CN113754450A - Corex炉出铁口高稳定性炮泥制备方法 - Google Patents
Corex炉出铁口高稳定性炮泥制备方法 Download PDFInfo
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Abstract
本发明公开了一种COREX炉出铁口高稳定性炮泥制备方法，将原料进行称量配比并混合，原料按正常生产炮泥的比例进行混合，在强制搅拌机中混匀搅拌3‑5min，保证充分的混合性，消除骨料与细粉之间存在的运行偏析；对混合后的物料搅拌足够时间，加入结合剂，结合剂的温度控制在25‑30℃，结合剂选用焦油和树脂复合的结合剂；采用轮碾机对结合后的炮泥进行碾压搅拌，碾压搅拌20‑25分钟，泥料的温度需控制于25‑30℃左右；炮泥挤出成型，将碾压搅拌好的炮泥倒入挤泥机进行挤出，塑料薄膜包装好的炮泥必须进行24～48h的合适的醒泥过程，以稳定结合剂与原料之间良好的侵润性，经过上述步骤生产的炮泥质量百分百成分为：Al2O325‑29%、SiO217‑21%、SiC 21‑26%、Si3N43‑7%、F.C 5‑7%。
Description
技术领域
本发明涉及一种COREX炉出铁口高稳定性炮泥制备方法。
背景技术
炮泥是用于封堵出铁口的一种可塑性耐火材料，高炉生产时出铁口每天都要重复多次打开和封堵。出铁时，炽热的铁水和熔渣流经出铁口，对炮泥产生物理化学反应和冲刷作用；出铁结束时，用泥炮将新炮泥压入出铁孔道，封住出铁口，防止铁水和熔渣流出，具有保护铁口区炉墙和炉底的作用。在高炉炉前出铁作业中，炮泥的功能如同阀门，要求炮泥维持出铁口孔道直径稳定，出铁速度均匀。随着炼铁技术的变革，非高炉冶炼技术逐步显现出技术优势，同比高炉的型化、冶炼强度的增加，非高炉冶炼系统实现了全氧的高效率冶炼，对炮泥的质量要求越来越高，而从环保的角度，炮泥在堵铁口时不冒烟，铁口周边气体中不含有害气体，从工艺安全的角度炮泥需要适应非高炉全氧高效率冶炼的技术特点。炮泥是由骨料、粉料、结合刑和液体组成的Al203-SiO2-SiC-C质材料，对炮泥性能的基本要求是，良好的塑性，挤出的泥料为致密泥柱，不发生断裂或松散；良好的润滑性，平稳挤入出铁孔内，不发生梗阻；在出铁孔处达到一定程度烧结，形成泥包，保护出铁口内侧衬体。
早期使用的炮泥，生产工艺简单，使用前一般用挤泥机挤成圆柱状泥块，使用时泥块放入泥炮中再挤压入出铁口内。炮泥用各种原料的配比波动较大，大部分是以焦粉、黏土：矾土熟料及焦油沥青为主要原料，加水搅拌而成的传统炮泥。这种炮泥一般体积密度小，耐渣铁侵蚀性差，在大中型高炉上使用时造成铁口深度不够，影响高炉正常生产，更不能满足非高炉熔融还原炼铁工艺的高效率冶炼安全要求。随着非高炉工艺全氧冶炼的大型化和长寿化，炮泥己从单纯的消耗性耐火材料向功能性耐火材料转变，不仅仅是封堵住铁口，而且还能保护炉缸区域的炉衬，从而延长熔融还原气化炉炉的寿命，同时也减少环境污染。
现代炼铁高炉对炮泥有如下要求：(1)易开口:需要出铁时，最终出尽渣铁。因此，炮泥必须具备良好的作业性能:出铁口内的炮泥能比较容易被钻通，以便及时出铁，炉炉前出铁作业的顺利进行。减轻炉前操作工人的劳动强度；(2)易封堵:确保高出铁过程结束后，应在短时间内将出铁口堵上，确保足够的打泥量，保持稳定的铁口深度；(3)良好的塑性:当炮泥堵任铁口时，炮泥应均匀地充满出铁口孔道，并在孔道内成型；(4)良好的粘合性:打入出铁口的新炮泥与孔内的旧炮泥有良好的粘合性，确保新、旧炮泥形成整体，防止因粘合不良产生缝原引起渗铁、渗渣，影响再次开铁口;(5)良好的烧结性:要求打入出铁口内的炮泥在低温、中温、高温三个温度阶段都能达到不同程度的烧结，及时封堵铁口，同时在炉缸内形成足够大的泥包，起到保护缸内衬砖的作用。所以，为使钢铁企业创造经济和环境效益，选择合适的处理工艺和利用途径来开发新型炮泥是十分必要和迫切的。文献检索：COREX炉是我公司在中国国内独有的铁矿石直接熔融还原铁技术。检索文献，未发现此类技术。
发明内容
本发明的目的在于提供一种COREX炉出铁口高稳定性炮泥制备方法，能够结合COREX炉铁水高温、高压、喷溅大的出铁条件，生产出一种可靠的高稳定性炮泥。
本发明采用的技术方案是：一种COREX炉出铁口高稳定性炮泥制备方法，制备步骤如下：步骤1：原料的粒度检查确定粉料与骨料的粒度合适，粉料能够作为结合剂的良好黏附基础材料； 步骤2：将原料进行称量配比并混合，并对批重进行控制混合称料，原料按正常生产炮泥的比例进行混合，在强制搅拌机中混匀搅拌3-5min，保证充分的混合性，消除骨料与细粉之间存在的运行偏析；步骤3：对混合后的物料搅拌足够时间，加入结合剂，结合剂用于各种原料的结合，结合剂的温度控制在25-30℃，结合剂选用焦油和树脂复合的结合剂；步骤4：搅拌碾泥，采用轮碾机对结合后的炮泥进行碾压搅拌，碾压搅拌20-25分钟，泥料的温度需控制于25-30℃左右；步骤5：炮泥挤出成型，将碾压搅拌好的炮泥倒入挤泥机进行挤出，炮泥呈条状均匀稳定挤出；步骤6：炮泥包装切割，在挤出的同时采用塑料薄膜包覆炮泥进行包装，随挤出的长度，采用切割设备对挤出包装好的炮泥进行切割分块以利于后期使用；步骤7：塑料薄膜包装好的炮泥必须进行24～48h的合适的醒泥过程，以稳定结合剂与原料之间良好的侵润性，该过程可进行炮泥放入尼龙袋进行打包；经过上述步骤生产的炮泥质量百分百成分为：Al2O3 25-29%、SiO2 17-21%、SiC 21-26%、Si3N4 3-7%、F.C 5-7%，在1200℃×3hr的条件下，本炮泥体积比重为2.26、显气孔率22.4%、抗弯强度11.9兆帕，抗压强度23.1兆帕。
本发明新型炮泥是树脂-焦油结合炮泥，用焦油作增塑剂，以酚醛树脂、沥青及无机磷酸盐作为结合剂。该新型炮泥具有树脂炮泥的早硬性及焦油炮泥的延伸铁口性，且减少了树脂的用量，降低了炮泥成本。其树脂为液状酚醛树脂加乌洛托品等硬化剂，也可以用液态甲阶酚醛树脂，或二者的混合物为结合剂。树脂的平均分子质量对炮泥的硬化速度有显著影响，平均分子质量越大，硬化速度越快，从而影响挤压作业。适合炮泥用酚醛树脂，通常为淡棕色透明液体，粘度30 PaS-50PaS(5℃-25℃)，体积密度为(25C时)1.21g/cm3，游离酚小于5%，游离甲醛小于0.9%，水分小于1.0%，固定碳占比40%-45%。炮泥成分中：(1)焦粉:焦粉耐高温、抗渣，透气性较好，与渣铁不易粘结，能起到炮泥快速干燥的作用，同时焦粉的气孔率高，导热性及导电性好，荷重变形温度高，抗渣、抗热震性稳定，使出铁口保持还原气氛，对碳化硅、碳化网格、碳素材料起保护作用。(2)碳化硅：碳化硅是人工合成的工业产品，将高纯度石英砂和石油住放入电阻炉内，置于1600-2500℃的高温下经过化学反应制成，其密度为3.17-3.37g/cm3，具有高导热率、高耐磨性和高温强度，热膨胀系数小，热震稳定性好，作为铁口炮泥的原料可以改善其抗熔渣侵蚀和抗冲刷能力。(3)刚玉:刚玉的密度为3.95-4.18g/cm3，软化温度较高(>1870℃)熔点高于2050℃，化学性质稳定，耐磨性较高，耐渣铁侵蚀性好，是优质的耐火材料。根据原料和加工方式的不同，分为电熔棕刚玉、电熔白刚玉及烧结刚玉，在炮泥中做粉料使用。(4)氮化硅:氮化硅(Si3N4)为人工合成的工业产品，无天然矿物。Si3N4与CO反应生成 Si0析出C，处于表面的Si3N与02反应生成Si02保护膜，有防止氧化的作用，炮泥中加入适量的 Si3N4可以提高炮泥的耐熔蚀和耐磨性能。(5)高铝骨料:在封堵出铁口的炮泥中，高铝骨料起骨架作用，属致密质耐火颗粒原料，粒径在3mm左右，耐火度达到1770℃。在保证一定的塑性前提下，其粒径越小越好。(6)黏土:黏土是由多种含水铝硅酸盐矿物组成的混合体，粒度1-2μm，在潮湿状态具有良好的塑性，是炮泥配料中不可缺少的材料，耐火度要求高于1580℃。(7)耐火材料添加剂:新型出铁口炮泥中还加有云母，用于改善不定性耐火材料的施工性能，用于改善炮泥的性能。耐火材料结合剂:用于强化耐火材料结合组织，使粉状或粒状耐火材料烧结起来并具有足够的强度。
本发明新型高炉炮泥质量优化的重要原因在于使用了 SiC、Si3N4、蓝晶石、绢云母、棕刚玉等。加入SiC及是利用其耐侵蚀、抗高温氧化和抗热震性能，解决全氧高效率冶炼后出铁温度剧烈波动造成铁口冲刷扩孔加剧问题;加蓝晶石是利用其高温影胀性控制线变化率，并且能增加炮泥的烧结强度，提高炮泥的耐用性；加绢云母是利用其含有钾、钠氧化物使烧成温度降低，使炮泥快干、速硬，同时还能增加炮泥的塑性；加入棕刚玉是利用其抗化学腐蚀性。
熔融还原炼铁技术采用全氧冶炼，其特点是炉温高，炉内压力和炉况波动大，冶炼条件与传统高炉没有可比性。八钢欧冶炉出铁时间延长达到150min以上，铁水温度最高可以达到1550℃，铁水流速最高可以达到12m/min以上，变化剧烈波动大，对铁口的浸蚀、冲刷剧烈，使得对出铁口的质量和泥质量提出了更高的要求。
我国成功年产100万吨，且持续生产的非高炉全氧熔融冶炼炉仅新疆八钢欧冶炉1台，设有出铁口有2个，平均每天出铁次数6-8次。最大日出铁量达到了4200t，出渣量达1680t，一次出铁速度在5.5～12.5t·min-¹，由于全氧冶炼的特点，最大出铁量达到20t·min-¹成为常规状态，出铁温度的前后波动达到了100℃，出铁温度同一炉可以从1480℃-1580℃变化，出铁时间大于150min。炮泥性能的优劣关系到高炉的生产与运行，如果炮泥质量不佳，就会产生各种问题，如断铁口、潮铁口、浅铁口等，甚至造成危害人身安全的事故。开发铁口孔径稳定、出铁均匀、铁口长深度，可提高还原炉的产量，减少耐火材料的消耗的高质量炮泥。本发明为还原炼铁炉欧冶炉开发的一种专用炮泥。主要指标见下表。
本发明新型炮泥质量和性能指标如下表所示：
本发明适用于同类型炼铁企业，新型铁口炮泥有适度的可塑性，可以方便炉前操作;气孔率适宜，便于排出水分和气体;体积稳定性较好，耐火度高，耐铁水和烟渣的冲剧和侵蚀，可以避免产生裂纹渗漏铁水，对于出铁口的维护有着非常重要的作用，对高炉的使用寿命起着重要的决定作用。新型炮泥容易钻孔，耐浸蚀，出铁时间长（可以达到1个小时以上），出铁平稳，同时炮泥对环境污染小，可以适应于同类企业的生产要求，并具有明显的经济效益、环境效益，有较高的实用价值和推广意义。
具体实施方式
一种COREX炉出铁口高稳定性炮泥制备方法，制备方法步骤如下：
步骤1：原料的粒度检查确定粉料与骨料的粒度合适，粉料能够作为结合剂的良好黏附基础材料；
步骤2：将原料进行称量配比并混合，并对批重进行控制混合称料，原料按正常生产炮泥的比例进行混合，在强制搅拌机中混匀搅拌3-5min，保证充分的混合性，消除骨料与细粉之间存在的运行偏析；
步骤3：对混合后的物料搅拌足够时间，加入结合剂，结合剂用于各种原料的结合，结合剂的温度控制在25-30℃，结合剂选用焦油和树脂复合的结合剂；
步骤4：搅拌碾泥，采用轮碾机对结合后的炮泥进行碾压搅拌，碾压搅拌20-25分钟，泥料的温度需控制于25-30℃左右；
步骤5：炮泥挤出成型，将碾压搅拌好的炮泥倒入挤泥机进行挤出，炮泥呈条状均匀稳定挤出；
步骤6：炮泥包装切割，在挤出的同时采用塑料薄膜包覆炮泥进行包装，随挤出的长度，采用切割设备对挤出包装好的炮泥进行切割分块以利于后期使用；
步骤7：塑料薄膜包装好的炮泥必须进行24～48h的合适的醒泥过程，以稳定结合剂与原料之间良好的侵润性，该过程可进行炮泥放入尼龙袋进行打包；
经过上述步骤生产的炮泥质量百分百成分为：Al2O3 25-29%、SiO2 17-21%、SiC21-26%、Si3N4 3-7%、F.C 5-7%，在1200℃×3hr的条件下，本炮泥体积比重为2.26、显气孔率22.4%、抗弯强度11.9兆帕，抗压强度23.1兆帕。
Claims (1)
1.一种COREX炉出铁口高稳定性炮泥制备方法，其特征在于制备步骤如下：步骤1：原料的粒度检查确定粉料与骨料的粒度合适，粉料能够作为结合剂的良好黏附基础材料； 步骤2：将原料进行称量配比并混合，并对批重进行控制混合称料，原料按正常生产炮泥的比例进行混合，在强制搅拌机中混匀搅拌3-5min，保证充分的混合性，消除骨料与细粉之间存在的运行偏析；步骤3：对混合后的物料搅拌足够时间，加入结合剂，结合剂用于各种原料的结合，结合剂的温度控制在25-30℃，结合剂选用焦油和树脂复合的结合剂；步骤4：搅拌碾泥，采用轮碾机对结合后的炮泥进行碾压搅拌，碾压搅拌20-25分钟，泥料的温度需控制于25-30℃左右；步骤5：炮泥挤出成型，将碾压搅拌好的炮泥倒入挤泥机进行挤出，炮泥呈条状均匀稳定挤出；步骤6：炮泥包装切割，在挤出的同时采用塑料薄膜包覆炮泥进行包装，随挤出的长度，采用切割设备对挤出包装好的炮泥进行切割分块以利于后期使用；步骤7：塑料薄膜包装好的炮泥必须进行24～48h的合适的醒泥过程，以稳定结合剂与原料之间良好的侵润性，该过程可进行炮泥放入尼龙袋进行打包；经过上述步骤生产的炮泥质量百分百成分为：Al2O3 25-29%、SiO2 17-21%、SiC 21-26%、Si3N4 3-7%、F.C 5-7%，在1200℃×3hr的条件下，本炮泥体积比重为2.26、显气孔率22.4%、抗弯强度11.9兆帕，抗压强度23.1兆帕。
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Application publication date: 20211207 |