CN117586032A - 钢包内衬工作层耐材修复用铝镁质湿法喷注料及配制方法 - Google Patents
钢包内衬工作层耐材修复用铝镁质湿法喷注料及配制方法 Download PDFInfo
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Abstract
本发明公开了一种钢包内衬工作层耐材修复用铝镁质湿法喷注料及配制方法,本喷注料的重量百分组分包括不同粒径的电熔白刚玉、电熔镁砂、氧化镁超细粉、氧化铝超微粉以及纯铝酸钙水泥结合剂、锂盐或氯化物盐的复合絮凝剂、有机增塑剂和减水剂。本配制方法按喷注料的重量组成比例称料;将颗粒料搅拌2~3分钟后投入细粉料混炼3~5分钟;将微粉料、复合絮凝剂、有机增塑剂和减水剂进行预混合,并混炼10~15分钟;将所有物料投入混合搅拌机混炼8~10分钟后出料装袋备用。本喷注料及配制方法在使用过程中与本体材料良好烧结,使工作层可以得到反复多次修复,大幅提高钢包包壁的使用寿命。
Description
技术领域
本发明涉及钢铁冶炼耐材技术领域,尤其涉及钢包内衬工作层耐材修复用铝镁质湿法喷注料及配制方法。
背景技术
在日趋激烈的市场竞争中,钢铁冶炼用耐火材料的成本目标没有最低只有更低,耐材企业对成本控制的极致化要求,一方面从产品入手,降低耐材的各项原料、制造、运输等成本;另一方面是提高产品寿命以获得更高的性价比。其中钢包耐材成本占钢铁冶炼耐材消耗的30%,是成本中心。但随着现代钢铁冶炼技术水平不断进步,低碳和超低碳洁净钢需要二次精炼,在钢包中采用LF、真空、强搅拌、喷吹氧化剂等方法,使得耐材的使用环境更加苛刻,进一步增加了其消耗。因此降低钢包耐材消耗成为控制钢铁冶炼耐材成本的一项重要任务。
为了有效控制钢包耐材成本,降低其消耗,科技工作者一直在不懈努力,在钢包包壁耐材方面,从高铝砖到铝镁碳砖再到现在的铝镁浇注料,不断地发展提高,取得了良好的使用效果。在修复技术方面,从挖修到套浇,从半干法喷补到湿法喷补,也取得了较大进步,并有效的控制了吨钢耐材综合消耗。尤其在近年来,钢包包壁整体浇注技术得到广泛应用,针对其的各种喷涂修复材料不断的在深入研究,有效提高了喷涂料的应用价值。传统包壁喷涂修补料喷涂施工密度低,反弹率高,结合强度不足,使用过程中存在异常熔损、剥落现象,导致钢包使用过程异常下线,影响生产秩序。
发明内容
本发明所要解决的技术问题是提供一种钢包内衬工作层耐材修复用铝镁质湿法喷注料及配制方法,本喷注料及配制方法在较低的加水量状态下,喷注料有较高的密度,较低的气孔率,附着率良好,反弹率低;在使用过程中与本体材料良好烧结,使工作层可以得到反复多次修复,大幅提高钢包包壁的使用寿命。
为解决上述技术问题,本发明钢包内衬工作层耐材修复用铝镁质湿法喷注料的重量百分组分包括粒径为3~1mm的电熔白刚玉30~40%、粒径≤1mm的电熔白刚玉20~30%、粒径≤88μm的电熔白刚玉20~30%、粒径≤1mm的电熔镁砂1~5%、粒径≤25μm的氧化镁超细粉0.5~2%、粒径≤1μm的氧化铝超微粉3~10%、纯铝酸钙水泥结合剂3~10%、锂盐或氯化物盐的复合絮凝剂0.01~1%、有机增塑剂0.02~1%、减水剂0.02~1%。
进一步,所述有机增塑剂是羧甲基纤维素钠、木质素磺酸钙、聚山梨酯中的一种或几种。
进一步,所述减水剂是聚羧酸钠、蜜胺类、磷酸盐类中的一种或几种。
一种上述钢包内衬工作层耐材修复用铝镁质湿法喷注料配制方法包括如下步骤:
步骤一、按喷注料的重量组成比例称料;
步骤二、将喷注料中的颗粒料搅拌2~3分钟后投入细粉料混炼3~5分钟;
步骤三、将喷注料中的微粉料、复合絮凝剂、有机增塑剂和减水剂进行预混合,并混炼10~15分钟;
步骤四、将步骤二和步骤三得到的物料投入混合搅拌机混炼8~10分钟后出料装袋备用;
其中,颗粒料包括3~1mm的电熔白刚玉、粒径≤1mm的电熔白刚玉、粒径≤1mm的电熔镁砂,细粉料包括粒径≤88μm的电熔白刚玉、纯铝酸钙水泥,微粉料包括粒径≤25μm的氧化镁超细粉、粒径≤1μm的氧化铝超微粉。
由于本发明钢包内衬工作层耐材修复用铝镁质湿法喷注料及配制方法采用了上述技术方案,即本喷注料的重量百分组分包括不同粒径的电熔白刚玉、电熔镁砂、氧化镁超细粉、氧化铝超微粉以及纯铝酸钙水泥结合剂、锂盐或氯化物盐的复合絮凝剂、有机增塑剂和减水剂。本配制方法按喷注料的重量组成比例称料;将颗粒料搅拌2~3分钟后投入细粉料混炼3~5分钟;将微粉料、复合絮凝剂、有机增塑剂和减水剂进行预混合,并混炼10~15分钟;将所有物料投入混合搅拌机混炼8~10分钟后出料装袋备用。本喷注料及配制方法在较低的加水量状态下,喷注料有较高的密度,较低的气孔率,附着率良好,反弹率低;在使用过程中与本体材料良好烧结,使工作层可以得到反复多次修复,大幅提高钢包包壁的使用寿命。
具体实施方式
本发明钢包内衬工作层耐材修复用铝镁质湿法喷注料的重量百分组分包括粒径为3~1mm的电熔白刚玉30~40%、粒径≤1mm的电熔白刚玉20~30%、粒径≤88μm的电熔白刚玉20~30%、粒径≤1mm的电熔镁砂1~5%、粒径≤25μm的氧化镁超细粉0.5~2%、粒径≤1μm的氧化铝超微粉3~10%、纯铝酸钙水泥结合剂3~10%、锂盐或氯化物盐的复合絮凝剂0.01~1%、有机增塑剂0.02~1%、减水剂0.02~1%。
优选的,所述有机增塑剂是羧甲基纤维素钠、木质素磺酸钙、聚山梨酯中的一种或几种。
优选的,所述减水剂是聚羧酸钠、蜜胺类、磷酸盐类中的一种或几种。
一种上述钢包内衬工作层耐材修复用铝镁质湿法喷注料配制方法包括如下步骤:
步骤一、按喷注料的重量组成比例称料;
步骤二、将喷注料中的颗粒料搅拌2~3分钟后投入细粉料混炼3~5分钟;
步骤三、将喷注料中的微粉料、复合絮凝剂、有机增塑剂和减水剂进行预混合,并混炼10~15分钟;
步骤四、将步骤二和步骤三得到的物料投入混合搅拌机混炼8~10分钟后出料装袋备用;
其中,颗粒料包括3~1mm的电熔白刚玉、粒径≤1mm的电熔白刚玉、粒径≤1mm的电熔镁砂,细粉料包括粒径≤88μm的电熔白刚玉、纯铝酸钙水泥,微粉料包括粒径≤25μm的氧化镁超细粉、粒径≤1μm的氧化铝超微粉。
实施例1
提供的铝镁质湿法喷注料含Al2O3质量百分数为91.67、MgO为3.78、CaO为2.26。具体配比是3-1mm 电熔刚玉砂35%,≤1mm 电熔刚玉砂24%,≤88μm 电熔刚玉砂20%,≤1mm 电熔镁砂2.5%,铝酸钙水泥8%,≤25μm氧化镁超细粉1.5%,≤1μm氧化铝超微粉9%,有机增塑剂0.5 %(外加),减水剂0.2%(外加),复合絮凝剂0.5%(外带),按配方称量后,按配制工艺进行生产,待用。
实施例2
提供铝镁质湿法喷注料含Al2O3质量百分数为90.48、MgO为5.72、CaO为1.41。具体配比是3-1mm 电熔刚玉砂32%,≤1mm 电熔刚玉砂26%,≤88μm 电熔刚玉砂25%,≤1mm 电熔镁砂5%,铝酸钙水泥5%,≤25μm氧化镁超细粉1%,≤1μm氧化铝超微粉6%,有机增塑剂0.5 %(外加),减水剂0.2%(外加),复合絮凝剂0.5%(外带),按配方称量后,按配制工艺进行生产,待用。
本喷注料具有如下特点:
1、电熔白刚玉、电熔镁砂等高纯原料的使用,纯铝酸钙水泥结合,不引入SiO2微粉,避免了SiO2与材料中Al2O3、MgO、CaO在高温下生成低熔物的形成,也减少了在使用过程中与钢水、渣中Al2O3、CaO反应生成低熔物的可能,保证了良好的高温强度及荷重软化温度,增强了材料的整体抗侵蚀性能
2、通过氧化镁超细粉和氧化铝超微粉的引入,超微细化Al2O3和MgO技术,使其在1000℃左右就开始发生固相烧结反应,并生成原位微细化尖晶石相,起到增强、增韧的作用,使喷注体具有良好的中高温强度,优异的热震稳定性能;
3、通过高效有机增塑剂和减水剂的复合添加,显著减少喷补过程中水的加入量,保证材料的密度,并提高材料的塑性;
有机增塑剂削弱了团聚颗粒间的应力,增加了微粉粒子的移动性、降低了微粉粒子间的团聚度,从而使颗粒、微粉粒子的塑性增加,保证了材料的均一稳定性和密度;
减水剂与水分子形成的溶剂化水膜,具有良好的润滑作用,有效降低亲水性材料的表面张力,降低颗粒材料之间的滑动阻力,起到减少加水量的作用;
4、通过复合絮凝剂使材料在喷注到工作面时瞬间固化,提高附着率的同时保证其高密度。锂盐或氯化物盐复合絮凝剂,通过锂盐(LiOH,Li2CO3,LiCl)和氯化物盐(CaCl2,AlCl3,NaCl)中的一种或几种复合使用,作用于不同离子,迅速加快水泥水化反应,产生絮凝作用,确保喷注材料到达工作面后不流淌,不脱落,反弹少。
本喷注料的主要原材料理化性能指标如表1:
表1
经检测本喷注料的指标如表2:
表2
项目 | 条 件 | 实施例1 | 实施例2 |
Al2O3% | 91.67 | 90.48 | |
MgO % | 3.78 | 5.72 | |
CaO% | 2.26 | 1.41 | |
加水量% | 5.1 | 5.2 | |
显气孔率% | 11.3 | 11.6 | |
体积密度g/cm3 | 3.12 | 3.15 | |
常温抗折强度MPa | 110℃*24h | 7.6 | 6.9 |
常温耐压强度MPa | 110℃*24h | 45 | 43 |
抗折强度 MPa | 1000℃*3h | 11.5 | 12.7 |
耐压强度 MPa | 1000℃*3h | 56 | 53 |
线变化率 % | 1000℃*3h | +0.01 | +0.02 |
抗折强度 MPa | 1600℃*3h | 17.5 | 18.3 |
耐压强度 MPa | 1600℃*3h | 88 | 92 |
线变化率 % | 1600℃*3h | +0.32 | +0.56 |
本喷注料将复合絮凝剂、有机增塑剂及减水剂引入铝镁质湿法喷注料中,使材料的加水量明显减少,接近于浇注料的加水量,并保证在喷注至工作面时即刻絮凝,不流淌,反弹少,接近于浇注料的施工体密度;同时将氧化镁微细粉和氧化铝超微粉引入到铝镁质湿法喷注料中,改善了材料的烧结性能,使其性能进一步接近浇注料的性能;不引入SiO2微粉,从源头杜绝了生成低熔物,确保产品性能。
本喷注料通过在钢铁厂的220吨精炼钢包上试用,钢种为IF钢、X系列管线钢、无取向、取向硅钢、耐侯钢、合金钢、低碳钢、高碳钢等,出钢温度1650℃,出钢230T,精炼钢水出站温度约1570℃~1590℃。工艺路线为:①转炉-LF精炼炉(平均精炼时间为90分钟)-连铸;②转炉-LF精炼炉(平均精炼时间为90分钟)-RH精炼(平均精炼时间为30分钟)-连铸;③转炉-RH精炼(平均精炼时间为30分钟)-连铸;④转炉-连铸。钢包通常在此多种工艺状态下平均小修包龄为25炉,中修包龄为50炉,经过一次喷涂后包龄达到100炉左右即下线进行大修。通过采用本铝镁质湿法喷注料后,同样工艺状态下同比包龄增加到125炉以上,综合消耗降低10%以上。跟踪观测其在整个使用周期中,包壁耐熔损,无异常剥落、开裂,侵蚀均匀。因此能够明显通过包龄提高,降低耐材消耗,取代现行的喷涂料,可有效控制钢包耐材成本,降低消耗。
Claims (4)
1.一种钢包内衬工作层耐材修复用铝镁质湿法喷注料,其特征在于:本湿法喷注料的重量百分组分包括粒径为3~1mm的电熔白刚玉30~40%、粒径≤1mm的电熔白刚玉20~30%、粒径≤88μm的电熔白刚玉20~30%、粒径≤1mm的电熔镁砂1~5%、粒径≤25μm的氧化镁超细粉0.5~2%、粒径≤1μm的氧化铝超微粉3~10%、纯铝酸钙水泥结合剂3~10%、锂盐或氯化物盐的复合絮凝剂0.01~1%、有机增塑剂0.02~1%、减水剂0.02~1%。
2.根据权利要求1所述的钢包内衬工作层耐材修复用铝镁质湿法喷注料,其特征在于:所述有机增塑剂是羧甲基纤维素钠、木质素磺酸钙、聚山梨酯中的一种或几种。
3.根据权利要求1所述的钢包内衬工作层耐材修复用铝镁质湿法喷注料,其特征在于:所述减水剂是聚羧酸钠、蜜胺类、磷酸盐类中的一种或几种。
4.一种权利要求1至权利要求3任一项所述钢包内衬工作层耐材修复用铝镁质湿法喷注料配制方法,其特征在于本配制方法包括如下步骤:
步骤一、按喷注料的重量组成比例称料;
步骤二、将喷注料中的颗粒料搅拌2~3分钟后投入细粉料混炼3~5分钟;
步骤三、将喷注料中的微粉料、复合絮凝剂、有机增塑剂和减水剂进行预混合,并混炼10~15分钟;
步骤四、将步骤二和步骤三得到的物料投入混合搅拌机混炼8~10分钟后出料装袋备用;
其中,颗粒料包括3~1mm的电熔白刚玉、粒径≤1mm的电熔白刚玉、粒径≤1mm的电熔镁砂,细粉料包括粒径≤88μm的电熔白刚玉、纯铝酸钙水泥,微粉料包括粒径≤25μm的氧化镁超细粉、粒径≤1μm的氧化铝超微粉。
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