CN114736002B - 一种用于焚烧炉的赤泥基料的耐高温氯腐蚀的陶瓷涂层的制备方法 - Google Patents

一种用于焚烧炉的赤泥基料的耐高温氯腐蚀的陶瓷涂层的制备方法 Download PDF

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CN114736002B
CN114736002B CN202210312674.XA CN202210312674A CN114736002B CN 114736002 B CN114736002 B CN 114736002B CN 202210312674 A CN202210312674 A CN 202210312674A CN 114736002 B CN114736002 B CN 114736002B
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徐应根
俞卫新
初希
吴雪儒
申伟伟
邹宝诚
王平
牛晓鸣
欧阳权
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Clp Huachuang Power Technology Research Co ltd
HEFEI KEDE SURFACE TECHNOLOGY CO LTD
Clp International New Energy Hainan Co ltd
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Abstract

本发明涉及一种用于焚烧炉的赤泥基料的耐高温氯腐蚀的陶瓷涂层的制备方法，属于高温涂层技术领域。涂料由骨料、粘结剂和分散剂混合均匀制成；骨料由赤泥、氧化铝、二氧化硅和铬绿混合均匀制得，粘结剂由磷酸、氢氧化铝、氧化镁、氧化锌和水混合均匀制得。以赤泥为基料的耐高温氯腐蚀的陶瓷涂层的结合强度26.5～31.3Mpa、耐高温腐蚀性能指数为0.119～0.163 mg/mm2、抗热震性能指数为7～16。本发明以赤泥为基料制备的陶瓷涂层，在焚烧炉的表面形成一层连续而致密的釉质保护膜，有效阻止了垃圾焚烧炉表面的高温氯腐蚀，从而有效提高了焚烧炉的使用寿命和运行的安全稳定性。

Description

一种用于焚烧炉的赤泥基料的耐高温氯腐蚀的陶瓷涂层的制 备方法
技术领域
本发明属于高温防护涂层技术领域，具体涉及一种耐高温氯腐蚀陶瓷涂层的制备方法。
背景技术
垃圾焚烧炉的长期稳定运行是火力发电企业的工作重点，但在焚烧炉中存在高温氯腐蚀的问题，从而严重影响了焚烧炉的安全运行，缩短焚烧炉使用寿命。涂层防护时解决这些问题的一种重要途径。
为了解决电站锅炉的结焦问题，研究人员开发了一系列高温防护涂层材料，例如：一种以镍基合金为基料的涂层，采用常规的非真空气雾化法或水雾法，易出现熔体过于黏稠现象，导致雾化困难，相应的成品合金粉末收得率低，且合金粉末含氧量过高，后续激光熔覆易出现裂纹、气孔等缺陷。
赤泥具有熔点高、化学稳定性好、可增加涂料粘稠度等特点，其不仅能引入符合耐高温氯腐蚀涂层性能要求的化学成分，而且来源广泛，价格低廉，无污染，同时还解决了废物回收利用的问题。
发明内容
为了实现垃圾焚烧炉的防护陶瓷涂层具有耐高温氯腐蚀、抗热震性良好、化学稳定性好，本发明提供一种用于焚烧炉的赤泥基料的耐高温氯腐蚀的陶瓷涂层的制备方法。
一种用于焚烧炉的赤泥基料的耐高温氯腐蚀的陶瓷涂层的制备操作步骤如下：
（1）制备粘结剂
将6～10.5g氢氧化铝、3～6g氧化镁、6～9g氧化锌和37～52.5g去离子水，依次缓慢加入质量浓度85%的75～90g磷酸溶液中，混合均匀，得到半透明的粘结剂；
（2）制备骨料
将50～70g赤泥、20～30g氧化铝、10～20g二氧化硅和5～10g铬绿充分混合均匀，得到骨料；
（3）制备陶瓷涂层材料
将上述粘结剂、骨料和1～5g分散剂聚丙烯酸充分搅拌均匀得到耐高温氯腐蚀的陶瓷涂层材料；
（4）制备金属过渡层
对待喷涂部位进行喷砂处理，直至喷砂表面清洁度达到Sa3.0级或以上，表面粗糙度达到15～25μm，喷砂处理后立即进行电弧喷涂Ni95Al5镍铝涂层做为金属过渡层，厚度为150～200μm；
（5）制备耐高温氯腐蚀的陶瓷涂层
在金属过渡层上进行刷涂上述涂料，每次刷涂阴干后厚度为50～100μm，阴干后再次刷涂一遍；对阴干后的涂层进行升温固化，升温速率为2℃/min，保温温度为650℃，保温时间为2小时，得到耐高温氯腐蚀的陶瓷涂层；
以赤泥为基料的耐高温氯腐蚀的陶瓷涂层的结合强度26.5～31.3Mpa、耐高温腐蚀性能指数为0.119～0.163 mg/mm2、抗热震性能指数为7～16。
本发明的有益技术效果体现在以下方面：
1.本发明以赤泥为陶瓷主要基料，赤泥来源于铝土矿中的具有污染性的残渣，将赤泥资源化合理利用，既解决了赤泥处理对环境污染的问题，又可以对锅炉受热面进行较好的防护；在锅炉受热面的设计寿命之内以赤泥为基料的陶瓷涂层的实际使用寿命可超过12000小时。
2.赤泥的主要组成为二氧化硅（SiO2）、三氧化二铝（Al2O3）、氧化钙（CaO）、和三氧化二铁（Fe2O3），以赤泥为骨料的热化学反应陶瓷涂层化学性质稳定，不与腐蚀性物质反应，具有良好的耐高温腐蚀性能；组成的陶瓷涂料与碳钢的热膨胀系数相当，因此具有较高的结合强度不易脱落；热化学反应涂层致密度高表面平整可减少表面的结焦和结渣。
附图说明
图1为实施例1制备的耐高温氯腐蚀热化学反应陶瓷涂层的显微形貌图。
图2为实施例2制备的耐高温氯腐蚀热化学反应陶瓷涂层的显微形貌图。
图3为实施例3制备的耐高温氯腐蚀热化学反应陶瓷涂层的显微形貌图。
图4为实施例4制备的耐高温氯腐蚀热化学反应陶瓷涂层的显微形貌图。
具体实施方式
为了更好地理解本发明的技术方案，下面结合具体实施例对本发明作进一步说明。
实施例1
一种以赤泥为基料的耐高温氯腐蚀热化学反应陶瓷涂层的制备步骤如下：
（1）将氢氧化铝6g、氧化镁3g、氧化锌6g和去离子水52.5g，依次缓慢加入到75g质量浓度85%的磷酸溶液中均匀混合成半透明溶液，得到粘结剂。
（2）将赤泥70g、氧化铝30g、二氧化硅20g和铬绿10g充分混合均匀，得到骨料。
（3）将上述粘结剂、骨料和5g分散剂聚丙烯酸充分搅拌均匀，得到耐高温氯腐蚀的热化学反应陶瓷涂层涂料。
（4）对垃圾焚烧炉表面待喷涂的部位进行喷砂处理，直至喷砂表面清洁度达到Sa3.0级以上；喷砂处理后立即进行电弧喷涂Ni95Al5镍铝涂层做为金属过渡层，金属过渡层的厚度为150μm。
（5）在金属过渡层上刷涂上述陶瓷涂层涂料，每次刷涂的厚度为50μm，阴干；再次刷涂一遍，阴干；进行升温固化，升温速率为2℃/min，保温温度为650℃，保温时间为2小时，得到耐高温氯腐蚀的热化学反应陶瓷涂层。
本实施例1的耐高温氯腐蚀的热化学反应陶瓷涂层显微表面见图1；通过GB/T8642-2002检测复合陶瓷涂层结合强度为31.3 Mpa；通过650℃下3mg/cm2的KCl和Na2SO4混合盐保温60小时检测复合陶瓷涂层的耐高温腐蚀性能，质量变化为0.119 mg/mm2；通过扫描电子显微镜测量涂层厚度为160μm；通过800℃-20℃水冷重复至涂层脱落次数检测复合陶瓷涂层的抗热震性能，次数为16次。
实施例2
一种以赤泥为基料的耐高温氯腐蚀热化学反应陶瓷涂层的制备步骤如下：
（1）将氢氧化铝7.5g、氧化镁3g、氧化锌6g和去离子水52.5g，依次缓慢加入到82.5g质量浓度85%的磷酸溶液中均匀混合成半透明溶液，得到粘结剂。
（2）将赤泥65g、氧化铝28g、二氧化硅16g和铬绿8g充分混合均匀，得到骨料。
（3）将上述粘结剂、骨料和4g分散剂聚丙烯酸充分搅拌均匀，得到耐高温氯腐蚀的热化学反应陶瓷涂层涂料。
（4）对垃圾焚烧炉表面待喷涂的部位进行喷砂处理，直至喷砂表面清洁度达到Sa3.0级以上；喷砂处理后立即进行电弧喷涂Ni95Al5镍铝涂层做为金属过渡层，金属过渡层的厚度为150μm。
（5）在金属过渡层上刷涂上述陶瓷涂层涂料，每次刷涂的厚度为50μm，阴干；再次刷涂一遍，阴干；进行升温固化，升温速率为2℃/min，保温温度为650℃，保温时间为2小时，得到耐高温氯腐蚀的热化学反应陶瓷涂层。
本实施例2的耐高温氯腐蚀的热化学反应陶瓷涂层显微表面见图2；通过GB/T8642-2002检测复合陶瓷涂层结合强度为27.8 Mpa；通过650℃下3mg/cm2的KCl和Na2SO4混合盐保温60小时检测复合陶瓷涂层的耐高温腐蚀性能，质量变化为0.121 mg/mm2；通过扫描电子显微镜测量涂层厚度为150μm；通过800℃-20℃水冷重复至涂层脱落次数检测复合陶瓷涂层的抗热震性能，次数为9次。
实施例3
一种以赤泥为基料的耐高温氯腐蚀热化学反应陶瓷涂层的制备步骤如下：
（1）将氢氧化铝9g、氧化镁4.5g、氧化锌7.5g和去离子水45g，依次缓慢加入到90g质量浓度85%的磷酸溶液中均匀混合成半透明溶液，得到粘结剂。
（2）将赤泥60g、氧化铝24g、二氧化硅14g和铬绿6g充分混合均匀，得到骨料。
（3）将上述粘结剂、骨料和2g分散剂聚丙烯酸充分搅拌均匀，得到耐高温氯腐蚀的热化学反应陶瓷涂层涂料。
（4）对垃圾焚烧炉表面待喷涂的部位进行喷砂处理，直至喷砂表面清洁度达到Sa3.0级以上；喷砂处理后立即进行电弧喷涂Ni95Al5镍铝涂层做为金属过渡层，金属过渡层的厚度为150μm。
（5）在金属过渡层上刷涂上述陶瓷涂层涂料，每次刷涂的厚度为50μm，阴干；再次刷涂一遍，阴干；进行升温固化，升温速率为2℃/min，保温温度为650℃，保温时间为2小时，得到耐高温氯腐蚀的热化学反应陶瓷涂层。
本实施例3的耐高温氯腐蚀的热化学反应陶瓷涂层显微表面见图3；通过GB/T8642-2002检测复合陶瓷涂层结合强度为26.5 Mpa；通过650℃下3mg/cm2的KCl和Na2SO4混合盐保温60小时检测复合陶瓷涂层的耐高温腐蚀性能，质量变化为0.141 mg/mm2；通过扫描电子显微镜测量涂层厚度为200μm；通过800℃-20℃水冷重复至涂层脱落次数检测复合陶瓷涂层的抗热震性能，次数为7次。
实施例4
一种以赤泥为基料的耐高温氯腐蚀热化学反应陶瓷涂层的制备步骤如下：
（1）将氢氧化铝10.5g、氧化镁6g、氧化锌9g和去离子水37.5g，依次缓慢加入到90g质量浓度85%的磷酸溶液中均匀混合成半透明溶液，得到粘结剂。
（2）将赤泥50g、氧化铝20g、二氧化硅10g和铬绿5g充分混合均匀，得到骨料。
（3）将上述粘结剂、骨料和1g分散剂聚丙烯酸充分搅拌均匀，得到耐高温氯腐蚀的热化学反应陶瓷涂层涂料。
（4）对垃圾焚烧炉表面待喷涂的部位进行喷砂处理，直至喷砂表面清洁度达到Sa3.0级以上；喷砂处理后立即进行电弧喷涂Ni95Al5镍铝涂层做为金属过渡层，金属过渡层的厚度为150μm。
（5）在金属过渡层上刷涂上述陶瓷涂层涂料，每次刷涂的厚度为50μm，阴干；再次刷涂一遍，阴干；进行升温固化，升温速率为2℃/min，保温温度为650℃，保温时间为2小时，得到耐高温氯腐蚀的热化学反应陶瓷涂层。
本实施例4的耐高温氯腐蚀的热化学反应陶瓷涂层显微表面见图4；通过GB/T8642-2002检测复合陶瓷涂层结合强度为29.8 Mpa；通过650℃下3mg/cm2的KCl和Na2SO4混合盐保温60小时检测复合陶瓷涂层的耐高温腐蚀性能，质量变化为0.163 mg/mm2；通过扫描电子显微镜测量涂层厚度为180μm；通过800℃-20℃水冷重复至涂层脱落次数检测复合陶瓷涂层的抗热震性能，次数为14次。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (1)

1.一种用于焚烧炉的赤泥基料的耐高温氯腐蚀的陶瓷涂层的制备方法，其特征在于，操作步骤如下：
（1）制备粘结剂
将6～10.5g氢氧化铝、3～6g氧化镁、6～9g氧化锌和37～52.5g去离子水，依次缓慢加入质量浓度85%的75～90g磷酸溶液中，混合均匀，得到半透明的粘结剂；
（2）制备骨料
将50～70g赤泥、20～30g氧化铝、10～20g二氧化硅和5～10g铬绿充分混合均匀，得到骨料；
（3）制备陶瓷涂层材料
将上述粘结剂、骨料和1～5g分散剂聚丙烯酸充分搅拌均匀得到耐高温氯腐蚀的陶瓷涂层材料；
（4）制备金属过渡层
对待喷涂部位进行喷砂处理，直至喷砂表面清洁度达到Sa3.0级以上，喷砂处理后立即进行电弧喷涂Ni95Al5镍铝涂层做为金属过渡层，厚度为150～200μm；
（5）制备耐高温氯腐蚀的陶瓷涂层
在金属过渡层上进行刷涂上述涂料，每次刷涂阴干后厚度为50～100μm，阴干后再次刷涂一遍；对阴干后的涂层进行升温固化，升温速率为2℃/min，保温温度为650℃，保温时间为2小时，得到耐高温氯腐蚀的陶瓷涂层；
以赤泥为基料的耐高温氯腐蚀的陶瓷涂层的结合强度26.5～31.3Mpa、耐高温腐蚀性能指数为0.119～0.163 mg/mm2、抗热震性能指数为7～16。
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