Modularized furnace lining manufacturing method for casting electric induction furnace

Abstract

The invention discloses a manufacturing method of a modular furnace lining for casting an electric induction furnace, which comprises the following steps of: dividing the furnace lining into module layers, namely a high-temperature oxidation-resistant shock-resistant and wear-resistant layer, an anti-permeation layer, a heat preservation and insulation layer, a leakage point detection layer and a secondary anti-permeation layer, so that each module layer of the furnace lining performs own functions; the device is simple in structure and suitable for induction heating electric furnaces of the IGBT module technology and traditional series silicon controlled rectifier harmonic electric furnaces, the service life of the furnace lining can be prolonged, the labor cost and the labor intensity can be reduced, meanwhile, all module layers are manufactured in the furnace lining frame, operation is easy, use is convenient, and the device has wide application prospects and development value in the field of the casting production industry.

Description

Technical Field

[0001] The present invention belongs to the technical field of high-end precision green intelligent casting, and more specifically relates to a method for manufacturing a modular furnace lining of a casting induction furnace. Background Art

[0002] The smelting electric furnace is one of the key core equipment in the casting production process. Currently in the casting production field, the induction heating electric furnace with new IGBT module technology and the traditional series thyristor harmonic electric furnace are the mainstream equipment.

[0003] Whether it is a traditional series thyristor harmonic electric furnace or a new IGBT module technology electric furnace, the inside of the furnace body must be lined before smelting. The quality of the lining directly determines the service life of the induction heating furnace and the life safety of the furnace operator. Therefore, the lining production is placed at the top priority in the casting production process.

[0004] At present, the furnace lining is made by using high-temperature resistant refractory materials, mixing them in a specific proportion, and then stacking them as a whole. This manufacturing process is outdated and backward. During the molten iron smelting process, the molten iron often penetrates the furnace lining and then meets the cooling water of the electric furnace. When the molten iron meets the water, the entire furnace body will explode instantly. The splashing high-temperature molten iron will not only damage the electric furnace, but also endanger the personal safety of the operator. Although the induction heating electric furnace on the existing market is equipped with safety protection systems such as a leakage furnace alarm system, an electric furnace induction coil temperature control detection system, and an electric furnace cooling water inlet and outlet pressure difference alarm system, the leakage points and cracks of the furnace lining cannot be detected. The furnace lining is not repaired in time due to leakage points. Under long-term operation, the leakage points of the furnace lining continue to expand, and then the molten iron instantly penetrates the furnace lining. Therefore, these safety protection systems are not effective, which puts forward new demands and challenges for the furnace lining materials and manufacturing processes. The present invention is based on the technical background of the current casting induction furnace lining materials and manufacturing processes. Summary of the invention

[0005] The present invention provides a modular furnace lining manufacturing method for a casting induction furnace.

[0006] The production is divided into various module layers, namely, high-temperature oxidation-resistant, shock-resistant and wear-resistant layer, anti-penetration layer, thermal insulation layer, leakage detection layer and secondary anti-penetration layer, so that each module layer of the furnace lining can perform its own functions. It is suitable for induction heating electric furnaces with IGBT module technology and traditional series thyristor harmonic electric furnaces. It can increase the service life of the furnace lining and reduce labor costs and labor intensity. At the same time, each module layer is made in the furnace lining frame, which is simple to operate and easy to use. It has broad application prospects and development value in the field of casting production industry.

[0007] In order to achieve the above purpose, the present invention adopts the following technical solutions:

[0008] A modular lining manufacturing method for a casting induction electric furnace, including a crucible, a lining body, locking bolts, and a profiling mold. The crucible is a carbon steel shell, and the lining body is a modular structure located inside the crucible, including a lining frame, a high-temperature oxidation-resistant, earthquake-resistant, and wear-resistant layer, an anti-permeation layer, a heat-insulating layer, a leak detection layer, and a secondary anti-permeation layer. The lining frame includes an inner ring, an outer ring, a ceramic fiber collar, and ceramic fiber connecting ribs. The inner ring and the outer ring are respectively locked and fixed by the ceramic fiber collar, and the inner ring and the outer ring are locked and fixed by the ceramic fiber connecting ribs. The materials for locking and fixing the inner ring and the outer ring are paste epoxy resin-based adhesives. The high-temperature oxidation-resistant, earthquake-resistant, and wear-resistant layer is supported by the lining frame and is composed of silicon carbide and fused-cast magnesia-chrome bricks in proportion, and then connected to the lining frame to form a sealing surface with an uneven surface. The anti-permeation layer is located between the high-temperature oxidation-resistant, earthquake-resistant, and wear-resistant layer and the heat-insulating layer and is composed of magnesia-carbon bricks, and the magnesia-carbon bricks are bonded and sealed by a paste epoxy resin-based adhesive. The heat-insulating layer is located between the anti-permeation layer and the leak detection layer and is composed of alumina hollow spheres and a small amount of silicon dioxide (S i O2), and the magnesia-carbon bricks are bonded and sealed by a phenolic resin adhesive. The leak detection layer is located between the heat-insulating layer and the secondary anti-permeation layer. This layer is internally provided with lightweight and transparent quartz glass with a thickness of 8 mm. The quartz glass located at the upper part of the lining is in a three-dimensional drum shape, and the quartz glass located at the lower part of the lining is in a three-dimensional conical drum shape. The secondary anti-permeation layer is located between the leak detection layer and the crucible and is fixedly connected to the crucible by locking bolts. It is composed of aluminum oxide and silicon carbide in proportion. The locking bolts fixedly connect the lining body and the crucible. The profiling mold includes a mold head and rubber. The material of the mold head is bakelite, and its shape imitates the crucible. The rubber is sleeved around and at the bottom of the mold head, and the shape of the rubber is serrated.

[0009] A modular lining manufacturing method for a casting induction electric furnace. The specific implementation of the lining body includes the following steps:

[0010] S1: Manufacturing the lining frame. Using ceramic fiber rod materials with a fiber rod diameter of Φ25 - Φ35 mm, the paste epoxy resin-based adhesive has a heat resistance of 1750 °C and a socket strength of 30 - 33 MPa.

[0011] S2: Manufacturing the secondary anti-permeation layer. Starting from the bottom of the lining, then to the conical surface at the lower part of the lining, and finally to the cylindrical surface at the upper part of the lining. Specifically, place the lining frame in the central area of the crucible, and the ceramic fiber rods of the lining frame are closely attached to the inner side of the crucible. Mix three materials of aluminum oxide (AL2O3), silicon carbide (S i C), and boron carbide (B4C) powder in proportion AL2O3: S iC: B4C is prepared in the ratio of (70% - 80%):(20% - 30%):(5% - 15%). Meanwhile, 5% - 15% of phenolic resin is added as a binder and evenly mixed. Then, 10% - 20% of pure water is added and stirred for 20 - 30 minutes to form a mud-like substance with a viscosity controlled at 6 - 8 Pa.s. The mud-like mixture is evenly arranged at the bottom and around the furnace lining frame and closely attached to the inner side of the crucible. While arranging it evenly, it is tamped and leveled to make the thickness of the secondary anti-seepage layer reach 45 - 55 cm. Then, it is baked with a natural gas flame for 10 - 20 minutes, and the flame temperature is 220°C - 260°C.

[0012] S3: Production of the leak point detection layer. The three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet-shaped quartz glass frame are respectively placed on the secondary anti-seepage layer. The three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet-shaped quartz glass frame include quartz glass and a glass frame. The quartz glass is placed inside the glass frame. The wall thickness of the glass frame is 5 mm, and the material is SUS310S. There are 3 rectangular sheet-shaped quartz glasses, which are evenly distributed on the secondary anti-seepage layer at the bottom of the furnace lining.

[0013] S4: Production of the thermal insulation layer. First, start from the bottom of the furnace lining, then to the conical surface of the lower part of the furnace lining, and finally to the cylindrical surface of the upper part of the furnace lining. Specifically, two materials, alumina hollow spheres (AL2O3) and silica (S i O2) powder, are prepared in the ratio of AL2O3:S i O2 = (60% - 80%):(5% - 15%). Meanwhile, 10% - 25% of phenolic resin is added as a binder and evenly mixed. Then, 20% - 30% of pure water is added and stirred for 15 - 25 minutes to form a mud-like substance with a viscosity controlled at 10 - 20 Pa.s. Since alumina is a basic oxide, dilute hydrochloric acid with a concentration of 2% - 3% is applied to the three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet-shaped quartz glass frame of the leak point detection layer with a fiber brush. A double decomposition chemical reaction occurs at the contact surface between the mud-like alumina hollow sphere mixture and the quartz glass frame, that is, Al2O3 + 6HCl = 2AlCl3 + 3H2O, generating aluminum chloride (AlCl3) and water (H2O) to enable the quartz glass to slide back and forth within the glass frame. Within the time range of 3 - 5 minutes, the mud-like alumina hollow sphere mixture is evenly arranged on the three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet-shaped quartz glass frame. While arranging it evenly, it is tamped and leveled, and at the same time, the quartz glass is continuously slid back and forth. The thickness of the leveled thermal insulation layer reaches 55 - 65 cm. Then, it is baked with a natural gas flame for 15 - 25 minutes, and the flame temperature is 260°C - 280°C.

[0014] S5: Production of the anti-seepage layer. Start from the bottom of the furnace lining, then proceed to the conical surface of the lower part of the furnace lining, and finally to the cylindrical surface of the upper part of the furnace lining. Specifically, mix magnesia-chrome powder (MgO-Cr₂O₃) and silicon carbide (S i C) in the ratio of (MgO-Cr₂O₃):S i C = (55% - 65%):

[0015] (20% - 30%). Among them, MgO:Cr₂O in magnesia-chrome powder (MgO-Cr₂O₃) 3＝ (45% - 60%):(8% - 16%). At the same time, add 25% - 35% of phenolic resin as a binder, mix evenly, then add 25% - 35% of pure water and stir well for 15 - 25 minutes to form a viscous mud-like substance with a viscosity controlled at 8 - 10 Pa·s. Evenly distribute the magnesia-chrome-silicon carbide mixture on the thermal insulation layer, compact and level it while distributing evenly, so that the thickness of the anti-seepage layer reaches 45 - 55 cm, and then bake it with natural gas flame for 10 - 20 minutes, with the flame temperature being 260°C - 280°C.

[0016] S6: Production of the high-temperature oxidation, earthquake resistance and wear-resistant layer. First, produce the high-temperature oxidation, earthquake resistance and wear-resistant layer at the bottom of the furnace lining. Specifically, mix magnesia-chrome powder (MgO-Cr₂O₃) and silicon carbide (S i C) in the ratio of (MgO-Cr₂O₃):S i C = (25% - 35%):(65% - 75%). Among them, MgO:Cr₂O in magnesia-chrome powder (MgO-Cr₂O₃) 3＝ (25% - 35%):

[0017] (12% - 16%), and then add 30% - 40% phenolic resin as a binder, mix evenly, and then add 30% - 40% pure water and stir well for 20 - 30 minutes to form a relatively viscous mud-like substance with a viscosity controlled at 9 - 12 Pa.s. Arrange the silicon carbide magnesium chromium powder mixture evenly on the anti-seepage layer at the bottom of the furnace lining, compact and level it while arranging it evenly, so that the thickness of the high-temperature oxidation and earthquake-resistant wear-resistant layer at the bottom of the furnace lining reaches 35 - 45 cm. Then bake it with natural gas flame for 5 minutes, and the flame temperature is 150°C - 170°C. Then place the profiling mold in the central position of the furnace lining and ensure it is perpendicular to the bottom of the furnace lining. Then apply pressure to the profiling mold towards the bottom of the furnace lining so that the profiling mold descends by a height of 6 - 8 mm. Then fill the gap formed between the profiling mold and the anti-seepage layer with the silicon carbide magnesium chromium powder mixture and compact it until the depth of the silicon carbide magnesium chromium powder mixture entering the profiling mold is 6 - 8 mm. Remove the die head of the profiling mold, and then take out the rubber of the profiling mold to make the contact surface between the furnace lining and the molten iron serrated. Finally, bake it evenly with natural gas flame for 20 - 30 minutes, and the flame temperature is 240°C - 260°C.

[0018] Preferably, alumina (AL2O3), silicon carbide (S i C), and boron carbide (B4C) powder are mixed as the material for the secondary anti-seepage layer, which can not only ensure the hardness requirements of the secondary anti-seepage layer but also enhance the anti-seepage performance of molten iron and the cooling water of the induction heating electric furnace.

[0019] Preferably, quartz glass, as the material for the leak point detection layer, can not only withstand high temperatures of 1300°C and above but also, due to its surface transparency characteristics, during the production process, after taking out the quartz glass, it can be more intuitively detected by the naked eye for the surface traces of the quartz glass, and the leak points and their positions in the furnace lining can be determined.

[0020] Preferably, alumina hollow spheres (AL2O3) and silicon dioxide (S i O2) powder are mixed as the material for the heat insulation layer. Alumina hollow spheres (AL2O3) have excellent heat insulation performance, and silicon dioxide (S i O2) has good high-temperature resistance and hardness, which can enhance the earthquake resistance of the furnace lining.

[0021] Preferably, magnesia-chrome powder (MgO-Cr2O3) and silicon carbide (S i C) are mixed as the material for the anti-seepage layer. The content of magnesia-chrome powder (MgO-Cr2O3) is greater than that of silicon carbide (S i C). Magnesia-chrome powder (MgO-Cr2O3) has excellent material tissue density, hardness, and high-temperature resistance. Silicon carbide (S i C) has high hardness and high-temperature resistance, ensuring the anti-seepage performance, hardness, and high-temperature resistance of the furnace lining.

[0022] Preferably, two materials, namely magnesia-chrome powder (MgO-Cr2O3) and silicon carbide (Si i C), are mixed as the material for the high-temperature oxidation, earthquake resistance and wear-resistant layer. The content of silicon carbide (Si i C) is greater than that of magnesia-chrome powder (MgO-Cr2O3). Magnesia-chrome powder (MgO-Cr2O3) has excellent material tissue density, hardness and high temperature resistance. Silicon carbide (Si i C) has high wear resistance, high temperature resistance and oxidation resistance, ensuring the oxidation resistance, wear resistance, earthquake resistance and high temperature resistance of the furnace lining.

[0023] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0024] 1. The part of the high-temperature oxidation, earthquake resistance and wear-resistant layer of the furnace lining in direct contact with the molten iron is serrated, greatly increasing the contact area with the molten iron, sharing the heat received by the material of the high-temperature oxidation, earthquake resistance and wear-resistant layer, thus avoiding local heating of the furnace lining. At the same time, it greatly alleviates the impact force of the molten iron on the furnace lining during melting and tumbling, and greatly reduces the risk of the furnace lining being penetrated by the molten iron.

[0025] 2. The furnace lining is made modularly, replacing the traditional overall stacked furnace lining made of mixed materials. The high-temperature oxidation, earthquake resistance and wear-resistant layer and the anti-permeation layer provide safety guarantees for the furnace lining, and the heat insulation layer ensures that the temperature of the molten iron is not lost, reducing production energy consumption.

[0026] 3. After single-shift production, the quartz glass of the leak detection layer is taken out, and the surface traces of the quartz glass are visually inspected to judge whether there are leaks and the positions of the leaks in the furnace lining, achieving the purpose of safe production per shift.

[0027] 4. It reduces the labor intensity of building the furnace lining, replacing the repetitive furnace lining building of the traditional overall stacked furnace lining. The modular furnace lining only needs to be made once. Its high-temperature oxidation, earthquake resistance and wear-resistant layer, anti-permeation layer, heat insulation layer, leak detection layer and secondary anti-permeation layer are clearly layered. Only repair is needed. When repairing, each layer is taken out and then recombined, which is simple and easy to operate.

[0028] 5. Compared with the prior art, the present invention can not only improve the service life of the casting induction furnace, but also ensure the personal safety of the operators. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the overall structure of a method for manufacturing a modular furnace lining of a casting induction furnace according to the present invention;

[0030] Figure 2 It is a front view of the furnace lining main body of a method for manufacturing a modular furnace lining of a casting induction furnace according to the present invention;

[0031] Figure 3 The top view of the furnace lining main body of a modular furnace lining manufacturing method for a casting induction electric furnace according to the present invention;

[0032] Figure 4 The front view of the furnace lining frame of a modular furnace lining manufacturing method for a casting induction electric furnace according to the present invention;

[0033] Figure 5 The top view of the furnace lining frame of a modular furnace lining manufacturing method for a casting induction electric furnace according to the present invention;

[0034] Figure 6 The front view of the profiling die of a modular furnace lining manufacturing method for a casting induction electric furnace according to the present invention;

[0035] Figure 7 The top view of the profiling die of a modular furnace lining manufacturing method for a casting induction electric furnace according to the present invention;

[0036] Figure 8 The front view of the quartz glass frame of a modular furnace lining manufacturing method for a casting induction electric furnace according to the present invention;

[0037] Figure 9 The top view of the quartz glass frame of a modular furnace lining manufacturing method for a casting induction electric furnace according to the present invention;

[0038] In the figure, 1. crucible, 2. furnace lining main body, 3. locking bolt, 4. profiling die, 21. furnace lining frame, 22. high-temperature oxidation and earthquake-resistant wear-resistant layer, 23. anti-permeation layer, 24. heat insulation layer, 25. ball, 25. leak detection layer, 26. secondary anti-permeation layer, 21-1. inner ring, 21-2. outer ring, 21-3. ceramic fiber collar, 21-4. ceramic fiber connecting rib, 25-1. quartz glass frame, 25-1-1. quartz glass, 25-1-2. glass frame Specific embodiments

[0039] The present invention will be further described below in conjunction with specific embodiments, but is not limited to the protection scope of the present invention.

[0040] Such as Figures 1 to 9As shown in the figure, a method for manufacturing a modular lining of a casting induction electric furnace includes a crucible 1, a lining main body 2, locking bolts 3, and a profiling die 4. The crucible 1 is a carbon steel shell, and the lining main body 2 is a modular structure located inside the crucible 1. It includes a lining frame 21, a high-temperature oxidation-resistant, earthquake-resistant, and wear-resistant layer 22, an anti-permeation layer 23, a heat-insulating layer 24, a leak detection layer 25, and a secondary anti-permeation layer 26. The lining frame 21 includes an inner ring 21-1, an outer ring 21-2, a ceramic fiber collar 21-3, and a ceramic fiber connecting rib 21-4. The inner ring 21-1 and the outer ring 21-2 are respectively locked and fixed by the ceramic fiber collar 21-3, and the inner ring 21-1 and the outer ring 21-2 are locked and fixed by the ceramic fiber connecting rib 21-4. The materials for locking and fixing the inner ring 21-1 and the outer ring 21-2 are paste-like epoxy resin-based adhesives. The high-temperature oxidation-resistant, earthquake-resistant, and wear-resistant layer 22 is supported by the lining frame 21 and is composed of silicon carbide and fused cast magnesia-chrome bricks in proportion. It is then connected to the lining frame and forms a sealing surface with an uneven surface. The anti-permeation layer 23 is located between the high-temperature oxidation-resistant, earthquake-resistant, and wear-resistant layer 22 and the heat-insulating layer 24 and is composed of magnesia-carbon bricks. The magnesia-carbon bricks are bonded and sealed by paste-like epoxy resin-based adhesives. The heat-insulating layer 24 is located between the anti-permeation layer 23 and the leak detection layer 25 and is composed of alumina hollow spheres and a small amount of silicon dioxide (S i O2). The magnesia-carbon bricks are bonded and sealed by phenolic resin adhesives. The leak detection layer 25 is located between the heat-insulating layer 24 and the secondary anti-permeation layer 26. This layer is internally provided with lightweight and transparent quartz glass with a thickness of 8 mm. The quartz glass located at the upper part of the lining is a three-dimensional drum shape, and the quartz glass located at the lower part of the lining is a three-dimensional conical drum shape. The secondary anti-permeation layer 26 is located between the leak detection layer 25 and the crucible 1 and is fixedly connected to the crucible 1 by the locking bolts 3. It is composed of aluminum oxide and silicon carbide mixed in proportion. The locking bolts 3 fixedly connect the lining main body 2 and the crucible 1. The profiling die 4 includes a die head 41 and rubber 42. The material of the die head 41 is bakelite, and its shape imitates the crucible 1. The rubber 42 is sleeved around and at the bottom of the die head 41, and the shape of the rubber 42 is serrated.

[0041] A method for manufacturing a modular lining of a casting induction electric furnace. The specific implementation of the lining main body includes the following steps:

[0042] Example 1

[0043] S1: Manufacturing the lining frame. Using ceramic fiber rod materials with a fiber rod diameter of Φ25 mm, the paste-like epoxy resin-based adhesive has a heat resistance of 1750 °C and a socket strength of 30 - 33 MPa.

[0044] S2: Fabrication of the secondary anti-seepage layer. Start from the bottom of the furnace lining, then proceed to the conical surface at the lower part of the furnace lining, and finally reach the cylindrical surface at the upper part of the furnace lining. Specifically, place the furnace lining frame in the central area of the crucible, and make the ceramic fiber rods of the furnace lining frame closely adhere to the inner side of the crucible. Mix three materials, namely aluminum oxide (AL2O3), silicon carbide (S i C), and boron carbide (B4C) powder, in the proportion of AL2O3:S i C:B4C = 70%:20%:5%. At the same time, add 5% phenolic resin as a binder, mix evenly, then add 10% pure water and stir for 20 minutes to form a mud-like mixture with a viscosity controlled at 6 Pa.s. Uniformly distribute the mud-like mixture at the bottom and around the furnace lining frame, and make it closely adhere to the inner side of the crucible. Compact and level it while uniformly distributing to make the thickness of the secondary anti-seepage layer reach 45 cm, and then bake it with natural gas flame for 10 minutes at a flame temperature of 220 °C. S3: Fabrication of the leak detection layer. Place the three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet quartz glass frame on the secondary anti-seepage layer respectively. The three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet quartz glass frame include quartz glass and a glass frame. The quartz glass is placed inside the glass frame. The wall thickness of the glass frame is 5 mm, and the material is SUS310S. There are 3 rectangular sheet quartz glasses, which are evenly distributed on the secondary anti-seepage layer at the bottom of the furnace lining.

[0045] S4: Fabrication of the thermal insulation layer. Start from the bottom of the furnace lining, then proceed to the conical surface at the lower part of the furnace lining, and finally reach the cylindrical surface at the upper part of the furnace lining. Specifically, mix two materials, namely aluminum oxide hollow spheres (AL2O3) and silicon dioxide (S i O2) powder, in the proportion of AL2O3:S iPrepare with O2 = 60%: 5%, and at the same time add 10% phenolic resin as a binder, mix evenly, then add 20% pure water and stir for 15 minutes to form a mud-like substance with a viscosity controlled at 10 Pa·s. Since aluminum oxide is a basic oxide, apply 2% dilute hydrochloric acid to the three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet quartz glass frame of the leak detection layer with a fiber brush. A double decomposition chemical reaction occurs at the contact surface between the mud-like aluminum oxide hollow sphere mixture and the quartz glass frame, that is, Al2O3 + 6HCl = 2AlCl3 + 3H2O, generating aluminum chloride (AlCl3) and water (H2O) to enable the quartz glass to slide back and forth within the glass frame. Within 3 minutes, evenly distribute the mud-like aluminum oxide hollow sphere mixture on the three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet quartz glass frame, tamping and leveling while distributing evenly, and continuously slide the quartz glass back and forth. The thickness of the leveled thermal insulation layer reaches 55 cm, and then bake it with a natural gas flame for 15 minutes, with the flame temperature at 260 °C.

[0046] S5: Production of the anti-permeation layer. Start from the bottom of the furnace lining, then to the conical surface at the lower part of the furnace lining, and finally to the cylindrical surface at the upper part of the furnace lining. Specifically, mix two materials, magnesia-chrome powder (MgO-Cr2O3) and silicon carbide (S i C), in the ratio (MgO-Cr2O3):S i C = 55%: 20%. Among them, in magnesia-chrome powder (MgO-Cr2O3), MgO:Cr2O 3＝ 45%: 8%. At the same time, add 25% phenolic resin as a binder, mix evenly, then add 25% pure water and stir thoroughly and evenly for 15 minutes to form a viscous mud-like substance with a viscosity controlled at 8 Pa·s. Evenly distribute the mud-like magnesia-chrome-silicon carbide mixture on the thermal insulation layer, tamping and leveling while distributing evenly to make the thickness of the anti-permeation layer reach 45 cm, and then bake it with a natural gas flame for 10 minutes, with the flame temperature at 260 °C.

[0047] S6: Production of the high-temperature oxidation, earthquake resistance, and wear-resistant layer. First, produce the high-temperature oxidation, earthquake resistance, and wear-resistant layer at the bottom of the furnace lining. Specifically, mix two materials, magnesia-chrome powder (MgO-Cr2O3) and silicon carbide (S i C), in the ratio (MgO-Cr2O3):S i C = 25%: 65%. Among them, in magnesia-chrome powder (MgO-Cr2O3), MgO:Cr2O 3＝25%: 12%, while adding 30% phenolic resin as a binder, mixing evenly, then adding 30% pure water and stirring thoroughly for 20 minutes to form a relatively viscous mud-like substance with a viscosity controlled at 9 Pa.s. Arrange the silicon carbide magnesium chromium powder mixture evenly on the anti-seepage layer at the bottom of the furnace lining, tamping and leveling while arranging evenly to make the thickness of the high-temperature oxidation and earthquake-resistant wear-resistant layer at the bottom of the furnace lining reach 35 cm. Then bake it with natural gas flame for 5 minutes at a flame temperature of 150 °C. Place the profiling mold at the central position of the furnace lining and ensure it is perpendicular to the bottom of the furnace lining. Then apply pressure to the profiling mold towards the bottom of the furnace lining to make the profiling mold drop by a height of 6 mm. Then fill the gap formed between the profiling mold and the anti-seepage layer with the silicon carbide magnesium chromium powder mixture and compact it until the depth of the silicon carbide magnesium chromium powder mixture entering the profiling mold is 6 mm. Remove the die head of the profiling mold and then take out the rubber of the profiling mold to make the contact surface between the furnace lining and the molten iron serrated. Finally, bake it evenly with natural gas flame for 20 minutes at a flame temperature of 240 °C.

[0048] Example 2

[0049] S1: Fabrication of the furnace lining frame. Use ceramic fiber rod materials with a fiber rod diameter of Φ30 mm. The paste epoxy resin-based adhesive has a heat resistance of 1750 °C and a socket strength of 30 - 33 MPa.

[0050] S2: Fabrication of the secondary anti-seepage layer. Start from the bottom of the furnace lining, then to the conical surface of the lower part of the furnace lining, and finally to the cylindrical surface of the upper part of the furnace lining. Specifically, place the furnace lining frame in the central area of the crucible, and the ceramic fiber rods of the furnace lining frame are closely attached to the inner side of the crucible. Mix three materials of aluminum oxide (AL2O3), silicon carbide (S i C), and boron carbide (B4C) powder in the proportion of AL2O3: S i C: B4C = 75%: 25%: 10%, while adding 10% phenolic resin as a binder, mixing evenly, then adding 15% pure water and stirring for 25 minutes to form a mud-like substance with a viscosity controlled at 7 Pa.s. Arrange the mud-like mixture evenly at the bottom and around the furnace lining frame and closely attach it to the inner side of the crucible, tamping and leveling while arranging evenly to make the thickness of the secondary anti-seepage layer reach 45 - 55 cm. Then bake it with natural gas flame for 15 minutes at a flame temperature of 240 °C.

[0051] S3: Production of the leak point detection layer. Respectively place the three-dimensional cylindrical quartz glass frame, the three-dimensional conical cylindrical quartz glass frame, and the rectangular sheet-shaped quartz glass frame on the secondary anti-permeation layer. The three-dimensional cylindrical quartz glass frame, the three-dimensional conical cylindrical quartz glass frame, and the rectangular sheet-shaped quartz glass frame include quartz glass and a glass frame. The quartz glass is placed inside the glass frame. The wall thickness of the glass frame is 5 mm, and the material is SUS310S. There are 3 rectangular sheet-shaped quartz glasses, which are evenly distributed on the secondary anti-permeation layer at the bottom of the furnace lining.

[0052] S4: Production of the thermal insulation layer. Start from the bottom of the furnace lining, then to the conical surface of the lower part of the furnace lining, and finally to the cylindrical surface of the upper part of the furnace lining. Specifically, mix two materials, alumina hollow spheres (AL2O3) and silica (S i O2) powder, in the ratio of AL2O3:S i O2 = 70%:10%, and at the same time add 20% phenolic resin as a binder, mix evenly, then add 25% pure water and stir for 20 minutes to form a mud-like substance with a viscosity controlled at 15 Pa.s. Since alumina is a basic oxide, use a fiber brush to apply 2.5% dilute hydrochloric acid on the three-dimensional cylindrical quartz glass frame, the three-dimensional conical cylindrical quartz glass frame, and the rectangular sheet-shaped quartz glass frame of the leak point detection layer. A double decomposition chemical reaction occurs at the contact surface between the mud-like alumina hollow sphere mixture and the quartz glass frame, that is, Al2O3 + 6HCl = 2AlCl3 + 3H2O, generating aluminum chloride (AlCl3) and water (H2O) to enable the quartz glass to slide back and forth within the glass frame. Within 4 minutes, evenly distribute the mud-like alumina hollow sphere mixture on the three-dimensional cylindrical quartz glass frame, the three-dimensional conical cylindrical quartz glass frame, and the rectangular sheet-shaped quartz glass frame. While evenly distributing, tamp and level it, and continuously slide the quartz glass back and forth. The thickness of the leveled thermal insulation layer reaches 60 cm, and then bake it with a natural gas flame for 20 minutes, with the flame temperature being 270 °C.

[0053] S5: Production of the anti-permeation layer. Start from the bottom of the furnace lining, then to the conical surface of the lower part of the furnace lining, and finally to the cylindrical surface of the upper part of the furnace lining. Specifically, mix two materials, magnesia-chrome powder (MgO-Cr2O3) and silicon carbide (S i (MgO-Cr2O3):S iC = 60%: 25% configuration, where in the magnesia-chrome powder (MgO-Cr₂O₃), MgO:Cr₂O₃ = 55%: 12%, and at the same time, 30% phenolic resin is added as a binder, and they are evenly mixed. Then, 30% pure water is added and stirred evenly for 20 minutes to form a viscous mud-like substance with the viscosity controlled at 9 Pa·s. The magnesia-chrome-silicon carbide mixture in mud form is evenly arranged on the thermal insulation layer, and while arranging evenly, it is tamped and leveled to make the thickness of the anti-seepage layer reach 50 cm. Then, it is baked with natural gas flame for 15 minutes, and the flame temperature is 270 °C.

[0054] S6: Fabrication of the high-temperature oxidation, earthquake-resistant and wear-resistant layer. First, fabricate the high-temperature oxidation, earthquake-resistant and wear-resistant layer at the bottom of the furnace lining. Specifically, the magnesia-chrome powder (MgO-Cr₂O₃) and silicon carbide (S i C) are configured in the ratio of (MgO-Cr₂O₃):S i C = 30%: 70%, where in the magnesia-chrome powder (MgO-Cr₂O₃), MgO:Cr₂O 3＝ 3 = 30%: 14%, and at the same time, 35% phenolic resin is added as a binder, and they are evenly mixed. Then, 35% pure water is added and stirred evenly for 25 minutes to form a relatively viscous mud-like substance with the viscosity controlled at 10 Pa·s. The silicon carbide-magnesia-chrome powder mixture is evenly arranged on the anti-seepage layer at the bottom of the furnace lining, and while arranging evenly, it is tamped and leveled to make the thickness of the high-temperature oxidation, earthquake-resistant and wear-resistant layer at the bottom of the furnace lining reach 40 cm. Then, it is baked with natural gas flame for 5 minutes, and the flame temperature is 160 °C. Then, the profiling die is placed at the central position of the furnace lining and ensured to be perpendicular to the bottom of the furnace lining. Then, pressure is applied to the profiling die towards the bottom of the furnace lining to make the profiling die descend by a height of 7 mm. Then, the silicon carbide-magnesia-chrome powder mixture is filled into the gap formed between the profiling die and the anti-seepage layer and compacted until the depth of the silicon carbide-magnesia-chrome powder mixture entering the profiling die is 7 mm. The die head of the profiling die is removed, and then the rubber of the profiling die is taken out to make the contact surface between the furnace lining and the molten iron in a serrated shape. Finally, it is evenly baked with natural gas flame for 25 minutes, and the flame temperature is 250 °C.

[0055] Example 3

[0056] S1: Fabrication of the furnace lining frame. Use ceramic fiber rod materials with the fiber rod diameter of Φ25 - Φ35 mm. The paste epoxy resin-based adhesive has a heat resistance of 1750 °C and a socketing strength of 30 - 33 MPa.

[0057] S2: Fabrication of the secondary anti-seepage layer. Start from the bottom of the furnace lining, then to the conical surface at the lower part of the furnace lining, and finally to the cylindrical surface at the upper part of the furnace lining. Specifically, place the furnace lining frame in the central area of the crucible, and the ceramic fiber rods of the furnace lining frame are closely attached to the inner side of the crucible. The powders of aluminum oxide (AL₂O₃), silicon carbide (S i C), and boron carbide (B₄C) are configured in the ratio of AL₂O₃:Si C: It is prepared with B4C = 80%: 30%: 15%. At the same time, 15% of phenolic resin is added as a binder, and they are evenly mixed. Then 20% of pure water is added and stirred for 30 minutes to form a mud shape, with the viscosity controlled at 8 Pa.s. The mud-like mixture is evenly arranged at the bottom and around the furnace lining frame and closely attached to the inner side of the crucible. While arranging it evenly, it is tamped and leveled to make the thickness of the secondary anti-seepage layer reach 55 cm, and then baked with natural gas flame for 20 minutes, with the flame temperature of 260 °C. S3: Production of the leak point detection layer. The three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet-shaped quartz glass frame are respectively placed on the secondary anti-seepage layer. The three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet-shaped quartz glass frame include quartz glass and a glass frame. The quartz glass is placed inside the glass frame. The wall thickness of the glass frame is 5 mm, and the material is SUS310S. There are 3 rectangular sheet-shaped quartz glasses, which are evenly distributed on the secondary anti-seepage layer at the bottom of the furnace lining.

[0058] S4: Production of the thermal insulation layer. It starts from the bottom of the furnace lining, then to the conical surface at the lower part of the furnace lining, and finally to the cylindrical surface at the upper part of the furnace lining. Specifically, two materials, alumina hollow spheres (AL2O3) and silica (S i O2) powder, are prepared in the ratio of AL2O3: S i O2 = 80%: 15%. At the same time, 25% of phenolic resin is added as a binder, and they are evenly mixed. Then 30% of pure water is added and stirred for 25 minutes to form a mud shape, with the viscosity controlled at 20 Pa.s. Since alumina is a basic oxide, 3% dilute hydrochloric acid is applied to the three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet-shaped quartz glass frame of the leak point detection layer respectively with a fiber brush. A double decomposition chemical reaction occurs at the contact surface between the mud-like alumina hollow sphere mixture and the quartz glass frame, that is, Al2O3 + 6HCl = 2AlCl3 + 3H2O, generating aluminum chloride (AlCl3) and water (H2O) to enable the quartz glass to slide back and forth within the glass frame. Within 5 minutes, the mud-like alumina hollow sphere mixture is evenly arranged on the three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet-shaped quartz glass frame. While arranging it evenly, it is tamped and leveled, and at the same time, the quartz glass is constantly slid back and forth. After leveling, the thickness of the thermal insulation layer reaches 65 cm, and then baked with natural gas flame for 25 minutes, with the flame temperature of 280 °C. S5: Production of the anti-seepage layer. It starts from the bottom of the furnace lining, then to the conical surface at the lower part of the furnace lining, and finally to the cylindrical surface at the upper part of the furnace lining. Specifically, two materials, magnesia-chrome powder (MgO-Cr2O3) and silicon carbide (S i (MgO-Cr2O3): S iC = 65%: 30% configuration, where MgO:Cr₂O in magnesia-chrome powder (MgO-Cr₂O₃) is 3＝ 60%: 16%, and at the same time add 35% phenolic resin as a binder, mix evenly, then add 35% pure water and stir well for 25 minutes to form a viscous mud shape, control the viscosity at 10 Pa·s, evenly distribute the magnesia-chrome-silicon carbide mixture on the thermal insulation layer, compact and level it while distributing evenly, so that the thickness of the anti-seepage layer reaches 55 cm, and then bake it with natural gas flame for 20 minutes, and the flame temperature is 280 °C.

[0059] S6: Fabrication of the high-temperature oxidation, earthquake-resistant and wear-resistant layer. First, fabricate the high-temperature oxidation, earthquake-resistant and wear-resistant layer at the bottom of the furnace lining. Specifically, mix two materials, magnesia-chrome powder (MgO-Cr₂O₃) and silicon carbide (S i C) in the ratio (MgO-Cr₂O₃):S i C = 35%: 75% configuration, where MgO:Cr₂O in magnesia-chrome powder (MgO-Cr₂O₃) is 3＝ 35%: 16%, and at the same time add 40% phenolic resin as a binder, mix evenly, then add 40% pure water and stir well for 30 minutes to form a relatively viscous mud shape, control the viscosity at 12 Pa·s, evenly distribute the silicon carbide-magnesia-chrome powder mixture on the anti-seepage layer at the bottom of the furnace lining, compact and level it while distributing evenly, so that the thickness of the high-temperature oxidation, earthquake-resistant and wear-resistant layer at the bottom of the furnace lining reaches 45 cm, then bake it with natural gas flame for 5 minutes, and the flame temperature is 170 °C. Then place the profiling die at the central position of the furnace lining and ensure it is perpendicular to the bottom of the furnace lining. Then apply pressure to the profiling die against the bottom of the furnace lining so that the profiling die descends by 8 mm. Then fill the gap formed between the profiling die and the anti-seepage layer with the silicon carbide-magnesia-chrome powder mixture and compact it until the depth of the silicon carbide-magnesia-chrome powder mixture entering the profiling die is 8 mm. Remove the die head of the profiling die and then take out the rubber of the profiling die to make the contact surface between the furnace lining and the molten iron serrated. Finally, bake it evenly with natural gas flame for 30 minutes, and the flame temperature is 260 °C.

[0060] The technical solution of the present invention has made an exemplary description of the invention. Obviously, the specific implementation of the present invention is not limited by the above methods. As long as various non-substantive improvements are made by adopting the method concept and technical solution of the present invention, or the concept and technical solution of the invention are directly applied to other occasions without improvement, they are all within the protection scope of the present invention.

Claims

1. A modular furnace lining manufacturing method for a casting induction electric furnace, characterized in that, including the following steps, S1. Making the furnace lining frame. Using ceramic fiber rod materials with a fiber rod diameter of Φ25 - Φ35 mm, the paste epoxy resin - based adhesive has a temperature resistance of 1750 °C and a socket strength of 30 - 33 MPa. S2. Fabrication of the secondary anti-seepage layer. Start from the bottom of the furnace lining, then proceed to the conical surface at the lower part of the furnace lining, and finally reach the cylindrical surface at the upper part of the furnace lining. Specifically, place the furnace lining frame in the central area of the crucible, and the ceramic fiber rods of the furnace lining frame are closely attached to the inner side of the crucible. Mix three materials, namely aluminum oxide (AL2O3), silicon carbide (S i C), and boron carbide (B4C) powder, according to the ratio AL2O3 / S i C / B4C = (70% - 80%) / (20% - 30%) / (5% - 15%). At the same time, add 5% - 15% of phenolic resin as a binder, mix evenly, then add 10% - 20% of pure water and stir for 20 - 30 minutes to form a mud-like substance with a viscosity controlled at 6 - 8 Pa.s. Uniformly arrange the mud-like mixture at the bottom and around the furnace lining frame, and closely attach it to the inner side of the crucible. While arranging it evenly, tamp and level it to make the thickness of the secondary anti-seepage layer reach 45 - 55 cm, and then bake it with natural gas flame for 10 - 20 minutes, with the flame temperature being 220°C - 260°C. S3. Making the leak - point detection layer. Respectively place the three - dimensional cylindrical quartz glass frame, three - dimensional conical cylindrical quartz glass frame, and rectangular sheet - shaped quartz glass frame on the secondary anti - permeation layer. The three - dimensional cylindrical quartz glass frame, three - dimensional conical cylindrical quartz glass frame, and rectangular sheet - shaped quartz glass frame include quartz glass and a glass frame. The quartz glass is placed inside the glass frame. The wall thickness of the glass frame is 5 mm and the material is SUS310S. There are 3 rectangular sheet - shaped quartz glasses, evenly distributed on the secondary anti - permeation layer at the bottom of the furnace lining. S4. Production of the thermal insulation layer. It starts from the bottom of the furnace lining, then goes to the conical surface of the lower part of the furnace lining, and finally to the cylindrical surface of the upper part of the furnace lining. Specifically, hollow alumina spheres (AL2O3) and silica (S i O2) powder are mixed in the ratio of AL2O3 / S i O2 = (60% - 80%) / (5% - 15%). At the same time, 10% - 25% of phenolic resin is added as a binder and evenly mixed. Then, 20% - 30% of pure water is added and stirred for 15 - 25 minutes to form a mud-like substance with a viscosity controlled at 10 - 20 Pa.s. Since alumina is a basic oxide, dilute hydrochloric acid with a concentration of 2% - 3% is applied to the three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet quartz glass frame of the leak detection layer respectively with a fiber brush. A double decomposition chemical reaction occurs at the contact surface between the mud-like hollow alumina sphere mixture and the quartz glass frame, that is, Al2O3 + 6HCl = 2AlCl3 + 3H2O, generating aluminum chloride (AlCl3) and water (H2O) to enable the quartz glass to slide back and forth within the glass frame. Within the time range of 3 - 5 minutes, the mud-like hollow alumina sphere mixture is evenly arranged on the three-dimensional cylindrical quartz glass frame, three-dimensional conical cylindrical quartz glass frame, and rectangular sheet quartz glass frame, while being tamped and leveled evenly, and the quartz glass is continuously slid back and forth at the same time. The thickness of the leveled thermal insulation layer reaches 55 - 65 cm, and then it is baked with a natural gas flame for 15 - 25 minutes, and the flame temperature is 260°C - 280°C. S5, Production of the anti-seepage layer. Start from the bottom of the furnace lining, then proceed to the conical surface of the lower part of the furnace lining, and finally reach the cylindrical surface of the upper part of the furnace lining. Specifically, mix two materials, magnesia-chrome powder (MgO-Cr2O3) and silicon carbide (S i C), in the proportion of (MgO-Cr2O3) / S i C = (55% - 65%) / (20% - 30%). Among them, MgO / Cr2O in the magnesia-chrome powder (MgO-Cr2O3) is 3＝ (45% - 60%) / (8% - 16%). At the same time, add 25% - 35% of phenolic resin as a binder, mix evenly, then add 25% - 35% of pure water and stir well for 15 - 25 minutes to form a viscous mud shape with the viscosity controlled at 8 - 10 Pa.s. Evenly distribute the magnesia-chrome-silicon carbide mixture in a mud shape on the thermal insulation layer, compact and level it while distributing evenly, so that the thickness of the anti-seepage layer reaches 45 - 55 cm, and then bake it with natural gas flame for 10 - 20 minutes, with the flame temperature being 260°C - 280°C. S6, Fabrication of the high-temperature oxidation, earthquake-resistant and wear-resistant layer. First, fabricate the high-temperature oxidation, earthquake-resistant and wear-resistant layer at the bottom of the furnace lining. Specifically, mix magnesia-chrome powder (MgO-Cr2O3) and silicon carbide (S i C) in the ratio of (MgO-Cr2O3) / S i C = (25% - 35%) / (65% - 75%). Among them, the ratio of MgO / Cr2O in magnesia-chrome powder (MgO-Cr2O3) is 3＝ (25% - 35%) / (12% - 16%). At the same time, add 30% - 40% of phenolic resin as a binder and mix evenly. Then add 30% - 40% of pure water and stir well for 20 - 30 minutes to form a relatively viscous mud with a viscosity controlled at 9 - 12 Pa.s. Uniformly distribute the silicon carbide-magnesia-chrome powder mixture on the anti-seepage layer at the bottom of the furnace lining, tamping and leveling it while distributing evenly, so that the thickness of the high-temperature oxidation, earthquake-resistant and wear-resistant layer at the bottom of the furnace lining reaches 35 - 45 cm. Then bake it with natural gas flame for 5 minutes, and the flame temperature is 150°C - 170°C. Then place the profiling mold at the central position of the furnace lining and ensure it is perpendicular to the bottom of the furnace lining. Then apply pressure to the profiling mold towards the bottom of the furnace lining so that the profiling mold descends by a height of 6 - 8 mm. Then fill the gap formed between the profiling mold and the anti-seepage layer with the silicon carbide-magnesia-chrome powder mixture and compact it until the depth of the silicon carbide-magnesia-chrome powder mixture entering the profiling mold is 6 - 8 mm. Remove the die head of the profiling mold and then take out the rubber of the profiling mold to make the contact surface between the furnace lining and the molten iron serrated. Finally, bake it evenly with natural gas flame for 20 - 30 minutes, and the flame temperature is 240°C - 260°C.

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