CN113860890B - 一种精炼炉用CaC2-C耐火材料及制备工艺 - Google Patents
一种精炼炉用CaC2-C耐火材料及制备工艺 Download PDFInfo
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Abstract
本发明涉及一种新型CaC2‑C质耐火材料,其主要是由40~98%的电石和2~60%的碳组成的,外加2~10%的无水树脂结合剂。按一定颗粒配比进行配料,经过混料、高压成型、涂层和固化处理的方法制成电石碳质不烧制品。该材料特别适用于带真空的钢铁精炼炉衬渣线。它具有抗钢液熔蚀、抗氧化、抗真空和抗含CaF2渣侵蚀的特点,具有非常高的使用寿命,同时还具有脱硫、脱氧和洁净钢水的作用。
Description
技术领域
本发明属于冶金耐火材料领域,具体涉及到一种精炼炉用CaC2-C耐火材料及生产制造工艺。
背景技术
自从上个世纪七十年代含炭耐火材料出现以来就得到了迅速发展,在整个冶金窑炉上得到了应用和推广,显著提高了冶金窑炉的使用寿命,降低了耐火材料消耗。在含碳耐火材料发展过程中,主要出现了以下几种含炭耐火材料:
(1)镁碳质耐火材料。该材料主要应用于炼钢转炉、电炉和精炼炉渣线部位,并取得了显著的效果。常用的牌号以碳含量多少来划分,主要有MT-3、MT-5、MT-8、MT-10、MT-12、MT-14、MT-16、MT-18八个牌号。它们的碳含量也分别为3%、5%、8%、10%、12%、14%、16%、18%。镁碳质耐火材料具有一个显著的特点,其耐炼钢渣的侵蚀性非常好,因此炼钢炉衬使用寿命延长和耐火材料单耗降低,而它显著的不足就是,在超高温和真空的条件下,性能显著下降,侵蚀很快。
(2)铝碳质耐火材料。该材料显著的特点是抗热震好,因此,被成功应用于钢液的控流系统,如整体塞棒、长水口、浸入式水口、滑板等,但是它抗碱性渣侵蚀能力不足,在炼钢炉内侵蚀较快,使用寿命较低,因此,不适合于精炼炉衬的耐火材料,特别是冶炼不锈钢、模具钢等优质特殊钢的精炼炉衬。
(3)镁钙碳质耐火材料。它适合于冶炼不锈钢的精炼钢包的熔池,而用在渣线虽然比镁碳砖好,但是因在真空条件下仍然有反应:CaO+C=Ca(g)+CO(g)而导致侵蚀很快和使用寿命仍然不能满足使用要求。
(4)铝镁碳质或镁铝碳质耐火材料。该材料兼顾了抗热震性和耐侵蚀性的优点,适用于一般钢包或普通精炼炉上,但是对于有VD、CaF2造渣以及特殊合金的优质特钢冶炼的条件下不适用,导致使用寿命和对钢的洁净度产生不良影响。
(5)铝碳化硅碳质耐火材料。该材料具有非常显著的抗热震和抗中性和酸性渣侵蚀的特点,其已被成功应用于炼铁系统的高炉出铁场、铁水包等冶金容器,而对于碱性炼钢的精炼钢包就不适用。
因此,到目前为止,对于冶炼不锈钢等优质特钢用的精炼炉衬渣线主要还是使用镁碳砖、镁钙碳砖以及镁钙砖,使用寿命只有十几次,甚至几次,不能满足使用要求,严重影响了优质钢的冶炼和成本的降低。
发明内容
本发明提供一种以电石和石墨为主要原料的CaC2-C耐火材料,以提高渣线耐火材料的抗侵蚀性、抗氧化性和抗热震性,提高特钢冶炼用精炼炉衬渣线的使用寿命。
电石主要应用于钢铁冶金作为脱氧剂和脱硫剂,同时作为重要的化工原料,电石水化制造乙炔,乙炔是有机合成的主要原料,也是气焊的主要燃料。干燥氧气能氧化碳化钙变成碳酸钙:2CaC2 +5O2=2CaCO3+2CO2,它的密度为2.22g/cm3,纯CaC2熔点2300oC,电石中CaC2含量一般80%左右,其熔点1980oC左右,CaC2含量为69%时,熔点最低到1750oC,影响电石熔点的因素取决于杂质的量和性质。
电石的耐火度高,导热性能好(导热系数:25oC:19w/m.k,500oC:21.5w/m.k,1000oC:5 w/m.k,1500oC:8.9w/m.k,2000oC:12.9w/m.k)和热膨胀低(热膨胀系数:10.3*10- 6m/oC),它在钢液中溶解度低,不与还原性渣起反应,与氧化物也没有共熔效应,不被钢渣所润湿和渗透。但是电石在实际应用中易于水化,水化后会产生易燃易爆的乙炔气体
为了解决上述问题,本发明专利所采用的技术方案如下:
一种精炼炉用CaC2-C耐火材料,包括一定质量比例的电石、碳和无水树脂结合剂。
优选方案为,所述电石的主要成分为碳化钙,其含量≥80%(优选大于90%)。
优选方案为,所述电石呈颗粒状,其中颗粒按粒径大小,分成3~20mm、3~1mm和≤1mm三级料;其质量配比为3~20mm :40~60%,3~1mm:25~35%,≤1mm:5~35%
优选方案为,所述碳为石油焦、电极石墨或天然石墨,优选为天然石墨,要求碳含量≥80%(优选碳含量≥95%)。
优选方案为,所述无水结合剂是指无水碳素树脂结合剂,其残炭量≥35%,粘度(25oC)3~25Pa.S,挥发分(105oC)≤10%,水分≤0.5%,游离酚≤0.5%。
优选方案为,所述电石的质量比为40~98%,碳的质量比为2~60%,无水树脂结合剂。
一种精炼炉用CaC2-C耐火材料的制备方法,按照配方比例进行混料、成型、用无水涂料涂层后,再经过固化而制得。
优选方案为,固化温度为≤300oC,以200oC为优,其保温时间大于12h为好。
优选方案为,所述无水材料的涂层厚度要求≥0.1mm,以0.3~1mm厚为佳。其作用是密封制品与外界隔绝,具有良好的防氧化和防水化的功能。
与现有技术相比,本发明的特点和有益效果是:
1)本申请所用碳化钙不容易被渣侵蚀,抵抗CaF2系渣的能力很强;可与碳共存,既不会降低熔点,也不会发生气化反应;热膨胀系数小和导热性好,抗热震性好,用它制成的产品在使用过程中衬不易开裂和剥落,有利于提高使用寿命;
2)碳化钙与碳组合成复合材料具有热稳定性好,抗渣,特别是抗含萤石渣的侵蚀能力强,抗热震和抗渗透能力强,因此具有良好的使用效果;
3)采用无水树脂结合剂,可有效防止镁钙碳砖内CaO+H2O=Ca(OH)2水化反应的发生。
4)产品成型后,表面采用无水防氧化涂料,该涂料涂层厚度0.3~1mm,有效隔绝空气密封制品,有效地防止了水化,保证了存放,同时在使用过程中高温下防止了该产品的氧化。
具体实施方式
以下结合具体实施方式对本发明作进一步说明。应该明白的是,下述说明仅是为了解释本发明,并不对其内容进行限定。如无特别说明,下述所用各成分的含量为重量百分比含量。
实施例
按照下表配方进行配料:
在混炼机上混料40min后,以200MPa成型压力在压力机上成型,涂层0.5mm防水化涂料,进入干燥的固化窑进行干燥,干燥温度为200oC,保温时间20h。然后进行性能测试,结果见下表所示,表2:实施例1-3的性能测试结果
由上述性能可知,本发明的材料具有非常好的抗含萤石渣的侵蚀性。应用于超高温和真空冶炼的条件下,本发明材料的使用寿命能提高40%以上。
Claims (8)
1.一种精炼炉用CaC2-C耐火材料,其特征在于,包括一定质量比例的电石、碳和无水结合剂,所述电石的主要成分为碳化钙,其含量≥80%;所述碳为天然石墨,要求碳含量≥80%;所述电石的占比为40~98%,碳的占比为2~60%,外加所述无水结合剂的占比为2-10%。
2.如权利要求1所述的耐火材料,其特征在于,所述碳化钙的含量大于90%。
3.如权利要求1所述的耐火材料,其特征在于,所述电石呈颗粒状,其中颗粒按粒径大小,分成3~20mm、3~1mm和≤1mm三级料;其质量配比为3~20mm :40~60%,3~1mm:25~35%,≤1mm:5~35%。
4.如权利要求1所述的耐火材料,其特征在于,所述天然石墨的碳含量≥95%。
5.如权利要求1所述的耐火材料,其特征在于,所述无水结合剂是指无水碳素树脂结合剂,其残炭量≥35%,粘度(25oC)3~25Pa.S,挥发分(105oC)≤10%,水分≤0.5%,游离酚≤0.5%。
6.如权利要求1所述的耐火材料的制备方法,其特征在于,按照配方比例进行混料、成型、用无水涂料涂层后,再经过固化而制得。
7.如权利要求6所述的制备方法,其特征在于,所述固化的温度为≤300oC,保温时间大于12小时。
8.如权利要求6所述的制备方法,其特征在于,所述无水涂料的涂层厚度要求≥0.1mm。
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