CN113463097A - 一种垃圾焚烧炉环境下的抗腐蚀复合涂层及其制备方法 - Google Patents
一种垃圾焚烧炉环境下的抗腐蚀复合涂层及其制备方法 Download PDFInfo
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Abstract
本发明涉及一种垃圾焚烧炉环境下的抗腐蚀复合涂层及其制备方法，属于垃圾焚烧锅炉水冷壁的耐高温氧化及熔融氯盐腐蚀技术领域。复合涂层包括Fe18Cr9Ni3B3Si1C热喷涂层和K600涂料层；其中Fe18Cr9Ni3B3Si1C热喷涂层为底层，位于K600涂料层与工件表面之间，K600涂料层为表层；本发明解决垃圾焚烧锅炉水冷壁易减薄及穿透爆管问题。
Description
技术领域
本发明涉及一种垃圾焚烧炉环境下的抗腐蚀复合涂层及其制备方法，属于垃圾焚烧锅炉水冷壁的耐高温氧化及熔融氯盐腐蚀技术领域。
背景技术
垃圾焚烧炉是最常用于城市生活垃圾减容、无害化处理的一种环保设备，由于垃圾焚烧炉利用生活垃圾作为燃料，与一般燃料（煤、石油、天然气）相比，垃圾的发热值低，含水量高，并含有多种且较高浓度的腐蚀介质。垃圾中常见的可燃物有废纸、皮革、塑料、橡胶、涂料、竹木、纺织品、淤泥、电子废弃物、氯化物等各种无机盐等，他们是垃圾燃烧的热源，所以在设备工作运行过程中，其锅炉水冷壁在实际使用中面临着高温、飞灰颗粒冲蚀及沉积盐腐蚀，尤其是水冷壁上的沉积氯盐腐蚀的恶劣环境。国内外对此已进行了大量研究表明，如Vaugham等在垃圾焚烧炉积盐或积灰中检测到氯含量高达20-27%；申请人在国内几个垃圾焚烧炉（义乌垃圾焚烧发电厂锅炉、广州垃圾焚烧发电厂锅炉、南昌垃圾焚烧发电厂锅炉等）积盐或积灰中检测到氯含量达15%-30%。因此，垃圾焚烧炉内极易产生高温熔融氯盐腐蚀，认为熔融氯盐腐蚀是其腐蚀的最主要因素。由于高温腐蚀使水冷壁管壁易减薄甚至穿透爆管，给锅炉的安全运行带来巨大的危险性。
发明内容
本发明为了解决垃圾焚烧锅炉水冷壁易减薄及穿透爆管问题，本发明目的在于提供一种垃圾焚烧炉环境下的抗腐蚀复合涂层及其制备方法。
本发明为了实现上述目的，采用如下技术方案：一种垃圾焚烧炉环境下的抗腐蚀复合涂层，复合涂层包括Fe18Cr9Ni3B3Si1C热喷涂层和K600涂料层；
其中Fe18Cr9Ni3B3Si1C热喷涂层为底层，位于K600涂料层与工件表面之间，K600涂料层为表层；
Fe18Cr9Ni3B3Si1C热喷涂层材料由Fe、Cr、Ni、B、Si、C及稀土组成，其中Cr的成分重量百分比为17～20%，Ni的成分重量百分比为8～10%，B的成分重量百分比为2.5～4%，Si的成分重量百分比为2.5～4%，C的成分重量百分比为0.7～1.0%，稀土的成分重量百分比为0.5～1.0%，Fe余量。
K600涂料层由A组分和B组分组成；
A组份为粉料，主要包括如下成分：纳米ZrO2、粒度范围为75～150nm；纳米Al2O3、粒度范围为75～150nm ；Al2O3微粉、粒度范围为15～75um ；BN微粉、粒度范围为15～75um ；
B组份为胶料，成分主要为水玻璃。
进一步的，A组份中纳米纳米纳米ZrO2重量百分比为10～20%、纳米纳米Al2O3重量百分比为60～80%、纳米Al2O3微粉重量百分比为5～15%、BN微粉重量百分比为5～15%。
进一步的，A组份与B组分的重量比为A组份：B组分=1～1.5。
进一步的，所述Fe18Cr9Ni3B3Si1C热喷涂层的厚度为0.5～0.8mm；所述K600涂料层的厚度为150～250um；工件表面的复合涂层厚度为0.65～1.05mm。
一种垃圾焚烧炉环境下的抗腐蚀复合涂层的制备方法，其制备方法的步骤如下：
第一步，工件表面预处理：去除基材表面的油脂、污垢、氧化皮、锈迹和油漆，使工件表面净化，清洁度达到Sa2.5级；然后采用10～18目的金刚砂进行喷砂处理，使工件表面粗化、活化，表面粗糙度达到Rz30～50；
第二步，电弧喷涂：采用电弧喷涂方法在经预处理的工件表面喷涂Fe18Cr9Ni3B3Si1C材料，形成底层涂层；
第三步，将K600涂料均匀涂装在Fe18Cr9Ni3B3Si1C热喷涂层上，涂装后的涂料可在室温下自然固化或加热条件下固化，室温下自然固化时间不低于24h，若在加热条件下固化，缓慢升温至80～100℃，保温0.5h烘干，然后缓慢升温至300℃，保温1h烧结固化。
进一步的，所述第二步的工艺参数为：电流160～300A，电压30～45V，喷涂距离120～250mm，压缩气体压力0.45～0.7MPa，喷枪移动速度250～500mm/s，喷涂角度60～90°，采用人工喷涂或采用自动化装置喷涂。
进一步的，所述第三步，将K600涂料均匀涂装在Fe18Cr9Ni3B3Si1C热喷涂层上的涂装方式为刷涂、滚涂或喷涂。
本发明所提供的垃圾焚烧炉环境下的抗腐蚀复合涂层，一方面，电弧喷涂层含有Ni、Cr等抗氧化及热腐蚀性元素，Cr元素含量大于15%，Cr固溶在Ni的面心立方晶体中，形成尖晶石结构，有很强的氧化和钝化的作用，可以进一步提高Cr2O3保护膜的抗腐蚀能力，大大降低熔盐熔解Cr2O3氧化膜的速率，从而抵抗熔盐的高温腐蚀；而且涂层材料含有约18%的Cr和8%的Ni，Cr和Ni的比例配合符合Tammann的n/8定律，耐蚀电位很高，钝化能力非常优良，涂层腐蚀速率极低，以致拥有极高的抗氧化性能和耐腐蚀性能。适量的B、Si具有优良的脱氧能力和浸润性，降低合金熔点，增加合金流动性，在基材表面均匀摊开，涂层组织结构均匀致密。稀土为表面活性元素，降低熔滴表面张力，提高粒子间及粒子与基材相互润湿效果，降低孔隙率，提高涂层结合强度。并降低涂层热膨胀系数，减少内应力，防止涂层裂纹。另一方面，K600涂料在高温下陶瓷化，可形成高硬度、致密光滑的陶瓷体，高温下结构稳定，阻止介质中腐蚀元素及氧气进入，其线膨胀系数和喷涂层接近，没有体积效应，有极强的结合力和热震稳定性，涂料具有阻止腐蚀元素进入的同时，并自身具有优异的耐高温稳定性和耐酸、碱、氯盐腐蚀性。因此，电弧喷涂层和K600涂料层强强结合形成的复合涂层具有优异的耐熔融氯盐腐蚀能力。
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。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
一种垃圾焚烧炉环境下的抗腐蚀复合涂层，复合涂层包括Fe18Cr9Ni3B3Si1C热喷涂层和K600涂料层；
其中Fe18Cr9Ni3B3Si1C热喷涂层为底层，位于K600涂料层与工件表面之间，K600涂料层为表层；
Fe18Cr9Ni3B3Si1C热喷涂层材料由Fe、Cr、Ni、B、Si、C及稀土组成，其中Cr的成分重量百分比为17～20%，Ni的成分重量百分比为8～10%，B的成分重量百分比为2.5～4%，Si的成分重量百分比为2.5～4%，C的成分重量百分比为0.7～1.0%，稀土的成分重量百分比为0.5～1.0%，Fe余量。
K600涂料层由A组分和B组分组成；
A组份为粉料，主要包括如下成分：纳米ZrO2、粒度范围为75～150nm；纳米Al2O3、粒度范围为75～150nm ；Al2O3微粉、粒度范围为15～75um ；BN微粉、粒度范围为15～75um ；
B组份为胶料，成分主要为水玻璃。
进一步的，A组份中纳米纳米纳米ZrO2重量百分比为10～20%、纳米纳米Al2O3重量百分比为60～80%、纳米Al2O3微粉重量百分比为5～15%、BN微粉重量百分比为5～15%。
进一步的，A组份与B组分的重量比为A组份：B组分=1～1.5。
进一步的，所述Fe18Cr9Ni3B3Si1C热喷涂层的厚度为0.5～0.8mm；所述K600涂料层的厚度为150～250um；工件表面的复合涂层厚度为0.65～1.05mm。
一种垃圾焚烧炉环境下的抗腐蚀复合涂层的制备方法，其制备方法的步骤如下：
第一步，工件表面预处理：去除基材表面的油脂、污垢、氧化皮、锈迹和油漆，使工件表面净化，清洁度达到Sa2.5级；然后采用10～18目的金刚砂进行喷砂处理，使工件表面粗化、活化，表面粗糙度达到Rz30～50；
第二步，电弧喷涂：采用电弧喷涂方法在经预处理的工件表面喷涂Fe18Cr9Ni3B3Si1C材料，形成底层涂层；
第三步，将K600涂料均匀涂装在Fe18Cr9Ni3B3Si1C热喷涂层上，涂装后的涂料可在室温下自然固化或加热条件下固化，室温下自然固化时间不低于24h，若在加热条件下固化，缓慢升温至80～100℃，保温0.5h烘干，然后缓慢升温至300℃，保温1h烧结固化。
进一步的，所述第二步的工艺参数为：电流160～300A，电压30～45V，喷涂距离120～250mm，压缩气体压力0.45～0.7MPa，喷枪移动速度250～500mm/s，喷涂角度60～90°，采用人工喷涂或采用自动化装置喷涂。
进一步的，所述第三步，将K600涂料均匀涂装在Fe18Cr9Ni3B3Si1C热喷涂层上的涂装方式为刷涂、滚涂或喷涂。
试验例1
首先通过机械方法或物理、化学方法对工件表面进行净化处理，除去基材表面的油污、斑点、锈迹等，表面完全呈现金属光泽，然后采用金刚砂进行喷砂处理，使工件表面粗化、活化，表面呈现色泽一致、均匀分布的轮廓。工件表面经预处理后，采用电弧喷涂方法在基体上喷涂Fe18Cr9Ni3B3Si1C材料，形成0.5mm厚度的热喷涂层。将K600涂料涂装在热喷涂层上，形成230um厚度的涂料层，最终形成厚度为0.73mm厚度的表面工作复合涂层。该复合涂层结构致密、组织均匀、结合强度高、高温下结构稳定，具有优异的耐熔融氯盐腐蚀能力。
试验例2
首先通过机械方法或物理、化学方法对工件表面进行净化处理，除去基材表面的油污、斑点、锈迹等，表面完全呈现金属光泽，然后采用金刚砂进行喷砂处理，使工件表面粗化、活化，表面呈现色泽一致、均匀分布的轮廓。工件表面经预处理后，采用电弧喷涂方法在基体上喷涂Fe18Cr9Ni3B3Si1C材料，形成0.7mm厚度的热喷涂层。将K600涂料涂装在热喷涂层上，形成150um厚度的涂料层，最终形成厚度为0.85mm厚度的表面工作复合涂层。该复合涂层结构致密、组织均匀、结合强度高、高温下结构稳定，对于熔融氯盐腐蚀具有极强的抵抗力。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。
Claims (7)
1.一种垃圾焚烧炉环境下的抗腐蚀复合涂层，其特征在于：复合涂层包括Fe18Cr9Ni3B3Si1C热喷涂层和K600涂料层；
其中Fe18Cr9Ni3B3Si1C热喷涂层为底层，位于K600涂料层与工件表面之间，K600涂料层为表层；
Fe18Cr9Ni3B3Si1C热喷涂层材料由Fe、Cr、Ni、B、Si、C及稀土组成，其中Cr的成分重量百分比为17～20%，Ni的成分重量百分比为8～10%，B的成分重量百分比为2.5～4%，Si的成分重量百分比为2.5～4%，C的成分重量百分比为0.7～1.0%，稀土的成分重量百分比为0.5～1.0%，Fe余量；
K600涂料层由A组分和B组分组成；
A组份为粉料，主要包括如下成分：纳米ZrO2、粒度范围为75～150nm；纳米Al2O3、粒度范围为75～150nm ；Al2O3微粉、粒度范围为15～75um ；BN微粉、粒度范围为15～75um ；
B组份为胶料，成分主要为水玻璃。
2.根据权利要求1所述的垃圾焚烧炉环境下的抗腐蚀复合涂层，其特征在于：A组份中纳米纳米纳米ZrO2重量百分比为10～20%、纳米纳米Al2O3重量百分比为60～80%、纳米Al2O3微粉重量百分比为5～15%、BN微粉重量百分比为5～15%。
3.根据权利要求1所述的垃圾焚烧炉环境下的抗腐蚀复合涂层，其特征在于：A组份与B组分的重量比为A组份：B组分=1～1.5。
4.根据权利要求1所述的垃圾焚烧炉环境下的抗腐蚀复合涂层，其特征在于：所述Fe18Cr9Ni3B3Si1C热喷涂层的厚度为0.5～0.8mm；所述K600涂料层的厚度为150～250um；工件表面的复合涂层厚度为0.65～1.05mm。
5.一种垃圾焚烧炉环境下的抗腐蚀复合涂层的制备方法，其制备方法的步骤如下：
第一步，工件表面预处理：去除基材表面的油脂、污垢、氧化皮、锈迹和油漆，使工件表面净化，清洁度达到Sa2.5级；然后采用10～18目的金刚砂进行喷砂处理，使工件表面粗化、活化，表面粗糙度达到Rz30～50；
第二步，电弧喷涂：采用电弧喷涂方法在经预处理的工件表面喷涂Fe18Cr9Ni3B3Si1C材料，形成底层涂层；
第三步，将K600涂料均匀涂装在Fe18Cr9Ni3B3Si1C热喷涂层上，涂装后的涂料可在室温下自然固化或加热条件下固化，室温下自然固化时间不低于24h，若在加热条件下固化，缓慢升温至80～100℃，保温0.5h烘干，然后缓慢升温至300℃，保温1h烧结固化。
6.根据权利要求5所述的垃圾焚烧炉环境下的抗腐蚀复合涂层的制备方法，其特征在于：所述第二步的工艺参数为：电流160～300A，电压30～45V，喷涂距离120～250mm，压缩气体压力0.45～0.7MPa，喷枪移动速度250～500mm/s，喷涂角度60～90°，采用人工喷涂或采用自动化装置喷涂。
7.根据权利要求5所述的垃圾焚烧炉环境下的抗腐蚀复合涂层的制备方法，其特征在于：所述第三步，将K600涂料均匀涂装在Fe18Cr9Ni3B3Si1C热喷涂层上的涂装方式为刷涂、滚涂或喷涂。
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