CN116003144A - Low-expansion refractory castable for induction heating furnace prepared from high-voltage electric porcelain reclaimed materials - Google Patents
Low-expansion refractory castable for induction heating furnace prepared from high-voltage electric porcelain reclaimed materials Download PDFInfo
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Abstract
The invention relates to the technical field of solid waste recycling, in particular to a low-expansion refractory castable for an induction heating furnace, which is prepared from high-voltage electric porcelain reclaimed materials. The refractory castable comprises the following components in parts by weight: 35 to 50 parts of high-voltage electric porcelain regenerated material, 9 to 31 parts of cordierite, 5 to 12 parts of andalusite, 2.5 to 8 parts of hydraulic binder and nano silica sol accounting for 7 to 10 percent of the total weight of dry materials, wherein SiO in the nano silica sol 2 The weight content of (2) is 25-35%. The high-voltage electric porcelain reclaimed material-based refractory castable provided by the invention has the advantages of good volume stability, good integrity, no cracking in large-area construction, and linear thermal expansion coefficient of less than or equal to 2.0 multiplied by 10 at 1200 DEG C ‑6 The water-cooling heat shock resistance is good, the water-cooling heat shock resistance is more than 50 times, the electrical insulation performance is good, the water-cooling heat shock resistance can be widely applied to heating furnaces as lining materials, and the water-cooling heat shock resistance is a preferred refractory material of electric induction heating furnaces.
Description
Technical Field
The invention relates to the technical field of solid waste recycling, in particular to a low-expansion refractory castable for an induction heating furnace, which is prepared from high-voltage electric porcelain reclaimed materials.
Background
The heating furnace is equipment for heating the product materials and the production workpieces, and does not need manual operation because the heating furnace is not used for directly heating the materials by open fire, so that the safety coefficient is greatly improved, and the possibility of safety accidents is also reduced. Therefore, the method is widely applied to forging and rolling procedures in the fields of iron and steel and color. At present, a high-alumina brick or a high-alumina castable prepared from natural high-alumina bauxite clinker is commonly selected as a refractory material for a heating furnace, and is easy to damage due to abrasion of a steel billet and penetration of oxide skin slag dropped from the steel billet in operation, and meanwhile, iron oxide impurities in raw materials are aggregated and poor in integrity, so that the refractory material cannot be applied to an induction heating furnace. There are also reports of a scheme of selecting corundum-mullite castable to replace high-alumina bricks or high-alumina castable, but the corundum-mullite castable has higher cost, and has poor integrity although slag resistance is improved, and especially, frequent thermal shock in an induction heating furnace can lead to cracking of refractory materials, so that metal oxide skin slag falls to a coil part, and a great risk is brought to the heating furnace, and even production shutdown is caused by line short circuit. Therefore, it is particularly important to find a refractory material that has good integrity, good volume stability, strong thermal shock resistance and good insulating properties.
The high-voltage ceramic is an insulating ceramic for high-voltage transmission lines, power stations and various electric appliances, and is an important component of the power industry. Along with the continuous upgrading and technical progress of the power system, the requirements on the insulator ceramic of the high-voltage system are greatly increased, the requirements on the performance of the high-voltage electric porcelain are also higher and higher, the strict requirements enable the rejection rate of the high-voltage electric porcelain to be even more than 20 percent, and the rejection rate of the high-voltage electric porcelain produced each year is hundreds of thousands of tons. The waste is mainly landfill treatment, so that a great deal of land resource waste and environmental pollution are caused.
The prior art uses the waste high-voltage electric porcelain for wear-resistant and skid-resistant pavement or as refractory aggregate, but the high-voltage electric porcelain in the schemes is only used as a structural filling material, so that the utilization added value is low, and the value is not exerted.
Disclosure of Invention
The invention combines the problems to be solved in the heating furnace, in particular to the refractory material of the induction heating furnace, develops the low-expansion refractory castable for the induction heating furnace prepared by the reclaimed material of the high-voltage electric porcelain on the basis of a large number of experiments, provides a new direction for the high-value utilization of the waste high-voltage electric porcelain, reduces the cost of the refractory material for the heating furnace, solves the problems of poor thermal shock resistance and poor integrity of the refractory material for the heating furnace, and solves the problems of land occupation and environmental pollution caused by the waste high-voltage electric porcelain.
Firstly, the invention provides a refractory castable, which comprises the following components in parts by weight:
35-50 parts of high-voltage electric porcelain regenerated material, 9-31 parts of cordierite, 5-12 parts of andalusite, 2.5-8 parts of hydraulic binder and nano silica sol accounting for 7-10% of the total weight of dry materials;
SiO in the nano silica sol 2 The weight content of (2) is 25-35%.
The technical scheme of the invention solves the problem of secondary recycling of a large number of waste high-voltage electric ceramics at present, creatively proposes the waste high-voltage electric ceramics as a raw material of refractory castable after a large number of test researches, and provides a new direction for recycling the waste high-voltage electric ceramics by development. The prepared castable is lower in volume density than the high-alumina brick, the high-alumina castable and the corundum-mullite castable, saves more materials per unit volume, can further save the input cost of the refractory castable, reduces the cost of the castable applied by an induction heating furnace and the like, reduces the load of equipment, improves the operation safety coefficient and prolongs the service life.
In addition, the invention also discovers that when the high-voltage electric porcelain reclaimed material is used for preparing the refractory castable, the low-expansion component cordierite with the content can fully play the coupling effect of the high-voltage electric porcelain reclaimed material and the low-expansion component cordierite, and the cordierite can promote the high-voltage electric porcelain reclaimed material to play good temperature and frequency stability, so that the linear thermal expansion coefficient of the refractory castable is far lower than that of the prior similar technology, and reaches 2.0 multiplied by 10 -6 And the volume stability of the refractory castable is kept within K, the integrity is better, the refractory castable is free from cracking in large-area construction and high-temperature use, the risk of the heating furnace caused by falling of metal oxide skin slag in the use process is avoided, and the production shutdown problem caused by short circuit due to falling of slag to a coil part is solved.
Meanwhile, the high-voltage ceramic reclaimed material is matched with a proper amount of cordierite and andalusite for use, the high-voltage ceramic reclaimed material with good mechanical strength and thermal shock resistance can promote the exertion of excellent toughness of the cordierite, and simultaneously, the micro-expansion generated by continuous crystal form transformation of the andalusite at high temperature is combined, so that the stress compensation and stress buffering effects of the material in the thermal shock process are remarkably improved, the prepared castable material has good thermal fatigue resistance and cyclic repeated heating performance, the thermal shock water cooling time is greater than 50 times, and the service life of a heating furnace is further prolonged. Meanwhile, andalusite can further promote the coupling effect of the high-voltage electric porcelain reclaimed material and cordierite, so that the linear thermal expansion coefficient of the refractory castable is greatly reduced.
In addition, in the system of the invention, the hydraulic binder is combined with the nano silica sol, so that the coupling effect of a combination mechanism on the strength at high, medium and low temperatures can be realized, the rapid formation of high-strength castable from the high-voltage ceramic reclaimed material, cordierite and andalusite can be promoted, the rapid baking can be realized without maintenance, and the difficult problems of rapid construction required by the tight construction and maintenance time and rapid rhythm of the heating furnace are solved.
In addition, the system fully exerts the advantages of low dielectric constant, low dielectric loss, high insulation resistivity, high electric resistance and the like of the high-voltage electric porcelain, and the prepared refractory castable has uniform and stable electric insulation performance at all use temperatures by being matched with cordierite and andalusite, so that the problem of corrosion of the refractory material in a high-temperature or electric induction environment caused by iron oxide enrichment brought by using natural raw materials in the prior art is solved.
As a preferred embodiment of the invention, the high-voltage electric porcelain reworked material is at least two of particles with the particle diameters of 0-1mm, 1-3mm, 3-5mm and 5-8 mm.
When the high-voltage electric porcelain reclaimed materials with different granularities are selected for compounding use, the performance of the refractory castable can be further improved.
In the practical application process, the regenerated high-voltage electric porcelain is waste produced after the production or use of the high-voltage electric porcelain, and the particles with different particle diameters are obtained after crushing, shaping, grading and ball milling. The shaping is a process of removing edges and corners of the crushed particles through collision of the particles, and then removing magnetic substances through an iron remover.
As a preferred embodiment of the present invention, the cordierite is at least one of particles having a particle diameter of 0 to 1mm and 1 to 3 mm.
As a preferred embodiment of the invention, the andalusite is at least one of andalusite with a particle size of 0-1mm and andalusite powder with a particle size of less than 0.088 mm.
As a preferred embodiment of the present invention, the hydraulic binder is aluminate refractory cement; preferably at least one of CA50, CA60, CA 70.
The hydraulic binder and the nano silica sol are selected to be compounded for better use effect.
As a preferred embodiment of the invention, the refractory castable further comprises the following components in parts by weight:
16-27 parts of matrix powder; the matrix powder is at least one of bauxite powder, flint clay powder, silicon micropowder and alumina powder.
As a preferred embodiment of the present invention, the particle size of the matrix powder is 0.088mm or less.
In the practical application process, the granularity of the matrix powder is more than 90% under a sieve of 0.088 mm.
As a preferred embodiment of the invention, the refractory castable further comprises the following components in parts by weight:
0.15 to 0.25 portion of additive; the additive is at least one of sodium tripolyphosphate, sodium hexametaphosphate, sodium citrate and sodium oxalate.
Preferably technical grade admixture.
Further, the present invention provides a method for preparing the refractory castable in any one of the above embodiments, including:
mixing the raw materials except the nano silica sol and then mixing with the nano silica sol.
Further, the invention also provides the application of the refractory castable or the preparation method of the refractory castable in any one of the embodiments in preparing a heating furnace.
Preferably, the heating furnace is an induction heating furnace.
Compared with the prior art, the invention has the beneficial effects that:
the high-voltage electric porcelain reclaimed material-based refractory castable provided by the invention has the advantages of good volume stability, good integrity, no cracking in large-area construction, and linear thermal expansion coefficient of less than or equal to 2.0 multiplied by 10 at 1200 DEG C -6 The water-cooling heat shock resistance is good, the water-cooling heat shock resistance is more than 50 times, the electrical insulation performance is good, the water-cooling heat shock resistance can be widely applied to heating furnaces as lining materials, and the water-cooling heat shock resistance is a preferred refractory material of electric induction heating furnaces.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The examples are not intended to identify the particular technology or conditions, and are either conventional or are carried out according to the technology or conditions described in the literature in this field or are carried out according to the product specifications. The reagents and instruments used, etc. are not identified to the manufacturer and are conventional products available for purchase by regular vendors.
The percentages in the following examples and comparative examples are by weight.
SiO in the nanosilicon sol solution in the following examples and comparative examples 2 The concentration of (2) was 30%.
Example 1
The embodiment provides a refractory castable prepared from waste high-voltage ceramic reclaimed materials, which is prepared by the following steps:
18% of high-voltage electric porcelain reclaimed material with the grain diameter of 5-8mm, 18% of high-voltage electric porcelain reclaimed material with the grain diameter of 3-5mm, 16% of cordierite with the grain diameter of 1-3mm, 9% of cordierite with the grain diameter of 0-1mm, 6% of andalusite with the grain diameter of 0-1mm, 6% of flint clay powder, 5% of alumina powder, 5% of silica micropowder, 11% of homogeneous alumina powder, 5.75% of CA60 cement, 0.1% of sodium tripolyphosphate, 0.08% of sodium hexaphosphate and 0.07% of sodium citrate are mixed and stirred uniformly, and then 9% of nano silica sol solution is added and stirred uniformly to obtain the ceramic composite ceramic material.
Example 2
The embodiment provides a refractory castable prepared from waste high-voltage ceramic reclaimed materials, which is prepared by the following steps:
18% of high-voltage electric porcelain reclaimed material with the grain diameter of 5-8mm, 20% of high-voltage electric porcelain reclaimed material with the grain diameter of 3-5mm, 19% of cordierite with the grain diameter of 1-3mm, 12% of cordierite with the grain diameter of 0-1mm, 5% of andalusite powder with the grain diameter of 0.088, 6.78% of silica micropowder, 11% of homogeneous alumina powder, 5% of CA60 cement, 3% of CA50 cement, 0.1% of sodium tripolyphosphate, 0.05% of sodium hexaphosphate and 0.07% of sodium citrate are uniformly mixed and stirred, and then 8.5% of nano silica sol solution is added and uniformly stirred, thus obtaining the ceramic composite ceramic material.
Example 3
The embodiment provides a refractory castable prepared from waste high-voltage ceramic reclaimed materials, which is prepared by the following steps:
18% of high-voltage electric porcelain reclaimed material with the grain size of 5-8mm, 18% of high-voltage electric porcelain reclaimed material with the grain size of 3-5mm, 16% of cordierite with the grain size of 1-3mm, 9% of cordierite with the grain size of 0-1mm, 6% of andalusite with the grain size of 0-1mm, 5% of andalusite powder with the grain size of 0.088, 6% of alumina powder, 6% of silica micropowder, 11% of homogeneous alumina powder, 4.78% of CA70 cement, 0.07% of sodium tripolyphosphate, 0.08% of sodium hexaphosphate and 0.07% of sodium citrate are mixed and stirred uniformly, and then 8.5% of nano silica sol solution is added and stirred uniformly to obtain the ceramic composite ceramic material.
Example 4
The embodiment provides a refractory castable prepared from waste high-voltage ceramic reclaimed materials, which is prepared by the following steps:
20% of high-voltage electric porcelain reclaimed material with the grain diameter of 5-8mm, 18% of high-voltage electric porcelain reclaimed material with the grain diameter of 3-5mm, 6% of high-voltage electric porcelain reclaimed material with the grain diameter of 1-3mm, 5% of high-voltage electric porcelain reclaimed material with the grain diameter of 0-1mm, 10% of cordierite with the grain diameter of 1-3mm, 7% of cordierite with the grain diameter of 0-1mm, 6% of andalusite powder with the grain diameter of 0.088, 8% of flint clay powder, 6% of silica micropowder, 6% of homogenized alumina powder, 7.8% of CA50 cement, 0.05% of sodium tripolyphosphate, 0.1% of sodium hexaphosphate and 0.05% of sodium oxalate are added after being uniformly mixed and stirred uniformly, and then 8% of nano silica sol solution is added after being uniformly stirred, so that the ceramic material is obtained.
Example 5
The embodiment provides a refractory castable prepared from waste high-voltage ceramic reclaimed materials, which is prepared by the following steps:
16% of high-voltage electric porcelain reclaimed material with the grain size of 3-5mm, 12% of high-voltage electric porcelain reclaimed material with the grain size of 1-3mm, 17% of high-voltage electric porcelain reclaimed material with the grain size of 0-1mm, 12% of cordierite with the grain size of 1-3mm, 7% of andalusite with the grain size of 0-1mm, 5% of andalusite powder with the grain size of 0.088, 5% of silica micropowder, 18% of homogeneous alumina powder, 3.85% of CA50 cement, 4% of CA70 cement and 0.15% of sodium tripolyphosphate are uniformly mixed and stirred, and then 7% of nano silica sol solution is added, and the mixture is uniformly stirred to obtain the ceramic composite ceramic.
Example 6
The embodiment provides a refractory castable prepared from waste high-voltage ceramic reclaimed materials, which is prepared by the following steps:
16% of high-voltage electric porcelain reclaimed material with the grain diameter of 3-5mm, 19% of high-voltage electric porcelain reclaimed material with the grain diameter of 1-3mm, 4% of cordierite with the grain diameter of 1-3mm, 20% of cordierite with the grain diameter of 0-1mm, 8% of andalusite with the grain diameter of 0-1mm, 17% of flint clay powder, 8% of silica micropowder, 2.83% of CA50 cement, 5% of CA70 cement and 0.17% of sodium tripolyphosphate are evenly mixed and stirred, and then 10% of nano silica sol solution is added, and evenly stirred, thus obtaining the ceramic composite ceramic material.
Example 7
The embodiment provides a refractory castable prepared from waste high-voltage ceramic reclaimed materials, which is prepared by the following steps:
16% of high-voltage electric porcelain reclaimed material with the grain diameter of 5-8mm, 19% of high-voltage electric porcelain reclaimed material with the grain diameter of 3-5mm, 13% of cordierite with the grain diameter of 1-3mm, 18% of cordierite with the grain diameter of 0-1mm, 6% of andalusite powder with the grain diameter of 0.088, 8% of silica micropowder, 13% of homogeneous alumina powder, 3.81% of CA50 cement, 3% of CA60 cement, 0.1% of sodium tripolyphosphate, 0.07% of sodium hexaphosphate and 0.02% of sodium citrate are uniformly mixed and stirred, and then 8.8% of nano silica sol solution is added and uniformly stirred, thus obtaining the ceramic composite ceramic material.
Example 8
The embodiment provides a refractory castable prepared from waste high-voltage ceramic reclaimed materials, which is prepared by the following steps:
18% of high-voltage electric porcelain reclaimed material with the grain diameter of 3-5mm, 24% of high-voltage electric porcelain reclaimed material with the grain diameter of 1-3mm, 20% of cordierite with the grain diameter of 0-1mm, 4% of andalusite with the grain diameter of 0-1mm, 8% of andalusite powder with the grain diameter of 0.088, 9% of alumina powder, 5.31% of silica micropowder, 9% of homogeneous alumina powder, 2.5% of CA60 cement, 0.18% of sodium tripolyphosphate and 0.01% of sodium citrate are uniformly mixed and stirred, and then 9.5% of nano silica sol solution is added, and the mixture is uniformly stirred, thus obtaining the ceramic composite ceramic material.
Comparative example 1
This comparative example provides a refractory castable with a method of preparation that differs from example 1 only in that:
and replacing the high-voltage electric porcelain regenerated material with mullite.
Comparative example 2
This comparative example provides a refractory castable with a method of preparation that differs from example 1 only in that:
cordierite was replaced with mullite.
Comparative example 3
This comparative example provides a refractory castable with a method of preparation that differs from example 1 only in that:
andalusite is replaced with mullite.
Test example 1
The refractory castable properties prepared in the above examples and comparative examples were tested and the results are shown in table 1 below.
TABLE 1 Performance test results
According to the test results, after the comparative example 1 is changed to mullite, each detection index is basically equivalent to that of the example 1, but since the ton unit price (about 2500 yuan/ton) of mullite is 1600 yuan higher than that of the high-voltage porcelain reclaimed material (about 900 yuan/ton after being processed into the reclaimed aggregate), the application cost of the comparative example 1 is higher in the practical application process.
In comparative example 2, only cordierite was changed to mullite, and the bulk density was significantly increased and the strength was increased, but the water-cooling thermal shock resistance was decreased, the thermal expansion coefficient was increased, and the toughness and integrity were deteriorated in terms of macroscopic material properties, and the service life was reduced.
In comparative example 3, only after the andalusite is changed to mullite, the volume density is reduced, the strength is increased, but the water-cooling thermal shock resistance is reduced, the thermal expansion coefficient is increased, the toughness and the integrity are deteriorated in the aspect of reflecting the macroscopic material performance, and the service life is reduced.
Test example 2
The refractory castable prepared by the embodiment is respectively used in the working lining of the induction heating furnace, is directly baked without maintenance after construction, does not burst, has no obvious thermal expansion in the use process, has good large-area use integrity, and does not crack after being used for one year.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. The refractory castable is characterized by comprising the following components in parts by weight:
35-50 parts of high-voltage electric porcelain regenerated material, 9-31 parts of cordierite, 5-12 parts of andalusite, 2.5-8 parts of hydraulic binder and nano silica sol accounting for 7-10% of the total weight of dry materials;
SiO in the nano silica sol 2 The weight content of (2) is 25-35%.
2. The refractory castable according to claim 1, wherein the high-voltage ceramic reclaimed material is at least two of particles having a particle diameter of 0-1mm, 1-3mm, 3-5mm, 5-8 mm.
3. The refractory castable according to claim 1 or 2, wherein the cordierite is at least one of particles having a particle diameter of 0 to 1mm and 1 to 3 mm.
4. A refractory castable according to any one of claims 1 to 3, wherein the andalusite is at least one of andalusite with a particle size of 0-1mm and andalusite with a particle size of 0.088mm or less.
5. The refractory castable according to any one of claims 1 to 4, wherein the hydraulic binder is aluminate refractory cement; preferably at least one of CA50, CA60, CA 70.
6. The refractory castable according to any one of claims 1 to 5, further comprising the following components in parts by weight:
16-27 parts of matrix powder; the matrix powder is at least one of bauxite powder, flint clay powder, silicon micropowder and alumina powder.
7. The refractory castable according to claim 6, wherein the particle size of the matrix powder is 0.088mm or less.
8. Refractory castable according to any one of claims 1 to 7, further comprising the following components in parts by weight:
0.15 to 0.25 portion of additive; the additive is at least one of sodium tripolyphosphate, sodium hexametaphosphate, sodium citrate and sodium oxalate.
9. The method for producing a refractory castable according to any one of claims 1 to 8, comprising:
mixing the raw materials except the nano silica sol and then mixing with the nano silica sol.
10. Use of the refractory castable according to any one of claims 1 to 8, or the preparation method according to claim 9, for preparing a heating furnace.
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