CN117049883A - 一种高炉主铁沟用抗氧化浇注料 - Google Patents

一种高炉主铁沟用抗氧化浇注料 Download PDF

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CN117049883A
CN117049883A CN202311033102.9A CN202311033102A CN117049883A CN 117049883 A CN117049883 A CN 117049883A CN 202311033102 A CN202311033102 A CN 202311033102A CN 117049883 A CN117049883 A CN 117049883A
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castable
parts
silicon carbide
equal
blast furnace
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姜志山
华松
黄秀光
王建
姜成超
李庆达
孙志红
周宪强
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HEBEI HAOXING REFRACTORY FURNACE CHARGE CO Ltd
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Abstract

本发明提供了一种高炉主铁沟用抗氧化浇注料,包括以下种类的原料:电熔致密刚玉、电熔棕刚玉、黑碳化硅、黑碳化硅微粉、多孔莫来石、氮化硅结合碳化硅、活性氧化铝微粉、红柱石、黑碳化硅微粉、亚微米硅微粉、纯铝酸钙水泥、抗氧化剂、防爆裂纤维、减水分散剂。本发明所述的抗氧化浇注料,采用精选高纯原材料,通过引入亚微米硅微粉和黑碳化硅微粉,由于其粒度超细分散性优良,比表面积大等特性,在浇注料中与其它材料颗粒粗中细结构互相填充,可有效提升浇注料在中低温烘烤条件下结合、烧结强度大幅度提升,明显增强了出铁沟浇注料的致密度、改善了其抗氧化性、可有效保障其中高温状态下的热震稳定性,稳步提高了高温抗折强度,耐磨性能及使用寿命。

Description

一种高炉主铁沟用抗氧化浇注料
技术领域
本发明涉及耐火材料技术领域,尤其涉及一种高炉主铁沟用抗氧化浇注料。
背景技术
随着高炉大型化和冶炼技术的不断提高,利用系数提升,高炉的出铁产量不断增加,通铁时间逐步延长,因而对高炉主铁沟用浇注料的性能也提出了更加苛刻的要求。由于出铁沟用耐火材料受高温铁水和渣的热态冲刷,又要受机械磨损和化学侵蚀,还不断承受温度梯度急骤变化等综合作用,因而容易产生微裂纹,这类微裂纹促使了铁水和渣的渗透侵蚀和结构破坏。高炉出铁沟主要使用Al2O3-SiC-C质浇注料、为了进一步提高主铁沟浇注料的性能和使用寿命,发明人研究了抗氧化性对Al2O3-SiC-C铁沟浇注料性能的影响。
为了进一步提高高炉出铁沟用Al2O3-SiC-C浇注料的性能和使用寿命,技术人员在不停地研究高炉出铁沟浇注料,以提高其通铁量和延长使用寿命,减少维护修补次数,降低耐火材料的损耗。技术人员基本上集中到研究各种添加物对Al2O3-SiC-C浇注料抗侵蚀、高强度等性能的影响。关于对抗氧化性能的影响主要集中在高温氧化,一般都做1000℃以上的Al2O3-SiC-C抗氧化试验研究。恰恰Al2O3-SiC-C浇注料的高温下氧化在并不最重要。因为高温下有渣铁粘附在铁沟浇注料层表面壁上,能有效阻止氧化。目前提高抗氧化的方法多集中在添加物上,常规的添加物有单质、碳化物、氮化物和硼化物以及它们的复合物,这些添加物在1000℃以下几乎不能发挥抗氧化的作用,在其在高温下氧化变成大体积的氧化物,有的是低温相而影响了抗侵蚀性。再就是改变碳结构和形貌。但是从原理上来讲,因非氧化物覆盖炭表面,这就阻止了扩散氧化而提高了抗氧化性。
目前而言,高炉出铁沟用浇注料技术配方主要采用Al2O3-SiC-C材料,主要原材料中成分纯度控制及杂质多且影响产品使用寿命;使用较多量铝酸盐水泥结合剂而影响其高温性能;颗粒级配组成简单且分布填充不均匀,造成产品堆积密度差,中低温结合强度较低及抗氧化性能较差,从而影响铁沟浇注料中高温使用过程中碳化硅部分氧化损失,从而影响产品的使用寿命。
现有技术中公开的高炉出铁沟浇注料主要包括以下几种,
1、低水泥结合出铁沟浇注料,以特级矾土、棕刚玉、白刚玉、氧化铝粉及铝酸盐水泥等为主要原料;低温强度高,高温抗折强度低。
2、无水泥出铁沟浇注料,以棕刚玉、白刚玉、氧化铝粉、硅微粉和水合氧化铝等为主要原料;采用凝聚结合,微粉量大,加水量多,造成产品密度较差,气孔率高而影响其烧结强度和耐磨性。
3、溶胶结合出铁沟浇注料,以棕刚玉、白刚玉、氧化铝微粉、硅微粉及改性硅铝溶胶等为主要原料;材料性质粘稠,气孔率高而体积密度较低,中高温耐冲刷性能较低。
现有技术所采取的技术方案中原材料粒度级配和添加剂等配方组合存在很多不完善之处,所采用的技术工艺方案中颗粒级配分布及其填充结构不均匀,从而影响堆积密度而造成产品结合强度较差,使用寿命无法达到长寿化,微粉组配缺失而影响中高温下的抗氧化性能等等各种因素从而影响其创造性及有益使用效果:因此,我们提供一种配方优化合理、制备方法简单易实现,安全型,环保型,可有效降低出铁沟耐材综合运行成本、提高大中型高炉主铁沟用浇注料抗氧化性能的耐材新产品,主铁沟浇注料使用寿命在一次通铁量可提升到20万吨以上,具有广泛的市场推广前景及应用价值。
发明内容
本发明的目的在于克服现有技术中的不足,提供一种高炉主铁沟用抗氧化浇注料。
本发明是通过以下技术方案实现的:一种高炉主铁沟用抗氧化浇注料,包括以下重量份数的原料:电熔致密刚玉30-40份、电熔棕刚玉15-25份、黑碳化硅15-22份、多孔莫来石5-10份、氮化硅结合碳化硅5-10份、活性氧化铝微粉5-10份、红柱石3-7份、黑碳化硅微粉3-6份、亚微米硅微粉2-4份、纯铝酸钙水泥结合剂0.5-2份、抗氧化剂1-3份、防爆裂纤维0.1-0.3份、减水分散剂0.15-0.5份;
所述亚微米硅微粉粒度≤0.5μm,亚微米硅微粉中二氧化硅含量≥97wt%;
选用亚微米硅微粉粒度≤0.5μm,二氧化硅含量≥97%,挪威进口,牌号971;其显微结构为球形颗粒,可显著提高浇注料施工流动性及分散性,早期结合强度较快,有效促进中低温抗氧化性能提高,对产品其它材料组合填充性能优越,保障产品使用寿命延长等特点;亚微米硅微粉在形成过程中,因相变的过程中受表面张力的作用,形成了非结晶相无定形圆球状颗粒,且表面较为光滑,有些则是多个圆球颗粒粘在一起的团聚体。它是一种比表面积很大,活性很高的火山灰物质,微小的球状体可以可减小颗粒摩擦,增强流动性。亚微米硅微粉可以充填于浇注料孔隙中,提高浇注料的体积密度降低气孔率,提高强度与抗氧化性能。硅微粉在水中易形成-Si-OH基,具有较强的亲水性与活性,增强浇注料的凝聚,改善浇注料的中低温性能。
所述黑碳化硅微粉粒度≤15μm,碳化硅含量≥98wt%。
通过选用添加黑碳化硅微粉粒度≤15μm,碳化硅含量≥98%,其特征是分散性优良、可促进提升铁沟料中低温烧结强度及抗氧化性能,形成釉面保护面;产品堆积密度好,具有优良的中高温抗耐磨性及热态抗折强度;碳化硅微粉具有熔点高、硬度高、强度高、热膨胀系数低、导热率高、化学性能稳定特点。碳化硅细粉和微粉在中高温下可以与氧气和碳反应生成SiO2保护膜,防止材料内部碳的氧化,提升材料的抗渣性能和抗氧化性能。碳化硅的纯度和粒度在很大程度上影响铁沟料的抗渣性能和使用寿命,碳化硅以颗粒料、细粉和微粉复合引入方式较好。
进一步地,所述防爆裂纤维选用有机纤维,所述有机纤维熔点为95℃、所述有机纤维的长度15-20mm。
进一步地,减水分散剂是由无机减水剂三聚磷酸钠和有机减水剂FDN-A组成,所述三聚磷酸钠和FDN-A的重量比为4-7:3-5。
进一步地,所述抗氧化剂为金属硅粉和金属铝粉混合物;金属硅粉粒度≤0.044mm,Si含量≥99wt%,金属铝粉粒度≤0.074mm,Al含量≥99wt%,所述金属硅粉和金属铝粉的重量比为3-6:4-5。
添加抗氧化剂为金属硅粉和金属铝粉,保持铁沟料的中高温抗氧化性能、形成保护层并提高其高温抗氧化、强度及耐冲刷性;
本发明的有益效果在于:与现有技术相比,本发明的高炉主铁沟用抗氧化浇注料具有以下优点:
1)本发明技术所制备的抗氧化浇注料,采用精选高纯原材料,通过引入亚微米硅微粉和黑碳化硅微粉,由于其粒度超细分散性优良,比表面积大等特性,在浇注料中与其它材料组合互相填充,可有效使浇注料在中低温烘烤条件下促进结合、强度大幅度提升,明显增强了出铁沟浇注料的致密度、改善了其抗氧化性、可有效保障其中高温的热震稳定性、稳步提高了高温抗折强度,耐磨性能和使用寿命;
2)本发明技术配方通过不同性能抗氧化材料的优化组合、发挥其在不同温度阶段状态下的优特点表现,减少或避免使用了挥发性极强含碳材料及添加剂等,本发明对球状沥青材料舍弃不添加,既减少了笨及有害挥发物和碳含量的排放利用环保,又净化了铁水质量,产品制备方法简单,易于实现,可有效降低了出铁场综合运行成本、节约优质耐火原料资源,使大中型高炉出铁沟浇注料一次通铁量提升至20万吨以上。
3)本发明通过选用多孔莫来石,粒度1-3mm,球形颗粒、筒压强度高、导热系数低等特点,填充到产品结构中,可有效节能降耗,多孔莫来石具有密度小、比表面积大、低的热导率和热膨胀系数、良好的抗腐蚀性能,在高温下具有良好的机械强度和化学稳定性,多孔莫来石可以提高浇注料的抗蠕变和抗热震性。
4)本发明可有效延长高炉主铁沟整体衬体使用寿命,现场安全性能明显提升,该发明具有显著的经济和社会效益。
具体实施方式
下面将结合发明实施例,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。
以下各实施例中:
电熔致密刚玉是由粒度8-12mm、5-8mm和3-5mm的三种原料组成,电熔致密刚玉中氧化铝含量为≥99wt%,颗粒体积密度(g/cm3)≥3.90,由于材料致密高、材料硬度大耐磨性好、耐高温铁水冲刷性优良,大颗粒部分采用三种配比组合,可有效稳定产品堆积架构,具体采用标准YB/T102-2007;
电熔棕刚玉是由粒度3-5mm和0-1mm的二种原料组成,电熔棕刚玉中氧化铝含量为≥95wt%,颗粒体积密度(g/cm3)≥3.85,由于材料致密高、材料硬度大耐磨性好、耐高温铁水冲刷性优良,颗粒采用二种配比组合,可有效稳定产品堆积分布合理,具体采用标准YB/T102-2007;
多孔莫来石是由粒度1-3mm,多孔莫来石中氧化铝含量为≥60wt%,体积密度(g/cm3)1.5-2,球形颗粒、筒压强度高、导热系数低等特点,填充到产品结构中,可有效节能降耗,具体为国内牌号KAL-60产品;多孔莫来石具有密度小、比表面积大、低的热导率和热膨胀系数、良好的抗腐蚀性能,在高温下具有良好的机械强度和化学稳定性,多孔莫来石可以提高浇注料的抗蠕变和抗热震性。
亚微米SiO2微粉中钾、钠等杂质含量极低,而普通SiO2微粉钾、钠等杂质含量相对较高;亚微米SiO2微粉呈明显的酸性。两种微粉微观颗粒形状都是球形,但亚微米SiO2微粉的最大粒径更小,
相比传统铁沟浇注料,引入亚微米SiO2微粉的铁沟浇注料的施工加水量大幅减少,最低达到3.7%;不同温度阶段的结合强度大幅度提高,最高达到30%;亚微米SiO2微粉的最佳引入量2%~4%(wt%)。
不同粒级硅微粉的特性见附表1。
两种SiO2微粉化学分析结果(wt%)如下表
黑碳化硅由粒度包含0.1-1mm,≤0.044mm和≤15μm三种粒度组成,碳化硅含量≥98wt%,采用细颗粒、细粉和微粉组合,分散性优良可促进中低温烧结强度、提升抗氧化性能,产品堆积密度好,提高浇注料的中高温抗耐磨性及热态抗折强度;
氮化硅结合碳化硅粒度≤0.044mm;氮化硅含量≥37wt%,碳化硅含量≥60wt%;具有显著的抗渣性能及抗氧化性能,可有效提高浇注料的中高温抗耐磨性及热态抗折强度;
活性氧化铝微粉粒度≤2μm,微粉中氧化铝含量为≥99wt%,为国产氧化铝微粉,具有优良的分散及流动性能;
红柱石粒度≤0.074mm,红柱石中氧化铝含量为≥58wt%,为国产(新疆),热膨胀系数小、中高温烧结性能优良;
纯铝酸钙水泥粒度≤0.045mm,氧化铝含量为≥71wt%,采用标准GB201-2000,牌号CA-71,可有效促进提升产品组合中颗粒、细粉和微粉的结合促凝、早期低温固化强度高,提高施工作业效率等特点;
抗氧化剂为金属硅粉和金属铝粉,金属硅粒度≤0.044mm,Si含量≥99wt%,金属铝粒度≤0.074mm,Al含量≥99wt%,金属硅粉和金属铝粉的重量比为3-6:4-5;
防爆裂纤维为由有机纤维,熔点95℃,纤维长度15-20mm,有效均匀分散到产品中,在低温烘烤时可快速熔解并形成排气通道以防止爆裂、提高产品应用安全和效率等优异性能;
减水分散剂是由无机减水剂三聚磷酸钠和有机减水剂FDN-A组成,所述三聚磷酸钠和FDN-A的重量比为4-7:3-5。其可提高产品配方组合中细粉、微粉及水泥的减水分散性,有效提升材料结合强度,实现提前施工作业效率。
所述的抗氧化浇注料的制备方法为:步骤一,称取电熔致密刚玉、电熔棕刚玉、黑碳化硅、多孔莫来石、氮化硅结合碳化硅、活性氧化铝微粉、黑碳化硅微粉、亚微米硅微粉、纯铝酸钙水泥结合剂、抗氧化剂、防爆裂纤维、减水分散剂。用1000型强制式搅拌机进行混合搅拌均匀,得到用于高炉主铁沟工作衬抗氧化浇注料,然后将得到的抗氧化浇注料称量后装入防潮1000kg/袋包装袋中,密封存放干燥处待用;
实施例1
一种高炉主铁沟用抗氧化浇注料,由以下重量的原料制成,电熔致密刚玉33份、电熔棕刚玉15份、黑碳化硅22份、多孔莫来石7份、氮化硅结合碳化硅5份、活性氧化铝微粉5份、红柱石4份、黑碳化硅微粉3份、亚微米硅微粉2份、纯铝酸钙水泥结合剂0.6份、抗氧化剂1份、防爆裂纤维0.22份、减水分散剂0.15份;
实施例2
一种高炉主铁沟用抗氧化浇注料,由以下重量的原料制成,电熔致密刚玉35份、电熔棕刚玉16份、黑碳化硅21份、多孔莫来石6份、氮化硅结合碳化硅6份、活性氧化铝微粉5.5份、红柱石4.5份、黑碳化硅微粉3.5份、亚微米硅微粉2份、纯铝酸钙水泥结合剂0.8份、抗氧化剂1.3份、防爆裂纤维0.2份、减水分散剂0.18份;
实施例3
一种高炉主铁沟用抗氧化浇注料,由以下重量的原料制成,电熔致密刚玉36份、电熔棕刚玉17份、黑碳化硅20份、多孔莫来石5份、氮化硅结合碳化硅6.5份、活性氧化铝微粉6份、红柱石5份、黑碳化硅微粉4份、亚微米硅微粉3份、纯铝酸钙水泥结合剂1份、抗氧化剂1.8份、防爆裂纤维0.17份、减水分散剂0.2份;
实施例4
一种高炉主铁沟用抗氧化浇注料,由以下重量的原料制成,电熔致密刚玉38份、电熔棕刚玉20份、黑碳化硅19份、多孔莫来石4.5份、氮化硅结合碳化硅7份、活性氧化铝微粉6.5份、红柱石5.5份、黑碳化硅微粉4.5份、亚微米硅微粉3.5份、纯铝酸钙水泥结合剂1.2份、抗氧化剂2份、防爆裂纤维0.15份、减水分散剂0.22份;
实施例5
一种高炉主铁沟用抗氧化浇注料,由以下重量的原料制成,电熔致密刚玉40份、电熔棕刚玉22份、黑碳化硅18.5份、多孔莫来石4份、氮化硅结合碳化硅7份、活性氧化铝微粉7份、红柱石6份、黑碳化硅微粉5份、亚微米硅微粉4份、纯铝酸钙水泥结合剂1.5份、抗氧化剂2.5份、防爆裂纤维0.12份、减水分散剂0.25份;
对比例
一种高炉主铁沟用抗氧化浇注料,由以下重量的原料制成,电熔棕刚玉43份、电熔白刚玉20、黑碳化硅18份、活性氧化铝微粉8份、纯铝酸钙水泥结合剂3份、防爆裂纤维0.20份、减水分散剂0.25份;普通硅微粉3、球状沥青2.5、金属硅粉2.5。
高炉主铁沟工作衬抗氧化浇注料对比实验检测指标:附表3-1
对本发明所制备的高炉主铁沟工作衬抗氧化浇注料产品的相关性能进行检测,具体检测性能结果如下:
上表中的材料分析及铁沟浇注料测试方法参照耐火材料相应国标或行业标准。
本发明所述的抗氧化浇注料,采用精选高纯原材料,通过引入亚微米硅微粉和黑碳化硅微粉,由于其粒度超细分散性优良,比表面积大等特性,在浇注料中与其它材料颗粒粗中细结构互相填充,可有效提升浇注料在中低温烘烤条件下结合、烧结强度大幅度提升,明显增强了出铁沟浇注料的致密度、改善了其抗氧化性、可有效保障其中高温状态下的热震稳定性,稳步提高了高温抗折强度,耐磨性能及使用寿命。
通过对材料及产品分析及检测结果证明;本发明抗氧化浇注料对于大中型高炉出铁沟均可适用,针对应用到具体不同容积高炉时,根据现场实际要求,技术方案可在上述数值范围内进行一定调整,以满足不同大小高炉的具体使用要求。
最后应说明的是:以上所述仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。

Claims (10)

1.一种高炉主铁沟用抗氧化浇注料,其特征在于,包括以下种类的原料:电熔致密刚玉、电熔棕刚玉、黑碳化硅、多孔莫来石、氮化硅结合碳化硅、活性氧化铝微粉、红柱石、亚微米硅微粉、纯铝酸钙水泥、抗氧化剂、防爆裂纤维、减水分散剂。
2.如权利要求1所述的一种高炉主铁沟用抗氧化浇注料,其特征在于,所述原料的重量组分如下:电熔致密刚玉30-40份、电熔棕刚玉15-25份、黑碳化硅15-22份、多孔莫来石5-10份、氮化硅结合碳化硅5-10份、活性氧化铝微粉5-10份、红柱石3-7份、黑碳化硅微粉3-6份、亚微米硅微粉2-4份、纯铝酸钙水泥0.5-2份、抗氧化剂1-3份、防爆裂纤维0.1-0.3份、减水分散剂0.15-0.5份。
3.如权利要求1所述的一种高炉主铁沟用抗氧化浇注料,其特征在于:所述亚微米硅微粉粒度≤0.5μm,亚微米硅微粉中二氧化硅含量≥97wt%。
4.如权利要求1所述的一种高炉主铁沟用抗氧化浇注料,其特征在于:所述黑碳化硅微粉粒度≤15μm,碳化硅含量≥98wt%。
5.如权利要求1所述的一种高炉主铁沟用抗氧化浇注料,其特征在于:所述防爆裂纤维选用有机纤维,所述有机纤维的熔点为95℃,所述有机纤维的长度15-20mm。
6.如权利要求1所述的一种高炉主铁沟用抗氧化浇注料,其特征在于:所述减水分散剂是由无机减水剂三聚磷酸钠和有机减水剂FDN-A组成,所述三聚磷酸钠和FDN-A的重量比为4-7:3-5。
7.如权利要求1所述的一种高炉主铁沟用抗氧化浇注料,其特征在于:所述抗氧化剂为金属硅粉和金属铝粉混合物;所述金属硅粉粒度≤0.044mm,Si含量≥99wt%,所述金属铝粉粒度≤0.074mm,Al含量≥99wt%,所述金属硅粉和金属铝粉的重量比为3-6:4-5。
8.如权利要求1所述的一种高炉主铁沟用抗氧化浇注料,其特征在于:所述多孔莫来石粒度为1-3mm,多孔莫来石中氧化铝含量为≥60wt%,体积密度为1.5-2g/cm3
9.如权利要求1所述的一种高炉主铁沟用抗氧化浇注料,其特征在于:所述黑碳化硅粒度包含0.1-1mm,≤0.044mm和≤15μm三种粒度组成,碳化硅含量≥98wt%。
10.如权利要求1所述的一种高炉主铁沟用抗氧化浇注料,其特征在于:所述氮化硅结合碳化硅粒度≤0.044mm;所述氮化硅结合碳化硅中氮化硅含量≥37wt%,碳化硅含量≥60wt%。
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CN117843352A (zh) * 2024-03-06 2024-04-09 北京利尔高温材料股份有限公司 一种高炉出铁沟浇注料

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117843352A (zh) * 2024-03-06 2024-04-09 北京利尔高温材料股份有限公司 一种高炉出铁沟浇注料
CN117843352B (zh) * 2024-03-06 2024-05-31 北京利尔高温材料股份有限公司 一种高炉出铁沟浇注料

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