Blast Furnace （BF） Iron Channel Refractory Design - ASC castable
2026-04-10
高炉铁钩耐材设计
Blast Furnace Iron Channel Refractory Design
一、设计总则 / General Design Principles
1. 设计目标：适配高炉出铁工艺要求，承受高温铁水（1350~1550℃）、熔渣冲刷与侵蚀，保证铁钩连续稳定运行，延长耐材使用寿命，降低吨铁耐材消耗，保障生产安全与环保达标。 Design Objective: Adapt to the requirements of blast furnace tapping process, withstand the scouring and erosion of high-temperature molten iron (1350~1550℃) and molten slag, ensure the continuous and stable operation of the iron channel, extend the service life of refractories, reduce the refractory consumption per ton of iron, and ensure the compliance of production safety and environmental protection.
2. 核心原则： Core Principles:
- 具备优异的抗铁水冲刷、抗熔渣侵蚀及抗热震稳定性，避免高温下开裂、剥落；
- Possess excellent resistance to molten iron scouring, molten slag erosion and thermal shock stability, avoiding cracking and spalling at high temperatures;
- 隔热保温性能良好，减少热损失，保护铁钩钢壳及周边设备；
- Good thermal insulation performance to reduce heat loss and protect the iron channel steel shell and surrounding equipment;
- 结构设计合理，施工便捷，维修、修补高效，适配高炉连续出铁节奏；
- Reasonable structural design, convenient construction, efficient maintenance and repair, adapting to the continuous tapping rhythm of the blast furnace;
- 优先选用无铬、低污染环保耐材，符合冶金行业环保标准；
- Prioritize the selection of chrome-free and low-pollution environmentally friendly refractories, complying with the environmental protection standards of the metallurgical industry;
- 兼顾经济性与实用性，优化材料配比，控制耐材消耗成本。
- Balance economy and practicality, optimize material ratio, and control the cost of refractory consumption.
二、整体结构与耐材分层设计 / Overall Structure & Layered Refractory Design
高炉铁钩整体结构从外至内依次为：钢壳 → 隔热层 → 永久层 → 工作层，关键部位配套专用预制件，确保结构稳定性与耐蚀性。
The overall structure of the blast furnace iron channel from outside to inside is: Steel Shell → Insulation Layer → Permanent Layer → Working Layer. Key parts are equipped with special precast parts to ensure structural stability and corrosion resistance.
1. 钢壳 / Steel Shell
作为铁钩承载基础，采用钢板焊接成型，保证足够的强度与刚性，防止高温变形，为内层耐材提供稳定支撑。
As the bearing foundation of the iron channel, it is formed by steel plate welding to ensure sufficient strength and rigidity, prevent high-temperature deformation, and provide stable support for the inner refractories.
2. 隔热层 / Insulation Layer
- 位置：钢壳内侧，紧贴钢壳布置；
- Position: Inside the steel shell, closely attached to the steel shell;
- 功能：阻隔高温传导，降低钢壳表面温度（控制在60℃以下），减少热损失，保护钢壳免受高温损伤；
- Function: Block high-temperature conduction, reduce the surface temperature of the steel shell (controlled below 60℃), reduce heat loss, and protect the steel shell from high-temperature damage;
- 常用材料：硅酸钙板、纳米隔热板、陶瓷纤维板；
- Common Materials: Calcium silicate board, nano insulation board, ceramic fiber board;
- 设计厚度：根据高炉吨位及出铁温度调整。
- Design Thickness: adjusted according to the blast furnace tonnage and tapping temperature.
3. 永久层 / Permanent Layer
- 位置：隔热层与工作层之间；
- Position: Between the insulation layer and the working layer;
- 功能：提供结构支撑，承受工作层重量及热应力，阻隔高温向隔热层、钢壳传导，可多次周转使用，减少工作层侵蚀对壳体的影响；
- Function: Provide structural support, bear the weight of the working layer and thermal stress, block the conduction of high temperature to the insulation layer and steel shell, can be reused multiple times, and reduce the impact of working layer erosion on the shell;
- 常用材料：高铝浇注料、莫来石浇注料，可采用预制件安装或现场整体浇注；
- Common Materials: High-alumina castable, mullite castable, which can be installed by precast parts or integrally cast on site;
- 设计厚度：80~150mm，大型高炉可适当加厚。
- Design Thickness: 80~150mm, which can be appropriately thickened for large blast furnaces.
4. 工作层 / Working Layer
- 位置：最内层，直接接触高温铁水与熔渣；
- Position: Innermost layer, directly in contact with high-temperature molten iron and molten slag;
- 功能：承受铁水冲刷、熔渣侵蚀及剧烈热震，是决定铁钩使用寿命的核心层；
- Function: Bear molten iron scouring, molten slag erosion and severe thermal shock, and is the core layer determining the service life of the iron channel;
- 常用材料：Al₂O₃-SiC-C浇注料（ASC浇注料）为主，根据铁钩类型（主沟、渣沟、支沟）调整配比，主沟渣线可选用尖晶石增强型浇注料；
- Common Materials: Al₂O₃-SiC-C castable (ASC castable) is the main material, and the ratio is adjusted according to the type of iron channel (main channel, slag channel, branch channel). spinel reinforced castable can be selected for the slag line of the main channel;
- 设计厚度：主沟150~300mm，渣沟、支沟100~200mm，根据通铁量目标调整。
- Design Thickness: 150~300mm for the main channel, 100~200mm for the slag channel and branch channel, adjusted according to the target iron throughput.
三、关键部位耐材设计 / Refractory Design for Key Parts
高炉铁钩关键部位（冲击区、渣线区、撇渣器、水口部位等）工况苛刻，需单独强化设计，提升耐蚀、抗冲刷性能。
The key parts of the blast furnace iron channel (impact zone, slag line zone, skimmer, nozzle part, etc.) have harsh working conditions and need separate strengthened design to improve corrosion and scouring resistance.
1. 冲击区 / Impact Zone
- 位置：高炉出铁口下方，铁水直冲区域，是冲刷最剧烈的部位；
- Position: Below the blast furnace tapping hole, the area directly impacted by molten iron, which is the most severely scoured part;
- 设计要求：高强度、高抗冲刷、抗热震，防止局部冲穿、剥落；
- Design Requirements: High strength, high scouring resistance, thermal shock resistance, preventing local penetration and spalling;
- 常用材料：刚玉质预制块、高铝-SiC复合预制件，可添加红柱石提升抗热震性；
- Common Materials: Corundum precast blocks, high-alumina-SiC composite precast parts, and andalusite can be added to improve thermal shock resistance;
- 结构设计：整体预制、加厚处理（比周边工作层厚30~50mm），与工作层紧密结合，避免缝隙漏铁。
- Structural Design: Integral prefabrication, thickening treatment (30~50mm thicker than the surrounding working layer), closely combined with the working layer to avoid iron leakage from gaps.
2. 渣线区 / Slag Line Zone
- 位置：铁水与熔渣的界面区域，承受熔渣长期侵蚀与渗透，是耐材损毁的主要部位之一；
- Position: The interface area between molten iron and molten slag, subject to long-term erosion and penetration of molten slag, which is one of the main parts of refractory damage;
- 设计要求：强抗渣侵蚀、抗渗透、抗剥落，适配不同炉渣碱度工况；
- Design Requirements: Strong slag corrosion resistance, penetration resistance, spalling resistance, adapting to different slag basicity working conditions;
- 常用材料：尖晶石质浇注料，可引入氮化硅、β-Si₃N₄提升抗渣性能，SiC加入量控制在合理范围以优化综合性能；
- spinel castables. Silicon nitride and β-Si₃N₄ can be introduced to improve slag resistance, and the addition amount of SiC is controlled within a reasonable range to optimize comprehensive performance;
- 结构设计：加厚砌筑或采用专用渣线砖，与工作层无缝衔接，减少熔渣渗透通道。
- Structural Design: Thickened masonry or special slag line bricks, seamlessly connected with the working layer to reduce molten slag penetration channels.
3. 撇渣器 / Skimmer
- 功能：实现铁水与熔渣的分离，防止熔渣进入后续铁水包，保障铁水洁净度；
- Function: Realize the separation of molten iron and molten slag, prevent molten slag from entering the subsequent molten iron ladle, and ensure the cleanliness of molten iron;
- 设计要求：抗侵蚀、抗冲刷、不粘渣铁，结构紧凑，分离效果好；
- Design Requirements: Corrosion resistance, scouring resistance, non-sticking to slag and iron, compact structure, and good separation effect;
- 常用材料：高铝-SiC-C预制件、可添加抗氧化剂ZrB₂（最佳加入量2%）提升使用寿命；
- Common Materials: High-alumina-SiC-C precast parts, and antioxidant ZrB₂ (optimal addition amount 2%) can be added to extend service life;
- 结构设计：整体预制成型，安装精度高，流道光滑，便于渣铁分离与清理。
- Structural Design: Integral prefabrication, high installation accuracy, smooth flow channel, convenient for slag-iron separation and cleaning.
4. 支沟与渣沟 / Branch Channel & Slag Channel
- 设计要求：适配铁水、熔渣的流动特性，抗冲刷、抗侵蚀，便于清理；
- Design Requirements: Adapt to the flow characteristics of molten iron and molten slag, scouring resistance, corrosion resistance, and easy cleaning;
- 常用材料：中低档Al₂O₃-SiC-C浇注料、高铝浇注料，渣沟可选用抗渣性更强的镁质浇注料；
- Common Materials: Mid-low grade Al₂O₃-SiC-C castable, high-alumina castable, and magnesia castable with stronger slag resistance can be selected for the slag channel;
- 结构设计：合理设置坡度（1%~3%），优化流场，减少局部冲刷，底部做防滑、防侵蚀处理。
- Structural Design: Reasonably set the slope (1%~3%), optimize the flow field, reduce local scouring, and perform anti-slip and anti-erosion treatment on the bottom.
四、材料性能设计指标（典型） / Typical Design Indicators of Material Performance
中文性能指标 / Chinese Performance Index | 英文性能指标 / English Performance Index | 典型设计值 / Typical Design Value |
|---|---|---|
体积密度 | Bulk Density | 2.80~3.10 g/cm³（工作层≥3.00 g/cm³） |
显气孔率 | Apparent Porosity | 12%~18%（低气孔设计≤14%） |
常温耐压强度 | Cold Crushing Strength (CCS) | ≥40 MPa（110℃烘干后） |
高温抗折强度 | Hot Modulus of Rupture (HMOR) | ≥10 MPa（1400℃保温3h） |
热震稳定性 | Thermal Shock Resistance | ≥15次热循环（ΔT=200℃/min），不开裂 |
抗渣侵蚀性 | Slag Corrosion Resistance | 侵蚀速率≤2 mm/h（1500℃渣蚀试验） |
导热系数 | Thermal Conductivity (λ) | 隔热层≤0.15 W/m·K，工作层1.5~3.0 W/m·K |
Al₂O₃含量 | Al₂O₃ Content | 工作层≥75%，高档品≥98% |
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2026-04-10
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