CN114538901A - 一种炼铁烧结机风箱支管用高强耐磨浇注料 - Google Patents
一种炼铁烧结机风箱支管用高强耐磨浇注料 Download PDFInfo
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Abstract
本申请提供的炼铁烧结机风箱支管用高强耐磨浇注料,它由如下重量份的原料制备而成:粒度为5~8mm的棕刚玉8~12份;粒度为3~5mm的棕刚玉20~30份;粒度为1~3mm的棕刚玉15~25份;粒度为0~1mm的棕刚玉8~12份;过筛目数不小于200目的致密刚玉6~8份;过筛目数不小于325目的微硅粉6~8份;纯铝酸钙水泥16~20份、耐热钢纤维2~4份、聚羧酸高效减水剂0.04~0.06份、柠檬酸0.04~0.06份、三聚磷酸钠0.4~0.6份。采用本申请提供的浇注料,以风箱钢结构为模具直接浇注为预制件,可对风箱支管进行快速安装及更换,不但解决了烧结机风箱受高温气流冲刷风箱变形问题,且由于本申请提供的预制件具有优异的耐火、耐酸、抗腐蚀等特性,可使风箱使用寿命提高1倍以上,显著降低了漏风率。
Description
技术领域
本发明属于耐火材料制备技术领域,具体涉及了一种炼铁烧结机风箱支管用高强耐磨浇注料。
背景技术
目前高炉炼铁仍是生铁生产的主流,其生铁产量约占总量的85%。近年来我国钢产量快速增加,对铁矿石需求量快速上升,因此降低炼铁生产成本具有重要的经济效益。现代高炉主要铁矿石料结构为高碱度烧结矿+球团矿,其中烧结矿因生产成本低,在高炉冶炼中占据主导作用,随着全球铁矿石资源的日渐匮乏,提高烧结矿入炉率已成为高炉降本的主要措施。烧结机是生产烧结矿的主要设备,其的高质、高效、环保、节能、低耗生产已成为行业技术攻关方向。
烧结机适用于铁矿石的烧结专业,它是抽风烧结的主体设备,可见不同成分、不同粒度的精矿粉、富矿粉烧结成块,在烧结过程中物料的磨损、烟气冲刷和烟气中SO2等酸性气体的腐蚀等作用,导致烧结机风箱及支管钢结构损坏严重,寿命很短,不得已在烧结机风箱支管内衬涂抹一层保护料来防烟气冲刷耐磨涂层或加隔热层,但经高温煤气流长期冲刷,内衬涂层或隔热层会大面积脱落,造成风箱钢板变形、刷透,漏风面积日渐增大,导致电耗大幅度增加,且造成烧结矿质量下降,人员劳动强度增加。因此,针对烧结机使用过程中需频繁停机对风箱内衬修补的现状,降低烧结机漏风率和提升烧结机风箱使用寿命,是当代烧结机的发展趋势。
耐火浇注料是一种由耐火物料加入一定量结合剂制成的粒状和粉状材料,具有较高流动性,以浇注方式成型的不定形耐火材料。其通过原料、工艺优化,可获得高强度、高耐磨性能。
因此,本申请针对烧结机使用过程中需频繁停机对风箱内衬修补的现状,提出一种可替换支管内衬,可应用于炼铁烧结机风箱支管用的高强耐磨浇注料,采用该浇注料可浇注为预制件,可直接与烧结机风管进行组装,以期降低烧结机漏风率和提升烧结机风箱使用寿命。
发明内容
本发明的目的就在于为解决现有技术的不足而提供一种应用于炼铁烧结机风箱支管用高强耐磨浇注料。
本发明的目的是以下述技术方案实现的:
一种炼铁烧结机风箱支管用高强耐磨浇注料,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉8~12份;
粒度为3~5mm的棕刚玉20~30份;
粒度为1~3mm的棕刚玉15~25份;
粒度为0~1mm的棕刚玉8~12份;
过筛目数不小于200目的致密刚玉6~8份;
过筛目数不小于325目的微硅粉6~8份;
纯铝酸钙水泥16~20份、耐热钢纤维2~4份、聚羧酸高效减水剂0.04~0.06份、柠檬酸0.04~0.06份、三聚磷酸钠0.4~0.6份。
优选的,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉10份;
粒度为3~5mm的棕刚玉25份;
粒度为1~3mm的棕刚玉20份;
粒度为0~1mm的棕刚玉10份;
过筛目数不小于200目的致密刚玉7份;
过筛目数不小于325目的微硅粉7份;
纯铝酸钙水泥18份、耐热钢纤维3份、聚羧酸高效减水剂0.05份、柠檬酸0.05份、三聚磷酸钠0.5份。
优选的,所述棕刚玉中Al2O3质量百分含量≥95%。
优选的,所述致密刚玉中Al2O3质量百分含量≥99%。
优选的,所述耐热钢纤维为446钢纤维。
优选的,所述聚羧酸高效减水剂减水率>15%。
本发明还提供了一种炼铁烧结机风箱耐磨支管预制件,它为采用如上所述的浇注料浇注而成。
本申请制备得到的浇注料,具有优异的耐磨、耐腐蚀、抗酸、抗碱性能,采用本申请提供的浇注料,以风箱钢结构为模具直接浇注为预制件,可对风箱支管进行快速安装及更换,不但解决了烧结机风箱受高温气流冲刷风箱变形问题,且由于本申请提供的预制件具有优异的耐火、耐酸、抗腐蚀等特性,可使风箱使用寿命提高1倍以上,显著降低了漏风率(<10%),大大减少了风箱内衬耐磨材料消耗,也降低了烧结机能耗,提高烧结机产量,在节约耐材资源的同时,也降低了烧结矿的生产成本,具有显著的经济和社会效益。
附图说明
图1是本申请提供的炼铁烧结机风箱耐磨支管预制件的照片。
具体实施方式
由于风箱支管长期受高温烟气冲刷以及和烟气中SO2等酸性气体的腐蚀,因此要求预制件浇注料具有较强的耐磨、耐腐蚀性能。现有技术中的耐火浇注料并不能满足上述要求,本申请通过对原料进行优化,获得了理想的浇注料。具体的,本发明提供的炼铁烧结机风箱支管用高强耐磨浇注料,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉8~12份;
粒度为3~5mm的棕刚玉20~30份;
粒度为1~3mm的棕刚玉15~25份;
粒度为0~1mm的棕刚玉8~12份;
过筛目数不小于200目的致密刚玉6~8份;
过筛目数不小于325目的微硅粉6~8份;
纯铝酸钙水泥16~20份、耐热钢纤维2~4份、聚羧酸高效减水剂0.04~0.06份、柠檬酸0.04~0.06份、三聚磷酸钠0.4~0.6份。
本申请采用连续级配的棕刚玉为主要骨料,并采用粒度较小的致密刚玉替换部分棕刚玉,棕刚玉由钒土直接制备而成,而致密刚玉由氧化铝制成,纯度更高,相比棕刚玉具有更加优异的耐磨、抗侵蚀、抗酸、抗碱性能,进而也可提高浇注料的耐磨、抗侵蚀、抗酸、抗碱性能。纯铝酸钙水泥,氧化铝含量较高,可良好的将不同粒径分布的棕刚玉结合,相比普通水泥可提高结合强度。微硅粉粒度小,比表面积大,具有良好的填充性能,可减少用水量,提高浇注料的体积密度和流动性,耐热钢纤维,可防止混料时棕刚玉和纯铝酸钙水泥在高温状态下产生涨差,并能有效提高产品韧性和抗冲击强度。在上述原料基础上,本申请采用聚羧酸高效减水剂替换现有技术中经常使用的六偏磷酸钠,并和三聚磷酸钠配合,作为分散剂和减水剂使用,经研究发现,聚羧酸高效减水剂相比其他原料,对棕刚玉体系的减水作用更加显著,与三聚磷酸钠配合使用后,进一步增强了减水性,提高了浇注料强度和耐磨性能,但是聚羧酸高效减水剂和三聚磷酸钠配合使用后,凝固速度过快,需加入一定的柠檬酸,减缓其凝结性能。
因此,在上述原料的综合作用下,本申请制备得到的浇注料,具有优异的耐磨、耐腐蚀、抗酸、抗碱性能,采用本申请提供的浇注料,以风箱钢结构为模具直接浇注为预制件(如图1所示),可对风箱支管进行快速安装及更换,不但解决了烧结机风箱受高温气流冲刷风箱变形问题,且由于本申请提供的预制件具有优异的耐火、耐酸、抗腐蚀等特性,可使风箱使用寿命提高1倍以上,显著降低了漏风率(<10%),大大减少了风箱内衬耐磨材料消耗,也降低了烧结机能耗,提高烧结机产量,在节约耐材资源的同时,也降低了烧结矿的生产成本,具有显著的经济和社会效益。
优选的,本发明提供的炼铁烧结机风箱支管用高强耐磨浇注料,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉10份;
粒度为3~5mm的棕刚玉25份;
粒度为1~3mm的棕刚玉20份;
粒度为0~1mm的棕刚玉10份;
过筛目数不小于200目的致密刚玉7份;
过筛目数不小于325目的微硅粉7份;
纯铝酸钙水泥18份、耐热钢纤维3份、聚羧酸高效减水剂0.05份、柠檬酸0.05份、三聚磷酸钠0.5份。
优选的,棕刚玉中Al2O3质量百分含量≥95%。
优选的,致密刚玉中Al2O3质量百分含量≥99%。
通过限定原料中有效成分的含量,可增强原料作用,有助于提高产品性能。
优选的,耐热钢纤维为446钢纤维,其中含有铬,具有更好的高温强度和高温耐腐蚀性。
优选的,聚羧酸高效减水剂减水率>15%。
实施例1
本实施例提供的炼铁烧结机风箱支管用高强耐磨浇注料,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉10份;
粒度为3~5mm的棕刚玉25份;
粒度为1~3mm的棕刚玉20份;
粒度为0~1mm的棕刚玉10份;
过筛目数不小于200目(75um)的致密刚玉7份;
过筛目数不小于325目(45um)的微硅粉7份;
纯铝酸钙水泥18份、446耐热钢纤维3份、聚羧酸高效减水剂0.05份(减水率20%)、柠檬酸0.05份、三聚磷酸钠0.5份。
其中,棕刚玉中Al2O3质量百分含量≥95%,致密刚玉中Al2O3质量百分含量≥99%。
将上述原料采用常规方法混合均匀,即可得到耐磨浇注料。
采用常规方法对本实施例得到的耐磨浇注料性能进行分析,结果如下所示:体积密度3.05g/cm3,耐火温度1380℃,1100℃耐压强度152Mpa,线变化率%(800℃3h)0.090,耐磨性(1100℃3h)4.3;各项性能均优于专利CN202110109949.5提供的管道耐磨浇注料。
采用该实施例提供的浇注料浇注的预制件,经多家钢铁公司烧结机使用,经2019年12月使用,截至2021年5月风箱结构完整,风箱寿命延长一倍以上,漏风率降低至10%以下,265m2烧结机年产量较使用前提高47万吨,每吨烧结矿按800元计算,多出经济效益为3760万元。
实施例2
本实施例提供的炼铁烧结机风箱支管用高强耐磨浇注料,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉12份;
粒度为3~5mm的棕刚玉25份;
粒度为1~3mm的棕刚玉18份;
粒度为0~1mm的棕刚玉11份;
过筛目数不小于200目的致密刚玉7份;
过筛目数不小于325目的微硅粉7份;
纯铝酸钙水泥18份、耐热钢纤维3份、聚羧酸高效减水剂0.06份、柠檬酸0.06份、三聚磷酸钠0.5份。其他参数同实施例1。
实施例3
本实施例提供的炼铁烧结机风箱支管用高强耐磨浇注料,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉8份;
粒度为3~5mm的棕刚玉30份;
粒度为1~3mm的棕刚玉15份;
粒度为0~1mm的棕刚玉10份;
过筛目数不小于200目的致密刚玉8份;
过筛目数不小于325目的微硅粉8份;
纯铝酸钙水泥20份、耐热钢纤维4份、聚羧酸高效减水剂0.05份、柠檬酸0.05份、三聚磷酸钠0.4份。其他参数同实施例1。
实施例4
本实施例提供的炼铁烧结机风箱支管用高强耐磨浇注料,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉11份;
粒度为3~5mm的棕刚玉22份;
粒度为1~3mm的棕刚玉20份;
粒度为0~1mm的棕刚玉10份;
过筛目数不小于200目的致密刚玉6份;
过筛目数不小于325目的微硅粉6份;
纯铝酸钙水泥16份、耐热钢纤维2份、聚羧酸高效减水剂0.05份、柠檬酸0.05份、三聚磷酸钠0.6份。其他参数同实施例1。
尽管已描述了本发明的优选实施例,但本领域内的技术人员一旦得知了基本创造性概念,则可对这些实施例作出另外的变更和修改。所以,所附权利要求意欲解释为包括优选实施例以及落入本发明范围的所有变更和修改。显然,本领域的技术人员可以对本发明进行各种改动和变型而不脱离本发明的精神和范围。这样,倘若本发明的这些修改和变型属于本发明权利要求及其等同技术的范围之内,则本发明也意图包含这些改动和变型在内。
Claims (7)
1.一种炼铁烧结机风箱支管用高强耐磨浇注料,其特征在于,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉8~12份;
粒度为3~5mm的棕刚玉20~30份;
粒度为1~3mm的棕刚玉15~25份;
粒度为0~1mm的棕刚玉8~12份;
过筛目数不小于200目的致密刚玉6~8份;
过筛目数不小于325目的微硅粉6~8份;
纯铝酸钙水泥16~20份、耐热钢纤维2~4份、聚羧酸高效减水剂0.04~0.06份、柠檬酸0.04~0.06份、三聚磷酸钠0.4~0.6份。
2.如权利要求1所述的炼铁烧结机风箱支管用高强耐磨浇注料,其特征在于,它由如下重量份的原料制备而成:
粒度为5~8mm的棕刚玉10份;
粒度为3~5mm的棕刚玉25份;
粒度为1~3mm的棕刚玉20份;
粒度为0~1mm的棕刚玉10份;
过筛目数不小于200目的致密刚玉7份;
过筛目数不小于325目的微硅粉7份;
纯铝酸钙水泥18份、耐热钢纤维3份、聚羧酸高效减水剂0.05份、柠檬酸0.05份、三聚磷酸钠0.5份。
3.如权利要求1所述的炼铁烧结机风箱支管用高强耐磨浇注料,其特征在于,
所述棕刚玉中Al2O3质量百分含量≥95%。
4.如权利要求1所述的炼铁烧结机风箱支管用高强耐磨浇注料,其特征在于,
所述致密刚玉中Al2O3质量百分含量≥99%。
5.如权利要求1所述的炼铁烧结机风箱支管用高强耐磨浇注料,其特征在于,
所述耐热钢纤维为446钢纤维。
6.如权利要求1所述的炼铁烧结机风箱支管用高强耐磨浇注料,其特征在于,
所述聚羧酸高效减水剂减水率>15%。
7.一种炼铁烧结机风箱耐磨支管预制件,其特征在于,它为采用如权利要求1~6任一项所述的浇注料浇注而成。
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