CN117362012A - Alkali-resistant wear-resistant corrosion-resistant castable and preparation method thereof - Google Patents

Alkali-resistant wear-resistant corrosion-resistant castable and preparation method thereof Download PDF

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CN117362012A
CN117362012A CN202311372044.2A CN202311372044A CN117362012A CN 117362012 A CN117362012 A CN 117362012A CN 202311372044 A CN202311372044 A CN 202311372044A CN 117362012 A CN117362012 A CN 117362012A
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resistant
alkali
corrosion
wear
castable
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陶平
邵飞
李鑫
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Yixing Haike Kiln Engineering Co ltd
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Yixing Haike Kiln Engineering Co ltd
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Abstract

The invention relates to the technical field of kiln castable preparation, in particular to an alkali-resistant wear-resistant corrosion-resistant castable and a preparation method thereof, comprising the following steps: 25 to 30 percent of MgO and 65 to 75 percent of Al 2 O 3 10-15% of auxiliary materials, 5-15% of functional filler, 0.1-1.5% of water reducer and the balance of main materials; the invention adds high content of MgO and Al 2 O 3 Can effectively resist the corrosion of alkaline medium and improve the alkali resistance, and the invention addsThe aluminum oxide, the calcium carbonate, the calcium peroxide and the aluminum powder, and the fiber and the aggregate in the functional filler can improve the erosion resistance of the material, and adapt to various corrosive media and erosion conditions; the component proportion of the alkali-resistant wear-resistant corrosion-resistant castable can provide excellent alkali resistance, wear resistance and corrosion resistance, has better technological properties, and is suitable for application requirements in high alkali and wear environments.

Description

Alkali-resistant wear-resistant corrosion-resistant castable and preparation method thereof
Technical Field
The invention relates to the technical field of kiln castable preparation, in particular to an alkali-resistant wear-resistant corrosion-resistant castable and a preparation method thereof.
Background
In recent years, the alkaline substances with the greatest damage to the furnace lining of the kiln are alkali metal sodium and potassium compounds, and the alkali metal compounds can undergo a series of physicochemical reactions in the smelting process of the kiln, so that the alkali metal compounds are circularly enriched, and the adverse effect on the kiln is generated. The alkali metal compound erodes the refractory material to cause the problems of cracking and damage of the furnace lining, etc., and causes the shutdown and environmental pollution of the industrial kiln.
In the combustion process of alkaline substances in the kiln, decomposed alkali metal compounds can cause the heating surface in the kiln to generate high-temperature corrosion. Waste from chemical industry, pharmacy, leather industry and the like contains a large amount of alkali metal compounds (such as compounds containing potassium and sodium) and the refractory materials for industrial hazardous waste incinerators mainly comprise chrome corundum bricks, chrome corundum castable and high-alumina castable.
The main components of the refractory materials are all Al 2 O 3 ，Al 2 O 3 Can react with a basic compound containing K, na to form beta-A1 2 O 3 With a certain volume expansion, the formation of new phases leads to a destruction of the tissue structure, severe cracking, flaking and destruction of the lining matrix, which leads to further corrosion of the internal material. The service life of the refractory material is greatly shortened, and the stable operation and the safe production of the incinerator are seriously influenced.
Disclosure of Invention
The invention provides an alkali-resistant wear-resistant corrosion-resistant castable and a preparation method thereof, aiming at the defects existing in the prior art.
The technical scheme of the invention is as follows: the alkali-resistant wear-resistant corrosion-resistant castable comprises the following components in percentage by weight: 25 to 30 percent of MgO and 65 to 75 percent of Al 2 O 3 10-15% of auxiliary materials, 5-15% of functional filler, 0.1-1.5% of water reducer and the balance of main materials;
the main materials comprise the following components in percentage by weight: 5-7% of cordierite particles, 35-40% of tricalcium aluminate, 20-30% of dicalcium aluminate and the balance of water;
the auxiliary materials comprise the following components in percentage by weight: 25-30% of aluminum oxide, 10-15% of calcium carbonate, 7-8% of calcium peroxide, 3-5% of aluminum powder and the balance of calcium citrate tetrahydrate;
the functional filler comprises the following components in percentage by weight: 20-30% of calcium hexaaluminate, 15-20% of Secar71 cement and 8-10% of active alpha-Al 2 O 3 Micro powder, 1-3% of fiber and the balance of aggregate.
Description: the castable contains MgO and Al 2 O 3 The components such as the alkali metal oxide can effectively resist corrosion of an alkaline medium, and ensure long-term stability of the material in an alkaline environment; the cordierite particles, the tricalcium aluminate, the dicalcium aluminate and the like in the main materials can provide good abrasion resistance, and can keep the stability of the materials in a high abrasion environment; the components such as alumina, calcium carbonate, calcium peroxide, aluminum powder and the like in the auxiliary materials and the heavy calcium hexaluminate and the like in the functional filler have good erosion resistance, so that the materials can be protected from being damaged by erosion substances; by adding Secar71 cement and active alpha-Al 2 O 3 The functional fillers such as micro powder and fiber can improve the processability, fluidity and crack resistance of the castable.
The preparation method of the alkali-resistant wear-resistant corrosion-resistant castable comprises the following steps:
s1, preparing a main material
Mixing cordierite particles, tricalcium aluminate, dicalcium aluminate and water according to a formula ratio, and stirring for 0.8-1.5 h to obtain a main material;
s2, preparing auxiliary materials
Weighing aluminum oxide, calcium carbonate, calcium peroxide, aluminum powder and calcium citrate tetrahydrate according to the formula proportion, mechanically mixing in a mortar for 45-55 min to obtain a mixture, and filling the mixture into a crucible with the bulk density of 1-1.2 g/cm 3 Placing Ti-C sheet with thickness of 0.8-1.2 mm on the mixture as ignition agent, then placing crucible into combustion synthesis reactor, making W wire in the reactor contact with Ti-C, turning on power supply to make W wire heat and ignite Ti-C, in the course of combustion synthesis measuring by means of W-3% Re/W-25% Re thermocoupleThe combustion temperature of the reaction system is measured, and auxiliary materials are obtained after combustion waves spread;
s3, preparing functional filler
Mixing heavy calcium hexaaluminate, secar71 cement and active alpha-Al according to the formula proportion 2 O 3 The micro powder, the fiber and the aggregate are kept at the temperature of 1400-1750 ℃ for 3 hours and are stirred uniformly to obtain the functional filler;
s4, forming and drying the blank
MgO and Al are mixed according to the formula proportion 2 O 3 Pouring the auxiliary materials, the functional filler and the main materials into a cement mortar stirrer for dry mixing, adding a water reducing agent and water for stirring for 5-15 min, and then placing into a molding test mold, wherein the water addition amount is 20-25% of the total mass of the erosion resistant castable; vibrating for 2-6 min by using a cement molding vibrating table to prepare a blank; after the green body is subjected to wet curing for 48 hours, drying for 24-36 hours at the temperature of 110-130 ℃ to obtain a dried green body;
s5, heat treatment
And (3) placing the dried blank in a muffle furnace, performing heat treatment at the temperature of 1100-1750 ℃, preserving heat for 3-6 h, and cooling to room temperature to obtain the anti-erosion castable.
Description: through accurate proportioning and proper process control, the main material, auxiliary material and functional filler with high stability can be obtained, which is helpful for ensuring that the castable can keep stable performance in the use process; the auxiliary material part in the preparation method is obtained by adopting a combustion synthesis mode, and the method can form a material with good erosion resistance. This helps to increase the resistance of the castable to aggressive media; the preparation method has relatively simple steps, the method comprises the steps of preparing main materials, auxiliary materials and functional fillers, forming and drying the blank body, and the like, so that the preparation process is easier to control, the practicability of the method is higher,
further, mgO and Al as described in step S4 2 O 3 The magnesium aluminate powder is added in the form of 20-30% of magnesium oxide micro powder by mass percent and the balance of magnesium aluminate spinel mixed by various granularities.
Description: the magnesium oxide micro powder has higher alkaline resistance, can enhance the alkali corrosion resistance and is beneficial to improving the alkali resistance; the addition of magnesia-alumina spinel particles can increase the hardness and wear resistance of the castable, so that the castable is more wear-resistant; the magnesia-alumina spinel mixed with various granularities has larger specific surface area and pore structure, can strengthen the binding force with other components, and improves the compactness and uniformity of the material; the magnesia-alumina spinel has better stability to high temperature and can maintain the structural stability of the material in a high-temperature environment.
Further, the particle size d50 of the magnesium oxide micro powder is 5 mu m; the magnesia-alumina spinel consists of magnesia-alumina spinel particles, fine powder and micro powder, and the mass ratio of the magnesia-alumina spinel particles to the micro powder is as follows: 6:3:2; the particle size of the magnesia alumina spinel is as follows: 5-3 mm, 3-1 mm and less than or equal to 1mm, and the mass ratio is as follows: 2:1:1, a step of; the granularity of the magnesia-alumina spinel fine powder is less than or equal to 0.088mm; the granularity of the magnesia-alumina spinel micropowder is less than or equal to 0.010mm.
Description: the smaller granularity is favorable for improving the compactness and uniformity of the material, so that the alkali resistance and the wear resistance of the material are enhanced, the magnesia-alumina spinel particles, the fine powder and the micro powder are mixed according to a certain proportion, the structure and the characteristics of the material can be effectively regulated, the overall performance of the material is improved, the magnesia-alumina spinel particles with a plurality of granularity levels are mixed for use, the pore structure and the surface area of the material can be increased, the erosion resistance and the wear resistance of the material are improved, the small granularity of the fine powder and the micro powder is favorable for enhancing the compactness and the cohesiveness of the material, and the erosion resistance of the castable is improved.
Further, the method for measuring the combustion temperature of the reaction system by the thermocouple in the step S2 comprises the following steps: uniaxially and bidirectionally pressing the mixture into a cylindrical sample with the relative density of 60-80% in a steel die; and drilling a small hole on two sides of the cylindrical sample, inserting one end of a W-3%Re/W-25%Re thermocouple into the two holes, connecting the other end of the thermocouple with an X-Y paperless recorder, igniting the sample in a reaction chamber, and measuring and recording the combustion wave spreading process by using the X-Y paperless recorder.
Description: and recording and drawing a time-temperature curve by using an X-Y paperless recorder, wherein the maximum temperature in the time-temperature curve is the combustion temperature, the time difference of the combustion temperature in the two curves is delta t, and the combustion wave velocity is 20 mm/' delta t.
Further, the diameter of the small holes on the two sides of the cylindrical sample is 2-5 mm, the depth is 7-9 mm, and the distance between the two holes is 20-30 mm; the wire diameter of the W-3%Re/W-25%Re thermocouple is 0.08-0.12 mm.
Description: the combustion process of the sample is measured by inserting the thermocouple, the maximum value of the combustion temperature can be accurately measured by drawing a time-temperature curve by using the paperless recorder, and the size of the holes on two sides of the cylindrical sample and the parameters of the thermocouple can be adjusted to adapt to different experimental requirements, so that the measurement result is more reliable.
Further, the aggregate in the functional filler is one or more of sintered or fused synthetic spinel, sintered or fused magnesia, siC, quartz, chromite, AZS, silons, calcium aluminate, vermiculite, foamed aluminum, perlite and calcium aluminate porous polymeric materials.
Description: the synthesized spinel, siC and quartz can obviously improve the wear resistance and prolong the service life of the material; the cordierite, AZS and calcium aluminate can improve the erosion resistance of the material and adapt to the erosion environments such as acid-base mediums and the like; the porous polymer material, foamed aluminum and perlite are selected to adjust the pore structure of the material and increase the light performance of the material, thereby improving the heat insulation performance of the material and reducing the weight load.
Further, the fibers in the functional filler comprise, in mass percent: 4-6% of organic fiber and the balance of steel fiber; the organic fiber adopts polypropylene fiber.
Description: the polypropylene fiber is added to accelerate the drying process and reduce heat stress damage to the maximum extent, so that the drying and firing time can be shortened; the addition of steel fibers can increase the tensile, compressive and bending strength of the castable and enhance the crack growth resistance and the spalling resistance.
Further, the functional filler in step S3 further includes a refractory auxiliary material, and the preparation method of the refractory auxiliary material includes: according to the mass percentage, 5 to 9 percent of crystalline flake graphite, 3 to 5 percent of phenolic resin, 1 to 2 percent of Si powder, 1 to 2 percent of Al powder, 0 to 8 percent of calcium hexaluminate fine powder and the balance of fused magnesia fine powder are premixed in a polyurethane barrel for 2 to 4 hours to obtain a refractory raw material, and the refractory raw material is mixed and ground to obtain a refractory auxiliary material.
Description: the flake graphite has good high temperature resistance, can be kept stable in a high-temperature environment, and enhances the heat resistance of the refractory material; the flake graphite and the phenolic resin can provide certain oxidation resistance, and effectively prevent the oxidation reaction from damaging the material; the addition of Si powder and Al powder can provide active metal elements, promote reaction, and increase the stability and service life of the material; the calcium hexaluminate fine powder and the fused magnesia fine powder can improve the structure of the material, increase the porosity and compactness, and improve the mechanical strength and the pressure resistance of the refractory auxiliary materials.
Further, the mixing and grinding method comprises the following steps: firstly adding fused magnesia fine powder into a stirrer to dry mix for 4-10 min, then pouring phenolic resin accounting for 60-70% of the total phenolic resin mass ratio to mix for 4-10 min, dividing the fireproof raw material into four parts with equal mass ratio, pouring the four parts into the stirrer in batches, mixing for 4-10 min each time when adding one part, finally adding the residual phenolic resin binder, mixing for 3-4 h, and solidifying for 24h at 200-240 ℃ after molding to obtain the fireproof auxiliary material.
Description: the refractory raw materials are added in batches according to the equal mass ratio and mixed, so that the reaction process is controlled, the reaction and combination of the components are promoted, and the complete reaction and thermal curing of the materials are ensured; after molding, the refractory auxiliary material is cured for a long time at a lower temperature, which is beneficial to improving the curing effect and the structural stability of the material; by the mixing and grinding method and the curing conditions, the integrity and uniformity of molding and curing of the refractory auxiliary materials can be ensured, and the refractory brick has good strength and refractory performance.
Compared with the prior art, the invention has the beneficial effects that:
the invention adds high content of MgO and Al 2 O 3 The corrosion of alkaline medium can be effectively resisted, and the alkali resistance is improved; combinations of cordierite particles and aluminates in the host material and weights in the functional fillerThe addition of the calcium hexaluminate and the Secar71 cement can obviously improve the wear resistance of the material and prolong the service life; the aluminum oxide, the calcium carbonate, the calcium peroxide and the aluminum powder, and the fiber and the aggregate in the functional filler can improve the erosion resistance of the material, and adapt to various corrosive media and erosion conditions; the component proportion of the alkali-resistant wear-resistant corrosion-resistant castable can provide excellent alkali resistance, wear resistance and corrosion resistance, has better technological properties, and is suitable for application requirements in high alkali and wear environments.
Detailed Description
The invention will be described in further detail with reference to the following embodiments to better embody the advantages of the invention.
Example 1
Example 1 is used for illustrating the composition ratio of an alkali-resistant wear-resistant corrosion-resistant castable, which is designed by the invention, and comprises the following components:
the alkali-resistant wear-resistant corrosion-resistant castable comprises the following components in percentage by weight: 27.5% MgO, 60% Al 2 O 3 12.5% of auxiliary materials, 10% of functional filler, 0.125% of water reducer and the balance of main materials;
the main materials comprise the following components in percentage by weight: 6% of cordierite particles, 37.5% of tricalcium aluminate, 25% of dicalcium aluminate and the balance of water;
the auxiliary materials comprise the following components in percentage by weight: 27.5% of aluminum oxide, 12.5% of calcium carbonate, 7.5% of calcium peroxide, 4% of aluminum powder and the balance of calcium citrate tetrahydrate;
the functional filler comprises the following components in percentage by weight: 25% by weight of calcium hexaaluminate, 17.5% of Secar71 cement, 9% of active alpha-Al 2 O 3 Micro powder, 2% of fiber and the balance of aggregate; the aggregate is fused synthetic spinel.
Example 2
Example 2 was designed based on the scheme in example 1, mainly to illustrate another alkali-resistant, wear-resistant and erosion-resistant castable with different composition ratios, comprising: 25% MgO, 65% Al 2 O 3 10% of auxiliary materials, 5% of functional filler, 0.1% of water reducer and the balance of main materials;
the main materials comprise the following components in percentage by weight: 5% of cordierite particles, 35% of tricalcium aluminate, 20% of dicalcium aluminate and the balance of water;
the auxiliary materials comprise the following components in percentage by weight: 25% of aluminum oxide, 10% of calcium carbonate, 7% of calcium peroxide, 3% of aluminum powder and the balance of calcium citrate tetrahydrate;
the functional filler comprises the following components in percentage by weight: 20% by weight of calcium hexaaluminate, 15% of Secar71 cement, 8% of active alpha-Al 2 O 3 Micropowder, 1% of fiber and the balance of aggregate.
Example 3
Example 3 was designed based on the scheme in example 1, mainly to illustrate another alkali-resistant, wear-resistant and erosion-resistant castable with different composition ratios, comprising: 30% MgO, 75% Al 2 O 3 15% of auxiliary materials, 15% of functional filler, 1.5% of water reducer and the balance of main materials;
the main materials comprise the following components in percentage by weight: 7% of cordierite particles, 40% of tricalcium aluminate, 30% of dicalcium aluminate and the balance of water;
the auxiliary materials comprise the following components in percentage by weight: 30% of aluminum oxide, 15% of calcium carbonate, 8% of calcium peroxide, 5% of aluminum powder and the balance of calcium citrate tetrahydrate;
the functional filler comprises the following components in percentage by weight: 30% by weight of calcium hexaaluminate, 20% of Secar71 cement, 10% of active alpha-Al 2 O 3 Micropowder, 3% of fiber and the balance of aggregate.
Example 4
Example 4 is used for illustrating a preparation method of an alkali-resistant, wear-resistant and corrosion-resistant castable designed in example 1 of the present invention, and the following contents are provided:
s1, preparing a main material
Mixing cordierite particles, tricalcium aluminate, dicalcium aluminate and water according to a formula ratio, and stirring for 1.15 hours to obtain a main material;
s2, preparing auxiliary materials
Weighing aluminum oxide, calcium carbonate, calcium peroxide, aluminum powder and calcium citrate tetrahydrate according to the formula proportion, mechanically mixing in a mortar for 50min to obtain a mixture, and filling the mixture into a crucible with the bulk density of 1.1g/cm 3 Placing a Ti-C sheet with the thickness of 1mm on the mixture as an ignition agent, then placing a crucible into a combustion synthesis reactor, enabling a W wire in the reactor to contact with Ti-C, switching on a power supply to enable the W wire to heat and ignite the Ti-C, measuring the combustion temperature of a reaction system through a W-3% Re/W-25% Re thermocouple in the combustion synthesis process, and obtaining auxiliary materials after combustion waves spread; the method for measuring the combustion temperature of the reaction system by the thermocouple comprises the following steps: uniaxially and bidirectionally pressing the mixture into a cylindrical sample with the relative density of 70% in a steel die; drilling a small hole on two sides of a cylindrical sample respectively, inserting one end of a W-3%Re/W-25%Re thermocouple into the two holes, connecting the other end of the thermocouple with an X-Y paperless recorder, igniting the sample in a reaction chamber, and measuring and recording a combustion wave spreading process by using the X-Y paperless recorder; the diameter of the small holes on the two sides of the cylindrical sample is 3.5mm, the depth is 8mm, and the distance between the two holes is 25mm; the wire diameter of the W-3%Re/W-25%Re thermocouple is 0.1mm;
s3, preparing functional filler
Mixing heavy calcium hexaaluminate, secar71 cement and active alpha-Al according to the formula proportion 2 O 3 Preserving the heat of the micro powder, the fiber and the aggregate for 3 hours at the temperature of 1575 ℃ and uniformly stirring to obtain the functional filler; the aggregate is fused into spinel, fused magnesia, cordierite, siC, quartz and chromite according to the same mass ratio; the fibers in the functional filler include: 5% of organic fibers and the balance of steel fibers; the organic fiber adopts polypropylene fiber;
s4, forming and drying the blank
MgO and Al are mixed according to the formula proportion 2 O 3 Pouring the auxiliary materials, the functional filler and the main materials into a cement mortar mixer for dry mixing, adding a water reducing agent and water for mixing for 10min, and then placing into a molding test mold, wherein the water addition amount is 22.5% of the total mass of the erosion resistant castable; shaping vibration with cementVibrating the table for 4min to obtain a blank; after the green body is subjected to wet curing for 48 hours, drying for 30 hours at the temperature of 120 ℃ to obtain a dried green body; the MgO and Al 2 O 3 Adding the magnesium oxide micropowder with the mass percentage of 25% and the rest of magnesium aluminate spinel mixed with various granularities; the granularity d50 of the magnesium oxide micro powder is 5 mu m; the magnesia-alumina spinel consists of magnesia-alumina spinel particles, fine powder and micro powder, and the mass ratio of the magnesia-alumina spinel particles to the micro powder is as follows: 6:3:2; the particle size of the magnesia alumina spinel is as follows: 4.1 to 4mm, 1.1 to 1mm and 1mm, and the mass ratio is as follows: 2:1:1, a step of;
the granularity of the magnesia alumina spinel fine powder is 0.088mm; the granularity of the magnesia-alumina spinel micropowder is 0.01mm;
s5, heat treatment
And (3) placing the dried blank in a muffle furnace, performing heat treatment at 1400 ℃, preserving heat for 4.5 hours, and cooling to room temperature to obtain the anti-erosion castable.
Experimental example
In this experimental example, the preparation method in the above example 4 is used as a control group, and different experimental groups are designed by changing different process parameters in the preparation method, so as to verify the performance of the deposition-preventing foam discharging agent, and the design scheme is as follows:
control group: the preparation method and process parameters in example 4 were used;
experiment group 1: the parameters were the same as the control group except for the following: the anti-corrosion castable comprises the following components in percentage by weight: 25% MgO, 65% Al 2 O 3 10% of auxiliary materials, 5% of functional filler, 0.1% of water reducer and the balance of main materials;
experiment group 2: the parameters were the same as the control group except for the following: the anti-corrosion castable comprises the following components in percentage by weight: 30% MgO, 75% Al 2 O 3 15% of auxiliary materials, 15% of functional filler, 1.5% of water reducer and the balance of main materials;
experiment group 3: the parameters were the same as the control group except for the following: the main materials comprise the following components in percentage by weight: 5% of cordierite particles, 35% of tricalcium aluminate, 20% of dicalcium aluminate and the balance of water;
experiment group 4: the remaining parameters were the same as in experimental group 4 except for the following: the main materials comprise the following components in percentage by weight: 7% of cordierite particles, 40% of tricalcium aluminate, 30% of dicalcium aluminate and the balance of water;
experimental group 5: the parameters were the same as the control group except for the following: the auxiliary materials comprise the following components in percentage by weight: 25% of aluminum oxide, 10% of calcium carbonate, 7% of calcium peroxide, 3% of aluminum powder and the balance of calcium citrate tetrahydrate;
experiment group 6: the remaining parameters were the same as in experimental group 5 except for the following: the auxiliary materials comprise the following components in percentage by weight: 30% of aluminum oxide, 15% of calcium carbonate, 8% of calcium peroxide, 5% of aluminum powder and the balance of calcium citrate tetrahydrate;
experiment group 7: the parameters were the same as the control group except for the following: the functional filler also comprises a refractory auxiliary material, and the preparation method of the refractory auxiliary material comprises the following steps: premixing 5% of crystalline flake graphite, 3% of phenolic resin, 1% of Si powder, 1% of Al powder and the balance of fused magnesia fine powder in a polyurethane barrel for 2 hours according to mass percent to obtain a refractory raw material, and mixing and grinding the refractory raw material to obtain a refractory auxiliary material; the mixing and grinding method comprises the following steps: firstly adding fused magnesia fine powder into a stirrer, dry-mixing for 4min, then pouring phenolic resin accounting for 60% of the total phenolic resin mass ratio, mixing for 4min, dividing the refractory raw material into four parts with equal mass ratio, pouring into the stirrer in batches, mixing for 4min each time when adding one part, finally adding the rest phenolic resin binder, mixing for 3h, and solidifying at 200 ℃ for 24h after molding to obtain the refractory auxiliary material.
Experiment group 8: the remaining parameters were the same as in experimental group 7 except for the following: the functional filler also comprises a refractory auxiliary material, and the preparation method of the refractory auxiliary material comprises the following steps: premixing 9% of crystalline flake graphite, 5% of phenolic resin, 2% of Si powder, 2% of Al powder, 8% of calcium hexaluminate fine powder and the balance of fused magnesia fine powder in a polyurethane barrel for 4 hours according to mass percent to obtain a refractory raw material, and mixing and grinding the refractory raw material to obtain a refractory auxiliary material; the mixing and grinding method comprises the following steps: firstly adding fused magnesia fine powder into a stirrer, dry-mixing for 10min, then pouring phenolic resin accounting for 70% of the total phenolic resin mass ratio, mixing for 10min, dividing the refractory raw material into four parts with equal mass ratio, pouring into the stirrer in batches, mixing for 10min each time when adding one part, finally adding the rest phenolic resin binder, mixing for 4h, and curing at 240 ℃ for 24h after molding to obtain the refractory auxiliary material.
Anti-erosion castable performance test
9 different erosion resistant castable materials are prepared by using the methods of the control group and the experimental groups 1-8, the performances of the prepared erosion resistant castable materials are detected, and erosion tests are carried out by respectively carrying out heat preservation at 800 ℃, 1000 ℃ and 1200 ℃ for 30 hours, wherein the specific detection results are shown in table 1;
table 1: performance test table for 9 different erosion resistant castable
The following conclusions can be drawn from the data in table 1:
1. the influence of different parameters of the proportion of the anti-erosion castable on the performance of the prepared anti-erosion castable is explored.
Comparing the control group with the experimental group 1 and the experimental group 2, the performance of the experimental group 2 is obviously better than that of the control example in the two groups of experiments, the apparent porosity of the experimental group 1 is the highest in a comprehensive view at different temperatures, and the comprehensive performance of the composite material can be enhanced by increasing the proportioning parameters, wherein the erosion resistance is obviously improved.
2. The influence of different parameter proportions of the main material on the performance of the prepared erosion resistant castable is explored.
When the control group is compared with the experimental group 3 and the experimental group 4, the performance of the control example is optimal, the parameter ratio is best, and the experimental group 3 is better than the experimental group 4 in the three groups of experiments.
3. The influence of different parameter proportions of the auxiliary materials on the performance of the prepared erosion resistant castable is explored.
When the comparison between the control group and the experimental group 5 and the experimental group 6 shows that the apparent porosity and the density change of the experimental group 5 are the smallest in the three groups of experiments, the control group is superior to the experimental group 6, and the parameter proportion of the auxiliary materials of the experimental group 5 can be preferentially adopted when the erosion-resistant castable is prepared.
4. The influence of different technological parameters for preparing the refractory auxiliary materials on the performance of the prepared erosion-resistant castable is explored.
When the comparison between the control group and the experimental groups 7 and 8 is carried out, the difference is not obvious, the erosion resistance of the erosion resistant castable is optimal under the parameter proportion of the experimental group 7, and compared with the comparison between the control group and the experimental group 8, the erosion resistance of the experimental group 8 is better.

Claims (10)

1. The alkali-resistant wear-resistant corrosion-resistant castable is characterized by comprising the following components in percentage by weight: 25 to 30 percent of MgO and 65 to 75 percent of Al 2 O 3 10-15% of auxiliary materials, 5-15% of functional filler, 0.1-1.5% of water reducer and the balance of main materials;
the main materials comprise the following components in percentage by weight: 5-7% of cordierite particles, 35-40% of tricalcium aluminate, 20-30% of dicalcium aluminate and the balance of water;
the auxiliary materials comprise the following components in percentage by weight: 25-30% of aluminum oxide, 10-15% of calcium carbonate, 7-8% of calcium peroxide, 3-5% of aluminum powder and the balance of calcium citrate tetrahydrate;
the functional filler comprises the following components in percentage by weight: 20-30% of calcium hexaaluminate, 15-20% of Secar71 cement and 8-10% of active alpha-Al 2 O 3 Micro powder, 1-3% of fiber and the balance of aggregate.
2. The method for preparing the alkali-resistant wear-resistant corrosion-resistant castable, as set forth in claim 1, comprising the steps of:
s1, preparing a main material
Mixing cordierite particles, tricalcium aluminate, dicalcium aluminate and water according to a formula ratio, and stirring for 0.8-1.5 h to obtain a main material;
s2, preparing auxiliary materials
Weighing aluminum oxide, calcium carbonate, calcium peroxide, aluminum powder and calcium citrate tetrahydrate according to the formula proportion, mechanically mixing in a mortar for 45-55 min to obtain a mixture, and filling the mixture into a crucible with the bulk density of 1-1.2 g/cm 3 Placing a Ti-C sheet with the thickness of 0.8-1.2 mm on the mixture as an ignition agent, then placing a crucible into a combustion synthesis reactor, enabling a W wire in the reactor to be in contact with Ti-C, switching on a power supply to enable the W wire to heat and ignite the Ti-C, measuring the combustion temperature of a reaction system through a W-3%Re/W-25%Re thermocouple in the combustion synthesis process, and obtaining auxiliary materials after combustion waves spread;
s3, preparing functional filler
Mixing heavy calcium hexaaluminate, secar71 cement and active alpha-Al according to the formula proportion 2 O 3 The micro powder, the fiber and the aggregate are kept at the temperature of 1400-1750 ℃ for 3 hours and are stirred uniformly to obtain the functional filler;
s4, forming and drying the blank
MgO and Al are mixed according to the formula proportion 2 O 3 Pouring the auxiliary materials, the functional filler and the main materials into a cement mortar stirrer for dry mixing, adding a water reducing agent and water for stirring for 5-15 min, and then placing into a molding test mold, wherein the water addition amount is 20-25% of the total mass of the erosion resistant castable; vibrating for 2-6 min by using a cement molding vibrating table to prepare a blank; after the green body is subjected to wet curing for 48 hours, drying for 24-36 hours at the temperature of 110-130 ℃ to obtain a dried green body;
s5, heat treatment
And (3) placing the dried blank in a muffle furnace, performing heat treatment at the temperature of 1100-1750 ℃, preserving heat for 3-6 h, and cooling to room temperature to obtain the anti-erosion castable.
3. The method for preparing alkali-resistant, wear-resistant and corrosion-resistant castable according to claim 2, wherein the MgO and Al in step S4 are as follows 2 O 3 The magnesium aluminate powder is added in the form of 20-30% of magnesium oxide micro powder by mass percent and the balance of magnesium aluminate spinel mixed by various granularities.
4. The method for preparing alkali-resistant, wear-resistant and corrosion-resistant castable according to claim 3, wherein the particle size d50 of the magnesium oxide micro powder is 5 μm; the magnesia-alumina spinel consists of magnesia-alumina spinel particles, fine powder and micro powder, and the mass ratio of the magnesia-alumina spinel particles to the micro powder is as follows: 6:3:2; the particle size of the magnesia alumina spinel is as follows: 5-3 mm, 3-1 mm and less than or equal to 1mm, and the mass ratio is as follows: 2:1:1, a step of; the granularity of the magnesia-alumina spinel fine powder is less than or equal to 0.088mm; the granularity of the magnesia-alumina spinel micropowder is less than or equal to 0.010mm.
5. The method for preparing the alkali-resistant, wear-resistant and corrosion-resistant castable according to claim 2, wherein the method for measuring the combustion temperature of the reaction system by the thermocouple in the step S2 is as follows: uniaxially and bidirectionally pressing the mixture into a cylindrical sample with the relative density of 60-80% in a steel die; and drilling a small hole on two sides of the cylindrical sample, inserting one end of a W-3%Re/W-25%Re thermocouple into the two holes, connecting the other end of the thermocouple with an X-Y paperless recorder, igniting the sample in a reaction chamber, and measuring and recording the combustion wave spreading process by using the X-Y paperless recorder.
6. The method for preparing the alkali-resistant, wear-resistant and corrosion-resistant castable according to claim 5, wherein the diameter of the small holes on the two sides of the cylindrical sample is 2-5 mm, and the distance between the two holes with the depth of 7-9 mm is 20-30 mm; the wire diameter of the W-3%Re/W-25%Re thermocouple is 0.08-0.12 mm.
7. The method for preparing the alkali-resistant, wear-resistant and corrosion-resistant castable according to claim 1, wherein the aggregate in the functional filler is one or more of sintered or fused synthetic spinel, sintered or fused magnesia, siC, quartz, chromite, AZS, silons, calcium aluminate, vermiculite, foamed aluminum, perlite and calcium aluminate porous polymeric materials.
8. The method for preparing the alkali-resistant, wear-resistant and corrosion-resistant castable according to claim 1, wherein the fibers in the functional filler comprise, in mass percent: 4-6% of organic fiber and the balance of steel fiber; the organic fiber adopts polypropylene fiber.
9. The method for preparing the alkali-resistant, wear-resistant and corrosion-resistant castable according to claim 1, wherein the functional filler in the step S3 further comprises a refractory auxiliary material, and the method for preparing the refractory auxiliary material comprises the following steps: according to the mass percentage, 5 to 9 percent of crystalline flake graphite, 3 to 5 percent of phenolic resin, 1 to 2 percent of Si powder, 1 to 2 percent of Al powder, 0 to 8 percent of calcium hexaluminate fine powder and the balance of fused magnesia fine powder are premixed in a polyurethane barrel for 2 to 4 hours to obtain a refractory raw material, and the refractory raw material is mixed and ground to obtain a refractory auxiliary material.
10. The method for preparing the alkali-resistant wear-resistant corrosion-resistant castable according to claim 9, wherein the mixing and grinding method is as follows: firstly adding fused magnesia fine powder into a stirrer to dry mix for 4-10 min, then pouring phenolic resin accounting for 60-70% of the total phenolic resin mass ratio to mix for 4-10 min, dividing the fireproof raw material into four parts with equal mass ratio, pouring the four parts into the stirrer in batches, mixing for 4-10 min each time when adding one part, finally adding the residual phenolic resin binder, mixing for 3-4 h, and solidifying for 24h at 200-240 ℃ after molding to obtain the fireproof auxiliary material.
CN202311372044.2A 2023-10-23 2023-10-23 Alkali-resistant wear-resistant corrosion-resistant castable and preparation method thereof Pending CN117362012A (en)

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