CN116751066A - 一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法 - Google Patents
一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法 Download PDFInfo
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Abstract
本申请涉及有色金属铝电解技术领域，提供了一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法，包括以下步骤：无烟煤在超高温2000‑2500℃下深度电煅得到骨料；骨料经破碎、球磨、筛分后得到粒径小于8mm的骨料颗粒；按配比进行称重；骨料与添加剂放入混捏锅干混时同时预热，粘结剂经导热油预热；将预热后的粘结剂倒入混捏锅中，湿混温度不得低于50‑60℃，湿混时间20‑40分钟；检测与包装。本发明具有强度高、热稳定性好、微孔率高、耐氧化等特性，以及较高的耐压强度、耐氧化性和更好的耐火阻热保温性，可显著降低炉底裂缝和熔液渗透侵蚀层层脱落导致的漏槽风险，能大幅提高铝电解槽内衬的使用寿命。
Description
技术领域
本发明涉及有色金属铝电解技术领域，具体为一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法。
背景技术
铝电解槽的使用寿命是一项衡量铝电解生产技术水平高低的综合性技术经济指标，也是铝电解技术水平与国际先进水平的主要差距之一。铝电解槽寿命的长短受“四场”机理(热场、电场、磁场、力场)、槽结构设计、智能控制、内衬材料、砌筑工艺、焙烧启动、生产操作等环节中诸多因素的影响。
当前工业铝电解槽最常见的阴极由阴极炭块和碳质糊料捣固而成。碳质糊料统称为内衬糊，其作用是将阴极炭块之间的缝隙、以及阴极炭块与侧部炭块之间的缝隙通过扎固联结起来，经过焙烧实现糊料的塑化和固化，使得槽底和侧部形成一个完整密封的腔体，在铝电解槽的焙烧和运行阶段避免金属铝液和熔融电解质的渗漏，同时吸收阴极炭块在电解槽焙烧和运行时产生的热膨胀，从而达到提高电流效率、延长电解槽寿命之目的。
铝电解槽正常生产中，阴极炭块与内衬糊直接接触于金属铝液和熔融电解质。阴极炭块在砌筑前已经过预先高温焙烧，具有良好的导热、导电、耐蚀、耐压等性能，而内衬糊因工艺要求必须在现场砌筑时进行捣固，其后必须经过电解槽的焙烧而进行塑化和固化处理。由于糊缝位于电解槽阴极的关键位置，业界的共识认为捣固缝是铝电解槽阴极的最薄弱环节，阴极的多数缺陷都与糊缝的损坏有关。因此，抛开捣固、焙烧过程中诸多外在影响因素，提高内衬糊自身质量尤为重要。
随着技术的不断进步，内衬糊已由早年的热捣糊(80-150℃)发展到冷捣糊(15-42℃)。焙烧收缩率是冷捣糊非常重要的一个性能指标，应尽量的小。国外多数铝电解厂要求冷捣糊的焙烧收缩率最大不超过0.20％，平均不大于0.15％。过大的焙烧收缩率容易在炭块与糊料之间形成缝隙。特别是采用石墨化阴极炭块的铝电解槽，其电解膨胀率很小，炭块的电解膨胀很难弥合电解槽启动初期因边部糊料焦化收缩而产生的缝隙，造成金属铝液和熔融电解质长时间向电解槽连部渗透，严重时会造成侧部漏炉。因此，有必要对传统冷捣糊加以改进。
发明内容
针对现有技术的不足，本发明提供了一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法，实现除具有传统冷捣糊的原有优点之外，还可显著降低冷捣糊的焙烧收缩率，同时提高其抵抗金属铝液和熔融电解质的侵蚀性，并进一步降低沥青挥发分(PAH)的挥发量。
为实现以上目的，本发明通过以下技术方案予以实现：一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法，包括以下步骤：
1)高温电煅：无烟煤在超高温2000-2500℃下深度电煅得到骨料；
2)配料：骨料经破碎、球磨、筛分后得到粒径小于8mm的骨料颗粒；
3)称重：按骨料、粘结剂、添加剂配比进行称重；
4)预热：骨料与添加剂放入混捏锅干混时同时预热，预热温度30-35℃；
粘结剂经导热油预热，预热温度70-80℃；
5)混捏：将预热后的粘结剂倒入混捏锅中，湿混温度不得低于50-60℃，湿混时间20-40分钟；
6)检测与包装：检测混捏好的糊料，并出锅、冷却和包装入库。
所述的铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊按以下重量百分比混捏面成：骨料80-84％、粘结剂14-19％、添加剂1-5％。
所述骨料采用电煅无烟煤，粘结剂采用专门炼制的进口优质环保的液体粘结剂，所述添加剂采用残阳极、碳化硅、棕刚玉粉三种添加剂以5:3:2比例干混均匀的混合物。
所述液体粘结剂的软化点为20-25℃，结焦值为35-38％。
本发明提供了一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法。
具备以下有益效果：
1、本发明通过添加剂的加入，使得生产出的冷捣糊具有强度高、热稳定性好、微孔率高、耐氧化等特性，较之传统的普通冷捣糊，降低了炉底裂缝、金属铝液与熔融电解质液渗透侵蚀层层脱落的风险，具有较高的耐压强度和耐氧化性，具有更好的耐火阻热保温性。能大大的提高炉体的使用寿命。
2、本发明由于使用专门炼制的进口优质环保粘结剂，生产出的冷捣糊扎固时产生的烟气中苯丙芘等致癌物质和其它有害成分比普通沥青掺加蒽油或煤焦油生产的普通冷捣糊减少40％以上，更加环保，更加有利于作业人员的身体健康。
3、本发明通过改变内衬糊成分构成降低其焙烧收缩率，同时提高其抵抗金属铝液和熔融电解质的侵蚀性，更好地满足铝电解槽正常运行的要求。
附图说明
图1为本发明的方法流程图。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
请参阅附图1，本申请提供一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法，包括：利用无烟煤高温电煅后所得到的骨料(电煅煤)经破碎、筛分、称重；
三种添加剂按比例干混均匀后称重与骨料干混同时预加热；
粘结剂称重、预加热；
骨料、添加剂、粘结剂混捏；制成冷捣糊成品包装、储存。
具体的，该铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法，包括以下步骤：
采用优质无烟煤在超高温2000-2500℃下深度电煅得到电煅煤骨料，将骨料经破碎球磨后进行筛分得到合适的骨料颗粒。
冷捣糊的原料为骨料、粘结剂和添加剂，原料各组分的重量百分比为：骨料80-84％；粘结剂14-19％；添加剂1-5％。
将骨料与添加剂放入混捏锅内进行干混，并同时对其预热，控制混捏温度和混捏时间以保证混合料的均匀性。
混匀后加入经过预热的粘结剂，控制合适的湿混工艺条件，保证湿混过程中粘结剂具有较好的流动性和浸入骨料孔隙的充分性。
选择的冷捣糊各原料分别为：
骨料：采用在超高温2000-2500℃下经深度电煅的无烟煤。此种电煅煤的石墨化程度高，可以减少骨料在铝电解槽焙烧阶段的二次煅烧机率。
粘结剂：选用专门炼制的进口优质环保粘结剂。
添加剂A：残阳极。残阳极是以煅后石油焦为主要原料掺合沥青混捏压制经2400℃高温焙烧，再经电解铝二次高温使用的剩余残极，其挥发份小于0.1％，强度大于32MPa，真比重大于2.1，残余收缩率为0，小于1微米的孔隙大于30％，具有很好的热稳定性，使炉体产生裂痕的机会变小。
添加剂B：碳化硅。碳化硅在高温条件下气化游离于冷捣糊的孔隙间，并与之结合堵塞孔隙，使炉衬的孔隙变小，微孔率大于30％，可有效阻止金属铝液和熔融电解质的渗透和冲刷而导致层层脱落现象。
添加剂C：棕刚玉粉。可进一步提高炉衬的抗氧化性。
三种添加剂以5:3:2比例干混均匀备用。
下面结合图1和实施例对本发明做进一步的阐述。
实施例1：
以高温电煅煤为骨料，破碎后进行筛分，得到粒径小于8mm的骨料颗粒，重量百分比为80％；
采用专门炼制的进口优质环保粘结剂，重量百分比为15％；
三种添加剂的重量百分比为5％。
将骨料与添加剂在混捏机中干混并同时对混料加热，干料温度不得低于30-35℃，干混时间20-25分钟。
干混完成后，将预先经过加热的粘结剂倒入混捏锅中进行湿混，湿混温度不得低于50-60℃，湿混时间20-40分钟。
目测骨料颗粒表面粘结剂的均匀性和糊料的湿润性。
目测合格后，每锅取2个样品进行检测。将糊料成品出锅、冷却、包装、入库。
检测结果：糊料焙烧失重9.30％，表观密度1.46g/cm3，真密度1.94g/cm3，电阻率65μΩm，耐压强度19.1MPa，膨胀收缩率10％，理化指标满足《铝电解用阴极糊》(YS/T65-2012)要求。
实施例2：
以高温电煅煤为骨料，破碎后进行筛分，得到粒径小于8mm的骨料颗粒，重量百分比为82％；
采用专门炼制的进口优质环保粘结剂，重量百分比为16％；
三种添加剂的重量百分比为2％。
将骨料与添加剂在混捏机中干混并同时对混料加热，干料温度不得低于30-35℃，干混时间20-25分钟。
干混完成后，将预先经过加热的粘结剂倒入混捏锅中进行湿混，湿混温度不得低于50-60℃，湿混时间20-40分钟。
目测骨料颗粒表面粘结剂的均匀性和糊料的湿润性。目测合格后，每锅取2个样品进行检测。将糊料成品出锅、冷却、包装、入库。
检测结果：糊料焙烧失重9.92％，表观密度1.45g/cm3，真密度1.93g/cm3，电阻率66μΩm，耐压强度20MPa，膨胀收缩率11％，理化指标满足《铝电解用阴极糊》(YS/T65-2012)要求。
实施例3：
以高温电煅煤为骨料，破碎后进行筛分，得到粒径小于8mm的骨料颗粒，重量百分比为84％；
采用专门炼制的进口优质环保粘结剂，重量百分比为15％；
三种添加剂的重量百分比为1％。将骨料与添加剂在混捏机中干混并同时对混料加热，干料温度不得低于30-35℃，干混时间20-25分钟。干混完成后，将预先经过加热的粘结剂倒入混捏锅中进行湿混，湿混温度不得低于50-60℃，湿混时间20-40分钟。
目测骨料颗粒表面粘结剂的均匀性和糊料的湿润性。目测合格后，每锅取2个样品进行检测。将糊料成品出锅、冷却、包装、入库。
检测结果：糊料焙烧失重9.30％，表观密度1.46g/cm3，真密度1.90g/cm3，电阻率65μΩm，耐压强度19MPa，膨胀收缩率13％，理化指标满足《铝电解用阴极糊》(YS/T65-2012)要求。
本发明环保铝电解用抗侵蚀微收缩冷捣内衬糊具有强度高、热稳定性好、微孔率高、耐氧化等特性，较之传统冷捣糊，降低了炉底裂缝和溶液渗透侵蚀层层脱落的风险，具有较高的耐压强度和耐氧化性，具有更好的耐火阻热保温性，能大幅提高铝电解槽内衬的使用寿命。
通过提高内衬糊自身质量进而保证捣固缝的质量，可显著降低大容量电解槽的漏槽风险。本发明已成功应用于铝电解槽，经过运行，电解槽各项参数正常，运行平稳，未发现漏槽现象，也无其他不良反应。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。
Claims (7)
1.一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊，其特征在于，按以下重量百分比混捏面成：骨料80-84％、粘结剂14-19％、添加剂1-5％。
2.根据权利要求1所述的一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊，其特征在于，所述骨料采用电煅无烟煤，粘结剂采用专门炼制的进口优质环保的液体粘结剂，所述添加剂采用残阳极、碳化硅、棕刚玉粉三种添加剂以5:3:2比例干混均匀的混合物。
3.根据权利要求2所述的一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊，其特征在于，所述液体粘结剂的软化点为20-25℃，结焦值为35-38％。
4.一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法，其特征在于，包括以下步骤：
1)高温电煅：无烟煤在2000-2500℃的超高温条件下深度电煅得到骨料；
2)配料：骨料经破碎、球磨、筛分后得到骨料颗粒；
3)称重：按骨料、粘结剂、添加剂配比进行称重；
4)预热：骨料与添加剂放入混捏锅干混时同时预热，粘结剂经导热油预热；
5)混捏：将预热后的粘结剂倒入混捏锅中，控制湿混温度与湿混时间；
6)检测与包装：检测混捏好的糊料，并出锅、冷却和包装入库。
5.根据权利要求4所述的一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法，其特征在于，所述步骤2)中，骨料颗粒的粒径小于8mm。
6.根据权利要求4所述的一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法，其特征在于，所述步骤4)中，骨料与添加剂放入混捏锅干混时同时预热，预热温度30-35℃；粘结剂经导热油预热，预热温度70-80℃。
7.根据权利要求4所述的一种铝电解槽阴极用抗侵蚀微收缩冷捣内衬糊的制备方法，其特征在于，所述步骤5)中，湿混温度不得低于50-60℃，湿混时间20-40分钟。
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