CN114031379A - 一种铝硅质高温喷涂料 - Google Patents
一种铝硅质高温喷涂料 Download PDFInfo
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- 238000005507 spraying Methods 0.000 title claims abstract description 42
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 title claims abstract description 19
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims abstract description 25
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 25
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 24
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 22
- 239000007921 spray Substances 0.000 claims abstract description 20
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 19
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 17
- 239000010439 graphite Substances 0.000 claims abstract description 17
- 229910052751 metal Inorganic materials 0.000 claims abstract description 17
- 239000002184 metal Substances 0.000 claims abstract description 17
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000010431 corundum Substances 0.000 claims abstract description 16
- 239000000571 coke Substances 0.000 claims abstract description 15
- 229910052849 andalusite Inorganic materials 0.000 claims abstract description 14
- 239000011863 silicon-based powder Substances 0.000 claims abstract description 13
- 238000001816 cooling Methods 0.000 claims description 11
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 239000000377 silicon dioxide Substances 0.000 claims description 9
- 239000000126 substance Substances 0.000 claims description 9
- 239000002131 composite material Substances 0.000 claims description 8
- 239000003973 paint Substances 0.000 claims description 8
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
- 239000010959 steel Substances 0.000 claims description 6
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 4
- 229910052681 coesite Inorganic materials 0.000 claims description 4
- 229910052906 cristobalite Inorganic materials 0.000 claims description 4
- 229910052760 oxygen Inorganic materials 0.000 claims description 4
- 239000001301 oxygen Substances 0.000 claims description 4
- 229910052682 stishovite Inorganic materials 0.000 claims description 4
- 229910052905 tridymite Inorganic materials 0.000 claims description 4
- 229910000975 Carbon steel Inorganic materials 0.000 claims description 2
- 229910052799 carbon Inorganic materials 0.000 claims description 2
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 2
- 239000002245 particle Substances 0.000 claims description 2
- 239000002699 waste material Substances 0.000 claims description 2
- 229910018125 Al-Si Inorganic materials 0.000 claims 2
- 229910018520 Al—Si Inorganic materials 0.000 claims 2
- 229910008458 Si—Cr Inorganic materials 0.000 claims 1
- 229910001570 bauxite Inorganic materials 0.000 claims 1
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 abstract description 20
- 239000002994 raw material Substances 0.000 abstract description 13
- 229910052742 iron Inorganic materials 0.000 abstract description 10
- 239000002893 slag Substances 0.000 abstract description 7
- 238000003723 Smelting Methods 0.000 abstract description 4
- 230000008439 repair process Effects 0.000 abstract description 3
- 238000005260 corrosion Methods 0.000 abstract description 2
- 230000007797 corrosion Effects 0.000 abstract description 2
- 230000035699 permeability Effects 0.000 abstract description 2
- 238000010276 construction Methods 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 239000011819 refractory material Substances 0.000 description 6
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- 239000003795 chemical substances by application Substances 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- 239000007767 bonding agent Substances 0.000 description 2
- 239000011449 brick Substances 0.000 description 2
- 230000003628 erosive effect Effects 0.000 description 2
- 238000010079 rubber tapping Methods 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- RHZUVFJBSILHOK-UHFFFAOYSA-N anthracen-1-ylmethanolate Chemical compound C1=CC=C2C=C3C(C[O-])=CC=CC3=CC2=C1 RHZUVFJBSILHOK-UHFFFAOYSA-N 0.000 description 1
- 239000003830 anthracite Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
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- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
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- 238000009991 scouring Methods 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 238000009628 steelmaking Methods 0.000 description 1
- 238000005496 tempering Methods 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
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Abstract
本发明提出一种铝硅质高温喷涂料，所述铝硅质高温喷涂料的原料，包括矾土、烧结莫来石、刚玉、红柱石、金属硅粉、石墨或焦炭，本发明的铝硅质高温喷涂料具有低污染、低风险、低成本且抗渣侵蚀和抗渗透性强等特性，且喷补过程中原料的回弹率低，取材方便、便于施工，适用于高炉、炼铁炉、鱼雷罐、出铁沟等部位，可获得良好经济和社会效益。
Description
技术领域
本发明属于耐火材料技术领域，具体涉及一种铝硅质高温喷涂料。
背景技术
高炉是炼铁生产的主要设备，它具有产量大、生产率高和成本低的优点。高炉冶炼过程包括原料准备、鼓风加热、煤气清洗、冶炼过程控制以及冶炼产品处理等环节。高炉炼铁过程中采用高压、高风温、大喷煤量喷吹工艺，对炉体破坏较大，因而对耐火材料要求更苛刻。在高炉炉役中后期，内衬砖局部破损严重，甚至出现炉皮发红等现象，影响高炉的正常生产。因此需及时对高炉内衬进行修补，以延长炉衬的使用寿命。而高炉大型化后，出铁沟的使用条件也发生了变化，铁水对沟壁的冲刷、磨损加剧，由于熔渣中含有比较复杂的化学成分，因此易与耐火材料中的成分发生反应，形成低熔点物质，造成耐火材料结构的破坏，同时，熔渣易于粘附在沟壁上，在炉前实施扒渣作业的同时，沟壁耐火材料会随着粘结的熔渣一起被清除掉，因此为了满足生产需求，需及时对出铁沟进行高温修补。
铁水的输送和预处理是连接炼铁与炼钢的重要工序，所采用的的主要高温设备有混铁车、铁水罐和混铁炉等。近年来，鱼雷罐已不再是承担铁水储运的单一功能容器冶金行业中运送高温铁水的鱼雷罐，口小腔大，修补施工难度大，需要工人进入鱼雷罐内部操作，因此采用支模浇注法施工很困难，而采用半干法喷补施工时，粉尘大，反弹多，浪费材料。
由于热态喷涂技术具有施工简单方便、实际操作时间短、投产较快等优点。随着喷涂技术不断地发展和更新，喷涂用耐火材料也快速发展。喷涂料是以气动方式来进行施工的不定形耐火材料，其主要材质是根据高温炉内具体使用环境来确定，因此研究开发一种的铝硅质高温喷涂料，用于高炉、炼铁炉、鱼雷罐及出铁沟等高温窑炉部位。
发明内容
本发明要解决的技术问题是：开发出一种适用于高炉、炼铁炉、鱼雷罐及出铁沟等高温炉衬的铝硅质高温喷涂料。本发明喷涂料采用的原料包括：包括矾土、烧结莫来石、刚玉、红柱石、金属硅粉为主要原料，同时引入石墨或焦炭，其中矾土的粒度为0.1-0.088mm，金属硅粉粒度为 ≤0.044mm，红柱石的粒度为 ≤0.088mm，石墨或焦炭的粒度为≤0.088mm，烧结莫来石粒度分别为0.5-0.1mm、＜0.1mm，刚玉的粒度为≤0.088mm。本发明铝硅质高温喷涂料，具有施工方便、低污染、低风险、低成本且抗渣侵蚀和抗渗透性强等特性。该喷涂料采用双通道喷枪进行高温喷涂，内通道输送喷涂料和氧气、外通道输送冷却空气。一方面，从内管输送的喷涂料在绝大多数时间内受被冷却外管的保护。另一方面，从外管输送的冷却空气从在距离喷涂火焰尾部10-30mm后部，以垂直于火焰90°的方向喷入炉内自由空间。这样，可以防止喷管因回火发生的爆燃，保证了高温喷涂过程中的施工安全性。
为了解决上述问题，本发明采取的技术方案为：
本发明以质量百分含量表示的配方为：0.1-0.088mm的矾土20-45%、0.5-0.1mm的烧结莫来石10-30%、＜0.1mm的烧结莫来石5-25%、≤0.088mm的刚玉10-30%、≤0.088mm的红柱石0-10%；另外，加入粒度≤0.044mm、纯度＞97%的金属硅粉5-15%、粒度≤0.088mm的石墨或焦炭2-12%，用于作为结合剂和发热剂。
所述焦炭的碳含量为85-95%，粒度≤0.088mm；所述石墨由废旧石墨制品制成，粒度≤0.088mm。
所述矾土的化学组成为Al2O3≥55%、Fe2O3＜2.0%、CaO＜0.6%，其粒度为0.1-0.088mm。
所述烧结莫来石，其化学成分为Al2O3≥60%，SiO2≥35%，CaO＜0.1%，其粒度为0.5-0.1mm、＜0.1mm。
所述刚玉Al2O3的质量百分含量为≥95%；粒度为≤0.088mm；所述红柱石的化学组成为Al2O3≥50%，SiO2≥40%，其粒度为≤0.088mm。
所述的铝硅质高温喷涂料通过同轴双通道喷枪送入炉内；其中，内管输送喷涂料和助燃氧气，外管输送冷却空气。所述同轴双通道喷管，其中内管由普碳钢制作，可自由伸缩；外管由耐热钢制作；耐热钢质的外通道管的前部开有侧门，从外管输入的冷却空气从侧门排出，或者在外管装L型管沿喷枪轴线反向朝后排出冷却气，既可冷却内管，又避免了干扰喷枪头部火焰。
本发明的积极有益效果：
本发明技术方案中，一种铝硅质高温喷涂料，采用矾土、烧结莫来石、刚玉以及红柱石为主要原料，刚玉采用≤0.088mm的粒度，使得喷补料在高温状态下保持良好的耐火度，使其热态强度高、耐磨性好、具有良好的抗侵蚀、耐磨损性。
本发明技术方案中，一种铝硅质高温喷涂料，采用金属硅作为发热剂，硅氧化后形成的硅酸钙作为结合剂形成喷射料衬体，避免了采用金属镁、金属铝等易燃易爆物质作发热剂带入的风险，同时采用粒度不超过0.5mm的耐火原料，在喷后很快吸热，喷射料的基质降温凝固，使得喷涂料在高温喷涂后冻结在原有炉衬上，由于喷涂后的炉衬颗粒回弹率低、减少了对铁渣成分的影响，有效提高了出铁质量。
本发明技术方案中，一种铝硅质高温喷涂料引入少量石墨或焦炭作为助发热剂，减少了金属硅的掺量，减少了喷射料衬体中二氧化硅的含量，防止了炉衬的熔损，提高了其使用寿命。
本发明技术方案中，使用风冷却技术，并使用不易燃的石墨和焦炭代替无烟煤，防止了燃料发生爆燃的危险。
本发明的技术方案中，喷涂料通过同轴双通道喷枪送入炉内；其中，普通钢质可插入内通道管输送喷涂料和助燃氧气；耐热钢质的外通道管的前部开有侧门，从外管输入的冷却空气从侧门排出，或者在外管装L型管沿喷枪轴线反向朝后排出冷却气，既可冷却内管，又避免了干扰喷枪头部火焰，不影响对炉衬的喷涂。
具体实施方式
以下结合实施例进一步阐述本发明，但并不限制本发明的内容。
以下实施例中一种铝硅质高温喷涂料，以质量百分含量表示，原料组成为：采用粒度为0.1-0.088mm的矾土20-45%、粒度0.5-0.1mm的烧结莫来石10-30%、粒度＜0.1mm的烧结莫来石5-25%、粒度≤0.088mm的刚玉10-30%、粒度≤0.088mm的红柱石0-10%、粒度≤0.044mm的金属硅粉5-15%、粒度≤0.088mm的石墨或焦炭2-12%组成。
实施例1
本发明一种铝硅质高温喷涂料，以质量百分含量表示，原料组成为：采用粒度为0.1-0.088mm的矾土30%、粒度0.5-0.1mm的烧结莫来石20%、粒度＜0.1mm的烧结莫来石15%、粒度≤0.088mm的刚玉15%、粒度≤0.088mm的红柱石5%、粒度≤0.044mm的金属硅粉8%、粒度≤0.088mm的石墨或焦炭7%组成。
实施例2
本发明一种铝硅质高温喷涂料，以质量百分含量表示，原料组成为：采用粒度为0.1-0.088mm的矾土35%、粒度0.5-0.1mm的烧结莫来石15%、粒度＜0.1mm的烧结莫来石20%、粒度≤0.088mm的刚玉10%、粒度≤0.088mm的红柱石8%、粒度≤0.044mm的金属硅粉6%、粒度≤0.088mm的石墨或焦炭6%组成。
实施例3
本发明一种铝硅质高温喷涂料，以质量百分含量表示，原料组成为：采用粒度为0.1-0.088mm的矾土20%、粒度0.5-0.1mm的烧结莫来石20%、粒度＜0.1mm的烧结莫来石10%、粒度≤0.088mm的刚玉20%、粒度≤0.088mm的红柱石10%、粒度≤0.044mm的金属硅粉10%、粒度≤0.088mm的石墨或焦炭10%组成。
实施例4
本发明一种铝硅质高温喷涂料，以质量百分含量表示，原料组成为：采用粒度为0.1-0.088mm的矾土40%、粒度0.5-0.1mm的烧结莫来石10%、粒度＜0.1mm的烧结莫来石5%、粒度≤0.088mm的刚玉16%、粒度≤0.088mm的红柱石4%、粒度≤0.044mm的金属硅粉13%、粒度≤0.088mm的石墨或焦炭12%组成。
实施例5
本发明一种铝硅质高温喷涂料，以质量百分含量表示，原料组成为：采用粒度为0.1-0.088mm的矾土25%、粒度0.5-0.1mm的烧结莫来石16%、粒度＜0.1mm的烧结莫来石25%、粒度≤0.088mm的刚玉11%、粒度≤0.088mm的红柱石3%、粒度≤0.044mm的金属硅粉15%、粒度≤0.088mm的石墨或焦炭5%组成。
利用本发明实施例1、2、3、4和5所制备产品的相关性能检测数据详见表1。
表1 本发明实施例1、2、3、4和5所制备产品的相关性能检测数据
| 指标 | 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 |
| 喷涂粘结抗折强度（MPa） | 13.5 | 12.92 | 12.23 | 12.65 | 13.0 |
| 常温耐压强度(MPa) | 74.3 | 72.4 | 71.68 | 72.13 | 73.69 |
| 反弹率（%） | 19.8 | 19.74 | 20.06 | 20.13 | 20.5 |
| 荷重软化温度（℃） | ＞1700 | ＞1700 | ＞1700 | ＞1700 | ＞1700 |
由表1所示，研发制备的一种铝硅质喷涂料具有低污染、低风险、低成本且抗侵蚀性强等特性，取材方便、便于施工，适用于高炉、炼铁炉、鱼雷罐及出铁沟等高温部位的损毁喷涂，可获得良好的经济和社会效益。
Claims (7)
1.一种铝硅质高温喷涂料，其特征在于：以质量百分含量表示，所述一种铝硅质高温喷涂料主要由矾土20-45%、烧结莫来石15-40%、刚玉10-30%、红柱石0-10%、金属硅粉5-15%、石墨或焦炭2-12%组成；所述金属硅粉的纯度＞95%，金属硅粉的粒度为≤0.044mm。
2.根据权利要求1所述的一种铝硅质高温喷涂料，其特征在于，所述焦炭的碳含量为85-95%，粒度≤0.088mm；所述石墨由废旧石墨制品制成，粒度≤0.088mm。
3.根据权利要求1所述的一种铝硅质高温喷涂料，其特征在于，所述矾土的化学组成为Al2O3≥55%、Fe2O3＜2.0%、CaO＜0.6%，其粒度为0.1-0.088mm。
4.根据权利要求1所述的一种铝硅质高温喷涂料，其特征在于，所述烧结莫来石，其化学成分为Al2O3≥60%，SiO2≥35%，CaO＜0.1%，其粒度为0.5-0.1mm、＜0.1mm。
5.根据权利要求1所述的一种铝硅质高温喷涂料，其特征在于，所述刚玉，其Al2O3的质量百分含量为≥95%，粒度为≤0.088mm；所述红柱石的化学组成为Al2O3≥50%，SiO2≥40%，其粒度为≤0.088mm。
6.根据权利要求4所述的一种铝硅质高温喷涂料，其特征在于，按质量百分含量表示，所述烧结莫来石，粒度为0.5-0.1mm的烧结莫来石10-30%；粒度 ≤0.1mm的烧结莫来石5-25%。
7.根据权利要求1所述的一种铝硅质高温喷涂料，其特征在于，喷涂料通过同轴双通道喷枪送入炉内；其中，内管输送喷涂料和助燃氧气，外管输送冷却空气；所述同轴双通道喷管，其中内管由普碳钢制作，可自由伸缩；外管由耐热钢制作；耐热钢质的外通道管的前部开有侧门，从外管输入的冷却空气从侧门排出，或者在外管装L型管沿喷枪轴线反向朝后排出冷却气，既可冷却内管，又避免了干扰喷枪头部火焰。
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