A casting material and construction method for preventing acid leakage from Mannheim furnace hearth

Abstract

The invention discloses a casting material for preventing acid leakage from a Mannheim furnace hearth and a construction method. The casting material for preventing acid leakage from a Mannheim furnace hearth comprises the following components in percentage by mass: high-aluminum aggregate: 60%-70%; high-aluminum fine powder: 15%-20%; cement: 5%-10%; nickel powder: 1%-2%; cadmium powder: 0.5%-1%; flexible steel wire: 5%-8%; water: adjusted in appropriate amount to a suitable construction consistency; the invention significantly improves the casting efficiency by adding the flexible steel wire. The crack resistance of the material ensures that no cracks will occur when the temperature of the Mannheim furnace is raised to 500°C, effectively preventing the penetration of sulfuric acid; by adding acid-resistant medium nickel and cadmium powder, the expansion performance of the casting material is matched with the acid-resistant high-alumina brick, avoiding the formation of gaps caused by differences in expansion coefficients, and further preventing sulfuric acid leakage; the present invention allows the furnace bed to form a whole, which expands or contracts evenly with the rise and fall of temperature, greatly extending the service life of the Mannheim furnace, reducing overhauls and shutdowns caused by acid leakage, and reducing maintenance costs.

Description

Technical Field

[0001] The invention belongs to the technical field of chemical equipment materials, and in particular relates to a casting material and a construction method for preventing acid leakage from a Mannheim furnace hearth. Background Art

[0002] Mannheim furnace is the main equipment used to produce potassium sulfate. Sulfuric acid and potassium chloride are added to the Mannheim furnace in a certain proportion. After high-temperature reaction, potassium sulfate and hydrogen chloride are generated. Potassium sulfate is pushed to the discharge port through the reaction zone and drying zone under the push of the stirring rake. The hearth of a conventional Mannheim furnace is made of acid-resistant bricks, or the center is cast and the rest is bricked in an inverted arc shape. As the temperature of the hearth bricks continues to rise during the heating process, gaps are generated between bricks and bricks, and between bricks and castables. During the production process, sulfuric acid will penetrate into the gaps, causing sulfuric acid to flow out from the bottom of the Mannheim furnace. The furnace must be shut down for overhaul, affecting the service life of the furnace.

[0003] Based on this, a casting material and a construction method are designed to prevent acid leakage from the hearth of the Mannheim furnace. Summary of the invention

[0004] In view of the above situation, in order to overcome the defects of the prior art, the present invention provides a casting material and a construction method for preventing acid leakage from the hearth of a Mannheim furnace, which effectively solves the problems raised in the above background.

[0005] To achieve the above object, the present invention provides the following technical solution: a casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following components in percentage by mass:

[0006] High alumina aggregate: 60%-70%;

[0007] High alumina fine powder: 15%-20%;

[0008] Cement: 5%-10%;

[0009] Nickel powder: 1%-2%;

[0010] Cadmium powder: 0.5%-1%;

[0011] Flexible steel wire: 5%-8%;

[0012] Water: Adjust the amount to a suitable construction consistency.

[0013] Preferably, the cement is one of silicate cement or aluminate cement.

[0014] Preferably, the length of each section of the flexible steel wire is 5 cm.

[0015] A method for constructing a casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following steps:

[0016] S1. Material preparation:

[0017] Accurately weigh the components according to the above proportions and ensure that the flexible steel wire is cut into 5 cm long sections for later use;

[0018] S2, mixing and stirring:

[0019] S2.1, dry mixing, dry mix the acid-resistant high-alumina aggregate, fine powder, cement, nickel powder and cadmium powder in a mixer for 5-10 minutes;

[0020] S2.2, add water and wet mix. First, slowly add an appropriate amount of water into the mixer while stirring. The amount of water added is adjusted according to the water absorption of the material and the construction consistency requirements. The wet mixing time is 10-15 minutes, until a uniform mixture without lumps is obtained;

[0021] S2.3, adding flexible steel wire, evenly adding flexible steel wire into the wet mixed mixture to ensure that the steel wire is evenly distributed to avoid local aggregation;

[0022] S3. Preparation of hearth:

[0023] S3.1. Stacking acid-resistant high-alumina bricks. In the Mannheim furnace, acid-resistant high-alumina bricks are used to stack the lower layer of the furnace bed. The bricks fit tightly together without any gaps.

[0024] S3.2. Clean the furnace bed and the surface of the furnace bed to ensure that there are no impurities and dust. At the same time, check whether the lower layer of the furnace bed is flat. If there is any unevenness, repair it;

[0025] S4. Casting:

[0026] S4.1. Lay the casting material. Lay the prepared casting material evenly on the upper layer of acid-resistant high-alumina bricks with a laying thickness of 45-55mm to ensure that the thickness of the casting layer is uniform;

[0027] S4.2. Compact the casting material using a vibrator or manually to remove bubbles and voids and ensure that the casting layer is dense;

[0028] S4.3. Smoothness: Use a scraper or spatula to smooth the surface of the casting material, ensuring that there are no protrusions or depressions on the surface and that it remains smooth and flat;

[0029] S5. Maintenance:

[0030] S5.1. Static curing: After casting, leave it at room temperature for 24-48 hours to allow the casting material to initially solidify;

[0031] S5.2, heat up and solidify, gradually heat up to 150-200℃ and keep it for 4-6h for preheating treatment to further solidify the internal structure of the casting material. After the preheating is completed, gradually heat up to 500℃, and the heating rate does not exceed 50℃ / h. Keep 500℃ constant temperature for 2-4h to fully solidify the casting material and ensure that the casting material and the acid-resistant high-alumina brick expand synchronously to a stable state;

[0032] S5.3. Natural cooling: After the temperature rise and curing is completed, cool naturally to room temperature.

[0033] Preferably, during the mixing and stirring of S2, the stirring rate of the stirrer is 200-300 rpm.

[0034] Compared with the prior art, the present invention has the following beneficial effects:

[0035] The invention significantly improves the anti-cracking performance of the casting material by adding flexible steel wire, ensures that no cracks are generated when the temperature of the Mannheim furnace is raised to 500° C., and effectively prevents sulfuric acid from penetrating.

[0036] By adding acid-resistant nickel and cadmium powder, the expansion performance of the casting material is matched with that of the acid-resistant high-alumina brick, avoiding the formation of gaps caused by differences in expansion coefficients and further preventing sulfuric acid leakage;

[0037] The casting material and construction method of the present invention enable the furnace bed to form an integral body, which can expand or contract evenly with the rise and fall of temperature, thereby greatly extending the service life of the Mannheim furnace, reducing major repairs and shutdowns due to acid leakage, and reducing maintenance costs. DETAILED DESCRIPTION

[0038] The technical solution of the present invention will be clearly and completely described below in conjunction with specific embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments; based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0039] The present invention provides a casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following components in percentage by mass:

[0040] High alumina aggregate: 60%-70%;

[0041] High alumina fine powder: 15%-20%;

[0042] Cement: 5%-10%;

[0043] Nickel powder: 1%-2%;

[0044] Cadmium powder: 0.5%-1%;

[0045] Flexible steel wire: 5%-8%;

[0046] Water: Adjust the amount to a suitable construction consistency.

[0047] The cement in this embodiment is one of silicate cement or aluminate cement.

[0048] The length of each section of the flexible steel wire in this embodiment is 5 cm.

[0049] A method for constructing a casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following steps:

[0050] S1. Material preparation:

[0051] Accurately weigh the components according to the above proportions and ensure that the flexible steel wire is cut into 5 cm long sections for later use;

[0052] S2, mixing and stirring:

[0053] S2.1, dry mixing, dry mix the acid-resistant high-alumina aggregate, fine powder, cement, nickel powder and cadmium powder in a mixer for 5-10 minutes;

[0054] S2.2, add water and wet mix. First, slowly add an appropriate amount of water into the mixer while stirring. The amount of water added is adjusted according to the water absorption of the material and the construction consistency requirements. The wet mixing time is 10-15 minutes, until a uniform mixture without lumps is obtained;

[0055] S2.3, adding flexible steel wire, evenly adding flexible steel wire into the wet mixed mixture to ensure that the steel wire is evenly distributed to avoid local aggregation;

[0056] S3. Preparation of hearth:

[0057] S3.1. Stacking acid-resistant high-alumina bricks. In the Mannheim furnace, acid-resistant high-alumina bricks are used to stack the lower layer of the furnace bed. The bricks fit tightly together without any gaps.

[0058] S3.2. Clean the furnace bed and the surface of the furnace bed to ensure that there are no impurities and dust. At the same time, check whether the lower layer of the furnace bed is flat. If there is any unevenness, repair it;

[0059] S4. Casting:

[0060] S4.1. Lay the casting material. Lay the prepared casting material evenly on the upper layer of acid-resistant high-alumina bricks with a laying thickness of 45-55mm to ensure that the thickness of the casting layer is uniform;

[0061] S4.2. Compact the casting material using a vibrator or manually to remove bubbles and voids and ensure that the casting layer is dense;

[0062] S4.3. Smoothness: Use a scraper or spatula to smooth the surface of the casting material, ensuring that there are no protrusions or depressions on the surface and that it remains smooth and flat;

[0063] S5. Maintenance:

[0064] S5.1. Static curing: After casting, leave it at room temperature for 24-48 hours to allow the casting material to initially solidify;

[0065] S5.2, heat up and solidify, gradually heat up to 150-200℃ and keep it for 4-6h for preheating treatment to further solidify the internal structure of the casting material. After the preheating is completed, gradually heat up to 500℃, and the heating rate does not exceed 50℃ / h. Keep 500℃ constant temperature for 2-4h to fully solidify the casting material and ensure that the casting material and the acid-resistant high-alumina brick expand synchronously to a stable state;

[0066] S5.3. Natural cooling: After the temperature rise and curing is completed, cool naturally to room temperature.

[0067] In the mixing and stirring of S2 of this embodiment, the stirring rate of the stirrer is 200-300 rpm.

[0068] Embodiment 1:

[0069] A casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following components in percentage by mass:

[0070] High alumina aggregate: 60%;

[0071] High alumina fine powder: 15%;

[0072] Cement: 5%;

[0073] Nickel powder: 1%;

[0074] Cadmium powder: 0.5%;

[0075] Flexible steel wire: 5%;

[0076] Water: Adjust the amount to a suitable construction consistency.

[0077] The cement in this embodiment is one of silicate cement or aluminate cement.

[0078] The length of each section of the flexible steel wire in this embodiment is 5 cm.

[0079] A method for constructing a casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following steps:

[0080] S1. Material preparation:

[0081] Accurately weigh the components according to the above proportions and ensure that the flexible steel wire is cut into 5 cm long sections for later use;

[0082] S2, mixing and stirring:

[0083] S2.1, dry mixing, dry mix the acid-resistant high-alumina aggregate, fine powder, cement, nickel powder and cadmium powder in a mixer for 5 minutes;

[0084] S2.2, add water and wet mix. First, slowly add an appropriate amount of water into the mixer while stirring. The amount of water added is adjusted according to the water absorption of the material and the construction consistency requirements. The wet mixing time is 10 minutes, until a uniform mixture without lumps is obtained;

[0085] S2.3, adding flexible steel wire, evenly adding flexible steel wire into the wet mixed mixture to ensure that the steel wire is evenly distributed to avoid local aggregation;

[0086] S3. Preparation of hearth:

[0087] S3.1. Stacking acid-resistant high-alumina bricks. In the Mannheim furnace, acid-resistant high-alumina bricks are used to stack the lower layer of the furnace bed. The bricks fit tightly together without any gaps.

[0088] S3.2. Clean the furnace bed and the surface of the furnace bed to ensure that there are no impurities and dust. At the same time, check whether the lower layer of the furnace bed is flat. If there is any unevenness, repair it;

[0089] S4. Casting:

[0090] S4.1. Lay the casting material. Lay the prepared casting material evenly on the upper layer of acid-resistant high-alumina bricks with a laying thickness of 45mm to ensure that the thickness of the casting layer is uniform;

[0091] S4.2. Compact the casting material using a vibrator or manually to remove bubbles and voids and ensure that the casting layer is dense;

[0092] S4.3. Smoothness: Use a scraper or spatula to smooth the surface of the casting material, ensuring that there are no protrusions or depressions on the surface and that it remains smooth and flat;

[0093] S5. Maintenance:

[0094] S5.1. Static curing: After casting, leave it at room temperature for 24 hours to allow the casting material to initially solidify;

[0095] S5.2, heat up and solidify, gradually heat up to 150℃ and keep it for 4h for preheating treatment to further solidify the internal structure of the casting material. After the preheating is completed, gradually heat up to 500℃, the heating rate does not exceed 50℃ / h, and keep 500℃ constant temperature for 2h to fully solidify the casting material and ensure that the casting material and the acid-resistant high-alumina brick expand synchronously to a stable state;

[0096] S5.3. Natural cooling: After the temperature rise and curing is completed, cool naturally to room temperature.

[0097] In the mixing and stirring of S2 of this embodiment, the stirring rate of the stirrer is 200 rpm.

[0098] Embodiment 2:

[0099] A casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following components in percentage by mass:

[0100] High alumina aggregate: 70%;

[0101] High alumina fine powder: 20%;

[0102] Cement: 10%;

[0103] Nickel powder: 2%;

[0104] Cadmium powder: 1%;

[0105] Flexible steel wire: 8%;

[0106] Water: Adjust the amount to a suitable construction consistency.

[0107] The cement in this embodiment is one of silicate cement or aluminate cement.

[0108] The length of each section of the flexible steel wire in this embodiment is 5 cm.

[0109] A method for constructing a casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following steps:

[0110] S1. Material preparation:

[0111] Accurately weigh the components according to the above proportions and ensure that the flexible steel wire is cut into 5 cm long sections for later use;

[0112] S2, mixing and stirring:

[0113] S2.1, dry mixing, dry mix the acid-resistant high-alumina aggregate, fine powder, cement, nickel powder and cadmium powder in a mixer for 10 minutes;

[0114] S2.2, add water and wet mix. First, slowly add an appropriate amount of water into the mixer while stirring. The amount of water added is adjusted according to the water absorption of the material and the construction consistency requirements. The wet mixing time is 15 minutes, until a uniform mixture without lumps is obtained;

[0115] S2.3, adding flexible steel wire, evenly adding flexible steel wire into the wet mixed mixture to ensure that the steel wire is evenly distributed to avoid local aggregation;

[0116] S3. Preparation of hearth:

[0117] S3.1. Stacking acid-resistant high-alumina bricks. In the Mannheim furnace, acid-resistant high-alumina bricks are used to stack the lower layer of the furnace bed. The bricks fit tightly together without any gaps.

[0118] S3.2. Clean the furnace bed and the surface of the furnace bed to ensure that there are no impurities and dust. At the same time, check whether the lower layer of the furnace bed is flat. If there is any unevenness, repair it;

[0119] S4. Casting:

[0120] S4.1. Lay the casting material. Lay the prepared casting material evenly on the upper layer of acid-resistant high-alumina bricks with a laying thickness of 55mm to ensure that the thickness of the casting layer is uniform;

[0121] S4.2. Compact the casting material using a vibrator or manually to remove bubbles and voids and ensure that the casting layer is dense;

[0122] S4.3. Smoothness: Use a scraper or spatula to smooth the surface of the casting material, ensuring that there are no protrusions or depressions on the surface and that it remains smooth and flat;

[0123] S5. Maintenance:

[0124] S5.1. Static curing: After casting, leave it at room temperature for 48 hours to allow the casting material to initially solidify;

[0125] S5.2, heat up and solidify, gradually heat up to 200℃ and keep it for 6h for preheating treatment to further solidify the internal structure of the casting material. After the preheating is completed, gradually heat up to 500℃, the heating rate does not exceed 50℃ / h, and keep 500℃ constant temperature for 4h to fully solidify the casting material and ensure that the casting material and the acid-resistant high-alumina brick expand synchronously to a stable state;

[0126] S5.3. Natural cooling: After the temperature rise and curing is completed, cool naturally to room temperature.

[0127] In the mixing and stirring of S2 of this embodiment, the stirring rate of the stirrer is 300 rpm.

[0128] Embodiment 3:

[0129] A casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following components in percentage by mass:

[0130] High alumina aggregate: 65%;

[0131] High alumina fine powder: 17.5%;

[0132] Cement: 7.5%;

[0133] Nickel powder: 1.5%;

[0134] Cadmium powder: 0.75%;

[0135] Flexible steel wire: 6.5%;

[0136] Water: Adjust the amount to a suitable construction consistency.

[0137] The cement in this embodiment is one of silicate cement or aluminate cement.

[0138] The length of each section of the flexible steel wire in this embodiment is 5 cm.

[0139] A method for constructing a casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following steps:

[0140] S1. Material preparation:

[0141] Accurately weigh the components according to the above proportions and ensure that the flexible steel wire is cut into 5 cm long sections for later use;

[0142] S2, mixing and stirring:

[0143] S2.1, dry mixing, dry mix the acid-resistant high-alumina aggregate, fine powder, cement, nickel powder and cadmium powder in a mixer for 7.5 minutes;

[0144] S2.2, add water and wet mix. First, slowly add an appropriate amount of water into the mixer while stirring. The amount of water added is adjusted according to the water absorption of the material and the construction consistency requirements. The wet mixing time is 12.5 minutes, until a uniform mixture without lumps is obtained;

[0145] S2.3, adding flexible steel wire, evenly adding flexible steel wire into the wet mixed mixture to ensure that the steel wire is evenly distributed to avoid local aggregation;

[0146] S3. Preparation of hearth:

[0147] S3.1. Stacking acid-resistant high-alumina bricks. In the Mannheim furnace, acid-resistant high-alumina bricks are used to stack the lower layer of the furnace bed. The bricks fit tightly together without any gaps.

[0148] S3.2. Clean the furnace bed and the surface of the furnace bed to ensure that there are no impurities and dust. At the same time, check whether the lower layer of the furnace bed is flat. If there is any unevenness, repair it;

[0149] S4. Casting:

[0150] S4.1. Lay the casting material. Lay the prepared casting material evenly on the upper layer of acid-resistant high-alumina bricks with a laying thickness of 50mm to ensure that the thickness of the casting layer is uniform;

[0151] S4.2. Compact the casting material using a vibrator or manually to remove bubbles and voids and ensure that the casting layer is dense;

[0152] S4.3. Smoothness: Use a scraper or spatula to smooth the surface of the casting material, ensuring that there are no protrusions or depressions on the surface and that it remains smooth and flat;

[0153] S5. Maintenance:

[0154] S5.1. Static curing: After casting, leave it at room temperature for 36 hours to allow the casting material to initially solidify;

[0155] S5.2. Heating and curing. Gradually heat up to 175℃ and keep it for 5h for preheating treatment to further solidify the internal structure of the casting material. After the preheating is completed, gradually heat up to 500℃, and the heating rate does not exceed 50℃ / h. Keep 500℃ constant temperature for 3h to fully solidify the casting material and ensure that the casting material and the acid-resistant high-alumina brick expand synchronously to a stable state;

[0156] S5.3. Natural cooling: After the temperature rise and curing is completed, cool naturally to room temperature.

[0157] In the mixing and stirring of S2 of this embodiment, the stirring rate of the stirrer is 250 rpm.

[0158] Embodiment 4:

[0159] A casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following components in percentage by mass:

[0160] High alumina aggregate: 63%;

[0161] High alumina fine powder: 16%;

[0162] Cement: 6%;

[0163] Nickel powder: 1.2%;

[0164] Cadmium powder: 0.6%;

[0165] Flexible steel wire: 6%;

[0166] Water: Adjust the amount to a suitable construction consistency.

[0167] The cement in this embodiment is one of silicate cement or aluminate cement.

[0168] The length of each section of the flexible steel wire in this embodiment is 5 cm.

[0169] A method for constructing a casting material for preventing acid leakage from a Mannheim furnace hearth, comprising the following steps:

[0170] S1. Material preparation:

[0171] Accurately weigh the components according to the above proportions and ensure that the flexible steel wire is cut into 5 cm long sections for later use;

[0172] S2, mixing and stirring:

[0173] S2.1, dry mixing, dry mix the acid-resistant high-alumina aggregate, fine powder, cement, nickel powder and cadmium powder in a mixer for 6 minutes;

[0174] S2.2, add water and wet mix. First, slowly add an appropriate amount of water into the mixer while stirring. The amount of water added is adjusted according to the water absorption of the material and the construction consistency requirements. The wet mixing time is 12 minutes, until a uniform mixture without lumps is obtained;

[0175] S2.3, adding flexible steel wire, evenly adding flexible steel wire into the wet mixed mixture to ensure that the steel wire is evenly distributed to avoid local aggregation;

[0176] S3. Preparation of hearth:

[0177] S3.1. Stacking acid-resistant high-alumina bricks. In the Mannheim furnace, acid-resistant high-alumina bricks are used to stack the lower layer of the furnace bed. The bricks fit tightly together without any gaps.

[0178] S3.2. Clean the furnace bed and the surface of the furnace bed to ensure that there are no impurities and dust. At the same time, check whether the lower layer of the furnace bed is flat. If there is any unevenness, repair it;

[0179] S4. Casting:

[0180] S4.1. Lay the casting material. Lay the prepared casting material evenly on the upper layer of acid-resistant high-alumina bricks with a laying thickness of 45-55mm to ensure that the thickness of the casting layer is uniform;

[0181] S4.2. Compact the casting material using a vibrator or manually to remove bubbles and voids and ensure that the casting layer is dense;

[0182] S4.3. Smoothness: Use a scraper or spatula to smooth the surface of the casting material, ensuring that there are no protrusions or depressions on the surface and that it remains smooth and flat;

[0183] S5. Maintenance:

[0184] S5.1. Static curing: After casting, leave it at room temperature for 30 hours to allow the casting material to initially solidify;

[0185] S5.2, heat up and solidify, gradually heat up to 170℃ and keep it for 4.5h for preheating treatment to further solidify the internal structure of the casting material. After the preheating is completed, gradually heat up to 500℃, the heating rate does not exceed 50℃ / h, and keep 500℃ constant temperature for 2.5h to fully solidify the casting material and ensure that the casting material and the acid-resistant high-alumina brick expand synchronously to a stable state;

[0186] S5.3. Natural cooling: After the temperature rise and curing is completed, cool naturally to room temperature.

[0187] In the mixing and stirring of S2 of this embodiment, the stirring rate of the stirrer is 220 rpm.

[0188] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0189] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A casting material for preventing acid leakage from a Mannheim furnace hearth, characterized in that: The following ingredients are included in mass percentage: High alumina aggregate: 60%-70%; High alumina fine powder: 15%-20%; Cement: 5%-10%; Nickel powder: 1%-2%; Cadmium powder: 0.5%-1%; Flexible steel wire: 5%-8%; Water: Adjust the amount to a suitable construction consistency.

2. A casting material for preventing acid leakage from a Mannheim furnace hearth according to claim 1, characterized in that: The cement is one of silicate cement and aluminate cement.

3. A casting material for preventing acid leakage from a Mannheim furnace hearth according to claim 1, characterized in that: The length of each section of the flexible steel wire is 5 cm.

4. A method for constructing a casting material for preventing acid leakage from a Mannheim furnace hearth, characterized in that: The following steps are involved: S1. Material preparation: Accurately weigh the components according to the above proportions and ensure that the flexible steel wire is cut into 5 cm long sections for later use; S2. Mixing and stirring: S2.1, dry mixing, dry mix the acid-resistant high-alumina aggregate, fine powder, cement, nickel powder and cadmium powder in a mixer for 5-10 minutes; S2.2, add water and wet mix. First, slowly add an appropriate amount of water into the mixer while stirring. The amount of water added is adjusted according to the water absorption of the material and the construction consistency requirements. The wet mixing time is 10-15 minutes, until a uniform mixture without lumps is obtained; S2.3, adding flexible steel wire, evenly adding flexible steel wire into the wet mixed mixture to ensure that the steel wire is evenly distributed to avoid local aggregation; S3. Preparation of hearth: S3.

1. Stacking acid-resistant high-alumina bricks. In the Mannheim furnace, acid-resistant high-alumina bricks are used to stack the lower layer of the furnace bed. The bricks fit tightly together without any gaps. S3.

2. Clean the furnace bed and the surface of the furnace bed to ensure that there are no impurities and dust. At the same time, check whether the lower layer of the furnace bed is flat. If there is any unevenness, repair it; S4. Casting: S4.

1. Lay the casting material. Lay the prepared casting material evenly on the upper layer of acid-resistant high-alumina bricks with a laying thickness of 45-55mm to ensure that the thickness of the casting layer is uniform; S4.

2. Compact the casting material using a vibrator or manually to remove bubbles and voids and ensure that the casting layer is dense; S4.

3. Smoothness: Use a scraper or spatula to smooth the surface of the casting material, ensuring that there are no protrusions or depressions on the surface and that it remains smooth and flat; S5. Maintenance: S5.

1. Static curing: After casting, leave it at room temperature for 24-48 hours to allow the casting material to initially solidify; S5.2, heat up and solidify, gradually heat up to 150-200℃ and keep it for 4-6h for preheating treatment to further solidify the internal structure of the casting material. After the preheating is completed, gradually heat up to 500℃, and the heating rate does not exceed 50℃ / h. Keep 500℃ constant temperature for 2-4h to fully solidify the casting material and ensure that the casting material and the acid-resistant high-alumina brick expand synchronously to a stable state; S5.

3. Natural cooling: After the temperature rise and curing is completed, cool naturally to room temperature.

5. A method for constructing a casting material for preventing acid leakage from a Mannheim furnace hearth according to claim 4, characterized in that: During the mixing and stirring of S2, the stirring rate of the stirrer is 200-300 rpm.