CN116283248A - 一种再熔铝炉用致密复相砖及其制造方法 - Google Patents

一种再熔铝炉用致密复相砖及其制造方法 Download PDF

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CN116283248A
CN116283248A CN202310053684.0A CN202310053684A CN116283248A CN 116283248 A CN116283248 A CN 116283248A CN 202310053684 A CN202310053684 A CN 202310053684A CN 116283248 A CN116283248 A CN 116283248A
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alumina
brick
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silicon carbide
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王小新
蒋利强
俞蓉嵘
喻轶球
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Sinofurnancecoslight Technology Co ltd
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Abstract

本发明涉及一种再熔铝炉用致密复相砖的制造方法，包括步骤：称取原料；将称取的原料送入混炼机进行混合，得到混合后原料；在再熔铝炉用致密复相砖模内倒入混合后原料，电动程控压砖机压制得到压制成型的砖块并出砖；高温隧道窑按照设定的升温制度逐步升温至对砖块热处理，再冷却。本发明的有益效果是：本发明制备得到的致密复相砖能降低整体材料的显气孔率，减少熔液的渗入通道，能有效降低铝液的渗透，降低材料与熔体的润湿性；本发明采用复相材料配伍，能增加熔炉内衬耐火材料的抗热震性能和抗冲刷性能，减弱深层化学反应和物理渗透，提高炉衬自身强度，减弱机械损坏；可以延长再熔铝炉的耐火内衬材料使用寿命至5年左右。

Description

一种再熔铝炉用致密复相砖及其制造方法
技术领域
本发明属于耐火砖领域，尤其涉及一种再熔铝炉用致密复相砖及其制造方法。
背景技术
再熔铝炉是用于加热熔炼废弃回收铝，得到铝液的熔炉；再熔铝炉的工作温度一般为700℃～1100℃；从使用温度来看，粘土质、莫来石质、高铝质定形或不定形耐火制品均可作为再熔铝炉的耐火内衬材料。
但是，再熔铝炉熔炼工况中会发生耐火内衬材料损毁，耐火内衬材料的损毁方式有以下几种：
1、表面化学反应：废弃回收铝经过加热，产生的高温铝液中的极为活泼的铝及镁等元素，易和耐火内衬材料中的二氧化硅发生化学反应，形成单质硅，破坏、剥落和侵蚀耐火材料结构，逐渐减薄耐火内衬材料；
2、深层化学反应：在再熔铝炉的工作温度下，一些合金元素（如镁等元素）易沿耐火材料气孔深入到耐火内衬材料内部，倒置耐火内衬材料疏松、体积膨胀并产生裂纹，进一步加速铝合金熔液对耐火内衬材料的渗透和侵蚀；
3、物理渗透：低粘度的铝合金熔体渗入到耐火内衬材料的孔隙后，随着炉料的加热、保温、倾倒及炉衬循环使用，耐火内衬材料遭遇急冷急热，不断发生膨胀和收缩，最终导致耐火内衬材料剥落；
4、机械损坏：废弃回收铝一般采用炉料压制成块的方式入炉熔炼，入炉熔炼过程易撞击和摩擦耐火内衬材料；另外，再熔铝炉工作时，空气、铝合金熔液以及耐火材料形成的气-液-固三相界面处易形成刚玉瘤，刚玉瘤与耐火内衬材料结合紧密；采用机械、熔剂或人工等方法清除时，会对耐火内衬材料的结构造成一定程度的破坏；
以上几种耐火内衬材料的损毁方式，加上再熔铝炉通常采用间歇式的操作方式，导致通常情况下再熔炉内衬耐火材料使用寿命仅约1年，再熔铝炉的使用寿命较短，成本较高。
发明内容
本发明针对现有再熔铝炉耐火内衬材料损毁的原因，提供一种再熔铝炉用致密复相砖及其制造方法。
这种再熔铝炉用致密复相砖，以质量份数计，由以下原料制成：低铝莫来石颗粒25～35份、均化矾土颗粒25～35份、碳化硅细粉和碳化硅超微粉混合物5～10份、活性氧化铝微粉5～10份、煅烧氧化铝粉5～10份、粘土1～10份、微硅粉1～3份和糊精液1～3份；
低铝莫来石颗粒中氧化铝的化学含量为45%；
均化矾土颗粒中氧化铝的化学含量为60%；
以质量份数计，5～10份碳化硅细粉和碳化硅超微粉混合物，由2～5份硅含量为98%的黑碳化硅细粉与2～5份的粒度为2-10微米的黑碳化硅微粉混合而成；
粘土为粒径为200目的广西维罗泥；
微硅粉为二氧化硅含量为97%的金属硅冶炼的炉灰收集活性微粉；
糊精液为黄糊精与水按1:10的比例混合的液体。
作为优选，活性氧化铝微粉为粒径D50为0.5-1微米的轻烧活性氧化铝。
作为优选，轻烧活性氧化铝中氧化铝含量典型值为99.5%、氧化纳含量典型值为0.14%、氧化钙含量典型值为0.02%、氧化硅含量典型值为0.03%、氧化钙含量典型值为0.1%、比表面积典型值为5.1M2/g、粒径D50为0.8ųm。
作为优选，煅烧氧化铝粉为粒径D50为3-5微米的重烧氧化铝。
作为优选，低铝莫来石颗的粒度为5-0mm；均化矾土颗粒的粒度为5-0mm。
这种再熔铝炉用致密复相砖的制造方法，包括以下步骤：
步骤1、以质量份数计，称取粒度为5-0mm的低铝莫来石颗粒25～35份、粒度为5-0mm的均化矾土颗粒25～35份、碳化硅细粉和碳化硅超微粉混合物5～10份、活性氧化铝微粉5～10份、煅烧氧化铝粉5～10份、粘土1～10份、微硅粉1～3份和糊精液1～3份；
步骤2、将经步骤1称取的原料送入混炼机进行混合，得到混合后原料；
步骤3、在再熔铝炉用致密复相砖模内倒入设定重量的混合后原料，电动程控压砖机压制得到压制成型的砖块并出砖；
步骤4、将经步骤3压制成型的砖块送入高温隧道窑，高温隧道窑按照设定的升温制度逐步升温至设定温度进行热处理，再进行冷却，得到再熔铝炉用致密复相砖。
作为优选，步骤2中混炼机为耐火材料行星式强制混合机；步骤2中混炼机将经步骤1称取的原料进行混合时，先加入低铝莫来石颗粒、均化矾土颗粒、碳化硅细粉和碳化硅超微粉混合物、活性氧化铝微粉、煅烧氧化铝粉、粘土和微硅粉先混合3分钟，再倒入糊精液湿混25分钟；将混炼机的混合总时长控制在28～30分钟。
作为优选，步骤3中电动程控压砖机采用型号为630吨的压机。
作为优选，步骤4中高温隧道窑的升温制度为100米高温隧道窑内按每2小时推1车的速率逐步升温至1520℃。
本发明的有益效果是：
本发明选择氧化铁等杂质含量低，富含莫来石相、高粘度玻璃项的均化矾土、低铝莫来石质耐火原料作为颗粒，加入碳化硅、活性氧化铝等基质原料，复相配伍经过压制烧结工艺成型的高致密性耐火内衬材料，制备得到的致密复相砖能降低整体材料的显气孔率，减少熔液的渗入通道，能有效降低铝液的渗透，降低材料与熔体的润湿性；
本发明采用复相材料配伍，能增加熔炉内衬耐火材料的抗热震性能和抗冲刷性能，减弱深层化学反应和物理渗透，提高炉衬自身强度，减弱机械损坏；可以延长再熔铝炉的耐火内衬材料使用寿命至5年左右。
具体实施方式
下面结合实施例对本发明做进一步描述。下述实施例的说明只是用于帮助理解本发明。应当指出，对于本技术领域的普通人员来说，在不脱离本发明原理的前提下，还可以对本发明进行若干修饰，这些改进和修饰也落入本发明权利要求的保护范围内。
作为一种实施例，再熔铝炉用致密复相砖的制造方法，具体包括以下步骤：
步骤1、以质量份数计，称取粒度为5-0mm的低铝莫来石颗粒25～35份、粒度为5-0mm的均化矾土颗粒25～35份、碳化硅细粉和碳化硅超微粉混合物5～10份、活性氧化铝微粉5～10份、煅烧氧化铝粉5～10份、粘土1～10份、微硅粉1～3份和糊精液1～3份；低铝莫来石颗粒中氧化铝的化学含量为45%；均化矾土颗粒中氧化铝的化学含量为60%；以质量份数计，5～10份碳化硅细粉和碳化硅超微粉混合物，由2～5份硅含量为98%的黑碳化硅细粉与2～5份的粒度为2-10微米的黑碳化硅微粉混合而成；活性氧化铝微粉为粒径D50为0.5-1微米的轻烧活性氧化铝，轻烧活性氧化铝中氧化铝含量典型值为99.5%、氧化纳含量典型值为0.14%、氧化钙含量典型值为0.02%、氧化硅含量典型值为0.03%、氧化钙含量典型值为0.1%、比表面积典型值为5.1M2/g、粒径D50为0.8ųm；煅烧氧化铝粉为粒径D50为3-5微米的重烧氧化铝；粘土为粒径为200目的广西维罗泥；微硅粉为二氧化硅含量为97%的金属硅冶炼的炉灰收集活性微粉；糊精液为黄糊精与水按1:10的比例混合的液体；
步骤2、将经步骤1称取的原料送入混炼机（耐火材料行星式强制混合机）进行混合，得到混合后原料；混合时先加入低铝莫来石颗粒、均化矾土颗粒、碳化硅细粉和碳化硅超微粉混合物、活性氧化铝微粉、煅烧氧化铝粉、粘土和微硅粉先混合3分钟，再倒入糊精液湿混25分钟；将混炼机的混合总时长控制在28～30分钟；
步骤3、在再熔铝炉用致密复相砖模内倒入设定重量的混合后原料，电动程控压砖机（采用型号为630吨的压机）在80%功率下0.5米行程内连续冲击7次后，压制得到压制成型的砖块并出砖；
步骤4、将经步骤3压制成型的砖块送入高温隧道窑，高温隧道窑按照设定的升温制度（100米高温隧道窑内按每2小时推1车的速率）逐步升温至1520℃进行热处理，再进行冷却，得到再熔铝炉用致密复相砖。
经过本实施例制备得到的再熔铝炉用致密复相砖的各项性能指标如下表1所示：
表1 本实施例制备得到的再熔铝炉用致密复相砖性能指标表
原料名称 原料在再熔铝炉用致密复相砖内的含量或复相砖的性能参数
Al2O3 含量≥46%
SiO2 含量≤50%
SiC 含量≥3%
Fe2O3 含量≤1.5%
气孔率 ≤13%
体积密度 ≥2.30 g/cm3
耐压强度 ≥70 MPa
荷重软化温度Ta ≥1450℃
热震稳定性（1100℃，水冷） ≥6次
由上表1可知，本实施例制备的再熔铝炉用致密复相砖能用在国内规模为20吨/日的再熔铝炉上，使用寿命可达到五年以上。

Claims (9)

1.一种再熔铝炉用致密复相砖，其特征在于，以质量份数计，由以下原料制成：低铝莫来石颗粒25～35份、均化矾土颗粒25～35份、碳化硅细粉和碳化硅超微粉混合物5～10份、活性氧化铝微粉5～10份、煅烧氧化铝粉5～10份、粘土1～10份、微硅粉1～3份和糊精液1～3份；
低铝莫来石颗粒中氧化铝的化学含量为45%；
均化矾土颗粒中氧化铝的化学含量为60%；
以质量份数计，5～10份碳化硅细粉和碳化硅超微粉混合物，由2～5份硅含量为98%的黑碳化硅细粉与2～5份的粒度为2-10微米的黑碳化硅微粉混合而成；
粘土为粒径为200目的广西维罗泥；
微硅粉为二氧化硅含量为97%的金属硅冶炼的炉灰收集活性微粉；
糊精液为黄糊精与水按1:10的比例混合的液体。
2.根据权利要求1所述再熔铝炉用致密复相砖，其特征在于：活性氧化铝微粉为粒径D50为0.5-1微米的轻烧活性氧化铝。
3.根据权利要求1所述再熔铝炉用致密复相砖，其特征在于：轻烧活性氧化铝中氧化铝含量典型值为99.5%、氧化纳含量典型值为0.14%、氧化钙含量典型值为0.02%、氧化硅含量典型值为0.03%、氧化钙含量典型值为0.1%、比表面积典型值为5.1M2/g、粒径D50为0.8ųm。
4.根据权利要求1所述再熔铝炉用致密复相砖，其特征在于：煅烧氧化铝粉为粒径D50为3-5微米的重烧氧化铝。
5.根据权利要求1所述再熔铝炉用致密复相砖，其特征在于：低铝莫来石颗的粒度为5-0mm；均化矾土颗粒的粒度为5-0mm。
6.一种如权利要求1至4任一项所述的再熔铝炉用致密复相砖的制造方法，其特征在于，包括以下步骤：
步骤1、以质量份数计，称取粒度为5-0mm的低铝莫来石颗粒25～35份、粒度为5-0mm的均化矾土颗粒25～35份、碳化硅细粉和碳化硅超微粉混合物5～10份、活性氧化铝微粉5～10份、煅烧氧化铝粉5～10份、粘土1～10份、微硅粉1～3份和糊精液1～3份；
步骤2、将经步骤1称取的原料送入混炼机进行混合，得到混合后原料；
步骤3、在再熔铝炉用致密复相砖模内倒入设定重量的混合后原料，电动程控压砖机压制得到压制成型的砖块并出砖；
步骤4、将经步骤3压制成型的砖块送入高温隧道窑，高温隧道窑按照设定的升温制度逐步升温至设定温度进行热处理，再进行冷却，得到再熔铝炉用致密复相砖。
7.根据权利要求6所述再熔铝炉用致密复相砖的制造方法，其特征在于：步骤2中混炼机为耐火材料行星式强制混合机；步骤2中混炼机将经步骤1称取的原料进行混合时，先加入低铝莫来石颗粒、均化矾土颗粒、碳化硅细粉和碳化硅超微粉混合物、活性氧化铝微粉、煅烧氧化铝粉、粘土和微硅粉先混合3分钟，再倒入糊精液湿混25分钟；将混炼机的混合总时长控制在28～30分钟。
8.根据权利要求6所述再熔铝炉用致密复相砖的制造方法，其特征在于：步骤3中电动程控压砖机采用型号为630吨的压机。
9.根据权利要求6所述再熔铝炉用致密复相砖的制造方法，其特征在于：步骤4中高温隧道窑的升温制度为100米高温隧道窑内按每2小时推1车的速率逐步升温至1520℃。
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