回轉(zhuǎn)窯用堿性磚第1頁/共29頁2Contents目錄

Rawmaterials原料Magnesia氧化鎂Properties特性SourcesandProduction來源及生產(chǎn)Typesofmagnesia氧化鎂的種類Qualitycriterias質(zhì)量標(biāo)準(zhǔn)

Spinels尖晶石礦物Spineltypes尖晶石的種類Flexibilizingeffect彈性效果Wedgesplittingtest楔形劈裂試驗

Productsandproperties火磚及其特性第2頁/共29頁3Magnesia氧化鎂

第3頁/共29頁4PropertiesofMgO氧化鎂MgO的特性highmeltingpointof2,800°C熔點(diǎn)高達(dá)2,800°C

(refractorinessdependsoftypeandquantityofsecondaryoxides)

(耐火度取決于氧化鎂的類型以及二次氧化物數(shù)量)

goodresistancetobasicslagandotherhot-chemicalattacks對堿性爐渣以及其他熱化學(xué)侵蝕具有良好的抵抗性highthermalconductivity導(dǎo)熱率高h(yuǎn)ighthermalexpansion熱膨脹率高poorthermalshockresistance抗熱震能力不足Improvement改善措施additionofa2ndlessexpansivecomponent“controlledinhomogeneousmicrostructure”添加另一種膨脹率小的組分,(形成）“可控的不均勻微觀結(jié)構(gòu)”Spinel尖晶石第4頁/共29頁5ProductionofMgOfrommagnesite

用菱鎂礦生產(chǎn)氧化鎂miningofmagnesite開采菱鎂礦Crushing破碎/sorting選礦Calcining煅燒+sintering燒結(jié)rotarykiln回轉(zhuǎn)窯

orshaftkiln立窯MgCO3 MgO+CO2magneticseparation磁選sinteredmagnesia燒結(jié)氧化鎂1600–1900°C第5頁/共29頁6Productionofsinteredmagnesiafromseawater

燒結(jié)海水氧化鎂的生產(chǎn)MgCl2+Ca(OH)2 Mg(OH)2+CaCl2Mg(OH)2 MgO+

H2O (Kauster)D~2g/cm3

Sintering燒結(jié)(1700–2000°C)D~3,4g/cm3orfusing電熔(2800°C)D~3,5g/cm31000°CBriquetting濾塊第6頁/共29頁7Rawmaterialmagnesia

氧化鎂原料

natural天然氧化鎂

synthetic合成氧化鎂:89-97% MgO 97,7-99,3%6-0,2% Fe2O3 0,5-0,1%1,5-0,1% Al2O3 <0,1%0,5-1,9% CaO 0,5-1,9%0,5-2,5% SiO2 <0,1-0,2%3,05-3,40g/cm3 bulkdensity容重

3,40-3,45g/cm3第7頁/共29頁8Qualitycriteria

質(zhì)量標(biāo)準(zhǔn)

ChemicalComposition化學(xué)成分

AmountofSecondaryPhases

SiO2,CaO,Fe2O3,Al2O3,MnO

二次相SiO2,CaO,Fe2O3,Al2O3,MnO的量CaO/SiO2ratio

鈣/硅比Boroncontent

硼含量PericlaseCrystalSize

方鎂石晶體尺寸BulkDensity/ApparentPorosity

容重/顯氣孔率第8頁/共29頁9Periclasecrystalsize

方鎂石晶體尺寸StandardSinteredmagnesia

標(biāo)準(zhǔn)燒結(jié)氧化鎂RD>3,38g/cm3Crystalsize:60–120μmFusedMagnesia電熔氧化鎂RD>3,38g/cm3Crystalsize:>500μm晶體尺寸：>500μmLargeCrystalSinteredMagnesia大晶體燒結(jié)氧化鎂RD>3,38g/cm3Crystalsize:+150μm第9頁/共29頁10SecondaryphasesofMgO

氧化鎂的二次相第10頁/共29頁11CaO/SiO2ratio

鈣硅(重量)比CaO/SiO2ratio鈣硅(重量)比Name名稱Formula分子式Short

NotationSm<11(0,94)1-1,51,5(1,4)1,5–22(1,87)>2PeriklasMgOM2840xxxxxxxMagnesiaferritMgFe2O4MF1715xxxxxxxSpinellMgAl2O4MA2135(x)(x)(x)(x)(x)(x)-ForsteritMg2SiO4M2S1890x------MonticellitCaMgSiO4CMS1492xxx----MerwinitCa3Mg[SiO4]2C3MS21575--xxx--DicalciumsilikatCa2SiO4C2S2130----xxxDicalciumferritCa2Fe2O5C2F1449------xBrownmilleritCa2FeAlO5C4AF1415------xCalciumaluminatCa3[AlO3]2C3A1535------(x)第11頁/共29頁12Spinelsasflexibilizers

尖晶石作為彈性改良劑第12頁/共29頁13Typesofspinels

尖晶石的種類AluminaSpinel氧化鋁尖晶石Ferritespinel鐵酸鹽尖晶石Chromiumspinel鉻尖晶石SpinelMgAl2O4鎂鋁尖晶石MagnesiaferriteMgFe2O4鎂鐵礦MagnesiochromiteMgCr2O4鎂鉻礦HercyniteFeAl2O4鐵鋁尖晶石MagnetiteFeFe2O4磁鐵礦ChromiteFeCr2O4鉻鐵礦GalaxiteMnAl2O4錳鋁尖晶石JakobsiteMnFe2O4錳鐵礦GahniteZnAl2O4鋅鋁尖晶石TrevoriteNiFe2O4A2+B23+O4A2+-IonsintetraedricalgapsA2+離子位于四面體間隙中CubicthightestpackingofO2—IonsO2-

離子立方緊密堆積B3+-IonsinoctaedricalgapsB3+離子位于八面體間隙中第13頁/共29頁14Chromite

鉻鐵礦Chromite鉻鐵礦

A2+B23+O4 A:Fe,Mg B:Cr,Fe,AlTypicalcompositionofchromiteforuseinrefractoryindustry:在耐火材料工業(yè)中使用的典型的鉻鐵礦成分SouthAfrica南非Turkey/Pakistan土耳其Cuba古巴Cr2O344,65532,2Fe2O328,216,414,8Al2O314,710,026,2SiO20,62,45,63第14頁/共29頁15MAspinel

鎂鋁尖晶石Spinel鎂鋁尖晶石

MgAl2O4In-situ:原位結(jié)合

additionoffusedalumina

orcalcinedalumina添加電熔氧化鋁或燒結(jié)氧化鋁 Pre-reacted:預(yù)制尖晶石sinteredspinelorfusedspinel燒結(jié)尖晶石或電熔尖晶石formationofMA-spinelduringfiring在燒成過程中形成鎂鋁尖晶石第15頁/共29頁16Hercynite,Galaxite–“ActiveSpinels”

鐵鋁尖晶石,錳鋁尖晶石-“活性尖晶石”Hercynite FeAl2O4

鐵鋁尖晶石

Galaxite MnAl2O4

錳鋁尖晶石

TypeHercynite鐵鋁尖晶石Galaxite錳鋁尖晶石BD密度4,24,2SiO20,110,13CaO0,180,15Fe2O347,051,23Mn2O349,23Al2O349,4746,34MgO1,851,56ProductionofhercyniteandgalaxiteviaelectrofusioninplantRadenthein在奧鎂Radenthein工廠，使用電熔方法生產(chǎn)鐵鋁尖晶石和錳鋁尖晶石第16頁/共29頁17Mechanismofconventionalspinels

傳統(tǒng)尖晶石的機(jī)理ForMAspinelbricks,theexpansionresultsfromthelowerthermalshrinkageofthespinelcomponentrelativetothemagnesiamatrixduringcooling(ThermalMisfit).Byacousticemissionmeasurements,microcrackformationcanbeobservedinatemperaturerangeofapp.900-200°C.對于鎂鋁尖晶石磚，由于鎂鋁尖晶石和氧化鎂膨脹率的不同，在冷卻期間，鎂鋁尖晶石相對于氧化鎂基質(zhì)較低的收縮率，會形成(熱錯位).通過聲學(xué)檢查，在溫度為900-200°C范圍，可觀察到微裂紋的形成。crackinitiationandcrackopeningduetothermalmisfit由于熱錯位，產(chǎn)生裂紋和裂縫firingcurve燒成曲線第17頁/共29頁18Activespinel

活性尖晶石?activespinel“developsadditionalflexibilityduringpracticalservicethroughdiffusionofFe2+andMg2+ions,evenwhenporesarefilledwithalkalinecompounds.“活性尖晶石”通過Fe2+

離子和Mg2+

離子的擴(kuò)散，在實(shí)際使用過程中可以產(chǎn)生額外的彈性，即使堿化合物充滿了(火磚的)孔隙。AlternativespineltechnologypatentedbyRHI

Refractories替代尖晶石技術(shù)是RHI奧鎂公司的專利activespinel活性尖晶石Magnesia氧化鎂diffusionzone擴(kuò)散區(qū)域MgOFeAl2O4第18頁/共29頁19Wedgesplittingtest

楔形劈裂試驗第19頁/共29頁20Forcevs.displacement

力對位移曲線圖structuralflexible結(jié)構(gòu)彈性好HighforceuntilcrackinitiationHighstoredelasticenergySpontaneouscrackpropagationSlowcrackpropagationthroughthewholesample—desirableBrittle脆位移力第20頁/共29頁21Excellentfracturemechanicalbehaviour

出色的斷裂機(jī)械性能Conv.Magnesia-Spinel-Brick傳統(tǒng)的鎂鋁尖晶石磚Magnesia-Herzynit-Brick鎂鐵尖晶石磚Magnesia-Galaxite-Brick鎂錳尖晶石磚位移力第21頁/共29頁22Rawmaterials–combinations–bricktypes

原料-組合–火磚類型ComponentA組分A

Resistor耐火主材料ComponentB組分B

Flexibilizer彈性改良劑80–95%5-20%MgOSynthetic合成原料Natural天然原料Chromite鉻鐵礦Spinel尖晶石Zirconia氧化鋯INSITU直接結(jié)合Duringburningprocess在燒制過程中:Corundum剛玉Tabularalumina片狀氧化鋁Calcinedalumina燒結(jié)氧化鋁Prefabricated預(yù)制Electrofusedorsintered電熔或燒結(jié)CaO*ZrO2ZrO2MA鎂鋁尖晶石Hercynite鐵鋁尖晶石Galaxite錳鋁尖晶石第22頁/共29頁23Typicalmicrostructureofrotarykilnbricks

回轉(zhuǎn)窯耐火磚典型的微觀結(jié)構(gòu)Reflectedlightmicroscopy20x()and100x()magnification.反光顯微照片20倍(上圖)及100倍(右圖)Sinteredmagnesia(1).Hercynite(2).Preparationresinfilledpores(3).燒結(jié)氧化鎂(1)，鐵鋁尖晶石(2)，制備樣品的樹脂(3)填充在孔隙中第23頁/共29頁24ProductoverviewplantDalian

奧鎂大連工廠產(chǎn)品第24頁/共29頁25Brickpropertiesoverview

耐火磚特性概況Standardsinteredmagnesia以標(biāo)準(zhǔn)燒結(jié)氧化鎂為原料制造的火磚Quality

品種Chromite鉻鐵礦MA-spinel鎂鋁尖晶石Hercynite鐵鋁尖晶石ANKRALSCANKRALRCANKRALRNHMANKRALZCCharacteristics特點(diǎn)

highselfcoatingreadiness

結(jié)窯皮能力強(qiáng)lowthermalconductivity

導(dǎo)熱率低highflexibility

彈性好limitedcorrosionresistance

抗化學(xué)侵蝕能力有限sensitivetoreducingconditions

對還原氣氛敏感l(wèi)imitedrefractoriness

耐火度有限highcorrosionresistance抗化學(xué)侵蝕能力強(qiáng)highflexibility

彈性好

highrefractoriness

耐火度高h(yuǎn)ighthermalconductivity

導(dǎo)熱率高insensitivetoreducing

operationconditions

對還原操作條件不敏感highcorrosionresistance抗化學(xué)侵蝕能力強(qiáng)

highflexibility彈性好

highrefractoriness

耐火度高lowerthermalconductivity

導(dǎo)熱率低highselfcoatingreadiness結(jié)窯皮能力強(qiáng)insensitivetoreducing

operationconditions

對還原操作條件不敏感Application應(yīng)用CBZ

withstablecoatingwithlowchemicalandthermalload,stableoperationconditions低化學(xué)和熱負(fù)荷，具有穩(wěn)定窯皮的主燒成帶，窯內(nèi)工況要穩(wěn)定。Liningareaswithoutstablecoatingincreasedchemicalandthermalload,reducingoperationconditions襯砌在窯皮不穩(wěn)定，化學(xué)和熱負(fù)荷高，還原氣氛區(qū)域Severeoperationconditions:

Liningareaswithoutstablecoating,highchemicalandthermalload,highmechanicalload,reducingoperationconditions襯砌在窯皮不穩(wěn)定，化學(xué)和熱負(fù)荷高,機(jī)械負(fù)荷高,還原氣氛區(qū)域第25頁/共29頁26Brickpropertiesoverview

耐火磚特性概況Highqualitysinteredmagnesia以高品質(zhì)燒結(jié)氧化鎂為原料制造的火磚Quality品種MA-spinel鎂鋁尖晶石Hercynite鐵鋁尖晶石ANKRALR1ANKRALR2ANKRALZ1Characteristics

特點(diǎn)

highestcorrosionresistance抗化學(xué)侵蝕能力強(qiáng)highflexibility

彈性好

highrefractoriness

耐火度高h(yuǎn)ighthermalconductivity

導(dǎo)熱率高insensitivetoreducing

operationconditions

對還原操作條件不敏感

highselfcoatingreadiness結(jié)窯皮能力強(qiáng)highestcorrosionresistance抗化學(xué)侵蝕能力強(qiáng)

highflexibility

彈性好highrefractoriness

耐火度高h(yuǎn)ighthermalconductivity

導(dǎo)熱率高insensitivetoreducing

operationconditions

對還原操作條件不敏感

Coatingrepellentbehaviour

具有排斥窯皮的特性

highestcorrosionresistance抗化學(xué)侵蝕能力強(qiáng)

highflexibility彈性好

highrefractoriness

耐火度高lowerthermalconductivity

導(dǎo)熱率低

highselfcoatingreadiness結(jié)窯皮能力強(qiáng)Application

應(yīng)用Mostsevereoperationconditions:

最惡劣的工況條件：Liningareaswithoutstablecoating,increasedchemicalandthermalload,reducingoperationconditions,clinkermel