CN115572154A - 一种环保型摆动流嘴用铁沟浇注料及其使用方法 - Google Patents
一种环保型摆动流嘴用铁沟浇注料及其使用方法 Download PDFInfo
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims abstract description 114
- 229910052742 iron Inorganic materials 0.000 title claims abstract description 61
- 238000000034 method Methods 0.000 title claims abstract description 20
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 42
- 239000000843 powder Substances 0.000 claims abstract description 34
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 28
- 239000000463 material Substances 0.000 claims abstract description 23
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 22
- 239000010431 corundum Substances 0.000 claims abstract description 22
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 20
- 229910001570 bauxite Inorganic materials 0.000 claims abstract description 17
- 239000000835 fiber Substances 0.000 claims abstract description 16
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000006229 carbon black Substances 0.000 claims abstract description 11
- 239000004568 cement Substances 0.000 claims abstract description 11
- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 11
- 229910052751 metal Inorganic materials 0.000 claims abstract description 10
- 239000002184 metal Substances 0.000 claims abstract description 10
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 10
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000002270 dispersing agent Substances 0.000 claims abstract description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000011521 glass Substances 0.000 claims abstract description 6
- 235000012239 silicon dioxide Nutrition 0.000 claims abstract description 6
- 239000011863 silicon-based powder Substances 0.000 claims abstract description 6
- 229910052580 B4C Inorganic materials 0.000 claims abstract description 5
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 claims abstract description 5
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims abstract description 5
- 230000008569 process Effects 0.000 claims description 12
- 229920002125 Sokalan® Polymers 0.000 claims description 9
- 239000004584 polyacrylic acid Substances 0.000 claims description 9
- 238000005245 sintering Methods 0.000 claims description 9
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 8
- 238000010521 absorption reaction Methods 0.000 claims description 8
- 238000002844 melting Methods 0.000 claims description 7
- 230000008018 melting Effects 0.000 claims description 7
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- 238000006243 chemical reaction Methods 0.000 claims description 3
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 2
- 238000005266 casting Methods 0.000 abstract description 12
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
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- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
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- QMQXDJATSGGYDR-UHFFFAOYSA-N methylidyneiron Chemical compound [C].[Fe] QMQXDJATSGGYDR-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明公开了一种环保型摆动流嘴用铁沟浇注料及其使用方法。该浇注料各组分按质量百分比计为：特制煅烧高铝矾土骨料68～72％；碳化硅0‑1mm:2～6％；氧化铝微粉3～5％；二氧化硅微粉2.5～3.5％；纯铝酸钙水泥0.8‑1％；特种炭黑1.2‑1.5％；碳化硅粉6～10％；碳化硼粉0.2～0.4％；金属铝粉0.1‑0.16％；金属硅粉1～1.5％；低温玻璃粉0.2‑0.3％；防爆纤维0.08～0.12％；分散剂0.1‑0.2％；致密刚玉粉4‑8％。该浇注料致密性好，中低温强度高、抗氧化性好，高温热态强度高，环保无污染，其中加水量≤4％，体密达3g/cm3以上，达到甚至超越常规刚玉质铁沟浇注料。
Description
技术领域
本发明属于不定形耐火材料领域，具体涉及一种环保型摆动流嘴用铁沟浇注料及其使用方法。
背景技术
高炉出铁场摆动流嘴是高温铁水从铁沟流向铁水包的重要通道，长期受到高温铁水的剧烈冲刷，目前一般采用含3％左右质量球沥青的刚玉质碳化硅碳质铁沟浇注料可以保证其使用要求。摆动流嘴处于高炉出铁场平台之外，暴露在空气中，摆动流嘴浇注料在烘烤和使用过程中大量的沥青挥发，产生可致癌的刺激性气体，污染空气，对炉前操作人员的健康造成不利影响。
目前国内每吨电熔刚玉耗电2300度，其能源成本是高铝矾土成本的5-10倍。以价格较低的高铝骨料替代浇注料中的价格昂贵的刚玉骨料不但是一个降低生产成本的过程，也是一个节约能源的环保问题。然而，由于传统高铝骨料相对于棕刚玉不但化学纯度较低，而且骨料本身致密性相对较差、吸水率较高，当高比例的高铝骨料替代铁沟浇注料中棕刚玉的时候，会导致浇注料加水量增大，水泥用量增大，浇注料整体纯度降低，抗渣性能明显降低，从而导致使用寿命明显降低，“得不偿失”。
因此，如何采保证使用性能不降低的情况下，彻底去除沥青污染，同时最大程度采用低能耗的高铝质原料替代高能耗的电熔刚玉，成为新时代环保型摆动流嘴用铁沟浇注料的一个重要课题。
发明内容
本发明的目的是针对现有技术的不足，提供了一种环保型摆动流嘴用铁沟浇注料，该浇注料具有强度高、体密高、环保无污染、原材料成本低、原材料能耗低等特点。
为了解决上述技术问题，本发明采用以下技术方案：
提供一种摆动流嘴用铁沟浇注料，各组分按质量百分比计为：
所述特制煅烧高铝矾土骨料中，所含Al2O3≥88wt％，Fe2O3≤1.5wt％，体积密度≥3.55g/cm3，吸水率0.8-1.5％；
所述二氧化硅微粉为98wt％≥SiO2≥94wt％，D90≥5微米；
所述氧化铝微粉为微晶转相氧化铝微粉。
按上述方案，所述特制煅烧高铝矾土骨料，通过铝矾土在铁皮竖窑中烧制得到，其中所用铁皮竖窑的装窑高度达22-23米，烧制过程中在1600-1620℃高温段熔融态下保温70-80小时。
本发明采用高压高温特种烧成工艺烧成高铝矾土，其中，通过设置较高的装窑高度，利用物料本身的重力可以提升内部压力，配合较长的高温段的烧制时间，所得特制煅烧高铝矾土骨料核心指标吸水率达到0.8％-1.5％，且具有超致密性，为传统高铝矾土不可比拟。
按上述方案，所述特制煅烧高铝矾土骨料粒径为0.1-8mm。
按上述方案，所述碳化硅0-1mm粒径为0-1mm，其中SiC≥98.5wt％，Fe2O3≤0.3wt％。
按上述方案，所述氧化铝微粉中，D90≤4.5微米；其主要化学成分为：Al2O3≥99.5wt％、Na2O≤0.1wt％；其中氧化铝原晶的晶体直径控制在0.45-0.55微米，α相转化率达到95％以上。该氧化铝微粉通过微晶转相工艺，具有优异的填充性能和活性，相较国内普通氧化铝微粉烘干强度提高30％-50％，活性非常稳定，具有更好的减水性能，流动性好，强度发展好。
按上述方案，所述二氧化硅微粉为98wt％≥SiO2≥94wt％,较高纯度的普通二氧化硅微粉，D90≥5微米。高纯或亚微米级二氧化硅微粉不适用本发明，其典型特征：SiO2≥99wt％，PH值小于4，D90≤0.5微米。
按上述方案，所述纯铝酸钙水泥可有效提升水泥低温、中温和高温强度及热机械性能，该铝酸钙水泥中主要化学成分为Al2O3 68.5-70.5wt％，CaO 28.5-30.5wt％，几乎不含其它杂质。
按上述方案，所述特种炭黑为德国产N990R型。
按上述方案，所述碳化硅粉中SiC含量≥98％，细度为≤74um。
按上述方案，所述碳化硼粉含量B4C≥94％,细度为≤45um。
按上述方案，所述金属铝粉，为氮气雾化工艺生产的，Al≥99％，细度为≤74um。
按上述方案，所述金属硅粉的粒度≤45μm，Si含量≥98.5％。
按上述方案，所述低温玻璃粉粒度≤45μm，软化温度320℃-340℃，烧结温度360℃-380℃。
按上述方案，所述防爆纤维，为聚丙烯防爆纤维，其熔点为160-180℃、长度为5.9-6.1mm。
按上述方案，所述分散剂为聚丙烯酸液体与氧化铝粉按1：3-1：4喷雾混合而成，聚丙烯酸分子量为5000-12000；优选日本花王产聚丙烯酸液体。所得分散剂对特种炭黑及D90≤4.5微米的微晶转相氧化铝微米均有极佳的分散效果，因此具有极佳的减水性能；同时不宜泌水，强度高，且有良好的稳定性，避免铁沟浇注料鼓胀开裂；该分散剂的减水性能与德国巴斯夫FS系列聚羧酸、聚乙二醇等最佳组合减水效果相当，但早期强度提高20-30％；国内聚丙烯酸不能达到此高效分散减水效果。
按上述方案，所述致密刚玉粉细度为≤74um；所含Al2O3≥98.5wt％，Fe2O3≤0.3wt％。
提供一种摆动流嘴用铁沟浇注料的使用方法，具体为：在所述浇注料中外加≤4％的水搅拌均匀。优选地，外加水量为3.8-4％。
本发明提供一种摆动流嘴用铁沟浇注料，具体工作机理如下：
首先，本发明采用高铝高压高温的新烧成工艺特制煅烧高铝矾土骨料，使其吸水率达到0.8-1.5％，具有超致密性，为传统高铝矾土不可比拟，达到甚至超越了电熔刚玉的级别水平，为低能耗高铝矾土替代高能耗的电熔刚玉提供了广阔的应用空间。
其次，本发明创新地设计得到环保型铁沟浇注料的新体系：微量水泥(1％以下)+普通硅微粉+微晶转相氧化铝微粉+特种炭黑+聚丙烯纤维组合。这种组合采用国内普通硅微粉为主结合剂，以微量水泥(1％以下)为促凝剂及助结合剂，同时彻底摒弃了铁沟浇注料中污染环境的球沥青，采用特种炭黑为增炭剂、减水剂、促凝剂、增强剂，由于特种炭黑为亚微米级材料，可以对基质形成良好的填充性，与硅微粉形成空间网络结构，产生充足的结合强度，这种组合不但弥补了球沥青的碳源问题，大大降低了球沥青挥发后留下的气孔，提高了浇注料的致密性和中低温强度，还降低了水泥用量，提高了铁沟浇注料的中温抗氧化性、高温热态强度。研究过程中发明人发现水溶性纤维对高纯硅微粉(亚微米级)及特种炭黑(亚微米级)形成干扰，削弱了亚微米级材料的填充性，导致浇注料加水量明显增大，流动性变差；并且发现两种亚微米级材料同时出现在浇注料中会形成干扰，不但削弱了亚微米级材料的填充性，还会导致浇注料流动性变差。基于上述原因，本发明采用这种新体系组合方式避免了采用高纯亚微米级硅微粉、炭黑、水溶性纤维三者在铁沟浇注料中产生的两两干扰的情况。
此外，本发明采用微量的低温玻璃粉融化后产生的液相，可以封闭因浇注料防爆剂产生的气孔，提高浇注料在低温段的抗氧化性及烧结性能。
与现有技术相比，本发明的有益效果为：
1.本发明提供了一种摆动流嘴用铁沟浇注料，以性能堪比电熔刚玉的特制煅烧高铝矾土骨料为主体原料，协同微量水泥(1％以下)+普通硅微粉+微晶转相氧化铝微粉+特种炭黑+聚丙烯纤维为核心组分以及低温玻璃粉，再配合碳化硅、氧化铝微粉、碳化硅粉、碳化硼粉、金属铝粉、金属硅粉、防爆纤维、分散剂和致密刚玉粉，所得浇注料致密性好，中低温强度高、抗氧化性好，高温热态强度高，其中加水量≤4％，体密均达到3g/cm3以上，达到甚至超越常规刚玉质铁沟浇注料；1450℃烧后耐压强度普遍超过100MPa，1400℃01h热态抗折强度超过5MPa，均超越常规刚玉质铁沟浇注料。
2.本发明最大程度采用低能耗的高铝质原料替代高能耗的电熔刚玉，且水泥用量低，所得摆动流嘴用铁沟浇注料各项目指标超过普通刚玉质铁沟浇注料的技术指标，在综合性能优异的同时有效降低能耗，绿色环保，成本低，具有广泛的应用前景。
3.本发明采用高铝高压高温的新烧成工艺，使特制煅烧高铝矾土的吸水率与致密性达到电熔刚玉水平，突破了多年来以高铝替代刚玉的主材自身性能不足的核心问题，为低能耗高铝矾土替代高能耗的电熔刚玉提供了广阔的应用空间。
具体实施方式
为了更好地理解本发明，下面结合实施例进一步阐明本发明的内容，但本发明的内容不仅仅局限于下面的实施例。
以下实施例中，各原料指标为：
特制煅烧高铝矾土，为采用高压高温特种烧成工艺烧成的铝矾土。其生产工艺为：矾土生料(Al2O3≥76％)→湿法球磨→泥浆池→除铁→均化及成分微调→压滤→压制成型→干燥→装入竖窑→烧制6天出窑(1300℃预热1.5天，升温1.5天，1600-1620℃高温段保温3天)→破碎筛分→包装出厂。所用窑炉为铁皮竖窑，设计窑炉的装窑高度达22米，铝矾土在窑炉中1600-1620℃高温段熔融态下保温72小时烧制得到一种新型特种高铝矾土，其核心指标吸水率达到0.8％-1.5％，为传统高铝矾土不可比拟，达到甚至超越了电熔刚玉的级别水平。其中特制煅烧高铝矾土粒径为0.1-8mm；所含Al2O3≥88wt％，Fe2O3≤1.5wt％，体积密度≥3.55g/cm3，吸水率0.8％-1.5％。
碳化硅0-1mm：SiC≥98.5wt％，Fe2O3≤0.3wt％。
氧化铝微粉，为微晶转相氧化铝微粉，D90≤4.5微米；其主要化学成分为：Al2O3≥99.5wt％、Na2O≤0.1wt％；其中氧化铝原晶的晶体直径控制在0.45-0.55微米，α相转化率达到95％以上。
二氧化硅微粉为98wt％≥SiO2≥94wt％，粒径为D90≥5微米。
纯铝酸钙水泥中主要化学成分为Al2O3 68.5-70.5wt％，CaO 28.5-30.5wt％，几乎不含其它杂质。
特种炭黑为德国产N990R型。
碳化硅粉中SiC含量≥98％，细度为≤74um。
碳化硼粉含量B4C>94％,细度为≤45um。
金属铝粉，为氮气雾化工艺生产的，Al≥99％，细度为≤74um。
金属硅粉的粒度≤45μm，Si含量≥98.5％。
低温玻璃粉粒度≤45μm，软化温度320℃-340℃，烧结温度360℃-380℃
防爆纤维，为聚丙烯防爆纤维，其熔点为160-180℃、长度为5.9-6.1mm。
分散剂为聚丙烯酸液体与氧化铝粉按1：3喷雾混合而成，其中聚丙烯酸液体为日本花王产，分子量为5000-12000。
致密刚玉粉细度为≤74um；所含Al2O3≥98.5wt％，Fe2O3≤0.3wt％。
实施例1
一种环保型摆动流嘴用铁沟浇注料，各组分及其所占质量百分比为：
将各原料按上述配比称取并充分混合；再加入水(水的质量为各原料总质量的4.0％)搅拌均匀后振动成型；成型后所得试样经自然干燥24h后在110℃下再进行热处理24h，制得环保型摆动流嘴用铁沟浇注料试样。
将本实施例所制得的环保型摆动流嘴用铁沟浇注料试样进行性能检测，结果如表1所示。采用的性能检测方法按照现行国家标准或行业标准进行，所得检测结果为3次平均检测结果(以下同)。
表1实施例1所制得的环保型摆动流嘴用铁沟浇注料试样的性能检测结果
实施例2
一种环保型摆动流嘴用铁沟浇注料，各组分及其所占质量百分比为：
将各原料按上述配比称取并充分混合；再加入水(水的质量为各原料总质量的3.8％)搅拌均匀后振动成型；成型后所得试样经自然干燥24h后在110℃下再进行热处理24h，制得环保型摆动流嘴用铁沟浇注料试样。
将本实施例所制得的环保型摆动流嘴用铁沟浇注料试样进行性能检测，结果如表2所示。采用的性能检测方法按照现行国家标准或行业标准进行，所得检测结果为3次平均检测结果(以下同)。
表2实施例2所制得的环保型摆动流嘴用铁沟浇注料试样的性能检测结果
实施例3
一种环保型摆动流嘴用铁沟浇注料，各组分及其所占质量百分比为：
将各原料按上述配比称取并充分混合；再加入水(水的质量为各原料总质量的3.9％)搅拌均匀后振动成型；成型后所得试样经自然干燥24h后在110℃下再进行热处理24h，制得环保型摆动流嘴用铁沟浇注料试样。
将本实施例所制得的环保型摆动流嘴用铁沟浇注料试样进行性能检测，结果如表3所示。采用的性能检测方法按照现行国家标准或行业标准进行，所得检测结果为3次平均检测结果(以下同)。
表3实施例3所制得的环保型摆动流嘴用铁沟浇注料试样的性能检测结果
实施例4
一种环保型摆动流嘴用铁沟浇注料，各组分及其所占质量百分比为：
将各原料按上述配比称取并充分混合；再加入水(水的质量为各原料总质量的4.0％)搅拌均匀后振动成型；成型后所得试样经自然干燥24h后在110℃下再进行热处理24h，制得环保型摆动流嘴用铁沟浇注料试样。
将本实施例所制得的环保型摆动流嘴用铁沟浇注料试样进行性能检测，结果如表4所示。采用的性能检测方法按照现行国家标准或行业标准进行，所得检测结果为3次平均检测结果(以下同)。
表4实施例4所制得的环保型摆动流嘴用铁沟浇注料试样的性能检测结果
上述结果表明，本发明所述一种环保型摆动流嘴用铁沟浇注料，具有强度高、体密高、环保无污染、原材料成本低、原材料能耗低等特点。
显然，上述实施例仅仅是为清楚地说明所作的实例，而并非对实施方式的限制。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而因此所引申的显而易见的变化或变动仍处于本发明创造的保护范围之内。
Claims (10)
1.一种摆动流嘴用铁沟浇注料，其特征在于，各组分按质量百分比计为：
所述特制煅烧高铝矾土骨料中，所含Al2O3≥88wt％，Fe2O3≤1.5wt％，体积密度≥3.55g/cm3，吸水率0.8-1.5％；
所述二氧化硅微粉中，98wt％≥SiO2≥94wt％，D90≥5微米；
所述氧化铝微粉为微晶转相氧化铝微粉。
2.根据权利要求1所述的铁沟浇注料，其特征在于，所述特制煅烧高铝矾土骨料，通过铝矾土在铁皮竖窑中烧制得到；其中所用铁皮竖窑的装窑高度达22-23米，烧制过程中在1600-1620℃高温段熔融态下保温70-80小时。
3.根据权利要求1所述的铁沟浇注料，其特征在于，所述特制煅烧高铝矾土骨料粒径为0.1-8mm。
4.根据权利要求1所述的铁沟浇注料，其特征在于，所述氧化铝微粉中，D90≤4.5微米；其主要化学成分为：Al2O3≥99.5wt％、Na2O≤0.1wt％；其中氧化铝原晶的晶体直径控制在0.45-0.55微米，α相转化率达到95％以上。
5.根据权利要求1所述的铁沟浇注料，其特征在于，所述纯铝酸钙水泥主要化学成分为Al2O3 68.5-70.5wt％，CaO 28.5-30.5wt％；所述特种炭黑为德国产N990R型。
6.根据权利要求1所述的铁沟浇注料，其特征在于，所述碳化硅0-1mm中，SiC≥98.5wt％，Fe2O3≤0.3wt％；所述碳化硅粉中，SiC含量≥98％，细度为≤74um；所述碳化硼粉中，B4C≥94％，细度为≤45um；所述金属铝粉中，Al≥99％，细度为≤74um；所述金属硅粉的粒度≤45μm，Si含量≥98.5％。
7.根据权利要求1所述的铁沟浇注料，其特征在于，所述低温玻璃粉粒度≤45μm，软化温度320℃-340℃，烧结温度360℃-380℃。
8.根据权利要求1所述的铁沟浇注料，其特征在于，所述防爆纤维，为聚丙烯防爆纤维，其熔点为160-180℃、长度为5.9-6.1mm；所述致密刚玉粉细度为≤74um；所含Al2O3≥98.5wt％，Fe2O3≤0.3wt％。
9.根据权利要求1所述的铁沟浇注料，其特征在于，所述分散剂为聚丙烯酸液体与氧化铝粉按1：3-1：4喷雾混合而成，其中聚丙烯酸分子量为5000-12000。
10.一种权利要求1-9任一项所述的摆动流嘴用铁沟浇注料的使用方法，其特征在于，具体为：在所述浇注料中外加≤4％的水搅拌均匀。
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| CN116874287A (zh) * | 2023-07-04 | 2023-10-13 | 河南通联研磨科技有限公司 | 一种生产烧结棕刚玉的方法 |
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| CN116835970B (zh) * | 2023-09-01 | 2024-03-08 | 义马瑞辉新材料有限公司 | 一种可快速烘烤的铁沟浇注料及其制备方法 |
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