CN1276895C - 耐火修补材料分批配料 - Google Patents
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Abstract
本发明涉及一种耐火修补分批配料材料,该材料包括一种耐火的、尤其是颗粒状碱性电阻成分和一种粘合剂系统,该粘合剂系统含有至少一种颗粒状硬沥青成分、至少一种可燃金属粉和至少一种易燃矿物油。
Description
本发明涉及用于修补耐火衬中,特别是在冶金加热炉或者容器中如转炉中的磨损区的耐火修补材料分批配料。
这种类型的修补材料也已知为热补材料,因为它们被引入到热加热炉或者热容器内。它们用于修补已知的预磨损(pre-worn)部位,即正在经历散裂或者剥落但还不需要完全除去和替换的耐火衬中的部位。在这种应用中,根据分批配料的性质和结构,材料经过如气动喷涂或者浇注(cast)或者浇铸(pour)或者通过离心被引入。喷涂对要被修补部位提供精确的和可控的应用,因此这是优选方法。
已知喷涂碱性热补材料,特别是包括碱性炉衬的碱性热补材料,这些材料与水配制并且通常不含有任何的碳。另外,还已知含碳和无水的碱性热补材料。然而这些修补材料不能被喷涂。
热补材料中的水导致在修补部位发生非常显著的热冲击并且因此导致对成功修补有不利影响的裂纹的形成。另外,在修补材料和修补部位之间仅能达到相对低的粘合力,因此降低了修补部位的耐磨性。另外,水攻击耐火衬的碱性材料,其通过水合可被破坏。
尽管含碳热补材料不具有上述含水热补材的缺点,但它们不能被喷涂。
本发明的目的是提供一种无水热补材料,该材料无毒并且没有健康和安全问题,可制成自由流动的形式或者滴流的形式,因此可被喷涂、浇注(cast)、浇铸(pour)或者离心,保证非常良好的粘合和耐磨性并且不引起任何有害的热冲击。
为达到这一目,本发明提供了一种包括耐火的、颗粒状电阻成分和粘合剂系统的耐火修补分批配料材料,其中粘合剂系统含有至少一种颗粒状硬沥青成分、至少一种可燃金属粉和至少一种易燃矿物油。
根据本发明,热补材料包括至少一种本身已知的耐火材料如MgO、白云石、Al2O3、MgAl2O4、SiO2、ZrO2、氧化铬形式的电阻成分。这种耐火材料被选作要被修补的衬里材料,其颗粒大小优选使用与加热炉或者容器的衬里材料的颗粒大小相匹配。
通常自由流动的颗粒状电阻成分被包埋在含有至少一种颗粒状硬沥青成分、至少一种在使用温度可燃的金属粉和至少一种在使用温度易燃的矿物油的多官能粘合剂系统中。
粘合剂系统以粘合剂的方式将电阻成分颗粒粘合在一起,因此可生成具有可控稠度的可加工热补材料。将稠度调整成这样的方式以使材料可以被喷涂或者浇注或者浇铸或者可自由流动或者可被离心;相应地,达到这一程度的材料是技术上普遍适用的。
粘合剂系统是自燃的并且最迟在其与热补部位接触时燃烧;另外,粘合剂系统反应是放热的。在应用过程中,粘合剂系统在修补部位首先变粘并且通过渗透到孔穴或者凹穴内而非常成功地将自身粘附或者包埋,因此甚至是已被磨损的陡峭垂直壁或者悬空壁部位也可以被修补。
然而,作为沥青结焦结果,粘合剂系统形成通过本身已知的碳键合机制而粘合到电阻成分上的碳基体,在其以所需方式被应用之后,基体碳(本身同样是已知的)相对于加热炉或者容器内冶金材料减少原位修补材料的润湿能力。
粘合剂系统的金属粉应该在约500℃燃烧,并且引起作为能量载体并且特别是重油如沥青稀释油(flux oil)或者废油的矿物油燃烧,因此硬沥青熔化产生热状态修补材料的所需迁移率和结焦,因此获得本发明所需的上述性质。
优选所使用的90wt%的细度<45μm的微细粒子金属粉被氧化,并且金属氧化物诱发修补材料的电阻颗粒之间以及修补材料的电阻颗粒与衬里材料之间的烧结反应,因此还通过陶瓷粘合产生非常好的粘结。
优选为沥青稀释油的矿物油既作为能量载体又粘合飞尘,因此当材料在被制造时不形成飞尘并且在修补工作过程中非常容易处理。在具体应用技术中它还用于调整材料的所需稠度。
例如,对于要被喷涂材料比自由流动材料使用稍微多的沥青稀释油。
为提高材料的碳键合,优选加入至少一种其他诸如石墨的碳载体,如片状石墨或者碳黑。
因此本发明的修补材料以碳键合和陶瓷键合而区分并因此保证了尤其高的耐磨性。通过选择电阻成分,该材料可以容易地与衬里材料相匹配以及基于稠度的选择而能被广泛应用。不产生热冲击。本发明的修补材料可使用标准喷涂机器喷涂。
根据本发明,优选使用以下热补材料的分批配料:
45-90wt%,特别是67-80wt%的电阻成分,如MgO溶渣;
1.5-25wt%,特别是4-10wt%的金属粉,如Si粉;
3.5-20wt%,特别是10-15wt%的硬沥青颗粒;
5-10wt%,特别是6-8wt%的矿物油,如沥青稀释油。
根据本发明,首先,热补材料分批配料的无水成分如电阻成分、硬沥青、金属粉,以及如果使用,加入量最多6wt%的其他碳载体成分,在强制式搅拌机(positive mixer)中混合,然后加入矿物油。然后将材料进行袋包装并运输以备加工。
通过实施例,含有以下组分的材料在强制式搅拌机中使用本发明方法被混合:
70wt%MgO溶渣;
4wt%片状石墨;
6wt%Si粉;
13wt%硬沥青颗粒;
7wt%沥青稀释油。
使用现有的旋转喷涂机器在钢制件部位上将修补材料喷涂在转炉的转炉嘴内将要修补的预磨损部位。甚至在30批次投料变化后修补部位仍然保持完整。相比之下,在这一钢制件内先前使用的已知修补材料仅承受最多15批次投料。
Claims (23)
1.一种包括耐火的、颗粒状电阻成分和粘合剂系统的耐火修补分批配料材料,其中粘合剂系统含有至少一种颗粒状硬沥青成分、至少一种在使用温度可燃的金属粉、至少一种在使用温度易燃的矿物油和0-6wt%至少一种另外的碳载体。
2.如权利要求1所述的修补材料,其中的耐火电阻成分为碱性电阻成分。
3.如权利要求1或2所述的修补材料,其中电阻成分是MgO和/或白云石和/或Al2O3和/或MgAl2O4和/或SiO2和/或ZrO2和/或氧化铬。
4.如权利要求1或2所述的修补材料,其中电阻成分的颗粒大小对应于要被修补的衬里材料的颗粒大小。
5.如权利要求1或2所述的修补材料,该材料具有可被喷涂或者浇注或者浇铸或者是自由流动或者可被离心的稠度。
6.如权利要求1或2所述的修补材料,该修补材料在使用温度以自燃方式反应。
7.如权利要求1或2所述的修补材料,该修补材料在使用温度发生放热反应。
8.如权利要求1或2所述的修补材料,该修补材料在使用温度形成碳键合。
9.如权利要求1或2所述的修补材料,该修补材料在使用温度形成陶瓷键合。
10.如权利要求1或2所述的修补材料,其中金属粉在500℃燃烧。
11.如权利要求1或2所述的修补材料,其中矿物油在使用温度燃烧。
12.如权利要求11所述的修补材料,其中的矿物油为重油。
13.如权利要求12所述的修补材料,其中的矿物油为沥青稀释油或者废油。
14.如权利要求1或2所述的修补材料,其中硬沥青在使用温度熔化和结焦,形成碳键合。
15.如权利要求1或2所述的修补材料,其中金属粉发生氧化并且在电阻颗粒之间以及在电阻颗粒和衬里材料之间引发烧结反应。
16.如权利要求1或2所述的修补材料,其中90wt%金属粉的粒子细度<45μm。
17.如权利要求1所述的修补材料,其中另外的碳载体为石墨。
18.如权利要求17所述的修补材料,其中的石墨为片状石墨或者碳黑。
19.如权利要求1或2所述的修补材料,该修补材料具有以下组成:
45-90wt%的电阻成分,
1.5-25wt%的金属粉,
3.5-20wt%的硬沥青颗粒,
5-10wt%的矿物油。
20.如权利要求1或2所述的修补材料,该修补材料具有以下组成:67-80wt%的电阻成分,
4-10wt%的金属粉,
10-15wt%的硬沥青颗粒
6-8wt%的矿物油。
21.如权利要求19所述的修补材料,其中的电阻成分为MgO溶渣,金属粉为Si粉,并且矿物油为沥青稀释油。
22.权利要求1或2所述的修补材料的生产方法,其中在强制式搅拌机混合电阻成分、硬沥青和金属粉的无水成分,以及0-6wt%另外的碳载体,然后加入矿物油。
23.权利要求22所述方法,其中材料进行袋包装。
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---|---|---|---|---|
JP4394144B2 (ja) * | 2005-07-22 | 2010-01-06 | 黒崎播磨株式会社 | カーボン含有耐火物及びその製造方法並びにピッチ含有耐火原料 |
FR2892716B1 (fr) | 2005-10-28 | 2008-04-18 | Saint Gobain Vetrotex | Composition de verre resistant aux alcalis et aux acides pour la fabrication de fils de verre |
US8618006B2 (en) | 2006-07-06 | 2013-12-31 | Vesuvius Crucible Company | Cement-free refractory |
TWI421227B (zh) | 2006-07-06 | 2014-01-01 | Vesuvius Crucible Co | 無水泥耐火物 |
DE102006031700A1 (de) * | 2006-07-08 | 2008-01-10 | Refratechnik Holding Gmbh | Verfahren für die Herstellung von basischen, kohlestoffhaltigen Erzeugnissen durch Gießformgebung und/oder bildsame Formgebung |
FR2907777B1 (fr) | 2006-10-25 | 2009-01-30 | Saint Gobain Vetrotex | Composition de verre resistant aux milieux chimiques pour la fabrication de fils de verre de renforcement. |
CN101747064A (zh) * | 2008-11-29 | 2010-06-23 | 郑州东方三力耐火材料有限公司 | 一种新型转炉热态自流修补料 |
KR101103798B1 (ko) * | 2009-05-14 | 2012-01-06 | 이형석 | 하강 방지용 세탁물 건조대 |
CN103373854B (zh) * | 2012-04-20 | 2015-08-19 | 上海梅山钢铁股份有限公司 | 一种转炉大面修补料及其制备方法 |
DE102012023318A1 (de) * | 2012-11-29 | 2014-06-05 | Refratechnik Holding Gmbh | Verwendung von ungebrannten feuerfesten Erzeugnissen als Zustellung von großvolumigen Industrieöfen sowie Industrieofen ausgekleidet mit den ungebrannten feuerfesten Erzeugnissen |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3236664A (en) * | 1966-02-22 | Pitch-bonded refractory comiposition | ||
US4102694A (en) * | 1975-05-28 | 1978-07-25 | Sumitomo Metal Industries, Limited | Refractory material for repairing blast furnaces |
US4096004A (en) * | 1976-07-19 | 1978-06-20 | Bate Michael D | Repair composition for steelmaking furnaces and the like |
US4436678A (en) * | 1981-06-23 | 1984-03-13 | Kyusyu Refractories Co., Ltd. | Method for hot repairing the inside of a furnace |
DE3806554A1 (de) * | 1988-03-01 | 1989-11-16 | Didier Werke Ag | Feuerfeste massen oder kitte und ihre verwendung |
DE10063607A1 (de) * | 2000-12-20 | 2002-06-27 | Refratechnik Holding Gmbh | Feuerfester Versatz sowie Formkörper hieraus und Verfahren zum Herstellen des Versatzes und des Formkörpers |
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2002
- 2002-11-18 DE DE10253712A patent/DE10253712B4/de not_active Expired - Fee Related
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2003
- 2003-10-27 ES ES03024532T patent/ES2227497T3/es not_active Expired - Lifetime
- 2003-10-27 DE DE50300083T patent/DE50300083D1/de not_active Expired - Lifetime
- 2003-10-27 EP EP03024532A patent/EP1420003B1/de not_active Expired - Lifetime
- 2003-10-27 AT AT03024532T patent/ATE276215T1/de active
- 2003-11-12 CA CA002448992A patent/CA2448992C/en not_active Expired - Fee Related
- 2003-11-13 KR KR1020030080224A patent/KR100660260B1/ko not_active IP Right Cessation
- 2003-11-13 BR BRPI0305199-4A patent/BR0305199B1/pt not_active IP Right Cessation
- 2003-11-17 PL PL363496A patent/PL208295B1/pl unknown
- 2003-11-17 RU RU2003133436/03A patent/RU2278092C2/ru not_active IP Right Cessation
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- 2003-11-18 CN CNB2003101183092A patent/CN1276895C/zh not_active Expired - Fee Related
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Also Published As
Publication number | Publication date |
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RU2278092C2 (ru) | 2006-06-20 |
EP1420003B1 (de) | 2004-09-15 |
JP2004168652A (ja) | 2004-06-17 |
PL208295B1 (pl) | 2011-04-29 |
KR100660260B1 (ko) | 2006-12-20 |
DE50300083D1 (de) | 2004-10-21 |
CA2448992A1 (en) | 2004-05-18 |
EP1420003A1 (de) | 2004-05-19 |
MXPA03010525A (es) | 2005-04-19 |
DE10253712A1 (de) | 2004-05-27 |
US20040102306A1 (en) | 2004-05-27 |
PL363496A1 (en) | 2004-05-31 |
CA2448992C (en) | 2006-10-03 |
ATE276215T1 (de) | 2004-10-15 |
BR0305199A (pt) | 2004-09-08 |
DE10253712B4 (de) | 2005-09-22 |
KR20040044131A (ko) | 2004-05-27 |
ES2227497T3 (es) | 2005-04-01 |
BR0305199B1 (pt) | 2013-03-05 |
JP3884425B2 (ja) | 2007-02-21 |
RU2003133436A (ru) | 2005-04-20 |
CN1500763A (zh) | 2004-06-02 |
US6846763B2 (en) | 2005-01-25 |
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