钢纤维浇注料：特性、应用以及案例 Steel fiber reinforced castables: properties, applications and case studies

钢纤维浇注料：特性、应用以及案例分析

Steel fiber reinforced castables: properties, applications and case studies

钢纤维浇注料的特性Characteristics of steel fiber castables

1 物理性能卓越
高强度与高韧性：钢纤维浇注料在配料中加入了一定量的耐热不锈钢纤维，使得材料浇注后炉墙整体强度显著增强。在常温下，其耐压强度和抗折性能远超传统浇注料，能够承受较大的机械冲击和载荷。例如，在一些工业窑炉的使用过程中，钢纤维浇注料可以有效抵抗炉内物料的冲击和磨损，延长炉体的使用寿命。
2 出色的热震稳定性：在高温环境下，钢纤维浇注料能够有效缓解温度梯度变化所产生的应力，防止炉墙因热胀冷缩而开裂或剥落。当窑炉启停炉时，温度会发生急剧变化，而钢纤维浇注料可以通过自身的特性，将这种温度变化对炉体的影响降到最低。
3 良好的体积稳定性：钢纤维浇注料在高温使用过程中，能够抑制浇注料的收缩，保持炉体结构的完整性。这一特性对于保证窑炉的正常运行至关重要，因为如果浇注料收缩过大，可能会导致炉体出现缝隙，影响炉内的温度分布和物料的正常流动。

1. Superior Physical Properties

High Strength and High Toughness: The addition of heat-resistant stainless steel fibers to the formulation of steel fiber castable significantly enhances the overall strength of the furnace wall after casting. At room temperature, its compressive strength and flexural strength far exceed those of traditional castables, enabling it to withstand greater mechanical impacts and loads. For example, in the use of some industrial kilns, steel fiber castable can effectively resist the impact and wear of materials inside the furnace, extending the service life of the furnace body.

2. Excellent Thermal Shock Resistance: In high-temperature environments, steel fiber castable can effectively alleviate the stress caused by temperature gradient changes, preventing the furnace wall from cracking or peeling due to thermal expansion and contraction. When the kiln is started and stopped, the temperature changes drastically, and steel fiber castable, through its inherent properties, minimizes the impact of these temperature changes on the furnace body.

3. Good Volumetric Stability: During high-temperature use, steel fiber castable can suppress the shrinkage of the castable, maintaining the integrity of the furnace structure. This characteristic is crucial for ensuring the normal operation of the kiln, because if the castable shrinks too much, it may cause gaps in the furnace body, affecting the temperature distribution and normal material flow inside the furnace.

二 化学性能优异
低钙含量与高温性能提升：由于减少了水泥的加入量，钢纤维浇注料降低了材料中的CaO含量，同时加入了超微粉，大大提高了产品的高温性能。在高温环境下，CaO容易与其他物质发生反应，导致材料性能下降，而低钙含量的钢纤维浇注料则可以有效避免这一问题。
抗化学侵蚀能力强：钢纤维浇注料能够抵抗各种化学物质的侵蚀，如酸性气体、碱性熔渣等。在一些化工、冶金等行业的窑炉中，炉内会产生各种化学物质，钢纤维浇注料可以保护炉体不受这些化学物质的侵蚀，延长炉体的使用寿命

II. Excellent Chemical Properties

Low Calcium Content and Improved High-Temperature Performance: By reducing the amount of cement added, the CaO content of the steel fiber castable is lowered, while the addition of ultrafine powder significantly improves the product's high-temperature performance. In high-temperature environments, CaO easily reacts with other substances, leading to a decline in material performance; the low-calcium content of the steel fiber castable effectively avoids this problem.

Strong Resistance to Chemical Erosion: The steel fiber castable resists the erosion of various chemical substances, such as acidic gases and alkaline slag. In kilns in some chemical and metallurgical industries, various chemical substances are generated inside the furnace; the steel fiber castable can protect the furnace body from the erosion of these chemicals, extending the furnace's service life.

钢纤维浇注料的使用场景

冶金行业
电炉炉顶与钢包包盖：在电炉炼钢过程中，炉顶和钢包包盖需要承受高温电弧辐射和钢水的冲刷，钢纤维浇注料的高强度和耐高温性能使其成为理想的选择。它可以有效抵抗高温和机械冲击，保证炉顶和钢包包盖的完整性，减少维修次数。

Application Scenarios of Steel Fiber Reinforced Castables

Metallurgical Industry: Electric Furnace Roof and Ladle Cover: During electric arc furnace steelmaking, the furnace roof and ladle cover need to withstand high-temperature electric arc radiation and the scouring of molten steel. The high strength and high-temperature resistance of steel fiber reinforced castables make them an ideal choice. They can effectively resist high temperatures and mechanical impacts, ensuring the integrity of the furnace roof and ladle cover and reducing maintenance frequency.

加热炉炉顶与均热炉炉墙：加热炉和均热炉是冶金行业中常用的设备，炉顶和炉墙需要长期处于高温环境下。钢纤维浇注料的热震稳定性和抗热震性能可以保证炉体在温度变化较大的情况下不出现开裂或剥落，提高设备的使用寿命。

Heating furnace roof and soaking furnace walls: Heating furnaces and soaking furnaces are commonly used equipment in the metallurgical industry, and their roofs and walls need to be exposed to high temperatures for extended periods. The thermal shock stability and resistance of steel fiber castables ensure that the furnace body does not crack or peel under significant temperature variations, thus extending the equipment's service life.

（二）建材行业
水泥回转窑冷却筒内衬：水泥回转窑是水泥生产过程中的关键设备，冷却筒内衬需要承受高温熟料的冲刷和磨损。钢纤维浇注料的耐磨性和耐高温性能可以有效保护冷却筒内衬，减少设备的维修和更换成本。

(II) Building Materials Industry
Cement Rotary Kiln Cooling Cylinder Lining: The cement rotary kiln is a key piece of equipment in the cement production process, and the cooling cylinder lining needs to withstand the erosion and wear of high-temperature clinker. The wear resistance and high-temperature resistance of steel fiber castables can effectively protect the cooling cylinder lining, reducing equipment maintenance and replacement costs.

竖式焙烧炉内衬：竖式焙烧炉用于焙烧各种物料，内衬需要承受高温和化学侵蚀。钢纤维浇注料的抗化学侵蚀能力和高温性能可以保证内衬在恶劣的环境下正常工作，提高焙烧炉的生产效率。

Vertical roasting furnace lining: Vertical roasting furnaces are used to roast various materials, and the lining needs to withstand high temperatures and chemical corrosion. The chemical corrosion resistance and high-temperature performance of steel fiber castables can ensure that the lining can work normally in harsh environments, improving the production efficiency of the roasting furnace.

具体应用项目

热回收焦炉炉底：在热回收焦炉炉底的施工中，我公司采用了钢纤维浇注料作为内衬材料。通过大面积地采用预制砖砌筑，并在间隙位置浇注钢纤维浇注料，具有施工方便快捷、施工周期短、施工质量易控制等优点。同时，工作层采用分块跳仓方法浇注，并留设膨胀缝，利于浇注时热量的扩散和结合水的排出，能够很好地适用于焦炉炉底大面积耐火材料的内衬砌筑施工。在使用过程中，钢纤维浇注料有效抵抗了炉内高温和机械冲击，保证了焦炉炉底的完整性，延长了焦炉的使用寿命。

Specific Application Projects

Heat Recovery Coke Oven Bottom: In the construction of the heat recovery coke oven bottom, our company adopted steel fiber castable as the lining material. By using precast bricks for large-area construction and pouring steel fiber castable in the gaps, it offers advantages such as convenient and quick construction, short construction period, and easy quality control. Simultaneously, the working layer is poured using a segmented, skip-fill method, with expansion joints left to facilitate heat diffusion and water drainage during pouring. This method is well-suited for the construction of large-area refractory linings for coke oven bottoms. During use, the steel fiber castable effectively resists the high temperatures and mechanical impacts inside the furnace, ensuring the integrity of the coke oven bottom and extending the service life of the coke oven.

阳极焙烧炉炉墙：在阳极焙烧炉炉墙的改造中，我公司与河南某耐火材料厂共同开发研制出了钢纤维耐火浇注料预制块炉墙。这种炉墙采用上下各两大块，中间三大块共计七大块，分三层拼装而成，替代传统的39层小块异型砖砌筑的炉墙。应用结果表明，钢纤维耐火浇注料预制块结构焙烧炉焙烧出的阳极无论是理化指标还是使用情况，完全达到了传统小块砖结构焙烧炉焙烧出的阳极质量要求，同时也满足了电解工艺的使用要求。而且，预制结构炉墙的修炉时间缩短，节约了人、财、物力，大大提高了劳动生产率。

Anode Calcination Furnace Wall: In the renovation of the anode calcination furnace wall, our company, in collaboration with a refractory materials factory in Henan Province, developed and manufactured a precast steel fiber refractory block furnace wall. This furnace wall consists of seven large blocks—two large blocks at the top and bottom, and three large blocks in the middle—assembled in three layers, replacing the traditional 39-layer furnace wall constructed of small, irregularly shaped bricks. Application results show that the anodes calcined in the precast steel fiber refractory block structure furnace fully meet the quality requirements of anodes calcined in the traditional small brick structure furnace, both in terms of physicochemical properties and performance, and also satisfy the requirements of the electrolysis process. Moreover, the precast structure furnace wall reduces furnace repair time, saving manpower, financial resources, and materials, and significantly improving labor productivity.