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Monolithic/castable Casting Technology for Blast Furnace Hearth

2026-04-17

高炉炉缸整体浇注技术介绍

Monolithic Casting Technology for Blast Furnace Hearth

一、技术概述

1. Technical Overview

高炉炉缸整体浇注技术是一种无砖缝、整体无缝的炉缸内衬重构技术，采用不定形耐火浇注料（刚玉 - 碳化硅质）直接在炭砖表面浇筑成型，替代传统陶瓷杯砌筑结构。

核心目的：隔离铁水、保护炭砖、稳定传热、延长炉缸寿命
适用场景：高炉大修、中修、炉缸侵蚀修复、新建高炉
技术定位：现代高炉长寿化、快速化、低成本修复核心技术

Monolithic casting for blast furnace hearth is a seamless, brick-free relining technology, using unshaped refractory castables (corundum-SiC based) poured directly onto carbon brick surfaces to replace traditional ceramic cup masonry.

Core Purpose: Isolate hot metal, protect carbon bricks, stabilize heat transfer, extend hearth service life
Applications: BF overhaul, intermediate repair, hearth erosion repair, new BF construction
Position: Key technology for longevity, rapidity, low cost in modern BF maintenance

二、工况与核心挑战

2. Working Conditions & Core Challenges

温度：1400～1600℃（铁水、熔渣）
侵蚀：铁水熔蚀、熔渣侵蚀、碱金属渗透、高温冲刷
热负荷：剧烈热震、高温蠕变、热应力集中
结构风险：砖缝渗铁、炭砖溶蚀、炉缸烧穿、环裂

Temperature: 1400～1600℃ (hot metal, slag)
Erosion: Hot metal corrosion, slag attack, alkali metal penetration, high-temperature scouring
Thermal Load: Severe thermal shock, high-temperature creep, thermal stress concentration
Structural Risks: Hot metal penetration through joints, carbon brick dissolution, hearth burn-through, ring cracking

三、技术核心优势（对比传统砌筑）

3. Core Advantages (vs. Traditional Masonry)

整体性强、无缝无隙：消除砖缝、无渗铁通道，100% 阻隔铁水
传热稳定、保护炭砖：1150℃凝铁等温线内移至陶瓷杯内，形成稳定渣铁粘滞层
修复高效、工期短：无需大量拆除炭砖，中修工期缩短 30～50%
材料性能优异：高致密、高强度、抗铁水、抗渣、抗碱、低蠕变
结构一体化：与炭砖紧密结合、无间隙、无填充层，传热效率提升
寿命延长：整体寿命提升 2～3 倍，减少大修频次

Superior Integrity, Seamless：Eliminates joints, no penetration paths, 100% hot metal isolation
Stable Heat Transfer, Carbon Brick Protection：1150℃ solidification isotherm shifts inward into ceramic cup, forming stable slag-metal viscous layer
Efficient Repair, Short Schedule：No massive carbon brick removal, intermediate repair time reduced by 30～50%
Excellent Material Properties：High density, high strength, hot metal/slag/alkali resistance, low creep
Integrated Structure：Tight bonding, no gaps, no filler layer with carbon bricks, improved heat transfer efficiency
Extended Service Life：Total life increased by 2～3 times, fewer overhauls

四、材料体系（核心）

4. Material System (Core)

主浇注料（陶瓷杯层）：溶胶结合刚玉 - 碳化硅泵送浇注料
- 成分：刚玉 (Al₂O₃≥90%) + 碳化硅 (SiC≥15%) + 微粉 + 溶胶结合剂
- 性能：高致密、抗铁水、抗渣、抗碱、热震稳定、可泵送、快干防爆
导热层（炭砖修复）：高导热浇注料（与微孔炭砖导热匹配）
界面剂：耐高温界面处理剂，增强浇注料与炭砖粘结

Main Castable (Ceramic Cup Layer)：Sol-bonded corundum-SiC pumpable castable
- Composition: Corundum (Al₂O₃≥90%) + SiC (≥15%) + micro-powder + sol binder
- Properties: High density, hot metal/slag/alkali resistance, thermal shock stable, pumpable, fast-drying explosion-proof
Thermal Conductive Layer (Carbon Brick Repair)：High thermal conductivity castable (matching micro-pore carbon brick)
Interface Agent：High-temperature interface treatment agent for enhanced bonding

五、典型结构设计（炉缸整体）

5. Typical Structural Design (Monolithic Hearth)

炉底：两层浇注（底层 500mm、上层 600mm），总厚1100mm
侧壁（陶瓷杯）：厚度250～350mm，无缝整体，铁口区、象脚区加厚
风口带：与侧壁一体浇注，无缓冲层
铁口：一次成型，深度2800mm，直弦状、无接缝
象脚区：斜模加厚，强化抗侵蚀
传热系统：炭砖 + 整体陶瓷杯，1150℃等温线稳定在陶瓷杯内

Hearth Bottom：Two-layer casting (bottom 500mm, top 600mm), total thickness 1100mm
Side Wall (Ceramic Cup)：Thickness 250～350mm, seamless monolithic, reinforced at taphole & elephant foot
Tuyere Zone：Integrated casting with side wall, no buffer layer
Taphole：One-time forming, depth 2800mm, straight chord shape, no joints
Elephant Foot Zone：Thickened with inclined formwork for enhanced erosion resistance
Heat Transfer System：Carbon brick + monolithic ceramic cup, 1150℃ isotherm stable inside ceramic cup