硅溶胶结合Al_2O_3-SiC-C体系铁沟料研究与生产应用
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摘要
铁沟料是使用于高炉出铁沟的一种不定形耐火材料,占高炉炉前用耐火材料70%以上。铁沟料的性能是影响高炉出铁沟使用寿命和通铁量大小的主要因素,并对高炉吨铁耐火材料成本、劳动强度、工作环境等有直接影响。本文针对重钢高炉出铁沟现用Al2O3-SiC-C质低水泥浇注料,存在使用寿命较短,一次性通铁量小的生产实际问题,对高炉出铁沟材料的使用条件和需具备的物理化学性能以及材料的损毁机理进行了分析研究。通过分析认为铁沟料在使用中寿命低、通铁量小主要是渣铁侵蚀、铁水冲刷、热冲击和高温氧化几方面共同作用的结果。本文对铁沟料用刚玉、碳化硅、碳素材料以及各种添加剂在铁沟料中的作用及其综合性能的影响进行了研究,就提高和改善铁沟料的抗渣性、抗冲刷性、抗热冲击能力和抗氧化性设计配制了新的溶胶结合Al2O3-SiC-C系高炉出铁沟材料。经过反复试验确定了材料的最佳配比,通过x射线荧光分析、偏光显微分析、扫描电镜(SEM)等测试手段,对新高炉出铁沟材料的物相、成分以及微观结构进行了分析。试验结果表明,通过添加烧结剂促进铝微粉和硅微粉在适当温度下反应生成莫来石相可以提高材料的抗热震稳定性,通过优化抗氧化剂可以提高材料的抗氧化性,通过优化碳化硅的级配、加入量等手段可以提高材料的抗渣蚀能力和抗冲刷能力。此外,论文还对硅溶胶取代水泥作为结合剂改善铁沟料的中高温性能进行了试验研究,并通过改善铁沟料的施工性能从而改善铁沟料的组织结构,进而提高了材料的高温性能。论文最后对新配置的高通铁量铁沟材料进行了生产性试验,结果表明:新的溶胶结合Al2O3-SiC-C系铁沟材料的抗渣性、抗热冲击性、抗氧化性、中高温性能等较改造前均有较大提高,一次性通铁量达到16.3万吨,较改造前提高60%以上。
Iron trough, as a kind of amorphous refractories, is the main blast furnace refractories with dosage of refractories more than 70 percent. The performance, life of iron trough and flux of iron directly affect the cost of refractories, labor intensity and working conditions. In fact, in Chongqing Steel Company, there were some problems such as low life, small flux of iron and so on. In this paper, in order to solve these problems there were some research on iron trough. The cooperation of iron erosion, molten iron eroding, thermal shock and high-temperature will reduce the life of iron trough and the flux of iron. In this paper, the effects of alumina, silicon carbide, carbon materials and various additives and the impact of comprehensive performance were studied. In order to improve the slag resistance, anti-erosion, thermal shock resistance and oxidation resistance of iron trough, a new sol-binded Al2O3-SiC-C material was used in this paper. By repeated tests the best ratio of the material was determined. The crystalline structure, composition and morphology of the materials were tested and analyzed by X-ray fluorescence analysis, analysis of polarizing microscopy, scanning electron microscopy. The test results show that mullite composed by aluminum micronization and silicon micronization can improve the thermal shock resistance, at the same time, better antioxidant and grade of silicon nitrification can increase the oxidation resistance and the slag resistance of the materials separately. Otherwise the improving structure of iron trough by using silicon gel as the substitution of cement can enhance the performance at high temperature. At last, flux of iron was improved by using the new iron trough. The results show that the slag resistance, anti-erosion, thermal shock resistance and oxidation resistance of Al2O3-SiC-C iron trough with sol were improved obviously. For example, the flux of iron was 163000 tons, which was enhanced 60 percent than the former.
Iron trough, as a kind of amorphous refractories, is the main blast furnace refractories with dosage of refractories more than 70 percent. The performance, life of iron trough and flux of iron directly affect the cost of refractories, labor intensity and working conditions. In fact, in Chongqing Steel Company, there were some problems such as low life, small flux of iron and so on. In this paper, in order to solve these problems there were some research on iron trough. The cooperation of iron erosion, molten iron eroding, thermal shock and high-temperature will reduce the life of iron trough and the flux of iron. In this paper, the effects of alumina, silicon carbide, carbon materials and various additives and the impact of comprehensive performance were studied. In order to improve the slag resistance, anti-erosion, thermal shock resistance and oxidation resistance of iron trough, a new sol-binded Al2O3-SiC-C material was used in this paper. By repeated tests the best ratio of the material was determined. The crystalline structure, composition and morphology of the materials were tested and analyzed by X-ray fluorescence analysis, analysis of polarizing microscopy, scanning electron microscopy. The test results show that mullite composed by aluminum micronization and silicon micronization can improve the thermal shock resistance, at the same time, better antioxidant and grade of silicon nitrification can increase the oxidation resistance and the slag resistance of the materials separately. Otherwise the improving structure of iron trough by using silicon gel as the substitution of cement can enhance the performance at high temperature. At last, flux of iron was improved by using the new iron trough. The results show that the slag resistance, anti-erosion, thermal shock resistance and oxidation resistance of Al2O3-SiC-C iron trough with sol were improved obviously. For example, the flux of iron was 163000 tons, which was enhanced 60 percent than the former.
引文
[1] Takahashi G. Adance and prospect of technologies for blast funace refractories in Japan [J]. Refractories (Tokyo), 1991, 3(10): 505-508.
[2] 吕春燕. 原位生成 Sialon 增强 Al2O3-SiC-C 铁沟浇注料研究. 耐火材料, 2005, (4): 27.
[3] Bonsall S B, Henry D. K. Wear mechanisms in alumina-silicon carbide-carbon blast furnace trough refractories [J]. Am, Ceram. Soc, 1985, 13(2): 331-336.
[4] Sterbesov S, Ivanov Y, Serbezova R, et al. Properties of ultra low cement castables in A12O3-SiC-C-SiO2 systems [C]. Unitecr'93 Congress. Refractories for the new World Economy. Proc.Conf:. Sao Paulo, 1993: 939-950.
[5] 陈显书, 王奎达. 浇注料在首钢高炉出铁沟上的应用. 炼铁, 1995, 14(4): 36-39.
[6] 王伟. 氧化铝基复合材料出铁沟预制件的研制与开发 [D]. 重庆: 重庆大学, 2001.
[7] 刘麟瑞, 林彬荫. 工业窑炉用耐火材料手册. 冶金工业出版社, 2005: 173-174.
[8] Sakano Y, Tskahashi H. Outlook for the refectories industy industry in Japan [J]. Am, Ceram, Soc, Bull. 1988, 67(7): 1164-1168.
[9] 吴靖斌. 高炉铁沟料的发展问题. 马钢科研, 1995, 1(4): 31-38.
[10] 谭远树. 影响攀钢高炉铁沟料使用寿命的因素 [J]. 攀钢技术, 2002, 25(2): 28-30.
[11] Li,T. Development and application of hot self-flow repairing mix for trough [C]. LTNITECR'O1. Cancun Nov, 2001: 1175-1179.
[12] Suzuki T, Tanimura T, Kishida R. Hot repair with resin bonded materials for blast furnace trough [J]. Refractories (Tokyo), 1994, 46( 11): 581-585.
[13] 李再耕, 王战民, 王守业. 添加Si, Al, Si3N4对Al2O3-SiC-C质浇注料性能的影响. 耐火材 料, 1994, 28(50): 251-256.
[14] 李键. 攀钢高炉铁沟粘渣侵蚀机理及材料性能改进研究. 武汉科技大学, 2001.
[15] Toritani Y. Behaviour of non-oxide in casting trough materials for blast furnace [J]. Refractories (Tokyo), 1991, 43(11): 614-617.
[16] Niu J, Terayama S, Kiminami T. Effect of graphite grains on properties of castables for a blast furnace trough[J]
[17] J. Tech. Assoc. Refract. Japan, 2002, 22(3): 219-222.
[18] R E. Johnson. Ultra-low cement castalbes-a new generation of trough bodies for increased cast life[J].
[19] 王战民, 李再耕.高炉出铁沟用耐火材料的发展[J]. 耐火材料, 1996, 30(2):109-112.
[20] 谭远树. 影响攀钢高炉铁沟料使用寿命的因素. 四川冶金, 2002: 27.
[21] 洛阳耐火材料研究院. 不定形耐火材料手册. 1999: 23-24.
[22] 王维邦. 耐火材料工艺学. 北京: 冶金工业出版社, 2005: 28-29.
[23] 洛阳耐火材料研究院. 不定形耐火材料手册, 1999: 156.
[24] 洛阳耐火材料研究院. 不定形耐火材料手册, 1999: 82.
[25] 韩行禄. 不定形耐火材料. 北京: 冶金工业出版社, 1993: 231-240.
[26] 李再耕. 不定形耐火材料技术发展动态. 耐火材料, 1997, 31(20):98-102.
[27] 刘麟瑞等. 工业窑炉用耐火材料手册. 冶金工业出版社, 2001: 12.
[28] 耐火材料标准汇编. 中国标准出版社, 2005.
[29] 李晓明, 吴清顺. 特种不定形耐火材料及不烧耐火砖. 北京: 冶金工业出版社, 1992.
[30] 王诚训. 复合不定形耐火材料. 北京: 冶金工业出版社, 2005: 49-53.
[31] J.W.Cook, C.L.Hewett and I.Hieger. J.Chen.Soc, 1993: 395.
[32] H.Mstsushita, BUNSEKI KAGAKU ,1976, 25: 76-78.
[33] 浇注料的爆裂与防爆裂对策. 耐火材料信, 2005: 13
[34] 李晓明. 微粉与新型耐火材料. 北京: 冶金工业出版社, 1997
[35] 黄文胜等. 免烘烤铁沟捣打料的研制与应用. 耐火材料, 2003: 79.
[36] 徐国涛等. 自洁净 Al2O3-SiC-C 质铁沟料的研究与应用. Ceramics Science & Art
[2] 吕春燕. 原位生成 Sialon 增强 Al2O3-SiC-C 铁沟浇注料研究. 耐火材料, 2005, (4): 27.
[3] Bonsall S B, Henry D. K. Wear mechanisms in alumina-silicon carbide-carbon blast furnace trough refractories [J]. Am, Ceram. Soc, 1985, 13(2): 331-336.
[4] Sterbesov S, Ivanov Y, Serbezova R, et al. Properties of ultra low cement castables in A12O3-SiC-C-SiO2 systems [C]. Unitecr'93 Congress. Refractories for the new World Economy. Proc.Conf:. Sao Paulo, 1993: 939-950.
[5] 陈显书, 王奎达. 浇注料在首钢高炉出铁沟上的应用. 炼铁, 1995, 14(4): 36-39.
[6] 王伟. 氧化铝基复合材料出铁沟预制件的研制与开发 [D]. 重庆: 重庆大学, 2001.
[7] 刘麟瑞, 林彬荫. 工业窑炉用耐火材料手册. 冶金工业出版社, 2005: 173-174.
[8] Sakano Y, Tskahashi H. Outlook for the refectories industy industry in Japan [J]. Am, Ceram, Soc, Bull. 1988, 67(7): 1164-1168.
[9] 吴靖斌. 高炉铁沟料的发展问题. 马钢科研, 1995, 1(4): 31-38.
[10] 谭远树. 影响攀钢高炉铁沟料使用寿命的因素 [J]. 攀钢技术, 2002, 25(2): 28-30.
[11] Li,T. Development and application of hot self-flow repairing mix for trough [C]. LTNITECR'O1. Cancun Nov, 2001: 1175-1179.
[12] Suzuki T, Tanimura T, Kishida R. Hot repair with resin bonded materials for blast furnace trough [J]. Refractories (Tokyo), 1994, 46( 11): 581-585.
[13] 李再耕, 王战民, 王守业. 添加Si, Al, Si3N4对Al2O3-SiC-C质浇注料性能的影响. 耐火材 料, 1994, 28(50): 251-256.
[14] 李键. 攀钢高炉铁沟粘渣侵蚀机理及材料性能改进研究. 武汉科技大学, 2001.
[15] Toritani Y. Behaviour of non-oxide in casting trough materials for blast furnace [J]. Refractories (Tokyo), 1991, 43(11): 614-617.
[16] Niu J, Terayama S, Kiminami T. Effect of graphite grains on properties of castables for a blast furnace trough[J]
[17] J. Tech. Assoc. Refract. Japan, 2002, 22(3): 219-222.
[18] R E. Johnson. Ultra-low cement castalbes-a new generation of trough bodies for increased cast life[J].
[19] 王战民, 李再耕.高炉出铁沟用耐火材料的发展[J]. 耐火材料, 1996, 30(2):109-112.
[20] 谭远树. 影响攀钢高炉铁沟料使用寿命的因素. 四川冶金, 2002: 27.
[21] 洛阳耐火材料研究院. 不定形耐火材料手册. 1999: 23-24.
[22] 王维邦. 耐火材料工艺学. 北京: 冶金工业出版社, 2005: 28-29.
[23] 洛阳耐火材料研究院. 不定形耐火材料手册, 1999: 156.
[24] 洛阳耐火材料研究院. 不定形耐火材料手册, 1999: 82.
[25] 韩行禄. 不定形耐火材料. 北京: 冶金工业出版社, 1993: 231-240.
[26] 李再耕. 不定形耐火材料技术发展动态. 耐火材料, 1997, 31(20):98-102.
[27] 刘麟瑞等. 工业窑炉用耐火材料手册. 冶金工业出版社, 2001: 12.
[28] 耐火材料标准汇编. 中国标准出版社, 2005.
[29] 李晓明, 吴清顺. 特种不定形耐火材料及不烧耐火砖. 北京: 冶金工业出版社, 1992.
[30] 王诚训. 复合不定形耐火材料. 北京: 冶金工业出版社, 2005: 49-53.
[31] J.W.Cook, C.L.Hewett and I.Hieger. J.Chen.Soc, 1993: 395.
[32] H.Mstsushita, BUNSEKI KAGAKU ,1976, 25: 76-78.
[33] 浇注料的爆裂与防爆裂对策. 耐火材料信, 2005: 13
[34] 李晓明. 微粉与新型耐火材料. 北京: 冶金工业出版社, 1997
[35] 黄文胜等. 免烘烤铁沟捣打料的研制与应用. 耐火材料, 2003: 79.
[36] 徐国涛等. 自洁净 Al2O3-SiC-C 质铁沟料的研究与应用. Ceramics Science & Art