A high-strength, corrosion-resistant chute prefabricated part for copper smelting and its preparation method

Abstract

The present invention relates to the technical field of refractory materials for copper smelting, and discloses a high-strength and erosion-resistant chute preform for copper smelting and a preparation method thereof, comprising the following raw materials in parts by mass: 60-80 parts of high-alumina bauxite, 10-15 parts of corundum, 5-10 parts of modified silicon carbide, 3-5 parts of reinforcing filler, 8-10 parts of ultrafine powder, 6-10 parts of cement, 0.2-0.5 parts of admixture, and 50-60 parts of deionized water. A cobalt silicate layer is in situ synthesized on the surface of silicon carbide to increase the contact area between silicon carbide and the chute preform raw material, thereby facilitating the formation of a dense chute preform, preventing silicon carbide from easily expanding and deforming at high temperatures, resulting in a decrease in the mechanical properties of the chute preform, and reducing the strength and erosion resistance of the chute preform. Nano-alumina has excellent resistance to metal solution penetration and the low permeability of compound clay, thereby enhancing the erosion resistance of the chute preform and causing the chute preform to exhibit excellent mechanical properties.

Description

Technical Field

[0001] The invention relates to the technical field of refractory materials for copper smelting, in particular to a high-strength, corrosion-resistant chute prefabricated part for copper smelting and a preparation method thereof. Background Art

[0002] After copper is smelted at a temperature of 1300℃-1400℃, it is formed into molten copper for pouring. It passes through the tundish, launder preform, swing launder, and finally is poured into the mold to form a copper plate. Therefore, the launder preform is also called refractory material. The launder preform is mainly made of refractory materials such as high-aluminum vanadium stone, corundum, silicon carbide, and ultra-fine powder. After high-frequency vibration molding, room temperature curing, and high-temperature firing, it has the characteristics of high strength, corrosion resistance, erosion resistance, and excellent thermal shock stability. It can well avoid local leakage of high-temperature melt during use.

[0003] Silicon carbide in the chute preform has excellent corrosion resistance, high temperature resistance and mechanical strength, and can withstand the scouring and erosion of high-temperature molten copper and maintain the integrity and stability of the structure. However, silicon carbide is easy to combine with oxygen at high temperatures, and is easy to expand and deform, reducing the service life of the chute preform. In addition, silicon carbide material has high hardness and high brittleness, which causes the chute preform to easily crack when subjected to the mechanical stress generated by the scouring of high-temperature molten copper, affecting the use of the chute preform; during the preparation process of the chute preform, the raw materials are not firmly bonded, and there are gaps or voids, which affects the overall performance of the preform. Summary of the Invention

[0004] The present invention provides a high-strength, corrosion-resistant chute preform for copper smelting and a preparation method thereof, which solves the problems that the chute preform is prone to cracks when subjected to mechanical stress generated by high-temperature copper liquid scouring and that gaps or voids exist between raw materials due to loose bonding.

[0005] The technical solution of the present invention:

[0006] A high-strength, corrosion-resistant chute prefabricated component for copper smelting, comprising the following raw materials in parts by weight: 60-80 parts of high-alumina bauxite, 10-15 parts of corundum, 5-10 parts of modified silicon carbide, 3-5 parts of reinforcing filler, 8-10 parts of ultrafine powder, 6-10 parts of cement, 0.2-0.5 parts of admixture, and 50-60 parts of deionized water;

[0007] The modified silicon carbide is obtained by mixing cobalt nitrate hexahydrate, urea and silicon carbide, and then mixing with pretreated carbon fibers;

[0008] The reinforcing filler is obtained by mixing and reacting cationic quaternary ammonium salt-modified clay, ammonium carbonate solution and aluminum nitrate nonahydrate.

[0009] A method for preparing a high-strength, corrosion-resistant chute prefabricated part for copper smelting comprises the following steps:

[0010] S1. The high alumina, corundum, modified silicon carbide, reinforcing filler, ultrafine powder, cement, admixture and deionized water were mixed and stirred at a rate of 800-1000r / min for 1-2h to obtain a mixed slurry;

[0011] S2. Place the mixed slurry in a preform mold, vibrate at 100-200 Hz for 30-40 minutes, cure at 20-30°C for 20-25 hours, demold, dry at 500-700°C for 1-3 hours, and cool to room temperature to obtain a chute preform.

[0012] Furthermore, the high alumina bauxite is 3-5 mm and has an Al2O3 content of 89-93%.

[0013] Furthermore, the corundum is brown corundum powder with a particle size of 170-190 mesh.

[0014] Furthermore, the ultrafine powder is selected from activated alumina powder or silica fume.

[0015] Furthermore, the cement is calcium aluminate cement, the main component of which is Al2O3, with a content of 85-90%.

[0016] Furthermore, the admixture is prepared by mixing sodium citrate, explosion-proof fiber, oxalic acid and metallic aluminum powder in a mass ratio of (6-8):(2-3):(0.5-1):(0.4-0.6).

[0017] Furthermore, the explosion-proof fiber has a diameter of 50-100 μm and a length of 3-5 mm.

[0018] Furthermore, the modified silicon carbide is specifically prepared by the following steps:

[0019] A1. Cobalt nitrate hexahydrate, ammonium fluoride, and urea were added to deionized water and stirred. Silicon carbide was then added and the reaction was stirred at 120-130°C for 4-6 hours. The mixture was cooled to room temperature and the solid was collected by filtration. The solid was washed, dried, and calcined at 600-800°C for 1-3 hours. The mixture was cooled to room temperature to obtain cobalt silicate-loaded silicon carbide.

[0020] A2. The carbon fiber was added to Tris-HCl buffer, stirred evenly, dopamine was added, and the reaction was stirred for 3-5h. The mixture was filtered, washed, and dried to obtain pretreated carbon fiber.

[0021] A3. Add the pretreated carbon fiber and cobalt silicate-loaded silicon carbide to deionized water, stir at 200-300 rpm for 30-40 minutes, let it stand, filter, wash with deionized water three times, and dry in a 70°C oven for 10 minutes to obtain modified silicon carbide.

[0022] Furthermore, in the above-mentioned reaction process A1, cobalt nitrate hexahydrate reacts at 120-130°C under the catalysis of ammonium fluoride and urea, so that the cobalt nitrate hexahydrate undergoes dehydroxylation and decarbonization reactions to form cobalt oxide, which is then calcined at 800-1200°C. The formed cobalt oxide can react with the silicon dioxide layer on the surface of silicon carbide, and through silicon-oxygen-cobalt bonds, a cobalt silicate layer is synthesized on the surface of the silicon carbide to obtain silicon carbide loaded with cobalt silicate.

[0023] Furthermore, during the above-mentioned reaction A2, in the Tris-HCl buffer, dopamine can self-polymerize on the surface of the carbon fiber to form polydopamine, forming pretreated carbon fiber, so that the surface of the carbon fiber carries a large number of phenolic hydroxyl groups, which is conducive to the adhesion of silicon carbide loaded with cobalt silicate to the surface of the carbon fiber.

[0024] Furthermore, during the above-mentioned reaction A3, the pretreated carbon fiber has excellent adhesion and contains a large number of phenolic hydroxyl groups on its surface, so that the cobalt silicate-loaded silicon carbide adheres to the surface of the pretreated carbon fiber to form modified silicon carbide.

[0025] Furthermore, in step A1, the ratio of the cobalt nitrate hexahydrate, ammonium fluoride, urea, deionized water and silicon carbide is (2-3) g: (0.1-0.3) g: (1-3) g: (80-120) mL: (5-6) g.

[0026] Furthermore, in step A2, the ratio of the carbon fiber, Tris-HCl buffer and dopamine is (1-3) g: (45-55) mL: (0.4-0.6) g.

[0027] Furthermore, in step A3, the ratio of the pretreated carbon fiber, the cobalt silicate-loaded silicon carbide, and the deionized water is (4-6) g: (8-12) g: (80-120) mL.

[0028] Furthermore, the silicon carbide particle size is 5-10 μm.

[0029] Furthermore, the carbon fiber has a length of 4-5 mm and a diameter of 50-100 nm.

[0030] Furthermore, the reinforcing filler is specifically prepared by the following steps:

[0031] B1. The clay was added to deionized water, stirred at 60-70 ° C for 1-2h, a cationic quaternary ammonium salt was added, and ultrasonic treatment was performed at 40-50KHz for 5-10min. The reaction was stirred for 1-2h, filtered, washed, and dried to obtain a cationic quaternary ammonium salt-modified clay;

[0032] B2. Aluminum nitrate nonahydrate and ammonium carbonate solution were added to deionized water and stirred evenly. Cationic quaternary ammonium salt-modified clay was added and stirred at 400-500 r / min for 1-2 hours. The mixture was stirred at 100-110°C for 3-5 hours. The mixture was filtered, washed, dried, calcined at 400-500°C for 1-2 hours, and cooled to room temperature to obtain a reinforcing filler.

[0033] Furthermore, during the above-mentioned B1 reaction process, the exchangeable cationic sodium ions contained between the clay layers can undergo cation exchange with the cationic quaternary ammonium salt N,N-dimethyldodecylamine, so that the cationic quaternary ammonium salt is intercalated into the clay layers, expanding the distance between the clay layers to obtain cationic quaternary ammonium salt-modified clay.

[0034] Furthermore, during the above-mentioned B2 reaction process, the oxygen-containing functional groups carried on the surface of the cationic quaternary ammonium salt-modified clay can electrostatically bond with the aluminum ions in aluminum nitrate nonahydrate, so that the aluminum ions are adsorbed on the clay surface, and ammonium carbonate provides hydroxide ions, thereby forming hydroxide on the surface of the cationic quaternary ammonium salt-modified clay. After reacting at 100-110°C, the hydroxide is thermally decomposed to form aluminum oxide crystals, which are calcined at 400-500°C to promote the growth of aluminum oxide crystals, thereby realizing the synthesis of nano-alumina on the surface of the cationic quaternary ammonium salt-modified clay to obtain a reinforced filler.

[0035] Furthermore, in step B1, the ratio of the clay, deionized water and cationic quaternary ammonium salt is (2-3) g: (45-55) mL: (1-2) g.

[0036] Furthermore, in step B2, the ratio of the aluminum nitrate nonahydrate, ammonium carbonate solution, deionized water and cationic quaternary ammonium salt modified clay is (1-2) g: (10-14) mL: (25-35) mL: (5-6) g.

[0037] Furthermore, the cationic quaternary ammonium salt is N,N-dimethyldodecylamine.

[0038] The clay particle size is 70-80 μm.

[0039] The present invention has the following beneficial effects:

[0040] (1) In the technical solution of the present invention, a cobalt silicate layer is synthesized in situ on the surface of silicon carbide, which increases the surface roughness of silicon carbide and the contact area between silicon carbide and the raw material of the chute preform, which is conducive to the formation of a dense chute preform. In addition, the formed cobalt silicate layer has high high temperature resistance and water resistance, preventing silicon carbide from easily combining with oxygen at high temperature to expand and deform, resulting in a decrease in the mechanical properties of the chute preform, and further reducing the strength and corrosion resistance of the chute preform.

[0041] (2) In the technical solution of the present invention, polydopamine is self-polymerized on the surface of the carbon fiber, so that the surface of the carbon fiber carries a large number of phenolic hydroxyl groups, which is conducive to the adhesion of silicon carbide loaded with cobalt silicate to the surface of the carbon fiber; the silicon carbide loaded with cobalt silicate is adhered to the surface of the pretreated carbon fiber. On the one hand, the roughness of the pretreated carbon fiber is increased, thereby increasing the contact area between the pretreated carbon fiber and the chute preform raw material, and the pretreated carbon fiber serves as a bridge for the chute preform raw material, so that the chute preform raw materials are more tightly bonded, the density of the chute preform is improved, and the high strength and corrosion resistance of the chute preform raw material are enhanced. On the other hand, the excellent aspect ratio of the carbon fiber is randomly distributed in the chute preform matrix, forming a network structure that can absorb stress, which can weaken the mechanical stress generated by the high-temperature copper water washing the chute preform, and avoid the high hardness and brittleness of the silicon carbide material, which causes the chute preform to be prone to cracks, affecting the use of the chute preform, and the carbon fiber effectively improves the mechanical properties of the chute preform.

[0042] (3) In the technical solution of the present invention, cationic quaternary ammonium salts are interspersed between clay layers, reducing the interaction between clay layers and improving the dispersibility of clay. Moreover, the surface of the clay modified by cationic quaternary ammonium salts has oxygen-containing functional groups that are negatively charged, which is conducive to the synthesis of nano-alumina on the clay surface. Combined with the low permeability of clay, the chute preform's resistance to metal solution penetration is improved, so that the chute preform has excellent mechanical strength. Nano-alumina is synthesized on the surface of the clay modified by cationic quaternary ammonium salts. Nano-alumina has a small size effect and can be filled into the gaps of the chute preform, thereby improving the density of the chute preform and enhancing the high temperature resistance and corrosion resistance of the chute preform. Nano-alumina has excellent resistance to metal solution penetration and is combined with the low permeability of clay to enhance the corrosion resistance of the chute preform, so that the chute preform exhibits excellent mechanical properties.

[0043] (4) In the technical solution of the present invention, the chute prefabricated part is prepared by using high-alumina bauxite as the main raw material, and adding corundum, modified silicon carbide, reinforcing filler, ultrafine powder, cement and admixtures, which has high mechanical properties and shows excellent corrosion resistance and high strength. DETAILED DESCRIPTION

[0044] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0045] The raw materials used in the examples of the present invention are as follows, and all reagents used are of analytical grade.

[0046] Among them, high alumina bauxite 4mm, Al2O3 content of 90%, was purchased from Zhengzhou Sijihuo Refractory Materials Co., Ltd.

[0047] Corundum is brown corundum powder with a particle size of 180 mesh, from Ruishi New Materials Technology Co., Ltd.

[0048] Ultrafine powder is silica fume with a silicon dioxide content of 99% and a particle size of 20-40μm.

[0049] The cement is calcium aluminate cement, Al2O3, content is 87.5%, Henan Fengkai Refractory Material Co., Ltd.

[0050] The explosion-proof fiber has a diameter of 80 μm and a length of 4 mm, Gongyi Aochuang Building Materials Co., Ltd.

[0051] The silicon carbide particle size is 8 μm, the carbon fiber length is 4.5 mm, and the diameter is 80 nm.

[0052] The clay particle size is 75 μm and the purity is 99.4%.

[0053] The cationic quaternary ammonium salt is N,N-dimethyldodecylamine.

[0054] Example 1

[0055] A high-strength, corrosion-resistant chute prefabricated component for copper smelting, comprising the following raw materials in parts by weight: 60 parts of high-alumina bauxite, 10 parts of brown corundum powder, 5 parts of modified silicon carbide, 3 parts of reinforcing filler, 8 parts of silica fume, 6 parts of calcium aluminate cement, 0.2 parts of an admixture, and 50 parts of deionized water;

[0056] A method for preparing a high-strength, corrosion-resistant chute prefabricated part for copper smelting comprises the following steps:

[0057] S1. The high-alumina bauxite, brown corundum powder, modified silicon carbide, reinforcing filler, silica fume, calcium aluminate cement, admixtures and deionized water were mixed and stirred at a rate of 800 r / min for 1 h to obtain a mixed slurry;

[0058] The admixture is prepared by mixing sodium citrate, explosion-proof fiber, oxalic acid and metallic aluminum powder in a mass ratio of 6:2:0.5:0.4.

[0059] S2. The mixed slurry was placed in a preform mold, vibrated at 100 Hz for 30 minutes, cured at 20°C for 20 hours, demolded, dried at 500°C for 1 hour, and cooled to room temperature to obtain a chute preform.

[0060] Modified silicon carbide is specifically prepared by the following steps:

[0061] A1. 2 g of cobalt nitrate hexahydrate, 0.1 g of ammonium fluoride, and 1 g of urea were added to 80 mL of deionized water and stirred. 5 g of silicon carbide was added and the reaction was stirred at 120°C for 4 h. The mixture was cooled to room temperature and the solid was collected by filtration. The solid was washed with deionized water three times and ethanol five times, dried in a 60°C oven for 10 min, calcined in a furnace at 600°C for 1 h, and cooled to room temperature to obtain cobalt silicate-loaded silicon carbide.

[0062] A2. 1 g of carbon fiber was added to 45 mL of Tris-HCl buffer (pH 8.5), stirred evenly, and 0.44 g of dopamine was added. The mixture was stirred for 3 h, filtered, washed three times with deionized water, and dried in a 70°C oven for 10 min to obtain pretreated carbon fiber.

[0063] A3. Add 4 g of pretreated carbon fiber and 8 g of cobalt silicate-loaded silicon carbide to 80 mL of deionized water, stir at 200 rpm for 30 min, let stand, filter, wash three times with deionized water, and dry in a 70°C oven for 10 min to obtain modified silicon carbide.

[0064] The reinforcing filler is specifically prepared by the following steps:

[0065] B1. 2 g of clay was added to 445 mL of deionized water and stirred at 60°C for 1 h to allow the clay to expand. 1 g of N,N-dimethyldodecylamine was then added and sonicated at 40 kHz for 5 min. The mixture was stirred for 1 h, filtered, washed three times with deionized water, and dried in an oven at 60°C for 10 min to obtain cationic quaternary ammonium salt-modified clay.

[0066] B2. Add 1 g of aluminum nitrate nonahydrate and 10 mL of 0.25 mol / L ammonium carbonate solution to 25 mL of deionized water and stir evenly. Add 5 g of cationic quaternary ammonium salt-modified clay and stir at 400 r / min for 1 h. Stir and react at 100°C for 3 h. Filter, wash three times with deionized water, dry in a 70°C oven for 1 h, place in a muffle furnace, calcined at 400°C for 1 h, and cool to room temperature to obtain a reinforcing filler.

[0067] Example 2

[0068] A high-strength, corrosion-resistant chute prefabricated component for copper smelting, comprising the following raw materials in parts by weight: 70 parts of high-alumina bauxite, 13 parts of brown corundum powder, 8 parts of modified silicon carbide, 4 parts of reinforcing filler, 9 parts of silica fume, 8 parts of calcium aluminate cement, 0.3 parts of an admixture, and 55 parts of deionized water;

[0069] A method for preparing a high-strength, corrosion-resistant chute prefabricated part for copper smelting comprises the following steps:

[0070] S1. The high-alumina bauxite, brown corundum powder, modified silicon carbide, reinforcing filler, silica fume, calcium aluminate cement, admixtures and deionized water were mixed and stirred at a rate of 900 r / min for 1.5h to obtain a mixed slurry;

[0071] The admixture is prepared by mixing sodium citrate, explosion-proof fiber, oxalic acid and metallic aluminum powder in a mass ratio of 7:2.5:0.8:0.5.

[0072] S2. The mixed slurry was placed in a preform mold, vibrated at 150 Hz for 35 minutes, cured at 25°C for 23 hours, demolded, dried at 600°C for 2 hours, and cooled to room temperature to obtain a chute preform.

[0073] Modified silicon carbide is specifically prepared by the following steps:

[0074] A1. 2.5 g of cobalt nitrate hexahydrate, 0.2 g of ammonium fluoride, and 2 g of urea were added to 100 mL of deionized water and stirred. 5.5 g of silicon carbide was added and the reaction was stirred at 125°C for 5 h. The mixture was cooled to room temperature and the solid was collected by filtration. The solid was washed with deionized water three times and ethanol five times, dried in a 60°C oven for 10 min, calcined in a furnace at 700°C for 2 h, and cooled to room temperature to obtain cobalt silicate-loaded silicon carbide.

[0075] A2. 2 g of carbon fiber was added to 50 mL of Tris-HCl buffer (pH 8.5), stirred evenly, and 0.5 g of dopamine was added. The mixture was stirred for 4 h, filtered, washed three times with deionized water, and dried in a 70°C oven for 10 min to obtain pretreated carbon fiber.

[0076] A3. Add 5 g of pretreated carbon fiber and 10 g of cobalt silicate-loaded silicon carbide to 100 mL of deionized water, stir at 250 rpm for 35 min, let stand, filter, wash three times with deionized water, and dry in a 70°C oven for 10 min to obtain modified silicon carbide.

[0077] The reinforcing filler is specifically prepared by the following steps:

[0078] B1. 2.5 g of clay was added to 50 mL of deionized water and stirred at 65°C for 1.5 h to allow the clay to expand. 1.5 g of N,N-dimethyldodecylamine was then added and ultrasonicated at 45 kHz for 8 min. The mixture was stirred for 1.5 h, filtered, washed three times with deionized water, and dried in an oven at 60°C for 10 min to obtain cationic quaternary ammonium salt-modified clay.

[0079] B2. Add 1.5 g of aluminum nitrate nonahydrate and 12 mL of 0.25 mol / L ammonium carbonate solution to 30 mL of deionized water and stir evenly. Add 5.5 g of cationic quaternary ammonium salt-modified clay and stir at 450 r / min for 1.5 h. Stir and react at 105 for 44 h. Filter, wash three times with deionized water, dry in a 70°C oven for 1 h, place in a muffle furnace, calcine at 450°C for 1.5 h, and cool to room temperature to obtain a reinforcing filler.

[0080] Example 3

[0081] A high-strength, corrosion-resistant chute prefabricated component for copper smelting, comprising the following raw materials in parts by weight: 80 parts of high-alumina bauxite, 15 parts of brown corundum powder, 10 parts of modified silicon carbide, 5 parts of reinforcing filler, 10 parts of silica fume, 10 parts of calcium aluminate cement, 0.5 parts of an admixture, and 60 parts of deionized water;

[0082] A method for preparing a high-strength, corrosion-resistant chute prefabricated part for copper smelting comprises the following steps:

[0083] S1. The high-alumina bauxite, brown corundum powder, modified silicon carbide, reinforcing filler, silica fume, calcium aluminate cement, admixtures and deionized water were mixed and stirred at a rate of 1000 r / min for 2h to obtain a mixed slurry;

[0084] The admixture is prepared by mixing sodium citrate, explosion-proof fiber, oxalic acid and metallic aluminum powder in a mass ratio of 8:3:1:0.6.

[0085] S2. The mixed slurry was placed in a preform mold, vibrated at 200 Hz for 40 minutes, cured at 30°C for 25 hours, demolded, dried at 700°C for 3 hours, and cooled to room temperature to obtain a chute preform.

[0086] Modified silicon carbide is specifically prepared by the following steps:

[0087] A1. 3 g of cobalt nitrate hexahydrate, 0.3 g of ammonium fluoride, and 3 g of urea were added to 120 mL of deionized water and stirred. 6 g of silicon carbide was added and the reaction was stirred at 130°C for 6 h. The mixture was cooled to room temperature and the solid was collected by filtration. The solid was washed three times with deionized water and five times with ethanol, dried in a 60°C oven for 10 min, calcined in a furnace at 800°C for 3 h, and cooled to room temperature to obtain cobalt silicate-loaded silicon carbide.

[0088] A2. 3 g of carbon fiber was added to 55 mL of Tris-HCl buffer (pH 8.5), stirred evenly, and 0.6 g of dopamine was added. The mixture was stirred for 5 h, filtered, washed three times with deionized water, and dried in an oven at 70°C for 10 min to obtain pretreated carbon fiber.

[0089] A3. Add 6 g of pretreated carbon fiber and 12 g of cobalt silicate-loaded silicon carbide to 120 mL of deionized water, stir at 300 rpm for 40 min, let stand, filter, wash three times with deionized water, and dry in a 70°C oven for 10 min to obtain modified silicon carbide.

[0090] The reinforcing filler is specifically prepared by the following steps:

[0091] B1. 3 g of clay was added to 55 mL of deionized water and stirred at 70°C for 2 h to allow the clay to expand. 2 g of N,N-dimethyldodecylamine was then added and ultrasonicated at 50 kHz for 10 min. The mixture was stirred for 2 h, filtered, washed three times with deionized water, and dried in an oven at 60°C for 10 min to obtain cationic quaternary ammonium salt-modified clay.

[0092] B2. Add 2 g of aluminum nitrate nonahydrate and 14 mL of 0.25 mol / L ammonium carbonate solution to 35 mL of deionized water and stir evenly. Add 6 g of cationic quaternary ammonium salt-modified clay and stir at 500 r / min for 2 h. Stir and react at 110°C for 5 h. Filter, wash three times with deionized water, dry in a 70°C oven for 1 h, place in a muffle furnace, calcined at 500°C for 2 h, and cool to room temperature to obtain a reinforcing filler.

[0093] Comparative Example 1

[0094] A high-strength, corrosion-resistant chute prefabricated component for copper smelting, comprising the following raw materials in parts by weight: 80 parts of high-alumina bauxite, 15 parts of brown corundum powder, 10 parts of modified silicon carbide, 5 parts of reinforcing filler, 10 parts of silica fume, 10 parts of calcium aluminate cement, 0.5 parts of an admixture, and 60 parts of deionized water;

[0095] A method for preparing a high-strength, corrosion-resistant chute prefabricated part for copper smelting comprises the following steps:

[0096] S1. The high-alumina bauxite, brown corundum powder, modified silicon carbide, reinforcing filler, silica fume, calcium aluminate cement, admixtures and deionized water were mixed and stirred at a rate of 1000 r / min for 2h to obtain a mixed slurry;

[0097] The admixture is prepared by mixing sodium citrate, explosion-proof fiber, oxalic acid and metallic aluminum powder in a mass ratio of 8:3:1:0.6.

[0098] S2. The mixed slurry was placed in a preform mold, vibrated at 200 Hz for 40 minutes, cured at 30°C for 25 hours, demolded, dried at 700°C for 3 hours, and cooled to room temperature to obtain a chute preform.

[0099] Modified silicon carbide is specifically prepared by the following steps:

[0100] A1. 3 g of carbon fiber was added to 55 mL of Tris-HCl buffer (pH 8.5), stirred evenly, and 0.6 g of dopamine was added. The mixture was stirred for 5 h, filtered, washed three times with deionized water, and dried in a 70°C oven for 10 min to obtain pretreated carbon fiber.

[0101] A2. Add 6 g of pretreated carbon fiber and 12 g of silicon carbide to 120 mL of deionized water, stir at 300 rpm for 40 min, let stand, filter, wash three times with deionized water, and dry in a 70°C oven for 10 min to obtain modified silicon carbide.

[0102] The reinforcing filler is specifically prepared by the following steps:

[0103] B1. 3 g of clay was added to 55 mL of deionized water and stirred at 70°C for 2 h to allow the clay to expand. 2 g of N,N-dimethyldodecylamine was then added and ultrasonicated at 50 kHz for 10 min. The mixture was stirred for 2 h, filtered, washed three times with deionized water, and dried in an oven at 60°C for 10 min to obtain cationic quaternary ammonium salt-modified clay.

[0104] B2. Add 2 g of aluminum nitrate nonahydrate and 14 mL of 0.25 mol / L ammonium carbonate solution to 35 mL of deionized water and stir evenly. Add 6 g of cationic quaternary ammonium salt-modified clay and stir at 500 r / min for 2 h. Stir and react at 110°C for 5 h. Filter, wash three times with deionized water, dry in a 70°C oven for 1 h, place in a muffle furnace, calcined at 500°C for 2 h, and cool to room temperature to obtain a reinforcing filler.

[0105] Comparative Example 2

[0106] A high-strength, corrosion-resistant chute prefabricated component for copper smelting, comprising the following raw materials in parts by weight: 80 parts of high-alumina bauxite, 15 parts of brown corundum powder, 10 parts of modified silicon carbide, 5 parts of reinforcing filler, 10 parts of silica fume, 10 parts of calcium aluminate cement, 0.5 parts of an admixture, and 60 parts of deionized water;

[0107] A method for preparing a high-strength, corrosion-resistant chute prefabricated part for copper smelting comprises the following steps:

[0108] S1. The high-alumina bauxite, brown corundum powder, modified silicon carbide, reinforcing filler, silica fume, calcium aluminate cement, admixtures and deionized water were mixed and stirred at a rate of 1000 r / min for 2h to obtain a mixed slurry;

[0109] The admixture is prepared by mixing sodium citrate, explosion-proof fiber, oxalic acid and metallic aluminum powder in a mass ratio of 8:3:1:0.6.

[0110] S2. The mixed slurry was placed in a preform mold, vibrated at 200 Hz for 40 minutes, cured at 30°C for 25 hours, demolded, dried at 700°C for 3 hours, and cooled to room temperature to obtain a chute preform.

[0111] Modified silicon carbide is specifically prepared by the following steps:

[0112] A1. 3 g of cobalt nitrate hexahydrate, 0.3 g of ammonium fluoride, and 3 g of urea were added to 120 mL of deionized water and stirred. 6 g of silicon carbide was added and the reaction was stirred at 130°C for 6 h. The mixture was cooled to room temperature and the solid was collected by filtration. The solid was washed three times with deionized water and five times with ethanol, dried in a 60°C oven for 10 min, calcined in a furnace at 800°C for 3 h, and cooled to room temperature to obtain cobalt silicate-loaded silicon carbide.

[0113] A2. Add 6 g of carbon fiber and 12 g of cobalt silicate-loaded silicon carbide to 120 mL of deionized water, stir at 300 rpm for 40 min, let stand, filter, wash three times with deionized water, and dry in a 70°C oven for 10 min to obtain modified silicon carbide.

[0114] The reinforcing filler is specifically prepared by the following steps:

[0115] B1. 3 g of clay was added to 55 mL of deionized water and stirred at 70°C for 2 h to allow the clay to expand. 2 g of N,N-dimethyldodecylamine was then added and ultrasonicated at 50 kHz for 10 min. The mixture was stirred for 2 h, filtered, washed three times with deionized water, and dried in an oven at 60°C for 10 min to obtain cationic quaternary ammonium salt-modified clay.

[0116] B2. Add 2 g of aluminum nitrate nonahydrate and 14 mL of 0.25 mol / L ammonium carbonate solution to 35 mL of deionized water and stir evenly. Add 6 g of cationic quaternary ammonium salt-modified clay and stir at 500 r / min for 2 h. Stir and react at 110°C for 5 h. Filter, wash three times with deionized water, dry in a 70°C oven for 1 h, place in a muffle furnace, calcined at 500°C for 2 h, and cool to room temperature to obtain a reinforcing filler.

[0117] Comparative Example 3

[0118] A high-strength, corrosion-resistant chute prefabricated component for copper smelting, comprising the following raw materials in parts by weight: 80 parts of high-alumina bauxite, 15 parts of brown corundum powder, 10 parts of modified silicon carbide, 5 parts of reinforcing filler, 10 parts of silica fume, 10 parts of calcium aluminate cement, 0.5 parts of an admixture, and 60 parts of deionized water;

[0119] A method for preparing a high-strength, corrosion-resistant chute prefabricated part for copper smelting comprises the following steps:

[0120] S1. The high-alumina bauxite, brown corundum powder, modified silicon carbide, reinforcing filler, silica fume, calcium aluminate cement, admixtures and deionized water were mixed and stirred at a rate of 1000 r / min for 2h to obtain a mixed slurry;

[0121] The admixture is prepared by mixing sodium citrate, explosion-proof fiber, oxalic acid and metallic aluminum powder in a mass ratio of 8:3:1:0.6.

[0122] S2. The mixed slurry was placed in a preform mold, vibrated at 200 Hz for 40 minutes, cured at 30°C for 25 hours, demolded, dried at 700°C for 3 hours, and cooled to room temperature to obtain a chute preform.

[0123] Modified silicon carbide is specifically prepared by the following steps:

[0124] A1. 3 g of cobalt nitrate hexahydrate, 0.3 g of ammonium fluoride, and 3 g of urea were added to 120 mL of deionized water and stirred. 6 g of silicon carbide was added and the reaction was stirred at 130°C for 6 h. The mixture was cooled to room temperature and the solid was collected by filtration. The solid was washed three times with deionized water and five times with ethanol, dried in a 60°C oven for 10 min, calcined in a furnace at 800°C for 3 h, and cooled to room temperature to obtain cobalt silicate-loaded silicon carbide.

[0125] A2. 3 g of carbon fiber was added to 55 mL of Tris-HCl buffer (pH 8.5), stirred evenly, and 0.6 g of dopamine was added. The mixture was stirred for 5 h, filtered, washed three times with deionized water, and dried in a 70°C oven for 10 min to obtain pretreated carbon fiber.

[0126] A3. Add 6 g of pretreated carbon fiber and 12 g of cobalt silicate-loaded silicon carbide to 120 mL of deionized water, stir at 300 rpm for 40 min, let stand, filter, wash three times with deionized water, and dry in a 70°C oven for 10 min to obtain modified silicon carbide.

[0127] The reinforcing filler is specifically prepared by the following steps:

[0128] 2 g of aluminum nitrate nonahydrate and 14 mL of 0.25 mol / L ammonium carbonate solution were added to 35 mL of deionized water and stirred evenly. 6 g of clay was added and stirred at 500 r / min for 2 h. The mixture was stirred and reacted at 110° C. for 5 h. The mixture was filtered, washed with deionized water three times, dried in an oven at 70° C. for 1 h, placed in a muffle furnace, calcined at 500° C. for 2 h, and cooled to room temperature to obtain a reinforcing filler.

[0129] Comparative Example 4

[0130] A high-strength, corrosion-resistant chute prefabricated component for copper smelting, comprising the following raw materials in parts by weight: 80 parts of high-alumina bauxite, 15 parts of brown corundum powder, 10 parts of modified silicon carbide, 5 parts of cationic quaternary ammonium salt-modified clay, 10 parts of silica fume, 10 parts of calcium aluminate cement, 0.5 parts of an admixture, and 60 parts of deionized water;

[0131] A method for preparing a high-strength, corrosion-resistant chute prefabricated part for copper smelting comprises the following steps:

[0132] S1. The high-alumina bauxite, brown corundum powder, modified silicon carbide, cationic quaternary ammonium salt-modified clay, silica fume, calcium aluminate cement, admixtures and deionized water were mixed and stirred at a rate of 1000 r / min for 2h to obtain a mixed slurry;

[0133] The admixture is prepared by mixing sodium citrate, explosion-proof fiber, oxalic acid and metallic aluminum powder in a mass ratio of 8:3:1:0.6.

[0134] S2. The mixed slurry was placed in a preform mold, vibrated at 200 Hz for 40 minutes, cured at 30°C for 25 hours, demolded, dried at 700°C for 3 hours, and cooled to room temperature to obtain a chute preform.

[0135] Modified silicon carbide is specifically prepared by the following steps:

[0136] A1. 3 g of cobalt nitrate hexahydrate, 0.3 g of ammonium fluoride, and 3 g of urea were added to 120 mL of deionized water and stirred. 6 g of silicon carbide was added and the reaction was stirred at 130°C for 6 h. The mixture was cooled to room temperature and the solid was collected by filtration. The solid was washed three times with deionized water and five times with ethanol, dried in a 60°C oven for 10 min, calcined in a furnace at 800°C for 3 h, and cooled to room temperature to obtain cobalt silicate-loaded silicon carbide.

[0137] A2. 3 g of carbon fiber was added to 55 mL of Tris-HCl buffer (pH 8.5), stirred evenly, and 0.6 g of dopamine was added. The mixture was stirred for 5 h, filtered, washed three times with deionized water, and dried in a 70°C oven for 10 min to obtain pretreated carbon fiber.

[0138] A3. Add 6 g of pretreated carbon fiber and 12 g of cobalt silicate-loaded silicon carbide to 120 mL of deionized water, stir at 300 rpm for 40 min, let stand, filter, wash three times with deionized water, and dry in a 70°C oven for 10 min to obtain modified silicon carbide.

[0139] Cationic quaternary ammonium salt modified clay is specifically prepared by the following steps:

[0140] 3 g of clay was added to 55 mL of deionized water and stirred at 70 °C for 2 h to expand the volume of the clay. 2 g of N,N-dimethyldodecylamine was added and ultrasonicated at 50 kHz for 10 min. The mixture was stirred and reacted for 2 h. The mixture was filtered, washed with deionized water three times, and dried in an oven at 60 °C for 10 min to obtain cationic quaternary ammonium salt-modified clay.

[0141] The performance of the chute preforms prepared in Examples 1-3 and Comparative Examples 1-4 was tested.

[0142] Mechanical property testing: GB / T 3985-2008 "Refractory materials - Determination of physical properties of refractory graphite and bauxite" was used to test the flexural strength and compressive strength of the chute prefabricated parts prepared above at different temperatures.

[0143] The test results are shown in Table 1 below.

[0144] Table 1 Performance test of chute preforms prepared in Examples 1-3 and Comparative Examples 1-4:

[0145]

[0146] It can be seen from the data in Table 1 that the chute preforms prepared in Examples 1-3 have high corrosion resistance and high strength.

[0147] In Comparative Example 1, the silicon carbide loaded with cobalt silicate was replaced with modified silicon carbide prepared from silicon carbide and added to the chute preform. Its mechanical properties decreased, proving that the in-situ synthesis of the cobalt silicate layer on the surface of the silicon carbide increased the surface roughness of the silicon carbide and the contact area between the silicon carbide and the raw material of the chute preform, which is conducive to the formation of a dense chute preform. In addition, the formed cobalt silicate layer has high high temperature resistance and water resistance, preventing the silicon carbide from easily combining with oxygen at high temperature to expand and deform, resulting in a decrease in the mechanical properties of the chute preform, thereby reducing the strength and corrosion resistance of the chute preform.

[0148] In Comparative Example 2, the pretreated carbon fiber is replaced by modified silicon carbide prepared from carbon fiber and added to the chute preform, and its mechanical properties decrease, which proves that polydopamine is formed by self-polymerization on the surface of the carbon fiber, which is conducive to the adhesion of silicon carbide loaded with cobalt silicate to the surface of the carbon fiber, and the pretreated carbon fiber serves as a bridge for the raw materials of the chute preform, making the bonding between the raw materials of the chute preform tighter, improving the density of the chute preform, and enhancing the high strength and corrosion resistance of the raw materials of the chute preform.

[0149] In Comparative Example 3, the cationic quaternary ammonium salt-modified clay was replaced with a reinforcing filler prepared from clay and added to the chute preform. Its mechanical properties decreased, proving that the cationic quaternary ammonium salt penetrated into the clay layers, reduced the interaction between the clay layers, and improved the dispersibility of the clay, which was conducive to the synthesis of nano-alumina on the clay surface. Combined with the low permeability of the clay, the chute preform's resistance to metal solution penetration was improved, resulting in the chute preform having excellent mechanical strength.

[0150] In Comparative Example 4, the reinforcing filler is replaced with cationic quaternary ammonium salt modified clay and added to the chute preform, and its mechanical properties decrease, which proves that nano alumina is synthesized on the surface of the cationic quaternary ammonium salt modified clay. Nano alumina has a small size effect and can be filled into the gaps of the chute preform, thereby improving the density of the chute preform and enhancing the high temperature resistance and corrosion resistance of the chute preform. Nano alumina has excellent resistance to metal solution penetration and the low permeability of the compound clay, which enhances the corrosion resistance of the chute preform, making the chute preform exhibit excellent mechanical properties.

[0151] Throughout the specification, references to terms such as "one embodiment," "example," or "specific example" indicate that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, schematic representations of these terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0152] The above contents are merely examples and explanations of the present invention. Those skilled in the art may make various modifications or additions to the described specific embodiments or replace them in similar ways. As long as they do not deviate from the invention or exceed the scope defined by the claims, they should all fall within the scope of protection of the present invention.

Claims

1. A high-strength, corrosion-resistant chute prefabricated part for copper smelting, characterized in that: The raw materials include the following parts by weight: 60-80 parts of high-alumina bauxite, 10-15 parts of corundum, 5-10 parts of modified silicon carbide, 3-5 parts of reinforcing filler, 8-10 parts of ultrafine powder, 6-10 parts of cement, 0.2-0.5 parts of admixture, and 50-60 parts of deionized water; The modified silicon carbide is specifically prepared by the following steps: A1. Cobalt nitrate hexahydrate, ammonium fluoride, and urea were added to deionized water and stirred. Silicon carbide was then added and the reaction was stirred at 120-130°C for 4-6 hours. The mixture was cooled to room temperature and the solid was collected by filtration. The solid was washed, dried, and calcined at 600-800°C for 1-3 hours. The mixture was cooled to room temperature to obtain cobalt silicate-loaded silicon carbide. A2. The carbon fiber was added to Tris-HCl buffer, stirred evenly, dopamine was added, and the reaction was stirred for 3-5h. The mixture was filtered, washed, and dried to obtain pretreated carbon fiber. A3. The pretreated carbon fibers and cobalt silicate-loaded silicon carbide were added to deionized water and stirred at 200-300 rpm for 30-40 min. After standing, the mixture was filtered, washed three times with deionized water, and dried in an oven at 70°C for 10 min to obtain modified silicon carbide. The reinforcing filler is specifically prepared by the following steps: B1. The clay was added to deionized water, stirred at 60-70 ° C for 1-2h, a cationic quaternary ammonium salt was added, and ultrasonic treatment was performed at 40-50KHz for 5-10min. The reaction was stirred for 1-2h, filtered, washed, and dried to obtain a cationic quaternary ammonium salt-modified clay; B2. Aluminum nitrate nonahydrate and ammonium carbonate solution were added to deionized water and stirred evenly. Cationic quaternary ammonium salt-modified clay was added and stirred at 400-500 r / min for 1-2 hours. The mixture was stirred at 100-110°C for 3-5 hours. The mixture was filtered, washed, dried, calcined at 400-500°C for 1-2 hours, and cooled to room temperature to obtain a reinforcing filler.

2. A high-strength, corrosion-resistant chute prefabricated part for copper smelting according to claim 1, characterized in that: In step A1, the ratio of the cobalt nitrate hexahydrate, ammonium fluoride, urea, deionized water and silicon carbide is (2-3) g: (0.1-0.3) g: (1-3) g: (80-120) mL: (5-6) g.

3. The high-strength, corrosion-resistant chute prefabricated part for copper smelting according to claim 1, characterized in that: In step A2, the ratio of the carbon fiber, Tris-HCl buffer and dopamine is (1-3) g: (45-55) mL: (0.4-0.6) g.

4. The high-strength, corrosion-resistant chute prefabricated part for copper smelting according to claim 1, characterized in that: In step A3, the ratio of the pretreated carbon fiber, the cobalt silicate-loaded silicon carbide, and deionized water is (4-6) g: (8-12) g: (80-120) mL.

5. The high-strength, corrosion-resistant chute prefabricated part for copper smelting according to claim 1, characterized in that: In step B1, the ratio of the clay, deionized water and cationic quaternary ammonium salt is (2-3) g: (45-55) mL: (1-2) g.

6. The high-strength, corrosion-resistant chute prefabricated part for copper smelting according to claim 1, characterized in that: In step B2, the ratio of the aluminum nitrate nonahydrate, ammonium carbonate solution, deionized water and cationic quaternary ammonium salt modified clay is (1-2) g: (10-14) mL: (25-35) mL: (5-6) g.

7. A method for preparing a high-strength, corrosion-resistant chute prefabricated part for copper smelting according to any one of claims 1 to 6, characterized in that: The method comprises the following preparation steps: S1. The high alumina, corundum, modified silicon carbide, reinforcing filler, ultrafine powder, cement, admixture and deionized water were mixed and stirred at a rate of 800-1000r / min for 1-2h to obtain a mixed slurry; S2. Place the mixed slurry in a preform mold, vibrate at 100-200 Hz for 30-40 minutes, cure at 20-30°C for 20-25 hours, demold, dry at 500-700°C for 1-3 hours, and cool to room temperature to obtain a chute preform.

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