锰渣与再生砖骨料制备免烧砖的性能及应用

锰渣与再生砖骨料均属于大宗固废,提升大宗固废利用率具有重要的环境效益和经济效益。本文利用锰渣、再生砖骨料等制备了免烧砖,探究了锰渣掺量对免烧砖各项性能的影响,且对其微观结构及有害物质浸出行为进行了分析。结果表明:制备的免烧砖外观质量优良,色泽均一,尺寸标准;结合强度要求和抗冻性要求,锰渣掺量不超过10%(质量分数)时,可制备出强度、耐水性和耐久性优异的MU20免烧砖,锰渣掺量不超过15%时,可制备出性能优异的MU15免烧砖;掺适量锰渣的免烧砖中形成了较多的钙矾石相,有利于强度发展。锰渣和再生砖骨料制备的免烧砖可以应用于人行道等市政工程,应用效果良好。研究结果可为锰渣低碳资源化利用以及生态砖制品的生产和应用提供技术支持。     

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.     

酚醛树脂加入量对钢包渣线再生镁碳砖性能的影响

利用钢包渣线用后镁碳砖再生料制备了钢包渣线再生镁碳砖,在再生料加入质量分数为80%的基础上,研究了酚醛树脂5323加入量(质量分数分别为3.25%、3.5%、3.75%、4.0%、4.25%)对再生镁碳砖致密度、强度和抗氧化性的影响。结果表明:1)随着酚醛树脂加入量的增加,200℃热处理后再生镁碳砖的致密度、常温耐压强度、常温抗折强度及高温抗折强度均增大,抗氧化性增强;2)随着酚醛树脂加入量的增加,900℃埋炭处理后试样的致密度增大,但当酚醛树脂加入量(w)达到4%后其致密度变化不大;3)再生镁碳砖中酚醛树脂加入量(w)以3.5%～4%为宜。     

Chemical corrosion mechanisms of magnesia–chromite and chrome-free refractory bricks by copper metal and anode slag

The penetration and corrosion resistance to copper and anode slag of six magnesia–chromite and six chrome-free refractory brick types were tested using static finger tests at a typical copper-refining temperature (1300 °C). The microstructures of the as-delivered and tested refractory types were investigated by means of electron-probe micro-analysis (EPMA) and scanning electron microscopy (SEM) techniques. The results showed that the overall wear rate of the fingers was very low, with the exception of the alumina-based brick made of fused corundum and magnesia–alumina spinel, and the magnesia-based brick made of sintered magnesia and zircon addition. In all refractory types new phases were formed as a result of slag-refractory interactions. Apart from the samples recovered from the copper zone of the latest generation of direct-bonded magnesia–chromite bricks, all the rest were completely infiltrated by copper and slag components (copper oxide, iron oxide, alumina and silica). However, the amount of infiltrated liquid in the chrome-free types was higher than in the magnesia–chromite bricks. Explanations are provided for the distinct infiltration behaviour. The results show that economically viable chrome-free refractory alternatives are still elusive for anode furnace linings.     

不同碳含量对镁碳砖性能的影响

研究了碳含量的变化对镁碳砖抗渣侵蚀性、抗氧化性能、高温抗折强度和热震稳定性的影响。研究结果表明：随碳含量增加,镁碳砖的体积密度、耐压强度降低;碳含量在6%~8%时,镁碳砖的高温抗折强度、热震稳定性、抗渣侵蚀性及抗氧化性能好;碳含量低,镁碳砖的抗渣侵蚀性降低;碳含量为14%时,镁碳砖的抗氧化性能最差。     

Post-mortem analysis of MgO–Al2O3–C bricks containing bauxite used in steel ladle walls

A serious problem with integrated masonry linings ladle was that the ladle wall bricks were difficult to be partially replaced. Thus, the service life of the ladle was determined by the properties of ladle wall bricks. In this study, the new generation of MgO–Al₂O₃–C bricks with bauxite aggregates was tested in a ladle lining of an integrated steel ladle for 103 cycles, and the corroded microstructure of the used brick was investigated. A multilayered structure of bauxite aggregates could be observed in the used brick, which inhibited the slag penetration along the boundary of the magnesia aggregates and reduced the degree of the aggregates fall off from the used bricks. Besides, during the process of slag penetration, bauxite aggregates could melt into the slag, which increased the viscosity of the slag and weakened the penetration ability of the slag. The MgO–Al₂O₃–C bricks with bauxite addition could improve the service life of the ladle to a certain extent.     

改性石墨对镁碳砖性能的影响

为了提高钢包渣线镁碳砖的使用寿命,将0~1%质量分数的改性石墨引入到钢包渣线用镁碳砖中,研究了其加入量对镁碳砖体积密度、显气孔率、常温耐压强度、热膨胀率和抗渣性的影响,并采用偏光显微镜分析了试样的显微结构。结果表明:引入少量改性石墨对镁碳砖的致密度略有负面影响,但改性石墨在高温下产生的体积膨胀能弥补砖的基质收缩和砖与砖之间的缝隙,从而提高镁碳砖的抗渣性;当改性石墨加入质量分数为0.8%时,镁碳砖中骨料与基质的缝隙最小,抗渣性最好。     

水泥工业用无铬碱性砖的发展情况

消除铬公害和在水泥窑内应用代用燃料促使白云石砖、尖晶石砖和镁锆砖组成的系列无铬碱性砖成功地替代着镁铬砖。当前无铬碱性砖还在不断开发和更新之中。     

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.     

The wear of magnesia refractories in electric furnaces for melting cast iron

Conclusions The wear of magnesia refractories, i. e., magnesite, perictase — spinel, and magnesite — chromite bricks and magnesite — phosphate mortar, in the walls of electric furnaces for melting cast iron is the result of the solution predominantly of the periclase crystals and to a lesser extent of the spinel in the lowbasicity ferrosilicate slag melt. Brick of the PShS type proved to be the most durable refractory. The use of high-alumina brick in the roof of the furnaces accelerates the wear of the magnesia bricks in the walls.To increase the durability of the lining of these furnaces trials should be carried out with an all-basic wall lining constructed of high-density PShSP-type brick on MF-1-type magnesite — phosphate mortar and a roof lining constructed of MKhS brick and the same mortar.Translated from Ogneupory, No. 4, pp. 44–49, April, 1976.     

Recycling industrial slags in production of fired clay bricks for sustainable manufacturing

Due to the production of industrial slags in massive amounts, there is a high demand for recycling these slags and avoiding their dumping in landfills. This article aims to recycle industrial slags in brick manufacturing and investigates the performance of fired clay bricks incorporating different kinds of industrial slags such as granulated blast furnace slag (GBS), ferrochromium slag (FCS), and steel slag (STS). For this purpose, two different dosages of slags (i.e., 10 and 20 wt % of clay) and two different firing temperatures (i.e., 1000 and 1100 ^oC) were considered. Various physical, mechanical, and durability tests were performed to evaluate the properties of bricks incorporating industrial slags. Results show that the compressive strength of the bricks incorporating industrial slags are well above the minimum compressive strength limits of bricks as per different building standards. The bricks incorporating industrial slag can be classified as load-bearing bricks for structural applications in accordance with the ASTM C469 standard. An increase in the porosity of bricks is observed with the addition of STS. However, reduced porosity is observed for bricks incorporating FCS and GBS than traditional bricks. Based on the water absorption and efflorescence test results, bricks incorporating industrial slags can be used as severe weather resistant bricks following ASTM C62 standard and slight efflorescence bricks per ASTM C67 standard. The amounts of heavy metals in the leachates of bricks are observed below the specified limits of the Environment Protection Authority. SEM images and EDS analysis of bricks are also supporting the results of this study. Based on the results, utilizing industrial slags in brick manufacturing can help recycle the abundant industrial wastes and develop the fired clay bricks with desired properties.     

A Retrospective Review of Alumina-magnesia-carbon Refractories

The residual expansion of in-situ spinel formation in using of alumina-magnesia-carbon(AMC)bricks monolizes the lining of steel-making ladles with the closure of their joints,which has been an effective solution avoiding washing out of the joints in ladle lining by the reduction of the penetration of liquid slag and molten steel.Alumina-magnesiacarbon refractories are overall reviewed,in terms of major raw materials,thermal evolution,corrosion and oxidation,and thermomechanical behavior,as well as type,addition and fraction of magnesia used.General commercial products contain 5%-10%MgO and 5%-10%C with a certain amount of metallic aluminum powder,which is believed to facilitate spinel formation at early stage of heating-up,although high magnesia containing AMC bricks are studied and used sometimes.With low ratio of Al₂O₃/C=12.9 and the carbon content of 6.4%C,AMC brick exhibits the highest corrosion resistance.It is important to determine the type,addition and fraction of magnesia used in AMC refractories for demonstrating high corrosion resistance and superior thermomechanical behavior.     

水泥窑用高性能镁铬砖的研制及应用

分析了普通镁铬砖在水泥窑上使用存在的不足之处。在原来普通镁铬砖工艺基础上引入特制的合成料,使制品的性能得到改善。高性能镁格砖在水泥窑上使用,寿命远远超过普通镁铬砖。     

Corrosion Resistance Mechanism of Magnesia Zirconia Brick to RH Furnace Slag

Magnesia zirconia brick containing 11 wt% zirconia was prepared with magnesia and monoclinic zirconia as starting materials in order to replace the chrome-containing materials for RH furnace.The corrosion resistance of magnesia zirconia brick and fused rebonded magnesia chrome brick (short for magnesia chrome brick) to high and low basicity slag of RH furnace was comparatively researched by rotary slag method and their slag resistance mechanisms were analyzed.The results show that:(1) because the reaction l...     

Service Results and Analysis of Fully Co—clinkered Magnesite—Chrome Brick in Slagline Area of VOD Vessel

Operating condition and service results of several tested bricks in slagline area of the VOD vessel are described,It has been shown that the fully co-clinkered magnesite chrome brikc is superior,followed by two-stage calcined magnesite-dolominte brick,preracted magnesite-chrome brick and one-stage calcined moagnesite-dolomite brick. Chemical and petrologial examination were carried out by conventional analysis and optical microscope respectively,The reason of damage of the tested bricks are discussed and described as follows:(1) MgO in brick is erosed and dissolved by slag to destroy structure of the direct bond;(2)slag penctrating into the brick and then reacting with it to from various belts leading to spalling;(3)reducing action of reucing agents;(4) vaporiztion of some composition in the brick at high temperature under vacuum causes reducing weight and increasing porosity and (5) serious machanic abrasion.Therefore,Some opinions on increasing lining life of VOD vessels are suggested.     

Corrosion behavior of carbon,Al2O3, and MgO refractories during the preparation of a Ti–Si–Al alloy via the aluminothermic reduction of a Ti-bearing blast-furnace slag

The extraction of Ti from Ti-bearing blast-furnace slag (TBFS) via aluminothermic reduction to prepare Ti–Si–Al alloy has several promising applications. However, the refractories of the furnace lining can dissolve into the molten slag and change the composition of the slag, not only shortening the life of the refractories, but also influencing the preparation of Ti–Si–Al alloys for industrial applications. The main purpose of this study was to explore the corrosion behavior of refractories (carbon, alumina, and magnesia bricks) and determine the most suitable refractories for the aluminothermic reduction of TBFS. Herein, for the first time, the dissolution equilibrium of refractories during the aluminothermic reduction of TBFS and its effect on aluminothermic reduction were revealed. The results revealed that the alumina and magnesia bricks were more effective for obtaining bulk Ti–Si–Al alloy and avoiding high mass loss of the Ti–Si–Al alloy compared to the carbon bricks. Furthermore, the corrosion of alumina and magnesia bricks increased with an increase in the content of the added CaO; however, the corrosion of the alumina bricks was more severe compared to the magnesia bricks. In addition, the largest extraction ratio of Ti (maximum value: 99.85%) was achieved when magnesia bricks were employed. The results of this study indicate that magnesia bricks are the optimal refractory for the preparation of Ti–Si–Al alloy via the aluminothermic reduction of TBFS. This work provides important experimental information for the industrial application of the aluminothermic reduction of TBFS in the preparation of Ti–Si–Al alloys.     

TiO_2对镁铬砖抗渣蚀性的影响

利用XRD分析和光学显微镜等测试手段 ,研究了添加TiO2 对镁铬砖抗渣蚀性的影响。结果表明 :炉渣中的CaO能分解镁铬砖中的二次尖晶石而使镁铬砖损毁 ,但加入TiO2 后 ,TiO2 能优先于尖晶石中的Cr2 O3与渣中CaO反应 ,生成高熔点的CaTiO3,从而抑制CaO对砖中镁铬尖晶石的分解 ,提高了镁铬砖的抗高钙渣渣蚀能力     

钢包渣线用超低碳MgO-MA-C砖的研制与应用

以高纯电熔镁砂、镁铝尖晶石微粉和纳米炭素为主要原料,分别加入总量为4%(质量分数)的硅粉、铝粉和硅粉-铝粉复合粉为防氧化剂,加入清洁的自来水混练均匀后,在500 t 摩擦压砖机上成型为碳质量分数小于1%的超低碳MgO-MA-C 标型砖试样.在对比各试样(包括普通MgO-C砖试样)的抗氧化性能、高温抗折强度、体积稳定性和抗渣性的基础上,对配方和生产工艺进行了优化,研制出了性能较好的超低碳(碳质量分数小于1%)MgO-MA-C砖.所研制砖在武钢200 t转炉钢包渣线区使用,平均使用次数达75次.     

Slag Resistance of Magnesite-chrome Brick Impregnated with Chrome-bearing Sols

Cr2O3 has eminent slag corrosion resistance.So,the magnesite-chrome brick is thought as an important refractory material used in RH refining furnace in the process of steel-making around the world.After chromebearing sots being prepared by sol-gel method,single sol (Cr(OH)3)and mixed sol(Mg(OH)2-Cr(OH)3)were impregnated into magnesite-chrome bricks by vacuum impregnation.The corrosion resistance of the impregnated bricks to silicon steel slag was studied by porosimetric analysis and fiactal dimension calculation.The results showed that the corrosion resistance of impregnated magnesite-chrome brick was better than that of the unimpregnated brick and the brick impregnated by MgSO4 solution,and the one which has surface-treated by Mg(OH)2-Cr(OH)3 sol was the best,mainly because of lower apparent porosity,smaller pores diameter and their smoother inner suoface.     

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。