CN116606561A - 电解铝碳素阳极抗氧化防腐蚀涂料 - Google Patents
电解铝碳素阳极抗氧化防腐蚀涂料 Download PDFInfo
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Abstract
本发明公开一种电解铝碳素阳极抗氧化防腐蚀涂料,由钠水玻璃、钾水玻璃、聚丙烯酰胺和/或聚氨基聚醚、聚三乙二醇、氧化铝粉、石英粉、铝粉、钠长石和/或钾长石、碳化硼和/或氮化硼组成;其中各组分的重量百分比为:钠水玻璃20‑25%、钾水玻璃12‑14%、氧化铝粉22‑25%、石英粉12%‑16%、聚丙烯酰胺和/或聚氨基聚醚5‑8%、钠长石和/或钾长石5‑8%、碳化硼和/或氮化硼3‑5%、铝粉4%、聚三乙二醇4‑8%。本发明的涂料解决碳素阳极氧化的问题,缓解炭块的氧化掉渣,裂纹,掉块问题,延长碳素阳极的使用寿命,同时涂料的使用不污染铝液,保证原铝的纯度。
Description
技术领域
本发明涉及特种涂料领域,具体涉及电解铝碳素阳极抗氧化防腐蚀涂料。
背景技术
目前,国内的铝工业生产采用冰晶石-氧化铝熔盐电解法,其工作原理是将熔融的冰晶石和氧化铝混合作为电解质,碳素体作为阳极,石墨作为阴极,通入强大的直流电后,在电解槽内的两极上进行电化学反应,阳极产物主要是二氧化碳和一氧化碳气体,阴极产物是铝液,铝液经过后序加工处理,形成高纯铝锭,供铸造工业使用。碳素体是电解铝工业的主要原料之一,由于碳素体主要成分为碳,在高温下容易出现阳极氧化的现象,使得碳素阳极净耗增加;氧化还会造成电解槽中炭渣过多,导致电解质的电阻率增大;电阻率的增大一方面使得电流效率降低,增加电解铝厂的耗电量,另一方面会造成电解槽过热,当电解槽温度大于1300℃的时候,会出现漏槽现象,严重时会引发安全生产事故。此外,冰晶石作为铝电解的助熔剂,具有很强的腐蚀性,特别在高温下,除了炭,铝以外的各种金属及非金属都能被腐蚀。一般的防氧化涂料在高温下容易过早的被腐蚀而失去防护作用。我公司生产研发的电解铝碳素阳极抗氧化防腐蚀涂料,在400℃以上烧结致密,在碳素阳极表面形成隔绝保护层,不仅能够提高碳素阳极的抗氧化性能,减少因掉落炭渣引起的耗电增加,稳定电解槽热平衡;同时能够防止冰晶石对涂料的高温腐蚀,提升碳素阳极的使用寿命。
在电解铝生产过程中,碳素阳极与二氧化碳和氧气发生的氧化反应是阳极过量消耗的最主要原因,并且产生脱落、掉渣等现象,降低电解反应的电流效率,此外悬浮在电解质中的炭渣碎块严重危害电解铝生产的正常进行,甚至导致事故停槽。
发明内容
为了提升碳素阳极的抗氧化性能,本发明提供了一种电解铝碳素阳极抗氧化防腐蚀涂料、应用该涂料的碳素阳极及其制备方法和应用。
本发明提供一种电解铝碳素阳极抗氧化防腐蚀涂料,由钠水玻璃、钾水玻璃、聚丙烯酰胺和/或聚氨基聚醚、聚三乙二醇、氧化铝粉、石英粉、铝粉、钠长石和/或钾长石、碳化硼和/或氮化硼组成;其中各组分的重量百分比为:钠水玻璃20-25%、钾水玻璃12-14%、氧化铝粉22-25%、石英粉12%-16%、聚丙烯酰胺和/或聚氨基聚醚5-8%、钠长石和/或钾长石5-8%、碳化硼和/或氮化硼3-5%、铝粉4%、聚三乙二醇4-8%。
本发明还提供一种碳素阳极,包括碳素电极和喷涂在其表面的的涂料。
本发明又提供一种碳素阳极的制备方法,包括:S1,在所述碳素电极表面喷涂一层所述涂料,在室温下干燥30~60分钟;S2,在S1步骤之后进行二次喷涂所述涂料,S1和S2步骤的总喷涂厚度为0.5~1mm;以及S3,将经过二次喷涂后的电极在室温下固化3~8小时。
本发明在提供一种上述碳素阳极在电解铝中应用。
本发明具有如下优点:(1)解决碳素阳极氧化的问题,缓解炭块的氧化掉渣,裂纹,掉块问题,延长碳素阳极的使用寿命;(2)防止冰晶石对涂料的高温腐蚀,延长涂层的防护效果;(3)涂料的使用不污染铝液,保证原铝的纯度;(4)延长涂料的保质期,防止涂料因老化而出现固化结块现象。
具体实施方式
本发明的电解铝碳素阳极抗氧化防腐蚀涂料是由钠水玻璃,钾水玻璃,聚丙烯酰胺和/或聚氨基聚醚、聚三乙二醇、氧化铝粉、石英粉、铝粉、钠长石和/或钾长石、碳化硼和/或氮化硼组成。其中组分的重量百分比为:钠水玻璃20-25%,钾水玻璃12-14%、氧化铝粉22-25%、石英粉12%-16%、聚丙烯酰胺和/或聚氨基聚醚5-8%、钠长石和/或钾长石5-8%、碳化硼和/或氮化硼3-5%、铝粉4%、聚三乙二醇4-8%。
本发明的涂料可以通过如下方法制备。首先将钠水玻璃,钾水玻璃,聚丙烯酰胺和/或聚氨基聚醚,聚三乙二醇加入混料机中,45℃以下搅拌2h制得预混物;然后将氧化铝粉,石英粉,钠长石和/或钾长石,碳化硼和/或氮化硼及铝粉放入混料机中搅拌2h(常温),出料,既得产品。
涂料中,聚丙烯酰胺、聚胺基聚醚、聚三乙二醇的加入可以对钠水玻璃、钾水玻璃改性,提高其抗老化能力。加入的醇、醚、胺等含有氧或氮原子的化合物能够与钠水玻璃、钾水玻璃中的硅羟基生成氢键,降低硅酸的缩聚从而降低涂料的老化倾向,延长涂料的保存时间,不会因老化而过早固化结块,3-6个月仍然保持良好的流动性。
氧化铝粉,钠长石或钾长石在涂料中承担耐高温骨架的作用,石英粉在高温下形成玻璃态物质与水玻璃形成复相烧结体,一起填充到骨架的缝隙中,增加涂层的致密度。铝粉和硼化物在高温下反应最终生成玻璃态的液体物质,填充复相烧结体中的孔隙,进一步增加了涂层致密性,防止电解铝液中冰晶石的高温腐蚀。
与未喷涂抗氧化防腐蚀涂料的碳素阳极相比,喷涂了本产品的碳素阳极,高温氧化烧失率降低了97%,在一个完整的电解周期内涂层能较好的覆盖在碳素阳极的表面,减少了炭块的氧化掉渣,稳定了电解槽的电流效率,以及电解槽的热平衡。此外涂料带入的K、Si杂质元素对电解质体系无不良影响,保证了铝液的质量。碳素阳极在喷涂了我公司产品后,延长了1.33天的换极周期,达到了防止碳素阳极在高温下被氧化和涂料被高温腐蚀的目的,降低了电解铝的生产成本。
在可选的实施方式中,使用该涂料的碳素阳极的制备方法,包括:S1,在碳素电极表面喷涂一层涂料,在室温下干燥30~60分钟;S2,在S1步骤之后进行二次喷涂涂料,S1和S2步骤的总喷涂厚度为0.5~1mm;以及S3,将经过二次喷涂后的电极在室温下固化3~8小时。
以下通过具体实例进一步描述本发明。不过这些实例仅仅是范例性的,并不对本发明的保护范围构成任何限制。
在下述实施例和对比例中,所使用到的试剂、材料以及仪器如没有特殊 的说明,均可商购获得。
实施例1(按重量份计)
钠水玻璃 20份
钾水玻璃 14份
氧化铝粉 25份
石英粉 12份
聚氨基聚醚 8份
聚三乙二醇 6份
钠长石 8份
碳化硼 3份
铝粉 4份
实施例2(按重量份计)
钠水玻璃 23份
钾水玻璃 12份
氧化铝粉 22份
石英粉 14份
聚丙烯酰胺 6份
聚三乙二醇 8份
钠长石 6份
碳化硼 5份
铝粉 4份
实施例3(按重量份计)
钠水玻璃 25份
钾水玻璃 13份
氧化铝粉 24份
石英粉 16份
聚丙烯酰胺 5份
聚三乙二醇 4份
钾长石 5份
氮化硼 4份
铝粉 4份
对实施例1-3的涂料进行测试,具体测试如下:
高温氧化烧失测试
喷涂了涂料的石墨在温度为900℃马弗炉中煅烧72小时的烧失重量与原重量的比值,该指标是用来评判涂料在高温下抗氧化防腐蚀的性能。
高温氧化烧失率=(煅烧后涂料加石墨烧失重量-涂料烧失重量)/石墨块重量×100%
具体实验步骤:按照实施例1,2,3 配制好涂料,使用SPQ30无气喷枪在30Mpa工作压力下对石墨块进行喷涂,使石墨块均匀的覆盖一层涂料,在室温下干燥40分钟;之后进行二次喷涂涂料,将经过二次喷涂后的石墨块在室温下固化5小时。然后将未喷涂涂料的石墨块和3个分别喷涂了实施例1,2,3涂料的石墨块一起放置于型号为SG-XS1200的马弗炉中,并在每块石墨上覆盖一层冰晶石粉,用以模拟电解铝液。然后进行高温煅烧,温度900℃,时间72小时。用以检验涂料对石墨块的高温抗氧化防腐蚀情况。测试数据如表1所示。
表1
喷涂了实施例1,2,3涂料的石墨块高温氧化烧失率分别为0.95%,0.81%,0.94%。相较于未喷涂涂料的石墨块,高温氧化烧失率分别降低了98.78%,98.96%,98.79%。
涂料存放周期测试
按照实施例1,2,3配置好涂料,并存放于阴凉干燥处,存放时长分别为0、3、6和8个月。将不同存放时间的涂料在30Mpa工作压力下对石墨进行喷涂及高温氧化烧失率测试。用以评价涂料的可存放周期。高温氧化烧失率的测试方法与前述相同。测试结果如表2所示。
表2
从表2所示数据可以看出,实施例1,2,3 种涂料在阴凉干燥处存放6个月之后仍然可以使用。
以上公开的本发明优选实施例只是用于帮助阐述本发明。优选实施例并没有详尽叙述所有的细节,也不限制该发明仅为所述的具体实施方式。显然,根据本说明书的内容,可作很多的修改和变化。本说明书选取并具体描述这些实施例,是为了更好地解释本发明的原理和实际应用,从而使所属技术领域技术人员能很好地理解和利用本发明。本发明仅受权利要求书及其全部范围和等效物的限制。
Claims (4)
1.一种电解铝碳素阳极抗氧化防腐蚀涂料,其特征在于,由钠水玻璃、钾水玻璃、聚丙烯酰胺和/或聚氨基聚醚、聚三乙二醇、氧化铝粉、石英粉、铝粉、钠长石和/或钾长石、碳化硼和/或氮化硼组成;
其中各组分的重量百分比为:钠水玻璃20-25%、钾水玻璃12-14%、氧化铝粉22-25%、石英粉12%-16%、聚丙烯酰胺和/或聚氨基聚醚5-8%、钠长石和/或钾长石5-8%、碳化硼和/或氮化硼3-5%、铝粉4%、聚三乙二醇4-8%。
2.一种碳素阳极,其特征在于,包括碳素电极和喷涂在其表面的权利要求1所述的涂料。
3.一种权利要求2所述的碳素阳极的制备方法,其特征在于,包括:
S1,在所述碳素电极表面喷涂一层权利要求1所述的涂料,在室温下干燥30~60分钟;
S2,在S1步骤之后进行二次喷涂所述涂料,S1和S2步骤的总喷涂厚度为0.5~1mm;以及
S3,将经过二次喷涂后的电极在室温下固化3~8小时。
4.一种权利要求2所述的碳素阳极在电解铝中应用。
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