A self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors and its construction method.

Abstract

A self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors and its construction method are disclosed. The method involves preparing a certain amount of the self-healing reinforcing agent for the ceramic fiber rope used in the coke oven door frame protection plate according to the mass percentages of each component. Then, the self-healing reinforcing agent is injected into the interior of the ceramic fiber rope and applied to its surface using a grouting machine and surface patching method. This invention provides a self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors and its construction method, which improves the sealing performance of the ceramic fiber rope used in the coke oven door frame protection plate during service, reduces the risk of sealing failure after service, and offers advantages such as advanced technology and energy conservation and environmental protection.

Description

Technical Field

[0001] This invention belongs to the field of self-healing technology of fiber materials. Specifically, it is a ceramic fiber rope self-healing reinforcing agent for coke oven doors and its construction method. Background Technology

[0002] Coke ovens are the most important and crucial equipment in the coking industry. They are being developed towards larger scale, greater intelligence, and environmental friendliness and energy conservation, and are equipped with complete sets of dust collection and removal equipment. However, in actual production, these devices struggle to comprehensively collect all the smoke and dust emitted during the coking process. Furthermore, as coke ovens are typically designed for a lifespan of over 20 years, problems inevitably arise after prolonged service, such as smoke emanating from the oven head and around the oven doors. The cause of this smoke is generally believed to be the instantaneous pressure rise in the carbonization chamber immediately after coal is charged, which subjects the oven head and around the oven doors to instantaneous pressure. This causes the ceramic fiber ropes used for the protective plates and oven door frames to loosen, allowing gas to escape from the carbonization chamber. In older coke ovens, the ceramic fiber ropes used for the oven door frame protective plates are prone to burning and carbonization after prolonged exposure to high temperatures, significantly reducing their elasticity and strength, making gas escape even more noticeable, and resulting in visible smoke emanating from the oven head and around the oven doors. In existing research, Chinese patent CN105237001B discloses a dry quenching coke oven castable for in-situ generation of aluminum nitride, using 45-65 wt% mullite, 2-8 wt% aluminum powder, 0-5 wt% aluminum-silicon alloy powder, 0-2 wt% elemental silicon powder, 4-6 wt% α-alumina micropowder, 2-4 wt% silica micropowder, and 4-6 wt% calcium aluminate cement as raw materials, with 0.1-0.3 wt% catalyst and 0.1-0.3 wt% water-reducing agent as additives; Patents CN117720338A, CN104098345B, and CN106145907A disclose the use of silica sol as a binder added to a repair and reinforcing agent; and US patent US20110250436A1 discloses a method for forming a ceramic coating and the resulting ceramic coating and structure, and accordingly discloses the following technical features: ceramic fibers of micron and submicron size dispersed in an aluminosilicate matrix, wherein the preferred ceramic fiber materials include alumina and silicon dioxide.

[0003] The above methods are usually used for casting refractory castables. There is also a method of spraying a coating on the surface of ceramic fiber products. The coating layer protects the ceramic fiber products from direct contact with high temperature, thereby improving the shape stability and resistance to powdering and peeling of the ceramic fiber products, and thus extending the service life of the fiber products.

[0004] However, such methods are currently commonly used for refractory fiber linings that are not subjected to external forces. Ceramic fiber rope is a type of fiber product that, in addition to the characteristics of conventional ceramic fiber products, also possesses advantages such as high strength, good toughness, and strong plasticity. It is often used for curtains or furnace door seals in industrial furnaces. The working environment of ceramic fiber rope means that it is frequently subjected to compression and alternating hot and cold impacts. Therefore, the aforementioned coating is not suitable for enhancing the anti-pulverization ability of ceramic fiber rope. Moreover, a common measure to suppress smoke emission is to perform hot patching in this area. However, it is difficult for the sealing material to use the fiber rope as a fixing surface, and the ceramic fiber rope used for coke oven door frame protection plates is often subjected to compression and alternating hot and cold impacts when the furnace door is opened and closed, making it difficult to achieve the expected sealing effect after patching. The use of ceramic fiber rope for coke oven door frame protection plates involves energy conservation and environmental protection issues related to coke ovens. However, in practical applications, patching or replacing with new fiber rope is often used, which not only affects production but is also not conducive to energy conservation and emission reduction. Ceramic fiber rope is a type of fiber product that shares the thermal insulation and stress-absorbing properties of conventional ceramic fiber products. However, over time, problems may arise such as roughening of the ceramic fiber surface, decreased elasticity, and reduced thermal insulation performance. This is because the fine crystals in the fiber product gradually grow or undergo crystal transformation, causing changes in fiber volume. When the growth of fine crystals or the accumulation of crystal transformation reaches a certain level, the increased stress generated by the volume change within the fiber leads to fiber breakage or even complete pulverization.

[0005] Therefore, the known structural forms of ceramic fiber ropes have the aforementioned inconveniences and problems. Summary of the Invention

[0006] The purpose of this invention is to propose a ceramic fiber self-healing reinforcing agent with different raw material types, and more importantly, different raw material particle sizes and functions. The raw material is in fine powder form (particle size less than 0.09 mm), and there is no need to waterproof the aluminum-silicon alloy powder. The purpose is twofold: firstly, to utilize the gas generated by the hydration reaction of the aluminum-silicon alloy powder (as shown in Formula 1, mainly the reaction between aluminum and water in the aluminum-silicon alloy to generate gas), allowing the pores created by the escaping gas to form a loose structure in the ceramic fiber rope self-healing reinforcing agent, thus facilitating the maintenance of the internal spatial structure of the ceramic fiber rope. Secondly, to maintain the spatial structure of the fiber rope, it is necessary to enable the incompletely hydrated aluminum-silicon alloy powder to generate ceramic fibers under the action of a catalyst within the operating temperature range, achieving self-healing of the fiber rope. Furthermore, there is no need for strict regulations on the atmospheric environment; that is, the operating atmosphere of the ceramic fiber rope self-healing reinforcing agent in this invention is the same as the operating atmosphere of the fiber rope.

[0007] Al + H2O → AlOOH + H2 (Formula 1) Another objective of this invention is to provide a construction method for a ceramic fiber rope for a coke oven door frame protection plate that enhances its self-healing properties and a ceramic fiber rope self-healing reinforcing agent for a coke oven door that extends its service life.

[0008] To achieve the above objectives, the technical solution of the present invention is: a self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, characterized in that it is made from the following components in the indicated mass percentages: 40-65 wt% mullite powder, 15-25 wt% alumina micro powder, 2-8 wt% aluminum-silicon alloy powder, 2-10 wt% kyanite powder, 10-16 wt% silica micro powder, 1-5 wt% chopped fiber, 2-5 wt% calcium aluminate cement, 1-3 wt% ball clay, 0.1-0.3 wt% catalyst, 0.1-0.3 wt% water-reducing agent, 20-40 wt% added silica sol, and 10-40 wt% added water.

[0009] The self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors of the present invention can be further implemented by the following technical measures.

[0010] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the mullite powder is sintered mullite powder or electrofused mullite powder.

[0011] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the mullite powder has a particle size of ≤0.088mm.

[0012] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the alumina micropowder has a particle size of ≤5μm.

[0013] The aforementioned self-healing reinforcing agent for ceramic fiber rope used in coke oven doors, wherein the silicon content of the aluminum-silicon alloy powder is ≥2% and the particle size of the aluminum-silicon alloy powder is ≤0.045mm.

[0014] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the kyanite powder has a particle size ≤0.88mm.

[0015] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the silicon micropowder contains ≥92% SiO2 and has a particle size of ≤0.6μm.

[0016] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the chopped fibers are selected from one or more of chopped alumina ceramic fibers, chopped steel fibers, and chopped mullite fibers.

[0017] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the diameter of the chopped fibers is ≤40μm and the length of the chopped fibers is ≤5mm.

[0018] The aforementioned ceramic fiber rope self-healing reinforcing agent for coke oven doors, wherein the ball clay particle size is ≤0.044mm.

[0019] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the catalyst is selected from one or more of nano-iron powder, nano-nickel powder, and nano-cobalt powder.

[0020] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the water-reducing agent is selected from one or more of sodium tripolyphosphate and sodium hexametaphosphate among inorganic water-reducing agents.

[0021] The aforementioned self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, wherein the silica sol is an alkaline silica sol with a SiO2 content of 20-30% and a particle size of ≤580nm.

[0022] A method for applying a self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, characterized by the following steps: a. Remove the furnace door of the coke oven carbonization chamber; b. Temporary insulation measures to seal the furnace opening of the carbonization chamber; c. Clean the tar and residual sealant from the area of ​​the furnace door frame protective plate; d. Use compressed air to purge and clean the surface of the ceramic fiber rope sealing the furnace door frame, protective plate, and furnace body; e. Grouting machine is used to grout the inside of the coke oven door frame protection plate with ceramic fiber rope, and the grouting position interval is 350-500mm; f. Use ceramic fiber rope to patch the protective plate of the coke oven door frame. Press down for 3-5 seconds before removing the trowel. g. Remove temporary insulation measures; h. Install the removed coke oven carbonization chamber door.

[0023] The self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors and its construction method of the present invention can be further realized by the following technical measures.

[0024] In the aforementioned method, the grouting needle of the grouting machine has an inner diameter of ≤6mm and a length of ≥50mm.

[0025] In the aforementioned method, the grouting pressure of the grouting machine is 20–60 MPa.

[0026] After adopting the above technical solution, the ceramic fiber rope self-healing reinforcing agent for coke oven doors and its construction method of the present invention have the following advantages: 1. Improve the sealing performance of ceramic fiber ropes used in the protective plates of coke oven door frames during service; 2. Reduce the risk of seal failure of ceramic fiber rope used in coke oven door frame protection plates after service; 3. Advanced technology, energy-saving and environmentally friendly. Attached Figure Description

[0027] Figure 1 SEM image of the formation of fibers from aluminum-silicon alloy at 1000℃.

[0028] Figure 2 TEM images and energy dispersive spectroscopy analysis of the formation of fibers from aluminum-silicon alloys at 1000℃. Detailed Implementation

[0029] The present invention will be further illustrated below through specific embodiments. Example

[0030] A self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection panels and its construction method: First, a certain amount of self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is prepared according to the mass percentage of each component. Then, the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is injected into the interior of the ceramic fiber rope and patched onto the surface of the ceramic fiber rope using a grouting machine and surface patching construction method.

[0031] The mass percentages of each component in the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plates are as follows: 45wt% mullite powder, 25wt% alumina micro powder, 7wt% aluminum-silicon alloy powder, 3wt% kyanite powder, 14wt% silica micro powder, 2wt% chopped fiber, 2wt% calcium aluminate cement, 2wt% ball clay, 0.1% nano cobalt powder catalyst, and 0.15wt% sodium tripolyphosphate water-reducing agent. The amount of added silica sol is 20wt%, and the amount of added water is 30wt%.

[0032] in: The inner diameter of the grouting needle of the grouting machine is ≤6mm, and the length is ≥50mm; The grouting pressure of the grouting machine is 20-60 MPa; The construction steps of the self-healing reinforcing agent for ceramic fiber rope used in the coke oven door frame protection plate of the present invention are as follows: Step 1: Remove the furnace door of the coke oven carbonization chamber; Step two: Temporary insulation measures are used to seal the furnace opening of the carbonization chamber; Step 3: Clean the tar and residual sealant from the furnace door frame protective plate area; Step 4: Use compressed air to purge and clean the surface of the ceramic fiber rope that seals the furnace door frame, protective plate, and furnace body. Step 5: Grouting machine injects grout into the inside of the coke oven door frame protection plate using ceramic fiber rope, with grouting positions spaced 350-500mm apart; Step 6: Use ceramic fiber rope to patch the protective plate of the coke oven door frame. Press down for 3-5 seconds before removing the trowel. Step 7: Remove the temporary insulation measures; Step 8: Install the removed coke oven carbonization chamber door. Example

[0033] A self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection panels and its construction method: First, prepare a certain amount of self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection panels according to the mass percentage of each raw material. Then, use a grouting machine and surface patching construction method to inject the self-healing reinforcing agent into the interior of the ceramic fiber rope used in coke oven door frame protection panels and patch it onto the surface of the ceramic fiber rope used in coke oven door frame protection panels.

[0034] The mass percentages of each raw material in the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plates are as follows: The mixture contains 52 wt% mullite powder, 20 wt% alumina micro powder, 4 wt% aluminum-silicon alloy powder, 6 wt% kyanite powder, 12 wt% silica micro powder, 2 wt% chopped fiber, 3 wt% calcium aluminate cement, 1 wt% spherical clay, 0.1 wt% nano cobalt powder catalyst, and 0.15 wt% sodium tripolyphosphate water-reducing agent. The amount of added silica sol is 27 wt%, and the amount of added water is 20 wt%.

[0035] in: The inner diameter of the grouting needle of the grouting machine is ≤6mm, and the length is ≥50mm; The grouting pressure of the grouting machine is 20-60 MPa; The construction steps of the self-healing reinforcing agent for ceramic fiber rope used in the coke oven door frame protection plate of the present invention are as follows: Step 1: Remove the furnace door of the coke oven carbonization chamber; Step two: Temporary insulation measures are used to seal the furnace opening of the carbonization chamber; Step 3: Clean the tar and residual sealant from the furnace door frame protective plate area; Step 4: Use compressed air to purge and clean the surface of the ceramic fiber rope that seals the furnace door frame, protective plate, and furnace body. Step 5: Grouting machine injects grout into the inside of the coke oven door frame protection plate using ceramic fiber rope, with grouting positions spaced 200-350mm apart; Step 6: Use ceramic fiber rope to patch the protective plate of the coke oven door frame. Press down for 3-5 seconds before removing the trowel. Step 7: Remove the temporary insulation measures; Step 8: Install the removed coke oven carbonization chamber door. Example

[0036] A self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection panels and its construction method: First, a certain amount of self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is prepared according to the mass percentage of each component. Then, the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is injected into the interior of the ceramic fiber rope and patched onto the surface of the ceramic fiber rope using a grouting machine and surface patching construction method.

[0037] The mass percentages of each raw material in the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plates are as follows: The mixture contains 56 wt% mullite powder, 15 wt% alumina micro powder, 2 wt% aluminum-silicon alloy powder, 9 wt% kyanite powder, 10 wt% silica micro powder, 3 wt% chopped fiber, 4 wt% calcium aluminate cement, 1 wt% spherical clay, 0.1 wt% nano-nickel powder catalyst, and 0.15 wt% sodium tripolyphosphate water-reducing agent. The amount of added silica sol is 33 wt%, and the amount of added water is 15 wt%.

[0038] in: The inner diameter of the grouting needle of the grouting machine is ≤6mm, and the length is ≥50mm; The grouting pressure of the grouting machine is 20-60 MPa; The construction steps of the self-healing reinforcing agent for ceramic fiber rope used in the coke oven door frame protection plate of the present invention are as follows: Step 1: Remove the furnace door of the coke oven carbonization chamber; Step two: Temporary insulation measures are used to seal the furnace opening of the carbonization chamber; Step 3: Clean the tar and residual sealant from the furnace door frame protective plate area; Step 4: Use compressed air to purge and clean the surface of the ceramic fiber rope that seals the furnace door frame, protective plate, and furnace body. Step 5: Grouting machine injects grout into the inside of the coke oven door frame protection plate using ceramic fiber rope, with grouting positions spaced 100-200mm apart; Step 6: Use ceramic fiber rope to patch the protective plate of the coke oven door frame. Press down for 3-5 seconds before removing the trowel. Step 7: Remove the temporary insulation measures; Step 8: Install the removed coke oven carbonization chamber door. Example

[0039] A self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection panels and its construction method: First, a certain amount of self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is prepared according to the mass percentage of each component. Then, the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is injected into the interior of the ceramic fiber rope and patched onto the surface of the ceramic fiber rope using a grouting machine and surface patching construction method.

[0040] The mass percentages of each raw material in the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plates are as follows: The mixture contains 40 wt% mullite powder, 15 wt% alumina micro powder, 8 wt% aluminum-silicon alloy powder, 8 wt% kyanite powder, 16 wt% silica micro powder, 5 wt% chopped fiber, 5 wt% calcium aluminate cement, 3 wt% spherical clay, 0.1 wt% nano-nickel powder catalyst, and 0.1 wt% sodium tripolyphosphate water-reducing agent. The amount of added silica sol is 20 wt%, and the amount of added water is 10 wt%.

[0041] in: The inner diameter of the grouting needle of the grouting machine is ≤6mm, and the length is ≥50mm; The grouting pressure of the grouting machine is 20-60 MPa; The construction steps of the self-healing reinforcing agent for ceramic fiber rope used in the coke oven door frame protection plate of the present invention are as follows: Step 1: Remove the furnace door of the coke oven carbonization chamber; Step two: Temporary insulation measures are used to seal the furnace opening of the carbonization chamber; Step 3: Clean the tar and residual sealant from the furnace door frame protective plate area; Step 4: Use compressed air to purge and clean the surface of the ceramic fiber rope that seals the furnace door frame, protective plate, and furnace body. Step 5: Grouting machine injects grout into the inside of the coke oven door frame protection plate using ceramic fiber rope, with grouting positions spaced 100-200mm apart; Step 6: Use ceramic fiber rope to patch the protective plate of the coke oven door frame. Press down for 3-5 seconds before removing the trowel. Step 7: Remove the temporary insulation measures; Step 8: Install the removed coke oven carbonization chamber door. Example

[0042] A self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection panels and its construction method: First, a certain amount of self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is prepared according to the mass percentage of each component. Then, the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is injected into the interior of the ceramic fiber rope and patched onto the surface of the ceramic fiber rope using a grouting machine and surface patching construction method.

[0043] The mass percentages of each raw material in the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plates are as follows: The mixture contains 45 wt% mullite powder, 17.5 wt% alumina micro powder, 5.5 wt% aluminum-silicon alloy powder, 10 wt% kyanite powder, 12.5 wt% silica micro powder, 4 wt% chopped fiber, 3 wt% calcium aluminate cement, 2.5 wt% spherical clay, 0.15 wt% nano-nickel powder catalyst, and 0.15 wt% sodium tripolyphosphate water-reducing agent. The amount of added silica sol is 25 wt%, and the amount of added water is 17.5 wt%.

[0044] in: The inner diameter of the grouting needle of the grouting machine is ≤6mm, and the length is ≥50mm; The grouting pressure of the grouting machine is 20-60 MPa; The construction steps of the self-healing reinforcing agent for ceramic fiber rope used in the coke oven door frame protection plate of the present invention are as follows: Step 1: Remove the furnace door of the coke oven carbonization chamber; Step two: Temporary insulation measures are used to seal the furnace opening of the carbonization chamber; Step 3: Clean the tar and residual sealant from the furnace door frame protective plate area; Step 4: Use compressed air to purge and clean the surface of the ceramic fiber rope that seals the furnace door frame, protective plate, and furnace body. Step 5: Grouting machine injects grout into the inside of the coke oven door frame protection plate using ceramic fiber rope, with grouting positions spaced 100-200mm apart; Step 6: Use ceramic fiber rope to patch the protective plate of the coke oven door frame. Press down for 3-5 seconds before removing the trowel. Step 7: Remove the temporary insulation measures; Step 8: Install the removed coke oven carbonization chamber door. Example

[0045] A self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection panels and its construction method: First, a certain amount of self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is prepared according to the mass percentage of each component. Then, the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is injected into the interior of the ceramic fiber rope and patched onto the surface of the ceramic fiber rope using a grouting machine and surface patching construction method.

[0046] The mass percentages of each raw material in the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plates are as follows: The mixture contains 50 wt% mullite powder, 20 wt% alumina micro powder, 5 wt% aluminum-silicon alloy powder, 6 wt% kyanite powder, 11 wt% silica micro powder, 3 wt% chopped fiber, 3 wt% calcium aluminate cement, 2 wt% spherical clay, 0.2 wt% nano-nickel powder catalyst, and 0.2 wt% sodium tripolyphosphate water-reducing agent. The amount of added silica sol is 30 wt%, and the amount of added water is 25 wt%.

[0047] in: The inner diameter of the grouting needle of the grouting machine is ≤6mm, and the length is ≥50mm; The grouting pressure of the grouting machine is 20-60 MPa; The construction steps of the self-healing reinforcing agent for ceramic fiber rope used in the coke oven door frame protection plate of the present invention are as follows: Step 1: Remove the furnace door of the coke oven carbonization chamber; Step two: Temporary insulation measures are used to seal the furnace opening of the carbonization chamber; Step 3: Clean the tar and residual sealant from the furnace door frame protective plate area; Step 4: Use compressed air to purge and clean the surface of the ceramic fiber rope that seals the furnace door frame, protective plate, and furnace body. Step 5: Grouting machine injects grout into the inside of the coke oven door frame protection plate using ceramic fiber rope, with grouting positions spaced 100-200mm apart; Step 6: Use ceramic fiber rope to patch the protective plate of the coke oven door frame. Press down for 3-5 seconds before removing the trowel. Step 7: Remove the temporary insulation measures; Step 8: Install the removed coke oven carbonization chamber door. Example

[0048] A self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection panels and its construction method: First, a certain amount of self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is prepared according to the mass percentage of each component. Then, the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is injected into the interior of the ceramic fiber rope and patched onto the surface of the ceramic fiber rope using a grouting machine and surface patching construction method.

[0049] The mass percentages of each raw material in the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plates are as follows: 57wt% mullite powder, 25wt% alumina micro powder, 2wt% aluminum-silicon alloy powder, 2wt% kyanite powder, 10wt% silicon micro powder The mixture contains 1 wt% chopped fiber, 2 wt% calcium aluminate cement, 1 wt% spherical clay, 0.25 wt% nano-nickel powder catalyst, and 0.25 wt% sodium tripolyphosphate water-reducing agent. The amount of added silica sol is 35 wt%, and the amount of added water is 32.5 wt%.

[0050] in: The inner diameter of the grouting needle of the grouting machine is ≤6mm, and the length is ≥50mm; The grouting pressure of the grouting machine is 20-60 MPa; The construction steps of the self-healing reinforcing agent for ceramic fiber rope used in the coke oven door frame protection plate of the present invention are as follows: Step 1: Remove the furnace door of the coke oven carbonization chamber; Step two: Temporary insulation measures are used to seal the furnace opening of the carbonization chamber; Step 3: Clean the tar and residual sealant from the furnace door frame protective plate area; Step 4: Use compressed air to purge and clean the surface of the ceramic fiber rope that seals the furnace door frame, protective plate, and furnace body. Step 5: Grouting machine injects grout into the inside of the coke oven door frame protection plate using ceramic fiber rope, with grouting positions spaced 100-200mm apart; Step 6: Use ceramic fiber rope to patch the protective plate of the coke oven door frame. Press down for 3-5 seconds before removing the trowel. Step 7: Remove the temporary insulation measures; Step 8: Install the removed coke oven carbonization chamber door. Example

[0051] A self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection panels and its construction method: First, a certain amount of self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is prepared according to the mass percentage of each component. Then, the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plate is injected into the interior of the ceramic fiber rope and patched onto the surface of the ceramic fiber rope using a grouting machine and surface patching construction method.

[0052] The mass percentages of each raw material in the self-healing reinforcing agent for ceramic fiber rope used in coke oven door frame protection plates are as follows: 65wt% mullite powder, 15.5wt% alumina micro powder, 2.5wt% aluminum-silicon alloy powder, 2.5wt% kyanite powder, 10wt% The mixture consists of silica fume, 1.5 wt% chopped fibers, 2 wt% calcium aluminate cement, 1 wt% spherical clay, and a total of 0.3 wt% sodium carbonate. The total amount of nickel powder catalyst and raw materials is 0.3 wt% sodium tripolyphosphate water-reducing agent, with an added amount of 40 wt% silica sol and 40 wt% water.

[0053] in: The inner diameter of the grouting needle of the grouting machine is ≤6mm, and the length is ≥50mm; The grouting pressure of the grouting machine is 20-60 MPa; The construction steps of the self-healing reinforcing agent for ceramic fiber rope used in the coke oven door frame protection plate of the present invention are as follows: Step 1: Remove the furnace door of the coke oven carbonization chamber; Step two: Temporary insulation measures are used to seal the furnace opening of the carbonization chamber; Step 3: Clean the tar and residual sealant from the furnace door frame protective plate area; Step 4: Use compressed air to purge and clean the surface of the ceramic fiber rope that seals the furnace door frame, protective plate, and furnace body. Step 5: Grouting machine injects grout into the inside of the coke oven door frame protection plate using ceramic fiber rope, with grouting positions spaced 100-200mm apart; Step 6: Use ceramic fiber rope to patch the protective plate of the coke oven door frame. Press down for 3-5 seconds before removing the trowel. Step 7: Remove the temporary insulation measures; Step 8: Install the removed coke oven carbonization chamber door.

[0054] This invention possesses substantial features and significant technological advancements. The self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors and its application method involve an aluminum-silicon alloy powder that reacts with water to generate bubbles. This allows the self-healing reinforcing agent to bond with the ceramic fiber rope fibers while simultaneously forming a loose internal structure. This not only strengthens the protection of the ceramic fibers but also helps maintain the internal spatial structure of the ceramic fiber rope. This characteristic can be understood from the chemical formula of the reaction between aluminum and water in the aluminum-silicon alloy powder (Al + H₂O → AlOOH + H₂). This reaction produces gas, which forms bubbles within the material. Excessive pores can lead to a porous material. Due to the chemical reaction between aluminum and water, aluminum powder is often added to refractory materials as an anti-explosion agent. The principle is to utilize the pores generated by the reaction to prevent the refractory material from exploding at reference high temperatures. Please refer to the literature Cai Manfei, Nie Jianhua, Yin Guoheng, et al., Influence of different explosion retardants on the performance of corundum-spinel castables [J]. Journal of Ceramics, 2017, 38(6): 862-86. However, in order to prevent excessive gas generation from causing the refractory material to become too porous and thus reduce its performance, the amount of aluminum powder added is usually less than 1%. At the same time, since ceramic fiber ropes are usually used for furnace door sealing, the working temperature is generally below 1000℃. Under this temperature condition, it is difficult to use the in-situ generation method to generate fibers in situ to achieve self-repair of ceramic fiber ropes. This invention reduces the fiber generation temperature by adding catalysts and alloy powders, thereby achieving the self-growth of fibers inside the ceramic fiber rope, and achieving the purpose of strengthening the sealing effect of the ceramic fiber rope and extending its service life.

[0055] In addition, the working temperature of ceramic fiber ropes used for coke oven door frame protection plates is generally below 1000℃. This invention achieves in-situ self-growth of internal fibers in ceramic fiber ropes by adding catalysts and alloy powders, thereby enhancing the sealing effect of ceramic fiber ropes used for coke oven door frame protection plates. The above characteristics are due to the fact that the internal fiber growth of the material is suitable for growth in a narrow space. The pores generated by the hydration of aluminum-silicon alloy powder, the raw materials and the ceramic fiber ropes cannot achieve the theoretically complete density, which just meets the spatial conditions for fiber growth. Please refer to the literature: Han C, Gu H, Zhang M, et al. Preparation and formation mechanism of Al-Si / Al2O3 core-shell structured particles fabricated via steam corrosion[J].Ceramics International, 2019, 45(11) and the literature Han C, Gu H, Zhang M, et al.Al–Si@Al2O3@mullitemicrocapsulesfor thermal energy storage: Preparation and thermal properties[J].SolarEnergyMaterialsandSolarCells, 2020, 217: 110697.DOI: 10.1016 / j.solmat .2020 .110697. The catalyst works by transforming fiber growth from a GS reaction mechanism to a GLS reaction mechanism, thereby lowering the activation energy for fiber formation. Apparently, this reduces the fiber formation temperature. Please refer to [link / reference]. Figure 1 and Figure 2 The image shown illustrates the microscopic morphology of fibers formed at 1000℃ from aluminum-silicon alloy. Its principle clearly explains the fiber growth inside the ceramic fiber rope.

[0056] The third type of chopped fiber provides support to other powders in the reinforcing agent while improving its toughness and resilience. This characteristic can be found in GB / T3003-2017 "Refractory Fibers and Products". Furthermore, chopped fibers (not limited to ceramic fibers) are a form of toughening ceramic materials, and the main structure of ceramic fiber ropes is also fiber. Therefore, the chopped fibers added to the self-healing reinforcing agent of ceramic fiber ropes have the same function as the original fibers in the ceramic fiber rope. Based on this, there is theoretical support for the effect of chopped fibers in improving the strength, toughness, and resilience of ceramic fiber ropes, and this effect can be determined even without performance testing. Existing solutions for smoke emanating from around the coke oven door often involve manual hot patching or replacing the original fiber rope. These techniques cannot completely seal the area of ​​the door frame protection plate, nor can they reinforce and extend the lifespan of the coke oven door frame protection plate with ceramic fiber rope; therefore, the sealing effect has a short duration. This invention achieves internal reinforcement and external protection of the ceramic fiber rope used in the coke oven door frame protection plate through internal grouting and surface patching, thereby extending the service life of the ceramic fiber rope and ultimately ensuring coke oven sealing. Starting from the internal structure and operating temperature of the ceramic fiber rope used in the coke oven door frame protection plate, this invention addresses the aging problem that occurs during service by proposing a self-repairing method using a reinforcing agent to improve its service life. It also provides an application method for this self-repairing reinforcing agent. This invention improves the sealing performance degradation problem that occurs during the service life of the ceramic fiber rope used in the coke oven door frame protection plate, reduces the risk of sealing failure after service, and has the advantages of advanced technology, energy saving, and environmental protection.

[0057] The above embodiments are for illustrative purposes only and are not intended to limit the invention. Those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention. Therefore, all equivalent technical solutions should also fall within the scope of this invention and are defined by the claims.

Claims

1. A self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors, characterized in that: It is made from the following components in the indicated weight percentages: 40-65 wt% mullite powder, 15-25 wt% alumina micro powder, 2-8 wt% aluminum-silicon alloy powder, 2-10 wt% kyanite powder, 10-16 wt% silica micro powder, 1-5 wt% chopped fiber, 2-5 wt% calcium aluminate cement, 1-3 wt% spherical clay, 0.1-0.3 wt% catalyst, 0.1-0.3 wt% water-reducing agent, 20-40 wt% added silica sol, and 10-40 wt% added water. The aluminum-silicon alloy powder reacts with water to generate pores, forming a loose structure to maintain the internal spatial structure of the ceramic fiber rope; this allows the aluminum-silicon alloy powder to generate ceramic fibers under the action of the catalyst within the working temperature range, enabling the fiber rope to self-repair and improving its sealing performance and resilience. The aluminum-silicon alloy powder has a silicon content of ≥2% and a particle size of ≤0.045mm. The catalyst is selected from one or more of nano-iron powder, nano-nickel powder, and nano-cobalt powder.

2. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The mullite powder is either sintered mullite powder or electrofused mullite powder.

3. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The mullite powder has a particle size of ≤0.088mm.

4. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The alumina micro powder has a particle size of ≤5μm.

5. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The kyanite powder has a particle size ≤0.88mm.

6. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The silicon micropowder contains ≥92% SiO2 and has a particle size of ≤0.6μm.

7. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The chopped fibers are selected from one or more of chopped alumina ceramic fibers, chopped steel fibers, and chopped mullite fibers.

8. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The diameter of the chopped fiber is ≤40μm and the length of the chopped fiber is ≤5mm.

9. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The particle size of the spherical clay is ≤0.044mm.

10. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The water-reducing agent is selected from one or more of the inorganic water-reducing agents, such as sodium tripolyphosphate and sodium hexametaphosphate.

11. The ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 1, characterized in that, The silica sol is an alkaline silica sol with a SiO2 content of 20-30% and a particle size of ≤580nm.

12. A method for applying the self-healing reinforcing agent for ceramic fiber ropes used in coke oven doors as described in claim 1, characterized in that... Includes the following steps: a. Remove the furnace door of the coke oven carbonization chamber; b. Temporary insulation measures to seal the furnace opening of the carbonization chamber; c. Clean the tar and residual sealant from the area of ​​the furnace door frame protective plate; d. Use compressed air to purge and clean the surface of the ceramic fiber rope sealing the furnace door frame, protective plate, and furnace body; e. Using a grouting machine, the self-healing reinforcing agent of the ceramic fiber rope used for the coke oven door frame protection plate is injected into the ceramic fiber rope used for the coke oven door frame protection plate. The grouting positions are spaced 350-500mm apart. f. Apply the self-healing reinforcing agent to the surface of the ceramic fiber rope on the coke oven door frame protection plate using the surface patching construction method. Press down for 3-5 seconds before removing the trowel during patching. g. Remove temporary insulation measures; h. Install the removed coke oven carbonization chamber door.

13. The construction method of the ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 12, characterized in that, The grouting needle of the grouting machine has an inner diameter of ≤6mm and a length of ≥50mm.

14. The construction method of the ceramic fiber rope self-healing reinforcing agent for coke oven doors as described in claim 12, characterized in that, The grouting pressure of the grouting machine is 20-60 MPa.

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