废镁铬砖细粉的加入对镁质浇注料烧结性的影响

将水泥回转窑烧成带废镁铬砖经处理后制成细粉料,用它代替镁质浇注料中的镁砂原料,研究了废镁铬砖细粉的加入对SiO2微粉结合镁质浇注料烧结性的影响.结果表明:加入适量的废镁铬砖细粉对于提高镁质浇注料的烧结程度和强度均有作用 ,但加入量不能太多.本实验条件下加入量为8%时,其烧结性能良好.对高温烧后试样的SEM及XRD分析可知,由于废镁铬砖细粉的加入而生成的尖晶石固溶体是促进镁质浇注料烧结、增加其结构致密性的原因.     

废镁铬砖在镁质浇注料中的应用

将宝钢RH炉废镁铬砖和电熔镁砂均破碎成5～3mm、3～1mm、<1mm的粒度,添加3%的粒度<1μm的二氧化硅微粉,按照浇注料的生产工艺制备了镁铬浇注料,研究了废镁铬砖在镁质浇注料中的应用。结果表明:浇注料悬浮液的碱度可控制在pH值=7～9,用0.15%(质量分数,下同)的六偏磷酸钠为减水剂时,该悬浮液ζ电位的绝对值最大,悬浮液最稳定,分散性也最好。随着废镁铬砖加入量的降低,烘干、中温和高温处理后的耐压强度、抗折强度、体积密度均逐渐增大。废镁铬料添加量为36%的试样FM3的性能指标均达到了纯镁质浇注料M4的;试样FM3对渣的抗熔蚀性能要优于试样M4的。     

铝铬渣对用后镁铬砖制备镁铬浇注料性能的影响

为实现用后镁铬砖的综合利用,本文以用后镁铬砖回收料为主要原料制备镁铬质耐火浇注料,研究了铁合金厂铝铬渣对用后镁铬砖制备镁铬质耐火浇注料体积密度、显气孔率、常温耐压强度、热震稳定性及抗渣性的影响.结果表明:铝铬渣对用后镁铬砖制备镁铬浇注料具有一定的促烧结作用,随着铝铬渣加入量增加,烧后试样常温耐压强度增大.随着浇注料结构中原位尖晶石量增加,试样显气孔率增大,体积密度减小.当铝铬渣加入量为10％时,试样的热震稳定性最好,热震前后试样的常温耐压强度保持率为93.8％,试样具有较好抗渣侵蚀性能,侵蚀层结构稳定均匀.     

高性能镁尖晶石质浇注料的研制

以不同粒度的电熔镁砂(≤8、≤0.088 mm)和铝镁尖晶石细粉(≤0.088 mm)为主要原料,经振动成型制备了一系列镁尖晶石质浇注料试样,探讨了镁质结合剂和活性氧化铝微粉加入量(w)分别为1%、2%、3%、4%和5%时对浇注料试样分别经110、1 000和1 600℃热处理后物理性能的影响,并将优选的合适配方试样与RH炉用烧成镁尖晶石砖进行了常规物理性能、抗热震性能和抗渣性能比较。结果表明:当镁质结合剂加入量(w)由1%增至2%时,试样经不同温度处理后的强度显著增加;但当其加入量超过2%(w)后,试样经不同温度处理后的强度尤其是在1 450℃的高温抗折强度逐渐向相反的方向变化;当活性氧化铝微粉加入量(w)由1%增至3%,试样经110℃热处理后的强度下降较快,但经1 000和1 600℃热处理后的强度和线膨胀率及高温抗折强度却呈现增加的趋势;当加入量超过3%(w)后,试样的高温抗折强度开始下降。研制的镁尖晶石质浇注料经1 600℃处理后具有较高的致密度及骨料和基质间存在微细裂纹的特征,与烧成镁尖晶石砖相比,具有较好的抗热震性能、抗渣性能和较低的高温强度。     

再生废镁铬砖生产镁铬砖的试验研究

本文讨论当Cr2O3以电熔镁铬砂、铬铁矿及RH炉废镁铬砖3种形式引入并控制Cr2O3含量分别为6％、8％、12％和16％时,镁铬砖试样的各项理化性能.结果表明:加入废镁铬砖的试样的各项性能略低于加入电熔镁铬砂的试样,但与加入铬铁矿的试样相差不大,且其高温抗折强度均大于加入铬铁矿的试样.通过本试验说明,利用废镁铬砖生产的镁铬砖,可以替代直接结合镁铬砖,应用在水泥回转窑、有色金属冶炼及重烧镁砂竖窑等热工设备.     

锆英石和氧化铝加入量对镁质浇注料性能的影响

研究了锆荚石和氧化铝的加入量对镁质浇注料常温物理性能、热震稳定性、高温抗折强度（１４５℃,１ｈ）及抗渣性能的影响。结果表明：锆英石和氧化铝的加入均降低了镁质浇注料的常温强度,提高了其热震稳定性,但对高温抗折强度影响不大;适量锆英石和氧化铝的加入均能改善镁质浇注料的抗渣渗透性。     

碳化硼加入量对氧化镁-氮化硅铁浇注料力学性能的影响

以97烧结镁砂为主要原料,加入3%质量分数的氮化硅铁细粉,以硅微粉作为结合剂,研究了外加不同量碳化硼(其质量分数分别为0、0.1%、0.2%、0.3%、0.4%、0.5%)对镁质浇注料常温物理性能和高温力学性能的影响,并借助扫描电镜对浇注料的显微结构进行了分析。结果表明:随着碳化硼加入量的增加,浇注料烘干强度下降,中、高温处理后强度变大,高温抗折强度下降。原因在于碳化硼在加热过程中氧化产生液相,促进材料烧结,使得材料致密,冷态强度增大;而由于液相的产生降低了镁质材料的直接结合程度,使得高温抗折强度减小。     

铝镁尖晶石对镁质浇注料性能的影响

针对镁质浇注料在使用过程中抗渣渗透能力差,易剥落等问题,本实验加入铝镁尖晶石对镁质浇注料进行改性研究.实验分为两部分:先将镁砂细粉、镁质添加剂和铝镁尖晶石细粉等机压成型,进行高温热处理,研究其物相组成和显微结构;然后以电熔镁砂为骨料,电熔镁砂细粉、氧化铝微粉、铝镁尖晶石细粉和镁质添加剂为基质,按骨料:细粉=75∶25进行配制,研究铝镁尖晶石加入量对镁质浇注料性能的影响.结果表明:在镁质材料中引入尖晶石,能促进结构致密化;加入9％的铝镁尖晶石的浇注料试样显气孔率低,线变化率小,体积密度大,强度大,抗渣性能最好,由于镁铝尖晶石生成时体积膨胀,使得材料结构致密化;同时能有效吸收渣中CaO及FeOx等成分,减少渣的渗透作用,从而提高了浇注料的抗渣性能.     

氮化硅铁加入量对镁质浇注料力学性能的影响

以镁砂为主要原料,以硅微粉作为结合剂,研究了不同氮化硅铁加入量对镁质浇注料常温物理性能和高温力学性能的影响,借助X射线衍射仪、扫描电镜等对浇注料的物相和显微结构等进行了分析.结果表明:随着氮化硅铁加入量的增加,浇注料烘干强度下降,中温强度先变大后变小,在氮化硅铁加入量为3%时达到极值点,高温强度先增大后下降;热态抗折强度在氮化硅铁加入量为3%时达到最大.氮化硅铁在加热过程能部分氧化成二氧化硅,进而形成纤维状的镁橄榄石,增大强度;铁相物质能和方镁石固溶,促进烧结.     

氮化硅加入量对镁质浇注料力学性能的影响

以镁砂为主要原料,以硅灰为结合剂,研究了不同氮化硅加入量对镁质浇注料的常温物理性能和高温力学性能的影响,用X射线衍射仪、扫描电镜等对浇注料的物相和显微结构等进行了分析.结果表明:经110℃,24h烘干的浇注料的常温抗压和抗折强度随着氮化硅加入量的增加而降低;经1 200℃,3 h烧结后的浇注料的常温抗压和抗折强度随着氮化硅加入量的增加先升高后降低,并在氮化硅加入量为3%(质量分数,下同)时达到极值点;经高温(1 500℃,3 h)烧结后的浇注料的常温抗压和抗折强度随着氮化硅加入量的增加而降低;烘干后的浇注料的高温(1 400℃)抗折强度在氮化硅加入量为3%时达到最大.在加热过程中氮化硅的作用包括两方面:一方面能部分氧化成二氧化硅,进而形成纤维状的镁橄榄石,增大浇注料的强度;另一方面氮化硅保留下来妨碍烧结,导致浇注料的强度降低.     

Three bond modes of basic refractories used for Ruhrstahl Heraeus degassing process

Magnesia–spinel brick and unburnt periclase–spinel–Al brick are being employed as a substitution of traditional magnesia–chrome brick in the chromium-free campaign of lining materials in Ruhrstahl Heraeus (RH) degasser. These three materials are investigated, in terms of physical properties, corrosion resistance and flexibility by wedge splitting test. Tracking their physical alterations and chemical reactions through burning or heating, three bond modes are discovered. Magnesia–chrome brick is subject to a series of phase transformation with rising temperature to yield a liquid envelop around chromite-ore particles, to further form porous rim while liquid is gradually absorbed by surrounding magnesia and eventually to precipitate secondary chromite spinel lied between magnesia particles by thoroughly dissociating chrome ore. The precipitated chromite spinel functions as the featured bond that enhances hot strength and corrosion resistance to slag, and additionally liquid coexistence improves the flexibility. The direct bond mode of magnesia particles in magnesia–spinel brick endures slag penetration by immanent character of MgO. Spinel incorporation in magnesia effectively improves thermal shock resistance. Due to minor negative value of permanent linear change after reheating, further sintering (densifying) in using at high temperature would bring a risk of loosening and open joints of magnesia–spinel lining. While used in RH degasser, unburnt periclase–spinel–Al bricks undergo a miraculous process of metallic Al melting, gaseous AlN and AlON formation, MgAlON whiskers germination combined with gaseous Mg reduced, and micron-size whisker network bond domination in their matrix. Such a whisker-network bond renders the material a successful eco-friendly alternative to magnesia–chrome refractory.     

Reactions of Secondary Phases with Carbon in Magnesia‐Carbon Bricks

Despite the excellent thermochemical properties of magnesia carbon bricks, these exhibit one weak characteristic during their use: their carbothermally induced wear. Carbon has a high affinity to oxygen, which leads to a reaction between magnesia and carbon, forming gaseous products at very low oxygen partial pressures in the surrounding atmosphere. When magnesia carbon material is furthermore applied at negative pressures, the precited carbothermic reduction processes effect an internal decomposition or even degradation of the bricks. Mostly, high‐purity magnesia varieties (MgO ≥ 96 wt%) are used for the production of magnesia carbon bricks because the low‐melting calcium silicate secondary phases in magnesia impair the high‐temperature resistance of these bricks. The fundamental question if and to which extent secondary phases react with carbon and which impact they have on the carbothermally induced wear of bricks has been unsolved so far. The following paper presents which influence the mineral secondary phases, monticellite, merwinite, and belite that are most commonly occurring in magnesia, have on the carbothermally induced wear. The respective studies were conducted by means of thermogravimetric and microstructural analyses. The results of these studies show that monticellite in the MgO–C microstructure brings about an increase in weight loss on account of carbothermic reduction processes. On the contrary, belite and merwinite in the MgO–C structure do not exhibit any negative impact on the thermal stability of the microstructure.     

Slag Resistance of Refractories for Direct Reduction of Laterite Nickel Ores in Rotary Kilns

Aiming at prolonging the service life of refractories for direct reduction of laterite nickel ores in rotary kilns, the slag resistance of ten materials(corundum bricks, chrome corundum bricks, silicon nitride bonded silicon carbide bricks, high alumina silicon carbide bricks, high alumina bricks, magnesia chrome bricks, magnesium aluminate spinel bricks, spinel chrome corundum bricks, chrome corundum castables and magnesia alumina chrome composite spinel bricks) was evaluated by rotary slag tests, which simulate the service conditions in rotary kilns. The corroded residual bricks were analyzed by SEM and EDS. The results show that the magnesia alumina chrome composite spinel brick possesses the advantages of magnesium aluminate spinel bricks and chrome corundum bricks; MgO-rich spinel can absorb the penetrated ferric oxide, and forms a dense zeylanite layer, which prevents the penetration of the molten laterite nickel ores; therefore, it is an ideal lining of rotary kilns for direct reduction of laterite nickel ores.     

A Short Communication on Refractories as Kiln Lining along Various Thermal Zones in Pre-calcining Cement Rotary Kiln

Modern cement rotary kiln is often large in size while rotating in high speed. Thermal condition within a rotary kiln is rather complex,exerting severe thermal and chemical attack on refractory of its kiln lining. In the present paper,the cause that leads to refractory failure was analyzed; requirements for refractory to overcome such failure was discussed. Composites and properties of different refractories most often used as kiln lining were assessed,including magnesia-chrome bricks,magnesia spinel bricks, dolomite bricks, silicon carbide mullite bricks and castables etc. Recommendation was made for refractories with suitable composites and properties to be used as kiln lining in each specific zone to best counteract the severe thermal conditions. A cost-effective configuration was presented to assemble kiln lining for rotary kiln's different zones in line with the regulation at JC/T 2196-2013 "Specifications of refractory for cement rotary kiln". Chromite-free refractories with property of high endurance to thermal attack and corrosion are required to be used in modern Pre-calcining cement rotary kilns.     

Microstructural changes and evolutions of elastic properties versus temperature of alumina and alumina–magnesia refractory castables

This paper deals with the evolutions of thermo-mechanical properties of castable refractories versus temperature. The measured properties are mainly Young's modulus evaluated by a high temperature ultrasonic technique and thermal expansion followed by dilatometry. Materials are alumina-based low cement castables with a fraction of alumina eventually substituted by spinel or magnesia. The granularity of the different used raw materials is chosen by using a packing model, in order to reduce the final porosity in the hydrated state. The interpretation of results is carried out by considering the materials as composites, constituted of aggregates (size > 100 μm) into a matrix where most of chemical and phase transformations occur. By using two-phase analytical models, it is shown that the evolutions of thermo-elastic properties of castables can be qualitatively predicted from measurements performed in a matrix-equivalent simplified material. Moreover, considering the elastic properties after heat treatment, the castable with magnesia is comparable to the castable processed with synthetic spinel.     

镁锆砖和镁铬砖的抗RH炉渣侵蚀性对比

为取代RH炉用镁铬材料,以电熔镁砂为主原料,分别加入单斜锆、脱硅锆、单斜锆与脱硅锆的混合粉、锆英石制备了ZrO2质量分数分别为15%和20%的镁锆砖,并利用静态坩埚法对比研究了镁锆砖和镁铬砖的抗RH炉渣侵蚀性。结果表明:对于Al2O3含量高且碱度(CaO/SiO2比)大的RH炉渣,镁锆砖抗侵蚀性能优于镁铬砖的;镁锆砖的侵蚀机理是砖中的ZrO2与渣中的CaO迅速反应,形成高熔点物相CaZrO3,能堵塞砖中的孔隙而形成致密保护层,从而阻止钢渣对镁锆砖的进一步侵蚀;而镁铬砖的侵蚀机理是渣中的Al2O3、Fe2O3等R3 和镁铬尖晶石中Cr3 交换,渣与砖反应生成的镁铝尖晶石和镁铁尖晶石使得材料变性,同时由于体积效应使镁铬材料鼓胀开裂,从而导致镁铬砖的严重侵蚀。     

氧化镁—锆英石钢包浇注料的研制

以电熔镁砂和锆英石为原料,研制了氧化镁-锆英石钢包浇注料,并研究了锆英石加入量对浇注料性能的影响及热处理温度对浇注料强度的影响,同时对其机理进行了探讨.     

Effects of Chrome Oxide Concentrate Powder on Properties of Magnesia Composite Materials

The magnesia composite materials were prepared using fused magnesia,used magnesia chrome bricks, magnesium aluminate spinel, alumina powder and chrome oxide powder as starting materials. In order to improve the performance of magnesia composite material,the influence of chrome oxide concentrate powder on the properties of magnesia composite material was researched. The apparent porosity,bulk density,cold crushing strength,linear expansion and thermal shock resistance of the specimens were determined. The results show that adding chrome oxide concentrate promotes the formation of the composite phases of three kinds of spinel,which is beneficial to the thermal shock resistance. The magnesia chrome spinel can not be formed at high temperatures theoretically,but can dissolve in the magnesia composite material. Comprehensively,the optimal addition of chrome oxide concentrate is 10. 0 mass% for the magnesia composite materials.     

添加浮选镁砂颗粒和Al2O3细粉对方镁石-尖晶石砖性能的影响

以烧结镁砂、浮选镁砂、电熔镁铝尖晶石和煅烧Al₂O₃细粉为主要原料,以木质素磺酸钙为结合剂,经混练、成型、1 650℃烧成制备了方镁石-尖晶石砖,主要研究了以浮选镁砂颗粒替代普通烧结镁砂颗粒以及在此基础上外加不同量煅烧Al₂O₃细粉（质量分数分别为0、3%和5%）对方镁石-尖晶石砖性能的影响。结果表明：1)以浮选镁砂颗粒替代普通烧结镁砂颗粒制备的方镁石-尖晶石砖,显气孔率和常温耐压强度降低,体积密度、抗热震性、高温强度和高温韧性提高。2)在以浮选镁砂颗粒替代普通烧结镁砂颗粒制备的方镁石-尖晶石砖中,随着煅烧Al₂O₃细粉引入量的增多,显气孔率和常温耐压强度降低,体积密度、抗热震性、高温强度和高温韧性提高。