CN116615401A - 超低热质量耐火制品 - Google Patents

超低热质量耐火制品 Download PDF

Info

Publication number
CN116615401A
CN116615401A CN202180085701.8A CN202180085701A CN116615401A CN 116615401 A CN116615401 A CN 116615401A CN 202180085701 A CN202180085701 A CN 202180085701A CN 116615401 A CN116615401 A CN 116615401A
Authority
CN
China
Prior art keywords
refractory article
less
fibers
colloidal
thermal conductivity
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.)
Pending
Application number
CN202180085701.8A
Other languages
English (en)
Inventor
S·D·小费尔南德斯
C·科斯塔
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unifrax I LLC
Original Assignee
Unifrax Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Unifrax Corp filed Critical Unifrax Corp
Publication of CN116615401A publication Critical patent/CN116615401A/zh
Pending legal-status Critical Current

Links

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
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • 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
    • C04B35/111—Fine ceramics
    • C04B35/117—Composites
    • 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
    • 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
    • C04B35/48—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 zirconium or hafnium oxides, zirconates, zircon or hafnates
    • C04B35/486—Fine ceramics
    • C04B35/488—Composites
    • 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
    • C04B35/624—Sol-gel processing
    • 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
    • C04B35/626—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
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62844—Coating fibres
    • C04B35/62847—Coating fibres with oxide ceramics
    • C04B35/62849—Silica or silicates
    • 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
    • C04B35/626—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
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62886—Coating the powders or the macroscopic reinforcing agents by wet chemical techniques
    • 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
    • C04B35/626—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
    • C04B35/63—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 using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/6303—Inorganic additives
    • 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
    • C04B35/626—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
    • C04B35/63—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 using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/6303—Inorganic additives
    • C04B35/6316—Binders based on silicon compounds
    • 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
    • F27D1/0003—Linings or walls
    • F27D1/0006—Linings or walls formed from bricks or layers with a particular composition or specific characteristics
    • 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
    • F27D1/0003—Linings or walls
    • F27D1/0006—Linings or walls formed from bricks or layers with a particular composition or specific characteristics
    • F27D1/0009—Comprising ceramic fibre elements
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3206—Magnesium oxides or oxide-forming salts thereof
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3208—Calcium oxide or oxide-forming salts thereof, e.g. lime
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3418—Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/44—Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
    • C04B2235/444—Halide containing anions, e.g. bromide, iodate, chlorite
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/522—Oxidic
    • C04B2235/5228—Silica and alumina, including aluminosilicates, e.g. mullite
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/522—Oxidic
    • C04B2235/5232—Silica or silicates other than aluminosilicates, e.g. quartz
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/604—Pressing at temperatures other than sintering temperatures
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/606—Drying
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/612—Machining
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/616—Liquid infiltration of green bodies or pre-forms
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/77—Density
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
    • C04B2235/9615—Linear firing shrinkage
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9669—Resistance against chemicals, e.g. against molten glass or molten salts
    • 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
    • F27D1/0003—Linings or walls
    • F27D1/004—Linings or walls comprising means for securing bricks

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Composite Materials (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)
  • Ceramic Products (AREA)
  • Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)

Abstract

一种超低热质量耐火制品包括被胶体无机氧化物浸渍的纤维。所述耐火制品具有以下性质的至少一种：(i)500kg/m3至1500kg/m3的密度；(ii)在700℃下1.0Wm/K或更低的热导率；和/或(iii)小于2.5％的在1400℃下的线性热收缩率。

Description

超低热质量耐火制品
对相关申请的交叉引用
本申请要求2020年10月20日提交的名称为“ULTRA-LOW THERMAL MASSREFRACTORY ARTICLE”的美国临时专利申请63/094,064的权益，其全文经此引入并入本文。
技术领域
本公开涉及隔热材料、包含其的系统，及其制造和使用方法。更特别地，本公开涉及超低热质量(ULTM)耐火制品，如支座、板、砖或块。
发明背景
隧道窑或炉可用于烧制卫生洁具件(例如洗脸盆、马桶等)、炻器和其它陶瓷制品。耐火板或耐火砖用于在烧制过程中支撑陶瓷工件并为窑或炉加衬。但是，仍然需要具有降低的热质量以及改进的耐久性的耐火制品。
详述
本公开的ULTM耐火制品的特征在于其密度、热导率和线性热收缩率的一种或多种。
特别地，根据一个或多个实施方案，本公开的ULTM耐火制品的密度为至少500kg/m3、至少600kg/m3、至少700kg/m3、至少800kg/m3、至少900kg/m3、至少950kg/m3、最多1500kg/m3、最多1400kg/m3、最多1300kg/m3、最多1200kg/m3、最多1100kg/m3、最多1000kg/m3、最多900kg/m3、最多850kg/m3、或前述上限和下限的任何逻辑组合，如500kg/m3至1500kg/m3、600kg/m3至1200kg/m3、或800kg/m3至1000kg/m3。相比之下，传统耐火材料具有大约3,000kg/m3的密度。由于低密度，ULTM耐火制品的重量可是传统耐火材料的一半。
此外，根据一个或多个实施方案，ULTM耐火制品具有最多1Wm/K、最多0.8Wm/K、最多0.6Wm/K、最多0.5Wm/K、最多0.3Wm/K、最多0.2Wm/K或大约0.2Wm/K的在700℃下的热导率(k值)。另一方面，传统耐火材料具有在700℃下大约18的k值。k值越低，该材料的隔热性越好。
另外，根据一个或多个实施方案，ULTM耐火制品具有最多2.5％、最多2.0％、最多1.5％、最多1.0％或小于1.0％的在1400℃下的线性热收缩率。相比之下，传统耐火材料在1400℃下的线性热收缩率为大约5.0％。
考虑到上述性质，ULTM耐火制品可以在高达1000℃、1200℃、1300℃、1500℃或1650℃的温度下隔热。此外，由于上述性质，ULTM耐火制品比传统耐火材料更快地加热和冷却。
通常，制造ULTM耐火制品的方法包括用至少一种胶体无机氧化物如胶体二氧化硅、氧化铝和/或氧化锆浸渍隔热陶瓷(无机)纤维，将浸渍的纤维置于模具中并将浸渍的纤维压制成所需厚度、形状和尺寸，在烘箱中干燥以产生具有所需特性的干燥板，和如果需要，将干燥纤维切割成最终尺寸。在替代性实施方案中，可以通过用磷酸替代胶体无机氧化物来生产ULTM耐火制品。
可用于制造ULTM耐火制品的陶瓷纤维可使用已知方法制造，或其可购得。在一些实施方案中，该纤维包含多晶羊毛(polycrystalline wool)(PCW)，并且含PCW的合适产品目前可从Unifrax I LLC (Niagara Falls，N.Y.)以商标SAFFIL获得。其它合适的起始陶瓷纤维毯和板目前可从Unifrax I LLC以商标DURABLANKET和DURABOARD获得。
在一个或多个实施方案中，陶瓷纤维具有大约43至大约47重量％的氧化铝含量和大约53至大约57重量％的二氧化硅含量(即铝硅酸盐纤维(RCF))。在另一些实施方案中，陶瓷纤维可具有大约29至大约31重量％的氧化铝含量、大约53至大约55重量％的二氧化硅含量和大约15至大约17重量％的氧化锆含量。该纤维可以是毯的形式，所述毯具有大约30至大约192kg/m3，在一些实施方案中大约64至大约128kg/m3的密度和大约1260℃至大约1430℃的温度等级(temperature grade)。
在另一些实施方案中，陶瓷纤维具有大约42至大约50重量％的氧化铝含量和大约50至大约58重量％的二氧化硅含量。在另一些实施方案中，陶瓷纤维可具有大约28至大约32重量％的氧化铝含量、大约52至大约56重量％的二氧化硅含量和大约14至大约18重量％的氧化锆含量(即，铝锆硅酸盐(alumino zirconia silicate)(AZS)纤维)。陶瓷纤维可以是板的形式，所述板具有大约150至大约350kg/m3的密度、大约3至大约10％的烧失量(LOI)和大约1260℃的温度等级。在一个或多个实施方案中，陶瓷纤维可包括碱土金属硅酸盐(AES)纤维，如可从Unifrax I LLC以商标ISOFRAX获得的那些，和/或高温陶瓷纤维，如高氧化铝纤维，如可从Unifrax I LLC以商标FIBERMAX获得的那些。
可用于浸渍陶瓷纤维的胶体无机氧化物溶液组合物可含有至少一种胶体无机氧化物，如胶体二氧化硅、氧化铝、氧化锆、二氧化钛、二氧化铈和/或氧化钇。可以使用可购得的胶体无机氧化物制剂，例如而非限制，可获自Nalco Company(Naperville，Ill.)的包含40％固体的NALCO胶体二氧化硅。但是，也可以使用其它等级的胶体二氧化硅，如30％固含量或更低，或大于40％固含量。
胶体无机氧化物溶液组合物可包含大约30至100重量％的胶体无机氧化物，如胶体二氧化硅。在某些实施方案中，胶体无机氧化物溶液可包含大约50至大约90％的胶体无机氧化物，如胶体二氧化硅，和在另一些实施方案中，大约80至100％的胶体无机氧化物，如胶体二氧化硅。
胶体无机氧化物溶液的其它组分可包括胶凝剂和足以溶解胶凝剂的量的水。胶凝剂组分可包括促进胶体无机氧化物的凝固或胶凝的无机盐或氧化物，例如在胶体二氧化硅的情况下，如乙酸铵、氯化钙、氯化镁、氧化镁等，以及酸，如乙酸、盐酸、磷酸等。选择胶凝剂的类型和浓度以使胶体悬浮液不稳定，并使得无机氧化物组分能够在ULTM耐火制品的压制过程中胶凝或凝固到位。
胶凝时间可以部分通过胶凝剂的浓度控制，因为胶凝时间通常随温度升高而降低。无机盐或氧化物胶凝剂的量可为溶液的大约0.01至大约10重量％不等。酸的量可为大约0.01至大约10重量％不等。胶凝时间可以部分通过胶凝剂的浓度控制，因为胶凝时间随温度升高而降低。足以溶解胶凝剂的水量可为溶液的0至大约70％不等。胶体无机氧化物溶液在一些实施方案中可另外包含大约0.01重量％至大约10重量％的量的着色剂，以使最终产品能够通过颜色区分。
在制造ULTM耐火制品的方法中，未处理的陶瓷纤维可以用胶体二氧化硅溶液浸渍至饱和点。浸渍的纤维可以在大约5至大约100吨的压力下压制。在某些实施方案中，可以使用大约20至大约40吨的压力。在一个或多个实施方案中，浸渍的纤维可以在上述压力下保持大约1至大约120分钟或大约1至大约5分钟的时间。压制的纤维可以在烘箱中在大约40至大约350℃或大约80至大约150℃的温度下干燥。
尽管ULTM耐火制品已被描述为可用作炉衬和工件支座，但ULTM耐火制品可用于任何其它适当的应用。例如，ULTM耐火制品可用作金属处理装置，如钢包、鱼雷罐车、出料槽(trough runners)、中间包和模具的背板。也就是说，ULTM耐火制品可以替代美国专利7,413,797中描述的背板，该专利全文经此引用并入本文。
应该理解的是，上述内容可能有所变化而不背离本公开的范围。
在一个或多个实施方案中，各种公开实施方案的要素和教导可以全部或部分组合在一些或所有公开实施方案中。此外，各种公开实施方案的一个或多个要素和教导可以至少部分省略，或至少部分与各种公开实施方案的一个或多个其它要素和教导组合。
任何空间参考，例如“上”、“下”、“上方”、“下方”、“之间”、“底部”、“垂直”、“水平”、“有角的”、“向上”、“向下”、“从一侧到另一侧(side-to-side)”、“从左到右”、“左”、“右”、“从右到左”、“从上到下”、“从下到上”、“顶部”、“底部”、“自底向上(bottom-up)”、“自顶向下(top-down)”等，仅用于说明的目的，而不限制上述结构的具体取向或位置。
在一个或多个实施方案中，尽管不同的步骤、过程和程序被描述为表现为不同的操作，但一个或多个步骤、一个或多个过程或一个或多个程序也可能以不同的顺序、同时或相继进行。在一个或多个实施方案中，步骤、过程或程序可以合并成一个或多个步骤、过程或程序。在一个或多个实施方案中，可能省略各实施方案中的一个或多个操作步骤。此外，在一些情况下，可以使用本公开的一些特征而没有相应地使用另一些特征。
尽管上面已经详细公开了若干实施方案，但所公开的实施方案不是限制性的，本领域技术人员容易认识到，在所公开的实施方案中有可能作出许多其它修改、变动和替换，而没有实质上背离本公开的新颖教导和优点。因此，所有这样的修改、变动和替换旨在包括在如以下权利要求书中限定的本公开的范围内。在权利要求中，任何装置加功能条款(means-plus-function clauses)旨在覆盖本文描述为执行所述功能的结构，并且不仅覆盖结构等同物，而且覆盖等同结构。此外，申请人的明确意图是不援引35U.S.C.§112(f)对本文中的任何权利要求施加任何限制，除非该权利要求明确地与相关功能一起使用词语“装置”。

Claims (20)

1.一种耐火制品，其包含无机纤维并具有以下性质的至少一种：
(i)500kg/m3至1500kg/m3的密度；
(ii)在700℃下1.0Wm/K或更低的热导率；和/或
(iii)小于2.5％的在1400℃下的线性热收缩率。
2.如权利要求1所述的耐火制品，其中所述无机纤维选自多晶羊毛、铝硅酸盐纤维、铝锆硅酸盐纤维和/或碱土金属硅酸盐纤维。
3.如权利要求1所述的耐火制品，其具有在700℃下0.5Wm/K或更低的热导率。
4.如权利要求1所述的耐火制品，其具有在700℃下0.2Wm/K或更低的热导率。
5.如权利要求1所述的耐火制品，其具有小于1.5％的在1400℃下的线性热收缩率。
6.如权利要求1所述的耐火制品，其具有小于1.0％的在1400℃下的线性热收缩率。
7.如权利要求1所述的耐火制品，其具有800kg/m3至1000kg/m3的密度。
8.如权利要求1所述的耐火制品，其中所述耐火制品具有以下性质：
(i)800kg/m3至1000kg/m3的密度；
(ii)在700℃下0.2Wm/K或更低的热导率；和
(iii)小于1.0％的在1400℃下的线性热收缩率。
9.一种形成耐火制品的方法，所述方法包括：
用至少一种胶体无机氧化物或磷酸浸渍无机纤维，
将浸渍的纤维置于模具中；
在模具中压制浸渍的纤维；和
将压制的浸渍纤维干燥以形成耐火制品。
10.如权利要求9所述的方法，其中所述无机纤维选自多晶羊毛、铝硅酸盐纤维、铝锆硅酸盐纤维和/或碱土金属硅酸盐纤维。
11.如权利要求9所述的方法，其包括用磷酸浸渍所述无机纤维。
12.如权利要求9所述的方法，其包括用所述至少一种胶体无机氧化物浸渍所述无机纤维，其中所述至少一种胶体无机氧化物包含胶体二氧化硅、胶体氧化铝和/或胶体氧化锆。
13.如权利要求9所述的方法，其进一步包括切割所述耐火制品。
14.如权利要求9所述的方法，其包括用包含所述至少一种胶体无机氧化物和胶凝剂的胶体溶液浸渍所述无机纤维。
15.如权利要求14所述的方法，其中所述至少一种胶体氧化物包含胶体二氧化硅，并且所述胶凝剂包含乙酸铵、氯化钙、氯化镁、氧化镁、乙酸、盐酸、磷酸或其组合。
16.如权利要求9所述的方法，其中所述耐火制品具有以下性质的至少一种：
(i)500kg/m3至1500kg/m3的密度；
(ii)在700℃下1.0Wm/K或更低的热导率；和/或
(iii)小于2.5％的在1400℃下的线性热收缩率。
17.如权利要求9所述的方法，其中所述耐火制品具有以下性质：
(i)500kg/m3至1500kg/m3的密度；
(ii)在700℃下1.0Wm/K或更低的热导率；和
(iii)小于2.5％的在1400℃下的线性热收缩率。
18.一种用于炉的支承板，其包括权利要求1的耐火制品。
19.一种用作炉衬的隔热砖，其包括权利要求1的耐火制品。
20.一种用于钢包、鱼雷罐车、出料槽、中间包和模具的背板，其包括权利要求1的耐火制品。
CN202180085701.8A 2020-10-20 2021-10-19 超低热质量耐火制品 Pending CN116615401A (zh)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US202063094064P 2020-10-20 2020-10-20
US63/094064 2020-10-20
PCT/US2021/071924 WO2022087583A1 (en) 2020-10-20 2021-10-19 Ultra-low thermal mass refractory article

Publications (1)

Publication Number Publication Date
CN116615401A true CN116615401A (zh) 2023-08-18

Family

ID=81289474

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202180085701.8A Pending CN116615401A (zh) 2020-10-20 2021-10-19 超低热质量耐火制品

Country Status (9)

Country Link
US (1) US20230257310A1 (zh)
EP (1) EP4232423A1 (zh)
JP (1) JP2023547820A (zh)
KR (1) KR20230087588A (zh)
CN (1) CN116615401A (zh)
CA (1) CA3196214A1 (zh)
CO (1) CO2023005884A2 (zh)
MX (1) MX2023004543A (zh)
WO (1) WO2022087583A1 (zh)

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7413797B2 (en) * 2006-05-31 2008-08-19 Unifrax Illc Backup thermal insulation plate
CN106927835B (zh) * 2015-12-30 2019-10-29 山东德艾普节能材料有限公司 高强度耐超高温的氧化锆纤维板或异型件的制备方法
CN110204322B (zh) * 2019-05-15 2021-07-27 唐山市凯伦保温材料有限公司 一种莫来石隔热耐火砖及其制备方法

Also Published As

Publication number Publication date
WO2022087583A1 (en) 2022-04-28
CA3196214A1 (en) 2022-04-28
EP4232423A1 (en) 2023-08-30
US20230257310A1 (en) 2023-08-17
MX2023004543A (es) 2023-07-05
KR20230087588A (ko) 2023-06-16
JP2023547820A (ja) 2023-11-14
CO2023005884A2 (es) 2023-05-29

Similar Documents

Publication Publication Date Title
CN101215176B (zh) 高强低导热节能耐火材料
CN101838149B (zh) 抗侵蚀莫来石砖制备原料和制备方法
CN100378029C (zh) 一种多孔尖晶石质陶瓷材料及其制备方法
Zhou et al. Preparation and characterization of mullite foam ceramics with porous struts from white clay and industrial alumina
JP4847400B2 (ja) 断熱材の製造方法、アルミナ−スピネル質耐火断熱材、窯炉容器、断熱材の施工方法、及び断熱材のリサイクル方法
ZA200607731B (en) Ceramic batch and associated product for fireproof applications
CN104311040B (zh) 一种用于制备镁硅硬质保温板的粉料、镁硅硬质保温板及其制备方法
JP2016052960A (ja) 珪石質キャスタブル耐火物及び珪石質プレキャストブロック耐火物
JP5943032B2 (ja) 軽量断熱アルミナ・マグネシア質耐火物の製造方法
JPS62265151A (ja) 成形材料
CN105481375A (zh) 一种节能耐火材料
CN106396727A (zh) 一种轻型耐火材料及其制备方法
US3008842A (en) Basic refractory insulating shapes
Suvorov et al. High-temperature heat-insulating materials based on vermiculite
CN116615401A (zh) 超低热质量耐火制品
US3106475A (en) Burned refractory product
CN109095902B (zh) 一种玻璃窑炉用铺面砖及其生产工艺
CN105294121A (zh) 一种抗热震的轻质耐火骨料
US3365318A (en) Low temperature burned refractory brick and method of making the same
Hubble Steel plant refractories
Ovčačík et al. Technology of refractory materials and heat insulating materials
JPS5919905B2 (ja) 耐火断熱ボ−ド
NO149175B (no) Fremgangsmaate til fremstilling av antibakterielt aktive rifamycin p-derivater
TR201710403A2 (tr) Mum döküm kalibi atik kumundan şamot refrakter tuğla (düşük alümi̇nali alümi̇na si̇li̇kat tuğla)
CN104944974A (zh) 热风炉用耐火砖的制备方法

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination