CN115321965A - 一种无水炮泥及其制备方法 - Google Patents
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Abstract
本申请公开了一种无水炮泥,包括以下重量份的原料:轻量化耐火骨料15‑35重量份;含铝骨料0‑25重量份;焦炭5‑10重量份;碳化硅10‑20重量份;氮化硅铁10‑30重量份;矾土细粉3‑10重量份;广西白泥2‑10重量份;改质高温沥青2‑6重量份;添加剂8‑15重量份;并且,还外加结合剂12‑18重量份。本申请还提供上述无水炮泥的制备方法。本申请提供的无水炮泥,具有很好的透气性同时保持良好的强度,并且体积密度降低,高炉打进铁口孔道相同体积的炮泥,添加轻量化耐火骨料的炮泥重量更少,可以降低单位铁量无水炮泥消耗量。
Description
技术领域
本申请耐火材料技术领域,特别是涉及一种无水炮泥及其制备方法。
背景技术
炮泥是一种不定形的功能性耐火材料,随着高炉向大型化、高强度和长寿命方向发展,对炮泥的性能也提出了更高的要求,现在炮泥的功能不仅仅是堵塞铁口,还要具有保护炉缸的作用,炮泥已从单纯的消耗性耐火材料向功能性耐火材料转变。
为了充分的排净渣铁,高炉希望尽量缩短铁次间隔时间,尽早打开铁口,留给炮泥的烧结时间比较短。而为了让炮泥能够在较短的时间就具备较高的强度,需要炮泥具有良好的透气性,使得炮泥能够尽快烧结。另外炮泥原料中不可避免含有一些水分、气体和一些可挥发物,也需要通道排出,也要求炮泥具有良好的透气性,让这些气体挥发分通过气孔形成的通道排出。
传统上要改善炮泥的透气性,一般可以通过如下一些措施:
第一、增加焦炭:焦炭本身是多孔性的材料,但是焦炭较脆,硬度不高,易碎,加入量过多会影响炮泥的高温强度。
第二、增加炮泥的粗颗粒的比例,减少细粉的比例。但颗粒过多,细粉过少会使得细粉不能很好的包裹骨料,影响炮泥泥料的塑形,继而影响炮泥的打泥和涨铁口深度的性能,同时颗粒级配不合理也会造成炮泥不够致密,强度偏低。
发明内容
为解决上述技术问题,本发明的第一个目的为提供一种无水炮泥;本发明的第二个目的为提供上述无水炮泥的制备方法;本申请提供的无水炮泥,具有很好的透气性同时保持良好的强度,并且体积密度降低,高炉打进铁口孔道相同体积的炮泥,添加轻量化耐火骨料的炮泥重量更少,可以降低单位铁量无水炮泥消耗量。
本发明提供的技术方案如下:
一种无水炮泥,包括以下重量份的原料:
轻量化耐火骨料15-35重量份;
含铝骨料0-25重量份;
焦炭5-10重量份;
碳化硅10-20重量份;
氮化硅铁10-30重量份;
矾土细粉3-10重量份;
广西白泥2-10重量份;
改质高温沥青2-6重量份;
添加剂8-15重量份;
并且,还外加结合剂12-18重量份。
优选地,包括以下重量份的原料:
轻量化耐火骨料15-30重量份;
含铝骨料0-10重量份;
焦炭8-10重量份;
碳化硅10-15重量份;
氮化硅铁20-25重量份;
矾土细粉8-10重量份;
广西白泥2-5重量份;
改质高温沥青2-5重量份;
添加剂10-15重量份;
并且,还外加结合剂12-17重量份。
优选地,轻量化耐火骨料包括轻量化微孔刚玉、轻量化莫来石、微孔高强轻质氧化铝中的任意一种或多种;
轻量化耐火骨料包括粒径3-1mm的颗粒,以及粒径1-0mm的颗粒,粒径3-1mm的颗粒与粒径1-0mm的颗粒重量比为(1-2):1。
优选地,含铝骨料为矾土骨料和/或棕刚玉骨料;其中,矾土骨料包括粒径3-1mm的颗粒,以及粒径1-0mm的颗粒,棕刚玉骨料为粒径3-1mm的颗粒。
优选地,
添加剂包括膨胀剂和/或促烧结剂;
结合剂为焦油和/或树脂。
优选地,
膨胀剂为蓝晶石、石英砂中的任意一种或多种;
促烧结剂为金属硅粉、绢云母、75#硅铁合金粉中的任意一种或多种;
结合剂中,树脂为2-6重量份,其余为焦油。
优选地,碳化硅包括粒径为1-0mm的90碳化硅,以及粒径为0.074-0mm的90碳化硅;
粒径1-0mm的碳化硅与粒径0.074-0mm的碳化硅重量比为(2-2.5):1。
优选地,
焦炭包括粒径为3-1mm的颗粒,以及粒径为1-0mm的颗粒;
氮化硅铁粒径为0.088-0mm;
矾土细粉的粒径为0.088-0mm;
广西白泥的粒径为0.088-0mm;
改制高温沥青的粒径为0-1mm。
上述无水炮泥的制备方法,包括以下步骤:
粒径范围在3-1mm或1-0mm的物料为颗粒,其他粒径范围的物料为细粉;
将细粉配料,预混20min以上;
将颗粒配料,干混3min以上,加入80-85%结合剂,湿混1-5min,加入预混好的细粉,继续湿混5-10min,加入剩余结合剂,混碾30min以上;
挤出成型,包裹静置至少一周后使用。
优选地,挤出成型前还包括检测马夏值的步骤;
若马夏值在0.4-1.2MPa之间,合格,进行挤出操作;
若马夏值不合格则添加预混料或焦油调整马夏值至合格。
本申请提供一种无水炮泥,包括以下重量份的原料:轻量化耐火骨料15-35重量份;含铝骨料0-25重量份;焦炭5-10重量份;碳化硅10-20重量份;氮化硅铁10-30重量份;矾土细粉3-10重量份;广西白泥2-10重量份;改质高温沥青2-6重量份;添加剂8-15重量份;并且,还外加结合剂12-18重量份。
本申请通过选用本身就具有相当多微气孔的轻量化骨料作为炮泥的颗粒,利用轻量化骨料同时具有微孔化和高强度的特性,从而很好地解决炮泥的透气性,同时不降低炮泥的强度。同时,由于轻量化骨料体积密度相对较轻,还可以降低炮泥的体积密度,高炉打进铁口孔道相同体积的炮泥,添加轻量化耐火骨料的炮泥重量更少,可以降低单位铁量无水炮泥消耗量。
具体而言,本申请选用的轻量化骨料本身具有较高的强度,加工过程也不会破坏其微观结构,轻量化骨料基质界面形成良好的桥接、穿插和互锁结构,使得材料强度增加。因此所制备的无水炮泥的强度并不会降低,并在实际检测结果中得到印证。并且由于透气性的改善,烧结强度提高25%-40%。
同时,由于轻量化骨料比同材质骨料体积密度降低10%左右,因此添加轻量化骨料的方案炮泥体积密度降低了2%左右。
申请人在1080-3200M3的高炉上使用上述无水炮泥实验成果,铁口深度和出铁时间等主要铁口指标明显改善,打泥量不变,但是铁口深度合格率提高了5%以上,显示炮泥更容易涨铁口深度了,出铁时间延长了12-28min,日均铁次能够减少1次以上,但是单次堵口的炮泥用量因为炮泥体积密度的降低还能得到2%以上的降低。这样吨铁炮泥消耗能够降低12%以上。
其中,结合剂的重量,是在其他原料之外外加的。配料时将除结合剂以外的物料按比例进行配料,然后按需加入结合剂。
其中,90碳化硅的“90”表示其中SiC的含量。
其中,轻量化耐火材料通常是指体积密度介于轻质耐火材料和重质耐火材料之间,且具有较低的热导率和足够的承载能力以及良好的抗侵蚀性能的一类耐火材料。目前尚无轻量耐火材料与轻质耐火材料和重质耐火材料有关体积密度或气孔率的具体划分。本申请所采用的轻量化耐火骨料包括一些人工合成的轻量化骨料,还包括一些使用轻量化骨料制备的耐火材料使用之后回收加工而成的骨料。
本申请所用轻量化耐火骨料主要用于炮泥的骨料(即颗粒)部分,因为加工成细粉可能会破坏这种材料的微孔结构。
本申请提供的无水炮泥制备时,先根据物料粒径划分为颗粒或细粉。其中,粒径范围在3-1mm或1-0mm的物料为颗粒,其他粒径范围(粒径0.074-0mm、粒径0.088-0mm)的物料为细粉;然后将细粉配料,预混20min以上;将颗粒配料,干混3min以上,加入80-85%结合剂,湿混1-5min,加入预混好的细粉,继续湿混5-10min,加入剩余结合剂,混碾30min以上;挤出成型,包裹静置至少一周后使用。优选还包括检测马夏值的步骤。
具体实施方式
为了使本领域的技术人员更好地理解本申请中的技术方案,下面将对本申请实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本申请的一部分实施例,而不是全部的实施例。基于本申请中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本申请保护的范围。
本申请所用的原料来源和商品型号如下:
实施例1-4
物料配比如下表所示:
上述无水炮泥的生产方法:
粒径范围在3-1mm或1-0mm的物料为颗粒,其他粒径范围的物料为细粉;
将细粉配料,预混20min以上;
将颗粒配料,干混3min以上,加入80%结合剂,湿混1min,加入预混好的细粉,继续湿混5min,加入剩余结合剂,混碾30min以上;
检测马夏值;马夏值根据高炉设备状况按照实际经验确定范围(范围值在0.4-1.2MPa之间),若合格,则进行下一步;若马夏值不合格则添加预混料或焦油调整马夏值至合格;
对实施例1-4所制备的无水炮泥检测如下:
按照下表中的方法对本发明实施例制备的炼铁高炉用无水炮泥进行性能检测(制样方法参照《YB-T4196-2018高炉用无水炮泥》行业标准),检测结果如下:
对所公开的实施例的上述说明,使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下,在其它实施例中实现。因此,本发明将不会被限制于本文所示的这些实施例,而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (10)
1.一种无水炮泥,其特征在于,包括以下重量份的原料:
轻量化耐火骨料15-35重量份;
含铝骨料0-25重量份;
焦炭5-10重量份;
碳化硅10-20重量份;
氮化硅铁10-30重量份;
矾土细粉3-10重量份;
广西白泥2-10重量份;
改质高温沥青2-6重量份;
添加剂8-15重量份;
并且,还外加结合剂12-18重量份。
2.根据权利要求1所述的无水炮泥,其特征在于,包括以下重量份的原料:
轻量化耐火骨料15-30重量份;
含铝骨料0-10重量份;
焦炭8-10重量份;
碳化硅10-15重量份;
氮化硅铁20-25重量份;
矾土细粉8-10重量份;
广西白泥2-5重量份;
改质高温沥青2-5重量份;
添加剂10-15重量份;
并且,还外加结合剂12-17重量份。
3.根据权利要求1-2中任一项所述的无水炮泥,其特征在于,轻量化耐火骨料包括轻量化微孔刚玉、轻量化莫来石、微孔高强轻质氧化铝中的任意一种或多种;
轻量化耐火骨料包括粒径3-1mm的颗粒,以及粒径1-0mm的颗粒,粒径3-1mm的颗粒与粒径1-0mm的颗粒重量比为(1-2):1。
4.根据权利要求1-2中任一项所述的无水炮泥,其特征在于,含铝骨料为矾土骨料和/或棕刚玉骨料;其中,矾土骨料包括粒径3-1mm的颗粒,以及粒径1-0mm的颗粒,棕刚玉骨料为粒径3-1mm的颗粒。
5.根据权利要求1-2中任一项所述的无水炮泥,其特征在于,
添加剂包括膨胀剂和/或促烧结剂;
结合剂为焦油和/或树脂。
6.根据权利要求5所述的无水炮泥,其特征在于,
膨胀剂为蓝晶石、石英砂中的任意一种或多种;
促烧结剂为金属硅粉、绢云母、75#硅铁合金粉中的任意一种或多种;
结合剂中,树脂为2-6重量份,其余为焦油。
7.根据权利要求1-2中任一项所述的无水炮泥,其特征在于,碳化硅包括粒径为1-0mm的90碳化硅,以及粒径为0.074-0mm的90碳化硅;
粒径1-0mm的碳化硅与粒径0.074-0mm的碳化硅重量比为(2-2.5):1。
8.根据权利要求1-2中任一项所述的无水炮泥,其特征在于,
焦炭包括粒径为3-1mm的颗粒,以及粒径为1-0mm的颗粒;
氮化硅铁粒径为0.088-0mm;
矾土细粉的粒径为0.088-0mm;
广西白泥的粒径为0.088-0mm;
改制高温沥青的粒径为1-0mm。
9.根据权利要求5所述的无水炮泥的制备方法,其特征在于,包括以下步骤:
粒径范围在3-1mm或1-0mm的物料为颗粒,其他粒径范围的物料为细粉;
将细粉配料,预混20min以上;
将颗粒配料,干混3min以上,加入80-85%结合剂,湿混1-5min,加入预混好的细粉,继续湿混5-10min,加入剩余结合剂,混碾30min以上;
挤出成型,包裹静置至少一周后使用。
10.根据权利要求9所述的无水炮泥的制备方法,其特征在于,挤出成型前还包括检测马夏值的步骤;
若马夏值在0.4-1.2MPa之间,合格,进行挤出操作;
若马夏值不合格则添加预混料或焦油调整马夏值至合格。
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