CN101977869A - 板砖及其制造方法 - Google Patents
板砖及其制造方法 Download PDFInfo
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- CN101977869A CN101977869A CN2009801100432A CN200980110043A CN101977869A CN 101977869 A CN101977869 A CN 101977869A CN 2009801100432 A CN2009801100432 A CN 2009801100432A CN 200980110043 A CN200980110043 A CN 200980110043A CN 101977869 A CN101977869 A CN 101977869A
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- Prior art keywords
- plate brick
- quality
- aluminium
- raw material
- thermal treatment
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000011449 brick Substances 0.000 title claims abstract description 98
- 238000004519 manufacturing process Methods 0.000 title claims description 22
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 90
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 89
- 239000002994 raw material Substances 0.000 claims abstract description 57
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 33
- 239000011230 binding agent Substances 0.000 claims abstract description 24
- 230000029087 digestion Effects 0.000 claims abstract description 21
- 238000002156 mixing Methods 0.000 claims abstract description 8
- 239000004411 aluminium Substances 0.000 claims description 85
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 61
- 238000007669 thermal treatment Methods 0.000 claims description 53
- 239000000203 mixture Substances 0.000 claims description 39
- 238000000034 method Methods 0.000 claims description 34
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 30
- 229910052863 mullite Inorganic materials 0.000 claims description 30
- 239000002245 particle Substances 0.000 claims description 16
- 229920003987 resole Polymers 0.000 claims description 11
- 239000004927 clay Substances 0.000 claims description 9
- 238000002425 crystallisation Methods 0.000 claims description 9
- 230000008025 crystallization Effects 0.000 claims description 9
- 239000000146 host glass Substances 0.000 claims description 9
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 9
- 229910052710 silicon Inorganic materials 0.000 claims description 9
- 239000010703 silicon Substances 0.000 claims description 9
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 9
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 9
- 238000000465 moulding Methods 0.000 claims description 8
- 229920002050 silicone resin Polymers 0.000 claims description 7
- 230000005496 eutectics Effects 0.000 claims description 6
- 229910052593 corundum Inorganic materials 0.000 claims description 3
- 239000010431 corundum Substances 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 abstract description 19
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 abstract description 6
- 229910052799 carbon Inorganic materials 0.000 abstract description 5
- 239000000126 substance Substances 0.000 abstract description 4
- 239000007788 liquid Substances 0.000 abstract description 2
- 150000001875 compounds Chemical class 0.000 abstract 1
- 239000003063 flame retardant Substances 0.000 abstract 1
- 239000000779 smoke Substances 0.000 abstract 1
- 239000007789 gas Substances 0.000 description 20
- 230000000052 comparative effect Effects 0.000 description 13
- 230000000694 effects Effects 0.000 description 12
- 238000005245 sintering Methods 0.000 description 8
- 238000006243 chemical reaction Methods 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 239000000843 powder Substances 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 238000000354 decomposition reaction Methods 0.000 description 5
- 239000000835 fiber Substances 0.000 description 5
- 230000004927 fusion Effects 0.000 description 5
- -1 phenolic aldehyde Chemical class 0.000 description 5
- 229910052570 clay Inorganic materials 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- 206010013786 Dry skin Diseases 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 230000006866 deterioration Effects 0.000 description 3
- 239000004615 ingredient Substances 0.000 description 3
- 238000004321 preservation Methods 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 229910018134 Al-Mg Inorganic materials 0.000 description 2
- 229910021365 Al-Mg-Si alloy Inorganic materials 0.000 description 2
- 229910021364 Al-Si alloy Inorganic materials 0.000 description 2
- 229910018467 Al—Mg Inorganic materials 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910000861 Mg alloy Inorganic materials 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910004298 SiO 2 Inorganic materials 0.000 description 2
- GANNOFFDYMSBSZ-UHFFFAOYSA-N [AlH3].[Mg] Chemical compound [AlH3].[Mg] GANNOFFDYMSBSZ-UHFFFAOYSA-N 0.000 description 2
- 239000000571 coke Substances 0.000 description 2
- 238000007598 dipping method Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 235000008373 pickled product Nutrition 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 238000004901 spalling Methods 0.000 description 2
- 229910052596 spinel Inorganic materials 0.000 description 2
- 239000011029 spinel Substances 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- YLQBMQCUIZJEEH-UHFFFAOYSA-N Furan Chemical compound C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical compound [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 229910021502 aluminium hydroxide Inorganic materials 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- VCRLKNZXFXIDSC-UHFFFAOYSA-N aluminum oxygen(2-) zirconium(4+) Chemical compound [O--].[O--].[Al+3].[Zr+4] VCRLKNZXFXIDSC-UHFFFAOYSA-N 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000003575 carbonaceous material Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000003486 chemical etching Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000012790 confirmation Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 230000003292 diminished effect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000000796 flavoring agent Substances 0.000 description 1
- 235000019634 flavors Nutrition 0.000 description 1
- 238000013467 fragmentation Methods 0.000 description 1
- 238000006062 fragmentation reaction Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 238000000892 gravimetry Methods 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 239000011295 pitch Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000004445 quantitative analysis Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 230000001953 sensory effect Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/14—Closures
- B22D41/22—Closures sliding-gate type, i.e. having a fixed plate and a movable plate in sliding contact with each other for selective registry of their openings
- B22D41/28—Plates therefor
- B22D41/30—Manufacturing or repairing thereof
- B22D41/32—Manufacturing or repairing thereof characterised by the materials used therefor
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- 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
- C04B35/101—Refractories from grain sized mixtures
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- 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
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- 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
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
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- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
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- C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
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Abstract
本发明提供使用时发烟、有刺激气味的气体产生量少、且耐用性高的板砖。具体为,本发明的板砖是在含有铝及/或铝合金为0.5~20质量%的耐火原料混合物中添加有机粘合剂,在混炼后进行成型,在400℃以上1000℃以下进行热处理,然后不浸渍焦油、沥青等含碳质液状物的板砖,压缩强度为180MPa以上,并且在使用高压釜的消化试验中重量增加率为1%以下。
Description
技术领域
本发明涉及在钢铁行业等中用于控制熔融金属的流量的滑动喷嘴装置等中使用的板砖及其制造方法。
背景技术
在用于控制熔钢流量的滑动喷嘴装置中使用耐火物制的板砖。作为该板砖,通常使用氧化铝·碳质材料,根据其制法大致分为非烧结品和烧结品。通常情况下,非烧结品通过在成型后在100~300℃进行热处理来制造。烧结品通过在1000℃以上的高温下进行烧结,烧结后浸渍沥青或焦油等来制造。
但是,这些板砖存在使用时发烟、产生刺激气味的问题。这是因为在非烧结品中产生作为粘合剂的酚醛树脂的分解气体,在烧结品中产生浸渍的焦油等的分解气体。
因此,作为分解气体产生少的板砖,以往已研究了在上述温度中间的400~1000℃进行热处理的所谓的轻烧品。
例如在专利文献1中记载了如下制造方法,即在将耐火原料、酚醛系树脂、以及由雾化球形粉形成的铝粉末的混合物进行混炼、成型后,在550~650℃的温度下进行加热处理的制造方法。加热处理温度低于550℃时,酚醛系树脂的耐氧化性劣化,同时产生分解气体,使用时会产生臭气;高于650℃时,认为生成炭化铝。并且认为生成炭化铝时,在常温、常压下容易与水反应而生成氢氧化铝,因伴随体积膨胀和重量增加,所以在保存过程中常发生板崩裂的问题。
专利文献2中记载了如下方法,即在由耐火性无机材料骨材为90~99.5重量%和铝或铝合金纤维为0.5~10质量%组成的混合物中添加酚醛树脂,在700℃、850℃或者1000℃进行热处理。认为通过在铝或铝合金的熔点(铝为660℃)以上进行热处理,使铝浸透在周围组织的颗粒间,从而可使耐火物的强度飞跃提高,并且还可使耐剥落性大幅提高。此外,热处理温度高于1000℃时,则不能保持作为纤维的良好特性,纤维和粉末之间特性上的差别逐渐消失,并且随着铝浸透的进行而在纤维存在的地方产生空隙,耐浸蚀性反而劣化。
在专利文献3中记载了如下制造方法,即由耐火性无机原料、碳质原料以及金属质原料组成,这些原料构成粒子径为0.1μm以上4000μm以下的连续粒度分布体系,加入酚醛树脂在非氧化性环境下在800~1500℃进行烧结,并且不进行浸渍处理的制造方法。此外,在该实施例中记载了在850℃烧结,显气孔率为5.0%的耐火物。
专利文献1日本特开2000-94121号公报
专利文献2日本特开平1-313358号公报
专利文献3日本特开平11-199328号公报
发明内容
在专利文献1的制造方法中,使用时分解气体的产生虽然减少,但与以往的烧结浸渍品相比耐用性相当差。其理由是,因作为结合组织的酚醛树脂进行分解挥发而形成多孔性组织,故强度不充分。此外,因为热处理温度的上限低为650℃,所以有时通过铝熔融、反应产生的强度表达效果也不充分。
另一方面,如专利文献2、专利文献3记载,在铝的熔点660℃以上、1000℃以下的温度进行热处理时,与专利文献1相比,通过铝熔融、反应使板砖的强度提高。但是,根据其热处理温度不同,板砖的耐用性大不相同,并非一定能够得到具有充分耐用性的板砖。
因此,本发明要解决的课题是,提供使用时发烟、有刺激气味的气体产生量少、并且耐用性高的板砖及其制造方法。
制造板砖时的热处理温度为400~1000℃的情况下,进行其热处理时,会发生铝的熔融、炭化铝的生成、其它铝化合物的生成等。因此,热处理后的板砖的特性因热处理温度不同而大不相同。所以在以往的板砖制造方法中,根据其热处理条件的不同而得到耐用性大不相同的板砖。
因此,本发明者对于在400~1000℃各种温度下进行热处理的板砖进行实炉试验,对发烟、刺激气味以及耐用性进行分析。其结果获知,与以往相比,作为发烟、有刺激气味的气体产生量少、且耐用性高的板砖,具备某种特性的板砖有用。
即本发明的板砖为在含有铝及/或铝合金为0.5~20质量%的耐火原料混合物中添加有机粘合剂,在混炼后进行成型,在400℃以上1000℃以下进行热处理,然后不浸渍焦油、沥青等含碳质液状物的板砖,其特征在于,压缩强度为180MPa以上,并且在利用高压釜的消化试验中重量增加率为1%以下。
制造板砖时的热处理温度高于400℃时,因热处理过程中酚醛树脂等有机粘合剂分解并挥发,所以组织形成多孔变为低强度,因此板砖的耐用性降低。另一方面,热处理温度为某种程度的温度以上时,由于铝及/或铝合金或发生熔融、或发生反应,因而强度提高。因此,为了使板砖具有充分的耐用性,须使压缩强度为180MPa以上。低于180MPa时,使用时强度不充分,因破碎、磨损等使耐用性不充分。
因为本发明的板砖使用含有铝及/或铝合金为0.5~20质量%的耐火原料混合物,并且在400℃以上1000℃以下进行热处理,所以根据热处理温度高等制造条件的不同,有时铝过度反应从而生成过剩的炭化铝。如果过剩生成炭化铝,则板砖的耐消化性降低。耐消化性不充分时因保存过程中组织发生龟裂,所以强度降低耐用性降低。特别是在高温多湿的环境下,即使短时间保存也会发生消化。具体为在利用高压釜的消化试验中重量增加率大于1%时,在保存板砖期间有时会发生消化。
此外,本发明的板砖,在其制造时也可使热处理温度为400℃以上800℃以下。因为热处理温度大于800℃时,容易过剩生成炭化铝。
作为本发明板砖中使用的有机粘合剂,可合并使用酚醛树脂和硅树脂。作为在热处理温度为400℃以上1000℃以下进行热处理的板砖的有机粘合剂,通过合并使用这些树脂,具有使炭化铝的耐消化性更加提高的效果。并且可使组织致密,形成高强度的板砖。
因为本发明的板砖使用了有机粘合剂,所以热处理温度过低时,板砖中会产生起因于有机粘合剂的气体。优选本发明的板砖中在1000℃产生的气体量为0.5cc/1g以上8cc/1g以下。如果气体产生量为8cc/1g以下,即使在实际现场使用,使用时板砖发烟少,几乎没有令人感到不愉快程度的异味。另一方面,气体产生量低于0.5cc/1g时,有时使用时板砖表面的气体膜形成不充分,对熔融金属的化学浸蚀的降低效果变小,耐用性变得不充分。
此外,因为本发明的板砖使用了有机粘合剂,所以如果热处理温度增高则气孔率增加。气孔率过高时因熔渣成份更多地向气孔中浸透而使耐浸蚀性降低。因此,显气孔率低时耐用性提高,故优选为2~10%,更优选为4~8%。显气孔率低于2%时,有时因组织变得过于致密而使耐热冲击性不足,大于10%时,因组织形成多孔而使耐浸蚀性不充分。
此外,板砖中铝的含有率优选为0.5质量%以上3.5质量%以下。热处理后使铝残留具有如下效果:实际使用时残留铝选择性地向热负荷大的处移动,发生自身浸渍从而维持致密性,使耐用性提高。为0.5质量%以下时耐用性呈降低趋势,大于3.5质量%时,由于使用时受热而转变为炭化铝、氧化铝,因组织变得过于致密而使耐热冲击性降低,所以耐用性呈降低趋势。
进而,根据本发明者的研究,已知热处理前后的板砖中的铝变化率对于板砖的耐用性以及使用时的发烟会产生大的影响。并且知道满足上述特性的板砖可用例如以下制造方法来制造。
其制造方法为在含有氧化铝质原料为75~97质量%、铝及/或铝合金为0.5~20质量%、硅、粘土、碳化硅以及碳化硼中的1种以上为0.1~15质量%的耐火原料混合物中添加有机粘合剂,在混炼后进行成型并进行热处理的板砖的制造方法,其特征在于,在热处理后的板砖中的铝含有率相对于耐火原料混合物中的铝含有率的比例为20%以上60%以下的条件下进行热处理,然后不浸渍焦油、沥青等含碳质液状物。
在本发明中,配合铝及铝合金的目的在于,如上所述为了提高耐用性,更加具体地说通过与其它耐火原料、环境气体及/或有机粘合剂等反应从而形成结合组织提高强度,以及用以防止使用过程中的氧化。铝及铝合金的配合量低于0.5质量%时其效果不充分,大于20质量%时耐热冲击性降低。在此,作为铝合金,可使用Al-Mg合金、Al-Si合金以及Al-Mg-Si合金中的1种以上的铝合金,而且从强度提高效果方面来看,优选使用Al含有率为30质量%以上的铝合金。
此外,在本发明的制造方法中,在热处理后的板砖中的铝含有率(B质量%)相对于耐火原料混合物中的铝含有率(A质量%)的比例((B/A)×100))为20%以上60%以下的条件下进行热处理。在上述比例低于20%的条件下进行热处理时,熔损增大、耐用性降低。另一方面,在上述比例大于60%的条件下进行热处理时,铝及/或铝合金的反应不充分,强度不充分,同时板砖的表面粗糙度变大,耐用性不充分,而且使用时气体产生增多。此外,耐火原料混合物中的铝含有率是作为耐火原料使用的铝及铝合金中的化学成分铝(Al)的含有率。合并使用铝和铝合金时,铝含有率为各自Al成分的合计量。此外,板砖中的铝含有率是指板砖中含有的金属Al的含有率。
在本发明的制造方法中,硅、粘土、碳化硅以及碳化硼中的1种以上低于0.1质量%时,耐消化性不充分,大于15质量%时,使用时出现过度烧结,耐剥落性降低。
进而在本发明的制造方法中,作为氧化铝原料,可使用高性能氧化锆莫来石为10~40质量%,该高性能氧化锆莫来石为以氧化锆结晶及莫来石作为主要成分,剩余部分由刚玉及/或基质玻璃组成的通过熔融法得到的氧化锆莫来石,其中,共晶氧化锆结晶的结晶粒径为1.0μm以下,且基质玻璃的含量为5质量%以下。该高性能氧化锆莫来石与以往的氧化锆莫来石相比,热膨胀率小,所以可得到耐用性极其优异的板砖。
本发明的板砖在不浸渍焦油、沥青等的情况下,显示出与以往浸渍了焦油、沥青的板砖同等的耐用性。
而且,来自有机粘合剂的有害物质经过热处理大部分都挥发,并且因为未浸渍焦油、沥青等,所以在使用时有害气体的产生非常少,可减少对人体、自然环境产生的不良影响。
此外,根据本发明的板砖的制造方法,通过控制热处理后的铝含有率,可更加确切且稳定地制造出使用时发烟、有刺激气味的气体产生少的耐用性优异的板砖。
进而,通过在耐火原料混合物中配合高性能氧化锆莫来石,可以制造出耐热冲击性更高、耐用性更高的板砖。
具体实施方式
本发明的板砖通过在下述制造方法中讨论制造条件而制造,即在含有铝及/或铝合金为0.5~20质量%的耐火原料混合物中添加有机粘合剂,在混炼后进行成型,在400℃以上1000℃以下进行处理,不浸渍焦油、沥青等。
具体来说,通过以下本发明的制造方法可得到本发明的板砖。
本发明的板砖的制造方法,在耐火原料混合物中配合铝及/或铝合金为0.5~20质量%。与其它金属相比,铝及铝合金通过与有机粘合剂配合,在400~1000℃的热处理后产生高的强度提高效果。作为铝及铝合金,可使用通常作为耐火物原料而使用的铝及铝合金,作为其形态,可使用薄片、雾化粉或纤维等。此外,作为铝合金,使用Al-Mg合金、Al-Si合金以及Al-Mg-Si合金中的1种以上,并且从强度提高效果方面来看,使用Al含有率为30质量%以上的铝合金。这些铝合金与铝同样,使用时也具有抗氧化效果,而且制造时通过在400~1000℃与有机粘合剂、环境气体或其它耐火原料等反应而产生强度提高效果。
铝及/或铝合金在耐火原料混合物中的配合量为0.5~20质量%。更加优选在单独使用铝时为0.5~10质量%,在单独使用铝合金时为0.5~20质量%,在合并使用铝和铝合金时其合计量为1~20质量%。
除此之外,在耐火原料混合物中,还可使用作为耐火物原料通常使用而可配合的物质,例如氧化铝质原料、金属、碳质原料、粘土、碳化硅以及碳化硼。
作为氧化铝质原料,可使用氧化铝、莫来石、铝镁尖晶石、氧化锆莫来石以及氧化铝-氧化锆中的1种以上。
进而,作为氧化锆莫来石可使用高性能氧化锆莫来石,该高性能氧化锆莫来石为以氧化锆结晶及莫来石为主要成分,剩余部分由刚玉及/或基质玻璃组成的通过熔融法得到的氧化锆莫来石,其中,共晶氧化锆结晶的结晶粒径为1.0μm以下,且基质玻璃的含量为5质量%以下。该高性能氧化锆莫来石可使用例如PCT/JP2009/051632中公开的高性能氧化锆莫来石。
在本发明中,在进一步需要耐热冲击性的使用条件下,通过使用这种高性能氧化锆莫来石,可以提高耐热冲击性,可以具备与以往烧结浸渍品同样的耐用性。
作为铝及铝合金以外的金属,可使用铬、铬合金、镁、铁、镍以及硅中的1种以上为0.1~10质量%。特别是从提高耐消化性的效果高这一点来看,更优选硅。
作为碳质原料,可使用石墨、沥青、及炭黑中的1种以上为0.1~10质量%。碳质原料具有使耐热冲击性提高的效果。
粘土、碳化硅以及碳化硼中的1种以上通过与铝及/或铝合金合并使用,可提高板砖的耐氧化性及耐消化性。粘土、碳化硅以及碳化硼中的1种以上可使用0.1~10质量%。
通过在耐火原料混合物中以0.1~15质量%的比例使用这些硅、粘土、碳化硅以及碳化硼中的1种以上,可更加提高耐消化性和耐氧化性。即在耐火原料混合物中,更优选氧化铝质原料为75~97质量%,铝及/或铝合金为0.5~20质量%,硅、粘土、碳化硅以及碳化硼中的1种以上为0.1~15质量%。
耐火原料混合物的粒度构成,更优选考虑到因不需浸渍焦油、沥青等含碳质液状物,而是通过热处理时铝的反应产生致密性和高强度来设计。通过这样可得到低气孔率且具备强度和耐热冲击性良好平衡的板砖。具体来说,优选使粒径1mm以上3mm以下的为15~45质量%,粒径100μm以上低于1mm的为20~40质量%,粒径10μm以上低于100μm的为10~30质量%,粒径低于10μm的为10~30质量%。粒径1mm以上3mm以下的粗粒部分,低于15质量%时弹性率上升,耐热冲击性呈降低趋势,大于45质量%时组织形成多孔,耐浸蚀性呈降低趋势。粒径100μm以上低于1mm的中间粒部分,低于20质量%时耐热冲击性呈减低趋势,大于40质量%时组织形成多孔,强度及耐浸蚀性呈降低趋势。粒径10μm以上低于100μm的微粉部分,低于10质量%时组织形成多孔,强度及耐浸蚀性呈降低趋势,大于30质量%时耐热冲击性呈现降低趋势。粒径10μm以下的超微粉部分,低于10质量%时组织形成多孔,强度呈降低趋势,大于30质量%时组织变得过于致密,耐热冲击性呈降低趋势。
在本发明中,在这种耐火原料混合物中添加有机粘合剂,进行混炼,通过摩擦压力机或者油压压力机等形成规定形状并进行热处理。
作为在耐火原料混合物中添加的有机粘合剂,可使用作为耐火物的粘合剂而被通常使用的酚醛树脂、呋喃树脂以及硅树脂等中的1种以上。这些有机粘合剂,也可稀释在聚乙二醇等溶剂中调节粘度后使用。
在这些有机粘合剂中,更优选合并使用酚醛树脂和硅树脂。通过这样,可使在400~1000℃下对板砖进行热处理时的耐消化性飞跃提高。以往硅树脂的耐氧化性、强度优异虽已为公知,但在本发明中首次证明使用铝及/或铝合金,在400~1000℃下进行热处理过的板砖的耐消化性提高效果非常优异。因此,即使不像以往那样浸渍焦油、沥青,也不会发生因消化引起的质量劣化。
热处理优选在将被加热处理物(板砖成型体)装在容器中的状态、在该容器中填充有焦炭粒的状态、或者使容器中形成氮气环境的状态等隔绝大气的条件下,即优选在非氧化环境下进行。由此可防止热处理过程中的氧化,可得到更加致密且高强度的板砖。
在本发明中,可使该热处理在热处理后的板砖中铝的含有率相对于耐火原料混合物中的铝含有率的比例为20%以上60%以下的条件下进行。
为了确定该热处理的条件,在作为对象的热处理炉中,在400℃以上1000℃以下左右的温度下改变热处理条件进行数次试验,对热处理后板砖中的铝含有率进行定量分析。然后确定热处理后板砖中的铝含有率相对于耐火原料混合物中的铝含有率为20%以上低于60%的热处理条件,即热处理炉、热处理温度、保持时间、马弗炉形状、升温速度等。在此所述的热处理温度是指用于控制热处理炉的温度而测定的温度。如上所述,将被加热处理物装入容器内,在容器外测量温度时,有时与被加热处理物的温度不同。如果可确定热处理条件,则其后不用测定每次进行热处理时的铝量即可在相应条件下进行热处理。
此外,耐火原料混合物中的铝含有率,可通过用铝的配合比例计算而求出。使用铝合金时,也可通过用该合金中的铝含有率计算耐火原料混合物中的铝含有率而求出。在本发明中耐火原料混合物不包含粘合剂及溶剂、水等液体。
此外,热处理后板砖中的铝的含有率,可通过ICP法或湿法等公知的方法求出。
热处理后,在不浸渍焦油、沥青等含碳质液状物的情况下作为板砖使用。
实施例
在表1~表3所示的耐火原料混合物中添加有机粘合剂后进行混炼,用摩擦压力机形成板砖。在成型后进行干燥,在表中的温度下进行热处理。板砖的大小为:纵长约500mm、横宽约200mm、厚度约40mm。
热处理通过在容器内装入板砖并充满焦炭粒,将该容器放入热处理炉(电炉)内而进行。使升温速度为50℃/h,在表中的各热处理温度下保持7小时,保持后停止加热,炉内温度变为400℃以下时取出密闭容器,在变为可操作的温度时取出板砖。热处理温度的控制用配置在密闭容器的上部的热电偶进行。
从热处理后的板砖上切取各试验样品,用JIS-R2205的方法测定显气孔率,用JIS-R 2206的方法测定压缩强度。气体产生量按照JACT的标准试验法,使用Georg Fischer公司的PGD型,测定1000℃下的气体产生量。但是在测定气体产生量之前,将试验样品在110℃干燥24小时。发烟及臭气在使用现场进行试验。即在70t浇桶的滑动喷嘴装置中,在第1次铸造刚刚结束后在作业现场进行浇桶的维护时,通过人体感觉观察到了从板砖上产生的发烟和臭气。在表中,有发烟或臭气时用×表示,几乎无发烟及臭气时用○表示。消化试验根据以下顺序进行。准备纵长为20mm、横宽为20mm、高度为20mm的样品,在110℃干燥24小时,然后测定重量W1。将该样品放入烧杯中,盖上表面皿以防水滴进入样品,然后放置在高压釜中,进行加热并在0.3MPa的压力下保持3小时。冷却后取出样品,在110℃干燥24小时后测定样品重量W2。重量增加率(%)为100×(W2-W1)/W1。
耐火原料混合物中的铝含有率通过用其配合比例计算而求出,热处理后板砖中的铝含有率用ICP法进行定量。此外,表1~表3所示的作为耐火原料的铝使用Al成分为100质量%的原料,铝-镁合金使用Al成分为50质量%、Mg成分为50质量%的原料。
在板砖的实炉试验中,使用热处理后在湿度90%、温度30℃的室内保存20天的板砖。在熔钢炉中使用5组,从第5次加料开始在使用前通过目视确认损伤状况,判断是否可用。表中表示5组的使用次数的平均值。
表1所示的实施例1~实施例4及比较例1~比较例7表示在不同的热处理温度下制造的情况。随着热处理温度升高,压缩强度提高,显气孔率呈增高趋势。实施例1~实施例4是在650℃、700℃以及750℃下进行了热处理的样品,压缩强度为180MPa以上,并且在消化试验中重量增加率为1%以下,在本发明的范围之内。而且热处理后的板砖中的铝含有率相对于耐火原料混合物中的铝含有率的比例为20%以上60%以下,在本发明的范围之内。这些实施例在实炉内的板砖使用结果为8次或9次,结果良好。此外,实施例3与实施例2比较时,不同之处仅在于作为有机粘合剂合并使用了酚醛树脂和硅树脂。显然实施例3的耐消化性优异,致密且强度高。而且板砖的寿命也多1次。
与此不同的是,热处理温度为600℃的比较例4的压缩强度低至169MPa,板砖的使用次数也少至6次。热处理后的板砖中的铝含有率相对于耐火原料混合物中的铝含有率的比例也多至68%。因该比较例4的热处理温度低,所以认为铝的熔融及反应不充分,未能得到充分的强度。热处理温度为450℃及550℃的比较例2及比较例3也是同样。
比较例5的热处理温度为850℃,但消化试验中的重量增加率为1.1%,在本发明的范围之外。该比较例5中,因为热处理后的板砖中的铝含有率相对于耐火原料混合物中的铝含有率的比例少至16%,所以认为过剩生成了炭化铝。此外,比较例5中形成了板砖的耐用性降低的结果。热处理后的铝残留量少时,耐用性呈降低趋势。热处理温度为1000℃的比较例6也是同样。
比较例1为以往的非烧结品,比较例7为以往的烧结后浸渍焦油的烧结品,气体产生量分别多至20.2cc/g、14.7cc/g。
表2所示的实施例5~7是使用铝-镁合金的情况,与仅使用铝时相比,即使热处理温度低,也具有充分的强度,耐消化性也优异。热处理后的板砖中的铝含有率相对于耐火原料混合物中的铝含有率的比例在本发明的范围之内,并且表现出良好的耐用性。
此外,实施例8是在耐火原料混合物中配合作为氧化铝质原料的铝镁尖晶石的例子,其也表现出充分的耐用性。
实施例9~12是改变了铝的配合量及耐火原料混合物的粒度构成的例子。热处理后铝的含有率为5质量%以上时与低于此值时相比,虽然板砖的耐用性略有降低,但还是处于实际使用没有问题的水平。
表3所示的实施例15及实施例16是使用了共晶氧化锆结晶的结晶粒径为1.0μm以下、且基质玻璃的含量为5质量%以下的高性能氧化锆莫来石(氧化锆莫来石B)的情况。与使用以往的氧化锆莫来石(氧化锆莫来石A)的实施例13及实施例14相比,结果耐用性优异。在此,氧化锆莫来石A使用化学成分Al2O3为44质量%、ZrO2为37质量%、SiO2为18质量%、基质玻璃含量为0.9质量%及共晶氧化锆结晶的结晶粒径为2.5μm的氧化锆莫来石,高性能氧化锆莫来石(氧化锆莫来石B)使用化学成分Al2O3为44质量%、ZrO2为37质量%、SiO2为18质量%、基质玻璃含量为0.9质量%及共晶氧化锆结晶的结晶粒径为0.2μm的氧化锆莫来石。
比较例9是不含有硅、粘土、碳化硅以及碳化硼的情况,但消化试验中的重量增加率大,与含有硅且作为有机粘合剂合并使用了酚醛树脂和硅树脂的实施例17相比,显然耐消化性差。
表1
表2
表3
Claims (7)
1.一种板砖,其为在含有铝及/或铝合金为0.5~20质量%的耐火原料混合物中添加有机粘合剂,在混炼后进行成型,在400℃以上1000℃以下进行热处理,然后不浸渍焦油、沥青等含碳质液状物的板砖,其特征在于,压缩强度为180MPa以上,并且在使用高压釜的消化试验中重量增加率为1%以下。
2.根据权利要求1所述的板砖,其中,所述热处理的温度为400℃以上800℃以下。
3.根据权利要求1或2所述的板砖,其中,作为有机粘合剂合并使用酚醛树脂和硅树脂。
4.根据权利要求3所述的板砖,其中,板砖中的铝含有率为0.5质量%以上3.5质量%以下。
5.根据权利要求4所述的板砖,其中,在1000℃产生的气体量为0.5cc/1g以上8cc/1g以下,显气孔率为2~10%。
6.一种板砖的制造方法,其为在含有氧化铝质原料为75~97质量%、铝及/或铝合金为0.5~20质量%、硅、粘土、碳化硅以及碳化硼中的1种以上为0.1~15质量%的耐火原料混合物中添加有机粘合剂,在混炼后进行成型,并进行热处理的板砖的制造方法,其特征在于,在热处理后的板砖中的铝含有率相对于耐火原料混合物中的铝含有率的比例为20%以上60%以下的条件下进行热处理,然后不浸渍焦油、沥青等含碳质液状物。
7.根据权利要求6所述的板砖的制造方法,其中,作为氧化铝质原料,使用高性能氧化锆莫来石为10~40质量%,该高性能氧化锆莫来石为以氧化锆结晶及莫来石作为主要成分,剩余部分由刚玉及/或基质玻璃组成的通过熔融法得到的氧化锆莫来石,其中,共晶氧化锆结晶的结晶粒径为1.0μm以下,且基质玻璃的含量为5质量%以下。
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KR101206947B1 (ko) | 2012-11-30 |
AU2009229913B2 (en) | 2011-12-22 |
GB2471054A (en) | 2010-12-15 |
JPWO2009119683A1 (ja) | 2011-07-28 |
AU2009229913A1 (en) | 2009-10-01 |
GB2471054B (en) | 2013-04-10 |
WO2009119683A1 (ja) | 2009-10-01 |
US20110077340A1 (en) | 2011-03-31 |
DE112009000724T5 (de) | 2011-07-28 |
US8349752B2 (en) | 2013-01-08 |
BRPI0908599B1 (pt) | 2019-07-30 |
KR20110004856A (ko) | 2011-01-14 |
DE112009000724B4 (de) | 2017-11-30 |
CN101977869B (zh) | 2013-09-04 |
BRPI0908599A2 (pt) | 2015-09-15 |
GB201017928D0 (en) | 2010-12-01 |
JP5565907B2 (ja) | 2014-08-06 |
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