A system and method for preparing high-performance tundish dry material

Abstract

The present invention relates to the field of refractory materials technology, and in particular to a system and method for preparing high-performance tundish dry material, wherein the preparation method includes the following steps: mixing, molding, drying, sintering, cooling, granulating, and applying the tundish dry material raw materials to obtain a tundish refractory lining sample, testing the thermal shock stability of the tundish refractory lining sample to obtain the actual thermal shock stability; if the actual thermal shock stability cannot meet the standard thermal shock stability requirements, the thermal shock stability requirements are met by adjusting the volume density of the tundish dry material particles; if the standard thermal shock stability requirements cannot be met by adjusting the volume density of the tundish dry material particles, the thermal shock stability requirements are met by adjusting the sintering heating rate. The present invention detects the thermal shock stability of the tundish dry material and adjusts various parameters in the preparation process according to the test results, so that the thermal shock stability of the tundish dry material produced in batches is consistent.

Description

Technical Field

[0001] The present invention relates to the technical field of refractory materials, and in particular to a system and method for preparing high-performance tundish dry material. Background Art

[0002] Chinese Patent Publication No. CN117756503A discloses a tundish dry material and a preparation method thereof, comprising the following steps: S1: selecting raw materials, including alumina, silica, magnesium oxide, additives, and rare earth elements according to specified percentages; S2: pre-treating, including washing and drying the selected raw materials; S3: uniformly mixing, using mechanical stirring, to form a mixture A; S4: high-temperature calcination, including calcining the homogeneous mixture A at high temperature; S5: cooling, including slowly cooling the calcined product at a constant temperature; S6: grinding, including grinding the cooled calcined product to obtain a fine-grained tundish dry material; S7: screening, including screening the ground product using a particle size screen; and S8: product testing, including quality inspection of the screened product.

[0003] It can be seen that in the process of preparing dry materials in tundishes, the existing technology has the following problems: due to the lack of thermal shock stability testing of the prepared dry materials in the tundishes, various parameters in the preparation process are adjusted according to the test results, resulting in inconsistent thermal shock stability of the dry materials in the tundishes produced in batches. Summary of the Invention

[0004] The technology lacks the ability to detect the thermal shock stability of the prepared dry material in the tundish, and adjusts various parameters in the preparation process based on the test results, resulting in inconsistent thermal shock stability of the dry material in the tundish during batch production.

[0005] To achieve the above object, the present invention provides a method for preparing high-performance tundish dry material, comprising the following steps:

[0006] The tundish dry material raw materials are mixed, formed, dried, sintered, cooled and granulated to obtain tundish dry material particles;

[0007] Applying a coating to the tundish dry material particles to obtain a tundish refractory lining sample, heating the tundish refractory lining sample to a test temperature, and testing the thermal shock stability of the tundish refractory lining sample to obtain actual thermal shock stability;

[0008] If the actual thermal shock stability cannot meet the standard thermal shock stability requirements, the volume density of the dry material particles in the tundish is adjusted to meet the thermal shock stability requirements;

[0009] If the volume density of the dry material particles in the tundish cannot meet the standard thermal shock stability requirements, the sintering heating rate can be adjusted to meet the thermal shock stability requirements;

[0010] measuring the bulk density of the dry material particles in the tundish to obtain an actual bulk density of the dry material particles in the tundish, comparing the actual bulk density of the dry material particles in the tundish with a standard bulk density of the dry material particles in the tundish to obtain a first bulk density comparison result, and determining whether to adjust the granulation parameters based on the first bulk density comparison result;

[0011] When adjusting the granulation pressure and granulation temperature, the granulation pressure is adjusted first. When the granulation pressure adjustment alone cannot meet the processing requirements, the granulation temperature is adjusted. When the granulation pressure is adjusted, the adjustment range is related to the real-time granulation temperature.

[0012] Among them, the granulation parameters include granulation pressure and granulation temperature.

[0013] Furthermore, the process of detecting the thermal shock stability of the refractory lining of the tundish to obtain the actual thermal shock stability includes:

[0014] The tundish refractory lining samples are tested by the water quenching method to obtain the actual comprehensive thermal shock stability. If the actual comprehensive thermal shock stability cannot be obtained through a single test, the actual comprehensive thermal shock stability of the tundish refractory lining samples are tested multiple times according to actual production conditions to obtain the actual comprehensive thermal shock stability assessment level;

[0015] Among them, the actual production situation includes the number of uses and the duration of use in a single use.

[0016] Furthermore, the process of repeatedly testing the actual comprehensive thermal shock stability of the tundish refractory lining sample according to actual production conditions to obtain the actual comprehensive thermal shock stability evaluation level includes:

[0017] The surface of the refractory lining sample of the tundish that has undergone the first water quenching method is observed by high temperature microscope to see if there is any cracking.

[0018] In the case of cracking, the crack area and the number of cracks are recorded to obtain cracking feedback; in the case of no cracking, the refractory lining sample of the ladle is tested according to the actual production situation to obtain a first test result, and it is judged whether it meets the thermal shock stability requirements based on the first test result.

[0019] Furthermore, in the case of cracks, the process of recording the crack area and the number of cracks to obtain crack feedback includes:

[0020] collecting crack distribution on the surface of the refractory lining sample of the tundish through a high-temperature microscope to obtain a crack distribution map, and analyzing the crack distribution map to obtain a first crack analysis result;

[0021] The first crack analysis result includes concentrated crack distribution and dispersed crack distribution.

[0022] Furthermore, the process of analyzing the crack distribution map to obtain a first crack analysis result includes:

[0023] If the first crack analysis result shows a dispersed distribution of cracks, the drying parameters are adjusted according to the crack area and number to meet the thermal shock stability requirements;

[0024] The drying parameters include drying temperature and drying time.

[0025] Furthermore, the process of analyzing the crack distribution map to obtain a first crack analysis result includes:

[0026] If the first crack analysis result shows a concentrated crack distribution, the distribution concentration of the dry material particles in the tundish during the coating construction process is adjusted according to the crack depth to meet the thermal shock stability requirements.

[0027] Furthermore, the process of determining whether to adjust the granulation parameters according to the first bulk density comparison result includes:

[0028] If the granulation pressure cannot meet the standard bulk density requirement of the dry material particles in the tundish, the granulation temperature can be adjusted to meet the standard bulk density requirement of the dry material particles in the tundish.

[0029] Furthermore, in the case where the volume density of the dry material particles in the tundish cannot meet the standard thermal shock stability requirements, the process of adjusting the sintering heating rate to meet the thermal shock stability requirements includes:

[0030] The sintered tundish dry material particles are sliced ​​to obtain tundish dry material particle slices. The pore distribution in the tundish dry material particle slices is observed to obtain a pore distribution result. The pore distribution result is used to determine whether the sintering heating rate should be adjusted to meet the thermal shock stability requirements.

[0031] The present invention provides a high-performance tundish dry material preparation system, comprising:

[0032] Raw material storage control module, used to control the amount of dry material added to each tundish;

[0033] The ingredient control module is used to accurately control the proportion of various raw materials and control the mixing equipment to mix;

[0034] Temperature acquisition module, used to obtain the temperature at each production stage;

[0035] Temperature control module, used to control the temperature at each production stage;

[0036] A data analysis module is connected to the raw material storage control module, the batching control module, the temperature acquisition module and the temperature control module, and is used to analyze the thermal stability of the dry material in the tundish and adjust the operating status of each module according to its thermal stability.

[0037] Compared with the prior art, the present invention significantly improves the thermal shock stability of the tundish dry material particles by optimizing process parameters such as mixing, forming, drying, and sintering, resulting in improved thermal shock resistance in high-temperature environments. Improving thermal shock stability means that the refractory lining of the tundish is less likely to crack or peel during high-temperature operations, thereby extending the tundish's service life and reducing replacement frequency and maintenance costs. A stable refractory lining can better protect the smelting quality of the metal within the tundish and reduce product quality issues caused by lining damage. By adjusting the bulk density and sintering temperature rise rate, the production process of the tundish dry material can be precisely controlled, improving production efficiency and product consistency. By improving the process, product scrapping and repair costs caused by insufficient thermal shock stability are reduced, reducing overall production costs. Improving material stability and service life reduces waste generation, which is beneficial to environmental protection. By optimizing the processing of the tundish dry material raw materials and the production process, this technical solution not only improves the thermal shock stability of the product, but also increases production efficiency and reduces costs, resulting in significant economic and social benefits.

[0038] Furthermore, by simulating the number and duration of actual production usage, the system can more realistically reflect the thermal shock stability of the refractory lining under actual operating conditions, providing more reliable assessment results. By testing and evaluating the refractory lining at different usage times, thermal shock stability can be graded, helping users select appropriate refractory tundish dry material particles based on their actual needs. Multiple testing and grading evaluations improve the accuracy of the refractory lining's thermal shock stability assessment, helping to reduce misjudgments. Based on the evaluation grade, users can more specifically select tundish dry material particles that suit their production needs, improving production efficiency and tundish dry material particle utilization. The evaluation identifies tundish dry material particles with higher thermal shock stability, thereby extending the service life of the refractory lining and reducing replacement frequency. Selecting tundish dry material particles with higher thermal shock stability can reduce maintenance and replacement costs and increase production line uptime. Testing and evaluation can effectively prevent damage and accidents caused by insufficient thermal shock stability of the refractory lining, ensuring production safety. By identifying possible thermal shock damage risks in advance, safety accidents caused by failure of dry material particles in the tundish during production can be effectively prevented.

[0039] Furthermore, by adjusting drying parameters, thermal stress on the tundish dry material particles during the drying process can be reduced, thereby improving their thermal shock resistance and reducing the occurrence of cracks. Reducing the number and size of cracks helps extend the service life of the tundish refractory lining, reducing replacement frequency and maintenance costs. Adjusting drying parameters based on the actual crack distribution allows for more precise control of the drying process and optimized operating conditions. By reducing downtime and repair time caused by cracks, the continuous operation time and overall efficiency of the production line can be improved. By comparing the number of cracks and adjusting drying parameters, product quality can be better controlled to ensure that the performance of the refractory lining meets production requirements. If the actual number of cracks is greater than the standard number of cracks, first adjust the drying temperature to quickly dry the tundish refractory lining samples. If the drying temperature is within the standard drying temperature range, there is no need to adjust the drying temperature. If the drying temperature is less than the minimum value of the standard drying temperature range, increase the drying temperature according to the drying temperature ratio parameter to speed up the drying process, saving time and improving production efficiency. If the drying temperature is greater than the maximum value of the standard drying temperature range, reduce the drying temperature according to the drying temperature ratio parameter to avoid excessive cracks on the surface of the tundish refractory lining samples due to excessive drying temperature, thereby reducing their service life. If the adjusted drying temperature still exceeds the maximum value of the standard drying temperature range, increase the drying time to improve the drying efficiency of the tundish refractory lining samples and reduce the number of cracks.

[0040] Furthermore, by adjusting the distribution concentration of the tundish dry material particles based on the crack depth, the stability of the tundish dry material particles under thermal shock conditions can be better ensured. A higher degree of particle compression helps reduce stress concentration caused by temperature changes, thereby reducing the risk of crack propagation. The optimized particle distribution concentration can improve the overall performance of the refractory tundish dry material particles, enabling them to withstand more frequent thermal cycles, thereby extending the service life of the refractory lining of the tundish. Since the thermal shock stability of the refractory tundish dry material particles is improved, the formation and propagation of cracks are reduced, which can reduce maintenance frequency and replacement costs, and improve production efficiency. By precisely controlling the particle distribution concentration, production interruptions caused by damage to the tundish dry material particles can be reduced, thereby improving the continuous operation time and overall efficiency of the production line. Good particle distribution concentration helps to improve the uniformity and thermal conductivity efficiency of the tundish lining, thereby improving the quality of the final product. The applied pressure value is positively correlated with the crack depth. When the crack depth is deeper, the pressure applied to the refractory lining of the tundish will increase to reduce the crack depth, thereby avoiding the crack depth being too deep, which may cause safety hazards to the refractory lining of the tundish during use and reduce the service life of the tundish.

[0041] Furthermore, by adjusting granulation parameters to increase the bulk density of the tundish dry material pellets, the thermal shock resistance of the tundish dry material pellets can be enhanced. A higher bulk density generally means better bonding between the particles, which helps the tundish dry material pellets resist crack formation and growth during thermal cycling. Adjusting the granulation pressure and temperature helps optimize the pellet formation process, thereby improving the overall performance of the tundish dry material pellets, including mechanical strength, wear resistance, and erosion resistance. By ensuring that the pellet bulk density meets the standard, consistent performance is ensured across each batch of tundish dry material pellets produced, which is crucial for maintaining stable production line operation. Increased compression reduces internal porosity, thereby lowering thermal resistance during heat transfer and improving thermal shock resistance. An appropriate granulation temperature promotes uniformity in the internal structure of the pellets, enhancing their mechanical strength and thermal stability. Improved thermal shock resistance means that the tundish refractory lining can withstand longer thermal cycling, thereby extending its service life. This reduces the number of repairs and replacements required due to substandard tundish dry material pellet performance, thereby reducing maintenance costs. Consistent tundish dry material pellet properties help improve production efficiency and reduce production interruptions.

[0042] Furthermore, by adjusting the sintering heating rate, the pore distribution is more uniform, reducing thermal stress concentration points within the tundish dry material pellets and improving their resistance to thermal shock. A more uniform pore distribution means more consistent performance of the tundish dry material pellets, which is particularly important for mass production, ensuring that each batch of tundish dry material pellets exhibits excellent thermal shock resistance. The optimized tundish dry material pellets exhibit improved thermal shock resistance, extending the service life of the tundish refractory lining, and reducing replacement frequency and maintenance costs. Precisely controlling the sintering heating rate reduces waste of tundish dry material pellets due to substandard thermal shock resistance, lowering production costs. This reduces production interruptions caused by tundish dry material pellet problems, improving the continuous operation time and overall efficiency of the production line. This improved performance directly impacts the quality of the final product. For example, in the steel industry, it can improve casting quality and reduce defects. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 Flowchart of the method for preparing high-performance tundish dry material in this embodiment;

[0044] Figure 2 This is a flow chart of a method for testing thermal shock stability of a method for preparing high-performance tundish dry material in this embodiment;

[0045] Figure 3 Flow chart of the process of adjusting the particle distribution concentration of the tundish dry material in the method for preparing the high-performance tundish dry material in this embodiment;

[0046] Figure 4 Schematic diagram of the preparation system of high-performance tundish dry material in this embodiment. DETAILED DESCRIPTION

[0047] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention.

[0048] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0049] It should be noted that, in the description of the present invention, terms such as "up", "down", "left", "right", "inside", and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0050] Furthermore, it should be noted that, in the description of the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0051] See also Figures 1-4 As shown, Figure 1 Flowchart of the method for preparing high-performance tundish dry material in this embodiment; Figure 2 This is a flow chart of a method for testing thermal shock stability of a method for preparing high-performance tundish dry material in this embodiment; Figure 3 Flow chart of the process of adjusting the particle distribution concentration of the tundish dry material in the method for preparing the high-performance tundish dry material in this embodiment; Figure 4 Schematic diagram of the preparation system of high-performance tundish dry material in this embodiment.

[0052] This embodiment provides a method for preparing high-performance tundish dry material, comprising the following steps:

[0053] Step S1, mixing, shaping, drying, sintering, cooling and granulating the tundish dry material raw materials to obtain tundish dry material particles;

[0054] Step S2, applying a coating to the tundish dry material particles to obtain a tundish refractory lining sample, heating the tundish refractory lining sample to a test temperature, and testing the thermal shock stability of the tundish refractory lining sample to obtain an actual thermal shock stability;

[0055] Step S3: if the actual thermal shock stability cannot meet the standard thermal shock stability requirement, the volume density of the dry material particles in the tundish is adjusted to meet the thermal shock stability requirement;

[0056] Step S4: If the volume density of the dry material particles in the tundish cannot meet the standard thermal shock stability requirement, the sintering heating rate is adjusted to meet the thermal shock stability requirement.

[0057] By optimizing process parameters such as mixing, forming, drying, and sintering, the thermal shock stability of tundish dry material particles can be significantly improved, resulting in improved thermal shock resistance in high-temperature environments. Improved thermal shock stability means the tundish refractory lining is less susceptible to cracking and spalling during high-temperature operations, thereby extending the tundish's service life and reducing replacement frequency and maintenance costs. A stable refractory lining better protects the molten metal within the tundish and reduces product quality issues caused by lining damage. By adjusting the bulk density and sintering temperature rise rate, the production process of tundish dry material can be precisely controlled, improving production efficiency and product consistency. These process improvements reduce product scrap and repair costs caused by insufficient thermal shock stability, lowering overall production costs. Improving material stability and service life reduces waste generation, benefiting the environment. By optimizing the raw material processing and production process of tundish dry material, this technical solution not only improves the thermal shock stability of the product, but also increases production efficiency and reduces costs, offering significant economic and social benefits.

[0058] Specifically, the process of testing the thermal shock stability of the refractory lining of the tundish to obtain the actual thermal shock stability includes:

[0059] The tundish refractory lining samples are tested by the water quenching method to obtain the actual comprehensive thermal shock stability. If the actual comprehensive thermal shock stability cannot be obtained through a single test, the actual comprehensive thermal shock stability of the tundish refractory lining samples are tested multiple times according to actual production conditions to obtain the actual comprehensive thermal shock stability assessment level;

[0060] Among them, the actual production situation includes the number of uses and the duration of use in a single use.

[0061] Specifically, the process of repeatedly testing the actual comprehensive thermal shock stability of the tundish refractory lining sample according to actual production conditions to obtain the actual comprehensive thermal shock stability evaluation level includes:

[0062] The surface of the refractory lining sample of the tundish that has undergone the first water quenching method is observed by high temperature microscope to see if there is any cracking.

[0063] The surface of the refractory lining sample of the tundish that has undergone the first water quenching method is observed by high temperature microscope to see if there is any cracking.

[0064] In the case of cracking, the crack area and the number of cracks are recorded to obtain cracking feedback; in the case of no cracking, the refractory lining sample of the ladle is tested according to the actual production situation to obtain a first test result, and it is judged whether it meets the thermal shock stability requirements based on the first test result.

[0065] This embodiment provides a method for testing the thermal shock stability of a tundish refractory lining using a water quenching method, comprising the following steps:

[0066] Step S21, cutting off a portion of the tundish refractory lining sample to obtain a tundish refractory lining test sample for a water quenching method;

[0067] Step S22, performing dust removal and drying treatment on the tundish refractory lining test sample, and preheating the treated tundish refractory lining test sample;

[0068] Step S23, placing the treated tundish refractory lining test sample into a high-temperature furnace for heating, and taking out the tundish refractory lining test sample that has reached the test temperature;

[0069] Step S24: quickly place the tundish refractory lining test sample that has reached the test temperature into a cooling device filled with room temperature water, and maintain the preset test time;

[0070] Step S25: Take out the tundish refractory lining test sample, remove the surface moisture, and observe whether there are cracks or surface peeling on the surface.

[0071] Preferably, the test temperature is selected to be 1300° C., and the preset test duration is 10 minutes.

[0072] In the case that a single test cannot obtain the actual comprehensive thermal shock stability, the refractory lining of the tundish is tested multiple times according to the actual production situation.

[0073] For example: In actual production, the refractory lining of the tundish is used 20 times, and the duration of each use is 4 hours.

[0074] When conducting multi-stage testing on the tundish refractory lining test samples, in order to ensure that the tundish refractory lining test samples meet the actual production requirements, the number of tests is increased to obtain the first test results.

[0075] During the test, the refractory lining of the tundish was used 23 times, with a single use time of 4 hours.

[0076] For the first test result, if the tundish refractory lining is used 20-22 times in the test and the single use time is 4 hours, the surface of the tundish refractory lining is observed by high-temperature microscope to see if there are any cracks. If there are no cracks, the actual comprehensive thermal shock stability assessment grade of the tundish refractory lining is Class III actual comprehensive thermal shock stability;

[0077] For the first test result, if the tundish refractory lining is used 23-25 ​​times in the test, and the single use time is 4 hours, the surface of the tundish refractory lining is observed by high-temperature microscope to see if there are any cracks. If there are no cracks, the actual comprehensive thermal shock stability assessment grade of the tundish refractory lining is Class II;

[0078] For the first test result, where the refractory lining of the tundish is used 26-30 times in the test and the single use time is 4 hours, a high-temperature microscope is used to observe whether there are cracks on the surface of the refractory lining of the tundish. If there are no cracks, the actual comprehensive thermal shock stability assessment level of the refractory lining of the tundish is first-class actual comprehensive thermal shock stability.

[0079] For the above situation, if there are cracks on the surface of the tundish refractory lining sample, the tundish refractory lining sample still meets the thermal shock stability requirements;

[0080] If the first test result shows that the tundish refractory lining has been used less than 20 times during the test, and the duration of each use is less than or equal to 4 hours, observe the surface of the tundish refractory lining using a high-temperature microscope to see if there are any cracks. If cracks are found, the tundish refractory lining sample still cannot meet the thermal shock stability requirements, and the cracking situation must be recorded;

[0081] In the case of cracks on the surface of the refractory lining sample of the tundish, the crack area and number are recorded, and the density of the dry material particles in the tundish is tested, and these data are used as cracking feedback.

[0082] By simulating the number and duration of actual production usage, the thermal shock resistance of the refractory lining under actual operating conditions can be more realistically reflected, providing more reliable assessment results. Testing and evaluating the refractory lining at different usage times allows for a grading of thermal shock resistance, helping users select appropriate tundish granules based on their actual needs. Multiple testing and grading assessments improve the accuracy of the refractory lining's thermal shock resistance assessment and help reduce misjudgments. Based on the assessment grade, users can more specifically select tundish granules that suit their production needs, improving production efficiency and tundish granule utilization. The assessment identifies tundish granules with higher thermal shock resistance, extending the life of the refractory lining and reducing replacement frequency. Selecting tundish granules with higher thermal shock resistance reduces maintenance and replacement costs and increases production line uptime. Testing and evaluation effectively prevent damage and accidents caused by insufficient thermal shock resistance of the refractory lining, ensuring production safety. By identifying possible thermal shock damage risks in advance, safety accidents caused by failure of dry material particles in the tundish during production can be effectively prevented.

[0083] Specifically, the process of recording the crack area and the number of cracks to obtain crack feedback includes:

[0084] collecting crack distribution on the surface of the refractory lining sample of the tundish through a high-temperature microscope to obtain a crack distribution map, and analyzing the crack distribution map to obtain a first crack analysis result;

[0085] The first crack analysis result includes concentrated crack distribution and dispersed crack distribution.

[0086] Specifically, the process of analyzing the crack distribution map to obtain the first crack analysis result includes:

[0087] If the first crack analysis result shows a dispersed distribution of cracks, the drying parameters are adjusted according to the crack area and number to meet the thermal shock stability requirements;

[0088] The drying parameters include drying temperature and drying time.

[0089] Use a high temperature microscope to observe the surface crack distribution of the refractory lining sample of the tundish treated by water quenching to obtain the crack distribution map, analyze the crack distribution map,

[0090] For the case where the crack distribution diagram is dispersed, the actual number of cracks is obtained based on the crack area, and the actual number of cracks is compared with the standard number of cracks, where the standard number of cracks is obtained based on historical crack data.

[0091] If the actual number of cracks is less than or equal to the standard number of cracks, the drying parameters are not adjusted;

[0092] If the actual number of cracks is greater than the standard number of cracks, the drying temperature is adjusted down and the drying time is increased according to the adjusted drying temperature. When the drying temperature is reduced, the reduced drying temperature value is determined by multiplying the difference between the standard number of cracks and the actual number of cracks by a preset parameter for reducing the drying temperature ratio. When the drying time is increased, the reduced drying time is determined by multiplying the reduced drying temperature by a preset compensation parameter for the effect of the reduced drying temperature on the drying time.

[0093] The difference between the standard number of cracks and the actual number of cracks is multiplied by the preset parameter for increasing the drying time ratio to determine the increased value;

[0094] In this embodiment, the standard number of cracks is set to 40, which is obtained based on historical data analysis; the standard drying temperature range is set to 260-300°C,

[0095] For example: by detecting that the actual number of cracks is 50,

[0096] Since the actual number of cracks is greater than the standard number of cracks, it is necessary to adjust the drying parameters.

[0097] If the initial drying temperature is 240°C and the preset drying temperature increase ratio parameter is 20, the value after the drying temperature is reduced is 240 + (50-40) × 20 = 260°C;

[0098] If the initial drying temperature is 280°C, there is no need to adjust the drying temperature;

[0099] If the initial drying temperature is 320°C and the preset drying temperature reduction ratio parameter is 20, the value after the drying temperature is reduced is 320-(50-40)×20=300°C;

[0100] The initial drying time is set to 4 hours, and the preset compensation parameter for the effect of the reduced drying temperature on the drying time is 0.1. The increased drying time is 4 + (300-260) × 0.1 = 8 hours.

[0101] After adjustment, the drying temperature was lowered to reduce thermal stress, and the drying temperature was adjusted to the standard drying temperature range according to the number of cracks. At the same time, considering that lowering the temperature may take longer to achieve the drying effect, the drying time was extended from 4 hours to 8 hours to allow the moisture in the dry material in the tundish to evaporate completely.

[0102] When the drying temperature reaches 300℃, stop heating and extend the drying time.

[0103] Among them, when the crack distribution diagram shows a dispersed distribution, the cracks are not in one crack area, but are distributed on the entire surface of the refractory lining of the tundish without a specific concentrated area; when the crack distribution diagram shows a concentrated distribution, the cracks are concentrated in one crack area.

[0104] By adjusting drying parameters, thermal stress on the tundish dry material particles during the drying process can be reduced, thereby improving their thermal shock resistance and minimizing cracking. Reducing the number and size of cracks helps extend the service life of the tundish refractory lining, reducing replacement frequency and maintenance costs. Adjusting drying parameters based on the actual crack distribution allows for more precise control of the drying process and optimized operating conditions. By reducing downtime and repair time caused by cracks, the continuous operation time and overall efficiency of the production line can be improved. By comparing the number of cracks and adjusting drying parameters, product quality can be better controlled to ensure that the refractory lining's performance meets production requirements. If the actual number of cracks is greater than the standard number of cracks, first adjust the drying temperature to quickly dry the tundish refractory lining samples. If the drying temperature is within the standard drying temperature range, there is no need to adjust the drying temperature. If the drying temperature is less than the minimum value of the standard drying temperature range, increase the drying temperature according to the drying temperature ratio parameter to speed up the drying process, saving time and improving production efficiency. If the drying temperature is greater than the maximum value of the standard drying temperature range, reduce the drying temperature according to the drying temperature ratio parameter to avoid excessive cracks on the surface of the tundish refractory lining samples due to excessive drying temperature, thereby reducing their service life. If the adjusted drying temperature still exceeds the maximum value of the standard drying temperature range, increase the drying time to improve the drying efficiency of the tundish refractory lining samples and reduce the number of cracks.

[0105] Specifically, the process of analyzing the crack distribution map to obtain the first crack analysis result includes:

[0106] If the first crack analysis result shows a concentrated crack distribution, the distribution concentration of the dry material particles in the tundish during the coating construction process is adjusted according to the crack depth to meet the thermal shock stability requirements.

[0107] This embodiment provides a process for adjusting the particle distribution concentration of dry material in the tundish, including:

[0108] Step S31, obtaining the initial distribution concentration of dry material particles in the tundish;

[0109] Step S31, measuring the depth of the crack using an ultrasonic detection method to obtain the actual depth of the crack;

[0110] Step S31, obtaining a target pressure value of the tundish dry material particles according to the actual crack depth and the initial pressure value;

[0111] Step S31 : obtaining the adjusted distribution concentration of the dry material particles in the tundish according to the target pressure value.

[0112] The initial pressure value is the pressure value applied to the dry material particles in the tundish during the initial coating process; the target pressure value is the pressure value adjusted according to the actual depth of the crack;

[0113] Determining a target pressure value according to the actual crack depth, wherein the target pressure value is correlated with the actual crack depth, and a correlation ratio between the target pressure value and the actual crack depth is determined by a preset proportional impact compensation parameter;

[0114] Use ultrasonic testing to measure the crack depth. Assuming the measurement results show that the crack depth is mainly concentrated between 0.5mm and 1mm, adjust the distribution concentration of the dry material particles in the tundish during the coating process based on the crack depth. The distribution concentration of the dry material particles in the tundish is the degree of compression between the particles.

[0115] For example:

[0116] Obtain the initial tundish dry material particle distribution concentration;

[0117] Before the initial application of dry material to the tundish, the initial distribution concentration of the particles was recorded. Image analysis techniques were used to evaluate the distribution of the particles and the initial degree of compression was recorded.

[0118] Use ultrasonic testing equipment to perform non-destructive testing on cracks in the refractory lining of the tundish;

[0119] The actual crack depth is calculated based on the propagation speed and time of the ultrasonic wave in the dry material particles of the tundish. Assuming that the measurement results show that the crack depth is mainly concentrated between 0.5mm and 1mm;

[0120] According to the crack depth, the pressure value that needs to be adjusted is determined. The deeper the crack depth, the higher the pressure required to ensure close bonding between particles and improve thermal shock stability.

[0121] The initial pressure value is the pressure value when applying for the first time, and the target pressure value is the pressure value that needs to be reached after considering the depth of the crack.

[0122] When the drying temperature is in the standard drying temperature range of 260-300℃, the crack depth range is 0.5-1mm. The adjusted pressure value is determined based on the initial pressure value and the compensation parameter of the pressure value on the crack depth.

[0123] In this embodiment, the compensation parameter for the effect of pressure on crack depth is set to 5.

[0124] If the crack depth is 0.4 mm, the reduced pressure value is 10 + 0.4 × 5 = 12 MPa;

[0125] If the crack depth is 1.2 mm, the increased pressure value is 10 + 1.2 × 5 = 16 MPa;

[0126] According to the target pressure value, adjust the pressure during the application process to change the distribution concentration of the particles.

[0127] Re-measure the particle distribution concentration to ensure that the distribution concentration under the target pressure value is achieved.

[0128] Adjust the pressure setting of the coating equipment to ensure that the correct pressure is applied during the coating process. Sample and analyze the dry material particles in the tundish after coating.

[0129] After smearing is completed, image analysis technology is used again to verify the distribution and concentration of the particles to ensure that the compression level reaches the new target value.

[0130] By adjusting the distribution concentration of the tundish dry material particles based on crack depth, the stability of the tundish dry material particles under thermal shock conditions can be better ensured. A higher degree of particle compression helps reduce stress concentration caused by temperature fluctuations, thereby reducing the risk of crack propagation. Optimizing the particle distribution concentration improves the overall performance of the refractory tundish dry material particles, enabling them to withstand more frequent thermal cycles and thus extending the service life of the tundish refractory lining. By improving the thermal shock resistance of the refractory tundish dry material particles and reducing crack formation and propagation, maintenance frequency and replacement costs can be reduced, thereby improving production efficiency. Precisely controlling the particle distribution concentration reduces production interruptions caused by tundish dry material particle damage, thereby increasing the continuous operation time and overall efficiency of the production line. A good particle distribution concentration helps improve the uniformity and thermal conductivity of the tundish lining, thereby enhancing the quality of the final product. The applied pressure value is positively correlated with the crack depth. When the crack depth is deeper, the pressure applied to the refractory lining of the tundish will increase to reduce the crack depth, thereby avoiding the crack depth being too deep, which may cause safety hazards to the refractory lining of the tundish during use and reduce the service life of the tundish.

[0131] Specifically, when the actual thermal shock stability cannot meet the standard thermal shock stability requirement, the process of adjusting the volume density of the tundish dry material particles to meet the thermal shock stability requirement includes:

[0132] measuring the bulk density of the dry material particles in the tundish to obtain an actual bulk density of the dry material particles in the tundish, comparing the actual bulk density of the dry material particles in the tundish with a standard bulk density of the dry material particles in the tundish to obtain a first bulk density comparison result, and determining whether to adjust the granulation parameters based on the first bulk density comparison result;

[0133] Among them, the granulation parameters include granulation pressure and granulation temperature;

[0134] When adjusting the granulation pressure and granulation temperature, the granulation pressure is adjusted first. When the granulation pressure adjustment alone cannot meet the processing requirements, the granulation temperature is adjusted. When the granulation pressure is adjusted, the adjustment range is related to the real-time granulation temperature.

[0135] Specifically, the process of determining whether to adjust the granulation parameters according to the first bulk density comparison result includes:

[0136] If the granulation pressure cannot meet the standard bulk density requirement of the dry material particles in the tundish, the granulation temperature can be adjusted to meet the standard bulk density requirement of the dry material particles in the tundish.

[0137] Use a densitometer to measure the actual bulk density of the dry material particles in the tundish, compare the actual bulk density of the dry material particles in the tundish with the standard bulk density of the dry material particles in the tundish, and obtain the first bulk density comparison result.

[0138] If the first bulk density comparison result shows that the actual bulk density of the tundish dry material particles is greater than or equal to the standard bulk density of the tundish dry material particles, there is no need to adjust the granulation parameters;

[0139] If the first bulk density comparison result shows that the actual bulk density of the tundish dry material particles is less than the standard bulk density of the tundish dry material particles, the granulation pressure and granulation temperature are determined according to the difference between the standard bulk density of the tundish dry material particles and the actual bulk density of the tundish dry material particles.

[0140] When adjusting the granulation pressure and granulation temperature, the granulation pressure should be adjusted first. When the granulation pressure adjustment alone cannot meet the processing requirements, the granulation temperature should be adjusted. When adjusting the granulation pressure, the adjustment range is related to the real-time granulation temperature.

[0141] If the granulation pressure cannot meet the standard bulk density, the granulation temperature needs to be adjusted. The granulation pressure is positively correlated with the difference between the standard bulk density of the dry material particles in the intermediate bag and the actual bulk density of the dry material particles in the intermediate bag; the granulation pressure and temperature are positively correlated with the difference between the standard bulk density of the dry material particles in the intermediate bag and the actual bulk density of the dry material particles in the intermediate bag.

[0142] Wherein, the standard volume density is obtained based on historical data;

[0143] If the first bulk density comparison result shows that the actual bulk density of the tundish dry material particles is less than the standard bulk density of the tundish dry material particles, the granulation pressure of the granulator is first adjusted, and then the granulator pressure is adjusted to the maximum value of the standard granulation pressure range. If the actual bulk density of the tundish dry material particles is still less than the standard bulk density of the tundish dry material particles, the granulation temperature is adjusted. The upper limit of the granulation pressure is determined according to the compensation parameter of the influence of the initial granulation pressure and the granulation temperature on the granulation pressure. The granulation pressure is negatively correlated with the granulation temperature.

[0144] In this embodiment, the initial granulation temperature is set to 180°C and the initial granulation pressure is set to 3 MPa.

[0145] When the granulation temperature is 180℃, adjust the granulation pressure and gradually increase it from 3MPa. When the granulation pressure is adjusted to 6MPa, if the actual volume density of the tundish dry material particles is still less than the standard volume density of the tundish dry material particles, adjust the granulation temperature to increase.

[0146] By adjusting granulation parameters to increase the bulk density of tundish dry material pellets, the thermal shock resistance of the tundish dry material pellets can be enhanced. A higher bulk density generally means better bonding between the pellets, which helps the tundish dry material pellets resist crack formation and growth during thermal cycling. Adjusting the granulation pressure and temperature helps optimize the pellet formation process, thereby improving the overall performance of the tundish dry material pellets, including mechanical strength, wear resistance, and erosion resistance. By ensuring that the pellet bulk density meets the standard, consistent performance is ensured across each batch of tundish dry material pellets produced, which is crucial for maintaining stable production line operation. Increased compression reduces internal porosity, thereby lowering thermal resistance during heat transfer and improving thermal shock resistance. An appropriate granulation temperature promotes uniformity in the pellet internal structure, enhancing mechanical strength and thermal stability. Improved thermal shock resistance means the tundish refractory lining can withstand longer thermal cycling, thereby extending its service life. This reduces the number of repairs and replacements due to substandard tundish dry material pellet performance, reducing maintenance costs. Consistent tundish dry material pellet properties help improve production efficiency and reduce production interruptions.

[0147] Specifically, when the volume density of the dry material particles in the tundish cannot meet the standard thermal shock stability requirements, the process of adjusting the sintering heating rate to meet the thermal shock stability requirements includes:

[0148] The sintered tundish dry material particles are sliced ​​to obtain tundish dry material particle slices. The pore distribution in the tundish dry material particle slices is observed to obtain a pore distribution result. The pore distribution result is used to determine whether the sintering heating rate should be adjusted to meet the thermal shock stability requirements.

[0149] The tundish dry material particles are sintered to solidify the particles and form a desired physical structure. After the sintering is completed, the sintered tundish dry material particles are sliced. In this embodiment, the cutting device includes but is not limited to a laser cutting machine and a grinding wheel cutting machine. Any device that can achieve a cutting effect can be used without specific limitation.

[0150] Cut the tundish dry material particles into thin slices to observe the internal structure. Use an optical microscope to observe the distribution of pores in the slices.

[0151] When the pore distribution result shows that the pore positions are unevenly distributed, the heating rate is adjusted according to the ratio of the pore area to the slice area to obtain the target heating rate, wherein the target heating rate is negatively correlated with the ratio of the pore area to the slice area, and the negative correlation ratio between the target heating rate and the ratio of the pore area to the slice area is determined by a preset proportional influence compensation parameter;

[0152] If the pore distribution result shows that the pore positions are evenly distributed, there is no need to adjust the heating rate.

[0153] By adjusting the sintering heating rate, a more uniform pore distribution is achieved, reducing thermal stress concentration points within the tundish pellets and improving their resistance to thermal shock. A more uniform pore distribution means more consistent performance within the tundish pellets, which is particularly important in mass production, ensuring that each batch of tundish pellets exhibits excellent thermal shock resistance. The optimized tundish pellets exhibit improved thermal shock resistance, extending the life of the tundish refractory lining, and reducing replacement frequency and maintenance costs. Precisely controlling the sintering heating rate reduces waste of tundish pellets due to substandard thermal shock resistance, lowering production costs. This reduces production interruptions caused by tundish pellet problems, improving production line uptime and overall efficiency. This improved performance directly impacts final product quality. For example, in the steel industry, it improves casting quality and reduces defects.

[0154] This embodiment also provides a high-performance tundish dry material preparation system, comprising:

[0155] Raw material storage control module, used to control the amount of dry material added to each tundish;

[0156] The ingredient control module is used to accurately control the proportion of various raw materials and control the mixing equipment to mix;

[0157] Temperature acquisition module, used to obtain the temperature at each production stage;

[0158] Temperature control module, used to control the temperature at each production stage;

[0159] A data analysis module is connected to the raw material storage control module, the batching control module, the temperature acquisition module and the temperature control module, and is used to analyze the thermal stability of the dry material in the tundish and adjust the operating status of each module according to its thermal stability.

[0160] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

Claims

1. A method for preparing high-performance tundish dry material, characterized in that: The following steps are included: The tundish dry material raw materials are mixed, formed, dried, sintered, cooled and granulated to obtain tundish dry material particles; Applying a coating to the tundish dry material particles to obtain a tundish refractory lining sample, heating the tundish refractory lining sample to a test temperature, and testing the thermal shock stability of the tundish refractory lining sample to obtain actual thermal shock stability; If the actual thermal shock stability cannot meet the standard thermal shock stability requirements, the volume density of the dry material particles in the tundish is adjusted to meet the thermal shock stability requirements; If the volume density of the dry material particles in the tundish cannot meet the standard thermal shock stability requirements, the sintering heating rate can be adjusted to meet the thermal shock stability requirements; measuring the bulk density of the dry material particles in the tundish to obtain an actual bulk density of the dry material particles in the tundish, comparing the actual bulk density of the dry material particles in the tundish with a standard bulk density of the dry material particles in the tundish to obtain a first bulk density comparison result, and determining whether to adjust the granulation parameters based on the first bulk density comparison result; When adjusting the granulation pressure and granulation temperature, the granulation pressure is adjusted first. When the granulation pressure adjustment alone cannot meet the processing requirements, the granulation temperature is adjusted. When the granulation pressure is adjusted, the adjustment range is related to the real-time granulation temperature. Among them, the granulation parameters include granulation pressure and granulation temperature; Slicing the sintered tundish dry material particles to obtain tundish dry material particle slices, observing the pore distribution in the tundish dry material particle slices to obtain pore distribution results, and judging whether to adjust the sintering heating rate to meet the thermal shock stability requirements based on the pore distribution results; If the pore distribution result shows that the pore positions are unevenly distributed, the heating rate is adjusted according to the ratio of the pore area to the slice area; If the pore distribution result shows that the pore positions are evenly distributed, there is no need to adjust the heating rate.

2. The method for preparing high-performance tundish dry material according to claim 1, characterized in that: The process of testing the thermal shock stability of the tundish refractory lining sample to obtain the actual thermal shock stability includes: The tundish refractory lining samples are tested by the water quenching method to obtain the actual comprehensive thermal shock stability. If the actual comprehensive thermal shock stability cannot be obtained through a single test, the actual comprehensive thermal shock stability of the tundish refractory lining samples are tested multiple times according to actual production conditions to obtain the actual comprehensive thermal shock stability assessment level; Among them, the actual production situation includes the number of uses and the duration of use in a single use.

3. The method for preparing high-performance tundish dry material according to claim 2, characterized in that: The process of repeatedly testing the actual comprehensive thermal shock stability of the tundish refractory lining sample according to actual production conditions to obtain the actual comprehensive thermal shock stability evaluation level includes: The surface of the refractory lining sample of the tundish that has undergone the first water quenching method is observed by high temperature microscope to see if there is any cracking. In the case of cracking, the crack area and the number of cracks are recorded to obtain cracking feedback; in the case of no cracking, the refractory lining sample of the ladle is tested according to the actual production situation to obtain a first test result, and it is judged whether it meets the thermal shock stability requirements based on the first test result.

4. The method for preparing high-performance tundish dry material according to claim 3, characterized in that: The process of recording the crack area and the number of cracks to obtain crack feedback includes: collecting crack distribution on the surface of the refractory lining sample of the tundish through a high-temperature microscope to obtain a crack distribution map, and analyzing the crack distribution map to obtain a first crack analysis result; The first crack analysis result includes concentrated crack distribution and dispersed crack distribution.

5. The method for preparing high-performance tundish dry material according to claim 4, characterized in that: The process of analyzing the crack distribution map to obtain a first crack analysis result includes: If the first crack analysis result shows a dispersed distribution of cracks, the drying parameters are adjusted according to the crack area and number to meet the thermal shock stability requirements; The drying parameters include drying temperature and drying time.

6. The method for preparing high-performance tundish dry material according to claim 5, characterized in that: The process of analyzing the crack distribution map to obtain a first crack analysis result includes: If the first crack analysis result shows a concentrated crack distribution, the distribution concentration of the dry material particles in the tundish during the coating construction process is adjusted according to the crack depth to meet the thermal shock stability requirements.

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