WO2018228141A1 - 基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法 - Google Patents

基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法 Download PDF

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WO2018228141A1
WO2018228141A1 PCT/CN2018/087687 CN2018087687W WO2018228141A1 WO 2018228141 A1 WO2018228141 A1 WO 2018228141A1 CN 2018087687 W CN2018087687 W CN 2018087687W WO 2018228141 A1 WO2018228141 A1 WO 2018228141A1
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slag
aluminum
refining
tungsten
reaction
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PCT/CN2018/087687
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French (fr)
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豆志河
张廷安
刘燕
吕国志
赵秋月
牛丽萍
傅大学
张伟光
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东北大学
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Priority to RU2019135677A priority Critical patent/RU2739040C1/ru
Publication of WO2018228141A1 publication Critical patent/WO2018228141A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C27/00—Alloys based on rhenium or a refractory metal not mentioned in groups C22C14/00 or C22C16/00
    • C22C27/04—Alloys based on tungsten or molybdenum
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B15/00—Other processes for the manufacture of iron from iron compounds
    • C21B15/02—Metallothermic processes, e.g. thermit reduction
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/04—Making ferrous alloys by melting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C35/00—Master alloys for iron or steel

Definitions

  • the invention relates to a method for preparing a tungsten-iron alloy, in particular to a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagation gradient reduction and slag washing refining.
  • Tungsten iron is one of the important iron alloys in the steel industry. Tungsten is the main element of alloy tool steel, which can significantly improve the wear resistance and machinability of steel. In addition to the formation of carbides in the steel, tungsten is partially dissolved in iron to form a solid solution. Tungsten in steel can increase tempering stability, red hardness, heat strength, and increased wear resistance due to the formation of carbides. It is mainly used for the smelting of tool steel, such as high speed steel and hot forging die steel. At present, the smelting methods of tungsten iron are mainly agglomeration method, iron extraction method and aluminothermic method.
  • the agglomeration method uses an open electric furnace that can move on the track and the upper part of the furnace body is detachable, and carbon is used as a reducing agent.
  • the raw materials are mainly refined tungsten ore, asphalt coke (or petroleum coke) and slag forming agent (aluminum bauxite), and the tungsten recovery rate is low.
  • the iron extraction method is suitable for smelting tungsten iron with a lower melting point of 70% tungsten. Silicon and carbon are used as reducing agents; 75% of ferrosilicon and a small amount of pitch coke (or petroleum coke) are used for reduction smelting. The recovery rate of tungsten is high, but the electricity consumption of smelting is also high.
  • the aluminothermic method uses recycled tungsten carbide and iron as raw materials, and aluminum as a reducing agent, and utilizes the heat energy of carbon and aluminum combustion in the tungsten carbide to convert tungsten and iron in the raw material into tungsten iron, thereby saving a large amount of electric energy, and cut costs.
  • the impurities in the raw material tungsten carbide are far lower than the impurities of the tungsten concentrate, the product quality is higher than that of tungsten iron which is made of tungsten concentrate.
  • the recovery rate of tungsten is also higher than that of tungsten concentrate.
  • this method is limited by the source of raw materials and is not suitable for mass production.
  • the invention is based on the disadvantages of low recovery rate of alloy elements, high energy consumption and limited production source by the current preparation of tungsten-iron alloy.
  • a new method for preparing tungsten-iron alloy based on aluminum thermal self-propagating gradient feeding reduction combined with slag washing and refining is proposed.
  • the present invention provides a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining, using WO 3 , Fe 2 O 3 , etc. as a starting material, and adopting a gradient feeding method.
  • the aluminum self-propagation reaction obtains a high-temperature melt, and then adjusts the alkalinity and melting point of the slag by adding a high alkalinity refining slag to the high-temperature melt, and performs slag washing and refining, and finally removes the slag to obtain a tungsten-iron alloy.
  • the technical solution of the present invention is:
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • the raw materials WO 3 , Fe 2 O 3 powder, aluminum powder, slag forming agent are divided into several batches, and the first batch of materials are put into the reaction furnace, and the magnesium powder is ignited from the top of the material to induce a self-propagating reaction.
  • the amount of aluminum is 0.95 to 1.00 of the stoichiometric ratio of the thermal self-propagation reaction of aluminum;
  • the raw materials WO 3 , Fe 2 O 3 powder and slag forming agent are uniformly mixed, and are added to the continuous mixing machine at a uniform flow rate, and the aluminum powder is added to the continuous mixing machine at a gradient decreasing flow rate, and mixed.
  • the uniform raw materials are continuously introduced into the reaction furnace for the aluminum thermal self-propagation reaction, and the whole mixing process and the whole reaction process are not interrupted until all the materials are completely reacted to obtain a high-temperature melt.
  • the theoretical stoichiometric ratio is 0.95 to 1.00 times;
  • the mass ratio of the raw materials WO 3 , Fe 2 O 3 powder, aluminum powder, and slag forming agent in the step (1) is 1.0: (0.2 to 0.49): (0.30 to 0.40): (0.07 to 0.39)
  • the number of several batches in the step (1) is ⁇ 4.
  • the weight of the first batch of materials in the step (1) accounts for 10 to 30% of the total amount of the materials
  • control parameters of the heat preservation smelting in the step (2) are: an electromagnetic induction frequency ⁇ 1000 Hz, a melting temperature of 1700 to 1800 ° C, and a holding time of 5 to 15 min.
  • the step (3) in the refining slag is in one of two: 1 the mass ratio of 10 to 25% of CaF 2, the balance being CaO; 2 a mass ratio of 10 to 25% of CaF 2, 5 to 10% of Na 2 O, the balance being CaO;
  • control parameter of the stirring slag refining in the step (3) is: using eccentric stirring, the eccentricity is 0.2-0.4, and the adding amount of the refining slag is 6-12% of the total amount of the raw materials, and the purity is ⁇ 99.95%.
  • the inert gas is a carrier gas, the stirring rate is 50-150 rpm, the refining temperature is 1700-1800 ° C, and the refining time is 10-30 min.
  • the chemical composition of the tungsten-iron alloy according to the mass percentage is: W 70.0-85.0%, Al ⁇ 2.0%, O ⁇ 1%, and the balance is Fe.
  • the invention adopts aluminum self-propagation of the first batch material with higher theoretical aluminum stoichiometric ratio than the thermal self-propagation reaction of aluminum, and obtains a high temperature high temperature melt, which is favorable for the subsequent low aluminum compound material.
  • the reaction is initiated; at the same time, the aluminum ratio of the front high and the low ensures that the melt is in a strong reducing atmosphere, thereby ensuring the complete reduction of the metal oxide; and, by gradually reducing the aluminum coefficient, it can be step by step
  • the excess reducing agent combined with iron and tungsten in the melt is gradually released, and gradually reacts with the tungsten oxide in the subsequently added low aluminum coefficient material, thereby effectively reducing the aluminum residue in the final product; and the more the batch is added
  • the invention further refines and refines by stirring slag, and adjusts the alkalinity and melting point of the slag by using the added refining slag to realize the thorough reaction of the slag gold interface chemical reaction and the slag gold separation, thereby effectively removing the inclusions such as alumina;
  • the thermal insulation smelting process makes full use of the system reaction heat, which can greatly reduce the energy consumption of the production process.
  • the present invention uses electromagnetic induction heating to perform thermal insulation smelting before stirring slag washing and refining to form an upper alumina-based slag layer and a lower alloy melt layer, which can effectively strengthen the gold slag separation process.
  • the chemical composition of the tungsten-iron alloy obtained by the invention according to the mass percentage is: W 70.0-85.0%, Al ⁇ 2.0%, O ⁇ 1%, and the balance is Fe, wherein the tungsten content is high and the aluminum content is low. The nature is stable.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • Fe 2 O 3 powder, aluminum powder, slag forming agent CaO the mass ratio is 1.0:0.28:0.33:0.07, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; the material is divided into 5 batches, the aluminum content of each batch is 1.20, 1.05, 1.0, 0.90, 0.85 times the theoretical stoichiometric ratio of aluminum thermal self-propagation reaction And the total aluminum content of the raw materials is 0.98 times of the theoretical chemical dose ratio of the aluminum thermal self-propagation reaction, and the weight of the first batch of materials accounts for 20% of the total material amount; the first batch of materials is put into the reaction furnace to take the magnesium powder from the materials. The top is ignited to initiate a self-propagating reaction, and other batch materials are added one after another until the reaction is completely obtained with a high temperature melt;
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1800°C, holding time 15min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 10% CaF 2 , 90% CaO; control parameters: the amount of refining slag added is 6% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 50 rpm, eccentricity is 0.21, refining temperature is 1800 °C, refining time 10 min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is: W 79.2%, Al 1.8%, O 0.8%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • Fe 2 O 3 powder, aluminum powder, slag forming agent CaO the mass ratio is 1.0:0.29:0.34:0.15, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; the material is divided into 6 batches, the aluminum content of each batch is 1.20, 1.1, 0.95, 0.90, 0.85 of the theoretical stoichiometric ratio of aluminum thermal self-propagation reaction, 0.80 times, and the total aluminum content of the raw materials is 0.97 times of the theoretical chemical dose ratio of the aluminum thermal self-propagation reaction, and the weight of the first batch of materials accounts for 28.6% of the total material amount; the first batch of materials is put into the reaction furnace to the magnesium powder. Ignite from the top of the material to initiate the self-propagating reaction, and gradually add other batch materials until the reaction is completely high-temperature melt;
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1750°C, holding time 10min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt, and the slag washing and refining is carried out; wherein the composition of the refining slag according to the mass ratio is: 20% CaF 2 , 80% CaO; control parameters: the amount of refining slag added is 8% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 100 rpm, eccentricity is 0.33, refining temperature is 1750 ° C, refining time 20min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is: W 78.1%, Al 1.5%, O 0.72%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • Fe 2 O 3 powder, aluminum powder, slag forming agent CaO the mass ratio is 1.0:0.32:0.34:0.35, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; the material is divided into 7 batches, the aluminum content of each batch is 1.20, 1.1, 1.0, 0.95, 0.925 of the theoretical stoichiometric ratio of aluminum thermal self-propagation reaction, 0.90, 0.85 times, and the total aluminum content of the raw materials is 0.95 times the theoretical chemical dose ratio of the aluminum thermal self-propagation reaction, and the weight of the first batch of materials accounts for 22.2% of the total material amount; the first batch of materials is put into the reaction furnace to Magnesium powder is ignited from the top of the material to initiate a self-propagating reaction, and other batch materials are successively added until the reaction is completely obtained with a high temperature melt
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1700°C, holding time 5min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 25% CaF 2 , 75% CaO; control parameters: the amount of refining slag added is 10% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 150 rpm, eccentricity is 0.4, refining temperature is 1700 ° C, refining time 30min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is W 76.8%, Al 0.86%, O 0.51%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • Fe 2 O 3 powder, aluminum powder, slag forming agent CaO the mass ratio is 1.0:0.41:0.36:0.36, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; raw material WO 3 , Fe 2 O 3 powder, slag forming agent are uniformly mixed, added to the continuous mixer at a uniform flow rate, while the aluminum powder is gradient
  • the decreasing flow rate is added to the continuous mixer, and the mixed raw materials are continuously introduced into the reaction furnace for the aluminum thermal self-propagation reaction, and the whole mixing process and the whole reaction process are not interrupted until all the materials are completely reacted to obtain a high-temperature melt;
  • the amount of aluminum in the continuous material introduced into the reaction furnace is decreased from 1.22 times of the theoretical stoichiometric ratio of the thermal self-propagation reaction of aluminum to 0.76 times, the gradient coefficient of variation a is
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1750°C, holding time 10min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 10% CaF 2 , 85% CaO, 5% Na 2 O; control parameters: the amount of refining slag added is 6% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 100 rpm, eccentricity is 0.2, refining temperature 1750 ° C, refining time is 20 min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is: W 75.4%, Al 1.6%, O 0.72%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • the ratio is 1.0:0.43:0.38:0.28, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2 mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; raw material WO 3 , Fe 2 O 3 powder, slag forming agent are uniformly mixed, added to the continuous mixer at a uniform flow rate, while the aluminum powder is gradient
  • the decreasing flow rate is added to the continuous mixer, and the mixed raw materials are continuously introduced into the reaction furnace for the aluminum thermal self-propagation reaction, and the whole mixing process and the whole reaction process are not interrupted until all the materials are completely reacted to obtain a high-temperature melt;
  • the amount of aluminum in the continuous material introduced into the reaction furnace is decreased from 1.21 times the theoretical stoichiometric ratio of the thermal self-propagation reaction of aluminum to 0.76 times, the gradient coefficient a is
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1700°C, holding time 10min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 10% CaF 2 , 80% CaO, 10% Na 2 O; control parameters: the amount of refining slag added is 8% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 100 rpm, eccentricity is 0.36, refining temperature 1700 ° C, refining time is 20 min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is W 74.5%, Al 1.1%, O 0.43%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • Fe 2 O 3 powder, aluminum powder, slag forming agent CaO the mass ratio is 1.0:0.45:0.38:0.29, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; raw material WO 3 , Fe 2 O 3 powder, slag forming agent are uniformly mixed, added to the continuous mixer at a uniform flow rate, while the aluminum powder is gradient
  • the decreasing flow rate is added to the continuous mixer, and the mixed raw materials are continuously introduced into the reaction furnace for the aluminum thermal self-propagation reaction, and the whole mixing process and the whole reaction process are not interrupted until all the materials are completely reacted to obtain a high-temperature melt;
  • the amount of aluminum in the continuous material introduced into the reaction furnace is decreased from the 1.16 times gradient of the theoretical stoichiometric ratio of the aluminothermic self-propagation reaction to 0.82 times, the gradient coefficient
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1700°C, holding time 15min, and the gold slag is separated to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 20% CaF 2 , 75% CaO, 5% Na 2 O; control parameters: the amount of refining slag added is 10% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 100 rpm, eccentricity is 0.4, refining temperature 1700 ° C, refining time is 30 min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is: W 72.1%, Al 0.71%, O 0.36%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • the ratio is 1.0:0.19:0.30:0.21, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2 mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; the material is divided into 5 batches, the aluminum content of each batch is 1.20, 1.05, 1.0, 0.90, 0.85 times the theoretical stoichiometric ratio of aluminum thermal self-propagation reaction And the total aluminum content of the raw materials is 0.975 times of the theoretical chemical dose ratio of the aluminum thermal self-propagation reaction, and the weight of the first batch of materials accounts for 20% of the total material amount; the first batch of materials is put into the reaction furnace, and the magnesium powder is used from the materials. The top is ignited to initiate a self-propagating reaction, and other batch materials are added one after another until the reaction is completely obtained with a high temperature melt;
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1800°C, holding time 15min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 10% CaF 2 , 90% CaO; control parameters: the amount of refining slag added is 6% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 50 rpm, eccentricity is 0.36, refining temperature is 1800 ° C, refining time 10 min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is W 84.1%, Al 1.68%, O 0.66%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • the ratio is 1.0:0.22:0.31:0.16, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2 mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; the material is divided into 6 batches, the aluminum content of each batch is 1.20, 1.1, 0.95, 0.90, 0.85 of the theoretical stoichiometric ratio of aluminum thermal self-propagation reaction, 0.80 times, and the total aluminum content of the raw material is 0.965 times the theoretical chemical dose ratio of the aluminum thermal self-propagation reaction, and the weight of the first batch material accounts for 28.6% of the total material amount; the first batch of materials is put into the reaction furnace to the magnesium powder. Ignite from the top of the material to initiate the self-propagating reaction, and gradually add other batch materials until the reaction is completely high-temperature melt;
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1750°C, holding time 10min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt, and the slag washing and refining is carried out; wherein the composition of the refining slag according to the mass ratio is: 20% CaF 2 , 80% CaO; control parameters: the amount of refining slag added is 8% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 100 rpm, eccentricity is 0.4, refining temperature is 1750 ° C, refining time 20min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is: W 83.5%, Al 1.2%, O 0.65%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • Fe 2 O 3 powder, aluminum powder, slag forming agent CaO the mass ratio is 1.0:0.24:0.32:0.14, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; the material is divided into 7 batches, the aluminum content of each batch is 1.20, 1.1, 1.0, 0.95, 0.925 of the theoretical stoichiometric ratio of aluminum thermal self-propagation reaction, 0.90, 0.85 times, and the total aluminum content of the raw materials is 0.95 times the theoretical chemical dose ratio of the aluminum thermal self-propagation reaction, and the weight of the first batch of materials accounts for 22.2% of the total material amount; the first batch of materials is put into the reaction furnace to Magnesium powder is ignited from the top of the material to initiate a self-propagating reaction, and other batch materials are successively added until the reaction is completely obtained with a high temperature melt
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1700°C, holding time 5min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 25% CaF 2 , 75% CaO; control parameters: the amount of refining slag added is 10% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 150 rpm, eccentricity is 0.32, refining temperature is 1700 ° C, refining time 30min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is: W 82.6%, Al 0.72%, O 0.32%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • Fe 2 O 3 powder, aluminum powder, slag forming agent CaO the mass ratio is 1.0:0.27:0.33:0.18, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; raw material WO 3 , Fe 2 O 3 powder, slag forming agent are uniformly mixed, added to the continuous mixer at a uniform flow rate, while the aluminum powder is gradient
  • the decreasing flow rate is added to the continuous mixer, and the mixed raw materials are continuously introduced into the reaction furnace for the aluminum thermal self-propagation reaction, and the whole mixing process and the whole reaction process are not interrupted until all the materials are completely reacted to obtain a high-temperature melt;
  • the amount of aluminum in the continuous material introduced into the reaction furnace is reduced from the 1.2-fold gradient of the theoretical stoichiometric ratio of the aluminothermic self-propagation reaction to 0.78 times, the gradient coefficient
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1750°C, holding time 10min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 10% CaF 2 , 85% CaO, 5% Na 2 O; control parameters: the amount of refining slag added is 6% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 100 rpm, eccentricity is 0.38, refining temperature 1750 ° C, refining time is 20 min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is: W 81.3%, Al 1.43%, O 0.62%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • Fe 2 O 3 powder, aluminum powder, slag forming agent CaO the mass ratio is 1.0:0.27:0.33:0.18, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; raw material WO 3 , Fe 2 O 3 powder, slag forming agent are uniformly mixed, added to the continuous mixer at a uniform flow rate, while the aluminum powder is gradient
  • the decreasing flow rate is added to the continuous mixer, and the mixed raw materials are continuously introduced into the reaction furnace for the aluminum thermal self-propagation reaction, and the whole mixing process and the whole reaction process are not interrupted until all the materials are completely reacted to obtain a high-temperature melt;
  • the amount of aluminum in the continuous material introduced into the reaction furnace is decreased from 1.19 times the theoretical stoichiometric ratio of the thermal self-propagation reaction of aluminum to 0.77 times, the gradient coefficient a is 0.001, and
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1700°C, holding time 10min, and the gold slag separation is realized to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 10% CaF 2 , 80% CaO, 10% Na 2 O; control parameters: the amount of refining slag added is 8% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 100 rpm, eccentricity is 0.26, refining temperature 1700 ° C, refining time is 20 min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is: W 80.6%, Al 0.89%, O 0.38%, and the balance is Fe.
  • a method for preparing a tungsten-iron alloy based on aluminum thermal self-propagating gradient reduction and slag washing refining comprises the following steps:
  • Fe 2 O 3 powder, aluminum powder, slag forming agent CaO the mass ratio is 1.0:0.3:0.34:0.24, and their particle sizes respectively satisfy: WO 3 particle size ⁇ 2mm, Fe 2 O 3 powder particle size ⁇ 0.2 Mm, aluminum powder particle size ⁇ 2mm, slag agent particle size ⁇ 0.2mm; raw material WO 3 , Fe 2 O 3 powder, slag forming agent are uniformly mixed, added to the continuous mixer at a uniform flow rate, while the aluminum powder is gradient
  • the decreasing flow rate is added to the continuous mixer, and the mixed raw materials are continuously introduced into the reaction furnace for the aluminum thermal self-propagation reaction, and the whole mixing process and the whole reaction process are not interrupted until all the materials are completely reacted to obtain a high-temperature melt;
  • the amount of aluminum in the continuous material introduced into the reaction furnace is decreased from the 1.12 times gradient of the theoretical stoichiometric ratio of the aluminothermic self-propagation reaction to 0.84 times, the gradient coefficient of variation
  • the high temperature melt is smelted by electromagnetic induction heating.
  • the control parameters are: electromagnetic induction frequency ⁇ 1000Hz, melting temperature is 1700°C, holding time 15min, and the gold slag is separated to obtain the upper alumina slag and the lower alloy.
  • the refining slag is sprayed in the lower alloy melt to carry out the stirring slag washing and refining; wherein the composition of the refining slag according to the mass ratio is: 20% CaF 2 , 75% CaO, 5% Na 2 O; control parameters: the amount of refining slag added is 10% of the total amount of raw materials, argon gas with purity ⁇ 99.95% as carrier gas, eccentric stirring rate is 100 rpm, eccentricity is 0.33, refining temperature 1700 ° C, refining time is 30 min;
  • the chemical composition of the tungsten-iron alloy prepared in this example according to the mass percentage is: W 78.4%, Al 0.68%, O 0.24%, and the balance is Fe.

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Abstract

本发明提供一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括：(1)铝热自蔓延梯度还原：第一种方式，将原料分成若干批次，将首批次物料投入反应炉中，以镁粉从物料顶部点燃以引发自蔓延反应，陆续加入其它批次物料，直至反应完全；第二种方式，将除铝粉以外的原料混合均匀，以均匀流速加入到连续混料机中，同时将铝粉以梯度递减流速加入到连续混料机中，混匀的原料同时连续引入反应炉中进行铝热自蔓延反应，直至所有物料完全反应；(2)保温熔炼得到上层氧化铝基熔渣和下层合金熔体；(3)在下层合金熔体中喷吹精炼渣进行搅拌渣洗精炼；(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。

Description

基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法 技术领域
本发明涉及制备钨铁合金的方法，具体涉及一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法。
背景技术
钨铁是钢铁工业重要铁合金之一，钨是合金工具钢的主要元素，能显著提高钢的耐磨性和切削性。钨在钢中除形成碳化物外，部分地溶入铁中形成固溶体。钨在钢中能增加回火稳定性、红硬性、热强性以及由于形成碳化物而增加的耐磨性。它主要用于工具钢，如高速钢、热锻模具用钢的冶炼。目前，钨铁的冶炼方法主要为结块法、取铁法、铝热法。结块法采用可在轨道上移动、炉体上段可拆的敞口电炉，用碳作还原剂。原料主要为精钨矿、沥青焦(或石油焦)和造渣剂(铝矾土)，该方法钨回收率较低。取铁法适于冶炼熔点较低的含钨70％的钨铁。采用硅和碳作还原剂；75％的硅铁和少量沥青焦(或石油焦)进行还原冶炼。钨回收率高，但是冶炼电耗也高。铝热法用再生碳化钨与铁为原料，以铝作还原剂，利用碳化钨中自身的碳和铝燃烧的热能，使原料中的钨和铁转化为钨铁，可节约大量的电能，并降低成本。同时由于原料碳化钨中的杂质远远低于钨精矿的杂质，产品质量均高于以钨精矿为原料的钨铁。钨的回收率也高于以钨精矿为原料的工艺。但是该方法受原料来源限制，不适用于大规模生产。
本发明基于目前制备钨铁合金过程中合金元素回收率较低、能耗高、生产受原料来源限制等缺点，提出一种基于铝热自蔓延梯度加料还原结合渣洗精炼制备钨铁合金的新方法。
发明内容
针对现有技术存在的问题，本发明提供一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，以WO 3、Fe 2O 3等为起始原料，采用梯度加料的方式进行铝热自蔓延反应得到高温熔体，再通过向高温熔体中加入高碱度精炼渣来调整渣的碱度和熔点，进行渣洗精炼，最后除渣得到钨铁合金。本发明的技术方案为：
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原，采用以下两种方式之一：
第一种方式，将原料WO 3、Fe 2O 3粉末、铝粉、造渣剂分成若干批次，将首批次物料投入反应炉中，以镁粉从物料顶部点燃以引发自蔓延反应，陆续加入其它批次物料，直至反应完全得到高温熔体，其中每批次物料的配铝量由铝热自蔓延反应理论化学计量比的1.1～1.25倍梯度递减至0.9～0.75倍，且原料总配铝量为铝热自蔓延反应理论化学计量比的0.95～1.00；
第二种方式，将原料WO 3、Fe 2O 3粉末、造渣剂混合均匀，以均匀流速加入到连续混料 机中，同时将铝粉以梯度递减流速加入到连续混料机中，混匀的原料同时连续引入反应炉中进行铝热自蔓延反应，整个混料过程和整个反应过程不发生间断，直至所有物料完全反应后得到高温熔体，
其中引入至反应炉中的连续物料的配铝量由铝热自蔓延反应理论化学计量比的1.1～1.25倍梯度递减至0.9～0.75倍，整个过程配铝量梯度变化的次数n满足关系式：n＝(b-c)/a，其中b表示最高配铝量，c表示最低配铝量，a表示配铝量梯度变化系数，并且0＜a≤0.05；原料总配铝量为铝热自蔓延反应理论化学计量比的0.95～1.00倍；
(2)通过电磁感应加热对高温熔体进行保温熔炼，得到上层氧化铝基熔渣和下层合金熔体；
(3)在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
进一步地，所述步骤(1)中原料WO 3、Fe 2O 3粉末、铝粉、造渣剂的质量比为：1.0∶(0.2～0.49)∶(0.30～0.40)∶(0.07～0.39)，粒度分别满足：所述WO 3粒度≤2mm，所述Fe 2O 3粉末粒度≤0.2mm，所述铝粉粒度≤2mm，所述造渣剂粒度≤0.2mm。
进一步地，所述步骤(1)中若干批次的数量≥4。
进一步地，所述步骤(1)中首批次物料的重量占总物料量的10～30％；
进一步地，所述步骤(2)中保温熔炼的控制参数为：电磁感应频率≥1000Hz，熔炼温度为1700～1800℃，保温时间5～15min。
进一步地，所述步骤(3)中精炼渣为以下两种中的一种：①按质量比10～25％的CaF 2，余量为CaO；②按质量比10～25％的CaF 2，5～10％的Na 2O，余量为CaO；
进一步地，所述步骤(3)中搅拌渣洗精炼的控制参数为：采用偏心搅拌，偏心率为0.2～0.4，精炼渣的加入量为原料总量的6～12％，以纯度≥99.95％的惰性气体为载气，搅拌速率为50～150rpm，精炼温度为1700～1800℃，精炼时间为10～30min。
进一步地，所述钨铁合金按照质量百分含量的化学组成为：W 70.0～85.0％，Al≤2.0％，O≤1％，余量为Fe。
本发明的有益效果为：
1、本发明通过较比铝热自蔓延反应的理论化学计量比高的配铝系数的首批次物料进行铝热自蔓延，得到较高温度的高温熔体，有利于后续低配铝系数物料的反应引发；同时前高后低的配铝系数保证了熔体处于强烈的还原气氛中，进而保证了金属氧化物的彻底还原；并且，以逐渐降低配铝系数的方式加料，可以一步步将熔体中与铁、钨结合的过量的还原剂被逐渐释放出来，与后续加入的低配铝系数物料中的钨的氧化物逐渐反应，有效降低最终产品中铝 残留量；且加料批次越多或连续加料配铝系数降低梯度越小，铝残留量越低。
2、本发明再通过搅拌渣洗精炼，利用加入的精炼渣调整渣的碱度和熔点，实现渣金界面化学反应和渣金分离的彻底进行，进而实现氧化铝等夹杂物有效地脱除；同时，保温熔炼过程充分利用了体系反应热，可以大大降低生产过程的能耗。此外，本发明在搅拌渣洗精炼前采用电磁感应加热进行保温熔炼，形成上层氧化铝基熔渣层，下层合金熔体层，可有效强化金渣分离过程。
3、本发明获得的钨铁合金按照质量百分含量的化学组成为：W 70.0～85.0％，Al≤2.0％，O≤1％，余量为Fe，其中钨含量较高，铝含量较低，性质稳定。
具体实施方式
在本发明的描述中，需要说明的是，实施例中未注明具体条件者，按照常规条件或制造商建议的条件进行。所用试剂或仪器未注明生产厂商者，均为可以通过市售购买获得的常规产品。
下面结合具体的实施例对本发明做进一步详细说明，所述是对本发明的解释而不是限定。
实施例1
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.28∶0.33∶0.07配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将物料分5批，每批的配铝量依次为铝热自蔓延反应理论化学计量比的1.20、1.05、1.0、0.90、0.85倍，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.98倍，首批次物料的重量占总物料量的20％；将首批次物料投入反应炉中，以镁粉从物料顶部点燃以引发自蔓延反应，陆续加入其它批次物料，直至反应完全得到高温熔体；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1800℃，保温时间15min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：10％CaF 2，90％CaO；控制参数为：精炼渣的加入量为原料总量的6％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为50rpm，偏心率为0.21，精炼温度为1800℃，精炼时间为10min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 79.2％，Al 1.8％，O 0.8％， 余量为Fe。
实施例2
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.29∶0.34∶0.15配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将物料分6批，每批的配铝量依次为铝热自蔓延反应理论化学计量比的1.20、1.1、0.95、0.90、0.85、0.80倍，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.97倍，首批次物料的重量占总物料量的28.6％；将首批次物料投入反应炉中，以镁粉从物料顶部点燃以引发自蔓延反应，陆续加入其它批次物料，直至反应完全得到高温熔体；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1750℃，保温时间10min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：20％CaF 2，80％CaO；控制参数为：精炼渣的加入量为原料总量的8％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为100rpm，偏心率为0.33，精炼温度为1750℃，精炼时间为20min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 78.1％，Al 1.5％，O 0.72％，余量为Fe。
实施例3
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.32∶0.34∶0.35配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将物料分7批，每批的配铝量依次为铝热自蔓延反应理论化学计量比的1.20、1.1、1.0、0.95、0.925、0.90、0.85倍，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.95倍，首批次物料的重量占总物料量的22.2％；将首批次物料投入反应炉中，以镁粉从物料顶部点燃以引发自蔓延反应，陆续加入其它批次物料，直至反应完全得到高温熔体；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1700℃，保温时间5min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：25％CaF 2，75％CaO；控制参数为：精炼渣的加入量为原料总量的10％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为150rpm，偏心率为0.4，精炼温度为1700℃，精炼时间为30min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 76.8％，Al 0.86％，O 0.51％，余量为Fe。
实施例4
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.41∶0.36∶0.36配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将原料WO 3、Fe 2O 3粉末、造渣剂混合均匀，以均匀流速加入到连续混料机中，同时将铝粉以梯度递减流速加入到连续混料机中，混匀的原料同时连续引入反应炉中进行铝热自蔓延反应，整个混料过程和整个反应过程不发生间断，直至所有物料完全反应后得到高温熔体；其中引入至反应炉中的连续物料的配铝量由铝热自蔓延反应理论化学计量比的1.22倍梯度递减至0.76倍，梯度变化系数a为0.005，整个过程配铝量梯度变化的次数为92次，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.98倍；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1750℃，保温时间10min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：10％CaF 2，85％CaO，5％Na 2O；控制参数为：精炼渣的加入量为原料总量的6％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为100rpm，偏心率为0.2，精炼温度为1750℃，精炼时间为20min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 75.4％，Al 1.6％，O 0.72％，余量为Fe。
实施例5
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.43∶0.38∶0.28配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将原料WO 3、Fe 2O 3粉末、造渣剂混合均匀，以均匀流速加入到连续混料机中，同时将铝粉以梯度递减流速加入到连续混料机中，混匀的原料同时连续引入反应炉中进行铝热自蔓延反应，整个混料过程和整个反应过程不发生间断，直至所有物料完全反应后得到高温熔体；其中引入至反应炉中的连续物料的配铝量由铝热自蔓延反应理论化学计量比的1.21倍梯度递减至0.76倍，梯度变化系数a为0.003，整个过程配铝量梯度变化的次数为150次，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.97倍；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1700℃，保温时间10min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：10％CaF 2，80％CaO，10％Na 2O；控制参数为：精炼渣的加入量为原料总量的8％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为100rpm，偏心率为0.36，精炼温度为1700℃，精炼时间为20min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 74.5％，Al 1.1％，O 0.43％，余量为Fe。
实施例6
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.45∶0.38∶0.29配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将原料WO 3、Fe 2O 3粉末、造渣剂混合均匀，以均匀流速加入到连续混料机中，同时将铝粉以梯度递减流速加入到连续混料机中，混匀的原料同时连续引入反应炉中进行铝热自蔓延反应，整个混料过程和整个反应过程不发生间断，直至所有物料完全反应后得到高温熔体；其中引入至反应炉中的连续物料的配铝量由铝热自蔓延反应理论化学计量比的1.16倍梯度递减至0.82倍，梯度变化系数a为0.001，整个过程配铝量梯度变化的次数为340次，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.98倍；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1700℃，保温时间15min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔 体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：20％CaF 2，75％CaO，5％Na 2O；控制参数为：精炼渣的加入量为原料总量的10％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为100rpm，偏心率为0.4，精炼温度为1700℃，精炼时间为30min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 72.1％，Al 0.71％，O 0.36％，余量为Fe。
实施例7
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.19∶0.30∶0.21配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将物料分5批，每批的配铝量依次为铝热自蔓延反应理论化学计量比的1.20、1.05、1.0、0.90、0.85倍，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.975倍，首批次物料的重量占总物料量的20％；将首批次物料投入反应炉中，以镁粉从物料顶部点燃以引发自蔓延反应，陆续加入其它批次物料，直至反应完全得到高温熔体；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1800℃，保温时间15min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：10％CaF 2，90％CaO；控制参数为：精炼渣的加入量为原料总量的6％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为50rpm，偏心率为0.36，精炼温度为1800℃，精炼时间为10min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 84.1％，Al 1.68％，O 0.66％，余量为Fe。
实施例8
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.22∶0.31∶0.16配料，它们的 粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将物料分6批，每批的配铝量依次为铝热自蔓延反应理论化学计量比的1.20、1.1、0.95、0.90、0.85、0.80倍，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.965倍，首批次物料的重量占总物料量的28.6％；将首批次物料投入反应炉中，以镁粉从物料顶部点燃以引发自蔓延反应，陆续加入其它批次物料，直至反应完全得到高温熔体；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1750℃，保温时间10min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：20％CaF 2，80％CaO；控制参数为：精炼渣的加入量为原料总量的8％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为100rpm，偏心率为0.4，精炼温度为1750℃，精炼时间为20min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 83.5％，Al 1.2％，O 0.65％，余量为Fe。
实施例9
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.24∶0.32∶0.14配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将物料分7批，每批的配铝量依次为铝热自蔓延反应理论化学计量比的1.20、1.1、1.0、0.95、0.925、0.90、0.85倍，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.95倍，首批次物料的重量占总物料量的22.2％；将首批次物料投入反应炉中，以镁粉从物料顶部点燃以引发自蔓延反应，陆续加入其它批次物料，直至反应完全得到高温熔体；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1700℃，保温时间5min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：25％CaF 2，75％CaO；控制参数为：精炼渣的加入量为原料总量的10％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为150rpm，偏心率为0.32，精炼温度为1700℃，精炼时间为30min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 82.6％，Al 0.72％，O 0.32％，余量为Fe。
实施例10
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.27∶0.33∶0.18配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将原料WO 3、Fe 2O 3粉末、造渣剂混合均匀，以均匀流速加入到连续混料机中，同时将铝粉以梯度递减流速加入到连续混料机中，混匀的原料同时连续引入反应炉中进行铝热自蔓延反应，整个混料过程和整个反应过程不发生间断，直至所有物料完全反应后得到高温熔体；其中引入至反应炉中的连续物料的配铝量由铝热自蔓延反应理论化学计量比的1.2倍梯度递减至0.78倍，梯度变化系数a为0.003，整个过程配铝量梯度变化的次数为140次，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.98倍；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1750℃，保温时间10min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：10％CaF 2，85％CaO，5％Na 2O；控制参数为：精炼渣的加入量为原料总量的6％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为100rpm，偏心率为0.38，精炼温度为1750℃，精炼时间为20min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 81.3％，Al 1.43％，O 0.62％，余量为Fe。
实施例11
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.27∶0.33∶0.18配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将原料WO 3、Fe 2O 3粉末、造渣剂混合均匀，以均匀流速加入到连续混料机中，同时将铝粉以梯度递减流速加入到连续混料机中，混匀的原料同时连续引入反应炉中进行铝热自蔓延反应，整个混料过程和整个反应过程不发生间断，直至所有物料完全反应后得到高温熔体；其 中引入至反应炉中的连续物料的配铝量由铝热自蔓延反应理论化学计量比的1.19倍梯度递减至0.77倍，梯度变化系数a为0.001，整个过程配铝量梯度变化的次数为420次，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.96倍；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1700℃，保温时间10min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：10％CaF 2，80％CaO，10％Na 2O；控制参数为：精炼渣的加入量为原料总量的8％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为100rpm，偏心率为0.26，精炼温度为1700℃，精炼时间为20min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 80.6％，Al 0.89％，O 0.38％，余量为Fe。
实施例12
一种基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，包括以下步骤：
(1)铝热自蔓延梯度还原
按照WO 3、Fe 2O 3粉末、铝粉、造渣剂CaO的质量比为1.0∶0.3∶0.34∶0.24配料，它们的粒度分别满足：WO 3粒度≤2mm，Fe 2O 3粉末粒度≤0.2mm，铝粉粒度≤2mm，造渣剂粒度≤0.2mm；将原料WO 3、Fe 2O 3粉末、造渣剂混合均匀，以均匀流速加入到连续混料机中，同时将铝粉以梯度递减流速加入到连续混料机中，混匀的原料同时连续引入反应炉中进行铝热自蔓延反应，整个混料过程和整个反应过程不发生间断，直至所有物料完全反应后得到高温熔体；其中引入至反应炉中的连续物料的配铝量由铝热自蔓延反应理论化学计量比的1.12倍梯度递减至0.84倍，梯度变化系数a为0.0008，整个过程配铝量梯度变化的次数为350次，且原料总配铝量为铝热自蔓延反应理论化学剂量比的0.95倍；
(2)通过电磁感应加热对高温熔体进行保温熔炼，控制参数为：电磁感应频率≥1000Hz，熔炼温度为1700℃，保温时间15min，实现金渣分离，得到上层氧化铝基熔渣和下层合金熔体；
(3)放掉上层90％的氧化铝基熔渣后，在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；其中精炼渣按质量比的组成为：20％CaF 2，75％CaO，5％Na 2O；控制参数为：精炼渣的加入量为原料总量的10％，以纯度≥99.95％的氩气为载气，偏心搅拌速率为100rpm，偏心率为0.33，精炼温度为1700℃，精炼时间为30min；
(4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
本实施例制得的钨铁合金按照质量百分含量的化学组成为：W 78.4％，Al 0.68％，O 0.24％，余量为Fe。
应当理解的是，对本领域普通技术人员而言，可以根据上述说明加以改进或变换，而所有这些改进和变换都应落入本发明要求的保护范围内。

Claims (8)

  1. 基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，其特征在于，包括以下步骤：
    (1)铝热自蔓延梯度还原，采用以下两种方式之一：
    第一种方式，将原料WO 3、Fe 2O 3粉末、铝粉、造渣剂分成若干批次，将首批次物料投入反应炉中，以镁粉从物料顶部点燃以引发自蔓延反应，陆续加入其它批次物料，直至反应完全得到高温熔体，其中每批次物料的配铝量由铝热自蔓延反应理论化学计量比的1.1～1.25倍梯度递减至0.9～0.75倍，且原料总配铝量为铝热自蔓延反应理论化学计量比的0.95～1.00；
    第二种方式，将原料WO 3、Fe 2O 3粉末、造渣剂混合均匀，以均匀流速加入到连续混料机中，同时将铝粉以梯度递减流速加入到连续混料机中，混匀的原料同时连续引入反应炉中进行铝热自蔓延反应，整个混料过程和整个反应过程不发生间断，直至所有物料完全反应后得到高温熔体，
    其中引入至反应炉中的连续物料的配铝量由铝热自蔓延反应理论化学计量比的1.1～1.25倍梯度递减至0.9～0.75倍，整个过程配铝量梯度变化的次数n满足关系式：n＝(b-c)/a，其中b表示最高配铝量，c表示最低配铝量，a表示配铝量梯度变化系数，并且0<a≤0.05；原料总配铝量为铝热自蔓延反应理论化学计量比的0.95～1.00倍；
    (2)通过电磁感应加热对高温熔体进行保温熔炼，得到上层氧化铝基熔渣和下层合金熔体；
    (3)在下层合金熔体中喷吹精炼渣，进行搅拌渣洗精炼；
    (4)将精炼后的高温熔体冷却至室温，除去上层熔炼渣后得到钨铁合金。
  2. 根据权利要求1所述的基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，其特征在于，所述步骤(1)中原料WO 3、Fe 2O 3粉末、铝粉、造渣剂的质量比为：1.0:(0.2～0.49):(0.30～0.40):(0.07～0.39)，粒度分别满足：所述WO 3粒度≤2mm，所述Fe 2O 3粉末粒度≤0.2mm，所述铝粉粒度≤2mm，所述造渣剂粒度≤0.2mm。
  3. 根据权利要求1所述的基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，其特征在于，所述步骤(1)中若干批次的数量≥4。
  4. 根据权利要求1所述的基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，其特征在于，所述步骤(1)中首批次物料的重量占总物料量的10～30％。
  5. 根据权利要求1所述的基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，其特征在于，所述步骤(2)中保温熔炼的控制参数为：电磁感应频率≥1000Hz，熔炼温度为1700～1800℃，保温时间5～15min。
  6. 根据权利要求1所述的基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，其 特征在于，所述步骤(3)中精炼渣为以下两种中的一种：①按质量比10～25％的CaF 2，余量为CaO；②按质量比10～25％的CaF 2，5～10％的Na 2O，余量为CaO。
  7. 根据权利要求1所述的基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，其特征在于，所述步骤(3)中搅拌渣洗精炼的控制参数为：采用偏心搅拌，偏心率为0.2～0.4，精炼渣的加入量为原料总量的6～12％，以纯度≥99.95％的惰性气体为载气，搅拌速率为50～150rpm，精炼温度为1700～1800℃，精炼时间为10～30min。
  8. 根据权利要求1所述的基于铝热自蔓延梯度还原与渣洗精炼制备钨铁合金的方法，其特征在于，所述钨铁合金按照质量百分含量的化学组成为：W 70.0～85.0％，Al≤2.0％，O≤1％，余量为Fe。
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