冶炼有色金属使用的耐火材料工艺（二）

  炼铜用耐火材料炼铜工艺过程中焙烧，熔炼，吹炼，精炼及熔化等都有各自的热工炉窑，它们所用的耐火材料介绍如下：

（1）焙烧设备，焙烧过程为放热反应，一般不需另加燃料，工作温度一般不超过820℃，也无侵蚀和磨损作用，通常用黏土砖，重要部位用高铝砖砌筑，寿命较长。

（2）熔炼设备，主要有鼓风炉、反射炉、白银炼铜炉、矿热电炉和闪速熔炼炉等。另外，还有顶吹转炉和三菱连续炼铜炉等，可将铜精矿直接熔炼成纯度较高的粗铜。

  鼓风炉：上部受炉料机械磨损，砌黏土砖。风口及斜炉墙采用汽化冷却，内衬砌黏土砖，主炉床承载铜液，工作层砌镁砖，镁铬砖或铬砖。

  反射炉：炉顶直接受高温火焰冲刷，急冷急热作用和化学侵蚀，损坏较快。拱顶一般用硅砖，使用寿命为3~6个月。吊顶普遍使用镁铝砖或镁铬砖，炉墙用烧成镁砖，镁铬砖和镁铝砖砌筑。

  白银炼铜炉：该炉是白银有色金属公司在反射炉基础上开发的新炉，炉体工作层采用烧成镁砖和镁铝砖砌筑，渣线区炉衬外部安装水冷铜套，炉底用卤水镁砂，铁粉捣打，风口用铝铬渣制的大砖拼砌。

  矿热电炉：炉衬损毁主要是高温铜液和熔渣的化学侵蚀和冲刷。炉顶的电极孔和装料口，一般用致密黏土砖或高铝砖砌筑，也可使用高强浇注料整体浇注。炉墙和炉床工作层均用镁砖或镁铬砖砌筑。放出口区衬体外侧安装水冷铜套，延长炉体的使用寿命。

  闪速炉：是将焙烧和熔炼两道工序合为一体的新炉型。炉型种类较多，一般采用芬兰奥托昆普型炉较多，炉内操作温度为1400~1500℃，炉衬工作层受高温，化学侵蚀和炉料摩擦作用，较易损坏，因此普遍用镁铬砖砌筑，渣线区安装水冷铜套，保护衬体，炉体用镁铬质捣打料，有的部位采用镁铬质耐火浇注料，使用寿命比砖砌的高。

  （3）吹炼炉，普遍为圆筒形卧式转炉，操作温度约为 1400℃，装料时温度降到600~700℃，温度波动频繁，受熔融物的侵蚀和冲刷，普遍采用烧成镁铬砖，直接结合镁铬砖和熔铸镁铬砖综合砌筑炉衬，使用寿命为 300~500炉

  （4）精炼设备，有反射炉和转炉两种。我国普遍采用反射炉精炼粗铜，炉衬工作层一般用镁砖和铝镁砖砌筑，耐火材料1t铜消耗为4~10kg。采用转炉精炼粗铜时，普遍采用烧成镁铬砖内衬，耐火材料1t铜消耗为1~5kg

（5）熔化设备，熔化炉亦称阴极炉，主要炉型有反射炉，竖炉和感应电炉等。

  反射炉：操作温度大约1600℃，炉体渣线及以下部位用镁砖砌筑，其余用铝镁砖砌筑，使用寿命为2年左右。

  竖炉：炉壁及烧嘴区等易损部位使用碳化硅砖砌筑，其余部位用高铝砖，靠炉壳部位用轻质浇注料整体浇注，炉底用碳化硅捣打料。

  感应电炉：炉衬一般用高铝砖砌筑，熔沟周围线圈通过的部位，一般采用硼砂结合的硅质捣打料捣制，熔化紫铜寿命为3~4个月，熔化黄铜寿命为10个月。

Refractory Materials for Smelting non-ferrous metals (2)

  In the process of copper smelting, roasting, melting, blowing, refining and melting have their own thermal furnace, and the refractories used in them are described as follows:

  (1) Roasting equipment, roasting process for exothermic reaction, generally do not need to add fuel, the working temperature is generally not more than 820℃, no erosion and wear, usually with clay bricks, important parts with high aluminum brick masonry, long life.

  (2) Smelting equipment, mainly blast furnace, reverberatory furnace, silver copper smelting furnace, mineral heat furnace and flash melting furnace. In addition, there are top-blown converter and Mitsubishi continuous copper smelting furnace, which can directly melt copper concentrate into higher purity crude copper.

  Blast furnace: the upper part is subjected to mechanical wear of the charge, laying clay bricks. The tuyere and inclined furnace wall are cooled by evaporation, the inner lining is made of clay bricks, the main furnace bed is loaded with copper liquid, and the working layer is made of magnesia brick, magnesia chrome brick or chrome brick.

  Reflector furnace: the top of the furnace is directly washed by high temperature flame, urgent cooling and urgent heat action and chemical erosion, and the damage is faster. The vault is generally made of silicon bricks with a service life of 3 to 6 months. The ceiling generally uses magnesia-aluminum bricks or magnesia-chromium bricks, and the furnace wall is built with burned magnesia-chrome bricks, magnesia-chrome bricks and magnesia-aluminum bricks.

  Baiyin Copper smelting furnace: This furnace is a new furnace developed by Baiyin Non-ferrous Metal Company on the basis of the reverberatory furnace. The working layer of the furnace body is built with burned magnesia brick and magnesia aluminum brick, the furnace lining in the slag line area is installed with water-cooled copper casing, the bottom of the furnace is made of brine magnesia, iron powder is rammed, and the tuyre is made of large bricks made of aluminum chrome slag.

  Mineral thermal furnace: Lining damage is mainly caused by chemical erosion and scouring of high temperature copper liquid and molten slag. The electrode holes and charging ports of the furnace top are generally constructed with dense clay bricks or high aluminum bricks, and can also be cast as a whole with high strength castable. The furnace wall and the working layer of the furnace bed are made of magnesia brick or magnesia chrome brick. Water cooled copper sleeve is installed outside the lining body of the outlet area to extend the service life of the furnace body.

  Flash furnace: It is a new furnace type that integrates the two processes of roasting and melting. There are many types of furnace types, generally using Finland Otokumpu type furnace more, the operating temperature in the furnace is 1400~1500℃, the working layer of the furnace lining is affected by high temperature, chemical erosion and the friction of the charge, and it is easy to damage, so the general use of magnesia chrome brick masonry, the installation of water-cooled copper sleeve in the slag line area, the protection of the lining body, the furnace body with magnesia chrome ramming material, some parts of the use of magnesia chrome refractory castable, Higher service life than brick.

  (3) The blowing furnace is generally a cylindrical horizontal converter, the operating temperature is about 1400 ° C, the temperature is reduced to 600~700 ° C when loading, the temperature fluctuates frequently, and is eroded and washed by the melt, the general use of burned magnesia chrome brick, directly combined with magnesia chrome brick and fused cast magnesia chrome brick integrated masonry lining, the service life is 300~500 furnace

  (4) Refining equipment, there are two kinds of reverberatory furnace and converter. In China, it is generally used to refine crude copper in reverberatory furnace, and the working layer of the furnace lining is generally built with magnesium brick and aluminum-magnesium brick, and the consumption of 1t copper in the refractory material is 4~10kg. When using converter to refine crude copper, it is generally used to burn magnesia chrome brick lining, and the consumption of 1t copper of refractory material is 1~5kg

  (5) Melting equipment, melting furnace is also called cathode furnace, the main furnace types are reverberatory furnace, shaft furnace and induction furnace.

  Reverberatory furnace: the operating temperature is about 1600℃, the slag line and the following parts of the furnace body are built with magnesium brick, the rest are built with aluminum magnesium brick, and the service life is about 2 years.

  Shaft furnace: the vulnerable parts such as the furnace wall and burner area are built with silicon carbide bricks, the rest of the parts are built with high aluminum bricks, the parts near the furnace shell are cast with light castable, and the bottom of the furnace is rammed with silicon carbide.

  Induction furnace: The furnace lining is generally built with high aluminum bricks, and the parts around the groove where the coil passes through are generally rammed with borax combined silica ramming material. The life of molten copper is 3 to 4 months, and the life of molten brass is 10 months.