CN116589290A - 一种石油石化加热炉炉衬喷涂的高辐射涂料及喷涂工艺 - Google Patents

一种石油石化加热炉炉衬喷涂的高辐射涂料及喷涂工艺 Download PDF

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CN116589290A
CN116589290A CN202310552843.1A CN202310552843A CN116589290A CN 116589290 A CN116589290 A CN 116589290A CN 202310552843 A CN202310552843 A CN 202310552843A CN 116589290 A CN116589290 A CN 116589290A
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董培仑
连畅
谢海乐
叶波
桂国喜
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Henan Aibang Technology Co ltd
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Abstract

本发明公开了一种石油石化加热炉炉衬喷涂的高辐射涂料及喷涂工艺，包括如下配比的原料，氧化锆5‑6%，小颗粒硅溶胶27‑27.5%，碳化硅14‑15%，氧化铬8.1%，棕刚玉27‑28%，磷酸二氢钾8‑8.5%，碳酸钙10‑11%和氧化钴1‑1.5%，其中所述棕刚玉中氧化铝含量不低于95%；该石油石化加热炉炉衬喷涂的高辐射涂料及喷涂工艺在使用时具有较高的耐火度，且稳定性强，不受酸、碱、盐环境的影响，另外涂料能够有效渗透，附着能力强，长久耐用，满足使用需求。

Description

一种石油石化加热炉炉衬喷涂的高辐射涂料及喷涂工艺
技术领域
本发明涉及高辐射涂料技术领域，尤其涉及一种石油石化加热炉炉衬喷涂的高辐射涂料及喷涂工艺。
背景技术
加热炉用涂料可以作为耐火材料使用在各种工业炉窑的吸热表面，利用涂层对热辐射的高吸收率和高发射率的原理，提高高温炉窑衬体对炉膛火焰热量的吸收，改善炉膛的热交换条件，使炉体散热下降，增加了能源利用的热效率，同时对炉膛基质材料具有良好的保护作用，延长炉窑使用寿命、减少维护工作量。此外，通过强化炉膛辐射传热，还能够改善炉内温度场的均匀性和受热物体的加热质量。
公告号为CN103525142B的中国发明专利公开了一种加热炉用热辐射涂料，包括基料、添加剂、粘合剂、增塑剂和溶剂，基料与添加剂选自锌铝尖晶石粉、锰铝尖晶石粉、钛铁矿粉、碳化硼、氧化铁、脱硅锆粉的五种或全部；粘合剂由液体磷酸二氢铝、液体磷酸二氢镁组成。所述基料与添加剂的重量百分比为6%-75%，粘合剂的重量百分比为5%-29%，增塑剂的重量百分比为0.5%-3%，余量为溶剂；解决了抗热冲击承受力弱结合和附着力不强的技术问题，同时能够提高能源利用热效率。
但是上述高辐射涂料在使用时发射率不稳定，其涂料颗粒无法悬空将导致喷涂后渗透力较差，在高温热辐射环境下将会影响其附着能力，缩短使用寿命，若将继续使用则需要再次停炉喷涂，影响生产同时增大成本。
发明内容
本发明的目的是解决上述问题而提供一种在使用时具有较高的耐火度，且稳定性强，不受酸、碱、盐环境的影响，另外涂料能够有效渗透，附着能力强，长久耐用的石油石化加热炉炉衬喷涂的高辐射涂料及喷涂工艺。
为实现上述目的，本发明的技术方案为：一种石油石化加热炉炉衬喷涂的高辐射涂料，包括如下配比的原料，氧化锆5-6%，小颗粒硅溶胶27-27.5%，碳化硅14-15%，氧化铬8.1%，棕刚玉27-28%，磷酸二氢钾8-8.5%，碳酸钙10-11%和氧化钴1-1.5%，余量为硅溶胶。
优选的，所述氧化锆5.6%，小颗粒硅溶胶27.2%，碳化硅4.5%，氧化铬8.1%，棕刚玉27.6%，磷酸二氢钾8.3%，碳酸钙10.4%和氧化钴1.3%，余量为硅溶胶。
优选的，所述棕刚玉中氧化铝含量不低于95%。
一种石油石化加热炉炉衬喷涂的高辐射涂料的喷涂工艺，包括如下步骤： S1：清除炉衬表面浮灰； S2：除去炉衬结渣； S3：炉衬表面补缝找平； S4：内衬表面预处理； S5：稀涂料喷涂； S6：稠涂料喷涂。
优选的，所述步骤S4中，将处理液喷涂至内衬表面进行预处理，其中处理液为胶水混合液，其比例为60:1。
优选的，所述步骤S5与S6中，稀料和稠料分别喷涂4-6遍。
优选的，所述稀料中水溶剂的体积为稠料中水溶剂体积的1.5倍。
优选的，所述步骤S6中，稠料喷涂后整体涂料厚度不小于2mm。
本发明公开的一种石油石化加热炉炉衬喷涂的高辐射涂料及喷涂工艺与现有技术相比，具有以下有益效果：1、提高石油石化加热炉炉衬发射率，增加炉衬对炉内的有效辐射；2、耐火度高，能够有效的保护石油石化加热炉炉衬，耐腐蚀，耐酸碱燃烧，优化高辐射涂料炉衬施工工艺；3、涂料喷涂时能够有效渗透附着能力强，长久耐用。
具体实施方式
一种石油石化加热炉炉衬喷涂的高辐射涂料，包括如下配比的原料，氧化锆（ZrO2）5-6%，小颗粒硅溶胶（2SiO2.5H2O）27-27.5%，碳化硅（SiC）14-15%，氧化铬（Cr2O3）8.1%，棕刚玉（ AL2O3≥95%）27-28%，磷酸二氢钾（KH2PO4）8-8.5%，碳酸钙（CaCO3）10-11%和氧化钴（CoO）1-1.5%，余量为硅溶胶，其中棕刚玉中氧化铝含量不低于95%。
实施例一：该高辐射涂料，包括如下配比的原料，氧化锆（ZrO2）5%，小颗粒硅溶胶（2SiO2.5H2O）27%，碳化硅（SiC）114%，氧化铬（Cr2O3）8.1%，棕刚玉（ AL2O3≥95%）27%，磷酸二氢钾（KH2PO4）8%，碳酸钙（CaCO3）10%和氧化钴（CoO）1%，余量为硅溶胶。
在该实施例中,具体性能参数如下：
在本实施例中，耐火度、发射率、附着力和抗震性能均可满足使用，但是在酸、碱、盐环境中均出现了不同程度的损伤，将会直接影响使用寿命。
实施例二：该高辐射涂料，包括如下配比的原料，所述氧化锆（ZrO2）5.6%，小颗粒硅溶胶（2SiO2.5H2O）27.2%，碳化硅（SiC）4.5%，氧化铬（Cr2O3）8.1%，棕刚玉（ AL2O3≥95%）27.6%，磷酸二氢钾（KH2PO4）8.3%，碳酸钙（CaCO3）10.4%和氧化钴（CoO）1.3%，余量为硅溶胶。
在该实施例中,具体性能参数如下：
项目 数值 项目 数值
容重g/cm3 1.6-1.8 黏度Pa.s 喷涂<20
耐火度℃ ≥1800 附着力(级) 1～2
发射率ε 0.92 耐酸性 40%H2SO4浸泡3天无变化
膨胀系数 5.72 ×10-6 耐碱性 20%NaOH浸泡3天无变化
抗震性能 ≥15次 耐盐性 10%NaCl浸泡3天无变化
抗老化性能 涂层1200℃，ε≥0.89 导热系数W/m.k 27.6
重烧线收缩率（%，1200℃） 1.7 使用寿命(年) 3-10
本实施例为本发明中优选实施例，其耐火度、附着力、发射率、耐酸、碱、盐性以及使用寿命均达到最佳效果；整体通过粉筛搅拌细化处理，呈现一种悬浮状态，在保证发射率的前提下，可以渗透到耐材基体中，与耐材渗态结合；同时辅助稀料稠料相结合的施工方式，保证涂料喷涂之后不脱落，能够使涂料更好的渗透到石油石化加热炉炉衬内部，与炉衬表面相互挤压结合，性能长久耐用。
实施例三：高辐射涂料，包括如下配比的原料，氧化锆（ZrO2）6%，小颗粒硅溶胶（2SiO2.5H2O）27.5%，碳化硅（SiC）15%，氧化铬（Cr2O3）8.1%，棕刚玉（ AL2O3≥95%）28%，磷酸二氢钾（KH2PO4）8.5%，碳酸钙（CaCO3）11%和氧化钴（CoO）1.5%，余量为硅溶胶。
在该实施例中,具体性能参数如下：
项目 数值 项目 数值
容重g/cm3 1.8-2.2 黏度Pa.s 喷涂<20
耐火度℃ ≥1800 附着力(级) 1
发射率ε 0.92 耐酸性 40%H2SO4浸泡3天无变化
膨胀系数 5.72 ×10-6 耐碱性 20%NaOH浸泡3天无变化
抗震性能 ≥15次 耐盐性 10%NaCl浸泡3天无变化
抗老化性能 涂层1200℃，ε≥0.89 导热系数W/m.k 27.6
重烧线收缩率（%，1200℃） 1.7 使用寿命(年) 2-8
在本实施例比重的涂料，虽然耐酸、碱、盐性能尚可，但是整体附着能力及使用寿命不佳，在使用时性能不耐久，在高温环境中易脱落。
基于上述三种实施例，该高辐射涂料的制备方法为：先将原材料研磨至粉末状，其中氧化锆（ZrO2）、小颗粒硅溶胶（2SiO2.5H2O）、碳化硅（SiC）和氧化铬（Cr2O3）粒度＜500nm，棕刚玉和磷酸二氢钾（KH2PO4）粒度＜0.01mm，碳酸钙（CaCO3）和氧化钴（CoO）粒度＜0.2mm，原料研磨细化后通过硅溶胶混合，此时原料粉末将在硅溶胶内呈现一种悬浮状态，较小涂料内部应力，增加涂料附着能力；在喷涂使用时，将悬浮的含胶颗粒喷涂至炉衬表面即可，喷涂后附着力强，易渗透且经久耐用。
本发明还公开一种石油石化加热炉炉衬喷涂的高辐射涂料的喷涂工艺，包括如下步骤： S1：清除炉衬表面浮灰，通过毛刷吸尘器等辅助工具将炉衬表面浮灰去除并收集；S2：除去炉衬结渣，通过硬质钢刷、平铲等工具，将炉衬表面结渣剔除； S3：结渣剔除后炉衬表面的裂缝、裂纹等将直接暴露外部，此时通过修补料对炉衬表面补缝找平，其中修补料为熔融石英、硼硅酸盐玻璃、棕刚玉粉末、氟性树脂和有机硅溶液的混合物，其比例为1:1.5:4:2:6；按该配比混合后不断搅拌，直至修补料呈膏状后，将其涂刷至裂缝、裂纹处，填缝后将炉衬表面抹平，避免坑洼、凸起； S4：内衬表面是通过喷涂处理液进行预处理，其中处理液为胶水混合液，其比例为60:1，预处理后将改善炉衬表面张力，能够进一步增大炉衬与涂料的结合能力； S5：稀涂料喷涂（一次喷涂），将上述高辐射涂料喷涂至预处理后的炉衬表面，喷涂4-6遍，使涂料能够渗透内衬表面； S6：稠涂料喷涂（二次喷涂），接着将浓稠的高辐射涂料喷涂至S5中稀料上，喷涂4-6遍，稠料喷涂后整体涂料厚度不小于2mm，进一步提高使用寿命。
其中所述稀料（S5中稀料）中水溶剂的体积为稠料（S6中稠料）中水溶剂体积的1.5倍。
显然，上述实施例仅仅是为清楚地说明所作的举例，而并非对实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引伸出的显而易见的变化或变动仍处于本发明创造的保护范围之中。

Claims (8)

1.一种石油石化加热炉炉衬喷涂的高辐射涂料，其特征在于，包括如下配比的原料，氧化锆5-6%，小颗粒硅溶胶27-27.5%，碳化硅14-15%，氧化铬8.1%，棕刚玉27-28%，磷酸二氢钾8-8.5%，碳酸钙10-11%和氧化钴1-1.5%，余量为硅溶胶。
2.根据权利要求1所述的石油石化加热炉炉衬喷涂的高辐射涂料，其特征在于，所述氧化锆5.6%，小颗粒硅溶胶27.2%，碳化硅14.5%，氧化铬8.1%，棕刚玉27.6%，磷酸二氢钾8.3%，碳酸钙10.4%和氧化钴1.3%，余量为硅溶胶。
3.根据权利要求2所述的石油石化加热炉炉衬喷涂的高辐射涂料，其特征在于，所述棕刚玉中氧化铝含量不低于95%。
4.一种根据权利要求1-3任一所述的石油石化加热炉炉衬喷涂的高辐射涂料的喷涂工艺，其特征在于，包括如下步骤： S1：清除炉衬表面浮灰； S2：除去炉衬结渣； S3：炉衬表面补缝找平； S4：内衬表面预处理； S5：稀涂料喷涂； S6：稠涂料喷涂。
5.根据权利要求4所述的石油石化加热炉炉衬喷涂的高辐射涂料的喷涂工艺，其特征在于，所述步骤S4中，将处理液喷涂至内衬表面进行预处理，其中处理液为胶水混合液，其比例为60:1。
6.根据权利要求4所述的石油石化加热炉炉衬喷涂的高辐射涂料的喷涂工艺，其特征在于，所述步骤S5与S6中，稀料和稠料分别喷涂4-6遍。
7.根据权利要求6所述的石油石化加热炉炉衬喷涂的高辐射涂料的喷涂工艺，其特征在于，所述稀料中水溶剂的体积为稠料中水溶剂体积的1.5倍。
8.根据权利要求4所述的石油石化加热炉炉衬喷涂的高辐射涂料的喷涂工艺，其特征在于，所述步骤S6中，稠料喷涂后整体涂料厚度不小于2mm。
CN202310552843.1A 2023-05-17 2023-05-17 一种石油石化加热炉炉衬喷涂的高辐射涂料及喷涂工艺 Pending CN116589290A (zh)

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Cited By (2)

* Cited by examiner, † Cited by third party
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CN117367130A (zh) * 2023-12-08 2024-01-09 山东鲁阳节能材料股份有限公司 一种窑炉纤维炉衬的修复方法
CN117367130B (zh) * 2023-12-08 2024-02-06 山东鲁阳节能材料股份有限公司 一种窑炉纤维炉衬的修复方法

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