CN114180979A - 用于渣罐的阻热喷涂料及其制备方法 - Google Patents
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Abstract
本发明公开了一种用于渣罐的阻热喷涂料及其制备方法,所述的阻热喷涂料的原料质量百分组成为:高铝棉5~10%;石英砂或回用高铝砖粉25~40%;宜兴泥或苏州土7~12%;液体结合剂5~10%;保水剂0.05~0.5%;发泡剂0.01~0.1%;水40~50%。本发明公开的渣罐阻热喷涂料的各项性能均较好,附着性能好、不反弹、强度高、抗渣侵蚀性能好、翻渣容易、导热系数低保温效果好,可实现高温液态渣直接上滚筒渣处理,缩短渣处理流程,有效提高罐龄,提高渣处理效率,减少粉尘污染。
Description
技术领域
本发明属于耐火材料不定型耐火材料领域。具体涉及一种用于渣罐的阻热喷涂料及其制备方法。
背景技术
目前炼钢区域的脱硫渣采用热态渣罐运输到落锤间,洒水冷却后渣与罐脱离,才可以倾翻,在翻罐过程中,可能出现钢渣黏罐现象,经处理,钢渣仍不能与渣罐脱离,渣罐就成为死罐,只能报废。产生黏罐和死罐,不但会造成经济损失,增加炼钢成本,严重时会导致渣罐周转短缺,影响生产。
通常渣罐底部会放入一部分废渣,可缓解黏连现象,但是翻渣时会出现黑色气体,污染环境。冷却后的渣,其强度较高,渣块较大,只能用落锤的方式进行破碎,存在较大安全隐患,处理过程的灰尘较大,含粉尘蒸汽难以控制,处理的流程较长。渣罐在热态下洒水,对罐体造成较大损伤,容易开裂,变形,导致每年大量罐体需要更换。变形严重的还会出现冷态渣无法倾倒出来成为死罐的情况。整个流程中,渣罐的周转效率较低。
最新的渣处理工艺,为液态渣直接用滚筒进行处理,可直接得到细小颗粒的渣粒,便于后期渣铁分离,此工艺同样面临渣对渣罐的粘附,以及液态渣快速冷却粘度增大,导致无法进入滚筒的情况。
急需一种渣罐喷涂料,可以对高温液态渣进行保温,使液态渣可直接进行滚筒渣处理,又可以防止渣对渣罐的粘附,提高渣罐的寿命。现渣罐喷涂多用氧化镁、氧化钙、矾土、石墨等材料做成浆体进行喷涂,现有方式,成本较高,且导热系数大,起不到保温隔热的作用。
因此,需要一种低成本,导热系数较小,从而能起到很好的隔热保温效果的渣灌喷涂料。
同时,需要说明的是,现有技术中,渣罐也可以叫渣包等,其为不同钢铁企业的各种不同的叫法,但均系指同一种产品。
发明内容
本发明为解决以上技术问题,提供一种附着性能好、不反弹、强度高、抗渣侵蚀性能好、翻渣容易、导热系数低保温效果好的用于渣罐的阻热喷涂料及其制备方法。
为了实现上述目的,本发明具有如下技术方案:
一种用于渣罐的阻热喷涂料,所述的阻热喷涂料的组成质量百分包括:高铝棉5~10%;石英砂或回用高铝砖粉25~40%;宜兴泥或苏州土7~12%;液体结合剂5~10%;保水剂0.05~0.5%;发泡剂0.01~0.1%;水40~50%;
所述的液体结合剂为液体磷酸二氢铝、硫酸铝溶液、钠水玻璃、钾水玻璃、硅溶胶中的一种或多种;
所述的高铝棉为硅酸铝纤维棉,主含量为Al2O3+SiO2≥80%。
较佳地,所述的发泡剂为十二烷基硫酸钠。
较佳地,所述的石英砂或回用高铝砖粉,其主含量为Al2O3+SiO2≥80%,颗粒度为20~200目。
较佳地,所述的宜兴泥或苏州土,其颗粒度为180~320目,SiO2≥35%。
较佳地,所述的高铝棉经喷吹成型。
本发明还提供了所述的用于渣罐的阻热喷涂料的制备方法,所述的制备方法包括以下步骤:
(1)将石英砂或回用高铝砖粉、宜兴泥或苏州土、保水剂、发泡剂进行混合3~5分钟搅拌均匀,制作预混合粉;
(2)将高铝棉加入搅拌机,然后加入水进行搅拌1~3min,再加入预混合粉进行搅拌3~5min,最后加入液体结合剂进行搅拌均匀,并通过加入5~10%的水调整喷涂料最终料性;
(3)将混合好的喷涂料放入槽罐中进行困料1h以上。
根据上述制备方法得到的用于渣罐的阻热喷涂料的体积密度≤1.7g/cm3;烘干后的体积密度≤1.0g/cm3;500℃导热系数≤0.18W/(m·K);烘干后不开裂;500℃烘干收缩率≤10%;喷涂不反弹,粘附力≥2000N。
本发明提供的用于渣罐的阻热喷涂料中,高铝棉为硅酸铝纤维棉,喷吹成型,主含量为Al2O3+SiO2≥80%,高铝棉的加入可有效降低喷涂料的体积密度,降低喷涂料的导热系数,使喷涂料具有较好的保温效果,高铝棉中的纤维可有效防止喷涂料开裂现象,使喷涂料在烘干后能保持较高的完整性。石英砂或回用高铝砖粉颗粒度为20~200目,小颗粒的主体材料可使喷涂料具有较好的喷涂性,180~320目的宜兴泥加入,可使喷涂料粘性增加,降低喷涂反弹率,液体结合剂的加入可有效提高喷涂料烘干后的强度,保水剂能适量调整喷涂料的粘性和保湿性,发泡剂能产生微孔,降低喷涂料的体积密度,提高喷涂料的保温效果。
本发明公开的技术方案还具有以下优点:主要原料资源丰富,生产工艺及设备简单,生产成本低廉,对环境无污染。
与现有渣罐喷涂技术相比,本发明具备以下优点:喷涂料导热系数低,保温效果好,纤维含量高,整体性好,所用的主料为石英砂或回用高铝砖粉,原料成本较低,耐温较高,工艺流程短,企业生产成本低,经济效益明显。
具体实施方式
为了使本发明的发明目的、技术方案和有益技术效果更加清晰,以下结合具体实施例对本发明进行详细说明。应当理解的是,本说明书中描述的实施例仅仅是为了解释本发明,并非为了限定本发明。
本发明提供的一种用于渣罐的阻热喷涂料,所述的阻热喷涂料的组成质量百分包括:高铝棉5~10%;石英砂或回用高铝砖粉25~40%;宜兴泥或苏州土7~12%;液体结合剂5~10%;保水剂0.05~0.5%;发泡剂0.01~0.1%;水40~50%。
在一些具体实施例中,所述的液体结合剂为液体磷酸二氢铝、硫酸铝溶液、钠水玻璃、钾水玻璃、硅溶胶中的一种或多种,可以有效提高喷涂料烘干后的强度。
在一些具体实施例中,所述的高铝棉为硅酸铝纤维棉,经喷吹成型,主含量为Al2O3+SiO2≥80%,可有效降低喷涂料的体积密度,降低喷涂料的导热系数,使喷涂料具有较好的保温效果,高铝棉中的纤维可有效防止喷涂料开裂现象,使喷涂料在烘干后能保持较高的完整性。
在一些具体的实施例中,所述的发泡剂为十二烷基硫酸钠,能产生微孔,降低喷涂料的体积密度,提高喷涂料的保温效果。
在一些具体的实施例中,所述的石英砂或回用高铝砖粉,其主含量为Al2O3+SiO2≥80%,颗粒度为20~200目,小颗粒的主体材料可使喷涂料具有较好的喷涂性。
在一些具体的实施例中,所述的宜兴泥或苏州土,其颗粒度为180~320目,SiO2≥35%,可使喷涂料粘性增加,降低喷涂反弹率。
本发明提供的用于渣罐的阻热喷涂料,同样可以用于渣包,达到渣罐/渣包保温的目的,使渣罐/渣包中液态高温渣能降温速度减慢,从而实现上滚筒渣处理,并具有不粘罐的作用。为达到保温的目的,引入高铝棉,并加入发泡剂,从而有效达到降低体密,降低导热系数的目的。
本发明还提供了所述的用于渣罐的阻热喷涂料的制备方法,具体的步骤为:(1)将石英砂或回用高铝砖粉、宜兴泥或苏州土、保水剂、发泡剂进行混合3~5分钟搅拌均匀,制作预混合粉;(2)将高铝棉加入搅拌机,然后加入水进行搅拌1~3min,再加入预混合粉进行搅拌3~5min,最后加入液体结合剂进行搅拌均匀,并通过加入5~10%的水调整喷涂料最终料性,使得料性蓬松粘稠;(3)将混合好的喷涂料放入槽罐中进行困料1h以上,使喷涂料中的宜兴泥充分释放粘性,然后使用。
根据上述制备方法得到的用于渣罐的阻热喷涂料的体积密度≤1.7g/cm3;烘干后的体积密度≤1.0g/cm3;500℃导热系数≤0.18W/(m·K);烘干后不开裂;500℃烘干收缩率≤10%;喷涂不反弹,粘附力≥2000N。
本发明公开的渣罐阻热喷涂料于2021年7月在宝钢开始实施,其粘附性好、不反弹、强度高、保温效果好、翻渣罐容易、不粘渣、提高了渣罐的使用效率,使渣罐中的高温液体渣可直接进行滚筒渣处理,缩短渣处理流程,便于渣铁分离。
为了能够更清楚地描述本发明的技术内容,下面结合具体实施例来进行进一步的描述。
本发明的渣罐阻热喷涂料的理化检测指标如表1所示:
表1
实施例1
一种用于渣罐的阻热喷涂料,原料重量百分比如表2所示。
表2
所述的阻热喷涂料的制备方法为:
(1)将26.5%石英砂、12%宜兴泥、0.15%羟丙基甲基纤维素、0.02%十二烷基硫酸钠进行混合3~5分钟搅拌均匀,制作预混合粉;(2)将10%高铝棉加入搅拌机,然后加入36.33%的水进行搅拌1~3min,再加入预混合粉进行搅拌3~5min,最后加入10%液体结合剂进行搅拌均匀,并通过加入5%的水调整喷涂料最终料性,料性蓬松粘稠。(3)将混合好的喷涂料放入槽罐中进行困料24h,使喷涂料中的宜兴泥充分释放粘性,然后使用。
本实施例得到的用于渣罐的阻热喷涂料的理化指标检测如表3所示:
表3
由表3中的数据可以得出,本实施例得到的渣罐阻热喷涂料各项性能均达到要求,施工喷涂无回弹,收缩小,无开裂,保温效果好,使用中翻渣容易,渣罐装高温液态渣进行滚筒渣处理温降慢,满足客户要求,大大提高了生产效率。
实施例2
一种用于渣罐的阻热喷涂料,原料重量百分比如表4所示。
表4
所述的阻热喷涂料的制备方法为:
(1)将30.92%回用高铝砖粉、10%宜兴泥、0.1%羟丙基甲基纤维素、0.06%十二烷基硫酸钠混合3~5分钟搅拌均匀,制作预混合粉;(2)将8%高铝棉加入搅拌机,然后加入35.92%的水进行搅拌1~3min,再加入预混合粉进行搅拌3~5min,最后加入8%钾水玻璃进行搅拌均匀,并通过加入7%的水调整喷涂料最终料性,料性蓬松粘稠;(3)将混合好的喷涂料放入槽罐中进行困料8h,使喷涂料中的宜兴泥充分释放粘性,然后使用。
本实施例得到的渣罐阻热喷涂料的理化指标检测如表5所示:
表5
由表5中的数据可以得出,本实施例得到的渣罐阻热喷涂料各项性能均达到要求,施工喷涂无回弹,收缩小,无开裂,保温效果好,使用中翻渣容易,渣罐装高温液态渣进行滚筒渣处理温降慢,满足客户要求,大大提高了生产效率。
实施例3
一种用于渣罐的阻热喷涂料,原料重量百分比如表6所示。
表6
所述的阻热喷涂料的制备方法为:
(1)将33.42%石英砂、8%苏州土、0.1%羟丙基甲基纤维素、0.08%十二烷基硫酸钠进行混合3~5分钟搅拌均匀,制作预混合粉;(2)将6%高铝棉加入搅拌机,然后加入35.4%的水进行搅拌1~3min,再加入预混合粉进行搅拌3~5min,最后加入8%液体磷酸二氢铝进行搅拌均匀,并通过加入9%的水调整喷涂料最终料性,料性蓬松粘稠;(3)将混合好的喷涂料放入槽罐中进行困料1h,使喷涂料中的苏州土释放粘性,然后使用。
本实施例得到的渣罐阻热喷涂料的理化指标检测如表7所示:
表7
由表7中的数据可以得出本实施例得到的渣罐阻热喷涂料各项性能均达到要求,施工喷涂无回弹,收缩小,无开裂,保温效果好,使用中翻渣容易,渣罐装高温液态渣进行滚筒渣处理温降慢,满足客户要求,大大提高了生产效率。
比较例1
一种用于渣罐的阻热喷涂料,原料重量百分比如表8所示。
表8
所述的阻热喷涂料的制备方法为:
(1)将26.5%石英砂、10%宜兴泥、0.15%羟丙基甲基纤维素、0.02%十二烷基硫酸钠进行混合3~5分钟搅拌均匀,制作预混合粉;(2)将10%海泡石纤维加入搅拌机,然后加入36.33%的水进行搅拌1~3min,再加入预混合粉进行搅拌3~5min,最后加入10%钠水玻璃进行搅拌均匀,并通过加入5%的水调整喷涂料最终料性,料性蓬松粘稠;(3)将混合好的喷涂料放入槽罐中进行困料24h,使喷涂料中的宜兴泥释放粘性,然后使用。
本实施例得到的渣罐阻热喷涂料的理化指标检测如表9所示:
表9
由表9中的数据可以得出,比较例得到的渣罐阻热喷涂料高温下收缩严重,体积密度高,导热系数高,保温效果差,未达到产品理化指标要求,不能上滚筒渣处理,对比例高铝棉换成海泡石纤维,实验数据说明了高铝棉比海泡石纤维更有效降低喷涂料体积密度,降低导热系数,且使用温度高。
比较例2
一种用于渣罐的阻热喷涂料,原料重量百分比如表10所示。
表10
所述的阻热喷涂料的制备方法为:
(1)将33.42%石英砂、8%苏州土、0.1%羟丙基甲基纤维素进行混合3~5分钟搅拌均匀,制作预混合粉;(2)将6%高铝棉加入搅拌机,然后加入39.48%的水进行搅拌1~3min,再加入预混合粉进行搅拌3~5min,最后加入8%磷酸二氢铝进行搅拌均匀,并通过加入5%水调整喷涂料最终料性,料性蓬松粘稠;(3)将混合好的喷涂料放入槽罐中进行困料24h,使喷涂料中的苏州土释放粘性,然后使用。
本实施例得到的渣罐阻热喷涂料的理化指标检测如表11所示:
表11
由表11中的数据可以得出,比较例得到的渣罐阻热喷涂料高温下收缩严重,体积密度高,导热系数高,保温效果差,未达到产品理化指标要求,不能上滚筒渣处理,对比例中未加入发泡剂十二烷基硫酸钠,喷涂料体积密度过高,未达到使用要求,也反应了十二烷基硫酸钠发泡降低体积密度,从而降低导热系数的作用。
上述列举实施例对一种渣罐阻热喷涂料及其制备方法进行了详细的描述,只是举例说明而不是限定性的,可按照其所限定的范围列举出多个实施例,因此在不脱离本发明主体构思下的修改和变化,都应属于本发明保护的范围之内。
Claims (7)
1.一种用于渣罐的阻热喷涂料,其特征在于,所述的阻热喷涂料的组成质量百分包括:高铝棉5~10%;石英砂或回用高铝砖粉25~40%;宜兴泥或苏州土7~12%;液体结合剂5~10%;保水剂0.05~0.5%;发泡剂0.01~0.1%;水40~50%;
所述的液体结合剂为液体磷酸二氢铝、硫酸铝溶液、钠水玻璃、钾水玻璃、硅溶胶中的一种或多种;
所述的高铝棉为硅酸铝纤维棉,主含量为Al2O3+SiO2≥80%。
2.根据权利要求1所述的用于渣罐的阻热喷涂料,其特征在于:所述的发泡剂为十二烷基硫酸钠。
3.根据权利要求1所述的用于渣罐的阻热喷涂料,其特征在于:所述的石英砂或回用高铝砖粉,其主含量为Al2O3+SiO2≥80%,颗粒度为20~200目。
4.根据权利要求1所述的用于渣罐的阻热喷涂料,其特征在于:所述的宜兴泥或苏州土,其颗粒度为180~320目,SiO2≥35%。
5.根据权利要求1所述的用于渣罐的阻热喷涂料,其特征在于:所述的高铝棉经喷吹成型。
6.一种权利要求1至5中任一项所述的用于渣罐的阻热喷涂料的制备方法,其特征在于:所述的制备方法包括以下步骤:
(1)将石英砂或回用高铝砖粉、宜兴泥或苏州土、保水剂、发泡剂进行混合3~5分钟搅拌均匀,制作预混合粉;
(2)将高铝棉加入搅拌机,然后加入水进行搅拌1~3min,再加入预混合粉进行搅拌3~5min,最后加入液体结合剂进行搅拌均匀,并通过加入5~10%的水调整喷涂料最终料性;
(3)将混合好的喷涂料放入槽罐中进行困料1h以上。
7.根据权利要求6所述的用于渣罐的阻热喷涂料的制备方法,其特征在于,所述的阻热喷涂料的体积密度≤1.7g/cm3;烘干后的体积密度≤1.0g/cm3;500℃导热系数≤0.18W/(m·K);烘干后不开裂;500℃烘干收缩率≤10%;喷涂不反弹,粘附力≥2000N。
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