The method of the online pressure sealing of blast-furnace tuyere coal gas and the leak stopping layer of formation
Technical field
The present invention relates to blast furnace and divide a mouthful leakage stopping technology field, specifically the method for the online pressure sealing of a kind of blast-furnace tuyere coal gas and the leak stopping layer based on the method formation.
Background technology
Along with plant-scale continuous expansion, the continuous enhancing of continuous prodution degree, leaks the financial loss caused and is also on the rise.Because the existence of leaking. not only make the energy and material constantly run off, and make poisonous, harmful, corrodibility is strong, inflammable, explosive, high temperature, high pressure various liquid mediums constantly leak. so that cause environmental pollution, cause fire, blast, poisoning and human casualty accident.Enterprise often causes the stopping production of whole production system because of the slight leakage in a place.
Blast furnace gas is the byproduct of Steel Plant's blast fumance, is mainly derived from the incomplete combustion of carbon containing thing.Blast furnace gas generally contains carbon monoxide, the carbonic acid gas of more than 20%, a small amount of hydrogen, nitrogen etc.In blast furnace gas component, carbon monoxide is colourless, odorless, tasteless, nonirritant gas, has severe toxicity.Generally speaking, carbon monoxide enters human body by respiratory tract and causes poisoning.Tuyere medium jacket of blast furnace upwarps distortion because a variety of causes causes, cause gas leak, overhead about 1.5 meters and platform operates perambulator person and frequently walk about, region, air port, especially leeward and table dead angle place more easily accumulates a large amount of leakage gas, bring high risks to safety in production, solving tuyere zone gas leak problem is the key technical problem that security critical is produced.
Traditional blast-furnace tuyere gas leak treatment process adopts the modes such as welding baffle plate to force leak stopping when being and waiting blast furnace staying to stop production, though above-mentioned Conventional processing methods can temporarily address the leakage concern, but due to have in tuyere medium sleeve water cycle cool and material is cast copper, and tuyere big sleeve does not have circulating water and material is cast steel, though can weld reluctantly under damping down state, but due to tuyere big sleeve and the middle difference of the cover coefficient of expansion and the difference of working condition after multiple wind, air port expanded by heating, welded seam produces cracking owing to being subject to the effect of thermal stresses, coal gas is caused again to leak.Therefore the coal gas leakage stopping technology innovation under this working condition seems particularly important.
Summary of the invention
In order to overcome the shortcoming that above-mentioned prior art exists, the object of the present invention is to provide the method for the online pressure sealing of a kind of blast-furnace tuyere coal gas, under the prerequisite not affecting blast-furnace tuyere function, under the condition namely without blast furnace staying stopping production, realize leaking tuyere gas carrying out online pressure sealing;
The method of the online pressure sealing of this blast-furnace tuyere gas leak, comprises the steps:
A). the surface preparation of blast-furnace tuyere leakage point, remove the dirt settling on surface near the leakage point of air port, make surface cleaning and surface coarsening activation;
B). on blast-furnace tuyere leakage point surface, utilize electric arc spraying equipment to spray the first alloy layer; The alloying element of described first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:5-10%, Fe:2-3%, Ni:80-90%, rare earth element: 2-5%; The arc voltage of electric arc spraying equipment is 30-40V, and working current is 160-260A; In this spraying process, the pressurized air of 0.6-0.8MPa is continual blows to spray-coating surface, and the direction that pressurized air blows is vertical with spray-coating surface; The thickness of the first alloy layer formed is 0.1-0.3mm;
C). at the first alloyed layer, utilize electric arc spraying equipment to spray the second alloy layer, the alloying element of described second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co-:5-10%, Cr:2-5%, Mo:3-10%, W:2-4%, rare earth element: 2-5%, all the other are Ni; The arc voltage of electric arc spraying equipment is 26-32V, working current: 200-240A; In this spraying process, the pressurized air of 0.6-0.8MPa is still continual blows to spray-coating surface: and the direction that pressurized air blows is vertical with spray-coating surface; The thickness of the second alloy layer formed is 0.5-2.0mm;
D). brush coating sealing reagent at the second alloyed layer.
Further technical scheme as aforesaid method: in step a, the surface preparation of blast-furnace tuyere leakage point adopts spray 6-10 order SiC sand to carry out Cress and surface active.
Further technical scheme as aforesaid method: the thickness of described second alloy layer is 0.8-1.5mm.
The leak stopping layer formed based on aforesaid method provided by the invention, comprises the first alloy layer, the second alloy layer; Described first alloy layer is sprayed on blast-furnace tuyere leakage point surface, and described second alloy layer is sprayed on the surface of described first alloy layer;
The alloying element of described first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:5-10%, Fe:2-3%, Ni:80-90%, rare earth element: 2-5%; The thickness of described first alloy layer is 0.1-0.3mm;
The alloying element of described second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co:5-10%, Cr:2-5%, Mo:3-10%, W:2-4%, rare earth element: 2-5%, all the other are Ni; The thickness of described second alloy layer is 0.5-2.0mm.
Further technical scheme as leak stopping layer: the thickness of described second alloy layer is 0.8-1.5mm.
The invention has the beneficial effects as follows: on blast-furnace tuyere gas leak point, electric arc spraying forms leak stopping layer, solve the gas leak problem in blast-furnace tuyere region, and the leak stopping coating formed has the features such as high temperature oxidation resisting, high ductibility, thermal shock resistance are good, can not ftracture by internal stress in blast furnace working process, make air port more traditional blocking method in work-ing life improve 2-3 doubly; Greatly reduce the risk of carbon monoxide poisoning, ensure the personnel safety of flushing and casting personnel, significant to safety in production; Simultaneously due to the prolongation in work-ing life, thus reduce the repair time, increase economic efficiency, be conducive to reducing costs, improving output and energy-saving and emission-reduction;
In addition during this spraying leak stopping layer, blast furnace need not stop production by damping down, overcomes the defect that the necessary blast furnace staying of traditional blocking method stops production; And safe operation process is reliable, detonation can not be there is and the accident such as even to explode; Site operation safe ready and leak stopping efficiency is high, cost is low.
Accompanying drawing explanation
Below in conjunction with drawings and Examples, the present invention is described further:
Fig. 1 is hot spray coating forming process schematic diagram;
In figure: the particle after 1 melting, 2 matrixes, 3 coatings.
Embodiment
The method of the online pressure sealing of this blast-furnace tuyere coal gas, under the prerequisite not affecting blast-furnace tuyere function, under the condition namely without blast furnace staying stopping production, realizes leaking tuyere gas carrying out online pressure sealing.
Embodiment one: the method for the online pressure sealing of this blast-furnace tuyere coal gas, comprises step:
A). the surface preparation of blast-furnace tuyere leakage point, remove the dirt settling on surface near the leakage point of air port, make surface cleaning and surface coarsening activation; In this step a, the surface preparation of blast-furnace tuyere leakage point adopts spray 6 order SiC sand to carry out cleaning and roughening and surface active.
B). blast-furnace tuyere leakage point surface, utilizes electric arc spraying equipment to spray the first alloy layer; The alloying element of described first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:5%, Fe:2%, Ni:88%, rare earth element: 5%.In step b, when spraying the first alloy layer, what take is Ultrasonic Arc Sprayed, and processing condition are: arc voltage 30, working current: 160.In the spraying process of this step b, the pressurized air of 0.8MPa is continual blows to spray-coating surface, and the direction that pressurized air blows is vertical with spray-coating surface.The pressure blowout that this pressurized air preferably adopts 0.8MPa constant.In addition, the thickness of described first alloy layer of step b formation is 0.1mm.
Spraying the first alloy layer can adopt metal wire material to pass through Ultrasonic Arc Sprayed, the forming process of the first alloy layer is as shown in 1a, 1b, 1c of Fig. 1, during thermospray, silk material by heat source to molten state or high-ductility state, under the thrust of adscititious gases or flame stream itself (being have employed pressurized air in this embodiment), atomization also high-velocity jet is surperficial to matrix 2, after melting, the particle 1 of coated material occurs fiercely to collide with matrix and is out of shape, flattens that to be deposited on matrix 2 surperficial, simultaneously chilling and rapid solidification, particle layer deposition and be piled into coating 3 so then.Namely coating is by the interlaced laminate structure in layer stacking in wave of infinite variety particle, namely forms the first alloy layer.
C). at the first alloyed layer, utilize electric arc spraying equipment to spray the second alloy layer, the alloying element of described second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co-:5%, Cr:5%, Mo:10%, W:4%, rare earth element: 5%, Ni:71%.In step c, when spraying the second alloy layer, silk material is adopted to be formed by Ultrasonic Arc Sprayed.Processing condition are: arc voltage is 26V, working current: 200A.In the spraying process of step c, the pressurized air of 0.6MPa is continual blows to spray-coating surface: and the direction that pressurized air blows is vertical with spray-coating surface; The thickness of the second alloy layer formed is 0.5mm.
D). follow-up sealing pores is carried out to described second alloy layer, the first alloy layer.Further: later stage sealing pores described in steps d adopts high temperature organosilicon paint to be sealed in the space of coating, prevents high-temperature gas etched the matrix.
Embodiment two: the method for the online pressure sealing of this blast-furnace tuyere coal gas, comprises step:
A). the surface preparation of blast-furnace tuyere leakage point, remove the dirt settling on surface near the leakage point of air port, make surface cleaning and surface coarsening activation; In this step a, the surface preparation of blast-furnace tuyere leakage point adopts spray 10 order SiC sand to carry out cleaning and roughening and surface active;
B). blast-furnace tuyere leakage point surface, utilizes electric arc spraying equipment to spray the first alloy layer; The alloying element of described first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:10%, Fe:3%, Ni:83%, rare earth element: 4%.In step b, when spraying the first alloy layer, what take is Ultrasonic Arc Sprayed, and processing condition are: arc voltage 40V, working current: 260A.In the spraying process of this step b, the pressurized air of 0.8MPa is continual blows to spray-coating surface, and the direction that pressurized air blows is vertical with spray-coating surface.In addition, the thickness of described first alloy layer of step b formation is 0.3mm.
C). at the first alloyed layer, utilize electric arc spraying equipment to spray the second alloy layer, the alloying element of described second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co-:6%, Cr:4%, Mo:8%, W:2%, rare earth element: 5%, Ni:75%.In step c, when spraying the second alloy layer, take be also a material by Ultrasonic Arc Sprayed, processing condition are: arc voltage is 32V, working current: 240A.In step c process, the pressurized air of 0.6MPa is continual blows to spray-coating surface: and the direction that pressurized air blows is vertical with spray-coating surface; The thickness of the second alloy layer formed is 2.0mm.
D). follow-up sealing pores is carried out to described second alloy layer, the first alloy layer.Further: later stage sealing pores described in steps d adopts high temperature organosilicon paint to be sealed in the space of coating.
Embodiment three: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment one difference is:
Step a) in the surface preparation of blast-furnace tuyere leakage point adopt spray 7 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:10%, Fe:2%, Ni:86%, rare earth element: 2%; In step b, when spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 35V, working current: 210A; The thickness of described first alloy layer that step b is formed is 0.15mm;
C). alloying element Co, Cr, Mo, W, Ni, the rare earth element of described second alloy layer; Mass percent is: Co:8%, Cr:5%, Mo:10%, W:3%, rare earth element: 4%, Ni:70%; In step c, when spraying the second alloy layer, Ultrasonic Arc Sprayed processing condition are: arc voltage 28V, working current: 220A; In step c process, the pressurized air of 0.6MPa is continual blows to spray-coating surface; The thickness of the second alloy layer formed is 0.8mm.
All the other do not state technology with embodiment one.
Embodiment four: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment one difference is:
Step a) in the surface preparation of blast-furnace tuyere leakage point adopt spray 8 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:8%, Fe:3%, Ni:84%, rare earth element: 5%;
In step b, when spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 32V, working current: 180A; The thickness of described first alloy layer that step b is formed is 0.2mm;
C). alloying element Co, Cr, Mo, W, Ni, the rare earth element of described second alloy layer; Mass percent is: Co:6%, Cr:5%, Mo:6%, W:2%, rare earth element: 5%, Ni:76%;
In step c, when spraying the second alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage is 29V, working current: 225A; The thickness of the second alloy layer formed is 1.0mm;
All the other do not state technology with embodiment one.
Embodiment five: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment one difference is:
Step a) in the surface preparation of blast-furnace tuyere leakage point adopt spray 8 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:6%, Fe:2%, Ni:90%, rare earth element: 2%;
In step b, when spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 37V, working current: 230A; The thickness of described first alloy layer that step b is formed is 0.2mm;
C). alloying element Co, Cr, Mo, W, Ni, the rare earth element of described second alloy layer; Mass percent is: Co:9%, Cr:5%, Mo:8%, W:4%, rare earth element: 2%, Ni:72%;
In step c, when spraying the second alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage is 30V, working current: 230A; The thickness of the second alloy layer formed is 1.2mm;
All the other do not state technology with embodiment one.
Embodiment six: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment one difference is:
Step a) in the surface preparation of blast-furnace tuyere leakage point adopt spray 9 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:3%, Fe:2%, Ni:90%, rare earth element: 5%;
In step b, when spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 38V, working current: 240A; The thickness of described first alloy layer that step b is formed is 0.25mm;
C). alloying element Co, Cr, Mo, W, Ni, the rare earth element of described second alloy layer; Mass percent is: Co:7%, Cr:3%, Mo:6%, W:4%, rare earth element: 3%, Ni:77%;
In step c, when spraying the second alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage is 31V, working current: 235A; The thickness of the second alloy layer formed is 1.5mm;
All the other do not state technology with embodiment one.
Embodiment seven: the method for the online pressure sealing of this blast-furnace tuyere coal gas, with embodiment one difference is:
Step a) in the surface preparation of blast-furnace tuyere leakage point adopt spray 9 order SiC sand to carry out cleaning and roughening and surface active;
B). Al, Fe, Ni, rare earth element in the first alloy layer, mass percent is: Al:7%, Fe:2%, Ni:89%, rare earth element: 2%;
In step b, when spraying the first alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage 39V, working current: 250A; The thickness of described first alloy layer that step b is formed is 0.28mm;
C). alloying element Co, Cr, Mo, W, Ni, the rare earth element of described second alloy layer; Mass percent is: Co:5%, Cr:5%, Mo:4%, W:3%, rare earth element: 3%, Ni:80%;
In step c, when spraying the second alloy layer, the processing condition of Ultrasonic Arc Sprayed are: arc voltage is 27V, working current: 210A; The thickness of the second alloy layer formed is 0.7mm;
All the other do not state technology with embodiment one.
The blast-furnace tuyere coal gas leak stopping layer formed by above-described embodiment, comprises the first alloy layer, the second alloy layer; Described first alloy layer is sprayed on blast-furnace tuyere leakage point surface, and described second alloy layer is sprayed on the surface of described first alloy layer; The alloying element of described first alloy layer comprises Al, Fe, Ni, rare earth element, and mass percent is: Al:5-10%, Fe:2-3%, Ni:80-90%, rare earth element: 2-5%; The thickness of described first alloy layer is 0.1-0.3mm;
The alloying element of described second alloy layer comprises Co, Cr, Mo, W, Ni, rare earth element; And mass percent is: Co:5-10%, Cr:2-5%, Mo:3-10%, W:2-4%, rare earth element: 2-5%, all the other are Ni; The thickness of described second alloy layer is 0.5-2.0mm.
When spraying the first alloy layer, liquid metal particle invades the combination forming mechanical rivet type in these tiny flaws.On matrix and the first alloy layer interface, the first alloy layer and the second alloy layer interface, Coating combination obtains very well.Uneven on interface, is conducive to the bonding strength improving coating.
Below to the many kinds of parameters of the first alloy layer utilizing processing method of the present invention to be formed, the second alloy layer, do following simultaneous test, to prove the effect of the plugged zone that present invention process method is formed:
(1) bonding strength of plugged zone:
The bonding strength of table 1 alloy layer
As can be seen from Table 1, although the main combination of sample alloy layer is mechanical bond, but because the NiAl alloy epitaxy layer (i.e. the first alloy layer) coating one deck bottoming forms the micro metallurgic bonding point of some Dispersed precipitate, the bonding strength improving coating and matrix can be significantly improved, and the size of itself and substrate combinating strength mainly depends on the bonding strength with prime coat and matrix, therefore the selection of prime coat material and the quality of coating quality very important to the performance of plugged zone.
(2) coating microhardness
The sample adopted is the metallographic specimen through polishing, polishing, and matrix is No. 45 steel, and plugged zone thickness is about 1.0mm.During test, added load is 300g, and the loading time is 10 seconds, and the microhardness result of matrix and alloy layer is respectively in table 2 and table 3.
The microhardness of table 2 matrix
The microhardness of table 3 alloy layer
As can be seen from the above table, the character of coating hardness and spray material is undivided, but alloy layer hardness and spray material hardness are had any different, even same spray material, alloy layer hardness is also different usually.Containing pore and hole in alloy layer, the weave construction of alloy layer has heterogencity, thus causes the heterogencity of alloy layer hardness.And the combined alloy layer that the first alloy layer, the second alloy layer are formed and plugged zone microhardness are higher.
(3) alloy layer thermal shock performance
Thermal shock resistance is tested:
1) sample be placed in cabinet-type electric furnace heat, be incubated 10 minutes, immerse immediately in cold water after taking-up;
2) be again put in electric furnace, heating;
3) repeated execution of steps 1,2, until alloy layer peel off that area accounts for the alloy layer total area 10%;
4) record to be heated to from alloy layer when peeling off take the number of times of water-cooled.
Sample is the single alloy layer utilizing the material of the second alloy layer to make, the combined alloy layer utilizing the first alloy layer and the second alloy layer to be formed, and under 500 DEG C and 700 DEG C of conditions, carry out thermal shock resistance test respectively, test-results is as shown in table 4:
Table 4 alloy layer thermal shock test data
Test proves: combined alloy layer thermal shock resistance is slightly better than single alloy layer thermal shock resistance, and this mainly due to the transition layer (namely first) that spraying end silk is formed afterwards, reduces cold cycling alternating stress, improve its thermal shock performance.
Above-described embodiment is only preferred embodiment of the present invention, does not represent the present invention and is only confined to above-described embodiment.