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CN106278204A - 一种中频炉炉衬修补用可塑料及其制备方法 - Google Patents

一种中频炉炉衬修补用可塑料及其制备方法 Download PDF

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CN106278204A
CN106278204A CN201610667073.5A CN201610667073A CN106278204A CN 106278204 A CN106278204 A CN 106278204A CN 201610667073 A CN201610667073 A CN 201610667073A CN 106278204 A CN106278204 A CN 106278204A
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袁添翼
李远兵
余东寿
袁聪
周伟强
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LENGSHUIJIANG HUAKE PERFORMANCE MATERIALS Co Ltd
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Abstract

本发明涉及一种中频炉炉衬修补用可塑料及其制备方法。其技术方案是：以18～30wt%的氧化铝粉、10～20wt%的蓝晶石、2～7wt%的氧化铬粉、2～5wt%的增塑剂为基质料，以50～65wt%的矾土颗粒为骨料，基质料和骨料之和为原料；先将基质料混合1~1.5h，再将骨料和混合后的基质料加入混碾机，外加原料3～5wt%的磷酸和3～5wt%的水，混碾，得到半干泥料。困料，再将困料后的半干泥料加入混碾机中，外加原料2～3wt%的磷酸、0.05～0.15wt%的缓蚀剂、0.1～0.5wt%的保湿剂和3~5wt%的水，混碾，得到混碾泥料，将混碾泥料挤泥成型，制得中频炉炉衬修补用可塑料。本发明生产成本低，所制制品保存时间长、易于施工操作和使用性能优良的特点。

Description

一种中频炉炉衬修补用可塑料及其制备方法
技术领域
本发明属于中频炉用耐火材料技术领域。具体涉及一种中频炉炉衬修补用可塑料及其制备方法。
背景技术
中频炉具有熔化速度快、生产效率高、使用灵活、污染小、电磁搅拌效果好和高效节能等特点，近年来被广泛的应用于不锈钢、特钢和铸造行业，并且不断向大功率、快速熔化和大容量方向发展。中频炉炉衬材料是中频炉的重要组成部分，在中频炉熔炼过程中，由于受到金属熔体和熔渣的侵蚀及频繁的温度变化所带来的热冲击，炉衬局部会出现裂纹或剥落的情况。修补用可塑料涂覆在裂纹或剥落的部位，可形成与炉衬结合为一体的修补层，以提高炉衬的使用寿命和减少耐火材料的消耗。
中频炉炉衬以刚玉（矾土）-尖晶石质捣打料应用最为广泛，修补刚玉（矾土）-尖晶石质捣打料炉衬时用的可塑料，要求具有粘结性强、耐高温、抗热震和耐冲刷等特点。目前，常见的修补用可塑料主要存在问题：1）粘结性较差，修补时易脱落；2）常温硬化慢、早期强度低；3）修补后使用寿命短；4）保存时间短；5）不易施工、修补时工作效率低。尤其是保存期短，极大地影响了修补用可塑料的使用。
发明内容
本发明旨在克服现有技术缺陷，提供一种生产成本低的中频炉炉衬修补用可塑料的制备方法，用该方法制备的中频炉炉衬修补用可塑料早期强度高、保存时间长、易于施工和使用性能优良。
为实现上述目的，本发明采用的技术方案包括以下步骤：以18～30wt%的氧化铝粉、10～20wt%的蓝晶石、2～7wt%的氧化铬粉、2～5wt%的增塑剂为基质料，以50～65wt%的矾土颗粒为骨料，基质料和骨料之和为原料；先将所述基质料在混料机中混合1~1.5h，再将所述骨料和混合后的基质料加入混碾机，外加所述原料3～5wt%的磷酸和3～5wt%的水，混碾8~10min，得到半干泥料。
将所述半干泥料装入密封容器中，困料24~48h，再将困料后的半干泥料加入混碾机中，外加所述原料2～3wt%的磷酸、0.05～0.15wt%的缓蚀剂、0.1～0.5wt%的保湿剂和3~5wt%的水，混碾5～8min，得到混碾泥料，将混碾泥料挤泥成型，制得中频炉炉衬修补用可塑料。
所述氧化铝粉的粒径级配是：粒径为0.044~0.023mm占氧化铝粉30～50wt%；粒径为5~2μm占所述氧化铝粉50～70wt%。
所述蓝晶石的粒径级配是：粒径为0.425~0.212mm占蓝晶石30～70wt%；粒径为0.088~0.044mm占蓝晶石30～70wt%。
所述氧化铬粉的粒径为0.2~8μm。
所述增塑剂为50wt%的膨润土、20wt%的羧甲基纤维素和30wt%的聚丙烯酰胺的混合物。
所述矾土颗粒的径级配是：粒径为5～3mm占矾土颗粒20～40wt%；粒径小于3mm且大于等于1mm占矾土颗粒10～50wt%；粒径小于1 mm且大于等于0.5mm占矾土颗粒10～30wt%；粒径小于0.5 mm且大于等于0.088mm占矾土颗粒10～45wt%。
所述缓蚀剂为60wt%的丙烯酸为和40wt%异丙烯膦酸的混合物。
所述保湿剂为2-丙烯酸胺基-2-甲基丙磺酸和草酸中的一种以上。
由于采用上述技术方案，本发明与现有技术相比具有以下积极效果：
（1）本发明制备的中频炉炉衬修补用可塑料采用了膨润土、羧甲基纤维素和聚丙烯酰胺作为复合型增塑剂，减少了细粉料的加入量，提高了修补料的可塑性。
（2）本发明采用2-丙烯酸胺基-2-甲基丙磺酸和草酸作为保湿剂，能有效延长可塑料的保存时间。
（3）本发明采用高铝矾土作为主要原料，其价格相对刚玉低廉，降低了生产成本。
（4）本发明采用的蓝晶石在高温下的莫来石化会伴随一定的体积膨胀，能有效的抵消可塑料在烧结过程中所产生的收缩。
因此，本发明生产成本低；所制备的中频炉炉衬修补用可塑料具有早期强度高、保存时间长、易于施工和使用性能优良的特点。
具体实施方式
下面结合具体实施方式对本发明做进一步的描述，并非对本发明保护范围的限制。
为避免重复，先将本具体实施方式所涉及的原料统一描述如下，实施例中不再赘述：
所述氧化铝粉的粒径级配是：粒径为0.044~0.023mm占氧化铝粉30～50wt%；粒径为5~2μm占所述氧化铝粉50～70wt%。
所述蓝晶石的粒径级配是：粒径为0.425~0.212mm占蓝晶石30～70wt%；粒径为0.088~0.044mm占蓝晶石30～70wt%。
所述氧化铬粉的粒径为0.2~8μm。
所述增塑剂为50wt%的膨润土、20wt%的羧甲基纤维素和30wt%的聚丙烯酰胺的混合物。
所述矾土颗粒的径级配是：粒径为5～3mm占矾土颗粒20～40wt%；粒径小于3mm且大于等于1mm占矾土颗粒10～50wt%；粒径小于1 mm且大于等于0.5mm占矾土颗粒10～30wt%；粒径小于0.5 mm且大于等于0.088mm占矾土颗粒10～45wt%。
所述缓蚀剂为60wt%的丙烯酸为和40wt%异丙烯膦酸的混合物。
实施例1
一种中频炉炉衬修补用可塑料及其制备方法。包括以下步骤：
以27～30wt%的氧化铝粉、12～16wt%的蓝晶石、3～5wt%的氧化铬粉、2～3wt%的增塑剂为基质料，以50～55wt%的矾土颗粒为骨料，基质料和骨料之和为原料；先将所述基质料在混料机中混合1~1.5h，再将所述骨料和混合后的基质料加入混碾机，外加所述原料3～5wt%的磷酸和3～5wt%的水，混碾8~10min，得到半干泥料。
将所述半干泥料装入密封容器中，困料24~48h，再将困料后的半干泥料加入混碾机中，外加所述原料2～3wt%的磷酸、0.05～0.15wt%的缓蚀剂、0.1～0.5wt%的保湿剂和3~5wt%的水，混碾5～8min，得到混碾泥料，将混碾泥料挤泥成型，制得中频炉炉衬修补用可塑料。
本实例中所述保湿剂为草酸。
实施例2
一种中频炉炉衬修补用可塑料及其制备方法。包括以下步骤：
以21～24wt%的氧化铝粉、18～20wt%的蓝晶石、2～4wt%的氧化铬粉、2～3wt%的增塑剂为基质料，以50～55wt%的矾土颗粒为骨料，基质料和骨料之和为原料；先将所述基质料在混料机中混合1~1.5h，再将所述骨料和混合后的基质料加入混碾机，外加所述原料3～5wt%的磷酸和3～5wt%的水，混碾8~10min，得到半干泥料。
将所述半干泥料装入密封容器中，困料24~48h，再将困料后的半干泥料加入混碾机中，外加所述原料2～3wt%的磷酸、0.05～0.15wt%的缓蚀剂、0.1～0.5wt%的保湿剂和3~5wt%的水，混碾5～8min，得到混碾泥料，将混碾泥料挤泥成型，制得中频炉炉衬修补用可塑料。
本实例中所述保湿剂为草酸。
实施例3
一种中频炉炉衬修补用可塑料及其制备方法。包括以下步骤：
以23～27wt%的氧化铝粉、11～14wt%的蓝晶石、3～5wt%的氧化铬粉、3～4wt%的增塑剂为基质料，以55～60wt%的矾土颗粒为骨料，基质料和骨料之和为原料；先将所述基质料在混料机中混合1~1.5h，再将所述骨料和混合后的基质料加入混碾机，外加所述原料3～5wt%的磷酸和3～5wt%的水，混碾8~10min，得到半干泥料。
将所述半干泥料装入密封容器中，困料24~48h，再将困料后的半干泥料加入混碾机中，外加所述原料2～3wt%的磷酸、0.05～0.15wt%的缓蚀剂、0.1～0.5wt%的保湿剂和3~5wt%的水，混碾5～8min，得到混碾泥料，将混碾泥料挤泥成型，制得中频炉炉衬修补用可塑料。
本实例中所述保湿剂为2-丙烯酸胺基-2-甲基丙磺酸。
实施例4
一种中频炉炉衬修补用可塑料及其制备方法。包括以下步骤：
以19～21wt%的氧化铝粉、16～18wt%的蓝晶石、2～4wt%的氧化铬粉、3～4wt%的增塑剂为基质料，以55～60wt%的矾土颗粒为骨料，基质料和骨料之和为原料；先将所述基质料在混料机中混合1~1.5h，再将所述骨料和混合后的基质料加入混碾机，外加所述原料3～5wt%的磷酸和3～5wt%的水，混碾8~10min，得到半干泥料。
将所述半干泥料装入密封容器中，困料24~48h，再将困料后的半干泥料加入混碾机中，外加所述原料2～3wt%的磷酸、0.05～0.15wt%的缓蚀剂、0.1～0.5wt%的保湿剂和3~5wt%的水，混碾5～8min，得到混碾泥料，将混碾泥料挤泥成型，制得中频炉炉衬修补用可塑料。
本实例中所述保湿剂为2-丙烯酸胺基-2-甲基丙磺酸。
实施例5
一种中频炉炉衬修补用可塑料及其制备方法。包括以下步骤：
以20～23wt%的氧化铝粉、10～13wt%的蓝晶石、3～7wt%的氧化铬粉、2～3wt%的增塑剂为基质料，以60～65wt%的矾土颗粒为骨料，基质料和骨料之和为原料；先将所述基质料在混料机中混合1~1.5h，再将所述骨料和混合后的基质料加入混碾机，外加所述原料3～5wt%的磷酸和3～5wt%的水，混碾8~10min，得到半干泥料。
将所述半干泥料装入密封容器中，困料24~48h，再将困料后的半干泥料加入混碾机中，外加所述原料2～3wt%的磷酸、0.05～0.15wt%的缓蚀剂、0.1～0.5wt%的保湿剂和3~5wt%的水，混碾5～8min，得到混碾泥料，将混碾泥料挤泥成型，制得中频炉炉衬修补用可塑料。
本实例中所述保湿剂为2-丙烯酸胺基-2-甲基丙磺酸和草酸的混合物。
实施例6
一种中频炉炉衬修补用可塑料及其制备方法。包括以下步骤：
以18～20wt%的氧化铝粉、10～13wt%的蓝晶石、3～5wt%的氧化铬粉、4～5wt%的增塑剂为基质料，以60～65wt%的矾土颗粒为骨料，基质料和骨料之和为原料；先将所述基质料在混料机中混合1~1.5h，再将所述骨料和混合后的基质料加入混碾机，外加所述原料3～5wt%的磷酸和3～5wt%的水，混碾8~10min，得到半干泥料。
将所述半干泥料装入密封容器中，困料24~48h，再将困料后的半干泥料加入混碾机中，外加所述原料2～3wt%的磷酸、0.05～0.15wt%的缓蚀剂、0.1～0.5wt%的保湿剂和3~5wt%的水，混碾5～8min，得到混碾泥料，将混碾泥料挤泥成型，制得中频炉炉衬修补用可塑料。
本实例中所述保湿剂为2-丙烯酸胺基-2-甲基丙磺酸和草酸的混合物。
本具体实施方式与现有技术相比具有以下积极效果：
（1）本具体实施方式制备的中频炉炉衬修补用可塑料采用了膨润土、羧甲基纤维素和聚丙烯酰胺作为复合型增塑剂，减少了细粉料的加入量，提高了修补料的可塑性。
（2）本具体实施方式采用2-丙烯酸胺基-2-甲基丙磺酸和草酸作为保湿剂，能有效延长可塑料的保存时间。
（3）本具体实施方式采用高铝矾土作为主要原料，其价格相对刚玉低廉，降低了生产成本。
（4）本具体实施方式采用的蓝晶石在高温下的莫来石化会伴随一定的体积膨胀，能有效的抵消可塑料在烧结过程中所产生的收缩。
（5）本具体实施方式中的各实施例制备的中频炉炉衬修补用可塑料的性能指标如表1所示，从表1可知，各项性能优良。
表1 各实施例的性能指标。
因此，本具体实施方式生产成本低；所制备的中频炉炉衬修补用可塑料具有早期强度高、保存时间长、易于施工和使用性能优良的特点。

Claims (9)

1.一种中频炉炉衬修补用可塑料的制备方法，包括以下步骤：
以18～30wt%的氧化铝粉、10～20wt%的蓝晶石、2～7wt%的氧化铬粉、2～5wt%的增塑剂为基质料，以50～65wt%的矾土颗粒为骨料，基质料和骨料之和为原料；先将所述基质料在混料机中混合1~1.5h，再将所述骨料和混合后的基质料加入混碾机，外加所述原料3～5wt%的磷酸和3～5wt%的水，混碾8~10min，得到半干泥料；
将所述半干泥料装入密封容器中，困料24~48h，再将困料后的半干泥料加入混碾机中，外加所述原料2～3wt%的磷酸、0.05～0.15wt%的缓蚀剂、0.1～0.5wt%的保湿剂和3~5wt%的水，混碾5～8min，得到混碾泥料，将混碾泥料挤泥成型，制得中频炉炉衬修补用可塑料。
2.根据权利要求1所述中频炉炉衬修补用可塑料的制备方法，其特征在于所述氧化铝粉的粒径级配是：粒径为0.044~0.023mm占氧化铝粉30～50wt%；粒径为5~2μm占所述氧化铝粉50～70wt%。
3.根据权利要求1所述中频炉炉衬修补用可塑料的制备方法，其特征在于所述蓝晶石的粒径级配是：粒径为0.425~0.212mm占蓝晶石30～70wt%；粒径为0.088~0.044mm占蓝晶石30～70wt%。
4.根据权利要求1所述中频炉炉衬修补用可塑料的制备方法，其特征在于所述氧化铬粉的粒径为0.2~8μm。
5.根据权利要求1所述中频炉炉衬修补用可塑料的制备方法，其特征在于所述增塑剂为50wt%的膨润土、20wt%的羧甲基纤维素和30wt%的聚丙烯酰胺的混合物。
6.根据权利要求1所述中频炉炉衬修补用可塑料的制备方法，其特征在于所述矾土颗粒的径级配是：粒径为5～3mm占矾土颗粒20～40wt%；粒径小于3mm且大于等于1mm占矾土颗粒10～50wt%；粒径小于1 mm且大于等于0.5mm占矾土颗粒10～30wt%；粒径小于0.5 mm且大于等于0.088mm占矾土颗粒10～45wt%。
7.根据权利要求1所述中频炉炉衬修补用可塑料的制备方法，其特征在于所述缓蚀剂为60wt%的丙烯酸为和40wt%异丙烯膦酸的混合物。
8.根据权利要求1所述中频炉炉衬修补用可塑料的制备方法，其特征在于所述保湿剂为2-丙烯酸胺基-2-甲基丙磺酸和草酸中的一种以上。
9.一种中频炉炉衬修补用可塑料，其特征在于所述中频炉炉衬修补用可塑料是根据权利要求1～8项中任意一项所述的中频炉炉衬修补用可塑料的制备方法所制备的中频炉炉衬修补用可塑料。
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