CN115403361A - High-strength wear-resistant castable and preparation method thereof - Google Patents

High-strength wear-resistant castable and preparation method thereof Download PDF

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Publication number
CN115403361A
CN115403361A CN202211064185.3A CN202211064185A CN115403361A CN 115403361 A CN115403361 A CN 115403361A CN 202211064185 A CN202211064185 A CN 202211064185A CN 115403361 A CN115403361 A CN 115403361A
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strength
castable
granularity
strength wear
resistant castable
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梁书杰
樊俊峰
张富掌
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Zhengzhou Junte Industry Co ltd
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Zhengzhou Junte Industry Co ltd
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Abstract

The invention discloses a high-strength wear-resistant castable and a preparation method thereof. Meanwhile, the magnesium casting material can absorb Al in molten steel and slag 2 O 3 The inclusion forms magnesia-alumina spinel on the surface, has good erosion resistance to alkaline slag and iron slag, and has the function of purifying molten steel. The water discharge can be reduced, and the possibility of cracking in the baking process of the magnesium material is reduced. At the same time, because of MgO particlesThe magnesium-oxygen-silicon chains are connected with each other, so that the strength of the casting material is improved. The density of the castable is reduced by the aid of the complex-phase hollow spheres, sintering of alumina at high temperature is promoted by the aid of catalytic action of titanium oxide, combination of components in the castable is promoted, the density is reduced on the whole, strength is improved, the hollow spheres also provide embedding effect, and combination effect of other materials and the hollow spheres is further improved.

Description

High-strength wear-resistant castable and preparation method thereof
Technical Field
The invention relates to the technical field of unshaped castable, in particular to a high-strength wear-resistant castable and a preparation method thereof.
Background
High alumina (Al as the main component) 2 O 3 With SiO 2 ) The refractory castable is neutral refractory material with acidic tendency, and is commonly used in the fields of metallurgical industry (blast furnace, hot blast furnace, regenerator, heating furnace, soaking furnace, annealing furnace, ingot casting system, etc.), building materials, petrochemical industry, light industry, etc., and the aluminum silicate refractory castable has the characteristics of light weight, high temperature resistance, thermal stability, low thermal conductivity, small thermal capacity, good mechanical vibration property, good heating and heat preservation properties, good expansibility, etc. And the magnesium castable (the main components of which are MgO and SiO) 2 ) Is a slightly alkaline refractory material, has the characteristics of high refractoriness, high refractoriness under load, and the like, and can absorb Al in molten steel and slag 2 O 3 The inclusion forms magnesia-alumina spinel on the surface, has good erosion resistance to alkaline slag and iron slag, and has the function of purifying molten steel.
Generally, in order to improve the effect of iron and steel smelting, when the inner lining of a smelting furnace is cast, the used casting material has two main parts and two auxiliary parts, wherein the main part is made of neutral high-alumina refractory casting material, and the auxiliary part is made of magnesia mixed into the main part to form magnesia casting material, and the two parts can play a role in coordination and promotion to improve the quality of iron and steel smelting. However, the magnesia castable has the obvious disadvantage that the used magnesia is easy to hydrate (namely MgO and H in the magnesia are mixed at normal temperature) 2 O is subjected to dissolution and precipitation reaction and simultaneously has great volume expansion to promote the magnesium casting material to generate internal stress), in the natural curing and drying process, because of the influence of the internal stress in the magnesium casting material, the phenomena of rising, cracking and the like are easy to occur, the strength and the high-temperature service performance of the casting material are influenced, and thus the large-scale use of the magnesium casting material is limited.
In the prior art, the basic mode for weakening the hydration of the magnesite is to adopt high-density large-crystal magnesite or to add organic matter to wrap the magnesite, so that the hydration resistance of the magnesite can be improved, but in practical application, the operation is difficult due to the restriction of factors such as product price and process. In addition, general castable has large density and heavy weight due to the influence of self granularity, and is easy to fall off when used as a lining, so that a high-strength wear-resistant castable which can improve pouring strength and promote combination on the basis of reducing density is urgently needed.
Disclosure of Invention
The invention aims to provide a high-strength wear-resistant castable and a preparation method thereof, and aims to solve the problems that a common castable is high in density, easy to fall off when used as a lining, and easy to rise and crack.
In order to solve the technical problems, the invention adopts the following technical scheme:
the high-strength wear-resistant castable comprises the following formula components in percentage by weight: 18-25% of first-grade alumina with the granularity of 200-250 meshes, 15-20% of sintered mullite with the granularity of 3-1 mm, 15-20% of sintered plate-shaped brown corundum with the granularity of 3-1 mm, 12-15% of kyanite with the granularity of 3-1 mm, 8-10% of active alumina micro powder, 8-10% of pure calcium aluminate cement, 6-8% of silicon carbide micro powder with the granularity of 3-1 mm, 2-5% of silica ultra-micro powder, 3-5% of magnesia with the granularity of 3-1 mm, 2-4% of a complex-phase hollow sphere with the granularity of 5-3 mm, 3-5% of toughening fiber with the length of 5-10mm and 0.1-0.3% of a water reducing agent.
The further technical scheme is as follows: the high-strength wear-resistant castable comprises the following chemical components in percentage by weight: al (Al) 2 O 3 62.3% of SiO 2 30.7% of Fe 2 O 3 2.31% of MgO, 1.75% of MgO, K 2 O is 0.76%, na 2 0.27% of O, and the inevitable balance.
The further technical scheme is as follows: the complex phase hollow sphere is a titanium oxide-based ceramic hollow sphere.
The further technical scheme is as follows: and the surface of the complex phase hollow sphere is subjected to rough treatment.
The further technical scheme is as follows: the toughening fibers comprise explosion-proof steel fibers and polypropylene fibers in a ratio of 1: 1.
The further technical scheme is as follows: the water reducing agent is one or more of polyphosphate, sulfonate, polycarboxylate and melamine.
A preparation method of a high-strength wear-resistant castable comprises the following steps:
s1, mixing primary alumina, sintered mullite, sintered tabular brown corundum, kyanite, activated alumina micro powder, pure calcium aluminate cement, silicon carbide micro powder, silicon oxide ultra-fine powder, magnesia, a complex-phase hollow sphere, toughening fibers and a water reducing agent according to the formula components in percentage by weight to obtain a uniformly mixed primary mixed material;
s2, storing the primary mixed material in a warehouse and temporarily storing the primary mixed material according to production batches;
s3, selecting the primary mixed material of each production batch in the S2, adding water and silica sol, and stirring to obtain a mixed material; then pouring the mixture into a mould, vibrating, maintaining, demoulding and carrying out heat treatment to prepare at least ten groups of formed refractory castable materials;
s4, performing experiments on the formed refractory castable in the S3 according to G3001 GB/T3001-2007 test method for normal temperature rupture strength of refractory materials and G3002 GB/T3002-2004 test method for high temperature rupture strength of refractory materials, and recording experiment parameters;
s5, experimental comparison standards are as follows: the flexural strength at 110 ℃ and the compressive strength at 1000 ℃ are respectively not less than 12MPa and 18MPa, and the compressive strength at 110 ℃ and the compressive strength at 1000 ℃ are respectively not less than 82MPa and 85MPa;
and S6, comparing the experimental result of the S4 with the experimental comparison standard in the S5, and filling and packaging the batch of primary mixed materials with the qualified rate of more than 80%.
The further technical scheme is as follows: during casting construction, 3-6% of water is added, mixed and stirred, and the weight of the high-strength wear-resistant casting material is calculated.
Compared with the prior art, the invention has the beneficial effects that:
1. the high-strength wear-resistant castable provided by the invention is mainly made of high-aluminum casting materials, is added with magnesia to form a magnesium casting material, and has the characteristics of light weight, high temperature resistance, wear resistance, thermal stability and good heat insulation performance. Meanwhile, the magnesium casting material can absorb Al in molten steel and slag 2 O 3 The inclusion forms magnesia-alumina spinel on the surface, has good erosion resistance to alkaline slag and iron slag, and simultaneouslyAlso has the function of purifying molten steel.
2. Proper amount of SiO is added into the high-strength wear-resistant castable 2 Ultrafine powder, siO in casting 2 After the superfine powder is in contact with water, hydroxyl, namely Si-OH bonds, are formed on the surface of the superfine powder, and after natural curing and drying, a siloxane network structure is formed through dehydration and bridging. At the same time, since the surface thereof has a large amount of 0 s not bonded 2- They are easily adsorbed to Mg on the surface of MgO particles 2+ Form magnesium-oxygen-silicon chain on ions, thereby reducing the reaction with Mg 2+ Bound OH - A group. The water molecules are reduced compared to the formation of H-O-Mg-O-H and hydrogen-silicon chains, respectively. One water molecule can be reduced for each formed magnesia-silica chain. The possibility of cracking during the baking of the magnesium material is reduced due to the reduced amount of discharged water. Meanwhile, as MgO particles are connected by magnesia-silica chains, the strength of the product, namely the casting material, is improved.
3. The waste titanium oxide-based hollow ceramic ball or other hollow ball with a cavity structure and high temperature resistance can be selected as the multiphase hollow ball in the high-strength wear-resistant casting material, the density of the casting material can be reduced on the basis of high temperature resistance by using the titanium oxide-based hollow ceramic ball, the sintering of alumina at high temperature is promoted by using the catalytic action of titanium oxide, the combination of all components in the casting material is promoted, the density is reduced on the whole, the strength is improved, the hollow ball also provides a mosaic effect, and the combination effect of other materials and the hollow ball is further promoted.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are some embodiments of the present invention, but not all embodiments.
Thus, the following detailed description of embodiments of the invention is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
In addition, the embodiments of the present invention and the features of the embodiments may be combined with each other without conflict.
The high-strength wear-resistant castable comprises the following formula components in percentage by weight: 18-25% of first-grade alumina with the granularity of 200-250 meshes, 15-20% of sintered mullite with the granularity of 3-1 mm, 15-20% of sintered plate-shaped brown corundum with the granularity of 3-1 mm, 12-15% of kyanite with the granularity of 3-1 mm, 8-10% of active alumina micro powder, 8-10% of pure calcium aluminate cement, 6-8% of silicon carbide micro powder with the granularity of 3-1 mm, 2-5% of silica ultra-micro powder, 3-5% of magnesia with the granularity of 3-1 mm, 2-4% of a complex-phase hollow sphere with the granularity of 5-3 mm, 3-5% of toughening fiber with the length of 5-10mm and 0.1-0.3% of a water reducing agent. The high-strength wear-resistant castable comprises the following chemical components in percentage by weight: al (Al) 2 O 3 62.3% of SiO 2 30.7% of Fe 2 O 3 2.31% of MgO, 1.75% of MgO, K 2 O is 0.76%, na 2 0.27% of O, and the inevitable balance. The complex phase hollow ball is a titanium oxide-based ceramic hollow ball. The surface of the hollow complex phase ball is rough treated.
The high-strength wear-resistant castable provided by the invention takes a high-aluminum casting material as a main material (comprising primary alumina, sintered mullite, sintered tabular brown fused alumina, kyanite, activated alumina micro powder, pure calcium aluminate cement, silicon carbide micro powder, toughening fiber and a water reducing agent), so that the high-strength wear-resistant castable has the characteristics of light weight, high temperature resistance, wear resistance, thermal stability, good heat preservation performance and the like. Adding magnesia to form SiO 2 Forming a magnesium casting material capable of absorbing Al in molten steel and slag 2 O 3 The inclusion forms magnesia-alumina spinel on the surface, has good erosion resistance to alkaline slag and iron slag, and has the function of purifying molten steel.
Proper amount of SiO is added into the high-strength wear-resistant castable 2 Ultrafine powder, siO in casting 2 The ultrafine powder forms hydroxyl groups on the surface when contacting waterI.e. Si-OH bonds, are dehydrated and bridged to form a siloxane network structure after natural curing and drying. At the same time, since the surface thereof has a large amount of 0 s not bonded 2- They are easily adsorbed to Mg on the surface of MgO particles 2+ Form magnesium-oxygen-silicon chain on ions, thereby reducing Mg and Mg 2+ Bound OH - A group. The water molecules are reduced compared to the formation of H-O-Mg-O-H and hydrogen-silicon chains, respectively. One water molecule can be reduced for each formed magnesia-silica chain. The possibility of cracking during the baking process of the magnesium material is reduced due to the reduced amount of discharged water. Meanwhile, as the MgO particles are connected by the magnesium-oxygen-silicon chain, the strength of the product, namely the casting material, is improved.
The diphase clean shot in this wear-resisting castable that excels in, the ceramic clean shot of titanium oxide base after can selecting for use abandonment, or other have cavity structure and high temperature resistance clean shots, utilize the ceramic clean shot of titanium oxide base, can be on high temperature resistance basis, reduce the density of castable, and utilize the catalytic action of titanium oxide, promote the sintering of alumina under high temperature, promote the combination of each component in the castable, reduce density on the whole and improve intensity, and the coarse surface of clean shot improves the gomphosis performance, provide the gomphosis position for other raw materials granule, further promote other materials and its combination effect, improve the intensity of pouring material.
Formula 1: 19% of primary alumina, 16% of sintered mullite, 16% of sintered tabular brown corundum, 12.8% of kyanite, 8% of active alumina micro powder, 8% of pure calcium aluminate cement, 6% of silicon carbide micro powder, 4% of silica ultra-micro powder, 4% of magnesia, 3% of smooth complex-phase hollow spheres, 3% of toughening fibers and 0.2% of water reducing agent.
And (2) formula: 20% of primary alumina, 16% of sintered mullite, 16% of sintered tabular brown corundum, 12.8% of kyanite, 8% of active alumina micro powder, 8% of pure calcium aluminate cement, 6% of silicon carbide micro powder, 2% of silica ultra-micro powder, 5% of magnesia, 3% of smooth complex-phase hollow spheres, 3% of toughening fibers and 0.2% of water reducing agent.
And (3) formula: 19% of primary alumina, 16% of sintered mullite, 16% of sintered tabular brown corundum, 12.8% of kyanite, 8% of active alumina micro powder, 8% of pure calcium aluminate cement, 6% of silicon carbide micro powder, 5% of silica ultra-micro powder, 3% of magnesia, 3% of smooth complex-phase hollow spheres, 3% of toughening fibers and 0.2% of water reducing agent.
And (4) formula: 19% of primary alumina, 16% of sintered mullite, 16% of sintered tabular brown corundum, 12.8% of kyanite, 8% of active alumina micro powder, 8% of pure calcium aluminate cement, 6% of silicon carbide micro powder, 4% of silica ultra-micro powder, 4% of magnesia, 3% of coarse complex-phase hollow spheres, 3% of toughening fibers and 0.2% of water reducing agent.
Table 1: comparison parameter of test performance of formula 1-4 products and common silicon-aluminum castable
Figure DEST_PATH_IMAGE002
Preferably, the toughening fibers include 1: 1 explosion proof steel fibers and polypropylene fibers.
Preferably, the water reducing agent is one or more of polyphosphate, sulfonate, polycarboxylate and melamine.
A preparation method of a high-strength wear-resistant castable comprises the following steps:
s1, mixing primary alumina, sintered mullite, sintered tabular brown corundum, kyanite, active alumina micro powder, pure calcium aluminate cement, silicon carbide micro powder, silicon oxide superfine powder, magnesia, a complex-phase hollow sphere, toughening fibers and a water reducing agent in one step according to the formula components in percentage by weight to obtain a uniformly mixed primary mixed material;
s2, storing the primary mixed material in a warehouse and temporarily storing the primary mixed material according to production batches;
s3, selecting the primary mixed material of each production batch in the S2, adding water and silica sol, and stirring to obtain a mixed material; then pouring the mixture into a mould, vibrating, maintaining, demoulding and carrying out heat treatment to prepare at least ten groups of formed refractory castable materials;
s4, performing experiments on the formed refractory castable in the S3 according to G3001 GB/T3001-2007 test method for normal temperature flexural strength of refractory materials and G3002 GB/T3002-2004 test method for high temperature flexural strength of refractory materials, and recording experiment parameters;
s5, experimental comparison standards are as follows: the flexural strength at 110 ℃ and the compressive strength at 1000 ℃ are respectively not less than 12MPa and 18MPa, and the compressive strength at 110 ℃ and 1000 ℃ are respectively not less than 82MPa and 85MPa;
and S6, comparing the experimental result of the S4 with the experimental comparison standard in the S5, and filling and packaging the batch of primary mixed materials with the qualified rate of more than 80%.
The further technical scheme is as follows: during casting construction, 3-6% of water is added, mixed and stirred based on the weight of the high-strength wear-resistant casting material.
Although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that various changes in the embodiments and/or modifications of the invention can be made, and equivalents and modifications of some features of the invention can be made without departing from the spirit and scope of the invention.

Claims (8)

1. The high-strength wear-resistant castable is characterized by comprising the following formula components in percentage by weight: 18-25% of first-grade alumina with the granularity of 200-250 meshes, 15-20% of sintered mullite with the granularity of 3-1 mm, 15-20% of sintered plate-shaped brown corundum with the granularity of 3-1 mm, 12-15% of kyanite with the granularity of 3-1 mm, 8-10% of active alumina micro powder, 8-10% of pure calcium aluminate cement, 6-8% of silicon carbide micro powder with the granularity of 3-1 mm, 2-5% of silica ultra-micro powder, 3-5% of magnesia with the granularity of 3-1 mm, 2-4% of a complex-phase hollow sphere with the granularity of 5-3 mm, 3-5% of toughening fiber with the length of 5-10mm and 0.1-0.3% of a water reducing agent.
2. A high-strength wear-resistant castable according to claim 1, wherein: the high-strength wear-resistant castable comprises the following chemical components in percentage by weight: al (Al) 2 O 3 62.3% of SiO 2 30.7% of Fe 2 O 3 2.31%, mgO 1.75%, K 2 O is 0.76%, na 2 0.27% of O, and the inevitable balance.
3. A high-strength wear-resistant castable according to claim 1, wherein: the complex phase hollow sphere is a titanium oxide-based ceramic hollow sphere.
4. A high-strength wear-resistant castable material according to claim 1, wherein: and the surface of the complex phase hollow sphere is subjected to rough treatment.
5. A high-strength wear-resistant castable according to claim 1, wherein: the toughening fibers comprise explosion-proof steel fibers and polypropylene fibers in a ratio of 1: 1.
6. A high-strength wear-resistant castable according to claim 1, wherein: the water reducing agent is one or more of polyphosphate, sulfonate, polycarboxylate and melamine.
7. A preparation method of a high-strength wear-resistant castable according to any one of claims 1-6, characterized by comprising the following steps:
s1, mixing primary alumina, sintered mullite, sintered tabular brown corundum, kyanite, active alumina micro powder, pure calcium aluminate cement, silicon carbide micro powder, silicon oxide superfine powder, magnesia, a complex-phase hollow sphere, toughening fibers and a water reducing agent in one step according to the formula components in percentage by weight to obtain a uniformly mixed primary mixed material;
s2, storing the primary mixed material in a warehouse and temporarily storing the primary mixed material according to production batches;
s3, selecting the primary mixed material of each production batch in the S2, adding water and silica sol, and stirring to obtain a mixed material; then pouring the mixture into a mould, vibrating, maintaining, demoulding and carrying out heat treatment to prepare at least ten groups of forming refractory castable materials;
s4, performing experiments on the formed refractory castable in the S3 according to G3001 GB/T3001-2007 test method for normal temperature rupture strength of refractory materials and G3002 GB/T3002-2004 test method for high temperature rupture strength of refractory materials, and recording experiment parameters;
s5, experimental comparison standards are as follows: the flexural strength at 110 ℃ and the compressive strength at 1000 ℃ are respectively not less than 12MPa and 18MPa, and the compressive strength at 110 ℃ and the compressive strength at 1000 ℃ are respectively not less than 82MPa and 85MPa;
and S6, comparing the experimental result of the S4 with the experimental comparison standard in the S5, and filling and packaging the batch of primary mixed materials with the qualified rate of more than 80%.
8. The preparation method of the high-strength wear-resistant castable according to claim 7, characterized by comprising the following steps: during casting construction, 3-6% of water is added, mixed and stirred, and the weight of the high-strength wear-resistant casting material is calculated.
CN202211064185.3A 2022-09-01 2022-09-01 High-strength wear-resistant castable and preparation method thereof Pending CN115403361A (en)

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