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大有作为的卡位复合式电炉炉顶预制件

作者：

　　电弧炉炉顶是电弧炉的重要元件，在冶炼过程中工作条件十分恶劣。例如，持续高温、机械振动、急冷急热、熔渣侵蚀、粉尘颗粒冲刷、酸性气体腐蚀等，都对其造成损坏。尤其是其三角区会比周围部位较早损坏，往往也是因为三角区耐材使用到了极限才造成炉顶耐材的整体下线。如果使用一种材料制作炉顶，在三角区损坏之后已经影响到整个炉顶使用时，提前下线，其外围部分的耐材就会造成浪费。因此，在这种情况下，复合电炉顶应运而生。即，三角区部位用纯度高的材料，外围部分用稍低档次材料复合制造。这样，炉顶三角区与外围寿命就可同步了。但是，这种复合炉顶在制作工艺上又存在着很大的难点：当以两种以上的材料制作炉顶预制件时，在成型时要么高档材料与低档材料容易掺杂，降低了三角区耐材的档次，从而得不到预想的效果；要么高档材料与低档材料之间的界面处理不好，导致界面处两种材料分层、裂纹、脱落等。这两种情况都制约了复合炉顶预制件的使用寿命。
　　
　　为解决上述复合炉顶预制件制造难点，荣大公司设计研发了一种带卡位式的复合炉顶结构，从而满足多种档次材料的混合预制。
　　
　　三角区是炉顶的关键部位，工作环境最为恶劣，必须要保证材料有较高的纯度，所以要求此件需要单独提前预制。待成型养护到期后脱模，等预制件获得足够的强度后再在其周围浇注外围部分；外围部分根据使用环境和易损程度又分为外围下部和外围上部两个部分，外围下部是热面，接近钢液面，材料档次仅次于中心三角区，外围上部相对而言为冷面，使用环境基本无异常。
　　
　　上述复合卡位式炉顶预制件，技术关键点在于：三角区单独预制，厚度（高度）较外围部分高；三角区上部设有三点均匀分布的卡托，防止频繁使用时脱落；三角区与外围接触的部分与垂直方向成3°~5°的夹角；三角区与外围接触面上均匀分布了若干个防止脱落的辅助卡位孔；卡位孔与水平方向成5°的夹角且向上倾斜；外围料分为上部和下部，为同批、一次性浇注成型。技术优点在于：在保证炉顶预制件使用寿命的同时，有效降低电弧炉炉顶对高能耗、高污染途径制备原料的依赖性，降低炉顶预制件的成本；有效解决了电弧炉炉顶预制件复合结构不紧密、三角区容易提前脱落等问题；实现了电弧炉炉顶三角区与外围部分寿命同步的设想。

大有作为的卡位复合式电炉炉顶预制件

图一卡位复合式电炉炉顶预制成品

大有作为的卡位复合式电炉炉顶预制件

图二正在使用的卡位复合式电炉炉顶预制件

大有作为的卡位复合式电炉炉顶预制件

图三卡位复合式电炉炉顶三角区形貌示意图

大有作为的卡位复合式电炉炉顶预制件

图四卡位复合式电炉炉顶外围成型后示意图

（北京联合荣大工程材料股份有限公司专家组）

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这里是占位文字

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