AU2021377556B2 - Sprayable fire-resistant composition and production method therefor - Google Patents
Sprayable fire-resistant composition and production method therefor Download PDFInfo
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- AU2021377556B2 AU2021377556B2 AU2021377556A AU2021377556A AU2021377556B2 AU 2021377556 B2 AU2021377556 B2 AU 2021377556B2 AU 2021377556 A AU2021377556 A AU 2021377556A AU 2021377556 A AU2021377556 A AU 2021377556A AU 2021377556 B2 AU2021377556 B2 AU 2021377556B2
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- magnesia
- refractory
- raw materials
- spinel brick
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- 239000000203 mixture Substances 0.000 title claims abstract description 80
- 238000004519 manufacturing process Methods 0.000 title claims description 16
- 230000009970 fire resistant effect Effects 0.000 title abstract 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 338
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 169
- 239000011449 brick Substances 0.000 claims abstract description 102
- 229910052596 spinel Inorganic materials 0.000 claims abstract description 101
- 239000011029 spinel Substances 0.000 claims abstract description 101
- 239000002994 raw material Substances 0.000 claims description 171
- 238000005507 spraying Methods 0.000 claims description 85
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 30
- 239000000463 material Substances 0.000 claims description 24
- 239000004568 cement Substances 0.000 claims description 17
- 238000002156 mixing Methods 0.000 claims description 10
- 238000004898 kneading Methods 0.000 claims description 9
- 239000002699 waste material Substances 0.000 abstract 2
- 239000012535 impurity Substances 0.000 description 8
- 238000005299 abrasion Methods 0.000 description 7
- 239000004927 clay Substances 0.000 description 6
- 238000002474 experimental method Methods 0.000 description 5
- 230000002349 favourable effect Effects 0.000 description 5
- 238000012216 screening Methods 0.000 description 5
- 229910019142 PO4 Inorganic materials 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 4
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 4
- 239000000920 calcium hydroxide Substances 0.000 description 4
- 235000011116 calcium hydroxide Nutrition 0.000 description 4
- 150000001735 carboxylic acids Chemical class 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
- 235000021317 phosphate Nutrition 0.000 description 4
- 239000011819 refractory material Substances 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 3
- 239000004115 Sodium Silicate Substances 0.000 description 3
- 150000007942 carboxylates Chemical class 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 230000001747 exhibiting effect Effects 0.000 description 3
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 3
- 239000010452 phosphate Substances 0.000 description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 3
- 229910052911 sodium silicate Inorganic materials 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 2
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 2
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 2
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000007670 refining Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 239000011398 Portland cement Substances 0.000 description 1
- 239000004111 Potassium silicate Substances 0.000 description 1
- 229910010413 TiO 2 Inorganic materials 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical class [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 150000001805 chlorine compounds Chemical class 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- UAMZXLIURMNTHD-UHFFFAOYSA-N dialuminum;magnesium;oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[O-2].[Mg+2].[Al+3].[Al+3] UAMZXLIURMNTHD-UHFFFAOYSA-N 0.000 description 1
- 150000001991 dicarboxylic acids Chemical class 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000000295 fuel oil Substances 0.000 description 1
- 150000004677 hydrates Chemical class 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 229910001629 magnesium chloride Inorganic materials 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 1
- 235000019341 magnesium sulphate Nutrition 0.000 description 1
- ZATZOOLBPDMARD-UHFFFAOYSA-N magnesium;hydrate Chemical class O.[Mg] ZATZOOLBPDMARD-UHFFFAOYSA-N 0.000 description 1
- 230000008774 maternal effect Effects 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 150000002763 monocarboxylic acids Chemical class 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 159000000001 potassium salts Chemical class 0.000 description 1
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 229910052913 potassium silicate Inorganic materials 0.000 description 1
- 239000013535 sea water Substances 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 239000001488 sodium phosphate Substances 0.000 description 1
- 229910000162 sodium phosphate Inorganic materials 0.000 description 1
- 159000000000 sodium salts Chemical class 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 150000003628 tricarboxylic acids Chemical class 0.000 description 1
- RYFMWSXOAZQYPI-UHFFFAOYSA-K trisodium phosphate Chemical compound [Na+].[Na+].[Na+].[O-]P([O-])([O-])=O RYFMWSXOAZQYPI-UHFFFAOYSA-K 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/03—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on magnesium oxide, calcium oxide or oxide mixtures derived from dolomite
- C04B35/04—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on magnesium oxide, calcium oxide or oxide mixtures derived from dolomite based on magnesium oxide
- C04B35/043—Refractories from grain sized mixtures
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D1/00—Casings; Linings; Walls; Roofs
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Furnace Housings, Linings, Walls, And Ceilings (AREA)
- Ceramic Products (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Fireproofing Substances (AREA)
Abstract
A sprayable fire-resistant composition according to the present invention includes primarily magnesia-spinel brick waste and magnesia feedstock as fire-resistant feedstock, wherein the magnesia-spinel brick waste content is 10 mass% or more relative to 100 mass% of the fire-resistant feedstock, and the magnesia feedstock content is from 0 mass%-90 mass% relative to 100 mass% of the fire-resistant feedstock.
Description
The present disclosure relates to a spraying refractory composition used mainly in steel
production facilities and a method for producing the same.
Refractories used in steel production facilities wear out with use and may be repaired by
being sprayed to extend their service life. For example, Patent Document 1 discloses a spray
repair material for steel refining furnaces that uses magnesia clinker and spinel clinker.
In another view, used brick chippings and spent unshaped refractories are sometimes reused
as refractory raw materials in response to the growing need for resource saving. For example,
Patent Document 2 discloses a method for producing a burned magnesia spinel brick by firing a
raw material mixture prepared by blending recycled raw material of used or unused burned
magnesia spinel bricks, alumina raw material, and magnesia raw material and/or spinel raw
material and in which the total content of Na20 + K 2 0 + TiO 2 impurities is less than 0.5% by mass
relative to the total mass of the raw materials excluding those impurities. Also, Patent Document
3 discloses an unshaped refractory for wet spraying with a spent alumina-magnesia unshaped
refractory blended into.
Patent Document 1: JP-A-58-120568
Patent Document 2: JP-A-2018-154516
Patent Document 3: JP-A-2005-179130
The reference to any prior art in this specification is not and should not be taken as an
acknowledgement or any form of suggestion that the prior art forms part of the common general
knowledge.
Spraying refractory compositions are generally required to have increased adhesion to
sprayed surfaces and reduced rebound loss. However, spraying refractory compositions in which
the products after use were blended into were insufficient for such requirements.
Additionally, chippings of used bricks and spent unshaped refractories contain a larger
amount of impurities than before their use, and the capability of refractories in which those are
blended as raw materials is generally considered poor. Thus, Patent Document 2 discloses a used
or unused burned magnesia spinel brick with a low impurity content as raw material for reuse.
Unfortunately, screening used materials is time-consuming and costly, and difficult to procure the
necessary amount.
An aspect of the present disclosure is embodied in view of the above-described actual
circumstances, and a desirable outcome of embodiments of the disclosure is to provide a spraying
refractory composition in which used material that is easy to procure is blended into, which
exhibits high adhesion and low rebound loss, and further enables short-time and low-cost screening.
In one aspect, the disclosure provides a spraying refractory composition comprising:
magnesia spinel brick chippings and a magnesia raw material mainly as refractory raw materials,
the purity of MgO in the magnesia raw material being 85% by mass or more, the content of the
magnesia spinel brick chippings being 10% by mass or more relative to 100% by mass of the
refractory raw materials, the content of the magnesia raw material being 0% by mass or more
and 90% by mass or less relative to 100% by mass of the refractory raw materials (except for the
case of 0% by mass), and the total content of the magnesia spinel brick chippings and the
magnesia raw material being 80% by mass or more relative to 100% by mass of the refractory
raw materials.
In another aspect, the disclosure provides a spraying refractory composition comprising:
magnesia spinel brick chippings and a magnesia raw material mainly as refractory raw materials,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to 100%
by mass of the refractory raw materials, the content of the magnesia raw material being 0% by
mass or more and 90% by mass or less relative to 100% by mass of the refractory raw materials, and the total content of Na20, K20, S03, and Cl contained in the magnesia spinel brick chippings being 0.5% by mass or more and 5.0% by mass or less relative to 100% by mass of the magnesia spinel brick chippings.
In another aspect, the disclosure provides a spraying refractory composition comprising:
magnesia spinel brick chippings and a magnesia raw material mainly as refractory raw materials,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to 100%
by mass of the refractory raw materials, the content of the magnesia raw material being 0% by
mass or more and 90% by mass or less relative to 100% by mass of the refractory raw materials,
and the total content of Na20, K20, SO3, and Cl contained in the refractory raw materials being
0.2% by mass or more and 5.0% by mass or less relative to 100% by mass of the refractory raw
materials.
In another aspect, the disclosure provides a spraying refractory composition comprising:
magnesia spinel brick chippings and a magnesia raw material mainly as refractory raw materials,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to 100%
by mass of the refractory raw materials, the content of the magnesia raw material being 0% by
mass or more and 90% by mass or less relative to 100% by mass of the refractory raw materials,
and the total content of Na20, K20, SO3, and Cl contained in the spraying refractory composition
being 1.0% by mass or more and 5.0% by mass or less relative to 100% by mass of the spraying
refractory composition.
In a further aspect, the disclosure provides a method for producing a spraying refractory
composition comprising the steps of mixing and kneading refractory raw materials and other
materials, the refractory raw materials containing magnesia spinel brick chippings and magnesia
raw material, the purity of MgO in the magnesia raw material being 85% by mass or more, the
content of the magnesia spinel brick chippings being 10% by mass or more relative to 100% by
mass of the refractory raw materials, the content of the magnesia raw material being 0% by mass
or more and 90% by mass or less relative to 100% by mass of the refractory raw materials
(except for the case of 0% by mass), the total content of the magnesia spinel brick chippings and
the magnesia raw material being 80% by mass or more relative to 100% by mass of the refractory raw materials, and the magnesia spinel brick chippings composed of a magnesia spinel brick after use in a cement rotary kiln.
In a further aspect, the disclosure provides a method for producing a spraying refractory
composition comprising the steps of mixing and kneading refractory raw materials and other
materials, the refractory raw materials containing magnesia spinel brick chippings and magnesia
raw material, the content of the magnesia spinel brick chippings being 10% by mass or more
relative to 100% by mass of the refractory raw materials, the content of the magnesia raw
material being 0% by mass or more and 90% by mass or less relative to 100% by mass of the
refractory raw materials, the total content of Na20, K20, S03, and Cl contained in the magnesia
spinel brick chippings being 0. 5 % by mass or more and 5 .0% by mass or less relative to 100%
by mass of the magnesia spinel brick chippings, and the magnesia spinel brick chippings
composed of a magnesia spinel brick after use in a cement rotary kiln.
In a further aspect, the disclosure provides a method for producing a spraying refractory
composition comprising the steps of mixing and kneading refractory raw materials and other
materials, the refractory raw materials containing magnesia spinel brick chippings and magnesia
raw material, the content of the magnesia spinel brick chippings being 10% by mass or more
relative to 100% by mass of the refractory raw materials, the content of the magnesia raw
material being 0% by mass or more and 90% by mass or less relative to 100% by mass of the
refractory raw materials, the total content of Na20, K20, S03, and Cl contained in the refractory
raw materials being 0. 2 % by mass or more and 5 .0% by mass or less relative to 100% by mass of
the refractory raw materials, and the magnesia spinel brick chippings composed of a magnesia
spinel brick after use in a cement rotary kiln.
In a still further aspect, the disclosure provides a method for producing a spraying
refractory composition comprising the steps of mixing and kneading refractory raw materials and
other materials, the refractory raw materials containing magnesia spinel brick chippings and
magnesia raw material, the content of the magnesia spinel brick chippings being 10% by mass or
more relative to 100% by mass of the refractory raw materials, the content of the magnesia raw
material being 0% by mass or more and 90% by mass or less relative to 100% by mass of the
refractory raw materials, the total content of Na20, K20, S03, and Cl contained in the spraying
- 3a - refractory composition being 1.0% by mass or more and 5.0% by mass or less relative to 100% by mass of the spraying refractory composition, and the magnesia spinel brick chippings composed of a magnesia spinel brick after use in a cement rotary kiln.
An embodiment of the disclosure relates to a spraying refractory composition containing
magnesia spinel brick chippings and a magnesia raw material mainly as refractory raw materials,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to 100%
by mass of the refractory raw materials, and the content of the magnesia raw material being 0%
by mass or more and 90% by mass or less relative to 100% by mass of the refractory raw materials.
The spraying refractory composition containing 0% by mass or more and 90% by mass or less of
magnesia raw material relative to 100% by mass of the refractory raw materials and 10% by mass
or more of magnesia spinel brick chippings relative to 100% by mass of the refractory raw
materials exhibits high adhesion and low rebound loss.
In an embodiment of the disclosure, the total content of the magnesia spinel brick chippings
and the magnesia raw material is preferably 80% by mass or more relative to 100% by mass of the
refractory raw materials. Such a spraying refractory composition exhibits higher adhesion and
lower rebound loss.
In an embodiment of the disclosure, the total content of Na20, K20, SO3, and Cl contained
in the magnesia spinel brick chippings is preferably 0.5% by mass or more and 5.0% by mass or
less relative to 100% by mass of the magnesia spinel brick chippings. The spraying refractory
composition containing the magnesia spinel brick chippings whose total content of Na20, K20,
S03, and Cl impurity is 0.5% by mass or more and 5.0% by mass or less exhibits high adhesion
and low rebound loss. Furthermore, the magnesia spinel brick chippings after use in cement
rotary kilns have a total content of Na20, K20, S03, and Cl impurity of 0.5% by mass or more and
5.0% by mass or less and can therefore be used without adjusting the components, accordingly
reducing the time and cost of screening and facilitating procurement.
In an embodiment of the disclosure, the total content of Na20, K20, S03, and Cl contained
in the refractory raw materials is preferably 0.2% by mass or more and 5.0% by mass or less
relative to 100% by mass of the refractory raw materials. When the total content of Na20, K20,
S03, and Cl contained in the refractory raw materials is 0.2% by mass or more and 5.0% by mass
- 3b - or less relative to 100% by mass of the refractory raw materials, the spraying refractory composition exhibits higher adhesion and lower rebound loss.
In an embodiment of the disclosure, the total content of Na20, K20, S03, and Cl contained
in the spraying refractory composition is preferably 1.0% by mass or more and 5.0% by mass or
less relative to 100% by mass of the spraying refractory composition. When the total content of
Na20, K20, S03, and Cl contained in the spraying refractory composition is 1.0% by mass or more
and 5.0% by mass or less relative to 100% by mass of the spraying refractory composition, the
spraying refractory composition exhibits higher adhesion and lower rebound loss.
Another embodiment of the disclosure relates to a method for producing a spraying
refractory composition with magnesia spinel brick chippings and magnesia raw material to be
mainly added as refractory raw materials, the content of magnesia spinel brick chippings being
% by mass or more relative to 100% by mass of the refractory raw materials, the content of the
magnesia raw material being 0% by mass or more and 90% by mass or less relative to 100% by
mass of the refractory raw materials, and the magnesia spinel brick chippings composed of a
magnesia spinel brick after use in a cement rotary kiln. The spraying refractory composition to
which chippings of a magnesia spinel brick after use in a cement rotary kiln are added exhibits
high adhesion and
- 3c - low rebound loss and, in addition, can reduce the time and cost of screening to facilitate procurement.
Preferred embodiments of the disclosure will now be described in detail. The embodiments described below are not intended to unworthily limit the content of the disclosure
stated in the appended claims, and not all the components of the described embodiments are
essential as the solution of the disclosure. A spraying refractory composition of an embodiment of the disclosure mainly contains
magnesia spinel brick chippings and magnesia raw material as refractory raw materials. The refractory raw materials are main raw materials of the spraying refractory composition. In an
embodiment of the disclosure, the refractory raw material may contain other common refractory raw materials as sub-constituents in addition to the magnesia spinel brick chippings and the
magnesia raw material. The total content of the magnesia spinel brick chippings and the
magnesia raw material is 80% by mass or more relative to 100% by mass of the refractory raw materials and is preferably 90% by mass or more, more preferably 95% by mass or more, and
particularly preferably 100% by mass.
Magnesia Spinel Brick Chippings Magnesia spinel bricks are used in cement rotary kilns, steel secondary refining furnaces,
and the like. Used magnesia spinel bricks (used material) are collected, crushed, and subjected
to grain size control and thus used as magnesia spinel brick chippings that will be used as a refractory raw material of a spraying refractory composition. Crushing and grain size control can
be performed in a process generally used in refractory raw material production. The content of magnesia spinel brick chippings is 10% by mass or more relative to 100%
by mass of the spraying refractory composition and is preferably 40% by mass or more, more
preferably 60% by mass or more, and still more preferably 70% by mass or more. Such a spraying refractory composition is favorable because of its higher adhesion and lower rebound
loss. Magnesia Raw Material
The content of magnesia raw material is 0% by mass or more and 90% by mass or less
relative to 100% by mass of the spraying refractory composition and is preferably 0% by mass or
more and 60% by mass or less, more preferably 0% by mass or more and 40% by mass or less,
and still more preferably 0% by mass or more and 30% by mass or less. Such a spraying
refractory composition is favorable because of its higher adhesion and lower rebound loss. The
magnesia raw material can be a generally used refractory raw material, such as natural magnesia,
seawater magnesia, or fused magnesia. The purity of MgO in the magnesia raw material is
preferably 85% by mass or more. Such magnesia raw material can increase the corrosion
resistance of the spraying refractory composition.
Total Content of Na20, K20, SO3, and Cl
The spraying refractory composition in which the magnesia spinel brick chippings
composed of a magnesia spinel brick after use in a cement rotary kiln exhibits, particularly,
increased adhesion and increased effect of reducing rebound loss. The reason for this is unclear,
but it is supposed that the total content of Na2O, K20, S03, and Cl impurity of the material after
use in the cement rotary kiln is suitable and contributes to increasing adhesion and reducing
rebound loss.
The total content ofNa2O, K20, S03, and Cl contained as impurities in the magnesia spinel
brick chippings is 0.5% by mass or more and 5.0% by mass or less relative to 100% by mass of
the magnesia spinel brick chippings and is preferably 1.0% by mass or more and 4.0% by mass or
less and more preferably 1.5% by mass or more and 3 .0% by mass or less. Such a spraying
refractory composition is favorable because of its higher adhesion and lower rebound loss.
Additionally, since the material after use in a cement rotary kiln can be used, the cost and time of
screening are reduced to facilitate procurement. However, when the total content of Na20, K20,
S03, and Cl contained in the magnesia spinel brick chippings is excessive, the corrosion resistance
and abrasion resistance of the spraying refractory composition can decrease.
The total content of Na2O, K20, S03, and Cl contained in the refractory raw materials is
0. 2 % by mass or more and 5.0% by mass or less relative to 100% by mass of the refractory raw
materials and is preferably 0.4% by mass or more and 4.0% by mass or less, more preferably 1.0%
by mass or more and 3.0% by mass or less, and still more preferably 1.2% by mass or more and
2.5% by mass or less. Such a spraying refractory composition is favorable because of its higher
adhesion and lower rebound loss. However, when the total content of Na20, K20, S03, and Cl
contained in the refractory raw materials is excessive, the corrosion resistance and abrasion
resistance of the spraying refractory composition can decrease.
The total content of Na20, K20, S03, and Cl contained in the spraying refractory
composition is 1.0% by mass or more and 5.0% by mass or less relative to 100% by mass of the
spraying refractory composition and is preferably 1.2% by mass or more and 4.0% by mass or less,
more preferably 1.45% by mass or more and 3.0% by mass or less, and still more preferably 1.8%
by mass or more and 2.5% by mass or less. Such a spraying refractory composition is favorable
because of its higher adhesion and lower rebound loss. However, when the total content ofNa20,
K20, S03, and Cl contained in the spraying refractory composition is excessive, the corrosion
resistance and abrasion resistance of the spraying refractory composition can decrease.
Grain Size Distribution
Refractory raw materials having a maximum grain diameter of about 5 mm increase
adhesion and reduce rebound loss and are thus preferred. The grain size distribution can be
appropriately adjusted according to the condition of the object to be repaired, and the refractory
raw materials include, for example, 15% to 40% by mass of less than 5 mm and 3 mm or more (5
mm to 3 mm) grains, 15% to 45% by mass of less than 3 mm and 1 mm or more (3 mm to 1 mm)
grains, 20% to 45% by mass of less than 1 mm and 0.3 mm or more (1 mm to 0.3 mm) grains, and
% by mass or less of less than 0.3 mm grains.
Additional Raw Materials
The spraying refractory composition of an embodiment of the disclosure may contain, for
example, fire clay, silicate, phosphate, carboxylic acid, carboxylate, sulfate, chloride, calcium
hydrate, and magnesium hydrate as additional raw materials. Example of fire clay can include
elutriated clay, kaolin, and bentonite. Fire clay can increase the adhesion of the spraying
refractory composition and reduce the rebound loss. Examples of silicate can include lithium
silicate, sodium silicate, and potassium silicate. Silicates increase the abrasion resistance of
sprayed constructs. Examples of phosphate can include sodium phosphate and aluminum
phosphate. Phosphates increase the abrasion resistance of sprayed constructs. The carboxylic acid may be any compound with a carboxy group, and examples can include monocarboxylic acids, dicarboxylic acids, tricarboxylic acids, and oxycarboxylic acids. Carboxylic acids can adjust the cohesiveness of the spraying material and reduce the rebound loss. Examples of carboxylate can include potassium salts, sodium salts, and aluminum salts of the above-cited carboxylic acids.
Such carboxylates can adjust the cohesiveness of the spraying material and reduce the rebound
loss. Examples of sulfate can include magnesium sulfate and its hydrate, and examples of
chloride can include magnesium chloride and its hydrate. Such sulfates and chlorides increase
the adhesion of the spraying refractory composition. Examples of calcium hydrate can include
hydrated calcium hydroxide, hydrated Portland cement, and hydrated alumina cement. Calcium
hydrates increase the abrasion resistance of sprayed constructs. Example of the magnesium
hydrate can include hydrated magnesium hydroxide. Magnesium hydrates increase the abrasion
resistance of sprayed constructs. These examples are simply examples, and not limited to these.
The total content of additional raw materials is preferably 10% by mass or less relative to 100%
by mass of the refractory raw materials. When the total content of additional raw materials is
% by mass or less, the above-described effects can be further enhanced.
Examples of the disclosure will now be described in detail.
Experimental Procedure
Spraying refractory compositions were produced by mixing refractory raw materials and
additional raw materials and kneading the mixture with a V mixer for 15 minutes, thus used in a
spraying experiment. Magnesia spinel brick chippings after use in a cement rotary kiln and
magnesia raw material were used as the refractory raw materials. Also, fire clay, sodium silicate,
a dicarboxylic acid, and calcium hydrate were used as additional raw materials. The
compositions (mass%) of the magnesia spinel brick chippings and the magnesia raw material are
presented in Table 1, and the percentages (mass%) of the constituents in each spraying refractory
composition are presented in Table 2.
[Table 1]
(mass%) MgO A120 3 Na 20+K 20+SO3+CI Magnesia spinel brick chippings 85 12 2.27 Magnesia raw material 91 0.8 0.03
[Table 2]
Example E le 1 2 3 4 5 6 7 1 2 5-3mm 33.0 33.0 33.0 20.0 20.0 20.0 20.0 Magane 3-1mm 41.0 41.0 10.0 30.0 30.0 . brick Less than 26.0 - chippings I mm26.0_262. E Total 33.0 74.0 100.0 20.0 30.0 50.0 76.0 5-3mm 20.0 0 3-1mm 30.0 20.0 33.0 30.0
ra maternal 1-0.3mm 41.0 26.0 26.0 26.0 41.0 26.0 than 26.0 26.0 24.0 24.0 24.0 24.0 26.0 24.0 Total 67.0 26.0 80.0 70.0 50.0 24.0 100.0 100.0 Fire clay 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 o Sodium silicate 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 Dicarboxylic acid 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Calcium hydrate 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Total amount of CiO. 0 S0 an 0.77 1.69 2.27 0.48 0.70 1.15 1.73 0.03 0.03 refractory raw materials Total amount of Na2O. K20.SO3. and 1.47 2.34 2.88 1.20 1.41 1.83 2.38 0.78 0.78 Cl in 100% by mass of spraying refractory composition _
The spraying experiment was conducted in a hot environment. An alumina-silica based
refractory was used as the surface to be sprayed. The surface to be sprayed had been heated in
advance with a heavy oil burner to be adjusted to 800°C. A gunning machine ROTEKTOR
manufactured by SAYAMA Mfg. Co., Ltd. was used as the spray machine. The spray machine
has a tank capacity of 0.2 m3 , a spraying pressure of 0.25 MPa, a material hose with a length of 10
m and a nominal diameter of 25A, and a nozzle with a length of 1 m. Dry spraying was applied,
and added water was mixed with the spraying refractory composition in the nozzle. The amount
of added water was adjusted to 15% to 25% by mass relative to 100% by mass of the spraying
refractory composition. The amount (M) of the spraying refractory composition sprayed was 15
kg.
The following were evaluated in the spraying experiment.
The degree of flaking off was visually observed during spraying and rated as A for samples
exhibiting no flaking off, B for samples exhibiting little flaking off, and C for samples exhibiting
much flaking off.
Also, the mass (R) of rebound was measured after spraying, and the adhesion percentage
(A) was calculated from the following equation:
A=(M-R)+Mx 100
Each mixture was subjected to the spraying experiment three times, and the results were
averaged to evaluate the adhesion percentage(%).
Evaluation Results
Table 3 presents the evaluation results.
[Table 3]
Example Comarative 1 2 3 4 :6 |7 1 2 *k °f B A A B B A |A C C pretg 83 85 89 80 80 82 . 86 79 76
In Comparative Examples 1 and 2, in which the content of magnesia spinel brick chippings
was less than 10% by mass relative to 100% by mass of the refractory raw materials, the degree of
flaking off was rated as C, and the adhesion percentage was less than 80%. In contrast, Examples
1 to 7, in which the content of magnesia spinel brick chippings was 10% by mass or more relative
to 100% by mass of the refractory raw materials, exhibited such good adhesion that the degree of
flaking off was rated as A or B and the adhesion percentage was 80% or more. Examples 2, 3,
6, and 7, in which the content of magnesia spinel brick chippings was 40% by mass or more relative
to 100% by mass of the refractory raw materials, exhibited particularly good adhesion such that
the degree of flaking off was rated as A and the adhesion percentage was 82% or more.
While embodiments of the present disclosure have been described in detail above, it will
be readily appreciated to those skills in the art that various modifications may be made in practice
without departing from the new features and effects of the disclosure. Therefore, such
modifications are all within the scope of the disclosure. For example, terms described at least once with a different term that is broader or synonymous in the present specification may be replaced with that different term at any section in the specification. The components in an embodiment are also not limited to those described in the embodiment and may be varied in various manners.
In the present specification and claims, the term 'comprising' and its derivatives including
'comprises' and 'comprise' is used to indicate the presence of the stated integers but does not
preclude the presence of other unspecified integers.
Claims (12)
1. A spraying refractory composition comprising:
magnesia spinel brick chippings and a magnesia raw material mainly as refractory raw
materials,
the purity of MgO in the magnesia raw material being 85% by mass or more,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to
100% by mass of the refractory raw materials,
the content of the magnesia raw material being 0% by mass or more and 90% by mass or
less relative to 100% by mass of the refractory raw materials (except for the case of 0% by mass),
and
the total content of the magnesia spinel brick chippings and the magnesia raw material
being 80% by mass or more relative to 100% by mass of the refractory raw materials.
2. A spraying refractory composition comprising:
magnesia spinel brick chippings and a magnesia raw material mainly as refractory raw
materials,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to
100% by mass of the refractory raw materials,
the content of the magnesia raw material being 0% by mass or more and 90% by mass or
less relative to 100% by mass of the refractory raw materials, and
the total content of Na20, K20, S03, and Cl contained in the magnesia spinel brick
chippings being 0.5% by mass or more and 5.0% by mass or less relative to 100% by mass of the
magnesia spinel brick chippings.
3. A spraying refractory composition comprising:
magnesia spinel brick chippings and a magnesia raw material mainly as refractory raw
materials,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to
100% by mass of the refractory raw materials, the content of the magnesia raw material being 0% by mass or more and 90% by mass or less relative to 100% by mass of the refractory raw materials, and the total content of Na20, K20, S03, and Cl contained in the refractory raw materials being
0.2% by mass or more and 5.0% by mass or less relative to 100% by mass of the refractory raw
materials.
4. A spraying refractory composition comprising:
magnesia spinel brick chippings and a magnesia raw material mainly as refractory raw
materials,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to
100% by mass of the refractory raw materials,
the content of the magnesia raw material being 0% by mass or more and 90% by mass or
less relative to 100% by mass of the refractory raw materials, and
the total content of Na20, K20, S03, and Cl contained in the spraying refractory
composition being 1.0% by mass or more and 5.0% by mass or less relative to 100% by mass of
the spraying refractory composition.
5. The spraying refractory composition according to any one of claims 2 to 4, wherein
the total content of the magnesia spinel brick chippings and the magnesia raw material is
% by mass or more relative to 100% by mass of the refractory raw materials.
6. The spraying refractory composition according to any one of claims 1, and 3 to 5, wherein
the total content of Na20, K20, S03, and Cl contained in the magnesia spinel brick
chippings is 0.5% by mass or more and 5.0% by mass or less relative to 100% by mass of the
magnesia spinel brick chippings.
7. The spraying refractory composition according to any one of claims 1, 2, and 4 to 6, wherein
the total content of Na20, K20, S03, and Cl contained in the refractory raw materials is
0. 2 % by mass or more and 5.0% by mass or less relative to 100% by mass of the refractory raw
materials.
8. The spraying refractory composition according to any one of claims 1to 3 and 5 to 7,
wherein
the total content of Na20, K20, S03, and Cl contained in the spraying refractory
composition is 1.0% by mass or more and 5.0% by mass or less relative to 100% by mass of the
spraying refractory composition.
9. A method for producing a spraying refractory composition comprising the steps of
mixing and kneading refractory raw materials and other materials,
the refractory raw materials containing magnesia spinel brick chippings and magnesia raw material,
the purity of MgO in the magnesia raw material being 85% by mass or more,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to
100% by mass of the refractory raw materials,
the content of the magnesia raw material being 0% by mass or more and 90% by mass or
less relative to 100% by mass of the refractory raw materials (except for the case of 0% by mass),
the total content of the magnesia spinel brick chippings and the magnesia raw material
being 80% by mass or more relative to 100% by mass of the refractory raw materials, and
the magnesia spinel brick chippings composed of a magnesia spinel brick after use in a
cement rotary kiln.
10. A method for producing a spraying refractory composition comprising the steps of
mixing and kneading refractory raw materials and other materials,
the refractory raw materials containing magnesia spinel brick chippings and magnesia raw material,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to
100% by mass of the refractory raw materials,
the content of the magnesia raw material being 0% by mass or more and 90% by mass or
less relative to 100% by mass of the refractory raw materials, the total content of Na20, K20, SO3,
and Cl contained in the magnesia spinel brick chippings being 0.5% by mass or more and 5.0% by
mass or less relative to 100% by mass of the magnesia spinel brick chippings, and the magnesia spinel brick chippings composed of a magnesia spinel brick after use in a cement rotary kiln.
11. A method for producing a spraying refractory composition comprising the steps of
mixing and kneading refractory raw materials and other materials,
the refractory raw materials containing magnesia spinel brick chippings and magnesia raw material,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to
100% by mass of the refractory raw materials,
the content of the magnesia raw material being 0% by mass or more and 90% by mass or
less relative to 100% by mass of the refractory raw materials,
the total content of Na20, K20, S03, and Cl contained in the refractory raw materials being
0.2% by mass or more and 5 .0% by mass or less relative to 100% by mass of the refractory raw
materials, and
the magnesia spinel brick chippings composed of a magnesia spinel brick after use in a
cement rotary kiln.
12. A method for producing a spraying refractory composition comprising the steps of
mixing and kneading refractory raw materials and other materials,
the refractory raw materials containing magnesia spinel brick chippings and magnesia raw material,
the content of the magnesia spinel brick chippings being 10% by mass or more relative to
100% by mass of the refractory raw materials,
the content of the magnesia raw material being 0% by mass or more and 90% by mass or
less relative to 100% by mass of the refractory raw materials,
the total content of Na20, K20, S03, and Cl contained in the spraying refractory
composition being 1.0% by mass or more and 5 .0% by mass or less relative to 100% by mass of
the spraying refractory composition, and the magnesia spinel brick chippings composed of a
magnesia spinel brick after use in a cement rotary kiln.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2020189561A JP6880428B1 (en) | 2020-11-13 | 2020-11-13 | Sprayed refractory composition and its manufacturing method |
| JP2020-189561 | 2020-11-13 | ||
| PCT/JP2021/037833 WO2022102325A1 (en) | 2020-11-13 | 2021-10-13 | Sprayable fire-resistant composition and production method therefor |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| AU2021377556A1 AU2021377556A1 (en) | 2023-06-15 |
| AU2021377556B2 true AU2021377556B2 (en) | 2024-05-02 |
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ID=76083855
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| AU2021377556A Active AU2021377556B2 (en) | 2020-11-13 | 2021-10-13 | Sprayable fire-resistant composition and production method therefor |
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| JP (1) | JP6880428B1 (en) |
| AU (1) | AU2021377556B2 (en) |
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Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS58120568A (en) * | 1982-01-08 | 1983-07-18 | 新日本製鐵株式会社 | Spraying repairing material for steel smelting furnace |
| JP4269148B2 (en) * | 2003-02-19 | 2009-05-27 | 株式会社ヨータイ | Basic refractory |
| JP4351526B2 (en) * | 2003-12-19 | 2009-10-28 | 黒崎播磨株式会社 | Unshaped refractories for wet spraying with used refractories |
| JP4273099B2 (en) * | 2005-07-29 | 2009-06-03 | 黒崎播磨株式会社 | Spraying material for repairing electric furnace lining for steelmaking and method for repairing spraying of electric furnace lining for steelmaking using the same |
| JP2011057536A (en) * | 2009-09-04 | 2011-03-24 | Shinagawa Refractories Co Ltd | Spinel refractory |
| JP6624133B2 (en) * | 2017-03-16 | 2019-12-25 | 品川リフラクトリーズ株式会社 | Manufacturing method of magnesia-spinel fired brick |
-
2020
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| AU2021377556A1 (en) | 2023-06-15 |
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