BR102020001687B1 - BASE FORMULATION FOR INDUCTION OVEN CRUISES, AND PRE-MOLDED CRUISE MANUFACTURE - Google Patents
BASE FORMULATION FOR INDUCTION OVEN CRUISES, AND PRE-MOLDED CRUISE MANUFACTURE Download PDFInfo
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- silica
- alumina
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- sio2
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- 239000000203 mixture Substances 0.000 title claims abstract description 36
- 238000009472 formulation Methods 0.000 title claims abstract description 30
- 230000006698 induction Effects 0.000 title claims description 21
- 238000004519 manufacturing process Methods 0.000 title claims description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 51
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 29
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 11
- 239000000654 additive Substances 0.000 claims abstract description 9
- 239000008119 colloidal silica Substances 0.000 claims abstract description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 8
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims abstract description 7
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 claims abstract description 7
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000005011 phenolic resin Substances 0.000 claims abstract description 7
- 229920001568 phenolic resin Polymers 0.000 claims abstract description 7
- 239000011044 quartzite Substances 0.000 claims abstract description 7
- 230000000996 additive effect Effects 0.000 claims abstract description 5
- 238000000265 homogenisation Methods 0.000 claims abstract description 4
- 239000000377 silicon dioxide Substances 0.000 claims description 13
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 claims description 6
- 229910000423 chromium oxide Inorganic materials 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 2
- 229910021487 silica fume Inorganic materials 0.000 claims description 2
- 239000001488 sodium phosphate Substances 0.000 claims description 2
- 229910000162 sodium phosphate Inorganic materials 0.000 claims description 2
- RYFMWSXOAZQYPI-UHFFFAOYSA-K trisodium phosphate Chemical compound [Na+].[Na+].[Na+].[O-]P([O-])([O-])=O RYFMWSXOAZQYPI-UHFFFAOYSA-K 0.000 claims description 2
- 229910052593 corundum Inorganic materials 0.000 claims 2
- 229910001845 yogo sapphire Inorganic materials 0.000 claims 2
- 229910052751 metal Inorganic materials 0.000 abstract description 4
- 239000002184 metal Substances 0.000 abstract description 4
- 238000000465 moulding Methods 0.000 abstract description 3
- 239000000126 substance Substances 0.000 abstract description 2
- 229910052681 coesite Inorganic materials 0.000 description 10
- 229910052906 cristobalite Inorganic materials 0.000 description 10
- 229910052682 stishovite Inorganic materials 0.000 description 10
- 229910052905 tridymite Inorganic materials 0.000 description 10
- 238000000034 method Methods 0.000 description 8
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 229910052596 spinel Inorganic materials 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- NUJOXMJBOLGQSY-UHFFFAOYSA-N manganese dioxide Chemical compound O=[Mn]=O NUJOXMJBOLGQSY-UHFFFAOYSA-N 0.000 description 3
- 238000005245 sintering Methods 0.000 description 3
- 239000011029 spinel Substances 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 229910000851 Alloy steel Inorganic materials 0.000 description 2
- 229910000640 Fe alloy Inorganic materials 0.000 description 2
- 229910026161 MgAl2O4 Inorganic materials 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 238000004806 packaging method and process Methods 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000617 Mangalloy Inorganic materials 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000005350 fused silica glass Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 239000012768 molten material Substances 0.000 description 1
- 239000011823 monolithic refractory Substances 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- 229910052845 zircon Inorganic materials 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
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- 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
- C04B35/10—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 aluminium oxide
- C04B35/107—Refractories by fusion casting
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- 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
- C04B35/10—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 aluminium oxide
- C04B35/107—Refractories by fusion casting
- C04B35/109—Refractories by fusion casting containing zirconium oxide or zircon (ZrSiO4)
-
- 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
- C04B35/14—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 silica
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- 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
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/653—Processes involving a melting step
- C04B35/657—Processes involving a melting step for manufacturing refractories
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B14/00—Crucible or pot furnaces
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Organic Chemistry (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Inorganic Chemistry (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Mold Materials And Core Materials (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Crucibles And Fluidized-Bed Furnaces (AREA)
Abstract
para trazer maior capacidade ao refratário na área de trabalho, quando da moldagem do cadinho. para tanto, duas composições foram desenvolvidas, sendo uma formulação base à base de sílica (sio2 ) e outra formulação base à base de alumina (al2o3 ). a formulação base à base de sílica (sio2 ) é composta por quartzito de pureza química entre 90 a 96% de sio 2 , sílica amorfa, óxido de cromo (cr2o3 ), aditivo à base de sílica coloidal e resina fenólica com controladores de tempo de desmoldagem à base de mgo. a formulação base à base de alumina (al2o3 ), é composta de alumina fundida marrom, óxido de magnésio sinterizado com 98% de teor de pureza, resina fenólica, e aditivos para ajuste do tempo de endurecimento a base de sílica coloidal (si02 ). ambas as formulações bases são preparadas em misturador planetário, com tempo de homogeneização de 5 minutos, recebendo aditivos e volume de água, para serem em seguidas, despejadas em moldes metálicos no formato do respectivo cadinho e vibradas em mesas vibratórias para a sua conformação final, sendo a formulação base à base de sílica (sio2 ) curada na temperatura de 250ºc, por 24 horas e formulação base à base de alumina (al2o3 ) curada na temperatura de 190ºc, por 24 horas.to bring greater capacity to the refractory in the work area, when molding the crucible. to this end, two compositions were developed, one being a base formulation based on silica (sio2) and another base formulation based on alumina (al2o3). the base formulation based on silica (sio2) is composed of quartzite of chemical purity between 90 to 96% sio2, amorphous silica, chromium oxide (cr2o3), additive based on colloidal silica and phenolic resin with time controllers mgo-based mold release. the base formulation based on alumina (al2o3), is composed of brown fused alumina, sintered magnesium oxide with 98% purity, phenolic resin, and additives to adjust the hardening time based on colloidal silica (si02). both base formulations are prepared in a planetary mixer, with a homogenization time of 5 minutes, receiving additives and a volume of water, to be then poured into metal molds in the shape of the respective crucible and vibrated on vibrating tables for their final conformation, with the base formulation based on silica (sio2) cured at a temperature of 250ºc, for 24 hours and the base formulation based on alumina (al2o3) cured at a temperature of 190ºc, for 24 hours.
Description
[001] Refere-se o presente relatório descritivo, a um pedido de patente de invenção para um aperfeiçoamento desenvolvido para pelo menos dois tipos de formulações bases distintas usadas na fabricação de Cadinhos de fornos de indução, sendo uma formulação à base de Sílica (Si02) e uma formulação à base de Alumina (A1203).[001] This descriptive report refers to a patent application for an improvement developed for at least two types of different base formulations used in the manufacture of induction oven crucibles, being a formulation based on Silica (Si02 ) and an Alumina-based formulation (A1203).
[002] Como é de conhecimento, no processo de fabricação de ferro e aço através de fornos de indução, o cadinho é um elemento de grande importância. Através de seu desempenho reduz o tempo de sinterização garantindo maior disponibilidade do forno de indução, com aumento de produção e redução de mão de obra, além de reduzir o consumo específico do refratário empregado, trazendo, portanto, substancial economia ao processo como um todo.[002] As you know, in the process of manufacturing iron and steel through induction furnaces, the crucible is an element of great importance. Through its performance, it reduces sintering time, ensuring greater availability of the induction furnace, increasing production and reducing labor, in addition to reducing the specific consumption of the refractory used, thus bringing substantial savings to the process as a whole.
[003] A figura 1, apenas exemplificativa, mostra um forno de indução cuja carcaça, de bloco monolítico refratário, possui estrutura de inclinação com eixos para mancalização em um suporte. Como se observa por essa figura 1, o cadinho é envolto em massa refratária seca, na área de trabalho, seguida de aplicação de concreto refratário aluminoso para proteção da bobina de indução (cobre), e superiormente é alinhado à bica de vazamento (saída de material derretido) na parte superior traseira da carcaça.[003] Figure 1, just an example, shows an induction furnace whose housing, with a refractory monolithic block, has an inclination structure with shafts for bearing in a support. As shown in Figure 1, the crucible is wrapped in dry refractory mass, in the work area, followed by the application of aluminous refractory concrete to protect the induction coil (copper), and is superiorly aligned with the leakage spout (outlet of molten material) at the top rear of the housing.
[004] Para o revestimento da área de trabalho, ou seja, a área de proteção da bobina, são usadas massas granuladas secas à base de Sílica, e de Alumina, de acordo com o tipo de metal a ser processado.[004] For the coating of the work area, that is, the protection area of the coil, dry granulated masses based on Silica and Alumina are used, according to the type of metal to be processed.
[005] A figura 2 mostra, esquematicamente e em corte, um cadinho pré-moldado, vendo-se a área de trabalho que recebe a aplicação da massa granulada seca de proteção da bobina, socada pelo processo de vibração e/ou manual, etapa extremamente importante para se obter um ótimo rendimento nestes fornos de indução sobre a face interna da bobina, a qual é revestida com uma camada de concreto refratário aluminoso, onde não devem haver saliências ou reentrâncias. Portanto, frestas devem ser eliminadas entre as espiras da bobina e a base, ou entre a bobina e a estrutura do topo. A superfície pode ser grosseiramente desempenada para facilitar a secagem. Em fornos tipo Box, com base de concreto, como nesse caso da figura 2, o revestimento da bobina deve ser estendido da base da bobina até a base de concreto, formando assim um bloco monolítico refratário.[005] Figure 2 shows, schematically and in section, a pre-molded crucible, seeing the work area that receives the application of the dry granulated mass to protect the coil, tamped by the vibration and/or manual process, step extremely important to obtain an optimal performance in these induction furnaces on the internal face of the coil, which is coated with a layer of aluminous refractory concrete, where there should be no protrusions or recesses. Therefore, gaps must be eliminated between the coil turns and the base, or between the coil and the top frame. The surface can be roughly straightened to facilitate drying. In Box type furnaces, with a concrete base, as in the case of Figure 2, the coil coating must be extended from the coil base to the concrete base, thus forming a monolithic refractory block.
[006] De qualquer forma, a instalação desse revestimento na área de trabalho usualmente obedece a procedimentos específicos e normalmente o fabricante fornece detalhes a serem seguidos, contidos em uma "folha de instrução". Dependendo do volume do forno de indução (por exemplo, 25 t) o tempo de aplicação da massa seca pelo processo de vibração e sinterização, pelo processo convencional (sem o uso do cadinho), ou seja, quando o próprio espaço do forno-cadinho é delimitado pela aplicação dessa referida massa seca, leva cerca de 24 horas. Isso, evidentemente, exige tempo de parada substancialmente prolongada em se tratando de processamentos em fornos de indução.[006] Anyway, the installation of this coating in the work area usually follows specific procedures and usually the manufacturer provides details to be followed, contained in an "instruction sheet". Depending on the volume of the induction furnace (for example, 25 t) the time of application of the dry mass by the vibration and sintering process, by the conventional process (without the use of the crucible), that is, when the space of the crucible furnace is delimited by the application of that dry mass, it takes about 24 hours. This, of course, requires substantially prolonged downtime when it comes to processing in induction furnaces.
[007] Portanto, considerando pelo menos os dois casos de massas granuladas secas acima citadas para o revestimento da área de trabalho, à base de Sílica e à base de Alumina, é necessário que seja otimizado o tempo de aplicação e de sinterização no início do processo de fusão nos fornos de indução. No caso do uso do Cadinho, pré-moldado, uma parte ou uma camada dessa massa seca refratária atualmente usada na área de trabalho, é substituída pelo corpo moldado. Com parte dessas massas vibradas a seco substituídas, a previsão é que este tempo seja reduzido em um valor superior à 50%.[007] Therefore, considering at least the two cases of dry granulated masses mentioned above for the coating of the work area, based on Silica and based on Alumina, it is necessary to optimize the application and sintering time at the beginning of the melting process in induction furnaces. In the case of using a pre-molded crucible, a part or a layer of this dry refractory mass currently used in the work area is replaced by the molded body. With part of these dry vibrated masses replaced, the forecast is that this time will be reduced by a value greater than 50%.
[008] É exatamente essa a proposta, motivo do pedido em questão, a aplicação do cadinho pré-moldado, no forno de indução, porém moldado com formulações bases desenvolvidas para que, além da redução do tempo de parada na recomposição do revestimento refratário do forno de indução (já que uma camada dessa massa é substituída pelo corpo moldado), seja alcançada maior qualidade a esse refratário aplicado.[008] This is exactly the proposal, reason for the request in question, the application of the pre-molded crucible, in the induction furnace, however molded with base formulations developed so that, in addition to reducing downtime in the recomposition of the refractory lining of the induction furnace (since a layer of this mass is replaced by the molded body), higher quality is achieved for this refractory applied.
[009] Assim, na moldagem do cadinho, a aplicação dessas formulações bases aperfeiçoadas, motivos desse pedido de patente, traz agilidade e eficácia para o trabalho desse importante elemento do forno de indução.[009] Thus, in the molding of the crucible, the application of these improved base formulations, reasons for this patent application, brings agility and efficiency to the work of this important element of the induction furnace.
[010] Para tanto, cada uma dessas formulações bases, no caso à base de Sílica (SiO2) e à base de Alumina (A1203), é preparada de forma distinta, com elementos específicos em um misturador planetário, recebendo respectivos aditivos e também volume de água nas suas massas em mistura, para ajuste de fluidez.[010] Therefore, each of these base formulations, in this case based on Silica (SiO2) and based on Alumina (A1203), is prepared differently, with specific elements in a planetary mixer, receiving respective additives and also volume of water in its mixed masses, for fluidity adjustment.
[011] Após preparadas, essas formulações bases são depositadas no respectivo molde conforme o cadinho projetado, ou seja, em moldes para cadinho à base de Sílica e à base de Alumina. Esses moldes são montados em mesas vibratórias e, após o processo de vibração, adquirem a conformação final para os cadinhos, com tratamento térmico para remoção de água, em dimensões e condições definidas de acordo com o cliente e as especificações do Forno de Indução.[011] Once prepared, these base formulations are deposited in the respective mold according to the designed crucible, that is, in molds for crucibles based on Silica and based on Alumina. These molds are mounted on vibrating tables and, after the vibration process, acquire the final conformation for the crucibles, with thermal treatment to remove water, in dimensions and conditions defined according to the customer and the specifications of the Induction Furnace.
[012] Como foi citado anteriormente, a figura 1 exemplifica um Forno de Indução contendo o Cadinho e a figura 2 exemplifica um Cadinho pré-moldado para forno de indução.[012] As previously mentioned, figure 1 exemplifies an Induction Oven containing the Crucible and figure 2 exemplifies a pre-molded Crucible for induction oven.
[013] Assim sendo, a "FORMULAÇÃO BASE PARA CADINHOS DE FORNO DE INDUÇÃO, E FABRICAÇÃO DE CADINHOS PRÉ- MOLDADOS ", objetivo desse presente pedido de patente de invenção, constitui-se de duas formulações bases para cadinho, sendo uma formulação para cadinho à base de Sílica e outra formulação à base de Alumina.[013] Therefore, the "BASE FORMULATION FOR INDUCTION OVEN CRUCKS, AND PRE-MOLDED CRUISE MANUFACTURE", purpose of this present patent application, consists of two base formulations for crucibles, one formulation for crucibles based on Silica and another formulation based on Alumina.
[014] A formulação base para o cadinho à base de Sílica (Si02) é composta por Quartzito de alta pureza química (>90% de Si02), Sílica Amorfa, Óxido de Cromo (Cr203), aditivo à base de Sílica Coloidal e Resina Fenólica com controladores de tempo de desmoldagem à base de MgO e/ou Cimento de Aluminato de Cálcio. Opcionalmente, essa formulação para cadinho à base de Sílica (Si02) pode utilizar-se de Sílica Fundida, parcial ou totalmente, em substituição ao Quartzito, além de, também opcionalmente, utilizar- se de Zirconita - Silicato de Zircônio (ZrSiO4), em substituição ao Óxido de Cromo (Cr203).[014] The base formulation for the crucible based on Silica (Si02) is composed of Quartzite of high chemical purity (>90% of Si02), Amorphous Silica, Chromium Oxide (Cr203), additive based on Colloidal Silica and Resin Phenolic with release time controllers based on MgO and/or Calcium Aluminate Cement. Optionally, this crucible formulation based on Silica (Si02) can use Fused Silica, partially or totally, to replace Quartzite, in addition to optionally using Zirconite - Zirconium Silicate (ZrSiO4), in replacement for Chromium Oxide (Cr203).
[015] De forma mais detalhada, a formulação base, à base de Sílica (Si02) é composta por 88,0 a 91,0% de Quartzito (nas frações granulométricas padrão Tyler de 4/8, 8/30, -30 e -140 mesh); 4 a 8% de Microsílica (contendo > 98% Si02); 0,8 a 1,2% de Resina Fenólica, 0,1 a 0,5% de Oxido de Magnésio (pureza > 98% MgO); 1 a 2,0% de Óxido de Cromo (malha 325; pureza > 98% Cr203) e 2 a 5% de Sílica Coloidal contendo 30% de Si02.[015] In more detail, the base formulation, based on Silica (Si02) is composed of 88.0 to 91.0% of Quartzite (in Tyler standard granulometric fractions of 4/8, 8/30, -30 and -140 mesh); 4 to 8% Microsilica (containing >98% Si02); 0.8 to 1.2% Phenolic Resin, 0.1 to 0.5% Magnesium Oxide (purity > 98% MgO); 1 to 2.0% Chromium Oxide (325 mesh; purity > 98% Cr203) and 2 to 5% Colloidal Silica containing 30% Si02.
[016] Essa mistura é feita em um misturador planetário (não mostrado) em tempo de homogeneização de 5 minutos, recebendo, a massa em revolvimento, volume de água para ajuste de fluidez. A mistura já homogeneizada é despejada em molde metálico no formato do cadinho desejado e vibrada em mesas vibratórias para a sua conformação final. Após o tempo de endurecimento da massa vibrada, o Cadinho é tratado termicamente na temperatura de 250°C por 24 horas para remoção da quantidade de água adicionada.[016] This mixture is made in a planetary mixer (not shown) in a homogenization time of 5 minutes, receiving, the revolving mass, a volume of water for fluidity adjustment. The already homogenized mixture is poured into a metal mold in the shape of the desired crucible and vibrated on vibrating tables for its final conformation. After the hardening time of the vibrated mass, the Crucible is heat treated at a temperature of 250°C for 24 hours to remove the amount of added water.
[017] Com a combinação de diferentes frações granulométricas de Quartzito, em: 4/8; 8/30; -30 e -140 mesh, obtém-se, após a cura, ótimo empacotamento do produto final resultando em alta densidade e resistência mecânica. A densidade de massa específica do cadinho é cerca de 2,25 g/cm3 e resistência à compressão de 29,0 MPa, conforme mostra a tabela a seguir, dando maior eficácia ao cadinho pré-moldado à base de Sílica (Si02) na fusão de Ferro e ligas de aço. Tabela 1 - Propriedades do Cadinho à base de Sílica (Si02)
[018] A formulação base para o Cadinho à base de Alumina (A1203) utiliza-se de Alumina Fundida Marrom, Óxido de Magnésio sinterizado com 98% de teor de pureza, resina fenólica, e aditivos de ajuste do tempo de endurecimento, à base de Sílica Coloidal (Si02).[018] The base formulation for the Alumina-based Crucible (A1203) uses Brown Fused Alumina, sintered Magnesium Oxide with 98% purity content, phenolic resin, and hardening time adjustment additives, based on of Colloidal Silica (Si02).
[019] Opcionalmente, essa formulação para Cadinho à base de Alumina pode utilizar-se de Alumina Tabular em substituição à Alumina Fundida, além de, também opcionalmente, substituir o Óxido de Magnésio sinterizado por Magnésia Fundida e/ou Espinélio (MgAl2O4). O emprego de Espinélio (MgAl2O4) e de Óxido de Cromo (Cr203) na moldagem do cadinho é necessária pois esses componentes reagem e combatem a escória gerada pela alta porcentagem de Dióxido de Manganês (Mn02), quando do processo de fabricação de aços no Forno de Indução. Essa escória ataca o cadinho pré-moldado, porém, sua resistência à corrosão é aumentada graças ao emprego dos dois componentes (Espinélio e Óxido de Cromo) acima citados.[019] Optionally, this Alumina-based crucible formulation can use Tabular Alumina in place of Fused Alumina, in addition to optionally replacing the sintered Magnesium Oxide by Fused Magnesia and/or Spinel (MgAl2O4). The use of Spinel (MgAl2O4) and Chromium Oxide (Cr203) in the molding of the crucible is necessary because these components react and fight the slag generated by the high percentage of Manganese Dioxide (Mn02) during the steel manufacturing process in the Furnace of Induction. This slag attacks the precast crucible, however, its resistance to corrosion is increased thanks to the use of the two components (Spinel and Chromium Oxide) mentioned above.
[020] De forma mais detalhada, a formulação base, à base de Alumina (A1203), é composta por 53 a 63% de Alumina Fundida Marrom nas frações granulométricas 4/10, 10/20 e -30 mesh; 20 na 24% de Alumina Fundida Branca; 8 a 12% de Óxido de Magnésio sinterizado (pureza > 98%) na fração -18 mesh; 3 a 8% de Alumina Calcinada reativa; 1 a 3% de Resina Fenólica em pó, 0,8 a 1,2% de aditivo dispersante à base de Fosfato de Sódio e 1,5 a 3,0% de Sílica Coloidal.[020] In more detail, the base formulation, based on Alumina (A1203), is composed of 53 to 63% of Brown Fused Alumina in 4/10, 10/20 and -30 mesh particle size fractions; 20 in 24% White Fused Alumina; 8 to 12% sintered Magnesium Oxide (> 98%) purity in the -18 mesh fraction; 3 to 8% reactive Calcined Alumina; 1 to 3% of Phenolic Resin powder, 0.8 to 1.2% of dispersing additive based on Sodium Phosphate and 1.5 to 3.0% of Colloidal Silica.
[021] Essa mistura é feita em um misturador planetário (não mostrado) em tempo de homogeneização de 5 minutos, recebendo, a massa em revolvimento, volume de água para ajuste de fluidez. A mistura já homogeneizada é despejada em molde metálico no formato do cadinho desejado e vibrada em mesas vibratórias para a sua conformação final. Após o tempo de endurecimento da massa vibrada o Cadinho é tratado termicamente na temperatura de 190°C por 24 horas para remoção da quantidade de água adicionada.[021] This mixture is made in a planetary mixer (not shown) in a homogenization time of 5 minutes, receiving, the revolving mass, a volume of water for fluidity adjustment. The already homogenized mixture is poured into a metal mold in the shape of the desired crucible and vibrated on vibrating tables for its final conformation. After the vibrated mass hardening time, the Crucible is heat treated at a temperature of 190°C for 24 hours to remove the amount of added water.
[022] Com a combinação de diferentes frações granulométricas de Alumina fundida, após a cura obtém-se ótimo empacotamento do produto final resultando em alta densidade e resistência mecânica > 25 Mpa, como mostra a tabela a seguir, dando maior eficácia na fusão de Ferro e ligas de aço, ao cadinho pré-moldado, à base de Alumina (A1 203), na fusão de aços de médio e alto carbono, aços de alta liga e aço manganês. Tabela 2 - Propriedades do Cadinho à base Alumina (A1203)
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