CN113620692B - 一种干式镁铬质捣打料 - Google Patents

一种干式镁铬质捣打料 Download PDF

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CN113620692B
CN113620692B CN202111028359.6A CN202111028359A CN113620692B CN 113620692 B CN113620692 B CN 113620692B CN 202111028359 A CN202111028359 A CN 202111028359A CN 113620692 B CN113620692 B CN 113620692B
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chromium
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magnesium
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任向阳
刘志强
翟耀杰
李新路
王炎超
翟柠崤
慕全定
姜东敏
翟鹏涛
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Henan Ruitai Fireproof Material Technology Co ltd
Henan Ruitai Energy Saving New Technology Co ltd
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Henan Ruitai Energy Saving New Technology Co ltd
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Abstract

本发明属于耐火材料生产技术领域,具体涉及一种干式镁铬质捣打料。该干式镁铬质捣打料由干料和外加剂组成;所述干料由以下质量分数的组分组成:骨料65~73%,粉料15~26%,添加剂8~10%;所述骨料由废弃镁铬砖粉碎而成,其中Cr2O3含量16~20%;所述添加剂由固体水玻璃、硅微粉、六偏磷酸钠按重量比(3~5):(3.5~4.5):(0.5~1.0)组成;所述外加剂为液态热塑性酚醛树脂。本发明的干式镁铬质捣打料,本发明以废弃镁铬质残砖为主要原料,采用无水结合剂,在中低温下捣打料即能产生较大强度,在满足高温窑炉的使用要求的基础上,避免了对上部镁铬砖的损伤,延长窑炉的使用寿命。

Description

一种干式镁铬质捣打料
技术领域
本发明属于耐火材料生产技术领域,具体涉及一种干式镁铬质捣打料,尤其是一种有色冶金高温炉用干式镁铬质捣打料。
背景技术
有色金属冶炼高温窑炉,如反射炉等多采用抗侵蚀性能的镁铬砖作工作衬,在镁铬砖工作衬与高温炉体之间,一般铺设一定厚度填料层,填料一般采用捣打料或浇注料。
填料层起到以下作用:(1)填充镁铬工作衬与炉底之间的缝隙,缓冲镁铬材料与高温炉体之间因温度变化产生的应力;(2)在使用过程中因冶炼操作、镁铬耐火砖质量等因素出现意外熔体渗漏时,填料层可以在一定时间内阻止熔体直接接触炉体,防止因高温熔体泄露造成人身伤害和财产损失。
铺设的浇注层或捣打料层一般采用镁铬质原料制作而成。一些用镁铬砖作工作衬的有色金属冶炼高温窑炉长期使用过程中产生大量的用后残砖,常年堆积无法处理,易于造成环境污染;另外,为便于施工,填料层在铺设施工时通常加入一定量的的水分,而碱性耐火材料较易水化,水化导致工作衬镁铬砖性能的降低,甚至导致炉窑炉衬使用寿命下降。
常规的干式捣打料在中低温下其强度较低,难以满足在其上部进行窑衬砌筑,尤其是难以满足经过约600℃工作温度使用后在上部再次砌筑窑衬的使用要求(更换窑衬情形)。
发明内容
本发明的目的在于提供一种干式镁铬质捣打料,解决常规捣打料在中低温下强度较低的问题。
为实现上述目的,本发明所采用的技术方案是:
一种干式镁铬质捣打料,由干料和外加剂组成;
所述干料由以下质量分数的组分组成:骨料65~73%,粉料15~26%,添加剂8~10%;所述骨料由废弃镁铬砖粉碎而成,其中Cr2O3含量16~20%;所述添加剂由固体水玻璃、硅微粉、六偏磷酸钠按重量比(3~5):(3.5~4.5):(0.5~1.0)组成;
所述外加剂为液态热塑性酚醛树脂。
本发明的干式镁铬质捣打料,以废弃镁铬质残砖为主要原料,采用无水结合剂,在中低温下捣打料即能产生较大强度,在满足高温窑炉的使用要求的基础上,避免了对上部镁铬砖的损伤,延长窑炉的使用寿命。
另外,本发明采用废弃镁铬砖为主要原料,实现了废弃资源的循环利用,节约了宝贵的原材料,降低了环境污染。同时,所用原料的成本低,降低了生产成本,提高了企业的经济效益,具有广阔的市场应用前景。
优选的,所述干料由以下质量分数的组分组成:骨料67~73%,粉料17~25%,添加剂8~10%。
优选的,固体水玻璃、硅微粉、六偏磷酸钠的重量比为:(3.9~4.7):(3.5~4.5):(0.6~0.8)。
优选的,骨料的粒径≤8mm,粉料的粒径≤0.074mm。进一步优选的,骨料采用5~8mm、3~5mm、<3mm三种粒径颗粒级配,重量比为(13~18):(19~25):(30~38)。更优选的,5~8mm、3~5mm、<3mm三种粒径颗粒按质量比(13~18):(19~22):(33~38)级配。
优选的,所述粉料由烧结镁砂和废弃镁铬砖粉按重量比(11~15):(6~10.2)组成。镁铬砖是镁砂和铬矿原料经过高温烧成(烧结温度高于镁砖)后形成。废弃镁铬砖是镁铬砖在长期高温条件下使用后的废弃物,可以看作是瘠性料,其烧结活性也远低于镁砂。添加烧结镁砂能够增强捣打料的烧结活性和黏性,烧结镁砂和废弃镁铬砖粉采用上述配比复配,不仅合理利用了废料,而且对提高捣打料的中低温强度有利。
进一步优选的,所述烧结镁砂中MgO的质量含量≥90%。
优选的,干料和外加剂混匀后捣打施工,在500~700℃的工作温度下使用。
具体实施方式
本发明采用废弃镁铬砖为主要原料,加入添加剂、外加剂制备而成一种干式镁铬质捣打料。
干式镁铬质捣打料采用无水结合剂,具有较高的中低温结合强度,提高了炉衬的使用寿命。本发明所用原料均为市售产品或废弃资源,以下将主要原料的情况说明如下:
废弃镁铬砖,其中Cr2O3含量16-20%。
烧结镁砂,MgO含量≥90%。
固体水玻璃,模数3.00,Na2O含量18.5-22.5%。
硅微粉,SiO2含量≥90%。
液态热塑性酚醛树脂,粘度5000-8000mPa·s,残碳量≥33%,固含量≥73%,水分≤3.5%。
本发明中,“%”如无特殊说明,均为质量百分数。
下面结合具体实施例对本发明的实施方式作进一步说明。
一、干式镁铬质捣打料的具体实施例
实施例1
本实施例的干式镁铬质捣打料,以质量百分比计,骨料用量占70%,粉料用量占21.2%,添加剂用量占8.8%,外加剂用量占骨料、粉料、添加剂之和的4%。
骨料的原料是废弃镁铬砖;骨料的粒径≤8mm,其中5mm~8mm骨料用量为18%,3mm~5mm骨料用量为19%,<3mm骨料占骨料总量的33%。
粉料的原料是废弃镁铬砖粉和烧结镁砂;粉料的粒径≤0.074mm。烧结镁砂粉料用量为11%,废弃镁铬砖粉用量为10.2%。
添加剂中各成分占比分别为:固体水玻璃粉4%、硅微粉4%、六偏磷酸钠0.8%。
外加剂为液态热塑性酚醛树脂,其用量为4%。
制作方法:
将废弃镁铬砖受到明显污染部分去除,然后将废弃镁砖和烧结镁砂破粉碎加工成符合粒度要求的骨料和粉料。
按比例称取规定质量的骨料、粉料和添加剂,将称取好的添加剂进行预先混合。
称取液态热塑性酚醛树脂。
将称量好的骨料、粉料和添加剂加入强制搅拌机中混合,混合过程中加入外加剂,强制搅拌10分钟后备用。
实施例2
本实施例的干式镁铬质捣打料,以质量百分比计,骨料用量占73%、粉料用量占17%,添加剂用量占10%,外加剂用量占骨料、粉料、添加剂之和的3.5%。
骨料的原料是废弃镁铬砖;骨料的粒径≤8mm,其中5mm~8mm骨料用量为13%,3mm~5mm骨料用量为22%,<3mm骨料占骨料总量的38%。
所述粉料的原料是废弃镁铬砖粉和烧结镁砂;粉料的粒径≤0.074mm。烧结镁砂粉料用量为11%,废弃镁铬砖粉用量为6%。
添加剂中各成分占比为:固体水玻璃粉4.7%、硅微粉4.5%、六偏磷酸钠0.8%。
外加剂为液态热塑性酚醛树脂,其用量为3.5%。
制作方法同实施例1。
实施例3
本实施例的干式镁铬质捣打料,以质量百分比计,骨料用量占67%、粉料用量占25%,添加剂用量占8%,外加剂用量占骨料、粉料、添加剂之和的5%。
所述骨料的原料是废弃镁铬砖;骨料的粒径≤8mm,其中5mm~8mm骨料用量为14%,3mm~5mm骨料用量为20%,<3mm骨料占骨料总量的33%。
粉料的原料是废弃镁铬砖粉和烧结镁砂;粉料的粒径≤0.074mm。烧结镁砂粉料用量为15%,废弃镁铬砖粉用量为10%。
添加剂中各成分的质量占比为:固体水玻璃粉3.9%、硅微粉3.5%、六偏磷酸钠0.6%。
外加剂为液态热塑性酚醛树脂,其用量为5%。
制作方法同实施例1。
二、对比例
对比例1
本实施例的干式镁铬质捣打料,以质量百分比计,骨料用量占70%,粉料用量占20%,添加剂用量占10%,外加剂用量占骨料、粉料、添加剂之和的4%。
骨料的原料是废弃镁铬砖;骨料的粒径≤8mm,其中5mm~8mm骨料用量为18%,3mm~5mm骨料用量为19%,<3mm骨料占骨料总量的33%。
粉料的原料是废弃镁铬砖粉和烧结镁砂;粉料的粒径≤0.074mm。烧结镁砂粉料用量为10%,废弃镁铬砖粉用量为10%。
添加剂中各成分占比分别为:固体水玻璃粉2%、硅微粉4%、六偏磷酸钠1.0%,轻烧镁粉3%。
外加剂为液态热塑性酚醛树脂,其用量为4%。
制作方法同实施例1。
对比例2
本实施例的干式镁铬质捣打料,以质量百分比计,骨料用量占70%,粉料用量占21%,添加剂用量占9%,外加剂用量占骨料、粉料、添加剂之和的4%。
骨料的原料是废弃镁铬砖;骨料的粒径≤8mm,其中5mm~8mm骨料用量为18%,3mm~5mm骨料用量为19%,<3mm骨料占骨料总量的33%。
粉料的原料是废弃镁铬砖粉和烧结镁砂;粉料的粒径≤0.074mm。烧结镁砂粉料用量为11%,废弃镁铬砖粉用量为10%。
添加剂中各成分占比分别为:固体水玻璃粉4%、硅微粉2%、六偏磷酸钠1.0%,硼酸2.0%。
外加剂为液态热塑性酚醛树脂,其用量为4%。
制作方法同实施例1。
对比例3
本实施例的干式镁铬质捣打料,以质量百分比计,骨料用量占70%,粉料用量占22%,添加剂用量占8%,外加剂用量占骨料、粉料、添加剂之和的4%。
骨料的原料是废弃镁铬砖;骨料的粒径≤8mm,其中5mm~8mm骨料用量为18%,3mm~5mm骨料用量为19%,<3mm骨料占骨料总量的33%。
粉料的原料是废弃镁铬砖粉和烧结镁砂;粉料的粒径≤0.074mm。烧结镁砂粉料用量为12%,废弃镁铬砖粉用量为10%。
添加剂中各成分占比分别为:固体水玻璃粉3%、硅微粉3%、六偏磷酸钠2.0%。
外加剂为液态热塑性酚醛树脂,其用量为4%。
制作方法同实施例1。
三、实验例
将各实施例的材料进行捣打施工操作后,对捣打料取样进行检测,结果如下表1所示。
表1捣打料的物理性能测试结果
Figure BDA0003244360170000051
由表1的结果可知,在110℃×24h烘干,此时常温结合剂发挥作用,耐压强度达到39~50MPa,体积密度为2.61~2.65g/cm3;在600℃的工作温度下,常规捣打料的结合强度处于较低区间,无法满足在其上部进行砌筑窑衬的要求,而本发明的捣打料在该温度下的耐压强度仍然达到21~25MPa,处于较高耐压强度范围,能够满足窑衬的首次砌筑或者更换窑衬后的再次砌筑过程。

Claims (8)

1.一种干式镁铬质捣打料,其特征在于,由干料和外加剂组成;
所述干料由以下质量分数的组分组成:骨料65~73%,粉料15~26%,添加剂8~10%;所述骨料由废弃镁铬砖粉碎而成,其中Cr2O3含量16~20%;所述添加剂由固体水玻璃、硅微粉、六偏磷酸钠按重量比(3~5):(3.5~4.5):(0.5~1.0)组成;
所述外加剂为液态热塑性酚醛树脂;所述干式镁铬质捣打料在镁铬砖工作衬与高温炉体之间使用,适用的工作温度为500~700℃;所述粉料由烧结镁砂和废弃镁铬砖粉按重量比(11~15):(6~10.2)组成。
2.如权利要求1所述的干式镁铬质捣打料,其特征在于,所述干料由以下质量分数的组分组成:骨料67~73%,粉料17~25%,添加剂8~10%。
3.如权利要求1或2所述的干式镁铬质捣打料,其特征在于,固体水玻璃、硅微粉、六偏磷酸钠的重量比为:(3.9~4.7):(3.5~4.5):(0.6~0.8)。
4.如权利要求1所述的干式镁铬质捣打料,其特征在于,骨料的粒径≤8mm,粉料的粒径≤0.074mm。
5.如权利要求4所述的干式镁铬质捣打料,其特征在于,骨料采用5~8mm、3~5mm、<3mm三种粒径颗粒级配,重量比为(13~18):(19~25):(30~38)。
6.如权利要求5所述的干式镁铬质捣打料,其特征在于,5~8mm、3~5mm、<3mm三种粒径颗粒按质量比(13~18):(19~22):(33~38)级配。
7.如权利要求1所述的干式镁铬质捣打料,其特征在于,所述烧结镁砂中MgO的质量含量≥90%。
8.如权利要求1所述的干式镁铬质捣打料,其特征在于,干料和外加剂混匀后捣打施工,在500~700℃的工作温度下使用。
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