CN109553424A - A kind of fiber reinforced high-temperature-resistant lightweight alumina-silica foaming coating - Google Patents

A kind of fiber reinforced high-temperature-resistant lightweight alumina-silica foaming coating Download PDF

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CN109553424A
CN109553424A CN201811324687.9A CN201811324687A CN109553424A CN 109553424 A CN109553424 A CN 109553424A CN 201811324687 A CN201811324687 A CN 201811324687A CN 109553424 A CN109553424 A CN 109553424A
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powder
additional
temperature
kiln
commercial goods
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CN109553424B (en
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魏瀚
赵洪亮
尹超男
胡建辉
王俊涛
徐琳琳
徐如林
周严敦
闫昕
何旺
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RUITAI TECHNOLOGY Co Ltd
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/66Monolithic refractories or refractory mortars, including those whether or not containing clay
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16Shaped 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 silicates other than clay
    • C04B35/18Shaped 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 silicates other than clay rich in aluminium oxide
    • C04B35/185Mullite 3Al2O3-2SiO2
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/10Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427Silicates other than clay, e.g. water glass
    • C04B2235/3463Alumino-silicates other than clay, e.g. mullite
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52Constituents or additives characterised by their shapes
    • C04B2235/5208Fibers
    • C04B2235/5212Organic

Abstract

A kind of fiber reinforced high-temperature-resistant light weight alumina matter foaming coating, using alumine powder, silicon powder, alumina powder as raw material.As bonding agent, additional zirconium aluminate refractory fibre can reach 1420 DEG C using temperature for Aluminum sol, aluminous cement.The step of preparation process of the present invention is simple, eliminates system bubble in advance, uses immediately after being conveniently prepared in situ in construction.Intensity can be generated in the present invention after rapid curing in 30-65min, the construction time can rationally be controlled.The present invention adapts to kiln abnormal shape region such as turning, groove, the construction at circular outer wall, avoids kiln special-shaped part thermal insulation material and contacts not close, the phenomenon that falling off loosening with kiln.

Description

A kind of fiber reinforced high-temperature-resistant lightweight alumina-silica foaming coating
Technical field
The invention patent belongs to heat insulating refractory materials production technical field, and in particular to a kind of fiber reinforced high-temperature-resistant Light weight alumina matter foaming coating.
Background technique
The heat loss inside kiln can be effectively reduced in kiln heat preservation, saves the consumption of fuel.Currently, high temperature kiln is protected Temp effect preferably calcium silicate board, this is because the bulk density of calcium silicate board is much smaller than light-weight refractory fireclay insulating refractory, Thermal coefficient is also far below insulation refractory material.But calcium silicate board is also faced with following problem: (1) hot conditions at present Under, service performance reduces, the aging of accelerated material, and thermal coefficient increases.The use temperature of calcium silicate board is in 800-1000 at present In the range of DEG C, but part high temperature kiln internal temperature is more than 1300 DEG C, such as use temperature >=1700 of sulphur-furnace heat-resistant lining DEG C, calcium silicate board is not suitable for as external thermal insulation heat-barrier material.(2) heat preservation at the single unsuitable special-shaped position of product size.It is different The calcium silicate board of thickness belongs to straight panel shape, should not apply when encountering special-shaped region such as turning, groove, circular outer wall in construction Work needs to cut straight panel to adapt to irregular kiln profile, but in this way it cannot be guaranteed that contacting with kiln closely, easily Cause the loosening of thermal insulation material, the generation of obscission.(3) the calcium silicate board wet-milling of quartz sand and slab during production Steam-cured needs consume a large amount of energy, be unfavorable for the saving to environmental resource.4. calcium silicate board mechanical strength is lower.Compared to The mechanical property of light-weight refractory heat-barrier material, calcium silicate board is lower, is easily broken by external force.So urgently needing a kind of energy For under kiln hot environment, and have bulk density lighter, thermal coefficient is smaller, and has that facilitate construction to adapt to kiln each The thermal insulation material at the special-shaped position of kind.Currently, industry personnels have done relevant research and development, a kind of porous light to heat-insulating heat-preserving material Heat insulating refractory materials and preparation method thereof, Patent No. 200810225985.2, it is burnt that this adopts heat insulating refractory material sawdust Powdered carbon reaches 0.45g/cm as pore creating material, density3.Its principal crystalline phase of the thermal insulation material is mullite and anorthite, due to material There are anorthites in material, and since product is burnt at 1500 DEG C, this causes product that can generate larger contraction, biggish receipts after firing Contracting will lead to hole contraction distortion existing for material internal, the processing work again after causing the decline of thermal insulation property and needing to fire Sequence, and the product special-shaped part at the scene of carrying out cannot be constructed by the way of smearing, and limit the use occasion of material.Ultra micro Hole high-intensity heat insulation refractory bricks and its manufacturing method, the patent No. 200910172604.3, the heat insulating products use a variety ofization Learn foaming agent and prepare micropore in the product, using alumine, floating bead, flyash, kaolin prepare High-Alumina, clay matter every Hot material.Due to containing Determination of Multi-Impurities such as Na in the raw material of use2O、K2O、S、Fe2O3, wherein Fe2O3Content maximum contain Amount has reached 2.5%, cannot use which results in the invention and show that the highest of material uses temperature in the high temperature environment, in specification Degree is 1400 DEG C, in addition, the product is only suitable for that product is made, manufacture craft needs that foam is prepared separately, and is not suitable for directly using With site operation.Light heat insulating castable, the patent No. 201110327920.0, the unsetting heat-insulating heat-preserving material can be existing Field is directly constructed, but the bonding agent that the invention uses in the description is mainly waterglass, contains more Na in ingredient2O、 K2O low melting point can generate more low melting point phase under high temperature, influence the military service performance of material at high temperature.
Summary of the invention
In order to avoid the appearance of problem above, this patent provides a kind of fiber reinforced high-temperature-resistant light weight alumina matter foaming painting Skinning loam, it is resistance to using alumine powder, mullite powder, silicon powder, Reactive alumina, aluminous cement, Aluminum sol, zirconium aluminate Fiery cellucotton, additive.Specific formula is as follows:
Alumine powder 20-50 %,
Mullite powder 50-80%
Silicon powder 0-25 %
Reactive alumina 0-10 %
Aluminous cement 25-55 %
Aluminum sol 0-10 %
Additional zirconium aluminate refractory fiber cotton 0.5-2.5%
Additional neopelex foaming agent 0.1-0.8%
FDN-A water-reducing agent 0.05-0.22%
Additional poly sodium acrylate 0.05-0.35%
Outer adding citric acid 0.01-0.18%
Additional polycarboxylate water-reducer 0.1-0.25 %
Additional carboxymethyl cellulose 1.1-2.9 %
External adding water 35-45%
Wherein alumine powder requires particle size diameter Al in 50-100 μm, raw material2O3>=80, mullite powder is commercial goods, It is required that fine abrasive grains diameter is at 75-90 μm, the silicon powder is commercial goods, it is desirable that SiO2>=99.8%, d50(50% tails over Boundary size)≤3 μm, Reactive alumina is commercial goods, d50(50% tails over boundary size)≤5 μm, silicon powder is city Sell commodity, it is desirable that SiO2>=94%, d50(50% tails over boundary size)≤3 μm, Aluminum sol is commercial goods, is milky liquid Body, pH value 5-6, sol particle is in 10-15nm, solvent solid concentration 20%.Zirconium aluminate refractory fiber cotton is commercial goods, fiber Length is in 2-5mm.
Using alumine powder or mullite powder, silicon powder, activated alumina as slurry raw material, aluminate cement, aluminium are molten As bonding agent, high strength flame resistant fibre, by above-mentioned raw materials external adding water 35-45%, dodecyl is added as enhancing green body in glue later Benzene sulfonic acid sodium salt foaming agent quickly stirs, and can be directly smeared after the completion of stirring in construction surface.
The step of preparation process of the present invention is simple, eliminates system bubble in advance, makes immediately after being conveniently prepared in situ in construction With specific beneficial effect is shown:
(1) it is formed using the raw material of part in-situ preparation mullite, since by high temperature, material internal occurs reaction in-situ and generates Continuous mullite phase improves material in elevated temperature strength, and maximum operation (service) temperature can reach 1420 DEG C, linear shrinkage after 1450 DEG C of burnings Rate is in the range of ± 2.0%.
(2) present invention has abandoned the way that heat preserving aggregate is added in traditional heat-insulating heat-preserving material, using high-temperature refractory fiber generation Aglite is replaced, compressive resistance reaches 4-6MPa;Using chemical foam blowing agent, slurry can be closed after expanding, is tiny Stomata, the bulk density and thermal coefficient of material can be effectively reduced, using YB/T4130-2005 Refractory Thermal Conductivity test Method measures material and can reach 0.05-0.25w/mk in 350 DEG C of thermal coefficients, and bulk density is in 220-490kg/cm3In range.
(3) using aluminous cement and Aluminum sol as bonding agent, aluminous cement makes to keep the temperature coating smearing the present invention Intensity can be generated by rapid curing in 30-65min on arbitrary surfaces, the construction time can rationally be controlled.
(4) Aluminum sol not only provides the dry tenacity of sample in formula of the invention, is converted into active oxidation at high temperature Simultaneously with the silicon ash in raw material reaction in-situ occurs for aluminum nanoparticles, promotes the combination of sample mullite high-temperature-phase, can be further Improve the high temperature bond intensity of sample.
The present invention adapts to kiln abnormal shape region such as turning, groove, the construction at circular outer wall, avoids kiln heteromorphism part Position thermal insulation material contacts not close, the phenomenon that falling off loosening with kiln.
Specific embodiment
Embodiment 1
Raw material are as follows: 40 % of alumine powder, silicon powder 10%, 10 % of Reactive alumina, 30 % of aluminous cement, Aluminum sol 10 %, additional zirconium aluminate refractory fiber cotton 1.5%, additional neopelex foaming agent 0.8%, FDN-A water-reducing agent 0.22%, additional poly sodium acrylate 0.35%, outer adding citric acid 0.12%, 0.25 % of additional polycarboxylate water-reducer, additional carboxylic first 2.5 % of base cellulose, 45 % of external adding water, wherein alumine powder requires particle size diameter Al in 50-120 μm, raw material2O3≥ 80, Reactive alumina is commercial goods, d50(50% tails over boundary size)≤5 μm, silicon powder is commercial goods, it is desirable that SiO2>=99.8%, d50(50% tail over boundary size)≤3 μm, Aluminum sol is commercial goods, is milky white liquid, pH value 6, Sol particle is commercial goods in 10-15nm, solvent solid concentration 20%, zirconium aluminate refractory fiber cotton, and cellucotton chopped length exists Coating is inserted fixing mould by 2-5mm, and sample 28min solidifies and generate intensity, through maintenance, demoulding, 110 DEG C (24 hours) After drying, it is heated to 1400 DEG C of heat preservations and sample after burning is made in 3 hours.
Embodiment 2
45 % of alumine powder
10 % of silicon powder
5 % of Reactive alumina
5 % of aluminous cement
35 % of Aluminum sol
Additional zirconium aluminate refractory fiber cotton 1.5%
Additional neopelex foaming agent 0.8%
FDN-A water-reducing agent 0.22%
Additional poly sodium acrylate 0.35%
Outer adding citric acid 0.12%
Additional 0.25 % of polycarboxylate water-reducer
Additional 2.5 % of carboxymethyl cellulose
External adding water 45%
Wherein alumine powder requires particle size diameter Al in 50-120 μm, raw material2O3>=80, Reactive alumina is commercially available Commodity, d50(50% tails over boundary size)≤5 μm, silicon powder is commercial goods, it is desirable that SiO2>=99.8%, d50(50% tails over Boundary size)≤3 μm, Aluminum sol is commercial goods, is milky white liquid, pH value 6, for sol particle in 10-15nm, solvent is solid Phase content 20%.Zirconium aluminate refractory fiber cotton is commercial goods, and fibre length is in 2mm.Coating is inserted into fixing mould, is tried Sample starts to solidify and generate intensity in 45min, after maintenance, demoulding, 110 DEG C of dryings in (24 hours), is heated to 1400 DEG C of guarantors Sample after burning is made within temperature 3 hours.
Embodiment 3
60 % of mullite miropowder
10 % of silicon powder
8 % of Reactive alumina
2 % of clay fine powder
20 % of aluminous cement
Additional 1.5 % of zirconium aluminate refractory fiber cotton
Additional 0.5 % of neopelex foaming agent
FDN-A water-reducing agent 0.12%
Additional poly sodium acrylate 0.15%
Outer adding citric acid 0.08%
Additional polycarboxylate water-reducer 0.1%
Additional carboxymethyl cellulose 0.4%
External adding water 42%
Wherein mullite miropowder is commercial goods, it is desirable that is finely ground to 50-120 μm, the silicon powder is commercial goods, it is desirable that SiO2 >=99.8%, d50 (50% tails over boundary size)≤3 μm, Reactive alumina is commercial goods, d50(50% tails over boundary Size)≤5 μm, clay fine powder is commercial goods, it is desirable that is finely ground to 180 mesh.Zirconium aluminate refractory fiber cotton is commercial goods, fiber Length is in 5mm.Coating is inserted into fixing mould, sample 29min solidifies and generates intensity through maintenance, demoulding, 110 DEG C (24 Hour) it is dry after, be heated to 1400 DEG C of heat preservations be made within 3 hours burn after sample.
Embodiment 4
50 % of mullite miropowder
8 % of silicon powder
10 % of Reactive alumina
2 % of clay fine powder
30 % of aluminous cement
Additional 1.5 % of zirconium aluminate refractory fiber cotton
Additional 0.7 % of neopelex foaming agent
FDN-A water-reducing agent 0.09%
Additional poly sodium acrylate 0.15%
Outer adding citric acid 0.08%
Additional polycarboxylate water-reducer 0.1%
Additional carboxymethyl cellulose 0.6%
External adding water 40%
Wherein mullite miropowder is commercial goods, it is desirable that is finely ground to 50-120 μm, the silicon powder is commercial goods, it is desirable that SiO2 >=99.8%, d50(50% tails over boundary size)≤3 μm, Reactive alumina is commercial goods, d50(50% tails over boundary Size)≤5 μm, clay fine powder is commercial goods, it is desirable that is finely ground to 180 mesh.Zirconium aluminate refractory fiber cotton is commercial goods, fiber Length is in 2mm.Coating is inserted into fixing mould, sample 30min solidifies and generates intensity through maintenance, demoulding, 110 DEG C (24 Hour) it is dry after, be heated to 1400 DEG C of heat preservations be made within 3 hours burn after sample.
Embodiment 5
40 % of mullite miropowder
18 % of silicon powder
10 % of Reactive alumina
2 % of clay fine powder
5 % of aluminous cement
Aluminum sol 25%
Additional 1.5 % of zirconium aluminate refractory fiber cotton
Additional 0.7 % of neopelex foaming agent
FDN-A water-reducing agent 0.07%
Additional poly sodium acrylate 0.15%
Outer adding citric acid 0.08%
Additional polycarboxylate water-reducer 0.1%
Additional carboxymethyl cellulose 0.6%
External adding water 45%
Wherein mullite miropowder is commercial goods, it is desirable that is finely ground to 50-120 μm, the silicon powder is commercial goods, it is desirable that SiO2 >=99.8%, d50(50% tails over boundary size)≤3 μm, Aluminum sol is commercial goods, is milky white liquid, pH value 6, colloidal sol Particle is commercial goods, d in 10-15nm, solvent solid concentration 20%, Reactive alumina50(50% tails over boundary size) ≤ 5 μm, clay fine powder is commercial goods, it is desirable that is finely ground to 180 mesh.Zirconium aluminate refractory fiber cotton is commercial goods, fibre length In 2mm.Coating is inserted into fixing mould, sample 35min solidifies and generates intensity through maintenance, demoulding, 110 DEG C (24 hours) After drying, it is heated to 1400 DEG C of heat preservations and sample after burning is made in 3 hours.
Comparative example
By the sweet potato powder of industrial mullite powder and mullite powder quality 10wt%, the six of the poly- sodium propionate of 0.6wt% and 0.5wt% are partially Sodium phosphate mixing, adds water and stirs the slurry for being configured to solid concentration 62.5wt%, ball milling obtains stable slurry after 10 hours.It will The triton x-100 of the 0.6wt% of pulp quality is added dropwise in slurry, stirs under 800 revs/min of revolving speed after stirring at low speed It mixes 5 minutes, a large amount of foams is generated in slurry.Foam slurry is added in mold, is placed on after being placed 1 hour in 80 DEG C of baking ovens. After heat preservation, be cooled to room temperature, then move into it is 12 hours dry in 60 DEG C of baking oven, it is finally dry 24 small in 120 DEG C of baking ovens again When.Green body after drying is warming up to 500 DEG C with 1 DEG C/min, keeps the temperature 1 hour, then with 5 DEG C/min to be warming up to 1300 DEG C of heat preservations 2 small When, sample is made.
Performance indicator Comparative example Embodiment 1 Embodiment 2 Embodiment 3 Embodiment 4 Embodiment 5
Bulk density (kg/m3) 578 350 380 393 420 460
Cold crushing strength (MaP) ≥2.0 ≥3.5 ≥3.5 ≥4.0 ≥4.5 ≥4.5
Line variation (%) after 1400 DEG C of burnings ≤-4.0 ≤-1.5 ≤-1.5 ≤-1.8 ≤-2.0 ≤-2.0
Thermal coefficient (350 DEG C ± 25 DEG C) w/mk 0.18 0.08 0.09 0.14 0.15 0.17
Maximum operation (service) temperature (DEG C) 1300 1400 1400 1450 1450 1450
Contrast product refers to the kiln currently used for the industrial departments such as metallurgy, machinery, petrochemical industry, electric power and building materials, heat Mullite insulation insulated pouring material in the liner of construction equipment, flue and smokestack.

Claims (2)

  1. A kind of coating 1. fiber reinforced high-temperature-resistant light weight alumina matter foams, it is characterised in that: the weight percent of the castable The formula of ratio are as follows:
    Alumine powder 20-50 %
    Silicon powder 0-10 %
    Reactive alumina 0-15 %
    Aluminous cement 25-55 %
    Aluminum sol 0-10 %
    Additional zirconium aluminate refractory fiber cotton 0.5-2.5 %
    Additional neopelex foaming agent 0.1-0.8%
    FDN-A water-reducing agent 0.05-0.22%
    Additional poly sodium acrylate 0.05-0.35%
    Outer adding citric acid 0.01-0.18%
    Additional polycarboxylate water-reducer 0.1-0.25 %
    Additional carboxymethyl cellulose 1.1-2.9 %
    External adding water 35-45%
    Wherein alumine powder requires particle size diameter Al in 50-120 μm, raw material2O3>=80%, Reactive alumina is commercially available Commodity, d50≤ 5 μm, silicon powder is commercial goods, it is desirable that SiO2>=94%, d50≤ 3 μm, Aluminum sol is commercial goods, is Milky white liquid, pH value 5-6, sol particle are commercially available quotient in 10-15nm, solvent solid concentration 20%, zirconium aluminate refractory fibre Product, fibre length is in 2-5mm.
  2. 2. the manufacturing process of coating according to claim 1, it is characterized in that: it is micro- with alumine powder, silicon powder, aluminium oxide As slurry raw material, aluminate cement, Aluminum sol refractory fiber cotton is added, additive will be outside above-mentioned raw materials as bonding agent in powder Add water 35-45%, neopelex foaming agent is added later and quickly stirs, completion to be mixed can be applied directly to construct Surface.
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US20210188710A1 (en) * 2019-12-18 2021-06-24 Harbisonwalker International, Inc. Foamed lightweight refractory monolithic composition
WO2021126438A1 (en) * 2019-12-18 2021-06-24 Harbisonwalker International, Inc. Foamed lightweight monolithic refractory composition
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