A quick repairing material for coke dry quenching coke drum, a preparation method and application thereof
Patent Information
- Application Number
- CN202610765555.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-05-29
- Publication Date
- 2026-09-15
Smart Images
Figure FT_1 
Figure FT_2
Abstract
Description
Technical Field
[0001] This invention relates to the field of rapid repair technology for refractory materials and metallurgical equipment, specifically to a rapid repair material for dry-quenched coke pots, its preparation method, and its application. Background Technology
[0002] Dry quenching technology, as a core energy-saving and environmentally friendly process in modern metallurgical industry, has gradually replaced traditional wet quenching technology. The coke pot, as a mobile high-temperature pressure vessel, is responsible for carrying and transporting red-hot coke (950-1100℃) from the coke oven to the dry quenching furnace for cooling. The refractory lining of the coke pot directly endures extremely harsh service conditions: First, the intense thermal shock generated when the red-hot coke is loaded causes the lining surface to heat up rapidly within minutes; second, the enormous kinetic energy of the falling coke causes repeated mechanical impacts and severe abrasive wear on the lining; third, the cyclical processes of empty, full, high-temperature, and cooling accumulate complex thermo-mechanical coupling stresses within the lining material; finally, the residual alkali metal vapors in the coke at high temperatures also cause chemical corrosion to the lining material. The long-term synergistic effect of the above factors makes the coke lining, especially the bottom and lower part of the wall that are most severely impacted, extremely prone to cracking, peeling, wear, and even penetrating damage, directly threatening the safe operation of the entire dry quenching system and the safety of surrounding equipment.
[0003] For damage to coke oven linings, the commonly used repair techniques in the industry include: The first is the traditional refractory castable repair method. This method requires cleaning the damaged area, setting up a template, mixing and casting the castable on-site, followed by a 24-72 hour period of moist curing and a strict baking and drying process. The template can only be removed and the material put into use after the material has gained sufficient demolding strength. This process typically results in 3 to 5 days of offline maintenance for the coke oven, severely restricting the continuous operation capability of the dry quenching system. The second is refractory spraying technology. This technology uses spraying equipment to spray semi-wet refractory material onto the damaged surface. Although the construction speed is relatively fast, the sprayed layer and the old lining mainly rely on mechanical anchoring, lacking a strong chemical bond, resulting in low bonding strength. Simultaneously, the spraying process introduces a large amount of air, leading to high porosity and a loose structure in the repair layer. Its wear resistance and corrosion resistance are far inferior to castable, resulting in a very short service life. It is often only a temporary emergency measure and cannot achieve long-term repair. The third method is manual application repair. This method relies on the worker's experience to apply plastic clay to the damaged area. The construction quality is difficult to control, and it is difficult to ensure the density and uniformity of the repair layer. In addition, the material loses water and shrinks greatly during the drying and initial heating process, which easily produces shrinkage cracks, providing a channel for subsequent erosion and damage.
[0004] Through the above technical analysis, it can be found that the entire industry has consistently failed to effectively resolve a series of deep-seated technical contradictions surrounding the rapid repair of coke ovens: including the contradiction between "rapid curing" and "long-term durability": fast-drying, high-strength materials often have poor high-temperature performance, while materials with good high-temperature performance require a slow drying and sintering process. The contradiction between "hot bonding" and "thermal shock resistance": materials that can bond to hot substrates often have thermal expansion behaviors that are difficult to match with the substrate over a wide temperature range. The contradiction between "convenience of construction" and "structural density": easy application or spraying usually comes at the cost of sacrificing the material's bulk density and strength.
[0005] In summary, developing a rapid repair material and its supporting construction method that can simultaneously overcome the above three sets of contradictions, achieve a balance between rapid curing, hot construction, high density and excellent thermal shock resistance, and form a strong and reliable bond with the original lining, has become a technical problem that the dry quenching coke industry urgently needs to solve. Summary of the Invention
[0006] To address the problems of low repair efficiency, poor hot bonding performance, poor thermal shock resistance and wear resistance in existing coke can linings, this invention provides a rapid repair material, preparation method and application for dry-quenched coke cans.
[0007] To achieve the above objectives, the present invention employs the following technical solution: This invention provides a rapid repair material for dry quenching coke cans, comprising, by weight percentage: 66.4%-78% aggregate system, 19.05%-30.1% matrix powder system, and 1.4%-3.5% admixture system; The aggregate system, by total mass of the repair materials, comprises 5%-8% microporous mullite powder, 10%-15% sintered spinel fine aggregate, and 40%-55% fused white corundum particles of different sizes. The matrix powder system comprises 8%-12% activated alumina micro powder, 5%-8% CA-70 type rapid-hardening high-alumina cement, 3%-5% silica fume, 3%-5% kyanite powder, and 0.05%-0.1% explosion-proof fiber. The admixture system comprises 0.1%-1.0% polycarboxylate superplasticizer, 1%-2% plastic clay, and 0.3%-0.5% nano-alumina sol.
[0008] Optionally, based on the total mass of the repair material, the fused white fused alumina particles of different sizes include 16%-20% of 30-50 mesh fused white fused alumina particles, 15%-20% of 50-150 mesh fused white fused alumina particles, and 14%-15% of 16-20 mesh fused white fused alumina particles.
[0009] Optionally, the microporous mullite powder has a particle size ≤0.088mm; the sintered spinel fine aggregate has a particle size of 18-20 mesh; the activated alumina micro powder has a particle size ≤0.044mm; the explosion-proof fiber has a length of 3-6mm; and the kyanite powder has a particle size of 320-330 mesh.
[0010] Optionally, the explosion-proof fiber is polypropylene fiber, and the Al2O3 content in the nano-alumina sol is 15wt%-25wt%.
[0011] The present invention also provides a method for preparing a rapid repair material for dry quenching coke pots as described above, comprising: The components, excluding the explosion-proof fiber and nano alumina sol, are dry-mixed to obtain a dry mixture. After adding water to the dry mix, add the fiber and nano alumina sol and stir to form a slurry to obtain a rapid repair material. The amount of water added is 5.5%-6.5% of the total amount of the aggregate system, matrix powder system and admixture system.
[0012] The application of rapid repair materials for dry quenching coke cans in repairing dry quenching coke cans includes: Activated alumina micro powder, silica fume, nano alumina sol, aluminum dihydrogen phosphate solution, and plastic clay are mixed and water is added to form a slurry to obtain a hot-state bonding slurry. Substrate treatment is performed on the area of the coke can to be repaired; Apply hot adhesive mortar to the area to be repaired after substrate treatment, and form an adhesive transition film in the area to be repaired; In batches, the rapid repair material is applied to the upper layer of the viscous transition film. After each layer is applied, it is tamped and compacted until the rapid repair material completely fills the area to be repaired and is higher than the original lining surface. The surface is then leveled and baked at a low temperature until the rapid repair material hardens, thus completing the repair of the dry quenching coke can.
[0013] Optionally, the mass concentration of the aluminum dihydrogen phosphate solution is 30%-50%; by mass percentage, the remaining components of the hot-state bonding slurry, excluding water, include 30%-50% activated alumina micropowder, 25%-35% silica fume, 3%-8% plastic clay, 8%-12% aluminum dihydrogen phosphate solution, and 12%-17% nano-alumina sol; after adding water, the water-to-solid ratio of the hot-state bonding slurry is 0.25-3.
[0014] Optionally, the aluminum dihydrogen phosphate solution has a mass concentration of 50%; by mass percentage, the remaining components of the hot-state bonding slurry, excluding water, include 40% activated alumina micro powder, 30% silica fume, 5% plastic clay, 10% aluminum dihydrogen phosphate solution, and 15% nano-alumina sol.
[0015] Optionally, the thickness of the viscous transition film is 1-2 mm.
[0016] Optionally, each layer of quick-repair material is coated with a thickness of 50-80mm, and the low-temperature baking temperature is 200-400℃, with a low-temperature baking time of 2-3h.
[0017] Compared with the prior art, the present invention has the following beneficial effects: This invention provides a rapid repair material for dry-quenched coke cans. This repair material is a ternary system comprising CA-70 rapid-hardening high-alumina cement, silica fume, and nano-alumina sol: the rapid-hardening cement provides rapid hydration and hardening at room temperature; silica fume fills micropores and promotes medium-temperature ceramization; and the nano-alumina sol sinters at high temperatures to form a strong ceramic bond. The three components work synergistically to achieve seamless strength transitions across a wide temperature range from room temperature to 1100°C, meeting the requirements for rapid deployment while ensuring that strength does not decrease or even increases under long-term high-temperature service. This addresses the problem of existing spray or coating materials failing to bond firmly to high-temperature substrates, or cracking after bonding due to mismatched thermal expansion. The aggregate system of the rapid repair material provided by this invention simultaneously includes sintered spinel fine aggregate and microporous mullite powder, introduces kyanite powder into the matrix, and works synergistically with explosion-proof fibers, significantly improving the volume stability and thermal shock resistance of the repair body under rapid heating and cooling. Meanwhile, the alumina-based component in the overall formula exhibits good thermal expansion compatibility with the original high-alumina lining of the coke tank, providing a materials science basis for subsequent hot bonding. Finally, the introduction of plastic clay adjusts the workability and water retention, while polycarboxylate superplasticizer reduces water consumption, giving the material excellent thixotropy and tamping properties. It does not flow during vertical application and can achieve high bulk density through layered, forceful tamping. Simultaneously, the synergistic effect of explosion-proof fibers and kyanite powder prevents cracking caused by rapid baking, maintaining the high-density structure. Therefore, this rapid repair material achieves convenient construction without formwork, obtains a dense structure close to that of castable refractory, and has a service life far exceeding traditional sprayed repair materials. Compared with existing repair materials, this rapid repair material achieves a balance between rapid curing, hot application, high density, and excellent thermal shock resistance, providing a reliable solution for the repair and maintenance of dry-quenched coke tanks in the dry-quenching industry.
[0018] Fused white fused alumina possesses high hardness and wear resistance, forming the framework of repair materials against the impact and abrasion of coke. Through optimized three-stage particle size distribution—coarse (16-20 mesh), medium (30-50 mesh), and fine (50-150 mesh)—the densest packing is achieved, significantly reducing inter-particle porosity. This reduces the need for matrix powder filling, thereby increasing the density and strength of the hardened repair. Simultaneously, the appropriate particle size distribution helps improve plastic tamping properties during construction, making the material easy to compact without delamination.
[0019] Microporous mullite powder ≤0.088mm can be uniformly dispersed in the matrix and plays a role in microporous stress buffering at high temperatures; sintered spinel fine aggregate of 18-20 mesh can resist thermal shock as fine aggregate without being too fine and losing its aggregate support function; activated alumina micro powder ≤0.044mm, the high fineness is conducive to its reaction with silica fume, cement, etc. at medium and high temperatures to form mullite or anorthite bonding phase, improving sintering strength; kyanite powder of 320-330 mesh, the uniform fineness ensures uniform expansion at high temperatures and accurately compensates for shrinkage; explosion-proof fiber length of 3-6mm melts during baking to form a three-dimensional microchannel network, effectively expelling water vapor and preventing cracking in the thickness direction.
[0020] This invention also provides a method for preparing a rapid repair material for dry-quenched coke cans as described above. This method ensures macroscopic uniform distribution of aggregates, cement, micro-powder, kyanite, clay, water-reducing agents, etc., by first dry-mixing all powdered and granular components (except fibers and sols) uniformly, thus avoiding localized agglomeration after subsequent water addition. Adding 70% water and stirring to initially moisten the dry mixture, followed by adding explosion-proof fibers and nano-alumina sol pre-dispersed in the remaining water, allows the fibers to be uniformly distributed in the slurry, forming a three-dimensional network. The nano-sol rapidly disperses in the aqueous medium and adsorbs onto the particle surface, playing a dual role of binding and dispersing. The preparation method is simple, requires no complex reaction conditions or equipment, and has low preparation cost and good economic efficiency.
[0021] The application of the aforementioned rapid repair material for dry-quenched coke cans addresses the problem in existing technologies where applying repair materials directly to a high-temperature substrate often leads to bonding failure due to substrate surface oxidation, differences in thermal expansion, or excessively rapid water evaporation. This application addresses this issue by pre-coating a slurry prepared from activated alumina, silica fume, nano-alumina sol, aluminum dihydrogen phosphate, and plastic clay. This slurry rapidly undergoes a dehydration condensation reaction on the hot substrate. Aluminum dihydrogen phosphate reacts with alumina to form an aluminum phosphate bound phase, the nano-sol forms a gel network, and the plastic clay provides thixotropy, forming a viscous transition film. This film not only forms a strong chemical bond and mechanical anchor with the old lining but also exhibits excellent chemical compatibility with subsequent repair materials. Then, considering the considerable depth of the coke can repair area, layers of 50-80 mm thickness are filled and forcefully tamped. This layer-by-layer tamping ensures that each layer fully expels air and makes close contact with the underlying and side substrates, avoiding voids, delamination, or uneven compaction that may occur with overall filling. This process achieves a balance between ease of construction and structural density, ensuring the integrity and density of the repair even in thick-walled repairs. Because the repair material itself has high thixotropy, it does not flow during vertical application, eliminating the need for formwork and simplifying the process. After repair, it only requires baking at 200-400℃ for 2-3 hours before use, resulting in higher repair efficiency and significant engineering benefits. Attached Figure Description
[0022] Figure 1 This is a schematic diagram of the preparation method of a rapid repair material for dry quenching coke pots according to the present invention.
[0023] Figure 2 This is a flowchart illustrating the application method of the rapid repair material for dry quenching coke cans of the present invention in repairing dry quenching coke cans. Detailed Implementation
[0024] To enable those skilled in the art to understand the features and effects of the present invention, the terms and expressions used in the specification and claims are explained and defined in general below. Unless otherwise specified, all technical and scientific terms used herein have the ordinary meaning understood by those skilled in the art regarding the present invention, and in case of conflict, the definitions in this specification shall prevail.
[0025] The theories or mechanisms described and disclosed herein, whether right or wrong, should not in any way limit the scope of the invention, that is, the contents of the invention can be implemented without being limited by any particular theory or mechanism.
[0026] In this document, all features defined by numerical ranges or percentage ranges, such as numerical values, quantities, contents, and concentrations, are for the sake of brevity and convenience only. Accordingly, descriptions of numerical ranges or percentage ranges should be considered as covering and specifically disclosing all possible sub-ranges and individual numerical values (including integers and fractions) within those ranges.
[0027] In this article, unless otherwise specified, “contains,” “includes,” “containing,” “has,” or similar terms cover the meanings of “composed of” and “mainly composed of,” for example, “A contains a” covers the meanings of “A contains a and others” and “A contains only a.”
[0028] For the sake of brevity, not all possible combinations of the technical features in each implementation scheme or embodiment are described herein. Therefore, as long as there is no contradiction in the combination of these technical features, the technical features in each implementation scheme or embodiment can be combined arbitrarily, and all possible combinations should be considered within the scope of this specification.
[0029] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.
[0030] The following examples use instruments and equipment conventional in the art. Experimental methods in the following examples, unless otherwise specified, are generally performed under conventional conditions or as recommended by the manufacturer. All raw materials used in the following examples are conventional commercially available products with specifications conventional in the art. In this specification and the following examples, unless otherwise specified, "%" refers to weight percentage, "parts" refers to parts by weight, and "ratio" refers to weight proportion.
[0031] The present invention will be further described in detail below with reference to specific embodiments. These descriptions are for explanation purposes only and are not intended to limit the scope of the invention.
[0032] This invention provides a rapid repair material for dry quenching coke cans, comprising, by weight percentage: 66.4%-78% aggregate system, 19.05%-30.1% matrix powder system, and 1.4%-3.5% admixture system; The aggregate system, by total mass of the repair materials, comprises 5%-8% microporous mullite powder, 10%-15% sintered spinel fine aggregate, and 40%-55% fused white corundum particles of different sizes. The matrix powder system comprises 8%-12% activated alumina micro powder, 5%-8% CA-70 type rapid-hardening high-alumina cement, 3%-5% silica fume, 3%-5% kyanite powder, and 0.05%-0.1% explosion-proof fiber. The admixture system comprises 0.1%-1.0% polycarboxylate superplasticizer, 1%-2% plastic clay, and 0.3%-0.5% nano-alumina sol. The fused white fused alumina particles of different sizes, based on the total mass of the repair material, include 16%-20% 30-50 mesh fused white fused alumina particles, 15%-20% 50-150 mesh fused white fused alumina particles, and 14%-15% 16-20 mesh fused white fused alumina particles. The microporous mullite powder has a particle size ≤0.088mm; the sintered spinel fine aggregate has a particle size of 18-20 mesh; the activated alumina micro powder has a particle size ≤0.044mm; the explosion-proof fiber has a length of 3-6mm; the kyanite powder has a particle size of 320-330 mesh; the explosion-proof fiber is polypropylene fiber; and the Al2O3 content in the nano-alumina sol is 15wt%-25wt%.
[0033] See Figure 1 The present invention also provides a method for preparing a rapid repair material for dry quenching coke pots as described above, comprising: S1: Dry mix all components except for explosion-proof fiber and nano alumina sol to obtain dry mix; S2: After adding water to the dry mixture, add the fiber and nano alumina sol and stir to form a slurry to obtain a rapid repair material. The amount of water added is 5.5%-6.5% of the total amount of the aggregate system, matrix powder system and admixture system.
[0034] See Figure 2 The application of the aforementioned rapid repair materials for dry quenching coke cans in repairing dry quenching coke cans includes: S1: Activated alumina micro powder, silica fume, nano-alumina sol, aluminum dihydrogen phosphate solution, and plastic clay are mixed and water is added to form a slurry, resulting in a hot-state bonding slurry. The aluminum dihydrogen phosphate solution has a mass concentration of 30%-50%. By mass percentage, excluding water, the remaining components of the hot-state bonding slurry contain: activated alumina micro powder (30%-50%), silica fume (25%-35%), plastic clay (3%-8%), aluminum dihydrogen phosphate solution (8%-12%), and nano-alumina sol (12%-17%). After adding water, the water-to-solid ratio of the hot-state bonding slurry is 0.25-3. Preferably, the aluminum dihydrogen phosphate solution has a mass concentration of 50%. By mass percentage, excluding water, the remaining components of the hot-state bonding slurry contain: activated alumina micro powder (40%), silica fume (30%), plastic clay (5%), aluminum dihydrogen phosphate solution (10%), and nano-alumina sol (15%).
[0035] S2: Perform substrate treatment on the area to be repaired in the coke pot, specifically: Within 2 hours of shutting down the coke tank, loose material in the damaged area of the coke tank repair zone can be thoroughly removed using a pneumatic pick or mechanical tools until a solid substrate is formed, creating a pit with regular edges.
[0036] High-pressure air is used to blow away the dust in the pit, without waiting for the coke pot to cool completely, allowing the surface temperature of the substrate to be in the range of 80-150℃.
[0037] S3: Apply the hot-pressed adhesive mortar to the area to be repaired after substrate treatment, and form an adhesive transition film in the area to be repaired, specifically as follows: Apply the prepared hot adhesive mortar quickly and evenly to the cleaned repair surface (including the bottom and sides) using a brush, to a thickness of about 1-2 mm. The mortar will quickly form a viscous transition film on the hot substrate.
[0038] S4: Apply the rapid repair material in batches to the viscous transition film. After each layer is applied, tamp and compact it until the rapid repair material completely fills the area to be repaired and is higher than the original lining surface. Smooth it and bake it at a low temperature until the rapid repair material hardens, thus completing the repair of the dry quenching coke pot. Specifically: Before the viscous transition film surface dries, fill the pit with repair material in batches within approximately 5 minutes. After each layer (approximately 50-80mm thick), tamp it firmly with a specialized tamping tool or pneumatic hammer to ensure a tight bond between the repair material and the substrate (especially the sides), expelling any internal air. Continue filling the pit with the rapid repair material until it is slightly higher than the original lining surface, then smooth it with a trowel. No wet curing or prolonged static setting is required. After the repair is complete, immediately use a gas torch or the residual heat of the coke can to bake the repaired area at a medium-low temperature (200-400℃) for 2-3 hours to accelerate hydration and hardening and expel physical water. After baking, the surface temperature of the repaired area should drop below 80℃ before coke loading can begin.
[0039] Traditional repair castables require 24-72 hours of curing before use, severely hindering production. This invention addresses this pain point by using a ternary synergistic rapid-hardening system of fast-setting cement, silica fume, and accelerator. This system enables repairs to achieve sufficient strength to withstand red-hot filling within 2-4 hours after application, breaking the industry barrier of "rapid curing inevitably sacrificing strength." Furthermore, addressing the issue of traditional repairs bulging, cracking, and peeling during thermal cycling due to mismatched coefficients of thermal expansion and internal vapor pressure, this application innovatively introduces spinel and microporous mullite composite aggregates to regulate thermal expansion behavior. It also utilizes the high-temperature expansion effect of kyanite powder to compensate for shrinkage. Simultaneously, it constructs micro-venting channels with explosion-proof fibers, increasing the material's thermal shock resistance (1100℃ water cooling) from the traditional <15 cycles to >20 cycles, with an optimal value of >35 cycles. This fundamentally solves the persistent problem of premature failure of repairs due to thermal shock.
[0040] Addressing the challenge of traditional materials failing to bond effectively to high-temperature substrates (>80℃) and requiring cooling during application, this invention utilizes a specialized nano-sol-phosphate composite hot-state bonding slurry. This slurry forms a strong chemical and mechanical bond on substrate surfaces at 80-150℃, with a hot-state bonding strength ≥2.5 MPa. This ensures that the repair and the original lining become a solid whole at high temperatures, preventing interfacial delamination.
[0041] Addressing the pain points of traditional repair processes, which are cumbersome, require formwork, lengthy curing, and complex baking, this invention employs a plastic tamping or spraying process, eliminating the need for formwork. The material possesses excellent thixotropic properties, preventing dripping during vertical application. Only simple low-to-medium temperature baking is required after application, compressing the traditional maintenance cycle, measured in days, to hours. Furthermore, it eliminates the need to wait for the equipment to fully cool down, allowing for direct operation while the tank remains warm (80-150℃). This allows the total time window from tank shutdown to production resumption to be controlled within 8-12 hours, making it particularly suitable for emergency repairs during production breaks, maximizing equipment uptime, and reducing maintenance downtime by 70%-90%. This directly avoids the huge coke production losses (up to millions of yuan per day) caused by prolonged shutdowns, while extending the lifespan of a single repair, reducing the number of repeated repairs within the year and associated labor, material, and hoisting costs. The rapid-response repair capability enhances the operational stability of the dry quenching system and the flexibility of production planning.
[0042] Furthermore, the optimized particle size distribution and admixture system of this application ensures stable material performance and ample operating time, reducing quality fluctuations caused by differences in on-site mixing or construction methods. Through precise matching of material design, the wear resistance, erosion resistance, and thermal shock stability of the repaired material approach or even reach the original lining design level, avoiding the vicious cycle of repeated repairs and achieving long-term effectiveness for a single repair. The material has good versatility and stable storage, and can replace many traditional materials, reducing the types of spare parts and inventory capital tied up. This invention is not a simple improvement on existing materials, but rather a comprehensive solution integrating materials, processes, and performance for the specific high-risk, high-loss scenario of rapid repair of dry-quenched coke ovens. Its core value lies in systematically resolving the contradictions that traditional technologies cannot simultaneously address, such as "speed and quality," "constructability and durability," and "hot bonding and thermal shock resistance," achieving a revolutionary shift from a "shutdown overhaul" mode to an "online rapid repair" mode, demonstrating outstanding technological advancement, engineering practicality, and significant economic benefits.
[0043] Example 1 This invention provides a method for preparing and applying a rapid repair material for dry-quenched coke cans as described above. The rapid repair material for dry-quenched coke cans comprises, by weight percentage: Aggregate system (71%), including: 30-50 mesh fused white corundum particles: 20%; 50-150 mesh fused white corundum particles: 15%; 16-20 mesh fused white corundum particles: 15%; 18-20 mesh sintered spinel fine aggregate: 13%; ≤0.088mm microporous mullite powder: 8%; The matrix powder system (27%) includes: ≤0.044mm activated alumina micro powder (α-Al2O3): 12%; CA-70 type rapid-hardening high-alumina cement: 5%; Silica fume (SiO2 micro powder): 4.95%; 325 mesh kyanite powder: 5%; Explosion-proof fiber (polypropylene fiber, length 3-6mm): 0.05%; The admixture system (2.0%) includes: Polycarboxylate superplasticizer (solid content): 0.1%; Plastic clay: 1.5%; Nano-alumina sol (Al2O3 content 20%): 0.4% (added during mixing in sol form); Water: Added at a rate of 5.5% of the total mass of the above components.
[0044] During preparation, all aggregates, powders, and additives (water-reducing agents, clay) except for explosion-proof fibers and nano-sols are added to a forced mixer and dry-mixed for 5 minutes until uniformly mixed.
[0045] Add 70% of the total water volume and stir for 2 minutes. Then add the explosion-proof fibers that have been pre-dispersed in the remaining water, as well as all of the nano-alumina sol. Continue stirring for 5 minutes until the material is uniform, moist, and plastic mud-like, with good cohesiveness and thixotropy (it can be formed into a ball when squeezed by hand, and it is not easy to break apart. It does not drip when applied to vertical surfaces), thus obtaining a rapid repair material.
[0046] The preparation of the hot-state bonding mortar, by dry weight percentage, includes: Activated alumina micro powder: 40% Silica fume: 30% Nano-alumina sol (Al2O3 content 20%): 15% (as a liquid binder, replacing water) Aluminum dihydrogen phosphate solution (50% concentration): 10% Plastic clay: 5% Before use on site, adjust the mixture to a slurry (paste) with a water-to-solid ratio of 0.25-0.3 to obtain a hot-state bonding slurry.
[0047] The steps for repairing a coke pot are as follows: Substrate preparation (begin within 2 hours of tank shutdown): Thoroughly remove loose material from the damaged area using a pneumatic drill or mechanical tools until a solid substrate is formed, creating a pit with regular edges. Use high-pressure air to blow away any dust from the pit. There is no need to wait for the tank to cool completely; the substrate surface temperature is permissible within the range of 80-150°C.
[0048] Apply the prepared hot adhesive mortar quickly and evenly to the cleaned repair surface (including the bottom and sides) using a brush, to a thickness of approximately 1.5 mm. The mortar will quickly form a viscous transition film on the hot substrate.
[0049] Before the adhesive grout dries to the surface (within about 5 minutes), fill the pit with the prepared plastic repair material in batches. After each layer (about 50 mm thick), use a special tamping tool or pneumatic hammer to tamp and compact it to ensure that the repair material is tightly bonded to the substrate (especially the sides) and to remove internal air.
[0050] Fill the repair material to a level slightly higher than the original lining surface and smooth it with a trowel. No wet curing or prolonged standing is required. After the repair is completed, the repaired area can be immediately baked at a medium-low temperature (300℃) for 2.5 hours using a gas torch or the residual heat of the coke oven to accelerate hydration and hardening and remove physical water.
[0051] Put into use: After baking, the surface temperature of the repaired body can be reduced to below 80℃ before coking can be carried out.
[0052] Example 2 Unlike Example 1, the rapid repair material for dry quenching coke pots, by weight percentage, comprises: Aggregate system (70%), including: 30-50 mesh fused white corundum particles: 16%; 50-150 mesh fused white corundum particles: 18%; 16-20 mesh fused white corundum particles: 15%; 18-20 mesh sintered spinel fine aggregate: 13%; ≤0.088mm microporous mullite powder: 8%; The matrix powder system (28%) includes: ≤0.044mm activated alumina micro powder (α-Al2O3): 11.9%; CA-70 type rapid-hardening high-alumina cement: 8%; Silica fume (SiO2 micro powder): 5%; 325-mesh kyanite powder: 3%; Explosion-proof fiber (polypropylene fiber, length 3-6mm): 0.1%; The admixture system (2.0%) includes: Polycarboxylate superplasticizer (solid content): 0.1%; Plastic clay: 1.5%; Nano-alumina sol (Al2O3 content 20%): 0.4% (added during mixing in sol form); Water: Added at a rate of 6.5% of the total mass of the above components.
[0053] The low-temperature baking temperature is 400℃ and the time is 2.5h.
[0054] Example 3 Unlike Example 1, the rapid repair material for dry quenching coke pots, by weight percentage, comprises: Aggregate system (74%), including: 30-50 mesh fused white corundum particles: 16%; 50-150 mesh fused white corundum particles: 20%; 16-20 mesh fused white corundum particles: 15%; 18-20 mesh sintered spinel fine aggregate: 15%; ≤0.088mm microporous mullite powder: 8%; The matrix powder system (23.5%) includes: ≤0.044mm activated alumina micro powder (α-Al2O3): 9.4%; CA-70 type rapid-hardening high-alumina cement: 6%; Silica fume (SiO2 micro powder): 5%; 325-mesh kyanite powder: 3%; Explosion-proof fiber (polypropylene fiber, length 3-6mm): 0.1%; The admixture system (2.5%) includes: Polycarboxylate superplasticizer (solid content): 0.1%; Plastic clay: 2.0%; Nano-alumina sol (Al2O3 content 20%): 0.4% (added during mixing in sol form); Water: Added at a rate of 6.5% of the total mass of the above components.
[0055] The low-temperature baking temperature is 250℃ and the time is 2 hours.
[0056] Example 4 Unlike Example 1, the rapid repair material for dry quenching coke pots, by weight percentage, comprises: Aggregate system (69%), including: 30-50 mesh fused white corundum particles: 20%; 50-150 mesh fused white corundum particles: 20%; 16-20 mesh fused white corundum particles: 14%; 10% of 18-20 mesh sintered spinel fine aggregate; ≤0.088mm microporous mullite powder: 5%; The matrix powder system (28.1%) includes: ≤0.044mm activated alumina micro powder (α-Al2O3): 12%; CA-70 type rapid-hardening high-alumina cement: 8%; Silica fume (SiO2 micro powder): 3%; 325-mesh kyanite powder: 5%; Explosion-proof fiber (polypropylene fiber, length 3-6mm): 0.1%; The admixture system (2.9%) includes: Polycarboxylate superplasticizer (solid content): 0.5%; Plastic clay: 2.0%; Nano-alumina sol (Al2O3 content 20%): 0.4% (added during mixing in sol form); Water: Added at a rate of 6.5% of the total mass of the above components.
[0057] The low-temperature baking temperature is 300℃ and the time is 2 hours.
[0058] Example 5 Unlike Example 1, the rapid repair material for dry quenching coke pots, by weight percentage, comprises: Aggregate system (71%), including: 30-50 mesh fused white corundum particles: 15%; 50-150 mesh fused white corundum particles: 18%; 16-20 mesh fused white corundum particles: 15%; 18-20 mesh sintered spinel fine aggregate: 15%; ≤0.088mm microporous mullite powder: 8%; The matrix powder system (26.1%) includes: ≤0.044mm activated alumina micro powder (α-Al2O3): 8%; CA-70 type rapid-hardening high-alumina cement: 8%; Silica fume (SiO2 micro powder): 5%; 325-mesh kyanite powder: 5%; Explosion-proof fiber (polypropylene fiber, length 3-6mm): 0.1%; The admixture system (2.9%) includes: Polycarboxylate superplasticizer (solid content): 1%; Plastic clay: 1.6%; Nano-alumina sol (Al2O3 content 20%): 0.3% (added during mixing in sol form); Water: The amount added is 5.8% of the total mass of the above components.
[0059] The low-temperature baking temperature is 400℃ and the time is 2 hours.
[0060] Example 6 Unlike Example 1, the rapid repair material for dry quenching coke pots, by weight percentage, comprises: The aggregate system (66.5%) includes: 30-50 mesh fused white corundum particles: 18.5%; 50-150 mesh fused white corundum particles: 17%; 16-20 mesh fused white corundum particles: 10%; 18-20 mesh sintered spinel fine aggregate: 14%; ≤0.088mm microporous mullite powder: 7%; The matrix powder system (30%) includes: ≤0.044mm activated alumina micro powder (α-Al2O3): 11.9%; CA-70 type rapid-hardening high-alumina cement: 8%; Silica fume (SiO2 micro powder): 5%; 325-mesh kyanite powder: 5%; Explosion-proof fiber (polypropylene fiber, length 3-6mm): 0.1%; The admixture system (3.5%) includes: Polycarboxylate superplasticizer (solid content): 1%; Plastic clay: 2%; Nano-alumina sol (Al2O3 content 20%): 0.5% (added during mixing in sol form); Water: The amount added is 6.3% of the total mass of the above components.
[0061] The low-temperature baking temperature is 200℃ and the time is 3 hours.
[0062] Example 7 Unlike Example 1, the rapid repair material for dry quenching coke pots, by weight percentage, comprises: The aggregate system (68.5%) includes: 30-50 mesh fused white corundum particles: 19.5%; 50-150 mesh fused white corundum particles: 18%; 16-20 mesh fused white corundum particles: 10%; 18-20 mesh sintered spinel fine aggregate: 14%; ≤0.088mm microporous mullite powder: 7%; The matrix powder system (29%) includes: ≤0.044mm activated alumina micro powder (α-Al2O3): 10.9%; CA-70 type rapid-hardening high-alumina cement: 8%; Silica fume (SiO2 micro powder): 5%; 325-mesh kyanite powder: 5%; Explosion-proof fiber (polypropylene fiber, length 3-6mm): 0.1%; The admixture system (2.5%) includes: Polycarboxylate superplasticizer (solid content): 1%; Plastic clay: 1%; Nano-alumina sol (Al2O3 content 20%): 0.5% (added during mixing in sol form); Water: The amount added is 6.3% of the total mass of the above components.
[0063] The low-temperature baking temperature is 400℃ and the time is 3 hours to accelerate hydration hardening and remove physical water.
[0064] Example 8 Unlike Example 1, the rapid repair material for dry quenching coke pots, by weight percentage, comprises: Aggregate system (69%), including: 30-50 mesh fused white corundum particles: 18%; 50-150 mesh fused white corundum particles: 18%; 16-20 mesh fused white corundum particles: 12%; 18-20 mesh sintered spinel fine aggregate: 14%; ≤0.088mm microporous mullite powder: 7%; The matrix powder system (28%) includes: ≤0.044mm activated alumina micro powder (α-Al2O3): 9.9%; CA-70 type rapid-hardening high-alumina cement: 8%; Silica fume (SiO2 micro powder): 5%; 325-mesh kyanite powder: 5%; Explosion-proof fiber (polypropylene fiber, length 3-6mm): 0.1%; The admixture system (3%) includes: Polycarboxylate superplasticizer (solid content): 0.7%; Plastic clay: 2%; Nano-alumina sol (Al2O3 content 20%): 0.3% (added during mixing in sol form); Water: The amount added is 6.3% of the total mass of the above components.
[0065] The low-temperature baking temperature is 300℃ and the time is 3 hours.
[0066] Comparative Example 1 By weight, the repair material components include: High-alumina bauxite with a particle size of 3mm to 5mm: 15 to 26 parts; Calcium hexaaluminate with a particle size of 1 mm to 3 mm: 18 to 25 parts; Calcite with a particle size of 1mm to 3mm: 10 to 20 parts; Biotite with a particle size ≤3mm: 12-19 parts; Wollastonite with a particle size ≤1mm: 9-11 parts; Pyrophyllite with a particle size ≤1mm: 4-6 parts; BaO with a particle size less than 0.088 mm: 3-5 parts; 2-4 parts of borosilicate glass powder with a particle size of 180 mesh; Calcium phosphate with a particle size less than 0.088 mm: 2-7 parts; Water-reducing agent: 1-2 parts Operating steps: Weigh all materials according to the above proportions and pour them into a mixer for 5-8 minutes to obtain a uniform repair material. Then add water to the prepared repair material, with the amount of water being 5%-7% of the total weight of the repair material, and stir for another 6-9 minutes. The mixed repair material can then be used to repair the damaged parts of the coke oven lining. After the repair is completed and cured for 3 days, demold the material, dry it at 110℃ for 24 hours, and then keep it at 300℃ for 24 hours. After natural cooling, it can be put into use.
[0067] Comparative Example 2 By weight, the repair material components include: 15-50 parts of fused silica; 1-30 parts of silica powder; 1-15 parts of metallic aluminum powder; 1-60 parts of boric acid; Sodium tripolyphosphate 0.1-5 parts.
[0068] The operation steps are as follows: After the above components are mixed evenly, the finished product is discharged. When using, it can be directly applied to the gaps and surfaces of damaged refractory bricks without any base material. Just make sure there is no obvious powder on the surface. After the repair is completed, the surface will quickly form a film and dry quickly. To ensure the effect or meet the test requirements, it is necessary to wait at least 48 hours for it to dry completely. High temperature drying can speed up the drying process and reduce the drying time, but it cannot guarantee that it will be completely dry.
[0069] The specific component comparison table of the above embodiments is as follows: Components Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 30-50 mesh fused white corundum particles 20 16 16 20 15 18.5 19.5 18 50-150 mesh fused white corundum particles 15 18 20 20 18 17 18 18 16-20 mesh fused white corundum particles 15 15 15 14 15 10 10 12 18-20 mesh sintered spinel fine aggregate 13 13 15 10 15 14 14 14 Microporous mullite powder 8 8 8 5 8 7 7 7 Activated alumina micro powder 12 11.9 9.4 12 8 11.9 10.9 9.9 CA-70 type rapid-hardening high-alumina cement 5 8 6 8 8 8 8 8 silica ash 4.95 5 5 3 5 5 5 5 Kyanite powder 5 3 3 5 5 5 5 5 Explosion-proof fiber 0.05 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Water reducing agent 0.1 0.1 0.1 0.5 1 1 1 0.7 plastic clay 1.5 1.5 2.0 2.0 1.6 2 1 2 Nanosol (solid) 0.4 0.4 0.4 0.4 0.3 0.5 0.5 0.3 Dry basis total 100 100 100 100 100 100 100 100 Performance tests were conducted on the materials after repair in the embodiments and comparative examples of the present invention, including: Thermal conductivity: measured using a DPRL-Ⅲ thermal conductivity tester.
[0070] Adhesion strength: The repair materials used in the examples and comparative examples were sprayed onto ordinary carbon steel sheets. After drying for 48 hours, the adhesion strength of the coating was measured using an adhesion strength tester.
[0071] High temperature resistance: The maximum normal operating temperature inside a dry quenching coke pot is 1000℃, and the repair material of this patent can fully meet various working conditions. By applying it to the surface of an actual brick and conducting a sintering test at 1500℃, the surface of the repair material was observed to see if there were any cracks, peeling, flaking, blistering, or other phenomena.
[0072] Thermal shock stability test: The repair materials of the examples and comparative examples were coated on the surface of the bricks and dried for 48 hours. After calcination at 1500℃ for 20 minutes in a muffle furnace, the effect of the number of rapid cooling cycles on surface cracking was observed by water cooling method. The rapid cooling and heating conditions of the coke oven during the operation cycle were simulated, and the number of times the surface cracked was recorded as the thermal shock stability test result.
[0073] High and low temperature fastness test: By simulating the working conditions inside the dry quenching coke oven, the repair material was coated on the surface of the brick and calcined inside the dry quenching coke oven. There was a certain temperature difference. After 25 days of high and low temperature calcination, the material was taken out and the coating adhesion strength and surface wear were measured using an adhesion strength tester.
[0074] Acid and alkali corrosion resistance test: The repair materials of the examples and comparative examples were sprayed on the surface of ordinary carbon steel and dried for 48 hours. The steel sheets were first immersed in a 10% sulfuric acid solution for 24 hours, and then immersed in a 10% caustic soda solution for 24 hours. The appearance of the coating was checked to see if there were any blistering, peeling, coating delamination, coating corrosion, or rust.
[0075] The test results of the above embodiments and comparative examples are as follows: name Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Comparative Example 1 Comparative Example 2 Thermal conductivity W / (m·K) 0.032 0.041 0.039 0.031 0.032 0.042 0.039 0.049 0.096 0.08 Bond strength (MPa) 85 78 82 84 81 75 70 82 65 62 High temperature resistance ℃ 1500 1500 1400 1250 1350 1300 1350 1250 900 1050 Thermal shock stability 85 times 70 times 72 times 68 times 72 times 70 times 74 times 73 times 55 times 57 times High and low temperature fastness 81 78 84 80 78 74 79 82 53 49 abrasion resistance No wear No wear Slight wear Slight wear No wear No wear Slight wear Slight wear Severe wear Severe wear Acid and alkali corrosion resistant Non-corrosive Slight corrosion Non-corrosive Non-corrosive Slight corrosion Obvious corrosion Slight corrosion Non-corrosive Severe corrosion Severe corrosion Expected Key Performance Indicators Application efficiency: 5.5-6.5% water addition, good plasticity, and operable time ≥40min.
[0076] Curing speed: After drying at 110℃ for 3 hours, the flexural strength is ≥ 8 MPa; after heat treatment at 1100℃ for 3 hours, the flexural strength is ≥ 20 MPa.
[0077] Hot bond strength: After application and baking on a substrate at 150℃, the bond strength with the old high-alumina lining is ≥2.5 MPa.
[0078] Thermal shock resistance (1100℃ water cooling): After ≥ 20 cycles, there is no cracking or peeling on the surface.
[0079] Abrasion resistance: According to ASTM C704 standard, abrasion amount ≤ 8 cm³.
[0080] Based on the actual working conditions and usage requirements of dry-quenched coke pots, and according to the tests conducted in this application, the thermal conductivity of the embodiment is significantly lower than that of the mainstream market formulation in the comparative example, indicating that the coke pot repair agent we developed has good thermal insulation effect; the bonding strength is significantly higher than that of the comparative example, and the high temperature resistance and high and low temperature fastness are also significantly higher than those of the comparative example, indicating that the high temperature resistance of the embodiment is significantly better than that of conventional products on the market; the thermal shock stability is significantly better than that of the comparative example, indicating that the embodiment has good thermal shock stability and can meet the actual use requirements; through comparative tests on acid and alkali corrosion resistance, the corrosion resistance of the embodiment is significantly higher than that of the comparative example, indicating that it has good corrosion resistance.
[0081] The above description is merely a preferred embodiment of the present invention and is not intended to limit the technical solution of the present invention in any way. Those skilled in the art should understand that, without departing from the spirit and principles of the present invention, the technical solution can be modified and replaced in several simple ways, and these modifications and replacements are all within the scope of protection covered by the claims.
Claims
1. A rapid repair material for coke drums of dry quenching, characterized in that, By weight percentage, it includes: 66.4%-78% aggregate system, 19.05%-30.1% matrix powder system and 1.4%-3.5% admixture system; The aggregate system, by total mass of the repair materials, comprises 5%-8% microporous mullite powder, 10%-15% sintered spinel fine aggregate, and 40%-55% fused white corundum particles of different sizes. The matrix powder system comprises 8%-12% activated alumina micro powder, 5%-8% CA-70 type rapid-hardening high-alumina cement, 3%-5% silica fume, 3%-5% kyanite powder, and 0.05%-0.1% explosion-proof fiber. The admixture system comprises 0.1%-1.0% polycarboxylate superplasticizer, 1%-2% plastic clay, and 0.3%-0.5% nano-alumina sol.
2. The quick repair material for dry quenching coke drums according to claim 1, characterized in that, Based on the total mass of the repair material, the electrofused white fused alumina particles of different sizes include 16%-20% of 30-50 mesh electrofused white fused alumina particles, 15%-20% of 50-150 mesh electrofused white fused alumina particles and 14%-15% of 16-20 mesh electrofused white fused alumina particles.
3. The quick patching material for dry quenching coke drums as claimed in claim 1 wherein, The microporous mullite powder has a particle size ≤0.088mm; the sintered spinel fine aggregate has a particle size of 18-20 mesh; the activated alumina micro powder has a particle size ≤0.044mm; the explosion-proof fiber has a length of 3-6mm; and the kyanite powder has a particle size of 320-330 mesh.
4. The quick patching material for dry quenching coke drums as claimed in claim 1 wherein, The explosion-proof fiber is polypropylene fiber, and the Al2O3 content in the nano alumina sol is 15wt%-25wt%. 5) The process for the preparation of a quick repairing material for coke drums of dry quenching according to any one of claims 1-4, characterized in that, include: The components, excluding the explosion-proof fiber and nano alumina sol, are dry-mixed to obtain a dry mixture. After adding water to the dry mix, add the fiber and nano alumina sol and stir to form a slurry to obtain a rapid repair material. The amount of water added is 5.5%-6.5% of the total amount of the aggregate system, matrix powder system and admixture system.
6. The application of the rapid repair material for dry-quenched coke cans according to claims 1-4 in repairing dry-quenched coke cans, characterized in that, include: Activated alumina micro powder, silica fume, nano alumina sol, aluminum dihydrogen phosphate solution, and plastic clay are mixed and water is added to form a slurry to obtain a hot-state bonding slurry. Substrate treatment is performed on the area of the coke can to be repaired. Apply hot adhesive mortar to the area to be repaired after substrate treatment, and form an adhesive transition film in the area to be repaired; In batches, the rapid repair material is applied to the upper layer of the viscous transition film. After each layer is applied, it is tamped and compacted until the rapid repair material completely fills the area to be repaired and is higher than the original lining surface. The surface is then leveled and baked at a low temperature until the rapid repair material hardens, thus completing the repair of the dry quenching coke can.
7. The application of the rapid repair material for dry-quenched coke cans according to claim 6 in the repair of dry-quenched coke cans, characterized in that, The aluminum dihydrogen phosphate solution has a mass concentration of 30%-50%; by mass percentage, the remaining components of the hot-state bonding slurry, excluding water, are: 30%-50% activated alumina micropowder, 25%-35% silica fume, 3%-8% plastic clay, 8%-12% aluminum dihydrogen phosphate solution, and 12%-17% nano-alumina sol; after adding water, the water-to-solid ratio of the hot-state bonding slurry is 0.25-3.
8. The application of the rapid repair material for dry-quenched coke cans according to claim 6 in the repair of dry-quenched coke cans, characterized in that, The aluminum dihydrogen phosphate solution has a mass concentration of 50%; by mass percentage, the hot-state bonding slurry, excluding water, comprises 40% activated alumina micro powder, 30% silica fume, 5% plastic clay, 10% aluminum dihydrogen phosphate solution, and 15% nano-alumina sol.
9. The application of the rapid repair material for dry-quenched coke cans according to claim 6 in the repair of dry-quenched coke cans, characterized in that, The thickness of the viscous transition membrane is 1-2 mm.
10. The application of the rapid repair material for dry-quenched coke cans according to claim 6 in the repair of dry-quenched coke cans, characterized in that, Each layer of rapid repair material should be 50-80mm thick, and the low-temperature baking temperature should be 200-400℃ for 2-3 hours.