板状刚玉的粒度范围为:1mm<粒度1≤2mm、0.5mm<粒度2≤1mm、0.044mm<粒度3≤0.5mm、0<粒度4≤0.044mm,不同粒度的重量比为:粒度1:粒度2:粒度3:粒度4=10:22:20:12。
电熔莫来石的粒度范围为:1≤粒度≤2mm;电熔莫来石是利用中低品位或废弃矾土经过2000℃高温电熔制备的含Ti2O3电熔莫来石,按重量百分比计,电熔莫来石的主要组分重量含量为Al2O3:70-75%,SiO2:10-15%,TiO2:5-8%。
该滑板砖的生产方法与实施例1相同,所得产品的性能指标为:显气孔率6.2%、体积密度3.07g/cm3、常温耐压强度172MPa、常温抗折强度15MPa,高温抗折强度(1400℃×0.5h埋碳)42MPa。残余抗折强度保持率74.5%(1100℃风冷3次),产品的热震稳定性和强度较好。
实施例5:
一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖,按重量百分比计,原料组成为:63%的板状刚玉、6%的CL370、6%的RG4000、20%的电熔莫来石、5%的金属铝粉,外加上述原料总量3.5%的热固性酚醛树脂。
板状刚玉的粒度范围为:1mm<粒度1≤2mm、0.5mm<粒度2≤1mm、0.044mm<粒度3≤0.5mm、0<粒度4≤0.044mm,不同粒度的重量比为:粒度1:粒度2:粒度3:粒度4=10:20:22:11。
电熔莫来石的粒度范围为:1≤粒度≤2mm;电熔莫来石是利用中低品位或废弃矾土经过2000℃高温电熔制备的含Ti2O3电熔莫来石,按重量百分比计,电熔莫来石的主要组分重量含量为Al2O3:70-75%,SiO2:10-15%,TiO2:5-8%。
该滑板砖的生产方法与实施例1相同,所得产品的性能指标为:显气孔率6.8%、体积密度3.06g/cm3、常温耐压强度140MPa、常温抗折强度13MPa,高温抗折强度(1400℃×0.5h埋碳)30MPa。残余抗折强度保持率70.4%(1100℃风冷3次),产品的热震稳定性和强度较好。
实施例6:
一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖,按重量百分比计,原料组成为:63%的板状刚玉、6%的CL370、6%的RG4000、20%的电熔莫来石、5%的金属铝粉,外加上述原料总量3.5%的热固性酚醛树脂。
板状刚玉的粒度范围为:1mm<粒度1≤2mm、0.5mm<粒度2≤1mm、0.044mm<粒度3≤0.5mm、0<粒度4≤0.044mm,不同粒度的重量比为:粒度1:粒度2:粒度3:粒度4=10:18:24:11。
电熔莫来石的粒度范围为:1≤粒度≤2mm;电熔莫来石是利用中低品位或废弃矾土经过2000℃高温电熔制备的含Ti2O3电熔莫来石,按重量百分比计,电熔莫来石的主要组分重量含量为Al2O3:70-75%,SiO2:10-15%,TiO2:5-8%。
该滑板砖的生产方法与实施例1相同,所得产品的性能指标为:显气孔率7.1%、体积密度3.06g/cm3、常温耐压强度145MPa、常温抗折强度13MPa,高温抗折强度(1400℃×0.5h埋碳)32MPa。残余抗折强度保持率68.1%(1100℃风冷3次),产品的热震稳定性和强度较好。
Claims (7)
1.一种添加氮化钛包裹莫来石的Al-Al2O3滑板砖,其特征在于,按重量百分比计,原料组成为:54-74%的刚玉、6-12%活性氧化铝微粉、10-30%的电熔莫来石、5-10%的金属铝粉,外加上述原料总量3-4%的热固性酚醛树脂。
2.如权利要求1所述的滑板砖,其特征在于,所述刚玉为板状刚玉,其粒度范围为:1mm<粒度1≤2mm、0.5mm<粒度2≤1mm、0.044mm<粒度3≤0.5mm、0<粒度4≤0.044mm,不同粒度的重量比为:粒度1:粒度2:粒度3:粒度4=0-20:18-22:20-24:11-14。
3.如权利要求1所述的滑板砖,其特征在于,所述活性氧化铝微粉的型号为RG4000和CL370,RG4000和CL370的重量比为1:1。
4.如权利要求1所述的滑板砖,其特征在于,所述电熔莫来石的粒度范围为:1mm≤粒度≤2mm。
5.如权利要求1所述的滑板砖,其特征在于,所述电熔莫来石是利用中低品位或废弃矾土,经过2000℃高温电熔制备得到的,按重量百分比计,电熔莫来石的主要组分重量含量为Al2O3:70-75%,SiO2:10-15%,TiO2:5-8%。
6.如权利要求1-5任一项所述的滑板砖的生产方法,其特征在于,包括以下步骤:
(1)将电熔莫来石在氮气气氛下,于1300℃热处理5-8h,得到氮化钛包裹的电熔莫来石原料,备用;
(2)按配比称取各原料,先将除酚醛树脂外的所有原料投入高速混练机中,以200-300转/分钟的转速混合2-5min,然后向高速混练机中加入酚醛树脂,继续以200-300转/分钟的转速混练30-40min后,得到成型用泥料,在温度20-35℃,湿度40-50%的恒温恒湿条件下困料8-12h后进行压制成型,得到滑板砖坯体;
(3)将坯体自然干燥24h后,送入干燥器烘干,干燥温度为200-230℃,在此温度下干燥8-10h;
(4)干燥后产品再经加箍、磨制、涂布,即制成本发明产品。
7.如权利要求6所述的滑板砖的生产方法,其特征在于,干燥器升温时在100℃之前的升温速率为5-10℃/h,100℃之后的升温速率为10-15℃/h。
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