CN115626815A - Refractory castable based on spherical micro powder and preparation process thereof - Google Patents
Refractory castable based on spherical micro powder and preparation process thereof Download PDFInfo
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- 238000002360 preparation method Methods 0.000 title claims abstract description 23
- 238000002347 injection Methods 0.000 claims abstract description 193
- 239000007924 injection Substances 0.000 claims abstract description 193
- 238000002156 mixing Methods 0.000 claims abstract description 159
- 239000002994 raw material Substances 0.000 claims abstract description 99
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 59
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 54
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 45
- 229910052863 mullite Inorganic materials 0.000 claims description 45
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- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 claims description 7
- 239000010443 kyanite Substances 0.000 claims description 7
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- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 9
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- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 description 1
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- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/101—Refractories from grain sized mixtures
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3418—Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3427—Silicates other than clay, e.g. water glass
- C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/74—Physical characteristics
- C04B2235/77—Density
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
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- C—CHEMISTRY; METALLURGY
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
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Abstract
The invention relates to a preparation process of a castable refractory, in particular to a preparation process of a castable refractory based on spherical micro powder, which comprises the following steps of S1, selecting the injection amount of each raw material and required standard parameters by a central control unit according to the requirements of a target castable refractory; s2, the mixing cylinder is conveyed to the discharge port of each material injection machine by a transmission mechanism, each material injection machine injects raw materials of refractory castable into the mixing cylinder according to the injection amount selected by the central control unit, and the mixing cylinder controls the stirring speed according to the total injection amount of the raw materials of the refractory castable so as to uniformly mix the raw materials of the refractory castable; and S3, detecting the high-temperature fire resistance and the fluidity of the produced refractory castable, comparing the detected high-temperature fire resistance and the fluidity with required standard parameters, and adjusting the grinding speed of each material injecting machine, the oscillation frequency of a screen in each material injecting machine and the barrel wall cleaning frequency of the mixing barrel so as to enable the properties of the refractory castable to meet the standard.
Description
Technical Field
The invention relates to the field of castable preparation, in particular to a refractory castable based on spherical micro powder and a preparation process thereof.
Background
The refractory castable is a granular or powdery material prepared by adding a certain amount of bonding agent into refractory materials, has high fluidity and is an unshaped refractory material molded by a pouring mode. Compared with other unshaped refractory materials, the castable has higher content of the binding agent and water and better fluidity, so the application range of the castable is wider, and the used material and the binding agent can be selected according to the use conditions. It can be directly cast into lining body, or cast or vibrated into prefabricated block. Waste time and energy in the production process of traditional castable production line, and production efficiency is low, and the operation precision is poor, is in extensive type production mode basically, especially throwing the material link, the adsorption phenomenon appears in powdered material easily, and the too much phenomenon of residual material on throwing the feed bin wall not only causes the waste and causes in the castable each raw materials content not conform to the standard and causes the inhomogeneous scheduling problem of compounding.
Chinese patent CN104030713B discloses a preparation method of a castable, which uses corundum particles, aluminum nitride fine powder, pure calcium aluminate cement and silica micropowder, adopts BaSO4, tiB2, srTiO3 and Na3AlF6 as an anti-aluminum liquid wetting additive in a composite way, and adds sodium tripolyphosphate accounting for 0.12 percent of the total weight of raw materials and polycarboxylate accounting for 0.03 percent of the total weight of the raw materials as a dispersing agent to prepare the castable with long service life and good thermal stability.
Disclosure of Invention
Therefore, the invention provides a refractory castable based on spherical micro powder and a preparation process thereof, which can solve the technical problem that the performance of the produced castable can not meet the standard through the preparation process, particularly the granularity of the spherical micro powder and the separate injection of various raw materials.
In order to achieve the above object, in one aspect, the present invention provides a preparation process of a refractory castable material based on spherical micro powder, comprising:
s1, selecting the injection amount of each raw material and required standard parameters by a central control unit according to the requirements of a target refractory castable;
s2, the mixing cylinder is conveyed to the discharge port of each material injection machine by a transmission mechanism, each material injection machine injects raw materials of refractory castable into the mixing cylinder according to the injection amount selected by the central control unit, and the mixing cylinder controls the stirring speed according to the total injection amount of the raw materials of the refractory castable so as to uniformly mix the raw materials of the refractory castable;
and S3, detecting the high-temperature fire resistance and the fluidity of the produced refractory castable, comparing the detected high-temperature fire resistance and the fluidity with required standard parameters, and adjusting the grinding speed of each casting machine, the oscillation frequency of an inner screen of each casting machine and the cleaning frequency of the wall of the mixing barrel so as to enable the properties of the refractory castable to meet the standard.
Further, in the step S1, the central control unit selects an injection amount of each raw material according to a requirement of a target refractory castable, when the requirement of the target refractory castable is M1, the central control unit selects a weight M11 as an injection amount of spherical mullite 60, a weight M12 as an injection amount of spherical alumina, a weight M13 as an injection amount of spherical silica micropowder, a weight M14 as an injection amount of alumina, and a weight M15 as an injection amount of silica fume, when the requirement of the target refractory castable is M2, the central control unit selects a weight M21 as an injection amount of spherical mullite 60, a weight M22 as an injection amount of spherical alumina, a weight M23 as an injection amount of spherical silica micropowder, a weight M24 as an injection amount of alumina, a weight M25 as an injection amount of silica fume, when the requirement of the target refractory castable is M3, the central control unit selects a weight M31 as an injection amount of spherical mullite 60, a weight M32 as an injection amount of spherical alumina, a weight M33 as an injection amount, a weight M34 as an injection amount of silica fume, wherein the injection amount of silica fume, wherein M1 is a requirement of spherical alumina, a high-temperature resistance of the raw material, and a high-temperature resistance of the raw material is a requirement of M3, wherein the high-temperature refractory castable.
Further, the central control unit obtains the weight m0 of the castable raw material in the mixing barrel, compares the weight with a preset weight D, selects the stirring speed in the mixing barrel, wherein,
when m0 is less than or equal to D1, the central control unit selects a first preset speed V1 as the stirring speed in the mixing barrel;
when D1 is larger than m0 and smaller than D2, the central control unit selects a second preset speed V2 as the stirring speed in the mixing barrel;
when m0 is larger than or equal to D2, the central control unit selects a third preset speed V3 as the stirring speed in the mixing cylinder;
the central control unit presets a weight D, sets a first preset weight D1, sets a second preset weight D2, presets a speed V, sets a first preset speed V1, sets a second preset speed V2 and sets a third preset speed V3.
Further, in the step S2, each of the material injecting machines and the stirrer injects the raw material into the mixing barrel for several times, the transmission mechanism injects the mixing barrel for several times in a reciprocating manner, the central control unit detects the high-temperature refractory performance of the refractory castable in the mixing barrel after the n/4 th time of raw material injection, if the high-temperature refractory performance of the refractory castable meets the standard, the central control unit determines that the grinding rotation speed and the oscillation frequency of the screen are not adjusted currently for each material injecting machine, and if the high-temperature refractory performance of the refractory castable does not meet the standard, the central control unit adjusts the grinding rotation speed and the oscillation frequency of the screen for each material injecting machine, and the first preset condition is that the difference between the total amount injected into the mixing barrel and the weight of the castable raw material in the mixing barrel is predicted to be within a preset range and m0 is not more than D1, where n/4 is an integer, and if the difference is a non-integer, the material is rounded downwards.
Further, under a second preset condition, the central control unit detects the flowability of the refractory castable in the mixing barrel after the n/2 th raw material injection, if the flowability of the refractory castable meets the standard, the central control unit judges that the raw material injection frequency and the stirring speed in the mixing barrel are not adjusted, if the flowability of the refractory castable does not meet the standard, the central control unit judges that the single injection amount of spherical mullite is increased, and the stirring speed of the mixing barrel is improved, wherein n is the preset raw material injection frequency, and the second preset condition is that the difference value between the total injection amount in the mixing barrel and the predicted weight of the castable raw material in the mixing barrel is within a preset range, and D1 is more than m0 and less than D2.
Further, under a second preset condition, the central control unit detects the high-temperature refractory performance of the refractory castable in the mixing barrel after 3/4 xn times of raw material injection, if the high-temperature refractory performance of the refractory castable meets the standard, the central control unit judges that the transmission rate of the transmission mechanism and the oscillation frequency of the screen are not adjusted, and if the high-temperature refractory performance of the refractory castable does not meet the standard, the central control unit adjusts the transmission rate of the transmission mechanism and the oscillation frequency of the screen, wherein 3/4 xn is an integer, and if the high-temperature refractory performance of the refractory castable is a non-integer, the central control unit rounds downwards.
Further, the difference value Δ M between the weight M0 of the raw material in the mixing cylinder and the weight M0 of the castable raw material in the prediction mixing cylinder is, wherein M0= Md × i, if the difference value is smaller than a preset difference value, the central control unit determines that the difference value between the total injection amount in the mixing cylinder and the weight of the castable raw material in the prediction mixing cylinder is within a preset range, if the difference value is larger than the preset difference value, the central control unit determines that the difference value between the total injection amount in the mixing cylinder and the weight of the castable raw material in the prediction mixing cylinder is not within the preset range, the central control unit adjusts the cleaning frequency and the screen oscillation frequency of the inner cylinder wall of the mixing cylinder, md is set as the single injection amount of the castable raw material in the mixing cylinder, and i is the injected number of times.
Further, the central control unit adjusts the cleaning frequency of the inner cylinder wall of the mixing cylinder, the oscillation frequency of the screen and the grinding rotation speed of each material injector according to a difference value Δ M between the weight M0 of the raw material in the mixing cylinder and the weight M0 of the castable raw material in the predicted mixing cylinder, sets Δ M = M0-M0, when the difference value Δ M is smaller than a first preset difference value Δ M1, the central control unit increases the oscillation frequency PZ of the screen to PZ1, sets PZ1= PZ1 x (1 + (Δm1- Δ M)/Δm 1), simultaneously increases the cleaning frequency PT of the inner cylinder wall of the mixing cylinder to PT1, sets PT1= PT x (1 + (m1- Δ M)/Δm 1), when the difference value Δ M is larger than a second preset difference value Δ M2, the central control unit judges that the grinding rotation speed of each material injector is reduced to VY1, and sets YV1= VU x (Δ 1)/(- Δ M2).
In another aspect, the invention provides a refractory castable material based on spherical micro powder, which comprises RM70 particles of 3-5 meshes, 1-3 meshes, 0-1 meshes and 200 meshes, cement, kyanite, spherical silicon micro powder, spherical alumina micro powder, spherical mullite RW60 micro powder, silica fume and an additive.
Further, 17 parts of 3-5 mesh RM70 particles, 30 parts of 1-3 mesh RM70 particles, 17 parts of 0-1 mesh RM70 particles, 18 parts of 200 mesh RM70 particles, 6 parts of cement, 2 parts of kyanite, 2 parts of spherical silicon micropowder, 4 parts of spherical mullite RW60 micropowder and 3 parts of silica fume are added, the water content is 6.5%, and the fluidity is 238.
Compared with the prior art, the preparation process for preparing the refractory castable has the beneficial effects that the preparation process can select proper raw material injection parameters according to the use scene of the castable, more particularly, the quality of particles which have great influence on the shape of the castable is mainly selected, the particles comprise spherical mullite 60 which has great influence on the fluidity, spherical alumina which has great influence on the compressive strength and the high-temperature strength and spherical silica micropowder which has great influence on the compressive strength and the rupture strength, and the content and the quality of the raw materials have important effects on the performance of the prepared castable. Therefore, when the central control unit determines the content of each raw material according to the use scene, the quality control of the spherical mullite 60, the spherical silica powder and the spherical alumina and the sufficient mixing of the raw materials of the mixing barrel are assisted, and the basic performance of the castable and the performance of the use scene are ensured to meet the standard.
Particularly, the weight is divided into two standards by the control unit, the optimal speed is selected as the stirring speed of the mixing cylinder by comparing the weight of the castable raw material in the mixing cylinder with the preset weight, the stirring speed is dynamically adjusted to be matched with the weight of the raw material in the mixing cylinder, and the stirring uniformity of the mixture in the mixing cylinder is improved.
Particularly, the invention adopts a multi-injection mode to improve the uniform stirring of each micro powder and a mixture, avoids uneven mixing caused by uniform feeding and influences the performance of a castable, and in the multi-injection process, in order to avoid that each micro powder in the early-stage injection process does not accord with the standard and cannot correct the performance of the castable in the later stage, if the difference value between the total injection amount in a mixing cylinder and the weight of the castable raw material in a predicted mixing cylinder is within a preset range and the weight in the mixing cylinder is less than or equal to a first preset weight, a central control unit judges that the high-temperature refractory performance of the castable after the n/4 th time of raw material injection is detected, if the refractory performance does not accord with the standard, the central control unit improves the particle size of each micro powder raw material injected in the later stage by improving the rotating speed of each injection machine and the oscillation frequency of a screen, and simultaneously avoids that the micro powder on the screen is gathered to reduce the discharge amount of a discharge port.
Particularly, when the difference value between the total injection amount in the mixing cylinder and the weight of the castable raw material in the mixing cylinder is predicted to be between a first preset weight and a second preset weight within a preset range, the invention detects the flowability of the castable after the n/2 th raw material injection, determines whether the flowability meets the standard, timely adjusts the flowability if not, avoids that the castable after bagging packaging does not meet the standard and causes construction abnormity, and the flowability of the finished castable does not meet the standard and has too large rework or blending difficulty, so that in the preparation process, when the second preset condition is met, the central control unit detects the flowability of the castable after the n/2 th raw material injection, and if the flowability does not meet the standard, the central control unit judges that the single injection amount of the spherical mullite is increased, namely the single injection amount of the second material injector is increased, the flowability of the castable is ensured, meanwhile, the stirring speed of the mixing cylinder is increased, and the added micro powder is fully stirred with each raw material.
Particularly, the invention detects the high-temperature fire resistance of the later-injected raw materials again under the second preset condition, and adjusts the preparation process parameters of the castable which does not meet the standard so as to ensure that the fire resistance of the produced castable meets the standard.
Particularly, the invention also provides a method for comparing the real-time weight in the mixing cylinder with the predicted weight, determining whether the current injection process is abnormal according to the comparison result, ensuring that the injection amount meets the standard, if the difference between the real-time weight and the predicted weight in the mixing cylinder obtained by the central control unit is smaller than a first preset difference, indicating that the real-time weight in the mixing cylinder is too low, the central control unit improves the cleaning frequency of the inner wall of the mixing cylinder to sweep the micro powder with viscosity on the wall into the mixing cylinder, and simultaneously improves the oscillation frequency of the screen of each injection machine, so that more particles with the particle size meeting the standard are discharged through the discharge port, and the discharge amount of the discharge port of each injection machine is prevented from not meeting the preset value, and the central control unit obtains that the difference between the real-time weight and the predicted weight in the mixing cylinder is larger than a second preset difference, indicating that the real-time weight in the mixing cylinder is too high, the cause that the casting material is injected in a single injection at the preset amount, the electromagnetic valve arranged at each discharge port controls the particle size to be larger in a particle size through volume, so that the particle output is caused by the too small pouring material, the particle size is prevented from being abnormally increased, and the particle size is caused by the grinding speed of the central control unit, and the particle size is prevented from causing the abnormal particle output.
Drawings
FIG. 1 is a graph of the particle size distribution of spherical alumina according to an embodiment of the present invention;
FIG. 2 is a graph showing the distribution of the spherical mullite RW60 particle size in the embodiment of the invention;
FIG. 3 is a CT9FG particle size distribution diagram according to the embodiment of the present invention;
FIG. 4 is a particle size distribution diagram of spherical silica powder according to an embodiment of the present invention;
FIG. 5 is a graph showing the distribution of the U particle size of an embodiment 951;
FIG 6 is a schematic structural diagram of refractory castable production equipment based on spherical micropowder according to the embodiment of the invention;
FIG. 7 is a schematic view of the structure of a material injection machine according to an embodiment of the present invention;
FIG. 8 is a schematic structural diagram of a mixing barrel according to an embodiment of the present invention.
Detailed Description
In order that the objects and advantages of the invention will be more clearly understood, the invention is further described below with reference to examples; it should be understood that the specific embodiments described herein are merely illustrative of the invention and do not delimit the invention.
Preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only for explaining the technical principles of the present invention, and do not limit the scope of the present invention.
It should be noted that in the description of the present invention, the terms of direction or positional relationship indicated by the terms "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, which are only for convenience of description, and do not indicate or imply that the device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.
Furthermore, it should be noted that, in the description of the present invention, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
The casting material product mullite low-cement casting material is used as a basic formula, spherical byproducts are introduced, wherein the spherical byproducts comprise spherical silicon micropowder (hairy) defective products, spherical mullite RW60 (W powder) and spherical alumina (W powder), raw materials in the original formula are replaced according to the characteristics of the three byproducts, wherein the raw materials of the casting material product mullite low-cement casting material are RM70 granular materials with 3-5,1-3,0-1 and 200 meshes, calcined alumina (CT 9 FG), silica fume (Eken 951U), cement (SECAR 71) and kyanite, and additives comprise citric acid, explosion-proof fibers and sodium tripolyphosphate.
Please refer to fig. 1, which is a particle size distribution diagram of CT9FG, 951U, spherical alumina-W powder, spherical RM60-W powder, and spherical silica micropowder of the present invention, wherein the particle size distribution table refers to table one, the particle size of CT9FG to be replaced is similar to that of spherical mullite RM60-W powder, and can be replaced, the alumina content of spherical RM60-W powder is lower, and the addition of alumina into the castable is partly because mullite is generated at high temperature, so that it is theoretically feasible to add the spherical mullite of mullite component directly, and the particle size replaced by spherical alumina-W powder is larger, but the spherical alumina component is similar to that of CT9FG, and the purity is much higher than that of CT9FG, so that the replacement of spherical alumina is feasible, and two types of spherical silica micropowder are respectively used to treat spherical waste to reduce the cost, increase the spherical product, improve the product performance, and both can be replaced from the viewpoint of particle size distribution and chemical index.
TABLE I particle size distribution table for CT9FG, 951U, spherical alumina-W powder, spherical RM60-W powder, and spherical silica micropowder
| Particle size distribution | <10 micron | <25 micron | <50 micron | <75 micron | <90 micron |
| CT9FG | 1.385 | 1.857 | 2.735 | 4.209 | 6.808 |
| Spherical alumina-W powder | 3.634 | 7.132 | 20.13 | 49.34 | 89.35 |
| Spherical mullite RM60-W powder | 1.336 | 1.659 | 2.218 | 3.197 | 5.125 |
| 951U | 0.134 | 0.224 | 0.434 | 5.049 | 9.234 |
| Spherical silicon micro powder | 0.132 | 0.216 | 0.392 | 1.602 | 4.969 |
In the first embodiment, spherical silica micropowder is used to replace silica fume, the specific mixture ratio is shown in table two, wherein, 1# is used as a basic control group, the castable produced by the castable is detected in the processes of adding 6.5% of water, 100 ℃ for 24h of volume density, compressive strength and flexural strength, 1000 ℃ for 3h of volume density, linear change, compressive strength and flexural strength, 1500 ℃ for 3h of volume density, linear change, compressive strength and flexural strength, and the detection result is shown in table three.
Second, the spherical silica micropowder replaces silica fume to produce castable
TABLE III, detection result of castable produced by replacing silica fume with spherical silica fume
Along with the gradual increase of the spherical silicon micropowder, the flowability is better and better, the linear expansion at medium and high temperature is smaller and smaller, the low-temperature strength value is lower and lower, the medium and high-temperature strength is lower and lower, and the volume density is gradually reduced, so that the contribution of increasing the spherical silicon micropowder lies in that the influence on the strength is larger and is not good. But with beneficial effects and improvements on line variations. And 3# is selected according to all indexes.
In the second embodiment, the spherical mullite 60 is used to replace calcined alumina, the specific mixture ratio is shown in table four, the castable produced by the method is tested for the fluidity of 6.5% of water addition, the volume density, the compressive strength and the breaking strength of 24 hours at 100 ℃, the volume density, the linear change, the compressive strength and the breaking strength of 3 hours at 1000 ℃, and the volume density, the linear change, the compressive strength and the breaking strength of 3 hours at 1500 ℃, and the test results are shown in table five.
Fourth, the spherical mullite 60 replaces the calcined alumina castable
Table five, the detection result of the castable produced by replacing calcined alumina with spherical mullite 60
With the gradual addition of the spherical RM60, the fluidity is increased, the low-temperature strength is firstly improved, the turning point is reduced, the medium-high temperature strength is not greatly changed, the influence of the volume density is not large, and the linear expansion change trend is gradually reduced. Therefore, the most beneficial contribution of adding the spherical RM60-W powder is the improvement of the flow value and the improvement of the construction performance, meanwhile, the influence on the line change is obvious, and 11# is selected according to all indexes.
In the third embodiment, spherical alumina is used instead of calcined alumina, the specific mixture ratio is shown in table six, the produced castable is tested for the fluidity of 6.5% of water addition, the volume density, the compressive strength and the breaking strength of 24 hours at 100 ℃, the volume density, the linear change, the compressive strength and the breaking strength of 3 hours at 1000 ℃, and the volume density, the linear change, the compressive strength and the breaking strength of 3 hours at 1500 ℃, and the test results are shown in table seven.
TABLE VI, production of casting material by replacing calcined alumina with spherical alumina
TABLE seven, detection results of castable produced by replacing silica fume with spherical alumina
With the gradual increase of the spherical alumina, the fluidity is increased first and then decreased because the spherical alumina particles are larger. The low-temperature strength is very small in folding resistance, but the compressive strength is very large, and the medium-high temperature strength is very high, so that the increase is obvious. The line change gradually decreases, and therefore the addition of spherical alumina contributes to the improvement of the strength at medium and high temperatures. While the line variation also decreases the trend. And selecting 18# by combining all indexes.
Example four, according to the above examples, 3#, 11# and 18# are selected and mixed, the formula is shown in table eight, the detection result of the prepared product is shown in table nine,
mixed casting material of Table eight, 3#, 11# and 18#
Table nine, 3#, 11# and 18# mixed castable test results
In conclusion, on the basis of the original ingredients of the casting material mullite low-cement casting material product, the spherical alumina or spherical RM60 is adopted to replace the alumina, and the spherical silica is adopted to replace the silica fume, so that the shape of the casting material can be obviously improved, and the fluidity, the linear change and the high-temperature breaking strength are obviously improved. The invention provides a castable which is produced according to different requirements without proportioning, wherein the 21# low-cement castable has high fluidity, less water addition and good construction performance, the 18# high-strength anti-explosion castable has high strength, particularly high-temperature strength, and the 22# reinforced high-strength anti-explosion castable has good construction performance and high-temperature strength.
Fig. 6 is a schematic structural diagram of a refractory castable production device based on spherical micro powder according to an embodiment of the present invention, including a first injector 1 for grinding spherical silica micro powder and injecting the spherical silica micro powder with a particle size meeting a standard into a mixing cylinder; the second material injection machine 2 is used for grinding the spherical mullite 60 and injecting the spherical mullite 60 with the grain diameter meeting the standard into the mixing cylinder; the third material injection machine 3 is used for grinding the spherical alumina and injecting the spherical alumina with the grain diameter meeting the standard into the mixing cylinder; the fourth material injection machine 4 is used for storing alumina powder and injecting the alumina powder into the mixing barrel; a fifth material injection machine 5 for storing silica fume and injecting the silica fume into the mixing barrel; and the stirrer 6 is used for stirring the RM70 granules of 3-5 meshes, 1-3 meshes, 0-1 meshes and 200 meshes, cement (SECAR 71) kyanite, citric acid, explosion-proof fibers and sodium tripolyphosphate to form a mixture, and injecting the mixture into the mixing barrel.
Specifically, in the embodiment of the invention, the stirring mechanism for stirring the RM70 granules of 3-5,1-3,0-1 and 200 meshes, the cement (SECAR 71) kyanite, the citric acid, the explosion-proof fiber and the sodium tripolyphosphate in the stirrer is not limited, and the stirring mechanism can be electromagnetic stirring or ultrasonic stirring.
The mixing cylinder 7 is arranged on the transmission mechanism and is used for receiving the spherical silica powder injected by the first grinding and injecting machine, the spherical mullite 60 injected by the second grinding and injecting machine, the spherical alumina injected by the third grinding and injecting machine, the alumina powder injected by the first storing and injecting machine, the silica fume injected by the second storing and injecting machine and the mixture injected by the mixing machine, and stirring the mixture to form a refractory castable; the transmission mechanism 8 is used for moving the mixing cylinder; and the support frame 9 is arranged above the support frame, and the first material injection machine, the second material injection machine, the third material injection machine, the fourth material injection machine, the fifth material injection machine, the stirrer and the transmission mechanism are arranged above the support frame.
And a central control unit (not shown in the figure), which is in communication connection with the first material injection machine, the second material injection machine, the third material injection machine, the fourth material injection machine, the fifth material injection machine, the stirrer and the transmission mechanism, and is used for adjusting the grinding rate of each material injection machine, the oscillation frequency of a screen in each material injection machine, the barrel wall cleaning frequency of the mixing barrel and the transmission rate of the transmission mechanism according to the detection result of the castable in the mixing barrel, so that the properties of the refractory castable meet the standard.
Specifically, each material injection machine according to the embodiment of the present invention has the same structure, and as shown in fig. 7, it is a schematic structural diagram of the material injection machine according to the embodiment of the present invention, including a grinding mechanism for grinding the micro powder in the material injection machine, the embodiment of the present invention does not limit the type, size, and dimension of the grinding mechanism, and it needs to be set according to the target particle size of each micro powder, the grinding mechanism may be a spherical grinding mechanism, or a grinding type grinder, the embodiment of the present invention provides a preferred embodiment, the grinding mechanism includes a first motor 111 for controlling a first grinder 112 provided with a plurality of grinding balls to rotate, and a second motor 114 for controlling a second grinder 113 provided with a plurality of grinding balls to rotate, the second grinder and the first grinder rotate in opposite directions, a screen 13 and an oscillating mechanism for controlling the oscillation frequency of the screen are provided below the grinding mechanism, the oscillating mechanism includes a first support seat 131 provided below the material injection machine, a first support seat provided above the first support seat connected to the screen, a second support seat provided below the second support seat 131 provided below the second support seat, and an oscillating spring 132 provided above the second support seat to prevent the second support seat from moving downward, and the second support seat 132 is provided above the second support seat and the second support seat 132 to oscillate the second spring to prevent the second grinder from moving downward, and the oscillating spring from affecting the discharge port of the second support seat 132.
Please refer to fig. 8, which is a schematic diagram of a mixing barrel according to an embodiment of the present invention, including a third motor 74 for controlling a rotation rate of a screw rod 76, a first gear 75 disposed on the screw rod, a second gear 72 disposed on the first gear, and a sweeper 73 connected to the second gear for sweeping powder on a wall of the mixing barrel.
Specifically, the preparation process of the refractory castable based on spherical micro powder comprises the following steps of,
s1, selecting the injection amount of each raw material and required standard parameters by a central control unit according to the requirements of a target refractory castable;
s2, the mixing cylinder is conveyed to the discharge port of each material injection machine by a transmission mechanism, each material injection machine injects raw materials of the refractory castable into the mixing cylinder according to the injection amount selected by the central control unit, and the mixing cylinder controls the stirring speed according to the total injection amount of the raw materials of the refractory castable so as to uniformly mix the raw materials of the refractory castable;
and S3, detecting the high-temperature fire resistance and the fluidity of the produced refractory castable, comparing the detected high-temperature fire resistance and the fluidity with required standard parameters, and adjusting the grinding speed of each casting machine, the oscillation frequency of an inner screen of each casting machine and the cleaning frequency of the wall of the mixing barrel so as to enable the properties of the refractory castable to meet the standard.
Specifically, the preparation process for preparing the refractory castable material can select proper raw material injection parameters according to the use scene of the castable material, more specifically, the quality of particles which have great influence on the shape of the castable material mainly comprises spherical mullite 60 which has great influence on the fluidity, spherical alumina which has great influence on the compressive strength and the high-temperature strength, and spherical silica micropowder which has great influence on the compressive strength and the flexural strength, and the content and the quality of the raw materials have important effects on the performance of the prepared castable material. Therefore, when the central control unit determines the content of each raw material according to the use scene, the quality control of the spherical mullite 60, the spherical silica powder and the spherical alumina and the sufficient mixing of the raw materials of the mixing barrel are assisted, and the basic performance of the castable and the performance of the use scene are ensured to meet the standard.
Specifically, according to the requirement of the target refractory castable, standard values are set for various required properties, wherein the basic property standard values are respectively 215mm in fluidity (the water addition amount is 6.5%), 120Mpa in medium-high temperature compressive strength (the medium-high temperature is 1000 ℃ for 3 h), 38Mpa in bending strength, 200Mpa in high-temperature compressive strength and 30Mpa in bending strength (the high temperature is 1500 ℃ for 3 h), when the requirement of the target refractory castable is high fluidity, the fluidity standard value is set to 215+ (10-15) mm, the high-temperature bending resistance is required, the high-temperature bending strength standard value is set to 30+ (2-5) Mpa, and the high-temperature compressive performance standard value is set to 200+ (8-15) mm.
In the step S1, the central control unit selects an injection amount of each raw material according to a requirement of a target refractory castable, when the requirement of the target refractory castable is M1, the central control unit selects a weight M11 as an injection amount of spherical mullite 60, a weight M12 as an injection amount of spherical alumina, a weight M13 as an injection amount of spherical silica micropowder, a weight M14 as an injection amount of alumina, and a weight M15 as an injection amount of silica fume, when the requirement of the target refractory castable is M2, the central control unit selects a weight M21 as an injection amount of spherical mullite 60, a weight M22 as an injection amount of spherical alumina, a weight M23 as an injection amount of spherical silica micropowder, and a weight M24 as an injection amount of alumina, and a weight M25 as an injection amount of silica fume, when the requirement of the target refractory castable is M3, the central control unit selects a weight M31 as an injection amount of spherical mullite 60, a weight M32 as an injection amount of spherical alumina, a weight M33 as an injection amount, a weight M34 as an injection amount of silica fume, wherein the M1 is a requirement of spherical mullite 60, the injection amount of spherical alumina, the spherical alumina injection amount of silica fume is a requirement of a high-temperature-resistant performance requirement, and the high-temperature-resistant fine powder is a requirement of M3, wherein the high-temperature-resistant fine powder is a requirement.
Specifically, in the embodiment of the invention, when the target refractory casting material is required to have strong fluidity, the central control unit is selected to have the spherical mullite 60 injection amount by weight, the spherical alumina injection amount by weight 0 part, the spherical silica micropowder injection amount by weight 2 parts, the alumina injection amount by weight 3 parts and the silica fume injection amount by weight 3 parts, when the target refractory casting material is required to have high-temperature bending resistance, the central control unit is selected to have the spherical mullite 60 injection amount by weight, the spherical alumina injection amount by weight 5 parts, the spherical silica micropowder injection amount by weight 2 parts, the alumina injection amount by weight 2 parts and the silica fume injection amount by weight 3 parts, when the target refractory casting material is required to have high-temperature pressure resistance, the central control unit is selected to have the spherical mullite 60 injection amount by weight, the spherical alumina injection amount by weight 0 part, the spherical silica micropowder injection amount by weight 5 parts, the spherical silica fume injection amount by weight 2 parts and the silica fume injection amount by weight 5 parts, the total weight of each raw material is a fixed value Mw, and the weight of the M =12 parts, and the weight Mh of the mixture in the mixer is set to be 90.33.33.33.h.
Wherein the central control unit obtains the weight m0 of the castable raw material in the mixing barrel and compares the weight with a preset weight D, selects the stirring speed in the mixing barrel, wherein,
when m0 is less than or equal to D1, the central control unit selects a first preset speed V1 as the stirring speed in the mixing barrel;
when D1 is larger than m0 and smaller than D2, the central control unit selects a second preset speed V2 as the stirring speed in the mixing cylinder;
when m0 is larger than or equal to D2, the central control unit selects a third preset speed V3 as the stirring speed in the mixing cylinder;
the central control unit presets a weight D, sets a first preset weight D1, sets a second preset weight D2, presets a speed V, sets a first preset speed V1, sets a second preset speed V2 and sets a third preset speed V3.
Specifically, the weight is divided into two standards by the control unit of the invention, the optimum speed is selected as the stirring speed of the mixing cylinder by comparing the weight of the castable raw material in the mixing cylinder with the preset weight, the stirring speed is dynamically adjusted to enable the stirring speed to be matched with the weight of the raw material in the mixing cylinder, and the stirring uniformity degree of the mixture in the mixing cylinder is improved.
In the step S2, the material injection machines and the stirrer inject raw materials into the mixing cylinder for several times, the transmission mechanism realizes the batch injection of the mixing cylinder in a reciprocating transmission manner, the central control unit detects the high-temperature refractory property of the refractory castable in the mixing cylinder after the n/4 th time of material injection, if the high-temperature refractory property of the refractory castable meets the standard, the central control unit judges that the grinding rotation speed of each material injection machine and the oscillation frequency of the screen are not adjusted currently, if the high-temperature refractory property of the refractory castable does not meet the standard, the central control unit adjusts the grinding rotation speed of each material injection machine and the oscillation frequency of the screen, the first preset condition is that the difference between the total injection amount in the mixing cylinder and the weight of the castable raw materials in the mixing cylinder is predicted to be within a preset range and m0 is not more than D1, wherein n/4 is an integer, and if the difference is a non-integer, the material is rounded downwards.
Specifically, the central control unit judges that the high-temperature fire resistance of the castable under the first preset condition does not meet the standard, and according to the difference between the high-temperature and high-temperature rupture strength G01 and the preset high-temperature rupture strength G01, the central control unit increases the grinding rotating speeds vy0 to vy1 of each castable, sets vy1= vy0 x (1 +. DELTA.e), and simultaneously increases the oscillation frequencies pz0 to pz1 of the screen, sets pz1= pz0 x (1 +. DELTA.e), wherein, DELTA.e = (G01-G01)/G01.
Specifically, the central control unit determines that the high-temperature refractory performance of the castable under the first preset condition does not meet the standard, and according to the difference between the high-temperature compressive strength G02 and the preset high-temperature compressive strength G02, the central control unit increases the grinding rotating speeds vy0 to vy1 of each injection machine, sets vy1= vy0 x (1 +. DELTA.e), and simultaneously increases the oscillation frequencies pz0 to pz1 of the screen, sets pz1= pz0 x (1 +. DELTA.e), wherein, DELTA.e = (G02-G02)/G02).
Specifically, the central control unit judges that the high-temperature fire resistance of the castable under the first preset condition does not meet the standard, and according to the difference between the high-temperature and high-temperature bending strength G01 and the preset high-temperature bending strength G01 and the difference between the high-temperature compressive strength G02 and the preset high-temperature compressive strength G02, the central control unit increases the grinding rotating speeds vy0 to vy1 of each injection machine, sets vy1= vy0 x (1 +. DELTA.e), and simultaneously increases the oscillation frequencies pz0 to pz1 of the screen, and sets pz1= pz0 x (1 +. DELTA.e), wherein DELTA.e = (G01-G01)/G01 x ((G02-G02)/G02).
Specifically, the embodiment of the invention explains the injection mode, the transmission mechanism controls the mixing cylinder to move from the transmission mechanism, the first material injection machine receives spherical silica powder with the particle size meeting the standard, the second material injection machine receives spherical mullite 60 with the particle size meeting the standard, the third material injection machine receives spherical alumina with the particle size meeting the standard, the fourth material injection machine receives alumina powder, the fifth material injection machine receives silica fume, the stirring machine receives the mixture, the transmission mechanism performs reverse transmission, the stirring machine receives the mixture, the fifth material injection machine receives silica fume, the fourth material injection machine receives alumina powder, the third material injection machine receives spherical alumina with the particle size meeting the standard, the second material injection machine receives spherical mullite 60 with the particle size meeting the standard, the first material injection machine receives spherical silica powder with the particle size meeting the standard, the second injection is performed, and the cycle is performed until the preset injection times are completed.
Specifically, in the embodiment of the invention, the high-temperature refractory performance is high-temperature compressive strength and high-temperature bending strength, the central control unit evaluates according to the requirement of a target castable, specifically, if the target requirement is high fluidity, a high-temperature bending strength basic standard value and a high-temperature compressive strength basic standard value are selected as the evaluation standards of the refractory performance, at this time, the evaluation mode that the refractory performance meets the standard is that the high-temperature compressive strength and the high-temperature bending strength of the castable are higher than the respective basic standard values, if the target requirement is high-temperature bending strength, the adjusted high-temperature bending strength is selected as an evaluation value, the evaluation mode that the refractory performance meets the standard is that the high-temperature compressive strength of the castable is higher than a preset high-temperature compressive strength basic standard value, the high-temperature bending strength is higher than the adjusted high-temperature bending strength standard value, if the target requirement is high-temperature compressive strength, the adjusted high-temperature compressive strength standard value is selected as the evaluation value, and the evaluation mode that the refractory performance meets the standard is that the high-temperature compressive strength of the castable is higher than the adjusted high-temperature compressive strength, and the high-temperature bending strength is higher than the preset high-temperature bending strength standard value, wherein the requirement that the refractory performance meets the high-temperature compressive strength standard and the high-temperature compressive strength meets the high-temperature bending strength standard requirement.
The invention adopts a multi-injection mode to improve the uniform stirring of each micro powder and a mixture, avoids uneven mixing caused by unified feeding and influences the performance of a castable, and in the process of multi-injection, in order to avoid that each micro powder in the process of early-stage injection does not meet the standard and the performance of the castable cannot be corrected in the later stage, if the difference value between the total injection amount in a mixing cylinder and the weight of the castable raw material in a predicted mixing cylinder is within a preset range and the weight in the mixing cylinder is less than or equal to a first preset weight, a central control unit judges that the high-temperature refractory performance of the castable after the injection of the nth/4 th raw material is detected, and if the refractory performance does not meet the standard, the central control unit improves the particle size of each micro powder raw material in the mixing cylinder in the later stage by improving the rotating speed of each injection machine and the oscillation frequency of a screen, and simultaneously avoids the reduction of the discharge amount caused by the aggregation of the micro powder on the screen.
Specifically, under a second preset condition, the central control unit detects the flowability of the refractory castable in the mixing barrel after injecting the n/2 th raw material, if the flowability of the refractory castable meets the standard, the central control unit judges that the raw material injection frequency and the stirring speed in the mixing barrel are not adjusted, if the flowability of the refractory castable does not meet the standard, the central control unit judges that the single injection amount of spherical mullite is increased, and the stirring speed of the mixing barrel is improved, wherein n is the preset raw material injection frequency, and the second preset condition is that the difference value between the total injection amount in the mixing barrel and the predicted castable raw material weight in the mixing barrel is within a preset range, and D1 is more than m0 and more than D2.
The central control unit increases the single injection amount of the spherical mullite to mm1, sets mm1= mm +1.2 × Δ u, increases the stirring speed V2 to V21 of the mixing barrel, and sets V21= V2 × (1 + Δu) according to the comparison between the current casting material fluidity and a preset fluidity standard value, wherein Δ u = (F0-F)/F0.
Specifically, when the difference value between the total injection amount in the mixing cylinder and the weight of the castable raw material in the mixing cylinder is predicted to be between a first preset weight and a second preset weight within a preset range, the flowability of the castable after the n/2 th raw material injection is detected, whether the flowability meets the standard or not is determined, if not, the flowability is adjusted in time, the situation that the castable after bagging and packaging does not meet the standard and causes construction abnormity is avoided, the flowability of the finished castable does not meet the standard, and the difficulty in rework or blending is too high is avoided, so that in the preparation process, when the second preset condition is met, the central control unit detects the flowability of the castable after the n/2 th raw material injection, and if the flowability does not meet the standard, the central control unit judges that the single injection amount of spherical mullite is increased, namely the single injection amount of the second injection machine is increased, the flowability of the castable is ensured, meanwhile, the stirring speed of the mixing cylinder is increased, and the added micro powder is fully stirred with each raw material.
Under a second preset condition, the central control unit detects the high-temperature refractory performance of the refractory castable in the mixing barrel after 3/4 xn times of raw material injection, if the high-temperature refractory performance of the refractory castable meets the standard, the central control unit judges that the transmission speed of the transmission mechanism and the oscillation frequency of the screen are not adjusted, if the high-temperature refractory performance of the refractory castable does not meet the standard, the central control unit adjusts the transmission speed of the transmission mechanism and the oscillation frequency of the screen, wherein 3/4 xn is an integer, and if the high-temperature refractory performance of the refractory castable is a non-integer, the central control unit rounds the transmission speed of the transmission mechanism and the oscillation frequency of the screen.
The central control unit determines that the high-temperature fire resistance of the castable under the second preset condition does not meet the standard, and according to the difference between the high-temperature and high-temperature breaking strength G10 and the preset high-temperature breaking strength G01, the central control unit reduces the transmission speed vc to vc1 of the transmission mechanism, sets vc1= vc x (1- Δ r), and simultaneously increases the oscillation frequency pzb to pzb1 of the screen, sets pzb1= pzb x (1- Δ r), wherein Δ r = (G01-G10)/G01, b =0,1.
The central control unit judges that the high-temperature fire resistance of the castable does not meet the standard under the second preset condition, and according to the difference between the high-temperature compressive strength G20 and the preset high-temperature compressive strength G02, the central control unit reduces the transmission speed vc to vc1 of the transmission mechanism, sets vc1= vc x (1-delta r), and simultaneously increases the oscillation frequency pzb to pzb1 of the screen, sets pzb1= pzb x (1-delta r), wherein delta r = (G02-G20)/G02, and b =0,1.
The central control unit judges that the high-temperature fire resistance of the castable under the second preset condition does not meet the standard, and the central control unit reduces the transmission speed vc to vc1 of the transmission mechanism according to the difference between the high-temperature and high-temperature rupture strength G10 and the preset high-temperature rupture strength G01 and the difference between the high-temperature compressive strength G20 and the preset high-temperature compressive strength G02, sets vc1= vc x (1- Δ r), and simultaneously increases the oscillation frequency pzb to pzb1 of the screen mesh, sets pzb1= pzb x (1- Δ r), wherein Δ r = (G02-G20)/G02 x ((G01-G10)/G01), and b =0,1.
Specifically, under a second preset condition, the high-temperature fire resistance of the raw materials injected in the later period is detected again, and the preparation process parameters of the castable which does not meet the standard are adjusted to ensure that the fire resistance of the produced castable meets the standard.
The method comprises the steps that the difference value delta M between the weight M0 of raw materials in a mixing barrel and the weight M0 of castable raw materials in a forecasting mixing barrel is obtained, wherein M0= Md x i, if the difference value is smaller than a preset difference value, a central control unit judges that the difference value between the total injection amount in the mixing barrel and the weight of castable raw materials in the forecasting mixing barrel is within a preset range, if the difference value is larger than the preset difference value, the central control unit judges that the difference value between the total injection amount in the mixing barrel and the weight of castable raw materials in the forecasting mixing barrel is not within the preset range, the central control unit adjusts the cleaning frequency of the inner barrel wall of the mixing barrel and the oscillation frequency of a screen, md is set as the single injection amount of castable raw materials in the mixing barrel, and i is the injected times.
The central control unit adjusts cleaning frequency of an inner cylinder wall of the mixing cylinder, oscillation frequency of the screen and grinding rotation speed of each material injection machine according to a difference value delta M between the weight M0 of the raw materials in the mixing cylinder and the weight M0 of the castable raw materials in the mixing cylinder, sets delta M = M0-M0, when the difference value delta M is smaller than a first preset difference value delta M1, the central control unit improves the oscillation frequency PZ of the screen to PZ1, sets PZ1= PZ1 x (1 + (. DELTA M1-. DELTA M)/. DELTA M1), simultaneously improves the cleaning frequency PT to PT1 of the inner cylinder wall of the mixing cylinder, sets PT1= PT x (1 + (. DELTA M1-. DELTA M)/. DELTA M1), when the difference value delta M is larger than a second preset difference value delta M2, the central control unit judges to reduce the grinding rotation speed VY to VY1 of each material injection machine, and sets YV1 VU 1= VUx (1- (. DELTA M2)/. DELTA M2).
Specifically, the first preset difference is a negative value, and the second preset difference is a positive value.
The invention also provides a method for controlling the particle size of the fine particles, which comprises the steps of comparing the real-time weight in the mixing cylinder with the predicted weight, determining whether the current injection process is abnormal according to a comparison result, ensuring that the injection amount meets the standard, if the difference between the real-time weight and the predicted weight in the mixing cylinder obtained by the central control unit is smaller than a first preset difference, indicating that the real-time weight in the mixing cylinder is too low, increasing the vibration frequency of screens of all injection machines by the central control unit through increasing the cleaning frequency of the inner wall of the mixing cylinder so as to sweep the fine particles with viscosity on the wall into the mixing cylinder, and discharging more fine particles with the particle size meeting the standard through a discharge port so as to avoid the discharge amount of each injection machine not meeting the preset value, wherein the central control unit obtains that the difference between the real-time weight and the predicted weight in the mixing cylinder is larger than a second preset difference, indicating that the real-time weight in the mixing cylinder is too high, and the undersize cause that the injection of the casting material is injected in a preset amount once, the electromagnetic valves arranged at each discharge port control the discharge machine control the particle size to control unit controls the particle size so as to increase the particle size, thereby avoiding the abnormal particle size output caused by the abnormal performance.
So far, the technical solutions of the present invention have been described in connection with the preferred embodiments shown in the drawings, but it is apparent to those skilled in the art that the scope of the present invention is not limited to these specific embodiments. Equivalent changes or substitutions of related technical features can be made by those skilled in the art without departing from the principle of the invention, and the technical scheme after the changes or substitutions can fall into the protection scope of the invention.
Claims (10)
1. A preparation process of a refractory castable based on spherical micro powder is characterized by comprising the following steps:
s1, selecting the injection amount of each raw material and required standard parameters by a central control unit according to the requirements of a target refractory castable;
s2, the mixing cylinder is conveyed to the discharge port of each material injection machine by a transmission mechanism, each material injection machine injects raw materials of the refractory castable into the mixing cylinder according to the injection amount selected by the central control unit, and the mixing cylinder controls the stirring speed according to the total injection amount of the raw materials of the refractory castable so as to uniformly mix the raw materials of the refractory castable;
and S3, detecting the high-temperature fire resistance and the fluidity of the produced refractory castable, comparing the detected high-temperature fire resistance and the fluidity with required standard parameters, and adjusting the grinding speed of each material injecting machine, the oscillation frequency of a screen in each material injecting machine and the barrel wall cleaning frequency of the mixing barrel so as to enable the properties of the refractory castable to meet the standard.
2. The preparation process of the spherical micro powder-based refractory castable according to claim 1, wherein in the step S1, the central control unit selects the injection amount of each raw material according to the requirement of the target refractory castable, when the requirement of the target refractory castable is M1, the central control unit selects the weight M11 as the spherical mullite 60 injection amount, the weight M12 as the spherical alumina injection amount, the weight M13 as the spherical silica micro powder injection amount, the weight M14 as the alumina injection amount, and the weight M15 as the silica fume injection amount, when the requirement of the target refractory castable is M2, the central control unit selects the weight M21 as the spherical mullite 60 injection amount, the weight M22 as the spherical alumina injection amount, the weight M23 as the spherical silica micro powder injection amount, the weight M24 as the alumina injection amount, the weight M25 as the silica fume injection amount, when the requirement of the target refractory castable is M3, the central control unit selects the weight M31 as the spherical mullite 60 injection amount, the weight M32 as the spherical alumina injection amount, the weight M33 as the spherical silica fume injection amount, the weight M34 as the silica fume injection amount, wherein the requirement of the high temperature resistant silica fume injection amount is M3, and the requirement of the high temperature resistant silica fume is M2, wherein the requirement is M3.
3. The preparation process of refractory castable material based on spherical micropowder according to claim 2, wherein the central control unit obtains the weight m0 of castable material in the mixing barrel and compares with a preset weight D, selects the stirring speed in the mixing barrel, wherein,
when m0 is less than or equal to D1, the central control unit selects a first preset speed V1 as the stirring speed in the mixing barrel;
when D1 is larger than m0 and smaller than D2, the central control unit selects a second preset speed V2 as the stirring speed in the mixing barrel;
when m0 is larger than or equal to D2, the central control unit selects a third preset speed V3 as the stirring speed in the mixing cylinder;
the central control unit presets a weight D, sets a first preset weight D1, sets a second preset weight D2, presets a speed V, sets a first preset speed V1, sets a second preset speed V2 and sets a third preset speed V3.
4. The process of claim 3, wherein in the step S2, the material injectors and the stirrer inject the material into the mixing barrel for several times, the transmission mechanism performs the batch injection of the mixing barrel in a reciprocating manner, the central control unit detects the high temperature refractory performance of the refractory castable in the mixing barrel after the n/4 th material injection, if the high temperature refractory performance of the refractory castable meets the standard, the central control unit determines that the grinding rotation speed of each material injector and the oscillation frequency of the screen are not currently adjusted, if the high temperature refractory performance of the refractory castable does not meet the standard, the central control unit adjusts the grinding rotation speed of each material injector and the oscillation frequency of the screen, and the first preset condition is that the difference between the total injection amount in the mixing barrel and the weight of the castable in the predicted mixing barrel is within a preset range and m0 is not greater than D1, wherein n/4 is an integer, and if the difference is a non-integer, the material is downwardly rounded.
5. The preparation process of the castable refractory according to claim 4, wherein under a second preset condition, the central control unit detects the flowability of the castable refractory in the mixing barrel after the n/2 th raw material injection, if the flowability of the castable refractory meets the standard, the central control unit judges that the injection times of the raw materials and the stirring rate in the mixing barrel are not adjusted, if the flowability of the castable refractory does not meet the standard, the central control unit judges that the single injection amount of the spherical mullite is increased, and the stirring rate of the mixing barrel is increased, wherein n is the preset raw material injection times, and the second preset condition is that the difference between the total injection amount in the mixing barrel and the predicted castable raw material weight in the mixing barrel is within a preset range and D1 is more than m0 and less than D2.
6. The process for preparing a refractory castable according to claim 5, wherein under a second preset condition, the central control unit detects the high temperature refractory performance of the refractory castable in the mixing drum after 3/4 xn times of raw material injection, if the high temperature refractory performance of the refractory castable meets the standard, the central control unit determines not to adjust the transmission rate of the transmission mechanism and the oscillation frequency of the screen, if the high temperature refractory performance of the refractory castable does not meet the standard, the central control unit adjusts the transmission rate of the transmission mechanism and the oscillation frequency of the screen, wherein 3/4 xn is an integer, and if the high temperature refractory performance of the refractory castable is not an integer, the central control unit rounds downwards.
7. The process for preparing a castable refractory according to claim 6, wherein the difference Δ M between the weight M0 of the raw material in the mixing barrel and the predicted weight M0 of the castable raw material in the mixing barrel, wherein M0= Md × i, if the difference is smaller than a preset difference, the central control unit determines that the difference between the total amount injected into the mixing barrel and the predicted weight of the castable raw material in the mixing barrel is within a preset range, and if the difference is larger than the preset difference, the central control unit determines that the difference between the total amount injected into the mixing barrel and the predicted weight of the castable raw material in the mixing barrel is not within the preset range, the central control unit adjusts the cleaning frequency of the inner barrel wall of the mixing barrel and the oscillation frequency of the screen, md is set as the single injection amount of the castable raw material in the mixing barrel, and i is the number of injected.
8. The preparation process of the refractory castable according to claim 7, wherein the central control unit adjusts the cleaning frequency of the inner cylinder wall of the mixing cylinder, the oscillation frequency of the screen and the grinding rotation speed of each material injector according to a difference Δ M between the weight M0 of the raw material in the mixing cylinder and the weight M0 of the castable raw material in the predicted mixing cylinder, sets Δ M = M0-M0, when the difference Δ M is smaller than a first preset difference Δ M1, the central control unit increases the oscillation frequency PZ of the screen to PZ1, sets PZ1= PZ1 x (1 + (Δm1- Δ M)/Δm 1), simultaneously increases the cleaning frequency PT of the inner cylinder wall of the mixing cylinder to PT1, sets 1= PT x (1 + (Δm1- Δ M)/m1), and when the difference Δ M is larger than a second preset difference Δ M2, the central control unit determines to reduce the grinding rotation speed VY to VY1 of each material injector, and sets YV1= vum Δ M — Δ M2- (- Δ M).
9. The refractory castable based on the spherical micro powder is characterized by comprising RM70 granular materials of 3-5 meshes, 1-3 meshes, 0-1 meshes and 200 meshes, cement, kyanite, spherical silicon micro powder, spherical alumina micro powder, spherical mullite RW60 micro powder, silica fume and an additive.
10. The refractory castable material based on spherical micropowder according to claim 9, wherein the castable material prepared from 17 parts of RM70 granules with 3-5 meshes, 30 parts of RM70 granules with 1-3 meshes, 17 parts of RM70 granules with 0-1 meshes, 18 parts of RM70 granules with 200 meshes, 6 parts of cement, 2 parts of kyanite, 2 parts of spherical silica micropowder, 4 parts of spherical mullite RW60 micropowder and 3 parts of silica fume has the water addition amount of 6.5% and the fluidity of 238mm.
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Application publication date: 20230120 |